Glow-worm Space Saver K.F.B 60 Installation And Servicing Instructions
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Glow-worm Space Saver K.F.B 60 Installation And Servicing Instructions

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Installation and Servicing Instructions
S P A C E S A V E R
K . F . B
60
GC 41 319 11
70
GC 41 319 12
Fanned Flue
Boiler
Fully Pumped system.
Open Vented or Sealed.
One Contact Local Service
Supplied By www.heating spares.co Tel. 0161 620 6677
To be left with user
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
This is a Cat I
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
220692C.01.98.
Appliance
2H
BS 6332
BS 5258

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  • Page 1 220692C.01.98. Installation and Servicing Instructions To be left with user S P A C E S A V E R K . F . B GC 41 319 11 GC 41 319 12 Fanned Flue Boiler Fully Pumped system. This is a Cat I Appliance Open Vented or Sealed.

  • Page 2: Table Of Contents

    Contents Location Map Section Title Page No GENERAL ....... 3 WATER SYSTEMS ....7 BOILER LOCATION ....11 FLUE and VENTILATION ..13 FLUE INSTALLATION ..... 15 A6 MATLOCK B6013 RIPLEY INSTALLATION ....... 21 A519 ASHBOURNE BELPER COMPLETION Nottingham Rd and COMMISSIONING ...

  • Page 3: General

    General The instructions consist of two parts, Installation and Servicing Instructions and Instructions for Use, which includes the Guarantee Registration Card. The instructions are an integral part of the WATER CONNECTIONS appliance and must, to comply with the 28mm COMPRESSIONS current issue of the Gas Safety GAS CONNECTION (Installations and Use) Regulations,be...
  • Page 4 General The Gas Safety (Installation and Use) Regulations, The Building Regulations, The Building Standards (Scotland) Regulations, (applicable in Scotland) Local Water Company Bye-laws, Health and Safety at Work Act, Control of Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations.
  • Page 5 Fuse to BS4265 sheet 2. Type F1A Data Label Position Fuse Rating Power rating * Note: The weight of the water is negligible Space Saver K.F.B 60 G.C. Number 41 319 11 Space Saver K.F.B 70 G.C. Number 41 319 12 220692C...

  • Page 6: Gas Supply

    General Gas Supply The gas installation shall be in accordance with the current issue of BS6891. The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion test the gas installation for soundness using the pressure drop method and suitable leak detection fluid, purge in accordance with the above...

  • Page 7: Water Systems

    The flow through the boiler must not be allowed to fall below..Space Saver K.F.B 60 - 12.6 litres/min (2.8 galls/min) Space Saver K.F.B 70 - 14.76 litres/min (3.2 galls/min) Where the water system can allow the boiler and pump to operate on bypass only, the bypass must be at least 2.0metres away from the boiler.

  • Page 8: Domestic Hot Water Cylinder

    Water Sysems (Open Vented) Open (Vented) Water Open (vented) system. System Recommended relationship between pump, cold feed and For an open (vented) system the boiler vent. must be supplied from an unrestricted UNRESTRICTED 450mm water supply taken from a feed and CONTINUOUSLY MIN.

  • Page 9: Sealed Water Systems

    Water Systems (Sealed) Sealed Water Systems The installation must comply with the 3 LITRES (0.66 gal) appropriate requirements of the current MAKE-UP BOTTLE (if required) issue of BS5449, BS6798, BS4814 and RELEASE POINT BS7074 Part 1 and 2. AUTO VENT NON- See the diagrammatic layout.

  • Page 10: Pressure Gauge

    Water Systems (Sealed) Pressure Gauge 0051M METHOD 1 COMBINED A pressure gauge with a set pointer and CHECK VALVE HEATING TEMPORARY AND VACUUM SYSTEM covering at least 0 to 4bar (0 to 60lb in HOSE BREAKER shall be fitted permanently to the system in a position where it can be seen when filling the system.

  • Page 11: Boiler Location

    Boiler Location The boiler may be installed in any room although particular attention is drawn to 70mm the requirements of the current issue of BS7671 with respect to the installation of a boiler in a room containing a bath or shower. Any electrical switch or boiler control using mains electricity 10mm should be so situated that it cannot be...

  • Page 12: Boiler

    Boiler Location Timber Frame If the boiler is to be installed in a timber frame building, it should be fitted in accordance with the Buildings British Gas Publication “Guide for Gas Installation in Timber Framed Housing” reference DM2. If in doubt, seek advice from the local gas undertaking or Hepworth Heating Ltd.

  • Page 13: Flue And Ventilation

    Flue and Ventilation The flue must be installed in accordance with the current issue of BS5440 Part 1. The boiler must be installed so that the terminal is exposed to the external air. It is important that the position of the terminal allows the free passage of air across it at all times.

  • Page 14: Boiler

    Flue and Ventilation Flue Position and Length Note. If a longer flue duct is required DO NOT extend the ducting. A special long flue system and terminal can be supplied and MUST be used. DETERMINE FLUE APPLICATION, LENGTH, AND TERMINAL POSITION BEFORE PROCEEDING.

  • Page 15: Flue Installation

    Flue Installation Rear Flue Application s t e p Having selected the boiler location with due regard to the terminal WALLPLATE/ position; TEMPLATE Using an adhesive tape temporarily position the wallplate/template on the wall. Mark out the centre and cut the hole for the flue using, preferably, a 115mm minimum core drill.
  • Page 16 Flue Installation Flue Duct (Standard s t e p or Long) Mark the duct to the length “Q”+11mm then cut square and remove any burrs. Q+11mm Air Duct/Terminal s t e p (Standard or Long) Mark the duct to the length “Q”+13mm then cut square and remove any burrs.

  • Page 17: Boiler

    Flue Installation Side Flue Application s t e p Having selected the boiler location, with due regard to boiler clearances and the terminal position. No. 10x1 WALLPLUG SCREW Position the wallplate/template on the wall. Mark the top and bottom boiler mounting hole positions.
  • Page 18 Flue Installation Flue Duct s t e p (Standard or Long) Mark the duct to length “S”+11mm then cut square and remove any burrs. S+11mm WALLPLATE /TEMPLATE STANDARD 1METRE AND 2 METRE FLUE TERMINAL KFB 70 ONLY. 1 METRE AND 2 METRE FLUE TERMINAL KFB 60 ONLY s t e p Terminal/Air Duct...
  • Page 19 Flue Installation s t e p Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/ terminal. FLUE DUCT AIR DUCT/TERMINAL ASSEMBLY s t e p Place the sealant from the loose items pack onto the flue manifold. Fully locate the flue manifold into the SEALANT air duct/terminal and flue duct...

  • Page 20: Boiler

    Flue Installation s t e p Wall Thickness up to FOAM SEAL 300mm Fit the self adhesive foam seal provided in the loose items pack around the air duct/terminal at the position shown. 10mm FOAM SEAL s t e p Wall Thickness over 300mm Fix the self adhesive foam seal around...

  • Page 21: Installation

    Installation s t e p Boiler Preparation FRONT Remove the front panel and place it PANEL on one side until required. Remove and discard internal packing piece. s t e p Remove the inner case by releasing the screws at the bottom and unhooking at the top, place on one side until required.

  • Page 22: Boiler

    Installation s t e p Rear Flue Boiler Installation MOUNTING THE BOILER IS SUPPLIED FOR BRACKET REAR FLUE OUTLET. Note: To reduce the total lifting weight remove the electrical control box and combustion chamber assembly by following the instructions in Section 6, step 18 and Section 10, steps 3,5,6,7,8 and 9.
  • Page 23 Installation s t e p Fit fan/fluehood assembly by engaging the fan outlet extension over the flue manifold spigot. FLUE MANIFOLD SPIGOT OUTLET EXTENTION Secure the fluehood assembly to the heat exchanger with the screws previously removed. s t e p If removed, refit the control box/ combustion chamber by reversing the instructions in Section 6, step 18 and...

  • Page 24: Boiler

    Installation s t e p Side Flue Boiler Installation Remove the appropriate blanking plate on the casing and fit it to the rear flue outlet. GASKET REAR VIEW BLANKING PLATE FAN REAR s t e p Remove the fan assembly from the OUTLET EXTENTION fluehood assembly, by removing the...

  • Page 25: Boiler

    Installation s t e p Note: To reduce the total lifting weight remove the electrical control box and combustion chamber assembly by following the instructions RIGHT HAND in Section 6, step 18 and Section 10, FLUE HOOD ASSEMBLY steps 3,5,6,7,8 and 9. Lift the boiler into position above the FAN SIDE top mounting bracket, allow the boiler...

  • Page 26: Boiler

    Installation s t e p Secure the flue assembly to the boiler, using the previously fitted dogpoint screws noting that these are keyhole fixings. Take the beige/grey sealant from the loose items pack and place firmly around the internal spigot of the flue manifold.

  • Page 27: Boiler

    Installation UNION s t e p Water System Connection OLIVE Connect the boiler to the water system using the fittings provided in the loose items pack. The flow connection is on the right. FLOW RETURN ELECTRICAL CONTROL BOX COVER s t e p Gas Supply Connection SECURING...

  • Page 28: Boiler

    Installation Electrical Connection The electrical installation must comply with the current issue of BS7671 and any local regulations which apply. and System Controls All controls and connections must be of the approved type. PUMP STRAIN RELIEF GLAND s t e p Cable Connection The boiler must be earthed.

  • Page 29: Completion And Commissioning

    Completion and Commissioning System Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Commissioning - All Make sure that the system has been thoroughly flushed Systems out with cold water without the pump in place. Refit the pump, fill the system with water, making sure that all air is properly vented from the system and pump.

  • Page 30: Boiler

    Completion and Commissioning BOILER THERMOSTAT CONTROL KNOB Initial Lighting and (Shown in the OFF position) Testing and Adjustment Refit the inner case, by hooking it over at the top and securing with the screws previously removed, at the bottom. Make sure that the case is correctly fitted and sealed.

  • Page 31: Boiler

    Completion and Commissioning Testing - Electrical Checks to ensure electrical safety should be carried out by a competent person. In the event of an electrical fault after installation of the system, preliminary electrical system checks as below should be carried out. 1.

  • Page 32: Boiler

    MAIN BURNER gas burning appliances and pilot lights are ADJUSTMENT SCREW (8mm off. ACROSS FLATS) Space Saver K.F.B 60 Approx. Gas Rate med max 1.95 Space Saver K.F.B 70 Approx. Gas Rate med max The gas rates are for guidance only, dependent on the heat setting.

  • Page 33: Boiler

    Completion and Commissioning Heating System Check that all remote controls are working as required. Allow the system to reach maximum working temperature and examine for water leaks. The boiler should then be turned off and the system drained off as rapidly as possible whilst still hot. Refill the system, vent and again check for water soundness.

  • Page 34: Front Panel Assembly

    Front Panel Assembly = 285 to 315mm s t e p Note. The front panel assembly has been designed with a variable adjustment to suit a range of available kitchen furniture, 700mm-728mm high by 285mm-315mm deep and will also suit installations in a cupboard. = 700 to 728mm It is delivered preset to 700mm high by 285mm deep.

  • Page 35: User Information

    Front Panel Assembly s t e p Locate the front panel assembly. s t e p Engage the bottom front panel assembly slide/catch and adjust as ADJUSTMENT necessary. SCREW SLIDE ASSEMBLY CATCH User Information User Information Instruct and demonstrate the efficient and safe operation of the boiler, heating system and if fitted, the domestic hot water system.

  • Page 36: Servicing

    Servicing To ensure the continued efficient and s t e p safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing FRONT PANEL will depend upon the particular installation conditions and usage, but in general once a year should be enough.
  • Page 37 Servicing Cleaning the Heat s t e p Exchanger Slacken the flue hood by loosening the extended brass screws at the left and right hand sides. FAN/FLUE HOOD SCREW (2) s t e p Remove the split pin and thermostat phials from the pocket, taking care not to kink the capillaries.
  • Page 38 Servicing FAN ELECTRICAL s t e p CONNECTIONS Disconnect the gas service cock at the union connection. AIR PRESSURE Disconnect the electrical connection PIPE UNION plug by pulling it out from the right hand side of the control box. CLIPS Remove the violet and red electrical connections on the fan and cable from SECURING...

  • Page 39: Main Burner

    Servicing s t e p The heat exchanger can now be cleaned with a suitably sized semi- 50mm stiff brush, using the cleaning plate, as shown to protect the rear insulation panel. DO NOT USE A BRUSH WITH METALLIC BRISTLES. Remove the paper and debris from the combustion chamber.
  • Page 40 Servicing PILOT TUBING NUT s t e p Pilot Burner, Ignition PILOT IGNITION Electrode and Pilot LEAD BURNER ASSEMBLY Injector SECURING SCREW (2) Pull off the ignition lead at the electrode (covered with a silicone SILICONE rubber sleeve). RUBBER SLEEVE Unscrew the tubing nuts at both ends releasing the pilot pipe.

  • Page 41: Fault Finding

    Fault Finding Electrical bk BLACK w WHITE br BROWN Important. On completion of the BLUE YELLOW service/fault finding task which has VIOLET PURPLE required the breaking and remaking of the electrical connections the earth continuity, polarity, short circuit and resistance to earth checks must be THERMOSTAT PUMP repeated using a suitable multimeter.
  • Page 42 Fault Finding KEY: - BLUE - PURPLE - BLACK - VIOLET - BROWN - WHITE - RED - YELLOW g/y - GREEN/YELLOW - MAIN TERMINAL STRIP - CONTROL THERMOSTAT - AIR PRESSURE SWITCH NUMBER = BECK LETTER = YAMATAKE OVERHEAT CONTROL CUT-OFF THERMOSTAT...
  • Page 43 Fault Finding Neon Indicators - An Aid to Fault Finding THE NEON INDICATORS ARE AN AID TO FAULT FINDING ONLY. FAILURE OF ANY OF THE NEON INDICATORS DOES NOT WARRANT THE REPLACEMENT OF AN OTHERWISE SATISFACTORY PRINTED CIRCUIT BOARD (PCB) Is neon 1 lit? Fault with mains supply or PCB fuse.

  • Page 44: Boiler

    Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.

  • Page 45: Boiler

    Fault Finding Pump overrun Operation The Control Thermostat has a pump overrun facility built into it, when the Control Thermostat is set at maximum only, the pump overrun will keep the pump running to allow the boiler to cool down after which it will stop, providing the remote controls are NOT calling for heat.

  • Page 46: Replacement Of Parts

    Replacement of Parts Replacement of parts must only be carried out by a competent person. BEFORE REPLACING ANY PARTS ISOLATE THE BOILER FROM THE ELECTRICAL SUPPLY AND TURN THE GAS SUPPLY OFF AT THE GAS COCK INDICATOR SLOT TO BE VERTICAL. Unless stated otherwise, all parts are replaced in the reverse order to removal.
  • Page 47 Replacement of Parts Control Thermostat CONTROL KNOB and Overheat Cutoff Gain access as Section 10, steps 1 to 5. Control Thermostat: SECURING Pull off the control thermostat knob, SCREW(2) WIRING remove the two screws securing the DIAGRAM thermostat to the control box. YELLOW Remove the electrical connections from PURPLE...

  • Page 48: Air Pressure Switch

    Replacement of Parts SECURING RED AIR SCREW (2) PRESSURE TUBE Air Pressure Switch Note: Alternative types of Air Pressure Switches may be fitted. Gain access as Section 10 steps 1 to 4. Remove the air pressure tubes and electrical connections, release the screws and nuts, remove the switch.

  • Page 49: Main Burner Injector

    Replacement of Parts s t e p ELECTRICAL Gain access as Section 10, steps 1, 2 CONNECTIONS and 5. Remove the electrical connections and disconnect the air tubes. Remove the fluehood/fan assembly screws and withdraw the assembly. EARTH CONNECTION Turn the flue hood over and release the two securing screws as shown.
  • Page 50 Replacement of Parts Insulation Gain access as Section 10, steps 1 to COMBUSTION CHAMBER SECURING SIDE SCREW (2) Combustion Chamber s t e p Sides and Rear: BAFFLE Remove the baffles. Remove the insulation and fit the replacement parts making sure they are fitted as shown.

  • Page 51: Spares

    If ordering from the local gas undertaking also quote the GC number of the appliance and part. Glow-worm Description GC No. Part No 800165 Gas valve assembly, inc item11...
  • Page 52 Because of our constant endeavour for improvement details may vary slightly from those given in these instructions. 220692C Supplied By www.heating spares.co Tel. 0161 620 6677...

This manual is also suitable for:

Space saver k.f.b 70

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