ORTAL Clear 200 Installation And Operation Manual Download Page 1

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Installation and Operation Manual – AU/NZ

(For 150 – 250 Units)

ORTAL Heating Systems Ltd.

Summary of Contents for Clear 200

Page 1: ...Installation and Operation Manual AU NZ For 150 250 Units ORTAL Heating Systems Ltd ...

Page 2: ...ouch any electrical switch do not use any phone in your building x Leave the building immediately x Immediately call you gas supplier from a neighbor s phone Follow the gas supplier s instructions x If you cannot reach your gas supplier call the fire department SAVE THESE INSTRUCTIONS Make yourself fully aware of all the following instructions and the many features of the Ortal room sealed gas fir...

Page 3: ...Gas Log and Other Fuel Effect Appliances x Patent Pending for screen barrier glass bracket USSN 60 040 074 NOTE Diagrams and illustrations in this manual are not to scale All fireplace drawings with correct dimensions are available on our website under Products Downloads Diagram NOTE For additional details about installing CC units and or units with Power Flues please refer to the specific manuals...

Page 4: ...rance Diagrams 28 ORTAL Fireplaces with Double Glass 31 Wall Support Sample Detail 33 Gas Setup 34 Gas Line Routing 41 Control Connections 41 Gas Control Assemblies and Components 42 Pilot and Thermocouple Maintenance 43 Flue System Information 54 Flueing Requirements 55 Flueing Diagrams 56 Flueing Diagram Typical Horizontal 57 Flueing Diagram Typical Vertical 58 Flueing Diagram Straight Vertical ...

Page 5: ...rocedure 119 Final Checks and Customer Instruction 119 Operating Warnings 120 Maintenance Instructions 121 General Maintenance Tips and Warnings 122 Maintenance Frequency and Equipment Checklist 123 Thermocouple Maintenance 123 Recommended Maintenance Equipment 123 ORTAL Factory Recommended Service Checklist 124 ORTAL Product Service Log 125 Manufacturer Contact Information 126 Appendix A Fireplac...

Page 6: ...sembly Diagram 73 Figure 19 Double Glass Parts 76 Figure 20 Double Glass Heat Barrier Parts 81 Figure 21 Framed Screen Assembly Parts 89 Figure 22 Protective Screen Parts 93 Figure 23 Inner Glass Parts 97 Figure 24 Back Panel Parts 101 Figure 25 Components for Front Bricks Installation 105 Figure 26 Components for Traditional Bricks Installation 107 Figure 27 Log Media Placement for Clear 150 H F ...

Page 7: ...gn and architectural needs integrating heat into the aesthetics of life ORTAL also welcomes clients visions for custom made fireplaces for special requirements sizes and uses Our high quality fireplaces are CSA AGA and CE certified ORTAL fireplaces are available in Australia New Zealand through ORTAL approved dealers who each have a strong commitment to offer the best installation and service Gree...

Page 8: ...E BARRIER IS FITTED TO THIS APPLIANCE TO REDUCE THE RISK OF FIRE OR INJURY FROM BURNS AND NO PART OF IT SHOULD BE PERMANENTLY REMOVED FOR PROTECTION OF YOUNG CHILDREN OR THE INFIRM A SECONDARY GUARD IS REQUIRED WARNING FIREPLACE TEMPERATURE Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies Children and adults should be alerted to the haza...

Page 9: ...s The appliance must be installed in accordance with the Manufacturer s instructions and the Manufactured Home Construction and Safety Standard If the information in these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this appliance WA...

Page 10: ...e appliance must be installed according to ORTAL requirements in addition to any local codes that may apply The appliance must be properly connected to an approved flueing system Refer to the specific appliance to determine flue size and pathway requirements In addition adhere to the following pre installation guidelines x Approved flue system manufacturers are x DuraVent x Heat Glo x Olympia x Co...

Page 11: ...mm orifice 2xMarked 260 with 7x0 58mm orifice Marked 800 with 7x1 05mm orifice Marked 1400 With single 3 8mm orifice 2xMarked 260 with 7x0 78mm orifice Nominal gas Consumption 55 MJ h 50 MJ h 52 MJ h 40 MJ h Inlet Pressure 1 13kPA 2 75kPa 1 13kPA 2 75kPa Manifold pressure 0 61kPA 2 3kPa 0 50kPA 1 6kPa Turndown Pressure 0 22kPa 1 5kPa 0 22kPa 0 87kPa The following table lists flue sizes for decorat...

Page 12: ...12 FR Front RS Right Side LS Left Side TS Three Sides SA Console Appliance TU Tunnel H High For all modules TR Traditional SC Space Creator ...

Page 13: ... x Appliances and Flue Clearances Overview on page 14 x Firebox Clearance Diagrams on page 16 x Diagrams for Mantel Clearances on page 18 x Mounting of Console Appliance Models on page 20 x Cool Wall Technology on page 26 x Television and Fireplace Installation on page 28 x ORTAL Fireplaces with Double Glass on page 31 x Wall Support Sample Detail on page 33 ...

Page 14: ...lace controls by going through the firebox This procedure requires removing the glass panel s taking out the interior design media and lifting the grill burner and bottom side explosion valve of the unit The technician would then return all these fireplace components when service is complete Fireplace dealers installers are advised to consult with their clients project architects and or interior d...

Page 15: ...of the fireplace glass opening to the floor This is the minimum height for the firebox to rest on the floor The legs cannot be removed Console Appliance models come with legs that are used for transportation purposes only These are connected with a bolt that must be removed once the unit is installed onsite Since these models do not have legs they can only be wall mounted ...

Page 16: ...ions Maintain clearances as shown in the figures below Clearances are to non combustible materials or 16mm Gyprock Fyrchek fire rated drywall or its equivalent The legend for the figures is provided in the following table 16mm Gyprock Fyrchek fire rated gypsum board Section cut Wood Combustible material Non combustible material Wood framing Metal framing FRONT TRADITIONAL TUNNEL SEE THRU ...

Page 17: ...17 LEFT SIDE OPEN LS RIGHT SIDE OPEN RS THREE SIDES TS ...

Page 18: ...al Figure 1 Mantel Clearances Recess and Flush Finishes LEGEND 16mm Gyprock Fyrchek fire rated gypsum board or equivalent Wood framing Combustible material Metal framing Non combustible materials Materials applicable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non combustible materials An exception is made only for fire rated 16mm Gyprock Fyr...

Page 19: ...icable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non combustible materials An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent where a non combustible material may be used The air flow area must be free from any obstruction to allow heat from the chase to be released ...

Page 20: ...structural requirements set forth by the building engineer local codes etc To mount the unit on a concrete wall 1 Position the unit at the desired height and mark the wall There should be a minimum 30cm and maximum 75cm distance from the bottom of the unit to the floor 2 Mount the Console Appliance hanging bracket using Hilti 9 5mm x 7 5mm KWIK BOLT 3 expansion anchors or equivalent with manufactu...

Page 21: ...21 Figure 3 Concrete Wall Mounting Detail ...

Page 22: ...Create an opening in the wall big enough to position the 10 x 20cm blocks between the wood studs at the desired height 3 Repair the opening with Hardy backer board or its equivalent 4 Make sure that the bracket has a minimum 10cm extra hardy backer board material around it 5 Mount the bracket with 9 5 x 10mm lag bolts Follow the bracket manufacturer s installation requirements and then mount the u...

Page 23: ...23 Figure 4 Wood Stud Mounting Detail ...

Page 24: ...nes for the Console Appliance models Please note that these drawings are not to scale All fireplace drawings with correct dimensions are available on our website under Products Downloads Diagram NOTE All dimensions in the diagrams are in milimeters Figure 5 Console Appliance Front Facing Models ...

Page 25: ...25 Figure 6 75 TS Console Appliance Rear View NOTE The dimensions for A and B show the center of the opening for gas after removing the bracket TS Console Appliance units are completely open in the rear ...

Page 26: ...above the firebox 71q Recommended minimum clearance between bottom edge of TV or other similar device and top of firebox opening is 30cm 30cm above the firebox 32q Excessively high wall temperatures surrounding the firebox can contribute to the following conditions x Distortion of the wall surface x Peeling or color change of the paint on the finished wall x Falling wall tiles glue will no longer ...

Page 27: ...lation of the TV above the firebox x Ability to hang artwork without fear of heat impact x Ability to use finish materials such as tiles Venetian plaster paint and regular paint not high temp without worry x Ability to use wood as a decorative finish material see ORTAL s clearance requirements x Savings on installation costs no need to return for overheating problems NOTE Make sure to review and u...

Page 28: ...to verify that their TV mounting and mantel design will not exceed the listed maximum operating temperature of their electronic goods The homeowner should also be careful to consider the placement of the equipment s power and signal lines If these lines are in or near the chase they need to be protected from heat The drawings in the following sections can be used as a guide for those consumers who...

Page 29: ... Materials applicable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non combustible materials An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent where a non combustible material may be used The air flow area must be free from any obstruction to allow heat from the chase to be released ...

Page 30: ...s Materials applicable for the installation of ORTAL fireplaces within the specified clearance dimensions are described as non combustible materials An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent where a non combustible material may be used The air flow area must be free from any obstruction to allow heat from the chase to be released ...

Page 31: ... wall surface below the fireplace POWER REQUIREMENT Make sure to prepare a 230 volt 20 amps dedicated power line outlet at the bottom area of the unit to provide power for the fan that circulates air between the panels and through the chase The following diagrams show two options for constructing the chase cavity air intake Please note that these drawings are not to scale All fireplace drawings wi...

Page 32: ...the installation of ORTAL fireplaces within the specified clearance dimensions are described as non combustible materials An exception is made only for fire rated 16mm Gyprock Fyrchek gypsum wallboard UL authorized or equivalent where a non combustible material may be used The air flow area must be free from any obstruction to allow heat from the chase to be released ...

Page 33: ...lt with your structural engineer and refer to your local building code for proper wall support The following drawing shows a recommended approach to this type of installation Please note that this drawing is not to scale All fireplace drawings with correct dimensions are available on our website under Products Downloads Diagram Figure 10 Wall Support Sample Detail ...

Page 34: ...m manufactured prior to March 2018 please visit ortalheat com The framing shown in the following diagrams show how to meet the requirements for framing with wood studs To frame with all metal studs only one layer of 15mm fireproof gyprock is required and is on the exterior of the framing and you don t need any 15mm fireproof gyprock on the interior If you plan on putting a TV above the fireplace y...

Page 35: ...89 475 222 1283 110 F 568 1350 475 254 1283 110H F 495 1367 475 254 1410 130 F 568 1520 475 254 1283 130H F 495 1520 475 254 1410 150 F 568 1770 475 254 1283 150H F 495 1770 475 254 1410 170 F 568 1970 475 254 1283 170H F 495 1970 475 254 1410 200 F 568 2210 475 254 1283 200H F 495 2210 475 254 1410 250 F 520 2683 475 254 1283 250H F 495 2683 475 254 1410 TR 90 530 1170 690 254 1720 TR 110 457 136...

Page 36: ...S 520 1305 538 1283 110H RS LS 457 1310 581 254 1410 130 RS LS 520 1473 538 254 1283 130H RS LS 457 1480 581 254 1410 150 RS LS 520 1724 538 254 1283 150H RS LS 457 1730 581 254 1410 170 RS LS 520 1924 538 254 1283 170H RS LS 457 1930 581 254 1410 200 RS LS 520 2164 538 254 1283 200H RS LS 457 2170 581 254 1410 250 RS LS 520 2664 538 254 1283 250H RS LS 457 2670 581 254 1410 ...

Page 37: ...005 484 222 1550 110 TN 570 1350 487 254 1283 110H TN 497 1367 487 254 1410 130 TN 570 1520 487 254 1283 130H TN 497 1520 487 254 1410 150 TN 570 1770 487 254 1283 150H TN 497 1770 487 254 1410 170 TN 570 1970 487 254 1283 170H TN 497 1970 487 254 1410 200 TN 570 2210 487 254 1283 200H TN 497 2210 487 254 1410 250 TN 516 2683 487 254 1283 250H TN 497 2683 487 254 1410 ...

Page 38: ...3 110 TS 519 1243 538 254 1283 110H TS 459 1243 581 254 1410 130 TS 519 1413 538 254 1283 130H TS 459 1413 581 254 1410 150 TS 519 1662 538 254 1283 150H TS 459 1662 581 254 1410 170 TS 519 1862 538 254 1283 170H TS 459 1862 581 254 1410 200 TS 519 2102 538 254 1283 200H TS 459 2102 581 254 1410 250 TS 519 2602 538 254 1283 250H TS 459 2602 581 254 1410 ...

Page 39: ...ce Creator SC Framing Diagram Unit Dimension A Dimension B Dimension C Dimension D Dimension E SC 75 483 964 492 222 1283 SC 120 464 1456 492 254 1283 SC 150 464 1757 492 254 1283 SC 200 464 2267 492 254 1283 ...

Page 40: ...age 41 x Gas Control Assemblies and Components on page 42Gas Conversion x To change the gas source of a fireplace you need to request a gas conversion kit Gas conversion can be performed only by technicians who have specific authorization to change these components The actual change must be done by the authorized technician Not all installers are authorized to provide gas conversion services The f...

Page 41: ...igure 11 Gas Conversion Parts To perform NG LPG conversion 1 Remove the front heat barrier and glass For details refer to Fireplace Heat Barrier on page 77 2 Remove the burner For details refer to Appendix B Removal Assembly of the Burner on page 130 3 Remove the pilot kit Remove the two pilot screws ...

Page 42: ...2 Pull the pilot down and twist slightly until it releases from the burner Then pull the receiver and the gas valve out NOTE Before continuing review Figure 12 to familiarize yourself with the components ...

Page 43: ...43 Figure 12 Exploded View of Pilot Parts Receiver and Gas Valve ...

Page 44: ...ect it from the receiver Remove the nut holding the thermocouple pipe and pull the pipe out Remove the nut holding the gas pipe and pull the pipe out NOTE If you have a new complete pilot kit skip Step 4 and continue with Step 5 ...

Page 45: ...le the pilot parts Assemble the injector nozzle with the ring valve eye and the gas tube nut Then insert the assembled parts into the gas tube Attach the assembled parts to the pilot base and then tighten the nut ...

Page 46: ...s a red dot in the hole 23mm The NG hole is 36mm and has a different shape Assemble the electrode with the spark plug connector and the heat gasket with the wire Use a lighter to dissolve the heat gasket to reinforce the parts ...

Page 47: ...ts to the pilot base and then tighten the connector nut Assemble the thermocouple pipe The NG pipe comes pre assembled with only one connector nut Insert the additional connector nut provided by ORTAL as shown in the figure below ...

Page 48: ...48 Attach the thermocouple pipe to the pilot base and then tighten the connector nut 5 Change the base pilot gasket every time you open the pilot base ...

Page 49: ...hen reassembling be careful not to overtighten If the orifice is removed together with the nut separate them using wrenches 15 and 17 as shown in the figure below If not use wrench 15 to remove it from the burner 7 Adjust the burner main aeration Loosen the burner main aeration nuts ...

Page 50: ...he nuts with an 8mm wrench In Ng the supporting trims needs to be all the way so the opening is fixed and cannot be changed In LPG the shutter needs to be removed completely NOTE For reinstallation perform the above steps in reverse x Pilot and Thermocouple Maintenance on page 43 ...

Page 51: ... to allow complete disconnection of the appliance from the gas supply piping system for servicing purposes Control Connections For information on remote and electronic systems please visit the manufacturer s website http www mertikmaxitrol com WARNING The appliance must be installed repaired and maintained by a qualified technician authorized to work according to local gas regulations ...

Page 52: ...lot orifice G25 Burner gas tube G02 Mertik gas valve G19 Pilot gas tube G73 Mertik receiver G34 Spark plug connector G07 Thermocouple block G35 TC connector G09 8 wire cable 500 mm G36 Olive D 4 G10 Switch w cables 180 500 mm G37 Nut for olive D 4 G11 Spark wire G38 Gasket pilot burn G12 Pilot G45 Cable G13 Spark plug G58 Connection fitting 4mm One piece G75 Thermocouple NG G47 Fitting for main li...

Page 53: ...specific authorization to change these components The actual change must be done by the authorized technician Not all installers are authorized to provide gas conversion services The following procedure is a guide for NG LPG conversion WARNING Before starting this procedure make sure to disconnect the main gas supply to the unit Figure 11 Gas Conversion Parts ...

Page 54: ...the burner For details refer to Appendix B Removal Assembly of the Burner on page 130 10 Remove the pilot kit Remove the two pilot screws Pull the pilot down and twist slightly until it releases from the burner Then pull the receiver and the gas valve out NOTE Before continuing review Figure 12 to familiarize yourself with the components ...

Page 55: ...55 Figure 12 Exploded View of Pilot Parts Receiver and Gas Valve ...

Page 56: ...ect it from the receiver Remove the nut holding the thermocouple pipe and pull the pipe out Remove the nut holding the gas pipe and pull the pipe out NOTE If you have a new complete pilot kit skip Step 4 and continue with Step 5 ...

Page 57: ...ble the pilot parts Assemble the injector nozzle with the ring valve eye and the gas tube nut Then insert the assembled parts into the gas tube Attach the assembled parts to the pilot base and then tighten the nut ...

Page 58: ...s a red dot in the hole 23mm The NG hole is 36mm and has a different shape Assemble the electrode with the spark plug connector and the heat gasket with the wire Use a lighter to dissolve the heat gasket to reinforce the parts ...

Page 59: ...ts to the pilot base and then tighten the connector nut Assemble the thermocouple pipe The NG pipe comes pre assembled with only one connector nut Insert the additional connector nut provided by ORTAL as shown in the figure below ...

Page 60: ...60 Attach the thermocouple pipe to the pilot base and then tighten the connector nut 12 Change the base pilot gasket every time you open the pilot base ...

Page 61: ...hen reassembling be careful not to overtighten If the orifice is removed together with the nut separate them using wrenches 15 and 17 as shown in the figure below If not use wrench 15 to remove it from the burner 14 Adjust the burner main aeration Loosen the burner main aeration nuts ...

Page 62: ...ure below Then tighten the nuts with an 8mm wrench In Ng the supporting trims needs to be all the way so the opening is fixed and cannot be changed In LPG the shutter needs to be removed completely NOTE For reinstallation perform the above steps in reverse ...

Page 63: ...h flames must be present The area around the injector should be inspected Any foreign material must be removed with a brush or vacuum Figure 13 Thermocouple Injector Always be present when the fireplace is in operation Thermocouple Maintenance Thermocouple integrity and operation must be checked The installer needs to confirm that the thermocouple is in place and is not cracked or damaged ...

Page 64: ...ace Restrictors and Flue Arrangement on page 64 x Flue Installation and Clearances on page 66 x Flue Termination Drawings on page 67 x Flue Maintenance on page 68 NOTE For information about the 107 164mm and 125 205mm room sealed pipe installation and specs please visit the appropriate manufacturer s website NOTE If the appliance has a Power Flue system please refer to the ORTAL Power Flue manual ...

Page 65: ...l clearances specified in Flue Installation and Clearances on page 66 Alternatively follow the flue system manufacturer s instructions provided that they meet local code The first section of flueing must be secured to the starter with a minimum of 3 sheet metal screws no longer than 12mm DO NOT use silicone to seal the sections If sealing is required by the flueing manufacturer or local code use M...

Page 66: ...66 Flueing Diagrams The following sections provide information for calculating flueing run distances x Flueing Diagram Typical Horizontal on page 57 x Flueing Diagram Typical Vertical on page 58 x ...

Page 67: ...degree elbows If needed for clearance two 45 degree elbows may be used directly on the unit with up to a 30cm section between them The V minimum starts above them They do not count in elbow totals V minimum x 180cm for Series 200 and 250 For flueing runs that exceed these maximums consider the ORTAL Power Flue system Contact your ORTAL dealer for more information Figure 14 Flueing Diagram Typical ...

Page 68: ...cm 270cm 900cm 270cm 990cm 180cm 990cm 270cm Flueing Diagram Typical Vertical Use the diagram and tables below to calculate distances for flueing runs You can use up to two 90 degree elbows If needed for clearance two 45 degree elbows may be used directly on the unit with up to a 30cm section between them The V minimum starts above them They do not count in elbow totals V V1 V2 For flueing runs th...

Page 69: ...ADITIONAL SERIES 200 250 Vertical V Horizontal H Vertical V Horizontal H 90cm 180cm 180cm 90cm 210cm 360cm 300cm 360cm 300cm 450cm 390cm 360cm 390cm 360cm 480cm 360cm 480cm 360cm 570cm 360cm 570cm 360cm 660cm 360cm 660cm 360cm 750cm 360cm 750cm 270cm 840cm 360cm 840cm 270cm 930cm 270cm 930cm 180cm 1020cm 270cm 1020cm 180cm ...

Page 70: ...Diagram Straight Vertical For Series 40 250 the maximum vertical distance is 12 meters For flueing runs that exceed this maximum consider the ORTAL Power Flue system Contact your ORTAL dealer for more information ...

Page 71: ...elbows of 45 degrees no additional length for the H calculation for the restrictor plate size is needed For example Total height of duct work 180cm V Length between the center of the two 45 degree elbows B 90cm The H calculation is H B so the restrictor plate size is 50mm per the table SCENARIO B If there are two 90 degree elbows in the flue system an additional 180cm must be added to the H calcul...

Page 72: ...ween the center of the 90 degree elbow and wall termination cap B 330cm The H calculation is H B 11 Therefore the restrictor plate size is 30mm per the table The value of 11 does not appear on the x scale of the table The choices are then 9 and 12 Always choose the next higher value which is also the smaller restrictor if there is a difference between the values provided ...

Page 73: ...ARIO D There are no 90 degree elbows or 45 degree angles The flueing is a straight vertical run For example Total height of duct work 720cm V The H calculation is 0 Therefore the restrictor plate size is 50mm ...

Page 74: ...formation NOTE Space Creator models may require special restrictors Traditional models do not require restrictors For Series 150 170 x A minimum 90cm vertical run is required before any 90 degree bends x A 45 degree offset is allowed for maximum 30cm This must be followed by a 90cm vertical run before offset 90 degree bend or termination For the correct size flue refer to Product List Models and B...

Page 75: ... x x x 0 5 x x x x x x x x x x x x 0 1 2 3 4 5 6 7 8 9 10 11 H Table 3 Restrictor Table Burner 135 Series 150 170 V Values in mm 9 50 40 40 30 30 0 0 0 0 x x x 8 50 40 40 30 30 0 0 0 0 x x x 7 50 50 40 30 30 0 0 0 0 x x x 6 50 50 40 30 30 0 0 0 0 x x x 5 50 50 40 30 30 0 0 0 x x x x 4 50 50 40 30 30 0 0 0 x x x x 3 50 50 40 30 30 0 0 0 x x x x 2 50 40 40 30 0 0 0 x x x x x 1 x x x x x x x x 0 x x ...

Page 76: ... a minimum of 3 self tapping screws Each elbow should be strapped to reduce movement or possible disconnection Follow the instructions of the flue system manufacturer Vertical Clearances x Maintain 3cm clearance to combustibles on entire circumference Horizontal Clearances x Maintain 3cm clearance to combustibles on bottom x Maintain 10cm clearance to combustibles on top x Maintain 7mm rise per ea...

Page 77: ...77 Flue Termination Drawings Flue Terminations ...

Page 78: ...ing in the inner lining and subsequently dripping from the joints This can cause corrosion in the system 2 Check for corrosion in areas exposed to the elements Components with rust spots or holes must be immediately replaced 3 Ensure that there is no foreign material in the flues Survey by removing the cap and shining a light down the flue 4 If possible check all joints and pipes to make sure that...

Page 79: ...x Removal Assembly of the Double Glass Heat Barrier and Inner Glass on page 75 x Removal Assembly of the Framed Screen on page 89 x Removal Assembly of the Protective Screen on page 93 x Removing Assembling the Inner Glass Screen Heat Barrier Units on page 97 x Removing Assembling the Back Panel on page 101 x Remote Control Setup and Operation on page 111 x Interior Design Media on page 116 x Cold...

Page 80: ... servicing need to be provided x Consider the minimum flue vertical and allowed horizontal lengths and number of bends Flue System Information on page 54 x Consider framing and finishing requirements surrounding framing and materials to be completed after fireplace installation The appliance must be installed on a flat solid continuous surface e g wood metal or concrete This may be the sub floor o...

Page 81: ...gs and seismic brackets to level and secure the unit see note below x Cut off ALL the zip ties x Move the components to the access panel location Be mindful of the routing for future service needs x Install the flueing components per the flueing manufacturer s instructions and ORTAL requirements x Go over the infill panel requirements and finishing details with the contractor x Protect the firepla...

Page 82: ...and safety barrier x Go over operation of the unit and remote with the homeowner x Set up return visit to clean glass after initial burn off period For more information about final inspection and homeowner instructions refer to Post installation Procedures on page 119 ...

Page 83: ...ure that the glass is fully in place and that the silicon is filling the space between the glass panels Place the front or center panel in place first and then slide the side panel into place so that the silicon edge touches the glass edge Figure 16 Glass Seal Assembly Diagram x Re apply silicon only if the original silicon is damaged Contact ORTAL if silicon is needed x If new silicon is applied ...

Page 84: ...perly prior to startup of the firebox An ORTAL fireplace can have one of the following heat barrier types x Double glass A barrier made of inner and outer glass and no screen For installation instructions refer to Removing Assembling Double Glass Heat Barrier on page 81 x Framed screen A front facing protective screen For installation instructions refer to Removal Assembly of on page 89 x Protecti...

Page 85: ...ble the double glass heat barrier Choose the procedure that is relevant to the type of unit you are working with Removing Assembling Double Glass Heat Barrier and Inner Glass Type 1 The procedure below shows how to remove the glass for units with a double glass heat barrier To re install the glass perform the steps in the opposite order ...

Page 86: ...86 Figure 17 Double Glass Parts To remove double glass 1 Using your index finger pull the side trim from the top 2 Using your index finger pull the front trim from the end ...

Page 87: ...87 3 Release the tempered glass brackets Loosen do not remove the upper bracket screws Remove the upper bracket Loosen the lower bracket screws Do not remove the lower bracket ...

Page 88: ... center of the glass as shown Pull up on the suction cup to lift the glass tilting it slightly towards you until you reach the top Be careful to avoid hitting the edge of the glass on the screws Pull the suction cup until the bottom of the glass clears the frame ...

Page 89: ...89 Pull the suction cup to take the glass out NOTE Repeat this process to remove the side glass ...

Page 90: ...the front and side blower grills until they release from the magnets 6 If glass stoppers are installed loosen their screws as shown below 7 Remove the inner ceramic glass in the same manner as the tempered glass ...

Page 91: ... Glass Heat Barrier and Inner Glass Type 2 The procedure below shows how to remove the glass of new design double glass units To re install the glass perform the steps in the opposite order Figure 18 Double Glass Heat Barrier Parts ...

Page 92: ... 1 Remove the side trim Hold the upper side of the side trim with your index finger and pull it until it releases from the top magnet Continue pulling the side trim until it is disconnected from the bottom magnet Repeat with the other side trim ...

Page 93: ...93 2 Remove the bottom trim Lift the end of the bottom trim with your index finger and pull it up until it releases from the magnets Then pull the bottom trim all the way out ...

Page 94: ...sing a screwdriver start removing the two screws from each of the front glass holders Then take them all the way out 4 Remove the double glass Using the suction cup hold the front glass from the center and raise it until it reaches the top ...

Page 95: ...ttom of the glass as shown in the figure Pull the glass down and take it out If necessary repeat the procedure to remove the side glass 5 Remove the double glass fan covers Pull each fan cover up until it is released ...

Page 96: ...ve the front glass brackets Using a suction cup hold the front glass from the center While holding the glass loosen the screws of the upper bracket Take all the bottom bracket screws out Then remove the bracket ...

Page 97: ...97 7 Remove the glass Pull the suction cup up to lift the glass until it reaches the top Pull the suction cup from the bottom until the glass clears the frame ...

Page 98: ...98 Pull the suction cup to take the glass all the way out If necessary remove the side glass by repeating Steps 6 and 7 ...

Page 99: ...99 Removal Assembly of the Framed Screen The procedure below shows how to remove the framed screen To re install it perform the steps in the opposite order Figure 19 Framed Screen Assembly Parts ...

Page 100: ...trim Using your index finger pull the upper side of the profile until it releases from the magnets Then remove it Remove the other side trim in the same manner 2 Remove the front trim Using a screwdriver remove the two screws from each side of the trim ...

Page 101: ...e and remove it 3 Remove the framed screen Using your hand push the holder from the middle to release the framed screen While holding the framed screen up pull the bottom of the screen with your other hand until it clears the frame ...

Page 102: ...102 Pull the framed screen down and out and remove it ...

Page 103: ...103 Removal Assembly of the Protective Screen The procedure below shows how to remove the protective screen To re install it perform the steps in the opposite order Figure 20 Protective Screen Parts ...

Page 104: ...104 To remove the protective screen 1 Remove the side trim by pulling out from the top 2 Remove the bottom trim by pulling up from the end 3 Remove the 4 5mm hex bolts with a 5mm Allen wrench ...

Page 105: ... tilt the screen bracket from the top down and towards you Carefully remove the screen Roll it up and set it aside NOTE If access to the firebox is needed continue with the following steps 5 Remove the trims in front of the glass Lift the trim up from the end and remove the trim ...

Page 106: ...and then remove the bracket While holding the glass corner remove the upper bracket Then rotate the glass corner Lift up the glass corner as shown in the picture on the left Then tilt the glass corner by pulling down from the bottom to the right as shown in the picture on the right and remove it ...

Page 107: ...Glass Screen Heat Barrier Units The procedure below shows how to remove the inner glass panes of ORTAL fireplace units with a screen heat barrier To re install the glass perform the steps in the reverse order Figure 21 Inner Glass Parts ...

Page 108: ...108 To remove the inner glass 1 Remove the side trim by pulling out from the top 2 Remove the bottom trim by pulling up from the end ...

Page 109: ...109 3 Loosen all the M10 bolts from the upper and lower brackets Do NOT remove the bolts 4 Remove the upper glass bracket Do NOT remove the bottom bracket ...

Page 110: ...he front glass by performing the following steps while holding the button of the suction cup down A Tilt the top side of the glass forward B Lift the glass up C Tilt the bottom side of the glass forward D Pull the glass down and out 7 If necessary remove the side glass using the same technique described in Step 6 ...

Page 111: ...el The procedure below shows how to remove the back panel of the unit The procedure is relevant for units that include a reflective panel or granite To re install the panel perform the steps in the reverse order Figure 22 Back Panel Parts ...

Page 112: ...lass and the front heat barrier Fireplace Heat Barrier on page 74 2 Remove the grill screws Lift the grill and pull it out 3 Remove the upper panel holders Hold the panel using a suction cup Remove the screws from each holder and take the holders out ...

Page 113: ...ove the side panel Lift the panel up as shown Tilt the panel from the bottom and pull it towards the fireplace center Pull the panel out and remove it If necessary remove the other side panel in the same manner ...

Page 114: ... bottom holders if present If the screws on the starter collar are type M10 remove them as shown in the figure below Do NOT remove Phillips screws from the starter collar Remove the rear panel in the same manner as the side panel see Step 4 ...

Page 115: ...115 75 65 Front Bricks Installation The following procedure provides guidelines for installing front bricks Figure 23 Components for Front Bricks Installation ...

Page 116: ...1 Remove the heat barrier and the glass Fireplace Heat Barrier on page 74 2 Insert the rear brick NOTE The side bricks hold the rear brick 3 Insert the left and right side bricks 4 Insert the right and left brick holders as shown ...

Page 117: ...117 Traditional Bricks Installation The following procedure provides guidelines for installing traditional bricks Figure 24 Components for Traditional Bricks Installation ...

Page 118: ...118 To install traditional bricks 1 Remove the heat barrier and the glass Fireplace Heat Barrier on page 74 2 Insert the rear lower brick 3 Insert the rear upper brick ...

Page 119: ...119 4 Insert the side bricks 5 Insert the brick holders for each side as shown NOTE The side bricks hold the rear bricks ...

Page 120: ...120 6 Push the right and left floor bricks into place as shown ...

Page 121: ...rmation and instructions for setting up and operating the remote control The redesigned GV60 handsets G6R H FB and G6R H FW operate exactly the same as the previous handset G6R H Only the symbols on the buttons have changed See the figure below for the corresponding symbols ...

Page 122: ...uding interference that may cause undesired operation Changes or modifications not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment NOTE Wiring of valve and receiver must be completed before starting ignition Failure to do so could damage the electronics Setting the Electronics Code Follow these guidelines to set the code on the ra...

Page 123: ...ith no options x The module for fan speed control and light dimmer includes mains power together with batteries in the receiver for automatic backup in case of power outage NOTE Double glass and power flued units will not operate during a power failure and need to be run with the AC Adapter x Without using a mains adapter battery replacement is recommended at the beginning of each heating season N...

Page 124: ...124 Operating Instructions Some options on the remote may not be available on all fireplaces For complete operating instructions please refer to the Homeowner s manual ...

Page 125: ...125 ...

Page 126: ...upply is turned off Handle media only when materials are cool x If media are not installed according to the installation instructions flame impingement and improper combustion could occur and result in soot and or excessive production of carbon monoxide CO Carbon monoxide is a colorless odorless and toxic gas x THIS APPLIANCE MAY EXHIBIT SLIGHT CARBON DEPOSITION The appliance is NOT designed to bu...

Page 127: ...127 Log Media Placement Figure 25 Log Media Placement for Clear 150 H F RS LS TS TU SC 170 H F RS LS TS TU Figure 26 Log Media Placement for Clear 200 H F RS LS TS TU SC Clear 200 F RS LS TS TU SC ...

Page 128: ... which the appliance rests if the floor is above ground level Gas line holes and other openings should be caulked or stuffed with un faced fiberglass insulation If the fireplace is being installed on a cement slab a sheet of plywood or other raised platform can be placed underneath to prevent cold transfer to the fireplace and into the room It also helps to sheetrock inside surfaces and tape and c...

Page 129: ...ch includes 1 Cleaning the glass with a ceramic glass cleaner otherwise the white film will remain 2 Checking the interior media 3 Checking for gas leaks 4 Performing an overall check to make sure that everything is working properly When these activities are complete initial startup is concluded and the fireplace may be operated by the owner Final Checks and Customer Instruction Before releasing t...

Page 130: ...y or loss of life WARNING DO NOT OPERATE YOUR APPLIANCE IF x The glass is NOT properly secured in place x Connection points are not sealed for appliances with glass to glass connections x Glass is cracked x You smell gas x Any part of the appliance has been under water x You have any doubt about safe operation of the unit If any part has been under water do not use the appliance Immediately call a...

Page 131: ...arnings on page 122 x Maintenance Frequency and Equipment Checklist on page 123 x ORTAL Factory Recommended Service Checklist on page 124 x ORTAL Product Service Log on page 125 NOTE Service recommendations presented are for standard ORTAL fireplace products Custom fireplaces may have different recommended service periods and activities ...

Page 132: ... authorized professional service technician to inspect the appliance and to replace any parts of the control system and any gas controls which have been under water WARNING HANDLING OF GLASS x NEVER operate the appliance without the glass properly securely in place x The glass must be removed ONLY by an authorized installer x The technician should ONLY remove the glass with the suction cup supplie...

Page 133: ...should be replaced annually or as needed in all commercial installations and in any residential unit where the fireplace is operated for an average of 10 hours or more per day For all other installations the thermocouple should be replaced every three years or as needed Recommended Maintenance Equipment Before proceeding with service read through the following checklist and make sure you have all ...

Page 134: ...ify that there is NO gas leak Yes No 8 Turn on the fireplace for visual inspection 30 sec 1 minute a Check if the system sparks Yes No b Check if the pilot turns on Yes No c Check if the burner turns on Yes No d Measure gas pressure Inlet kPA Manifold kPA 9 Let the glass cool down 10 Remove glass a Clean the glass b Remove the media and clean vacuum the burner Yes No c Return media per installatio...

Page 135: ...135 ORTAL Product Service Log ...

Page 136: ...136 Manufacturer Contact Information For all service issues please contact your local dealer ...

Page 137: ... troubleshooting Checklist on page 108 x Normal Sequence of Fireplace Operation on page 110 x Troubleshooting Pilot Problems on page 111 x Troubleshooting Thermocouple Problems on page 113 x Troubleshooting Main Burner Problems on page 114 x Troubleshooting Beeping on page 116 x Mertix Maxitrol External Source Operation on page 118 ...

Page 138: ...form these steps 1 Check the batteries and 6V transformer connection 2 Verify that the switch on the valve is on Figure 27 On Off and Manual Pilot Valve Switches 3 Verify that the gas is on 4 Using the purge port purge the gas line of air up to the valve see figure below ...

Page 139: ... NG should be 7 WC 6 Verify that the valve and receiver wires are properly connected and tight and that the interrupter block is tight hand tight plus turn Figure 28 Valve Receiver Wires and Interrupter Block 7 Verify that the manual pilot valve operator is in the ON position Figure 27 on page 128 ...

Page 140: ... by sequential beeps If there is a fault weak batteries the On Off switch is off or other issues a single long beep will sound 2 If the initial check is okay the system initiates spark to the pilot and opens gas to the pilot 3 Once the pilot is on the pilot heats up the thermocouple 4 When the thermocouple is heated to the specified temperature it will allow the flow of the millivolt to the valve ...

Page 141: ...tion on page 130 3 Locate the valve and receiver a Once the receiver is located pull it from the holder b Disconnect the wire for the spark wire Refer to Figure 28 on page 129 for details c Put a small wire on the receiver spark wire port and place the other side of the wire close to the metal body without touching about 3mm While watching the small wire turn the unit on and see if there is a spar...

Page 142: ...Pilot Turns Off After Igniting and After Burner Turns On 1 Review the Normal Sequence of Fireplace Operation on page 130 2 Remove the heat barrier and the glass For instructions refer to Fireplace Heat Barrier on page 74 3 Make sure that the valve is mounted horizontally unless it is a hanging Console Appliance unit 4 Turn the unit on and see if the pilot is still turning off after the burner turn...

Page 143: ... receiver properly and is tight 7 Verify that the thermo current cable SW is securely placed in the interrupter block Testing the Thermocouple Perform these steps to test the thermocouple Do not begin testing until the thermocouple check has been completed 1 Remove the heat barrier and the glass For instructions refer to Fireplace Heat Barrier on page 74 2 Turn off gas to the unit 3 Turn the unit ...

Page 144: ...ow x There is a problem with the flame Check whether the pilot stays on when the main burner turns off x If the pilot stays on make sure the remote thermostat is set to the desired temperature or to the highest temperature allowed on the remote so the system does not turn the burner off x If the pilot does not stay on check the appearance of the flame before the fireplace turns off Refer to Troubl...

Page 145: ...r one The flame is jumping from the burner Too much draw in the fireplace Review the flue run If the size of the restrictor in the unit is incorrect replace it with the correct size If it is the right restrictor replace it with a bigger one Part of the burner is not turning on x Too much CO in the fireplace due to CO backfeeding or an unapproved flue run x Too much media x Burner ports are clogged...

Page 146: ...146 Troubleshooting Beeping ...

Page 147: ...147 ...

Page 148: ...148 Mertix Maxitrol External Source Operation The following figure is taken from the Mertix Maxitrol guide ...

Page 149: ...he Burner The procedure below shows how to remove the burner To re install perform the steps in the opposite order WARNING Before starting this procedure make sure to disconnect the main gas supply to the unit Figure 30 Burner Components ...

Page 150: ...eat barrier and glass For details refer to Fireplace Heat Barrier on page 74 2 Remove the grill screws and take the grill out 3 Disconnect the pilot by removing the two screws holding it NOTE It is recommended to cover the work area with a blanket ...

Page 151: ...the burner Remove the four burner screws Lift the burner and pull it out of the fireplace Attach wrenches 15 and 17 as shown in the figure below Then hold wrench 17 and rotate wrench 15 until the gas pipe releases from the burner ...

Page 152: ... Base The procedure below shows how to remove the burner base To re install it perform the steps in the opposite order WARNING Before starting this procedure make sure to disconnect the main gas supply to the unit Figure 31 Burner Base Components ...

Page 153: ...e 1 Remove the heat barrier and glass For details refer to Fireplace Heat Barrier on page 74 2 Remove the back panel holders as needed by removing the screws holding them 3 Remove the burner base Remove the screws holding the base ...

Page 154: ...154 Pull the base until it releases Tilt the base as shown in the figure below ...

Page 155: ...155 Pull the base out as shown ...

Page 156: ... Ortal 2018 Rev 3 0 October 2018 KPMANUALAUAGA ...

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ORTAL Clear 200, Installation And Operation Manual

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