221098C.01.99
Installation and Servicing Instructions To be left with the user
G.C.37 314 15 G.C.37 314 14
For use with a specially designed Glow-worm Back Boiler Unit only 3914 S 3915 S
References in these instructions to British Standards and Statutory Regulations/Requirements apply only to the United Kingdom. For Ireland the rules in force must be used. BS 6332 This is a Cat I Appliance BS 5258 2H
Customer Services: Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT Tel: (01773) 828100 General/Sales enquiries : Fax: (01773) 828070 One Contact Local Service Tel: (01773) 824141 Fax: (01773) 820569
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If this fire front is to be fitted to a Glow-worm back Sheet Metal Parts boiler WITHOUT a combustion products discharge WARNING. When installing or servicing this fire front safety device please read the supplementary instructions care should be taken when handling metal parts at the back of this booklet. (components), to avoid any possibility of personal The instructions consist of three parts, Installation and injury. Servicing Instructions for the Back Boiler Unit, Installation and Servicing Instructions for the Fire Front and Instructions for Use, including the Guarantee 1.2 Statutory Requirements Registration Card. The instructions are an integral part The installation of this fire front must be carried out by a of the appliance and must, to comply with the current competent person, in accordance with the current issue issue of the Gas Safety (Installation and Use) and relevant requirements of:- Regulations, be handed to the user on completion of the Manufacturer’s instructions, supplied. installation. The Gas Safety (Installation and Use) Regulations, as 1 General Notes and Information amended, The Building Regulations, the Local Gas Undertaking, The Building Standards (Scotland) This Glow-worm gas fire front is to be used with a Regulations (applicable in Scotland), The Health and specially designed Glow-worm Back Boiler Unit only. Safety at Work Act, Control of Substances Hazardous to Health, The Electricity at Work Regulations and any This fire front and back boiler are NOT suitable for applicable local regulations. fitting to a precast flue. Detailed recommendations are contained in the current The fire front is delivered packed in two cardboard issue of the following British Standards and Codes of cartons, which together contain all the parts necessary Practice:- for the installation of the fire front. BS1251, BS5440 Part 1 and 2, BS5871, BS6891, If the back boiler and fire front are to be installed at the BS7671. same time please read both sets of installation instructions before starting. Manufacturer’s notes must not be taken as overriding statutory requirements. Wherever possible, all materials, appliances and components to be used shall comply with the requirements of applicable British Standards. CE Mark Where no British Standards exist, materials and The CE mark on this appliance shows compliance with:- equipment should be fit for their purpose and of suitable 1. Directive 90/396/EEC on the approximation of the quality and workmanship. Laws of the Member States relating to appliances burning gaseous fuels. 1.1 Important Notice 2. Directive 89/336/EEC on the approximation of the This fire front is for use only on G20 gas. Laws of the Member States relating to electromagnetic compatibility. This fire front is fitted with a safety device which will shut it down if there is a lack of oxygen. If the fire shuts down frequently for no apparent reason the first things to be checked are the chimney and the air inlets into the room. An additional cause 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 is used again.
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FLAT AREA FIRE FIXING FACE 3916 BBU S
CL 289mm 289mm 327mm 327mm 690mm
339mm 351mm 351mm 339mm
Diagram 1.1
1.3 Data Gas connection- from the service cock Total weight - 49kg Injector - upper Bray 18/180 - lower Bray 18/320 Burner pressure setting - cold 13.0mbar 5.18in wg - hot 13.2mbar 5.28in wg Heat input - gross - 6.7kW 22,750Btu/h Heat output - nominal - 4.03kW 13,670Btu/h Fire serial No. - On chassis - visible when front casting is removed Data label - Inside of right hand side panel The fire front burner is lit by means of an electronic spark generator unit. All dimensions are given in millimetres (except as noted).
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CL MAXIMUM 3917 S 445mm 445mm SHELF 150mm DEPTH 150mm
150mm 150mm 840mm 840mm
FLAT AREA FIRE FIXING FACE Diagram 1.2
1.4 Fire Front Location 1.5 Clearances This fire front can only be fitted to a Glow-worm 45/2 or Restrictions must not be placed around the assembled 56/2 back boiler unit which itself has been installed in fire front, see diagram 1.2. accordance with the Glow-worm Installation and A shelf or surround of a maximum depth of 150mm may Servicing Instructions. be fitted, provided clearances are as shown in The back boiler air duct acts as a support for the fire diagram 1.2. However, for every additional 25mm extra front. above the fire front the depth of the shelf may be increased by 25mm. The top of the fire front must be secured to the vertical fire front fixing wall face. This wall face may be a Combustible furniture or materials must not be placed chimney breast or surround, see diagram 1.2. closer than 1metre in front of the fire front. The fire front flue spigot projects into the back boiler flue collector assembly. The gas supply is taken from the back boiler gas service cock. The back boiler must be correctly positioned in the builder’s opening as the fire front is located by connection to it.
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Note. Refer to Section 2 in the Back Boiler Installation 2.4 Flue Book before starting. The back boiler flue collector assembly accepts the fire front flue spigot. 2.1 With Hearth Note: Provision must be made during the installation of A fireproof hearth under the fire front must have the the back boiler for total ventilation requirement for the minimum dimensions as shown in diagram 2.1. combined appliance. See relevant section in back boiler installation instructions. 2.2 With Surround See diagram 2.2. The fire front casing should cover the opening. A wider opening will require any opening left to be covered with a non-combustible finished material, see INSTALLATION CENTRE LINE diagram 2.3. 3919 S The surround must have a minimum clear, flat area as shown in diagram 1.2. Any projection on the surround 406mm must be outside this area. to 460mm Any combustible material on the fire front fixing face area of the surround must be removed, see diagram 2.3. 560mm This area, to the depth removed, should then be rendered to with a sand/cement mixture. 590mm CL 2.3 Without Surround or Hearth The fire front fixing wall face must be flat over an area as shown in diagram 1.2. This also shows the minimum clearances for shelves or projections on the fire front FRONT PREPARED fixing wall face. OPENING BASE The information in the last two paragraphs of “With Diagram 2.2 Surround” should now be followed. Under no account must carpet or other combustible material be laid directly under the fire front, unless the minimum clearances shown in diagram 1.2 is achieved. 3920 S
The dimension is taken from the bottom of the fire front 280mm 280mm plinth to the top of the carpet pile or other floor covering. 220mm 220mm
Opus illustrated 3918 S
BUILDERS OPENING
C 680mm
L 560mm
1 /2in. 12mm INSTALLATION 50mm Non- CENTRE combustible LINE MIN. material 135mm 1 /2in 2in. REMOVE COMBUSTIBLE MATERIAL FROM PREPARED 760mm THIS AREA BASE 30in. 340mm 1 13 /2in. Diagram 2.1 Diagram 2.3
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FIRE BODY PACK 4337 S
FIRE BODY ASSEMBLY
WALL SEALING PLATE FLUE SPIGOT
LITERATURE
COMBUSTION FUEL CHAMBER EFFECT BOTTOM PLATE BED
OPULENCE CASING PACK OPUS CASING PACK
CANOPY CANOPY
R.H. SIDE PANEL L.H. SIDE PANEL L.H. SIDE PANEL R.H. SIDE PANEL R.H. SIDE CASTING L.H. SIDE CASTING FRONT FRONT L.H. SIDE CASTING CASTING R.H. SIDE CASTING CASTING
PLINTH PLINTH
R.H. L.H. LEG LEG R.H. L.H. LEG LEG Diagram 3.1
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KEY 6135 SCREW FRONT LEG A M5x30 LEVELLING SCREW
SCREW SIDE B M5x14 CASTINGS
SCREW UPPER WALL C M5x40 MOUNTING
ANCHOR UPPER WALL D NUT MOUNTING
SCREW FRONT LEG E M5x8 FIXING
SCREW WALL SEALING F 1 No. 10 x 1 /2in. PLATE FIXING
WALL WALL SEALING G PLUG PLATE FIXING
SCREW UPPER SIDE H RETAINING
SCREW FLUE SPIGOT FIXING J 3 No. 8 x /8in.
SCREW SENSING TUBE K M4x10 FIXING SCREW
TAPTITE SCREW SENSING TUBE MOUNTING L M4x6 BRACKET SCREW
FILTER
LIQUID BATTERY COAL
SENSING OLIVE (2) TUBE FIRE FRONT MOUNTING SENSING BRACKET TUBE ASSEMBLY CONTROL KNOB BBU SENSING FIBRE WASHER (2) TUBE GAS SUPPLY PIPE
TUBING NUT (2) SIDE EXTENSION (2)
Diagram 3.1
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3.1 Unpacking 5171 The fire front is delivered in two packs, one contains the body assembly, fuel effect pieces and supply tube pack. The other contains the fire front castings, side panels, plinth and loose items pack. Refer to diagram 3.1. to identify the parts. To unpack carton 1, lift out the top fitting containing the fire spigot and combustion chamber bottom plate, lift out the cardboard front fitting, the supply tube pack and the two boxes containing the fuel effect pieces. GLASS Lift the outer carton clear to leave the fire front sitting in RETAINING the base tray. BRACKET To unpack carton 2, lift out the cardboard tray containing the plinth and side panels. Lift out the loose items pack, legs box and canopy. Remove the internal cardboard fitting and lift out the lower front and side castings. Put these items on one side until required. Check contents of loose items pack against list. Remove the glass front panel, see diagram 3.2. PULL FORWARDS AND UP 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 Assembly Note. This is marked “Homeglow BBU” GLASS Leave the fire front sitting in the base tray. FRONT PANEL Remove the two plastic transit studs securing the wall Diagram 3.2 sealing plate to the rear of the fire front and put it on one side until required. Secure the spigot assembly to the fire front back with the self taping screws provided, in the loose items pack, 3923 S see diagram 3.3. FLUE SPIGOT ASSEMBLY Note. There are eight self tapping screws in the pack, one spare.
3.3 Gas Supply Tube and Sensing Tubes Preparation Remove the plastic ferrule from the bulkhead connector on the air duct and discard. Fix the flared end of the back boiler sensing tube to the bulkhead connection on the boiler air duct with the tubing nut provided. Slide the sensing tube mounting bracket assembly over the back boiler sensing tube and fix to the casing with the screw provided, see diagram 4.2. J SECURING Important. Make sure that the mounting bracket SCREW (7) assembly is pushed back to the fire front face of the boiler casting and check 3mm distance is achieved and the back boiler sensing tube does not extend above the sensing tube bracket assembly, see diagram 4.2. Diagram 3.3 Note: After fitting the combustion products discharge safety device sensing tube please refer to the Gas Supply Tube ‘commisioning’ section of the back boiler unit and Measure the distance “C”, see diagram 3.5, from the relight the boiler to test the device. front mark “P” on the air duct to the fire front fixing wall face. Check that the gas service cock is in the Off position, see Use a straight edge across the opening. diagram 3.4. Shorten the plain end of the gas supply tube by the The inlet supply tube, back boiler sensing tube assembly distance “C”. No shortening is required when mark “P” and fire front sensing tube are packed in the supply tube is level with the fire front fixing wall face, “C” being zero. pack, see diagram 3.1. The maximum distance for “C” will be 67mm (25/ in). This supply tube and fire front sensing tube may need to 8 be cut, at the plain end, dependent on the model and position of the back boiler in the opening.
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Firefront sensing tube
Shorten the plain end of the fire front sensing tube by *'C' = Distance from fire fixing wall face to datums 5078 distance “D”, no shortening of the tube is required when on back boiler air duct. This represents the 45/2 back boiler is fitted and point “P” is level with the length of pipe that requires cutting off. fire fixing wall face. Similarly when a 56/2 back boiler is fitted no shortening is required when point “N” is level with the fire fixing wall face. In both cases “D” is zero the maximum distance of “D” for both the 45/2 and 56/2 'P' back boiler will be 25mm, see diagram 3.6. BACK *'C' Deburr the tube end inside and out. BOILER AIR 3.4 Battery DUCT Remove the fire front from the base tray. Take the battery from the fittings pack and fit as shown in diagram 4.1, make sure that the terminals are correctly fitted. *'C' FIRE FIXING WALL FACE GAS SERVICE GAS FIRE COCK UNION SUPPLY TUBE Diagram 3.5 5245
*'D' = Distance from fire fixing wall face to datums on back boiler air duct. This represents the BACK length of pipe that requires BOILER cutting off. ONLY 'ON' FIRE FRONT TURNED SENSING FULLY CLOCKWISE *'D' TUBE
56 BBU/2 FIRE 90˚ FIXING WALL FACE BACK 56/2 BOILER & BBU FIRE 'ON' *'D' TURNED TO N MID POSITION 45 BBU/2 FIRE FIXING WALL FACE 45/2 180˚ BBU *'D' P 'OFF' TURN FULLY ANTI- CLOCKWISE BACK BOILER AIR DUCT Diagram 3.4 Diagram 3.6
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4.1 Battery
SECURING 5283 Remove the fire front from the base tray. SCREW Take the battery from the fittings pack and fit as shown in 9V ALKALINE diagram 4.1, make sure the terminals are correctly fitted. BATTERY
4.2 Positioning the Fire Front SECURING SPARK SCREW Remove and discard the plastic ferrule from the bulkhead GENERATOR connector.
Fix the flared end of the back boiler sensing tube to the ELECTRICAL bulkhead connection on the boiler air duct with the tubing CONNECTIONS nut provided. Slide the sensing tube mounting bracket IGNITION assembly over the back boiler sensing tube and fix to the LEAD casting with the screw provided, see diagram 4.2. Fit the sensing tube filter onto the fitting assembly, see diagram 4.2. Take care not to damage the filter. Important. Make sure that the mounting bracket assembly Diagram 4.1 is pushed back to the front face of the boiler casting and check 3mm distance is achieved and back boiler sensing tube does not extend above sensing tube fitting, see SENSING L MOUNTING diagram 4.2. 6171 TUBE BRACKET 6171 Place the wall sealing plate onto the back boiler air duct, MOUNTING SCREW mark the fixing holes, remove the plate and drill the holes BRACKET ASSEMBLY to suit the plugs and screws provided, from supply tube SENSING TUBE pack, leave sufficient screw proud to accept the wall MOUNTING sealing plate keyholes, see diagram 4.3. BRACKET Fit the wall sealing plate and tighten the screws, making ASSEMBLY sure that the “wings” are flush with the fire fixing wall 3mm FRONT FACE OF face, see diagram 4.3. BOILER CASTING Place the fire front onto the back boiler air duct, check BACK that the fire front spigot is central in the flue collector BOILER assembly, push back into contact with the fire front SENSING TUBE fixing wall face, see diagram 4.4. BULKHEAD CONNECTION Mark the fire front fixing points through the mounting TUBING NUT BOILER bracket holes at the top, see diagram 4.4. AIR DUCT Diagram 4.2 Pull the fire front forwards and remove. Drill the fire front fixing face using a 10mm masonry
drill to a minimum depth of 40mm to accept the anchor 5166 nuts and screws provided. G F Place the anchor nuts and screws into the holes, screw up, but leave 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 or metal an alternative and rigid form of fastening for the fire front must be used and extra care NOTE: taken. WINGS Fit the fire front sensing tube to the flue collector with the FLUSH WITH two securing screws, see diagram 4.5. WALL Diagram 4.3
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SPIGOT
BACK BOILER AIR DUCT
FLUE FLUE COLLECTOR COLLECTOR FIRE FRONT ASSEMBLY ASSEMBLY FIRE FRONT
Diagram 4.4
SENSING TUBE
5072 TUBING OLIVE SECURING NUT SCREW (2) FLUE Diagram 4.6 COLLECTOR
Note, place the tubing nut and olive from the loose items pack onto the prepared end of the sensing tube, see diagram 4.5. Offer the appliance up to the back boiler air duct and FIRE FRONT push into position taking care not to damage fire front SENSING sensing tube and filter, lift slightly to engage mounting TUBE brackets onto screws, engage sensing tube into bulk head connection, see diagram 4.6. Tighten the fire securing screws, see diagram 4.7. Tighten the sensing tube nut onto the bulkhead, see TUBING diagram 4.8. NUT
OLIVE
Diagram 4.5
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MOUNTING FIRE FRONT BRACKET TUBE NUT 5167
3928 S SENSING TUBE TUBE NUT
C SECURING SCREW (2) M5 X 40mm
C SECURING SCREW (2) Diagram 4.8 ANCHOR NUT D LOCK NUT (A) 3929 S
UNION NUT (B)
Diagram 4.7 JOINT (C) 4.3 Gas Connection Place the tubing nut and olive, from the loose items pack, onto the prepared end of the gas supply tube, GAS SUPPLY see diagram 4.9. PIPE Connect the gas supply, as diagram 4.9 tighten the nut GAS SERVICE COCK and olive at the gas service cock. To tighten the other end use a spanner to hold the locknut (A) at the bulkhead fitting and ensure that it does not turn, tighten the union nut (B) on the supply tube in the usual manner, see diagram 4.9. Make sure that joint (B) is checked for gas soundness, by checking it when carrying out the other gas soundness TUBING checks in Section 5.1. NUT Fit the left hand side panel, see diagram 4.10. OLIVE
Diagram 4.9
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UPPER SIDE UPPER SIDE FIBRE FIBRE RETAINING RETAINING R.H. SIDE 3930 S SCREW LOCATING PIN SCREW WASHER PANEL WASHER AND HOLE H H
GAS CONTROL KNOB
R.H. SIDE PANEL
L.H. SIDE PANEL LOCATING PIN AND HOLE
LOCATING PIN AND HOLE Diagram 4.10
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5.1 Lighting and Testing 5081 Make sure that the electrical supply to the back boiler is PRESSURE isolated. GAS TEST POINT TAP The fire front is fitted with a combustion products discharge safety device which will shut it down if there is a lack of oxygen. If the fire shuts down frequently for no apparent reason the first things to be checked are the chimney and air inlets into the room. An additional cause could be that the filter in the gas tap is blocked. Any problems found must be put right, by a competent person before the fire is used again. The combustion products discharge safety device MUST NOT be adjusted or disconnected. If replacing use only Diagram 5.1 the correct and approved parts. Remove the pressure test nipple screw and fit a suitable pressure gauge, see diagram 5.1. 5082 Place the right hand side panel onto the pins, see diagram 4.10, but do not secure at this time. VERTICAL Turn the gas service cock to back boiler and fire ON, see diagram 3.4. To check for gas soundness use the pressure drop method and apply suitable leak detection fluid to all joints, replace glass panel, see diagram 3.2. Fit the control knob to the tap spindle, see diagram 5.2. IMPORTANT. If the burner does not light within three seconds, release the tap, wait ten seconds and repeat the lighting operation. GAS Push the control knob fully in and turn it anti-clockwise CONTROL FLAT DOWN to 1 - ignition, see diagram 5.2, clicking of the ignition KNOB POSITION will be heard and the burner will light. Keep the knob pushed in for ten seconds, to energise the flame supervision device, during this time the ignition system will continue to operate, indicated by the clicking. APPLIANCE IGNITION & POSITION 2 Air may be present in the supply to the fire front so that OFF POSITION 1 the initial lighting operation may need to be repeated. With the burner lit, visually check for leaks whilst changing tap settings. To change settings: 0 - 1 Push in and turn 1 - 2 Push in and turn
2 - 3 Push in and turn POSITION 3 POSITION 4 3 - 4 Push in and turn Diagram 5.2 If the burner goes out, wait three minutes before relighting, for any 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. (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 pilots.
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FUEL EFFECT PIECES LOCATIONS BOTTOM 4329 S PLATE 5174 4 5
2 3 2 1
FUEL EFFECT 4 5 BASE
Diagram 5.3
5.2 Internal Parts - Fitting 2 1 3 CAUTION: If any of the internal fire front parts are damaged DO NOT light or further test the fire front until FUEL EFFECT PIECES 1 to 5 Diagram 5.4 replacement parts are fitted. Refit gas tap control knob. FUEL Swing the side panels out by about 5mm, to their stops. Left Right 5088 Side EFFECT Side WARNING: The glass panel can be hot. BASE (see note) Remove the glass panel, see diagram 3.2. Follow sequence in diagram 5.3 to 5.11 to fit the combustion chamber bottom plate (inside base tray) and internal fire front parts. RETAINING Note. The fuel effect pieces are marked on their backs. BRACKETS Replace front glass panel.
FUEL EFFECT BASE SUPPORT ANGLE FOR NOTE: FUEL EFFECT PIECES Fuel Effect Base 1, 2 AND 3 seats behind retaining brackets Diagram 5.5
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FUEL EFFECT PIECE POSITION 1 FUEL EFFECT PIECE POSITION 4 4331 S 4334 S
LOCATION LOCATION RECESS 4 RECESS 1
NOTE: FUEL EFFECT PIECE MUST SIT ON SUPPORT ANGLE Diagram 5.6 Diagram 5.9
FUEL EFFECT PIECE POSITION 2 FUEL EFFECT PIECE POSITION 5 4332 S 4335 S
LOCATION RECESS 5 LOCATION RECESS 2
NOTE: FUEL EFFECT PIECE MUST SIT ON SUPPORT ANGLE Diagram 5.7 Diagram 5.10
FUEL EFFECT PIECE POSITION 3 COMPLETED FUEL 3943 S
4333 S EFFECT BED
LOCATION LUG 3
Ensure corners of fuel effect pieces 4 and 5 are seated on NOTE: FUEL EFFECT PIECE MUST flat areas of fuel effect pieces SIT ON SUPPORT ANGLE 1, 2 and 3 Diagram 5.8 Diagram 5.11
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5.3 Decorative Castings Fit the front casting as diagram 5.12, decorative side castings as diagram 5.13, front legs and feet as diagram 5.14 and canopy as diagram 5.15. 3944 S
LOCATION PIN LOCATION SLOT VIEWED FROM REAR 3946 S
FRONT SECURING CASTING SCREW (2) E
LEG
VIEWED FROM REAR Diagram 5.14 Diagram 5.12
LOCATING
CANOPY 3947 S PIN
SIDE 3945 S CASTING
LOCATING HOLE
SECURING SCREW (3) B M5 x 14mm Diagram 5.13 Diagram 5.15
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5.4 Heat Settings
Light the fire front burner as the relevant part of 5154 Section 5.1. Refer to diagram 5.16. At tap position 1 - centre section flame effect. APPLIANCE OFF At tap position 2 - centre section flame effect with outer sections fuel bed glow. At tap position 3 - centre and outer sections flame effect with fuel bed glow. At tap position 4 - (full on) full flame effect and fuel bed glow. In the unlikely event of the flame going out when the fire front burner is on, then turn off. Wait 3 minutes before relighting. IGNITION POSITION AND CENTRE If relighting for any other reason, wait 2 minutes before SECTION doing so. FLAME EFFECT
CENTRE SECTION FLAME EFFECT WITH OUTER SECTIONS FUELBED GLOW
CENTRE AND OUTER SECTIONS FLAME EFFECT WITH FUELBED GLOW
FULL FLAME EFFECT WITH FUELBED GLOW
Diagram 5.16
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5.5 Test for Clearance of Products
Notes: 5175 WARNING: Take care, the appliance will get hot during tests. DRAUGHT For the test you will need a smoke match, extension and DIVERTER a torch. IN ALL CASES, if spillage continues after the specified test periods steps must be taken to rectify the fault(s). Possible causes include, flue obstruction, down draught or restricted fresh air supply into the room. L.H. SIDE If the problem cannot be put right the appliance must be PANEL disconnected and expert advice sought.
Test Where No Fan is Present Close all outside doors and windows in the room where the appliance is installed. Light the fire front only and set to tap position 4. After 5 minutes apply a spillage test as shown in diagram 5.17 and 5.18. During tests smoke should be drawn into SMOKE MATCH the fire draught diverter and the boiler draught diverter. EXTENSION If spillage occurs, leave fire front alight for up to a further 10 minutes and repeat test. Turn the fire front TORCH off. Next light the back boiler only. After 10 minutes apply spillage test as shown in diagram 5.17 and 5.18. 25mm During tests smoke should be drawn into the fire front 25mm draught diverter and boiler draught diverter. If spillage occurs, leave the back boiler alight for up to a further 5 minutes and repeat tests. Leave the back boiler alight. Now light fire front. After 10 minutes apply spillage tests as shown in diagram 5.17 and 5.18. During tests MATCH smoke should be drawn into the fire draught diverter and EXTENSION Diagram 5.17 boiler draught diverter. If spillage occurs leave back boiler and fire front alight
for up to a further 5 minutes and repeat tests. 10 5176 10 10 Test Where a Fan is Present (A fan means an extract fan or a fan for other open flued appliances or a circulating fan for a warm air unit, DIVERTER whether or not gas fired). With the fan switched off PLATE SIDE VIEW FRONT VIEW carryout the appropriate spillage test with all doors and windows closed, as above. If the above spillage test is satisfactory continue as follows:- 560 SMOKE Open all doors connecting the room containing the MATCH appliance and the room in which the fan is fitted. EXTENSION Close all other doors and windows in the premises. FIRE SPIGOT NOT SHOWN FOR CLARITY If the fan is in the same room as the appliance, close all doors and windows in that room. Diagram 5.18 Switch the fan on and repeat the spillage test as above.
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5.6 Plinth Fitting Fit the controls cover plinth onto the guides and push it back as far as it will go, see diagram 5.19. 3951 S
PLINTH Diagram 5.19
6 I n s t r u c t i o n s t o U s e r
Hand the Instructions for Use to the user and instruct in If the burner should go out repeat the above operation, the safe and economical use of the fire front and back but now keep the knob pushed in for a little longer. boiler. Once lit operate the gas tap normally. Advise the customer that they should read their Users This is a temporary measure only and the fault must be instructions before operating the fire and always follow put right as soon as possible. the advice in the Section headed “Cleaning your Fire”. Advise the user of the precautions necessary to prevent Advise that any smell which may be apparent on initial damage to the system, boiler and the building, in the lighting is quite normal and it will quickly disappear. event of the heating system being out of use during frost Important: Advise that soft wall coverings, for example, or freezing conditions. blown vinyl wallpaper, are easily affected by heat, they Advise that the fire front is fitted with a safety device may, therefore, scorch or become discoloured when and refer to the instructions for use. close to a heating appliance. This should be borne in mind when having a heating appliance installed and Reminder, leave these instructions with the user. when redecorating. Advise the user, to ensure the continued efficient and 5338 safe operation of the appliance it is recommended that it MATCH is checked and serviced as necessary at regular intervals. EXTENSION The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let BURNER out any property containing a gas appliance. It is the Law that servicing is carried out by a competent person. Show how to light the fire front, in the event of a power or ignition system failure, with a spill or long match, see diagram 6.1. Remove the front casting. Hold a lighted spill or long match and insert it beneath the front lighting assembly, position the spill so that the flame is over the burner. Keep the spill in position, push in and turn the gas tap to position 1 and the burner will light keep knob pushed in MATCH OR SPILL for about 10 seconds and the burner will stay light. Diagram 6.1
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Notes (a) To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked 3953 S and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. (b) It is the Law that servicing is carried out by a competent person. (c) Make sure the fire is cold before carrying out any servicing. (d) Before servicing isolate the gas and electrical supplies. (e) After servicing (or replacing parts) always test for 5mm 5mm gas soundness with a suitable leak detection fluid. (To test the gas tap, refix the fire front and apply leak detection fluid to all joints, replace the glass panel, light the burner and visually check all the joints for leakage whilst changing tap settings). (f) Carryout functional check on controls, see Section 4 and 5. (g) Other than for replacing the glass panel, internal fire front parts and lighting the fire front should be removed from its fixings by reversing the instructions in Section 4 and 5. Make sure that the Diagram 7.1 side panels and feet are removed. Refit controls cover plinth so that the fire can stand upright. (h) Unless stated otherwise reassemble all parts in the reverse order to removal. LOWER FRONT 4854B (i) The back boiler should be serviced at this time, refer BAFFLE to Back Boiler Installation and Servicing Instructions. (j) The combustion products discharge safety device MUST NOT be adjusted or disconnected. If replacing use only the correct and approved parts.
7.1 Glass Panel Lift canopy off. Swing open side panels to their stops, about 5mm, as SECURING SCREWS (3) diagram 7.1. To remove the glass panel, refer to diagram 3.2.
7.2 Internal Fire Front Parts Remove internal fire front parts as diagram 5.10 to 5.3. Examine these parts and replace as necessary. BURNER 7.3 Burner and Injectors BAFFLE Remove the front casting, see diagram 5.12. Remove the lower front baffle, see diagram 7.2. SECURING SCREWS (2) Remove the burner baffle, see diagram 7.2. Remove the side castings, see diagram 5.13. Diagram 7.2 Remove right hand leg, see diagram 5.14. Remove right hand leg support bracket, see diagram 7.4.
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Disconnect the supply pipe unions at the injectors also L.H. BURNER R.H. BURNER the union connection at front, see diagram 7.5. 4855 SECURING SCREW SECURING SCREW Remove the two burner securing screws, see diagram 7.5. Swing burner out for access, see diagram 7.6. Unscrew the injectors, inspect, clean or replace as necessary, see diagram 7.7. Do not clean the holes with a wire or sharp instrument. Remove the injector box cover screw and plate, see diagram 7.7, clean out dust and debris. Brush away any lint and dust from the burner and surrounds. Using a soft brush or vacuum cleaner. Do not use a brush with wire bristles.
BURNER UNION CONNECTION
SECURING 3955 S UNION SCREW (2) CONNECTION Diagram 7.5 5172
BURNER BAFFLE
BURNER
Diagram 7.3 BURNER
PULL FORWARDS 5080 Diagram 7.6
INJECTOR BOX COVER 3958 S
SECURING R.H. LEG SCREW SUPPORT INJECTORS (4) BRACKET SECURING SCREW Diagram 7.4 Diagram 7.7
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7.4 Combustion Products Discharge Safety 5075
Device 5075
Remove the burner refer to Section 7.3. TUBE Check the condition of the electrode and thermocouple, NUT with a soft brush, see diagram 7.8. Make sure the electrode is in line with the earth post and spark gap is as in diagram 7.9.
7.5 Ignition Lead Remove the burner refer to Section 7.3. Disconnect the union connections, remove the mounting bracket securing screws and combustion products discharge safety device, see diagram 7.8. Check the ignition lead, see diagram 7.8. Replace if required, refer to Section 9.5.
Note. When refitting the combustion products discharge TUBE safety device, take care not to trap the ignition lead under NUT the mounting bracket.
7.6 Gas Tap and Micro Switch Assembly COMBUSTION PRODUCTS Note: This item need not be serviced annually. DISCHARGE SAFETY DEVICE Remove micro switch electrical connections, see diagram 7.10. Disconnect all union connections and remove the tubes in the order shown diagram 7.11. Disconnect the thermocouple nut, see diagram 7.12. When replacing only tighten the nut a quarter turn beyond finger tight. Remove the gas tap bracket securing screws, MOUNTING see diagram 7.12. BRACKET Remove the gas tap assembly. To service the gas tap remove the gas tap niting plate assembly securing screws, see diagram 7.13. Take care as there is a spring beneath the niting plate. SECURING Remove the plug, pin, spring washer, plain washer and SCREW (2) “O” ring, see diagram 7.13. Clean and relubricate using a suitable grease. When replacing make sure the operating disc, with retaining washer and micro switch and leads are TUBE correctly located, see diagram 7.13 and 7.10. NUT
SECURING IGNITION LEAD SCREW (2) Diagram 7.7
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ELECTRODE 5248 3960 S GAS TAP MOUNTING EARTH SPARK GAP BRACKET SECURING POST + 1.0 SCREW 3 - 0.5
MICRO SWITCH
ELECTRICAL CONNECTIONS CL EARTH ELECTRODE POST INSULATION MICRO SWITCH
TOP VIEW NUT (2)
ELECTRODE GAS TAP MOUNTING BRACKET 18 INSULATION SECURING SCREW (2)
Diagram 7.10 67 EARTH POST
Diagram 7.9
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1 4
8 5089
6 2
GAS TAP SECURING
SCREWS 5090 9
5 7 3
9 5 THERMOCOUPLE NUT 7 Diagram 7.11 Diagram 7.12
GAS TAP BODY 5091 GAS TAP BRACKET AND NITING PLATE PLUG ASSEMBLY 'O' RING WASHER SPRING
SECURING SCREW Diagram 7.13
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ELECTRODE 5252 5251 ELECTRODE
MICRO SWITCH
MICRO SWITCH SPARK GENERATOR
RED RED RED RED
Diagram 8.2
8.1 Fire Front Ignition Remove decorative castings, glass panel and fuel bed, refer to appropriate parts of Section 7. Refer to diagram 8.3. SPARK GENERATOR 8.2 Electrical Refer to pictorial wiring diagram 8.1 and functional flow diagram 8.1. Diagram 8.1 Refer to pictorial wiring diagram 8.1 and functional flow diagram 8.2.
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Check that gas is available Does the pilot light using a match ? YES NO YES Turn off appliance tap, turn on appliance tap. Does the fire light ? Change pilot filter NO
Ensure gap is within specified Check that gas is available at burner, using a tolerance, refer to SERVICING. match, ensuring correct functioning of burner turn tap to energise ignition. on all setting positions. Check that electrode, Does the fire light ? micro switch and ignition unit connections are YES NO satisfactory. Check that burner pressure is as specified - correct any fault found.
Disconnect ignition lead from NO 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 YES earth and ignition unit, leaving 4mm gap between blade and spade connector. Turn tap Replace faulty electrode and to energise ignition. Is there a spark at gap ? reassemble ignition system. Turn tap to energise igniter. NO YES Does the fire light ?
NO YES Disconnect red leads from ignition Renew ignition lead and unit. Turn tap to energise ignition. Is reassemble ignition system. there continuity between red leads ?
YES NO
Change the ignition unit battery. Turn tap to energise ignition. Rectify faulty leads or Does the fire light ? replace micro switch. YES NO
Change ignition unit.
Check several times that ignition is satisfactory.
Diagram 8.3
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Supplied By www.heating spares.co Tel. 0161 620 6677 8 F a u l t F i n d i n g 5243 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.
Hold down control tap in ignition position. Ignite burner, allowing thermocouple to attain operating temperature. Measure the OPEN CIRCUIT voltage.
Faulty thermocouple. NO Replace combustion IsIs voltagevoltage greatergreater products discharge thanthan 15mV?15mV? YES safety 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 these two values intersect on the graph.
Faulty thermocouple. THERMOCOUPLE In which area of the Replace combustion CIRCUIT IS B graph is the intersect A products discharge SATISFACTORY safety device. C
Faulty magnet unit in gas tap. Replace gas tap
Diagram 8.4
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8.3 Thermocouple 17
To test a thermocouple, a meter with a range of 0 to 16 0065M 30mV is required together with a thermocouple 15 interrupter test unit, similar to a British Gas Multimeter 6 unit. 14 Refer to fault finding diagram 8.4 and diagnosis graph, 13 ABC diagram 8.5. 12 11 8.4 Combustion Products Discharge Safety 10 Device 9 If the device operates it indicates there could be a problem with the chimney or, the pilot filter in the gas 8 tap is blocked. First make sure air vents are free Open Circuit Voltage (millivolts) 7 from obstructions, by carrying out spillage checks as 01234567891011 Section 5.5. If all is in order refer to diagram 8.3 to Closed Circuit Voltage (millivolts) check if the pilot filter is blocked. DIAGNOSIS GRAPH FOR FIRE THERMOCOUPLE CIRCUIT Diagram 8.5
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Notes: 5283 (a) Make sure that the fire is cold before replacing any SECURING parts. SCREW (b) Replacement of parts must be carried out by a 9V ALKALINE competent person. BATTERY (c) Remove the internal fire front parts as the relevant SECURING part of Section 5.2. SPARK SCREW (d) Before removing or replacing any fire front parts GENERATOR turn the gas supply service cock to “Back Boiler Only On”, see diagram 3.4. ELECTRICAL (e) Isolate the electrical supply to the back boiler and CONNECTIONS fire front. IGNITION LEAD (f) Other than for replacing the burner, injectors and internal fire front parts the fire front should be removed from its fixings be reversing the instructions in Section 4 and 5. Make sure that the Diagram 9.1 side panels and legs are removed. Refit controls cover so that the fire front can stand upright. (g) After replacing or disconnecting any gas carrying component, always test for gas soundness, using a suitable leak detection fluid and carry out functional check of controls. (h) To test the gas tap apply leak detection fluid to all joints, light the burner and check all the joints for leakage at all tap settings. (j) Unless stated otherwise reassembly of all parts is in the reverse order to removal. (k) The combustion products discharge safety device MUST NOT be adjusted or disconnected.
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GAS TAP BRACKET 5477 AND NITING PLATE ASSEMBLY
FILTER
GAS TAP
CROSS SECTION VIEW
FILTER Diagram 9.2
9.1 Burner 9.5 Ignition Lead Refer to Section 7.3. Refer to Section 7.3 to remove the burner. Disconnect the tube nuts, remove the mounting bracket 9.2 Injectors securing screws, remove the ignition lead (black end), see diagram 7.8. Refer to Section 7.3. Remove side panel securing stop screw and open panel, 9.3 Gas Tap and Micro Switch Assembly see diagram 4.10. Remove the ignition lead (clear end), see diagram 9.1. Refer to Section 7.5, and diagram 7.10 to remove the micro switch. Note. When refitting the combustion products discharge safety device, take care not to trap the ignition lead under the mounting bracket. 9.4 Combustion Products Discharge Safety Device 9.6 Spark Generator Remove canopy. Remove right hand side panel, see diagram 4.10. Refer to Section 7.3 to remove the burner. Remove the right hand side casting, see diagram 5.13. Disconnect the union connections, remove the mounting Remove retaining screw, disconnect the electrical leads bracket securing screws and combustion products and then release the spark generator from the location tab discharge safety device, see diagram 7.8. at the rear, see diagram 9.1. Pull off the lower sensing tube. When replacing take care not to damage the “O” ring seals. 9.7 Gas Tap Pilot Filter Remove right hand side panel, see diagram 4.10. Gain access to the gas tap as Section 7.6. Remove the thermocouple nut, see diagram 7.12. The filter, which is very small, is in the pilot port of the Remove the ignition lead, see diagram 9.1. gas tap, to remove use a small non-metallic tool. Note. When refitting the combustion products discharge When fitting the replacement it is important that the safety device, take care not to trap the ignition lead filter is seated correctly as shown in diagram 9.2. under the mounting bracket. When refitting make sure that the spark gap is as shown in diagram 7.9.
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When replacement parts are required please apply to The GC No.37 314 14, Opus, 37 314 15 Opulence, and your local supplier. the serial number, to be found on the chassis, visible when front casting is removed. Please quote the name of the fire front, “Opus” or “Opulence”. Refer to diagram 10.1 for the illustration of the replacement parts.
Key No. Part No. G.C. Part No. Description 1 210213 136 918 Rear fuel effect piece 2 210214 136 919 Fuel effect piece - 1 3 210215 136 920 Fuel effect piece - 2 4 210216 136 921 Fuel effect piece - 3 5 210217 136 922 Fuel effect piece - 4 6 210218 136 923 Fuel effect piece - 5 7 448093 136 924 Glass panel assembly 8 230169 398 444 Injector - upper 9 230201 398 422 Injector - lower 10 203437 162 100 Combustion products discharge safety device 12 202014 360 188 Microswitch 13 WW4617 312 997 Ignition lead 14 448103 136 925 Gas tap control knob - Opus 2 14 448235 136 926 Gas tap control knob - Opulence 2 15 800449 136 927 Gas tap 16 202179 152 949 Spark generator 17 208673 162 208 Filter
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7 1
5
3 6
2
4
8
10 9
13
12
15
17 16
14 Diagram 10.1
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These fire fronts are fitted with combustion products Turn the thermostat control knob “B” to “Off” position, safety devices that is, fully anticlockwise, “Off” to be against the pointer. As these fire fronts may be fitted to Glow-worm 45, 56, 45R and 56R back boiler units WITHOUT a combustion Push in and slightly turn gas control knob “A” products discharge safety device, the following clockwise until “ ” is against its setting point, that is, instructions must be read and followed in place of those set to “Off”. in the main Installation and Servicing Instructions. Push in slightly and turn gas control knob “A” To check if a combustion products discharge safety anticlockwise until “ ” is against its setting point, then device, refer to inset in diagram 11.1, if one is fitted this push fully in and hold in. At the same time press and supplement MUST be ignored. release piezo button “D” until pilot burner “E” lights. Look at flame through viewing window “F”. 11.1 General At initial lighting of the boiler air may be present and To fit the fire front to one of the above EXISTING several attempts may be needed to light the pilot. Keep GLOW-WORM BACK BOILER UNITS follow the the control knob “A” pushed in whilst operating the instructions below. ignition button. NOTE: Kit No. 451484 will be required. When the pilot is alight and stable, keep knob “A” fully pushed in for about 15 seconds then release. Check that 1. Replace the existing draught diverter front with the the pilot is still alight, look through window “F”. new part supplied in Kit No. 451484. To fit follow the instructions supplied with the kit. If the pilot burner fails to stay alight turn gas control knob “A” “Off”. that is, fully clockwise. Wait three minutes. Repeat the lighting operation, only now keep 11.2 Installation the control knob “A” pushed in for a little longer than 2. Do not fit the back boiler sensing tube as required in before after the pilot has lit. the main installation and servicing instructions. NOTE. Always wait three minutes before attempting to 3. If necessary isolate the power supply to the back relight the pilot after it has gone out for any reason. boiler unit and remove the existing wiring used Push control knob “A” in slightly and turn anticlockwise previously for a fire front with lights. 4. Any reference in the installation and servicing instructions to the back boiler combustion products discharge safety device must be ignored.
Lighting the Boiler The boiler controls are placed behind the fire front plinth. To remove the plinth, pull it gently forwards until it is free. Refer to diagram 11.1 to identify controls. Turn off the electrical supply at the mains supply outside the appliance. Check that all controls are calling for heat. The clock, room thermostat and programmer, if fitted, will be away from the unit, see manufacturer’s instructions supplied with them.
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INSET: Showing a Combustion Products Discharge Safety Device fitted. 5342
'E' PILOT BURNER
SETTING 'F' VIEWING POINT WINDOW
SETTING 'A' POINT GAS VALVE 'B' CONTROL 'D' PIEZO THERMOSTAT KNOB OFF UNIT CONTROL PILOT/IGNITION KNOB BUTTON MAIN BURNER BOILER CONTROLS Diagram 11.1
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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 FUEL This 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 makes sense 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 recommend that you use 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 heavy duty polythene bags, 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 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. INSULATION and SEALS Ceramic 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 going to the lavatory. If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
Because of our constant endeavour for improvement details may vary slightly from those in the instructions.
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