Valor 961 Installation And Owner's Manual

5134403/01

Model 961

Inset live fuel effect gas fire

Incorporating the control.

Fitted with one of the following fascia:

Aurora, Solaris or Lunar.

(G.C. Number 32-032-88)

INSTALLER: Please leave this guide with the owner

INSTALLATION AND OWNER GUIDE

For technical advice firstly contact your retailer. If further advice is required then call

0161703 8157 for The Midlands and North or

01462 813 138 for The South.

Valor Fires, Erdington, Birmingham B24 9QP

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

those given in this publication

THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20).

UNDER NO CIRCUMSTANCES IS THIS FIRE TO BE CONVERTED TO LPG.

AN LPG KIT DOES NOT EXIST FOR THIS GAS FIRE.

THIS APPLIANCE IS SUITABLE ONLY FOR INSTALLATION IN THE UNITED

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

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Safety First.

This fire is CE Approved and designed to meet the appropriate British Standards and

Safety Marks.

Quality and Excellence.

This fire has been 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

The manufacturer is a member of SBGI and HHIC (Heating and Hot water Industry

Council) that work to ensure high standards of safety, quality and performance.

Careful Installation

The manufacturer 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.

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INSTALLER GUIDE

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INSTALLER GUIDE

FOR OWNER GUIDE SEE PAGES 42 TO 52

INSTALLER GUIDE

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CONTENTS

Section Heading Page

INSTALLER GUIDE 4 - 41 OWNER GUIDE 42 - 52

1. SAFETY 6

2. ACCESSORIES 6

3. APPLIANCE DATA 7

4. GENERAL INSTALLATION REQUIREMENTS 8

5. PACK CONTENTS 16

6. FIREPLACE CHECK 18

7. IGNITION CHECK 19

8. GAS SUPPLY CONNECTION 20

9. PREPARING APPLIANCE FOR INSTALLATION 20

10. CONVECTION BOX INSTALLATION 23

10.1 Method 1 - Front fixing to fireplace surround. 23

10.2 Method 2 - Cable retention and floor fixing. 23

10.3 Sealing floor front - All installations. 25

11. BURNER AND SUPPLY PIPE INSTALLATION 26

11.3 Inlet pressure check. 27

12. FITTING THE CERAMIC FUEL EFFECT 27

13. FITTING THE GLASS PANEL 28

14. FULL OPERATING CHECKS 28

14.2 Check for spillage. 29

14.3 Flame supervision and spillage monitoring system. 30

15. OUTLET BAFFLE AND FASCIA FITTING 30

16. FINAL REVIEW 32

17. SERVICING & PARTS REPLACEMENT 33

17.1 Checking the aeration setting of the burner. 33

17.2 To remove the ignition microswitch. 34

17.3 To remove the gas shut-off microswitch. 34

17.4 To remove the fascia. 35

17.5 To replace the control slide unit. 35

17.6 To replace the control slide button. 35

17.7 To remove the glass panel. 36

17.8 To remove the window assembly. 36

17.9 To remove the ceramic side walls. 37

17.10 To remove the electronic ignition generator. 38

17.11 To remove the complete burner unit. 38

17.12 To remove the thermocouple interrupter block. 38

17.13 To remove the pilot unit. 39

17.14 To remove the shut-off tap. 39

17.15 To remove the gas flow rate controller. 40

17.16 To replace the burner. 40

17.17 To remove the main burner injector. 41

17.18 To remove the appliance from the fireplace. 41

INSTALLER GUIDE

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1. SAFETY

Installer

Before continuing any further with the installation of this appliance please read the following guide to manual handling.

 The lifting weight (kg) of this appliance is as below:

Model Heat Engine Firefront Combined Weight Solaris 8.64 13.24 21.89 Lunar 8.64 12.47 21.11 Aurora 8.64 12.47 21.11

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.

2. ACCESSORIES

This appliance can be fitted to a conventional precast flue system when using the 05654K1 spacer kit. Note: When set to its minimum depth (approximately 170mm including the foam seal) the spacer frame is suitable for the shallowest of precast flues (approximately 65mm deep).

INSTALLER GUIDE

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3. APPLIANCE DATA

Under no circumstances is this fire to be converted to LPG. An LPG conversion kit does not exist for this gas fire.

The appliance information label is located on the base of the fire underneath the burner module.

The efficiency of this appliance has been measured as specified in BS 7977 - 1 and the result is as below:

Model

Efficiency % (Gross)

961 80

The gross calorific value of the fuel has been used for this efficiency calculation. The test data from which it has been calculated has been certified by Advantica Certification services (0087). The efficiency value may be used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings.

The conversion of net efficiency to gross was achieved by multiplying the net efficiency by the following conversion factor from Table E3 of SAP 2005, rounding down to the nearest whole number.

Gas Natural (G20)

Inlet Pressure 20mbar

Input - Max. (Gross) 5.00kW (17,060 Btu/h)

Input - Min. (Gross) 2.5kW (8,530 Btu/h)

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

Gas Connection 8mm pipe

Burner Injector Cat 82 - 065

Pilot & Atmosphere Sensing Device Copreci Ref. O.D.S 21500/166

Ignition Electronic (Battery 9V PP3)

Aeration Setting See section 17.1

Gas Conversion factor from net to gross efficiency

Natural Gas 0.901

This product uses fuel effect pieces and burner compartment walls 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. RCF waste is classed as a stable, nonreactive hazardous waste and may be disposed at a landfill licensed to accept such 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.

4. GENERAL INSTALLATION REQUIREMENTS

4.1 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. 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 EN 1856 Part 1 Chimneys - Requirements for metal chimneys. BS 715 Specification for metal flue boxes for gas-fired appliances not

exceeding 20kW BS EN 1858 Chimneys - Components - Concrete flue blocks BS EN 1806 Chimneys - Clay / ceramic flue blocks BS EN 1856 Part 1 Chimneys - Requirements for metal chimneys BS 5440 Part 1 Installation of flues BS 5440 Part 2 Installation and maintenance of flues and ventilation for gas

appliances of rated input not exceeding 70 kW net (1st, 2nd

and 3rd family gases). BS 6461 Part 1 Masonry chimney & flues - Installation BS 1251 Fireplace components BS 5871 Part 2 Installation - Inset LFE gas fires BS 6891 Gas pipework installation

INSTALLER GUIDE

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INSTALLER GUIDE

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BS 8303 Parts 1,2 & 3 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 also conform to the relevant parts of: a) The current edition of IS 813 “Domestic Gas Installations”. b) All relevant national and local rules in force. Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

4.2 In the United Kingdom, as supplied, the appliance can be installed in the following situations: -

4.2.1 To a fireplace complete with surround and hearth as shown in figure 1 and complying with BS1251 after removal of the fireback and sufficient material behind the fireback for a debris catchment space. The required fireplace, hearth, debris catchment area and clearance dimensions are shown in figure 1.

Figure 1. Hearth and fireplace opening dimensions.

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4.2.1.1 ‘Hole-in-the-wall’ Installations

 It is recommended that a hearth should be installed as in section 4.9.  If a reduced depth hearth is 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 100 mm. It is recommended that the reduced hearth has a depth from the fixing plane of the fire of 100mm minimum. This is necessary to support the ash pan casting. Where there is no floor covering or carpet and the floor is of a type that is likely to be covered in such a way in the future then the distance from the base of the fireplace opening in the wall to the floor level should be increased to at least 175mm.

4.2.2 To a fireplace incorporating a metal flue box complying with the constructional requirements of the current edition of BS 715 and with a flue conforming to BS EN

1856 part 1. The dimensions of the flue box must conform to those shown in figure 2. Important Note: Where the flue box has a base sheet that is single wall (i.e. a single metal sheet) the flue box must be mounted on a non-combustible hearth. The hearth material must be at least 12mm thick.

4.2.3 To a precast concrete or clay flue block system conforming to BS EN 1858 with dimensions as in figure 3 (A spacer frame is available for precast flue installations that are shallower than the 225mm dimension shown in figure 3 See section 2 headed ‘Accessories’). BS 1289 part 1 recommends 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.

4.2.4 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.

Figure 2. Metal flue box dimensions

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4.3 Suitable flues and minimum flue sizes are as follows: -

It should be noted that, as with many appliances, sharp bends or horizontal runs in metal flues at the top of the system can be a cause of problems in these types of installation.



225mm x 225mm conventional

brick flue.



175mm diameter lined brick or

stone flue.



200mm diameter factory made insulated flue manufactured to BS4543 Part 2.



175mm diameter flue pipe. See BS6461 Part 1 for suitable materials.



Single wall, twin wall or flexible flue liner with a minimum diameter of 125mm. The materials to be used are stainless steel or aluminium as specified in BS EN 1856 Part 1. 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.



A properly constructed precast concrete or clay flue system conforming to BS1289 or BS EN 1858. This system is only suitable if the conditions stated in section 4.2.3 are met.

4.4 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.

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

4.6 Any chimney damper or restrictor should be removed. If removal is not possible,

they must be secured in the open position.

Figure 3. Precast or clay flue block system

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4.7 If the appliance is intended to be installed to a chimney that 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.

4.8 If the fireplace opening is an underfloor draught type, it must be sealed to stop any draughts.

4.9 The appliance must be mounted behind a non-combustible hearth unless the conditions of section 4.2.1.1 are met (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 surface of the hearth must be sufficiently flat to enable the bottom of the front surround and the bottom front cover to be aligned horizontally. Any excessive unevenness (uneven tiles, Cotswold stone, etc.) should be rectified. The appliance must not stand on combustible materials or carpets.

4.10 The front face of the fireplace should be reasonably flat over the area covered by the convection 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 convection box can be made.

4.11 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.

4.12 This appliance must not be installed in any room that contains a bath or shower or where steam is regularly present.

4.13 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.

4.14 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 Installations” which makes clear the conditions that must be met to demonstrate that sufficient ventilation is available.

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4.15 If the appliance is to be fitted against a wall with combustible cladding, the cladding must be removed from the area covered by the fascia. The cladding must also not touch the fascia (See figure

4). We suggest that the actual fascia is used as a template to mark the area for combustible cladding removal and that this area is increased by at least 2mm all round.

4.16 The minimum height from the base of the fireplace opening 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 = 700mm.

• For a shelf deeper than 150mm: 700mm + 12.5mm for every 25mm depth over 150mm (See Graph 1).

Figure 4. Removal of combustible cladding (Fascia may differ from that shown)

Graph 1. Combustible shelf clearances

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4.17 The appliance is fitted with an A.S.D (Atmosphere sensing device). If the appliance closes down after a period of operation for no apparent reason, the consumer should be informed to stop using the appliance until the installation and appliance have been thoroughly checked. The A.S.D will shut the appliance down if an unacceptable amount of harmful products of combustion accumulate. Under no circumstances should the A.S.D be altered or bypassed in any way. Only a genuine manufacturer’s replacement part should be fitted. The individual A.S.D components are not replaceable.

4.18 A fireguard complying with BS 8423 should be fitted for the protection of young children, the elderly, the infirm and pet animals.

4.19 Proprietary terminals must comply with BS 715 or BS 1289. Any terminal or termination must be positioned in accordance with BS 5440 Part 1 to ensure that the products of combustion can be safely dispersed into the outside atmosphere. Where the appliance is connected to an unlined brick chimney it is generally unnecessary for the chimney pot to be replaced or for a terminal to be fitted unless the flue has a diameter smaller than 170mm.

4.20 The minimum allowable distance from the outside of the appliance fascia to a corner wall having combustible material or any other combustible surface which projects beyond the front of the appliance is shown in figure 5. A 10mm access clearance from a non-combustible surface is necessary at the left side.

INSTALLER GUIDE

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Figure 5. Appliance dimensions and clearances (The fascia may differ from that shown and dimensions are subject to manufacturing tolerances)

Key Description

Model

Solaris Lunar Aurora

A Height (mm) 654 636 616

B Width (mm) 518 518 518

C Depth into room (mm) 76 79 73

Minimum mandatory clearance

to combustible surfaces

projecting beyond the front of

appliance (mm).

100 100 100

Recommended clearance to non-

combustible surfaces for access

purposes (mm).

50 50 50

INSTALLER GUIDE

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5. PACK CONTENTS

The items required for this appliance are packed in sections. Section 1 - Fire unit contains:

1 Burner and convection box unit. 1 Burner tray trim (Supplied in separate pack). 1 Outlet baffle for the convected air outlet 2 Tapping Screws for outlet baffle. 1 Nut and olive for 8mm inlet pipe. 1 ‘T’ connector and pressure test point. 1 Flue restrictor plate. 3 Tapping Screws (For flue restrictor). 2 Small “U” seals (For convection box side flanges). 1 Strip of floor sealing tape. 6 Fibre / wooden plugs. 4 Woodscrews. 2 Fire retaining cables. 2 Cable clamps. 4 Eyebolts. 1 Rubber grommet (For rear of convector box). 2 Machine screws (For fascia hanging). 2 Washers for fascia hanging. 1 PP3 Battery. 1 Smoke match tube. 2 Fireback spacing brackets. 4 Tapping Screws (For fireback spacing brackets). 1 Length of self adhesive foam seal. 1 Literature pack. 1 Ceramic fuel effect set. 4 Tapping screws for fascia hood. 1 Slider control position label

Section 2 - fascia pack contains: 1 Fascia and ash pan casting.

Carefully remove all the contents. Take special care in handling the ceramic pieces. Take care not to bend or distort the slide control linkage when handling the fascia. Check that all the listed parts are present and in good condition.

INSTALLER GUIDE

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Figure 6. Pack contents (Items are not to scale)

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Valor 961 Installation And Owner's Manual

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