VALLEY FORGE Caribbean Glow PI27 Guide

INSTALLATION AND USER INSTRUCTIONS
All instructions must be handed to user for safekeeping
Revision A - 10/08
Country(s) of destination - GB/IE
INSET FLUELESS
HIGH EFFICIENCY GAS FIRE
MODEL : PI27
Valley Forge Limited, Ravensdale, Dundalk, Co. Louth, Ireland
Tel: [phone] • Fax: [phone] • International code : 00+353+42
Caribbean Glow

‘Edwardian’ firefront
Please note : Except where otherwise stated, all rights,
including copyright in the text, images and layout of this
booklet is owned by Valley Forge Limited. You are not per-
mitted to copy or adapt any of the content without the
prior written permission of Valley Forge Limited.
The products covered by this booklet are protected under
patent GB2275331B.
©2008 Valley Forge Limited.

INSTALLATION INSTRUCTIONS
IMPORTANT NOTES
This appliance is a high efficiency, flueless catalytic flame effect gas fire. It provides radiant and convected warmth both
efficiently and safely utilising the latest type catalytic converter and burner technology. The appliance does not require
a flue system of any type as the catalytic converter cleans the flue products to provide a complete combustion system,
which is intrinsically safe. It is designed to operate on Natural Gas (see data badge) and is factory set for operation on
the gas type, and at the pressure stated on the appliance data plate.
The appliance incorporates a combustion monitoring system (Oxygen Depletion System). It must not be adjusted or
put out of operation. If replaced then manufacturer’s original parts must be used.
In the UK, it is the LAW that all gas appliances and fittings are installed by a competent person and in accordance with the Gas
Safety (Installation and Use) Regulations 1998, the relevant British Standards for Installation, Codes of Practice and the
Manufacturers' Instructions. In the Republic of Ireland, the appliance must be installed by a competent GI1 regestered installer.
At the time of writing, CORGI registered operatives are the only class of person considered as 'competent' by the HSE
under the above regulations. The installation shall also be carried out in accordance with the following:
Failure to comply with the above could lead to prosecution and deem the manufacturer’s warranty invalid.
This appliance must be installed in accordance with the rules in force and used only in a sufficiently ventilated space.
The appliance is designed to fit various types of situations as described in sections 3.0 and 4.0. The appliance must be
installed in a correctly sized room (see section 3.1), and the correct purpose provided ventilation must be provided (see
section 4.1). It should be noted that heaters create warm air currents. These currents move heat to wall surfaces next
to the heater. Installing the heater next to vinyl or cloth wall coverings or operating the heater where impurities in the
air (such as tobacco smoke, candle smoke etc.) exist, may cause the walls to become discoloured.
This appliance is intended as a secondary source of heat only and should not be used in a room without some form of
background heating present. If the appliance is used in a room as the sole source of heat, then condensation may occur
on colder surfaces within the room.
On first light up of a new appliance, initial curing of high temperature paint and burning off of lubricants may occur for
the first few hours of operation. During this period some smoke may be emitted from the outlet grille, this should be
no cause for concern. Accordingly, the room should be well ventilated with all windows and doors open during this
period. During this period the appliance may cause smoke alarms to sound. If this happens, reset the alarms, but do not
remove the batteries.
Consult ALL instructions before installation and use of this appliance. This appliance is free from any asbestos material.
1
Section Contents Page No.
1.0 Important Notes 1
2.0 Appliance Data 2
3.0 Installation Requirements 2
3.1 Room Sizing 2
4.0 Site Requirements 2
4.1 Ventilation 5
5.0 Unpacking the Appliance 5
5.1 Component Checklist 5
6.0 Appliance Installation 5
6.1 Preparing the Appliance 5
6.2 Gas Supply Routes 6
6.3 Installation Method 1 6
6.4 Installation Method 2 7
6.5 Installation Method 3 8
6.6 Installation Method 4 9
7.0 Final Fitting 9
Section Contents Page No.
7.1 Cable Fixing 9
7.2 Checking the Burner & Spark Gap 10
7.3 Fitting the Fuel Bed (Euphoria models) 10
7.4 Fitting Decorative Hood/Frame 11
8.0 Testing and Commissioning 11
8.1 Operating the Appliance 11
8.2 Setting Pressure 12
8.3 Briefing the Customer 12
9.0 Servicing 12
9.1 Cleaning the Coals 13
9.2 Servicing the Burner Tray 13
9.3 Pilot Assembly 13
9.4 Catalyst 14
9.5 Testing for Firebox Leakage 14
10.0 Troubleshooting Guide 15
User Instructions
•Manufacturers' Instructions.
•For UK: The Building Regulations issued by the Department for Communities and Local Government, the
Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department.
•For UK : Relevant British standards insofar as the relevant areas are not covered by these instructions.
•For Republic of Ireland: Reference should be made to the current edition of IS813.
1.0
©2008 Valley Forge Limited.

APPLIANCE DATA
INSTALLATION REQUIREMENTS
The fire has been designed to be installed in two main applications; either to fit into a suitable opening created
in the inner leaf of an outside wall or false chimney breast/extended fire surround built to conceal the appliance.
The appliance can also be fitted into an unserviceable or inoperative fireplace served by a natural draught flue
but the old flue must be sealed off. It will be necessary to ventilate the old flue to prevent condensation and
dampness forming, however any air vent used to ventilate the old flue must not be sited within 500mm of this
appliance. If the flue can be ventilated to the outside of the building then this is usually the best solution. If in
doubt then advice should be sought from a local building control officer.
The appliance must be installed onto a suitable non-combustible insulating surface at least 12 mm thick cover-
ing the entire base area of the box. The fire must be used with a back panel capable of withstanding 150°C min-
imum. Any combustible materials directly behind the fire frame (or back panel) and close to the cavity box of
the fire must be removed and replaced with non-combustible material such as cement, browning, 'Superlux'
board or equivalent materials.
ROOM SIZING
The room size should be a minimum of 27m3(e.g. 11’ x 11’ x 8’) to allow adequate circulation of air and ensure
the correct operation of the fire. This volume may include adjacent spaces but these spaces must not be sepa-
rated by a door. To calculate a room size in cubic metres (m3) divide the room volume in cubic feet (ft3) by 35.3.
SITE REQUIREMENTS
This appliance may be installed in any room in the home except bathrooms or bedrooms. Installation in living
rooms is common, however other rooms such as kitchens, dining rooms and hallways are permitted, providing
a suitable natural gas supply is available, and rooms sizing and ventilation requirements are strictly adhered to
(see sections 3.1 and 4.1).
The appliance is designed to be versatile, and as such will operate correctly when exposed to normal gentle
draughts experienced within the home. It is not recommended, however that the appliance be installed in areas
where it is likely to be exposed to persistent strong draughts, that may be generated by outside doors or win-
dows, air vents etc. It is recommended that the appliance should not be installed within 1 metre of any air vent.
Gas Group
Inlet Pressure (± 2.0mbar)
Regulator Pressure
Max Energy Input (Gross)
Max Energy Input (Net)
Max Gas Rate
Min Energy Input (Gross)
Min Energy Input (Net)
Min Energy Input (Gross)
Min Energy Input (Net)
Burner Pressures -
High Cold (±1.5 mbar).
High Hot (±1.5 mbar).
Low Cold (± 0.75 mbar).
Low Hot (± 0.75 mbar).
Flow restrictor orifice
Injector
Oxypilot (SIT/Bray)
Gas control
Gas Inlet restrictor elbow
Ignition
Spark Gap (± 1.0mm)
G20 Natural Gas CAT I2H
20 mbar
N/A
2.3 kW
2.07 kW
0.23 m3/h
1.3 kW
1.17 kW
166 W
150 W
18.0 mbar
18.2 mbar
4.5 mbar
4.6 mbar
1.16 mm
N/A
9110
BM733/NGC 6802-D
8mm
Piezo spark
4.0 mm
2.0
3.0
3.1
4.0
2
©2008 Valley Forge Limited.

SITE REQUIREMENTS (continued)
Basic opening sizes (all dimensions in mm)
The basic opening dimensions for the appliance are as follows;
The opening must be within these sizes in order to accommodate
the full depth of the fire box in non-combustible applications.
Applications involving combustible materials e.g. timber battens in
false chimney breasts, must use appropriate clearances and insula-
tion methods as described in the relevant section of these instruc-
tions. Opening depth
‘c’
includes any plaster, cement or infill/back
panels that form part of the installation.
Consideration for cable fixings, any hearth that may be required etc.
should be made in addition to the basic sizes given in table 1.
•Cable fixings at rear - allow an extra 20mm depth.
•Hearth to be installed - allow the height of the hearth (minimum 50mm).
The appliance must be sited on a solid base (indicated in figure 1).
This base may be combustible (i.e. laminate or wooden flooring) but
must not be carpet or fabric of any kind. If the room in which the
appliance is to be installed is carpeted or has a fabric floor covering
then a small solid hearth will be required, meeting the dimensions
specified in table 1 and illustrated in figure 2.
In all installations, the wall or back panel of the installation must be
flat, non-combustible and meet the dimensions specified in table 1
and illustrated in figure 2.
The appliance may be installed as a ‘hole in the wall’ type installation, however a small hearth or ledge must be
provided to support the base of the appliance and decorative facia. In this situation the thickness of the hearth
or ledge may be as desired, but it must have the strength to support the weight of the appliance and the facia.
4.0
‘a’
‘b’
‘c’
‘e’
‘d’
‘f’
‘i’
‘j’
‘k’
Dimension:
‘a’
minimum
‘a’
maximum
‘b’
minimum
‘b’
maximum
‘c’
minimum
‘c’
maximum
‘d’
minimum
‘e’ minimum
‘f’
minimum
‘g’ minimum
‘g’ maximum
‘h’
minimum
‘h’ maximum
‘i’ minimum
‘i’ maximum
‘j’ minimum
‘j’
maximum
‘k’ minimum
‘k’ maximum
Figure 1
Figure 2
Base area
This area to be
flat and non-
combustible
Hearth
(if required)
‘h’
‘g’
Figure 3
3
560
610
410
470
105
None
50
560
140
560
As desired
655
As desired
560
610
410
470
105
None
Table 1
©2008 Valley Forge Limited.

SITE REQUIREMENTS (continued)
Clearances to non-combustibles
Non combustible surfaces are defined as brick, metal, marble, concrete etc. and also a number of man-made
materials impervious to flame. If in doubt refer to the material manufacturer for further information before pro-
ceeding with installation.
The wall/back panel for the opening must always be non-combustible. Bare plasterboard must be protected by
non-combustible plaster or replaced with non-combustible material (e.g. Superlux board). Any gap between wall
boards and the wall must be filled using glass fibre insulation, silicone mastic or similar material to prevent heat
ingress.
Any type of fire surround used with this appliance must be adequately sealed to the wall and floor to prevent
excess draughts around the back of the fire. The temperature rating of any surround used must be 150°C mini-
mum.
Clearances to the sides of the appliance are 100mm (4”). Clearance to the front of the appliance is 500mm (20”).
The sides and back of the appliance may be installed directly onto a non-combustible surfaces.
A non combustible shelf of any depth may be positioned above the appliance provided it is no closer than 200
mm from the top of the appliance glass panel and the wall above the appliance is non combustible. The shelf
itself and any articles placed on it must also be tolerant of high temperatures.
Clearances to combustible materials
Combustible materials are defined as wood, fabrics, or other materials likely to combust if exposed to flame.
Generally, any material, which is likely to discolour, melt or misshape when exposed to moderate heat, should
be considered as a combustible material or surface.
Clearance to the sides of the appliance facia are 100mm (4”) but curtains, drapes and other fabrics are not per-
mitted within a distance of 500mm (20”) of the appliance sides. No such materials are permitted directly above
the appliance regardless of distance.
The minimum clearance to the ceiling above the appliance is 800mm (31.5”) measured from the top of the appli-
ance glass panel.
Combustible materials should not be positioned directly in front of the appliance within a distance of one metre.
A combustible shelf may be fixed to the wall above the fire, providing that it complies with the dimensions given
below.
The shelf depth may be greater but the height must also be increased accordingly. An increase in height of 25
mm is required for every 12.5 mm of additional shelf depth. For shelves that are too low protective devices can
be used such as metal heat deflectors, but it must be assured that the shelf does not reach an unacceptable tem-
perature before relying on such a solution.
Under no circumstances should any electrical equipment e.g. plasma screen TV sets etc. be positioned on the
wall above the appliance.
Clearance to the sides and rear of the firebox are a 75mm (3“) air-gap. Clearance to the top of the firebox is a
100mm (4”) air-gap.
It should be established that any mirrors or picture frames etc. to be positioned on the wall above the appliance
are able to withstand prolonged exposure to moderate heat and moisture before proceeding with their installa-
tion.
If the appliance is to be mounted on a dry lined wall or a timber framed construction wall then the integrity and
ability of the wall to carry the weight of the appliance must be confirmed. It is important in these circumstances
that any vapour control barrier is not damaged, and that any structural members of the house frame are not dam-
aged - refer to section 6.5.
4.0
Maximum depth of shelf Minimum distance from hearth to underside of shelf
150mm 950 mm
100mm 850 mm
4
©2008 Valley Forge Limited.

VENTILATION
For UK: A minimum of 100cm2purpose provided ventilation is required for this appliance. This may be achieved
either with one vent 100cm2at a high or low position in the room, or split ventilation i.e. 50cm2be installed at
high level and 50cm2be installed at low level within the room. An openable window or equivalent is also
required. To reduce the possibility of draughts, road noise or insects entering the room via the air vent, we rec-
ommend the use of “Black Hole”, “Vortex” or “Centurion” type vents featuring internal baffles. The requirements
of any other gas, oil or solid fuel appliances operating in the same room or space must be taken into consider-
ation when assessing ventilation.
Any ventilation fitted must comply with BS 5871 part 2 and BS5871 part 4.
Ventilation fitted under, or within immediate vicinity of the appliance must not be used as it may adversely effect
performance of the ODS system.
For Republic of Ireland: Permanent openings with a minimum open area of 120cm2 are required. The total
requirement shall be equally divided between high and low level openings on the same wall separated by a miu-
mum vertical distance of 1.6 metres (63”). Refer to the current edition of IS813 and any relevant rules in force.
For UK and Republic of Ireland: The appliance shall not be installed within one metre of any existing air vent,
and any new air vent shall not be installed within one metre of the appliance.
UNPACKING THE APPLIANCE
Lift off the remaining packaging components. Check that the components supplied correlate with the compo-
nent checklist. Please dispose of all the packaging materials at your local recycling centre.
COMPONENT CHECKLIST
APPLIANCE INSTALLATION
Note: Ensure that the gas supply is isolated before commencing installation of the appliance.
The fireplace opening and environment must be in compliance with specifications laid down in the appropriate
sections of these instructions.
PREPARING THE APPLIANCE
Remove the appliance from its carton as described previously and stand on a dustsheet. Remove the hood and
glass panel and place safely to one side.
Knock out holes are provided in the rear and sides of the firebox for use where concealed pipework is required.
Note: Knock out holes are also provided in the sides of the inner firebox if a side-entry pipe routing is required,
but it is essential to seal these holes with grommets. Knock out the appropriate hole in the cavity box with a
sharp tap from a hammer and fit the rubber grommet supplied. A small incision can now be made in the rub-
ber to slip snugly around the outside of the supply pipe and sleeving.
Warning : Do not install or use the appliance without this seal in place.
5.0
5.1
6.0
6.1
4.1
QUANTITY DESCRIPTION
1 Firebox and burner assembly
1 Set of manufacturer’s instructions
1 Cast firefront and ashpan
1 Rubber grommet
1 Cable fixing kit
1 Screw pack including wallplugs
5
©2008 Valley Forge Limited.

GAS SUPPLY ROUTES
Following preparation of the fixing method, the concealed gas supply (if required), can now be installed.
When the opening is ready for installation the gas supply can be routed. If the gas pipe has been sleeved the
ends of the sleeving must be sealed. The end of the 8mm pipe should be temporarily sealed to prevent the
ingress of debris during fixing.
An inlet restrictor elbow is supplied as part of the appliance.
All installation pipework must be in accordance with the current edition of BS 6891, and for timber framed
dwellings, the current edition of IGE/UP/7.
In order to avoid unnecessary pressure drops, no more than 1.5m of 8mm diameter pipe must be used. If a con-
cealed gas connection is to be made, the supply pipe should always be sleeved through walls and floors using
the shortest possible route. For concealed supply pipe routing, pipes must (where possible) be vertical and pro-
viding there is sufficient wall thickness available, they should be placed in pipe chases. Horizontal pipe runs
should be avoided. Prior to chasing a solid wall, an inspection should be made to note the proximity of any
cables/sockets outlets which may already be buried. Pipes must be secured using suitable clips and protected
against corrosion. Ideally factory finished protected pipework and fittings should be used. Joints should be kept
to a minimum and compression fittings must not be used. The pipework installation must be tested for tightness
before any protection is applied and/or the pipework and fittings are buried.
INSTALLATION METHOD 1 (against a non-combustible inside wall)
This method requires no modifications to the internal wall of a property and is achieved by using either a
surround with extended rebate or a false chimney breast of minimum 105mm internal depth. If cable fixings are
to be used then the minimum depth should be 125mm.
A false chimney breast should be installed, taking into account any guidance given in the section on timber
framed buildings as far as insulation and clearances are concerned. When the false chimney breast is construct-
ed from combustible materials the firebox must be separated from any combustible materials by a minimum
75mm air gap at the sides and rear and 100mm air gap above the firebox. Alternatively the firebox may be insu-
lated with 75mm of fibre glass wool or rock wool to the sides, rear and 100 mm to the top.
6.2
6.3
Figure 4
False chimney breast
Non combustible back panel
Non combustible inside wall of building
Outer leaf of building
6
©2008 Valley Forge Limited.

INSTALLATION METHOD 2 (recessing into a non-combustible wall)
This method allows for installation of the appliance with the rear of the firebox recessed into the inner leaf of a
cavity wall. This should enable a standard fire surround and back panel/hearth set to be fitted to the wall with
the fire presented naturally in a flush fitted manner. The structural integrity of the wall must be maintained.
Check the cavity insulation type (if applicable). If cavity insulation is of a loose fill variety, take precautions to pre-
vent excessive loss of material when the inner leaf is opened up by packing the cavity firmly with a minimum
50mm of rockwool or glass fibre. This will hold back any loose material now or in the future.
To maintain the structural integrity of the wall it is recommended that a suitable lintel is fitted. It is sometimes
possible to install this appliance without a lintel, depending on the type of wall. The guidance of a qualified pro-
fessional or local building control officer is essential to confirm this.
Mark out the area of the proposed fireplace opening on the wall. Obtain a suitable concrete or steel lintel from
a builder's merchant. Drill four holes at the corners of the lintel position and squarely over the fireplace open-
ing, and if possible centrally under a block joint . Clear out the block work in the area and insert the lintel by saw,
or stitch drill and chisel. Do not dry bed the lintel - always bed on mortar and securely slate pin. Clear out the
block work from below the lintel to form the opening for the firebox to be inserted.
The top of the exposed area of cavity must be sealed against the ingress of moisture dripping from above. The
best way to do this is a cavity tray but an easier and quicker method is to affix a 'Supalux' or equivalent board
into the cavity. Slope the board towards the outside wall and support with screws, cement, 'Unibond' or silicone
mastic etc. This will guide all moisture, harmlessly, to the outside wall. The exposed sides of the cavity must be
packed with a suitable depth (minimum 50mm) of glass fibre or rock wool to prevent draughts and heat loss,
even if no loose fill material is present. It is good practice to insulate the rear of the fire from the cavity to pre-
vent heat loss and condensation.
The hearth may now be put in place (If fitted). Again this should not bridge the cavity where it projects into
the wall space. Finally install the fireplace or fire surround and back panel/marble to its finished location.
6.4
Figure 5
Outer leaf of building
Non combustible back panel
Non combustible inside wall of building
Lintel
7
Figure 6
©2008 Valley Forge Limited.

INSTALLATION METHOD 3 (timber framed buildings)
Where removal of any part of a timber frame is undertaken the structural integrity of the wall must be retained.
The advice of your local building control officer should be sought. If the property is under any NHBC warranty
it is also advised that their advice on this kind of modification is sought.
Either of the two preceding installation methods may be adapted for timber framed buildings, providing extra
care is taken in ensuring combustible materials are adequately protected from the effects of heat.
The appliance must be installed in accordance with the British Gas documents DM2 and DM3 or the Institute
of Gas Engineers published procedure document IGE/UP/7.
Special attention must be paid to the location of studwork frames of the inner leaf and the appliance positioned
accordingly. Wires and pipes that run within the wall must also be taken into account.
Installation as per method 1 (against inner wall)
When using this
method of installation
the following amend-
ments should be
incorporated. A
75mm air gap or
75mm of insulation
(e.g. rockwool) must
be provided between
combustible materials
and the sides and rear
of the cavity box. A
100 mm air gap or
100mm of insulation
(e.g. rockwool) must
be provided to the
top of the cavity box.
It is also a good idea
to enable as much air-
flow as possible, into
and out of the area behind the fire without excessive heat loss from the room when the fire is off.
Installation as per method 2 (recessing into a wall)
When setting the
appliance into the
wall find a suitable
position between
frame timbers and
open up the hole.
Secure back the
damp proof mem-
brane to prevent
ingress of damp.
Again 50mm insula-
tion plus a 12mm
thick fire retardant
board, 'Superlux' or
equivalent, must be
provided between
combustible materials
and the sides and rear
of the cavity box. 100 mm of insulation plus a 12 mm thick fire retardant board, 'Superlux' or equivalent, must
be provided to the top of the cavity box. The exposed cavity should be sealed off using non-combustible board,
('Supalux' or equivalent), made into a 4-sided box. It is also good practice to further insulate the cavity with a
50mm layer of Rockwool outside the Superlux box. Note that the appliance should not be allowed to bridge the
cavity in this installation method. It is also a good idea to enable as much airflow as possible, into and out of the
area behind the fire without causing excessive heat loss from the room when the fire is off.
6.5
8
Figure 7
Outer leaf of building
Non combustible back panel
Combustible inside
wall of building
Rockwool insulation 75mm sides
and rear, 100mm top
False chimney breast
50mm of Rockwool to insulate cavity
Superlux Box, 12mm thick, External dims;
Height 677, Width 529mm, Depth 167mm.
Rockwool insulation, 50mm sides
and rear, 100mm top.
Combustible inside
wall of building
Figure 8
©2008 Valley Forge Limited.

INSTALLATION METHOD 4
This method allows for a ‘hole in the wall’ installation
of the appliance with the rear part recessed into the
inner leaf of a cavity wall. The structural integrity of the
wall must be maintained. The wall must be non-com-
bustible.
Refer to section 6.4 (recessing into a non-combustible
wall).
If the appliance is to be wall mounted then the entire
base of the appliance must be supported by a non-
combustible shelf. The dimensions of such a shelf are
given in section 4.0 (site requirements).
FINAL FITTING
If not previously carried out, insert the firebox into the opening. If the appliance is to be screw fixed to the back
panel/wall or inside of the opening then suitable locations for such fixings should be established, and a suitable
number and type of such fixings should be established to ensure the appliance is securely fixed.
There are no purpose provided screw fixing points provided on the firebox as the location of these points will
vary from installation to installation, depending on the strength of the surrounding materials and the various sizes
of opening that the appliance may be required to fit into. A cable fixing kit, however, is provided and should be
used wherever possible as the default fixing method.
Carefully insert the firebox into the opening and guide the gas pipe through the sealing grommet into its final
routing position and fit the restrictor inlet elbow supplied to the gas pipe. Secure the firebox by inserting screws
in the previously prepared locations (if screw fixing) or refer to the following section if cable fixing.
CABLE FIXING
When using this method for fixing, the minimum depth of the opening must be increased from 105 mm to 125
mm. This is to allow for the eyebolts and a space for the cable tensioning. Remove the appliance glass panel by
removal of the four retaining screws. Remove the burner unit -
refer to section 9.2.
Drill four holes to a depth of 42mm, using a 8mm drill bit, in
the positions shown in figure 11 and fit the wallplugs. If the
fireplace does not allow for the exact layout shown, the eye-
bolts should be fixed to give as similar a configuration as pos-
sible. Thread both tensioning cables through the holes in the
protruding tabs on the rear of the firebox then through the eye-
lets and back through the lower holes in the firebox.
Push the firebox back into the fireplace, centralise, pull the
loose cables through the holes and into the bottom of the cav-
ity box. Thread the cable tensioners onto the cables with the
nuts screwed down close to the tensioner head. Slide the
screwed nipple onto the cable, pull cable taut and tighten nip-
ple. Adjust tensioner using a suitable spanner to pull the appliance back into position, to allow an even pull
around the fireplace opening. Visually inspect and repeat if necessary to achieve a good fit.
Note: Surplus cable MUST NOT be cut off, as this will prevent proper re-installation after servicing. Coil up
the surplus cable and tuck the coils out of the way.
6.6
7.0
9
Figure 9
7.1
A
B
C
A. 350 mm
B. 330 mm
C. 70 mm
Dimension ‘A’
can be +/-10mm
Figure 11
©2008 Valley Forge Limited.

CHECKING THE BURNER AND SPARK GAP
Contemporary models : There are no imitation fuel bed components to install. The appliance features a ribbon
burner which is designed to produce a continuous band of flame over it’s length. The burner should be visual-
ly inspected to ensure it is free from any foreign matter.
If it is necessary to clean or dust off the burner then (if fitted) the glass
door should be removed by removal of the four retaining screws. Re-fit
the glass door after cleaning or inspection, ensuring a good seal.
Coal effect models : The burner should be visually inspected to ensure
it is free from any foreign matter. If it is necessary to clean or dust off
the burner then (if fitted) the glass door should be removed by removal
of the four retaining screws. Fit the fuel bed as described in section 7.3.
All models : The gap between the spark electrode and the pilot should
be 3 - 5mm to produce a good spark. There should be no need to adjust this. If under any circumstances the
piezo electric spark fails, the pilot cannot be lit manually.
FITTING THE FUEL BED (Coal effect models only)
The appliance features a coal style fuel
effect.
1. Place the rear coal strip onto the shelf
behind the burner as shown in figure 14.
Ensure that the four protruding screw heads
engage the hollow areas on the underside of
the piece.
2. Position the front coal piece onto the front
of the burner as shown in figure 15.
Re-fit the glass panel using 4 M6 screws.
The fire is designed to operate correctly with
the supplied components according to the
instructions. Never add coals. Never put
combustible or non-combustible materials,
rubbish or other matter into the fire.
7.3
10
7.2
Figure 12 Spark gap
Figure 13
Figure 14
Figure 15
©2008 Valley Forge Limited.

FITTING THE DECORATIVE FRAME, FRONT AND HOOD
The appliance is supplied with a decorative frame
and hood. Attach the hood using two M6 screws as
shown in figure 16.
Remove all protective packaging from the frame. The
frame is retained by four magnets on the front face of
the firebox as shown in figure 17. Position the frame
onto the magnets. Position the cast rirefront.
TESTING AND
COMMISSIONING
Turn on and test the gas supply up to the fire for any
leaks, in accordance with the current edition of
BS6891.
OPERATING THE APPLIANCE
The control knob is supplied in the loose parts pack.
Fit the control knob onto the valve spindle as shown
in figure 18.
The pilot is visible behind the left hand side of the
burner. Push in and turn the control knob to the
SPARK position, and hold there for a few seconds.
Continue turning anti-clockwise through the spark
click to the PILOT light position, ensuring the pilot has
lit. If not, return the knob clockwise, and repeat.
When the pilot lights after the spark, keep the knob
depressed for approximately ten seconds. Now
release the knob and the pilot should stay alight. If the
pilot is extinguished during use, wait three minutes
before repeating the ignition procedure.
To achieve the HIGH setting, push the control knob
in slightly and continue turning anti-clockwise to the
high position. The main burner should light after a
few seconds. To decrease the setting to low, turn the
control knob clockwise to the LOW setting.
To turn to the PILOT position from the HIGH or LOW positions, press the control knob in, and return to the pilot
position and release. To turn the fire off, keep the knob pressed in, return to the OFF position and release.
11
7.4
8.0
Figure 16
8.1
Figure 17
Figure 18
©2008 Valley Forge Limited.

SETTING PRESSURE
The pressure test point is located on the left hand side of the
appliance, on the main burner pipe, next to the brass restric-
tor/connector. Release the setting pressure test point screw
(shown in figure 19), and attach a pressure gauge.
Light the fire on the HIGH setting.
To commission the appliance, the burner pressure must be in
accordance with the figures stated in section 2.0 of these
instructions. The fire is factory set to achieve these pressures
and any significant variation could indicate a supply problem.
If the pressure is too high, the gas supply meter may be set
incorrectly. This should be checked with the fire running and
if necessary reset by the gas supplier.
If the burner pressure is too low, then check the inlet pressure with the appliance running. If this is less than the
inlet pressure stated in section 2.0 of these instructions it will need to be reset by the gas supplier. If the setting
pressure is too low, but the meter pressure is acceptable, then a problem in the supply pipework is to be sus-
pected.
Upon satisfactory checking of the burner pressure, turn the fire off, disconnect the pressure gauge and refit the
test point screw. Light the fire and check for gas soundness.
In the event that the burner pressure is not in accordance with the figures stated in the data section of these
instructions, the appliance must not be commissioned, and the manufacturer should be contacted for guidance.
BRIEFING THE CUSTOMER
All instructions must be handed to the user for safekeeping. Show the customer how to light and control the fire.
After commissioning the appliance, the customer should be instructed on the safe use of the appliance and the
need for regular servicing. Frequency of service depends on usage, but MUST be carried out at least once annu-
ally. Advise that cleaning of the fire maybe achieved when the fire is cold using a damp cloth and mild detergent
on most surfaces. Advise that the fire will emit a "newness" smell for a time after initial commissioning and that
extra ventilation may be needed during this time. Recommend that a guard be used for the protection of young
children, pets, the elderly and the infirm.
SERVICING
Isolate the fire from the gas supply. Ensure that the fire is fully cold before attempting service. A suggested pro-
cedure for servicing is detailed below.
1. Lay out the dustsheet and tools.
2. Remove the hood (two M6 screws) and front and frame/facia.
3. Remove the glass door assembly (four M6 screws) and clean carefully.
4. Carefully remove the ceramic components (where supplied).
5. Inspect the catalyst and clean if necessary with a soft brush.
6. Disconnect the gas supply and remove the four screws retaining the burner (two in the burner legs
and two in the rear of the firebox).
7. Lift away burner assembly.
8. Strip off the burner pipes and clean thoroughly.
9. Clean the in-line restrictor, pilot assembly and the burner tube. Do not attempt to remove the pilot
injector as this can cause damage.
10. Re-assemble and re-fit the burner tray.
11. Turn on the gas supply and leak test. Check pilot and burner for good ignition.
12. If applicable, refit the ceramics as per these installation instructions.
13. Refit the glass door assembly, ensuring a good seal.
14. Refit the hood, front and frame/facia.
15. Check any purpose provided ventilation is un-obstructed.
16. Light the fire and check setting pressures.
17. Carry out combustion check as per section 9.4.
17. Check safe operation of the appliance.
For specific servicing instructions, see relevant sections.
12
8.2
8.3
9.0
Figure 19
©2008 Valley Forge Limited.

CLEANING THE CERAMICS (where applicable)
Remove the fire front and place to one side. Remove the hood. Remove the glass door assembly. Remove the
ceramic components. Gently clean in the open air with a soft brush. Be careful not to create dust from the
ceramics. Where necessary replace damaged components with genuine spares. Seal scrap ceramic compo-
nents in plastic bags and dispose at proper refuse sites as directed. If using a vacuum cleaner a HEPA filtering
system is recommended.
Re-fit the ceramics by referring to the relevant section of these instructions. Refit the glass door assembly ensur-
ing a good seal. Refit the hood.
SERVICING THE BURNER TRAY AND GAS ASSEMBLY
Firstly, remove the hood and front fret/facia, the
glass panel, data plate and disconnect the gas con-
nection at the isolator elbow. Remove the burner
tray by removing the four securing screws shown
in figure 20.
Remove the pilot and main burner pipes and blow
through to dislodge any debris. Now remove the
restrictor elbow and blow through to make sure it
is entirely clear. Unclip the pilot lint gauze and
clean with a soft brush.
Clean the exterior of the pilot assembly with a soft
brush and blow through the flame ports on the
pilot head. Check the aeration holes are free from
lint or dirt. The pilot assembly can be removed if required by disconnecting the electrode HT lead, gas pipe and
unscrewing the mounting screws and lifting away.
The pilot assembly is a non-serviceable item and should not be taken apart. Aeration holes must be absolutely
clear internally for proper operation. NEVER MODIFY OR BEND THE THERMOCOUPLE TO MAKE THE PILOT
STAY ALIGHT. Modifications are dangerous and can have serious unseen effects on safety. If the pilot will not
stay lit there is a problem with dirt, the gas supply to it, or the thermocouple needs replacement.
The gas valve is a non-serviceable item. If this needs replacement, remove M4 securing screw holding the valve
in place, remove all pipe unions, electrode lead, thermocouple lead and then the complete valve. Replacement
must be original manufacturers parts. Re-assembly is the reverse of removal. Ensure setting pressures are as stat-
ed in Section 2; Appliance Data.
Re-assembly in the reverse of removal.
PILOT ASSEMBLY
Clean the pilot assembly with a soft brush and blow through. Check the aeration holes are free of any dirt or
lint. Clean thoroughly internally, the connection can be removed from the base of the pilot unit using two span-
ners to make cleaning easier. Do not damage or try to dismantle the pilot injector.
The unit is factory set and the only check necessary is to ensure the spark gap is correct. See specifications for
gas setting.
NEVER MODIFY OR BEND THE THERMOCOUPLE TO MAKE THE PILOT STAY ALIGHT. If the pilot will not stay
lit there is a problem with dirt, the gas supply, or the thermocouple needs replacement. Modifications are dan-
gerous and can have a serious unseen effect on safety and therefore MUST not be done. Replacements must be
original manufacturers parts. Re-assemble in the reverse of removal. Ensure setting pressures are as stated in
Section 2; Appliance Data.
9.2
9.1
9.3
Figure 20
13 ©2008 Valley Forge Limited.

CATALYST
It is recommended that the catalytic converter is inspected for signs of damage and dirt during routine servicing
procedures. The expected life of the catalyst is in excess of 11,000 hours (10 years of normal use). After this time
the catalytic converter should be replaced.
If there are any deposits of dirt or soot on the catalyst they should be cleaned with a soft brush and a vacuum
cleaner. If removed for cleaning ensure the seals are in good condition before replacing the catalytic converter.
New seals will usually be required.
The performance of the catalyst may be checked using an analyser as follows. Any analyser used should con-
form to BS7927 : 1998 + A1 : 1999 or BS EN 50379-3.
Important: The temperature of the gases emmited by the catalytic converter is in excess of 400 oC. Measuring
gas of this temperature may damage some types of gas analysers. If in doubt consult the equipment manufac-
turer.
Position gas sample probe directly in front of the catalyst underneath the hood, in the centre of the upper fire-
box. Ignite the fire as per the operating instructions, and run at high setting for 15 minutes. Record the carbon
dioxide (CO2) concentration and then the carbon monoxide (CO) concentration as displayed by the analyser -
also noting the units in which the values are expressed.
Most analysers display carbon dioxide (CO2) concentrations in percentage (%) terms and carbon monoxide
concentration in parts per million (ppm) terms.
In order to calculate the combustion ratio for the appliance (CO/CO2) it is first necessary to express both gas
concentrations in terms of percentage. To convert from parts per million (ppm) to a percentage (%) divide the
ppm figure by 10,000. Examples : 35ppm = 0.0035%, 15ppm = 0.0015%, 5ppm = 0.0005%.
Now divide the concentration of carbon monoxide (CO) expressed in percent by the concentration of carbon
dioxide (CO2) to obtain the appliance combustion ratio.
The combustion ratio of the gasses emitted by the catalytic convertor should not exceed 0.0015.
If replacing the catalytic converter, remove the
hood, front fret/facia and the grille (as shown in fig-
ure 21). The catalytic converter retaining clamp is
secured with 4 nuts and slip proof washers, locat-
ed on the inside of the firebox, at the top, remove
these nuts and the clamp can be removed.
Withdraw the clamp, followed by the catalytic
converter and its seals from the firebox and dis-
card.
Refit a new catalytic converter and seal in reverse
order.
TESTING FOR FIREBOX LEAKAGE
Appliances that are several years old or have been extensively dismantled should be checked for soundness. It
is important that all the products of combustion pass through the catalytic converter at the top of the firebox
before leaving the appliance.
The firebox is heated by lighting for a few minutes to provide a flow through the firebox. The burner is then
shut off and a smoke pellet or match introduced at the base of the fire underneath the burner tray. Large
quantities of smoke will emerge from the top of the appliance, but none should emerge from the joints or gas-
ket faces, especially around the door.
It is important to note that the appliance can never be expected to be 100% smoke tight and small quantities
of smoke may be seen in corners of joints and gasket faces etc without affecting safety when the fire is in
operation.
9.4
9.5
CO (%)
CO2 (%) = ratio
Figure 21
14 ©2008 Valley Forge Limited.

TROUBLESHOOTING GUIDE
Fire sparks but pilot does not light No gas to fire - check isolators are open.
Pipe work blockage or kink - rectify.
Air not fully purged - re-purge supply or wait longer.
Spark earthing to metal work - check gap is correct.
Blocked pilot - check and replace where necessary.
Pilot lights but then goes out Severe restriction in gas supply - clear obstruction.
Faulty thermocouple - replace pilot unit.
Blocked pilot - replace.
Blocked lint gauze - clean.
Hold control knob in for longer.
Check the control knob does not foul on the data plate.
If the pilot will not stay lit there is a problem with dirt, the gas sup-
ply, or the thermocouple is in need of replacement. Modifications
are dangerous and can have a serious unseen effect on safety.
NEVER MODIFY OR BEND THE THERMOCOUPLE TO MAKE THE
PILOT STAY ALIGHT.
Fire does not spark at pilot Electrode lead detached - refit.
Spark gap too large or small - reset correctly.
Faulty piezo unit - replace gas valve.
Debris shorting out electrode - clean.
Spark shorting to metalwork under tray - realign electrode lead.
Fire runs for a time and then cuts off Check pilot has extinguished.
Ensure room sizing and ventilation are adequate (See Section 3.1
and 4.1)
Loose or faulty thermocouple - rectify.
Blocked pilot - replace.
Dirt or lint in pilot aeration hole or on the lint gauze - clean thor-
oughly.
If the pilot will not stay lit there is a problem with dirt, the gas supply,
or the thermocouple needs replacement. Modifications are danger-
ous and can have a serious unseen effect on safety.
NEVER MODIFY OR BEND THE THERMOCOUPLE TO MAKE THE
PILOT STAY ALIGHT.
Pilot flame shrinks when fire is on high Poor gas flow to fire - check pressure with fire on high.
If pressure is low - remove any restriction in pipework or valve.
Check all isolators are adequately sized and fully open.
Check meter pressure is adequate.
If the pilot will not stay lit there is a problem with dirt, the gas sup-
ply, or the thermocouple needs replacement. Modifications are
dangerous and can have a serious unseen effect on safety.
NEVER MODIFY OR BEND THE THERMOCOUPLE TO MAKE THE
PILOT STAY ALIGHT.
Fire smells when first lit or in use Newness smell from brand new appliance.
Leakage occurring - Carry out leakage test and rectify any problems.
Low temperature sealants or combustible materials used in incor-
rect positions.
10.0
15 ©2008 Valley Forge Limited.

USER INSTRUCTIONS
Section Contents Page No
1.0 Important Notes 1
2.0 Fire Front 2
3.0 Clearances to Combustibles 2
4.0 Ventilation and Room Size 3
5.0 Operating Instructions 3
6.0 Combustion Monitoring System 3
7.0 Fitting the Fuel Bed 4
8.0 Cleaning 4
9.0 Servicing 4
10.0 List of Replacement Parts 4
IMPORTANT NOTES
The installation and Servicing of this fire MUST only be carried out by a competent person (such as a CORGI
registered fitter) in accordance with the Gas Safety (Installation and Use) Regulations 1998, the relevant British
Standards, Codes of Practice, the Building Regulations and the manufacturer's instructions.
Failure to comply with the above could lead to prosecution and invalidate the appliance warranty.
Keep a note of the installer's name and address, CORGI registration number, the original purchase receipt and
the date of installation (see section 9.0 of these instructions). Failure to produce this information may invalidate
the warranty.
The appliance should be serviced regularly to ensure continued safe operation. See the servicing section for fur-
ther reference.
Parts of this appliance become naturally hot during use. It is recommended that a suitable fireguard conform-
ing to BS 8423 is used, especially where young children, pets, the elderly or infirm are concerned. The manu-
facturer of this appliance considers all surfaces as working surfaces with the exception of the control knob and
control panel.
Combustible items, such as flooring and furniture and soft wall coverings (such as blown vinyl or embossed
paper), low temperature surrounds etc may discolour if fitted too close to the fire. See relevant section for fur-
ther details on clearances to combustibles. No combustible materials or flooring should protrude onto the
hearth (if fitted).
This appliance incorporates a combustion monitoring system (ODS).
DO NOT burn any foreign material on this fire. Under no circumstances shall the appliance be used if the glass
front door or panel has been removed, damaged or is open. Do not place any objects on top of the appliance.
The integral catalysts should be checked by the installer upon servicing to ensure there are no defects or obstruc-
tions that may prevent the satisfactory flow of combustion products. The expected life of the catalyst is in excess
of 11,000 hours (10 years of normal use). After this time the catalyst should be replaced.
This appliance is only suitable for the gas type for which it is supplied.
WARNING: Due to the nature of this product the area around the top of the appliance (i.e. the grille) gets very
hot. Care should be taken when operating the appliance.
1.0
1©2008 Valley Forge Limited.

FIREFRONT
This fire is supplied with a particular style of fire front. Use of the fire front will ensure an adequate airflow under
the firebox for the correct functioning of this appliance. Compliance with safety standards cannot be guaranteed
when another style of front is used.
CLEARANCES TO COMBUSTIBLES
Clearances to non-combustibles
Non combustible surfaces are defined as brick, metal, marble, concrete etc. and also a number of man-made
materials impervious to flame. If in doubt refer to the material manufacturer for further information before pro-
ceeding with installation.
The wall/back panel for the opening must always be non-combustible. Bare plasterboard must be protected by
non-combustible plaster or replaced with non-combustible material (e.g. Superlux board). Any gap between wall
boards and the wall must be filled using glass fibre insulation, silicone mastic or similar material to prevent heat
ingress.
Any type of fire surround used with this appliance must be adequately sealed to the wall and floor to prevent
excess draughts from around the back of the fire. The temperature rating of any surround used must be 150°C
minimum.
Clearances to the sides of the appliance are 100mm (4”). Clearance to the front of the appliance is 500mm (20”).
The sides and back of the appliance may be installed directly onto a non-combustible surfaces.
A non combustible shelf of any depth may be positioned above the appliance provided it is no closer than 200
mm from the top of the appliance glass panel and the wall above the appliance is non combustible. The shelf
itself and any articles placed on it must also be tolerant of high temperatures.
Clearances to combustible materials
Combustible materials are defined as wood, fabrics, or other materials likely to combust if exposed to flame.
Generally, any material, which is likely to discolour, melt or misshape when exposed to moderate heat, should
be considered as a combustible material or surface.
Clearance to the sides of the appliance facia are 100mm (4”) but curtains, drapes and other fabrics are not per-
mitted within a distance of 500mm (20”) of the appliance sides. No such materials are permitted directly above
the appliance regardless of distance.
The minimum clearance to the ceiling above the appliance is 800mm (31.5”) measured from the top of the appli-
ance glass panel.
Combustible materials should not be positioned directly in front of the appliance within a distance of one metre.
A combustible shelf may be fixed to the wall above the fire, providing that it complies with the dimensions given
below.
The shelf depth may be greater but the height must also be increased accordingly. An increase in height of 25
mm is required for every 12.5 mm of additional shelf depth. For shelves that are too low protective devices can
be used such as metal heat deflectors, but it must be assured that the shelf does not reach an unacceptable tem-
perature before relying on such a solution.
Under no circumstances should any electrical equipment e.g. plasma screen TV sets etc. be positioned on the
wall above the appliance.
Clearance to the sides and rear of the firebox are a 75mm (3“) air-gap. Clearance to the top of the firebox is a
100mm (4”) air-gap.
It should be established that any mirrors or picture frames etc. to be positioned on the wall above the appliance
are able to withstand prolonged exposure to moderate heat and moisture before proceeding with their installa-
tion.
2.0
3.0
2
Maximum depth of shelf Minimum distance from hearth to underside of shelf
150mm 950 mm
100mm 850 mm
©2008 Valley Forge Limited.

VENTILATION AND ROOM SIZE
For UK: Purpose provided ventilation of 100cm2is required for this appliance. An openable window or equiva-
lent is also required. Any ventilation fitted must comply with BS 5871 part 4 and BS 5440 part 2. Ventilation fit-
ted under, or within immediate vicinity of the appliance must not be used as it may adversely effect perform-
ance of the combustion monitoring system (ODS) system. The appliance shall not be installed within 1 metre
of any existing air vent, and any new air vent shall not be installed within 1 metre of the appliance.
The requirements of other appliances operating in the space or room must be taken into consideration when
assessing ventilation requirements, this will have been carried out by your CORGI registered installer. A supply
of fresh air into the room is advisable to maintain temperatures within limits.
For Republic of Ireland: Permanent openings with a minimum open area of 120cm2 are required. The total
requirement shall be equally divided between high and low level openings on the same wall separated by a miu-
mum vertical distance of 1.6 metres (63”). Refer to the current edition of IS813 and any relevant rules in force.
For UK and Republic of Ireland: The appliance shall not be installed within one metre of any existing air vent,
and any new air vent shall not be installed within one metre of the appliance.
For UK and Republic of Ireland: The room size should be a minimum of 27m3(e.g. 11’ x 11’ x 8’) to allow ade-
quate circulation of air and ensure the correct operation of the fire. This volume may include adjacent spaces
but these spaces must not be separated by a door. Note : To calculate a room size in cubic metres (m3) divide the
room volume in cubic feet (ft3) by 35.3.
It should be noted that heaters create warm air currents. These currents move heat to wall surfaces next to the
heater. Installing the heater next to vinyl or cloth wall coverings or operating the heater where impurities in the
air (such as tobacco smoke, candle smoke etc.) exist, may cause the walls to become discoloured.
This appliance is intended as a secondary source of heat only and should not be used in a room without some
form of background heating present. If the appliance is used in a room as the sole source of heat, then con-
densation may occur on colder surfaces within the room.
OPERATING INSTRUCTIONS
The control knob is marked as shown in figure 1. The
pilot is visible behind the left hand side of the burner.
Push in and turn the control knob to the SPARK posi-
tion, and hold there for a few seconds. Continue turn-
ing anti-clockwise through the spark click to the
PILOT light position, ensuring the pilot has lit. If not,
return the knob clockwise, and repeat.
When the pilot lights after the spark, keep the knob
depressed for approximately ten seconds. Now
release the knob and the pilot should stay alight. If the
pilot is extinguished during use, wait three minutes
before repeating the ignition procedure.
To achieve the HIGH setting, push the control knob
in slightly and continue turning anti-clockwise to the
high position. The main burner should light after a few seconds. To decrease the setting to low, turn the control
knob clockwise to the LOW setting.
To turn to the PILOT position from the HIGH or LOW positions, press the control knob in, and return to the pilot
position and release. To turn the fire off, keep the knob pressed in, return to the OFF position and release.
COMBUSTION MONITORING SYSTEM
This fire is fitted with a combustion monitoring safety device (ODS). If the fire shuts down during use for no
apparent reason then several reasons may be suspected. If a door or window has been opened creating a
draught, then pilot disturbance could be the problem and removal of the draught should resolve this. The fire
can then be re-lit in accordance with the previous section. A grommet seal may also be missing from the fire-
box causing abnormal draught to shut down the pilot. Call your installer to check seals are properly fitted.
If pilot disturbance is not the cause, then the ODS safety system may be in operation. Switch the appliance OFF,
call in your installer to check the appliance and ventilation. Remedial work must be carried out as required. DO
NOT allow the appliance to be used until the appliance and installation is passed as safe. If the pilot continues
to be extinguished you must call your installer to check the operation of the complete appliance.
3
4.0
5.0
Figure 1
6.0
©2008 Valley Forge Limited.