glowworm space saver kfb 60 and 70 installation and ...€¦ · installation and servicing...

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

Hepworth Heating Ltd.,Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:Tel: (01773) 824141 Fax: (01773) 820569One Contact Local Service

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

This is a Cat I2H ApplianceBS 6332BS 5258

Fully Pumped system.Open Vented or Sealed.

Fanned FlueBoiler

4757

S P A C E S A V E R

K . F . B60 GC 41 319 11

70 GC 41 319 12

220692C.01.98.

To be left with user

Installation and Servicing Instructions


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GENERAL ............................... 3

WATER SYSTEMS .................. 7

BOILER LOCATION ................ 11

FLUE and VENTILATION ........ 13

FLUE INSTALLATION ............. 15

INSTALLATION ....................... 21

COMPLETIONand COMMISSIONING ........... 29

FRONT PANELASSEMBLY ............................ 34

USER INFORMATION ............ 35

SERVICING ............................ 36

FAULT FINDING ..................... 41

REPLACEMENTOF PARTS .............................. 46

SPARES ................................. 51

Contents Location Map

1

2

3

4

5

6

7

8

9

10

11

12

13

Information for the Installer and Service Engineer

Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.

The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

Insulation and Seals

Ceramic fibre and glass fibre used in insulation panels, rope and gaskets.

These can cause irritation to skin, eyes and the respiratory tract.

If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken.

Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to thelavatory.

If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.

Thermostat

This contains a very small amount of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does notcause a problem, but in cases of skin contact, wash with cold water.

If swallowed drink plenty of water and seek medical attention.

Cut-Off Devices

These contain activated charcoal and a very small amount of chlorodifluormethane in the sealed phial and capillary.If broken, under normal circumstances the fluid does not cause a problem.

If there is irritation to the eyes or skin then seek medical attention.

Control of Substances Hazardous to Health

BELPER

MilfordSite

A6 DERBY

MILFORD

A6 MATLOCK

A519 ASHBOURNE

B6013 RIPLEY

A609 NOTTINGHAM

Nottingham RdSite N

Belper and MilfordFactory Sites

Belper

2890


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General 1

3060

The instructions consist of two parts,Installation and Servicing Instructionsand Instructions for Use, which includesthe Guarantee Registration Card. Theinstructions are an integral part of theappliance and must, to comply with thecurrent issue of the Gas Safety(Installations and Use) Regulations,behanded to the user on completion ofthe installation.

Important NoticesThis boiler is for use on natural gas(G20) as distributed in the UnitedKingdom and cannot be used on anyother gas.

Wherever possible, all materials,appliances and components to be usedshall comply with the requirements ofapplicable British Standards.

Where no British Standard exists,materials and equipment should be fit fortheir purpose and of suitable quality andworkmanship.

This boiler must have fully pumpedcircuits, but is suitable for use with openvented or sealed water systems.

This boiler is not suitable for outdoorlocations.

Sheet Metal PartsWARNING. When installing orservicing the boiler care should be takenwhen handling sheet metal parts to avoidany possibility of personal injury.

StatutoryRequirementsThe installation of the boiler MUST becarried out by a competent person inaccordance with the relevantrequirements of the current issue of:

Manufacturer’s instructions supplied.

55

70 35

R F

WATER CONNECTIONS28mm COMPRESSIONS

GAS CONNECTIONRc1/

2(1/

2"B.S.P.T.)

TOP VIEW

450

40

285-315

SIDEFLUEOUTLET

130700-728

125458

FRONT VIEW

445

155

125

SIDE VIEW

REARFLUEOUTLET 687

50

15

FRONT VIEWBOILER OUTLINE

102

63

FLUETERMINALDETAIL

ALL DIMENSIONS ARE IN MILLIMETRES


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General1 The Gas Safety (Installation and Use)Regulations, The Building Regulations,The Building Standards (Scotland)Regulations, (applicable in Scotland)Local Water Company Bye-laws, Healthand Safety at Work Act, Control ofSubstances Hazardous to Health, TheElectricity at Work Regulations and anyapplicable local regulations.

Detailed recommendations arecontained in the current issue of thefollowing British Standards and Codesof Practice, BS6798, BS5440 Part 1 and2, BS6700, BS5449, BS6891, BS4814,BS7074 Part 1 and 2, BS5446, BS7478,BS7593, BS7671.

Manufacturer’s notes must not be takenas overriding statutory requirements.

B.S.I. CertificationThe boiler is certificated to the currentissue of BS6332 Part 1, invoking thecurrent issue of BS5258 Part 1 forperformance and safety. It is, therefore,important that no alteration is made tothe boiler without permission, inwriting, from Hepworth Heating Ltd.

Any alteration that is not approved byHepworth Heating Ltd., could invalidatethe B.S.I. Certification of the boiler, thewarranty and could also infringe thecurrent issue of the StatutoryRequirements.

CE MarkThe CE Mark on this appliance showscompliance with Directive 90/396/EECon the approximation of the Laws of theMember States relating to appliancesburning gaseous fuels.

The CE Mark on this appliance showscompliance with Directive 73/23/EECon the harmonization of the Laws of theMember States relating to electricalequipment designed for use withincertain voltage limits.


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General 1

Range RatingThe boiler is range rated and may beadjusted to suit individual systemrequirements, refer to the relevantcolumn of the table.

Data Table

in wg 5.6 5.9

mbar 14.0 14.6

Btu/h 50000 60000

kW 14.66 17.59

in wg 4.9 5.2

mbar 12.2 13.0

in wg 4.2 4.6

mbar 10.6 11.4

Btu/h 60000 70000

kW 17.59 20.52

Btu/h 55000 65000

kW 16.12 19.05

Nominal min

Heat med

Input max(Gross)

Nominal min

Heat med

Ouput max

Burner min

Setting med

Pressure max

Space Saver Space SaverRange Rating K.F.B K.F.B

60 70

Btu/h 70064 84416

kW 20.54 24.74

Btu/h 75000 89709

kW 21.98 26.29

Btu/h 64935 78947

kW 19.03 23.14

Data Label Position

3038

Space Saver Space Saver

Model K.F.B K.F.B60 70

Lifting 32.4kg 32.4kgWeight (71.4lb) (71.4lb)

Total 46.1kg 46.1kgWeight (dry)* (101.6lb) (101.6lb)

Water 2.13 litres 2.13 litresContent (0.47 gal) (0.47 gal)

Gas Rc1/2 Rc1/2

Connection (1/2" BSPT) (1/2" BSPT)

Water 28mm 28mmConnection Compression Compression

Electrical 240V~50Hz fused 3A maxsupply

Internal Fuse to BS4265 sheet 2. Type F1AFuse Rating

Power rating 55W

* Note: The weight of the water is negligible

Space Saver K.F.B 70

G.C. Number 41 319 12

Space Saver K.F.B 60

G.C. Number 41 319 11


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General1

Gas Supply

Electrical Supply

Safety Valve

The gas installation shall be in accordance with thecurrent issue of BS6891.

The supply from the governed meter must be ofadequate size to provide a steady inlet workingpressure of 20mbar (8in wg) at the boiler.

On completion test the gas installation for soundnessusing the pressure drop method and suitable leakdetection fluid, purge in accordance with the abovestandard.

WARNING. THIS BOILER MUST BE EARTHED.

All system components shall be of an approved typeand shall be connected in accordance with the currentissue of BS7671 and any applicable local regulations.

Connection of the boiler and system controls to themains supply must be through a common isolator andmust be fused 3A maximum. The method ofconnection should be, preferably, an unswitchedshuttered socket outlet and 3 pin plug, both to thecurrent issue of BS1363.

Alternatively, a double pole isolating switch may beused, provided it has a minimum contact separationof 3mm in both poles. The isolator should be clearlymarked showing its purpose. See also Section 6,Electrical Connection and System Controls.

Wiring to the boiler must be to the current issue ofBS6500 Table 16, not less than 0.75mm2 (24/0.20mm).

The boiler is provided with a draining tap at thelower right hand side for draining the heat exchangerin the event of the boiler being out of use duringfreezing conditions.

A draining tap must also be provided at the lowestpoints of the system which will allow the entiresystem and hot water cylinder to be drained.

Draining taps shall be to the current issue of BS2879.

A safety valve need not be fitted to an open ventedsystem.

Draining Tap


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A BYPASS MUST BE FITTED, see also Section 7.

The flow through the boiler must not be allowed to fallbelow......

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 pumpto operate on bypass only, the bypass must be at least2.0metres away from the boiler.

If an inhibitor is to be used refer to the current issue ofBS5449 and BS7593, contact a manufacturer for theirrecommendations as to the best product to use.

When using in an existing system take special care todrain the entire system, including the radiators, thenthoroughly cleaning out before fitting the boiler whetheror not adding an inhibitor

2Water Systems

Bypass

Inhibitor

Notes: Open Ventedand Sealed WaterSystems

PumpSee chart for pressure drop of the boiler.

The pump should be fitted in the flowpipe from the boiler and have isolatingvalves each side, integral if possible.

The variable duty pump should be set togive a temperature difference of 11oC(20oF) between flow and return with thethermostat set at “MAX” which is about82oC (180oF).

High resistance microbore systems mayrequire a higher duty pump.

P R E S S U R E D R O P O F B O I L E RFlow rate (litres / minute)

Wat

er p

ress

ure

drop

(m

m h

ead

of w

ater

)

Wat

er p

ress

ure

drop

(in

ches

hea

d of

wat

er)

Flow rate (gallons / minute)0

0 5 10 15 20 25 30 350

200

400

600

800

1000

1200

1400

0

10

20

30

40

50

1 2 3 4 5 6 7

UNIT

litre / min.

gal / min.

19.1

4.2

22.9

5.0

22.9

5.0

26.7

60 70Min.

HEAT SETTING

At 11˚C (20˚F) differentialW A T E R F L O W R A T E

Max.60 70

5.9

4778


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Water Sysems (Open Vented)1

2886Open (vented) system.

Recommendedrelationship betweenpump, cold feed andvent.

UNRESTRICTEDCONTINUOUSLY22mm (MIN) VENT

FEED ANDEXPANSIONCISTERN

15mm (MINIMUM)UNRESTRICTEDCOLD FEED

22mm (MINIMUM)BY-PASS WITHLOCKSHIELD VALVE

450mmMIN.HEIGHT

1metre MIN.27.5metres MAX.

BOILER

PUMP

150mmMAX

FLOW

RET.

RE

T.

CY

LIN

DE

R

FLO

WH

EA

TIN

G

Open (Vented) WaterSystemFor an open (vented) system the boilermust be supplied from an unrestrictedwater supply taken from a feed andexpansion cistern situated at amaximum height of 27.5 metres (90ft)above the boiler.

The cold feed supply must be 15mmminimum size.

The vent must rise continuously and beunrestricted.

It is important that the relative positionsof the pump, cold feed and open ventare as shown.

Domestic Hot WaterCylinderThe hot water cylinder must be of thedouble feed fully indirect type. Not theself priming type.


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Water Systems (Sealed) 2

2888

Sealed Water SystemsThe installation must comply with theappropriate requirements of the currentissue of BS5449, BS6798, BS4814 andBS7074 Part 1 and 2.

See the diagrammatic layout.

Safety ValveA safety valve must be fitted to a sealedsystem.

It shall be preset, non-adjustable with alift pressure of 3bar, incorporatingseating of a resilient material, a testdevice and a connection for drain.

The drain from the safety valve must berouted clear of any electrical fittingsand positioned so that any discharge canbe seen.

Expansion Vessel A diaphragm type expansion vessel, conforming to thecurrent issue of BS4814 (see also BS7074 Part 1 and 2)must be connected at a point close to the inlet side of thecirculating pump, see the diagrammatic layout, unlesslaid down differently by the manufacturer.

The expansion vessel volume depends on the total watersystem volume and the initial system design pressure.For any system an accurate calculation of vessel size isgiven in the current issue of BS7074 Part 1.

Example: For an initial system design pressure of0.7bar, the minimum total vessel volume required is0.063xTotal System volume.

Note. A higher initial design pressure requires a largervolume expansion vessel.

Guidance on vessel sizing is also given in the currentissue of BS5449 and BS7074 Part 1.

The charge pressure must not be less than the static headof the system, that is, the height of the highest point ofthe system above the expansion vessel.

The water capacity of the boiler is given in the DataTable.

BOILER

3 LITRES (0.66 gal)MAKE-UP BOTTLE(if required)

NON-RETURNVALVE

AUTOAIRVENT

FLOW

22mm (min)BYPASS

WITHLOCKSHIELD

VALVE

RETURN

DRAINCOCK

SAFETYVALVE

(Make-upalternatives)

EXPANSIONVESSEL

PRESSUREGAUGE

CIRCULATINGPUMP

FILLING POINT

AIRRELEASEPOINT

HE

AT

ING

CIR

CU

IT


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Water Systems (Sealed)2

METHOD 1

METHOD 2

METHOD 3

SUPPLY STOPVALVESUPPLY

PIPE

HOSEUNIONS

SERVICINGVALVE

TEMPORARYHOSE

HEATINGSYSTEM

HEATINGSYSTEMTEMPORARY

HOSE

HOSEUNIONS

SERVICINGVALVE

SUPPLYPIPE

SUPPLY STOPVALVE

DOUBLE CHECKVALVE ASSEMBLY

HEATINGSYSTEMSERVICING

VALVE

SUPPLYSTOP VALVE

SUPPLYPIPE

HOSEUNIONS DOUBLE CHECK

VALVE ASSEMBLY

OVERFLOWCISTERN

COMBINEDCHECK VALVEAND VACUUMBREAKER

PRESSUREREDUCINGVALVE

0051M

Filling Sealed WaterSystemsProvision for filling the system at low levelmust be made. Three methods are shown in thediagram. There must be no permanentconnection to the mains water supply, eventhrough a non-return valve.

Pressure GaugeA pressure gauge with a set pointer andcovering at least 0 to 4bar (0 to 60lb in2)shall be fitted permanently to thesystem in a position where it can beseen when filling the system.

Domestic Hot WaterCylinderSINGLE FEED INDIRECTCYLINDERS ARE NOT SUITABLE

The hot water cylinder must be of theindirect coil type. It must be suitablefor working at a gauge pressure of0.35bar above the safety valve setting.

UNVENTEDWhere a storage system will not have avent to atmosphere the installation mustcomply with the Building Regulationsand the local Water Company bylaws,see also the current issue of BS5546and BS6700.

If fitting into an existing system thelocal authority must be informed.

Water Make UpProvision should be made for replacingwater loss from the system using afilling loop or a make up bottlemounted in a position higher than thetop point of the system, connectedthrough a non-return valve to the returnside of either the heating circuit or thehot water cylinder.

Alternatively, provision for make upcan be made by pre-pressurisation ofthe circuit.


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3Boiler Location

WHERE EXTERNAL ACCESS TO THEFLUE IS NOT PRACTICAL THEN

CLEARANCE MUST BE ADEQUATETO PERMIT INSTALLATION OFF THE

FLUE ASSEMBLY

✽

70mm

10mm 5mm

5mm

5mm

5mm10mm

100mm

2891

500mm

The boiler may be installed in any roomalthough particular attention is drawn tothe requirements of the current issue ofBS7671 with respect to the installationof a boiler in a room containing a bathor shower. Any electrical switch orboiler control using mains electricityshould be so situated that it cannot betouched by a person using the bath orshower. The electrical provisions of theBuilding Standards (Scotland) areapplicable to such installations inScotland.

The boiler must be mounted on a flatwall which is sufficiently robust to takeits complete weight, see Data Table.

Boiler ClearancesThe boiler must be positioned so that atleast the minimum operational andservicing spaces are as shown.


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Boiler Location2

Timber FrameBuildings

If the boiler is to be installed in a timber framebuilding, it should be fitted in accordance with theBritish Gas Publication “Guide for Gas Installationin Timber Framed Housing” reference DM2. If indoubt, seek advice from the local gas undertaking orHepworth Heating Ltd.

Cupboard orCompartmentVentilationWhere the boiler is fitted in a cupboardor compartment, permanent high andlow level ventilation must be provided.The ventilation areas required are givenin the Table.

Where the installation of the boiler willbe in an unusual location, specialprocedures are necessary, refer to thecurrent issue of BS6798 for guidance.

A compartment used to enclose theboiler must be designed andconstructed specifically for thispurpose.

An existing cupboard or compartmentmodified for the purpose may be used.Refer to the current issue of BS6798 forguidance.

The doorway opening should be ofsufficient size to allow for easy removalof the boiler.

S P A C E S A V E R K . F . B 6 0

VENTILATION HIGH LEVEL LOW LEVELREQUIREMENTS VENT AREA VENT AREA

FROM ROOMOR SPACE

FROMOUTSIDE

198cm 2 (30in2) 198cm2 (30in2)

99cm 2 (15in2) 99cm 2 (15in2)

S P A C E S A V E R K . F . B 7 0

VENTILATION HIGH LEVEL LOW LEVELREQUIREMENTS VENT AREA VENT AREA

FROM ROOMOR SPACE

FROMOUTSIDE

237cm2 (36in2) 237cm 2 (36in2)

119cm2 (18in2) 119cm2 (18in2)


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4Flue and Ventilation

A DIRECTLY BELOW AN OPENABLE WINDOW, AIR VENT, 300OR ANY OTHER VENTILATION OPENING

B BELOW GUTTER, DRAIN/SOIL PIPE 75

C BELOW EAVES 200

D BELOW A BALCONY OR CAR PORT 200

E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 75

F FROM INTERNAL OR EXTERNAL CORNERS 300

G ABOVE ADJACENT GROUND OR BALCONY LEVEL 300

H FROM A SURFACE FACING THE TERMINAL 600

I FACING TERMINALS 1200

J FROM OPENING (DOOR/WINDOW) 1200IN CARPORT INTO DWELLING

K VERTICAL FROM A TERMINAL 1500

L HORIZONTALLY FROM A TERMINAL 300

MIN.SPACING

(mm)

MINIMUM SITING DIMENSIONSFOR FLUE TERMINALS

A

A

FG E

A

G

G

G

B,C B,C

F FK

K

K

C

G

L L

Car Port etc.

H,I

JD

FK

0103

MThe flue must be installed in accordancewith the current issue of BS5440 Part 1.

The boiler must be installed so that theterminal is exposed to the external air.

It is important that the position of theterminal allows the free passage of airacross it at all times.

Terminal PositionThe minimum acceptable spacings fromthe terminal to obstructions andventilation openings are as shown in thediagram.

Where the terminal is fitted within600mm (24in) below plastic gutteringan aluminium shield 1500mm (5ft) longshould be fitted to the underside andimmediately beneath the guttering oreaves.

Where the terminal is fitted within450mm (18in) below eaves or paintedguttering an aluminium shield 750mm(2ft6in) long should be fitted to theunderside and immediately beneath theguttering or eaves.

Terminal ProtectionA terminal guard is required if personscould come into contact with theterminal or the terminal could besubject to damage.

If a terminal guard is required, it mustbe positioned to provide a minimum of50mm clearance from any part of theterminal and be central over theterminal.

A suitable terminal guard can be boughtfrom,

Tower Flue Components Ltd.,Morley Road,Tonbridge,Kent.TN9 1RAtheir reference K3.

4783


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t o

Flue and Ventilation2

t o

s t e p

5s t e p

1

s t e ps t e p

1611

&

t o

s t e p

16s t e p

6

REAR FLUE APPLICATION

FOLLOW

FLUE INSTALLATION

SIDE FLUE APPLICATION

FOLLOW

FLUE INSTALLATION

Flue Position andLengthNote. If a longer flue duct is requiredDO NOT extend the ducting. A speciallong flue system and terminal can besupplied and MUST be used.

DETERMINE FLUE APPLICATION,LENGTH, AND TERMINALPOSITION BEFORE PROCEEDING.

Refer to the relevant diagrams inSection 4.

For wall thickness of less than 300mmthe boiler can be fully installed frominside.

For a wall thickness of over 300mm thecut hole will need to be made goodfrom the outside.

The rear and side flue assemblies aredesigned for internal installation, butshould it be necessary due toinsufficient clearances or boilerlocation they can be installed from theoutside.

Rear Flue LengthsDistance 'R'

STD 75mm to 692mm1m 692mm to 1022mm2m 1022mm to 2022mm

R

2877

Side Flue LengthsDistance 'S'

STD 75mm to 692mm1m 692mm to 1022mm2m 1022mm to 2022mm

S

2876


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s t e p

5Flue Installation

s t e p

1

s t e p

3

5.5mm DRILL SIZE

No. 10x11/2inSCREW

WALLPLUG

300mm MAXLENGTH

QQ

115mmMINIMUMHOLE

WALLPLATE/TEMPLATE

2892

2If the wall thickness “Q” is less than300mm cut the wall sleeve to therequired length.

Fit the wall sleeve.

Make good around the wall sleeve atboth internal and external wall faces(through the wall sleeve if internalaccess only is available).

If the wall thickness “Q” is greater than300mm the wall sleeve must be fittedflush with the INSIDE wall face. If theinner end of the sleeve sticks out into acavity then, if desired, the wall sleevecan be trimmed back to the depth of theinner skin of the brickwork. Make goodat the internal wall face, leave theexternal wall face until later.

Rear Flue ApplicationHaving selected the boiler locationwith due regard to the terminalposition;

Using an adhesive tape temporarilyposition the wallplate/template on thewall.

Mark out the centre and cut the hole forthe flue using, preferably, a 115mmminimum core drill.

Reposition the wallplate/templateensuring alignment with the flue hole.Mark the top and bottom boilermounting hole positions.

Remove wallplate/template, drill holesand then secure wallplate/template to thewall with the fittings provided in theloose items pack.


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Flue Installation5

Q

Q+13mm

STANDARDFLUE TERMINAL

1m 2m FLUETERMINAL

Q

Q+11mm

2893

s t e p

s t e p

4

5

s t e p

11

Continue at

Flue Duct (Standardor Long)Mark the duct to the length“Q”+11mm then cut square andremove any burrs.

Air Duct/Terminal(Standard or Long)Mark the duct to the length “Q”+13mmthen cut square and remove any burrs.

STANDARD, 1 METRE AND 2 METRE FLUETERMINAL KFB 70 ONLY.1 METRE AND 2 METRE FLUE TERMINALKFB 60 ONLY


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5Flue Installation

300mm MAXLENGTH

5.5mm DRILL SIZE

No. 10x11/2inSCREW

WALLPLUG

115mmMINIMUMHOLE

125mm

QQ

2894

s t e p

s t e p

6

s t e p

8

7

Side Flue ApplicationHaving selected the boiler location,with due regard to boiler clearancesand the terminal position.

Position the wallplate/template on thewall. Mark the top and bottom boilermounting hole positions.

Remove the wallplate/template, drillthe holes and then secure the wallplate/template with the fittings provided.

Mark and extend the flue horizontalcentre line to the corner of theadjacent surface.

Mark out and cut the hole for the flueusing, preferably, a 115mm minimumcore drill.

If the wall thickness “Q” is less than300mm cut the wall sleeve to therequired length.

Fit the wall sleeve.

Make good around the wall sleeve atboth the internal and external wallfaces (through the wall sleeve ifinternal access only is available).

If the wall thickness “Q” is greater than300mm the wall sleeve must be fittedflush with the internal wall face.

Make good at the internal wall face,leave the external wall face until later.

If the inner end of the sleeve sticks outinto the cavity then, if desired, the wallsleeve can be trimmed back to the depthof the inner skin of the brickwork.


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Flue Installation5

s t e p

9

2895

s t e p

10

S+11mm

S

S+13mm

WALLPLATE/TEMPLATE

WALLPLATE/TEMPLATE

Flue Duct(Standard or Long)Mark the duct to length “S”+11mmthen cut square and remove any burrs.

Terminal/Air Duct(Standard or Long)Mark the duct to the length “S”+13mmthen cut square and remove any burrs.

STANDARDFLUE TERMINALKFB 60

S

STANDARD 1METRE AND 2 METRE FLUETERMINAL KFB 70 ONLY.1 METRE AND 2 METRE FLUE TERMINALKFB 60 ONLY

1m 2m FLUETERMINAL


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5Flue Installation

s t e p

s t e p

11

12

s t e p

133mm DRILL SIZE

2896

AIR DUCT/TERMINALASSEMBLY

FLUEDUCT

SEALANT

AIR DUCT/TERMINALAND FLUE DUCTASSEMBLY

FLUE MANIFOLD

5mm

Air Duct/Terminal andFlue Duct AssemblyLocate the flue duct into the air duct/terminal.

Place the sealant from the loose itemspack onto the flue manifold.

Fully locate the flue manifold into theair duct/terminal and flue ductassembly as shown, ensuring correctalignment of the “TOP”s.

Drill two 3mm diameter holes throughthe air duct/terminal and flue manifold.

Secure the air duct/terminal to the fluemanifold with the two self tapping screwssupplied in the loose items pack.

It should now not be possible to removethe manifold.


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Flue Installation5

s t e p

14

3039

s t e p

16

s t e p

15

Wall Thickness up to300mmFit the self adhesive foam seal providedin the loose items pack around the airduct/terminal at the position shown.

Wall Thickness over300mmFix the self adhesive foam seal aroundthe air duct/terminal such that, wheninstalled, the seal will be within thewall sleeve.

If the boiler is not to be fitted forsometime cover the hole in the wall.

On all installations push the flueassembly into and through the wallsleeve and hole such that it is withinthe wall sleeve and does not stick outinto the room. Do not push the flueassembly too far into the hole as it hasto be pulled back into the boiler andsecured to the keyhole fixings.

Note: That the foam seal is a tight fit inthe wall sleeve, so either the wallsleeve will need to be rigidly fixed inthe wall, that is, the cement has fullyset or it can be held from the other sidewhilst inserting the flue assembly.

FOAM SEAL

Q-25mm

FOAM SEAL

10mm

Q

Q

WALLSLEEVE


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6 Installation

s t e p

s t e p

1

2

3040

s t e p

4s t e p

8s t e p

17s t e p

21

s t e p

9s t e p

21

t o t o&

t o

WHEN FITTING A REAR FLUE

FOLLOW STEPS

WHEN FITTING A SIDE FLUEFOLLOW STEPS

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3

FAN/FLUEHOODSCREW (2)

Boiler PreparationRemove the front panel and place iton one side until required.

Remove and discard internal packingpiece.

Remove the inner case by releasingthe screws at the bottom andunhooking at the top, place on oneside until required.

Remove the violet and red electricalconnections from the fan.

Break the air pressure switch tubesconnections.

Remove the fan/flue hood assembly byremoving the two screws one at each side.

FRONTPANEL

SCREW (3)

INNERCASE

CLEAR

RED

AIR PRESSURESWITCHTUBES

ELECTRICALCONNECTIONS

RESETBUTTON


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Installation6

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3041

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5

Rear Flue BoilerInstallationTHE BOILER IS SUPPLIED FORREAR FLUE OUTLET.

Note: To reduce the total lifting weightremove the electrical control box andcombustion chamber assembly byfollowing the instructions in Section 6,step 18 and Section 10, steps 3,5,6,7,8and 9.

Lift the boiler into position above thetop mounting bracket, allow the boilerto slide down the wall onto the top andbottom wall mounting brackets.

Check the engagement by pulling theboiler forward at its base, there shouldbe no forward movement.

When the boiler is correctly locatedsecure it with the two screws.

Secure the flue assembly to the boiler,using the previously fitted dogpointscrews noting that these are keyholefixings.

Make sure of the correct location of theflue to the boiler.

LOCATIONLUG

KEYHOLE

BOTTOMMOUNTINGBRACKET

TOPMOUNTINGBRACKET


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3042

7

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8

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17

Continue at

Fit fan/fluehood assembly byengaging the fan outlet extensionover the flue manifold spigot.

Secure the fluehood assembly to theheat exchanger with the screwspreviously removed.

If removed, refit the control box/combustion chamber by reversing theinstructions in Section 6, step 18 andSection 10, steps 3,5,6,7,8 and 9.

Reconnect the violet and red electricalconnections to the fan, the polarity ofthe connections is not important.

Reconnect the air pressure switch tubesas shown.

FLUEMANIFOLDSPIGOT

FANOUTLETEXTENTION

ELECTRICAL CONNECTIONS

AIRPRESSURESWITCHTUBES

RED

WHITERED


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3043

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11RIGHT HANDFLUE HOODASSEMBLY

Side Flue BoilerInstallationRemove the appropriate blanking plateon the casing and fit it to the rear flueoutlet.

Remove the fan assembly from thefluehood assembly, by removing thetwo screws.

Partially refit the securing screws intothe fan.

Turn the fan assembly to the requiredflue outlet direction.

Fit the flue hood over the partiallyfitted securing screws in the specialkey hole slot sandwiching the gasketsand spacer between, take care not todamage the gaskets.

Turn the flue hood in the directionshown.

Remove and discard the fan rearoutlet extension from the fan byreleasing the clip.

Fit the fan side outlet extension,supplied in the loose items pack.

Secure with the clip previouslyremoved.

REAR VIEW GASKET

BLANKINGPLATEFAN REAR

OUTLETEXTENTION

FAN SECURINGSCREW

FLUE HOODASSEMBLY

KEYHOLE SLOT

FAN SECURING SCREW (4)

GASKETSANDSPACER

GASKET

SPACER

GASKET


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6 Installation

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13

3044Note: To reduce the total lifting

weight remove the electrical controlbox and combustion chamberassembly by following the instructionsin Section 6, step 18 and Section 10,steps 3,5,6,7,8 and 9.

Lift the boiler into position above thetop mounting bracket, allow the boilerto slide down the wall onto the top andbottom wall mounting brackets.

Check the engagement by pulling theboiler forwards at its base, there shouldbe no forwards movement.

When the boiler is correctly locatedsecure it with the two screws.

RIGHT HANDFLUE HOODASSEMBLY

FAN SIDEOUTLETEXTENSION LEFT HAND

FLUE HOODASSEMBLY

THIS ENDTO FAN

TOPMOUNTINGBRACKET

BOTTOMMOUNTINGBRACKET


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3045

ELECTRICALCONNECTION(S)

Secure the flue assembly to the boiler,using the previously fitted dogpointscrews noting that these are keyholefixings.

Take the beige/grey sealant from theloose items pack and place firmlyaround the internal spigot of the fluemanifold.

Make sure of the correct location of theflue and boiler.

If removed, refit the control box/combustion chamber by reversing theinstructions in Section 6, step 18 andSection 10, steps 3,5,6,7,8 and 9.

Loosely fit one extended brassfluehood/fan assembly screw to theheat exchanger on the side that theflue exits. Slide the fluehood/fanassembly flange under this extendedbrass screw whilst turning the assemblyto enable engagement of the fan outletextension onto the flue manifold spigot.

After fitting the fan outlet extension tothe spigot smooth the sealant over thejoint.

When correctly located, secure theassembly by fitting the other extendedbrass screw and tighten both down.

Reconnect the violet and redelectrical connections to the fan, thepolarity of the connections is notimportant.

Reconnect the air pressure switchtubes.

BEIGE/GREYSEALANT

FANOUTLETEXTENTION

EXTENDED BRASSFLUE HOOD FANASSEMBLY SCREW

FLUE HOOD/FAN ASSEMBLY

AIR PRESSURESWITCH TUBES

FANOUTLETEXTENSION

FLUEMANIFOLDSPIGOT

CLEAR

RED


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6 Installation

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3046

Water SystemConnectionConnect the boiler to the water systemusing the fittings provided in the looseitems pack.

The flow connection is on the right.

Gas SupplyConnectionRemove the electrical controls boxcover.

Connect the gas supply to the gasservice cock on the boiler makingsure it is turned off.

Check for gas soundness up to thecock, in accordance with the currentissue of BS6891.

UNIONNUT

OLIVE

RETURN

FLOW

ELECTRICALCONTROLBOX COVER

SECURINGSCREW (4)

INDICATORSLOT(SHOWN OFF)


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Installation6

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21

240V ~ 50HzPERMANENTMAIN SUPPLYFUSED AT 3AMP

CIRCULATIONPUMP

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20

Electrical Connectionand System Controls

The electrical installation must comply with the currentissue of BS7671 and any local regulations which apply.

All controls and connections must be of the approved type.

Cable ConnectionThe boiler must be earthed.

The incoming cables should be routedfrom the right hand side of the boiler.

Remove the terminal connection plugas shown.

Connect the incoming supply andremote controls cables through therestraining glands.

The earth conductor must be of agreater length so that if the cable isstrained the earth is the last to becomedisconnected.

Test the insulation resistance of themains cable to earth.

Test for polarity of the mains cables.

Check earth continuity and short circuitof cables.

Replace the terminal connection plug.

Secure the cables in the plastic clips.

✻ Remove RED link between 7 and 12 (switch live)when fitting a time control etc.(if no switch is fittedthe pump will run continuously)..

✻ RED LINK

5

6

7

8

10

11

12

9

E

L

N

L

N

E

BROWN

BLUE

BROWN

BLUE

G/Y

G/Y

G/YSL

L

N

✻ RED LINK

LONGEREARTH LEADS

TERMINAL CONNECTIONPLUG MAINS AND REMOTECONTROLS WIRING

TERMINALPLUG CONNECTION

✻ RED LINK MAINS ANDSWITCH LIVESTRAIN RELIEFGLAND

PUMPSTRAINRELIEFGLAND

2905


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7Completion and Commissioning

Sealed WaterSystems Only

Flush the whole system without the pump in place.Refit the pump and fill the system until the pressuregauge registers 1.5bar (21.5lbf/in2). Clear any airlocksand check for water soundness.

Check the operation of the safety valve, by allowingthe water pressure to rise until the valve opens.The valve should open within +/-0.3bar (+/-4.3lbf/in2)of 3bar (42.6lbf/in2). Where this is not possibleconduct a manual check and test.

Release cold water to initial system design pressure.

The set pointer on the pressure gauge should be set tothe initial design pressure.

If air is present in the system, this may, in certaincircumstances, cause the overheat thermostat to trip. Ifthis occurs advise the user to operate the controlthermostat on a low setting until all air has beenexpelled.

SystemCommissioning - AllSystems

Commissioning should be carried out by a competentperson in accordance with the current issue of BS6798.Make sure that the system has been thoroughly flushedout with cold water without the pump in place. Refitthe pump, fill the system with water, making sure thatall air is properly vented from the system and pump.

Clear any airlocks and check for water soundness.


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Completion and Commissioning7

3047Initial Lighting and

Testing andAdjustmentRefit the inner case, by hooking it overat the top and securing with the screwspreviously removed, at the bottom.

Make sure that the case is correctlyfitted and sealed.

Identify the controls by reference to thediagram.

Check that the boiler is isolated fromthe electrical supply.

Make sure that the boiler thermostat isturned to the “Off” position.

Turn the gas service cock “On”, theindicator slot to be horizontal.

The pilot gas rate is preset and MUSTNOT be adjusted, see Servicing, Step15.

For future reference stick the selfadhesive arrow indicator from the looseitems pack, to the data label against therating that the boiler is going to be setto.

Loosen the main burner pressure testpoint screw and fit a suitable pressuregauge.

Make sure that any remote controls arecalling for heat.

Switch on or connect the electricalsupply to the boiler and heating system.

Warning. The gas valve and fanoperate on MAINS voltage, terminalswill become “LIVE”.

BOILER THERMOSTAT CONTROL KNOB(Shown in the OFF position)

VIEWINGWINDOW

GAS SERVICECOCK


NOTE:Do not adjustany othersetting screws.

PRESSURETEST POINT


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Testing - Electrical Checks to ensure electrical safety should be carriedout by a competent person.

In the event of an electrical fault after installation ofthe system, preliminary electrical system checks asbelow should be carried out.

1. Test insulation resistance to earth of mainscables.

2. Test the earth continuity and short circuit of allcables.

3. Switch on the electrical supply to the boiler andtest the polarity of the mains supply.

Turn the boiler thermostat knob fully clockwise tothe maximum setting.

The lighting sequence is automatic, as follows:

The fan operates

The spark ignition operates

The pilot solenoid opens

The pilot burner lights

The ignition spark stops

The main solenoid opens -

and after a short period of time the main burner willlight, view through window.

The main burner will remain alight until switchedoff, either by the boiler thermostat or a remotesystem control.

(When the boiler switches “Off”, both the pilot andmain burner go out. The automatic lightingsequence will operate again when heat is required).


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Completion and Commissioning7

3048

Testing - GasWith the boiler on proceed as follows:

Test for gas soundness around the boilergas components using a suitable leakdetection fluid, in accordance with thecurrent issue of BS6891.

Check the main burner gas pressure atleast 10 minutes after the burner has lit,refer to Data Label.

If necessary, adjust the gas pressure toobtain the required setting (screw at rearof the gas valve) turning anti-clockwise,viewed from the front, to decrease thepressure.

Should any doubt exist about the gas rate,check it using the gas meter test dial and astop watch, at least 10 minutes after theburner has lit, making sure that all othergas burning appliances and pilot lights areoff.

Space Saver K.F.B 60 Approx. Gas Ratemin med max

m3/h 1.8 1.95 2.1ft3/h 64 69 74

Space Saver K.F.B 70 Approx. Gas Ratemin med max

m3/h 2.2 2.4 2.5ft3/h 78 83 89

The gas rates are for guidance only,dependent on the heat setting.

Turn the boiler thermostat knob fullyanti-clockwise to “Off”. Remove thepressure gauge from the test point andrefit the screw, making sure that a gastight seal is made.

When the boiler thermostat is turned tothe “Off” position, by hand, wait at least30 seconds before turning “On” again.

There may be an initial smell given offfrom the boiler when new, this is quitenormal and it will disappear after a shortperiod of time.

Refit the electrical controls box coverwith the four screws previously removed.

Note: The neon indicator lights on theprinted circuit board are an aid to faultfinding, for details refer to Section 11.

DO NOTADJUST

8mmSPANNER

MAIN BURNERADJUSTMENTSCREW (8mmACROSS FLATS)


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Heating System Check that all remote controls are working asrequired.

Allow the system to reach maximum workingtemperature and examine for water leaks. Theboiler should then be turned off and the systemdrained off as rapidly as possible whilst still hot.

Refill the system, vent and again check for watersoundness.

For sealed systems adjust to initial design pressure.Any set pointer on the pressure gauge should be setto coincide with the indicating pointer.

The overrun thermostat will keep the pump runningwhen the boiler shuts down, so long as thetemperature within the boiler is above apredetermined level, providing the controlthermostat is set at maximum.

When commissioning the system the boiler shouldbe fired with the bypass fully closed on full service,that is, central heating and domestic hot water. Thesystem should then be balanced, adjusting the pumpand lockshield valve as necessary. Having achieveda satisfactory condition, operate the boiler with thebypass closed on minimum load, normally centralheating only with one radiator operating in the mainliving area. The valve should be opened graduallyto achieve the appropriate flow rate as quoted inSection 2. If necessary readjust the pump.

Under NO circumstances should this valve be left inthe FULLY CLOSED position.

Operational Checks Adjust the boiler thermostat and any systemcontrols to their required settings.

Do not attempt to adjust the thermostat calibration.

Operate the boiler again on full service and checkthat the balancing is satisfactory, making furtheradjustments as necessary to the system, radiatorvalves and bypass.

On open vented systems there must be no pumpingover of water or entry of air at the vent above thefeed and expansion cistern.

If thermostatic radiator valves are fitted care mustbe taken to ensure that there is an adequate flow ratewhen the valves are closed. Refer to the currentissue of BS7478 on the use of thermostatic radiatorvalves.


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Front Panel Assembly8

3059

BOILERMOUNTING WALL

FRONTPANELTOPMOUNTINGBRACKET

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1

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2

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3

Note. The front panel assembly hasbeen designed with a variableadjustment to suit a range of availablekitchen furniture, 700mm-728mm highby 285mm-315mm deep and will alsosuit installations in a cupboard.

It is delivered preset to 700mm high by285mm deep.

Measure the height of the cupboard orcompartment, “H”.

Adjust the front panel height “H” asnecessary.

Measure the depth of the cupboard orcompartment, “D”.

Adjust the front panel top mountingbracket as necessary.

Slide the right hand side cover plate(supplied in the fittings pack) intoposition.

D = 285 to 315mm

H = 700 to 728mm

W = 470mm

TOP HOLE FIXING700 to 714mm

H

BOTTOM HOLE FIXING714 to 728mm

W

H

D 'MINUS' 1mm

ADJUSTMENTSCREW


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8Front Panel Assembly

9

2908

ADJUSTMENTSCREW

SLIDEASSEMBLY CATCH

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4

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5

Locate the front panel assembly.

Engage the bottom front panelassembly slide/catch and adjust asnecessary.

Instruct and demonstrate the efficient and safeoperation of the boiler, heating system and if fitted, thedomestic hot water system.

Advise the user of the precautions necessary to preventdamage to the system and building in the event of theheating system being out of use during frost andfreezing conditions.

Advise the user, to ensure the continued efficient andsafe operation of the boiler it is recommended that it ischecked and serviced as necessary at regular intervals.The frequency of servicing will depend upon theparticular installation conditions and usage, but ingeneral once a year should be enough.

It is the law that servicing must be carried out by acompetent person.

Draw attention, if applicable, to the current issue of theGas Safety (Installation and Use) Regulations, Section35, which imposes a duty of care on all persons wholet out any property containing a gas appliance.

Reminder, leave these instructions with the user.

User Information

User Information

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1

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3049

FRONT PANEL

ELECTRICALCONTROLSBOX COVER

To ensure the continued efficient andsafe operation of the boiler it isrecommended that it is checked andserviced as necessary at regularintervals. The frequency of servicingwill depend upon the particularinstallation conditions and usage, but ingeneral once a year should be enough.

It is the Law that servicing must becarried out by a competent person.

BEFORE STARTING A SERVICEREMOVE THE FRONT PANEL asshown, for Access, ISOLATE THEBOILER FROM THE ELECTRICALSUPPLY AND TURN THE GASSUPPLY OFF AT THE GAS SERVICECOCK, INDICATOR SLOT TO BEVERTICAL.

Unless stated otherwise, all parts arereplaced in the reverse order toremoval.

After completing any servicing alwaystest for gas soundness and if necessarycarry out functional checks of controls.

AccessRemove the electrical control boxcover by removing the four screws.

Note: As an aid to Servicing the airpressure switch tube connection can beused to obtain a products of combustionreading.

Follow Steps 1, 2 and 4.

Remove the RED tube from theconnection on the air pressure switchand insert the analyser probe into thetube.

Switch on the electrical supply tooperate the fan and turn on the gassupply.

On completion of the test switch off theelectrical and gas supplies and reconnectthe red tube to the air pressure switch.

Remove the inner case, by unscrewingat the bottom and unhooking at the top.

SECURINGSCREW(4)


GAS SERVICECOCK

INNERCASE

SCREW (3)


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10Servicing

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3050

FAN/FLUE HOODSCREW (2)

SPLIT PIN

OVERHEATCUT-OFFPHIAL

Cleaning the HeatExchangerSlacken the flue hood by loosening theextended brass screws at the left andright hand sides.

Remove the split pin and thermostatphials from the pocket, taking carenot to kink the capillaries.

When replacing the phials make surethat they are still covered with heatsink compound.

Disconnect the air pressure switchtubes.

WHITE

AIRPRESSURESWITCHTUBES

RED

THERMOSTATPHIAL

PHIALPOCKET


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Servicing10

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3051

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11

Disconnect the gas service cock at theunion connection.

Disconnect the electrical connectionplug by pulling it out from the righthand side of the control box.

Remove the violet and red electricalconnections on the fan and cable fromthe securing clips.

Remove the electrical control box/combustion chamber cover assemblyby removing the ten securing screws,withdraw the complete assembly.

Slacken the air pressure pipe union andturn through 90o.

Remove the rear flueway cleaningplate.

Remove the heat exchanger frontcover, by removing the eight securingscrews.

Place a sheet of paper in the base ofthe combustion chamber.

Remove the three baffles.

FAN ELECTRICALCONNECTIONS

AIR PRESSUREPIPE UNION

SECURINGSCREWS (10)

ELECTRICALCONNECTIONSPLUG

GAS SERVICE COCKUNION CONNECTION

REAR FLUEWAYCLEANING PLATE

SECURINGSCREW (6)

HEATEXCHANGERFRONTCOVER

BAFFLES (3)

CLIPS


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10

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12

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13

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3108

Servicing

The heat exchanger can now becleaned with a suitably sized semi-stiff brush, using the cleaning plate,as shown to protect the rearinsulation panel.

DO NOT USE A BRUSH WITHMETALLIC BRISTLES.

Remove the paper and debris fromthe combustion chamber.

Correctly refit the baffles previouslyremoved, each is marked TOP on itsupper face.

Refit the heat exchanger front cover.

Tighten down the fan flue screws.

Refit the cleaning plate.

Main BurnerRemove the main burner by releasingthe two securing nuts as shown. Brushor vacuum away any deposits, ensurethat the flame ports are clean.

DO NOT USE A BRUSH WITHMETALLIC BRISTLES.

Make sure that the pilot burner shield islocated between the burner bracket asshown.

Main InjectorThe main injector can be removedand cleaned.

When cleaning the injector do not usea wire or sharp instrument on thehole.

380m

m M

IN.

50mm

20mm

40mm

SEMI-STIFFNYLON BRISTLESCLEANING BRUSH

CLEANINGPLATE

VIEW OF MAINBURNER INJECTORWITH BURNER REMOVED

SECURINGNUTS

INJECTOR

BURNERBRACKET

PILOTBURNER SHIELD


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4781

SPARK GAP3.5-4.5mm

15-20mm

Pilot Burner, IgnitionElectrode and PilotInjectorPull off the ignition lead at theelectrode (covered with a siliconerubber sleeve).

Unscrew the tubing nuts at both endsreleasing the pilot pipe.

Remove the pilot burner securingscrews to release the pilot burner andelectrode assembly.

Clean the pilot burner and electrode.

Remove the pilot injector byunscrewing it from the pilot burner,clean it by blowing through it.

When refitting take care not to damagethe electrode and check that the sparkgap is as shown.

PILOT TUBING NUT

SILICONERUBBERSLEEVE

PILOTBURNERASSEMBLYSECURINGSCREW (2)

IGNITIONLEAD

PILOTPIPE

PILOT TUBING NUT

PILOT BURNER

PILOT INJECTOR


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11Fault Finding

2914

ElectricalImportant. On completion of theservice/fault finding task which hasrequired the breaking and remaking ofthe electrical connections the earthcontinuity, polarity, short circuit andresistance to earth checks must berepeated using a suitable multimeter.

Refer to Fault Finding, Wiring andFunctional Flow diagrams.

Electrical SupplyFailureFailure of the electrical supply willcause the burner to go out. Operationwill normally resume on restoration ofthe electrical supply. If the boiler doesnot relight after an electrical supplyfailure the overheat device may needresetting.

Remove the front panel as Section 1,Step 1 and press the reset button on topof the electrical controls box cover, seediagram at Step 3. If the cut offoperates at any other time press thereset button and the burner shouldrelight. If the fault persists refer toFault Finding Chart.

(N/C)

br

FUSETYPE F11 AMP

AIR PRESSURE SWITCH CONNECTIONS

SPARKELECTRODE

O/H CUTOFF

CONTROL STAT

FAN

AIRPRESSURESWITCH

PILOTSOLENOID

MAINSOLENOID

10

10

10

10

N

1

2 3

(N/O) (C)

L

6 3

(N)

(SL)

(N)

(N)

(N)

(L)

b

w

br

y

y

r v

r

bk b

y

b

bbkb

KEY

bk BLACKbr BROWNb BLUEv VIOLET p PURPLE

w WHITEr REDy YELLOW

12

MAIN TERMINAL STRIP CONNECTIONS

CONTROL THERMOSTAT CONNECTIONS

PRINTED CIRCUIT BOARD CONNECTIONS

8

79

8

7

9

11

PUMPbr b

br

r

brbr

THERMOSTATPUMP

OVERRUN

p

b

b

*RED LINK

*RED LINK may have been removed to fit remote controls.


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Fault Finding11

FANOVERHEAT

CUT-OFF

AIR PRESSURESWITCH

PRINTED CIRCUITBOARD

SPARKELECTRODE

GASVALVE

SWITCHEDLIVE

CIRCULATIONPUMPFUSE

TYPE F11 AMP

240V~50HzPERMANENT

MAINS SUPPLYFUSED 3 AMP

CHASSISEARTHPOST

CHASSISEARTH

CONTROLTHERMOSTAT

Remove RED linkbetween 7 and 12when fitting a timecontrol etc. (If noswitch is fitted the

pump will runcontinuously).

ENL

NLE12

11

10

9

8

7

6

5

NC NOC

1 23

9 8 67

3

g/y

g/y

r

r vbk b br

br

b

g/y

g/y

w

y

bk

g/y

g/y

g/y

b

br

b

br

v

r

y

p

br

ry

KEY:b - BLUEbk - BLACKbr - BROWNr - REDg/y - GREEN/YELLOW

- MAIN TERMINAL STRIP

- CONTROL THERMOSTAT

- AIR PRESSURE SWITCH NUMBER = BECK LETTER = YAMATAKE

p - PURPLEv - VIOLETw - WHITEy - YELLOW

3109


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11Fault Finding

NEON INDICATORS (4)

Neon Indicators - An Aid to Fault FindingTHE 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.

Overheat cut off device tripped or thermostat, overheat cut off device faulty - see detailed fault finding chart.

Air flow proving fault - that is fan or air pressure switch - see detailed fault finding chart.

Ignition, pilot or flame proving fault -see detailed fault finding chart.

Gas valve / harness problem - seedetailed working? fault finding chart.

Is neon 2 lit?

Is neon 3 lit?

Is neon 4 lit?

Is main burner operating?

System satisfactory

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

4754

3054


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Fault Finding11Before 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 printedcircuit board fuse. Check the air tubes to the air pressure switch. Switch on the electrical supply and check for correct polarity.

Turn the boiler thermostat to its maximum setting. Also check fuses.

Is there 240V~ between 12 and10 and between 11 and 10 ?

Is there 240V~ between yellow connection on overheat device and 10 ?

Is there 240V~ between 6 on thermostat and 10 ?

Is there 240V~ between

1 on air pressure switch and 10 ?

Is there 240V~ between 3 on air

pressure switch and 10 ?

Does fan run?

Does fan Hunt? Replace printed circuit board.

Check lead continuity and inspect electrode and lead for damage.

Check for pilot jet blockage, incorrect electrode adjustment.If satisfactory replace gas valve.

Isolate supply, test harness and replaceas required.

Inspect electrode lead / connectionfor poor contact. Check electrical supply polarity and correct if necessary.If satisfactory replace printed circuit board

Isolate supply, test harness continuity.If satisfactory replace printed circuit board.

Correct power supply problem.

Check overheat reset.If satisfactory replace overheat device.

Replace thermostat.

Check yellow cable between printed circuitboard and air pressure switch.If satisfactory replace printed circuit board.

Replace air pressure switch.

Is there 240V~ between motor connections on fan?

Isolate electrical supply test fan harnesscontinuity.If satisfactory replace printed circuit board.

Inspect air tubes for leaks, kinks and correct fitting. If satisfactory replace faulty air pressure switch.

Is there a spark at pilot burner?

Does pilot light?

With pilot lit does spark stop?

Replace gas valve.System satisfactory.

Does main burner light?

Is neon 4 lit?

Is neon 3 lit?

Replace fan.

Is neon 2 lit?

Is neon 1 lit?

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

Is there 240V~ between 2 on air

pressure switch and 10 ?

Is there 240V~ between pilot gas valvesolenoid blue and brown connections?

Is there 240V~ between main gas valve solenoid black and blue cables?

AIR PRESSURE SWITCH

MAIN TERMINAL STRIP

CONTROL THERMOSTAT

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11Fault Finding

Fault FindingTurn boiler Control Thermostat to maximum, with the remote controls calling for heat,

does the pump continue to run after the appliance has shut down on boiler control thermostat?

Pump overrun OperationThe 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 NOTcalling for heat.

Turn off remote controls, does the pump stop after a short period of time

Faulty Pump overrun.Replace Control Thermostat

Pump overrun in order.

Is there 240V~ on 11 ?

Is there 240V~ on 9 forpump?

Is there 240V~ on 9 connection on thermostat?

Faulty permanent live feed.Replace.

Faulty connections between thermostat and terminal strip.Repair.

Faulty internal wiring betweenterminal block and thermostat.Repair.

Faulty pump / wiring ? Replaceor repair as necessary.

NO

NO NO

NO

NO

YES

YES

YES

YES

YES

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Replacement of Parts12

Pilot Burner/Injectorand Ignition LeadGain access as Section 10, steps 1 to 4.

Pull off the ignition lead at theelectrode (covered with a siliconerubber sleeve) and printed circuitboard.

Unscrew the tubing nuts at both endsreleasing the pilot pipe.

Remove the pilot burner byunscrewing the two securing screws asshown.

The pilot burner or injector can now bereplaced.

ElectrodeGain access as Section 10, steps 1 to 4.

Pull off the ignition lead at theelectrode.

Remove the electrode securing screw.

The electrode can now be replaced.

Printed Circuit Board(PCB)Gain access as Section 10, steps 1 to 4.

Do not disturb the heat shield earthconnector.

Disconnect the three electrical plugs,ignition lead, the earth and mainscables.

Pull the board away from the supports.

When fitting the replacement makesure that it is correctly located on to thesecuring posts and make sure that allthe connections are remade.

PILOT TUBING NUT PILOTBURNERINJECTOR

3055

PILOTBURNERASSEMBLYSECURINGSCREW (2)

IGNITIONLEAD

ELECTRODESECURINGSCREW

SILICONERUBBERSLEEVE

ELECTRODE

PILOTPIPE

PILOT TUBINGNUT

SECURINGPOST

IGNITIONLEAD

ELECTRICALPLUGS (3)

HEAT SHIELDEARTH LEAD

Replacement of parts must only be carried out by a competent person.

BEFORE REPLACING ANY PARTS ISOLATE THE BOILER FROM THE ELECTRICAL SUPPLYAND 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.

After replacing any parts always test for gas soundness and if necessary carryout functional checks of controls.


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12Replacement of Parts

Control Thermostatand Overheat CutoffGain access as Section 10, steps 1 to 5.

Control Thermostat:Pull off the control thermostat knob,remove the two screws securing thethermostat to the control box.

Remove the electrical connections fromthe thermostat body.

Overheat Cutoff:Remove the nut securing the overheatcutoff, withdraw the assembly.

Control Thermostat/Overheat CutoffNow remove the split pin and then thethermostat phials from the pocket.

Make sure that the thermostatcapillaries are correctly routed and thephials are securely fitted into thepocket.

Note: The position of the two phialsshould be as shown when replacing inthe pocket.

Reconnect the electrical leads asshown.

When replacing either of thesethermostats make sure that the phial issmeared with the heat sink compoundsupplied with the replacement.

3056

CONTROL KNOB

SECURINGSCREW(2) WIRING

DIAGRAM

YELLOW

PURPLE

YELLOWRED

BROWN

3689

7

SPLIT PINPHIALPOCKET

OVERHEATCUTOFFPHIAL

THERMOSTATPHIAL

SEAL

CUT OUT

SECURING NUT

WIRINGDIAGRAM

YELLOW

PURPLE

BROWNRED

YELLOWWH

ITE

OVERHEAT CUTOFF

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Air Pressure SwitchNote: Alternative types of AirPressure Switches may be fitted.

Gain access as Section 10 steps 1 to 4.

Remove the air pressure tubes andelectrical connections, release thescrews and nuts, remove the switch.

When fitting the replacement makesure that all the plastic tubes andelectrical connections are made asshown.

Gas ValveGain access as Section 10, steps 1 to 4.

Disconnect all electrical leads from thegas valve.

Disconnect the pilot pipe at the pilotburner.

Undo the four screws at the outletmanifold and disconnect the gasservice cock union.

Transfer the half union of the gasservice cock to the inlet of thereplacement gas valve. Also transferthe pilot supply pipe. Use a littlethread sealant on the external threads toensure gas soundness.

Fit the new valve, take care not todamage the “O” ring.

It will be necessary to purge thepipework and valve before relighting,check gas pressure settings, refer toSection 7.

SECURINGSCREW (2)

CLEAR AIRPRESSURE TUBE

RED

YELLOW

GAS SERVICECOCK UNION

SECURINGSCREW (4) BROWN

"O" RING

G/YBLACK

BLUE

WIRINGDIAGRAM

BECK

YAMATAKE

3057RED AIR

PRESSURE TUBE

YELLOW

BLACK

SECURINGSCREW (2)

RED AIRPRESSURETUBE

BLACK

RED

CLEAR AIRPRESSURETUBE

PILOTBURNER

ELECTRICALLEADS

PILOTPIPE

EARTHCONNECTOR


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12Replacement of Parts

Main Burner

Main Burner Injector

Gain access as Section 10, steps 1 to 5 and 9.

Remove burner as in Section 10, step 13.

Gain access as Section 10, steps 1 to 5 and 9.

Remove the injector as in Section 10, steps 13 and 14.

FanGain access as Section 10, steps 1, 2and 5.

Remove the electrical connections anddisconnect the air tubes.

Remove the fluehood/fan assemblyscrews and withdraw the assembly.

Turn the flue hood over and release thetwo securing screws as shown.

Remove the sealant from the fan outletand manifold.

Take the beige/grey sealant suppliedwith the replacement fan and placefirmly around the internal spigot of theflue manifold.

After fitting the fan outlet to the spigotsmooth the sealant over the joint.

Make sure that when fitting thereplacement fan to the flue hood that itis the correct way round for connectionto the flue, refer to the diagram inSection 6, also steps 10 and 11.

Make sure that the earth connectionis remade onto the new fan assembly.

The polarity of the other connections isnot important.

3058

SECURINGSCREW (2)

FAN/FLUEHOODSCREW (2)

AIR PRESSURESWITCH TUBES

ELECTRICALCONNECTIONS

s t e p

1

s t e p

2

EARTHCONNECTION


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Viewing Window Gain access as Section 10, steps 1 to 4.

Remove the two screws and then the window.

When replacing take care not to damage the gasket.

InsulationGain access as Section 10, steps 1 to10.

Combustion ChamberSides and Rear:Remove the baffles.

Remove the insulation and fit thereplacement parts making sure they arefitted as shown.

s t e p

1

s t e p

2

Heat Exchanger FrontCover Panel:Remove panel, Section 10, step 10.

Upper Insulation: push up and pull outto remove.

Lower insulation: remove the securingscrews and angle and remove theinsulation.

When refitting either, make sure that itis fitted as shown.

3107

COMBUSTIONCHAMBERSIDE

BAFFLE

70 ILLUSTRATED

COMBUSTIONCHAMBER REAR

SECURINGSCREW (2)

COMBUSTIONCHAMBERFRONT PANELS

SECURINGSCREW (2)

SECURINGSCREW (2)


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13Spare Parts

Part IdentificationThe key number in the diagram and thelist will help to identify the part.

OrderingWhen ordering any spare parts pleasequote the part number and descriptionfrom the list together with the modelname and serial number.

If ordering from the local gasundertaking also quote the GC number ofthe appliance and part.

4760

1

2

10

11

12

3

4

5 6B

6A

Key Glow-worm Description GC No.No Part No

1 800165 Gas valve assembly, inc item11 313 3002 202539 Thermostat 397 8933 202538 Overheat thermostat 397 8944 900817 Printed circuit board 313 3015 440073 Fan assembly (60) - special 397 9875 800238 Fan assembly (70) - special 313 397

6A 202135 Air pressure switch - Yamatake 313 303 6B 440165 Air pressure switch - special 313 391

7 203428 Pilot assembly - inc. 8 and 14 313 3048 800187 Pilot injector - special 313 3929 205701 Main injector (60) - special 313 3939 205702 Main injector (70) - special 313 39410 440108 Control knob - thermostat - assembly 313 30611 208040 “O” ring - gas valve 334 59212 202015 Fuse to BS4265 sheet 2. type F1A 334 75013 WX1800 Ignition lead 313 30714 800188 Electrode - special 313 395

8

7

9

14

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Because of our constant endeavour for improvement details may vary slightly from those given in these instructions.

glowworm space saver kfb 60 and 70 installation and ...€¦ · installation and servicing...

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