Glow-worm Space Saver K.F.B 60, Space Saver K.F.B 70 Installation And Servicing Instructions

Supplied By www.heating spares.co Tel. [phone]

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

60 GC 41 319 11

4757

70 GC 41 319 12

Fanned Flue

Boiler

Fully Pumped system.

Open Vented or Sealed.

This is a Cat I2H Appliance

BS 6332
BS 5258

Customer Services:
Tel: [phone]

One Contact Local Service

Fax: [phone]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

Supplied By www.heating spares.co Tel. [phone]

Contents

Section Title Page No

Location Map

1
2
3

SECTION

4
5
6
7

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

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

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

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

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

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

COMPLETION

and COMMISSIONING ........... 29

8

FRONT PANEL

ASSEMBLY ............................ 34

9
10
11
12

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

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

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

REPLACEMENT

OF PARTS .............................. 46

A519 ASHBOURNE

Milford

Site

MILFORD

A6 DERBY

Belper and Milford

Factory Sites

A6 MATLOCK

B6013 RIPLEY

BELPER

Nottingham Rd

Site

N

2890

A609 NOTTINGHAM

Belper

13

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

Control of Substances Hazardous to Health

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 the

lavatory.

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 not

cause 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.

2

220692C

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

2

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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
appliance and must, to comply with the
current issue of the Gas Safety
(Installations and Use) Regulations,be
handed to the user on completion of
the installation.

Important Notices

General

70

TOP VIEW

R F

55

35

WATER CONNECTIONS
28mm COMPRESSIONS

GAS CONNECTION
Rc1/2(1/2"B.S.P.T.)

SIDE

40

FLUE
OUTLET

1

3060

SECTION

This boiler is for use on natural gas
(G20) as distributed in the United
Kingdom and cannot be used on any
other gas.

Wherever possible, all materials,
appliances and components to be used
shall comply with the requirements of
applicable British Standards.

Where no British Standard exists,
materials and equipment should be fit for
their purpose and of suitable quality and
workmanship.

This boiler must have fully pumped
circuits, but is suitable for use with open
vented or sealed water systems.

This boiler is not suitable for outdoor
locations.

Sheet Metal Parts

450

458

FRONT VIEW

445

155

285­315

130
700­728

125

SIDE VIEW

WARNING. When installing or
servicing the boiler care should be taken
when handling sheet metal parts to avoid
any possibility of personal injury.

REAR
FLUE
OUTLET

Statutory
Requirements

The installation of the boiler MUST be
carried out by a competent person in
accordance with the relevant
requirements of the current issue of:

Manufacturer’s instructions supplied.

FRONT VIEW
BOILER OUTLINE

ALL DIMENSIONS ARE IN MILLIMETRES

3

15

125

50

687

FLUE
TERMINAL
DETAIL

102

63

3

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1

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

SECTION

Electricity at Work Regulations and any
applicable local regulations.

Detailed recommendations are
contained in the current issue of the
following British Standards and Codes
of Practice, BS6798, BS5440 Part 1 and
2, BS6700, BS5449, BS6891, BS4814,
BS7074 Part 1 and 2, BS5446, BS7478,
BS7593, BS7671.

Manufacturer’s notes must not be taken
as overriding statutory requirements.

General

B.S.I. Certification

The boiler is certificated to the current
issue of BS6332 Part 1, invoking the
current issue of BS5258 Part 1 for
performance and safety. It is, therefore,
important that no alteration is made to
the boiler without permission, in
writing, from Hepworth Heating Ltd.

Any alteration that is not approved by
Hepworth Heating Ltd., could invalidate
the B.S.I. Certification of the boiler, the
warranty and could also infringe the
current issue of the Statutory
Requirements.

CE Mark

The CE Mark on this appliance shows
compliance with Directive 90/396/EEC
on the approximation of the Laws of the
Member States relating to appliances
burning gaseous fuels.

The CE Mark on this appliance shows
compliance with Directive 73/23/EEC
on the harmonization of the Laws of the
Member States relating to electrical
equipment designed for use within
certain voltage limits.

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Range Rating

The boiler is range rated and may be
adjusted to suit individual system
requirements, refer to the relevant
column of the table.

General

Range Rating K.F.B K.F.B

Nominal min

Heat med

Input max
(Gross)

Nominal min

Heat med

Ouput max

Burner min

Setting med

Pressure max

Btu/h 64935 78947

kW 19.03 23.14

Btu/h 70064 84416

kW 20.54 24.74

Btu/h 75000 89709

kW 21.98 26.29

Btu/h 50000 60000

kW 14.66 17.59

Btu/h 55000 65000

kW 16.12 19.05

Btu/h 60000 70000

kW 17.59 20.52
in wg 4.2 4.6
mbar 10.6 11.4

in wg 4.9 5.2
mbar 12.2 13.0

in wg 5.6 5.9

mbar 14.0 14.6

Space Saver Space Saver

60 70

1

SECTION

Data T able

Data Label Position

Space Saver Space Saver

Model K.F.B K.F.B

60 70

Lifting 32.4kg 32.4kg
Weight (71.4lb) (71.4lb)

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

Water 2.13 litres 2.13 litres
Content (0.47 gal) (0.47 gal)

1

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

Water 28mm 28mm

Connection Compression Compression

Electrical 240V~50Hz fused 3A max
supply

Internal Fuse to BS4265 sheet 2. Type F1A
Fuse Rating

Power rating 55W

3038

/

2

Rc1/

* Note: The weight of the water is negligible

2

5

Space Saver K.F.B 60

G.C. Number 41 319 11

Space Saver K.F.B 70

G.C. Number 41 319 12

5

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1

General

Gas Supply

SECTION

Electrical 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
standard.

WARNING. THIS BOILER MUST BE EARTHED.
All system components shall be of an approved type

and shall be connected in accordance with the current
issue of BS7671 and any applicable local regulations.

Connection of the boiler and system controls to the
mains supply must be through a common isolator and
must be fused 3A maximum. The method of
connection should be, preferably, an unswitched
shuttered socket outlet and 3 pin plug, both to the
current issue of BS1363.

Draining T ap

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

Wiring to the boiler must be to the current issue of
BS6500 Table 16, not less than 0.75mm2 (24/

0.20mm).

The boiler is provided with a draining tap at the
lower right hand side for draining the heat exchanger
in the event of the boiler being out of use during
freezing conditions.

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

Draining taps shall be to the current issue of BS2879.

Safety V alve

A safety valve need not be fitted to an open vented
system.

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Water Systems

2

Notes: Open Vented
and Sealed Water
Systems

Pump

See chart for pressure drop of the boiler.
The pump should be fitted in the flow

pipe from the boiler and have isolating
valves each side, integral if possible.

The variable duty pump should be set to
give a temperature difference of 11oC
(20oF) between flow and return with the
thermostat set at “MAX” which is about
82oC (180oF).

High resistance microbore systems may
require a higher duty pump.

UNIT

litre / min.

gal / min.

1400
1200
1000

800
600
400

WATER FLOW RATE

At 11˚C (20˚F) differential

HEAT SETTING

Min.

60 70

19.1

4.2

Flow rate (gallons / minute)

1234567

0

22.9

5.0

60 70

22.9

5.0

Max.

26.7

5.9

50
40
30
20

4778

SECTION

Bypass

200

0

Water pressure drop (mm head of water)

PRESSURE DROP OF BOILER

A BYPASS MUST BE FITTED, see also Section 7.
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.

0 5 10 15 20 25 30 35

Flow rate (litres / minute)

10
0

Water pressure drop (inches head of water)

Inhibitor

If an inhibitor is to be used refer to the current issue of
BS5449 and BS7593, contact a manufacturer for their
recommendations as to the best product to use.

When using in an existing system take special care to
drain the entire system, including the radiators, then
thoroughly cleaning out before fitting the boiler whether
or not adding an inhibitor

7

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1

Water Sysems (Open Vented)

Open (Vented) Water
System

For an open (vented) system the boiler
must be supplied from an unrestricted
water supply taken from a feed and
expansion cistern situated at a

SECTION

maximum height of 27.5 metres (90ft)
above the boiler.

The cold feed supply must be 15mm
minimum size.

The vent must rise continuously and be
unrestricted.

It is important that the relative positions
of the pump, cold feed and open vent
are as shown.

Domestic Hot Water
Cylinder

450mm
MIN.
HEIGHT

1metre MIN.

27.5metres MAX.

Open (vented) system.
Recommended
relationship between
pump, cold feed and
vent.

UNRESTRICTED
CONTINUOUSLY
22mm (MIN) VENT

FEED AND
EXPANSION
CISTERN

15mm (MINIMUM)
UNRESTRICTED
COLD FEED

22mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE

RET.

RET.

CYLINDER

2886

FLOW

The hot water cylinder must be of the
double feed fully indirect type. Not the
self priming type.

BOILER

PUMP

HEATING

FLOW
150mm
MAX

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Water Systems (Sealed)

Sealed W ater Systems

The installation must comply with the
appropriate requirements of the current
issue of BS5449, BS6798, BS4814 and
BS7074 Part 1 and 2.

See the diagrammatic layout.

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

AUTO
AIR

NON­RETURN
VALVE

VENT

2

2888

AIR
RELEASE
POINT

SECTION

Safety V alve

A safety valve must be fitted to a sealed
system.

It shall be preset, non-adjustable with a
lift pressure of 3bar, incorporating
seating of a resilient material, a test
device and a connection for drain.

The drain from the safety valve must be
routed clear of any electrical fittings
and positioned so that any discharge can
be seen.

Expansion V essel

FILLING POINT

CIRCULATING
PUMP

PRESSURE
GAUGE

EXPANSION
VESSEL

(Make-up
alternatives)

FLOW

LOCKSHIELD

CIRCUIT

HEATING

RETURN

22mm (min)

BYPASS

WITH

VALVE

DRAIN
COCK

SAFETY
VALVE

BOILER

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

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

Example: For an initial system design pressure of

0.7bar, the minimum total vessel volume required is

0.063xTotal System volume.
Note. A higher initial design pressure requires a larger

volume expansion vessel.
Guidance on vessel sizing is also given in the current

issue of BS5449 and BS7074 Part 1.
The charge pressure must not be less than the static head

of the system, that is, the height of the highest point of
the system above the expansion vessel.

The water capacity of the boiler is given in the Data
Table.

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2

Water Systems (Sealed)

Pressure Gauge

A pressure gauge with a set pointer and
covering at least 0 to 4bar (0 to 60lb in2)
shall be fitted permanently to the
system in a position where it can be
seen when filling the system.

SECTION

Domestic Hot Water
Cylinder

SINGLE FEED INDIRECT
CYLINDERS ARE NOT SUITABLE

The hot water cylinder must be of the
indirect coil type. It must be suitable
for working at a gauge pressure of

0.35bar above the safety valve setting.

UNVENTED

Where a storage system will not have a
vent to atmosphere the installation must
comply with the Building Regulations
and the local Water Company bylaws,
see also the current issue of BS5546
and BS6700.

METHOD 1

TEMPORARY
HOSE

SUPPLY
PIPE

METHOD 2

TEMPORARY
HOSE

SUPPLY
PIPE

METHOD 3

CISTERN

HOSE
UNIONS

SUPPLY STOP
VALVE

DOUBLE CHECK
VALVE ASSEMBLY

HOSE
UNIONS

SUPPLY STOP
VALVE

OVERFLOW

SERVICING
VALVE

COMBINED
CHECK VALVE
AND VACUUM
BREAKER

SERVICING
VALVE

SERVICING
VALVE

PRESSURE
REDUCING
VALVE

0051M

HEATING
SYSTEM

HEATING
SYSTEM

HEATING
SYSTEM

10

If fitting into an existing system the
local authority must be informed.

Water Make Up

Provision should be made for replacing
water loss from the system using a
filling loop or a make up bottle
mounted in a position higher than the
top point of the system, connected
through a non-return valve to the return
side of either the heating circuit or the
hot water cylinder.

Alternatively, provision for make up
can be made by pre-pressurisation of
the circuit.

SUPPLY
STOP VALVE

SUPPLY
PIPE

HOSE
UNIONS

DOUBLE CHECK
VALVE ASSEMBLY

Filling Sealed Water
Systems

Provision for filling the system at low level
must be made. Three methods are shown in the
diagram. There must be no permanent
connection to the mains water supply, even
through a non-return valve.

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The boiler may be installed in any room
although particular attention is drawn to
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
should be so situated that it cannot be
touched by a person using the bath or
shower. The electrical provisions of the
Building Standards (Scotland) are
applicable to such installations in
Scotland.

Boiler Location

10mm

70mm

5mm

3

2891

SECTION

5mm

The boiler must be mounted on a flat
wall which is sufficiently robust to take
its complete weight, see Data Table.

Boiler Clearances

The boiler must be positioned so that at
least the minimum operational and
servicing spaces are as shown.

500mm

10mm

100mm

✽

WHERE EXTERNAL ACCESS TO THE

5mm

FLUE IS NOT PRACTICAL THEN

CLEARANCE MUST BE ADEQUATE

TO PERMIT INSTALLATION OFF THE

FLUE ASSEMBLY

5mm

11

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2

Boiler Location

Timber Frame
Buildings

SECTION

Cupboard or
Compartment
Ventilation

Where the boiler is fitted in a cupboard
or compartment, permanent high and
low level ventilation must be provided.
The ventilation areas required are given
in the Table.

Where the installation of the boiler will
be in an unusual location, special
procedures are necessary, refer to the
current issue of BS6798 for guidance.

A compartment used to enclose the
boiler must be designed and
constructed specifically for this
purpose.

If the boiler is to be installed in a timber frame
building, it should be fitted in accordance with the
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.

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

VENTILATION HIGH LEVEL LOW LEVEL
REQUIREMENTS VENT AREA VENT AREA

FROM ROOM
OR SPACE

FROM
OUTSIDE

198cm2 (30in2) 198cm2 (30in2)

99cm2 (15in2) 99cm2 (15in2)

An existing cupboard or compartment
modified for the purpose may be used.
Refer to the current issue of BS6798 for
guidance.

The doorway opening should be of
sufficient size to allow for easy removal
of the boiler.

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

VENTILATION HIGH LEVEL LOW LEVEL
REQUIREMENTS VENT AREA VENT AREA

FROM ROOM
OR SPACE

FROM
OUTSIDE

237cm2 (36in2) 237cm2 (36in2)

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

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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.

4

0103M

A

C

It is important that the position of the
terminal allows the free passage of air
across it at all times.

Terminal Position

The minimum acceptable spacings from
the terminal to obstructions and
ventilation openings are as shown in the
diagram.

Where the terminal is fitted within
600mm (24in) below plastic guttering
an aluminium shield 1500mm (5ft) long
should be fitted to the underside and
immediately beneath the guttering or
eaves.

Where the terminal is fitted within
450mm (18in) below eaves or painted
guttering an aluminium shield 750mm
(2ft6in) long should be fitted to the
underside and immediately beneath the
guttering or eaves.

Terminal Protection

A terminal guard is required if persons
could come into contact with the
terminal or the terminal could be
subject to damage.

If a terminal guard is required, it must
be positioned to provide a minimum of
50mm clearance from any part of the
terminal and be central over the
terminal.

A suitable terminal guard can be bought
from,

B,C

A

F

G

Car Port etc.

MINIMUM SITING DIMENSIONS
FOR FLUE TERMINALS

A DIRECTLY BELOW AN OPENABLE WINDOW, AIR VENT, 300

OR 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) 1200

IN CARPORT INTO DWELLING

K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300

G

A

E

G

H,I

B,C

K

F

F

G

J

K

K

L

L

K

G

D

F

SPACING

SECTION

MIN.

(mm)

4783

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

13

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2

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.

SECTION

DETERMINE FLUE APPLICATION,
LENGTH, AND TERMINAL
POSITION BEFORE PROCEEDING.

Refer to the relevant diagrams in
Section 4.

For wall thickness of less than 300mm
the boiler can be fully installed from
inside.

For a wall thickness of over 300mm the
cut hole will need to be made good
from the outside.

The rear and side flue assemblies are
designed for internal installation, but
should it be necessary due to
insufficient clearances or boiler
location they can be installed from the
outside.

2876

R

Rear Flue Lengths

Distance 'R'

S T D 75mm to 692mm

1m 692mm to 1022mm

2m 1022mm to 2022mm

REAR FLUE APPLICATION

FOLLOW

FLUE INSTALLATION

step

1

step

11

SIDE FLUE APPLICATION

FOLLOW

FLUE INSTALLATION

step

6

t o

&

t o

t o

step

5

step

16

step

16

2877

S

Side Flue Lengths

Distance 'S'

S T D 75mm to 692mm

1m 692mm to 1022mm
2m 1022mm to 2022mm

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Flue Installation

5

Rear Flue Application

Having selected the boiler location
with due regard to the terminal
position;

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.

If the wall thickness “Q” is less than
300mm cut the wall sleeve to the
required length.

step

2892

1

WALLPLATE/
TEMPLATE

SECTION

115mm
MINIMUM
HOLE

step

2

Fit the wall sleeve.
Make good around the wall sleeve at

both internal and external wall faces
(through the wall sleeve if internal
access only is available).

If the wall thickness “Q” is greater than
300mm the wall sleeve must be fitted
flush with the INSIDE wall face. If the
inner end of the sleeve sticks out into a
cavity then, if desired, the wall sleeve
can be trimmed back to the depth of the
inner skin of the brickwork. Make good
at the internal wall face, leave the
external wall face until later.

Reposition the wallplate/template
ensuring alignment with the flue hole.
Mark the top and bottom boiler
mounting hole positions.

step

3

WALLPLUG

Q

No. 10x11/2in
SCREW

Q

300mm MAX
LENGTH

Remove wallplate/template, drill holes
and then secure wallplate/template to the
wall with the fittings provided in the
loose items pack.

15

5.5mm DRILL SIZE

15

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5

Flue Installation

Flue Duct (Standard
or Long)

Mark the duct to the length
“Q”+11mm then cut square and
remove any burrs.

SECTION

Air Duct/Terminal
(Standard or Long)

step

4

step

5

2893

Q+11mm

Q

Mark the duct to the length “Q”+13mm
then cut square and remove any burrs.

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

1m 2m FLUE
TERMINAL

STANDARD
FLUE TERMINAL

Q+13mm

Continue at

step

11

16

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Q

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Flue Installation

5

Side Flue Application

Having selected the boiler location,
with due regard to boiler clearances
and the terminal position.

Position the wallplate/template on the
wall. Mark the top and bottom boiler
mounting hole positions.

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

Mark and extend the flue horizontal
centre line to the corner of the
adjacent surface.

step

6

step

7

WALLPLUG

2894

No. 10x11/2in
SCREW

SECTION

5.5mm DRILL SIZE

125mm

Mark out and cut the hole for the flue
using, preferably, a 115mm minimum
core drill.

If the wall thickness “Q” is less than
300mm cut the wall sleeve to the
required length.

Fit the wall sleeve.
Make good around the wall sleeve at

both the internal and external wall
faces (through the wall sleeve if
internal access only is available).

If the wall thickness “Q” is greater than
300mm the wall sleeve must be fitted
flush with the internal wall face.

step

8

115mm
MINIMUM
HOLE

Q

Q

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

If the inner end of the sleeve sticks out
into the cavity then, if desired, the wall
sleeve can be trimmed back to the depth
of the inner skin of the brickwork.

17

300mm MAX
LENGTH

17

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Supplied By www.heating spares.co Tel. [phone]

5

Flue Installation

Flue Duct
(Standard or Long)

Mark the duct to length “S”+11mm
then cut square and remove any burrs.

SECTION

step

2895

9

S+11mm

WALLPLATE
/TEMPLATE

S

Terminal/Air Duct
(Standard or Long)

Mark the duct to the length “S”+13mm
then cut square and remove any burrs.

STANDARD 1METRE AND 2 METRE FLUE
TERMINAL KFB 70 ONLY.
1 METRE AND 2 METRE FLUE TERMINAL
KFB 60 ONLY

step

10

1m 2m FLUE
TERMINAL

STANDARD
FLUE TERMINAL
KFB 60

S+13mm

18

220692C

18

WALLPLATE
/TEMPLATE

S

Supplied By www.heating spares.co Tel. [phone]

Flue Installation

5

Air Duct/Terminal and
Flue Duct Assembly

Locate the flue duct into the air duct/
terminal.

Place the sealant from the loose items
pack onto the flue manifold.

Fully locate the flue manifold into the
air duct/terminal and flue duct
assembly as shown, ensuring correct
alignment of the “TOP”s.

step

11

step

12

2896

SECTION

FLUE
DUCT

AIR DUCT/TERMINAL
ASSEMBLY

SEALANT

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

Secure the air duct/terminal to the flue
manifold with the two self tapping screws
supplied in the loose items pack.

It should now not be possible to remove
the manifold.

step

13

AIR DUCT/TERMINAL
AND FLUE DUCT
ASSEMBLY

FLUE MANIFOLD

5mm

3mm DRILL SIZE

19

19

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5

Flue Installation

Wall Thickness up to
300mm

Fit the self adhesive foam seal provided
in the loose items pack around the air
duct/terminal at the position shown.

SECTION

Wall Thickness over
300mm

step

14

step

15

FOAM SEAL

10mm

3039

Q

FOAM SEAL

Fix the self adhesive foam seal around
the air duct/terminal such that, when
installed, the seal will be within the
wall sleeve.

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

On all installations push the flue
assembly into and through the wall
sleeve and hole such that it is within
the wall sleeve and does not stick out
into the room. Do not push the flue
assembly too far into the hole as it has
to be pulled back into the boiler and
secured to the keyhole fixings.

step

16

Q-25mm

Q

WALL
SLEEVE

Note: That the foam seal is a tight fit in
the wall sleeve, so either the wall
sleeve will need to be rigidly fixed in
the wall, that is, the cement has fully
set or it can be held from the other side

20

whilst inserting the flue assembly.

220692C

20

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Installation

6

Boiler Preparation

Remove the front panel and place it
on one side until required.

Remove and discard internal packing
piece.

Remove the inner case by releasing
the screws at the bottom and
unhooking at the top, place on one
side until required.

step

1

step

2

FRONT
PANEL

3040

SECTION

Remove the violet and red electrical
connections from the fan.

Break the air pressure switch tubes
connections.

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

WHEN FITTING A REAR FLUE

FOLLOW STEPS

step

4

step

t o t o&

8

step

17

step

step

21

INNER
CASE

SCREW (3)

3

AIR PRESSURE
SWITCH
TUBES

RESET
BUTTON

CLEAR

RED

WHEN FITTING A SIDE FLUE

FOLLOW STEPS

step

9

t o

step

21

ELECTRICAL
CONNECTIONS

21

FAN/FLUE
HOOD
SCREW (2)

21

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6

Rear Flue Boiler
Installation

THE BOILER IS SUPPLIED FOR
REAR FLUE OUTLET.

Installation

step

3041

4

TOP
MOUNTING
BRACKET

SECTION

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.

Lift the boiler into position above the
top mounting bracket, allow the boiler
to slide down the wall onto the top and
bottom wall mounting brackets.

Check the engagement by pulling the
boiler forward at its base, there should
be no forward movement.

When the boiler is correctly located
secure it with the two screws.

BOTTOM
MOUNTING
BRACKET

step

5

22

Secure the flue assembly to the boiler,
using the previously fitted dogpoint
screws noting that these are keyhole
fixings.

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

220692C

step

6

LOCATION
LUG

KEYHOLE

22

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Installation

6

Fit fan/fluehood assembly by
engaging the fan outlet extension
over the flue manifold spigot.

Secure the fluehood assembly to the
heat exchanger with the screws
previously removed.

step

7

FAN
OUTLET
EXTENTION

3042

FLUE
MANIFOLD
SPIGOT

SECTION

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

Reconnect the violet and red electrical
connections to the fan, the polarity of
the connections is not important.

Reconnect the air pressure switch tubes
as shown.

step

8

ELECTRICAL CONNECTIONS

WHITE

RED

RED

AIR
PRESSURE
SWITCH
TUBES

Continue at

step

17

23

23

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6

Installation

Side Flue Boiler
Installation

Remove the appropriate blanking plate
on the casing and fit it to the rear flue

SECTION

outlet.

Remove the fan assembly from the
fluehood assembly, by removing the
two screws.

Partially refit the securing screws into
the fan.

Turn the fan assembly to the required
flue outlet direction.

step

9

step

10

REAR VIEW

GASKET

FAN REAR
OUTLET
EXTENTION

3043

BLANKING
PLATE

FAN SECURING
SCREW

FLUE HOOD
ASSEMBLY

Fit the flue hood over the partially
fitted securing screws in the special
key hole slot sandwiching the gaskets
and spacer between, take care not to
damage the gaskets.

Turn the flue hood in the direction
shown.

Remove and discard the fan rear
outlet extension from the fan by
releasing the clip.

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

Secure with the clip previously
removed.

step

11

GASKET

SPACER

GASKET

RIGHT HAND
FLUE HOOD
ASSEMBLY

FAN SECURING SCREW (4)

KEYHOLE SLOT

24

220692C

24

GASKETS
AND
SPACER

Supplied By www.heating spares.co Tel. [phone]

Installation

6

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.

Lift the boiler into position above the
top mounting bracket, allow the boiler
to slide down the wall onto the top and
bottom wall mounting brackets.

Check the engagement by pulling the
boiler forwards at its base, there should
be no forwards movement.

step

12

FAN SIDE
OUTLET
EXTENSION

THIS END
TO FAN

3044

RIGHT HAND
FLUE HOOD
ASSEMBLY

SECTION

LEFT HAND
FLUE HOOD
ASSEMBLY

When the boiler is correctly located
secure it with the two screws.

step

13

TOP
MOUNTING
BRACKET

BOTTOM
MOUNTING
BRACKET

25

25

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6

Installation

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

SECTION

loose items pack and place firmly
around the internal spigot of the flue
manifold.

Make sure of the correct location of the
flue and boiler.

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

Loosely fit one extended brass
fluehood/fan assembly screw to the
heat exchanger on the side that the
flue exits. Slide the fluehood/fan
assembly flange under this extended
brass screw whilst turning the assembly
to enable engagement of the fan outlet
extension onto the flue manifold spigot.

step

14

step

15

3045

BEIGE/GREY
SEALANT

FAN
OUTLET
EXTENTION

EXTENDED BRASS
FLUE HOOD FAN
ASSEMBLY SCREW

26

After fitting the fan outlet extension to
the spigot smooth the sealant over the
joint.

When correctly located, secure the
assembly by fitting the other extended
brass screw and tighten both down.

Reconnect the violet and red
electrical connections to the fan, the
polarity of the connections is not
important.

Reconnect the air pressure switch
tubes.

step

16

FLUE HOOD/
FAN ASSEMBLY

FLUE
MANIFOLD
SPIGOT

ELECTRICAL
CONNECTION(S)

RED

AIR PRESSURE
SWITCH TUBES

CLEAR

FAN
OUTLET
EXTENSION

220692C

26

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Installation

6

Water System
Connection

Connect the boiler to the water system
using the fittings provided in the loose
items pack.

The flow connection is on the right.

Gas Supply
Connection

Remove the electrical controls box
cover.

step

17

step

18

RETURN

ELECTRICAL
CONTROL
BOX COVER

SECURING
SCREW (4)

UNION
NUT

OLIVE

FLOW

3046

SECTION

Connect the gas supply to the gas
service cock on the boiler making
sure it is turned off.

Check for gas soundness up to the
cock, in accordance with the current
issue of BS6891.

step

19

27

INDICATOR
SLOT
(SHOWN OFF)

27

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6

Installation

Electrical Connection
and System Controls

SECTION

Cable Connection

The boiler must be earthed.
The incoming cables should be routed

from the right hand side of the boiler.
Remove the terminal connection plug

as shown.

Connect the incoming supply and
remote controls cables through the
restraining glands.

step

20

step

21

The electrical installation must comply with the current

issue of BS7671 and any local regulations which apply.

All controls and connections must be of the approved type.

PUMP
STRAIN
RELIEF
GLAND

TERMINAL
PLUG CONNECTION

TERMINAL CONNECTION
PLUG MAINS AND REMOTE
CONTROLS WIRING

✻ RED LINK

LONGER
EARTH LEADS

MAINS AND
SWITCH LIVE
STRAIN RELIEF
GLAND

2905

The earth conductor must be of a
greater length so that if the cable is
strained the earth is the last to become
disconnected.

Test the insulation resistance of the
mains cable to earth.

Test for polarity of the mains cables.
Check earth continuity and short circuit

of cables.
Replace the terminal connection plug.
Secure the cables in the plastic clips.

SL

✻ RED LINK

5
6

7
8
9

10

N

11

L

12

G/Y

G/Y

BLUE

BROWN

BLUE

BROWN

G/Y

CIRCULATION
PUMP

E
N

240V ~ 50Hz
PERMANENT

L

MAIN SUPPLY

N

FUSED AT 3AMP

L

E

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

28

220692C

28

✻ RED LINK

Supplied By www.heating spares.co Tel. [phone]

Completion and Commissioning

7

System
Commissioning - All
Systems

Sealed Water
Systems Only

Commissioning should be carried out by a competent
person in accordance with the current issue of BS6798.
Make sure that the system has been thoroughly flushed
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.

Clear any airlocks and check for water soundness.

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

Check the operation of the safety valve, by allowing
the 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 possible
conduct a manual check and test.

Release cold water to initial system design pressure.

SECTION

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

If air is present in the system, this may, in certain
circumstances, cause the overheat thermostat to trip. If
this occurs advise the user to operate the control
thermostat on a low setting until all air has been
expelled.

29

29

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7

Completion and Commissioning

Initial Lighting and
Testing and
Adjustment

Refit the inner case, by hooking it over

SECTION

at the top and securing with the screws
previously removed, at the bottom.

Make sure that the case is correctly
fitted and sealed.

Identify the controls by reference to the
diagram.

Check that the boiler is isolated from
the electrical supply.

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

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

The pilot gas rate is preset and MUST
NOT be adjusted, see Servicing, Step

15.

BOILER THERMOSTAT CONTROL KNOB
(Shown in the OFF position)

VIEWING
WINDOW

GAS SERVICE
COCK

3047

INDICATOR
SLOT
(SHOWN OFF)

NOTE:
Do not adjust
any other
setting screws.

For future reference stick the self
adhesive arrow indicator from the loose
items pack, to the data label against the
rating that the boiler is going to be set
to.

Loosen the main burner pressure test
point screw and fit a suitable pressure
gauge.

Make sure that any remote controls are
calling for heat.

Switch on or connect the electrical
supply to the boiler and heating system.

Warning. The gas valve and fan
operate on MAINS voltage, terminals
will become “LIVE”.

PRESSURE
TEST POINT

30

220692C

30

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Completion and Commissioning

7

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. Test insulation resistance to earth of mains
cables.

2. Test the earth continuity and short circuit of all
cables.

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

Turn the boiler thermostat knob fully clockwise to
the maximum setting.

The lighting sequence is automatic, as follows:

The fan operates
The spark ignition operates
The pilot solenoid opens

SECTION

The pilot burner lights
The ignition spark stops
The main solenoid opens -

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

The main burner will remain alight until switched
off, either by the boiler thermostat or a remote
system control.

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

31

31

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7

Completion and Commissioning

Testing - Gas

With the boiler on proceed as follows:
Test for gas soundness around the boiler

gas components using a suitable leak
detection fluid, in accordance with the
current issue of BS6891.

SECTION

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

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

Should any doubt exist about the gas rate,
check it using the gas meter test dial and a
stop watch, at least 10 minutes after the
burner has lit, making sure that all other
gas burning appliances and pilot lights are
off.

Space Saver K.F.B 60 Approx. Gas Rate

min med max

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

3048

MAIN BURNER
ADJUSTMENT
SCREW (8mm
ACROSS FLATS)

Space Saver K.F.B 70 Approx. Gas Rate

min med max

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

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

Turn the boiler thermostat knob fully
anti-clockwise to “Off”. Remove the
pressure gauge from the test point and
refit the screw, making sure that a gas
tight seal is made.

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

There may be an initial smell given off
from the boiler when new, this is quite
normal and it will disappear after a short
period of time.

Refit the electrical controls box cover
with the four screws previously removed.

8mm
SPANNER

DO NOT
ADJUST

Note: The neon indicator lights on the
printed circuit board are an aid to fault
finding, for details refer to Section 11.

32

220692C

32

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Completion and Commissioning

7

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.

SECTION

Refill the system, vent and again check for water
soundness.

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

The overrun thermostat will keep the pump running
when the boiler shuts down, so long as the
temperature within the boiler is above a
predetermined level, providing the control
thermostat is set at maximum.

When commissioning the system the boiler should
be fired with the bypass fully closed on full service,
that is, central heating and domestic hot water. The
system should then be balanced, adjusting the pump
and lockshield valve as necessary. Having achieved
a satisfactory condition, operate the boiler with the
bypass closed on minimum load, normally central
heating only with one radiator operating in the main
living area. The valve should be opened gradually
to achieve the appropriate flow rate as quoted in
Section 2. If necessary readjust the pump.

Operational Checks

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

Adjust the boiler thermostat and any system
controls to their required settings.

Do not attempt to adjust the thermostat calibration.
Operate the boiler again on full service and check

that the balancing is satisfactory, making further
adjustments as necessary to the system, radiator
valves and bypass.

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

If thermostatic radiator valves are fitted care must
be taken to ensure that there is an adequate flow rate
when the valves are closed. Refer to the current
issue of BS7478 on the use of thermostatic radiator
valves.

33

33

220692C

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8

Front Panel Assembly

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.

SECTION

It is delivered preset to 700mm high by
285mm deep.

Measure the height of the cupboard or
compartment, “H”.

Adjust the front panel height “H” as
necessary.

step

1

step

2

H = 700 to 728mm

W = 470mm

TOP HOLE FIXING
700 to 714mm

W

D = 285 to 315mm

3059

H

BOTTOM HOLE FIXING
714 to 728mm

Measure the depth of the cupboard or
compartment, “D”.

Adjust the front panel top mounting
bracket as necessary.

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

step

3

BOILER
MOUNTING WALL

ADJUSTMENT
SCREW

H

D

'MINUS' 1mm

34

220692C

34

FRONT
PANEL
TOP
MOUNTING
BRACKET

Supplied By www.heating spares.co Tel. [phone]

Front Panel Assembly

8

Locate the front panel assembly.

Engage the bottom front panel
assembly slide/catch and adjust as
necessary.

step

4

step

5

2908

SECTION

ADJUSTMENT
SCREW

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.

Advise the user of the precautions necessary to prevent
damage to the system and building in the event of the
heating system being out of use during frost and
freezing conditions.

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

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

SLIDE
ASSEMBLY

CATCH

9

SECTION

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

Reminder, leave these instructions with the user.

35

35

220692C

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10

Servicing

To ensure the continued efficient and
safe operation of the boiler it is
recommended that it is checked and
serviced as necessary at regular
intervals. The frequency of servicing
will depend upon the particular
installation conditions and usage, but in

SECTION

general once a year should be enough.
It is the Law that servicing must be

carried out by a competent person.
BEFORE STARTING A SERVICE

REMOVE THE FRONT PANEL as
shown, for Access, ISOLATE THE
BOILER FROM THE ELECTRICAL
SUPPLY AND TURN THE GAS
SUPPLY OFF AT THE GAS SERVICE
COCK, INDICATOR SLOT TO BE
VERTICAL.

Unless stated otherwise, all parts are
replaced in the reverse order to
removal.

After completing any servicing always
test for gas soundness and if necessary
carry out functional checks of controls.

step

1

step

2

step

3

SECURING
SCREW(4)

3049

FRONT PANEL

ELECTRICAL
CONTROLS
BOX COVER

INDICATOR
SLOT
(SHOWN OFF)

36

Access

Remove the electrical control box
cover by removing the four screws.

Note: As an aid to Servicing the air
pressure switch tube connection can be
used to obtain a products of combustion
reading.

Follow Steps 1, 2 and 4.
Remove the RED tube from the

connection on the air pressure switch
and insert the analyser probe into the
tube.

Switch on the electrical supply to
operate the fan and turn on the gas
supply.

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

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

step

4

GAS SERVICE
COCK

INNER
CASE

SCREW (3)

step

5

220692C

36

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Servicing

10

Cleaning the Heat
Exchanger

Slacken the flue hood by loosening the
extended brass screws at the left and
right hand sides.

Remove the split pin and thermostat
phials from the pocket, taking care
not to kink the capillaries.

When replacing the phials make sure
that they are still covered with heat
sink compound.

step

6

step

7

FAN/FLUE HOOD
SCREW (2)

PHIAL
POCKET

3050

SECTION

SPLIT PIN

OVERHEAT
CUT-OFF
PHIAL

Disconnect the air pressure switch
tubes.

step

8

THERMOSTAT
PHIAL

RED

AIR
PRESSURE
SWITCH
TUBES

WHITE

37

37

220692C

Supplied By www.heating spares.co Tel. [phone]

10

Servicing

Disconnect the gas service cock at the
union connection.

Disconnect the electrical connection
plug by pulling it out from the right
hand side of the control box.

SECTION

Remove the violet and red electrical
connections on the fan and cable from
the securing clips.

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

Slacken the air pressure pipe union and
turn through 90o.

step

9

CLIPS

FAN ELECTRICAL
CONNECTIONS

AIR PRESSURE
PIPE UNION

SECURING
SCREWS (10)

ELECTRICAL
CONNECTIONS
PLUG

3051

Remove the rear flueway cleaning
plate.

Remove the heat exchanger front
cover, by removing the eight securing
screws.

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

Remove the three baffles.

step

10

step

11

GAS SERVICE COCK
UNION CONNECTION

REAR FLUEWAY
CLEANING PLATE

SECURING
SCREW (6)

HEAT
EXCHANGER
FRONT
COVER

38

220692C

38

BAFFLES (3)

Supplied By www.heating spares.co Tel. [phone]

Servicing

10

The heat exchanger can now be
cleaned with a suitably sized semi­stiff 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.

Correctly refit the baffles previously
removed, each is marked TOP on its
upper face.

Refit the heat exchanger front cover.
Tighten down the fan flue screws.
Refit the cleaning plate.

Main Burner

Remove the main burner by releasing
the two securing nuts as shown. Brush
or vacuum away any deposits, ensure
that the flame ports are clean.

step

12

step

13

3108

50mm

SECTION

380mm MIN.

20mm

40mm

SEMI-STIFF
NYLON BRISTLES
CLEANING BRUSH

CLEANING
PLATE

PILOT
BURNER SHIELD

DO NOT USE A BRUSH WITH
METALLIC BRISTLES.

Make sure that the pilot burner shield is
located between the burner bracket as
shown.

Main Injector

The main injector can be removed
and cleaned.

When cleaning the injector do not use
a wire or sharp instrument on the
hole.

BURNER
BRACKET

INJECTOR

step

14

VIEW OF MAIN
BURNER INJECTOR
WITH BURNER REMOVED

39

SECURING
NUTS

220692C

39

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10

Servicing

Pilot Burner, Ignition
Electrode and Pilot
Injector

SECTION

Pull off the ignition lead at the
electrode (covered with a silicone
rubber sleeve).

Unscrew the tubing nuts at both ends
releasing the pilot pipe.

Remove the pilot burner securing
screws to release the pilot burner and
electrode assembly.

Clean the pilot burner and electrode.
Remove the pilot injector by

unscrewing it from the pilot burner,
clean it by blowing through it.

When refitting take care not to damage
the electrode and check that the spark
gap is as shown.

step

15

IGNITION
LEAD

SILICONE
RUBBER
SLEEVE

PILOT TUBING NUT

4781

PILOT
BURNER
ASSEMBLY
SECURING
SCREW (2)

PILOT
PIPE

PILOT TUBING NUT

15-20mm

SPARK GAP

3.5-4.5mm

PILOT BURNER

40

220692C

40

PILOT INJECTOR

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Fault Finding

11

Electrical

Important. On completion of the
service/fault finding task which has
required the breaking and remaking of
the electrical connections the earth
continuity, polarity, short circuit and
resistance to earth checks must be
repeated using a suitable multimeter.

Refer to Fault Finding, Wiring and
Functional Flow diagrams.

Electrical Supply
Failure

Failure of the electrical supply will
cause the burner to go out. Operation
will normally resume on restoration of
the electrical supply. If the boiler does
not relight after an electrical supply
failure the overheat device may need
resetting.

Remove the front panel as Section 1,
Step 1 and press the reset button on top
of the electrical controls box cover, see
diagram at Step 3. If the cut off
operates at any other time press the
reset button and the burner should
relight. If the fault persists refer to
Fault Finding Chart.

L

THERMOSTAT

SPARK
ELECTRODE

FUSE
TYPE F1
1 AMP

KEY

bk BLACK
br BROWN
b BLUE
v VIOLET p PURPLE

PUMP

OVERRUN

(L)

11

7

p

9

w

rv

AIR
PRESSURE
SWITCH

brbr

9

8

br b

PUMP

br

b

O/H CUTOFF

y

CONTROL STAT

FAN

r

bk

y

w WHITE
r RED
y YELLOW

br

7

LINK

6

2

*

12

3

3

(N/C)

r

(N/O) (C)

1

RED

(SL)

2914

SECTION

8

b

10

(N)

10

b

(N)

b

y

RED LINK may have been removed

to fit remote controls.

*

41

br

PILOT
SOLENOID

bk

MAIN
SOLENOID

AIR PRESSURE SWITCH CONNECTIONS
MAIN TERMINAL STRIP CONNECTIONS
CONTROL THERMOSTAT CONNECTIONS
PRINTED CIRCUIT BOARD CONNECTIONS

b

b

10

10

(N)

b

(N)

N

41

220692C

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11

Fault Finding

SECTION

AIR PRESSURE

SWITCH

C

NC NO

123

FAN

g/y

CHASSIS

EARTH

KEY:

b - BLUE
bk - BLACK
br - BROWN

v

r

r - RED
g/y - GREEN/YELLOW

- MAIN TERMINAL STRIP

- CONTROL THERMOSTAT
AIR PRESSURE SWITCH

-

NUMBER = BECK LETTER = YAMATAKE

p - PURPLE
v - VIOLET
w - WHITE
y - YELLOW

3109

OVERHEAT

CUT-OFF

CONTROL

THERMOSTAT

y

p

7

w

986

3

br

r

y

CHASSIS

EARTH

r

v

g/y

POST

42

r

y

PRINTED CIRCUIT

BOARD

SPARK

ELECTRODE

FUSE

TYPE F1

1 AMP

bk

GAS

VALVE

bk

br

g/y

b

g/y

CIRCULATION

5
6
7
8

9
10
11
12

b

br

g/y

SWITCHED

LIVE

PUMP

g/y

b

br

b

br

g/y

240V~50Hz

PERMANENT

E
N

L

N

L

E

MAINS SUPPLY

Remove RED link

FUSED 3 AMP

between 7 and 12

when fitting a time

control etc. (If no

switch is fitted the

pump will run

continuously).

220692C

42

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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.

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 - see
detailed 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

11

4754

SECTION

43

NEON INDICATORS (4)

3054

43

220692C

Supplied By www.heating spares.co Tel. [phone]

11

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

Is neon 1 lit?

YES

SECTION

Is neon 2 lit?

YES

Fault Finding

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

NO

NO

YES

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

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

NO

YES

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

NO

YES

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

NO

Correct power supply problem.

Check overheat reset.
If satisfactory replace overheat device.

Replace thermostat.

4780

Is neon 3 lit?

YES

Is neon 4 lit?

YES

NO

NO

Is there 240V~ between
1 on air pressure switch and 10 ?

NO

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

YES

Is there 240V~ between 3 on air
pressure switch and 10 ?

NO

Replace air pressure switch.

YES

NO

Does fan run?

YES

Replace fan.

Is there 240V~ between motor connections
on fan?

YES

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

YES

Does fan Hunt? Replace printed circuit board.

NO

Is there 240V~ between 2 on air
pressure switch and 10 ?

NO

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

YES

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

NO

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

YES

NO

Is there a spark at pilot burner?

YES

Does pilot light?

YES

With pilot lit does spark stop?

YES

Does main burner light?

YES

44

220692C

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

NO

YES

Replace gas valve.System satisfactory.

44

NO

NO

NO

NO

Check lead continuity and inspect electrode
and lead for damage.

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

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

Isolate supply, test harness and replace
as required.

AIR PRESSURE SWITCH

MAIN TERMINAL STRIP

CONTROL THERMOSTAT

Supplied By www.heating spares.co Tel. [phone]

Fault Finding

11

Pump overrun Operation

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

The Control Thermostat has a pump overrun facility built into it, when the Control Thermostat is set at maximum only,

calling for heat.

Fault Finding

Turn 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?

YES

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

YES

NO NO

Is there 240V~ on 11 ?

Faulty Pump overrun.
Replace Control
Thermostat

NO

Faulty permanent live feed.
Replace.

YES

4756

SECTION

Pump overrun in order.

Is there 240V~ on 9
connection on thermostat?

YES

Is there 240V~ on 9 for
pump?

YES

NO

NO

Faulty connections between
thermostat and terminal strip.
Repair.

Faulty internal wiring between
terminal block and thermostat.
Repair.

Faulty pump / wiring ? Replace
or repair as necessary.

45

45

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12

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.

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

SECTION

Pilot Burner/Injector
and Ignition Lead

Gain access as Section 10, steps 1 to 4.
Pull off the ignition lead at the

electrode (covered with a silicone
rubber sleeve) and printed circuit
board.

Unscrew the tubing nuts at both ends
releasing the pilot pipe.

Remove the pilot burner by
unscrewing the two securing screws as
shown.

The pilot burner or injector can now be
replaced.

Electrode

IGNITION
LEAD

ELECTRODE
SECURING
SCREW

SILICONE
RUBBER
SLEEVE

ELECTRODE

PILOT TUBING NUT

PILOT
PIPE

PILOT
BURNER
INJECTOR

PILOT
BURNER
ASSEMBLY
SECURING
SCREW (2)

3055

46

Gain access as Section 10, steps 1 to 4.
Pull off the ignition lead at the

electrode.
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 earth

connector.
Disconnect the three electrical plugs,

ignition lead, the earth and mains
cables.

Pull the board away from the supports.
When fitting the replacement make

sure that it is correctly located on to the
securing posts and make sure that all
the connections are remade.

IGNITION
LEAD

PILOT TUBING
NUT

HEAT SHIELD
EARTH LEAD

ELECTRICAL
PLUGS (3)

SECURING
POST

220692C

46

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Replacement of Parts

12

Control Thermostat
and Overheat Cutoff

Gain access as Section 10, steps 1 to 5.

Control Thermostat:

Pull off the control thermostat knob,
remove the two screws securing the
thermostat to the control box.

Remove the electrical connections from
the thermostat body.

Overheat Cutoff:

Remove the nut securing the overheat
cutoff, withdraw the assembly.

Control Thermostat/
Overheat Cutoff

PHIAL
POCKET

SECURING
SCREW(2)

SPLIT PIN

OVERHEAT
CUTOFF
PHIAL

YELLOW

PURPLE

BROWN

RED

YELLOW

CONTROL KNOB

WIRING
DIAGRAM

7

689

3

3056

SECTION

Now remove the split pin and then the
thermostat phials from the pocket.

Make sure that the thermostat
capillaries are correctly routed and the
phials are securely fitted into the
pocket.

Note: The position of the two phials
should be as shown when replacing in
the pocket.

Reconnect the electrical leads as
shown.

When replacing either of these
thermostats make sure that the phial is
smeared with the heat sink compound
supplied with the replacement.

THERMOSTAT
PHIAL

SEAL

CUT OUT

SECURING NUT

WIRING

DIAGRAM
OVERHEAT
CUTOFF

YELLOW

PURPLE

47

OVERHEAT CUTOFF

WHITE

BROWN

RED

YELLOW

47

220692C

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12

Replacement of Parts

Air Pressure Switch

Note: Alternative types of Air
Pressure Switches may be fitted.

Gain access as Section 10 steps 1 to 4.

SECTION

Remove the air pressure tubes and
electrical connections, release the
screws and nuts, remove the switch.

When fitting the replacement make
sure that all the plastic tubes and
electrical connections are made as
shown.

SECURING
SCREW (2)

RED

SECURING
SCREW (2)

BLACK

YELLOW

RED AIR
PRESSURE TUBE

CLEAR AIR
PRESSURE TUBE

YAMATAKE

BECK

RED AIR
PRESSURE
TUBE

3057

Gas V alve

Gain access as Section 10, steps 1 to 4.
Disconnect all electrical leads from the

gas valve.
Disconnect the pilot pipe at the pilot

burner.
Undo the four screws at the outlet

manifold and disconnect the gas
service cock union.

Transfer the half union of the gas
service cock to the inlet of the
replacement gas valve. Also transfer
the pilot supply pipe. Use a little
thread sealant on the external threads to
ensure gas soundness.

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

BLACK

PILOT
BURNER

PILOT
PIPE

SECURING
SCREW (4)

YELLOW

EARTH

CONNECTOR

RED

GAS SERVICE
COCK UNION

BLUE

BLACK

G/Y

CLEAR AIR
PRESSURE
TUBE

ELECTRICAL
LEADS

BROWN

It will be necessary to purge the
pipework and valve before relighting,
check gas pressure settings, refer to
Section 7.

48

220692C

48

WIRING
DIAGRAM

"O" RING

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Replacement of Parts

12

Fan

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

Remove the electrical connections and
disconnect the air tubes.

Remove the fluehood/fan assembly
screws and withdraw the assembly.

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

Remove the sealant from the fan outlet
and manifold.

Take the beige/grey sealant supplied
with the replacement fan and place
firmly around the internal spigot of the
flue manifold.

After fitting the fan outlet to the spigot
smooth the sealant over the joint.

step

1

3058

ELECTRICAL
CONNECTIONS

SECTION

EARTH

CONNECTION

AIR PRESSURE
SWITCH TUBES

FAN/FLUEHOOD
SCREW (2)

Make sure that when fitting the
replacement fan to the flue hood that it
is the correct way round for connection
to the flue, refer to the diagram in
Section 6, also steps 10 and 11.

Make sure that the earth connection
is remade onto the new fan assembly.

The polarity of the other connections is
not important.

step

2

SECURING
SCREW (2)

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.

49

49

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12

Replacement of Parts

Insulation

Gain access as Section 10, steps 1 to

10.

SECTION

Combustion Chamber
Sides and Rear:

Remove the baffles.
Remove the insulation and fit the

replacement parts making sure they are
fitted as shown.

COMBUSTION
CHAMBER
SIDE

step

1

COMBUSTION
CHAMBER REAR

3107

SECURING
SCREW (2)

BAFFLE

70 ILLUSTRATED

Heat Exchanger Front
Cover Panel:

Remove panel, Section 10, step 10.
Upper Insulation: push up and pull out

to remove.
Lower insulation: remove the securing

screws and angle and remove the
insulation.

When refitting either, make sure that it
is fitted as shown.

Viewing Window

step

2

COMBUSTION
CHAMBER
FRONT PANELS

SECURING
SCREW (2)

Gain access as Section 10, steps 1 to 4.

SECURING
SCREW (2)

Remove the two screws and then the window.

50

220692C

When replacing take care not to damage the gasket.

50

Supplied By www.heating spares.co Tel. [phone]

Spare Parts

13

Part Identification

The key number in the diagram and the
list will help to identify the part.

Ordering

When ordering any spare parts please
quote the part number and description
from the list together with the model
name and serial number.

If ordering from the local gas
undertaking also quote the GC number of
the appliance and part.

8

7

14

12

5 6B

4760

1

2

10

11

3

SECTION

9

4

6A

13

Key Glow-worm Description GC No.

No Part No

1 800165 Gas valve assembly, inc item11 313 300
2 202539 Thermostat 397 893
3 202538 Overheat thermostat 397 894
4 900817 Printed circuit board 313 301
5 440073 Fan assembly (60) - special 397 987
5 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 14 313 304
8 800187 Pilot injector - special 313 392
9 205701 Main injector (60) - special 313 393

9 205702 Main injector (70) - special 313 394
10 440108 Control knob - thermostat - assembly 313 306
11 208040 “O” ring - gas valve 334 592
12 202015 Fuse to BS4265 sheet 2. type F1A 334 750
13 WX1800 Ignition lead 313 307

14 800188 Electrode - special 313 395

51

51

220692C

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SECTION

52

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

220692C

52