Installation and Servicing Instructions...1 G e n e r a l 150mm 445mm 445mm 150mm MAXIMUM SHELF DEPTH 150mm 150mm 840mm 840mm 3917 S FLAT AREA FIRE FIXING FACE Diagram 1.2 1.4 Fire

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

221098C.01.99

Installation and ServicingInstructions

G . C . 3 7 3 1 4 1 4G . C . 3 7 3 1 4 1 5

F o r u s e w i t ha s p e c i a l l y d e s i g n e d

G l o w - w o r m B a c k B o i l e r U n i t o n l y

3914 S39

15 S

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

One Contact Local Service

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

General/Sales enquiries :Tel: (01773) 824141 Fax: (01773) 820569

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

BS 6332BS 5258

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

For Ireland the rules in force must be used.

This is a Cat I2H

Appliance


2221098C

1 G e n e r a l

Sheet Metal Parts

WARNING. When installing or servicing this fire frontcare should be taken when handling metal parts(components), to avoid any possibility of personalinjury.

1.2 Statutory Requirements

The installation of this fire front must be carried out by acompetent person, in accordance with the current issueand relevant requirements of:-

Manufacturer’s instructions, supplied.

The Gas Safety (Installation and Use) Regulations, asamended, The Building Regulations, the Local GasUndertaking, The Building Standards (Scotland)Regulations (applicable in Scotland), The Health andSafety at Work Act, Control of Substances Hazardous toHealth, The Electricity at Work Regulations and anyapplicable local regulations.

Detailed recommendations are contained in the currentissue of the following British Standards and Codes ofPractice:-

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

Manufacturer’s notes must not be taken as overridingstatutory requirements.

CE Mark

The CE mark on this appliance shows compliance with:-

1. Directive 90/396/EEC on the approximation of theLaws of the Member States relating to appliancesburning gaseous fuels.

2. Directive 89/336/EEC on the approximation of theLaws of the Member States relating to electromagneticcompatibility.

If this fire front is to be fitted to a Glow-worm backboiler WITHOUT a combustion products dischargesafety device please read the supplementary instructionsat the back of this booklet.

The instructions consist of three parts, Installation andServicing Instructions for the Back Boiler Unit,Installation and Servicing Instructions for the Fire Frontand Instructions for Use, including the GuaranteeRegistration Card. The instructions are an integral partof the appliance and must, to comply with the currentissue of the Gas Safety (Installation and Use)Regulations, be handed to the user on completion of theinstallation.

1 General Notes and Information

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

This fire front and back boiler are NOT suitable forfitting to a precast flue.

The fire front is delivered packed in two cardboardcartons, which together contain all the parts necessaryfor the installation of the fire front.

If the back boiler and fire front are to be installed at thesame time please read both sets of installationinstructions before starting.

Wherever possible, all materials, appliances andcomponents to be used shall comply with therequirements of applicable British Standards.

Where no British Standards exist, materials andequipment should be fit for their purpose and of suitablequality and workmanship.

1.1 Important Notice

This fire front is for use only on G20 gas.

This fire front is fitted with a safety device which willshut it down if there is a lack of oxygen. If the fire shutsdown frequently for no apparent reason the first things tobe checked are the chimney and the air inlets into theroom. An additional cause could be that the filter, in thegas tap has become blocked. Any problems found mustbe put right, by a competent person, before the fire isused again.


3 221098C

1 G e n e r a l

Diagram 1.1

3916

BB

U S

FLAT AREAFIRE FIXING FACE

289mm

339mm 351mm 351mm 339mm

690m

m

289mm327mm 327mm

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 frontcasting is removed

Data label - Inside of right hand side panel

The fire front burner is lit by means of an electronicspark generator unit.

All dimensions are given in millimetres(except as noted).

CL


4221098C

1 G e n e r a l

150mm445mm 445mm

150mm

MAXIMUMSHELFDEPTH

150mm 150mm

840m

m

840m

m

3917

S

FLAT AREAFIRE FIXING FACE Diagram 1.2

1.4 Fire Front Location

This fire front can only be fitted to a Glow-worm 45/2 or56/2 back boiler unit which itself has been installed inaccordance with the Glow-worm Installation andServicing Instructions.

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

The top of the fire front must be secured to the verticalfire front fixing wall face. This wall face may be achimney breast or surround, see diagram 1.2.

The fire front flue spigot projects into the back boilerflue collector assembly.

The gas supply is taken from the back boiler gas servicecock.

The back boiler must be correctly positioned in thebuilder’s opening as the fire front is located byconnection to it.

1.5 Clearances

Restrictions must not be placed around the assembledfire front, see diagram 1.2.

A shelf or surround of a maximum depth of 150mm maybe fitted, provided clearances are as shown indiagram 1.2. However, for every additional 25mm extraabove the fire front the depth of the shelf may beincreased by 25mm.

Combustible furniture or materials must not be placedcloser than 1metre in front of the fire front.

CL


5 221098C

2 T y p e s o f I n s t a l l a t i o n a n d F l u e

Diagram 2.2

Diagram 2.1

50mmMIN.

340mm131/

2in.

760mm30in.

2in.

3918

S

Opus illustrated

INSTALLATION CENTRE LINE

CL

406mmto

460mm

FRONTOPENING

560mmto

590mm

3919

S39

20 S

PREPAREDBASE

Diagram 2.3

BUILDERSOPENING

INSTALLATIONCENTRE

LINE

CL

REMOVECOMBUSTIBLEMATERIAL FROMTHIS AREA

PREPAREDBASE

280mm280mm

220mm220mm

560m

m

680m

m

135mm1/2in

1/2in. 12mmNon-

combustiblematerial

Note. Refer to Section 2 in the Back Boiler InstallationBook before starting.

2.1 With Hearth

A fireproof hearth under the fire front must have theminimum dimensions as shown in diagram 2.1.

2.2 With Surround

See diagram 2.2. The fire front casing should cover theopening.

A wider opening will require any opening left to becovered with a non-combustible finished material, seediagram 2.3.

The surround must have a minimum clear, flat area asshown in diagram 1.2. Any projection on the surroundmust be outside this area.

Any combustible material on the fire front fixing facearea of the surround must be removed, see diagram 2.3.This area, to the depth removed, should then be renderedwith a sand/cement mixture.

2.3 Without Surround or Hearth

The fire front fixing wall face must be flat over an areaas shown in diagram 1.2. This also shows the minimumclearances for shelves or projections on the fire frontfixing wall face.

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

Under no account must carpet or other combustiblematerial be laid directly under the fire front, unless theminimum clearances shown in diagram 1.2 is achieved.

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

2.4 Flue

The back boiler flue collector assembly accepts the firefront flue spigot.

Note: Provision must be made during the installation ofthe back boiler for total ventilation requirement for thecombined appliance. See relevant section in back boilerinstallation instructions.


6221098C

3 F i r e F r o n t P r e p a r a t i o n

FIRE BODY PACK

OPULENCE CASING PACK OPUS CASING PACK

Diagram 3.1

4337

S

FRONTCASTING

PLINTH

L.H.LEG

PLINTH

R.H. SIDECASTING

WALLSEALINGPLATE

COMBUSTIONCHAMBERBOTTOM PLATE

FLUE SPIGOT

FUELEFFECTBED

LITERATURE

FIREBODYASSEMBLY

R.H. SIDEPANEL

R.H.LEG

L.H. SIDEPANEL

L.H. SIDECASTING

R.H. SIDECASTING

CANOPYCANOPY

L.H. SIDECASTING

FRONTCASTING

R.H. SIDEPANEL

L.H. SIDEPANEL

L.H.LEG

R.H.LEG


7 221098C


6135

Diagram 3.1

KEY

SCREW FRONT LEGM5x30 LEVELLING SCREW

SCREW UPPER WALLM5x40 MOUNTING

ANCHOR UPPER WALLNUT MOUNTING

SCREW WALL SEALINGNo. 10 x 1 1/

2in. PLATE FIXING

WALL WALL SEALINGPLUG PLATE FIXING

SCREW SIDEM5x14 CASTINGS

A

J

H

G

F

E

D

C

B

SCREW UPPER SIDERETAINING

SCREW FRONT LEGM5x8 FIXING

SCREW SENSING TUBEM4x10 FIXING SCREWK

L TAPTITE SCREW SENSING TUBE MOUNTINGM4x6 BRACKET SCREW

SCREW FLUE SPIGOT FIXINGNo. 8 x 3/

8in.

LIQUIDCOAL

TUBINGNUT (2)

FIRE FRONTSENSINGTUBE

CONTROLKNOB

GAS SUPPLYPIPE

FIBRE WASHER (2)

SIDE EXTENSION (2)

OLIVE (2)

BBUSENSINGTUBE

SENSINGTUBEMOUNTINGBRACKETASSEMBLY

BATTERY

FILTER


8221098C


Diagram 3.2

PULL FORWARDSAND UP

5171

3923

S

Diagram 3.3

FLUE SPIGOT ASSEMBLY

SECURINGSCREW (7)

J

GLASSFRONT PANEL

3.1 UnpackingThe fire front is delivered in two packs, one contains thebody 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. toidentify the parts.

To unpack carton 1, lift out the top fitting containing thefire spigot and combustion chamber bottom plate, lift outthe cardboard front fitting, the supply tube pack and thetwo boxes containing the fuel effect pieces.

Lift the outer carton clear to leave the fire front sitting inthe base tray.

To unpack carton 2, lift out the cardboard tray containingthe plinth and side panels. Lift out the loose items pack,legs box and canopy. Remove the internal cardboardfitting and lift out the lower front and side castings.

Put these items on one side until required. Checkcontents of loose items pack against list.

Remove the glass front panel, see diagram 3.2.

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

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 wallsealing plate to the rear of the fire front and put it on oneside until required.

Secure the spigot assembly to the fire front back withthe self taping screws provided, in the loose items pack,see diagram 3.3.

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

3.3 Gas Supply Tube and Sensing TubesPreparationRemove the plastic ferrule from the bulkhead connectoron the air duct and discard.

Fix the flared end of the back boiler sensing tube to thebulkhead connection on the boiler air duct with thetubing nut provided. Slide the sensing tube mountingbracket assembly over the back boiler sensing tube andfix to the casing with the screw provided, see diagram 4.2.

Important. Make sure that the mounting bracketassembly is pushed back to the fire front face of theboiler casting and check 3mm distance is achieved andthe back boiler sensing tube does not extend above thesensing tube bracket assembly, see diagram 4.2.

Note: After fitting the combustion products dischargesafety device sensing tube please refer to the‘commisioning’ section of the back boiler unit andrelight the boiler to test the device.

Check that the gas service cock is in the Off position, seediagram 3.4.

The inlet supply tube, back boiler sensing tube assemblyand fire front sensing tube are packed in the supply tubepack, see diagram 3.1.

This supply tube and fire front sensing tube may need tobe cut, at the plain end, dependent on the model andposition of the back boiler in the opening.

GLASSRETAININGBRACKET

Gas Supply TubeMeasure the distance “C”, see diagram 3.5, from thefront 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 thedistance “C”. No shortening is required when mark “P”is level with the fire front fixing wall face, “C” being zero.

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


9 221098C

56 BBU/2FIREFIXINGWALL FACE

45 BBU/2FIREFIXINGWALL 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 3.4

BACKBOILERONLY 'ON'TURNEDFULLYCLOCKWISE

BACKBOILER &FIRE 'ON'TURNED TOMID POSITION

90˚

180˚

'OFF'TURN FULLYANTI-CLOCKWISE

Diagram 3.6

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 3.5

5078

5245

GAS SERVICECOCK UNION

Firefront sensing tubeShorten the plain end of the fire front sensing tube bydistance “D”, no shortening of the tube is required when45/2 back boiler is fitted and point “P” is level with thefire fixing wall face. Similarly when a 56/2 back boileris fitted no shortening is required when point “N” is levelwith the fire fixing wall face. In both cases “D” is zerothe maximum distance of “D” for both the 45/2 and 56/2back boiler will be 25mm, see diagram 3.6.

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 shownin diagram 4.1, make sure that the terminals are correctlyfitted.


10221098C

SENSING TUBEMOUNTING BRACKETASSEMBLY

MOUNTINGBRACKET SCREW

3mm

BACKBOILERSENSING TUBE

BULKHEADCONNECTIONTUBING

NUT BOILERAIR DUCT

SENSINGTUBEMOUNTINGBRACKETASSEMBLY

FRONT FACE OFBOILER CASTING

6171L

4 I n s t a l l a t i o n

4.1 Battery

Remove the fire front from the base tray.

Take the battery from the fittings pack and fit as shown indiagram 4.1, make sure the terminals are correctly fitted.

4.2 Positioning the Fire Front

Remove and discard the plastic ferrule from the bulkheadconnector.

Fix the flared end of the back boiler sensing tube to thebulkhead connection on the boiler air duct with the tubingnut provided. Slide the sensing tube mounting bracketassembly over the back boiler sensing tube and fix to thecasting with the screw provided, see diagram 4.2. Fit thesensing tube filter onto the fitting assembly, see diagram4.2. Take care not to damage the filter.

Important. Make sure that the mounting bracket assemblyis pushed back to the front face of the boiler casting andcheck 3mm distance is achieved and back boiler sensingtube does not extend above sensing tube fitting, seediagram 4.2.

Place the wall sealing plate onto the back boiler air duct,mark the fixing holes, remove the plate and drill the holesto suit the plugs and screws provided, from supply tubepack, leave sufficient screw proud to accept the wallsealing plate keyholes, see diagram 4.3.

Fit the wall sealing plate and tighten the screws, makingsure that the “wings” are flush with the fire fixing wallface, see diagram 4.3.

Place the fire front onto the back boiler air duct, checkthat the fire front spigot is central in the flue collectorassembly, push back into contact with the fire frontfixing wall face, see diagram 4.4.

Mark the fire front fixing points through the mountingbracket holes at the top, see diagram 4.4.

Pull the fire front forwards and remove.

Drill the fire front fixing face using a 10mm masonrydrill to a minimum depth of 40mm to accept the anchornuts and screws provided.

Place the anchor nuts and screws into the holes, screw up,but leave sufficient screw thread proud to accept the firefront.

Note, if the fire front fixing wall face is not of a solidconstruction, to a minimum depth of 40mm, for example,hollow brick or metal an alternative and rigid form offastening for the fire front must be used and extra caretaken.

Fit the fire front sensing tube to the flue collector with thetwo securing screws, see diagram 4.5.

SECURINGSCREW

SPARKGENERATOR

ELECTRICALCONNECTIONS

9V ALKALINEBATTERY

SECURINGSCREW

IGNITIONLEAD

Diagram 4.1

5283

NOTE:WINGSFLUSHWITHWALL

G F

Diagram 4.3

Diagram 4.251

6661

71


11 221098C

MARKFRONTFIXINGHOLES

SPIGOT

FLUECOLLECTORASSEMBLY

FIRE FRONT


Diagram 4.5

Diagram 4.4

5257

5072

5258


SECURINGSCREW (2)

FLUECOLLECTOR

TUBINGNUT

OLIVE

FRONTFIXINGSCREW

SPIGOT

BACKBOILERAIRDUCT

FLUECOLLECTORASSEMBLY

FIRE FRONT

OLIVETUBINGNUT

SENSINGTUBE

Diagram 4.6

Note, place the tubing nut and olive from the loose itemspack onto the prepared end of the sensing tube, seediagram 4.5.

Offer the appliance up to the back boiler air duct andpush into position taking care not to damage fire frontsensing tube and filter, lift slightly to engage mountingbrackets onto screws, engage sensing tube into bulk headconnection, see diagram 4.6.

Tighten the fire securing screws, see diagram 4.7.

Tighten the sensing tube nut onto the bulkhead, seediagram 4.8.


12221098C

5167

TUBE NUT


TUBE NUT


Diagram 4.8

OLIVE

JOINT (C)

UNIONNUT (B)

LOCKNUT (A)

GAS SUPPLYPIPE

GAS SERVICE COCK

TUBINGNUT

Diagram 4.9

3929

S

3928

S

Diagram 4.7

MOUNTINGBRACKET

SECURINGSCREW (2)M5 X 40mm

SECURINGSCREW (2)

C

C

ANCHORNUT D

4.3 Gas Connection

Place the tubing nut and olive, from the loose itemspack, onto the prepared end of the gas supply tube,see diagram 4.9.

Connect the gas supply, as diagram 4.9 tighten the nutand olive at the gas service cock.

To tighten the other end use a spanner to hold thelocknut (A) at the bulkhead fitting and ensure that it doesnot turn, tighten the union nut (B) on the supply tube inthe usual manner, see diagram 4.9.

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

Fit the left hand side panel, see diagram 4.10.


13 221098C


Diagram 4.10

L.H. SIDEPANEL

GAS CONTROLKNOB

UPPER SIDERETAININGSCREW

LOCATING PINAND HOLE


R.H. SIDE PANEL

FIBREWASHER


UPPER SIDERETAININGSCREW

FIBREWASHER R.H. SIDE

PANELHH

3930

S


14221098C

5 L i g h t i n g , T e s t i n g a n d F i t t i n g o f I n t e r n a l P a r t s

5.1 Lighting and Testing

Make sure that the electrical supply to the back boiler isisolated.

The fire front is fitted with a combustion productsdischarge safety device which will shut it down if thereis a lack of oxygen. If the fire shuts down frequently forno apparent reason the first things to be checked are thechimney and air inlets into the room. An additionalcause could be that the filter in the gas tap is blocked.Any problems found must be put right, by a competentperson before the fire is used again.

The combustion products discharge safety device MUSTNOT be adjusted or disconnected. If replacing use onlythe correct and approved parts.

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

Place the right hand side panel onto the pins, seediagram 4.10, but do not secure at this time.

Turn the gas service cock to back boiler and fire ON,see diagram 3.4.

To check for gas soundness use the pressure dropmethod and apply suitable leak detection fluid to alljoints, 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 threeseconds, release the tap, wait ten seconds and repeat thelighting operation.

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

Keep the knob pushed in for ten seconds, to energise theflame supervision device, during this time the ignitionsystem will continue to operate, indicated by theclicking.

Air may be present in the supply to the fire front so thatthe initial lighting operation may need to be repeated.

With the burner lit, visually check for leaks whilstchanging tap settings.

To change settings:

0 - 1 Push in and turn




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

Check that the gas pressure is as stated in the DataSection 1.3 or on the Data Label. (Right hand side panel)

If there is any doubt about the gas rate, check at themeter, having first turned off all other gas appliances andpilots.

Diagram 5.1

GASTAP

PRESSURETEST POINT

5081

Diagram 5.2

GASCONTROLKNOB

IGNITION &POSITION 1

POSITION 2APPLIANCEOFF

POSITION 4POSITION 3

FLAT DOWNPOSITION

VERTICAL

5082


15 221098C


4329

S

FUEL EFFECT PIECES LOCATIONS

5

312

4

3

122

4 5

FUEL EFFECT PIECES 1 to 5 Diagram 5.4

FUELEFFECTBASE

FUELEFFECT

BASE(see note)

LeftSide

RightSide

RETAININGBRACKETS

5088

NOTE:Fuel Effect Baseseats behindretaining brackets Diagram 5.5

SUPPORT ANGLE FORFUEL EFFECT PIECES1, 2 AND 3

FUELEFFECTBASE

5174

Diagram 5.3

BOTTOMPLATE

5.2 Internal Parts - Fitting

CAUTION: If any of the internal fire front parts aredamaged DO NOT light or further test the fire front untilreplacement parts are fitted.

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 3.2.

Follow sequence in diagram 5.3 to 5.11 to fit thecombustion chamber bottom plate (inside base tray) andinternal fire front parts.

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

Replace front glass panel.


16221098C

Diagram 5.6

Diagram 5.7

Diagram 5.8

Diagram 5.10

Diagram 5.9


Diagram 5.11

COMPLETED FUELEFFECT BED 39

43 S

FUEL EFFECT PIECE POSITION 1 FUEL EFFECT PIECE POSITION 4

FUEL EFFECT PIECE POSITION 2 FUEL EFFECT PIECE POSITION 5

FUEL EFFECT PIECE POSITION 3

NOTE: FUEL EFFECT PIECE MUSTSIT ON SUPPORT ANGLE

LOCATIONRECESS 1


LOCATIONRECESS 2


LOCATIONLUG 3

LOCATIONRECESS 4

LOCATIONRECESS 5

4333

S

4334

S

4331

S43

32 S

4335

S

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


17 221098C


Diagram 5.15

LOCATINGHOLE

3947

S

Diagram 5.12

VIEWED FROM REAR

3944

S

Diagram 5.13

SIDECASTING

3945

S

Diagram 5.14VIEWED FROM REAR

3946

S

FRONTCASTING

LOCATION PIN

SECURINGSCREW (3)M5 x 14mm

LEG

E

SECURINGSCREW (2)

CANOPY LOCATINGPIN

LOCATIONSLOT

B

5.3 Decorative Castings

Fit the front casting as diagram 5.12, decorative sidecastings as diagram 5.13, front legs and feet as diagram5.14 and canopy as diagram 5.15.


18221098C


Diagram 5.16

APPLIANCE OFF

IGNITION POSITIONAND CENTRESECTIONFLAME EFFECT

CENTRE SECTIONFLAME EFFECTWITH OUTERSECTIONSFUELBED GLOW

CENTRE ANDOUTER SECTIONSFLAME EFFECTWITH FUELBEDGLOW

FULL FLAMEEFFECT WITHFUELBED GLOW

5154

5.4 Heat Settings

Light the fire front burner as the relevant part ofSection 5.1.

Refer to diagram 5.16.

At tap position 1 - centre section flame effect.

At tap position 2 - centre section flame effect with outersections fuel bed glow.

At tap position 3 - centre and outer sections flame effectwith fuel bed glow.

At tap position 4 - (full on) full flame effect and fuel bedglow.

In the unlikely event of the flame going out when the firefront burner is on, then turn off. Wait 3 minutes beforerelighting.

If relighting for any other reason, wait 2 minutes beforedoing so.


19 221098C


Diagram 5.17

L.H. SIDEPANEL

25mm25mm

SMOKE MATCHEXTENSION

5175

10

1010

DIVERTERPLATE

SIDE VIEW FRONT VIEW

Diagram 5.18

FIRE SPIGOT NOTSHOWN FOR CLARITY

560 SMOKEMATCHEXTENSION

5176

DRAUGHTDIVERTER

5.5 Test for Clearance of Products

Notes:

WARNING: Take care, the appliance will get hotduring tests.

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

IN ALL CASES, if spillage continues after the specifiedtest periods steps must be taken to rectify the fault(s).

Possible causes include, flue obstruction, down draughtor restricted fresh air supply into the room.

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

Test Where No Fan is Present

Close all outside doors and windows in the room wherethe appliance is installed.

Light the fire front only and set to tap position 4.After 5 minutes apply a spillage test as shown in diagram5.17 and 5.18. During tests smoke should be drawn intothe fire draught diverter and the boiler draught diverter.

If spillage occurs, leave fire front alight for up to afurther 10 minutes and repeat test. Turn the fire frontoff.

Next light the back boiler only. After 10 minutes applyspillage test as shown in diagram 5.17 and 5.18.During tests smoke should be drawn into the fire frontdraught diverter and boiler draught diverter.

If spillage occurs, leave the back boiler alight for up to afurther 5 minutes and repeat tests.

Leave the back boiler alight.

Now light fire front. After 10 minutes apply spillagetests as shown in diagram 5.17 and 5.18. During testssmoke should be drawn into the fire draught diverter andboiler draught diverter.

If spillage occurs leave back boiler and fire front alightfor up to a further 5 minutes and repeat tests.

Test Where a Fan is Present

(A fan means an extract fan or a fan for other open fluedappliances or a circulating fan for a warm air unit,whether or not gas fired). With the fan switched offcarryout the appropriate spillage test with all doors andwindows closed, as above.

If the above spillage test is satisfactory continue asfollows:-

Open all doors connecting the room containing theappliance and 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 alldoors and windows in that room.

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

MATCHEXTENSION

TORCH


20221098C

6 I n s t r u c t i o n s t o U s e r


Diagram 6.1

MATCH ORSPILL

Diagram 5.19

5.6 Plinth Fitting

Fit the controls cover plinth onto the guides and push itback as far as it will go, see diagram 5.19.

Hand the Instructions for Use to the user and instruct inthe safe and economical use of the fire front and backboiler.

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

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

Important: Advise that soft wall coverings, for example,blown vinyl wallpaper, are easily affected by heat, theymay, therefore, scorch or become discoloured whenclose to a heating appliance. This should be borne inmind when having a heating appliance installed andwhen redecorating.

Advise the user, to ensure the continued efficient andsafe operation of the appliance it is recommended that itis checked and serviced as necessary at regular intervals.The frequency of servicing will depend upon theparticular installation and usage, but in general once ayear should be enough.

Draw attention, if applicable, to the current issue of theGas Safety (Installation and Use) Regulations, Section35, which imposes a duty of care on all persons who letout any property containing a gas appliance.

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

Show how to light the fire front, in the event of a poweror ignition system failure, with a spill or long match, seediagram 6.1.

Remove the front casting.

Hold a lighted spill or long match and insert it beneaththe front lighting assembly, position the spill so that theflame is over the burner.

Keep the spill in position, push in and turn the gas tap toposition 1 and the burner will light keep knob pushed infor about 10 seconds and the burner will stay light.

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

Once lit operate the gas tap normally.

This is a temporary measure only and the fault must beput right as soon as possible.

Advise the user of the precautions necessary to preventdamage to the system, boiler and the building, in theevent of the heating system being out of use during frostor freezing conditions.

Advise that the fire front is fitted with a safety deviceand refer to the instructions for use.

Reminder, leave these instructions with the user.

MATCHEXTENSION

BURNER

5338

3951

S

PLINTH


21 221098C

7 S e r v i c i n g

Notes

(a) To ensure the continued efficient and safe operationof the appliance it is recommended that it is checkedand serviced at regular intervals. The frequency ofservicing will depend upon the particular installationand usage, but in general once a year should beenough.

(b) It is the Law that servicing is carried out by acompetent person.

(c) Make sure the fire is cold before carrying out anyservicing.

(d) Before servicing isolate the gas and electricalsupplies.

(e) After servicing (or replacing parts) always test forgas soundness with a suitable leak detection fluid.(To test the gas tap, refix the fire front and applyleak detection fluid to all joints, replace the glasspanel, light the burner and visually check all thejoints for leakage whilst changing tap settings).

(f) Carryout functional check on controls, see Section 4and 5.

(g) Other than for replacing the glass panel, internal firefront parts and lighting the fire front should beremoved from its fixings by reversing theinstructions in Section 4 and 5. Make sure that theside panels and feet are removed. Refit controlscover plinth so that the fire can stand upright.

(h) Unless stated otherwise reassemble all parts in thereverse order to removal.

(i) The back boiler should be serviced at this time, referto Back Boiler Installation and ServicingInstructions.

(j) The combustion products discharge safety deviceMUST 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, asdiagram 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.

7.3 Burner and Injectors

Remove the front casting, see diagram 5.12.

Remove the lower front baffle, see diagram 7.2.

Remove the burner baffle, see diagram 7.2.

Remove the side castings, see diagram 5.13.

Remove right hand leg, see diagram 5.14.

Remove right hand leg support bracket, see diagram 7.4.

5mm5mm

3953

S

Diagram 7.1

4854

B

LOWER FRONTBAFFLE

SECURING SCREWS (3)

SECURING SCREWS (2)

BURNERBAFFLE

Diagram 7.2


22221098C

4855L.H. BURNER

SECURING SCREWR.H. BURNER

SECURING SCREW

BURNER

UNION CONNECTION

UNIONCONNECTION

5080

R.H. LEGSUPPORTBRACKET

SECURINGSCREW(4)

7 S e r v i c i n g

Diagram 7.7

3958

S

SECURINGSCREW

INJECTORS

INJECTOR BOXCOVER

Disconnect the supply pipe unions at the injectors alsothe union connection at front, see diagram 7.5.

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 asnecessary, see diagram 7.7.

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

Remove the injector box cover screw and plate, seediagram 7.7, clean out dust and debris. Brush away anylint and dust from the burner and surrounds.

Using a soft brush or vacuum cleaner.

Do not use a brush with wire bristles.

Diagram 7.5

Diagram 7.4

Diagram 7.3

3955

S

PULL FORWARDS

BURNER

Diagram 7.6

5172

BURNERBAFFLE

BURNER

SECURINGSCREW (2)


23 221098C

7 S e r v i c i n g

7.4 Combustion Products Discharge SafetyDevice

Remove the burner refer to Section 7.3.

Check the condition of the electrode and thermocouple,with a soft brush, see diagram 7.8.

Make sure the electrode is in line with the earth post andspark 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 mountingbracket securing screws and combustion productsdischarge 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 dischargesafety device, take care not to trap the ignition lead underthe mounting bracket.

7.6 Gas Tap and Micro Switch Assembly

Note: This item need not be serviced annually.

Remove micro switch electrical connections, seediagram 7.10.

Disconnect all union connections and remove the tubesin the order shown diagram 7.11.

Disconnect the thermocouple nut, see diagram 7.12.When replacing only tighten the nut a quarter turnbeyond finger tight.

Remove the gas tap bracket securing screws,see diagram 7.12.

Remove the gas tap assembly.

To service the gas tap remove the gas tap niting plateassembly securing screws, see diagram 7.13.Take care as there is a spring beneath the niting plate.Remove the plug, pin, spring washer, plain washer and“O” ring, see diagram 7.13.

Clean and relubricate using a suitable grease.

When replacing make sure the operating disc, withretaining washer and micro switch and leads arecorrectly located, see diagram 7.13 and 7.10.

5075

Diagram 7.7

SECURINGSCREW (2)

SECURINGSCREW (2)

TUBENUT

MOUNTINGBRACKET

TUBENUT

COMBUSTION PRODUCTSDISCHARGE SAFETYDEVICE

TUBENUT

IGNITIONLEAD

5075


24221098C

7 S e r v i c i n g

Diagram 7.10

GAS TAP MOUNTINGBRACKET SECURINGSCREW


MICRO SWITCH

SECURINGSCREW (2)

INSULATIONMICROSWITCH

INSULATION

NUT (2)

GAS TAPMOUNTINGBRACKET

EARTH POST

ELECTRODE

18

67

ELECTRODE

SPARK GAP3 + 1.0

- 0.5

EARTH POST

ELECTRODE

TOP VIEW

EARTH POST

CL

Diagram 7.9

5248

3960

S


25 221098C

7 S e r v i c i n g

Diagram 7.11

THERMOCOUPLENUT

Diagram 7.12

Diagram 7.13

4

6

9

5 7 3

5

7

9

GAS TAP SECURINGSCREWS

GAS TAPBODY

PLUG'O' RING

WASHERSPRING

GAS TAPBRACKET ANDNITING PLATEASSEMBLY

SECURINGSCREW

8

2

1

5089

5090

5091


26221098C

8 F a u l t F i n d i n g

ELECTRODE

RE

D

RE

D

MICROSWITCH

SPARKGENERATOR

Diagram 8.1

5251

Diagram 8.2

ELECTRODE

MICROSWITCH

SPARK GENERATOR

RED

RED

5252

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.

8.2 Electrical

Refer to pictorial wiring diagram 8.1 and functional flowdiagram 8.1.

Refer to pictorial wiring diagram 8.1 and functional flowdiagram 8.2.


27 221098C

Diagram 8.3


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

5478


28221098C

Diagram 8.4

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 combustionproducts dischargesafety device.

Faulty thermocouple.Replace combustionproducts dischargesafety 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

5243


Is voltage greaterthan 15mV?


29 221098C

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

0065

M8.3 Thermocouple

To test a thermocouple, a meter with a range of 0 to30mV is required together with a thermocoupleinterrupter test unit, similar to a British Gas Multimeter 6unit.

Refer to fault finding diagram 8.4 and diagnosis graph,diagram 8.5.


If the device operates it indicates there could be aproblem with the chimney or, the pilot filter in the gastap is blocked. First make sure air vents are freefrom obstructions, by carrying out spillage checks asSection 5.5. If all is in order refer to diagram 8.3 tocheck if the pilot filter is blocked.



30221098C

9 R e p l a c e m e n t o f P a r t s

SECURINGSCREW

SPARKGENERATOR


9V ALKALINEBATTERY

SECURINGSCREW

IGNITIONLEAD

5283

Diagram 9.1

Notes:

(a) Make sure that the fire is cold before replacing anyparts.

(b) Replacement of parts must be carried out by acompetent person.

(c) Remove the internal fire front parts as the relevantpart of Section 5.2.

(d) Before removing or replacing any fire front partsturn the gas supply service cock to “Back BoilerOnly On”, see diagram 3.4.

(e) Isolate the electrical supply to the back boiler andfire front.

(f) Other than for replacing the burner, injectors andinternal fire front parts the fire front should beremoved from its fixings be reversing theinstructions in Section 4 and 5. Make sure that theside panels and legs are removed. Refit controlscover so that the fire front can stand upright.

(g) After replacing or disconnecting any gas carryingcomponent, always test for gas soundness, using asuitable leak detection fluid and carry out functionalcheck of controls.

(h) To test the gas tap apply leak detection fluid to alljoints, light the burner and check all the joints forleakage at all tap settings.

(j) Unless stated otherwise reassembly of all parts is inthe reverse order to removal.

(k) The combustion products discharge safety deviceMUST NOT be adjusted or disconnected.


31 221098C

9.1 Burner

Refer to Section 7.3.

9.2 Injectors

Refer to Section 7.3.

9.3 Gas Tap and Micro Switch Assembly

Refer to Section 7.5, and diagram 7.10 to remove themicro switch.


Remove canopy.

Refer to Section 7.3 to remove the burner.

Disconnect the union connections, remove the mountingbracket securing screws and combustion productsdischarge safety device, see diagram 7.8.

Pull off the lower sensing tube. When replacing takecare not to damage the “O” ring seals.

Remove right hand side panel, see diagram 4.10.

Remove the thermocouple nut, see diagram 7.12.

Remove the ignition lead, see diagram 9.1.

Note. When refitting the combustion products dischargesafety device, take care not to trap the ignition leadunder the mounting bracket.

When refitting make sure that the spark gap is as shownin diagram 7.9.

GAS TAP

FILTER

GAS TAP BRACKETAND NITING PLATEASSEMBLY

FILTER

CROSSSECTIONVIEW

Diagram 9.2

5477

9.5 Ignition Lead

Refer to Section 7.3 to remove the burner.

Disconnect the tube nuts, remove the mounting bracketsecuring screws, remove the ignition lead (black end),see diagram 7.8.

Remove side panel securing stop screw and open panel,see diagram 4.10.

Remove the ignition lead (clear end), see diagram 9.1.

Note. When refitting the combustion products dischargesafety device, take care not to trap the ignition lead underthe mounting bracket.

9.6 Spark Generator

Remove right hand side panel, see diagram 4.10.Remove the right hand side casting, see diagram 5.13.

Remove retaining screw, disconnect the electrical leadsand then release the spark generator from the location tabat the rear, see diagram 9.1.

9.7 Gas Tap Pilot Filter

Gain access to the gas tap as Section 7.6.

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

When fitting the replacement it is important that thefilter is seated correctly as shown in diagram 9.2.

9 R e p l a c e m e n t o f P a r t s


32221098C

10 S p a r e P a r t s

When replacement parts are required please apply toyour local supplier.

Please quote the name of the fire front, “Opus” or“Opulence”.

The GC No.37 314 14, Opus, 37 314 15 Opulence, andthe serial number, to be found on the chassis, visiblewhen front casting is removed.

Refer to diagram 10.1 for the illustration of thereplacement parts.

Key No. Part No. G.C. Part No. Description1 210213 136 918 Rear fuel effect piece2 210214 136 919 Fuel effect piece - 13 210215 136 920 Fuel effect piece - 24 210216 136 921 Fuel effect piece - 35 210217 136 922 Fuel effect piece - 46 210218 136 923 Fuel effect piece - 57 448093 136 924 Glass panel assembly8 230169 398 444 Injector - upper9 230201 398 422 Injector - lower10 203437 162 100 Combustion products discharge safety device12 202014 360 188 Microswitch13 WW4617 312 997 Ignition lead14 448103 136 925 Gas tap control knob - Opus 214 448235 136 926 Gas tap control knob - Opulence 215 800449 136 927 Gas tap16 202179 152 949 Spark generator17 208673 162 208 Filter


33 221098C

Diagram 10.1

5178

7 1

5

3

2

6

4

9

8

10

13

12

16

10 S p a r e P a r t s

14

15

17


34221098C

These fire fronts are fitted with combustion productssafety devices

As these fire fronts may be fitted to Glow-worm 45, 56,45R and 56R back boiler units WITHOUT a combustionproducts discharge safety device, the followinginstructions must be read and followed in place of thosein the main Installation and Servicing Instructions.

To check if a combustion products discharge safetydevice, refer to inset in diagram 11.1, if one is fitted thissupplement MUST be ignored.

11.1 General

To fit the fire front to one of the above EXISTINGGLOW-WORM BACK BOILER UNITS follow theinstructions below.

NOTE: Kit No. 451484 will be required.

1. Replace the existing draught diverter front with thenew part supplied in Kit No. 451484. To fit followthe instructions supplied with the kit.

11.2 Installation

2. Do not fit the back boiler sensing tube as required inthe main installation and servicing instructions.

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

4. Any reference in the installation and servicinginstructions to the back boiler combustion productsdischarge safety device must be ignored.

Lighting the Boiler

The boiler controls are placed behind the fire frontplinth.

To remove the plinth, pull it gently forwards until it isfree.

Refer to diagram 11.1 to identify controls.

Turn off the electrical supply at the mains supply outsidethe 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’sinstructions supplied with them.

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

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, thenpush fully in and hold in. At the same time press andrelease piezo button “D” until pilot burner “E” lights.Look at flame through viewing window “F”.

At initial lighting of the boiler air may be present andseveral attempts may be needed to light the pilot. Keepthe control knob “A” pushed in whilst operating theignition button.

When the pilot is alight and stable, keep knob “A” fullypushed in for about 15 seconds then release. Check thatthe pilot is still alight, look through window “F”.

If the pilot burner fails to stay alight turn gas controlknob “A” “Off”. that is, fully clockwise. Wait threeminutes. Repeat the lighting operation, only now keepthe control knob “A” pushed in for a little longer thanbefore after the pilot has lit.

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

Push control knob “A” in slightly and turn anticlockwise

11 S u p p l e m e n t a r y I n s t a l l a t i o n I n s t r u c t i o n s


35 221098C

11 S u p p l e m e n t a r y I n s t a l l a t i o n I n s t r u c t i o n s

'E' PILOT BURNER

BOILER CONTROLS Diagram 11.1

5342INSET: Showing a Combustion Products Discharge

Safety Device fitted.

SETTINGPOINT

'F' VIEWINGWINDOW

SETTINGPOINT'A'

GAS VALVECONTROLKNOB'D' PIEZO

UNITBUTTON

'B'THERMOSTATCONTROLKNOB

OFFPILOT/IGNITIONMAIN BURNER


36221098C

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

Information for the Installer and Service Engineer.

Under Section 6 of the Health and Safety at Work Act 1974, we are required to provide informationon 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 irritationto eyes, skin and respiratory tract, consequently, it makes sense to take care when handling thesearticles 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 installationand servicing we recommend that you use a HEPA filtered vacuum to remove any dust and sootaccumulated in and around the fire before and after working on the fire. When replacing thesearticles 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 maybe disposed of at a tipping site licensed for the disposal of industrial waste. Protective clothing isnot required when handling these articles, but we recommend you follow the normal hygiene rules ofnot smoking, eating or drinking in the work area and always wash your hands before eating ordrinking.

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 areusual only if the material is broken.

Normal handling should not cause discomfort, but follow normal good hygiene and wash your handsbefore eating, drinking or going to the lavatory.

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

C o n t r o l o f S u b s t a n c e s H a z a r d o u s t o H e a l t h

Documents

Installation and Servicing Instructions...1 G e n e r a l 150mm 445mm 445mm 150mm MAXIMUM SHELF DEPTH 150mm 150mm 840mm 840mm 3917 S FLAT AREA FIRE FIXING FACE Diagram 1.2 1.4 Fire