Bosch 19/24CBI Installation And Servicing Instructions Download Page 11

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Fig.10. Boiler wiring diagram

Flame

Sense

Electrode

Spark

Electrode

Gas Valve

Air pressure

switch

Overheat

Thermostat

Fan

Control Board

ange

User control

potentiometer/switch

black

white

own

violet

black

orange

brown

grey

white

COM

Temperature

sensor

Pump Live

Pump Neutral

Permanent Neutral

Permanent Live

Switched Live (Boiler Demand)

earth

Installer

Connections

blue

brown

Polarity of these connections is not
important.

3 pin header

Summary of Contents for 19/24CBI

Page 1: ...Bi GC NUMBER 41 311 55 LPG APPLIANCE OUTPUTS IMPORTANT THESE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE LEFT WITH THE USER OR AT THE GAS METER Read the instructions before starting work they have been written to make the installation easier and prevent hold ups 9 14CBi N G Minimum 9 0 kW Maximum 14 0 kW 9 14CBi LPG Minimum 10 0 kW Maximum 14 0 kW 14 19CBi N G Minimum 14 0 kW Maximum 19 1 kW 14 ...

Page 2: ...m a householder who will be advised that he or she must call back the installer who has not fulfilled his obligations to record the information required by the initiative 2 1 General Information The Worcester boilers provide a heat output of between 9 14kW 9 14CBi 14 19kW 14 19CBi 19 24kW 19 24 CBi factory set at mid range and contain a temperature control and all the appropriate safety controls T...

Page 3: ...mand the burner will go out and the pump will continue to run for up to 4 minutes and the fan for 1 minute to dissipate the residual heat Domestic Hot Water The supply of domestic hot water depends upon the type of hot water equipment installed and the control system The use of unvented cylinders must be in accordance with the manufacturers instructions and relevant to British Standards The boiler...

Page 4: ...20 57 11 5 2 18 16 52 17 96 8 5 1 90 14 00 15 38 6 0 1 63 23 45 25 74 12 0 2 72 21 25 23 35 9 8 2 47 19 05 21 16 7 8 2 24 14 00 15 28 27 2 0 63 12 00 13 18 20 4 0 54 10 00 11 17 15 4 0 45 19 05 20 57 25 4 0 84 16 52 17 96 19 0 0 73 14 00 15 38 13 9 0 63 23 45 25 74 29 9 1 05 21 25 23 35 24 6 0 96 19 05 21 16 20 2 0 87 Table 1 Factory set at maximum input BURNER PRESSURE Natural Gas Net Input Gross...

Page 5: ... 19 05 23 45kw NOx CLASSIFICATION FOR CBi APPLIANCES Class 1 SEDBUK NUMBER AND BAND 9 14CBi NG 78 5 D 14 19CBi NG 79 4 D 19 24CBi NG 78 4 D 9 14CBi LPG 81 0 D 14 19CBi LPG 81 7 D 19 24CBi LPG 80 8 D Table 5 The appliance can be installed on the above clearance dimensions however for improved access the following is suggested Improved access 50mm is recommended For improved access minimum clearance...

Page 6: ...und on the opposite side The appliance is NOT suitable for external installation The wall must be able to support the weight of the appliance Refer to Table 4 The specified clearances must be available for installation and servicing Refer to Table 7 and Fig 2 The appliance can be installed in a cupboard compartment to be used for airing clothes providing that the requirements of BS6798 and BS5440 ...

Page 7: ...ow level Both high and low level vents must communicate with the same room or must be on the same wall to outside air The minimum requirements are 6 Air Supply 5 Flue terminal positions 7 L L K K F F G A M E J F HI D G A B C Fig 4 Siting of the flue terminal TERMINAL POSITION MIN DISTANCE TERMINAL POSITION MIN DISTANCE A directly below an openable window or I From a terminal facing a terminal 1200...

Page 8: ...a closed circuit in a house can be found on Page 8 25 Fig R24 2a of the Water Regulation Guide and Water Bylaws 2000 Scotland The appliance must not be operated without the system being full of water and correctly pressurised All connections in the system must withstand a pressure of up to 3 bar The system and the appliance must be properly vented Repeated venting loses water from the system and u...

Page 9: ...ion Vessel For system wiring please refer to Fig 10 and the controls manufacturers details Bypass balancing valve or bathroom radiatior with two lockshield valves Pressure Gauge Relief Valve Fig 8 Sealed system filling and make up Primary cold feed 15mm min Heating vent 22mm min Feed and Vent Cistern Diverting valves Boiler Pump Radiator S H Minimum static head 1 2m measured from the highest point...

Page 10: ...d system wiring centre must be through a common fused double pole isolator situated adjacent to the appliance The isolator must have a contact separation of 3mm minimum in all poles A single switched live cable should be wired into the boiler from the system wiring centre The mains and pump cables must be fed through the mains lead bracket secured through the cable clamp and connected to the conne...

Page 11: ...3 X4 X5 X6 1 orange 1 1 X7 User control potentiometer switch black white brown grey violet red violet red black orange brown grey white NC NO COM Temperature sensor Pump Live Pump Neutral Permanent Neutral Permanent Live Switched Live Boiler Demand earth Installer Connections blue brown Polarity of these connections is not important 3 pin header ...

Page 12: ... wiring centre L switched Pump not to be connected to system wiring centre Pump supplied from boiler only L N E Timer Room thermostat Tank thermostat System water valves 230V 50Hz 5A Fuse System components wired into terminal strip in accordance with component manufacturers instructions Frost stat Common isolator for wiring centre and boiler Should be located adjacent to the boiler MainsEarth TOPC...

Page 13: ...crew 9 Cabinet fixing screw 10 Gas valve 11 Spark electrode 12 Burner injector 13 Temperature sensor 14 Overheat thermostat 15 Air pressure switch 16 Flow pipe 17 Return pipe 18 Combustion test point 19 Sensing tubes 20 Fan 21 Flue hood 22 Inner case cover fixing points 4 23 Outer case earth tag 24 Side cover plate 25 Wire clip 26 Pressure tube junction 1 2 22 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 14: ...perature sensor 14 Overheat thermostat 15 Air pressure switch 16 Flow pipe 17 Return pipe 18 Combustion test point 19 Sensing tubes 20 Fan 21 Fan clamp 2 screws 22 Inner case cover fixing points 4 23 Flue hood 24 Outer case earth tag 25 Side cover plate 26 Wire clip 27 Front baffle Fig 12b Boiler Assembly 14 19 and 19 24CBi Shown set for horizontal flue or vertical flue 1 2 23 22 3 4 5 6 7 8 9 10 ...

Page 15: ...e at 110mm diameter ii Fix the wall mounting plate do not fully tighten the screws iii Measure the wall thickness L Min 220mm Max 375mm If L is less than 220mm thick then it is necessary to cut the flue To do this subtract L from 220 and cut all flue parts by this amount Ensure that the ducts are square and free from burrs Always check dimensions before cutting The minimum length L is 100mm with c...

Page 16: ...eflowandreturnpipestothesystem Itisimportant that the flow and return pipes are not fixed near to the boiler using clips that put a strain on the connections A drain point should be fitted close to the appliance if bottom connections are made Always consider the possible need to disconnect and remove the boiler 11 1 7 Installation of Flue onto Boiler i Pull the flue into position so that the holes...

Page 17: ...ssure tube extension 2 3 red tube 4 clear tube 5 7 Fig 16 Fan Flue hood Assembly with Rear Only Flue Kit 6 NOTE The polarity of wires is not important 9 10 8 ve ve 11 12 Fig 15 Fixing the appliance to the wall mounting plate 1 2 6 3 4 5 7 8 1 Telescopic flue assembly 2 Wall mounting plate 3 Fixing or security screw 4 Levelling feet 2 5 Restrictor plate with rectangular hole 6 Gasket 7 Flue fixing ...

Page 18: ...lt Drill the 5 fixing holes 60mm deep for the No 12 size plugs 11 2 4 Boiler Preparation i Remove the appliance casing by releasing the screw at the centre base Disconnect the earth connection at the base and lift off ii Release the four screws and remove the inner casing cover iii Release the two wing nuts and remove the combustion chamber front panel The cover is located into notches at the base...

Page 19: ...5 2 2225 3 2500 19 24CBi 3 2975 9 14 and 14 19CBi iv Measure length L Refer to Fig 20 21 22 v For installation of standard flue up to 750mm refer to Section 11 2 6 For installation of flue greater than 750mm refer to Section 11 2 7 For installation of bend kits refer to Sections above and Section 11 2 8 For installation of vertical adaptor refer to Section 11 2 9 For installation of internal fitti...

Page 20: ...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 Measure the lengths X and Y Refer to Fig 23 The maximum value of X using the turret assembly only is 506mm Reduce the ducts to the appropriate length e g X 406mm cut 100mm from the air duct and 120mm to cover the entry into the 45 or...

Page 21: ...ng ring 11 2 11 Install the Boiler IMPORTANT Thoroughly flush the system before connecting the boiler Any system cleanser must be fully flushed from the system before adding any inhibitor i Lift the boiler onto the wall mounting plate See Fig 27 ii Level the boiler using the two levelling feet at the base of the back panel iii Fit the bottom fixing screw or optional security screw iv Connect the g...

Page 22: ... 11 2 13 Completion of the Installation Check that all the gas and water connections have been tightened Lower the base plate control panel Refer to Fig 30 The permanent mains and switched live supply to the boiler must come from the system junction box Refer to Fig 11 A 4 core cable is recommended Feed the 4 core cable and the pump cables through the bracket and secure in the cable clamp Refer to...

Page 23: ...ed system has been installed then fill through a WRc approved filling kit to an initial pressure of 2 5bar Check for water soundness throughout the system Vent each radiator in turn Remove the cap from the pump and turn the shaft about half a turn Replace the cap Check that the relief valve sealed system operates by turning the knob anti clockwise until it releases 12 2 Set the Expansion Vessel Pr...

Page 24: ...comprehensive maintenance contract 13 6 Tell the user that any work on the appliance must only be carried out by a competent person 14 1 The extent of the service will be determined by the operating condition of the appliance It is the law that any service work is carried out by a competent person 14 2 Inspection Check that the terminal and the terminal guard if fitted are clear and undamaged If t...

Page 25: ... top and bottom after covering the burner injector To clean the heat exchanger flueways remove the stainless steel baffles from the appliance the rear combustion chamber cover can be tilted for better access The front and rear flueways can be cleaned with a brush being careful to protect the rear combution chamber insulation The inner flueway can be cleaned with a scraper Check the combustion cham...

Page 26: ...might retain water 15 4 Component Replacement 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 15 Replacement Of Parts 26 1 Inner case 8 Base controls fixing screw 2 J bolts and wing nuts 2 9 Cabinet fixing screw 3...

Page 27: ...tat 15 Casing support 16 Return pipe 17 Flow pipe 18 Air pressure switch 19 Combustion test point 20 Air pressure switch fixing clip 4 21 Flue hood 22 Fan 23 Sensing tubes 24 Outer case earth tag 25 Side cover plate 4 5 6 7 8 7 9 8 10 14 15 11 12 14 11 16 17 18 19 20 21 22 23 Fig 35 Base Control Board Assembly 1 2 3 4 5 6 7 8 1 Base control assembly 2 Base control assembly fixing point 3 Gas valve...

Page 28: ...ata plate on the cabinet where required pressure will be indicated Alter the red arrow if a new setting is made The adjustment screw must be sealed by a dab of paint to stop unauthorized adjustment Switch off the appliance disconnect the pressure gauge and tighten the test point screw Refer to Fig 31 Check for gas soundness 15 4 2 Spark Electrode Remove the inner casing cover and the combustion ch...

Page 29: ...connections are correctly made to the new fan Refer to Fig 37 and 37a Do not use any sealant on the fan flue duct connection The polarity of wires onto the fan is not important 29 1 1 Flue hood 2 Fan 3 Sensing connection 4 Sensing connection 5 Flue turret 6 Fan clamp 7 Fan clamp fixing screw 2 3 red tube 4 clear tube 5 6 7 Fig 37 Fan Flue hood Assembly with Horizontal Flue 1 1 Flue hood 2 Fan 3 Se...

Page 30: ...he position of each pressure tube carefully disconnect the tubes and electrical connections from the switch Unclip and remove the switch if there is more than 50mm clearance Refer to Fig 40 If there is minimum clearance then remove the inner casing cover and release the two screws Remove the air pressure switch and mounting bracket complete Ensure that the connections are correctly made on the rep...

Page 31: ...ly burner blade assembly and the access plate at the left hand side of the inner casing Pull off the leads from the sensor and overheat thermostats Pull off the clip to remove the sensor and unscrew the overheat thermostat Pull out the clips securing the flow and return pipes and remove them from the manifolds It will be necessary to disconnect the pipes from the system adjacent to the boiler Unsc...

Page 32: ...cover IX Switch on the gas supply and open the gas cock at the appliance Check for leaks at the gas valve inlet X Refit the base control assembly XI Recommission the appliance Refer to Section 12 Commissioning for details Adjust the burner setting pressure as required Refer to Table 1 and Fig 31 XII Fix the Red Arrow on the data plate to show the boiler setting If the setting has been altered the ...

Page 33: ...ctrode Assembly 1 87161421400 9 E60 481 Sensor Electrode Assembly 1 87161421390 10 E60 482 Spark Electrode Lead 1 87161218050 11 E60 483 Sensor Electrode Lead 1 87161421370 12 E60 484 Heat Exchanger Assembly 9 14CBi 1 87161216990 13 E60 485 Heat Exchanger Assembly 14 19 19 24CBi 1 87161217000 14 E60 486 Insulation Kit 9 14CBi 1 77161018540 15 E60 487 Insulation Kit 14 19 19 24CBi 1 77161017960 16 ...

Page 34: ...run Boiler demand light on Pump supply on Ignition sequence Boiler cycles to satisfy temperature set by facia control knob Temperature Sensor disconnected Ignition sequence inhibited fan and pump may run for short period Boiler overheat Overheat thermostat trip Lockout light constant Protection Systems re attempt ignition MAX 4 times lockout light flashing Fan continues for 1 minute FAIL PASS PASS...

Page 35: ...ystem 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 WARNING In addition to the controls the overheat thermostat and fan are connected directly to the per...

Page 36: ...ate electrical supply from external system No Create a new demand Does the fan run Yes No Is there 230V across the fan terminals WARNING if NO both fan terminals will be LIVE Does the pump run Check fuse F1 on the control board Has it blown No No No Replace fan Yes Air pressure switch is stuck on Replace air pressure switch Yes Replace fuse and investigate cause Suggestions connections to or fault...

Page 37: ...oiler demand With the boiler cool does the pump run Yes Switch off mains supply Remove boiler cover and inspect the temperature sensor Is it correctly fitted to the manifold with heat conductive paste on its surface Yes Gain access to control board and inspect the slide switch at the front of the board In normal domestic installation this switch should be in the left normal position Yes Yes Yes Re...

Page 38: ... leads Yes Replace control board Yes During spark period is there 216V D C across the pins at connector X2 Replace gas valve or check cable to it Yes No Yes TURN OFF GAS SUPPLY Remove the combustion chamber cover Is the sense right electrode and lead in good condition and is gap correct See Section 15 4 3 No Repair or replace flame sense or cable to it Replace control board Note It is not possible...

Page 39: ...et to maximum Less than 75 C Such a fault is likely to be caused by one or more of the following Low gas pressure Partially blocked flue Partially blocked heat exchanger Blocked dirty burner Gas valve sticking Control board fault Faulty themister Replace control board Move control knob to lower setting Check thermister sensor heat conductive paste ...

Page 40: ...40 ...

Page 41: ... U C E RB E E NF I T T E D Y E S N O WHATTYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE f t3 h r MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE l t s m i n FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE ...

Page 42: ...Y NAME TEL N o CORGI ID CARD SERIAL N o COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL N o CORGI ID CARD SERIAL N o COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL N o CORGI ID CARD SERIAL N o COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL N o CORGI ID CARD SERIAL N o COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL N o CORGI ID ...

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Page 44: ...onditions of Sale a copy of which may be obtained on application PUBLICATION 8 716 115 015a 02 08 This manual is to be used in conjunction with the variant part number of the bar code below Bosch Group Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 753130 Technical Helpline 08705 266241 Worcester Bosch Group is a trading name of BBT Thermotechnology U...

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