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13.1 Hand over the User Booklet and explain how to operate the
appliance safely and efficiently.
13.3 Tell the user what to do if the appliance is not to be used in
very cold conditions.
13.4 Tell the user what to do if the system pressure falls.
13.5 Explain that regular servicing will maintain the safe and
efficient operation and extend the life of the appliance. WHS can
offer a 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 the appliance is in a compartment or cupboard check that the
specified clearances are clear. Refer to Table 8.
Check all the joints and connections in the system and remake
any that show signs of leakage. Refill and re-pressurise as
described in Section 12-Commissioning.
Operate the appliance and take note of any irregularities. Refer to
Section 18-Fault Finding.
Check the combustion performance
Remove the cap from the sample point on the top of the
appliance and connect the meter. Refer to Fig 35.
With the appliance at maximum rate and stable expect readings
of about 6.5% - 7.00% CO2 and 0.002% CO.
Refit the sample point cap after the test.
Always test for gas soundness after the service has been
completed.
Disconnect the electrical supply at the mains and turn off the
gas supply at the gas service cock on the appliance before
starting any service procedures.
14.3 Component Access
Remove some or all of the following parts to gain access to
components.

Cabinet Front Panel.

Lift off the supports. 

Facia.

Unscrew the two screws and lower. Refer to Fig 18.

Inner Casing.

Unscrew the four screws and remove. Refer to Fig 18.

Combustion Chamber.

Unscrew the two screws at the top.

Loosen but do not remove the two wing-nut extended screws at
the sides, unhook the clips and remove the chamber. Refer to Fig 41
and 42.

Fan.

Carefully pull off the electrical connections and the tubes

from the air flow detector. Unscrew the three screws to remove
the fan assembly. Refer to Fig 51.

Flue Hood.

Remove the fan. Unscrew the two screws at the front

and withdraw the hood. Ensure that the replaced hood passes
under the lip at the rear of the appliance. 

Burner

. Remove the combustion chamber. Release the union nut

at the top of the gas valve. Carefully pull-off the connections to
the spark electrode and separate the in-line connector to the
flame sensing electrode. Refer to Fig 43 and 44.
14.4 Component Cleaning
Do not use a brush with metal bristles to clean components.
Clean the fan taking care not to block air flow detector.
Clean the burner to ensure that the blades and injector are clear.
Do not us a metal probe to clean the injector.
Clean the electrodes and check the alignment. Replace if there is
any sign of deterioration. 

Clean the heat exchanger after covering the gas inlet tube.
Straighten any distorted fins on the heat exchanger.
Check the combustion chamber insulation and replace if there is
any sign of damage or deterioration. Refer to Section 15.4.5.
Carefully refit any components removed and check that all
screws are tight and the connections properly re-made with the
appropriate gaskets/O-rings.
Re-commission, as necessary, for correct operation to the users
requirements. Refer to Section 12 Commissioning.

Important:

Turn off the gas and electricity supplies and drain,

where necessary, before replacing any components.
15.1 Always check for gas soundness where relevant and carry-
out functional checks as described in Section 12-Commissioning.
Any O-ring or gasket that appears damaged must be replaced.

15.2 Component Access

Refer to Section 14.3 Inspection and Servicing for access to
components.

15.3 Draining the Appliance

Turn off the heating flow and return valves at the appliance.
Refer to Fig 16.
Remove the casing bottom panel by releasing it from the clips.
Fit a tube to each of the drain connections and open the taps.
Refer to Fig 47. Close the taps when the flow has stopped.
Important: A small quantity of water will remain in some
components. Protect any electrical components when removing
items that might retain water.

15.4 Component Replacement

Refer to Fig 41, 42 and 43 for the location of the components.
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

14. Inspection And Service

13. Instructions To The User

21

Fig.40 . User controls.

24SBi

System 
pressure
gauge

C.H temperature control and
On/Off knob

Mains indicator

Reset button

Содержание Worcester 15SBi

Страница 1: ...ER 41 311 44 N G 15SBi GC NUMBER 41 311 45 L P G 24SBi GC NUMBER 41 311 46 L P G APPLIANCE OUTPUTS Natural Gas LPG Propane 24SBi Minimum 15 0 kW 15 0 kW Maximum 24 0 kW 24 0 kW 15SBi Minimum 6 0 kW 6 0 kW Maximum 15 0 kW 15 0 kW 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 m...

Страница 2: ...rmation The appliance is set to give the mid range output of 19 5kW 24SBi or 10 8kW 15SBi Kits are available to convert the appliance from Natural Gas to Propane operation and vice versa 2 2 Electrical Supply 230V 50Hz Load 180 watts External fuse 5A Internal fuse F1 4A 2 3 Gas supply The 24SBi appliance requires a maximum of 2 86 m3 h of natural gas G20 or 1 1 m3 h of propane G31 The 15SBi applia...

Страница 3: ...ack flow prevention devices including water meters are fitted the expansion of hot water into cold water main can be prevented This can result in a pressure build up that may cause damage to the boiler and household devices such as showers washing machines etc In these cases we recommend that a mini expansion vessel be fitted adjacent to the boiler in the cold water pipe 2 10 Operation Central Hea...

Страница 4: ...Natural Gas OUTPUT INPUT Net GAS RATE kW kW m bar m3 h 15 17 5 4 5 1 85 19 5 22 1 8 2 34 24 27 12 5 2 86 BOILER ADJUSTED FOR G31 Propane 15 17 5 13 5 0 72 19 5 22 1 22 5 0 9 24 27 35 5 1 1 Table 1 24SBi FLUE DETAILS HORIZONTAL FLUE mm WALL HOLE DIAMETER EXTERNAL FIX 110 INTERNAL FIX 150 STANDARD FLUE MINIMUM LENGTH 100 MAXIMUM LENGTH 725 EXTENDED FLUE MAXIMUM LENGTH 4000 FLUE ASSEMBLY DIAMETER 100...

Страница 5: ...res INITIAL INITIAL CHARGE PRESSURE bar PRESSURE bar 0 5 1 0 1 5 1 0 72 92 N A 1 5 39 53 64 Table 8 PERFORMANCE SPECIFICATIONS PRIMARY WATER CAPACITY 2 0 litres MAXIMUM MAINS INLET PRESSURE 10 bar MAXIMUM CENTRAL HEATING FLOW TEMPERATURE 85 C nom MAXIMUM CENTRAL HEATING SYSTEM SET PRESSURE 2 5 bar MINIMUM CENTRAL HEATING SYSTEM SET PRESSURE 0 5 bar OUTPUT TO CENTRAL HEATING NATURAL GAS G20 15SBi 6...

Страница 6: ...The appliance can be installed in a cupboard compartment to be used for airing clothes providing that the requirements of BS6798 and BS5440 2 are followed Refer to Section 2 4 The clearance between the front of the appliance and the cupboard compartment door should be not less than 250mm LPG Installation Refer to Section 1 10 4 Siting The Appliance 6 Fig 2 Appliance casing dimensions and required ...

Страница 7: ...that does not allow these clearances then permanent air vents are required in the compartment one at a high level and one at a low level Both high and low level air vents must communicate with the same room or must both be on the same wall to the 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 ...

Страница 8: ... NOT suitable for direct water supply Do not connect to a direct cylinder The SBi can be connected to any indirect cylinder i e unvented or thermal store all the benefits of a dry loft and mains pressure hot water can be realised Refer to a separate leaflet or contact Worcester Heat Systems Technical Helpline 0990 266241 8 Domestic Hot Water 7 Sealed System 8 Fig 5 System layout if using built in ...

Страница 9: ...ustment RV LV LV RV RV RV LV LV INDIRECT CYLINDER APPLIANCE Refer to fig 1 Appliance Water Flow Diagram Heating Return Heating Flow Safety Discharge Cylinder Return Hot Water Flow BS Stop Valve Fixed Cylinder Type Mains Cold Water Radiator Valve Flow RV Lockshield Valve Return LV Note A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance CH Zone Valve D...

Страница 10: ...fused three pin plug and unswitched socket outlet both complying with BS1363 or a double pole isolator with a contact separation of 3mm in all poles NOTE There must be no other permanent electrical supply to the system This ensures the safety of a single fused supply A room thermostat must be suitable for mains voltage operation A mechanical timer to fit into the facia is available A frost thermos...

Страница 11: ...lectrode Gas Valve Air Flow Switch Mid Position Valve Y Plan Optional Facia Mounted Timer Optional Cylinder Thermostat Overheat Cut off Fan Control Board X1 X10 1 1 1 X11 X12 X2 X3 X4 X5 X6 br bl bl y bl bl Blue br Brown y Yellow g Green 1 br br br 2 orange 2 red 2 green Pump ...

Страница 12: ... 1 Cylinder Thermostat Satisfied Call C Y O S X5 Top Pin X5 Top Pin X4 Top Pin Pump Fan N N N N Reset Button Temperature Control Temperature Sensor Air Flow Switch Flame Sense N N Mid Position Valve white grey orange Y Plan S Plan Zone Valve CH Spark Boiler Demand Electronics High Voltage Safety Low Voltage Fan Pump Gas Valve X3 Pin 1 X3 Pin 4 X3 Pin 3 Overheat Thermostat X3 Pin 2 A Mid Position V...

Страница 13: ...he plugs and fix the mounting plate and manifold assembly to the wall Refer to Fig 15 11 5 Gas and Water Pipes Fix the appropriate fitting to the gas cock to connect the inlet supply pipe Refer Fig 16 It is important that the system pipes are not fixed near the appliance using clips that put a strain on the connections Before the appliance is connected to the wall manifold thoroughly flush the sys...

Страница 14: ...k the maximum flue length and if it is less than 1m total overall length then fit the restrictor ring as shown in Fig 21 24SBi 75mm Horizontal flue up to 1m 75mm Vertical flue up to 1m 15SBi 74mm Horizontal flue up to 1m 79mm Vertical flue up to 1m The standard 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...

Страница 15: ...m accommodating a 10mm Service clearance and a 100mm wall Minimum rear flue length 296mm accommodating a 100mm wall If L is between 1175 1475mm 1 extension 1925 2225mm 2 extension 2675 2975mm 3 extension 3425 3725mm 4 extension it is not necessary to cut the ducts 15 Fig 22 Standard flue assembly Appliance casing Fixing screw Turret assembly Terminal assembly L Fig 20 Mid position diverter valve O...

Страница 16: ... 11 10 Fitting of the Flue Assembly without access to the Terminal The rubber gasket kit is available from Worcester Heat Systems NOTE A larger diameter opening opening in the wall is required Refer to Table 2 Prepare the flue assembly as descried in Section 11 8 Fit the rubber sealing gasket centrally onto the terminal assembly and tighten the clamp Refer to Fig 27 Apply the plastic tape to the a...

Страница 17: ...l be necessary to cut the air and flue ducts of the extension to a plain length of 100mm and reduce the length of the terminal assembly i e Z 350mm remove 75mm from the terminal assembly 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 as...

Страница 18: ...y cable is longer than the live and neutral leads Fit the facia mounted clock Refer to Fig 34 Connect any external controls ensuring that the leads pass through the appropriate clamps refer to Fig 12 and 33 Test for gas soundness as described in BS6891 If the appliance is not commissioned immediately replace the cabinet and facia bottom panel Check that the gas and electricity services have been t...

Страница 19: ...anti clockwise until it releases Refer to Fig 37 12 2 Set the Expansion Vessel Pressure The charge pressure of the expansion vessel as dispatched is 0 5bar which is equivalent to a static head of 5m 17ft The charge pressure must not be less than the static head at the point of connection A Schraeder type valve is fitted to the expansion vessel to allow the charge pressure to be increased if necess...

Страница 20: ...t all the radiators heat up evenly If necessary carefully vent 12 9 Balance the system to give a temperature differential of 11 C An adjustable by pass is fitted to the appliance 12 10 Set the room thermostat to minimum and check that the burner goes out Reset the room thermostat and the burner will re light Turn off the gas service cock The burner will go out but after a short pause the appliance...

Страница 21: ...hdraw the hood Ensure that the replaced hood passes under the lip at the rear of the appliance Burner Remove the combustion chamber Release the union nut at the top of the gas valve Carefully pull off the connections to the spark electrode and separate the in line connector to the flame sensing electrode Refer to Fig 43 and 44 14 4 Component Cleaning Do not use a brush with metal bristles to clean...

Страница 22: ...nsing Tubes 3 Flue Hood 4 Overheat Thermostat 5 Combustion Chamber 6 Combustion Chamber Fixing Screws 7 Gas Pipe Burner Assembly 8 Burner Assembly 9 Spark Electrode Assembly 10 Return Pipe 11 Flow Pipe 12 Flow Sensor 13 Heat Exchanger 14 Auto Air Vent 15 Combustion Sampling Point 16 Wing Nut 16 ...

Страница 23: ...Hood 4 Overheat Thermostat 5 Combustion Chamber 6 Combustion Chamber Fixing Screws 7 Gas Pipe Burner Assembly 8 Burner Assembly 9 Spark Electrode Assembly 10 Flow Pipe 11 Flow Sensor 12 Heat Exchanger 13 Auto Air Vent 14 Combustion Sampling Point 10 Fig 42 Inner Casing 24SBi 14 ...

Страница 24: ...e leads at the electrodes Loosen the screw and remove the electrode assembly Refer to Fig 44 15 4 3 Flame Sense Electrode Remove the inner casing and the combustion chamber Lower the f acia Separate the in line connector located in the controls compartment Remove the burner Refer to Section 15 4 4 Loosen the screw and remove the electrode assembly Refer to Fig 44 Ensure that the new electrode is a...

Страница 25: ...move the casing bottom panel and disconnect the discharge pipe and pressure gauge sensor Refer to section 15 4 6 Withdraw the clip and withdraw at an angle the valve Refer to Fig 37 and 43 15 4 8 Diverter Valve if fitted Remove the cabinet front panel and lower the facia panel Drain the appliance as described in Section 15 3 preceding Disconnect the electrical connections Pull out the correct clip...

Страница 26: ...ections and remove the heat exchanger 15 4 12 Pump Remove the cabinet front panel and lower the facia panel Drain the appliance as described in Section 15 3 preceding Release the water connections and remove the pump Refer to Fig 50 Disconnect and transfer the electrical connections to the new pump Set the pump speed to that of the replaced pump Do not forget to fit the gaskets at the connections ...

Страница 27: ...he connections Pull off the clip and remove the sensor Refer to Fig 49 15 4 17 Overheat Thermostat Carefully pull off the connections Twist the sensor to expose the fixing screws Refer to Fig 49 Unscrew and remove the sensor Carefully position the replacement sensor so that the connections are away from the flue hood 15 4 18 Auto Air Vent Drain the appliance as described in Section 15 3 preceding ...

Страница 28: ...812 1 87161428120 68 299352 24SBi Heat Exchanger Giannoni ref PR22 323 003 spec D2107 1 87161428000 117 15SBi Insulation Pack 1 77161922040 117 24SBi Insulation Pack 1 77161922040 75 E00 717 Auto Air Vent 38 in BSP Caleffi Mini Call 502030 1 87161405000 93 299 506 Pressure Gauge 4 Bar Dark Gray 1 87161423000 45 375 699 Pressure Relief valve Caleffi 312439 1 8716142 4040 36 E01 602 Pump c w Harness...

Страница 29: ...29 M T W Th F S Su P DAY HR MIN ADV R I AUTO O RUN DHW CH Set 8 3 7 ...

Страница 30: ...ng room stat calling Facia control knob above position I Fan ON Pump ON 20 second delay Reset on facia APS ON LOCKOUT all outputs OFF EXCEPT pump Gas valve and sparking ON Flame sense No flame sense for 8 seconds Burner ON This sequence is cycled to satisfy temperature set by facia control knob Temperature Sensor disconnected Fan and burner OFF Pump running Failed ignition Overheat of gas to water...

Страница 31: ...ary electrical system 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 Switch on the mains electrical supply Is the facia indicator illuminated Is there mai...

Страница 32: ... of connection X5 Drop down the facia and expose the three PCB rear connectors Is there 230V at pins 3 4 of connector X11 centre connector Refer to above section Does the fan run and normal ignition take place BOILER DEMAND TEST No No No No No No No Yes Yes Yes Yes Yes Yes Yes Set the system to create a boiler demand Turn facia control knob to maximum Does the Fan run Press the facia reset button ...

Страница 33: ... NOTE In the unlikely event of this not solving the problem Inspect the pressure pick up venturi in the fan Yes No Rectify flue problem Yes Is there continuity on the two green wires No Repair or replace harness Yes Replace control board Section 15 4 9 Yes Yes Boiler has LOCKED OUT probably due to overheating Is the boiler fully water pressurised and is all air vented Yes Switch off mains supply a...

Страница 34: ... approx 210V DC across pins 1 4 of connector X3 during spark sequence Replace control board Section 15 4 9 No Yes Replace the gas valve Section 15 4 1 Does the flame continue for more than 10 seconds NOTE Reverse live neutral polarity will cause this fault And system should be cool No Switch off mains supply Remove boiler front panel and combustion chamber cover Is the sense electrode and lead in ...

Страница 35: ...heck or replace room thermostat For Y plan system Replace control board For S plan system Replace DHW zone valve For Y plan system Replace mid position valve For S plan system Replace CH zone valve Complete systems outside the boiler are not the responsibility of Worcester Heat Systems But as a fault finding guide Check the IMPORTANT NOTES on Page 4 of the wiring guide booklet and use any propriet...

Страница 36: ...old are subject to our official Conditions of Sale a copy of which may be obtained on application PUBLICATION 8 716 115 065a 05 08 Bosch Group Worcester Heat Systems Limited 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 bel...

Страница 37: ...37 ...

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