Logic HE™ Range Balanced Flue Instructions for Use, Installation & Servicing For use in GB & IE (Great Britain & Republic of Ireland). IMPORTANT THE OUTER CASING, FRONT AND GLASS PANEL BECOME EXTREMELY HOT DURING OPERATION AND WILL RESULT IN SERIOUS INJURY AND BURNS IF TOUCHED. IT IS THEREFORE RECOMMENDED THAT A FIREGUARD COMPLYING WITH BS 8423:2002 IS USED IN THE PRESENCE OF YOUNG CHILDREN, THE ELDERLY OR INFIRM. This product contains a Heat resistant glass panel. This panel should be checked during Installation and at each servicing interval. If any damage is observed on the front face of the glass panel (scratches, scores, cracks or other surface defects), the glass panel must be replaced and the appliance must not be used until a replacement is installed. Under no circumstances should the appliance be used if any damage is observed, the glass panel is removed or broken. It is essential that ALL of the screws that retain the glass frame are replaced and tightened correctly. Under no circumstances should the appliance be operated if any of these screws are loose or missing. These Instructions must be left with the appliance for future reference and for consultation when servicing the appliance. Please make the customer aware of the correct operation of the appliance before leaving these instructions with them. The commissioning sheet found on Page 3 of this Instruction manual must be completed by the Installer prior to leaving the premises. PR1869 Issue 3 (February 2014) Contents Logic HE Balanced Flue Covering the following models: Gas Type Logic He Bf Manual Control Remote Control Slide Control Coal White Stones Coal White Stones Coal White Stones Nat Gas 101-135 101-208 101-174 101-182 101-237 101-386 LPG 101-458 101-687 101-738 101-777 101-639 101-753 Appliance Commissioning Checklist.......................3 User Instructions........................................................4 Installation Instructions...........................................12 Technical Specification for White Stone Effect ......................... 12 Technical Specification for Coal Effect ..................................... 13 Site Requirements..................................................................... 16 Installation................................................................................. 18 Commissioning.......................................................................... 26 Servicing Instructions..............................................27 Fault Finding.............................................................................. 27 How to replace parts................................................................. 30 Basic spare parts list - White Stone Effect................................ 38 Basic spare parts list - Coal Effect............................................ 39 Service Records....................................................................... 40 2 To receive your Extended Warranty your Gazco appliance must have been purchased from our Expert Retailer Network and registered within one month of purchase or installation. Please note that all warranties are effective from the date of purchase. Any Gazco product purchased outside of our Extended Retailer Network, or not registered within the stated time will carry a standard 12 month warranty. It is a condition of the Extended Warranty that the installation complies with the relevant Building Regulations and is carried out by a suitably trained and qualified individual (GasSafe in the UK or equivalent in other countries) with the certificate of installation and the Commissioning Report on Page 3 completed and retained by the end user. Full terms and conditions are detailed in the Warranty Statement on the Gazco website www.gazco.com. In the event of any conflict of information the wording on the website shall prevail. Important Note: Should any problems be experienced with your product, claims must first be submitted to the Expert Retailer where the appliance was purchased from who will offer immediate assistance or contact Gazco on your behalf. Appliance Commissioning Checklist To assist us in any guarantee claim please complete the following information:- IMPORTANT NOTICE Explain the operation of the appliance to the end user, hand the completed instructions to them for safe keeping, as the information will be required when making any guaranteed claims. FLUE CHECK PASS FAIL 1. Flue Is correct for appliance 2. Flue flow Test 3. Spillage Test GAS CHECK 1. Gas soundness & let by test 2. Standing gas pressure mb 3. Appliance working pressure (on High Setting mb 4. Gas rate m3/h NB All other gas appliances must be operating on full 5. Does Ventilation meet appliance requirements SAFETY CHECK 1. Glass checked to ensure no damage, scratches, scores or cracks. 2. Glass frame secured correctly and all screws replaced RETAILER AND INSTALLER INFORMATION Retailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engineer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date of Purchase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Safe Reg No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date of Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 User Instructions Welcome Congratulations on purchasing your Logic HE fire, if installed correctly Gazco hope it will give you many years of warmth and pleasure for which it was designed. The purpose of this manual is to familiarise you with your appliance, and give guidelines for its installation, operation and maintenance. If, after reading, you need further information, please do not hesitate to contact your Gazco retailer. WARNING Do not place curtains above the appliance: You must have 300mm (1’) clearance between the appliance and any curtains at either side. 1.4 No furnishings or other objects should be placed within 1 metre of the front of the appliance. 1.5 If a shelf is fitted, a distance of 400mm above the appliance is required. 1.6 If any cracks appear in the glass panel do not use the appliance until the panel has been replaced. 1.7 Do not obstruct the flue terminal in any way, i.e. by planting flowers, trees, shrubs etc. in the near vicinity, or by leaning objects against the terminal guard. In the event of a gas escape or if you can smell gas, please take the following steps: 1.8 Do not put any objects on the terminal guard; it will lose its shape. • Immediately turn off the gas supply at the meter/emergency control valve 1.9 If you use a garden sprinkler, do not let quantities of water into the flue terminal. • Extinguish all sources of ignition • Do not smoke • Do not operate any electrical light or power switches (On or Off) 1.10 In the unlikely event the appliance is receiving interference from other electronic devices, the handset/Control box can be reprogrammed. Please consult your retailer if you think this may be the case. • Ventilate the building(s) by opening doors and windows • Ensure access to the premises can be made Please report the incident immediately to the National Gas Emergency S ervice Call Centre on 0800 111 999 (England, Scotland and Wales) , 0800 002 001 (N. Ireland) or in the case of LPG, the gas supplier whose details can be found on the bulk storage vessel or cylinder. The gas supply must not be used until remedial action has been taken to correct the defect and the installation has been recommissioned by a competent person. 1. General 1.1 1.3 Installation and servicing must only be carried out by a competent person whose name appears on the Gas Safe register. To ensure the engineer is registered with Gas Safe they should possess an ID Card carrying the following logo: 1.11 This product is guaranteed for 5 years from the date of installation, as set out in the terms and conditions of sale between Gazco and your local Gazco retailer. Please consult with your local Gazco retailer if you have any questions. In all correspondence always quote the Model Number and Serial Number. IMPORTANT : NEVER position an LCD/Plasma TV above this appliance. 2. Operating the Appliance 2.1 There are three types of control systems available for this appliance: 1. Manually Operated Control 2. Remote Control 3. Slide Control Follow the relevant section for specific operation. Manual Control 2.2 Locate the control valve on the appliance. It has a single manual control, see Diagram 1: 1 1.2 In all correspondence, please quote the appliance type and serial number, which can be found on the data badge located on a plate attached to the lower slotted trim. Rotate anti-clockwise 4 User Instructions Lighting the Pilot 2.3 Push the valve knob in and rotate anti-clockwise until 2 clicks are heard. The pilot should now be lit. 2.4 Hold in for a further 10 seconds. When released the pilot should remain lit. If the pilot does not remain lit, repeat until the operation is successful. YELLOW FLAMES APPEAR WHEN THE APPLIANCE HAS REACHED SUFFICIENT HEAT – (10 TO 20 MINUTES). IF THE APPLIANCE IS EXTINGUISHED OR GOES OUT IN USE, WAIT 3 MINUTES BEFORE TRYING TO RELIGHT. Switching OFF the Appliance 2.7 5 To switch the appliance off turn the control knob clockwise until it is returned to the off position, see Diagram 5. Rotate clockwise Locating the Pilot Coal Effect The pilot is located on the front right hand side of the appliance. To view the pilot look down through the GAZCO logo between the glass and the front coal, see Diagram 2. Rotate clockwise 2 The knob should be upright. Remote Control Front Coal Gap in logo The pilot on Remote Control appliances must be lit manually from the valve unit before operation. The control valve is at the foot on the right-hand side of the appliance. It has two controls, see Diagram 6: White Stone Effect 1. The right-hand knob controls the pilot ignition. The pilot is located on the rear right hand side of the appliance and is clearly visible when lit, see Diagram 3. 2. The left-hand knob controls the main burner. 3 Lighting the Pilot 2.8 To start the left-hand and right-hand control knobs must both point to off ( ): 6 Adjusting the Flame height 2.5 2.6 From the pilot position push the valve knob in slightly and rotate anti-clockwise until the first stop point is felt. This denotes the lowest setting. Push the valve knob in slightly and rotate further in an anticlockwise direction. The final stop point is the highest setting. 4 Off position Pilot position 2.9 Press in the right-hand control knob and rotate anti-clockwise until a click is heard. Continue to press in. The knob points to the pilot ( ). The pilot is lit. 2.10 Keep the knob depressed for 10 seconds before releasing. The pilot remains lit. Repeat the above steps if the pilot does not stay lit. NOTE: If the pilot goes out, the Interlock system prevents you lighting again for a short period. 2.11 If, after repeating the above steps the pilot does not light, contact your Retailer or Installer. Low Setting High Setting 5 User Instructions 2.12 Turn the right-hand control to point to main burner ( ). The appliance can now be controlled by the remote handset. 2.13 The Standard remote controls the appliance when: — the pilot is lit. — the right-hand control points to main burner operate position. It regulates the temperature from low to high and back. It can also turn the main burner off leaving just the pilot burning and ready to operate. ready to 7 Remote Control 2.20 To turn the main burner of the appliance off using the handset press and keep pressing the Off button ( ) The main burner goes out leaving the pilot burning and ready to operate Controls on Appliance 2.21 Use the controls on the appliance to turn the appliance off by turning the left-hand control knob until it points to Off ( ). A click is heard and the main burner goes out leaving the pilot burning and ready to operate CAUTION: IN RARE INSTANCES, NOISES FROM SOURCES OUTSIDE THE REMOTE CAN OPERATE THE MAIN BURNER. IF THIS OCCURS, ALWAYS TURN THE CONTROL TO PILOT ( ) OR OFF. A B C Slide Control This appliance is operated using the slide control on the top right hand side of the decorative front. When the appliance is OFF the slide control will be at the highest point, see Diagram 8. 8 To light the main burner: 2.14 Press buttons A & B simultaneously. The remote’s LED light flashes to show communication between the appliance's controls and the remote. OFF High Setting Low Setting Adjusting the Flame height: Ignition Point 2.15 Press and hold buttons A & B simultaneously to increase the flame height. A clicking sound indicates that the appliance is at maximum. 2.16 Press and hold button C to decrease the flame height. Continue to press C to turn off the main burner. To make small adjustments to flame height: 2.17 Press and hold down button B and press button A once to make a slight increase. This increases the temperature by stages. 2.22 Push the slide control down as far as possible to its lowest point, see Diagram 8, this is the ignition point. Keep the slide control pressed down for 5 seconds to ensure the pilot is lit. Then release. The appliance should light on its lowest setting. Repeat to further adjust. 2.18 Press button C once to slightly reduce the flame height. Lighting the Pilot YELLOW FLAMES APPEAR WHEN THE APPLIANCE HAS REACHED SUFFICIENT HEAT – (10 TO 20 MINUTES). IF THE APPLIANCE IS EXTINGUISHED OR GOES OUT IN USE, WAIT 3 MINUTES BEFORE TRYING TO RELIGHT. 2.23 When released the slide control automatically raises to a natural stop point, see Diagram 8. Repeat the above steps if the appliance does not light. Switching OFF the Appliance 2.24 If, after repeating the above steps the pilot does not light, contact your Retailer or Installer. Adjusting the Flame height THE REMOTE CONTROL CAN TURN THE MAIN BURNER OFF AND LEAVE THE PILOT BURNING AND READY TO OPERATE . 2.19 To switch off the appliance completely (no pilot burning) return both control knobs to the off position ( ). 2.25 Increase the flame height and temperature by carefully moving the slide control up until the next stop point is felt, see Diagram 8. This denotes the highest setting. 2.26 Carefully move the slide control down to the lower stop point to return to the lowest setting. 6 User Instructions YELLOW FLAMES APPEAR WHEN THE APPLIANCE HAS REACHED SUFFICIENT HEAT – (10 TO 20 MINUTES). IF THE APPLIANCE IS EXTINGUISHED OR GOES OUT IN USE, WAIT 3 MINUTES BEFORE TRYING TO RELIGHT. 4.7 The glass frame must be refitted to the appliance following cleaning or servicing. Ensure that the fibre glass seal on the box is intact, then lower the glass frame onto the 2 lower fixing screws, see Diagram 10, Arrow A. 4.8 Fit the other 6 fixing screws, see Diagram 10, Arrow B. 4.9 Tighten all 8 screws to secure the frame, see Diagram 10. Replace ALL of the securing screws ensuring that a screw is present in all fixing slots. NEVER OPERATE THE APPLIANCE WHEN THE GLASS FRAME IS REMOVED OR BROKEN. Refer to the separate decorative front instructions to replace the front on the appliance. Switching OFF the Appliance 2.27 To turn the appliance off lift the slide control to its highest stop point, see Diagram 8. The pilot goes out. 3. Changing the Battery (Slide Control Model only) 3.1 The battery box is located at the bottom left of the appliance behind the ash cover, see Diagram 9. 9 9V Battery Ignition Unit UNDER NO CIRCUMSTANCES SHOULD THE APPLIANCE BE USED IF ANY OF THE GLASS FRAME RETAINING SCREWS ARE LOOSE OR MISSING. White Stone Effect 4.10 Remove the white stones and place on a dry clean surface. Do not remove the enamel back panel. 3.2 Remove the old battery and replace with a new high quality (Duracell or similar) 9V battery. 4. Cleaning the Appliance 4.1 Make sure the appliance and surrounds are cool before trying to clean. 4.2 Refer to the separate decorative front instructions to remove the front from the appliance. 4.3 Remove the glass frame by unscrewing the 2 lower outer pozi-head screws, see Diagram 10, Arrow A, by several turns, there is no need to fully remove these 2 screws. 4.4 Remove the remaining 6 screws, see Diagram 10, Arrow B. B B 4.12 Carefully clean the burner and tray assembly using a vacuum cleaner with soft brush attachment, ensure all debris is removed from the burner ports. 4.13 Replace the white stones by referring to Section 5A. Coal Effect 4.14 Remove the ceramic coals and fuel bed and place on a dry clean surface. 4.15 Check the burner cover gasket for damage. Replace any damaged parts with genuine Gazco replacement parts, contact your Gazco retailer. 4.16 Carefully clean the burner and tray assembly using a vacuum cleaner with soft brush attachment, ensure all debris is removed from the burner ports. 10 B 4.11 Use a damp cloth and mild non-abrasive cleaner on the enamel back panel. B WARNING: Take care when using a vacuum cleaner on the burner gasket as this is extremely delicate and may deteriorate after use. 4.17 Replace the ceramics by referring to section 5B. B A B A 4.5 Lift the glass frame clear of the appliance and carefully place to one side. 4.6 To clean the glass surface, Gazco recommends you use a ceramic glass product generally sold for cleaning ceramic hobs. 7 User Instructions 5. Arrangement of the Fuel Bed 5.2 12 Advice on handling and disposal of fire ceramics Lean the white stones against the burner ledges to disguise the ledges, see Diagram 12. The fuel effect and side panels of this appliance are made from Refractory Ceramic Fibre (RCF), a material which is commonly used for this application. Protective clothing is not required when handling these articles, but we recommend you follow normal hygiene rules of not smoking, eating or drinking in the work area and always wash your hands before eating or drinking. 5.3 To ensure that the release of RCF fibres are kept to a minimum, during installation and servicing a HEPA filtered vacuum is recommended to remove any dust accumulated in and around the appliance before and after working on it. When servicing the appliance it is recommended that the replaced items are not broken up, but are sealed within heavy duty polythene bags and labelled as RCF waste. RCF waste is classed as stable, non-reactive hazardous waste and may be disposed of at a licensed landfill site. Excessive exposure to these materials may cause temporary irritation to eyes, skin and respiratory tract; wash hands thoroughly after handling the material. 13 ONLY USE THE CORRECT TYPE AND QUANTITY OF WHITE STONES. ALWAYS FOLLOW THE FUEL BED LAYOUT AS STATED IN THESE INSTRUCTIONS. NEVER CHANGE THE LAYOUT FROM THAT SHOWN HERE. 5.1 Arrange the white stones in the areas highlighted in Diagram 11. They should be evenly distributed. A NOTE: IT IS IMPORTANT THE WHITE STONES DO NOT COVER THE PORT AREA IN BETWEEN THE BURNER LEDGES. 5.4 Ensure that no stones overhang or fill the pilot area, see Diagram 14, Arrow B. 5A. White Stone Layout Check that the port area, see Diagram 13, Arrow A is clear of white stones. This can be easily done by gently running a screwdriver or similar object along this area. 14 B B 11 NOTE: STONES SHOULD NOT BE PLACED DIRECTLY IN FRONT OF THE PILOT CROSS LIGHTING FLAME. 5B. Coal Effect Layout NOTE: CERAMIC PARTS ARE FRAGILE. HANDLE WITH CARE. ONLY USE THE CORRECT TYPE AND QUANTITY OF CERAMIC COMPONENTS 5.5 Place the rear panel against the rear of the box resting on the shelf. 8 User Instructions 5.6 Slide one of the side panels into the box ensuring it touches the rear panel. 5.7 Gently ease the front edge of the side panel behind the flange so it lies flat against the wall of the box. 5.8 Repeat with the second side panel, Diagram 15. 5.12 Place the front coal centrally in the channel at the front of the tray. The relationship between the front coal and the flame baffle is shown, Diagram 18. 18 15 5.13 There are three sizes of coal used. Small x3, medium x4 and large x1. For identification, Diagram 19. Left 5.9 Right 19 Locate the top panel on top of the sides and rear by lifting it up and forward inside the box. 5.10 Slide it backwards and down behind the side panels to rest on the rear panel, Diagram 16. LARGE 16 MEDIUM SMALL 5.14 Place the single large coal in the central dent of the front coal resting against the flame baffle, Diagram 20. 20 5.11 Position the flame baffle centrally on the tray and ensure the stepped lower edge engages against the rear edge of the burner skin, Diagram 17. 17 5.15 Place the left front medium coal in the recess between the flame baffle and the front coal, Diagram 21. 21 9 User Instructions 5.16 Place the front right medium coal on the front coals and against the flame baffle, Diagram 22. 5.20 Place the left hand small coal in the recess between the flame baffle and the front coal, Diagram 26. 22 5.17 Place the rear left medium coal on the recess behind the front row of coals resting on the rear panel, Diagram 23. 26 5.21 Place the centre rear small coal in the recess behind the large centre coal, Diagram 27. 23 5.18 Place the rear right medium coal in the recess behind the front row of coals resting on the rear pane, Diagram 24. 24 27 5.22 It is essential that gaps are left between the coals to maximise the performance of the appliance. 6. Flame Failure Device 5.19 Place the right hand small coal in the recess between the flame baffle and the front coal, Diagram 25. 6.1 This is a safety feature incorporated on this appliance which automatically switches off the gas supply if the pilot goes out and fails to heat the thermocouple. IF THIS OCCURS DO NOT ATTEMPT TO RELIGHT THE APPLIANCE FOR 3 MINUTES. 7. Running In 7.1 During initial use of a new GAZCO appliance a strong odour will be encountered as various surface coatings become hot for the first time. Although these odours are harmless it is recommended that the appliance is operated on maximum for 4 to 8 hours in order to fully burn off these coatings. After this period the odours should then disappear. If the odours persists, please contact your installer for advice. 7.2 During the first few hours of burning there may be discolouration of the flames. This will also disappear after a short period of use. 25 8. Servicing 8.1 10 The appliance must be serviced every 12 months by a qualified Gas Engineer. In all correspondence always quote the Model number and the Serial number which may be found on the data badge. User Instructions 9. Ventilation 9.1 This appliance requires no additional ventilation. 10. Installation Details 10.1 Your installer should have completed the commissioning sheet at the front of this book. This records the essential installation details of the appliance. In all correspondence always quote the Model number and Serial number. 11. Hot Surfaces 11.1 Parts of this appliance become hot during normal use. 11.2 Regard all parts of the appliance as a working surface, except for the control access panel and the slider handle (slide control model only). 11.3 Provide a suitable fire guard to protect young children and the infirm. 11 Installation Instructions Technical Specification - Stone Effect Covering the following models: Model Logic HE Stone Effect Gas Type Manual Control Remote Control Slide Control Nat Gas 101-208 101-182 101-386 LPG 101-687 101-777 101-753 Gas Cat. Gas Type Working Pressure Aeration Injector I2H Natural G20 20mb 6 x 10 I3P Propane (G31 37mb 12 x 15 Gas Rate m3/hr Input kW (Gross) Country High Low High Low 200 0.324 0.2 3.4 2.1 GB, IE 95 0.139 0.079 3.4 2.1 GB, IE Manual Logic HE Remote Slide Manual Logic HE Remote Slide Efficiency 86% Net (Class 1) NOx Class 4 Flue Outlet Size Ø 100mm Flue Inlet Size Ø 152mm Gas Inlet Connection Size Ø 8mm 12 Installation Instructions Technical Specification - Coal Effect Covering the following models: Gas Cat. Model Logic HE Coal Effect Gas Type Manual Control Remote Control Slide Control Nat Gas 101-135 101-174 101-237 LPG 101-458 101-738 101-639 Gas Type Working Pressure Aeration Injector Logic HE Input kW (Gross) High Low High Low 0.381 0.219 4.0 2.3 0.403 0.219 4.2 2.3 Slide 0.39 0.219 4.1 2.3 Manual 0.150 0.083 4.0 2.2 0.154 0.083 4.1 2.2. 0.154 0.083 4.1 2.2 Manual Logic HE Gas Rate m3/hr Remote Remote I2H I3P Natural G20 Propane (G31 20mb 37mb 8 x 15 23 x 15 (2) Slide 260 104 Country GB, IE GB, IE Efficiency 86% Net (Class 1) NOx Class 3 Flue Outlet Size Ø 100mm Flue Inlet Size Ø 152mm Gas Inlet Connection Size Ø 8mm The net efficiency of this appliance has been measured as specified in EN613:2001 and the result after conversion to gross using the appropriate factor from Table E4 of SAP 2009 is 77.5%. The test data has been certified by BSI Testing Services. The gross efficiency value may be used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. 13 Installation Instructions Technical Specification COMPLETE FRONT OPTIONS FRONT Manual & Remote Slide Control 912-396, 912-018 - DESIGNIO 2 901-493, 901-511, 901-526 901-539, 901-580, 901-643 EVOLUTION 912-601 - FUTURA 8687BK - FUSION 8699GP + 8699IR - 912-239 - 912-197, 912-221, 912-316 901-385, 901-403, 901-414 WINCHESTER 8697MB + 8697P 901-369, 901-372 DIMENSION2 912-322 - 8695GP + 8695IR - RICHMOND * 8679 - STOCKTON * 8696 - YM98906 - DESIGNIO PROGRESS TEMPO STEEL ** YEOMAN * FRAME & FRONT COMBINATIONS Box Profil2 Frame *** Arts2 Frame *** Arts Front Holyrood Front * Spanish Front * Manual & Remote Slide Manual & Remote Slide All Models All Models All Models Matt Black 912-232 901-272 912-862 901-167 901-425 912-020 912-083 Polished Brass Effect 912-140 901-286 - - 901-530 912-226 912-160 Polished Steel Effect 912-027 901-299 - - - - - Brushed Steel Effect 912-358 901-310 - - - - - Polished Brass - - 912-508 901-194 - - - Polished Stainless - - 912-914 901-206 - - - Brushed Stainless - - 912-268 901-214 - - - Highlight Polished - - - - 901-296 912-257 912-127 Polished Chrome - - - - 901-476 912-392 912-216 FINISH * Not available on the Stone Effect ** Not available on the Coal Effect *** A Box Profil2 Frame or Arts2 Frame must be used in conjunction with an Arts, Holyrood or Spanish Front 14 Installation Instructions Technical Specification OVERALL EXTERNAL DIMENSIONS 160mm 160mm 210mm 240mm MINIMUM AND MAXIMUM FLUE SIZE MINIMUM FLUE LENGTH 20mm MAXIMUM FLUE LENGTH 160mm 15 Installation Instructions Site Requirements 1. Flue & Chimney Requirements NOTE: This appliance can only be installed in conjunction with the flue supplied. You must adhere to the following: 1.1 The flue must be sited in accordance with BS5440: Part 1 (latest edition), see Diagram 1. 1.2 Fit a guard to protect people from any terminal less than 2 metres above any access such as level ground, a balcony or above a flat roof. 1.3 The flue must be securely fixed and fire precautions followed in accordance with local and national codes of practice. 1.4 The horizontal terminal can be reduced in length, see Diagram 2. 2 1 UK Dimensions 16 Dimension Terminal Position Minimum Distance (mm) A* Directly below an opening, air brick, opening widows etc 300 mm B* Above an opening, air brick, opening windows etc. 300 mm C* Horizontal to an opening, air brick, opening windows etc. 300 mm D Below gutters, soil pipes or drain pipes 300 mm E Below eaves 300 mm F Below balconies or car port roof 600 mm G From a vertical drain pipe or soil pipe 300 mm H From an internal or external corner 600 mm I Above ground, roof or balcony level 300 mm J From a surface facing the terminal (or boundary) 600 mm K From a terminal facing the terminal 600 mm L From an opening in the car port (e.g. door, window) into dwelling 1200 mm M Vertically from a terminal on the same wall 1500 mm N Horizontally from a terminal on the same wall 300 mm O From the wall in which the terminal is mounted N/A P From a vertical structure on the roof N/A Q Above intersection with roof N/A * In addition, the terminal should not be nearer than 300mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame. H The reference to external corners does not apply to building protrusions not exceeding 450mm, such as disused chimneys on external walls. Installation Instructions Site Requirements Timber Framed Buildings 1.5 It will be necessary to provide additional clearance when the flue passes through a wall containing any combustible materials so as to prevent a fire hazard. 4.2 3 1.6 The hole through which the flue will pass, must have a steel sleeve which is positioned so that an air gap of at least 25mm is maintained between the outer surface of the flue, and any part of the sleeve. The minimum opening dimensions are shown, see Diagram 3. A B C 1.7 For further guidance on the installation of gas appliances in timber framed buildings, contact your local buildings control authority. E 2. Gas Supply 2.1 D F DIMENSIONS MIN MAX A 420 mm 450 mm B 560 mm 575 mm C 165mm - D 300 mm - E 420 mm - F 12 mm - Before installation, ensure that the local distribution conditions (identification of the type of gas and pressure) and the adjustment of the appliance are compatible. 4.3 This appliance can only be installed on an outside wall with suitable clearances for the flue terminal and guard (if required). 2.2 Ensure the gas supply delivers the required amount of gas and is in accordance with the rules in force. 4.4 2.3 Factory-sheathed/wrapped soft copper tubing with small ridges which allow pipe movement are considered to be a suitable alternative to a pipe sleeve, when recessing the unit into a cavity wall the gas supply is best fed through the wall from the outside. Soft soldered joints can only be used outside the appliance. This appliance is not suitable for installation into a combustible wall. All combustible material must be removed from the area shown, see Diagram 4. 300 720 860 This appliance is supplied complete with a factory fitted isolation device incorporated into the inlet connection. No further isolation device is therefore required. 560 2.4 4 3. Ventilation 3.1 150 This appliance requires no additional ventilation. 4. Appliance Location NOTE: It is recommended you construct the back panel of the fireplace from natural materials cut into three or more sections to prevent cracking. Resin-based materials may not be suitable. This appliance is an effective heat producer and attention must be paid to the construction and finish of the fireplace. 4.1 This appliance must stand on a non combustible hearth that is at least 12mm thick. If the appliance is greater than 50mm above the floor, then no hearth is required, although due consideration should be given to how the heat may affect the floor material. 4.5 420 The maximum depth of combustible shelf is 150mm at a minimum height of 300mm above the fireplace opening. 17 Installation Instructions 1. Safety Precautions 1.1 2.2 The position of the gas inlet pipe is shown, see Diagram 1. 1 For your own and other’s safety, you must install this appliance according to local and national codes of practice. Failure to install the appliance correctly could lead to prosecution. Read these instructions before installing and using this appliance. 35mm 1.2 These instructions must be left intact with the user. 1.3 Do not attempt to burn rubbish on this appliance. 1.4 Keep all plastic bags away from young children. 1.5 Do not place any object on or near to the appliance and allow adequate clearance above the appliance. 2.3 All supply pipes must be purged of any debris that may have entered, prior to connection to the appliance. IF THE APPLIANCE IS EXTINGUISHED OR GOES OUT IN USE, WAIT 3 MINUTES BEFORE ATTEMPTING TO RELIGHT THE APPLIANCE. 2.4 The gas supply enters through the silicone panel located on the rear of the outer box. This will need to be slit with a sharp knife prior to passing the supply pipe through. IMPORTANT: REFER TO DATA BADGE AND TECHNICAL SPECIFICATION AT THE FRONT OF THE MANUAL TO ENSURE THE APPLIANCE IS CORRECTLY ADJUSTED FOR THE GAS TYPE AND CATEGORY APPLICABLE IN THE COUNTRY OF USE. 120mm 3. Preparing the Appliance 3.1 FOR DETAILS OF CHANGING BETWEEN GAS TYPES REFER TO SERVICING, SECTION 10, REPLACING PARTS. Remove the backing from the self-adhesive silicone sealing strip and apply to the rear flange of the firebox ensuring that the strip is positioned as close to the outer edge as is practically possible, see Diagram 2, arrow A. 2 Unpacking 1.6 Remove the appliance from its packaging, and check that it is complete and undamaged. Put the loose ceramic parts to one side so that they are not damaged during installation. 2. Installation of the Gas Supply For specific gas types and working pressures see Technical Specifications, pages 12 and 13. TO CHANGE FROM ONE GAS TYPE TO ANOTHER A COMPLETE ENGINE ASSEMBLY AND DATA BADGE WILL BE REQUIRED. SEE SECTION 10 REPLACING PARTS. 2.1 Before installation, ensure that the local distribution conditions (identification of the type of gas and pressure) and the adjustment of the appliance are compatible. See Technical Specification on pages 12 and 13. A B 3.2 Gas pipe entry must come through the rear right-hand side of the box. The rubber seal must be cut using a sharp knife to allow the isolating elbow to pass through it. Ensure the rubber is not damaged when doing this, see Diagram 2, arrow B. 3.3 A means of isolation is provided with the appliance. This must be fitted to the supply pipe prior to installing the firebox. 3.4 The appliance can either be recessed into an inner leaf of the wall. A 20mm rebated surround or 20mm thick back panel must be used with this method. Or it can be installed in front of the wall in conjunction with a fire surround constructed of a studwork frame, Diagram 3 for options. If using a back panel constructed from natural materials such as stone, the panel should consist of 3 or more sections to reduce the risk of cracking. 18 Installation Instructions 3 5 160mm 20mm 4. Non Recessed Installation 4.1 Mark the position of the flue on the inner wall by measuring from the top of the finished hearth level, Diagram 4. 4 4.6 The void into which the appliance is fitted must be ventilated to prevent a build up of heat. If the void is sealed then it will be necessary to fit vents at both low and high levels of approximately 50cm2. These vents should take cold air from the room and return warm air back into the room. 5. Recessed Installation 4.2 A 152mm (6’) diameter hole is required to install the flue. This can be achieved by either: a) Core drill b) Hammer and chisel. It is advisable to drill small holes around the circumference when using method b. Make good both ends of the hole. 4.3 It will now be necessary to construct a studwork frame to house the appliance. The minimum depth of the aperture must be 165mm. This includes an air gap of 5mm behind the appliance. The sides must be lined with non-combustible material for the full depth of the aperture. 4.4 Combustible parts of the studwork frame must not be any closer than the minimum dimensions shown in Diagram 5. These dimensions need to be maintained even if the frame work is protected by non combustible material. 4.5 Do not pack the void around or above the appliance with insulation material such as mineral wool. This method of installation requires structural alteration to the intended location. A suitable supporting lintel must be installed to maintain the structural integrity of the surrounding blockwork. 5.1 Mark the position of the lintel so that it sits centrally over the intended installation. Remove the blockwork and install the lintel using mortar to ensure a strong bond with the surrounding wall, see Diagram 6. 6 5.2 With the lintel in position mark the width of the aperture and remove the blockwork. 5.3 Seal the cavity with non combustible board, to prevent any insulation touching the appliance. 5.4 Ensure that there is a minimum of 10mm gap left between the back of the appliance and the outer wall. There must be no combustible materials behind this appliance. 19 Installation Instructions 5.5 Mark the position of the flue on the wall by measuring from the top of the finished hearth level, see Diagram 7. 7 6.6 Secure the appliance in place using screws and rawl plugs provided. 6.7 PURGE THE SUPPLY PIPE. This is essential to expel any debris that may block the gas controls. Connect the elbow to the appliance inlet pipe. 6.8 Connect a suitable pressure gauge to the test point located on the inlet elbow and turn the gas on. 6.9 Light the appliance and check for leaks . 6.10 Turn the appliance to maximum and check that the supply pressure is as stated on the databadge 5.6 A 152mm (6’) diameter hole is required to install the flue. This can be achieved by either: a) Core drill b) Hammer and chisel It is advisable to drill small holes around the circumference when using method b. Make good both ends of the hole. 6. Installation of the Appliance 6.1 6.11 Turn the gas supply off and replace the test point screw. Turn the gas on and check the test point for leaks. 7. Removing the Glass Frame 7.1 Remove the glass frame by unscrewing the 2 lower outer pozi-head screws, see Diagram 9, Arrow A, by several turns, there is no need to fully remove these 2 screws. 7.2 Remove the remaining 6 screws, see Diagram 9, Arrow B. 9 B B B The flue can be cut to length, measure the thickness of the wall the flue is passing through, then deduct 12mm. This is the length required when measuring from the line on the flue label. This must be level with the outside wall face when fitted, see Diagram 8. 8 B A B B A 7.3 Lift the glass frame clear of the appliance and carefully place to one side. 6.2 There is a cardboard fitment in the terminal. This is to support the flue whilst it is cut to length. REMOVE THE REMAINDER OF THE CARDBOARD AFTER CUTTING TO SIZE. 6.3 Remove the compression elbow from the appliance and connect it to the gas supply pipe, taking note of its orientation. NOTE: TO AID INSTALLATION OF THE GAS PIPE, THE BURNER UNIT CAN BE REMOVED. SEE REPLACING PARTS, SECTION 2. 6.4 Attach the flue to the appliance and seal using the aluminium tape provided. 6.5 As the appliance is positioned into the opening of the enclosure, pass the flue pipe through the hole in the wall. It will be necessary to pass the supply pipe with the elbow through the silicone panel on the right hand side of the box. 20 Installation Instructions 8. Arrangement of the Fuel Bed 8.2 11 Advice on handling and disposal of fire ceramics Lean the white stones against the burner ledges to disguise the ledges, see Diagram 11. The fuel effect and side panels of this appliance are made from Refractory Ceramic Fibre (RCF), a material which is commonly used for this application. Protective clothing is not required when handling these articles, but we recommend you follow normal hygiene rules of not smoking, eating or drinking in the work area and always wash your hands before eating or drinking. 8.3 To ensure that the release of RCF fibres are kept to a minimum, during installation and servicing a HEPA filtered vacuum is recommended to remove any dust accumulated in and around the appliance before and after working on it. When servicing the appliance it is recommended that the replaced items are not broken up, but are sealed within heavy duty polythene bags and labelled as RCF waste. RCF waste is classed as stable, non-reactive hazardous waste and may be disposed of at a licensed landfill site. Excessive exposure to these materials may cause temporary irritation to eyes, skin and respiratory tract; wash hands thoroughly after handling the material. 12 ONLY USE THE CORRECT TYPE AND QUANTITY OF WHITE STONES. ALWAYS FOLLOW THE FUEL BED LAYOUT AS STATED IN THESE INSTRUCTIONS. NEVER CHANGE THE LAYOUT FROM THAT SHOWN HERE. 8.1 Arrange the white stones in the areas highlighted in Diagram 10. They should be evenly distributed. A NOTE: IT IS IMPORTANT THE WHITE STONES DO NOT COVER THE PORT AREA IN BETWEEN THE BURNER LEDGES. 8.4 Ensure that no stones overhang or fill the pilot area, see Diagram 13, Arrow B. 8A. White Stone Layout Check that the port area, see Diagram 12, Arrow A is clear of white stones. This can be easily done by gently running a screwdriver or similar object along this area. 13 B B 10 NOTE: STONES SHOULD NOT BE PLACED DIRECTLY IN FRONT OF THE PILOT CROSS LIGHTING FLAME. 8B. Coal Effect Layout NOTE: CERAMIC PARTS ARE FRAGILE. HANDLE WITH CARE. ONLY USE THE CORRECT TYPE AND QUANTITY OF CERAMIC COMPONENTS 8.5 Place the rear panel against the rear of the box resting on the shelf. 21 Installation Instructions 8.6 Slide one of the side panels into the box ensuring it touches the rear panel. 8.7 Gently ease the front edge of the side panel behind the flange so it lies flat against the wall of the box. 8.8 Repeat with the second side panel, Diagram 14. 812 Place the front coal centrally in the channel at the front of the tray. The relationship between the front coal and the flame baffle is shown, Diagram 17. 17 14 8.13 There are three sizes of coal used. Small x3, medium x4 and large x1. For identification, Diagram 18. Left 8.9 Right 18 Locate the top panel on top of the sides and rear by lifting it up and forward inside the box. 8.10 Slide it backwards and down behind the side panels to rest on the rear panel, Diagram 15. LARGE 15 MEDIUM SMALL 8.14 Place the single large coal in the central dent of the front coal resting against the flame baffle, Diagram 19. 19 8.11 Position the flame baffle centrally on the tray and ensure the stepped lower edge engages against the rear edge of the burner skin, Diagram 16. 16 8.15 Place the left front medium coal in the recess between the flame baffle and the front coal, Diagram 20. 20 22 Installation Instructions 8.16 Place the front right medium coal on the front coals and against the flame baffle, Diagram 21. 8.20 Place the left hand small coal in the recess between the flame baffle and the front coal, Diagram 25. 21 8.17 Place the rear left medium coal on the recess behind the front row of coals resting on the rear panel, Diagram 22. 25 8.21 Place the centre rear small coal in the recess behind the large centre coal, Diagram 26. 22 8.18 Place the rear right medium coal in the recess behind the front row of coals resting on the rear pane, Diagram 23. 23 26 8.22 It is essential that gaps are left between the coals to maximise the performance of the appliance. 9. Fitting the Glass Frame 9.1 Ensure that the fibre glass seal on the box is intact, then lower the glass frame onto the 2 lower fixing screws, see Diagram 27, Arrow A. 9.2 Fit the other 6 fixing screws, see Diagram 27, Arrow B. 9.3 Tighten all 8 screws to secure the frame, Diagram 26. Replace ALL of the securing screws ensuring that a screw is present in all fixing slots. 8.19 Place the right hand small coal in the recess between the flame baffle and the front coal, Diagram 24. 27 B 24 B B B A B B A NEVER OPERATE THE APPLIANCE WHEN THE GLASS FRAME IS REMOVED OR BROKEN. Refer to the separate decorative front Instructions to replace the front on the appliance. 23 Installation Instructions UNDER NO CIRCUMSTANCES SHOULD THE APPLIANCE BE USED IF ANY OF THE GLASS FRAME RETAINING SCREWS ARE LOOSE OR MISSING. White Stone Effect The pilot is located on the rear right hand side of the appliance and is clearly visible when lit, see Diagram 30. 30 10. Operating the Appliance 10.1 There are three types of control systems available for this appliance: 1. Manually Operated Control 2. Remote Control 3. Slide Control Follow the relevant section for specific operation. Adjusting the Flame height 10.5 From the pilot position push the valve knob in slightly and rotate anti-clockwise until the first stop point is felt. Manual Control 10.2 Locate the control valve on the appliance. It has a single manual control, see Diagram 28: 28 This denotes the lowest setting. 10.6 Push the valve knob in slightly and rotate further in an anticlockwise direction. The final stop point is the highest setting 31 Rotate anti-clockwise Off position Pilot position Lighting the Pilot 10.3 Push the valve knob in and rotate anti-clockwise until 2 clicks are heard. The pilot should now be lit. Low Setting YELLOW FLAMES APPEAR WHEN THE APPLIANCE HAS REACHED SUFFICIENT HEAT – (10 TO 20 MINUTES). IF THE APPLIANCE IS EXTINGUISHED OR GOES OUT IN USE, WAIT 3 MINUTES BEFORE TRYING TO RELIGHT. 10.4 Hold in for a further 10 seconds. When released the pilot should remain lit. Switching OFF the Appliance If the pilot does not remain lit, repeat until the operation is successful. Locating the Pilot 10.7 To switch the appliance off turn the control knob clockwise until it is returned to the off position, see Diagram 32. 32 Coal Effect The pilot is located on the front right hand side of the appliance. To view the pilot look down through the GAZCO logo between the glass and the front coal, Diagram 29. Gap in logo 24 Rotate clockwise Rotate clockwise 29 Front Coal High Setting The knob should be upright. Installation Instructions 34 Remote Control The pilot on Remote Control appliances must be lit manually from the valve unit before operation. The control valve is at the foot on the right-hand side of the appliance. It has two controls, see Diagram 32: 1. The right-hand knob controls the pilot ignition. 2. The left-hand knob controls the main burner. A B C Lighting the Pilot 10.8 To start the left-hand and right-hand control knobs must both point to off ( ): 33 To light the main burner: 10.14 Press buttons A & B simultaneously. The remote’s LED light flashes to show communication between the appliance's controls and the remote. Adjusting the Flame height: 10.15 Press and hold buttons A & B simultaneously to increase the flame height. A clicking sound indicates that the appliance is at maximum. 10.9 Press in the right-hand control knob and rotate anticlockwise until a click is heard. Continue to press in. The knob points to the pilot ( ). The pilot is lit. 10.10 Keep the knob depressed for 10 seconds before releasing. The pilot remains lit. Repeat the above steps if the pilot does not stay lit. NOTE: If the pilot goes out, the Interlock system prevents you lighting again for a short period. 10.16 Press and hold button C to decrease the flame height. Continue to press C to turn off the main burner. To make small adjustments to flame height: 10.17 Press and hold down button B and press button A once to make a slight increase. This increases the temperature by stages. Repeat to further adjust. 10.18 Press button C once to slightly reduce the flame height. YELLOW FLAMES APPEAR WHEN THE APPLIANCE HAS REACHED SUFFICIENT HEAT – (10 TO 20 MINUTES). IF THE APPLIANCE IS EXTINGUISHED OR GOES OUT IN USE, WAIT 3 MINUTES BEFORE TRYING TO RELIGHT. 10.11 If, after repeating the above steps the pilot does not light, contact your Retailer or Installer. 10.12 Turn the right-hand control to point to main burner ( ). The appliance can now be controlled by the remote handset. Switching OFF the Appliance 10.13 The Standard remote controls the appliance when: — the pilot is lit. — the right-hand control points to main burner operate position. It regulates the temperature from low to high and back. It can also turn the main burner off leaving just the pilot burning and ready to operate. ready to THE REMOTE CONTROL CAN TURN THE MAIN BURNER OFF AND LEAVE THE PILOT BURNING AND READY TO OPERATE 10.19 To switch off the appliance completely (no pilot burning) return both control knobs to the off position ( ). Remote Control 10.20 To turn the main burner of the appliance off using the handset press and keep pressing the Off button ( ) The main burner goes out leaving the pilot burning and ready to run Controls on Appliance 10.21 Use the controls on the appliance to turn the appliance off by turning the left-hand control knob until it points to Off ( ). A click is heard and the main burner goes out leaving the pilot burning and ready to run 25 Installation Instructions/ Commissioning CAUTION: IN RARE INSTANCES, NOISES FROM SOURCES OUTSIDE THE REMOTE CAN OPERATE THE MAIN BURNER. IF THIS OCCURS, ALWAYS TURN THE CONTROL TO PILOT ( ) OR OFF. Slide Control This appliance is operated using the slide control on the top right hand side of the decorative front. When the appliance is OFF the slide control will be at the highest point, see Diagram 34. 1. Commissioning 1.1 Complete the Commissioning Checklist at the front of this manual covering: — Flue checks — Gas checks — Fuel effect layout - flame picture 1.2 Upon completion of the commissioning and testing of the installation and correct operation of the appliance, the installer must instruct the user how to operate the appliance. 1.3 Guide the user through the User Instructions paying particular attention to: a) Regular servicing (Section 8 of the User Instructions). b) Ventilation (Section 9 of the User Instructions) - point out the ventilation positions where applicable. c) Hot surfaces (Section 11 of the User Instructions). 34 OFF High Setting Low Setting Ignition Point Lighting the Pilot 10.22 Push the slide control down as far as possible to its lowest point, see Diagram 34, this is the ignition point. Keep the slide control pressed down for 5 seconds to ensure the pilot is lit. Then release. The appliance should light on its lowest setting. 10.23 When released the slide control automatically raises to a natural stop point, see Diagram 34. Repeat the above steps if the appliance does not light. 10.24 If, after repeating the above steps the pilot does not light, contact your Retailer or Installer. Adjusting the Flame height 10.25 Increase the flame height and temperature by carefully moving the slide control up until the next stop point is felt, see Diagram 34. This denotes the highest setting. 10.26 Carefully move the slide control down to the lower stop point to return to the lowest setting. YELLOW FLAMES APPEAR WHEN THE APPLIANCE HAS REACHED SUFFICIENT HEAT – (10 TO 20 MINUTES). IF THE APPLIANCE IS EXTINGUISHED OR GOES OUT IN USE, WAIT 3 MINUTES BEFORE TRYING TO RELIGHT. Switching OFF the Appliance 10.27 To turn the appliance off lift the slide control to its highest stop point, see Diagram 34. The pilot goes out. 26 Servicing Instructions Servicing/Fault Finding Charts 1. Servicing Requirements 1.1 Before Testing: IMPORTANT – The glass panel on this appliance should be checked for any signs of damage on the front face of the glass panel (scratches, scores, cracks or other surface defects). If damage is observed, the glass panel must be replaced and the appliance must not be used until a replacement is installed. Under no circumstances should the appliance be used if any damage is observed. Please isolate the appliance until a replacement glass panel has been obtained and installed. Replacement glass panels can be purchased from Gazco via the retailer from which the appliance was purchased or any other Gazco distributor. —Conduct a gas soundness test for the property ensuring there are no leaks before servicing. —Check the operation of the appliance before testing. 1.2 Special checks: This appliance must be serviced at least once a year by a competent person. —Clean the burner using a vacuum cleaner with a soft brush attachment. Ensure all debris is removed from the burner ports. —Check the flue terminal position complies with the requirements, and that the terminal is not obstructed. —Clean away any debris under the burner. —Check the condition of ceramics, pilot and burner cover gasket. —Ensure that the glass frame is secured correctly and that all retaining screws are in place. All tests must be carried out in accordance with the current Gas Safe recommendations. 1.4 Correct any faults found during the initial tests 1.4 Re-commission the appliance in accordance with Commissioning Procedures of these instructions. 1.5 Advise the customer of any remedial action taken. SYSTEM OK GO TO THE NEXT CHART IGNITION FUNCTIONAL CHECK 2 There is a blockage in the system, check the inlet test point, the mag seating and valve No Has the system got any air in it? Yes Purge the gas pipes and retry Yes Is the gas pressure correct? No Correct and retry. Yes Is the gas turned on to the appliance? No Check isolation tap and gas meter, retry. No Will the pilot light with a match? Yes Check alignment of pilot burner head. Change the ignition lead. See Replacing Parts, Section 6. Yes Is the control being operated correctly? No Consult users book and retry No Does the pilot light? Yes Operate the valve. Is there a spark? No Ensure there is no debris around the pilot assembly, (e.g. soot, etc.) which could short the spark, clean the area. PILOT WILL NOT LIGHT IGNITION FUNCTIONAL CHECK 1 Yes 27 28 Replace the peizo unit. No Is the ignition lead detached from the piezo in the valve? No Replace the electrode Yes Yes No No Remove the ignition lead from electrode. With insulated pliers. Hold the tip 3.5mm from the pilot pipe work, is there a spark when the system is operated? No Has ignition lead become detached or is connection poor? Yes Is the gap between electrode and thermocouple 4.0mm? Yes From Ignition Fault Finding Chart 1 Yes Yes Ensure there is no debris around the pilot assembly, (e.g. soot etc.) which could short the spark, clean the area. Ensure there is no debris around the pilot assembly, (e.g. soot etc.) which could short the spark, clean the area. Check for defective or damaged control knob spindle or cam operation. Check for correct location of piezo components. Correct and retry. Correct and retry. Reset the electrode gap, retry Is the valve being operated correctly? Replace the electrode Replace the ignition lead and retry No Remove the ignition lead from electrode. With insulated pliers. Hold the tip 3.5mm from the pilot pipe work, is there a spark when the valve 'clicks'? No Has ignition lead become detached or is connection poor? Yes Operate the valve to light the pilot, can repetitive clicks be heard? From Ignition Fault Finding Chart 1 Yes No Replace the ignitor unit No Check for defective or damaged: - Microswitch and leads. - Control Mechanism. Correct and retry. Is there a spark? Correct and retry. Is the valve being operated correctly? No Consult the users instructions, retry. Replace the batteries in the ignitor unit and retry NO SPARK NO SPARK Consult the users instructions, retry. IGNITION FUNCTIONAL CHECK 2B SLIDE CONTROL IGNITION FUNCTIONAL CHECK 2A MANUAL & REMOTE Yes Servicing Instructions Fault Finding Charts Servicing Instructions Fault Finding Charts FLAME FAILURE FUNCTIONAL CHECK 3 PILOT WILL NOT STAY LIT OR APPLIANCE GOES OUT IN USE Ensure there is no debris around the pilot assembly, (e.g. soot etc.) Light the pilot and keep the control knob pushed in at least 10 seconds before letting go. With the pilot running is the gas pressure as stated on the data badge? No No No Change the pilot injector No Problem is with the pipe work or fittings which lead to the appliance. Correct and retry. Yes Is the pilot flame of the correct length? Is the thermocouple in its correct position in the pilot bracket, see Replacing parts, secton 3. Yes Will pilot stay alight? Yes Yes No Is thermocouple connection good in back of valve? Run for 3 mins, turn off, time interval until mag unit shuts with a click. Is this greater than 7 seconds? Tighten the connection and retry. Replace thermocouple Will pilot stay alight? No Change mag unit. Yes Is the flue working? No Yes With the appliance running on full is the gas at the pressure stated on the data badge? Yes No No Yes Rectify flue Run for 3 mins, turn off, time interval until mag unit shuts with a click. Is this greater than 7 seconds? Yes SYSTEM OK 29 Servicing Instructions - Replacing Parts 1. General 1.1 All principal components can be replaced without removing the appliance from its installation, although it is essential that the gas supply to the appliance is turned off at the isolation device before proceeding further. 1.2 Before replacing some of the components it will first be necessary to remove the burner assembly from the appliance by following the instructions below. 1.3 If for any reason the flue has to be removed from the appliance, the seal must be replaced in the inner spigot. 2. Removing the Burner Unit Ensure the appliance is cold before proceeding. 2.1 Turn the gas supply off at the isolation device. Then disconnect the supply pipe. 2.2 Remove the decorative front from the appliance by referring to the separate instructions supplied. 2.3 Remove the glass frame by unscrewing the 2 lower outer screws, see Diagram 1, Arrow A, by several turns, there is no need to fully remove these 2 screws. Refer to the separate decorative front instructions to replace the front on the appliance. UNDER NO CIRCUMSTANCES SHOULD THE APPLIANCE BE USED IF ANY OF THE GLASS FRAME RETAINING SCREWS ARE LOOSE OR MISSING. 2.9 Remove the white stones (Stone Effect) or ceramic coals and liners (Coal Effect) and place on a clean dry surface. 2.10 Remove glass frame seal from the appliance. Push the arrow-headed spring clips out of the body. It may be necessary to slightly compress the clips to ease removal, see Diagram 2, Detail A. NOTE: Only the lower seven clips need to be removed. 2 2 1 1 Detail A 2.4 Remove the remaining 6 screws, see Diagram 1, Arrow B. 1 B B B 2.11 Fully remove the 2 lower outer fixing screws from the appliance, see Diagram 1, Arrow A. B Manual Control 2.8 B A B 3 A 2.5 Lift the glass frame clear of the appliance and carefully place to one side. 2.6 The glass frame must be refitted to the appliance following cleaning or servicing. Ensure that the fibre glass seal on the box is intact, then lower the glass frame onto the 2 lower fixing screws, see Diagram 1, Arrow A. 2.7 Fit the other 6 fixing screws, see Diagram 1, Arrow B. 2.8 Tighten all 8 screws to secure the frame, see Diagram 1. Replace ALL of the securing screws ensuring that a screw is present in all fixing slots. NEVER OPERATE THE APPLIANCE WHEN THE GLASS FRAME IS REMOVED OR BROKEN. 30 Remove the lower screw positioned centrally below the control valve knob, see Diagram 3. Posi screw 2.12 The burner unit can now be removed from the appliance, see 2.19. Remote Control 2.13 The burner unit can now be removed from the appliance, see 2.19. Servicing Instructions - Replacing Parts Slide Control All Models 2.14 Remove the battery before carrying out work on this appliance. Removing the battery: 2.15 The appliance battery is located at the bottom left of the appliance behind the ash cover, see Diagram 4. 4 9V Battery Ignition Unit 2.19 The burner unit can now be removed from the appliance. Lift the front of the assembly up and out from the appliance Take care not to damage the door seal. 2.20 Replace in reverse order. 2.21 When refitting the burner unit, ensure the rear of the tray slides under the retaining bracket on the rear of the appliance, see Diagram 7. NOTE: The burner unit and pipe work have been removed for clarity. 7 Retaining Bracket Retaining Bracket Burner Tray 2.16 Remove the 2 lower screws positioned either side of the control valve bracket, see Diagram 5. Detail A 5 Manual Control model shown Burner Tray 3. Pilot Unit 2.17 Remove the M4 lock nut and spacer securing the slider arm to the appliance, see Diagram 6. Ensure that the spacer is retained and replaced when the burner unit is reassembled. The pilot unit assembly consists of three components which can be individually changed, these are:- 3a. Pilot Injector 3b. Electrode 3c. Thermocouple 3a. Pilot Injector - Stone Effect 3.1 6 Undo the pilot pipe from the bulkhead fitting and from the underside of the pilot unit, see Diagram 8. 8 M4 Lock Nut and spacer 2.18 The burner unit can now be removed from the appliance, see 2.19. Take care not to catch the slide mechanism when removing the burner. 3.2 Remove the pipe and the injector drops out from the pilot unit. Take care not to loose or damage the injector. 3.3 Replace in reverse order and check for gas leaks. 31 Servicing Instructions - Replacing Parts 3a. Pilot Injector - Coal 3.4 3b. Electrode Undo the pilot pipe from the valve and from the under side of the pilot unit, see Diagrams 9, 10 or 11. 9 Manual Control 10 Remote Control 3.7 Pull the ignition lead from the electrode and undo the retaining nut, see Diagram 12. 12 3.8 Replace with new electrode. Do not over tighten the nut as this could break the new component. 3.9 Replace the ignition lead. 3.10 Replace in reverse order. 3c. Thermocouple 11 Slide Control 3.10 Disconnect the thermocouple from the gas valve, see Diagram 13, 14 or 15. 13 3.5 Remove the pipe and the injector drops out from the pilot unit. Take care not to loose or damage the injector. 3.6 Replace in reverse order and check for gas leaks. Manual Control Remote Control 14 D 32 Servicing Instructions - Replacing Parts Slide Control 15 5. Gas Valve Manual Control & Remote Control 5.1 To remove the gas valve first remove the thermocouple, see Diagram 17 or 18, Arrow A. 17 Manual Control B E 3.11 Undo the thermocouple nut in the pilot unit by half a turn. This will release the thermocouple. LOGIC HE STONE 3.12 Remove the sealing plate, see Diagram 16, by removing the pozi head screw. NOTE: The sealing plate needs to be re-sealed after the new thermocouple is fitted. D A C 16 18 Remote Control E WHEN REPLACING WITH A NEW THERMOCOUPLE TAKE CARE TO BEND THE NEW COMPONENT TO THE EXACT SHAPE OF THE ORIGINAL ONE. D Undo the pilot pipe from the gas valve, see Diagram 17 or 18, Arrow B. 5.3 Undo the inlet pipe from the gas valve, see Diagram 17 or 18, Arrow C. 5.4 Undo the main injector feed pipe from the gas valve, see Diagram 17 or 18, Arrow D. 5.5 Disconnect the ignition lead from the pilot unit, see Diagram 17 or 18, Arrow E. (For Logic HE Stone, the sealing plate needs to be removed, see Diagram 16). 3.15 Lock the retaining nut just enough to grip the thermocouple. 4. Piezo Manual & Remote only A B 5.2 3.13 Replace in reverse order. 3.14 When replacing the thermocouple into the pilot unit ensure the component is pushed fully into the hole. There is a stop on the thermocouple to set the height. C Manual model only: Note: For the Manual Control Valve the Ignition lead and Piezo are part of one complete unit and must be replaced at the same time, see Section 6. Remote Control: Manual and Remote: 4.1 The Piezo assembly used on this appliance is not serviceable and is unlikely to fail. If a new piezo is required it will be necessary to change the gas valve, refer to Section 5. 5.7 The gas valve can now be removed from the burner unit. 5.8 To replace the gas valve reverse the above procedure. Make sure the sealing plate on Logic HE Stone models is re-sealed. 5.6 5.9 Pull off the gas valve control knob and remove the locking nut using a 17mm spanner. Check for gas leaks. 33 Servicing Instructions - Replacing Parts 5.17Undo 2 screws securing the gas valve to the bracket, see Diagram 22. Slide Control 22 5.10 To remove the gas valve first remove the thermocouple, see Diagram 19, Arrow A. 19 Screws 5.18 Replace in reverse order. 5.19 Check for gas leaks. A C D B 5.11 Undo the pilot pipe from the gas valve, see Diagram 19, Arrow B. 6. Ignition Lead 6.1 The different control versions of this appliance have different servicing requirements for the Ignition Lead. Follow the relevant section for each product. Manual Control 5.12 Undo the inlet pipe from the gas valve, see Diagram 19, Arrow C. 5.13 Undo the main injector feed pipe from the gas valve, see Diagram 19, Arrow D. 5.14 Disconnect the 2 leads from the micro-switch, see Diagram 20. 20 6.2 The Ignition lead and Piezo on this appliance are part of one complete unit and must be replaced at the same time. To replace the unit remove the control knob on the front of the valve cover and undo the nut securing the valve, see Diagram 23. 23 Leads Bracket Micro-switch 5.15 Undo the screw from the end of the spindle and remove the bracket, see Diagram 21. Ensure the bracket is replaced during reassembly. 6.3 Disconnect all other valve connections on the rear of the valve. 5.16 Undo the 2 screws securing the bracket to the bottom of the burner unit, see Diagram 21. 6.4 6.5 21 The valve will now come off. Remove the clip from around the front of the valve, see Diagram 24. 24 Screw 34 Screw Ignition lead Clip Piezo Servicing Instructions - Replacing Parts 6.6 Rotate the piezo anti-clockwise until a tab appears in the slot at the front, see Diagram 25. 25 6.13 Disconnect the ignition lead from the gas valve and the pilot, see Diagram 28. 28 Piezo Ignition lead Tab 6.7 Withdraw the Piezo unit forward from the valve. 6.8 Replace with a new unit and re-assemble the valve into the burner unit . 6.9 Check the operation of the Piezo ignitor making sure that both ignition ‘clicks’ are functioning. 6.10 Reassemble the appliance. 6.14 Replace with a new ignition lead following the same route as the old one. Replace the valve cover and the pilot assembly. 6.15 Refit the burner. 6.16 Check the operation of the new ignition lead. 6.17 Remote Control 6.11 Undo the single screw that secures the left hand side of the control cover, see Diagram 26. 26 Reassemble the appliance. Slide Control 6.18 Disconnect the ignition lead from the ignition unit and the pilot unit, see Diagram 29. 29 Pilot Unit Ignition Unit Ignition Lead 6.12 To release the right hand side of the control cover insert the narrow blade screwdriver into the slot shown in Diagram 27, lever it gently and pull from the right hand side at the same time. The cover will now come off, there is a small cylindrical metal spacer inside the cover, this must be kept and replaced on the fixing screw during re-assembly. 27 6.19 Replace with a new ignition lead following the same route as the old one. 3.20 Refit the burner. 3.21 Check the operation of the new ignition lead. 3.22 Reassemble the appliance. 35 Servicing Instructions - Replacing Parts 7. Main Injector 7.1 8. Mag Unit Undo the injector compression nut and bulkhead nut, see Diagram 30, 31 or 32, arrows D and E, pull the pipe clear of the injector body. 30 8.1 Undo the thermocouple nut, see Diagram 33, 34 or 35, Arrow B. 33 Manual Control Manual Control D B E 34 Remote Control 31 Remote Control D B E Slide Control 32 35 Slide Control D E B 7.2 Rotate the injector until it is fully removed. 8.2 7.3 Replace with the correct replacement injector. When ordering, always state the model, gas type and serial number. Undo the mag unit retaining nut at the back of the control valve behind the thermocouple nut. 8.3 After removing the retaining nut, the mag unit can be tapped out and a replacement fitted. 7.4 Reassemble and turn the gas supply on, check for any leaks. 8.4 Replace the mag unit retaining nut and tighten. Note - this is a gas-tight seal. 8.5 Replace the thermocouple and check for gas leaks. 8.6 After reassembly, carry out the flame failure functional check as detailed in the Fault Finding chart, especially the time it takes for the mag unit to close. 36 Servicing Instructions - Replacing Parts 9. Ignition Unit (Slide Control Model only) 10. Changing between Gas Types 9.1 Remove the battery, see Section 2. 9.2 Remove the 2 leads and the pilot ignition lead from the ignition unit, see Diagram 36. 36 Manual Control: BURNER ASSEMBLY Pilot Ignition Lead Screw (Behind unit) Screw The following parts must be changed when converting an appliance from one gas type to another: DATABADGE NG LPG NG LPG LOGIC HE COAL GZ8187 GZ8335 PR1053 PR1059 LOGIC HE STONE GZ8152 GZ8333 PR1060 PR1061 Remote Control: BURNER ASSEMBLY Leads 9.3 9.4 Undo the 2 screws securing the unit in place, see Diagram 33. Replace in reverse order. NG LPG LOGIC HE COAL GZ10733 GZ11165 LOGIC HE STONE GZ11168 GZ11169 DATABADGE NG LPG PR1878 Slide Control: BURNER ASSEMBLY NG LPG LOGIC HE COAL GZ9476 GZ11113 LOGIC HE STONE GZ11116 GZ11124 DATABADGE NG LPG PR1591 Note: The control valve will be set for the particular appliance and gas type. In all instances, when ordering new parts, be sure to quote the appliance type and serial number. Use only genuine Gazco replacement parts. Non-standard components will invalidate the guarantee and may be dangerous. 37 Servicing Instructions - Replacing Parts 11. Spares Part Lists - Stone Effect Manual Remote WHITE STONES CE0732 VITREOUS ENAMEL LINER GZ8303 Slide Control NATURAL GAS PARTS MAIN BURNER INJECTOR IN0051 PILOT ASSEMBLY PI0069 AERATION PLATE GZ3869 GAS VALVE (NG ONLY) GC0156 GC0088K GC0168 LPG PARTS MAIN BURNER INJECTOR IN0049 PILOT ASSEMBLY PI0070 AERATION PLATE GZ3867 GAS VALVE (LPG ONLY) GC0158 GC0088K GC0168 MISCELLANEOUS IGNITION LEAD/PIEZO GC0159 GC0090 EL0578 MAGNETIC UNIT GC0160 GC0166 GC0173 CONTROL KNOB GC0058 - - WINDOW SEAL FA0600 THERMOCOUPLE PI0074 ELECTRODE PI0075 IGNITOR UNIT - - EL0573 UPGRADE KIT - 8455 - CONTROL VALVE COVER - GC0087 - MICROSWITCH - - EL0572 38 Servicing Instructions - Replacing Parts 12. Spares Part Lists - Coal Effect Manual Remote FRONT COAL CE0490 FLAME BAFFLE CE0758 SIDE PANEL LH CE0754 SIDE PANEL RH CE0755 REAR PANEL CE0757 TOP PANEL CE0756 LOOSE COAL SET CE0496 Slide Control NATURAL GAS PARTS MAIN BURNER INJECTOR IN0001 PILOT ASSEMBLY PI0069 AERATION PLATE GZ3966 GAS VALVE (NG ONLY) GC0156 GC0088K BURNER COVER GASKET GC0168 CE0836 LPG PARTS MAIN BURNER INJECTOR IN0056 PILOT ASSEMBLY PI0070 AERATION PLATE N/A GAS VALVE (LPG ONLY) GC0158 GC0088K BURNER COVER GASKET GC0168 CE0837 MISCELLANEOUS IGNITION LEAD/PIEZO GC0159 GC0090 EL0578 MAGNETIC UNIT GC0160 GC0166 GC0173 CONTROL KNOB GC0058 - - WINDOW SEAL FA0600 THERMOCOUPLE PI0077 ELECTRODE PI0075 IGNITOR UNIT - - EL0573 UPGRADE KIT - 8455 - CONTROL VALVE COVER - GC0087 - MICROSWITCH - - EL0572 39 Service Records 1ST SERVICE Date of Service:.......................................................................... Date of Service:.......................................................................... Next Service Due:...................................................................... Next Service Due:...................................................................... Signed:....................................................................................... Signed:....................................................................................... Retailer's Stamp/Gas Safe Registration Number Retailer's Stamp/Gas Safe Registration Number 3RD SERVICE 4TH SERVICE Date of Service:.......................................................................... Date of Service:.......................................................................... Next Service Due:...................................................................... Next Service Due:...................................................................... Signed:....................................................................................... Signed:....................................................................................... Retailer's Stamp/Gas Safe Registration Number Retailer's Stamp/Gas Safe Registration Number 5TH SERVICE 6TH SERVICE Date of Service:.......................................................................... Date of Service:.......................................................................... Next Service Due:...................................................................... Next Service Due:...................................................................... Signed:....................................................................................... Signed:....................................................................................... Retailer's Stamp/Gas Safe Registration Number Retailer's Stamp/Gas Safe Registration Number 7TH SERVICE 8TH SERVICE Date of Service:.......................................................................... Date of Service:.......................................................................... Next Service Due:...................................................................... Next Service Due:...................................................................... Signed:....................................................................................... Signed:....................................................................................... Retailer's Stamp/Gas Safe Registration Number Retailer's Stamp/Gas Safe Registration Number 9TH SERVICE 40 2ND SERVICE 10TH SERVICE Date of Service:.......................................................................... Date of Service:.......................................................................... Next Service Due:...................................................................... Next Service Due:...................................................................... Signed:....................................................................................... Signed:....................................................................................... Retailer's Stamp/Gas Safe Registration Number Retailer's Stamp/Gas Safe Registration Number Gazco Limited, Osprey Road, Sowton Industrial Estate, Exeter, Devon, England EX2 7JG Technical Customer Services: (01392) 261950 Fax: (01392) 261951 E-mail: [email protected] A member of the Stovax Group E&OE
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