Valor Heating Pro Genesis BR645VA Assembly instructions

3002557/01
Another product from the professional heating, plumbing and bathrooms range
INSTALLER GUIDE
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20)
WHEN CONVERTED USING CONVERSION KIT NO. 0591149 THIS
APPLIANCE IS FOR USE WITH PROPANE GAS (G31)
THIS APPLIANCE IS FOR USE IN THE UNITED KINGDOM (GB) AND
THE REPUBLIC OF IRELAND (IE) ONLY.
We trust that this Installer Guide gives sufficient details to enable the appliance to be
installed and maintained satisfactorily. However, if further information is required, our
AdviceLine will be pleased to help.
Please telephone [phone] (Local call rates apply in the United Kingdom).
In the Republic of Ireland call 353 183 75114
INSTALLER: Please leave this guide with the owner
© Valor Heating
Model BR645VA
(G.C. 32-032-34)
INSET LIVE FUEL
EFFECT GAS FIRE

INSTALLER’S GUIDE
Page 2
CONTENTS
1 APPLIANCE DATA ......................................................................................................3
2 GENERAL INSTALLATION REQUIREMENTS ....................................................4
3 PRE-INSTALLATION PREPARATION ...................................................................9
3.1 Pack Contents...........................................................................................................9
3.2 Fireplace Flue Pull ...................................................................................................9
3.3 The Flue Restrictor...................................................................................................9
3.4 Appliance Preparation........................................................................................... 10
3.5 The Gas Supply Pipe............................................................................................. 10
4 FIREBOX INSTALLATION..................................................................................... 11
4.1 Cable Retention...................................................................................................... 11
4.2 Floor Sealing ......................................................................................................... 12
5 BURNER INSTALLATION ...................................................................................... 12
5.1 Preliminary Burner Checks................................................................................... 12
5.2 Reference Pressure Check..................................................................................... 13
6 FITTING THE CERAMICS...................................................................................... 14
7 FULL OPERATING CHECKS................................................................................. 16
7.1 Recheck Control Settings...................................................................................... 16
7.2 Check for Spillage................................................................................................. 16
7.3 Flame Supervision & Spillage Monitoring System .............................................. 17
8 FINAL REVIEW......................................................................................................... 18
9 SERVICING & PARTS REPLACEMENT ............................................................. 19
9.1 To Replace Burner Plaques................................................................................... 19
9.2 To Remove the Complete Burner Unit ................................................................. 20
9.3 To Remove the Pilot Unit ..................................................................................... 20
9.4 To Remove the Gas Tap........................................................................................ 20
9.5 To Remove the Piezo Generator ........................................................................... 21
9.6 To Grease the Control Tap.................................................................................... 21
9.7 To Remove the Main Burner Elbow Injector ....................................................... 21
9.8 To Remove the Appliance From the Fireplace..................................................... 21
SHORT LIST OF SPARES............................................................................................ 22
Because our policy is one of constant development and improvement, details may vary
slightly from those given in this publication

INSTALLER’S GUIDE
Page 3
1 APPLIANCE DATA
This product uses fuel effect pieces, burner compartment walls and gaskets containing
Refractory Ceramic Fibres (RCF), which are man-made vitreous silicate fibres. Excessive
exposure to these materials may cause temporary irritation to eyes, skin and respiratory
tract. Consequently, it makes sense to take care when handling these articles to ensure that
the release of dust is kept to a minimum. To ensure that the release of fibres from these
RCF articles is kept to a minimum, during installation and servicing we recommend that
you use a HEPA filtered vacuum to remove any dust and soot accumulated in and around
the fire before and after working on the fire. When replacing these articles we recommend
that the replaced items are not broken up, but are sealed within a heavy duty polythene
bag, clearly labelled as RCF waste. This is not classified as “hazardous waste” and may be
disposed of at a tipping site licensed for the disposal of industrial waste. Protective
clothing is not required when handling these articles, but we recommend you follow the
normal hygiene rules of not smoking, eating or drinking in the work area and always wash
your hands before eating or drinking.
This appliance does not contain any component manufactured from asbestos or asbestos
related products.
The appliance data label is on the control plate below the right side of the burner tray. It
is visible when the bottom front cover is removed.
Gas Natural (G20) Propane (G31)*
Inlet Pressure 20mbar 37mbar
Input - Max. (Gross) 6.0kW (20,500Btu/h) 6.1kW (20,800Btu/h)
Input - Min. (Gross) 2.2kW (7500Btu/h) 3.6kW (12280Btu/h)
Output - Max. 3.0kW (10,200Btu/h) 3.1kW (10,580Btu/h)
Output - Min 1.1kW (3750Btu/h) 1.8kW (6140Btu/h)
Burner Test Pressure (Cold) 18.2±0.75mbar
(7.3±0.3in w.g.)
35.6±0.75mbar
(14.3±0.3in w.g.)
Gas Connection 8mm pipe 8mm pipe
Burner Injector Bray Cat. 18 Size 360 Bray Cat. 15 Size 170
Pilot & Atmosphere Sensing
Device
SIT Ref. OP NG9030 SIT Ref. OP LPG9222
Ignition Piezo Electric. Integral with
Gas Tap
Piezo Electric. Integral with
Gas Tap
Aeration Non-adjustable Non-adjustable
* When converted using Kit 0591149
Fire surround: height = 585mm width = 445mm
Appliance depth: 65mm

INSTALLER’S GUIDE
Page 4
2 GENERAL INSTALLATION
REQUIREMENTS
2.1 The installation must be in accordance with these instructions.
For the user’s protection, in the United Kingdom it is the law that all gas appliances are
installed by competent persons in accordance with the current edition of the Gas Safety
(Installation and Use) Regulations. Failure to install the appliance correctly could lead to
prosecution. The Council for the Registration of Gas Installers (CORGI) requires its
members to work to recognised standards.
In the United Kingdom the installation must also be in accordance with:
All the relevant parts of local regulations.
All relevant codes of practice.
The relevant parts of the current editions of the following British Standards:-
BS 715
BS 1251
BS 1289 Part 1
BS EN 1806
BS 4543 Part 2
BS 5440 Part 1
BS 5440 Part 2
BS 5871 Part 1
BS 6461 Part 1
BS 6891
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 also conform to the relevant parts of:
a) The current edition of IS 813
b) All relevant national and local rules in force.
2.2 If the appliance is intended to be installed to a chimney that was previously used
for solid fuel, the flue must be swept clean prior to installation. All flues should be
inspected for soundness and freedom from blockages.
2.3 Any chimney dampers or restrictors should be removed. If removal is not possible
they must be fixed in the open position.
2.4 In the United Kingdom (GB) special ventilation bricks or vents are not normally
required in the room for this appliance.
In the Republic of Ireland (IE), permanent ventilation must comply with the regulations
currently in force.

INSTALLER’S GUIDE
Page 5
Figure 1 Masonry Fireplace
2.5 Note that soft wall coverings (e.g. embossed vinyl, etc.) are easily affected by heat.
They may scorch or become discoloured when close to a heating appliance. Please bear
this in mind when installing.
2.6 The minimum allowable distance from the outside of the appliance case to a corner
wall or other combustible surface which projects beyond the front of the appliance is
100mm at either side.
2.7 The minimum height from the top surface of the hearth to the underside of any
shelf made from wood or other combustible materials is detailed below.
• For a shelf up to 150mm deep: Minimum height = 750mm.
• For a shelf deeper than 150mm: 750mm + 12.5mm for every 25mm depth over
150mm.
2.8 The appliance must not be installed in any room, which contains a bath, or shower
or where steam is regularly present.
2.9 In the United Kingdom, as supplied, this appliance can be installed in the following
situations: -
2.9.1 A masonry chimney with a
minimum diameter of 175mm (7”)
free from any obstruction, and with
any damper or restrictor plate in
the chimney removed or secured,
and having a minimum effective
flue height of 3m (10ft). Note the
relevant flat surface area
requirement – See figure 1. A
masonry chimney having a
correctly installed flue liner to
BS715 and with a minimum flue
diameter of 125mm is also
acceptable. Chair brick removal
may not be required providing at
least 50mm clearance is available
from the flue outlet to any fireplace
component. The appliance is
designed to cater for low lintel
installations (min height 505mm) providing a minimum distance of 25mm is maintained
between the lintel and the front face of the fireplace (i.e. 25mm rebated fire surround).

INSTALLER’S GUIDE
Page 6
Figure 3 Metal Flue Box
Figure 2. Pre-cast Fireplace
2.9.2 To a fireplace that has a precast
concrete or clay flue block system
conforming to BS1289 or BS EN 1806.
The appliance is suitable for
installations conforming to older
versions of BS1289 as well as the
current edition. The flue blocks must
have a minimum width not less than
63mm and a cross-sectional area not
less than 13,000mm2
.Older editions of
BS1289 required a cross-sectional area
of 13,000mm2. The current revision of
the standard requires 16,500mm2. This
appliance is suitable in both cases. The
total depth of the opening measured
from the finished front of the fireplace
(Including plaster, surround etc.) must
be not less than 118mm. See figure 2.
The current versions of BS1289 and
BS EN 1806 recommend that there
should be an air space or insulation
between the flue blocks and the
plaster because heat transfer may
cause cracking on directly plastered
flues. However, generally this
appliance is suitable for installations
under all circumstances unless there
is a history of cracking problems.
Remember that faults such as
cracking may be caused by poorly
built and restrictive flues, e.g.
mortar extrusions, too many bends,
flue heights below three metres,
restrictive terminations, etc.
2.9.3 A metal flue box conforming
to BS715 with a minimum internal
depth of 150mm. Incombustible mineral wool insulation of not less than 50mm thickness
must be applied to the top surface of the firebox and it must stand on a non-combustible
hearth. See figure 3.

INSTALLER’S GUIDE
Page 7
2.9.4 If the fireplace opening is greater than the acceptable dimensions given in this
guide, do not use the back of a fire surround or marble to reduce the opening. This
may cause cracking of the surround back or marble.
2.10 The following flues are suitable:
•225mm x 225mm conventional brick flue.
If a flue liner is used, it must be a minimum of 125mm diameter. The liner must be sealed
to the surrounding area above the fireplace opening and to the top of the chimney. An
approved terminal must be fitted.
•A properly constructed precast flue conforming to B.S 1289.
•A flue pipe with a minimum diameter of 127mm. See B.S 6461 Part 1 for suitable
materials. Metal flue pipes must comply with B.S 715.
2.10.1 The minimum effective height of the flue must be 3m.
2.10.2 The flue must be clear of any obstruction and its base must be clear of debris.
2.10.3 The flue must be completely sealed so that combustion products do not come
into contact with combustible materials outside the chimney.
2.10.4 The flue must serve only one fireplace.
2.11 If the fireplace opening is an underfloor draught type, it must be sealed to stop any
draughts.
2.12 An extractor fan may only be used in the same room as this appliance, or in any
area from which ventilation for the appliance is taken, if it does not affect the safe
performance of the appliance. Note the spillage test requirements detailed further on in
this manual. If the fan is likely to affect the appliance, the appliance must not be installed
unless the fan is permanently disconnected.
2.13 A fireguard complying with BS6539 or BS6778 should be fitted for the protection
of young children, the elderly, or the infirm.
2.14 The appliance is fitted with an A.S.D (Atmosphere sensing device). If the
appliance closes down after a period of operation for no apparent reason, the consumer
should be informed to stop using the appliance until the installation and appliance have
been thoroughly checked. The A.S.D will shut the appliance down if an unacceptable
amount of harmful products of combustion accumulate. Under no circumstances should
the A.S.D be altered or bypassed in any way. Only a genuine manufacturers replacement
part should be fitted. The individual A.S.D components are not replaceable.
2.15 This appliance may be installed with a surround with a minimum approved
temperature rating of 150 degrees. The fire surround must be sealed to the wall.

INSTALLER’S GUIDE
Page 8
Figure 4 Hearth
2.16 The appliance must be
mounted on a non-combustible
hearth in accordance with
Figure 4. The hearth material
must have a minimum
thickness of 12.5mm (1/2”).
The periphery of the hearth (or
fender) should be at least 50mm
above floor level to discourage
the placing of carpets or rugs
over it.
2.17 Propane gas appliances
must not be installed in a room,
which is built entirely below
ground level (See BS 5871
Pt2).
2.18 Proprietary terminals must comply with BS 715 or BS 1289. Any terminal or
termination must be positioned in accordance with BS 5440 Part 1 to ensure that the
products of combustion can be safely dispersed into the outside atmosphere. Where the
appliance is connected to an unlined brick chimney it is generally unnecessary for the
chimney pot to be replaced or for a terminal to be fitted unless the flue has a diameter
smaller than 170mm.

INSTALLER’S GUIDE
Page 9
3 PRE-INSTALLATION PREPARATION
3.1 Pack Contents
The carton contains the following:-
1Hotbox, Trims and Burner assembly
1 Casting pack
1 Literature Pack
1Loose parts pack including:-
1 Front coal Matrix 2 Tension Cables
1 Rear coal Matrix 2 Cable Adjusters
1 Loose coals Pack 1 Flue restrictor with 2 securing screws
1 Burner tray trim 2 Eyescrews
3 Self-Adhesive Foam seals 2 Fibre Plugs
1 Strip of Floor Sealing Tape
1 Nut and Olive for 8mm Inlet Pipe
Remove all the items carefully to prevent damage. Take special care when handling the
ceramic components. Some items may be contained in the packaging fitments - Examine
the packaging carefully before discarding. Check that all the items are present and
undamaged.
3.2 Fireplace Flue Pull
Close all doors and windows in the room in which the appliance is to be installed. After
confirming with a match that smoke is drawn into the flue, light a 13 gram smoke pellet
and check that there is a definite flow through the flue. Verify outside that the smoke
exits from one terminal only and that the termination is suitable. Observe, where
possible, upstairs rooms and loft spaces for signs of escaping smoke indicating a
defective flue. If there is not a definite flow warm the flue for a few minutes and repeat
the smoke pellet test. If there is still no definite flow the flue may need remedial work –
Do not fit the appliance until there is a definite flow through the flue.
3.3 The Flue Restrictor
This appliance is supplied with a flue restrictor for use where the flue draught is
excessive. The restrictor must not be fitted where a precast flue or a 125mm flue
liner is used. For flue liners greater than 125mm and all other installations the restrictor
should be fitted. There may however, be certain exceptional circumstances where fitting

INSTALLER’S GUIDE
Page 10
Figure 7 Burner fixing points
Figure 6 Fixing restrictor
Figure 5 Bending the Restrictor
the restrictor causes the fire to fail the spillage
test. In such cases the restrictor will have to be
removed. After removal conduct the spillage
check again.
The restrictor is packed flat with the appliance
and will require bending prior to fixing. Bend the
restrictor as shown in figure 5.
Fit the restrictor as shown in figure 6 using the
two screws provided.
3.4 Appliance Preparation
•Remove any transit tape and packing and
inspect for any evidence of mishandling which
might affect the performance. Each unit is
flame tested before it leaves the factory and as
a result there may be slight discoloration
around the burner ports. There may also be
slight thermal cracking across the burner
surface that is perfectly normal and is not
detrimental to performance.
•The burner assembly is retained by one
screw set in the front leg - See Figure 7.
Remove the screw and carefully remove the
burner assembly by lifting and sliding forward
from the firebox. The burner is produced from a
soft ceramic material and should be handled
carefully.
•A foam seal is supplied which will need to
be attached to the rear face of the firebox frame
on all three sides. Ensure that all joints are
butted together to prevent air gaps.
3.5 The Gas Supply Pipe
8mm rigid tubing must be used to connect the gas supply to the appliance. An olive and
nut are provided for connection to the “T” connector on the appliance. The connector can
be rotated to allow connection from either side or the rear. The connector includes a
valve for isolating the gas supply.
3.5.1 If a concealed connection from inside the fireplace is required then, before the
appliance is fitted into the fireplace it will be necessary to extend the supply line so
that it will project through the sealed grommet at the back of the firebox and run to the
“T” connector.