Focal Point Excelsior Expanse Guide

INSTALLATION AAND UUSER

INSTRUCTIONS

All iinstructions mmust bbehhanded ttouuser ffor ssafekeeping

Revision A - 05/04

Country(s) of destination - GB/IE

Excelsior

EXXPPAANNSSEE

Focal Point Fires plc, Avon Trading Park, Christchurch, Dorset BH23 2BT

Tel: 01202 499330 Fax: 01202 499326

www.focalpointfires.co.uk

e-mail: [email protected]

INSTTALLATTION IINSTTRUCTTIONS

PPrelimminnary NNotes BBefore IInnstallationn

This appliance is an Inset Live Fuel Effect appliance which provides radiant

warmth utilising the latest type burner technology.

The fire is designed to fit various types of fireplaces and natural draught flues as

listed in the Installation Requirements.

The appliance must be installed by a competent person in accordance with

Gas Safety (Installation and Use) Regulations 1998. It is strongly recommended

that a CORGI registered engineer be used for this purpose.

Read all these instructions before commencing installation.

This appliance must be installed in accordance with the rules in force and only

used in a sufficiently ventilated space.

The appliance is designed for installation on to a non-combustible hearth of at

least 300mm depth.

This appliance is factory set for operation on the gas type, and at the pressure

stated on the appliance data plate.

This appliance is available in either a manual control version, or a battery pow-

ered remote control version, with a number of fuel effect options. These

instructions cover both control options, and all fuel effect options. See the rele-

vant sections of these instructions for further details.

IMPORTANT NNOTES

This fire is an Inset Live Fuel Effect Gas Fire providing radiant warmth. It is designed to operate on Natural Gas

only. See Data Plate on appliance.

It is the LAW that all gas appliances and fittings are installed by a competent person (such as a CORGI registered

fitter) and in accordance with the Gas Safety (Installation and Use) Regulations 1998, the relevant British

Standards for Installation, Codes of Practice and in accordance with the Manufacturers’ Instructions. The

installation shall also be carried out in accordance with the following regulations:

The Building Regulations issued by the Department of the Environment, the Building Standards (Scotland)

(Consolidation) Regulations issued by the Scottish Development Department.

BS 5871 part 2

BS 5440 part 1

BS 8303

BS 1251

BS 6891

BS 6461 part 1

Failure ttoccomply wwith tthesserreggulationssccould llead ttopprosseccution aand ddeem tthe wwarranty iinvalid.

Thissaapplianccemmusstbbeiinsstalled iinaaccccordanccewwith tthe rrulessiinfforcceaand uussed oonly iinaassufficciently vventilated

sspacce. CConssult aall iinsstrucctionssbbefore iinsstallation aand uusseooftthissaappliancce. TThissaappliancceiissiintended ffor ddecco-

rative ppurpossess.

Thissaappliancceiissffree ffrom aany aassbesstossmmaterial. RRefracctoriessaand ccoal bbed aare cconsstruccted ffrom cceramiccffibre.

Note ::RRemote ccontrol mmodelssoonly - This appliance features a battery-opearated remote control system, and

under normal usage will need new batteries approximately every twelve months.

Remote control Handset requirements - 1 x ‘PP3’ type (9 volt)

Reciever/motor unit requirements - 4 x ‘AA’ type (1.5 volt)

Refer to the appropriate section of these instructions for details of how to change the batteries.

Secction

1.0

2.0

3.0

4.0

5.0

6.0

7.0

7.1

8.0

9.0

Contentss

Important Notes

Appliance Data

Installation Requirements

Site Requirements

Ventilation

Flue Boxes

Unpacking the Appliance

Component Checklist

Preparing the Appliance

Preparing the Opening

PaggeNNo.

Secction

10.0

11.0

11.1

11.2

12.0

12.1

13.0

14.0

14.1

14.2

15.0

16.0

Contentss

Gas Supply

Fitting the Firebox

Cable Fixing

Gas Connection

Fuel Bed Layout (coal versions)

Fuel Bed Layout (pebble versions)

Fitting Fireframe and Front

Testing & Commissioning

Operating the fire (manual versions)

Operating the fire (remote versions)

Servicing

Troubleshooting Guide

PaggeNNo.

Note - FFor RRepubliccoofIIreland, rreferencce

sshould bbemmade ttotthe rrelevant sstandardss

ggoverninggiinsstallation, pparticcularly iinrreggard

to fflue ssizinggaand vventilation. SSee IIS813,

ICP3, IIS3277aand aany oother rrulessiinfforcce.

1.0

INSTALLATION RREQUIREMENTS

This appliance MUST NOT be installed into a room containing a bath or shower, or where steam may be

present. The fire has been designed to fit into a builders’ opening or fireplace conforming to BS 1251 (and meet-

ing certain dimensional requirements), or a suitable flue box complying with the constructional requirements of

BS 715. The flue box must be installed onto a suitable non-combustible insulating surface at least 12mm thick,

covering the entire base are of the box.

The flue must have an effective height of at least three meters, as measured from the hearth to the top of the flue.

Any flue damper plates or restrictors should be removed and no other restriction fitted to the flue. Where removal

is not practical, the restriction must be fixed in the fully open position.

A natural draught flue system is required, and if previously used for solid fuel or oil burning, the flue and chimney

must be swept prior to appliance installation. The flue must be checked before installation by using a smoke pel-

let or similar to ensure proper draw and that leakage is not evident at any joints. Repair and re-test as necessary

before the appliance is installed.

The flue must be connected to only one fireplace, and the flue must not vent more than one appliance (i.e. not

shared with a gas back boiler). There must be no opening in the flue apart from the one that the appliance is

installed into, and the one venting the gases into the air. A suitable terminal may be fitted, such as class GC1, as

regulations allow.

This appliance is suitable for use with a “lightweight” surround and back panel of 150ºc minimum rating.

SITE RREQUIREMENTS

The fireplace opening should be inspected and repairs made where necessary. Any chair brick or fireback may

be left in place, providing that the dimensional requirements for debris collection and spigot clearance are met.

The opening WIDTH and HEIGHT dimensions should be between 400mm and 460mm wide, and 540mm to

570mm high.

Opening DEPTH should be 210mm or greater. Opening DEPTHS include any plaster or infill panels which form

part of the installation.

APPLIANCE DDATA

Manual Control Version Remote Control Version

Gas Group G20 Natural Gas CAT I2H G20 Natural Gas CAT I2H

Inlet Pressure 20 mbar 20 mbar

Max Energy Input (gross) 6.8 kW 6.8 kW

Min Energy Input (gross) 3.5 kW 3.5 kW

Pilot Energy Input (gross) 166 W 166 W

Setting Pressure (cold) 15.8 mbar (+/- 0.75mbar) 15.8 mbar (+/- 0.75mbar)

Main Injector Burner Stereo size 81/Bray cat. 82/420 Stereo size 81/Bray cat. 82/420

Gas Inlet Connection 8mm Inlet Restrictor Elbow 8mm Inlet Restrictor Elbow

Gas Control Valve Dungs BM 733/NGC 6802 Mertik Maxitrol GV34 Series

Ignition Integral Piezo spark Integral Piezo spark

Spark Gap 3.5 to 4.5mm 3.5 to 4.5mm

Weight 20 Kg 21 Kg

Please see Data Badge affixed to appliance for current data.

This aappliancceiisffor uuse oonlyywwith tthe ggas ttyype, aand aattthe ppressure sstated oontthe aappliancce

Data BBadge, aand iisffor ddeccorative ppurposes.

2.0

3.0

4.0

SITE RREQUIREMENTS - ccontinued

This appliance requires a natural draught flue system which may be one of the following;

225mm x 225mm (9in x 9in) brick or stone.

175mm (7in) minimum diameter lined brick or stone.

175mm (7in) minimum diameter twin wall flue conforming to BS 715.

Any existing under grate draught device must be sealed off.

The opening wall must be non-combustible and have adequate flat surface for appliance sealing.

The appliance requires a hearth with non-combustible surface of at least 12mm thick. The top surface must be at

least 50mm above the surrounding floor level, or be surrounded by a raised edge or fender 50mm high.

To enable the products of combustion to be cleared properly up the flue, the outlet on top of the firebox must

have a minimum 50mm clearance between it and the back wall of the opening or other obstruction. The area

immediately above the outlet must form a smooth path into the flue.

Any type of fire surround used with this appliance must be adequately sealed to the wall and floor.

A combustible shelf may be fixed to the wall above the fire, providing that it complies with the dimensions given

below.

A non-combustible shelf may be fitted to within 10mm of the top edge of the fireframe. Combustible materials,

such as wood, may be fitted to within 100mm (4in) of either side of the frame of the appliance, providing the

forward projection does not exceed 100mm (4in). Any combustible side walls must be at least 500mm to the side

of the radiant heat source.

As with all heating appliances, any decorations, soft furnishings, and wall coverings (i.e. flock, blown vinyl and

embossed paper) positioned too close to the appliance may discolour or scorch.

A. Opening height: 540mm

min/570 mm max.

B. Opening width: 400mm

min/460mm max.

C. Mounting depth: 210mm

D. Hearth must extend minimum

of 150mm either side of the

opening.

E. Hearth must extend minimum

of 300mm in front of the opening.

F. Non-combustible hearth must

be a minimum of 50mm in height,

or be surrounded by 50mm high

fender.

G. 500mm, this area must be flat

and vertical to ensure a good seal.

H. 585mm, this area must be flat

and vertical to ensure a good seal.

4.0

Maximum ddepth oofsshelf MMinimum ddisstancceffrom ffinisshed hhearth

ssurfaccettouundersside oofsshelf

100mm (4in) 745mm (29 1/4 in)

150mm (6in) 845mm (33 1/4 in)

203mm (8in) 895mm (35 1/4 in)

VENTILATION

No purpose provided ventilation is normally required for this appliance. The requirements of other appliances

operating in the same room or space must be taken into consideration when assessing ventilation.

If spillage is detected when commissioning the appliance then amongst other problems there may be insufficient

natural ventilation for the correct operation of the flue. This is potentially a greater problem should the property

be of modern nature. If the appliance does not spill with windows open but does with windows closed, this

proves that lack of ventilation is the problem, if not, it will be the flue at fault. Installation of an air brick is the best

solution. Any ventilation fitted must comply with BS 5871 part 2 and BS 5440 part 2.

Spillage detected during commissioning is almost always a result of poor flue performance, which cannot be cor-

rected by any amount of ventilation.

For Republic of Ireland ventilation may be required, see IS 813, ICP3, IS 327, and any other rules in force.

PREFABRICATED FFLUE BBOXES

This appliance can be fitted into a number of proprietory flue boxes, provided that the minimum dimensions

given in the diagram below are complied with. The flue outlet of the fire must nnot obscure the flue outlet from

the flue box. A smooth path into the flue must exist.

Consstrucctional NNote:

The frame of the fire, any back panel or other infill panel, and the flue box must be sealed

together so that there is no possibility of leakage between them. Adequate clearances to combustible materials

(e.g. false chimney breast construction) must be maintained.

The mmanufaccturerss’iinsstrucctionssffor tthe ffittinggooftthe pprefabriccated fflue bbox sshall bbeccomplied wwith aataall ttimess.

Some flue boxes may require minor adaption when fitting the fire using the cable fixing kit.

The firebox, base of the flue box, and the hearth may be drilled to allow plugs and screws to secure installation.

It is important that the sealing requirements of the appliance are met at all times and that the flue box is well

sealed to any back or infill panel.

Note: TThe DDEPTH ddimenssionsssshown aare iincclussive oofaany bbacckooriinfill ppanelss.

5.0

175mm min internal dia

twin wall flue tube

210mm min depth

400 mm min

opening width

540mm min

opening height

6.0

UNPACKING TTHE AAPPLIANCE

Stand the carton right way up, cut the strapping bands and remove the top end cap. Read all the instructions

before continuing to unpack or install this appliance.

Remove the box containing the fire front, and the bags and boxes containing the ceramic parts. Remove the card-

board packing pieces, and any bags containing other fittings or parts. When all loose parts have been removed,

the outer sleeve may be lifted off to reveal the appliance. Check that the components supplied correlate with the

checklist given in section 7.1. Please dispose of the packaging materials at your local recycling centre.

COMPONENT CCHECKLIST

QUAANTITY DESCRIPTION

1 Firebox and burner tray assembly.

1 Decorative frame, one of several finishes.

1 Fire front with separate ashpan cover, one of several designs and finishes.

1 Moulded ceramic fibre combustion matrix.

22 Individual ceramic coals (coal effect option only)

22 Individual ceramic pebbles (pebble effect option only)

2 Moulded ceramic front coal strip (coal effect option only)

2 Moulded ceramic front strip (pebble effect option only)

3 Ceramic radiant panels.

1 Set of manufacturers instructions and warranty card.

1 Cable fixing kit comprising; 2 cables, 2 tensioners, 2 clamps, 4 fixing eyes, 4 fibre rawl plugs.

2 Ceramic brick panel retaining clips

1 Remote control handset (remote control option only)

1 Pack of batteries (1 x ‘PP3’, 4 x ‘AA’) (remote control option only)

1 Self tapping screw pack

3 Lengths of self adhesive sealing strip.

1 Rubber grommet.

PREPARING TTHE AAPPLIANCE

Note: EEnssure tthat tthe ggassssupply iissiissolated bbefore ccom-

menccinggiinsstallation ooftthe aappliancce.

The fireplace opening and environment must be in com-

pliance with the specifications laid down in the

appropriate sections of these instructions.

Remove the appliance from it’s carton as described pre-

viously and stand upon a dust sheet or similar. Place the

decorative frame, firefront, ceramics and fixings safely to

one side. Remove the burner from the assembly by

releasing the two screws through the tray legs. The tray

is now free, and may be lifted away.

The three radiant panels may now be fixed inside the firebox. Select the textured side

of each panel and insert as follows; Lay the firebox on it’s back. Lay the large rectan-

gular panel onto the rear face of the firebox. The side panels should be fitted by inserting their front edges into

the pre-fitted retaining brackets on the front face of the firebox. Gently align the side panels with the side of the

firebox, over the top of the back panel already in place. Make sure that the side panels are pushed

firmly to

the roof of the firebox, and

bacck

firmly to retain the back panel. Make small adjustments to line up the mortar

lines if required (brick patterned pads only). Secure the side panels using the small ‘Z’ shaped brackets and screws

provided. The screws should locate into the pre-punched holes in the sides of the firebox.

7.0

7.1

8.0

PREPARING TTHE AAPPLIANCE - ccontinued

Knockout holes are provided in the rear and sides of the firebox for use where concealed pipework is required.

Where necessary, knock out the appropriate hole with a sharp tap from a hammer, and fit the rubber grommet

supplied. A small incision can now be made in the rubber to slip snugly around the outside of the pipe and sleev-

ing.

Do nnot iinsstall ooruussetthe aapplianccewwithout tthe ssealssiinpplacce.

If a hole is inadvertently opened, reseal with an

intact grommet. Failure to fit the seal correctly will cause flue suction to act upon the area under the burner, result-

ing in poor performance and intermittent cutting out of the burner.

Apply the self adhesive sealing strips to the back of the fireframe to give a continuous seal.

PREPARING TTHE OOPENING

Before installing the fire, check the flue using a smoke pellet. All of the smoke should travel up the flue and exit

correctly from the terminal. If problems are found, DO NOT fit the fire until corrective action is completed.

Protect the decorative hearth whilst pushing the firebox in and out of the opening. Part of the packaging will make

an ideal hearth saver pad.

Before running the gas supply into the opening, offer up the firebox to the fireplace to check the fit is good.

Ensure that it slides in correctly, the sealing face sits flat and square to the wall or infill panel, and that the base is

firm on the floor of the opening as no leaks are permissible here. At this stage it is essential to ensure that the

spigot outlet of the firebox is not restricted in any way. Remove the firebox and take any necessary measurements

before making good and preparing for final installation.

CABLE FIXING. For fixing of the fire by the cable method, see the relevant section. The cable fixing locations

should be marked on the back of the opening and the holes drilled. Fit the fibre rawlplugs and eyebolts to these

holes.

Note: PPlassticcrrawlpluggssaare NNOT ssuitable ffor tthissaappliccation.

SCREW FIXING. For fixing by screw, mark and drill the firebox base, and the relevant points in the opening or on

the wall. Rawlplugs will again be required. Pre-punched holes are not provided for this purpose to allow you to

choose the optimum positions.

Sccrew ffixinggvvia tthe ffirebox fframe iissnnot rreccommended aass,ddependant oontthe ttype

of ttrim ffitted, llarggeaareassooftthe bblacckppainted fframe mmay bbevvissible wwhen tthe iinsstallation iissccompleted.

GAS SUPPLY. Following preparation for the fixing method, the concealed gas supply, where required, can now

be put into place. Refer to the gas supply section for suggested pipe routes. The ends of the sleeving in which the

gas pipe is run should be sealed. The ends of the 8mm supply pipe should be temporarily sealed to prevent the

ingress of debris during fixing.

GAS SSUPPLY RROUTING

When the opening is ready for installation of the fire, the gas supply can be routed as shown in the diagrams

below. IMPORTANT - Wherever a concealed connection is made a rubber grommet must be used to seal the

firebox.

8.0

9.0

Fireplace opening

Firebox

Grommets

Fireplace opening

Firebox

Grommets

Isolation elbow position

Manual ccontrol vversions Remote ccontrol vversions

10.0

GAS SSUPPLY RROUTING ((continued)

The gas pipe must be suitably protected where it passes through fireplace openings. Any sleeving should be

sealed to the pipe at its ends.

This appliance is fitted with an inlet restictor elbow.

The open end of the supply pipe should be sealed temporarily during the installation of the firebox to prevent the

ingress of dirt and dust.

The appliance firefront is specially notched to allow the gas pipe to pass through when an over hearth supply is

necessary.

FITTING THE FIREBOX

The firebox may be fitted to the opening by using screw fixing or by the cable kit as described in the relevant

section. Leave the polythene coating in place until fitting procedures are complete to eliminate any risk of scratch-

ing the decorative finish.

To fit the firebox, firstly check the fire goes fully back into the opening. Secure the fire box by drilling and screw-

ing down the frame or base of the firebox, or use the cable fixing method.

INSTALLATION BBYCCABLE FFIXING KKIT

If this method is to be adopted then an extra 30mm fitting depth

should be allowed for Fitting depth for the firebox becomes a

recommended 240mm.

Drill the four holes for the rawl plugs, as shown in the diagram.

If the fireplace configuration does not allow the exact layout

given, the eyebolts should be positioned as close to the correct

layout as possible.

Before finally fitting cables, ensure the self adhesive sealing

strips are in position on the back of the appliance frame. The

fireframe must be sealed evenly to the fireplace opening all

around the periphery.

Thread the tensioning cables through the holes in the top of the fire-

box, then the eyelets, and finally through the lower holes in the back

of the firebox, as shown in the photographs.

Note: TThe bburner ttray MMUST bberremoved aasspper rrelevant ssecction tto

ggain aaccccessssttotthe ccable aadjussterss.

Push the appliance back into to fireplace, centralise, and pull the

loose tensioning cables through the holes into the firebox. Thread

the tensioner bolts onto the cables, with the nuts screwed down

close to the tensioner head.

Slide the screwed nipple onto the cable, pull cable tight, and tighten

nipple.

The tension of the cable may now be adjusted by using a suitable

spanner on the tensioner nuts to pull the appliance tightly against the

fireplace opening. Visually inspect the seal and reseat if necessary.

Note: DDO NOT ccut ooff eexccessssccable.

Surplus cable must not be cut

off, as it will be impossible to refit the fire after servicing. Coil up the surplus cable,

and locate at rear of firebox.

Note ::IIfrrunninggaacconccealed ggassssupply, eenssure ggrommetssaare sseccure aaround

inccominggppipess.

11.0

11.1 A. 200mm

B. 350mm

C. 60mm

Dimension can

be +/-10mm

10.0

GAS CONNECTION

Refit the burner tray into the firebox, fit the two

screws through the locating holes in the tray legs,

and tighten.

Purge the gas supply thoroughly to remove air and

dirt/debris

BEFORE

connection. Now disconnect

the inlet restrictor elbow from the inlet pipe.

Connect the previously installed gas supply to inlet

restrictor elbow, and re-fit the restrictor elbow to the

inlet pipe of the appliance.

If using an across hearth connection, ensure the

decorative fireframe and firefront will clear the sup-

ply route.

If the data/control plate is not already fitted, attach with two screws, ensuring the control knob is free to be

depressed fully.

FUEL BED LAYOUT

Coal EEffect OOption

1. Remove the combustion matrix from its protective

packaging, and position onto the burner tray as

shown. The front edge of the matrix should sit snugly

behind the back edge of the burner rails. Do not fit the

matrix on top of the burner rails.

2. Next, remove the front coal strips from the protec-

tive packaging and position as shown. The rear edge of

the front coal strips should fit in front of the burner rail.

Again, do not to place on top of the burner rails. When

the front coal strips are in position bend up the three

metal tags at the front of the tray to retain (inset).

11.2

12.0

Correct

Incorrect

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