Worcester Bosch Highflow 3.5 RSF Installation And Servicing Instructions Download Page 3

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Summary of Contents for Highflow 3.5 RSF

Page 1: ...G INSTRUCTIONS GC NUMBER 41 311 40 BOILER OUTPUT To Hot Water Maximum 23 4 kw 80 000 Btu h To Central Heating Minimum 8 8 kW 30 000 Btu h Maximum 23 4 kW 80 000 Btu h IMPORTANT THIS APPLIANCE IS FOR U...

Page 2: ...Standards Scotland Consolidation current lEE wiring regulations and bye laws of the local water undertaking It should be in accordance with the relevant recommendations of the following British Standa...

Page 3: ...c heads are measured from the top of the casing to the highest point of the system See Fig_s 24 and 25 Table 3 HORIZONTAL VERTICAL FLUE DETAILS See Notes Below REAR FLUE PRIMARY FLUE WALL OR CEILING H...

Page 4: ...ensure a nominal pressure of 20 mbar Bin wg at the appliance equivalent to a pressure of about 18 5 19 mbar at the gas valve The complete installation mcluding the meter should be inspected and tested...

Page 5: ...ed head screws and single posidrive screw retaining the top of the right hand side panel J Draw the side panels forward and lift out NOTE The control panel is supported in position by a single posidri...

Page 6: ...ance MUST be turned off immediately and the problem rectified 6 7 AIR SUPPLY VERTICAL FLUES 1 The room in which the appliance is installed does not require a purpose air vent 2 If the appliance is ins...

Page 7: ...RD FLUE KIT MINIMUM HEIGHT H 1557mm 61 3in MAXIMUM HEIGHT H 2000mm 79in WITH EXTENSION KIT MAXIMUM HEIGHT H 3000mm 118in BOTTOM OF FLUE OUTLET SOCKET H 45mm 1 8in 1 l_ G GENERAL GUIDANCE SITING OF VER...

Page 8: ...and 7 To gain access to the top flue outlet cover first re move the access cover Fig 6 Fig 4 Wall preparation Rear outlet Dimensions mm in 1 5 r 1 600 23 6 L 1 1 r I r I J 1 t _ _ a Remove the top air...

Page 9: ...135mm 5 3in F 90mm 3 5 n A 60mm 2 4in mn g s cr LOcn rn Drnoc Jc J 2 22 E E E E E E E E E E N 0 lO o o r mro D Dr r roro Fig 7 Flue Air Duct Socket Clamping Screws NOTE A SIMILAR METHOD IS USED TO CLA...

Page 10: ...e Pass the flue duct through the wall and push the end fully home into the rear flue duct socket Working through the top air duct socket tighten the rear flue duct clamping screw Make sure the flue du...

Page 11: ...1 n 110mm 4 S n I A 0 I DIAMETER DO NOT CUT FROM THE END WITH TWO HOLES Flue duct Rear flue application OVERALL LENGTH L PLUS 51mm 2 0 n c CUT FLUE DUCT TO REQUIRED LENGTH FROM EITHER END ENSURE END...

Page 12: ...nding centrally in front of the hole in the wall Position the back panel about 40mm 1 6 in front of the wall face Pass the flue duct through the wall and push the end fully home into the rear flue duc...

Page 13: ...EALANT AROUND THE OUTSIDE OF THE STANDARD DUCT Flue duct Rear flue application OVERALL LENGTH L PLUS 51mm 2 0in i_ i o l 900mm 3 5in I 60mm 2 4in I 1 1 DIAMETER 6 dl T REDUCE LENGTH OF REDUCE LENGTH O...

Page 14: ...NOTE USE SUPPORT SPIDER AS SHOWN BELOW FROM THIS END ENSURE END IS SQUARE AND FREE OF BURRS Fig 14 Rear flue duct assembly FOR WALL THICKNESSES FLUE LENGTHS FROM 1201mm to 2000mm 47 3in to 78 7in USE...

Page 15: ...he terminal will engage and push over the section of flue duct connected to the boiler provided the air and flue ducts have been cut accurately 7 Move the appliance into its final position The air duc...

Page 16: ...duct air duct H 9 2a 1557mm 2000mm 61 3in 78 7i n 9 2b 2001 mm 3000mm 78 8in 118 1 in I 9 2a BOILER FLUE ASSEMBLV VERTICAL 1557mm 2000mm 61 3in 78 7in For overall flue height H between 1587mm 2000mm 6...

Page 17: ...4 17 4 a Retain the AIR duct in position by tightening the seal ing plate clamping screw Fig 19 Ensure the assembly is vertical RECHECK TO ENSURE THAT ANY STUB PIPE CON NECTIONS REQUIRED HAVE BEEN MA...

Page 18: ...mm 5in FLUE 110mm 4 7in DIAMETER OUTLET SOCKET FOR CONNECTION OF SECONDARY FLUE SYSTEM TO BS 5440 1 TOP CLAMPING SCREW DIVERTER oono A FLUE DUCT EXPANSION JOINT OF APPROXIMATELY 100mm 4in OVERLAP IS A...

Page 19: ...lue length to that used for the air ducts i e H Fig 21 This is the overall length of 60mm 2 4in diameter flue duct required b Assemble the flue ducts D and E and F Fig 21b c Reduce the length of the f...

Page 20: ...RALL VERTICAL FLUE LENGTHS FROM 2001mm to 3000mm 78 8in to 118 81nl USE THE STANDARD VERTICAL AND EXTENSION FLUE KITS REFER TO FIG 22 IMPORTANT REFER TO INSTRUCTIONS IN SECTION 9 2b BEFORE CUTTING AIR...

Page 21: ...TTED OVER FLUE DUCT AND PUSHED AGAINST EXPANDED END SELF TAPPING SCREWS PROVIDED SELF TAPPING SCREWS PROVIDED AIR OUCT 1 FLUE DUCT FIX WITH SELF TAPPING SCREWS _ PROVIDED _ BOTH SOCKETS REQUIRE A gK T...

Page 22: ...have a resistance to flow of water not greater than that of a straight pipe 9 metres long The termination of the discharge pipe must be visible but in a location not readily accessible to persons Disc...

Page 23: ...nce will ac commodate differing system volumes depending upon the initial charge pressure and pre pressurisation pressure of the system if any Refer ence should be made to Table 8 to establish the sys...

Page 24: ...E ADRAIN COCK SHOULD BE I I INSTALLED AT THE LOWEST POINT OF THE SYSTEM AND I I BENEATH THE BOILER I I I I I I I I I I I I I I I I I I I I I I I I I LOCKSHIELD RADIATOR I VALVE VALVE I 11 OPEN VENT PR...

Page 25: ...water unless separate arrange ments for expansion water are made The final 600mm mains cold water connection to the unit should be made in copper only 2 HOT SUPPLY AND FLOW REGULATING The appliance i...

Page 26: ...th a contact separation of 3mm in all poles and supplying the boiler and system controls only Mains Cable 0 75mm 24 X 0 20mm to BS 6500 80 C Should the factory fitted mains cable need to be replaced t...

Page 27: ...THERMOSTAT pk PINK VIOLET lJr BROWN y YELLOW or OHANGE w WHITE p T9 10 RED p PURPLE Purge pipework of air by loosening the gas valve inlet union and purging until gas is smelt Refer to Fig 31 Tighten...

Page 28: ...e and size Refer to item 11 for sizes and method of adjustment If the pilot and burner will not light contact Worcester Heat Systems Ltd Ser vice Department a Check the pilot pipe for gas soundness at...

Page 29: ...elector switches to 24hr setting Set both appliance thermostats to maximum The boiler will fire and commence to heat up the rad iators Allow to operate for 45 minutes venting as necessary Check for wa...

Page 30: ...ance COLD as follows i Isolate the electrical supply to the appliance ii Refer to Section 3 Page 4 Remove the appliance front panel and top cover iii Test the valve by grasping and turning clockwise f...

Page 31: ...e collector hood to the top of the combustion chamber sufficiently for the hood to be drawn for ward about 1Omm Fig 33 When the screw heads are at the back of the keyhole slots lift the rear of the fa...

Page 32: ...water operates correctly When the priority thermostat is satisfied switch the central heating on and check that the diverter valve operates and supp lies hot water to the central heating circuit 32 e...

Page 33: ...nd Inspection Subsection 5 Remove the fan sealing gasket Fig 36b b Slacken the screw A at the top of the fan outlet fix ing it to the collector hood back panel Fig 33 c Remove the three slotted head s...

Page 34: ...minal at the top right hand side of the sequence control board Withdraw the lead through the plastic grommet in the bottom of the control panel Fig 37 j Pass the capillary tube and thermostat phial up...

Page 35: ...ions from the rear of the thermostat f Push the thermostat body back to disengage the spindle from the mounting bracket g Withdraw the thermostat threading the capillary through the plastic grommet in...

Page 36: ...minals NOTE the plugs are dissimilar and therefore not inter connectable d Release the inlet gas union connection at the gas service cock Fig 43 e Remove the four M5 hex head screws securing the right...

Page 37: ...ealed the primary expan sion pipe will be capped In this case drain down the central heating system Drain cock Fig 43 Disconnect the union where the safety valve discharge pipe is attached to the safe...

Page 38: ...sub section 5 b Remove the damaged sealing strip and fit the re placement strip Check that the new strip is pressed home 8venly around all four sides of the collector hood Ensure there is no gap where...

Page 39: ...ront door top cover boiler front cover and facia b Remove the pozidrive screw attaching the bottom of the baffle plate behind the control panel to the top of the boiler Remove the two M5 hex head scre...

Page 40: ...tronal Worcester Heat Systems 1 ZAMAJ163 104 371402 Pump Delay Timer Board Pactrol 408401 1 ZAGAS080 105 368289 Relay Omron MY4 1 ZDELE183 107 324978 Electronic Sequence Board Vernitron 22507 005 1 ZA...

Page 41: ...ol lo 24 39 22 e u 166 106 107 36 i6 25 105 33 35 110 54 0 55 51 34 50 38 0 104 fj 101 172 If CD 16 19 cp co en 0 l 0 I l 0 r c 0 3 108 174 52 32 43 37 131 1...

Page 42: ...ERE A LIVE SUPPLY TO TERMINALS 1 2 l I YES NO f REPLACE PROGRAMMER I ON MODELS FITTED WITH A PROGRAMMER SELECT EACH AVAILABLE PROGRAMME IN TURN AND ROTATE THE DIAL CLOCKWISE WITH THE AID OF A MULTIMET...

Page 43: ...PILOT LIGHT CLEAN PILOT CHECK PILOT I INJECTOR IS NOT SUPPLY OF GAS TO THE J BLOCKED DOES THE PILOT INLET SIDE OF THE GAS LIGHT VALVE YES 1 YES NO J REPLACE I Icou m RESTRICTOR ON GAS VALVE I GAS VAL...

Page 44: ...THERE A LIVE SUPPLY AT PRESSURE IS CHANGEOVER TERMINAL 8 OF THE RELAY SATISFACTORY YES YES REPLACE GAS VALVE CHECK IS THERE LIVE SUPPLY AT NO HIGH LOW OPERATION TERMINAL 6 OF THE MAIN TERMINAL STRIP...

Page 45: ...NER GO OUT AND OR THE SYSTEM BOIL IF SO REPLACE BOTH THE HOT WATER CONTROL AND HOT WATER LIMIT STATS IS THE HOT WATER HEAT EXCHANGER ABOVE eo c IL ____1 NO I REPLACE HOT WATER LIMIT I THERMOSTAT DOES...

Page 46: ...NOTES 46...

Page 47: ...NOTES 47...

Page 48: ...3 This booklet ts accurate at the dale of printing but will be superseded and should be disregarded if specifications and or appearances are changed in the interests of continued improvement All goods...

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