Valor Ultimate Assembly instructions

5108620/02

INSTALLER GUIDE

We trust that these instructions give sufficient details to enable this appliance to be

installed and maintained satisfactorily. However, if further information is required, our

Valor Technical Helpline will be pleased to help.

Telephone 08706 061 065 (National call rates apply in the United Kingdom)

In the Republic of Ireland call 0044 08706 061 065

INSTALLER: Please leave this guide with the

owner

Ultimate

Model 717

(GC No. 32-032-52)

INSET LIVE FUEL EFFECT GAS FIRE

THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20)

WHEN CONVERTED USING CONVERSION KIT NO. 0595221 THIS

APPLIANCE IS FOR USE WITH PROPANE GAS (G31)

THIS APPLIANCE IS SUITABLE ONLY FOR INSTALLATION IN THE UNITED

KINGDOM (GB) AND THE REPUBLIC OF IRELAND (IE).

Safety First.

Valor fires are CE Approved and designed to meet the appropriate British Standards and

Safety Marks.

Quality and Excellence.

At the heart of every Valor fire.

All Valor fires are manufactured to the highest standards of quality and excellence and

are manufactured under a BS EN ISO 9001 quality system accepted by the British

Standards Institute.

The Highest Standards

Valor is a member of the Society of British Gas Industries which works to ensure high

standards of safety, quality and performance.

Careful Installation

Valor is a CORGI registered company. All our gas fires must be

installed by a competent CORGI Registered Installer in accordance

with our Installer Guide and should not be fitted directly on to a

carpet or floor of combustible material.

Valor Heating, Erdington, Birmingham B24 9QP

www.valor.co.uk

Because our policy is one of constant development and improvement, details may vary slightly from those

given in this publication

Page 2

INSTALLER GUIDE

CONTENTS

Section Heading

Page

1. SAFETY 4

2. APPLIANCE DATA 5

3. GENERAL INSTALLATION REQUIREMENTS 6

4. PACK CONTENTS

5. FIREPLACE CHECK

5.1 Fireplace check

5.2 Fireplace Flue Pull

6. IGNITION CHECK

7. GAS SUPPLY CONNECTION

8. PREPARING APPLIANCE FOR INSTALLATION

8.1 Appliance Preparation

8.2 The Flue Restrictor

9. CONVECTION BOX INSTALLATION

9.1 Method 1- Front Fixing to Fireplace Surround

9.2 Method 2 - Cable Retention

9.3 Floor Sealing

10. BURNER & SUPPLY PIPE INSTALLATION

10.1 Burner & Supply Pipe Installation

10.2 Preliminary Burner Checks

10.2.1 Lighting the burner

10.2.2 Operating the burner.

10.3 Reference Pressure Check

11. FITTING THE FRONT SURROUND

12. CERAMIC COALS INSTALLATION

13. FIREFRONT CASTING8INSTALLATION

14. FULL OPERATING CHECKS

15. SPILLAGE & FLAME SUPERVISION CHECKS

15.1 Check for Spillage

15.2 Flame Supervision & Spillage Monitoring System

16. FINAL REVIEW

17. SERVICING & PARTS REPLACEMENT

17.1 Checking the aeration setting of the burner.

17.2 To Remove the Fire Front Surround

17.3 To Remove the Burner Unit

17.4 To Remove the Pilot Unit

17.5 To Remove the gas valve

17.6 To Replace the Burner

17.7 To Remove the Main Burner Injector

17.8 To Remove the Appliance from the Fireplace

18. SHORT LIST OF SPARES

Page 3

INSTALLER GUIDE

1. SAFETY

Installer

Before continuing any further with the installation of this appliance please read the

following guide to manual handling

!The lifting weight of this appliance is 12.95 kg

!One person should be sufficient to lift the fire. If for any reason this weight is

considered too heavy then obtain assistance.

When lifting always keep your back straight. Bend your legs and not your back.

!Avoid twisting at the waist. It is better to reposition your feet.

!Avoid upper body/top heavy bending. Do not lean forward or sideways whilst

handling the fire.

Always grip with the palm of the hand. Do not use the tips of fingers for support.

!Always keep the fire as close to the body as possible. This will minimise the

cantilever action.

!Use gloves to provide additional grip.

!Always use assistance if required.

Page 4

INSTALLER GUIDE

2. APPLIANCE DATA

This product uses fuel effect pieces and a burner compartment rear wall

containing Refractory Ceramic Fibres (RCF), which are man-made vitreous

silicate fibres. Excessive exposure to these materials may cause irritation to eyes,

skin and respiratory tract. Consequently, it is important to take care when

handling these articles to ensure that the release of dust is kept to a minimum. 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 a heavy duty polythene

bag, 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.

This appliance does not contain any component manufactured from asbestos or

asbestos related products.

* When converted using Kit 0595221

The appliance data label is located on a plate at the base of the fire. This can be seen by

removing the lower hanging trim.

Page 5

INSTALLER GUIDE

Gas Natural (G20) Propane (G31) *

Inlet Pressure 20mbar 37mbar

Input - Max. (Gross) 6.0kW (20,500Btu/h) 6.1kW (20,800Btu/h)

Input - Min. (Gross) 2.3kW (7,850Btu/h) 3.8kW (12,965Btu/h)

Inlet Test Pressure (Cold) 20.0 ± 1.0mbar (8.0 ± 0.4in

w.g.)

37.0 ± 1.0 mbar (14.85 ±

0.4in w.g.)

Gas Connection 8mm pipe 8mm pipe

Burner Injector Stereomatic Cat 82 - 069 Stereomatic Size 128

Pilot & Atmosphere Sensing

Device Copreci Ref. O.D.S

21500/166

Copreci Ref. O.D.S

21500/166 Fitted with RBM

180 - 02 injector

Ignition Piezo Electric. Integral with

Gas Tap

Piezo Electric. Integral with

Gas Tap

Aeration See section 17.1 Non-adjustable

3. GENERAL INSTALLATION REQUIREMENTS

3.1 The installation must be in accordance with these instructions.

For the user’s protection, in the United Kingdom it is the law that all gas appliances are

installed by competent persons in accordance with the current edition of the Gas Safety

(Installation and Use) Regulations. Failure to install the appliance correctly could lead

to prosecution. The Council for the Registration of Gas Installers (CORGI) requires its

members to work to recognised standards.

In the United Kingdom the installation must also be in accordance with:

All the relevant parts of local regulations.

All relevant codes of practice.

The relevant parts of the current editions of the following British Standards: -

BS 715 BS 1251 BS 1289 Part 1 BS EN 1806

BS 4543 Part 2 BS 5440 Part 1 BS 5440 Part 2 BS 5871 Part 1

BS 6461 Part 1 BS 6891

In England and Wales, the current edition of the Building Regulations issued by the

Department of the

Environment and the

Welsh Office

In Scotland, the current

edition of the Building

Standards (Scotland)

Regulations issued by

the Scottish Executive.

In Northern Ireland, the

current edition of the

Building regulations

(Northern Ireland) issued

by the Department of the

Environment for

Northern Ireland.

In the republic of Ireland

the installation must be

carried out by a

competent person and

installed in accordance with:

a) The current edition of IS 813 “Domestic gas installations”

b) All relevant national and local rules in force.

c) The current building regulations

Page 6

INSTALLER GUIDE

Figure 1. Hearth and Fireplace Opening Dimensions

Where no specific instructions are given, reference should be made to the relevant

British Standard Code of Practice.

3.2 In the United Kingdom, as supplied, this appliance can be installed in the

following situations: -

3.2.1 A masonry chimney with a minimum diameter of 175mm (7”) free from any

obstruction, and with any damper or restrictor plate in the chimney removed or secured,

and having a minimum effective flue height of 3m (10ft). A masonry chimney having a

correctly installed flue liner to BS715 and with a minimum flue diameter of 125mm is

also acceptable. Chair brick removal may not be required providing at least 50mm

clearance is available from the flue outlet to any fireplace component.

3.2.1.1 ‘Hole-in-the-wall’ Installations

! It is recommended that a hearth should be installed as in figure 1.

If a hearth is not fitted, the fire must be installed so that the distance from the

base of the fireplace opening in the wall to the finished floor level is at least 72mm.

3.2.2 To a fireplace incorporating a metal flue box conforming to BS715 with a

minimum internal depth of 195mm. Incombustible mineral wool insulation of not less

than 100mm thickness must be applied to the top surface of the firebox (See figure 2)

and it must stand on a non-combustible hearth. See figure 1.

3.2.3 To a fireplace that has a precast

concrete or clay flue block system

conforming to BS1289 or BS EN

1806. The appliance is suitable for

installations conforming to older

versions of BS1289 as well as the

current edition. The flue blocks must

have a minimum width not less than

63mm and a cross-sectional area not

less than 13,000mm2.Older editions

of BS1289 required a cross-sectional

area of 13,000mm2. The current

revision of the standard requires

16,500mm2. This appliance is

suitable in both cases. The total depth

of the opening measured from the

finished front of the fireplace

(Including plaster, surround etc.)

Page 7

INSTALLER GUIDE

Figure 2. Metal Flue Box

must be not less than the dimension shown in figure 3.

The current versions of BS1289 and BS EN 1806 recommend that there should be an air

space or insulation between the flue blocks and the plaster because heat transfer may

cause cracking on directly plastered flues. However, generally this appliance is suitable

for installations under all circumstances unless there is a history of cracking problems.

Remember that faults such as cracking may be caused by poorly built and restrictive

flues, e.g. mortar extrusions, too

many bends, flue heights below

three metres, restrictive

terminations, etc.

3.2.4 If the fireplace opening is

greater than the acceptable

dimensions given in this guide, do

not use the back of a fire surround

or marble to reduce the opening.

This may cause cracking of the

surround back or marble.

3.3 The following flues are

suitable:

! 225mm x 225mm

conventional brick flue.

If a flue liner is used, it must be a

minimum of 125mm diameter.

The liner must be sealed to the

surrounding area above the

fireplace opening and to the top of

the chimney. An approved

terminal must be fitted.

! 200mm diameter factory made

insulated flue manufactured to BS

4543.

! A properly constructed precast flue conforming to B.S 1289 or BS EN 1806.

A flue pipe with a minimum diameter of 175mm. See B.S 6461 Part 1 for suitable

materials. Metal flue pipes must comply with B.S 715.

! Single wall, twin wall or flexible flue liner of minimum diameter 125mm. The

materials used are stainless steel or aluminium as specified in B.S. 715.

3.3.1 The minimum effective height of the flue must be 3m.

3.3.2 The flue must be clear of any obstruction and its base must be clear of debris.

Page 8

INSTALLER GUIDE

Figure 3. Pre-cast Fireplace

3.3.3

The flue must be completely sealed so that combustion products do not come into

contact with combustible materials outside the chimney.

3.3.4 The flue must serve only one fireplace.

3.4 The flue must conform to BS 5440: Part 1 in design and installation.

The flue, measured from the bottom of the fireplace opening to the bottom of the

terminal, shall be not less than 3m in actual vertical height. When calculated in

accordance with BS 5440: Part 1 Annex A, the minimum equivalent

height of the flue

shall be 2.0m of 125mm dia. flue pipe.

3.5 The flue must not be used for any other appliance or application.

3.6 Any chimney dampers or restrictors should be removed. If removal is not

possible they must be fixed in the open position.

3.7 If the appliance is intended to be installed to a chimney, which was previously

used for solid fuel, the flue must be swept clean prior to installation. All flues should be

inspected for soundness and freedom from blockages.

3.8 If the fireplace opening is an underfloor draught type, it must be sealed to stop

any draughts.

3.9 The appliance must be mounted behind a non-combustible hearth (N.B.

conglomerate marble hearths are considered as non-combustible). The appliance can be

fitted to a purpose made proprietary class “O”-150°C surround. The hearth material

must be at least 12mm thick. The periphery of the hearth (or fender) should be at least

50mm above floor level to discourage the placing of carpets or rugs over it.

The appliance must not stand on combustible materials or carpets (See figure 1).

3.10

The front face of the fireplace should be reasonably flat over the area covered by

the convector box top and side flange seals to ensure good sealing. These faces should

be made good if necessary. The fireplace floor should be reasonably flat to ensure that a

good seal with the convector box can be made.

Page 9

INSTALLER GUIDE

3.11 The minimum height from the top surface of the hearth to the underside of any

shelf made from wood or other combustible materials is detailed below.

• For a shelf up to 150mm deep: Minimum height = 750mm.

• For a shelf deeper than 150mm: 150mm + 12.5mm for every 25mm depth over

150mm. (See Graph 1)

3.12 Note that soft wall coverings (e.g. embossed vinyl, etc.) are easily affected by

heat. They may scorch or become discoloured when close to a heating appliance. Please

bear this in mind when installing.

3.13

The appliance must not be installed in any room, which contains a bath, or shower

or where steam is regularly present.

3.14

An extractor fan may only be used in the same room as this appliance, or in any

area from which ventilation for the appliance is taken, if it does not affect the safe

performance of the appliance. Note the spillage test requirements detailed further on in

this manual. If the fan is likely to affect the appliance, the appliance must not be

installed unless the fan is permanently disconnected.

3.15 Normal adventitious ventilation is usually sufficient to satisfy the ventilation

requirements of this appliance. In GB reference should be made to BS 5871 Part 2 and

in IE reference should be made to the current edition of IS 813 “Domestic gas

Page 10

INSTALLER GUIDE

Graph 1. Combustible shelf clearances

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