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

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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
Glow-worm 45F, 45FR, 56F or 56FR
Back Boiler Units
Customer Services: Tel: (01773) 828100
One Contact Total Service
Fax: (01773) 828070
BS 6332 BS 5258
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
Supplied By www.heating spares.co Tel. 0161 620 6677
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
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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
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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
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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
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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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5.5 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.
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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
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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. 0161 620 6677
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. 0161 620 6677
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
Supplied By www.heating spares.co Tel. 0161 620 6677
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. 0161 620 6677
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
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