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Valor Dream 2 Installer's Manual

Manual is about: Model 641 Inset Live Fuel Effect Gas Fire

Summary of Dream 2

  • Page 1

    3002499/02 installer guide this appliance is for use with natural gas (g20) when converted using conversion kit no. 0591301 this appliance is for use with propane gas (g31) this appliance is for use in the united kingdom (gb) and the republic of ireland (ie) only. We trust that these instructions gi...

  • Page 2: Installer’S Guide

    Installer’s guide page 2 safety first. Valor fires are ce approved and designed to meet the appropriate british standards and safety marks. Quality and excellence. At the heart of every valor fire. All valor fires are manufactured to the highest standards of quality and excellence and are manufactur...

  • Page 3: Installer’S Guide

    Installer’s guide page 3 s a f e t y 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 24.0 kg. One person should be sufficient to lift the fire. If for any reason this weight...

  • Page 4: Installer’S Guide

    Installer’s guide page 4 contents safety ...............................................................................................................................................3 1 appliance data.....................................................................................................

  • Page 5: Installer’S Guide

    Installer’s guide page 5 1 a p p l i a n c e d a t a 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 respir...

  • Page 6: Installer’S Guide

    Installer’s guide page 6 figure 1. Hearth & fireplace opening 2 g e n e r a l i n s t a l l a t i o n r e q u i r e m e n t s 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 co...

  • Page 7: Installer’S Guide

    Installer’s guide page 7 the environment for northern ireland. In the republic of ireland the installation must also conform to the relevant parts of: a) the current edition of is 813 b) all relevant national and local rules in force. 2.2 in the united kingdom, as supplied, the appliance can be inst...

  • Page 8: Installer’S Guide

    Installer’s guide page 8 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,...

  • Page 9: Installer’S Guide

    Installer’s guide page 9 2.5 the flue must conform to bs 5440: part 1 in design and installation. The flue, measured from the bottom of the fireplace opening to the bottom of the terminal, shall be not less than 3m in actual vertical height. When calculated in accordance with bs 5440: part 1 annex a...

  • Page 10: Installer’S Guide

    Installer’s guide page 10 graph 1. Combustible shelf clearances 2.12 the minimum height from the top surface of the hearth to the underside of any shelf made from wood or other combustible materials is shown in graph 1. 2.13 note that soft wall coverings (e.G. Embossed vinyl, etc.) are easily affect...

  • Page 11: Installer’S Guide

    Installer’s guide page 11 2.17 propane gas appliances must not be installed in a room that is built entirely below ground level (see bs 5871 part 2). 2.18 if the appliance is to be fitted against a wall with combustible cladding, the cladding must be removed from the area covered by the outer surrou...

  • Page 12: Installer’S Guide

    Installer’s guide page 12 3 p a c k c o n t e n t s the items required for this appliance are packed in two sections. Section 1 - fire unit contains: 1 burner & hotbox unit 1 burner front baffle 1 nut & olive for 8mm inlet pipe 1 flue restrictor plate 2 screws (for flue restrictor) 2 screws (for fir...

  • Page 13: Installer’S Guide

    Installer’s guide page 13 2 cable clamps 4 eyebolts 1 rubber grommet 1 knurled shouldered screw for control linkage fixing 1 pp3 battery 1 smoke match tube 2 fireback spacing brackets 1 rear ceramic wall support bracket 1 length of self adhesive foam seal 1 literature pack 1 fireslide slider control...

  • Page 14: Installer’S Guide

    Installer’s guide page 14 figure 6. Pack contents.

  • Page 15: Installer’S Guide

    Installer’s guide page 15 figure 7. Fireplace areas 4 f i r e p l a c e c h e c k 4.1 4.1.1 fireplace size the fireplace must comply with the requirements described in section 2.2. This will probably entail removing the fireback and infill material behind the fireback. The debris catchment area show...

  • Page 16: Installer’S Guide

    Installer’s guide page 16 if method 2 is chosen, make sure that the areas at the back and towards the centre of the fireplace floor are sound enough to take the eyebolts and screws. If these areas have deteriorated due to prolonged use, they should be made sound with a suitable cement. 4.1.3 install...

  • Page 17: Installer’S Guide

    Installer’s guide page 17 figure 10. Pilot ignition system figure 9. Control pivot bracket figure 8. Battery fitting 5 i g n i t i o n c h e c k before attempting to install, it is worth checking that the electronic ignition system performs satisfactorily. ● fit the battery to the ignition block loc...

  • Page 18: Installer’S Guide

    Installer’s guide page 18 6 g a s s u p p l y c o n n e c t i o n 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 suppl...

  • Page 19: Installer’S Guide

    Installer’s guide page 19 figure 13. Fireback spacers figure 12. “u” seals figure 11. Burner attachment points 7 p r e p a r i n g a p p l i a n c e f o r i n s t a l l a t i o n important before continuing with the installation of this gas fire the aeration setting on the burner must be checked. Th...

  • Page 20: Installer’S Guide

    Installer’s guide page 20 in figure 13.Secure the fireback spacers using the screws removed previously and the two supplied with the fire. 8. This appliance is supplied with a flue restrictor for use where the flue draught is excessive. The restrictor must not be fitted where a precast flue or a flu...

  • Page 21: Installer’S Guide

    Installer’s guide page 21 figure 16. Front fixing 8 h o t b o x i n s t a l l a t i o n 8.1 method 1 - front fixing to fireplace surround 1. Make sure that the fireplace front surround area is sound enough to take the rawlplugs and woodscrews. If necessary, make sound with a suitable cement. 2. Plac...

  • Page 22: Installer’S Guide

    Installer’s guide page 22 figure 18. Upper cable retention figure 17. Eyebolt positions 8.2 method 2 - cable retention and floor fixing. 1. Make sure that the relevant areas at the fireplace back or floor are sound enough to take the eyebolts and screws. If these areas have deteriorated due to prolo...

  • Page 23: Installer’S Guide

    Installer’s guide page 23 figure 21. Lower cable retention figure 20. Floor fixing figure 19. Cable route 6. Thread the cables through the eyebolts. Return the cables through the holes near the bottom of the convection box back panel, (for precast or clay block flue systems return the cables through...

  • Page 24: Installer’S Guide

    Installer’s guide page 24 figure 22. Floor sealing 12. Inspect the installation of the convection box against the fireplace surround. If the convection box is aligned squarely and the sealing is satisfactory, fully tighten the cable retainers. 13. If the convection box is not correctly aligned, rele...

  • Page 25: Installer’S Guide

    Installer’s guide page 25 figure 23. Control pivot rotation 9 b u r n e r & s u p p l y p i p e i n s t a l l a t i o n 9.1 burner & supply pipe installation 1. Refit the burner unit to the hotbox with two screws. 2. Connect the supply line to the appliance. 3. Pressure check the installation pipewo...

  • Page 26: Installer’S Guide

    Installer’s guide page 26 figure 24. Pressure test point 9.3 reference pressure check the appliance is pre-set to give the correct heat input at the inlet pressure shown in section 1 of this manual. No adjustment is necessary. 1. Check the burner pressure by fitting a pressure gauge at the test poin...

  • Page 27: Installer’S Guide

    Installer’s guide page 27 figure 26. Side wall installation. Figure 25. Ceramic rear wall installation 1 0 c e r a m i c w a l l s i n s t a l l a t i o n 1. Fit the rear ceramic wall support bracket to the rear of the hotbox using two screws. The “l” shaped section should be on top with the two sid...

  • Page 28: Installer’S Guide

    Installer’s guide page 28 figure 28. Front casting top location figure 27. Attach slider to firefront 1 1 f r o n t s u r r o u n d & c o n t r o l l i n k a g e i n s t a l l a t i o n 1. Attach the slider control to the rear of the front surround using 2 taptite screws (see figure 27). Slide the c...

  • Page 29: Installer’S Guide

    Installer’s guide page 29 figure 31. Fitting the burner baffle figure 30. Control bar & pivot bracket 3. Swing the bottom control linking bar towards the centre of the fire to clear the right side of the surround. Slide the surround unit sideways, if necessary, to align the bottom fixing holes with ...

  • Page 30: Installer’S Guide

    Installer’s guide page 30 figure 33. Front coal location figure 32. Ceramic base location 1 2 c e r a m i c c o a l s i n s t a l l a t i o n 1. Place the ceramic base coal in the burner compartment. The bottom rear face of the coal should rest on the angled ledges at the back of the burner compartm...

  • Page 31: Installer’S Guide

    Installer’s guide page 31 5. Install the 12 loose coals as follows. The underside of each coal is marked with a letter ‘a’ to ‘l’ and an arrow. 6. The coals should be positioned so that the arrows always point towards the back of the firebox. When located into position the stem of each arrow should ...

  • Page 32: Installer’S Guide

    Installer’s guide page 32 11. Hold coal ‘d’ upright with the arrow pointing to the top. Locate coal ‘d’ as shown in figure 37. 12. Hold coal ‘e’ upright with the arrow pointing to the top. Locate coal ‘e’ as shown in figure 38. 13. Hold coal ‘f’ upright with the arrow pointing to the top. Locate coa...

  • Page 33: Installer’S Guide

    Installer’s guide page 33 15. Locate coals ‘g’ to ‘k’ so that they are firmly seated in the valleys in the coal base. 16. Hold coal ‘g’ upright with the arrow pointing to the top. Locate coal ‘g’ as shown in figure 40. 17. Hold coal ‘h’ upright with the arrow pointing to the top. Locate coal ‘h’ as ...

  • Page 34: Installer’S Guide

    Installer’s guide page 34 19. Hold coal ‘j’ upright with the arrow pointing to the top. Locate coal ‘j’ as shown in figure 43 20. Hold coal ‘k’ upright with the arrow pointing to the top. Locate coal ‘k’ as shown in figure 44 21. Hold coal ‘l’ upright with the arrow pointing to the top. Locate coal ...

  • Page 35: Installer’S Guide

    Installer’s guide page 35 figure 46. Control 1 4 f u l l o p e r a t i n g c h e c k s 14.1 check the control settings the control position markings on the front surround are shown in figure 46. Please note: • when first turned on from cold, the flames will appear predominantly blue. • when operatin...

  • Page 36: Installer’S Guide

    Installer’s guide page 36 figure 47. Smoke match tube position 14.2 check for spillage a spillage check must be made before leaving the installed appliance with the customer. Make this with all the ceramic coals in position. 1. Close all doors and windows in the room containing the appliance. 2. Lig...

  • Page 37: Installer’S Guide

    Installer’s guide page 37 1. Light the appliance. Set the slide control to the maximum burning position and leave for one minute. 2. Set the control to the low burning position. Isolate the gas supply at the inlet elbow. The pilot and main burner will go out. Note the time when the pilot goes out. L...

  • Page 38: Installer’S Guide

    Installer’s guide page 38 1 5 f i n a l r e v i e w 1. If a gap is visible between the inner sides of the front surround and the ceramic side walls, gently slide the walls forward. 2. Visually inspect the appliance. Clean off any marks incurred during installation. 3. Advise the customer how to oper...

  • Page 39: Installer’S Guide

    Installer’s guide page 39 1 6 s e r v i c i n g & p a r t s r e p l a c e m e n t always turn off the gas supply before commencing any servicing (the appliance inlet “t” connector incorporates an isolating valve). It is recommended that, at least once a year, the appliance is disconnected and the fi...

  • Page 40: Installer’S Guide

    Installer’s guide page 40 figure 51. Thermocouple interrupter block figure 50. Microswitches figure 49. Microswitch cover removal • check that the appliance is clean and that soot or debris is not blocking the gaps between the coals causing an imperfect flame. • check that soot or debris is not impa...

  • Page 41: Installer’S Guide

    Installer’s guide page 41 figure 54. Front surround top location figure 53. Front surround bottom location figure 52. Control linkage disconnection 16.3 to remove the gas shut-off microswitch see figures 49, 50 & 51. The gas shut-off microswitch is stamped v4nt9c2ycgpx or v4nt9c2ycaux. 1. Remove the...

  • Page 42: Installer’S Guide

    Installer’s guide page 42 figure 56. Burner attachment points figure 55. Control slide & button fixings has been detached (see 3 above). Carefully lift the surround unit upward to clear the upper retaining brackets on the hotbox - see figure 54. Pull the surround clear and place carefully aside. 6. ...

  • Page 43: Installer’S Guide

    Installer’s guide page 43 figure 58. Removal of electronic generator. Figure 57. Ceramic support bracket removal. 2. Remove the battery. 3. Remove the burner unit – see section 16.6. 4. If lying the burner on its back, unscrew and remove the two ceramic support brackets from the top of the burner un...

  • Page 44: Installer’S Guide

    Installer’s guide page 44 figure 60. Pilot unit removal (dust cage not shown for clarity) figure 59. Thermocouple interrupter block 4. Remove the interrupter block by unscrewing from the gas shut-off tap. 5. Refit in the reverse order. If the microswitch leads cannot be easily attached to the interr...

  • Page 45: Installer’S Guide

    Installer’s guide page 45 figure 61. Shut-off tap (viewed from rear with burner turned over) 2. Once removed, ensure that the dust cage is cleaned before refitting. Make sure that it locates squarely onto the pilot unit without any gaps between the cage edges and the pilot unit. 3. When the thermoco...

  • Page 46: Installer’S Guide

    Installer’s guide page 46 figure 63. Burner injector removal figure 62. Flow rate controller 16.12 to remove the gas flow rate controller see figure 62. 1. Remove the burner unit - see section 16.6. 2. If lying the burner on its back, unscrew and remove the two ceramic support brackets from the top ...

  • Page 47: Installer’S Guide

    Installer’s guide page 47 2. If lying the burner on its back, unscrew and remove the two ceramic support brackets from the top of the burner unit. This will avoid damage to the brackets and the worksurface (see figure 57) 3. Disconnect the main burner pipe from the injector at the venturi end. If ne...

  • Page 48: Installer’S Guide

    Installer’s guide page 48 figure 65. Burner plaque positions 16.14 to replace burner plaques see figure 65. 1. Remove the bottom front and fire front castings. 2. Remove the loose coals, the front coals and the base coal. 3. The plaques can be then be removed as follows without detaching the front s...

  • Page 49: Installer’S Guide

    Installer’s guide page 49 16.15 to remove the appliance from the fireplace 1. Remove the burner unit - see section 16.6. If the fire retention is as method 1 (see section 8.1 of installation instructions), remove the screws. If the fire retention is as method 2 (see section 8.2 of installation instr...

  • Page 50: Installer’S Guide

    Installer’s guide page 50 1 7 s h o r t l i s t o f s p a r e s.

  • Page 51: Installer’S Guide

    Installer’s guide page 51 key no. Description no. Off maker’s part no. A shut-off tap 1 730k146 b gas flow rate controller 1 730k147 c thermocouple interrupter block 1 720a142 d ignition microswitch 1 720a269 e gas shut-off microswitch 1 020k931 f pilot unit - for natural gas appliances 1 720a249 pi...