AEG G20 User's Manual
Contents
1. fibre back side cheek assembly in position 2 Place the coal support shelf on the stainless steel channel the machined groove on the underside of the shelf is located on the rear flange of the channel 3 Place the two shaped burner inserts in channel between the two burner flame ports check that a minimum gap of approx 6mm is maintained between the rear of the burner insert and the front edge of the coal support shelf 4 Position the front simulated coal on the shelf provided above the control facia panel See fig 20 COAL LAYOUT Position 3 large coals 2 triangular and 4 large coals on edge straddle the gaps of the coal support shelf and run the strata front to rear as the first layer fig 21 Place 4 medium as a second layer sitting on the gaps of the front coals and resting against the rear coals fig 22 Finally place the remaining 5 small coals as shown in fig 23 Small adjustments to the coal layout may be made to give the best visual appearance however additional coals must not be used If any fibre component is lost or broken the appliance must not be used until a replacement is obtained Page 7 CHECKING OPERATION OF FIRE Turn on the Gas supply at the meter and to the appliance at the isolating cock Purge the air to the appliance Rotate the control knob to the ignition position depress the control and push the piezo to ignite the pilot Check that the electrode is sparking between the tip of the thermocouple and continue2. left hand side of the opening All the smoke must be drawn into the flue If spillage occurs allow a further 10 minutes Should spillage still occur examine the chimney for the fault and rectify The test should be carried out with all windows and doors closed if an extractor fan is situated in the room this test should be repeated with the fan running If there is a connected room with an extractor fan the test should be repeated with all the doors to that room opened and the extractor fan running Demonstrate the lighting and extinguishing procedures to the user ADVISE THAT The curing effect of heating the coals will cause an initial odour which although not harmful may require additional ventilation until the odour has disappeared Any debris or soot is cleaned from the appliance Advise the customer that they should read their Users Instructions before operating the fire and always follow the advice in the section headed Removal of Debris or Soot Deposits The appliance must be serviced annually by a competent person in accordance with these instructions and the appliance is checked for spillage in accordance with the method detailed in these instructions Complete the section in the enclosed registration leaflet Advise that any component part of this appliance be guaranteed against defective workmanship or faulty materials for a period of twelve months from the date of purchase Any such part will be replaced free of charge on
3. materials may be become discoloured by convection heat Soft furnishings must be kept clear from the radiant heat of the fire and from impinging the hearth area The hearth must not be covered by any combustible materials such as carpets etc This product uses fuel effect pieces gaskets and insulation material containing Refractory Ceramic Fibre RCP which are man made vitreous silicate fibres Excessive exposure to these materials may cause temporary irritation to eyes skin and respiratory tract consequently it makes sense to take care when handling these articles to ensure that the release of dust is kept to a minimum This fire will run for 5 4 hours on one therm of gas with the gas control on the high setting TO LIGHT THE APPLIANCE 1 Remove the fret by lifting upwards controls cover 2 Press and turn the gas control until the indicator mark is opposite to IGN keeping the control fully depressed Press and release the ignition button Check that the pilot flame has lit at all ports Keep the gas control depressed for a further 20 seconds Release the gas control and check the pilot remains alight 3 Depress the gas control slightly and turn fully anti clockwise until the indicator is opposite the small flame symbol The burner will now ignite from the pilot assembly and run at the low rate Page 2 4 Depress the gas control slightly and turn clockwise until the indicator mark is opposite to the large flame symbol The burner wil
4. until a pilot ignition is established Depress the control knob slightly and rotate anti clockwise until the index symbol is aligned with the small flame symbol on the indicator label release and rotate the control knob to the high position large flame symbol Check that the flame picture is satisfactory prior to carrying out the spillage test To check the gas pressure at the appliance allow the coals and the coal bed to cool and turn off the gas supply at the isolating cock Remove the hexagon headed screw and connect a manometer to the pressure test point turn on the gas and ignite the fire allow to heat up and check that the gas pressure is 20 1 mbar any appreciable drop may indicate losses through the pipework The pressure test point may also be used to check for leakage of the joints to the appliance Allow the coal bed to cool before replacing the screw Turn the gas control to the OFF position wait for 90 seconds fully depress the gas control turn to the ignition position and release the control Attempt to light the pilot with an already prepared match or taper If the pilot lights the FSD is faulty SPILLAGE CHECK Light the appliance and set to the maximum setting locate the front and fret in position and leave to warm up for approx 5 minutes Check for satisfactory clearance of combustion products by inserting a lighted smoke match on a vertical plane 30mm down 10mm inside the rear edge of the inner canopy and 70mm from the
5. 0102 095 50721 CE LFE MKII ROYAL BELMONT USERS Pages 2 3 INSTALLATION Pages4 8 AND SERVICING INSTRUCTIONS THIS CAT l APPLIANCE IS FOR USE ON NATURAL GAS G20 AT A SUPPLY PRESSURE OF 20 mbar IN GB and IE HAND THESE INSTRUCTIONS TO THE USER USERS INSTRUCTIONS DESCRIPTION This Royal Cozy Fires Inset Live Fuel Effect gas fire has been developed to give a realistic coal burning appearance with the instant control and convenience of gas The fire has been constructed to enable it to be installed into most applications where the warmth and comfort of an open fire with high radiant and convection heat is required The coal bed uses ceramic simulated coals and is to give a realistic appearance and to allow secondary air to be entrained into the bed to ensure clean combustion An aerated twin ported steel burner is used running parallel across the front of the fire combined with a single gas control with a variable high low setting This is fitted with a Flame Supervision Device FSD to ensure that should the pilot flame be extinguished for any reason including turning off the appliance the gas supply to the burner is cut off until a full lighting sequence is repeated A separate Piezo igniter is used to ignite an oxy pilot sensor ODS this will cause the appliance to shut off in the event of the flame extinguishing and also in the event of continued spillage occurring under hazardous or blocked flue conditions The fire b
6. ENING REQUIREMENTS in Diameter Flue Chair brick and Builders opening Class 1 See Figs 2 amp 3 5in Diameter Flue and Metal Flue Box Class 2 See Figs 4 amp 5 Pre cast Flues See Figs 6 8 Page 5 INSTALLATION USING A 5 DIAMETER METAL FLUE BOX IMPORTANT Restrictor plates must be removed See Fig 15 When the metal flue box is to be built in as a false chimney breast using timber stud work with a plasterboard facing the metal flue box should be enveloped with insulation material such as Rockwool or similar to prevent a build up of heat within the structure Either an air gap of 75mm should be maintained between any combustible materials and any part of the metal flue box or a minimum of 25mm of insulation material between the metal flue box and the combustible material It is important that both the back panel and the appliance are sealed to the metal flue box to prevent any leakage of flue products or reduction in the flue draught See Figs 4 amp 5 PRE CAST FLUE INSTALLATIONS IMPORTANT Restrictor Plates must be removed See Fig 15 See Figs 6 8 CHECKING CONDITION AND COMPATIBILITY OF THE CHIMNEY Check that the chimney conforms to the required specifications as previously stated Examine the condition and carry out any remedial work as necessary if the flue has been used for solid fuel it should be swept and a smoke test carried out to check that satisfactory smoke clearance has been established If all the smoke is
7. T Oxy Pilot NG 9022 GAS CONNECTION 8 mm O D Tube WEIGHT 22 kg Note None of the materials used in the manufacture of this appliance contain asbestos INSTALLATION NOTES Care should be taken to ensure when the appliance is installed into a Pre cast flue the chimney breast is lined to prevent the plaster etc cracking through excessive temperatures A certain amount of discolouration blueing may be seen on the stainless steel combustion chamber this is normal due to the temperatures produced in the fire bed A hearth must always be provided a minimum of 340mm and a minimum of 150mm either side of the fire opening with a minimum thickness of 12mm and a perimeter height of 50mm This is to deter combustible materials carpets etc being placed on the hearth The area under the firebox must have a minimum non combustible thickness of 25mm Page 4 In most installations a back panel will be required this will also need a minimum fire resistance rating of Class O 100 C Check that the chimney and flue structure are sound and conform to the following flue requirements 1 A conventional brick or stone chimneys with a minimum effective cross sectional dimension of 225x225 mm A lined flue with a minimum diameter of 175 mm having a chair brick and throat forming lintel conforming to BS 1251 or a builders opening measuring 550 mm high x 400 470 mm wide with a sufficient depth for debris collection If a chair brick is fitted a minimum dept
8. ed consists of ceramic fibre components and coals all are removable for cleaning purposes when required It is important when relaying the coal bed and coals to follow the instructions correctly IMPORTANT NOTES This appliance has been designed and manufactured to the requirements of the British Standards Institution BS 5258 Part 16 1990 and is for use on Natural Gas Only All gas appliances must be installed by a competent person in accordance with the current Gas Safety Installation and Use Regulations 1994 as amended or the rules in force and in accordance with the manufacturers instructions failure to do so could lead to prosecution The chimney or flue unless new must be swept before installation It is recommended that the appliance is serviced annually by a competent person and the flue checked for satisfactory clearance of products and that there is no excessive build up of soot The curing effect of heating the coals will cause an initial odour which although not harmful may require additional ventilation until the odour has disappeared The appliance has a naked flame a fireguard conforming to BS 6539 or BS 6778 should be used for the protection of the very young elderly and infirm Combustible materials should not be put on or left in the hearth nor should the coal bed be used to burn rubbish or other materials Care must be taken on the selection of wall coverings within close proximity of the fire as some vinyl and embossed
9. h requirement for the appliance is shown in Figs 2 amp 3 if insufficient depth is available the chair brick will have to be removed 2 Atwin walled metal flue box manufactured to BS 715 with a twin walled 125 mm diameter flue and a minimum effective flue height of 3 metres See Figs 4 amp 5 3 A pre cast flue conforming to the requirements of BS 1289 Pt 1 1986 and BS 1289 1975 including properly constructed pre cast flues with a cross sectional area of 13000sq mm See Figs 6 8 NOTE Dampers register plates or incorrect flue terminals must not restrict the flues listed above The flue must only service a single appliance and not have any branches or traps that may impede the natural draught Any flue damper plate or restrictors shall be removed or fixed in the fully opened positions The front and base of the fire opening must be flat and square to ensure a good seal with the appliance this is to ensure that there is no reduction in draught through the fire which may cause spillage to occur CONTENTS CHECK LIST Convector Box and Front Trim Goal Post Burner Unit Burner Inserts Coal Support Shelf Fibre Back Set of Coals 7 Large 4 Medium 2 Triangular Front and Fret and 5 Small Short length of Bundy 43mm Concealed Supply Pipe In line Connector RH Conversion Supply Pipe Users Installation and Servicing Instructions Plastic Fixing Plugs 4 off Wood Screws 4 off Installation Brackets M4 x 10 Screws FIRE SURROUND AND OP
10. in Fig 9 Where a concealed gas supply is used the installer is reminded of the requirements of BS 6891 1988 dealing with enclosed pipes The Standard requires that when a gas pipe is fed through a wall the pipe should be enclosed in a tight sleeve to protect against failure caused by movement and shall be constructed to prevent passage of gas either between the pipe and sleeve or sleeve and wall Permanent sealant e g fire cement etc should not be used as these would prevent removal of the firebox if so required Page 6 DISMANTLING THE FIRE PRIOR TO INSTALLING The lower front panel assembly is removed by lifting upwards and pulling forwards Remove the canopy to gain access to the Bezel or Goal post trim securing screws The canopy is held in position by dimpled spring clips on both the side flanges remove by exerting an even pull forward See Fig 11 Remove the outer bezel Goal post trim by unscrewing the four M4 taptite screws on the inner flanges and the four No 8 self tapping screws in the corners It will be necessary to dismantle the burner from the convector box before installing the box in the opening to remove the burner unscrew the two screws securing the fibre back side cheek assembly in position and remove remove the coal support shelf and burner inserts Unscrew the two screws at the base of the aperture in the fascia panel and withdraw the burner INSTALLING THE APPLIANCE IN POSITION With the gas supply pipe laid
11. ions in mm Fig 1 150 a ON Hatched area must be non combustible and flat to ensure a seal around the appliance PA 150 395 470 Fig 3 XS Cross Section of a typical chairbrick layout using components to BS 8303 615 550 590 700 min Fig 2 i Depth A is to be a minimum of 145 mm from the knee to the front face of the surround to satisfy the debris collection requirement Depth B is nominally 70 mm If no chairbrick is fitted the minimum distance required between the rear of the opening and the front face of the surround is 210 mm without spacer frame fitted This hatched area must be a non combustible material and flat to ensure a seal around the appliance Fig 5 Fig 4 ERRE 19 G6 75mm Air iba A 5mm Insulated ttl gs Mg gy ty d e n 615 l must be taken to ensure the flue spigot of the appliance does not impede the flue outlet of the metal flue box J The area beneath the d metal flue box must be a non combustible material 25mm thick cdi Pre Cast Flue Installations IMPORTANT The Restrictor Plates must be removed See Page 10 Surround thickness when flue outlet depth is maintained Ensure that flue outlet does not protrude into flue Fig 7 SY UP SOLA Se TEE TS NYC M the appliance L he The Dimensions marked may be used to cut a template if required o MAE FA The hatched area mus
12. ixing nut from turning rotate the body of the igniter to unscrew and withdraw the igniter from the front Replace in reverse order and reconnect the HT lead IV TO REPLACE THE OXY PILOT ASSEMBLY The operation of the oxy pilot depends on the proximity of the spark electrode and the thermocouple tip if either of these components are defective the assembly must be replaced This is achieved by removing the tube nut from the base of the pilot and the thermocouple from the FSD also the igniter lead and the two M4 screws securing the bracket to the framework Replace in reverse order the spark gap is shown in Fig 18 Page 9 SHORT PARTS LIST For spares contact the manufacturer at the address below DESCRIPTION CROSSLEE No GC No Piezo Igniter 40245 397 686 Oxy Pilot Burner Assy SIT 42313 Control Knob 40232 170 014 Control Valve 42143 Main Injector Stereomatic 42168 Coal Support 42981 Burner Inserts 2 42952 Front Coal Mould 40481 Set of Coals 42937 Fibre Back Panel 42953 HEAT INPUT 18 500 Btu h 5 42 kW GROSS Royal Cozyfires are manufactured by CROSSLEE plc Aber Park Industrial Estate Aber Road Flint Flintshire CH6 5EX Spares Tel 01422 203963 Fax 01422 204475 Service GSA Ltd 01703 516611 Customer Service 01422 200660 Fax 01422 206304 Technical Help Line 0906 8633268 Calls charged at 50p per minute N N 614 550 4 i 19 _ 140 128 All dimens
13. l now run at its maximum rate To turn the appliance off return the control to the off position 6 If for any reason the fire cuts out return the control knob to the off position and wait 3 minutes before re lighting tA REMOVAL OF DEBRIS OR SOOT DEPOSITS Allow the appliance to cool sufficiently before removing all of the coals and firebed components for cleaning purposes Once all the ceramics are removed from the firebed check that no debris is located in the burner slots both front and rear If any debris is present it may easily be removed by using a small piece of thin cardboard to ease out any foreign matter Be sure to remove the cardboard after use Should any soot accumulation become excessive the fuel effect pieces should be removed from the fire for cleaning Cleaning should be carried out in a well ventilated area or in the open air by gently brushing with the pieces held away from your face so that you avoid inhaling the dust We do not recommend the use of a normal domestic vacuum cleaner which may blow dust back into the air Any sooty deposit on the thermocouple probe can be cleaned off using a non fluffy cloth ASSEMBLY OF THE FUEL BED COMPONENTS 1 Locate the fibre back side cheeks in position Place the coal support shelf on the stainless steel channel the machined groove on the underside of the shelf is located on the rear flange of the channel two additional location dowels are fitted to prevent
14. mm Add 12 5mm to this clearance for every 25mm increase in depth of shelf Page 3 INSTALLATION AN SERVICING INSTRUCTIONS THE FOLLOWING SECTION LISTS THE INSTALLATION REGULATIONS AND REQUIREMENTS All gas appliances must be installed by a competent person in accordance with the current Gas Safety Installation and Use Regulations 1994 as amended or the rules in force and in accordance with the manufacturers instructions failure to do so could lead to prosecution The following are the relevant Codes of Practice and British Standards BS 8303 1986 BS 5440 Pt1 1990 amp Pt2 1989 The Building Regulations issued by the BS1251 1987 BS 5871 Pt2 1991 amp Pt3 1991 Department of the Environment The BS 6891 1988 BS 6461 Pt1 1984 Building Standards Scotland Consolidation BS 715 1989 BS 1289 Ptl 1986 Regulations issued by the Scottish Development BS 7566 Pts 1 4 1992 Department TECHNICAL DATA Overall height of fire 614 mm Minimum height of opening required 550mm Maximum height of opening 590 mm Minimum width of opening required 395 mm Maximum width of opening with spacer 470 mm Forward projection from opening 140mm With controls cover Min depth of openings See Figs 1 8 TYPE OF GAS G20 Only Supply Pressure 20 mbar Imbar Cold GAS INPUTS Gross Maximum 5 42 kW 18500 Btu h Minimum 2 34 kW 8000 Btu h Pilot 0 26 kW 890 Btu h Main Injector Type Bray Cat 82 380 Or Stereomatic 046 19 196 68M Pilot Assembly SI
15. not drawn into the flue pre heat the flue with a blowtorch or similar and re check If there is any uncertainty examine for the cause and if necessary seek expert advice GAS SUPPLY BEFORE COMMENCING WORK TURN OFF ANY APPLIANCES THAT ARE FED BY THE METER AND ISOLATE THE GAS SUPPLY BY TURNING OFF AT THE METER The gas connection to this appliance is made with 8mm o d rigid or semi rigid tube to a pressure test elbow situated on the L H side of the burner as shown below It is advisable to provide a means of isolating the gas supply to the appliance for servicing with either a restrictor elbow or isolation cock such as shown below Provision is made in the rear L Hand corner of the outer casing to allow a gas supply to be fed to the burner assembly A blanking plate and gasket is supplied with cutouts and slots that will enable a seal to be made around the supply pipe If a restrictor elbow is to be used it will be necessary to cut and form the bundy pipe supplied Any pipe used under the burner must be in rigid tube such as Bundy 3 pieces of Bundy are included in the fitting kit to assist the installer a A short piece for use with a restrictor elbow b A formed section for connection to an isolation cock and c a formed section for R Hand supply using the inline connector supplied The inlet pipe support bracket can be removed if necessary to gain greater access by unscrewing the Control mounting lock nut and lifting over the spindle as shown
16. receipt of the purchasers address at the cost of postage only provided that 1 It is accompanied by the registration section cut out of the booklet together with the original purchase receipt which will be returned with the replacement part 2 A competent person has carried out installation repairs and or adjustments such as the supplier s representative or a CORGI registered installer Page 8 MAINTENANCE AND SERVICING GENERAL A REMOVAL OF DEBRIS OR SOOT DEPOSITS Allow the appliance to cool sufficiently before removing all of the coals and firebed components for cleaning purposes Once all the ceramics are removed from the firebed check that no debris is located in the burner slots both front and rear If any debris is present it may easily be removed by using a small piece of thin cardboard to ease out any foreign matter Be sure to remove the cardboard after use To ensure that the release of fibres from these RCF articles is kept to a minimum during installation and servicing we recommend that you use a HEPA filtered vacuum to remove any dust and soot accumulated in and around the fire before and after working on the fire When replacing these articles we recommend that the replaced items are not broken up but are sealed within heavy duty polythene bags clearly labelled as RCF waste This is not classified as hazardous waste and may be disposed of at a tipping site licensed for the disposal of industrial waste Protective clothing i
17. s not required when handling these articles but we recommend you follow the normal hygiene rules of not smoking eating or drinking in the work area and always wash your hands before eating or drinking Any sooty deposit on the thermocouple probe can be cleaned off using a non fluffy cloth DO NOT USE ABRASIVE MATERIALS B SERVICING COMPONENTS BELOW THE BURNER ASSEMBLY TURN OFF THE GAS SUPPLY TO THE APPLIANCE Remove coals coal supports burner inserts front simulated coal and fibre back side cheek assembly To gain access to components below the burner assembly it has to be removed from the vent box case by disconnecting the gas supply at the inlet elbow and unscrewing the two screws at the base of the facia panel I TO CLEAN OR REPLACE THE INJECTOR Unscrew the compression nut connecting the gas supply to the elbow injector while supporting the injector This is to prevent distortion of the framework unscrew and remove the gas supply tube from the gas control valve hold the injector lock nut with a spanner and rotate the injector Replace in reverse order II TO REPLACE THE GAS CONTROL Tap FSD Disconnect the three gas pipes and the thermocouple from the control Pull off the knob and lay to one side Undo the retaining nut at the front of the tap niting assembly to withdraw control from the mounting bracket Replace in reverse order III TO REPLACE THE PIEZO IGNITER Pull off the HT lead from the rear of the igniter prevent the metal f
18. t be a non combustible material and flat to ensure a seal around A Depth or thickness of the Back Panel required to ensure a seal with the appliance mm 400 The Dimensions marked may be used to cut a template if required Contact point with opening 275 Fig 8 Formed section of bundy 4 N n S s Isolation N COCk Lome al Paca PERS Fig 9 Inlet pipe support bracket Restrictor elbow Restrictor Elbow if fitted dE M UM suy Pipe j Tw gt lt or 36mm i N Ma Blanking plate CA r lt a a Sg To remove the canopy pull Gasket forward as shown 183mm ee ENS il d Fig 10 Fig 11 Fixing screws securing the Goal Post Trim in position Fig 12 Coal Support Shelf bs Fibre Back Grm Inline Connector t Supply Pipe R Hand Feed had d Runs along rear of control panel Fixing screws Supply Pipe a L Hand feed j racket position for Bracket reversed F pe sien for 18 opening y Fig 15 NOTE 2 Screws to be replaced c Restrictor plates to be removed when the appliance is used on either a Pre cast flue or insulated 125mm Diameter Flue to BS715 Fibre Back panel Coal Support Sheit Fibre back fixing screws Pilot Thermocouple Electrode 4 AX Restrictor Elbow if fitted Fig 16 Gas Control Valve 6 Ne Lm Pressure Test Elbo
19. the shelf being incorrectly placed 3 Place the two shaped burner inserts in channel between the two burner flame ports check that a minimum gap of approx 6mm is maintained between the rear of the burner insert and the front edge of the coal support shelf 4 Position the front simulated coal on the shelf provided above the control facia panel COAL LAYOUT Position 3 large coals 2 triangular and 4 large coals on edge straddle the gaps of the coal support shelf and run the strata front to rear as the first layer fig 21 Place 4 medium as a second layer sitting on the gaps of the front coals and resting against the rear coals fig 22 Finally place the remaining 5 small coals as shown in fig 23 Small adjustments to the coal layout may be made to give the best visual appearance however additional coals must not be used If any fibre component is lost or broken the appliance must not be used until a replacement is obtained VENTILATION Additional purpose built ventilation is not required for this appliance in GB only for Ireland IE ventilation is required with a minimal cross sectional area of 100 sq CMS and should be checked regularly to ensure that it is free from obstruction CLEARANCE TO SIDE timber surrounds etc Minimum clearance required to any combustible material to the side of the appliance must be 150mm CLEARANCE TO SHELVES Minimum clearance to the underside of a 150mm deep combustible shelf from the hearth must be 833
20. to the required position and the surround fitted and sealed to the chimney correctly this is to prevent any seepage of the flue products and to prevent any ingress of air into the flue from anywhere other than the flue outlet of the fire The method to be used to secure the appliance in position is either screwed directly onto the front face of the back panel through the mounting brackets or fixed to the internal side walls of the builders opening using the four fixing brackets provided These can be rotated to accommodate most openings as shown in Fig 14 plastic plugs and wood screws are supplied for these brackets It is very important when fitting the trim that when it is secured in position that the rear of the trim has an effective seal with the back panel or fixing wall A seal is fitted to the trim during manufacture Continue the supply and replace the burner ensuring that the rear legs locate in the two up formed tags in the base plate and complete the gas connection to the burner Replace the canopy NOTE Before offering the convector box into the opening the hearth should be protected from damage or scratches that may occur during installation The complete installation should be tested for Gas soundness IT IS VERY IMPORTANT THAT THE RESTRICTOR PLATES ARE REMOVED AND THE SCREWS REPLACED WHEN THE APPLIANCE IS INSTALLED INTO EITHER A PRE CAST OR A 5in 125mm DIAMETER FLUE ASSEMBLY OF THE FUEL BED COMPONENTS 1 Locate the
21. w 4 Medium Coals sitting on the gaps of the Ironi coals resting against rear coals Fig 22 py SENSE fs li M Nn HOR er A 5 Small Coals
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