Bosch Worcester 2000, Worcester GC2000iW C, Worcester GC2000iW 30 C NG, Worcester GC2000iW 25 C NG Installation And Maintenance Instructions Manual

0 (0)

Installation and Maintenance Instructions

Gas-fired condensing combi appliance

Worcester 2000

GC2000iW C

6 721 814 551 (2019/09) UK/IE

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Table of contents

1 Explanation of symbols and safety instructions . . . . . . . . . . . 3

1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4

2 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4 Appliance type overview . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.6 Pipe work positions and flue outlet. . . . . . . . . . . . . . . . . 8

3.7 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.8 Product data for energy consumption. . . . . . . . . . . . . . 10

3.9 Standard accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.9.1 Appliance accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.9.2 Programmer/timer accessories. . . . . . . . . . . . . . . . . . . 10

4 Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1 System preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1.1 Artificially softened water . . . . . . . . . . . . . . . . . . . . . . . 11

4.1.2 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . 11

4.1.3 System layouts examples. . . . . . . . . . . . . . . . . . . . . . . . 12

4.1.4 System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2 Mains supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2.3 Water supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 Appliance location and clearances . . . . . . . . . . . . . . . . 14

4.3.1 Appliance location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.3.2 Rooms containing a bath or shower . . . . . . . . . . . . . . . 15

4.3.3 Appliance clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.4 Flue systems considerations . . . . . . . . . . . . . . . . . . . . . 16

4.4.1 Flue length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4.2 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4.3 Plume management system. . . . . . . . . . . . . . . . . . . . . . 18

4.4.4 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.4.5 Plume re-direct and plume management terminal

positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.5 Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.1 Condensate pipe work. . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.2 Condensate production . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.3 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.4 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.6 Pressure relief discharge. . . . . . . . . . . . . . . . . . . . . . . . 28

4.6.1 Pressure relief pipe work. . . . . . . . . . . . . . . . . . . . . . . . 28

4.6.2 Alternative PRV connections - Combined PRV/

condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.7 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 29

4.7.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.1 Position the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.1.1 Mounting bracket fixing . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2 Appliance connections . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.3 Hanging the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4 Flue turret/adaptor installation. . . . . . . . . . . . . . . . . . . 33

5.5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.5.1 Installer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.5.2 Cable preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.5.3 Key (accessories). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . . 36

6.2 Water treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.2.1 Filling the appliance and adding Inhibitor. . . . . . . . . . . 37

6.3 Circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.4.1 Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.4.2 Screen display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4.3 Switching on the device. . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4.4 Setting the flow temperature. . . . . . . . . . . . . . . . . . . . . 39

6.4.5 Setting the DHW heating . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4.6 Setting the heating control device . . . . . . . . . . . . . . . . 40

6.4.7 After commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.4.8 Setting summer mode . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.5 Chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.5.1 Setting the appliance to maximum . . . . . . . . . . . . . . . . 40

6.5.2 Setting the appliance to minimum . . . . . . . . . . . . . . . . 40

6.5.3 Exiting chimney sweep mode . . . . . . . . . . . . . . . . . . . . 40

6.6 Checking gas inlet pressure. . . . . . . . . . . . . . . . . . . . . . 40

6.7 Checking the gas rate. . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.8 Checking for gas leaks during operation. . . . . . . . . . . . 41

6.9 CO and combustion check. . . . . . . . . . . . . . . . . . . . . . . 42

6.10 Checking flue integrity. . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.11 Flue gas analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.12 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 44

6.12.1 Fitting the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.12.2 Appliance/product guarantee . . . . . . . . . . . . . . . . . . . . 44

7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.1 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2 Anti-seize protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8 Settings in the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8.1 Operating the service menu . . . . . . . . . . . . . . . . . . . . . 45

8.2 Service functions overview . . . . . . . . . . . . . . . . . . . . . . 46

8.2.1 Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8.2.2 Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8.2.3 Menu 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8.2.4 Menu 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8.2.5 Menu 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.2.6 Menu 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.2.7 Menu 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.1 Inspection and maintenance considerations . . . . . . . . 51

9.2 Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.2.1 Calling up the last fault saved . . . . . . . . . . . . . . . . . . . . 51

9.3 Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

9.4.1 Checking heating block . . . . . . . . . . . . . . . . . . . . . . . . . 52

9.5 Check working gas inlet pressure . . . . . . . . . . . . . . . . . 52

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Table of contents

9.6 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

9.7 Checking the flue integrity . . . . . . . . . . . . . . . . . . . . . . . 53

9.8 Cleaning the siphon and heat exchanger . . . . . . . . . . .53

9.8.1 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . .53

9.8.2 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

9.9 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . .58

10 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

10.1 Component access. . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

10.2 Draining the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .59

10.3 Checking the strainer in the cold water pipe. . . . . . . . .59

10.4 Checking the plate heat exchanger . . . . . . . . . . . . . . . .60

10.5 Checking the expansion vessel . . . . . . . . . . . . . . . . . . .60

10.6 Adjusting the operating pressure of the heating

system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

10.7 Removing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . .60

10.8 Removing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.9 Removing the automatic air vent valve . . . . . . . . . . . . .61

10.10 Removing the motor of the diverter valve . . . . . . . . . . .61

10.11 Removing the heat exchanger . . . . . . . . . . . . . . . . . . . . 62

10.12 Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . .62

10.13 Reattaching the casing on the side . . . . . . . . . . . . . . . .63

11 Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

11.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

11.2 Table of operation and fault displays. . . . . . . . . . . . . . .64

11.3 Pump operation and diagnosis . . . . . . . . . . . . . . . . . . .71

11.4 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . . 72

12 Environmental protection/disposal. . . . . . . . . . . . . . . . . . . . .73

13 Technical Specifications/Logs . . . . . . . . . . . . . . . . . . . . . . . . .74

13.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

13.2 Component resistance characteristics . . . . . . . . . . . . .75

13.2.1 Sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

13.3 Heating curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

13.4 Internal wiring of the appliance . . . . . . . . . . . . . . . . . . .76

13.4.1 Electircal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

13.5 Setting values for output . . . . . . . . . . . . . . . . . . . . . . . .77

13.5.1 Gas setting values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

13.6 Gas Boiler System Commissioning Checklist and

Warranty Validation Record . . . . . . . . . . . . . . . . . . . . . .78

13.7 Inspection and maintenance checklist . . . . . . . . . . . . .79

13.8 Service and Interim Boiler Work Record . . . . . . . . . . . .80

1 Explanation of symbols and safety instructions

1.1 Explanation of symbols

Warnings

In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken.

The following signal words are defined and can be used in this document:

DANGER:

DANGER indicates that severe or life-threatening personal injury will

occur.

WARNING:

WARNING indicates that severe to life-threatening personal injury may

occur.

CAUTION:

CAUTION indicates that minor to medium personal injury may occur.

NOTICE:

NOTICE indicates that material damage may occur.

Important information

The info symbol indicates important information where there is no risk to people or property.

Additional symbols

Symbol Meaning

▶ a step in an action sequence  a reference to a related part in the document

• a list entry – a list entry (second level)

Table 1

Worcester 2000 – 6 721 814 551 (2019/09)

Explanation of symbols and safety instructions

1.2 General safety instructions

H Please read these instructions carefully before

starting installation.

• These instructions are applicable to the Worcester appliance model(s) stated on the front cover of this manual only and must not be used with any other make or model of appliance.

• These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations.

• This appliance must be installed by a competent registered gas engineer, such as a Gas Safe registered engineer including a British Gas engineer. Failure to install correctly could lead to prosecution.

• If you are in any doubt, contact the Worcester, Bosch Group help line (0330 123 3366).

• Distance learning and training courses are available from Worcester.

• The BENCHMARK Commissioning Checklist can be found on page 78 of this Installation manual.

H Notices for the target group

These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life.

▶ Read the installation instructions (heat source,

heating controller, etc.) before installation.

▶ Observe the safety instructions and warnings. ▶ Follow national and regional regulations, technical

regulations and guidelines.

▶ Record all work carried out.

H Intended use

The appliance may only be used for heating water or domestic hot water in domestic properties.

▶ Observe the details on the data plate and the

specifications (installation manual) to ensure correct use of this appliance.

▶ Worcester Bosch offer flue gas systems which are

suitable for use with the appliance. It is the responsibility of the designer/installer of the flue to ensure this flue gas system operates correctly and in a safe manner.

H If you smell gas

A gas leak could potentially cause an explosion. If you smell gas, observe the following rules:

▶ Prevent flames or sparks:

– Do not smoke, use a lighter or strike matches. – Do not operate any electrical switches or unplug

any equipment.

– Do not use the telephone or ring doorbells. ▶ Turn off the gas at the meter or regulator. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Move well away from the building: call the National

Gas Emergency Service on 0800 111 999. ▶ L.P.G. boilers: Call the supplier’s number on the

side of the gas tank.

H Risk to life from carbon monoxide poisoning There is a risk to life from escaping flue gases

▶ Do not modify the flue gas system. ▶ Ensure that flue pipes and gaskets are undamaged.

If flue pipes are damaged or leaking:

▶ Turn off and isolate the appliance. ▶ Open windows and doors. ▶ If necessary, leave the building and warn your

neighbours. ▶ Prevent anyone from entering the building. ▶ Rectify any damage to the flue system immediately.

H Installation and maintenance

Installation and maintenance must only be carried out by a competent registered gas engineer, such as Gas Safe registered engineer or British Gas engineer.

▶ Carry out a gas tightness test after completing work

on gas-carrying components. ▶ Only use original spares.

H Electrical work

Electrical work must only be carried out by a qualified electrician:

▶ Before starting electrical work;

– Ensure that the electricity supply is safely

Isolated and secured to prevent inadvertent reconnection. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

– Using test equipment approved to GS38 to

confirm that the electricity supply is disconnected.

▶ Refer to the manufacturer’s information when

installing non Worcester components and systems

to the Worcester appliance.

Worcester 2000 – 6 721 814 551 (2019/09)

Explanation of symbols and safety instructions

H Handover to the user

When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions.

▶ Explain how to operate the heating system and draw

the user's attention to any safety relevant action.

▶ Explain that modifications and repairs must only be

performed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer.

▶ Leave the installation instructions with the

completed Benchmark Checklist (or a certificate confirming compliance with IS 813, Eire only) and the operating instructions with the user or at the gas meter.

H Servicing

Advise the user to have the system serviced annually by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. Approved spares must be used to help maintain the efficiency, safety and reliability of the appliance.

H Benchmark Service Record

The service engineer must complete the Benchmark Service Record at the back of this manual after each service.

Benchmark places responsibilities on both manufacturers and installers.

The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot water Industry Council who manage and promote the scheme. Visit hhic.org.uk for more information.

H Combustion and corrosive materials

Do not store or use any combustible materials (paper,

thinners, paints etc.) inside or within the vicinity of the

appliance.

Chemically aggressive substances can corrode the

appliance and invalidate any warranty.

H Fitting and modification

Fitting the appliance and any controls to the appliance

may only be carried out by a competent engineer in

accordance with the current Gas Safety (Installation

and Use) Regulations.

Flue systems must not be modified in any way other

than as described in the fitting instructions. Any

misuse or unauthorised modifications to the

appliance, flue or associated components and

systems could invalidate the warranty. The

manufacturer accepts no liability arising from any such

actions, excluding statutory rights.

H General manual handling guidelines

▶ Only remove packaging at the time of the final

installation.

▶ Always use Health and Safety guidance for manual

handling of an appliance. – Never lift or carry more than the safe guidance

limit on your own.

– Always use appropriate methods and equipment

when lifting/carrying an appliance. ▶ Never lift or carry packages by the shipping straps. ▶ During handling and unpacking, wear safety gloves

to prevent injuries to your hands through sharpedged appliance components.

▶ Dispose of packing materials appropriately.

H Important handling instructions

Care should be taken when transporting, lifting and carrying the appliance.

▶ Use a means of transport suitable for handling

appliances (e.g. sack truck with strap, stair climbing or step trolley).

▶ When handling appliances, secure them against a

fall. ▶ Let only trained personnel undertake the handling. ▶ The correct method for handling heavy objects

should be strictly observed, at all times.

H Health and safety

The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).

Worcester 2000 – 6 721 814 551 (2019/09)

Regulations

2 Regulations

Installation regulations

Current Gas Safety (Installation and Use) Regulations:

All gas appliances must be installed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer in accordance with the current regulations. Failure to install appliances correctly could lead to prosecution.

The appliance must be installed in accordance with, and comply to, the current:

Gas Safety Regulations, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation),

Building Regulations (Northern Ireland), local water by-laws,

Health and Safety Document 635 (The Electricity at Work Regulations

1989) and any other local requirements.

EU Regulations No. 811/2013 - Energy Labelling.

Building Regulations Part L1A 2013 - new dwellings

If the installation is in a new build property or it is a first time installation in an existing property, the heating systems must conform to current building regulations Part L1A.

The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling can be controlled as one zone.

An alternative would be individual electronically controlled TRVs.

For dwellings with a floor area over 150m temperature control for each zone is required. It is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators except the area where the room thermostat is sited.

, separate time and

Irish Standards

The current relevant Irish standards should be followed, including:

• ECTI – National rules for electrical installations

• IS 813 – Domestic Gas Installations

Timber framed buildings

Where the appliance is to be fitted to a timber framed building the guidelines laid down in BS5440: Part 1 and IGE “Gas Installations in Timber Frame Buildings” should be adhered to.

Potable water

All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS.

CH Water

Salt based artificially softened water must not be used to fill the central heating system.

Building Regulations Part L1B 2010 - existing dwellings

For appliance replacements on an existing system, it is not necessary to zone the upstairs and downstairs separately, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat.

While the system is drained down, it is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators except the area where the room thermostat is sited.

British Standards

Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice.

• BS7074:1 – Code of practice for domestic and hot water supply

• BS6891 – Installation of low pressure gas pipe work up to 28mm (R1)

• BS5546 – Installation of gas hot water supplies for domestic purposes

• EN12828 – Central heating for domestic premises

• BS5440:1 – Flues and ventilation for gas appliances of rated heating not

exceeding 70kW (net): Flues

• BS5440:2 – Flues and ventilation for gas appliances of rated heating not

exceeding 70kW (net): Air Supply

• BS7593 – Treatment of water in domestic hot water central heating systems

• BS6798 – Installation of gas fired boilers of rated input up to 70kW (net)

• BS7671 – IET Wiring Regulations

Worcester 2000 – 6 721 814 551 (2019/09)

Product Information

3 Product Information

Appliance features

• Aluminium-silicon heat exchanger, which has an extra-large surface

area for enhanced heat exchanger efficiency.

• NOx emissions 39mg/kWh.

• Direct burner ignition.

• Zero pressure governor gas valve with fully modulating fan.

• Display for appliance status and access to diagnostics, system and

commissioning parameters.

• 1 hour memory retention after power interruption.

• Low electrical power consumption during operation and stand-by

modes.

• Modulating pump.

• Condensing in CH and DHW modes.

• Two star Hot Water Comfort measured to EN13203 Part 1 in comfort

mode with DHW pre-heat ON.

• Eco mode, to use gas on demand.

• Plate type DHW heat exchanger.

• Galvanised steel wall mounting bracket.

• Only Worcester controls, see accessories list for available controls.

– Worcester Comfort+ II RF control included with every 2000

boiler.

• Condensfit II flue systems 60/100 and 80/125 mm allows plume re-

direction.

• Condensfit II flue systems 60/100 allows the ability to attach plume

management kit.

• Front accessible components for maintenance.

3.1 Misuse

Appliance must be used as per the intended use statement. Operation outside the parameters of the intended use is considered misuse and could cause harm to people and damage to property.

Accessories should be as per accessories list. Minimum operational parameters are included in this document.

Using the appliance outside of its intended use may also invalidate the manufacturer's guarantee.

3.2 Scope of delivery

Fig. 1

[1] Wall mounted gas-fired condensing combi appliance. [2] Wall mounting bracket. [3] Fittings pack. [4] Condensate hose connector. [5] Valves set. [6] Compression fitting adapters set. [7] Literature pack:

– Installation and Maintenance Instructions, – User Instructions,

– Wall mounting template. [8] Guarantee card [9] ErP labels and system fiche. [10] Comfort+ II RF controller and Key

3.3 Declaration of Conformity

The design and operation of this product comply with European Directives and the supplementary national requirements. Conformity has been demonstrated by the CE marking.

You can ask for a copy of the declaration of conformity for this product. For this see the contact address on the back cover of these instructions.

0010029387-001

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3.4 Appliance type overview

This appliance are for use with:

• Natural Gas (Cat.II 2H type C13, C33 & C53)

This document refers to the following appliance types:

Appliance type Part number Gas Council number

GC2000iW 25 C NG 7 736 902 027 47-800-25 GC2000iW 30 C NG 7 736 902 028 47-800-24

Table 2 Type overview

The name of the appliance consists of the following parts:

• GC2000iW: Type name

• 25 or 30: Hot water output in kW

• C: Combi appliance

• NG: Gas type (Natural Gas)

Product Information

3.5 Product identification

Data plate

The data plate includes the product performance information, approval data and serial number. The data plate location can be found in the product overview.

Additional type plate

The product name and the most important product data are shown on the additional data plate. The additional type plate can be found on the outside of the product in an easily accessible location.

3.6 Pipe work positions and flue outlet

# Function From left

case edge

3 DHW Outlet 133mm 15mm

4 PRV Discharge 172.5mm 15mm

5 Gas 200mm 22mm

6 DCW Inlet 267mm 15mm

7 CH Return 332mm 22mm

Table 4 Pipe dimensions

For servicing purposes, keep condensate and pressure release valve discharge pipes away from other hydraulic components.

Diameter of pipe

• Compression fitting (via adaptor)

• Fittings not supplied

• Compression fitting (via adaptor)

Fig. 2 Pipe and flue outlet dimensions

Description Dimensions (mm)

X Appliance width 400 Y Appliance height 724 Z Appliance depth 300 W Flue centre from appliance left side 200 D Flue centre from rear of appliance 125

Table 3 Appliance and flue outlet dimensions

# Function From left

1 Condensate Outlet 60mm 22mm

2 CH Flow 68mm 22mm

Diameter of pipe

case edge

• Rubber push fit connection

• Compression fitting (via adaptor)

0010029389-001

Worcester 2000 – 6 721 814 551 (2019/09)

3.7 Product overview

Product Information

Fig. 3 Product overview

Worcester 2000 – 6 721 814 551 (2019/09)

0010029397-001

Product Information

Legend to figure 3:

[1] Inspection aperture [2] Flue connection [3] Heating block temperature limiter [4] Electrode set [5] Ignition transformer [6] Control pressure test point [7] Gas-air mixing chamber [8] Heating block [9] Gas valve [10] Condensate sump [11] Cover for inspection aperture [12] Diverter valve motor [13] Diverter valve [14] Automatic air vent [15] Heating pump [16] Pump speed adjuster and LED indicator [17] Pressure relief valve (heating circuit) [18] Plate heat exchanger [19] KEY accessory housing (wireless gateway) [20] Pressure gauge [21] Position for code plug (KIM) [22] Control unit [23] DHW temperature sensor [24] Pressure switch [25] Flow turbine [26] Fuse (replacement) [27] Condensate trap [28] Data plate [29] Condensate trap locking mechanism [30] Gas supply pressure test point [31] Flue gas temperature limiter [32] Flow temperature sensor [33] Schrader valve [34] Expansion vessel [35] Fan [36] Air-gas manifold with non-return valve [37] Heating flow [38] Flow temperature sensor at heating [39] Bracket [40] Combustion air intake

3.8 Product data for energy consumption

The product data on energy consumption can be found in the operating instructions for the user.

3.9 Standard accessories

3.9.1 Appliance accessories

Part number Description

7 716 192 746 Worcester CondenseSure 7 733 600 236 Greenstar System filter (22mm) 7 733 600 237 Greenstar System filter (28mm) 7 733 600 266 Greenstar System filter mini (22mm) 7 733 600 476 Greenstar Brass system filter (22mm) 7 716 192 610 Worcester keyless filling link 7 733 600 091 Heat exchanger cleaning kit

Table 5 Appliance accessories

3.9.2 Programmer/timer accessories

The programmers/timers listed can be used with the appliances stated on the front of this manual.

Part number Description

7 738 112 324 Comfort +II RF (programmable room

thermostat)

7 738 111 064 Sense II weather compensation controller

1) Preheat time control available

2) Landlord function is not compatible with the Worcester 2000

3) Power and gas consumption will not display accurately on the Comfort+ II RF. The electricity consumption for both CH and DHW assumes the pump is running at 100% speed permanently. As a result the indicated consumption will be the highest possible. Actual consumption is likely to be less.

Table 6 Control accessories

Bosch EasyControl smart control system

Part number Description

7 736 701 341 EasyControl (white) 7 736 701 392 EasyControl (black) 7 736 701 555 EasyControl TRV set (white) 7 736 701 556 EasyControl TRV set (black)

Table 7 EasyControl accessories

1) 2)3)

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4 Pre-Installation

NOTICE:

Risk of damage to system or appliance!

Before installation

▶ All the following Pre-Installation sections must be read and

requirements met before starting appliance or flue installations.

4.1 System preparation

4.1.1 Artificially softened water

It is possible to have an ion exchange water softener fitted to the cold water system of the property. However, the appliance requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system.

Alternatively there are water softening/treatment appliances that do not adjust or alter the pH levels of the water. With these appliances it may not be necessary to provide an untreated water by-pass to the primary water filling point of the heat system.

NOTICE:

▶ Salt based softened water must not be used to fill the central heating

system.

4.1.2 Water systems and pipe work

Primary system plastic pipework:

• Any plastic pipe work must have a polymeric barrier, complying with BS 7921 and installed to BS 5955 with 600mm (minimum) length of copper connected to the appliance.

• Plastic pipe work used for under-floor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50°C with 1000mm (minimum) length of copper or steel pipe connected to the appliance.

Primary system/connections/valves:

• Do not use galvanised pipes or radiators.

• All system connections, taps and mixing valves must be capable of sustaining a pressure of 3 bar.

• Radiator valves should conform to BS 2767:10.

• All other valves should conform to BS 1010.

• It is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators, except the area where the room thermostat is sited which must be fitted with lockshield valves that are left open.

• The circulating pump speed is fixed therefore as system

circulation can be significantly adjusted or stopped by TRV's or zone valves, a system bypass must be installed to give at least a 3 metre circuit when activated.

• Drain cocks are required at all the lowest points on the system.

• Air vents are required at all high points on the system.

Showers/Bidets:

• If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill-over level then an anti-siphon appliance must be fitted to the shower hose.

• Bidets with direct hot and cold mains water can be used (with the approval of the local water authority) and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays.

Hot water:

• Taps and mixing valves must be capable of sustaining a pressure up to 10 bar.

Pre-Installation

• Hot water temperature and flow rate are affected by the size and insulation of pipe work making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A mixing valve can be fitted if a more permanent temperature setting is required.

• If using more than one outlet at once causes water flow starvation, fit flow balancing valves or Ball-O-Fix valves to the appropriate outlets.

Primary system considerations - Combi & System appliances Sealed system

• The CH sealed system must be filled using a WRAS approved filling loop or comply with examples in 4.1.4 "System fill" section.

• Where the system volume is more than 100 litres or exceeds 2.5 bar at maximum heating temperature an additional expansion vessel [2] must be fitted as close as possible to the appliance in the central heating return.

• Pressurise the extra expansion vessel [2] to the same value as the built-in expansion vessel - refer to the Technical data page.

0010021117-001

Fig. 4 Additional expansion vessel

[1] Appliance expansion vessel [2] Additional expansion vessel [3] Pressure relief discharge [4] Heating return [5] Heating flow

Checking the size of the expansion vessel

To determine whether an additional expansion vessel is required: Follow the steps below:

▶ Calculate the total system volume (litres).

– Plot a line vertically on the chart ( Fig. 5).

▶ Determine the central heating maximum operating flow temperature.

– Plot a line horizontally on the chart ( Fig. 5).

▶ Determine the pre-charge in the expansion vessel based on static

head, 1 meter = 0.1 bar. – Static head should be measured between the expansion vessel

and the highest point on the system (top of the highest radiator). ▶ Select a curve from the key below (1-5). ▶ System pressure should be set at 0.1 - 0.25 bar higher than the

vessel pre-charge. – It must be at least to the minimum on appliances with an analogue

gauge.

– Minimum pressure settings may need to be adjusted to suit on,

appliances with a digital gauge, in the applicable menu function.

– Intelligent filling settings may need to be adjusted to suit on,

appliances with the automatic filling accessory, in the applicable

menu function.

If the dissected lines are in area A then no additional expansion is required.

If the dissected line is in are B then an additional expansion vessel must be installed ( Fig. 4).

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Pre-Installation

T[°C]

Sealed primary system - 2 x central heating zones:

• Requirement for new builds if the floor area of a property is over 150m

0 100 200 300 400 500

Fig. 5 Curves for the expansion vessel

1 Pre-charge pressure 0.5 bar (minimum) 2 Pre-charge pressure 0.75 bar 3 Pre-charge pressure 1.0 bar 4 Pre-charge pressure 1.2 bar 5 Pre-charge pressure 1.3 bar A Operational capacity of the expansion vessel (left of the relevant

curve) B Additional expansion vessel required (right of the relevant curve) T Maximum operating temperature [ °C] V Total System Volume [l]

The default pre-charge pressure for the appliance is 0.75 bar

600 700

V[l]

0010016558-002

Fig. 7 Separated heating zones

[1] Appliance [2] Zone valves

4.1.4 System fill

Integral filling link

• An optional filling link accessory is available to fill the system. – Refer to filling link instructions for fitting and operation.

Filling primary sealed systems

NOTICE:

Filling the primary sealed system

The system must not be filled with salt based softened water.

▶ Ensure the primary water filling point uses an untreated cold water

connection from the mains supply, before a water softener.

0010021228-002

4.1.3 System layouts examples

Sealed primary system - Single central heating circuit:

Typical primary system example

Fig. 6 Single central heating circuit example

[1] Appliance

0010021227-002

• Filling the system must comply with one of the following methods shown.

• The filling point must be at low level and must never be a permanent connection to the mains water supply.

• Filling loops must be WRAS approved.

• If the external filling link is sited away from the appliance, then a pressure gauge should be installed at the filling point.

External filling loop

3 3

Fig. 8 External filling loop system fill example

[1] Cold mains inlet pipe [2] Stop valve [3] Check valve [4] Test point [5] Hose union [6] Central heating flow pipe

0010012942-001

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Pre-Installation

4.2 Mains supply

4.2.1 Electrical supply

• Supply: 230V AC - 50 Hz

• This appliance must not be connected to a three phase supply.

• The wiring between the appliance and the electrical supply must comply with the latest IET wiring regulations that apply to wiring a fixed appliance for Class 1 equipment.

• The correct type of RCD must be employed where additional protection is required that is suitable for a low energy DC modulating pump according to IET wiring regulations.

• External 3 A fuse to BS1362.

• The appliance must be earthed.

• Cable: PVC insulated 0.75mm 90 °C, to BS EN50525.

• Any additional components that are connected to the appliance with mains electrical supply must not have a separate supply.

• Additional equipment wired to the appliance must comply with the latest IET wiring regulations.

• Appliance protection rating - IPX4D

4.2.2 Gas supply

• Appliances using Natural Gas (NG) must be connected to a governed meter.

• Installation and connection of the gas supply to the appliance must be in accordance with the latest version of BS6891.

• Gas pipe sizing should be calculated to ensure no more than the permitted mbar drop between the meter to the appliance inlet. ( chapter 6).

• The meter and pipe work to the meter must be checked, preferably by the gas supplier. This is to ensure that the equipment is in good working order and can meet the gas flow and pressure requirements, in addition to the demand from any other appliance being served.

Pipe sizing (NG)

Gas pipe work:

▶ Gas installation pipe work must be designed to ensure the pressure

loss between the meter outlet (NG)  table 20 ”Allowed mbar pressure drop”.

Basic pipe sizing calculation

(24 x 0.2mm) temperature rated to

Natural Gas (NG):

Discharge rates for copper tube with 1mbar differential pressure between the ends for Natural Gas.

Discharge rates for Natural Gas (m3/hr)

with straight horizontal copper tube

Pipe Pipe Size (mm)

Length (m) 15 22 28 35

2.9 8.7 18 32 6 1.9 5.8 12 22 9

1.5 4.6 9.4 17

12 Discharge 1.3 3.9 8 15 15

m3/hr 1.1 3.4 7 13 20 0.95 2.9 5.9 11 25

0.92 2.5 5.2 9.5

30 0.88 2.3 4.7 8.5

Table 8 Natural Gas

Natural Gas:

▶ When using this table to estimate the gas flow rate in pipe work of a

known length, the effective length will be increased by 0.5m for each 90° elbow and tee fitted and by 0.3m for each 90° bend.

4.2.3 Water supply

Use in hard water areas:

Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the HW heat exchanger is limited by the electronic control.

In areas where temporary water hardness exceeds 200ppm, consideration may need to be given to the fitting of a scale prevention appliance. In such circumstances, the advice of the local water authority should be sought.

Keyless filling link accessory

Minimum static pressure.

▶ A minimum static pressure of 1.75bar is recommended for correct

operation of the Keyless filling link.

Basic pipe sizing calculation.

▶ This method is only a guide - for more complex design please

refer to latest version of BS6891 and training given in ACS.

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Pre-Installation

Water mains pressure:

• Minimum mains water pressure, for maximum performance refer to section 13.1 "Technical data".

• Maximum mains fed water static pressure 10 bar. If necessary fit a pressure reducing valve.

NOTICE:

Non return, back flow prevention appliances (including those associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage the appliance and other household appliances.

NOTICE:

Non return valves in the cold water feed system.

If a non return valve is fitted on the mains inlet, then pressure can increase significantly over normal standing pressure when the appliance carries out a HW preheat or due to fast acting valves closing on other appliances/outlets.

▶ To ensure water pressure stays at a level that will not damage the

appliance or other household appliances, we would recommend that a 3bar pressure reducing valve and mini expansion vessel are fitted.

• Where the mains water supply has a non-return, back flow prevention valve fitted, a mini expansion vessel [3] should be connected to the mains water inlet pipe [1] between the non-return valve [2] and the appliance[4] as shown below.

3 4

0010015563-001

DANGER:

Danger from explosive and flammable materials:

Storage of explosive and flammable materials.

▶ Do not store flammable materials (paper, curtains, clothing, primer,

paint, …) in proximity to the appliance.

NOTICE:

Damage to appliance:

Contaminated combustion air.

▶ Do not use any cleaners containing chlorine or hydrogen halide (i.e.

spray cans, primers, cleaners, paint and glue). ▶ Do not store or use these substances in the appliance, room. ▶ Avoid the build up of dust.

NOTICE:

Damage to appliance:

Extreme temperatures may cause damage to the heating system.

▶ Ensure the appliance location’s ambient temperature is above 0 °C

and below 50°C.

NOTICE:

Damage to system:

The heating system pipe work can be damaged by frost if installed in an internal unheated area, such as a loft, basement or garage. The appliance internal frost protection only monitors the system water temperature within the appliance to provide protection for the appliance.

▶ No system frost protection available. ▶ The system pipe work in the internal unheated area should be

insulated. ▶ If the appliance is to be shut down for an extended period, drain the

central heating system.

Fig. 9 Mini expansion vessel location

[1] Mains water inlet pipe [2] Non-return valve [3] Mini expansion vessel - part no. 7 716 192 105 [4] Appliance

4.3 Appliance location and clearances

4.3.1 Appliance location

• Follow local regulations for the location within the property that the appliance is to be installed.

• This appliance is only suitable for installing internally within a property at a suitable location onto a flat, fixed rigid surface capable of supporting the appliance weight.

• The appliance is not suitable for external installation.

• Protect installation area against dust and moisture.

• Provide fresh air.

No surface protection is required against heat transfer from the appliance

The appliance must be installed where:

▶ The area is well lit, allowing to clearly see the appliance to carry out

any work or checks.

▶ An engineer can gain clear and safe access to work on the product or

component, including making adequate provision for visual inspection of flues in voids.

▶ The homeowner can gain clear and safe access to the controls, check,

top up or reset the appliance.

▶ Roof space installations must fully conform to BS 5410 part 1: roof

space installations.

▶ Products in roof spaces must have permanent fixed lighting, a

permanent fixed retractable ladder and a fixed floor area sufficient to allow access for normal use and servicing around the product and between and the access hatch. We would also recommend that a remote pressure gauge and filling loop are sited where the customer can gain easy access for checking and topping up.

Worcester 2000 – 6 721 814 551 (2019/09)

4.3.2 Rooms containing a bath or shower

CAUTION:

Risk of electric shock

▶ Any switch or appliance control using mains electricity must not be

within reach of a person using the bath or shower.

• In all cases the installation must be in accordance with the latest

amendments to the latest edition of the IET Wiring Regulations (BS7671).

• Check the IP rating of any control units to be used on this appliance.

• Circuit breaking devices should be used in accordance with the

regulations.

• Figure 10 is for guidance only.

600mm

Pre-Installation

600mm

2250mm

0010017086-001

Fig. 10 Bathroom installations

[1] Zone 1 [2] Zone 2 [2*] Without the end wall, zone 2 must extend 600mm from the bath [A] 600mm radius from the bath or shower

• Appliance protection rating - IPX4D

4.3.3 Appliance clearances

Appliance clearances

• The following details covering the installation, service and

maintenance clearances for the appliance.

CAUTION:

Risk of damage to appliance or property

The appliance will overheat if the clearance space around the appliance is restricted by objects.

▶ Do not restrict this space with the addition of cupboards, shelves etc.

next to or around the appliance.

▶ Do not store any combustible materials on or next to the appliance,

such as clothes, towels, paper or plastic bags.

Fig. 11 Appliance minimum clearances

Minimum clearances

Description Dimensions (mm)

X Appliance width 400 Y Appliance height 724

2250mm

Z Appliance depth 300

Installation/Maintenance

1 Overall clearance height 1115/1155 2 Overall clearance depth 850 3 In front of appliance 600 4 Overall clearance width 410 5 Above the appliance 191/231 6 Either side of appliance 5 7 Below the appliance 200 8 Compartment depth 320 9 Appliance to removable door 20

1) Height for either 60/100 flue or 80/125 flue

Table 9 Appliance minimum clearances

Appliances in compartments

Follow the latest requirements of BS6798 and BS5440 and note:

• Minimum clearances must be maintained.

• An access door is required to install, service and maintain the appliance and any ancillary equipment.

• If the appliance is installed in an unventilated airing/storage cupboard, there is no requirement to make a partition between the appliance and the storage space as long as the minimum clearances around the appliance are maintained.

0010012940-001

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Pre-Installation

4.4 Flue systems considerations

WARNING:

Flue systems

Possible flue gas escape

▶ Use Worcester, Bosch Group approved Condensfit II flue systems

only, no other manufacturer’s flue have been tested or approved for use with Worcester, Bosch Group appliances.

CAUTION:

Concealed flue systems:

▶ Where a flue system is going to be concealed, provision must be

made for service and inspection.

▶ Voids containing concealed flues must have at least one inspection

hatch no less than 300mm square.

▶ Flue joints within the void must not be more than 1.5 metres from the

edge of the inspection hatch. ▶ Inspection hatches should be located at changes of direction. ▶ If this is not possible, bends should be viewable from both directions.

Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions.

Flue kit part numbers

Part number Flue Ø Description

7 716 191 082 60/100 Telescopic horizontal flue kit 7 716 191 171 60/100 Extended telescopic horizontal flue kit 7 733 600 048 60/100 Horizontal high level telescopic flue kit 7 719 003 702 80/125 Telescopic horizontal flue kit 7 719 002 430 60/100 Vertical balanced flue kit 7 719 002 431 80/125 Vertical balanced flue kit

Table 10 Flue kit assembly part numbers

4.4.1 Flue length

Horizontal maximum flue lengths

Flue length [L] Flue length [L]

Appliance 60/100 80/125

GC2000iW 25 C 9,000mm 12,000mm GC2000iW 30 C 9,000mm 12,000mm

Table 11 Maximum flue lengths - Horizontal flues

Effective flue length

Bend 60/100 80/125

45° 1m 1m 90° 2m 2m

Table 13 Effective length of bends

4.4.2 Flue options

The systems have different maximum flue lengths, refer to the following example flue options for those maximum flue lengths.

Horizontal high level flue assembly

60/100 mm

383 mm - 603 mm

130 mm Min

0010015190-001

Fig. 12 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – 60/100 = 202 - 603mm – 80/125 = N/A

Telescopic horizontal flue assembly

60/100 mm

[A] 350 mm - 570 mm [B] 570 mm - 790 mm

130 mm Min

0010015191-001

Fig. 13 Horizontal flue option

Telescopic horizontal flue assembly [A]

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 180 - 570mm – 80/125 = 405 - 600mm

Extended telescopic horizontal flue assembly [B]

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 570 - 790mm – 80/125 = N/A

Horizontal fixed length flue assembly

Vertical maximum flue lengths

Flue length [L] Flue length [L]

Appliance 60/100 80/125

GC2000iW 25 C 12,000mm 15,000mm GC2000iW 30 C 12,000mm 15,000mm

Table 12 Maximum flue lengths - Vertical flues

Flue system bends

NOTICE:

Effective flue lengths of bends:

Each bend used has an equivalent straight flue length.

▶ Refer to the table 13.

1050 mm

330 mm Min

0010015192-001

Fig. 14 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 330 - 1,050mm – 80/125 = N/A

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Pre-Installation

Extended horizontal flue

0010015193-001

Fig. 15 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths".

Horizontal flue with additional 90° elbow

0010015194-001

Fig. 16 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus the 90° bend equivalent straight flue length as stated in Table 13 "Effective length of bends".

Horizontal flue with additional 90° elbows

High level horizontal flue with additional 90° elbow

0010015197-001

Fig. 19 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus the 90° bend equivalent straight flue length as stated in Table 13 "Effective length of bends".

High level horizontal flue with additional 90° elbows

0010015198-001

Fig. 20 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus 2 x 90° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

0010015195-001

Fig. 17 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus 2 x 90° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

High level horizontal flue

Fig. 18 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths".

Vertical balanced flue assembly

= 300 mm

B = 500 mm

0010015199-001

Fig. 21 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue

lengths".

0010015196-001

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Pre-Installation

Vertical balanced flue with 90° elbow offset

= 300 mm

B = 500 mm

0010015200-001

Fig. 22 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue lengths"

minus 2 x 90° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

Vertical balanced flue with 45° elbow offset

NOTICE:

Plume management length:

▶ The plume management length must be a minimum of 500mm and

must not exceed the maximum straight length for a horizontal Ø 60/ 100mm flue with a 60mm plume management system as stated previously.

Horizontal plume management runs

▶ The initial horizontal run from the terminal elbow must have a

minimum 10° fall back, (stop tabs in the elbow prevent less than 10°) to the appliance for proper disposal of condensate.

▶ Any further horizontal runs after an elbow can be 3°.

WARNING:

Minimum plume management length:

The minimum distance of 500mm must be maintained between air inlet and exhaust.

▶ Do not terminate the plume management inside the terminal

exclusion zone (shaded area) shown in figure 25.

= 300 mm

B = 500 mm

0010015201-001

Fig. 23 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue lengths"

minus 2 x 45° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

4.4.3 Plume management system

For every extra 1,000mm of plume management after the first 500mm, the internal 60/100 flue length must be reduced by 700mm, up to a maximum of 4,500mm of plume management.

2,800

2,100

1,400

[mm]

Fig. 24 Reduction to flue length as plume length increases graph

[1] Reduction to flue length [mm] (maximum reduction 2,800mm) [2] Plume length [mm] (maximum plume length 4,500mm)

700

500 1,500 2,500 3,500 4,500

[mm]

0010023114-001

±80°

0010013548-001

Fig. 25 Terminal exclusion zone

NOTICE:

Cutting the 500mm pipe

▶ The Plume management extension kit contains the components

required for such a configuration.

4.4.4 Flue terminal positions

CAUTION:

Flue terminal positions

▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products

entering the building.

Worcester 2000 – 6 721 814 551 (2019/09)

Vertical flue terminal positions

Pre-Installation

1/2

1500

RIDGE FLUERIDGE VENT

600

BOUNDARY LINE

BOUNDARIES

1500

300

500

1200

300

1500

600

300

1500

500

600

400

300

400

600

500

2000

600

1500

Fig. 26 Vertical flue terminal positions

Key to figure 26:

[1] 1,500mm measured between a vertical flue terminal and an

opening or vented window. 500mm measured horizontally between a vertical flue terminal and an opening or vented window providing the flue terminal is at least 300mm above the opening.

[2] Minimum clearance to an additional flue, 600mm to a room

sealed flue or 1,500mm to an open flue.

[3] 300mm clearance from a vertical flue terminal adjacent to a

boundary line, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting a terminal in relation to boundary lines.

[4] 600mm minimum clearance measured from an opening or vented

skylight to a vertical flue terminal. If the terminal is within 1,500mm of the opening or vented skylight then it must be at least 300mm above the opening.

[5] 500mm clearance measured horizontally from a vertical flue to a

vertical structure. Not required if the terminal is 300mm above the structure.

[6] The flue must not penetrate the roof in the shaded area.

The terminal must be at least 1,500mm from the opening or vent when sited below the window or 600mm when sited to either side or above.

[7] 400mm measured diagonally from a pitched roof or 500mm in

regions with heavy snow fall. 300mm measured vertically from the air intake to the closest intersection with the roof.

[8] 1,200mm separation measured between a vertical flue and a

horizontal flue terminal.

[9] For the purpose of determining suitable flue terminal positions for

gas appliances, the boundary can be considered to extend to the

0010021441-002

centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways.

[10] 1,500mm measured between a vertical flue terminal and an

opening or vented window. 500mm measured horizontally between a vertical flue terminal and an opening or vented window providing the flue terminal is at least 300mm above the opening.

Note:

▶ Where a vertical flue terminates in an area that is enclosed on 3 sides,

the flue must be no more than 1,000mm below the lowest roof line. You must ensure that all clearances are maintained and that products of combustion disperse safely from the area.

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Pre-Installation

Horizontal flue terminal positions

300

1500

300

BOUNDARY LINE

OPENING OPPOSITE

2000

300

600

TOP

600

SKYLIGHTDORMA

600

1500

600

200

300

200

300

600

300

600

300

1200

1000

300

1200

BOUNDARY LINE

200

1/2

100

BOUNDARIES

Fig. 27 Horizontal flue terminal positions

200

BELOW GROUND OPEN LIGHT WELL

<1000

300

100

600

300150

100

300

0010021442-002

Worcester 2000 – 6 721 814 551 (2019/09)

Key to figure 27:

[1] 200mm below eaves and 75mm below gutters, pipe and drains. [2] The dimension below eaves, gutters, pipes and drains can be

reduced to 25mm, as long as the flue terminal is extended by 100mm past any overhang. The telescopic flue joint must be sealed with suitable silicone sealant if it is external to the building.

[3] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[4] 1,200mm separation measured between terminals facing each

other.

[5] 600mm distance to a surface or boundary line facing a terminal,

unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[6] The terminal must be at least 1,500mm from the opening or vent

when sited below the window or 600mm when sited to either side or above.

[7] 600mm diagonally to an opening door, air vent or opening

window.

[8] 1,200mm separation measured between a vertical flue and a

horizontal flue terminal.

[9] For the purpose of determining suitable flue terminal positions for

gas appliances, the boundary can be considered to extend to the centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways.

[10] 300mm to an internal or external corner. 300mm above a

surface, such as the ground/ floor level or roof surface. * If the terminal section is less than 150mm and has two screws securing it to the elbow, the terminal section will not require a supporting bracket.

[11] 300mm above, below and either side of an opening door, air vent

or opening window.

[12] Below ground level in an open lightwell. The flue must be at least

600mm from the opposing surface and have at least 300mm clearance either side and below. The flue terminal must be no more than 1,000mm from the top of the lightwell.

[13] Flues should clear any LPG storage by 1,000mm horizontally and

300mm above.

[14] Proximity of flue duct outlet to boundaries, 2,000mm distance to

an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

[15] 300mm from an opening or vented window, 150mm to a fixed

unvented window.

[16] The dimension below eaves, balconies and car ports can be

reduced to 25mm, as long as the flue terminal is extended to clear any overhang. The telescopic flue joint of the terminal must be sealed with suitable silicon sealant if it is external to the building.

Pre-Installation

Note:

▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000mm from the top of a light well

due to the build up of combustion products.

▶ Dimensions from a flue terminal to a fanned air inlet to be determined

by the ventilation equipment manufacturer.

▶ A flue terminal guard shall be fitted whenever a terminal or air inlet is

fitted less than 2,000mm above ground, above a balcony or above a flat roof to which people have access.

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Pre-Installation

4.4.5 Plume re-direct and plume management terminal positions

Maximum and minimum plume management lengths:

▶ A minimum distance of 500mm must be maintained between the

plume management outlet and the flue air intake.

▶ The maximum plume management length is 4.5 metres for the

appliances detailed on the front of this manual.

▶ The 45° bend is equivalent to 0.75 metres of straight plume

management and the 90° bend is equivalent to 1.5 metres.

NOTICE:

▶ All measurements are the minimum clearances required. ▶ Refer to “Horizontal flue terminal positions” for all concentric flue

terminal positions unless the flue position is specified in figure 28 “Plume re-direct and plume management terminal positions”.

▶ Terminals must be positioned so to avoid combustion products

entering the building.

▶ Support the flue at approximately one metre intervals and at a change

of direction, use suitable brackets and fittings.

180°

±80°

200

300

200

300

150

300

600

BOUNDARY LINE

300

150

BOUNDARY LINE

TOP

200

1200

±45°

2000

600

EXCLUSION ZONE

OPENING

OPPOSITE

300

TOP

±80°

600

300

BOUNDARY LINE

600

300

150

1,500

150

300

1500

300

≥140

≥5

EXCLUSION ZONE

150

100

200

600

300

100

≥5

EXCLUSION ZONE

300

150

TOP

300

150

FLUE TERMINAL GUARD

7 716 191 176

0010021676-001

Fig. 28 Plume re-direct and plume management terminal positions

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Pre-Installation

Key to figure 28 - Plume re-direction terminal positions:

[1] This feature allows some basic plume re-direction options on a

standard telescopic horizontal flue terminal. 300mm minimum clearances to a opening e.g. window. However the minimum clearances to an opening in the direction that the plume management is facing, must be increased to 1,500mm. Where the flue is less than 150mm to a drainpipe and plume redirection is used the deflector should not be directed towards the drainpipe.

[2] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[3] Where the flow of products of combustion is not at right angles to

the boundary, the 600mm dimension may be measured in the direction of flow as long as the terminal is not less than 300mm from the boundary.

[4] When redirecting the flue discharge the terminal end must be at

least 1,500mm from any opening in the direction of the discharge to prevent combustion products from entering the building.

Key to figure 28 - Plume management terminal positions:

[5] 600mm distance facing a surface or a boundary line, unless it will

cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting a terminal in relation to surfaces or boundary lines.

[6] Proximity of flue duct outlet to boundaries, 2000mm distance to

an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

[7] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[8] 300mm distance from a boundary line to the air intake as long as

the exhaust terminal faces away from the boundary line. The exhaust terminal must have a minimum 300mm clearance to a surface below and there must be at least 600mm clearance when measured horizontally in a straight line from the exhaust terminal to any other surface.

[9] Plume Management kit air intake can be reduced to 150mm

providing the flue exhaust outlet is no less than 300mm adjacent to a boundary line.

[10] Above, below and either side of an opening door, air vent or

opening window. Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance.

[11] Below balcony or overhang. The air intake clearance can be

reduced to 150mm providing the flue exhaust outlet has a 200mm clearance.

[12] 1,200mm between terminals facing each other

[13] Internal/external corners. The air intake clearance can be reduced

to 150mm providing the flue exhaust outlet has a 300mm clearance.

[14] Clearances no less than 200mm from the lowest point of the

balcony or overhang.

[15] If a plume management kit is installed within the confines of a

carport or other covered, partially enclosed extension, then the exhaust terminal must be positioned at least 1200mm away from any opening into the building which is sited within the footprint of the carport. If the exhaust terminal is extended at least 300mm beyond the footprint of the carport then the distance from the terminal to an opening within the carport can be reduced to 600mm.

The exhaust terminal can also be routed though the roof of the carport providing 25mm clearance is provided around the flue pipe to any flammable material and that it extends at least 300mm above the roof. The air intake must have a minimum 150mm clearance to any opening in the building in order to ensure the integrity of the structure is maintained. If the exhaust terminates within the footprint of the carport then the carport must have at least 2 sides completely open. If the exhaust terminates at least 300mm beyond the footprint of the carport then the carport must have at least one completely open side. The exhaust terminal must be positioned to ensure that plume will not cause nuisance or damage to vehicles and that minimum clear distances in front of the terminal will not be impeded by vehicles.

Note:

▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000mm from the top of a light well

due to the build up of combustion products.

▶ Dimensions from a flue terminal to a fanned air inlet to be determined

by the ventilation equipment manufacturer.

▶ Plume kits running horizontally must have at least a 3° fall back to the

appliance for proper disposal of condensate, except or the initial horizontal run from the terminal. The initial plume kit horizontal run will have at least a 10° fall back to the appliance, due to the terminal elbow design, for proper disposal of the condensate.

1) 600mm in case two plume management kits are used on opposing terminals.

Each terminal should use a minimum length of 500mm plume management.

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Pre-Installation

4.5 Condensate discharge

Full details on condensate discharge.

▶ Follow the latest version of BS6798 and HHIC guidance.

For correct installation and trouble free operation of the appliance the following advice should be followed:

1. It is a requirement that the condensate drain is installed

internally.

2. If external disposal is the only means of condensate discharge, then the CondenseSure siphon or a condensate pump must be fitted.

3. All condensate pipe work must ‘fall’ from the appliance by a minimum of 3° (52mm per metre) to ensure adequate condensate flow.

4. The pipe work route must allow air to be supplied back to the appliance for correct operation.

5. Connection to a rainwater down pipe must include an air break.

Also:

• Assessment of the risk of the condensate pipe freezing must be carried out and appropriate precautions taken where necessary. This must take into account the specific site conditions.

• The condensate pipe work connected to the condensate drain outlet on the appliance should have a minimum internal diameter (ID) of 19mm.

• Keep external pipe work as short as possible. Further precautions against freezing must be taken if external pipe runs exceed 3m.

• External pipe work should have a minimum internal diameter (ID) of 30mm.

• Minimise the number of bends and connectors.

• Remove burrs after cutting pipe.

• Remove surplus solvent from the interior of the pipe.

• The condensate pipe work shall be run in standard drainpipe material, e.g. poly(vinyl chloride) (PVC), unplasticised (vinyl chloride) (PVC-U), acrylonitrilebutadiene.styrene (ABS), polypropylene (PP) or chlorinated poly(vinyl chloride) (PVC.C).

4.5.1 Condensate pipe work

NOTICE:

General consideration

▶ Where a new or replacement appliance is being installed, access to

an internal “gravity discharge” point should be one of the factors considered in determining appliance location.

▶ Condensate pipe connection at the appliance:

The condensate pipe must have a nominally outside diameter of 22mm plastic pipe.

▶ Ensure there are no blockages in the pipe run. ▶ Ensure that the discharge method for the installation can effectively

handle the condensate waste from the appliance.

4.5.2 Condensate production

When the appliance is in operation it can produce between 1 to 2 litres of condensation per hour.

This discharge is a constant drip feed during the production of condensate and does not release in frequent large volume discharges repeatedly.

4.5.3 Internal connections

Good Practice

▶ The following guidance indicates the good practices that must be

maintained for the Installation and Maintenance of a product.

Soil stack connection

 Figure 29

In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted.

Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the appliance under gravity to a suitable internal foul water discharge point such as an internal soil and vent stack. A suitable permanent connection to the foul waste pipe should be used.

0010012746-001

Fig. 29 Disposal to soil vent stack

[1] Condensate discharge from appliance [2] Soil and vent stack [3] Minimum 450mm and up to 3 storeys

NOTICE:

Unheated internal areas.

The condensate discharge may freeze in areas during prolonged cold temperatures.

▶ Internal pipe runs in unheated areas such as lofts, basements and

garages should be treated as external runs and consideration should be given to using a CondenseSure siphon.

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Pre-Installation

Waste pipe connection

 Figure 30

Alternatively if the first option is not possible an internal kitchen, bathroom or washing machine waste pipe etc. can be used. Ensure that the condensate drain pipe is connected “down stream” of the waste trap and that the condensate drain enters into the top of the pipe using a swept tee.

75mm

min.

75mm

Max.

min.

0010012767-001

Fig. 30 Waste pipe disposal

[1] Condensate discharge from appliance [5] Visible air break at plug hole [6] 75mm sink waste trap

Condensate pump

 Figure 31

Where direct connection to a “gravity discharge” pipe work is not physically possible, or where very long internal runs would be required to reach a suitable discharge point, condensate should be removed using a proprietary condensate pump, of a specification recommended by the condensate pump manufacturer.

• The pump outlet should discharge to a suitable “gravity discharge”

outlet. – The condensate then flows, by gravity, through the 22mm plastic

pipe to the condensate discharge point.

Fig. 31 Condensate pump example

[1] Condensate discharge from appliance [7] Condensate pump [8] Pipe work transition [C] Gravity discharge pipe work

Proprietary condensate pump

▶ Ensure minimum and maximum pump lifting heights are followed as

per condensate pump manufacturers instructions.

Min.

0010023656-001

4.5.4 External connections

NOTICE:

Risk of condensate discharge freezing

▶ No external disposal of condensate unless the CondenseSure

siphon or a condensate pump is fitted.

NOTICE:

Rainwater down pipe or external drain disposal

Untreated condensate must not be allowed to flow into streams or rivers

▶ A rainwater down pipe or an external drain shall only be used for

condensate disposal if the down pipe or external drain is connected to a combined foul and rainwater drainage system

▶ Refer to BS 6798 for more information on condensate disposal

NOTICE:

Grey water recovery system

Contamination of recovered water

▶ Condensate disposal shall not be allowed into a grey water recovery

system that is intended for re-use

External disposal considerations

NOTICE:

Freezing conditions

Frozen condensate will block the condensate drain pipe and stop the appliance from running

▶ Pipe lengths should be kept to a minimum and the routed as vertically

as possible.

NOTICE:

Condensate waste disposal

▶ Care should be taken when siting a soak-away to avoid causing

damage to existing services and building footings.

If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered. If this method is chosen then the following measures should be adopted:

▶ A CondensSure external siphon accessory (part number:

7716192746) or third party condensate pump must be used.

▶ The external run be kept as short as possible and ideally should not

exceed three metres. Additional precaution against freezing must be taken if the external pipe run does exceed three metres.

▶ The pipe should be run internally as far as possible before going

externally and the pipe diameter should be increased to a minimum internal diameter (ID) of 30mm before it passes through the wall to the exterior. The pipe should be insulated externally using suitable waterproof and weather resistant insulation.

▶ The hole through the wall for the condensate pipe should be sealed to

the building fabric on the internal and external face using a suitable building material.

▶ The external pipe should take the shortest and least exposed route to

the discharge point, and should "fall" as steeply as possible away from the appliance, with no horizontal runs in which condensate might stand.

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Pre-Installation

▶ The use of fittings, elbows etc. should be kept to a minimum and any

internal burrs on cut pipe work should be removed so that the internal pipe section is as smooth as possible.

▶ All external pipe drainage will be improved if the end is cut at 45° as

opposed to a straight cut.

▶ In situations where there are likely to be extremes of temperature or

exposure, the use of a proprietary trace-heating system for external pipe work, incorporating an external frost thermostat, should be considered. All other guidance above and the instructions for the trace heating system, should be closely followed.

▶ As well as trace heating, other methods for protecting pipe work that

are run externally should be considered to prevent freezing during prolonged periods.

– Insulation materials can be used, these should be of class “O”

grade with an outer coating that is weather proof and have a UV resistant finish. A minimum of 19mm thick insulation is recommended for 32mm external pipes.

– The use of a drain cover (such as those to prevent leaf blockage)

may offer further protection from wind chill.

– An air break on the external pipe work can reduce the risk of the

appliance being inoperable due to the blocking and backing up of the condensate.

Good Practice

▶ The following guidance indicates the good practices that must be

maintained for the Installation and Maintenance of a product.

Rain water down pipe with external air break

 Figure 32

• Refer to following example to dispose of condensate to a rain water down pipe.

• An air break or rain water hopper must be utilised, between the appliance condensate outlet and the drainpipe, outside the property, to avoid flooding of the appliance should the downpipe become obstructed.

0010012784-002

Fig. 32 Disposal into rain water down pipe

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size [10] External rain water pipe to foul water [11] External air break [12] Air gap [13] Strap-on fitting [14] 43mm 90° male/female bend [20] Rain water hopper

Open drain or gully

 Figure 33

Where the pipe terminates over an open drain or gully:

• Refer to following example to dispose of condensate to an open drain or gully.

• The pipe should terminate below the grating level, but above water level, in order to minimise “wind chill” at the open end.

• The use of a drain cover (such as those used to prevent blockage by leaves) may offer further protection from wind chill.

Fig. 33 Disposal to open drain or gully

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size

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