Glowworm SAXONY 2 BBU FIRE FRONT Operating manual

Supplied By www.heating spares.co Tel. [phone]
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
221648B. 02. 00
All replacement parts
All labour charges
All call-out charges
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:
Guarantee Registration
BBU Fire Front
For use with a specially designed
Glow-worm Back Boiler Unit only
This is a Cat I2H Appliance
BS 6332
BS 5258
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
These instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration
Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be handed to the user on completion of the installation.
To beleftwiththeuser
7446
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Instructions for Use
Installation and Servicing
G.C. No. 37 047 11
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0181 380 2555

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Important Information
Introduction 3
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
Fault Finding 8 29
Replacement Parts 9 32
Supplementary Installation Instructions 10 35
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
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.
UnderSection6oftheHealthandSafetyatWorkAct1974,wearerequiredtoprovideinformationonsubstanceshazardoustohealth.
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
licensedforthedisposalofindustrialwaste. Protectiveclothingisnotrequiredwhenhandlingthesearticles,butwerecommendyou
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.
Normalhandlingshould not causediscomfort,but follow normalgoodhygiene and washyourhands before eating,drinkingor going
to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
SERVICING
INSTRUCTIONS
INSTALLATION
INSTRUCTIONS

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Instructions for Use
ThisfirefrontmaybefittedtoaGlow-wormbackboilerWITHOUT
aflueblockagesafetydevice. Pleaserefertothesupplementary
instructions at the end of the Instructions for Use, especially
“Lighting the Boiler”.
Theinstructions 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
GuaranteeRegistrationCard.Theinstructions formanintegral
partofthe applianceandmust,tocomply withthecurrentissue
oftheGasSafety(InstallationandUse)Regulations,behanded
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.
ThisGlow-wormfirefrontistobeusedwithaspeciallydesigned
Glow-worm Back Boiler Unit only.
The fire front and back boiler must be fitted as a
complete appliance.
Thisisacombinedcentralheatingbackboilerandgasfirefront.
Thebackboilerandfirefrontcanbeoperatedeithertogetheror
independently.
Intheeventofapowerorignitionsystemfailurethefirefrontcan
stillbe used on its own, instructions on how to do this are given
under “Lighting the Fire Front with a Match or Spill”.
Aslightsmellmayoccur,forashorttime,afterinitiallighting,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.
Combustiblefurnituremustnotbeplacedcloserthan1metrein
front of the fire front.
Clothingorotherflammablematerialsmustnotbeplacedonthe
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,
scorchorbecomediscolouredwhenclosetoaheatingappliance.
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.
Thefirefrontmustnotbeusedifthispanelisbrokenormissing.
WARNING. Theglasspanelgetsveryhotwhenthefirefrontis
on and MUST NOT be touched.
The glass panel does not provide full protection for the young,
elderlyorinfirm. Insuchcasesextra security mustbeprovided
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
theparticularinstallation and usage, but ingeneralonce 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.
ItistheLawthatservicingiscarriedoutbyacompetentperson.
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
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
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,providedclearancesareasdiagram1,however,forevery
extra 25mm above the fire front the depth of the shelf may be
increased by 25mm.
Onnoaccountmaycarpetorothercombustiblematerialbelaid
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.

Supplied By www.heating spares.co Tel. [phone]
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Instructions for Use
Diagram 2
183mm
7448
Frost
CAUTION. If the back boiler is to be out of use for any long
periodoftimeduringsevereweatherconditionswerecommend
that the whole of the system, including the back boiler be
drained off to avoid the risk of freezing up.
Ifanimmersionheaterisfittedinthedomestichotwatercylinder
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)mustbethroughoneunswitchedshuttered
socketoutletanda3Afused3pinplug,bothtothecurrentissue
ofBS1363. Alternatively,afused3Afuseddoublepoleisolating
switch may be used, having a minimum double pole contact
separation of 3mm, serving only the appliance and system
controls.
Thecoloursofthreecoreflexiblecableare,blue-neutral,brown
- live, green and yellow - earth.
As the markings on your plug may not correspond with these
colours, continue as follows:-
Thewirecolouredblue mustbeconnectedtotheterminalmark
“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 .
Diagram 1
628mm
C
L
FLAT AREA
FIRE FIXING FACE
150mm 430mm 430mm
150mm
840mm
7447
Lighting the Appliance
Back Boiler
Thisapplianceisfittedwithaflueblockagesafetydevicewhich
will shut down the appliance in the event of abnormal flue
conditions.ThisdeviceisNOTasubstituteforanindependently
mountedCarbonMonoxidedetector. Ifitshutsdownfrequently
fornoapparentreasonthefirstthingsthatmustbecheckedare
the chimney and air inlets into the room.
Any problems found must be put right, by a competent person,

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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.
Thebackboilercontrolsarefittedbehindthefirefrontplinth,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
awayfromtheunit. Refertomanufacturer’sinstructionssupplied
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”
clockwiseuntil“O”isagainstitssettingpoint,thatis,setto“Off”.
Partially push in and turn multifunctional control knob “A” anti-
clockwise until “ ” is against its setting point, then push in
fullyandholdin. At thesametimepressandrelease 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”.
Ifthepilotfailsto stayalightturngascontrolknob“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. Alwayswaitthreeminutesbeforeattemptingtorelightthe
pilot after it has gone out for any reason.
Whenthepilotisalight,pushcontrolknob“A”inslightlyandturn
it anticlockwise until “ “ is against the setting point.
Note. Ifthemultifunctional control knob “A”isturned until “ ”
isagainstthesettingpoint,asafetylockpreventsitbeingturned
onagain. Noattemptshouldbemadetoturnthemultifunctional
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 82oC.
Check that the external controls are calling for heat.
Refit the fire front plinth by carefully fitting the top edge of the
plinthintothesliders,thenpushitbackwardsasfarasitwillgo.
To Turn the Back Boiler Off
For short periods, turn control thermostat control knob “B”
anticlockwiseuntil“O”isoppositeitssettingpoint. Thepilot 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
controlknob“A”clockwise until“ ”isagainstitssetting point.
Turn control thermostat control knob “B” anticlockwise to “O”.
Switch off the electrical supply to the appliance.
To relight, follow the full lighting procedure.
Diagram 3
7458
PLINTH
MAX
MIN
5156
Diagram 4
THERMOSTAT
CONTROL KNOB 'B' OFF
PILOT/IGNITION
MAIN BURNER
SETTING
POINT
MULTI-FUNCTIONAL
CONTROL KNOB 'A'
PIEZO UNIT
BUTTON 'D'
SETTING
POINT
PILOT BURNER 'E'
VIEWING
WINDOW 'F'

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Lighting the Fire Front
CAUTION. Iftheglasspanelorinternalfireparts 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
willshutitdownifthereisaproblemwiththechimney. Ifthefire
front shuts down frequently, for no apparent reason the first
thing to be checked are the chimney and the air inlets into the
room. Anadditionalcausecouldbethatthefilter,in thegastap
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. Iftheburnerdoesnotlightwithinthreeseconds,
release the control knob, wait ten seconds and repeat the
lighting operation.
Keeptheknobpushedinfortenseconds,duringwhichtimethe
ignitionsystemwillcontinuetooperate,indicatedbytheclicking.
Airmaybepresentinthesupplytothefirefrontsothattheinitial
lighting operation may need to be repeated.
To change settings:-
Push in and turn. Refer to diagram 5.
Iftheburner goes out for anyreasonwhilst the fire is turnedon,
turn off.
Wait three minutes before relighting as above.
If relighting for any other reason wait two minutes before doing
so.
Itcantakeseveralminutesforthefueleffectpiecestoglowand
the flame effect to appear.
To turn off, turn the tap fully clockwise to “O” position and
release.
Ifthereisavisiblebuildupofsootonthefueleffectpiecesfollow
the instructions in Section on “Cleaning the Fire”.
Lighting the Fire Front with a Match or Spill
Thisisatemporary measure,tobeusedonlyin theeventofthe
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.
Holdalightedspillorlongmatchandpositionitsothattheflame
is over the burner, see diagram 6.
Keepthespillinposition,pushinandturnthegastaptoposition
“1. “ignition and the burner will light. Keep the knob pushed
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
replacedortheignitionsystemberepairedassoonaspossible.
Cleaning your Fire
WARNING. Thisappliancecontainsmetalparts(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
occasionalwipeoverwithadampclothwillhelpremovemarks.
Do not use an abrasive cleaning powder or liquid.
Instructions for Use
Diagram 5
APPLIANCE OFF
IGNITION POSITION
AND CENTRE
SECTION
FLAME EFFECT
CENTRE SECTION
FLAME EFFECT
WITH OUTER
SECTIONS
FUELBED GLOW
CENTRE AND
OUTER SECTIONS
FLAME EFFECT
WITH FUELBED
GLOW
FULL FLAME
EFFECT WITH
FUELBED GLOW
7581

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Instructions for Use
Diagram 6
SPILL
BURNER
SPILL
5094
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.
Cleaningshouldbecarriedoutinawellventilatedareaorinthe
openair,bygentlybrushingwiththepiecesheldawayfromyour
facesothatyouavoidinhalingthedust. Wedonotrecommend
theuse of a normal domestic vacuum cleaner, which may blow
dust back into the air.
CAUTION. Ifreplacinguseonlythefueleffectpiecesapproved
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
Thebatterysupplied,should,undernormalusagelastforabout
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
screwstop,swingopentherighthandsidepanelasdiagram18.
Fit the battery as shown in diagram 19, make sure that the
terminals are correctly fitted. Diagram 7
7449
5mm 5mm
7559
GLASS
RETAINING
BRACKET
Diagram 8
GLASS
FRONT PANEL
PULL FORWARDS
AND UP
Replacement Parts
If replacement parts are required apply to your local supplier.
Pleasequotethenameofthefirefront,“Saxony2”,tobefound
on the control knob bezel.
The back boiler serial number can be found on the base after
removal of the plinth.
Thefirefrontserialnumbercanbefoundonthechassis,visible
when the front casting is removed.

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Diagram 11
Diagram 12
Diagram 13
Diagram 14
LOCATION
RECESS 1
LOCATION
RECESS 2
LOCATION
LUG 3
LOCATION
RECESS 4
4331 S
4332 S
4333 S
4334 S
FUEL EFFECT PIECE POSITION 1
FUEL EFFECT PIECE POSITION 2
FUEL EFFECT PIECE POSITION 3
FUEL EFFECT PIECE MUST
SIT ON SUPPORT ANGLE
NOTE:
NOTE: FUEL EFFECT PIECE MUST
SIT ON SUPPORT ANGLE
FUEL EFFECT PIECE MUST
SIT ON SUPPORT ANGLE
NOTE:
FUEL EFFECT PIECE POSITION 4
SUPPORT ANGLE FOR
FUEL EFFECT PIECES
1, 2 AND 3 Diagram 10
Left
Side
FUEL
EFFECT
BASE
5088
Fuel Effect Base
seats behind
retaining brackets
NOTE:
Right
Side
FUEL
EFFECT
BASE
(see note)
RETAINING
BRACKETS
Diagram 9
5
3
1
2
4
3
1
2
2
45
FUEL EFFECT PIECES 1 to 5
FUEL
EFFECT
BASE
4329 S
FUEL EFFECT PIECES LOCATIONS
Instructions for Use

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Diagram 15
LOCATION
RECESS 5
4335 S
FUEL EFFECT PIECE POSITION 5
Instructions for Use
Diagram 16
Ensure corners of fuel effect
pieces 4 and 5 are seated on
flat areas of fuel effect pieces
1, 2 and 3
COMPLETED FUEL
EFFECT BED
Diagram 17
CANOPY LOCATING
PIN LOCATING
HOLE
4850 3943 S
Diagram 19
5283
SECURING
SCREW
SPARK
GENERATOR
ELECTRICAL
CONNECTIONS
9V ALKALINE
BATTERY
SECURING
SCREW
IGNITION
LEAD
Diagram 18
7562
SECURING
SCREW
STOP
FIBRE
WASHER
R.H. SIDE
PANEL
GAS CONTROL KNOB

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Supplementary Instructions
Thisapplianceisfittedwithaflueblockagesafetydevicewhich
will shut down the appliance in the event of abnormal flue
conditions.ThisdeviceisNOTasubstituteforanindependently
mounted Carbon Monoxide detector.
AsthisfirefrontmaybefittedtoaGlow-worm45,56,45Ror56R
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”.
Pushinslightlyandturngascontrolknob“A”anticlockwiseuntil
“” 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
attemptsmaybeneededtolightthepilot. Keepcontrolknob“A”
pushed in whilst operating the ignition button.
When the pilot is alight and stable, keep knob “A” fully pushed
inforabout15secondsthenrelease. Checkthatthepilotisstill
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
lightingoperation,onlynow keepcontrolknob“A”pushedinfor
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 “ ” is against the
settingpoint,asafetylockpreventsitbeingturnedonagain. 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.
Adjustthethermostattotherequiredsettingbetween“MIN”and
“MAX”. “MAX” is about 82oC.
Check that all external controls are set to your requirements.
Refittheplinthbycarefullylocatingthetopedgeoftheplinthinto
the sliders, then push gently back as far as it will go.
'E' PILOT BURNER
BOILER CONTROLS Diagram 20
INSET: Showing a Flue Blockage
Safety Device fitted.
SETTING
POINT 'F' VIEWING
WINDOW
'D' PIEZO
UNIT
BUTTON
'B'
THERMOSTAT
CONTROL
KNOB
OFF
PILOT/IGNITION
MAIN BURNER
'A'
GAS VALVE
CONTROL
KNOB
SETTING
POINT
5342

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1 General
Diagram 1.1
7450
FLAT AREA
FIRE FIXING
FACE
286mm 616mm
690mm
628mm
344mm
326mm
442mm
1 General Notes and Information
ThisfirefrontmaybefittedtoaGlow-wormbackboilerWITHOUT
aflueblockagesafetydevice. Pleaserefertothesupplementary
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,
whichtogethercontainallthepartsnecessaryfortheinstallation
of the fire front.
Ifthebackboilerandfirefrontaretobeinstalledatthesametime
pleasereadbothsetsofinstallationinstructionsbeforestarting.
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
causecouldbethatthefilter,inthegastaphasbecomeblocked.
Any problems found must be put right by a competent person,
before the fire front is used again.
Sheet Metal Parts
WARNING. When installing or servicing this fire front care
should be taken when handling metal parts (components) to
avoid any 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.
TheGasSafety(InstallationandUse)Regulations, TheBuilding
Regulations,theLocalGasUndertaking,TheBuildingStandards
(Scotland) Regulations (applicable in Scotland), The Health
and Safety at Work Act, Control of Substances Hazardous to
Health,The Electricityat WorkRegulations andany applicable
local regulations.
Detailedrecommendationsarecontainedinthecurrentissueof
the following British Standards and Codes of Practice:-
BS1251, BS5440 Part 1 and 2, BS5871, BS6891, BS7671.
Manufacturer’snotesmust not betakenas overriding statutory
requirements.

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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
casting removed
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.
Thetop ofthe firefront mustbe securedto thevertical firefront
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.
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.

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C
L
2Types of Installation and Flue
BUILDERS
OPENING
280
680
INSTALLATION
CENTRE
LINE
C
L
HEARTH MOUNTED
Remove Combustible
Material From this Area
PREPARED
BASE
Diagram 2.3
Diagram 2.2
INSTALLATION CENTRE LINE
406mm to
460mm
FRONT
OPENING
560mm
to
590mm
PREPARED
BASE
7594
5076
Note. RefertoSection2intheBackBoilerInstallationbookbefore
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
Seediagram2.2. Thefirefrontcasingshouldcovertheopening.
A wider opening will require any opening left to be covered with
a non-combustible finished material, see diagram 2.3.
Thesurroundmusthaveaminimum clear, flatareaasshownin
diagram 1. (Instructions for Use). Any projections on the
surround must be outside this area.
Anycombustible 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
Thefirefrontfixingwallfacemustbeflatoveranareaasshown
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.
Onnoaccountmustcarpetorothercombustiblematerialbelaid
directly under the fire front, unless the minimum clearances
shown in diagram 2 (Instructions for Use) are achieved.
Thedimension is taken from the bottom ofthe fire front plinth to
the top of the carpet pile or other floor covering.
2.4 Flue
Thebackboilerfluecollectorassemblyacceptsthefirefrontflue
spigot.
Note. Provisionmustbemadeduringtheinstallationoftheback
boiler for the total ventilation requirement for the combined
appliance. See relevant section in the Back Boiler Installation
Instructions.
762mm
50mm
MIN.
12mm
NON-COMBUSTIBLE
MATERIAL
350mm
Diagram 2.1
7456
13mm

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COMBUSTION
CHAMBER
BOTTOM PLATE
FLUE SPIGOT
FIRE
BODY
ASSEMBLY
WALL
SEALING
PLATE
L.H. SIDE
CASTING
FUEL
EFFECT
BED
LITERATURE
L.H. SIDE
PANEL
CANOPY
FRONT
CASTING
PLINTH
REAR
SUPPORT
LEGS (2)
R.H. SIDE
PANEL
R.H. SIDE
CASTING
L.H.
LEG
R.H.
LEG
3 Fire Front Preperation
CASING PACK
Diagram 3.1
FIRE BODY PACK
7629

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ASCREW FRONT LEG
M5x30 LEVELLING SCREW
BSCREW SIDE
M5x14 CASTINGS
CSCREW UPPER WALL
M5x40 MOUNTING
D ANCHOR UPPER WALL
NUT MOUNTING
ESCREW FRONT LEG
M5x8 FIXING
FSCREW WALL SEALING
No. 10 x 11/2PLATE FIXING
GWALL WALL SEALING
PLUG PLATE FIXING
SCREW UPPER SIDE
RETAINING
3 Fire Front Preperation
KEY
Diagram 3.2
JSCREW FLUE SPIGOT FIXING
No.8x3/8in.
KSCREW SENSING TUBE
M4x10 FIXING SCREW
LTAPTITE SCREW SENSING TUBE MOUNTING
M4x6 BRACKET SCREW
LIQUID
COAL
TUBING
NUT (2)
FIRE FRONT
SENSING
TUBE CONTROL
KNOB
GAS SUPPLY
PIPE
FIBRE WASHER (2)
SIDE EXTENSION (2)
OLIVE (2)
BBU
SENSING
TUBE
SENSING
TUBE
MOUNTING
BRACKET
ASSEMBLY
BATTERY
FILTER
H

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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.
Theothercontainsthefirefrontcastings,sidepanels,plinthand
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.
Lifttheoutercartoncleartoleavethefirefrontsittinginthebase
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.
Itissuggestedthatthesideextensions,fromthecastingspack,
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.
3.3 Gas Supply Tube and Sensing Tubes
Preparation
Remove the plastic ferrule from the bulkhead connector on the
air duct and discard.
Fixtheflaredendofthebackboilersensingtubetothebulkhead
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
fittingassembly,seediagram 4.1.Takecarenottodamagethe
filter.
Important. Make sure that the mounting bracket assembly is
pushedbacktothefirefrontfaceoftheboilercastingandcheck
3mm distance is achieved and the back boiler sensing tube
doesnotextendabovethesensingtubebracketassembly,see
diagram 4.1.
Note. After fitting the flue blockage safety device sensing tube
pleaserefertothe'commisioning'sectionofthebackboilerunit
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.
Thissupplytubeandfirefrontsensingtubemayneedtobecut,
at the plain end, dependent on the model and position of the
back boiler in the opening.
Diagram 3.3
GLASS RETAINING
BRACKET
GLASS
FRONT PANEL
4844
Diagram 3.4
FLUE SPIGOT ASSEMBLY
SECURING
SCREW (7)
J
3923 S
Gas Supply Tube
Measurethedistance“C”, seediagram3.6,fromthefrontmark
“P” on the air duct to the fire front fixing wall face.
Use a straight edge across the opening.
Shortentheplainendofthegassupplytubebythedistance“C”.
No shortening is required when mark “P” is level with the fire
front fixing wall face, “C” being zero.
The maximum distance for “C” will be 67mm (25/8in).

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3 Fire Front Preperation
56/2 BBU
FIRE
FIXING
WALL FACE
45/2 BBU
FIRE
FIXING
WALL FACE
N
BACK BOILER
AIR DUCT
56/2
BBU
45/2
BBU
P
*'D'
*'D'
*'D'
FIRE FRONT
SENSING
TUBE
*'D' = Distance from fire fixing
wall face to datums on
back boiler air duct.
This represents the
length of pipe that requires
cutting off.
Diagram 3.7
6140
Diagram 3.5
BACK
BOILER
ONLY 'ON'
TURNED
FULLY
CLOCKWISE
BACK
BOILER &
FIRE 'ON'
TURNED TO
MID POSITION
90˚
'OFF'
TURN FULLY
ANTI-
CLOCKWISE
180˚
5078
BACK
BOILER
AIR
DUCT
*'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'
*'C'
*'C'
GAS FIRE
SUPPLY TUBE
FIRE FIXING
WALL FACE
Diagram 3.6
5245
GAS SERVICE
COCK UNION
Firefront sensing tube
Shorten the plain end of the fire front sensing tube by distance
“D”,noshorteningofthetubeisrequired 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
bothcases“D”iszero themaximumdistanceof“D”forboththe
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
diagram19.(InstructionsforUse).makesurethattheterminals
are correctly fitted.

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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
sufficientscrewproudtoacceptthewallsealingplatekeyholes,
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
backintocontactwiththefirefront fixing wall face,seediagram
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. Ifthefirefrontfixingwallfaceisnotofasolidconstruction,
to a minimum depth of 40mm, for example, hollow brick or
metal,analternative and rigidformof fastening forthefire 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.
Offertheapplianceuptothebackboilerairductandpushback
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.
4 Installation
SENSING
TUBE
FITTING
ASSEMBLY
THREAD CUTTING
SCREW(Taptite)
3 mm
BACK
BOILER
SENSING TUBE
BULKHEAD CONNECTION
TUBING
NUT BOILER AIR DUCT
SENSING
TUBE
FITTING
ASSEMBLY
FRONT FACE
OF BOILER
CASTING
FILTER
Diagram 4.2
NOTE:
WINGS
FLUSH
WITH
WALL
GF
5166
Diagram 4.1
6138
Diagram 4.3
MARK
FRONT
FIXING
HOLES
SPIGOT
FLUE
COLLECTOR
ASSEMBLY FIRE FRONT
5246

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4 Installation
FIRE FRONT
SENSING
TUBE
SECURING
SCREW (2)
FLUE
COLLECTOR
TUBING
NUT
OLIVE
FRONT
FIXING
SCREW SPIGOT
BACK
BOILER
AIR
DUCT
FLUE
COLLECTOR
ASSEMBLY FIRE FRONT
OLIVE
TUBING
NUT
SENSING
TUBE
Diagram 4.5
Diagram 4.4
5074
SECURING
SCREW (2)
M5 x 40mm
C
MOUNTING
BRACKET
ANCHOR
NUT D
C
SECURING
SCREW (2)
Diagram 4.6
5093
4.3 Gas Connection
Placethetubingnutandolive,fromthelooseitemspack,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.
Totightentheother end,useaspannertohold thelocknut(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
checkingitwhencarryingouttheothergassoundnesschecks
as in Section 5.1.
Fit the left hand side panel, see diagram 4.9.

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Diagram 4.9
FIBRE
WASHER FIBRE
WASHER
SECURING SCREW
STOP SECURING SCREW
STOP
LOCATING PIN
AND HOLE
LOCATING PIN
AND HOLE
L.H. SIDE
PANEL
R.H. SIDE
PANEL
R.H. SIDE PANEL
GAS CONTROL
KNOB
LOCATING PIN
AND HOLE
JJ
4849
Diagram 4.7
TUBE NUT
SENSING
TUBE
TUBE NUT
OLIVE
JOINT (C)
UNION
NUT (B)
LOCK
NUT (A)
GAS SUPPLY
PIPE GAS SERVICE COCK
TUBING
NUT
Diagram 4.8
3929 S
5167
4 Installation