Valor Dream 2 Installer'S Manual Download Page 1

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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 give sufficient details to enable this appliance to be

installed and maintained satisfactorily. However, if further information is required, our

Valor Technical Helpline

will be pleased to help.

Telephone

08706 061 065

INSTALLER: Please leave this guide with the owner

Dream 2

INSET LIVE FUEL EFFECT GAS FIRE

INCORPORATING THE

VALOR

CONTROL

Model 641

(GC No. 32-032-49)

Summary of Contents for Dream 2

Page 1: ...AND IE ONLY We trust that these instructions give sufficient details to enable this appliance to be installed and maintained satisfactorily However if further information is required our Valor Technical Helpline will be pleased to help Telephone 08706 061 065 INSTALLER Please leave this guide with the owner Valor Heating Dream 2 Dream 2 Dream 2 Dream 2 INSET LIVE FUEL EFFECT GAS FIRE INCORPORATING...

Page 2: ...ghest Standards Valor is a member of the Society of British Gas Industries which works to ensure high standards of safety quality and performance Careful Installation Valor is a CORGI registered company All our gas fires must be installed by a competent CORGI Registered Installer in accordance with our Installer Guide and should not be fitted directly on to a carpet or floor of combustible materia...

Page 3: ...o 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 ...

Page 4: ... Control Settings 35 14 2Check For Spillage 36 14 3Flame Supervision Spillage Monitoring System 36 15FINAL REVIEW 38 16SERVICING PARTS REPLACEMENT 39 16 1Checking the aeration setting of the burner 39 16 2To Remove the Ignition Microswitch 40 16 3To Remove the Gas Shut Off Microswitch 41 16 4To Remove the Fire Front Surround 41 16 5To Replace the Control Slide Unit 42 16 6To Replace the Control Sl...

Page 5: ...zardous 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 a...

Page 6: ...k to recognised standards In the United Kingdom the installation must also be in accordance with All the relevant parts of local regulations All relevant codes of practice 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 EN 1806 BS 4543 Part 2 BS 5440 Part 1 BS 5440 Part 2 BS 5871 Part 2 BS 6461 Part 1 BS 6891 BS 8303 In ...

Page 7: ... as in figure 1 If a reduced depth Hearth is fitted the fire must be installed so that the distance from the base of the fireplace opening in the wall to the finished floor level is at least 85mm It is recommended that the reduced hearth has a depth from the fixing plane of the fire of 100mm minimum This is necessary to support the lower front casting 2 2 2 To a fireplace incorporating a metal flu...

Page 8: ...p bends or horizontal runs in metal flues at the top of the system can be a cause of problems in these types of installation 225mm x 225mm conventional brick flue 175mm diameter lined brick or stone flue 200mm diameter factory made insulated flue manufactured to BS4543 175mm diameter flue pipe See BS6461 Part 1 for suitable materials Single wall twin wall or flexible flue liner with a minimum diam...

Page 9: ...oor draught type it must be sealed to stop any draughts 2 10 The appliance must be mounted behind a non combustible hearth N B conglomerate marble hearths are considered as non combustible The appliance can be fitted to a purpose made proprietary class O 150 C surround The hearth material must be at least 12mm thick The periphery of the hearth or fender should be at least 50mm above floor level to...

Page 10: ...ntains a bath or shower or where steam is regularly present 2 15 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...

Page 11: ...m the outside of the appliance case to a corner wall having combustible material or any other combustible surface which projects beyond the front of the appliance is shown in figure 5 A 10mm access clearance from a non combustible surface is necessary at the left side See figure 5 2 20 Proprietary terminals must comply with BS 715 or BS 1289 Any terminal or termination must be positioned in accord...

Page 12: ...flue restrictor 2 Screws For Fireback spacing brackets 2 Washers For case hanging 2 Screws For Rear Ceramic wall support bracket 1 Ceramic back wall 1 Pair of ceramic side walls 1 Left Hand Front coal 1 Right Hand Front coal 1 Main coal bed 1 Pack of 12 loose coals identified by the letters A to L 2 Small U seals for hotbox side flanges 1 Strip of floor sealing tape 6 Fibre plugs 4 Woodscrews 2 Fi...

Page 13: ...r Ceramic wall support bracket 1 Length of self adhesive foam seal 1 Literature pack 1 Fireslide slider control 2 Taptite screws Section 2 Fire Front contains 1 Fire front surround 1 Firefront casting 1 Bottom front cover casting Carefully remove all 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 ...

Page 14: ...INSTALLER S GUIDE Page 14 Figure 6 Pack contents ...

Page 15: ...a covered by the outer surround The cladding must also not touch the surround See figure 4 We suggest that the actual surround is used as a template to mark the area for combustible cladding removal and that this area is increased by at least 2mm all round 4 1 3 Soundness for appliance attachment Two primary methods of retaining the appliance are provided 1 By fixing to the fireplace front surroun...

Page 16: ...lue Pull Close all doors and windows in the room in which the appliance is to be installed After confirming with a match that smoke is drawn into the flue light a 13 gram smoke pellet and check that there is a definite flow through the flue Verify outside that the smoke exits from one terminal only and that the termination is suitable Observe where possible upstairs rooms and loft spaces for signs...

Page 17: ... figure 8 The positive terminal is to the bottom as you insert Rotate the control pivot bracket as far as it will go This should close the ignition circuit Sparks should be seen tracking from the electrode pin to the thermocouple tip See figure 9 If there are no sparks make the following checks a Check condition of battery and that it is correctly fitted b Check spark gap between electrode wire an...

Page 18: ...nection from inside the fireplace is required then before the appliance is fitted into the fireplace it will be necessary to extend the supply line so that it will project through the chosen removable circular panel at the back of the hotbox and run to the elbow at the front The pipe run from the supply line up to the rear opening in the hotbox must be kept away from the area which will be taken b...

Page 19: ...rear of the hotbox Decide which one of these is to be used for rear entry Using a suitable tool apply pressure to the centre of the removable circular panel There is a grommet in the installation kit supplied with the fire Fit this into the hole Pierce the grommet to allow the pipe to pass through it The grommet should envelop the pipe If the hole is larger than the pipe seal it with tape Do not p...

Page 20: ... to be removed After removal conduct the spillage check again The restrictor is packed loose with the appliance and is fixed with two screws See figure 14 9 There is a length of self adhesive foam seal supplied with the fire This will need to be fitted to the outer rear edges of the side and top flanges of the hotbox Cut a 485mm length of foam seal Be careful not to stretch the seal when measuring...

Page 21: ...stalled If a concealed connection is being used insert the hotbox into the fireplace feeding the supply pipe through the pierced hole in the rear seal 3 Mark the fireplace front surround through the four fixing holes in the side flanges of the hotbox See figure 16 4 Remove the hotbox Drill four holes in the fireplace front surround at the marked positions using a no 12 masonry drill 5 Insert a raw...

Page 22: ...e cables 3 Insert a fibre plug into each hole Use the fibre plugs supplied with this appliance Never use plastic plugs instead of the fibre plugs supplied Screw the eyebolts into the plugs Make sure that the bolts are secure 4 Place the convection box unit close to the fireplace but allow sufficient access into the fireplace opening so that the cables can be threaded through the eyebolts and retur...

Page 23: ... a hole into the fireplace floor through each of the two holes in the base of the convection box using a no 12 masonry drill See figure 20 9 Insert a fibre plug into each hole Use the rawlplugs supplied with this appliance Never use plastic plugs instead of the fibre plugs supplied Fit a woodscrew in each plug and tighten Always screw the base into position before applying tension to the cables Th...

Page 24: ... push the cable retainers back against the V brackets Again tighten the screws in the retainers and apply tension to the cables by turning the hexagonal adjusters clockwise as far as possible 14 Underneath the V shaped brackets is a hole Feed the free length of the cables into these holes so that they are available to allow easy removal and refitting of the appliance during subsequent service call...

Page 25: ...e the ignition circuit and simultaneously open the gas tap allowing the gas to flow to the pilot Wait a few seconds while the air is purged The electronically generated sparks should light the pilot 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...

Page 26: ... 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 24 Check the pressure with the appliance alight and set at maximum output 2 After checking turn off the appliance Remove the pressure gauge and replace the test point sealing screw 3 Relight the appliance Turn to the maximum output position and test around the seal...

Page 27: ...nderneath See figure 25 2 Fit the ceramic rear wall inside the L bracket on the back face of the burner compartment Push the ceramic wall flat against the back face of the burner compartment See figure 25 3 Fit the ceramic side walls against the side faces of the burner compartment The bottom edges of the walls should rest in the ledges at the sides of the firebox Slide them in from the front and ...

Page 28: ...r than the bottom of the front surround 2 Carefully lift the front surround Do not lift it by the control button Place the front surround against the fireplace front surface so that the two retaining plates at the back of the surround are directly above the two upper retaining brackets at the top of the hotbox Lower the surround unit making sure that the retaining plates locate fully into the brac...

Page 29: ...r with that in the control pivot bracket Join them with the knurled shouldered screw See figure 30 Make sure that the isolating valve is closed Slide the control button fully from top to bottom and back to make sure that the slide and pivot mechanisms move smoothly Note that some resistance should be felt when the slide button reaches the burner fully on position 5 Fit the burner baffle to the fro...

Page 30: ...brackets See figure 32 Installer Note that the small round holes in the burner plaques that will be covered by the base coal are not gas burner ports They are simply a consequence of the plaque manufacturing process 2 Place the left hand ceramic front coal in position in front of the base coal See figure 33 3 Place the right hand ceramic front coal in position in front of the base coal This should...

Page 31: ...at 90 to the rear of the firebox 7 Hold coal A upright with the arrow pointing to the top Locate coal A as shown in figure 34 8 Locate coals B to E so that they are firmly seated in the valleys in the coal base and front coal 9 Hold coal B upright with the arrow pointing to the top Locate coal B as shown in figure 35 10 Hold coal C upright with the arrow pointing to the top Locate coal C as shown ...

Page 32: ...2 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 coal F as shown in figure 39 14 This will complete the second row of loose coals Figure 39 Second row Coal F Figure 38 Second row Coal E Figure 37 Second row Coal D ...

Page 33: ...ith 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 shown in figure 41 18 Hold coal I upright with the arrow pointing to the top Locate coal I as shown in figure 42 Figure 42 Third row Coal I Figure 41 Third row Coal H Figure 40 Third row Coal G ...

Page 34: ...ure 44 21 Hold coal L upright with the arrow pointing to the top Locate coal L as shown in figure 45 1 3 F R O N T C A S T I N G S I N S T A L L A T I O N 14 1 1 Place the firefront casting centrally on the hearth in front of the firefront surround 2 Place the bottom front cover casting in position below the fire front casting Figure 45 Third row Coal L Figure 44 Third row Coal K Figure 43 Third r...

Page 35: ...tain in this position to ignite the pilot The burner should ignite at its lowest setting within 4 seconds of the pilot igniting Keep at this position for a further 10 seconds to allow the pilot flame to stabilise 4 Release the button The button should automatically spring up to the low heat position If the flames go out at this stage or when checking the rest of the setting positions try the full ...

Page 36: ...installed with the flue restrictor see section 7 point 8 remove the restrictor reseal the appliance and retest If smoke is still not drawn into the appliance disconnect the appliance and seek expert advice 5 If the above test is satisfactory open all internal connecting doors hatches etc in the room Keep all doors and windows that open to the outside of the building closed Recheck for spillage as ...

Page 37: ...an electromagnetic valve shutting off the gas supply through the tap The valve is located in the body of the tap The valve should operate within 60 seconds of the pilot going out If the valve does not operate within this time limit do not allow the appliance to be used until the fault has been corrected This monitoring system must not be adjusted bypassed or put out of operation This monitoring sy...

Page 38: ...oals must be added over and above those supplied with the appliance and that any replacements must only be the authorised spares Warn that ignoring this advice could cause incomplete clearance of the products of combustion with consequent health hazards 6 Advise the customer that the appliance will operate to its maximum potential if the flue is primed during the first 20 30 minutes of use To do t...

Page 39: ...e 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...

Page 40: ...on instructions Always test for gas soundness and spillage after servicing the appliance 16 2 To Remove the Ignition Microswitch See figures 49 50 The ignition microswitch is stamped V4NT9C4YC 1 Remove the bottom front cover and the fire front casting 2 Remove the burner baffle by sliding upward 3 Detach the microswitch cover by removing one screw and pulling clear of the location lug See figure 4...

Page 41: ...e thermocouple interrupter block See figure 51 5 Detach the bridging bracket microswitch assembly and insulation pad by removing two screws See figure 50 6 Replace in the reverse order When refitting the leads to the interrupter block make sure that they are secured firmly to give a good electrical contact 16 4 To Remove the Fire Front Surround 1 Remove the bottom front cover and the fire front ca...

Page 42: ...s securing the plastic slide mechanism to the rear of the front surround See figure 55 4 Replace in the reverse order 16 6 To Replace the Control Slide Button 1 Remove the front surround See section 16 4 2 Detach the slide button by removing two screws See figure 55 3 Replace in the reverse order 16 7 To Remove the Burner Unit 1 Remove the bottom front and fire front castings and the front surroun...

Page 43: ...ard Be careful not to apply tension to the microswitch leads 7 Remove the two fixing screws that attach the generator unit to the support bracket The igniter generator can now be removed see figure 58 8 Remove the two leads to the switch and remove the spark lead If necessary mark them to ensure that they are replaced on to the correct terminals 9 Replace the generator 10 Refit in the reverse orde...

Page 44: ... 6 8 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 9 Detach the pilot pipe from the gas shut off tap 10 Detach the thermocouple from the interrupter block by unscrewing the thermocouple nut 11 Detach the electrode lead from the underside of the electrode ta...

Page 45: ...m the tap See section 16 8 paragraphs 2 4 3 Detach the pilot pipe from the tap 4 Detach the inlet pipe 5 Remove the hexagonal nut securing the tap to the mounting bracket 6 Detach the elbow by unfastening the hexagonal nut connecting it to the flow rate controller Lift the tap complete with elbow clear 7 Loosen the hexagonal locknut securing the elbow to the tap Remove the elbow by rotating it 8 I...

Page 46: ... 16 11 paragraphs 2 6 5 Detach the burner pipe from the controller Support the controller while detaching to prevent excessive strain 6 Remove the nut and washer securing the control pivot bracket to the controller at the front Support the pivot bracket while removing the nut to prevent possible damage to the microswitch 7 Remove the hexagonal bolt securing the control pivot bracket to the control...

Page 47: ...id damage to the brackets and the worksurface see figure 57 3 Disconnect the main burner pipe from the injector at the venturi end If necessary loosen the pipe at the flow rate controller end to swing the pipe clear of the injector 4 Unscrew the injector from the rear support bracket 5 Refit in the reverse order Figure 64 Removal of ceramic support platform ...

Page 48: ... the gasket ends inwards to form a dividing gasket between the plaques 8 Place the new left hand plaque in position The left side of the plaque must touch the inside edge of the retaining flange at the left side of the burner well 9 Place the new right hand plaque in position Make sure that the centre section of the combination gasket is between the two plaques If there is any play between the pla...

Page 49: ...of installation instructions remove the screws If the fire retention is as method 2 See section 8 2 of installation instructions slacken the hexagonal adjusters on the cable retainers and unscrew the thumbscrews to release the cables 2 Refit as described in the relevant installation sections Make sure gas soundness sealing spillage test and performance are satisfactory ...

Page 50: ...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: ...0A249 Pilot unit For Propane Gas Appliances 720A300 G Injector Bray cat 18U size 420 For Natural Gas Appliances 1 720A072 Injector Stereomatic size 170 and carrier For Propane Gas Appliances 3002350 H Igniter unit 1 730K180 J Burner plaque gasket set 1 000B235 K Battery 9V Size PP3 1 700K706 L Ceramic left side wall 1 3002107 M Ceramic right side wall 1 3002109 N Back wall 1 3002108 P Base coal 1 ...

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Valor Dream 2, Installer'S Manual

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