Table of Contents
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Installation and Servicing
Energysaver
Combi 2
80
G.C. No. 47-047-13
Condensing
Combination Boiler
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.
The 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.
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
100
G.C. No. 47-047-14
Appliance
2H
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.
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
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
221854B.04.01
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Table of Contents
Related Manuals for Glow-worm Energysaver Combi 2 80 47-047-13
Summary of Contents for Glow-worm Energysaver Combi 2 80 47-047-13
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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: Important Information
Contents CONTENTS DESCRIPTION SECTION PAGE No. Introduction INSTRUCTIONS Operating the Boiler FOR USE Clock Setting General Information INSTALLATION Boiler Position Flue Location and Ventilation INSTRUCTIONS Heating System Domestic Hot Water System Installation Preparation Flue Preparation Boiler Fixing Gas, Water and Condensate Conns. Electrical Connections Commissioning Servicing... -
Page 3: Gas Leak Or Fault
‘reset’ button. This should Electrical Supply Failure restart the boiler. To obtain service call your installer or Heatcall (Glow-worm’s The boiler will not work without an electrical supply. own service organisation) using the telephone number given on Normal operation of the boiler should resume when the electrical the front page of these instructions. -
Page 4: User Controls
Operating the Boiler User Controls If in doubt, contact you installation/servicing company for advice. As a safety feature the boiler will stop working if the condensate The boiler is factory preset to supply domestic hot water up to ’ drain becomes blocked. The display will repeatedly flash ‘ C and central heating up to 70 ‘8 ’... -
Page 5: Clock Setting
Clock Setting Setting Instructions for Electro/mechanical This is a 24 hour clock/timer, that is 1pm is '13:00', and has 8 “ON” and 8 “OFF” daily switching actions. Clock - if fitted It is fitted with a lithium battery back up which protects the Refer to diagram 2. -
Page 6: Installation Instructions
1 Installation Instructions CONDENSATE SIPHON Condensate Drain BOILER Connection INSIDE WALL FIXING FACE REFER TO THE WALL TEMPLATE FOR PIPE DIMENSIONS Diagram 1.1 1.1 Installation Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3 pin plug. Where no British Standards exists, materials and equipment should be fit for their purpose and of suitable quality and The mains supply cable and other cables connected to the... -
Page 7: General Information
1 General Information TABLE 1 C.H. Max D.H.W.Max MIN NOMINAL kW 27.5 27.5 HEAT Btu/h 93,830 93,830 27,266 INPUT 32.5 32.5 11.7 GROSS Btu/h 110,890 110,890 39,920 NOMINAL kW 24.5 24.5 HEAT Btu/h 83,600 83,600 23,200 OUTPUT 28.6 28.6 10.0 Btu/h 97,583 97,583... -
Page 8: Boiler Position
2 Boiler Position 2.1 Location The boiler is not suitable for fitting outdoors. Any electrical switch or boiler control using mains electricity must be positioned so that it cannot be touched by a person using a bath or shower. The boiler must be mounted on a flat wall which is sufficiently robust to take its weight, refer to Table 2. -
Page 9: Flue Location And Ventilation
3 Flue Location and Ventilation 3.1 Flue Position and Length 3.3 Terminal Position There are several flueing options available for the Energysaver The minimum acceptable siting dimensions for the terminal Combi, e.g. horizontal, vertical and twin flue. from obstructions, other terminals and ventilation openings are shown in diagram 3.4. -
Page 10: Timber Frame Buildings
3 Flue Location and Ventilation 3.4 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage. If a terminal guard is required, it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal. -
Page 11: Heating System 4
4 Heating System 4.1 General 4.4 Bypass The boiler is for use only with sealed central heating systems. The boiler is fitted with a manual bypass, see diagram 4.3. This valve may be adjusted by the installer if necessary to ensure at The safety valve is an integral part of the boiler and it cannot be least 1053 litres/hr for ES80 and 1230 litres/hr for ES100 flow adjusted. -
Page 12: Water Treatment
4 Heating System 4.6 Water Treatment 4.7 Draining Tap For optimum performance after installation, the boiler and its A draining tap must be provided at the lowest points of the associated central heating system should be flushed in system, which will allow the entire system to be drained. accordance with BS7593:1992 using a cleanser such as Sentinel The flow and return isolation valves are provided with drain X300 or X400, or Fernox Superfloc. -
Page 13: Domestic Hot Water System 5
5 Domestic Hot Water System 5.1 Water Pressure The maximum working pressure of the domestic hot water circuit is 8 bar. If the cold water supply pressure exceeds this, then a pressure reducing valve must be fitted in the supply to the boiler. -
Page 14: Installation Preparation
6 Installation Preparation 6.5 Pre Plumbing Extended flue length 2.5˚ The wall mounting jig can now be pre-plumbed without the Inclined boiler being mounted if necessary. All water, gas and electric Standard flue length connections are on the wall mounting jig with the exception of the condense drain, the position of which is shown on the wall template for pre plumbing purposes. -
Page 15: Flue Preparation 7
7 Flue Preparation 7.1 Flue Length X + 196 ( AIR DUCT ASSEMBLY) All dimensions are in mm. For a rear flue, measure the distance from the outside wall face BOILER to the boiler mounting wall. Check that the flue length will be MOUNTING suitable, see diagram 3.1 for a standard flue system. -
Page 16: Flue Attachment To Boiler
7 Flue Preparation 7.6 Flue Attachment To Boiler Fit flue elbow ‘G’ to air pipe ‘B’ and flue duct ‘A’. A small amount of lubricant can be applied to the rubber seals in the elbow to Refer to section 8 and fix the boiler in position prior to completing facilitate this. -
Page 17: Boiler Fixing 8
8 Boiler Fixing Boiler Fixing DOMESTIC Having previously secured the wall mounting jig and hanging WATER bracket to the wall, lift the boiler into position in the following DRAIN VALVES DRAIN manner. To assist in the lifting of the boiler, remove the front POINT POINT panel. -
Page 18: Safety Valve Discharge
9 Gas, Water, and Condensate Connections Make sure that the drain points on the isolating valves are positioning towards the front of the boiler, also that the drain and CONDENSATE operating screw heads are accessible. SIPHON 9.3 Safety Valve Discharge The pipe from the safety valve must not discharge above an entrance, window or any type of public access area. -
Page 19: Table
10 Electrical Connections 10.4 Frost Thermostat 10.2 Heating System Controls Mains electricity must NOT be connected to the black This boiler has its own frost protection device to protect the electrical connector plug. boiler. Additional frost protection may be required for exposed pipework. -
Page 20: Filling Domestic Water Circuit
11 Commissioning Please ensure the "Benchmark" logbook is completed and left Flashing digits indicate a fault. Refer to fault finding if any fault with the user. persists, see section 13. After the burner has lit, the boiler will initially heat up the 11.1 Filling Domestic Water Circuit domestic hot water cylinder. -
Page 21: Temperature Display
11 Commissioning ELECTRICAL PROTECTIVE PROTECTIVE CAP CONNECTIONS PRESSURE TEST POINT ELECTRICAL CONNECTIONS ELECTRICAL PRESSURE TEST CONNECTIONS POINT COMBI 2 - 80 COMBI 2 - 100 Diagram 11.2a Diagram 11.2b Temperature Options Repeated pressing of the 'mode' button gives the display sequence shown in diagram 11.4. -
Page 22: Control Options
11 Commissioning Control Options The current function that the boiler is performing is shown by a number with a flashing decimal point, see table below. There are two control options available: Normal mode and Holiday mode, see diagram 11.4. Minimum Input Lock Normal mode uses the domestic hot water and central heating temperatures selected. - Page 23 11 Commissioning NOTE:- The SYMBOL (flashing decimal point) indicates the selected options BOILER TEMPERATURE (Decimal Point illuminated means boiler is firing) Press 'mode' - 65 C Press 'mode' - 55 C Domestic hot water options For use with a supplementary (select one only) Press 'mode' - hot water cylinder...
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Page 24: Frost Protection
11 Commissioning The operating sequence of the appliance during central heating DOMESTIC HOT WATER SEQUENCE TABLE and domestic hot water production can be checked against the following two tables. DISPLAY ACTION (Operating CENTRAL HEATING SEQUENCE TABLE function) DISPLAY ACTION No demand. (Operating function) Create demand by turning on... -
Page 25: Spark Electrode
12 Servicing 12.4 Spark Electrode 12.1 General Remove the spark plug lead and two securing screws. Withdraw To ensure the continued efficient and safe operation of the the spark electrode and viewing window from the combustion boiler it is recommended that it is checked and serviced at chamber, see diagram12.3. - Page 26 12 Servicing 12.5 Condensate Siphon SPARK ELECTRODE Place a container beneath the drain cap on the condensate SECURING SCREW siphon. (2 OFF) Carefully remove the cap at the base of the condensate drain trap, see diagram 9.1. Remove any solids found. Check for any debris in the outlet pipe of the condensate drain and clean as necessary.
- Page 27 12 Servicing Open one or more hot water taps to drain the hot water circuit. SECURING Undo and remove the drain screw on the cold water inlet valve PLATE and drain away any remaining water. Undo the connecting nuts on either end of the water inlet pipe and remove the pipe from the boiler.
- Page 28 12 Servicing 12.11 Heat Exchanger - Major Servicing Refer to Fault Finding sections 13.1, (fault code .) and 13.4 before carrying out a major service of the heat exchanger. TORX SCREWS If it is suspected that the heat exchanger has become partially (6 OFF) blocked internally, proceed as follows.
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Page 29: Fault Finding
13 Fault Finding Black BLACK LOW Blue VOLTAGE PLUG Brown Room thermostat Green Clock/timer Yellow Frost thermostat Green/Yellow FLAME IGNITION AND White IONISATION ELECTRODE Orange 230V/50Hz Grey WHITE Red/White r/wh MAINS PLUG Blue/White bl/wh P.C INTERFACE AUTOMATIC CONTROL MODULE X1-1 CHASSIS X1-2 EARTH POINT... - Page 30 13 Fault Finding 13.1 Digital Display - Fault Codes Press the 'reset' button. If the fault code is not removed then an internal fault has If a fault has occurred during operation of the boiler the display occurred in the Automatic Control Module. will start flashing.
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Page 31: Central Heating
13 Fault Finding 13.3 Thermistor Characteristics If after checking all previous points the error code is still present, this suggests that the heat exchanger has become partially All three thermistors used on the boiler can be checked for blocked. See section 12.11 for major service of heat exchanger. accuracy against the chart below if their performance is suspect. -
Page 32: Replacement Of Parts
14 Replacement of Parts 14.1 General Remove the gas pipe. Remove the domestic hot water pipe. Replacement of parts must be carried out by a competent person. Undo the left hand nut from the bypass valve, see diagram 4.3. Before replacing any parts the boiler should be isolated from the Remove the pump. - Page 33 14 Replacement of Parts 14.11 Gas Valve Remove the injector pipe as described in section 12.3. Remove the gas injector as described in section 14.10. POCKET Remove the electrical connections from the gas valve, see diagram 11.2. Undo the gas pipe nut from beneath the base panel. Undo and remove the two securing screws from beneath the DOMESTIC HOT base panel.
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Page 34: Pressure Gauge
14 Replacement of Parts Remove the cylinder securing collar, see diagram 11.1. ELECTRICAL Remove the automatic air vent non- return valve from the top of CONNECTION the boiler and temporarily replace the cylinder securing collar. (2 OFF) Undo the pipe connections to the cylinder. While holding the cylinder in place, remove the cylinder securing THERMISTOR collar on top of the boiler. -
Page 35: Heat Exchanger
14 Replacement of Parts 14.19 Heat Exchanger Refer to section 12.9 and drain the boiler heating circuit. Refer to Section 12.10 and drain the boiler hot water circuit. The right hand casing panels should be removed as described in section 12.8. Remove the gas valve as described in section 14.11. -
Page 36: Spare Part List
14 Replacement of Parts 14.23 Control Door ELECTRICAL AIR PRESSURE CONNECTIONS Open the control door and pull the brass lugs out of their SWITCH locations in the fascia, see diagram 11.3. 14.24 Mini Expansion Vessel CLIPS If the mini expansion vessel option is fitted it can be replaced by the following method. - Page 37 MODEL Energysaver combi 80 Energysaver combi 2 80 KIT Pt. No. S801056 MODEL Energysaver combi 100 Energysaver combi 2 100 British Gas ICC 1 KIT Pt. No. S801145 Technical Helpline: 01773 828300 Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk...
- Page 38 Requirements It is the Law that any replacement of parts is carried out by a competent person approved at the time by the Health and Safety Executive. Before commencing with the replacement of a part the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve.
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Page 39: Gas Valve Setting
Operational Gas Inlet Pressure LPG MODELS - ONLY With ALL other gas appliances operating, check the Please refer to the specific instruction relating to your operational supply pressure at the gas service isolation model and check/adjust the CO2 value, refer to table valve test point, refer to your Installation literature supplied overleaf. - Page 40 Models SETTING - OUTPUT SETTING - OUTPUT MAX. GAS RATES Nat. Gas G20 - Case Off Nat. Gas G20 - Case On CO/CO2 Nat. Gas G20 Ratio OUTPUT MIN. 8.3 kW MAX. 28.0kW MIN. 8.3 kW MAX. 28.0kW MAXIMUM E/S Combi 100 9.0 - 9.4%CO2 9.2 - 9.6%CO2 0.004...
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