24CDi/28CDi/35CDiII RSF

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Bosch Group 24CDi/28CDi/35CDi II RSF WALL MOUNTED COMBINATION BOILER FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING…
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Bosch Group 24CDi/28CDi/35CDi II RSF WALL MOUNTED COMBINATION BOILER FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS 24CDi 28CDi 35CDi II GC NUMBER (N.G) 47 311 30 47 311 34 47 311 58 GC NUMBER (L.P.G.) 47 311 31 47 311 35 47 311 59 Worcester supports the Benchmark code of practice BOILER OUTPUT Automatic Modulating Control Domestic Central Hot Water Heating 24CDi 9 - 24kW 9 - 24kW 28CDi 9 - 28kW 9 - 24kW 35CDi II 9.5 - 35.3kW 10.5 - 27.5kW IMPORTANT: THESE INSTRUCTIONS APPLY IN THE UK ONLY THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER This appliance must be installed by a competent person in accordance with the Gas Safety (Installation and Use) Regulations 1998 Contents 1. Installation Regulations .............................................. Page 2 11. Electrical ...................................................................... Page 10 2. General Information .................................................... Page 2 12. Installation.................................................................... Page 13 3. Technical Data .............................................................. Page 4 13. Commissioning ............................................................ Page 17 4. Siting the Appliance .................................................... Page 6 14. Instructions to the User .............................................. Page 19 5. Siting the Flue Terminal .............................................. Page 7 15. Inspection and Servicing ............................................ Page 20 6. Air Supply .................................................................... Page 7 16. Replacement of Parts .................................................. Page 21 7. Sealed Primary Systems ............................................ Page 8 17. Short Parts List ............................................................ Page 27 8. Gas Supply.................................................................... Page 8 18. Operational Flow Diagrams........................................ Page 29 9. Open Vent Primary Systems ...................................... Page 9 19. Fault Finding ................................................................ Page 31 10. Domestic Hot Water .................................................... Page 9 20. Conversion Instructions.............................................. Page 39 encourage the correct installation, commissioning and servicing of 1. Installation Regulations domestic central heating boilers and system equipment. The 'checklist' is a vital document that must be completed by 1.1 Gas Safety (Installation & Use) Regulations 1998: It is the law the installer at the time of installation. It confirms that the boiler that all gas appliances are installed by a competent person in has been installed and commissioned according to the accordance with the above regulations. Failure to install appliances manufacturers instructions. correctly could lead to prosecution. It is in your interest, and that of Without the completion of the checklist, manufacturers may refuse safety, to ensure compliance with the law. to respond to a call-out from a householder, who will be advised 1.2 The manufacturers notes must not be taken, in any way, as that he or she must call back the installer, who has not fulfilled his overriding statutory obligations. obligations to record the information required by the initiative. 1.3 The compliance with a British Standard or European Norm does It is important that: not, of itself, confer immunity from legal obligations. The services and the system are properly flushed as specified. 1.4 The installation of the appliance must be in accordance with the The User is clearly instructed on the correct operation of the relevant requirements of the Gas Safety Regulations, current IEE appliance. Regulations, Building Regulations, Building Standards (Scotland) The benefits of regular servicing are explained - to maintain the and local water bye-laws. efficiency and extend the life of the appliance. 1.5 The installation should follow the recommendations of the 2.1. General Information following British Standards unless otherwise indicated: 2.1.1. The appliance is set to provide the maximum output for BS6798 - Specification for the installation of gas fired hot water domestic hot water and a central heating load of 24kW (24/28CDi) boilers of rated input not exceeding 60kW (Gross). or 27.5kW (35CDi II). The hot water flow rate is limited to a nominal BS5449 - Central heating for domestic premises. 9 l/min (24CDi) or 10 l/min (28CDi) or 12 l/min (35CDi II) at a BS5546:1 - Installation of gas hot water supplies for domestic maximum temperature rise of 40°C. purposes. 2.1.2. The sanitary water section of the appliance is suitable for BS5440/1 - Flues and ventilation for gas appliances of rated input water mains pressures of up to 10bar. not exceeding 60kW (Gross): Flues. 2.1.3. Conversion kits are available to convert the appliance from BS5440/2 - Flues and ventilation for gas appliances of rated input Natural Gas to Propane operation and vice versa. The kits include not greater than 60kW (Gross): Air supply. conversion instructions. BS 5482 - Domestic butane and propane gas burning installations - 2.2 Electrical Supply permanent dwellings. Mains supply: 230V ~ 50 Hz. 180Watts. BS6891 - Installation of low pressure gas pipework installations up External fuse: 3A (BS 1362). Internal fuses: T 2A (F1), and T 1.25A (F2). to 28mm (R1). 2.3 Gas Supply BS6700 - Domestic water supply in buildings. Check the data plate (located on the inner cover of the appliance) to BS7593 - Water treatment in domestic heating systems. ensure the appliance has been set up for the correct gas supply. The 1.6. To ensure that the installation will perform to the highest appliance can be set up for either of the following gases: Natural standards, the system and components should conform to any gas (G20) or Propane (G31). A conversion kit including other relevant standards. instructions is available to change the appliance from one gas to 1.7. The appliance and/or components conform, where applicable, the other. with the Essential Requirements of the Gas Appliance Directive, the The boilers require a gas flow in m3/h of: Boiler Efficiency Directive, the EMC Directive and the Low Voltage NG (G20) LPG (G31) Directive. 24CDi 2.9 1.13 1.8. In accordance with the requirements of COSSH the appliance 28CDi 3.3 1.3 does not contain any substances which are harmful to health. 35CDi II 4.16 1.6 1.9. Product Liability regulations indicate that, in certain The meter governor or regulator should deliver a dynamic pressure circumstances, the installer can be held responsible, not only for of 20mbar for natural gas or 37mbar for propane at the appliance, mistakes on his part but also for damage resulting from the use of which is about 18.5mb or faulty materials. We advise that, to avoid any risk, only quality 35.5 mbar at gas valve inlet pressure test point. approved branded fittings are used. The complete installation, including the gas meter (G20), must be 1.10. LPG Installation. The appliance shall not be installed in a room tested for soundness and purged. Refer to BS 6891. or internal space below ground level when it is intended for use with LPG. This does not preclude the installation into rooms which 2.4 Packing are basements with respect to one side of the building but open to The appliance and flue components are packed in separate cartons. the ground on the opposite side. 2.5 Installation 1.11. The advice and instructions given in this document covers, as The appliance is suitable for indoor installations only. far as possible, the foreseeable situations which may arise. Contact A wall-spacing frame to allow pipe runs behind the appliance is Worcester Technical Department, Telephone: 08705 266241, for available. advice on specific installations. An inlet water filter is fitted to the mains cold water inlet on the appliance. The appliance is fitted with a system filling link assembly. See Page 8. 2. General Information The appliance is suitable for connection to a sealed or open vented primary system (35CDi II SEALED SYSTEM ONLY). The Benchmark initiative is the new code of practice to 2 Any specified ventilation openings made into a wall or balancing using ‘Ball-o-Fix’ type valves is recommended to avoid an compartment door must not be obstructed. excessive reduction in flow to individual outlets. For further If the appliance is to be fitted into a compartment then the information contact Worcester Bosch Technical Helpline. compartment must conform to the requirements of BS 5440:2. 2.10 Safety Considerations Notwithstanding the instructions given in BS 5440:2, this appliance The appliance must not be operated in a waterless condition. may be fitted in a compartment with no vents as long as the The appliance must not be operated with the boiler inner casing minimum clearances stated in Section 6: Air Supply, are cover removed. maintained. Work must not be carried out on the appliance without the gas and Do not place anything on top of the appliance. electricity supplies being switched off. The clearances specified for servicing must be maintained. Refer to Checks must be made to ensure that, where applicable, the Fig. 2. ventilation openings made into walls and partitions are of the 2.6 Flue correct size and are not obstructed. The appliance has a multi-directional horizontal fanned flue system. IMPORTANT: Where back-flow prevention devices, including The standard telescopic flue assembly accommodates flue lengths water meters, are fitted the expansion of hot water into cold from 297mm to 725mm. water main can be prevented. This can result in a pressure Extension flue lengths available are from 726mm up to 4000mm build-up that may cause damage to the boiler and household (24CDi) or up to 3000mm (28CDi and 35CDi II). devices such as showers, washing machines etc. A vertical flue assembly kit is available. In these cases we recommend that a mini-expansion vessel be fitted adjacent to the boiler in the cold water pipe. Optional 45° and 90° flue bends are available. 2.11 Operation A terminal guard, Type K2, GC 393 553, is available from Tower Flue Components, Vale Rise, Tonbridge,TN9 1TB. Domestic Hot Water: With a demand for hot water the burner will light at its maximum setting and then automatically adjust its Do not allow the flue terminal fitted to the outside wall to become output to maintain the temperature of the delivered water. When obstructed or damaged. hot water is no longer required, the burner will extinguish. The fan A kit for the internal fixing of the flue is available separately. and pump may continue to run for a short period to dissipate the 2.7 Controls residual heat from the appliance. The ON/OFF switch will turn the mains electricity on and off at the Central Heating: With a demand for heating the burner will light at appliance. its minimum setting and gradually increase to give the maximum Note: There is still a live connection to the appliance. output. The output of the appliance is then automatically adjusted The electronic control system and gas valve modulate the heat to maintain the temperature of the system. The output can reduce input in response to the central heating and domestic hot water down to its minimum of setting. If the system no longer requires temperature settings. even the minimum output to maintain the desired room The Central Heating Temperature control knob provides for the temperature the burner will extinguish. The fan and pump may selection of domestic hot water only (turned fully anti-clockwise) or continue to run to dissipate the residual heat from the appliance. central heating and domestic hot water (turned clockwise). The appliance will remain off for a fixed period of three minutes The position of the Domestic Hot Water control knob will determine before re-lighting to automatically meet the system requirements. the temperature of the water delivered to the tap or shower or Domestic Hot Water and Central Heating: The appliance will bath. supply heat to the central heating system as required. A demand A choice of facia mounted programmers are available as optional for domestic hot water at a tap or shower will override the central extras. A remote mounted programmer may be connected to the heating requirement for the period of the domestic hot water appliance. demand. When hot water is no longer required the appliance will return to the central heating state and its normal mode of The integral facia displays indicate the status of the appliance. operation. The fan may continue to run to dissipate the residual There is provision for the connection of a mains voltage room heat from the appliance as necessary. thermostat and/or a frost thermostat. The electronic controls prevent rapid cycling of the appliance in the Fig. 1. Appliance water flow diagram. central heating mode. 1. Automatic air 2.8 System Notes 1 vent. IMPORTANT: Check that no dirt is left in the water pipework as 2. Gas to water 2 this could cause damage to the appliance. Thoroughly flush the heat heating system and the cold water mains supply in accordance exchanger. with the recommendations of BS7593: 1992. 3. Circulating Remove all system cleanser before adding any inhibitor. pump. The water pipe connections throughout a sealed system must be 4. Water to water capable of sustaining a pressure of up to 3 bar. Boiler heat exchanger. Radiator valves must conform to the requirements of BS 5. Water 2767:1991. diverting The relief valve discharge must be directed away from any electrical valve. components or where it would cause a hazard to the user. 6. CH flow. A drain cock to BS 2879 must be fitted to the lowest point of the 3 13 7. DHW out. system. For circuit design purposes it is important that due note is taken of 8. Mains cold the information given in Table 3 relating to the available pump water in. head. 9. CH return 4 2.9 Showers, Bidets, Taps and Mixing Valves 10.Safety Hot and cold taps and mixing valves used in the system must be 12 discharge. suitable for operating at the mains pressure. 11. Central heating Thermostatically controlled or pressure equalising shower valves by-pass will guard against the flow of water at too high a temperature. adjustment. If a pressure equalising valve is used, set the Domestic Hot Water 12.Pressure relief temperature control knob to the ‘MAX’ position. 5 valve. Hot and cold mains fed water can be supplied direct to an over-rim 11 13.Sealed system flushing bidet subject to local Water Company requirements. expansion With all mains fed systems the flow of water from the individual vessel. taps will vary with the number of outlets operated simultaneously 6 7 8 9 10 and the cold water mains supply pressure to the property. Flow 3 Table 1 Note: Gross Heat Input x 0.901 (NG) or x 0.922 (propane) = Net Heat Input. 3. Technical Data NOMINAL BOILER RATINGS BOILER ADJUSTED FOR BOILER ADJUSTED FOR (10 minutes after lighting) G20 (Natural Gas) G31 (Propane) 24CDi 28CDi 35CDi II 24CDi 28CDi 35CDi II MAX. OUTPUT (DHW) kW 24.0 28.0 35.3 24.0 28.0 35.3 MAX. INPUT (net) kW 27.0 31.5 39.2 27.0 31.5 39.2 BURNER PRESSURE mbar 14.8 15.5 13.5 35.5 35.5 34.7 3 GAS RATE m /h 2.9 3.3 4.15 1.13 1.3 1.6 MAX. OUTPUT (CH) kW 24.0 24.0 27.5 24.0 24.0 27.5 MAX. INPUT (net) kW 27.0 27.0 30.1 27.0 27.0 30.1 BURNER PRESSURE mbar 14.8 10.8 8 35.3 24.3 21.3 3 GAS RATE m /h 2.9 2.9 3.19 1.13 1.3 1.23 MIN. OUTPUT (DHW) kW 9.0 9.0 9.5 9.0 9.0 9.5 MIN. INPUT (net) kW 11.4 11.4 11.9 11.4 11.4 11.9 BURNER PRESSURE mbar 1.5 1.0 0.9 5.4 3.8 3.1 3 GAS RATE m /h 1.2 1.2 1.26 0.46 0.5 0.49 Table 2. FLUE DETAILS HORIZONTAL FLUE mm WALL HOLE DIAMETER EXTERNAL FIX 110 INTERNAL FIX 150 STANDARD FLUE (From flue outlet centre) MIN UNCUT LENGTH 425 MAXIMUM LENGTH 725 24CDi 4000 EXTENDED FLUE MAXIMUM LENGTH 28CDi and 35CDi II 3000 FLUE ASSEMBLY DIAMETER 100 Table 3 PUMP HEAD BOILER OUTPUT HEAD MIN. FLOW RATE FLOW/ RETURN DIFFERENTIAL kW Metres L/min. °C 9.0 4.2 11.7 11°C 24CDi 20.5 12.5°C 24.0 2.0 28CDi 28.5 12°C 27.5 1.9 35CDi II 28.5 12°C Table 4 MECHANICAL SPECIFICATIONS CENTRAL HEATING FLOW - COMPRESSION 22mm CENTRAL HEATING RETURN - COMPRESSION 22mm COLD WATER INLET - COMPRESSION 15mm DOMESTIC HOT WATER FLOW - COMPRESSION 15mm GAS INLET Rp 3⁄4 RELIEF VALVE DISCHARGE 15mm Copper Tube 24/28CDi 35CDi II CASING HEIGHT 850mm 850mm CASING WIDTH 450mm 500mm CASING DEPTH 360mm 370mm WEIGHT - DRY 45kg 49kg WEIGHT - MAXIMUM INSTALLATION 42kg 46kg WEIGHT - PACKAGED 48kg 53kg 4 Table 5 PERFORMANCE SPECIFICATIONS PRIMARY WATER CAPACITY 2.0 litres MAXIMUM MAINS INLET PRESSURE 10 bar MINIMUM MAINS INLET PRESSURE (working) for max. hot water flow 1.2 bar MINIMUM MAINS INLET PRESSURE (working) to operate appliance 0.7 bar MAXIMUM CENTRAL HEATING FLOW TEMPERATURE 82°C nom MAXIMUM CENTRAL HEATING SYSTEM SET PRESSURE 1.5 bar DOMESTIC HOT WATER TEMPERATURE RANGE 50 - 62°C 24CDi 28CDi 35CDi II OUTPUT TO DOMESTIC HOT WATER NATURAL GAS (G20) 9.0 - 24 kw 9.0 - 28kw 9.5 - 35.3kw LPG - PROPANE (G31) 9.0 - 24 kw 9.0 - 28kw 9.5 - 35.3kw OUTPUT TO CENTRAL HEATING NATURAL GAS (G20) 9.0 - 24 kw 9.0 - 24kw 10.5 - 27.5kw LPG - PROPANE (G31) 9.0 - 24 kw 9.0 - 24kw 10.5 - 27.5kw DOMESTIC HOT WATER SPECIFIC RATE AT 30° RISE 11.8 l/min 13.5 l/min 16.8 l/min MAXIMUM DOMESTIC HOT WATER FLOW RATE FROM APPLIANCE AT 40° RISE 9.0 l/min 10 l/min 12 l/min NOx CLASSIFICATION Class 2 SEDBUK* NATURAL GAS 78.1% D 78.9% D 78.5% D SEDBUK* LPG - PROPANE 81% D 80.7% D 80.8% D *The value is used in the UK Government Standard Assesment Proceedure (SAP) for the energy rating of dwellings. The test data from which it has been calculated have been certified by the Gastec notified body. Table 6a (24CDi) DOMESTIC HOT WATER - TEMPERATURE RISE DISCHARGE RATE l/min 7 8 9 10 TEMPERATURE RISE °C 49 42.9 38.1 34.3 Table 6b (28CDi) DOMESTIC HOT WATER - TEMPERATURE RISE DISCHARGE RATE l/min 7 8 9 10 TEMPERATURE RISE °C 57.3 50.2 44.6 40.1 Table 6c (35CDi II) DOMESTIC HOT WATER - TEMPERATURE RISE DISCHARGE RATE l/min 9 10 11 12 TEMPERATURE RISE °C 57.3 50.2 44.6 40.1 Table 7 GAS SUPPLY SYSTEM - BASED ON NG (G20) TOTAL LENGTH OF GAS SUPPLY PIPE meters 3 6 9 GAS DISCHARGE RATE m3/h PIPE DIAMETER mm 8.7 5.8 4.6 22 18.0 12.0 9.4 28 Table 8 CLEARANCES (mm) INSTALLATION SERVICE ABOVE APPLIANCE FLUE ELBOW 30 30 IN FRONT OF APPLIANCE 600 600 BENEATH APPLIANCE 200 200 RIGHT AND LEFT HAND SIDE 10 10 Table 9 SYSTEM CAPACITY WITH A 10 LITRE VESSEL TOTAL SYSTEM VOLUME litres INITIAL INITIAL CHARGE PRESSURE bar PRESSURE bar 0.5 1.0 1.5 1.0 72 92 n/a 1.5 39 53 64 5 4. Siting The Appliance Fig. 2. Appliance casing dimensions and required clearances. 4.1 The appliance may be installed in any room although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations BS 7671 and, in Scotland, the electrical 30mm* provisions of the Building Regulations applicable in Scotland, 159mm with respect to the installation of appliances in rooms containing 24/28CDi baths or showers. 197 35CDi II 24/28CDi Where a room sealed appliance is installed in a room containing mm 225mm a bath or shower, any electrical switch or appliance control using Side view 35CDi II 250mm 850mm mains electricity must not be able to be touched by a person 35CDi II Front view using the bath or shower. 370mm 35CDi II 4.2 The appliance is not suitable for external installation. 500mm 4.3 The appliance does not require any special wall protection. 24/28CDi 360mm 600mm* 24/28CDi 4.4 The wall must be capable of supporting the weight of the 450mm appliance. See Table 4. 4.5 The specified clearances must be available for installation 10mm* 10mm* and for servicing. See Fig. 2. and Table 8. 200mm* 4.6 The appliance can be installed in a cupboard used for airing clothes provided that the requirements of BS 6798 an
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