Bosch 14-19CBI User Manual

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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

Worcester supports the

Benchmark code of practice

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

9/14CBi N.G.

 

14/19CBi N.G.

 

19/24CBi N.G.

Minimum

9.0 kW

 

Minimum

14.0 kW

 

Minimum

19.1 kW

Maximum

14.0 kW

 

Maximum

19.1 kW

 

Maximum

23.5 kW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9/14CBi LPG

 

14/19CBi LPG

19/24CBi LPG

Minimum

10.0 kW

 

Minimum

14.0 kW

 

 

Minimum

19.1 kW

 

Maximum

14.0 kW

 

Maximum

19.1 kW

 

 

Maximum

23.5 kW

 

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.

 

Contents

 

 

1.

Installation Regulations . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

2

2.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

2

3.

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

4

4.

Siting the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

6

5.

Flue Terminal Positions . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

7

6.

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

7

7.

System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

8

8.

Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

8

9.

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 10

1.Installation Regulations

1.1Gas 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.

1.2The manufacturers notes must not be taken, in any way, as overriding statutory obligations.

1.3The compliance with a British Standard or European Norm does not, in itself, confer immunity from legal obligations.

1.4The 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.

1.5The 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.

1.6The appliance and/or components must conform, where applicable, to all relevant Directives.

1.7In accordance with COSSH the appliance does not contain any substances which are harmful to health.

1.8Product 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.

1.9These 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.

1.10The appliance shall not be installed into a room or internal space below ground level when it is intended for use with LPGpropane (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.

10. Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10 11. Installing the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15 12. Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . Page 23 13. Instructions to the User . . . . . . . . . . . . . . . . . . . . . . . . . . Page 24 14. Inspection and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . Page 24 15. Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26 16. Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . Page 32 17. Component Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 33 18. Operational Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . Page 34 19. Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 35

2. Introduction

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-outfrom 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 atmid-rangeand 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 systemby-passmaybe 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

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.

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

(ii)

 

Multi-DirectionalHorizontal Flue Kit.

 

 

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

Side view

 

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.

(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-outreset.

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-onconnector 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

Flow Return

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 connections.

NOTE: When changing from a top connection to one at the bottom 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.

3

3. Technical Data

 

 

 

 

 

 

 

 

The data plate is fixed to the inner casing cover.

Table 1.

Factory set at maximum input

 

 

 

 

 

NOMINAL BOILER RATINGS (10 Minutes After Lighting)

 

 

APPLIANCE

 

 

OUTPUT

INPUT (Net)

BURNER

 

GAS RATE

 

 

 

 

 

kW

kW

PRESSURE

 

m3/h

 

 

 

 

 

m bar.

 

 

9/14CBi NG

14.00

15.28

11.0

 

1.62

 

 

 

11.50

12.70

7.3

 

1.41

 

 

 

9.00

10.11

4.5

 

1.07

 

14/19CBi NG

19.05

20.57

11.5

 

2.18

 

 

 

16.52

17.96

8.5

 

1.90

 

 

 

 

 

14.00

15.38

6.0

 

1.63

 

19/24CBi NG

23.45

25.74

12.0

 

2.72

 

 

 

 

21.25

23.35

9.8

 

2.47

 

 

 

19.05

21.16

7.8

 

2.24

 

9/14CBi LPG

14.00

15.28

27.2

 

0.63

 

 

 

12.00

13.18

20.4

 

0.54

 

 

 

10.00

11.17

15.4

 

0.45

 

14/19CBi LPG

19.05

20.57

25.4

 

0.84

 

 

 

16.52

17.96

19.0

 

0.73

 

 

 

 

14.00

15.38

13.9

 

0.63

 

19/24CBi LPG

23.45

25.74

29.9

 

1.05

Natural Gas: Net Input = Gross Input x 0.901

 

 

 

21.25

23.35

24.6

 

0.96

 

 

19.05

21.16

20.2

 

0.87

Propane: Net Input = Gross Input x 0.921

Table 2.

FLUE DETAILS

HORIZONTAL FLUE

 

 

 

mm

 

 

 

 

 

 

 

WALL HOLE DIAMETER

 

EXTERNAL FIX

110

 

 

 

 

 

 

 

 

 

 

 

INTERNAL FIX

150

 

 

 

 

 

 

 

 

STANDARD TELESCOPIC FLUE KIT

 

 

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)

 

 

 

 

 

 

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

Table 3 9/14CBi

 

 

Table 3 14/19CBi

 

 

HYDRAULIC RESISTANCE

BOILER OUTPUT

RESISTANCE

MIN. FLOW RATE

FLOW/RETURN

DIFFERENTIAL

kW

Metres

L/min.

°C

 

 

 

 

9.0

0.06

6.5

20

 

 

 

0.13

11.7

11

 

 

 

 

 

14.0

0.28

18.2

11

 

 

 

 

NOTE: Pump is fitted externally

HYDRAULIC RESISTANCE

BOILER OUTPUT

RESISTANCE

MIN. FLOW RATE

FLOW/RETURN

DIFFERENTIAL

kW

Metres

L/min.

°C

 

 

 

 

14.0

0.09

10

20

 

 

 

0.26

18.2

11

 

 

 

 

 

19 .05

0.52

24.8

11

 

 

 

 

Table 3 19/24CBi

 

 

 

HYDRAULIC RESISTANCE

 

BOILER OUTPUT

RESISTANCE

MIN. FLOW RATE

FLOW/RETURN

DIFFERENTIAL

kW

Metres

L/min.

°C

 

 

 

 

19.05

0.15

13.7

20

 

 

 

0.52

24.8

11

 

 

 

 

 

23.44

0.73

30.5

11

 

 

 

 

4

Table 4

 

 

 

 

 

 

 

 

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 5

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

* 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.

 

Table 6

 

 

 

 

 

 

 

 

GAS SUPPLY SYSTEM - BASED ON NG (G20)

 

TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres

 

3

 

 

6

9

12

 

 

MAXIMUMGAS

DISCHARGERATE

-PRESSUREDROP1mbar. m3/h

PIPE DIAMETERmm

 

8.7

 

 

5.8

4.6

3.9

22

 

18.0

 

 

12.0

9.4

8.0

28

 

 

 

 

 

 

 

 

 

GAS SUPPLY SYSTEM - BASED ON PROPANE (G31)

 

TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres

 

3

 

6

9

12

PIPE DIAMETERmm

 

1.5

 

 

15

 

8.0

 

5.2

4.2

3.6

22

 

15.9

 

8.8

8.5

7.2

28

 

 

 

 

 

 

 

 

Table 7

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 *

 

 

 

**

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.

Table 8

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

 

 

 

 

 

 

5

4. Siting The Appliance

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.

Fig. 2. Appliance casing dimensions and required clearances.

Fig. 3. Appliance pipework connections

165mm

FLOW

RETURN

88mm 36mm

25mm GAS

External

 

30mm*

 

 

flue turret

100mm

30mm

 

 

 

 

 

(Rear only flue)

Rear only flue

 

 

 

Side view

 

 

260mm

600mm*

Front view

390mm

142mm

Rear only flue

600mm

200mm*

5mm*

5mm*

Fixing clip

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

6

5. Flue terminal positions

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-enterthe building. Refer to Fig 4.

Fig. 4. Siting of the flue terminal.

*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.

6. Air Supply

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.

Above Appliance (when using Rear only Flue)

30mm

Above Appliance (when using

horizontal flue)

180mm

In front

 

340mm

Below

 

200mm

Right-handside

 

105mm

Left-handside

 

105mm

 

 

 

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:

Model

Position of vent

Air from room

Air from outside

 

 

 

 

19/24CBi

High

255cm2

128cm2

 

 

 

 

 

Low

255cm2

128cm2

 

 

 

 

14/19CBi

High

207cm2

104cm2

 

 

 

 

 

Low

207cm2

104cm2

 

 

 

 

9/14CBi

High

152cm2

76cm2

 

 

 

 

 

Low

152cm2

76cm2

 

 

 

 

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.

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

B,C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L

K

 

 

 

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

HI

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

J

 

 

 

E

 

 

 

 

 

M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL POSITION

 

 

 

 

 

 

MIN. DISTANCE

 

TERMINAL POSITION

MIN. DISTANCE

A– directly below an openable window or

 

 

 

 

 

 

300mm

I–

From a terminal facing a terminal

1200mm

 

other opening e.g. air brick.

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7. System

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-overrunfunction 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-passis required if the controls i.e.2-portvalves, 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 aby-passlocated 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 R24-2aof 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.

8. Domestic Hot Water

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.

For system wiring please refer to

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

Feed and

 

 

Vent Cistern

 

 

Primary

S.H.

 

cold feed

Domestic hot

 

(15mm min.)

 

water cylinder

Heating vent

 

 

(22mm min.)

 

 

 

 

Diverting

 

 

valve

Boiler

 

Pump

 

Bypass or

150mm max

 

 

uncontrolled

 

 

 

 

radiator

 

 

(if required)

 

 

8

Fig. 10. and the controls manufacturers details.

S.H. – Minimum static head 1.2m measured from the highest point in the

heating system (top surface of the appliance S.H. 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

Radiator

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

For system wiring please refer to

Fig. 10. and the controls

 

manufacturers details.

Feed and

 

 

 

Vent Cistern

 

 

 

 

 

 

S.H. – Minimum static head 1.2m

 

 

 

measured from the highest point in the

 

 

S.H.

heating system (top surface of the appliance

Primary

 

or highest point in the heating system) to the

S.H.

 

water level in the feed and expansion tank

cold feed

Domestic hot

 

 

(15mm min.)

 

water cylinder

 

Heating vent

 

 

 

(22mm min.)

 

 

 

 

 

Diverting

N.B. A drain cock should be

 

 

valves

 

 

installed at the lowest point of

 

 

 

 

 

 

the heating circuit

Boiler

 

Pump

Radiator

 

Bypass or

 

150mm max

 

 

 

uncontrolled

 

 

 

 

 

 

radiator

 

Fig. 7. Fully pumped sealed system.

Note:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A drain cock

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LV

should be fitted

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

at the lowest RV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RV

 

 

 

 

 

point of the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

heating circuit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and beneath

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the appliance

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RV

 

 

 

 

Flow

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heating

 

 

 

 

 

 

 

 

 

 

Lockshield Valve - Return LV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Radiator Valve - Flow RV

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

Heating return

Non return

Non return

 

valve

valve

 

Hose union

 

Stop cock

Test cockTemporary hose

 

 

 

 

 

 

For system

 

 

 

 

 

 

wiring

 

 

 

 

 

 

please refer to

 

 

 

 

 

 

Fig. 10. and the

 

 

 

 

 

 

controls

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

manufacturers

INDIRECT

 

 

 

 

details.

CYLINDER

 

 

 

 

 

 

 

 

 

 

 

 

HeatingReturn

APPLIANCE

ReturnCylinder

 

 

Pressure

 

 

Gauge

Bypass

 

Expansion

Flow

Vessel

balancing valve or

 

bathroom

Water

 

radiatior with two

 

 

Relief

lockshield valves

Hot

Valve

 

 

 

Mains Cold Water

BS

Stop Valve Fixed Cylinder Type or sealed systems - Approved connection

 

 

Make up

Auto

 

vessel

 

 

Heating return air vent

Non return

 

 

valve

 

 

Stop

1200mm (48 in)

 

cock

 

above the highest

Fill point

 

point of the system.

9

9. Gas Supply

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).

10. Electrical

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.

Fig.9 . Mains electricity and controls

 

 

 

connections.

10

11

12 13

14

9

1

2

8

7

Earth post detail.

Note: Pump earth (top connection) Mains earth (bottom connection)

 

 

3

6

5

4

Pump Earth

Mains Earth

1.

Base plate

9.

Gas valve connection

2.

Control board

10. Mains lead bracket

3.

Control knob

11. Spark electrode connection

4.

Fuse 4A

12.

Air pressure switch, temperature sensor,

5.

External control connector block

 

overheat thermostat connection

6.

Earth post

13.

Fan connection

7.

Cable clamp

14.

Flame sense connection

8.Internal earth connection

10