Professional Documents
Culture Documents
INSTALLATION AND
SERVICING INSTRUCTIONS
For Boilers newer
than FD485
This appliance is for use with Natural Gas or LPG (Cat II 2H3P TYPE C12 & C32)
24i GC NUMBER 47 311 69 (N.G.)
GC NUMBER 47 311 71 (L.P.G.)
28i GC NUMBER 47 311 70 (N.G.)
GC NUMBER 47 311 72 (L.P.G.)
GB/IE
APPLIANCE OUTPUTS
Minimum
Maximum
Domestic
Hot Water
Central
Heating
24i
7.5 kW
23.5 kW
28i
8.0 kW
27.5 kW
Contents
1. Installation Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
3. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4. Siting the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
5. Flue Terminal Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6. Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7. Sealed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
8. Open Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
9. Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
10. Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
.........................................................
1. Installation Regulations
The appliance is suitable for installation in GB and IE only and
should be installed in accordance with the rules in force.
1.1 Gas Safety (Installation & Use) Regulations 1998:
It is the law in GB that a competent person in accordance with
the above regulations installs all gas appliances.
Failure to install appliances correctly could lead to prosecution.
It is in your interest, and that of safety, to ensure compliance
with the law.
2. Introduction
2.1 The Benchmark initiative is the new code of
practice to encourage the correct installation, commissioning and
servicing of domestic central heating boilers and system equipment.
The 'Log-book' is a vital document that must be completed
by the installer at the time of installation. It confirms that the
boiler has been installed and commissioned according to the
manufacturers instructions.
A Declaration of Conformity (refer to IS813 Annex D 1) must
be completed by the installer and a copy supplied to the
appliance operator for boilers installed in Eire.
Without the completion of the Log-book and/or Declaration,
manufacturers may refuse to respond to a call-out from a
householder, who will be advised that he or she must call back the
installer, who has not fulfilled his obligations to record the
information required by the initiative.
Service:
To ensure the continued efficient operation of the appliance it must
be checked 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 registered
(by CORGI in GB) engineers.
1.7 The appliance does not contain any substances which are
harmful to health.
1.8 In certain circumstances, the installer can be held
responsible, not only for mistakes on his part but also for
damage resulting from the use of faulty materials. We advise
that, to avoid any risk, only quality approved branded fittings
and the specified replacement parts are used.
2.8 System
These appliances are suitable for sealed systems only.
All dirt must be flushed from the system before
connecting the appliance. The system can be pre-piped and
flushed before the appliance is fitted. If a system cleaner has
been used then it must be completely removed before initially
filling the system and adding, where necessary, an inhibitor.
The connections in the system must withstand an operating pressure of
upto 3 bar.
Radiator valves must conform to BS2767: 10:1977.
Table 3 gives the pump head available for the system and the
required temperature differential.
A drain cock must be fitted to the lowest point and an air vent to
the highest point of the system.
In Eire the requirements in respect of the system given in the
current Irish Building Regulations must be followed and further
guidance is available in Annex M of IS813.
2.5 Installation
The appliance is suitable for indoor installation only and for use
with a sealed system only.
Do not place anything on top of the appliance.
This is a room sealed appliance and a separate combustion air
supply is not required in any room or compartment in which the
appliance is fitted.
If the appliance is fitted in a cupboard or a compartment is built
around it after installation, then the structure must conform to the
appropriate standards. However, because of the low casing losses,
there is no need for cooling ventilation openings in the compartment
provided that the specified clearances are maintained.
The spaces specified for servicing must be maintained.(See Table 8).
There is space for the service pipes to pass through the side channels at
the back of the appliance.
2.6 Flue
Standard Multi-Directional Horizontal Flue Kit can be
adjusted from 425mm to 725mm without cutting.
The minimum length is 265 mm with cutting.
Extended flue lengths up to a maximum of 3m are available.
Optional 45 and 90 flue bend kits are available NOTE: When
using flue bends the maximum flue length is reduced.
If access to the flue terminal will be a problem then a kit is available
to enable the horizontal flue to be fitted from inside the house.
Do not allow the flue terminal fitted to the outside wall to
become obstructed or damaged.
A terminal guard, Type K2, GC 393 553, is available from Tower
Flue Components, Vale Rise, Tonbridge, TN9 1TB.
A vertical flue system is available with a maximum height of
4.1m including the flue terminal assembly.
Refer to the separate vertical flue system booklet .
2.10 Safety
The appliance must not be operated with the inner casing
cover removed or without being full of water and pressurised.
The gas and electricity supplies must be turned off before
working on the appliance.
The appliance can only be electrically isolated externally.
Temperature monitoring controls are fitted to prevent
overheating.
Automatic frost protection is provided together with
automatic pump seizure protection.
The gas valve solenoids are automatically checked for gas
soundness.
IMPORTANT: Where back-flow prevention devices, including
water meters, are fitted the expansion of hot water into cold
water main can be prevented. This can result in a pressure
build-up that may cause damage to the boiler and household
devices such as showers, washing machines etc.
In these cases we recommend that a mini-expansion vessel
be fitted adjacent to the boiler in the cold water inlet pipe.
The domestic hot water circuit should be in copper pipe.
2.11 Operation
2.11.1 Central Heating:
A demand for heat will ignite the burner.
It will operate at minimum pressure for 19 seconds before
increasing to the maximum pressure over a period of 1 minute
and then automatically match the system requirements. At the
end of the demand the burner will go out, the pump will
continue to run for up to 3 minutes and the fan for 35 seconds.
There is an anti-cycle time of 3 minutes.
2.7 Controls
The electronic control system and gas valve modulate the heat
input in response to the domestic hot water temperature and the
central heating setting.
3
11
12
1.
2.
3.
4.
5.
6.
7.
CH flow
Domestic hot water flow
Mains cold water inlet
CH return
Pressure relief valve discharge
Domestic water flow turbine
Circulating pump
8. Expansion vessel
9. Primary heat exchanger
10. Expansion vessel charge point
11. Relief valve
12. Boiler drain point
13. Charging link (optional extra)
13
3. Technical Data
Table 1.
24i
Table 1.
28i
8.0
27.5
Table 2.
FLUE DETAILS
HORIZONTAL FLUE
WALL HOLE DIAMETER
STANDARD FLUE
EXTERNAL FIX
mm
110
INTERNAL FIX
mm
130
MINIMUM LENGTH mm
EXTENDED FLUE
275/*425
MAXIMUM LENGTH mm
725
MAXIMUM LENGTH mm
3000
mm
100
VERTICAL FLUE
VERTICAL DUCT
MAXIMUM LENGTH mm
3000
mm
1100
TERMINAL ASSEMBLY
* NOTE : Minimum uncut length
Table 3
MAXIMUM AVAILABLE PUMP HEAD
HEAD
Metres
FLOW/RETURN
DIFFERENTIAL
C
4.5
10.4
11
23.5
2.2
18.3
18
27.5
2.0
18.3
21
BOILER OUTPUT
kW
Table 4
MECHANICAL SPECIFICATIONS
CENTRAL HEATING FLOW - COMPRESSION
24i
22mm
28i
22mm
RETURN - COMPRESSION
22mm
22mm
15mm
15mm
15mm
15mm
GAS INLET
Rp 4
Rp 4
15mm
15mm
CASING HEIGHT
600mm
600mm
CASING WIDTH
400mm
440mm
CASING DEPTH
325mm
325mm
WEIGHT - LIFT
22kg
23.5kg
WEIGHT - PACKAGED
37kg
40kg
WEIGHT - DRY
34.7kg
5
37.5kg
0.39
1.23
Table 5
PERFORMANCE SPECIFICATIONS
PRIMARY WATER CAPACITY
litres
24i
3
28i
3
IP 20
IP 20
bar
10
10
bar
0.9
0.9
bar
0.1
0.1
55
55
82 (nom)
82 (nom)
bar
2.5
2.5
bar
0.5
0.5
23.5
27.5
23.5
27.5
11.2
13.1
8.4
9.8
15.2
17.8
150
150
kw
Class 2
SEDBUK NUMBER NG
78.0
78.9
80.4
82.1
SEDBUK BAND*
* The value is used in the UK Government Standard Assessment Procedure [SAP] for the energy rating of dwellings. The test data from
which it has been calculated have been certified by the GASTEC notified body.
Table 6
DISCHARGE RATE l/min
TEMPERATURE RISE C
TEMPERATURE RISE C
9
37
44
10
34
39
Table 7
GAS SUPPLY SYSTEM - BASED ON NG (G20)
TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres
3
6
9
12
GAS DISCHARGE RATE - PRESSURE DROP 1 mbar. m3/h PIPE DIAMETER mm
8.7
5.8
4.6
3.9
22
18.0
12.0
9.4
8.0
28
Table 8
CLEARANCES
INSTALLATION
30
200
600
10
(mm)
SERVICE
30
200
600
10
Refer to Section 6.
* If vertical flue then 200mm above top of boiler.
** Front clearance is to a removable panel (eg. door).
Table 9
INITIAL
PRESSURE bar
1.0
1.5
SYSTEM CAPACITY
TOTAL SYSTEM VOLUME litres
INITIAL CHARGE PRESSURE bar
0.5
1.0
1.5
57
75
N/A
31
42
52
6
UNVENTILATED COMPARTMENT
30
200
25**
25
18
A
Dimensions
A,B,E,F
Please ensure that the external system flow rate returning to the
appliance is greater than 2 litres/minute.
130
C
D
E
A
B
C
D
E
F
30
158
24i = 400
=
=
=
=
=
=
24i
70
88
135
200
265
330
28i
90
108
155
220
285
350
All dimensions in mm
28i = 440
10
10
200
All dimensions in mm
Unventilated Compartment for clearances refer to Table 8
102
203
CH Flow
Relief Valve Discharge
DHW Outlet
Gas
Cold Water Inlet
CH Return
600
600
325
200
All dimensions in mm
Unventilated Compartment Refer to Table 8
D,E.
L
A
I
TERMINAL POSITION
H
H
MIN. DISTANCE
Instructions
6. Air Supply
6.1 A separate vent for combustion air is not required. Refer to
BS5440:2.
7. Sealed System
300mm Above
the highest point
of the system
1.Central Heating Return
2.Auto Air vent
3.Non-return Valve
4.Make-up Vessel
5.Stop Cock
Heating
return
Hose union
Stop
cock
Temporary hose
Test cock
Mains cold
water
APPLIANCE
Refer to 'Water
Flow Diagram'
Fig.2.
Radiator
valve
Hot water out
Lockshield
valve
Heating
return
Heating
flow
Water main
11. Electrical
Fan
Flame
sense
electrode
Spark
electrode
CH
sensor
Gas valve
Regulator
Valve
DHW
sensor
Pump
Safety
Valve
Flow
turbine
Safety
Valve
Control Board
green/yellow
ST2
ST16
black
green
white
ST1
black
Link
blue
Mains in
brown
blue
brown
ST15
2 brown
white
red
Earth tabs
Spark
Generator
2 yellow
11
2 blue
2 orange
2 green
2 violet
2 red
white
LIVE
IN
ST2 Pin N
ST2 Pin L
On/Off
switch
12
ST15
right
pin
ST2
(LS)
red
Electronics
Electronics
N
Convert AC to low
voltage electronics
low high
ST1
right
pin
ST2
(LR)
Spark
Indicators
Settings
Electronics/
microprocessor
(Safety Low Voltage)
white
ST1
centre
pin
Optional link
Room
thermostat
ST2
(NS)
Transformer
Fuse F2
(1.25A Slow)
Red
Red
Flame detect
Error
indicator indicator/reset
Outputs
(Ls)
(for other features)
ST2
centre pole
Fuse F1
(2A Slow)
Spark
electrodes
Overheat cut-off
Flame sense
DHW sensor
CH sensor
Flow sensor
Main valves
Regulator valve
Inputs
CH Control knob
Electronics
Fan
Pump
9
7
11.2 Unpacking
Open the carton and check the contents against the packing list.
11.3 Boiler Preparation
Lift out the wall mounting assembly.
NOTE: The wall mounting assembly can be removed from the
carton without having to remove the boiler.
12
2
3
13
10
11
!
IMPORTANT
102
203
All dimensions in mm
13
Fibre
Washer
4
65
CH
Flow
65
65
65
DHW
Flow
Gas
DHW
Cold *
Inlet
CH
Return
Lower fixing
screws (2)
1. Cabinet
2. Control
3. Facia cover
4. Facia cover clips (4)
5. Cabinet fixing screws (2)
2
1. Appliance fixing bracket
2. Fixing screw
14
6
1
4
3
!
IMPORTANT
1.
2.
3.
4.
Terminal
assembly
L
1. Relief valve
2. Relief valve discharge connection
3. Relief valve securing clip
4. System connection point
5. Expansion vessel connection
6. Expansion vessel
securing clip
7. Flexible connector from
pump
8. O-ring
Flue
turret
assembly
Fixing screw
Telescopic adjustment
Appliance
casing
3
11.8 Air and Flue Duct Preparation
11.8.1 The method of installation of the flue system may be
varied to suit the actual site conditions. The instructions for
connecting and fixing the ducts must, however, be strictly
followed.
4
9
6
2
24i
76mm
None
76mm
None
28i
80mm
None
80mm
None
11.8.3 Fit the flue restrictor ring by unscrewing the flue spigot
from the boiler. Refer to Fig. 19.
The standard telescopic flue assembly is suitable (without
cutting) for flues from 425mm up to 725mm measured from the
centre-line of the boiler flue outlet to the outer face of the wall.
Refer to Fig. 20.
The minimum length of the standard flue, after cutting is 275mm.
If L is greater than 725mm then extension duct kit/s will be required
- each kit extends the flue by 750mm up to a maximum of 3000
mm.
6
10
1. Inner casing cover
2. Control panel fixing screws (2)
3. Inner casing cover fixing screws (2)
4. Control panel
5. Controls connector cover
6. Controls connector cover fixing screws (2)
7. Programmer (optional)
8. Facia control panel fixing screw
9. Top support lug (2)
10. Bottom support lug (2)
EXTENSION
1
2
3
15
Terminal
assembly
L
Flue
turret
assembly
Fixing screw
Fixing screw
casing
Terminal
assembly
Flue
turret
assembly
Flue
turret
assembly
Terminal
assembly
1175 - 1475mm
1925 - 2225mm
2675 - 2975mm
(1 extension)
(2 extension)
(3 extension)
725 - 1175mm
1475 - 1925mm
2225 - 2675mm
(1 extension)
(2 extension)
(3 extension)
Fix the flue ducts together before fixing the surrounding air duct.
The cut ducts fit into the terminal assembly.
Make good the internal wall face and the external brickwork or
rendering.
16
From inside push the assembly through the wall so that the
gasket flange is against the outer face. Refer to Fig. 25.
It may be necessary to adjust the legs of the flue centering ring.
Align the flue turret and push fully onto the socket on the
appliance. Tighten the clamping ring. Refer to Fig. 24.
Seal the gap around the duct at the inner wall face with the
flexible seal provided and make good.
Flue Terminal
Flue duct
OPTIONAL
If Z is less than 425mm it will be necessary to cut the air and flue
ducts of the extension to a plain length of 100mm and reduce
the length of the terminal assembly eg. Z=350mm - remove
75mm from the terminal assembly.
Rubber sealing
gasket
Flue terminal
Clamping ring
Y-162
Plain tube
X
17
120mm
1
3
100mm
*5mm
Flue Turret
Bend
*When connecting to an elbow the flue duct must be
5mm longer than the air duct.
4
5
14
ST2
13
6
Series
connection
point
Flue Duct
Air Duct
11
9
8
1. Controls connector
cover
2. Controls connector
cover fixing screws (2)
3. Facia control panel
4. Earth connection (tags)
Adapter
5. Earth connection
(screws)
6. Cable clamp
7. Fuse F1 2A (slow)
8. Cable clamps
(pump and fan)
Flue Spigot
18
12
10
8
9. ST15 Pump
10. ST1 Fan
11. Fuse F2 1.25A (slow)
12. Commissioning switch
(gas valve mode switch)
13. Internal controls
connectors
14. Mains and external
controls connectors
Live
Neutral
Switched Live
ST2
Remove Link
2
230 V Programmer Connections
Ns Ls LR spare
Switched Live
Remove Link
Motor
Live
Motor
19
ive
dL
he
itc
Sw
Ne
ut
ral
e
Liv
Remove Link
Neutral
1.
2.
3.
4.
5.
6.
7.
Neutral
Live
ST2
Check that the pressure relief valve operates by turning the knob
anti-clockwise until it releases. Refer to Fig. 17. Water should be
expelled from the discharge pipe.
13.2 This text describes the filling and venting of the appliance and
system when the optional internal filling loop is fitted.
Any external filling loop must be WRAS approved. Refer to Fig. 8 b.
It is very important that the appliance and system are fully vented.
Pull off the clip on bottom panel. Refer to Fig. 32.
Remove the cabinet by pulling off the clip-on facia cover.
Unscrew the two fixing screws, release the sides and lift from the
top location.
Check that the electrical supply and the gas supply to the
appliance are turned off and that all the water connections
throughout the system are tight.
Open the system valves at the appliance. Refer to Fig 13.
Open all the radiator valves.
Pump cap
Electrical
connections
cover
1. Bottom panel
2. Filling key
3. Fixing clips
13.6 Clock/Programmer
The controls fitted to the appliance should be set up at this
stage. Refer to the instructions sent with the control.
Maximum
2mm
Allen key
Minimum
3mm
Allen key
4
2
1. Filling loop
2. Filling key
3. Lock/unlock Fill position
4. CH Return
5. Mains water inlet
5
13.3 Remove the key from the bottom panel and insert into the
filling loop. Refer to Fig. 32 and 33.
Open the mains cold water inlet valve .
Turn the key clockwise to unlock the filling loop.
The system will fill.
Vent each radiator in turn. The automatic air vent will vent the
appliance.
It is very important that the appliance and system are fully
vented and that all air pockets are removed.
Remove the cap from the pump and turn the shaft about half a
turn. Replace the cap. Refer to Fig. 34.
4
2
3
6
20
Clockwise to
increase
Anti-clockwise
to decrease
Slight
movement
only is
required
Central Heating
Check that all the radiator valves are open.
Check that the system is fully vented and set to the required
pressure as indicated on the gauge.
Check that the clock/programmer is set to operate continuously.
Set the room thermostat and the heating temperature control to
maximum.
The burner will light and the appliance will modulate its output
from minimum to maximum over a period of about two minutes.
Check that all the radiators are heating up evenly. Shut down all
but one of the radiators and observe the burner pressure fall.
Open all the radiators and check that the burner pressure rises.
Balance the system to give the required temperature differential.
Refer to Table 3.
Max
Min
Check that the gas and electricity supplies are turned off.
Connect pressure gauges to the gas valve to measure the inlet
pressure and the burner pressure. Refer to Fig. 35.
The appliance is fully set up in the factory and no adjustment
should be necessary.
Unscrew and remove the control connector cover to display the
mode switch. Refer to Fig. 18.
Check that all the radiator valves are open. Check that the
system is fully vented and pressurised and set to the required
pressure as indicated on the gauge.
Set the temperature control knob to maximum and the
clock/programmer to operate continuously.
Fully open a hot tap.
Set the mode switch to MAX. Refer to Fig. 36.
Turn on the gas and electricity supplies.
A continuous spark will occur until the burner is alight and
sensed by the control circuit. The burner will remain at its
maximum domestic hot water pressure for 1 minute. Refer to
Table 1. It should not be necessary for the gas valve to be
adjusted.
Note: The burner pressure is factory set and if, after checking that
the dynamic (working) supply pressure is sufficient i.e. 18.5mb
approx. [NG] or 36mbar approx. [LPG] at the gas valve inlet
pressure test point, the correct pressure cannot be obtained then
Worcester Heat Systems Service Department should be contacted.
If the appliance does not light then check that it is not in the
lock-out state by gently pressing the reset button for 5 seconds.
Refer to Fig. 37.
Set the mode switch to Normal.
Turn off the hot tap.
The burner pressure will drop to the minimum setting and will
ramp up to the maximum central heating pressure appropriate
to the appliance and the gas. Refer to Table 1.
Set the mode switch to MIN.
The burner pressure will drop to the minimum burner pressure
appropriate to the appliance and the gas for both the central
heating and domestic hot water modes. Refer to Table 1.
Set the mode switch back to Normal.
Turn the electricity supply off and then back on to reset the
controls.
Replace the controls connector cover.
NOTE: For flues greater than 725mm without a restrictor the CO2
may be up to 0.5% lower.
These figures cover all flue conditions.
1
1.
2.
3.
4.
1. Flue connections
2. Combustion products test point
4
6
2
5
9
2
7
8
6
1. Inner casing cover
2. Cabinet fixing screws (2)
3. Inner casing cover fixing screws (2)
4. Facia control panel
5. Controls connector cover
6. Controls connector cover fixing screws (2)
7. Programmer (optional)
8. Facia control panel fixing screw
9. Top support lug
10. Bottom support lug
22
10
6
10
4
3
11
1. Flue hood
7. Fan assembly
2. Overheat thermostat
3. Burner
23
Inner Case Cover Unscrew the two screws and lift off. Refer to Fig. 39.
Combustion Chamber Cover Unscrew the two screws, lift and
pull forward to remove. Refer to Fig. 41.
Fan
Carefully pull off the electrical connections and the
tubes from the airflow-sensing device. Unscrew the
three screws and remove the fan assembly. Refer to Fig.
42.
Flue Hood Remove the fan. Slide out the hood. Ensure the rear
seal is in good condition and secure before replacing
the flue hood. Refer to Fig. 43.
Burner
Remove the combustion chamber. Carefully pull-off
the connections to the spark electrodes and
disconnect the flame sense electrode lead. Unscrew
the support bracket and withdraw the burner
assembly. Refer to Fig. 44.
1
2
3
1. Flue hood
2. Rear sealing strip (on back panel)
3. Combustion chamber cover locating channel
1. Fan assembly
2. Flow sensor
3. Flue hood
4. Fan fixing screws (3)
1. Burner assembly
2. Spark electrode assembly
3. Flame sense electrode
4. Injector
5. Support bracket fixing screw
24
DHW Circuit: Turn off the mains cold water supply at the
appliance. Refer to Fig. 13. Open a hot tap below the level of the
Component Access
Refer to Section 15, Inspection and Servicing for access to
components.
Draining the Appliance
Primary System: Turn off the heating flow and return valves at
the appliance. Refer to Fig. 13.
Open the drain tap. Fit a tube to the drain tap. Refer to Fig. 45.
Close the drain tap when the flow from the appliance has
stopped.
appliance to drain the domestic hot water from the appliance.
Important: A small quantity of water will remain in some
components even after the appliance has been drained.
Protect any electrical components when removing items from
the water circuits.
NOTE: After re-opening the mains cold water inlet valve, draw
off a little water from a tap to ensure that there is water in the
heat exchanger.
Component Replacement
Refer to Fig. 41 and 46 for an indication of the location of the
various components.
Replace any components removed from the appliance in the
reverse order using new gaskets/O-rings/sealant/heat transfer
paste where necessary. Always check that any electrical
connections are correctly made and that all screws are tight.
Remove casing and cover panels and lower the facia onto lower
lugs, as necessary, to gain access to the components. Refer to
Section 15, Inspection and Servicing.
1 Gas Valve
Remove the burner assembly as described in Section 15.4.
Carefully pull-off the electrical connections to the valve.
Remove the injector and copper washer.
Remove the two screws securing the manifold at the rear of the
combustion chamber.
Unscrew the union connection beneath the valve and ease the
valve and injector manifold from the boiler.
Use new gaskets when replacing the valve.
Do not forget to replace the burner injector and copper
washer.
Set the Gas Valve:
Connect a pressure gauge to the burner and inlet pressure test
points on the valve. Refer to Fig. 35.
Switch on the gas and electricity supplies.
Check for gas tightness at the gas valve inlet.
Refer to Section 13-Commissioning, for the method of checking
the pressures.
Check for gas soundness at the gas valve outlet.
Adjust the maximum and start pressure [minimum], as necessary,
to obtain the required pressures.
Switch off the appliance and disconnect the pressure gauge and
tighten the screw.
Check for gas soundness at the test point.
To set the burner pressure. Refer to Fig. 35.
The minimum and maximum burner pressures must be set after
a new gas control has been fitted.
Only slight adjustment is required to change pressure.
Follow the procedure described in Section 13 - Commissioning.
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 13.8. - Appliance Operation.
Turn the gas valve mode switch to maximum. Refer to Fig. 36.
Adjust the maximum pressure adjustment screw on the gas
valve to give a burner pressure of 13.6 mbar (24i), 14.7mbar (28i)
for natural gas.
For propane, the maximum pressure adjustment screw should
be adjusted to give a pressure of 35.3mbar (28i).
Turn the gas valve mode switch to minimum.
Adjust the start pressure adjustment screw on the gas valve to
give a pressure of 1.4mbar (24i), 1.2mbar (28i) for natural gas or
3.4mbar (28i), 4.6mbar (24i) for propane.
Turn the gas valve mode switch back to normal.
After completing the adjustments, check the minimum and
maximum pressures and re-adjust as necessary.
4
1. Pump head
2. Boiler drain point
3. Flexible hose to expansion vessel
connection
4. O-ring
2
10
6
7
1. Gas valve
2. Pump
3. Pressure gauge
4. Relief valve
5. Manifold assembly
6. DHW sensor
25
3.5-4.5mm
2 Spark Electrode
Remove the inner casing cover and the combustion chamber cover.
Carefully pull off the lead from the electrode. Unscrew the screw
and remove the assembly. Refer to Fig. 48.
Ensure that the electrode is at the correct height above the
burner blade.
4 Burner
Remove the inner casing cover and the combustion chamber cover.
Carefully pull-off the connections to the spark electrodes and
disconnect the flame sense electrode. Unscrew the single screw
fixing the support bracket and withdraw the burner assembly. Refer
to Fig 49.
5-6mm
Flame sensor
detail
3
4
1
5
3.5-4.5mm
Spark electrode
detail
26
1. Burner
2. Spark electrode assembly
3. Flame sensor
4. Burner injector
5. Support bracket fixing screw
1. Pump
2. Pressure gauge connection
3. System connection hose
4. Air vent fixing clip
5. Air vent cartridge
6. By-pass pipe
7. 0-Ring
7 Relief Valve
Remove the clip-on facia cover, cabinet, unscrew the single screw
and lower the facia onto the lower support lugs.
Check that the appliance has been fully drained.
Disconnect the relief valve discharge pipe .
Pull down the fixing clip and pull out the relief valve. Refer to Fig. 17.
NOTE: The clip does not need to be fully removed.
6 Pressure Gauge
Remove the clip-on facia cover, cabinet, unscrew the single screw
and lower the facia panel onto the lower support lugs. Refer to
Fig. 39 and 40. Check that the appliance has been fully drained.
Slide the captive clip upwards and remove the pressure-sensing
head. Refer to Fig. 52.
Unclip the gauge head from its mounting bracket and remove.
Refer to Fig. 51.
Check the condition of the O-ring at the pressure capillary head
before fitting the replacement gauge.
3
2
1. Flow turbine
2. Clips (2)
3. O-ring
4. Filter/Flow restrictor
4
2
4
24i White 8 l/min
28i Blue 10 l/min
3
8 Flow Turbine/ Filter/ Restrictor
Drain the DHW circuit as described at the start of Section 16.
Remove the clip-on facia cover, cabinet, unscrew the single screw
and lower the facia panel onto the lower support lugs.
Separate the turbine in-line electrical connector.
Remove the two fixing clips and withdraw the turbine assembly.
1. Pump
2. Pressure gauge capillary
3. Pressure gauge head
4. Mounting bracket
27
12 Clock/Programmer
Remove the clip-on facia.
Remove the clock/programmer assembly by releasing the clip at
the top of the clock/programmer and ease away from the
control panel being careful not to pull on the connector lead.
Unplug the connector at the control board. Refer to Fig. 57.
Comprehensive instructions are sent with the new control.
1. Filter
2. Restrictor
2
Fig. 57. Programmer connection
1
7
6
10 Control Board
Check that the appliance is electrically isolated.
Remove the clip-on facia cover, cabinet and the connections
cover. Carefully disconnect all the electrical connections. Refer to
Fig. 39.
Remove the facia panel unscrew the four screws and remove the
cover from the rear of the facia.
Lift out the control board. Refer to Fig. 56.
Pull out and transfer the transformer to the board.
Re-commission the appliance to check and set the burner
pressures. Refer to Section 13, Commissioning.
5
4
3
11 Transformer
Unscrew the four screws and remove the cover from the rear of
the facia as described in 16.10 preceding.
Pull out the transformer. Refer to Fig. 56.
1.
2.
3.
4.
5.
6.
7.
4
2
5
Facia
Control panel (boiler outer casing in place)
Programmer cover
Programmer location
Programmer connections
Programmer connector plug
Programmer
13 Fan
Remove the inner casing cover.
Remove the fan as described in Section 15.4, Inspection and
Servicing.
Ensure that all the connections are correctly made to the new
fan.
1
1. Control panel
2. Rear cover
3. Rear cover fixing screws (4)
4. Transformer
5. Control board
28
19 Expansion Vessel
It will be necessary to remove the appliance from the wall to
replace the expansion vessel.
Alternatively the specified replacement can be fitted into the
heating system return as close to the appliance as possible.
Re-fill and pressurise the system as described in Section 13
Commissioning.
17 DHW Sensor
Remove the clip-on facia cover and cabinet. Lower the facia onto
the lower support lugs.
Carefully pull off the connections. Unscrew the clip and remove
the sensor.
Apply a small quantity of heat transfer paste to the face of the
replacement sensor. Refer to Fig. 60.
18 Pump
Check that the system valves have been shut and the appliance
has been fully drained. NOTE: A little water will remain in some
components.
Remove the clip on facia cover and cabinet. Place the facia control panel onto the lower support lugs.
Remove the burner as described in Section 16.4 preceding.
Disconnect the flexible hose at the relief valve assembly.
Pull out the clip to disconnect the pressure gauge capillary head.
Refer to Fig. 52.
Raise and remove the clip securing the by-pass pipe to the central heating flow pipe. Refer to Fig. 52.
Pull out the flat clip securing the brass fitting at the top of the pump.
Unscrew the fitting from inside the combustion chamber. Refer to
Fig. 41.
Undo the union connection beneath the pump and carefully
withdraw the pump. Take care when releasing the by-pass pipe.
Support the pump and disconnect electrically.
Transfer the by-pass pipe, expansion vessel flexible connector
and the drain point and pressure gauge connector to the new
pump. Transfer the inlet and outlet connections. Use new O-rings
and seals where necessary.
Reconnect the electrical leads.
Fit the new pump assembly in the reverse order using new Orings and seals where necessary.
!
IMPORTANT
1. Primary Sensor
2. Fixing clip
3. Flow pipe
1
4
1. DHW sensor
2. DHW sensor fixing clip
and screw
Alternatively:
Unscrew, using a 4mm Allen to release the four fixing screws,
and remove the pump head. Refer to Fig. 45.
Access is improved if the pressure gauge head and bracket are
temporarilly removed.
Transfer the electrical connections to the new pump head and
set the speed at maximum.
Refit the pump head taking care not to scratch the pump mating
faces.
Open the system valves and re-fill, re-pressurise and fully vent the
appliance and the system ensuring that there are no air-locks.
2
1
29
5
2
6
3
1. Heat exchanger
4. Overheat thermostat
2. O-ring (4)
4
3
2
OPAQUE
RED
23 Sight Glass
Remove and replace the inner casing cover complete.
Inspection and Servicing. Refer to Section 15.
3. Electrical connections
4. Air pressure switch fixing bracket
5. Fixing screw
30
Key
No.
G.C. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
H05-333
H05-352
H05-337
H05-338
E80-454
E94-710
E01-612
H05-408
173-015
375-696
E88-181
H05-261
H05-264
H05-247
H05-248
E88-176
375-699
H05-366
H05-206
H05-452
H05-229
H05-231
H05-239
E88-183
E88-184
E88-184
H05-403
Part
Burner 24 NG
Burner 28 NG
Gas Valve NG
Gas Valve LPG
Air Pressure Switch
E lectrode Spark
E lectrode FlameSense
Fan
Overheat Stat
Thermistor Sensor
Flow Sensor
Heat Exchanger 24 kW
Heat Exchanger 28 kW
Insulation Set 24 kW
Insulation Set 28 kW
Pressure Gauge
Pressure Relief Valve
Pump
Expansion Vessel
Control Board
Silicone Sponge 24/28kW sides
Silicone Sponge 24kW top/bottom
Silicone Sponge 28kW top/bottom
Transformer
Flow Regulator 24kW White
Flow Regulator 28kW Blue
Auto Air Vent
Qty
WHS
Part No.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
31
1-2
27
10
3-4
7
28
14 -15
16
12 -13
17
18
20
19
25-26
11
24
21-23
32
MAIN SWITCH
ON
CENTRAL
HEATING
DEMAND
Pump on.
Fan ON/
ignition
sequence.
Burner Light
On.
Three minute
wait
19 second
minimum
burner
pressure then
ramp up
pressure over
next one
minute
Room
thermostat
and/or mains
programmer
(or link) On
AND
facia
programmer
(if fitted) On
AND
CH control
knob On
Modulate gas
to maintain
flow
temperature
set by control
knob
(50-82C)
DEMAND
END
Overrun
function
(see overleaf)
Flow sensor
signal
(Tap open)
MAIN SWITCH
ON
DOMESTIC
HOT WATER
DEMAND
(Priority over
CH demand)
YES
Is CH
interrupted?
Pump continue
4 seconds if
primary temp
above DHW
setting. Burner
to MAX.
Modulate gas
to maintain
delivered
water
temperature
(55C)
NO
Ignition
sequence and
burner to MAX
DHW temp
drops to
<55C
Primary
78C
Over
temperature
shut-down if
water
temperature
above 80C
Primary
temperature
94C
33
DEMAND
END
Overrun
function
(see overleaf)
OVERRUN FUNCTION
END DHW
DEMAND
END CH
DEMAND
Pump runs
for
3 minutes
AUTOFROSTAT FUNCTION
No demand
and primary
temperature
below 8C
Internal
"Autofrostat"
demand
Run pump
Monitor
central
heating
sensor
Below
5C
5C
to
9C
Above
9C
Commence normal
central heating mode
until temperature
reaches 20C
34
Return to
normal off
state
FAULT LIST
OBSERVED FAULT
COMMON CAUSES
SEE TEST
Ignition lockout
Overheat lockout
Internal error
(reset lockout by gently
pressing reset button
for 5 seconds)
Autofroststat.
Board fault.
G
H
35
TEST A
No
Check electrical
supply to boiler.
Yes
Switch off electrical
power.
Has fuse F1 blown?
No
No
Yes
Yes
Yes
Replace fuse.
This will be caused by
fuse fatigue or by the
board.
Replace transformer.
TEST B
No
There is no heat
demand. Check room
thermostat or external
programmer (or link).
Yes
Is there a facia
mounted programmer
at connection ST5 at
right-hand end of
board?
No
Replace
control
board.
Yes
Remove programmer
connector from edge
of board. Does the
boiler now ignite?
No
Yes
Correctly set or
replace programmer.
36
No
Replace
control
board.
No
TEST C
No
Yes
Yes
Re-connect the 3-way
connector and open a
tap to run the turbine.
Is there between 1.5V
and 4.5V across the
green and black
wires/terminals?
Is there continuity in
the main harness?
Replace control
board.
Yes
No
Replace turbine.
37
Replace main
harness.
No
Yes
Remove front panel.
Reset and restart the
boiler. Can a flame be
seen through the spy
glass?
No
No
No
Repair or replace
spark electrode
or HT leads
Yes
Yes
No
Yes
Turn off boiler. Remove
the multiway
connector from board
position ST16. Test
resistance across pins
1 and 2 (brown wires)
also pins 8 and 9
(violet).
Is resistance between
60 and 100 ?
Yes
Replace
control board.
No
Yes
Remove brown
connector from gas
valve.
Is there continuity
from brown and violet
connectors
to multiway
connector?
No
Repair or replace
harness.
Yes
TEST D
No
Remove blue
connector from gas
valve. Is there
continuity from blue
wires to multiway
connector?
Yes
Yes
No
Yes
Replace control board.
If problem not solved
replace gas valve.
No
Rectify fault.
Yes
Reset and restart the
boiler in CH mode.
Does the pump run?
No
Replace or repair
pump.
Yes
38
No
Repair or
replace
harness.
Yes
Turn off boiler. Remove
inner casing cover and
check position of
primary sensor (on
heat exchanger in
front of overheat
thermostat).
Is it correctly fixed to
pipe?
No
Yes
Remove combustion
chamber cover.
Is the sense electrode
and lead in good
condition and is gap
correct?
No
Yes
Remove multiway
connector from board
position ST16.
Is there continuity
from pin 10 (white
wire) to flame sensor?
No
Yes
Check the flashing
fault signal occur at
the start of a demand.
No
Yes
Relace control board.
NOTE: It is not
possible to reliably
check the cross-light
performance of the
burner, or the
efficiency of the
gas/water heat
exchanger.
If there is still a
problem, investigate
flue problems or
replace burner or
injector or heat
exchanger.
39
Is the multiway
connector at board
position ST16 pushed
fully home on to the
board?
No
Yes
Check the DHW
sensor. Is it correctly
fitted onto the pipe
with heat conductive
paste between the
pipe and sensor?
No
Yes
Remove multiway
connector from board
position ST16. Test
resistance across pins
16 and 17 ( yellow
wire). Is it between 1
kOhm and 30 kOhm?
No
Is there continuity
from individual pins
16 and 17 to DHW
sensor?
No
Repair or replace
harness.
Yes
Check or replace
DHW sensor.
TEST E
Yes
Test resistance across
contacts 12 and 13
(red wire). Is it
between 1 kOhm and
30 kOhm?
No
Is there continuity
from individual
contacts 12 and 13 to
CH sensor?
No
Yes
Check or replace
CH sensor.
Yes
Test resistance across
contacts 14 and 15
(green wire).
Is it open circuit?
No
Yes
Turn off electrical
supply.
Remove fan connector
from board position
ST1.
Test resistance across
contacts to black &
white cables.
Is it between 75 and
175 ohms?
No
Yes
Test resistance across
contacts to black &
red cables. Is it
between 30 and 90
ohms?
Check/repair fan
harness or repalce fan.
No
Yes
40
Repair or replace
harness.
Yes
Replace multiway
connector to position
ST16 (but not fan
connector at ST1) and
reset/restart the
boiler.
Is there mains 230V
across the right (L)
and left (N) tracks at
board position ST1?
NOTE: Take care not to
short L to N.
No
Yes
Replace fan connector
ST1.
Remove electrical
connectors from air
pressure switch and
reset/restart boiler.
Is there continuity
between C and NO
terminals (where wires
were fitted) when the
fan runs?
(Test within 30
seconds).
No
No
Replace tubes. If
condensation has
occurred, also replace
pressure switch and
check condition of
Venturi in the fan.
Yes
Inspect the flue. Is it
free of any
restrictions?
No
Yes
Replace air pressure
switch.
Note: In the unlikely
event of this not
solving the problem
inspect the pressure
pick-up (Venturi) in the
fan or fan may not be
running freely.
Yes
No
Remove multiway
connector from board
position ST16.
Is there continuity of
the green cables to
the air pressure
switch?
No
Yes
Yes
Replace control board.
TEST F
Turn to 'NORM'
position
41
Repair cables or
replace main harness.
TEST G
No
Yes
TEST H
Boiler is running in
Autofrost stat mode.
See Section 17.
Hot water
temperature always
too hot during a
demand (not
regulating).
TEST I
Yes
No
No
Turbine sticking or
seized.
Replace the turbine.
Yes
It is not possible to
easily isolate the fault.
The most likely causes
are control board (fail),
heat exchanger
(blocked) or
gas valve (sticking).
42
Max
2mm
Allen key
Burner
pressure
test point
1. Ensure the gas service cock is turned OFF and the electrical
supply is ISOLATED.
2. Refer to the Servicing Instrucions to remove the cabinet front
panel and inner casing.
3. Follow the dismantling instructions to remove the burner.
Refer to Installation and Service Instructions Section: Inspection
and Servicing.
4. Remove the injector and replace with the relevent injector
from the kit. Refer to Installation and Service Instructions
Section: Inspection and Servicing.
5. Remove the nut end cap and bracket at the opposite end of
the burner and insert the gauze from the kit for NG to LPG or
remove it for LPG to NG.
6. Refit the end cap ensuring that the support bracket is in the
correct orientation.
7. Remove the gas valve and replace with the gas valve
supplied in the kit. Refer to Installation and Service Instructions
Section: Replacement of Parts.
8. Re-assemble the burner and inner-casing.
9. Turn on the gas and electricity supplies and follow the
Table 1.
24i
Electrical
connections
modulator
(Blue:Blue)
Inlet
pressure
test point
Clockwise to
increase
Anti-clockwise
to decrease
Slight
movement
only is
required
11. Refit the plastic sealing cap to the gas valve modulating
valve adjuster and seal with a dab of paint or similar.
12. Turn off the boiler and when cool peel off the arrow from the
data plate on the combustion chamber front panel and re-stick
against the gas type for which the boiler has been converted
and adjusted.
13. Replace the boiler front panel.
The conversion is now complete.
Table 1.
28i
8.0
27.5
QTY
1
1
1
1
1
2
1
1
1
1
1
Gas valve
sealing
cap
Main gas
valve
connections
Min
3mm
Allen key
DESCRIPTION
Conversion Instructions
LPG Gas Valve Dungs BM771 sl 040 (for LPG to NG)
NG Gas Valve Dungs BM771 sl 040 (for NG to LPG)
Burner gauze
Fibre washer
O rings
Injector 2.7mm 24i LPG
Injector 2.78mm 28i LPG
Injector 4.3mm 24i NG
Injector 4.5mm 28i NG
Copper washer
43
PART No
8 716 105 654
8 716 105 650
8 716 142 601
8 710 103 043
8 716 140 827
8 716 156 373
8 716 140 209
8 716 105 033
8 716 140 208
8 716 101 994
0.39
1.23
Worcester Heat Systems Limited (Bosch Group), Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624. Fax: (01905) 754619.
Technical Helpline (08705) 266241.
www.worcester-bosch.co.uk
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.