Page 2 - Installation Regulations
1.1 Gas Safety (Installation & Use) Regulations 1998. It is the law that all gas appliances are installed by a competentperson in accordance with the above regulations. Failure toinstall appliances correctly could lead to prosecution. It is inyour interest, and that of safety, to ensure complian...
Page 3 - MUST
working at a gauge pressure of at least 0.35bar above the reliefvalve setting if on a sealed system.Where a storage system will not have a vent to atmosphere theinstallation must comply with Building Regulations and WaterCompany bye-laws. If connecting to an existing system the localauthority should...
Page 6 - Siting The Appliance; * Space required for installation and servicing. Refer to Table 7
The appliance may be installed in any room subject to therequirements of the current IEE regulations and, in Scotland, therelevant electrical provisions of the Building Regulations withrespect to the installation of appliances in rooms containingbaths or showers.If the appliance is installed in a ro...
Page 7 - Flue terminal positions; U N L E S S
The flue system must be installed following the requirements ofBS5440:1.The standard flue kit length is 425 - 725mm. Extension kits forflues up to 3.0m are available.A rear flue suitable for walls from 220 - 375mm thick is availablewhich can be contained within the boiler casing.The terminal must no...
Page 8 - Domestic Hot Water; For system wiring please refer to
The system must comply with requirements of BS6798 andBS5449. General: The appliance is only suitable for connection to indirect fullypumped sealed and open vent systems. The minimum statichead is 1.2m and the maximum is 30m.The pump MUST be wired to the boiler control to ensure that the p u m p - o...
Page 11 - Control Board
11 Fig.10. Boiler wiring diagram Flame Sense Electrode Spark Electrode Gas Valve Air pressure switch Overheat Thermostat Fan Control Board X1 X2 X3 X4 X5 X6 1 or ange 1 1 X7 User control potentiometer/switch black white br own gr ey violet re d violet re d black orange brown grey white NC NO COM Tem...
Page 13 - Shown set for Rear Only flue kit
13 Fig. 12a. Boiler Assembly 9/14CBi Shown set for Rear Only flue kit 1. Inner case2. J bolts and wing nuts (2)3. Combustion chamber cover4. Burner5. Burner fixing screw6. Control knob7. Indicator lights8. Base/controls fixing screw9. Cabinet fixing screw10. Gas valve11. Spark electrode12. Burner in...
Page 14 - Shown set for horizontal flue or vertical flue
14 1. Inner case2. J bolts and wing nuts (2)3. Combustion chamber cover4. Burner5. Burner fixing screw6. Control knob7. Indicator lights8. Base/controls fixing screw9. Cabinet fixing screw10. Gas valve11. Spark electrode12. Burner injector13. Temperature sensor14. Overheat thermostat 15. Air pressur...
Page 15 - Installation of the Boiler with a; Unpacking the Boiler; Drill the hole for the flue at 110mm diameter.; Installing The Appliance
NOTE: READ THIS SECTION FULLY BEFORE COMMENCING THE INSTALLATION To install a boiler with a rear only flue refer to Section 11.1. To install a boiler with a telescopic horizontal flue kit referto Section 11.2. To install a boiler with a vertical flue refer to Section 11.2. and theliterature with the...
Page 17 - The polarity of wires is
17 1 1. Flue hood2. Fan3. Sensing connection ( + ) 4. Sensing connection (—)5. Top outlet sealing plate6. Fan lead clip7. Fan fixing screws (2)8. Pressure tube junction9. — ve pressure tube 10. + ve pressure tube 11. — ve pressure tube extension12. + ve pressure tube extension 2 3 (+) (red tube) 4 (...
Page 18 - Installation of the Boiler with a; Release the four screws and remove the inner casing cover.
11.1.8 Completion of the Installation C h e c k t h a t a l l t h e g a s a n d wa t e r c o n n e c t i o n s h ave b e e ntightened. Lower the base plate/control panel. Refer to Fig. 17. The permanent mains and switched live supply to the boilermust come from the system junction box. Refer to Fig....
Page 19 - Fig.19. Flue turret fixing and combustion
11.2.5 Flue Preparation (i) Drill the hole for the flue at Ø110mm unless the optional internal fitting kit (WHS part No. 7 716 191 019) is used inwhich case a Ø150mm hole is required. (ii) Fix the wall mounting plate onto the wall. Ensure it is level before tightening the screws. (iii) The method of...
Page 20 - Telescopic Horizontal Flue Kit up to; Cut the ducts as necessary, ensuring that the ducts are; Telescopic Horizontal flue Kit; However extension ducts need to be cut if
11.2.6 Telescopic Horizontal Flue Kit up to 750mm in Length (i) The standard flue can be telescopically adjusted to any length between 425mm and 725mm.It will only be necessary to cut the standard assembly if L<425mm. Cut the flue turret assembly and the terminal assembly by the same amount i.e L...
Page 21 - Thoroughly flush the system before connecting the; Fig.25 Vertical Adaptor
11.2.9 Vertical Adaptor for Horizontal Flues An adapter is available for an initial short section of vertical flue.Refer to Fig. 25.Measure and cut the flue as described in Section 11.2.7. T h e f i rs t , ve r t i c a l , s e c t i o n ( e q u i va l e n t to d i m e n s i o n X ) i smeasured from ...
Page 22 - 2 Installation of Flue onto Boiler; With the fluehood on the boiler refit the fan:; Flue Turret Kit
11.2.12 Installation of Flue onto Boiler (i) Fit the clamping ring around the flue spigot but leave loose.From the inside push the assembly through the wall. Alignthe flue turret and push fully onto the spigot on the appliance. (ii) Slide the clamping ring into position so that the hole in the spigo...
Page 23 - Commissioning The Appliance
C l e a n s i n g a n d I n h i b i t i n g a C e n t r a l H e a t i n g Installation in compliance with Benchmark It is accepted good practice in compliance with BS 7593, Pas 33 andBenchmark, to cleanse both an existing central heating system whenfitting a replacement boiler, and when fitting a ne...
Page 24 - Inspection And Service
12.8 Central Heating Check that the external controls are calling for heat to the heatingcircuit.Check that all the radiators heat up evenly. If necessary carefully vent. 1 2 . 9 B a l a n c e t h e s ys t e m to g i ve t h e c o r re c t t e m p e ra t u re differential. Refer to Table 3. Refer to ...
Page 26 - Replacement Of Parts
Important: Turn off the gas and electricity supplies and drain, where necessary, before replacing any components. 15.1 Always check for gas soundness where relevant and carry out functional checks as described in Section 12 Commissioning.Any O-ring, gasket or seal that appears damaged must bereplace...
Page 28 - If the left hand clearance is >50mm then the gas valve
15.4.1 Gas Valve NOTE: If the left hand clearance is >50mm then the gas valve can be replaced with the burner and combustion chamber coverin place by unscrewing the four extended screws at the manifoldon the outside of the inner casing. The manifold gasket should bereplaced if it is damaged or ha...
Page 29 - Fig. 37 . Fan/Flue hood Assembly with Horizontal Flue
15.4.5 Control Board Lower the base plate/control assembly and carefully disconnectthe plug-in connector and all the electrical connections. Refer toFig. 35.Release the five clips and lift out the control board. Refer to Fig. 35.Pull out and replace, if necessary, a failed fuse. 15.4.6 Fan Remove th...
Page 30 - the clear tube to the connection marked (
15.4.7 Air Flow Sensor Remove the fan as described in 14.3. Unscrew and withdraw,through the fan outlet, the air flow sensor. Refer to Fig .38 and38a.The detector is 'handed' - do not force it into place. 15.4.8 Temperature Sensor Remove the access panel to give improved access with minimumside clea...
Page 31 - NOTE: Some water will remain in the heat exchanger.; Fig. 41. Heat Exchanger Baffles in Position
15.4.11 Combustion Chamber Insulation T h e i n s u l a t i o n p a d s a re m a n u fa c t u re d f ro m a m a t e r i a l i naccordance with COSHH.Remove the casing, inner casing cover and combustion chambercover. Front Insulation: Unscrew the clamp at the top of the combustion chamber cover to re...
Page 32 - Conversion Instructions; Conversion from LPG — NG
These instructions should only be read if converting appliancefrom Natural Gas to LPG or vice versa. Only components supplied by Worcester, Bosch Group should beused. Only competent persons should attempt the conversion. Conversion from Natural Gas to LPG should not be carried outon appliances insta...
Page 34 - Operational Flow Diagram; Pr
34 18. Operational Flow Diagram M ains 230V supply BOILER HEA T DEMAND Pump continues fo r 4 minutes DEMAND OFF Boiler demand fr om sy stem junction bo x AND User contr ol knob ON Run f a n 20 seconds o r wa it fo r the end of the f a n o verrun Boiler demand light on Pump supply on Ignition sequenc...
Page 35 - LIGHT SITUATION DURING FAULT
35 19. Fault Finding NOTE : This fault finding information is for guidance only. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control for this boiler incorporates three lights: Boiler demand, flame on and lockout.These for...
Page 38 - FAIL POINT E 'BURNER LOCK; NOTE: Do not attempt to light the boiler
FAIL POINT E 'BURNER LOCK OUT' Is the gas supply connected and at the correct pressure? Remove boiler casing. Reset and restart the boiler. Can a flame be seen through the spyglass? Note: there is a 20 second delay from fan on to spark. Yes No Rectify gas supply problem. No TURN OFF GAS SUPPLY. Remo...
Page 39 - FAIL POINT F
39 FAIL POINT F Delivered primary water temperature always too hot. (Over 85°C) Delivered primary water temperature appears too low with control knob set to maximum. (Less than 75°C) Such a fault is likely to be caused by one or more of the following: Low gas pressure Partially blocked flue Partiall...
Page 41 - GAS BOILER COMMISSIONING CHECKLIST
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROL TO HOT W ATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BO...
Page 42 - SERVICE INTERVAL RECORD; It is recommended that your heating system is serviced regularly
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described...
Page 44 - Bosch Group
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....
