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ORTAL Clear 150 Installation And Operation Manual

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Installation and Operation Manual – AU/NZ
(For 150 – 250 Units)
ORTAL Heating Systems Ltd.

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Summary of Contents for ORTAL Clear 150

  • Page 1 Installation and Operation Manual – AU/NZ (For 150 – 250 Units) ORTAL Heating Systems Ltd.
  • Page 2 SAVE THESE INSTRUCTIONS Make yourself fully aware of all the following instructions and the many features of the Ortal room sealed gas fireplace appliance. DO NOT DISCARD THIS MANUAL! INSTALLER: Leave this manual with party responsible for use and operation.
  • Page 3 Testing Standards and Document Information The ORTAL decorative room sealed gas appliances have been tested and approved by AGA for use with Natural Gas (NG). Standard references: Australian Standard AS5263-0:2016 - Decorative Gas Log and Other Fuel Effect Appliances Patent Pending for screen barrier glass bracket: USSN 60/040,074 NOTE: Diagrams and illustrations in this manual are not to scale.

  • Page 4: Table Of Contents

    Cool Wall Technology ..........................26 Television and Fireplace Installation ....................... 28 TV Placement Considerations ......................28 TV Installation Clearance Diagrams ....................28 ORTAL Fireplaces with Double Glass ....................... 31 Wall Support Sample Detail ........................33 Gas Setup ..............................34 Gas Line Routing ............................41 Control Connections ..........................
  • Page 5 General Maintenance: Tips and Warnings .................... 122 Maintenance Frequency and Equipment Checklist ................123 Thermocouple Maintenance ......................123 Recommended Maintenance Equipment ..................123 ORTAL Factory Recommended Service Checklist .................. 124 ORTAL Product Service Log........................125 Manufacturer Contact Information ......................126 Appendix A: Fireplace Troubleshooting Guide.................... 127 Pre-troubleshooting Checklist .......................
  • Page 6 Figure 25: Components for Front Bricks Installation ................105 Figure 26: Components for Traditional Bricks Installation ..............107 Figure 27: Log Media Placement for Clear 150 H F/RS/LS/TS/TU/SC, 170 H F/RS/LS/TS/TU ....117 Figure 28: Log Media Placement for Clear 200 H F/RS/LS/TS/TU/SC, Clear 200 F/RS/LS/TS/TU/SC .. 117 Figure 29: On/Off and Manual Pilot Valve Switches ................

  • Page 7: Introduction And Company Profile

    Our product sophistication allows installation in more locations inside the home. ORTAL offers the largest selection of modern gas fireplaces in Australia & New Zealand available in an array of sizes to suit design and architectural needs integrating heat into the aesthetics of life. ORTAL also welcomes clients’...

  • Page 8: Fireplace Safety Information And Warnings

    Fireplace Safety Information and Warnings This section provides safety guidelines and instructions. It is important to SAVE THESE INSTRUCTIONS and to make yourself fully aware of all the safety protocols and the many features of the ORTAL room sealed gas fireplace appliance.
  • Page 9 WARNING – GLASS HANDLING The glass must ONLY be removed by an authorized installer. The authorized technician should ONLY remove the glass with the suction cups supplied by the manufacturer. To prevent damage to the glass edges, lower the glass to rest in a safe place. Follow these guidelines for glass handling: Step 1: Prepare a safe place for the glass to rest.

  • Page 10: Certifications And Codes

    The appliance is not approved for closet installation. The appliance must be installed according to ORTAL requirements in addition to any local codes that may apply. The appliance must be properly connected to an approved flueing system. Refer to the specific appliance to determine flue size and pathway requirements.

  • Page 11: Product List: Models And Burners

    The following table lists flue sizes for decorative flued gas fireplaces. BURNER MODELS: FR/RS/LS/TS/SA/TU/H/TR Flue SIZE B135 Clear 150, Clear 170, Space Creator 150 125/205mm B160 Clear 200, Clear 250, Space Creator 200 125/205mm The following table explains the acronyms used.
  • Page 12 Front Right Side Left Side Three Sides Console Appliance Tunnel High (For all modules) Traditional Space Creator...

  • Page 13: Fireplace Clearances

    Diagrams for Mantel Clearances on page 18 Mounting of Console Appliance Models on page 20 Cool Wall Technology on page 26 Television and Fireplace Installation on page 28 ORTAL Fireplaces with Double Glass on page 31 Wall Support Sample Detail on page 33...

  • Page 14: Appliances And Flue Clearances: Overview

    Concepts and Definitions Access Panels: These are typically required for all ORTAL fireplaces. They allow for efficient and comfortable access to the fireplace receiver and valves, which is required to service the unit(s). Also, access panels can be uniquely placed and designed to not disturb the aesthetic incorporation of the fireplace to its surrounding living space.
  • Page 15 Fireplace Legs: All ORTAL built-in fireplaces (Clear Front, LS, RS, TS, and Space Creator) come standard with legs that measure: Protective screen units: 21cm from the bottom of the fireplace glass opening to the floor This is the minimum height for the firebox to rest on the floor. The legs cannot be removed.

  • Page 16: Firebox Clearance Diagrams

    Firebox Clearance Diagrams This manual is based on installation of front-facing ORTAL fireplaces. To install other ORTAL fireplace styles, modify the instructions per ORTAL Framing Dimensions. Maintain clearances as shown in the figures below. Clearances are to non-combustible materials, or 16mm Gyprock Fyrchek fire rated drywall or its equivalent.
  • Page 17 LEFT SIDE OPEN (LS) RIGHT SIDE OPEN (RS) THREE SIDES (TS)

  • Page 18: Diagrams For Mantel Clearances And Shelf Details

    All fireplace drawings with correct dimensions are available on our website under Products>Downloads>Diagram NOTE: For detailed information about framing and finishes, please refer to the Ortal Builder’s Manual. Figure 1: Mantel Clearances: Recess and Flush Finishes...

  • Page 19: Figure 2: Shelf Detail

    Metal framing Combustible material Non-combustible materials: Materials applicable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non-combustible materials. An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent, where a non-combustible material may be used.

  • Page 20: Mounting Of Console Appliance Models

    Mounting of Console Appliance Models This section provides guidelines and diagrams related to mounting of Console Appliance models. Recommendations for Wall Mounting The following procedures present manufacturer-recommended instructions for mounting on concrete walls and wood stud walls. WARNING: Console Appliances are Wall Mounted units ONLY. They cannot be placed in closed surroundings like bookcases, cupboards or closed walls.

  • Page 21: Figure 3: Concrete Wall Mounting Detail

    Figure 3: Concrete Wall Mounting Detail...
  • Page 22 To mount the unit on a wood stud wall: 1. Position the unit at the desired height and mark the wall. There should be a minimum 30cm and maximum 75cm distance from the bottom of the unit to the floor. 2.

  • Page 23: Figure 4: Wood Stud Mounting Detail

    Figure 4: Wood Stud Mounting Detail...

  • Page 24: Console Appliance Installation Diagrams

    Console Appliance Installation Diagrams The following diagrams present installation guidelines for the Console Appliance models. Please note that these drawings are not to scale. All fireplace drawings with correct dimensions are available on our website under Products>Downloads>Diagram NOTE: All dimensions in the diagrams are in milimeters. Figure 5: Console Appliance Front Facing Models...
  • Page 25 Figure 6: 75 TS Console Appliance: Rear View NOTE: The dimensions for A and B show the center of the opening for gas (after removing the bracket). TS Console Appliance units are completely open in the rear.

  • Page 26: Cool Wall Technology

    Cool Wall Technology ORTAL’s unique Cool Wall technology is a technique that reduces the heat from the glass and the firebox and prevents excessive heat buildup, thereby avoiding any damage that may result from high heat temperatures. ORTAL’s cool wall system enables the option of installing a TV or other similar electronic components above the fireplace, as well as the ability to use finishing materials that a hot wall surface would prohibit.
  • Page 27 ORTAL’s Cool Wall Solution allows for the wall to breathe, releasing the excess heat from the chase to maintain a temperature from a high point of 210 C (immediately above the firebox) to 90 C (one foot above the firebox).

  • Page 28: Television And Fireplace Installation

    Most TV manufacturers specify in their instructions that the TV should not be installed on, near or above a heat source. However, the decision of where to place the TV ultimately rests solely with the homeowner. ORTAL will not be held liable for any adverse effects on a TV or other equipment located near ORTAL fireplaces.
  • Page 29 Metal framing Combustible material Non-combustible materials: Materials applicable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non-combustible materials. An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent, where a non-combustible material may be used.
  • Page 30 Metal framing Combustible material Non-combustible materials: Materials applicable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non-combustible materials. An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent, where a non-combustible material may be used.

  • Page 31: Ortal Fireplaces With Double Glass

    ORTAL Fireplaces with Double Glass When installing double glass fireplaces, it is essential to maintain cool air flow between the glass panels and through the chase cavity. In order to maintain air flow between the glass panels and to allow cool room air to enter into the chase cavity, an opening must be provided in the exterior finish surface underneath the firebox.
  • Page 32 Metal framing Combustible material Non-combustible materials: Materials applicable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non-combustible materials. An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent, where a non-combustible material may be used.

  • Page 33: Wall Support Sample Detail

    Wall Support Sample Detail ORTAL fireplaces must not carry any structural weight. The framing must be supported by another surface, not by the firebox. Please consult with your structural engineer and refer to your local building code for proper wall support.
  • Page 34 The following diagrams show framing dimensions in a flush application as an example. A flush application is not the only possible application for ORTAL fireplaces. Please visit our website for more information. The leg height used for calculating the framing dimensions in the following diagrams is the double glass leg height 250mm, which will be standard leg height for both double glass and screen units starting March 2018 with serial #15275 (see page 13 for details on leg height).
  • Page 35 Front (F) & Traditional (TR) Series Framing Diagram Unit Dimension A Dimension B Dimension C Dimension D Dimension E 40H70 F 1550 60x80 F 1550 75x65 F 1005 1550 75 F 1283 110 F 1350 1283 110H F 1367 1410 130 F 1520 1283...
  • Page 36 Corner (RS/LS) Series Framing Diagram Unit Dimension A Dimension B Dimension C Dimension D Dimension E 40H70 RS/LS 1550 75 RS/LS 1283 110 RS/LS 1305 1283 110H RS/LS 1310 1410 130 RS/LS 1473 1283 130H RS/LS 1480 1410 150 RS/LS 1724 1283 150H RS/LS...
  • Page 37 Tunnel (TN) Framing Diagram Unit Dimension A Dimension B Dimension C Dimension D Dimension E 40H70 TN 1550 60x80 TN 1550 75x65 TN 1005 1550 110 TN 1350 1283 110H TN 1367 1410 130 TN 1520 1283 130H TN 1520 1410 150 TN 1770...
  • Page 38 Three Side (TS) Framing Diagram Unit Dimension A Dimension B Dimension C Dimension D Dimension E 40H70 TS 1550 75 TS 1283 110 TS 1243 1283 110H TS 1243 1410 130 TS 1413 1283 130H TS 1413 1410 150 TS 1662 1283 150H TS...
  • Page 39 Space Creator (SC) Framing Diagram Unit Dimension A Dimension B Dimension C Dimension D Dimension E SC 75 1283 SC 120 1456 1283 SC 150 1757 1283 SC 200 2267 1283...

  • Page 40: Gas Setup

    Gas Setup ORTAL fireplaces are closed room sealed systems that can operate with natural gas (NG) or (Universal LPG). The following sections present detailed information about gas routing, pressures, conversion, maintenance and more: Gas Line Routing on page 41 Gas Control Assemblies and Components on page 42Gas Conversion To change the gas source of a fireplace, you need to request a gas conversion kit.
  • Page 41 WARNING: Before starting this procedure, make sure to disconnect the main gas supply to the unit. Figure 11: Gas Conversion: Parts To perform NG-LPG conversion: 1. Remove the front heat barrier and glass. (For details, refer to Fireplace Heat Barrier on page 77.) 2.
  • Page 42 Pull the pilot down and twist slightly, until it releases from the burner. Then, pull the receiver and the gas valve out. NOTE: Before continuing, review Figure 12 to familiarize yourself with the components.
  • Page 43 Figure 12: Exploded View of Pilot Parts, Receiver and Gas Valve...
  • Page 44 Pull the wire to disconnect it from the receiver. Remove the nut holding the thermocouple pipe, and pull the pipe out. Remove the nut holding the gas pipe, and pull the pipe out. NOTE: If you have a new, complete pilot kit, skip Step 4 and continue with Step 5.
  • Page 45 4. Assemble the pilot parts: Assemble the injector (nozzle) with the ring valve (eye) and the gas tube nut. Then, insert the assembled parts into the gas tube. Attach the assembled parts to the pilot base, and then tighten the nut.
  • Page 46 NOTE: The LPG nozzle has a red dot in the hole (.23mm). The NG hole is .36mm and has a different shape: Assemble the electrode with the spark plug connector, and the heat gasket with the wire. Use a lighter to dissolve the heat gasket, to reinforce the parts.
  • Page 47 Attach the assembled parts to the pilot base, and then tighten the connector nut. Assemble the thermocouple pipe. The NG pipe comes pre-assembled with only one connector nut. Insert the additional connector nut provided by ORTAL as shown in the figure below.
  • Page 48 Attach the thermocouple pipe to the pilot base, and then tighten the connector nut. 5. Change the base pilot gasket every time you open the pilot base.
  • Page 49 6. Change the orifice: Using wrench (17), remove the nut holding the orifice. NOTE: When reassembling, be careful not to overtighten. If the orifice is removed together with the nut, separate them using wrenches (15 and 17), as shown in the figure below. If not, use wrench (15) to remove it from the burner. 7.
  • Page 50 Adjust the burner main aeration as shown in the figure below. Then, tighten the nuts with an 8mm wrench. In Ng the supporting trims needs to be all the way so the opening is fixed and cannot be changed In LPG the shutter needs to be removed completely. NOTE: For reinstallation, perform the above steps in reverse.

  • Page 51: Gas Line Routing

    Gas Line Routing Correctly size and route the gas supply line from the supply regulator to the area where the appliance is to be installed. WARNING –The main gas valve must be installed to allow complete disconnection of the appliance from the gas supply piping system for servicing purposes.

  • Page 52: Gas Control Assemblies And Components

    Gas Control Assemblies and Components Assemblies and components are listed and described in the tables following the figure. CAT. NR. ORTAL DESCRIPTION CAT. NR. ORTAL DESCRIPTION G121 Main burner gas fitting LPG pilot orifice Burner gas tube Natural gas pilot orifice...
  • Page 53 Gas Conversion To change the gas source of a fireplace, you need to request a gas conversion kit. Gas conversion can be performed only by technicians who have specific authorization to change these components. The actual change must be done by the authorized technician. Not all installers are authorized to provide gas conversion services. The following procedure is a guide for NG-LPG conversion.
  • Page 54 To perform NG-LPG conversion: 8. Remove the front heat barrier and glass. (For details, refer to Fireplace Heat Barrier on page 77.) 9. Remove the burner. (For details, refer to Appendix B: Removal / Assembly of the Burner on page 130) 10.
  • Page 55 Figure 12: Exploded View of Pilot Parts, Receiver and Gas Valve...
  • Page 56 Pull the wire to disconnect it from the receiver. Remove the nut holding the thermocouple pipe, and pull the pipe out. Remove the nut holding the gas pipe, and pull the pipe out. NOTE: If you have a new, complete pilot kit, skip Step 4 and continue with Step 5.
  • Page 57 11. Assemble the pilot parts: Assemble the injector (nozzle) with the ring valve (eye) and the gas tube nut. Then, insert the assembled parts into the gas tube. Attach the assembled parts to the pilot base, and then tighten the nut.
  • Page 58 NOTE: The LPG nozzle has a red dot in the hole (.23mm). The NG hole is .36mm and has a different shape: Assemble the electrode with the spark plug connector, and the heat gasket with the wire. Use a lighter to dissolve the heat gasket, to reinforce the parts.
  • Page 59 Attach the assembled parts to the pilot base, and then tighten the connector nut. Assemble the thermocouple pipe. The NG pipe comes pre-assembled with only one connector nut. Insert the additional connector nut provided by ORTAL as shown in the figure below.
  • Page 60 Attach the thermocouple pipe to the pilot base, and then tighten the connector nut. 12. Change the base pilot gasket every time you open the pilot base.
  • Page 61 13. Change the orifice: Using wrench (17), remove the nut holding the orifice. NOTE: When reassembling, be careful not to overtighten. If the orifice is removed together with the nut, separate them using wrenches (15 and 17), as shown in the figure below. If not, use wrench (15) to remove it from the burner. 14.
  • Page 62 Adjust the burner main aeration as shown in the figure below. Then, tighten the nuts with an 8mm wrench. In Ng the supporting trims needs to be all the way so the opening is fixed and cannot be changed In LPG the shutter needs to be removed completely. NOTE: For reinstallation, perform the above steps in reverse.

  • Page 63: Pilot And Thermocouple Maintenance

    Pilot and Thermocouple Maintenance The pilot flame must be visually checked. The pilot flame has two distinct flames. One engulfs the thermocouple, and the other reaches the main burner. Both flames must be present. The area around the injector should be inspected. Any foreign material must be removed with a brush or vacuum.

  • Page 64: Flue System Information

    NOTE: For information about the 107/164mm and 125/205mm room sealed pipe installation and specs, please visit the appropriate manufacturer’s website. NOTE: If the appliance has a Power Flue system, .please refer to the ORTAL Power Flue manual for more information.

  • Page 65: Flueing Requirements

    Flueing Requirements When installing the flueing, follow all instructions of the flueing system manufacturer. For vertical and horizontal distances, refer to the charts in the Flueing Diagrams section. Maintain all clearances specified in Flue Installation and Clearances on page 66. Alternatively, follow the flue system manufacturer’s instructions, provided that they meet local code.

  • Page 66: Flueing Diagrams

    Flueing Diagrams The following sections provide information for calculating flueing run distances: Flueing Diagram: Typical Horizontal on page 57 Flueing Diagram: Typical Vertical on page 58...

  • Page 67: Flueing Diagram: Straight Vertical

    The V minimum starts above them. They do not count in elbow totals. V minimum = 180cm for Series 200 and 250 For flueing runs that exceed these maximums, consider the ORTAL Power Flue system. Contact your ORTAL dealer for more information. Figure 14: Flueing Diagram: Typical Horizontal...
  • Page 68 If needed for clearance, two 45-degree elbows may be used directly on the unit with up to a 30cm section between them. The V minimum starts above them. They do not count in elbow totals. V =V1 + V2 For flueing runs that exceed these maximums, consider the ORTAL Power Flue system. Contact your ORTAL dealer for more information.

  • Page 69: Figure 15: Flueing Diagram: Typical Vertical

    Figure 15: Flueing Diagram: Typical Vertical V1= minimum of 90cm for the following product series: SERIES 150/170 SERIES 200/250 SERIES TRADITIONAL Vertical Horizontal Vertical Horizontal 90cm 180cm 180cm 90cm 210cm 360cm 300cm 360cm 300cm 450cm 390cm 360cm 390cm 360cm 480cm 360cm 480cm 360cm...
  • Page 70 Flueing Diagram: Straight Vertical For Series 40-250, the maximum vertical distance is 12 meters. For flueing runs that exceed this maximum, consider the ORTAL Power Flue system. Contact your ORTAL dealer for more information.

  • Page 71: Working With Vertical Elbows

    Working with Vertical Elbows When doing an installation involving vertical elbows, keep the following guidelines in mind: Only two 90-degree elbows are allowed per installation. An installation involving more than two 90- degree elbows requires manufacturer’s approval. Each 90-degree bend can be calculated as 2 x 45-degree bends. For example, an installation can have two 45-degree bends and one 90-degree bend, OR four 45-degree bends and no 90-degree bends.
  • Page 72 SCENARIO C The first 90-degree elbow is not taken into calculation of the (H) length for the restrictor plate size. For example: Total height of duct work = 450cm (V) Length between the center of the 90-degree elbow and wall termination cap = (B) = 330cm The (H) calculation is (H) = (B) = 11.
  • Page 73 SCENARIO D There are no 90-degree elbows or 45-degree angles. The flueing is a straight vertical run. For example: Total height of duct work = 720cm (V) The (H) calculation is = 0. Therefore, the restrictor plate size is 50mm...

  • Page 74: Fireplace Restrictors And Flue Arrangement

    Numbers other than zero: The number represents the width required for the size of restrictor that has to be assembled. All these dimensions are shown in cm/mm. If the length (vertical or horizontal) does not appear in the table, consult with ORTAL before proceeding. For special flueing systems, please contact ORTAL for more information.
  • Page 75 Values in mm Table 3: Restrictor Table: Burner 135 – Series 150/170 Values in mm Table 4: Restrictor Table: Burner 160 – Series 200-250...

  • Page 76: Flue Installation And Clearances

    Flue Installation and Clearances When installing the flueing, be sure that the flue pipe is supported by the structural surrounding and not by the firebox. Secure the flue connection to the fireplace with a minimum of 3 self-tapping screws. Each elbow should be strapped to reduce movement or possible disconnection.

  • Page 77: Flue Termination Drawings

    Flue Termination Drawings Flue Terminations...

  • Page 78: Flue Maintenance

    Flue Maintenance Regular inspection of the flueing system by an authorized service technician every six months is recommended. The following maintenance routing is recommended: 1. Inspect for excessive condensation, e.g., water droplets forming in the inner lining, and subsequently dripping from the joints. This can cause corrosion in the system. 2.

  • Page 79: Fireplace Installation Instructions

    Fireplace Installation Instructions The following sections describe fireplace components and describe installation operations: Selecting a Location on page 70 Installation Sequence on page 71 Working with Glass Panels on page 73 Fireplace Heat Barrier on page 74 Removal / Assembly of the Double Glass Heat Barrier and Inner Glass on page 75 Removal / Assembly of the Framed Screen on page 89 Removal / Assembly of the Protective Screen on page 93 Removing/Assembling the Inner Glass (Screen Heat Barrier Units) on page 97...

  • Page 80: Selecting A Location

    Selecting a Location Keep the following factors in mind when selecting a location for the fireplace: Minimum clearances to combustible materials must be met (Fireplace Clearances on page 13). Adequate clearances for servicing need to be provided. Consider the minimum flue vertical and allowed horizontal lengths and number of bends (Flue System Information on page 54).

  • Page 81: Installation Sequence

    It is crucial to the finishing that the unit is stable, level and plumb. The legs are zero clearance. Wood shims are acceptable. Third Trip to Site: Startup Phase Perform a visual inspection to confirm that all work was completed per ORTAL specifications. Confirm that gas is properly connected and live. Remove the safety barrier and glass.
  • Page 82 Remove protective layers and clean glass. Install the glass and safety barrier. Go over operation of the unit and remote with the homeowner. Set up return visit to clean glass after initial burn off period. For more information about final inspection and homeowner instructions, refer to Post-installation Procedures on page 119.

  • Page 83: Working With Glass Panels

    Working with Glass Panels 5mm ceramic glass front and side panels are provided. Contact ORTAL for replacement parts if required. 3/16 tempered glass exterior panels can be serviced locally. Silicon comes pre-applied to any glass-to-glass connections (LS, RS, TS and SC models), on both sides of the glass.

  • Page 84: Fireplace Heat Barrier

    The barrier must be installed properly prior to startup of the firebox. An ORTAL fireplace can have one of the following heat barrier types: Double glass: A barrier made of inner and outer glass (and no screen). For installation instructions, refer to Removing/Assembling Double Glass Heat Barrier on page 81.

  • Page 85: Removal / Assembly Of The Double Glass Heat Barrier And Inner Glass

    Removal / Assembly of the Double Glass Heat Barrier and Inner Glass The two procedures in this section explain how to remove and reassemble the double glass heat barrier. Choose the procedure that is relevant to the type of unit you are working with. Removing/Assembling Double Glass Heat Barrier and Inner Glass (Type 1) The procedure below shows how to remove the glass for units with a double glass heat barrier.
  • Page 86 Figure 17: Double Glass: Parts To remove double glass: 1. Using your index finger, pull the side trim from the top. 2. Using your index finger, pull the front trim from the end.
  • Page 87 3. Release the tempered glass brackets: Loosen – do not remove – the upper bracket screws. Remove the upper bracket. Loosen the lower bracket screws. Do not remove the lower bracket.
  • Page 88 4. Remove the tempered glass: Attach the suction cup to the center of the glass, as shown. Pull up on the suction cup to lift the glass, tilting it slightly towards you, until you reach the top. Be careful to avoid hitting the edge of the glass on the screws. Pull the suction cup until the bottom of the glass clears the frame.
  • Page 89 Pull the suction cup to take the glass out. NOTE: Repeat this process to remove the side glass.
  • Page 90 5. Pull the front and side blower grills until they release from the magnets. 6. If glass stoppers are installed, loosen their screws, as shown below. 7. Remove the inner (ceramic) glass in the same manner as the tempered glass.

  • Page 91: Removing/Assembling Double Glass Heat Barrier And Inner Glass (Type 2)

    Removing/Assembling Double Glass Heat Barrier and Inner Glass (Type 2) The procedure below shows how to remove the glass of new design double glass units. To re-install the glass, perform the steps in the opposite order. Figure 18: Double Glass Heat Barrier: Parts...
  • Page 92 To remove the double glass heat barrier: 1. Remove the side trim: Hold the upper side of the side trim with your index finger, and pull it until it releases from the top magnet. Continue pulling the side trim until it is disconnected from the bottom magnet. Repeat with the other side trim.
  • Page 93 2. Remove the bottom trim: Lift the end of the bottom trim with your index finger, and pull it up until it releases from the magnets. Then, pull the bottom trim all the way out.
  • Page 94 3. Remove the Double Glass holders: Using a screwdriver, start removing the two screws from each of the front glass holders. Then take them all the way out. 4. Remove the double glass: Using the suction cup, hold the front glass from the center and raise it until it reaches the top.
  • Page 95 Pull the bottom of the glass as shown in the figure: Pull the glass down, and take it out. If necessary, repeat the procedure to remove the side glass. 5. Remove the double glass fan covers: Pull each fan cover up until it is released.
  • Page 96 6. Remove the front glass brackets: Using a suction cup, hold the front glass from the center. While holding the glass, loosen the screws of the upper bracket. Take all the bottom bracket screws out. Then, remove the bracket.
  • Page 97 7. Remove the glass: Pull the suction cup up to lift the glass until it reaches the top. Pull the suction cup from the bottom until the glass clears the frame.
  • Page 98 Pull the suction cup to take the glass all the way out. If necessary, remove the side glass by repeating Steps 6 and 7.

  • Page 99: Removal / Assembly Of The Framed Screen

    Removal / Assembly of the Framed Screen The procedure below shows how to remove the framed screen. To re-install it, perform the steps in the opposite order. Figure 19: Framed Screen Assembly: Parts...
  • Page 100 To remove the framed screen: 1. Remove the side trim: Using your index finger, pull the upper side of the profile until it releases from the magnets. Then, remove it. Remove the other side trim in the same manner. 2. Remove the front trim: Using a screwdriver, remove the two screws from each side of the trim.
  • Page 101 Lift the trim from the side, and remove it. 3. Remove the framed screen: Using your hand, push the holder from the middle to release the framed screen. While holding the framed screen up, pull the bottom of the screen with your other hand until it clears the frame.
  • Page 102 Pull the framed screen down and out, and remove it.

  • Page 103: Removal / Assembly Of The Protective Screen

    Removal / Assembly of the Protective Screen The procedure below shows how to remove the protective screen. To re-install it, perform the steps in the opposite order. Figure 20: Protective Screen: Parts...
  • Page 104 To remove the protective screen: 1. Remove the side trim by pulling out from the top. 2. Remove the bottom trim by pulling up from the end. 3. Remove the 4-5mm hex bolts with a 5mm Allen wrench.
  • Page 105 4. Remove the protective screen: Twist the screen bracket 90 degrees. Gently tilt the screen bracket from the top down and towards you. Carefully remove the screen. Roll it up and set it aside. NOTE: If access to the firebox is needed, continue with the following steps. 5.
  • Page 106 6. Remove the corner glass (only if necessary): Remove the two screws from the bottom bracket, and then remove the bracket. While holding the glass corner, remove the upper bracket. Then, rotate the glass corner. Lift up the glass corner, as shown in the picture on the left. Then, tilt the glass corner by pulling down from the bottom to the right (as shown in the picture on the right), and remove it.

  • Page 107: Removing/Assembling The Inner Glass (Screen Heat Barrier Units)

    Removing/Assembling the Inner Glass (Screen Heat Barrier Units) The procedure below shows how to remove the inner glass panes of ORTAL fireplace units with a screen heat barrier. To re-install the glass, perform the steps in the reverse order. Figure 21: Inner Glass: Parts...
  • Page 108 To remove the inner glass: 1. Remove the side trim by pulling out from the top. 2. Remove the bottom trim by pulling up from the end.
  • Page 109 3. Loosen all the (M10) bolts from the upper and lower brackets. Do NOT remove the bolts. 4. Remove the upper glass bracket. Do NOT remove the bottom bracket.
  • Page 110 5. Attach the suction cup as shown. Make sure that the line on the suction cup bottom is not showing. 6. Remove the front glass by performing the following steps while holding the button of the suction cup down. A. Tilt the top side of the glass forward. B.

  • Page 111: Removing/Assembling The Back Panel

    Removing/Assembling the Back Panel The procedure below shows how to remove the back panel of the unit. The procedure is relevant for units that include a reflective panel or granite. To re-install the panel, perform the steps in the reverse order. Figure 22: Back Panel: Parts...
  • Page 112 To remove the back panel: 1. Remove the front glass and the front heat barrier (Fireplace Heat Barrier on page 74). 2. Remove the grill screws. Lift the grill and pull it out. 3. Remove the upper panel holders: Hold the panel, using a suction cup. Remove the screws from each holder, and take the holders out.
  • Page 113 4. Remove the side panel: Lift the panel up, as shown: Tilt the panel from the bottom, and pull it towards the fireplace center. Pull the panel out and remove it. If necessary, remove the other side panel in the same manner.
  • Page 114 5. Remove the rear panel: Remove the bottom holders (if present). If the screws on the starter collar are type (M10), remove them as shown in the figure below. Do NOT remove Phillips screws from the starter collar. Remove the rear panel in the same manner as the side panel (see Step 4).

  • Page 115: 75/65 Front Bricks Installation

    75/65 Front Bricks Installation The following procedure provides guidelines for installing front bricks. Figure 23: Components for Front Bricks Installation...
  • Page 116 To install front bricks: 1. Remove the heat barrier and the glass (Fireplace Heat Barrier on page 74). 2. Insert the rear brick. NOTE: The side bricks hold the rear brick. 3. Insert the left and right side bricks. 4. Insert the right and left brick holders, as shown.

  • Page 117: Traditional Bricks Installation

    Traditional Bricks Installation The following procedure provides guidelines for installing traditional bricks. Figure 24: Components for Traditional Bricks Installation...
  • Page 118 To install traditional bricks: 1. Remove the heat barrier and the glass (Fireplace Heat Barrier on page 74). 2. Insert the rear lower brick. 3. Insert the rear upper brick.
  • Page 119 4. Insert the side bricks. 5. Insert the brick holders for each side, as shown. NOTE: The side bricks hold the rear bricks.
  • Page 120 6. Push the right and left floor bricks into place, as shown.

  • Page 121: Remote Control Setup And Operation

    Remote Control Setup and Operation This section provides safety information and instructions for setting up and operating the remote control. The redesigned GV60 handsets G6R-H…FB and G6R-H…FW operate exactly the same as the previous handset G6R-H… Only the symbols on the buttons have changed. See the figure below for the corresponding symbols.

  • Page 122: Radio Frequency Handset

    Radio Frequency Handset 315 MHz for Australia and New Zealand. Operation is subject to the following conditions: This device may not cause harmful interference This device must accept any interference received, including interference that may cause undesired operation. Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

  • Page 123: Batteries

    Batteries Handset: 3 x “AAA” (alkaline recommended). Low battery indicator on handsets with display. Handsets without display: the red LED gets darker. Battery replacement is recommended after 2 years. The handset may display options that are not available on all fireplaces Receiver: 4 x 1.5V “AA”...

  • Page 124: Operating Instructions

    Operating Instructions Some options on the remote may not be available on all fireplaces. For complete operating instructions, please refer to the Homeowner’s manual.

  • Page 126: Interior Design Media

    Interior Design Media ORTAL offers media such as logs and stones, that can be provided with the fireplace unit. This section provides guidelines for safe placement of media. WARNINGS –INSTALLING AND HANDLING MEDIA DO NOT install the interior design media until appliance installation is complete, the gas line is connected and tested for leaks, and initial burner operation has been inspected and approved.
  • Page 127 Log Media Placement Figure 25: Log Media Placement for Clear 150 H F/RS/LS/TS/TU/SC, 170 H F/RS/LS/TS/TU Figure 26: Log Media Placement for Clear 200 H F/RS/LS/TS/TU/SC, Clear 200 F/RS/LS/TS/TU/SC...

  • Page 128: Cold Climate Insulation

    Cold Climate Insulation Seal all cracks around your appliance with noncombustible material and wherever cold air could enter the room. It is especially important to insulate outside chase cavity between fastenings, and under the floor on which the appliance rests if the floor is above ground level. Gas line holes and other openings should be caulked or stuffed with un-faced fiberglass insulation.

  • Page 129: Post-Installation Procedures

    The following sections present post-installation operations. Initial Burning Period Following installation of an ORTAL fireplace, there is a 12-hour minimum burning period. This 12-hour period must include a minimum of 4 hours of continuous burning. During this time, the customer/installer may notice: The glass developing a white or “cloudy”...

  • Page 130: Operating Warnings

    Operating Warnings ORTAL room sealed gas fireplace heaters are sealed combustion, air-circulating gas fireplaces designed for residential applications. For your safety, please read the following warnings carefully before lighting your fireplace. If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life.

  • Page 131: Maintenance Instructions

    Maintenance Frequency and Equipment Checklist on page 123 ORTAL Factory Recommended Service Checklist on page 124 ORTAL Product Service Log on page 125 NOTE: Service recommendations presented are for standard ORTAL fireplace products. Custom fireplaces may have different recommended service periods and activities.

  • Page 132: General Maintenance: Tips And Warnings

    General Maintenance: Tips and Warnings WARNING – SERVICING It is recommended that an authorized service technician perform a routine inspection at the beginning of each heating season. Turn off the gas BEFORE servicing the fireplace. WARNING – BURNER AND FLUE INSPECTIONS Periodic checks should be made of the burner for correct position and condition.

  • Page 133: Maintenance Frequency And Equipment Checklist

    Maintenance Frequency and Equipment Checklist Under normal circumstances, the factory recommendation is to have the unit serviced at least once a year (annual service). Units meeting the following conditions should have more frequent service: Units installed in commercial/public spaces should be serviced every 3 months (quarterly). Units installed in climates near the ocean or in other settings where corrosion buildup is more likely should be serviced every 6 months (semi-annual service) Thermocouple Maintenance...

  • Page 134: Ortal Factory Recommended Service Checklist

    Model Type: Serial #: Date: Before, during and after service, if there is any doubt, stop and call ORTAL. If there is any NO answer, close the gas valve and correct. If you cannot correct, discontinue operation, lockout unit and call ORTAL.

  • Page 135: Ortal Product Service Log

    ORTAL Product Service Log...

  • Page 136: Manufacturer Contact Information

    Manufacturer Contact Information For all service issues, please contact your local dealer.

  • Page 137: Appendix A: Fireplace Troubleshooting Guide

    Appendix A: Fireplace Troubleshooting Guide This appendix provides information and guidelines for troubleshooting, including: Pre-troubleshooting Checklist on page 108 Normal Sequence of Fireplace Operation on page 110 Troubleshooting Pilot Problems on page 111 Troubleshooting Thermocouple Problems on page 113 Troubleshooting Main Burner Problems on page 114 Troubleshooting Beeping on page 116 Mertix Maxitrol External Source Operation on page 118...

  • Page 138: Pre-Troubleshooting Checklist

    Pre-troubleshooting Checklist Before you begin troubleshooting, perform these steps: 1. Check the batteries and 6V transformer connection. 2. Verify that the switch on the valve is on. Figure 27: On/Off and Manual Pilot Valve Switches 3. Verify that the gas is on. 4.
  • Page 139 5. Using the purge port, check the pressure of inlet/ supply (see figure above). Inlet pressure for NG should be 7 WC 6. Verify that the valve and receiver wires are properly connected and tight, and that the interrupter block is tight (hand-tight plus ¼ turn). Figure 28: Valve/Receiver Wires and Interrupter Block 7.

  • Page 140: Normal Sequence Of Fireplace Operation

    Turn the fireplace on by pressing the Off and Flame Up buttons simultaneously (buttons 1 and 2 in the figure below). Figure 29: ORTAL Remote Control Once the fireplace is turned on, the following sequence of events will occur: 1. The system checks itself for any trouble. This is accompanied by sequential beeps.

  • Page 141: Troubleshooting Pilot Problems

    If the spark is strong and jumping, proceed to the next step. 8. If the problem is not resolved, replace the spark plug. Call ORTAL if a spark plug is needed. Pilot Turns Off After Igniting But Before Burner Turns On...

  • Page 142: Pilot Turns Off After Igniting And After Burner Turns On

    5. Make sure the pilot assembly and the pilot hood screw are tight and that there is a gasket. Whenever the pilot assembly is disturbed, replace the gasket. 6. If the problem is not resolved, call ORTAL. Pilot Turns Off After Igniting and After Burner Turns On 1.

  • Page 143: Troubleshooting Thermocouple Problems

    5. If the problem is not resolved, the thermocouple should be replaced. Complete a part claim/replacement form and call ORTAL for replacement.

  • Page 144: Troubleshooting Main Burner Problems

    Troubleshooting Main Burner Problems The tables below provide instructions for troubleshooting issues related to the main burner and the flame. Problem Possible Causes Recommended Actions Main burner does not turn Manual pilot valve Verify that the manual pilot valve operation is in on.

  • Page 145: Troubleshooting Flame Issues

    Troubleshooting Flame Issues Problem Possible Causes Recommended Actions Too much CO in the Review the flue run. If the size of the restrictor There is a faint or blue fireplace, due to CO in the unit is incorrect, replace it with the flame.

  • Page 146: Troubleshooting Beeping

    Troubleshooting Beeping...

  • Page 148: Mertix Maxitrol External Source Operation

    Mertix Maxitrol External Source Operation The following figure is taken from the Mertix Maxitrol guide.

  • Page 149: Appendix B: Removal / Assembly Of The Burner

    Appendix B: Removal / Assembly of the Burner The procedure below shows how to remove the burner. To re-install, perform the steps in the opposite order. WARNING: Before starting this procedure, make sure to disconnect the main gas supply to the unit. Figure 30: Burner Components...
  • Page 150 To remove the burner: 1. Remove the front heat barrier and glass. For details, refer to Fireplace Heat Barrier on page 74. 2. Remove the grill screws and take the grill out. 3. Disconnect the pilot by removing the two screws holding it. NOTE: It is recommended to cover the work area with a blanket.
  • Page 151 4. Disconnect and remove the burner: Remove the four burner screws. Lift the burner and pull it out of the fireplace. Attach wrenches (15 and 17) as shown in the figure below. Then, hold wrench (17) and rotate wrench (15) until the gas pipe releases from the burner.

  • Page 152: Appendix C: Removal / Assembly Of The Burner Base

    Appendix C: Removal / Assembly of the Burner Base The procedure below shows how to remove the burner base. To re-install it, perform the steps in the opposite order. WARNING: Before starting this procedure, make sure to disconnect the main gas supply to the unit. Figure 31: Burner Base Components...
  • Page 153 To remove the burner base: 1. Remove the heat barrier and glass. For details, refer to Fireplace Heat Barrier on page 74. 2. Remove the back panel holders (as needed) by removing the screws holding them. 3. Remove the burner base: Remove the screws holding the base.
  • Page 154 Pull the base until it releases. Tilt the base as shown in the figure below.
  • Page 155 Pull the base out, as shown.
  • Page 156 © Ortal 2018 Rev. 3.0 October 2018 KPMANUALAUAGA...

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