Glowworm REVIVAL 37 315 16 User guide

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220562A.05.95
Installation and Servicing Instructions
Tobeleftwiththeuser
REVIVAL
FIRE G.C. No. 37 315 16
FIREBLAZE
FIRE G.C. No. 37 315 14
For use with
Glow-worm 45F, 45FR, 56F or 56FR
Back Boiler Units
This is a Cat I2H Appliance
4031
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Total Service
Customer Services:
Tel: [phone]
Fax: [phone]
BS 6332
BS 5258

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1 G e n e r a l
Diagram 1.1
Sheet Metal Parts
WARNING. When installing or servicing this fire care
should be taken when handling sheet metal parts, to
avoid any possibility of personal injury.
1.2 Statutory Requirements
The installation of this fire front must be carried out by a
competent person, in accordance with the current issue
and relevant requirements of:
Manufacturer's instructions, supplied.
The Gas Safety (Installation and Use) Regulations,
The Building Regulations, Local Gas Undertaking, The
Building Standards (Scotland) Regulations (applicable in
Scotland), The Health and Safety at Work Act and
Control of Substances Hazardous to Health, The
Electricity at Work Regulations and any applicable local
regulations.
Detailed recommendations are contained in the current
issue of the following British Standards and Codes of
Practice:
BS1251, BS5440 Part 1 and 2, BS5871, BS6891,
BS7671.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
1.3 B.S.I. Certification
This fire front is certificated to the current issue of S.I.T
15, for performance and safety. It is, therefore,
important that no alteration is made to the fire without
permission, in writing, from Hepworth Heating Ltd.
725mm
4019
The instructions consist of three parts, Installation and
Servicing Instructions for the Back Boiler, Installation
and Servicing Instructions for the Fire Front and
Instructions for Use. They are the property of the user
and must be handed to them on completion of the
installation.
1 General Notes and Information
This Glow-worm Gas fire front is to be used only with a
Glow-worm 45F, 45FR, 56F or 56FR Back Boiler Unit.
The fire front is delivered in two cardboard cartons,
which together contain all the parts necessary for the
installation of the fire front.
If the back boiler and fire front are to be installed at the
same time please read both sets of Installation
Instructions before starting.
Wherever possible, all materials, appliances and
components to be used shall comply with the
requirements of applicable British Standards.
Where no British Standards exists, materials and
equipment should be fit for their purpose and of suitable
quality and workmanship.
1.1 Important Notice
This fire front and back boiler are for use on natural gas
as distributed in the United Kingdom (G20) and cannot
be used on any other gas.
191mm 560mm 191mm

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Diagram 1.3
1 G e n e r a l
Any alteration that is not approved by Hepworth Heating
Ltd., could invalidate the B.S.I. Certification, the warranty
and could also infringe the current issue of the Statutory
Requirements, see Section 1.2.
C.E Mark
The CE mark on this appliance shows compliance with
Directive 90/396/EEC on the approximation of the Laws
of the Member States relating to appliances burning
gaseous fuels.
1.4 Data
Gas connection - from service cock
Weight - Total - 43kg in two packs
Injector - Bray 18/380
Burner pressure at
setting II - hot - 15.3mbar
- cold - 14.7mbar
Heat input - nominal - 5.28kW (18,000Btu/h)
Heat output - nominal - 1.40kW (4,780Btu/h)
Data label - at rear left hand side
of fire front
All dimensions, except as noted, are given in millimetres.
1.5 Fire Front Location
This fire front can only be fitted to a Glow-worm 45F,
45FR, 56F or 56FR back boiler unit which itself has been
installed in accordance with the Glow-worm Installation
and Servicing Instructions for the back boiler.
Before fitting the fire front it is important to make sure
that the annular space between the back boiler flue liner
and the chimney is sealed at the base and top of the
chimney, as shown in diagram 1.3.
The back boiler air duct acts as a support for the
combustion chamber assembly.
The fire front must be secured to a vertical fire fixing
wall face. This wall face may be a chimney breast or
surround having a minimum flat area as shown in
diagram 1.2.
The combustion chamber flue spigot assembly projects
into the the back boiler flue collector assembly.
The gas supply is taken from the back boiler gas service
cock.
The back boiler must be correctly positioned in the
builder’s opening as the fire front is located by
connection to it.
1.6 Clearances
Restrictions must not be placed around the assembled fire
front, see diagram 1.2.
A shelf or surround of a maximum depth of 150mm may
be fitted, provided clearances are as shown in diagram 1.2.
However, for every 25mm above the fire front the depth
of the shelf may be increased by 25mm.
Combustible furniture or materials must not be placed
closer than 1metre (39in) in front of the fire front.
4018
825
305 305 150
MAX SHELF DEPTH
100
25
25
INSTALLATION
CENTRE LINE
FLAT AREA
FIRE FIXING
FACE
PREPARED BOILER BASE
Diagram 1.2
SEALING AND
CLAMPING
PLATE
AIR SPACE
600 mm
150mm (6in) plug ofMineral Wool
or similar- support as required
3102

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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
Diagram 2.1
Diagram 2.2
Diagram 2.3
2.1 Hearth
In ALL cases a fireproof hearth to the minimum
dimensions as shown in diagram 2.1, must be fitted.
2.2 With Surround
The combustion chamber assembly is designed to fit into
a standard builder’s opening as shown in diagram 2.2.
A wider opening will require to be reduced in width
using non-combustible materials.
The surround must have a minimum clear flat area as
shown in diagram 1.2. Any projection on the surround
must be outside this area.
Any combustible material, for example, blown vinyl
wall covering, on the fire front fixing face area of the
surround must be removed, see diagram 2.3.
This area, to the depth removed should then be rendered
with a sand/cement mixture.
2.3 Without Surround
The fire front fixing wall face must be flat over an area
as shown in diagram 1.2. This also shows the minimum
clearances for shelves or projections on the fire front
fixing wall face.
The information regarding the fire front opening must be
followed together with the last two paragraphs of “With
Surround”.
2.4 Flue and Ventilation
The back boiler flue collector assembly accepts the
combustion chamber assembly flue spigot.
Note. Provision must have been made during
installation of the back boiler for the total ventilation
requirement of the combined appliance. See the relevant
Section in the Back Boiler Installation and Servicing
Instructions
350mm
MIN
674mm MIN
13mm MIN NON-COMBUSTIBLE MATERIAL
FIREBLAZE SHOWN
4009
270 270
50
INSTALLATION
CENTRE
LINE
BUILDERS
OPENING
2967
719
PREPARED
BASE
REMOVE
COMBUSTIBLE
MATERIAL FROM
THIS AREA
560mm
to
590mm
406mm
to
450mm
PREPARED
BASE
3099
C
L

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3 U n p a c k i n g
Diagram 3.1
FIRE
BODY
PACK
FUEL
PACK
FIREBLAZE
CASING
PACK
REVIVAL
CASING
PACK
FIRE
FRONT
FUEL
EFFECT
BED
BASE
3/8 in
OLIVE
CONTROL KNOB
AND EXTENSION
8mm
OLIVE
GAS
SUPPLY
TUBE
UNION
NUT
9V ALKALINE
BATTERY LOOSE
ITEMS
PACK
FUEL
EFFECT
BED
FUEL
EFFECT
PIECES
INSULATION
COMBUSTION
CHAMBER
ASSEMBLY
LITERATURE
FRET
ASHPIT COVER ASHPIT COVER
FRET
FIRE
FRONT
4029

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Diagram 3.2
3 U n p a c k i n g
Diagram 3.3
3.1 Unpacking
The fire front is delivered in two packs, one contains the
combustion chamber assembly, fuel pack(s) and loose
items pack. The other contains the fire front, fret, ash pit
cover and fire control knob extension.
Refer to diagram 3.1 to identify the parts.
Check contents of loose items pack against packed list.
3.2 Gas Supply to Fire Front
Check that the gas service cock is in the boiler only on
position, see diagram 3.2.
The inlet supply tube is packed with the loose items.
The supply tube may need to be cut at the larger end
dependent upon the position of the back boiler unit in the
opening.
Measure the distance “C”, see diagram 3.3, from the
front mark “P” on the air duct to the fire fixing wall face.
Use a straight edge across the opening.
Shorten the gas supply tube by distance “C” + 21mm at
the larger end.
The maximum distance for “C” will be 25mm (1inch).
Deburr the tube end inside and out.
GAS SERVICE
COCK UNION
BACK BOILER
ONLY 'ON'
BACK BOILER
AND FIRE 'ON'
'OFF'
GAS FIRE
SUPPLY TUBE
FIRE FIXING
WALL FACE
BACK
BOILER
AIR DUCT (MAX. SHOWN) 'C'
'P'
'C'
'C'
2669
"C" = Distance from fire fixing wall face to
datums on back boiler air duct.
This represents the length of pipe
that requires cutting off.
3097

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4 I n s t a l l a t i o n
Diagram 4.1
Diagram 4.2
4.1 Positioning the Combustion Chamber
Assembly
Note: Before fitting, again make sure the wall surface to
which the combustion chamber assembly is to be fitted is
vertical and flat. Any unevenness may cause the whole
assembly to become twisted or distorted when fixing to
the wall.
Place the combustion chamber assembly into the fire
opening and make sure that the flue spigot fits into the
boiler flue collector assembly and locates onto the back
boiler combustion chamber extension and burner
assembly, see diagram 4.1.
Push well back to the fire fixing wall face.
Mark the four combustion chamber assembly fixing
points (making sure that the area is sufficiently firm),
through the holes in the surround refer to diagram 4.2.
Pull the combustion chamber assembly forwards and
remove.
Drill the fire front fixing wall face, using a 10mm
masonry drill to a minimum depth of 40mm to accept the
reusable anchor nuts and screws provided.
Place the anchor nuts in the holes.
Note. If the fire front fixing wall face is not of a solid
construction to a minimum depth of 40mm, for example,
hollow brick or metal an alternative and rigid form of
fastening for the combustion chamber assembly must be
used and extra care taken.
Fit the combustion chamber assembly, making sure that
it is correctly positioned onto the back boiler unit, see
diagram 4.1, secure with the screws provided.
Important: If the electrical supply to the boiler comes
from the right, make sure that when fitting the
combustion chamber assembly the cable is routed and
clear, as shown in diagram 4.1.
2971 2970
B.B.U. COMBUSTION
CHAMBER EXTENSION
AND BURNER ASSEMBLY
FIRE FIXING
WALL FACE
FLUE COLLECTOR
ASSEMBLY
FLUE
SPIGOT
COMBUSTION CHAMBER ASSEMBLY
COMBUSTION CHAMBER ASSEMBLY
SECURING
SCREW ANCHOR
NUT
=SECURING SCREW POSITION

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5 L i g h t i n g , T e s t i n g a n d F i t t i n g I n t e r n a l P a r t s .
Diagram 4.3
4 I n s t a l l a t i o n
4.2 Gas Connection
Place the union nut and olive, from the loose items pack,
onto the prepared end of the gas supply tube, see
diagram 4.3.
Connect the gas supply tube, as diagram 4.3 tighten the
nut and olive at the gas service cock and union nut at the
gas tap.
5.1 Lighting and Testing
Make sure that the gas tap is in the off position, that is,
the flat on the drive rod faces the wall, see diagram 5.1.
Take the length of black insulating material from the
loose items pack. Slide the insulation down the drive
rod as shown in diagram 5.1 and then fit the control
knob.
MAKE SURE THAT THE ELECTRICAL SUPPLY TO
THE BACK BOILER IS SWITCHED OFF.
Take the ash pit cover from the packing, make sure that
the harness strain relief is fully located into the slot and
that the locknut is tightened.
Now fit the strain relief bracket by removing the burner
fixing screw, place the strain relief bracket on top of
burner end bracket and then replace screw, see
diagram 4.3.
Connect the wiring harness to the microswitch and
electrode, see diagram 7.3 and 7.4.
Fit the battery, from the loose items pack, see
diagram 9.1.
Note the ash pit cover can be left connected up to the
micro switch and tap.
Remove the pressure test nipple screw and fit a suitable
pressure gauge, see diagram 5.2.
Turn the gas service cock to BACK BOILER AND
FIRE “ON”, see diagram 3.2.
To check for gas soundness apply leak detection fluid to
the two joints on the previously fitted gas supply tube.
WARNING: Take care when carrying out the following
check, as the burner flame is fully exposed.
Push the control knob in slightly and turn it
anti-clockwise to position I , now fully push in,
clicking of the ignition will be heard and the burner will
light.
IMPORTANT: If the burner does not light within 3
seconds, release the tap, wait 10 seconds and repeat the
lighting operation.
Keep the knob pushed in for 10 seconds, during this time
the ignition system will continue to operate, indicated by
the clicking.
3/8 IN
OLIVE
UNION
NUT AND
OLIVE
STRAIN
RELIEF
BRACKET
UNION
NUT AND
OLIVE
BURNER
FIXING
SCREW
UNON
NUT
4021

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5 L i g h t i n g , T e s t i n g a n d F i t t i n g I n t e r n a l P a r t s .
Diagram 5.1
Air may be present in the supply to the fire so that the
initial lighting operation may need to be repeated.
With the burner lit. Check joints at all tap positions for
gas soundness in accordance with the current issue of
BS6891.
To change settings, refer to diagram 5.4.
Check that the gas pressure is as stated in the Data
Section or on the Data Label.
If there is any doubt about the gas rate, check at the
meter, having turned off all other gas appliances and
pilot lights.
The gas rate for this fire front is about 0.63m3/h
(17.75ft3/h), equal to, after 10 minutes, about 3 minutes
23 seconds for 1ft3.
Push in and turn the control knob fully clockwise to turn
off, remove the pressure gauge, replace the test nipple
screw and ensure that a gas tight seal is made.
5.2 Fire Front
Remove the castings from the packaging.
Lift the fire front up, take care as it is heavy, and slide it
down to locate the pins into the brackets, see
diagram 5.3.
Secure the fire front to the combustion chamber
assembly (base), using the M4 screw provided in the
loose items pack, see diagram 5.3.
WALL LINE
12˚
DRIVE ROD
Flat facing the wall
INSULATION SLEEVE
CONTROL KNOB
3517
Diagram 5.2
PRESSURE
TEST POINT
4020
Diagram 5.3
4017
LOCATION
PEG (2)
LOCATION
HOLES
FIRE
FRONT
SECURING
SCREW
FIRE FRONT
RETAINING
NUT

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Diagram 5.6
Diagram 5.4
5.3 Internal Parts - Fitting
CAUTION. If the insulation, fuel effect bed base, fuel
effect bed and fuel effect pieces are damaged do not light
the fire or further test before replacement parts are fitted.
USE ONLY THE “FUEL EFFECT” APPROVED FOR
THIS FIRE FRONT.
To fit the insulation, fuel effect bed base, (pulling it
forward to fit by using the finger holes) fuel effect bed
and fuel effect pieces follow the sequence given in
diagram 5.5, 5.6, 5.8 and 5.9.
Diagram 5.7 shows the different shapes of the fuel effect
pieces and fuel effect bed.
Fit fret, see diagram 5.10.
5.4 Heat Settings
Refer to diagram 5.4.
In the unlikely event of the burner going out whilst fire
is on, turn off. Wait 3 minutes before relighting.
If relighting for any other reason, wait 2 minutes before
doing so.
LOW AND IGNITION
HIGH
PUSH IN AND TURN
ANTI-CLOCKWISE
3518
INSULATION
4016
“A” NOTE: USE FINGER HOLES
LEFT AND RIGHT TO PULL
DOWN FUEL EFFECT BED BASE
4015
FINGER
HOLE A
FUEL EFFECT BED BASE
FUEL EFFECT BED BASE
LOCATING
BRACKET
FINGER HOLES PULL
DOWN
Diagram 5.5

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Diagram 5.7
Diagram 5.8 Diagram 5.10
Diagram 5.9
Round fuel effect
pieces (2)
Oblong fuel effect
pieces (3)
Triangular fuel effect
pieces (5)
NOTE: The depressions indicate the position
of fuel effect pieces.
The 2 front fuel effect pieces have no
depressions for location.
(Dotted lines indicate positions.)
4013
Depressions Positions for 2
front effect pieces
FUEL
EFFECT
BED
4012
FUEL
EFFECT
BED REAR
SUPPORT (2)
FUEL EFFECT
BED
FRONT
SUPPORT (2)
FUEL EFFECT
BED
4014
FRET
LOCATION
PEG (2)
Note: Take care not to damage fuel
bed and fuel when lifting the fret
POSITION OF ROUND
FUEL EFFECT PIECES
POSITION OF ROUND AND OBLONG
FUEL EFFECT PIECES
POSITION OF ROUND OBLONG
AND TRIANGULAR FUEL
EFFECT PIECES
LOCATION
HOLE (2)
4014

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Diagram 5.11
Diagram 5.12
5.5 Test for Clearance of Products
Notes.
(a) WARNING. The fire front burner has an open flame.
(b) WARNING: Take care. The appliance will get hot
during testing.
(c) For the test you will need a smoke match and an
extension.
(d) IN ALL CASES, if spillage continues after the
specified test periods steps must be taken to rectify the
fault(s).
Possible causes include, flue obstruction, down draught
or restricted fresh air supply into the room.
If the problem cannot be put right the appliance must be
disconnected and expert advice sought.
TEST: WHERE NO FAN IS PRESENT
Close all outside doors, doors and windows in the room
in which the appliance is fitted.
Light the fire front only and set to tap position II. After
5 minutes apply a spillage test as shown in diagram 5.11.
If spillage occurs, leave fire front alight for up to a
further 10 minutes and repeat test. Turn the fire front
off.
Next light the boiler only. After 10 minutes apply
spillage test as shown in diagram 5.11.
If spillage occurs, leave the boiler alight for up to a
further 5 minutes and repeat tests.
Leave the boiler alight.
Now light fire front. After 10 minutes apply spillage
tests as shown in diagram 5.11.
If spillage occurs leave the boiler and fire front alight for
up to a further 5 minutes and repeat the tests.
TEST: WHERE A FAN IS PRESENT
A fan means an extract fan or a fan for other open flued
appliances or a circulating fan for a warm air unit,
whether or not gas fired). With the fan switched off
carry out the appropriate spillage test with all doors and
windows closed, as above.
If the above spillage test is satisfactory proceed as
follows:
Open all doors connecting the room containing the
appliance and the room in which the fan is fitted. Close
all other doors and windows in the premises.
If the fan is in the same room as the appliance, close all
doors and windows in that room. Switch the fan on and
repeat the spillage test as above.
5.6 Completion
Fit ash pit cover by hooking up under the fret, see
diagram 5.12.
4011
ASHPIT
COVER
ASHPIT
COVER
FRET
FIREBLAZE SHOWN
4030
38mm
38mm SMOKE
MATCH

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Diagram 6.1
Diagram 6.2
Hand the Instructions for Use to the user and make sure
that they are understood.
Instruct the user in the correct operation of the fire front
and boiler.
Advise the user that, if desired, the control knob
extension, from the loose items pack, can be used, see
diagram 6.2.
Before demonstrating lighting the fire front with a spill
or long match, warn the user that the fire front has an
exposed flame. Refer to diagram 6.1.
Hold a lighted spill or long match and insert it into the
hole as shown in diagram 6.1, position the spill so that
the flame is over the burner.
Keep the spill in position, push in slightly and turn the
gas tap knob to position I , now fully push in for
about 10 seconds and the burner will light, if not, repeat
the process.
Once lit operate the gas tap normally.
Advise that this is a temporary measure only and the
battery should be replaced or the ignition system be
repaired as soon as possible.
Advise the user that there are wires behind the ash pit
cover and care should be taken when removing it.
Advise that any smell which may be apparent on initial
lighting is quite normal and it will quickly disappear.
Important. Advise that soft wall coverings, for example,
blown vinyl wallpaper, are easily affected by heat, they
may, therefore, scorch or become discoloured when
close to a heating appliance. This should be borne in
mind when having a heating appliance installed and
when redecorating.
Advise that to ensure the continued efficient and safe
operation of the appliance it is recommended that it is
checked and serviced at regular intervals. The frequency
of servicing will depend upon the particular installation
and usage, but in general once a year should be enough.
Draw attention, if applicable to the current issue of the
Gas Safety (Installation and Use) Regulations
Section 35, which imposes a duty of care on all persons
who let out any property containing a gas appliance
It is the law that any servicing must be carried out by a
competent person.
Reminder, leave these instructions with the user.
6 I n s t r u c t i o n s t o U s e r
40103519
SPILL
CONTROL
KNOB
EXTENSION
CONTROL
KNOB

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Diagram 7.1
7 S e r v i c i n g
7.1 Notes.
(a) To ensure the continued efficient and safe operation
of the appliance it is recommended that it is checked
and serviced at regular intervals. The frequency of
servicing will depend upon the particular installation
and usage, but in general once a year should be
enough.
(b) It is the law that any servicing must be carried out by
a competent person.
(c) Make sure the fire front is cold before carrying out
any servicing.
(d) BEFORE SERVICING ISOLATE THE GAS AND
ELECTRICAL SUPPLIES.
(e) After servicing of parts always test for gas
soundness with a suitable leak detection fluid.
To test the gas tap apply leak detection fluid to all
joints, light the burner and check all the joints for
leakage at all tap settings.
WARNING: Take care as the burner flame is fully
exposed.
(f) Carry out functional check on controls.
(g) After removing or disconnecting any pipe work
always make sure that it is refitted correctly and
does not interfere with the fitting of the fire front.
(h) Unless stated otherwise reassembly of all
components should be in the reverse order to that for
removal.
(j) It is recommended that the back boiler be serviced at
this time.
Refer to Back Boiler Installation and Servicing
Instructions.
7.2 Fire Front - Castings
Remove the ash pit cover by unhooking from the fret,
take care as there are wires attached, see diagram 5.12.
The ash pit cover can be left attached by the harness to
the micro switch/gas tap.
Remove the fret by unhooking from the fire surround,
see diagram 5.10.
When removing the fire front, first remove the M4 screw
from the base of the combustion chamber assembly, see
diagram 5.3. Lift the fire front up to clear the location
pins, see diagram 5.3.
Take care when removing the fire front as it is heavy.
GAS INLET
UNION
GAS INLET
UNION
L.H. BURNER
MOUNTING
SCREW
ELECTRODE
BRACKET
SECURING
NUT
THERMOCOUPLE
LOCK NUT
INJECTOR
L.H. MOUNTING
BRACKET
WING NUT
THERMOCOUPLE BRACKET
4028

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Diagram 7.2
7.3 Fuel Effect and Insulation
Carefully remove the fuel effect pieces, see diagram 5.8.
Carefully remove the fuel effect bed by lifting clear, see
diagram 5.7.
Carefully remove the fuel effect bed base by lifting clear,
see diagram 5.6.
Note: When refitting the fuel effect bed base make sure
it is correctly fitted, see insert “B” in diagram 5.6.
Carefully remove the insulation by lifting clear, see
diagram 5.5.
Clean these items with a soft brush, do not use a vacuum
cleaner.
If any of these items are damaged they must be replaced
before the fire front is used again.
Clean out the combustion chamber base with a brush or
vacuum cleaner.
7 S e r v i c i n g
7.4 Combustion Chamber Assembly
Make sure that the gas supply is isolated at the gas
service cock, fire off position, see diagram 3.2.
Disconnect the gas supply tube at the gas service cock,
see diagram 4.3.
Remove the four securing screws, see diagram 4.2.
Pull the combustion chamber assembly forwards and
remove by lifting over the gas service cock.
Take care if the ash pit cover and harness are attached to
the micro switch/tap.
7.5 Burner
The burner can be cleaned whilst in place, using a
suitable brush and vacuum cleaner.
Do no use a brush with wire bristles.
7.6 Injector
Clean around the injector.
If necessary disconnect the gas inlet union nut from the
injector, see diagram 7.1. Remove the injector. Do not
use a wire or sharp instrument to clean out the holes.
LOCK NUT AND
SHAKE PROOF
WASHER
THERMOCOUPLE
THERMOCOUPLE
NUT
4024

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Diagram 7.3
7 S e r v i c i n g
Diagram 7.4
7.7 Thermocouple and Electrode
Inspect and clean the tips of both items.
Check that the electrode spark gap is as shown in
diagram 7.3.
7.8 Gas Tap and Micro Switch Assembly
Note. This item need not be serviced every year.
If servicing is required, remove the leads at the
microswitch and electrode then disconnect all union
connections at the tap, see diagram 7.5.
Disconnect the thermocouple from the tap, see
diagram 7.2.
Remove the bottom split pin from the connecting drive
rod, see diagram 7.5.
Disconnect the gas supply pipe union and remove the
pipe.
To remove the gas tap and micro switch remove the two
screws from the gas tap bracket, see diagram 7.5 and
withdraw the tap complete with bracket.
To service the gas tap, remove the operating disc, see
diagram 7.6 and lift off.
Remove the gas tap niting plate securing screws, see
diagram 7.6. Take care as there is a spring beneath the
niting plate. Remove the plug, pin, spring washer, plain
washer and “O” ring, see diagram 7.6.
Clean and relubricate using a suitable grease.
When replacing make sure the operating disc, with
circlip underneath, micro switch and leads are correctly
located, see diagram 7.6 and 7.4.
ELECTRODE DETAIL
4026
Electrode tip must fall
within boxed area
3 to
5mm
1mm THERMOCOUPLE
DETAIL
Centreline of thermocouple must
fall within boxed area on third row
of ports
208 CHECK DIMENSION
3.5 to
4.5mm
2mm
2mm
2mm
1mm
EARTH
LEAD
MICRO
SWITCH
LEADS
IGNITION
LEAD
WIRING
HARNESS
STRAIN RELIEF
LOCKNUT
R.H. SECURING
BRACKET
SECURING
SCREW
4023

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Diagram 7.6
7 S e r v i c i n g
4022
PLUG
'O' RING
WASHER
SPRING
PIN
CONTROL
SPINDLE
CIRCLIP
OPERATING
DISK
GAS
TAP
BODY
GAS TAP
BRACKET
MICRO SWITCH
BRACKET
SECURING
SCREW (2)
SECURING
SCREW (2)
MICRO SWITCH
Diagram 7.5
UNION
NUT
THERMOCOUPLE
NUT
GAS TAP
BRACKET
SECURING
SCREW (2)
SPLIT
PIN
CONNECTING
DRIVE ROD
GAS TAP
SECURING
SCREW (2)
UNION
NUTS
GAS
SUPPLY
4025

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220562A
8 F a u l t F i n d i n g
Diagram 8.1
NO
YES
YES
NO
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
Turn off appliance tap,
turn on appliance tap.
Does the fire light ?
FIRE WILL NOT LIGHT
START HERE
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.
Ensure gap is within specified
tolerance, refer to SERVICING.
turn tap to energise ignition.
Does the fire light ?
Disconnect ignition lead from
electrode, place connector
within 4mm of burner and turn
tap to energise igniter. Is there
a spark at the gap ? 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 ?
Replace faulty electrode and
reassemble ignition system.
Turn tap to energise igniter.
Does the fire light ?
Disconnect brown leads from ignition
unit. Turn tap to energise ignition. Is
there continuity between brown leads ?
Renew ignition lead and
reassemble ignition system.
Change battery ignition unit.
Turn tap to energise ignition.
Does the fire light ? Rectify faulty leads or
replace micro switch.
Change ignition unit.
Check several times that ignition is satisfactory.
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Diagram 8.2
Diagram 8.3
8 F a u l t F i n d i n g
8.1 Fire Front Ignition
Remove the ash pit cover, front fret and fuel effect beds
and pieces.
Refer to diagram 8.1 “Fire Front Ignition Fault Finding”,
diagram 8.4 and 8.5.
8.2 Thermocouple
To test a thermocouple, a meter with a range of 0 to
30mV is required together with a thermocouple
interrupter test unit similar to the British Gas Minitest 6
Multimeter and Interrupter.
Refer to fault finding diagram 8.3 and diagnosis graph,
diagram 8.2.
Closed Circuit Voltage (millivolts)
DIAGNOSIS GRAPH FOR FIRE
THERMOCOUPLE CIRCUIT
Open Circuit Voltage (millivolts)
01234567891011
7
8
9
10
11
12
13
14
15
16
17
ABC
0065M
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.
NO
YES
Hold down control tap in ignition position. Ignite burner, allowing thermocouple to attain
operating temperature. Measure the OPEN CIRCUIT voltage.
Is voltage greater
than 7mV? Faulty thermocouple.
Replace.
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 Faulty thermocouple.
Replace.
Faulty magnet unit in gas tap.
Replace gas tap
BA
C
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220562A
Diagram 8.5
8 F a u l t F i n d i n g
Diagram 8.4
9 R e p l a c e m e n t o f P a r t s
9.1 Burner
Disconnect the gas inlet pipe union nut, the electrode
assembly nut and the left hand burner mounting bracket
securing screw, see diagram 7.1.
Remove the burner wing nut, releasing the burner.
Remove the injector, burner alignment screw and burner
left hand mounting bracket, see diagram 7.1.
9.2 Injector
To remove the injector follow the instructions in
Section 7.6, paragraph 2.
9.3 Gas Tap and Micro Switch Assembly
Follow the instructions in Section 7.8 up to and
including paragraph 6.
Note: When replacing micro switch now follow
instructions in Section 7.8 up to and including
paragraph 7.
Make sure that the wiring harness strain relief is
correctly located into the slot secured by the locknut, see
diagram 7.3 and 7.4.
9.4 Electrode
Disconnect ignition lead from the electrode and remove
securing nut to release the electrode from the burner, see
diagram 7.3.
When replacing make sure that the spark gap is as shown
in diagram 7.3.
Notes
(a) Make sure the fire front is cold before replacing any
parts.
(b) Replacement of parts must be carried out by a
competent person.
(c) Remove the fire front castings as in Section 7.2.
(d) Remove the fuel bed, fuel effect bed base, fuel effect
pieces and insulation as in Section 7.3.
(e) BEFORE REMOVING OR REPLACING ANY
FIRE FRONT PART TURN THE GAS SERVICE
COCK TO “BACK BOILER ONLY ON”, see
diagram 3.2.
(f) ISOLATE THE ELECTRICAL SUPPLY TO THE
BACK BOILER.
(g) After replacing or disconnecting any gas carrying
component, always test for gas soundness, using a
suitable leak detection fluid and carry out functional
check of controls.
(h) To test the gas tap apply leak detection fluid to all
joints, light the burner and check all the joints for
leakage at all tap settings.
WARNING: Take care as the burner flame is fully
exposed.
(i) After removing or disconnecting any pipe work
always make sure that it is refitted correctly and
does not interfere with the fitting of the fire front.
(j) Unless stated otherwise reassembly of all parts is in
the reverse order to removal.
MICRO
SWITCH
ELECTRODE
BROWN
BROWN
EARTH
SPARK
GENERATOR
AV PP3 9V
ALKALINE
BATTERY
3177 3123
ELECTRODE
MICRO
SWITCH
SPARK GENERATOR
BROWN
BROWN
EARTH