Valor BOLERO BR626 Assembly instructions

For
G.C. No. 32-032-10
600B350/04
INSTALLER GUIDE
VALOR BOLERO
(MODEL BR626)
9500436- Brass
9500437 – Chrome
9500438 - Black
Inset Live Fuel Effect Gas Fire
GB IE
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)
Please leave this Installer Guide with the user
This appliance is for use with natural gas (G20)
This appliance is for use in the United Kingdom (GB)
and the Republic of Ireland (IE) only.
Conversion to LPG (Propane) can be undertaken by
use of a Valor conversion kit 591159.
CUSTOMER CARE

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INSTALLATION NOTES
In your own interest and for safety, 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 & Use) Regulations and
Amendments. Failure to install the appliance correctly could lead to prosecution. The Confederation for the
Registration of Gas Installers (CORGI) requires its members to work to recognised standards.
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 beforeeating 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.
The installation must be in accordance with these instructions.
In the United Kingdom the installation must also be in accordance with:
a) All the relevant parts of local regulations.
b) The Building Regulations issued by the Department of the Environment 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 2
BS 5872 Part 3
BS 6461 Part 1
BS 6891
In the Republic of Ireland the installation must also conform to the relevant parts of:
a) The current editions of:-
IS 813 (1996 as amended)
ICP3
IS327
b) All relevant national and local rules in force.
If the appliance is intended to be installed to a chimney which 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.
The minimum effective height of the chimney or flue must be 3m (10ft) from the hearth to thepoint of
termination of the flue.
The chimney or fluemust have any damper or restrictor removed, or permanently secured in the fully open
position.
The flue must not be used for any other appliance or application.
If the fireplace opening is of underfloor draught type, it must be sealed to stop any draughts.

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A fireguard complying with BS6539 or BS6778 should be fitted for the protection of young children, the elderly, or
the infirm.
In the United Kingdom (GB) no special ventilation bricks or vents are required in the room for this appliance.
However, any requirement relating to other appliances which may be in the same room must be taken into
consideration.
In the Republic of Ireland (IE), permanent ventilation must comply with theregulations currently in force.
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.
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 Valor supplied replacement part should be fitted. The individual
A.S.D components are not replaceable.
Note that soft wall coverings (e.g. embossed vinyl, etc.) are easily affected by heat. They may scorch or become
discoloured when closeto a heating appliance. Please bear this in mind when installing.
TECHNICAL SPECIFICATION
Fire surround height: 620mm
Fire surround width 560mm
Appliance insert depth: 233mm
Height of opening required: 535mm min.
570mm max.
Width of opening required: 405mm min.
490mm max.
Gas: Natural Gas (G20) LPG Propane (G31)
Conversion kit 591159.
Inlet Pressure: 20mbar (8in. w.g) 37mbar (14.8in. w.g)
Max. input (Gross): 6.85kW (23,375 Btu/h) 6.7kW (22,860 Btu/h)
Min. input (Gross): 2.2kW (7,500Btu/h) 3.6kW (12,280Btu/h)
Burner Test Pressure (cold): 17.3+0.75mbar (6.9+0.3in. w.g.) 35.1+0.75mbar
(14.1+0.3in. w.g.)
Gas connection: 8mm pipe.
Burner Injector: Bray Cat 31 Size 440 Bray Cat 18 Size 180
ASD Pilot:: SIT ref. OP NG 9030 SIT ref. OP LPG 9222
Ignition: Piezo electric. Integral with gas tap
Aeration: Non adjustable.
Clearance to combustible side panels: 100mm
The minimum height from the top surface 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 = 750mm.
•For a shelf deeper than 150mm
Minimum height = 750mm + 12.5mm for every 25mm depth over 150mm.
PACK CONTENTS
1 Burner & Fire Box Unit 2 Cable Retention Bolts
1 Nut & Olive for 8mm inlet pipe 2 Fire Retaining Cables
1 Front Coal 1 Owners Guide
1 Main Coal Bed 1 Burner Tray Trim
1 Pack 14 Loose Coals 1 Rear Support Bracket
3 Self Adhesive Foam Seals 1 Floor Sealing Tape
2 Fibre Wall Plugs 1 Front Casting Pack
2 Eyebolts 1 Guarantee Pack

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LOCATION
This appliance is not suitable for installation in a room or internal space containing a bath or shower, or where
steam is regularly present or in a private garage.
This appliance is suitable for the following:-
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 (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 be required. At least 50mm clearance must be 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 45mm is maintained between the lintel and the front face of the fireplace (i.e. fire
surround with a min rebate of 45mm).
2. A sheet metal flue system conforming with
BS4543 or BS715, the flue diameter being a
minimum of 125mm (5”) (see Figure 3) with
a minimum internal depth of 240mm.
Incombustible mineral wool insulation of not
less than 50mm thickness must be applied to
the top surface of the system firebox, as
shown in figure 3.
Fi
g
ure 1 Masonr
y
Fire
p
lace
575 MIN
FLAT
SURFACE
575 MIN FLAT
SURFACE
570 MAX
535 MIN
490 MAX
405 MIN
250
Figure 2 Factory MadeFlue System

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Figure 4.
Fire Surround: 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.
Hearth Requirements: The appliance must be
mounted on a non-combustible hearth in
accordance with Figure 3. 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.
INSTALLATION AND COMMISSIONING INSTRUCTIONS
PLEASE READ CAREFULLY BEFORE STARTING WORK
Fireplace, Flue and Ventilation Details
Read the important installation notes on the previous pages before proceeding with the installation of your fire.
Only when you have complied with all the requirements should you proceed any further. Note the hearth
requirements.
Remove any transit tape and packing and inspect for any evidence of mishandling which might affect the
performance. Each unit is flame and soundness tested before it leaves the factory and as a result there may be
slight discoloration around the burner ports.
8mm (5/16) Bundy or semi-rigid tubing must be used to connect the appliance to the gas supply.
If a concealed gas pipe fixing is to be used, offer the gas pipe through the appropriate grommet. A nut and olive
are provided for an 8mm pipe inlet connection to the elbow at the bottom front of the appliance. The elbow
can be rotated to allow a connection from any direction. The elbow includes a valve for isolating the gas supply.
The burner assembly is retained by two
screws positioned at each side of the
burner tray assembly and one positioned
through the front leg. (see Fig.4).
Carefully remove the burner assembly
by lifting and sliding forward from the
firebox.
Fit Foam Seals: 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.
Figure 3 Hearth

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Cable Retention:Cables and eyebolts are supplied for the retention of the appliance. Ensure that the internal
fireplace components are sufficiently sound to take the eyebolts and wall plugs. Drill two holes in the rear wall
of the fireplace for the eyebolt plugs using a No.10 masonry drill. The nominal position of the holes should be
as shown in figure 5. The holes should be equidistant each side of the centre line of the fireplace to ensure that
the appliance finishes centrally in the opening when tension is applied to the cables.
Insert a fibre plug into each hole. Use the rawlplugs supplied with this appliance - Never use plastic plugs instead of
the fibre plugs supplied. Screw the eyebolts into the plugs. Make sure that the bolts aresecure.
Place the convection box unit close to the fireplace but allow sufficient access into the fireplace opening so that
the cables can be threaded through the eyebolts and returned through the back of the convection box.
If a concealed connection is being used, insert the gas supply pipe through a suitable gas inlet point.
The convection box has two holes on each end of the debris deflector (see figure 5) Insert one end of each cable
(one cable each side) from the back through the lower of the two holes and return the end through the upper of
the holes as shown in figure 5c. Give the cables a pull so that they grip against the debris deflector flanges. On
no account should plastic wall plugs be used.
Thread the cables through the eyebolts in the rear wall. Return the cables through the holes near the bottom of
the convection box back panel and through the “V” shaped brackets near the bottom front sides of the
convection box (see figure 5).
Place the convection box fully back into the fireplace opening so that it is sealed against the fireplace front
surround.
Fit a cable retainer over the bottom end of each cable.
Pull each cable taut. Push the cable retainers hard up against the “V” brackets. Tighten the screws in the
retainers so that they clamp the cables in position. Apply tension to the cables by turning the hexagonal adjusters
by hand (see figure 5).
Inspect the fit of the convection box to the fireplace surround. If it is aligned squarely and the sealing is
satisfactory, fully tighten the cable retainers.
If the convection box is not correctly aligned, release the tension on the cables by slackening the screws and
turning the hexagonal adjusters fully anticlockwise. The convection box should then automatically realign itself.
Pull each cable taut again and push the cable retainers back against the “V” brackets. Again, tighten the screws in
the retainers and apply tension to the cables by turning the hexagonal adjusters clockwise as far as possible.
Figure 5 Cable Retention Method

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Push the free length of the cables inside the convection box so that they are available to allow easy removal and
refitting of the appliance during subsequent service calls. If the sealing foam does not fully compress, then the
adjusters and nipples may require to be slackened and the cable pulled up tighter before re-tightening the
adjuster. Do not cut off any excess cable, instead coil up the cable against the flange, as it may be required for
servicing purposes.
Fit Ceramic Rear Support: The Ceramic
rear support can be found wrapped in a
plastic bag in the side fitment of the
appliance. This must be fitted using the two,
black, self tapping screws found within the
screw pack.
Position the Ceramic rear support through
the slot in the Burner Tray from the
underside (see Figure 6), align the fixing
holes and secure using two screws
(Previously mentioned).
Replace the burner assembly intoposition in the firebox, without refitting the retaining screw at this stage. Cut
and shape the gas supply pipe to suit the chosen direction of entry and the gas inlet fitting position. Refit and
tighten the burner assembly retaining screws. Connect thesupply line to the appliance.
For left hand side connection: The supply pipe will have to be close to the inner face of the surround to the
fire front casting to be correctly positioned. The fire surround casting has a small cut-out at the bottom of each
side suitable foran 8mm pipe to pass through.
For right hand side connection. The supply pipe will also have to be formed to go behind the control knob
and burner support bracket.
Pressure check the installation pipework for gas soundness in accordance with the current edition of BS6891. A
long brush may be required to reach some joints.
PRELIMINARY BURNER CHECKS
Some burner operations can be checked at this stage. Checking now will mean that less disassembly will be
required it any problems are found.
A full check should still be made, however, after final installation.
If closed, open the isolating valve at the inlet elbow.
Depress the control knob and turn anticlockwise partially towards the “PILOT/IGN” position until some
resistance is felt. Keep depressed at this position to purge air from the system then, while keeping it depressed,
turn fully to the “PILOT/IGN” position. A spark should be generated at the pilot while turning. The spark
should ignite the pilot. If not turn the control knob back to the off position and repeat the procedure.
When pilot ignition has been achieved, keep the control knob depressed for approximately ten seconds to allow
the thermocouple probe to warm up and then release it. If the pilot does not remain alight, ensure that the air
has been purged, that the pilot orifice is clear and that the thermocouple connections are sound. Replace the
pilot unit if necessary (see servicing section of this manual).
When the pilot is alight and stable, partially depress the knob and turn to “LOW”. The pilot should then light
the main burner at its low setting. There may be a delay of up to four seconds between the pilot lighting and
ignition of the gas at the main burner. This is normal and is due to the time required to fill the main burner
compartment with sufficient gas for ignition.
When the burner is operating properly, partially depress the control knob and gradually turn it anti-clockwise.
The burner flames should gradually increase until the knob reaches the “HIGH” position.
When the above checks have been completed partially depress the control knob and turn to “OFF”.
Figure 6

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If the above checks are satisfactory, continue with the installation. If not, check the control and ignition
circuitry and components as described in the servicing section of this manual.
CHECK REFERENCE PRESSURE
The appliance is pre-set to give the correct heat input at the inlet pressure shown in the Technical Specification
section of this manual. No adjustment is necessary. Check the burner pressure by fitting a pressure gauge at
the test point. The test point is on the pipe situated below the bottom right corner of the burner unit. Check
the pressure with the appliance alight and set at maximum output.
After checking, turn off the appliance. Remove the pressure gauge and replace the test point sealing screw.
Relight the appliance. Turn to the maximum output position and test around the sealing screw for gas
soundness with a suitable leak detection fluid.
FITTING BURNER TRIM
To fit the burner trim, simple position and slide the trim over the front flanges of the burner tray, making sure
that it is pushed all the way down, (See Figure 7).
FITTING THE CERAMICS
Place the front base coal in the burner compartment so
that it rests on the ledges at the sides and front. Pull the
coal forward sothat it is immediately behind the front
rim of the burner compartment. (See Figure 8).
Figure 7 Fitting Burner Trim
Figure 8 Front Base Coal Positioning

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Place the rear base coal matrix in the burner compartment directly
behind the front coal. It should rest on the ledge at the back of
the burner compartment. (See Figure 9).
Install the 14 loose coals as follows. Begin the coal
build by placing a single coal in the centre of the front
coal, ensuring that it bridges across to the matrix as
shown in figure 10.
Place the other 4 coals resting between the front coal
and the coal matrix each side of the first). Please note
the coals should bridge across the front coal to the rear
coal matrix not placed in between. (See Figure 11).
Figure 9 Rear Base Matrix positioning
Figure 10 Front Row of Coals in Position
Figure 11 Positioning Front Row of Coals