Baxi Fires Division Dream BR660VA Assembly instructions

5113131/01
INSTALLER GUIDE
We trust that this guide gives sufficient details to enable this appliance to be installed
and maintained satisfactorily. However, if further information is required, our
Baxi Fires Division Technical Helpline will be pleased to help.
Telephone [phone] (National call rates apply in the United Kingdom)
In the Republic of Ireland telephone [phone]
INSTALLER: Please leave this guide with the
owner
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20).
WHEN CONVERTED USING CONVERSION KIT NO. 0591149 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).
Model BR660VA
POWER FLUE INSET GAS FIRE
Fitted with
Anthem,
Camden,
Dream or
Sonnet Plusfascia
(GC No. 32-032-44)
© Baxi Heating U.K. Ltd.

Safety First.
Baxi Fires Division fires are CE Approved and designed to meet the appropriate British
Standards and Safety Marks.
Quality and Excellence.
At the heart of every Baxi Fires Division fire.
All Baxi Fires Division 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
Baxi Fires Division is a member of the Society of British Gas Industries which works to
ensure high standards of safety, quality and performance.
Careful Installation
Baxi Fires Division 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.
Baxi Fires Division, Erdington, Birmingham B24 9QP
www.firesandstoves.co.uk
Because our policy is one of constant development and improvement, details may vary slightly from those
given in this publication
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INSTALLER GUIDE

CONTENTS
Section Heading Page
1. SAFETY 4
2. APPLIANCE DATA 4
3. GENERAL INSTALLATION REQUIREMENTS 5
4. APPLIANCE DIMENSIONS 12
5. UNPACKING 14
6. PREPARING FOR INSTALLATION 16
7. WALL PREPARATION 17
8. INSTALLATION OF ELECTRICS, FIREBOX AND FAN BOX 22
9. GAS SUPPLY INSTALLATION 29
10. FITTING THE CERAMICS 31
11. FITTING THE FASCIA AND FIREFRONT 31
12. CHECKS 33
13. FINAL REVIEW 35
14. SERVICING PARTS AND REPLACEMENT 36
14.1 To replace the burner plaques. 36
14.2 To remove the pilot unit. 37
14.3 To completely remove the burner unit. 38
14.4 To remove the gas tap/F.S.D & solenoid assembly. 38
14.5 To remove the piezo generator. 39
14.6 To remove the main burner injector. 39
14.7 To remove an “On” or “Off” switch. 39
14.8 To gain access to the electrical control components. 39
14.9 To remove the distribution block. 40
14.10 To remove the fan. 40
14.11 To remove the pressure switch 40
14.12 Pressure switch strip down. 41
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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 as below: -
Heat Engine (kg) Fan Box (kg) Fascia / firefront (kg) Total (kg)
Anthem 9.0 6.0 2.01 17.01
Camden 9.0 6.0 0.71 15.71
Dream 9.0 6.0 13.0 28.0
Sonnet Plus 9.0 6.0 4.5 19.5
!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. APPLIANCE DATA
This product uses fuel effect pieces, gaskets 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.
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INSTALLER GUIDE

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 0591149.
The appliance data label is located on a plate at the base of the fire. This can be seen by
removing the fire front castings / fire front.
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, all electrical supply installation must be installed in accordance
with the current edition of the IEE Wiring Regulations (BS7671).
In the United Kingdom the installation must also be in accordance with:
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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) 2.2kW (7,500Btu/h) 3.6kW (12,280Btu/h)
Output - Max. 3.12kW (10,600Btu/h) 3.6kW (12,280Btu/h)
Output - Min 1.1kW (3,750Btu/h) 1.8kW (6,140Btu/h)
Inlet Test Pressure (Cold) 14.9 ± .75mbar (6.0 ± 0.3in
w.g.)
34.9 ± 0.75 mbar (14.0 ±
0.3in w.g.)
Gas Connection 8mm pipe 8mm pipe
Burner Injector Bray Cat. 18 Size 400 Bray Cat. 18 Size 170
Pilot & Atmosphere Sensing
Device SIT Ref. NGOP9044 SIT Ref. OPLPG9222
Ignition Piezo Electric. Integral with
Gas Tap
Piezo Electric. Integral with
Gas Tap
Aeration Non-adjustable Non-adjustable
Electrical Supply 230V ~ 50Hz AC 230V ~ 50 Hz AC
Fan motor rating 55W 55W
Fuse rating 3A 3A

a) All the relevant parts of local regulations.
b) The current edition of the Building Regulations issued by the Department of the
Environment and the Welsh Office or the Building Standards (Scotland) (Consolidation)
Regulations issued by the Scottish Development Department.
c) All relevant codes of practice.
The relevant parts of the current editions of the following British Standards:-
BS 5440 Part 1
BS 5871 Part 2 & 3
BS 6891
In the republic of Ireland the installation must also conform with:
a) The current edition of IS 813 “Domestic gas installations”
b) All relevant national and local rules in force.
c) The current ETCI National Rules for Electrical Installation.
Where no specific instructions are given, reference should be made to the relevant
British Standard Code of Practice.
3.1.2
Electrical isolation of the unit should be by means of a switched 3A fuse spur that
should be readily accessible to the user, easily identifiable and sited within reach of the
mains cable provided. It should only connect this appliance.
3.1.3 This fire is a fan flued appliance for installation on an outward facing wall of a
conventional home which does not have a purpose built flue or chimney.
3.1.4
As supplied, the appliance is suitable for homes constructed of brick, stone, etc.,
the appliance can be installed into walls up to a maximum thickness as shown below.
If the fire box is in front of the finished wall surface: 600mm (23 5/8in) max.
These dimensions are from the finished internal wall surface (including any surround
material) to the external wall surface.
3.1.5
Installation to a timber framed building should be in accordance with the relevant
sections of Institute of Gas Engineers publication IGE/UP/7 “Gas installations in timber
frame buildings”. Please note that advice should be sought before installing in a
timber frame building since the alterations required may nullify any NHBC cover
relating to the property. If in doubt, guidance should be requested from your local
authority planning or building department.
This appliance must be mounted with a non-combustible hearth (See figure 1) (N.B.
conglomerate marble hearths are considered as non-combustible). The fire box must be
mounted on a non-combustible surface level with the hearth. The hearth must project at
least 300mm forward of the fire box front and be at least 625mm wide (see illustrations
in “wall preparation” section). 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
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INSTALLER GUIDE

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
casting to be aligned horizontally. Any excessive unevenness (uneven tiles, Cotswold
stone, etc.) should be rectified.
3.1.6 The appliance must not stand on combustible materials or carpets.
The appliance must not be fitted directly against a combustible wall. If the
appliance is to be fitted against a wall with combustible cladding or skirting board, such
materials must be removed from the area covered by the fascia of the appliance. We
suggest that the fascia is used as a template to mark the area for combustible cladding
removal.
The appliance can be fitted to a purpose made proprietary class “O” 150°C surround.
The opening in the surround or wall recess for the fire box must be within the limits
shown in figure 1.
3.1.7. ‘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 88
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 lower front casting. The minimum
shelf height will have to be taken from the base of the fireplace opening.
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INSTALLER GUIDE
Figure 1. Hearth and recess requirements

3.1.8 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 = 700mm.
!For a shelf deeper than 150mm: 700mm + 12.5mm for every 25mm depth over
150mm (See Graph 1).
3.1.9 The front face of the wall should be reasonably flat over the area that will be
covered by the fire box top and side flanges to ensure a good seal. The minimum height
from the top surface of the hearth to the underside of any shelf made from wood or
other combustible materials is as follows:-
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.
3.1.10
The appliance must not be installed in any room that contains a bath or shower or
where steam is regularly present.
3.1.11
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, or provision is made to ensure that
the fan and the appliance cannot be used at the same time.
A fan-powered flue system tends to depressurise the room containing the appliance.
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INSTALLER GUIDE
Graph 1.

3.1.12 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, however the spillage check (See further on in this
guide) may indicate a need for further ventilation in order to ensure that there is
adequate air replacement. If necessary seek expert advice.
3.1.13 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 manufacturers replacement
part should be fitted. The individual A.S.D components are not replaceable.
3.1.14
A fireguard complying with BS 8423 should be fitted for the protection of young
children, the elderly, or the infirm.
3.1.15 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 100mm.
For access purposes a 50mm clearance is recommended from non-combustible surfaces.
3.2 Flue Siting
3.2.1
The flue terminal should be located so that the wind can blow freely across it at all
times and where any blockage due to leaves, snow, etc. is unlikely. The minimum
allowable distances from the terminal are shown in figure 2.
Note: The distances are from the edge of the vertical exit slots in the terminal not from
the edges of the rectangular box (See figure 4).
3.2.2 This appliance is supplied with a terminal guard. In England and Wales, the
Building Regulations require that the terminal guard is fitted if the flue terminal can
come in contact with people near the building or be subject to damage. Even if the
regulations do not demand it, we recommend that the guard is fitted to prevent damage
or blockage of the flue system by leaves etc.
A concealed gas supply connection can be made through the rear panel. Visible front
connection can be from the left or right side after an opening has been cut in the
appropriate side of the hearth casting.
Electrical connection is from the left side.
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INSTALLER GUIDE

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INSTALLER GUIDE
Figure 2
Dimension Terminal Position Minimum
A* Directly below an opening, air brick, opening window etc. 300mm
B* Above an opening, air brick, opening window etc. 300mm
C* Horizontally to an opening, air brick, opening window etc. 300mm
DBelow gutters, soil pipes or drain pipes 75mm
EBelow eaves 200mm
FBelow balconies or car port roof 200mm
GFrom a vertical drain pipe or soil pipe 150mm
HFrom an internal or external corner 200mm
IAbove ground, roof or balcony level 300mm
JFrom a surface facing the terminal 600mm
KFrom a terminal facing the terminal 1200mm
LFrom an opening in a car port (e.g. door, window) into 1200mm
MVertically from a terminal on the same wall 1500mm
NHorizontally from a terminal on the same wall 300mm
OProjection outward from wall 50mm
*In addition, the terminal should not be nearer than 150mm to an opening in the
building fabric formed for the purpose of accommodating a built-in element such as a
window frame or door frame (See figure 3).
Minimum distances for terminal positions shown in the table are from slot openings.
(See Figure 4)

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INSTALLER GUIDE
Figure 3
Figure 4

4. APPLIANCE DIMENSIONS
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INSTALLER GUIDE
Figure 5. Appliance dimensions (Shown with Sonnet Plus fascia)

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INSTALLER GUIDE
ASonnet Plus Anthem & Dream Camden
470mm 492mm 518mm
BSonnet Plus, Anthem & Camden Dream
600mm 636mm
C325mm
D525mm
E350mm
F235mm
G125mm
H475mm
I53mm
J5mm
K550mm
L600mm Max. (Flue tube uncut)
150mm min.
M (Fan box projection) 205mm when sited outside wall
55mm when recessed in outer wall
N285mm
O (Flue tube diameter) 125mm
P (Terminal guard projection) 305mm
Q355mm
R (Recess width) 390mm min.
425mm max.
S (Recess depth) 140mm min
T (Recess height) 560mm min.
580mm max
U (Clearance to wall etc. projecting
forward of appliance firebox)
100mm min.

5. UNPACKING
The pack contains:
1Burner & firebox unit with
attached Rockwool jacket
1Fan box assembly
1Flue duct
1Ceramic fuel effect pack (Not
shown)
1Burner tray trim (Not supplied on
Anthem model)
1Terminal weather shield
1Literature pack
1Smoke match tube
2Rolls aluminium tape
1Nut & olive for 8mm inlet pipe
1Retention kit
(4 wall plugs, 4 eye bolts, 2 tension
adjusters and two cable assemblies).
10 Wall plugs
10 Woodscrews
2Taptite screws (For fan box)
1Rockwool jacket top section
2Cable ties
1Firebox fixing bracket assembly
(2 brackets, 4 “P” clips & 6 self
tapping screws)
1Terminal guard fixing assembly
(4 screws & washers )
(Terminal guard in separate pack)
1Fire front casting
1Front cover casting
2Black machine screws
(For fascia fitting)
Carefully remove the contents. Take special care in handling
the ceramic fireback and the ceramic fuel effect pieces. Check that the listed parts are
present and in good condition.
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INSTALLER GUIDE
Section 2 - Anthem:
1
Fascia pack (Contains three separate
pieces and six magnets)
1Firefront casting
1Bottom front cover casting
Section 2 - Dream:
1Fascia
1Firefront casting
1Bottom front cover casting
Section 2 - Camden:
1
Fascia pack (Contains three separate
pieces and six magnets)
1Firefront
Section 2 - Sonnet Plus:
1
Fascia (Supplied fitted to hotbox)
1Firefront casting
1Bottom front cover casting

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INSTALLER GUIDE

6. PREPARING FOR INSTALLATION
Check ignition spark.
Before attempting to install, it is worth checking that
the piezo electric spark ignition system operates
satisfactorily.
To initiate the spark, depress the control knob and
while keeping it depressed, turn anticlockwise through
approximately 60° to the “PILOT/IGN” position. A
spark should track from the electrode pin to the
thermocouple tip. If there is no spark or incorrect
tracking, check the spark gap between the electrode
wire and thermocouple tip (See figure 7). If the spark
gap is correct, check the ignition wiring.
In the majority of cases, the burner
unit will need to be detached. Detach
the burner unit from the convection
box by removing two screws (See
figure 8).
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INSTALLER GUIDE
Figure 7. Pilot ignition system.
Figure 8. Burner unit removal.

7. WALL PREPARATION
7.1 General.
1. Make sure that the installation will comply with
all the relevant requirements in part 3 of this
manual.
2. Attempt to keep the hole sizes as close to the
minimum dimensions as possible in order to
minimise the sealing required
3. Make sure that the damp course or any electrical
wiring, piping etc. in the wall is not affected when
cutting the installation hole.
4. Any gas supply pipe installed in the wall, floor or
cavity of a cavity wall must be continuous and
enclosed in a factory fitted gas tight sleeve (Ref:
Gas safety (Installation & Use) Regulations 1994 as
amended & Certificate of exemption no.1 1996)
7.2 Brick, stone etc. building. Main case in front
of wall (Figure 9).
1. This installation is for use with a fire surround
or false chimney breast having a minimum depth
of 140mm (5¼in.). The flue length may be cut to
suit the wall thickness. (See prepare flue
assembly section) Combustible material within a
false chimney breast must be at least 75mm from
the fire box.
2. The non-combustible hearth must project at
least 300mm in front of the convection box front
flanges and be at least 625mm wide (Figures 1 &
9).
3. The cavity should be sealed where the flue tube
hole has been cut. We recommend filling fully
across the cavity with Rockwool or equivalent to
at least 100mm around the opening (See figure
13)
7.3 Brick, stone etc. building. Main case
recessed into wall.
(Figure 10)
1. This installation has the fire box recessed into the inner wall of the building. The
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INSTALLER GUIDE
Figure 10. Main case recessed
into wall.
Figure 9. Main case in front of
wall.

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INSTALLER GUIDE
front flanges of the fire box and the appliance
fascia will abut the front surface of the wall.
2. The non-combustible hearth must project at least
345mm in front of the convection box front flanges
and be at least 625mm wide (Figure 1).
The recess in the inner wall for the fire box should
be to the size shown in figure 1. The bottom of this
recess should be at the same level as the top
surface of the hearth.
A lintel may be required above the recess for the
fire box. If in doubt, seek expert building advice
before commencing to cut the recess.
Whenever a lintel is required to support the
recess in the inner leaf of a brick/blockwork
building, follow the method outlined below.
(See figures 11 and 12).
7.4 Lintel installation.
1.The lintel should be either steel (Catnic) or
reinforced precast concrete. It should be
750mm long x 75mm deep x inner leaf
thickness.
2. The opening should be, as near as
possible, centrally below a joint in the
inner leaf block.
3. Cut out the opening for the lintel.
Where cutting through masonry, drill
pilot holes and then cut out the slot
using a mechanical cutter. This will
minimise damage to the surrounding
structure.
4. Insert the lintel. Bed the lintel on
mortar. Don’t dry bed. Slate pin to
ensure the lintel and structure above is
secure and safe
5.
Make the opening below the lintel by removing the masonry and clearing debris. If
the cavity has loose fill (e.g. granular) insulation material, pack the edges of the opening
with Rockwool as you proceed to hold back the insulating material.
6. The wall cavity must not be bridged other than by the flue tube assembly. The fire
box must not project into the cavity between the inner and outer walls by more than
10mm.
Figure 13. Flue pipe insulation
Figure 12.
Figure 11.

See wall preparation for flue tube.
The cavity should be sealed where the opening has been cut. We recommend filling
fully across the cavity with Rockwool or equivalent to at least 100mm all around the
flue tube. Fill at the bottom of the opening to the level of the hearth/fireplace floor. It
may be simplest to back fill the cavity with the insulation material and then cut through
the insulation to the size of the flue box hole.
7.5 Timber frame building. Firebox in front of wall
This installation is for use in timber framed buildings in conjunction with a fire
surround having a minimum
depth of 140mm (5 5/8in).
1. The non-combustible
hearth must project at least
300mm in front of the
convection box flanges and
be at least 625mm wide.
For this type of installation
the hearth must be at least
50mm thick over its total
area (Figure 1). Installation
must be in accordance with
the current edition of
Institute of Gas Engineers
publication IGE/UP/7.
2. The back surface of the
firebox and flue tube
assembly must be separated
from the timber frame by
25mm of non-combustible
material. This can consist of
the usual 13mm plasterboard wall lining plus 12mm of “Superlux” or similar non-
combustible material. The opening should be between studs.
7.6 Wall preparation for flue tube.
1.
The flue must be installed so that it is at right angles to the back panel of the fire all
round the flue circumference. The fire itself should be fitted vertically against a flat
wall. Where this is difficult to achieve due to building inaccuracies care should be
taken to ensure that the back of the fire is not stressed in any way due to distortion of
the assembly when tightening the fixing screws. Where necessary, non-combustible
packing pieces should be used to provide a satisfactory fixing surface.
2.
Before cutting the hole in the wall make sure that the height to the top surface of the
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INSTALLER GUIDE
Figure 14.

finished floor is known. The
height from this surface to the
flue hole centre is shown in
figure 15.
3. If a loose hearth or plinth
is to be used, the height from
its top surface must be used
when determining the flue
height.
4. Place dust sheets on the
floor and over any
furnishings etc.
5. Make sure that the centre
of the flue hole is as shown in
figure 15.
6. Cut the hole for the flue
unit.
7.7 Core drilling.
1. Drill a pilot hole through the wall. Inspect the
hole to ensure that it is in the brickwork and not
in mortar. If it is in mortar, it is advisable to
reposition the hole approximately 25mm away
(Ensuring that all other clearances to firebox are
complied with.). Remember to reposition the
screw fixing holes.
2. Drill the flue hole with a 5in. (127mm) core
drill.
3. Remove any combustible wall cladding
material from the area behind the firebox as
described previously.
7.8 Hammer and chisel cutting.
1.
Mark a 127mm (5in) diameter circle for the flue hole. Chisel out the area marked.
It may be necessary to make good both the internal and external wall faces. To achieve
a neat finish and to make any future removal of the flue unit easier, it is recommended
that a cardboard cylinder is formed around the flue unit and inserted in the hole whilst
making good. Remove the cardboard cylinder after making good.
7.9 Combustible walls (wood, fibreboard, plasterboard etc.).
1.
Building regulations require that the outer surface of the flue tube and terminal must
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INSTALLER GUIDE
Figure 16.
Figure 15.