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

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Installation and Servicing

BBU Fire Front

G.C. No. 37 047 11

For use with a specially designed

Glow-worm Back Boiler Unit only

This is a Cat I

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.

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

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

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

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

All replacement parts

All labour charges

All call-out charges

One Contact Local Service

Supplied By www.heating spares.co Tel. 0161 620 6677

Instructions for Use

To b e l e f t w i t h t h e u s e r

BS 6332

BS 5258

Appliance

Guarantee Registration

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0181 380 2555

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

221648B. 02. 00

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Page 1 221648B. 02. 00 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r BBU Fire Front G.C. No. 37 047 11 For use with a specially designed Glow-worm Back Boiler Unit only BS 6332 BS 5258...
Page 2: Table Of Contents
Important Information CE Mark The CE mark on this appliance shows compliance with:- 1. Directive 90/396/EEC on the approximation of the Laws of the Member States relating to appliances burning gaseous fuels - Boiler and Fire. 2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits - Boiler only.
Page 3: Lighting The Fire Front
Instructions for Use BS6539 “Fireguards for use with solid fuel appliances” or the This fire front may be fitted to a Glow-worm back boiler WITHOUT current issue of BS6778 “Fireguards for use with portable, free a flue blockage safety device. Please refer to the supplementary standing or wall mounted heating appliances”.
Page 4 Instructions for Use 150mm 430mm 430mm 150mm 840mm 628mm FLAT AREA FIRE FIXING FACE Diagram 1 Frost CAUTION. If the back boiler is to be out of use for any long period of time during severe weather conditions we recommend that the whole of the system, including the back boiler be drained off to avoid the risk of freezing up.
Page 5 Instructions for Use before the boiler is used again. control on again until at least three minutes have gone by. If the burner go out, wait three minutes before relighting, but Turn on the electrical supply to the unit. check as above. Turn the control thermostat knob “B”...
Page 6 Instructions for Use Lighting the Fire Front CAUTION. If the glass panel or internal fire parts are damaged do not light or use the fire front before replacement parts are fitted. The fire front is fitted with a flue blockage safety device which will shut it down if there is a problem with the chimney.
Page 7 Instructions for Use Glass Panel and Internal Fire Front Parts Replacement Parts Lift the canopy off, see diagram 7. Take care as it is made of If replacement parts are required apply to your local supplier. cast iron. Please quote the name of the fire front, “Saxony 2”, to be found Swing the side panels open, see diagrams 7 &...
Page 8 Instructions for Use FUEL EFFECT PIECE POSITION 2 FUEL EFFECT PIECES LOCATIONS FUEL EFFECT BASE LOCATION RECESS 2 NOTE: FUEL EFFECT PIECE MUST SIT ON SUPPORT ANGLE Diagram 12 Diagram 9 FUEL EFFECT PIECES 1 to 5 FUEL EFFECT PIECE POSITION 3 FUEL Left Right...
Page 9 Instructions for Use FUEL EFFECT PIECE POSITION 5 LOCATION RECESS 5 SECURING SCREW STOP FIBRE Diagram 15 WASHER COMPLETED FUEL R.H. SIDE EFFECT BED PANEL Ensure corners of fuel effect pieces 4 and 5 are seated on flat areas of fuel effect pieces 1, 2 and 3 GAS CONTROL KNOB Diagram 18...
Page 10: Supplementary Instructions
Supplementary Instructions At initial lighting of the boiler air may be present and several This appliance is fitted with a flue blockage safety device which attempts may be needed to light the pilot. Keep control knob “A” will shut down the appliance in the event of abnormal flue pushed in whilst operating the ignition button.
Page 11 1 General FLAT AREA FIRE FIXING FACE 286mm 616mm 690mm 442mm 326mm 344mm 628mm Diagram 1.1 1 General Notes and Information Sheet Metal Parts This fire front may be fitted to a Glow-worm back boiler WITHOUT WARNING. When installing or servicing this fire front care should be taken when handling metal parts (components) to a flue blockage safety device.
Page 12 1 General 1.3 Data Gas connection - from the service cock Total weight - 54kg Bray 18/180 Injector - upper - Bray 18/320 - lower - Burner pressure setting - cold - 13.0mbar 5.2in wg 13.2 mbar 5.3in wg - hot - 6.7kW - 22,750Btu/h Heat input - gross...
Page 13: Types Of Installation And Flue
2 Types of Installation and Flue Note. Refer to Section 2 in the Back Boiler Installation book before starting. 2.1 With Hearth A fireproof hearth under the fire front must have the minimum dimensions as shown in diagram 2.1. 2.2 With Surround See diagram 2.2.
Page 14: Fire Front Preperation
3 Fire Front Preperation FIRE BODY PACK FIRE BODY ASSEMBLY FLUE SPIGOT WALL SEALING PLATE FUEL EFFECT COMBUSTION LITERATURE CHAMBER BOTTOM PLATE CASING PACK CANOPY L.H. SIDE PANEL R.H. SIDE L.H. SIDE PANEL CASTING FRONT CASTING L.H. PLINTH R.H. SIDE CASTING REAR SUPPORT...
Page 15 3 Fire Front Preperation SCREW FRONT LEG M5x30 LEVELLING SCREW SCREW SIDE M5x14 CASTINGS SCREW UPPER WALL M5x40 MOUNTING ANCHOR UPPER WALL MOUNTING SCREW FRONT LEG M5x8 FIXING SCREW WALL SEALING No. 10 x 1 PLATE FIXING WALL WALL SEALING PLUG PLATE FIXING SCREW...
Page 16 3 Fire Front Preperation 3.1 Unpacking Gas Supply Tube The fire front is delivered in two packs, one contains the body Measure the distance “C”, see diagram 3.6, from the front mark assembly, fuel effect pieces and supply tube pack. “P”...
Page 17 3 Fire Front Preperation Firefront sensing tube *'C' = Distance from fire fixing wall face to datums Shorten the plain end of the fire front sensing tube by distance on back boiler air duct. This represents the “D”, no shortening of the tube is required when 45/2 back boiler is fitted and point “P”...
Page 18: Installation
4 Installation 4.1 Wall Section Plate Place the wall sealing plate onto the back boiler air duct, mark the fixing holes, remove the plate and drill the holes to suit the plugs and screws provided, in the supply tube pack, leave sufficient screw proud to accept the wall sealing plate keyholes, see diagram 4.2.
Page 19 4 Installation SECURING MOUNTING SCREW (2) BRACKET FLUE COLLECTOR SECURING SCREW (2) M5 x 40mm FIRE FRONT SENSING TUBE TUBING SECURING SCREW (2) OLIVE ANCHOR Diagram 4.4 FRONT Diagram 4.6 FIXING SCREW SPIGOT 4.3 Gas Connection Place the tubing nut and olive, from the loose items pack, onto the prepared end of the gas supply tube, see diagram 4.8.
Page 20 4 Installation SENSING LOCK TUBE NUT TUBE NUT (A) TUBE NUT UNION NUT (B) JOINT (C) GAS SUPPLY PIPE GAS SERVICE COCK Diagram 4.7 TUBING OLIVE Diagram 4.8 SECURING SCREW SECURING SCREW LOCATING PIN R.H. SIDE STOP STOP AND HOLE PANEL FIBRE FIBRE...
Page 21: Lighting, Testing And Fitting Internal Parts
5 Lighting, Testing and Fitting Internal Parts 5.1 Lighting and Testing Make sure that the electrical supply to the back boiler is isolated. This fire front is fitted with a flue blockage safety device which will shut down the fire if there is an unacceptable spillage of products at the draught diverter.
Page 22: Instructions For Use 6
5 Lighting, Testing and Fitting Internal Parts 5.2 Internal Parts - Fitting Caution. If any of the internal fire front parts are damaged DO NOT light or further test the fire front until replacement parts are fitted. Refit gas tap control knob. Swing the side panels out by about 5mm, to their stops.
Page 23: Diagram
5 Lighting, Testing and Fitting Internal Parts BOTTOM PLATE LOCATION PIN LOCATION SLOT Diagram 5.3 VIEWED FROM REAR LEVELLING SCREW WASHER SECURING FRONT SCREW (2) CASING Diagram 5.4 Diagram 5.6 REAR VIEW LOCATING PIN REAR SECURING SCREW (1) FRONT SECURING ADJUSTING SCREWS SCREW (2) L Diagram 5.5...
Page 24: Diagram
5 Lighting, Testing and Fitting Internal Parts Test Where No Fan is Present Close all outside doors and windows in the room where the appliance is installed. Light the fire front only and set tap position to 4. After five DRAUGHT minutes apply a spillage test as shown in diagram 5.8 and 5.9.
Page 25: Instructions For Use
6 Instructions for Use Hand the Instructions for Use to the user and instruct in the safe and economical use of the fire front and back boiler. Advise the customer that they should read their Users instructions before operating the fire and always follow the SPILL advice in the Section headed “Cleaning your Fire”.
Page 26 7 Servicing Remove the RH. leg support bracket, see diagram 7.2. LOWER Disconnect the supply pipe unions at the injectors also the union FRONT connection at the front, see diagram 7.3. BAFFLE Remove the two burner securing screws, see diagram 7.3. Swing the burner out for access, see diagram 7.4.
Page 27: Diagram
7 Servicing L.H. BURNER R.H. BURNER SECURING SCREW SECURING SCREW TUBE TUBE BURNER UNION UNION CONNECTION CONNECTION FLUE BLOCKAGE UNION SAFETY DEVICE CONNECTION NOTE: Chamfered edge to be on Diagram 7.3 this side. MOUNTING BRACKET BURNER PULL FORWARDS SECURING SCREW (2) Diagram 7.4 INJECTOR BOX COVER...
Page 28: Diagram
7 Servicing ELECTRODE GAS TAP MOUNTING BRACKET SECURING SCREW EARTH SPARK GAP POST + 1.0 - 0.5 MICRO SWITCH ELECTRICAL CONNECTIONS EARTH INSULATION ELECTRODE POST MICRO SWITCH NUT (2) TOP VIEW GAS TAP MOUNTING ELECTRODE BRACKET INSULATION SECURING SCREW (2) Diagram 7.8 EARTH POST...
Page 29: Diagram
7 Servicing GAS TAP SECURING SCREWS THERMOCOUPLE Diagram 7.10 Diagram 7.9 GAS TAP BODY GAS TAP BRACKET AND NITING PLATE PLUG ASSEMBLY 'O' RING WASHER SPRING SECURING SCREW Diagram 7.11 221648B Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 30: Fault Finding
8 Fault Finding 8.1 Fire Front Ignition Remove decorative castings, glass panel and fuel bed, refer to appropriate parts of Section 7. Refer to diagram 8.3. 8.2 Electrical Refer to functional flow diagram 8.2 and pictorial wiring diagram 8.1. 8.3 Thermocouple To test a thermocouple, a meter with a range of 0 to 30mV is required together with a thermocouple interrupter test unit, similar to the British Gas Minitest 6 unit.
Page 31 8 Fault Finding START HERE FIRE WILL NOT LIGHT Check that gas is available Does the pilot light using a match ? Turn off appliance tap, turn on appliance tap. Change pilot filter Does the fire light ? Ensure gap is within specified Check that gas is available at burner, using a tolerance, refer to SERVICING.
Page 32 8 Fault Finding Disconnect appliance thermocouple from the gas tap. Check that all connections are clean and in good condition. Fit test meter interrupter into the magnet unit. Fit appliance thermocouple into the test meter interrupter. Hold down control tap in ignition position. Ignite burner, allowing thermocouple to attain operating temperature.
Page 33: Replacement Parts
9 Replacement Parts Notes. 9.7 Spark Generator Make sure that the fire is cold before replacing any parts. Remove right hand side panel, see diagram 4.9. Replacement of parts must be carried out by a competent Remove the right hand side casting, see diagram 5.5. person.
Page 34 9 Replacement Parts GAS TAP BRACKET AND NITING PLATE ASSEMBLY FILTER GAS TAP CROSS SECTION VIEW FILTER Diagram 9.1 9.10 Replacement Parts When replacement parts are required please apply to your local supplier. Please quote the name of the fire front, “Saxony 2”. The GC number can be found on the chassis, visible when front casting is removed.
Page 35 9 Replacement Parts Diagram 9.2 221648B Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 36: Supplementary Installation Instructions
10 Supplementary Installation Instructions As these fire fronts may be fitted to Glow-worm 45, 56, 45R or 56R back boiler units WITHOUT a flue blockage safety device, the following instructions must be read and followed in place of those in the main Installation and Servicing Instructions. To check if a flue blockage safety device is fitted, refer to the inset in diagram 20 (Instructions for Use).