Valor 495 Assembly instructions

600A737/02
MODEL 495
Radiant / Convector
Gas Fire
HIGHLIGHT
Code 4950 - Charcoal Case with Coals
Code 4951 - Autumn Brown Case with Logs
INSTALLER GUIDE
Please keep in a safe place for future reference

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This Installer Guide gives sufficient details to enable the appliance to be installed
and maintained. If further information is required, our Valor AdviceLine will
be pleased to help.
Please telephone [phone] (Local call rates apply)
These appliances are for use with natural gas
G20)
These appliances are for use in the United
Kingdom (GB) and the Republic of Ireland (IE)
onl
y
.
Please leave this Installer Guide with the user
CUSTOMER CARE

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Page
Specification 4
Installation Conditions 4
Unpacking 6
Closure Plate
Fitting 7
Flue Pull Check 7
Fire Preparation 7
Ignition Spark Check 8
Fire Installation 8
Gas Supply Connection 8
Fitting Ceramic Fuel Effect Pieces 9
•Coal Effect 9
•Log Effect 12
Operation Check 13
Reference Pressure Check 13
Spillage Check 14
Outer Case Fitting 14
Final Checks & Owner Instruction 15
Servicing 16
•Window Unit 16
•Outer Case 16
•Fuel Effect 16
•Rear Burner Tube 16
•Front Burner Tube 16
•Electrode 16
•Pilot & Cross Lighting Burner 17
•Pilot Jet 17
•Gas
Tap 17
•Piezo Generator 17
•Greasing Tap 17
•Flue Switch 18
•Controls & Pipework Manifold 18
•Thermocouple 18
•Burner Injectors 18
•Short Spares List 19
CONTENTS

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1 SPECIFICATION
1.1 No component on this appliance is manufactured from asbestos or asbestos relatedproducts.
1.2 The appliance data badge is on the inner face of the back panel at the left side. There is also a label giving the
serial number on the right side of the outer case near the bottom.
1.3 Appliance data:-
The overall dimensions are shown in Fig.1
Gross Weight: 28.27kg
Net Weight: 25.37kg.
Burner type:Aerated front and rear simplex tubes with combined pilot and cross lighting burner.
Gas Type: Natural (G20)
Gas Connections: An RP1/4 (1/4in. B.S.P) elbow connector is provided for connection to the
appliance inlet pipe located at the centre back.
Gas input(Max. gross): With Logs - 5.80kW/h. With Coals 5.5kW/h
Injectors: Front burner -Bray Cat 18 Size 220
Rearburner- Bray Cat 77 Size 170
Pilot - Bray Cat 960 Size 25
Pressure Setting Cold: 17.6 + 0.75mbar (7.1 + 0.3in.w.g)
Aeration Adjustment: None required
Control Tap: Four position fitted with flame supervision device and integral piezo-electric igniter.
Pilot Unit: Right side of firebox. Combined Pilot jet, thermocouple sensor and Electrode.
Flue switch: Heat activated. At right side of downdraught diverter.
2. INSTALLATION CONDITIONS
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.
2.2 In the United Kingdom the installation must also be in accordance with:
a) All the relevant parts of local regulations.
b) The current edition ofthe Building Regulations issuedby the Department of the Environment and the Welsh Office
or the Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department.
c) All relevant codes of practice.
d) The relevant parts of the current editions of the following British Standards:-
BS 715
BS 1251
BS 1289 Part 1
BS 1289 Part 2
BS 4543 Part 2
BS 5440 Part 1
BS 5440 Part 2
BS 5871 Part 1
BS 6461 Part 1
BS 6891
In the republicof Ireland the installation must also conform with the relevant parts of:
a) The current editions of:-
IS 813
ICP3
b) All relevant national and local rules in force.
2.3 The flue must have a minimum equivalent height of 3m.
The flue must serve only one fireplace.
The flue must be clear ofany obstruction.
Any damper or register place should be removed. If removal is not possible without carrying our structural work, the
damper orplate may be left inthe flue provided that it is permanently secured in the fully open position.
If the appliance is intended to be installed to a chimney which was previously used for solid fuel, the flue must be swept
prior to installation
The flue must be completely sealed so that combustion products do not come into contact with combustible materials
outside the chimney.
The flue and fireplace interiormust be clear of debris, brick up etc.

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Suitable flues are:-
a) 225mm x 225mm conventional brick flue. If a liner is used it must be 127mm (5in.) minimum diameter, The liner
must be sealed to the surrounding area above the fireplace opening and to the top of the chimney with an approved
terminal being used.
b) A precast concrete or clay flue block system conforming to BS1289. This 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.
c) A flue pipe 127mm (5in.) minimum diameterof -see B.S 6461 Part 1 for suitable materials. Metal flue pipes and flue
boxes must comply withB.S 715.
2.4 In the United Kingdom, no special ventilation bricks or air vents are required in the room for this appliance.
In the Republic of Ireland, ventilation must comply with the rules in force.
2.5 Any air supply entering the fireplace from below floor level must be completely sealed off.
2.6 This fire is only suitable for hearth mounting. The hearth must be non-combustible and at least 760mm wide x
300mm deep. The non-combustible hearth material must be at least 12mm thick. Its top surface should be preferably
50mm above floorlevel in orderto discourage the placing of carpets orrugs overit.
2.7 The fireplace opening must be within the following dimensions:-
(a) Conventional fireplace:
Width: Max. 457mm
Min. 305mm
Height: Max. 650mm
Min. 508mm
Min. Depth: 165mm
(b) Pre-cast flue:
Width: Max. 457mm
Min. 305mm
Height: Max. 650mm
Min. 610mm
Min. Depth: 115mm
(c) Metal Flue box:
Width: Max. 457mm
Min. 380mm
Height: Max. 650mm
Min. 518mm
Min. Depth: 180mm
If a panel has to be fitted to the fireplace to meet the required opening sizes, it must be made of a non-combustible
material.
2.8 There must be a flat area 10mm minimum width outside each side and above the top of the closure plate to
enable the sealing tape to be properly secure. Note that the closure plate canbe cut if necessary -see section4.
2.9 This fire canbe fitted to apurpose made proprietary class "O" -100 C or 150 C surround.
2.10 The flue spigot and any spigot extension must be capable of passing through the closure plate by a least 25mm
with a minimum clearance of 50mm between its open end and the nearest obstruction. There must also be a minimum
clearance of 165mm between the back of the closure plate and the back of the catchment spare (Fig.2). The catchment
space below the flue spigot must extend at least 250mm downwards measured from the bottom of the flue spigot (Fig.2).
2.11 If the fire is to be fitted against walls with combustible cladding, the cladding must be removed from the area
shown in Fig.3.
2.12 Please note that soft wall coverings (e.g. embossed vinyls etc.) are easily affected by hear. They may, therefore,
scorch or become discoloured when close to a heating appliance. Please bear this in mind when installing.
2.13 Aminimum side clearance of150mm measured from the case rearsides must be maintained on all installations to
allow easy operation ofthe control knob and to give access forremoving the outercase when servicing -see Figure 1.
2.14 The space between the fireplace front face and the back of the outer case must not be filled in - see figure 1.
2.15 Acombustible shelfmay be fitted overthe appliance providedthat the following conditions are satisfied:-
(a) In the case of a shelf not more than 150mm deep, there is at least 75mm clearance above the extreme top surface
of the fire.
(b) For a shelf of greaterdepth there is an additional clearance of 12.5mm for each extra 25mm of added shelf depth.
2.16 There is no restriction on the depth of non-combustible projections but a space of at least 50mm should be
allowedabove the top ofthe appliance to enable removal of the outer case.

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3. UNPACKING
The carton contains the following:-
1 Fire assembly
1 Set of ceramic fuel effects
1 Window trim
1 Closure plate
1 Flue spigot
1 Pack fixing screws
2 Plastic Caps for foot screws
1 Smoke match tube.
Remove all the items carefully to prevent damage. Some items may be contained in the packaging fitments - Examine
the packaging carefully before discarding. Check that allthe items are present andundamaged.
Fig. 1 Overall Dimensions
Fig. 2 Catchment Space
Fig. 3 Areato be free ofCombustible Cladding

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4. FIT THE CLOSURE PLATE
The closure plate (Fig 4) must be fitted andsealedto the opening using
a suitable heat resistant material. The air relief opening at the bottom
of the closure plate must not be reduced in size by cutting or covered
by sealing tape etc. (see Fig.5). If necessary cut straight across the top
of the closure plate so that it overlaps the opening by 25mm.
5. CHECK FOR FLUE PULL
Apply a lighted match orsmoke match to the flue spigot opening in the
closure plate and observe the smoke. If there is a definite flow into the
opening,proceedwith fitting the fire. If there is not a definite flow into
the opening, pre-heat the chimney for a few minutes and re-test for
flow. If there is still no definite flow, the chimney may require
attention. Do not fit the fire - seek expert advice.
6. PREPARE THE FIRE
6.1 Stand the fire upright.
6.2 Remove the window unit by detaching the knurled screws at
the sides near the top. Lift the window unit up to clear locations at the
bottom and place carefully aside (see Fig.6)
6.3 Remove the control knob by pulling clear of the gas tap
spindle
6.4 Detach the control bezel by removing the knurled screw
below the controlknob opening (see figure 1).
6.5 Remove the knurled screws at the case sides (see Fig.1)
6.6 Pull the bottom of the case forwards. Lift the case upwards to
clear the top rear brackets. Then lift forwards to clear. Place carefully
aside.
6.7 Fit the flue spigot to the back of the fire using the four screws
provided. Note: No spigot restrictor is necessary for this appliance. Fig. 6 Window Removal
Fig. 5 Closure Plate sealing
Fi
g
. 4 Closure Plate

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7. CHECK IGNITION SPARK
The pilot electrode is situated at the right side of the firebox above the
rear port of the pilot and cross lighting burner - see figure 7.
Check that there is an ignitionspark at the pilot port.
7.1 Place the control bezel over the gas tap spindle and locate the
two pegs in the holes inthe gas tap bracket. The indicator mark on the
bezel will allow the rotation of the control knob at each setting to be
checked while the outer case is detached.
7.2 Fit the controlknob over the gas tap spindle.
7.3 To initiate a spark, depress the control knob. While keeping it
depressed,turnto IGN position. The spark should be produced while
turning.
7.4 If there is no spark produced during several attempts, check
that the electrode lead is properly connected to the electrode and that
the spark gap is correct. Replace parts, if necessary, as described in the
relevant servicing sections of this manual.
8. INSTALL THE FIRE
8.1 To prevent damage to the hearth, the fire is supplied with two plastic caps (in the accessory pack). Fit these caps
over the heads of the levelling screws.
8.2 Place the fire centrally onthe hearthensuring that the spigot lines up with the spigot hole in the closure plate and
gently slide into place. The spigot must enterthe closure plate to adepth ofat least 25mm.
8.3 If the fire is fitted to a recessed fireplace, an extension flue spigot up to a maximum total length of 125mm,
measured from the back of the fire, may be used. This must be a tight fit over the flue spigot and be secured by at least
two self tapping screws.
8.4 Level the fire by slackening the two lock nuts and turning the levelling screws in the front feet up or down as
required while they bear onthe hearth. When the fire is levelandsquare to the wall, retighten the locknuts.
9. CONNECT THE GAS SUPPLY
9.1 To gain access to the appliance connection point, the
centre panel in the firebox floor must be removed by
unscrewing four screws and lifting it clear (see fig. 8).
9.2 Prepare a suitable gas supply point adjacent to the fire.
9.3 Provision for isolation of the gas supply upstream of the
fire must be provided for safety and servicing.
9.4 The supply pipe must be of rigid material (e.g. copper).
A flexible connection must not be made.
9.5 The appliance inlet pipe is fitted with an RRP1/4
(1/4in.B.S.P) elbow connector the connection to the supply
pipe.
9.6 After connecting the supply line to the appliance,
pressure test the installation pipework for gas soundness in
accordance with the current editionof B.S 6891.
9.7 Refit the firebox floor panel.
Fig. 7 Pilot Ignition System
3-4mm
Fig. 8 Firebox Floor Panel Removal

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10 INSTALL THE CERAMIC FUEL EFFECT PIECES
10. Appliance code no.4950 is supplied with coalfueleffect pieces - see section10.1
Appliance code no.4951 is suppliedwithlog fuel effect pieces - see section10.2
10.1 Coal effect installation:
10.1.1 Locate the coal bed (embossed "A"on its underside) inthe firebox.
The back face should be against the rear of the firebox. The rear underside of
the coal bedshouldrest on the ledge at the back of the firebox. The vertical face
of the recess at the bottom front of the coal bed should be behind the black
front cross rail of the firebox. The extreme front of the coal bed should sit on
the top edge of the cross rail- see figure 9.
10.1.2 Position the front centre coal (embossed "B" on its underside) in
the well in the coal bedmarked "B"- see figure 10.
The narrow "nose" should locate in the "U" shaped valley at the front of
the coal bed. The "nose" should be behind the vertical ledge at the front
of this valley and should not rest on top of it. The bottom of the coal
should rest on the ridges at each side of the location well marked "B" in
the coal bed.
Fig.10 Coal“B” Location
Fig.9 Coal Bed“A” Location

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10.1.3 Position the front left coal (embossed "C" on its underside) in the well
in the coal bed marked "C" - see figure 11.
The narrow "nose" should locate in the "U" shaped cut-out at the front left of
the coal bed. The bottom of the coal should rest on the ridges at each side of
the location well marked "C" in the coal bed. The 'ear' at the rear right of coal
"C" should rest inthe depression in the ridge at the right side of the wall.
10.1.4 Position the rear right coal (embossed "D" on its underside) in
the well in the coal bedmarked "D" - see figure 12.
The pointed rear of the coal should rest o the ledge in the "V" cut-out at
the rear of the well in the coal bed marked "D". The other two corners of
the coal should rest on the ledges at the front and right side of the well in
the coal bed.
Fig.12 Coal“D” Location
Fig.11 Coal“C” Location

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10.1.5 Position the rear left coal (embossed "E" on its underside) - see figure
13. The groove underneath coal "E" should locate over the narrow ridge (also
embossed "E") situated towards the rear left of the coal bed. The left side of
coal "E" should drop behind the high point at the front of the vertical ridge.
The back edge of coal "E" should touch the front face of the back line of coals
in the coal bed.
Fig.13 Coal“E” Location

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10.2 Log Effect Installation
10.2.1 Place the rear log (the log with only one short stub) in the retaining cradle
behind the rear burner tube with its back against the firebox back wall (Fig.14). The
short stub should be at the top right of the log. Centre the log so that the gap to the
firebox walls is the same at each side.
10.2.2 Place the front log on the retaining cradles between the rear and front
burner tubes (Fig.15). Centre the log so that the gap to the firebox walls is the
same at each side.
10.2.3 Place the cross log in position (see Fig.16). The front of this log is
indicated by the letter "F" embossed on its underside. Make sure that the front
of the log is seated inside the hollow in the front log and is not raised in front of it.
Fig. 16 Cross Log Location
Fig. 15 Front Log Location
Fig. 14 Rear Log Location

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10.3 Replace the window unit. Locate its bottom edge in the support channels at the firebox sides. Refix the knurled
screws at the sides near the top.
11. CHECK APPLIANCE OPERATION
The Flame Supervision & Blocked Flue Monitoring System
The pilot/cross lighting unit incorporates a system which will automatically shut off the gas supply if the flame goes out.
The appliance also incorporates a system which will shut off the gas supply if the flue is faulty. If the flue is faulty, the hot
products of combustion will pass over and actuate a heat sensitive switch located at the right side of the downdraught
diverter. When actuated the switch will shut off the gas supply.
If the gas supply is shut off due to activation of any part of the above system, the appliance must not be used until the cause is
identified and corrected.
This monitoring system must not be adjusted, bypassed or put out of operation.
This monitoring system, or any of its parts, must only be exchanged using Valor Authorised parts.
11.1 Depress the control knob. Turn anticlockwise until resistance is felt just before the piezo electric ignition is
activated. Keep the knob depressed for a few seconds to purge air from the gas pipes. When it is judged that the air has
been purged, keep the knob depressed andturnto the IGN position. A spark should be produced which should ignite the
pilot and cross lighting burner.
11.2 When ignition has been achieved, keep the control knob depressed for approximately five seconds to allow the
thermocouple probe to warm up thenrelease it. If the burner does not remainalight, ensure that the air has beenpurged.
11.3 Check that the burner is correctly alight at all settings as shown in the following table:-
Control Knob Setting Burner Appearance
IGN Pilot and cross lighting burner only on.
1 Pilot and cross lighting burner on.
Front burner on low.
2 Pilot and cross lighting burner on.
Front burner on low.
Rear burner on high.
3 Pilot and cross lighting burner on.
Front burner on high.
Rear burner on high.
11.4 Turn off after checking. To turn off, push the control partially in, turn clockwise to OFF and release the knob. If
any resistance is experiencedat the IGNposition,release the knob before turning to OFF.
Note: If the fire is turned off while hot, wait three minutes before relighting.
12. CHECK THE REFERENCE PRESSURE
The burner aeration is non adjustable. The appliance is preset to give the correct heat input on Natural Gas at 20 mbar
(8in. w.g) inlet pressure and no further adjustment is necessary.
12.1 The burnerpressure shouldbe checked at the pressure test point locatedon the pipe connecting the gas tap to the
front main burner. The pressure check should be carried out using a calibrated pressure gauge after removing the pressure
test sealing screw. The fire should be alight and the control knob should be at setting 3.
12.2 The pressure setting should be within the limits shown in the appliance specifications - see section 1 in this
manual.
12.3 After checking the pressure, turn off the fire, remove the pressure gauge and replace the pressure test sealing
screw. Test the sealing screw forgas soundness.

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13. TEST FOR SPILLAGE A spillage test must be made before the installed fire is left with
the customer. Carry out the test in the following manner before
refitting the outer case
(Note: This appliance is supplied with a special smoke match
tube).
13.1 Close all doors and windows in the room containing
the fire.
13.2 Light the fire and set the controlto No.3 position.
13.3 After the appliance has been alight for five minutes
test with a lighted smoke match inserted in the special tube
supplied. Insert the tube horizontally at the left side along the
rear edge of the downdraught diverter up to the mark on the
tube (100mm from the end) -see figure 17.
13.4 The installation is satisfactory if smoke is drawn into
the downdraught diverter.
13.5 If the smoke is not drawn in, leave for a further ten
minutes and then repeat the test.
13.6 If the smoke is still not drawn in, remove the
appliance and inspect the sealing ofthe closure plate. If this is
satisfactory but spillage persists open all doors and windows
and recheck as above.
If the test is then satisfactory it indicates that the room lacks
sufficient ventilation. If still unsatisfactory, the chimney may
require attention.
Disconnect the fire and seek expert advice.
13.7 If an extractor fan is installed in the same room as the
fire or a connecting room, check that spillage does not occur with the fan operating and all doors between the fan and the
fire open.
14. FIT THE OUTER CASE
14.1 Detach the control knob and control bezel.
14.2 Refit the outer case. Make sure that the flange at the top
rear of the outer case locates over the top corner brackets on the
back panel.
14.3 Secure the case at the bottom sides with the knurled screws
previously removed.
14.4 Refit the control bezel using the knurled screw. Make sure
that the two pegs on the bezel locate in the holes in the gas tap
bracket.
14.5 Fit the control knob over the gas tap spindle. Push firmly
on.
14.6 Make sure that the fuel effect pieces are not dislodged
whenrefitting the case.
14.7 If necessary, adjust the brass dogs at the casing front sides
by slackening the screws behind the dogs and moving the dogs until
they rest on the hearth. Retighten the screws.
14.8 Fit the window trim. Insert the trim side channels under
the bottom front of the hood. Slide them evenly upwards. Push
the channels gently against the window frame sides so that the trim
channels are fully upright. Slide the trim channels down so that the
flanges on the inside of the channels locate fully over the angled
brackets onthe window frame sides -see figure 18.
Fig. 17 Spillage Test
Fig. 18 Window Trim Location

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15. MAKE FINAL CHECKS AND INSTRUCT USER
15.1 Recheck the operation of the fire on all control positions.
15.2 Instruct the useron the correct operationof the fire and especially point out the following:-
15.2.1 The fire has a pilot. To light the pilot,the controlknob must be depressed and turned to the IGN position.
15.2.2 The pilot flame can be viewed to ensure that it is alight. Show the user where to view the pilot. Point out the
illustration in the users instructions showing how to view the pilot.
15.2.3 Point out that the pilot can be left alight. Advise though, that the pilot consumes approximately 1/3kW and also
that ifthe premises are to be left unoccupied for alengthy period the pilot shouldbe turned off.
15.2.4 Explain the full lighting and control position sequence and how to turn off.
15.3 Advise that the fire can be lit with along matchor taperif necessary.
15.4 Advise the user that the window will require cleaning periodically both outside and inside as described in the
users instructions. Explain how to remove and replace the window unit and fuel effects for cleaning etc. Stress that
cleaning shouldonly be carried out when the fire is cold.
15.5 Advise that the fire may give off a slight odour while new. This is normal and it will disappear after a short period
of use.
15.6 Advise the user that the bright metal firebox interior will colour with use and that this is quite normal.
15.7 Emphasise that if the glass panel is broken or damaged, the fire should be turned off and not used until the
window unit is refitted with an authorised replacement.
15.8 Recommendthat the appliance shouldbe serviced andthe chimney inspectedby a competent person (In the UK a
CORGI registered person) at least annually.
If the applianceis in premises in theUnited Kingdom occupied by a tenant,point outthat by law a landlord musthave any gasappliance,
flue and pipework which is situated in a tenant’s premises checked for safety at least every 12 months.
15.9 Handover to the customerthese instructions, the users instructions and the smoke match tube.

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16. SERVICING
Turn off the gas and make sure that the appliance is cool before commencing any servicing.
Always test for gas soundness after refitting the appliance.
We recommend annual servicing including disconnecting the appliance, checking the catchment space behind the closure plate
and clearing any debris. Reseal the closure plate to the wall as described in the installation instructions.
Always re-check for spillage after servicing the appliance.
16.1 To Remove the Window Unit
16.1.1 Detach the window trim by sliding its side channels upwards to clear the location brackets on the window frame
sides. Pull the bottom of the trim forward slightly and then pull down to clear the outer case hood.
16.1.2 Remove the window unit by detaching the knurled screws at the sides near the top. Lift the window unit up to
clear the locations at the bottom and place carefully aside (see Fig.6).
16.1.3 Refit in the reverse order.
16.2 To Remove the Outer Case
16.2.1 Remove the control knob by pulling clear of the gas tap spindle.
16.2.2 Detachthe control bezelby removing the knurled screw below the controlknob opening (see Fig 1).
16.2.3 Remove the knurledscrews at the case sides (see Fig.1).
16.2.4 Pull the bottom of the case forwards. Lift the case upwards to clear the top rear brackets. Then lift forwards to
clear. Place carefully aside.
16.2.5 Refit in the reverse order. When refitting, make sure that the flange at the top rear of the outer case locates over
the top corner brackets on the backpanelandthat the pegs inthe control bezellocate in the holes inthe gas tap bracket.
16.3 To Remove the Fuel Effects
16.3.1 Remove the window unit as described in section 16.1
16.3.2 Remove the fueleffects.
16.3.3 Refit in the reverse order. Replace the effects as described in the relevant fuel effect installation instructions.
16.4 To Remove the Rear Burner Tube
16.4.1 Remove the window unit - see section 16.1
16.4.2 Remove the ceramic fuel effects.
16.4.3 Unscrew the two screws securing the burner tube to the left side of the firebox. Lift the burnertube clear.
16.4.4 Refit in the reverse order. When refitting, make sure that the burner tube is properly located over the injector
carrier at the right side.
16.5 To Remove the Front Burner Tube
16.5.1 Remove the outercase - see section 16.2
16.5.2 Remove the window unit - see section 16.1
16.5.3 Remove the ceramic fuel effects
16.5.4 Remove the screwsecuringthe firebox front cross railat the left side.
16.5.5 Slacken the screw securing the cross rail at the right side and swing the rail down at the left side to give access to
the burnertube screws.
16.5.6 Unscrew the two screws securing the burner tube to the left side of the firebox. Lift the burnertube clear.
16.5.7 Refit in the reverse order. When refitting make sure that the burner tube is properly located over the injector
carrier at the right side.
16.6 To Remove the Electrode
16.6.1 Remove the outercase - see section 16.2
16.6.2 Though not essential for access to the electrode, it is recommended that the fuel effects are removed so that the
electrode tip position can be checked when replaced - see section 16.3
16.6.3 Remove the two screws securing the electrode unit to the bulkhead panel outside the right side of the firebox.
Pull the electrode with lead attached clear.
16.6.4 Disconnect the lead from the electrode.
16.6.5 Refit in the reverse order.

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16.7 To Remove the Pilot & Cross Lighting Burner
16.7.1 Remove the outercase - see section 16.2
16.7.2 Remove the window unit - see section 16.1
16.7.3 Remove the ceramic fuel effects.
16.7.4 To gain clear access to the pilot burner screw, detach the
right hand front log support by removing two screws - see figure
19.
16.7.5 Remove the pilot and cross lighting burner by
unscrewing the two screws fixing it to the bracket at the right side
of the firebox- see figure 19.
16.7.6 Refit in the reverse order.
16.8 To Remove the Pilot Jet
16.8.1 Remove the pilot and cross lighting burner - see section
16.7
16.8.2 Disconnect the pilot pipe at the jet end and spring clear
of the carrier.
16.8.3 Remove the pilot jet andcarrier from the bracket.
16.8.4 Refit in the reverse order.
16.9 To Remove the Gas Tap and Piezo Unit
16.9.1 Remove the outercase - see section 16.2
16.9.2 Disconnect the electrode lead.
16.9.3 Remove the gas tap securing nut
16.9.4 Remove the gas tap bracket by unscrewing one
screw, attaching it to the back panel and two screws
attaching it to the bulkhead panel - see Fig.20 screws 'A'
and 'B'
16.9.5 Disconnectthe four pipes fromthe gas tap.
16.9.6 Disconnect the thermocouple and flue switch
wires from the gas tap interrupter block (Fig.20 a).
16.9.7 Remove the interrupterblock from the gas tap.
16.9.8 Refit in the reverse order.
When reconnecting the thermocouple nut to interrupter
block, make sure that the flue switch wires are properly
located. Initially screw the thermocouple nut until finger
tight, then finally tighten a further quarter turn with a
spanner.
16.10 To Remove the Piezo Generator
16.10.1 Remove the gas tap andpiezo unit as 16.9 above.
16.10.2 Make sure that the tap is inthe off position.
16.10.3 Remove the circlip holding the piezo unit to the tap.
Remove the piezo unit.
16.10.4 Refit in the reverse order.
When reconnecting the thermocouple nut to interrupter block, make
sure that the flue switch wires are properly located. Initially screw
the thermocouple nut until finger tight, then finally tighten a further
quarter turn with a spanner.
16.11 To Grease the Control Tap
16.11.1 Detach the tap and remove the piezo generator as 16.10
above making sure that the tap is in the offposition.
16.11.2 Remove the two screws from the head of the tap. Remove the niting head and spindle complete with collar and
spring.
16.11.3 Note the positionof the slot inthe plug - mark its positionon the tap body.
Fig. 20a Flue Switch Wires & Interrupter Block
Fig. 20 Manifold View
Fig. 19 Firebox Internal Fixings

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Remove the plug rotating slightly while pulling.
16.11.4 Clean and grease the plug lightly with a suitable grease. Do not apply excessive grease. Particularly, make sure
that the gas ports inthe tap are not restricted by grease.
16.11.5 Push the plug into the tap body andposition the slot in line withthe mark previously made onthe tap body.
16.11.6 Reassemble the niting head and spindle complete with collar and spring making sure that the components are
correctly engaged.
Check the operationof the tap.
When reconnecting the thermocouple nut to interrupter block, make sure that the flue switch wires are properly located.
Initially screw the thermocouple nut until finger tight, then finally tighten a further quarter turn with a spanner.
16.12 To Remove the Flue Switch 16.12.1 Remove the gas tap to gainaccess to the interrupter block as
described in section 16.9.
16.12.2 Loosenthe thermocouple connection to the interrupter block and
detach the flue switch wires (see fig.20a).
16.12.3 Detachthe flue switch from the right side ofthe downdraught
diverter by removing two screws (Fig. 21).
16.12.4 Refit in the reverse order.
When reconnecting the thermocouple nut to interrupter block, make sure that
the flue switch wires are properly located. Initially screw the thermocouple
nut until finger tight, then finally tighten a further quarter turn with a spanner.
16.13. To Remove Controls And Pipework Manifold
16.13.1 Remove the outercase - see section 16.2
16.13.2 Remove the window unit - see section 16.1
16.13.3 Remove the ceramic fuel effects.
16.13.4 Disconnect the inlet pipe from the lower joint of the in line connector - see figure 20.
16.13.5 Remove the two screws securing the bulkhead panel to the firebox right front flange and front cross member see
figure 19.
16.13.6 Remove the screwsecuringthe firebox front cross railat the left side.
16.13.7 Remove the front burner tube - see section16.5.6.
16.13.8 Remove the rearburnertube -see section16.4.3
16.13.9 Remove the three screws securing the bulkheadpanelinside the firebox right side - see figure 19.
16.13.10Remove the screw securing the gas tap bracket to the appliance back panel- see figure 20 screw "A".
16.13.11Detachthe flue switch from the right side of the downdraught diverterby removing two screws (Fig.21).
Carefully pull the switch through the hole in the back panel.
16.13.12To remove the control and pipework manifold, swing the rear of the unit away from the firebox until the gas tap
bracket is clearof the cut-out in the backpanel side flange then pullthe unit up and sideways.
16.13.13Refit inthe reverse order.Whenreconnecting the thermocouple nut to interrupterblock,make sure that the flue
switch wires are properly located. Initially screw the thermocouple nut until finger tight, then finally tighten a further
quarter turn with a spanner.
When relocating the unit,make sure that the thermocouple probe does not get damagedby contact withthe fireboxside.
16.14 To Remove the Thermocouple
16.14.1 Remove the control and pipework manifold - see section 16.13.
16.14.2 Undo the thermocouple from the interrupter block on the control tap (The flue switch wires will then be loose).
16.14.3 Undo the nut securing the thermocouple probe to the manifoldpanelandwithdraw the thermocouple.
16.14.4 Refit in the reverse order.
When reconnecting the thermocouple nut to interrupter block, make sure that the flue switch wires are properly located.
Initially screw the thermocouple nut until finger tight, then finally tighten a further quarter turn with a spanner. When
relocating the manifold unit, make sure that the thermocouple probe does not get damaged by contact with the firebox
side.
16.15 To Remove the Front or Rear Burner Injector
16.15.1 Remove the control and pipework manifold - see section 16.13
16.15.2 Loosen the pipe running to the relevant injector at the tap end.
16.15.3 Disconnect the relevant pipe from the injector carrier and swing clear.
16.15.4 Dismantle the relevant injectorfrom the carrier inside the bulkheadpanel.
Fig. 21 Flue Switch Screws

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16.15.5 Refit inthe reverse order.Whenreconnecting the thermocouple nut to interrupter block, make sure that the flue
switch wires are properly located. Initially screw the thermocouple nut until finger tight, then finally tighten a further
quarter turn with a spanner.
When relocating the manifold unit, make sure that the thermocouple probe does not get damaged by contact with the
firebox side.

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SHORT SPARES LIST
Key No. Description No. off Part No.
A Gas Tap & Spark Generator Copreci 1 561189
B Spark Generator Copreci with 175mm long lead 1 525569
C Pilot InjectorBray Cat.960 Size 25 1 540069
D Electrode APCO Ref. 50197 1 525599
E Thermocouple OrkliT100/9 - 400mm long 1 522999
F InjectorBray Cat. 77 Size 170 1 540079
G InjectorBray Cat.18 Size 220 1 540099
H Rear Burner with Shutter 1 540129
J Front Burner with Shutter 1 525669
K Window Unit 1 540149
L Coal Bed “A” 1 540199
M Set of Coal Overlays “B” to “E” 1 540189
N Front Log 1 540269
P Rear Log 1 525979
Q Cross Log 1 525989
R Flue Switch 1 538949