Baxi EBONY SUPER Installation And Servicing Instructions

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Please leave these Instructions with the User

Baxi Ebony Super

Gas Fire

Comp No. 236202 - Issue 4 – 10/99

Baxi Ebony Super - G.C.No 32 077 37

Installation and Servicing
Instructions

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Ebony Super Baxi Heating Ltd.

Installation Instructions – Page 2

INTRODUCTION

The Baxi Ebony Super is a hearth or wall mounted gas fired room
heater with a flame and coal effect. Input at maximum setting is

5.42kW (18,500 Btu/h) corresponding to a net output of 3.47kW
(11,840 Btu/h) approx. The fire is available for use with Gas Type
G20 (Natural Gas) at 20mbar. The fire is controlled by a control
knob positioned on the right hand side of the case. Ignition is by a
piezo spark to the burner.
The control knob has six positions giving a choice of four output
rates:

NATURAL GAS PROPANE
Position
Position
Position 1 - Low. Position 4 - High (c) Hearth: If the fire is to be hearth mounted the hearth must be

The outer case has two concealed lamps to illuminate the artificial
coal bed. This light effect is operated by a switch below the control
knob. It may be used with or without the gas fire.

- OFF Position 2 - Medium

- Pilot. Position 3 - Medium High.

NOTICE

Discolouration of Wall Surfaces

Most heating appliances generate warm air convection
currents and transfer heat to any wall surface against which
they are situated.

Some soft furnishings (such as blown vinyl wallpapers) may
not be suitable for use where they are subjected to
temperatures above normal room levels and the manufacturers
advice should be sought before using this type of wall
covering adjacent to any heating appliance.

The likelihood of wall staining from convected air currents will
be increased in environments where high levels of cigarette
smoke or other contaminants exist.

GENERAL

The installation must be carried out by a CORGI Registered
Installer or other competent person and be in accordance with the
relevant requirements of the GAS SAFETY (Installation and Use)
REGULATIONS (as amended), the BUILDING REGULATIONS
(Scotland) (Consolidation), the LOCAL BUILDING REGULATIONS
and the CURRENT I.E.E. WIRING REGULATIONS. It should also
be in accordance with the relevant BRITISH
STANDARD CODES OF PRACTICE.

IMPORTANT INFORMATION

This product contains Refractory Ceramic Fibres (R.C.F.) which are
man-made vitreous silicate fibres. Excessive exposure to these
materials may cause temporary irritation to eyes, skin and
respiratory tract. Care must be taken when handling these articles
to ensure the release of dust or fibres is kept to a minimum.
To ensure that the release of fibres from these articles is kept to a
minimum, during installation and servicing it is recommended that a
H.E.P.A. filtered vacuum is used to remove any dust, soot or other
debris accumulated in and around the appliance. This should be
performed before and after working on the installation. It is
recommended that any replaced item(s) are not broken up but
sealed within heavy duty polythene bags and clearly labelled
“R.C.F. 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 it
is recommended that gloves are worn and the normal hygiene rules
of not smoking, eating or drinking in the work area are followed and
always wash hands before eating or drinking.

have a flat vertical area and an opening size to the dimension
shown (Fig. 2). A shelf may be fitted above the fire provided that it
does not exceed 150mm (6in deep) and is at least 100mm (4in)
above the top of the fire. A clearance of 75mm (3in) is required at
each side of the fire for access during servicing.

(b) Fireplace opening: At the height of the flue outlet the fireplace

should have a minimum dimension of 100mm (4in) from the
front face of the opening to the fireplace back brick (Fig. 3).

There must be a minimum height of 250mm (10in) from the
bottom of the catchment space to the base of the the flue
spigot.

of non-combustible materials, at least 13mm (½ in) thick and
measuring at least 326mm (12 13/I6 in) deep and 750mm (29
9/16in) wide (with the fireplace opening central). The top
surface of the hearth should preferably be 50mm (2in) above
the floor level. The floor behind the fire opening in the area of
the closure plate rectangular cutout must be no higher than
the finished hearth level. The fire must not be fitted directly on
to a combustible floor or carpet.

(d) Wall Fixing: The fire may be fitted on to a suitable non-

combustible wall so that the bottom of the rear legs is not less

than 100mm (4in) above the finished floor level (Fig. 4).

FLUE (BS 5440: Part 1)
(a) Existing chimneys: A chimney which has previously been

used to burn solid fuel MUST be swept before beginning the

installation and any restrictions such as dampers or register

plates. must be removed. The chimney must be at least

310cm (10ft) in height and also meet the following

requirements:

(i) It must NOT be cracked.
(ii) It must serve only one room.
(iii) It must not communicate with any void, space or any room

other than that in which the fire is situated.

(iv) It must NOT be blocked by paper, rubble etc.
(v) It must have a positive updraught.
(vi) The cross sectional area of the flue must not be less than

120cm2 (19in2).

If there is no positive updraught DO NOT FIT THE FIRE and seek
expert advice. Positive updraught can be detected by the use of a
lighted match or smoke match (see relevant paragraph under
INSTALLATION). Any underdraught vent or additional air supply
openings that enter the fireplace must be completely sealed off.

(b) Pre-cast flue: The fire is suitable for fitting into properly

designed and constructed pre-cast flues complying with the

requirements of BS 1289 of at least 310cm (10ft) in height and

having a flue way of at least 197mm x 67mm (7 ¾ in x 2 5/8in)

or equivalent cross sectional area.

NOTE: It must be ensured that any mortar between the blocks
is not extruded into the flueway and that if raking blocks are
used they must be fitted according to the manufacturers
instructions.

SITE REQUIREMENTS

(a) Fireplace or surround: The fireplace or
surround must be of non-combustible material and

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Appliance Details – Page 3

Dimensions
HEIGHT
WIDTH
DEPTH

INPUT
OUTPUT
SETTING PRESSURE

(COLD)
GAS

ELECTRICAL
(MAIN INPUT)

THERMOCOUPLE
(OUTPUT)
RESISTOR
BURNER
PILOT IGNITION

WEIGHT

HEIGHT FROM HEARTH TO TOP OF FLUE SPIGOT BS 6891 Gas Installation

TAP Duplex with rotary piezo BS 5440:Part 1 Flues

BURNER INJECTORS 230

Projection in room
706mm (27 13/16 in)
750mm (29 ½ in)
326mm (12 13/16 in)

High - 5.42kW (18,500 Btu/h)
Low - 2.10kW (7,200Btu/h)
High - 3.47kW (11,840 Btu/h)

14.1 mbar± 1.0mbar

5.6in w.g. ± 0.4in w.g.
Natural Gas

230 volts ~ 50 Hz - 3A - 120W

9.4 to 13mV
68 ohms
Aerated - Duplex
Piezo Unit - Spark Gap

2.5mm - 4.0mm
40kg (88 lbs)

B.S. CODES OF PRACTICE

489mm (19 ¼ in) BS 5871 :Part 1 Installation of Gas Fires,

Convectors and Fire/Back Boilers

and flame failure device BS 5440:Part 2 Air Supply
operated by Oxy-pilot BS 5258:Part 5 Fire Construction

BS 6332:Part 2 Fire Efficiency

ELECTRICAL CONNECTION

THIS APPLIANCE MUST BE EARTHED
ALL EXTERNAL WIRING BETWEEN THE APPLIANCE AND

THE ELECTRICAL SUPPLY SHALL COMPLY WITH
CURRENT I.E.E. REGULATIONS. The mains lead has the

following specifications: 16/0.2mm - 3 core PVC covered - PVC
insulated wire to BS 6500.
IMPORTANT: Mains lead wires:

Green and yellow – Earth
Blue – Neutral
Brown – Live

FOR THE MAINS PLUG USE A 3AMP FUSE. The
appliance is supplied with approximately 3 metres of wire and a
mains plug. A longer cable may be fitted as follows:
Resistor

(a) Remove the socket and plug from the cable supplied.
(b) Re-assemble on the longer cable ensuring both

socket and plug are wired correctly.

If a different mains plug is used from the one supplied with
appliance proceed as follows:

The wire which is coloured green and yellow must be
connected to the terminal in the plug which is marked by
the letter ‘E’ or by the earth symbol or coloured green or
green and yellow. The wire which is coloured blue must be
connected to the terminal which is marked with the letter
N’ or coloured black. The wire which is coloured brown
must be connected to the terminal which is marked with
the letter ‘L’ or coloured red.

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Installation – Page 4

PREPARATION

(a) Where the closure plate is more than adequate in height to

cover the fireplace opening, trim a minimum of 35mm (1
3/8 in) from the top of the closure plate to prevent the
sealing tape being seen above the fire. Where the closure
plate is inadequate to cover the fireplace opening
completely or where it is required for the sake of
appearance a NON-COMBUSTIBLE infill panel or
surround may be used. The infill panel should be provided
with a rectangular opening at least 508mm (20in) high by
305mm (12in) wide and must be securely fixed and sealed
to the wall to prevent air leakage into the flue.

(b) Fit the closure plate centrally across the fire opening and

seal all four edges but ensure that the ventilation hole at
the bottom of the closure plate is not covered and that the
floor behind the closure plate does not restrict the
ventilation hole.

(c) Apply a lighted taper, match or smoke match to the flue

spigot opening in the closure plate before fitting the fire. If
there is a definite flow into the opening in the closure plate,
proceed with the installation. If there is not a definite flow
into the opening, pre-heat the chimney for a few minutes
then re-check for the flue pull. If there is still no definite
flow into the flue spigot opening in the closure plate the
chimney may require attention. DO NOT FIT THE FIRE ­SEEK EXPERT ADVICE.

HEARTH FIXING
Fireplace or Surround

(a) Fit the fire backing plate to the fire using the M5 x 8mm

thread forming screws provided. The backing plate may be
screwed to the wall for extra support if necessary (Fig. 6).

(b) Position the fire (minus the outer case) against the closure

plate and determine the position of the gas connection.

(c) Adjust the feet to level the fire (Fig.7). Check that the fire is

sufficiently stable.

WALL FIXING

(a) Fit the two wall mounting brackets using the four No. 8 x

3/8in self tapping screws provided (Fig. 7).

(b) Fit the fire backing plate to the fire using the M5 x 8mm

thread forming screws provided.(Fig. 6)

(c) Mark the position of the bottom two fixing screws then drill

and plug the wall (Fig. 4).

(d) Fix two No. 8 x 1 ½in screws into the wall leaving 3 - 4mm

(1/8 in - 5/32 in) clearance under the screw head then
locate the fire onto the screws.

(e) Push the fire backwards until the fire backing plate touches

the surround or finished wall face. Mark the position of the

two lower securing holes in the fire backing plate (Fig. 6).
(f) Remove the fire then drill and plug the wall.
(g) Replace the fire then screw the fire back to the wall and

tighten all four screws.

CONNECTING THE GAS SUPPLY

Rc ¼ (¼in BSP internal taper).

NOTE: If a hole has to be cut in the closure plate for the gas
supply pipe, seal the opening between the gas pipe and the
closure plate, ensuring that the ventilation hole is kept
clear.

(a) Make the gas connection to the union elbow.
(b) Fit the control knob and make sure that the tap is off. (Turn

fully clockwise).
(c) Turn the gas on, check for gas soundness.

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Commissioning the Fire – Page 5

Check the gas pressure (Figs 7 and 11)

(a) Remove the packing securing the coal bed as follows:

(i) Slide the glass front panel retaining clamps

sideways.

(ii) Lift the glass front panel bottom edge out of the

locating channel and carefully remove the glass front

panel.
(iii) Remove the packing securing the coal bed.
(iv) Carefully remove the coal bed and withdraw it from

the plastic bag.

CAUTION: The coal bed is extremely fragile and must be
handled accordingly. Gloves should be worn and any
inhalation of the dust should be avoided. Keep the coals
away from children at all times. Please read the
Important Information Section on page 2.

(v) Replace the coal bed and glass front panel.

(b) Remove the pressure test point sealing screw from the

control tap and connect a pressure gauge.

(c) To light the fire burner: Push in and turn the fire control

knob anti-clockwise to the positive stop. The pilot which
can be seen through the lower right hand gap between the
coal should now light. If it fails to light turn the control knob
to the ‘OFF position and repeat until lighting occurs.
Continue to hold in the control knob for a further 15
seconds. Release slowly and the pilot should stay alight.

CAUTION: If the pilot does not light or stay alight or if the
pilot flame goes out for any reason turn the control knob to
the ‘OFF’ position and wait for 3 minutes before attempting
to light the pilot again.

(d) Push in the control knob and turn fully anti-clockwise.

Check that the ignition is satisfactory.

(e) Check the fire pressure with the control knob turned fully

anti-clockwise. The pressure should be 14.1mbar ±

1.0mbar (5.6 in wg ± 0.4 in wg). No adjustment is provided
on the fire. Turn the control knob to the ‘OFF’ ( ) position.
Remove the pressure gauge and refit the pressure test
point sealing screw. Turn the fire on full again and check
for gas soundness using a suitable leak detection fluid.

TEST FOR SPILLAGE

(a) Check that all four edges of the closure plate are sealed.
(b) After fitting the fire ensure that all doors and windows of

the room are closed and they are not opened until the fire
has been checked for clearance of products.

IMPORTANT NOTE: If there is an extractor or
ceiling fan in the room or adjoining room then the
spillage test must be performed with the fan
turned on and any interconnecting doors between the
fan and the appliance left open.

(c) Light the fire and leave on full rate for 5 minutes.
(d) The fire should be checked visually for the absence of

spillage by holding a smoke match 50mm (2in) inside the
draught diverter behind the fire ensuring that the smoke is
drawn into the flue outlet (Fig.8). If there is any doubt
repeat the test after a further 10 minutes. If spillage still
persists the chimney may be faulty. The cause of the fault
MUST be identified and corrected before leaving the fire
installed. IF THE FAULT CANNOT BE CORRECTED,
TURN OFF AND DISCONNECT THE GAS SUPPLY TO
THE FIRE - SEEK EXPERT ADVICE.

(e) Remove the control knob.

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Fit the Outer Case – Page 6

(a) Fit the main electrical cable to the outer case. The cable

can be routed to the left or right hand side of the case to
suit the nearest adjacent electrical socket. Fit the cable in
the pair of clips fixed on the outer case (2 each side). Use
the ‘P clip in the pack, at the rear of the outer case (Fig. 9).

(b) Lift the outer case over the heat exchanger and locate the

two ‘vee’ notches in the top of the case into the vee’
notches at the top of the heat exchanger support legs (Fig.

6).

(c) Secure the outer case to the inner case using the two

screws provided then locate the cover panel in the spring
clips (Fig. 7).

(d) Fit the control knob and check the operation of the fire at

all tap settings.

(e) Plug in the electrical supply, operate the switch below the

control knob and check that the two 60W bulbs light,
indicating that the circuit is live. In the event of an electrical
fault after installation preliminary electrical system checks
should be carried out for earth continuity, short circuits
polarity and resistance to earth.

NOTE: For access to the lamps and glass front panel
remove the reflector assembly complete by first lifting the
assembly upwards and swinging its lower edge forward
and downwards.

(f) Instruct the user in the use of the fire including the removal

of the reflector assembly and the operation of the light
effect. Stress the importance of regular servicing and hand
over the user’s instructions.

(g) Advise the user that any smells emitted from the appliance

on initial lighting will quickly clear away with use.

IMPORTANT: It is possible that some soot may be
deposited on the coals after use. This is acceptable proving
it is not allowed to accumulate.

1. Remove the outer case (for access to all controls)
(a) Pull off the control knob.
(b) Remove the cover panel under the front of the fire by

grasping it firmly by its side edges and pulling forwards.
(c) Remove the two case securing screws (Fig.7).
(d) Lift the case away from the heat exchanger.

2. Remove the glass front panel (Fig. 10)
(a) Ensure that the glass front panel is cold.
(b) Slide the glass front panel retaining clamps sideways.
(c) Lift the glass front panel bottom edge out of the
locating channel and carefully remove the glass front panel.

3. Remove the coal bed (Fig. 10)

CAUTION: The coal bed is extremely fragile and must

be handled accordingly. Gloves should be worn and

any inhalation of the dust should be

avoided. Keep the coals away from children at all

times. Please read the Important Information

Section on page 2.

(a) Lift the coal bed away from the locating pins.

4. Remove the burner (Figs. 10, 11 and 12)
(a) If fitted, remove the screw holding the pilot shield to the

burner rail.
(b) Remove the screw holding the pilot assembly to it’s

bracket.
(c) Disconnect the compression nuts from the injectors.
(d) Remove the two screws securing the burner.
(e) Ease the pilot assembly forwards and slide the burner out

above the glass locating channel.
(f) Using a soft brush remove all deposits from the top of the

burner and burner ports.
(g) Remove the injectors from the end of the burner and clean

or replace as necessary.

NOTE: During annual appliance servicing the pilot
assembly should be inspected for damage to any of the
component parts and any lint or debris should be carefully
removed from the aeration hole.

Servicing the Fire

Turn off the gas and withdraw the plug from the electrical supply
before any servicing.

IMPORTANT

Always check for gas soundness before and after servicing
the fire particularly gas carrying joints which may have
been disturbed. At least once a year remove the fire and
check behind the closure plate for any accumulation of
rubble. Reseal the four edges of the closure plate and any
opening between the closure plate and any rear entrance
gas supply but ensure that the ventilation hole at the
bottom of the closure plate is not covered. Before Servicing
please read the Important Information Section on page 2.

5. Replace the parts in the reverse order of dismantling.

Make sure that:
(a) The electrode sleeve is pulled up on the electrode and the

electrode gap is correct (Fig. 12).
(b) The coal bed is correctly fitted over its locating pins.
(c) The glass front panel sealing rope is replaced if it is in any

way damaged.
(d) The glass front panel is replaced if it is in any way

damaged or cracked.

NOTE: This is heat resistant glass and must not be
replaced by ordinary glass.

6. Check the gas pressure. Temporarily fit the control knob

and light the fire. Check that ignition is satisfactory and the

gas pressure is correct - see ‘Commissioning the fire’.

7. Test for spillage. see ‘Commissioning the fire’.

8. Refit the outer case, control knob, case securing screws,

controls cover plate and plug in the electrical supply.

Check the operation of the fire at all tap settings. Operate

the switch below the control knob and check the operation

of the lamps.

NOTE: If the pilot is persistantly extinguished the flue may
be unsound and should be investigated immediately.

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Fit the Outer Case – Page 7

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Changing Components – Page 8

Before changing any components please read the
Important Information Section on page 2.

The following components can be removed as described below
after first removing the outer case. Turn off the gas and
withdraw the plug from the electrical supply before removing the
outercase.

ENSURE THAT THE FIRE IS COLD
GAS CONTROL TAP (Flame Failure Device)

(a) Greasing the tap plug (Fig. 13). Pull off the plastic cap

and then the spark electrode lead from the piezo unit and
undo the two set screws and washers securing the niting
plate to the tap body.

Remove the piezo unit complete with the gas tap spindle
and spring. Now remove the plug and apply suitable
grease sparingly, e.g. Kluber N322B. (Excessive grease
may block the gasways). On re-assembling care must be
taken to ensure that both the plug and spring are in place.

(b) To exchange the component (Fig. 11). (Disconnect the

gas supply and remove the fire from the fireplace.) Pull off
the plastic cap and disconnect the spark electrode lead
from the piezo unit. Disconnect the four tubes at the gas
tap. Disconnect the thermocouple from the gas tap.
Remove the 3 screws securing the gas tap bracket to the
inner case and remove the complete assembly. Remove
the locknut holding the gas tap to the bracket and remove
the gas tap.

On re-assembly ensure that the spark electrode lead is correctly
fitted and that the plastic cap is pushed on the piezo unit.
Ensure that the pilot filter supplied with the new tap is fitted.

BURNER (Figs. 10,11 and 12)
(a) Remove the glass front and coal bed as described above.
(b) If fitted, remove the screw holding the pilot shield to the

burner rail.
(c) Remove the screw holding the pilot assembly to it’s

bracket.
(d) Disconnect the compression nuts from the injectors.
(e) Remove the two screws securing the burner.
(f) Ease the pilot assembly forwards and slide the burner out

above the glass locating channel.
(g) Remove the injectors from the burner.

PILOT/THERMOCOUPLE/ELECTRODE
ASSEMBLY (Fig. 12)

NOTE: The thermocouple cannot be changed as an
individual component. The complete assembly must be
changed in the event of one or other component failure(s).

(a) Disconnect the gas supply and remove the fire from the

fireplace.
(b) Pull back the sleeve and disconnect the lead from the

electrode.
(c) Undo the nut on the pilot feed pipe.
(d) Remove the screw holding the assembly to the bracket.
(e) Undo the thermocouple from the gas tap.
(f) Remove the assembly from the fire.
(g) On re-assembly, shape the thermocouple in a similar

manner to the original.
ELECTRO MAGNETIC UNIT (Fig. 11 and 13)

(a) Remove the gas tap as explained in Gas Control Tap

section (b).
(b) Remove the electro magnet retaining nut and withdraw the

electro magnet unit.

GLASS FRONT PANEL (Fig. 10)
(a) Ensure that the glass front panel is cold.
(b) Slide the glass front panel retaining clamps sideways.
(c) Lift the glass front panel bottom edge out of the locating

channel and carefully remove the glass front panel.
On re-assembly ensure that:
(a) The glass front panel sealing rope is replaced if it is in

anyway damaged.
(b) The glass front panel is replaced if it is in anyway

damaged or cracked.

NOTE: This is a heat resistant glass front and must not be
replaced by ordinary glass.

COAL BED (Fig. 10)

Remove the glass front panel as described above.
Remove the coal bed by lifting it carefully away from the
locating pins.

CAUTION: The coal bed is extremely fragile and must be
handled accordingly. Gloves should be worn and any
inhalation of the dust should be avoided. Keep the coals
away from children at all times. Please read the
Important Information Section on page 2.

On re-assembly ensure that the coal bed is correctly located
over the locating pins.

PIEZO UNIT (Fig. 13)
(a) Pull off the plastic cap and disconnect the spark electrode

lead from the piezo unit.
(b) Undo the tabs on the rear of the piezo unit and remove.
(c) Replace the piezo unit twisting the tabs to retain it firmly in

position. Re-connect the spark electrode lead and re-fit the

plastic cap.

RESISTOR

(a) Check that the mains lead is disconnected.
(b) Remove the screw securing the light bulb cover and lift

upwards.
(c) Remove the clip securing the resistor to the cover and

disconnect the 2 wires.
(d) Replace the Resistor and reassemble in reverse order.

LIGHT SWITCH

Pull off the two flag terminals from the switch noting their
relative positions. Press together the retaining arms on the rear
of the switch and remove from the bezel. Replace the switch
and terminals.

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Short Parts List – Page 9

BAXI EBONY SUPER
B.G.C. No 32 077 37

Key NoDescription G.C N

A Seal - Glass Frame 155 747 043111
B Glass & Frame Assembly 155 758 040955
C Knob- Gas Tap Control 156 431 234551
D Flame Failure Device/Gas Tap E05 653 242512
E Piezo Unit - Vernitron 66111 393 734 042941
F Electro Magnet Unit E01 617 239413
G Injector F11 - Cat 18/230 381 879 092133
H Burner - Aeromatic

Baxi Special 155 949 043210

I Oxy - pilot Assembly 350mm

SIT OP 9402 378 914 236204

J Lead- Electrode 378 915 236199
K Coal Bed 156 429 235149
L Filter - Pilot 205 723 082412

o

Manufact’rs

o

Part N

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Page 10