Glow-worm COMPACT 100p Instructions For Installation And Operation Manual
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Glow-worm COMPACT 100p Instructions For Installation And Operation Manual

Glow-worm COMPACT 100p Instructions For Installation And Operation Manual

Fanned flue combination boiler with honeywell gas control
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Installation and Servicing

COMPACT 100p
G.C. No. 47 047 05A
Fanned Flue Combination Boiler
With Honeywell gas control
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
221680G.11.00
Hepworth Heating Ltd.,
General/Sales enquiries:

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Summary of Contents for Glow-worm COMPACT 100p

  • Page 1: Instructions For Use

    221680G.11.00 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r COMPACT 100p G.C. No. 47 047 05A Fanned Flue Combination Boiler With Honeywell gas control...

  • Page 2: Table Of Contents

    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 Setting Instructions for Electro/mechanical Setting the Clock - diagram 2 Clock - if fitted 1. With both AUTO and RUN switches set to the central position, press R reset button, the display will flash. This clock has a twenty four hour dial, that is, 1pm is 13. 2.
  • Page 5 Instructions for Use To Light the Boiler 12. Check the light “E” is illuminated on the control fascia. 1. Check that all four isolating valves are open, the levers in line 13. Set the summer / winter button “J”, light “H” or “F” will with the valve body, see diagram 3.
  • Page 6 Instructions for Use ‘H’ PRESSURE SUMMER/ WINTER ‘A’ ‘J’ GAUGE BUTTON CONTROL CLOCK TIMER ‘C’ ‘G’ KNOB ‘B’ IF FITTED ‘E’ ‘F’ MAINS ELECTRIC CONTROLS ‘D’ ‘K’ FASCIA PIEZO SWITCH CONTROLS COVER KEY TO NEON LIGHTS ‘G’ LOW WATER PRESSURE ‘H’...

  • Page 7: General Data

    1 General Data 22mm COMPRESSION FLUE CENTRAL HEATING 15mm COMPRESSION DOMESTIC WATER Rc 1 / 2 ( 1 / 2 in. BSPT) GAS CONNECTION Diagram 1.1 TABLE 1 1.1 Installation Lift Weight 33.4kg (73.63b) Materials and equipment should be fit for their purpose and of Total Weight 42.8kg (94.36lb) suitable quality and workmanship.

  • Page 8: Gas Supply

    The electrical installation shall be in accordance with the current rules in force in the countries of destination at the time of installation. HEPWORTH HEATING LTD., Connection of the whole electrical system of the boiler and any BELPER,DERBYS. DE56 1JT...

  • Page 9: Boiler Location

    If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from the local gas undertaking or Hepworth Heating Ltd. 221680G...

  • Page 10: Flue And Ventilation

    Extended Top Outlet Flue Pack - Pt. No. 230487 1 Metre Extension Kit - Pt. No. 230484 Optional Wall Liner Kit No. 900862 A Flue Bend Kit or Vertical Flue Kit can be supplied, see Hepworth Heating "Flue Options Guide" for configurations MINIMUM MINIMUM SITING DIMENSIONS FOR available.

  • Page 11: Heating System

    4 Heating System 5.00 Dt at 60000 btu output Dp (MH2O) 4.00 3.00 2.00 1.00 0.00 Circuit flow rate (l/min) Diagram 4.1 4.1 General Notes 4.7 Bypass The boiler is intended for use in a sealed system only. The bypass is an integral part of the boiler and cannot be adjusted.

  • Page 12: Domestic Hot Water System

    4 Heating System 4.10 Draining METHOD 1 COMBINED CHECK VALVE A draining tap must be provided at the lowest points of the HEATING TEMPORARY system, which will allow the entire system to be drained. An AND VACUUM SYSTEM HOSE BREAKER additional draining tap MUST be fitted close to the boiler.

  • Page 13: Installation Preparation And Gas/Water Connections

    6 Installation Preparation and Gas / Water Connections The installation requires the following components :- SAFETY DISCHARGE Plumbing jig Carton PIPE ROUTING POSITION 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 36mm 15mm 117mm SCREW & TAPE SCREW ’X’ & TAPE ’Y’ SIDE FLUE REAR FLUE ’Y’ plus 50mm = FLUE LENGTH ’X’...
  • Page 15 7 Flue Preparation Note: Should any one of the flue sections require cutting to obtain desired flue system length, cut at the end opposite the expanded end. If the boiler is not to be fitted for some time cover the hole in the wall.

  • Page 16: Mounting The Boiler And Flue Fitting

    8 Mounting the boiler and Flue Fitting 8.1 Boiler Mounting SECURING INNER CASE SCREW (4) Remove the inner case front, see diagram 8.1. FRONT To assist with the location of the flue elbow into the fan outlet remove the fan by removing the securing screws, the electrical connections by pulling the boots not the wires and air pressure switch tubes, see diagram 8.2.
  • Page 17 8 Mounting the Boiler and Flue Fitting BOILER WATER PIPES RETAINING LUG BOILER SERVICE COCKS (4) GAS SUPPLY PIPE TOP MOUNTING TUBING BRACKET SEALING WASHER (4) (INSERT INTO TUBING NUT) FLOW RESTRICTOR (DOMESTIC WATER INLET) Diagram 8.4 SECURING SCREW (4) FLUE ELBOW (REAR FLUE PRODUCTS...

  • Page 18: Electrical Connections

    9 Electrical Connections 9.1 Supply Cable Connection SECURING CONTROLS CAUTION: To prevent an induced current from switching the 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 19 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 20: Commissioning

    10 Commissioning Please ensure the “Benchmark” logbook is completed and left WARNING 230V 50Hz BURNER with the user. ELECTRICAL PRESSURE TEST CONNECTIONS POINT 10.1 Filling Domestic Water Circuit Check that the boiler is isolated from the electrical supply, at the external isolator.
  • Page 21 10 Commissioning achieved, obtain it by turning the small adjusting nut, (clockwise CABLE ENTRY to increase the pressure). Always adjust the minimum pressure CLOCK-TIMER first. COVER COVER Reconnect the grey wire and adjust pressures on potentiometers. If the maximum pressure is unattainable, check that the gas supply is of adequate size, refer to Section 1.7 “Gas Supply”.
  • Page 22 10 Commissioning Lower the pressure to the initial cold fill design pressure, using WRAP AROUND the external draining tap, close to the boiler, refer to Table 1 and Section 4.10. 10.10 Completion Refit the inner case front. Fit the side panels, hook into the threaded lugs at the top, see diagram 10.3.

  • Page 23: General Data

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

  • Page 24: Fault Finding

    12 Servicing 12.8 Completion 12.7 Operational Checks Hook the outer case front on the top and secure with the nuts Check the safety valve manually by turning the knob in the previously removed, see diagram 10.5. direction of the arrow. Light the boiler, carry out operational checks and any necessary adjustments as described in Commissioning in the Installation Instructions.
  • Page 25 13 Fault Finding ON/OFF PERMANENT TERMINAL TO TEST FOR COMPONENT OPERATION / FAILURE SWITCH MAINS 230V-50HZ BLOCK Power to the appliance :- Test for 230V~ across live (brown) and earth (yellow and green), 230V~ across live and neutral brown brown (blue), and zero potential across neutral and earth.
  • Page 26 13 Fault Finding PILOT WILL NOT LIGHT START HERE Check gas line-open all cocks, Does pilot stay alight when rectify any blockages, purge out multi-functional control any air. Does pilot light? knob is released? Apply match to pilot burner instead PILOT SATISFACTORY of pressing piezo unit button.
  • Page 27 13 Fault Finding Check that gas,water and electricity are available at the boiler. There must be no external voltage applied to the control board via the central heating controls to the P.C.B. Before commencment of test, isolate the boiler electricity supply, ensure that the remote controls are not calling for duty (no red link in terminal block) Refer to functional flow diagrams in conjuction with the following fault finding.
  • Page 28 13 Fault Finding Winter Mode Summer Mode Continued. Continued. Press button to change to summer mode. Does summer mode Change P.C.B. LED illuminate? Change flow Using spare flow sensor. sensor. Connect to P.C.B. Turn hot water demand on. Then blow down flow sensor. Does fan goto fast speed? Change Does the fan goto fast speed?
  • Page 29 13 Fault Finding Winter Mode Continued. BOILER FAULT FINDING When demand from T/Sat is Change P.C.B. Is there 230v at requested, does the pump operate? pump? Change pump. Change P.C.B. Is there 230v at Does fan go to high speed? fan terminals? Change fan.
  • Page 30 13 Fault Finding With the boiler cold, check connections of the thermocouple, boiler overheat cut-off and gas valve. Disconnect overheat cut-off connectors at points A and B at the gas valve, see diagram. Test continuity of the overheat cut-off. Is there continuity? Faulty boiler overheat cut-off, renew.
  • 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 14.1 Fan FLUE Before starting refer to Section 11. COLLECTOR Disconnect the two electrical connectors at the fan by pulling the boots not the wires, see diagram 8.2. Disconnect the two air pressure switch flexible tubes from the fan.
  • Page 33 14 Replacement of Parts Disconnect the pilot supply tube, holding the pilot injector hexagon with another spanner, then remove the pilot burner. Check the spark gap upon assembly, see diagram 14.4. Make sure the pilot injector is fitted. Test joints for gas soundness with suitable leak detection fluid with the gas control knob depressed.
  • Page 34 14 Replacement of Parts 14.10 Domestic Hot Water Thermistor. 14.6 Pilot Injector Before starting, refer to Section 11. Before starting, refer to Section 11. Open the controls cover door. Remove the two screws securing Remove the sealing angle, secured with a single screw, see the controls facia, see diagram 9.1.
  • Page 35 14 Replacement of Parts RETAINING BRACKET ELECTRICAL CONNECTION SECURING SCREW (2) RESISTOR ELECTRICAL CONTROL CONNECTION (2) VALVE Diagram 14.6 Top right hand side of boiler Diagram 14.7 DOMESTIC HOT WATER THERMISTOR ELECTRICAL CONNECTION BOILER OVERHEAT CUTOFF CENTRAL HEATING RETAINING CLIP GAS CONTROL VALVE WATER...
  • Page 36 14 Replacement of Parts 14.17 Gas Control Valve 14.15 Control Board Before starting refer to Section 11. Before starting refer to Section 11. Remove the case base, see diagram 10.4. Open the controls cover door. Remove the two screws securing the controls facia, see diagram 9.1.
  • Page 37 14 Replacement of Parts 14.18 Modulator FASCIA Before starting refer to Section 11. Open the controls cover door. Remove the two screws securing the controls facia, see diagram 9.1. SECURING Hinge the control fascia open. SCREW (2) Disconnect the two electrical connectors at the modulator, see diagram 14.14.
  • Page 38 14 Replacement of Parts Disconnect the pressure gauge connection from the safety Refer to diagram 14.18. valve, see diagram 14.12. Disconnect the domestic inlet pipe. Disconnect the union nuts to release the safety valve, see Remove the water flow sensor assembly. diagram 14.12.
  • Page 39 14 Replacement of Parts 14.25 Air Pressure Switch Before starting refer to Section 11. Disconnect the electrical connectors at the microswitch, see diagram 14.19. Disconnect the air pressure tubes. UNION NUT Remove pressure switch see diagram 14.19. 14.26 Heat Exchanger Before starting refer to Section 11.
  • Page 40 14 Replacement of Parts Connect the cables, the polarity of the two connectors is not important. COMBUSTION FRONT CHAMBER Tighten the screws evenly to secure the flue collector and INSULATION combustion chamber front panel. FRONT PANEL Make up water loss and pressurise the system, refer to Commissioning in the Installation Instructions.
  • Page 41 14 Replacement of Parts 14.29 Mini Expansion Vessel (If fitted) Remove the mini-expansion vessel. GASKET When refitting use the new sealing washer supplied. 14.30 Viewing Window (Combustion Chamber) GLASS Remove outer case front as section 11.4. Remove the viewing window, secured with two screws. When fitting a new window use the gasket provided, see diagram 14.22.
  • Page 42 14 Replacement of Parts PRESSURE SWITCH GREY WHITE RESISTOR or- ORANGE BLUE bk- BLACK YELLOW br - BROWN PURPLE g/y- GREEN/ YELLOW VIOLET BOILER OVERHEAT CUT-OFF PUMP CONTROL THERMISTOR VALVE THERMISTOR (CENTRAL HEATING) (DOMESTIC HOT WATER) WATER PRESSURE SWITCH 230V-50Hz WATER PERMANENT FLOW...

  • 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. 221680G...

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