Valor Fires 541 Camden Instructions for use

© Baxi Heating U.K. Limited 2008.
5133756/01
INSTALLER: Please leave this guide with the owner
Model 541
ROOM SEALED RADIANT / CONVECTOR
GAS FIRE
Fitted with one of the following fascia.
Camden, Seattle, Sonnet or
Ultimate.
(GC No. 32-032-64)
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
Valor Fires 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 AND OWNER GUIDE

© Baxi Heating U.K. Limited 2008.
All rights reserved. No part of this publication may be reproduced in any material form
(including photocopying), stored in any medium by electronic means (including in any
retrieval system or database) or transmitted, in any form or by any means, whether
electronic, mechanical, recording or otherwise, without the prior written permission of
the copyright owner.
Applications for the copyright owner's permission to reproduce any part of this
publication should be made, giving details of the proposed use, to the following
address: The Company Secretary, Baxi Heating UK Limited, The Wyvern Business
Park, Stanier Way, Derby, DE21 6BF.
Warning: Any person who does any unauthorised act in relation to a copyright work
may be liable to criminal prosecution and civil claims for damages.
Valor Fires, 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
Page 2
© Baxi Heating U.K. Limited 2008.
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20).
UNDER NO CIRCUMSTANCES IS THIS FIRE TO BE CONVERTED TO LPG.
AN LPG KIT DOES NOT EXIST FOR THIS GAS FIRE.
THIS APPLIANCE IS SUITABLE ONLY FOR INSTALLATION IN THE UNITED
KINGDOM (GB) AND THE REPUBLIC OF IRELAND (IE).

Page 3
Safety First.
Valor Fires fires are CE Approved and designed to meet the appropriate British
Standards and Safety Marks.
Quality and Excellence.
All Valor Fires 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 Fires is a member of SBGI and HHIC (Heating and Hot water Industry Council)
that work to ensure high standards of safety, quality and performance.
Careful Installation
Valor Fires 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.
© Baxi Heating U.K. Limited 2008.

Page 4
© Baxi Heating U.K. Limited 2008.
INSTALLER GUIDE
FOR OWNER GUIDE SEE PAGES 38 TO 51
INSTALLER GUIDE

CONTENTS
Section Heading Page
INSTALLER GUIDE 4 - 37
OWNER GUIDE 38 - 51
1. SAFETY 6
2. APPLIANCE DATA 7
3. LIST OF AVAILABLE KITS 8
4. APPLIANCE AND RECESS DIMENSIONS 9
5. GENERAL INSTALLATION REQUIREMENTS 10
6. UNPACKING AND PRELIMINARY CHECKS 16
7. GAS SUPPLY CONNECTION 18
8. WALL PREPARATION 18
9. FLUE AND TERMINAL INSTALLATION 23
9.1 Cutting flue to size. 23
9.2 Fitting to wall. 24
9.3 Fitting the terminal guard. 25
10. GAS CONNECTION 25
11. CERAMIC COALS INSTALLATION 26
12. CERAMIC PEBBLES INSTALLATION 28
13. WINDOW FITTING 30
14. FULL OPERATING CHECKS 30
14.1 Check for leaks. 30
14.2 Check control operation. 30
14.3 Checking inlet pressure. 31
15. FASCIA FITTING 32
16. FINAL REVIEW 33
17. SERVICING & PARTS REPLACEMENT 34
17.1 To remove fascia. 34
17.2 To remove window unit. 35
17.3 To remove the ceramic fuel effect and rear wall. 35
17.4 To remove the complete burner module. 35
17.5 To remove the burner from the burner module. 36
17.6 To remove the injector. 36
17.7 To remove the pilot unit. 36
17.8 To remove the gas valve. 37
Page 5
© Baxi Heating U.K. Limited 2008.
INSTALLER GUIDE

1. SAFETY
Installer
Before continuing any further with the installation of this appliance please read the
following guide to manual handling:
The approximate lifting weight (kg) of this appliance is as below:
Model Heat Engine Fascia Fire front Combined Weight
inc. ceramics
Camden 12.75 1.31 0.95 15.01
Seattle 12.75 1.31 0.95 15.01
Sonnet 12.75 1.31 3.65* 17.71
Ultimate 12.75 1.31 3.65* 17.71
* This weight is based on the heaviest casting which is Brass. Black or Chrome
castings may be lighter depending upon the method and manufacture and materials
used.
One person should be sufficient to lift the fire. If for any reason this weight is
considered too heavy then obtain assistance.
When lifting always keep your back straight. Bend your legs and not your back.
Avoid twisting at the waist. It is better to reposition your feet.
Avoid upper body/top heavy bending. Do not lean forward or sideways whilst
handling the fire.
Always grip with the palm of the hand. Do not use the tips of fingers for support.
Always keep the fire as close to the body as possible. This will minimise the
cantilever action.
Use gloves to provide additional grip.
Always use assistance if required.
Page 6
© Baxi Heating U.K. Limited 2008.
INSTALLER GUIDE

2. APPLIANCE DATA
Befre continuing with the installation of this appliance please complete the
information on the last pages of this guide.
The appliance data label is located on a plate at the base of the fire. This can be
seen by removing the lower front casting / fire front.
The efficiency of this appliance has been measured as specified in BS EN 613 and
the result is as below:
Model Efficiency % (Gross)
541 76
The gross calorific value of the fuel has been used for this efficiency calculation. The
test data from which it has been calculated has been certified by Advantica
Certification services (0087). The efficiency value may be used in the UK
Government's Standard Assessment Procedure (SAP) for energy rating of dwellings.
The conversion of net efficiency to gross was achieved by multiplying the net
efficiency by the following conversion factor from Table E3 of SAP 2005, rounding
down to the nearest whole number.
This product uses a fuel effect, a burner compartment rear wall 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. RCF waste is classed
as a stable, non-reactive hazardous waste and may be disposed at a landfill
licensed to accept such waste. Protective clothing is not required when
handling these articles, but we recommend you follow the normal hygiene rules
of not smoking, eating or drinking in the work area and always wash your
hands before eating or drinking.
This appliance does not contain any component manufactured from asbestos
or asbestos related products.
Page 7
© Baxi Heating U.K. Limited 2008.
Gas Conversion factor from net to gross efficiency
Natural Gas 0.901
INSTALLER GUIDE

3. LIST OF AVAILABLE KITS
Description Part number
Spacer kit (5 inch) 0595121
Spacer kit (3 inch) 0595131
Timber frame Flue Clearance kit. 0583141
This kit includes : -
1 off Insulation for rear of fire.
1 off Flue clearance sleeve.
1 off Drip collar.
1 off External wall plate.
Under no circumstances is the fire to be recessed into Timber frame constructions.
For timber framed installations see section 8.
Page 8
© Baxi Heating U.K. Limited 2008.
Gas Natural
Inlet pressure 20mbar
Input - Max. (Gross) 3.65kW (12,454 Btu/h)
Input - Min. (Gross) 1.5kW (5,118 Btu/h)
Inlet pressure (Cold) 20.0 ± 1.0mbar (8.0 ± 0.4in w.g.)
Gas connection 8mm pipe
Main burner Simplex aerated
Burner injector Cat. 92 size 280
Pilot unit Left side of firebox. Combined pilot jet, thermocouple sensor
and electrode. SIT ref. NGOP9706
Ignition Integral piezo on gas valve.
Aeration adjustment None required
Controls
Manual pilot and main burner off/on control (Right control).
Separate variable manual control for main burner (Left
control). Fitted with flame supervision device and integral
piezo igniter.
Walls Minimum 102mm (4in.) thick.
Maximum 660mm (26in.) thick.
INSTALLER GUIDE

4. APPLIANCE AND RECESS DIMENSIONS
This appliance must not be recessed into a combustible wall.
Page 9
© Baxi Heating U.K. Limited 2008.
Figure 1. Appliance dimensions and clearances (Fire dimensions are subject to
manufacturing deviation) Fascia may differ from that shown
Key Description
Model
Ultimate &
Sonnet
Camden &
Seattle
AAppliance height (mm) 607 607
BAppliance width (mm) 487 487
CAppliance depth into room (mm) 140 172
D
Minimum mandatory clearance to combustible
surfaces projecting beyond the front of appliance
(mm).
102 102
ERecommended clearance to non-combustible
surfaces for access purposes (mm). 51 51
INSTALLER GUIDE

5. GENERAL INSTALLATION REQUIREMENTS
5.1 The appliance can be installed into the following:
a) A minimum 4.5in rebate surround or Valor Fires 5in. spacer kit Part No
0595121. Where either of these are mounted to a combustible wall make sure that
there is no combustible material or combustible cladding in the area indicated on the
wall fixing template.
b) A 2in rebate surround in conjunction with the Valor Fires 3in. spacer kit Part No
0595131. Where the surround is mounted to a combustible wall make sure that there
is no combustible material or combustible cladding in the area indicated on the wall-
fixing template.
c) Recessed into a builder’s opening or cavity of a non- combustible wall. The
cavity can be elevated. The minimum cavity size is shown in figure 2. A lintel may be
required above the recess opening. If in doubt seek expert building advice. Lintel
construction details are given in section 8 of this guide. This appliance must not be
recessed into a combustible wall
5.2 Note that soft wall coverings (e.g. embossed vinyl etc.) are easily affected by
heat. They may therefore, scorch or become discoloured when close to a heating
appliance. Please bear this in mind when installing.
5.3 Installation to a timber-framed building should be in accordance with the
relevant sections of The 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.
Page 10
© Baxi Heating U.K. Limited 2008.
Figure 2. Recess and flue hole dimensions
INSTALLER GUIDE

Under no circumstances is the fire to be recessed into Timber frame
constructions. For timber framed installations see section 8.
5.4 The installation must be in accordance with this guide.
For the user’s protection, in the United Kingdom it is the law that all gas appliances
are installed by competent persons in accordance with the current edition of the Gas
Safety (Installation and Use) Regulations. Failure to install the appliance correctly
could lead to prosecution. CORGI requires its members to work to recognised
standards.
In the United Kingdom the installation must also be in accordance with:
All the relevant parts of local regulations.
The current edition of the Building Regulations issued by the Department of the
Environment and the Welsh Office, the Building Standards (Scotland) (Consolidation)
Regulations issued by the Scottish Development Department or the Building
Regulations (Northern Ireland) issued by the Department of the Environment for
Northern Ireland.
All relevant codes of practice.
The relevant parts of the current editions of the following British Standards:-
BS 5440 Part 1- Installation of flues
BS 5871 Part 1- Installation - Gas fires
BS 6891- Installation of low pressure gas pipework of up to 35mm (R1 ¼) in
domestic premises (2nd family gas) - specification.
In the republic of Ireland the installation must also conform to:
a) The relevant parts of the current edition of IS 813 “Domestic Gas Installations”
b) All applicable national and local rules in force.
Where no specific instructions are given, reference should be made to the relevant
British Standard Code of Practice.
5.5 A minimum clearance of 51mm should be maintained at each side of the fire for
servicing access.
Any combustible side wall or other combustible projection must be at least 102mm
clear from direct exposure to the radiant surface of the appliance unless suitably
protected.
Page 11
© Baxi Heating U.K. Limited 2008.
INSTALLER GUIDE

5.6 The minimum height from the base of the fire to the underside of any shelf
made from wood or other combustible materials is as follows:-
•For a shelf up to 150mm deep
Minimum height = 780mm.
•For a shelf deeper than 150mm
780mm + 12.5mm for every 25mm depth over 150mm.
(See graph 1)
There is no restriction on the position or depth of non-combustible projections for all
normal installations. Installation into an unusually tightly restricted recess, however,
could cause the temperature of the appliance surfaces to become unacceptably high.
5.7 It is advisable that combustible fabrics such as curtains are not fitted above the
fire. If, however, this is unavoidable, the extreme bottom edge of the fabric must be at
least 780mm above the top surface of the hearth or finished floor.
5.8
For installations that are elevated and recessed.
Models fitted with a fire front or fire front casting set shall have a hearth / plinth
fitted. The minimum depth of the hearth / plinth from the fixing plane of the fire is
recommended as below.
Model Minimum Depth (mm)
Sonnet & Ultimate 160
Camden & Seattle 192
On models with fire front casting sets this is necessary to support the ‘ash pan’
casting. The hearth / plinth will minimise the visibility of the heat engine components.
Page 12
© Baxi Heating U.K. Limited 2008.
Graph 1. Combustible shelf clearances.
INSTALLER GUIDE

For installations that are not elevated.
This appliance does not require a non-combustible hearth. It can be installed on any
hard surface. This surface should be level and sufficiently flat to enable the bottom of
the fascia / fire front / castings to be aligned horizontally. Any unevenness (Uneven
tiles, Cotswold stone etc.) should be rectified.
The appliance must not stand on carpet or other textured surfaces which may
interfere with the flow of convection air through the bottom of the appliance.
The floor surface that must be free of carpets, rugs or other fabric coverings should
be at least as wide as the appliance fascia and project forward at least 300mm from
the rear wall. In order to prevent carpet etc. being placed within this area, we strongly
recommend that the appliance is installed on a raised hearth or that the periphery of
this area is bordered by a fender.
5.9 The appliance can be fitted to a purpose made proprietary class “O” 150°C
surround. We recommend that the surround manufacturer is contacted to confirm
compatibility.
5.10 A hole 152mm (6in) dia. is required through the wall for the flue unit. The height
of the hole centre is shown in figure 2 and on the wall-fixing template supplied with
the appliance.
5.11 This appliance can be installed in any room which contains a bath, shower or
where steam is regularly present.
5.12 A concealed gas supply connection can be made through the rear left panel.
Visible front connection can be from the left or right side.
5.13 No special ventilation bricks or vents into the room containing the appliance are
required.
5.14 A terminal guard is supplied with this appliance.
In England and Wales the Building Regulations require a terminal guard to be fitted if
the terminal could come into contact with people near the building or be subject to
damage.
In the republic of Ireland the installation must also conform to the relevant parts of the
current edition of IS 813 “Domestic Gas Installations”
We recommend that the guard is fitted where contact with or damage to the terminal
is possible even if regulations do not demand it.
Page 13
© Baxi Heating U.K. Limited 2008.
INSTALLER GUIDE

5.15 If the fire is to be fitted against a wall with
combustible cladding, the cladding must be
removed from the area shown in figure 3.
5.16 Minimum allowable distances from the
terminal are shown in figures 4 and 5.
Page 14
© Baxi Heating U.K. Limited 2008.
Figure 3. Area to be free of
combustible cladding.
INSTALLER GUIDE

*In addition, the terminal should not be nearer than 300mm 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 5).
** The reference to external corners does not apply to building protrusions not
Page 15
© Baxi Heating U.K. Limited 2008.
Key Terminal position
Minimum
distance
(mm)
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. 300mm
EBelow eaves. 300mm
FBelow balconies or car port roof. 600mm
GFrom a vertical drain pipe or soil pipe. 300mm
H** From an internal or external corner. 600mm
IAbove ground, roof or balcony level. 300mm
JFrom a surface facing the terminal. 600mm
KFrom a terminal facing the terminal. 600mm
LFrom an opening in a car port (e.g. door, window) into dwelling. 1200mm
MVertically from a terminal on the same wall. 1500mm
NHorizontally from a terminal on the same wall. 300mm
Figure 4.
INSTALLER GUIDE

exceeding 450mm, such as disused chimneys on external walls.
6. UNPACKING AND PRELIMINARY CHECKS
6.1 Unpacking.
1 Main fire assembly with fascia.
1 Ceramic fuel effect (Packed in the fire).
1 Nut & olive for 8mm inlet pipe.
1 Fire front / fire front casting set.
1 Flue unit.
1 Wall fixing template.
2 Fire retaining cables.
2 Eyebolts.
2 Fibre wall plugs.
2 No 6 self tapping screws.
8 Woodscrews.
8 Plastic wall plugs.
1 Length of flue sealing tape.
1 Literature pack.
1 Terminal guard (supplied flat).
Page 16
© Baxi Heating U.K. Limited 2008.
Figure 5.
INSTALLER GUIDE

6.2 Appliance disassembly.
Fascia removal (See figure 6).
Remove the two screws securing the bottom of the
fascia to the sides of the convection box.
Raise the fascia to allow the retaining lugs at the top
to clear the slots in the convection box hood and then
lift clear.
Place the fascia in a safe place
away from your immediate work
area.
Window and ceramic fuel effect
removal.
Unscrew and remove the three
spring loaded window fixing screws
and bushes from the base of the
window frame (See figure 7). Keep
the screws and bushes in a safe
place.
Gently swing the base of the
window frame forward while lifting
the frame upwards. The window
should lift clear of the fire. Put the
window in a safe place away from
your immediate work area.
Carefully remove the ceramic fuel effect in its
packaging. The ceramic fuel effect base is a single
piece. The individual ceramic pieces are packed
separately. Put them in a safe place.
6.3 Preliminary checks.
Check ignition spark (See figure 8).
The pilot burner and electrode unit is at the left
front corner of the burner.
Push in the right hand control knob and turn
anticlockwise through the ignition position marked
and up to the pilot position marked .
A spark should flash across from the pilot electrode
to the pilot burner hood. If there is no spark, check
that the spark gap is as shown.
Page 17
© Baxi Heating U.K. Limited 2008.
Figure 8. Ignition
Figure 7. Window
removal
Figure 6. Fascia removal
INSTALLER GUIDE

7. GAS SUPPLY CONNECTION
A nut & olive are provided for an 8mm pipe inlet connection to the inlet ‘T’ connector
at the bottom front of the appliance. This can be rotated to allow a connection from
any direction and includes a valve for isolating the gas supply.
The supply pipe must be rigid material. Flexible pipe must not be used.
Concealed supply pipe connecting from rear of the appliance.
Before the appliance is installed it will be necessary to extend the supply line so that
it will project through the sealed opening at the back of the fire case and run to the
inlet ‘T’ connector at the front.
Make sure that the supply line run up to the rear opening is kept away from the area
that will be taken by the appliance case when it is installed.
Note that when fitted the centre of the appliance inlet ‘T’ connector is 25mm above
the floor.
Cut a slit in the seal at the back of the appliance case. The seal must envelop the
pipe. Do not slit the seal unless the supply pipe is to pass through it.
Cap the open end of any supply pipe installed before the wall is drilled to
prevent any debris or dust etc. entering the pipe.
8. WALL PREPARATION
8.1 Select appliance position.
The flue must be installed so that it is at right angles to the back panel of the fire all
round the flue circumference.
For timber framed buildings make sure that the flue opening will be between studs.
When being recessed into a non-combustible wall or builders opening 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 appliance when tightening the fixing
screws. Where necessary, non-combustible packing pieces should be used to
provide a satisfactory fixing surface.
8.2 Constructing a recessed opening.
Under no circumstances is the fire to be recessed into timber frame
constructions or any other combustible wall.
The recess in the wall for the appliance should be within the sizes shown in figure 2.
The bottom of the recess should be at the same level as the finished floor in front of
the appliance.
A lintel may be required above the recess for the convection box. If in doubt, seek
expert building advice before commencing to cut the recess.
Page 18
© Baxi Heating U.K. Limited 2008.
INSTALLER GUIDE

8.2.1 Fitting a lintel.
Whenever a lintel is required to support the recess in the inner leaf of a
brick/blockwork building, follow
the method outlined below (See
figure 9).
The lintel should be either
steel (Catnic) or reinforced
precast concrete. It should be
750mm long x 75mm deep x
inner leaf thickness.
The opening should be, as
near as possible, centrally below
a joint in the inner leaf block.
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.
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.
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.
8.2.2 Preparing a wall cavity.
The wall cavity must not be bridged other than by the flue unit. The appliance case
must not project into the cavity between the inner and outer walls by more than
10mm.
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 above and
each side of the recess opening (See figure 10).
An alternative to rockwool above the opening is to seal across the top of the cavity
with superlux board or equivalent. The board should slope downward to the back so
that any moisture will be channeled to the outside (See figure 10).
Page 19
© Baxi Heating U.K. Limited 2008.
Figure 9. Lintel installation
INSTALLER GUIDE

8.3 Combustible wall materials.
For brick or other non-combustible wall constructions, be sure to remove any
combustible wall cladding material from the area shown in figure 2.
For Timber frame buildings, the back surface of the appliance case must be
separated from the timber frame by 25mm of non-combustible material. This can
consist of the usual 12.5mm thick plasterboard plus a 12.5mm thick sheet of non-
combustible insulating material (e.g. fibre cement board). As an option, a pre-cut
insulating sheet is available from your appliance supplier or direct from Valor Fires –
Ask for Valor Fires part no. 0591221. The insulating sheet can be used to seal the
annular gap between the flue unit and the inner leaf sleeve (See section 8.5). Do not
permanently fix the insulating sheet to the wall at this stage (See section 9.2).
8.4 Cutting the flue hole for brick, stone etc. building.
Cut the hole for the flue unit. Make sure that it is straight and level. Though a hammer
and chisel can be used, using a core drill is by far the quickest and simplest method
for normal brickwork.
Before cutting the hole in the wall make sure that the height to the top surface of
the finished floor or hearth is known. The height from this surface to the flue hole
centre is shown in figure 2. The terminal position must also comply with the location
requirements given in section 5.16.
Place dust sheets on the floor and over any furnishings etc.
Place the template against the wall. Make sure that the centre of the flue hole is as
shown in figure 2.
Page 20
© Baxi Heating U.K. Limited 2008.
Figure 10.
INSTALLER GUIDE