Focal Point POLARIS User manual

INSTALLATION AAND UUSER IINSTRUCTIONS

All iinstructions mmust bbehhanded ttouuser ffor ssafekeeping

Revision A - 07/05

Country(s) of destination - GB/IE

POLARIS

SSTTOONNEEEEFFFFEECCTTDDEECCOORRAATTIIVVEEGGAASSFFIIRREE

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 Decorative Fuel Effect appliance which provides radi-

ant warmth utilising the latest type burner technology.

The fire is designed to fit into a purpose made builder’s opening, and use natu-

ral 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 which

must project at least 240mm in front of the appliance.

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

stated on the appliance data plate.

Polaris

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 ffuel bbed aare cconsstruccted ffrom cceramiccffibre.

Secction

1.0

2.0

3.0

4.0

5.0

6.0

6.1

7.0

8.0

9.0

Contentss

Important Notes

Appliance Data

Installation Requirements

Site Requirements

Ventilation

Unpacking the Appliance

Component Checklist

Installation of Appliance

Fuel Bed Layout

Testing & Commissioning

PaggeNNo.

Secction

10.0

10.1

10.2

10.3

10.4

10.5

11.0

12.0

Contentss

Operating the fire

Spark Failure

Setting Pressure

Flue Spillage Monitoring System

Testing for Spillage

Briefing the Customer

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 purpose made builders’ opening meeting certain dimensional

requirements.

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.

2.0

3.0

A. Opening height:

360mm Min / 470mm Max.

B. Opening width:

455mm Min / 545mm Max.

C. Opening depth: 355 mm Min.

‘A’

‘B’

‘C’

APPLIANCE DDATA

Manual Control Version

Gas Group G20 Natural Gas CAT I2H

Inlet Pressure 20 mbar

Max Energy Input (gross) 5.5 kW

Min Energy Input (gross) 3.5 kW

Pilot Energy Input (gross) 166 W

Setting Pressure (cold) 12.2 mbar (+/- 0.75mbar)

Main Injector Burner Stereo size 77

Gas Inlet Connection 8mm Inlet Restrictor Elbow

Gas Control Valve Dungs BM 733/Negabahn 6801

Ignition Integral Piezo spark

Spark Gap 3.5 to 4.5mm

Weight 20 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.

INSTALLATION RREQUIREMENTS ((continued)

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 has been tested for use with circular flues of a minimum internal diameter of 175mm.

The flue termination (cowl) must be of a type suitable for use with an inset Decorative Fuel Effect Fire BS5871

part 3 contains further details.

SITE RREQUIREMENTS

The fireplace opening should be inspected and repairs made where necessary. It will usually be necessary to

remove any chair brick that may be in place.

The opening WIDTH and HEIGHT dimensions should be between 455mm and 545mm wide, and 360mm to

470mm high.

Opening DEPTH should be 355mm or greater. Opening DEPTHS include any plaster or infill panels which form

part of the installation.

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

225mm xx2225mm ((9in xx99in) bbrick oorsstone.

175mm ((7in) mminimum ddiameter llined bbrick oorsstone.

175mm ((7in) mminimum ddiameter ttwin wwall fflue cconforming ttoBBS7715.

Any existing under grate draught device must be sealed off.

The opening wall must be non-combustible.

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.

3.0

4.0

A. Front face of the stone effect body to be flush with fireplace opening.

B. Hearth must extend minimum of 240mm in front of the stone effect body.

C. Hearth must extend minimum of 90mm either side of the stone effect body.

D. Overall hearth width must be at least 540mm.

E. Recommended 70mm minimum for access to control knob.

Hearth

Builders’

opening

SITE RREQUIREMENTS ((continued)

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 fireplace opening.

Combustible materials, such as wood, may be fitted to within 100mm (4in) of either side of the fireplace open-

ing , 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.

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. Ventilation located under-

neath or within the immediate vicinity of the fire MUST NOT be used as it may adversely affect the performance

of the O.D.S. system.

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.

UNPACKING TTHE AAPPLIANCE

Stand the carton the right way up, and remove the individual boxes from the outer carton.

Read all the instructions before continuing to unpack or install this appliance.

Remove the stone effect body from it’s box and remove all packaging. Remove the burner unit from it’s box and

remove all packaging. Remove the ceramic pebbles. These will need to be individually unwrapped. Remove the

cardboard packing pieces, and any bags containing other fittings or parts.

Check that the components supplied correlate with the checklist given in section 6.1.

Please dispose of the packaging materials at your local recycling centre.

4.0

5.0

6.0

Maximum ddepth oofsshelf MMinimum ddistance ffrom ffinished hhearth

surface ttouunderside oofsshelf

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

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

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

COMPONENT CCHECKLIST

QUAANTITY DESCRIPTION

1 Burner tray assembly.

1 Stone effect body.

1 Bag of granular burner medium.

13 Individually packaged ceramic pebbles.

1 Set of manufacturers instructions.

1 Screw and rawlplug pack.

1 Fitting template.

INSTALLATION OF AAPPLIANCE

Notess:EEnssure tthat tthe ggassssupply iissiissolated bbefore ccommenccinggiinsstallation ooftthe aappliancce.

Checcktthat tthe tthermoccouple cconnecction nnut iinto tthe rrear ooftthe vvalve iisssseccure.

Smoke ttessttthe fflue ttoeenssure pproper ddraw aand tthat tthere aare nnolleakssppressent.

Locate the gas supply point. This appliance is suitable for all gas connections, including those concealed behind

the opening.

Using the fitting template provided mark out and drill the

position of the four fixing screws as required using a 7mm

masonry bit. These hole positions are shown on the tem-

plate together with the position of the inlet restrictor

elbow and the outer profile of the stone effect body.

IMPORTANT : The front face of the stone effect body

should be flush (i.e. on the same vertical plane) as the fire-

place opening when the appliance is installed in it’s final

position.

Insert the fibre rawlplugs into the fixing holes and then

using the fixing screws provided secure the burner unit to

the hearth/base of builders’ opening. Remove any protec-

tive film from the lower decorative trim.

Using 8mm diameter pipe, connect the appliance to the

gas supply point. The appliance must be fitted with rigid

or semi-rigid pipe of 8mm external diameter. The appli-

ance is factory fitted with an inlet restrictor elbow.

Keep the amount of 8mm pipe used in the supply to a

minimum - less than 1.2m where possible. A long run of

pipe may cause an unacceptable drop in the supply pres-

sure.

The stone effect body of the fire is simply placed onto the

four supporting lugs and then sits under it’s own weight.

Similarly, the upper decorative trim sits on top of the stone

effect body. No additional fixing is required.

FUEL BED LAYOUT

Please refer to the relevant section of the user instructions.

TESTING AND COMMISSIONING

Turn on and test the gas supply up to the fire for any leaks,

in accordance with current edition of BS6891.

When the appliance is first used, protective oils coating

the firebox may burn off. It is advisable to ventilate the room during this period for at least one hour.

7.0

6.1

Securing the burner

Fitting the stone effect body

Fit the upper decorative trim

8.0

9.0

OPERATING TTHE FFIRE

The pilot is visible at the rear of the fuel bed. The control knob is

located on the right hand side of the appliance. Push in and turn the

control knob to the SPARK position, and hold there for a few sec-

onds.

Continue turning anti-clockwise through the spark click to the

PILOT light position, ensuring the pilot has lit. If not, return the knob

clockwise, and repeat.

When the pilot lights after the spark, keep the knob depressed for approximately ten seconds. Now release the

knob and the pilot should stay alight. If not, repeat ignition. If the pilot is extinguished

duringguusse

, wait three min-

utes before repeating the ignition procedure.

To achieve the HIGH setting, push the control knob in slightly and continue turning anti-clockwise to the high

position. The main burner should light after a few seconds. To decrease the setting to LOW, turn the control knob

clockwise to the low setting.

To turn to the PILOT position from the HIGH or LOW positions, press the control knob in, and return to the pilot

position and release.

To turn the fire OFF, keep the knob pressed in, return to the off position and release.

A safety interlock prevents re-ignition of the pilot flame until the thermocouple has cooled sufficiently to allow

the magnetic valve unit to reset itself.

SPARK FAILURE

The gap between the spark electrode and the pilot should be 3.5 - 4.5mm to produce a good spark. There should

be no need to adjust this. If under any circumstances the electric spark fails, the pilot may be lit manually by pro-

ceeding with the ignition sequence as previously described, and after turning the control knob through the spark

position, the knob should be held in and the pilot lit with a taper.

SETTING PRESSURE

Remove the screw from the pressure test point.

The pressure test point is situated on the front of the gas

control as shown and may be accessed by removing the

knob and the control plate.

The setting pressure should be in accordance with the fig-

ures stated on page 2 of these instructions. The fire is facto-

ry set to achieve these pressures, and any significant varia-

tion could indicate a supply problem.

If the pressure is too high, the gas supply meter may be set

incorrectly. This should be checked with the fire running

and if necessary reset by the gas supplier.

If the pressure is too low, then check the meter governor pressure with the appliance running. If this is incorrect

it will need to be reset by the gas supplier. If the setting pressure is too low, but the meter pressure is acceptable,

then a problem in the supply pipework is to be suspected. This will be dirt and debris, kinked or inadequate size

pipes, restriction in a fitting or solder flashing across a joint. (NOTE: you will not get an accurate reading of the

inlet pressure with a pressure gauge on the end of the supply pipe - this is the static pressure in the system. You

must use a T piece and measure the supply pressure with the fire on High - the dynamic pressure). Refit and tight-

en the screw into the pressure test point when the test is complete.

10.0

10.1

10.2

FLUE SPILLAGE MONITORING SYSTEM

This fire is fitted with a flue spillage safety device (ODS). If the fire shuts down during use for no apparent reason

then several things may be suspected. If a door or window has been opened creating a draught, then pilot dis-

turbance is the problem, and removal of the draught should resolve this. The gas pressure reaching the fire must

also be checked. The thermocouple connection into the back of the gas control valve may also have worked

loose during installation, simply tighten to remedy if this is the case.

If pilot disturbance is not the cause, then the ODS safety system may be in operation. Switch the appliance OFF,

check the flue and carry out any remedial work required. Relight the fire and carry out a spillage test. DO NOT

allow the appliance to be used if it continues to fail a spillage test. The aeration hole of the pilot must be careful-

ly cleaned out on each annual service to ensure continued function of the ODS.

The spillage monitoring system shall not be adjusted, modified, or put out of operation by the installer. Any spare

parts fitted MUST be of a type supplied for the purpose by the appliance manufacturer.

If the fire is not spilling, then further guidance should be sought, using the Troubleshooting section as a guide.

TESTING FOR SPILLAGE

Close all doors and windows to the room containing the appliance. Let the fire run on HIGH for five minutes.

Take a smoke match, light it, and using a smoke match tube, hold it at the top edge of the fire opening, 25mm

down and 25mm in. Starting 50mm in from either side, run the smoke match across the opening. All the smoke

should be drawn away up the flue. Any smoke returning into the room indicates that spillage is occurring. If the

initial spillage test fails, run the fire for a further 10 minutes and repeat the test. When the test has been completed

satisfactorily, repeat with any extractor fans in the premises running on the highest setting, and any communicat-

ing doors open. Finally, repeat with all doors open.

NOTE: IIfsspillaggeiisssstill iindiccated aafter uundertakinggaall ooftthe aabove, tthere mmay bbeaaffault iintthe fflue, ooriinssufficcient

ventilation iissppressent.

If the problem cannot be rectified immediately, then expert advice should be sought. Inform the user, disconnect

the fire, and attach an explanatory label.

BRIEFING TTHE CCUSTOMER

All instructions must be handed to the user for safekeeping.

Show tthe ccusstomer hhow ttolligght aand ccontrol tthe ffire

After commissioning the appliance, the customer should be instructed on the safe use of the appliance and the

need for regular servicing. Frequency of service depends on usage, but MUST be carried out at least once

annually.

Scratched and other superficial damage to any matt black paintwork of the appliance can be covered with

matching heatproof spray. Use only the manufacturers’ recommended spray paint. Paint only when the fire is OFF

and cold. Always mask off the surrounding area to prevent contamination with overspray. Ventilate the room dur-

ing the use of the spray.

DO NOT attempt to spray paint the pebbles or ceramics, or wash them in water.

10.3

10.4

10.5

Match

Crimp

Tube

Cross section of smoke match tube

Make a smoke match tube from 10mm

diameter tube. Seal off one end and crimp

the tube to prevent the smoke match from

sliding down inside.

A.25mm down

from top of

opening

B. 25mm in

from front of

opening.

C. Disregard

outer 50mm

either side of

fireplace open-

ing

Smoke Match

In Tube

SERVICING

Ensure that the fire is fully cold before attempting service. A suggested procedure for servicing is detailed below.

1. Lay out the dust sheet and tools.

2. Inspect the area around the top of the fireplace opening for signs of spillage.

3. Carefully remove the ceramic components and the upper decorative trim.

4. Carefully lift off the stone effect body.

5. Isolate the gas supply at the appliance inlet elbow, and disconnect the gas supply pipe.

6. Remove the four screws securing the burner to the hearth.

7. Remove the burner unit from the fireplace opening and empty the granular burner medium.

6. Check the base of the fireplace opening for rubble accumulation and remove. If debris is excessive,

initiate remedial work on the flue.

7. Check the flue with smoke pellet for correct operation.

8. Strip off the burner pipes and clean thoroughly.

9. Clean out the injector and pilot assembly. DO NOT attempt to dismantle the pilot unit.

10. Ensure the injector is aligned squarely in the injector bracket. Re-assemble and re-fit the burner tray.

11. Re fit and replace the ceramics, using genuine spares where necessary.

12. Turn on the gas supply, and leak test.

13. Check any purpose provided ventilation is un-obstructed.

14. Light the fire and test for spillage.

15. Check setting pressure and safe operation of the appliance.

For specific servicing instructions, see the relevant sections.

CLEANING TTHE CCERAMICS

Remove the ceramic components. Gently clean in the open air. Be careful not to create dust from the pebbles.

Where necessary replace damaged components with genuine spares. Seal scrap components in plastic bags

and dispose of at proper refuse sites as directed.

Re-fit the pebbles carefully by referring to the relevant section of these instructions.

CLEANING TTHE SSTONE EFFECT BODY

The stone effect body may be cleaned using a soft dry brush or by using a mild water-based detergent and a cloth.

If these methods of cleaning are unsuccessful, and as a last resort, stubborn marks may be removed by gently rub-

bing with a fine abrasive paper i.e. wet and dry paper. It is not recommended to use water unless the entire body

can be removed from the fire and rinsed under a tap. Do not refit the body to the fire until completely dry.

Whichever method of cleaning is to be employed, it is recommended that a small hidden area be tested before

proceeding to clean the entire body. Do nnot uuse ppolish, wwax oorssolvent bbased ccleaners oorddetergent aastthese mmay

stain oorddiscolour tthe bbody.

DISMANTLING TTHE BBURNER TTRAY

Remove the burner as previously described. The pilot unit can be removed by undoing the tubing nut, the ther-

mocouple nut on the rear of the valve, lint arrestor, two securing screws, and lifting away. Remove the tubing nut

from the valve end of the pilot pipe, and blow through to dislodge any debris that may be present. Clean the exte-

rior of the pilot assembly with a soft brush and blow through the flame ports on the pilot head. Check the aera-

tion holes are free from lint or dirt. The pilot assembly is a non-serviceable item, and should not be taken apart.

The aeration hole must be absolutely clear internally for proper operation. A thoroughly cleaned (inside and out)

oxypilot will cure a wide range of ignition faults.

Remove the two tubing nuts on the ends of the gas pipe to the injector elbow. Release the screw through the

supporting leg and lift assembly clear. The injector pipe can now be checked for debris. Remove the nut

retaining the injector elbow. Blow through the elbow to remove any debris.

The valve is not field serviceable, apart from the pilot filter. Remove the control knob by pulling it forwards, then

remove the largest of the three screws on the face of the valve. Slide the filter out and clean away any debris that

may have accumulated. The filter element should also be blown clean. This component should not require

replacement, however if signs of deterioration are evident then a genuine spare must be used. If a large amount

of debris is present in the filter then the pipework and control should be thoroughly cleaned before re-assembly.

11.0

11.1

11.2

11.3

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