Glow-worm COMPACT 80p Instructions For Use, Installation & Servicing Download Page 25 | Manualshive

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Supplied By www.heating spares.co Tel. 0161 620 6677

25

221679H

13 Fault Finding

7468

7495

Diagram 13.2

MAINS FUNCTIONAL FLOW

TO TEST FOR COMPONENT OPERATION / FAILURE

Power to the appliance :-

Test for 230V~ across live

(brown) and earth (yellow and green), 230V~ across live and
neutral (blue), and zero potential across neutral and earth.

Thermistors :-

With the power off unplug the connector and

test resistance is 10k

Ω

at 25

°

C.

Domestic Hot Water demand sensor :-

With a tap open

the supply to the sensor measure between the red and black
cables on X5a should be 12Vdc. The signal from the sensor
measured between the white and black cables X5a should
be between 1Vdc and 11Vdc dependent of the flow rate.

Overheat thermostat :-

With the power off unplug the

connectors and test for continuity (zero resistance).

Power to the gas control valve :-

With a demand on

test

for voltages of

230Vac ~ across the red and purple cable

connectors and 24Vdc ~ across the grey and grey cable
connectors. When burner pressure at maximum.

Power to the fan :-

With a demand on and the front cover

removed test for 230V~ at the fan connectors at high speed
and 108V at low speed

Fan failure :-

with the power off and the supply leads to the

fan disconnected (pull the boots only) the resistance across
the fan coil should be 45

Ω

to 50

Ω

.

Pump :-

With the power off unplug the connector from the

pump. Restore the power and check that there is 230V~
between live (brown) and neutral (blue) or live and the
appliance earth.

Air pressure switch :-

This is a change over device. With

the fan at pilot only there should be 230V at the C and NC (No
air state terminals. With the appliance running and the fan
at full speed there should be 230Vac at C, Nc and No (Air
State).

Water pressure switch :-

With no water pressure and

Power On, check there is 230V~ on the black and grey
cables and 0V on the grey cable X5b. With water applied to
the system and power on, check there is 230V~ on the black
and grey cables and on the white cable X5b. This will prove
operation of the water pressure switch.

LOW VOLTAGE
FUNCTIONAL FLOW

F1
2AT

red

red

red

red

purple

brown

yellow

blue

brown

brown

brown

brown

blue

N

OVERHEAT
CUTOFF

CONTROL BOARD

GAS

VALVE

ON/OFF

SWITCH

TERMINAL

BLOCK

PERMANENT
MAINS 230V-50HZ

FAN

PUMP

TRANSFORMER

240/24V

24V

LOW

VOLTAGE

X3

X3

X4

X4

X3

X3

X2

X2

X2

X2

X2

X2

X2

X2

L

N/C

N/O

N/C2

N/O4

C

grey

red

violet

AIR
PRESSURE
SWITCH

X5b

X5b

X5b

C1

grey

black

blue

white

LOW WATER
PRESSURE
SWITCH

FAN SPEED
RESISTOR

brown

3.15AT

grey

grey

red

white

black

X6

X6

X6

MODULATING

VALVE

DHW

FLOW

SENSOR

purple

purple

DHW THERMISTOR

orange

orange

orange

orange

X6

X1

X1

CH THERMISTOR

24v~

CONTROL BOARD

X5a

X5a

X5a

X5a

X5a

«
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24
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27
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Summary of Contents for COMPACT 80p

Page 1: ...orm 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 If this card is missing you can obtain a copy or record your registration by telephoning the Hea...

Page 2: ...designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility Substances Hazardous to Health The adhesives and sealants used in this appliance are cured and give no known hazard in this state INSULATION PADS CERAMIC FIBRE GLASSYARN MINERAL WOOL These can cause irritation to skin eyes and the res...

Page 3: ...ed spur box The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively a fused 3A 3 pin plug and shuttered unswitched socket may be used Thecoloursofthreecoreflexiblecableare blue neutral brown live green and yellow earth As the markings on your plug may not correspond with these colours continue as follows The wire ...

Page 4: ...ting the Clock Diagram 2 1 With both AUTO and RUN switches set to the central position press R reset button the display will flash 2 Set RUN switch to 3 Set day of week by pressing button DAY 4 Set time of day by pressing buttons HR and MIN 5 Set RUN switch to the central position colon will flash this indicates the clock is set With the clock set the factory preset programme shown below will oper...

Page 5: ...ower than in the summer To achieve the same outlet water temperature in the winter it will be necessary to reduce the water flow rate using the hot water tap Summer Winter Selector Button Forcentralheatingsetbutton J toWinterlight F willilluminate as shown in diagram 4 The main burner will light When the heating is controlled by a room thermostat and or a time switch button J must be set to Winter...

Page 6: ...n handling and cleaning with particular regard to edges The boiler casing can be cleaned using a mild liquid detergent with a damp cloth then a dry cloth to polish Do not use any form of abrasive or solvent cleaner as you may damage the paint work Boiler Casing CAUTION Do not remove or adjust the casing in any way as incorrect fitting may result in incorrect operation or failure to operate at all ...

Page 7: ... 2 1 6 Data See table 1 and diagrams 1 1 1 2 1 3 The Seasonal Efficiency Domestic Boilers UK SEDBUK is 72 2 ThevalueisusedintheUKGovernment sStandardAssessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by B S I Lift Weight 33 4kg 73 63b Total Weight 42 8kg 94 36lb Gas connection Ø 15mm compression Heating and return Ø 22mm comp...

Page 8: ...e of at least 0 75mm2 24 0 20mm 1 General Data HEPWORTHHEATINGLTD BELPER DERBYS DE561JT COMPACT 80P 457501 SERIAL HEATING CIRCUIT PMS 2 5 bar DOMESTIC CIRCUIT PMW 10 bar SPECIFIC WATER RATE 11 22 l min No GCNo 47 047 04A 0086 86 AU 582 GB IE 230V 50Hz 150W Fusedat 3A Foruse on G20 20 mbar G20 This boileris intendedexclusively tobe installedona gas supply witha governedmeter MIN DHW MAX CH MAX HEAT...

Page 9: ...ment Where the installation of the boiler will be in an unusual position the current issue of BS6798 gives detailed guidance on these requirements An existing cupboard or compartment modified for the purpose may be used providing minimum clearances are maintained Details of essential requirements for cupboard or compartment design are given in the current issue of BS6798 The doorway opening should...

Page 10: ... Access Flue All flue assemblies are designed for internal installation given that there is sufficient clearances opposite to the flue for the installation of the flue If there is insufficient clearance the flue can be installed from outside For a wall thickness up to 300mm provided that there is sufficient space and the optional wall liner kit is used the flue can be installed from the inside For...

Page 11: ...uired a valve can be incorporated in the main flow or return of the system valve A shown in the flow diagram 4 2 This valve must be lockable and positioned so that inadvertent closure or unauthorised interference is not possible Diagram 4 1 4 Heating System 4 7 Bypass The bypass is an integral part of the boiler and cannot be adjusted No external system bypass is required 4 8 Filling Sealed System...

Page 12: ... domestic hot water service must be in accordance with the rules in force in the countries of destination 5 2 Water Pressure For the minimum and maximum working pressures of the domestic hot water circuit of the boiler refer to Diagram 1 2 If the cold water supply pressure exceeds the maximum a governor must be fitted in the supply to the boiler to reduce the pressure to within the limits given 5 ...

Page 13: ... vessel Refer to the wall template If connecting from above a piping kit 457160 is available and is recommended If necessary temporarily fit the boiler Flush out the domestic water and heating system before connecting the boiler Make the connections to the domestic hot water outlet and the heating system by means of the isolating valves see diagram 6 1 While making the connections Do not subject a...

Page 14: ...132mm FLUE LENGTH REAR FLUE Y plus 50mm FLUE LENGTH Y X Y plus 50mm FLUE LENGTH Y C L C L Diagram 7 1 7508 7 Flue Preparation 7506 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 rings this should...

Page 15: ...l included in the wall liner kit must be used in place of the one supplied with the flue pack see diagram 7 3 for position of self adhesive seal 7 5 Top Outlet Side Flue Fixing Make good the area around the flue inside and outside after installation of the boiler Important If the wall liner kit is used the self adhesive foam seal included in the wall liner kit must be used in place of the one supp...

Page 16: ... push the boiler back see diagram 8 4 Ensure the bottom boiler bracket is sitting on top of the service cock bracket see diagram 8 3 Fit the flow restrictor into the domestic water inlet see diagram 8 4 Secure all tubing nuts finger tight plus 3 4 turn maximum Connect the gas pipe to the isolation valve ensuring that the sealing washer supplied fitted is in position 8 3 Boiler Securing Secure the ...

Page 17: ...HOWN SECURING SCREW 4 PRODUCTS PROBE 8 Mounting the Boiler and Flue Fitting Diagram 8 3 SECURING SCREW 2 SERVICE COCK BRACKET BOILER SECURING LUG Note The lug must be positioned on top of the service cock bracket 8083 Diagram 8 4 BOILER WATER PIPES SERVICE COCKS 4 GAS SUPPLY PIPE SEALING WASHER 4 INSERT INTO TUBING NUT FLOW RESTRICTOR DOMESTIC WATER INLET TUBING NUT ...

Page 18: ... System Controls All external controls and wiring are required to provide a minimum of reinforced insulation at 250Vrms between the parts of those devices operating at mains hazardous voltage and the user accessible parts af those devices The heating system should have installed a programmer and room thermostat controlling the boiler Thermostatic radiator valves may be installed in addition to the...

Page 19: ... BLOCK MAINS POTENTIAL FROST STAT L N R1 R2 3 AMP FUSE L N 230V 50Hz PERMANENT MAINS SUPPLY POTENTIAL FREE ROOM STAT NO FROST STAT TO BOILER RED LINK REMOVE WHEN CONNECTING SYSTEM CONTROLS 5 WAY TERMINAL BLOCK POTENTIAL FREE ROOM STAT L N R1 R2 DOUBLE POLE ISOLATOR JUNCTION BOX 3 AMP FUSE L N 230V 50Hz PERMANENT MAINS SUPPLY 230V 50Hz ROOM STAT NO FROST STAT TO BOILER RED LINK REMOVE WHEN CONNECTI...

Page 20: ...is pressure also Refit inner case front 10 3 Preparation for Lighting Turn on the gas service cock slot in line with the length of the cock Test for soundness and purge air from the gas supply Switch power ON at the mains electrical supply at the external isolator and switch at the boiler Light the pilot refer to relevant parts of Light the boiler Instructions for Use Loosen the burner pressure te...

Page 21: ...a Hinge the control facia open Remove the plastic plugs Using the burner adjusting tool supplied clockwise to increase see diagram 10 2 Turn the adjuster slowly always making adjustment by reducing below the required pressure then increasing up to the required setting Isolate the boiler from the electrical supply Remove the pressure gauge and tighten the test point screw Test for gas soundness aro...

Page 22: ...oiler Instruct and demonstrate the operation of any heating system controls Advise the user that to ensure the continued efficient and safe operation of the appliance it is recommended that it is checked andservicedatregularintervals Thefrequencyofservicingwill dependupontheparticularinstallationandusage butingeneral once a year should be enough Draw attention if applicable to the current issue of...

Page 23: ... the system pressure Before any parts of this circuit are disconnected reduce the system pressure at the external draining tap turn the central heating isolating valves off and drain at the drain points on the appropriate valves see diagram 6 1 All water containing parts of the domestic hot water circuit of the boiler will be under the supply water pressure Before any parts of this circuit are dis...

Page 24: ... the controls facia see diagram 10 1 Hinge the control facia forward Remove the clock timer cover see diagram 9 1 Disconnect the clock wiring harness plug and connect the link This is a temporary measure and the clock should be repaired or replaced as soon as possible 13 3 Electrical Preliminaryelectricalsystemchecks asoutlinedinaMultimeter Instruction book are the first checks to be carried out d...

Page 25: ...boots only the resistance across the fan coil should be 45Ω to 50Ω Pump With the power off unplug the connector from the pump Restore the power and check that there is 230V between live brown and neutral blue or live and the appliance earth Air pressure switch This is a change over device With thefanatpilotonlythereshouldbe230VattheCandNC No air state terminals With the appliance running and the f...

Page 26: ...released PILOT SATISFACTORY Does pilot flame envelop thermocouple Check aeration If necessary Clean pilot rectify blockage in pilot injector or replace Check thermocouple circuit using Thermocouple fault finding diagram On pressing piezo unit button is there a spark across electrode gap Pull ignition lead off electrode Hold end of lead close to pilot burner and operate piezo unit Is there a spark ...

Page 27: ...emove cable restraints Check all connections on the control board and the boiler components rectify or renew as necessary Two spare fuses are provided Can pilot be lit Refer to pilot fault finding Switch on main supply Do mains and winter mode LEDs illuminate Change P C B Does low water pressure LED flash Is there enough system pressure Is there continuity between common and N O Change P C B Re pr...

Page 28: ...modureg Change P C B Change gas valve Summer Mode Continued YES Winter Mode Continued YES YES YES YES Connect a manometer to gas valve and check burner pressure Adjust hot water burner pressure potentiometer Does burner pressure adjust accordingly YES NO NO NO NO NO YES NO NO YES NO Is there a decrease in electrical resistance across the hot water thermistor as temperature rises Change thermistor ...

Page 29: ...ecrease in electrical resistance accross the terminals as the temperature increases Change thermistor Reconnect thermistor turn on hot water tap fully Does the central heating pump stop Change flow sensor Burner pressure increases to domestic hot water setting Adjust domestic hot water burner pressure potentiometer Does burner pressure alter accordingly Change P C B Slowly close hot water tap Does...

Page 30: ...ntinuity Re connect boiler overheat cut off to points A and B Disconnect thermocouple at point D of the gas valve Test continuity between point C and the body of the gas valve Is there continuity YES Thermocouple and boiler overheat circuit satisfactory Faulty cut off connectors into gas valve Either at A or C Renew where faulty Faulty thermocouple renew Faulty boiler overheat cut off renew YES NO...

Page 31: ...lty clock timer Replace YES YES YES Check continuity of clock timer harness ensure an electrical supply is available ensure that remote controls are calling for heat NB The clock can be by passed by refitting the plug link which should be inside the clock timer cover Isolate the boiler from electrical supply remove outer case Disconnect and insulate the cables from heating common and heating on Sw...

Page 32: ...ot assembly forwards to clear taking care not to damage the combustion chamber insulation or the pilot burner assembly When refitting make sure that the main burner is fitted correctly on assembly located on the main injector and horizontal the tips of the rearmost blade under the two burner guides Locate the combustion chamber front panel under the front edge of the flue hood on assembly then sec...

Page 33: ...ured with a spring clip see diagram 14 2 Ease the spark electrode through the sealing angle Open the controls cover door Remove the two screws securing the controls facia see diagram 9 1 Hinge the control fascia open Disconnect the ignition lead from the piezo unit see diagram 14 9 Check the spark gap upon the assembly see diagram 14 4 14 Replacement of Parts Diagram 14 4 SPARK GAP 4 5mm to 5 5mm ...

Page 34: ... of the gas control valve see diagrams 14 5 and 14 7 Unclip to remove the overheat cut off see diagram 14 8 14 9 Domestic Hot Water Boiler Overheat Cut off Before starting refer to Section 11 Open the controls cover door see diagram 4 user instructions Remove the two screws securing the controls facia see diagram 9 1 Hinge the control fascia open Disconnect the overheat cutoff electrical connector...

Page 35: ...72 Diagram 14 9 PIEZO UNIT SECURING NUT IGNITION LEAD EARTH LEAD 7237 Diagram 14 10 CAREFULLY BEND THE RETAINING CLIPS FORWARD TO RELEASE MULTI PIN CONNECTORS MULTI PIN CONNECTORS SECURING SCREW 2 7034 Diagram 14 8 TRANSFORMER BOILER OVERHEAT CUTOFF CENTRAL HEATING DOMESTIC HOT WATER THERMISTOR CENTRAL HEATING HOT WATER THERMISTOR WATER PRESSURE SWITCH RETAINING CLIP ELECTRICAL CONNECTION GAS CONT...

Page 36: ...ng kinks and sharp bends 7238 Diagram 14 11 14 17 Gas Control Valve Before starting refer to Section 11 Remove the case base see diagram 10 4 Openthecontrolscoverdoor Removethetwoscrewssecuring the controls facia see diagram 9 1 Hinge the control fascia open Remove the main burner refer to Section 14 2 Remove the gas control knob Remove the access cover in the base of the combustion chamber secure...

Page 37: ...boiler if necessary refer to Commissioning in the Installation Instructions Test joints for gas soundness with suitable leak detection fluid with the gas control knob depressed 14 19 Automatic Bypass Valve Before starting refer to Section 11 Remove the case base see diagram 10 4 Openthecontrolscoverdoor Removethetwoscrewssecuring the controls facia see diagram 9 1 Hinge the control fascia open Iso...

Page 38: ...tom of the pump see diagram 14 16 It may be necessary to slacken the union nut at the automatic bypass and water cock Remove the pump Discard the sealing washer from the bottom fixing Make sure that the flow direction arrow is pointing upward on the pump when fitting the pump to the lower pipework use the new sealing washer provided Set the flow adjuster on the pump to maximum setting The flow rat...

Page 39: ...htwoscrews seediagram 14 2 Remove the combustion chamber cover see diagram 14 1 Remove the main burner refer to Section 14 2 Remove the automatic air vent see diagram 14 17 If renewing the heat exchanger transfer the air vent to the new one using the new sealing washers supplied Disconnect the union nuts of the heat exchanger to remove it Take care there may be some water retained in the heat exch...

Page 40: ...er to be 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 Remove the outer case front side panels and inner case front refer to Sections 11 4 and 11 5 Release the water pressure and drain the domestic hot water and central heating ...

Page 41: ...he backing paper and secure with new self adhesive aluminium foil gasket see diagram 14 23 Ensure no air bubbles are trapped underneath the foil Important Make sure that the mica window fully covers the opening and that the hole in the aluminium foil gasket is centred over opening 14 32 Inner Case Front Seal Remove outer case front as section 11 4 Remove the old seal clean out the old adhesive Glu...

Page 42: ...ED AT 3 15A FUSED AT 2A ROOM STAT CLOCK TIMER C N C N O C1 N O4 N C2 PUMP WATER FLOW E N L br br w r r r y bk w bk g g g br br br X4 X2 X3 X5b X5a X6 X1 p or or r br b p p r r or or or br b g y p g v b r r y br 230V TRANSFORMER PLUG PLUG PLUG PLUG CHASSIS EARTH G Y g y g y NOTE 2 1 NOTE 1 2 C N C N O NOTE 1 Red link to be removed when external roomstat is used 2 Plug C W link to be removed when cl...

Page 43: ...in injector assembly E26740 3 203433 Pilot burner 379485 4 202627 Spark electrode 278131 5 203518 Pilot injector 381656 6 202435 Thermocouple 378204 7 801183 Boiler overheat cut off assembly E27356 8 202529 Domestic hot water limit control 9 202712 Piezo unit E26688 10 204546 Pressure gauge assembly E26683 11 227067 Control board inc 16 17 12 202810 Transformer E26700 13 801169 Gas Control valve a...

Page 44: ... Tel 0161 620 6677 44 221679H Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions Diagram 15 1 7267 15 Spare Parts 1 13 7 2 11 12 10 20 3 5 4 6 8 15 19 22 18 9 16 17 21 14 ...

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