Robinson Willey A88028 User guide

1SERVICE AND INSTALLATION

Installation & Servicing Instructions

PLEASE LEAVE THESE INSTRUCTIONS WITH THE USER

FOR USE WITH NATURAL GAS ONLY

G.C. No. 32 170 19 ÿProduct Code No. A88028

The Data Badge and Serial Number are located on the left hand side of the back panel.

Cat IG20 at 20mbar in GB and IE

ATHENA LF

CONTENTS LAYOUT

INTRODUCTION AND GENERAL INSTALLATION REQUIREMENTS

1.0 TECHNICAL DATA

2.0 CONDITIONS OF INSTALLATION

2.1 SITING GENERAL

2.2 FLUES AND CHIMNEYS

2.2.1 Brick Chimney, 178mm diameter (7 inch) Stone or Lined Flue and 125mm diameter (5 inch) Flue

2.2.2 Pre-Cast Flue

2.2.3 Metal Fluebox 125mm diameter (5 inch) Flues

2.3 SHELF HEIGHT AND SIDE CLEARANCES

2.3.1 Combustible Shelf

2.3.2 Non-Combustible Shelf

3.0 INSTALLATION OF FIRE

3.1 UNPACKING

3.2 PREPARATION OF FIRE

3.2.1 Spigot Restrictor

3.3 METHODS OF INSTALLATION

3.3.1 Fixing by Tension Cable

3.3.2 Fixing Directly onto Wall

3.4 GAS CONNECTION

3.4.1 Concealed Connection

3.4.2 Front Connection

3.5 TEST FOR GAS SOUNDNESS

4.0 COMMISSIONING

4.1 INSTALL FUEL EFFECT COMPONENTS

4.2 CHECK GAS PRESSURE

4.3 FIT TRIM AND FENDER

4.4 TEST FOR SPILLAGE

4.5 CHECK IGNITION

4.6 CHECK OPERATION OF FSD

5.0 INSTRUCT USER

6.0 SERVICING INSTRUCTIONS

6.1 REMOVE BURNER TRAY

6.2 MAIN BURNER INJECTOR

6.3 GAS TAP ASSEMBLY

6.4 PILOT ASSEMBLY

6.5 FUEL EFFECT COMPONENTS

6.6 MAIN BURNER

6.7 CONTROL KNOB

6.8 IGNITION UNIT

6.9 IGNITION BATTERY

6.10 IGNITION MICRO SWITCH

6.11 THERMOCOUPLE BREAK MICRO SWITCH

7.0 HINTS ON FAULT FINDING

8.0 SHORT LIST OF PARTS

INTRODUCTION

1.0 TECHNICAL DATA

GENERAL INSTALLATION REQUIREMENTS

NO COMPONENT OF THIS FIRE IS MANUFACTURED FROM ASBESTOS OR ASBESTOS RELATED PRODUCTS.

The ATHENA L.F. is an open fronted inset live coal effect gas fire specially designed for Pre-Cast Flue application and is also

suitable for use with Brick Chimneys, twin walled or insulated Metal/Pre-fabricated Flues of 125mm minimum diameter and

Flueboxes conforming to the constructional requirements of BS 715. It is fitted with a combined flame supervision and oxygen

depletion monitoring device. The fire is for hearth mounting only on a non-combustible hearth. The fire is for use on Natural Gas

only.

1.1 DIMENSIONS

(Overall) mm

Height 682

Width 635

Depth 115

Forward Projection 100

Height to top of flue aperture 529

Weight 18 Kg

1.2 INPUTS AND PRESSURES

Maximum Heat Input (Gross) 6.0 kW 20470 Btu/h

Minimum Heat Input (Gross) 2.3 kW 7848 Btu/h

Supply Pressure 20.0 mbar

Setting Pressure Cold 13.0 mbar ± 1mbar

Gas Rate Adjustment NONE

1.3 BURNER AND CONTROL DETAILS

Main Burner ÿ 992174

Pilot Burner SIT OP 9063

Injector (Main Burner) Bray Cat 82/440

Ignition Battery Operated Electronic Ignition. Battery Size 9V MN1604 or 6LR61

Control Tap Concentric (with FSD) Model Number TESA 2762-025

Spark Gap 3.0mm to 5.0mm

Control Knob Settings OFF, HIGH, MED, ECON, PILOT

In your own interest and that of safety, it is the law that all gas appliances are installed by competent persons in accordance with

the current Gas Safety (Installation and Use) Regulations. Failure to install appliances correctly could lead to prosecution.

The installation MUST be in accordance with these installation instructions, all the relevant parts of the Local and National Building

Regulations or Building Standards (Scotland) (Consolidation) Regulations and the relevant recommendations of the current editions

of the following British Standards:

B.S. 5871 : Part 2

B.S. 5440 : Parts 1 & 2

B.S. 6891

B.S. 6461 : Parts 1 & 2

B.S. 715

B.S. 1251

B.S. 1289 : 1975

B.S. 1289 : Part 1 : 1986

B.S. 1289 : Part 2 : 1989

Any other relevant British Standard Code of Practice and/or Local Building Regulations and in accordance with the rules in force.

2.1 SITING GENERAL

This fire is suitable for hearth mounting only on a non-combustible hearth at least 13mm thick and measuring at least 630mm wide

by 330mm deep. Its top surface should preferably be 50mm above the floor level in order to discourage the placing of carpets or

rugs over it. It MUST NOT be fitted directly on a combustible wall. The fire should be installed so that no part of a combustible wall

i.e. not part of the fire surround but a full wall at 90 to the fire is less than 500mm from the radiant source. If this is not possible the

combustible side wall must be suitably protected.

FIREPLACE OPENING

The front opening of the fireplace must be between 305mm and 457mm wide and between 560mm and 585mm high (see Section

2.2). If the opening is greater it must be bricked up until the opening is a maximum of 585mm high and 457mm wide, alternatively a

non-combustible infill panel may be used to achieve the required dimensions.

DO NOT USE THE BACK OF A FIRE SURROUND OR MARBLE TO ACHIEVE THE ABOVE DIMENSIONS.

There must be a minimum flat surface area around the fireplace opening shown by the dotted lines in fig. 1 to ensure a good seal

between the fireplace and the fire. This area should be sound enough to take the wall plugs and screws supplied for front fixing.

Ensure that the base of the fireplace is level with the hearth and reasonably flat to prevent the fire rocking. Purpose built ventilation

bricks or additional air vents are not normally required in the room in which the fire is fitted unless specified by the rules in force.

IMPORTANT: When fitting any heating appliance or wallpapering a room in which one is fitted, soft wall coverings such as heat

sensitive wallpapers may become heat damaged or discoloured especially in the area above the fire. Please bear this in mind

when installing or decorating.

IMPORTANT NOTE

Plaster Applied Directly to Pre-cast Flue Blocks.

Some Pre-cast flues built to B.S. 1289:1975 may have plaster applied directly to the flue blocks.

A recommendation was made, in the revision B.S. 1289 part 1:1986, NOT to apply plaster directly to the flue blocks, otherwise

cracking of the plaster could occur.

It is not recommended to install this fire into such installations, unless remedial action is taken.

2.2 FLUES AND CHIMNEYS

2.2.1 SITE REQUIREMENTS FOR 228mm BY 228mm (9in BY 9in) BRICK CHIMNEY/178mm (7in)

STONE OR LINED CHIMNEY AND 125MM (5in) DIAMETER FLUE

The minimum dimensions for the fireplace opening for a brick chimney are as shown in Fig. 1. It will not normally be necessary to

remove any chair brick provided the minimum depth is obtained. A chimney previously used to burn solid fuel must be swept prior

to installation.

The chimney must be inspected to ensure that:

(a) It serves only one fireplace.

(b) It is properly sealed so that combustion products do not escape from the flue into the room.

(d) Any restriction such as damper, register plate, etc. must be removed or secured in the fully open position.

(e) Any underdraught ventilation or additional air supply

entering the fireplace or on the hearth must be

sealed off.

(f) It must have at least 3 metre effective flue height.

(g) It must have a positive updraught.

CHECK THE FLUE FOR GOOD DRAUGHT

Apply a lighted paper or smoke match to the top of the

opening in the fireplace. Observe if there is a definite flow

into the chimney and if so proceed with fitting the fire.

If no flow is indicated, warm the chimney for several minutes

and then re-check. If downdraught is observed a suitable

terminal must be fitted and the chimney re-checked.

If persistent no-flow or downdraught condition is observed

DO NOT FIT THE FIRE, SEEK EXPERT ADVICE.

2.0 CONDITIONS OF INSTALLATION

635 mm MIN

686 mm MIN

Fig. 1

2.2.2 PRE-CAST FLUE OF MINIMUM SIZE (Fig. 2)

This fire can be installed into a properly constructed pre-cast

flue conforming to B.S. 1289 : 1975 or B.S. 1289 : Part 1 :

1986 or B.S. 1289 : Part 2 : 1989 of at least 3 metres

effective height and having flueways of at least 198mm by

67mm or equivalent cross-sectional area with no dimension

less than 63mm. The fireplace opening width must be

between a maximum 457mm and a minimum 305mm. The

fireplace opening height must be between a maximum of

585mm and a minimum 560mm and a depth of at least

120mm above the hearth level.

NOTES:

1. The minimum dimensions for the flat area around the

opening are 686 mm high x 635 mm wide.

2. The flue spigot restrictor MUST NOT be fitted.

Ensure that any mortar fangs between the blocks do not

protrude into the flueways and if raking blocks are used they

are fitted according to the manufacturers instructions and

mortar is not allowed to drop down and accumulate in the

raked portions.

CHECK THE FLUE FOR GOOD DRAUGHT AS DETAILED

IN SECTION 2.2.1.

Fig. 2

PRECAST FLUE INSTALLATION

635 MIN*635 MIN*

615 MAX

560 MIN

615 MAX

560 MIN

457 MAX

305 MIN

457 MAX

305 MIN

120mm

MIN

120mm

MIN

686 MIN*686 MIN*

2.2.3 METAL FLUE BOX/125mm DIAMETER FLUES

(Figs. 3A and 3B)

This fire may be installed in a double walled or insulated

metal box built to the requirements of B.S. 715 e.g.

Selkirk, Product Code Number 0404805, using our

fixing kit G.C. Number 159 634 ÿNumber 992137.

The box must be lagged as detailed in Fig. 3B and

mounted on a non-combustible plinth at least 25mm

thick. Ensure that the base of the opening is level with

the hearth. A larger box built to the requirements of B.S.

715 and insulated as in Fig. 3B may be used. The front

opening must be as shown in Fig. 3A. The flue should

be twin walled e.g. Selkirk IL flues, or insulated type of

at least 125mm internal diameter and with a minimum

effective height of 3 metres. The depth of the opening

must be at least 200mm.

NOTES:

1. If the flat area around the front opening of the box

is less than as specified in Fig. 1, it may be

necessary to use additional sealing material to

achieve a good seal.

2. The flue spigot restrictor MUST NOT be fitted.

Fig. 3B

Refer to the following

illustrations for

configuration.

Cover the top, rear and

sides of the fire housing as

shown with 100mm (4in)

loft insulation material as

shown. If the gap between

the fire housing and any

combustible material is

less than 100mm, squeeze

the insulation material

between the two surfaces.

The minimum distance

from any studding or other

combustible material and

the flue pipe or any part of

the fire housing must be

25mm (1in).

Note: The plaster board does not overlap the

edge of the fire housing. Any non-combustible

fire surround material used overlaps as

shown. The non-combustible fire surround

material must be sealed to the fire housing.

Non-combustible fire

surround material

The non-combustible material

must be sealed to the fire

housing to form an air tight seal

all around.

Non-combustible fire

surround material

Fire housing

Sealant

Fig. 3A

FREESTANDING

GAS FLUE BOX

SELKIRK CODE 0404805

125 I/D

FLUE

CENTRE

457

610

212

407

560

200

2.3 SHELF HEIGHT AND SIDE CLEARANCES

The fire may be fitted beneath a shelf.

2.3.1 COMBUSTIBLE SHELF

The underside of a combustible shelf not more than 150mm deep must be at least 923mm from the hearth which gives a clearance

of 237mm above the fire. For deeper shelves, add 13mm shelf height for every 25mm increase in depth. For every 25mm decrease

in shelf depth subtract 13mm from the shelf height.

2.3.2 NON-COMBUSTIBLE SHELF

The underside of a non-combustible shelf not more than 75mm deep must be at least 25mm above the top of the fire. This

clearance is necessary for outer case removal. For deeper shelves, allow 13mm in shelf height for every 25mm increase in depth.

SIDE CLEARANCES:

A clearance of at least 25mm must be left on either side of the fire to facilitate removal of the outer case during servicing.

FIRE SURROUND:

The fire is suitable for purpose-made proprietary hearths/surrounds with temperature rating of 150 C.

3.1 UNPACKING

The fire is packed with the back coal and side cheeks already fitted in position. When unpacking refer to the check list to ensure

that all of the components are present and undamaged. Remove the top fitment from the carton. Lift the carton surround clear of

the fire. Remove the pack containing the coal bed and 9 loose coals. Remove the outer case from the fire, by lifting the it to clear

the two top locating brackets. Lift the fire clear of the bottom fitment of the carton.

Take out the polythene bag containing the fire fixing kit and comprising:

(i) 2 Fixing Cables

(ii) 2 Cable Adaptors

(iii) 2 Grub Screws

(iv) 4 Eye Screws

(v) 1 Spigot Restrictor

(vi) 4 Screws and Wall Plugs (fire fixing)

3.2 PREPARATION OF FIRE

3.2.1 SPIGOT RESTRICTOR

The spigot restrictor is supplied loose with the fire and

should be fitted only in the case of installation to a brick

chimney, 178mm diameter stone/lined flue of at least

3 metres effective height, with good draught.

DO NOT fit the spigot restrictor if installation is to a

PRE-CAST FLUE or a METAL FLUEBOX / 5 INCH

FLUE. Fit the spigot restrictor if applicable using

2 screws (Fig. 4).

3.0 INSTALLATION OF FIRE

Fig. 4

SPIGOT RESTRICTOR 2 SCREWS

3.3 METHOD OF INSTALLATION

There are two methods for securing the fire to the wall which are:

(a) Fixing by tension cable.

(b) Screwing the fire directly to the wall.

It is recommended, where drilling holes in the front face of the fireplace surround is unacceptable or otherwise risky e.g. a marble

surround, that fixing by tension cable is employed.

IMPORTANT NOTES

(a) If the surface of the fireplace is uneven it is necessary to prepare the surface so that a positive seal can be achieved

between the fire and the wall.

(b) If the fire is to be connected using a concealed gas connection then it is necessary to prepare the pipework prior to fitting the

fire to the wall. Refer to Section 3.4.1. (Concealed Connection).

3.3.1 FIXING BY TENSION CABLE

FIT MOUNTING EYE SCREWS

Mark the position for eye screws in the back of the opening according to the dimensions in Fig. 5. Drill the four 6mm holes and plug

the holes with the wall plugs. Fix the eye screws to the holes.

FIXING THE CABLE

First remove the burner tray (see Section 6.1). Insert the free end of each cable through the respective hole in the firebox and then

through the eye screws (refer to Fig. 5). Thread the free ends of the cable through the holes in the tensioning bolts located in the

base of the fire from the rear. Insert the fire into the opening so that the seal on the back of the fire is compressed against the face

of the fireplace/surround. Any visible gaps indicate a deviation from flatness of the surround face which MUST be corrected. Pull

the cable taut each side of the fire and insert the cable adaptors over the ends of the cable (Fig. 5). While keeping the cable taut

slide the adaptor against the tensioning bolt and tighten the grub screw to lock the cable. Using a spanner unscrew each tensioning

bolt by about 20mm to tension the cable. Prevent the cable adaptors from rotating while unscrewing the tensioning bolts. Refit the

burner tray.

Fig. 5

Fig. 6

73mm

115mm

3.3.2 FIXING DIRECTLY TO SURROUND FACE

Mark the four positions of the fixing holes on the front face of the fireplace surround using the fire as a template. Drill 6mm holes

and plug the holes with the wall plugs supplied. Insert the fire into the opening in the fireplace until the seal on the back of the fire is

compressed against the surround face at every point. Note that any visible gaps between the surround face and the seal indicate a

deviation from flatness on the surround face and MUST be rectified. Screw the fire to the wall.

3.4 GAS CONNECTION

NOTE: The appliance must be connected to gas with rigid or semi-rigid tubing. A means of isolating the gas supply must be fitted

upstream of the appliance inlet to facilitate connection and subsequent servicing. The supply pipe to the fire should be installed so

that it is easy to remove the fire from the opening during servicing. Ensure that a service cock (which may be in the form of a union

restrictor elbow) is provided for isolation of the fire for servicing at a later date.

If a concealed connection from within the fireplace is required then, before the appliance is fitted into the fireplace, it will be

necessary to extend the supply line so that it will project through the sealed opening situated at the back of the firebox to the

appliance inlet elbow.

3.4.1. CONCEALED CONNECTION

The dimensions below indicate the required position of the supply pipe to enable it to pass through the aperture in the fire back.

Refer to Fig. 6.

(a) Remove the burner tray from the fire to improve access (see Section 6.1).

(b) Make connection from concealed point to finish in the position indicated in Fig. 6.

Ensure there is a union connection at this point. The inlet elbow provided with the fire should be fitted to the supply.

(c) The pipe run from the supply line up to the rear opening in the firebox must be kept clear of the area which will be taken by

the box when it is installed.

3.4.2 FRONT CONNECTION

After fixing the fire to the surround (Section 3.3) it is possible to connect the gas supply from either the right or left hand side. The

union elbow on the fire which has an R 1/4 internal thread should be connected to the supply pipe.

3.5 TEST FOR GAS SOUNDNESS

The gas installation, including metre, should be inspected and tested for gas soundness and purged.

Refer to B.S. 6891 : 1988 when performing gas soundness testing.

4.0 COMMISSIONING

4.1 INSTALL FUEL EFFECT COMPONENTS

The fuel effect components comprise:

(a) Rear Coal

(b) Two Side Cheeks

(d) Nine Loose Coals

The Coal Bed and the loose coals are illustrated in Fig.

7A. The fire is supplied with the rear coal and side

cheeks already fitted as illustrated in Fig. 7B.

Unpack the pack containing the coal bed and the loose

coals and check that these are undamaged.

DO NOT INSTALL THE FIRE WITH BROKEN OR

MISSING COALS. USE ONLY THE COALS SUPPLIED

WITH THE FIRE.

1. The underside of the coal bed has grooves

matching the raised ports of the burner top. Fit the

coal bed by placing it onto the burner. Take care

to avoid damage as you insert it past the pilot

burner (Refer to Fig. 7C). Ensure that it is

correctly located in the burner tray by sliding it

sideways and front to back.

2. Notice that there are five depressions at the front

of the coal bed and four depressions at the rear

(as shown in Fig. 7A). Place five loose coals in

the front recesses with their decorative faces

forward. Similarly place the remaining four loose

coals on top of the recesses formed by the front

loose coals and touching the rear coal (Fig. 7D).

Ensure that the loose coals are stable and not

likely to fall off.

Fig. 7A

Fig. 7B

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