Royal Cozyfires Super Hot Toater Installation And Servicing Instructions - User Manual

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Issue 5

SUPER HOT TOASTER

USERS (Pages 2-3)/ INSTALLATION (Pages 4-7)

AND SERVICING INSTRUCTIONS

THIS CAT I

APPLIANCE IS FOR USE

ON NATURAL GAS G20 AT A SUPPLY

PRESSURE OF 20mbar IN GB and IE

HAND THESE INSTRUCTIONS TO THE USER

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The Super Hot Toaster has a single aerated burner, the design of which produces two parallel ribbons of flame
which run across the front of the fire bed. The rear ribbon of flame is ignited first and the front ribbon cross-lights
from it instantaneously. A single gas control selects ignition (pilot only) and can be turned anticlockwise to select
a high rate and then a reduced input at the maximum rotation. For extra safety the control is designed so that gas
cannot be allowed to reach the burner until pilot ignition has been proven. A separate push button piezo igniter
provides pilot ignition.

A Flame Supervision Device (FSD) is fitted. This ensures that if the pilot goes out for any reason (including being
turned off), the gas flow to the burner is cut off until the full lighting procedure is repeated. The oxy-pilot or
O.D.S. will cause the appliance to ‘shut off’ in the event of continued spillage occurring under hazardous or
blocked flue conditions. The burner assembly is fixed to the base of the radiant box which also includes a fire back
made of ceramic fibre, this forms an insulating surface to reflect heat into the fire bed, raising its temperature and
increasing the amount of heat radiated into the room. A decorative brass trim completes the front face of the
appliance.

There are two types of front and fret available for this appliance; these have perforated frets to allow air to be
entrained into the fire bed to ensure clean combustion. The optional fire fronts and frets are listed in figure 11. If
other Fronts and Frets are to be used they must have a minimum open area in the fret of 20 square centimetres and
60 square centimetres in the Front, as shown in figure 11.

A flame adjustment lever is fitted to allow a longer softer flame to be used to enhance the appearance of the
firebed; this can be operated in either the high or low position via the control lever on the front fascia panel.

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The Super Hot Toaster is a decorative fuel effect appliance designed and manufactured to the requirements of
the British Standards Institution BS 5258 Part 12: 1990 and is for use on Natural Gas only

All gas appliance installations must be installed by a competent person in accordance with the current Gas
Safety (Installation and Use) Regulations 1994 (as amended) or the rules in force and in accordance with the
attached Installation Instructions, failure to do so could lead to prosecution.

Areas of this appliance will become hot after prolonged running and it is recommended that for the protection of
the very young, elderly and infirm a fireguard conforming to BS 6539 or BS 6778 be used.

Care should be taken to prevent any damage being caused to surrounding soft furnishings or decor e.g. many
embossed vinyl wall coverings may become discoloured if located too close to the appliance. Clearances required
for combustible shelves are shown on page 3.

It is recommended that the chimney or flue should be swept annually by a competent person and the appliance
checked for spillage (smoke test) and that there are no excessive deposits of soot.

The curing effect of heating the coals will cause an initial odour which, although not harmful, may require
additional ventilation until the odour has disappeared. This appliance will run on Full for approximately 4.4
hours on one therm of gas.

This product uses fuel effect pieces, gaskets and insulation material containing Refractory Ceramic Fibre
(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.

72/,*+77+($33/,$1&(

Remove the fret (controls cover), to gain access to the controls

Press and turn the gas control until the indicator mark is opposite to IGN. Keep the control fully depressed.
Press and release the ignition button. Check that the pilot flame has lit at all ports. Keep the gas control
depressed for a further 20 seconds. Release the gas control and check the pilot remains alight.

Depress the gas control slightly and turn fully anticlockwise until the indicator mark is opposite the small
flame symbol. The burner will now ignite from the pilot assembly and run at the low rate.

Page 2

Depress the gas control slightly and turn clockwise until the indicator mark is opposite to the large flame
symbol. The burner will now run at its maximum rate.

To turn the appliance ‘off’, return the control to the ‘off’ position.

If for any reason the fire cuts out, return the control knob to the `off’ position and wait 3 minutes before re-
lighting.

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Allow the appliance to cool for two to three hours before removing all of the coals and ceramic blocks for
cleaning purposes. Once all the ceramics are removed from the fire bed check that no debris is located in the
burner slots (both front & rear). If any debris is present it may easily be removed by using a small piece of thin
cardboard to ease out any foreign matter. Be sure to remove the cardboard after use.

Cleaning should be carried

out in a well-ventilated area or in the open air, by gently brushing with the pieces held away from your face so
that you avoid inhaling the dust. We do not recommend the use of a normal domestic vacuum cleaner, which
may blow dust back into the air.
.

6(77,1*837+(&2$/%('

(See the identification sheet figure 13)

Components
2 burner inserts.

12 Large Coals.

Coal support shelves (L&R hand).

5 Medium Coals.

Artificial coal front.

2 Triangular Coals

Place the left and right coal support shelves with the rebate on the underside, over the rear flange of the support
channel. Place the two shaped burner inserts into the channel between the front and rear ports of burner. Locate
the fibre artificial coal front on the shelf above the fascia panel. Figure 7.

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First Layer. Position 4 large coals with their rear edge on the burner inserts. Place 3 large coals at the rear of the
coal support shelf and lay 2 further at the sides of the shelf. These coals are placed on their edge. 3 more large
coals are placed on the coal support shelf to complete the first layer. See figure 8.

Second Layer. Two triangular coals are placed one either side ensuring that they rest against the side and
straddle the gap between the front and second row large coal. Position the remaining 5 medium coals in the
positions shown in figure 9.

To obtain the best visual appearance it may be necessary to make slight adjustments to the position of the coals.

NOTE: Additional coals must not be used

If any of the coals or the coal bed becomes damaged, lost or

broken, replacements must be obtained before the appliance is used.

9(17,/$7,21

Purpose built ventilation is not required for this appliance in GB only. For Ireland (IE) ventilation is required
with a minimal cross sectional area of 100 sq. cms and should be checked regularly to ensure that it is free from
obstruction. It must be fitted in accordance with the rules in force.

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Minimum clearances to underside of a 150mm (6ins) combustible shelf from the top of the fire opening must be
228mm (9ins). Add 12.5mm (1/2in) to this clearance for every 25mm (1in) increased depth of shelf.

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Minimum Clearance required to any combustible material to the side of the appliance must be 150mm (6in)

Page 3

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The appliance must be installed by a competent person in accordance with the current Gas Safety (Installation and
Use) Regulations 1994 (as amended) or the rules in force and in accordance with the manufacturers instructions,
failure to do so could lead to prosecution.

The following are the relevant Codes of Practice and British Standards.

The Building Regulations issued by the Department of the Environment.

The Building Standards (Scotland)(Consolidation) Regulations issued by the Scottish Development

Department.

BS 8303 1986

BS 5440 Pt1 1990 & Pt2 1989

BS 7566 Pts 1-4 1992

BS 1251 1987

BS 5871 Pt3 1991

BS 6891 1988

BS 6461 Pt1 1984

Important Notes
The fire place, chimney or flue must be sound and conform to the requirements of BS 83O3 1986 & BS 6461 Part
1 1984.

The effective flue height must be a minimum of 3 metres and should be a 225mm x 225mm brick, stone or a lined
flue with a minimum diameter of 175mm. Any permanent flue restrictions must be removed, and any variable
dampers locked fully open or removed. The flue must be swept prior to installation, unless new.

A hearth must always be provided to project forwards of the brass trim a minimum of 300mm and a minimum of
150mm either side of the fire opening. The hearth must be a minimum thickness of 12mm with a perimeter height
of 50mm to deter combustible materials, carpets etc, being placed on the hearth. The area under the firebox must
have a minimum non-combustible thickness of 25mm. In most installations a back panel will be required, this will
need a minimum fire resistance rating of Class O (100

C).

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Height

560mm overall size of Box

Width

410mm overall size of Box

Depth

265mm overall size of Box

Height of Trim

605mm

Width of Trim

505mm

Overall Depth inc. Front & Fret using (MACH 11)

340m

" " " " " " " (JB)

360mm

Maximum heat input (HIGH) (GROSS)

6.95 kW, 23,700 Btu/h

Minimum heat input (LOW) (GROSS)

3.83 kW, 13,000 Btu/h

Supply pressure (cold)

20 mbar +/- 1 mbar

Injector marking

Bray Cat. 82/510

Pilot

OP Oxy/Pilot NG 9022

Gas Connection

8mm O/D Tube

Page 4

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(See figure 13 for identification)

VENT BOX ASSEMBLY C/W: Burner assembly and Brass trim.

1 Simulated coal front
L & R Hand coal support shelves
2 Burner inserts
12 Large, 5 Medium and 2 Triangular Coals.
Fitting kit
Installation & Users Instructions.

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If a fire back (chair brick) is fitted in the existing builders opening it will be necessary to remove it together with
any infill or rubble. Any remedial work should be carried out including levelling the base beneath the fire. The
sizes required for the opening are shown in Fig 2.

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To prevent any damage and to assist with the installation of the appliance both the burner and the trim should be
removed. The trim is removed by lifting the trim vertically observing that the lugs locate over the flanges of the
box. To remove the burner from the box unscrew the two screws at the base of the fascia panel and pull the burner
forward observing that the rear feet locate under two lugs in the base panel.

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BEFORE COMMENCING WORK, TURN OFF ANY APPLIANCES THAT ARE FED BY THE METER
AND ISOLATE THE SUPPLY BY TURNING OFF AT THE METER.

The gas connection to this appliance is made with 8mm O/D rigid or semi rigid tube to a pressure test elbow
situated on the left-hand side of the burner as shown in Fig 1. It advisable to provide a means of isolating the gas
supply to the appliance for servicing with either a restrictor elbow or isolation cock as shown in Fig 1. A 45mm
length of Bundy is supplied for use with a restrictor elbow or a 90 degree bend for use with an isolation cock; (the
supply tube support bracket may be removed as shown in Fig 4. Provision is made in the rear of the box to make a
concealed connection; (additional holes may be drilled as required). The installer is reminded of the requirements
of BS 6891 1988 dealing with enclosed pipes. The standard requires that when a gas pipe is fed through a wall, the
pipe should be enclosed in a tight sleeve to protect against failure caused by movement and shall be constructed to
prevent a passage of gas either between the pipe and sleeve or sleeve and the wall. If a gas supply is required to be
fed from either the left or right across the front of the appliance it should be routed as shown in Fig 7. It is only the
MACH II Cast Iron Front & Fret that has provision for this requirement alternative Fronts & Frets will need
modifying to allow access for the supply tube, see Fig 5. If a JB front and fret is being used it will require two
stops to be fitted using the self-tap screws and spacers shown in Fig 7.

Page 5

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Position the box in the centre of the opening with a sufficient gap between the front flanges and the surround to
enable the tags on the rear of the brass trim to slide over. (Where a concealed gas supply is used feed the supply to
the position of the burner connection). The box is secured in place with the two 10x11/4 round headed screws and
plastic plugs supplied in the fitting kit using the two holes in the base of box. Replace the burner assembly in
position ensuring that the rear legs locate under the tags in the base plate and secure with the two screws provided.
Complete the gas connection to the burner as required and fit the brass trim by locating the tags in the cut outs in
the side flanges and sliding the trim down until the top tag locates over the top flange, remove the protective
plastic coating before lighting fire.

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A Pressure Test Point at the inlet elbow enables verification of the inlet pressure of the appliance under operating
conditions and can also be used to check the gas soundness of the connections to the appliance gas control. To
check the joints of the burner assembly for gas soundness it will be necessary to carry out the examination prior to
installing into the case. If a manometer is used care must be taken to ensure that it is not disconnected with the gas
turned on and the fuel bed hot.

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The inlet pressure should be observed at 20mbar +/- 1mbar when the appliance is operating at its maximum rate.
Any significant reduction below an inlet pressure of 20mbar will indicate a restriction in the gas supply to the
appliance that should be identified and corrected. If there are any other appliances that are relatively high rated
(e.g. a central heating boiler) fed from the same gas supply branch, it is advisable to perform this observation with
both appliances in operation.

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(See figure 13 for identification of components)

Position the two burner inserts between the front and rear ports of the burner, and place the simulated coal front in
position as shown in figure 7. The L&R Hand coal support shelves are positioned so that the rebated channel on
the under side locate over the rear flange of the fibre support channel. Two stops prevent the shelf closing the gap
between the back of the burner inserts and the front edge of the shelf; there should be a minimum gap of 6mm.

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To obtain the best visual appearance it may be necessary to make slight adjustments to the position of the coals.

NOTE: Additional coals must not be used

If any of the coals or the coal bed becomes damaged, lost or

broken, replacements must be obtained before the appliance is used

Page 6

72/,*+77+($33/,$1&(

Pull the adjustment lever out, this will reduce the warming up period.

Press and turn the gas control until the indicator mark is aligned with the IGN mark and keep the control fully
depressed.

After a sufficient period has elapsed to allow the system to be purged of air, press

and release the igniter

button until a pilot flame has been established, (check that

the pilot has lit on both the ports. Keep the

control depressed for a further 20 seconds.

Release the gas control and check that the pilot remains lit.

Depress the gas control slightly and turn fully anti-clockwise until the indicator mark is aligned with the small
flame symbol. The burner will cross light from the pilot.

Depress the gas control slightly and turn clockwise until the indictor mark is aligned with the large flame
symbol. The burner will now be at maximum rate.

Turn the gas control to the OFF position, wait for 3 minutes, fully depress the gas control, turn to IGN position
and release the control. Attempt to ignite the pilot with an already lighted match or taper. If the pilot ignites the
FSD is faulty.

Re-light the appliance. With the adjustment lever pulled forward and the control set to the maximum rate
(large flame) position, place the Fire front & fret in position and leave to heat up for 5 minutes, and check for
satisfactory clearance of products by inserting a lighted smoke match into the opening in the position shown in
Fig 10, i.e. 100mm below the top, and 40mm inside of the front face of the opening. All the smoke must be
drawn into the flue. If spillage occurs, allow a further 10 minutes. Should spillage still occur examine the
chimney for the fault and rectify the cause. The test should be repeated if an extractor fan is situated in the
room, or in any connecting room, with all the doors in that room opened.

Remove the Fret and push the flame adjustment lever inwards, replace the Fret and check that the flame picture
changes to a longer softer flame.

Demonstrate the lighting and extinguishing procedures to the user.

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The curing effect of heating the coals will cause an initial odour, which although not harmful, may require
additional ventilation until the odour has disappeared.

The appliance must be serviced annually by a competent person; i.e. a CORGI registered installer in
accordance with these instructions and that the appliance is checked for spillage in accordance with the method
detailed in these instructions.

The appliance is fitted with an Oxy-pilot to prevent the continued operation in the event of spillage occurring. If
the fire shuts ‘OFF’ repeatedly the appliance must be turned off and not used until an expert is consulted.

Advise the customer that they should read their Users Instructions before operating the fire and always follow
the advice in the section headed `Removal of Debris or Soot Deposits'

Complete the section in the enclosed registration leaflet. Advise that any component or part of this appliance is
guaranteed against defective workmanship or faulty materials for a period of twelve months from the date of
purchase.

Any such part will be replaced free of charge on receipt of the purchasers address at the cost of postage only,
provided that:

It is accompanied by the registration section cut out of the booklet together with the original purchase receipt,
which will be returned with the replacement part.

A competent person has carried out installation repairs or adjustments, such as the supplier's representative
or a CORGI registered installer.

Page 7

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GENERAL

REMOVAL OF DEBRIS OR SOOT DEPOSITS;

Allow the appliance to cool for one hour before removing all the coals and coal bed components for cleaning
purposes. Once all the components have been removed from the fire bed check that no debris has become lodged
in the burner ports (both front and rear). If any debris is present it may be easily removed with a thin piece of card
or similar to ease out any foreign matter. 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 heavy duty polythene
bags, 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. Any soot deposits may be removed from either the
Thermocouple or Electrode tips with a soft cloth, do not use abrasive materials.

B. SERVICING COMPONENTS BELOW THE BURNER ASSEMBLY
To remove trim, lift vertically to allow the formed tags in the rear of the trim to slide out of the notches in the
flanges of the box. (Assemble in the reverse sequence). Remove the coals, coal supports, burner inserts and front
simulated coal. To gain access to the components below the burner assembly it has to be removed from the Vent
Box by disconnecting the gas supply at the inlet elbow and unscrewing the two screws at the base of the fascia
panel. Where the supply is fed from the right hand side across the front of the appliance it will be necessary to
disconnect the supply from the isolation tap or restrictor elbow.

i) TO CLEAN OR REPLACE THE INJECTOR: Unscrew the compression nut connecting the gas supply to the
injector elbow while supporting the injector to prevent any distortion of the frame work. Unscrew and remove the
gas supply tube from the gas control valve, hold the injector lock nut with a spanner and rotate the injector.
Replace in the reverse order.

ii) TO REPLACE THE GAS CONTROL / FSD: Disconnect the three gas pipes and the thermocouple from the
gas control. Pull the control knob from the spindle, unscrew the lock nut securing the front of the control valve
(niting plate assembly), and remove the gas control valve. Replace in the reverse order.

iii) TO REPLACE THE PIEZO IGNITER: Pull the igniter lead from the piezo igniter tab. Hold the piezo lock nut
and rotate the piezo to unscrew and remove. Replace in the reverse order.

iv) TO REPLACE THE OXY-PILOT ASSEMBLY: The assembly is not an item that can be serviced as part of its
calibration depends on the proximity of the spark electrode and thermocouple tip. The assembly can be replaced
by removing the tube nut and the tube from the base of the pilot, the thermocouple from the FSD, the igniter lead
and the two M4 screws securing the bracket to the framework. Replace in reverse order, the spark gap is shown in
figure 12.

v) PROTECTIVE SIDE PLATES; These stainless steel plates are pushed over the flanges of the fibre retaining
channels and can be replaced if required.

Page 8

FIRE FRONTS & FRETS SUITABLE FOR THIS APPLIANCE.

The illustration shown is the recommended MACH II Front and Fret, if an alternate Front and Fret is used, it is
important to maintain the equivalent ventilation to that shown. Fronts and Frets are available under the following
part numbers: -

TYPE

GC No

CODE No

TYPE

GC No

CODE No

MACH 11 BLACK

32 183 25

C022G

JB BLACK

32 183 38

C019G

MACH 11 BRASS

32 183 48

C024G

63$5(6$1'6(59,&(

For spares and service, apply to your local Supplier, Installer or direct to the manufacturer, stating that the
appliance is a Super Hot Toaster quoting the GC Appliance Number and Serial Number from the data badge
located on the front controls panel.

Advantage should be taken of regular servicing and inspection for gas appliances to ensure their continued safe
operation.

6+2573$576/,67

Description

Crosslee No

GC No

Piezo Igniter

40245

397 686

Control Knob

40232

Control Valve

41833

Oxy-Pilot Burner Assembly

42313

170 415

Main Injector

41180

389 515

Coal Support

43010

Burner Inserts

42952

Front Simulated Coal

40481

Set of Coals

43011

Protective Side plates

41072

170 249

Maximum Heat Input (Gross)

6.95 kW 23700 Btu/h

Royal Cozyfires are manufactured by:

CROSSLEE plc

Aber Park Industrial Estate,

Aber Road, Flint, Flintshire. CH6 5EX

Spares Tel 01422 203963

Fax: 01422 204475

Service (GSA Ltd) 01703 516611

Customer Service 01422 200660

Fax 01422 206304

*Technical Help Line 0906 8633268

*Calls charged at 60p per minute

No Fig 6 issued with this document