Bosch Worcester 14/19CBI, 19/24CBI, Worcester 9/14CBI, Worcester 19/24CBI Installation And Servicing Instructions

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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 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.

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 m

/h of

natural gas (G20), 1.05 m

/h propane (G31).

The 14/19CBi appliance requires a maximum of 2.18 m

/h of

natural gas (G20), 0.84 m

/h propane (G31).

The 9/14CBi appliance requires a maximum of 1.62 m

/h of

natural gas (G20), 0.63 m

/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 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.

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. m

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 255cm

128cm

Low 255cm

128cm

14/19CBi High 207cm

104cm

Low 207cm

104cm

9/14CBi High 152cm

76cm

Low 152cm

76cm

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.

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

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 m

/h of

natural gas (G20), 1.05 m

/h propane (G31).

The 14/19CBi appliance requires a maximum of 2.18 m

/h of

natural gas (G20), 0.84 m

/h propane (G31).

The 9/14CBi appliance requires a maximum of 1.62 m

/h of

natural gas (G20), 0.63 m

/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 0.75mm

(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

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

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

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

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