Flavel Calypso Installation, Maintenance & User Instructions
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Flavel Calypso Installation, Maintenance & User Instructions

Inset live fuel-effect gas fires
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Kenilworth, Linear,
Caress, Calypso,
Rhapsody,
Opulence &
Expression "Plus"
INSET LIVE FUEL-EFFECT GAS FIRES
Installation, Maintenance & User Instructions.
Hand these instructions to the user after installation.
Model No's FKPC**MN, FKPC**SN, FKPC**TN2 & FKPC**RN2 are for
use on Natural Gas (G20) at a supply pressure of 20 mbar in G.B. /
I.E.
** denotes variant of trim / fascia where applicable

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  • Page 1 Kenilworth, Linear, Caress, Calypso, Rhapsody, Opulence & Expression “Plus” INSET LIVE FUEL-EFFECT GAS FIRES Installation, Maintenance & User Instructions. Hand these instructions to the user after installation. Model No’s FKPC**MN, FKPC**SN, FKPC**TN2 & FKPC**RN2 are for use on Natural Gas (G20) at a supply pressure of 20 mbar in G.B. / I.E.

  • Page 2: Table Of Contents

    CONTENTS PAGE Section 1 Information and Requirements PAGE Appliance Information Conditions of Installation Flue and chimney suitability Fireplace / surround suitability Shelf position Chimney inspection Fire place opening / catchment space Fitting to metal flue boxes Hearths Pre-cast flue installations 1.10 Spillage monitoring system Section 2...

  • Page 3: Information And Requirements

    SECTION 1 INFORMATION AND REQUIREMENTS APPLIANCE INFORMATION Model FKPC**MN (MC) FKPC**RN2 (RC) FKPC**SN (SC) FKPC**TN2 (EFC) Gas Type Main injectors (2 off) Size 260 Size 280 Pilot Type Copreci ERTA OXYP 21100 / 141 (MC) PG-83-10 21100 / 162 (SC) (RC &...
  • Page 4 Fire box Dimensions Width : (with trim, no spacer) 498mm Height : (with trim, no spacer) 600mm Depth : (overall-without fender) 170mm Gas Connection 8mm Compression (Supplied with fire) Efficiency Declaration The efficiency of this appliance has been measured as specified in BS 7977-1 : 2009 and the result is 63%.

  • Page 5: Conditions Of Installation

    INSTALLATION REQUIREMENTS CONDITIONS OF INSTALLATION It is the law that all gas appliances are installed only by a GAS SAFE Registered Installer, in accordance with these installation instructions and the Gas Safety (Installation and Use) Regulations 1998 as amended. Failure to install appliances correctly could lead to prosecution.

  • Page 6: Fireplace / Surround Suitability

    FIREPLACE / SURROUND SUITABILITY The fire must only be installed on a hearth it must not be installed directly onto carpet or other combustible floor materials. The fire is suitable for fitting to non-combustible fire place surrounds and proprietary fire place surrounds with a temperature rating of at least 150 o c. If a heating appliance is fitted directly against a wall without the use of a fire surround or fire place all combustible material must be removed from behind the trim.

  • Page 7: Fire Place Opening / Catchment Space

    Check the chimney pot / terminal and general condition of the brickwork or masonry. If the chimney or flue is in poor condition or if there is no up-draught do not proceed with the installation. If there is a history of down-draught conditions with the chimney / flue, a tested and certificated flue terminal or cowl suitable for the relevant flue type should be considered.

  • Page 8: Fitting To Metal Flue Boxes

    120mm if the black 50mm spacer frame is used. This spacer frame can be purchased from Flavel Fires as an optional extra. This appliance is suitable for use in fireplaces fitted with an existing chairbrick without the need for removal of the chairbrick, providing the minimum depth of the fireplace exceeds 260mm.

  • Page 9: Hearths

    If in doubt about the suitability of the fire contact Flavel Fires for advice before proceeding. This fire has been designed to fit standard 100mm pre-cast starter blocks with 3 inch rebated surrounds.

  • Page 10: Installation Of Fire

    Fire box / burner assembly 1 off Boxed ceramic base, front ceramic rail and 18 coals (16 large, 2 small) - Kenilworth, Caress, Rhapsody & Calypso models only 1 off Boxed ceramic base, front ceramic rail and 18 pebbles (16 large, 2...
  • Page 11 For manual control models proceed as follows :- 2.2.1 Remove the burner heat shield from the front of the fire box to allow access to the burner. See figure 3 below. Fig. 3 2.2.2 Ensure that the hearth is protected from damage and carefully lift the fire box into the fire opening, then slide it back into position.
  • Page 12 For slide control models proceed as follows: 2.2.4 Remove the burner heat shield from the front of the fire box to allow access to the burner. See figure 5 below. Fig. 5 2.2.5 Ensure that the hearth is protected from damage and carefully lift the fire box into the fire opening, then slide it back into position.
  • Page 13 Fig. 6 2.2.7 Unscrew the burner assembly fixing screws at either side of the firebox, and the two fixing screws at the base of the fire (see figure 7 below). Carefully pull the base of the burner forwards. The burner can now be removed from the appliance.
  • Page 14 For remote & electronic fire control models proceed as follows: 2.2.8 Remove the trim. Remove the burner heat shield from the front of the fire box to allow access to the burner. See figure 8 below. Fig. 8 2.2.9 Ensure that the hearth is protected from damage and carefully lift the fire box into the fire opening, then slide it back into position.
  • Page 15 Continue for all models Whilst the fire box is still in position, decide which side the gas supply is to enter the fire from. If concealed pipe work is required plan the pipe run to enter the fire box through one of the openings in the sides of the fire box below the fuelbed support panel and connect to the isolating / inlet elbow.
  • Page 16 The preferred method of fixing which is suitable for almost all situations is the cable fixing method which is described in the following section in detail. To fit using the preferred cable method proceed as follows- 2.2.11 Mark out and drill 4 off No 14 (6mm) holes in the back face of the fire opening in the positions shown below in figure 12 Fig.
  • Page 17 Fig. 13 2.2.16 Evenly tighten the tensioning nuts to tension both cables and pull the fire snugly against the wall. Do not overtighten, it is only necessary to pull the seal up against the sealing face of the wall, it does not need to be compressed.

  • Page 18: Gas Tightness And Inlet Pressure (Manual Control Models)

    2.2.20 Before making the final gas connection, thoroughly purge the gas supply pipework to remove all foreign matter, otherwise serious damage may be caused to the gas control valve on the fire. GAS TIGHTNESS AND INLET PRESSURE - MANUAL CONTROL MODELS.

  • Page 19: Gas Tightness And Inlet Pressure (Remote / Electronic Fire Control Models)

    GAS TIGHTNESS AND INLET PRESSURE - REMOTE CONTROL OR ELECTRONIC FIRE CONTROL MODELS 2.5.1 Remove the pressure test point screw from the inlet elbow and fit a manometer. 2.5.2 Turn on the main gas supply and carry out a gas tightness test. 2.5.3 Light the fire, see page 29 to 34 for full details of the operating method for the fire.

  • Page 20: Assembling Fuel Bed And Commissioning

    SECTION 3 ASSEMBLING FUEL BED AND COMMISSIONING ASSEMBLING THE CERAMICS AND FUEL BED - COAL MODELS 3.1.1 Place the ribbed ceramic fuelbed base on top of the fuelbed support and pull fully forwards to the burner. Make sure that the fuelbed base is located centrally in the fire box.
  • Page 21 3.1.3 Fit five of the large sized coals onto the front ceramic rail, ensuring that they are evenly spaced. Use the recess’s in the front ceramic rail as a guide for placement. (See figure 16 below) Fig. 16 3.1.4 Select four of the large coals and arrange behind the front row of coals, ensuring that flame paths as indicated below are not interupted.
  • Page 22 3.1.5 Select three of the large coals and arrange along the rear of the fuelbed, using the ribs in the rear of the fuelbed as a guide for placement. (See figure 18 below) Fig. 18 3.1.6 Select two small coals and position to fill the gaps at each end of the third row of coals, as shown.
  • Page 23 3.1.7 Select the remaining four large coals and position on the rear of the fuel-bed matrix. (See figure 20 below). Fig. 20 The exact position and fit of the coals may be finely adjusted to give the most pleasing and random appearance. Warning : Use only the coals supplied with the fire.
  • Page 24 ASSEMBLING THE CERAMICS AND FUEL BED - LINEAR MODELS 3.2.1 Place the ribbed ceramic fuelbed base on top of the fuelbed support and pull fully forwards to the burner. Make sure that the fuelbed base is located centrally in the fire box. Ensure that the fuelbed base fit fully down onto the fuel bed support and is not lodged on the burner.
  • Page 25 3.2.3 Pick pebbles A to E and arrange along the the front rail, ensuring that they are evenly spaced. Use the recess’s in the front ceramic rail as a guide for placement. (See figure 23 below). Fig. 23 Pebble C Pebble D Pebble E Pebble A...
  • Page 26 3.2.5 Select pebbles K, L & M and arrange along the rear of the fuelbed, using the ribs in the rear of the fuelbed as a guide for placement. Select the two small pebbles (J & N) and position to fill the gaps at each end of the third row of pebbles (See figure 25 below).

  • Page 27: Lighting The Appliance (Manual Control Models)

    LIGHTING THE APPLIANCE - MANUAL CONTROL MODELS 3.3.1 Turn on the gas isolation tap. 3.3.2 Depress the control knob and turn anti-clockwise to the position marked pilot. Hold in the control knob for a few seconds to purge the pipe work. 3.3.3 Continue to hold-in the control knob and press the igniter button.

  • Page 28: Lighting The Appliance (Slide Control Models)

    LIGHTING THE APPLIANCE - SLIDE CONTROL MODELS 3.4.1 Turn on the isolation valve. Depress the control lever fully downwards to the position marked. Hold down the control lever for a few seconds to allow the gas to reach the pilot. 3.4.2 The fire will then begin its ignition sequence.

  • Page 29: Fitting The Batteries (Remote & Efc Models)

    FITTING THE BATTERIES - REMOTE CONTROL & ELECTRONIC FIRE CONTROL MODELS 3.5.1 The control valve is located at the base of the fire as shown below in figure 26. Fig. 26 Position of battery cover on control valve 3.5.2 Remove the battery compartment cover from the control valve as indicated below in figure 27 and fit the 3 off AA sized batteries to the control valve unit.

  • Page 30: Manually Lighting Remote Or Efc Models

    3.5.4 On remote control models fit two off AA batteries to the handset in the direction shown inside the handset moulded into the plastic. 3.5.5 For Remote control model operation please see section 3.7 3.5.6 For Electronic fire control operation please see section 3.8 LIGHTING THE FIRE MANUALLY VIA THE CONTROL VALVE 3.6.1 These products can be operated manually by using the buttons directly...
  • Page 31 LIGHTING THE FIRE - REMOTE CONTROL MODELS 3.7.1 Ensure valve power isolation switch is in the on position - see figure 27 Hold the handset with one hand ensuring your hand is wrapped around the back and that your hand is in contact with both sides of the handset.

  • Page 32: Lighting The Appliance (Remote Control Models)

    LIGHTING THE APPLIANCE - REMOTE CONTROL MODELS (CONTINUED) 3.7.3 To decrease the heat input level of the burner hold the handset as described in section 3.7.1 to unlock the keypad then press and release the - button. Pressing and releasing the - button will lower the heat input level one step at a time.

  • Page 33: Lighting The Appliance (Electronic Fire Control Models)

    LIGHTING THE APPLIANCE - ELECTRONIC FIRE CONTROL MODELS. 3.8.1 To light the fire using the EFC switch press and hold the power button continuously until the red light illuminates next to the operation symbol (this typically takes two seconds). As the red light illuminates release immediately the power button.
  • Page 34 3.8.5 If you are not intending to use the fire for a long period (i.e. over the summer months) the battery life can be extended by sliding the power isolator switch to the left (to the “0” position away from the “1” position) on the valve itself, which is located behind the ashpan cover on the fire.

  • Page 35: Checking For Clearance Of Combustion Products

    CHECKING FOR CLEARANCE OF COMBUSTION PRODUCTS 3.9.1 Close all doors and windows in the room. 3.9.2 Light the fire and allow to run for approximately 5 minutes on high position. 3.9.3 After approximately 5 minutes hold a smoke match 10mm inside and below the centre of the lower front edge of the top of the fire as shown overpage in figure 32.
  • Page 36 3.9.6 After ensuring that the fire is safe to use it should be left in the high position to fully warm up. During this time a slight odour may be noticed, this is due to the “newness” of the fire and will soon disappear. At this stage any minor adjustments to the coals should be made using suitable long handled tongs and taking care not to damage the coals.

  • Page 37: 13 Fitting Of Trims / Frets / Fascia's As Applicable

    3.10 FITTING THE TRIM (RHAPSODY / CALYPSO MODELS) 3.10.1 Refitting the trim is achieved by locating the rear flange of the trim over the flange on the firebox mounting face at the top and each side. 3.11 FITTING THE TRIM OR FASCIA (KENILWORTH / LINEAR / OPULENCE / EXPRESSSION MODELS) 3.11.1...
  • Page 38 3.13 TO FIT THE FENDER (RHAPSODY & CARESS CONTEMORARY MODELS) 3.13.1 Attach L/H & R/H Brackets to fender with M6 pozi screws which locate onto the burner heat shield at in front of the burner assembly. See figure 35, 36 & 37 below and overpage. Fig.

  • Page 39: Maintenance

    Servicing Notes Servicing should be carried out annually by a competent person such as a GAS SAFE registered engineer. This is a condition of the Flavel guarantee schemes. The service should include visually checking the chimney and fire opening for accumulations of debris and a smoke test to check for a positive up-draught in the chimney.

  • Page 40: Removal Of The Control Tap (Manual Control Models)

    Removing the Control Tap from the fire. 4.3.1 Remove the burner assembly as in section 4.1. 4.3.2 Pull the control knob off the control tap spindle. 4.3.3 Loosen and remove the three gas pipe retaining nuts from the control tap and release the ends of the gas pipes from the control tap body. Loosen and remove the thermocouple securing nut from the end of the control tap.

  • Page 41: Removal Of The Battery Igniter (Slide Control Models)

    4.5.3 Isolate the gas supply and remove the inlet pipe from the appliance inlet elbow. The control lever operating cable can be seen running across the base of the fire, below the burner. To release the cable, unscrew the cable securing screw located in the centre of the aluminium operating arm and release the front part of the operating arm, thereby freeing the cable from the burner (see figure 27 overpage).

  • Page 42: Removing The Oxy-Pilot Assembly (Slide Control Models)

    Removing the Oxy-Pilot Assembly Note: Because this appliance is fitted with an atmosphere sensing ‘Oxy- Pilot’ it is not possible to replace the thermocouple separately, because the thermocouple position is factory set to a tight tolerance. Any replacement of parts on the pilot requires a complete new pilot assembly. 4.8.1 Remove the burner assembly as in section 4.1 4.8.2...

  • Page 43: Removal Of The Burner Assembly (Remote & Electronic Fire Control Models)

    4.9.3 To fit the replacement cable, thread the end of the new cable into the long length of p.t.f.e. sleeve (as supplied) , taking care not to kink the sleeve. Now carefully feed the sleeve and cable into the left hand cable guide tube until the ends emerge above the control lever.
  • Page 44 Remote & Electronic Fire Control Models – For Diagrams refer to Section 2 4.10 Removing the burner assembly from the fire. 4.10.1 Prepare work area (lay down dust sheets etc.) 4.10.2 Lift the fender and ash pan cover of the way and put them in a safe location.

  • Page 45: Replacing The Batteries (Remote & Electronic Fire Control Models)

    4.12.4 Re-assemble in reverse order and carry out a gas tightness test. Re-fit coals as shown in section 3. The fender and ash pan cover or fascia can now be re-positioned. 4.13 Replacing the Batteries (Within the Firebox) 4.13.1 Remove the fender and ashpan assembly The battery holder is located on the valve at the right hand side of the burner.

  • Page 46: Part Shortlist / Fret Information

    PARTS SHORTLIST Replacement of parts must be carried out by a competent person such as a GAS SAFE registered gas installer. The part numbers of the replaceable parts are as follows, these are available from BFM Europe who may be contacted at the address shown on the rear cover.

  • Page 47: Conditions Of Installation & About Your New Fire

    SECTION FIVE - USER INSTRUCTIONS 5.1 INSTALLATION INFORMATION CONDITIONS OF INSTALLATION It is the law that all gas appliances are installed only by a competent (e.g. GAS SAFE registered) Installer, in accordance with the installation instructions and the Gas Safety (Installation and Use) Regulations 1998. Failure to install appliances correctly could lead to prosecution.
  • Page 48 ABOUT YOUR NEW FLAVEL GAS FIRE The Flavel Kenilworth, Linear, Caress, Calypso, Rhapsody, Opulence & Expression Plus fuel effect gas fires incorporates a unique and highly developed fuel bed which gives the realism of a loose coal / pebble layout combined with realistic flames and glow.

  • Page 49: 5.2 Operating The Fire - Manual Control Models

    5.2 OPERATING THE FIRE - MANUAL CONTROL MODELS The controls are located behind the ashpan cover which is situated behind the Ashpan / Fender. The controls, comprise a control valve to adjust the gas flow and a push button piezo igniter. To light the fire proceed as follows:- 5.2.1 Depress the control knob and turn anti-clockwise to the position marked pilot.

  • Page 50: 5.3 Operating The Fire - Slide Control Models

    5.3 OPERATING THE FIRE - SLIDE CONTROL MODELS The controls comprise a control lever, to turn the fire on and off and adjust the gas rate. The control lever is located at the top right hand side of the fire. Depressing the control lever fully operates the igniter and lights the pilot flame and ignition rate gas.
  • Page 51 WARNING : If the fire goes out for any reason or is turned off and it is necessary to re-light the fire it is important to allow the fire to cool for 3 minutes before attempting to re-light it.

  • Page 52: Operating The Fire (Remote Control Models)

    OPERATING THE FIRE - REMOTE CONTROL MODELS 5.4.1 The controls comprise a remote handset, to turn the fire on and off and adjust the gas rate. Ensure valve power isolation switch is in the on position - see figure 4. Hold the handset with one hand ensuring your hand is wrapped around the back and that your hand is in contact with both sides of the handset.
  • Page 53 OPERATING THE FIRE - REMOTE CONTROL MODELS (CONTINUED) 5.4.3 To decrease the heat input level of the burner hold the handset as described in section 5.4.1 to unlock the keypad then press the and release the - button. Pressing and releasing the - button will lower the heat input level one step at a time.

  • Page 54: Operating The Fire (Electronic Fire Control Models)

    OPERATING THE FIRE - ELECTRONIC FIRE CONTROL MODELS. 5.5.1 To light the fire using the EFC switch press and hold the power button continuously until the red light illuminates next to the operation symbol (this typically takes two seconds). As the red light illuminates release immediately the power button.
  • Page 55 LIGHTING THE APPLIANCE - ELECTRONIC FIRE CONTROL MODELS (CONTINUED) 5.5.3 To increase the heat input level of the fire’s burner pressing and releasing the + button will increase the heat input level one step at a time. Pressing the + button continuously will move the heat input level to the maximum.

  • Page 56: Manually Operation Of Remote Or Efc Models

    MANUAL OPERATION OF REMOTE CONTROL & ELECTRONIC FIRE CONTROL MODELS 5.6.1 These products can therefore be operated manually should the need arise. The control valve is located at the base of the fire as shown below in figure 3. Fig. 3 Position of control valve 5.6.2...

  • Page 57: 5.8 Replacing The Batteries In Slide And Remote / Electronic Fire Control Models

    5.6.3 To operate the fire press and hold the “power” button as shown in figure 2 on the previous page for two seconds, release as soon as the red indicator light in figure 4 on the previous page illuminates. The burner will start its ignition sequence and light to the maximum heat input level.

  • Page 58: 5.10 Spillage Monitoring System/ Cleaning Instructions

    5.9 SPILLAGE MONITORING SYSTEM All models regardless of control type are fitted with a spillage monitoring system which shuts down the fire if the evacuation of combustion products from the fire is affected by a partially or fully blocked flue. If this system operates the fire will go out.

  • Page 59: Re-Assembling The Ceramics And Fuel Bed (Coal/Pebble Variants)

    5.11 ASSEMBLING FUEL BED & CERAMICS - COAL MODELS 5.11.1 Place the ribbed ceramic fuelbed base on top of the fuelbed support and pull fully forwards to the burner. Make sure that the fuelbed base is located centrally in the fire box. Ensure that the fuelbed base fit fully down onto the fuel bed support and is not lodged on the burner.
  • Page 60 5.11.3 Fit five of the large sized coals onto the front ceramic rail, ensuring that they are evenly spaced. Use the recess’s in the front ceramic rail as a guide for placement. (See figure 7 below) Fig. 7 5.11.4 Select four of the large coals and arrange behind the front row of coals, ensuring that flame paths as indicated below are not interupted.
  • Page 61 5.11.5 Select three of the large coals and arrange along the rear of the fuelbed, using the ribs in the rear of the fuelbed as a guide for placement. (See figure 9 below) Fig. 9 5.11.6 Select two small coals and position to fill the gaps at each end of the third row of coals, as shown.
  • Page 62 5.11.7 Select the remaining four large coals and position on the rear of the fuel-bed matrix. (See figure 11 below). Fig. 11 The exact position and fit of the coals may be finely adjusted to give the most pleasing and random appearance. Warning : Use only the coals supplied with the fire.
  • Page 63 5.12 ASSEMBLING THE CERAMICS AND FUEL BED - PEBBLE MODELS 5.12.1 Place the ribbed ceramic fuelbed base on top of the fuelbed support and pull fully forwards to the burner. Make sure that the fuelbed base is located centrally in the fire box. Ensure that the fuelbed base fit fully down onto the fuel bed support and is not lodged on the burner.
  • Page 64 5.12.3 Pick pebbles A to E and arrange along the the front rail, ensuring that they are evenly spaced. Use the recess’s in the front ceramic rail as a guide for placement. (See figure 14 below). Fig. 14 Pebble C Pebble D Pebble E Pebble A...
  • Page 65 5.12.5 Select pebbles K, L & M and arrange along the rear of the fuelbed, using the ribs in the rear of the fuelbed as a guide for placement. Select the two small pebbles (J & N) and position to fill the gaps at each end of the third row of pebbles (See figure 16 below).
  • Page 66 USER REPLACEABLE PARTS The only user replaceable parts on this fire are the fuelbed components and coals / pebbles which may be replaced as described in the above section. Replacement of any other parts must be carried out by a competent person such as a GAS SAFE registered gas installer.
  • Page 67 Due to our policy of continual improvement and development the exact accuracy of illustrations and descriptions contained in this book cannot be guaranteed. TROUBLE SHOOTING ADVICE FOR REMOTE CONTROL & ELECTRONIC FIRE CONTROL MODELS PRIOR TO REQUESTING A SERVICE CALL Please locate the Indicator light on the control valve behind the ashpan cover (see figure 4 on page 56), if it shows any of the following flashing sequences then the problem requires the batteries in the control valve and / or handset changing, be advised that...

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