Worcester Combi RSF 240, Installation And Servicing Instructions

Page 1: ...R 47 311 12 BOILER OUTPUT Automatic Modulating Control To Domestic Hot Water Minimum 9 2 kW 31 400 Btu h Maximum 24 0 kW 82 000 Btu h To Central Heating Minimum 9 2 kW 31 400 Btu h Maximum 24 0 kW 82 000 Btu h IMPORTANT THIS APPLIANCE IS FOR USE WITH NATURAL GAS ONLY THESE INSTRUCTIONS APPLY IN THE UK ONLY THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR AT THE GAS METER I I ...

Page 2: ...ter heat exchanger to provide domestic hot water Fully modulating controls in the central heating and domestic hot water modes of operation An expansion vessel pressure gauge and pressure relief valve Aby pass for the central heating system Temperature safety cut out controls 2 9 Domestic Hot Water Page 9 1o Electrical Page 10 11 Instaiiation Page 13 12 Commissioning Page 18 13 Instructions to the...

Page 3: ...taps and mixing valves used in the system must be suitable for operating at a mains pressure of up to 10 bar Thermostatically controlled or pressure equalising shower valves will guard against the flow of water at too high a temper ature Hot and cold mains fed water can be supplied direct to an over rim flushing bidet subject to local Water Company requirements With all mains fed systems the flow ...

Page 4: ...TING RETURN FITTING 22 mm Compression COLD WATER MAINS INLET FITTING 15 mm Compression DOMESTIC HOT WATER OUTLET FITTING 15 mm Compression GAS INLET FITTING Rc1 2 PRESSURE RELIEF VALVE DISCHARGE FITTING 15 mm Compression OVERALL HEIGHT including flue elbow 1100 mm 43 3 in CASING HEIGHT 900 mm 35 4 in CASING WIDTH 450 mm 17 7 in CASING DEPTH 320 mm 12 6 in WEIGHT including water 47 6 kg 105lb INSTA...

Page 5: ...upboard used for airing clothes provided that the requirements of BS 6798 and BS 5440 2 are strictly followed 4 8 The airing space must be separated from the boiler space by a perforated non combustible partition Expanded metal or rigid wire mesh are acceptable provided that the major dimension is less than 13 mm See BS 6798 1987 4 9 No combustible surface must be within 75 mm of the cas ing See B...

Page 6: ...ids Fig 4 Siting of the flue terminal MINIMUM SITING DIMENSIONS FOR POSITIONING THE BALANCED FLUE TERMINAL A 6 Sa Vertical Flue System 5a 1 Avertical flue with a primary length of between 500 mm and 2000 mm can be fitted to the appliance 5a 2 It is recommended that any secondary flue be of the twin walled type such as that manufactured by Rite Vent or Selkirk Refer to BS 5440 Pt 1 for details of s...

Page 7: ...the appliance 7 for Installation and Servicing will normally be adequate for venti lation See Section 4 6 6 4 The minimum free areas required are given below Position of Air from Air direct air vents the room from outside High Level 277 cm2 138cm2 43 in2 21 5 in2 Low Level 277 cm2 138cm2 43 in2 21 5 in2 6 5 Refer to BS 6798 and BS 5440 2 for additional information 7 7 The filling point must be at ...

Page 8: ...Auto air vent i illt Fill Point Heating Return 300mm 112in min above the highest point of the system continuously from the appliance to the feed and expansion cis tern 8 4 Apressure reliefvalve is not required on an open vented sys tern If the pressure relief valve is left in position then a discharge pipe must be fitted which terminates in a position such that any water or steam discharge does no...

Page 9: ... and mixing valves used with this appli ance must be suitable for operating at a pressure of up to 10 bar 150 lb in 9 10 No anti syphonage arrangements are necessary except for some loose head showers See also Section 9 11 following 9 11 Thermostatically controlled or pressure equalising shower valves will guard against the flow of water at too high a temper ature 9 12 The head of a loose head sho...

Page 10: ... is available as an extra Instructions are supplied with the programmer kit 10 9 Atime switch or programmer can be fitted externally to the appliance 10 1 0 SAFETY CHECK After installation or in the event of an electrical fault the electrical system shall be checked for short circuits fuse failure incorrect polarity of connections earth continuity and resistance to earth r T r Indicator Lights I O...

Page 11: ...een and yellow bk black or orange I r red w white y yellow g grey v violet pk pink I I _ _1 L L T I I I I I I I I I I I Spark Electrode w br bl l I I 1 I 1 I I I Pump Overrun Thermostat or _____ _j I __ _l_L r r I I I I I I I I I I ______ I I I I _ __ l E H 11 Gas Valve Domestic Hot W Water Sensor r r J Main Valve Modureg Regulator Pilot Valve I I I I I I I I I I I L ...

Page 12: ...i I 15 15 BOARD RELAY RY1 ELECTRONICS FUSE F2 T315 mA X31PIN 41 red ELECTRONICS X31PIN 51 CENTRAL HEATING SENSOR DOMESTIC HOT WATER SENSOR TEMPERATURE CONTROL POTENTIOMETER I I I 0 01 I I I I a CN2 IPIN L21 white 3 w a brown CN51PIN FLI CN21PIN L31 brown I I I I SAFETY I CIRCUITS H _ _ 1 I I I _____ _J L N N N Fig 10 Functional flow diagram PUMP N N Fig 11 Room thermostat connections Remove link T...

Page 13: ...lue position Mounting wall Mounting plate 13 Check that the position chosen for the appliance is in accor dance with the instructions given in Sections 4 and 5 The distance from the bottom of the mounting plate to the top of the appliance casing is 106mm Hold the appliance mounting plate to the wall Check that the plate is horizontal See Fig 13 Mark the position of the fixing holes and the positio...

Page 14: ...3 a and b Sealed System Unscrew and discard the automatic air vent cap See Fig 15 Open Vent System Undo the three screws securing the casing sealing plate Discard the plate and retain the gasket See Fig 16 Remove and discard the automatic air vent Fit the preformed pipe optional extra using the three screws washers and gasket See Fig 17 Connect the feed and expansion tank If the air and flue duct ...

Page 15: ...r the air ducts Push the assembly through the wall from outside the premises Fix the assembly to the flue elbow Drill through the holes in the elbow into the flue duct and fix with the screws provided Access is gained by slightly withdraw ing the flue duct Spread a smear of silicone sealant around the elbow and push the air duct into position Drill and fix the air duct to the elbow See Figs 21 and...

Page 16: ...f the flue duct Drill and screw together the air ducts From outside push the assembly through the wall and enter the ducts into the flue outlet elbow Pull back the air duct slightly to allow access to the flue duct Drill through the holes in the elbow into the flue duct and fix with the screws provided Spread a smear of silicone sealant around the elbow and push the air duct into position Drill an...

Page 17: ...ve the complete Operating Switch assem bly Fit the programmer and tighten the four screws Plug the programmer into terminal X1 0 on the main driver board Lower the control box as described in Section 14 3 d Connect the mains electrical supply to the appliance and con nect any room and or frost thermostats The electrical leads to the room and frost thermostats must pass through the appropri ate hol...

Page 18: ...ead of 5 metres 17ft The charge pressure must not be less than the static head at the point of connection See Fig 5 ASchraider type tyre valve is fit ted to the expansion vessel to allow the charge pressure to be increased if necessary Set the System Pressure Fill the system until the pressure gauge shows 2 5 bar 37 lb ins and check for water soundness Release water from the TO FAN 18 m MAIN DRIVE...

Page 19: ...adiator valves are fitted then one rudiator should be left uncontrolled The bypass valve should never be fully closed 19 If the heat load is in excess of 16 1 kW 54 900 Btu h then reset the controls to the maximum of 24 kW 82 000 Btu h by care fully rotating the adjustment potentiometer to its maximum postion Access is gained to the adjustment point by lowering the electrical control box Indicate ...

Page 20: ...erminal guard if fitted are clear If the appliance is in a compartment check that the ventilation openings in the compartment door or walls are clear See Sec tion 6 Air Supply Check the system and remake any joints or fittings which show signs of leakage Refill vent and with a sealed system re pressurise as described in Secti011 12 2 Operate the appliance and the system taking note of any faults W...

Page 21: ... ports are clear Remove any blockages with a non metallic brush Inspect the injector and clean with a soft brush Replace the inJector It It appears damaged Do not use a wire brush or anything likely to cause damage Clean the Pilot Burner Assembly Brush with a soft brush Remove the pilot injector and clean by rinsing it in warm water Replace the spark electrode if it appears damaged Fit the elec tr...

Page 22: ...that the electricity supply to the appliance is turned off Before removing any component holding water it is important that as much water as possible is removed from the appliance a Central Heating Circuit Turn off the central heating flow and return valves at the appliance See Fig 3 Fit a tube to the drain tap on the Water to Water heat exchanger and open the tap about one turn See Fig 39 Close t...

Page 23: ...urn connection at the bottom left of the inner casing and manoeuvre the heat exchanger from the casing Carefully remove the left hand insulation pad and the exposed access plate 1tansfer the return pipe to the new heat exchanger leaving the connector nut loose Fit the replacement heat exchanger in the reverse order ensuring all the fibre washers are in place and a layer of heat sink com pound is o...

Page 24: ...er Rear insulation pad Side insulation f21 I Main burner Fig 39 Appliance components lower assembly Central heating sensor Sealing plate ___ _1 rl Expansion vessel Water to Water heat exchanger Mains cold inlet filter Domestic hot water flow restrictor housing 24 ...

Page 25: ... from the appliance Fig 40 Circulating pump 25 Fit the replacement gas valve in the reverse order ensuring the sealing washers are correctly fitted Turn on the gas supply and check for soundness To replace the Modureg head only Pull off the suction pressure compensating tube and the electri cal connections Unscrew the two screws securing the Modureg head to the main body and remove Fit the new Mod...

Page 26: ...ir positions Fit the replacement pump in the reverse order using new sealing washers Ease back the sleeved connector to allow the fitting of the bottom washer Alternatively replace the pump head only by removing the four Allen screws Open the valves and fill and re pressurise the system as described in Section 12 2 Note The direction of flow should be downwards The speed should always be set to ma...

Page 27: ...ng the control box assembly in the servicing position as described in Section 14 3 d Disconnect the capillary at the pressure relief valve Fit the replacement gauge in the reverse order ensuring the fibre washer is in place Open the valves and fill and re pressurise the system as described in Section 12 2 Temperature control p otentiometer Operating Switch _0 EJ Indicator lights 1 1 0 __ 0 x l Pre...

Page 28: ... the servicing position as described in Section 14 3 d Set the central heating operating pressure to 6 3 mb 2 5 in wg 28 by adjusting anticlockwise to increase the pressure and clock wise to decrease the pressure the central heating potentiometer accessed through an opening in the rear of the control box This must be done with the boiler operating in the central heating mode The adjustment is made...

Page 29: ...2 79 371 537 Water to Water Heat Exchanger 1 SSA6161 1 57 379 216 Diverter Valve Interalbion D2040 1 ZAGAS166 97 397 899 Main Driver Board HoneywellW411 58 1226 1 ZAGAS228 98 397 569 Ignition Control Board Pactrol 41 5000 1 ZAGAS096 31 378 029 Overheat Thermostat Ranco LM7 P5050 1 ZAMA 133 17 299 303 Fan Assembly SifanWFFB0221 016 or Torin 76258 1 SSA6072 1 100 379 560 Air Pressure Switch SIT 0 38...

Page 30: ...ntil primary watertemperature falls below 60 C_ up sequence SEE DE AILED SEQUENCE ABOVE 3 Pump Overrun Function Fan off Domestic hot water temperature monitored by domestic hot water sensor Domestic hot water temperature rises above pre set level watertemperature at factory pre setlevel 2 Domestic Hot Water Mode Gas to Water heat excbang2r excess temperature causes boiler overheat thermos to trip ...

Page 31: ...e and pilotvalve off 1 Central Heating Mode AUTOMATIC START UP SEQUENCE Air pressure switch test FAIL Wait Pump on PASS sense air pressure Wait Pump and fan on D Central heating temperature above set level m Heatinputmodulated to maintain flow temperature setby Temperature Control Potentiometer Stop sparking Senseflame NOT PRESENT Wait Pump and fan on Operating Switch off EITHER DEMAND indicator o...

Page 32: ...o terminal __ Check the mains electrical supply X7 pin 1 and external wiring Is there a240V supply at the top end offuse F1 Replace the STANDBYindicator light NO NO __ Fuse F1 has blown Check all cables __ for damage orshort circuits to chassis Is cablingdamaged IYES Repair fault and replace Fuse F1 START OF CENTRAL HEATING TEST Setthe Operating Switch or programmer to HEATING WATER and set the te...

Page 33: ...e between 1 5 and r Y_E_S_ 25 kohms across the white wires t __IL_No __________ Replace the main driver board Checkthe connections at the central heating sensor or replace Is there a240V supply at pin Lon terminal CN1 IYES the sensor NO __ Checkor replace the overheat thermostat NO Is there a240V supply at pin L2 on __ Replace the sequence board terminal CN2 IYES Is there a240V supply at pin L3 on...

Page 34: ...NO NO _ Has the spark electrode stopped sparking _ Check the overall condition ofthe _ Replace the sequence board YES sparkelectrode Is it in poor condition YES Replace the spark electrode Is there a240V supply at pin ML on NO terminal CN4 _ Replace the sequence board NO I Y ES_____ Check the gas supply to the appliance and checkthe burnerfor blockages Is the gas flowing correctly I YES Replace th...

Page 35: ...em controls NO Remove the Molex plugfrom terminal X1 Measure the resistance as follows Between purple and yellow pins 10kohms between purple and pink pins between zero and 10kohms depending on the settingofthe temperature control potentiometer Is this correct IYES NO Replace the temperature control potentiometer onthe facia panel NO Remove the left hand Molex plug Replace the central heating senso...

Page 36: ...ermostat tYES NO YES YES Does an automatic start up sequence occur ending in full burnerignition YES NO Does the fan run NO Remove the plated screw in the centre ofthe pump and turn the shaft with aflat bladed screwdriver Does the pump now run __ Does the fan run then stop then run etc 4 I I 5 I I t YES Replace the sequence board 36 __ Replace the pump NO __ Is there approximately 24V AC across th...

Page 37: ...s the Modureg terminals decrease as the flow rate reduces YES Replace the Modureg NO __ The overheatthermostat has activated Reset the overheat thermostat and repeat this test NO __ Does the DEMAND indicator light go out immediately tYES Replace the main driver board I I I NO Is there a240V supply at pin L2 on __ Replace the sequence board terminal CN2 IYES NO Is there a240V supply at pin L3 on __...

Page 38: ...Y Indicator does not illuminate NO Is there a240Vsupply at pin 3on Replace the pump overrun terminal X6 thermostat tYES Replace the pump NO When the primary temperature Replace the pump overrun drops below60 C approx does thermostat the pump stop YES End of pump overrun test OVERHEAT PROTECTION TEST NO Does the burnershut down ifthe Replace the system overheat Gas toWater heat exchanger thermostat...

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Page 40: ...1905 754619 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 sol are subj ct to our official Conditions ofSale a copy of which may be obtained on application 8 716 115 056a 05 08 ...