Assembly instruction. Content. Model... Rectangular tiled stove (series 800)

Transcription

1 Assembly instruction Rectangular tiled stove (series 00) Model... Content Tests and approvals... 2 Explanation of symbols / foreword... Body Preparations... 4 Important measurements... 5 Overall installation sequence... 6 Assembly Radiation plate installation... 1 Tiles and cassette Tiling - preparations Tiling - recommendations Tiling - assembly... 2 Cassette - assembly Fan installation

2 Tests and approvals Gabriel Keramik AB Strandavägen 62 SE-0 52 Timmernabben, Sweden 0 EN 15250:2007 Slow heat release appliance fired by solid fuel Follow the manufacturers instruction and maintenance manual. Use only recommended fuel. Total fuel loading mass Approx. 11 kg Single fuel batch Approx. kg Distance to adjacent combustible material: Rectangular: Rear/side 5/00 mm Round: 50 mm CO emission: 0.0% Flue gas temperature (mean): 0 C Flue gas mass flue: 16.2 g/s Flue gas draught: 12.1 Pa Connection to shared chimney: Yes Thermal output: 165 MJ Thermal storage capacity: 100% 50% 25% Peak After:. h 1.0 h 21.1 h Energy efficiency:.4% Fuel type: Wood logs Technical description The Gabriel tiled stoves are built with an ingenious module system of fire-proof material, consisting of an inner core and an outer mantle, which are separated from each other. The inner core absorbs a large part of the heat expansion and reduces the furnace heat movement. The efficient 5-channel flue gas principle gives a high energy efficiency and radiates a uniform and pleasant heat into the room over a longer period. The Gabriel tiled stoves can either be rear connected to an existing approved chimney, or top mounted with a prefabricated module steel or precasted block chimney. A building permit is needed when building a new tiled stove. Before starting to fire, the tiled stove installation has to be inspected and approved by the Building Control Officer. (See local and national regulations regarding installation of fire places.) The Gabriel tiled stoves are CE-approved by the accredited test laboratory SP Technical Research Institute of Sweden, and fulfil the environmental and safety requirements stipulated in the new European standard for Slow heat release appliance fired by solid fuel. CE-marking The Gabriel tiled stoves are Swedish products and fulfill the requirements for CE-marking, meaning that they comply with EU health, environmental and safety requirements. CE stands for Communaútes Européennes. CE-marked products can be produced and sold in every member country of EU and EES community without any national product restrictions. A CE-marked product is normally provided with the document EU declaration of conformity in which the manufacturer assures that the product fulfills the requirements designated by EU. EU-declaration of conformity Products covered by this declaration Product type: Slow heat release appliance fired by solid fuel Models: Rectangular tiled stoves (00 series) Round tiled stoves (00 series) Round tiled stoves Studio (400 series ) In conformity with: EU building directive CPD/106/EEG Comply with EU-standard: EN Intended use: Domestic heating Fuel: Wood Manufacturer: Gabriel Keramik AB Address: Strandavägen 62, SE-0 52 Timmernabben Production site: Timmernabben, Sweden Test laboratory (0402): SP Technical Research Institute of Sweden Address: Box 57, SE Borås, Sweden Test report no CPD The traditional 5-channel fl ue gas principle is still incomparable Heat accumulating, dense, fire-resistant material for longlasting heat radiation Fan for efficient heat radiation Lars Burmeister Manager Director, Gabriel Keramik AB Low temperature fl ue gas outlet Inner core Outer mantle Expansion area Fan controlled direct heat through channels in the hot air cassette for efficient heat radiation Airfl ow on the inside keeps the glass cleaner Extra large glass door enhances the fire side comfort Connection for combustion air from the outside New installation / building registration A building permit from the local housing authorities is required when build-ing a tiled stove. You shall also consult your chimney sweep before building the stove. Weight from 100 to 100 kg. Bearing support is required. 2 RECTANGULAR

3 Explanation of symbols/foreword Safety instructions Read these instructions carefully before starting the assembly. Incorrect assembly can cause serious damage and fire risk. Make sure prior to the assembly that the building permit is approved and that the local chimney sweep has approved the installation. Foreword Marking with a pen Important positions, areas for sawing and placing of mortar are marked with a pen. Control measurement Shows important measurements during assembly. Rendered areas Shows the areas that shall be rendered with clay mortar. General Gabriel tiled stoves consist of prefabricated modules, cast from fireproof material. The stoves should be built by an approved tradesman. A building permit is needed when building a new tiled stove. Before starting to fire, the tiled stove has to be inspected by the Building Control Officer, (see local and national regulations regarding installation of fire places). Distance and measurements As to the following pictures in this manual you place the first module 50 mm from a combustible wall. A non-combustible hearth shall be placed on the floor in front of the stove (for size, see local regulations). A 00 mm free space is needed in front of the soot holes on each side of the stove. The hole in the base for inlet air to the convection heat must not be blocked. The manual s control measurements (page 5) are very important, while the other measurements should be seen as a guide during the assembly. Support The foundation and floor support of the stove has to be approved before assembly. The weight of the stove is between kg depending on the model and flue connection. Therefore the foundation requires sufficient bearing capacity and shall be checked and approved in accordance with the building permit, (consult your local building authorities). Thickness of joints The joints between the modules are approx.10 mm. Use a suitable wet brush for neat, tight joints. Saw Shows where the prefabricated modules should be sawn. Insulation Shows where you place the insulation. Trowel Shows where the clay mortar is placed. Flue connection Gabriel stoves can be either rear or top connected. A prefabricated flue can be directly connected on the top of the stove. Check with your local dealer for the best solution. Step-by-step installation Please follow the step-by-step assembly and pay attention to the control measurements that are shown. A certain tolerance is allowed but make sure the control measurements are kept as it has a profound impact on the tiling, which is to follow. The thickness of joints should be approx.10 mm. For good adherence, wipe the contact surfaces with a squeezed sponge before jointing. During the assembly the outer rings are always to be one step ahead of the inner blocks. Equipment Trowels, brick layer, a long water level, radiator brush, folding rule, chisel, buckets, sponge, rubber mallet, covering plastic, angular grinder, hack saw, ladders (2), joint sponge, wooden wedges. Material included in the delivery Clay and sand - Clay mortar mix: 1:½ (1 part of clay to ½ part of sand). Tile adhesive Grout Silicon - if during transport a module is broken it can easily be fixed with the supplied heat-resistant silicon or clay mortar by gluing the pieces together. RECTANGULAR

4 Preparations Measurement for ø 150 mm flue pipe connection 40 mm Toppanslutning connection 210 mm Rear Bakanslutning connection C/C c/c 2115 mm mm Combustible wall 10 mm ø 150 mm Measurement for ø 125 mm combustion air inlet connection Combustible wall Base block ø 125 mm 4 RECTANGULAR

5 Important measurements RECTANGULAR Control and guide measurements (all measurements in mm) = Control measurement Outer mantle a Inner core No Ingen joints fog 7 6a a 2 1 * * * 1 17 shows the numbers of all parts, see page 6. 0 Färdigt Floor golvplan level 0 Against a straight wall (50 mm) Combustible wall 50 mm 5 mm Radiation plate 55 mm Base block 2 mm RECTANGULAR 5

6 Overall installation sequence a a a 2 1 Start A 6 RECTANGULAR

7 Assembly 1 Before starting the assembly, make sure that the support is approved according to your building permit and that it is in level with the floor. Mark on the floor exactly where the stove is going to be placed. The opening for convection air (fan) can be either from the left or right side by turning the baseblock up-side-down. min 50 min 50 2 Set the base block (1) with a 10 mm thick layer of mortar on the prepared floor. Make sure the regulation distance to the wall is kept. 1 Check the distance to the wall (min. 50 mm) Set the firebox block (2) with mortar. Level vertically at the rear with the baseblock. 2 Seal/insulate between the firebox blocks. 25 mm 25 mm 2 mm Check that the height is within the tolerance (2 mm). RECTANGULAR 7

8 Assembly 4 Set the outer ring () with mortar and seal / insulate between the firebox blocks. Seal/insulate between the firebox blocks. 5 a Set the outer ring (a) with mortar. Be aware of the soot hole dimension (ø100 mm) For a better joint, wipe the contact surfaces with a squeezed sponge mm 6 Make sure that no mortar falls between the firebox block and the outer ring Set the firebox block (6) with mortar. The firebox block must not touch the outer rings (the firebox block must be allowed to expand freely without affecting the outer ring). Seal with insulation at the front edge of the U-formed blocks. Make sure the soot hole is min. 100 mm. Check the height, see page 5. Insulation RECTANGULAR

9 Assembly 7 Set the outer ring () with mortar. Make sure there is space for soot hole and flange. 100 mm 100 mm 6 Set the second firebox block (6) on top of the first one. Make sure that no mortar falls between the blocks. Seal with insulation at the front edge of the U-formed blocks. 105 mm Make sure that no mortar falls between the firebox block and the outer ring Set the outer ring () with mortar. Check the heights, see page 4. RECTANGULAR

10 Assembly 10 6 Set the third firebox block (6) on top the second one. Make sure that no mortar falls between the blocks. Seal with insulation at the front edge of the U-formed blocks. Make sure that no mortar falls into the expansion gap at the back of the firebox blocks. 11 Set the outer ring () with mortar Set the fourth firebox block (6) on top of the third one. Make sure that no mortar falls between the blocks. Seal with insulation at the front edge of the U-formed blocks. Make sure that no mortar falls into the expansion gap at the back of the firebox blocks. 10 RECTANGULAR

11 Assembly 1 Set outer ring () with mortar. Check that the height is within tolerance (550 mm) 550 mm 14 4 Set outer ring (4) mm 6a Set the fifth firebox block (6a) on top of the fourth one. Make sure that no mortar falls between the blocks. Seal with insulation at the front edge of the U-formed blocks. Note! Remove any excess mortar that has fallen to the bottom in the left and right smoke gas channel. Clean the channels with a wet brush. Make sure that no mortar falls into the expansion gap at the back of the firebox blocks. RECTANGULAR 11

12 Assembly 16 7 Cut the insulation. Set the top of the firebox block (7) in mortar. min. 500 Before continuing above the firebox opening, construct a prop to support both the outer ring and the firebox top block as shown in the picture. This will enable you to continue without disturbing the vertical measurements as you progress. The support will also be of help when tiling above the firebox mm 5 Set the outer shelf block (5) with mortar. Cut a piece of insulation to seal the space under the shelf. Check that the height is within the tolerance (1020 mm). 1 Set the outer ring () with mortar. 12 RECTANGULAR

13 Assembly 1 Place the inner block () on top of the firebox block (7) without mortar joint. Make sure that this and the following blocks are in level and do not ignore any irregularities. 20 Carefully centre and set the outer rings with mortar (). Make sure that the outer ring () is one step ahead of each inner block () - set without mortar - during the assembly. Outer rings and inner blocks must not be in contact. Level vertically and horizontally. Check the control measurements, see page 5. For a better joint, wipe the contact surfaces of the outer rings with a squeezed sponge. Afterwards gently brush the mortar joints with a wet radiator brush. RECTANGULAR 1

14 Assembly 21 Set outer ring () with mortar Set the church roof (10). Place a thin strip of insulation, 2 mm, between the block and outer ring to prevent soot accumulation Set the flame protection block (11) with mortar. 14 RECTANGULAR

15 Assembly 24 Set outer ring () with mortar. 25 Set outer ring () with mortar Set the divider block (12) in mortar. RECTANGULAR 15

16 Assembly 27 12a 11 Set the flame protection block (11) and the divider block (12a) with mortar. The divider block (12a) and flame protection block (11) must be 2-4 mm below the outer ring to leave enough space for the whole inner core to expand upwards. 2 Place the allocated insulation strip on top of the divider and flame protection blocks. Smear a small string of wet mortar just to fix the insulation to the following top lid. The insulation shall function as an expansion gap towards the divider so that the inner block can move vertically. Don t forget the insulation strips. 2 1 Set the top lid (1) with mortar. 16 RECTANGULAR

17 Assembly mm 14 Set the damper lid (14) with mortar. Check that the height is within the tolerance (200 mm) 1 15 Set the damper in a bed of mortar and make sure it runs freely. The inside of the blocks shall be rendered with clay mortar (easiest done before the assembly). Top flue connection Set the blocks (15) with mortar. Join the two blocks together with the heat-resistant silicon or mortar. Rear flue connection to an existing chimney. Cut the back of the blocks for a suitable connection. 0 mm 2 The two blocks (15) shall be set in mortar 5 mm inside the vertical line of the body. Except for the rear where they shall be in line with the body. 5 mm 5 mm Render and brush the soot channel surfaces. Make sure the damper runs freely. RECTANGULAR 17

18 Assembly 16 Set the small lid (16) in mortar. If needed, cut to size for the either of the two flue pipe installations The supporting pieces (17) shall be adjusted according to the size of the crown tiles RECTANGULAR

19 Radiation plate installation The radiation plate installation 1 1 Loosen and turn the upper heat plate (1) so that the bent edge is towards the stove body. Screw it together with the lower heat plate (20) as shown. Place the brackets 1) on the top of the stove, secure with silicon. When the stove body assembly is completed: Screwed Hang the rdiation plate on the brackets as shown. 20 Radiation plate RECTANGULAR 1

20 Tiling and preparations IMPORTANT STEPS PRIOR TO TILING Mark the centre line (Figur1 page 21) Check that the floor is level. Check the body surface. Is it vertical? Be aware that you must compensate for any irregularities. All tiles must be level - vertically and horizontally. Adhesive shall be applied on both tiles and body with an mm toothed trowel. (Figur 2 page 21) For the best result a joint width of 2 mm is recommended. Wooden wedges recommended. Seal with adhesive between tiles and body around the firebox and the soot holes. Do not block the air inlet hole/grate for convection heat. Corner tiles are fixed to create a shadow line as shown (Picture page 21). Keep to the marked lines while tiling (Picture page 21). Be sure that the rear edge is straight towards the wall. (Picture page 21) Start tiling from the bottom centre and tile towards the sides. The tiles are hand-made - there might be some variations in measurements and colours. 20 RECTANGULAR

21 Tiling and preparations Picture 1 Picture 2 Mark the centre line Adhesive shall be applied on both tiles and body with an mm toothed trowel. Picture Picture 4 Be sure that the rear edge is straight towards the wall. Keep to the marked lines while tiling Schattenkante ca. 2 mm Shadow lineapprox.2 Skugglist ca 2 mm mm RECTANGULAR 21

22 Recommendations for the tile setting RECOMMENDATIONS FOR THE TILE SETTING The tiles are marked with letters according to the tile plan (Do not unpack all the tiles at the same time as they may be mixed up and placed in the wrong position.) To get a nice end result, we recommend to unpack the tiles row by row as you progress following the letter markings on the wrapping (Picture 6, page 2). 1 Start by positioning the tile G in the center, then continue to the sides and check that the last tiles J and O are protruding about 5 10 mm from the edge of the base block (Picture 5 below) and at the same distance to the wall. Set the corner tiles T in a mm layer of adhesive. Continue with the foot-sims, always starting from the middle and work out to the sides. Picture 5 O J The tiles protrudes about 5 10 mm Fix 5 mm M G Fix 5 mm Base block Tile Adhesive T E G E T Fix mm 2 Tile around the fireplace. Measure and check the diagonals so that they are equal. Make sure that the tiles are level and plumb by placing a level on both tiles (M and K, and M and L). 4 Continue with the corner tiles U and go to the wall. Keep a straight line at the back. Have in mind the shadow line of about 2 mm the corner tiles provide. (Picture page 21). 5 6 Repeat the procedure and 4 above. 7 The shelf tiles (V, Y, X and Z) should be set with the provided silicone or mortar. (Picture 7 page 2). When using silicone make sure the shelves are free from dust. 12 Start from the center and work yourself out towards the sides. Make sure to keep a straight line at the rear as well as the highlighted lines. (Picture and 4 page 21). 22 RECTANGULAR

23 Tiling - Assembly 12 S Picture 6 S Crown 11 R R Frieze 10 C A U A B A U A C Picture 7 Q D A C C A U U F A F A B A U U U C A A C V V Y X X Z 5 6 A A P D U K H 4 U L M M U A A D P D Q 7 Shelf tiles (V, Y, X and Z) should be set in silicone or mortar as shown in picture 7 above. Footsims 1 O E T E 2 G E T G J Start from the center RECTANGULAR 2

24 Cassette assembly in round and rectangular tiled stoves 5 0/125 0/100 Outdoor inlet air Mount the reduction flange to the flexible tube and connect the flange and tube to inlet air through the floor Indoor inlet air Mount the reduction flange to the flexible tube and connect the flange and tube to inlet air through the base. 6 Place the enclosed rockwool sheet in the firebox. Cut out a square hole same size as the hole in the fire box block. NOTE! The cassette is installed in the same way in round and rectancular stoves. 7 Fit in the cassette so that the steel flanges round the cassette are inside the tiles and the brass frame is in contact with the tiles. Note! If the cassette does not fit correctly at the bottom edge this can be compensated by removing some rockwool in the forward edge. Alternatelive a thin layer of mortal can be laid at the rear edge under the rockwool plate. Thereafter the cassette should rest stable and even on the bottom. The brass frame should at the same time fit tightly against the tiles. 24 RECTANGULAR

25 Cassette assembly in round and rectangular tiled stoves Pass the flexible tube through the hole in the cassette bottom and fit it over the connecting flange and fasten the flange plaate. Mount the damper in the bottom of the cassette, do not forget the cotter pins. Make sure the damper has a free action. 40 Fasten the cover plate. RECTANGULAR 25

26 Cassette assembly in round and rectangular tiled stoves 41 Mount the vermiculite plate in the bottom. NOTE! The cassette is installed in the same way in round and rectancular stoves mm Protect the brass frame and tiles around the cassette with masking tape to ensure a neat silicon seal. When the cassette is in perfect position, pull it out again approx. 20 mm and apply a silicon string just inside the edge around the brass frame, then push the cassette back in. Even the seal with a wet finger (to dip the finger in water with dish-washing detergent is an easy way to get a neat silicon seal). Remove the masking tape. 4 Insulate behind the cassette, around the sides and in the front edge between the cassette and the body. 26 RECTANGULAR

27 Cassette assembly in round and rectangular tiled stoves Insert the steel plate vertically and over the cassete. Turn the plate horizontally and pull it back to be in close contact with thefire box block (7) and at the same time is wedged into the space between the cassette and the body, see pictures and Install the last vemiculite plates on the two tubes in the cassette and push it as far back as possible. This improves the combustion and forces the flame forward. Fan installation in round and rectangular stoves 46 Cut the sealing block to shape, use e.g a hack saw blade. Ensure that it fits exactly and seals around the base block walls. Make sure the sealing block is not pushed to far in as it will restrict the inlet convection air flow to the cassette. Press the fan carefully into the pre cut hole in the sealing block. Sealing block Note! The fan must be mounted so that air is sucked into the fan. The air flow passes through channels in the cassette and exit through the upper front edge. RECTANGULAR 27

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