Valor 639 Assembly instructions

MODEL
639
Open Decorative
Gas Fire
(G.C No. 32-032-47)
INSTALLER’S GUIDE
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20)
WHEN CONVERTED USING CONVERSION KIT NO. 0591301 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 these instructions give sufficient details to enable this appliance to
be installed and maintained satisfactorily. However, if further information is
required, our Valor Technical Helpline will be pleased to help.
Please telephone [phone]
INSTALLER: Please leave this guide with the owner
© Valor Heating
3002369/03

INSTALLER’S GUIDE
Page 2
Safety First.
Valor fires are CE Approved and designed to meet the appropriate British
Standards and Safety Marks.
Quality and Excellence.
At the heart of every Valor fire.
All Valor 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 is a member of the Society of British Gas Industries which works to ensure
high standards of safety, quality and performance.
Careful Installation
Valor 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 or floor of combustible material.
Valor Heating, Erdington, Birmingham B24 9QP
www.valor.co.uk
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
CONTENTS
1. SAFETY ..........................................................................................................4
2. LIST OF ACCESSORIES .............................................................................4
3. APPLIANCE DATA ......................................................................................5
4. GENERAL INSTALLATION REQUIREMENTS ....................................6
5. UNPACKING ...............................................................................................12
For models supplied with a firefront..............................................................12
For models supplied with a coal effect fuel bed ............................................12
For models supplied with a Pebble effect fuel bed ........................................12
6. INSTALLATION OF APPLIANCE ..........................................................13
7. BURNER AND SUPPLY PIPE INSTALLATION................................... 16
Lighting the fire..............................................................................................16
8. INSTALLING THE FUEL BED COMPONENTS ..................................18
9. FITTING THE FIREFRONT.....................................................................29
10. FULL OPERATING CHECKS ..................................................................31
Flame Supervision & Spillage Monitoring System .......................................32
Final commissioning ......................................................................................32
11. SERVICING & PARTS REPLACEMENT ..............................................33
Checking the aeration setting of the burner....................................................34
12. SHORT LIST OF SPARES.........................................................................37

INSTALLER’S GUIDE
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1.SAFETY
Installer
•Before continuing any further with the installation of this appliance please read
the following guide to manual handling
•The lifting weight of this appliance is 9 kg. 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.
2.LIST OF ACCESSORIES
The following accessories are available: -
Description Part Number
•All Models
LPG Conversion kit 0591301
•‘Quattro’, ‘Majestic’ and Models not supplied with a firefront
Replacement chairbrick 0552311
Replacement chairbrick Brass effect Trim 0552321
Replacement chairbrick Chrome effect Trim 0552331
Replacement chairbrick Black Trim 0552341
•‘Azure’ Model
Replacement chairbrick 0552301

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3.APPLIANCE DATA
This product uses fuel effect pieces 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. 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 located below the burner and is visible when the fire
front cover is removed.
639 (Natural Gas) 639 (Propane)*
Gas Natural (G20) Propane (G31)
Inlet Pressure 20mbar (8in. w.g.) 37mbar (14.8in. w.g.)
Input - Max. ( Gross) 6.85kW (23,380Btu/h) 6.7kW (22,860Btu/h)
Input - Min. ( Gross ) 2.3kW (7,850Btu/h) 4.0kW (13,650Btu/h)
Burner injector Bray Cat.18U Size 420 Stereomatic. Size 170
Burner Test Pressure-
Cold
17.9mbar + 0.75mbar
(7.2in w.g. + 0.3in w.g.)
35.85 mbar + 0.75mbar
(14.4in w.g. + 0.3in w.g.)
Inlet Pipe Connection 8mm 8mm
Pilot & Atmosphere
Sensing Device
OP NG9030 OP LPG9222
Ignition Integral Piezo Spark Integral Piezo Spark
Aeration Non-Adjustable Non-Adjustable
*When converted using kit 0591301

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4.GENERAL INSTALLATION REQUIREMENTS
4.1 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:
a) All the relevant parts of local regulations.
b)All relevant codes of practice.
c) The relevant parts of the current editions of the following British Standards:-
BS 1251
BS 4543 Part 2
BS 5440 Part 1
BS 5440 Part 2
BS 5871 Part 3
BS 6461 Part 1
BS 6891
BS 8303
d)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
with the relevant parts of:
The current editions of:-
3IS 813
3ICP3
3IS327
1. All relevant national and local rules in force.
4.2 As supplied the appliance can be installed in the following situations: -
•To a fireplace complete with surround and hearth as shown in figure 1 and
complying with BS1251. The required fireplace, hearth, and clearance
dimensions are shown in figure 1.
•Into a fireplace that has a fireback of nominal size 400mm and conforming to
BS1251.

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Into a Replacement Chair Brick as below: -
•‘Quattro’, ‘Majestic’ and Models not supplied with a firefront
Into a Valor Replacement Chairbrick. Part number 0552311
•‘Azure’ Model
Into a B&Q Replacement Chairbrick. Part number 0552301
Suitable flues and minimum flue sizes are as follows: -
2. 225mm x 225mm conventional brick flue.
3. 175mm diameter lined brick or stone flue.
4. 200mm diameter factory made insulated flue manufactured to BS4543.
5. 175mm diameter flue pipe. See BS6461 Part 1 for suitable materials.
The minimum effective height of the flue must be 3m.
The flue must not be used for any other appliance or application.
Any chimney damper or restrictor should be removed. If removal is not possible,
they must be secured in the open position.
If the appliance is intended to be installed to a chimney that was previously used for
Figure 1. Hearth and Fireplace Opening

INSTALLER’S GUIDE
Page 8
solid fuel, the flue must be swept clean prior to installation. All flues should be
inspected for soundness and freedom from blockages.
4.3 If the fireplace opening is an underfloor draught type, it must be sealed to
stop any draughts.
4.4 The appliance must be mounted behind a non-combustible hearth (N.B.
conglomerate marble hearths are considered as non-combustible). The appliance can
be fitted to a minimum class “O” – 100°C surround. The hearth material must be at
least 12mm thick. 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 (See figure 1).
The surface of the hearth must be sufficiently flat to enable the bottom of the front
surround and the bottom front cover to be aligned horizontally. Any excessive
unevenness (uneven tiles, Cotswold stone, etc.) should be rectified.
4.4.1. ‘Hole-in-the-wall’ Installations
•It is recommended that a hearth should be installed as in figure 1.
•If a reduced depth Hearth is fitted, the fire must be installed so that the
distance from the base of the fireplace opening in the wall to the finished
floor level is 85mm minimum. It is recommended that the reduced hearth
has a depth from the fixing plane of the fire of 100mm minimum. This is
necessary to support the lower front casting.
4.5 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
4.6 The appliance must not stand on combustible materials or carpets.
4.7 The minimum height from the top of the hearth 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 = 860mm.
•For a shelf deeper than 150mm
860mm + 12.5mm for every 25mm depth over 150mm
(See Graph 1).

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4.8 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.
4.9 This appliance must not be installed in any room that contains a bath or shower
or where steam is regularly present.
4.10 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.
In the United Kingdom (GB) no special ventilation bricks or vents are normally
required in the room for this appliance.
In the Republic of Ireland (IE) permanent ventilation must comply with the rules in
force.
4.11 Propane gas appliances must not be installed in a room that is built entirely
below ground level (see BS 5871 Part 3).
Graph 1. Combustible shelf clearances.

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4.12 If the appliance is to
be fitted against a wall with
combustible cladding, the
cladding must be removed
from the area shown in
figure 2
4.13 Combustible side
projections up to 75mm
forward of the fixing plane
of the fire are to be a
minimum of 125mm from
the fireplace opening (See
figure 3)
4.14.1 Combustible side
projections greater than
75mm forward of the fixing
plane of the fire are to be a minimum of 178mm from the fireplace opening (See
figure 3).
4.14.2 Non-combustible side projections to be 75mm from the fireplace
opening (See figure 3)
Figure 2. Removal of Combustible cladding

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Firefront Dimension ‘X’ (mm) Dimension ‘Y’ (mm)
Azure 400 65
Quattro 390 65
Majestic 400 50
Figure 3. Appliance dimensions

INSTALLER’S GUIDE
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5.UNPACKING
Contents:
1 Burner assembly
1Nut & olive for 8mm inlet pipe
2Screws
2 Plastic screw plugs
1Fuel bed matrix support plate
2Self tapping screws
1Combined instruction guide
For models supplied with a firefront
1Firefront and Cover
For models supplied with a coal effect fuel bed
2 Front coals (1 x right hand 1 x left hand )
1 Coal matrix
1Pack of loose coals containing 12 coals
For models supplied with a Pebble effect fuel bed
2 Front Pebbles (1 x right hand 1 x left hand )
1 Pebble matrix
1Pack of loose pebbles containing 16 pebbles
Carefully remove the contents. Take special care in handling the ceramic
components and the coals / Pebbles. Check that all the listed parts are present and
in good condition.

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6.INSTALLATION OF APPLIANCE
INSTALLATION
6.1 Fireplace size
The fireplace must comply with the requirements described in section 4.
6.2 Fireplace flue pull.
Visually inspect the flue for any obstruction, and that a smooth transition from the
fireplace opening into the flue is available. 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.
IMPORTANT
Before continuing with the installation of this gas fire the aeration setting
on the burner must be checked. This is factory set. See section 11
(Servicing and parts replacement).

INSTALLER’S GUIDE
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6.3 Installation of the
burner unit
6.3.1 Prior to installation of
the burner the coal matrix
support plate must be fitted
(See figure 4). Two self-
tapping screws retain the
plate.
6.3.2 Burner Positioning
•The two tags at the side
of the burner can be
folded against the side of
the burner tray. This may be
required for installations where
the width of the fireplace
opening is restricted (See figure
5)
•Place the burner unit centrally
within the fireplace opening.
Position the burner to the rear of
the opening, this may be
extended forward providing
the front of the burner tray
does not protrude beyond the
front plane of the fireplace
opening (See figure 6).
6.3.3 Locating the burner.
Method 1.
•Place the burner assembly in
position.
•Mark on the hearth the
position of the fixing holes at
the bottom front of the front
leg.
•Remove the burner assembly.
Figure 6. Burner Positioning
Figure 5. Burner tags.
Figure 4. Fitting the coal support plate

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•Using a 6mm masonry drill, drill into the hearth at the marked positions.
•Insert the supplied plastic screw
plugs.
•Replace the burner assembly
and fix in position using the
wood screws provided (See
figure 7)
Method 2.
•Place the burner assembly in
the position (See figure 8).
•Mark on the fireplace floor the
position of one of the fixing
holes in the bracket that is
attached to the rear of the front
leg. There are two holes in this
bracket to allow the soundest
and most even surface of the
fireplace floor to be used for
fixing.
•Remove the burner assembly.
•Using a 6mm masonry drill,
drill into the hearth at the
marked position.
•Insert the supplied screw
plug.
•Remove the fixing bracket
from the front leg by undoing
the screw.
•Place the bracket in position
on the fireplace floor and fix
in position using the
woodscrew provided.
•Place the burner assembly back in position and attach to the bracket by refitting
the screw.
Figure 8. Locating the burner (Method 2)
Figure 7. Locating the burner (Method 1)

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7.BURNER AND SUPPLY PIPE INSTALLATION
A nut and olive is provided for an 8mm-pipe inlet connection directly to the gas
control. The elbow can be rotated to allow a connection from any direction. The
elbow includes a valve for isolating the gas supply.
The supply pipe must be rigid material. Flexible pipe must not be used. Connect the
supply line to the appliance.
Pressure check the installation pipework for gas soundness in accordance with the
current edition of BS6891.
Preliminary burner checks.
Some burner operations can be checked at this stage. Checking now will mean that
less disassembly will be required if any problems are found. A full check should
still be made, however, after final installation.
Lighting the fire
If closed,open the isolating elbow valve. Depress the control knob and rotate it
anticlockwise to the pilot ignition position. A ‘click’ will be heard as the integral
piezo operates. A spark should be seen between the electrode and thermocouple tip.
Turn the control knob clockwise to the ‘Off’ position. Repeat this operation until a
flame appears at the pilot. There may be a delay before the pilot lights due to air
being purged from the system. When a flame appears at the pilot keep the control
knob depressed and hold the pilot ignition position for five seconds. When the
control knob is released the pilot flame should remain lit.
Operating the burner.
When the pilot burner is operating properly, gradually turn the control knob anti-
clockwise to ‘HIGH’ (Depress the knob slightly to get past the pilot ignition
position). The main burner should now light. Depress the control knob slightly to
release from the ‘HIGH’ position and turn back (clockwise) to ‘LOW’. While
turning, the burner flames should gradually become lower but remain alight.
Depress the control knob slightly to release from the ‘LOW’ position and turn back
(clockwise) to the Pilot ignition position. The main burner should extinguish but the
pilot should remain alight. Depress the control knob slightly and turn back
(clockwise) to turn OFF.
This will extinguish the pilot.

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Check reference pressure.
The appliance is pre-set to give the correct heat input at the inlet pressure shown
within Appliance data section of this manual. No further adjustment is necessary.
The burner pressure should be checked by fitting a pressure gauge at the test point
accessible to the right of the control knob (See figure 9). The pressure should be
checked with the appliance alight and the control set at ‘HIGH’. After checking the
pressure, turn off the appliance. Remove the pressure gauge and replace the test
point sealing screw. Re-light the appliance. Turn to ‘HIGH’ position and test
around the sealing screw for gas soundness using a suitable leak detection fluid.
Figure 9. Pressure test point position

INSTALLER’S GUIDE
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Figure 11. Front Coal Location
Figure 10. Ceramic Base Location
8.INSTALLING THE FUEL BED COMPONENTS
8.1 This section is for
models supplied with a
‘Coal’ effect fuel bed
only.
For ‘Pebbles’ see section
8.2
1. Place the ceramic
base coal in the burner
compartment. The bottom
rear face of the coal should
rest against the angled
ledge at the back of the
burner tray. The coal does
not rest on top of the
angled ledge. The bottom
front edges of the coal base
should locate against the
left and right hand side
brackets. (See figure 10).
(Installer - Note that the small round holes
in the burner plaques that will be covered by
the base coal are not gas burner ports. They
are simply a consequence of the plaque
manufacturing process).
2. Place the left-hand ceramic front coal
in position in front of the base coal (See
figure 11).
3. Place the right hand ceramic front coal
in position in front of the base coal. This
should overlap the left-hand coal. Push the
two sides together to minimise the gap. (See
figure 11).
4. There will be a gap between the rear
of the front coals and the front of the base
coal. (See figure 11).

INSTALLER’S GUIDE
Page 19
5. Install the 12 loose
coals as follows. The
underside of each coal is
marked with a letter ‘A’ to
‘L’ and an arrow.
6. The coals should be
positioned so that the arrows
always point towards the
back of the firebox. When
located into position the
stem of each arrow should
be at 90° to the rear of the
fireplace opening (See
figure12).
7. Hold coal ‘A’ upright
with the arrow pointing to
the top. Locate coal ‘A’ as
shown in figure
12.
8. Locate
coals ‘B’ to ‘E’
so that they are
firmly seated in
the valleys in the
coal base and
front coal.
9. Hold coal
‘B’ upright with
the arrow pointing
to the top. Locate
coal ‘B’ as shown
in figure 13.
10. Hold coal ‘C’
upright with the
arrow pointing to
the top. Locate coal
‘C’ as shown in
figure 14.
Figure 14. Second row “Coal C”
Figure 13. Second row “Coal B”
Figure 12.Front Row “Coal A”

INSTALLER’S GUIDE
Page 20
11. Hold coal ‘D’
upright with the
arrow pointing to
the top. Locate coal
‘D’ as shown in
figure 15.
12. Hold coal ‘E’
upright with the
arrow pointing to
the top. Locate
coal ‘E’ as shown
in figure 16.
13. Hold coal
‘F’ upright with
the arrow
pointing to the
top. Locate coal
‘F’ as shown in
figure 17.
14. This will
complete the second
row of loose coals.
Figure 17. Second row “Coal F”
Figure 16. Second row “Coal E”
Figure 15. Second row “Coal D”