Valor BR622 Assembly instructions

MODEL BR622
(GC32 - 032 - 09)
INSET LIVE FUEL EFFECT GAS FIRE
INCORPORATING THE
VALOR CONTROL
WITH
ADORN,
VISAGE,
ELEGANT or
ICON Front
THIS APPLIANCE IS FOR USE WITH NATURAL GAS (G20)
WHEN CONVERTED USING VALOR CONVERSION KIT No.591159 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 advice line will be pleased to help.
Ring 0345 626 341 (local call rates apply).
INSTALLER GUIDE
Please keep in a safe place for future reference
600B624/03
May 2000

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
Because our policy is one of constant development and improvement, details may vary slightly from
those given in this publication
© Valor Heating
Because our policy is one of constant development and improvement, details may vary slightly from those given in this publication.

Page
Appliance Data.......................................................................................................................................4
General Installation Requirements.........................................................................................................4
Contents of Packs.................................................................................................................................8
Ignition Spark Check............................................................................................................................9
Fireplace Requirements.......................................................................................................................9
Gas Supply Pipe.................................................................................................................................10
Preparing Appliance for Installation....................................................................................................11
Convection Box Installation..............................................................................................................12
Burner Installation..............................................................................................................................15
Ceramic Walls Installation..................................................................................................................15
Front Surround & Control Linkage Installion......................................................................................16
Ceramic Coals Installation............................................................................................................18
Operating Checks...........................................................................................................................19
• Fire Controls Check.........................................................................................................19
• Reference Pressure Check..................................................................................................20
• Spillage Check.............................................................................................................20
Front - Final Installation...................................................................................................................22
Final Review.................................................................................................................................22
Servicing & Parts Replacement......................................................................................................23
• Ignition Microswitch .........................................................................................................23
• Gas Shut-off Microswitch..................................................................................................23
• Fire Front.........................................................................................................................24
• Control Slide Button (Visage & Icon............................................................................24
• Control Slide Unit......................................................................................................25
• Burner Unit........................................................................................................................25
• Electronic Ignition Generator...............................................................................................25
• Thermocouple Interrupter Block..........................................................................................26
• Pilot Unit............................................................................................................................26
• Gas Shut-off Tap..........................................................................................................26
• Gas Flow Rate Controller......................................................................................................27
• Injector - Main Burner.........................................................................................................27
• Burner Plaques.............................................................................................................28
• Removing Appliance from Fireplace.................................................................................28
• Spare Parts - Short List .......................................................................................................29
LIST OF CONTENTS
Page 3

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 a tie below the
burner and is visible when the bottom front
cover is removed.
Gas: Natural (G20) Propane (G31)*
Inlet Pressure 20mbar 37mbar
Input - Max. (Gross) 6.85kW (23,400 Btu/h) 6.7kW (22,860 Btu/h)
Input - Min. (Gross) 2.7kW (9,410 Btu/h) 4.3kW (14,670 Btu/h)
Output - Max. 4.2kW (14,300 Btu/h) 4.1kW (13,900 Btu/h)
Output - Min. 1.3kW (4,440 Btu/h) 2.0kW (6,820 Btu/h)
Burner Test Pressure (Cold) 17.3±0.75mbar 35.1±0.75mbar
(7.0±0.3in w.g.) (14.1±0.3in w.g.)
Gas Connection 8mm pipe 8mm pipe
Burner Injector Bray Cat. 31 Size 440 Bray Cat. 18 Size 180
Pilot & Atmosphere
Sensing Device SIT Ref. OP9030 SIT Ref. OPLPG9222
Ignition Electronic (Battery 9V PP3) Electronic (Battery 9V PP3)
Aeration Non-adjustable Non-adjustable
*When converted using kit 591159
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:
a) All the relevant parts of local regulations.
b) The current edition of the Building
Regulations issued by 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 2
BS 6461 Part 1
BS 6891
BS 8303
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.
Page 4
1.APPLIANCE DATA
INSTALLER GUIDE
2. GENERAL INSTALLATION
REQUIREMENTS

2.2 As supplied the appliance can be installed
in the following situations:-
2.2.1 To a fireplace complete with surround and
hearth as shown in figure 1 and
complying with BS1251 after removal of
the fireback and sufficient material behind
the fireback for a debris catchment space.
The required fireplace, hearth, debris
catchment area and clearance dimensions
are shown in figure 1.
2.2.2 To a fireplace incorporating a metal flue
box complying with the constructional
requirements of the current edition of
BS715. The dimensions of the flue box
must conform to those shown in figure 2.
2.3 With the addition of optional accessory
spacing kit 617K together with a
sufficiently deep surround and hearth, this
appliance can be fitted in the following
situations. Full installation requirements
and instructions are provided with the kit.
2.3.1 To a fireplace that has a precast concrete
or clay flue block system conforming to
BS1289. 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 distance from the back face of the flue
starter blocks to the extreme front face of
the fireplace including all surfacings must
Page 5
INSTALLER GUIDE
figure 1 Hearth & Fireplace opening
figure 2 Metal flue box
figure 3 Precast or clay block system
requirements for use with kit 617K
figure 4 Fireplace with fireback to
BS1251. Requirements for
use with kit 617K

be no less than the distance shown in
figure 3. The distance from the front face
of the flueway opening in the lintel block
(or equivalent) to the extreme front face of
the fireplace including all surfacings must
be no more than the distance shown in
figure 3. If this maximum is exceeded
poor clearance of combustion products
could result.
The flue starter blocks should not be
modified.
The current version of BS1289
recommends 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.
2.3.2 Into a fireplace that has a fireback of
nominal size 400mm or 450mm and
conforming to BS1251. The distance from
the front face of the flueway opening in
the lintel (or equivalent) to the extreme
front face of the fireplace including all
surfacings must be no more than the
distance shown in figure 4. If this
maximum is exceeded poor clearance of
combustion products could result.
2.4 Suitable flues and minimum flue sizes are
as follows:-
a) 225mm x 225mm conventional brick flue.
b) 175mm diameter lined brick or stone flue.
c) 200mm diameter factory made insulated
flue manufactured to BS4543.
d) 175mm diameter flue pipe. See BS6461
Part 1 for suitable materials.
e) Single wall, twin wall or flexible flue liner
with a minimum diameter of 125mm. The
materials to be used are stainless steel or
aluminium as specified in BS715.
f) A properly constructed precast concrete or
clay flue system conforming to BS1289 Part 1
or 2. This system is only suitable when the
conditions stated in section 2.3 are met.
It should be noted that, as with many
appliances, sharp bends or horizontal runs
in metal flues at the top of the system
can be a cause of problems in these types
of installation.
2.5 The minimum effective height of the flue
must be 3m.
2.6 The flue must not be used for any other
appliance or application.
2.7 Any chimney damper or restrictor should
be removed. If removal is not possible,
they must be secured in the open
position.
2.8 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.
2.9 If the fireplace opening is an underfloor
draught type, it must be sealed to stop
any draughts.
2.10 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 purpose made
proprietary class “O”-150 0
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.
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.
The appliance must not stand on
combustible materials or carpets.
Page 6
INSTALLER GUIDE

If the appliance is to be fitted against a
wall with combustible cladding, the
cladding must be removed from the area
covered by the outer surround (see figure
5). We suggest that the actual surround is
used as a template to mark the area
for combustible cladding removal.
The distance from the outside edge of the
appliance front surround to a corner wall
or other projection extending
further forward than the front of the
appliance on either side must not be less
than that shown in figure 5.
2.11 The front face of the fireplace should be
reasonably flat over the area covered by
the convection box top and side flange
seals to ensure good sealing. These faces
should be made good if necessary.
The fireplace floor should be reasonably
flat to ensure that a good seal with the
convection box can be made (see figure
25).
2.12 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 = 818mm.
• For a shelf deeper than 150mm
818mm + 12.5mm for every 25mm depth
over 150mm.
2.13 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.
2.14 This appliance must not be installed in any
room which contains a bath or shower or
where steam is regularly present.
2.15 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.
2.16 No special ventilation bricks or vents are
required in the room for this appliance.
2.17 Propane gas appliances must not be
installed in a room which is built entirely
below ground level (see BS 5871 Part 2).
Page 7
INSTALLER GUIDE
figure 5 Front surrounds
Adorn
Visage
Icon

The items required for this appliance are packed
in two sections.
Section 1 - Fire Unit contains:
1 Burner & Convection box Unit
1 Nut & olive for 8mm inlet pipe
1 Flue restrictor plate
3 Screws (For flue restrictor)
1 Ceramic back wall
1 Pair of ceramic side walls
1 Front coal
1 Main coal bed
1 Pack of loose coals containing 1 large,
8 medium & 2 small coals
2 Small “U” seals for convection box
side flanges
1 Strip of floor sealing tape
4 Fibre plugs
4 Woodscrews
2 Fire retaining cables
2 Cable clamps
2 Eyebolts
1 Knurled shouldered screw for control
linkage fixing
1 PP3 Battery
1 Smoke match tube
9 Machine screws (5mm) (For use with kit
617K)
1 Users instruction booklet
Section 2 - “Adorn” Fire Front contains:
1 Fire front surround with sliding control
1 Bottom front cover casting
1 Canopy Shield
3 Tapping screws for canopy shield
2 Machine screws for front surround fixing
or
Section 2 - “Visage” Fire Front contains:
1 Fire front surround with sliding control
1 Fire front casting
1 Bottom front cover casting
1 Canopy shield
2 Front surround securing brackets
3 Tapping screws for canopy shield
4 Machine screws for front surround &
securing brackets
or
Section 2 - “Icon” Fire Front contains:
1 Fire front surround with sliding control
1 Bottom front cover
1 Top shield
3 Tapping screws for top shield
2 Machine screws for front surround fixing
2 Knurled screws for bottom front cover
fixing
Carefully remove all the contents. Take
special care in handling the ceramic walls
and the coals. Take care not to bend or
distort the slide control linkage when
handling the fire front surround.
Check that all the listed parts are present
and in good condition.
Page 8
INSTALLER GUIDE
3.UNPACKING
figure 6 Pack Contents

3.1 Check Ignition Spark
Before attempting to install, it is worth
checking that the electronic ignition
system performs satisfactorily.
3.1.1 Fit the battery to the ignition block located
below the burner tray at the left side (see
figure 7). The positive (+) terminal is to
the right as you insert.
3.1.2 Rotate the control pivot bracket clockwise
as far as it will go (see figure 8).
This should close the ignition circuit.
Sparks should be seen tracking from the
electrode pin to the thermocouple tip (see
figure 9).
If there are no sparks make the following
checks.
a) Check condition of battery and that it is
correctly fitted.
b) Check spark gap between electrode wire
and thermocouple tip (see figure 9).
c) If a & b are satisfactory, check the ignition
circuit and components - see the servicing
section in this manual.
4.1 INSTALLATIONS NOT REQUIRING
OPTIONAL SPACING KIT 617K
4.1.1 Fireplace size
The fireplace must comply with the
requirements described in section 2.2.
This will probably entail removing the
fireback and infill material behind the
fireback. The debris catchment area
shown in figure 10 must be kept clear of
obstructions.
4.1.2 Fireplace general condition
The fireplace floor should be reasonably
flat to ensure that the convection box can
be installed without it rocking and so that
a good seal can be made at the bottom
front of the box. The front face of the
fireplace should be reasonably flat over
the area covered by the convection box
top and side flange seals to ensure good
sealing. These faces should be made good
if necessary. If the appliance is to be fitted
against a wall with combustible cladding,
the cladding must be removed from the
area covered by the fire front surround
(see figure 5). We suggest that the actual
fire front is used as a template to mark the
area for combustible cladding removal.
Page 9
INSTALLER GUIDE
4.THE FIREPLACE
figure 10 Fireplace areas
figure 7 Battery Fitting
figure 8 Control pivot
rotation
figure 9
Pilot ignition
system

4.1.3 Soundness for appliance attachment
Two primary methods of retaining the
appliance are provided:-
1) By fixing to the fireplace front surround.
2) Using concealed tension cables fixed to
the rear of the fireplace opening together
with secondary fixing to the fireplace floor.
The methods are detailed in section 7 of
this manual. Before selecting the retention
method, consult with the customer.
Method 2 is provided for instances where
drilling holes in the front surface of the
fireplace surround is unacceptable to the
customer or otherwise impractical. N.B. It
is unwise to attempt to drill into marble
without the proper tools and equipment.
If method 1 is chosen, make sure that the
front surround area is sound enough to
take the rawlplugs and woodscrews. If
necessary, make sound with a suitable
cement. If method 2 is chosen, make sure
that the areas at the back and towards the
centre of the fireplace floor are sound
enough to take the eyebolts and screws. If
these areas have deteriorated due to
prolonged use, they should be made
sound with a suitable cement.
4.1.4 Installations using a metal flue box
The whole of the top surface of the metal
flue box must be covered with a 100mm
layer of mineral wool or equivalent
insulation (see figure 2).
4.2 INSTALLATIONS REQUIRING SPACING
KIT 617K
The Valor accessory kit 617K must be
used for all installations described in
section 2.3 of this manual. Full
instructions for its installation are included
with the kit.
4.3 FIREPLACE FLUE PULL
After preparing the fireplace, carry out the
flue flow test as detailed in BS5440: Part 1.
Note - A 13 gramme smoke pellet will
generate the required volume of smoke,
anything smaller may give a false pass
result.
Observe the smoke. If there is a definite
flow into the opening continue with the
installation. If there is not a definite flow,
preheat the chimney for ten minutes and
recheck If there is still no definite flow, the
chimney may need attention. Do not fit
the appliance. Seek expert advice.
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 supply pipe must be rigid material.
Flexible pipe must not be used.
5.1 CONCEALED SUPPLY PIPE CONNECTION
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
opening at the back of the convection box
and run to the elbow at the front. If the
installation includes the optional spacing
kit 617K, the kit and surround should be
installed before extending the supply line.
The pipe run from the supply line up to
the rear opening in the convection box
must be kept away from the area which
will be taken by the convection box when
it is installed (See figure 10).
Note that the centre of the appliance inlet
elbow is 25mm above the fireplace floor.
The inlet elbow should be removed from
the appliance and fitted to the supply pipe
at this stage.
Page 10
INSTALLER GUIDE
5.GAS SUPPLY PIPE