Bosch thermotechnik Worcester 230 combi rsf User guide

.---~~~ORCESTER----.

Bosch Thermotechnik

230

Combi RSF

WALL

MOUNTED

COMBINATION

BOILER

FOR

CENTRAL

HEATING

AND

MAINS

FED

DOMESTIC

HOT

WATER

INSTALLATION

AND

SERVICING

INSTRUCTIONS

GCNo.

47

311

14

BOILER

OUTPUT

Automatic

Modulating

Control

To

Domestic

Hot

Water

Minimum

9.2

kW

(31,400

Btu/h)

Maximum 23.0

kW

(78,500

Btu/h)

To

Central

Heating

Minimum

9.2

kW

(31

,400

Btu/h)

Maximum 23.0

kW

(78,500

Btu/h)

IMPORTANT:

THIS

APPLIANCE

IS

FOR

USE

WITH

NATURAL

GAS

ONLY

THESE

INSTRUCTIONS

APPLY

IN

THE

UK

ONLY

THESE

INSTRUCTIONS

ARE

TO

BE

LEFT

WITH

THE

USER

OR

AT

THE

GAS

METER

Contents

1. Installation Regulations

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Page 2

2.

General

Information ..

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3.

Technical

Data

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Page 4

4.

Siting

the

Appliance

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Page 5

3.

Siting

the

Flue

Terminal

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Page 6

6.

Air

Supply

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Page 7

7.

Sealed

System

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Page 7

8.

Domestic

Hot

Water

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8

1. Installation

Regulations

1.1

Gas

Safety (Installation

and

Use)

Regulations 1984

All

gas appliances must be installed

by

a competent person

in

accordance

with

the above regulations.

Failure

to install appli·

ances correctly

could

lead to prosecution.

1.2

The

manufacturers notes must not

be

taken,

in

any way,as

overriding statutory obligations.

1.3

The

compliance with a

British

Standard does

not,

of

itself,

con·

fer

immunity

from

legal

obligations.

In

particular the installation

of

this appliance must be

in

accordance

with

the relevant require·

ments

of

the

Gas

Safety

(Installation and

Use)

Regulations 1984

as

amended, current

lEE

Wiring

Regulations

BS

7671, local

Building

Regulations,

Building

Standards

(Scotland)(Consolidation)

and bylaws

of

the local Water Company. Health and Safety

Document

No

.

635

(Electricity

at

Work

Regulations).

It should

be

in

accordance

with

the relevant recommendations

of

the

follow·

ing

British

Standards.

BS

6798:1987 Specification

for

installation

of

gas

fired

hot water

boilers

of

rated input not exceeding

60

kW.

BS

5449:1990

Central

Heating

for

Domestic

Premises.

BS

5546:1990 Installation

of

gas hot water supplies

for

domes·

tic

purposes.

BS

5440:1:1990 Flues and Ventilation

for

gas appliances

of

rated input not exceeding 60

kW:

Flues.

BS

5440:2:1989 Flues and Ventilation

for

gas appliances

of

rated input not exceeding

60kW:

Air

Supply

.

BS

6891

:19881nstallation

of

low

pressure gas pipework installa·

tions

up

to

28

mm

(R1).

1.4

To

ensure that the installation

will

perform

to

the highest

standards, the system and components should

conform

to any

other relevant

British

Standards

in

addition to those mentioned

in

the instructions.

2.

General

Information

2.1

This

appliance

is

not suitable

for

external installation.

2.2

The

appliance controls are set to provide a maximum out-

put

of

23

kW

for

the domestic hot water and a central heating

load

of

up

to

16.1

kW.

2.3

The

control

circuit

provides automatic

ignition.

Apermanent

pilot

is

not

used.

2.4

PRINCIPLE

APPLIANCE

COMPONENTS

See

Fig

. 1.

A

low

thermal capacity

Gas

to

Water heat exchanger.

A

Water

to

Water

heat exchanger to

provide

domestic hot water.

Fully

modulating controls

in

the central heating and domestic

hot

water modes

of

operation.

An

expansion

vessel,

pressure gauge and pressure

relief

valve.

Aby-pass

for

the

central heating system.

Temperature safety cut-out controls.

Awater

flow

regulator.

2

9.

Electrical

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Page

9

1

0.

Installation

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Page

12

11

. Commissioning .............

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Page

17

12. Instructions

to

the

User

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Page

19

13. Inspection and

Servicing

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Page

19

14. Replacement

of

Parts

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Page

21

15. Short Parts

List

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Page

28

16. Operational

Flow

Diagrams

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Page

30

17.

Fault

Finding

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Page

32

A standard horizontal

flue

assembly

giving

flue

lengths from

1

00

mm

to 500

mm

.

An

optional extra extension

flue

kit to provide

for

flue

lengths

up

to

1500 mm

long.

An

optional

facia

mounted programmer instead of the standard

Operating Switch.

2.5

ELECTRICAL

SUPPLY

Mains supply:

240V

- , 50

Hz,

270 watts. External

fuse

3A.

Internal

fuses:

T2A

(F1)

and

T315mA

(F2).

2.6

GAS

SUPPLY

The

boiler

requires 2.69 m'

/h

(95

.2

ft

'/hr)

of

gas.

The

gas

meter

and supply pipes must be capable

of

supplying this quantity of

gas

in

addition

to

the demand

from

any other appliances being

served.

The

table below

gives

an indication

of

limiting gas pipe

lengths and the allowance to be made

for

fittings.

Refer

to

BS6891

for

further information.

The

meter governor should deliver a dynamic pressure

of

20

mbar

(Sin

wg.)

at the appliance, equivalent to a pressure of

about 18.5-19 mbar at the

gas

valve.

The

complete installation, including the

gas

meter, must

be

test-

ed

for

soundness and purged.

Refer

to

BS

6891.

TOTAL

LENGTH

OF

GAS

SUPPLY

PIPE

(metres) Pipe

Diameter

3 6 9

(mm)

Gas

Discharge Rate

(m3

/h)

2.9 - -

15

8.7

5.8

4.6

22

18

.0

12

.0

9.4

28

Note

:

Each

fitting

used

in

the gas

line

from

the meter

is

equivalent to a

length

of

straight

pipe

which

must be added to the straight pipe

length

to

give

the

total

length.

ie

:

Elbow

=

0.5

metres

,

Tee

=0.5metres, 90°

Bend

=0.3metres.

2.7

PACKING

The

appliance and

flue

components are packed

in

separate car-

tons.

2.8

GENERAL

INSTALLATION

The

appliance

is

only

for

connection to a sealed system.

The

specified ventilation openings made

into

a wall

or

compart-

ment door must not

be

obstructed.

If

the appliance

is

to

be

fitted into a compartment then the com-

partment must conform

to

the requirements

of

BS

6798

: 1987:

Section

6.

Do

not place anything on top

of

the appliance.

The

cl

earancEs specified

for

se:vic:ing

r.1ust

be

maintained.

Fig.

1. Appliance

water

flow diagram.

Waterflow

manifold

I__

Central

heating

by-pass

adjuster

L__

Automatic

air

vent

Gas

to

Water

I h h

eat

axe

anger

~a-·

~

----

--

Boiler

J

Sealed

system

expansion

vessel

~

Circulating

pump

Water

to

Water

heat

exchanger

-

'l!..---

JVvV\1

~

1-c

--

---Waterdivertor

,__

valve

' -

1--0---~

-

-,.

f-*

'

I

o

c9

I

Pressure

relief

val

ve

-

Domestic

hot

water

out

I'

__

Mains

cold

water

in

-

Central

heating

retmn

--

Central

heatin

flow

2.9

FLUE

The

appliance has a multi-directional horizontal fanned

flue

sys-

tem-right,

left

or

rear.

The

standard

flue

assembly length

is

from

1

00

mm

to

500

mm.

An

extension

flue

length

from

501

mm

to

1500

mm

is

available.

Aterminal guard,

Type

K2,

GC

393

553,

is

available

from

Tower

Flue

Components,

Vale

Rise,

Tonbridge,TN9

1

TB.

Do

not

al.low

the

flue

terminal fitted to the outside wall to

become

obstructed or damaged.

A

kit

for

internal

fixing

of

the

flue

is

available separately.

2.1

0

CONTROLS

The

electronic control system and gas valve modulate the heat

input

in

response to the central heating and domestic hot water

temperature settings between minimum and maximum.

The

Operating

Switch

provides

for

the selection

of

domestic hot

water

only

(WATER)

or central heating and domestic hot water

(HEATING

&

WATER)

or

OFF.

A

facia

mounted programmer

is

available as

an

optional extra.

Aremote mounted programmer may

be

connected

to

the

appli-

ance.

The

integral

facia

displays indicate the status

of

the appliance.

There

is

provision

for

the connection

of

a mains voltage

room

thermostat

and/

or a frost thermostat.

The

electro'lic contrcls

prfv~~nt

nrid

cyr:!ing

cf the

applia:1ce

in

·,~IR

Cc'YJ~t.:tl

·,ei{tir.5.i

/.!.ode

2_11

SYSTEM

NOTES

WARNING

Check

that no dirt

is

left in either the gas or water pipework as

this could cause damage to the appliance. Thoroughly flush

the heating system and

the

cold water mains supply. Purge

the gas supply before finally connecting the appliance.

The

water pipe connections throughout a sealed system must

be capable

of

sustaining a pressure

of

upto 3 bar.

Radiator valves must conform to the requirements

of

BS

2767

1991.

The

relief

valve discharge must be directed away

from

any

elec·

trical

components or where

it

would cause a hazard

to

the user.

Adrain

cock

to

BS

2879 must

be

fitted

to

the lowest point

of

the

system.

For

circuit design purposes

it

is

important that due note

is

taken

of

the information given

in

Table 3 relating

to

the available

pump head.

2.12

SHOWERS,

BIDETS,

TAPS

AND

MIXING

VALVES

Hot

and

cold

taps and

mixing

valves used

in

the

system must

be suitable

for

operating at a mains pressure

of

up

to

10 bar.

Thermostatically controlled

or

pressure equalising shower valves

will

guard against the

flow

of

water at too high a temperature.

Hot

and

cold

mains

fed

water can

be

supplied direct

to

an over·

rim

flushing bidet subject to local Water Company require-

ments.

With

all

mains

fed

systems the

flow

of

water

from

the individual

taps

will

vary with the number

of

outlets operated simultane-

ously and the

cold

water mains supply pressure

to

the property.

Flow

balancing using

'Ball-o-Fix'

type valves

is

recommended to

avoid an excessive reduction

in

flow

to individual outlets.

For

further information contact Worcester Heat Systems

Ltd.

2.13

SAFETY

CONSIDERATIONS

The

appliance must not be operated

in

a waterless condition.

The

appliance must not

be

operated with the boiler inner casing

cover removed.

Work

must not

be

carried out

on

the appliance without the gas

and electricity supplies being switched

off.

Checks

must

be

made to ensure that the ventilation openings

made into

walls

and partitions are

of

the correct

size

and are

not obstructed.

2.14

OPERATION

Domestic Hot Water:

With

a demand

for

hot water the burner

will

light

at its maximum setting and then automatically adjust

its output

to

maintain the temperature

of

the delivered water.

When

hot water

is

no

longer required, the burner

will

extin·

guish.

The

pump

will

continue to

run

for

a short period to

dissi-

pate the residual heat

from

the

appliance.

Central Heating: With a demand

for

heating the burner

will

light

at its minimum setting and gradually increase

to

give

the

maximum output.

The

output of the appliance

is

then automati·

cally

adjusted

to

maintain the temperature

of

the system.

The

output can reduce down to a minimum

of

9.2

kW.

If

the system

no

longer requires even the minimum output

to

maintain the

desired room temperature the burner

will

extinguish.

The

pump

will

continue to run to dissipate the residual heat

from

the appli·

ance.

The

appliance

will

remain

off

for

a

fixed

period

of

two

min·

utes before

re-lighting

to

automatically meet the system require·

ments.

Domestic Hot Water

and

Central Heating:

The

appliance

will

supply heat

to

the central heating system as required. A

de·

mand

for

domestic hot water

at

a tap

or

shower

will

override

the central heating requirement

for

the period

of

the domestic

hot water demand.

When

hot

water

is

no

longer required the

appliance

will

return

to

the central heating state and its normal

mc3~

('~

0pennior.

The

pump will

continv.e

~o

run

~r:.

dissipate

ti:.;

r•'SLLBll'lr:J:

from

the

applii?.no~

as

ne·~B',scuv.

· · 3.

TechniCal

Data

The

Data Plate

is

fixed

to

the control box casing.

TABLE

1 TABLE 2 - Flue Details

NOMINAL BOILER

RATINGS

Horizontal Flue

mm

inches

Output

Input

Burner

Setting

Pressure

Gas

Rate

Wall Hole Diameter

110

4.25

kW

Btu/h

kW

Btu/h

mbar.

in.wg.

m3/h

ft

3/h

9.2

31,400

13.0

44,300

2.5

1.0

1.22

43.0

16.1

54,900

21.0

71,600

6.8

2.7

1.97

69.5

Standard

Flue-

Minimum

Length

100

4

Standard Flue -

Maximum

Length 500 19

Extended

Flue-

Maximum

Length

1500

59

23.0

78,500

28.8

98,200

13.5

5.4

2.69

95.2

TABLE

3

AVAILABLE PUMP HEAD

Boiler

Output

Head

Min.

Flow

Rate

Temp.

rise

across

feet

litres/min

gal/min

heating

flow

kW

Btu

/h

metres

and

return

9.2

31,400

4.9

15.9 12.0

2.64

11

°(

(20°F)

16.1

54

,

900

2.54

8.25

21.0

4.63

23.0

78,500

2.0

6.5

21.0

4.63

15°CI27°F}

TABLE

4

SPECIFICATIONS

CENTRAL

HEATING

FLOW

FITTING

22

mm

Compression

CENTRAL

HEATING

RETURN

FITTING

22

mm

Compression

COLD

WATER

MAINS

INLET

FITTING

15

mm

Compression

DOMESTIC

HOT

WATER

OUTLET

FITTING

15

mm

Compression

GAS

INLET

FITTING

Rcl /2

PRESSURE

RELIEF

VALVE

DISCHARGE

FITTING

15

mm

Compression

OVERALL

HEIGHT

(including flue elbow)

11

00

mm

143.3

in.)

CASING

HEIGHT

900

mm

(35.4

in.)

CASING

WIDTH

450

mm

(17.7

in.)

CASING

DEPTH

360

mm

(14.2

in.)

WEIGHT

(including water) 47.6 kg (105lb.)

INSTALLATION

WEIGHT

45.6 kg

(1

00 lb.)

PACKAGED

WEIGHT

48.5 kg

(1

07

lb.)

TABLE

5

SPECIFICATIONS

PRIMARY

WATER

CAPACITY

2.7

lit

res

(0.6

galls.)

MAXIMUM

COLD

SU?PLY

PRESSURE

10 Bar

(150

psi)

MINIMUM

COLD

SUPPLY

PRESSURE

(WORKING)

FOH

MAXIMUM

HOT

WATER

FLOW

1.6 Bar

(23

.5

psi)

MINIMUM

COLD

SUPPLY

PRESSURE

(WORKING)

TO

OPERATE

THE

APPLIANCE

0.6 Bar

(9

psi)

MAXIMUM

CENTRAL

HEATING

FLOW

TEMPERATURE

Nominally

82

°C

(180°

F)

OUTPUT

TO

DOMESTIC

HOT

WATER

Modulating 9.

2-23

kW

(31

,400-78,500

Btu/h)

OUTPUT

TO

CENTRAL

HEATING

Modulating 9.2-23

kW

(31

,400-78,500 Btu/h)

MAXIMUM

DOMEST!C

HOT

WATER

FLOW

RATE

FROM

THE

APPLIANCE

Nominally 8.0 litres/min (±

15

%)

t-

(1.75 gallons/min)

EQUIVALENT

DOMESTIC

HOT

WATER

FLOW

RATE

TO

GIVE

A

TEMPERKIURE

RISE

Nominaily 9A J!tresim!n I

'

I

r_;.o

:

-35°C

: ;2.07 p!i:Jn

s/

m!n) 1

I •

_.......... ,.,..-....,....,...,,,._

,_._..

,.,.,

__

..

_ _..,.......__...,..._ _

__

,_..,,

,

,._,

__,._..,.._.....,.._.,,

..

_ , , _

___

.,_~-'"'--..

...

-...

·.

>,

-•--a-.--..,-_..._....,.._...,....._.,

,

•.

w,.,..

..,

.... _

,...,..,

__

.,_,

,. _ _ _

~

•.;

,...

...

oJ

..

_,_.,.

,

_..,.

..

__

~..,.--...o.-.v

.

4

4. Siting the Appliance

4.1

The appliance

may

be

instaUed in

any

room although par-

ticular attention

is

drawn

to

the

requirements

of

the

current

I.E.E.

Wiring Regulations

BS

7671 and, in Scotland, the electri-

cal

provisions

of

the

Building

Regulations

applicable

in

Scotland,

with

respect

to

the

installation

of

appliances

in

rooms containing

baths

or showers.

Where a room

sealed

appliance is installed in a room contain-

ing a

bath

or

shower,

any

electrical switch

or

appliance control

using mains electricity

must

not

be

able

to

be

touched

by a

person using

the

bath

or

shower.

4.2

The

appliance

is

not

suitable for external installation.

4.3

The

appliance does not require any special wall protection.

4.4

The

wall must

be

capable of supporting the weight of the

appliance. See Table

4.

4.5

If

the appliance

is

to be fitted

in

a timber framed building,

refer

to

the

British

Gas

publication

DM2 "Guide for Gas

Installations

in

Timber Framed Housing

".

4.6

The

following clearances

must

be

available

for

installation

Installation Servicing

Above the

flue

elbow

30mm

In

front

600mm

Below

230mm

Right

hand side

20mm

Left

hand side

Smm

and for servicing. See

Fig.

2.

4.7 The appliance can be installed

in

a cupboard used for airing

clothes provided

that

the

requirements

of

BS

6798

and

BS

5440:2 are strictly followed.

4.8 The airing space must be separated from the boiler space by

a perforated non-combustible partition. Expanded metal or rigid

wire mesh are acceptable provided

that

the major dimension

is

less than

13

mm. See

BS

6798:1987.

4.9

No

combustible surface must be within 75

mm

of the cas·

ing

.

See

85476:4.

4.1

0

The

distance between

the

inner face

of

a cupboard door

and the cabinet front should

not

be less than 75

mm

.

4.11 Always consider the possible need to disconnect the pipes

from

the appliance after installation.

Fig.

2.

Appliance casing dimensions

and

required clearances.

100mm

/

f

30mm

Space

required

above

flue

elbow

for

installation

and

servicing

.

.,__...._

_

_.__...,

-------------------,

600mm

Space

required

in

front

SIDE

VIEW

lor

installation

and

servicing.

I

------~-------

[._225mm

FRONT

VIEW

..._.

___

450mm

--~

~

Fixing

holes

--.1

I

413

mm

CRS.

I

. .

/J/J

::,-~~:-T-----~~.--_J

i i

Space

required

below

/).

lor

installation

and

servicing.

Space

required

at

left

hand

side-+-!

~

-+1

·

/)~

_________

j t

lor

installation

and

servicing.

iL

__________

_

____

j

20mm

f

150mm

I

!

I

1

900mm

I

!

I

il

Space

required

at

righl

hand

side

lor

inslallation

and

servicing.

5

Fig.

3. Appliance pipework connections..

-~·

-m=

=n

-w.~o

_

...

-~TUq_,

Central

heating

flow

-1_-;..::...::;;;.:.J

Central

heating

return

Mains

cold

water

in

----.J---

Domestic

hot

water

out

-t-------

216

mm

··

-----t.t

Pressure

relief

valve

discharge

-1~-------

306

mm----1

Gas

cock

-1-------------

405

mm--------t.-l

5. Siting

the

Flue Terminal

See

Fig.

4

5.1 The

flue

must be installed as specified in

BS

5440:Part

1.

5.2

The terminal

must

not

cause

an obstruction nor

the

dis-

charge cause a nuisance.

5.3

If

the

terminal is fitted within 850

mm

of a plastic or painted

gutter or within

450

mm of painted eaves then an aluminium

shield

at

least 750 mm long should be fitted to the underside of

Fig.

4. Siting of the flue terminal.

the gutter

or

painted surface.

5.4 If a terminal

is

fitted less

than

2 metres above a surface to

which people have access then a guard must be fitted. See

Sec-

tion 2.9.

5.5 The terminal guard must be evenly spaced about the

flue

terminal

and

fixed to

the

wall using plated screws.

5.6

In

certain weather conditions a terminal

may

steam and

sit-

ing

where this could cause a nuisance should be avoided.

5.7 Take care to ensure

that

combustion products do not enter

ventilated roof voids.

MINIMUM

SITING

DIMENSIONS

FOR

POSITIONING

THE

BALANCED

FLUE

TERMINAL

POSITION

A-

directly below an openable

window

or

MIN.

DISTANCE

other opening e.g. air brick. 300

mm

(12 in.)

A

B-

Below gutters, soil pipes

or

drain

pipes. 75 mm

(3

in.)

C-

Below

eaves.

25 mm(1 in.)

0-

Below balconies

or

car

port

roof.

25mm

(1

in.)

E-

From vertical drain pipes and soil pipes.

25mm

(1

in.)

F-

From internal

or

external corners.

25mm(1

in.)

G- Above ground, roofor balcony level. 300 mm

(12

in.)

H-

From asurface facing a terminal.

600

mm

(24

ln.)

1-

From a terminal facing a terminal

1200

mm

(47

in.)

K

1-

From

an

opening in acar

port

(e.g

.door

window)

into

dwelling.

1200

mm

(4

7 in.)

K-

Vertically from a terminal on the same

wall. 150

mm

(6

in.)

L-

Horizontally from a terminal on the same

wall. 300 mm (12

in.)

M-

From door,

window

or

air vent (achieve

where possible).

150

mm

(6

in.)

6

6. Air Supply

6.1

The

appliance does not require a separate vent

for

combus-

tion

air.

6.2 Installations

in

cupboards or compartments require perma-

nent vents for cooling purposes, one

at

high level and one at low

level,

either direct to outside air or to a room. Both vents

must

pass to the same room or be on the same wall to the outside air.

6.3 There

must

be sufficient clearance around

the

appliance

to

allow

proper circulation of ventilation

air.

The

clearances required

for

Installation and Servicing

will

normally be adequate

for

venti·

7. Sealed Sysytem

See

Figs.

5

and

6

7.1

The

system must comply with

the

requirements

of

BS

6

798

and

BS

5449.

7.2

The

appliance

must

not

be

operated without the

system

being

full

of water, properly vented and pressurised.

7.3

The

pressure relief valve operates

at

3 bar(45lb/in'). The dis-

charge

must

be directed away from electrical components

or

where

it

might be a hazard to the user.

7.4

The

pressure gauge indicates

the

system pressure which

must be maintained.

7.5

The

8 litre expansion vessel

is

charged to 0.5 bar and

is

suit·

able

for

a static head of 5 metres (17.5ft).

The

pressure can

be

increased

if

the static head

is

greater than 5 metres (17.5ft).

7.6

With

an

initial system pressure of 0.5 bar, a system capacity

of about 83 litres can be accommodated.

Refer

to

BS

7074

Pt.

1

for

more information. The charge pressure can be increased but

with a decrease

in

system volume.

Fig.

5.

Sealed primary water system.

;~-;--;III-I~

l

r~

,-;

,-

1

-~-~~;

I::

I I I I I I I

I:

:::II': I I

lation.

See

Section 4.6.

6.4 The-minimum

free

areas required are given below.

Position

of

Air from

Air

direct

air

vents

the

room from outside

High

Level 260 em'.

130cm

'.

(40

in'.) (20 in')

Low

Level

260 em'.

130

em'.

(40

in'.) (20in'.)

6.5

Refer

to

BS

6798 and

BS

5440:2 for additional information.

7.7

The

filling

point

must

be

at

low

level.

See

Figs.

5 and 6.

7.8

Water loss

must

be

replaced. See

Fig

6. The connection

should be

made

in

the

central heating return

as

close to

the

appliance as possible. See

Figs

. 5 and 6

7.

9

The

make-up vessel

must

be fitted with a non·return valve.

7.1 0 Repeated venting loses water from the system.

It

is

essen-

tial

that

this

water

is

replaced and

the

system pressure main·

tained. · ·

7.11 Connections to the mains water supply

must

not

be

made

without the authority of

the

local Water Company.

7.12

The

pump is set at maximum and must not

be

adjusted.

7.1 3 Connections

in

the system must resist a pressure

of

up to 3

bar.

7.14

Radiator valves

must

conform to

BS

2767:1991 .

7.1 5 Other valves used should conform to the requirements of

BS

1010.

7.1

6

To

make use

of

the extra heating available from the appli-

ance at the end of any demand,

it

is

recommended

that

a single

small radiator

be

left permanently open.

:

•;:::!

1 I I I r 1 • 1 1 r I I

: : : 1 , 1 1 1 1 1 1 1 , , 1 1 1 I 1 1

Automatic

air

vent

--

-

-r

...

+'~~~~t

Appliance

casing

'1

I I I I ! ' I I

L,

~

I I I I I

~

I I

I.,

\''"--------?.

,1;-------_r~

--GastoWater

y

~

7

~~~

~--

.-

t-

-

--

-

~

--

-

-{

-

--

---

-...L.-----,

' I I

____

L

__________

..:.

__

---------,

I

i I

I

Sealed

system

...

- ·

--expansion

vessel

:

Diverter

valve

Water

to

Water

heat

exchanger

Lockshield

valve

Radiator

valve

lllllllll

J

11111111

Note.

A

drain

cock

should

be

installed

at

the

lowest

po

i

nt

of

the

heating

circuit

and

beneath

the

appliance.

Central

heating

by·pass

adjuster

"""tf+-+-t-+--'

Fill

point

----

-'

Heating

.

return

Heating

flow

Note

.

The

mains

cold

inlet

connection

to

the

appliance

must

come

before

any

ot

her

connection

from

the

cold

s

upply

.

i

Domestic

T

coldwater

British

Standard

--

stop

valve

.

Fixed

spindle

type.

+-

Water

main

·

'-----~--·

~--~---~~~-~-~--~----

.

__._...,..

.....

~_.,.

:

·

·-&.--:..--------·--------------~--~--·

Fig.

6. System filling

and

make·up

Heating

return

Worcester

Combi-Fill

System

Non

return

Non

return

valve

+-

~Hose

unionl

.

c:

::n

:r::

.

~

1

-.

~-

!!

il

Stop

cock

::

II

~~

...

~

==~-},'

Test

cock

Temporary

hose

8. Domestic

Hot

Water

8.1

The

following

are general requirements and,

if

necessary,

reference should

be

made to the

local

Water

Company

before

fitting

the

appliance.

8.2

MAINS

COLD

WATER

INLET.

Devices

capable

of

preventing

the

flow

of

expansion water must not

be

fitted unless separate

arrangements have been made.

An

expansion vessel connection

point

is

provided

within

the

appliance.

An

Rc'

I>

connection

is

provided

on

the

flow

switch.

See

Fig.

36

.

A

Zilmet

Z160

is

the preferred type. Athread sealant compatible

with

potable water must

be

used.

8.3

The

final

600

mm

of

the mains

cold

water connection to the

appliance

should

be

made

in

copper tube

only.

8.4

The

appliance

is

suitable

for

a mains pressure

of

up to 10

bar

(150

lb/id).

8.5

The

appliance

is

fitted

with

a mains supply

isolating

valve.

8.6

The

maximum

domestic hot water

flow

rate

is

8.0

litres/

min

(±15%) (1.75gallons/min).

8.7

In

winter

(when

the mains

inlet

water temperature

is

lower)

a

reduced

flow

rate at the taps

will

be

required

to

achieve the

maximum

hot water

delivery

temperature available

in

warmer

weather.

8.8

It

is

suggested that

long

pipe runs to the taps or shower

should

be

insulated

to

prevent the rapid

cooling

of

domestic hot

water after a tap or shower has been turned

off

.

Heating

return

Auto

air

vent

..

,...........-

Fill

point

Heating

return

300

mm

{12

in)

min

.

above

the

highest

point

of

the

system.

8.9 Hot

and

cold

taps

and mixing valves used with this

appliance must

be

suitable

for

operating at a pressure

of

up to

1

0 bar

(1

50

lblin').

8.1

0

No

anti-syphonage arrangements

are

necessary except

for

some

loose head showers.

See

also

Section

8.1

0

following

.

8.11

Thermostatically controlled or pressure equalising shower

valves

will guard against the flow

of

water

at

too high a

temperature.

8.1

2

The

head

of

a loose head shower must not

fall

closer than

25

mm

(1

in)

above the top edge

of

the bath

to

prevent its

immersion

in

bathwater. Alternatively the shower must be

fitted

with an anti-syphonage device at

the

point

of

the

flexible

hose

connections.

8.

13

The

supply

of

hot and

cold

mains water direct

to

a bidet

is

permitted, (subject to local Water Company requirements),

provided that the bidet

is

of

the over-rim flushing type.

The

outlet(s)

should

be

shrouded

and

unable

to

have

any

temporary

hand

held

spray attached.

No

anti-syphonage arrangements are

necessary.

8.14

As

the

maximum

temperature

of

the

Water

to

Water

heat

exchanger

is

limited

by

the control

circuit,

there

is

normally

no

need

for

water treatment to prevent scale accumulation.

In

exceptional circumstances a device

to

prevent

scale

formation

can

be

fitted.

Installation of a

scale

inhibitor

assembly

should be

in

accordance

with

the requirements

of

the

local

Water

Company.

An

isolating valve should

be

fitted

to

allow

servicing.

The

water

hardness can

be

determined using a standard test paper or

by

reference

to the

local

Water

Company

.

9. Electrical

See

Figs

.

7,

8,

9,

1

o.

and

11

.

9.1

MAINS

SUPPLY.

240

V

-,50

Hz,

270

watts.

External

Fuse

3A.

Internal

Fuses

:

T2A

(F1)

and

T315rriA

(F2)

.

9.2

It

must

be

possible

to

completely isolate the appliance.

9.3

Connection

to

the

mains

supply should be

via

a double

pole

isolator with a contact separation

of

3mm

in

all

poles

and

supplying

the appliance

and

controls

only.

9.4

The

appliance must

be

earthed.

9.5

Mains

Cable.

0.

75

mm

2

(24

x

0.20

mm)

to

BS

6500

Table

16.

The

mains

cable

must

be

connected

into

the

terminals

marked L

(Brown

or

Red

lead),

N

(Blue

or

Black

lead)

and the earth stud

and

be

held

securely

in

the

cable

clamp.

For

access

refer

to

Section

13.

9.6

The

wiring

between

the

appliance

and

the electrical supply

shall

comply

with

current

lEE

Wiring

Regulations

and any

local

regulations

which

apply.

9.7

If

a

room

and/or

frost

thermostat

is

to

be

fitted

refer

to

Figs

.

1

0

and

11

.

The

thermostats must be suitable

for

use

on

mains

voltage.

9.8 A facia mounted programmer

is

available as an extra.

Instructions are supplied

with

the programmer

kit.

9.9 A

time

switch

or programmer can

be

fitted

externally to the

appliance.

9.10

SAFETY

CHECK.

After

installation or

in

the event

of

an

electrical

fault

the electrical system

shall

be

checked

for

short

circuits,

fuse

failure,

incorrect polarity

of

connections,earth con·

tinuity

and resistance to earth.

Fig.

7.

Wiring

Diagram

-

Control

panel and.

facia.

(All

components shown viewed

from

front of !ippliance)

r-----------T--------------r-------------------,

I

Indicator

Ughts

I

Operating

Switch

I • I

j I I I

ll

·-~

I

""ffl'~::

~

-

'

t~

Ill

i

DEMAND

br

I I

I I g I I

I : I

m••

1

l--------------.L

-------

-

---

__

..J_______

---------------1

l

Temperature

Control

I

a______________

-----------

__

Po~e~i~eter__

_

______________

j

Control

Facia

Control

Panel

.---------------

-c:

br

:!1

1 I

r---------

br_.1

1

-----..,

Air

Row

Pressure

Switch

.._

__

TO

SPidiK

ELeCTRODE

..-----

1

I

--o

IGNiiiON

I

3X

X11

bk

L!J

I

-----l

~m·

~

~~bk

f"!lresr

awrheatThennostat

l

BOARD

1

br

• : 410 3 °

~F2

FUSE

J

TO TO

FAN

PILOT&

MAIN

GAS

VALVE

r---

__

:;--ftl:xs

4 !

~

3 A

F1

MAIN

DRIVER

BOARD

1

br

: 1L

tj

FUSE

1g}l

bl

2NX7

X1

y

0

3(

2

pk

4£

xs

X4

X3 X2

3 I v

112

312312345123

4561234

5

61

ill

"'

~

i5

br

~

0

..

g l.!t I

bk

d!

I

gv

-w u I

~

gytmre!rtuJ!~tllJr~~uJ.tr_riJ

~

¥~tVV~

~~~

bl

o if g

wbr

br

J

CN2 0 0 I

L1

L2

L3

CN1J

-----

bt--.:.J

y

MAINSw

~ ~

illl

;~

..;:

~

"~~.,-

-~

L....-~----1

OVIIIUI

il

Iii

oMIITER

HEATWG

HOT

WtiiBI

MODIJlATING

THBioiOSTilT

~

VALVE

SENSOII

SENSOR

SOLENOID

12

MICRO-SWITCH

COLOUR

CODE

br-

brown

bl

.-

blue

gy-

green

and

yellow

bk-

black

or-

orange

r-

red

w

-white

y

'-

yellow

g-

grey

v-

violet

pk-

pink

Fig.

8.

Wiring

Diagram

-Components outside control panel.

(All

components shown

viewed

from

front

of

appliance)

,------------

1

r---------

1

//

I (

I I

I :

Centrifugal

Fan

Unit

I I

I \

0_{_n

I I

COLOUR

CODE

I : br-

brown

bl-

blue

gy-

gree~

and

yellow

bk-

black

or-

orange

I 1

r-

red

w-

white

y-

yellow

g-

grey

v-

violet

pk-

pink

br

bl

I

r__L

_____________

-----

~~------------------

1 I .

-.-

~-==·.-::::::::-::::;!

_L

-.

___.

.

--::::::..-

·- .

L.-·-

:T

·.

==

··

- ·

-·

~

-

-·-

1 I

I I

I

~

l

Central

Spark

Electrode

@

w

-------l

-......._,_

I

'"

I

'I I

1 I

I I

Pump

Overrun

Thermostat

-----I

_____

_j

I

-:

·.::=:.

·.-::=.:.

:=:.·:~:

I I

1 I

I I

/)

I

_____

,/

I

1

Heating--------------

r

Sensor

-------------

1

~---'

---------1

br

gy

bl

D G

I

~

Gas

Valve

1

"'

>

~

c:

·c;;

~

-c

c:

y y

"'

.2

0:::

Modulating

Solenoid

~~

Domestic

Hot

~Uf?l

Water

Sensor

r r

E H c J

I

..L

r·

:

I

.-----------------------------~---.-----------------------------------,,---------~~N

L

+

UVE

IN

I

!

I

black

POWER

ON

INDICATOR

X111PIN21

FROST

THERMOSTAT

IIF

FlmDI

FUSE

F1

I

_c::;]_

sftw

X41~N

~~-

L_j

-

-X41PIN

51

brown

XIOIPIN

3)

white

X10

!PIN

21

Of'ERATING

SWITCH

lOR

P!lOGRAMMERI

WPIN31

MICRO

SWITCH

...

CH

I

'

I

grey

X31PIN31

L

________

_

X5(PIN1)

brown

black

DEMAND

INDICATOR

X111PIN11

TRANSFORMER

PUMP

OVERRUN

THERMOSTAT

I

orange

L

_________________

_

XS!PIN21

X6!PIN3)

brown

OVERHEAT

THERMOSTAT

------,Iff,-:---

MAIN

DRMR

BOARD

1 " " I

IGNITION

ljj

1

BOARD

I I I I

~

L........

..

I

aECTRONICS

I

~I

FUSE

F2

5

315mA

SLOW

~

XJIPIN

l)

~

ELECTRONICS

I

)(3

I!PI~~r

White

CENTRAL

HEATING

SENSOR

DOMESTIC

HOT

WATER

SENSOR

I

I I

I

~

brown

-

CNSIPIN

Fll

rCN2(PIN

L31

brown

TEMPERATURE

CONTROl

POTENTIOMETER

I

I I II

SAFETY

I •

v~••

I

CIRCUITS

I

_____

_j

I

L,

___

_

I

-N

~N

N

Fig.

9. Functional flow diagram.

PUMP

~------------------------------------

----

------~N

r---------------------------------------

--

--------~N

~--------------------------------------------------------------------------------------------------

~---------------------------------------------------~

I ng. 10. Room thermostat

l connections.

!

I

!

I

Remove

link

'

i

2 3 4 5

Terminal

X4

on

main

driver

board.

Honeywell

room

thermostat

T60608

(or

similar).

l

_______________________________________

_,

Fig.

11

. Frost thermostat

connections.

Terminal

X4

on

driver

board.

Honeywell

frost

thermostat

T4160A

(or

similar).

·

10.

Installation

The

appliance

is

only suitable

for

fitting to a sealed system.

1

0.1

The

standard

flue

length

is

from

1

00

mm

to

500

mm

mea·

sured

from

the appliance casing

to

the outer

wall.

The

extended

flue

length

is

from

501

mm

to 1500

mm.

Only

one

extension may be used.

The

flue

must

be

installed as specified

in

BS

5440 Part 1.

Note.

READ

THIS

SECTION

FULLY

BEFORE

COMMENCING

INSTALLATION

10.2

GENERAL

FITIING.

Check

that the appliance carton contains:·

Appliance

Installers Instruction Pack Appliance Mounting Plate

Users

Information Pack Installer Hardware

Pack

Check

that the position chosen

for

the appliance

is

in

accor·

Fig.

12. Appliance mounting plate

and

flue position.

0

.L---l...-f--,."1--

~~~~'."'

~-~:·~':~

_·;:

l--

--"~"~~

~~;~-

Rear

flue

opening

cen1re

line

indica1ors

-

Appliance

casing

REAR

FLUE

POSITION

Fig.

13. Marking

out

the side flue position.

Mounting

wall

dance with the instructions given

in

Sections 4 and

5.

The

distance

from

the bottom

of

the mounting plate to the top

of

the appliance

.:a

sing

is

106mm.

Hold

the appliance mounting plate

to

the

wall.

Check

that the

plate

is

horizontal.

See

Fig

12.

Mark the position

of

the

fixing

holes and the position

of

the

flue

hole centre

line

onto the wall.

Draw

a horizontal line

along

the

bottom

of

the mounting plate.

Rear

Flue

·

Mark

a vertical

line

through the

flue

hole

centre

point.

Measure upwards 208

mm

from

the bottom

of

the mounting

plate and mark the point.

This

is

the centre point

of

the

flue

duct

hole.

See

Fig

12.

Side Flue · Extend a horizontal line from the bottom

of

the

mounting plate along

the

appropriate

wall. Check

that

it

remains horizontal and measure 208 mm upwards and mark a

horizontal

line.

Measure 130

mm

from

the junction

of

the walls

and mark a vertical

line

which

will

then

give

the position

of

the

flue

hole.

See

Fig

13.

SIDE

FLUE

POSITION

Side

flue

hole

110mm

dia.

(150

mm

dia.

for

internal

fixing).

~

~----------------------~~

00

0

o 0 0°

130mm

Mounting

plate

208

mm

:------

"'-,

Sidewall

J

I '-...

I

......_

'

......_

. .

....,,..,__.__.,._~~~~~.,..._-~,.

.

~-~·--

·

~•

..

-......_...._

..

...__ __

,.:.on.n...,..._~~.....,.._-.-_..,..,

___

_.

,_

•.

~

1?.

Drill

the two

fixing

holes 60

mm

deep

for

No

.

12

size plugs.

Cut

the

flue

duct

hole

at

11

0

mm

diameter (150 mm

dia

.

for

internal

fitting).

Ensure that the

hole

is

horizontal through the

wall

.

Fix

the appliance mounting plate, and check that

it

is

horizontal

before tightening the two screws.

The

gas and water pipes can be led towards the appliance at this

stage.

See

Fig

3.

The

primary system should be

flushed

and treat·

ed

in

accordance with the recommendations

of

BS

7593:1992.

Also

flush the primary

cold

water supply pipe before the

appli·

ance

is

fitted to the

wall

.

Hang

the appliance onto the

walt.

Drill

(at a slight

rising

angle)

through the two appliance

fixing

holes at the bottom

of

the cas·

ing

.

Plug

and

fix

the casing bottom. Connect the gas, water and

pressure relief valve connections to the appliance. A 1

5

mm

shut·off valve (supplied

with

the Installer

Pack)

must be fitted to

the cold water supply connection.

See

Fig

3.

Remove the cabinet front panel and the inner casing cover.

Refer

to Section 13.3

(a

and

b).

Unscrew and discard the automatic

air

vent cap.

See

Fig

14.

If

the air and

flue

duct assembly

is

to

be

fitted

from

inside the

room then the ducts must be cut to length, assembled and

inserted through the

wall

at this stage before fitting the

flue

elbow

to the appliance.

Refer

to Section 10.4

following

for

the

assembly

of

the air and

flue

ducts.

Remove

the

fan.

See

Section

13

.

3(e).

1

0.3

AIR AND FLUE DUCT PREPARATION AND

ASSEMBLY

Check

the contents

of

the standard

flue

duct

kit

against the

packing

list.

Similarly

check the extension duct

kit

if

applicable.

Remove all the packing from the ducts

and

tenninal assem·

bly.

The

standard

flue

kit

accommodates a

flue

assembly up to 500

mm

long measured

from

the appliance casing

to

the outer

wall

face

.

See

dimension L

Figs

.

16

and 17.

When

dimension Lis great·

er

than 500

mm

the extension

flue

assembly

will

be

required.

Measure and cut the air and

flue

ducts to length ensuring that

the

cuts are square and

free

from

burrs.

Always

check

the dimen·

sions

before cutting the ducts.

Fig.

14. Automatic air vent.

Unscrew

and

discard

the

cap

Automatic

air

vent

1111l1l1llln1lllll

Gas

to

Water

heat

exchanger

Boiler

flow

•

I )

\.._____-~-~---·-----"

13

EXTERNAL

FITTING

OF

THE

DUCT

ASSEMBLY

Rear Flue Assembly

Measure distance

L.

See

Fig

16

Air

duct length =L + 73

mm.

Flue

duct length = L + 128

mm.

Do

not cutthe drilled end

of

either duct.

Assemble the

air

and

flue

ducts to the terminal.

Drill

through the

holes

in

the terminal into the air duct and

fix

using the screws

provided.

See

Fig

. 18.

Join

the extension ducts to the standard

ducts as indicated

in

Fig.

19

applying a smear

of

silicone sealant

to

the end

of

the

flue

duct.

Drill

and screw together the air ducts.

Push

the assembly through the wall

from

outside the premises.

Fix

the assembly to the

flue

elbow.

Drill

through the holes

in

the elbow into the

flue

duct and

fix

with

the screws provided.

Access

is

gained by slightly withdraw·

ing

the

flue

duct. Spread a smear

of

silicone

sealant around the

elbow

and push the air duct into position.

Drill

and

fix

the

air

duct

to

the

elbow.

See

Figs

.

18

and

20.

Align

the

flue

elbow

with

the spigot

on

the appliance.

See

Fig.

15.

Align

the clamp with the top

of

the spigot and tighten. seal any

small

gaps

in

the spigot beneath the clamp with a small quantity

of

sealant.

Make

good the internal and external brickwork

or

rendering.

Refit

the

fan.

Do

not use any sealant on the joint. Replace the

inner casing

cover.

Side Flue Assembly

Measure distance

L.

See

Fig

17

Air

duct length = L + 170

mm.

Flue

duct length =

L+

225

mm.

Do

not cut the drilled end

of

either duct.

Assemble the

air

and

flue

ducts to the terminal.

Drill

through the

holes

in

the terminal into the air duct and

fix

using the screws

provided.

See

Fig

. 18.

join

the extension ducts

to

the standard

ducts as indicated

in

Fig.

19 applying a smear

of

silicone sealant

to the end

of

the

flue

duct.

Drill

and screw together the air ducts.

From

outside, push the assembly through the

wall

and enter the

ducts into the

flue

outlet elbow.

Pull

back the

air

duct slightly to allow access to the

flue

duct.

Drill

through the holes

in

the elbow into the

flue

duct and

fix

with the screws provided. Spread a smear of silicone sealant

around the

elbow

and push the air duct into position.

Drill

and

fix

the air duct

to

the elbow.

See

Figs.

18 and 20.

Align

the

flue

elbow

with the spigot on the appliance using

sili

·

cone sealant.

See

Fig

. 15.

Align

the clamp with the top

of

the spigot. Seal any small gaps

in

the spigot beneath the clamp with a

small

quantity

of

sealant.

Make

good the internal

and

external brickwork

or

rendering.

Refit

the

fan.

Do

not use any sealant

on

the joint.

Replace

the

inner casing

cover.

Fig.

15. Flue elbow fixing.

Flue

elbow

Appliance

lop

panel

~·~-~~~---------p··-""'·

1

0.4

INTERNAL

FITIJNG

OF

THE

DUCT

ASSEMBLY

The

rubber

sealing

gasket and the clamping

ring

are available

from

Worcester

Heat

Systems.

Measure

and

cut

the

ducts as previously described

for

external

fitting

(Section

1

0.3).

Fix

the ducts

to

the terminal and

fit

the

rubber sealing gasket and clamp to the terminal.

Centralise

the

gasket and tighten the

clamping

ring.

See

Fig

21.

Slide

the

flue

centring

ring

onto the

air

duct and tighten the

screw.

See

Fig.

22.

Fix

the ducts

and

terminal assembly

to

the

flue

outlet

elbow

as described

in

Section

10.3 preceding.

Push the assembly through

the

wall

so

that the gasket

flange

is

against the outside

face

of

the

wall

.

See

Fig

22.

Align

the

flue

elbow

with

the spigot

on

the appliance.

Align

the

clamp with the top

of

the spigot.

Seal

any small gaps

in

the

spigot beneath

the

clamp

with

a

small

quantity

of

sealant.

See

Fig.

15.

Refit

the

fan.

Do

not

use any sealant

on

the

joint.

Replace

the

inner casing

cover.

Seal

the

gap around the duct

with

the

flexible

seal

provided and

make

good.

See

Fig

22

.

Fig.

1

6.

Flue

duct length

(rear

flue).

1

0.5

FINAL

INSTALLATION

Check

that

all

the water connections and the gas connection

have been tightened.

If

a

facia

mounted programmer

is

to

be

fitted,

unscrew the upper

two

screws

holding

the

facia

panel

in

place

and

carefully

lower

the

facia.

See

Fig

23.

Unplug

the Operating

Switch

from

terminal

X1

0

on

the main

driver board.

See

Fig.7

.

Unscrew

the

four

screws holding the

switch plate

and

remove

the complete Operating

Switch

assem·

bly.

Fit

the programmer

and

tighten the

four

screws.

Plug

the

programmer

into

terminal

X1

0

on

the

main

driver board.

Lower

the control

box

as described

in

Section

13

.

3(d)

.

Connect

the mains

electrical

supply to the appliance at terminal

X7.

Ensure

that the earth

lead

is

longer than the

live

and neutral

leads and securely

fixed

into the cup washer

on

the earthing

stud.

See

Fig.7.

Connect any room and/or frost thermostats.

The

electrical leads must pass through the appropriate

holes

in

the control panel

and

be

fixed

with the cable clamps provided.

See

Fig.

24.

Refit

the

facia

panel.

~~--m

___

I_Jk-~:::00·

/ / I

Flue

assembly

l I

/ I l I

1 I

10

mm

---:

~--

_J

I /

,_.-,1__

---l

----

' I

(-=========~

External

wall

face

Rear

face

of

appliance

and

face

of

mounting

wall.

--

Note.

Diagram

shows

the

appliance

mounted

on

an

internal

wall

but

In

many

cases

will

be

mounted

directly

on

to

the

external

wall,

in

which

case

L

will

be

the

overall

thickness

of

the

external

wall.

Fig.

17.

Flue

duct length (side

flue).

L L

Distance

between

rear

face

of

appliance

and

I------=~-----

external

wall

face

including

any

rendering.

~·~,~

___4

____

-----

---r-

------..,

/ / I

Flue

assembly

i l

/

I

I /

I I

(-=========)

Appliance

side

panel

--

External

wall

face

L

Distance

between

side

panel

and

external

wall

~----------+--

·

lace

including

any

rendering

.

"'-~--~-----------·-----~

.0

-~·-~-~-~--

·

-----~-~-----

·

14

Fig.

18.

Flue

elbow,

ducts

and

terminal

assembly.

Flue

elbow

to

air

duct

fiXing

screws

Flue

duct

length

=L

+

128

mm

(rear

fluel--------

L+

225

mm

(side

flue

F"/7Z!'-------1-

Air

duct

to

tenminal

Air

duct

~T

j

fixing

screws

Flue

duct

L

Flue

elbow

to

flue

duct

fixing

screws

~

Appliance

casing

Fig.

19.

Flue

assembly using

the

extension ducts.

Fig.

20.

Flue

elbow.

Access

to

the

flue

fixing

holes

-----~~

~

__

Flue

duct

length=L

+

128

mm

(rearllue)

________________

__,,_1

L+

225

mm

(side

llue)

Air

duct

fixing

screws

Standard

flue

duct

Standard

air

duct~

Air

duct

length=

L+

73

mm

(rear

flue)

L+

170

mm

(side

llue)

1----------------L------------------~

Applimce

cas

i

ng

____

...)

15

Fig.

21

.

Terminal

assembly

for

internal

fitting

of

the

flue.

'"-

-··--~~-------

·

-

Test

the gas

supply

pipework

up

to

the

appliance

for

soundness

as

indicated

in

BS

6891.

Refer

to

Section

11

for

a

full

description

of

the

filling,

venting

and

the pressurising

of

the system.

If

the appliance

is

not to

be

commissioned immediately, replace

the

cabinet

front

panel.

Check

that the gas supply, the electrical

supply

and

the

water connections are

all

turned

off.

If

the premises are to

be

left unoccupied during frosty

condi-

tions,

then commission the appliance

as

described

in

Section

11

and

leave

it

under

the control

of

the

frost

thermostat or leave

operating continuously

with

the

room

thermostat set at 6°C

or

drain

the appliance and system.

Fig.

22.

Duct

and terminal assembly

for

internal

fitting

of

the

flue.

Air

duct

Rubber

sealing

gasket

Fig.

24.

Electrical

cable exits

from

control

box.

IGNITION

BOARD

Fig.

23. Appliance casing

and

control

equipment fixings.

• r-·

Inner

casing

cover

fixing

screws

(4)

• •

:J

c

Control

box

fixing

screws

(2)

Upper

facia

panel

fixing

screws

(2)

~

I

-··

··~-c

d)

E)

··~

- i

:...:::--

.

-·

..........................

·, ,·

--·\.001-

I

Lower

facia

panel

fixing

screws

(2)

MAIN

DRIVER

BOARD

TO TO

EARTH

MAINS

TO

TO TO

TO

PILOT

&

MAIN

FAN

GAS

VALVE

!

'-----~-

16

PUMP

OVER-RUN

lliERMOSTAJ

TO

ROOM

lliERMOSTAT

!OPTIONALI

WATER

CENTRAL

DOMESTIC

MODULATING

DIVERTER

H!:ATING

HOT

WATER

SOLENOID

VALVE

SENSOR

MICRO-SWITCH

TO

FROST

THERMOSTAT

!OPTIONAL{

11

. Commissioning

11

.1

The

appliance

is

dispatched

with

the controls set to

pro·

vide a maximum output

for

domestic hot water

of

23

kW

(78,500 Btu/h) and satisfy a central heating load

of

16.1

kW

(54,900

Btu/h).

The

controls can

be

reset to increase the heat

load

capability

to

23

kW

(78,500

Btu/h).

Refer

to

Section

11.4 -Central

Heating.

It

is

not necessary to set the output below

16.1

kW

(54,900

Btu/h) as

it

is

automatically modulated

to

satisfy lower heat

loads.

Domestic

Hot

Water System.

Check

that the

mains

water

sup-

ply

has been

fully

flushed

out at Installation.

Central Heating System.

Check

that the central heating system

has been

fully

flushed out at installation.

Gas

Service .

The

complete system, including

the

meter, must

be

inspected and tested

for

soundness and purged as indicated

in

BS

6891.

11

.2 APPLIANCE AND CENTRAL HEATING SYSTEM

PREPARATION

Remove

the cabinet

front

panel.

Check

that the electrical supply and the gas

service

to the

appli-

ance

are

off.

See

Fig

3.

Check

that

all

the water connections throughout

the

system

are

tight.

Open

the system valves at the appliance.

See

Fig

3.

Open

all

the

radiator

valves,

fill

the system and

vent

each radiator

in

turn.

The

automatic air vent

(fixed

to

the

flow

manifold)

will

vent the

appliance.

Remove

the boiler inner casing

cover

to check that

the

air

vent cap has been removed.

See

Figs

14

and

23.

Replace

the

cover

immediately.

Check

that the pressure relief valve operates

by

turning the

knob

anti-clockwise

until

it

releases. Water should be

expelled

from

the discharge

pipe.

See

Fig.

25.

Lower

the control box

to

gain

access.

Refer

to

Section

13.3(d).

Set the Expansion Vessel Pressure

The

charge pressure

of

the

expansion vessel as dispatched

is

0.5

bar,

which

is

equivalent to a static

head

of

5 metres

(17

ft).

The

charge pressure must not

be

less

than the static head at the

point

of

connection.

See

Fig.

5.

ASchraider type tyre

valve

is

fit-

ted

to

the expansion vessel

to

allow

the charge pressure to

be

increased

if

necessary.

Set the System Pressure

Fill

the system until the pressure gauge shows 2.5 bar

(37

lblins') and check

for

water soundness.

Release

water

from

the

system

using

the

relief

valve

test

knob

until

the

System

Design

Pressure

is

obtained,

up

to

a

maximum

of

1.5

bar.

System

Design

Pressure

in

bar =

Static

Head

of

the System

in

bar+

0.3

Note:

1bar

is

equivalent

to

1

0,2

metres

(33.5

ft)

of

water.

Set

the

movable pointer

on

the pressure gauge

to

coincide

with

the

indicating

pointer

giving

a permanent

record

of

the set

sys-

tem pressure.

If

the pressure indicated

on

the

pressure gauge

is

greater than

2.6

bar

when

operating at the maximum central heating

tem-

perature,

an

extra expansion vessel must

be

fitted

to

the system

as

close

as possible to

the

appliance central heating return

con·

nection.

The

appliance

{as

dispatched)

can

accommodate a system

val·

ume

of

about

83

litres.

Refer

to

BS

7074 Part

1.

If

the system

volume

is

in

excess

of

that accommodated

by

the expansion

vessel

fitted

to

the appliance then

an

extra

vessel

must

be

fitted

as

close

as

possible to the central heating return connection

of

the

appliance.

Any

extra vessel

fitted

must

be

pressurised to

the

same

figure

as

the

il'tegrc.l

vessel.

if

the

expcmsi0n

v~ssel

fails

then the

speci-

fir:rl

repia::·~m::'nt

•~•-l::'t

1

JP.

:'itted

'17

Fig.

25. Pressure relief valve.

r

Pressure

gauge

capillary

connection

Pressure

relief

valve

discharge

pipe

11.3 PROGRAMMER

Any

programmer fitted

on

the appliance should be set up at this

stage

following

the instructions sent

with

the programmer.

The

programmer

will

retain the setting

for

up

to

four

weeks

following

an

interruption

in

the electricity supply.

11

.4 APPLIANCE OPERATION

Check

that the

electrical

supply to the appliance is

off.

Set

the

Operating

Switch

(or

Programmer)

to

OFF.

Remove

the

inner

casing

cover.

Refer

to

Section

13.3(b).

Disconnect

the electrical connections

from

the modulating

sole·

noid.

Do

not

leave

them unprotected.

See

Fig.

26.

Turn

on

the

gas

supply and reconnect

the

electricity supply.

Set

the Operating Switch (or Programmer)

to

HEATING

&

WATER.

Acontinuous

ignition

spark

will

occur

until

the

pilot

is

alight

and

sensed

by

the control

circuit.

The

main burner

will

light

and

remain at

its

minimum setting. Test

for

gas

soundness

at the joint between the pilot pipe and the burner with leak

detection

fluid.

Observe

the

pilot

flame.

It

should

be

about 18-20

mm

long and

envelope

the spark electrode

tip.

If

not,

refer

to

Section

13.4.

See

Fig.

32.

If

the pilot

still

does not

light,

contact Worcester

Heat

Systems

Service

Department.

Set

the Operating

Switch

(or

Programmer)

to

OFF

and

discon-

nect

the

electrical

supply at the mains.

Replace the inner casing cover.

Reconnect

the

electrical

connections to the gas

valve.

Loosen

the

burner pressure test point screw and connect a pressure gauge.

See

Fig

26.

Domestic Hot Water.

Switch

on

the electricity supply.

Set

the

Operating

Switch

(or

Programmer)

to

WATER

and

fully

open

a hot water tap.

The

boiler

should

light

at a burner pressure

of

between 1

2.5

and

13.5

mbar

(5.0

and 5.4

in.wg.).

If

the burner pressure

is

low,

check

that the supply pressure

at

the

gas

valve

inlet

is

at least

19

mbar

{7

.6

in.

wg).

Note:

The

burner pressure

is

factory set and

if

(after checking

that the supply pressure

is

sufficient)

the

correct pressure

is

not

obtained then Worcester Heat Systems Service Department

should

be

contacted.

If

the

appliance does not

light,

check

that

it

is

not

in

the

over-

heat 'lockout' state

by

pressing

the

thermostat reset button.

See

Fig.

27.

Gradually

close

the hot tap and

check

that the burner pressure

drops.

Fully

open

the tap and check that the burner pressure

rises.

Fully

close

the tap and

check

that the burner

goes

off.

The

pump

will

continue running

until

the

appliance has cooled to a

preset

te:nperat~.<re.

Set

tl1e

O~·eruting

Switc';

(or

Pr•.)gr,m:mcr)

t•:.

O:fF.

Fig.

26.

Gas

valve.

PiloVmain

gas

valve

connections

!Black:

blue:

brown

:

green/yellow)

------....._

Central Heating

Check

that

all

the

radiator valves are

open.

Set the

room

thermo·

stat and the

Central

Heating Temperature Control

to

maximum.

On

sealed systems check that the system

is

pressurised and set

to

the required pressure

as

indicated

on

the gauge.

Set the Operating Switch (or Programmer) to

HEATING

&

WATER.

The

burner

will

light.

The

appliance

will

modulate its output from 9.2

kW

(31

,400

Btu/h)

to

the set output

of

16.1

kW

(54,900 Btu/h) over a

peri·

od

of

about

two

minutes.

Check

the system to ensure that

all

the radiators

are

heating

up

evenly.

Shut

down

all

but one

of

the radiators and observe the burner

pressure

fall.

Open

all

of the radiator valves and

check

that the

burner pressure rises.

Balance

the system so that the required temperature difference

across the central heating

flow

and return pipes

is

obtained.

See

Table

3.

Adjust

the central heating by-pass valve until the same temper·

ature

difference

is

obtained. See

Fig

28.

This

should

be

carried

out with

only

a

single

radiator operating.

If

thermostatic radiator

valves are

fitted

then one radiator should be

left

uncontrolled.

The

bypass

valve

should never be

fully

closed.

If

the heat load

is

in

excess

of

16.1

kW

(54,

900

Btu/h) then reset

the controls

to

the maximum

of

23

kW

(78,500 Btu/h) by care·

fully

rotating the adjustment potentiometer to its maximum

postion.

Access

is

gained

to

the adjustment point

by

lowering

the electrical control

box.

Indicate the

new

setting pressure

on

the data plate.

Set

the room thermostat

to

minimum and check that the burner

goes

out.

Reset

the

room

thermostat

to

maximum and the burn·

er

will

relight and

follow

the normal operating procedure.

Check

for

proper ignition

of

the burner after a break

in

the gas

supply.

Turn

off

the gas service cock and wait

for

60

seconds.

The

main burner and pilot

wil.l

go out but sparking from the

electrode

will

continue.

Carefully

open the gas

service

cock and

observe the burner religh: and

follow

the normal sequence

of

op~raUon.

18

Minimum

pressure

adjuster

Maximum

pressure

adjuster

~---

Nole.

Cloclwise

to

increase

and

antl-clocl;wise

to

decrease

the

pressure.

Modulating

solenoid

Pressure

compensating

connection

!at

rear)

Electrical

connections

·modulator

!Yellow:

yellow}

Set the Operating

Switch

(or

Programmer)

to

OFF.

Turn

off

the gas service

cock

and the electrical supply

to

the

appliance.

Drain

the system

while

the appliance

is

still

hot.

Refill,

vent and,

with

a sealed system, re·pressurise

as

described

in

Section

11

.2.

Domestic Hot Water

and

Central Heating

Turn

on

the electricity supply

to

the appliance and

open

the gas

supply

cock

at the appliance.

Set the Operating Switch

(or

Programmer)

to

HEATING

&

WATER.

If

a programmer

is

fitted,

set the domestic

hot

water to

Continuous or 24Hrs and the central heating to

ON.

The

burner

will

light

and heat

will

pass

into

the system.

Turn

on a hot water

tap and check that

fully

heated hot water

is

discharged

from

the

tap.

Close

the tap and the burner

will

go

off.

The

appliance

will

then

return

to

the central heating mode and automatically balance

with the system requirements.

Set the Operating

Switch

(or

Programmer)

to

OFF

and the burner

will

go

out.

11.5

COMPLETION

OF

COMMISSIONING

Disconnect the pressure gauge and tighten the test point screw.

Restart the appliance and

check

for

gas soundness around the

test point screw.

Refit

the cabinet

front

panel.

If

the

appliance

is

being passed over

to

the user immediately,

refer

to

Section

12-

Instructions to the

User

and set

the

controls

to the user's requirements.

If

the appliance

is

to

be

left inoperative,

check

that

the

Operating

Switch

is

set to

OFF.

Turn

off

the gas service cock and switch

off

the electricity supply.

If

there

is

any possibility of the appliance and system being left

inoperative during frosty conditions, drain the appliance and

system.

For

short inoperative periods

leave

the boiler under the

control

of

a frost thermostat

oc

operating continuously under

I:~Je

control

of

a

room

thennostat set

:~t

6°C.

Fig.

27. Overheat thermostatreset button.

Overheat

thermostat

reset

button

12. Instructions

To

The User ·

12.1

Tell

the user

how

to

operate the appliance and hand

over

the

Users

Instructions

leaflet.

12.2

Tell

the user what

to

do

if

the the heating system

is

not

to

be

used

in

frosty

weather.

13. Inspection

and

Servicing

13.1

To

ensure continued efficient operation

of

the appliance

it

must be checked and serviced as necessary at regular inter·

vals.

The

frequency

of

servicing

will

depend upon the particu·

Jar

installation conditions and usage, but once per year should

generally

be adequate.

The

extent

of

the service required

by

the appliance

is

determined by the operating condition

of

the

appliance when tested by

fully

qualified engineers.

Any

service work must be carried out by competent engineers

such as British

Gas

or

Corgi

registered personnel.

13. 2

PRE-SERVICE

INSPECTION

Check

that the

flue

terminal and the terminal guard,

(if

fitted),

are

clear.

If

the

appliance

is

in

a compartment,

check

that the ventilation

openings

in

the compartment

door

or

walls

are

clear.

See

Section

6-

Air

Supply.

Check

the

system

and

remake any

joints

or

fittings

which

show

signs

of

leakage.

Refill,

vent

and-re·pressurise

as

described

in

Section

11.

2.

Operate

the appliance and the system taking note

of

any

faults.

Warning

Disconnect

the electrical supply at the

mains

and turn

off

the

gas

supply

at the gas

service

cock

on

the appliance

before

ser-

vicing

.

See

Fig

.3.

After

completing the service

alway::-

test

for

g<~s

soundness

as

ir.r.\icat~d

i;

aS

(-8CI~.

19

Fig.

28. Central heating by-pass adjuster.

~!

0 0

0

12.3

Tell

the user the sealed system set pressure.

12.4

Tell

the user

of

the importance

of

regular

servicing.

Worces·

ter

Heat

Systems

Ltd

offer

a comprehensive maintenance

con·

tract.

12.5

Set

the system controls

to

the user's requirements.

12.6

If

an

external programmer

has

been

fitted

which

has

a

pro-

grammable

domestic

hot

water

facility

then

it

is

suggested that

this

be

set

to

Continuous

or

the equivalent.

13. 3 DISMANTLE THE APPLIANCE

To

carry

out a

full

and comprehensive

service

of

the appliance

remove

the

following

parts

to

gain

access

to

the components

which

need

to

be

checked

or

serviced.

(a)

Cabinet Front Panel.

Remove

by

lifting

off

the supports.

(b)

Inner

Casing

Cover.

Remove

the cabinet

front

panel.

Unscrew

the

four

screws

securing

the

cover

to

the

casing and

lift

off.

See

Fig

23.

(c)

Facia

Panel.

Check

that the electricity supply

to

the

appli-

ance

is

turned

off.

Remove

the cabinet

front

panel.

Unscrew

the

two

upper

screws

as

shown

in

Fig

23

and

lower

the

facia

taking

care

not

to

damage the pressure gauge

capillary

tube

or

electri·

cal

connections.

(d)

Control

Box.

Remove

the

cabinet

front

panel.

Unscrew

the

two

screws

as shown

in

Fig.

23,

Support the assembly

and

allow

it

to

hinge

down

into

the

servicing

position.

Make

sure

no

damage

is

done

to

the pressure gauge

capillary

tubes

or

electrical

wires.

(e)

Fan.

Remove

the inner casing

cover.

Unplug

the electrical

connections,

pull

off

the sensing tube and

unscrew

the three

fix·

ing

screws

.

Remove

the

fan

assembly.

See

Fig

29.

(~

Flue

Hood

Assembly.

Remove

the the

fan

assembly.

Unscrew

the

two

screws

fixing

the

flue

hood

and

slide

the

fiue

hood

assembly

from

the

appliance.

See

Fig

29.

When

refitting

the

hood

ensure that

the

rear return passes

under

the

lip

at the

rear

of

the combustion chamber.

(g)

Combustion Chamber

Cover.

Remove

the the inner casing

cover.

Unscrew

the

six

screws securing the

cover

and remove

the

cover.

See

Fig

29.

(h)

Main

Burner Assembly.

Remove

the combustion chamber

cover.

Unscrew

the

pilot

fixing

screws.

Pull

out the electrode.

Undo

the

pilot

pipe

and

remove

the

pilot burner.

See

Fig

30.

Un·

screw

the

two

screws and

remm·~

the burner assembly

by

lifting

th~

fmPt

of

the bmnr;r

.:~nd

pui!ir-

>,

fcrvvard

~C!e

fi2 :'•t.

Fig.

29.

Appliance

components and

fixings

(upper

assembly}.

77

~

f

Bt------

Fan

assembly

ixing

screws

(3)

Flue

hood

0

010

0 0 -

Inner

casing

Combustion

chamber

cover

fixing

screws

(4)

Combustion

chamber

cover

0 0 0

0

Fig.

30.

Pilot

burner

assembly.

~Sparl<electrode

Pilot

injector

0 \

20

Bosch Thermotechnik WORCESTER 230 Combi RSF User guide

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