Glow-worm Homeglow 2 BBU Installation & Servising Instruction

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221100C.08.98
Installation & Servicing Instructions
T o be left with the user
2
For use with
a specially designed
Glow-worm Back Boiler Unit only
FIRE G.C No. 37 314 16
2481
References in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
One Contact Local Service
For Ireland the rules in force must be used.
This is a Cat I
Customer Services: Tel: (01773) 828100 Fax: (01773) 828070
Appliance
2H
BS 6332 BS 5258
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
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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
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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
lower - Bray Cat 18/280 Pressure setting - Hot 14.2mbar at Setting 4
Cold 13.6mbar
Heat input ­(Gross) 21,000 Btu/h nominal
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
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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
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Diagram 2.3
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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
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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
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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
br BROWN b BLUE 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
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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
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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
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Diagram 6.3
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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
2471 2472
GLASS SUPPORT ANGLE
VERTICAL LUG
Diagram 6.4
GLASS SUPPORT ANGLE Ensure glass base sits on support angle
11
Diagram 6.6
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Note: Refer to GLASS and GRID ARRANGEMENT Note: 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
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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 h 2482 f2482 g
Diagram 6.18
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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
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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.
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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.
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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
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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
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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
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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
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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
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22
Diagram 8.11
Page 23
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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
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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
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24
Diagram 9.3
Page 25
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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
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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
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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.
THERMOCOUPLE CIRCUIT IS SATISFACTORY
In which area of the graph is the intersect
B
Faulty magnet unit in gas tap. Replace gas tap
NO
YES
A
C
Faulty thermocouple. Replace combustion products discharge safety device.
Faulty thermocouple. Replace combustion products discharge safety device.
27
Diagram 9.6
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1 0 R e p l a c e m e n t P a r t s
Key No. Part No. Description GC Part No.
1 452606 Control tap assy c/w piezo 162 179 2 203075 Injector - upper 389 522 3 203076 Injector - lower 398 422 4 203438 Combustion Products Discharge Safety Device 162 173 5 WW4607 Ignition lead 136 824 6 432558 Front glass assembly 136 832 7 432614 Control knob 136 835 8 203763 Coal effect piece - rear 152 821 9 203764 Coal effect piece - left hand 152 822 10 203765 Coal effect piece - right hand 152 823 11 203766 Coal effect - No.1 152 824 12 203767 Coal effect - No.2 152 825 13 203768 Coal effect - No.3 152 826 14 203769 Coal effect - No.4 152 827 15 203790 Coal effect - No.5 152 828 16 203791 Coal effect - No.6 152 829 17 203792 Coal effect - No.7 152 830 18 210136 Insulation - side - left hand No.1 136 852 19 210137 Insulation - side - left hand No.2 136 853 20 210138 Insulation - side -right hand No.1 136 854 21 210139 Insulation - side -right hand No.2 136 855 22 210140 Insulation - rear 136 851 23 203761 Fuel grid - left hand 136 849 24 203780 Fuel grid - right hand 136 850 25 209132 Fuel bed glass 136 856 26 209131 Lamp cover glass 136 857 27 208509 Knurl headed nuts 152 864
28 208673 Filter 162 208
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.
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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
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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.
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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
br BROWN b BLUE r RED 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
br BROWN
TO FIRE FRONT
SIX WAY TERMINAL BLOCK
b BLUE bk BLACK g/y GREEN AND YELLOW
Diagram 11.2
31
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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.
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