5112077/02 INSTALLER GUIDE Model 541 ROOM SEALED RADIANT / CONVECTOR GAS FIRE Fitted with Ultimate fascia (GC No. 32-032-64) THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20). THIS APPLIANCE IS SUITABLE ONLY FOR INSTALLATION IN THE UNITED KINGDOM (GB) AND THE REPUBLIC OF IRELAND (IE). We trust that this guide gives sufficient details to enable this appliance to be installed and maintained satisfactorily.
INSTALLER GUIDE Safety First. Baxi Fires Division fires are CE Approved and designed to meet the appropriate British Standards and Safety Marks. Quality and Excellence. All Baxi Fires Division fires are manufactured to the highest standards of quality and excellence and are manufactured under a BS EN ISO 9001 quality system accepted by the British Standards Institute.
INSTALLER GUIDE CONTENTS Section Heading Page 1. SAFETY 2. APPLIANCE DATA 3. APPLIANCE AND RECESS DIMENSIONS 4. GENERAL INSTALLATION REQUIREMENTS 5. UNPACKING AND PRELIMINARY CHECKS 6. GAS SUPPLY CONNECTION 7. WALL PREPARATION 7.1 Select appliance position. 7.2 Constructing a recessed opening. 7.3 Combustible wall materials. 7.4 Cutting the flue hole for brick, stone etc. building. 7.5 Cutting the flue hole in timber frame buildings. 7.6 Prepare appliance fixing holes. 8.
INSTALLER GUIDE 1. SAFETY Installer Before continuing any further with the installation of this appliance please read the following guide to manual handling: ! The lifting weight of this appliance is 17.25 kg. ! One person should be sufficient to lift the fire. If for any reason this weight is considered too heavy then obtain assistance. ! When lifting always keep your back straight. Bend your legs and not your back. ! Avoid twisting at the waist. It is better to reposition your feet.
INSTALLER GUIDE Gas Inlet pressure Input - Max. (Gross) Input - Min. (Gross) Inlet pressure (Cold) Gas connection Main burner Burner injector Natural 20mbar 3.65kW (12,454 Btu/h) 1.5kW (5,118 Btu/h) 20.0 ± 1.0mbar (8.0 ± 0.4in w.g.) 8mm pipe Simplex aerated Bray Cat. 92 size 280 Pilot unit Left side of firebox. Combined pilot jet, thermocouple sensor and electrode. SIT ref. NGOP9706 Ignition Aeration adjustment Integral piezo on gas valve.
INSTALLER GUIDE 3. APPLIANCE AND RECESS DIMENSIONS Figure 1. Appliance and recess dimensions (Appliance dimensions are subject to manufacturing deviation). This appliance must not be recessed into a combustible wall 4. GENERAL INSTALLATION REQUIREMENTS 4.1 The appliance can be installed into the following :a) A minimum 4.5in rebate surround or Baxi Fires Division 5in. spacer kit Part No 0595121.
INSTALLER GUIDE c) Recessed into a builder’s opening or cavity of a non- combustible wall. The minimum cavity size is shown in figure 1. A lintel may be required above the recess opening. If in doubt seek expert building advice. Lintel construction details are given in section 7 of this guide. This appliance must not be recessed into a combustible wall 4.2 Note that soft wall coverings (e.g. embossed vinyl etc.) are easily affected by heat.
INSTALLER GUIDE 4.5 A minimum clearance of 51mm should be maintained at each side of the fire for servicing access. Any combustible side wall or other combustible projection must be at least 102mm clear from direct exposure to the radiant surface of the appliance unless suitably protected. 4.6 The minimum height from the base of the fire to the underside of any shelf made from wood or other combustible materials is as follows:• For a shelf up to 150mm deep Minimum height = 780mm.
INSTALLER GUIDE tiles, Cotswold stone etc.) should be rectified. The appliance must not stand on carpet or other textured surfaces which may interfere with the flow of convection air through the bottom of the appliance. The floor surface that must be free of carpets, rugs or other fabric coverings should be at least as wide as the appliance fascia and project forward at least 300mm from the rear wall. In order to prevent carpet etc.
INSTALLER GUIDE Key A* B* C* D E F G H** I J K L M N Terminal position Minimum distance (mm) Directly below an opening, air brick, opening window etc. 300mm Above an opening, air brick, opening window etc. 300mm Horizontally to an opening, air brick, opening window etc. 300mm Below gutters, soil pipes or drain pipes. 300mm Below eaves. 300mm Below balconies or car port roof. 600mm From a vertical drain pipe or soil pipe. 300mm From an internal or external corner.
INSTALLER GUIDE exceeding 450mm, such as disused chimneys on external walls. Figure 3b. 5. UNPACKING AND PRELIMINARY CHECKS 5.1 Unpacking. 1 Main fire assembly with fascia. 1 Ceramic fuel bed (Packed in the fire). 1 Nut & olive for 8mm inlet pipe. 1 Fire front casting and ash pan pack. 1 Flue unit. 1 Wall fixing template. 2 Fire retaining cables. 2 Eyebolts. 2 Fibre wall plugs. 2 No 6 self tapping screws. 8 Woodscrews. 8 Plastic wall plugs. 1 Length of flue sealing tape. 1 Literature pack.
INSTALLER GUIDE 5.2 Appliance disassembly. Fascia removal (See figure 4). ! Remove the two screws securing the bottom of the fascia to the sides of the convection box. ! Raise the fascia to allow the retaining lugs at the top to clear the slots in the convection box hood and then lift clear. ! Place the fascia in a safe place away from your immediate work area. Window and ceramic fuel effect removal.
INSTALLER GUIDE 6. GAS SUPPLY CONNECTION A nut & olive are provided for an 8mm pipe inlet connection to the inlet ‘T’ connector at the bottom front of the appliance. This can be rotated to allow a connection from any direction and includes a valve for isolating the gas supply. The supply pipe must be rigid material. Flexible pipe must not be used. Concealed supply pipe connecting from rear of the appliance.
INSTALLER GUIDE expert building advice before commencing to cut the recess. 7.2.1 Fitting a lintel. Whenever a lintel is required to support the recess in the inner leaf of a brick/blockwork building, follow the method outlined below (See figure 7). ! The lintel should be either steel (Catnic) or reinforced precast concrete. It should be 750mm long x 75mm deep x inner leaf thickness. ! The opening should be, as near as possible, centrally below a joint in the inner leaf block.
INSTALLER GUIDE Figure 8. 7.3 Combustible wall materials. ! For brick or other non-combustible wall constructions, be sure to remove any combustible wall cladding material from the area shown in figure 1. ! For Timber frame buildings, the back surface of the appliance case must be separated from the timber frame by 25mm of non-combustible material. This can consist of the usual 12.5mm thick plasterboard plus a 12.5mm thick sheet of non-combustible insulating material (e.g. fibre cement board).
INSTALLER GUIDE ! Place the template against the wall. Make sure that the centre of the flue hole is as shown in figure 1. ! Pierce the template at the centre of the screw fixing holes and the flue hole and mark the positions on the wall. Remove the template. 7.4.1 Core drilling. ! Drill a pilot hole through the wall. Inspect the hole to ensure that it is in the brickwork and not in mortar.
INSTALLER GUIDE Figure 9. Timber frame wall preparation 7.6 Prepare appliance fixing holes. 7.6.1 Screwing case to wall. ! Recheck the position of the screw fixing holes relative to the flue hole. ! Drill the four fixing holes to a minimum depth of 42mm using a 7mm diameter masonry drill. ! Insert four plastic wall plugs supplied. 7.6.2 Using cable retention. ! Thread the two tension cables through the appliance case side holes as shown in figure 10.
INSTALLER GUIDE 8. FLUE AND TERMINAL INSTALLATION 8.1 Cutting flue to size. ! For outset appliances with surround or spacer Measure the total wall thickness from the outside surface of the wall to the inside face of the surround or spacer. Deduct 35mm from this measurement to obtain the correct length of flue unit required (See figures 11a & 11b). ! For appliances inset in a recess Measure the total finished wall thickness including plaster etc.
INSTALLER GUIDE Figure 11b. Flue unit installation - Timber framed building. 8.2 Fitting to wall. ! Fit the flue tubes firmly over the spigots at the rear of the fire. Make sure that the seam on the flue tube is not at the bottom. Push on until the outer (air) tube just covers the slots in the appliance outer spigot (See figure 12). ! Secure the flue to the fire by drilling through the outer flue tube and Figure 12.
INSTALLER GUIDE ! Case fixing to wall: Offer the fire complete with flue unit through the wall, Insert the four fixing screws and tighten. ! Cable retention: Fit the eyebolts onto the cables. Thread the cables through the appliance case sides as shown in figure 10. Offer the fire complete with flue unit through the wall. Pull the cables taut. ! Timber frame building with combustible outer leaf (e.g. shiplap boarding): A metal or other non-combustible end plate must be fitted on the outside of the wall.
INSTALLER GUIDE 10. CERAMIC COALS INSTALLATION The ceramic fuel effect may cause staining / discolouration to decorative surfaces. It is therefore advisable to protect decorative surfaces. 1. Fit the ceramic coal into the fire above the burner. The front of the ceramic coal should locate on the horizontal faces but behind the vertical faces of the two location brackets positioned at the front of the burner module. See figure 14.
INSTALLER GUIDE 3. Hold coal ‘B’ upright with the arrow pointing to the top. Locate coal ‘B’ as shown in figure 16. Figure 16. 4. Hold coal ‘C’ upright with the arrow pointing to the top. Locate coal ‘C’ as shown in figure 17. Figure 17. 5. Hold coal ‘D’ upright with the arrow pointing to the top. Locate coal ‘D’ as shown in figure 18. Figure 18. 6. Hold coal ‘E’ upright with the arrow pointing to the top. Locate coal ‘E’ as shown in figure 19. Figure 19.
INSTALLER GUIDE 11. WINDOW FITTING Fitting the window. ! Locate the channel at the top of the window over the top of the firebox opening. ! Refit the three spring loaded screws and washers. Tighten sufficiently to seal the firebox. ! Pull the bottom of the window forward and release to check that the window opens slightly and returns in the event of a delayed ignition explosion. 12. FULL OPERATING CHECKS 12.1 Check for leaks.
INSTALLER GUIDE marked . The main burner should now light at its low position. The left-hand knob is for burner flame adjustment. Turning it anticlockwise should gradually increase the flame height. The flame height control does not have to be re-set every time the fire is lit. It can be kept at any position enabling the customer to use the right hand control only to ignite the burner at the set flame height. After checking turn the right hand knob to off.
INSTALLER GUIDE 13. FASCIA FITTING ! Remove any protective film from the fascia. ! Locate the two lugs at the top of the fascia in the slots in the convection box hood. Swing the bottom of the fascia sides back against the convection box and lower the fascia so that the lugs are fully seated in the slots in the convection box hood (See figure 22). ! Refit the two screws to secure the bottom of the fascia sides to the convection box side brackets. ! Fit the fire front casting between the fascia sides.
INSTALLER GUIDE showing how to view the pilot. ! Advise the customer that the pilot can be left alight but mention that if the premises are to be left unoccupied for a lengthy period, it is advisable to turn the pilot off. ! Emphasise that if the glass panel is broken or damaged, the fire should be turned off and not used until the window unit is refitted with an authorised replacement.
INSTALLER GUIDE 15.1 To remove fascia. ! Remove the bottom front casting. ! Lift the fire front casting clear by lifting the fire front casting up and forward. This will release the locating screw heads at the back of the casting from the keyholes in the fascia sides. ! Remove the two screws securing the bottom of the fascia to the sides of the convection box ! Raise the fascia to allow the retaining lugs at the top to clear the slots in the convection box hood and then lift clear (See figure 24). 15.
INSTALLER GUIDE 15.4 To remove the complete burner module. ! Remove the fascia (See section 15.1). ! Remove the window unit (See section 15.2). ! Lift out the ceramic fuel effect and rear wall (See section 15.3). ! Isolate the gas supply using the inlet ‘T’ connector on the appliance. ! Unscrew the nut from the top of the inlet ‘T’ connector. ! Detach the burner front cover by unscrewing the 10 screws at the front of the burner module shown in figure 26. Figure 26. Burner module fixing screws. 15.
INSTALLER GUIDE 15.7 To remove the pilot unit. (See figure 27). Note: The Pilot unit must be replaced as a whole assembly. Its individual components are not separately replaceable. ! Remove the complete burner module as in section 15.4 ! Remove the electrode lead at the pilot. Do this by holding the lead as close to the electrode as possible. This will limit the possibility of damaging the lead connection. Figure 27. Pilot fixings. ! Unscrew the nut connecting the pilot to the pilot pipe.
