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Flavel Castelle Installation, Maintenance And User Instructions

Flavel castelle inset fuel effect gas fireplace
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Castelle
INSET FUEL EFFECT GAS FIRE
Installation, Maintenance & User Instructions
Hand these instructions to the user following installation
Model No's FPCL**RN is only for use on Natural Gas (G20) at a
supply pressure of 20 mbar in G.B. / I.E.
** denotes colour variant

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Summary of Contents for Flavel Castelle

  • Page 1 Castelle INSET FUEL EFFECT GAS FIRE Installation, Maintenance & User Instructions Hand these instructions to the user following installation Model No’s FPCL**RN is only for use on Natural Gas (G20) at a supply pressure of 20 mbar in G.B. / I.E.

  • Page 2: Table Of Contents

    CONTENTS 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 chair bricks Precast flues Metal flue boxes 1.10 Wall / hearth mounting 1.11 Spillage monitoring system...

  • Page 3: Information And Requirements

    SECTION 1 INFORMATION AND REQUIREMENTS APPLIANCE INFORMATION Model FPCL**RN Gas Type Main injector (1 off) Size 1.65mm Pilot Type S.I.T. Oxystop YA OP 9061 Max. Gross Heat Input : 5.0kW Min. Gross Heat Input : 2.8kW Cold Pressure : 20.0 +/-1.0 mbar Ignition : 6V Battery Generator Electrode Spark Gap...

  • Page 4: 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 5: Fireplace / Surround Suitability

    FIREPLACE / SURROUND SUITABILITY The fire must not be installed directly onto carpet or other combustible floor materials. See page 9 for further details regarding hearth panels. 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 6: Fire Place Opening / Catchment Space

    There must be no leakage of smoke through the structure of the chimney during or after the smoke pellet test and it is important to check inside upstairs rooms adjacent to the chimney / flue. Check the chimney pot / terminal and general condition of the brickwork or masonry.
  • Page 7 Table A - Installation Depth Requirements for a Flavel Castelle being installed into a brick built chimney, requiring 12.0 litres of debris collection volume (figure 2). The chimney requires a minimum of 50mm clearance when measured from the mouting face of the fire behind the firebox to accomodate 12.0 litres of debris collection.

  • Page 8: Fitting To Chair Bricks

    FITTING TO PRE-CAST FLUE INSTALLATIONS To install the fire box in to pre-cast flue starter blocks, there must be at least 100mm from the mounting face of the fire to the rear of the pre-cast flue starter block to allow sufficient space for debris collection. It is important to consider this depth if choosing a fire surround as the thickness of the fire surround must be sufficient to give a total depth of at least 100mm to the rear of the starter block, otherwise there will be insufficient depth.

  • Page 9: Wall / Hearth Mounting

    1.10 WALL / HEARTH MOUNTING This appliance must be fitted on a flat, non-combustible base of minimum thickness 12mm. In addition, a non-combustible hearth or physical barrier should be provided in front of the fire. With “hole in the wall” type installations, where it may be desirable not to fit a hearth panel or physical barrier, the product may be installed in accordance with Document J of the building regulations so that every part of theflame or incandescent material is at least 225mm above the floor level.

  • Page 10: Spillage Monitoring System

    1.11 SPILLAGE MONITORING SYSTEM This appliance is fitted with an atmosphere sensing spillage monitoring system in the form of an oxygen sensing pilot. This is designed to shut the fire off in the event of a partial or complete blockage of the flue causing a build up of combustion products in the room in which the fire is operated.

  • Page 11: Installation Of Fire

    SECTION 2 INSTALLATION OF FIRE UNPACKING THE FIRE Carefully lift the fire out of the carton. Remove the loose item packaging carefully from the front of the appliance. Check the contents as listed :- Packing Check List 1 off Fire box / burner assembly 1 off Boxed ceramic log set (boxed inside combustion chamber) 1 off...

  • Page 12: Preparation Of Firebox Opening

    PREPARATION OF THE FIREBOX OPENING 2.3.1. If installing the product into a hole in the wall type installation, create an opening as shown in figure 4 below. If installing into a conventional opening with a hearth panel, create an opening as shown in figure 5 below.
  • Page 13 2.3.2 Remove the firebox / burner assembly from the packaging. Remove the fuel-bed set from the combustion chamber and store in a safe location. Remove the firebox mounting plate from the rear face of the firebox assembly by unscrewing the 4 off M5 retaining screws as shown below in figure 6.
  • Page 14 2.3.4 The firebox mounting plate should then be secured to the fireplace opening as created in section 2.3, via the mounting holes as indicated below in figure 7. Fig. 7 430mm 500mm 12mm Base Centre Hole Only 25mm 215mm 25mm 305mm 610mm 2.3.5...
  • Page 15 2.3.7 Remove the 6 off screws to remove the burner gauze, then 4 off screws to remove the ceramic support and finally 4 off burner mounting screws as shown below in figure 8, then lift the burner unit clear of the firebox. Fig.
  • Page 16 Continue for all models 2.3.9 Decide which side the gas supply is to enter the fire from. Plan the pipe run to enter the fire box through one of the openings in the sides or rear of the fire box below the fuelbed support panel and connect to the isolating / inlet elbow.

  • Page 17: Gas Tightness And Burner Pressure

    2.3.11 With the fire securely in place, if a concealed gas connection has been made through the access holes in the rear of the fire, the holes should be closed around the pipe with the grommet supplied to prevent leakage of air through the gap around the pipe, failure to do may lead to flame reversal, which will invalidate the guarantee.

  • Page 18: Assembling Fuel Bed And Commissioning

    SECTION 3 ASSEMBLING FUEL BED AND COMMISSIONING NOTE : The position of the fuel-bed components are critical to the performance of the product. Therefore please ensure that the fuel-bed components are positioned as described in the following section prior to requesting a service call due to soot build up, poor flame pattern etc.
  • Page 19 3.1.3 Place a single layer of bark chippings over the burner as shown below in figure 13. Fig. 13 3.1.4 Fit the rear base log as shown below in figure 14. Fig. 14 Rear log...
  • Page 20 3.1.5 Fit log A as shown below in figure 15, onto the rear log. Fig. 15 Log A 3.1.6 Fit log B as shown below in figure 16, onto the rear log. Fig. 16 Log B...
  • Page 21 3.1.7 Fit log C as shown below in figure 17 onto the rear log. Fig. 17 Log C 3.1.8 Fit Log D as shown below in figure 18, using the cut-out in Log C as a guide for placement. Fig. 18 Log D...
  • Page 22 3.1.9 Fit Log E as shown below in figure 19, using the cut-out’s in Log D and Log A as a guide for placement. Fig. 19 Log E Warning : Use only the logs supplied with the fire. When replacing the logs remove the old logs and discard them.

  • Page 23: Fitting The Fascia

    FITTING THE FASCIA 3.2.1 Fit the fascia as shown below in figure 20, and secure with 2 off screws per side. Ensure the top edge of the fascia has hooked over the top edge of the firebox. Fig. 20 2 off securing screws per side 3.2.2 Fit the draught diverter cover (as supplied in the loose items pack) as...

  • Page 24: Lighting The Appliance

    LIGHTING THE APPLIANCE 3.3.1 The control valve is positioned below the burner unit when viewed from the front. 3.3.2 To operate the appliance automatically via the remote control handset, ensure that the on / off switch is switched to the “on” position as shown below in figure 21.
  • Page 25 Fig. 22 “LED” handset light “UP” button “DOWN” / “STANDBY” “STAR” / “OFF” button button 3.3.7 To reduce the heat input, press the “DOWN / STANDBY” button until the flame reduces to the low rate heat input setting. “DOWN” arrow on the handset.

  • Page 26: Checking For Clearance Of Combustion

    CHECKING FOR CLEARANCE OF COMBUSTION PRODUCTS 3.4.1 Close all doors and windows in the room. 3.4.2 Light the fire and allow to run for approximately 5 minutes on high position. 3.4.3 After approximately 5 minutes hold a smoke match 20mm inside the draught diverter aperture at the centre as shown below in figure 23.

  • Page 27: Removal & Re-Fitting The Draught Diverter Cover

    REMOVAL & RE-FITTING THE DRAUGHT DIVERTER COVER 3.5.1 The draught diverter cover plate is supplied in the loose items pack. 3.5.2 Position in the glass fascia assembly as shown below in figure 24. Fig. 24 Draught diverter cover...

  • Page 28: Removal & Re-Fitting The Flue Restrictor Baffle

    REMOVAL / RE-FITTING OF THE FLUE RESTRICTOR BAFFLE 3.6.1 The flue restrictor baffle is supplied in the loose items pack. When installing into 125mm (5 inch) diameter lined brick or stone flue, or insulated pre-fabricated metal flue box to BS 715 / BS EN 1856-2 and pre-cast flues the restrictor baffle must not be fitted.

  • Page 29: Maintenance

    Servicing should be carried out annually by a competent person such as a GAS SAFE registered engineer and must include an annual Oxy-pilot change. This is a condition of the Flavel Fires 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 30: Removal Of The Pilot Assembly

    4.2.3 Disconnect pilot, main and injector pipes and disconnect the wiring loom thermocouple and ignition wire, the valve can then be removed. Re-assemble in reverse order, refit the fuel-bed referring to section 3.1 for the correct coal layout. The fascia can now be replaced, see section 3.2 for diagram.

  • Page 31: Parts Shortist

    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 Ltd. who may be contacted at the address shown below.

  • Page 32: 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 33 ABOUT YOUR NEW FLAVEL CASTELLE The Flavel Castelle log effect gas fire incorporates a unique and highly developed fuel bed which gives the realism of a loose log layout combined with realistic flames and glow. The use of durable ceramic material in the construction of the fuelbed components ensures long and trouble free operation.

  • Page 34: Operating The Fire

    OPERATING THE FIRE - REMOTE CONTROL VARIANTS 5.2.1 Open the controls access door. The control valve is positioned in the centre of the fire when viewed from the front. 5.2.2 To operate the appliance automatically via the remote control handset, ensure that the on / off switch is switched to the “on”...

  • Page 35: Spillage Monitoring System

    Fig. 2 “LED” handset light “UP” button “DOWN” / “STANDBY” “STAR” / “OFF” button button 5.2.7 To reduce the heat input, press the “DOWN / STANDBY” button until the flame reduces to the low rate heat input setting. “DOWN” arrow on the handset.

  • Page 36: Re-Assembling The Fuel-Bed

    ASSEMBLING THE CERAMICS AND FUEL BED 5.4.1 Place the fuel-bed front ceramic fibre as shown below in figure 1. Fig. 1 Front ceramic fibre 5.4.2 Place the left hand and right hand front ceramic fibre pieces as shown below in figure 2. Fig.
  • Page 37 5.4.3 Place a single layer of bark chippings over the burner as shown below in figure 3. Fig. 3 5.4.4 Fit the rear base log as shown below in figure 4. Fig. 4 Rear log...
  • Page 38 5.4.5 Fit log A as shown below in figure 5, onto the rear log. Fig. 5 Log A 5.4.6 Fit log B as shown below in figure 6, onto the rear log. Fig. 6 Log B...
  • Page 39 5.4.7 Fit log C as shown below in figure 7 onto the rear log. Fig. 7 Log C 5.4.8 Fit Log D as shown below in figure 8, using the cut-out in Log C as a guide for placement. Fig. 8 Log D...
  • Page 40 5.4.9 Fit Log E as shown below in figure 9, using the cut-out’s in Log D and Log A as a guide for placement. Fig. 9 Log E Warning : Use only the logs supplied with the fire. When replacing the logs remove the old logs and discard them.

  • Page 41: Removal & Re-Fitting The Glass Fascia

    REMOVAL & RE-FITTING THE GLASS FASCIA 5.5.1 Fit the fascia as shown below in figure 10, and secure with 2 off screws per side. Ensure the top edge of the fascia has hooked over the top edge of the firebox. Fig.

  • Page 42: Removal & Re-Fitting The Draught Diverter Cover

    REMOVAL & RE-FITTING THE DRAUGHT DIVERTER COVER 5.6.1 The draught diverter cover plate can be removed for cleaning purposes or during routine removal / replacement of the glass fasica assembly. 5.6.2 Simply lift from the glass fascia assembly as shown below in figure 11 and replace in reverse order as necessary.

  • Page 43: 5.7 Cleaning The Fuel-Bed / Glass Fascia Assembly

    5.7 CLEANING THE FUEL-BED / GLASS FASCIA ASSEMBLY We do not recommend cleaning of the logs or fuelbed components as these are fragile and damage may result. None of these parts must be washed or exposed to any cleaning agents or water. Any damaged parts must be replaced by contacting your dealer or telephoning BFM Europe Ltd.

  • Page 44: User Replaceable Parts

    USER REPLACEABLE PARTS The only user replaceable parts on this fire are the fuelbed components and the glass fascia assembly which may be replaced as described in section 5.4/5.5 Replacement of any other parts must be carried out by a competent person such as a GAS SAFE registered gas installer.

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