Glow-worm REVIVAL 37 315 16, FIREBLAZE 37 315 14 Installation And Servicing Instructions

Supplied By www.heating spares.co Tel. [phone]

220562A.05.95

Installation and Servicing Instructions

To be left with the user

REVIVAL

FIRE G.C. No. 37 315 16

FIREBLAZE

FIRE G.C. No. 37 315 14

4031

This is a Cat I2H Appliance

For use with

Glow-worm 45F, 45FR, 56F or 56FR

Back Boiler Units

Customer Services:
Tel: [phone]

One Contact Total Service

Fax: [phone]

BS 6332
BS 5258

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

Supplied By www.heating spares.co Tel. [phone]

191mm

1 G e n e r a l

560mm

4019

191mm

725mm

The instructions consist of three parts, Installation and
Servicing Instructions for the Back Boiler, Installation
and Servicing Instructions for the Fire Front and
Instructions for Use. They are the property of the user
and must be handed to them on completion of the
installation.

1 General Notes and Information

This Glow-worm Gas fire front is to be used only with a
Glow-worm 45F, 45FR, 56F or 56FR Back Boiler Unit.

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

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

Wherever possible, all materials, appliances and
components to be used shall comply with the
requirements of applicable British Standards.

Where no British Standards exists, materials and
equipment should be fit for their purpose and of suitable
quality and workmanship.

Diagram 1.1

Sheet Metal Parts

WARNING. When installing or servicing this fire care
should be taken when handling sheet metal parts, to
avoid any possibility of personal injury.

1.2 Statutory Requirements

The installation of this fire front must be carried out by a
competent person, in accordance with the current issue
and relevant requirements of:

Manufacturer's instructions, supplied.
The Gas Safety (Installation and Use) Regulations,

The Building Regulations, Local Gas Undertaking, The
Building Standards (Scotland) Regulations (applicable in
Scotland), The Health and Safety at Work Act and
Control of Substances Hazardous to Health, The
Electricity at Work Regulations and any applicable local
regulations.

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

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

1.1 Important Notice

This fire front and back boiler are for use on natural gas
as distributed in the United Kingdom (G20) and cannot
be used on any other gas.

220562A

Manufacturer’s instructions must not be taken as
overriding statutory requirements.

1.3 B.S.I. Certification

This fire front is certificated to the current issue of S.I.T
15, for performance and safety. It is, therefore,
important that no alteration is made to the fire without
permission, in writing, from Hepworth Heating Ltd.

2

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1 G e n e r a l

Any alteration that is not approved by Hepworth Heating
Ltd., could invalidate the B.S.I. Certification, the warranty
and could also infringe the current issue of the Statutory
Requirements, see Section 1.2.

C.E Mark

The CE mark on this appliance shows compliance with
Directive 90/396/EEC on the approximation of the Laws
of the Member States relating to appliances burning
gaseous fuels.

1.4 Data

Gas connection - from service cock

Weight - Total - 43kg in two packs
Injector - Bray 18/380
Burner pressure at
setting II - hot - 15.3mbar

- cold - 14.7mbar
Heat input - nominal - 5.28kW (18,000Btu/h)
Heat output - nominal - 1.40kW (4,780Btu/h)
Data label - at rear left hand side

of fire front

All dimensions, except as noted, are given in millimetres.

1.5 Fire Front Location

This fire front can only be fitted to a Glow-worm 45F,
45FR, 56F or 56FR back boiler unit which itself has been
installed in accordance with the Glow-worm Installation
and Servicing Instructions for the back boiler.

Before fitting the fire front it is important to make sure
that the annular space between the back boiler flue liner
and the chimney is sealed at the base and top of the
chimney, as shown in diagram 1.3.

The back boiler air duct acts as a support for the
combustion chamber assembly.

The fire front must be secured to a vertical fire fixing
wall face. This wall face may be a chimney breast or
surround having a minimum flat area as shown in
diagram 1.2.

The combustion chamber flue spigot assembly projects
into the 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.

MAX SHELF DEPTH

305

25

825

INSTALLATION
CENTRE LINE

AIR SPACE

150mm (6in) plug ofMineral Wool
or similar- support as required

305

100

PREPARED BOILER BASE

150

4018

25

FLAT AREA
FIRE FIXING
FACE

Diagram 1.2

3102

SEALING AND
CLAMPING
PLATE

600 mm

1.6 Clearances

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

A shelf or surround of a maximum depth of 150mm may
be fitted, provided clearances are as shown in diagram 1.2.
However, for every 25mm above the fire front the depth
of the shelf may be increased by 25mm.

Combustible furniture or materials must not be placed
closer than 1metre (39in) in front of the fire front.

3

Diagram 1.3

220562A

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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

2.1 Hearth

In ALL cases a fireproof hearth to the minimum
dimensions as shown in diagram 2.1, must be fitted.

2.2 With Surround

The combustion chamber assembly is designed to fit into
a standard builder’s opening as shown in diagram 2.2.

A wider opening will require to be reduced in width
using non-combustible materials.

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

Any combustible material, for example, blown vinyl
wall covering, on the fire front fixing face area of the
surround must be removed, see diagram 2.3.

This area, to the depth removed should then be rendered
with a sand/cement mixture.

2.3 Without Surround

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
fixing wall face.

The information regarding the fire front opening must be
followed together with the last two paragraphs of “With
Surround”.

13mm MIN

NON-COMBUSTIBLE

MATERIAL

FIREBLAZE SHOWN

406mm
to
450mm

4009

350mm
MIN

674mm MIN

Diagram 2.1

3099

560mm
to
590mm

2.4 Flue and Ventilation

The back boiler flue collector assembly accepts the
combustion chamber assembly flue spigot.

Note. Provision must have been made during
installation of the back boiler for the total ventilation
requirement of the combined appliance. See the relevant
Section in the Back Boiler Installation and Servicing
Instructions

270

BUILDERS

OPENING

INSTALLATION

CENTRE

REMOVE
COMBUSTIBLE
MATERIAL FROM
THIS AREA

PREPARED
BASE

270

LINE

C

PREPARED

L

BASE

Diagram 2.2

2967

719

50

Diagram 2.3

220562A

4

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3 U n p a c k i n g

4029

GAS
SUPPLY
TUBE

8mm
OLIVE

INSULATION

COMBUSTION
CHAMBER
ASSEMBLY

LITERATURE

CONTROL KNOB
AND EXTENSION

FUEL

PACK

FUEL
EFFECT
PIECES

FUEL
EFFECT
BED

FUEL

EFFECT

BED

BASE

UNION
NUT

3/8 in
OLIVE

9V ALKALINE
BATTERY

FIRE
FRONT

FRET

FIRE
FRONT

FRET

LOOSE
ITEMS
PACK

FIRE
BODY
PACK

REVIVAL

CASING

PACK

ASHPIT COVER

ASHPIT COVER

5

FIREBLAZE

CASING

PACK

Diagram 3.1

220562A

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3 U n p a c k i n g

3.1 Unpacking

2669

The fire front is delivered in two packs, one contains the
combustion chamber assembly, fuel pack(s) and loose
items pack. The other contains the fire front, fret, ash pit
cover and fire control knob extension.

BACK BOILER
ONLY 'ON'

GAS SERVICE
COCK UNION

Refer to diagram 3.1 to identify the parts.
Check contents of loose items pack against packed list.

3.2 Gas Supply to Fire Front

Check that the gas service cock is in the boiler only on
position, see diagram 3.2.

The inlet supply tube is packed with the loose items.
The supply tube may need to be cut at the larger end

dependent upon the position of the back boiler unit in the
opening.

Measure the distance “C”, see diagram 3.3, from the
front mark “P” on the air duct to the fire fixing wall face.

Use a straight edge across the opening.
Shorten the gas supply tube by distance “C” + 21mm at

the larger end.
The maximum distance for “C” will be 25mm (1inch).
Deburr the tube end inside and out.

BACK BOILER
AND FIRE 'ON'

'OFF'

Diagram 3.2

"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'

BACK
BOILER

(MAX. SHOWN) 'C'

AIR DUCT

'C'

GAS FIRE
SUPPLY TUBE

3097

'C'

FIRE FIXING
WALL FACE

Diagram 3.3

220562A

6

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

4.1 Positioning the Combustion Chamber
Assembly

Note: Before fitting, again make sure the wall surface to
which the combustion chamber assembly is to be fitted is
vertical and flat. Any unevenness may cause the whole
assembly to become twisted or distorted when fixing to
the wall.

Place the combustion chamber assembly into the fire
opening and make sure that the flue spigot fits into the
boiler flue collector assembly and locates onto the back
boiler combustion chamber extension and burner
assembly, see diagram 4.1.

Push well back to the fire fixing wall face.
Mark the four combustion chamber assembly fixing

points (making sure that the area is sufficiently firm),
through the holes in the surround refer to diagram 4.2.

Pull the combustion chamber assembly forwards and
remove.

Drill the fire front fixing wall face, using a 10mm
masonry drill to a minimum depth of 40mm to accept the
reusable anchor nuts and screws provided.

FLUE COLLECTOR
ASSEMBLY

FLUE
SPIGOT

2970

Place the anchor nuts in the holes.
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 combustion chamber assembly must be
used and extra care taken.

Fit the combustion chamber assembly, making sure that
it is correctly positioned onto the back boiler unit, see
diagram 4.1, secure with the screws provided.

Important: If the electrical supply to the boiler comes
from the right, make sure that when fitting the
combustion chamber assembly the cable is routed and
clear, as shown in diagram 4.1.

B.B.U. COMBUSTION

FIRE FIXING
WALL FACE

CHAMBER EXTENSION
AND BURNER ASSEMBLY

Diagram 4.1

COMBUSTION CHAMBER ASSEMBLY

SECURING
SCREW

COMBUSTION CHAMBER ASSEMBLY

=SECURING SCREW POSITION

Diagram 4.2

2971

ANCHOR
NUT

7

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

4.2 Gas Connection

Place the union nut and olive, from the loose items pack,
onto the prepared end of the gas supply tube, see
diagram 4.3.

Connect the gas supply tube, as diagram 4.3 tighten the
nut and olive at the gas service cock and union nut at the
gas tap.

STRAIN
RELIEF
BRACKET

UNON
NUT

BURNER
FIXING
SCREW

UNION
NUT AND
OLIVE

4021

UNION
NUT AND
OLIVE

3/8 IN
OLIVE

Diagram 4.3

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 I n t e r n a l P a r t s .

5.1 Lighting and Testing

Make sure that the gas tap is in the off position, that is,
the flat on the drive rod faces the wall, see diagram 5.1.
Take the length of black insulating material from the
loose items pack. Slide the insulation down the drive
rod as shown in diagram 5.1 and then fit the control
knob.

MAKE SURE THAT THE ELECTRICAL SUPPLY TO
THE BACK BOILER IS SWITCHED OFF.

Take the ash pit cover from the packing, make sure that
the harness strain relief is fully located into the slot and
that the locknut is tightened.

Now fit the strain relief bracket by removing the burner
fixing screw, place the strain relief bracket on top of
burner end bracket and then replace screw, see
diagram 4.3.

Connect the wiring harness to the microswitch and
electrode, see diagram 7.3 and 7.4.

Fit the battery, from the loose items pack, see
diagram 9.1.

Note the ash pit cover can be left connected up to the
micro switch and tap.

Remove the pressure test nipple screw and fit a suitable
pressure gauge, see diagram 5.2.

Turn the gas service cock to BACK BOILER AND
FIRE “ON”, see diagram 3.2.

To check for gas soundness apply leak detection fluid to
the two joints on the previously fitted gas supply tube.

WARNING: Take care when carrying out the following
check, as the burner flame is fully exposed.

Push the control knob in slightly and turn it
anti-clockwise to position I , now fully push in,
clicking of the ignition will be heard and the burner will

light.
IMPORTANT: If the burner does not light within 3

seconds, release the tap, wait 10 seconds and repeat the
lighting operation.

Keep the knob pushed in for 10 seconds, during this time
the ignition system will continue to operate, indicated by
the clicking.

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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 I n t e r n a l P a r t s .

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

With the burner lit. Check joints at all tap positions for
gas soundness in accordance with the current issue of
BS6891.

To change settings, refer to diagram 5.4.
Check that the gas pressure is as stated in the Data

Section or on the Data Label.
If there is any doubt about the gas rate, check at the

meter, having turned off all other gas appliances and
pilot lights.

The gas rate for this fire front is about 0.63m3/h
(17.75ft3/h), equal to, after 10 minutes, about 3 minutes
23 seconds for 1ft3.

Push in and turn the control knob fully clockwise to turn
off, remove the pressure gauge, replace the test nipple
screw and ensure that a gas tight seal is made.

5.2 Fire Front

Remove the castings from the packaging.

LOCATION
PEG (2)

4020

PRESSURE
TEST POINT

Diagram 5.2

4017

Lift the fire front up, take care as it is heavy, and slide it
down to locate the pins into the brackets, see
diagram 5.3.

Secure the fire front to the combustion chamber
assembly (base), using the M4 screw provided in the
loose items pack, see diagram 5.3.

WALL LINE

12˚

CONTROL KNOB

DRIVE ROD
Flat facing the wall

3517

LOCATION
HOLES

FIRE FRONT
RETAINING
NUT

FIRE

FRONT

SECURING

SCREW

Diagram 5.3

INSULATION SLEEVE

Diagram 5.1

9

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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 I n t e r n a l P a r t s .

5.3 Internal Parts - Fitting

3518

CAUTION. If the insulation, fuel effect bed base, fuel
effect bed and fuel effect pieces are damaged do not light
the fire or further test before replacement parts are fitted.

USE ONLY THE “FUEL EFFECT” APPROVED FOR
THIS FIRE FRONT.

To fit the insulation, fuel effect bed base, (pulling it
forward to fit by using the finger holes) fuel effect bed
and fuel effect pieces follow the sequence given in
diagram 5.5, 5.6, 5.8 and 5.9.

Diagram 5.7 shows the different shapes of the fuel effect

PUSH IN AND TURN
ANTI-CLOCKWISE

pieces and fuel effect bed.
Fit fret, see diagram 5.10.

5.4 Heat Settings

Refer to diagram 5.4.
In the unlikely event of the burner going out whilst fire

is on, turn off. Wait 3 minutes before relighting.

LOW AND IGNITION

HIGH

FUEL EFFECT BED BASE

Diagram 5.4

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

INSULATION

Diagram 5.5

FINGER
HOLE

A

4016

4015

FUEL EFFECT BED BASE

FINGER HOLES

LOCATING
BRACKET

“A” NOTE: USE FINGER HOLES

LEFT AND RIGHT TO PULL
DOWN FUEL EFFECT BED BASE

220562A

10

PULL
DOWN

Diagram 5.6

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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 I n t e r n a l P a r t s .

Oblong fuel effect
pieces (3)

Round fuel effect
pieces (2)

Triangular fuel effect
pieces (5)

NOTE: The depressions indicate the position

of fuel effect pieces.
The 2 front fuel effect pieces have no
depressions for location.
(Dotted lines indicate positions.)

4013

4014

POSITION OF ROUND

FUEL EFFECT PIECES

POSITION OF ROUND AND OBLONG

FUEL EFFECT PIECES

Depressions

FUEL EFFECT
BED

Positions for 2
front effect pieces

FUEL
EFFECT
BED

Diagram 5.7

FUEL
EFFECT
BED REAR
SUPPORT (2)

4012

POSITION OF ROUND OBLONG

AND TRIANGULAR FUEL

EFFECT PIECES

LOCATION
PEG (2)

Diagram 5.9

4014

FUEL EFFECT
BED
FRONT
SUPPORT (2)

LOCATION

Diagram 5.8

HOLE (2)

11

FRET

Note: Take care not to damage fuel
bed and fuel when lifting the fret

Diagram 5.10

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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 I n t e r n a l P a r t s .

5.5 Test for Clearance of Products

Notes.
(a) WARNING. The fire front burner has an open flame.
(b) WARNING: Take care. The appliance will get hot

during testing.
(c) For the test you will need a smoke match and an

extension.
(d) 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.

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

TEST: WHERE NO FAN IS PRESENT
Close all outside doors, doors and windows in the room

in which the appliance is fitted.
Light the fire front only and set to tap position II. After

5 minutes apply a spillage test as shown in diagram 5.11.

38mm

4030

38mm

SMOKE
MATCH

Diagram 5.11

4011

If spillage occurs, leave fire front alight for up to a
further 10 minutes and repeat test. Turn the fire front
off.

Next light the boiler only. After 10 minutes apply
spillage test as shown in diagram 5.11.

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

Leave the boiler alight.
Now light fire front. After 10 minutes apply spillage

tests as shown in diagram 5.11.
If spillage occurs leave the boiler and fire front alight for

up to a further 5 minutes and repeat the tests.
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,
whether or not gas fired). With the fan switched off
carry out the appropriate spillage test with all doors and
windows closed, as above.

If the above spillage test is satisfactory proceed as
follows:

ASHPIT
COVER

FRET

ASHPIT
COVER

Open all doors connecting the room containing the
appliance 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 all
doors and windows in that room. Switch the fan on and
repeat the spillage test as above.

5.6 Completion

Fit ash pit cover by hooking up under the fret, see
diagram 5.12.

220562A

12

FIREBLAZE SHOWN

Diagram 5.12

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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 make sure
that they are understood.

Instruct the user in the correct operation of the fire front
and boiler.

Advise the user that, if desired, the control knob
extension, from the loose items pack, can be used, see
diagram 6.2.

Before demonstrating lighting the fire front with a spill
or long match, warn the user that the fire front has an
exposed flame. Refer to diagram 6.1.

Hold a lighted spill or long match and insert it into the
hole as shown in diagram 6.1, position the spill so that
the flame is over the burner.

Keep the spill in position, push in slightly and turn the
gas tap knob to position I , now fully push in for
about 10 seconds and the burner will light, if not, repeat

the process.
Once lit operate the gas tap normally.
Advise that this is a temporary measure only and the

battery should be replaced or the ignition system be
repaired as soon as possible.

40103519

SPILL

Diagram 6.1

CONTROL
KNOB
EXTENSION

Advise the user that there are wires behind the ash pit
cover and care should be taken when removing it.

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

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

Advise that to ensure the continued efficient and safe
operation of the appliance it is recommended that it is
checked 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.

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 out any property containing a gas appliance

It is the law that any servicing must be carried out by a
competent person.

Reminder, leave these instructions with the user.

CONTROL
KNOB

Diagram 6.2

13

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7 S e r v i c i n g

7.1 Notes.

(a) To ensure the continued efficient and safe operation

of the appliance it is recommended that it is checked
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 any servicing must be carried out by

a competent person.

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

any servicing.

(d) BEFORE SERVICING ISOLATE THE GAS AND

ELECTRICAL SUPPLIES.

(e) After servicing of parts always test for gas

soundness with a suitable leak detection fluid.
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.

WARNING: Take care as the burner flame is fully
exposed.

(f) Carry out functional check on controls.

(h) Unless stated otherwise reassembly of all

components should be in the reverse order to that for
removal.

(j) It is recommended that the back boiler be serviced at

this time.
Refer to Back Boiler Installation and Servicing

Instructions.

7.2 Fire Front - Castings

Remove the ash pit cover by unhooking from the fret,
take care as there are wires attached, see diagram 5.12.
The ash pit cover can be left attached by the harness to
the micro switch/gas tap.

Remove the fret by unhooking from the fire surround,
see diagram 5.10.

When removing the fire front, first remove the M4 screw
from the base of the combustion chamber assembly, see
diagram 5.3. Lift the fire front up to clear the location
pins, see diagram 5.3.

Take care when removing the fire front as it is heavy.

(g) After removing or disconnecting any pipe work

always make sure that it is refitted correctly and
does not interfere with the fitting of the fire front.

GAS INLET
UNION

GAS INLET
UNION

L.H. MOUNTING
BRACKET

INJECTOR

4028

ELECTRODE
BRACKET
SECURING
NUT

THERMOCOUPLE
LOCK NUT

L.H. BURNER
MOUNTING
SCREW

THERMOCOUPLE BRACKET

220562A

14

WING NUT

Diagram 7.1

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7 S e r v i c i n g

7.3 Fuel Effect and Insulation

Carefully remove the fuel effect pieces, see diagram 5.8.
Carefully remove the fuel effect bed by lifting clear, see

diagram 5.7.
Carefully remove the fuel effect bed base by lifting clear,

see diagram 5.6.
Note: When refitting the fuel effect bed base make sure

it is correctly fitted, see insert “B” in diagram 5.6.
Carefully remove the insulation by lifting clear, see

diagram 5.5.
Clean these items with a soft brush, do not use a vacuum

cleaner.
If any of these items are damaged they must be replaced

before the fire front is used again.
Clean out the combustion chamber base with a brush or

vacuum cleaner.

7.4 Combustion Chamber Assembly

Make sure that the gas supply is isolated at the gas
service cock, fire off position, see diagram 3.2.

Disconnect the gas supply tube at the gas service cock,
see diagram 4.3.

Remove the four securing screws, see diagram 4.2.
Pull the combustion chamber assembly forwards and

remove by lifting over the gas service cock.
Take care if the ash pit cover and harness are attached to

the micro switch/tap.

7.5 Burner

The burner can be cleaned whilst in place, using a
suitable brush and vacuum cleaner.

Do no use a brush with wire bristles.

7.6 Injector

Clean around the injector.
If necessary disconnect the gas inlet union nut from the

injector, see diagram 7.1. Remove the injector. Do not
use a wire or sharp instrument to clean out the holes.

THERMOCOUPLE
NUT

THERMOCOUPLE

4024

LOCK NUT AND
SHAKE PROOF
WASHER

15

Diagram 7.2

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7 S e r v i c i n g

Electrode tip must fall

ELECTRODE DETAIL

within boxed area

1mm

3.5 to

4.5mm

1mm

2mm

208 CHECK DIMENSION

7.7 Thermocouple and Electrode

Inspect and clean the tips of both items.
Check that the electrode spark gap is as shown in

diagram 7.3.

THERMOCOUPLE
DETAIL

3 to
5mm

Centreline of thermocouple must
fall within boxed area on third row
of ports

2mm

2mm

MICRO
SWITCH
LEADS

4026

Diagram 7.3

4023

7.8 Gas Tap and Micro Switch Assembly

Note. This item need not be serviced every year.
If servicing is required, remove the leads at the

microswitch and electrode then disconnect all union
connections at the tap, see diagram 7.5.

Disconnect the thermocouple from the tap, see
diagram 7.2.

Remove the bottom split pin from the connecting drive
rod, see diagram 7.5.

Disconnect the gas supply pipe union and remove the
pipe.

To remove the gas tap and micro switch remove the two
screws from the gas tap bracket, see diagram 7.5 and
withdraw the tap complete with bracket.

To service the gas tap, remove the operating disc, see
diagram 7.6 and lift off.

Remove the gas tap niting plate securing screws, see
diagram 7.6. Take care as there is a spring beneath the
niting plate. Remove the plug, pin, spring washer, plain
washer and “O” ring, see diagram 7.6.

R.H. SECURING
BRACKET
SECURING
SCREW

IGNITION
LEAD

WIRING
HARNESS

EARTH
LEAD

STRAIN RELIEF
LOCKNUT

Diagram 7.4

Clean and relubricate using a suitable grease.
When replacing make sure the operating disc, with

circlip underneath, micro switch and leads are correctly
located, see diagram 7.6 and 7.4.

220562A

16

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7 S e r v i c i n g

4025

UNION
NUTS

GAS
SUPPLY

CONNECTING
DRIVE ROD

SPLIT
PIN

GAS TAP
BRACKET
SECURING
SCREW (2)

GAS TAP
SECURING
SCREW (2)

UNION
NUT

THERMOCOUPLE
NUT

OPERATING
DISK

CIRCLIP

CONTROL
SPINDLE

PIN

SPRING

WASHER

'O' RING

PLUG

Diagram 7.5

MICRO SWITCH
BRACKET

MICRO SWITCH

SECURING
SCREW (2)

SECURING
SCREW (2)

4022

GAS TAP
BRACKET

GAS
TAP
BODY

17

Diagram 7.6

220562A

Supplied By www.heating spares.co Tel. [phone]

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

4483

START HERE

YES

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

NO

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

YES

NO

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

YES

Replace faulty electrode and
reassemble ignition system.
Turn tap to energise igniter.
Does the fire light ?

FIRE WILL NOT LIGHT

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.

NO

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 ?

NO

YES

NO

YES

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

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

YES

Change ignition unit.

Check several times that ignition is satisfactory.

YES

NO

Renew ignition lead and
reassemble ignition system.

NO

Rectify faulty leads or
replace micro switch.

Diagram 8.1

220562A

18

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

8.1 Fire Front Ignition

Remove the ash pit cover, front fret and fuel effect beds
and pieces.

Refer to diagram 8.1 “Fire Front Ignition Fault Finding”,
diagram 8.4 and 8.5.

8.2 Thermocouple

To test a thermocouple, a meter with a range of 0 to
30mV is required together with a thermocouple
interrupter test unit similar to the British Gas Minitest 6
Multimeter and Interrupter.

Refer to fault finding diagram 8.3 and diagnosis graph,
diagram 8.2.

17

16
15
14
13
12

11

10

9
8

Open Circuit Voltage (millivolts)

7

01234567891011

Closed Circuit Voltage (millivolts)
DIAGNOSIS GRAPH FOR FIRE

THERMOCOUPLE CIRCUIT

ABC

Diagram 8.2

0065M

0086M

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.

Is voltage greater
than 7mV?

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.

THERMOCOUPLE
CIRCUIT IS
SATISFACTORY

In which area of the
graph is the intersect

B

NO

YES

Faulty thermocouple.
Replace.

A

Faulty thermocouple.
Replace.

C

Faulty magnet unit in gas tap.
Replace gas tap

19

Diagram 8.3

220562A

Supplied By www.heating spares.co Tel. [phone]

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

ELECTRODE

EARTH

SPARK
GENERATOR

BROWN

AV PP3 9V
ALKALINE
BATTERY

BROWN

MICRO
SWITCH

Diagram 8.4

3177

3123

ELECTRODE

MICRO
SWITCH

SPARK GENERATOR

BROWN

BROWN

EARTH

Diagram 8.5

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

Notes
(a) Make sure the fire front is cold before replacing any

parts.

(b) Replacement of parts must be carried out by a

competent person.
(c) Remove the fire front castings as in Section 7.2.
(d) Remove the fuel bed, fuel effect bed base, fuel effect

pieces and insulation as in Section 7.3.
(e) BEFORE REMOVING OR REPLACING ANY

FIRE FRONT PART TURN THE GAS SERVICE

COCK TO “BACK BOILER ONLY ON”, see

diagram 3.2.
(f) ISOLATE THE ELECTRICAL SUPPLY TO THE

BACK BOILER.
(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.

WARNING: Take care as the burner flame is fully

exposed.
(i) After removing or disconnecting any pipe work

always make sure that it is refitted correctly and

does not interfere with the fitting of the fire front.
(j) Unless stated otherwise reassembly of all parts is in

the reverse order to removal.

220562A

9.1 Burner

Disconnect the gas inlet pipe union nut, the electrode
assembly nut and the left hand burner mounting bracket
securing screw, see diagram 7.1.

Remove the burner wing nut, releasing the burner.
Remove the injector, burner alignment screw and burner

left hand mounting bracket, see diagram 7.1.

9.2 Injector

To remove the injector follow the instructions in
Section 7.6, paragraph 2.

9.3 Gas Tap and Micro Switch Assembly

Follow the instructions in Section 7.8 up to and
including paragraph 6.

Note: When replacing micro switch now follow
instructions in Section 7.8 up to and including
paragraph 7.

Make sure that the wiring harness strain relief is
correctly located into the slot secured by the locknut, see
diagram 7.3 and 7.4.

9.4 Electrode

Disconnect ignition lead from the electrode and remove
securing nut to release the electrode from the burner, see
diagram 7.3.

When replacing make sure that the spark gap is as shown
in diagram 7.3.

20

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

9.5 Ignition Lead

Disconnect the lead from the spark generator and
electrode. Slacken the locknuts securing the strain
reliefs see diagram 7.4 and 9.1 and then remove the
harness. Remove the strain relief(s) securing screws and
remove the ignition lead from the harness.

When replacing the harness make sure that it is correctly
fitted and secured by the strain reliefs.

9.6 Thermocouple

Disconnect the thermocouple at the gas tap, see
diagram 7.2, remove the wing nut and withdraw the
thermocouple complete with its bracket.

Remove the thermocouple from the bracket.
Make sure that when refitting the thermocouple bracket

the dimple on it engages in the hole in the burner
bracket.

When refitting the thermocouple only tighten the union
nut at the gas tap a quarter turn beyond finger tight.

9V ALKALINE
BATTERY

9.7 Spark Generator

Disconnect the ignition lead and brown cables from the
spark generator.

Slacken the strain relief locknut and remove from the
support bracket.

Remove the two screws securing the spark generator,
heat shield and strain relief support bracket and earth
terminal then pull the generator clear, see diagram 9.2.

When reconnecting the polarity of the connections from
the generator to the micro switch is not important.

9.8 Battery

The battery is 9V and we recommend that it be of the
alkaline type, obtained locally.

When fitting make sure that it is connected as shown in
diagram 9.1.

POSITIVE

POSITIVE

3125

WIRING
HARNESS

(Fireblaze Illustrated)

SUPPORT
BRACKET

STRAIN
RELEIF

ASHPIT
COVER

NEGATIVE

NEGATIVE

BATTERY CONNECTION

Diagram 9.1

ASHPIT
COVER

3124

STRAIN
RELEIF

9V ALKALINE
BATTERY

(Fireblaze Illustrated)

21

HEAT
SHIELD

SPARK
GENERATOR

SECURING SCREW (2)

Diagram 9.2

220562A

Supplied By www.heating spares.co Tel. [phone]

1 0 S p a r e P a r t s

When spare parts are required please apply to your local
supplier.

Use only the Fuel Effect approved for this fire front.
Do not use more Fuel Effect pieces than shown.
Please quote the name of the appliance, Fireblaze or

Revival with 45F, 45FR, 56F or 56FR Back Boiler Unit
together with the appropriate GC numbers. Refer to data
label, positioned on the rear of the left hand side of the
fire front or the appliance name label positioned on the
ashpit cover.

The fire front serial number, which must be quoted, can
be found on the label on the fire chassis adjacent to the
boiler electrical control box.

The boiler serial number can be found on the base, after
removal of the ashpit cover.

Key No Part No Description GC No

1 445012 Control tap assy c/w micro switch 152 966
2 202179 Spark generator - spare 152 949
3 205711 Injector 398 410
4 202622 Electrode 162 064
5 202430 Thermocouple 385 865
6 WW4606 Ignition lead 334 621
7 210209 Fuel effect pieces - pack 162 061
8 210210 Fuel effect bed 162 071
9 445012 Control knob assembly 152 966
10 230100 Control knob extension 152 920
11 800258 Micro switch assembly 152 941

220562A

22

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1 0 S p a r e P a r t s

7

4027

5

4

8

2

6

1

3

10

11

9

23

Diagram 10.1

220562A

Supplied By www.heating spares.co Tel. [phone]

Control of Substances Hardous to Health

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
After handling wash hands thoroughly.

INSULATION PADS/CERAMIC FIBRE
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.

220562A

24