Worcester C1, Installation And Servicing Instructions

Page 1: ...ural Gas GC NUMBER 47 311 53 N G APPLIANCE OUTPUTS Natural Gas Domestic Central Heating Minimum 8 5 kW 8 5 kW Maximum 28 0 kW 28 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 make the installation easier and prevent hold ups 0 I C1 ...

Page 2: ...for mains water pressure of upto 10bar 2 2 Electrical Supply 230V 50Hz Load 180 watts External fuse 3A Internal fuses F1 2A F2 1 6A 20mm 2 3 Gas Supply The appliance requires a maximum of 3 38 m3 h of natural gas G20 The installation and the connection of the gas supply to the appliance must be in accordance with BS6891 The meter or regulator should deliver a dynamic pressure of 20 mbar G20 at the...

Page 3: ...ing 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 Heating A demand for heat will ignite...

Page 4: ...SION 22mm RETURN COMPRESSION 22mm COLD WATER INLET COMPRESSION 15mm DOMESTIC WATER FLOW COMPRESSION 15mm GAS INLET Rp 3 4 RELIEF VALVE DISCHARGE PUSH FIT 15mm CASING HEIGHT 800mm CASING WIDTH 440mm CASING DEPTH 360mm WEIGHT LIFT 42 3kg WEIGHT UNPACKED 45 8kg WEIGHT PACKAGED 52kg Table 4 FLUE DETAILS HORIZONTAL FLUE mm WALL HOLE DIAMETER EXTERNAL FIX 110 INTERNAL FIX 150 STANDARD FLUE MINIMUM LENGT...

Page 5: ...0 MAXIMUM MAINS INLET PRESSURE bar 10 MINIMUM MAINS INLET PRESSURE WORKING FOR MAXIMUM FLOW bar 1 3 MINIMUM MAINS INLET PRESSURE WORKING FOR OPERATION bar 0 5 DOMESTIC HOT WATER TEMPERATURE RANGE C 40 62 MAXIMUM CENTRAL HEATING FLOW TEMPERATURE C 82 nom MAXIMUM CENTRAL HEATING SYSTEM SET PRESSURE bar 2 5 MINIMUM CENTRAL HEATING SYSTEM PRESSURE bar 0 5 OUTPUT TO DOMESTIC HOT WATER kw NATURAL GAS G2...

Page 6: ...hes providing that the requirements of BS6798 and BS5440 Part 2 are followed Refer to Section 2 4 The airing space must be separated from the boiler space by a perforated non combustible partition Expanded metal or rigid wire mesh is acceptable provided that the major dimension is less than 13mm The clearance between the front of the appliance and the cupboard compartment door should be not less t...

Page 7: ...an those above minimum clearances given in Section 4 Siting The Appliance then permanent 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 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 F...

Page 8: ...Refer to Fig 9 The system and the appliance must be properly vented Repeated venting loses water from the system which must be replaced The make up connection must be close to the appliance in the heating return pipe through an approved non return valve Refer to Fig 10 The connection to the mains water supply must have the approval of the local Water Company The integral by pass is not adjustable ...

Page 9: ...ance with the requirements of the local Water Company An isolating valve should be fitted to allow servicing The water hardness can be determined by reference to the local Water Company The appliance requires a maximum of 3 38 m3 h of natural gas G20 Refer to Table 7 A natural gas appliance must be connected to a governed meter The installation and connection of the gas supply to the appliance mus...

Page 10: ...de Spark transformer Mains in Link Control Board CH sensor front of heat exchanger Flow switch ST16 2 blue 2 orange 2 brown brown blue blue brown 2 violet white 2 red 2 yellow 2 pink ST12 ST8 ST15 ST1 Pump Gas valve Reg Main Main 2 green brown yellow Overheat cut off device DHW sensor ...

Page 11: ...s Electronics Electronics Inputs Outputs 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 knob DHW control knob Convert AC to low vo...

Page 12: ...it the plugs and insert the bottom screws Offer the assembly to the wall utilising the keyhole slots on the manifold assembly and fix to the wall Refer to Fig 15 and 16 Check that the assembly is properly aligned before tightening the screws 11 6 Gas and Water Pipes Remove the gas cock and fix the appropriate fitting to connect the inlet pipe and refit Refer Fig 16 Pre plumbing is not recommended ...

Page 13: ... however be strictly followed Remove all packing material from the flue components Fit the flue restrictor ring by unscrewing and removing the flue spigot from the boiler Refer to Fig 19 Restrictor Size 79mm to all Horizontal and Vertical flues upto 725mm long The standard telescopic flue assembly is suitable without cutting for flues from 425mm up to 725mm measured from the centre line of the boi...

Page 14: ...ret assembly and the terminal assembly by the same amount i e L 350 remove 75mm from each assembly Minimum side flue length 330mm accommodating a 10mm Service clearance and a 100mm wall Minimum rear flue length 300mm accommodating a 100mm wall If L is between 1175 1475mm 1 extension 1925 2225mm 2 extension 2675 2975mm 3 extension it is not necessary to cut the ducts If L is between 725 1175mm 1 ex...

Page 15: ...end on the flue turret A 90 bend is equivalent to 1m of straight duct A 45 bend is equivalent to 0 5m of straight duct A maximum flue assembly of 2m is possible with 1 X 90 bend and 1m with 2 X 90 bends Measure the lengths X Y and Z Refer to Fig 26 The maximum value of X using the turret assembly only is 506mm Reduce the ducts to the appropriate length i e X 406mm cut 100mm from the air duct and 1...

Page 16: ... remove the socketed ends The minimum measured distance is 167mm Seal the air duct to the spigot using silicone sealant Fix the adaptor with the clamp and screw provided 11 14 Completion of the Installation Check that all the connections on the manifold have been tightened Refer to Fig 6 Remove the facia bottom panel Refer to Fig 29 Connect the mains electricity supply lead to the appliance and se...

Page 17: ... thermostat external control mains voltage ST8 5 Fuse F2 6 Controls 24V ST13 7 Mains harness 8 Fan ST1 9 Pump ST5 10 Earth tag 11 Cable clamps threaded 11 Fig 32 Mains Voltage External Controls Connections 230 V Room Thermostat Connections Ns Ls LR ST8 Ns Ls LR ST8 Remove Link Neutral Live Switched Live Neutral Live Switched Live Motor 230 V Programmer Connections 230 V room thermostat and Program...

Page 18: ...7ft 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 necessary Refer to Fig 34 The expansion vessel must be charged to 0 35bar less than the initial system design pressure Note 1bar 10 2m 33 5ft of water 12 3 Set the System Pressure Fill the system until the ...

Page 19: ...appropriate to the appliance and the gas Refer to Table 1 Gradually close the tap and check that the burner pressure falls Fully open the tap and check that the pressure rises Close the tap and check that the burner goes out The fan may continue running until the appliance has cooled to a pre set temperature 12 8 Central Heating Check that all the radiator valves are open Check that the system is ...

Page 20: ...the service has been completed 14 3 Component Access To service the appliance it may be necessary to remove some or all of the following parts to gain access to components which may need to be checked or replaced Cabinet Unscrew the screw at the top of the cabinet release the side Lift up and away from the top locating pegs Facia Panel Unscrew the two screws and lower Refer to Fig 40 Unscrew the f...

Page 21: ...embly Flue hood Combustion chamber flue hood fixing screws Heat exchanger Combustion chamber fixing screw Burner connection Burner Combustion chamber Primary sensor Overheat thermostat at rear Combustion products test point front cap Combustion chamber fixing screw ...

Page 22: ...t Refer to Fig 41 and 45 for an indication of the location of the various 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 Remove casing and cover panels and lower the facia as necessary to gain access t...

Page 23: ...the union connection beneath the burner and remove the burner from the appliance Refer to Fig 44 Do not omit the gasket when fitting the new burner 15 4 5 Combustion Chamber Insulation Remove the burner as described in 15 3 4 preceding Remove the primary heat exchanger as described in 15 4 21 following Replace the side and front pads in the combustion chamber assembly Refer to Fig 48 Replace the r...

Page 24: ...d Disconnect the relief valve drainpipe Unclip and pull out the valve Refer to Fig 51 24 Fig 48 Combustion Chamber Insulation Fig 49 Pressure Gauge head Fig 50 Pressure Gauge capillary fixing Fig 51 Relief valve drain connection Pump Relief Valve Drain Connection push fit Boiler Drain Pressure Gauge Capillary Relief Valve Insulation panel front Combustion chamber assembly Fixing screws Insulation ...

Page 25: ...ter 15 4 10 Control Board Remove the facia bottom panel and carefully disconnect all the electrical connections Refer to Fig 33 Remove the cabinet and lower the facia panel as described in Section 14 3 Inspection and Servicing Disconnect the earth connection at the appliance Refer to Fig 45 Unscrew the four screws and remove the metal cover Refer to Fig 54 Lift out the control board Refer to Fig 5...

Page 26: ... fitting the replacement sensor 15 4 16 Overheat Thermostat Remove the cabinet and the inner casing Carefully pull off the connections Unscrew the two screws and remove the sensor Refer to Fig 58 Apply a small quantity of heat transfer paste to the face of the replacement sensor Carefully reposition the sensor so that the connections are away from the flue hood Reconnect the sensor 15 4 17 DHW Sen...

Page 27: ...ealant Loctite 575 when fitting the replacement air vent Remove the cap Refer to Fig 34 15 4 21 Primary Heat Exchanger Check that the appliance has been fully drained as described in 15 3 preceding Remove the combustion chamber as described in Section 14 3 Inspection and Servicing Remove the temperature sensors as described in 15 4 15 16 and 17 preceding Undo the four union connections and remove ...

Page 28: ...nerCaseSeal WHS 1 87161216020 57 E27 620 Air Flow Switch Huba 605 99486 1 87161423870 59 E27 623 Control Board Junkers Heatronic 1 87483003360 63 375 696 Primary CH Sensor Elmwood 1 87161423020 63 375 696 DHW Sensor Elmwood 1 87161423020 66 299 495 Overheat Thermostat Elmwood 1 87161423890 69 E25 322 Spark Electrode Assembly Vulcano 1 8708107 0080 70 E25 323 Flame Sense Electrode Vulcano 1 8 70810...

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Page 30: ...ure set by control knob DEMAND END Overrun function see overleaf 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 Pump continue 4 seconds if primary temp above DHW setting Burner to MAX for 4 seconds Modulate gas to maintain delivered water temperature set by control knob Is CH i...

Page 31: ...tral heating sensor Return to normal off state AUTOFROSTAT FUNCTION Run pump 20 C END DHW DEMAND END CH DEMAND If primary temp over 85 pump cycles for 2 seconds every 10 seconds until temp below 85 Pump runs for 3 minutes If primary temp above 80 fan runs until temp below 80 C 35 seconds minimum If primary temp below 80 run fan for 35 seconds After 3 minutes the pump runs if primary temp over 95 u...

Page 32: ...uring 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 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 rema...

Page 33: ... to boiler Replace control board Section 15 4 10 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 15 4 10 Remove control board from facia See Section 15 4 10 and sepa rate transformer from board Measure resistance across the two pairs of adjacent pins on the transformer Are any pair above 100 ohms Rep...

Page 34: ...onnector from board edge Does CH lamp now light Yes Correctly set or replace electronic programmer Yes Yes Red diode is damaged Replace control board Section 15 4 10 Replace control board Section 15 4 10 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 acros...

Page 35: ... FAIL POINT G Primary Overheat No Re fix sensor to pipe No No Repair or replace pump Section 15 4 18 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 co...

Page 36: ...er cover Reset and restart the 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 200 ohms Replace control board Section 15 4 10 If problem not solved replace gas valve Section 15 4 1 Repair or replace flame sensor Section 15 4 3 o...

Page 37: ... continuity from brown and violet wires to the multiway connector Check or replace CH sensor Section 15 4 15 Is there continuity from contacts 17 and 18 to DHW sensor Check or replace DHW sensor Section 15 4 17 Is there continuity from contacts 12 and 13 to CH sensor Repair or replace harness Repair or replace harness Repair or replace harness Is the multiway connector at board position ST16 pushe...

Page 38: ...ue for blockage Also investigate sense tubes and pressure switch Remove electrical connectors from pressure switch and restart boiler Is there continuity between C and NO terminal where green wires were fitted when the fan runs Pressure switch has not closed Are the silicon tubes in good condition and free of condensation Replace air pressure switch Section 15 4 22 Note In the unlikely event of th...

Page 39: ...5 4 15 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 pressure No No Repair wires or replace harness No Yes Yes Repl...

Page 40: ...official Conditions of Sale a copy of which may be obtained on application PUBLICATION 8 716 145 216 f 04 02 Manufactured exclusively for British Gas by 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 numb...

Page 41: ...G C NUMBER 47 311 53 0 I C1 USER INSTRUCTIONS CUSTOMER CARE GUIDE ...

Page 42: ...y Worcester Heat Systems and the strictest quality control standards are demanded throughout every stage of production The result is that your new C1 appliance offers you the very best of everything quality efficiency economical running costs proven reliability and value for money What s more you also have the assurance of our no nonsense 1 year parts and labour guarantee No wonder that more and m...

Page 43: ...d not be used until the fault has been corrected by a competent person GENERAL DESCRIPTION See Fig 1 The C1 MODELS are combined domestic hot water and central heating appliances They consist of a gas fired boiler having a varying output of between 8 5kW and 28kW and all the necessary controls to provide mains fed domestic hot water and central heating The appliances are fitted with a manual Operat...

Page 44: ... set by the adjustment of the Heating Temperature Control Knob See Fig 2 If the system no longer requires heat to maintain the desired room temperature the burner will extinguish The pump will continue to run for a short period to dissipate the residual heat from the appliance and then switch off The appliance will supply heat to the central heating system as required A demand for hot water at a t...

Page 45: ...eration of the appliance Should water leaks be found in the system or excessive venting be required from any radiator a service engineer should be contacted and the system corrected GENERAL NOTES The appliance must be fitted to a sealed heating system which is pre pressurised Your installer will advise you on the minimum and maximum pressure that should be indicated on the pressure gauge See Fig 2...

Page 46: ...atically controlled shower valves will guard against the flow of water at too high a temperature If using a pressure equalising valve set the Domestic Hot Water temperature control knob to the MAX position Hot and cold mains fed water can be supplied direct to an overrim flushing bidet subject to local water company requirements With all mains fed systems the flow of water from the individual taps...

Page 47: ... the airing space is separated from the boiler space by a perforated non combustible partition as described in BS 6798 1987 CIRCULATING PUMP This may be fitted with a speed adjuster If so it will be factory set at maximum and should not be changed FROST PRECAUTIONS If the appliance is not to be used for a long period of time and there is a likelihood of freezing then the appliance should be draine...

Page 48: ...delivered at the domestic hot water taps between fully clockwise and anti clockwise positions By slightly reducing the flow of domestic water from the tap the delivery temperature of the water will be further increased This is of particular advantage in the winter for example to increase bath water temperature and to remove heavy grease deposits on plates etc Also this will provide an added advant...

Page 49: ... times per second lockout Domestic hot water demand indicator OFF No demand for domestic hot water ON Domestic hot water demand FLASHING FAST Air flow fault five times per second Central heating and domestic hot water demand indicators BOTH FLASHING SLOW Overheat cut off once per second Flame detection indicator OFF Burner off ON Burner on 0 I Fig 2 Controls Mains electricity On Off Mains electric...

Page 50: ...the O position Switch off the mains electricity A facia mounted electronic programmer will retain its settings for about two weeks after which it will return to the factory set programme The display will disappear after approximately 12 hours A facia mounted mechanical programmer will require resetting once the operating switch has been set to O or the mains supply has been disconnected ELECTRICIT...

Page 51: ...and holding in for 5 seconds Check that the gas supply has not been interrupted If this condition continues to occur then call a service engineer AIR FLOW DEVICE The appliance will enter a lockout condition in the event of an air flow fault If the controls fail to detect the correct air flow through the appliance the electricity supply to the gas valve will be interrupted If an air flow fault has ...

Page 52: ...12 If your C1 appliance should fail to operate correctly please call British Gas on APPLIANCE FAILS TO OPERATE 0845 9 60 50 40 IMPORTANT Do not touch or adjust any sealed component ...

Page 53: ...r to realise its maximum working life and to ensure it continues to operate at peak efficiency and performance it is essential that your boiler receives regular competent servicing and annual maintenance checks beyond the initial 12 month guarantee period To arrange for a British Gas Three Star Cover agreement please call 0845 9 60 50 40 ...

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Page 55: ...te the first 12 month service has been carried out to the satisfaction of Worcester Heat Systems Limited when requested 3 That any product or part thereof returned for servicing under the guarantee must be accompanied by a claim stating the Model Serial Number Date of Installation 4 That Worcester Heat Systems Limited will not accept responsibility for damage caused by faulty installation neglect ...

Page 56: ...postpaid Guarantee Registration Card within 14 days of purchase The card will register you as the owner of your new C1 appliance and while this will not affect your statutory rights in any way it will assist us to maintain an effective and efficient customer service by establishing a reference and permanent record for your boiler IMPORTANT SERIAL NUMBER Copy the number off the Guarantee Card FOR Y...