Valor Fires 541 Instructions for use

© Baxi Heating U.K. Limited 2010.
5133756/03
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 2010.
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, Brooks House,
Coventry Road, Warwick, CV34 4LL
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 2010.
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
This gas fire must be installed by a competent GAS SAFE REGISTER engineer
(GAS SAFE REGISTER or CORGI engineer outside of UK) in accordance with our
installer guide and should not be fitted directly on to a carpet.
© Baxi Heating U.K. Limited 2010.

INSTALLER GUIDE
FOR OWNER GUIDE SEE PAGES 40 TO 51
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.

CONTENTS
Section Heading Page
INSTALLER GUIDE 4 - 39
OWNER GUIDE 40 - 51
1. SAFETY 7
2. APPLIANCE DATA AND EFFICIENCY 8
2.1 General information. 8
2.2 Efficiency. 9
3. LIST OF AVAILABLE KITS 9
4. APPLIANCE AND RECESS DIMENSIONS 12
5. GENERAL INSTALLATION REQUIREMENTS 12
5.1 Regulations, Standards and Law. 12
5.1.1 Considerations for timber framed buildings. 12
5.2 Ventilation requirements. 13
5.3 Fireguard requirements. 13
5.4 Room considerations. 13
5.5 Fireplace preparation. 13
5.6 The surround. 13
5.7 Hearth / plinth requirements. 14
5.8 Fireplace clearances. 15
5.9 Installation options. 16
5.10 Terminal guard and terminal clearances. 16
6. UNPACKING AND PRELIMINARY CHECKS 19
6.1 Unpacking. 19
6.2 Appliance disassembly. 19
6.3 Preliminary checks. 20
7. GAS SUPPLY CONNECTION 20
8. WALL PREPARATION 21
8.1 Select appliance position. 21
8.2 Constructing a recessed opening. 21
8.3 Combustible wall materials. 22
8.4 Cutting the flue hole for brick, stone etc. building. 23
8.5 Cutting the flue hole in timber frame buildings. 24
8.6 Prepare appliance fixing holes. 25
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.
Continued on next page

Section Heading Page
9. FLUE AND TERMINAL INSTALLATION 25
9.1 Cutting flue to size. 25
9.2 Fitting to wall. 27
9.3 Fitting the terminal guard. 28
10. GAS CONNECTION 28
11. CERAMIC COALS INSTALLATION 29
12. CERAMIC PEBBLES INSTALLATION 31
13. WINDOW FITTING 33
14. FULL OPERATING CHECKS 33
14.1 Check for leaks. 33
14.2 Check control operation. 33
14.3 Checking inlet pressure. 34
15. FASCIA FITTING 35
16. FINAL REVIEW 36
17. SERVICING & PARTS REPLACEMENT 37
17.1 To remove fascia. 37
17.2 To remove window unit. 38
17.3 To remove the ceramic fuel effect and rear wall. 38
17.4 To remove the complete burner module. 38
17.5 To remove the burner from the burner module. 38
17.6 To remove the injector. 39
17.7 To remove the pilot unit. 39
17.8 To remove the gas valve. 39
INSTALLER GUIDE
CONTENTS (Continued)
Page 6
© Baxi Heating U.K. Limited 2010.

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.
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
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.

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.
2. APPLIANCE DATA AND EFFICIENCY
2.1 General information.
Under no circumstances is this fire to be converted to LPG. An LPG conversion kit
does not exist for this gas fire.
The appliance information label is located on a plate at the base of the fire. This can
be seen by removing the lower front casting / fire front.
Before continuing with the installation of this appliance please complete the
information on the last pages of the owner guide.
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© Baxi Heating U.K. Limited 2010.
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

2.2 Efficiency.
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.
3. LIST OF AVAILABLE KITS
Description Part number
Spacer kit (5 inch) 0595121
Spacer kit (3 inch) 0595131
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© Baxi Heating U.K. Limited 2010.
INSTALLER GUIDE
Gas Conversion factor from net to gross efficiency
Natural Gas 0.901

4. APPLIANCE AND RECESS DIMENSIONS
This appliance must not be recessed into a combustible wall.
INSTALLER GUIDE
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
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© Baxi Heating U.K. Limited 2010.
See figure 4

Figure 2. Recess and flue hole dimensions
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.
Figure 1 (Continued).

5. GENERAL INSTALLATION REQUIREMENTS
5.1 Regulations, Standards and Law.
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. GAS SAFE REGISTER and CORGI require their 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 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 England and Wales, the current edition of the Building Regulations issued by the
Department of the Environment and the Welsh Office.
In Scotland, the current edition of the Building Standards (Scotland) Regulations
issued by the Scottish Executive.
In Northern Ireland, the current edition of the Building regulations (Northern
Ireland) issued by the Department of the Environment for Northern Ireland.
In the republic of Ireland the installation must be carried out by a competent person
and also conform to the relevant parts of:
a) The current edition of IS 813 “Domestic Gas Installations”
b) All relevant national and local rules in force.
Where no specific instructions are given, reference should be made to the relevant
British Standard Code of Practice.
5.1.1 Considerations for timber framed buildings.
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.
Under no circumstances is the fire to be recessed into timber frame
constructions. For timber framed installations see section 8.
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.

5.2 Ventilation requirements.
No special ventilation bricks or vents are required into the room containing the
appliance.
5.3 Fireguard requirements.
A fireguard complying with BS 8423 should be fitted for the protection of young
children, the elderly, the infirm and pet animals.
5.4 Room considerations.
5.4.1 This appliance can be installed in any room which contains a bath, shower or
where steam is regularly present.
5.4.2 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.
5.4.3 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.
5.5 Fireplace preparation.
5.5.1 The front face of the fireplace should be reasonably flat over the area covered
by the convection box top and side flange seals to ensure good sealing. These faces
should be made good if necessary. The fireplace floor should be reasonably flat to
ensure that a good seal with the convection box can be made.
5.5.2 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.
5.5.3 Combustible cladding.
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.
5.6 The surround.
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.
INSTALLER GUIDE
Figure 3. Area to be free of
combustible cladding.
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© Baxi Heating U.K. Limited 2010.

5.7 Hearth / plinth requirements.
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.
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.
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.

5.8 Fireplace clearances.
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 figure 4)
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.
5.8.2 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.
INSTALLER GUIDE
Figure 4. Combustible shelf clearances.
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© Baxi Heating U.K. Limited 2010.

5.9 Installation options.
5.9.1 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.
5.9.2 A concealed gas supply connection can be made through the rear left panel.
Visible front connection can be from the left or right side.
5.10 Terminal guard and terminal clearances.
5.10.1 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.
5.10.2 Minimum allowable distances from the terminal are shown in figures 5 and 6.
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.

INSTALLER GUIDE
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 5.
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© Baxi Heating U.K. Limited 2010.

*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
exceeding 450mm, such as disused chimneys on external walls.
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.
Figure 6.

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).
6.2 Appliance disassembly.
Fascia removal (See figure 7).
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 8). 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.
INSTALLER GUIDE
Figure 8. Window
removal
Figure 7. Fascia removal
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© Baxi Heating U.K. Limited 2010.

6.3 Preliminary checks.
Check ignition spark (See figure 9).
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.
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.
INSTALLER GUIDE
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© Baxi Heating U.K. Limited 2010.
Figure 9. Ignition