Worcester 350 Combi Installation And Servicing Instructions Download

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Summary of Contents for 350 Combi

Page 1: ... 13 BOILER OUTPUT Automatic Modulating Control To Domestic Hot Water Minimum 9 0 kW 30 700 Btu h Maximum 35 17 kW 120 000 Btu h To Central Heating Minimum 9 0 kW 30 700 Btu h Maximum 25 0 kW 85 300 Btu h IMPORTANT THIS APPLIANCE IS FOR USE WITH NATURAL GAS ONLY THESE INSTRUCTIONS APPLY IN THE UK ONLY THESEINSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER ...

Page 2: ... components should conform to any other relevant British Standards in addition to those mentioned in the instructions 2 General Information 2 1 This section contains a summary of essential information Refer to the appropriate main sections for more information 2 2 This appliance is not suitable for external installation 2 3 The appliance controls are set to provide a maximum output of 35 17kW for ...

Page 3: ...an over 3 rim flushing bidet but is subject to local Water Company require ments 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 furthe...

Page 4: ...INS INLET FmiNG 15 mm Compression DOMESTIC HOT WATER OUTLET FITTING 15 mm Compression GAS INLET CONNECfiON Rc3 4 PRESSURE RELIEF VALVE DISCHARGE FITTING 15 mm Compression OVERALLAPPLIANCE HEIGHT including flue bend 925 mm 36 4 in CASING HEIGHT 900 mm 35 4 in CASJNGWIIJfH 500 mm 19 7 in CASINGDEPTH 310 mm 12 2 in DRY WEIGHT 67 kg 148 lb MAXIMUM INSTALLATION WEIGHT 60 kg 1 32 lb PACKAGED WEIGHT 72 k...

Page 5: ...ation Servicing Above the flue bend 35mm 35mm In front 600mm 600mm Below 200mm 200mm Right and left hand side 25 mm 5mm If a side flue connection is made then 25 mm must be left at that side for possible service access 5 TABLE 7 TOTAL LENGTH OF GAS SUPPLY PIPE metres Pipe I I Diameter 3 6 9 mm Gas Discharge Rate m3 h 8 7 I 5 8 I 4 6 22 18 0 I 12 0 I 9 4 28 Each fitting used in the gas line from th...

Page 6: ...d for I I I 1 installation and servicing iI I 600 Spacerequiredfor installationand servicing ______l ______ J 1 All dimensions in millimetres Fig 3 Appliance pipework connections and flue positions Cabinet side panel Nominal D imension Pressure relief valve drain 322 Central heating return 252 Bypass adjuster 235 Drain tap 206 Central heating flow 202 Mains cold water in 144 Domestic hot water out...

Page 7: ...stem See Figs 5 and 6 7 1 The system must comply with the requirements of BS 6798 and BS 5449 The appliance must not be operated without the system being full of water properly vented and pressurised 7 2 Pressure Relief Valve The valve complies with BS 6759 and will operate at 3 bar 45 lb in2 The discharge pipe must be directed away from electrical items or wiring and from where it might be a haza...

Page 8: ...h standard stop valve Fixed spindle type Lowwater pressure switch I I i Central heating return Central heating flow Fig 6 System filling and make up Heating return Worcester Combi Fill System Non return Non return valve valve Hose unionl ___ P V4 u r t 4 ll ll Stop cock 11 II Test cock Temporary hose 8 the system usually a leak must be rectified 7 1 0 Water Mains Connection There must be no connec...

Page 9: ... bidet is per mitted 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 8 8 USE IN HARD WATER AREAS As the maximum temperature of the domestic hot water heat exchanger is limited by the electronic control circuit th...

Page 10: ...e br y Central heating sensor Spark electrode w Gas valve soleniods Modureg y head Gas valve soleniods Domestic hot water overheat thermostat Domestic hot water sensor Flow switch br Low system pressure switch 10 Airflow pressure switch Central heating pump w Flame sensing electrode Domestic hot water pump ...

Page 11: ... X4 UVEIN white Xl P IN21 LOW SYSTEM PRESSURE SWITCH Xl PIN 41 _ bla ck4 o_ X9 P IN 1 1 STANDBY INDICATOR FROST THERMOSTAT IIF FITTEDI 1 x 5 X4 Indicator Ughts I Operating Switdl DEMAND INDICATOR XJ I N 11 I I XS I N 91 I I I I I I I ___ DRIVER BOARD 11 STANDBY DEMAND LON PRESSURE I Q 0 I I I I I I I I grey pink min max I I I I _J X20 I N 91 L tGNmON BOARD RESI5TDR ON FAN ASSEMBlY MAINS N N N N ...

Page 12: ...nifold 10 3 FIXING THE APPLIANCE Remove the cabinet front panel from the appliance by pulling it away from the clips at the bottom of the casing and lifting it off the top supports Remove the inner casing cover and the inner cover panel by removing the eight screws See Fig 22 Fix the air duct clamp assembly packed in the installer pack to the appropriate openi g as follows See Fig 17 Pull offthe f...

Page 13: ...ng Measure the length L See Fig 13 Air duct length L 1Smm Cut the flue duct to length leaving the cut end smooth and square Do not cut the drilled end Flue duct length L 142mm Cut the flue duct to length Assemble the air and flue ducts and the terminal assembly Do not forget to fit the internal support spider to an extended flue system See Fig 14 join any extended air ducts together applying a thi...

Page 14: ...ll Duct Lengths 1 2 2 0 metres Separately assemble the standard and extended air and flue ducts Do not permanently fix together Cut the ducts to the required overall length Fig 12 Wall thickness W Fig 13 Dimension Lfor side flue assembly I L Fig 14 Air duct and flue duct assembly Duct fixing screws Flue support spider Duct fixing screws Air duct extension Air duct Air duct Flue duct Extended flue ...

Page 15: ...ront of the switch L 1 F I Fan fixing screw n Fig 16 Blanking off the flue openings not used Fig 17 Air duct clamp assembly L Inner sealing ring Sealing gasket Fig 18 Air and flue duct clamps side connection shown Sensing pipe 15 20mm 1 1 r I I I I I I L_ Flue duct clamp Flue duct ENLARGEMENT CROSS SECTION B Silicon rubber Inner ring Outer ring Air duct Silicon seal ...

Page 16: ... the bottom and lifting it off the top supports Remove the inner cover panel by unscrewing the four screws See Fig 22 Unscrew the two screws at each end of the control box Pull for ward and lower the control box assembly See Fig 22 Open the central heating system valves on the manifold See Fig 21 Open all the radiator valves and fill the system The automatic air vent fixed to the flow manifold wil...

Page 17: ...p Domestic hotwater inlet tap Fig 22 Cover and electrical panel fixings Cabinet 0 T 0 Top panel fixing screws 21 fixing screws 4 Boiler inner casing cover 0 0 0 Inner cover panel ___ four fixing screws Facia fixingscrews 31 0 f i t 0 Control box fixing screws 2 Bottom panel fixing screws 2 17 Central heating flow and return taps Fig 23 Casing bottom panel assembly Control box sidesupport Fig 24 Pr...

Page 18: ...system to ensure that all the radiators are heating up evenly Shut down all the radiators but one and observe the burner pres sure fall Open all of the radiator valves and check that the burner pressure rises Balance the system so that the required temperature difference across the heating flow and return pipes is obtained relevant to the heating load See Table 3 Shut all the radiators and adjust ...

Page 19: ...quirements Refer to Section 11 12 7 If an external programmer has been fitted which has a pro grammable domestic hot water facility then it is suggested that this be set to Continuous or 24 Hours or the equivalent Maximum burner pressure adjuster Modureg cap Fig 27 Central heating burner pressure adjusting screw Central heating burner pressure adjustment screw PRESSURE ADJUSTMENT CENTRAL HEATING F...

Page 20: ...d and remove the hooks from the combustion chamber cover Withdraw the clamping bars from their rear bracket and lift the flue hood assembly from the appliance If the fan is not to be removed separately then discon nect the electrical supply the suction tubes and the flue duct as described in the preceding note See Fig 15 g Burner Blade Assembly Remove the combustion chamber cover Remove the spark ...

Page 21: ...hood 0 0 Combustion chamber cover 0 0 0 Fig 30 Spark electrode and flame sensing electrode I 3 5mm 0 5mm totop of burner blade Spark electrode 3mm 1mm Wing nut C ombustionchamber cover fixing screws 4 0 totop of burner blade i Flame sensingelectrode u t t D DDDDDDDDDDDDDD D Electrode fixing nut cy I Electrode mounting brackets 3screws 21 0 I I ...

Page 22: ... 31 Burner assembly Ftg C E xtended fixing screw gscrews E xtended flxm l I I I Lower fixing screw 22 Jllll I I I ...

Page 23: ... stopped Some water will remain in the expansion vessel pumps and Gas to Water heat exchanger and extra care must be taken when removing these components b Appliance Hot Water Circuit Turn off the mains water supply valve at the appliance See Figs 21 and 28 This is operated using a flat blade screwdriver Later versions of the water flow regulator have a drain screw which must be loosened to remove...

Page 24: ...the burner pressure See Fig 26 The minimum and maximum burner pressures must be set after a new gas control has been fitted Follow the procedure described in Section 11 4 Appliance Start Up The minimum burner pressure must be set first as any adjustment of the minimum pressure influences the maximum pressure set ting Remove the fixing screw and remove the Modureg head cover Remove the compensating...

Page 25: ...essel to release the connection Remove the vessel Take care when removing the ves sel as a small quantity of water remains inside the vessel Set the clip in its open position and fit the new vessel in the reverse 25 order using a new 0 ring The assembly is aided if the 0 ring is lubricated with soap solution Open the valves fill and re pressurise the system as described in Section 11 2 13 Central ...

Page 26: ...ck that the arrow on the flow switch points upwards Open the mains water supply valve 17 Flow Switch See Figs 9b and 41 Check that the electrical supply has been turned off Remove components as described in Section 14 2 a and b Drain the hot water circuit as described in Section 14 3 b Unscrew the flow switch Unplug the switch connection at the main driver board connection X1 Release the cord stra...

Page 27: ...and remove the pressure gauge and capillary from the facia See Fig 40 Fit a new gauge and capillary in the reverse order Open the valves fill and re pressurise the system as described in Section 11 2 23 Central Heating Temperature Control Potentiometer See Figs 20 and 40 Check that the electrical supply has been turned off Remove the facia See Section 14 2 a Remove the control knob by grasping it ...

Page 28: ...position See Figs 42 and 43 Reconnect the plug to the driver board and re assemble the appli ance 26 a Facia Mounted Programmer See Fig 40 Check that the electrical supply has been turned off Remove the facia See Section 14 2 a 28 Unplug the programmer from the main driver board Undo the four nuts securing the programmer to the facia and remove Fit the new programmer in the reverse order and conne...

Page 29: ...mbustion chamber cover See Section 13 3 d Remove the burner blade assembly as described in Section 13 3 g Unscrew the two extended screws securing the burner manifold to the bottom of the casing Pull the manifold to the left to with draw it from the right hand support bracket and remove from the casing See Fig 44 Fit a new burner in the reverse order Examine the 0 ring and replace if it appears da...

Page 30: ...18 1 SPK0105 with 0 rings and washers 59 395 761 Flow Regulator 12 1itres minute Type E Red 1 ZBUNC122 360 374 628 Flow Switch with plug SIKA VK315M 1 SSA010090 63 324 822 Gauze Filter 3 3613 Worcester 1 ZBUNC230 106 386 226 Water Pressure Switch Novomec FPS37414A 1 ZAGAS1 12 196 386 238 Main Driver Board Pactrol413000 1 ZAGAS125 197 386 239 Ignition Board Pactrol 41 3100 1 ZAGAS126 199 386 243 Tr...

Page 31: ...26 8f8 OJ oo 318 I 240 106 223 99 241 199 236 E 3 238 169 190 172 76 63 59 HC350 010712a 31 ...

Page 32: ...w fan below4 5 mbar burnerpressure Burnerpressure increasestosetlevel overoneminute II 13 Centralheating temperature 5 C above set level Heat inputmodulated to maintain water temperature SetbyT emperature ControlKnob Centralheating Demand satisfied 1 Central Heating Mode AUTOMATIC START UP SEQUENCE ID u ll 1 1 r m I L I test PASS roMM Fanto lowspeed Senseairpressure FAIL I NOT PRESENT Wail I I Res...

Page 33: ...following 2112minute delay Fanoverrun operates ifcentralheatingis satisfied m Demand indicator illuminated pumplortwo secnnds _ duringhighfan pulse m 2 DomesticHotW ater Mode 3 Fan Overrun Function m Centralheatingand domestichot water pumps offand primary water temperature above7S C I m Fullspeed fan untilthe primarytemperature tans to 6s c 4 Overheat Protection Gas to Waterheat exchangerexcess t...

Page 34: ...ck themains supplyand external wiring Is the L OW PRESSURE indicator illuminated Pressthe overheatthermostatreset Is there alivesupply to Lon button IstheSTANDBY indicator terminal X4 NO YES YES illuminated Lowsystem waterpressure prevails Investigate andrectify Fuse F1has blown S witch off the electrical mainssupply Areany connectionsor cablesshortingto thechassis orshowinganysign of Remove theco...

Page 35: ...he driverboard assembly Replacethe ignitionboard R eplace the driverboard assembly NO Checkthatthe applianceis notin an anticyde delaybyswitchingthe OperatingSwitchOFF ON Replace the airpressureswitch I Repairthe fault NO _ Istherelessthan 2V DConthe red pin ofterminalXB 1 YES YES Isthere 39VDC on the orange pin of Replacethe ignitionboard terminalXB NO NO _ YES 35 F ree the fan ifstuckor replace ...

Page 36: ...ace theignition board 00 00 00 Does theflame continue afterthe sparkingstops ____ This causesa lockout condition ____ Checktheflamesensorelectrodeand ____ Replace the ignitionboard Investigateand rectifytheburnerjets leadforconditionandsetting Does YES gasvalveand gassupply Restartthe theflame continue appliance Doesthe flame continue YES NO 1 Jmoffthe appliance andconnecta ___ Doestheboilershutdo...

Page 37: ...b YES NO potentiometeronthe facia YES _ R emovethe Molex plug from terminal X2 Isthere aresistance of 1 5to 25 kohms acrossthebrown and yellow pins IYES R eplace the driverboard assembly NO NO _ Replace the central heating sensm NO Graduallytum offtheradiators one by one so that the appliance shuts down asthe system temperature rises abovetheset level Does the STANDBY indicator remain on H igh lim...

Page 38: ... aterflow rateat least 3litres min 0 7 gallons min YES l YES NO Investigateandrectifylowflowrate NO Istherealivesupplyon the pinkpin of _ Is thereapproximately47VDConthe Replacetheflowswitch terminalX8 brown top pin ofterminal Xl YES I l Replace theDEMAND indicator Replace thedriverboard assembly NO NO NO Doesthe hotwater pumprun Does the centralheatingpump run Istherealive supplyto the brownpin R...

Page 39: ... i Replacetheignition board Is there SV DC on the orange pin of Replace the transformer Removethe Molex plugfrom rerminal terminalX2 1sthere an open circuit YES __ _ 1 YES Is thereless than2V DConthe red NO pinofterminal XS NO YES Replacethe air pressureswitch Repairthefault NO YES Replacethe driverboardassembly Isthere39VDCon the orange pin of Replace the ignition board terminal X8 NO NO NO Isthe...

Page 40: ...tely fully opened again YES 1 Jm offthetap Does theboiler shutdown immediately IYES NO INO Reset the thermostat NO Does thevoltage on thewhite pin of 1 terminal XS increase as the flow rate reduces Replace the gas valve YES NO Alockout condition has occurred Usethe potentiometerRV2 on the driverboard to reducethe domestic hotwatertemperature Repeat the test Ifalockoutoccurs again then replace the ...

Page 41: ...ox __ Is there less than 2VDC on the red pin ofterminal XS __ Replacethe ignitionboard IYES End offan over run test Replacethedriver board assembly OVERHEAT PROTECTION TEST NO Does the applianceshutdown ifthe Replace thesystem overheat primarywaterflowfrom theGas to thermostat Waterheatexchangerexceeds 100 C LOW SYSTEM PRESSURE PROTECTION TEST NO Does the applianceshutdownifthe Replace the low sys...

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Page 44: ...oklet is accurate at the date of printing but will be superseded and should be disregarded if specifications arrd or appearances are changed in the interests of continued improvement All goods sold are subject to our official Conditions of Sale a copy of which may be obtained on application 8 716 114 720a 11 07 ...

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Worcester 350 Combi, Installation And Servicing Instructions

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