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9.1 

The size of the flow and return pipework is given in Section 3

– Table 4. The components required to connect the appliance to
an open vent system are available as an optional extra kit.

9.2 

The feed and expansion cistern should be arranged so that

there is a minimum static head of 0.3 metres (12 inches) above
the top of the appliance or above the highest point in the heating
circuit, whichever is the higher. See Fig. 7

9.3 

The feed and vent pipe should be 22mm diameter and rise

continuously  from  the  appliance  to  the  feed  and  expansion
cistern.

9.4 

A  pressure  relief  valve  is  not  required  on  an  open  vented

system.

9.5 

Air  within  the  appliance  will  be  expelled  via  the  feed  and

vent connection or dissipated into the rest of the system which
must be fitted with manual air vents at any high point.

9.6 

The pump is set to maximum and must not be reset.

9.7 

If it is required to use the appliance for domestic hot water

before  the  central  heating  circuit  is  connected,  a  22mm  copper
by-pass  must  be  connected  between  the  central  heating  flow
and return. Refer to Section 12 and Fig. 7.

N.B: 35CDi

II 

IS NOT SUITABLE FOR OPEN VENT SYSTEMS.

9. Open V

ent Primary Systems

9

10.1 

The  following  are  general  requirements  and,  if  necessary,

reference  should  be  made  to  the  local  Water  Company  before
fitting the appliance.

10.2 MAINS COLD WATER INLET

. Devices capable of preventing

the  flow  of  expansion  water  must  not  be  fitted  unless  separate
arrangements have been made. An expansion vessel connection
point is provided within the appliance. An Rc1/8” connection is
provided. A mini expansion vessel kit is available from Worcester
Heat  Systems  Ltd.  A  thread  sealant  compatible  with  potable
water must be used. Refer to Section 2.9.

10.3 

The final 600mm of the mains cold water connection to the

appliance should be made in copper tube only.

10.4 

The  appliance  is  suitable  for  a  mains  pressure  of  up  to  10

bar.

10.5 

The appliance is fitted with a mains supply isolating valve.

10.6 

The  maximum  domestic  hot  water  flow  rate  is  9.0

litres/min (±15%) 24CDi or 10.0 litres/min (±15%) 28CDi or
12.0 litres/min (±10%) 35CDi

II.

10.7 

In  winter  (when  the  mains  inlet  water  temperature  is

lower) a reduced flow rate at the taps may be required to achieve
the hot water delivery temperature available in warmer weather.

10.8 

It  is  suggested  that  long  pipe  runs  to  the  taps  or  shower

should be insulated to prevent the rapid cooling of domestic hot
water after a tap or shower has been turned off.

10.9 

Hot  and  cold  taps  and  mixing  valves  used  with  this

appliance must be suitable for operating at mains pressure and
temperatures of 65°C.

10.10 

No  anti-syphonage  arrangements  are  necessary  except

for some loose head showers. See Clause 12. 

10.11 

Thermostatically controlled or pressure equalising shower

valves  will  guard  against  the  flow  of  water  at  too  high  a
temperature.

10.12 

The head of a loose head shower must not fall closer than

25mm (1in) above the top edge of the bath to prevent its immersion
in bath water. Alternatively the shower must be fitted with an anti-
syphonage device at the point of the flexible hose connections.

10.13 

The supply of hot and cold mains water direct to a bidet is

permitted,  subject  to  local  Water  Company  requirements,
provided  that  the  bidet  is  of  the  over-rim  flushing  type.  The
outlet(s) should be shrouded and unable to have any temporary
hand held spray attached. No anti-syphonage arrangements are
necessary.

10.14 

As the maximum temperature of the Water to Water heat

exchanger  is  limited  by  the  control  circuit,  there  is  normally  no
need  for  water  treatment  to  prevent  scale  accumulation.  In
exceptional  circumstances  a  device  to  prevent  scale  formation
can be fitted.
Installation  of  a  scale  inhibitor  assembly  should  be  in
accordance  with  the  requirements  of  the  local  Water  Company.
An isolating valve should be fitted to allow servicing. The water
hardness  can  be  determined  using  a  standard  test  paper  or  by
reference to the local Water Company.

10. Do

mestic Hot Water

Fig. 7. Open vent water system.

Lockshield
valve

Radiator
valve

S.H.

S.H.

Heating
return

Hot water out

Stop valve

Water main

British Standard
stop valve.
Fixed spindle type

Combined feed and
vent pipe (22mm),
must rise continuously

Static Head (S.H.): Minimum static head
0.3m (12ins) measured from the top
surface of the appliance or the highest
point in the heating system to the water
level in the feed and expansion tank.

Open vent pipe
(supplied as
optional extra)

Mains

cold

water

Heating
flow

NOTE: A drain cock should be installed at the lowest
point of the heating circuit and beneath the appliance.

Summary of Contents for 24CDi

Page 1: ...P G 47 311 31 47 311 35 47 311 59 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 Installat...

Page 2: ...tallations 2 1 General Information 2 1 1 The appliance is set to provide the maximum output for domestic hot water and a central heating load of 24kW 24 28CDi or 27 5kW 35CDi II The hot water flow rate is limited to a nominal 9 l min 24CDi or 10 l min 28CDi or 12 l min 35CDi II at a maximum temperature rise of 40 C 2 1 2 The sanitary water section of the appliance is suitable for water mains press...

Page 3: ...to an over rim 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 infor...

Page 4: ...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 GAS RATE m3 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 GAS RATE m3 h 1 2 1 2 1 26 0 46 0 5 0 49 Table 1 BOILER ADJUSTED ...

Page 5: ...PG PROPANE 81 D 80 7 D 80 8 D Table 5 DOMESTIC HOT WATER TEMPERATURE RISE DISCHARGE RATE l min 7 8 9 10 TEMPERATURE RISE C 49 42 9 38 1 34 3 Table 6a 24CDi 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 6b 28CDi 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 ...

Page 6: ...bustible partition Expanded metal or rigid wire mesh are acceptable provided that the major dimension is less than 13mm See BS 6798 4 8 The distance between the inner face of a cupboard door and the cabinet front should not be less than 75mm 4 9 The pipe connection positions on the manifold are shown in Fig 3 allowing the system to be pre piped and flushed before the appliance is fitted Always con...

Page 7: ...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 given below 6 5 Refer to BS 6798 and BS 5440 2 for additional information 6 Air Supply 5 Siting The Flue Terminal 7 POSITION OF AIR FROM AIR DIRECT AIR VENTS THE ROOM F...

Page 8: ... must not be made without the authority of the local Water Company 7 11 The pump is set at maximum and must not be adjusted 7 12 Connections in the system must resist a pressure of up to 3bar 7 13 Radiator valves must conform to BS2767 10 7 14 Other valves used should conform to the requirements of BS1010 7 15 No special system inhibitor is needed 8 1 The boilers require a gas flow in m3 h of NG G...

Page 9: ...e taps may be required to achieve the hot water delivery temperature available in warmer weather 10 8 It is suggested that long pipe runs to the taps or shower should be insulated to prevent the rapid cooling of domestic hot water after a tap or shower has been turned off 10 9 Hot and cold taps and mixing valves used with this appliance must be suitable for operating at mains pressure and temperat...

Page 10: ...the clamps provided The controls must be earthed at the connection on the control board Refer to Fig 11 and 13 11 8 A choice of programmers to fit into the facia are available to control the CH Full instructions are sent with the programmer Refer to Fig 15 11 9 On very rare occasions an external frost thermostat might be considered where parts of the system are remote from the appliance Refer to W...

Page 11: ...n Electronics Electronics Electronics Electronics Electronics Inputs Outputs Spark Indicators Settings Regulator valve CH demand indicator Red Spark electrodes DHW demand indicator Red Flame detect indicator Red Main valve Main valve Flow switch CH sensor DHW sensor Air pressure switch Flame sense Overheat cut off 24V programmer Reset button Gas valve mode switch CH pressure adjust pot CH Control ...

Page 12: ...Cover Fixing Screws Fig 13 Mains Voltage External Controls Connections 230 V Room Thermostat Connections Ns Ls LR Spare ST8 Ns Ls LR Spare ST8 Remove Link Neutral Live Switched Live Neutral Live Switched Live Motor 230 V Programmer Connections 230 V room thermostat and Programmer Connections Ns Ls LR Spare ST8 Neutral Live S w it c h e d L iv e Neutral L i v e S w i t c h e d L i v e Motor Fig 14 ...

Page 13: ...pacing frame is used then the 197mm dimension should be increased by 35mm see instructions supplied with frame Check the position and alignment of the holes before drilling the fixing holes 60mm deep for No 12 plugs and the flue holes Ø110 for external fitting and Ø150 for internal fitting Ensure that the flue hole is horizontal through the wall Refer to Fig 16 12 5 Wall mounting Plate and Manifol...

Page 14: ... Horizontal flue up to 1m 28CDi 77mm Horizontal flue up to 1m 35CDi II 85mm Horizontal flue up to 1m The standard uncut telescopic flue assembly is suitable 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 19 20 If L 725mm then extension duct kit s will be required each kit 14 Fig 17 Fixing the appliance to the wall...

Page 15: ... not be removed Fix the flue ducts together before fixing the surrounding air duct the cut ducts fit into the flue assembly 12 10 Fitting the Flue Assembly with Access to the Terminal Prepare the flue duct assembly as described in Section 12 9 Apply the plastic tape to the air duct in contact with the external brickwork From inside push the assembly through the wall Align the flue turret and push ...

Page 16: ...ssembly If Z in 425 725mm it is not necessary to cut the terminal assembly or use a second extension duct as the length can be set telescopically If Z 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...

Page 17: ...domestic hot water and central heating load of 24 kW 24 28CDi or 27 5kW 35CDi II The appliance automatically modulates to satisfy lower heat loads Domestic Hot Water Circuit Confirm that the mains water supply has been flushed out at installation If not it will be necessary to disconnect the cold water inlet pipe from the appliance and thoroughly flush Central Heating System Confirm that the syste...

Page 18: ...pressure If the pressure indicated on the pressure gauge is greater than 2 6 bar when operating at the maximum central heating temperature an extra expansion vessel must be fitted to the system as close as possible to the appliance central heating return connection The appliance as dispatched can accommodate a system volume of about 83 litres Refer to BS 7074 Part 1 If the system volume is in exce...

Page 19: ...edure Check for proper ignition of the burner after a break in the gas supply Turn off the gas service cock and wait for 60 seconds The burner will go out but sparking from the electrode will continue for 10 seconds when the appliance will enter a lockout state Carefully open the gas service cock press the lockout reset button and observe the burner re light and follow the normal sequence of opera...

Page 20: ...nge down the facia taking care not to distort the pressure gauge capillary tube or electrical connections d Bottom panel Hinge down the facia panel Disengage the front edge of the bottom panel from the two clips and remove the bottom panel from the appliance e Fan Remove the inner casing cover Carefully unplug the electrical connections and pull off the sensing tubes Unscrew the three fixing screw...

Page 21: ...lose the drain taps when the flow has stopped Be careful not to overtighten the drain taps Some water will remain in the expansion vessel pump diverter valve water to water and Gas to Water heat exchangers and extra care must be taken when removing these components b Domestic Hot Water Circuit Turn off the mains cold supply valve at the appliance and open the lowest hot water tap A quantity of wat...

Page 22: ... heat exchanger as described in Sections 15 3 b e and f and 16 4 5 Remove the fibre insulation pads from the combustion chamber side rear and front sections To avoid the risk of fine particles dampen the pads before removal Fit the replacement pads in the reverse order taking care not to damage them Open the valves and fill and re pressurise the system as described in Section 13 2 7 Burner See Fig...

Page 23: ...or 3 1 mbar 35CDi II for natural gas or 5 4mbar 24CDi or 3 8mbar 28CDi or 3 1mbar 35CDi II for propane Turn the gas mode switch on the rear of the facia to maximum Adjust the maximum pressure screw on the gas valve to give a burner pressure of 14 8mbar 24CDi or 15 5mbar 28CDi or 13 5mbar 35CDi II for natural gas or 35 5mbar 24CDi or 35 5mbar 28CDi or 34 7mbar 35CDi II for propane Turn the gas mode...

Page 24: ...bed in Section 15 3 c Remove the bottom panel as described in Section 15 3 d Pull out the retaining clip and remove the pressure gauge connection Undo the discharge pipe connection and remove the valve taking care not to distort the pipework Fit the replacement valve in reverse order Reconnect the discharge pipe Open the valves and fill and re pressurise the system as described in Section 13 2 16 ...

Page 25: ...ge down the facia panel into the servicing position as described in Section 15 3 c Follow the proceedures as described in Section 16 4 18 and remove the water divering valve from the appliance Remove the water filter from the cold water inlet Discard or clean the filter Fit the replacement filter push fit in the reverse order Reassemble the appliance in the reverse order Open the valves and fill a...

Page 26: ... over the four mounting posts and push back squarely until the plastic catch on the end of each post clicks into place Reassemble in the reverse order and ensure i the spark electrode leads are re connected Polarity is not important ii the connectors are fitted to the correct terminals Connectors are not interchangeable and will only fit the termi nals from which they were removed Reassemble the f...

Page 27: ... Water Heat Exchanger Giannoni Ref PVW 12 E D2108 1 8 716 142 900 0 42 E00 711 Water to Water Heat Exchanger Giannoni Ref PVW 14 E 1 8 716 142 903 0 42 Water to Water Heat Exchanger Giannoni Ref PVW 16E 1 8 716 102 672 0 68 E00 716 Automatic Air Vent Intermes Ref 02 05 010 1 8 716 140 500 0 85 299 506 System Pressure Gauge Cewal spec D2111 1 8 716 142 300 0 40 375 699 Pressure Relief Valve Caleffi...

Page 28: ...28 109 ...

Page 29: ...ure set by control knob DEMAND END Pump continue four minutes Fan continue fifteen seconds CENTRAL HEATING FUNCTION AND AND AND DOMESTIC HOT WATER FUNCTION MAIN SWITCH ON Green Light On Flow switch On Tap open DOMESTIC HOT WATER DEMAND Priority over CH demand HW light On Pump On Fan ON High speed 28CDi Fan ON High for 2 sec then Low speed 35CDi II Ignition Sequence Burner on Four second ramp to ma...

Page 30: ...primary temperature still increases above 90 C Run pump for two seconds OVERRUN FUNCTION AND Pulse pump for 2 seconds every 10 seconds 35CDi II Above 9 C Commence normal central heating mode until temperature reaches 30 C 5 C to 9 C Below 5 C No demand and primary temperature below 8 C Internal Autofrostat demand Wait in normal off state for 30 minutes Run pump for four minutes Monitor central hea...

Page 31: ... individual or groups of lights being permanently off on or flashing every normal fault can be identified To use the fault finding system select a box below which represents the light situation during your fault Then refer to the appropriate following section This fault finding system assumes that the appliance has been operating correctly until the time of failure PRELIMINARY CHECKS Preliminary e...

Page 32: ...y to boiler Replace control board Section 16 4 23 FAIL POINT A No No Yes Yes Yes No Replace fuse This will be caused by fuse fatigue or by the board Has fuse F2 blown Replace control board Section 16 4 23 Remove control board from facia See Section 16 4 23 and sepa rate transformer from board Measure resistance across the two pairs of adjacent pins on the transformer Is any pair above 100 ohms Rep...

Page 33: ...rogrammer Yes Yes Red diode is damaged Replace control board Section 16 4 23 Replace control board Section 16 4 23 With a hot water tap fully open does the boiler ignite and appear to run normally in hot water mode Remove multiway connector from board position ST16 With tap still open is there continuity across contacts 19 and 20 2 pink wires Remove the black cover from the microswitch assembly Wi...

Page 34: ...INT G Primary Overheat No Re fix sensor to pipe No No Repair or replace pump Section 16 4 14 No Reset the controls and restart the boiler Does the pump run Yes Remove inner casing cover and inspect the primary sensor left of heat exchanger Is it correctly fixed to pipe Yes Remove the multiway connector from board position ST16 Is there a short circuit across contacts 5 6 Fault caused by control bo...

Page 35: ...he boiler Does a spark occur across the electrodes Turn off boiler Remove the multiway connector from board position ST16 Test resistance across contacts 7 and 8 brown wires and 9 and 10 violet wires Are both reading below 100 ohms Replace control board Section 16 4 23 If problem not solved replace gas valve Section 15 4 11 Repair or replace flame sensor Section 16 4 10 or wiring Replace gas valve...

Page 36: ...1 Remove both brown connectors from gas valve First remove pressure switch bracket Is there continuity from brown and violet wires to the multiway connector Check or replace CH sensor Section 16 4 12 Is there continuity from contacts 17 and 18 to DHW sensor Check or replace DHW sensor Section 16 4 13 Is there continuity from contacts 12 and 13 to CH sensor Repair or replace harness Repair or repla...

Page 37: ...solving the problem inspect the pressure pick up Venturi in the fan Repair or replace fan Section 16 4 3 or cable Repair or replace fan Section 16 4 3 or cable Air pressure switch is shorting Replace switch Section 16 4 2 28CDi and 35CDi II 24CDi 28CDi and 35CDi II Remove fan connector from board position ST1 and restart boiler in the fault mode After 5 seconds is there mains 230V from the left N ...

Page 38: ...or poorly fixed to pipe Repair or replace sensor Section 16 4 14 Water temperature very low low gas pressure with all knobs set to maximum Remove multiway connector from board position ST16 Is the resistance across contacts 1 and 2 blue wires below 60 ohms Remove blue top connector from gas valve Is there continuity along blue wires to multiway connector Is the gas set to correct pressure Set pres...

Page 39: ...o confirm gas soundness and correct boiler operation 10 Check and adjust the setting pressures to the values in the table below and adjust if necessary Refer also to the Installation and Service Instructions Section Replacement of Parts To Set the Burner Pressure 11 Refit the plastic sealing cap to the gas valve modulating valve adjuster and seal with a dab of paint or similar 12 Turn off the boil...

Page 40: ...ject to our official Conditions of Sale a copy of which may be obtained on application PUBLICATION 8 716 102 567j 01 03 Worcester Heat Systems Limited Bosch Group Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619 Technical Helpline 08705 266241 www worcester bosch co uk This manual is to be used in conjunction with the variant part number of the bar code below 28CDi 24...

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