Glow-worm COMPACT 75e Instructions For Use Installation And Servicing

Fanned flue combination boiler

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Installation and Servicing

COMPACT 75e

G.C. No. 47 047 06A

Fanned Flue Combination Boiler

This is a Cat I

The instructions consist of three parts, User, Installation and Servicing Instructions, which include 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)

Glow-worm appliances' are manufactured to the very highest standard so we are pleased

In the centre 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

Instructions for Use

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

Appliance

Regulations, be handed to the user on completion of the installation.

Guarantee Registration

Thank you for installing a new Glow-worm appliance in your home.

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

Nottingham Road, Belper, Derbyshire. DE56 1JT

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

221895A.04.01

Hepworth Heating Ltd.,

General/Sales enquiries:

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Summary of Contents for Glow-worm COMPACT 75e

Page 1 Guarantee Registration Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances' are manufactured to the very highest standard so we are pleased to offer our customers' a Comprehensive First Year Guarantee. In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and return as soon as possible.
Page 2: Table Of Contents
Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
Page 3 Instructions for Use Introduction Alternatively a fused 3A 3 pin plug and shuttered unswitched socket may be used. Please read these instructions and follow them carefully for the The colours of three core flexible cable are, blue - neutral, brown safe and economical use of your Combination boiler.
Page 4 Instructions for Use 3. Set day of week by pressing button DAY. Setting Instructions for Electro/mechanical Clock - if fitted 4. Set time of day by pressing buttons HR and MIN. 5. Set RUN switch to the central position, colon will flash, this This clock has a twenty four hour dial, that is, 1pm is 13.
Page 5 Instructions for Use 4. Open a hot water tap, check that water flows, then close it. Summer / Winter Selector Button 5. If you are in any doubt about the boiler being filled with water Adjust the central heating water temperature control knob “N” to contact your installation/servicing company or the local gas desired setting.
Page 6 Instructions for Use CONTROLS SANITARY WATER FASCIA PRESSURE TEMPERATURE SUMMER/ WINTER ‘A’ ‘M’ ‘J’ GAUGE CONTROL KNOB BUTTON ‘L’ ‘F’ CLOCK TIMER ‘P’ ‘C’ IF FITTED ‘H’ RESET ‘G’ BUTTON ‘D’ ‘Q’ ‘K’ ‘E’ CENTRAL HEATING MAINS WATER ELECTRIC TEMPERATURE ‘B’...
Page 7: General Data
1 General Data Optional flue kits are available Horizontal top outlet and Vertical. Diagram 1.1 STD/EXD. EASYFIT TABLE 1 1.1 Installation Materials and equipment should be fit for their purpose and of Lift Weight 31.7kg (69.89b) suitable quality and workmanship. Total Weight 41.1kg (90.61lb) 1.2 Important Notice...
Page 8 1 General Data 1.7 Gas Supply Thermostatic radiator valves may be installed, however they must not be fitted in a room where the room thermostat is The gas installation shall be in accordance with the rules in force located. in the countries of destination. Note: All systems must have at least one radiator not fitted with The supply from the governed meter must be of adequate size a thermostatic valve.
Page 9: Boiler Position
2 Boiler Position 2.1 Location 25 ABOVE THE TOP OF THE BOILER CASE OR THE FLUE ELBOW IF FITTED This boiler must be installed in accordance with the rules in force in the countries of destination. This boiler is not suitable for fitting outside. Any electrical switch must be positioned so that it cannot be touched by a person using the bath or shower.
Page 10: Flue And Ventilation
3 Flue and Ventilation The guard should be similar to that shown in diagram 3.1 . 3.1 General The flue must be installed in accordance with the rules in force 3.6 Room Ventilation in the countries of destination. Ventilation must be provided in accordance with the rules in force in the countries of destination.
Page 11: Heating System
The remaining circulating pressure head available from the boiler is shown in diagram 4.1, Glow-worm pump. When fitting the boiler into an existing system, special care should be taken to drain the entire system, including radiators, 4.5 Expansion Vessel...
Page 12: Domestic Hot Water System
4 Heating System ALTERNATIVE METHODS OF FILLING DOMESTIC WATER METHOD 1 COMBINED CHECK VALVE HEATING TEMPORARY AND VACUUM SYSTEM HOSE BREAKER BOILER SERVICING HOSE ADDITIONAL VALVE UNIONS EXPANSION VESSEL (if required) SUPPLY STOP SUPPLY VALVE OPTIONAL FILLING PIPE KIT AVAILABLE METHOD 2 No.
Page 13: Installation Preparation And Gas/Water Connections
6 Installation Preparation and Gas / Water Connections The installation requires the following components :- SAFETY DISCHARGE PIPE ROUTING POSITION Plumbing jig Carton Boiler Carton Flue Pack 6.1 Plumbing Jig Remove from the wall template, then follow the instructions given on the template. COLD HEATING Note: Leaving the service cock bracket (lower jig) fixing screws...
Page 14: Flue Preparation
7 Flue Preparation STD/EXTD TOP OUTLET FLUE PACK 'X' plus 254mm (RH) = flue length 'X' plus 10mm (LH) = flue length FLUE LENGTH FLUE LENGTH MAX 840mm (extd.) MAX 840mm (extd.) EASYFIT MAX 570mm (std/easyfit) MAX 570mm (std/easyfit) 'X' plus 282mm (RH) = flue length 5mm* 15mm 'X' plus 38mm (LH) = flue length...
Page 15 7 Flue Preparation 7.1 Flue Position and Length Determine flue application, length and terminal position before starting, refer to diagram 7.1. Note: The Standard Top Outlet Flue Pack, Easyfit Top Outlet Flue Pack and the Extended Top Outlet Flue Pack contains a flue duct extension piece complete with "O"...
Page 16: Mounting The Boiler
8 Mounting the boiler 8.1 Boiler Mounting COMBUSTION Remove the inner case front, secured by two clamps at the CHAMBER PANEL bottom lift up and unhook from the threaded lugs at the top, see RETAINING diagram 8.1. LUG (4) Remove the combustion chamber panel transit screws, see diagram 8.2.
Page 17 8 Mounting the boiler 8.2 Water and Gas Connections RETAINING LUG Locate the boiler water pipes and gas supply pipe making sure the washers are retained in the tubing nuts onto the isolation valves, fully push the boiler back, see diagram 8.8. BOILER Ensure the bottom boiler bracket is sitting on top of the service cock bracket, see diagram 8.6.
Page 18 8 Mounting the boiler Fit the air duct into the flue spigot by pulling the air duct into the 8.6 Top Outlet Side or Rear Flue Fixing flue spigot, locating cutouts. Turn the air duct anti-clockwise to lock into the cutouts, see diagram 8.10. Position the restrictor plate supplied in the loose items pack, between the flue elbow and boiler , (gasket facing upwards).
Page 19 8 Mounting the boiler RESTRICTOR TABLE FLUE MAX FLUE RESTRICTOR OUTLET LENGTH PLATE CASE REAR UP TO 0.5m CASE REAR 0.5m TO 2.5m TOP LHS UP TO 2.5m TOP RHS UP TO 2.5m TOP REAR UP TO 2.5m Make sure that the ductings do not slope down towards the Secure the fan to the flue collector with the securing screw and boiler.
Page 20: Electrical Connections
9 Electrical Connections 9.1 Supply Cable Connection SECURING CAUTION: To prevent an induced current from switching the CONTROLS SCREW (2) central heating on, when not required, it is important that the FASCIA heating system control cables are separated from the other mains supply cables.
Page 21 9 Electrical Connections TO BOILER EXTERNAL CLOCK INTEGRAL CLOCK TO BOILER RED LINK. 5 WAY TERMINAL BLOCK 5 WAY TERMINAL BLOCK REMOVE WHEN CONNECTING ANY HEATING SYSTEM CONTROLS (R1) (R2) (R1) (R2) LINK MAINS POTENTIAL FROST STAT. SWITCH CONTACTS CLOCK JUNCTION TIME CONTROL...
Page 22: Commissioning
10 Commissioning The burner pressure is factory preset and no adjustment should Please ensure the “Benchmark” logbook is completed and left be required. with the user. Check the burner pressure is within +/-0.2mbar. of 14.7mbar. If 10.1 Filling Domestic Water Circuit this is incorrect, the burner pressure may be adjusted to the correct setting by turning the hot water gas pressure adjuster Check that the boiler is isolated from the electrical supply, at the...
Page 23 10 Commissioning 10.8 Ignition Rate Lower the pressure to the initial cold fill design pressure, using the external draining tap, close to the boiler, refer Table 1 and Set the mains electrical switch “B” to 0, located on the controls Section 4.10.
Page 24 10 Commissioning Draw attention, if applicable, to the current issue of the Gas Advise the user of the precautions necessary to prevent damage Safety (Installation and Use) Regulations, Section 35, which to the system and building in the event of the heating system imposes a duty of care on all persons who let out any property being out of use during frost and freezing conditions.
Page 25: General Data
11 General Data 11.3 Isolation of Boiler SPARE PARTS Before starting any servicing or the replacement of parts, isolate REMEMBER, When replacing a part on this appliance, use the boiler from the electrical supply at the external isolator. only spare parts that you can be assured conform to the safety and performance specification that we require.
Page 26: Servicing
12 Servicing Do not use a brush with metallic bristles. 12.2 Cleaning Heat Exchanger Place a sheet of paper or similar in the combustion chamber, to 12.4 Service Checks act as a collector for deposits removed. Inspect the spark and sensing electrodes, Clean or renew if Brush the heat exchanger with a suitable brush, remove paper necessary, refer to Sections 14.4 and 14.5.
Page 27: Fault Finding
12 Servicing inspect the condition of all seals and joints, renewing them as 3.5mm necessary. Check the condition of the combustion chamber insulation. If renewing, refer to Section 4.27. 12.6 Spark Gap Check that the spark and sensing gaps are as shown in diagram 12.6.
Page 28 13 Fault Finding 13.2 Clock/Timer ON/OFF PERMANENT TERMINAL If the clock has failed it can be bypassed by disconnecting the SWITCH MAINS 230V-50HZ BLOCK plug and reconnecting the link, see diagram 13.1. brown brown Gain access by removing the two screws securing the controls facia, see diagram 9.1.
Page 29 13 Fault Finding 13.3 Electrical Before replacing any part please read points below:- Replacement of parts must only be carried out by a competent Preliminary electrical system checks, as outlined in a Multimeter person. Instruction book, are the first checks to be carried out during a fault finding procedure.
Page 30 13 Fault Finding Check appliance installation and that it is mechanically correct. Check filters are clean and allow adequate water flow. Is mains L.E.D. illuminated. Check fuses and power supply. Open a tap to create demand. If lockout L.E.D. is illuminated, press reset. Demand L.E.D.
Page 31 13 Fault Finding NB. The clock can be by passed by refitting the plug link which should be inside the clock timer cover. Check continuity of clock/timer harness, ensure an electrical supply is available, ensure that remote controls are calling for heat. Isolate the boiler from electrical supply remove outer case.
Page 32: Replacement Parts
14 Replacement of Parts 14.1 Fan AIR PRESSURE CLEAR ELECTRICAL TUBES Before starting refer to Section 11. CONNECTION Disconnect the two electrical connectors at the fan by pulling the boots not the wires, see diagram 14.1. Remove the two flexible tubes from the fan, see diagram 14.1. Note: When replacing the tubes from the air pressure switch ensure the lower (red) tube from the fan connects to the upper connection of the switch.
Page 33 14 Replacement of Parts Remove the pressure gauge, see diagram 14.6. THERMISTOR GAS CONTROL Locate the supplied washer under the pressure gauge connection CENTRAL VALVE when refitted to the safety valve. HEATING CLIP 14.8 Control Board Before starting refer to Section 11. OVERHEAT CUTOFF Remove the two screws securing the controls facia, see diagram...
Page 34 14 Replacement of Parts SECURING SCREW CONTROL BOARD SENSING SUPPORT IGNITION LEADS Diagram 14.8 LEAD POSTS (4) MULTI PIN CONNECTORS SKT. HEAD MULTI PIN CONTROL CAPSCREW CONNECTOR VALVE CAREFULLY BEND THE RETAINING CLIPS FORWARD TO RELEASE MULTI PIN Diagram 14.7 CONNECTORS 14.11 Low Water Pressure Switch Before starting refer to Section 11.
Page 35 14 Replacement of Parts 14.13 Diverter Switch RETAINING CLIPS Before starting refer to Section 11. Isolate the boiler from the electrical supply. LOW WATER PRESSURE Remove outer case front as section 11.4. SWITCH Remove the two screws securing the controls cover door and controls fascia, see diagram 9.1.
Page 36 14 Replacement of Parts DIVERTER SWITCH WATER INLET FILTER RETAINING CLIP 'O' RING ELECTRICAL SECURING REGULATOR DIVERTER VALVE PLUG) Diagram 14.12 Diagram 14.15 SECURING RETAINING Make sure O RING CLIP CLIP spindle is PRESSURE located DIFFERENTIAL properly MICRO SWITCH DIVERTER VALVE SECURING Diagram 14.16...
Page 37 14 Replacement of Parts Remove the plate to plate heat exchanger, refer to Section 14.20 Hydro Block Assembly Left hand side 14.23. (see diagram 14.18) Remove the bypass tube refer to Section 14.22. Before starting refer to Section 11. Remove the right hand side of the hydro block. Remove the two screws securing the controls cover door and See inset on diagram 14.18 to remove heating return filter.
Page 38 14 Replacement of Parts 14.24 Expansion Vessel Remove securing Before starting refer to Section 11. screws and push Renewal of the expansion vessel requires the boiler to be back to release removed from the wall. As an alternative, a separate expansion vessel of the same specification may be connected as close as possible to the boiler, leaving the original in position, refer to the Installation Instructions.
Page 39 14 Replacement of Parts 14.25 Automatic Air Vent Before starting refer to Section 11. AIR VENT AUTOMATIC AIR VENT Remove the automatic air vent, see diagram 14.23. SLACKEN THE SMALL CAP ON THE AIR VENT. THIS MUST NOT BE RE-TIGHTENED. SECURING CLIP 14.26 Heat Exchanger...
Page 40 14 Replacement of Parts COMBUSTION REAR CHAMBER INSULATION FRONT PANEL SIDE INSULATION SIDE INSULATION FRONT INSULATION Diagram 14.25 14.27 Combustion Chamber Insulation MICA WINDOW Remove outer case front as section 11.4. Remove the inner case front as Section 11.5. Unhook the combustion chamber front, see diagram 8.2. Remove the burner see section 14.2.
Page 41 14 Replacement of Parts 14.29 Inner Casing Seal ELECTRICAL CONNECTION (4) Before starting refer to Section 11. SECURING Remove the old seal, clean out the old adhesive. SCREW (4) Glue the new seal into place, making sure that there are no breaks in it.
Page 42 14 Replacement of Parts AIR PRESSURE SWITCH GREY WHITE ORANGE BLUE bk- BLACK YELLOW br - BROWN PURPLE g/y- GREEN/ YELLOW DIVERTER SWITCH THERMISTOR (CENTRAL HEATING) BOILER DOMESTIC OVERHEAT HOT WATER FLOW CUT-OFF THERMISTOR MICRO SWITCH (DOMESTIC HOT WATER) PLUG PRESSURE DIFFERENTIAL MICRO SWITCH...
Page 43: Spare Parts
15 Spare Parts 15.1 Part Identification The key number in diagram 15.1 and the first column of the list will help identify the spare part. 15.2 Ordering When ordering any spare part, please quote the part number and the description from the list together with the model name and serial number information from the data label.
Page 44 15 Spare Parts Diagram 15.1 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221895A...

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