Assembly Instruction

Transcript

Assembly instruction Round tiled stove (series 300) Model.................................... Content Tests and approvals............................. 2 Explanation of symbols / foreword....... 3 Body Preparations....................................... 4 Important measurements...................... 5 Overall installation sequence................ 6 Assembly...................................... 7-17 Tiles and cassette Tiling - preparations........................... 18 Tiling - assembly.......................... 19-23 Cassette installation...................... 24-27 Fan installation................................. 27 2012-07-02 Tests and approvals GABRIEL KERAMIK AB CE-marking The Gabriel tiled stoves are Swedish products and fulfil 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 fulfils the requirements designated by EU. Gabriel Keramik AB Strandavägen 62 SE-380 52 Timmernabben, Sweden 08 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 Single fuel batch Distance to adjacent combustible Rectangular: Rear/side Round: CO emission: Flue gas temperature (mean): Flue gas mass flue: Flue gas draught: Connection to shared chimney: Thermal output: Thermal storage capacity: 100 % 50 % Peak After: 3.9 h 13.0 h Energy efficiency: Fuel type: EU-declaration of conformity Approx. 11 kg Approx. 3 kg material: 35/300 mm 50 mm 0.083% 80 °C 16.2 g/s 12.1 Pa Yes 165 MJ 25 % 21.1 h 93.4 % 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”. Products covered by this declaration Product type: Slow heat release appliance fired by solid fuel Models: Rectangular tiled stoves (800 series) Round tiled stoves (300 series) Round tiled stoves Studio (400 series ) In conformity with: EU building directive CPD89/106/EEG Comply with EU-standard: EN 15250 Intended use: Domestic heating Fuel: Wood Manufacturer: Gabriel Keramik AB Address: Strandavägen 62, SE-380 52 Timmernabben Production site: Timmernabben, Sweden Test laboratory (0402): SP Technical Research Institute of Sweden Address: Box 857, SE-50115 Borås, Sweden Test report no. 0402-CPD-502101 Lars Burmeister Manager Director, Gabriel Keramik AB The traditional 5-channel flue gas principle is still incomparable Low temperature flue gas outlet Inner core Outer mantle Expansion area Heat accumulating, dense, fire-resistant material for longlasting heat radiation Fan controlled direct heat through channels in the hot air cassette for efficient heat radiation Airflow on the inside keeps the glass cleaner Extra large glass door enhances the fire side comfort Fan for efficient heat radiation Connection for combustion air from the outside New installation / building registration A building permit from the local housing authorities is required when building a tiled stove. You shall also consult your chimney sweep before building the stove. Weight from 1300 to 1800 kg. Bearing support is required. 2 • ROUND Explanation of symbols/foreword GABRIEL KERAMIK AB 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. Marking with a pen Saw Important positions, areas for sawing and placing of mortar are marked with a pen. Shows where the prefabricated modules should be sawn. Control measurement Insulation Shows important measurements during assembly. Shows where you place the insulation. Rendered areas Trowel Shows the areas that shall be rendered with clay mortar. Shows where the clay mortar is placed. Foreword General Flue connection 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). 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. 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 300 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 1300-1800 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 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. 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, 2 ladders, joint sponge, wooden wedges. Material included in the delivery • • • • Clay and sand - Clay mortar mix: 1:3½ (1 part of clay to 3½ 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. The joints between the bottom modules are approx.10 mm and 5 mm for the under modules. Use a suitable wet brush for neat, tight joints ROUND • 3 Preparations GABRIEL KERAMIK AB Measurement for ø 150 mm flue pipe connection In a corner 318 mm min. 50 mm Ø 150 mm Top plate Rear connection c/cC/C 2095 mm Bakanslutning 2095 mm Against a straight wall Combustible wall min. 50 mm 278 mm min. 50 mm 318 mm TopToppanslutning connection 2245 mm 2245 mm 318 mm Ø 150 mm Ø 150 mm 318 mm Top plate Measurement for ø 125 mm combustion air inlet connection In a corner Against a straight wall Combustible wall Combustible wall 415 mm min. 50 mm Base blok Ø 730 mm 4 • ROUND 415 mm 415 mm 415 mm min. 50 mm 415 mm 415 mm min. 50 mm min. 50 mm 278 mm Combustible wall Important measurements • ROUND GABRIEL KERAMIK AB Control and guide measurements (all measurements in mm) = Control measurement Outer section 17 16 Inner section 15 14 1896 7 1795 7 7 1587 7 12 13 12 13 11 13 1516 10 7 1379 10 7 7 10 No joints 1171 7 10 10 7 10 963 6 946 9 846 8a 5 8a 508 5 4 8 8 3 338 2 338 1* 338 2 1 Floor level * 1–17 shows the numbers of all parts, see page 6. Corner / wall position In a corner Against a straight wall Combustible wall Combustible wall min. 50 mm min. 50 mm Base block Sockelring Ø 730 730 mm mm Ø min. 50 mm ROUND • 5 Preparations GABRIEL KERAMIK AB 10 17 7 16 10 7 9 15 8A 14 6 12 13 8A 7 12 5 13 8 7 5 11 13 8 7 4 10 3 7 10 2 7 10 1 7 10 7 Start A 6 • ROUND Assembly GABRIEL KERAMIK AB 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. 1 Mark on the floor exactly where the stove is going to be placed. Also mark the direction of the opening. The example on the picture shows 45° from existing 90° corner. 1000 00 10 710 45° min 50 min 50 In a corner 2a Set the base block (1) with a 15 mm thick layer of mortar on the prepared floor. Make sure the regulation distance to the wall is kept. Level vertically and horizontally, see figure 1. 1 Check the distance to the wall (min. 50 mm) 500 mm Against a straight wall 2b 1 Set the base block (1) with a 15 mm thick layer of mortar on the prepared floor. Make sure the regulation distance to the wall is kept. Level vertically and horizontally, see figure 1. Check the distance to the wall (min. 50 mm) 700 mm ROUND • 7 Assembly GABRIEL KERAMIK AB Set the firebox block (2) with mortar. Mark the centre line on the first block, it will help you to position the opening and the soot hole correctly. 3 2 338 mm 4 Set the outer block (3) with mortar. The opening shall face the 45°marking on the floor (figure 1). 3 Seal with insulation where indicated. 328 m m 5 Set the outer block (4) with mortar, level with the previous block. Level vertically and horizontally. 4 250 mm 8 • ROUND For a better joint, wipe the contact surfaces with a squeezed sponge, then brush with a wet radiator brush. This is a general instruction for the whole assembly. Assembly GABRIEL KERAMIK AB S 6 Set the firebox (8) with mortar. The firebox block may not touch the outer block (the firebox block must be allowed to expand freely without affecting the outer block). Level vertically and horizontally. Push the firebox block backwards as much as possible. Place the insulation and pull the firebox block back to ”lock” the indsulation. 8 Make sure that no mortar falls between the firebox block and the outer block. 7 8 5 8 Set the outer block (5) with mortar. Level vertically and horizontally. Set the second firebox block (8) on top of the first one. Make sure that no mortar falls between the blocks. Level vertically and horizontally. Make sure that no mortar falls between the firebox block and the outer block. ROUND • 9 Assembly GABRIEL KERAMIK AB Set the outer block (5) with mortar. Level vertically and horizontally. 5 9 Check that the height is within the tolerane (500 mm) 500 m m 10 Set the outer block (6) with mortar. 6 For a better joint, wipe the contact surfaces with a squeezed sponge, then brush with a wet radiator brush. Set the third firebox block (8A) on top of the second one. Make sure that no mortar falls between the firebox block and the outer block. Level vertically and horizontally. 11 11 8A 963 mm Make sure that no mortar falls between the firebox block and the outer block. 10 • ROUND Assembly GABRIEL KERAMIK AB Set the fourh firebox block (8A) on top of the third one. Make sure that no mortar falls between the firebox block and the outer block. 12 12 8A Make sure that no mortar falls between the firebox block and the outer block. 13 Cut the two insulation strips and set the top of the firebox block (9) with mortar. 9 963 mm min. 500 14 14 7 953 mm Before continuing above the firebox opening, construct a prop to support both the outer block and the firebox top block as shown in the picture. The support will also be of help when tiling above the firebox. Keep the support in position till the next day or even longer. Set the outer block (7) in mortar. Ø 630 mm Ø 680 mm ROUND • 11 Assembly 15 GABRIEL KERAMIK AB 10 Place the inner block (10) on top of the firebox block without mortar joint. Make sure that this and the following blocks are in level and do not ignore any irregularities. Seal/isulate the hollow space under the outer ring as indicated. 16 10 7 10 10 7 7 10 10 7 7 10 7 12 • ROUND Carefully centre and set the outer blocks (7). Make sure that the outer block is one step ahead of each inner block - set without mortar - during the assembly. Outer blocks 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 with a squeezed sponge. Afterwards gently brush the mortar joints with a wet radiator brush. Assembly GABRIEL KERAMIK AB 17 17 18 18 19 Set the outer block (7) in mortar. Level vertically and horizontally. 7 7 11 Set the outer block (7) in mortar. Level vertically and horizontally. Set the “church roof” (11). Level vertically and horizontally. Seal with 2-3 mm insulation. Make sure that no mortar falls between the firebox block and the outer block. ROUND • 13 Assembly GABRIEL KERAMIK AB 20 Set the flame protection block (13) with mortar. Level vertically and horizontally. 13 21 7 Set the outer block (7) with mortar. Level vertically and horizontally. 22 7 Set the outer block (7) with mortar. Level vertically and horizontally. 1898 mm 14 • ROUND Assembly 23 23 24 24 GABRIEL KERAMIK AB 12 13 12 13 Set the divider block (12) and the flame protection block (13) with mortar. Level vertically and horizontally. Set the divider block (12) and the flame protection block (13) with mortar. Level vertically and horizontally. The divider block (12) and flame protection block (13) must be 2-4 mm below the outer block to allow the inner body to expand. 25 25 Smear a small string of mortar on top of the divider block and the flame protection block. Fix the insulation in the mortar string. The insulation creates an expansion gap aginst the divider block, allowing the inner core to move vertically. ROUND • 15 Assembly GABRIEL KERAMIK AB 26 Set the top lid (14) with mortar. Level vertically and horizontally. 14 Ø 125 mm 27 15 Set the damper lid (15) with mortar. Level vertically and horizontally. Set the damper frame with a thin bed of mortar and make sure the damper runs freely. 2004 mm 15 mm 28 16 Lay mortar over the damper and the pipeattachment. Set the Leca blocks (16) with mortar. The inside of the blocks shall be rendered with clay mortar (easiest done before the assembly). Top flue connection Join the two blocks together with the heat-resistant silicon or mortar. Side flue connection to an existing chimney. Cut the back of the block for a suitable connection. 16 • ROUND Assembly 29 29 GABRIEL KERAMIK AB Render and brush the soot channel surfaces, also the downside of the top lid when it is installed. 17 Ø 150 mm Top connected chimney Set the top lid (17) with mortar and make sure it is in level with the underlying flue gas hole. Side connected chimney Turn the lid to fit the hole exactly over the underlying block. Fill and even with mortar. ROUND • 17 Tiling and preparations GABRIEL KERAMIK AB Assembly tiles and cassette IMPORTANT STEPS PRIOR TO TILING • Mark the centre line. • Check that the floor is level. • Check the body surface. Is it vertical? Be aware that you must compensate for any irregularities. • All tiles shall be in level vertically and horizontally. • For best adherence - apply adhesive on both tiles and body with an 8 mm toothed trowel. • For the best result a joint width of 2-3 mm is recommended. Wooden wedges recommended. • Seal with adhesive between tiles and body at the firebox and the soot holes. • Start tiling from the bottom and the centre and work towards the sides. • Do not block the hole/grate for inlet air for convection heat. • The tiles are hand-made - there might be some variations in measurements and colours. TILING PLAN 66 66 cm cm tiles kakel 27” 27 " tiles kakel 30”" tiles kakel 18 • ROUND akel a m ell a a Assembly - tiles 1 GABRIEL KERAMIK AB Level and mark the centre line from the top down to the base. (Devide the firebox into two equal halves). 30 45° 45° 2 31 32 3 Fix the first tile exactly in the centre of the marking as shown. Apply as much adhesive to fix the tile approx. 5 mm from the stove body. Level vertically and horizontally. Place a tile list temporarily (use a match or similar as joint) and level it with the firebox block. ROUND • 19 Assembly - tiles GABRIEL KERAMIK AB Set tiles around the base starting from the centre. Level vertically and horizontally. 33 1 5 34 34 6 35 Mount the grate and the last tile. Each tile list (foot simms) is manufactued with a support at the back, which must carefully be removed to fit in properly. Set the tile lists from centre towards the sides. Check that the upper edge of the tile lists are level with the bottom of the firebox. Note: For better adhesiveness, apply the tile lists with a dryer adhesive. 20 • ROUND Assembly - tiles GABRIEL KERAMIK AB 7 36 Apply the tiles intended for the soot holes. Level vertically and horizontally. 37 8 Continue the tiling around the firebox opening and then around the firebox. 4 7 3 5 It is important to level the tiles vertically and horizontally to be able to install the cassette in exact position. 8 6 2 1 38 Check again that the tiling around the firebox opening is vertically and horizontally levelled. The cassette must be fitted close to each tile around the firebox opening. ROUND • 21 Assembly - tiles GABRIEL KERAMIK AB Complete the centre section by tiling around the firebox. Start from the bottom. Level vertically and horizontally. 39 10 Each centric tile list is manufactued with a support at the back, which must carefully be removed to fit in properly. Apply two centric tile lists (use a somewhat dryer adhesive). Start from the centre. 11 40 Note: Check the body level by fixing a 66 cm tile as shown, level tile and tile list and proceed the tiling upwards. You might have to adjust the tile lists and tiles to “get free” if there are irregularities higher up on the body. Important! Check the body for irregularities that have to be compensated. Also check vertical and horiontal level. 41 12 22 • ROUND Mount the whole section of centric tile lists. Start from the inner side and work towards the edges. Assembly - tiles 42 14 43 GABRIEL KERAMIK AB Apply the 66 cm tiles. Start with the row above the mid simms (wasteline lists). Work from the centre towards the sides. Repeat the following rows, always level vertically and horizontally. Before applying the frieze, carefully remove the support at the back. Start with the soot hole frieze tiles. Proceed towards the sides. Level vertically and horizontally. 44 15 Apply the crown tiles exactly over the soot hole frieze tiles.Proceed towards the sides. TIP! Place a load with a blank surface on top of the stove. Then you can apply tape on the upper edge of the crown tiles to be able to keep them in position and to adjust them. ROUND • 23 Cassette installation GABRIEL KERAMIK AB 45 Outdoor cumbustion air inlet Indoor cumbustion air inlet Mount the reduction flange to the flexible tube and connect to the flange for inlet air through the floor. Mount the reduction flange to the flexible tube and connect to the flange for inlet air through the base. 46 Place the enclosed rockwool sheet. Cut out a square hole the same size as the hole in the firebox plate as indicated. 47 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 or with a thin layer of mortar in the rear edge under the plate. Thereafter the cassette should rest stable and even on the bottom. The brass frame should at the same time fit tight against the tiles. 24 • ROUND Cassette installation 48 49 50 GABRIEL KERAMIK AB Pass the flexible tube through the cassette bottom and fit it over the connecting flange. Fasten the flange plate. Mount the damper in the bottom of the cassette, do not forget the cotter pins. Make sure the damper has a free action. Fasten the cover plate. ROUND • 25 Cassette installation GABRIEL KERAMIK AB Place the vermiculite plate in the bottom. 51 52 20mm Protect the brass frame and tiles around the cassette with masking tape to ensure a neat silicon seal. Pull out the cassette approx. 20 mm and apply silicon just inside the edge around the brass frame, then push the cassette back in. Even the seal with a wet finger (dipping the finger into water with washing-up liquid will make it easier to get a neat joint). Remove the masking tape. 53 26 • ROUND Insulate behind the cassette, around the sides and in the front edge between the cassette and the body. Cassette installation GABRIEL KERAMIK AB 54 2 3 4 Insert the steel plate vertically over the edge of the cassette. Turn the plate horizontally and pull it backwards firm and tight against the top of the fire box block so that it at the same time is fitted tight between the cassete and the body as shown in picture 3 and 4. 1 Install the last vemiculite plate on the two tubes in the cassette and push it as far back as possible. This improves the combustion and forces the flame forward. 55 Fan installation 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. 56 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. ROUND • 27 GABRIEL KERAMIK AB www.gabrielkakelugnar.se Tel. +46 (0)499 233 00