Wonderfire Nexus Instructions de montage

s supplied, this appliance is for use with natural gas (G20)

hen converted using conversion kit no. 591149 this

appliance is for use with propane gas (G31)

This appliance is for use in the United Kingdom (GB) and

the Re

ublic of Ireland

(

)

onl

600B731/02

Model BR648 VA

(G.C. 32-032-38)

INSTALLER’S GUIDE

We trust that this Installer Guide gives sufficient details to enable the appliance to

be installed and maintained satisfactorily. However, if further information is

required, our AdviceLine will be pleased to help.

Please telephone 0345 626341 (Local call rates apply in the United Kingdom).

In the Republic of Ireland call 353 183 75114.

INSTALLER: Please leave this guide with the owner

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INSTALLER’S GUIDE

Page 2

CONTENTS

1 APPLIANCE DATA..................................................................................................3

2 GENERAL INSTALLATION REQUIREMENTS................................................4

3 PRE-INSTALLATION PREPARATION...............................................................9

3.1 Pack Contents...........................................................................................................9

3.2 Fireplace Flue Pull ...................................................................................................9

3.3 Appliance Preparation..............................................................................................9

3.4 The Gas Supply Pipe............................................................................................. 10

4 FIREBOX INSTALLATION................................................................................. 11

4.1 Cable Retention..................................................................................................... 11

4.2 Floor Sealing......................................................................................................... 12

5 BURNER INSTALLATION.................................................................................. 12

5.1 Preliminary Burner Checks................................................................................... 12

5.2 Reference Pressure Check..................................................................................... 13

6 FITTING THE CERAMICS.................................................................................. 14

7 FULL OPERATING CHECKS............................................................................. 16

7.1 Recheck Control Settings...................................................................................... 16

7.2 Check for Spillage................................................................................................. 16

7.3 Flame Supervision & Spillage Monitoring System.............................................. 17

8 FINAL REVIEW..................................................................................................... 18

9 SERVICING & PARTS REPLACEMENT ......................................................... 19

9.1 To Replace Burner Plaques................................................................................... 19

9.2 To Remove the Complete Burner Unit................................................................. 20

9.3 To Remove the Pilot Unit ..................................................................................... 20

9.4 To Remove the Gas Tap........................................................................................ 20

9.5 To Remove the Piezo Generator........................................................................... 21

9.6 To Grease the Control Tap.................................................................................... 21

9.7 To Remove the Main Burner Elbow Injector ....................................................... 21

9.8 To Remove the Appliance From the Fireplace..................................................... 21

10 SHORT LIST OF SPARES.................................................................................... 22

Wonderfire, Erdington, Birmingham B24 9QP

www.firesandstoves.com.uk

Because our policy is one of constant development and improvement, details may vary

slightly from those given in this publication

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INSTALLER’S GUIDE

Page 3

1 APPLIANCE DATA

This product uses fuel effect pieces and gaskets containing Refractory Ceramic Fibres

(RCF), which are man-made vitreous silicate fibres. Excessive exposure to these materials

may cause temporary irritation to eyes, skin and respiratory tract. Consequently, it makes

sense to take care when handling these articles to ensure that the release of dust is kept to a

minimum. To ensure that the release of fibres from these RCF articles is kept to a

minimum, during installation and servicing we recommend that you use a HEPA filtered

vacuum to remove any dust and soot accumulated in and around the fire before and after

working on the fire. When replacing these articles we recommend that the replaced items

are not broken up, but are sealed within a heavy duty polythene bag, clearly labelled as

RCF waste. This is not classified as “hazardous waste” and may be disposed of at a tipping

site licensed for the disposal of industrial waste. Protective clothing is not required when

handling these articles, but we recommend you follow the normal hygiene rules of not

smoking, eating or drinking in the work area and always wash your hands before eating or

drinking.

This appliance does not contain any component manufactured from asbestos or asbestos

related products.

The appliance data label is on the control plate below the right side of the burner tray. It

is visible when the bottom front cover is removed.

Gas Natural (G20) Propane (G31)*

Inlet Pressure 20mbar 37mbar

Input - Max. (Gross) 6.0kW (20,500Btu/h) 6.1kW (20,800Btu/h)

Input - Min. (Gross) 2.2kW (7500Btu/h) 3.6kW (12280Btu/h)

Output - Max. 3.0kW (10,200Btu/h) 3.1kW (10,580Btu/h)

Output - Min 1.1kW (3750Btu/h) 1.8kW (6140Btu/h)

Burner Test Pressure (Cold) 18.2±0.75mbar

(7.3±0.3in w.g.) 35.6±0.75mbar

(14.3±0.3in w.g.)

Gas Connection 8mm pipe 8mm pipe

Burner Injector Bray Cat. 18 Size 360 Bray Cat. 15 Size 170

Pilot & Atmosphere Sensing

Device SIT Ref. OP9030 SIT Ref. OPLPG9222

Ignition Piezo Electric. Integral with

Gas Tap Piezo Electric. Integral with

Gas Tap

Aeration Non-adjustable Non-adjustable

* When converted using Kit 591149

Fire surround: height = 585mm width = 445mm

Appliance depth: 115mm

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INSTALLER’S GUIDE

Page 4

2 GENERAL INSTALLATION

REQUIREMENTS

2.1 The installation must be in accordance with these instructions.

For the user’s protection, in the United Kingdom it is the law that all gas appliances are

installed by competent persons in accordance with the current edition of the Gas Safety

(Installation and Use) Regulations. Failure to install the appliance correctly could lead to

prosecution. The Council for the Registration of Gas Installers (CORGI) requires its

members to work to recognised standards.

In the United Kingdom the installation must also be in accordance with:

All the relevant parts of local regulations.

All relevant codes of practice.

The relevant parts of the current editions of the following British Standards:-

BS 715

BS 1251

BS 1289 Part 1

BS EN 1806

BS 4543 Part 2

BS 5440 Part 1

BS 5440 Part 2

BS 5871 Part 1

BS 6461 Part 1

BS 6891

In England and Wales, the current edition of the Building Regulations issued by the

Department of the Environment and the Welsh Office

In Scotland, the current edition of the Building Standards (Scotland) Regulations issued

by the Scottish Executive.

In Northern Ireland, the current edition of the Building regulations (Northern Ireland)

issued by the Department of the Environment for Northern Ireland.

In the republic of Ireland the installation must also conform to the relevant parts of:

a) The current edition of IS 813

b) All relevant national and local rules in force.

2.2 If the appliance is intended to be installed to a chimney which was previously used

for solid fuel, the flue must be swept clean prior to installation. All flues should be

inspected for soundness and freedom from blockages.

2.3 Any chimney dampers or restrictors should be removed. If removal is not possible

they must be fixed in the open position.

2.4 In the United Kingdom (GB) special ventilation bricks or vents are not normally

required in the room for this appliance.

In the Republic of Ireland (IE), permanent ventilation must comply with the regulations

currently in force.

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INSTALLER’S GUIDE

Page 5

Figure 1 Masonry Fireplace

2.5 Note that soft wall coverings (e.g. embossed vinyl, etc.) are easily affected by heat.

They may scorch or become discoloured when close to a heating appliance. Please bear

this in mind when installing.

2.6 The minimum allowable distance from the outside of the appliance case to a corner

wall or other combustible surface which projects beyond the front of the appliance is

100mm at either side.

2.7 The minimum height from the top surface of the hearth to the underside of any

shelf made from wood or other combustible materials is detailed below.

• For a shelf up to 150mm deep: Minimum height = 750mm.

• For a shelf deeper than 150mm: 750mm + 12.5mm for every 25mm depth over

150mm.

2.8 The appliance must not be installed in any room, which contains a bath, or shower

or where steam is regularly present.

2.9 In the United Kingdom, as supplied, this appliance can be installed in the following

situations:-

2.9.1 A masonry chimney with a

minimum diameter of 175mm (7”)

free from any obstruction, and with

any damper or restrictor plate in

the chimney removed or secured,

and having a minimum effective

flue height of 3m (10ft). Note the

relevant flat surface area

requirement – See figure 1. A

masonry chimney having a

correctly installed flue liner to

BS715 and with a minimum flue

diameter of 125mm is also

acceptable. Chair brick removal

may not be required providing at

least 50mm clearance is available

from the flue outlet to any fireplace

component. The appliance is

designed to cater for low lintel

installations (min height 505mm) providing a minimum distance of 25mm is maintained

between the lintel and the front face of the fireplace (i.e. 25mm rebated fire surround).

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INSTALLER’S GUIDE

Page 6

Figure 2 Pre-cast Fireplace

Figure 3 Metal Flue Box

2.9.2 To a fireplace that has a precast

concrete or clay flue block system

conforming to BS1289 or BS EN 1806.

The appliance is suitable for

installations conforming to older

versions of BS1289 as well as the

current edition. The flue blocks must

have a minimum width not less than

63mm and a cross-sectional area not

less than 13,000mm2.Older editions of

BS1289 required a cross-sectional area

of 13,000mm2. The current revision of

the standard requires 16,500mm2. This

appliance is suitable in both cases. The

total depth of the opening measured

from the finished front of the fireplace

(Including plaster, surround etc.) must

be not less than 118mm. See figure 2.

The current versions of BS1289 and

BS EN 1806 recommend that there

should be an air space or insulation

between the flue blocks and the

plaster because heat transfer may

cause cracking on directly plastered

flues. However, generally this

appliance is suitable for installations

under all circumstances unless there is

a history of cracking problems.

Remember that faults such as

cracking may be caused by poorly

built and restrictive flues, e.g. mortar

extrusions, too many bends, flue

heights below three metres, restrictive

terminations, etc.

2.9.3 A metal flue box conforming to

BS715 with a minimum internal depth

of 150mm. Incombustible mineral wool insulation of not less than 50mm thickness must

be applied to the top surface of the firebox and it must stand on a non-combustible

hearth. See figure 3.

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INSTALLER’S GUIDE

Page 7

2.9.4 If the fireplace opening is greater than the acceptable dimensions given in this

guide, do not use the back of a fire surround or marble to reduce the opening. This

may cause cracking of the surround back or marble.

2.10 The following flues are suitable:

•225mm x 225mm conventional brick flue.

If a flue liner is used, it must be a minimum of 125mm diameter. The liner must be sealed

to the surrounding area above the fireplace opening and to the top of the chimney. An

approved terminal must be fitted.

•A properly constructed precast flue conforming to B.S 1289.

•A flue pipe with a minimum diameter of 127mm. See B.S 6461 Part 1 for suitable

materials. Metal flue pipes must comply with B.S 715.

2.10.1 The minimum effective height of the flue must be 3m.

2.10.2 The flue must be clear of any obstruction and its base must be clear of debris.

2.10.3 The flue must be completely sealed so that combustion products do not come

into contact with combustible materials outside the chimney.

2.10.4 The flue must serve only one fireplace.

2.11 If the fireplace opening is an underfloor draught type, it must be sealed to stop any

draughts.

2.12 An extractor fan may only be used in the same room as this appliance, or in any

area from which ventilation for the appliance is taken, if it does not affect the safe

performance of the appliance. Note the spillage test requirements detailed further on in

this manual. If the fan is likely to affect the appliance, the appliance must not be installed

unless the fan is permanently disconnected.

2.13 A fireguard complying with BS6539 or BS6778 should be fitted for the protection

of young children, the elderly, or the infirm.

2.14 The appliance is fitted with an A.S.D (Atmosphere sensing device). If the

appliance closes down after a period of operation for no apparent reason, the consumer

should be informed to stop using the appliance until the installation and appliance have

been thoroughly checked. The A.S.D will shut the appliance down if an unacceptable

amount of harmful products of combustion accumulate. Under no circumstances should

the A.S.D be altered or bypassed in any way. Only a genuine manufacturers replacement

part should be fitted. The individual A.S.D components are not replaceable.

2.15 This appliance may be installed with a surround with a minimum approved

temperature rating of 150 degrees. The fire surround must be sealed to the wall.

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INSTALLER’S GUIDE

Page 8

Figure 4 Hearth

2.16 The appliance must be

mounted on a non-combustible

hearth in accordance with

Figure 4. The hearth material

must have a minimum thickness

of 12.5mm (1/2”). The

periphery of the hearth (or

fender) should be at least 50mm

above floor level to discourage

the placing of carpets or rugs

over it.

2.17 Propane gas appliances

must not be installed in a room,

which is built entirely below

ground level (See BS 5871 Pt2).

2.18 Proprietary terminals must comply with BS 715 or BS 1289. Any terminal or

termination must be positioned in accordance with BS 5440 Part 1 to ensure that the

products of combustion can be safely dispersed into the outside atmosphere. Where the

appliance is connected to an unlined brick chimney it is generally unnecessary for the

chimney pot to be replaced or for a terminal to be fitted unless the flue has a diameter

smaller than 170mm.

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INSTALLER’S GUIDE

Page 9

3 PRE-INSTALLATION PREPARATION

3.1 Pack Contents

The carton contains the following:-

1Hotbox, Trims and Burner assembly

1 Casting pack

1 Literature Pack

1 Strip of Floor Sealing Tape

1 Nut and Olive for 8mm Inlet Pipe

1Loose parts pack including:-

1 Front coal Matrix 2 Tension Cables

1 Rear coal Matrix 2 Cable Adjusters

1 Loose coals Pack 2 Eyescrews

1 Burner tray trim 2 Fibre Plugs

3 Self-Adhesive Foam seals

Remove all the items carefully to prevent damage. Take special care when handling the

ceramic components. Some items may be contained in the packaging fitments - Examine

the packaging carefully before discarding. Check that all the items are present and

undamaged.

3.2 Fireplace Flue Pull

Close all doors and windows in the room in which the appliance is to be installed. After

confirming with a match that smoke is drawn into the flue, light a 13 gram smoke pellet

and check that there is a definite flow through the flue. Verify outside that the smoke

exits from one terminal only and that the termination is suitable. Observe, where

possible, upstairs rooms and loft spaces for signs of escaping smoke indicating a

defective flue. If there is not a definite flow warm the flue for a few minutes and repeat

the smoke pellet test. If there is still no definite flow the flue may need remedial work –

Do not fit the appliance until there is a definite flow through the flue.

3.3 Appliance Preparation

•Remove any transit tape and packing and inspect for any evidence of mishandling

which might affect the performance. Each unit is flame tested before it leaves the factory

and as a result there may be slight discoloration around the burner ports. There may also

be slight thermal cracking across the burner surface that is perfectly normal and is not

detrimental to performance.

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INSTALLER’S GUIDE

Page 10

Figure 5 Burner fixing point

•The burner assembly is retained by one

screw set in the front leg - See Figure 5.

Remove the screw and carefully remove the

burner assembly by lifting and sliding forward

from the firebox. The burner is produced from

a soft ceramic material and should be handled

carefully.

•A foam seal is supplied which will need

to be attached to the rear face of the firebox

frame on all three sides. Ensure that all joints

are butted together to prevent air gaps.

3.4 The Gas Supply Pipe

8mm rigid tubing must be used to connect the gas supply to the appliance. An olive and

nut are provided for connection to the “T” connector on the appliance. The connector can

be rotated to allow connection from either side or the rear. The connector includes a

valve for isolating the gas supply.

3.5.1 If a concealed connection from inside the fireplace is required then, before the

appliance is fitted into the fireplace it will be necessary to extend the supply line so

that it will project through the sealed grommet at the back of the firebox and run to the

“T” connector.

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