Valor Dream 2, Dream 2 641 Installer's Manual
3002499/02
INSTALLER GUIDE
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20)
WHEN CONVERTED USING CONVERSION KIT NO. 0591301 THIS
APPLIANCE IS FOR USE WITH PROPANE GAS (G31)
THIS APPLIANCE IS FOR USE IN THE UNITED KINGDOM (GB) AND THE
REPUBLIC OF IRELAND (IE) ONLY.
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
INSTALLER: Please leave this guide with the owner
© Valor Heating
Dream 2
Dream 2Dream 2
Dream 2
INSET LIVE FUEL EFFECT GAS FIRE
INCORPORATING THE
VALOR
CONTROL
Model 641
(GC No. 32-032-49)
INSTALLER’S GUIDE
Page 2
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
INSTALLER’S GUIDE
Page 3
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 24.0 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.
INSTALLER’S GUIDE
Page 4
CONTENTS
SAFETY ...............................................................................................................................................3
1 APPLIANCE DATA.......................................................................................................................... 5
2 GENERAL INSTALLATION REQUIREMENTS...............................................................................6
3 PACK CONTENTS ........................................................................................................................12
4 FIREPLACE CHECK .....................................................................................................................15
5 IGNITION CHECK..........................................................................................................................17
6 GAS SUPPLY CONNECTION .......................................................................................................18
7 PREPARING APPLIANCE FOR INSTALLATION.........................................................................19
8 HOTBOX INSTALLATION.............................................................................................................21
8.1 Method 1 - Front Fixing to Fireplace Surround .................................................... 21
8.2 Method 2 - Cable Retention and Floor Fixing....................................................... 22
8.3 Sealing Floor Front - All installations ................................................................... 24
9 BURNER & SUPPLY PIPE INSTALLATION.................................................................................25
10 CERAMIC WALLS INSTALLATION............................................................................................. 27
11FRONT SURROUND & CONTROL LINKAGE INSTALLATION...................................................28
12CERAMIC COALS INSTALLATION.............................................................................................. 30
13FRONT / CASTINGS INSTALLATION .......................................................................................... 34
14FULL OPERATING CHECKS........................................................................................................ 35
14.1Check the Control Settings .................................................................................... 35
14.2Check For Spillage................................................................................................. 36
14.3Flame Supervision & Spillage Monitoring System............................................... 36
15FINAL REVIEW..............................................................................................................................38
16SERVICING & PARTS REPLACEMENT.......................................................................................39
16.1Checking the aeration setting of the burner........................................................... 39
16.2To Remove the Ignition Microswitch.................................................................... 40
16.3To Remove the Gas Shut-Off Microswitch........................................................... 41
16.4To Remove the Fire Front Surround...................................................................... 41
16.5To Replace the Control Slide Unit ........................................................................ 42
16.6To Replace the Control Slide Button..................................................................... 42
16.7To Remove the Burner Unit .................................................................................. 42
16.8To Remove the Electronic Ignition Generator ...................................................... 42
16.9To Remove the Thermocouple Interrupter Block ................................................. 43
16.10 To Remove the Pilot Unit ................................................................................... 44
16.11 To Remove the Shut-Off Tap.............................................................................. 45
16.12 To Remove the Gas Flow Rate Controller.......................................................... 46
16.13 To Remove the Main Burner Injector................................................................. 46
16.14 To Replace Burner Plaques................................................................................. 48
16.15 To Remove the Appliance from the Fireplace.................................................... 49
17SHORT LIST OF SPARES ............................................................................................................50
INSTALLER’S GUIDE
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1 APPLIANCE DATA
This product uses fuel effect pieces, burner compartment walls and gaskets 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.
The appliance data label is located on a ‘pivot’ plate at the base of the fire. This can be
seen be pulling on the raised tab.
Gas Natural (G20)
Propane (G31)*
Inlet Pressure 20mbar 37mbar
Input - Max. (Gross) 6.85kW (23,400 Btu/h) 6.7kW (22,860 Btu/h)
Input - Min. (Gross) 2.7kW (9,410 Btu/h) 4.3kW (14,670 Btu/h)
Burner Test Pressure (Cold) 17.0 ± 0.75mbar (6.82 ±
0.3in w.g.)
35.85 ± 0.75mbar (14.4 ±
0.3in w.g.)
Gas Connection 8mm pipe 8mm pipe
Burner Injector Bray Cat. 18U Size 420 Stereomatic Size 170
Pilot & Atmosphere
Sensing Device
SIT Ref. OP NG9030 SIT Ref. OP LPG9222
Ignition Electronic
(Battery 9V PP3)
Electronic
(Battery 9V PP3)
Aeration Non-adjustable Non-adjustable
*When converted using kit 0591301.
INSTALLER’S GUIDE
Page 6
Figure 1. Hearth & Fireplace Opening
2 GENERAL INSTALLATION
REQUIREMENTS
2.1 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 1289 Part 2
BS EN 1806
BS 4543 Part 2
BS 5440 Part 1
BS 5440 Part 2
BS 5871 Part 2
BS 6461 Part 1
BS 6891
BS 8303
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
INSTALLER’S GUIDE
Page 7
the Environment for
Northern Ireland.
In the republic of Ireland
the installation must also
conform to the relevant
parts of:
a) The current edition of
IS 813
b) All relevant national
and local rules in force.
2.2 In the United
Kingdom, as supplied, the
appliance can be installed in
the following situations: -
2.2.1 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.
2.2.1.1 ‘Hole-in-the-wall’ Installations
• It is recommended that a hearth should be installed as in figure 1.
• 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 85mm. 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 lower
front casting.
2.2.2 To a fireplace incorporating a metal flue box complying with the constructional
requirements of the current edition of BS715. The dimensions of the flue box must
conform to those shown in figure 2.
A precast concrete or clay flue block system conforming to BS1289 with dimensions as
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
Figure 2. Metal Flue box dimensions
INSTALLER’S GUIDE
Page 8
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.
2.2.3 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.
2.4 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.
• 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 BS715. 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 1806. This system is only suitable if the conditions stated in section 2.2.2 are met.
Figure 3. Precast or clay flue block system
INSTALLER’S GUIDE
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2.5 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.
2.6 The flue must not be used for any other appliance or application.
2.7 Any chimney damper or restrictor should be removed. If removal is not possible,
they must be secured in the open position.
2.8 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.
2.9 If the fireplace opening is an underfloor draught type, it must be sealed to stop any
draughts.
2.10 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 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.
2.11 The front face of the fireplace should be reasonably flat over the area covered by
the hotbox 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 hotbox
can be made.
INSTALLER’S GUIDE
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Graph 1. Combustible shelf clearances
2.12 The minimum height from the top surface of the hearth to the underside of any
shelf made from wood or other combustible materials is shown in graph 1.
2.13 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.
2.14 This appliance must not be installed in any room that contains a bath or shower
or where steam is regularly present.
2.15 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.
2.16 In the United Kingdom (GB) no special ventilation bricks or vents are normally
required in the room for this appliance. In the Republic of Ireland (IE) permanent
ventilation must comply with the regulations currently in force.
INSTALLER’S GUIDE
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2.17 Propane gas appliances must not be installed in a room that is built entirely below
ground level (See BS 5871 Part 2).
2.18 If the appliance is to be fitted against a wall with combustible cladding, the
cladding must be removed from the area covered by the outer surround. The cladding
must also not touch the surround. (See figure 4). We suggest that the actual surround 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.
2.19 The minimum allowable
distance from the outside of the
appliance case 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. See figure 5.
2.20 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.
Figure 4. Removal of combustible
cladding
INSTALLER’S GUIDE
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3 PACK CONTENTS
The items required for this appliance are packed in two sections.
Section 1 - Fire Unit contains:
1 Burner & Hotbox Unit
1 Burner front baffle
1 Nut & olive for 8mm inlet pipe
1 Flue restrictor plate
2 Screws (For flue restrictor)
2 Screws (For Fireback spacing brackets)
2 Washers (For case hanging)
2 Screws (For Rear Ceramic wall support bracket)
1 Ceramic back wall
1 Pair of ceramic side walls
1 Left Hand Front coal
1 Right Hand Front coal
1 Main coal bed
1 Pack of 12 loose coals identified by the letters ‘A’ to ‘L’
2 Small “U” seals for hotbox side flanges
1 Strip of floor sealing tape
6Fibre plugs
4 Woodscrews
2 Fire retaining cables
Figure 5 Continued. Appliance dimensions
INSTALLER’S GUIDE
Page 13
2 Cable clamps
4 Eyebolts
1 Rubber grommet
1 Knurled shouldered screw for control linkage fixing
1 PP3 Battery
1 Smoke match tube
2 Fireback spacing brackets
1 Rear Ceramic wall support bracket
1 Length of self adhesive foam seal
1 Literature pack
1 Fireslide slider control
2 Taptite screws
Section 2 - Fire Front contains:
1 Fire front surround.
1 Firefront casting
1 Bottom front cover casting
Carefully remove all the contents. Take special care in handling the ceramic walls and
the coals. Check that all the listed parts are present and in good condition.
INSTALLER’S GUIDE
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Figure 6. Pack contents
INSTALLER’S GUIDE
Page 15
Figure 7. Fireplace Areas
4 FIREPLACE CHECK
4.1
4.1.1 Fireplace size
The fireplace must comply
with the requirements
described in section 2.2.
This will probably entail
removing the fireback and
infill material behind the
fireback. The debris
catchment area shown in
figure 7 must be kept clear
of obstructions.
4.1.2 Fireplace general
condition
The fireplace floor should be
reasonably flat to ensure that
the hotbox can be installed
without it rocking and so
that a good seal can be made at the bottom front of the box. The front face of the
fireplace should be reasonably flat over the area covered by the hotbox top and side
flange seals to ensure good sealing. These faces should be made good if necessary. If the
appliance is to be fitted against a wall with combustible cladding, the cladding must be
removed from the area covered by the outer surround. The cladding must also not touch
the surround. (See figure 4). We suggest that the actual surround 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.
4.1.3 Soundness for appliance attachment
Two primary methods of retaining the appliance are provided: -
1) By fixing to the fireplace front surround.
2) Using concealed tension cables fixed to the rear of the fireplace opening together
with secondary fixing to the fireplace floor.
The methods are detailed in section 8 of this manual. Before selecting the retention
method, consult with the customer. Method 2 is provided for instances where drilling
holes in the front surface of the fireplace surround is unacceptable to the customer or
otherwise impractical. N.B. It is unwise to attempt to drill into marble without the proper
tools and equipment.
If method 1 is chosen, make sure that the front surround area is sound enough to take the
Fibre plugs and woodscrews. If necessary, make sound with a suitable cement.
INSTALLER’S GUIDE
Page 16
If method 2 is chosen, make sure that the areas at the back and towards the centre of the
fireplace floor are sound enough to take the eyebolts and screws. If these areas have
deteriorated due to prolonged use, they should be made sound with a suitable cement.
4.1.3 Installations using a metal flue box
The whole of the top surface of the metal flue box must be covered with a 100mm layer
of mineral wool or equivalent insulation. (See figure 2).
4.2 Fireplace Flue Pull
Close all doors and windows in the room in which the appliance is to be installed. After
confirming with a match that smoke is drawn into the flue, light a 13 gram smoke pellet
and check that there is a definite flow through the flue. Verify outside that the smoke
exits from one terminal only and that the termination is suitable. Observe, where
possible, upstairs rooms and loft spaces for signs of escaping smoke indicating a
defective flue. If there is not a definite flow warm the flue for a few minutes and repeat
the smoke pellet test. If there is still no definite flow the flue may need remedial work –
Do not fit the appliance until there is a definite flow through the flue.
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