Boschhome 14 19Cbi Users Manual 8 716 115 015

914CBI to the manual 48903307-4cca-458f-8070-a257b5ce6268

2015-01-21

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9/14CBi, 14/19CBi, 19/24CBi

WALL MOUNTED BOILERS FOR CENTRAL HEATING

AND INDIRECT SUPPLY OF DOMESTIC HOT WATER

INSTALLATION AND

SERVICING INSTRUCTIONS

This appliance is for use with Natural Gas or LPG (Cat II 2H3P).

9/14CBi GC NUMBER 41 311 50 (N.G.) 9/14CBi GC NUMBER 41 311 51 (LPG)

14/19CBi GC NUMBER 41 311 52 (N.G.) 14/19CBi GC NUMBER 41 311 53 (LPG)

19/24CBi GC NUMBER 41 311 54 (N.G.) 19/24CBi GC NUMBER 41 311 55 (LPG)

APPLIANCE OUTPUTS

IMPORTANT: THESE INSTRUCTIONS APPLY IN THE UK ONLY

AND MUST BE LEFT WITH THE USER OR AT THE GAS METER

Read the instructions before starting work - they have been written to make

the installation easier and prevent hold-ups.

9/14CBi N.G.

Minimum 9.0 kW

Maximum 14.0 kW

9/14CBi LPG

Minimum 10.0 kW

Maximum 14.0 kW

14/19CBi N.G.

Minimum 14.0 kW

Maximum 19.1 kW

14/19CBi LPG

Minimum 14.0 kW

Maximum 19.1 kW

19/24CBi N.G.

Minimum 19.1 kW

Maximum 23.5 kW

19/24CBi LPG

Minimum 19.1 kW

Maximum 23.5 kW

Worcester supports the

Benchmark code of practice

1.1 Gas Safety (Installation & Use) Regulations 1998.

It is the law that all gas appliances are installed by a competent

person in accordance with the above regulations. Failure to

install appliances correctly could lead to prosecution. It is in

your interest, and that of safety, to ensure compliance with the

law.

1.2 The manufacturers notes must not be taken, in any way, as

overriding statutory obligations.

1.3 The compliance with a British Standard or European Norm

does not, in itself, confer immunity from legal obligations.

1.4 The installation of the appliance must be in accordance with

the relevant requirements of the Gas Safety Regulations, current

IEE Regulations, Building Regulations, Building Standards

(Scotland) and local water bye-laws.

1.5 The installation should follow the recommendations of the

following British Standards unless otherwise indicated and to

any other relevant standards.

BS5440:1 - Flues and ventilation for gas appliances: Flues

BS5440:2 - Flues and ventilation for gas appliances: Air supply.

BS5449 - Central heating for domestic premises.

BS5546:1 - Installation of gas hot water supplies.

BS5482 - Domestic Propane Gas Burning Installations.

BS6700 - Domestic water supply (when relevant).

BS6798 - Installation of gas fired hot water boilers.

BS6891 - Low pressure gas pipework installations up to 28mm

(R1).

BS7593 - Water treatment.

1.6 The appliance and/or components must conform, where

applicable, to all relevant Directives.

1.7 In accordance with COSSH the appliance does not contain

any substances which are harmful to health.

1.8 Product Liability regulations indicate that, 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 are used.

1.9 These instructions cover, as far as possible, the foreseeable

situations which may arise. Contact The Worcester Technical

Department, Telephone: 08705 266241, for advice on specific

installations.

1.10 The appliance shall not be installed into a room or internal

space below ground level when it is intended for use with LPG-

propane (G31). This does not preclude the installation into a

room or space which are basements with respect to one side of

the building but are open to the ground on the opposite side.

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 ‘checklist’ is a vital document that must be completed by

the installer at the time of installation and handed to the

householder. It confirms that the boiler has been installed and

commissioned according to the manufacturers instructions.

Without the completion of the checklist, 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.

2.1 General Information

The Worcester boilers provide a heat output of between 9-14kW

(9/14CBi), 14-19kW (14/19CBi) & 19-24kW (19/24 CBi) factory set at

mid-range and contain a temperature control and all the appropriate

safety controls. They are suitable for fully pumped open vent or

sealed systems.

They can be connected to a domestic hot water supply system

through an external S or Y plan system.

2.2 Electrical Supply

230V - 50Hz. Load 125 watts. External fuse 5A to BS 1362, Internal

fuse F1 - 4A.

IP Rating: IP 20.

2.3 Gas supply

The 19/24CBi appliance requires a maximum of 2.72 m3/h of

natural gas (G20), 1.05 m3/h propane (G31).

The 14/19CBi appliance requires a maximum of 2.18 m3/h of

natural gas (G20), 0.84 m3/h propane (G31).

The 9/14CBi appliance requires a maximum of 1.62 m3/h of

natural gas (G20), 0.63 m3/h propane (G31).

The installation and the connection of the gas supply to the

appliance must be in accordance with BS6891or BS5482 for LPG.

The meter or regulator should deliver a dynamic pressure of 20

mbar for natural gas (G20) at the appliance, which is equivalent

to about 19.0 mbar at the gas valve inlet pressure test point, or a

dynamic pressure of 37 mbar for propane (G31) - equivalent to

36.0 mbar at gas valve inlet pressure test point.

2.4 Installation

The appliance is suitable for indoor installation only and for use

with a fully pumped open vent or sealed system with an indirect

cylinder. It is not suitable for use with a direct cylinder.

If the appliance is fitted in a cupboard or a compartment is built

around it after installation, then the structure must conform with

the requirements of BS6798. The spaces specified for servicing

must be maintained. Refer to Section 6.

2.5 System

All dirt and system cleanser must be fully flushed from

any system to be connected to the appliance. Refer to Fig. 5,6 and 7.

A system by-pass maybe required dependent on the system which can

take the form of a single uncontrolled radiator located at least 2m from

the boiler - usually in the bathroom. See Section 7 for more details.

The connections in any system must withstand a pressure of up to 3 bar..

Radiator valves must conform to BS2767:10.

2.6 Domestic Hot Water

Single feed direct cylinders are NOT suitable and must not be used.

A HW cylinder must be of the indirect coil type and suitable for

2. Introduction1. Installation Regulations

1. Installation Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 11. Installing the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15

2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 12. Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . Page 23

3. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4 13. Instructions to the User . . . . . . . . . . . . . . . . . . . . . . . . . . Page 24

4. Siting the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 14. Inspection and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . Page 24

5. Flue Terminal Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7 15. Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26

6. Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7 16. Conversion Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . Page 32

7. System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8 17. Component Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 33

8. Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8 18. Operational Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . Page 34

9. Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10 19. Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 35

Contents 10. Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10

working at a gauge pressure of at least 0.35bar above the relief

valve setting if on a sealed system.

Where a storage system will not have a vent to atmosphere the

installation must comply with Building Regulations and Water

Company bye-laws. If connecting to an existing system the local

authority should be informed.

2.7 Flue

There are 3 fluing options available.

(i) Rear Only Flue Kit.

(ii)

Multi-Directional Horizontal Flue Kit.

(iii) Vertical Flue Kit

A vertical flue option is also available with flue lengths from

1.1m (without cutting) to a maximum of 3.35m (19/24CBi) or

4.1m (9/14 and 14/19CBi). Optional 45° and 90° bends are

available with this option. NOTE: When using flue bends the flue

length is reduced (see Section11.2.8).

2.8 Controls

A control knob adjusts the boiler temperature, switches the

boiler ON or to STANDBY and acts as a lock-out reset.

2.9 Safety

The appliance must not be operated with the inner casing cover removed.

The gas and electricity supplies must be turned off before

servicing or working on the appliance.

The casing is earthed through a push-on connector at the base.

When the casing is refitted this connection MUST be remade.

Fig. 1. Water flow diagram.

Pipes

Return Flow

Alternative position

of Flow and Return pipes

NOTE: Flow pipe is at the rear

in the alternative position.

2.10 Operation

Central Heating

A demand for heat will ignite the burner. The temperature is

controlled by the integral sensor. At the end of the demand the

burner will go out and the pump will continue to run for up to 4

minutes and the fan for 1 minute to dissipate the residual heat.

Domestic Hot Water:

The supply of domestic hot water depends upon the type of hot

water equipment installed and the control system.

The use of unvented cylinders must be in accordance with the

manufacturers instructions and relevant to British Standards.

The boiler is despatched from the factory with the flow and

return pipework prepared for top outlet connection.

The pipework can be orientated to allow connection from the

bottom by simply unplugging the bayonet style pushfit connec-

tions.

NOTE: When changing from a top connection to one at the bot-

tom the pipe functions are reversed.

Top flow pipe becomes the bottom return pipe.

Top return pipe becomes the bottom flow pipe.

The drain off point on the return pipe becomes an air vent if the

pipes are reversed. In this case a drain point should be fitted

close to the appliance.

Flue can be fitted within

the height of the casing from

220mm to 375mm without

cutting.

The minimum length is

100mm with cutting.

No flue bends or extensions

can be fitted to this system.

Side view

Flow Return

Standard Flue Kit

can be adjusted from

425mm to 725mm without

cutting.

The minimum length is 250

mm with cutting.

Extended flue lengths upto

a maximum of 2.5m

(19/24CBi) and 3.0m (9/14

and 14/19CBi) are available.

Optional 45° and 90° flue

bend kits are available

NOTE: When using flue

bends the maximum flue

length is reduced (see

Section 11.2.8).

If access to the flue is a

problem then this option

combined with an internal

flue fixing kit should be

used.

The data plate is fixed to the inner casing cover.

3. Technical Data

HYDRAULIC RESISTANCE

BOILER OUTPUT RESISTANCE MIN. FLOW RATE

kW Metres L/min. °C

0.06 6.5 20

0.13 11.7 11

14.0 0.28 18.2 11

Table 3 9/14CBi

FLUE DETAILS

HORIZONTAL FLUE mm

WALL HOLE DIAMETER EXTERNAL FIX 110

INTERNAL FIX 150

MINIMUM LENGTH 425

MAXIMUM LENGTH 725

EXTENDED FLUE MAXIMUM LENGTH 2.5m (19/24CBi) or 3.0m (9/14 and 14/19CBi)

INTERNAL FLUE - REAR ONLY WITHIN CABINET MINIMUM LENGTH 220

MAXIMUM LENGTH 375

FLUE ASSEMBLY DIAMETER 100

VERTICAL FLUE MINIMUM LENGTH 1100

MAXIMUM LENGTH INCLUDING TERMINAL 3.35m (19/24CBi) or 4.1m (9/14 and 14/19CBi)

Table 2.

FLOW/RETURN

DIFFERENTIAL

NOMINAL BOILER RATINGS (10 Minutes After Lighting)

OUTPUT INPUT (Net) GAS RATE

kW kW m bar. m3/h

14.00 15.28 11.0 1.62

11.50 12.70 7.3 1.41

9.00 10.11 4.5 1.07

19.05 20.57 11.5 2.18

16.52 17.96 8.5 1.90

14.00 15.38 6.0 1.63

23.45 25.74 12.0 2.72

21.25 23.35 9.8 2.47

19.05 21.16 7.8 2.24

14.00 15.28 27.2 0.63

12.00 13.18 20.4 0.54

10.00 11.17 15.4 0.45

19.05 20.57 25.4 0.84

16.52 17.96 19.0 0.73

14.00 15.38 13.9 0.63

23.45 25.74 29.9 1.05

21.25 23.35 24.6 0.96

19.05 21.16 20.2 0.87

Table 1. Factory set at maximum input

BURNER

PRESSURE

Natural Gas: Net Input = Gross Input x 0.901

Propane: Net Input = Gross Input x 0.921

NOTE: Pump is fitted externally

9.0

HYDRAULIC RESISTANCE

BOILER OUTPUT RESISTANCE MIN. FLOW RATE

kW Metres L/min. °C

0.09 10 20

0.26 18.2 11

19 .05 0.52 24.8 11

Table 3 14/19CBi

FLOW/RETURN

DIFFERENTIAL

14.0

NOTE: FOR VERTICAL FLUE REFER TO A SEPARATE LEAFLET FOR INFORMATION

HYDRAULIC RESISTANCE

BOILER OUTPUT RESISTANCE MIN. FLOW RATE

kW Metres L/min. °C

0.15 13.7 20

0.52 24.8 11

23.44 0.73 30.5 11

Table 3 19/24CBi

FLOW/RETURN

DIFFERENTIAL

19.05

9/14CBi NG

14/19CBi NG

19/24CBi NG

9/14CBi LPG

14/19CBi LPG

19/24CBi LPG

APPLIANCE

STANDARD TELESCOPIC FLUE KIT

GAS SUPPLY SYSTEM - BASED ON NG (G20)

TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres

3 6 9 12

MAXIMUM GAS DISCHARGE RATE - PRESSURE DROP 1mbar. m3/h PIPE DIAMETER mm

8.7 5.8 4.6 3.9 22

18.0 12.0 9.4 8.0 28

Table 6

CLEARANCES (mm)

INSTALLATION SERVICE

ABOVE APPLIANCE - INTERNAL REAR FLUE 30 30

ABOVE APPLIANCE - EXTERNAL FLUE TURRET 180 180

IN FRONT OF APPLIANCE 600 600

BENEATH APPLIANCE 200 200

RIGHT HAND SIDE 5 5

LEFT HAND SIDE 5 5 *

Table 7

SEALED SYSTEM CAPACITY - 10 litre vessel

TOTAL SYSTEM VOLUME litres

INITIAL INITIAL CHARGE PRESSURE bar

PRESSURE bar 0.5 1.0 1.5

1.0 72 92 N/A

1.5 39 53 64

Table 8

PERFORMANCE SPECIFICATIONS

PRIMARY WATER CAPACITY 9/14CBi 1.6 litres 14/19 & 19/24CBi 2.1 litres

STATIC HEAD MINIMUM 1.2M MAXIMUM 30M

MAXIMUM FLOW TEMPERATURE 82°C (nom)

MAXIMUM CENTRAL HEATING SYSTEM OPERATING PRESSURE (Sealed System) 2.5 bar

MINIMUM CENTRAL HEATING SYSTEM SET PRESSURE (Sealed System) 0.12 bar

OUTPUT TO CENTRAL HEATING 9/14CBi 9.0 - 14.0kw 14/19CBi 14.0 - 19.05kw 19/24CBi 19.05 - 23.45kw

NOx CLASSIFICATION FOR CBi APPLIANCES Class 1

SEDBUK NUMBER AND BAND* 9/14CBi NG 78.5 D 14/19CBi NG 79.4 D 19/24CBi NG 78.4 D

9/14CBi LPG 81.0 D 14/19CBi LPG 81.7 D 19/24CBi LPG 80.8 D

Table 5

The appliance can be installed on the above clearance dimensions however, for improved access the following is suggested:

* Improved access - 50mm is recommended

** For improved access minimum clearance when fitted to an adjacent LHS wall is 100mm

NOTE: It is possible to fit the appliance in an unventilated compartment. Refer to Section 6 for details.

MECHANICAL SPECIFICATIONS

FLOW - COPPER TAILS 22mm

RETURN - COPPER TAILS 22mm

GAS INLET 15mm COMPRESSION

CASING HEIGHT 600mm

CASING WIDTH 390mm

CASING DEPTH 260mm

WEIGHT - LIFT 9/14CBi 28kg 14/19 & 19/24CBi 33.5kg

WEIGHT - PACKAGED 9/14CBi 41kg 14/19 & 19/24CBi 47kg

Table 4

GAS SUPPLY SYSTEM - BASED ON PROPANE (G31)

TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres

3 6 9 12 PIPE DIAMETER mm

1.5 — — — 15

8.0 5.2 4.2 3.6 22

15.9 8.8 8.5 7.2 28

* The value is used in the UK Government Standard Assesment Procedure (SAP) for the energy rating of dwellings. The test data from which it has been calculated

have been certified by the GASTEC noified body.

The appliance may be installed in any room subject to the

requirements of the current IEE regulations and, in Scotland, the

relevant electrical provisions of the Building Regulations with

respect to the installation of appliances in rooms containing

baths or showers.

If the appliance is installed in a room containing a bath or

shower, any switch or appliance control using mains electricity

must NOT be able to be touched by a person using the bath or

shower.

The appliance shall not be installed in a room or internal space

below ground level when it is intended for use with LPG propane

(G31). This does not preclude the installation into a room or

space which are basements with respect to one side of the

building but are open to the ground on the opposite side.

The appliance is NOT suitable for external installation.

The wall must be able to support the weight of the appliance.

Refer to Table 4.

The specified clearances must be available for installation and

servicing. Refer to Table 7 and Fig.2.

The appliance can be installed in a cupboard/compartment to

be used for airing clothes providing that the requirements of

BS6798 and BS5440/2 are followed.

The clearance between the front of the appliance and the

cupboard/compartment door should be not less than 25mm for

air circulation.

4. Siting The Appliance

Fig. 2. Appliance casing dimensions and

required clearances.

Side view

260mm 600mm*

30mm*

200mm* 5mm*

* Space required for installation and servicing. Refer to Table 7

Front view

390mm

5mm*

36mm

150mm

600mm

Fig. 3. Appliance pipework connections

Fixing clip

GAS

25mm

36mm

88mm

165mm

FLOW

RETURN

100mm 30mm

(Rear only flue)

Rear only flue

External

flue turret

142mm

The flue system must be installed following the requirements of

BS5440:1.

The standard flue kit length is 425 - 725mm. Extension kits for

flues up to 3.0m are available.

A rear flue suitable for walls from 220 - 375mm thick is available

which can be contained within the boiler casing.

The terminal must not cause an obstruction nor the combustion

products a nuisance.

If the terminal is less than 2m above a surface to which people

have access then a guard must be fitted. The guard must be

evenly spaced about the terminal and fixed with plated screws.

A guard Type K2 can be obtained from Tower Flue Components,

Vale Rise, Tonbridge, TN9 1TB.

It is essential that products of combustion cannot re-enter the

building. Refer to Fig 4.

A separate vent for combustion air is not required.

The appliance can be fitted in a cupboard or compartment with

no vents for cooling, but the minimum clearances must be

increased to those given below. Refer to BS6798.

Note: the clearance at the front is to a removable panel, e.g. door.

The user must be informed not to restrict the clearances by the

addition of extra shelves etc and that flammable materials must

not be stored in this compartment.

If the appliance is fitted in a cupboard or compartment with less

clearance than those stated in the table above (minimum

clearances are given in Section 4 Siting the Appliance) then

permanent air vents for cooling are required, one at high level

and one at low level. Both high and low level vents must

communicate with the same room or must be on the same wall

to outside air. The minimum requirements are:

6. Air Supply5. Flue terminal positions

EJF

B,C

Fig. 4. Siting of the flue terminal.

TERMINAL POSITION MIN. DISTANCE TERMINAL POSITION MIN. DISTANCE

A– directly below an openable window or I– From a terminal facing a terminal 1200mm

other opening e.g. air brick. 300mm J– From an opening in a car port (e.g. door

B– Below gutters, soil pipes or drain pipes.* 75mm window) into dwelling. 1200mm

C– Below eaves.* 25mm K– Vertically from a terminal on the same

D– Below balconies or car port roof.* 25mm wall. 1500mm

E– From vertical drain pipes and soil pipes.* 25mm L– Horizontally from a terminal on the same

F– From internal or external corners. 25mm wall. 300mm

G– Above ground, roof or balcony level. 300mm M– From door, window or air vent.

H– From a surface facing a terminal. 600mm 300mm

Model Position of vent Air from room Air from outside

19/24CBi High 255cm2128cm2

Low 255cm2128cm2

14/19CBi High 207cm2104cm2

Low 207cm2104cm2

9/14CBi High 152cm276cm2

Low 152cm276cm2

Above Appliance (when using Rear only Flue) 30mm

Above Appliance (when using horizontal flue) 180mm

In front 340mm

Below 200mm

Right-hand side 105mm

Left-hand side 105mm

If the boiler is fitted between kitchen units and a decorative

door panel is fitted then the top and bottom of the space must

be left open.

*NOTE: A minimum of 75mm must be achieved

where the terminal is near fusible or combustible

material such as plastic drain pipes, guttering or a

carport roof UNLESS suitable heat shields are

provided.

The system must comply with requirements of BS6798 and

BS5449.

General:

The appliance is only suitable for connection to indirect fully

pumped sealed and open vent systems. The minimum static

head is 1.2m and the maximum is 30m.

The pump MUST be wired to the boiler control to ensure that the

pump-overrun function operates to prevent the risk of

overheating and hence nuisance shutdown.

The controls must be wired to ensure that the boiler does not

cycle when electronically controlled zone valves are closed.

A by-pass is required if the controls i.e. 2-port valves, can result

in the closure of the CH and DHW circuits when the boiler is hot.

If mechanically operated thermostatically controlled valves are

fitted on all radiators then a by-pass located at least 2m from the

boiler is required.

A bypass is generally unecessary on a system using a 3 way diverter

valve as one port will be open to flow at all times. This will be

satisfactory for the pump overrun requirement. However if TRV's are

used throughout then a bypass or open radiator may be necessary.

Sealed System:

A sealed system must include an expansion vessel, pressure

relief valve and pressure gauge - these are available as

proprietary kits, the sealed system expansion vessel and fittings

must be connected at the neutral point of the system on the

entry to the pump. A pump and diverter valves are also required

as appropriate to the system. Refer to Fig 5,6,7.

The sealed system must be filled through a WRc approved filling

kit. Refer to Fig.8. The approved method for temporary

connection for filling a closed circuit in a house can be found on

Page 8.25. Fig R24-2a of the Water Regulation Guide and Water

Bylaws 2000 Scotland.

The appliance must not be operated without the system being

full of water and correctly pressurised.

All connections in the system must withstand a pressure of up to

3 bar.

The system and the appliance must be properly vented.

Repeated venting loses water from the system and usually

indicates that there is a leak.

The appliance is NOT suitable for direct water supply.

Do not connect to a direct cylinder.

The CBi can be connected to any indirect cylinder, i.e unvented or

thermal store, and all the benefits of a "dry loft" and mains

pressure hot water can be realised. Contact The Worcester

Technical Helpline. 08705 266241.

Cylinder

Indirect coil type or a direct cylinder with an immersion calorifier

that is suitable for a pressure of 0.35bar above the setting of the

pressure relief valve. Single feed indirect cylinders are NOT

suitable for sealed systems. Any connection to the mains water

supply must conform to the relevant Building and Water

Regulations and be approved by the local Water company.

8. Domestic Hot Water7. System

Fig. 5. System layout if using Honeywell 'Y' plan

Primary

cold feed

(15mm min.)

Heating vent

(22mm min.)

Feed and

Vent Cistern

Diverting

valve

Boiler Pump Radiator

S.H. – Minimum static head 1.2m

measured from the highest point in the

heating system (top surface of the appliance

or highest point in the heating system) to the

water level in the feed and expansion tank

N.B. A drain cock should be

installed at the lowest point of

the heating circuit

Domestic hot

water cylinder

S.H.

150mm max

For system wiring please refer to

Fig. 10. and the controls

manufacturers details.

Bypass or

uncontrolled

radiator

(if required)

Heating return

Non return

valve

Non return

valve Hose union

Test cock

Temporary hose

Stop cock

Auto

air vent

Heating return

Stop

cock

Fill point

Non return

valve

Make up

vessel

1200mm (48 in)

above the highest

point of the system.

Note:

A drain cock

should be fitted

at the lowest

point of the

heating circuit

and beneath

the appliance

Fig. 7. Fully pumped sealed system.

LV LV

INDIRECT

CYLINDER

APPLIANCE

Heating Return

Heating Flow

Cylinder Return

Hot Water Flow

Stop Valve Fixed Cylinder Type or sealed systems - Approved connection

Mains Cold Water

Radiator Valve - Flow RV

Lockshield Valve - Return LV

Expansion

Vessel

For system

wiring

please refer to

Fig. 10. and the

controls

manufacturers

details.

Bypass

balancing valve or

bathroom

radiatior with two

lockshield valves

Pressure

Gauge

Relief

Valve

Fig. 8. Sealed system filling and make-up.

Primary

cold feed

(15mm min.)

Heating vent

(22mm min.)

Feed and

Vent Cistern

Diverting

valves

Boiler Pump Radiator

S.H. – Minimum static head 1.2m

measured from the highest point in the

heating system (top surface of the appliance

or highest point in the heating system) to the

water level in the feed and expansion tank

N.B. A drain cock should be

installed at the lowest point of

the heating circuit

Domestic hot

water cylinder

S.H.

150mm max

Fig. 6. System layout if using Honeywell 'S' plan

For system wiring please refer to

Fig. 10. and the controls

manufacturers details.

Bypass or

uncontrolled

radiator

The gas supplier must be contacted to check the suitability of

the appliance for the local gas supply conditions before

connecting the appliance.

The 19/24CBi appliance requires a maximum of 2.72 m3/h of

natural gas (G20), 1.05 m3/h propane (G31).

The 14/19CBi appliance requires a maximum of 2.18 m3/h of

natural gas (G20), 0.84 m3/h propane (G31).

The 9/14CBi appliance requires a maximum of 1.62 m3/h of

natural gas (G20), 0.63 m3/h propane (G31). Refer to Table 1.

A natural gas appliance must be connected to a governed meter.

The installation of the gas supply to the appliance must be in

accordance with BS6891.

The meter and the pipework to the appliance must be checked,

preferably by the gas supplier, to ensure that a dynamic pressure

of 20mbar for natural gas is available at the appliance

[equivalent to about 19.0 mbar at the gas valve inlet pressure

connection] and that the gas flow is adequate for all the installed

gas appliances or a dynamic pressure of 37 mbar equivalent to

36 mbar at gas valve inlet pressure connection on propane (G31).

Mains Supply: 230V, 50 Hz, 125 watts.

External Fuse: 5A (must be to BS1362).

Internal Fuse: F1 4A (Spare supplied with appliance).

IP Rating: IP 20.

The appliance must be earthed and it must be possible to

completely isolate the appliance.

The mains cable must be 0.75mm2(24 x 0.2mm) to

BS6500 - Table 15 or 16

Mains supply to the boiler and system wiring centre must be

through a common fused double pole isolator situated adjacent

to the appliance. The isolator must have a contact separation of

3mm minimum in all poles. A single switched live cable should

be wired into the boiler from the system wiring centre.

The mains and pump cables must be fed through the mains lead

bracket, secured through the cable clamp and connected to the

connector plug. Refer to Fig. 9, 10 and 11.

Frost protection of the boiler is provided on the control board.

A frost thermostat should be considered where parts of the

system are remote from the appliance. For any frost thermostat

function, the boiler temperature control knob must not be set to

the 'OFF' position. The frost thermostat must be fitted to the

system junction box in accordance with the manufacturers

instructions. Refer to Fig. 11.

Safety Check: If there is an electrical fault after installation check

for fuse failure, short circuits, incorrect polarity of connections,

earth continuity or resistance to earth.

10. Electrical

Fig.9 . Mains electricity and controls

connections.

9. Gas Supply

1. Base plate

2. Control board

3. Control knob

4. Fuse 4A

5. External control connector block

6. Earth post

7. Cable clamp

8. Internal earth connection

9. Gas valve connection

10. Mains lead bracket

11. Spark electrode connection

12. Air pressure switch, temperature sensor,

overheat thermostat connection

13. Fan connection

14. Flame sense connection

11 12 13

Earth post detail.

Note: Pump earth (top connection)

Mains earth (bottom connection)

Pump Earth

Mains Earth

Fig.10. Boiler wiring diagram

Flame

Sense

Electrode

Spark

Electrode

Gas Valve

Air pressure

switch

Overheat

Thermostat

Fan

Control Board

X5 X6

orange

User control

potentiometer/switch

black

white

brown

grey

violet

red

violet

red

black

orange

brown

grey

white

COM

Temperature

sensor

Pump Live

Pump Neutral

Permanent Neutral

Permanent Live

Switched Live (Boiler Demand)

earth

Installer

Connections

blue

brown

Polarity of these connections is not

important.

3 pin header

Fig.11 . System wiring diagram

Control Board

Pump L

Pump N

Permanent N

Permanent L

Switched L

(Boiler Demand)

Earth post

Cable clamp

OUTSIDE OF BOILER

INSIDE OF BOILER

System

wiring centre

Terminal strip

Boiler/pump

demand from

system wiring

centre

L switched

Pump not to be

connected to

system wiring

centre

Pump

(supplied from

boiler only)

Timer

Room thermostat

Tank thermostat

System water valves

230V 50Hz

(5A Fuse)

System components wired into terminal strip

in accordance with component manufacturers instructions

Frost stat

Common isolator

for wiring centre

and boiler

Should be located

adjacent to the

boiler

Mains Earth (TOP CONNECTION)

Pump Earth

(BOTTOM CONNECTION)

Fig. 12a. Boiler Assembly 9/14CBi

Shown set for Rear Only flue kit

1. Inner case

2. J bolts and wing nuts (2)

3. Combustion chamber cover

4. Burner

5. Burner fixing screw

6. Control knob

7. Indicator lights

8. Base/controls fixing screw

9. Cabinet fixing screw

10. Gas valve

11. Spark electrode

12. Burner injector

13. Temperature sensor

14. Overheat thermostat

15. Air pressure switch

16. Flow pipe

17. Return pipe

18. Combustion test point

19. Sensing tubes

20. Fan

21. Flue hood

22. Inner case cover fixing points (4)

23. Outer case earth tag

24. Side cover plate

25. Wire clip

26. Pressure tube junction

17 18

1. Inner case

2. J bolts and wing nuts (2)

3. Combustion chamber cover

4. Burner

5. Burner fixing screw

6. Control knob

7. Indicator lights

8. Base/controls fixing screw

9. Cabinet fixing screw

10. Gas valve

11. Spark electrode

12. Burner injector

13. Temperature sensor

14. Overheat thermostat

15. Air pressure switch

16. Flow pipe

17. Return pipe

18. Combustion test point

19. Sensing tubes

20. Fan

21. Fan clamp (2 screws)

22. Inner case cover fixing points (4)

23. Flue hood

24. Outer case earth tag

25. Side cover plate

26. Wire clip

27. Front baffle

Fig. 12b. Boiler Assembly 14/19 and 19/24CBi

Shown set for horizontal flue or vertical flue

20 21

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 refer

to Section 11.2.

To install a boiler with a vertical flue refer to Section 11.2. and the

literature with the flue kit.

11. Installation of the Boiler with a

Rear Only Flue Kit

11.1 Unpacking the Boiler

Check the contents against the packing list.

Remove the wall mounting template, the mounting plate

assembly and the external flue turret connector and restrictors.

11.1.2 Site Preparation

Check that the correct position for the appliance has been chosen

and that the wall is sound, flat and will support the weight of the

appliance. Refer to Sections 4 & 5 and Tables 4 to 8.

11.1.3 Fixing Holes and Flue Opening

Hold the template to the wall. Check that the template is level.

Mark the position of the fixing holes and the flue opening. Refer to Fig 13.

Mark the position of the bottom fixing point for a screw or

optional security bolt.

11.1.4 Flue Preparation

(i) Drill the hole for the flue at 110mm diameter.

(ii) Fix the wall-mounting plate - do not fully tighten the

screws.

(iii) Measure the wall thickness L - Min 220mm, Max 375mm.

If L is less than 220mm thick then it is necessary to cut

the flue. To do this subtract L from 220 and cut all flue

parts by this amount.

Ensure that the ducts are square and free from burrs.

Always check dimensions before cutting.

The minimum length L is 100mm with cutting.

(iv) Adjust the telescopic flue assembly to a length L+5mm

and secure with the screw supplied. Refer to Fig. 14.

(v) Apply the plastic tape onto the duct in contact with the

wall (position shown in Fig. 14.).

(vi) Remove the inner flue duct (with the fixing bar).

(vii) Push the outer duct assembly through the wall mounting

plate and wall. Tighten the wall mounting plate fixing

screws after checking that the plate is level.

11. Installing The Appliance

Fig. 14 . Flue assembly - Rear Only Flue Kit

1. Telescopic flue assembly

2. Terminal

3. Flange

4. Flue tube with fixing bar

5. Indents

6. Gasket - fitted to inner case

L + 5

Tape

Fig. 13a . Wall plate

36mm

Top of

boiler to

centre of

flue

=142mm

Centre line of flue

Centre line of boiler

Fig. 13b . Flue and wall plate

Flue fixing position

Fig. 13 . Fixing the wall mounting plate.

Centre line

of boiler

Centre line

of flue

36mm

11.1.5 Boiler Preparation

(i) Remove the appliance casing by releasing the screw at

the centre base. Disconnect the earth connection at the base

and lift off.

(ii) Release the four screws and remove the inner casing cover.

(iii) Release the two wing-nuts and remove the combustion

chamber front panel. The cover is located into notches at

the base of the side plates. Leave the stainless steel baffles

in place.

(iv) Disconnect the fan electrical terminals and the sensing

tube from the junction pieces. Slide the flue hood/fan

assembly out of the boiler.

(v) From the literature pack take the self adhesive gasket

and stick around the rear flue opening on the outside of

the casing ensuring that the fixing holes are not blocked

(see Fig. 14b).

11.1.6 Install the Boiler

IMPORTANT: Thoroughly flush the system before connecting the

boiler. Any system cleanser must be flushed from the system

before adding any inhibitor.

(i) Lift the boiler onto the wall mounting plate. See Fig. 15.

(ii) Level the boiler using the two levelling feet at the base of the

back panel.

(iii) Fit the bottom fixing screw (or optional security screw).

(iv) Connect the gas supply using the nut and olive supplied in the

literature pack - details of the position are shown in Fig. 3.

(v) Connect the flow and return pipes to the system. It is important

that the flow and return pipes are not fixed near to the boiler

using clips that put a strain on the connections.

A drain point should be fitted close to the appliance if bottom

connections are made.

Always consider the possible need to disconnect and remove

the boiler.

11.1.7 Installation of Flue onto Boiler

(i) Pull the flue into position so that the holes in the flange

line up with those in the case

NOTE: The correct rectangular flue restrictor must now be fitted

when the boiler is on the wall.

9/14CBi and 14/19CBi 19/24CBi

66 X 62 (Rectangular) 77 X 62 (Rectangular)

(ii) From the inside, place the correct restrictor in position

over the flue opening and using the screws provided, fix

through the inner casing into the flue system.

(iii) Slide the inner flue duct with fixing bar into the flue.

(iv) Slide the fluehood and fan assembly back into position

engaging the fan outlet into the inner duct assembly

and reconnect the fan electrical terminals (polarity is not

important). Reconnect the pressure sensing tubes onto the

junction pieces. See Fig. 16.

(v) Ensure that the combustion chamber is slotted underneath

the flue hood and re-assemble with the combustion

chamber front and 'J' bolts.

Fig. 14a . Rear only flue assembly

Tape

L + 5

245

1. Telescopic flue assembly

2. Terminal assembly

3. Flange / flue assembly

4. Indents

5. Wall mounting plate

6. Flue tube with fixing bar

Fig. 14b . Rear of casing

Gasket

1. Flue hood

2. Fan

3. Sensing connection (+)

4. Sensing connection (—)

5. Top outlet sealing plate

6. Fan lead clip

7. Fan fixing screws (2)

8. Pressure tube junction

9. — ve pressure tube

10. + ve pressure tube

11. — ve pressure tube extension

12. + ve pressure tube extension

3 (+)

(red tube)

4 ( —)

(clear tube)

Fig. 16 . Fan/Flue hood Assembly with Rear Only Flue Kit

NOTE: The polarity of wires is

not important

+ve

—ve

Fig. 15 . Fixing the appliance to the wall mounting plate.

1. Telescopic flue assembly

2. Wall mounting plate

3. Fixing or security screw

4. Levelling feet (2)

5. Restrictor plate with rectangular hole

6. Gasket

7. Flue fixing screws

8. Flue tube with fixing bar

11.1.8 Completion of the Installation

Check that all the gas and water connections have been

tightened.

Lower the base plate/control panel. Refer to Fig. 17.

The permanent mains and switched live supply to the boiler

must come from the system junction box. Refer to Fig.11. A 4

core cable is recommended.

Feed the 4 core cable and the pump cables through the bracket

and secure in the cable clamp. Refer to Fig. 17.

Fit all the supply and pump wires to the 5 way plug before fitting

the plug to the socket on the board. This will avoid stress to the

board when using a screwdriver. Refer to Fig.11. for the

connections.

Check that the cables cannot touch the inner casing.

Test for gas soundness as described in BS6891.

If the appliance is not commissioned immediately, refit the

combustion cover, inner casing cover, base/controls assembly

and the casing. Re-connect the earth connection at the base of

the casing. Check that the gas and electricity services have been

turned off.

REFER NOW TO SECTION 12 - COMMISSIONING THE

APPLIANCE

11.2 Installation of the Boiler with a

Telescopic Horizontal Flue Kit

11.2.1 Unpacking the Boiler

Check the contents against the packing list.

Remove the wall mounting template, the mounting plate

assembly and the flue spigot and restrictors.

The flue spigot is positioned within the boiler carton and not in

the accessory pack.

11.2.2 Site Preparation

Check that the correct position for the appliance has been chosen

and that the wall is sound, flat and will support the weight of the

appliance. Refer to Sections 4 & 5 and Tables 4 and 8.

11.2.3 Fixing Holes and Flue Opening

Hold the template to the wall. Check that the template is level.

Mark the position of the fixing holes and the flue opening. Refer to Fig 13.

Mark the position of the bottom fixing point for a screw or

optional security bolt.

Drill the 5 fixing holes 60mm deep for the No.12 size plugs.

11.2.4 Boiler Preparation

(i) Remove the appliance casing by releasing the screw at

the centre base. Disconnect the earth connection at the base

and lift off.

(ii) Release the four screws and remove the inner casing cover.

(iii) Release the two wing-nuts and remove the combustion

chamber front panel. The cover is located into notches at

the base of the side plates. Leave the stainless steel baffles

in place.

(iv) Disconnect the fan electrical terminals and the sensing

tube from the junction pieces. Slide the flue hood/fan

assembly out of the boiler.

(v) Remove the blanking plate from the top of the inner

casing and refit onto the rear flue opening ensuring a good

seal.

(vi) From the literature pack take the self adhesive gasket

and stick around the top flue opening on the outside of

the casing ensuring that the fixing holes are not blocked

(see Fig. 19).

(vii) Fix the spigot and the appropriate restrictor (if the flue is

less than 1m in length) to the top of the inner casing. Refer

to Fig. 19.

The fixing screw hole on the spigot must be pointing to

the front.

(viii) The boiler is supplied for flow and return connections at

the top. If a bottom connection is required then pull out

the clips, remove and invert the pipes. Refer to Fig. 1.

NOTE: When changing the connections the pipe functions are

reversed -

Top flow becomes the bottom return

Top return becomes bottom flow

Fig.17 . Mains electricity and controls

connections.

1. Base plate

2. Control board

3. Control knob

4. Fuse 4A

5. External control connector block

6. Earth post

7. Cable clamp

8. Internal earth connection

9. Gas valve connection

10. Mains lead bracket

11. Spark electrode connection

12. Air pressure switch,

temperature sensor,

overheat thermostat

connection

13. Fan connection

14. Flame sense conection

11 12 13

IMPORTANT: Top Exit Restrictors

9/14CBi and 14/19CBi 19/24CBi

Ø72mm Ø79mm

152mm

Fig. 18. Fixing the wall mounting plate.

Centre of boiler

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 in

which 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 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.

Remove all packing material from the flue components.

The standard telescopic flue assembly is suitable for lengths

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. 17.

If the length needed is greater than 725mm then extension duct

kit/s will be required - each kit extends the flue by 750mm up to

a maximum of 2.5m (19/24CBi) or 3.0m (9/14 and 14/19CBi).

See table below.

EXTENSION MAXIMUM FLUE LENGTH mm

1 1475

2 2225

3 2500 (19/24CBi)

3 2975 (9/14 and 14/19CBi)

(iv) Measure length L. Refer to Fig 20, 21, 22.

(v) For installation of standard flue up to 750mm refer to

Section 11.2.6.

For installation of flue greater than 750mm refer to

Section 11.2.7.

For installation of bend kits refer to Sections above and

Section 11.2.8.

For installation of vertical adaptor refer to Section 11.2.9.

For installation of internal fitting kit refer to Sections

above and Section 11.2.10.

Fig.20 . Extension Duct.

Appliance casing

Fixing screws Fixing screw

Turret

assembly Terminal

assembly

Ducts of equal length

Shorten first extension fitted

to the turret assembly if more

than one extension is fitted

Fig.21. Flue duct length (side flue). Fig.22 . Flue duct length (rear flue).

Flue

Turret

assembly

Terminal

assembly

Rear face of appliance

and face of mounting

wall

External

wall face

Fig.19. Flue turret fixing and combustion

sensing point

1. Flue spigot fixing screws

2. Flue spigot

3. Restrictor ring (if required)

4. Gasket

5. Flue spigot fixing holes

6. Combustion sensing

point

7. Clamping ring

8. Fixing screw hole

Tape

Fixing

screws

Tape

Fixing

screws

Tape

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=350 - remove 75mm

from each assembly.

The minimum length L is 250mm with cutting.

General: Cut the ducts as necessary, ensuring that the ducts are

square and free from burrs. Always check the dimensions before

cutting.

(i) Fix the flue assembly together using the self-tapping

screws provided. Refer to Fig. 21, 22.

(ii) Apply the plastic tape onto the duct in contact with the

wall (see Fig. 21, 22).

If an internal fitting kit is to be used refer now to Section 11.2.10

otherwise refer to Section 11.2.11.

11.2.7 Telescopic Horizontal flue Kit

Greater Than 750mm in Length

If bends are to be used refer also to Section 11.2.8.

(i) By adding extension duct kits to the standard flue kit it is

not necessary to cut the extension ducts if

L is between

1175 - 1475mm (1 extension)

1925 - 2225mm (2 extension)

(ii) However extension ducts need to be cut if

L is between

725 - 1175mm (1 extension)

1475 - 1925mm (2 extension)

2225 - 2500mm (3 extension) 19/24 CBi

2225 - 2975mm (3 extension) 14/19 and 19/24CBi

(iii) To shorten the duct the first extension only should be cut.

To work out the length to be cut off:

(No. of extensions x 750) + 425 — L = length to be cut.

NOTE: Extension duct measurements do not include the

socketed end. Unless specifically instructed the socketed

end must not be removed.

(iv) Fix the flue assembly together using the self tapping

screws provided (see Fig. 20).

(v) Apply the plastic tape onto the duct in contact with the

wall (see Fig. 20).

If an internal fitting kit is to be used refer now to Section 11.2.10

otherwise refer to Section 11.2.11.

11.2.8 Flue Bends

90° and 45° directional bends are available. A maximum of two

45° or 90° bends may be used in addition to the first bend on

the flue turret.

A 90° bend is equivalent to 750mm of straight duct.

A 45° bend is equivalent to 375mm of straight duct.

Measure the lengths X and Y. Refer to Fig.23.

The maximum value of X using the turret assembly only is

506mm. Reduce the ducts to the appropriate length e.g. X =

406mm, cut 100mm from the air duct and 120mm (to cover the

entry into the 45° or 90° elbow) from the flue duct. Refer to

Fig.24.

The final section, dimension Y, of the flue system must include a

section of plain duct assembly i.e . an extension assembly with

the sockets removed. Reduce the final section, including the

terminal assembly, by the appropriate amount i.e. Air duct Y -

81mm and the flue duct Y - 51mm. Refer to Fig.23.

If Y is smaller than425mm 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 e.g. Y=350mm -

remove 75mm from the terminal assembly.

If Y is between 425 and 725mm it is not necessary to cut the

terminal assembly or use a second extension duct as the length

can be set telescopically.

If Y is greater than 725mm then two extension duct assemblies

will be required, the first assembly being cut to length as plain

tubes.

If more than two extension ducts are needed in any section to

achieve the required length then the final section of the

assembly must not be less than 325mm without cutting the

terminal assembly.

NOTE: The flue duct of the final extension must be 30mm longer

than the air duct.

Each section must be connected to the previous section of the

flue bend by fixing the flue ducts together and then similarly

fixing the air ducts which engage the elbows.

Fix the flue assembly together using the self tapping screws

provided.

Apply the plastic tape onto the duct in contact with the wall (see

Fig. 23).

If an internal fitting kit is to be used refer now to Section 11.2.10

otherwise refer to Section 11.2.11.

Fig. 23. Flue bends.

Air Y – 81mm

Flue Y – 51mm

Tape

Swaged ends

Plain ends

Note: Connections to and from

bend should be plain ended and

the same length.

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.

The first, vertical, section (equivalent to dimension X) is

measured from the top of the boiler casing. Cut the vertical

section of the extension duct to 167mm less than the measured

distance. Do not remove the socketed ends.

The minimum measured distance is 167mm.

Seal the air duct to the turret using silicone sealant.

11.2.10 Fitting of the Flue Assembly without access

to the Terminal

An internal flue fixing kit (WHS part No. 7 716 191 019) is

available from Worcester, Bosch Group.

NOTE: A larger diameter opening (Ø150mm) in the wall is

required. Refer to Table 2.

Prepare the flue assembly as described in Section 11.2.6 - 11.2.8.

Fit the rubber sealing gasket centrally onto the terminal

assembly and tighten the clamp. Refer to Fig. 26.

Apply the plastic tape to the air duct in contact with the external

brickwork.

From inside push the assembly through the wall so that the

gasket flange is against the outer face. Refer to Fig. 26.

It may be necessary to adjust the legs of the flue centring ring.

11.2.11 Install the Boiler

IMPORTANT: Thoroughly flush the system before connecting the

boiler. Any system cleanser must be fully flushed from the system

before adding any inhibitor.

(i) Lift the boiler onto the wall mounting plate. See Fig. 27.

(ii) Level the boiler using the two levelling feet at the base of the

back panel.

(iii) Fit the bottom fixing screw (or optional security screw).

(iv) Connect the gas supply using the nut and olive supplied in the

literature pack - details of the position are shown in Fig. 3.

(v) Connect the flow and return pipes to the system. It is

important that the flow and return pipes are not fixed

near to the boiler using clips that put a strain on the

connections.

A drain point should be fitted close to the appliance if bottom

connections are made.

Always consider the possible need to disconnect and remove

the boiler.

120mm

100mm

Fig. 24 - Elbow to Flue Turret

Assembly.

Flue Turret

Bend

Fig.25 Vertical Adaptor

Flue Duct

Air Duct

Adaptor

Flue Spigot

Fig.26 . Terminal assembly for internal

fitting of the flue.

1. Flue centring ring

2. Air duct

3. Flue duct

4. Rubber sealing gasket

5. Flue Terminal

Rubber sealing

gasket

Clamping ring

Flue terminal

Tape

Fig. 27 . Fixing the appliance to the wall

mounting plate.

Appliance

1. Levelling feet (2)

2. Fixing or security

screw

3. Boiler support

4. Wall plate

Fixing screw hole

Clamping

ring

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. Align

the flue turret and push fully onto the spigot on the appliance.

(ii) Slide the clamping ring into position so that the hole in

the spigot lines up with the hole in the ring. Tighten the

ring in this position. Through the fixing hole screw the self

drilling screw into the flue (see Fig. 29).

(iii) Remove the fan from the fan/fluehood assembly by

removing the two fan flange fixing screws and also

releasing the fan clamping bracket.

(iv) Disconnect the two end lengths of the pressure sensing

hoses up to and the connection joints (approx 150mm of

hose). Both of these hoses should be discarded. Refer to

Fig. 16.

(v) Slide the flue hood only back into the boiler facing the

opposite way to before. Ensure that the flue hood hits the

stops at the rear and the rear combustion chamber slots

in underneath (see Fig. 28).

(vi) With the fluehood on the boiler refit the fan:

(a) Remove the fan lead from the top clip.

(b) With the fan in close proximity to the fluehood re-

attach the fan electrical terminals to the fan. The

polarity of the connection to the fan motor is not

important.

should slide into the clips at the rear of the flue hood.

(d) The fan should then slide upwards into the flue

outlet to enable the fan clamp to be fitted and

tightened into position.

(vii) Re-assemble the front combustion chamber with the 'j'

bolts and replace inner case door.

11.2.13 Completion of the Installation

Check that all the gas and water connections have been

tightened.

Lower the base plate/control panel. Refer to Fig. 30.

The permanent mains and switched live supply to the boiler

must come from the system junction box. Refer to Fig.11. A 4

core cable is recommended.

Feed the 4 core cable and the pump cables through the bracket

and secure in the cable clamp. Refer to Fig. 30.

Fit all the supply and pump wires to the 5 way plug before fitting

the plug to the socket on the board. This will avoid stress to the

board when using a screwdriver. Refer to Fig.11. for the

connections.

Check that all the cables cannot touch the inner casing.

Test for gas soundness as described in BS6891.

If the appliance is not commissioned immediately, refit the

combustion cover, inner casing cover, base/controls assembly

and the casing. Re-connect the earth connection at the base of

the casing. Check that the gas and electricity services have been

turned off.

REFER NOW TO SECTION 12 - COMMISSIONING THE

APPLIANCE

Fig.29 . Flue Turret Fixing .

1. Flue turret assembly

2. Clamp

3. Appliance

4. Fixing screw hole

1. Flue hood

2. Fan

3. Sensing connection (+)

4. Sensing connection ( )

3 (+)

(Red tube)

4 ( )

(Clear tube)

Fig. 28 . Fan/Flue hood Assembly with

Flue Turret Kit

Fig. 30 . Mains electricity and controls

connections.

1. Base plate

2. Control board

3. Control knob

4. Fuse 4A

5. External control connector block

6. Earth post

7. Cable clamp

8. Internal earth connection

9. Gas valve connection

10. Mains lead bracket

11. Spark electrode connection

12. Air pressure switch,

temperature sensor,

overheat thermostat

connection

13. Fan connection

14. Flame sense connection

11 12 13

5. Flue turret

6. Fan clamp

7. Fan clamp fixing screw

Cleansing and Inhibiting a Central Heating

Installation in compliance with Benchmark

It is accepted good practice in compliance with BS 7593, Pas 33 and

Benchmark, to cleanse both an existing central heating system when

fitting a replacement boiler, and when fitting a new central heating

system. Then treat with a 'Corrosion Protector.'

Worcester recommend only products from water treatment manu-

facturers participating in Benchmark. These include:

Fernox Sentinel

Alpha-Fry Technologies Betz Dearborn Ltd

Tandem House Foundry Lane

Marlowe Way Widnes

Beddington Farm Road Cheshire

Croydon WA8 8UD

CRO 4XS

Tel: 01799 521133 Tel: 0151 424 5351

Please call either of the above for a specific cleansing method

statement if so required. Below is a general guide for flushing,

which we would advise you to follow along with the chemical

manufacturers recommendations.

Fill up and commission the system in the normal way, i.e: flush

at least once without firing the boiler to remove loose debris.

Then add the cleansing agent, with regard to COSHH, this must

be in the system for a minimum of 1 hour with the system at

normal operating temperature. A longer period of time, up to 48

hours, would be more beneficial to the cleansing process, espe-

cially if heavy sludge deposits are suspected to be present (see

water analysis kit).

Drain the system thoroughly at least twice to remove the cleans-

ing agent and any debris/flux present. This is a crucial part of

the cleansing process and must be done correctly. A TDS meter

is recommended to ensure adequate flushing.

Once you are sure that the system has been cleansed thoroughly,

then add a mixed metal corrosion protector. This will protect

against the formation of scale, corrosion and microbiological

growths. A minimum of one treatment should be added per system.

The label that is supplied by the manufacturer with the corrosion

protector treatment, shall be correctly filled in and attached to

the boiler. Also, the instructions in the Benchmark logbook will

be adhered to.

Please note that the corrosion protector level should be checked

on an annual basis. This is normally done at the time of the

mandatory boiler service. Water analysis test kits and postal

analysis services are available from water treatment suppliers for

this purpose.

Failure to comply with these recommendations, may invalidate

the boiler warranty. If any of the above is unclear, then please

contact The Worcester Technical Services for further advice.

12.1 Remove the outer casing by first loosening the base screw.

Disconnect the earth and lift off the casing.

Check that the electricity and gas supplies to the appliance are

turned off and that all the water connections throughout the

system are tight.

Open any system valves.

Open all the radiator valves. Remove any air vent caps.

If a sealed system has been installed then fill through a WRc

approved filling kit to an initial pressure of 2.5bar.

Check for water soundness throughout the system.

Vent each radiator in turn.

Remove the cap from the pump and turn the shaft about half a

turn. Replace the cap.

Check that the relief valve (sealed system) operates by turning

the knob anti-clockwise until it releases.

12.2 Set the Expansion Vessel Pressure - Sealed System

The

charge pressure of an expansion vessel is usually 0.5bar, which

is equivalent to a static head of 5m [17ft].

The charge pressure must not be less than the static head at the

point of connection. The expansion vessel must be charged to

0.3bar less than the initial system design pressure.

Note: 1bar = 10.2m = 33.5ft of water.

12.3 Set the System Pressure

Fill the system initially until the pressure gauge is at 2.5bar and check for leaks.

Release water through the drain cock until the required system

pressure is obtained, up to a maximum of 1.5bar.

Set the pointer on the pressure gauge to record the set system pressure.

If the pressure indicated on the gauge is greater than 2.65bar

when operating at the maximum central heating temperature,

the expansion vessel is too small and a larger vessel must be fitted.

The boiler with a 10 litre expansion vessel can accommodate a

sealed system volume of about 90 litres. Refer to BS7074 Part 1,

BS5449 and Table 9.

12.4 Clock/Programmer

Any controls fitted to the system should be set up at this stage.

12.5 Check that the gas and electricity supplies are turned off.

Connect a pressure gauge to the burner pressure test point on

the gas valve. Refer to Fig. 31.

12.6 Light the Boiler

Switch on the gas and electricity supply.

Set the temperature control knob to maximum and any clocks or

programmer to operate continuously.

The gas supply pipe will be purged by the boiler.

The control will work as follows:

(i) Pre-purge (air) for approximately 20 seconds.

(ii) Spark and gas for approximately 5 seconds

(iii) Purge (air) for approximately 10 seconds

The boiler will attempt to light a maximum of 5 times before

going to lockout. To reset the product turn the control knob

fully anti-clockwise and back.

NOTE: The burner pressure is factory set and may be reset to

match the system requirements. If, after checking that the

supply pressure is sufficient i.e. 19 mbar approx [NG] or 36 mbar

approx [PROPANE] at the gas valve inlet pressure test point, the

required pressure cannot be obtained then contact The

Worcester Service Department Tel: 08705 266241.

Reset the pressure as necessary by adjusting the screw on the

gas valve. Refer to Table 1 and Fig.31.

12.7 Domestic Hot Water

Check that the cylinder thermostat, if fitted, is set to between 55°C

and 60°C.

Check that all external controls are calling for heat and that the

flow pipe to the cylinder is hot after a short period.

12. Commissioning The Appliance

Fig. 31. Gas Valve.

1. Gas valve

2. Solenoids

3. Connector

4. Inlet pressure test point

5. Burner pressure test point

6. Burner pressure adjustment screw

GAS

INLET

12.8 Central Heating

Check that the external controls are calling for heat to the heating

circuit.

Check that all the radiators heat up evenly. If necessary carefully vent.

12.9 Balance the system to give the correct temperature

differential. Refer to Table 3. Refer to Section 7. for bypass

requirements.

12.10 Set the room thermostat to minimum and check that the

burner goes out. Reset the room thermostat and the burner will re-light.

Turn off the gas service cock at the boiler. The burner will go out

but, after a short pause, the appliance will make 5 attempts to

restart sparking for 5 seconds and then 'lock-out'. After 60

seconds carefully open the gas service cock at the boiler, operate

the reset control and observe the burner re-light and follow the

normal sequence of operation. Refer to Fig. 32.

Turn off the gas service cock at the boiler and the electricity

supply to the appliance.

Drain the system while the appliance is hot.

Refill, vent and re-pressurise the system (Sealed System) adding a

suitable proprietary inhibitor. Further information is available

from Worcester Technical Information Dept, Telephone 08705

266241.

12.11 Completion of Commissioning

Disconnect the pressure gauge from the gas valve and tighten

the test point screw.

Restart the appliance and check for gas soundness around the

test point screw.

Fix the red arrow on the data plate to show the boiler setting. If

the setting has been altered the adjustment screw should be re-

sealed by a dab of paint to stop un-authorized adjustment.

Refit the casing, reconnect the earth and tighten the clip.

If the appliance is to be passed over to the user immediately

then set any controls to the users requirements.

If the appliance is to be left inoperative in frosty conditions then

set a programmer, if fitted, to continuous and the appliance to

operate at a low temperature under the control of a frost

thermostat, if fitted, to protect remote parts of the system.

The boiler has its own integral frost protection which will also

protect a compact system.

If there is any possibility of the appliance being left totally

unused in freezing conditions then switch off the gas and

electricity and drain the appliance and the system.

Complete the Benchmark Log-book.

13.1 Hand over the User Booklet and the Benchmark

Log-book and explain how to operate the appliance safely and

efficiently.

13.3 Tell the user what to do if the appliance is not to be used in

very cold conditions.

13.4 Tell the user what to do if the system (Sealed System)

pressure falls.

13.5 Explain that regular servicing, of a maximum of 12 months

between services, will maintain the safe and efficient operation

and extend the life of the appliance. Worcester can offer a

comprehensive maintenance contract.

13.6 Tell the user that any work on the appliance must only be

carried out by a competent person.

14.1 The extent of the service will be determined by the

operating condition of the appliance. It is the law that any

service work is carried out by a competent person.

14.2 Inspection

Check that the terminal and the terminal guard, if fitted, are clear

and undamaged.

If the appliance is in a compartment or cupboard check that the

specified clearances are clear. Refer to Table 7 and Section 6 Air

Supply.

Check all the joints and connections in the system and remake

any that show signs of leakage. Refill and re-pressurise (Sealed

System) as described in Section 12 Commissioning.

Operate the appliance and take note of any irregularities. Refer to

Section 18-Fault Finding.

Check the combustion performance

Lift off the cap from the sample point on the top of the boiler and

connect the meter. Refer to Fig 30/30a.

With the appliance at maximum rate and stable expect readings

of about:

Refit the sample point cap after the test.

Always test for gas soundness after the service has been

completed.

Disconnect the electrical supply at the mains and turn off the

gas supply at the gas service cock on the appliance before

starting any service procedures.

14.3 Component Access

Ensure that the gas and electricity supplies are isolated before

accessing the following parts.

Remove some or all of the following parts to gain access to the

components.

Outer Case. Loosen the screw and clip at the base, disconnect

the earth tag, lift the case up and pull forwards.

Base/Control Assembly. Remove the single screw and lower.

Refer to Fig. 33a/b.

Inner Case Door. Remove the four corner screws and lift the

door off.

Combustion Chamber Front Cover. Loosen the two wing-nuts

and slide the 'J' bolts out of the slots. Pull the front cover

forwards and upwards to remove from the boiler.

NOTE: On the 9/14CBi the RHS bolt and clamping bracket must

be removed.

Fan - Rear Only Flue. Remove the combustion chamber front

cover. Carefully pull off the electrical connections and the

pressure tubes from the air flow detector. Slide out the fan and

flue hood assembly. Ensure that the combustion chamber rear

fits under the lip on the fluehood. To remove the fan, remove the

two fixing screws and release the clamping bracket.

14. Inspection And Service

13. Instructions To The User

Fig. 32. User controls.

12 3 4

1. Boiler demand 2. Burner ON 3. Lock-out

4. Temperature control knob/ ON-STANDBY/ Lock-out reset

0.003 - 0.007 7.2 - 8.1 0.002 - 0.005 6.0 - 6.8

0.003 - 0.007 8.1 - 8.7 0.002 - 0.005 6.9 - 7.7

0.002 - 0.005 6.6 - 7.5 0.002 - 0.005 5.6 - 6.5

0.002 - 0.005 7.8 - 8.5 0.002 - 0.005 6.3 - 7.0

0.008 - 0.012 7.1 - 7.7 0.008 - 0.012 7.0 - 7.8

0.005 - 0.010 8.0 - 8.9 0.008 - 0.015 7.8 - 8.5

9/14CBi NG

LPG

APPLIANCE

14/19CBi NG

LPG

19/24CBi NG

LPG

CO CO2CO CO2

SHORT FLUE WITH

RESTRICTOR PLATE

FITTED

LONG FLUE WITHOUT

RESTRICTOR PLATE

FITTED

Fan - Horizontal Flue. Remove the combustion

chamber cover. Carefully pull off the electrical connections and

the tubes from the air flow detector. Loosen the two clamps to

remove the fan . Refer to Fig 34.

Flue Hood - Horizontal Flue. Remove the fan, see

above. Remove the combustion chamber cover and withdraw

the hood. When refitting ensure that the combustion front fits

under the lip of the flue hood.

Burner Blade Assembly. Remove the combustion chamber

cover. Undo the screw at the right hand end of the burner.

Carefully pull-off the connections to the spark electrode. Slide the

burner blade assembly off the injector and remove. Carefully pull

off the flame sense electrode lead. Refer to Fig 33/33a.

Control Board Cover. To gain access to the control board remove

cover from the front clip, with a screwdriver (if necessary) and

unclip from the rear of the controls tray.

14.4 Component Cleaning

Do not use a brush with metal bristles to clean components.

Clean the fan taking care not to block air flow detector.

Clean the burner to ensure that the blades are clear. Do not use a

metal probe to clean the injector.

Clean the electrodes and check the alignment. Replace if there is

any sign of deterioration.

Clean the heat exchanger from top and bottom after covering the

burner injector. To clean the heat exchanger flueways remove the

stainless steel baffles from the appliance - the rear combustion

chamber cover can be tilted for better access. The front and rear

flueways can be cleaned with a brush being careful to protect the

rear combution chamber insulation. The inner flueway can be

cleaned with a scraper.

Check the combustion chamber insulation and replace if there is

any sign of damage or deterioration. Refer to Section 15.4.11.

Carefully refit any components removed and check that all

screws are tight and the connections properly re-made with the

appropriate gaskets/O-rings/seals.

Re-commission, as necessary, for correct operation to the users

requirements. Refer to Section 12 Commissioning.

Fig. 33a. Inner Casing and control

9/14CBi

1. Inner case 8. Base/controls fixing screw

2. J bolts and wing nuts (2) 9. Cabinet fixing screw

3. Combustion chamber cover 10. Gas valve

4. Burner 11. Spark electrode

5. Burner fixing screw 12. Burner injector

6. Control knob 13. Temperature sensor

7. Indicator lights 14. Overheat thermostat

15. Air pressure switch 22. Inner case cover fixing points (4)

16. Flow pipe 23. Outer case earth tag

17. Return pipe 24. Side cover plate

18. Combustion test point 25. Wire clip

19. Sensing tubes 26. 9/14CBi clamping bracket

20. Fan 27. Pressure tube junction

21. Flue hood

17 18 19

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 be

replaced.

15.2 Component Access

Refer to Section 14.3 Inspection and Servicing for access to

components.

15.3 Draining the Appliance

Isolate the appliance.

Remove the casing. Refer to Section 14.3.

Fit a tube to the drain connection from the system (top connection

only) and open the tap. Refer to Fig 34. Close the tap when the flow

has stopped.

IMPORTANT: A small quantity of water will remain in some

components. Protect any electrical components when removing

items that might retain water.

15.4 Component Replacement

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.

15. Replacement Of Parts

1. Inner case 8. Base/controls fixing screw

2. J bolts and wing nuts (2) 9. Cabinet fixing screw

3. Combustion chamber cover 10. Gas valve

4. Burner 11. Spark electrode

5. Burner fixing screw 12. Burner injector

6. Control knob 13. Temperature sensor

7. Indicator lights 14. Overheat thermostat

15. Air pressure switch 22. Inner case cover fixing points (4)

16. Flow pipe 23. Flue hood

17. Return pipe 24. Outer case earth tag

18. Combustion test point 25. Side cover plate

19. Sensing tubes 26. Wire clip

20. Fan 27. Front baffle

21. Fan clamp (2 screws)

Fig. 33b. Inner Casing and control

14/19 and 19/24CBi

20 21

Fig. 34 . Inner Casing - Gas and Electric

Controls. 9/14CBi shown.

1. Inner casing

2. J bolts and wing nuts (2)

3. Combustion chamber cover

4. Burner assembly

5. Inner case cover fixing

points (4)

6. Base/control fixing point

7. Gas valve

8. Burner manifold fixing

screws (4 + 4)

9. Burner manifold

10. Drain point (top flow return)

11. Flow and return pipe fixing clip

12. Access panel

13. Temperature sensor

14. Overheat thermostat

15. Casing support

16. Return pipe

17. Flow pipe

18. Air pressure switch

19. Combustion test point

20. Air pressure switch fixing clip (4)

21. Flue hood

22. Fan

23. Sensing tubes

24. Outer case earth tag

25. Side cover plate

16 17 18

Fig. 35 . Base/Control Board Assembly

45678

1. Base/control assembly

2. Base/control assembly fixing

point

3. Gas valve

4. Inner connections earth tag

5. External controls earth post

points (4)

6. Cable clamp

7. External controls connection

8. Control knob

9. Fuse

10. Outer case earth tag

NOTE: Control board cover not shown.

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 cover

in place by unscrewing the four extended screws at the manifold

on the outside of the inner casing. The manifold gasket should be

replaced if it is damaged or has deteriorated.

Check that the gas supply is isolated.

Remove the inner casing cover, the combustion chamber cover

and the burner blade assembly. Refer to Section 14.3.

Unscrew and lower the base plate/control assembly.

Unplug the electrical connection at the gas valve.

Unscrew and remove the side plate adjacent to the manifold.

Undo the four screws securing the gas cock to the valve. Take

care not to damage the control panel.

Undo the four pozi-head screws to remove the gas valve and

burner manifold assembly.

Undo the four pozi-head screws inside the casing to separate the gas

valve from the manifold.

Use new O-rings when replacing the valve.

Set the Gas Valve:

Connect a pressure gauge to the burner pressure test point on

the valve. Refer to Fig. 31.

Switch on the gas and electricity supplies. Check for gas

soundness at the gas valve inlet.

Refer to Section 12 Commissioning for the method of checking

the pressures.

Check for gas soundness at the gas valve outlet.

Adjust the gas valve to obtain the required pressure. Refer to the

data plate on the cabinet where required pressure will be indicated.

Alter the red arrow if a new setting is made.

The adjustment screw must be sealed by a dab of paint to stop

unauthorized adjustment.

Switch off the appliance, disconnect the pressure gauge and

tighten the test point screw. Refer to Fig. 31.

Check for gas soundness.

15.4.2 Spark Electrode

Remove the inner casing cover and the combustion chamber

cover.

Carefully pull off the leads at the electrodes. Remove the burner

blade assembly. Refer to Section 14.3.

Unscrew and remove the electrode assembly. Refer to Fig. 36 and 36a.

15.4.3 Flame Sense Electrode

Remove the inner casing cover and the combustion chamber

cover.

Pull off the connections to the spark electrode. Carefully remove

the burner blade assembly. Refer to Section 14.3.

Carefully pull off the lead from the electrode.

Unscrew and remove the electrode assembly. Refer to Fig. 36 and 36a.

Ensure that the new electrode is at the correct height and

position on the burner blade.

15.4.4 Burner Blade Assembly

Remove the inner casing cover and the combustion chamber cover.

Remove the burner blade assembly. Refer to Section 14.3.

Fig. 36. Burner Blade Assembly 14/19 and

19/24CBi

1. Burner blade assembly

2. Burner fixing screw

3. Flame sense electrode

4. Spark electrode

5. Burner baffle (not removable from

the burner

Fig. 36a . Burner Blade Assembly 9/14CBi

Spark Electrode Gaps

2.5

4.1±0.2

Flame Sense Electrode Gap

3.1±0.2

Spark Electrode Position

Both Burners

Flame Sense Electrode Position

Both Burners

15.4.5 Control Board

Lower the base plate/control assembly and carefully disconnect

the plug-in connector and all the electrical connections. Refer to

Fig. 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 the inner casing and combustion chamber cover .

Remove the fan as described in Section 14.3 Inspection and

Servicing. The flue hood gasket should be replaced if it is

damaged or has deteriorated.

Ensure that all the connections are correctly made to the new

fan. Refer to Fig. 37 and 37a.

Do not use any sealant on the fan/flue duct connection.

The polarity of wires onto the fan is not important.

1. Flue hood

2. Fan

3. Sensing connection (+)

4. Sensing connection ( )

5. Flue turret

6. Fan clamp

7. Fan clamp fixing screw

3 (+)

(red tube)

4 ( )

(clear tube)

Fig. 37 . Fan/Flue hood Assembly with Horizontal Flue

1. Flue hood

2. Fan

3. Sensing connection (+)

4. Sensing connection (—)

5. Top outlet sealing plate

6. Fan lead clip

7. Fan fixing screws (2)

8. Pressure tube junction

9. — ve pressure tube

10. + ve pressure tube

3 (+)

(red tube)

4 ( —)

(clear tube)

Fig. 37a . Fan/Flue hood Assembly with Rear Only Flue

NOTE: The polarity of wires is

not important

+ve

—ve

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 and

38a.

The detector is 'handed' - do not force it into place.

15.4.8 Temperature Sensor

Remove the access panel to give improved access with minimum

side clearance.

Carefully pull-off the connections.

Remove grommet.

Pull off the clip and remove the sensor. Refer to Fig .39.

When replacing component ensure heat sink compound is

added around contact area.

15.4.9 Overheat Thermostat

Remove the access panel to give improved access with minimum

side clearance.

Carefully pull-off the connections.

Remove grommet.

Unscrew and remove the sensor (see above).

When replacing component ensure heat sink compound is

added around contact area.

15.4.10 Air Pressure Switch

Noting the position of each pressure tube carefully disconnect

the tubes and electrical connections from the switch. Unclip and

remove the switch if there is more than 50mm clearance. Refer

to Fig.40.

If there is minimum clearance then remove the inner casing

cover and release the two screws. Remove the air pressure

switch and mounting bracket complete.

Ensure that the connections are correctly made on the

replacement switch. Red tube to the connection marked (+) and

the clear tube to the connection marked ( —).

Fig. 39. Sensor and Overheat Thermostat

1. Sensor clip with grommet

2. Temperature sensor

3. Overheat thermostat

4. Thermostat pocket

5. Flow manifold

6. Flow pipe

7. Grommet

Fig. 40. Air Pressure Switch

1. Air pressure switch

2. Fixing clips (4) - mounting bracket

3. Sensing tube connection - clear to ' ' on fan

4. Sensing tube connection - red to '+' on fan

5. Electrical connection COM - brown

6. Electrical connection NO - grey

7. Electrical connection NC - white

Fig. 38 - 9/14CBi Fig. 38a - 14/19 and

19/24CBi

15.4.11 Combustion Chamber Insulation

The insulation pads are manufactured from a material in

accordance with COSHH.

Remove the casing, inner casing cover and combustion chamber

cover.

Front Insulation: Unscrew the clamp at the top of the

combustion chamber cover to replace insulation.

Side Insulation: Release the clip at the bottom and slide

out the insulation.

Rear Insulation: Remove the burner blade assembly and

cover the burner injector.

Remove the fan and flue hood assembly.

Remove the side insulation pads.

Unscrew the combustion chamber rear panel and lower.

Cut the rear insulation board to remove it from the boiler.

Cut the replacement board approximately 90mm from the

top so that the joint will be behind the heat exchanger.

Slide in the top section followed by the bottom section.

Refer to Fig.37.

On replacement ensure that the fixing screw returns

through the hole in the rear bracket.

15.4.12 Heat Exchanger

Shut off the gas and electricity supplies.

Drain the appliance.

Protect the electrical components.

NOTE: Some water will remain in the heat exchanger.

Remove the casing, inner casing cover, combustion chamber

cover, heat exchanger baffles, fan and flue hood assembly,

burner blade assembly and the access plate at the left hand side

of the inner casing.

Pull off the leads from the sensor and overheat thermostats. Pull

off the clip to remove the sensor and unscrew the overheat

thermostat.

Pull out the clips securing the flow and return pipes and remove

them from the manifolds. It will be necessary to disconnect the

pipes from the system adjacent to the boiler.

Unscrew the slotted hex head screw at the base of the

combustion chamber rear panel.

Slide the panel upwards and unscrew the two screws exposed at

the right and left hand sides at the rear.

Unscrew the four hex head screws, two at each side, securing the

steel side plates to the inner casing.

Lower the combustion chamber rear panel by pulling the lower

fixing point in front of the securing bracket.

Unscrew the two M6 nuts whilst supporting the heat exchanger

(the approximate weight is: 9/14CBi - 18kg, 14/19 and

19/24CBi - 24kg).

Lift out the heat exchanger assembly complete with side plates

and manifolds. Take care as the combustion chamber rear panel

is now unattached.

Transfer the side plates to the new heat exchanger

Fit the new heat exchanger in the reverse order.

Re-commission the appliance. Refer to Section 12.

Fig. 41. Heat Exchanger Baffles in Position

on the Heat Exchanger

1. Heat exchanger baffle

2. Wire fixing clip

3. Heat exchanger

4. Flow and return manifolds

These instructions should only be read if converting appliance

from Natural Gas to LPG or vice versa.

Only components supplied by Worcester, Bosch Group should be

used.

Only competent persons should attempt the conversion.

Conversion from Natural Gas to LPG should not be carried out

on appliances installed in a room or internal space below

ground level.

Turn off the gas and electricity supplies to the boiler.

NOTE: Turning the control knob to off does not isolate the boiler.

16.1 Conversion

(I) Remove the outer casing by loosening the fixing screw at

the base and lifting off. Refer to Fig. 12a/b.

(II) Remove the inner casing door and combustion chamber

front. Refer to Section 14.3.

(III) Lower the base/control assembly. Refer to Section 14.3.

(IV) Remove the burner blade assemby. Refer to Section 14.3.

(V) Unscrew and replace the burner injector and washer with

the new one from the kit. Refer to Tables 9 and10.

(VI) Transfer the spark and flame electrode assemblies to the

new burner blade assembly. Refer to Sections 15.4.2 - 4 for

details of positions.

(VII) Fit the new burner blade assembly into the appliance not

forgetting to re-connect the electrode leads.

(VIII) Refit the combustion chamber front and inner case cover.

(IX) Switch on the gas supply and open the gas cock at the

appliance. Check for leaks at the gas valve inlet.

(X) Refit the base control assembly.

(XI) Recommission the appliance.

Refer to Section 12. Commissioning for details.

Adjust the burner setting pressure as required. Refer to

Table 1 and Fig. 31.

(XII) Fix the Red Arrow on the data plate to show the boiler

setting. If the setting has been altered the adjustment

screw should be resealed by a dab of paint to stop un-

authorized adjustment.

(XIII) If converting to an LPG boiler add LPG sticker to the casing

door. If converting from LPG to NG then remove the LPG

sticker from the casing door.

(XIV) Refit the cabinet casing.

(XV) Complete the Benchmark checklist.

16. Conversion Instructions

9/14CBi 14/19CBi 19/24CBi

LPG — NG Kit No. 7 716 192 269 7 716 192 279 7 716 192 271

Burner Injector 8 716 157 116 (3.4mm) 8 716 103 168 (3.8mm) 8 716 157 115 (4.3mm)

Injector Washer 8 716 101 994 8 716 101 994 8 716 101 994

Bunner Blade Assembly 8 716 142 654 8 716 142 653 8 716 142 653

9/14CBi 14/19CBi 19/24CBi

NG — LPG Kit No. 7 716 192 270 7 716 192 277 7 716 192 272

Burner Injector 8 716 102 407 (2.1mm) 8 716 103 169 (2.5mm) 8 716 102 411 (2.7mm)

Injector Washer 8 716 101 994 8 716 101 994 8 716 101 994

Bunner Blade Assembly 8 716 102 408 8 716 102 412 8 716 102 412

LPG Label ZK LAB 147 ZK LAB 417 ZK LAB 417

Table 9. Conversion from LPG — NG

Table 10. Conversion from NG — LPG

1 E60-473 Burner Assembly NG 9/14CBi 1 8 716 121 773 0

Burner Assembly LPG 9/14CBi 1 8 716 103 210 0

2 E60-474 Burner Assembly NG 14/19, 19/24CBi 1 8 716 121 767 0

Burner Assembly LPG 14/19, 19/24CBi 1 8 716 103 211 0

3 E60-475 Injector Burner 3.4mm NG 9/14CBi 1 8 716 157 116 0

Injector Burner 2.1mm LPG 9/14CBi 1 8 716 102 407 0

Injector Burner 3.8mm NG 14/19CBi 1 8 716 103 168 0

Injector Burner 2.5mm LPG 14/19CBi 1 8 716 103 169 0

4 E60-476 Injector Burner 4.3mm NG 19/24CBi 1 8 716 157 115 0

Injector Burner 2.7mm LPG 19/24CBi 1 8 716 102 411 0

5 E60-477 Gas Valve NG 1 8 716 156 769 0

6 E60-478 Air Pressure Switch 9/14, 14/19CBi 1 8 716 146 165 0

7 E60 479 Air Pressure Switch 19/24CBi 1 8 716 146 163 0

8 E60-480 Spark Electrode Assembly 1 8 716 142 140 0

9 E60-481 Sensor Electrode Assembly 1 8 716 142 139 0

10 E60-482 Spark Electrode Lead 1 8 716 121 805 0

11 E60-483 Sensor Electrode Lead 1 8 716 142 137 0

12 E60-484 Heat Exchanger Assembly 9/14CBi 1 8 716 121 699 0

13 E60-485 Heat Exchanger Assembly 14/19, 19/24CBi 1 8 716 121 700 0

14 E60-486 Insulation Kit 9/14CBi 1 7 716 101 854 0

15 E60-487 Insulation Kit 14/19, 19/24CBi 1 7 716 101 796 0

16 E60-492 Control Board PCB 1 8 716 146 332 0

17 E60-493 Overheat Thermostat 1 8 716 142 399 0

18 375 696 Primary/Domestic Thermister Sensor Kit 1 8 716 142 302 0

19 E60-498 Fan Assembly 9/14CBi 1 8 716 104 581 0

20 E60-499 Fan Assembly 14/19, 19/24CBi 1 8 716 104 582 0

21 E60-500 Fuse 4A Fast blow 20 X 5mm 10 8 716 156 008 0

22 E60-503 O-Ring Kit HT/Exchanger 1 8 716 101797 0

23 E60-504 Gas Section Sealing Kit 1 8 716 101 798 0

17. Short Parts List

Key G.C. No. Part Manufacturer’s Reference Qty WHS

No. Part No.

18. Operational Flow Diagram

Mains

230V

supply

BOILER

HEAT

DEMAND

Pump

continues

for

minutes

DEMAND

OFF

Boiler demand

from system

junction box

AND

User control

knob ON

Run fan

seconds

or wait for

the end of

the fan

overrun

Boiler

demand

light on

Pump

supply

Ignition

sequence

Boiler cycles

to satisfy

temperature

set by facia

control

knob

Temperature

Sensor disconnected

Ignition sequence inhibited

(fan and pump may run for

short period)

Boiler

overheat

Overheat

thermostat

trip.

Lockout

light

(constant)

Protection Systems

re-attempt

ignition

(MAX 4

times)

lockout

light

(flashing)

Fan

continues

for

minute

FAIL

PASS

FAIL

Run pump

continuously

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 form the basis for this fault finding guide.

To use this guide, select box below which represents the light situation during your fault, then refer to the appropriate section.

This guide assumes a component failure has occured following a period of normal running. It is not intended to solve installation errors.

PRELIMINARY CHECKS

Preliminary electrical system checks are the first electrical checks to be carried out during a fault-finding procedure. On completion of the

Service/Fault-finding task which has required the breaking and remaking of electrical connections, check (a) EARTH CONTINUITY,

(b) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH.

WARNING: In addition to the controls, the overheat thermostat and fan are connected directly to the permanent live supply. Under

all circumstances remove the permanent live supply before touching these parts.

WITH A SYSTEM BOILER DEMAND AND USER CONTROL SET TO MAXIMUM:

LIGHT SITUATION DURING FAULT

NO LIGHTS AT ALL FAULT POINT A

FAULT POINT B

DEMAND LIGHT ONLY

FAULT POINT C

BURNER LIGHT ONLY

ON OR OFF OFF LOCKOUT LIGHT ON

CONSTANTLY

ON OR OFF OFF LOCKOUT LIGHT

FLASHING

FAULT POINT D

FAULT POINT E

OTHER FAULTS NOT COVERED BY ABOVE FAULT POINT F

Remove connector

X5 and test

resistance between

the red and violet

cables. Is the

resistance between

1 kohm and

30 kohm?

FAIL POINT A

Yes

NOTE: It is normal to see only a

demand light if the boiler is hot

and the burner has temporarily

shut off.

Ensure boiler is cool and user

control set to maximum.

Replace sensor

or check

cables to it.

Gain access to the

control board.

Is there 230V at connector

X1 between pins SL & N?

Replace control board.

Yes

No boiler demand

from the heating

system. Investigate

system.

FAIL POINT B

Gain access to the

control board.

Is there 230V at connector

X1 between pins

'PERM LIVE' & 'N'?

No permanent live

supply to control

board. Investigate

electrical supply from

external system.

Create a new demand.

Does the fan run?

Yes

Is there 230V

across the fan

terminals?

WARNING:

if NO, both fan

terminals will

be LIVE.

Does the

pump

run?

Check fuse F1

on the control

board.

Has it blown?

No No No

Replace fan.

Yes

Air pressure switch

is stuck on.

Replace air pressure

switch.

Yes

Replace fuse and

investigate cause.

Suggestions:

connections to (or

faults within) pump,

fan, gas valve,

system wiring,

possible board fault.

Yes

Does the fan run

continuously?

Fan cycles on & off.

Is there any sign of

blockage in the flue or

air pressure tubes?

Replace control board.

Yes

Clear blockage.

Yes

Air pressure switch not

changing over. Check flue and

air pressure sense tubes. Are

they clear and not damaged?

Repair fault.

Replace air pressure switch.

If this does not solve the

problem check the venturi in

the fan housing.

Yes

FAIL POINT C

Is the boiler in a very cold

environment

i.e is the primary water

temperature below 5°C?

Boiler is running in

'Autofroststat' mode.

Yes

Demand light has

failed. Replace control

board if it is

considered a problem.

FAIL POINT D

Is the system fully

water pressurised

and is all air vented?

The system should have a

bypass fitted as described in

Section 7. SYSTEM and Figs.

5, 6 & 7. Is bypass fitted and

correctly adjusted?

Yes

Remove connector at X5.

With boiler cool is there a

short circuit between the

orange & black cables?

Reset the lockout and create

a boiler demand.

With the boiler cool does

the pump run?

Yes

Switch off mains supply.

Remove boiler cover

and inspect the

temperature sensor.

Is it correctly fitted to the

manifold with heat

conductive paste on its

surface?

Yes

Gain access to control board

and inspect the slide switch

at the front of the board.

In normal domestic

installation this switch

should be in the left

'normal' position.

Yes

Replace control board.

Rectify fault/leak.

Add or adjust system

bypass.

No Replace pump or

check cables to it.

No Refit sensor to

manifold or add heat

conductive paste.

Use a suitable

implement to push

switch to the 'normal'

left position. The

'heatstore' right position

is for commercial

applications only.

No Replace overheat

thermostat or check

wiring to it.

FAIL POINT E 'BURNER LOCKOUT'

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.

Remove inner casing

cover.

Reset and restart boiler.

Does a spark occur

across the electrodes?

No Are the electrodes

and gap and

connections

in good order?

No Repair or replace

spark electrode

or HT leads.

Yes

Replace control board.

Yes

During spark period

is there 216V D.C.

across the pins at

connector X2?

Replace gas valve or

check cable to it.

Yes

TURN OFF GAS SUPPLY.

Remove the combustion

chamber cover. Is the

sense (right) electrode

and lead in good

condition and is gap

correct?

See Section 15.4.3

No Repair or replace

flame sense

or cable to it.

Replace control board.

Note: It is not possible

to reliably check the

cross light performance

of the burner.

In the unlikely event of

such a fault, investigate

condition of flue,

burner and injector.

Also check polarity of

mains voltage supply.

Yes

NOTE: Do not attempt to light the boiler

with the combustion chamber cover

removed.

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

Partially blocked heat exchanger

Blocked/dirty burner

Gas valve sticking

Control board fault

Faulty themister

Replace control board.

Move control knob to lower

setting.

Check thermister

sensor/heat conductive

paste.

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/ST AT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT

TIME & TEMPERATURE CONTROL TO HOT W ATER CYLINDER T/ST AT & PROGRAMMER/TIMER

COMBI BOILER

HEATING ZONE VALVES FITTED NO T REQUIRED

HOT W ATER ZONE VALVES FITTED NO T REQUIRED

THERMOSTATIC RADIA TOR VALVES FITTED

AUT O M A TIC BYPASS TO SYSTEM FITTED N O T REQUIRED

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURERS INSTRUCTIONS?

THE SYSTEM CLEANER USED

THE INHIBIT O R USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE ft3

/hr

BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

CENTRAL HEATING FLOW TEMPERATURE ¡C

CENTRAL HEATING RETURN TEMPERATURE ¡C

FOR COMBINATION BOILERS ONLY

HAS A W ATER SCALE REDUCER BEEN FITTED? YES NO

W H AT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ft3

/hr

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

COLD WATER INLET T E MPERATURE ¡C

HOT W ATER OUTLET TEMPERATURE ¡C

W ATER FLOW RATE

lts/min

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH

THE MANUFACTURERS INSTRUCTIONS? YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT W ATER SYSTEM COMPLIES

WITH CURRENT BUILDING REGULATIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED

IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS

IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2RATIO READING? N/A YES CO/CO2RATIO

THE OPERATION OF THE APPLIANCE AND SYSTEM

CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURERS LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

/hr

COMMISSIONING ENGS NAME PRINT CORGI ID No.

SIGN DATE

BOILER SERIAL No. NOTIFICATION No.

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLIST

COLLECTIVE MARK

N/A

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 in the boiler manufacturer s instructions. Always use the manufacturer s specified spare part when replacing all controls

SERVICE 1

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 2

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 3

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 4

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 5

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 6

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 7

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 8

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 9

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 10

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

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 8 716 115 015a (02/08)

This manual is to be used in conjunction

with the variant part number of the bar

code below:

Bosch Group

Worcester, Bosch Group, Cotswold Way, Warndon, Worcester WR4 9SW.

Telephone: 01905 754624. Fax: 01905 753130.

Technical Helpline 08705 266241.

Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Limited.

www.worcester-bosch.co.uk

Boschhome 14 19Cbi Users Manual 8 716 115 015

914CBI to the manual 48903307-4cca-458f-8070-a257b5ce6268

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