Glow-worm COMPACT 80e Instructions For Use Manual
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Glow-worm COMPACT 80e Instructions For Use Manual

Fanned flue combination boiler
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Installation and Servicing

COMPACT 80e
G.C. No. 47 047 07A
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
2H
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
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Nottingham Road, Belper, Derbyshire. DE56 1JT
Tel: (01773) 824141 Fax: (01773) 820569
221742D.11.00
Hepworth Heating Ltd.,
General/Sales enquiries:

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Summary of Contents for Glow-worm COMPACT 80e

  • Page 1: Instructions For Use

    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 TABLE 1 1.1 Installation Lift Weight 31.7kg (69.89b) Materials and equipment should be fit for their purpose and of Total Weight 41.1kg (90.61lb) suitable quality and workmanship. Gas connection Ø...

  • Page 8: Heating System Controls

    1 General Data 1.9 Heating System Controls 1.7 Gas Supply The heating system should have installed: a timer and room The gas installation shall be in accordance with the rules in force thermostat controlling the boiler. in the countries of destination. Thermostatic radiator valves may be installed, however they The supply from the governed meter must be of adequate size must not be fitted in a room where the room thermostat is...

  • 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 3.1 General 3.6 Room Ventilation The flue must be installed in accordance with the rules in force Ventilation must be provided in accordance with the rules in in the countries of destination. force in the countries of destination. The boiler is room sealed, so where the boiler is fitted in a room or space, a permanent air 3.2 Terminal Position vent is not required.

  • 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 carton the wall template, then follow the instructions given on the template.

  • Page 14: Flue Preparation

    7 Flue Preparation TOP OUTLET FLUE PACK FLUE LENGTH FLUE LENGTH MAX 840mm (extd.) MAX 840mm (extd.) MAX 570mm (std) MAX 570mm (std) 15mm 54mm 15mm 239mm SCREW & TAPE SCREW ’X’ TOP OUTLET/ TOP OUTLET/ & TAPE SIDE FLUE REAR FLUE ’Y’...
  • 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 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 CHAMBER PANEL Remove the inner case front, secured by two clamps at the RETAINING bottom lift up and unhook from the threaded lugs at the top, see 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: Electrical Connections 9

    8 Mounting the boiler 8.5 Rear Outlet Flue Fixing FITTED TO HYDRO BLOCK Make sure that the ductings do not slope down towards the boiler. GAS SUPPLY Fit the air duct into the flue spigot by pulling the air duct into the flue spigot, locating cutouts.
  • Page 19 8 Mounting the boiler Make sure that the ductings do not slope down towards the boiler. Remove the fan from the flue collector, secured with a screw and retaining lip. Fit the flue connecting sleeve onto the fan, see diagram 8.12. Fit the fan to the flue ducting, Holding it up in position fit the flue collector, see diagram 8.13.

  • 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 15.01mbar. 10.1 Filling Domestic Water Circuit If 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 Remove the pressure gauge and tighten the test point screw. 10.11 Instruct the User Test for gas soundness around the burner pressure test point Instruct and demonstrate the lighting procedure, then advise with the main burner alight, using leak detection fluid. Take care the user of the efficient and safe operation of the boiler.
  • Page 24 10 Commissioning WRAP AROUND CASE SECURING SCREWS BASE CUTOUT CUTOUT Diagram 10.3 SECURING NUT (2) SIDE OUTER PANEL CASE FRONT SECURING SECURING SCREW (2) SCREW (2) Diagram 10.4 Diagram 10.5 221742D...

  • Page 25: General Data

    11 General Data 11.1 Servicing or Replacing Parts 11.3 Isolation of Boiler To ensure the continued efficient and safe operation of the Before starting any servicing or the replacement of parts, isolate boiler it is recommended that it is checked and serviced as the boiler from the electrical supply at the external isolator.

  • Page 26: Servicing

    12 Servicing Before replacing any of the parts removed during servicing, 12.3 Cleaning Main Burner inspect the condition of all seals and joints, renewing them as Use a vacuum cleaner or suitable brush to clean the burner necessary. thoroughly, making sure that all burner ports are clear and Check the condition of the combustion chamber insulation.

  • Page 27: Fault Finding

    12 Servicing 12.6 Spark Gap Check that the spark and sensing gaps are as shown in diagram 12.6. 12.7 Operational Checks Light the boiler, carry out operational checks and any necessary adjustments as described in “Commissioning” in the Installation 1.5mm Instructions.
  • 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 MAINS 230V-50HZ BLOCK SWITCH 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 Of Parts

    14 Replacement of Parts 14.6 Boiler Overheat Cutoff 14.1 Fan Before starting refer to Section 11. Before starting refer to Section 11. Disconnect the electrical connections, unclip to remove the Disconnect the two electrical connectors at the fan by pulling the overheat cutoff, see diagram 14.4.
  • Page 33 14 Replacement of Parts Remove the pressure gauge, see diagram 14.6. THERMISTOR GAS CONTROL CENTRAL Locate the supplied washer under the pressure gauge connection 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 SOCKET CONNECTORS HEAD MULTI PIN CAPSCREW CONNECTOR CONTROL 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 CLIP Before starting refer to Section 11. LOW WATER Isolate the boiler from the electrical supply. 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 Make sure RETAINING SECURING CLIP O RING spindle is CLIP located PRESSURE properly DIFFERENTIAL MICRO SWITCH DIVERTER VALVE SECURING Diagram 14.16...
  • Page 37 14 Replacement of Parts Remove securing pins 4,5 and 6, see diagram 14.18. 14.20 Hydro Block Assembly Left hand side (see diagram 14.18) Remove the plate to plate heat exchanger, refer to Section 14.23. Before starting refer to Section 11. Remove the bypass tube refer to Section 14.22.
  • 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 14.30 Air Pressure Switch ELECTRICAL CONNECTION (4) Before starting refer to Section 11. SECURING Disconnect the two electrical connectors at the air pressure switch, see diagram 14.27. SCREW (4) Remove the flexible tubes from the switch. Remove the air pressure switch, secured with two screws.
  • 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. 221742D...

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