Glow Worm Compact 60 boiler leak created whilst fitting a Magnatec

[SMP1]

I'm a fairly proficient DIYer and was fitting a ADEY Magnatec to my daughters central heating system, connecting it to the return flow beneath the boiler (recommended as the ideal position in the instructions).
In order to install I needed to slightly modify the pipework to allow sufficient space, so disconnected the return flow pipe from the boiler "water service stopcock" (as described in the parts list found online). I also disconnected the "water service stopcock" from the boilers "pressure relief connector" which is a plastic pipe, so I could clean it up as it was a bit mucky and possibly weeping very slightly, however I'm now struggling to reconnect this to achieve a watertight fit.

Looking at the parts in the online schematic, it show that there is just the nut and a washer to join the two together, I thought maybe I'd dropped and lost a bit. Unlike a compression fitting where the olive helps obtain a nice tight fit, I don't quite see how the nut and washer achieve the same, as there is only a very very minor lip on the end of the pipe, which you can just feel with a finger nail. The "water service stopcock" is held in place by a spring clip against the casing framework but then tightening the nut, with the washer inserted, is very difficult to slide onto the plastic pipe due to very limited space. I've connected it a few times and it fails to achieve a tight fit.

Has anyone any experience of fitting these and know what I might be doing wrong. The washer is slightly compressed after use but not actually damaged. I've also found all parts available online as spares, but am not sure whether I would still have the same issues with new parts.

I've attached some photo's, showing the water service stopcock, nut and washer. The area beneath the boiler where it fits and another pic showing the same connection for the central heating outflow. I've also shown an image from the schematic and the spare part image for the pressure relief connector.

Any advice would be much appreciated, it seems such a silly issue to have?

Regards

Steve

 

[Riley]

It's not immediately obvious from your pictures but is it possible that you cross threaded the plastic part

 

[rpm]

Looking at the old rubber washer you can see the ridge in it, can you use the other side of this washer? And I would try cleaning the mating face that this seals against with wire wool, lastly what is the White and Blue stuff in picture 3?

 

[SMP1]

Riley thanks for responding. There is no thread on the plastic part, its just like a smooth tube apart from what feels like a very very slight ridge on the end of the pipe if you feel it with a finger nail.

 

[SMP1]

RPM I agree that there are ridges in the washer and can try what you've suggested but I'm not even sure the washer is mating against the end of the nut when tightened. It feels like it is getting caught on the thread and twisting on its side when tightened, its such a confined space there is no easy way to slide the nut and washer smoothly onto the pipe.

 

[SMP1]

I also meant to say that the white stuff in picture 3 is like a build up of hard water scale, picture 3 is the other main ch feed from the boiler. The reason i removed the stopcock connector was that it was also coated in white and i wanted to clean it up. I think the blue your referring to if the nut maybe the result of the flash light.

 

[rpm]

Thinking the compression on the washer may have caused it to expand the outside diameter hence the problem you describe so time for a new washer at the very least.

 

[snowhead]

I would have expected to see a flat collar as part of the end of the plastic elbow and that the nut shouldn't pull off.

I suspect it's either disintegrated or been missing from when originally installed, hence the leak.

There's no way a washer is going to seal against the plain end of a pipe.

That part has been revised it's this now, different material;

https://www.dhsspares.co.uk/product/glowworm-2000801209-prv-connect-pipe-comp-e-1330869

 

[thereisawizza]

I would have expected to see a flat collar as part of the end of the plastic elbow.
I suspect it's either disintegrated or been missing from when originally installed, hence the leak.

There's no way a washer is going to seal against the plain end of a pipe

Yup, mullered. I think this is one of the Glow-Worms that is mostly Saunier Duval. Also, this is actually a boiler component technically......

 

[SMP1]

I would have expected to see a flat collar as part of the end of the plastic elbow and that the nut shouldn't pull off.

I suspect it's either disintegrated or been missing from when originally installed, hence the leak.

There's no way a washer is going to seal against the plain end of a pipe.

That part has been revised it's this now, different material;

https://www.dhsspares.co.uk/product/glowworm-2000801209-prv-connect-pipe-comp-e-1330869

Snowhead many thanks for the response and the link. Its interesting that the picture in your link shows what looks like a replacement part that is now metal and I assume that the nut is included and holds firm against some sort of collar, which would resolve the issue. Funnily enough image 5 that I supplied was the revised part number but the site I obtained it from still showed a picture of the old part. The fact its been replaced seems to indicate that this may have been a problem in the past.

I feel more confident ordering the replacement part and that it will resolve the issue, its probably worth replacing the part for both feeds as the other one is also covered in scale no doubt due to some minor leakage.

Once again many thanks.

 

[rpm]

There's no way a washer is going to seal against the plain end of a pipe.

That part has been revised it's this now, different material;

https://www.dhsspares.co.uk/product/glowworm-2000801209-prv-connect-pipe-comp-e-1330869

Would expect a washer against a flat face and a male spigot that went inside another part then the nut caused the compression (ie iso valve on cistern fill valve stem), this might explain the mark shown on the rubber washer in photo1.

For £14 just buy new and start again.

 

[SMP1]

Would expect a washer against a flat face and a male spigot that went inside another part then the nut caused the compression (ie iso valve on cistern fill valve stem), this might explain the mark shown on the rubber washer in photo1.

For £14 just buy new and start again.

rmp I will buy the new parts, as you say its not worth messing around. I will phone the supplier on Monday and check on the parts to ensure whats its made of. I think the washer is a separate part and the o ring shown in the part picture is for the other end.

Many thanks for everyones input, hopefully I will get the parts by Tuesday or Wednesday and can fully resolve and then close the post.