Masport BALTIMORE MONACO NAPLES User manual

SERVICE
MANUAL
for
TO BE USED ONLY BY AUTHORISED PERSONNEL
PART No 591060
Issue D — © November 2001
BALTIMORE
MONACO
NAPLES &
SEVILLE
GAS FIRES

CONTENTS
TROUBLESHOOTING Page
A. Pilot will not light after repeated attempts .......................................................... 2
B. ECS fire won’t light after repeated attempts....................................................... 3
C. Spark OK, but pilot refuses to light (not ECS) ................................................... 4
D. Pilot will light but will not remain alight (not ECS)............................................. 5
E. Standard heaters. Pilot alight but burner won’t light in 10 seconds...................... 6
F. Thermostat heaters. Pilot alight but burner won’t light in 30 seconds.................. 7
G. Thermostat heaters. Erratic operation................................................................. 8
H. No flame modulation on ECS models................................................................. 8
I. Sooting.............................................................................................................. 8
BALTIMORE & MONACO ASSEMBLY AND DIS-ASSEMBLY
Removing and fitting glass, louvre assembly, dress guard, front panel.......................9, 10
Disconnecting the flue..................................................................................................11
Removing and replacing the cabinet .............................................................................11
Access panels, removing and replacing...................................................................11, 12
Removing and replacing the burners.............................................................................12
Removing and replacing the pilot assembly and pilot jet .........................................12, 13
Accessing the main injectors.........................................................................................14
Removing control valves and regulators.......................................................................14
Accessing the fan assembly ....................................................................................14, 15
Removing and replacing the pedestal and pedestal foot.................................................15
Accessing the thermodisc.............................................................................................15
NAPLES & SEVILLE ASSEMBLY AND DIS-ASSEMBLY
Removing and replacing the glass.................................................................................16
Fitting louvre assemblies and dress guards..............................................................16, 17
Removing and replacing burners...................................................................................17
Removing and replacing the pilot assembly...................................................................17
Accessing the main injectors ..................................................................................17, 18
Accessing the control valve..........................................................................................18
Removing and replacing the fascia................................................................................18
Accessing the fan...................................................................................................18, 19
Accessing and retro-fitting the thermodisc....................................................................19
SERVICE ADJUSTMENTS
Gas pressure adjustment.........................................................................................20, 21
Checking the flue draught ............................................................................................21
Converting Baltimore from LPG to NG........................................................................22
Converting Naples, Seville from LPG to NG................................................................23
Remote control installation.....................................................................................24, 25
Thermostatic controls ......................................................................................25, 26, 27
Receiver switch positions.............................................................................................27
ECS information..............................................................................................28, 29, 30
Wiring diagrams.....................................................................................................31, 32
DRAWINGS
Pages 33 to 41
TABLES
No 1. Gas pressures ..............................................................................................42
No 2. Pilot jet sizes ...............................................................................................42
No 3. Main burner jet sizes....................................................................................42
Abbreviated Parts List...................................................................................Back Cover
1

A
— PILOT WILL NOT LIGHT AFTER REPEATED ATTEMPTS
Is it an ECS model? Go to B
YES
YES
YES
YES
NO
NO
NO
NO
NO
Has it Battery
ignition? Is there a spark at
the igniter? Replace battery, check
battery contacts Spark? YES
Go to
A6
Go to A6 Check switch
at valve
1 Does the
Piezo 'click'? What type of Piezo? Rotating
Knob Remove control rod and
operate directly at Piezo
Push
Button Replace Piezo,
go to A1
Defective
Service
or replace
control rod
assembly.
Go to A1
4OK
23
5
NO
Is there a spark
at the igniter?
6
NO
Is there carbon
on the pilot head?
7 YES 8
Clean and go to A6
NO. Go to A11
Is the spark gap correct?
See Drawing No. 1
11 NO Replace electrode assembly.
Go to A9
12
Are all connecting wires
secure at both ends?
13
A strong spark
every time?
9YES 10 Spark OK. Go to C
to check gas supply
YES
NO
YES
14 Is the high tension wire
shorting to the heater?
YES YES Replace wire.
Go to A9
15
16 Fix. Go to A9 17 Is the electrode
insulator cracked? YES 18 Replace electrode
assembly.
Go to A9
19 Fit new Piezo or
battery ignition module.
Go to A9
NO
NO
Check switch
wiring Switch OK
Wiring OK
2

NO
B
— ECS FIREWON'T LIGHT AFTER REPEATED ATTEMPTS
Note: The ECS pilot shuts off each time the fire is extinguished and re-lights each time the fire is
started. When operating correctly, the pilot spark ceases as soon as the pilot flame is established,
and the main burners ignite automatically shortly thereafter.
FIRST:- Check that the mains power supply and the gas supply are valid
and that any gas valves are fully open.
1Aim the handpiece at the receiver and
press the top round button
2Does the red indicator
on the handpiece flash? NO 3Check batteries.
Try again 4Indicator flashes?
Handpiece OK
Handpiece faulty
YES
YES
Does receiver indicator
light and remain alight?
5YES Does spark begin
in three seconds?
6YES 7 Pilot
ignites? YES
Does spark
cease?
8Do burners
ignite?
9
YESNO
YES
NORMAL
10 Check for gas
pressure at valve outlet
OK
Gas line or
injectors clogged
11
Clean and re-test.
NONE NO
Is flame sensor
in pilot flame?
12
Faulty valve or
ignition module
NO
Adjust or replace
sensor electrode
Check wire
connections
and earth return
from burners
to valve
14
BAD
Fix and
re-test
YES
NO NO – Go to F 1 NO – Go to B 23
Hold handpiece close to
receiver and try again
16
Receiver
indicator on?
17
NO
18Press start/stop
switch by receiver
Receiver
indicator on? YES
19
YES Replace weak
batteries. Go to B1
NO
20Check mains
and re-test
Receiver
indicator on? YES Go to B 6
21
NO OK
22
Check all receiver
cable connections
and re-test. If still
no indicator light,
faulty receiver,
receiver loom or
control box.
15 Verify ignition
loom plugs are firmly
home. Check control
box fuse. Re-test
Follow steps A 11
to A 18 and re-test
BAD
27
OK
Go to B 7 BAD
Replace ignition
module and re-test
23Gas supply faulty. Purge line
by repeated re-test, pressing
RESET switch at rear when
spark ceases after each try.
Pilot ignites?
YES
Go to B 8
NO
24 Hold match flame at
pilot while spark is on.
Does flame blow sideways?
See Drawings 5 & 6
YES
NO
OK
Go to B 7
Continue purging
air by repeated
starting attempts
25 Check for gas
pressure at valve inlet
PRESSURE
26 Check for
blocked pilot jet
or tube. Clean
and re-test
STILL
NO GAS
Faulty
gas
valve
Remedy gas
supply
NO
PRESSURE
3
FAULTY Refer to 'ECS
electrical function' 6.2
Is there carbon on
the flame sensor? NO
YES Clean and
re-test
13
Replace faulty
handpiece. Go
to B1
From F15 OK

C
— SPARK OK BUT PILOT REFUSES TO LIGHT (Not ECS)
12
Pilot
Ignites 3
4
No
Ignition
5
YES
6
10
78
14
YES
11
13
YES
NO
YES
15
18
Is flame
satisfactory?
Does flame
remain when knob
is released 15
secs after ignition?
YES
Press control down
in 'Pilot' position and
hold match flame at pilot
See Drawing No 5
Wait several
minutes for
pure gas
NO YES Go to D
Turn pilot OFF
and attempt re-lighting
five times
(without match)
Does match
flame blow
sideways?
Is flame
weak?
Disconnect control
rod and adapter (*) and
hold valve down in 'Pilot'
position
Purge air from
system until pilot
ignites. Go to 2
Does pilot
light four out of
five times?
YES
OK for service
Go to A9
Is gas pressure
OK after
regulator?
9
Is pilot jet
clear?
Is pilot jet
correct size?
YES
Adjust regulator,
test ignition.
Go to 2
Clean jet and re-
test. Go to 2
Replace jet and
re-test. Go to 2
(*) = Some models only
Adjust pilot gas
flow (*) or replace
Pilot gas filter (*)
Re-test. Go to 2
Does match
flame blow
sideways?
YES
Fit new control
rod. Re-test.
Go to 2
See Drg Nos 5 & 6
12
17
FIRST :-
• Check that all shut-off valves in the gas supply are open.
• For LPG models, check for gas in the bottle and open the bottle valve.
• Check for a gas smell near the pilot, and wait for it to disperse
before starting this procedure.
See Drg Nos 5 & 6
See Table No 1
16
19
See Drawing No 2
See Table No 2
NO
NO
NO
NO
NO
NO
NO
4

D
— PILOT LIGHTS BUT WILL NOT REMAIN ALIGHT (Not ECS)
Does the
pilot remain alight?
12
3
NO
YES
4
56
7
Disconnect the valve control rod (and adaptor if fitted), and operate
the valve directly.
Replace or service
the control rod
and re-test
YES
Is the thermocouple
connection tight at
the control valve?
NO Tighten connection
and re-test
Is the thermocouple
output at least 15 mV
when the pilot is alight?
Is the flame impinging
on the thermocouple?
8
YES Replace faulty control
valve and re-test
NO Adjust the pilot
flame size. Go to C11
YES
Is there soot on
the thermocouple?
9 10
NO Replace thermocouple
and re-test
YES
Clean thermocouple and adjust
pilot air mixture sleeve (*)
for cleaner pilot flame. Go to 3
11
(*) = Some models only
NO
5

E
— STD HEATERS, PILOT ALIGHT BUT BURNER
WILL NOT LIGHT WITHIN TEN SECONDS
12
3
NO
YES
4
56
7
YES
NO
8
YES
Is the gas pressure low
after the regulator? Adjust the pressure
and re-test
Are the logs
correctly positioned?
Re-arrange logs
correctly and re-test
Are the main burner jets
the correct sizes? Fit correct jets
and re-test
Is a jet blocked? Clean the jet
and re-test
See Drawing No 7
See Table No 3
FIRST :-
• For an LPG heater, check that there is ample gas in the bottle.
• For a Thermostat heater, verify that the sensor is not warmer than
the temperature set-point.
NO
NO
6

12
3
NO
4
Is the thermostat
sensing temperatures
above room temperatures? Move the thermostat
away from heat sources
(e.g. the heater or sunlight)
YES
YES
78
YES
NO
YES
Wall mounted? Programmable?
9Does the heater light when
the wires at the two terminals
on the wall thermostat are
connected together by a
jumper wire?
NO
56
NO
Is the thermostat a
remote one? ( Hand held
or wall mounted)
Ensure that room air
can circulate freely past
the sensing bulb
YES
10
12
YES
13 15
Replace batteries
and re-test
Is the thermopile
output more than 325 mV
when disconnected
from the control valve?
14
Does the heater light when
the two thermostat terminals on the
valve (ACC models), the receiver control
box (RMT models) or the terminals
on the cabinet back (ECS models) are
connected by a jumper wire?
YES
See Drawing Nos 8, 9, 10
YES
Replace the
wall thermostat
and re-test
Do the batteries in the
hand unit or the ACC
receiver require replacing?
(Usually once a season)
11 Do the batteries in
the wall thermostat
require replacing?
(Usually once a season)
(*) = Some models only
Replace control
valve and re-test
Replace thermopile
and re-test
16 Repair wiring from heater
to wall unit or valve to
receiver and re-test
17 18
YES
Is the room temperature
above the set temperature? Normal operation
NOTE: When hand-held remote thermostats are set to MANUAL, they do not operate as thermostats
but give direct control. In the AUTO setting they transmit a thermostat signal to the receiver from time
to time, so there can be some delay, when in this setting, before the fire receives a signal to light or
change flame height (modulate). In the MANUAL setting, there is no time delay for signals to the
receiver. The modulating hand-held thermostat (IRRC 400) steps up or down its various fire height
settings one step at a time, so when the fire is lit in a cold room, the fire level can be more quickly
moved to a higher setting by switching to MANUAL, signalling the desired flame level with the ▲
button and then moving back to the AUTO setting.
F
— THERMOSTAT HEATERS. PILOT ALIGHT BUT BURNER
WILL NOT LIGHT WITHIN 30 SECONDS.
THE PILOT MUST BE ALIGHT BEFORE THE THERMOSTAT CAN TURN ON THE FIRE.(Not ECS).
Is it
an ECS?
NO
Go to B 15
YES
NO
NO
NO
NO
NO
NO
7

G
— THERMOSTAT HEATERS. ERRATIC OPERATION
ROOM TEMPERATURE FLUCTUATES TOO WIDELY
Ensure that the wall thermostat or hand unit are exposed to free-flowing room air but not in draughts or
too close to windows.
HEATER CYCLES ON AND OFF TOO FREQUENTLY
Move the wall unit or hand unit further away from the heater, ensuring that it is exposed to free-flowing
room air but not in draughts or near windows. A powerful heater in a relatively small room must shut off
shortly after starting unless its maximum heat output is reduced by turning down the high fire setting.
H— NO FLAME MODULATION ON RMT AND ECS MODELS.
These models are controlled by the IRRC 400 hand-held remote or the ECS handpiece. These remote
controls have the capability of modulating the flame (turning the flame height up and down).
RMT MODELS:
With the fire alight, switch the remote control to MANUAL. Pressing the ▲and ▼buttons beside the
display should alter the number of horizontal bars in the display beside the flame symbol. As the number
of bars increases, the flame height should rise and vice versa. When all bars are cleared from the display,
the fire will extinguish. If the flame height does not alter with the display changes, first make sure that
the remote has good batteries and is close to the receiver and aiming at it. Check the voltage at the
'FLAME LEVEL' terminals of the receiver control box while they are still connected to the valve. The
voltage should range from about 10 volts to about 22 volts dc as the number of display bars changes
from 1 to 5. If the voltage is changing correctly but the flame level is not, the wiring between the control
box and the valve may be faulty or the valve itself may be faulty. If the voltage is incorrect, first verify
the connections between the receiver and the control box, and then the connections between the control
control box and the valve. If they are valid, check the modulating coil on the valve for discontinuity in
the winding. If it is OK, the receiver or receiver control box are probably the cause of the problem.
ECS MODELS:
The flame modulation is controlled by the top rocker switch of the handpiece. When the fire is alight,
holding down the + end should increase flame height while holding down the – end will decrease it. The
change in flame height is stepless and it takes 15 or 20 seconds to run through the full range. As for the
RMT models (above), the voltage should be checked only while the modulating coil on the valve is
connected. Ease the connectors at the top of the modulating coil part way off and measure the voltage at
the exposed lower part of the terminals. The normal voltage range is approximately 3 volts to 11.5 volts
dc. If the measured voltages are correct and the flame is not modulating, then the valve is probably
faulty. A faulty modulating coil winding will result in a false voltage reading at the coil.
I — SOOTING.
If you encounter sooting inside the glass, check the following items:-
• Verify that the gas pressure is correct.
• Verify that the correct sizes of jets are fitted (see Tables 2, 3).
• Increase the primary air intake, if necessary, by opening the rotary sleeves on the main burners
(adjacent to the main jets).
• If the problem persists, check to see whether the main manifold (the one into which the main jets
are screwed) has been forced from its correct position. Over-enthusiastic tightening of the nut on
the main feed pipe, or levering on the main jets while the burners are being installed or removed
can cause the main jets to discharge up or down hill. The gas streams will then not be central in
their venturies and they will not draw in sufficient primary air. To adjust the manifold, remove the
pedestal front panel, extract four screws holding the inspection plate at the right, and, using a 7/8"
hex socket through the inspection port, flex the manifold to its correct position. This can be done
while the fire is alight so that the results can be observed while adjusting.
NOTE. Avoid making adjustments when burning the final dregs of gas in an LPG bottle as these
can be very 'dirty'. 8

1. BALTIMORE & MONACO ASSEMBLY AND DIS-ASSEMBLY
1.1 REMOVING THE GLASS
1. Remove the louvre assembly by lifting it up about 5mm and pulling it carefully toward you.
2. Remove the dress guard if fitted. For the Baltimore, first remove the front panel (below the glass). Do
this by removing the two retaining plates underneath the front panel, and then lifting its rear corners off
their support posts. Once the panel is clear, swing the bottom of the guard out from the heater and lift
the guard off the two top retaining posts. For the Monaco, un-clip the guard from the glass retainers.
3. Baltimore. Before lifting the top trim clear, provide support for the three glass pieces to prevent them
from falling and breaking. Adhesive tape will do this.
4. Remove the two top glass trim fastening screws (positioned horizontally, one at each end of the trim),
slide the trim forward and lift it clear.
5. Lift the front glass clear first, followed by each side glass. As each side glass is removed, a spring, a
backing strip and a glass rope will be released from behind its rear vertical edge.
6. Monaco. Remove two fastening screws securing the top glass trim.
7. Prise forward the top glass trim and lift it clear. Note. This will release the top edges of the left and right
glass retainers.
8. Lift the glass retainers to remove them, keeping a hand on the glass to ensure that it does not fall
forward.
9. Lift the glass clear.
1.2 FITTING THE GLASS , THE LOUVRE ASSEMBLY, THE DRESS
GUARD AND THE FRONT PANEL.
1.2.1 GLASS ASSEMBLY
1. Baltimore. Clean all inside glass surfaces carefully and keep fingerprints off them as they are assembled.
2. Assemble both side glasses. Fit the spring, the backing strip and the glass rope (in that order) into each
retaining slot and then each glass, MAKING SURE THAT THE SMOOTH EDGES WILL BE
AGAINST THE FRONT GLASS. Push them back against their springs until the front edges drop into
the front slot.
3. The front glass can then be fitted, TAKING CARE THAT THE BEVELLED EDGES FACE THE
FRONT (i.e. away from the side glasses). Offer the front glass into position with its lower edge just
above the top of the bottom retaining channel. Press the front glass back against the side glasses,
compressing the springs until it the glass is directly above the
9

channel. Maintaining the backward pressure, slide the front glass down into the channel.
4. For safety, strap the glasses together with a piece of adhesive tape at each top corner to prevent them
from falling out while the top trim is being fitted.
5. Slide the top trim into position under its guides and replace the two horizontal retaining screws. Before
tightening the screws, ensure that the three glass pieces are seated snugly against the top glass tape to
prevent any leakage. Do not over-tighten the screws.
6. Remove the adhesive tape and clean the glass.
7. Monaco. Assembly is the reverse of the above removal procedure. Clean the inside surface of the glass
and keep fingerprints off it as it is re-assembled.
8. Place the glass in position, noting that the bottom edge of the glass has no gasket.
9. Replace the left and right glass retainers, fitting their lower ends behind the bottom glass trim.
10. Slide the top glass trim into place, making sure the top ends of the side glass retainers are captured. Fit
the two fastening screws.
1.2.2 LOUVRE ASSEMBLY
1. Fit the slot at each end of the louvre assembly over its retaining post. For the Monaco, ensure that the
centre support plate engages its loop.
2. Press downward gently to engage the posts.
3. Confirm correct engagement by pulling forward on the louvre assembly.
1.2.3 DRESS GUARD (IF REQUIRED)
1. Baltimore. The front panel must be removed for fitting and removing the dress guard.
2. Angling the guard forward at the top, fit the two lugs at the top of the guard over the posts at each end
of the top of the glass assembly.
3. Swing the lower edge of the guard under the front glass support.
4. The guard is retained in position by fitting the front panel. (See 1.2.4)
5. Monaco. The guard simply clips behind the top and bottom edges of the glass retainers.
1.2.4 FRONT PANEL (Baltimore only)
1. Fit the keyhole slot at each end of the front panel over its retaining post.
2. Press downward gently to engage the posts.
3. Confirm correct engagement by pulling gently forward on the front panel.
4. Swing the front panel up into position and fix it there using the two clamp plates and screws vertically
from below.
10

1.3 DISCONNECTING THE FLUE
1. Shut off the gas supply at the valve behind the heater.
2. Remove the access panel on the rear of the cabinet.
3. Disconnect the gas line at the heater.
4. Lift the flue sleeve about 75mm and support it with a wooden block.
5. Slacken any flue clamp and lift the flue while moving the heater from beneath it.
6. Slide the heater away from the wall, supporting the flue and trim on a suitable spacer.
7. Keep the heater upright at all times to avoid displacing the logs.
1.4 REMOVING THE CABINET
1. Remove the front panel (Baltimore only), the dress guard (if fitted), the louvre assembly and the glass (in
that order) as detailed in Section 1.1. For the Monaco, remove the bottom glass trim (one screw at each
end and three into the baseplate.
2. Remove all access panels ( See Section 1.6.), the pedestal rear panel and the fan (if any).
3. Disconnect the gas supply.
4. Disconnect the flue, where applicable. See Section 1.3.
5. Remove the control knob (STD models) and disconnect the Piezo lead from the bottom of the Piezo
(ACC and RMT models prior to December 2000).
6. Remove the diverter hood from the rear of the cabinet.
7. Withdraw the screws holding the rear panel of the cabinet to the heat exchanger.
8. Extract all the screws under the bottom outer edge of the cabinet.
9. Remove the screws inside the front of the firebox which fix the firebox sides to the cabinet.
10. Remove any control rod(s).
11. The cabinet can now be lifted straight up. Take care not to lose the bush in the control panel (STD
models).
1.5 REPLACING THE CABINET
1. Lower the cabinet carefully over the firebox until it reaches the baseplate.
2. Re-connect the Piezo lead (if fitted).
3. Feed the control rod(s) up through the heat shield and the control panel (where applicable).
4. Attach the lower end of the rod(s) at the valve (as required).
5. Fit the bush on the control rod (STD models).
6. Replace all the cabinet retaining screws, taking care not to over-tighten.
7. Replace the screws holding the rear panel of the cabinet to the heat exchanger.
8. Replace the diverter hood at the rear of the cabinet.
9. Re-fit the control knob (STD models).
10. Replace the glass, the louvre assembly, the dress guard (if fitted) and the Baltimore front panel. See
Section 1.2. Replace the Monaco front glass retainer, ensuring that the spacers are fitted on the end
fastening screws between the glass retainer and the side panel to allow easy fitting of the side access
panel.
11. Re-assemble all access panels, the fan (if any) and the rear pedestal panel.
12. Re-install the flue and gas supply and check for gas leaks.
1.6 ACCESS PANELS
1.6.1 REMOVING THE REAR ACCESS PANEL
1. Remove four screws, three on the face and one underneath.
2. Lift the panel clear.
1.6.2 REPLACING THE REAR ACCESS PANEL
1. Offer the panel into position and re-fit the screws. Do not overtighten.
1.6.3 REMOVING THE SIDE ACCESS PANEL
1. Remove two screws below the panel. In the case of the Monaco, the whole of the right hand side of the
cabinet is the access panel.
2. Lift the panel gently upward, pulling the lower edge outward.
3. Lower the panel until it is clear of the pins.
11

1.6.4 REPLACING THE SIDE ACCESS PANEL
1. Fit the large holes in the panel over the top locating pins.
2. Pushing upward, swing the bottom of the panel in until the screw holes align.
3. Replace the two screws. Do not overtighten.
1.6.5 REMOVING THE PIEZO/FAN SWITCH ACCESS PANEL (Not ECS)
1. Remove the screws securing the panel to the top rear of the cabinet.
2. Lift the panel clear.
1.6.6 REPLACING THE PIEZO/FAN SWITCH ACCESS PANEL (Not ECS)
1. Offer the panel into position and re-fit the screws. Do not overtighten.
1.7 REMOVING AND REPLACING THE BURNERS
NOTE: When fitting or replacing the burners, take care to avoid levering the injector jets up or down
as this may cause mis-alignment of the gas jets in their venturi tubes, resulting in insufficient
primary air intake.
1. Disconnect the gas and power supplies.
2. Remove the front panel, dress guard (if fitted), louvre assembly and glass . See Section 1.1.
3. Remove the embers and store them in a plastic bag.
4. Carefully remove the logs.
5. Remove the log supports (one at each end of the front burner).
6. Remove the two screws retaining each burner, and lift the burners clear while moving them to the left to
disengage them from their injector jets.
7. Follow the above steps in reverse to replace the burners. When re-installing the embers, ensure that they
do not cover the small gas outlet holes in the burner. (See Drawing 2).
1.8 REMOVING AND REPLACING THE PILOT ASSEMBLY
1. Remove the burners, following steps 1 – 6 in Section 1.7.
2. Disconnect the Piezo wire, (the thermopile and thermocouple, if fitted) and the gas pipe to the pilot.
3. Withdraw the screws fixing the pilot assembly to the burner tray.
4. The pilot assembly can now be disconnected and lifted clear.
5. Follow the above order in reverse to replace the pilot assembly.
1.9 ACCESSING THE PILOT JET
The various pilot jets are reached for removal as illustrated below.
NOTE: Always smear ROCOL MOLYCOTE J166 on the pilot tube retaining nut threads when re-fitting the
pilot tube. 12

EARLY MODELS
TOP LOADING PILOT SIDE ENTRY PILOT
CURRENT MODELS
SEE DRAWING 1 FOR CORRECT SPARK GAPS
13

1.10 ACCESSING THE MAIN INJECTORS
1. Remove the burners (See 1.7)
2. The injectors can now be unscrewed from the manifold. WARNING. On some models the jet sizes in the
front and back injectors are different. Take care not to mix them up. (See Table 3).
3. Note. When replacing an injector, it should not be over-tightened, and a small amount of teflon thread
sealant (not tape) should be applied to the thread to prevent gas leakage.
1.11 REMOVING CONTROL VALVES AND REGULATORS (Baltimore & Monaco)
1.11.1 STANDARD MODELS
1. Turn off the gas supply.
2. Remove the access panels. See Section 1.6.1 and 1.6.3.
3. Disconnect the gas pipe at the inlet to the regulator. See Drawing No 8.
4. Disconnect the pipe between the regulator and the control valve.
5. At the control valve, disconnect the pipes to the burner and the pilot.
6. Also disconnect the thermocouple connection to the control valve.
7. Disconnect the control rod.
8. After removing their mounting screws the pressure regulator and control valve can be lifted clear.
9. Re-assemble in the reverse order, taking care to check for gas leaks.
1.11.2 ACC and RMT MODELS
1. Turn off the gas supply.
2. Remove the access panels. See Section 1.6.1 and 1.6.3.
3. Disconnect the gas pipe at the inlet to the control valve. See Drawing Nos 9 & 10.
4. At the control valve, disconnect the pipes to the burner and the pilot.
5. Disconnect the thermocouple connection to the control valve.
6. Also disconnect the thermopile connection to the control valve.
7. Disconnect the thermostat wires (if any). On RMT models, disconnect the modulating coil wires.
8. Disconnect the control rods.
9. After removing the mounting screws the control valve can be lifted clear.
10. Re-assemble in the reverse order, taking care to check for gas leaks. Correect wire connections are
shown in the wiring diagram in 5.2.
1.11.3 ECS Models
1. Turn off the gas supply.
2. Remove the access panels. See Section 1.6.1 and 1.6.3.
3. Remove the valve top heat shield (3 screws).
4. Disconnect the wiring loom from the reset switch (on the rear access panel), the thermodisc switch (on
the rear of the firebox), the modulating coil (on the valve) and the earth terminal on the valve. Un-plug
the ignition loom at the top of the control box.
5. Disconnect the spark wire, the flame sensing wire and the earth wire from the ignition module on the
valve.
6. Leaving the ignition loom connected to the ignition module, carefully slide the ignition module vertically
from its mounting on the gas control valve.
7. Disconnect the gas pipe at the inlet to the control valve. See Drawing No 11.
8. At the control valve, disconnect the pipes to the burner and the pilot.
9. Remove the screws at each end of the valve mounting cradle and lift the valve clear.
10. Re-assemble in the reverse order, taking care to check for gas leaks.
1.12 ACCESSING THE FAN ASSEMBLY
1.12.1 NZ STD Models
These have the fan assembly mounted inside the pedestal rear panel.
1. Un-plug the lead from the mains supply.
2. Pull off the fan speed control knob.
3. Remove four screws at the rear of the pedestal.
4. Operating from the speed knob end, move the fan assembly away from you while swinging the far end
rearward until the assembly can be lifted clear.
5. Reverse the extraction procedure when re-assembling.
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1.12.2 ACC and RMT Models
These have the fan assembly mounted inside the pedestal rear panel. A thermodisc switch is fitted
adjacent to the rear of the firebox.
1. Un-plug the lead from the mains supply.
2. Remove the four retaining screws at the rear of the pedestal.
3. Lift the fan assembly carefully away from the pedestal until the loom connector block is exposed.
4. Disconnect the connector block and lift the fan clear.
5. Reverse the extraction procedure when re-assembling.
1.12.3 Aust. STD Models
These have the fan assembly mounted on the rear of the heater cabinet. The mains cord enters the fan
assembly and an internal loom extends up to the three speed switch at the top control panel. No
thermodisc switch is fitted.
1. Un-plug the lead from the mains supply.
2. If fixing screws are fitted along the top of the fan housing, remove them.
3. While supporting the housing from falling outward, lift it up to disengage it from the keyhole slots.
4. Carefully swing the top of the fan housing away from the heater cabinet until it can be lifted clear of the
cabinet at its bottom edge which sits in a ‘V’ formation on the opening in the cabinet.
5. Swing the right end (viewed from the rear) of the fan housing away from the heater and move the
housing a little to the right to expose the plug and socket in the fan loom.
6. Disconnect the plug and socket and lift the fan clear.
7. Reverse the extraction procedure when re-assembling.
1.12.4 ECS Models - Aust. and N.Z.
These have the fan assembly mounted on the rear of the heater cabinet. The mains supply is delivered
through the ECS control box which is mounted inside the rear pedestal panel. Speed control is provided
by a signal from the handpiece to the receiver which is processed by the ECS control box. A thermodisc
switch is fitted adjacent to the rear of the firebox.
To extract and replace the fan assembly, follow steps 1 – 7 in 1.12.3
1.13 REMOVING AND REPLACING THE PEDESTAL
1. Remove the fan (see Section 1.11) or pedestal rear panel as applicable.
2. Remove the front panel, dress guard (if fitted), louvre assembly and glass . See Section 1.1.
3. Remove the logs carefully.
4. Disconnect the thermostat bulb if attached to the pedestal.
5. Remove the four screws retaining the pedestal to the baseplate.
6. Lift the firebox clear. Note: The heat shield below the baseplate will still be partially attached.
7. Reverse the removal sequence when re-assembling the pedestal.
1.14 REMOVING AND REPLACING THE PEDESTAL FOOT
1. First carefully disconnect the receiver loom at the plug near the receiver control box (RMT models) or at
the plug on the rear pedestal panel (ECS models).
2. To remove the foot, carefully slide the foot and trim forward, keeping it in contact with the floor to
avoid damaging the finish on the pedestal.
3. To replace the foot, make sure the decorative trim is correctly in place before sliding the foot and trim
back around the pedestal, again keeping the foot in contact with the floor to avoid pedestal finish
damage.
4. Re-connect the receiver loom (if applicable).
1.15 ACCESSING THE THERMODISC (Recent Baltimores & Monacos except Aust. STD)
If the heater has a fan mounted on the rear of the cabinet, remove the fan (see 1.12) to reach the
thermodisc. If easier access is needed, also remove the rear access panel.
For other models, remove the rear access panel to access the thermodisc.
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2. NAPLES & SEVILLE ASSEMBLY & DIS-ASSEMBLY
2.1 REMOVING AND REPLACING THE NAPLES GLASS
1. Remove the top louvre assembly and the bottom right louvre assembly by lifting upward, then outward.
2. Swing the bottom left louvre assembly open and lift it off its hinge.
3. If a dress guard is fitted, release it by springing out the clips which hook behind the vertical sides of the
glass frame.
4. While supporting the glass bay window
assembly, remove the two horizontal fastening
screws (at the ends of the top of the assembly).
5. Pull the glass assembly outwards at the top
until it is about 15˚ from vertical, then lift it up
out of the bottom retaining channel in the base
of the firebox.
6. To replace the glass assembly, follow the
above steps in the reverse order, taking care to
clean the inside surfaces of the glass assembly
beforehand, and making sure that the glass
sealing strips are correctly positioned when
swinging the assembly into position.
2.2 REMOVING AND REPLACING THE SEVILLE GLASS
1. Remove the top louvre assembly by lifting upward then outward.
2. If a dress guard is fitted, lift off the bottom right louvre assembly, swing open the bottom left louvre
assembly and lift it off its hinge. Spring the bottom retaining clips of the dress guard downwards and
swing the bottom of the guard out from the heater. Lift the guard off the two top retaining lugs.
Spring the bottom retaining clips of the dress
guard downwards and swing the bottom of the
guard out from the heater. Lift the guard off
the two top retaining lugs.
4. Remove the two top glass trim fastening
screws (positioned horizontally, one at each
end of the trim), slide the trim toward you and
lift it clear.
5. Remove the two black cover trims, one at
either end of the glass, by lifting them upwards
and then out. Pull the top of the trim forward
before the bottom.
6. Lift the glass clear and place it where it will not
be damaged.
7. To replace the glass assembly, follow the
above steps in the reverse order, taking care to
clean the inside surface of the glass assembly
beforehand, and making sure that the glass
sealing strips are correctly positioned when
fitting the glass.
2.3 FITTING THE LOUVRE ASSEMBLIES AND DRESS GUARDS
2.3.1.1 LOUVRE ASSEMBLIES (NAPLES)
1. With the exception of the bottom left louvre assemblies, the louvre assemblies simply hook over their
retaining posts.
2. Press downward gently to engage the posts. 16

3. Confirm correct engagement by pulling forward on the louvre assembly.
4. The bottom left louvre assemblies are hinged for easy access to the controls. To attach (or detach) the
bottom left louvre, hold it in a position 60° from fully closed.
5. When attaching, tilt the louvre away from the heater at the top so that the bottom eye of the hinge can be
hooked over the bottom hinge pin.
6. Keeping the bottom eye engaged on the pin, lift the louvre until its top hinge eye can be swung onto the
top hinge pin.
7. Lower the louvre into position and swing it shut.
8. Follow this procedure in reverse to detach the louvre.
FITTING THE LOUVRE - VIEWED FROM INSIDE THE FIREBOX
2.3.1.2 LOUVRE ASSEMBLIES (SEVILLE)
1. With the exception of the bottom left louvre assemblies on New Zealand Sevilles, the louvre assemblies
simply hook over their retaining posts.
2. Press downward gently to engage the posts.
3. Confirm correct engagement by pulling forward on the louvre assembly.
4. The bottom left louvres on N.Z. Sevilles are hinged similarly to the ones on Naples models. Follow the
instructions in 2.3.1.1 for attaching and removing these louvre assemblies.
2.3.2 DRESS GUARDS (IF REQUIRED)
Naples:
1. The guard is retained simply by clipping its retaining lugs between the glass and the steel frame at each
side of the side glasses.
Seville:
1. The louvre assemblies must be removed for fitting and removing the dress guard.
2. Angling the guard forward at the top, fit the two lugs at the top of the guard over the lugs at each end of
the top glass trim.
3. Swing the lower edge of the guard inwards to engage the bottom lugs under the firebox base..
4. Replace the louvre assemblies.
2.4 REMOVING AND REPLACING THE BURNERS
NOTE: When fitting or replacing the burners, take care to avoid levering the injector jets up or down
as this may cause mis-alignment of the gas jets in their venturi tubes, resulting in insufficient
primary air intake.
1. Remove the glass or glass assembly. See 2.1 or 2.2.
2. Remove the embers and keep them in a suitable container such as a plastic bag.
3. Carefully remove the logs.
4. Remove the log supports (one at each end of the front burner).
5. Remove the two screws retaining each burner, and lift the burners clear while moving them to the left to
disengage then from their injector jets.
6. Follow the above steps in reverse to replace the burners. When re-installing the embers, ensure that they
do not cover the small gas outlet holes in the burner.
2.5 REMOVING AND REPLACING THE PILOT ASSEMBLY
1. Remove the burners following steps 1 – 5 in 2.4.
2. To provide easier access, remove the heat shield above the valve by extracting the screws holding it to
the firebox base.
3. Follow steps 2 – 5 in 1.8.
2.6 ACCESSING THE MAIN INJECTORS
1. Remove the burners. See 2.4. 17

2. The injectors can now be unscrewed from the manifold. WARNING. On some models the jet sizes in the
front and back injectors are different. Take care not to mix them up.
3. Note. When replacing an injector, it is should not be over-tightened, and a small amount of teflon thread
sealant (not tape) should be applied to the thread to prevent gas leakage.
2.7 ACCESSING THE CONTROL VALVE (NAPLES & SEVILLE)
1. Remove the glass or glass assembly. See 2.1 or 2.2.
2. Turn off the gas and un-plug the lead from the mains power supply.
3. Disconnect the gas supply pipe at the inlet to the control valve.
4. Remove the embers, logs and log supports. See 2.4, steps 2 – 4.
5. Remove the heat shield above the valve by extracting the screws holding it to the firebox base.
6. Extract the four screws holding the burner tray to the firebox base.
7. Lift the burner tray clear. The control valve, pilot assembly and manifold lift clear as a complete assembly
and these parts can be removed and serviced as required.
8. Reassemble in the reverse order, taking care to check for gas leaks.
2.8 REMOVING AND REPLACING THE FASCIA
1. Un-plug the lead from the mains supply.
2. Extract the six screws, two each side and two at the top, which hold the fascia to the firebox cabinet.
3. Taking care not to strain the wiring looms, ease the fascia away from the firebox. The looms can be
disconnected at the switches, if necessary, by carefully prising the connectors from the spade terminals.
4. Before re-fitting the fascia, make sure the looms are connected to the switches correctly. The three wire
loom connects to the fan speed switch, red wire to the top terminal, brown wire to the centre terminal
and orange wire to the bottom terminal. The two wire loom connects to the two terminals on the burner
ON-OFF switch. No colour coding is necessary.
2.9 ACCESSING THE FAN
1. Un-plug the lead from the mains supply.
2. Remove the glass. See 2.1 and 2.2.
3. Remove the embers and the logs.
4. Remove the screws holding the rear access panel to the inside of the back of the firebox. Later models
have keyholes for the screws, so they do not need to be removed completely.
5. Remove the fan heat shield just in front of the fan. On later models, the fan heatshield is an integral part
of the access panel, and it comes clear as the panel is removed by lifting upwardly.
6. Remove the fan deflector (above the fan) by extracting two screws at each end and lifting it free. See
diagram.
18

7. Release the fan by removing one screw at each end of the fan mounting plate. On later models the fan
mounting screw holes are keyhole slotted, so the fan can be lifted up without slackening the screws.
8. Lift the fan up until the bottom edge of its mounting plate comes clear of the locating slot at the rear of
the base of the firebox, disconnect the wiring loom at the plug near the fan, and lift it free.
9. Assembly is a reversal of the extraction procedure. Take care to engage the bottom edge of the fan
mounting plate in its locating slot.
2.10 ACCESSING THE THERMODISC (Aust. Naples & Seville only)
1. Follow steps 1 to 5 in 2.9 above. The thermodisc will be seen mounted inside the cavity behind the
firebox on the left hand side. It can be removed by releasing its mounting plate screws just inside the
firebox. The function of the thermodisc is to automatically start the fan after the heater has reached a
sufficiently high temperature, and to stop the fan when the heater has cooled after being shut down.
2.11 RETRO-FITTING A THERMODISC SWITCH (SEVILLE & NAPLES)
1. Ensure that the electrical power supply is disconnected.
2. Remove the glass, the logs and the fan access panel. (See 2.9. Do not remove the fan.)
3. Connect the thermodisc loom to the two terminals at the back of the thermodisc.
4. Remove the two fasteners on the left sidewall of the firebox (near the fan access opening).
5. Attach the thermodisc bracket using these two holes, ensuring that the bracket is on the outside of the
firebox and that the thermodisc protrudes rearwards.
6. Feed the thermodisc loom beside the burner tray toward the front of the unit.
7. Remove the bottom louvre to gain access to the existing loom junction at the front left hand end of the
unit.
8. Disconnect the existing brown supply terminals and connect them to each of the terminals at the end of
the thermodisc loom.
9. Replace the fan access panel, the logs, the glass and the bottom louvre.
10. Restore the mains supply and test, remembering that the fan will start about eight to ten minutes after
establishing a high fire.
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