Bosch Worcester 240 Combi OF Installation And Servicing Instructions Download | Manualshive

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Summary of Contents for Worcester 240 Combi OF

Page 1: ...G INSTRUCTIONS GC NUMBER 47 311 09 BOILER OUTPUT Automatic Modulating Control To Domestic Hot Water and Central Heating Minimum 9 2 kW 31 400 Btu h Maximum 24 0 kW 82 000 Btu h IMPORTANT THIS APPUANCE IS FOR USE WITH NATURAL GAS ONLY THESE INSTRUCTIONS APPLY IN THE UK ONLY THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER ...

Page 2: ...rmal capacity Gas to Water heat exchanger AWater to Water heat exchanger to provide domestic hot water Fully modulating controls in the central heating and domestic hot water modes of operation An expansion vessel pressure gauge and pressure relief valve Aby pass for the central heating system Temperature safety cut out controls Awater flow regulator 2 10 Electrical Page 10 11 Installation Page 13...

Page 3: ...ry with the number of outlets operated simultane ously 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 or even starvation to indi vidual outlets For further information contact Worcester Heat Systems Ltd 2 12 SAFETY CONSIDERATIONS The appliance must not be operated in a waterless condition T...

Page 4: ...S INLET FrrnNG Rc1 2 PRESSURE RELIEF VALVE DISCHARGE FriTING 15 mm Compression CASING HEIGHT 900 mm 35 4 in CASING WIDTH 450 mm 17 7 in CASING DEPTH 360 mm 14 2 in WEIGHT including water 48 kg 10Sib INSTALLATION WEIGHT 46 kg 101 lb PACKAGED WEIGHT 49 kg 1 08 lb TABLE4 SPECIFICATIONS PRIMARY WATER CAPACITY 2 7 litres 0 6 galls MAXIMUM COLD SUPPLY PRESSURE 10 Bar 1 50 psi MINIMUM COLD SUPPLY PRESSUR...

Page 5: ...n front 600mm 600mm Below 900mm 230mm Right hand side 100mm 100mm Left hand side 100mm 100mm 4 7 No combustible surface must be within 75 mm of the cas ing See BS476 4 4 8 Always consider the possible need to disconnect the pipes from the appliance after installation 4 9 Boilers in roof spaces or in understair locations require special conditions Refer to BS 6798 4 10 The appliance must have a min...

Page 6: ... is taken through the ceiling and into the roof space or room above then a sleeve of non com bustible material allowing an air space of at least 25 mm between the flue and the sleeve must be provided The flue pipe must be held in the centre of the sleeve 6 Air Supply 6 1 The room in which an appliance is installed must have a per manent air vent to outside air or to a room which itself has 6 direc...

Page 7: ...n return va Hose union l 1 t t zr u I 1 l i Stop cock II II Test cock Temporary hose 7 7 8 Water loss must be r placed See Fig 6 The connection should be made in the central heating return as close to the appliance as possible 7 9 The make up vessel if fitted must be fitted with a non return valve 7 10 Repeated venting loses water from the system it is essen tial that this water is replaced and th...

Page 8: ..._______ __ lockstoeld v Radllltor valvt l tlllllll J llllllll Nott Adr0111 cock should be InStalled at the lowest poont ofthe heattng c1rcut ill1d beneath the appliance 9 Domestic Hot Water 9 1 The following are general requirements and if necessary reference should be made to the local Water Company before fit ting the appliance 9 2 MAINS COLD WATER INLET Devices capable of preventing the flow of...

Page 9: ...mitted subject to local Water Company requirements pro vided that the bidet is of the over rim flushing type The outlet s 9 should be shroucded and unable to have any temporary hand held spray attached No anti syphonage arrangements are nee essary 9 14 As the maximum temperature of the Water to Water heat exchanger is limited by the control drcuit there is normally no need for water treatment to p...

Page 10: ...n the live and neutral leads 10 6 The wiring between the appliance and the electrical supply shall comply with current lEE Wiring Regulations and any local regulations which apply 10 7 If a room and or frost thermostat is to be fitted refer to Figs 10 and 11 The thermostats must be suitable for use on mains voltage 10 8 A facia mounted programmer is available as an extra Instructions are supplied ...

Page 11: ...wn bl blue gy green and yellow bk black or orange J r red w white y yellow g grey v violet pk pink I I L L T I I I I I I I I I I I Pump Overrun Thermostat 1 _____ _J I _ J 1 Tj I I I I I I I I I I I I I I I i Diverter Valve Micro Switch br gy bl 11 Main Valve Modureg Regulator Gas Valve Domestic Hot I I I I I I I I I I I J Water 1 Thermostat 1 Domestic Hot Water Sensor ...

Page 12: ... iOHW Xl PIN Jl h l w lie XII IPIN 11 Xl IPIN 11 white I _ CH r OPERATING SWITCH a ed ElECTRONICS lOR PROGRAMMER I D IW Xl iPINSl W4TER OMRTER V4LVE I L _j XS PIN Jl C NTR4l H 4TING SENSOR red XS IPIN 11 a DOMES11C HOT WATI R SENSOR brown T Tl MI ERATURE CONTROt I OTI NTIOMETtR L brown GAS PUMP OVERRUN THERMOSTAT Oflnge I VALVES __ N XI IPIN 11 I __ L PI I _____ _j btOWI l Fig 9 Functional flow di...

Page 13: ...ill the fixing holes 60 mm deep for No 12 size plugs and fix the appliance mounting plate and check that it is horizontal before tightening the screws The gas and water pipes can be led towards the appliance at this stage See Fig 3 It is recommended that temporary connec tions be made to thoroughly flush the central heating system Also flush the primary cold water supply pipe before the appli ance...

Page 14: ...t water system only Gas to Water heat exchanger Fig 14 Pipe connection for open vent systems To Gas to Water heat exchanger 14 Fig 15 Appliance casing and control equipment fixings r f I I Inner casing cover Cabiletside panel fixing screws 2 0 I Control box fixing screws 2 Upper fac1 apanel fixing screws 2 I ___ 301 m e Lower facia panel fixing screws 2 ...

Page 15: ...res 17 ft The charge eressure must not be less than the static head at the point of connection See Fig 4 A Schraider type tyre valve is fitted to the expansion vessel to allow the charge pressure to be increased if necessary Set the System Pressure Fill the system until the pressure gauge shows 2 5 bar 37 lblins and check for water soundness Release water from the system using the relief valve tes...

Page 16: ...essure must be adjusted at the potentiometer located at the rear of the control box Adjust the potentiometer to give a burner pressure of 14 S mbar This 16 figure can only be achieved if the burner pressures are correctly set in the domestic hot water mode Balance the system so that the required temperature difference across the central heating flow and return pipes is obtained See lable 3 Adjust ...

Page 17: ...ys test for gas soundness as indicated in BS 6891 14 3 DISMANTLE THE APPUANCE To carry out a full and comprehensive service of the appliance remove the following parts to gain access to the components which need to be checked or serviced a Cabinet Panels Remove the front panel by lifting off the supports Lower the control box as described in Section 14 3 d Pull off the lead from the spark generato...

Page 18: ...Fig 20 Appliance components and fixings upper assembly Combustion chamber cover fixing screws 4 Combustion chamber cover Diverter baffle Access cover Fig 21 Pilot burner assembly 2mm Thermocouple 0 18 ...

Page 19: ...the electricity supply to the appliance is turned off 19 Before removing any component holding water it is important that as much water as possible is removed from the appliance a Appliance 1 un off the central heating flow and return valves at the appliance See Fig 3 Fit a tube to the drain tap on the Water to Water heat exchanger and open the tap about one turn See Fig 26 Close the drain tap whe...

Page 20: ... electrode cable and pull out the electrode Fit the replacement burner in the reverse order ensuring that the pilot injector is in place Fit the electrode lead before replacing the electrode Check the pilot burner settings as shown in Fig 23 9 Main Burner Injector See Fig 22 Remove fhe main burner as described in Section 15 4 6 Unscrew the brass injector at the back of the combustion cham ber Fit ...

Page 21: ... components lower assembly Wiler divtrttr valva Waterlli ltn viM mitro swiltclch t t oJ assembly Mains cold inletlitlf Domestic hot water Oomntic hotwater tlow overheat thermostat mtrictor housilg Expansion YISSII 21 W1ter to water heat uchlllgtr Domestic hot water sensor I I Side insulationpad I Pilot QIS pipe Thermocouple Eltttrodt lead Spart generator red knob Owmeat thermoslll lnds D rain cock...

Page 22: ...tting and remove the sensor Fit the replacement sensor in the reverse order ensuring a layer of heat sink compound is between the faces Refit the leads 17 Circulating Pump See Fig 27 Check that the electricity supply to the appliance is turned off Drain the appliance as described in Section 15 3 a Hang the control box assembly in the servicing position as described in Section 14 3 d Undo the two u...

Page 23: ...hat the electricity supply to the appliance is turned off Lower the control box assembly as described in Section 14 3 d Using a pair of fine nosed pliers pull the circlip off and remove the micro switch assembly from the valve Lower the facia as described in Section 14 3 c Carefully pull off the Molex connec tion from terminal X3 on the driver board Remove the strain relief bush to withdraw the sw...

Page 24: ...to the appliance is turned off Hang the control box assembly in the servicing position as described in Section 14 3 d Carefully pull off the two leads from the thermostat Loosen the two M3 screws holding the thermostat to the fitting and remove the thermostat Fit the replacement thermostat in the reverse order ensuring a layer of heat sink compound is between the faces Refit the leads 27 Driver Bo...

Page 25: ...Pack Thermocouple Spark Generator Overheat Thermostat Domestic Water Umit Thermostat plus paste 57 81 7 22 53 llii 6036 Manufacturer s Reference Honeywell V4600N3061 HoneyweU V7335A3008 Aeromatic AC 23 053578 Aeromatic 600049 Stereomatic 4 4mm Dia l ype 7 Honeyweii Q385A 2010 Honeywell 45 004 108 001 38 36A Honeywell 45900413 01 o Glannoni PR 20 321 Jntermes 02 50 010 Elmwood 6655 9428 4 Cewal Cal...

Page 26: ...s Mlin gas valve off rJ Bumer incrtlseS from 2 2mblr to the set level over a one minute period mCentral helling temperlblrt IbM set IML m Hut input I I to llllintiin flow temperlblre set by T emperllllle Control Potentiometet 1 Central Heating Mode 1 1 1 1 Repeltedly Depress press red After20 seconds slowly ga ignUr button 1 releae gavalve button Pilottllme valve until pilot 30 seconds f tlime his...

Page 27: ...llld llld P ilnlrfWiler lenlperiiiUie _ 60 c II Pllmp on until pnn ry 1 Wiler lllnpellbllt 1 1 fills below 60 c Vld VF ON AutOIMtlc start SEE D TAILED SEQUENCE ABOVE 3 Pump OVenun Function llcmry IMI 2 Domestic HotWater Mode I GIS to Wiler belt adllneer tenlperlllllt boiler themiOIIIt to trip GIS VIM slllls clown but pump llld incliatDr liB is rl llllin on If Demand still msts 4 OVerheat Protectio...

Page 28: ... YES NO Start of pilot lighting test Solopt a Dt WI h01progr illnuodi10olfllm room th m ostM 11 nuodi10 n bll U NO I nun fdlow tht rwa O lt allOII ol b ghmg SIIA II IO lltbao tl ill ddwdpei n soqm e 10 poomA C n pdalllame beobse ved YES ct ecktha tilepdal tsaewG NO Chtd nkmol corl t y set Ill fuly dociw1se lg l1er adsond ond unscr WII g two rewkJtrcns Does COIWC1lonS Does tht ongnrter pro00cr a pl...

Page 29: ...the pump overrun thermosta Remove the plated screw in the centre ofthe pump and tum the shaft with aflat bladed screwdriver Does the pump now run Replace the pump Is there a240vsupply at NO pin 1on terminal XS YES Check connectiOns to gas valveor replace gas valve 29 Refer to failure at point Aand B is there approx 24V ac across the test pmson the driver board YES RernO IetheC H molex p lug from t...

Page 30: ...aconstant low voltage for approximately two minutes and then graduaDyincrease0 lel the next one minute Note The voltage values are not important YES Remove the Molex plug from terminal X1 Measure the resistance asfollows Between purple and yellow pins 10kDhms between purple and pink pins between zero and 101cohmsdepending on the setting ofthe temperature centro potentiometer Is this correct YES Re...

Page 31: ...ill illuminated YES 1 Remove the plated screw inthe Does the main burnerlight centreofthe pumpand tum the shaft with aflat bladed screwdriver Does the pumpnow run IRefer to failure at point E 31 IRefer to section STANDBY lndiatorI lightdoes not illwninlle Replace the Operating Switch or programmer IReplace the pumpoverrun thermostat Replace the pump Investigateand rectify low flow rate j ...

Page 32: ...ly YES STAR Of PUMP 0 f RRU J t s With no central heating or domestiC hot water demand and with primary water above 60 1 apprcx does the pump operate YES When the primary temperature drops below 60 lapprox does the pump stop YES Does the burner shut down if the Gas toWater heat exchanger water exceeds 100 C Is the STANDBY indicator Ught illuminated YES Replace the pumpoverrun thermostat Replace th...

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Page 36: ...4619 This booklet is accurate at the date of printing but will be superseded and should be disregarded ifspecifications and or appearances are changed in the Interests of continued Improvement All goods sold are subject to our offidal Conditions of Sale a copy of which may be obtained on application 8 716 114 713a 11 07 ...

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