Valor Ultimate Turbochim BR517R Assembly instructions

*Covered by GB Patent 2.202.622B
600B 208/02
MODEL BR517R
(G.C. 32-032-11)
ULTIMATE TURBOCHIM*
&
SUPERFLAME RF*
Rear Fan Flued
Inset Gas Fires
INSTALLER GUIDE
Please keep in a safe place for future reference

2
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
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)
This appliance is for use in the United Kingdom (GB)
and the Republic of Ireland (IE) only.
CUSTOMER CARE

3
Page
Appliance data 4
General installation requirements 5
Contents of pack 9
Preparing appliance for installation 10
Wall preparation 11
•General 11
•Brick etc. building. Appliance in front of wall 11
•Brick etc. building. Appliance recessed in wall 12
•Timber frame building. Appliance in front of wall 14
Electrical installation 16
Installing appliance 17
Electrical tests 18
Terminal guard, front surround & gas supply
installation 19
Ceramic coals & walls installation 21
Full operating checks 22
Final review 24
Servicing & parts replacement 25
•Burner plaques replacement 25
•Front surround removal 26
•Pilot unit removal 26
•Burner unit complete removal 26
•Gas tap/F.S.D. & solenoid assembly removal 27
•Piezo generator removal 27
•Main burner injector removal 27
•Fan switch removal 27
•Electrical control components access 28
•Distribution block removal 28
•Air pressure switch removal 28
•Fan removal 29
Short list of spares 30
CONTENTS

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This product uses fuel effect pieces. It makes sense to take care when handling
these articles to ensure that the release of dust is kept to a minimum.
This appliance does not contain any component manufactured from asbestos or
asbestos related products.
The appliance data label and wiring diagram are on a tie below the burner and
are visible when the bottom front cover is removed.
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 (7,500Btu/h) 3.6kW (12,280Btu/h)
Output - Max. 3.12kW (10,600Btu/h) 3.6kW (12,280Btu/h)
Output - Min 1.1kW (3,750Btu/h) 1.8kW (6,140Btu/h)
Burner Test Pressure
(Cold) 18.2±0.75mbar (7.3±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 Size360 Bray Cat.18 Size 170
Pilot & Atmosphere
Sensing Device SIT Ref. OP9044 SIT Ref. OPLPG9222
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
*When converted using kit 591149
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.
c) 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 for installation on an outward facing wall
of a conventional home which does not have a purpose built flue or chimney.
2.3.1 As supplied, the appliance is suitable for homes constructed of brick,
stone, etc. For homes constructed of brick, stone, etc. the appliance can be
installed into walls up to a maximum thickness as shown below.
If the convection box is recessed into the wall: 413mm (16¼ in) max.
If the convection box is in front of the finished wall surface: 305mm (12in)
max.
These dimensions are from the finished internal wall surface (including any surround
material) to the external wall surface.
2.3.2 For timber framed buildings, the optional clearance box part no. 517TFK
must be installed. For timber framed buildings, the appliance is suitable for
walls up to 292mm (11½” ) maximum thickness measured from the external
wall surface to the internal plasterboard (or similar) wall surface.
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
PART2:GENERAL INSTALLATION REQUIREMENTS

6
nullify any NHBC cover relating to the property. If in doubt, guidance should be
requested from your local authority planning or building department.
2.4 This appliance must be mounted with a non-combustible hearth (n.b
conglomerate marble hearths are considered as non-combustible). The fire box
and fan box must be mounted on a non-combustible surface. The hearth must
project at least 345mm forward of the convection box front and beat least
620mm wide (See illustrations in “wall preparation” section. The hearth
materialmust be at least 12mm thick. The periphery of the hearth (or fender)
should be at least 50mm above floor levelto discourage the placing of carpets or
rugs over it. For timber framed buildings the hearth must be at least 50mm deep
over all its area so that the clearance box can be satisfactorily installed.
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.
2.5 The appliance must not be fitted directly against a combustible
wall. If the appliance is to be fitted against a wall with combustible cladding or
skirting board, such materials must be removed from the area covered by the
metal outer surround of the appliance. 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.
2.6 The opening in the surround or wall recess for the convection box must
be within the limits shown in figure 1(c)
2.7 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.
2.8 The front face of the wall should be reasonably flat over the area which
will be covered by the convection box top and side flanges to ensure a good
seal.
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.

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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 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. Normally no additional ventilation should be required. 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.
In the Republic of Ireland (IE), permanent ventilation must comply with the
rules currently in force.
(a) Appliance Dimensions (b) Shelf & Corner Wall Clearances
(c) Opening Requirements
Figure 1

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2.14 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 2. 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 2a).
Dimension Terminal Position Minimu
m
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 pipe or soilpipe 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 15mm
2.15 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.
2.16 A concealedgas supply connection can be madethrough the right side
panel or near theright corner of the rear panel.Visiblefront connection can be
from the left or right side.
2.17 Electrical connection is from the left side.
Figure 2 Terminal positions & minimum distances
Minimum distances for
terminal positions shown
in the table are from slot
openings
Figure 2a

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The fire front will be one of the following options:
Ultimateblack & brass surround
Ultimate all black suerround
Superflame.
The pack contains:
1 Burner & convection box unit fitted with front surround and fanned flue
unit
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 5 loose coals
1Template
1 Smoke match tube
1 Terminal weather shield
1Terminalguard
2 Screws & washers for terminal guard
6 Wall plugs
6 Woodscrews
1 Fire front casting
1 Bottom front cover casting
2 Finials for front cover casting (Superflame only)
1 Literature pack
Carefully remove the contents. 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
Figure 3 Pack contents

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4.1 Check ignition spark
Before attempting to install, it is worth checking that the piezo electric
spark ignition system operates satisfactorily.
To initiate the spark, depress the control knob and while keeping it
depressed, turn anticlockwise through approximately 60° to the
“PILOT/IGN” position. A spark should track from the electrode pin to
the thermocouple tip. If there is no spark or incorrect tracking, check
the spark gap between the electrode wire and thermocouple tip (see
figure 4). If the spark gap is correct, check the ignition wiring.
4.2 Remove the two screws securing the bottom of the front
surround to the sides of the convection box. Raise the front
surround to allow the retaining lugs at the top to clear the slots in
the convection box hood and then lift clear (see figure 5).
4.3 In the majority of cases (Fixing the appliance to the floor,
removal of mains cable for ease of connection to isolating
switch), the burner unit will need to be detached. Detach the burner
unit from the convection box by removing two screws (see figure 6).
Figure 6 Burner Removal Points
Figure 5 Front Surround Removal
PART4:PREPARING APPLIANCE FOR INSTALLATION
Figure 4 Pilot Ignition System

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5.1 GENERAL
5.1.1 Make sure that the installation will comply with all the relevant
requirements in part 2 of this manual.
5.1.2 Attempt to keep the hole sizes as close to the minimum dimensions as
possible in order to minimise the sealing required
5.1.3 Make sure that the damp course or any electrical wiring, piping etc in the
wall is not affected when cutting the installation hole.
5.1.4 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)
5.2 BRICK, STONE ETC. BUILDING. CONVECTION BOX
IN FRONT OF WALL
(Figure 7)
5.2.1 This installation is for use with a
fire surround or false chimney breast
having a minimum depth of 114mm
(4½in.). The maximum possible
surround depth will depend on the wall
thickness bearing in mind that the
terminal must project at least 15mm
beyond the external face of the wall to
allow the end cover to be removed and
refitted during servicing.
5.2.2 Combustible material within a
false chimney breast must be at least
75mm from the convection box.
5.2.3. The non-combustible hearth
must project at least 345mm in front of
the convection box front flanges and be
at least 620mm wide (Figure 7).
5.2.4 Make a hole through the wall to
cater for the flue box (Figure 7).
The bottom of the hole must be at the
same level as the top surface of the
hearth.
5.2.5 In almost every case, it will not be
necessary to support the hole with a
lintel. If, however the wall is of poor construction
seek expert building advice before commencing to
cut the hole.
5.2.6 The cavity should be sealed where the flue
box hole has been cut. We recommend filling
fully across the cavity with Rockwool or
equivalent to at least 100mm above and each side
of the opening. Fill at the bottom of the opening
to the level of the hearth/fireplace floor. See figure
7a.
Figure 7a Cavity sealing
PART5: WALL PREPARATION
Figure 7

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5.3 BRICK, STONE ETC. BUILDING. CONVECTION BOX
RECESSED INTO WALL (Figure 8)
5.3.1 This installation has the convection box
recessed into the wall of the building. The front
flanges of the convection box and the appliance
metal decorative surround will abut the front
surface of the wall.
5.3.2.The non-combustible hearth must project
at least 345mm in front of the convection box
front flanges and be at least 620mm wide (Figure
8).
5.3.3 The recess in the inner wall for the
convection box should be to the size shown in
figure 1. The bottom of this recess should be at the
same level as the top surface of the hearth.
5.3.4 A lintel may be required above the recess for
the convection box. If in doubt, seek expert
building advice before commencing to cut the
recess.
Whenever a lintel is required to support the recess
in the inner leaf of a brick/blockwork building,
follow the method outlined below. See figures 8a & 8b.
1. The lintel should be either steel (Catnic) or reinforced
precast concrete.It should be 750mm long x 75mm deep x
inner leaf thickness.
2. The opening should be, as near as possible, centrally below a
joint in the inner leaf block.
3. Cut out the opening for the lintel.
Where cutting through masonry, drill pilot holes and then
cut out the slot using a mechanical cutter. This will
minimise damage to the surrounding structure.
4. Insert the lintel. Bed the lintel on mortar. Don’t dry bed.
Slate pin to ensure the lintel and structure above is secure
and safe
5. Make the opening below the lintel by removing the masonry
and clearing debris. If the cavity has loose fill (e.g. granular)
insulation material, pack the edges of the opening with
Rockwool as you proceed to hold back the insulating
material.
5.3.5 Note that more clearance between the recess and the
convection box is required at the left side than at the right side
(Figure 1c). Bear this in mind when centring the flue box hole.
5.3.6 The rectangular hole through the wall to cater for the flue
box should be to the size shown in Figure 8. The bottom of the
hole should be at the same level as the top surface of the hearth. In
almost every case, it will not be necessary to support this hole with
a lintel. If, however the wall is of poor construction seek expert
building advice before commencing to cut the hole.
5.3.7 The wall cavity must not be bridged other than by the flue box. The
convection box must not project into the cavity between the inner and outer
walls by more than 10mm.
Figure 8b
Figure 8a
Figure 8

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5.3.8 The cavity should be sealed where the opening
has been cut. We recommend filling fully across the
cavity with Rockwool or equivalent to at least
100mm above and each side of the recess opening.
Fill at the bottom of the opening to the level of the
hearth/fireplace floor. It may be simplest to back fill
the cavity with the insulation material and then cut
through the insulation to the size of the flue box
hole.
An alternative to rockwool above the opening is to
seal across the top of the cavity with superlux board
or equivalent. The board should slope downwards to
the back so that any moisture will be channelled to
the outside.
See figure 8c.
Figure 8c Cavity sealing

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5.4 TIMBER FRAME BUILDING. CONVECTION BOX IN
FRONT OF WALL (Figures 9 & 9a)
5.4.1 This installation is for use in timber framed
buildings in conjunction with a fire surround having
a minimum depth of 127mm (5in.). The maximum
possible surround depth will depend on the wall
thickness bearing in mind that the terminal must
project at least 15mm beyond the external face of the
wall to allow the end cover to be removed and refitted
during servicing.
5.4.2 This installation requires the optional clearance
box part no. 517TFK. The kit is suitable for
combustible inner walls up to a maximum total
thickness of 180mm.
5.4.3. The non-combustible hearth must project at
least 345mm in front of the convection box front
flanges and be at least 620mm wide (Figure 9). For
this type of installation the hearth must be at least
50mm thick over its total area. Kit 517TFK is
designed for use with a hearth which is at least
50mm thick over its total area. For a hearth less
than 50mm thick but at least 25mm thick, the
bottom flange of the kit can be cut off. A hearth
less than 25mm thick over its total area can not be
used.
5.4.4 Installation must be in accordance with the
current edition of The Institute of Gas Engineers
publication IGE/UP/7 “Gas installations in timber
frame buildings”.
5.4.5 The back surface of the convection box and
front flanges of the clearance kit must be separated
from the timber frame by 25mm of non-
combustible material. This can consist of the usual
13mm plasterboard wall lining plus 12mm of
“Supalux”or similar non-combustiblematerial.
5.4.6 The clearance box requires a rectangular
opening 285mm wide x 335mm high through the combustible inner leaf. The
bottom of this opening must be 25mm below the top surface of the hearth
5.4.7 The opening should be between studs.
5.4.8 If creating the opening involves cutting through the sole plate and/or
bottom plate frame of the building, secure the cut ends to the substrate by
pinning or equivalent.
5.4.9 Make sure that the vapour barrier is cut carefully and made good to
maintain its integrity .
5.4.10A sloping plate should be fitted above the clearance kit in accordance with
The Institute of Gas Engineers publication IGE/UP/7 “Gas installations in
timber frame buildings”. Section 8.2.1.7. See figures 9 & 9a.
5.4.11Installing the clearance kit in the cut opening (See figure 9a).
1) Measure the distance from the face of the inside wall (including any
“Supalux” or other insulation mentioned in section 5.4.5) to the cavity in the
wall.
2) Cut the clearance kit to size so that it will not project into the cavity by more
than 10mm.
Figure 9a
Figure 9

15
3) Insert the box into the opening
4) Mark the securing hole positions on the wall.
5) Remove the box. Drill the wall and insert plugs if necessary.
6) Refit the box. Secure with the screws provided with the kit.
7) Mark the securing hole positions on the wall
8) Seal any gaps between the inside wall surface and the box flanges with a bead
of a suitable sealant.
9) Install the surround.

16
10)
6.1 Install a power supply at a switched fuse having a minimum separation
of 3mm at all poles. The spur should be readily accessible to the user, easily
identifiable and preferably sited adjacent to the appliance. It should only connect
this appliance.
6.2 To simplify installation of the cable supplied, it may be most convenient
to disconnect it from the appliance as described below, install it to the wall and
then reconnect to the appliance:
To disconnect the cable:
1) Detach the burner (See section 4.3).
2) Detach the control unit from the convection box left side flange by
removing two screws (see figure 10). Carefully pull the unit slightly
forward.
3) Detach thefan wiring loomconnection (See figure 11).
4) Detach the plastic vacuum tube from the metal vacuum pipe (see
figure 11).
5) Detach the control unit cover by removing one screw (See figure
12).
6) Remove the cable by releasing the cable clamp and detaching the
three leads.
6.3 When installing the cable, leave a minimum of 200mm of the
cable slack at the cable clamp end to allow installation of the appliance after
reconnection to the control box and to allow future removal of the control
box for servicing.
6.4 If the spur is at the right side of the appliance, run the cable under
the hearth. The cable must not run directly under or behind the appliance.
Figure 12 Control cover fixing
Figure 11 Fan loom & vacuum
pipe connections
PART6:ELECTRICAL INSTALLATION
Figure 10 Electrical control
unit fixings

17
7.1 If the gas supply pipe is to enter through the concealed rear
or side opening, pierce the relevant grommet (See figure 13). If the
supply pipe is sleeved, trim the sleeve back where it enters the
appliance and seal the sleeve to the pipe.
If using the concealed side opening, we suggest that the supply pipe
is cut so that it enters the side of the appliance by approximately
25mm and, after fitting the unit to the wall, using a compression
elbow, connect to a formed pipe running to the appliance elbow.
7.2 An installation template is supplied which includes a diagram
for forming the pipe so that it avoids various components
below the burner
7.3 If the unit is to be fixedto the floor:
•Place the template in position and mark the floor at the
positions of the two fixing holes.
•Drill two holes at the marked positions using a no. 10 drill
and plug.
7.4 For fixing the unit to the wall (see figure 14):
•Offer the unit to the prepared hole in the wall. Gently
push back until the convection box is squarely against the
wall.
•Mark through the four holes in the convection box side
flanges.
•Remove the unit.
•Drill four holes at the marked positions using a no. 10 drill and plug.
7.5 Place the unit back in position.
•The slack length of cable should be looped in the space at the left side of the
convection box .
7.6 If wall fixing , fit woodscrews through the convection box flanges.
7.7 If floor fixing, fit woodscrews through the convection box base. Replace
the burner unit.
7.8 If necessary, seal any gaps between the wall and the convection box
flanges with a bead of suitablesealant.
7.9 Seal the flue box to the external wall surface.
PART7:APPLIANCE INSTALLATION
Figure 14 Wall fixing positions
Figure 13 Concealed openings

18
8.1 Switch on power supply. The red indicator light at the left
side of the burner should be on.
8.2 Press and hold in the “on” switch. Within two seconds, the
Fan motor should start and the indicator light should go out.
8.3 Release the “on” switch. The fan should continue to run.
8.4 Press the “off” switch. The fan should stop and the
indicator light should come on.
8.5 The fan has a “boost” speed intended to clear any minor
exhaust obstructions. To check its operation:
i. Switch the fan on (8.1 to 8.3 above).
ii. Go outside the building and place a hand over the rectangular exhaust outlet
of the terminal. The fan should be heard to increase to “boost” speed within
approximately two seconds.
iii. Remove the hand. The fan should revert to normal speed after approximately
three seconds.
8.6 The unit includes a blocked flue sensor system. To check its operation:
i. Switch the fan on (8.1 to 8.3 above).
ii. Block off the rectangular exhaust outlet of the terminal. The system should
shut down and the indicator should light within ten seconds.
iii. After checking remove the flue blockage.
If the above tests are not satisfactory, refer to the servicing section of this
manual.
Note:At times of very windy weather orlow voltage conditions the fan may switch between
boost and normal speeds. A click from the atmospheric pressure sensor may be heard as the
fan switches speeds.
PART7:INSTALLING APPLIANCE
PART8:ELECTRICAL TEST
Figure 15 Wiring diagram
Figure 15a Controls

19
9.1 Fit the weather shield and guard to the back of the flue unit as
detailed below (seefigures 16 & 16a).
9.1.1 Remove the two screws near the sides of the terminal end just
below the louvres. Remove the screw near the bottom of the terminal
end.
9.1.2 Slacken the terminal end plate to remove the lifting strap. Discard
the strap. Replace the end plate.
9.1.3 Place the weather shield in position aligning the holes in the
shield with those at the sides of the end plate. Secure with the two
screws previously removed. see figure 16.
9.1.4 Fit the terminal guard. Secure the guard at the bottom with the
screw and washer previously removed. Secure the guard at the
top between the two right hand columns of louvres using the
screw and washer supplied in the pack. see figure 16a.
9.2 Locate the two lugs at the top of the front surround in the
slots in the convection box hood. Swing the bottom of the
surround sides back against the convection box and lower the
surround so that the lugs are fully seated in the slots in the
convection box hood.
9.3 Refit the two screws to secure the surround sides to the
convection box brackets.
9.4 Connect the supply line to the appliance.
Unless the supply pipe connection is from the left front side, the
supply pipe will have to be formed to avoid various components
below the burner. An installation template is supplied which
contains a diagram for bending this supply pipe.
9.5 Pressure check the installation pipework for gas soundness
in accordance with the current edition of BS6891. Do not use
leak detection sprays on this appliance. Sprays may affect the
operation of electrical components. Keep all liquid detection fluids
clear of electrical components. A long brush may be required to reach some joints.
9.6 Preliminary Burner Checks
Some burner operations can be checked at this stage. Checking now will mean
that less disassembly will be required if any problems are found. A full check
should still be made, however, after final installation.
9.6.1 Switch on electrical power supply. The red indicator light at the left side
of the burner should be on.
9.6.2 If closed, open the isolating valve at the inlet elbow.
9.6.3 Press and hold in the “on” switch. Within two seconds, the Fan motor
should start and the indicator light should go out.
9.6.4 Release the “on” switch. The fan should continue to run.
9.6.5 Depress the control knob and turn anticlockwisepartially 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
Figure 16aTerminal Guard Installation
PART9:TERMINAL GUARD, FRONT SURROUND & GAS
SUPPLY
Figure 16 Weather Shield
Installation

20
fully to the “PILOT/IGN” position. A spark should be generated at the pilot
while turning. The spark should ignite the pilot.
9.6.6 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).
9.6.7 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.
9.6.8 With the burner at “LOW”, 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”.
9.6.9 Press the “off” switch. The fan should stop and the indicator light
should come on.
9.6.10 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.
9.7 Check Reference Pressure
The appliance is pre-set to give the correct heat input at the inlet
pressure shown in part 1 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 (See figure 17). Check the pressure with
the fan on, 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 suitableleak detection fluid (Do not use a
liquid detection spray See section 9.5 ).
Figure 17 Pressure test point