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1 G e n e r a l N o t e s a n d I n f o r m a t i o n
485
2449
783
All dimensions on diagrams are in millimetres (except as noted)
If this fire front is to be fitted to a Glow-worm back
boiler WITHOUT a combustion products discharge
safety device please read the supplementary instructions
at the back of this booklet.
The instructions consist of three parts, Installation and
Servicing Instructions for the Back Boiler Unit,
Installation and Servicing Instructions for the Fire Front
and Instructions for Use, which includes the Guarantee
Registration Card. The instructions are an integral part
of the appliance and must, to comply with the current
issue of the Gas Safety (Installation and Use)
Regulations, be handed to the user on completion of the
installation.
This Glow-worm gas fire front is to be used with a
specially designed Glow-worm Back Boiler Unit only.
The fire front is delivered packed in one cardboard
carton, which contains all the parts necessary for the
installation of the fire front, see Section 4.
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 exist, materials and
equipment should be fit for their purpose and of suitable
quality and workmanship.
1 General Notes and Information
1.1 Important Notice
The fire is fitted with a safety device which will shut it
down if there is a lack of oxygen. If the fire shuts down
frequently for no apparent reason the first things to be
checked are the chimney and air inlets into the room.
An additional cause could be that the filter, in the gas tap
has become blocked. Any problems found must be put
right, by a competent person, before the fire is used
again.
This fire front is for use only on G20 gas.
Sheet Metal Parts
WARNING. When installing or servicing this fire front
care should be taken when handling sheet metal parts, to
avoid any possibility of personal injury.
PREPARED
BASE
338692
Diagram 1.1
221100C
2
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1 G e n e r a l N o t e s a n d I n f o r m a t i o n
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 provided.
The Gas Safety (Installation and Use) Regulations,
The Building Regulations, The Local Gas Undertaking,
The Local Water Company, The Building Standards
(Scotland), applicable in Scotland, The Health and
Safety at Work Act, The 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:-
BS5440 Part 1 and 2, BS5871, BS6891, BS7671.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
CE Mark
The CE mark on this appliance shows compliance with:-
1. Directive 90/396/EEC on the approximation of the
Laws of the Member States relating to appliances
burning gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the
Laws of the Member States relating to electrical
equipment designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the
Laws of the Member States relating to electromagnetic
compatibility
1.3 Data
Gas connection -from boiler service cock
2476
446
INSTALLATION
CENTRE LINE
FLAT AREA
FIXING FACE
446
100
MIN
PREPARED BOILER BASE
MAX SHELF
DEPTH
150
883
Diagram 1.2
1.4 Fire Front Location
This fire front can only be fitted to a Glow-worm
45/2 or 56/2 back boiler unit which itself has been
installed in accordance with the Glow-worm Installation
and Servicing Instructions.
The back boiler air duct acts as a support for the fire
front. The top of the fire front must be secured to the
vertical fire front fixing wall face. This wall face may be
a chimney breast or surround, see diagram 1.2. The fire
front flue spigot projects into the back boiler flue
collector assembly.
The gas supply is taken from the back boiler gas service
cock.
The back boiler must be correctly positioned in the
builder’s opening as the fire front is located by
connection to it.
Electrical supply - from boiler electrical control
box 230V~50Hz
Electrical power input -50W fire only
Weight -36kg (79lb)
Injectors- upper -Bray Cat 77/160
Heat output -12,100 Btu/h nominal
Data label -bottom right of combustion
chamber side.
All dimensions, except as noted, on diagrams are in
millimetres.
1.5 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 in front of the fire front.
3
221100C
Page 4
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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
Note. Refer to Section 2 in the Back Boiler Installation
book before starting.
2.1 With Hearth
A fireproof hearth under the fire front must have the
minimum dimensions as shown in diagram 2.1.
2.2 With Surround
See diagram 2.2. The fire front casing should cover the
opening.
A wider opening will require any opening left to be
covered with a non combustible finished material, see
diagram 2.3.
Any greater opening will require corner infill.
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 on the fire front fixing face
area of the surround must be removed, see diagram 2.2.
This area, to the depth removed should then be rendered
with a sand/cement mixture.
13mm MIN
NON- COMBUSTIBLE
MATERIAL
706mm
MIN
INSTALLATION CENTRE LINE
CORNER
IN-FILL
(not required
to be full
depth of
opening
2451
300mm MIN
50mm
MIN
Diagram 2.1
1553
510mm
to
580mm
560mm MIN
to
590mm MAX
2.3 Without Surround or Hearth
The fire front fixing wall face must be flat over an area
as shown in diagram 1.2. This also shows the minimum
clearances for shelves or projections on the fire front
fixing wall face.
The information in the last two paragraphs of “With
Surround” above should now be followed.
Under no account must carpet or other combustible
material be laid directly under the fire front, unless the
minimum clearances shown in diagram 1.2 is achieved.
The dimension is taken from the bottom of the fire front
plinth to the top of the carpet pile or other floor covering.
2.4 Flue
The back boiler flue collector assembly accepts the fire
front flue spigot.
Note. Provision must have been made during
installation of the back boiler for total ventilation
requirement for the combined appliance. See relevant
section in Back Boiler Installation and Servicing
Instructions.
PREPARED
BASE
100mm
MIN
270mm
INSTALLATION
REMOVE
COMBUSTIBLE
MATERIAL FROM
THIS AREA
BUILDERS
OPENING
CENTRE
LINE
C
L
450mm
MIN
Diagram 2.2
2555
270mm
750mm
135mm
PREPARED
BASE
221100C
4
Diagram 2.3
Page 5
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3 F i r e F r o n t P r e p a r a t i o n
FUEL
SUPPORT
GRID
INSULATION
CASING
COALS
HEARTH
CASTING
TRIM
CONTROL KNOB
CASING
FIXING PACK INCLUSIVE
OF BACK BOILER
SENSING TUBE
FLUE
SPIGOT
BODY
ASSEMBLY
2457
COLOURED
GLASS
GLASS
BASE
3.1 Unpacking
Remove the fire front flue spigot assembly.
Lift out the polystyrene tray which contains all the loose
parts, check these against diagram 3.1, also a loose items
pack, check contents against packed list.
Lift the outer carton clear to leave the fire front sitting on
the base tray.
The front glass panel must be removed before removal of
the fire front casing.
To remove the front glass panel release the three knurl
headed nuts and clamping plate, see diagram 3.2.
Place the glass panel aside until required.
To remove the casing release the two screws, as
diagram 6.26 tilt the casing forwards and lift it off,
leaving the fire front sitting in the base.
Note. Remove the black protective film from the canopy
trim, hearth trim and glass panel sides.
PLINTH
Diagram 3.1
2468
CLAMPING
PLATE
KNURLED
SCREW
(3 OFF)
FRONT
GLASS
PANEL
5
Diagram 3.2
221100C
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3 F i r e F r o n t P r e p a r a t i o n
3.2 Flue Spigot Assembly
Note. This is marked “Homeglow BBU”.
Leave the fire front sitting in the base tray.
Secure the spigot assembly to the fire front back with the
self tapping screws provided, from the loose items pack,
see diagram 3.3.
Note, there are eight self tapping screws in the pack, two
are spare.
3.3 Gas Supply to Fire Front
2452
FLUE
SPIGOT
SECURING
SCREW
Check that gas service cock is in the Off position,
see diagram 6.3.
The inlet supply tube is packed with the fire front plinth.
This supply tube may need to be cut, at the plain end,
dependent on the model and position of the back boiler
in the opening.
Measure the distance “C”, see diagram 3.4, from the
front mark “P” on the air duct to the fire front fixing wall
face.
Use a straight edge across the opening.
Shorten the plain end of the gas supply tube by distance
“C”. No shortening is required when mark “P” is level
with the fire fixing wall face, “C” being zero.
The maximum distance for “C” will be 67mm.
Deburr the tube end inside and out.
3.4 Back Boiler Sensing Tube Fixing
Removed plastic ferrule from bulkhead connector.
Fix the flared end of the back boiler sensing tube to the
bulkhead connection on the boiler air duct with the
tubing nut provided. Slide the sensing tube mounting
bracket assembly over the back boiler sensing tube and
fix to the casting with the screw provided,
see diagram 3.5. Fit the sensing tube fitting onto the
fitting assembly, see diagram 3.5. Take care not to
damage the filter.
Important. Make sure that the mounting bracket
assembly is pushed back to the front face of the boiler
casting, and check 3mm. distance is achieved and the
back boiler sensing tube does not extend above sensing
tube fitting, see diagram 3.5.
Note. After fitting the combustion products discharge
safety device sensing tube please refer to the
'commisioning' section of the back boiler unit and relight
the boiler to test the device.
Diagram 3.3
*'C' = Distance from fire fixing wall face to
datums on back boiler air duct. This represents
the length of pipe that requires cutting off.
56
45
'P'
* 'C'
BACK
BOILER
AIR
DUCT
* 'C'
FIRE FIXING
WALL FACE
GAS FIRE
SUPPLY TUBE
FILTER
SENSING
TUBE
FITTING
ASSEMBLY
3 mm
BACK
BOILER
SENSING TUBE
Diagram 3.4
THREAD CUTTING
SCREW(Taptite)
SENSING
TUBE
FITTING
ASSEMBLY
FRONT FACE
OF BOILER
CASTING
1558
6138
TUBING
NUT
221100C
6
BULKHEAD CONNECTION
BOILER AIR DUCT
Diagram 3.5
Page 7
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4 E l e c t r i c a l W i r i n g
4.1 General
The fire front electrical supply, 230V~50Hz, is taken
from the back boiler electrical control box.
A cable and plug assembly is supplied in the “loose
items” pack.
Refer to Back Boiler Installation Instructions,
Section 5.2 Control Box Access, for control box
removal.
Isolate electrical supply to the boiler.
4.2 Wiring
WARNING. This fire front must be earthed.
The cable supplied must be connected to the terminal
strip and earthing post inside the control box. Note,
these connections can be made when the back boiler
electrical connections are made, see back boiler
installation instructions, diagram 5.1 or 5.1A.
Thread cable through front of control box, see
diagram 4.1.
Connect incoming mains earth conductor to unwired
earthing post, see diagram 4.1, 4.2 or 5.1A, 5.5A in Back
Boiler Installation Instruction.
4.3 Testing
Checks to ensure electrical safety should be carried out
by a competent person.
After installation preliminary electrical system checks as
below should be carried out:
1. Test insulation resistance to earth of mains cables.
2. Test the earth continuity and short circuit of all
cables.
3. Test the polarity of the mains.
4498
EARTH
STUD
TERMINAL
STRIP
Connect incoming mains neutral conductor to N and live
conductor to L.
If additional controls are to be used the link between SL1
and SL2 MUST be removed.
The controlling supply from any such devices are to be
connected to terminal SL2, see diagram 4.2 or 5.1A, in
Back Boiler Installation Instruction.
Note, both the fire front and back boiler must be
supplied from the same isolating switch.
Place the strain relief grommet, from the loose items
pack, around the cable, squeeze the halves together.
Position location flats and push grommet into the hole in
the control box, see diagram 4.1.
Refer to “Control Box Fitting” in the Back Boiler
Installation Instructions.
CABLE/CONNECTOR
ASSEMBLY
EARTH
STUD
g/y
CONNECTOR
g/y
br
b
STRAIN
RELIEF
GROMMET
Diagram 4.1
TO BOILER
b
bk
b
br
L1
N1
FIRE CABLE
CONNECTION
IN THE BACK BOILER
CONTROL BOX
br
L
SL1
SL2
bk
br
bk
230V~50Hz
MAINS SUPPLY
FUSED AT 3AMP
4499
N
b
g/y
7
KEY
brBROWN
bBLUE
bk BLACK
g/y GREEN AND YELLOW
Diagram 4.2
221100C
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5 I n s t a l l a t i o n
5.1 Positioning the Fire Front
Remove the fire front from the base tray.
Place the fire front onto the back boiler air duct, check
that the fire front spigot is central in the flue collector
assembly, push into contact with the fire front fixing
face, see diagram 5.1.
1561
FLUE
COLLECTOR
ASSEMBLY
Mark the fire front fixing points through the mounting
bracket holes at the top, see diagram 5.2.
Pull the fire front forward and remove.
Drill the fire front fixing face using a 10mm masonry
drill to a minimum depth of 40mm to accept the anchor
nuts and screws provided.
Place the anchor nuts and screws into holes, screw up
but leave sufficient screw thread proud to accept the fire
front.
Note, if the fire front fixing wall face is not of a solid
construction to a minimum depth of 40mm, for example,
hollow brick or metal an alternative and rigid form of
fastening for the fire front must be used and extra care
taken.
Refer to diagram 5.3.
Offer fire front up at a slight angle to engage fire spigot
and position mounting bracket holes over screws in fire
front fixing wall face.
Lower fire front to locate fire front flue spigot into flue
collector assembly and onto back boiler air duct, push
back onto fire front fixing wall face and tighten up
securing screws.
BACK
BOILER
AIR
DUCT
Enlarged view of
mounting bracket
SECURING
SCREW
(2)
FIRE FIXING
WALL FACE
GAS SERVICE
COCK
Diagram 5.1
2450
MOUNTING BRACKETS
SECURING SCREWS
POSITION
ANCHOR
NUT
221100C
SECURING
SCREW
(2)
8
MOUNTING BRACKET
FLUE
COLLECTOR
ASSEMBLY
Diagram 5.2
2458
Diagram 5.3
Page 9
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5 I n s t a l l a t i o n
5.2 Gas and Electrical Connection
Place the tubing nut and olive, from the loose items
pack, onto the prepared end of the gas supply tube, see
diagram 5.4.
Connect the gas supply, as diagram 5.4, tighten the nut
and olive at the gas service cock.
To tighten the other end use a spanner to lock the
hexagon nut (A) at the bulkhead fitting and make sure
that it does not turn, tighten the nut (B) on the supply
tube in the usual manner, see diagram 5.4.
Make sure that joint (C) is checked for gas soundness,
as Section 6.1.
Connect the plug and socket as shown in diagram 5.5.
Make sure that the socket is fully engaged into the plug
on the fire front.
JOINT (C)
NUT (A)
NUT (B)
GAS
SUPPLY
TUBE
UNION NUT
UNION
NUT
2480
OLIVE
GAS
SERVICE
COCK
Note, when removing fire front do not break the union
nut connection at gas service cock, see diagram 5.4.
SWITCH
PLUG
6 L i g h t i n g a n d 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
6.1 Lighting and Testing
Make sure that the electrical supply to the back boiler is
isolated.
The fire front is fitted with a Combustion Products
Discharge Safety Device which will shut it down if there
is a lack of oxygen. If the fire shuts down frequently for
no apparent reason the first things to be checked are the
chimney and air inlets into the room. An additional
cause could be that the filter, in the gas tap has become
blocked. Any problems found must be put right, by a
competent person before the fire is used again.
IGNITION
GAS
RATE
KNOB IN 'OFF'
POSITION
Push in and turn
anti-clockwise
Diagram 5.4
2465
SOCKET
Diagram 5.5
2465
The combustion products discharge safety device
MUST NOT be adjusted or disconnected.
If replacing use only the correct and approved parts.
Make sure that the flat on the drive rod faces the wall
before fitting the control knob, see diagram 6.1.
9
Diagram 6.1
221100C
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6 L i g h t i n g a n d 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
Remove the pressure test point screw and fit a suitable
pressure gauge, see diagram 6.2.
Turn the gas service cock to back boiler and fire On, see
diagram 6.3.
To check for gas soundness, using the pressure drop
method, apply suitable leak detection fluid to all joints,
replace front glass panel.
Push the control knob in and turn it slowly anticlockwise to 1 - ignition.
As the knob is turned a click of the ignition will be heard
and the burner will light. Keep the knob pushed in for
10 seconds.
With the burner lit, visually check for leaks whilst
changing tap positions.
To change settings:
0 - 1 Push in and turn
1 - 2 Turn only
2 - 3 Push in and turn
3 - 4 Push in and turn
4 - 5 Turn only
Note, air may be present in the supply to the fire front so
the initial lighting operation may need to be repeated.
BACK
BOILER
ONLY 'ON'
TURNED
FULLY
CLOCKWISE
GAS SERVICE
COCK UNION
3924 S
Check that the gas pressure is as quoted 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.
The rate for this fire front, after 10 minutes, is about
2mins 50secs for 1ft3.
If the burner does not light first time, wait 10 seconds
then repeat the above sequence.
Turn the burner off, remove pressure gauge, replace test
nipple screw and make sure that a gas tight seal is made.
5297
90˚
BACK
BOILER &
FIRE FRONT
'ON' TURNED
TO MID
POSITION
180˚
'OFF'
TURN FULLY
ANTICLOCKWISE
PRESSURE
TEST POINT
Diagram 6.2
221100C
10
Diagram 6.3
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6 L i g h t i n g a n d 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
6.2 Internal Parts - Fitting
CAUTION. If any of the glass panels, side and rear
insulation, support grid or coal effect pieces are damaged
do not light or further test the fire front before
replacement parts are fitted.
Remove the front glass panel, see diagram 3.2.
Check that the bulbs are screwed in, see diagram 8.9.
See diagram 8.10, operate switch to check that the lights
are working.
Follow the order given in diagram 6.4 to 6.22, to fit the
internal parts.
When replacing the front glass panel push it up into the
retaining angle, position the clamping plate and only
finger tighten the knurl headed nuts.
COLOURED
GLASS
VERTICAL
LUG
PLAIN GLASS
COLOURED
GLASS
BASE
FUEL
SUPPORT
GRID
FUEL
SUPPORT
GRID LUG
GLASS
SUPPORT
LUG
2474
COLOURED
GLASS
SUPPORT
ANGLE
Ensure glass base sits
on support angle
PLAIN
GLASS
BASE
PLAIN
GLASS
BASE
Diagram 6.5
24712472
GLASS
SUPPORT
ANGLE
VERTICAL
LUG
Diagram 6.4
GLASS
SUPPORT
ANGLE
Ensure glass base sits
on support angle
11
Diagram 6.6
221100C
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Note: Refer to GLASS and GRID ARRANGEMENTNote: Refer to GLASS and GRID ARRANGEMENT
2482 d2482 c
L.H. FUEL
SUPPORT
GRID
2482 c2482 d
L.H. FUEL
SUPPORT GRID
FRONT SIDE CHEEK
(L.H. ILLUSTRATED)
FRONT
SIDE
CHEEK
Diagram 6.7
Diagram 6.9
R.H. FUEL
SUPPORT GRID
REAR SIDE CHEEK
(L.H. ILLUSTRATED)
Diagram 6.8
REAR
SIDE
CHEEK
Diagram 6.10
2482 e
REAR CHEEK
221100C
REAR
CHEEK
Diagram 6.11
REAR COAL
12
REAR
COAL
2482 e
Diagram 6.12
Page 13
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6 L i g h t i n g a n d 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
PIN FITS
2482 f2482 g
INTO
HOLE
Ensure Coal
projections sit
on the chrome rail
L.H. FRONT COAL
COAL 1. (L.H.)
Diagram 6.13
Diagram 6.15
R.H. FRONT COAL
Note: There should be no
gap between the front of
'Coal 2' and the back of the
'L.H Front Coal'
COAL 2. (L.H.)
Diagram 6.14
Diagram 6.16
2482 h
COAL
SITS
ON PIN
Note: There should be no gap between the front
of 'Coal No 3' and the back of 'L.H Front Coal'
COAL 3. (L.H.)
Diagram 6.17
COAL 4. (R.H.)
13
2482 h2482 f2482 g
Diagram 6.18
221100C
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6 L i g h t i n g a n d 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
2482 a
Note: 'Coal 5' sits
on top of 'Coal 4'
at R.H.S
Minimise gap
at front
COAL 5. (R.H.)COAL 6. (R.H.)
6800
Diagram 6.19
PIN
2482 b2482 b
Diagram 6.20
Note: Ensure there are gaps
behind 'Coals 3, 5 and 6'.
PIN FITS IN
GROOVE
ON REAR
COAL
PIN
To ensure that
the pin of NO7
sits in the base of
the groove, it may
be necessary
to adjust the
"rear coal".
COAL 7. (CENTRE)Diagram 26
COMPLETE COALS
ARRANGEMENT
Diagram 6.22
221100C
14
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6.3 Heat Settings
Light the fire front as relevant part of Section 6.1.
See diagram 6.1.
At tap position 1 - centre area only, reduced flame effect.
At tap position 2 - centre area only and flame effect.
At tap position 3 - centre area and partial outer and flame
effect.
At tap position 4 - (Full on) whole area and flame effect.
At tap position 5 - whole area but reduced flame effect.
In the unlikely event of the flame going out whilst the
fire front is on, then turn off. Wait 3 minutes before
relighting.
If relighting for any other reason, wait 2 minutes before
doing so.
6.4 Test for Clearance of Products
Notes
WARNING. Take care. The appliance will get hot
during testing.
To carry out the test on the boiler you will need a smoke
match extension and a torch.
For test, view for spillage each side above fire spigot as
shown in diagram 6.23.
The underbed light will help to make the smoke more
visible.
IN ALL CASES, if spillage continues after the specified
test periods steps must be taken to put the fault(s) right.
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.
15
221100C
Page 16
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6 L i g h t i n g a n d 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
Test Where No fan is Present
Close all outside doors and doors and windows in the
room in which the appliance is installed.
Light the fire front only and set to tap position 4.
After 5 minutes apply a spillage test as shown in
diagram 6.23 and 6.24. During tests smoke should be
drawn into the fire draught diverter and the boiler
draught diverter.
If spillage occurs, leave fire alight for up to a further 10
minutes and repeat tests. Turn the fire front off.
Next, light the boiler only. After 10 minutes apply
spillage tests as shown in diagram 6.23 and 6.24. During
tests smoke should be drawn into the fire front draught
diverter and boiler draught diverter.
If spillage occurs, leave the boiler alight for up to a
further 5 minutes and repeat tests.
Leave the back boiler alight.
Light the fire front and set to tap position 4. After 10
minutes apply spillage tests as shown in diagram 6.23
and 6.24. During tests smoke should be drawn into the
fire front draught diverter and boiler draught diverter.
60mm
SMOKE MATCH
EXTENSION
2453
140mm
25˚
If spillage occurs, detected by looking above fire spigot,
see diagram 6.24. Leave the boiler and fire front alight
for up to a further 5 minutes and repeat tests.
Test. Where a Fan is Present
A fan means an extract fan or a fan for other open 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 carry on as
follows:-
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 on the fan and
repeat the spillage test as above.
6.5 Case Fitting
Remove the front glass panel and clamp by releasing the
knurl headed nuts.
Diagram 6.23
Refit the controls cover plinth, push it back as far as it
will go, see diagram 6.27.
When the fire front is removed, it must always stand on
the plinth, to protect the thermocouple.
Refit the outer casing, secure with the two screws
previously removed, see diagram 6.26.
Refit the front glass panel and clamp.
In all cases only finger tighten the knurl headed fixings.
Fit the front hearth casting and the brass trim, see
diagram 6.25.
221100C
16
Page 17
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6 L i g h t i n g a n d 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
SIDE VIEW
560 SMOKE
MATCH
EXTENTION
NOTE:
Ensure trim
is located
beneath the
side surround
10
10
DIVERTER
PLATE
FRONT VIEW
FIRE SPIGOT NOT
SHOWN FOR
CLARITY
Diagram 6.24
1890
2473
2463
SECURING
SCREW (2)
CASING
Diagram 6.26
2469
BRASS
TRIM
HEARTH
CASTING
LOCATION
HOLE
Diagram 6.25
PLINTH
Diagram 6.27
17
221100C
Page 18
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7 I n s t r u c t i o n s t o U s e r
Hand the Instructions for Use to the user and instruct in
the safe and economical use of the fire and back boiler,
including lighting the fire with a spill, see below.
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.
Advise that any smell which may be apparent on first
lighting is quite normal and it will quickly disappear.
Advise that the trims (not the decorative motif) are solid
brass and they only may be cleaned with a proprietary
metal cleaner and polish, such as “Duraglit”.
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.
2475
MATCH
EXTENSION
Diagram 7.1
Advise the user, to ensure the continued efficient and
safe operation of the appliance it is recommended that it
is checked and serviced as necessary at regular intervals.
The frequency of servicing will depend upon the
particular installation and usage, but in general once a
year should be enough.
It is the law that servicing is carried out by a competent
person.
Advise that the under fuel bed lighting can be used at
any time.
Demonstrate lighting the fire front with a spill or long
match, see diagram 7.1.
Remove the brass trim and front hearth casting.
Hold a lighted spill or long match and insert it into the
hole in the front plate, position the spill so that the flame
is over the burner.
Keep the spill in position, push in and turn the gas tap
knob to position 1, keep knob pushed in for about 10
seconds and the burner will light.
Once lit operate the gas tap normally.
Advise that this is a temporary measure, to be used only
if the ignition system should fail.
Advise the user of the precautions necessary to prevent
damage to the system, boiler and the building, in the
event of the heating system being out of use during frost
or freezing conditions.
Advise the user that the boiler and fire front are both
fitted with a combustion products discharge safety
devices and refer to the instructions for use.
Reminder, leave these instructions with the user.
221100C
18
Page 19
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8 S e r v i c i n g a n d R e p l a c e m e n t o f P a r t s
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 servicing is carried out by a
competent person.
(c) Make sure that the fire front is cold before carrying
out any servicing.
(d) Before servicing or replacing parts isolate the gas and
electrical supplies.
(e) After servicing or replacement of parts always test for
gas soundness with a suitable leak detection fluid (to test
the gas tap refix the fire and apply leak detection fluid to
all joints replace front glass panel, light the burner and
visually check all the joints for leakage whilst changing
tap settings).
(f) Carry out functional check on controls. See Section 5
and 6.
(g) It is suggested that other than for servicing or
replacing the glass panels, coal effect pieces, insulation
and bulbs etc., the fire front be removed from its fixings
by reversing the instructions in Section 5 and 6.
8.2 Coal Effect Pieces, Supports and Glass
Bases
Remove the glass panel as above.
Remove the coal effect pieces and clean with a soft
brush. Do not use a vacuum cleaner. Take care when
cleaning the coal effect pieces as with use they become
brittle.
Remove the coal effect support grids and clean with a
soft brush.
Clean out the combustion chamber.
Clean as necessary the glass base and coloured glass
panel. Clean the reflectors.
UNION
CONNECTOR
PILOT TUBE
UNION
CONNECTION
5298
(h) Unless stated otherwise reassembly of all
components should be in the reverse order to that for
removal.
(i) The back boiler should be serviced at this time, refer
to the Back Boiler Installation and Servicing
Instructions.
(j) The combustion products discharge safety device
MUST NOT be adjusted or disconnected.
If replacing use only the correct and approved parts.
8.1 Front Glass Assembly
Remove the brass trim and the front hearth casting and
unscrew the three knurl headed nuts and remove the
clamping plate and glass panel.
Remove the glass panel as above, clean both sides with a
ceramic hob cleaner and then buff.
When replacing only finger tighten the knurl headed
nuts.
INJECTOR
BOX
PLATE
SECURING
SCREW
INJECTORS
BURNER
SECURING
SCREW
BURNER
SUPPLY
PIPES
Diagram 8.1
19
221100C
Page 20
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8 S e r v i c i n g a n d R e p l a c e m e n t o f P a r t s
8.3 Burner and Injectors
Disconnect the supply pipe unions at the injectors, the
front union connection and the pilot tube union
connection from the combustion products discharge
safety device, see diagram 8.1. Disconnect the ignition
lead from piezo unit on the gas tap, see diagram 8.5.
Disconnect the thermocouple at the base of the gas tap,
see diagram 8.5.
Unfasten the burner securing screws at each end and
remove taking care not to damage the thermocouple
capillary and ignition lead, see diagram 8.5.
Unscrew the injectors, inspect, clean or replace as
necessary. Do not clean with a wire or a sharp
instrument.
Remove injector box cover screw and plate, clean out
dust etc., see diagram 8.2.
Brush away any lint and dust from the burner, etc.
8.5 Combustion Products Discharge Safety
Device
Remove the burner refer to Section 8.3.
Check the condition of the electrode and thermocouple,
clean with a soft brush.
8.6 Ignition Lead
Remove burner as Section 8.3.
Slide the silicone cover of the electrode, disconnect the
and ignition lead at both ends. When fitting a
replacement the clear end is fitted to the electrode.
COMBUSTION PRODUCTS
DISCHARGE SAFETY DEVICE
THERMOCOUPLE
SECURING
SCREW (2)
5296
To replace slide the silicone cover off the electrode,
disconnect the ignition lead, remove the mounting
bracket securing screws and the combustion products
discharge safety device, see diagram 8.3.
Before replacing bend the new thermocouple capillary to
shape using the old one as a template, avoid making
sharp bends.
Make sure the spark gap is as in diagram 8.4.
INJECTOR
BOX
5294
PILOT TUBE
UNION
CONNECTION
ELECTRODE
EARTH
POST
SILICONE
COVER)
IGNITION LEAD
(CLEAR END)
THERMOCOUPLE
Diagram 8.3
SPARK GAP
+ 1
3
- 0.5
5295
INJECTORS
ELECTRODE
SECURING
SCREW
221100C
Diagram 8.2
20
C
L
TOP VIEW
EARTH
POST
Diagram 8.4
Page 21
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8 S e r v i c i n g a n d R e p l a c e m e n t o f P a r t s
8.7 Gas Tap and Piezo
Note. This item need not be serviced every year.
Make sure the gas is turned off before removing the gas
tap, see diagram 6.3.
Remove glass panel, casing and internal parts by
reversing the procedure in Section 3.1 and 6.
Remove fire from the wall by reversing the instructions
in Section 5.1 and 5.2.
When refitting make sure that these parts are replaced
strictly in accordance with the instructions in these
sections.
Remove split pin from (connecting) drive rod, see
diagram 8.5, place rod to one side, when refitting make
sure that the flat at the top faces the wall.
Remove gas tap bracket screws, see diagram 8.5 and 8.6.
Remove securing screws at each end of the burner,
see diagram 8.5.
Release supply pipe union nut, see diagram 8.6.
Turn the whole assembly including the burner through
90o and lift out, see diagram 8.7 and 8.8.
GAS TAP BRACKET
SECURING SCREW
5319
SUPPLY PIPE
UNION NUT
Diagram 8.6
5320
To replace piezo unit, straighten twist tags, fit new unit
and twist tags to secure.
To service the gas tap remove the two securing screws
and disconnect all union connections at the gas tap, see
diagram 8.11.
Take care as the filter in the gas tap may be loose.
When servicing take care, as there is a spring beneath.
Remove the plug, pin, spring washer, plain washer and
“O” ring, see diagram 8.11.
Clean and re-lubricate using a suitable grease.
BURNER
SECURING
SCREW
SPLIT
PIN
GAS TAP
BRACKET
SECURING
SCREW
5299
Turn burner and gas tap
assembly through 90˚
Diagram 8.7
5321
PIEZO UNIT
THERMOCOUPLE
IGNITION LEAD
CONNECTOR
Diagram 8.5
21
Remove burner and gas tap assembly
rearwards from appliance
Diagram 8.8
221100C
Page 22
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8 S e r v i c i n g a n d R e p l a c e m e n t o f P a r t s
Note:
To carry out the work below, first generally follow the
instructions in Section 3.1 and 6.1.
8.8 Insulation
Refer to diagram 6.9 to 6.11 to remove/replace
insulation.
8.9 Glass Base
Refer to diagram 6.6 to remove glass base.
8.10 Underbed Lighting
Note. The bulbs are not covered by the product
guarantee.
Remove the coloured glass panel to gain access, before
replacing a “failed” bulb, check that it is screwed in as
these are Edison Screw bulbs (SES).
See diagram 6.2, 6.3 and 8.9.
8.11 Light Switch
Remove switch cover, pull off wired tags.
Fit and connect new switch, see diagram 8.10.
SWITCH
OPERATING
CAM
SECURING
SCREW (2)
WIRED
TAGS
CIRCLIP
COVER
Diagram 8.10
PIEZO UNIT
2464
5525
8.12 Gas Tap Pilot Filter
Gain access to the gas tap as Section 8.7.
The filter, which is very small, is in the pilot port of the
gas tap, to remove use a small non-metallic tool.
When fitting the replacement it is important that the
filter is seated correctly as shown in diagram 8.11.
PHILIPS SES
EDISON SCREW CAPS
2467
PLUG
AND PIN
ASSEMBLY
BODY
SLOT
CROSS
SECTION
FILTER
PRESSURE
TEST POINT
Diagram 8.9
221100C
22
Diagram 8.11
Page 23
Supplied By www.heating spares.co Tel. 0161 620 6677
9 F a u l t F i n d i n g
9.1 Fire Front Ignition
Remove casing as in Section 3.1 and refer to
diagram 9.4.
9.2 Electrical
Checks on the mains electrical system of the fire, that is,
earth continuity, polarity and resistance to earth, should
be carried out as outlined in a multimeter instruction
book.
2483
2 x 25W LAMPS
EDISON SCREW
TYPE SES
RED
VIOLET
Remove casing as in Section 3.1.
Isolate the back boiler and fire front from the electrical
supply.
Disconnect fire front electrical socket from plug, see
diagram 9.1.
Refer to electrical fault finding diagram 9.3, functional
flow diagram 9.2.
On completion of the fault finding task which has
required breaking and remaking of electrical connections
then checks, earth continuity, polarity and resistance to
earth must be repeated.
CHASSIS
EARTH
GRN/YEL
CONNECTOR
BROWN
L
RED
L
VIOLET
RED
230V~ 50Hz MAINS
E
FROM BOILER
N
CONTROL
BOX FUSED AT 3A
BLUE
SWITCH
Diagram 9.1
N1
1569
ILLUMINATION
BULBS
23
RED
RED
VIOLET
VIOLET
Diagram 9.2
BLUE
N
N
221100C
Page 24
Supplied By www.heating spares.co Tel. 0161 620 6677
9 F a u l t F i n d i n g
Isolate the electrical supply and remove the socket from the plug.
Connect Voltmeter across the socket pins 'L' and 'N'.
Turn on the electrical supply. Is Voltage between 216V and 240V?
4547
YES
Isolate the electricity supply.
Remove bulbs and test them for continuity.
Is there continuity?
YES
Remove cover from plug.
Is there continuity between terminal 'L'
on plug switch (red cable)?
YES
Remove bulb holder from mountings.
Is there continuity between terminal 'L'
on plug and left hand bulb holder and
terminal (red cable) with switch 'ON'?
YES
NO
NO
NO
NO
Refer to B.B.U. electrical fault finding.
Faulty bulb(s), replace.
Faulty Switch and Cable assembly, replace.
Faulty Switch and Cable assembly, replace.
Switch 'OFF', repeat above procedure.
Is there continuity?
NO
Switch assy in order. Individually test red
and violet cables between bulb holders
for continuity. Is there continuity?
YES
Is there any continuity between left hand
bulb holder and N1 on plug terminal
(violet cable)?
YES
Replace bulbs and test continuity of
bulb holders at the terminals on bulb holders.
Is there continuity?
YES
Replace bulb holders.
Electrical circuit in order.
YES
NO
NO
NO
Faulty Switch and Cable assembly, replace.
Faulty red cable, replace.
Faulty violet cable, replace.
Faulty bulb holders, replace.
ELECTRICAL FAULT FINDING
221100C
24
Diagram 9.3
Page 25
Supplied By www.heating spares.co Tel. 0161 620 6677
9 F a u l t F i n d i n g
START HERE
Spark
across gap,
ignition
Spark
across gap,
ignition
Turn off appliance tap; turn
on appliance tap and
observe spark
No spark
across
gap
Spark
no
ignition
Ensure gap is within specified
tolerance, refer to SERVICING
Turn tap to energise igniter
No spark
across
gap
Spark
no
ignition
Disconnect ignition lead from
electrode, place connector
within 4mm of burner and
operate piezo
Spark
across gap,
ignition
Replace faulty Combustion Products
Replace faulty electrode and
Discharge Safety Device and
reassemble ignition system
reassemble ignition system.
Spark
across gap,
ignition
Spark
no
ignition
Spark
no
ignition
Ensure gap is within specified
tolerance. Turn tap to energise
igniter
Spark
across gap,
ignition
Spark
no
ignition
Fire will not light
Check that gas is available.
Does the pilot light using a match.
YES
NO
Change pilot filter.
Using a match, ensure correct
functioning of burner in
all setting positions. Check that
electrode and piezo unit connections
are satisfactory. Check that
burner pressure is as specified.
Correct any fault found.
Remove ignition lead from piezo unit
and place screwdriver between
appliance chassis earth and piezo
unit, leaving 4mm gap between blade
and spade connector.
Operate igniter.
Spark
across
gap
No spark
across
gap
Renew ignition lead and
reassemble ignition system
Spark
across gap,
ignition
Spark
no
ignition
Change piezo unit and
reassemble ignition system
Spark
across gap
ignition
Check several times that
ignition is satisfactory
5466
FIRE IGNITION FAULT FINDING
25
END
Diagram 9.4
221100C
Page 26
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9 F a u l t F i n d i n g
9.3 Thermocouple
Remove casing as described in Section 3.1.
To test a thermocouple, a meter with a range of 0 to 30 mV
is required together with a thermocouple interrupter test
unit.
Refer to fault finding diagram 9.3 and diagnosis graph,
diagram 9.4, 9.5 and 9.6.
9.4 Combustion Products Discharge Safety
Device
If the device operates it indicates there could be a problem
with the chimney or, the pilot filter in the gas tap is
blocked. First make sure air vents are free from
obstructions, by carrying out spillage checks as Section 6.3.
If all is in order refer to diagram 9.4 to check if the pilot
filter is blocked.
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 9.5
0021
221100C
26
Page 27
Supplied By www.heating spares.co Tel. 0161 620 6677
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.
5243
Is voltage greater
than 15mV?
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.
Supplied By www.heating spares.co Tel. 0161 620 6677
1 0 R e p l a c e m e n t P a r t s
Key No.Part No.DescriptionGC Part No.
1452606Control tap assy c/w piezo162 179
2203075Injector - upper389 522
3203076Injector - lower398 422
4203438Combustion Products Discharge Safety Device162 173
5WW4607Ignition lead136 824
6432558Front glass assembly136 832
7432614Control knob136 835
8203763Coal effect piece - rear152 821
9203764Coal effect piece - left hand152 822
10203765Coal effect piece - right hand152 823
11203766Coal effect - No.1152 824
12203767Coal effect - No.2152 825
13203768Coal effect - No.3152 826
14203769Coal effect - No.4152 827
15203790Coal effect - No.5152 828
16203791Coal effect - No.6152 829
17203792Coal effect - No.7152 830
18210136Insulation - side - left hand No.1136 852
19210137Insulation - side - left hand No.2136 853
20210138Insulation - side -right hand No.1136 854
21210139Insulation - side -right hand No.2136 855
22210140Insulation - rear136 851
23203761Fuel grid - left hand136 849
24203780Fuel grid - right hand136 850
25209132Fuel bed glass136 856
26209131Lamp cover glass136 857
27208509Knurl headed nuts152 864
28208673Filter162 208
When replacement parts are required please apply to
your local supplier.
Please quote the name of the fire front, “Glow-worm
Homeglow 2 BBU”.
The GC No. 37 314 16 and serial number, to be found on
the front after the Front Decorative plate is removed.
221100C
28
Page 29
Supplied By www.heating spares.co Tel. 0161 620 6677
1 0 R e p l a c e m e n t P a r t s
27
18
19
11
22
21
20
15
17
13
8
16
12
9
24
23
14
10
7
5336
6
25
26
2
3
4
1
Diagram 10.1
29
221100C
Page 30
Supplied By www.heating spares.co Tel. 0161 620 6677
11 Supplementary Instructions
These fire fronts are fitted with combustion products
discharge safety devices.
As these fire fronts may be fitted to a Glow-worm 45,
56, 45R or 56R back boiler units WITHOUT a
combustion products discharge safety device, the
following instructions must be read and followed in
place of those in the main Installation and Servicing
Instructions.
To check if a combustion products discharge safety
device is fitted, refer to inset in diagram 11.1, if one is
fitted this supplement MUST be ignored.
11.1 General
To fit the fire front to one of the above EXISTING
GLOW-WORM BACK BOILER UNITS follow the
instructions below.
11.2 Installation
1. Do not fit the back boiler sensing tube as required in
the main installation and servicing instructions.
2. Fit the electrical connection supplied with the fire
front to the back boiler unit control box, see diagram
11.2 to identify if a four or six way terminal block is
fitted. Continue to fit the fire front as the relevant part of
the main installation and servicing instructions.
3. Any references in the installation and servicing
instructions to the back boiler unit combustion products
discharge safety device must be ignored.
Push in and slightly turn gas control knob “A” clockwise
until “” is against its setting point, that is, set to “Off”.
Push in slightly and turn gas control knob “A”
anticlockwise until “” is against its setting point, then
push fully in and hold in.
At the same time press and release piezo button “D”
until pilot burner “E” lights. Look at flame through
viewing window “F”.
At initial lighting of the boiler air may be present and
several attempts may be needed to light the pilot.
Keep the control knob “A” pushed in whilst operating
the ignition button.
When the pilot is alight and stable, keep knob “A” fully
pushed in for about 15 seconds then release. Check that
the pilot is still alight, look through window “F”.
If the pilot burner fails to stay alight turn gas control
knob “A” “Off”, that is, fully clockwise. Wait three
minutes. Repeat the lighting operation, only now keep
the control knob “A” pushed in for a little longer that
before after the pilot has lit.
NOTE. Always wait three minutes before attempting to
relight the pilot after it has gone out for any reason.
Push control knob “A” in slightly and turn anticlockwise
until “” is against the setting point.
Note. If gas control knob “A” is turned to until “” is
against the setting point, a safety lock prevents it being
turned on again. No attempt should be made to turn the
valve on again until at least three minutes have elapsed.
11.3 Lighting the Boiler
The boiler controls are placed behind the fire front
plinth.
To remove the plinth, pull it gently forwards until it is
free.
Refer to diagram 11.1 to identify the controls.
Turn off the electrical supply at the mains supply outside
the appliance.
Check that all controls are calling for heat.
The clock, room thermostat and programmer, if fitted,
will be away from the unit, see manufacturer’s
instructions supplied with them.
Turn the thermostat control knob “B” to “Off” position,
that is, fully anticlockwise, “Off” to be against the
pointer.
Turn on the electrical supply to the unit.
Turn thermostat control knob “B” clockwise until
“MAX” is against the setting point, the main burner will
light.
Adjust the thermostat to the required setting between
“MIN” and “MAX”. “MAX” is about 82oC.
Check that all external controls are set to your
requirements.
Refit the plinth by carefully locating the top edge of the
plinth into the sliders, then push gently back as far as it
will go.
221100C
30
Page 31
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11 Supplementary Instructions
SETTING
POINT
'B'
THERMOSTAT
CONTROL
KNOB
INSET: Showing a Combustion Products Discharge
Safety Device fitted.
'E' PILOT BURNER
'F' VIEWING
WINDOW
'A'
'D' PIEZO
UNIT
GAS VALVE
CONTROL
KNOB
BUTTON
5342
SETTING
POINT
OFF
PILOT/IGNITION
MAIN BURNER
BOILER CONTROLS
KEY
brBROWN
bBLUE
rRED
g/y GREEN AND YELLOW
EARTH
g/y
STUD
g/y
PERMANENT
LIVE
N1
L
bbbr
g/y
TO FIRE FRONT
TO BOILER
FOUR WAY TERMINAL BLOCK
Diagram 11.1
g/y
EARTH
STUD
g/y
SLN
E
N
L
g/y
230V
50Hz ~
MAINS
SUPPLY
FUSED
AT 3A
r
b
TO BOILER
bk
br
b
L1
N1
SL1
b
br
bk
230V 50Hz ~
MAINS SUPPLY
SL2
br
bk
b
L
br
5341
N
b
g/y
FUSED AT 3A
KEY
brBROWN
TO FIRE FRONT
SIX WAY TERMINAL BLOCK
bBLUE
bkBLACK
g/y GREEN AND YELLOW
Diagram 11.2
31
221100C
Page 32
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Control of Substances Hazardous 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.
GLASS YARN, 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.
221100C
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