Valor CHURCHILL 32-810-58 Assembly instructions

INSTALLER GUIDE
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.
INSTALLER: Please leave this guide with the owner
Manufactured exclusively for British Gas & Scottish Gas by Valor Heating
For Service Phone [phone]
Because our policy is one of constant development and improvement, details may vary
slightly from those given in this publication.
© Valor Heating
3002402/02
Churchill
Balanced Flue
(GC No. 32-810-58)
ROOM SEALED RADIANT/ CONVECTOR GAS FIRE
(Manufacturer ref. 4733)

INSTALLER’S GUIDE
Page 2
CONTENTS
SAFETY..................................................................................................................... 3
LIST OF ACCESSORIES .......................................................................................3
1. APPLIANCE DATA......................................................................................... 4
2. GENERAL INSTALLATION REQUIREMENTS ...................................... 5
Terminal Position ...............................................................................................9
3. UNPACKING..................................................................................................10
4. PREPARE THE FIRE ...................................................................................11
5. PREPARE THE WALL.................................................................................12
Cut the Flue Hole –Timber Frame Buildings .................................................14
6. PREPARE FLUE UNIT.................................................................................15
7. TERMINAL GUARD FITTING...................................................................18
8. CHECK IGNITION SPARK.........................................................................19
9. CONNECT TO THE GAS SUPPLY ............................................................19
10. FITTING COALS...........................................................................................20
11. CHECK APPLIANCE OPERATION..........................................................23
12. CHECK THE REFERENCE PRESSURE ..................................................23
13. REPLACE OUTER CASE ............................................................................ 24
14. MAKE FINAL CHECKS AND INSTRUCT USER ...................................24
15. SERVICING....................................................................................................25
15.1 To Remove Outer Case. ..........................................................................25
15.2 To Remove Window Unit .......................................................................25
15.3 To Remove The Ceramic Fuel Items ......................................................25
15.4 To Remove Burner(s) ..............................................................................25
15.5 To Remove Injectors(s) ...........................................................................26
15.6 To Remove Thermocouple ......................................................................26
15.7 To Remove Electrode Pin........................................................................26
15.8 To Remove Pilot Pipe & Jet ....................................................................26
15.9 To Remove The Gas Tap And Piezo Unit...............................................26
15.10 To Remove The Piezo Generator ............................................................27
15.11 To Grease The Control Tap.....................................................................27
SHORT LIST OF SPARES ...................................................................................28

INSTALLER’S GUIDE
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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 23 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.
LIST OF ACCESSORIES
Description Part number
Timber frame Flue Clearance kit. 0583141
This kit includes : -
1 off Flue clearance sleeve
1 off Drip collar
1 off External wall plate
1 off Insulation blanket (This can be discarded)
For timber framed installations see section 5.

INSTALLER’S GUIDE
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1. APPLIANCE DATA
The overall dimensions are shown in figure 1.
Main Burner: Simplex aerated
Flame Effect Burner: Simplex aerated.
Gas Connection: RP 1/4 (1/4in. B.S.P) Isolating Elbow (Female).
Gross Gas Consumption: 4.9kW at maximum position.
Maximum output: 3.54kW
Injectors: -
Main Burner: Bray Cat. 960 Size 240
Flame Effect Burner: Bray Cat. 960 Size 130
Pressure Setting (Cold): 18.2 + 0.75mbar
Aeration Adjustment: None required.
Control Tap: Variable position fitted with flame supervision device
and integral piezo igniter.
Pilot Unit: Right side of firebox. Combined Pilot jet
thermocouple sensor and electrode.
No component on this appliance is manufactured from asbestos or asbestos related
products.
Figure 1. Overall dimensions

INSTALLER’S GUIDE
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The appliance data label is at the left side of the rear case and is visible after
removing the case front. In addition, for customer reference, there is a label giving
the appliance serial number on the outside of the case at the bottom right side.
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 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.
2. GENERAL INSTALLATION REQUIREMENTS
2.1 Walls: -
Minimum 102mm (4in.) thick
Maximum 660mm (26in.) thick.
Suitable for use with combustible walls provided that there is no combustible
material or combustible cladding in the area indicated on the wall fixing template.
Please note that soft wall coverings (e.g. embossed vinyls etc.) are easily affected by
heat. They may therefore, scorch or become discoloured when close to a heating
appliance. Please bear this in mind when installing.
2.2 Installation to a timber-framed building should be in accordance with the
relevant sections of The Institute of Gas Engineers publication IGE/UP/7 “Gas
installations in timber frame buildings”.
Please note that advice should be sought before installing in a timber frame
building since the alterations required may nullify any NHBC cover relating to the
property. If in doubt, guidance should be requested from your local authority
planning or building department.
For timber framed installations see section 5.

INSTALLER’S GUIDE
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2.3 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.
2.4 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 5440 Part 1 BS 5871 Part 1 BS 6891
In the republic of Ireland the installation must also conform
a) With the relevant parts of the current editions of IS 813 and ICP3
b)All relevant national and local rules in force.
2.5 For combustible projections up to a depth of 178mm (Measured from the rear
fixing plane of the fire) a minimum clearance of 75mm should be maintained at the
left and right side of the fire. This is measured from the extreme side of the case.
This will allow easy access to the control knob and knurled nuts for removal of the
outer case. This clearance is mandatory for temperature requirements.
2.6 For any combustible projections beyond 178mm (Measured from the rear
fixing plane of the fire) a minimum clearance of 100mm should be maintained at the
left and right side of the fire. This is measured from the extreme side of the case.
This clearance is mandatory for temperature requirements.
2.7 For non-combustible projections a minimum clearance of 75mm should be
maintained at the left and right side of the fire. This is measured from the extreme
side of the case. This will allow easy access to the control knob and knurled nuts
for removal of the outer case.
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.

INSTALLER’S GUIDE
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2.8 The minimum height from the extreme top surface of the fire to the underside
of a shelf or other projection made of wood or any other combustible material is
shown in graph 1.
2.9 There is no restriction on the depth of non-combustible projections but a space
of at least 30mm should be allowed above the top of the appliance to enable removal
of the case front.
2.10 It is advisable that combustible fabrics such as curtains are not fitted above the
fire. If, however, this is unavoidable, a clearance of at least 150mm must be
maintained from the extreme bottom edge of the fabric to the extreme top surface of
the fire.
2.11 The appliance can be installed with or without a non-combustible hearth. If a
non-combustible hearth is installed, there must be a minimum clearance from the
top surface of the hearth to the absolute bottom of the appliance of 18mm (see figure
1). The hearth must be at least 700mm wide x 300mm deep. The non-combustible
hearth material must be at least 12mm thick. Its top surface should be preferably
50mm above floor level to discourage the placing of carpets or rugs over it.
If the appliance is not installed with a hearth meeting the above conditions, the
minimum distance from the top surface of the finished floor covering (including any
carpet etc.) to the absolute bottom of the appliance must be at least 40mm (see
figure 1).
2.12 A hole 152mm (6in) is required through the wall for the flue unit.
Graph 1. Combustible shelf clearances.

INSTALLER’S GUIDE
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Figure 2 Terminal Positions
The minimum height of the hole centre is shown in figure 1 and on the wall fixing
template.
2.13 Minimum allowable distances from the terminal are shown in table 1 and
figure 2: -
2.14 In England and Wales the Building Regulations require a terminal guard to be
fitted if the terminal could come into contact with people near the building or be
subject to damage.
Fitting a terminal guard is recommended where contact with or damage to the
terminal is possible even if regulations do not demand it.
A suitable guard is supplied with this fire.
2.15 No special ventilation bricks or vents into the room containing the appliance
are required.

INSTALLER’S GUIDE
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Table 1.
Dimension
(See figure 2)
Terminal Position Minimum
Distance
A* Directly below an opening, air brick, opening
window etc.
300mm
B* Above an opening, air brick, opening window etc. 300mm
C* Horizontally to an opening, air brick, opening
window etc.
300mm
D Below gutters, soil pipes or drain pipes 300mm
E Below eaves 300mm
F Below balconies or car port roof 600mm
G From a vertical drain pipe or soil pipe 300mm
H From an internal or external corner 600mm
I Above ground, roof or balcony level 300mm
J From a surface facing the terminal 600mm
K From a terminal facing the terminal 600mm
L From an opening in a car port (e.g. door, window)
into dwelling
1200mm
M Vertically from a terminal on the same wall 1500mm
N Horizontally from a terminal on the same wall 300mm
O From the wall on which the terminal is mounted N/A
P From a vertical structure on the roof N/A
Q Above intersection with roof N/A
*In addition, the terminal should not be nearer than 300mm to an opening in the
building fabric formed for the purpose of accommodating a built-in element such as
a window frame or door frame. See figure 3.

INSTALLER’S GUIDE
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Figure 3
3. UNPACKING
The carton contains the following: -
1 Fire assembly
1 Ceramic fuel base
4 Ceramic coals
1 Flue unit
1 Terminal Guard
1 Inlet elbow
1 Pack fixing screws and wall plugs
1 Wall fixing template
1 Length of flue sealing tape
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 all
the items are present and undamaged.

INSTALLER’S GUIDE
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Figure 4 Window Removal
4. PREPARE THE FIRE
4.1 Stand the fire upright
4.2 Detach the case front by removing the knurled nuts and washers at the case sides
(see figure1).
4.3 Pull the bottom of the case forwards and then left to remove.
4.4 Remove the window unit by detaching the 12 wing nuts securing the window frame
(see figure 4) and pulling forward.

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5. PREPARE THE WALL
The flue must be installed so that it is at
right angles to the back panel of the fire all
round the flue circumference. The fire
itself should be fitted vertically against a
flat wall. Where this is difficult to achieve
due to building inaccuracies care should be
taken to ensure that the back of the fire is
not stressed in any way due to distortion of
the assembly when tightening the fixing
screws. Where necessary, non-
combustible packing pieces should be used
to provide a satisfactory fixing surface.
Before cutting the hole in the wall make
sure that the height to the top surface of
the finished floor is known. The minimum
acceptable height from this surface to the
flue hole centre is shown in figure 5.
If a loose hearth or plinth is to be used, the height from its top surface must be used when
determining the minimum flue height. Where installation is to a timber frame wall, the
appliance should be positioned so that the right side wall fixings are into timber studs to
absorb any pressure generated by operating the control knob.
Proprietary cavity fixings should be used at the left side if the fixing at this side is into
plasterboard.
5.1 Place dustsheets on the floor and over any furnishings etc.
5.2 Place the template against the wall. Make sure that the centre of the flue hole is not
less than the minimum shown in figure 5.
5.3 Pierce the centre of the screw fixing holes and the flue hole and mark the positions
on the wall.
Remove the template.
5.4 Cut the hole for the flue unit. Make sure that it is straight and level. Though a
hammer and chisel can be used, using a core drill is by far the quickest and simplest
method for normal brickwork.
5.5 Core Drilling
5.5.1 Drill a pilot hole through the wall. Inspect the hole to ensure that it is in the
brickwork and not in mortar. If it is in mortar, it is advisable to reposition the hole
approximately 25mm away (making sure that the minimum side clearances and height are
complied with). Remember to reposition the screw fixing holes.
Figure 5 Wall Drilling

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5.5.2 Drill the flue hole with a
6in. (152mm) core drill.
Where practical, it is
recommended that the hole is
drilled from inside the
building to about half the wall
depth with the remainder
drilled from outside. This
ensures that the edges of the
hole are clean on both sides.
5.6 Hammer & Chisel
Cutting
5.6.1 Mark a 152mm (6in)
diameter circle for the flue
hole. Chisel out the area
marked.
5.6.2 It may be necessary to
make good both the
internal and external wall
faces. To achieve a neat
finish and to make any
future removal of the flue
unit easier, it is
recommended that a
cardboard cylinder be
formed around the flue
unit and inserted in the
hole while making good.
Remove the cardboard
cylinder after making
good.
5.7 Recheck the screw
fixing holes relative to the
flue hole.
5.8 Drill the four fixing holes to a minimum depth of 42mm using a 7mm diameter
masonry drill.
5.9 Insert the four wall plugs supplied.
5.10 Remove any combustible wall cladding material from the area shown in figure 6.
5.11 Leaving a Hole, Building under Construction
It will be convenient to use a non-corrosive metal tube 160mm diameter built into the wall
at the correct position for the flue unit.
Figure 7. Wall Cover plate
Figure 6 Combustible Cladding Removal

INSTALLER’S GUIDE
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Figure 8 Timber frame wall preparation
5.12 Combustible Walls (Wood, Fibreboard, Plasterboard etc.)
Building regulations require that the inlet and outlet ducts and terminal bust not be closer
than 25mm to combustible material.
5.12.1 Mark out and cut a hole 202mm diameter through the combustible part of the
wall. A 152mm diameter hole can be cut through non-combustible parts of the wall (see
figure 7).
5.12.2 Cover the hole with a rectangular sheet steel plate 500mm x 235mm with a
152mm diameter hole cut out of the centre (see figure 7). The steel should be not less
than 1.5mm thick. Fix with suitable screws and plugs.
5.12.3 Where the whole wall is of combustible material, a non-corrosive plate
455mm x 455mm with a 152mm diameter hole in the centre must be fitted to the outer
wall. The hole through the wall should be lined with a non-corrosive metal tube 202mm
diameter
Cut the Flue Hole –Timber Frame Buildings
Drill the pilot hole and hole in outer wall as section 5.5.

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●Since the flue will pass through combustible material in the inner leaf of the wall, a
non-combustible sleeve 203mm (8in.) diameter will be required round the flue. See
figure 8.
A Timber Frame Flue Clearance Kit is available. Part Number 0583141
●Cut a hole through the inner leaf to accommodate a non-combustible sleeve 203mm
(8in.) outside diameter. To minimise the effect of breaking through the vapour control
layer (VCL), if possible, cut the hole approximately 10mm undersize so that the sleeve
will be forced through the layer. A recommended technique for cutting the inner leaf is
shown in figure 8.
●Fit the non-combustible sleeve to the inner leaf. The sleeve must extend to be at least
flush with the breather membrane/timber sheathing but must not protrude more than
10mm into the cavity.
●The annular gap between the flue unit and the sleeve must be sealed to prevent air heat
and moisture passing along it.
6. PREPARE FLUE UNIT
(See Figure 9 & 10)
6.1 Measure the total wall
thickness from the outside
surface to the inside face. Add
80mm to this measurement to
obtain the correct length of
flue unit required.
6.2 Mark off the flue length
on the outer (air) tube
measuring from the end of the
terminal.
6.3 Insert the polystyrene
ring between the inner and
outer tubes to support them
and cut both tubes squarely at
the marked distance.
6.4 Important: Remove all
polystyrene from the flue
unit after cutting.
Figure 9. Flue unit Installation.

INSTALLER’S GUIDE
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Timber Framed Buildings
Figure 10. Flue Unit Installation

INSTALLER’S GUIDE
Page 17
Figure 11 Flue Securing
6.5 Fit the flue unit tubes firmly over the spigots at the rear of the fire. Make sure that
the seam on the flue tube is not at the bottom. Push on until the outer tube touches the
screw heads on the outer spigot.
6.6 If it is felt of benefit, the flue unit may be additionally secured to the fire with one
or two suitable self tapping screws (we suggest No.6) before installing into the wall as
follows: -
6.6.1 Using a suitable metal cutting drill bit, drill through the outer flue tube and outer
spigot at a distance of between 6mm & 7mm from the cut end of the outer flue tube - See
figure 11.
6.6.2 Fit the self-tapping screw(s) in
the drilled hole(s).
6.7 Seal the flue unit all round the
circumference of the fire spigot with
the tape supplied.
6.8 Insert the plugs into the wall
fixing holes. Insert the top right
fixing screw leaving the plain shank
proud to allow the top-fixing
keyhole in the fire back to go over
the screw.
6.9 Offer the fire complete with
flue unit through the wall and hook
the top right keyhole slot over the
previously fitted wall screw.
6.10 Insert the top left and two
bottom fixing screws and tighten.
6.11 Seal the outer flue tube to the
outside surface of the wall with
fireclay or cement. Make sure that
the slots in the flue terminal are
not closer than 8mm to the wall
and are not obstructed by cement.

INSTALLER’S GUIDE
Page 18
Figure 12 Terminal Guard
7. TERMINAL GUARD FITTING
Fitting Terminal Guard
7.1 Fold the terminal guard as shown in
figure 12.
7.2 Place the guard centrally over the flue
terminal.
7.3 Holding the guard in position and using it
as a template, mark on the wall the positions of
the four fixing holes.
7.4 Remove the guard. Drill and plug the
holes with the four plugs supplied.
7.5 Replace the guard and refix with four
woodscrews supplied.

INSTALLER’S GUIDE
Page 19
Figure 13 Pilot & Ignition Unit
8. CHECK IGNITION SPARK
The pilot ignition unit is situated at the bottom right side of the firebox - See figure 13.
Check that there is an ignition spark
between the pilot hood and the
electrode pin.
8.1 Depress the control knob and,
while keeping it depressed, turn to
IGN position. Turning the control
should normally cause two
consecutive sparks to occur between
the pilot hood and the electrode pin.
8.2 If there is no spark, check that
the wire connection is secure.
8.3 If there is still no spark
disconnect the electrode wire from
the pilot unit and place the end of
the wire close to a bright metal part
of the appliance.
8.4 Operate the control again
keeping your hand away from the
end of the wire. If there is a spark, the pilot unit is at fault.
8.5 The spark gap on the pilot unit is non-adjustable. Replace the pilot unit or its
components.
8.6 If there is no spark, the gas tap piezo unit should be changed.
9. CONNECT TO THE GAS SUPPLY
9.1 Extend the gas supply pipe to a convenient point beneath the appliance and connect
it to the inlet pipe at the right side of the fire using the Rp1/4 (1.4in. B.S.P) isolating
elbow provided.
The supply pipe must be of rigid material (e.g. copper). Flexible connections must not be
used.
9.2 Provision for isolation of the gas supply upstream of the fire must be provided for
safety and servicing.
9.3 Pressure test the installation for gas soundness in accordance with the current
edition of B.S.6891.

INSTALLER’S GUIDE
Page 20
Figure 15 Front Right Coal “B”
Location
Figure 14 Fuel Bed “A” Location
10. FITTING COALS
10.1 Place the fuel bed (embossed 'A'
underneath) in position. The front edge of the
fuel bed locates under the flange of the locating
strip at the base of the firebox - see figure 14.
10.2 Place the front right coal (embossed 'B'
underneath) in position. The flat bottom front
face of the coal should rest on the metal ledge
immediately behind the bottom front of the firebox opening. Slide the coal to the right
side. See figure 15.