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  4. 14/19CBi
  5. Installation And Servicing Instructions

Worcester 14/19CBi Installation And Servicing Instructions

Summary of 14/19CBi

  • Page 1

    Bosch group 9/14cbi n.G. Minimum 9.0 kw maximum 14.0 kw 9/14cbi lpg minimum 10.0 kw maximum 14.0 kw 14/19cbi n.G. Minimum 14.0 kw maximum 19.1 kw 14/19cbi lpg minimum 14.0 kw maximum 19.1 kw 19/24cbi n.G. Minimum 19.1 kw maximum 23.5 kw 19/24cbi lpg minimum 19.1 kw maximum 23.5 kw 9/14cbi, 14/19cbi,...

  • Page 2

    1.1 gas safety (installation & use) regulations 1998. It is the law that all gas appliances are installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your interest, and that of safety, to ensure complianc...

  • Page 3

    Where a storage system will not have a vent to atmosphere the installation must comply with building regulations and water company bye-laws. If connecting to an existing system the local authority should be informed. 2.7 flue there are 3 fluing options available. (i) rear only flue kit. (ii) multi-d...

  • Page 4

    The data plate is fixed to the inner casing cover. 4 3. Technical data hydraulic resistance boiler output resistance min. Flow rate kw metres l/min. °c 0.06 6.5 20 0.13 11.7 11 14.0 0.28 18.2 11 table 3 9/14cbi flue details horizontal flue mm wall hole diameter external fix 110 internal fix 150 mini...

  • Page 5

    5 gas supply system - based on ng (g20) total length of gas supply pipe (copper) metres 3 6 9 12 maximum gas dischargerate - pressure drop 1mbar. M 3 /h pipe diameter mm 8.7 5.8 4.6 3.9 22 18.0 12.0 9.4 8.0 28 table 6 clearances (mm) installation service above appliance - internal rear flue 30 30 ab...

  • Page 6

    The appliance may be installed in any room subject to the requirements of the current iee regulations and, in scotland, the relevant electrical provisions of the building regulations with respect to the installation of appliances in rooms containing baths or showers. If the appliance is installed in...

  • Page 7

    The flue system must be installed following the requirements of bs5440:1. The standard flue kit length is 425 - 725mm. Extension kits for flues up to 3.0m are available. A rear flue suitable for walls from 220 - 375mm thick is available which can be contained within the boiler casing. The terminal m...

  • Page 8

    The system must comply with requirements of bs6798 and bs5449. General: the appliance is only suitable for connection to indirect fully pumped sealed and open vent systems. The minimum static head is 1.2m and the maximum is 30m. The pump must be wired to the boiler control to ensure that the pump-ov...

  • Page 9

    Heating return non return valve non return valve hose union test cock temporary hose stop cock auto air vent heating return stop cock fill point non return valve make up vessel 1200mm (48 in) above the highest point of the system. 9 note: a drain cock should be fitted at the lowest point of the heat...

  • Page 10

    The gas supplier must be contacted to check the suitability of the appliance for the local gas supply conditions before connecting the appliance. The 19/24cbi appliance requires a maximum of 2.72 m 3 /h of natural gas (g20), 1.05 m 3 /h propane (g31). The 14/19cbi appliance requires a maximum of 2.1...

  • Page 11

    11 fig.10. Boiler wiring diagram flame sense electrode spark electrode gas valve air pressure switch overheat thermostat fan control board x1 x2 x3 x4 x5 x6 1 or ange 1 1 x7 user control potentiometer/switch black white br own gr ey violet re d violet re d black orange brown grey white nc no com tem...

  • Page 12

    12 fig.11 . System wiring diagram control board x1 pump l pump n permanent n permanent l switched l (boiler demand) earth post cable clamp outside of boiler inside of boiler system wiring centre terminal strip boiler/pump demand from system wiring centre l switched pump not to be connected to system...

  • Page 13

    13 fig. 12a. Boiler assembly 9/14cbi shown set for integrated flue kit 1. Inner case 2. J bolts and wing nuts (2) 3. Combustion chamber cover 4. Burner 5. Burner fixing screw 6. Control knob 7. Indicator lights 8. Base/controls fixing screw 9. Cabinet fixing screw 10. Gas valve 11. Spark electrode 1...

  • Page 14

    14 1. Inner case 2. J bolts and wing nuts (2) 3. Combustion chamber cover 4. Burner 5. Burner fixing screw 6. Control knob 7. Indicator lights 8. Base/controls fixing screw 9. Cabinet fixing screw 10. Gas valve 11. Spark electrode 12. Burner injector 13. Temperature sensor 14. Overheat thermostat 15...

  • Page 15

    Note: read this section fully before commencing the installation to install a boiler with a rear only flue refer to section 11.1. To install a boiler with a telescopic horizontal flue kit refer to section 11.2. To install a boiler with a vertical flue refer to section 11.2. And the literature with t...

  • Page 16

    16 11.1.6 install the boiler important: thoroughly flush the system before connecting the boiler. Any system cleanser must be flushed from the system. (i) lift the boiler onto the wall mounting plate. See fig. 15. (ii) level the boiler using the two levelling feet at the base of the back panel. (iii...

  • Page 17

    17 1 1. Flue hood 2. Fan 3. Sensing connection ( + ) 4. Sensing connection (—) 5. Top outlet sealing plate 6. Fan lead clip 7. Fan fixing screws (2) 8. Pressure tube junction 9. — ve pressure tube 10. + ve pressure tube 11. — ve pressure tube extension 12. + ve pressure tube extension 2 3 (+) (red t...

  • Page 18

    11.1.8 completion of the installation check that all the gas and water connections have been tightened. Lower the base plate/control panel. Refer to fig. 17. The permanent mains and switched live supply to the boiler must come from the system junction box. Refer to fig.11. A 4 core cable is recommen...

  • Page 19

    11.2.5 flue preparation (i) drill the hole for the flue at Ø110mm unless the optional internal fitting kit (whs part no. 7 716 191 019) is used in which case a Ø150mm hole is required. (ii) fix the wall mounting plate onto the wall. Ensure it is level before tightening the screws. (iii) the method o...

  • Page 20

    11.2.6 telescopic horizontal flue kit up to 750mm in length (i) the standard flue can be telescopically adjusted to any length between 425mm and 725mm. It will only be necessary to cut the standard assembly if l assembly by the same amount i.E l=350 - remove 75mm from each assembly. The minimum leng...

  • Page 21

    11.2.9 vertical adaptor for horizontal flues an adapter is available for an initial short section of vertical flue. Refer to fig. 25. Measure and cut the flue as described in section 11.2.7. The first, vertical, section (equivalent to dimension x) is measured from the top of the boiler casing. Cut t...

  • Page 22

    11.2.12 installation of flue onto boiler (i) fit the clamping ring around the flue spigot but leave loose. From the inside push the assembly through the wall. Align the flue turret and push fully onto the spigot on the appliance. (ii) slide the clamping ring into position so that the hole in the spi...

  • Page 23

    Water treatment: for optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance with the guidelines given in bs7593: 1992 – treatment of water in domestic hot water heating systems. Full instructions are supplied with proprietary cle...

  • Page 24

    13.1 hand over the user booklet and the benchmark log-book 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 (sealed system) pressure falls. 13.5 expla...

  • Page 25

    Burner blade assembly. Remove the combustion chamber cover. Undo the screw at the right hand end of the burner. Carefully pull-off the connections to the spark electrode. Slide the burner blade assembly off the injector and remove. Carefully pull off the flame sense electrode lead. Refer to fig 33/3...

  • Page 26

    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, gasket or seal that appears damaged must be repla...

  • Page 27

    27 fig. 34 . Inner casing - gas and electric controls. 9/14cbi shown. 2 3 1 1. Inner casing 2. J bolts and wing nuts (2) 3. Combustion chamber cover 4. Burner assembly 5. Inner case cover fixing points (4) 6. Base/control fixing point 7. Gas valve 8. Burner manifold fixing screws (4 + 4) 9. Burner m...

  • Page 28

    15.4.1 gas valve note: if the left hand clearance is >50mm then the gas valve can be replaced with the burner and combustion chamber cover in place by unscrewing the four extended screws at the manifold on the outside of the inner casing. The manifold gasket should be replaced if it is damaged or ha...

  • Page 29

    15.4.5 control board lower the base plate/control assembly and carefully disconnect the plug-in connector and all the electrical connections. Refer to fig. 35. Release the five clips and lift out the control board. Refer to fig. 35. Pull out and replace, if necessary, a failed fuse. 15.4.6 fan remov...

  • Page 30

    15.4.7 air flow sensor remove the fan as described in 14.3. Unscrew and withdraw, through the fan outlet, the air flow sensor. Refer to fig .38 and 38a. The detector is 'handed' - do not force it into place. 15.4.8 temperature sensor remove the access panel to give improved access with minimum side ...

  • Page 31

    15.4.11 combustion chamber insulation the insulation pads are manufactured from a material in accordance with coshh. Remove the casing, inner casing cover and combustion chamber cover. Front insulation: unscrew the clamp at the top of the combustion chamber cover to replace insulation. Side insulati...

  • Page 32

    These instructions should only be read if converting appliance from natural gas to lpg or vice versa. Only components supplied by worcester heat systems should be used. Only competent persons should attempt the conversion. Conversion from natural gas to lpg should not be carried out on appliances in...

  • Page 33

    1 e60-473 burner assembly ng 9/14cbi 1 8 716 121 773 0 burner assembly lpg 9/14cbi 1 8 716 103 210 0 2 e60-474 burner assembly ng 14/19, 19/24cbi 1 8 716 121 767 0 burner assembly lpg 14/19, 19/24cbi 1 8 716 103 211 0 3 e60-475 injector burner 3.4mm ng 9/14cbi 1 8 716 157 116 0 injector burner 2.1mm...

  • Page 34

    34 18. Operational flow diagram m ains 230v supply boiler hea t demand pump continues for 4 minutes demand off boiler demand fr om sy stem junction bo x and user contr ol knob on run f an 20 seconds or w ait f or the end of the f an ov errun boiler demand light on pump supply on ignition sequence bo...

  • Page 35

    35 19. Fault finding note: this fault finding information is for guidance only. Worcester heat systems cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control for this boiler incorporates three lights: boiler demand, flame on and lockout. These for...

  • Page 36

    36 remove connector x5 and test resistance between the red and violet cables. Is the resistance between 1 kohm and 30 kohm? Fail point a no yes note: it is normal to see only a demand light if the boiler is hot and the burner has temporarily shut off. Ensure boiler is cool and user control set to ma...

  • Page 37

    Fail point c is the boiler in a very cold environment i.E is the primary water temperature below 5°c? Boiler is running in 'autofroststat' mode. Yes demand light has failed. Replace control board if it is considered a problem. No fail point d is the system fully water pressurised and is all air vent...

  • Page 38

    Fail point e 'burner lock out' is the gas supply connected and at the correct pressure? Remove boiler casing. Reset and restart the boiler. Can a flame be seen through the spyglass? Note: there is a 20 second delay from fan on to spark. Yes no rectify gas supply problem. No turn off gas supply. Remo...

  • Page 39

    39 fail point f delivered primary water temperature always too hot. (over 85°c) delivered primary water temperature appears too low with control knob set to maximum. (less than 75°c) such a fault is likely to be caused by one or more of the following: low gas pressure partially blocked flue partiall...

  • Page 40

    This booklet is accurate at the date 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 sold are subject to our official conditions of sale, a copy of which may be obtained on application....

  • Page 41

    41.

  • Page 42: Bosch Group

    Bosch group vertical balanced flue system installation instructions room sealed non-condensing combination/system boilers and water heaters 24i 47 311 37/38 15sbi 41 311 43/45 28i 47 311 54 24sbi 41 311 44/46 25si 47 311 49/50 9/14 cbi 41 311 50/51 28si 47 311 51/52 14/19 cbi 41 311 52/53 c1 47 311 ...

  • Page 43

    2 the flue system must be installed in accordance with bs 5440: part 1 2000 where applicable. When installed the minimum clearance between the terminal and any adjoining vertical walls or obstructions must be at least 500mm. The terminal must not be installed within 600mm of an openable window, air ...

  • Page 44

    3 2.1. Terminal assembly the overall height of the terminal assembly is 1100mm. Note. A minimum of 300mm shall extend above the surface of the roof. Refer to fig. 2. 2.2. Nominal flue height (no offset). The maximum equivalent flue heights, excluding the flue terminal assembly are: table 2. 24i, 28i...

  • Page 45

    4 3.1. Flue height and offsets. Determine the height of the flue system and if offsets are needed for the system to miss ceiling/roof joists and any other obstruction. Refer to fig. 8. 3.2. Installation of boiler. Refer to the relevant installation and servicing instructions for the fitting of the w...

  • Page 46

    5 3.8. Positioning the flue system it may be necessary to deviate from the following method of installation because of site conditions. However, joints must be sealed and fixed as described. Align the centre of the flue spigot with the ceiling and mark the centre position. Refer to fig. 8. Cut a hol...

  • Page 47

    6 4.1 air and flue duct lengths - no offset for a flat roof measure the distance from the appliance top panel to the outside edge of the hole diameter marked on the inside surface of the roof. This is dimension 'e 1 ' refer to fig. 9. For a pitched roof, measure the distance from the appliance top p...

  • Page 48

    7 4.2 air and flue duct lengths - offset with vertical adapter (90° or, where applicable, 45° bends) 1st vertical section: measure from the top of the flue spigot on the appliance to the centre-line of the horizontal section of the offset. Dimension 'j'. Refer to fig. 10. Duct length = j — 173mm not...

  • Page 49

    8 4.3 air and flue duct lengths - offset without vertical adapter (90° or, where applicable, 45° bends) measure the distance from the centre of the flue spigot on top of the appliance to the centre line of the vertical sections. Dimension d. Refer to fig. 11,12. Duct length: 90° bends = d — 162mm 45...

  • Page 50

    9 air inlet flange weather sealing collar (secure with screw provided and seal with silicone sealant) roof flashing (not supplied) flat roof pitched roof ceiling fire stop spacer note: 45° bends may be applied in any system layout as with 90° bends. Note: for more information on bends in flue see in...

  • Page 51

    Terminal assemblly height 1100mm diameter 106mm smear silicone sealant on this joint. Seal ensure the ducts are correctly located into the socketed joints. Vertical flue adaptor 88mm high. Clamping ring appliance front seal fixing screws note: the flue terminal must be connected a minimum of 55mm ab...

  • Page 52

    11 important: do not forget to fix the fire stop spacer as the assembly of the system proceeds. 5.9 fix the flue terminal assembly fit the roof flashing loosely to the roof. From outside, pass the terminal assembly through the roof flashing. From inside the roof space align the assembly with the air...

  • Page 53

    This booklet is accurate at the date 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 sold are subject to our official conditions of sale, a copy of which may be obtained on application....