Valor ULTIMATE TURBOCHIM 517SF Assembly instructions

*Covered by GB Patent 2.202.622B
600A938/04
ULTIMATE TURBOCHIM*
MODEL 517SF
Side Fan Flued
Inset Gas Fires
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 AdviceLine will
be pleased to help.
Please telephone [phone] (Local call rates apply)
Please leave this Installer Guide with the user
Natural gas models are for G20
Propane gas models are for G31
These appliances are for use in the United
Kingdom (GB) and the Republic of Ireland (IE)
only.
CUSTOMER CARE

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Page
Appliance data 4
General installation requirements 5-9
Contents of packs 10
Preparing appliance for installation 11
Electrical installation 12
Gas supply & flue duct siting 13-14
Fan box installation 15
Flue duct installation 16-19
Electrical tests 20
Terminal guarding 21
Front surround & gas supply installation 22-23
Ceramic coals & walls installation 24-25
Full operating checks 26-27
•Control settings check 26
•Spillage check 26-27
•Flame supervision & monitoring system check 27
Final review 28
Servicing & parts replacement 29-32
•Burner plaques replacement 29-30
•Front surround removal 30
•Pilot unit removal 30
•Burner unit removal 30
•Gas tap, F.S.D. & solenoid removal 31
•Piezo generator removal 31
•Main burner elbow injector removal 31
•Fan switch removal 31
•Electrical control components access 31-32
•Distribution block removal 32
•Air pressure switch removal 32
•Fan removal 32
Short list of spares 33
CONTENTS

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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 manufacturedfrom asbestos or
asbestos related products.
The appliance data label and wiring diagram are on a plate chained below the
burner and visible when the bottom front cover is removed.
Natural Gas
Appliances Propane Gas Appliances
Gas G20 G31
Inlet Pressure 20mbar 37mbar
Input - Max. (Gross) 6.0kW (20,500Btu/h) 6.1kW (20,800Btu/h)
Input - Min. (Gross) 2.2kW (7,500Btu/h) 3.6kW (12,200Btu/h)
Output - Max. 3.12kW (10,600Btu/h) 3.17kW (10,800Btu/h)
Output - Min 1.1kW (3,750Btu/h) 1.87kW (6,350Btu/h)
Burner Test Pressure
(Cold) 18.2±0.75mbar (7.3±0.3in w.g.) 36.2±0.75mbar (14.53±0.3in w.g.)
Gas Connection 8mm pipe 8mm pipe
Burner Injector Bray Cat. 82 Size360 Bray Cat. 92 Size 190
Pilot & Atmosphere
Sensing Device SIT Ref. OP9044 SIT Ref. OPLPG9221
Ignition Piezo Electric. Integral
with Gas Tap Piezo Electric. Integral with Gas Tap
Aeration Non-adjustable Non-adjustable
Electrical supply 230V ~50Hz AC 230V ~50Hz AC
Fan motor rating 55W 55W
Fuse rating 3A 3A
PART1: APPLIANCE DATA

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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, all electrical supply installation must be installed in
accordance with the current edition of the IEE Wiring Regulations (BS7671).
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) 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 2
BS 6891
In the republic of Ireland the installation must also conform with:
a) The current editions of:-
IS 813
ICP3
IS327
b) All relevant national and local rules in force.
The current ETCI National Rules for Electrical Installation.
2.2 Electrical isolation of the unit should be by means of a switched fuse
spur that should be readily accessible to the user, easily identifiable and
preferably sited adjacent to the appliance. It should only connect this appliance.
2.3 This fire is a fan flued appliance. This appliance is designed for
installation in a room which does not have a purpose built flue or chimney and
where it is intended to be against a wall where the fanned flue can not be sited
directly behind the heater.
PART2:GENERAL INSTALLATION REQUIREMENTS

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Fig. 1 General installation dimensions
Surround Cut-out
Dimensions

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2.4 The appliance is suitable for the following flue duct arrangements:-
i. A straight horizontal run up to a maximumof 4.5m. For normal timber
frame buildings astraightrun will not be possible.See section 2.5.
ii. A horizontal run up to a maximumof 3m including oneor two bends.
Minimum wall thickness 90mm.
iii. A vertical run up to a maximum of 3m (two bends are required for a
vertical installation). Minimum wall thickness 90mm.
The above run lengths are the total measurements from the rear of the fan box to the duct
connection at the side of the appliance
The flue duct can be fitted to either side of the appliance.
Figure 1 shows the critical installation dimensions
2.4.1 The standard appliance is supplied with a total of 3m of straight ducting.
The following optional extra kits are available:
Kit No. 517IBK - Internal elbow bend kit
Kit No. 517EBK - External elbow bend kit.
Kit No.517 FDK - 1.5m extra flue duct length with covers.
Kit No.517DK - 1.5m extra flue duct length without covers.
2.5 This appliance is suitable for installation in conventional buildings
constructed of brick, stone etc. and in timber framed buildings.
2.5.1 Installation in timber framed buildings 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.
In timber framed installations an annular non-combustible sleeve should be
fitted around the flue tube where it passes through the combustible inner wall.
There should be a minimum 25mm air gap between the flue tube and the
sleeve. The gap shall be sealed to prevent the passage of air, heat and moisture.
The space between the flue ducts and the wall on which the appliance is
mounted is less than 25mm. Elbow bends will therefore be necessary to allow
the annular sleeve to clear of the wall on which the appliance is mounted.
2.6 This appliance must be mounted with a non-combustible hearth (n.b
conglomerate marble hearths are considered as non-combustible). The fire box
must be mounted on a non-combustible surface. The hearth must project at
least 345mm forward of the convection box front and be at least 620mm wide
(See figure 1). The hearth material must be at least 12mm thick. The periphery
of the hearth (or fender) should beat 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, the burner bracket and the bottom front cover casting 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.

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2.7 The appliance must not be fitted directly against a combustible
wall. If the appliance is to be fitted against a wall with combustible cladding,
such materials must be removed from the area covered by the metal outer
surround of the appliance (see figure 1). We suggest that the actual surround is
used as a template to mark the area for combustible cladding removal.
•The appliance can be fitted to a purpose made proprietary class “O” 150°C
surround.
•The cut-out area in the surround should be between the size limits shown in
figure 1.
2.8 The minimum allowable distance from the outside edge of the
metal front surround of the appliance to a corner wall having
combustible materials is 178mm at either side (see figure 2).
2.9 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.
2.10 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.
2.11 The appliance must not be installed in any room which contains a bath or
shower or where steam is regularly present.
2.12 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 extractor fan is likely to affect the
appliance, the appliance must not be installed unless the fan is permanently
disconnected.
2.13 A fan-powered flue system tends to depressurise the room containing the
appliance. In the United Kingdom no additional ventilation should normally be
required. In the Republic of Ireland permanent ventilation must comply with
the rules in force. In exceptional circumstances however, the spillage check (See
further on in this guide) may indicate a need for further ventilation in order to
ensure that there is adequate air replacement. If necessary seek expert advice.
2.14 Make sure that the damp course or any electrical wiring, piping etc in the
wall is not affected when cutting the flue box or spigot installation hole.
2.15 Any gas supply pipe installed in the wall, floor or cavity of a cavity wall
must be continuous and enclosed in a factory fitted gas tight sleeve (Ref: Gas
safety (Installation & Use) Regulations 1994 as amended & Certificate of
exemption no.1 1996).
Fig. 2

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2.16 Propane gas appliances must not be installed in a room which is built
entirely below groundlevel(seeBS 5871 Part 2).
2.17 A concealedgas supply connection can bemade through grommetnear
the right corner of the rear panel. Visible front connection can be from the left
or right side.
2.18 Electrical connection to the isolating switched fused spur is from the left
side.
2.19 The flue terminal should be located so that the wind can blow freely
across it at all times and where any blockage due to leaves, snow, etc. is unlikely.
The minimum allowable distances from the terminal are shown in the
following table and figure 3. Note:The distances are from the edge of the vertical exit
slots in the terminal not from the edges of the rectangular box (See figure 3a).
Dimension Terminal Position Minimum
Distance
ADirectly below an opening, air brick, windows,
etc. 300mm
BBelow gutters, soil pipes or drain pipes 75mm
CBelow eaves 200mm
DBelow balconies or car port roof 200mm
EFrom a vertical drain pipeor soil pipe 75mm
FFrom an internal or external corner 200mm
GAbove ground, roof or balcony level 300mm
HFrom a surface facing the terminal 600mm
IFrom a terminal facing the terminal 1200mm
JFrom an opening in a car port (e.g. door,
window) into dwelling 1200mm
KVertically from a terminal on the same wall 1500mm
LHorizontally from a terminal on the same wall 300mm
MProjection outwards from wall 50mm
2.20 This appliance is supplied with a terminal guard. In England and Wales,
the Building Regulations require that the terminal guard is fitted if the flue
terminal can come in contact with people near the building or be subject to
damage. Even if the regulations do not demand it, we recommend that the
guard is fitted to prevent damage or blockage of the flue system by leaves etc.
Fig. 3
Minimum distances for
terminal positions shown
in the table are from slot
openings
Fig. 3a

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This appliance is contained in two packs The packs contain the following (see
figure 4).
Pack 1 contains:
1 Burner & convection box unit
fitted with front surround*.
1 Fan & flue box unit (with wall
mounting brackets attached)*.
1Terminalguard.
1 Flue duct connector unit &
gasket.
1 Flue duct Z coupling.
1 Nut & olive for 8mm inlet pipe.
1 Ceramic back wall.
1 Pair of ceramic side walls.
1 Front base coal left & right
halves.
1Rearbasecoal.
1 Pack of 7 loose coals.
1 Pipe bending template.
1 Surround cutting metal template.
1 Smoke match tube.
1 Terminal weather shield.
1 Junction box with cable clip,
earth lead sleeve & fixings.
1 Fire front casting.
1 Strip gasket & sealing tape (For
surround insulation)
1 Bottom front cover casting.
6 Wood screws & plugs.
2 Stainless steel screws.
4 Self tapping screws.
1 Literature pack.
Pack 2 contains:
2 1.5m long flue ducts.
2 1.5m long duct backing plates.
2 1.5m long duct front covers.
4 Duct support brackets
4 Machine screws & nuts
4 Spring clips (for cable).
3 Joint covers.
1 Duct bridging tube
4 Woodscrews, plastic washers &
wall plugs
2 Lengths sealing tape
Carefully remove the contents.
* The fan box unit and the convection box unit are linked by the fan supply
cable - Take care when removing the units froom the carton. Take special care
in handling the ceramic walls and the coals. Check that all the listed parts are
present and in good condition.
PART3: UNPACKING
Fig. 4 Pack contents