Worcester Combi rsf 240 User guide

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

Bosch Thermotechnik

240

Combi RSF

WALL

MOUNTED

COMBINATION

BOILER

FOR

CENTRAL

HEATING

AND

MAINS

FED

DOMESTIC

HOT

WATER

INSTALLATION AND

SERVICING INSTRUCTIONS

GC

NUMBER

47

311

12

BOILER

OUTPUT

Automatic

Modulating

Control

To

Domestic

Hot

Water

Minimum 9.2 kW

(31

,400

Btu/h)

Maximum

24.0

kW (82,000

Btu/h)

To

Central

Heating

Minimum 9.2 kW (31,400

Btu/h)

Maximum

24.0

kW (82,000

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

I

Contents ,

1.

Instailation

Requirements.............................................

Page

2

2.

General

Information......................................................

Page

2

3.

Technical

Data................................................................

Page

4

4.

Siting

the

Appliance......................................................

Page

5

5.

Siting

the

Flue

Terminal................................................

Page

6

Sa.

Vertical

Flue

System

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

....

Page

6

6.

Air

Supply

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

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

Page

7

7.

Sealed

System

..

.....

...

......

..

..........

..

...

..

....

...

....

..........

....

Page

7

8.

Open

Vent

Primary

Water

System

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

Page

8

, 1. Installation Regulations

1.1

Gas

Safety

(Installation

and

Use)

Regulations

1984

Ail

gas appliances must

be

instailed

by

a competent

person

in

accordance

with

the

above

regulations.

Failure

to

instaii

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

instaiiation

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,

local

Building

Regula·

tions,

Building

Standards

(Scotland)(Consolidation)

and

byelaws

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

following

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

:1

988

Installation

of

low

pressure gas

pipework

instaila·

tions

up

to

28

mm

(R

1

).

1.4

To

ensure that the instaiiation

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.

0

2.

General Information

2.1

This

appliance

is

not

suitable

for

external instaiiation.

2.2

The

appliance

controls

are

set

to

provide

a

maximum

out·

put

of

24

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

Wnter

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.

2

9.

Domestic

Hot

Water

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

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

Page

9

1

o.

Electrical

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

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

Page

10

11

. Instaiiation

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

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

Page

13

12.

Commissioning

..........

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

Page

18

13.

Instructions

to

the

User

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

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

Page

19

14.

Inspection

and

Servicing

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

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

Page

20

15.

Replacement

of

Parts....................................................

Page

22

16.

Short

Parts

List

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

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

Page

29

17.

Operational

Flow

Diagram

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

:............................

Page

30

18.

Fault

Finding

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

Page

32

Awater

flow

regulator.

Astandard horizontal

flue

assembly

giving

flue

lengths

from

1

00

mm

to

1

000

mm.

An

optional extra extension

flue

kit

to

provide

for

flue

lengths

up

to

2000

mm

long.

An

optional vertical

flue

system.

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

2.81

m3

/h

(99.3

ft3/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

=

0.5

metres,

90°

Bend

=

0.3

metres.

2.7

PACKING

The

appliance and

flue

components

are

packed

in

separate

car·

tons.

2.8

GENERAL

INSTALLATION

The

appliance

is

supplied

for

connection

to

a

sealed

system but

is

suitable

for

use

with

an

open

vent system.

The

connections

are

supplied

as

an

optional

kit.

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

clearances

specified

for

servicing

must

be

maintained.

Fig.

1.

Appliance

water

flow

diagram.

Waterflow

manifold

L___

Automatic

air

vent

Gas

to

Water

heat

exchanger

Boiler

4---,

'

I

PressJre

relief

valve

-

Domestic

hot

water

out

--

Mains

cold

water

in

-

Central

heating

return

--

Central

heating

flow

2.9

FLUE

The

appliance has a multi-directional horizontal fanned

flue

system -

right,

left

or

rear.

The

standard

flue

assembly length

is

from

100

mm

to

1000

mm.

An

extension

flue

length

from

1001

mm

to 2000

mm

is

avail-

able.

A

vertical

flue

is

available

with

a primary

flue

length

from

500

mm

to

2000

mm.

Aterminal

guard,

'!Vpe

1<2,

GC

393

553,

is

available

from

1bwer

Flue

ComporterttS,

Vale

Rise,

'lbnbridge,

TN9

1TH.

Do

not allow the

flue

terminal fitted

to

the outside

wall

to

become

obstructed

or

damaged.

An

optional extra internal

flue

fixing

kit

is

available.

When

ordering

the

kit

the

following

part number must

be

quoted -

ZEGAS206.

For

fitting

instructions

refer

to

Section

11.4.

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.

Afada mounted programmer

Is

available

as

an

opliortal

extra. A

remote mounted programmer may be connected to

the

appli<mr.P.

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

electronic

co~trols

prevent

rapid

cycling

of

the

appliance

in

the

central

heating

mode.

3

2.11 SYSTEM NOTES

WARNING

Check

that

no

dirt

is

left

in

either

the

gas

and

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

BS2767

(10):

1972.

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 temper·

ature.

Hot

and

cold

mains

fed

water can

be

supplied direct

to

an

over·

rim

flushing

bidet subject

to

local

Water

Company

requirements.

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

thP.

tP.mperature

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

maxi·

mum output.

The

output

of

the appliance

is

then automatically

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

demand

for

domestic hot

water

ctl

a

lap

or

shower

wtll

overrldP.

the central heating requirement

for

the period

of

the domestic

hot water demand.

When

hot water

is

no

longer required the

burner

will

extinguish and the appliance

will

return

to

the

cen-

tral heating state and

its

normal

mode

of

operation.

The

pump

will

continue

to

run

to

dissipate the

residual

heat

from

the

appli-

ance

as

necessary.

, 3. Technical Data

The

Data Plate

is

fixed to the control box casing.

TABLE

1

TABLE

2 - Flue Details

NOMINAL

BOILER

RATINGS

Horizontal Flue (Side

or

Rear)

mm

inches

Output

Input

Burner

Setting

Gas

Rate

Pressure

Wall Hole Diameter

110

4.25

kW

Btu/h

kW

Btu/h

m

bar.

in.wg.

m3/h

ft

3/h Wall Hole Diameter

(using

optional

extra

Internal

fitting

kit)

150 6

9.2

31,400

13.0

44,300

2.0

0.8

1.22

43.0

Standard

Flue

-Minimum Length 100 4

16.1

54,900

21.0

71,600

6.3

2.5

1.97

69.5

Standard

Flue

-Maximum Length 1000 39

24.0

82,000

30.0

102,300

14.0

5.6

2.81

99.3

Extended

Flue

-Maximum Length 2000 78

TABLE

3

AVAILABLE PUMP

HEAD

Boiler

Output

Head

Min.

Flow

Rate

Temp.

rise

across

heating

flow

kW

Btu/h

metres

feet

litres/min

gal/min

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

24.0

82,000

2.0

6.5

21.0

4.63

16'C

(29'F)

Vertical Flue

mm

inches

Ceiling Hole Diameter 120 4.75

Minimum PrimaryDuct Length 500 20

Maximum Primary Duct Length 2000 78

TABLE4

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

Rc1;2

PRESSURE

RELIEF

VALVE

DISCHARGE

FITTING

15

mm

Compression

OVERALL

HEIGHT

(including flue elbow) 1100

mm

(43.3 in.)

CASING

HEIGHT

900

mm

(35.4 in.)

CASING

WIDTH

450

mm

(17.7 in.)

CASING

DEPTH

320

mm

(12.6 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

2.7litres

(0.6

galls.)

MAXIMUM

COLD

SUPPLY

PRESSURE

10 Bar (150

psi)

MINIMUM

COLD

SUPPLY

PRESSURE

(WORKING)

FOR

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)

MAXIMUM

STATIC

HEAD

(PRIMARY)

25 metres

(81

ft)

MIMIMUM

STATIC

HEAD

(PRIMARY)

0.3 metres

(1

ft)

OUTPUT

TO

DOMESTIC

HOT

WATER

Modulating

9.2-24

kW

(31

,400-82,000 Btu/h)

OUTPUT

TO

CENTRAL

HEATING

Modulating

9.2-24

kW

(31

,400-82,000

Btu/h)

MAXIMUM

DOMESTIC

HOT

WATER

FLOW

RATE

FROM

THE

APPLIANCE

Nominally 8.5

litres/min

(±15%) •

(1.87 gallons/min)

EQUIVALENT

DOMESTIC

HOT

WATER

FLOW

RATE

TO

GIVE

A

TEMPERATURE

RISE

Nominally

9.8litres/min

OF

35°C (2.16 gallons/min)

4

4. Siting The Appliance

4.1

The

appliance

may

be

installed

in

any

room

although

par·

ticular

attention

is

drawn

to

the

requirements

of

the

current

I.E.E.

Wiring

Regulations

and,

in

Scotland,

the

electrical

provi·

sions

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

"Guide

for

Gas

Installations

in

Timber

Framed

Housing".

4.6

The

following

clearances must

be

available

for

installation

and

for

servicing.

See

Fig.

2.

Installation

Servicing

Above

the

flue

elbow

30mm 30mm

Above

-

Vertex

Flue

150mm 150mm

In

front

600mm 600mm

Below

230mm 230mm

Right

hand

side

20mm 20mm

Left

hand

side

Smm Smm

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

BS476:4.

4.10

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.

4.12

The

appliance has a

vertical

flue

option.

See

Section

Sa.

Fig.

2. Appliance casing dimensions and required clearances.

100mm

r:~:

:.~.~.~~.~~~:~:•1ys~~

for

installation

and

servicing.

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

________________

..,

I

///////////

I ( I I f

I I

150m

I I

I

m

I I

I

-----

-i

-------

I

I I

I

l225mm

..... I

I I

900m

Ill

Mounting

wall

SIDE

VIEW

600

mm

Space

required

in

front

I

I I

FRONT

VIEW

I

I I

for

installation

and

servicing.

320mm

I

450

mm

I

/

Fixing

holes

I r--

41.3

mm

CRS.

____,

I

~-~0~:

__

f

_________

..J

1

1 I

~

1

Space

required

below

5

mm

1 : 1

!

li

I

114-J

"llfI

/).

1

for

installation

and

servicing.

Space

required

at

left

hand

side

---+-1

I+-

-+1

/).

_________

j +

for

installation

and

servicing.

!L

______________

_j

20mm

I

~

Space

required

at

right

hand

side

fu1

insl~ll~tion

and

servicing.

5

Fig.

3.

Appliance pipework connections.

~,

~ORCESTER

240

POvmiOH.

WATER•oo

OfFoo

HEATING&WAURee

u

=m=

:e··,_

- =

:..:::;.r

-

OE!d.o.ND.

Central

heating

flow

---lr-----t

Central

heating

return

Mains

cold

water

in

--1----

Pressure

relief

valve

discharge

--+---------

306

mm

--..-j

..I

\

..

. .

min

TEMPERATURE

ma•

Gas

cock

-1-------------405

mm

-------~

5. Siting

the

Flue Terminal

See

Fig.

4

5.1

The

flue

must

be

installed as

specified

in

BS

5440:Part

1.

5.3

The

terminal must not cause an obstruction nor the

dis-

charge

cause a nuisance.

5.4

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

the

gutter

or

painted

surface.

5.5

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.

5.6

The

terminal guard must

be

evenly

spaced about the

flue

terminal and

fixed

to

the

wall

using

plated

screws

5.7

In

certain weather conditions a terminal

may

steam and

sit·

ing

where

this

could

cause a nuisance should

be

avoided.

5.8

Take

care

to

ensure that combustion products

do

not enter

ventilated

roof

voids.

Fig.

4. Siting of the flue terminal.

MINIMUM

SITING

DIMENSIONS

FOR

POSITIONING

THE

BALANCED

FLUE

TERMINAL.

A

6

Sa. Vertical Flue System

5a.1

A

vertical

flue

with

a primary length

of

between 500

mm

and

2000

mm

can

be

fitted

to

the appliance.

5a.2

It

is

recommended that

any

secondary

flue

be

of

the

twin·

walled

type such

as

that manufactured

by

Rite-Vent

or

Selkirk.

Refer

to

BS

5440:

Pt.1

for

details

of

secondary

flue

lengths.

5a.3

The

secondary

flue

must

fit

into a

Gas

Council

approved

ridge

tile

or

GC1

terminaL

5a.4

Fitting

instructions

for

a

vertical

flue

are enclosed

with

the

flue

kit.

TERMINAL

POSITION

MIN.

DISTANCE

--·~-

A-Directly

below

an

openable window

or

300

mm

(12in.)

other opening

e.g.

air brick.

B-Below

gutters, soil pipes or drain pipes.

75mm

(3in.)

C-Below

eaves.

25mm

(1in.)

0-Below

balconies or car port roof.

25mm

(1in.)

E-From

vertical drain pipes and soil pipes.

25mm

(1in.)

F

-From

internal or external corners.

25mm

(1in.)

G-Above

ground, roof or balcony level. 300

mm

(12in.)

H-From

a surface facing aterminal. 600

mm

(24in.)

I

-From

a terminal facing a terminal. 1200

mm

(47in.)

J

-From

an

opening in a car

port

(e.g.

door,

window) into dwelling. 1200 mm (47in.)

K-Verlicdlly

frum d lermindl un lhe

~dme

wall. ·tSOmm

(6tn.)

L-Horlzontally

from a terminal on the same

wall. 300

mm

(12ln.)

M-From

door, window or air vent (achieve

where possible).

150mm

(6in.)

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

7. Sealed

Syst~m

·

See

Figs.

5

and

6

7.1

The

system must

comply

with

the requirements

of

BS

6798

and

BS

5449:1.

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/inl

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

10

litre

expansion vessel

is

charged

to

0.5

bar and

is

suitable

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 104litres

can

be

accommodated.

Refer

to

BS

707

4

Pt.

1

for

more

information.

The

charge

pressure can

be

increased but

with

a decrease

in

system

volume.

Fig.

5. Sealed primary water system.

Lockshield

valve.

Radiator

valve.

lllllllll

J

Note.

A

drain

cock

should

be

installed

at

the

lowest

point

of

the

heating

circuit

and

beneath

the

appliance.

7

for

Installation and

Servicing

will

normally

be

adequate

for

venti·

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

277

cm

2• 138cm2•

(43

in

2

.)

(21.5

in

2)

Low

Level

277

cm

2• 138cm2•

(43

in

2

.)

(21.5

in

2

.)

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.

7.13

Connections

in

the system must resist a pressure

of

up

to

3

bar.

7.14

Radiator

valves

must

conform

to

BS

2767(10):1972.

7.15

Other

valves

used should

conform

to

the requirements

of

BS

1010.

7.16

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.

A~~li•nr.e

r.••ino.

H~=t2:1•t-

·Gas

to

Water

heat

exchanger

Sealed

system

....

-·--expansionvessel

-·Water

to

Water

heat

exchanger

Central

heating

by-pass

adjuster

-~+-----l-++-----1

Fill

point

-----'

Heating

return

Heating

flow.

Domestic

hot

water

out

~

I

Note.

The

mains

cold

inlet

connection

to

the

appliance

must

come

before

any

other

connection

from

the

cold

supply.

Domestic

cold

water.

__

British

Standard

stop

valve.

Fixed

spindle

type.

+-

Water

main.

Fig.

6.

System filling and make-up.

Heating

Return

Non

return

valve

+-

Worcester

Combi·Fill

System

8. Open Vent Primary Water System

See

Fig.

7

8.1

The

size

of

the

flow

and return

pipework

is

given

in

Section

3 -

Table

4.

The

components

required

to

connect the

appliance

to

an

open

vent

system

are

available

as

an

optional extra

kit.

8.2

The

feed

and expansion cistern should

be

arranged

so

that

there

is

a

minimum

static head

of

0.3

metres

(12in.)

above

the

top

of

the appliance or

above

the highest point

in

the heating

circuit,

whichever

is

the

higher.

See

Fig.

7.

8.3

The

feed

and

vent

pipe

should

be

22

mm

diameter

and

rise

Fig.

7.

Open vent water system.

S.H.-Minimumstatic

head

300mm

112

in.)

measured

from

the top

surface

of

the

appliance

or

highest

point

in

the

heating

system

to

the

water

level

in

the

feed

and

expansion

tank.

Feed

and

expansion

tank

-------,

Lockshield

valve.

Radiator

valve.

lllllllll

J

11111111

Note.

A

drain

cock

sho~ld

be

installed

at

the

lowest

point

of

the

heating

circuit

and

beneath

the

appliance.

I

8

Heating

Return

Auto

air

vent

~""'i'illt--

Fill

Point

'

Heating

Return

300mm

112in)

min.

above

the

highest

point

of

the

system.

continuously

from

the

appliance

to

the

feed

and expansion

cis·

tern.

8.4 Apressure

relief

valve

is

not

required

on

an

open

vented

sys·

tern.

If

the pressure

relief

valve

is

left

in

position

then a

discharge

pipe

must

be

fitted

which

terminates

in

a

position

such that

any

water

or

steam

discharge

does

not

cause a hazard

to

the

occu·

pants

or

damage

electrical

components.

8.5

Air

within

the appliance

will

be

expelled

via

the

feed

and

vent connection

or

dissipated

into

the rest

of

the system

which

must

be

fitted

with

manual

air

vents at

any

high

point.

8.6

The

pump

is

set

to

maximum

and

must not

be

reset.

8.

7

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.

Central

heating

Appliance

casing.

t-!~~~·t--

Gas

to

Water

heat

exchanger

-·Water

to

Water

heat

exchanger

by-pass

adjuster

-~+-+-!-+--'

Fill

point

----

.../

Heating

return

Heating

flow.

Domestic

hot

water

out

I

Note.

The

mains

cold

inlet

connection

to

the

applianoe

must

come

before

any

other

connection

from

the

cold

supply.

Domestic

cold

water.

--

British

Standard

stop

valve.

Fixed

spindle

type.

..,

Water

main.

9. Domestic

Hot

Water

I

9.1 The following are general requirements and,

if

necessary,

reference should be made to the local Water Company before

fitting the appliance.

9.2

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 (Rc'/2)

is

provided adjacent to the

flow

switch within the

appliance.

A Zilmet 2160 expansion vessel

is

the preferred type. A thread

sealant compatible with potable water must be used.

9.3 The

final

600 mm

of

the mains cold water connection to the

appliance should be made

in

copper tube only.

9.4 The appliance

is

suitable

for

a mains pressure of up to 10

bar (150 lb/in').

9.5 The appliance

is

fitted with a mains supply isolating valve.

9.6

The

maximum

domestic

hot

water

flow

rate

is

8.5

litres/min. (± 15%)

(1

.87 gallons/min.).

9.7

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.

9.8

It

is

a requirement

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. Refer

to

BS5546:1990.

9

9.9 Hot and cold taps and mixing valves used with this appli-

ance must be suitable

for

operating

at

a pressure ofup to 10 bar

(150 lb/in').

9.10

No

anti-syphonage arrangements are necessary except for

some loose head showers. See also Section

9.11

following.

9.11 Thermostatically controlled or pressure equalising shower

valves

will

guard against the

flow

of water at too high a temper-

ature.

9.12

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

bath water. Alternatively the shower must be

fit-

ted with an anti-syphonage device

at

the point of the flexible

hose connections.

9.13

The

supply

of

hot and cold mains water direct

to

a bidet

is

permitted, (subject to local Water Company requirements),

pro-

vided 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

nec-

essary.

9.14

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

accor-

dance 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.

· 10. ElecJrical

See

Figs.

8,

9,

10,11

and

12.

1

0.1

MAINS

SUPPLY.

240

V - ,

50

Hz, 270 watts.

External

Fuse

3A.

Internal

Fuses:

T2A

(F1)

and

T315mA

(F2).

10.2

It

must

be

possible

to

completely

isolate the

appliance.

10.3

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.

10.4

The

appliance must

be

earthed.

10.5 Mains

Cable.

0.75

mm

2

(24

x 0.20

mm)

to

BS

6500

Thble

16.

Ifa

new

cable

is

needed

it must

be

connected

into

the

terminals

marked L

(Brown

or

Red

lead),

N

(Blue

or

Black

lead)

and

the

Fig.

8. Wiring Diagram-Control panel

and

facia.

(All

components shown viewed

from

front

of

appliance)

earth stud and

be

held

securely

in

the

cable

clamp.

For

access

refer

to

Section

14.

10.6

The

wiring

between

the

appliance

and

the

electrical

supply

shall

comply

with

current

lEE

Wiring

Regulations

and any

local

regulations

which

apply.

10.7

If

a room and/or

frost

thermostat

is

to

be

fitted

refer

to

Figs.

11

and

12.

The

thermostats must

be

suitable

for

use

on

mains

voltage.

10.8 A facia mounted programmer

is

available

as

an extra.

Instructions are

supplied

with

the

programmer

kit.

1

0.

9 A

time

switch

or

programmer

can

be

fitted

externally

to

the

appliance.

1

0.1

0

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

continuity

and resistance

to

earth.

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Worcester Combi RSF 240 User guide

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