Glow-worm Opulence 2 BBU, Opus 2 BBU Installation & Servicing Instructions Manual

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

221098C.01.99

Installation and Servicing

Instructions

T o be left with the user

3914 S

G.C.37 314 15

a specially designed

Glow-worm Back Boiler Unit only

G.C.37 314 14

For use with

3915 S

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: [phone]
Fax: [phone]

Appliance

2H

BS 6332
BS 5258

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries :

Tel: [phone] Fax: [phone]

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

1 G e n e r a l

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, including 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.

1 General Notes and Information

This Glow-worm gas fire front is to be used with a
specially designed Glow-worm Back Boiler Unit only.

This fire front and back boiler are NOT suitable for
fitting to a precast flue.

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

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

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

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

1.1 Important Notice

This fire front is for use only on G20 gas.
This fire front 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 the 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.

Sheet Metal Parts

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

1.2 Statutory Requirements

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

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

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

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

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

Manufacturer’s notes 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 89/336/EEC on the approximation of the
Laws of the Member States relating to electromagnetic
compatibility.

2221098C

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

289mm

1 G e n e r a l

FLAT AREA

FIRE FIXING FACE

C

L

327mm

327mm

3916 BBU S

289mm

690mm

339mm 351mm 351mm 339mm

1.3 Data

Gas connection- from the service cock
Total weight - 49kg
Injector - upper Bray 18/180

- lower Bray 18/320

Burner pressure setting

- cold 13.0mbar 5.18in wg

- hot 13.2mbar 5.28in wg
Heat input - gross - 6.7kW 22,750Btu/h
Heat output - nominal - 4.03kW 13,670Btu/h
Fire serial No. - On chassis - visible when front

casting is removed

Data label - Inside of right hand side panel
The fire front burner is lit by means of an electronic

spark generator unit.

Diagram 1.1

All dimensions are given in millimetres
(except as noted).

3

221098C

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

150mm

1 G e n e r a l

C

L

445mm 445mm

150mm 150mm

MAXIMUM
SHELF
DEPTH

3917 S

150mm

840mm

FLAT AREA
FIRE FIXING FACE

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.

840mm

Diagram 1.2

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 additional 25mm extra
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.

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.

4221098C

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

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.

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 2.3.
This area, to the depth removed, should then be rendered
with a sand/cement mixture.

2.4 Flue

The back boiler flue collector assembly accepts the fire
front flue spigot.

Note: Provision must be made during the installation of
the back boiler for total ventilation requirement for the
combined appliance. See relevant section in back boiler
installation instructions.

INSTALLATION CENTRE LINE

406mm

to

460mm

560mm

to

C

L

590mm

3919 S

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” 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.

Opus illustrated

1

/2in. 12mm

50mm
MIN.

2in.

760mm
30in.

Non-

combustible

material

1

/2in

340mm
131/2in.

3918 S

REMOVE
COMBUSTIBLE
MATERIAL FROM
THIS AREA

FRONT
OPENING

280mm

BUILDERS

INSTALLATION

220mm220mm

OPENING

C

L

CENTRE

LINE

PREPARED
BASE

280mm

135mm

PREPARED
BASE

Diagram 2.2

680mm

560mm

3920 S

Diagram 2.1

5

Diagram 2.3

221098C

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

3 F i r e F r o n t P r e p a r a t i o n

FIRE BODY PACK

FIRE
BODY
ASSEMBLY

FLUE SPIGOT

LITERATURE

COMBUSTION

FUEL
EFFECT
BED

CHAMBER
BOTTOM PLATE

OPULENCE CASING PACK OPUS CASING PACK

4337 S

WALL
SEALING
PLATE

L.H. SIDE
PANEL

L.H. SIDE
CASTING

FRONT
CASTING

PLINTH

CANOPY

R.H. SIDE
PANEL

R.H. SIDE
CASTING

CANOPY

L.H. SIDE
CASTING

L.H. SIDE
PANEL

R.H. SIDE
PANEL

FRONT
CASTING

PLINTH

R.H. SIDE
CASTING

R.H.
LEG

L.H.
LEG

6221098C

L.H.
LEG

R.H.
LEG

Diagram 3.1

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

3 F i r e F r o n t P r e p a r a t i o n

A

B

C

D

E

F

G

H

KEY

SCREW FRONT LEG

M5x30 LEVELLING SCREW

SCREW SIDE

M5x14 CASTINGS

SCREW UPPER WALL

M5x40 MOUNTING

ANCHOR UPPER WALL

NUT MOUNTING

SCREW FRONT LEG

M5x8 FIXING

SCREW WALL SEALING

No. 10 x 1 1/2in. PLATE FIXING

WALL WALL SEALING
PLUG PLATE FIXING

SCREW UPPER SIDE

RETAINING

6135

J

K

L

SENSING
TUBE
MOUNTING
BRACKET
ASSEMBLY

BBU
SENSING
TUBE

SCREW FLUE SPIGOT FIXING

No. 8 x 3/8in.

SCREW SENSING TUBE

M4x10 FIXING SCREW

TAPTITE SCREW SENSING TUBE MOUNTING

M4x6 BRACKET SCREW

FILTER

BATTERY

FIRE FRONT
SENSING
TUBE

LIQUID
COAL

OLIVE (2)

GAS SUPPLY
PIPE

CONTROL
KNOB

FIBRE WASHER (2)

TUBING
NUT (2)

7

SIDE EXTENSION (2)

Diagram 3.1

221098C

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

3 F i r e F r o n t P r e p a r a t i o n

3.1 Unpacking

The fire front is delivered in two packs, one contains the
body assembly, fuel effect pieces and supply tube pack.

The other contains the fire front castings, side panels,
plinth and loose items pack. Refer to diagram 3.1. to
identify the parts.

To unpack carton 1, lift out the top fitting containing the
fire spigot and combustion chamber bottom plate, lift out
the cardboard front fitting, the supply tube pack and the
two boxes containing the fuel effect pieces.

Lift the outer carton clear to leave the fire front sitting in
the base tray.

To unpack carton 2, lift out the cardboard tray containing
the plinth and side panels. Lift out the loose items pack,
legs box and canopy. Remove the internal cardboard
fitting and lift out the lower front and side castings.

Put these items on one side until required. Check
contents of loose items pack against list.

Remove the glass front panel, see diagram 3.2.
It is suggested that the side extensions, from the castings

pack, be fitted at this time to the left and right hand side
panels.

NOTE: These are a slide fit onto the louvres.

3.2 Flue Spigot Assembly

Note. This is marked “Homeglow BBU”
Leave the fire front sitting in the base tray.
Remove the two plastic transit studs securing the wall

sealing plate to the rear of the fire front and put it on one
side until required.

Secure the spigot assembly to the fire front back with
the self taping screws provided, in the loose items pack,
see diagram 3.3.

Note. There are eight self tapping screws in the pack,
one spare.

5171

GLASS
RETAINING
BRACKET

PULL FORWARDS
AND UP

GLASS
FRONT PANEL

Diagram 3.2

3923 S

FLUE SPIGOT ASSEMBLY

3.3 Gas Supply Tube and Sensing Tubes
Preparation

Remove the plastic ferrule from the bulkhead connector
on the air duct and discard.

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 casing with the screw provided, see diagram 4.2.

Important. Make sure that the mounting bracket
assembly is pushed back to the fire front face of the
boiler casting and check 3mm distance is achieved and
the back boiler sensing tube does not extend above the
sensing tube bracket assembly, see diagram 4.2.

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.

Check that the gas service cock is in the Off position, see
diagram 3.4.

The inlet supply tube, back boiler sensing tube assembly
and fire front sensing tube are packed in the supply tube
pack, see diagram 3.1.

This supply tube and fire front sensing tube may need to
be cut, at the plain end, dependent on the model and
position of the back boiler in the opening.

SECURING

J

SCREW (7)

Diagram 3.3

Gas Supply Tube

Measure the distance “C”, see diagram 3.5, 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 the

distance “C”. No shortening is required when mark “P”
is level with the fire front fixing wall face, “C” being zero.

The maximum distance for “C” will be 67mm (25/8in).

8221098C

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

3 F i r e F r o n t P r e p a r a t i o n

Firefront sensing tube

Shorten the plain end of the fire front sensing tube by
distance “D”, no shortening of the tube is required when
45/2 back boiler is fitted and point “P” is level with the
fire fixing wall face. Similarly when a 56/2 back boiler
is fitted no shortening is required when point “N” is level
with the fire fixing wall face. In both cases “D” is zero
the maximum distance of “D” for both the 45/2 and 56/2
back boiler will be 25mm, see diagram 3.6.

Deburr the tube end inside and out.

3.4 Battery

Remove the fire front from the base tray.
Take the battery from the fittings pack and fit as shown

in diagram 4.1, make sure that the terminals are correctly
fitted.

GAS SERVICE
COCK UNION

*'C' = Distance from fire fixing wall face to datums
on back boiler air duct. This represents the
length of pipe that requires cutting off.

'P'

BACK
BOILER
AIR
DUCT

*'C'

GAS FIRE
SUPPLY TUBE

*'C'

FIRE FIXING
WALL FACE

Diagram 3.5

5078

BACK
BOILER
ONLY 'ON'
TURNED
FULLY
CLOCKWISE

BACK
BOILER &
FIRE 'ON'
TURNED TO
MID POSITION

'OFF'
TURN FULLY
ANTI­CLOCKWISE

90˚

180˚

Diagram 3.4

*'D' = Distance from fire fixing
wall face to datums on
back boiler air duct.
This represents the
length of pipe that requires
cutting off.

*'D'

56/2

BBU

N

45/2

BBU

P

BACK BOILER
AIR DUCT

5245

FIRE FRONT
SENSING
TUBE

56 BBU/2
FIRE
FIXING
WALL FACE

*'D'

45 BBU/2
FIRE
FIXING
WALL FACE

*'D'

Diagram 3.6

9

221098C

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

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

4.1 Battery

Remove the fire front from the base tray.
Take the battery from the fittings pack and fit as shown in

diagram 4.1, make sure the terminals are correctly fitted.

SECURING
SCREW

5283

9V ALKALINE
BATTERY

4.2 Positioning the Fire Front

Remove and discard the plastic ferrule from the 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 4.2. Fit the
sensing tube filter onto the fitting assembly, see diagram

4.2. 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 back boiler sensing
tube does not extend above sensing tube fitting, see
diagram 4.2.

Place the wall sealing plate onto the back boiler air duct,
mark the fixing holes, remove the plate and drill the holes
to suit the plugs and screws provided, from supply tube
pack, leave sufficient screw proud to accept the wall
sealing plate keyholes, see diagram 4.3.

Fit the wall sealing plate and tighten the screws, making
sure that the “wings” are flush with the fire fixing wall
face, see diagram 4.3.

Place the fire front onto the back boiler air duct, check
that the fire front spigot is central in the flue collector
assembly, push back into contact with the fire front
fixing wall face, see diagram 4.4.

Mark the fire front fixing points through the mounting
bracket holes at the top, see diagram 4.4.

Pull the fire front forwards and remove.

SPARK
GENERATOR

ELECTRICAL
CONNECTIONS

SENSING
TUBE
MOUNTING
BRACKET
ASSEMBLY

3mm

TUBING
NUT

BACK
BOILER
SENSING TUBE

BULKHEAD
CONNECTION

BOILER
AIR DUCT

SECURING
SCREW

IGNITION
LEAD

Diagram 4.1

L

MOUNTING
BRACKET
SCREW

SENSING TUBE
MOUNTING
BRACKET
ASSEMBLY

FRONT FACE OF
BOILER CASTING

Diagram 4.2

6171

6171

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 the 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.

Fit the fire front sensing tube to the flue collector with the
two securing screws, see diagram 4.5.

10221098C

5166

G

F

NOTE:
WINGS
FLUSH
WITH
WALL

Diagram 4.3

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

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

MARK
FRONT
FIXING
HOLES

FLUE
COLLECTOR
ASSEMBLY

SPIGOT

FIRE FRONT

52575072

FRONT
FIXING
SCREW

FLUE
COLLECTOR
ASSEMBLY

5258

SPIGOT

BACK
BOILER
AIR
DUCT

FIRE FRONT

SECURING
SCREW (2)

FLUE
COLLECTOR

TUBING
NUT

OLIVE

Diagram 4.4

FIRE FRONT
SENSING
TUBE

SENSING
TUBE

TUBING

OLIVE

NUT

Diagram 4.6

Note, place the tubing nut and olive from the loose items
pack onto the prepared end of the sensing tube, see
diagram 4.5.

Offer the appliance up to the back boiler air duct and
push into position taking care not to damage fire front
sensing tube and filter, lift slightly to engage mounting
brackets onto screws, engage sensing tube into bulk head
connection, see diagram 4.6.

Tighten the fire securing screws, see diagram 4.7.
Tighten the sensing tube nut onto the bulkhead, see

diagram 4.8.

Diagram 4.5

11

221098C