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Valor COSYFLAME TURBOCHIM 528 Installer's Manual

Rear fan flued inset gas fires with live fuel effect
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Summary of Contents for Valor COSYFLAME TURBOCHIM 528

  • Page 1 VA L O R C O S Y F L A M E T U R B O C H I M * ( M O D E L 5 2 8 ) VA L O R S E C R E T T U R B O C H I M * ( M O D E L 5 2 7 )
  • Page 2 (GB) and the Republic of Ireland (IE) only. 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 0345 626341 (Local call rates apply)

  • Page 3: Table Of Contents

    PART1: APPLIANCE DATA ................................4 PART2: GENERAL INSTALLATION REQUIREMENTS...................... 4 PART 3: UNPACKING..................................9 PART 4: PREPARING FOR INSTALLATION......................... 10 PART 5: WALL PREPARATION..............................10 General ......................................10 Brick, Stone Etc. Building. Main Case In Front Of Wall ......................10 Brick, Stone Etc.

  • Page 4: Part1: Appliance Data

    PART1: APPLIANCE DATA This appliance does not contain any component manufactured from asbestos or asbestos related products. The appliance data label and wiring diagram are on a plate chained below the burner and visible when the control cover is removed. Gas: Natural (G20) Inlet pressure:...
  • Page 5 Installation to a timber framed building should be in accordance with the relevant sections of 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.
  • Page 6 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.
  • Page 7 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.
  • Page 8 470mm 600mm 325mm 525mm 350mm 235mm 125mm 475mm 53mm 550mm 600mm max. (Flue tube uncut) 150mm min. N (Fan box projection) 205mm when sited outside wall 55mm when recessed in outer wall 285mm R (Flue tube diameter) 125mm S (Terminal guard projection) 305mm 355mm V (Recess width)

  • Page 9: Part 3: Unpacking

    PART 3: UNPACKING Fig. 4 Appliance units The pack contains: Nut & olive for 8mm inlet pipe Burner & firebox unit with attached Retention kit ( 4 wall plugs, 4 eye bolts, 2 tension Rockwool jacket Fan box assembly adjusters and two cable assemblies). Flue duct Wall plugs Woodscrews...

  • Page 10: Part 4: Preparing For Installation

    PART 4: PREPARING FOR INSTALLATION 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.

  • Page 11: Brick, Stone Etc. Building. Main Case Recessed Into Wall

    Brick, Stone Etc. Building. Main Case Recessed Into Wall (Figure 8) This installation has the fire box recessed into the inner wall of the building. The front flanges of the fire box and the appliance metal decorative surround will abut the front surface of the wall. The non-combustible hearth must project at least 345mm in front of the convection box front flanges and be at least 625mm wide (Figure 1).

  • Page 12: Wall Preparation For Flue Tube

    Wall preparation for flue tube. The flue must be installed so that it is at right angles to the back panel of the fire all round the flue circumference. The fire itself should be fitted vertically against a flat wall. Where this is difficult to achieve due to building inaccuracies care should be taken to ensure that the back of the fire is not stressed in any way due to distortion of the assembly when tightening the fixing screws.

  • Page 13: Fixing The Appliance In Position

    The area immediately behind the firebox must be separated from the combustible elements of the inner wall by 25mm thickness of non combustible material. This can consist of the usual 13mm plasterboard wall lining plus 12mm of “Superlux” or similar non-combustible material - see figure 12. Fixing the appliance in position There are two methods of fixing that may be used: 1.

  • Page 14: Part 6: Installation Of Electrics, Firebox And Fan Box

    PART 6: INSTALLATION OF ELECTRICS, FIREBOX AND FAN BOX Important : Under no circumstances should the electrical loom be fed between the inner and outer sections of the flue tube. Obtain the wiring loom and lay the loom through hole in the wall ensuring that the end with two connectors and earthing tags is outside the building.

  • Page 15: Securing Firebox To Wall - Cable Retention

    Securing firebox to wall - cable retention Assemble retention cables into firebox. Insert cables into cable anchor points in upper rear of firebox and then tape together adjoining edges of the jacket as shown in figure 16. Offer the firebox up to the wall and feed the retention cable through the installed eyebolts.

  • Page 16: Fan Box Installation

    Fan box installation Before installation can proceed it will be necessary to remove the fan unit from the fan box. Remove the 2 cover retaining screws and withdraw the fan unit. See figure 19 Checking inside for any loose unwanted packaging For transit purposes the weather shield is supplied as a loose part.

  • Page 17: Electrical Installation

    Electrical installation 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.

  • Page 18: Electrical Test

    Electrical test Fig. 29 Switch on power supply to the appliance. The red indicator light at the left side of the burner should be on. Press and hold in the “on” switch at the front of the burner. Within a few seconds, the Fan motor should start and the indicator light should go out.

  • Page 19: Part 7: Gas Supply Installation

    PART 7: GAS SUPPLY INSTALLATION 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.

  • Page 20: Check Reference Pressure

    Check Reference Pressure . The appliance is pre-set to give the correct setting pressure as 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 32).
  • Page 21 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.

  • Page 22: Part 9: Checks

    Place the two remaining small coals alongside the main coals as per figures 41 and 42. Fig. 41 Fig. 42 PART 9: CHECKS Recheck Control Settings Now that all the ceramic fuel effects are in position, the control operation must be fully rechecked.

  • Page 23: Check For Spillage

    The spillage monitoring system must not be adjusted, bypassed or put out of operation. This monitoring system, or any of its parts, must only be exchanged using Valor Authorised parts.

  • Page 24: Part 10: Front Casting Assembly & Final Review

    PART 10: FRONT CASTING ASSEMBLY & FINAL REVIEW Front casting assembly for model 527 (See fig. 44) • Remove the nut from the threaded stud on the brass finials • Locate the brass bar in the slots at the top of the front casting.

  • Page 25: Part 11: Servicing Parts And Replacement

    PART 11: SERVICING PARTS AND REPLACEMENT • Always turn off the gas and isolate the electric supply before commencing any servicing and make sure that the appliance is cold. (The inlet elbow for this appliance incorporates an isolating valve). • Check that the appliance is clean and that soot or debris is not blocking the gaps between the coals causing an imperfect flame.

  • Page 26: To Completely Remove The Burner Unit

    To Completely Remove The Burner Unit • Remove the ceramics, remove the front cover castings, disconnect the appliance at the isolating valve, and detach the burner unit from the fire box. • Detach the burner wiring loom connection at the right side of the burner (see figure 48).

  • Page 27: To Gain Access To The Electrical Control Components

    To Gain Access to the Electrical Control Components • Remove the burner unit as described above. • Detach the control unit from the fire box (left hand side) flange by removing two screws (see figure 50). Carefully withdraw the unit. •...

  • Page 28: Short List Of Spares

    Short List Of Spares Key No. Description No. off Part No. Air pressure switch 567359 Electrical control unit 567369 Injector (Elbow type) Bray cat 82 size 360 545959 Gas tap & spark generator 545969 Spark generator 521069 Control knob 545979 Pilot unit 545949 Solenoid valve...
  • Page 29 BS EN ISO 9001 quality system accepted by the British Standards Institute. The Highest 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.

This manual is also suitable for:

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