Valor COSYFLAME BR623 Assembly instructions

For
600B336/03
VALOR COSYFLAME
(MODEL BR623)
&
VALOR SECRET
(MODEL BR427)
&
VALOR GRAMPIAN
(MODEL BR427)
Inset Live Fuel Effect Gas Fires
(G.C.32-032-15)
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
Advice Line will be pleased to help.
Please telephone [phone] (Local call rates apply)
Please leave this Installer Guide with the user
CUSTOMER CARE
As supplied, this appliance is for use with natural
gas (G20)
When converted using Valor conversion kit no.
591149 this appliance is for use with propane gas
(G31)
These appliances are for use in the United
Kingdom (GB) and the Republic of Ireland (IE) only.

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CONTENTS
Installation Notes .......................................................................................................................4
Technical specification ...............................................................................................................5
Pack Contents ............................................................................................................................6
General Installation Requirements ............................................................................................6
•Fire Surround........................................................................................................................7
•Hearth Requirememnts ........................................................................................................7
Installation and Commissioning Instructions .............................................................................7
•Fireplace, flue and Ventilation Details..................................................................................7
•Foam Seal .............................................................................................................................7
•Cable Retention ...................................................................................................................8
•Floor Sealing .........................................................................................................................8
•Preliminary Burner Checks ..................................................................................................8
•Check Reference Pressure ...................................................................................................9
Fitting the Ceramics ...................................................................................................................9
Full Operating Checks ..............................................................................................................11
•Recheck Control Settings ...................................................................................................11
•Check for Spillage ..............................................................................................................11
•Flame Supervision & Spillage Monitoring System ..............................................................11
Final Review .............................................................................................................................12
Servicing ...................................................................................................................................13
•Burner Plaque Removal .....................................................................................................13
•Burner Unit Removal .........................................................................................................13
•Pilot Unit Removal .............................................................................................................13
•Gas Tap Removal ...............................................................................................................14
•Piezo Generator Removal ..................................................................................................14
•Greasing Gas Tap ...............................................................................................................14
•Injector Removal ................................................................................................................14
•Removing Appliance ..........................................................................................................14
Short List of Spares ..................................................................................................................15
Useful Telephone Numbers ......................................................................................................16

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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 before eating 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 6461 Part 1
BS 6891
In the Republic of Ireland the installation must also conform with the relevant parts of:
a) The current editions of:-
IS 813
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 the point of termination of the flue.
The chimney or flue must 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.
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 the regulations currently in force.

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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
close to a heating appliance. Please bear this in mind when installing.
Propane gas appliances must not be installed in a room, which is built entirely below ground level (See BS 5871 Pt2).
TECHNICAL SPECIFICATION
Fire surround height: 600mm
Fire surround height: 470mm
Appliance depth: 115mm
Height of opening required: 535mm min.
575mm max.
Width of opening required: 335mm min.
435mm max.
Gas Natural (G20) Propane (G31)*
Inlet Pressure 20mbar 37mbar
Input - Max. (Gross) 6.0kW (20,500Btu/h) 6.1kW (20,800Btu/h)
Input - Min. (Gross) 2.2kW (7500Btu/h) 3.6kW (12280Btu/h)
Output - Max. 3.5kW (11,900Btu/h) 3.6kW (12,280Btu/h)
Output - Min 1.1kW (3750Btu/h) 1.8kW (6140Btu/h)
Burner Test Pressure (Cold) 17.0±0.75mbar
(6.8±0.3in w.g.) 35.6±0.75mbar (14.3±0.3in w.g.)
Gas Connection 8mm pipe 8mm pipe
Burner Injector Bray Cat. 18 Size 360 Bray Cat. 18 Size 170
Pilot & Atmosphere Sensing
Device SIT Ref. OP9030 SIT Ref. OPLPG9222
Ignition Piezo Electric. Integral with
Gas Tap Piezo Electric. Integral with Gas Tap
Aeration Non-adjustable Non-adjustable
* When converted using Kit 591149
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 Hotbox and Burner assembly
1 Firefront Pack
1 Ceramics Pack
3 Self-Adhesive Foam seals
2 Tension Cables
2 Cable Adjusters
2 Eyescrews
2 Fibre Plugs
1 Strip of Floor Sealing Tape
1 Literature Pack
1 Nut and Olive for 8mm Inlet Pipe

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GENERAL INSTALLATION REQUIREMENTS
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 not be required providing at least 50mm clearance is
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 25mm is maintained between the lintel and the front face of the fireplace
(i.e. 25mm rebated fire surround).
2. 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 total depth of the opening measured from the finished front of the fireplace (Including plaster, surround etc.)
must be not less than 118mm (Figure 2).
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.
3. 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 150mm. 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.
Figure 2 Pre-cast Fireplace
Figure 1 Masonry Fireplace
Figure 3 Factory Made Flue System

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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 4. 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.
The burner is produced from a soft ceramic material and should be handled carefully.
The burner tray assembly has been tested before it leaves the factory and is in perfect working order.
Remove any transit tape and packing and inspect for any evidence of mishandling which might affect the performance. Each unit
is flame tested before it leaves the factory and as a result there may be slight discoloration around the burner ports. There may
also be slight thermal cracking across the burner surface that is perfectly normal and is not detrimental to performance.
8mm (5/16) Bundy or semi-rigid tubing must be used to connect the appliance to the gas supply.
Centre the appliance in the fireplace opening taking care not to scratch or damage the hearth.
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 one screw set in
the front leg (see Fig.5). Remove the screw and
carefully remove the burner assembly by lifting and
sliding forward from the firebox.
FOAM SEAL: 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 5 Burner fixing points
Figure 4 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. These should be fitted in
accordance with Figure 6, using the wall plugs and a
No.10 drill. Use only the fibre wall plugs supplied
(or similar). On no account should plastic wall plugs be
used.
Method: Assemble one end of the cable to the top
of the fire by passing it through the small round hole
and locking by positioning the cable end in the
adjacent slot. Pass the other end of the cable
through the eyebolt & hole in the lower side of the
appliance and fit adjusters in accordance with Figure
7. With the adjusters fully screwed in, carefully
manoeuvre the appliance into the fireplace opening.
Take up any slack on the cables, and tighten cable
nipples into position.
Tighten the appliance into the fireplace opening by
turning the adjuster nuts to compress the sealing
foam sufficiently to provide an effective seal. Do not
overtighten.
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.
FLOOR SEALING
Using the floor sealing tape supplied, seal the bottom of the
convection box to the fireplace and hearth floor. Run the tape over
the burner-fixing bracket.
Replace the burner assembly into position 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.
Refit the burner unit to the appliance to the front leg bracket by the screw.
Connect the supply line to the appliance.
For side connection passing in front of the surround. 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 pipe should pass through the cutout in the casting side.
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,
Figure 7 Cable Adjustment
Figure 6 Cable Retention Method

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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”.
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 THE CERAMICS
Fit the ceramic rear wall (figures 8
& 9). The featheredge of the
ceramic rear wall must be at the
top.
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 so that it is
immediately behind the
front rim of the burner
compartment. (See Fig 10
& 11).
Figure 9 Ceramic rear wall position
Figure 8 Ceramic rear wall &
Bracket fixing
Figure 11 Front Base Coal in Position
Figure 10 Front Base Coal Positioning

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Place the rear base coal in
the burner compartment
behind the front coal. It
should rest on the ledge at
the back of the burner
compartment and its rear
face should touch the rear
ceramic wall (See Figure 12
& 13).
Install the 9 loose coals as
follows. The smooth
surfaces of the coals
should be at the bottom
and back. Select the two
smallest coals and put
them aside until all the
other coals are installed.
Place four of the medium
size coals in the four
valleys of the front coal.
Place the left side coal so
that the customer will be
able to see the pilot flame
(Figures 14 & 15).
Place the three remaining
medium size coals behind
and approximately midway
between each of the coals in
the front row (Figures 16 &
17).
Place the two remaining
small coals alongside the
main coals (Figures 18 &
19).
Figure 19 Side Coals in Position
Figure 18 Positioning Side Coals
Figure 17 Second Row of Coals in Position
Figure 16 Positioning Second Row of Coals
Figure 15 Front Row of Coals in Position
Figure 14 Positioning Front Row of Coals
Figure 13 Rear Base Coal in Position
Figure 12 Rear Base Coal Positioning