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Bosch Appliances 24I RSF Boiler User Manual

1. Pi Side casing Inner casing fixing cover screws 4 screws 4 A Facia panel 2 fixing F screws 2 er Bottom facia panel fixing 3 ae m a Cabinet Front Panel Remove by lifting off the supports b Inner Casing Cover Check that the electricity supply to the appliance is turned off Remove the cabinet front panel Unscrew the four screws securing the cover to the casing and lift off See Fig 29 c Facia Panel Check that the electricity supply to the appliance is turned off Remove the cabinet front panel Unscrew the two upper screws as shown in Fig 29 and hinge down the facia taking care not to damage the pressure gauge capillary tube or electrical connections f Fig 30 Appliance components and fixings N upper assembly Flue Gas Test Point Flue hood Fan assembly fixing screws 4 Overheat thermostat Combustion chamber cover fixing clips 2 Burner fixing screws 2 19 d Bottom panel Unclip and remove the appliance bottom panel e Fan Remove the inner casing cover Carefully unplug the electrical connections and pull off the sensing tubes Unscrew the four fixing screws and remove the fan assembly See Fig 30 f Combustion Chamber Front Remove the inner casing cover Undo the spring clips fixing the combustion
2. 600mm z gt an 2 1 00mm umm V Space required for installation and servicing E 5 Siting The Flue See Fig 3 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 discharge cause a nuisance 5 3 If the terminal is fitted within 850mm of a plastic or painted gutter or within 450mm of painted eaves then an aluminium shield at least 750mm long should be fitted to the underside of 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 Section 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 siting where this could cause a nuisance should be avoided 5 7 Take care to ensure that combustion products do not enter ventilated roof voids 6 Air Supply 6 1 The appliance does not require a separate vent for combustion air 6 2 The appliance can be fitted in a cupboard with no vents for cooling but the minimum clearances must be increased to those given below note the clearances at the front are for a removable panel e g a door Above the Turret 20mm In front 250mm Below 200mm Right hand side 75mm Left hand side 75mm 6 3 If the appliance is to be fitted in a
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4. 7 1 E 40mm Appliance side panel E External wall face Ss L_ gt Ne 11 4 EXTERNAL FITTING OF THE DUCT ASSEMBLY Measure distance L Side flue duct length L 184mm See Fig 14 Rear flue duct length L 181mm See Fig 13 Do not cut either the turret or the terminal assembly ducts unless L 350 to 450mm 1 Should L 350 to 450mm then cut the terminal assembly ducts reducing the length of the ducts to 200mm Then cut each extension duct to 200mm See Fig 15 Assemble the flue as described below ensuring the correct length L 184mm for side flues or L 181mm for rear flues A Fig 15 350 450 Special Terminal assembly reduced to 200mm a Rear flue L 181mm Side flue L 184mm Turret assembly with full standard duct lengths Flue extension duct length 200mm lt Appliance casing Air extension duct L 350mm 450mm length 200mm A f Fig 16 Standard flue assembly N Rear flue L 181mm Turret Side flue L 184mm assembly Terminal 3 F assembly Appliance casing eZ 2 If L is within the range 127mm to 350mm then the flue can be telescopically adjusted to the correct length 1 184mm for side flues or L 181mm for rear flues The ducts are then fixed by drilling a pilot hole through the hole in the air duct and screwing the self tapping screw provided into the t
5. Table 1 NOMINAL BOILER RATINGS OUTPUT INPUT Net M GAS RATE kW Btu h kW Btu h m bar in wg m h ft h NATURAL GAS 7 5 25 600 9 60 32 750 1 0 0 4 1 01 35 7 23 4 80 000 26 05 88 890 13 6 5 4 2 76 97 5 PROPANE 7 5 25 600 9 60 82 750 3 5 14 0 39 13 9 23 4 80 000 26 05 88 890 35 0 14 0 1 07 37 8 Table 2 FLUE DETAILS HORIZONTAL FLUE Side or Rear mm inches FLUE DIAMETER 100 3 9 WALL HOLE DIAMETER 110 4 25 WALL HOLE DIAMETER using internal flue fitting kit 150 5 9 STANDARD FLUE MINIMUM LENGTH 127 5 0 STANDARD FLUE MAXIMUM LENGTH 350 14 0 EXTENDED FLUE MAXIMUM LENGTH 2500 98 4 Table 3 AVAILABLE PUMP HEAD BOILER OUTPUT HEAD MIN FLOW RATE TEMPERATURE RISE ACROSS HEATING kW Btu h Metres Feet L min Gal Min FLOW AND RETURN 7 5 25 600 6 0 19 7 9 8 23 23 4 80 000 2 6 8 5 30 5 6 7 Table 4 SPECIFICATIONS CENTRAL HEATING FLOW FITTING 22mm Compression CENTRAL HEATING RETURN FITTING 22mm Compression COLD WATER MAINS INLET FITTING 15mm Compression DOMESTIC HOT WATER OUTLET FITTING 15mm Compression GAS INLET FITTING Rc inch PRESSURE RELIEF VALVE DISCHARGE FITTING 15 mm Copper Tube OVERALL HEIGHT including flue turret 960mm 37 8 inches CASING HEIGHT 800mm 31 5 inches CASING WIDTH 450mm 17 7 inches CASING DEPTH 360mm 14 2 inches WEIGHT including water 44 kg INSTALLATION WEIGHT 39 kg PACKAGED WEIGHT 44 kg
6. Appliance Operation Adjust the maximum pressure adjustment screw on the gas valve to give a burner pressure of 13 6 mbar on natural gas for propane the maximum pressure adjustment must be increased to maximum clockwise this should give 33 0 35 0 mbar End the demand and reset the appliance by interrupting the mains electricity supply Otherwise there is a four minute anti cycle delay at the end of a demand 21 Restart the appliance in central heating mode and adjust the minimum adjustment screw on the gas valve to give a pressure of 1 0 mbar on natural gas or 3 5 mbar on propane See Fig 33 After completing the adjustments check the minimum and maximum pressures and re adjust as necessary Once this has been done the clear cap should be re fitted to the adjuster and the retaining screw tightened Coat the screw with paint or nail varnish to prevent user adjustment Maximum pressure adjuster 27 Gas valve Main gas valve Minimum Note Clockwise to ies ap pressure increase and anti Black blue brown adjuster clockwise to green yellow decrease the pressure Burner pressure test point Inlet pressure test point x 12 Central Heating Sensor See Fig 34 Check that the electricity supply to the appliance is turned off Hinge the facia assembly in the servicing position as described in Section 14 3 c and d Carefully pull off the two leads from the sensor Pull off the senso
7. water flow switch Pressure relief valve m T Fixed by pass Domestic Safety discharge etus C H Domestic flow cold return supply 2 5 ELECTRICAL SUPPLY Mains supply 230V 50 Hz 180 watts External fuse 3A Internal fuses 2AT HRC F1 and 1 AF 22 2 6 GAS SUPPLY The boiler requires 2 76 m h 97 5 ft hr of natural gas with a calorific value of 37 78 MJ m 1014 Btu ft 1 07 m h 37 8 ft hr of propane with a calorific value of 95 65 MJ m 2568 Btu ft The meter governor should deliver a dynamic pressure of 20 mbar 8in w g at the appliance equivalent to a pressure of about 19 19 5 mbar at the gas valve on natural gas or 37 0 mbar 14 8in w g at the appliance for propane 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 complete installation including the gas meter must be tested for soundness and purged Refer to BS 6891 Total length of gas supply pipe Pipe size metres Omm 3 6 9 12 Gas Propane Discharge 15 2 zi 15 Rate 8 0 5 2 42 3 6 22 15 9 8 8 8 5 7 2 28 m hr Natural Gas 8 7 5 8 4 6 22 18 0 12 0 9 4 28
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9. 355mm If the air and flue duct assembly is to be fitted from inside the room then the ducts must be adjusted to length assembled and inserted through the wall at this stage before fitting the flue turret to the appliance Refer to Section 11 3 following for the assembly of the air and flue ducts Remove the fan See Section 14 3 e 11 3 AIR AND FLUE DUCT PREPARATION AND ASSEMBLY Check the contents of the standard flue kit against the packing list Similarly check the extension kits if applicable Remove all the packing from the flue and terminal assembly The standard flue kit accommodates a flue assembly up to 350mm long measured from the appliance casing to the outer wall face See dimension L Figs 13 and 14 When dimension L is greater than 350mm extension flue assemblies will be required It will not be necessary to cut either the ducts attached to the turret or the terminal unless L 350 to 450mm f Fig 13 Rear flue 40mm _ External Z wall face a Rear face of appliance and face of mounting wall 2 12 Measure and cut the extension ducts to length ensuring that the cuts are square and free from burrs Always check the dimensions before cutting the ducts All extension duct dimensions refer to the straight lengths The socketed ends must not be removed or included in any measurement f Fig 14 Side flue Make good
10. CENTRAL HEATING Fue J 22 16 Pressure Relief Valve See Fig 35 Drain the central heating circuit as described in Section 15 3 a Hinge down the facia assembly as described in Section 14 3 c Remove the Bottom panel as described in Section 14 3 d Undo the discharge pipe connection and remove the valve retaining clip Remove the valve taking care not to distort the pipework Fit the replacement valve in reverse order Reconnect the discharge pipe Open the valves and fill and re pressurise the system as described in Section 12 2 17 Water Flow Switch See Fig 36 Check that the electricity supply to the appliance is turned off Drain the domestic hot water circuit as described in Section 15 3 b Remove the two upper screws and hinge down the facia panel as described in Section 14 3 c Undo the two union nuts securing the T piece and remove the housing from the pipework Disconnect the electrical connection Fit the replacement water flow switch in the reverse order ensuring new fibre washers are fitted to the new switch body E rig 36 Water Flow Switch Side View Flow Restrictor Water Flow Switch T Piece M 18 Domestic Hot Water Flow Restrictor See Fig 36 Remove the water flow switch as described in Section 15 4 17 Undo the two union nuts securing the T piece and remove the housing from the pipework The plastic flow restrictor is located within the T pi
11. Fig 30 Close the pressure relief valve when the flow has stopped Some water will remain in the expansion vessel pump and Gas to Water heat exchangers and extra care must be taken when removing these components b Domestic Hot Water Circuit Turn off the mains cold supply valve at the appliance and open the lowest hot water tap A quantity of water will remain in the Gas to Water heat exchanger extra care must be taken when removing this component 15 4 COMPONENT REPLACEMENT 1 Automatic Air Vent See Figs 30 and 32 Remove the inner casing cover as described in Section 14 3 b Drain the central heating circuit as described in Section 15 3 a Unscrew air vent from the heat exchanger Fit the replacement assembly ensuring thread sealant is applied and the dust cap is removed Open the valves and fill and re pressurise the system as described in Section 12 2 Fig 32 Combustion chamber Heat exchanger Overheat Thermostat vama Hot water heat exchanger connections j Cut outs in combustion chamber sides 2 Air Pressure Switch See Fig 34 Check that the electricity supply to the appliance is turned off Remove the cabinet front panel as described in Section 14 3 a and lower the facia Section 14 3 c Carefully pull off the sensing tubes and the electrical connections from the switch Remember to note their positions Unscrew the two screws behind the Air Pressure Switch a
12. 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 eive the total length i e Bend 0 5 metres Tee 0 5 metres 90 Bend 0 3 metres 2 7 PACKING The appliance and flue components are packaged separately 2 8 GENERAL INSTALLATION The appliance is for connection to a sealed system only The specified ventilation openings made into a wall or compartment door must not be obstructed If the appliance is to be fitted into a compartment then the compartment must conform to the requirements of BS 6798 1987 Section 7 Do not place anything on top of the appliance The clearances specified for servicing must be maintained 2 9 FLUE The appliance has a multi directional fanned flue system The standard telescopic flue assembly length is from 127mm to 350mm Extension flue lengths available are from 350mm to 2500mm An optional vertical flue kit to provide for flue lengths up to 3000mm including vertical flue terminal A terminal guard Type K2 GC 393 553 is available from Tower Flue Components Vale Rise Tonbridge TN9 1TB Do not allow 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 10 CONTROLS The electronic control system and gas valve modulate the heat input in response to the domestic hot water temperature and central heating sett
13. PRIMARY WATER CAPACITY 3 0 litres MAXIMUM COLD SUPPLY PRESSURE 10 Bar 150 psi MINIMUM COLD SUPPLY PRESSURE working for max hot water flow 0 9 bar MINIMUM COLD SUPPLY PRESSURE working to operate appliance 0 1 bar MAXIMUM CENTRAL HEATING FLOW TEMPERATURE Nominally 82 C 180 F OUTPUT TO DOMESTIC HOT WATER Modulating 7 5 to 23 4 kW OUTPUT TO CENTRAL HEATING Modulating 7 5 to 23 4 kw MAXIMUM DOMESTIC HOT WATER FLOW RATE from the appliance Nominally 8 0 15 litres min OF 30 C SPECIFIC RATE EQUIVALENT DOMESTIC HOT WATER FLOW RATE TO GIVE A TEMP RISE Nominally 11 2 litres min 4 4 Siting The Appliance 4 1 The appliance may be installed in any room although particular attention is drawn to the requirements of the current IEE Wiring Regulations BS 7671 and in Scotland the electrical 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 containing 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 The following clearanc
14. 11 The pump is set at maximum and must not be adjusted 7 12 Connections in the system must sustain a pressure of up to 3 bar 7 13 Radiator valves must conform to BS 2767 10 7 14 Other valves used should conform to the requirements of BS 1010 7 15 The appliance is fitted with a fixed internal by pass But it is advisable to keeps one radiator permanently open 8 Open Vent System The appliance is NOT suitable for connection to an open vented system a N Fig 4 Sealed primary water system Automatic air vent ld Expansion Mains cold E vessel water ES i D Radiator Pod seel d Fa valve i Hot water Lockshield d out valve ZEE Heating Y X X X British Standard ii Heating stop valve flow Fixed spindle type gt NOTE drain cock should installed at Water main gt the lowest point of the heating circuit and beneath the appliance Filling Loop Detail UN Heating Return Non return Non return Valve Valve Hose union Stop cock Test cock Temporary Hose J 9 Hot Water Supply 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 ar
15. cupboard or compartments with less clearance than those above minimum clearances given in Section 4 Siting The Appliance then permanent vents for cooling are required 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 4 The minimum free areas required are given below POSITION OF AIR FROM AIR DIRECT AIR VENTS THE ROOM FROM OUTSIDE HIGH LEVEL 270cm 135cm LOW LEVEL 270cm 135cm 6 5 Refer to BS 6798 and BS 5440 2 for additional information Fig 3 Siting of the flue terminal ro OA S 4e g abo sm N g E WY Ms ES S a EN re Fh fis 24 TERMINAL POSITION A directly below an openable window or From a terminal facing a terminal 1200mm 47in other opening e g air brick 300mm 12in From an opening in a car port e g door Below gutters soil pipes or drain pipes 75mm 3in window into dwelling 1200mm 47in Below eaves 25mm 1in Vertically from a terminal on the same Below balconies or car port roof 25mm 1in wall 150mm 6in From vertical drain pipes and soil pipes 25mm 1in Horizontally from a terminal on the same From internal or external corners 25mm 1in wall 300mm 12in Above ground roof or balcony level 300mm 12in M From door window or air vent achieve From a surface facing a terminal 600mm 24in where possi
16. installed in a room or inter nal space below ground level 1 Ensure the gas service cock is turned OFF and the elec trical supply is isolated 2 Refer to section 14 3 Dismantle the Appliance to remove the boiler front panel and inner casing Follow the dismantling instructions to remove the burner 3 Remove the injector and replace with the injector from the kit 4 Remove the nut end cap and bracket from the end of the burner 4 1 For conversion to Natural gas remove the internal gauze 4 2 For conversion to LPG fit the gauze into the burner body Parts List 5 Refit the end cap ensuring the bracket is in the correct orientation 6 Refit the burner to the appliance and re assemble the inner casing 7 Follow the dismantling instructions to remove the gas valve and refit the new valve See Installation Instructions Section 15 4 11 Replacement of Parts Component Replacement Gas Valve 8 Turn on the gas and electricity supplies and following the commissioning procedure confirm gas soundness and correct boiler operation 9 Set the gas pressure to the required rate for the new gas type as specified on the data plate When this is done refit the cap to the adjuster and seal its retaining screw with paint or nail varnish 10 Turn off the boiler and when cool peel off the arrow from the data plate and re stick it against the gas type for which the appliance is now converted 11 Replace the boiler front panel The co
17. the wall align the flue turret with the socket on the appliance push the turret down to fully engage it and clamp in place with the turret clamping ring See Fig 18 Make good the internal and external brickwork or rendering Refit the fan and replace the inner casing cover Fig 17 Extensions Turret assembly Appliance casing Rear flue L 181mm gt Side flue L 184mm I Extensions of equal length Shorten first extension fitted to the turret assembly L 450mm 2500mm 11 5 INTERNAL FITTING 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 11 4 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 19 Slide the flue centering ring onto the air duct and tighten the screw See Fig 20 Fix the ducts and terminal assembly to the flue turret as described in Section 11 4 preceding f Fig 19 Terminal assembly for internal fitting of the flue Rubber sealing gasket Flue terminal Clamping ring m i Apply the plastic tape provided to the last section of flue where it will be sealed to the external brickwork Push the assembly through the wall so that the gasket flange is against the
18. 7 VERTICAL ADAPTER Measure and fit the flue as in Section 11 6 Flue bends except the first section length is measured from the case top and the ducts are cut to X 168mm The minimum length for X is 190mm See Fig 22 N f Fig 22 Vertical adaptor with horizontal flue 5 Vertical flue adaptor required for upwards section 2 41 Appliance TOTAL STRAIGHT FLUE LENGTH X V 4ZorX Z 2500mm with one bend 1750mm with two bends 1000mm with three bends P 11 8 FINAL INSTALLATION Check that all the water and gas connections have been tightened If a facia mounted programmer is to be fitted follow instructions with the programmer Remove the facia bottom panel as described in Section 14 3 c Connect the mains electrical supply to the appliance at terminal X1 See Fig 23 Connect any room and or frost thermostats The electrical leads must pass through the appropriate space in the control panel and be fixed with the cable clamps provided Refit the facia panel Test the gas supply pipework up to the appliance for soundness as indicated in BS 6891 Refer to Section 12 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 eas supply the electrical supply and the water connections are all turned off If the premises are to be left unoccupied during frosty conditions then dra
19. 8 A facia mounted mechanical programmer is available as an optional extra Instructions are supplied with the programmer kits 10 9 A time switch or programmer can be fitted externally to the appliance 10 10 The boiler provides automatic frost protection the use of a frost thermostat is not recommended However if an external frost thermostat is considered necessary then it must be used in conjunction with a programmer Important To provide external frost protection the appliance must have the Central Heating Temperature Control Knob set to supply heating the appliance may then be left with the central heating turned off on the programmer Connection must be made at X2 terminals RI and CL For advice on external frost thermostats contact Worcester Heat Systems Technical Helpline 10 11 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 N Fig 7 Mains electricity connections x2 Strain relief clamp M Programmer and room thermostat strain relief clamps D Green yellow UN F
20. AANIORCESTER Bosch Group 24i RSF WALL MOUNTED COMBINATION BOILER FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS 4 2 RA v woncEsTER GC NUMBERS N G 4731137 L P G 47 311 38 Benchmark Worcester Bosch supports the Benchmark code of practice BOILER OUTPUT To Domestic Hot Water Modulated Control Minimum 7 5 kW 25 600 Btu h Maximum 23 4 kW 80 000 Btu h To Central Heating Modulated Control Auto Range Rated Minimum 7 5 kW 25 600 Btu h Maximum 23 4 kW 80 000 Btu h THESE INSTRUCTIONS APPLY IN THE UK ONLY THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER This appliance must be installed by a competent person in accordance with the Gas Safety Installation and Use Regulations 1994 1 Installation Requirements Page 2 2 General Information oos cea seem Page 2 B Data Tables 22 32 Page 4 4 Siting the Appliance Page 5 B Siting the FUG sto eater se Page 6 6 Alt SUDply DOE Reis Page 6 7 Sealed System s sees Page 7 8 Open Vent ec dis e eC pg ere Page 7 9 Hot Water SUPPLY sce nc rh teer phe Page 8 Q0 xElectricali 2224 dedi rer oe REP Page 9 11 Installing the App
21. E01 893 Gas Valve LPG SIT 8 716 142 430 0 E01 596 Air Pressure Switch Huba 605 99484 8716 142 4140 5 375 697 Spark Electrode Assembly Buccleuch 8 716 142 100 0 E01 612 Flame Sensor Buccleuch 87161203450 E01 930 Flame Sensor Harness 8716 120 126 0 7 E01 598 Ignition Harness Buccleuch 8716 120 2360 8 E01 599 Gas to Water Heat Exchanger Giannonni 8 716 142 905 0 9 01 600 Insulation Pack WHS 7716192216 0 10 E01 601 Auto Air Vent Intermes 8 716 140 504 0 11 299 506 Pressure Gauge Cewal 8 716 142 300 0 12 375 699 Pressure Relief Valve Caleffi 3141 3bar 8 716 142 404 0 oa oa oa oa _ E 13 E01 602 Pump with Harness Grundfos 15 60 special 8 716 143 107 0 14 E01 603 Expansion Vessel 8Ltr 389mm Dia Winkelman Panhof 8716 142 5020 15 E01 604 PCB Boiler Control Pactrol 8 716 146 300 0 16 E04 582 Temperature Thermistors Elmwood 8 716 142 384 0 E01 900 CH Thermistor Clip 8 716 148 313 0 299 495 DHW Thermistor Clip 8 716 148 303 0 18 E01 605 DHW Flow Regulator 8716141 0520 19 324 822 Gauze Filter WHS 8 716 148 401 0 20 299 363 Flow Sensor WHS 8716 141 0000 21 01 606 Fan Assembly SIFAN 8 716 120 993 0 22 01 607 Safety Temperature Limiter Ranco LM7 8716 142 307 0 23 E01 886 Flow Switch Assembly SIKA 87161209710 24 299 357 Fuse Pack WHS 7716192 206 0 25 E01 610 Gas
22. FOR EXTENDED PERIODS f Fig 5 230V room thermostat connections 99090999 7 x2 Removelink 9 T E E 2 0 f Fig 6 230V programmer connections N 988886 od V 7 Remove link Switched live Neutral Motor 10 Electrical 10 1 MAINS SUPPLY 230 V 50 Hz 180 watts External Fuse 3A Internal Fuses 2AT HRC F1 and 1 AF F2 10 2 It must be possible to completely isolate the appliance 10 3 The following connection alternatives must be used A 3 amp fused three pin plug and unswitched shuttered socket outlet both complying with the requirements of BS 1363 or 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 75mm 24 x 0 20mm to BS 6500 Table 16 The mains cable must be connected into the terminal X1 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 undo the three bottom screws and remove the facia access cover See Fig 7 10 6 The wiring between the appliance and the electrical supply shall comply with current IEE Wiring Regulations and any local regulations which apply 10 7 If a room thermostat and or external programmer is to be fitted refer to Figs 5 and 6 The devices must be suitable for use with mains voltage 10
23. NG VALVES Hot and cold taps and mixing valves used in the system must be suitable for operating at mains pressure Thermostatically controlled 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 requirements With all mains fed systems the flow of water from the individual taps will vary with the number of outlets operated simultaneously 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 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 unobstructed and the correct size 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 extinguish The fan and pump may continue to run for a short period to dissipate the residual heat from the appliance Central Heating
24. With a demand for heating the burner will light at its minimum setting and gradually increase to give a controlled temperature rise When the required heating temperature is achieved 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 7 5 kW If the system no longer requires even the minimum output to maintain the desired room temperature the burner will extinguish The fan and pump may continue to run to dissipate the residual heat from the appliance The appliance will remain off for a fixed period before re lighting to automatically meet the system requirements Domestic Hot Water and Central Heating The appliance will supply heat to the central heating system as required A demand 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 mode of operation The fan may continue to run to dissipate the residual heat from the appliance as necessary 2 15 DOMESTIC SUPPLY Devices capable of preventing the flow of expansion water must not be fitted unless separate arrangements have been made The data plate is fixed to the inner casing cover 3 Data Tables
25. ature 9 12 The head of a loose head shower must not fall closer than 25mm 1in above the top edge of the bath to prevent its immersion in bath water Alternatively the shower must be fitted 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 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 9 14 LIME SCALE In temporary hard water areas more than 350mg litre or 200ppm calcium bicarbonate it is recommended that a proprietary scale reducer is fitted in the mains cold water connection to the appliance Consult the local water company for additional advice 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 by reference to the local Water Company 9 15 NOTE HOT WATER ONLY If required the appliance may be used for Hot Water only before the Central Heating is connected A 22mm copper by pass pipe at least 4 meters long must be connected between the Central Heating Flow and Return but it is advisable to connect a small radiator instead IT IS NOT RECOMMENDED TO USE THE BOILER IN THIS CONDITION
26. ble 150mm 6in 7 Sealed System See Figs 4 7 1 The system must comply with the requirements of BS 6798 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 discharge 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 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 up to 100 litres can be accommodated For system capacities greater than this an extra expansion vessel must be fitted Refer to BS 7074 Pt 1 for more information The charge pressure can be increased but with a consequent decrease in system volume 7 7 The filling point must be at low level See Fig 4 7 8 Water loss must be replaced See Fig 4 The connection should be made in the central heating return as close to the appliance as possible 7 9 Repeated venting loses water from the system It is essential that this water is replaced and the system pressure maintained 7 10 Connections to the mains water supply must not be made without the authority of the local Water Company 7
27. bly Flue Gas Test Point Flue hood Fan assembly fixing screws 4 Overheat thermostat Combustion chamber cover fixing clips 2 Burner fixing screws 2 Note 1 bar is equivalent to 10 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 system pressure If the pressure indicated on the pressure gauge is greater than 2 6 bar when operating at the maximum central heating temperature an extra expansion vessel must be fitted to the system as close as possible to the appliance central heating return connection The appliance as dispatched can accommodate a system volume of about 100 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 integral vessel If the expansion vessel fails then the specified replacement must be fitted m 26 Pressure relief valve Pressure relief valve Turn knob anti clockwise to test AU 7 e NS 0 SS DOMESTIC OUTLET CENTRAL HEATING DISCHARGE Fue wy 12 3 PROGRAMMER Any programmer fitted on the appliance sho
28. chamber front See Fig 30 g Flue Hood Assembly Remove the fan assembly Remove the combustion chamber front Lift and slide the flue hood assembly from the appliance See Fig 30 When refitting the hood ensure that the rear return edge passes under the lip at the rear of the combustion chamber h Bumer Assembly Remove the combustion chamber front Pull off the two spark electrode leads and disconnect the flame sense lead Undo the burner fixing screws Lift up and remove the burner assembly from the appliance See Fig 31 B f Fig 31 Burner and electrode assembly 2 P Spark electrode 14 4 SERVICE OF COMPONENTS Clean the Fan Any dust or fluff should be removed with a soft brush or by blowing Take care not to distort the pressure sensing device Clean the Main Burner Brush the blade tops and mixing tube with a soft brush and check that all the flame ports are clear Remove any blockages with a non metallic brush Inspect the injector and clean with a soft brush Replace the injector if it appears damaged Do not use a wire brush or anything likely to cause damage Replace the spark and sense electrodes if they appear damaged Clean the Gas to Water Heat Exchanger Clean the heat exchanger using a soft brush Remove the deposits from the bottom of the combustion chamber Do not distort any of the blades Combustion Chamber Insulation Examine and replace any pads that are damaged Remo
29. ct 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 13 Instructions to the User and set the controls to the users requirements If the appliance is to be left inoperative check that the Central Heating Temperature Control 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 If the premises are to be left unoccupied during frosty conditions then drain the appliance and system For short inoperative periods leave the appliance under the control of the built in frost thermostat or the remote frost thermostat if fitted or leave operating continuously with the room thermostat set at 6 C 13 Instructions To The User 13 1 Tell the user how to operate the appliance and hand over the Users Instructions leaflet 13 2 Tell the user what to do if the heating system is not to be used in frosty weather 13 3 Tell the user the sealed system set pressure 13 4 Tell the user of the importance of regular servicing Worcester Heat Systems Ltd offer a comprehensive maintenance contract 13 5 Set the system controls to the user s requirements 13 6 If an external programmer has been fitted
30. do the M4 extended nut and remove the spark electrode assembly from the burner Fit the replacement electrode in the reverse order checking that the spark gap is 3 5 to 4 5mm Fig 31a Spark electrode assembly 3 5 4 5mm 10 Flame Sensor See Fig 31 Remove the burner as described in sections 14 3 h and 15 4 8 Undo the M3 screw and remove the sense electrode from the burner Fit the replacement electrode in the reverse order checking that the sense gap is 5 to mm 11 Gas Valve See Figs 33 and 34 Check that the electricity and gas supplies to the appliance are turned off Hinge down the control box assembly in the servicing position as described in Section 14 3 d Whilst supporting the valve unscrew the plug retaining screw and carefully pull off the electrical solenoid plug connection and the two modureg leads Undo the 8 manifold screws and remove the gas valve See Fig 34 Fit the replacement gas valve in the reverse order ensuring the O rings are correctly fitted Turn on the gas supply and check for soundness To set the burner pressure See Fig 33 The minimum and maximum burner pressures must be set after a new gas control has been fitted The maximum burner pressure must be set first as any adjustment of the maximum pressure influences the minimum pressure setting Start the appliance in the domestic hot water mode as described in section 12 4
31. ece on the water flow switch Fit the replacement flow restrictor and reassemble in the reverse order ensuring the fibre washers are in place 19 Pressure Gauge Check that the electricity supply to the appliance is turned off Drain the central heating circuit as described in Section 15 3 a Remove the two upper screws and hinge down the facia panel as described in Section 14 3 c Prize back the retaining clips securing the gauge to the facia panel remove wire clip and unplug the gauge from the pump inlet pipe Fit the replacement gauge in the reverse order ensuring the O ring is in place Open the valves and fill and re pressurise the system as described in Section 12 2 20 Control Board Check that the electricity supply to the appliance is turned off Undo the 3 screws and remove the facia bottom panel Remove the two upper screws and hinge down the facia assembly Carefully pull off all the connectors Disconnect the mains supply lead at terminal X1 and the earth connection at the back Remove the four corner screws on the back of the facia and separate the metal back panel from the plastic facia Remove and retain the brass nut and washer Release the six pillars on the control board and pull the control board forward off the back panel Fit the replacement board in the reverse order ensuring it is pushed firmly onto the six pillars and clicks into place Special care should be taken with the brass post and nut to
32. ections fitted to the elbow must have unswaged ends The length of the air ducts should be Z 196mm The inner flue duct must be 30mm longer than the air duct If Z 196mm is less than 160mm then the terminal section will need to be shortened to the same length as the extension flue section fitted to the elbow length Z 100 If flue extensions are needed to attain the required length care must be taken to ensure that the last section of flue is longer than 260mm Each extension must be connected to the previous section of flue or bend by firstly fitting the inner flue ducts together and pilot drilling and fixing as above See Fig 21 Then the outer air ducts can be similarly fixed using the pair of screws provided The flue terminal section can then be telescopically adjusted and fixed as before See Fig 21 ensuring the correct length of Z 41 The silicon sealant supplied should be applied to the flue ducts which engage into elbows See Fig 21 From inside push the assembly through the wall Alien the flue turret with the socket on the appliance push the turret down to fully engage it and clamp in place with the turret clamping ring See Fig 18 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 f Fig 21 Flue bends 56mm Side flue X 63mm Rear flue X 60mm 14 11
33. ensure a good earth contact Check earth continuity between the incoming earth and the appliance chassis Refit the facia panel and hinge the control box assembly in the servicing position as described in Section 14 3 c 21 Gauze filter See Fig 37 Remove the water flow switch as described in section 15 4 17 Undo the lower union nut on flow switch housing Undo the nut on the isolating valve and remove the mains water inlet pipe Carefully extract the filter from the valve end of the pipe Replace the filter and refit the pipe in reverse order 22 Flue flow sensor See Fig 38 Check that the electricity supply to the appliance is turned off Remove the fan assembly as described in Section 14 3 e Unscrew the single central retaining screw and withdraw the sensor from the fan Fit the new sensor ensuring the correct orientation and carefully tighten the retaining screw Refit the fan assembly in reverse order rig 37 Gauze Filter R Isolating Valve Ke Gauze Filter f Fig 38 Flue flow sensor xe Positive a 16 Conversion Instructions These instructions should be used when converting appli ances from natural gas to LPG and vice versa Only components supplied by Worcester Heat Systems should be used Only competent persons should attempt the conversion Conversion from Natural Gas to LPG should not be carried out on appliances
34. ents it is necessary to have a constant output and for the appliance to be at equilibrium Turn on a tap to create a hot water demand Wait until the appliance reaches thermal equilibrium approx 10 minutes Remove the test point sealing screw on the appliance top panel See Fig 30 Connect to the test point with a piece of tubing Expected measurements should be between For Natural Gas Equivalent flue Carbon Carbon length metres Dioxide Monoxide 0 5 6 9 0 0008 1 0 7 0 0 0009 1 5 0 0010 2 0 7 3 0 0012 2 5 7 4 0 0013 For Propane Equivalent flue Carbon Carbon length metres Dioxide Monoxide 0 5 7 9 0 0017 1 0 8 0 0 0020 1 5 8 2 0 0024 2 0 8 5 0 0030 2 5 8 8 0 0035 When calculating the equivalent flue length flue bend is equivalent to 750mm of straight flue After taking the measurement replace and tighten the sealing screw IMPORTANT Disconnect the electrical supply at the mains and turn off the gas supply at the gas service cock on the appliance before servicing After completing the service always test for gas soundness as indicated in BS 6891 14 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 f Fig 29 Appliance casing and control equipment fixings
35. eplace Is gas pressure present at input to burner Faulty gas valve Replace Gas valve OK 32 N Modulating Valve Check Remove X6 measure resistance between pins 15 amp 16 Is resistance nominally 1250hms YES Is minimum pressure observed at burner at all times Is pressure at burner With pressure above Faulty modulating valve Reconnect X6 and measure always the same minimum remove Modureg Replace gas valve voltage across modulating Lead Does pressure drop to valve during operation minimum Gas valve OK Does voltage go above 6 25V NO Faulty PCB Replace Flow Switch Check Remove X6 Close all taps to set no domestic flow Is open circuit observed NO Faulty flow switch at X6 pins 1 amp 2 Replace Open a tap fully to set domestic flow HARNESS OK Is short circuit observed NO at X6 pins 182 Faulty flow switch Replace Flow Switch OK 33 19 Component Parts List Key G C No Part Manufacturer s Reference Qty WHS No Part No 1 E01 579 Burner Assembly Natural Gas Aeromatic 23 053586 8 716 142 6040 E01 580 Burner Assembly LPG Aeromatic 23 053587 8716 142611 0 2 E01 591 Injector Natural Gas Stereomatic 4 3mm 8716 140 224 0 E00 741 Injector LPG Stereomatic 2 78mm 8 716 140 209 0 3 E01 892 Gas Valve Natural Gas SIT 8716142413 0
36. es must be available for installation and for servicing See Fig 2 note the clearances at the front are for a removable panel e g door 4 6 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 Above 180mm In front 0 In front to a fixed surface 600mm Below 200mm Right hand side 10mm Left hand side 10mm Notwithstanding the instructions given in BS 5440 2 this appliance may be fitted in a compartment with no vents as long as the minimum clearances stated in Section 6 Air Supply are maintained 4 7 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 13mm See BS 6798 1987 4 8 No combustible surface must be within 75mm of the casing See BS476 4 4 9 Always consider the possible need to disconnect the pipes from the appliance after installation 4 10 LPG Installation The appliance shall not be installed in a room or internal space below ground level when it is intended for use with LPG This does not preclude the installation into rooms which are basements with respect to one side of the building but open to ground level on the opposite side Fig 2 Appliance casing dimensions and required clearances 225mm Front view Side view 800mm
37. g that all the fibre washers are correctly fitted and a layer of heat sink compound is on the thermostat Open the valves and fill and re pressurise the system as described in Section 12 2 Auto air vent Central heating heat exchanger connections Pump bulk head connector 6 Combustion Chamber Insulation Check that the electricity supply to the appliance is turned off Drain the central heating circuit as described in Section 15 3 a Remove the inner casing cover fan flue hood assembly burner and Gas to Water heat exchanger as described in Sections 14 3 b e and f and 15 4 5 Remove the fibre insulation pads from the combustion chamber side rear and front sections Fit the replacement pads in the reverse order taking care not to damage them Open the valves and fill and re pressurise the system as described in Section 12 2 7 Burner See Fig 31 Check that the electricity and gas supplies to the appliance are turned off Remove the burner assembly as described in Section 14 3 h Fit the replacement burner in the reverse order taking care not to damage the electrode leads 8 Burner Injector See Fig 31 Remove the burner as described in Section 14 3 h Unscrew the brass injector from the manifold Fit the replacement injector in the reverse order 9 Spark Electrode Assembly See Fig 31a Remove the combustion chamber front as described in 14 3 g Carefully pull off the two electrode leads Un
38. ich may arise Contact Worcester Heat Systems Technical Helpline for advice on specific installations 2 General Information 2 1 This appliance is not suitable for external installation 2 2 The appliance controls are set to provide a maximum output of 23 4 kW for the domestic hot water and central heating load 2 3 The control circuit provides direct burner ignition A pilot is not used 2 4 PRINCIPAL APPLIANCE COMPONENTS See Fig 1 A low thermal capacity Gas to Water heat exchanger incorporating an integral Hot 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 A fixed by pass for the central heating system A Temperature safety cut out control A water flow regulator A standard telescopic horizontal flue assembly giving flue lengths from 127mm to 350mm Optional extra extension flue kits to provide for flue lengths up to 2500mm An optional vertical flue kit to provide for flue lengths up to 3000mm including vertical flue terminal Optional facia mounted mechanical programmer g UN Fig 1 Water flow diagram pou Bi thermal gt sf gasto water INNAM 0 i eal heat exchanger z Sealed j 1 system a N expansion vessel E pump Domestic
39. ig 8 Wiring diagram Flame sense electrode Spark electrode S Spark transformer Flow switch X5 X xi x2 E X6 E 000009 een T TU U UL s Link Link 45 of 8 5 25 as as 2 pink l 3 s 85 Mains in E 512 DHW sensor Air pressure switch Fan 2 2 5 ss 22 5 valve Main sco 1 Reg 2 NO CH Safety sensor limit stat NO Fig 9 Functional flow diagram Overheat stat Air pressure switch Flow signal CH temp sensor DHW temp sensor CH control POT Modulating valve X6 Pins 15 amp 16 X6 Pins8 amp 9 X6 Pins 5 6 amp 7 X6 Pins 19 amp 20 X6 Pins1 amp 2 X6 Pins3 amp 4 X4 Pin 1 LOW VOLTAGE ELECTRONICS Microcontroller X3 Pin 1 AA GAS VALVE F2 1 25AT X5 Pin 1 ROOM STAT FULL SEQUENCE CONTROLLER MAINS PROGRAMMER CLOCK 10 11 Installing The Appliance The appliance is only suitable for fitting to a sealed system 11 1 FLUE OPTIONS The standard flue length is from 127mm to 350mm measured from the appliance casing to the outer wall Extension flue kits a vertical take off adapter 45 and 90 flue bends are available to increase the length and redirect the flue as follows Horizontal balanced flue a From 127mm to 2500mm straight flue b From 127mm to 1750mm when 90 flue bend is required c From 127mm to 1000mm when two 90 flue bends a
40. in the appliance and system For short inoperative periods leave the appliance under the control of the built in frost thermostat or the remote frost thermostat if fitted or leave operating continuously with the room thermostat set at 6 C f Fig 23 Mains electricity connections x2 Strain relief clamp i Programmer and room thermostat strain relief clamps M Green yellow 15 12 Commissioning The Appliance 12 1 SUMMARY The appliance is dispatched with the controls set to provide a maximum output for domestic hot water and central heating of 23 4 kW 80 000 Btu h The appliance automatically modulates to satisfy lower heat loads Domestic Hot Water and Central Heating Systems Check that both the mains water supply and central heating systems have 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 12 2 APPLIANCE AND CENTRAL HEATING SYSTEM PREPARATION Remove the cabinet front panel Check that the electrical supply and the gas service to the appliance are off Check that all the water connections throughout the system are tight Open the system valves at the appliance Open all the radiator valves fill the system and vent each radiator in turn Remove the inner casing cover as described in section 14 3 b See Fig 24 N f Fig 24 Appliance casing and cont
41. ine onto the wall See Fig 10 Rear flue hole 110mm dia 150mm dia for internal fixing Side flue position Fig 11 Marking out the side flue position Side flue hole 110mm dia 150mm dia for internal fixing 1 S e E 11 Side Flue Extend the flue hole centre line from Fig 11 along the appropriate wall Check that it remains horizontal and mark a horizontal line Measure 222mm from the junction of the walls and mark a vertical line which will then give the position of the flue hole Drill the two fixing holes 60mm deep for No 12 size plugs Cut the flue duct hole at 110mm diameter 150mm dia for internal fitting Ensure that the hole is horizontal through the wall Fit the wall mounting bracket Drill the two fixing holes 60mm deep for No 12 size plugs For the boiler retaining screws Fix the wall plate and check that it is horizontal before tightening the 2 screws Hang the appliance on the wall plate and screw the appliance to the wall using the screws provided Connect the gas water and pressure relief valve connections to the appliance The primary system should be flushed and treated in accordance with the recommendations of BS7593 1992 f Fig 12 Appliance pipework connections N A Safety Relief 50mm B CH Flow 95mm C DHW Out 160mm D Gas Inlet 225mm E Mains Cold Water In 290mm F CH Return
42. ing between minimum and maximum The Central Heating Temperature control knob provides for the selection of domestic hot water only Turned fully anti clockwise or central heating and domestic hot water Turned clockwise A facia mounted programmer is available as an optional extra A remote mounted programmer may be connected to the appliance There is provision for the connection of a mains voltage room thermostat and or a frost thermostat The electronic controls prevent rapid cycling of the appliance in the central heating mode 2 11 SYSTEM NOTES IMPORTANT Check that no dirt is left in either the gas or water pipework as this could cause damage to the appliance The heating system should be flushed and treated in accordance with the recommendations of BS 7593 1992 Thoroughly flush cold water mains supply and 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 up to 3 bar Radiator valves must conform to the requirements of BS 2767 1991 The relief valve discharge must be directed away from any electrical components or where it would cause a hazard to the user A drain 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 section 3 relating to the available pump head 2 12 SHOWERS BIDETS TAPS AND MIXI
43. ir positions Fit the replacement pump in the reverse order using new sealing washers Alternatively replace the pump head only by removing the four Allen screws on the pump remove the head and support whilst removing the electrical connections Refit the new head Open the valves and fill and re pressurise the system as described in Section 12 2 Note The direction of flow should be upwards The speed should always be set to maximum 15 Expansion Vessel Drain the central heating circuit as described in Section 15 3 a Isolate the gas supply at the mains Then either fit a separate expansion vessel on the central heating return to the appliance or replace the existing vessel as described below Drain the domestic circuit as described in Section 15 3 b Disconnect the flue system at the boiler Disconnect the appliance pipework at the appliance entry points ensuring precautions are taken to cope with any water remaining in the appliance Remove the appliance from the wall Disconnect the expansion vessel from the appliance by undoing the fitting nut at it s base Fit the replacement vessel in the reverse order Open the valves and fill and re pressurise the system as described in Section 12 2 f ig 35 Pressure relief valve N Pressure relief valve Turn knob anti clockwise to test 25 E SUE E g S Kms KS DOMESTIC OUTLET SAFETY DISCHARGE
44. k 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 burner will go out but sparking from the electrode will continue for 10 seconds when the appliance will enter a lockout state Carefully open the gas service cock interrupt the mains power supply to the appliance for a few seconds to reset the controls and observe the burner re light and follow the normal sequence of operation 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 re pressurise as described in Section 12 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 Central Heating temperature control knob to demand and any programmer to HEATING amp WATER If a programmer is fitted set the domestic hot water to Continuous or 24 Hrs 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 after a short delay fully heated hot water is discharged from the tap Close the tap and the burner will go off After a short time the appliance will then return to the central heating mode and automatically balance with the system requirements Set the Central Heating Temperature Control Knob to OFF and the burner will go out 12 5 COMPLETION OF COMMISSIONING Disconne
45. ket Pack WHS 77161922180 ACCESSORIES 299 360 Mechanical Programmer Kit Deihl 7 716 192 0020 E01 940 Gas Conversion Kit NG to LPG 7 716 192 1310 E01 941 Gas Conversion Kit LPG to NG 7 716 192 132 0 E05 341 Mini Expansion Vessel Kit Including new pipe and Expansion Vessel 7 716 1921880 FLUE OPTIONS E01 942 Telescopic Horizontal Flue Kit 127 350 mm 7 716 191 005 0 E01 943 Extension Flue Kit 750mm 7 716 191 006 0 E01 944 Vertical Flue Kit 7 716 191 0150 E01 945 Vertical Flue Adaptor 7 716191 0160 E01 946 Internal Fixing Kit Telescopic Flue 7 716191 0190 E01 058 Flue Elbow Kit 90 deg 7 716191 0130 E01 059 Flue Elbow Kit 45 deg 7716191 0140 34 MMO M 1 _________ M ________ MEL 35 AANIORCESTER Bosch Group Worcester Heat Systems Limited Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619 Technical Helpline 0990 266241 This booklet is accurate at the date of printing but will be superseded and should be disregarded if specifications and or appearances are changed in the interests of continued improvement All goods sold are subject to our official Conditions of Sale a copy of which may be obtained on application PUBLICATION 8 716 145 028C 11 98
46. liance Page 11 12 Commissioning the Appliance Page 16 13 Instructions to the Page 18 14 Inspection and Page 18 15 Replacement of Parts Page 20 16 Conversion Instructions ceres rte Page 23 17 Operational How Diagrams Page 24 US FaultFinding rt Eur RRPTPMASUS Page 26 19 Component Parts 51 Page 34 1 Installation Regulations 1 1 Gas Safety Installation and Use Regulations October 1994 all gas appliances must be installed by a competent person in accordance with the above regulations Failure to install appliances 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 confer immunity from legal obligations In particular the installation of this appliance must be in accordance with the relevant requirements of the following Gas Safety Installation and Use Regulations 1994 as amended Current IEE Wiring Regulations BS 7671 Local Building Regulations Building Standards Scotland Consolidation Bylaws of the local Water Company Health and Safety Document No 635 Electricity at Work Regulations The British Gas Material and Installation Specification for central heating and h
47. nd remove the switch from the appliance Fit the replacement switch in the reverse order ensuring that the electrical connections have been made to the correct terminals on the switch Check that the sensing tubes are fitted correctly 3 Fan See Fig 30 Check that the electricity supply to the appliance is turned off Remove the fan assembly as described in Section 14 3 e Fit the replacement fan in the reverse order 4 Overheat Thermostat See Fig 30 and 32 Check that the electricity supply to the appliance is turned off Remove the inner casing cover as described in Section 14 3 b Carefully pull off the two wires from the thermostat head Undo the retaining nut on the top of the appliance and remove the retaining clip from the heat exchanger Carefully withdraw the thermostat from the appliance Fit the replacement thermostat in the reverse order ensuring that some heat sink compound is between the thermostat and the heat exchanger 5 Gas to Water Heat Exchanger See Fig 32 Check that the electricity supply to the appliance is turned off Drain the central heating circuit and domestic circuits as described in Section 15 3 a and b Remove the inner casing cover fan flue hood assembly combustion chamber front overheat thermostat automatic air vent and combustion chamber side insulation as described in Sections 14 3 b e f and 9 15 4 1 and 15 4 4 Fit the replacement heat exchanger in the reverse order ensurin
48. nversion is now complete Item No Description Natural Gas to LPG Kit 7 716 192 131 LPG to Natural Gas Kit 7 716 192 132 1 Burner Injector 8 716 140 209 8 716 140 224 Stereomatic 2 78mm Stereomatic 4 3mm 2 Burner Gauze 8 716 142 601 Remove Gauze Gas Valve 8 716 142 430 8 716 142 413 uo dund pue ugy 10 ugy 310 4201 uonrusi IN3S3ud sajnutu p ue samuru 2 Jaye sjnd duind 5295 9 10 G3IJSIIVS aNvwad ONILVAH IVHLIN3O 440 8A EA sey 340 1eurure1801d 10 yams 340 1ejsouugu 1008 uo pue 10 uej 8 yua ut uo yem 52956 Jaye mo aui UOTUS IN3S8V amssaid asuas suedo 259 U23IMS s azentu Sunp ieds dois 39N3fh 03S dN LYVLS SILVINNOLNV puewap uyeysoyo ny puau 195 uau1 pue asuel 10 Kpeorjeuioqne ainssa1d jeuing Josuas 8 Aq amnqeraduia MO M 3oNanoas 5 JIIVWOInV Spuodes 09 0 amssaid ONILVSH TVHINdO uo wool pue
49. ot water It should be in accordance with the relevant recommendations of the following British Standards BS6798 1987 Specification for installation of gas fired hot water boilers of rated input not exceeding 60 kW BS5449 1990 Central Heating for Domestic Premises BS5546 1990 Installation of gas hot water supplies for domestic purposes BS5440 1 1990 Flues and Ventilation for gas appliances of rated input not exceeding 60 kW Flues BS5440 2 1989 Flues and Ventilation for gas appliances of rated input not exceeding 60kW Air Supply BS6891 1988 Installation of low pressure gas pipework installations up to 28mm R1 BS7593 1993 Central Heating system cleansing and flushing BS5482 PART 1 Domestic Butane and Propane gas burning installations in permanent dwellings 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 1 5 The appliance complies with the Essential Requirements of the Gas Appliance Directive and other Directives currently applicable 1 6 This appliance contains no asbestos products There is no potential hazard due to the appliance being electrically unsafe There are no substances used that are a potential hazard in relation to the COSHH Regulations 1988 1 7 The advice and instructions given in this document covers as far as possible the foreseeable situations wh
50. outside face of the wall See Fig 20 Align the flue turret with the socket on the appliance push the turret down to fully engage it and clamp in place with the turret clamping ring See Fig 18 Refit the fan and replace the inner casing cover Seal the eap around the duct with the flexible seal provided and make good See Fig 20 11 6 FLUE BENDS See Figs 21 and 22 Measure distances X Y and Z as appropriate Side flue duct length X 63mm See Fig 21 Rear flue duct length X 60mm See Fig 21 Cut the flue and air ducts which are to make up the first section X such that both the assemblies are of equal length either X 63mm or X 60mm Extensions will be necessary to allow X to be larger than 250mm Any extension ducts are fixed by drilling a pilot hole through the hole in the duct or elbow and screwing the self tapping screw S Fig 20 Duct and terminal assembly for internal fitting of the flue Flue centring ring Flue terminal NIS A 7 i E E Flue duct Air duct Rubber sealing E provided into the two ducts See Fig 21 The length Y is the distance between bends the ducts must be cut to Y 162mm The swaged ends must be removed from the extension tube and only the air duct needs fixing See Fig 21 Z is the final flue length from the last elbow to the outside face of the external wall The first duct s
51. p 20 between 6900hms amp 33k Replace thermistor OK Faulty Replace 28 Overheat Thermostat Check The overheat thermostat can be reset by pressing the reset button but if it trips immediately or on a regular basis a serious problem has occurred therefore contact your installer Reset thermostat Does button hold in YES Ensure appliance is cool and retest Is capillary broken YES Is capillary firmly ATTACH to heat Replace overheat ATTACH to exchanger exchanger thermostat YES Secure Connector Is mains present at the pump connector X3 pins 1 amp 2 YES Faulty pump Fan Check Is fan connector secure on the PCB X4 YES Is mains present at the fan connector X4 pins 1 amp 2 YES Secure Connector 29 H Thermistor Check Remove connectors from thermistor Is resistance between terminals of thermistor between 690ohms amp 33k Thermistor OK Faulty thermistor Harness Continuity Check Remove appropriate connectors Is continuity observed NO between each end of wire in question Faulty harness or connector Harness OK Harness Short Check Remove appropriate connectors Is short circuit observed between pair of wires in question Faulty harness Harness OK 30 Ignition Check Is fan running YES Doe
52. r and spring retaining clip from the pipe Fit the replacement sensor in reverse order with a layer of heat sink compound between the faces Refit the leads Electrical connections modulator Blue Blue J Modulating solenoid Fig 34 Gas valve pump and air pressure N switch Top gas valve Gas connection 4 bolts valve Air pressure switch connecting tubes Pump Pressure gauge Central Heating Sensor connection Gas valve electrical Lower pump Air pressure connection switch oe J 13 Domestic Hot Water Sensor Check that the electricity supply to the appliance is turned off Hinge the facia assembly in the servicing position as described in Section 14 3 c and d Carefully pull off the two leads from the sensor Undo and remove the clamping screw Pull off the sensor and spring retaining clip from the pipe Fit the replacement sensor in the reverse order ensuring a layer of heat sink compound is between the faces Refit the leads 14 Circulating Pump See Figs 32 and 34 Check that the electricity supply to the appliance is turned off Drain the central heating circuit as described in Section 15 3 a Hinge the facia assembly in the servicing position as described in Section 14 3 c Undo the two union nuts and the pipe to the expansion vessel remove the pump from the pipe work Support the pump and remove the electrical cover Disconnect the electrical wires taking note of the
53. rangements have been made A mini expansion vessel kit is available which contains the necessary parts for fitting an internal expansion vessel to the appliance See Section 19 COMPONENT PARTS LIST A thread sealant compatible with potable water must be used An external expansion vessel may be fitted on the mains cold water connection to the appliance 9 3 The final 600mm 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 Ib im 9 5 The appliance is fitted with a mains supply isolating valve 9 6 The maximum domestic hot water flow rate is 8 0 litres min 15 1 8 gallons min 9 7 In winter when the mains inlet water temperature is lower a reduced flow rate at the taps may be required to achieve the type of hot water delivery temperature available in warmer weather 9 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 9 9 Hot and cold taps and mixing valves used with this appliance must be suitable for operating at mains pressure and temperatures of 65 C 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
54. re required A 90 flue bend is equivalent to 750mm of straight flue A 45 flue bend is equivalent to half a 90 bend Refer to Figs 21 and 22 to determine whether extension kits 90 flue bend 45 flue bend or adapters are required The maximum number of 90 flue bends allowed is two Flue components Turret clamping ring Flue turret assembly Flue terminal assembly Extension air duct Extension flue duct In line 90 flue bend In line 45 flue bend 8 Vertical flue adapter The flue must be installed as specified in BS 5440 Part 1 NOTE READ THIS SECTION FULLY BEFORE COMMENCING INSTALLATION 11 2 GENERAL FITTING Check that the appliance carton contains Appliance Installers Instruction Pack Appliance Wall Plate Users Information Pack Installer Hardware Pack and an appliance template Check that the position chosen for the appliance is in accordance with the instructions given in Sections 4 and 5 Hold the template to the wall Check that the template is horizontal See Fig 10 Mark the position of the fixing holes and the position of the flue Noo pw bs Mounting wall 166mm 60mm e A Fixing holes Mounting alternatives plate Appliance casing 740mm Rear flue position lt _ 400 EN f Fig 10 Appliance mounting plate and flue position Rear flue hole 110mm dia 150mm dia for internal fixing Mounting wall hole centre l
55. rol equipment fixings Pi Side casing Inner casing fixing cover screws 4 screws 4 Facia panel 9 fixing F screws 2 er a o Bottom facia panel fixing screws 3 9 7 The automatic air vent will vent the appliance Check that the air vent cap has been removed See Fig 25 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 26 Lower the control box to gain access Refer to Section 14 3 c 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 17ft The charge pressure must not be less than the static head at the point of connection A Schraider type tyre valve is fitted 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 Ib ins and check for water soundness Release water from the system using the relief valve test knob until the initial System Design Pressure is obtained up to a maximum of 1 5 bar Initial System Design Pressure bar Expansion Vessel Charge Pressure 0 3 bar 16 Fig 25 Appliance components and fixings a upper assem
56. s sparking occur 2 O YES Does ignition occur YES Does burner continue YES Does gas pressure modulate YES Ignition OK NO NO Is sparking present at NO the electrodes YES Is flame sense NO electrode in flame YES Is lead secure NO both ends YES HARNESS OK Faulty PCB Replace Are ignition leads connected both ends securely Are leads breaking down YES Eri Uu Replace leads Ensure flame sense electrode in flame at minimum burner pressure Secure lead NO NO Faulty PCB Replace Connect ignition leads securely Ignition coil faulty replace PCB Air Pressure Switch Check Remove BROWN and WHITE terminals from air pressure switch With no demand is a short circuit observed NO Air pressure switch at exposed APS faulty terminals Is there mains 230V at fan connector X4 pins 1 and 3 Reconnect the WHITE amp BROWN wire and remove the GREEN wire Initiate a demand Does the fan run Fan or fan cable faulty Air pressure switch faulty With fan running disconnect BROWN wire DO NOT touch chassis with it Is a short circuit observed across exposed APS terminals Gas Valve Check Is gas pressure present at input to gas valve Ensure gas supply Is live output present at X5 pins 1 amp 2 relative to neutral at pin 3 Faulty board R
57. sure switch Flow signal CH temp sensor DHW temp sensor CH control POT Modulating Ive 5816 val X6 Pins 1 X6 Pins 8 amp 9 X6 Pins 5 6 amp 7 X6 Pins 1 amp 2 X6 Pins 19 amp 20 X6 Pins 3 amp 4 LOW VOLTAGE ELECTRONICS Microcontroller X3 Pin 1 Mains GAS VALVE X5 Pin 1 ROOM STAT FULL SEQUENCE CONTROLLER MAINS PROGRAMMER CLOCK 26 Fault in Central Heating Is mains LED flashing NO Is mains LED illuminated YES Is control knob set for demand YES Is aroom thermostat fitted YES Is room thermostat calling for heating YES Is programmer fitted YES Is programmer calling for heat YES Is pump running YES Has overheat thermostat tripped NO YES NO NO NO NO NO NO YES Turn control knob fully clockwise Ensure link is fitted at X2 pins 5 amp 6 Set room stat to call for heat Ensure link is fitted at X2 pins 2 amp 3 Set clock to call for heat 27 Fault in Domestic Hot Water YES Is mains LED flashing Is mains LED iluminated YES YES Has overheat thermostat tripped NO No mains LED Is mains present at X1 pins 1 amp 3 YES Is F1 2ATHRC OK YES Is F2 1 25AT OK Connect mains supply Replace fuse Replace fuse Faulty PCB Replace Flashing mains LED Is resistance between pins 3 amp 4 between 690ohms amp 33k YES Is resistance between pins 19 am
58. t the supply pressure is sufficient the correct pressure is not obtained then Worcester Heat Systems Service Department should be contacted 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 fan may continue running until the appliance has cooled 2 17 Central Heating Check that all the radiator valves are open Check that the system is pressurised and set to the required pressure as indicated on the gauge Set any Programmer to HEATING amp WATER Turn on the gas and electricity supplies Set the room thermostat and the Central Heating Temperature Control to maximum The burner will light The appliance will modulate its output between 7 5 and 23 4 kw over a period of about twenty 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 Section 3 Data Tables Set the room thermostat to minimum and check that the burner goes out Reset the room thermostat to maximum and the burner will re light after a short anti cycle delay and follow the normal operating procedure Chec
59. uld be set up at this stage following the instructions sent with the programmer 12 4 APPLIANCE OPERATION Turn off the gas and electricity supplies to the appliance Undo the two screws and hinge down the facia Loosen the burner pressure test point screw and connect a pressure gauge See Fig 27 Maximum pressure Fig 27 Gas valve Main gas valve Minimum adjuster connections pressure Note Clockwise to Black blue brown adjuster increase and anti green yellow clockwise to decrease the pressure test point Inlet pressure test point Electrical connections modulator Blue Blue Modulating solenoid Ne Domestic Hot Water Set any Programmer to HEATING amp WATER Turn on the gas and electricity supplies Set the Central Heating temperature control knob to Off A tap should be opened to create a hot water demand then a continuous ienition spark will occur until the burner is alight and sensed by the control circuit The burner will light and remain at its maximum setting The burner pressure should be between 13 4 and 13 8 mbar on Natural gas 33 0 and 35 0 mbar on Propane If the burner pressure is low check that the supply pressure at the gas valve inlet is at least 19 mbar for Natural gas 37 mbar for Propane Test for gas soundness at the joint between the burner and the gas valve with leak detection fluid Note The burner pressure is factory set and if after checking tha
60. ve any dust or deposits using a soft brush Reassemble the appliance in the reverse order Check that all components are in place and correctly fixed Leave the cabinet front panel to be fitted after checking the operation of the appliance 14 5 TEST THE APPLIANCE On completion of the service and reassembly of the appliance check for gas soundness and the correct operation of the appliance as described in Section 12 Commissioning Refit the cabinet front panel and reset the controls to the users requirements 15 Replacement Of Parts 15 1 IMPORTANT Switch off the electricity and gas supplies before replacing any components After the replacement of any components check for gas soundness where relevant and carry out functional checks as described in Section 12 Commissioning 15 2 COMPONENT ACCESS To replace components it is necessary to remove one or more sections of the cabinet and cover plates within the appliance as described in Section 14 3 The facia panel may also need to be hinged down as described in Section 14 3 c 15 3 DRAINING THE APPLIANCE Check that the electricity supply to the appliance is turned off Before removing any component holding water it is important that as much water as possible is removed from the appliance a Central Heating Circuit Turn off the central heating flow and return valves at the appliance Open the pressure relief valve make sure that the dust cap on the auto air vent is removed See
61. which has a programmable domestic hot water facility then it is suggested that this be set to Continuous or the equivalent f Fig 28 User controls E on Reset button Mains indicator System pressure gauge O A v WwoncEsTER 26i C H temperature control and on off knob EN 18 14 Inspection And Service 14 1 SERVICING To ensure continued efficient operation of the appliance it must be checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular 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 14 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 12 2 Operate the appliance and the system taking note of any faults Measurement of the Flue Gases For consistency of results of the flue gas measurem
62. wo ducts See Fig 16 3 If L is within any of the following ranges it will not be necessary to cut the extension ducts 0 88m to 1 10m 1 63m to 1 85m or 2 38m to 2 50m Each extension must be connected to the first section of flue or the previous extension by firstly fitting the inner flue ducts together and pilot drilling and fixing See Fig 17 Then the outer air ducts can be similarly fixed using the pair of screws provided The flue terminal section can then be telescopically adjusted and fixed as before See Fig 16 ensuring the correct length L 184mm for side flues or L 181mm for rear flues f Fig 18 Flue turret fixing N Flue turret Reset button Flue Gas Ne Test Point ring v Turret clamping 4 In the event of L not falling within any of the above ranges it will be necessary to cut the FIRST extension length The air and flue duct lengths should both be reduced to the same length L 240mm where one extension is used L 990mm with two extensions and L 1 740mm with three See Fig 17 The flue can then be assembled ensuring that the cut extension is fitted to the turret duct assembly first and that the flue is adjusted to the correct length of L 184mm for side flues or L 181mm for rear flues See Fig 16 5 Finishing the flue Apply the plastic tape provided to the last section of flue where it will be sealed to the external brickwork From inside push the assembly through

Bosch Appliances 24I RSF Boiler User Manual

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