Glowworm Space Saver K-F-B 30 Guida utente

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

One Contact Local Service

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

221051B.01.98

To be left with user

4757

S P A C E S A V E R

K .F .B

30 GC 41 319 08

40 GC 41 319 09

50 GC 41 319 10

This is a Cat I2H Appliance

BS 6332

BS 5258

Reference in these instructions to

British Standards and Statutory Regulations/

Requirements apply only to the United Kingdom.

For Ireland the rules in force must be used.

Fully Pumped system.

Open Vented or Sealed.

Fanned Flue Boiler

Installation and Servicing Instructions

221051B

SECTION

Section Title Page No

Contents Location Map

Control ofSubstances Hazardous to Health

2890

BELPER

Milford

Site

A6 DERBY

MILFORD

A6 MATLOCK

A519 ASHBOURNE

B6013 RIPLEY

A609 NOTTINGHAM

Nottingham Rd

Site

Belper and Milford

Factory Sites

Belper

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.

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

GENERAL ........3

WATER SYSTEMS ........7

BOILER LOCATION ........11

FLUE and VENTILATION .......13

FLUE INSTALLATION ........15

INSTALLATION ........ 21

COMPLETION

and COMMISSIONING ........29

FRONT PANEL

ASSEMBLY ........34

USER INFORMATION ........35

SERVICING ........36

FAULT FINDING ........41

REPLACEMENT

OF PARTS ........46

SPARES ........ 51

3221051B

SECTION

General 1

72.5

350

WATER

CONNECTIONS

22mm COMPRESSIONS

GAS CONNECTION

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

125

102

FRONT VIEW

BOILER OUTLINE

50 63

REAR FLUE

OUTLET

125

687

105

345

358

FRONT VIEW SIDE VIEW

700-

728 130

285-

315

SIDE FLUE

OUTLET

TOP VIEW

R F

TOP FLUE

OUTLET

All dimensions are in millimetres

2885

115

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 Gas Safety (Installation

and Use) Regulations, be handed to the

user on completion of the installation.

Important Notices

This boiler is for use only on G20 gas.

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

WARNING. When installing or servicing

the boiler care should be taken when

handling sheet metal parts to avoid any

possibility of personal injury.

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

The Gas Safety (Installation and Use)

Regulations, The Building Regulations,

The Building Standards (Scotland)

Regulations, (applicable in Scotland)

Local Water Company Bye-laws, The

Health and Safety at Work Act, Control of

Substances Hazardous to Health, The

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, BS5546

Part 1, BS5449, BS6891, BS4814,

BS7074 Part 1 and 2, BS6700, BS7478,

BS7593, BS7671.

Manufacturer’s instructions must not be

taken as overriding statutory

requirements.

221051B

SECTION

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

This boiler meets the requirements of

Statutory Instrument, No. 3083, The

Boiler (Efficiency) Regulations, and

therefore is deemed to meet the

requirements of Directive 92/42/EEC on

the efficiency requirements for new hot

water boilers fired with liquid or

gaseous fuels.

Type test for purposes of Regulation 5

certified by:

Notified body 0086.

Product/production certified:

Notified body 0086.

The CE Mark on this appliance shows

compliance with:-

1. Directive 90/396/EEC on the

approximation of the Laws of the

Member States relating to appliances

burning gaseous fuels.

2. 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.

3. Directive 89/336/EEC on the

approximation of the Laws of the

Member States relating to

electromagnetic compatibility.

Space Saver K.F.B 40pace Saver K.F.B 40

pace Saver K.F.B 40pace Saver K.F.B 40

pace Saver K.F.B 40

G.C.Number4131909

Space Saver K.F.B 50pace Saver K.F.B 50

pace Saver K.F.B 50pace Saver K.F.B 50

pace Saver K.F.B 50

G.C.Number4131910

Space Saver K.F.B 30Space Saver K.F.B 30

Space Saver K.F.B 30

G.C.Number4131908

3038

Data Label Position

5221051B

SECTION

General 1

in wg 4.3 5.3 4.0

mbar 10.8 13.1 10.0

in wg 6.1 6.7 5.0

mbar 15.3 16.6 12.4

Btu/h 31,566 44,136 56,570

kW 9.25 12.9 16.58

Btu/h 37,500 50,000 62,500

kW 11.0 14.65 18.32

Btu/h 20,000 30,000 40,000

kW 5.86 8.79 11.72

in wg 2.7 3.8 3.3

mbar 6.8 9.4 8.1

Btu/h 30,000 40,000 50,000

kW 8.79 11.72 14.65

Btu/h 25,000 35,000 45,000

kW 7.33 10.25 13.19

Nominal min

Heat med

Input max

(Gross)

Nominal min

Heat med

Ouput max

Burner min

Setting med

Pressure max

Space Saver Space Saver Space Saver

Range Rating K - F - B K - F - B K - F - B

30 4 0 5 0

Btu/h 25,476 38,217 50,630

kW 7.47 11.2 14.84

Space Saver Space Saver Space Saver

Model K - F - B K - F - B K - F - B

30 4 0 5 0

Lifting 25.0kg 25.0kg 25.0kg

Weight (55lb) (55lb) (55lb)

Total 30.0kg 30.0kg 30.0kg

Weight (dry)* (66lb) (66lb) (66lb)

Water 1.7 litres 1.7 litres 1.7 litres

Content (0.37 gal) (0.37 gal) (0.37 gal)

Gas Rc1/2Rc1/2Rc1/2

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

Water 22mm 22mm 22mm

Connection Compression Compression Compression

Electrical 240V~50Hz fused 3A max

supply

Internal Fuse to BS4265 sheet 2. Type F1A

Fuse Rating

Power rating 55W

* Note: The weight of the water is negligible

Range Rating

The boiler is range rated and may be

adjusted to suit individual system

requirements, refer to the relevant

column of the table.

DataTable

221051B

SECTION

General

Gas Supply

Electrical Supply

DrainingTap

SafetyValve

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. This method of

connection should be, preferably, an unswitched

shuttered socket outlet and 3 pin plug, both to the

current issue of BS1363.

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.

A safety valve need not be fitted to an open vented

system.

7221051B

SECTION

Water Systems

Bypass

Inhibitor

PRESSURE DROP OF BOILER

Flow rate (litres / minute)

Water pressure drop (mm head of water)

Water pressure drop (inches head of water)

Flow rate (gallons / minute)

0123456

51015202530

250

500

750

1000

1250

1500

UNIT

litre / min.

gal / min.

7.6

1.7

11.5

2.5

15.3

3.4

11.5

2.5

15.3

3.4

19.1

4.2

Min.

HEAT SETTING

At 11˚C (20˚F) differential

WATER FLOW RATE

Max.

4779

Notes: Open Vented

and Sealed 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.

A BYPASS MUST BE FITTED, see also Section 7.

The flow through the boiler must not be allowed to

fall below......

Space Saver KFB30 - 6.4litres/min (1.4galls/min)

Space Saver KFB40 - 8.4litres/min (1.8galls/min)

Space Saver KFB50 - 10.5litres/min (2.3galls/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.

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.

221051B

SECTION

BOILER

CEILING

THE WATER LEVEL IN STATIC CONDITION

MUST BE ABOVE THE BEND IN THE PIPE.

45˚

APPROX.

COLD

FEED

TOP OF THE

APPLIANCE

WITHOUT

CASE

NOTE: VENT PIPE AND COLD

FEED PIPE MUST BE

MADE FROM Ø22 TUBE.

COLD

FEED

RETURN

SLIGHT RISE

FLOW

PUMP

150mm

MAX

300mm

MIN

120mm

MIN

300mm

MIN

300mm

MAX

620mm

MIN

CENTRE

LINE

Water Sysems (Open Vented)

2887

Low Head Installation

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 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 HotWater

Cylinder

The hot water cylinder must be of the

double feed fully indirect type. Not the

self priming type.

6003

FEED AND

EXPANSION

CISTERN

22mm VENT

(MIN.)

15mm (MINIMUM)

COLD FEED

OPEN VENTED FULLY PUMPED WATER SYSTEM

RECOMMENDED RELATIONSHIP BETWEEN

PUMP COLD FEED AND VENT

450mm

MIN.

HEIGHT

1150mm

MIN.

RETURN

FLOW

CYLINDER

PUMP

HEATING

150mm

MAX.

There must always

be a cold water path

to the return

connection

of the boiler.

BOILER 15mm (MINIMUM)

BY-PASS WITH

LOCKSHIELD VALVE

FLOW

RET.

9221051B

SECTION

3 LITRES (0.66 gals)

MAKE-UP BOTTLE

(if required)

NON-RETURN

VALVE

AUTO

AIR

VENT

FLOW

DRAIN

COCK BOILER

SAFETY

VALVE

(Make-up

alternatives) EXPANSION

VESSEL

PRESSURE

GAUGE

CIRCULATING

PUMP

FILLING POINT

AIR

RELEASE

POINT

HEATING

CIRCUIT

15mm (min)

BY-PASS WITH

LOCKSHIELD

VALVE

RETURN

Water Systems (Sealed) 2

5812

ExpansionVessel

SealedWater Systems

The installation must comply with the

appropriate requirements of the current

issue of BS5449 Part 1, BS6798, BS4814

and BS7074 Part 1 and 2.

See the diagrammatic layout.

SafetyValve

A safety valve must be fitted to a sealed

water 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.

Where a safety valve is fitted the drain

from it must be routed clear of any

electrical fittings but positioned so that

any discharge can be seen.

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 Section 7.2.

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 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.

221051B

SECTION

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.

Domestic HotWater

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

any local Water Company Bylaws, see

also the current issue of BS5446 and

BS6700.

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 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

of the hot water cylinder.

Alternatively, provision for make up can

be made by pre-pressurisation of the

circuit.

Filling Sealed 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.

METHOD 1

METHOD 2

METHOD 3

SUPPLY STOP

VALVE

SUPPLY

PIPE

HOSE

UNIONS SERVICING

VALVE

TEMPORARY

HOSE

HEATING

SYSTEM

HEATING

SYSTEM

TEMPORARY

HOSE

UNIONS SERVICING

VALVE

SUPPLY

PIPE

SUPPLY STOP

VALVE

DOUBLE CHECK

VALVE ASSEMBLY

HEATING

SYSTEM

SERVICING

VALVE

SUPPLY

STOP VALVE

SUPPLY

PIPE

HOSE

UNIONS DOUBLE CHECK

VALVE ASSEMBLY

OVERFLOW

CISTERN

COMBINED

CHECK VALVE

AND VACUUM

BREAKER

PRESSURE

REDUCING

VALVE

0051M

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