Instructions for Use Installation and Servicing

Supplied By www.heating spares.co Tel. 0161 620 6677

Hepworth Heating Ltd.,Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:Tel: (01773) 824141 Fax: (01773) 820569One Contact Local Service

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

221648B. 02. 00

All replacement parts

All labour charges

All call-out charges

Thank you for installing a new Glow-worm appliance in your home.

Glow-worm appliances' are manufactured to the very highest standard so we are pleasedto offer our customers' a Comprehensive First Year Guarantee.

In the center pages are to be found your Guarantee Registration Card, which we recommend you complete andreturn as soon as possible.

If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall CustomerService number 01773 828100.

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

Guarantee Registration

BBU Fire Front

For use with a specially designedGlow-worm Back Boiler Unit only

This is a Cat I2H Appliance

BS 6332BS 5258

Reference in these instructions to British Standards and StatutoryRegulations/Requirements apply only to the United Kingdom.

For Ireland the rules in force must be used.

These instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee RegistrationCard. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety

(Installation and Use) Regulations, be handed to the user on completion of the installation.

To b e l e f t w i t h t h e u s e r

7446

❏✔

❏✔

❏✔

Instructions for UseInstallation and Servicing

G.C. No. 37 047 11

REGISTER YOUR GLOW-WORM APPLIANCEFOR 1ST YEAR GUARANTEE PROTECTION

CALL 0181 380 2555


2221648B

Important Information

Introduction 3Lighting the Boiler 4Lighting the Fire Front 6Cleaning 6Supplementary Instructions 10

General Data 1 11Types of Installation and Flue 2 13Fire Front Preperation 3 14Installation 4 18Lighting, Testing and Fitting Internal Parts 5 21Instructions for Use 6 25

Servicing and Replacement of Parts 7 25Fault Finding 8 29Replacement Parts 9 32Supplementary Installation Instructions 10 35

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

CE MarkThe CE mark on this appliance shows compliance with:-

1. Directive 90/396/EEC on the approximation of the Laws of the Member States relating to appliancesburning gaseous fuels - Boiler and Fire.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to electricalequipment designed for use within certain voltage limits - Boiler only.

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagneticcompatibility - Boiler and Fire.

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.Under Section 6 of the Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.

The Adhesives and sealants used in this appliance are cured and give no known hazard in this state.

FUELBEDS, ARTIFICIAL FUELThis product uses fuel effect Pieces containing Refractory Ceramic Fibre (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 makessense 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 recommendthat you use a HEPA filtered vacuum to remove any dust and soot accumulated in and around the fire before and after working onthe fire. When replacing these articles we recommend that the replaced items are not broken up, but are sealed within heavy dutypolythene bags, clearly labelled as RCF waste. This is not classified as “hazardous waste” and may be disposed of at a tipping sitelicensed for the disposal of industrial waste. Protective clothing is not required when handling these articles, but we recommend youfollow the normal hygiene rules of not smoking, eating or drinking in the work area and always wash your hands before eating ordrinking.

INSULATION and SEALSCeramic fibre and glass fibre used in insulation panels rope and gaskets.

These can cause irritation to skin, eyes and the respiratory tract.

If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken.

Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or goingto the lavatory.

If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.

SERVICING

INSTRUCTIONS

INSTALLATION

INSTRUCTIONS


3 221648B

Instructions for Use

This fire front may be fitted to a Glow-worm back boiler WITHOUTa flue blockage safety device. Please refer to the supplementaryinstructions at the end of the Instructions for Use, especially“Lighting the Boiler”.

The instructions consist of two parts, Installation and ServicingInstructions for the Back Boiler Unit, Use, Installation andServicing Instructions for the Fire Front, which includes theGuarantee Registration Card. The instructions form an integralpart of the appliance and must, to comply with the current issueof the Gas Safety (Installation and Use) Regulations, be handedto the user on completion of the installation.

The Gas Safety (Installation and Use)RegulationsIn your interests and that of safety it is the Law that ALL gasappliances are installed by a competent person in accordancewith the current issue of the above regulations.

GeneralThese notes should be read and carefully followed for the safeand economical use of your back boiler and fire front.

Important NoticeThis appliance is for use only on G20 gas.

This Glow-worm fire front is to be used with a specially designedGlow-worm Back Boiler Unit only.

The fire front and back boiler must be fitted as acomplete appliance.

This is a combined central heating back boiler and gas fire front.The back boiler and fire front can be operated either together orindependently.

In the event of a power or ignition system failure the fire front canstill be used on its own, instructions on how to do this are givenunder “Lighting the Fire Front with a Match or Spill”.

A slight smell may occur, for a short time, after initial lighting, thisis quite normal and will quickly disappear.

With a little use the interior of the fire front will discolour andacquire the appearance of a solid fuel fire.

Combustible furniture must not be placed closer than 1metre infront of the fire front.

Clothing or other flammable materials must not be placed on thefire front casing.

The convection air openings at the top of the fire front and airinlet grilles at the sides and base must never be obstructed.

Important. Soft wall coverings, for example, blown vinylwallpaper, are easily affected by heat, they may therefore,scorch or become discoloured when close to a heating appliance.This should be borne in mind when having a heating appliancefitted and when redecorating.

The glass panel on this fire front conforms to the requirementsof the current issue of BS1945 and satisfies the HeatingAppliance (Fireguard) Regulations.

The fire front must not be used if this panel is broken or missing.

WARNING. The glass panel gets very hot when the fire front ison and MUST NOT be touched.

The glass panel does not provide full protection for the young,elderly or infirm. In such cases extra security must be providedby fitting a fireguard which complies with the current issue of

BS6539 “Fireguards for use with solid fuel appliances” or thecurrent issue of BS6778 “Fireguards for use with portable, freestanding or wall mounted heating appliances”.

MaintenanceTo ensure the continued efficient and safe operation of theappliance it is recommended that it is checked and serviced atregular intervals. The frequency of servicing will depend uponthe particular installation and usage, but in general once a yearshould be enough.

If this appliance is installed in rented property there is a duty ofcare imposed on the owner of the property by the current issueof the Gas Safety (Installation and Use) Regulations, Section35.

It is the Law that servicing is carried out by a competent person.

To obtain service, please call your installer or Heatcall (Glow-worm’s own service organisation) using the telephone numbergiven on the fire plinth.

Please be advised that the ‘Benchmark’ logbook should becompleted by the installation engineer on completion ofcommissioning and servicing.

All CORGI Registered Installers carry a CORGI ID card, andhave a registration number. Both should be recorded in yourboiler Logbook. You can check your installer is CORGI registeredby calling CORGI direct on :- 01256 372300.

Heat Input - Fire FrontThis gas fire front will run for about 4.4hrs at full on rate on onetherm of gas. The price of a therm of gas will vary according tothe tariff in your area.

At tap position 1 - centre section flame effect

At tap position 2 - centre section flame effect withouter section fuel bed glow

At tap position 3 - centre and outer sections flameeffect with fuel bed glow

At tap position 4 - (full on) full flame effect and fuelbed glow

Gas Leak or FaultIf a gas leak or fault exists or is suspected the appliance mustbe turned off, including the electrical supply and must not beused until the fault has been put right. Advice/help should beobtained from your installation/servicing company or the localgas undertaking.

ClearancesA shelf or surround of a maximum depth of 150mm may befitted, provided clearances are as diagram 1, however, for everyextra 25mm above the fire front the depth of the shelf may beincreased by 25mm.

On no account may carpet or other combustible material be laiddirectly under the fire front, unless the minimum clearancesshown in diagram 2 is achieved.

The dimension is taken from the bottom of the fire front castingto the top of the carpet pile or other floor covering.


4221648B


Diagram 2

183mm

7448

FrostCAUTION. If the back boiler is to be out of use for any longperiod of time during severe weather conditions we recommendthat the whole of the system, including the back boiler bedrained off to avoid the risk of freezing up.

If an immersion heater is fitted in the domestic hot water cylindermake sure that it is switched off.

If in doubt your installation/servicing company or the local gasundertaking should be contacted

Electrical SupplyWARNING The boiler must be earthed.

Connection of the appliance and any system controls to t h emains (230V~50Hz) must be through one unswitched shutteredsocket outlet and a 3A fused 3 pin plug, both to the current issueof BS1363. Alternatively, a fused 3A fused double pole isolatingswitch may be used, having a minimum double pole contactseparation of 3mm, serving only the appliance and systemcontrols.

The colours of three core flexible cable are, blue - neutral, brown- live, green and yellow - earth.

As the markings on your plug may not correspond with thesecolours, continue as follows:-

The wire coloured blue must be connected to the terminal mark“N” or black.

The wire coloured brown must be connected to the terminalmarked “L” or red.

The wire coloured green and yellow must be connected to theterminal marked “E”, green or the earth symbol .

Diagram 1

628mm

CL

FLAT AREAFIRE FIXING FACE

150mm 430mm 430mm

150mm

840mm

7447

Lighting the Appliance

Back BoilerThis appliance is fitted with a flue blockage safety device whichwill shut down the appliance in the event of abnormal flueconditions. This device is NOT a substitute for an independentlymounted Carbon Monoxide detector. If it shuts down frequentlyfor no apparent reason the first things that must be checked arethe chimney and air inlets into the room.

Any problems found must be put right, by a competent person,


5 221648B


before the boiler is used again.

If the burner go out, wait three minutes before relighting, butcheck as above.

The back boiler controls are fitted behind the fire front plinth, seediagram 3.

To remove the plinth, grasp each side and pull gently forwardsuntil it is free, see diagram 3.

Refer to diagram 4 to identify the controls.

Turn the electrical supply off at the mains outside the unit.

See that all other controls are calling for heat.

The clock, room thermostat and programmer, if fitted, will beaway from the unit. Refer to manufacturer’s instructions suppliedwith these items.

Turn the control thermostat knob “B” to the “O” position, that is,fully anti-clockwise (“O” to be against the pointer).

Partially push in and turn multifunctional control knob “A”clockwise until “O” is against its setting point, that is, set to “Off”.

Partially push in and turn multifunctional control knob “A” anti-clockwise until “ ” is against its setting point, then push infully and hold in. At the same time press and release button “D”until the pilot burner “E” lights. Look at the flame throughviewing window “F”.

At initial lighting of the back boiler air may be present andseveral attempts may be needed to light the pilot.Keep the multifunctional control knob “A” pushed in whilstoperating the button “D”.

When the pilot is alight and stable, keep knob “A” pushed in forabout 15 seconds and then release. Check that the pilot is stillalight by looking through window “F”.

If the pilot fails to stay alight turn gas control knob “A” “Off”, thatis, fully clockwise. Wait three minutes. Repeat the lightingprocedure, only now keep the control knob “A” pushed in for alittle longer than before, after the pilot has lit.

Note. Always wait three minutes before attempting to relight thepilot after it has gone out for any reason.

When the pilot is alight, push control knob “A” in slightly and turnit anticlockwise until “ “ is against the setting point.

Note. If the multifunctional control knob “A” is turned until “ ”is against the setting point, a safety lock prevents it being turnedon again. No attempt should be made to turn the multifunctional

control on again until at least three minutes have gone by.

Turn on the electrical supply to the unit.

Turn the control thermostat knob “B” clockwise until “Max” isagainst the setting point, the main burner will now light.

Adjust the control thermostat to the required setting between“Min” and “Max”. “Max” is about 82oC.

Check that the external controls are calling for heat.

Refit the fire front plinth by carefully fitting the top edge of theplinth into the sliders, then push it backwards as far as it will go.

To Turn the Back Boiler OffFor short periods, turn control thermostat control knob “B”anticlockwise until “O” is opposite its setting point. The pilot willstay alight.

To relight the main burner turn control thermostat control knob“B” clockwise to the desired setting between “Min” and “Max”.

For longer periods, push in slightly and turn multifunctionalcontrol knob “A” clockwise until “ ” is against its setting point.Turn control thermostat control knob “B” anticlockwise to “O”.Switch off the electrical supply to the appliance.

To relight, follow the full lighting procedure.

Diagram 374

58

PLINTH

MAX

MIN

5156

Diagram 4

THERMOSTATCONTROL KNOB 'B'

OFFPILOT/IGNITIONMAIN BURNER

SETTINGPOINT

MULTI-FUNCTIONALCONTROL KNOB 'A'PIEZO UNIT

BUTTON 'D'

SETTINGPOINT

PILOT BURNER 'E'

VIEWINGWINDOW 'F'


6221648B

Lighting the Fire FrontCAUTION. If the glass panel or internal fire parts are damageddo not light or use the fire front before replacement parts arefitted.

The fire front is fitted with a flue blockage safety device whichwill shut it down if there is a problem with the chimney. If the firefront shuts down frequently, for no apparent reason the firstthing to be checked are the chimney and the air inlets into theroom. An additional cause could be that the filter, in the gas taphas become blocked.

Push the control knob fully in and turn it anticlockwise to “1 “ignition, clicking of the ignition will be heard and the burner willlight.

IMPORTANT. If the burner does not light within three seconds,release the control knob, wait ten seconds and repeat thelighting operation.

Keep the knob pushed in for ten seconds, during which time theignition system will continue to operate, indicated by the clicking.

Air may be present in the supply to the fire front so that the initiallighting operation may need to be repeated.

To change settings:-

Push in and turn. Refer to diagram 5.

If the burner goes out for any reason whilst the fire is turned on,turn off.

Wait three minutes before relighting as above.

If relighting for any other reason wait two minutes before doingso.

It can take several minutes for the fuel effect pieces to glow andthe flame effect to appear.

To turn off, turn the tap fully clockwise to “O” position andrelease.

If there is a visible build up of soot on the fuel effect pieces followthe instructions in Section on “Cleaning the Fire”.

Lighting the Fire Front with a Match or SpillThis is a temporary measure, to be used only in the event of thefailure of the battery or the spark generator.

Make sure that the fire front is cold before starting.

Remove the front casting, see diagram 5.6.

Hold a lighted spill or long match and position it so that the flameis over the burner, see diagram 6.

Keep the spill in position, push in and turn the gas tap to position“1. “ ignition and the burner will light. Keep the knob pushedfor about ten seconds and the burner will stay alight.

If the burner should go out repeat the above, but now keep theknob pushed in for a little longer.

Once lit operate the control knob normally.

This is a temporary measure only and the battery should bereplaced or the ignition system be repaired as soon as possible.

Cleaning your FireWARNING. This appliance contains metal parts (components)and care should be taken when handling and cleaning, withparticular regard to edges.

Any cleaning work must only be carried out when the fire frontis cold.

Under normal circumstances dusting should be enough. Anoccasional wipe over with a damp cloth will help remove marks.

Do not use an abrasive cleaning powder or liquid.


Diagram 5

APPLIANCE OFF

IGNITION POSITIONAND CENTRESECTIONFLAME EFFECT

CENTRE SECTIONFLAME EFFECTWITH OUTERSECTIONSFUELBED GLOW

CENTRE ANDOUTER SECTIONSFLAME EFFECTWITH FUELBEDGLOW

FULL FLAMEEFFECT WITHFUELBED GLOW

7581


7 221648B


Diagram 6

SPILL

BURNER

SPILL

5094

Glass Panel and Internal Fire Front PartsLift the canopy off, see diagram 7. Take care as it is made ofcast iron.

Swing the side panels open, see diagrams 7 & 18.

Remove the glass panel, see diagram 8.

Clean the front glass panel inside and out with a proprietaryceramic hob cleaner.

Should any soot accumulation become excessive, the fueleffect pieces should be removed from the fire for cleaning.Cleaning should be carried out in a well ventilated area or in theopen air, by gently brushing with the pieces held away from yourface so that you avoid inhaling the dust. We do not recommendthe use of a normal domestic vacuum cleaner, which may blowdust back into the air.

CAUTION. If replacing use only the fuel effect pieces approvedfor this fire front.

When replacing fit as shown in diagrams 9 to 16.

Note. Each fuel effect piece is numbered on its back.

DO NOT USE MORE FUEL EFFECT PIECESTHAN SHOWN.

To Replace the BatteryThe battery supplied, should, under normal usage last for about18 months.

The replacement is 9V and we recommend that it be of thealkaline type which can be bought locally.

Remove the canopy as diagram 7. Take care as it is made ofcast iron. Remove the gas control knob, remove the securingscrew stop, swing open the right hand side panel as diagram 18.Fit the battery as shown in diagram 19, make sure that theterminals are correctly fitted.

Diagram 7

7449

5mm

5mm

7559

GLASSRETAININGBRACKET

Diagram 8

GLASSFRONT PANEL

PULL FORWARDSAND UP

Replacement PartsIf replacement parts are required apply to your local supplier.

Please quote the name of the fire front, “Saxony 2”, to be foundon the control knob bezel.

The back boiler serial number can be found on the base afterremoval of the plinth.

The fire front serial number can be found on the chassis, visiblewhen the front casting is removed.


8221648B

Diagram 11

Diagram 12

Diagram 13

Diagram 14

LOCATIONRECESS 1

LOCATIONRECESS 2

LOCATIONLUG 3

LOCATIONRECESS 4

4331

S

4332

S43

33 S

4334

S

FUEL EFFECT PIECE POSITION 1



FUEL EFFECT PIECE MUSTSIT ON SUPPORT ANGLE

NOTE:

NOTE: FUEL EFFECT PIECE MUSTSIT ON SUPPORT ANGLE

FUEL EFFECT PIECE MUSTSIT ON SUPPORT ANGLE

NOTE:


SUPPORT ANGLE FORFUEL EFFECT PIECES1, 2 AND 3 Diagram 10

LeftSide

FUELEFFECTBASE

5088

Fuel Effect Baseseats behindretaining brackets

NOTE:

RightSide

FUELEFFECTBASE(see note)

RETAININGBRACKETS

Diagram 9

5

312

4

3

122

4 5

FUEL EFFECT PIECES 1 to 5

FUELEFFECTBASE

4329

S

FUEL EFFECT PIECES LOCATIONS



9 221648B

Diagram 15

LOCATIONRECESS 5

4335

S



Diagram 16

Ensure corners of fuel effectpieces 4 and 5 are seated onflat areas of fuel effect pieces1, 2 and 3

COMPLETED FUELEFFECT BED

Diagram 17

CANOPYLOCATING

PINLOCATING

HOLE

4850

3943

S

Diagram 19

5283

SECURINGSCREW

SPARKGENERATOR

ELECTRICALCONNECTIONS

9V ALKALINEBATTERY

SECURINGSCREW

IGNITIONLEAD

Diagram 18

7562

SECURINGSCREWSTOP

FIBREWASHER

R.H. SIDEPANEL

GAS CONTROL KNOB


10221648B

Supplementary Instructions

This appliance is fitted with a flue blockage safety device whichwill shut down the appliance in the event of abnormal flueconditions. This device is NOT a substitute for an independentlymounted Carbon Monoxide detector.

As this fire front may be fitted to a Glow-worm 45, 56, 45R or 56Rback boiler unit WITHOUT a flue blockage safety device, thefollowing instructions on how to light the boiler should be readand followed in place of those in the main instructions for use.

To check if a flue blockage safety device is fitted, refer to theinset in diagram 18, if one is fitted this supplement MUST beignored.

Lighting the BoilerThe boiler controls are placed behind the fire front plinth, seediagram 3.

To remove the plinth, pull it gently forwards until it is free.

Refer to diagram 20 to identify the controls.

Turn off the electrical supply at the mains supply outside theappliance.

Check that all controls are calling for heat.

The clock, room thermostat and programmer, if fitted, will beaway from the unit, see manufacturer’s instructions suppliedwith them.

Turn the thermostat control knob “B” to “Off” position, that is,fully anticlockwise, “Off” to be against the pointer.

Push in and slightly turn gas control knob “A” clockwise until“ ” is against its setting point, that is, set to “Off”.

Push in slightly and turn gas control knob “A” anticlockwise until“ ” is against its setting point, then push fully in and hold in.At the same time press and release piezo button “D” until pilotburner “E” lighted. Look at flame through viewing window “F”.

At initial lighting of the boiler air may be present and severalattempts may be needed to light the pilot. Keep control knob “A”pushed in whilst operating the ignition button.

When the pilot is alight and stable, keep knob “A” fully pushedin for about 15 seconds then release. Check that the pilot is stillalight, look through window “F”.

If the pilot burner fails to stay alight turn gas control knob “A”“Off”, that is, fully clockwise. Wait three minutes. Repeat thelighting operation, only now keep control knob “A” pushed in fora little longer than before after the pilot has lit.

NOTE. Always wait three minutes before attempting to relightthe pilot after it has gone out for any reason.

Push control knob “A” in slightly and turn anticlockwise until“ “ is against the setting point.

Note. If gas control knob “A” is turned until “ ” is against thesetting point, a safety lock prevents it being turned on again. Noattempt should be made to turn the valve on again until at leastthree minutes have elapsed.

Turn on the electrical supply to the unit.

Turn the boiler thermostat knob “B” clockwise until “MAX” isagainst the setting point, the main burner will light.

Adjust the thermostat to the required setting between “MIN” and“MAX”. “MAX” is about 82oC.

Check that all external controls are set to your requirements.

Refit the plinth by carefully locating the top edge of the plinth intothe sliders, then push gently back as far as it will go.

'E' PILOT BURNER

BOILER CONTROLS Diagram 20

INSET: Showing a Flue Blockage Safety Device fitted.

SETTINGPOINT

'F' VIEWINGWINDOW

'D' PIEZOUNITBUTTON

'B'THERMOSTATCONTROLKNOB

OFF

PILOT/IGNITION

MAIN BURNER

'A'GAS VALVECONTROLKNOB

SETTINGPOINT

5342


11 221648B

1 General

Diagram 1.1

7450FLAT AREA

FIRE FIXINGFACE

286mm 616mm

690mm

628mm344mm

326mm

442mm

1 General Notes and InformationThis fire front may be fitted to a Glow-worm back boiler WITHOUTa flue blockage safety device. Please refer to the supplementaryinstructions at the end of this booklet, especially “Lighting theBoiler”.

This Glow-worm gas fire front is to be used with a speciallydesigned Glow-worm Back Boiler Unit only.

This fire front and back boiler are NOT suitable for fitting to aprecast flue.

The fire front is delivered packed in two cardboard cartons,which together contain all the parts necessary for the installationof the fire front.

If the back boiler and fire front are to be installed at the same timeplease read both sets of installation instructions before starting.

Wherever possible, all materials, appliances and componentsto be used shall comply with the requirements of applicableBritish Standards.

Where no British Standards exist, materials and equipmentshould be fit for their purpose and of suitable quality andworkmanship.

1.1 Important NoticeThis fire front is for use only on G20 gas.

This fire front is fitted with a flue blockage safety device whichwill shut down the fire if there is an unacceptable spillage ofproducts at the draught diverter. If the fire front shuts downfrequently for no appreant reason the first things to be checkedare the chimney and the air inlets into the room. An additionalcause could be that the filter, in the gas tap has become blocked.Any problems found must be put right by a competent person,before the fire front is used again.

Sheet Metal PartsWARNING. When installing or servicing this fire front careshould be taken when handling metal parts (components) toavoid any possibilty of personal injury.

1.2 Statutory RequirementsThe installation of this fire front must be carried out by acompetent person, in accordance with the current issue andrelevant requirements of:-

Manufacturer’s instructions, supplied.

The Gas Safety (Installation and Use) Regulations, The BuildingRegulations, the Local Gas Undertaking, The Building Standards(Scotland) Regulations (applicable in Scotland), The Healthand Safety at Work Act, Control of Substances Hazardous toHealth, The Electricity at Work Regulations and any applicablelocal regulations.

Detailed recommendations are contained in the current issue ofthe following British Standards and Codes of Practice:-

BS1251, BS5440 Part 1 and 2, BS5871, BS6891, BS7671.

Manufacturer’s notes must not be taken as overriding statutoryrequirements.


12221648B

1 General

1.3 DataGas connection - from the service cock

Total weight - 54kg

Injector - upper - Bray 18/180

- lower - Bray 18/320

Burner pressure setting

- cold - 13.0mbar 5.2in wg

- hot - 13.2 mbar 5.3in wg

Heat input - gross 6.7kW - 22,750Btu/h

Heat output -nominal 4.03kW - 13,670Btu/h

Fire serial number - on chassis - visible when frontcasting removed

Data label - Inside of right hand side panel

The fire front burner is lit by means of a battery operatedelectronic spark generator unit.

1.4 Fire Front LocationThis fire front can only be fitted to a Glow-worm 45/2 or 56/2back boiler unit, which itself has been fitted in accordance withthe Glow-worm Installation and Servicing Instructions.

The back boiler must be correctly positioned in the builder’sopening as the fire front is located by connection to it.

The back boiler air duct acts as a support for the fire front.

The top of the fire front must be secured to the vertical fire frontfixing wall face. This wall face may be a chimney breast orsurround, see diagram 1. (Instructions for Use).

The fire front flue spigot sticks out into the back boiler fluecollector assembly.

The gas supply is taken from the back boiler gas service cock.

1.5 ClearancesRestrictions must not be placed around the assembled firefront, see diagram 1. (Instructions for Use).

A shelf or surround of a maximum depth of 150mm may befitted, provided clearances are as shown indiagram 1. (Instructions for Use). However, for every extra25mm above the fire front the depth of the shelf may beincreased by 25mm.

Combustible furniture or materials must not be placed closerthan 1metre in front of the fire front.


13 221648B

CL

2 Types of Installation and Flue

BUILDERSOPENING

280

680

INSTALLATIONCENTRE

LINE

CL

HEARTH MOUNTEDRemove CombustibleMaterial From this Area

PREPAREDBASE

Diagram 2.3

Diagram 2.2

INSTALLATION CENTRE LINE

406mm to460mm

FRONTOPENING

560mmto

590mm

PREPAREDBASE

7594

5076

Note. Refer to Section 2 in the Back Boiler Installation book beforestarting.

2.1 With HearthA fireproof hearth under the fire front must have the minimumdimensions as shown in diagram 2.1.

2.2 With SurroundSee diagram 2.2. The fire front casing should cover the opening.

A wider opening will require any opening left to be covered witha non-combustible finished material, see diagram 2.3.

The surround must have a minimum clear, flat area as shown indiagram 1. (Instructions for Use). Any projections on thesurround must be outside this area.

Any combustible material on the fire front fixing face area of thesurround must be removed, see diagram 2.3. This area, to thedepth removed, should then be rendered with a sand/cementmixture.

2.3 Without Surround or HearthThe fire front fixing wall face must be flat over an area as shownin diagram 1. (Instructions for Use). This also shows theminimum clearances for shelves or projections on the fire frontfixing wall face.

The information in the last two paragraphs of “With Surround”should now be followed.

On no account must carpet or other combustible material be laiddirectly under the fire front, unless the minimum clearancesshown in diagram 2 (Instructions for Use) are achieved.

The dimension is taken from the bottom of the fire front plinth tothe top of the carpet pile or other floor covering.

2.4 FlueThe back boiler flue collector assembly accepts the fire front fluespigot.

Note. Provision must be made during the installation of the backboiler for the total ventilation requirement for the combinedappliance. See relevant section in the Back Boiler InstallationInstructions.

762mm

50mmMIN.

12mm

NO

N-C

OM

BU

ST

IBLE

MA

TE

RIA

L

350mm

Diagram 2.1

7456

13mm


14221648B

COMBUSTIONCHAMBERBOTTOM PLATE

FLUE SPIGOT

FIREBODYASSEMBLY

WALLSEALINGPLATE

L.H. SIDECASTING

FUELEFFECTBEDLITERATURE

L.H. SIDEPANEL

CANOPY

FRONTCASTING

PLINTH

REARSUPPORTLEGS (2)

R.H. SIDEPANEL

R.H. SIDECASTING

L.H.LEG

R.H.LEG

3 Fire Front Preperation

CASING PACK

Diagram 3.1

FIRE BODY PACK

7629


15 221648B

A SCREW FRONT LEGM5x30 LEVELLING SCREW

BSCREW SIDEM5x14 CASTINGS

C SCREW UPPER WALLM5x40 MOUNTING

D ANCHOR UPPER WALLNUT MOUNTING

E SCREW FRONT LEGM5x8 FIXING

F SCREW WALL SEALINGNo. 10 x 11/

2PLATE FIXING

GWALL WALL SEALINGPLUG PLATE FIXING

SCREW UPPER SIDERETAINING


KEY

Diagram 3.2

JSCREW FLUE SPIGOT FIXING

No.8x3/8in.

K SCREW SENSING TUBEM4x10 FIXING SCREW

L TAPTITE SCREW SENSING TUBE MOUNTINGM4x6 BRACKET SCREW

LIQUIDCOAL

TUBINGNUT (2)

FIRE FRONTSENSINGTUBE

CONTROLKNOB

GAS SUPPLYPIPE

FIBRE WASHER (2)

SIDE EXTENSION (2)

OLIVE (2)

BBUSENSINGTUBE

SENSINGTUBEMOUNTINGBRACKETASSEMBLY

BATTERY

FILTER

H


16221648B


3.1 UnpackingThe fire front is delivered in two packs, one contains the bodyassembly, fuel effect pieces and supply tube pack.

The other contains the fire front castings, side panels, plinth andloose items pack. Refer to diagram 3.1. to identify the parts.

To unpack carton 1, lift out the top fitting containing the firespigot and combustion chamber bottom plate, lift out thecardboard front fitting, the supply tube pack and the two boxescontaining the fuel effect pieces.

Lift the outer carton clear to leave the fire front sitting in the basetray.

To unpack carton 2, lift out the cardboard tray containing theplinth and side panels. Lift out the loose items pack, legs boxand canopy. Remove the internal cardboard fitting and lift outthe lower front and side castings.

Put these items on one side until required. Check contents ofloose items pack against list.

Remove the glass front panel, see diagram 3.3.

It is suggested that the side extensions, from the castings pack,be fitted at this time to the left and right hand side panels.

NOTE: These are a slide fit onto the louvres.

3.2 Flue Spigot AssemblyNote. This is marked “Homeglow BBU”

Leave the fire front sitting in the base tray.

Remove the two plastic transit studs securing the wall sealingplate to the rear of the fire front and put it on one side untilrequired.

Secure the spigot assembly to the fire front back with the selftaping screws provided, in the loose items pack, see diagram3.4.

Note. There are eight self tapping screws in the pack, onespare.

3.3 Gas Supply Tube and Sensing TubesPreparationRemove the plastic ferrule from the bulkhead connector on theair duct and discard.

Fix the flared end of the back boiler sensing tube to the bulkheadconnection on the boiler air duct with the tubing nut provided.Slide the sensing tube mounting bracket assembly over theback boiler sensing tube and fix to the casing with the screwprovided, see diagram 4.1. Fit the sensing tube filter onto thefitting assembly, see diagram 4.1. Take care not to damage thefilter.

Important. Make sure that the mounting bracket assembly ispushed back to the fire front face of the boiler casting and check3mm distance is achieved and the back boiler sensing tubedoes not extend above the sensing tube bracket assembly, seediagram 4.1.

Note. After fitting the flue blockage safety device sensing tubeplease refer to the 'commisioning' section of the back boiler unitand relight the boiler to test the device.

Check that the gas service cock is in the Off position, seediagram 3.5.

The inlet supply tube, back boiler sensing tube assembly andfire front sensing tube are packed in the supply tube pack, seediagram 3.2.

This supply tube and fire front sensing tube may need to be cut,at the plain end, dependent on the model and position of theback boiler in the opening.

Diagram 3.3

GLASS RETAININGBRACKET

GLASS FRONT PANEL

4844

Diagram 3.4

FLUE SPIGOT ASSEMBLY

SECURINGSCREW (7)

J

3923

S

Gas Supply TubeMeasure the distance “C”, see diagram 3.6, from the front mark“P” on the air duct to the fire front fixing wall face.

Use a straight edge across the opening.

Shorten the plain end of the gas supply tube by the distance “C”.No shortening is required when mark “P” is level with the firefront fixing wall face, “C” being zero.

The maximum distance for “C” will be 67mm (25/8in).


17 221648B


56/2 BBUFIREFIXINGWALL FACE

45/2 BBUFIREFIXINGWALL FACE

N

BACK BOILER AIR DUCT

56/2BBU

45/2BBU

P

*'D'

*'D'

*'D'


*'D' = Distance from fire fixing wall face to datums on back boiler air duct. This represents the length of pipe that requires cutting off.

Diagram 3.7

6140

Diagram 3.5

BACKBOILERONLY 'ON'TURNEDFULLYCLOCKWISE

BACKBOILER &FIRE 'ON'TURNED TOMID POSITION

90˚

'OFF'TURN FULLYANTI-CLOCKWISE

180˚

5078

BACKBOILERAIRDUCT

*'C' = Distance from fire fixing wall face to datums on back boiler air duct. This represents the length of pipe that requires cutting off.

'P'

*'C'

*'C'

GAS FIRESUPPLY TUBE

FIRE FIXINGWALL FACE

Diagram 3.6

5245

GAS SERVICECOCK UNION

Firefront sensing tubeShorten the plain end of the fire front sensing tube by distance“D”, no shortening of the tube is required when 45/2 back boileris fitted and point “P” is level with the fire fixing wall face.Similarly when a 56/2 back boiler is fitted no shortening isrequired when point “N” is level with the fire fixing wall face. Inboth cases “D” is zero the maximum distance of “D” for both the45/2 and 56/2 back boiler will be 25mm, see diagram 3.7.

Deburr the tube end inside and out.

3.4 BatteryRemove the fire front from the base tray.

Take the battery from the fittings pack and fit as shown indiagram 19. (Instructions for Use). make sure that the terminalsare correctly fitted.


18221648B

4.1 Wall Section PlatePlace the wall sealing plate onto the back boiler air duct, markthe fixing holes, remove the plate and drill the holes to suit theplugs and screws provided, in the supply tube pack, leavesufficient screw proud to accept the wall sealing plate keyholes,see diagram 4.2.

Fit the wall sealing plate and tighten the screws, making surethat the “wings” are flush with the fire fixing wall face, seediagram 4.2.

4.2 Positioning the Fire FrontPlace the fire front onto the back boiler air duct, check that thefire front spigot is central in the flue collector assembly, pushback into contact with the fire front fixing wall face, see diagram4.3.

Mark the fire front fixing points through the mounting bracketholes at the top, see diagram 4.3.

Pull the fire front forwards and remove.

Drill the fire front fixing wall face using a 10mm masonry drill toa minimum depth of 40mm to accept the anchor nuts andscrews provided.

Place the anchor nuts and screws into the holes, screw up, butleave sufficient screw thread proud to accept the fire front.

Note. If the fire front fixing wall face is not of a solid construction,to a minimum depth of 40mm, for example, hollow brick ormetal, an alternative and rigid form of fastening for the fire frontmust be used and extra care taken.

Fit the fire front sensing tube to the flue collector with the twosecuring screws. see diagram 4.4.

Place the tubing nut and olive from the supply pack onto theprepared end of the sensing tube, see diagram 4.4.

Offer the appliance up to the back boiler air duct and push backinto position taking care not to damage fire front sensing tubeand filter, lift slightly to engage mounting bracket onto screws,engage sensing tube into bulkhead connection, see diagram4.5.

Tighten the fire securing screws, see diagram 4.6.

Tighten the sensing tube nut onto the bulkhead, see diagram4.7.

4 Installation

SENSING TUBEFITTINGASSEMBLY

THREAD CUTTING SCREW(Taptite)

3 mm

BACKBOILERSENSING TUBE

BULKHEAD CONNECTIONTUBINGNUT BOILER AIR DUCT

SENSINGTUBEFITTINGASSEMBLY

FRONT FACE OF BOILER CASTING

FILTER

Diagram 4.2

NOTE:WINGSFLUSHWITHWALL

G F

5166

Diagram 4.1

6138

Diagram 4.3

MARKFRONTFIXINGHOLES

SPIGOT

FLUECOLLECTORASSEMBLY

FIRE FRONT

5246


19 221648B

4 Installation


SECURINGSCREW (2)

FLUECOLLECTOR

TUBINGNUT

OLIVE

FRONTFIXINGSCREW

SPIGOT

BACKBOILERAIRDUCT

FLUECOLLECTORASSEMBLY

FIRE FRONT

OLIVETUBINGNUT

SENSINGTUBE

Diagram 4.5

Diagram 4.4

5074

SECURINGSCREW (2)M5 x 40mm

C

MOUNTINGBRACKET

ANCHORNUT D

CSECURINGSCREW (2)

Diagram 4.6

5093

4.3 Gas ConnectionPlace the tubing nut and olive, from the loose items pack, ontothe prepared end of the gas supply tube, see diagram 4.8.

Connect the gas supply, as diagram 4.8, tighten the nut andolive at the gas service cock.

To tighten the other end, use a spanner to hold the locknut (A)at the bulkhead fitting and make sure that it does not turn,tighten union nut (B) on the supply tube in the usual manner,see diagram 4.8.

Make sure that joint (B) is checked for gas soundness, bychecking it when carrying out the other gas soundness checksas in Section 5.1.

Fit the left hand side panel, see diagram 4.9.


20221648B

Diagram 4.9

FIBREWASHER

FIBREWASHER

SECURING SCREWSTOP

SECURING SCREWSTOP

LOCATING PINAND HOLE


L.H. SIDEPANEL

R.H. SIDEPANEL

R.H. SIDE PANEL

GAS CONTROLKNOB


J J

4849

Diagram 4.7

TUBE NUT

SENSINGTUBE

TUBE NUT

OLIVE

JOINT (C)

UNIONNUT (B)

LOCKNUT (A)

GAS SUPPLYPIPE

GAS SERVICE COCK

TUBINGNUT

Diagram 4.8

3929

S

5167

4 Installation


21 221648B

5 Lighting, Testing and Fitting Internal Parts

5.1 Lighting and TestingMake sure that the electrical supply to the back boiler isisolated.

This fire front is fitted with a flue blockage safety device whichwill shut down the fire if there is an unacceptable spillage ofproducts at the draught diverter. If the fire front shuts downfrequently for no apparent reason the first things to be checkedare the chimney and air inlets into the room. An additional causecould be that the filter, in the gas tap, has become blocked. Anyproblems found must be put right by a competent person beforethe fire front is used again.

The flue blockage safety device MUST NOT be adjusted ordisconnected. If replacing use only the correct and approvedparts.

Remove the pressure test nipple screw and fit a suitablepressure gauge, see diagram 5.1.

Place the right hand side panel onto the pins, see diagram 4.9,but do not secure at this time.

Turn the gas service cock to back boiler and fire ON, seediagram 3.5.

To check for gas soundness use the pressure drop method andapply suitable leak detection fluid to all joints, replace the glasspanel, see diagram 3.3.

Fit the control knob to the tap spindle, see diagram 5.2.

IMPORTANT NOTE. If the burner does not light within threeseconds, release the tap, wait ten seconds and repeat thelighting operation.

Push the control knob fully in and turn it anti-clockwise to 1 - ignition, see diagram 5.2, clicking of the ignition will be heardand the burner will light.

Keep the knob pushed in four ten seconds, to energise theflame supervision device, during this time the ignition systemwill continue to operate, indicated by the clicking.

Air may be present in the supply to the fire front so that the initiallighting operation may need to be repeated.

With the burner lit, visually check for leaks whilst changing tapsettings.

To change settings:

0 - 1 Push in and turn




If the burner goes out, wait three minutes beforerelighting, forany other reason wait for two minutes.

Check that the gas pressure is as stated in the Data Section 1.3,or on the Data Label on the right hand side panel.

If there is any doubt about the gas rate, check at the meter,having first turned off all other gas appliances and pilot lights.

The rate for this fire front, after ten minutes, is about 2.7minutesfor 1ft3.

Turn the burner off, remove control knob, release right handside panel and pressure gauge, replace the test point screw andmake sure a gas tight seal is made.

Refit, close and secure the side panels, see diagram 4.9.

Diagram 5.2

GASCONTROLKNOB

IGNITION &POSITION 1

POSITION 2APPLIANCEOFF

POSITION 4POSITION 3

FLAT DOWNPOSITION

VERTICAL

5082

GASTAP

PRESSURETESTPOINT

Diagram 5.1

5081


22221648B


5.2 Internal Parts - FittingCaution. If any of the internal fire front parts are damaged DONOT light or further test the fire front until replacement parts arefitted.

Refit gas tap control knob.

Swing the side panels out by about 5mm, to their stops.

Warning. The Glass panel can be hot.

Remove the glass panel, see diagram 3.3.

Fit the combustion chamber bottom plate, inside base tray, seediagram 5.3.

Follow sequence in diagrams 9 to 16. (Instructions for Use). tofit internal fire front parts.

Note. The fuel effect pieces are marked on their backs.

5.3 Decorative CastingsFit the front legs as diagram 5.4, decorative side castings asdiagram 5.5, front casing as diagram 5.6, replace glass panelassembly as diagram 3.3, and canopy as diagram 17.(Instructions for Use). Take care as it is made of cast iron.

Note. The canopy is fitted with two adjusting screws, seediagram 5.7. These should be adjusted so that the canopysides fit parallel to the side panels.

This adjustment can be done when the canopy is in place.

5.4 Fitting of PlinthBefore fitting the plinth please read the instructions on it.

Fit the plinth onto the guides and push it back as far as it will go,see diagram 3. (Instructions for Use).

5.5 Heat SettingsLight the fire front burner as the relevant part ofSection 6.1.

Refer to diagram 5. (Instructions for Use).

At tap position 1 - centre section flame effect.

At tap position 2 - centre section flame effect withouter sections fuel bed glow.

At tap position 3 - centre and outer sections flameeffect with fuel bed glow.

At tap position 4 - (full on) full flame effect and fuelbed glow.

In the unlikely event of the flame going out when the fire frontburner is on, then turn off. Wait three minutes before relighting.

If relighting for any other reason, wait two minutes before doingso.

5.6 Test for Clearance of ProductsNotes

WARNING. Take care, the appliance will get hot during tests.

For the test you will need a smoke match, extension and a torch.

IN ALL CASES, if spillage continues after the specified testperiods steps must be taken to put the fault(s) right.

If the problem cannot be put right the appliance must bedisconnected and expert advice sought.


23 221648B

Diagram 5.5

BREARSECURINGSCREW (1)

FRONT SECURINGSCREW (2) L

7457

BOTTOMPLATE

Diagram 5.350

71

SECURINGSCREW (2)

LEVELLINGSCREW

WASHER

Diagram 5.4

5073

F

A48

48Diagram 5.6

LOCATION PIN

VIEWED FROM REAR

FRONTCASING

LOCATIONSLOT

Diagram 5.7

LOCATING PIN

ADJUSTING SCREWS

REAR VIEW



24221648B


10

10 10

DIVERTERPLATE

FIRE SPIGOT NOTSHOWN FOR CLARITY

560 SMOKEMATCHEXTENSION

FRONT VIEWSIDE VIEW

TORCH

25 mm25 mm

MATCH EXTENSION

L.H. SIDEPANEL

DRAUGHTDIVERTER

SMOKE MATCHEXTENSION

Diagram 5.8

Diagram 5.9

5169

5168

Test Where No Fan is PresentClose all outside doors and windows in the room where theappliance is installed.

Light the fire front only and set tap position to 4. After fiveminutes apply a spillage test as shown in diagram 5.8 and 5.9.During tests smoke should be drawn into the fire draughtdiverter and the boiler draught diverter.

If spillage occurs, leave the fire front alight for up to a further tenminutes and repeat test. Turn the fire front burner off.

Next light the back boiler only. After ten minutes apply spillagetest as shown in diagram 5.8 and 5.9. During tests smokeshould be drawn into the fire front draught diverter and boilerdraught diverter.

If spillage occurs, leave the back boiler alight for up to a furtherfive minutes and repeat tests.

Leave the back boiler alight.

Now light the fire front. After ten minutes apply spillage tests asshown in diagram 5.8 and 5.9. During tests smoke should bedrawn into the fire draught diverter and boiler draught diverter.

If spillage occurs leave back boiler and fire front alight for up toa further five minutes and repeat tests.

Test Where a Fan is PresentA fan means an extract fan or a fan for other open fluedappliances or a circulating fan for a warm air unit, whether or notgas fired. With the fan switched off carryout the appropriatespillage test with all doors and windows closed, as above.

If the above spillage test is satisfactory carry on as follows:

Open all doors connecting the room containing the applianceand the room in which the fan is fitted.

Close all other doors and windows in the premises.

If the fan is in the same room as the appliance, close all doorsand windows in that room.

Switch the fan on and repeat the spillage test as above.


25 221648B

6 Instructions for Use

Hand the Instructions for Use to the user and instruct in the safeand economical use of the fire front and back boiler.

Advise the customer that they should read their Usersinstructions before operating the fire and always follow theadvice in the Section headed “Cleaning your Fire”.

Advise that any smell which may be apparent on initial lightingis quite normal and it will quickly disappear.

Advise that the fire front is fitted with a flue blockage safetydevice, and refer to the Instructions for Use.

Important. Advise that soft wall coverings, for example, blownvinyl wallpaper, are easily affected by heat, they may, therefore,scorch or become discoloured when close to a heating appliance.This should be borne in mind when having a heating applianceinstalled and when redecorating.

Advise the user that, to ensure the continued efficient and safeoperation of the appliance it is recommended that it is checkedand serviced at regular intervals. The frequency of servicingwill depend upon the particular installation and usage, but ingeneral once a year should be enough.

Draw attention, if applicable. to the current issue of the GasSafety (Installation and Use) Regulations, Section 35, whichimposes a duty of care on all persons who let out any propertycontaining a gas appliance.

It is the Law that any servicing is carried out by a competentperson.

Refer to the Instructions for Use and show how to light the firefront, in the event of an ignition system failure, with a spill or longmatch

Advise the user of the precautions necessary to preventdamage to the system, boiler and the building, in the event ofthe heating system being out of use during frost or freezingconditions.

Reminder, leave these instructions with the user.

Diagram 6.1

5094

SPILL

BURNER

SPILL

3 Flue Systems7 Servicing

NotesTo ensure the continued efficient and safe operation of theappliance it is recommended that it is checked and serviced atregular intervals. The frequency of servicing will depend uponthe particular installation and usage, but in general once a yearshould be enough.

It is the Law that servicing is carried out by a competent person.

Make sure that the fire is cold before carrying out any servicing.

After servicing, or replacing parts, always test for gas soundnesswith a suitable leak detection fluid. To test the gas tap, refix thefire front and apply leak detection fluid to all joints, replace theglass panel, light the burner and visually check all joints forleakage whilst changing tap settings.

Carry out functional check on controls, see Section 4 and 5.

Other than for replacing the glass panel, internal fire front partsand lighting the fire front should be removed from its fixings byreversing the instructions in Section 4 and 5. Make sure thatthe side panels and feet are removed. Refit controls cover plinthso that the fire can stand upright.

Unless stated otherwise reassembly all parts in the reverseorder to removal.

The back boiler should be serviced at this time, refer to BackBoiler Installation and Servicing Instructions.

The flue blockage safety device MUST NOT be adjusted ordisconnected. If replacing use only the correct and approvedparts.

7.1 Glass PanelLift canopy off, take care as it is made of cast iron.

Swing open side panels to their stops, about 5mm, as diagram7 & 18 (Instructions for Use).

To remove the glass panel, refer to diagram 3.3.

7.2 Internal Fire Front PartsRemove internal fire front parts as diagrams 15 to 11. (Instructionsfor Use).

Remove bottom plate, see diagram 5.3.

Examine these parts and replace as necessary.

7.3 Burner and InjectorsRemove the front castings, see diagram 5.6.

Remove the lower front baffle, see diagram 7.1.

Remove the burner baffle, see diagram 7.1.

Remove the RH. leg, see diagram 5.4.

Remove the side castings, see diagram 5.5.

Advise the user that the ‘Benchmark’ logbook should becompleted by the installation engineer on completion ofcommissioning or servicing.


26221648B

R.H. LEGSUPPORTBRACKET

SECURINGSCREW(4)

Diagram 7.2

5191

7 Servicing

4854LOWER

FRONTBAFFLE

SECURING SCREWS (3)

SECURING SCREWS (2)

BURNERBAFFLE

Diagram 7.1

Remove the RH. leg support bracket, see diagram 7.2.

Disconnect the supply pipe unions at the injectors also the unionconnection at the front, see diagram 7.3.

Remove the two burner securing screws, see diagram 7.3.

Swing the burner out for access, see diagram 7.4.

Unscrew the injectors, inspect, clean or replace as necessary,see diagram 7.5.

Do not clean the holes with a wire or sharp instrument.

Remove injector box cover screw and plate, see diagram 7.5,clean out dust and debris. Brush away any lint and dust from theburner and surrounds. Using a soft brush or vacuum cleaner.

Do not use a brush with wire bristles.

7.4 Flue Blockage Safety DeviceRemove the burner, refer to Section 7.3.

Check the condition of the electrode and thermocouple, cleanwith a soft brush, see diagram 7.6.

Make sure the electrode is in line with the earth post and sparkgap is as in diagram 7.7.

7.5 Ignition LeadRemove the burner, refer to Section 7.3.

Disconnect the tube nuts, remove the mounting bracket securingscrews and flue blockage safety device, see diagram 7.6.

Check the ignition lead, see diagram 7.6. Replace if required,refer to Section 9.5.

Note. When refitting the flue blockage safety device, take carenot to trap the ignition lead under the mounting bracket.

7.6 Gas Tap and Micro Switch AssemblyNote. This item need not be serviced annually.

Remove micro switch electrical connections, see diagram 7.8

Disconnect all union connections and remove the tubes in theorder shown in diagram 7.9.

Take care as the filter in the pilot port may be loose.

Disconnect the thermocouple nut, see diagram 7.10.

When replacing only tighten the nut a quarter turn beyond fingertight.

Remove the gas tap bracket securing screws, see diagram7.10.

Remove the gas tap assembly.

To service the gas tap remove the gas tap niting plate assemblysecuring screws, see diagram 7.11. Take care as there is aspring beneath the niting plate. Remove the plug, pin, springwasher, plain washer and “O” ring, see diagram 7.11.

Clean and relubricate using a suitable grease.

When replacing make sure the operating disc, with retainingwasher and micro switch leads are correctly located, seediagram 7.8 and 7.11.


27 221648B

4855L.H. BURNER

SECURING SCREWR.H. BURNER

SECURING SCREW

BURNER

UNION CONNECTION

UNIONCONNECTION

7 Servicing

Diagram 7.5

INJECTORS

INJECTOR BOXCOVER

PULL FORWARDS

BURNER

Diagram 7.4

5172

Diagram 7.3

3958

S

SECURINGSCREW

NOTE:Chamfered edge to be onthis side.

UNIONCONNECTION

5075

Diagram 7.6

SECURINGSCREW (2)

SECURINGSCREW (2)

TUBENUT

MOUNTINGBRACKET

TUBENUT

FLUE BLOCKAGESAFETY DEVICE

TUBENUT

IGNITIONLEAD


28221648B

Diagram 7.8

GAS TAP MOUNTINGBRACKET SECURINGSCREW

ELECTRICALCONNECTIONS

MICRO SWITCH

SECURINGSCREW (2)

INSULATIONMICROSWITCH

INSULATION

NUT (2)

GAS TAPMOUNTINGBRACKET

3960

S

5248

Diagram 7.7

EARTH POST

ELECTRODE

18

67

ELECTRODE

SPARK GAP3 + 1.0

- 0.5

EARTH POST

ELECTRODE

TOP VIEW

EARTH POST

CL

7 Servicing


29 221648B

7 Servicing

Diagram 7.9

THERMOCOUPLENUT

Diagram 7.10

Diagram 7.11

5

7

9

GAS TAP SECURINGSCREWS

GAS TAPBODY

PLUG'O' RING

WASHERSPRING

GAS TAPBRACKET ANDNITING PLATEASSEMBLY

SECURINGSCREW

1

2

3

4

5

6

7

8

9

5089

5091

5090


30221648B

8 Fault Finding

Diagram 8.1

ELECTRODE

RE

D

RE

D

MICROSWITCH

SPARKGENERATOR

5251

Diagram 8.2

5252

ELECTRODE

MICROSWITCH

SPARK GENERATOR

RED

RED

8.1 Fire Front IgnitionRemove decorative castings, glass panel and fuel bed, refer toappropriate parts of Section 7.

Refer to diagram 8.3.

8.2 ElectricalRefer to functional flow diagram 8.2 and pictorial wiring diagram8.1.

8.3 ThermocoupleTo test a thermocouple, a meter with a range of 0 to 30mV isrequired together with a thermocouple interrupter test unit,similar to the British Gas Minitest 6 unit.

Refer to fault finding diagram 8.4 and diagnosis graph, diagram8.5.

8.4 Flue Blockage Safety DeviceIf the device operates it indicates there could be a problem withthe chimney or, the pilot filter in the gas tap is blocked. Firstmake sure air vents are free from obstruction, by carrying outspillage checks as Section 5.6. If all is in order refer to diagram8.3 to check if the filter is blocked.


31 221648B

8 Fault Finding

Diagram 8.3

5478

NOYES

YES

NO

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

Turn off appliance tap, turn on appliance tap.Does the fire light ?

FIRE WILL NOT LIGHTSTART HERE

Check that gas is available at burner, using a match, ensuring correct functioning of burner on all setting positions. Check that electrode, micro switch and ignition unit connections are satisfactory. Check that burner pressure is as specified - correct any fault found.

Ensure gap is within specifiedtolerance, refer to SERVICING. turn tap to energise ignition.Does the fire light ?

Disconnect ignition lead from electrode, place connector within 4mm of burner and turn tap to energise igniter. Is there a spark at the gap ? Remove ignition lead from ignition unit and

place screw driver between appliance chassis earth and ignition unit, leaving 4mm gap between blade and spade connector. Turn tap to energise ignition. Is there a spark at gap ?Replace faulty electrode and

reassemble ignition system.Turn tap to energise igniter. Does the fire light ?

Disconnect red leads from ignition unit. Turn tap to energise ignition. Is there continuity between red leads ?

Renew ignition lead and reassemble ignition system.

Change the ignition unit battery. Turn tap to energise ignition. Does the fire light ?

Rectify faulty leads or replace micro switch.

Change ignition unit.

Check several times that ignition is satisfactory.

Check that gas is availableDoes the pilot light using a match ?

Change pilot filter

NOYES


32221648B

8 Fault Finding

Diagram 8.4

Diagram 8.5

Closed Circuit Voltage (millivolts)DIAGNOSIS GRAPH FOR FIRETHERMOCOUPLE CIRCUIT

Ope

n C

ircui

t Vol

tage

(m

illiv

olts

)

0 1 2 3 4 5 6 7 8 9 10 117

8

9

10

11

12

13

14

15

16

17

A B C

Disconnect appliance thermocouple from the gas tap. Check that all connections are

clean and in good condition. Fit test meter interrupter into the magnet unit. Fit appliance

thermocouple into the test meter interrupter.

NO

YES

Hold down control tap in ignition position. Ignite burner, allowing thermocouple to attainoperating temperature. Measure the OPEN CIRCUIT voltage.

Is voltage greaterthan 15mV?

Faulty thermocouple.Replace flue blockagesafety device.

Faulty thermocouple.Replace flue blockagesafety device.

Note the open circuit reading then measure the CLOSED CIRCUIT voltage. Note this voltage.Referring to the diagnosis graph, mark the open circuit voltage on the VERTICAL axis,and the closed circuit voltage on the HORIZONTAL axis. Note the point where thesetwo values intersect on the graph.

THERMOCOUPLECIRCUIT ISSATISFACTORY

In which area of thegraph is the intersect

Faulty magnet unit in gas tap.Replace gas tap

B A

C

Is voltage greaterthan 15mV?

5243

0065

M


33 221648B

9 Replacement Parts

Notes.

Make sure that the fire is cold before replacing any parts.

Replacement of parts must be carried out by a competentperson.

Remove the internal fire front parts as the relevant part ofSection 5.2.

Before removing or replacing any fire front parts turn the gassupply service cock to “Back Boiler Only On”, see diagram 3.5.

Isolate the electrical supply to the back boiler and fire front.

After replacing or disconnecting any gas carrying components,always test for gas soundness, using a suitable leak detectionfluid and carryout functional check of controls.

To test the gas tap apply leak detection fluid to all joints, light theburner and check all the joints for leakage at all tap settings.

Unless stated otherwise reassembly of all parts is in the reverseorder to removal.

9.1 BurnerRefer to Section 7.3.

9.2 InjectorsRefer to Section 7.3.

9.3 Gas Tap and Micro Switch AssemblyRefer to Section 7.5 and diagram 7.8 to remove the microswitch.

9.4 Flue Blockage Safety DeviceRefer to Section 7.3 to remove burner.

Disconnect the union connections, remove the mounting bracketsecuring screws and flue blockage safety device, see diagram7.6.

Remove the right hand side panel, see diagram 4.9.

Remove the right hand side casting, see diagram 5.5.

Remove the thermocouple nut. see diagram 7.10.

Remove the ignition lead, see diagram 19 (Instructions for Use).


When refitting make sure the spark gap is as shown in diagram7.7.

9.5 Ignition LeadRefer to Section 8.3 to remove the burner.

Disconnect the ignition lead to the electrode.

Disconnect the union connections, remove the mounting bracketsecuring screws, remove the ignition lead (black end), seediagram 7.6.

Remove right hand side panel, see diagram 4.9.

Remove right hand side casting, see diagram 5.5.

Remove the ignition lead(clear end), see diagram 19 (Instructionsfor Use).


9.7 Spark GeneratorRemove right hand side panel, see diagram 4.9.

Remove the right hand side casting, see diagram 5.5.

Remove retaining screw, disconnect the electrical leads andthen release the spark generator from the location tab at therear, see diagram 19 (Instructions for Use).

9.8 BatteryThe battery is 9V and we recommend that it be of the alkalinetype, bought locally.

When fitting make sure that it is fitted as shown in diagram 19(Instructions for Use).

9.9 Gas Tap Pilot FilterRemove right hand side panel, see diagram 4.9.

Gain access to the tap as Section 7.6.

The filter, which is very small, is in pilot port of the gas tap, toremove use a small non-metallic tool.

When fitting the replacement it is important that the filter isseated correctly as shown in diagram 9.1.


34221648B

1 210213 136 918 Rear fuel effect piece

2 210214 136 919 Fuel effect piece - 1





7 448093 136 924 Glass panel assembly

8 230169 398 444 Injector - upper

9 230201 398 442 Injector - lower

10 202437 162 100 Flue blockage safety device

12 202014 360 188 Microswitch

13 WW4617 312 997 Ignition lead

14 448103 135 925 Gas tap control knob

15 800449 136 927 Gas tap

16 202179 152 949 Spark generator

17 208673 162 208 Filter

Key No. Part No Part No.G.C.. Description

GAS TAP

FILTER

GAS TAP BRACKETAND NITING PLATEASSEMBLY

FILTER

CROSSSECTIONVIEW

Diagram 9.1

5477

9.10 Replacement PartsWhen replacement parts are required please apply to your localsupplier.

Please quote the name of the fire front, “Saxony 2”.

The GC number can be found on the chassis, visible when frontcasting is removed.

Refer to diagram 9.1 for the illustration of the replacement parts.

These fire fronts are fitted with flue blockage safety devices.

9 Replacement Parts


35 221648B

9 Replacement Parts

Diagram 9.2

7

1

6

4

2

3

5

9

8

13

5092

10

16

12

14

15

17


36221648B

Because of our constant endeavour for improvement details may vary slightly from those in the instructions.

10 Supplementary Installation Instructions

As these fire fronts may be fitted to Glow-worm 45, 56, 45R or56R back boiler units WITHOUT a flue blockage safety device,the following instructions must be read and followed in place ofthose in the main Installation and Servicing Instructions.

To check if a flue blockage safety device is fitted, refer to theinset in diagram 20 (Instructions for Use).If one is fitted this supplement MUST be ignored.

10.1 GeneralTo fit the fire front to one of the above EXISTING GLOW-WORMBACK BOILER UNITS follow the instructions below.

10.2 Installation1. Do not fit the back boiler sensing tube as required in

the main installation and servicing instructions.

2. If necessary isolate the power supply to the backboiler unit and remove the existing wiring usedpreviously for a fire front with lights.

3. Any references in the installation and servicinginstructions to the back boiler unit flue blockage safetydevice must be ignored.

10.3 Lighting the BoilerTo light the boiler refer to lighting the boiler supplementaryinstructions in the Instructions for Use.

Documents

Instructions for Use Installation and Servicing