British Gas RD 628 Installation And Servicing Instructions

Page 1
RD 628
WALL MOUNTED COMBINATION BOILERS FOR CENTRAL HEATING
AND MAINS FED DOMESTIC HOT WATER
INSTALLATION AND
SERVICING INSTRUCTIONS
This appliance is for use with Natural Gas GC NUMBER 47 108 14 (N.G.)
GB
Domestic Central Heating
Hot Water
Minimum 8.1 kW 8.1 kW Maximum 28 kW 28 kW
IMPORTANT: THESE INSTRUCTIONS APPLY IN THE UK ONLY
AND MUST BE LEFT WITH THE USER OR AT THE GAS METER
Read the instructions before starting work - they have been written to make
the installation easier and prevent hold-ups.
Page 2
1.1 Gas Safety (Installation & Use) Regulations 1998:
It is the law that a competent person in accordance with the above regulations installs all gas appliances. 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 by-laws.
1.5 The installation should follow the recommendations of the following British Standards unless otherwise indicated. 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. BS5482 - Domestic propane gas burning installations. BS5546:1 - Installation of gas hot water supplies. BS6700 - Domestic water supply in buildings. BS6798 - Installation of gas fired hot water boilers. BS6891 - Low pressure gas pipework installations upto 28mm (R1). BS7593 - Water treatment. BS7671 - Requirements for electrical installations.
1.6 The appliance does not contain any substances which are harmful to health.
1.7 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.
1.8 These instructions cover, as far as possible, the foreseeable situations, which may arise. Contact Worcester Heat Systems Technical Department, Telephone: 08705 266241, for advice on specific installations.
2.1 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 'Log-book' is a vital document that must be completed by the installer at the time of installation. It confirms that the boiler has been installed and commissioned according to the manufacturers instructions.
Without the completion of the Log-book or a suitable document, 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.
SERVICE:
To ensure continued efficient operation of the appliance it must be checked at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage and can be up to 2 years. The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers. Any service work must be carried out by competent engineers such as British Gas or Corgi registered personnel.
2.2 General Information
The appliance is set to give the maximum output of 28 kW to the domestic hot water and to the heating system. The hot water flow rate is limited to a nominal 10 l/min at a maximum temperature rise of 40°C. The sanitary water section of the appliance is suitable for mains water pressure of upto 10bar.
2.3 Electrical Supply
230V - 50Hz. Load 180 watts. External fuse 3A (to BS 1362), Internal fuses F1 - 2A, F2 - 1.25A (20mm).
2.4 Gas Supply
The appliances require a maximum of 3.25 m
3
/h of natural gas (G20). The installation and the connection of the gas supply to the appliance must be in accordance with BS6891. The meter or regulator should deliver a dynamic pressure of 20 mbar (G20) which is equivalent to about 19 mbar at the gas valve inlet pressure test point.
2.5 Installation
The appliance is suitable for indoor installation only and for use with a sealed system only. Do not place anything on top of the appliance. This is a room sealed appliance and a separate combustion air supply is not required in any room or compartment in which the appliance is fitted. If the appliance is fitted in a cupboard or a compartment is built around it after installation, then the structure must conform to the requirements of BS6798 and BS5440 Part 2. However, because of the low casing losses, there is no need for cooling ventilation openings in the compartment as long as increased clearances are used. See Fig. 5. The spaces specified for servicing must be maintained.(See Table 8). There is space for the service pipes to pass at the back of the appliance.
2. Introduction1. Installation Regulations
2
1. Installation Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 10. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 11. Installing the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
3. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4 12. Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . Page 21
4. Siting the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7 13. Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 24
5. Flue Terminal Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8 14. Inspection and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . Page 24
6. Air Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9 15. Replacement of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 27
7. Sealed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9 16. Short Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 32
Open Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9 17. Operational Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . Page 34
8. Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10 18. Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 36
9. Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
Page 3
2.6 Flue
Multi-Directional Horizontal Flue Kit.
Standard Flue Kit can be adjusted from 425mm to 725mm without cutting. The minimum length is 265 mm with cutting. Extended flue lengths up to a maximum of 4m for natural gas appliances. 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 terminal could be a problem then a kit is available to enable the horizontal flue to be fitted from inside the house. A vertical flue system is available. The flue terminal fitted to the outside wall must not be obstructed or damaged. A terminal guard Type K2 GC 393553 is available from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
2.7 Controls
The appliance has controls for switching the appliance On or Off, [this does not electrically isolate the appliance] for adjusting the CH and DHW temperatures. The CH control knob also switches the CH off and on. A room thermostat and/or an externally mounted programmer for mains voltage operation may be connected to the appliance.
2.8 System
All dirt must be flushed from the system before connecting the appliance. The system can be pre-piped and flushed before the appliance is fitted. The connections in the system must withstand an operating pressure of up to 3 bar. Radiator valves must conform to BS2767: 10:1977. Table 3 gives the pump head available for the system and the required temperature differential. A drain cock must be fitted to the lowest point and an air vent to the highest point of the system.
2.9 Showers, Bidets, Taps and Mixing Valves
All taps and mixing valves must be suitable for the available mains pressure and temperatures upto 65
o
C. It may be necessary to fit a pressure reducing valve. Hot and cold mains fed water can be supplied to overrim bidets but is subject to local water company requirements. The flow of water from individual outlets varies on all mains fed systems that are not fitted with flow balancing valves. Thermostatically controlled or pressure equalising shower valves give extra comfort and protection. If a pressure equalising valve is fitted then the domestic hot water temperature should be set to maximum.
2.10 Safety The appliance must not be operated with the inner casing cover removed or without being full of water and pressurised. The gas and electricity supplies must be turned off before working on the appliance.
Temperature monitoring controls are fitted to prevent overheating. Automatic frost protection is provided together with automatic pump seizure protection. The gas valve solenoids are automatically checked for gas soundness.
IMPORTANT: Where back-flow prevention devices, including water meters, are fitted the expansion of hot water into cold water main can be prevented. This can result in a pressure build-up that may cause damage to the boiler and household devices such as showers, washing machines etc.
In these cases we recommend that a mini-expansion vessel be fitted adjacent to the boiler in the cold water pipe.
2.11 Operation
2.11.1 Central Heating:
A demand for heat will ignite the burner. It will operate at minimum pressure for 15 seconds before increasing to the maximum pressure over a period of 1 minute and then automatically match the system requirements. At the end of the demand the burner will go out, the pump will continue to run for upto 4 minutes or the fan for 15 seconds. There is an anti-cycle time of 3 minutes.
2.11.2 Domestic Hot Water:
A demand for hot water will light the burner. The pressure will immediately rise to maximum. At the end of the demand the fan will continue to run for 15 seconds if there is no heating demand. There is an anti-cycle time of 10 seconds.
2.11.3 Domestic hot water & Central Heating mode
**The demand for hot water will override the CH function when the appliance is in the heating and hot water mode of operation. In winter it may be necessary to reduce the flow at the taps to maintain the delivery temperature.
Fig. 1. Facia controls
3
Fig. 2. Water flow diagram.
1
2
3
4
7
6
1. Mains On/Off control 5. Optional programmer
2. CH temperature control 6. Lockout indicator light and
3. DHW temperature control reset button
4. System pressure gauge 7. Burner indicator light
5
1
2 3 4
7
6
1. CH flow 7. Circulating pump
2. Domestic hot water flow 8. Expansion vessel
3. Domestic hot water supply 9. Primary heat exchanger
4. CH return 10. Automatic air vent
5. Pressure relife valve discharge 11. By pass
6. Domestic water flow turbine
5
8
9
10
11
Page 4
4
3. Technical Data
MAXIMUM AVAILABLE PUMP HEAD
BOILER OUTPUT HEAD MIN. FLOW RATE
kW Metres L/min. °C
6.9 5.2 9 11 12 3.8 15.6 11 18 1.8 22 11.7 28 1.8 22 18
Table 3
MECHANICAL SPECIFICATIONS
CENTRAL HEATING FLOW - COMPRESSION 22mm RETURN - COMPRESSION 22mm COLD WATER INLET - COMPRESSION 15mm DOMESTIC WATER FLOW - COMPRESSION 15mm GAS INLET Rp
3
4
RELIEF VALVE DISCHARGE (PUSH-IN) 15mm CASING HEIGHT 740mm CASING WIDTH 440mm CASING DEPTH 360mm WEIGHT - LIFT (2 person lift) 36kg WEIGHT - PACKAGED 50kg WEIGHT - DRY 40kg
Table 4
FLUE DETAILS
HORIZONTAL FLUE
WALL HOLE DIAMETER EXTERNAL FIX mm 110
INTERNAL FIX mm 130
STANDARD FLUE MINIMUM LENGTH mm 275/*425
MAXIMUM LENGTH mm 725 EXTENDED FLUE MAXIMUM LENGTH mm 4000 FLUE ASSEMBLY DIAMETER mm 100
Table 2.
FLOW/RETURN
DIFFERENTIAL
* NOTE : Minimum uncut length
NOMINAL BOILER RATINGS (10 Minutes After Lighting)
BOILER ADJUSTED FOR G20 (Natural Gas)
OUTPUT INPUT (Net) GAS RATE
kW kW m bar. m
3
/h
8.1 9.2 0.7 0.97 28 30.7 13.1 3.25
Table 1.
BURNER
PRESSURE
Natural Gas: Net Input = Gross Input x 0.901
NOTE: With longer flue lengths, not using a restrictor, the mini­mum burner pressure will rise to 1.1mbar on G20 appliances.
Page 5
PERFORMANCE SPECIFICATIONS
PRIMARY WATER CAPACITY litres 2.0 IP RATING (WHOLE OF BOILER) - WITH/WITHOUT PROGRAMMER FITTED IP 20 MAXIMUM MAINS INLET PRESSURE bar 10 MINIMUM MAINS INLET PRESSURE (WORKING) FOR MAXIMUM FLOW bar 1.0 MINIMUM MAINS INLET PRESSURE (WORKING) FOR OPERATION bar 0.25 DOMESTIC HOT WATER TEMPERATURE RANGE °C 40 - 60 MAXIMUM CENTRAL HEATING FLOW TEMPERATURE °C 82 (nom) MAXIMUM CENTRAL HEATING SYSTEM SET PRESSURE bar 2.65 MINIMUM CENTRAL HEATING SYSTEM PRESSURE bar 0.5 OUTPUT TO CENTRAL HEATING & DHW kW NATURAL GAS (G20) 28 DOMESTIC HOT WATER SPECIFIC RATE - 30°C RISE l/min 13.5 MAXIMUM DOMESTIC HOT WATER FLOW RATE - 40°C RISE l/min 10 FLUE GAS MASS FLOW RATE 17.4 FLUE GAS TEMPERATURE °C 146.0 NOx CLASSIFICATION Class 3 SEDBUK NUMBER 78.2 SEDBUK BAND* D
5
GAS SUPPLY SYSTEM - BASED ON NG (G20)
TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres
3 6 9 12
GAS DISCHARGE RATE - PRESSURE DROP mbar. m
3
/h PIPE DIAMETER mm
8.7 5.8 4.6 3.9 22
18.0 12.0 9.4 8.0 28
Table 7
CLEARANCES (mm)
INSTALLATION SERVICE UNVENTILATED COMPARTMENT
ABOVE FLUE ELBOW 30 3 0 15 0 IN FRONT OF APPLIANCE 600 600 *240 BENEATH APPLIANCE 200 200 200 RIGHT AND LEFT HAND SIDE 10 10 80
Table 8
SYSTEM CAPACITY
TOTAL SYSTEM VOLUME litres
INITIAL INITIAL CHARGE PRESSURE bar PRESSURE bar 0.5 1.0 1.5
1.0 57 75 N/A
1.5 31 42 52
Table 9
Refer to Section 6. * Front clearance is to a removable panel (eg. door)
DOMESTIC HOT WATER TEMPERATURE RISE
DISCHARGE RATE l/min 7 8 9 10
TEMPERATURE RISE °C 57 50 45 40
Table 6
Table 5
* The value is used in the UK Government Standard Assessment Procedure [SAP] for the energy rating of dwellings. The test data from which it has been calculated have been certified by the GASTEC notified body.
Page 6
Fig. 4. Appliance casing dimensions and
required clearances (side view).
All dimensions in mm
Fig. 6. Side flue opening
A CH Flow = 75 B DHW Flow = 140 C Gas = 205 D Cold Water Inlet = 270 E CH Return = 335 F Relief Valve Discharge = 395
Fig. 3. Appliance casing dimensions and required clearances for installation/servicing
All dimensions in mm
30
150
10
10
6
B
C
D
E
190
(A, B, C, D,)
20
A B C D E
F
View of underside of appliance showing
connections
Valves shown closed.
Fig. 7. Pipework connections
All dimensions in mm
11 4
600
740
230
360
200
200
F
All dimensions in mm
11 4
Fig. 5. Unventilated compartment clearances
230
200mm
150mm from the top of the flue elbow
80mm
80mm
240mm
From a removable panel eg. door
A
Page 7
The appliance may be installed in any room but refer 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. Where a room sealed 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 IP rating of the appliance does not allow the appliance to be fitted in the shaded areas as shown in fig. A. The appliance is NOT suitable for external installation No special wall protection is required. 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 8 and Fig.3, 4. The appliance can be installed in a cupboard/compartment to be used for airing clothes providing that the requirements of BS6798 and BS5440 Part 2 are followed. Refer to Section 2.5. The airing space must be separated from the boiler space by a perforated non-combustible partition. Expanded metal or rigid wire mesh is acceptable provided that the major dimension is less than 13mm. The clearance between the front of the appliance and the cupboard or compartment door should be not less than 75mm.
4. Siting The Appliance
7
Fig. A. IP Zones.
Do not fit appliance in shaded areas.
ZONE 1
ZONE 2
NOTE: ZONE 1 If a demountable shower is installed within ZONE 1, then the start of ZONE 2 will be 1.2m away from the shower outlet at the wall.
Page 8
8
K
H
H
A
G
C
D,E.
J
N
Q
F
P
Q
B
I
L
N
N
M
M
Q
I
TERMINAL POSITION MIN. DISTANCE
Aa– Directly below an opening, air brick,
opening windows etc. 300 mm
B– Above an opening, air brick,
opening windows etc. 300mm
C–Horizontally to an opening, air brick,
opening windows etc. 300mm D–Below gutters, soil pipes or drain pipes. 75mm E– Below eaves. 200 mm F–Below balconies or car port roof. (lowest point) 200 mm G–From a vertical drain pipe or soil pipe. 150 mm H–From an internal or external corner. 300 mm I–Above ground, roof or balcony level. 300 mm J–From a surface facing the terminal. 600 mm K–From a terminal facing the terminal 1200 mm L–From an opening in a car port (e.g. door
window) into dwelling. 1200 mm
M–Vertically from a terminal on the same
wall. 1500 mm
N–Horizontally from a terminal on the same
wall. 300 mm
O–From the wall on which the terminal
is mounted N/A P–From a vertical structure on the roof N/A Q– Above intersection with roof N/A
NOTE N/A = Not applicable
a
In addition, the terminal should be not nearer than 150mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
Do not fit the flue terminal less than300mm from a neighbouring property, including party walls and boundary lines.
Fig. 8. Siting of the flue terminal.
The flue system must be installed following the requirements of BS5440: 1. Standard horizontal flue kit length is 330 – 725mm with extension kits for flues upto 4m for natural gas. The terminal must not cause an obstruction or the combustion products a nuisance. Under some conditions the terminal might steam and positions where this might be a nuisance should be avoided. Refer to Fig. 8 and Fig. B. 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 flue terminal guard is available from Tower Flue Components, Vale Rise, Tonbridge, TN9 1TB.
5. Flue terminal positions
Fig. B. Siting a vertical flue terminal
Terminal position for a flat roof.
Terminal position for a pitched roof.
Page 9
6.1 A separate vent for combustion air is not required. Refer to BS5440:2. If the appliance is in a cupboard or compartment then, because of the low casing losses, it is not necessary to have any cooling ventilation for the boiler. Refer to Section 2.5. There must be increased clearance around the appliance to allow the free movement of the air. Refer to Table 8 and Fig 3, 4 and 5.
6.2 If the appliance is to be fitted in a cupboard or compartments with less clearance than the minimum clearances given in Section
4. (Siting The Appliance) then permanent vents for cooling are required. One at high level and one at low level, either direct to outside air or to a room. Both vents must pass to the same room or be on the same wall to the outside air.
6.4 The minimum free areas required are:
The system must comply with requirements of BS6798 and BS5449 and must not be operated without being full of water and correctly pressurised. Refer to Fig 8. The pressure relief valve will operate at 3 bar. The discharge pipe, of 15mm diameter, must be directed as such that the discharge of water or steam is visible, will not discharge onto the occupants of the premises or cause any damage to the premises, in particular any electrical components or wiring. The expansion vessel, to BS4814, has a capacity of 8 litres charged to 0.5 bar, which is suitable for a static head of 5 metres. A schraider type valve allows the pressure to be increased if the static head is greater than 5 metres. If the expansion vessel fails then it must be replaced with the designated spare part. Refer to BS 7074:1, BS5449 and Table 9 for a guide to the available system capacity. The maximum system design pressure is 1.5 bar. If the pressure is above 2.65 bar when the appliance is at maximum temperature then an additional expansion vessel must be fitted as near to the appliance as possible in the return pipe. The pressure gauge shows the system pressure. Fill and pressurise the system through the filling loop supplied. The system and the appliance must be fully vented. Repeated venting loses water from the system, which must be replaced. The make-up connection must be close to the appliance in the heating return pipe through an approved non-return valve. Refer to current building regulations or Good Practice Guide 302 which lists the requirements. Plastic pipes must not be directly connected to the boiler. A copper to plastic transition piece should be positioned a minimum of 600mm from the boiler. Some plastic pipes are permeable to oxygen and must be avoided. A plastic pipe with a polymeric barrier should be used. The connection to the mains water supply must have the approval of the local Water Company. The pump is set at maximum and should not be adjusted. All connections in the system must withstand a working pressure of up to 3 bar. The radiator valves must conform to BS 2767:10 and other valves to BS1010.
Open Vent System
This appliance is NOT suitable for connection to an open vent system.
7. Sealed System6. Air Supply
9
Fig. 9. Sealed primary water system.
Lockshield valve
Radiator valve
Heating return
Hot water out
Water main
British Standard stop valve. Fixed spindle type
NOTE: A drain cock should be installed at the lowest point of the heating circuit and below the level of the appliance.
Mains cold
water
Heating flow
APPLIANCE
Refer to
'Water Flow
Diagram'
Fig.2.
Cold water inlet
POSITION OF AIR FROM AIR DIRECT
AIR VENTS THE ROOM FROM OUTSIDE
HIGH LEVEL 307cm
2
154cm
2
LOW LEVEL 307cm
2
154cm
2
Page 10
It may be necessary to contact the local Water Company before connecting the appliance.
Where back-flow prevention devices, including water meters, are fitted the expansion of hot water into cold water main can be prevented. This can result in a pressure build-up that may cause damage to the boiler and household devices such as showers, washing machines etc. In these cases we recommend that a mini-expansion vessel be fitted adjacent to the boiler in the cold water pipe.
The last 600mm of mains water pipe before the appliance must be in copper. The domestic hot water circuit of the appliance is suitable for a mains pressure of upto 10bar. A pressure reducing valve must be fitted if necessary. A mains water supply isolating valve is fitted. The maximum hot water flow rate is set at the factory to 10 l/mi giving a nominal temperature rise of 40
o
C with the temperature
control at maximum. This rate is equivalent to a Specific Rate of
12.9 l/min at a rise of 30
o
C. Refer to Table 6. The temperature rise, upto the maximum set by the user, is maintained by the automatic modulation of the heat input. In winter when the mains inlet water temperature is lower it may be necessary to reduce the water flow at the tap or shower to maintain the maximum delivery temperature. It is recommended that long pipe runs to taps or showers are insulated to prevent the rapid cooling of the water. Hot and cold taps and mixing valves must be suitable for the available mains pressure. No anti-syphonage arrangements are necessary for fixed head showers. The hose of a loose-head shower must be fixed so that the shower head cannot get closer than 25mm to the top edge of the bath to prevent its immersion in the water. Alternatively the shower can be fitted with an anti-syphonage device at the flexible hose connection. Thermostatically controlled or pressure balancing shower valves will give extra comfort and guard against extreme temperature. Hot and cold mains water direct to a bidet is, subject to the approval of the local water company, permissible provided that the bidet is of the overrim flushing type. The outlets must be shrouded and unable to be fitted with a hand-held spray. No anti­syphon arrangements are needed.
LIME SCALE: In areas of temporary hardness [>200ppm of calcium carbonate] it is suggested that a proprietary scale reducer is fitted in the mains cold water connection to the appliance. Installation of a scale inhibitor assembly must be in accordance with the requirements of the local Water Company. The water hardness can be determined by reference to the local Water Company. An isolating valve should be fitted to allow servicing.
The appliance requires a maximum of 3.25m
3
/h of natural gas (G20). A natural gas appliance must be connected to a governed meter. The installation and connection 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 isolation valve (contact gas supplier if in doubt) equivalent to about 19mbar at the gas valve inlet pressure test point and that the gas flow is adequate for all the installed gas appliances operating together.
Mains supply: 230V ~ 50 Hz 180watts. External fuse 3A to BS1362. Internal fuses F1-T2A, F2-TI.25A (20mm). Spare internal fuses are supplied with the appliance. The appliance must be earthed and it must be possible to completely isolate the appliance. The mains cable must be 0.75mm
2
(24x0.20 mm) to BS6500 ­Table 15 or 16 and must be connected to the terminal ST12 marked L (red or brown lead), N (black or blue lead) and the Earth stud (green or green/yellow lead) and secured with the cable clamp. The Earth lead must still be slack when the other leads are taut. Refer to Fig 14 and 15.
The appliance must be earthed
The wiring between the appliance and the electrical supply shall comply with current IEE wiring regulations (and any local regulations which apply) for fixed wiring to a stationary appliance. NB It must be possible to completely isolate the appliance with at least 3mm contact separation in both poles. A room thermostat or externally mounted programmer must be suitable for mains voltage operation. The leads must be securely fixed in the cable clamps. See fig. 35. A fascia mounted digital programmer or mechanical timer or receiver for wireless programmable room thermostat is available as an optional extra. Instructions are supplied with the product.
10. Electrical
8. Domestic Hot Water
10
9. Gas Supply
Fig 10 - System Fill
Fig 11 - System make up
1.Central Heating Return
2.Auto Air vent
3.Non-return Valve
4.Make-up Vessel
5.Stop Cock
6.Fill Point
4
1
2
3
5
6
300mm Above
the highest point
of the system
Mains Water Supply
Page 11
Control Board
11
Fig. 12. Wiring diagram.
Fan
Flame sense electrode
Spark electrode
Spark Generator
Mains in
Link
CH sensor (front of heat exchanger)
Flow turbine
ST16
2 blue
green
2 brown
brown
blue
blue
brown
green
red
yellow
ST2
ST15
ST1
Pump
Gas valve
black
white
black
Overheat cut-off device
DHW sensor
Air
Pressure
Switch
2 green
white
black
Code Plug
Regulator
&
Solenoid
Valve
Main
Solenoid
Valve
red
black
blue
green/yellow
black
blue
black
red
black
red
white
ST5
Diagnostic
Module
Page 12
12
Fig. 13. Functional flow diagram.
On/Off
switch
ST2
(LS)
ST2
(L
R)
ST2
(N
S)
ST1
centre
pin
ST15
right
pin
Pump
Fan
ST2 Pin N
Optional link
Room
thermostat
Transformer
Fuse F2
(1.25A Slow)
Fuse F1
(2A Slow)
N
N
ST2 Pin L
LIVE
IN
Electronics
Electronics
Inputs
Outputs
Spark Indicators
Settings
Regulator valve
Spark
electrodes
Error
indicator/reset
Red
Main valve
Flow sensor
CH sensor
DHW sensor
Air pressure switch
Flame sense
Overheat cut-off
24V programmer (if applicable)
Gas valve mode switch
CH Control knob
DHW control knob
Convert AC to low
voltage electronics
Electronics/
microprocessor
(Safety Low Voltage)
Flame detect
indicator
Red
ST2
centre pole
(Ls)
(for other features)
low
high
Electronics
ST1
right
pin
Reset button
white
red
Diagnostic Module
Page 13
Note: READ THIS SECTION FULLY BEFORE COMMENCING THE INSTALLATION.
11.1 General
The appliance is only suitable for fitting to a sealed system. The flue must be installed as specified in BS5440:1 and the current Building Regulations.
11.2 Unpacking IMPORTANT HANDLING INSTRUCTIONS
1. It is advised that two people are used to carry the carton from
the van to the point of installation.
2. Once the outer carton has been removed and the ancillary components placed to one side, the boiler now stands in its base. The boiler is laid down, whilst one person straddles the boiler and lifts, tilting up the base, the companion removes the base and places it to one side.
Additional requirements for roof space installation:
3. The boiler should be first unpacked before ascending ladder to
loft space.
4. Two sets of steps should be used.
5. Two people should share the lifting of the boiler up to the loft
hatch, where the boiler is entered into the loft space tilted and slid on its back into the loft.
Once the appliance is removed from its packaging and check the contents against the packing list. Unscrew the service connections and remove the wall mounting assembly. NOTE: The wall mounting assembly can be removed from the carton without having to remove the boiler.
11.3 Site Preparation
Check that the correct position for the appliance has been chosen. Refer to Section 4 and Table 8. Check that the wall is flat and will support the weight of the appliance. Refer to Table 4.
11.4 Fixing Holes and Flue Opening
Hold the wall mounting assembly or template against the wall. Check that the assembly or template is level. Mark the position of the fixing holes and the flue opening. Refer to Fig 16. The diamond cut-out indicates the centre line of the appliance. Mark the centrelines of the pipe connections to aid the pre­plumbing of the system pipework. Pre-plumbing is not recommended if no movement in the pipes is available. Check the position of the fixing points and flue opening before drilling the fixing holes 60mm deep for the No. 12 size plugs and cutting the flue duct hole at 110mm diameter [150mm diameter
for internally fitted flues].
11.5 Wall Mounting and Manifold Assembly
Fit the plugs and insert the bottom screws. Check that all service valves are closed. Offer the assembly to the wall utilising the keyhole slots on the manifold assembly and fix to the wall. Refer to Fig 16 and 17. Check that the assembly is properly aligned before tightening the screws.
11.6 Gas and Water Pipes
Remove the gas cock and fix the appropriate fitting to connect the inlet pipe and refit. Refer Fig 16. If it is necessary for any of the pipes to run up the back of the appliance then they must be arranged to avoid the flue outlet. Pipework must not run horizontally within the limits of the casing. It is important that the pipes are not fixed near the appliance using clips that put a strain on the connections.
Before the appliance is fitted to the wall thoroughly flush the system and mains water supply.
11. Installing The Appliance
13
Fig. 16. Wall mounting assembly
20
218
75
480
60
60
65
338
740
367
All dimensions in mm
Fig. 14. Access to internal fuses and
electrical connections.
Fig. 15 . Mains electricity connections.
1
2
3
4
1. Connection cover fixing screws
2. Connection cover
3. Control panel
4. Connections
Ns
Ls
L
R
L
N
230V
MAINS
Ns
Ls
ADM
module
230V
Page 14
11.7 Install the Boiler
Pull off the clip on facia cover and remove the cabinet by unscrewing the two fixing screws, releasing the sides and lifting from the top location. Check that the gas and water valves are closed. Refer to Fig 17. Fit the new seals, in the hardware pack, to the service valves on the manifold.
Lift the appliance to the wall, engage in the top support and lower onto the manifold assembly. Tighten the gas and water connections. Fit a discharge pipe to the relief valve leading it away from any electrics or where it might be a hazard. Lower the facia to gain access. The pipe must not be less than 15mm in diameter and must run continuously downward outside the appliance. Refer to Fig 20.
14
65
65
65
65
Wall
Frame
Wall
Frame
CH
Flow
DHW
Flow
Gas
DHW
Cold Inlet
CH
Return
Fibre
Washer
Fig. 17 . Manifold assembly
All dimensions in mm
Fig. 20 . Relief valve drain connection
1
Fig. 18 . Facia cover
1
1. Appliance
2. Controls
3. Facia cover
4. Facia cover clips (4)
2
3
4
Fig. 19 . Wall mounting frame
1. Wall mounting frame
2. Hanging bracket
3. Appliance
4. Support hook
2
1
3
4
5
2
3
4
1. Pump
2. Boiler drain
3. Pressure gauge capillary
4. Relief valve
5. Relief valve drain connection (push fit)
Page 15
11.8 Air and Flue Duct Preparation
The method of installation of the flue system may be varied to suit the actual site conditions. The instructions for connecting and fixing the ducts must, however, be strictly followed.
Remove all packing material from the flue components.
Fit the flue restrictor ring by unscrewing the flue spigot from the boiler. Refer to Fig. 22. The standard telescopic flue assembly is suitable (without cutting) for flues from 425mm up to 725mm measured from the centre-line of the boiler flue outlet to the outer face of the wall. Refer to Fig.23. The minimum length of the standard flue, after cutting is 275mm. If L is greater than 725mm then extension duct kit/s will be required
- each kit extends the flue by 750mm up to a maximum of 4000 mm for natural gas boilers. See table below.
EXTENSION MAXIMUM FLUE LENGTH mm
1 1475 2 2225 3 2975 4 3725 5 4000
11.9 Measure and Cut the Ducts. General: Cut the ducts as necessary, ensuring that the cuts are
square and free from burrs. Always check the dimensions before cutting. Measure the distance L. Refer to Fig. 23, 24, 25 and 26.
The standard flue can be telescopically adjusted to any length between 425mm and 725mm measured from the centre of the turret without the need to cut the ducts. Fix the flue assembly together using the self-tapping screws provided. Refer to Fig. 23.
It will only be necessary to cut the standard assembly if L is less
than 425mm. Cut the flue turret assembly and
the terminal assembly by the same amount eg. if L=350 – remove 75mm (425-350) from each
assembly.
15
Fig. 22. Flue spigot and restrictor
1
2
3
4
Fig. 21. Inner case and facia fixing
Fig.23. Standard flue assembly
L
Fixing screw
Flue turret assembly
Appliance casing
Telescopic adjustment
Terminal assembly
3
1. Inner casing cover
2. Cabinet fixing screws (4)
3. Inner casing cover fixing screws (2)
4. Inner casing cover fixing screws (2)
5. Facia control panel
6. Controls connector cover
7. Controls connector cover fixing screws (2)
8. Programmer (optional)
9. Facia control panel fixing screw
10. Top support lug (2)
11. Bottom support lug (2)
1
4
5
7 2
6
7
10
9 8 2
11
RESTRICTOR RINGS
Flue length
Horizontal up to 725mm 78mm Horizontal above 725mm None Vertical terminal length only 1200mm 82mm Vertical flue greater than 1200mm None
1. Flue spigot fixing screws
2. Flue spigot
3. Restrictor ring
4. Flue spigot fixing holes
Page 16
It is not necessary to cut the ducts
If L is between 1175 - 1475mm (1 extension)
1925 - 2225mm (2 extension) 2675 - 2975mm (3 extension) 3425 - 3725mm (4 extension)
It will be necessary to cut the ducts
If L is between 725 - 1175mm (1 extension)
1475 - 1925mm (2 extension)
2225 - 2675mm (3 extension) 2975 - 3425mm (4 extension) 3725 - 4000mm (5 extension)
It is necessary to shorten the assembly by cutting the first extension duct assembly eg. L = 1000mm - remove 175mm from the air and flue ducts (1175 – 1000 = 175mm).
NOTE: Extension duct measurements do not include the socketed end. Unless specifically instructed the socketed end must not be removed.
Fix the flue ducts together before fixing the surrounding air duct, the cut ducts fit into the terminal assembly.
11.10 Fitting the Flue Assembly with Access to the Terminal.
Prepare the flue duct assembly as described in Section 11.8. Apply the plastic tape to the air duct to be in contact with the external brickwork. From inside push the assembly through the wall. Align the flue turret and push fully onto the spigot on the appliance. Tighten the clamping ring. Refer to Fig.27.
Make good the internal wall face and the external brickwork or rendering.
11.11 Fitting of the Flue Assembly without access to the Terminal.
The rubber gasket kit is available from Worcester Heat Systems. NOTE: A larger diameter opening in the wall is required. Refer to Table 2.
16
Fig. 24. Extension duct
L
Fixing screw
Flue turret assembly
Appliance casing
Terminal assembly
Fixing screw
Ducts of equal length
Fig. 25. Flue duct length - side
L
Flue turret assembly
Terminal assembly
Flue turret assembly
Terminal assembly
Fig. 26. Flue duct length - rear
L
Page 17
Prepare the flue assembly as described in Section 11.8. Fit the rubber sealing gasket centrally onto the terminal
assembly and tighten the clamp. Refer to Fig. 28.
Apply the plastic tape to the air duct to be in contact with the external brickwork.
From inside push the assembly through the wall so that the gasket flange is against the outer face. Refer to Fig. 28. It may be necessary to adjust the legs of the flue centering ring. Align the flue turret and push fully onto the socket on the appliance. Tighten the clamping ring. Refer to Fig 27. Seal the gap around the duct at the inner wall face with the flexible seal provided and make good.
11.12 Flue Bends.
90° and 45° bends are available. A maximum of two bends may be used in addition to the first bend on the flue turret. A 90° bend is equivalent to 750mm of straight duct. A 45° bend is equivalent to 375mm of straight duct.
A maximum flue assembly of 3250mm for natural gas is possible with 1 X 90° bend and 2500mm with 2 X 90° bends. Measure the lengths X,Y and Z. Refer to Fig.29. The maximum value of X using the turret assembly only is 506mm. Reduce the ducts to the appropriate length eg. X = 406mm, cut 100mm from the air duct and 120mm (to cover the entry into the 45° or 90° elbow) from the flue duct. Refer to Fig.30.
NOTE: The flue system ducts between the elbows, dimension Y, requires the socketed ends (of the first extension if two or more are used) to be removed and the air and flue tubes to be cut to the same length. Cut the ducts to a length Y – 162mm. Refer to Fig.29. The final section, dimension Z, of the flue system must include a section of plain duct assembly eg. an extension assembly with the sockets removed. Reduce the final section, including the terminal assembly, by the appropriate amount eg: Air duct Z - 81mm and the flue duct Z – 51mm. Refer to Fig.29.
If Z is less than 425mm it will be necessary to cut the air and flue ducts of the extension to a plain length of 100mm and reduce the length of the terminal assembly eg. Z=350mm - remove 75mm from the terminal assembly.
If Z is between 425 - 725mm it is not necessary to cut the terminal assembly or use a second extension duct as the length can be set telescopically.
17
Fig. 27 . Flue Turret Fixing
1
2
3
1. Flue turret assembly
2. Clamp
3. Appliance
Fig. 28 . Terminal assembly for internal
fitting of the flue.
Flue centering ring
Flue Terminal
Rubber sealing gasket
Clamping ring
Flue terminal
Air duct
Flue duct
Rubber sealing gasket
Fixing clamp
Fig. 29. Flue bends
X
Z
Y
Y-162
Plain tube
Page 18
If Z is greater than 725mm then two extension duct assemblies will be required, the first assembly being cut to length as plain tubes.
If more than two extension ducts are needed in any section to achieve the required length then the final section of the assembly must not be less than 275mm without cutting the terminal assembly. NOTE: The flue duct of the final extension must be 30mm longer than the air duct.
Each section must be connected to the previous section of the flue bend by fixing the flue ducts together and then similarly fixing the air ducts which engage the elbows.
Fit the assembly as described in Section 11.9, 11.10 as appropriate. Make good the internal and external brickwork or rendering.
11.13 Vertical Adaptor for Horizontal Flues
An adaptor is available for an initial short section of vertical flue. Refer to Fig. 31. Measure and cut the flue as described in Section 11.11. The first, vertical, section (equivalent to dimension X) is measured from the top of the boiler casing. Cut the vertical section of the extension duct to 167mm less than the measured distance. Do not remove the socketed ends. The minimum measured distance is 167mm. Seal the air duct to the spigot using silicone sealant.
11.14 Completion of the Installation
Check that all the gas and water connections on the manifold have been tightened. Undo the two screws and remove the connections cover panel. Refer to Fig 32.
Connect the mains supply lead to the appliance and secure in the cable clamp. Make sure the lead is isolated before connection. Refer to section 10. Check that there is sufficient loose lead to allow the release of the facia panel assembly and that the earth lead of the mains supply is longer than the live and neutral leads. Fit the facia-mounted clock or programmer. Full instructions are sent with the control. Refer to Fig 33 and 34. Connect any external controls ensuring that the leads pass through the appropriate cable clamp. Refer to Section 10 and Fig 35 and 36. Test for gas soundness as described in BS6891. If the appliance is not to be commissioned immediately, replace the connection cover panel and the cabinet. Check that the gas and electricity services have been turned off.
18
120mm
100mm
Fig. 30 - Elbow to Flue Turret
Assembly.
Fig. 31 Vertical Adaptor.
Flue Duct
Air Duct
Adaptor
Flue Spigot
Flue Turret
Bend
Fig. 32. Facia connections cover
2
2
1
1. Controls connector cover
2. Controls connector cover fixing screws (2)
*5mm
*When connecting to an elbow the flue duct must be
5mm longer than the air duct.
Fig. 33. Programmer connection
1. Facia (gently pull forward to un-clip and remove)
2. Control panel (boiler outer casing in place)
3. Programmer cover (un-clip to remove. See Fig. 34)
4. Programmer location in detail
5. Programmer connections (See Fig. 34)
6. Programmer connector plug
7. Programmer
1
2
3
5
6
4
7
Page 19
19
Fig. 34. Programmer cover
Fig. 35. Facia connections
Fig 36 - Mains Voltage External Controls
Connections
230 V room thermostat and Programmer Connections
Ns
Ls
L
R
Neutral
Live
Neutral
Live
Switched Live
Motor
1
2
3
1. Programmer connections
2. Boiler outer casing
3. Cover panel
3
4 5
15
ST2
6
Series
connection
point
7
8
9
8
10
11
12
13
14
2
2
1
1. Controls connector cover
2. Controls connector cover fixing screws (2)
3. Facia control panel
4. Earth connection (tags)
5. Earth connection (screws)
6. Cable clamp
7. Fuse F1 2A (slow)
8. Cable clamp
9. ST15 Pump
10. ST1 Fan
11. Fuse F2 1.25A (slow)
12. Code plug
13. Commissioning switch (gas valve mode switch)
14. Internal controls connectors
15. Mains and external controls connectors (230 Volt)
ST2
Remove Link
230 V Room Thermostat Connections
Ns
Ls
L
R
ST2
Neutral
Live
Switched Live
Remove Link
spare
Neutral
Ns
Ls
L
R
ST2
Remove Link
Live
Switched Live
Motor
230 V Programmer Connections
spare
Page 20
FILLING LOOP ASSEMBLY CONNECTION
The filling loop assembly is packed in a box with the installation instructions and screw pack.
Parts list of pack:
Charging Link Assembly.............................................8 716 104 592
Charging Key Assembly..............................................8 716 104 591
Filter
3
/8" Thimble........................................................8 716 104 618
4 x Socket Head Cap Screw M4x 6mm.................2 910 141 116
4 x M4 Lock Washer....................................................2 916 699 130
2 x O Ring......................................................................8 716 140 806
1. Fully close the isolating valves on both the DHW inlet and CH return connections.
2. Check that the boiler or Pre-filling Kit (7 716 192 282) is installed correctly onto the Manifold Assembly and the gas and water con­nections are tight.
3. Unscrew the blanking plugs from both the DHW inlet and CH return connections.
4. Place the filter inside the inlet side of the Charging Link ensuring that the filter mesh is inside the inlet.
5. Fit the Charging Link assembly onto the DHW inlet and CH return connections ( see Fig. 37).
Do not insert the Charging Key at this stage.
Ensure that the Charging Link is pushed in fully to the stop tabs on both sides of the Charging Link (see Fig. 38).
6. Fit two M4 screws complete with washers to each of the two con­nections. NB. It is not possible to access the third screw hole so this can be left.
Do not attempt to turn the brass hexagon connectors.
7. Ensure that the white plastic Control Screw on the Charging Link is
turned fully into its closed position (see Fig. 39).
8. Open the isolating valves on both the DHW inlet and CH return con­nections.
9. Insert the Charging Key by initially aligning the arrow on the key with the "unlock" symbol on the Charging Link body. Ensure that the key is inserted fully and turn to the "lock" position. Check that the key is secure (see Fig. 39).
10. To fill the system from the DHW inlet turn the white plastic Control Screw on the Charging Link to the fully out position.
11. Once the system has been filled turn the white Control Screw to its closed position and then remove the Charging Key by turning back to its "unlock" position and withdrawing. Store the Charging Key in the clip provided on the inside of the bottom panel. Fit the bottom panel in position.
20
Charging Key
CH Return Connection
Blanking Plug
Charging Link Assembly
Filter
M4 Screw and Washer
DHW Inlet Connection
Fig. 37.
Ta b
Fig. 38.
Ta b
Charging Key
Fig. 39.
Control Screw
Page 21
12.1 Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance with the guidelines given in BS7593: 1992 – Treatment of water in domestic hot water heating systems. Full instructions are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should be used in accordance with the manufacturers instructions. Remove all system cleanser before adding any inhibitor. Suitable flushing agents and inhibitors are available from Betz Dearborn on 0151 4209563, Fernox on 01799 550811 and Salamandor on 0121 378 0952.
Remove the cabinet by pulling off the clip-on facia cover. Unscrew the two fixing screws, release the sides and lift from the top location. Check that the electrical supply and the gas supply to the appliance are turned off and that all the water connections throughout the system are tight. Open the system valves at the appliance. Refer to Fig 17. Open all the radiator valves. Remove the automatic air vent cap. Refer to Fig 40.
Fill the system through the Worcester Filling Link and Key. Refer to Section 7, Sealed System. Vent each radiator in turn. The automatic air vent, cap removed, will vent the appliance. Refer to Fig 40. It is very important that the appliance and system are fully vented and that all air pockets are removed. Remove the cap from the pump and turn the shaft about half a turn. Replace the cap. Refer to Fig 41.
Check that the pressure relief valve operates by turning the knob anti-clockwise until it releases. Lower the facia to gain access to the relief valve. Refer to Fig 20. Water should be expelled from the discharge pipe.
The appliance [as dispatched] can accommodate a system volume of 100 litres. Refer to BS7074 Part 1, BS5449 and Table 8. If the system volume is greater then an extra vessel must be fitted as close as possible to the appliance central heating return connection and pressurised to the same figure as the integral vessel.
12.2 Set the Expansion Vessel Pressure
The charge pressure of the expansion vessel as dispatched is
0.5bar, which is equivalent to a static head of 5m [17ft]. The charge pressure must not be less than the static head at the point of connection. A Schraeder type valve is fitted to the
expansion vessel to allow the charge pressure to be increased if necessary. Refer to Fig 40. The expansion vessel must be charged to 0.35bar less than the initial system design pressure.
Note: 1bar = 10.2m = 33.5ft of water.
12.3 Set the System Pressure
Fill the system until the pressure gauge is at 2.5bar and check for leaks. Release water from the system using the relief valve test knob until the required system pressure is obtained, upto a maximum of 1.5bar. Set the pointer on the pressure gauge to record the set system pressure. If the pressure indicated on the gauge is greater than 2.65bar when operating at the maximum central heating temperature then an extra expansion vessel must be fitted to the system as close as possible to the appliance central heating return connection.
12.4 Clock/Programmer
The controls fitted to the appliance should be set up at this stage using the instructions supplied with the clock/programmer.
12.5 Checking the Burner Pressure
12.5 Check that the gas and electricity supplies are turned off. Connect a pressure gauge to the gas valve to measure the inlet and burner pressure. Refer to Fig 42.
12. Commissioning The Appliance
21
Fig. 40. Automatic air vent and combustion
test point
Fig. 41. Pump venting.
Pump
Pump cap
Electrical connections cover
Fig. 42. Gas valve.
Modulating solenoid valve
Burner pres­sure test point
Burner connection
Safety solenoid valve
Gas
Inlet pressure test point
Minimum pressure adjustment screw
Maximum pressure adjustment screw
Automatic air vent
Flue connections
Expansion vessel charg­ing point
Expansion vessel
Wall mounting frame
Combustion products test point (front cap)
Page 22
Unscrew and remove the control connector cover to display the mode switch. Refer to Fig 42. Check that all the radiator valves are open. Check that the system is fully vented, pressurised and set to the required pressure as indicated on the gauge. Set the temperature control knobs to maximum and the clock/programmer to operate continuously. Fully open a hot tap.
Set the mode switch to MAX. Refer to Fig 43. Turn on the gas and electricity supplies. A continuous spark will occur until the burner is alight and sensed by the control circuit. The burner will remain at its maximum domestic hot water pressure for 1 minute. Refer to Table 1. It should not be necessary for the gas valve to be adjusted. Note: The burner pressure is factory set and if, after checking that the dynamic (working) supply pressure is sufficient i.e. 18.5mb approx. at the gas valve inlet pressure test point, the correct pressure cannot be obtained then Worcester Heat Systems Service Department should be contacted. If the appliance does not light then check that it is not in the ‘lock-out’ state by gently pressing the reset button for 5 seconds. Refer to Fig 46. Set the mode switch to Normal (BETRIEB). Turn off the hot tap. The burner pressure will drop to the minimum setting and will ramp up to the maximum central heating pressure appropriate to the appliance and the gas. Refer to Table 1. Set the mode switch to MIN. The burner pressure will drop to the minimum burner pressure appropriate to the appliance and the gas for both the central heating and domestic hot water modes. Refer to Table 1. Test for gas soundness at the joint between the burner and the gas valve with leak detection fluid. Set the mode switch back to Normal. Turn the electricity supply off and then back on to reset the controls. Replace the controls connector panel.
12.6 Operation of the appliance
Domestic Hot Water Turn the central heating temperature control knob fully anti­clockwise. Open a hot tap near the appliance. The burner will light and go to the maximum burner pressure appropriate to the appliance and the gas. Refer to Table 1. Gradually close the tap and check that the burner pressure falls. Fully open the tap and check that the pressure rises. Close the tap and check that the burner goes out. The fan and pump may continue running until the appliance has
cooled to a pre-set temperature.
12.7 Central Heating
Check that all the radiator valves are open. Check that the system is fully vented, pressurised and set to the required pressure as indicated on the gauge. Check that the clock/programmer is set to operate continuously. Set the room thermostat and the central heating temperature control to maximum. The burner will light and the appliance will modulate its output from minimum to maximum over a period of about two minutes. Check that all the radiators are heating up evenly. Shut down all but one of the radiators and observe the burner pressure fall. Open all the radiators and check that the burner pressure rises.
Balance the system to give the required temperature differential. Refer to Table 3.
Set the room thermostat to minimum and check that the burner goes out. Reset the room thermostat to maximum and the burner will re­light and follow the normal operating procedure.
12.8 Check flame failure device
Turn off the gas service cock. The burner will go out but sparking from the electrode will continue for 10 seconds when the appliance will ‘lock-out’. After 60 seconds car
efully open the gas service cock, press the reset button and observe the burner re­light and follow the normal sequence of operation. Refer to Fig 17 and 46. Turn off the gas service cock and the electricity supply to the appliance.
Drain the system while the appliance is hot. Refill, vent and re-pressurise the system as described in Section
12.1 preceding, adding, if necessary, a suitable proprietary inhibitor. Further information is available from Betz Dearborn on 0151
4209563.
12.9 Domestic Hot Water and Central Heating
Set all controls to maximum. Turn on the electricity supply to the appliance and open the gas service cock at the appliance. The burner will light and heat will pass into the system. Turn on a hot tap and check that hot water is soon discharged from the tap. Close the tap and the burner will go off. The appliance will then return to the central heating mode and automatically balance with the system requirements.
12.10 Completion of Commissioning
Turn off the appliance and disconnect the pressure gauge and tighten the test point screw. Restart the appliance and check for gas soundness around the test point screw. Refit the cabinet. If the appliance is to be passed over to the user immediately then set the controls to the users requirements. If the appliance is to be left inoperative in frosty conditions then set the programmer, if fitted, to off. Do not turn the electricity or gas supplies off. The appliance will operate under the control of the integral frost protection facility. If there is any possibility of the appliance being left totally unused in freezing conditions then switch off the gas and electricity and drain the appliance and the system. The appliance must be fully recommissioned when it is returned to service. The venting of the system is very important.
22
Fig.43. Mode adjustment
Betrieb
Max
S4 Min
Page 23
Appliance Data Monitoring
If the external Gateway module is fitted, then the operating system must be commissioned at this stage.
Commissioning of ADM and Gateway
Check if Gateway is plugged into the telephone line and mains.
1. Remove the cover from the Gateway.
2. Unplug the power connector from the side of the Gateway.
3. Reconnect the power to the Gateway. Press and hold SW1 and SW2 within 5 seconds of powering up, see Fig. 44.
4. Observe 2 distinct ‘clicks’ from the relays on the Gateway.
5. Release the switches. Note only RED LED (RHS) ON. The
Gateway is now reset.
6. Press SW1, observe 0.5 Hz flashing of green LED. The Gateway is now in “House Address Creation mode” which lasts for approx. 1 minute.
7. Wait until GREEN LED (LHS) flashes 3 seconds ON and 1 second OFF - the Gateway has now created the “House Address”.
8. Push the switch SW1 on the ADM while powering up the appliance, see Fig. 45.
Observe LED on ADM flashing. The flashing rate is 0.5 Hz, the ADM is now in “House Address Acquisition mode”.
9. Return to the Gateway and press SW1. Observe GREEN LED (LHS) through the side of the box flashing at about 3,4 Hz. The Gateway is now in “House Address Distribution mode”
“House address Acquisition mode” on the ADM and “House Address Distribution mode” on the Gateway must overlap. Note the times are as follows, the ADM will stay in “House address Acquisition mode” for 100 seconds and the Gateway will stay in “House address Distribution mode” for 60 seconds.
10. After 100 seconds from step 8 observe ADM LED flashing at 2 Hz.
11. After 60 seconds from step 9 observe GREEN LED (LHS) on Gateway ON.
12. The Gateway will now cause the Gateway to dial into BG. A click of the relay will be heard from the Gateway at each end of the dialling in.
13. Now power down the Heatronic, remove JP1, replace all covers and power up again.
The system is now set up.
23
Fig. 44. Gateway module
SW1
SW2
LEDs
(Green, Left Hand Side Yellow, Middle Red, Right Hand Side)
SW1
LED
Fig. 45. ADM module
SENSOR
Page 24
Hand over the User Booklet. Explain how to operate the appliance safely and efficiently. Tell the user what to do if the appliance is not to be used in very cold conditions. Tell the user what to do if the system pressure falls. Explain that regular servicing will maintain the safe and efficient operation and extend the life of the appliance. Tell the user that any work on the appliance must only be carried-out by a competent, CORGI registered, person.
14.1
To ensure the continued efficient operation of the appliance it must be checked at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage and can be up to 2 years. The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers. Any service work must be carried out by competent registered engineers such as British Gas or Corgi registered personnel.
14.2 Inspection Ensure that the appliance is switched off and electrically isolated before commencing inspection.
Check that the terminal and the terminal guard, if fitted, are clear and undamaged. If the appliance is in a compartment or cupboard check that the specified service space around the appliance is clear. Refer to Table 8. Check all the joints and connections in the system and remake any that show signs of leakage. Refill and re-pressurise as described in Section 12-Commissioning. Operate the appliance and take note of any irregularities. Refer to Section 18-Fault Finding for rectification procedures. Check the combustion performance Remove the cap from the sample point on the top of the appliance. Refer to Fig 40. Connect the sampling meter. With the appliance at maximum rate and stable in the DHW mode expect readings of:
CO
2 5.6—6.4% CO 0.006—0.010%
NB For flues greater than 725mm without a restrictor the CO
2
may be up to 0.5% lower. These figures cover all flue conditions.
Refit the cap after the test. Disconnect the electrical supply at the mains and turn off the gas supply at the gas service cock on the appliance before starting any service procedures. Always test for gas soundness after the service has been completed.
14.3 Component Access
To service the appliance it may be necessary to remove some or all of the following parts to gain access to components which may need to be checked or replaced. Cabinet Pull off the clip-on facia cover. Unscrew the two
screws and release the sides. Lift up and away from the top locating pegs.
Facia Panel Unscrew the single screw, lift off and lower onto the
lower support lugs. Refer to Fig 42 & 43.
14. Inspection And Service
13. Handover
24
Fig. 47. Inner case and facia fixing
3
1. Inner casing cover
2. Cabinet fixing screws (4)
3. Inner casing cover fixing screws (2)
4. Inner casing cover fixing screws (2)
5. Facia control panel
6. Controls connector cover
7. Controls connector cover fixing screws (2)
8. Programmer (optional)
9. Facia control panel fixing screw
10. Top support lug (2)
11. Bottom support lug (2)
1
4
5
7 2
6 7
10
9 8
2
11
1
2
3
1. Mains On/Off control 5. Optional programmer
2. CH temperature control 6. Lockout indicator lamp and
3. DHW temperature control reset button
4. System pressure gauge 7. Burner indicator lamp
4
6
5
7
Fig. 48. Facia in service position
Fig. 46. Facia controls
Page 25
25
Fig. 49. Inner case components
1. Flue hood
2. Primary sensor
3. Heat exchanger
4. Combustion chamber assembly
5. Spark electrode assembly
6. Inner case cover fixing (bottom)
7. Burner assembly
3
1
4
5
8
2
6
7
9
10
11
8. Combustion chamber fixing screw
9. Inner case
10. Fan assembly
11. Inner case cover fixing (top)
12. Combustion sensor point
13. Air pressure switch
13
12
Page 26
Inner Case Cover Unscrew the four screws and remove. Refer to Fig 47. Combustion Chamber Unscrew the two screws at the top and
the two wing nut extended screws at the sides, pull forward and remove. Refer to Fig 49.
Fan Carefully pull off the electrical connections and the
tubes from the airflow-sensing device. Unscrew the four screws and remove the fan assembly. Refer to Fig 50.
Flue Hood Remove the fan. Unscrew the four screws and slide
out the hood. Refer to Fig 52.
Burner Remove the combustion chamber. Carefully pull-off
the connections to the spark electrodes. Pull off the connection to the flame sense electrode. Unscrew the support bracket. Release the union nut beneath the burner and carefully remove the burner. Refer to Fig 51.
14.4 Component Cleaning
Only use a non-metallic brush to clean components. Do not use a metal probe to clean the injectors. Clean the fan taking care not to block air flow detector. Clean the burner to ensure that the blades and injectors are clear. Clean the electrodes, replace if there is any sign of deterioration. Clean the heat exchanger. Cover the gas inlet tube and remove any deposits from the heat exchanger from the top and bottom. Carefully straighten any distorted fins on the heat exchanger. Check the combustion chamber insulation and replace if there is any sign of damage or deterioration. Refer to Section 15.5. Clean the controls in-situ using a non-metallic brush. Carefully refit any components removed in the reverse order. Check that all screws are tight and the connections properly remade with the appropriate gaskets/O-rings. Re-commission, as necessary, for correct operation to the users requirements. Refer to Section 12 Commissioning.
26
Fig. 50. Fan assembly
Fig. 52. Flue hood
Fig. 51. Burner assembly
1
2
3
1. Flue hood fixing screws (4)
2. Flue hood
3. Flue hood/Heat exchanger guide
1
2
3
4
1. Fan assembly
2. Fan assembly fixing screws (4)
3. Flue hood
4. Flue hood fixing screws (4)
5. Air Flow detector
2
3
1
4
5
1. Burner assembly
2. Spark electrode assembly
3. Spark electrode assembly fixing screw
4. Flame sense elctrode
5. Flame sense elctrode fixing screw
5
Page 27
IMPORTANT: Turn off the gas supply and electrically isolate the appliance before replacing any components.
After the replacement of any components always check for gas soundness where relevant and carry out functional checks as described in Section 12-Commissioning. Any O-ring or gasket that appears damaged must be replaced. Complete gasket and O-ring packs are available for gas and water connections on the appliance.
Component Access
Refer to Section 14, Inspection and Servicing for access to components.
Draining the Appliance
Primary System: Turn off the heating flow and return valves at the appliance. Refer to Fig 17.
Open the drain tap a short tube is already connected to the drain point. Refer to Fig. 20. Close the drain tap when the flow from the appliance has stopped.
DHW Circuit: Turn off the mains cold water supply at the appliance. Refer to Fig 16. Open a hot tap below the level of the appliance to drain the domestic hot water from the appliance.
Important: A small quantity of water will remain in some components even after the appliance has been drained. Protect any electrical components when removing items from the water circuits.
Component Replacement
Refer to Fig 47 and 49 for an indication of the location of the various components. Replace any components removed from the appliance in the reverse order using new gaskets/O-rings/sealant/heat transfer paste where necessary. Always check that any electrical connections are correctly made and that all screws are tight. Remove casing and cover panels and lower the facia onto lower lugs, as necessary, to gain access to the components. Refer to Section 14, Inspection and Servicing.
15.1 Gas Valve
Unscrew the union connections above and below the gas valve and remove the assembly. Disconnect/unplug the electrical connections from the valve. Use new gaskets when replacing the valve. Refer to Fig 53. Set the Gas Valve: Connect a pressure gauge to the burner and inlet pressure test points on the valve. Refer to Fig 42. Switch on the gas and electricity supplies. Check for gas tightness at the gas valve inlet. Refer to Section 12-Commissioning for the method of checking the pressures. Check for gas soundness at the gas valve outlet. Adjust the maximum and start pressure [minimum], as necessary, to obtain the required pressures. Switch off the appliance and disconnect the pressure gauge. and tighten the screw. Refer to section 12.5 Check for gas soundness at the test point.
15. Replacement Of Parts
27
Fig. 53 . Lower casing - gas and water
controls.
1
9
8
7
6
5
4
3
2
1. Gas valve
2. Pump
3. Pressure guage
4. Relief valve
5. Manifold assembly
6. Control panel in lowered position
7. DHW sensor
8. DHW flow turbine
9. Control panel top support
10. Drain tap
11. Drain tube
Fig. 54. Spark electrode assembly
1
3
2
1. Spark electrode assembly
2. Fixing screw
3. Burner blade assembly (LH)
10 11
Page 28
15.2 Spark Electrode
Remove the inner casing cover and the combustion chamber. Carefully pull off the lead from the electrode. Unscrew the screw and remove the assembly. Refer to Fig 54. Ensure that the electrode is at the correct height above the burner blade.
15.3 Flame Sense Electrode
Remove the inner casing cover and the combustion chamber. Remove burner as in 15.4. Carefully pull off the leads from the electrode assembly. Unscrew the screw and remove the assembly. Refer to Fig 55.
15.4 Burner
Remove the inner casing cover and the combustion chamber. Remove the spark electrode connections. Unscrew the two burner bracket fixing screws. Release the union connection beneath the burner and remove the burner from the appliance. Refer to Fig. 51. and 56. Do not omit the gasket when fitting the new burner.
28
Fig. 55. Flame sense electrode
1
3
2
1. Flame sense electrode
2. Fixing screw
3. Burner blade assembly (RH)
Fig. 56. Burner
1. Flame sense elctrode
2. Spark electrode assembly
3. Burner blade assembly (LH)
4. Burner manifold
5. Burner blade assembly location points
6. Burner blade assembly (RH)
7. Cross- lighting strip fixing screws (2)
6
2
3
1
4
7
5
5
8
9
10
10
13
12
11
8. Cross-lighting strip
9. Cross-lighting strip fixing holes (2)
10. Burner assembly
11. Burner support bracket
12. Burner fixing screw
13. Bracket fixing screws (2)
Page 29
15.5 Combustion Chamber Insulation, Front &Sides
Remove inner casing door and combustion chamber. Remove damaged insulation, replacement is the reverse of removal. See Fig 57. Removal must be by sliding panels.
Combustion Chamber Insulation, Rear Remove side panels before removing heat exchanger as
described in 15.21. Pull insulation forward and up to remove. Replacement is the reverse of removal. Refer to Fig 57.
15.6 Pressure Gauge
Remove the clip-on facia cover, cabinet and lower the facia panel onto the lower support lugs. Refer to Fig 48. Check that the appliance has been fully drained. Withdraw the clip and remove the pressure-sensing head. Refer to Fig 58. Unclip the gauge head from its mounting bracket and remove. Refer to Fig 58. Do not omit the washer from the pressure capillary when fitting the replacement gauge.
15.7 Relief Valve
Remove the clip-on facia cover, cabinet and lower the facia onto the lower support lugs. Check that the appliance has been fully drained. Unclip and pull-out the valve body. Refer to Fig 59
15.8 Flow Switch
Drain the DHW circuit as described at the start of Section 15 preceding. Remove the clip on facia cover, cabinet and lower the facia panel onto the lower support lugs. Separate the in-line connector. Remove the two fixing clips and withdraw the turbine. Refer to Fig 60. Do not omit the gaskets when fitting the replacement turbine.
29
Fig. 58. Pressure Gauge head
Fig. 59. Relief valve boiler drain connection
Fig. 54. Combustion Chamber Insulation.
2
3
1
1. Insulation panel-side
2. Insulation panel-front
3. Combustion chamber assembly
1
2
4
3
1. Pump
2. Pressure guage capillary
3. Pressure guage head
4. Mounting bracket
1
6
2
3
5
1. Pump
2. Boiler drain
3. Pressure gauge capillary
4. Boiler Drain ON/OFF
5. Relief valve
6. Relief valve drain connection (push fit)
Fig. 60. Water flow turbine.
2
2
1
1. Flow turbine
2. Flow turbine clips
4
Page 30
15.9 Inlet Water Filter
Remove the flow switch as described in 15.8 preceding. Taking care, remove flow restrictor assembly from the flow turbine. Carefully clean wire mesh by back flushing with water or replace assembly if necessary. Refer to Fig 61.
15.10 Control Board
Remove the clip-on facia cover, cabinet and the connections cover. Carefully disconnect all the electrical connections. Refer to Fig 35 and 48. Remove the facia panel and unscrew the four screws and remove the cover from the rear of the facia. Refer to Fig 62. Lift out the control board. Refer to Fig 62 Pull out and transfer the transformer to the new board. Re-commission the appliance to check and set the burner pressures. Refer to Section 12, Commissioning.
15.11 Transformer
Unscrew the four screws and remove the cover from the rear of the facia as described in 15.10 preceding. Refer to Fig 62. Pull out and transfer the transformer to the new board. Refer to Fig 62.
15.12 Clock/Programmer
Remove the facia by gently pulling it away from the boiler to release the clips. Remove the clock/programmer assembly by releasing the clip at the top of the clock/programmer and ease away from the control panel being careful not to pull on the connector lead. Unplug the connector at the control board. Refer to Fig 63. Comprehensive instructions are sent with the new control.
15.13 Fan Remove the inner casing cover. Remove the fan as described in Section 14.3, Inspection and Servicing. Ensure that all the connections are correctly made to the new fan.
15.4 Air Flow Detector Remove the fan as described in 15.13 preceding. Unscrew and withdraw, through the fan outlet, the airflow detector. Refer to Fig 50.
30
Fig. 62. Control board
Fig. 61.Inlet water filter
1
2
3
4
5
1. Control panel 4. Transformer
2. Rear cover 5. Control board
3. Rear cover fixing screws (4)
Fig. 63. Programmer connection
1. Facia (gently pull forward to un-clip and remove)
2. Control panel (boiler outer casing in place)
3. Programmer cover (un-clip to remove. See Fig. 34)
4. Programmer location in detail
5. Programmer connections (See Fig. 34)
6. Programmer connector plug
7. Programmer
1
2
3
5
6
4
7
Page 31
15.15 Primary [ch] Sensor
Remove the clip-on facia cover, cabinet and inner casing cover. Carefully pull-off the connections. Release the clip and lift out the sensor. Refer to Figs 49 & 64. Do not omit the heat transfer paste when fitting the replacement sensor.
15.16 Overheat Thermostat
Remove the clip-on facia cover, cabinet and the inner casing cover. Refer to fig.67 Carefully pull-off the connections. Unscrew the two screws and remove the thermostat and fixing bracket. Refer to Fig 65. Apply a small quantity of heat transfer paste to the face of the replacement thermostat. Carefully position the thermostat so that the connections are away from the flue hood.
15.17 DHW Sensor
Remove the clip-on facia cover, cabinet and lower the facia onto the lower support lugs. Carefully pull off the connections. Unscrew the clip and remove the sensor. Refer to fig.53 Apply a small quantity of heat transfer paste to the face of the replacement sensor. Refer to Fig 66.
15.18 Pump
Check that the primary circuit has been fully drained. Use a 4mm Allen key to release the four pump head fixing screws and remove the pump head. Refer to Fig 53. Disconnect and transfer the electrical connections to the new pump head. Take care not to scratch the mating surfaces.
15.19 Expansion Vessel
It will be necessary to remove the appliance from the wall to replace the expansion vessel. Refer to fig.40 Alternatively the specified replacement can be fitted into the heating system return as close to the appliance as possible. Re-fill and pressurise the system as described in Section 13 Commissioning.
15.20 Auto Air Vent
Drain the primary circuit. Unscrew and remove the auto air vent. Do not omit the sealing washer when fitting the replacement air vent. Remove the cap. Refer to Fig.40
15.21 Primary Heat Exchanger
Check that the appliance has been fully drained. Remove the temperature sensors as described in 15.15, 16 and 17 preceding. Remove the combustion chamber, fan and flue hood as described in Section 14.3, Inspection and Servicing and burner as described in 15.4. NOTE: The heat exchanger is unsupported when both the combustion chamber and flue hood are removed. Undo the four union connections and remove the heat exchanger. Do not omit the sealing washers when fitting the replacement heat exchanger. Refer to Fig 67.
31
Fig. 64. Primary (CH) sensor.
1. CH Sensor
2. Clip
2
1
Fig. 65. Overheat thermostat
1
2
3
1. Overheat thermostat
2. Fixing bracket
3. Overheat thermostat fixing screw
Fig. 66. DHW sensor
1
2
3
1. DHW sensor
2. DHW sensor fixing bracket and screw
3. DHW outlet pipe
Page 32
22 Air pressure Switch
Squeeze and push down the two plastic lugs and remove the pressure switch from under the bracket. See Fig 68. Remove the fixing clip (see Fig 68) and fit to the new air pressure switch insuring that the orientation of the clip to the air connec­tions is the same. Remove the electrical connections to the old switch and fit to the new switch in the same position. Place the replacement switch under the mounting bracket and locate the plastic lugs in the two holes in the bracket and push up until the lugs are fully home. Connect the RED tube to the
+ve connector and the WHITE tube to the -ve connector.
23 Sight Glass
Remove and replace the inner casing cover complete. Refer to Section 15.3, Inspection and Servicing. Refer to Fig 47.
32
Fig. 67. Primary heat exchanger
1
2
3
4
5
6
1. Heat exchanger
2. CH flow/return pipes
3. DHW inlet/outlet pipes
4. Seal
5. Overheat thermostat
6. Primary sensor
Fig. 68. Air flow pressure switch
1
2
3
4
5
1. Air pressure switch
2. Tube connectors
3. Securing clips
4. Air pressure switch fixing clip
5. Fixing bracket
6. Electrical connections
Fig. 67. Air flow pressure switch location
1. Air pressure switch
2. Air pressure switch fixing clip
3. Sensing tubes
3
1
3
2
2
6
Page 33
1 E88-143 Burner 28 NG RSF 1 8 716 105 008 0 2 E88-145 Gas Valve CE428 1 8 747 003 601 0
3 E88-146 Air Pressure Switch 1 8 716 104 896 0 4 E88-169 E lectrode Set (Flame and Ignition) 1 8 716 101 901 0 5 E88-170 Overheat Stat 1 8 717 206 200 0 6 375-696 NTC/Thermistor DHW 1 8 716 142 302 0 7 E88-171 NTC/Thermistor CH 1 8 714 500 029 0 8 378-809 Air Vent Manual
1
/4BSP 1 8 716 140 516 0
9 299-363 Air Flow Sensor 1 8 716 141 000 0 10 E88-173 Heat Exchanger 28 kW 1 8 715 406 814 0 11 E88-175 Insulation Pack 28 RSF 1 8 761 105 010 0 12 E88-176 Pressure Gauge 1 8 716 142 398 0 13 E27-580 Pressure Relief Valve 1 8 716 156 764 0 14 E88-177 Pump 1 8 716 143 116 0 15 E27-587 Expansion Vessel 1 8 715 407 154 0 16 E88-178 Control Board 1 8 748 300 417 0 17 E88-180 Fan Assembly 1 8 716 104 815 0 18 E88-181 Flow Sensor 1 8 716 146 164 0 19 E88-182 Seal-Door Extrusion 1 8 716 104 609 0 20 E88-183 Transformer 1 8 747 210 294 0 21 E88-185 Flow Regulator 28 kW 1 8 716 141 253 0 22 E88-189 Code Plug 28 RSF 1 8 714 421 133 0
A001 Charging Link Assembly 1 7 716 192 281 A002 Installer Pre-Filling Kit 1 7 716 192 282 A006 Simplefit Telescopic Flue Kit - F105H500 1 7 716 191 068 A007 Vertical Flue Kit 1 7 716 191 079 A008 90° Flue Elbow - F106E90 1 7 716 191 013 A009 45° Flue Elbow (Pair) - F 106E45 2 7 716 191 014 A010 Vertical Flue Adaptor Kit 1 7 716 191 016 A011 Security Kit 1 7 716 192 246 A012 Mechanical Programmer 1 7 716 192 027
A013 Digital Programmer 1 7 716 192 028
Key G.C. No. Part Qty WHS No. Part No.
33
16. Short Parts List
Accessories and Kits
Page 34
34
1
2
3
4
7
5
6
8
9
10
11
12
4
15
13
16
19
14
17 - 18
20
22
23
21
Page 35
Room
thermostat
and/or mains
programmer
(or link) On
facia
programmer
(if fitted) On
CH control
knob On
35
17. Operational Flow Diagrams
MAIN SWITCH
ON
CENTRAL HEATING DEMAND
Pump on.
Fan ON/
ignition
sequence.
Burner Light
On.
Three minute
wait
Gas valve Off.
Burner light
off. (Pump still
On)
Over tempera-
ture shut-
down if flow
temperature
5°C above set
value
Fifteen second
minimum
burner
pressure then
ramp up
pressure over
next one
minute
Modulate gas
to maintain
flow
temperature
set by control
knob
(50-82°C)
DEMAND
END
Overrun function
(see overleaf)
CENTRAL HEATING FUNCTION
AND
AND
DOMESTIC HOT WATER FUNCTION
MAIN SWITCH
ON
Flow sensor
signal
(Tap open)
DOMESTIC
HOT WATER
DEMAND
(Priority over
CH demand)
Pump continue
4 seconds if
primary temp
above DHW
setting. Burner
to MAX.
Modulate gas
to maintain
delivered
water
temperature
set by control
knob
(40-60°C)
Is CH
interrupted?
DHW temp
drops to user
set point
Over
temperature
shut-down if
water
temperature
above 80°C
Primary
temperature
94°C
DEMAND
END
Overrun
function
(see overleaf)
YES
NO
Ignition
sequence and
burner to MAX
Gas valve off.
Primary
78°C
Gas valve off.
Pump on
Page 36
Commence normal
central heating mode
until temperature
reaches 20°C
36
Pump overrun
function active
for 3 minutes
OVERRUN FUNCTION
Run pump
END DHW
DEMAND
END CH
DEMAND
Pump runs
for
3 minutes
Pump on if
primary temp
above 80°
until temp
below 75°C
AUTOFROSTAT FUNCTION
Monitor
central
heating
sensor
Below
5°C
5°C
to
9°C
Above
9°C
No demand and primary temperature
below 8°C
Internal
"Autofrostat"
demand
Return to
normal off
state
Fan low speed
35 seconds
Fan low speed if
primary temp
above 80°C until
below 75°C.
Page 37
Note: This fault-finding information is for guidance only. Worcester Heat Systems cannot be held responsible for costs incurred by persons not deemed to be competent.
By flashing at various rates, the oval shaped facia light will indicate specific fault conditions. If this is used with other observations during a fault, then every normal fault can be identified.
To use the fault finding system, use the table below to select the failure condition during your fault. The most common causes are listed, then refer to the test in the following section. This fault finding system assumes that the appliance has been operating normally until the time of failure (ie not a first installation fault).
PRELIMINARY CHECKS
Preliminary electrical system checks are the first electrical checks to be carried out during a fault-finding procedure. On completion of the Service/Fault-Finding task which has required the breaking and remaking of electrical connections, check (a) EARTH CONTINUITY, (b) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH.
18. Fault Finding
37
B
OBSERVED FAULT COMMON CAUSES SEE TEST
No lights and no functions (with demand)
No CH function (DHW OK)
No DHW function (CH OK)
Flash once per second
Ignition lockout Overheat lockout Internal error
Flash 4 times per second
No mains Voltage supply. Fuse F1 or F2 blown. Transformer or connector failed. Board fault. ADM (Appliance Diagnostic Module) fault.
No link at ST2 Ls to Lr, or failed external control input to Lr.
Failed programmer. Board fault.
Flow sensor failure. DHW sensor (LED 4 flash/second). Board fault.
No gas or low gas pressure. Weak spark or spark not across elecrodes. Gas valve leaking or failed. Low water pressure or boiler dry. Pump fail. Primary sensor position. Flame sensor fail or connector. Overheat stat tripped or disconnected or faulty. Blocked burner. Blocked heat exchanger. Faulty harness. Board fault. Diagnostic Module fault.
Code plug missing or failed. CH or DHW Sensor fault or out of position. Air pressure switch fault or condense in tubes. Fan fail or stiff. Blocked flue. Faulty harness. Board fault.
A
C
D
E
FAULT LIST
G
Gas Valve mode switch on min or max.
Autofroststat. Board fault.
Sensor off pipe.
Low gas pressure. Pot P1 not turned up. Stiff/sticking gas valve. Stiff/sticking flow sensor. Board fault.
F
H
I
Flash 8 times per second
GV mode switch
Burner on with no demand
Water temperature too hot
Water temperature too cool
(reset lockout by gently pressing reset button for 5 seconds)
Page 38
38
Is there a 230V AC live
supply across
Terminal ST2 pins L
and N?
Switch off electrical
power.
Has fuse F1 blown?
Caused by mains 230V parts
external to the control board
ie. (wiring to or faults within):
pump, fan, transformer or
other external controls
connected to ST2 (including
Diagnostic Module, although
this failure is unlikely).
Check all these parts for
malfunction.
Repair/replace part, replace
fuse F1 and run the boiler.
Note: Tracks on board may
have also been damaged.
Replace board if necessary.
Check electrical
supply to boiler.
Has fuse F2 blown?
TEST A
No
Yes
Yes
No
likely to be caused by control board internal
fault, low voltage
wiring (eg. shorts to
chassis) or Diagnostic
Module (less likely).
Replace Fuse F2 and
check wiring or
replace control board.
Remove control board from facia
and separate transformer from board. Measure resistance across the two pairs of adjacent pins on the transformer. Is any coil above
100 ohms?
Replace transformer.
Yes
Yes
No
Replace control
board.
In the unlikely of
this not solving
the problem
replace Dianostic
Module.
No
NOTE: It is normal for
there to be no facia
lights if the boiler is in
normal overtempera-
ture condition.
Continue this test if
this fault occurs when
the appliance is cold.
Is there a 230V AC live
supply across
Terminal ST2 pins Lr
and N?
TEST B
No
Yes
Yes
Replace
control
board.
NOTE: Lights will be
off and pump will run
if boiler is in 3min
anticycle condition.
With CH control knob
fully clockwise, if
there is still no CH
function, continue:
There is no heat
demand. Check room
thermostat or external
programmer (or link).
Is there a facia
mounted programmer
at connection ST5 at
right-hand end of
board?
No
No
Remove programmer
connector from edge
of board. Does the
boiler now ignite?
Correctly set or
replace programmer.
Yes
Page 39
39
Re-connect the 3-way connector and open a
tap to run the turbine.
Is there 3VDC across
the green and black
wires/terminals?
Is there continuity in
the main harness?
Disconnect the 3 way
in-line connector to
the turbine.
Is there 5VDC between
the two outer pins
(main harness side)?
Take care not to
damage the pins.
No No
Yes
Yes
Replace control
board.
Replace main
harness.
TEST C
Yes
Replace turbine.
No
Page 40
40
Is the boiler fully
water pressurised and
is all air vented?
Rectify fault.
No
No
No
Reset and restart the
boiler in CH mode.
Does the pump run?
Yes
Test resistance across
contacts 1 and 2
(blue wires).
Is the reading below
100 ohms?
Repair or
replace
harness.
Remove front panel.
Reset and restart the boiler. Can a flame be seen through the spy
glass?
Remove blue
connector from gas
valve. Is there
continuity from blue
wires to multiway
connector?
Replace gas valve
Remove inner cover.
Reset and restart the
boiler. Does a spark
occur across the
electrodes?
Turn off boiler. Remove
the multiway
connector from board
position ST16. Test
resistance across
contacts 5 and 6
(brown wires) Is the reading
between 100 & 200
ohms?
In the unlikely event of
this not solving the
problem, replace the
Diagnostic Module.
Are the electrodes and
gap and connections
in good order?
Replace
control board.
In the unlikely event of this not
solving the problem, replace the
Diagnostic Module.
Remove brown
connector from gas
valve.
Is there continuity
from brown wires
to multiway
connector?
Repair or replace
harness.
Repair or replace
spark electrode
or HT leads
Is the gas supply
connected and at the
correct pressure?
Rectify gas supply
problem.
No
No No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Replace control board.
If problem not solved
replace gas valve.
Yes
Replace or repair
pump.
Yes
No
TEST D
Test resistance of each
ignition cable.
Is it 2000-3000 ohms?
Yes
No
Replace (both) ignition
cables
Yes
Is there continuity
between pins 3 and 4?
(green wires to HL
stat)
Replace overheat stat
or wiring to it.
No
Page 41
41
Remove combustion
chamber cover.
Is the sense electrode
and lead in good
condition and is gap
correct?
Replace flame sensor
or wiring.
No
No
Remove multiway
connector from board
position ST16.
Is there continuity
from pin 7 (green wire)
to flame sensor?
Yes
Yes
Yes
Relace control board.
NOTE: It is not
possible to reliably
check the cross-light
performance of the
burner, or the
efficiency of the
gas/water heat
exchanger.
If there is still a
problem, investigate
flue problems or
replace burner or
injector or heat
exchanger.
Does the flashing fault
signal occur at the start of a demand?
If flashing occurs at
the end of a demand.
Gas valve leak is
detected.
Replace gas valve.
No
Yes
If flashing occurs during a
demand.
Pump could be partially
blocked.
Clean pump & flush system.
Re-fix sensor to pipe.
No
Turn off boiler. Remove inner casing cover and
inspect the primary
sensor (on heat
exchanger in front of
overheat thermostat).
Is it correctly fixed to
pipe?
Yes
Page 42
42
Remove multiway
connector from board
position ST16. Test
resistance across
contacts 12 and 13
(black & yellow wires).
Is it between 1 kOhm
and 30 kOhm?
Test resistance across
contacts 9 and 10
(black & red wires). Is
it between 1 kOhm
and 30 kOhm?
Is there continuity
from individual
contacts 12 and 13 to
DHW sensor?
Check or replace
DHW sensor.
Is there continuity
from individual
contacts 9 and 10 to
CH sensor?
Repair or replace
harness.
Repair or replace
harness.
Is the multiway
connector at board
position ST16 pushed
fully home on to the
board?
Push fully home
No
No
No
No
No
Yes
Yes
Yes
Check the DHW
sensor. Is it correctly
fitted onto the pipe
with heat conductive
paste between the
pipe and sensor?
Yes
No
Re-fix sensor onto pipe
Is the Code plug fitted
and
fully home?
Fit/push fully home
Yes
No
TEST E
Check or replace
CH sensor.
Test resistance across
contacts 10 and 11
(black & blue wires).
Is it open circuit?
Turn off electrical
supply.
Remove fan connector
from board position
ST1.
Test resistance across
contacts to black &
white cables.
Is it between 75 and
175 ohms?
Check/repair fan
harness or repalce fan.
Air pressure switch
is shorting.
Check tubes for
blockage or replace
switch.
No
No
Yes
Yes
Yes
Test resistance across
contacts to black &
red cables. Is it
between 20 and 60
ohms?
Yes
Yes
No
Page 43
43
Replace control board.
In the unlikely event of this not solving the problem replace code
plug.
Pressure switch has
opened during
operation.
Check flue for
blockage.
Also investigate sense
tubes and pressure
switch.
Replace fan connector
ST1.
Remove electrical
connectors from air
pressure switch and
reset/restart boiler.
Is there continuity between C and NO
terminals (where wires
were fitted) when the
fan runs?
(Test within 30
seconds).
Pressure switch has
not closed. Are the silicon tubes in good condition and free of
condensation.
Replace air pressure
switch.
Note: In the unlikely
event of this not solving the problem inspect the pressure
pick-up (Venturi) in the
fan or fan may not be
running freely.
Inspect the flue. Is it
free of any
restrictions?
Rectify flue problem.
Does the burner ignite
(burner light on) and
run for a short priod
before the fault
occurs?
Replace control board.
Repair cables or
replace main harness.
Replace tubes. If
condensation has
occurred, also replace
pressure switch and
check condition of
Venturi in the fan.
No
No
No
No
Yes
Yes
Yes
Yes
Turn to 'NORM'
position
The gas valve mode
switch (concealed by
the facia side panel)
is not set correctly
TEST F
Replace multiway
connector to position
ST16 (but not fan
connector at ST1) and
reset/restart the
boiler.
Is there mains 230V
across the right (L) and left (N) tracks at board position ST1?
NOTE: Take care not to
short L to N.
Yes
Remove multiway
connector from board
position ST16.
Is there continuity of
black & blue cables to
the air pressure
switch?
No
No
Yes
Yes
Page 44
44
Boiler is running in
“Autofrost stat” mode.
See Section 17.
Replace control board.
Note: A damp board
could cause this fault.
Is the boiler in a very
cold environment (less
than 5°C)?
TEST G
No
Yes
Is the CH limit
potentiometer
(concealed behind
facia bottom panel)
set to maximum?
Does the problem
occur in CH mode
only?
Water flow
temperature very low
(with all knobs set at
maximum).
TEST I
No
Yes
It is not possible to easily isolate the fault. The most likely causes are control board (fail),
heat exchanger
(blocked) or
gas valve (sticking).
Hot water
temperature always
too hot during a
demand (not
regulating).
TEST H
Hot water sensor
could be off or poorly
fixed to pipe.
Repair or replace.
Yes
Problem occurs in the
HW mode only.
Check flow sensor:
with boiler cool,
slowly open a HW tap.
Does the boiler ignite
with a flow of about
3 l/min?
(Check using a
measuring jug and
stop watch i.e 500ml
in 10 sec.
Yes
No
Turbine sticking or
seized.
Replace the turbine.
Page 45
45
Page 46
46
Page 47
47
Page 48
This manual is to be used in conjunction with the variant part number of the bar code below:
Manufactured exclusively for British Gas by
Worcester Heat Systems Limited ( Bosch Group), Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624. Fax: (01905) 754619.
PUBLICATION 8 716 105 430a 05/03
Page 49
ROOM SEALED FLUE TERMINAL KIT
For use on the Danesmoor Front Service Room Sealed Oil Appliances
INSTALLATION INSTRUCTIONS
The appliance/flue system should be installed by a competent person
Page 50
Contents
1. Installation Regulations Page 1
2. General Information Page 1
3. Flue Lengths, Bends & Extensions Page 1
4. Measurement of Ducts Page 1
5. Siting of Flue Terminal Page 4
6. Installation Page 4
7. Accessory/Spare Parts List Page 7
1. Installation Regulations
1.1. The appliance/flue system should be installed by a competent person. The person installing the appliance/flue system should be aware of the Health and Safety at Work Act and take appropriate action to ensure the regulations are adhered to. In order to give optimum efficiency and trouble free operation the appliance/flue system must be commissioned by an OFTEC registered engineer, as required by the building regulations.
1.2. The manufacturers notes must not be taken, in any way, as overriding statutory obligations.
1.3. The roomed sealed terminal has been designed to discharge the products of combustion without the need for a conventional chimney.
2. General Information
IMPORTANT: In addition to the following notes, reference must be made to the appli­ance Installation and Servicing instructions.
2.1. The flue system covered in these instructions can only be used with Danesmoor Front Service (FS) Oil Appliances.
2.2. These instructions cover both low level dis­charge and high level horizontal flue systems.
2.3. The method of installation of the flue system may be varied to suit the actual site conditions. The instructions for connection and fixing the ducts must be adhered to.
2.4. There are three sizes of telescopic flue system available:
1. Short RS flue kit for wall thickness of 100mm (4 inch) to 150mm (6 inch)
2. Standard RS flue kit for wall thickness of 230mm (9 inch) to 400mm (15 inch)
3. Long RS flue kit for wall thickness of 400mm (15 inch) to 730 (28.7 inch)
3. Flue Lengths, Bends and Extensions.
3.1. The maximum flue length allowable is 2.5 metres as shown in Figs 1 and 2.
3.2. Extension kits are available in 500mm and 1000mm sections.
3.3. 90° and 45° bends are available. In addition to the 90° bend supplied with the flue kit one extra 90° bend or two 45° bend may be used. A 90° bend is equivalent to 1000mm of straight duct. A 45° bend is equivalent to 500mm of straight duct. Therefore, if one extra 90° or two 45° bends are used the maximum straight ducting must not exceed
1.5 metres. It is not recommended to cut the flue extensions.
4. Measurement of the Ducts
Flueing options are shown in figures 1 and 2. Choose the duct depending on the wall thickness (L) and or the flue length required. L is the distance from the outside of the appliance casing to the outside face of the wall.
4.1. Rear Discharge Low Level Flues as shown in figure 1a and 1b.
Using the Short RS flue kit If L is between 100 – 150mm – (no extensions) Using the Standard RS flue kit If L is between: 230 – 400mm – (no extensions) 730 – 900mm – (500mm extension) 1230 – 1400mm – (1000mm extension) 1730 – 1900mm – (1000mm and 500mm extensions) 2230 – 2400mm – (2 x 1000mm extensions) Using the Long RS flue kit If L is between: 400 – 730mm – (no extensions) 900 – 1230mm – (500mm extension) 1400 – 1730mm – (1000mm extension) 1900 – 2230mm – (1000mm and 500mm extensions) 2400 – 2500-(2 x 1000mm extensions)
4.2. Rear Discharge High Level Horizontal flue with one 90° Bend as shown in figure 1c.
L is calculated by taking the dimension from Section
4.1 for Rear Discharge Low Level Flues and subtract­ing the vertical extension length L1
1
Page 51
Page 52
185mm
L
Fig. 2a. Low level horizontal flue with 90° bend
Total straight length of L must not exceed 2500mm
Fig. 2c. High level horizontal flue with two 45° bends
Fig. 2d. Side exit of flue with two 90° Bends
Fig. 2b. High level horizontal flue with one 90° bend
100mm
L1
119
218
H
100mm
855
754mm
185
L2
Total straight length of L1 + L2 must not exceed 1500mm
Distance from centre of boiler to centre of flue terminal (S) S = 185 +L1
185mm
66
10 0 mm
L2
100mm
L1
Y
10 4
H
L3
42
100mm
185mm
218
58
L2
L1
119
S
Fig. 2. Side discharge flue systems.
Centre of flue terminal to floor H = 754 + L1
Total straight length of L1 + L2 must not exceed 2500mm
Total straight length of L1 + L2 + L3 must not exceed 2500mm
H = 799 + L1 + Y
Y=353 (500mm extension)
or
Y=707 (1000mm extension)
L
Front view
Front view
Front view
Plan view
3
Page 53
Page 54
tion and screwing through with the self tapping screws provided.
6.2. The following guide explains two possible meth­ods of assembly. The boiler can be fixed in position and the flue fed back through the wall (Method 1), or the flue can be assembled onto the boiler and the boiler /flue then pushed back against the wall to feed the flue through the wall (Method 2). In both cases the telescopic flue must be securely fastened at the required length using the two self tapping screws provided.
Method 1.
6.3. Remove the 4 inch (103mm) conventional flue spigot and gasket from the flue outlet plate by undo­ing the three screws.
Note: To create a good seal between the boiler and air box assembly only use the flue ring gas­ket supplied within the RS flue kit.
6.4. Position the new flue ring gasket on the flue out-
let plate and clamp the flue tube in place using the flue tube retainer and screws as shown in fig 4.
6.5. When fitting an elbow directly to the air box, push the elbow fully down on the air box collar and rotate the elbow to the required position (left, rear or right) ensuring that the air tube is pointing to the front of the appliance as shown in fig 4.
6.6. Using the fixing holes as a guide , drill through with the 2.8mm drill bit provided in the kit and fasten the elbow to the air box collar using the two self tap­ping screws provided. Where access to a fixing hole is not possible (e.g. left and right flue options), drill a new securing hole position, at the same height, as far as possible from the other screw.
6.7. When fitting a vertical extension attach the exten­sion to the air box and then attach the elbow to the extension in a similar manner to 6.5 to 6.6.
6.8. Add any further extensions/elbows in a similar manner to 6.5 to 6.7, until the last section before exiting the wall is reached.
6.9. Slide the air box/flue assembly onto the flue tube and push down until the assembly bottoms out on the flue tube. This must leave a minimum air gap of 15mm between the air box and the flue outlet plate. The nominal air gap will be 27mm when an elbow is fitted directly to the air box and 17mm when an extension is fitted.
6.10. Using the flue as a guide, mark the position of the hole required to accept the flue terminal or meas­ure the flue centre position as shown in figs 1 and 2.
6.11.Remove the air box/flue assembly.
6.12. Cut a round hole in the wall of minimum diame-
ter 150 mm.
Fig. 6a. Fitting of rubber sealing gasket
Rubber sealing gasket
Rubber sealing gasket
Flue terminal
Locating slot
A
Flue terminal
Fig. 6b. Fitting of rubber sealing gasket
Fig. 7. Connection of the flexible air hose to the burner and air box
Locking band
Burner aircowl
Burner
Locking band
Flexible duct
Flue section
Airbox
5
Page 55
L2
Page 56
an extension is fitted.
6.35. Using the flue as a guide, mark the position of the hole required to accept the flue terminal or meas­ure the flue centre position as shown in figs 1 and 2.
6.36. Measure and note the distance from the rear of the boiler to the wall for rear exit flues, or from the appliance cabinet side to the wall for left/right exit flues. This will be used to calculate the flue length “L”.
6.37. Pull the boiler forward to allow fitting of the flue terminal.
6.38. Cut a round hole in the wall of minimum diame­ter 150 mm.
6.39. Measure and note the wall thickness through the hole. This will be used to calculate the flue length “L”.
6.40. Fix any further extensions to the elbow in a sim­ilar manner to 6.28 to 6.30.
6.41. Check that the telescopic flue slides freely. Push the telescopic terminal section onto the last elbow/extension and fasten in a similar manner to
6.28 to 6.30.
6.42. Calculate the length “L” as shown in figs 1 & 2 in conjunction with Section 4 i.e. distance from rear of appliance to outside face of the wall, or distance from side of appliance cabinet to outside face of the wall.
6.43. Slide the telescopic terminal to set the length “L” from the outside of appliance to the inside edge “A” of the terminal seal locating slot. See fig 6a.
6.44. Using the fixing holes as a guide , drill through with the 2.8mm drill bit provided in the kit and fasten
the telescopic terminal section using the two self tapping screws provided.
6.45. Slide the boiler back into position carefully feeding the flue terminal through the hole in the wall.
6.46. Where vertical flue sections have been fitted raise the air box/flue assembly by 3mm per 1 metre flue extension, to allow for the flue tube expansion, and fix the assembly in place. the wall bracket is pro­vided in the 1 metre extension kit.
6.47. To prevent rain running back into the terminal, it is recommended that the terminal exit slopes down by a few degrees. This can be achieved by holding the terminal strip down at the external end and plac­ing packaging material between the topside of the terminal and the wall, inside the hole. Check the slope using the spirit level.
6.48. Make good the internal and external brickwork or rendering.
6.49. Push the rubber sealing gasket over the termi­nal. The locating rib of the rubber seal fits into the locating slot of the flue terminal as shown in Fig. 6a and 6b.
6.50. Undo the locking band on the burner air cowl and remove the air inlet silencer tube.
6.51. Fix the flexible duct between the burner and air box using the locking band provided within the kit and the locking band removed from the burner air cowl. Tighten sufficiently to form a good seal. See Fig. 7.
Note: If the flue assembly is taken apart after the appliance has been running the 80mm flue tube seals within the flue tubes should be replaced.
7. Accessory/spare parts List
Short RS flue kit 7 716 190 027 Standard RS flue kit 7 716 190 023 Long RS flue kit 7 716 190 024
RS 500mm Extension Flue Kit 7 716 190 025 RS 1000mm Extension Flue Kit 7 716 190 026 RS 90° Elbow Flue Kit 7 716 190 028 RS 45° Elbow Flue Kit 7 716 190 029 Wall Bracket Front Service Flue Kit 7 716 190 030 Seal flue tube 80mm 8 716 105 588 0 Seal air tube 125mm 8 716 105 590 0 Seal 80mm Air box 8 716 106 145 0 Flue ring gasket 8 716 142 226 0
7
H
Page 57
Page 58
RD 628
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
G.C. NUMBER: 47 108 14
Page 59
EXCELLENCE COMES AS STANDARD
Page No.
Operating Instructions
.................................... 3-11
Fault and Breakdowns 12
Maintenance and Extended Warranty
Information ............ 13-14
Guarantee Details ... 15-16
CONTENTS
2
Thank you for purchasing a RD 628 gas-fired combination
appliance.
RD 628 appliances are made by Worcester Heat Systems
and the strictest quality control standards are demanded throughout every stage of production.
The result is that your new RD 628 appliance offers you the very best of everything - quality, efficiency, economical running costs, proven reliability and value for money.
What’s more, you also have the assurance of our no-
nonsense 1 year parts and labour guarantee.
Page 60
GENERAL INFORMATION
GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1998
It is the law that all gas appliances must be 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. The manufacturers notes must not be taken, in any way, as over-riding statutory obligations.
WARNING: This appliance must be earthed and protected by a 3 amp fuse to BS 1362.
ELECTRICITY SUPPLY: 230V ~ 50Hz
IMPORTANT: To get the best from your RD 628 appliance please
read these instructions carefully.
NOTE: In the event of a fault the appliance should not be used until the fault has been corrected by a competent person.
BENCHMARK
The Benchmark initiative is a code of practice to encourage the correct installation, commissioning and servicing of domestic central heating boilers and system equipment.
A 'log book' is dispatched with every appliance, This is a vital
document that needs to be completed by the installer at the time of installation. It confirms that the boiler has been installed and commissioned according to the manufacturers instructions.
All CORGI Registered Installers carry a CORGI ID card and have a registration number. Both should be recorded in your central heating log book. You can check that your installer is CORGI registered by calling CORGI on 01256 372300.
Without the completion of the log book, manufacturers may refuse to respond to a call-out request. It is important that your installer has given you the fully completed log book.
GENERAL DESCRIPTION
(See Fig.1.)
The RD 628 is a combined domestic hot water and central heating appliance. It consists of a gas fired boiler having a varying output of between 8.1 and 28kW, and all the necessary controls to provide mains fed domestic hot water and central heating.
The appliances are fitted with a manual ON/OFF Switch.
The appliances can operate in one of two modes. Hot water only or hot water and central heating.
3
Page 61
4
Hot Water Mode:
When a demand is made for hot water by opening a tap or shower, the flow turbine will energise the boiler. The burner will light at its maximum setting and hot water will be delivered to the tap or shower.
When hot water is no longer required the appliance pump or fan may continue to operate to dissipate the excess heat within the boiler.
Fig. 1. System Diagram.
Automatic air vent
Primary heat exchanger
Circulating
pump
Fixed by-pass
Relief valve
CH
flow
Domestic hot water
flow
Domestic
cold
supply
CH
return
Relief valve discharge
Domestic water flow turbine
Expansion vessel
Page 62
GENERAL NOTES
5
CENTRAL HEATING SYSTEM
During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. Should the upper area of a radiator be at a lower temperature than the base of the radiator, it should be vented by releasing air through the venting screw at the top of each radiator. Make sure your installer shows you how to carry out the operation. Repeated venting will reduce the quantity of water in the system and this must be replenished for safe and satisfactory operation of the appliance. Should water leaks be found in the system or excessive venting be required from any radiator, a service engineer should be contacted and the system corrected.
The appliance must be fitted to a sealed heating system which is pre-pressurised. Your installer will advise you on the minimum and maximum pressure that should be indicated on the pressure gauge. See Fig. 2. Check regularly that this pressure is maintained and contact your installer or maintenance engineer if there is a permanent significant drop in pressure indicated on the gauge. If the system loses pressure it should be re-pressurised as instructed by the installer (N.B.
Maximum operating pressure 2.5 bar).
SEALED HEATING SYSTEM
Page 63
6
Your installer will have provided adequate space around the appliance for safety and servicing. Do not restrict this space by the addition of cupboards, shelves etc. close to the appliance.
NOTE: If the appliance is to be enclosed after the installation then the instructions given in Section 6, Air Supply, of the Installation Book MUST be followed.
ROOM THERMOSTAT
A room thermostat must be fitted for control of the central heating temperature. It will be located in one room of the home. The method of setting a room thermostat varies with the type and manufacture. Refer to the instructions supplied with the room thermostat.
THERMOSTATIC RADIATOR VALVES
If thermostatic radiator valves are to be fitted to the system then they must conform to the requirements of BS2767 It is advisable to leave one valve permanently set at maximum to prevent the boiler short cycling.
SHOWERS, BIDETS, TAPS AND MIXING VALVES
Standard hot and cold taps and mixing valves used with the appliance must be suitable for operating at mains pressure. Thermostatically controlled shower valves will guard against the flow of water at too high a temperature.
If using a pressure equalising valve, set the Domestic Hot Water temperature control knob to the ‘MAX’ position.
Hot and cold mains fed water can be supplied direct to an overrim flushing bidet subject to local water company requirements.
With all mains fed systems the flow of water from the individual taps will vary with the number of outlets operated simultaneously and the cold water mains supply pressure to the property. Flow balancing using ‘Ball-o-Fix’ type valves is recommended to avoid an excessive reduction in flow to individual outlets.
For further information contact Worcester Heat Systems technical Helpline.
HOT AND COLD FLOW
If the flow of water demanded from both hot and cold service outlets is dependent upon mains supply, it may not be possible in some installations to operate all outlets simultaneously.
WATER MAINS FAILURE
It is important to note that in the event of a mains water supply failure, no tap water will be available until the mains supply is restored. The appliance can still be used for heating provided that the system is of the sealed system type.
RSF
Left-hand side 10 80 Right-hand side 10 80 In Front 600 240 Above the casing 180 30 Below 200 200
CLEARANCES
Unventilated
compartment
above flue elbow or turret
Minimum clearances in millimetres.
Page 64
7
USE IN HARD WATER AREAS
Normally there is no need for scale protection. However, in areas of exceptionally hard water supply it is recommended that an In-Line scale inhibitor be fitted.
Installation should be strictly in accordance with the requirements of the local Water Company. An isolating valve to facilitate servicing should be incorporated.
The water hardness may be determined using the standard test paper or by reference to the local Water Company.
For further information contact Worcester Heat Systems technical Helpline.
VENTILATION OF ROOM SEALED FANNED FLUE (RSF) APPLIANCES
These are room sealed appliances and any ventilation openings in a wall or door must not be obstructed. Do not allow the flue terminal fitted on the outside wall to become obstructed or damaged.
NOTE: Do not place anything on top of the appliance.
If the appliance is fitted in a compartment do not use the compartment for storage purposes unless it conforms to the requirements of BS 6798:1987: Section 6. It is essential that the airing space is separated from the boiler space by a perforated non­combustible partition as described in BS 6798:1987.
CIRCULATING PUMP
This may be fitted with a speed adjuster. If so it will be factory set at maximum and should not be changed.
FROST PRECAUTIONS
If the appliance is not to be used for a long period of time and there is a likelihood of freezing, then the appliance should be drained.
The Worcester Heat Systems technical Helpline will advise you on suitable frost protection.
For short periods the built-in frost protection of the appliance will be adequate.
SERVICE
Annual servicing is important in order to ensure continuing high efficiency and long life for your appliance. Three star service cover from British Gas can offer comprehensive cover for your central heating - please call 0845 9 60 50 40 for further details.
WARNING
If a gas leak exists, or is suspected, turn off the gas supply to the appliance at the service cock and consult your local service engineer.
Do not touch any electrical switches to turn them either on or off. Open all windows and doors. Do not smoke. Extinguish all naked lights.
CLEANING
Do not use abrasive cleaners on the outer casing. Use a damp cloth and a little detergent.
UNDER NO CIRCUMSTANCES SHOULD ANY SEAL ON THE BOILER BE BROKEN.
Page 65
OPERATION OF CONTROLS
8
The appliance is fitted with the following controls:
OPERATING SWITCH
In the 0position there is no mains electricity to the control
board.
In the ‘I’ position mains electricity is connected to the control
board.
CENTRAL HEATING TEMPERATURE CONTROL
The position of this knob will determine the temperature of the water delivered to the radiators between fully clockwise and anti­clockwise to the mark. When the knob is turned anti-clockwise past the position towards the ‘’(Summer Position), then the appliance will operate in the HOT WATER mode only and no heat will be delivered to the radiators.
DOMESTIC HOT WATER TEMPERATURE CONTROL
The position of this knob will determine the temperature of the water delivered at the domestic hot water taps between fully clockwise and anti- clockwise positions.
By slightly reducing the flow of domestic water from the tap, the delivery temperature of the water will be further increased. This is of particular advantage in the winter, for example to increase bath water temperature and to remove heavy grease deposits on plates, etc. Also this will provide an added advantage of reducing the delay before hot water is obtained.
FACIA MOUNTED PROGRAMMER (if fitted)
Your installer may have mounted either a mechanical or an electronic programmer into the facia of your appliance. Operating instructions are supplied with the programmer.
RESET BUTTON
Press this button in for five seconds if the indicator light is flashing slowly.
If indicator lamp is flashing fast turn power OFF and ON at the boiler to reset.
SYSTEM PRESSURE GAUGE
The black needle will show the actual pressure in the system.
When operating the pressure indicated must not be greater than
2.5bar. If it is then contact your installer.
Page 66
9
INDICATOR LIGHTS
Flame detection indicator:
OFF: Burner off ON: Burner on
Fig. 2. Controls.
Mains electricity
On/Off
Fault indicator and
reset button
Flame detection
indicator
CH temp
control knob
DHW temp
control knob
System pressure
gauge
!
Fault indicator:
FLASHING SLOW: Ignition lockout or
(once per second) boiler overheat
FLASHING FAST: Appliance fault (five times a second)
Page 67
10
TO LIGHT THE APPLIANCE
Check that the water valves to the central heating circuit are open. Check that the black needle on the pressure gauge is not below
the required pressure.
Switch on the mains electricity. Set the room thermostat to
maximum. Turn the central heating temperature control knob fully clockwise.
The burner will light and the red flame detection indicator will light. Set the central heating and hot water temperature control knobs
and the room thermostat, if fitted, to the desired temperature.
TO STOP THE APPLIANCE
For Short Periods
Turn the central heating temperature control knob fully anti-
clockwise to the ‘O’ position.
For Long Periods
Turn the operating switch to the ‘O’ position. Switch off the
mains electricity.
A facia mounted electronic programmer will retain its settings for about two weeks, after which it will return to the factory set programme. The time will be saved for approximately 7 hours. The display will disappear after approximately 1 hour.
A facia mounted mechanical programmer will require resetting once the operating switch has been set to ‘O’, or the mains supply has been disconnected.
ELECTRICITY SUPPLY FAILURE
If the electricity supply fails the appliance will not operate. Once the supply is restored the appliance will return to normal operation. If a programmer is fitted, check that the settings have been maintained.
OVERHEAT CUT-OFF THERMOSTAT
The appliance will enter a lockout condition in the event of overheating.
An overheat cut-off thermostat is fitted to the appliance which will interrupt the electricity supply to the gas valve.
If the overheat cut-off has operated, the fault indicator will flash once a second. If this condition continues to occur, then call a service engineer.
The appliance can be reset by pressing the fault indicator button and holding in for 5 seconds when the appliance has cooled.
IGNITION LOCKOUT
The appliance will enter a lockout condition in the event of the
burner failing to ignite.
If the burner fails to light after 5 attempts the electricity supply
to the gas valve will be interrupted.
TO LIGHT AND STOP THE APPLIANCE
Page 68
11
If ignition lockout has occurred, the fault indicator will flash
slowly (approximately once per second).
The appliance can be reset by pressing the reset button and holding in for 5 seconds. Check that the gas supply has not been interrupted.
If this condition continues to occur, then call a service engineer.
AIR FLOW DEVICE
The appliance will enter a lockout condition in the event of an air flow fault.
If the controls fail to detect the correct air flow through the appliance the electricity supply to the gas valve will be interrupted.
If an air flow fault has occurred, the fault indicator will flash (approximately five times per second).
The appliance will try to re-light after a waiting period of approximately 5 minutes Check that the flue terminal has not been obstructed or damaged.
If this condition continues to occur, then call a service engineer.
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If your RD 628 appliance should fail to operate correctly, please call
British Gas on:
APPLIANCE FAILS TO OPERATE
0845 9 60 50 40
IMPORTANT
Do not touch or adjust
any sealed component
12
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MAINTAINING YOUR APPLIANCE
13
Your new RD 628 gas-fired appliance represents a long-term
investment in a reliable, high quality product.
In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is essential that your boiler receives regular, competent servicing and annual maintenance checks beyond the initial 12 month guarantee period.
To arrange for a British Gas Three Star Cover agreement please call 0845 9 60 50 40.
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14
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YOUR RD 628 GUARANTEE
15
This appliance is guaranteed against faulty materials or workmanship for a period of twelve calendar months from the date of installation subject to the following conditions and exceptions.
1. That during the currency of this
guarantee any components of the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and free of labour charges by Worcester Heat Systems Limited.
2. That the householder may be asked
to prove the date of installation, that the appliance was correctly commissioned and, where appropriate, the first 12 month service has been carried out to the satisfaction of Worcester Heat Systems Limited when requested.
3. That any product or part thereof
returned for servicing under the
guarantee must be accompanied by a claim stating the Model, Serial Number, Date of Installation.
4. That Worcester Heat Systems Limited will not accept responsibility for damage caused by faulty installation, neglect, misuse or accidental damage, the non­observance of the instructions contained in the installation and Operating Instructions Leaflets.
5. That the appliance has been used only for normal domestic purposes for which it was designed.
6. That this guarantee applies only to equipment purchased and used in mainland Great Britain.
This guarantee is given in addition to all your normal statutory rights.
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GUARANTEE REGISTRATION
8 716 105 431a 05/03
You should complete and return the postpaid Guarantee
Registration Card within 14 days of purchase.
The card will register you as the owner of your new RD 628 appliance and, while this will not affect your statutory rights in any way, it will assist us to maintain an effective and efficient customer service by establishing a reference and permanent record for your boiler.
IMPORTANT: SERIAL NUMBER. Copy the number off the Guarantee Card.
FOR YOUR OWN RECORD
MODEL
SERIAL NUMBER
TYPE/SIZE DATE OF INSTALLATION
Do not forget to keep the Log book in a safe place.
MANUFACTURED EXCLUSIVELY FOR BRITISH GAS BY
Worcester Heat Systems Limited. Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619.
Technical Helpline (08705) 266241.
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