Owner's Manual Residential Factory Built Fireplace Operation • Maintenance • Installation The OPEL AP Keep these instructions for future use. RSF-IIP_12-05 Page 2 OPEL AP Dear Customer, The OPEL AP incorporates technology with elegance to give you a beautiful view of the fire without compromising on heating efficiency or environmental quality. We have designed your new OPEL AP to be easy to install, operate and maintain. It is in your best interest to become familiar with it. Study your manual to be sure that the installation is correct, then follow the guidelines for operation and maintenance. We, at RSF Woodburning Fireplaces, congratulate you on your choice of the OPEL AP, and are confident that you have purchased a fireplace that is simply, the best. Sincerely, The RSF Woodburning Fireplaces Team April 2003 TABLE OF CONTENTS SAFETY FIRST 3 Do’s and Don’ts 3 Creosote Formation and Need for Removal GENERAL SPECIFICATIONS 3 Combustion Control System 3 Ash Pan 4 Firescreen 4 Thermostat 4 Internal Circulating Blower 4 Gravity Vent System 4 Central Heat System 4 Catalytic Combustor OPERATION 5 Lighting 5 First Fire 5 Refueling 5 Refractory Bricks Installation MAINTENANCE 6 Cleaning 6 Disposal of Ashes 6 Doors 6 Glass 7 Gold Plating 7 Chimney Cleaning 7 Paint 7 Catalytic Combustor INSTALLATION 8 Location 8 Ceiling Clearance 8 Outside Air Duct 9 General Assembly Illustration 11 Chimney 11 Chimney Installation 12 Masonry Chimney 13 Chase Enclosure 14 14 14 14 15 15 15 Radiation Shield Offset Chimney Framing In Spark Guard Mantel Hearth Extension Beneath Heath Extension OPTIONS 16 Wall Thermostat 17 Circulating Blower 17 Catalytic Combustor 19 Gold / Pewter Louvers 19 Rock Retainer Kit 21 Remote Venting 21 Gravity Vent System 22 Central Heat System 26 Zone Heating SCHEMATIC WIRING DIAGRAMS 28 Thermostat 28 Circulating Blower 29 Central Heat System 29 All Systems 30 Zone Heating FIREPLACE OPTIONS 31 Fireplace Options REPLACEMENT PARTS 32 Fireplace 33 Assemblies LABEL 34 Label WARRANTY 35 Warranty Page 3 OPEL AP SAFETY FIRST CREOSOTE: Formation and removal DO’S AND DON’TS When wood is burned slowly, it produces tar and other organic vapours which combine with expelled moisture to form creosote. The creosote vapours condense in the relatively cool chimney flue of a slow burning fire. When ignited, this creosote makes an extremely hot fire. The chimney should be inspected periodically during the heating season to see if a creosote build-up has occurred. If a significant layer of creosote has accumulated (1/4” or more), it should be removed to reduce the risk of chimney fire. If this fireplace is not properly installed, a house fire may result. For your safety, follow the installation directions. Contact local building or fire officials about restrictions and installation requirements in your area. NOTE: We strongly recommend installers to be WETT or WHERF certified. To ANYONE using this fireplace: These DO’s and DO NOTs are for your safety. 1. DO read this instruction manual before lighting your first fire. 2. DO burn seasoned wood fuel or processed solid fuel firelogs. 3. To avoid glass breakage, DO NOT slam the fireplace door. 4. DO NOT use gasoline-type lantern fuel, kerosene, charcoal lighter fluid or similar liquids to start or freshen up a fire in this fireplace. Keep all such liquids well away from the fireplace. WARNING: Burn dry wood only! DO NOT BURN: - driftwood - treated wood - coal - garbage - plastic Do not use construction scraps (e.g. 2x4 or plywood scraps) as your only supply of fuel as you may overheat and seriously damage the fireplace. Do not use more than 3 densified fuel logs (e.g. Presto Logs) at a time. Do not poke or stir the logs while they are burning. Use only firelogs that have been evaluated for fireplace use and refer to firelog warnings and caution markings prior to use. 5. DO NOT overfire the fireplace. If the chimney connector behind the top louver glows red, or if you are unable to slow down the burning rate of the fire, you are probably overfiring the fireplace. GENERAL SPECIFICATIONS 6. DO operate the fireplace with doors fully open or fully closed. If doors are left partly open, gas and flame may be drawn out of the fireplace opening, creating risks of both fire and smoke. Since the doors are sealed, all combustion air must come through a draft control. This control has a bimetal coil to allow more air when the unit is cold, and less air when the unit is hot, guarding against overheating. It can be controlled either manually through the lever below the door handles, or automatically through the optional electric wall thermostat. For the first few days, it is best to operate the fireplace with the manual control fully on (moved to the right as far as possible). Just control the fire as you would any normal fireplace using two or three large logs at a time for a smaller fire, or more logs for more heat. Once you become familiar with operating the fireplace with the control open, you can start experimenting with lower settings. Remember: when the fireplace is hot, the control will not need as much movement to reduce the fire as when it is cold. The bimetal coil will already have shut the damper part way. 7. DO keep all combustible materials (furniture, shoes, etc.) at least 4 feet away from the front of the fireplace. 8. If the Opel AP is equipped with a catalyst it needs periodic inspection for proper operation. If you have the catalyst installed, DO NOT burn chemical chimney cleaners. They contain contaminants that will render the catalyst inoperative. 9. DO NOT use a fireplace insert or other products not specified for use with this fireplace. 10. If you use the fireplace with the doors wide open, install a firescreen (FDFS) to prevent logs and sparks from burning your floor. 11. Always verify that your ash pan is in place before igniting a fire. THE COMBUSTION CONTROL SYSTEM THE ASH PAN The Opel AP is equipped with an ash pan to easily remove ashes from the firebox. To remove the ashes, open the doors and, with a poker, remove the ash pan plug from its hole. Push the ashes through the hole (making sure that the ash pan is in proper position). When the Page 4 OPEL AP ash pan is full, open the bottom louvers of the fireplace. The louvers can be easily opened by pulling the right hand side of the louvers. It is held in place by a magnet. Remove ash pan and dispose of ashes properly. Replace ash pan and louvers. Replace plug in hole, making sure it is properly placed before starting a fire. Do not remove the ashes from the firebox while they are still hot. The ash pan is not built to resist hot ashes or embers. Under no circumstances should the fireplace be operated without the ash pan plug and pan in place. FIRESCREEN (option) If you want to use the fireplace with the doors completely open, you have to run it with the firescreen (FDFS) in front of the opening. The firescreen will prevent sparks from falling on the floor. Do not leave the fireplace unattended when using the firescreen. THERMOSTAT (option) If you want a constant temperature, day and night, you will be surprised to see what the wall thermostat option can do for you. Once you have your fire burning, just set the manual control on low (push the draft control lever all the way to the left) and let the automatic thermostat take over. Your room temperature will stay as even as though you were heating with oil, gas, or electricity — except you will find wood heat more comfortable (see options: Wall Thermostat FDHC4). NOTE: This thermostat controls the combustion air rate, not the internal circulating blower. Also, when you are using the automatic thermostat during cold weather, you will find that the fire burns cleaner if the manual setting is on medium or higher. This will keep the thermostat from shutting the fireplace right down during the automatic on / off cycle. INTERNAL CIRCULATING BLOWER (option) If you have the optional internal blower installed, adjust the speed of the blower to the output you require. The blower speed control should be installed at a convenient place on the wall. When a fire is burning, the thermal switch installed inside the fireplace will turn on at 110° F, allowing the blower to operate. When the Opel AP cools to 90° F, the switch deactivates the blower. The maximum heat output of the fireplace is greater with the blower running (see options: Circulating Blower FDHB5-N). The handle is located between the top louvers of the fireplace. Simply turn the lever to adjust the air flow through the gravity vent ducting. As the hot air rises, it will be distributed through the insulated ducting to the outlet (see options: Gravity Vent System FDV). CENTRAL HEAT SYSTEM (option) You have the option to heat remote rooms in your home with the heat generated by your fireplace. If this option is installed, there will be a wall thermostat installed in the main room you want to heat, away from the room which contains the fireplace. This thermostat controls the blower, which brings air to the other rooms in your home, keeping them at the temperature you desire. When the blower is running, it takes air from the room the Opel AP is in, draws it around the fireplace and distributes it (see options: Central Heating System FDHC6 / FDHB6). NOTE: The blower (FDHB6) can push warm air either up or down, and can also be zone controlled ( See Options: Zone Heating). HINT: If some evening you would like to enjoy the ambience of the wood flame, but you are a little too warm, turn up the central heating thermostat and open a window by the thermostat. This will keep your room in front of the fire from getting too warm. CATALYTIC COMBUSTOR (option) If the Opel AP is equipped with a catalyst, it ignites creosote-forming gases in wood smoke at significantly lower temperatures. As a result, you get less creosote and more heat from your fire at low to medium burn rates. Less fuel goes up your chimney in the form of smoke. In addition to the list on page 3, DO NOT burn chemical chimney cleaners, as they can contain contaminants that will render the catalyst inoperative. The catalytic option comes with a bypass damper which serves two functions: a) to eliminate smoking into the room when the doors are opened; b) to allow the fire to start quickly when the fireplace is cold. GRAVITY VENT SYSTEM (option) Make sure the bypass damper above the right door is pulled all the way out before opening the doors. When starting a fire, the bypass damper should be left open long enough to establish sufficient draft (approximately 30 minutes). If there are areas in your home that you would like to heat either in an upper level or an adjacent room, the gravity vent system can provide this heat without the use of a blower. It is controlled by a gravity vent damper. The temperature in the firebox and the gases entering the catalyst must be raised to at least 500° F for catalytic activity to be initiated. When you start the fire, keep a medium to high fire for about 30 minutes to stabilize the Page 5 OPEL AP The doors should be opened slowly, moving both doors together, to keep smoke from spilling into your room. If you do have smoke spillage, check to see that all kitchen and bathroom fans have been shut off. They can cause a vacuum in the house, which pulls smoke out of the fireplace. Fireplace face Thick facing Pull hook Rod extension bypass eye Set screw Handle Decorative collar Figure 1a: Bypass control with extension rod catalyst at a sufficient operating temperature. If the fire is allowed to die down too soon after starting, the catalyst may stop working. After the 30 minutes of a medium to high burn, however, the catalyst will operate with the heat generated by the burning smoke, even with a low fire. OPERATION LIGHTING Slide the draft control under the doors all the way to the right. Light a fire in the fireplace, starting with paper and kindling only. Then add 2-3" diameter pieces of wood. After the fire is established, close the doors to prevent overheating (see the Combustion Control section). Never use any flammable liquids. Once a coal bed is established, add standard cord wood. Leave the draft control open until the fire is well lit, then adjust it to the level you desire. WARNING: Do not use a grate or elevate the fire. THE FIRST FIRE Before the first fire, be absolutely sure to wipe off all fingerprints and debris from the gold plating. The plating undergoes a sealing process during this first fire, and the acid from your finger prints will permanently etch the gold plating. You will experience a slow start-up during the first fire. The refractory bricks still contain moisture and take a good hot fire to get rid of the moisture. While there is moisture in the bricks, the bricks will be black with smoke deposits. When the moisture is gone, the bricks will be white. You may also experience a slight odour during the first few fires. This odour results from curing paint and the burn-off of oil. REFUELING Fuel wood can be of any species, however, ensure that the wood is well seasoned and kept under cover. Sixteen to eighteen inch lengths work the best. NOTE: The central heat and internal blowers, if installed, should be shut off during refuelling. If you have the Opel AP with the catalyst: after refuelling a cool fire or a fire that has burned down to a cool coal bed, operate the fire at a medium to high burn rate for at least 10 minutes to ensure that the catalyst reaches operating temperature. REFRACTORY BRICKS INSTALLATION Before lighting your first fire you must make sure the refractory is properly installed inside the firebox. This is easily accomplished with the following instructions. First, through the front opening of the fireplace pass the baffle (11.6.P). Next, place the baffle parallel to the opening with the narrower portion on top. Slide the baffle onto the bracket at the top of the firebox until it is as far back as it can go. Install the back left and back right (11.11.P and 11.12.P) at the back of the firebox with the joint in the center. These will be secured in place by the two side rear (11.9.P and 11.10.P) refractories. To install these two refractories, put the top corner into the bracket and slide the entire refractory into place. The two small front refractories (11.7.P and 11.8.P) are installed with the finished side towards the front of the unit. See (Figure 1b) below for more details. These refractories have been designed specifically for the Opel AP and no modifications are required to ensure a proper fit. 11.6.P 11.9.P 11.11.P 11.7.P 11.12.P 11.14.P 11.15.P 11.10.P 11.8.P Figure 1b: Refractory bricks installation Page 6 OPEL AP MAINTENANCE CLEANING Adjust here The high-heat paint and gold plating can be cleaned with a soft moist cloth. Use a mild detergent and water. Do not use abrasive cleaners! Loosen DISPOSAL OF ASHES Tighten Clean the ashes before they become too deep, i.e., before you have a spillage problem when opening the doors. When removed from the ash pan, ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes should be placed on a noncombustible floor or on the ground, well away from all combustible materials, pending final disposal. If the ashes are disposed of by burial, or otherwise locally dispersed, they should be retained in the closed container until all cinders have thoroughly cooled. Figure 2: Door adjustment DOORS Keep the door latch and hinges lubricated with all-purpose grease at least annually. To adjust the door closer, tighten the Allen screw (as shown in Figure 2) to ensure that the door closes tightly. The hinges can be adjust by loosening the nut underneath (Picture 1). Close the right hand door while the door closer is not latched. Adjust the door so that the joint between the two doors is straight and level. Push the door firmly against the facade of the fireplace while tightening the hinge nuts. Use a screwdriver on the bottom of the hinge pin and a wrench to tighten the nut. Be sure that the door latch can easily go into its slot on the façade. Adjust the left hand door so that the top arch and the joint are flush with the right hand door. With the right hand door open, push on the left hand door firmly against the façade of the fireplace while tightening the hinge nuts. Re-tighten the door closer as described above. Picture 1 If the door seal is damaged to the point where it does not seal tightly, replace the gasket. The Gasket Replacement Kit (FDGRK2) is available from your dealer. It is normal to push on the handle to close the doors (Picture 3). To verify that the doors are well sealed, insert a piece of paper between the door and the fireplace (Picture 4). Along the top of the door you should be able to tear the paper when it is pulled out. On the side and bottom part, you should be able to pull out the piece of paper with some resistance (Picture 5). NOTE: An improperly adjusted door seal can have a significant effect of the performance and durability of the fireplace. A poorly adjusted door can result in reduced efficiency, excessive wood consumption and pre-mature fireplace failure. Picture 2 GLASS In a controlled combustion firebox temperatures are not always high enough to keep the glass perfectly clean. A good hot fire in the morning usually cleans off most of the deposits that have accumulated during the night. Remember the drier the wood, the cleaner the glass. A Page 7 OPEL AP Picture 3 word of caution: although heat will not break the glass, a good blow can. Be careful not to hit the glass. Picture 4 Picture 5 CHIMNEY CLEANING WARNING: Never clean this glass with an abrasive cleaner. Use only a cleaner recommended by your dealer. Never clean the glass while it is hot, a serious burn can result. There are a number of excellent wood stove glass cleaners available. Check the chimney for creosote build-up every week until experience shows how often cleaning is necessary. A build-up of 1/4 inch or more should be cleaned before more creosote accumulates. Use a 7 inch diameter wire brush. The baffle in the firebox must be removed to gain access to the flue from below. If your glass breaks: Baffle removal: See your dealer for the exact replacement glass. If the gasket is damaged, it must be replaced with the identical kind (14.10.2). Place the gasket on the door frame between the door and the glass (it is self-sticking). 1. Remove the secondary air tube and the refractory liners. 1. Remove the door from the fireplace by lifting it off the hinges. 2. Slide the baffle towards the front of the fireplace and rotate it so that you can lower it to the bottom of the fireplace opening. 3. Remove the baffle through the door opening. 2. Remove the clips holding the glass. Follow the reverse procedure to re-install it. 3. Clean out any bits of glass and dirt from the gasket. PAINT 4. Place the new glass into the opening and replace the clips being careful not to over-tighten the screws. 5. Check the glass by trying to move it back and forth. It should feel snug, but move slightly without too much effort. GOLD PLATING If you have gold/pewter doors or gold/pewter louvers you will be happy to know that they will not tarnish however they are not scratch resistant. They require a totally abrasive free cleaner. Use only mild soap and warm water to clean the gold when the surface is cool. The use of any household cleaner, such as Windex, abrasive cleaners, or any form of acid, may permanently etch or remove some of the gold plating. Before every fire, be absolutely sure to wipe off all fingerprints from the gold plating. Acid from debris or your fingerprints may permanently etch the gold plating. You may touch up the face of the Opel AP with STOVE BRIGHT Flat Black high temperature paint. The correct paint is available from your dealer. When you paint the face of the fireplace, remove the gold items (i.e., doors and louvers), and cover the area surrounding the fireplace with newspaper. Follow the directions outlined on the spray can. DO NOT attempt to paint while the fireplace is still warm. Keep the spray can away from any source of heat or open flame. Ensure that there is adequate ventilation in the room from the time you start painting until the paint is dry. CATALYTIC COMBUSTOR (option) The catalyst is warranted by the catalyst manufacturer, please insure that you keep the warranty card. If the catalyst fails, it should be replaced with Applied Ceramics Model 3621202-52-C. The dimensions of the catalyst are 3.875" x 12.25" x 2". Page 8 OPEL AP It is important to periodically monitor the operation of the catalyst to ensure that it is functioning properly and to determine when it needs to be replaced. A non-functioning catalyst will result in a loss of heating efficiency, and an increase in creosote and emissions. Catalysts should be visually inspected at least three times during the heating season to determine if physical degradation has occurred. Actual removal of the catalyst is not recommended unless a more detailed inspection is needed because of a noticeable decrease in performance. You can get an indication of whether the catalyst is working by comparing the amount of smoke leaving the chimney when the smoke is going through the chimney after light-off has been achieved, to the amount of smoke leaving the chimney when the bypass damper is open: 1. Light the fire in accordance with the instructions under lighting. After the fireplace is warm, set the manual control (and the thermostat, if this option is installed) to low. 2. With the bypass damper closed, the smoke is routed through the catalyst. Go outside and observe the emissions leaving the chimney. 3. Open the bypass damper and again observe the emissions leaving the chimney. Significantly more smoke should be seen when the exhaust is not routed through the catalyst, i.e., with the bypass damper open. Be careful not to confuse smoke with steam from wet wood. The catalytic combustor is self-cleaning, and requires very little maintenance. Any loose ash should be removed with a paintbrush. If the catalyst is plugged with creosote, you may try burning it off by leaving the bypass damper in a partially open position and pushing the draft control all the way to the right. You may also burn off the excess creosote with a propane torch. WARNING: Do not use sharp or hard tools to clean the catalytic combustor as this will damage it. Catalyst removal and replacement 1. Remove the screws holding the brackets, one on each side of the catalyst. 2. Carefully ease out the catalyst, using a knife blade if it is tight. 3. Replace the catalyst the same way it was removed. If the gasket is loose, re-cement it to the outside using a silicone adhesive. A damaged gasket should be replaced with 3M “Interam” 1/16” x 2” x 36”. INSTALLATION Check local codes concerning restrictions and installation requirements in your area. WARNING: Remove the doors before installation and place them in a safe area to reduce the possibility of: a) Vandalism ; b) Sub-trade tool abrasion, chipping, or breaking of glass ; c) Gold finish damage because of muriatic acid, plaster, cement, paint and harmful sprays or liquids. LOCATION Your Opel AP fireplace may be installed in many different ways (see Figure 4) without any special floor reinforcement. WARNING: If this fireplace is not properly installed, a house fire may result. For your safety, follow the installation directions and clearances. 1. Note the location of roof and floor joists. Choose a location that does not require cutting them. 2. Do not build shelves or cupboards in the area above the fireplace. This space must be kept empty. 3. If at all possible, run the chimney up the inside of the house. If it must be run up outside, it should be enclosed in an insulated enclosure (see Installation: Chase Enclosure). Remember, a cold chimney causes poor draft! CEILING CLEARANCE Ceiling clearance is the distance from the top of the fireplace to the ceiling. If the space between the top of the fireplace and the ceiling joists is less than 37 inches, the enclosure around the fireplace MUST be vented. Place a minimum 3" X 10" vent grille into holes cut within one foot of both the floor and ceiling levels, to allow room air to circulate through the fireplace enclosure and reduce heat buildup. These vent grills may be placed vertically or horizontally. Under no circumstances is the distance between the ceiling and the top of the unit to be less than 25 inches (see Figure 3). OUTSIDE AIR DUCT After the fireplace is correctly positioned, connect the combustion air inlet to the outside (see Figure 5). A 4 inch diameter duct can be used if the total run of the pipe is less than 25 feet. If the total run is longer than 25 feet, a 5 inch diameter pipe must be used. Page 9 OPEL AP Rain cap - See the manual for flue height requirements. Storm collar - The central heat blower may be installed on the left side. Roof flashing - Gravity vent may be installed on the left, right or both sides. Radiation shield and storm collar Ceiling Radiation shield Central heat blower Back draft damper Header Gravity vent damper handle Hearth extension Metal sheet and DUROCK© board (see page 16) B-vent components for gravity system only (or Ultrablack double wall connector made by ICC). Ceiling clearance (minimum from the top of the fireplace) : 25” for vented enclosure 37” for sealed enclosure Fresh air hood 24” minimum depth of opening The hearth can be made of any permanently affixed, non-combustible material Electrical knockouts 5” wide sheet metal spark guard Figure 3: Assembly drawing Page 10 OPEL AP 18” 58” Block 24” 38 1/2” 8 3/4” min. to side wall 38 1/2” 82” These framing dimensions are larger than required for ease of installation. The fireplace has a minimum clearance of 0” to standoff (see unit dimensions Figure 13). 49” 38 1/2” NOTE: When framing with 2x6’s and installing the gravity vent option, be sure to allow for the 2” minimum clearance between the header and the B-vent pipe. (see Figure 13) for gravity vent locations. 24” Figure 4: Location and framing dimensions 1. Find a convenient location for the combustion air duct and register. The location of the register may be above or below floor level. 3. Place the insulated flexible duct over the register tube and outside air connector sleeve. At both ends, carefully pull back the insulation and plastic cover, exposing the flexible duct. Then at each end, attach the duct with metal screws to the inlet and tube. Carefully push the insulation and cover back over the duct. Tape the plastic cover in place with the 2" aluminum duct. 2. Make a 4 1/4"(5 1/4" if using a 5" diameter duct) hole in the outside wall of the house. Mount the register in the hole from the outside with the inlet facing down. 2 1 Outside air connection Outside air register 2” aluminium duct tape Opel AP Insulated flexible air duct Outside wall Figure 5: Outside air connection and installation options CAUTION: When running duct around corners, be sure to prevent crimping that would restrict the combustion airflow. Use an insulated duct rated at over 200° F. Our testing has shown that as long as the 5" diameter insulated duct is utilized properly, there is no restriction on the length of the run. It is recommended that the duct does not exceed 12 ft. vertical height rise above the base of the unit. The air inlet should never be less than 5 ft. below the top of the chimney flue and should not terminate in attic spaces. Page 11 OPEL AP Outside air control The Opel AP is designed to use outside air for combustion but you may choose to use inside air for combustion air instead. To do so, open the sliding door on the bottom inside right of the fireplace (behind the bottom louvers). Note that the fireplace uses outside air when the handle is closer to the back of the fireplace and inside air when it’s closer to the front. We recommend the use of outside air for combustion. CHIMNEY This fireplace is certified for use with 7” ICC Model EXCEL chimney. The chimney system height from the top of the fireplace must be a minimum of 12 ft. and a maximum of 40 ft. 3. Place the first chimney length on the fireplace. Secure the chimney length to the fireplace with the three screws provided. The chimney must extend at least 3 ft. above its point of contact with the roof and at least 2 ft. higher than any wall, roof, or building within 10 ft. of it. NOTE: If the chimney is higher than 5 ft. above the roof, it must be secured using a roof brace. 4. Put the roof flashing into place. Seal the joint between the roof and the flashing with roofing tar. For sloping roofs, place the flashing under the upper shingles and on top of the lower shingles. Nail the flashing to the roof using roofing nails. If the chimney is enclosed to the roof: We recommend that the minimum height be increased by approximately 1 ft. for every 2000 ft. elevation above sea level. Every 30° or 45° elbow also increases the minimum height by 1 ft. For example, if you are living 6000 ft. above sea level, your chimney should terminate at least 15 ft. from the top of the fireplace (12 ft. + 3 ft. for the 6000 ft.). (See Table 1) for more precise recommended flue heights. CHIMNEY INSTALLATION -USA: use a vented flashing. -CANADA: use a vented flashing or a roof radiation shield (ERRS) and a regular flashing. 5. Place the storm collar over the chimney and flashing. Seal it around the chimney with silicone sealer (DO NOT use roofing tar). NOTE: The clearance between the chimney and combustible material must be 2" or more. DO NOT fill this area with insulation. 6. Fit the rain cap on the chimney. Secure it tightly in place. 1. Cut and frame the required holes in the floor, ceiling and roof where the chimney will pass through. Use a plumb bob. The rough opening in the framing size is 13 1/4” square. 7. Read the EXCEL Chimney installation manual concerning requirements for supports, bracing, anchors, etc. 2. From below, install a radiation shield in each floor through which the chimney passes. At the attic level, install a radiation shield and a storm collar as shown in (Figure 6). 8. The maximum height of chimney that can be supported by the top of the fireplace is 18 feet. TABLE 1 MINIMUM RECOMMENDED FLUE HEIGHTS IN FEET FROM THE TOP OF THE FIREPLACE NUMBER OF ELBOWS Elevation(ft) 0 2 x 15° 0-1000 1000-2000 2000-3000 3000-4000 4000-5000 5000-6000 6000-7000 7000-8000 8000-9000 9000-10000 12’ 12’6” 13’ 13’6” 14’ 14’6” 15’ 15’6” 16’ 16’6” 13’ 13’6” 14’ 14’6” 15’ 15’6” 16’ 16’6” 17’ 17’6” 4 x 15° 14’ 14’6” 15’ 15’6” 16’ 17’ 17’6” 18’ 18’6” 19’ 2 x 30° 4 x 30° 2 x 45° 4 x 45° 15’ 15’6” 16’ 17’ 17’6” 18’ 18’6” 19’ 20’ 20’6” 18’ 19’ 19’6” 20’ 21’ 21’6” 22’ 23’ 24’ 24’6” 16’ 16’6” 17’ 18’ 18’6” 19’ 20’ 20’6” 21’ 22’ 20’ 20’ 21’6” 22’6” 23’ 24’ 24’6” 25’6” 26’6” 27’ Page 12 OPEL AP space clearance at all points around the chimney from floor to roof flashing. If the chimney is enclosed in drywall, openings will probably be required in order to verify clearances at all points. Rain cap 2’ min. 10’ min. NOTE: openings must be framed to adequately support any chimney supports and roof assemblies Storm collar 3’ min. Flashing 2” min. WARNING: DO NOT PACK REQUIRED AIR SPACES WITH INSULATION OR OTHER MATERIALS 1-hour fire rated enclosure required when chimney passes occupied living space (closets, etc.). 2” min. clearance from chimney. 5. Chimney will be used only for the fireplace and may not be used to vent a furnace, water heater or any other appliance. Storm collar 6. If major repairs are required to meet the above conditions, a new chimney should be constructed. Radiation shield New chimney installation: To ensure adequate draft and to facilitate cleaning, the fireplace must be connected to 37” min. (84 from the chimney using 7" diameter EXCEL chimbase to ceiling) for sealed enclosure ney with an elbow, as shown in (Figure 7). An ICC 7" rigid stainless steel liner and a 45° 25” min. (72 from stainless steel elbow are attached to the base to ceiling) for vented enclosure chimney and secured in place using a liner adapter (FDM). If you use a 6 x 10 clay liner you will need to ovalize the stainless steel liner to fit into the clay liner. It is recommended that you position your fireplace Louverd before building the chimney. The factory vents built chimney sections can easily be installed as the layers of brick are being placed. Opel AP Figure 6: Chimney installation MASONRY CHIMNEY WARNING: When contemplating using an existing chimney, it must first be thoroughly inspected by an authority having jurisdiction to determine the following: NOTE: If the ceiling is high enough some vertical chimney can be installed before the 45° or 30° elbow is installed. Excel liner or other liner list1. It is a well constructed, lined ed to ULC-S635, ULC-S640 masonry chimney, fully in or UL1777 accordance with Local Building Codes and the National Building Code of Canada 12” min. to NBCC 9.21 or NFPA 211. combustible ceiling Clearance as per NBCC 9.21 or NFPA 211 Metal firestop 2. It has been thoroughly cleaned of any soot or creosote residue Excel 7” chimney and inspected to determine that 18” min. length it is in good condition. 3. There is no attic insulation of any type in contact with the chimney and no insulation stuffed in around the chimney at any point, for any reason. 4. There is, as per NBCC 9.21 or NFPA 211, the necessary air Excel elbow Masonry adaptor (FDM) Figure 7: Connection to masonry chimney Page 13 OPEL AP Existing chimney installation: If it is difficult to install rigid stainless on an existing chimney, a listed stainless steel flex liner can be used. Special care is to be taken when installing the flexible liner. A positive connection is assured with the masonry adaptor (FDM) available from your dealer. The stainless steel flex liner connects to the masonry adaptor with a flexible/rigid adaptor (LAF) and is secured with the 3 stainless steel rivets provided. The masonry adaptor is then secured to the Excel chimney with the 3 screws provided. The stainless steel liner fits inside the clay liner all the way to the top of the masonry chimney. It is not meant to replace the clay liner. After mortaring in place, the connection should not be visible. Care must be taken when cleaning to ensure that the stainless steel flex liner is not dislodged. As depicted in (Figure 7), the EXCEL chimney is to be a minimum of 18" from the connection point at the elbow to the masonry adaptor. The uppermost part of the metal chimney where it enters the masonry chimney must be a minimum of 12 inches from the ceiling. 1. Sight-in and mark the outline of where the factorybuilt chimney will penetrate the masonry chimney. 2. Using a large (3/4" - 2") masonry drill bit, drill a hole exactly in the center of the oval outline. With a masonry hammer and drill, slowly enlarge the hole to the size required. Remember to work from the center out. Be especially careful with the clay liner behind the brick because three sides of it must stay in place. Storm collar 3. Bring the stainless steel liner down from the top of the chimney. If you are using a rigid liner you will need enough room to secure an elbow to it with at least two screws. For chimneys with less than 10" X 10" inside you may find it easier to install a flex liner and secure the end with a special adapter (LAF) available from your dealer. 4. Move the fireplace forward enough to install the length of EXCEL chimney then move the fireplace back into position as you connect the masonry adaptor to the EXCEL chimney. CHASE ENCLOSURE If the chimney runs up the outside of the house, it must be enclosed in a chase structure. It is best to locate the chase away from any overhead obstructions and meet all clearances from such objects. The chase should be constructed in such a way that it is an extension of the home. It should be well insulated between the footings and the floor of the home to prevent heat loss. If the climate in your area is mild, insulate the chase at least to the first fire-stop. If the climate in your area is very cold, insulate the chase to the top to keep the flue warmer, to increase the draft, and reduce creosote buildup. 10 ft 2 ft min. Storm collar Use offset support 12” min. Flashing* Offset Rise Radiation shield Insulation Chase liner of fire rated gypsum board is recommended (may be required by local authorities) Radiation shield Fire stop, joist radiation shield Offset suport In USA: Use vented flashing 3 metal screws in each joint Figure 8: Offset chimney installation 2” min. clearance to combustibles Opel AP In CANADA: Use Roof Radiation Shield (ERRS) and a regular flashing Figure 9: Chimney installation with chase enclosure Page 14 OPEL AP NOTE: In USA if the chase is enclosed or flashed to the roof as shown in (Figure 9), then the flashing must be vented. FRAMING IN If required by local codes, make certain that the walls have been properly insulated, vapor sealed and sheathed with a fire rated gypsum board (see Figure 9). The enclosure walls can be framed with any suitable materials (2x4 or 2x6 studs, plywood, gypsum board, etc.). Because of the high heat output potential of the Opel AP, combustible material must NOT go closer to the fireplace than the standoffs, top, back and sides. REMEMBER: Check local codes concerning installation requirements and restrictions in your area. If you like, framing can be set back to allow the facing to be flush with the front of the fireplace. RADIATION SHIELD Each top standoff has a notch where the gypsum board can be inserted when finishing. A radiation shield must be placed where the chimney passes through each floor level overhead. This will assist in retarding any spread of fire and act to contain the fire within the area below the radiation shield. In front of each side standoff there is a gypsum board bracket to lean the finishing wall on. Under no circumstance the gypsum board or finishing wall should be placed below this bracket or notch line. OFFSET CHIMNEY SPARK GUARD Maximum offset angle: Maximum number of elbows: 45° 4, resulting in two (2) offsets. An elbow may be installed directly on top of the fireplace if required. Use the offset option if you need to clear a joist or pass around a cupboard. Install the fireplace and chimney as described earlier. When you require an elbow, proceed as follows: Install a 5" piece of sheet metal centered under the joint between the fireplace and the hearth extension. This will make certain that sparks cannot lodge in the crack and start a fire. If you are preparing a raised installation, then Flashing* 12” min. 2 ft min. 10 ft. 2” min. to combustibles See the detailed offset chart in the EXCEL installation instructions. 1. Install the required elbow. Turn it in the desired direction, and fasten it to the other section with the 3 metal screws provided at the joint. Wall support 2. Install enough lengths to obtain the desired offset. Secure each joint with 3 metal screws. 3. Use another elbow to return the chimney to the vertical direction. Radiation shield and offset, roof or wall support 4. Install a roof support, wall support, or an offset support at each offset to support the weight of the flue (elbows are not designed to support a flue above an offset). Insulated firestop in angle(30° or 45°) Opel AP Z-shaped spark guard for raised installation must be custom supplied by installer (minimum 26 gauge steel) Opel AP Non-combustible flooring In USA: Raised platform Figure 10: Z-shaped spark guard Use vented flashing In CANADA: Use Roof Radiation Shield (ERRS) and a regular flashing Figure 11: Offset chimney through a wall Page 15 OPEL AP a “Z” shaped spark guard must be installed. The height of the Z-shaped spark guard must equal the distance between the floor and the base of the unit. The minimum depth the spark guard must extend beneath the Opel AP is 2 1/2 inches. The spark guard must run the full length of the fireplace. (Z-SHAPED GUARD NOT SUPPLIED.) 8” max. Mantel MANTEL A masonry or other non-combustible mantel may be placed directly above the top louvers. If a wood or other combustible mantel is desired, then it must be at least 28” (54" from the base of the fireplace) above the top of the door opening (see Figure 14). 54” 46 ¾” 12” min. from side wall to edge of louvers HEARTH EXTENSION The area immediately in front of the fireplace must be protected by a non-combustible material such as brick, tile, stone, or slate. The protection must extend at least 16" in front and 8" on both sides of the fireplace opening. There is no minimum thickness required for the hearth extension. 16” 23” 38 ½” Non-combustible hearth Insulation ¾” NOTE: Metal sheet and Durock© cement board (in USA only). Figure 12: Clearance to combustibles BENEATH HEARTH EXTENSION Installation required in the USA only. 11” 11” Opening for gravity vent only 11¼” 24” to standoff 1 ½” Opening for central heat or gravity vent ducting ½” If the fireplace is raised 4” or more, the area in front of the fireplace just needs to be covered with a non-combustible material such as metal, brick, stone or slate, it does not require the Durock© board. There is no minimum thickness required for this non-combustible hearth extension. The 5” wide spark guard must be 48” to top standoff installed underneath either the hearth extension or the Durock© board. 37” to standoff 5 ¾” 25” 39 ¼” 18 7/8” 1 ¼” The Opel AP must use a metal sheet and 1/2” Durock© cement board beneath the hearth extension - unless it is raised at least 4 inches above the base of the hearth. The metal sheet and Durock© board must have the same dimension as the hearth extension, namely, 16” wide and 38 1/2” long. NOTE: if the Opel AP is installed on a concrete floor, the Durock© board and spark guard are not required. 29 ½” 36” Figure 13: Unit dimensions 1 ¾” 15 ¼” 4 1/8” Page 16 OPEL AP 23 1/2” min. to combustible top facing (49 3/4” from the base of the fireplace) Combustible top facing may protrude 1” max. from the face of the fireplace 28” min. to mantel (54” from the base of the fireplace) automatically controls the amount of combustion air to the fire, leaving your home at an even preset temperature. If you seriously plan to heat your home with the fireplace, the thermostat option will increase comfort, end the C o m b u s t i b l e fuss of continued manual adjustment, and side facing or reduce wood consumption. surround may extend 8” max. For more heat output and increased air circufrom the face of the fireplace lation, you can add the internal blower (FDHB5). For larger homes in colder climates, this is an important option if you plan to use the fireplace as a serious source of heat. NOTE: It will be difficult to install the internal blower if wiring is not run during framing. If there is any chance that this option will be installed in the future, power should be run to the fireplace and wire must be run to a switch box at a convenient place on the wall for mounting the blower control. 7 1/4” min. from door opening to combustible facing Figure 14: Clearance to combustibles OPEL AP OPTIONS Just a few comments about your Opel AP options. The size and shape of your home and how you intend to use your fireplace will determine the options you require. For a basic, high-efficiency fireplace, you won’t need any options or electricity. Automatic temperature control can be accomplished by adding the thermostat option (FDHC4). The thermostat Black White Ground (bare) Top louvers Draft control Keyhole with pendant stops Wall thermostat (FDHC4) This optional kit allows you to control the temperature by a remote mounted electric wall thermostat. See wiring diagram (Figure 34) To thermostat 110 V Pendant end chain (FDHC4 kit) Transformer If you desire even heat throughout your home strictly from your fireplace, or if you want to move heat to a remote area of your home, it is recommended that you incorporate the central heat option (parts FDHB6, FDHC6 and FDHC6-1). A thermostatically controlled blower takes heat from the fireplace, and distributes the warm air throughout your home even a couple of stories up or down. WALL THERMOSTAT (FDHC4) Terminal block (cover removed) Damper motor (FDHC4) If you have rooms directly above or adjacent to the room with the fireplace that you would like to heat, you may consider the gravity vent option (FDV). The gravity vent distributes hot air to these rooms and requires no blower to assist its operation. However, with the internal blower (FDHB5-N) installed, there will be some increase in warm air movement to rooms serviced by the gravity vent. Mounting Screws bracket Figure 15: Thermostat control installation NOTE: It is strongly recommended that this kit be installed during framing so that the wiring can be easily hidden. 1. Remove both top and bottom louvers. The top louver is held in place by springs underneath, so push down from the top, then rotate and pull forward. The bottom louvers can be opened by pulling the right hand side of the louvers. To completely remove the louvers, when opened, push up the louver to remove the bottom of the hinge rod from its hole and pull the louvers. 2. The damper motor and transformer are mounted on a bracket in the bottom right hand corner of the fireplace (see Figure 15). Page 17 OPEL AP 3. BEFORE fastening the controls with the 2 screws provided, thread the supplied chain through the spare keyhole in the draft control and attach a pendant to the end, just like the chain that is beside it. Let the chain down on the same side of the heat shield as the existing chain, and attach it to the lever on the damper motor with another pendant. Push the pendant snug into the hole in the lever. Then mount the controls to the bracket. 4. Adjust the chain on the draft control lever until it is just snug but the damper is still closed. When the damper motor is energized, the damper should open all the way. Lock the chain onto the keyhole with another pendant just like the chain beside it. 1. Remove the bottom louver. (See operation #1 in the above section.) Pull the louver from the right hand side toward you. Lift the louver to remove the bottom of the hinge rod from its hole. Remove the top of the hinge rod from the top hole. 2. Remove the ash pan, to do so, you will need to remove the plug from the inside of the firebox. 3. Remove the ash pan’s drawer. Remove the screw located on the right hand side of the drawer at its back. 4. Mount the blower on its 90º bracket. Be sure that the wires are connected to the blower before mounting. 5. Wire the thermostat as shown in (Figure 15), making sure the wall control is sufficiently away from the direct radiation of the fireplace. Make certain that it is at least 10 ft. away from the fireplace, but in the same room. 5. Hold the blower with the outlet facing up from the back. Fit the blower through the louver opening. CIRCULATING BLOWER (FDHB5-N) 7. Mount the thermal switch on its support as shown in (Figure 17). The thermal switch support is located just beneath the bottom of the firebox on the right hand side leg. Push the clips on to the support as far as they will go. NOTE: It is important that the wiring for the blower kit is installed during framing so that the wiring can be easily hidden. 6. Slide the blower into place between the two brackets. You should see the wheels of the blower. NOTE: One thermal switch is all that is required to operate the internal blower, the central heat blower, or both. Blower speed control Circulating blower Terminal block Thermal switch bypass 8. Locate the provided speed control in a switch box at a convenient location on the wall and connect it with conventional 90° C 14 gauge wire (see Figure 16). 9. Replace the ash pan drawer and screw, the ash pan and the louver. CATALYTIC COMBUSTOR (FDCCO) Thermodisc Figure 16: Circulating blower (See also the instruction sheet included with the catalytic combustor kit.) Mounting clips Thermal switch Terminal switch The (FDCCO) Catalytic Kit of the Opel AP includes: Circulating blower Bottom louver Louver retention Figure 17: Circulating blower location (sectional view) - Cotter pin - Template - Bypass rod - Bypass damper - Catalytic bypass frame(with rope seal) - Catalytic converter - Tapping screws (10) and washers (2) - Retaining brackets (4) - Fiberglass rope seal - Control eye, handle and extension Page 18 OPEL AP Preparation of the fireplace 1. Remove doors and all refractory liners. 2. Lay unit on its back for easier access. 3. Remove the screen above the door opening by removing the 4 screws in behind (Picture1). If the unit has been fired already, oil the screws before removing them or they may break. 4. Remove secondary air tube by removing the screw on the left side (Picture 2). 5. Remove the baffle. (See instructions on page 8, baffle removal section.) 6. Break off the baffle support brackets by bending the brackets up and down with vice grips (Picture 3). Installation of the catalytic combustor 1. Hook the template provided into the top louver opening, flush with the right side. 2. Use a punch to make a mark through the small hole on the front of the template (Picture 4), then remove template and discard. Make a pilot hole at the punchmark, then drill a 33/64” hole (Picture 5). 1 3. Take the bypass rod and, from inside the fireplace, push the long end through the hole you just drilled. On the outside, pull the bar out as far as it will go (Picture 6). 4. With a cotter pin, connect the bypass rod to the bypass damper (Picture 7). The bent lip side faces the back of the unit with the connecting bracket facing up. 5. Install the new catalytic holder. It only goes in one way as shown in (Picture 8). The bottom of the catalytic holder must be at 18 ¾” from the bottom of the firebox (Picture 9). 6. Install the retaining brackets as shown using the self tapping screws provided (Picture 10). 2 7. Install a set of brackets close to the face of the unit on the angle portion of the catalyst holder. Make sure that the holes for the secondary air tube remain open (Picture 11). 8. Carefully put the catalytic in place (Picture 12) and hold in place with the 1/4” screws and washers provided. 9. Replace the primary air screen and the secondary air tube. 3 Figure 18a: Installation of the catalytic kit Page 19 OPEL AP 10. You can now stand up the Opel AP again, then put back the refractory liners and the doors. After the facing is installed 1. Attach the control eye to the bypass rod by tightening the setscrew with a 1/8” Allen wrench (Picture 13). 2. If the bypass rod is too short due to thick brick facing, attach the extension. Measure the required length from the threaded end and cut off excess before installing the control eye. 3. Insert the handle into the control eye. GOLD / PEWTER LOUVERS (FDL) The standard black louvers above and below the doors can be replaced with a gold plated louvers or pewter louvers (OPLG) if you wish. You may order these from your dealer. NOTE: There are 2 positions for the louvers: flush with the front or protruding from the front. Dismantling and assembling louvers Figure 18b: Installation of the catalytic kit 1. The top louvers are held in place by springs underneath. Therefore, push down from the top and pull out. To remove the bottom, remove the screw on each side of the louvers. 2. Take the assembly apart by removing the top nuts from the rods. Note that there are two washers underneath the top nuts on the bottom louvers. These washers are placed to provide space for the air control lever. Make sure they go back when you reassemble the louvers. 3. Assemble the new louvers the same way the old ones came apart, reusing the original rods and spacers. Leave about 1/4" of the rod protruding above the top nut. Make sure you replace the washers under the top nuts of the bottom louvers. 4. Put the reassembled louvers back into the fireplace. NOTE: Although the gold plating will not tarnish, care must be taken not to scratch the surface. ROCK RETAINER KIT (FDK) Facing Facing material may only be non-combustible such as metal, brick, rock, concrete board, or ceramic tile. 4 5 6 7 Page 20 OPEL AP Gypsum board is NOT an acceptable facing material. Follow these steps: WARNING: DO NOT restrict airflow through the inlet and outlet louvers of the stove. If two (2) gravity vent kits are installed with the dampers removed, only then may the upper louver area be blocked. NOTE: Remove the fireplace doors and louvers, and store them in a safe place until the masonry work is finished. Acid from the cleaning operation will permanently damage the gold plating. Installation If you desire to fully face the fireplace with thin masonry, it is recommended that you purchase the rock retainer kit (part FDK with the upper louvers in place, or the FDK-1 with the upper opening blocked) to help keep the facing in place. It is NOT recommended for brick or other selfsupporting materials. 1. Install the expanded metal on the top half of the fireplace using drill and tap screws at locations shown (see Figure 19). If there is a bypass rod above the door, allow for it to come through. For thick rock, the rod extension (R6414) may be required. 18 ¾” Figure 18c: Installation of the catalytic kit 8 9 10 11 12 13 Page 21 OPEL AP 2. Install the metal edging on each side of the doors, making sure that the edges fit nicely with the arch edge above. There are right and left side expanded metal pieces. The expanded metal is correctly installed when the expanded metal is facing upwards, to catch the mortar. A wider steel lintel bar may be required for heavy rock. 3. Cover the rest of the area with wire mesh, or metal lath, flush with the heavy expanded metal. Make sure nails or staples used for fastening mesh penetrate the studs at least 1". 4. Mortar must be “thin set” or “thin bed” type, inherently polymer modified. Do not add water to the mixture (this applies to the grout as well). If the mortar is not modified, you should add a synthetic latex additive. Mix to a firm, moist consistency. 5. Using a plasterer or mason’s trowel, apply a scratch coat that covers the wire mesh. Let the mortar set before adding another coat. This will take several hours. Afterwards, apply a thinner coat and the facing. Do not spread plaster over more than a workable area so that the mortar will not set before the facing is applied. 6. If additional mortar is required, use a grout bag to fill in the joints. Take extra care to avoid smearing on the surface of the facing. NOTE: If you wish to cover the top louver using an FDK1 you must provide access to the air control located inside the right side of the top louver opening. The FDK1 has a removable panel which permits access to the air control. The masonry which covers this panel should be installed in such a way that it can be removed if necessary. IMPORTANT: No substitution of any of these parts is allowed. These genuine RSF Woodburning Fireplaces parts have the correct clearances. These clearances must be maintained for your safety. The FDV system incorporates standard 8" B-vent components for installation. Single wall pipe is not allowed due to the high temperature of the air in a gravity vent system. Any listed brand of 8" B-vent pipe may be used and is not a part of the FDV. The maximum pipe length is 15 ft. from the top of the fireplace to the outlet. The Bvent components can be replaced by UltraBlack double wall black connector made by ICC only. NOTE: If two gravity vent lines are installed, then two FDV kits must be ordered. (Figure 23) indicates the minimum clearances and framing dimensions. Passing through a combustible wall or ceiling requires a minimum clearance of 2" from combustibles. WARNING: Every measurement and clearance on the illustrations must be followed to assure safety of the installation. Installation CAUTION: Do not replace the grill from the FDV with shutters. Do not allow heat to be trapped in the gravity vent system. 1. Plan the gravity vent run first. Be aware that the maximum actual pipe length between the top of the fireplace and the outlet is 15 feet. There is no maximum number of elbows in a run, but the run must never go in a downward direction as this can trap heat in the gravity vent system. Thickness of sheeting REMOTE VENTING The gravity vent system can distribute air to an upper level or a room next door without an extra blower. If you use two gravity vent kits you may block off the upper louver area with the desired facing. The central heat option allows heat to be sent up to 50 ft. away. (Figure 21) illustrates various certified ways of incorporating the two systems. Framing Metal edging THE GRAVITY VENT SYSTEM (FDV) The FDV kit includes: - A grill - A grill adaptor - A B-vent starter section - A shut-off damper (do not use with upper louvers blocked) Drill and tap screws Figure 19: Installation of rock retainer kit Use only the predrilled holes in the FDK kit to attach it to the fireplace. Page 22 OPEL AP Stones, tile or brick Mortar WARNING: If you are blocking off the upper louvers of the Opel AP, do not install the shut-off dampers. Optional masonry retainer kit 7. Install the B-vent pipe between the B-vent starter and the grill adapter. Fasten each joint with 3 screws (if the B-vent pipe manufacturer allows this in its instruction manual). Insert the B-vent pipe in the grill adapter and fasten it with three screws. The B-vent pipe needs only to be inserted into the adapter enough to be able to screw it in place. This allows you about 3 1/2" of play. 8. Once the wall facing around the gravity vent grill adapter has been completed, install the grill with the supplied screws. The gravity vent is now ready for operation. THE CENTRAL HEAT SYSTEM Hearth Figure 20: Facing with masonry Wire mesh Plywood or gypsum board 2. The grill adapter is designed to be installed underneath the gypsum board in the wall. Frame a 13" x 13" hole to accept the gravity vent grill adapter in the desired location. Fit the gravity vent grill adapter into the framed hole and fasten it into place with nails or screws. If you are installing the outlet in an already finished area, you must remove the gypsum board and frame a 13" x 13" hole in the existing framing, in order to meet the required clearances. 3. Remove the outer cover to the left, right, or both sides of the flue outlet, on the Opel AP. Required components: 1) Part FDHC6 : A blower control center, a thermostat and a thermal switch. 2) Part FDHC6-1: A back draft damper 3) Part FDHB6 : A maximum 636 C.F.M. blower with a variable speed motor, 2 noise reduction collars, a blower speed control, and a mounting bracket. NOTE: Parts 2 and 3 must be used together for this system. Use of any substitutes will de-certify the system. 4. Cut the insulation to the size of the opening and remove the cover plate underneath (it is taped in place). 5. Install the B-vent starter section. The slot in the B-vent starter section should be facing the front and the hole should be facing the back. Bend up the four tabs at the base of the starter section to hold it in place. 6. Install the shut-off damper at the base of the starter section. The shut-off damper enables the manual control of hot air flowing through the gravity vent pipe. With the top louver removed, and the angular portion of the rod in hand, insert the damper rod into the hole in the starter section. Next, make sure that the washer and spring on the control arm are both on the outside of the starter section and that the rod has fit snugly into the slot. A definite tension should exist between the shut-off damper rod and the starter section. Replace the louvers. The damper rod should protrude above the top of the louvers. -no ducting -top grill open -1 gravity vent kit -top grill open -central heating duct kit -top grill open -2 gravity vent kits -top grill closed -central heating duct kit -1 gravity vent kit -top grill open -2 gravity vent kits -top grill open Figure 21: Remote venting options for the Opel AP Page 23 OPEL AP From the louver opening bend out two of the lower tabs to prevent the damper from being pulled out. Grill adapter 4. Before proceeding with the installation of the blower, make sure that the electrical service to the blower is in the OFF position. All wiring should be in accordance with local ordinances and the National Electric Code. B-vent starter Grill Figure 22: Gravity vent kit (FDV) The 8” back-draft damper prevents hot air from travelling into the C vent (single wall) ducting unless the Central Heat Blower (FDHB6) is operating. When the thermostat calls for heat, the blower turns on and opens the one-way valve. At the same time, the room air is drawn through the upper and lower louvers, which mixes and reduces the overall temperature of the forced air that travels through the ducting. NOTE: The blower can basically be installed anywhere in the home, however some thought should go into the planning to ensure that the blower noise does not affect rooms you would like kept quiet. If the central heating system ductwork is passing through an area in your home that you do not wish to be heated, then the ducting should be insulated. Length of runs should be as short as possible to conserve space and minimize cost. Maximum duct length should not exceed 50 feet from the fireplace to the furthest outlet. There is a loss of about 15% performance at 50 feet. WARNING: If the back-draft damper is not installed, the central heat ducting may become too hot for the surrounding combustible materials. Any substitute for the FDHC6-1 kit will void all warranty coverage by RSF Woodburning Fireplaces. NOTE: The blower automatically shuts off if the air temperature reaches 180° F inside the ducting. 5. Locate the blower in a convenient location. The blower may be installed vertically or horizontally. The horizontal installation can utilize either the supplied mounting bracket or, if you want to install the blower farther away from the ceiling, you can use plumber’s strapping. A vertical installation must include the mounting bracket. Installation 1. Remove the cover left side only. 2. Cut the insulation to the size of the opening and remove the cover plate underneath (it is taped in place). NOTE: If you have an existing hot air system, you may safely ‘tie in’ to this hot air system. However, no hot air duct is Grill and adaptater to be connected to the return air of another central heating system. Optional gravity vent outlet 59” min. 3. Install the back draft damper crimped side up, making sure it is pushed all the way down. Bend out the 4 middle tabs to fasten the damper to the top of the fireplace. 4” min. 4” min. 2” min. “B” vent starter(s) here 2” min. 59” min. 59” min. 2” min. Front view Figure 23: Gravity vent clearances 6. Connect the INLET of the blower to the ducting coming from the fireplace, using 8” diameter metal ducting (rigid or flex). Any other size will not work properly. Use only metal ducting between the fireplace and the blower. You may use plastic ducting after the blower, provided the temperature rating of the ducting is at least 250° F. Do not use plastic ducting in a chase. NOTE: The central heat ducting may be run at a 0” clearance to combustibles. Side view Page 24 OPEL AP Thermostat Central heat control kit (FDHC6) Thermal switch Figure 24: Central heating kit (FDHC6) Blower speed control Mounting bracket Back draft damper (FDHC6-1) eters. Houses vary in size and layout, so duct systems must be specifically designed for each home. The diagrams on this sheet are examples only. The cross sectional area of the distribution system must total at least 50 square inches. If you have more than 50 square inches, some of the system may be shut off, but there must always be 50 square inches of ducting open at all times. For example, if 5" pipe is used for distribution, the cross section of each is 20 square inches. The minimum allowable ducting would be three runs of 5" pipe. (Figures 27 & 28) illustrate two examples of “tying-in” to existing ductwork. Directing air in the right direction will reduce reverse flow when the existing furnace blower is off. Some reverse flow will not cause any problems. CAUTION: Tie-ins into existing ductwork must be down stream from the existing furnace. Central heat variable speed blower 2 noise reduction collars Figure 25: Central heat blower kit (FDHB6-1) 7. To install the blower (for the FDHB6 only): attach the noise reduction collars to either side of the blower using 1/2” self-tapping screws. 8. Ductwork can then be run to the desired rooms. Up to six 5" or five 6" diameter runs can be installed from this system. NOTE: Runs must be balanced as air travels along the path of least resistance. Balance the airflow by diameter and length of runs. Longer runs should have larger diam- NOTE: When the central heating blower is in operation, it removes air from the room containing the fireplace. If this room can be closed off from the rest of the house (e.g. with a door), a grill with at least a 100 square inch open area must be installed to allow the air to return to the fireplace. Otherwise periodic smoking from the fireplace will result. 9. Wire the blower to a 115-volt, 15-amp breaker through the thermostat provided. The variable speed switch provided should be installed in a convenient location near the fireplace so the blower can be shut off during refueling. The blower control center should be placed in an accessible location near the blower. It should be mounted in a 4 x 4 electrician’s box. You have two options of how you can connect the central heat blower to the blower control assembly. Ideal blower thermostat location Hot air Cool air Warm air registers Central heat blower Air circulation through fireplace and home with central heat blower in the ‘OFF’ cycle. Figure 26: Central heat ducting options (single floor) Air circulation through fireplace and home with central heat blower in the ‘ON’ cycle (blower thermostat calling for heat). Page 25 OPEL AP a) If you would like the blower to turn on when the thermostat calls for heat, first locate the thermostat in the principal room heated by the duct system. Do not install it in the room where the fireplace is installed. There are yellow black and red wires coming out of the relay as shown in the wiring diagram. Connect the wire from #4 of the terminal block to the black wire and put the wire connector on the red wire for protection. (See Figures 36 and 37 for schematic wiring diagrams.) b) If the fireplace is in a small room and/or you would like the central heat blower to remove air from this room when it becomes too hot, locate the thermostat in the room with the fireplace. Connect the wire from #4 of the terminal block to the red wire and put the wire connector on the black wire for protection. (See Figures 36 and 37 for schematic wiring diagrams.) (Figure 29) shows some ways of ducting the hot air from the blower. You are not restricted in the size of pipe, as long as the total cross sectional area of all runs combined is not less than 50 square inches. The diagram shows alternate blower locations. Only one external blower can be installed. Example 1: tie-in to heat plenum for circulation throughout all rooms Figure 27: Examples of air circulation when tying-in to existing ductwork Example 2: tie-in to part of the duct system 45° tie-in Blower Deflector Cold air return Cold air return Central heat blower OPEL AP Furnace OPEL AP Figure 28: Example tie-ins to A) central heat duct and B) central heat plenum Furnace Page 26 OPEL AP 10. If the blower fails to operate, check the following: a) Consult the wiring diagram to assure proper connections. b) To assure proper contact, check the motor lead wiring, incoming supply wiring and capacitor connections. c) If possible, use a meter to test for continuity between the fan leads. Please note that the capacitor will show no reading if it is tested with a meter. 11. If the blower still fails to operate, consult your local RSF Woodburning Fireplaces authorized dealer for repair/replacement instructions. ZONE HEATING (FDHCZ1 AND FDHCZ2) For more regional heat control, the OPEL AP is ideally suited for zone heating. (Figure 31) shows an example of a three-zone system. The thermostat simultaneously opens the desired valve and starts the blower when heat is required. The zone control system consists of: FDHCZ-1 (Figure 32): (1 time) NOTE: The FDHCZ-1 replaces the FDHC6 if you are installing the zone system. FDHCZ-2 (Figure 33): (1 to 3 depending of how many zone you want to control) The system is wired similarly to the central heat system (Figures 36 and 37) with the addition of the blower control and the blower center (see Figure 38). The whole system runs on 24V AC. Make sure that the thermostats are matched with the correct zone valve. NOTE: the Opel AP must be installed in accordance with all local codes, if any; if not, follow the current CSA C22.1 in Canada or NFPA 70 in the USA. Install and use as per the manufacturer’s installation and operating instructions. - 1 control box - 1 blower transformer relay - 1 thermal switch Noise reduction collars Alternative blower location 2 duct 6” diameter runs Zero clearance 4” min. 3 duct 5” diameter runs B-vent pipe Figure 29: Central heat location options 59” min. Blower Back draft damper - 1 zone valve (normally closed) - 1 thermostat Page 27 OPEL AP Black White Ground (bare) Red Yellow To thermostat To speed control Speed Thermocontrol stat Option1: warning thermostat (see schematic wiring diagram Figure 36) Blower control detail To blower To terminal Blower control Terminal bloc Option 2: cooling thermostat (see schematic wiring diagram Figure 36) 110 V Terminal detail BWG Figure 30: Central heat system wiring diagram Blower Zone damper Figure 31: Zone heating - example 3 zone Blower control centre Zone control box Figure 32: Zone control kit (FDHCZ-1) Blower detail Zone thermostats Zone register Thermostat Thermal switch Figure 33: Zone heating kit (FDHCZ-2) Page 28 OPEL AP Draft damper thermostat Draft damper motor Terminal block 24V Transformer black white ground (bare) Figure 34: Wiring for the thermostat 110V Thermal switch bypass (optional) Internal blower Thermal switch Terminal block black white ground (bare) 110V Figure 35: Wiring for the circulating blower Blower speed control Page 29 OPEL AP Blower control thermostat Thermal switch Central blower speed switch Terminal block 18 ga LVT External central heat blower black white black white yellow white black Relay *For a warming thermostat, 1 should be the red wire and 2 should be the black wire 2* ground (bare) *For a cooling thermostat, 1 should be the black wire and 2 should be the red wire 1* 110V Figure 36: Wiring for the central heat system Draft damper thermostat Draft damper motor Thermal switch Internal blower Internal blower speed control Blower control thermostat Central blower speed switch Terminal block 18ga LVT Transformer External central heat blower black white black 24V Relay yellow white black white 2* ground (bare) 1* 110V Figure 37: Wiring for all systems combined *For a warming thermostat, 1 should be the red wire and 2 should be the black wire *For a cooling thermostat. 1 should be the black wire and 2 should be the red wire Page 30 OPEL AP Blower control Fuse Jumper Zone thermostat (Heat Only) Thermal switch Zone valves (8”NC) Zone dampers zone 1 zone 1 zone 2 black zone 2 zone 3 Draft damper motor zone 3 Draft damper thermostat Internal blower Thermal switch Internal blower speed control External blower control Terminal switch 18ga LVT black white black 110V Figure 38: Wiring for all systems with a zone heat system yellow ground (bare) 24V relay white black white External central heat blower Page 31 OPEL AP 1 1 Removable top louvers 2 Primary air tube 3 Secondary air tube 4 Air wash grid 5 High heat refractory lining 6 Ceramic glass 7 Convection chamber 8 Adjustable hinge pins 9 Andiron 2 3 7 5 6 8 4 10 Adjustable latch 11 Removable bottom louvers 12 Combustion air control knob 13 210 CFM blower, included rheostat (option) 10 9 13 12 11 OPEL AP cut-away view FIREPLACE OPTIONS FDCCO FDFS FDGRK2 FDHB5-N FDHB6 FDHC4 Opel catalytic kit Firescreen Gasket replacement kit Blower Blower - central heat Thermostat kit FDHC6 FDHC6-1 FDHZ1 FDHZ2 FDK FDK-1 FDL FDM Central heat control Back draft damper Zone heat control Zone damper (elect.) Rock retainer kit Rock retainer kit w/o opening Gold louver kit Brick chimney adaptor REPLACEMENT PARTS NOT AVAILABLE PART OF ASSEMBLY N/A P/A DESCRIPTION NEW CODE OLD CODE PRICE Ash pan plug 1.5.3.NPT 15,00 Ash pan 1.5.2.P 50,00 Floor shield assembly 1.5.6.P N/A Top louver fin (black) 10.1.NPR A959 10,00 Top louver fin (gold) 10.11.NPR 30,00 Top louver fin (pewter) 10.21.NPR 30,00 Top louver hardware assembly 99.10.03.P 15,00 Nut 1/4-20 Hex 14.3.52 R1415 P/A Louver rod 14.9.1 R6416 P/A Spacer 1/4" X 1 3/8" 14.8.5 R6149 P/A Retention spring for louvers 14.5.3 R6309 P/A Bottom louver fin (black) 10.2.NP 10,00 Bottom louver fin (gold) 10.12.NP 30,00 Bottom louver fin (pewter) 10.22.NP 30,00 Bottom louver hardware assembly 99.10.04.P 45,00 Louver rod 14.9.1 R6416 P/A Spacer 1/4" X 1 3/8" 14.8.5 R6149 P/A Bolt 1/4" x 4 1/2" Hex 14.1.63 R1227 P/A Nut 1/4-20 Hex 14.3.52 P/A Nut 1/4-20 Stover 14.3.54 R1416 P/A Lower louver magnet stop 10.3.NP 4,00 Magnet bracket assembly 1.10.3.NP 10,00 Black door set FDDB 400,00 Gold door set FDDG 800,00 Pewter door set FDDP 800,00 Radiation fire shield 9.9.P A990 5,00 Glass retaining brackets 9.11.P A975 4,00 Gasket replacement kit FDGRK2 25,00 Door gasket (5/8) 14.10.3 R7005 P/A Door gasket (1/4) 14.10.5 R7009 P/A Door handle assembly (left) 99.09.02.P 15,00 Door handle (left) 1.9.2.P A970A 10,00 Door handle grip (wood) 14.6.1 R6012 5,00 Washer 14.2.81 R1321P P/A Locknut 2-way 14.3.83 R1324 P/A Door handle assembly (right) 99.09.01.P 20,00 Door handle (right) 1.9.3.P A971A 10,00 Door handle spacer 14.17.30 R6426 P/A Door closer pawl 14.17.31 A1283 5,00 Door handle grip (wood) 14.6.1 R6012 5,00 Washer 14.2.83 R1321P P/A Locknut 2-way 14.3.83 R1324 P/A Hinge pin 14.17.76 10,00 Chrome cap for Opel doors 14.17.43 R6271 3,00 Black door set including glass FDDBO 550,00 Gold door set including glass FDDGO 950,00 Pewter door set including glass FDDPO 950,00 includes FDDB, FDDG, FDDP P/A Ceramic glass 14.7.2 A974/R6257/9-9.8.P 150,00 Glass gasket 14.10.2 R7002 10,00 Smoke baffle 11.6.P 8.1.P - A1092 50,00 Refractory complete set 99.11.01.P 200,00 Front side left refractory 11.7.P 30,00 Front side right refractory 11.8.P 30,00 Back side left refractory 11.9.P 35,00 Back side right refractory 11.10.P 35,00 Back left refractory 11.11.P 35,00 Back right refractory 11.12.P 35,00 Left bottom refractory 11.14.P 40,00 Right bottom refractory 11.15.P 40,00 Draft control gasket 7.2.DNP A989 4,00 Draft control assembly 1.7.5.DP A985 130,00 Primary air screen 7.9.P A942-2 25,00 Secondary air tube 7.8.P A1137 55,00 Draft control lever 4.1.DNP A953W 10,00 Spring 14.5.6 R6307 2,00 Draft control knob 14.6.2 R6000 4,00 Chain and pendant assembly 99.06.01.P 10,00 Chain # 10 14.17.3 R6110 P/A Detachable pendant 14.17.4 R6121 P/A Terminal block assembly 99.12.01.P 25,00 Terminal block 1.12.1.DNPR AA1088W P/A Terminal block cover 12.2.DNPR AA1089 P/A OPEL AP Page 32 NOT AVAILABLE PART OF ASSEMBLY OLD CODE N/A P/A PRICE 15,00 50,00 N/A A959 10,00 30,00 30,00 15,00 R1415 P/A R6416 P/A R6149 P/A R6309 P/A 10,00 30,00 30,00 45,00 R6416 P/A R6149 P/A R1227 P/A P/A R1416 P/A 4,00 10,00 400,00 800,00 800,00 A990 5,00 A975 4,00 25,00 R7005 P/A R7009 P/A 15,00 A970A 10,00 R6012 5,00 R1321P P/A R1324 P/A 20,00 A971A 10,00 R6426 P/A A1283 5,00 R6012 5,00 R1321P P/A R1324 P/A 10,00 R6271 3,00 550,00 950,00 950,00 P/A 14.7.2 A974/R6257/9-9.8.P 150,00 14.10.2 R7002 10,00 11.6.P 8.1.P - A1092 50,00 99.11.01.P 200,00 11.7.P 30,00 11.8.P 30,00 11.9.P 35,00 11.10.P 35,00 11.11.P 35,00 11.12.P 35,00 11.14.P 40,00 11.15.P 40,00 7.2.DNP A989 4,00 1.7.5.DP A985 130,00 7.9.P A942-2 25,00 7.8.P A1137 55,00 4.1.DNP A953W 10,00 14.5.6 R6307 2,00 14.6.2 R6000 4,00 99.06.01.P 10,00 14.17.3 R6110 P/A 14.17.4 R6121 P/A 99.12.01.P 25,00 1.12.1.DNPR AA1088W P/A 12.2.DNPR AA1089 P/A NEW CODE 1.5.3.NPT 1.5.2.P 1.5.6.P 10.1.NPR 10.11.NPR 10.21.NPR 99.10.03.P 14.3.52 14.9.1 14.8.5 14.5.3 10.2.NP 10.12.NP 10.22.NP 99.10.04.P 14.9.1 14.8.5 14.1.63 14.3.52 14.3.54 10.3.NP 1.10.3.NP FDDB FDDG FDDP 9.9.P 9.11.P FDGRK2 14.10.3 14.10.5 99.09.02.P 1.9.2.P 14.6.1 14.2.81 14.3.83 99.09.01.P 1.9.3.P 14.17.30 14.17.31 14.6.1 14.2.83 14.3.83 14.17.76 14.17.43 FDDBO FDDGO FDDPO REPLACEMENT PARTS DESCRIPTION Ash pan plug Ash pan Floor shield assembly Top louver fin (black) Top louver fin (gold) Top louver fin (pewter) Top louver hardware assembly Nut 1/4-20 Hex Louver rod Spacer 1/4" X 1 3/8" Retention spring for louvers Bottom louver fin (black) Bottom louver fin (gold) Bottom louver fin (pewter) Bottom louver hardware assembly Louver rod Spacer 1/4" X 1 3/8" Bolt 1/4" x 4 1/2" Hex Nut 1/4-20 Hex Nut 1/4-20 Stover Lower louver magnet stop Magnet bracket assembly Black door set Gold door set Pewter door set Radiation fire shield Glass retaining brackets Gasket replacement kit Door gasket (5/8) Door gasket (1/4) Door handle assembly (left) Door handle (left) Door handle grip (wood) Washer Locknut 2-way Door handle assembly (right) Door handle (right) Door handle spacer Door closer pawl Door handle grip (wood) Washer Locknut 2-way Hinge pin Chrome cap for Opel doors Black door set including glass Gold door set including glass Pewter door set including glass includes FDDB, FDDG, FDDP Ceramic glass Glass gasket Smoke baffle Refractory complete set Front side left refractory Front side right refractory Back side left refractory Back side right refractory Back left refractory Back right refractory Left bottom refractory Right bottom refractory Draft control gasket Draft control assembly Primary air screen Secondary air tube Draft control lever Spring Draft control knob Chain and pendant assembly Chain # 10 Detachable pendant Terminal block assembly Terminal block Terminal block cover OPEL AP Page 33 Page 34 OPEL AP We recommend that our products be installed and serviced by professionals who are certified in the U.S. by NFI (National Fireplace Institute) or in Canada by WETT (Wood Energy Technical Training). Page 35 OPEL AP OPEL AP - Limited Warranty 30 Year Limited Warranty All RSF Woodburning Fireplaces models are warranted against defects in material and workmanship for a period of 30 years, subject to the following conditions: During the first year RSF Woodburning Fireplaces will repair or replace, at our option, any parts which upon examination by an authorized RSF Woodburning Fireplaces representative are found to be defective, except the parts listed in the EXCLUSIONS portion of this warranty. RSF Woodburning Fireplaces will also pay reasonable labor costs for the repair work. During the second through fifth years RSF Woodburning Fireplaces will repair or replace, at our option, any parts which upon examination by an authorized RSF Woodburning Fireplaces representative are found to be defective, except the parts listed in the EXCLUSIONS portion of this warranty. RSF Woodburning Fireplaces shall not be responsible for any labor costs associated with this repair work. During the sixth through thirtieth years RSF Woodburning Fireplaces will provide replacement parts, if available, at 50% of the published retail price, except for the parts listed in the EXCLUSIONS portion of this warranty. RSF Woodburning Fireplaces shall not be responsible for any labor costs associated with this repair work. EXCLUSIONS · Electrical components are warranted for one year only. · Glass and gold plating. · Damage due to normal wear and tear, such as paint discoloration, worn gaskets, eroded or cracked refractory components. · Repairs or replacements necessitated by vandalism, neglect, abuse, over-firing, improper fuel or fuel loads, or failure to adequately service the unit, as stated in the owner’s manual. · Repairs or replacements (particularly charges for travel and labor) not authorized by RSF Woodburning Fireplaces in advance. LIMITATIONS All items found to be defective will be replaced or repaired upon return of the defective part to an authorized RSF Woodburning Fireplaces dealer. RSF Woodburning Fireplaces will not be responsible for freight costs related to shipping replacement parts. Any complete fireplace, or part thereof, that is replaced or serviced under this warranty will be warranted for a period not exceeding the remaining term of the original warranty. This warranty is not transferable. This warranty does not apply to damage to the appliance while in transit. This warranty does not apply if the installation does not conform to the installation requirements in the owner’s manual. RSF Woodburning Fireplaces is free of liability for any damages caused by the appliance, as well as material and labor charges incurred in the removal or re-installation of any RSF Woodburning Fireplaces fireplace under this warranty. Incidental or consequential damages are not covered by this warranty. The remedies set forth herein are exclusive, and the liability of the seller shall not exceed the price of the fireplace or part thereof upon which the liability is based. This warranty is expressly in lieu of all other warranties expressed or implied, including the warranties of merchantability and fitness for use and all other obligations or liabilities on the part of RSF Woodburning Fireplaces.