221102B.11.97 Installation & Servicing Instructions To be left with the user MELODY BBU Fire Front GC No. 37 314 09 For use with a specially designed Glow-worm Back Boiler Unit only 5098 References 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. This is a Cat I 2H Appliance BS 6332 BS 5258 One Contact Local Service 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
1 General 690 FIRE FRONT FIXING WALL FACE 253 236 5122 624 647 DIMENSIONS ARE IN mm 23 PREPARED BASE OVERALL DIMENSIONS Diagram 1.1 If this fire front is to be fitted to a Glow-worm Back Boiler WITHOUT a combustion products discharge safety device refer to the Supplementary Instructions at the back of this booklet. 1 General The instructions consist of three parts, Installation and Servicing Instructions for the Fire Front and Back Boiler Unit and Instructions for use, 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. General Notes and Information The Glow-worm Melody BBU 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 in one cardboard carton, which contains all the parts necessary for the installation of the fire front. If the fire front and back boiler are to be installed at the same time please read both sets of instructions before starting. Wherever possible, all materials, appliances and components to be used shall comply with the requirements of applicable British Standards. Where no British Standards exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship. 1.1 Important Notice The fire is fitted with a safety device which will shut it down if there is a lack of oxygen. If the fire shuts down frequently for no apparent reason the first things to be checked are the chimney and air inlets into the room. An additional cause could be that the filter, in the gas tap has become blocked. Any problems found must be put right, by a competent person, before the fire is used again. This fire front is for use only on G20 gas. Sheet Metal Parts Warning. When installing or servicing this fire front care should be taken when handling sheet metal parts (components), to avoid any possibility of personal injury. 1.2 Data Gas connection Weight from back boiler gas service cock 23kg (50lb) Injectors Upper Bray 19/130 Lower Bray 22/240 Pressure Hot 15mbar (6in wg) Cold 14.6mbar (5.9in wg) Heat input gross 5.28kW (18,000Btu/h) Data label Left hand side of heat exchanger 221102B 2
1 General 1.3 Statutory Requirements The fitting of this fire front must be carried out by a competent person, in accordance with the current issue and relevant requirements of:- Manufacturer s instructions, supplied. The Gas Safety (Installation and Use) Regulations, The Building Regulations, The Building Standards (Scotland) Regulations, (applicable in Scotland), Local gas undertaking, Health and Safety at Work Act, Control of Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations. Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice:- BS5440 Parts 1 and 2, BS5871, BS6891. Manufacturer s instructions must not be taken as overriding statutory requirements. SHELF DEPTH MAX 150 747 FLAT AREA FIRE FRONT FIXING FACE 836 100 OUTLINE OF FIRE FRONT 5111 PREPARED BASE MINIMUM FLAT AREA AND FIXTURES CLEARANCES Diagram 1.2 1.4 B.S.I Certification This fire front is certificated to the current issue of BS5258 Part 8 invoking the current issue of BS6332 for safety and performance, it is, therefore, important that no change is made, without permission, in writing, from Hepworth Heating Ltd. Any change that is not approved by Hepworth Heating Ltd., could invalidate the B.S.I. Certification, the warranty and could infringe the statutory requirements. 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. 2. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electro magnetic compatibility. 1.5 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 installed in accordance with the Glow-worm installation instructions. The back boiler air duct acts as a support for the fire front. The fire front must be secured to the vertical fire front fixing wall face, at the top. This wall face may be a chimney breast or surround, see diagram 1.2. The fire front flue spigot projects into the back boiler flue collection assembly. The gas supply is taken from the back boiler service cock. The back boiler must have been correctly positioned in the builder s opening as the fire front is located by connection to the back boiler. 1.6 Clearances Restrictions should not be placed around the assembled fire front, see diagram 1.2. A shelf up to 150mm deep may be fitted above, with a minimum space of 100mm between the top of the fire front and the underside of the shelf, see diagram 1.2. There should be a clearance of at least 1metre from any part of the radiant heating surface to any combustible side wall or fixture. 3 221102B
2 Types of Installation 2.1 With Hearth A fire proof hearth under the fire front must have the minimum dimensions as shown in diagram 2.1. 2.2 With Surround The opening in a surround should not be greater than 580mm wide. The surround must have a minimum, clear, flat area as shown in diagram 1.2. Any projections on the surround must be outside this area. Any combustible material on the fire front fixing wall 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. 300 13 OUTLINE OF FIRE FRONT 710 NON-COMBUSTIBLE MATERIAL 5112 50 2.3 Without Surround or Hearth The fire front fixing wall face must be flat over an area as shown in diagram 1.2, this also shows the minimum clearances for shelves or projections on the fire front fixing wall face. The front opening in the fire front fixing wall face should not be greater than 580mm wide. Any combustible material on the fire front fixing face area must be removed, see diagram 2.3. This area, to the depth removed, should then be rendered with sand/ cement mixture. MINIMUM HEARTH DIMENSIONS REMOVE COMBUSTIBLE MATERIAL FROM THIS AREA 648 BUILDERS OPENING INSTALLATION CENTRE LINE C L Diagram 2.1 200 PREPARED BASE 424 1694 REMOVAL OF COMBUSTIBLE MATERIAL Diagram 2.3 3.1 Refer to the current issue of BS5440 Part 1. The back boiler flue collector assembly accepts the fire front flue spigot. Note. Provision must have been made during the installation of the back boiler for the total ventilation requirement of the combined fire front and back boiler unit. Refer to the relevant Section in the Back Boiler Installation Instructions. 3 Flue and Ventilation 221102B 4
4 Fire Front Preparation 4.1 Unpacking Lift out the plinth pack containing the plinth, loose items pack and inlet supply tube pack. Remove the top fittings and lift out the fire front. Do not lift by the louvres. Note. There is a packing piece attached to the bottom of the fire front. Lay the fire front down on its back. Remove the packing piece, unscrew the two transit legs and throw them away, see diagram 4.1. Remove the wood transit strips, secured with panel pins, from the bottom of the wooden case sides. Check contents of loose items pack against the packed list. 4.2 Casing Removal With the fire front on its back, remove case securing screws at left and right hand sides, see diagram 4.2. Ease the bottom of the casing upwards and away to disengage the upper lugs, withdraw from the heat exchanger. Place casing aside, on its back, until required. Take care not to damage the rear surround side louvres. TRANSIT LEG (2) PACKING PIECE SECURING SCREW (4) 5387 Diagram 4.1 SECURING SCREW 4.3 Radiants To remove radiant pack, lift and pull bottom forwards, see diagram 4.3. Unpack radiants and place carefully on one side until required. Diagram 4.2 1707 5148 RADIANT PACK Diagram 4.3 5 221102B
4 Fire Front Preparation 4.4 Flue Spigot Assembly Stand the fire front upright, unscrew flue spigot from base of fire front. Fit the flue spigot using the eight self tapping screws supplied in the loose items pack, see diagram 4.4. SPIGOT SECURING SCREWS (8) 1637 4.5 Gas Supply to Fire Front The inlet supply tube is packed with the fire front plinth in the loose items pack. This supply tube may need to be cut, at the plain end, dependent on the model and position of the back boiler in the opening. Measure the distance C, see diagram 4.5, from the front mark P on the air duct to the fire front fixing wall face. Use a straight edge across the opening. FLUE SPIGOT Diagram 4.4 Shorten the plain end of the gas supply tube by the distance C. No shortening is required when P is level with the fire front fixing wall face, C being zero. The maximum distance for C will be 67mm. Deburr the tube end inside and out. *'C'=Distance from fire front fixing wall face to datums on back boiler air duct. This represents the length of pipe that requires cutting off. BACK BOILER AIR DUCT (MAX SHOWN) *'C' 1558 *'C' FIRE FRONT FIXING FIRE FRONT WALL FACE GAS SUPPLY TUBE Diagram 4.5 221102B 6 Supplied By www.heating spares.co Tel. 0161 620 6677
5 Installation 5.1 Back Boiler Sensing Tube Remove and discard the plastic ferrule from the bulkhead connection on the Back Boiler air duct. Fix the flared end of the back boiler sensing tube to the bulkhead connection on the boiler air duct with the tubing nut provided. Slide the sensing tube fitting assembly over the back boiler sensing tube and fix to the casting with the thread cutting screw (taptite) provided, see diagram 5.1. Fit the sensing tube filter onto the fitting assembly, see diagram 5.1. Take care not to damage the filter. IMPORTANT: Make sure that the sensing tube fitting assembly is pushed back to the front face of the boiler casting and check 1mm. distance is achieved and back boiler sensing tube does not extend above sensing tube fitting, see diagram 5.1. Note: After fitting the combustion products discharge safety device sensing tube please refer to the 'Commisioning' section of the back boiler unit and relight the boiler to test the device. SENSING TUBE FITTING ASSEMBLY 1 mm TUBING NUT FILTER THREAD CUTTING SCREW(Taptite) SENSING TUBE FITTING ASSEMBLY FRONT FACE OF BOILER BACK CASTING BOILER SENSING TUBE BULKHEAD CONNECTION BOILER AIR DUCT 6129 Diagram 5.1 5.2 Positioning the Fire Front Place the fire front onto the back boiler air duct, check that the fire front flue spigot is central in the flue collector assembly, push into contact with the fire front fixing wall face, see diagram 5.2. Mark the fire front fixing points through the mounting bracket holes, at the top, see diagram 5.3. 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, supplied in the loose items pack. Place anchor nuts and screws into holes, screw up, but leave sufficient thread proud the accept the fire front. Note. If the fire front fixing face is not of a solid construction, to a minimum depth of 40mm, that is, hollow brick or metal an alternative and rigid form of fastening must be used and extra care taken. FLUE COLLECTOR ASSEMBLY BACK BOILER AIR DUCT SECURING SCREW (2) FIRE FRONT FIXING WALL FACE GAS SERVICE COCK 2499 1561 Diagram 5.2 ANCHOR NUT FIRE FRONT MOUNTING HOLES Enlarged view of mounting bracket Diagram 5.3 7 221102B
5 Installation 5.3 Securing Refer to diagram 5.4. Offer the fire front up at a slight angle to engage fire front spigot, position mounting bracket holes over the screws in fire front fixing wall face. Lower fire front to locate fire front flue spigot into flue collector assembly and onto back boiler air duct, push back onto fire front fixing wall face, tighten up securing screws. SECURING SCREW (2) FLUE COLLECTOR ASSEMBLY 2501 5.4 Gas Connection Position the tubing nut and olive, packed in the loose items pack onto the prepared end of the gas supply tube, see diagram 5.5. Connect the gas supply tube, the flared end to the elbow on the gas tap, the plain end to the gas service cock, tighten at each end, see diagram 5.5. BACK BOILER AIR DUCT Diagram 5.4 5285 UNION NUT GAS SUPPLY TUBE GAS SERVICE COCK TUBING NUT OLIVE Diagram 5.5 6 Commisioning 6.1 Initial Lighting The fire front is fitted with a combustion products discharge safety device which will shut it down if there is a lack of oxygen. If the fire front shuts down frequently for no apparent reason the first things to be checked are the chimney and air inlets into the room. An additional cause may be that the filter in the gas tap has become blocked, to check refer to Fire Front Fault Finding Chart. Any problems found must be put right, by a competent person, before the fire front is used again. The combustion products discharge safety device MUST NOT be adjusted or disconnected. If replacing use only the correct and approved parts. Take large washer and fire front control knob from loose items pack. Place large washer over connecting rod and fit fire front control knob. Check that the control knob is in the Off position, that is indicator pointing along the fire front to the left. Turn gas service cock to back boiler and fire front ON, see diagram 6.1. Test for gas soundness at the connections of the fire front supply tube, previously fitted, using a suitable leak detection fluid. Remove silencer securing screw and silencer, see diagram 7.5. 221102B 8
6 Commisioning Remove the pressure test point screw from gas tap, see diagram 6.2 and connect a suitable pressure gauge. To light the fire front, refer to diagram 6.3 and Instructions for Use. Note. Air may be present in the supply tube so the initial lighting operation may need to be repeated. Wait 10 seconds before repeating lighting operation. GAS SERVICE COCK UNION 3924 S 6.2 Testing With the fire front working at full rate, allow to warm up for ten minutes. Check that inlet gas pressure is as stated in Data Section of these instructions or refer to data label. Check for gas soundness at all joints and gas carrying components using a suitable leak detection fluid. If there is any doubt about the gas rate check at the meter, having first turned off all other gas appliances and pilot lights. The rate for this fire front is about 3 minutes 32 seconds for 1ft 3. Turn the control knob fully clockwise to the Off position, that is, indicator pointing along the fire front to the left. Remove the pressure gauge, replace the test point screw, make sure a gas tight seal is made. Replace the silencer. When the fire front is cold fit the radiants, having first removed the polythene wrappings. Insert the top of the radiant first and lower to fit between the lower front and rear support. The top of the radiant must rest back onto the upper support, see diagram 7.3. It will be found easier to insert the radiants at the centre and move them left and right. BACK BOILER ONLY 'ON' TURNED FULLY CLOCKWISE BACK BOILER & FIRE FRONT 'ON' TURNED TO MID POSITION 90 'OFF' TURN FULLY ANTI- CLOCKWISE 180 Diagram 6.1 9 221102B
6 Comissioning 6.3 Test for Clearance of Products Note: 1. Take care. The appliance gets hot during testing. 2. To carry out test on boiler you will need a 300mm smoke match extension and a torch. 3. Before inserting the match mark extension at 40mm, see diagram 6.5. 4. For test insert smoke match at each side and view for spillage above fire front spigot as shown in diagram 6.5. TEST: WHERE NO FAN IS PRESENT Close all outside doors and doors and windows in the room in which the appliance is installed. Light the fire front only. After 5 minutes apply spillage tests as shown in diagram 6.4 and 6.5. During tests smoke should be drawn into the fire front heat exchanger canopy and the boiler draught diverter. If spillage occurs leave fire front alight for up to a further 10 minutes and repeat tests. Next, light the boiler only. After 10 minutes apply spillage tests as shown in diagram 6.4 and 6.5. During tests smoke should be drawn into the fire front heat exchanger canopy and boiler draught diverter. If spillage occurs, leave the boiler alight for up to a further 5 minutes and repeat tests. Now light the boiler and fire front. After 10 minutes apply spillage tests as shown in diagram 6.4 and 6.5. During tests smoke should be drawn into the fire front heat exchanger canopy and boiler draught diverter. If spillage occurs, leave the boiler and fire front alight for up to a further 5 minutes and repeat tests. TEST. WHERE A FAN IS PRESENT (A fan means an extract fan, or a fan for other open flued appliances, or a circulating fan for a warm air unit, whether or not gas fired). With the fan switched off carry out the appropriate spillage test with all doors and windows closed, as above. If the above tests are satisfactory continue as follows, Open all doors connecting the room containing the appliance and the room in which the fan is fitted. Close all other doors and windows in the premises. If the fan is in the same room as the appliance close all doors and windows in that room. Switch on fan and repeat spillage test as above. In ALL cases, if spillage continues after the specified test periods steps MUST be taken to put right the fault(s). Possible causes include, flue obstructions, down draught or restricted fresh air supply into the room. Engage the two casing lugs to locate into the slots of the fire front, see diagram 6.6. Secure the casing with the casing securing screws, previously removed, at left and right hand sides, see diagram 6.7. Carefully locate top of plinth into sliders and push it back as far as it will go. PRESSURE TEST POINT SCREW 0 0 0 4 SETTING 4 4 SETTING 3 4 1 1 1 3 SETTING 2 1 2 2 3 2 3 All 3 radiants FULL Centre radiant FULL End radiants HALF 5115 Diagram 6.2 Centre radiant only FULL 1683 6.4 Case Fitting Leave fire front control knob in place. Offer the casing to the fire front, inclining it back at the top, passing control knob through hole in casing at the right. 0 4 3 SETTING 1 2 Centre radiant only HALF Diagram 6.3 221102B 10
6 Commissioning 6.5 Instruct the User in the Correct Operation of the Fire Front and Back Boiler Hand the Instructions for Use to the user and instruct in the correct use of the fire front and back boiler, including lighting the fire front with a match. Advise that any smell which may be apparent on initial lighting is quite normal and will quickly disappear after a short period of use. Important. Advise that soft wall coverings, for example, blown vinyl wallpaper, are easily affected by heat, they may, therefore, scorch or become discoloured when close to a heating appliance. This should be borne in mind when having a heating appliance installed and when redecorating. Advise that to ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance. It is the Law that any servicing must be carried out by a competent person. Advise that the boiler is fitted with a Combustion Products Discharge Safety Device and refer to the Instructions for Use. Reminder, leave these instructions with the user. CASING LOCATION BRACKET (Fitted to chassis) 5124 HEAT EXCHANGER CANOPY SMOKE MATCH TIP 1679 MATCH EXTENSION RADIANT CASING LOCATION PIN (Fitted to casing) Diagram 6.4 40 DIVERTER PLATE Mark extension smoke match 1889 Diagram 6.6 5331 PLINTH FIRE FRONT SPIGOT NOT SHOWN FOR CLARITY 300 SMOKE MATCH EXTENSION Diagram 6.5 SECURING SCREWS Diagram 6.7 11 221102B
7 Servicing 7.1 Servicing Notes MAKE SURE FIRE FRONT IS COLD. Servicing must be carried out by a competent person. The combustion products discharge safety device MUST NOT be adjusted or disconnected. If replacing use only the correct and approved parts. Before starting a service, turn gas service cock OFF, see diagram 6.1. Isolate the electrical supply to the back boiler. After completing a service, always test for gas soundness and carry out functional check of controls. Unless stated otherwise all parts are replaced in the reverse order to removal. If any parts require replacement, refer to Replacement of Parts Section. Note. It is recommended that after removal of the radiants the fire front be removed from the back boiler to ease the servicing and maintenance operations. 7.2 Casing Removal Remove the fire front plinth by sliding it forward until it disengages, see diagram 6.7. Remove case securing screws at left and right hand sides, see diagram 6.7. Ease the bottom of the casing forwards and lift to disengage the upper lugs, withdraw forwards. To exchange a radiant first ensure the fire front is cold and remove dressguard. Lift up the radiant at the bottom and withdraw forward. RADIANT UPPER SUPPORT LOWER BACK SUPPORT 0723 Diagram 7.1 Insert top of radiant first, then the bottom and lower into position between the support angles. Ensure that the top of the radiants rest back against the upper support. 0706 7.3 Radiant Removal Lift up the centre radiant from the bottom and withdraw forwards, move the other radiants to the centre and remove in a similar way, see diagram 7.1. Before replacing radiants remove any loose debris from the top of the burner. Clean all around the fire front chassis, burner and injectors with a soft brush or vacuum cleaner. Take care not to damage the Combustion Products Discharge Safety Device. To replace, insert top radiant first, then the bottom, lower into position, see diagram 7.2. It will be found easier to replace radiants at the centre and move left and right. It is recommended that the radiant position be changed from time to time. LOWER FRONT SUPPORT Diagram 7.2 221102B 12
7 Servicing BURNER SECURING SCREW (2) CONNECTING ROD SPLIT PIN 5117 PIEZO COMBUSTION PRODUCTS DISCHARGE SAFETY DEVICE SECURING SCREWS (2) ELECTRODE PILOT TUBE PILOT TUBE NUT GAS SUPPLY TUBE NUT GAS SUPPLY TUBE IGNITION LEAD (CLEAR END) SILICONE COVER TUBE NUT IGNITION LEAD THERMOCOUPLE COMBUSTION PRODUCTS DISCHARGE SAFETY DEVICE PILOT TUBE THERMOCOUPLE NUT Diagram 7.3 7.4 Fire Front Disconnection Disconnect union nut at elbow at gas tap, see diagram 5.5. Slacken, but do not remove, mounting bracket screws, see diagram 5.3. Pull fire front forwards at the bottom, tilt and lift to disengage fire fixing screws from mounting bracket holes, remove from the back boiler. 7.5 Burner and Injectors Disconnect thermocouple nut and pilot tube nut at gas tap, see diagram 7.3. NOTE Take care as there is a filter in the pilot port. Remove connecting rod split pin. Release the connecting rod from the gas tap assembly see diagram 7.3. Support the burner and unfasten burner securing screws, see diagram 7.3. Lower burner and gas tap assembly taking care not to damage the thermocouple lead and pilot tube. Disconnect lead from piezo. Remove silencer securing screw and silencer, remove the locknut securing the gas tap, see diagram 7.4. The upper and lower injectors can be unscrewed from the gas tap, see diagram 7.4. Clean injectors as necessary. Do not clean injectors with a wire or sharp instrument. Clean the burner with a soft brush, or vacuum cleaner. Refit injectors in correct positions, see diagram 7.4. 13 221102B
7 Servicing GAS TAP FILTER 5469 UPPER INJECTOR CROSS SECTION VIEW LOWER INJECTOR LOCKNUT SILENCER SECURING SCREW FILTER GAS TAP Diagram 7.4 7.6 Combustion Products Discharge Safety Device Check the condition of the electrode and thermocouple, clean with a soft brush, see diagram 7.3. Make sure the electrode is in line with the earth post and the spark gap is as shown in diagram 7.5. NOTE: It is recommended that the back boiler be serviced before refitting the fire front, refer to Back Boiler Installation Instructions. EARTH POST ELECTRODE 5119 SPARK GAP 3 + 1-0.5 7.7 Fire Front Refitting See relevant part of Section 5.3 and 5.4 ELECTRODE C L EARTH POST TOP VIEW Diagram 7.5 221102B 14
8 Replacement of Parts 8.1 Notes on Replacing Parts MAKE SURE FIRE FRONT IS COLD. Replacement of parts should be carried out by a competent person. Before removing or replacing any fire front part, turn gas service cock to Back Boiler Only On, see diagram 6.1. Isolate the electrical supply to the back boiler. After replacing or disconnecting any gas carrying part, always test for gas soundness and carry out functional check of controls. Unless stated otherwise all parts are fitted in the reverse order to removal. 8.2 Dress Guard and Radiants To remove the dress guard, grasp at the sides and flex centre outwards to release two location pins on one side then the other, see diagram 8.1. Take care not to damage the chrome with the dress guard location pins. To change a broken radiant, refer to relevant parts of Section 7.3. 8.3 Injectors Remove casing as Section 7.2. Remove injectors as Section 7.5. 8.4 Gas Tap Remove casing as Section 7.2. Disconnect lead at piezo, see diagram 7.3. Disconnect thermocouple nut, pilot tube nut and gas supply tube nut, see diagram 7.3. NOTE Take care as there is a filter in the pilot port. Remove connecting rod split pin. Release the connecting rod from the gas tap assembly, see diagram 7.3. Remove silencer, see diagram 7.4. Remove locknut securing gas tap, see diagram 7.4. Remove the gas tap. 8.5 Piezo Unit Remove casing as in Section 7.2. Proceed as the relevant parts of Section 8.4. With the tap in the Off position, fully clockwise, remove the two screws and washers securing the piezo unit bracket to the tap. Take care when removing as there is a spring underneath the bracket. LOCATING PINS 1678 Diagram 8.1 8.6 Combustion Products Discharge Safety Device Remove casing as Section 7.2. Disconnect lead silicone cover. Disconnect lead and pilot tube nut from Combustion Products Discharge Safety Device. Disconnect thermocouple nut from gas tap, remove Combustion Products Discharge Safety Device securing screws, see diagram 7.3. Remove Combustion Products Discharge Safety Device. 8.7 Ignition Lead Remove casing as Section 7.2. Disconnect lead silicone cover. Disconnect the lead at each end and remove. Fit new lead with clear end to electrode, see diagram 7.3. Check the fire front system, by reference to the relevant part of Section 6. 8.8 Burner Remove casing as Section 7.2. Remove burner as relevant part of Section and 7.5. Remove gas tap as Section 8.4 and Combustion Products Discharge Safety Device as Section 8.6. 8.8 Gas Tap Pilot Filter Remove the casing as Section 7.2. Remove the gas tap as Section 8.4. The filter, which is very small, is in the pilot port of the gas tap, to remove use a small non-metallic tool. When fitting the replacement it is important that the filter is seated correctly as shown in diagram 7.4. 15 221102B
9 Fault Finding START HERE Fire will not light 5466 across gap, Turn off appliance tap; turn on appliance tap and observe spark No spark across gap no Ensure gap is within specified tolerance, refer to SERVICING Turn tap to energise igniter Check that gas is available. Does the pilot light using a match. YES NO Change pilot filter. Using a match, ensure correct functioning of burner in all setting positions. Check that electrode and piezo unit connections are satisfactory. Check that burner pressure is as specified. Correct any fault found. across gap, No spark across gap no Disconnect lead from electrode, place connector within 4mm of burner and operate piezo across gap, no Replace faulty electrode and reassemble system across gap, no Ensure gap is within specified tolerance. Turn tap to energise igniter across gap, no Remove lead from piezo unit and place screwdriver between appliance chassis earth and piezo unit, leaving 4mm gap between blade and spade connector. Operate igniter. across gap No spark across gap Renew lead and reassemble system across gap, no Change piezo unit and reassemble system across gap Check several times that is satisfactory END FIRE FRONT IGNITION FAULT FINDING Diagram 9.1 221102B 16
9 Fault Finding 5243 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 position. Ignite burner, allowing thermocouple to attain operating temperature. Measure the OPEN CIRCUIT voltage. Is voltage greater than 15mV? NO YES Faulty thermocouple. Replace combustion products discharge safety device. Note the open circuit reading then measure the CLOSED CIRCUIT voltage. Note this voltage. Referring to the diagnosis graph, mark the open circuit voltage on the VERTICAL axis, and the closed circuit voltage on the HORIZONTAL axis. Note the point where these two values intersect on the graph. THERMOCOUPLE CIRCUIT IS SATISFACTORY B In which area of the graph is the intersect C A Faulty thermocouple. Replace combustion products discharge safety device. Faulty magnet unit in gas tap. Replace gas tap Diagram 9.2 9.1 Fire Front Ignition Remove casing as Section 7.2. Refer to Fire Front Ignition Fault Finding, diagram 9.1. 9.2 Thermocouple To test a thermocouple, a meter with a range of 0 to 30mV is required together with a thermocouple interrupter test unit. Refer to Fault Finding diagram 9.2 and Diagnosis Graph diagram 9.3. 9.3 Combustion Products Discharge Safety Device If the device operates it indicates there could be a problem with the chimney or, the pilot filter in the gas tap is blocked. First make sure air vents are free from obstruction, by carrying out spillage checks as Section 6.3. If all is in order refer to diagram 9.1 to check if the pilot filter is blocked. Open Circuit Voltage (millivolts) 17 16 15 14 13 12 11 10 9 8 A B C 0065M 7 0 1 2 3 4 5 6 7 8 9 10 11 Closed Circuit Voltage (millivolts) DIAGNOSIS GRAPH FOR FIRE THERMOCOUPLE CIRCUIT Diagram 9.3 17 221102B
10 Spare Parts 10.1 Part Identification The key number of the list will identify the part number and description, see diagram 10.1. 10.2 Ordering When ordering spare parts quote the part number and description, stating the model Melody BBU and serial number of the fire front from the data label. The data label can be seen after the casing has been removed as in Section 7.2. If ordering from British Gas you will also require the fire front GC number in addition to the GC number of the part. 1 5120 2 3 4 7 9 8 5 6 Diagram 10.1 Key No. Part No. Description GC No. 1 427504 Dress guard assembly 152 744 2 203746 Radiant pack 136 376 3 427524 Control knob assembly 152 746 4 800772 Combustion Products Discharge Safety Device *** *** 5 WW4615 Ignition lead 136 399 6 205736 Injector - lower *** *** 7 207735 Injector - upper *** *** 8 203653 Gas tap and piezo *** *** 9 202708 Piezo unit - spare 152 732 10 208673 Filter *** *** 221102B 18
11 Supplementary Instructions These fire fronts are fitted with combustion products discharge safety devices. As these fire fronts may be fitted to Glow-worm 45, 56, 45R or 56R back boiler units WITHOUT a combustion products discharge 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 combustion products discharge safety device is fitted, refer to the inset in diagram, if one is fitted this supplement MUST be ignored. General To fit the fire front to one of the above EXISTING GLOW-WORM BACK BOILER UNITS follow the instructions below. Installation 1. Do not fit the back boiler sensing tube as required in the main installation and servicing instructions. 2. If necessary isolate the power supply to the back boiler unit and remove the existing wiring used previously for a fire front with lights. 3. Any references in the installation and servicing instructions to the back boiler unit combustion products discharge safety device must be ignored. Lighting the Boiler The boiler controls are placed behind the fire front plinth. To remove the plinth, pull it gently forwards until it is free. Refer to diagram 11.1 to identify controls. Turn off the electrical supply at the mains supply outside the appliance. Check that all controls are calling for heat. The clock, room thermostat and programmer, if fitted, will be away from the unit, see manufacturer s instructions supplied with them. Turn the thermostat control knob B to Off position, that is, fully anticlockwise, Off to be against the pointer. Push in and slightly turn gas control knob A clockwise until is against its setting point, that is, set to Off. Push in slightly and turn gas control knob A anticlockwise until is against its setting point, then push fully in and hold in. At the same time press and release piezo button D until pilot burner E lights. Look at flame through viewing window F. At initial lighting of the boiler air may be present and several attempts may be needed to light the pilot. Keep the control knob A pushed in whilst operating the button. When the pilot is alight and stable, keep knob A fully pushed in for about 15 seconds then release. Check that the pilot is still alight, look through window F. If the pilot burner fails to stay alight turn gas control knob A Off. that is, fully clockwise. Wait three minutes. Repeat the lighting operation, only now keep the control knob A pushed in for a little longer than before after the pilot has lit. NOTE. Always wait three minutes before attempting to relight the pilot after it has gone out for any reason. Push control knob A in slightly and turn clockwise until is against the setting point. Note. If gas control knob A is turned until is against the setting point, a safety lock prevents it being turned on again. No attempt should be made to turn the valve on again until at least three minutes have elapsed. Turn on the electrical supply to the unit. Turn the boiler thermostat knob B clockwise until MAX is against the setting point, the main burner will light. Adjust the thermostat to the required setting between MIN and MAX. MAX is about 82oC. Check that all external controls are set to your requirements. Refit the plinth by carefully locating the top edge of the plinth into the sliders, then push gently back as far as it will go. 19 221102B
11 Supplementary Instructions INSET: Showing a Combustion Products Discharge Safety Device fitted. 5342 'E' PILOT BURNER SETTING POINT 'F' VIEWING WINDOW 'B' THERMOSTAT CONTROL KNOB 'D' PIEZO UNIT BUTTON 'A' GAS VALVE CONTROL KNOB SETTING POINT OFF PILOT/IGNITION MAIN BURNER BOILER CONTROLS Diagram 11.1 Control of Substances Hazardous to Health Information for the Installer and Service Engineer. Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state. RADIANTS After handling wash hands thoroughly. INSULATION PADS/CERAMIC FIBRE These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention. Because of our constant endeavour for improvement details may vary slightly from those in the instructions 221102B 20