Glowworm Space Saver K.F.B 60 User guide

Supplied By www.heating spares.co Tel. [phone]
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
This is a Cat I2H Appliance
BS 6332
BS 5258
Fully Pumped system.
Open Vented or Sealed.
Fanned Flue
Boiler
4757
S P A C E S A V E R
K .F .B
60 GC 41 319 11
70 GC 41 319 12
220692C.01.98.
To be left with user
Installation and Servicing Instructions

Supplied By www.heating spares.co Tel. [phone]
2
220692C
2
SECTION
Section Title Page No
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
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 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.
Control ofSubstances Hazardous to Health
BELPER
Milford
Site
A6 DERBY
MILFORD
A6 MATLOCK
A519 ASHBOURNE
B6013 RIPLEY
A609 NOTTINGHAM
Nottingham Rd
Site
N
Belper and Milford
Factory Sites
Belper
2890

Supplied By www.heating spares.co Tel. [phone]
3220692C
3
SECTION
General 1
3060
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
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
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.
55
70 35
R F
WATER CONNECTIONS
28mm COMPRESSIONS
GAS CONNECTION
Rc1/2(1/2"B.S.P.T.)
TOP VIEW
450
40
285-
315
SIDE
FLUE
OUTLET
130
700-
728
125
458
FRONT VIEW
445
155
125
SIDE VIEW
REAR
FLUE
OUTLET 687
50
15
FRONT VIEW
BOILER OUTLINE
102
63
FLUE
TERMINAL
DETAIL
ALL DIMENSIONS ARE IN MILLIMETRES

Supplied By www.heating spares.co Tel. [phone]
4
220692C
4
SECTION
General
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
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.
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.

Supplied By www.heating spares.co Tel. [phone]
5220692C
5
SECTION
General 1
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
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 Saver
Range 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.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)
Gas Rc1/2Rc1/2
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
* 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

Supplied By www.heating spares.co Tel. [phone]
6
220692C
6
SECTION
General
1
Gas Supply
Electrical Supply
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. The 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.
DrainingTap

Supplied By www.heating spares.co Tel. [phone]
7220692C
7
SECTION
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.
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
2
Water Systems
Bypass
Inhibitor
Notes: OpenVented
and SealedWater
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.
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)
0
0 5 10 15 20 25 30 35
0
200
400
600
800
1000
1200
1400
0
10
20
30
40
50
1234567
UNIT
litre / min.
gal / min.
19.1
4.2
22.9
5.0
22.9
5.0
26.7
60 70
Min.
HEAT SETTING
At 11˚C (20˚F) differential
WATER FLOW RATE
Max.
60 70
5.9
4778

Supplied By www.heating spares.co Tel. [phone]
8
220692C
8
SECTION
Water Sysems (Open Vented)
1
2886
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
450mm
MIN.
HEIGHT
1metre MIN.
27.5metres MAX.
BOILER
PUMP
150mm
MAX
FLOW
RET.
RET.
CYLINDER
FLOW
HEATING
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.

Supplied By www.heating spares.co Tel. [phone]
9220692C
9
SECTION
Water Systems (Sealed) 2
2888
Sealed Water 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.
Safety Valve
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.
ExpansionVessel 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.
BOILER
3 LITRES (0.66 gal)
MAKE-UP BOTTLE
(if required)
NON-
RETURN
VALVE
AUTO
AIR
VENT
FLOW
22mm (min)
BYPASS
WITH
LOCKSHIELD
VALVE
RETURN
DRAIN
COCK
SAFETY
VALVE
(Make-up
alternatives) EXPANSION
VESSEL
PRESSURE
GAUGE
CIRCULATING
PUMP
FILLING POINT
AIR
RELEASE
POINT
HEATING
CIRCUIT

Supplied By www.heating spares.co Tel. [phone]
10
220692C
10
SECTION
Water Systems (Sealed)
2
METHOD 1
METHOD 2
METHOD 3
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
HEATING
SYSTEM
TEMPORARY
HOSE
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
Filling SealedWater
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.
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 the local Water Company bylaws,
see also the current issue of BS5546
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
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.

Supplied By www.heating spares.co Tel. [phone]
11 220692C
11
SECTION
3
Boiler Location
WHERE EXTERNAL ACCESS TO THE
FLUE IS NOT PRACTICAL THEN
CLEARANCE MUST BE ADEQUATE
TO PERMIT INSTALLATION OFF THE
FLUE ASSEMBLY
✽
70mm
10mm 5mm
5mm
5mm
5mm
10mm
100mm
2891
500mm
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.
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.

Supplied By www.heating spares.co Tel. [phone]
12
220692C
12
SECTION
Boiler Location
2
Timber Frame
Buildings 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.
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.
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 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)
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)

Supplied By www.heating spares.co Tel. [phone]
13 220692C
13
SECTION
4
Flue and Ventilation
ADIRECTLY BELOW AN OPENABLE WINDOW, AIR VENT, 300
OR ANY OTHER VENTILATION OPENING
BBELOW GUTTER, DRAIN/SOIL PIPE 75
CBELOW EAVES 200
DBELOW A BALCONY OR CAR PORT 200
EFROM VERTICAL DRAIN PIPES AND SOIL PIPES 75
FFROM INTERNAL OR EXTERNAL CORNERS 300
GABOVE ADJACENT GROUND OR BALCONY LEVEL 300
HFROM A SURFACE FACING THE TERMINAL 600
IFACING TERMINALS 1200
JFROM OPENING (DOOR/WINDOW) 1200
IN CARPORT INTO DWELLING
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 300
MIN.
SPACING
(mm)
MINIMUM SITING DIMENSIONS
FOR FLUE TERMINALS
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
Car Port etc.
H,I
JD
F
K
0103M
The flue must be installed in accordance
with the current issue of BS5440 Part 1.
The boiler must be installed so that the
terminal is exposed to the external air.
It is important that the position of the
terminal allows the free passage of air
across it at all times.
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,
Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent.
TN9 1RA
their reference K3.
4783

Supplied By www.heating spares.co Tel. [phone]
14
220692C
14
SECTION
t o
Flue and Ventilation
2
t o
step
5
step
1
step
step
16
11
&
t o
step
16
step
6
REAR FLUE APPLICATION
FOLLOW
FLUE INSTALLATION
SIDE FLUE APPLICATION
FOLLOW
FLUE INSTALLATION
Flue Position and
Length
Note. If a longer flue duct is required
DO NOT extend the ducting. A special
long flue system and terminal can be
supplied and MUST be used.
DETERMINE FLUE APPLICATION,
LENGTH, AND TERMINAL
POSITION BEFORE PROCEEDING.
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.
Rear Flue Lengths
Distance'R'
STD 75mmto692mm
1m 692mmto1022mm
2m 1022mmto2022mm
R
2877
Side Flue Lengths
Distance'S'
STD 75mmto692mm
1m 692mmto1022mm
2m 1022mmto2022mm
S
2876

Supplied By www.heating spares.co Tel. [phone]
15 220692C
15
SECTION
step
5
Flue Installation
step
1
step
3
5.5mm DRILL SIZE
No. 10x11/2in
SCREW
WALLPLUG
300mm MAX
LENGTH
Q
Q
115mm
MINIMUM
HOLE
WALLPLATE/
TEMPLATE
2892
2
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 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.
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.
Reposition the wallplate/template
ensuring alignment with the flue hole.
Mark the top and bottom boiler
mounting hole positions.
Remove wallplate/template, drill holes
and then secure wallplate/template to the
wall with the fittings provided in the
loose items pack.

Supplied By www.heating spares.co Tel. [phone]
16
220692C
16
SECTION
Flue Installation
5
Q
Q+13mm
STANDARD
FLUE TERMINAL
1m 2m FLUE
TERMINAL
Q
Q+11mm
2893
step
step
4
5
step
11
Continue at
Flue Duct (Standard
or Long)
Mark the duct to the length
“Q”+11mm then cut square and
remove any burrs.
Air Duct/Terminal
(Standard or Long)
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

Supplied By www.heating spares.co Tel. [phone]
17 220692C
17
SECTION
5
Flue Installation
300mm MAX
LENGTH
5.5mm DRILL SIZE
No. 10x11/2in
SCREW
WALLPLUG
115mm
MINIMUM
HOLE
125mm
Q
Q
2894
step
step
6
step
8
7
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.
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.
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.

Supplied By www.heating spares.co Tel. [phone]
18
220692C
18
SECTION
Flue Installation
5
step
9
2895
step
10
S+11mm
S
S+13mm
WALLPLATE
/TEMPLATE
WALLPLATE
/TEMPLATE
Flue Duct
(Standard or Long)
Mark the duct to length “S”+11mm
then cut square and remove any burrs.
Terminal/Air Duct
(Standard or Long)
Mark the duct to the length “S”+13mm
then cut square and remove any burrs.
STANDARD
FLUE TERMINAL
KFB 60
S
STANDARD 1METRE AND 2 METRE FLUE
TERMINAL KFB 70 ONLY.
1 METRE AND 2 METRE FLUE TERMINAL
KFB 60 ONLY
1m 2m FLUE
TERMINAL

Supplied By www.heating spares.co Tel. [phone]
19 220692C
19
SECTION
5
Flue Installation
step
step
11
12
step
13 3mm DRILL SIZE
2896
AIR DUCT/TERMINAL
ASSEMBLY
FLUE
DUCT
SEALANT
AIR DUCT/TERMINAL
AND FLUE DUCT
ASSEMBLY
FLUE MANIFOLD
5mm
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.
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.

Supplied By www.heating spares.co Tel. [phone]
20
220692C
20
SECTION
Flue Installation
5
step
14
3039
step
16
step
15
WallThickness up to
300mm
Fit the self adhesive foam seal provided
in the loose items pack around the air
duct/terminal at the position shown.
WallThickness over
300mm
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.
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
whilst inserting the flue assembly.
FOAM SEAL
Q-25mm
FOAM SEAL
10mm
Q
Q
WALL
SLEEVE