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. |
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14/19CBi N.G. |
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19/24CBi N.G. |
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Minimum |
9.0 kW |
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Minimum |
14.0 kW |
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Minimum |
19.1 kW |
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Maximum |
14.0 kW |
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Maximum |
19.1 kW |
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Maximum |
23.5 kW |
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9/14CBi LPG |
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14/19CBi LPG |
19/24CBi LPG |
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Minimum |
10.0 kW |
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Minimum |
14.0 kW |
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Minimum |
19.1 kW |
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Maximum |
14.0 kW |
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Maximum |
19.1 kW |
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Maximum |
23.5 kW |
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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.
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Contents |
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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-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
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)
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Multi-Directional Horizontal Flue Kit. |
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Standard Flue Kit |
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can be adjusted from |
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425mm to 725mm without |
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cutting. |
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The minimum length is 250 |
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mm with cutting. |
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Extended flue lengths upto |
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a maximum of 2.5m |
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(19/24CBi) and 3.0m (9/14 |
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and 14/19CBi) are available. |
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Optional 45° and 90° flue |
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bend kits are available |
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NOTE: When using flue |
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bends the maximum flue |
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length is reduced (see |
Side view |
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Section 11.2.8). |
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If access to the flue is a |
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problem then this option |
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combined with an internal |
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flue fixing kit should be |
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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-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
Flow Return |
NOTE: Flow pipe is at the rear |
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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
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The data plate is fixed to the inner casing cover. |
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Table 1. |
Factory set at maximum input |
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NOMINAL BOILER RATINGS (10 Minutes After Lighting) |
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APPLIANCE |
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OUTPUT |
INPUT (Net) |
BURNER |
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GAS RATE |
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kW |
kW |
PRESSURE |
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m3/h |
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m bar. |
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9/14CBi NG |
14.00 |
15.28 |
11.0 |
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1.62 |
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11.50 |
12.70 |
7.3 |
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1.41 |
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9.00 |
10.11 |
4.5 |
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1.07 |
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14/19CBi NG |
19.05 |
20.57 |
11.5 |
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2.18 |
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16.52 |
17.96 |
8.5 |
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1.90 |
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14.00 |
15.38 |
6.0 |
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1.63 |
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19/24CBi NG |
23.45 |
25.74 |
12.0 |
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2.72 |
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21.25 |
23.35 |
9.8 |
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2.47 |
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19.05 |
21.16 |
7.8 |
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2.24 |
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9/14CBi LPG |
14.00 |
15.28 |
27.2 |
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0.63 |
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12.00 |
13.18 |
20.4 |
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0.54 |
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10.00 |
11.17 |
15.4 |
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0.45 |
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14/19CBi LPG |
19.05 |
20.57 |
25.4 |
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0.84 |
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16.52 |
17.96 |
19.0 |
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0.73 |
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14.00 |
15.38 |
13.9 |
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0.63 |
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19/24CBi LPG |
23.45 |
25.74 |
29.9 |
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1.05 |
Natural Gas: Net Input = Gross Input x 0.901 |
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21.25 |
23.35 |
24.6 |
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0.96 |
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19.05 |
21.16 |
20.2 |
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0.87 |
Propane: Net Input = Gross Input x 0.921 |
Table 2.
FLUE DETAILS
HORIZONTAL FLUE |
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mm |
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WALL HOLE DIAMETER |
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EXTERNAL FIX |
110 |
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INTERNAL FIX |
150 |
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STANDARD TELESCOPIC FLUE KIT |
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MINIMUM LENGTH |
425 |
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MAXIMUM LENGTH |
725 |
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EXTENDED FLUE |
MAXIMUM LENGTH |
2.5m (19/24CBi) or 3.0m (9/14 and 14/19CBi) |
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INTERNAL FLUE - REAR ONLY WITHIN CABINET |
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MINIMUM LENGTH |
220 |
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MAXIMUM LENGTH |
375 |
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FLUE ASSEMBLY DIAMETER |
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100 |
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VERTICAL FLUE |
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MINIMUM LENGTH |
1100 |
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MAXIMUM LENGTH INCLUDING TERMINAL |
3.35m (19/24CBi) or 4.1m (9/14 and 14/19CBi) |
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NOTE: FOR VERTICAL FLUE REFER TO A SEPARATE LEAFLET FOR INFORMATION |
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Table 3 9/14CBi |
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Table 3 14/19CBi |
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HYDRAULIC RESISTANCE
BOILER OUTPUT |
RESISTANCE |
MIN. FLOW RATE |
FLOW/RETURN |
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DIFFERENTIAL |
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kW |
Metres |
L/min. |
°C |
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9.0 |
0.06 |
6.5 |
20 |
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0.13 |
11.7 |
11 |
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14.0 |
0.28 |
18.2 |
11 |
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NOTE: Pump is fitted externally
HYDRAULIC RESISTANCE
BOILER OUTPUT |
RESISTANCE |
MIN. FLOW RATE |
FLOW/RETURN |
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DIFFERENTIAL |
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kW |
Metres |
L/min. |
°C |
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14.0 |
0.09 |
10 |
20 |
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0.26 |
18.2 |
11 |
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19 .05 |
0.52 |
24.8 |
11 |
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Table 3 19/24CBi |
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HYDRAULIC RESISTANCE |
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BOILER OUTPUT |
RESISTANCE |
MIN. FLOW RATE |
FLOW/RETURN |
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DIFFERENTIAL |
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kW |
Metres |
L/min. |
°C |
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19.05 |
0.15 |
13.7 |
20 |
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0.52 |
24.8 |
11 |
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23.44 |
0.73 |
30.5 |
11 |
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4
Table 4 |
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MECHANICAL SPECIFICATIONS |
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FLOW - COPPER TAILS |
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22mm |
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RETURN - COPPER TAILS |
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22mm |
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GAS INLET |
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15mm COMPRESSION |
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CASING HEIGHT |
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600mm |
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CASING WIDTH |
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390mm |
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CASING DEPTH |
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260mm |
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WEIGHT - LIFT |
9/14CBi 28kg |
14/19 & 19/24CBi 33.5kg |
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WEIGHT - PACKAGED |
9/14CBi 41kg |
14/19 & 19/24CBi 47kg |
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Table 5 |
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PERFORMANCE SPECIFICATIONS |
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PRIMARY WATER CAPACITY |
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9/14CBi 1.6 litres 14/19 & 19/24CBi 2.1 litres |
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STATIC HEAD |
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MINIMUM 1.2M |
MAXIMUM 30M |
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MAXIMUM FLOW TEMPERATURE |
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82°C (nom) |
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MAXIMUM CENTRAL HEATING SYSTEM OPERATING PRESSURE (Sealed System) |
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2.5 bar |
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MINIMUM CENTRAL HEATING SYSTEM SET PRESSURE |
(Sealed System) |
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0.12 bar |
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OUTPUT TO CENTRAL HEATING |
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9/14CBi 9.0 - 14.0kw |
14/19CBi 14.0 - 19.05kw 19/24CBi 19.05 - 23.45kw |
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NOx CLASSIFICATION FOR CBi APPLIANCES |
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Class 1 |
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SEDBUK NUMBER AND BAND* |
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9/14CBi NG 78.5 D |
14/19CBi |
NG 79.4 D |
19/24CBi |
NG 78.4 D |
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9/14CBi LPG 81.0 D |
14/19CBi |
LPG 81.7 D |
19/24CBi |
LPG 80.8 D |
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* 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.
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Table 6 |
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GAS SUPPLY SYSTEM - BASED ON NG (G20) |
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TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres |
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3 |
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6 |
9 |
12 |
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MAXIMUMGAS |
DISCHARGERATE |
-PRESSUREDROP 1mbar. m3/h |
PIPE DIAMETERmm |
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8.7 |
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5.8 |
4.6 |
3.9 |
22 |
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18.0 |
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12.0 |
9.4 |
8.0 |
28 |
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GAS SUPPLY SYSTEM - BASED ON PROPANE (G31) |
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TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres |
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3 |
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6 |
9 |
12 |
PIPE DIAMETERmm |
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1.5 |
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— |
— |
— |
15 |
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8.0 |
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5.2 |
4.2 |
3.6 |
22 |
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15.9 |
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8.8 |
8.5 |
7.2 |
28 |
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Table 7
CLEARANCES |
(mm) |
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INSTALLATION |
SERVICE |
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ABOVE APPLIANCE - INTERNAL REAR FLUE |
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30 |
30 |
ABOVE APPLIANCE - EXTERNAL FLUE TURRET |
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180 |
180 |
IN FRONT OF APPLIANCE |
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600 |
600 |
BENEATH APPLIANCE |
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200 |
200 |
RIGHT HAND SIDE |
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5 |
5 |
LEFT HAND SIDE |
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5 |
5 * |
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** |
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 |
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INITIAL CHARGE PRESSURE |
bar |
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PRESSURE bar |
0.5 |
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1.0 |
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1.5 |
1.0 |
72 |
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92 |
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N/A |
1.5 |
39 |
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53 |
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64 |
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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 |
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30mm* |
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flue turret |
100mm |
30mm |
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(Rear only flue) |
Rear only flue |
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Side view |
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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-enter the 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 |
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Above Appliance (when using |
horizontal flue) |
180mm |
In front |
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Below |
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Right-hand side |
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Left-hand side |
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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 |
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19/24CBi |
High |
255cm2 |
128cm2 |
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Low |
255cm2 |
128cm2 |
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14/19CBi |
High |
207cm2 |
104cm2 |
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Low |
207cm2 |
104cm2 |
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9/14CBi |
High |
152cm2 |
76cm2 |
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Low |
152cm2 |
76cm2 |
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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
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TERMINAL POSITION |
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MIN. DISTANCE |
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TERMINAL POSITION |
MIN. DISTANCE |
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A– directly below an openable window or |
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300mm |
I– |
From a terminal facing a terminal |
1200mm |
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other opening e.g. air brick. |
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J– |
From an opening in a car port (e.g. door |
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B– Below gutters, soil pipes or drain pipes.* |
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window) into dwelling. |
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C– Below eaves.* |
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25mm |
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D– Below balconies or car port roof.* |
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25mm |
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wall. |
1500mm |
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E– |
From vertical drain pipes and soil pipes.* |
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25mm |
L– |
Horizontally from a terminal on the same |
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F– |
From internal or external corners. |
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25mm |
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wall. |
300mm |
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G– Above ground, roof or balcony level. |
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300mm |
M– From door, window or air vent. |
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H– From a surface facing a terminal. |
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600mm |
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300mm |
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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-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.
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 |
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Vent Cistern |
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Primary |
S.H. |
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cold feed |
Domestic hot |
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(15mm min.) |
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water cylinder |
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Heating vent |
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(22mm min.) |
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Diverting |
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valve |
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Boiler |
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Pump |
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Bypass or |
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150mm max |
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uncontrolled |
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radiator |
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(if required) |
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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 |
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manufacturers details. |
Feed and |
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Vent Cistern |
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S.H. – Minimum static head 1.2m |
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measured from the highest point in the |
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S.H. |
heating system (top surface of the appliance |
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or highest point in the heating system) to the |
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S.H. |
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water level in the feed and expansion tank |
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cold feed |
Domestic hot |
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(15mm min.) |
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water cylinder |
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Heating vent |
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(22mm min.) |
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Diverting |
N.B. A drain cock should be |
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valves |
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installed at the lowest point of |
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the heating circuit |
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Boiler |
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Pump |
Radiator |
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150mm max |
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uncontrolled |
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radiator |
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Fig. 7. Fully pumped sealed system.
Note: |
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A drain cock |
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should be fitted |
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at the lowest RV |
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point of the |
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heating circuit |
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and beneath |
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the appliance |
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Flow |
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Heating |
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Lockshield Valve - Return LV |
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Radiator Valve - Flow RV |
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Fig. 8. Sealed system filling and make-up.
Heating return
Non return |
Non return |
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valve |
valve |
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Hose union |
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Stop cock
Test cock Temporary hose
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For system |
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wiring |
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please refer to |
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Fig. 10. and the |
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controls |
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manufacturers |
INDIRECT |
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details. |
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CYLINDER |
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HeatingReturn |
APPLIANCE |
ReturnCylinder |
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Pressure |
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Gauge |
Bypass |
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Expansion |
Flow |
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Vessel |
balancing valve or |
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bathroom |
Water |
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radiatior with two |
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Relief |
lockshield valves |
Hot |
Valve |
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Mains Cold Water
BS
Stop Valve Fixed Cylinder Type or sealed systems - Approved connection
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Make up |
Auto |
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vessel |
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Heating return air vent |
Non return |
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valve |
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Stop |
1200mm (48 in) |
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cock |
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above the highest |
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Fill point |
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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 |
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connections. |
10 |
11 |
12 13 |
14
9
1
2
8
7
Earth post detail.
Note: Pump earth (top connection) Mains earth (bottom connection)
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3 |
6 |
5 |
4 |
Pump Earth
Mains Earth
1. |
Base plate |
9. |
Gas valve connection |
2. |
Control board |
10. Mains lead bracket |
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3. |
Control knob |
11. Spark electrode connection |
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4. |
Fuse 4A |
12. |
Air pressure switch, temperature sensor, |
5. |
External control connector block |
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overheat thermostat connection |
6. |
Earth post |
13. |
Fan connection |
7. |
Cable clamp |
14. |
Flame sense connection |
8.Internal earth connection
10
Fig.10. Boiler wiring diagram
Fan
Air pressure |
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switch |
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NC |
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white |
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grey |
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NO |
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brown |
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COM |
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Overheat
Thermostat
orange
*black
Spark
Electrode
Temperature
sensor
*
violet red
Gas Valve
X4
X3
1
blue
X2
brown
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earth |
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Pump Live |
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Installer |
Pump Neutral |
X1 |
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Connections |
Permanent Neutral |
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Permanent Live |
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Switched Live (Boiler Demand) |
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*Polarity of these connections is not important.
Flame
Sense
Electrode
orange |
black |
white |
brown |
grey |
violet |
red |
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X5 |
1 |
X6 |
1 |
X7 |
Control Board
User control potentiometer/switch
3 pin header
Fig.11 . System wiring diagram
System components wired into terminal strip
in accordance with component manufacturers instructions
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Timer |
Room thermostat |
Frost stat |
Tank thermostat |
System water valves |
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System |
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wiring centre |
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Boiler/pump |
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Terminal strip |
L switched |
demand from |
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system wiring |
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centre |
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230V 50Hz |
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(5A Fuse) |
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E |
Common isolator |
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N |
for wiring centre |
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L |
and boiler |
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Should be located |
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adjacent to the |
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boiler |
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OUTSIDE OF BOILER
INSIDE OF BOILER
Pump not to be connected to system wiring centre
Pump (supplied from boiler only)
Cable clamp
Control Board
Earth post
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CONNECTION) |
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(TOP |
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Earth |
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Mains |
Earth |
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Pump |
CONNECTION) |
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(BOTTOM |
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Pump L |
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Pump N |
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Permanent N |
X1 |
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Permanent L |
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Switched L |
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(Boiler Demand) |
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12
Fig. 12a. Boiler Assembly 9/14CBi Shown set for Rear Only flue kit
17 |
18 |
16 |
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15
14
13
25
12
11
24
23
10
26
19
21
9
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
20
22
1
2
3
4
5
6
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7 |
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8 |
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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
13
Fig. 12b. Boiler Assembly 14/19 and 19/24CBi
Shown set for horizontal flue or vertical flue
17 |
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18 |
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20 |
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16 |
19 |
21 |
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22 |
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15 |
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23 |
1
2
14
3
13
27
26
4
12
11 |
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5 |
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25 |
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6 |
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24 |
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10 |
8 |
7 |
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9 |
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1. |
Inner case |
15. |
Air pressure switch |
2. |
J bolts and wing nuts (2) |
16. |
Flow pipe |
3. |
Combustion chamber cover |
17. |
Return pipe |
4. |
Burner |
18. |
Combustion test point |
5. |
Burner fixing screw |
19. |
Sensing tubes |
6. |
Control knob |
20. |
Fan |
7. |
Indicator lights |
21. Fan clamp (2 screws) |
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8. |
Base/controls fixing screw |
22. |
Inner case cover fixing points (4) |
9. |
Cabinet fixing screw |
23. |
Flue hood |
10. Gas valve |
24. |
Outer case earth tag |
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11. Spark electrode |
25. |
Side cover plate |
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12. Burner injector |
26. |
Wire clip |
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13. Temperature sensor |
27. |
Front baffle |
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14. Overheat thermostat |
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