Fundamentals of a gas fire New Zealand August 2017 1
INDEX Fundamentals of a gas fire 3. Ventilation To room space 4. Mechanical ventilation & Smart home connection 5 8. Finish 9 10. Finish face details Decorative & Space heaters 11. Star ratings 12 15. Opening sales questions 16 17. Installation 18 20. Flame types 21. Gas pressures 22 23. Aeration Settings 24 25. Commissioning & Hand over 2
Key Elements Decorative Ventilation With any open fronted fire installation, fixed ventilation to the room space is mandatory under the AS/NZS5601.1 2013 code. Ventilation is required to maintain a balance of pressure between the outside and the room in which the fire is installed. Correct ventilation is achieved by a simple formula. So for a 200mm diameter flue, the radius (r) is 100mm. So Free ventilation area (A) will be 100 x 100 x 22 divided by 7 = 31,428mm. The vents allow the equalisation of pressure within the space where the fire is installed and can be supplied in any number of sizes, quantities and finishes provided they meet the minimum requirement as per the above formula or as specified on the specific units brochure & specifications. Required for open fronted appliances Not required for sealed appliances. Minimum open areas as per instruction booklets (usually starts approx32000mm2) Must be in the room where appliance is located. Is required to enable air to be replaced for what is exiting the flue. Lack of ventilation is a major cause of spillage of flue gases In this installation, ventilation will be brought in via a linear wall diffuser located here. 3
Key Elements Decorative Ventilation interlocks All open fronted fires require permanent ventilation within the space that houses the fire. Where open fronted fires are installed into sealed building such as 7 star or Basix applications mechanical ventilation is supplied. A fresh air interlock simply allows the fire control system to operate a motorised damper system via proving switches to ensure the fire only operates when the damper is open and is supplying ventilation to the space. When the fire is off, the damper is closed. CBUS / smart home connection C Bus is a microprocessor based control system for homes and commercial buildings. All Real Flame products that we offer for C Bus operation, are based on a simple on/off process. C Bus control of fires that include remote control functions is not allowed. C Bus is connected to either the GPO which the fire is plugged into, or to the on/off wall switch. 4
Finish One of the most common issues with the installation process is correct construction design. There are many aspects to consider during design stage that will make the installation of a gas fire an easy process. Using the previous points, will assist in a smooth process from the sale through to installation to a happy customer. The 4 key considerations are; 1. A design that allows for an approved flue run that can terminate to the atmosphere according to the code. 2. A design that correctly illustrates the framework that will house the fire allowing for the correct clearances. 3. A design that uses the appropriate materials for construction around the fire. 4. A design that considers the aesthetic of the space. The final phase of selection is finish. There are literally hundreds of possible finishes for a Real Flame gas fires. Key Elements Decorative & Space heaters Use your imagination! 5
Key Elements - Decorative & Space heaters Finish Decorative fires 6
Key Elements - Decorative & Space heaters Finish Decorative fires 7
Key Elements Decorative & Space heaters Finish Decorative fires 8
Key Elements - Decorative & Space heaters Finish Decorative fires 9
Key Elements - Decorative & Space heaters Finish Space Heaters 10
Star ratings Space heaters Understanding a STAR LABEL. The STAR LABEL has a number of items on it that tell the customer how efficient the products is and more importantly how it measures against other similar products. Model B Model A The example on the right shows a typical swing tag. This one is the Captiva 900. If compared to a similar fire, you can see the difference in efficiency. 2 STARS 32 Mj/Hr 18185 Mj 6.8 kw 4.06 STARS 30 Mj/Hr 12506 Mj 6.93 kw The top red band shows how many STARS the fire was given by the testing authority. The number in the RED box is the assumed amount of gas consumed in a typical season. The kw output noted beneath the red box tells the customer how much heat output the fire produces. Model A 12506 M/j $218.85 PA Model B 18185 M/j $318.23 PA M/j input is ENERGY. A gas log fire burns energy (gas) in the same way a car burns petrol. The combustion process generates power in the form of output (kw). As we combust the gas a given percentage is exhausted in the form of carbon dioxide and water. kw output is POWER. We measure this output to allow us to determine the size of space that we can heat. Typically 1kW of power will heat between 6m2 and 15m2 depending on a large number of factors such as geographic position, aspect, construction style and insulation. 11
Opening questions Remember how overwhelmed you were when you first visited the showroom. You just looked from one fire to the next, also remember we can have up to 70 different configurations of fires. Remember how long it took you to get your head around the range of fires. Understand that when a client first walks into our showroom they are also taken back by our amazing range of fires. Understand that they will only be able to concentrate for a few moments, until their mind starts drifting across the range. We must be able to establish why they are here, what their needs are and find a solution quickly and effectively. You have to visualise their situation and come up with a solution. The best way to do this is to ask the following four questions. 12
Opening questions 1. Is it a new or existing home? New off the plans or newly constructed.? 2. Is there an existing fireplace or is it a new built fireplace? 3. Why a fireplace? Is it an internal wall? Is it an external wall? Is the home double storey? Is it for charm romance and ambience? Will it be used for primary or supplementary heat or a bit of both.? 4. What Style / design Are they after..? Old world? Traditional? Modern? 13
Opening questions In a few moments you will have established the clients needs. Visualise the solution, based on your clients comments. Focus on the solution. - Take them to the visualised fire and demonstrate the fire that fits their needs. - Do a quote (tick all reference boxes Finishes, gas type, flue type) - Give them the appropriate brochure. - Highlight the fire, application and accessories on the specification sheet. Action - Close / Give specifications or details required. - Refer to installer for on site obligation free quote. - Note any follow up in your log / crm. Remember gas fires can only be installed by a licenced gas fitter. Variations from standard approved product. - Every now and again a client will want something out of the ordinary. being made and manufactured in house we have the ability to oblige, however, there is a strict process that has to be adhered to. 1. client must record their request in writing. 2. that request must be submitted to our R and D department for evaluation. 3. R and D will evaluate and advise both you and the client of the outcome For everyone s protection we have adopted the simple rule: if it is not in writing, it is not approved 14
Installation Domestic installations vary in type according to aesthetics, construction restraints and budget. Typically we break installs into the following categories; 1. Type 1: A fire that will be installed into an existing masonry fireplace with approved draft. 2. Type 2: A fire installed in conjunction with a prefabricated firebox into an existing masonry fireplace using the firebox flue system to remove waste products (or no flue with ODS) or in a timber frame. 3. Space Heater: Afirefor zero clearance applications where the firebox is installed in a frame that has the appropriate clearances from combustibles or in an existing masonry fireplace. Both applications require a complete flue system. 15
Installation Type 1, Appliance Installation. An appliance that consists of an assembly or kit that comprises a burner, simulated fuel effect logs and coals, grate and decorative surround that is designed to be installed in a fireplace of indeterminate specifications and in which the chimney is intended to convey flue products to outside air. An assembly or kit shall have the burner, gas manifold and controls provided as a single assembly and may require assembly of such parts as logs, granules, grate and decorative surround. They should also include an ODS system. (described in next slide) Note: It is critical that the fireplace is a working fireplace in that it draws all combustion products up the chimney and does not spill flue gases in anyway. Fixed permanent ventilation is Required within the room or Space where the fire is situated. 16
Installation Type 2, Appliance Installation. An appliance that consists of a complete assembly that includes a fire box/surround and a conventional fabricated flue system. The flue shall be either supplied with the appliance or clearly specified by the manufacturer in the installation instructions. Note: If the type 2 appliance is installed into a fireplace the complete flue system still needs to be installed unless the fire has an ODS system fitted. Fixed permanent ventilation is required within the room or space where the fire is situated. 17
Fundamentals Flame types. Decorative fires rely on a flame being slightly rich to create the yellow tall flame. This is controlled by the amount of primary air that is entrained in the burner and the burner design. Decorative burners do have a very low soot level. Primary air burning Air induced by injector Secondary air burning Air supplied around burner This is why it is important the injector is the correct size, the air ventilation is correct, the aeration gaps are set correct and gas pressures are correct. Incorrectly setting the above will result is excessive soot and a very dirty flame. Injectors in conjunction with the pressure determine the gas consumption of the appliance. The higher the pressure, the higher the gas consumption. The larger the diameter, the higher the gas consumption. Injectors also have a vital role in entraining the primary air when burning, this is why a certain size is used and the air openings around the injector are controlled. Calorific value of gases. Natural gas 38.3mj/m3. LPG 98mj/m3. ULPG 118mj/m3. LPG & ULPG compared to Natural gas will use a smaller size injector at a higher pressure to entrain more air into the burner. 18
Installation 3. Space Heater Installation. A room sealed appliance that has a minimum efficiency of 70%. The appliance consists of a complete zero clearance firebox and appropriate flue system. Note: If the appliance is installed into a fireplace the complete flue system needs to be installed. 19
Fundamentals 20
Fundamentals Gas pressures. The measured pressure is usually the burner pressure on the outlet side of the valve. This is important to check to ensure the burner is not over gassed (over gassing will cause sooting and heat damage to componetry and the appliance) or undergased which may cause heating issues or ignition problems. Gas pressures must be checked while the appliance is running. It is good practice when commissioning to ensure the inlet pressure is at least 1.13kPa for Natural gas and 2.75 kpa for LPG. If the inlet pressures are lower the valve will be set incorrectly and when the system pressure increases the burner pressure will increase. Also check that when igniting and or running the inlet pressure does not drop. This is a common sign of undersized piping. Regulator setting. Nat gas 1.13 KPa LPG 2.75kPa Some valves are a on/off valve only and a regulator is fitted prior to the valve. The regulator should be adjusted to give slightly to enable the required burner pressure upto 1.13 / 2.75Kpa pending gas type. The valve should then be set to control the pressure. The regulator will then ensure the valve never supplies more than the nominated rate. 21
Fundamentals Aeration settings This controls the primary air entrained into the burner. The injector while injecting gas into the aeration tube entrains air which then mixes in the mixing tube with the gas. When this exits the burner the gas air mixture then burns as the clear blue part of the flame. The quenching or cooling of the flame just prior to complete combustion creates the incandescent effect (yellow flame) and soot. Old Magiglo burner (up to end 2014 Nat gas shown) Current Magiglo burner Landscape burner (Nat gas shown) 22
NEW MAGIGLO AERATION SETTINGS ROUND CAPS. 23
Commissioning Prechecks Ensure the appliance is installed to suit the room and application. The appliance location is to regulations. The gas supply is correct. The gas supply isolation valve is accessible. Flexihoses are installed to regulations. Not used in inaccessible spaces! The gas supply is checked for leaks. The flue run is correct well sealed, supported, and exit cowl correctly located to meet AS/NZS5601.1 2013 Gas Installation codes. Ensure the appliance is the correct gas type. Check logs and coals / pebble placement. Burner channel should not be obstructed. Ensure the pilot / spark area has no pebbles / coals within 10mm of electrodes. 24
Operation once appliance is running SPILLAGE TESTING Check the inlet gas pressure (recommended appliance is turned off when fitting manometer) Adjust the regulator if required. Check the burner pressure and adjust if required. Note some appliances have a minimum and maximum rate that needs to be checked. Ensure there are no gas leaks. Ensure the flame is even. Ensure the flame colour is correct and not excessively yellow / orange. When starting cold, ensure the flame / pilot is not lifting from burner (mainly space heaters). Check the appliance for spillage of flue gases into the room. To ensure the appliance is operating safely and no combustion products are entering the room. The appliance should be allowed to operate for 5 minutes. Test while the appliance is operating at high (or worst case). Spillage should be checked around seals, louvers and potential room entry points. (eg infill panels on existing fireplaces). Check background levels as there may be other existing sources. Check with and without exhaust fans on. Spillage can be checked using a combustion analyser, co meter. For checking draw on appliances smoke matches. Handover Advise the customer on how to use the appliance. Advise where the electrical isolation switch and gas isolation valve is located. Appliance should be clean, undamaged, and unmarked. 25