Glowworm SAXONY 2 BBU FIRE FRONT Instructions For Use Installation And Servicing

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

Instructions for Use

Installation and Servicing

T o be left with the user

BBU Fire Front

G.C. No. 37 047 11

221648B. 02. 00

7446

For use with a specially designed

Glow-worm Back Boiler Unit only

BS 6332
BS 5258

This is a Cat I2H Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

These instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration

For Ireland the rules in force must be used.

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.

Guarantee Registration

Thank you for installing a new Glow-worm appliance in your home.

Glow-worm appliances' are manufactured to the very highest standard so we are pleased

to offer our customers' a Comprehensive First Year Guarantee.

In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and

return as soon as possible.

If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer

Service number 01773 828100.

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

One Contact Local Service

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0181 380 2555

Customer Services:
Tel: [phone]
Fax: [phone]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

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

Important Information

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 - Boiler and Fire.

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 - Boiler only.

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic
compatibility - Boiler and Fire.

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

This product uses fuel effect Pieces containing Refractory Ceramic Fibre (RCF), which are man-made vitreous silicate fibres.
Excessive exposure to these materials may cause temporary irritation to eyes, skin and respiratory tract, consequently, it makes
sense to take care when handling these articles to ensure that the release of dust is kept to a minimum.

To ensure that the release of fibres from these RCF articles is kept to a minimum, during installation and servicing we recommend
that you use a HEPA filtered vacuum to remove any dust and soot accumulated in and around the fire before and after working on
the fire. When replacing these articles we recommend that the replaced items are not broken up, but are sealed within heavy duty
polythene bags, clearly labelled as RCF waste. This is not classified as “hazardous waste” and may be disposed of at a tipping site
licensed for the disposal of industrial waste. Protective clothing is not required when handling these articles, but we recommend you
follow the normal hygiene rules of not smoking, eating or drinking in the work area and always wash your hands before eating or
drinking.

INSULATION and SEALS

Ceramic fibre and glass fibre used in insulation panels rope and gaskets.
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.

CONTENTS DESCRIPTION SECTION PAGE No.

Introduction 3

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Lighting the Boiler 4
Lighting the Fire Front 6
Cleaning 6
Supplementary Instructions 10

General Data 1 11
Types of Installation and Flue 2 13
Fire Front Preperation 3 14
Installation 4 18
Lighting, Testing and Fitting Internal Parts 5 21
Instructions for Use 6 25

Servicing and Replacement of Parts 7 25

SERVICING

Fault Finding 8 29
Replacement Parts 9 32

INSTRUCTIONS

Supplementary Installation Instructions 10 35

2221648B

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

Instructions for Use

This fire front may be fitted to a Glow-worm back boiler WITHOUT
a flue blockage safety device. Please refer to the supplementary
instructions at the end of the Instructions for Use, especially
“Lighting the Boiler”.

The instructions consist of two parts, Installation and Servicing
Instructions for the Back Boiler Unit, Use, Installation and
Servicing Instructions for the Fire Front, which includes the
Guarantee Registration Card. The instructions form 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.

The Gas Safety (Installation and Use)
Regulations

In your interests and that of safety it is the Law that ALL gas
appliances are installed by a competent person in accordance
with the current issue of the above regulations.

General

These notes should be read and carefully followed for the safe
and economical use of your back boiler and fire front.

Important Notice

This appliance is for use only on G20 gas.
This Glow-worm fire front is to be used with a specially designed

Glow-worm Back Boiler Unit only.
The fire front and back boiler must be fitted as a

complete appliance.
This is a combined central heating back boiler and gas fire front.

The back boiler and fire front can be operated either together or
independently.

In the event of a power or ignition system failure the fire front can
still be used on its own, instructions on how to do this are given
under “Lighting the Fire Front with a Match or Spill”.

A slight smell may occur, for a short time, after initial lighting, this
is quite normal and will quickly disappear.

With a little use the interior of the fire front will discolour and
acquire the appearance of a solid fuel fire.

Combustible furniture must not be placed closer than 1metre in
front of the fire front.

Clothing or other flammable materials must not be placed on the
fire front casing.

The convection air openings at the top of the fire front and air
inlet grilles at the sides and base must never be obstructed.

Important. 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
fitted and when redecorating.

The glass panel on this fire front conforms to the requirements
of the current issue of BS1945 and satisfies the Heating
Appliance (Fireguard) Regulations.

The fire front must not be used if this panel is broken or missing.
WARNING. The glass panel gets very hot when the fire front is

on and MUST NOT be touched.
The glass panel does not provide full protection for the young,

elderly or infirm. In such cases extra security must be provided
by fitting a fireguard which complies with the current issue of

BS6539 “Fireguards for use with solid fuel appliances” or the
current issue of BS6778 “Fireguards for use with portable, free
standing or wall mounted heating appliances”.

Maintenance

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.

If this appliance is installed in rented property there is a duty of
care imposed on the owner of the property by the current issue
of the Gas Safety (Installation and Use) Regulations, Section

35.
It is the Law that servicing is carried out by a competent person.
To obtain service, please call your installer or Heatcall (Glow-

worm’s own service organisation) using the telephone number
given on the fire plinth.

Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.

All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on :- 01256 372300.

Heat Input - Fire Front

This gas fire front will run for about 4.4hrs at full on rate on one
therm of gas. The price of a therm of gas will vary according to
the tariff in your area.

At tap position 1 - centre section flame effect
At tap position 2 - centre section flame effect with

outer section fuel bed glow

At tap position 3 - centre and outer sections flame

effect with fuel bed glow

At tap position 4 - (full on) full flame effect and fuel

bed glow

Gas Leak or Fault

If a gas leak or fault exists or is suspected the appliance must
be turned off, including the electrical supply and must not be
used until the fault has been put right. Advice/help should be
obtained from your installation/servicing company or the local
gas undertaking.

Clearances

A shelf or surround of a maximum depth of 150mm may be
fitted, provided clearances are as diagram 1, however, for every
extra 25mm above the fire front the depth of the shelf may be
increased by 25mm.

On no account may carpet or other combustible material be laid
directly under the fire front, unless the minimum clearances
shown in diagram 2 is achieved.

The dimension is taken from the bottom of the fire front casting
to the top of the carpet pile or other floor covering.

3

221648B

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

Instructions for Use

150mm

430mm 430mm

150mm

C

L

7447

840mm

FLAT AREA
FIRE FIXING FACE

Frost

CAUTION. If the back boiler is to be out of use for any long
period of time during severe weather conditions we recommend
that the whole of the system, including the back boiler be
drained off to avoid the risk of freezing up.

If an immersion heater is fitted in the domestic hot water cylinder
make sure that it is switched off.

If in doubt your installation/servicing company or the local gas
undertaking should be contacted

Electrical Supply

WARNING The boiler must be earthed.
Connection of the appliance and any system controls to t h e

mains (230V~50Hz) must be through one unswitched shuttered
socket outlet and a 3A fused 3 pin plug, both to the current issue
of BS1363. Alternatively, a fused 3A fused double pole isolating
switch may be used, having a minimum double pole contact
separation of 3mm, serving only the appliance and system
controls.

The colours of three core flexible cable are, blue - neutral, brown

- live, green and yellow - earth.

As the markings on your plug may not correspond with these
colours, continue as follows:-

The wire coloured blue must be connected to the terminal mark
“N” or black.

The wire coloured brown must be connected to the terminal
marked “L” or red.

The wire coloured green and yellow must be connected to the
terminal marked “E”, green or the earth symbol

.

628mm

Diagram 1

7448

183mm

Diagram 2

Lighting the Appliance
Back Boiler

This appliance is fitted with a flue blockage safety device which
will shut down the appliance in the event of abnormal flue
conditions. This device is NOT a substitute for an independently
mounted Carbon Monoxide detector. If it shuts down frequently
for no apparent reason the first things that must be checked are
the chimney and air inlets into the room.

Any problems found must be put right, by a competent person,

4221648B

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Instructions for Use

before the boiler is used again.
If the burner go out, wait three minutes before relighting, but

check as above.
The back boiler controls are fitted behind the fire front plinth, see

diagram 3.
To remove the plinth, grasp each side and pull gently forwards

until it is free, see diagram 3.
Refer to diagram 4 to identify the controls.
Turn the electrical supply off at the mains outside the unit.
See that all other controls are calling for heat.
The clock, room thermostat and programmer, if fitted, will be

away from the unit. Refer to manufacturer’s instructions supplied
with these items.

Turn the control thermostat knob “B” to the “O” position, that is,
fully anti-clockwise (“O” to be against the pointer).

Partially push in and turn multifunctional control knob “A”
clockwise until “O” is against its setting point, that is, set to “Off”.

Partially push in and turn multifunctional control knob “A” anti­clockwise until “
fully and hold in. At the same time press and release button “D”
until the pilot burner “E” lights. Look at the flame through
viewing window “F”.

At initial lighting of the back boiler air may be present and
several attempts may be needed to light the pilot.
Keep the multifunctional control knob “A” pushed in whilst
operating the button “D”.

When the pilot is alight and stable, keep knob “A” pushed in for
about 15 seconds and then release. Check that the pilot is still
alight by looking through window “F”.

If the pilot fails to stay alight turn gas control knob “A” “Off”, that
is, fully clockwise. Wait three minutes. Repeat the lighting
procedure, only now keep the control knob “A” pushed in for a
little longer than 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.

When the pilot is alight, push control knob “A” in slightly and turn
it anticlockwise until “

Note. If the multifunctional control knob “A” is turned until “
is against the setting point, a safety lock prevents it being turned
on again. No attempt should be made to turn the multifunctional

” is against its setting point, then push in

“ is against the setting point.

control on again until at least three minutes have gone by.
Turn on the electrical supply to the unit.
Turn the control thermostat knob “B” clockwise until “Max” is

against the setting point, the main burner will now light.
Adjust the control thermostat to the required setting between

“Min” and “Max”. “Max” is about 82
Check that the external controls are calling for heat.
Refit the fire front plinth by carefully fitting the top edge of the

plinth into the sliders, then push it backwards as far as it will go.

o

C.

To Turn the Back Boiler Off

For short periods, turn control thermostat control knob “B”
anticlockwise until “O” is opposite its setting point. The pilot will
stay alight.

To relight the main burner turn control thermostat control knob
“B” clockwise to the desired setting between “Min” and “Max”.

For longer periods, push in slightly and turn multifunctional
control knob “A” clockwise until “
Turn control thermostat control knob “B” anticlockwise to “O”.
Switch off the electrical supply to the appliance.

To relight, follow the full lighting procedure.

PLINTH

”

” is against its setting point.

7458

Diagram 3

PILOT BURNER 'E'

SETTING
POINT

MAX

MIN

THERMOSTAT
CONTROL KNOB 'B'

PIEZO UNIT
BUTTON 'D'

VIEWING
WINDOW 'F'

MULTI-FUNCTIONAL
CONTROL KNOB 'A'

5

5156

SETTING
POINT

OFF
PILOT/IGNITION
MAIN BURNER

Diagram 4

221648B

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Instructions for Use

Lighting the Fire Front

CAUTION. If the glass panel or internal fire parts are damaged
do not light or use the fire front before replacement parts are
fitted.

The fire front is fitted with a flue blockage safety device which
will shut it down if there is a problem with the chimney. If the fire
front shuts down frequently, for no apparent reason the first
thing 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.

Push the control knob fully in and turn it anticlockwise to “1
ignition, clicking of the ignition will be heard and the burner will
light.

IMPORTANT. If the burner does not light within three seconds,
release the control knob, wait ten seconds and repeat the
lighting operation.

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

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

To change settings:­ Push in and turn. Refer to diagram 5.
If the burner goes out for any reason whilst the fire is turned on,

turn off.
Wait three minutes before relighting as above.
If relighting for any other reason wait two minutes before doing

so.
It can take several minutes for the fuel effect pieces to glow and

the flame effect to appear.
To turn off, turn the tap fully clockwise to “O” position and

release.
If there is a visible build up of soot on the fuel effect pieces follow

the instructions in Section on “Cleaning the Fire”.

7581

APPLIANCE OFF

“

IGNITION POSITION
AND CENTRE
SECTION
FLAME EFFECT

CENTRE SECTION
FLAME EFFECT
WITH OUTER
SECTIONS
FUELBED GLOW

Lighting the Fire Front with a Match or Spill

This is a temporary measure, to be used only in the event of the
failure of the battery or the spark generator.

Make sure that the fire front is cold before starting.
Remove the front casting, see diagram 5.6.
Hold a lighted spill or long match and position it so that the flame

is over the burner, see diagram 6.
Keep the spill in position, push in and turn the gas tap to position

“ ignition and the burner will light. Keep the knob pushed

“1.
for about ten seconds and the burner will stay alight.

If the burner should go out repeat the above, but now keep the
knob pushed in for a little longer.

Once lit operate the control knob normally.
This is a temporary measure only and the battery should be

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

Cleaning your Fire

WARNING. This appliance contains metal parts (components)
and care should be taken when handling and cleaning, with
particular regard to edges.

Any cleaning work must only be carried out when the fire front
is cold.

Under normal circumstances dusting should be enough. An
occasional wipe over with a damp cloth will help remove marks.

Do not use an abrasive cleaning powder or liquid.

CENTRE AND
OUTER SECTIONS
FLAME EFFECT
WITH FUELBED
GLOW

FULL FLAME
EFFECT WITH
FUELBED GLOW

Diagram 5

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Instructions for Use

Glass Panel and Internal Fire Front Parts

Lift the canopy off, see diagram 7. Take care as it is made of
cast iron.

Swing the side panels open, see diagrams 7 & 18.
Remove the glass panel, see diagram 8.
Clean the front glass panel inside and out with a proprietary

ceramic hob cleaner.
Should any soot accumulation become excessive, the fuel

effect pieces should be removed from the fire for cleaning.
Cleaning should be carried out in a well ventilated area or in the
open air, by gently brushing with the pieces held away from your
face so that you avoid inhaling the dust. We do not recommend
the use of a normal domestic vacuum cleaner, which may blow
dust back into the air.

CAUTION. If replacing use only the fuel effect pieces approved
for this fire front.

When replacing fit as shown in diagrams 9 to 16.
Note. Each fuel effect piece is numbered on its back.
DO NOT USE MORE FUEL EFFECT PIECES

THAN SHOWN.

To Replace the Battery

The battery supplied, should, under normal usage last for about
18 months.

The replacement is 9V and we recommend that it be of the
alkaline type which can be bought locally.

Remove the canopy as diagram 7. Take care as it is made of
cast iron. Remove the gas control knob, remove the securing
screw stop, swing open the right hand side panel as diagram 18.
Fit the battery as shown in diagram 19, make sure that the
terminals are correctly fitted.

Replacement Parts

If replacement parts are required apply to your local supplier.
Please quote the name of the fire front, “Saxony 2”, to be found

on the control knob bezel.
The back boiler serial number can be found on the base after

removal of the plinth.
The fire front serial number can be found on the chassis, visible

when the front casting is removed.

7449

5mm

5mm

Diagram 7

BURNER

7559

5094

SPILL

GLASS
RETAINING
BRACKET

PULL FORWARDS
AND UP

GLASS
FRONT PANEL

SPILL

Diagram 6

7

Diagram 8

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Instructions for Use

FUEL EFFECT PIECES LOCATIONS

4

2

2

1

4

2

1

FUEL EFFECT PIECES 1 to 5

Left
Side

FUEL
EFFECT
BASE
(see note)

5

5

3

3

FUEL
EFFECT
BASE

Diagram 9

Right
Side

4329 S

5088

FUEL EFFECT PIECE POSITION 2

NOTE:

FUEL EFFECT PIECE MUST
SIT ON SUPPORT ANGLE

FUEL EFFECT PIECE POSITION 3

4332 S

LOCATION
RECESS 2

Diagram 12

4333 S

NOTE:

Fuel Effect Base
seats behind
retaining brackets

FUEL EFFECT PIECE POSITION 1

RETAINING
BRACKETS

SUPPORT ANGLE FOR
FUEL EFFECT PIECES
1, 2 AND 3

LOCATION
RECESS 1

FUEL
EFFECT
BASE

Diagram 10

4331 S

LOCATION
LUG 3

NOTE:

FUEL EFFECT PIECE MUST
SIT ON SUPPORT ANGLE

FUEL EFFECT PIECE POSITION 4

LOCATION
RECESS 4

Diagram 13

4334 S

NOTE:

FUEL EFFECT PIECE MUST
SIT ON SUPPORT ANGLE

Diagram 11

8221648B

Diagram 14

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FUEL EFFECT PIECE POSITION 5

LOCATION
RECESS 5

Instructions for Use

4335 S

7562

SECURING
SCREW
STOP

COMPLETED FUEL
EFFECT BED

Ensure corners of fuel effect
pieces 4 and 5 are seated on
flat areas of fuel effect pieces
1, 2 and 3

CANOPY

Diagram 15

Diagram 16

LOCATING

PIN

LOCATING

HOLE

3943 S

4850

GAS CONTROL KNOB

SECURING
SCREW

FIBRE
WASHER

R.H. SIDE
PANEL

Diagram 18

5283

9V ALKALINE
BATTERY

Diagram 17

9

SPARK
GENERATOR

ELECTRICAL
CONNECTIONS

SECURING
SCREW

IGNITION
LEAD

Diagram 19

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Supplementary Instructions

This appliance is fitted with a flue blockage safety device which
will shut down the appliance in the event of abnormal flue
conditions. This device is NOT a substitute for an independently
mounted Carbon Monoxide detector.

As this fire front may be fitted to a Glow-worm 45, 56, 45R or 56R
back boiler unit WITHOUT a flue blockage safety device, the
following instructions on how to light the boiler should be read
and followed in place of those in the main instructions for use.

To check if a flue blockage safety device is fitted, refer to the
inset in diagram 18, if one is fitted this supplement MUST be
ignored.

Lighting the Boiler

The boiler controls are placed behind the fire front plinth, see
diagram 3.

To remove the plinth, pull it gently forwards until it is free.
Refer to diagram 20 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.

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” lighted. 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 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 control knob “A” pushed in for
a little longer than 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 until “

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.

Turn on the electrical supply to the unit.
Turn the boiler thermostat 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 82
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.

o

C.

” is against the

SETTING
POINT

'B'
THERMOSTAT
CONTROL
KNOB

BOILER CONTROLS

INSET: Showing a Flue Blockage

Safety Device fitted.

'E' PILOT BURNER

'F' VIEWING
WINDOW

'A'

'D' PIEZO
UNIT
BUTTON

GAS VALVE
CONTROL
KNOB

5342

SETTING
POINT

OFF

PILOT/IGNITION

MAIN BURNER

Diagram 20

10221648B

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1 General

FLAT AREA
FIRE FIXING

286mm 616mm

FACE

442mm

7450

690mm

326mm
344mm

1 General Notes and Information

This fire front may be fitted to a Glow-worm back boiler WITHOUT
a flue blockage safety device. Please refer to the supplementary
instructions at the end of this booklet, especially “Lighting the
Boiler”.

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 flue blockage safety device which

will shut down the fire if there is an unacceptable spillage of
products at the draught diverter. If the fire front shuts down
frequently for no appreant 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 front is used again.

628mm

Diagram 1.1

Sheet Metal Parts

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

1.2 Statutory Requirements

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

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

Regulations, 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.

11

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1 General

1.3 Data

Gas connection - from the service cock
Total weight - 54kg
Injector - upper - Bray 18/180

- lower - Bray 18/320

Burner pressure setting

- cold - 13.0mbar 5.2in wg

- hot - 13.2 mbar 5.3in wg
Heat input - gross 6.7kW - 22,750Btu/h
Heat output -nominal 4.03kW - 13,670Btu/h
Fire serial number - on chassis - visible when front

Data label - Inside of right hand side panel

The fire front burner is lit by means of a battery operated
electronic spark generator unit.

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 fitted in accordance with
the Glow-worm Installation and Servicing Instructions.

The back boiler must be correctly positioned in the builder’s
opening as the fire front is located by connection to it.

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. (Instructions for Use).

The fire front flue spigot sticks out into the back boiler flue
collector assembly.

The gas supply is taken from the back boiler gas service cock.

casting removed

1.5 Clearances

Restrictions must not be placed around the assembled fire
front, see diagram 1. (Instructions for Use).

A shelf or surround of a maximum depth of 150mm may be
fitted, provided clearances are as shown in
diagram 1. (Instructions for Use). However, for every extra
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.

12221648B

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

2 Types of Installation and Flue

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. (Instructions for Use). Any projections 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.

2.3 Without Surround or Hearth

The fire front fixing wall face must be flat over an area as shown
in diagram 1. (Instructions for Use). 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.

On no account must carpet or other combustible material be laid
directly under the fire front, unless the minimum clearances
shown in diagram 2 (Instructions for Use) are 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 be made during the installation of the back
boiler for the total ventilation requirement for the combined
appliance. See relevant section in the Back Boiler Installation
Instructions.

INSTALLATION CENTRE LINE

406mm to

460mm

FRONT
OPENING

C

L

7594

560mm

to

590mm

PREPARED
BASE

Diagram 2.2

7456

NON-COMBUSTIBLE

MATERIAL

12mm

50mm

13mm

MIN.

762mm

350mm

Diagram 2.1

13

BUILDERS

OPENING

INSTALLATION

CENTRE

HEARTH MOUNTED
Remove Combustible
Material From this Area

C

L

LINE

280

PREPARED

5076

680

BASE

Diagram 2.3

221648B

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3 Fire Front Preperation

FIRE BODY PACK

LITERATURE

FIRE
BODY
ASSEMBLY

CASING PACK

FLUE SPIGOT

FUEL
EFFECT
BED

7629

WALL
SEALING
PLATE

COMBUSTION
CHAMBER
BOTTOM PLATE

L.H. SIDE
CASTING

L.H. SIDE
PANEL

L.H.
LEG

PLINTH

CANOPY

R.H. SIDE
PANEL

FRONT
CASTING

R.H. SIDE
CASTING

REAR
SUPPORT
LEGS (2)

14221648B

R.H.
LEG

Diagram 3.1

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

3 Fire Front Preperation

KEY

A

B

C

SCREW FRONT LEG

M5x30 LEVELLING SCREW

SCREW SIDE

M5x14 CASTINGS

SCREW UPPER WALL

M5x40 MOUNTING

D ANCHOR UPPER WALL

NUT MOUNTING

E

F

G

H

SCREW FRONT LEG

M5x8 FIXING

SCREW WALL SEALING

No. 10 x 11/

2

PLATE FIXING

WALL WALL SEALING
PLUG PLATE FIXING

SCREW UPPER SIDE

RETAINING

SCREW FLUE SPIGOT FIXING

J

No.8x3/8in.

K

L

TAPTITE SCREW SENSING TUBE MOUNTING

SENSING
TUBE
MOUNTING
BRACKET
ASSEMBLY

BBU
SENSING
TUBE

SCREW SENSING TUBE

M4x10 FIXING SCREW

M4x6 BRACKET SCREW

FILTER

BATTERY

FIRE FRONT
SENSING
TUBE

TUBING
NUT (2)

LIQUID
COAL

OLIVE (2)

CONTROL
KNOB

FIBRE WASHER (2)

GAS SUPPLY
PIPE

SIDE EXTENSION (2)

15

Diagram 3.2

221648B

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3 Fire Front Preperation

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 3.3.
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

3.4.
Note. There are eight self tapping screws in the pack, one

spare.

Gas Supply Tube

Measure the distance “C”, see diagram 3.6, 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 (2

GLASS RETAINING
BRACKET

5

/8in).

4844

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 4.1. Fit the sensing tube filter onto the
fitting assembly, see diagram 4.1. Take care not to damage the
filter.

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 4.1.

Note. After fitting the flue blockage 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 3.5.

The inlet supply tube, back boiler sensing tube assembly and
fire front sensing tube are packed in the supply tube pack, see
diagram 3.2.

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.

GLASS
FRONT PANEL

FLUE SPIGOT ASSEMBLY

Diagram 3.3

SECURING

J

SCREW (7)

3923 S

16221648B

Diagram 3.4

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

3 Fire Front Preperation

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 3.7.
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 19. (Instructions for Use). make sure that the terminals
are correctly fitted.

GAS SERVICE
COCK UNION

6140

*'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 3.6

5078

BACK
BOILER
ONLY 'ON'
TURNED
FULLY
CLOCKWISE

BACK
BOILER &
FIRE 'ON'
TURNED TO
MID POSITION

'OFF'
TURN FULLY
ANTI­CLOCKWISE

90˚

180˚

Diagram 3.5

*'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

56/2 BBU
FIRE
FIXING
WALL FACE

*'D'

45/2 BBU
FIRE
FIXING
WALL FACE

*'D'

Diagram 3.7

17

221648B

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4 Installation

4.1 Wall Section Plate

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, in the supply tube pack, leave
sufficient screw proud to accept the wall sealing plate keyholes,
see diagram 4.2.

Fit the wall sealing plate and tighten the screws, making sure
that the “wings” are flush with the fire fixing wall face, see
diagram 4.2.

4.2 Positioning the Fire Front

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

4.3.
Mark the fire front fixing points through the mounting bracket

holes at the top, see diagram 4.3.
Pull the fire front forwards and remove.
Drill the fire front fixing wall 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 4.4.

Place the tubing nut and olive from the supply pack onto the
prepared end of the sensing tube, see diagram 4.4.

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

4.5.
Tighten the fire securing screws, see diagram 4.6.
Tighten the sensing tube nut onto the bulkhead, see diagram

4.7.

MARK
FRONT
FIXING
HOLES

5166

G

F

NOTE:
WINGS
FLUSH
WITH
WALL

Diagram 4.2

5246

SPIGOT

SENSING
TUBE
FITTING
ASSEMBLY

3 mm

TUBING
NUT

FILTER

THREAD CUTTING

SCREW(Taptite)

FRONT FACE
OF BOILER

BACK

CASTING

BOILER
SENSING TUBE

BULKHEAD CONNECTION

BOILER AIR DUCT

SENSING
TUBE
FITTING
ASSEMBLY

Diagram 4.1

6138

FLUE
COLLECTOR
ASSEMBLY

FIRE FRONT

Diagram 4.3

18221648B

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

4 Installation

SECURING
SCREW (2)

FLUE
COLLECTOR

TUBING
NUT

OLIVE

FIRE FRONT
SENSING
TUBE

Diagram 4.4

MOUNTING
BRACKET

C

SECURING
SCREW (2)

ANCHOR
NUT

5093

C

SECURING
SCREW (2)
M5 x 40mm

D

FRONT
FIXING
SCREW

FLUE
COLLECTOR
ASSEMBLY

BACK
BOILER
AIR
DUCT

FIRE FRONT

SPIGOT

5074

Diagram 4.6

4.3 Gas Connection

Place the tubing nut and olive, from the loose items pack, onto
the prepared end of the gas supply tube, see diagram 4.8.

Connect the gas supply, as diagram 4.8, tighten the nut and
olive at the gas service cock.

To tighten the other end, use a spanner to hold the locknut (A)
at the bulkhead fitting and make sure that it does not turn,
tighten union nut (B) on the supply tube in the usual manner,
see diagram 4.8.

Make sure that joint (B) is checked for gas soundness, by
checking it when carrying out the other gas soundness checks
as in Section 5.1.

Fit the left hand side panel, see diagram 4.9.

SENSING
TUBE

TUBING
NUT

OLIVE

Diagram 4.5

19

221648B

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

4 Installation

TUBE NUT

TUBE NUT

SENSING
TUBE

Diagram 4.7

5167

LOCK
NUT (A)

JOINT (C)

GAS SUPPLY
PIPE

3929 S

UNION
NUT (B)

GAS SERVICE COCK

TUBING
NUT

SECURING SCREW
STOP

J

FIBRE
WASHER

LOCATING PIN
AND HOLE

SECURING SCREW
STOP

J

FIBRE
WASHER

OLIVE

Diagram 4.8

R.H. SIDE
PANEL

GAS CONTROL
KNOB

4849

L.H. SIDE
PANEL

LOCATING PIN
AND HOLE

20221648B

R.H. SIDE PANEL

LOCATING PIN
AND HOLE

Diagram 4.9

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

5 Lighting, Testing and Fitting Internal Parts

5.1 Lighting and Testing

Make sure that the electrical supply to the back boiler is
isolated.

This fire front is fitted with a flue blockage safety device which
will shut down the fire if there is an unacceptable spillage of
products at the draught diverter. If the fire front 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 front is used again.

The flue blockage safety device MUST NOT be adjusted or
disconnected. If replacing use only the correct and approved
parts.

Remove the pressure test nipple screw and fit a suitable
pressure gauge, see diagram 5.1.

Place the right hand side panel onto the pins, see diagram 4.9,
but do not secure at this time.

Turn the gas service cock to back boiler and fire ON, see
diagram 3.5.

To check for gas soundness use the pressure drop method and
apply suitable leak detection fluid to all joints, replace the glass
panel, see diagram 3.3.

Fit the control knob to the tap spindle, see diagram 5.2.
IMPORTANT NOTE. If the burner does not light within three

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

Push the control knob fully in and turn it anti-clockwise to 1

- ignition, see diagram 5.2, clicking of the ignition will be heard
and the burner will light.

Keep the knob pushed in four ten seconds, to energise the
flame supervision device, during this time the ignition system
will continue to operate, indicated by the clicking.

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

With the burner lit, visually check for leaks whilst changing tap
settings.

To change settings:

0 - 1 Push in and turn
1 - 2 Push in and turn
2 - 3 Push in and turn
3 - 4 Push in and turn

If the burner goes out, wait three minutes beforerelighting, for
any other reason wait for two minutes.

Check that the gas pressure is as stated in the Data Section 1.3,
or on the Data Label on the right hand side panel.

If there is any doubt about the gas rate, check at the meter,
having first turned off all other gas appliances and pilot lights.

The rate for this fire front, after ten minutes, is about 2.7minutes

3

.

for 1ft
Turn the burner off, remove control knob, release right hand

side panel and pressure gauge, replace the test point screw and
make sure a gas tight seal is made.

Refit, close and secure the side panels, see diagram 4.9.

GAS
TAP

VERTICAL

5082

GAS
CONTROL
KNOB

APPLIANCE

OFF

FLAT DOWN
POSITION

IGNITION &

POSITION 1

PRESSURE
TEST
POINT

Diagram 5.1

POSITION 2

5081

21

POSITION 4POSITION 3

Diagram 5.2

221648B

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5 Lighting, Testing and Fitting Internal Parts

5.2 Internal Parts - Fitting

Caution. If any of the internal fire front parts are damaged DO
NOT light or further test the fire front until replacement parts are
fitted.

Refit gas tap control knob.
Swing the side panels out by about 5mm, to their stops.
Warning. The Glass panel can be hot.
Remove the glass panel, see diagram 3.3.
Fit the combustion chamber bottom plate, inside base tray, see

diagram 5.3.
Follow sequence in diagrams 9 to 16. (Instructions for Use). to

fit internal fire front parts.
Note. The fuel effect pieces are marked on their backs.

5.3 Decorative Castings

Fit the front legs as diagram 5.4, decorative side castings as
diagram 5.5, front casing as diagram 5.6, replace glass panel
assembly as diagram 3.3, and canopy as diagram 17.
(Instructions for Use). Take care as it is made of cast iron.

Note. The canopy is fitted with two adjusting screws, see
diagram 5.7. These should be adjusted so that the canopy
sides fit parallel to the side panels.

This adjustment can be done when the canopy is in place.

5.4 Fitting of Plinth

Before fitting the plinth please read the instructions on it.
Fit the plinth onto the guides and push it back as far as it will go,

see diagram 3. (Instructions for Use).

5.5 Heat Settings

Light the fire front burner as the relevant part of
Section 6.1.

Refer to diagram 5. (Instructions for Use).
At tap position 1 - centre section flame effect.
At tap position 2 - centre section flame effect with

outer sections fuel bed glow.

At tap position 3 - centre and outer sections flame

effect with fuel bed glow.

At tap position 4 - (full on) full flame effect and fuel

bed glow.

In the unlikely event of the flame going out when the fire front
burner is on, then turn off. Wait three minutes before relighting.

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

5.6 Test for Clearance of Products

Notes
WARNING. Take care, the appliance will get hot during tests.
For the test you will need a smoke match, extension and a torch.
IN ALL CASES, if spillage continues after the specified test

periods steps must be taken to put the fault(s) right.
If the problem cannot be put right the appliance must be

disconnected and expert advice sought.

22221648B

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

5 Lighting, Testing and Fitting Internal Parts

BOTTOM
PLATE

LEVELLING
SCREW

F

Diagram 5.3

5071

5073

4848

LOCATION PIN

LOCATION
SLOT

VIEWED FROM REAR

WASHER

SECURING
SCREW (2)

A

7457

REAR
SECURING
SCREW (1)

B

Diagram 5.4

FRONT
CASING

Diagram 5.6

REAR VIEW

LOCATING PIN

FRONT SECURING
SCREW (2)

L

Diagram 5.5

23

ADJUSTING SCREWS

Diagram 5.7

221648B

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

5 Lighting, Testing and Fitting Internal Parts

Test Where No Fan is Present

Close all outside doors and windows in the room where the
appliance is installed.

Light the fire front only and set tap position to 4. After five
minutes apply a spillage test as shown in diagram 5.8 and 5.9.
During tests smoke should be drawn into the fire draught
diverter and the boiler draught diverter.

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

Next light the back boiler only. After ten minutes apply spillage
test as shown in diagram 5.8 and 5.9. During tests smoke
should be drawn into the fire front draught diverter and boiler
draught diverter.

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

Leave the back boiler alight.
Now light the fire front. After ten minutes apply spillage tests as

shown in diagram 5.8 and 5.9. During tests smoke should be
drawn into the fire draught diverter and boiler draught diverter.

If spillage occurs leave back boiler and fire front alight for up to
a further five 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 carryout 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 the fan on and repeat the spillage test as above.

5168

DRAUGHT
DIVERTER

L.H. SIDE
PANEL

SMOKE MATCH
EXTENSION

TORCH

25 mm

25 mm

MATCH EXTENSION

10

10

DIVERTER
PLATE

560 SMOKE
MATCH
EXTENSION

Diagram 5.8

5169

10

FRONT VIEWSIDE VIEW

FIRE SPIGOT NOT
SHOWN FOR CLARITY

Diagram 5.9

24221648B

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

6 Instructions for Use

Hand the Instructions for Use to the user and instruct in the safe
and economical use of the fire front and back boiler.

Advise the customer that they should read their Users
instructions before operating the fire and always follow the
advice in the Section headed “Cleaning your Fire”.

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

Advise that the fire front is fitted with a flue blockage safety
device, and refer to the Instructions for Use.

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

Advise the user that, to ensure the continued efficient and safe
operation of the appliance it is recommended that it is checked
and serviced at regular intervals. The frequency of servicing
will depend upon the particular installation and usage, but in
general once a year should be enough.

Draw attention, if applicable. to the current issue of the Gas
Safety (Installation and Use) Regulations, Section 35, which
imposes a duty of care on all persons who let out any property
containing a gas appliance.

It is the Law that any servicing is carried out by a competent
person.

Refer to the Instructions for Use and show how to light the fire
front, in the event of an ignition system failure, with a spill or long
match

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.

Reminder, leave these instructions with the user.

5094

SPILL

BURNER

SPILL

Diagram 6.1

Advise the user that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning or servicing.

3 Flue Systems

7 Servicing

Notes

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.

It is the Law that servicing is carried out by a competent person.
Make sure that the fire is cold before carrying out any servicing.
After servicing, or replacing parts, always test for gas soundness

with a suitable leak detection fluid. To test the gas tap, refix the
fire front and apply leak detection fluid to all joints, replace the
glass panel, light the burner and visually check all joints for
leakage whilst changing tap settings.

Carry out functional check on controls, see Section 4 and 5.
Other than for replacing the glass panel, internal fire front parts

and lighting the fire front should be removed from its fixings by
reversing the instructions in Section 4 and 5. Make sure that
the side panels and feet are removed. Refit controls cover plinth
so that the fire can stand upright.

Unless stated otherwise reassembly all parts in the reverse
order to removal.

The back boiler should be serviced at this time, refer to Back
Boiler Installation and Servicing Instructions.

The flue blockage safety device MUST NOT be adjusted or
disconnected. If replacing use only the correct and approved
parts.

7.1 Glass Panel

Lift canopy off, take care as it is made of cast iron.
Swing open side panels to their stops, about 5mm, as diagram

7 & 18 (Instructions for Use).
To remove the glass panel, refer to diagram 3.3.

7.2 Internal Fire Front Parts

Remove internal fire front parts as diagrams 15 to 11. (Instructions
for Use).

Remove bottom plate, see diagram 5.3.
Examine these parts and replace as necessary.

7.3 Burner and Injectors

Remove the front castings, see diagram 5.6.
Remove the lower front baffle, see diagram 7.1.
Remove the burner baffle, see diagram 7.1.
Remove the RH. leg, see diagram 5.4.
Remove the side castings, see diagram 5.5.

25

221648B

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7 Servicing

4854

LOWER

FRONT

BAFFLE

SECURING SCREWS (3)

SECURING SCREWS (2)

BURNER
BAFFLE

Remove the RH. leg support bracket, see diagram 7.2.
Disconnect the supply pipe unions at the injectors also the union

connection at the front, see diagram 7.3.
Remove the two burner securing screws, see diagram 7.3.
Swing the burner out for access, see diagram 7.4.
Unscrew the injectors, inspect, clean or replace as necessary,

see diagram 7.5.
Do not clean the holes with a wire or sharp instrument.
Remove injector box cover screw and plate, see diagram 7.5,

clean out dust and debris. Brush away any lint and dust from the
burner and surrounds. Using a soft brush or vacuum cleaner.

Do not use a brush with wire bristles.

7.4 Flue Blockage Safety Device

Remove the burner, refer to Section 7.3.
Check the condition of the electrode and thermocouple, clean

with a soft brush, see diagram 7.6.
Make sure the electrode is in line with the earth post and spark

gap is as in diagram 7.7.

7.5 Ignition Lead

Remove the burner, refer to Section 7.3.
Disconnect the tube nuts, remove the mounting bracket securing

screws and flue blockage safety device, see diagram 7.6.
Check the ignition lead, see diagram 7.6. Replace if required,

refer to Section 9.5.
Note. When refitting the flue blockage safety device, take care

not to trap the ignition lead under the mounting bracket.

Diagram 7.1

7.6 Gas Tap and Micro Switch Assembly

Note. This item need not be serviced annually.
Remove micro switch electrical connections, see diagram 7.8
Disconnect all union connections and remove the tubes in the

order shown in diagram 7.9.
Take care as the filter in the pilot port may be loose.
Disconnect the thermocouple nut, see diagram 7.10.
When replacing only tighten the nut a quarter turn beyond finger

tight.
Remove the gas tap bracket securing screws, see diagram

7.10.
Remove the gas tap assembly.
To service the gas tap remove the gas tap niting plate assembly

securing screws, see diagram 7.11. Take care as there is a
spring beneath the niting plate. Remove the plug, pin, spring
washer, plain washer and “O” ring, see diagram 7.11.

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

washer and micro switch leads are correctly located, see
diagram 7.8 and 7.11.

SECURING
SCREW
(4)

R.H. LEG
SUPPORT
BRACKET

5191

Diagram 7.2

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7 Servicing

L.H. BURNER

SECURING SCREW

BURNER

UNION

UNION CONNECTION

CONNECTION
NOTE:

Chamfered edge to be on
this side.

R.H. BURNER

SECURING SCREW

UNION
CONNECTION

Diagram 7.3

4855

5075

TUBE
NUT

TUBE
NUT

FLUE BLOCKAGE
SAFETY DEVICE

INJECTOR BOX
COVER

BURNER

PULL FORWARDS

Diagram 7.4

5172

3958 S

MOUNTING
BRACKET

SECURING
SCREW (2)

TUBE
NUT

SECURING
SCREW

INJECTORS

Diagram 7.5

27

SECURING
SCREW (2)

IGNITION
LEAD

Diagram 7.6

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7 Servicing

EARTH
POST

ELECTRODE

ELECTRODE

C

L

SPARK GAP

+ 1.0

3

- 0.5

EARTH
POST

5248

3960 S

GAS TAP MOUNTING
BRACKET SECURING
SCREW

MICRO SWITCH

ELECTRICAL
CONNECTIONS

INSULATION

MICRO
SWITCH

ELECTRODE

67

TOP VIEW

18

EARTH
POST

Diagram 7.7

NUT (2)

INSULATION

SECURING
SCREW (2)

GAS TAP
MOUNTING
BRACKET

Diagram 7.8

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7 Servicing

1

8

6

4

5089

2

GAS TAP SECURING
SCREWS

5090

9

5

7

3

9

5

THERMOCOUPLE

7

Diagram 7.9

GAS TAP

GAS TAP

BODY

NUT

Diagram 7.10

5091

BRACKET AND
NITING PLATE
ASSEMBLY

'O' RING

PLUG

WASHER

SPRING

SECURING
SCREW

29

Diagram 7.11

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8 Fault Finding

8.1 Fire Front Ignition

Remove decorative castings, glass panel and fuel bed, refer to
appropriate parts of Section 7.

Refer to diagram 8.3.

8.2 Electrical

Refer to functional flow diagram 8.2 and pictorial wiring diagram

8.1.

8.3 Thermocouple

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

Refer to fault finding diagram 8.4 and diagnosis graph, diagram

8.5.

8.4 Flue Blockage 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 obstruction, by carrying out
spillage checks as Section 5.6. If all is in order refer to diagram

8.3 to check if the filter is blocked.

ELECTRODE

RED

RED

SPARK
GENERATOR

5251

MICRO
SWITCH

5252

ELECTRODE

MICRO
SWITCH

SPARK GENERATOR

RED
RED

Diagram 8.1

30221648B

Diagram 8.2

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YES

START HERE

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

NO

8 Fault Finding

FIRE WILL NOT LIGHT

Check that gas is available
Does the pilot light using a match ?

YES

5478

NO

Change pilot filter

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

YES

NO

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

YES

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

NO

YES

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

Check that gas is available at burner, using a
match, ensuring correct functioning of burner
on all setting positions. Check that electrode,
micro switch and ignition unit connections are
satisfactory. Check that burner pressure is as
specified - correct any fault found.

NO

Remove ignition lead from ignition unit and
place screw driver between appliance chassis
earth and ignition unit, leaving 4mm gap
between blade and spade connector. Turn tap
to energise ignition. Is there a spark at gap ?

NO

YES

Renew ignition lead and
reassemble ignition system.

YES

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

YES

NO

Change ignition unit.

Check several times that ignition is satisfactory.

31

NO

Rectify faulty leads or
replace micro switch.

Diagram 8.3

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8 Fault Finding

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

Is voltage greater

than 15mV?

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 flue blockage
safety device.

Faulty thermocouple.
Replace flue blockage
safety device.

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

32221648B

Diagram 8.4

0065M

ABC

Diagram 8.5

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9 Replacement Parts

Notes.
Make sure that the fire is cold before replacing any parts.
Replacement of parts must be carried out by a competent

person.
Remove the internal fire front parts as the relevant part of

Section 5.2.
Before removing or replacing any fire front parts turn the gas

supply service cock to “Back Boiler Only On”, see diagram 3.5.
Isolate the electrical supply to the back boiler and fire front.
After replacing or disconnecting any gas carrying components,

always test for gas soundness, using a suitable leak detection
fluid and carryout functional check of controls.

To test the gas tap apply leak detection fluid to all joints, light the
burner and check all the joints for leakage at all tap settings.

Unless stated otherwise reassembly of all parts is in the reverse
order to removal.

9.1 Burner

Refer to Section 7.3.

9.2 Injectors

Refer to Section 7.3.

9.3 Gas Tap and Micro Switch Assembly

Refer to Section 7.5 and diagram 7.8 to remove the micro
switch.

9.7 Spark Generator

Remove right hand side panel, see diagram 4.9.
Remove the right hand side casting, see diagram 5.5.
Remove retaining screw, disconnect the electrical leads and

then release the spark generator from the location tab at the
rear, see diagram 19 (Instructions for Use).

9.8 Battery

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

When fitting make sure that it is fitted as shown in diagram 19
(Instructions for Use).

9.9 Gas Tap Pilot Filter

Remove right hand side panel, see diagram 4.9.
Gain access to the tap as Section 7.6.
The filter, which is very small, is in 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 9.1.

9.4 Flue Blockage Safety Device

Refer to Section 7.3 to remove burner.
Disconnect the union connections, remove the mounting bracket

securing screws and flue blockage safety device, see diagram

7.6.
Remove the right hand side panel, see diagram 4.9.
Remove the right hand side casting, see diagram 5.5.
Remove the thermocouple nut. see diagram 7.10.
Remove the ignition lead, see diagram 19 (Instructions for Use).
Note. When refitting the flue blockage safety device, take care

not to trap the ignition lead under the mounting bracket.
When refitting make sure the spark gap is as shown in diagram

7.7.

9.5 Ignition Lead

Refer to Section 8.3 to remove the burner.
Disconnect the ignition lead to the electrode.
Disconnect the union connections, remove the mounting bracket

securing screws, remove the ignition lead (black end), see
diagram 7.6.

Remove right hand side panel, see diagram 4.9.
Remove right hand side casting, see diagram 5.5.
Remove the ignition lead(clear end), see diagram 19 (Instructions

for Use).
Note. When refitting the flue blockage safety device, take care

not to trap the ignition lead under the mounting bracket.

33

221648B

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9 Replacement Parts

GAS TAP BRACKET
AND NITING PLATE
ASSEMBLY

9.10 Replacement Parts

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

Please quote the name of the fire front, “Saxony 2”.
The GC number can be found on the chassis, visible when front

casting is removed.
Refer to diagram 9.1 for the illustration of the replacement parts.
These fire fronts are fitted with flue blockage safety devices.

FILTER

FILTER

5477

GAS TAP

CROSS
SECTION
VIEW

Diagram 9.1

Key No. Part No Part No.G.C.. Description

1 210213 136 918 Rear fuel effect piece
2 210214 136 919 Fuel effect piece - 1
3 210215 136 920 Fuel effect piece - 2
4 210216 136 921 Fuel effect piece - 3
5 210217 136 922 Fuel effect piece - 4
6 210218 136 922 Fuel effect piece - 5
7 448093 136 924 Glass panel assembly
8 230169 398 444 Injector - upper
9 230201 398 442 Injector - lower
10 202437 162 100 Flue blockage safety device
12 202014 360 188 Microswitch
13 WW4617 312 997 Ignition lead
14 448103 135 925 Gas tap control knob
15 800449 136 927 Gas tap
16 202179 152 949 Spark generator
17 208673 162 208 Filter

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9 Replacement Parts

5092

1

7

5

3

6

2

4

8

15

10

9

13

12

16

17

14

35

Diagram 9.2

221648B

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10 Supplementary Installation Instructions

As these fire fronts may be fitted to Glow-worm 45, 56, 45R or
56R back boiler units WITHOUT a flue blockage 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 flue blockage safety device is fitted, refer to the
inset in diagram 20 (Instructions for Use).
If one is fitted this supplement MUST be ignored.

10.1 General

To fit the fire front to one of the above EXISTING GLOW-WORM
BACK BOILER UNITS follow the instructions below.

10.2 Installation

1. Do not fit the back boiler sensing tube as required in
the main installation and servicing instructions.

2. If necessary isolate the power supply to the back
boiler unit and remove the existing wiring used
previously for a fire front with lights.

3. Any references in the installation and servicing
instructions to the back boiler unit flue blockage safety
device must be ignored.

10.3 Lighting the Boiler

To light the boiler refer to lighting the boiler supplementary
instructions in the Instructions for Use.

Because of our constant endeavour for improvement details may vary slightly from those in the instructions.

36221648B