Assembly instruction
Round tiled stove (series 300)
Model....................................
Content
Tests and approvals............................. 2
Explanation of symbols / foreword....... 3
Body
Preparations....................................... 4
Important measurements...................... 5
Overall installation sequence................ 6
Assembly...................................... 7-17
Tiles and cassette
Tiling - preparations........................... 18
Tiling - assembly.......................... 19-23
Cassette installation...................... 24-27
Fan installation................................. 27
2012-07-02
Tests and approvals
GABRIEL KERAMIK AB
CE-marking
The Gabriel tiled stoves are Swedish products and
fulfil the requirements for CE-marking, meaning that
they comply with EU health, environmental and
safety requirements. CE stands for Communaútes
Européennes. CE-marked products can be produced
and sold in every member country of EU and EES
community without any national product restrictions.
A CE-marked product is normally provided with the
document “EU declaration of conformity” in
which the manufacturer assures that the product fulfils
the requirements designated by EU.
Gabriel Keramik AB
Strandavägen 62
SE-380 52 Timmernabben, Sweden
08
EN 15250:2007
Slow heat release appliance
fired by solid fuel
Follow the manufacturers instruction and maintenance manual. Use only recommended fuel.
Total fuel loading mass
Single fuel batch
Distance to adjacent combustible
Rectangular: Rear/side
Round:
CO emission:
Flue gas temperature (mean):
Flue gas mass flue:
Flue gas draught:
Connection to shared chimney:
Thermal output:
Thermal storage capacity:
100 %
50 %
Peak
After: 3.9 h
13.0 h
Energy efficiency:
Fuel type:
EU-declaration of conformity
Approx. 11 kg
Approx. 3 kg
material:
35/300 mm
50 mm
0.083%
80 °C
16.2 g/s
12.1 Pa
Yes
165 MJ
25 %
21.1 h
93.4 %
Wood logs
Technical description
The Gabriel tiled stoves are built with an ingenious
module system of fire-proof material, consisting of an
inner core and an outer mantle, which are separated
from each other. The inner core absorbs a large part
of the heat expansion and reduces the furnace heat
movement. The efficient 5-channel flue gas principle
gives a high energy efficiency and radiates a uniform
and pleasant heat into the room over a longer period.
The Gabriel tiled stoves can either be rear connected
to an existing approved chimney, or top mounted
with a prefabricated module steel or precasted block
chimney.
A building permit is needed when building a new
tiled stove. Before starting to fire, the tiled stove
installation has to be inspected and approved by
the Building Control Officer. (See local and national
regulations regarding installation of fire places.)
The Gabriel tiled stoves are CE-approved by the
accredited test laboratory SP Technical Research
Institute of Sweden, and fulfil the environmental and
safety requirements stipulated in the new European
standard for “Slow heat release appliance fired by
solid fuel”.
Products covered by this declaration
Product type:
Slow heat release appliance fired by solid
fuel
Models:
Rectangular tiled stoves (800 series)
Round tiled stoves (300 series)
Round tiled stoves Studio (400 series )
In conformity with:
EU building directive CPD89/106/EEG
Comply with EU-standard: EN 15250
Intended use:
Domestic heating
Fuel:
Wood
Manufacturer:
Gabriel Keramik AB
Address:
Strandavägen 62,
SE-380 52 Timmernabben
Production site:
Timmernabben, Sweden
Test laboratory (0402): SP Technical Research Institute of Sweden
Address:
Box 857, SE-50115 Borås, Sweden
Test report no.
0402-CPD-502101
Lars Burmeister
Manager Director, Gabriel Keramik AB
The traditional
5-channel flue gas
principle is still
incomparable
Low temperature
flue gas outlet
Inner core
Outer mantle
Expansion area
Heat accumulating,
dense, fire-resistant
material for longlasting heat radiation
Fan controlled direct
heat through channels
in the hot air cassette for
efficient heat radiation
Airflow on the
inside keeps the
glass cleaner
Extra large glass
door enhances the
fire side comfort
Fan for efficient
heat radiation
Connection for combustion
air from the outside
New installation / building registration
A building permit from the local housing authorities is required when building
a tiled stove. You shall also consult your chimney sweep before building the stove.
Weight from 1300 to 1800 kg. Bearing support is required.
2 • ROUND
Explanation of symbols/foreword
GABRIEL KERAMIK AB
Safety instructions
Read these instructions carefully before
starting the assembly. Incorrect assembly
can cause serious damage and fire risk.
Make sure prior to the assembly that the
building permit is approved and that the
local chimney sweep has approved the
installation.
Marking with a pen
Saw
Important positions, areas for sawing and
placing of mortar are marked with a pen.
Shows where the prefabricated modules
should be sawn.
Control measurement
Insulation
Shows important measurements during
assembly.
Shows where you place the insulation.
Rendered areas
Trowel
Shows the areas that shall be rendered
with clay mortar.
Shows where the clay mortar is placed.
Foreword
General
Flue connection
Gabriel tiled stoves consist of prefabricated modules,
cast from fireproof material. The stoves should be
built by an approved tradesman.
A building permit is needed when building a new
tiled stove. Before starting to fire, the tiled stove has
to be inspected by the Building Control Officer (see
local and national regulations regarding installation
of fire places).
Gabriel stoves can be either rear or top connected.
A prefabricated flue can be directly connected on the
top of the stove. Check with your local dealer for the
best solution.
Distance and measurements
As to the following pictures in this manual you place
the first module 50 mm from a combustible wall. A
non-combustible hearth shall be placed on the floor
in front of the stove (for size, see local regulations).
A 300 mm free space is needed in front of the soot
holes on each side of the stove. The hole in the
base for inlet air to the convection heat must not be
blocked. The manual’s control measurements (page 5)
are very important, while the other measurements
should be seen as a guide during the assembly.
Support
The foundation and floor support of the stove has to
be approved before assembly.
The weight of the stove is between 1300-1800 kg
depending on the model and flue connection.
Therefore the foundation requires sufficient bearing
capacity and shall be checked and approved in
accordance with the building permit (consult your
local building authorities).
Thickness of joints
Step-by-step installation
Please follow the step-by-step assembly and pay
attention to the control measurements that are shown.
A certain tolerance is allowed but make sure the
control measurements are kept as it has a profound
impact on the tiling, which is to follow.
For good adherence, wipe the contact surfaces with
a squeezed sponge before jointing.
During the assembly the outer rings are always to be
one step ahead of the inner blocks.
Equipment
Trowels, brick layer, a long water level, radiator
brush, folding rule, chisel, buckets, sponge, rubber
mallet, covering plastic, angular grinder, hack saw,
2 ladders, joint sponge, wooden wedges.
Material included in the delivery
•
•
•
•
Clay and sand - Clay mortar mix: 1:3½ (1 part of clay to 3½ part of sand).
Tile adhesive
Grout
Silicon - if during transport a module is broken it can easily be fixed with the supplied heat-resistant silicon or clay mortar by gluing the pieces together.
The joints between the bottom modules are
approx.10 mm and 5 mm for the under modules.
Use a suitable wet brush for neat, tight joints
ROUND • 3
Preparations
GABRIEL KERAMIK AB
Measurement for ø 150 mm flue pipe connection
In a corner
318 mm
min. 50 mm
Ø 150 mm
Top plate
Rear connection
c/cC/C
2095
mm
Bakanslutning
2095
mm
Against a straight wall
Combustible wall
min. 50 mm
278 mm
min. 50 mm
318 mm
TopToppanslutning
connection 2245
mm
2245
mm
318 mm
Ø 150 mm
Ø 150 mm
318 mm
Top plate
Measurement for ø 125 mm combustion air inlet connection
In a corner
Against a straight wall
Combustible wall
Combustible wall
415 mm
min. 50 mm
Base blok
Ø 730 mm
4 • ROUND
415 mm
415 mm
415 mm
min. 50 mm
415 mm
415 mm
min. 50 mm
min. 50 mm
278 mm
Combustible wall
Important measurements • ROUND
GABRIEL KERAMIK AB
Control and guide measurements (all measurements in mm)
= Control measurement
Outer section
17
16
Inner section
15
14
1896
7
1795
7
7
1587
7
12
13
12
13
11
13
1516
10
7
1379
10
7
7
10
No
joints
1171
7
10
10
7
10
963
6
946
9
846
8a
5
8a
508
5
4
8
8
3
338
2
338
1*
338
2
1
Floor level
* 1–17 shows the numbers of all parts, see page 6.
Corner / wall position
In a corner
Against a straight wall
Combustible wall
Combustible wall
min. 50 mm
min. 50 mm
Base
block
Sockelring
Ø 730
730 mm
mm
Ø
min. 50 mm
ROUND • 5
Preparations
GABRIEL KERAMIK AB
10
17
7
16
10
7
9
15
8A
14
6
12
13
8A
7
12
5
13
8
7
5
11
13
8
7
4
10
3
7
10
2
7
10
1
7
10
7
Start A
6 • ROUND
Assembly
GABRIEL KERAMIK AB
Before starting the assembly,
make sure that the support is
approved according to your
building permit and that it is in
level with the floor.
1
Mark on the floor exactly where the
stove is going to be placed. Also
mark the direction of the opening.
The example on the picture shows
45° from existing 90° corner.
1000
00
10
710
45°
min 50
min 50
In a corner
2a
Set the base block (1) with a 15
mm thick layer of mortar on the
prepared floor. Make sure the regulation distance to the wall is kept.
Level vertically and horizontally,
see figure 1.
1
Check the distance to the
wall (min. 50 mm)
500 mm
Against a straight
wall
2b
1
Set the base block (1) with a 15
mm thick layer of mortar on the
prepared floor. Make sure the regulation distance to the wall is kept.
Level vertically and horizontally,
see figure 1.
Check the distance to the
wall (min. 50 mm)
700 mm
ROUND • 7
Assembly
GABRIEL KERAMIK AB
Set the firebox block (2) with
mortar.
Mark the centre line on the first
block, it will help you to position
the opening and the soot hole
correctly.
3
2
338 mm
4
Set the outer block (3) with mortar.
The opening shall face the 45°marking on the floor (figure 1).
3
Seal with insulation where
indicated.
328 m m
5
Set the outer block (4) with mortar,
level with the previous block. Level
vertically and horizontally.
4
250 mm
8 • ROUND
For a better joint, wipe
the contact surfaces with
a squeezed sponge, then
brush with a wet radiator
brush. This is a general
instruction for the whole
assembly.
Assembly
GABRIEL KERAMIK AB
S
6
Set the firebox (8) with mortar.
The firebox block may not touch
the outer block (the firebox block
must be allowed to expand freely
without affecting the outer block).
Level vertically and horizontally.
Push the firebox block backwards
as much as possible. Place the insulation and pull the firebox block
back to ”lock” the indsulation.
8
Make sure that no mortar
falls between the firebox
block and the outer block.
7
8
5
8
Set the outer block (5) with mortar.
Level vertically and horizontally.
Set the second firebox block (8) on
top of the first one. Make sure that
no mortar falls between the blocks.
Level vertically and horizontally.
Make sure that no mortar
falls between the firebox
block and the outer block.
ROUND • 9
Assembly
GABRIEL KERAMIK AB
Set the outer block (5) with mortar.
Level vertically and horizontally.
5
9
Check that the height is
within the tolerane (500 mm)
500 m m
10
Set the outer block (6) with mortar.
6
For a better joint, wipe the
contact surfaces with a
squeezed sponge, then
brush with a wet radiator
brush.
Set the third firebox block (8A)
on top of the second one. Make
sure that no mortar falls between
the firebox block and the outer
block.
Level vertically and horizontally.
11
11
8A
963 mm
Make sure that no mortar
falls between the firebox
block and the outer block.
10 • ROUND
Assembly
GABRIEL KERAMIK AB
Set the fourh firebox block (8A)
on top of the third one.
Make sure that no mortar falls
between the firebox block and the
outer block.
12
12
8A
Make sure that no mortar
falls between the firebox
block and the outer block.
13
Cut the two insulation strips and set
the top of the firebox block (9) with
mortar.
9
963 mm
min.
500
14
14
7
953 mm
Before continuing above
the firebox opening,
construct a prop to support both
the outer
block and
the firebox
top block as
shown in
the picture.
The support
will also be
of help when
tiling above
the firebox. Keep the support in position till the next
day or even longer.
Set the outer block (7) in mortar.
Ø 630 mm
Ø 680 mm
ROUND • 11
Assembly
15
GABRIEL KERAMIK AB
10
Place the inner block (10) on top
of the firebox block without
mortar joint. Make sure that
this and the following blocks are
in level and do not ignore any
irregularities.
Seal/isulate the hollow space
under the outer ring as indicated.
16
10
7
10
10
7
7
10
10
7
7
10
7
12 • ROUND
Carefully centre and set the outer
blocks (7). Make sure that the
outer block is one step ahead
of each inner block - set without
mortar - during the assembly. Outer
blocks and inner blocks must not
be in contact. Level vertically and
horizontally.
Check the control measurements,
see page 5.
For a better joint, wipe
the contact surfaces with
a squeezed sponge. Afterwards gently brush the
mortar joints with a wet
radiator brush.
Assembly
GABRIEL KERAMIK AB
17
17
18
18
19
Set the outer block (7) in mortar.
Level vertically and horizontally.
7
7
11
Set the outer block (7) in mortar.
Level vertically and horizontally.
Set the “church roof” (11).
Level vertically and horizontally.
Seal with 2-3 mm insulation.
Make sure that no mortar
falls between the firebox
block and the outer block.
ROUND • 13
Assembly
GABRIEL KERAMIK AB
20
Set the flame protection block (13)
with mortar.
Level vertically and horizontally.
13
21
7
Set the outer block (7) with mortar.
Level vertically and horizontally.
22
7
Set the outer block (7) with
mortar.
Level vertically and horizontally.
1898 mm
14 • ROUND
Assembly
23
23
24
24
GABRIEL KERAMIK AB
12
13
12
13
Set the divider block (12) and the
flame protection block (13) with
mortar.
Level vertically and horizontally.
Set the divider block (12) and the
flame protection block (13) with
mortar.
Level vertically and horizontally.
The divider block (12) and flame
protection block (13) must be
2-4 mm below the outer block to
allow the inner body to expand.
25
25
Smear a small string of mortar
on top of the divider block and
the flame protection block. Fix
the insulation in the mortar string.
The insulation creates an expansion gap aginst the divider block,
allowing the inner core to move
vertically.
ROUND • 15
Assembly
GABRIEL KERAMIK AB
26
Set the top lid (14) with mortar.
Level vertically and horizontally.
14
Ø 125 mm
27
15
Set the damper lid (15) with mortar.
Level vertically and horizontally.
Set the damper frame with a thin
bed of mortar and make sure the
damper runs freely.
2004 mm
15 mm
28
16
Lay mortar over the damper and
the pipeattachment. Set the Leca
blocks (16) with mortar. The inside
of the blocks shall be rendered with
clay mortar (easiest done before
the assembly).
Top flue connection
Join the two blocks together with
the heat-resistant silicon or mortar.
Side flue connection to an existing chimney.
Cut the back of the block for a suitable connection.
16 • ROUND
Assembly
29
29
GABRIEL KERAMIK AB
Render and brush the soot
channel surfaces, also the
downside of the top lid when
it is installed.
17
Ø 150 mm
Top connected chimney
Set the top lid (17) with mortar
and make sure it is in level with the
underlying flue gas hole.
Side connected chimney
Turn the lid to fit the hole exactly
over the underlying block. Fill and
even with mortar.
ROUND • 17
Tiling and preparations
GABRIEL KERAMIK AB
Assembly tiles and cassette
IMPORTANT STEPS PRIOR TO TILING
• Mark the centre line.
• Check that the floor is level.
• Check the body surface. Is it vertical? Be aware that you must compensate for any irregularities.
• All tiles shall be in level vertically and horizontally.
• For best adherence - apply adhesive on both tiles and body with an 8 mm toothed trowel.
• For the best result a joint width of 2-3 mm is recommended. Wooden wedges recommended.
• Seal with adhesive between tiles and body at the firebox and the soot holes.
• Start tiling from the bottom and the centre and work towards the sides.
• Do not block the hole/grate for inlet air for convection heat.
• The tiles are hand-made - there might be some variations in measurements and colours.
TILING PLAN
66
66 cm
cm
tiles
kakel
27”
27 "
tiles
kakel
30”"
tiles
kakel
18 • ROUND
akel a
m
ell
a
a
Assembly - tiles
1
GABRIEL KERAMIK AB
Level and mark the centre line from
the top down to the base. (Devide
the firebox into two equal halves).
30
45°
45°
2
31
32
3
Fix the first tile exactly in the centre
of the marking as shown. Apply
as much adhesive to fix the tile
approx. 5 mm from the stove body.
Level vertically and horizontally.
Place a tile list temporarily (use a
match or similar as joint) and level
it with the firebox block.
ROUND • 19
Assembly - tiles
GABRIEL KERAMIK AB
Set tiles around the base starting
from the centre. Level vertically and
horizontally.
33
1
5
34
34
6
35
Mount the grate and the last tile.
Each tile list (foot simms) is
manufactued with a support at the back, which must
carefully be removed to fit in
properly.
Set the tile lists from centre towards
the sides. Check that the upper
edge of the tile lists are level with
the bottom of the firebox.
Note:
For better adhesiveness, apply
the tile lists with a dryer adhesive.
20 • ROUND
Assembly - tiles
GABRIEL KERAMIK AB
7
36
Apply the tiles intended for the soot
holes. Level vertically and horizontally.
37
8
Continue the tiling around the
firebox opening and then around
the firebox.
4
7
3
5
It is important to level the
tiles vertically and horizontally to be able to install the
cassette in exact position.
8
6
2
1
38
Check again that the tiling around
the firebox opening is vertically
and horizontally levelled. The cassette must be fitted close to each
tile around the firebox opening.
ROUND • 21
Assembly - tiles
GABRIEL KERAMIK AB
Complete the centre section by
tiling around the firebox. Start from
the bottom. Level vertically and
horizontally.
39
10
Each centric tile list is manufactued with a support at the
back, which must carefully
be removed to fit in properly.
Apply two centric tile lists (use a
somewhat dryer adhesive). Start
from the centre.
11
40
Note:
Check the body level by fixing
a 66 cm tile as shown, level tile
and tile list and proceed the tiling
upwards. You might have to adjust
the tile lists and tiles to “get free” if
there are irregularities higher up on
the body.
Important!
Check the body for irregularities that have to be
compensated. Also check
vertical and horiontal level.
41
12
22 • ROUND
Mount the whole section of centric
tile lists. Start from the inner side
and work towards the edges.
Assembly - tiles
42
14
43
GABRIEL KERAMIK AB
Apply the 66 cm tiles. Start with
the row above the mid simms
(wasteline lists). Work from the
centre towards the sides. Repeat
the following rows, always level
vertically and horizontally.
Before applying the frieze,
carefully remove the support
at the back.
Start with the soot hole frieze tiles.
Proceed towards the sides. Level
vertically and horizontally.
44
15
Apply the crown tiles exactly over
the soot hole frieze tiles.Proceed
towards the sides.
TIP!
Place a load with a blank surface on top of the stove. Then
you can apply tape on the
upper edge of the crown tiles
to be able to keep them in position and to adjust them.
ROUND • 23
Cassette installation
GABRIEL KERAMIK AB
45
Outdoor cumbustion air inlet
Indoor cumbustion air inlet
Mount the reduction flange to the flexible tube and
connect to the flange for inlet air through the floor.
Mount the reduction flange to the flexible tube and
connect to the flange for inlet air through the base.
46
Place the enclosed rockwool sheet.
Cut out a square hole the same
size as the hole in the firebox plate
as indicated.
47
Fit in the cassette so that the steel
flanges round the cassette are inside the tiles and the brass frame
is in contact with the tiles.
Note:
If the cassette does not fit correctly
at the bottom edge this can be
compensated by removing some
rockwool in the forward edge or
with a thin layer of mortar in the
rear edge under the plate. Thereafter the cassette should rest stable
and even on the bottom. The brass
frame should at the same time fit
tight against the tiles.
24 • ROUND
Cassette installation
48
49
50
GABRIEL KERAMIK AB
Pass the flexible tube through the
cassette bottom and fit it over
the connecting flange. Fasten the
flange plate.
Mount the damper in the bottom
of the cassette, do not forget the
cotter pins. Make sure the damper
has a free action.
Fasten the cover plate.
ROUND • 25
Cassette installation
GABRIEL KERAMIK AB
Place the vermiculite plate in the
bottom.
51
52
20mm
Protect the brass frame and tiles
around the cassette with masking
tape to ensure a neat silicon seal.
Pull out the cassette approx. 20
mm and apply silicon just inside
the edge around the brass frame,
then push the cassette back in.
Even the seal with a wet finger
(dipping the finger into water with
washing-up liquid will make it
easier to get a neat joint). Remove
the masking tape.
53
26 • ROUND
Insulate behind the cassette,
around the sides and in the front
edge between the cassette and the
body.
Cassette installation
GABRIEL KERAMIK AB
54
2
3
4
Insert the steel plate vertically
over the edge of the cassette. Turn
the plate horizontally and pull it
backwards firm and tight against
the top of the fire box block so that
it at the same time is fitted tight
between the cassete and the body
as shown in picture 3 and 4.
1
Install the last vemiculite plate on
the two tubes in the cassette and
push it as far back as possible.
This improves the combustion and
forces the flame forward.
55
Fan installation
Cut the sealing block to shape,
use e.g a hack saw blade.
Ensure that it fits exactly and
seals around the base block
walls.
56
Make sure the sealing block is not
pushed to far in as it will restrict
the inlet convection air flow to the
cassette.
Press the fan carefully into the pre
cut hole in the sealing block.
Sealing block
Note! The fan must be mounted so that air is sucked into the
fan. The air flow passes through
channels in the cassette and exit
through the upper front edge.
ROUND • 27
GABRIEL KERAMIK AB
www.gabrielkakelugnar.se
Tel. +46 (0)499 233 00