Worcester Highflow 400 RSF, Installation And Servicing Instructions

Page 1: ...kW 82 000 Btu h To Central Heating On Off Control Range Rated Minimum 8 8 kW 30 000 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 This appliance must be installed by a competent person in accordance with the Gas Safety Installation and Use Regul...

Page 2: ...mestic hot water A heatbank having a nominal capacity of 60 litres of circulating primary hot water positioned in the lower half of the appliance A water diverter valve to direct the boiler output either to domestic hot water or central heating as required Multifunctional gas valve and electrical control system to individually control the domestic hot water and central heating An integral circulat...

Page 3: ...ITH THE RECOMMENDATIONS OF BS 7593 1992 PURGE THE GAS SUPPLY BEFORE FINALLY CONNECTING THE APPLIANCE The water pipe connections throughout a sealed system must be capable of sustaining a pressure of up to 3 bar Radiator valves must conform to the requirements of BS2767 10 1972 The relief valve drain outlet must be directed away from any electrical components or where it would cause a hazard to the...

Page 4: ... When hot water is no longer required the burner and pump will continue to operate until the heatbank is back to the required temperature The appliance will return to the central heating state and its normal mode of operation 4 Return Valve Flow Valve Water Manifold Top Section Manual Air Vent Pressure Relief Valve By Pass Adjuster Water to Water Heat Exchanger Water Manifold Bottom Section Water ...

Page 5: ...CAL BALANCED FLUE DETAILS mm inches CEILING HOLE DIAMETER 130 5 0 MINIMUM AIR DUCT LENGTH 100 4 0 MAXIMUM AIR DUCT LENGTH 4500 177 0 Table 3 FLUE DETAILS mm inches WALL HOLE DIAMETER 120 4 5 WALL HOLE DIAMETER FOR OPTIONAL EXTRA INTERNAL FLUE FIXING KIT 150 6 0 STANDARD HORIZONTAL FLUE MINIMUM LENGTH SIDE AND REAR 100 4 0 STANDARD HORIZONTAL FLUE MAXIMUM LENGTHS REAR 500 19 6 SIDE 1000 39 3 EXTEND...

Page 6: ...m Copper Tube GAS INLET 22 mm Copper Tube PRESSURE RELIEF VALVE DRAIN CONNECTION 22 mm Copper Tube OVERALL CASING HEIGHT 860 mm 33 8 in OVERALL CASING WIDTH 600 mm 23 6 in OVERALL CASING DEPTH 600 mm 23 6 in Table 6 SPECIFICATIONS PRIMARY CAPACITY INCLUDING HEATBANK 60 Litres 13 2 galls MAXIMUM INLET DOMESTIC WATER PRESSURE 10 Bar 150 psi MINIMUM INLET DOMESTIC WATER PRESSURE WORKING 1 0 Bar 15 0 ...

Page 7: ...equired each side for servicing Floor Level 450 860 1310 Cabinet Height 10 Wall Fig 2 Appliance cabinet dimensions and minimum clearances required Flue position Rear View Side View Appliance Front 600 170 All pipes set in 25mm from rear of appliance Flue position on rear of inner casing 830 785 715 550 335 275 30 50 115 5 6 7 95 25 75 25 4 120 3 2 1 Fig 3 Appliance pipework connections and flue po...

Page 8: ...m Right side 5 mm 5 mm Left side 300 mm 5 mm A G D H I F J E A B C G M F F L L K K Fig 4 Siting of the flue terminal MINIMUM SITING DIMENSIONS FOR POSITIONING THE BALANCED FLUE TERMINAL TERMINAL POSITION MIN DISTANCE A directly below an openable window or other opening e g air brick 300 mm 12 in B Below gutters soil pipes or drain pipes 75 mm 3 in C Below eaves 25 mm 1 in D Below balconies or car ...

Page 9: ...flue length When deciding the flue length required always measure to the outside of the wall where the flue terminal will be fixed When measuring between the centre lines of the flue ducts allow 83mm for each flue bend 83mm Straight flue length Flue length Flue terminal Outside wall 83mm Appliance Standard flue length 100 to 500mm Appliance Maximum flue length 3000mm Frame 1 Flue Option 1 Standard...

Page 10: ... second 90 flue bend The flue system must be assembled from the Standard Horizontal Side Flue Kit extension flue kits and a second 90 flue bend The flue may be any length providing the total straight length does not exceed 2300 mm when measured from the appliance cabinet See Fig 5 Frame 6 The horizontal section of flue and second 90 flue bend may be positioned in any horizontal direction to suit t...

Page 11: ...urn valve 7 10 Repeated venting loses water from the system It is essential that this water is replaced and the system pressure maintained 7 11 There must be no connection to the mains water without the authority of the local Water Company 7 12 The pump is set at maximum and must not be adjusted 7 13 Connections in the system must resist a pressure of up to 3 bar 7 14 Radiator valves must conform ...

Page 12: ... the appliance will be expelled via the feed and vent connection or dissipated into the rest of the system which must be fitted with manual air vents at any high point 8 7 The pump is set to maximum and must not be reset 8 Open Vent Primary System 12 Hot Water Out S H S H Mains Cold Water Lockshield Valve Radiator Valve Heating Flow Heating Return 22mm dia Vent Pipe Circulating Pump Spherical Plug...

Page 13: ...e device at the point of the flexible hose connections 9 11 The supply of hot and cold mains water direct to a bidet is permitted 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 9 12 As the maximum temperature of...

Page 14: ...or frost thermostat is to be fitted refer to Fig 11 10 8 The thermostats must be suitable for use on mains voltage 10 9 A facia mounted programmer is available as an optional extra Instructions are supplied with the programmer kit See Fig 12 10 10 A timeswitch or programmer can be fitted externally to the appliance 10 11 SAFETY CHECK After installation or in the event of an electrical fault the el...

Page 15: ... brown brown CN4 PIN ML CN3 PIN PL CN2 PIN L1 grey white brown CN2 PIN L3 CN2 PIN L2 CN5 PIN FL brown CONTROL BOARD IGNITION BOARD NO NC C grey ROOM THERMOSTAT IF FITTED N N brown CN1 PIN L N N AIR FLOW PRESSURE SWITCH brown N X11 PIN 4 ELECTRONICS ELECTRONICS WITH 5 MINS OFF DELAY DEMAND INDICATOR N RLA RLB HEATING CONTROL STAT X15 PIN 2 WHITE X15 PIN 3 WHITE RLC X3 PIN 5 black Fig 10 Functional ...

Page 16: ... most suitable flue option for the installation the position of the hole for the flue must now be marked on the wall walls FLUE OPTION 1 See Fig 5 The location of the centre point position for the Rear Flue is obtained from the flue centre lines previously marked This is the Rear Flue centre point position See Fig 13 FLUE OPTION 2 See Fig 5 Draw a horizontal line from the Rear Flue centre point po...

Page 17: ...tub pipes to the appliance pipework should be done at this stage Refer to Section 3 and Fig 3 Pipework must be arranged to clear the flue system See Section 5b and Fig 5 Before the appliance is fitted to the central heating system thoroughly flush the heating system and the mains cold water supply pipe 17 Flue Option 6 Centre line position for horizontal duct Flue Option 3 Rear flue extension cent...

Page 18: ...l onto electrical components or where it might be a hazard to the user See Fig 15 ii the drain pipe must fall throughout its length OPEN VENT SYSTEM If the appliance is to used on an open vent system the expansion vessel and flexible hose are not required Remove from the bottom manifold connection and discard Fit the 22 mm copper vent pipe supplied as an optional extra to this connection See Fig 1...

Page 19: ...rculating pump Domestic water expansion vessel connection To lower the expansion vessel follow instructions 1 to 4 1 Remove cabinet front panel Refer to Fig 12 2 Raise facia and control box into the service position Refer to Fig 12 3 Unscrew one fixing screw 4 Lower expansion vessel to rest on the floow By pass adjusting screw Pressure relief valve Primary manual air vent Inner casing fixing screw...

Page 20: ...trictor Rings are supplied with the hardware pack A restrictor ring must be fitted into the flue terminal the size will depend on the Flue Option chosen Refer to the following table for restrictor size When fixing the flue restrictor ring refer to Fig 24 NOTE For flue options using two or three flue bends the restrictor rings are NOT required and MUST be discarded The optimum route for the flue mu...

Page 21: ... the flue terminal into the air duct with the drill provided Apply a smear of silicone sealant to the end of the air duct and fix into the flue terminal using the screws provided See Fig 22 Fit the flue duct into the flue bend Ensure it is located correctly against the stop Drill two holes through the holes in the flue bend See Fig 22 Fit the air duct over the outside of the flue duct Ensure it is...

Page 22: ...with the screws provided ASSEMBLE THE FLUE DUCTS Follow the procedure for measuring cutting sealing and fixing as described in Section 11 3 Note If the extension is longer than 1500 mm a flue duct support must be fitted before the ducts are finally assembled The flue duct support must be fitted half way along the flue duct for effective support See Fig 23 ASSEMBLE THE FLUE DUCT INTO THE AIR DUCT A...

Page 23: ...located firmly between the end of the air duct and flue terminal See Fig 24 Drill through the holes in the flue terminal into the air duct with the drill provided Apply a smear of silicone sealant to the end of the air duct and fix into the flue terminal using the screws provided Note Do not apply a smear of silicone sealant around the end of the flue duct that fits into the flue terminal Fit the ...

Page 24: ...to this flue bend followed by the first flue bend Ensure the first flue bend is aligned correctly with the appliance Fix each end of the air duct to the flue bends with the screws provided The flue duct must fit correctly between the flue bends The duct is trapped between the flue bends and does not require fixing screws See Fig 26 Follow the procedure for fixing the assembly to the appliance as d...

Page 25: ...ue ducts are located correctly in the flue adaptor Ensure the holes in the air and flue ducts are next to the flue adaptor Do not apply silicone sealant to the inner joints Flue terminal Clamping screw accessible on top of the inner casing Top of appliance inner casing View on top of appliance Do not apply silicone sealant to this joint Flue restrictor ring Flue adaptor Flue position located on re...

Page 26: ...to the appliance and connect any room and or frost thermostats Refer to Section 10 Fig 9 and 12 The leads from the thermostats must pass through holes provided in the control box at the right hand side and be clamped using the strain relief bushes provided in the pack Check that the control box and facia can be withdrawn into the Service Position before fixing any leads outside the appliance Refit...

Page 27: ...flue terminal The two flue lengths when added together must not exceed 2300mm First 90 flue bend Air duct C Ð 58 mm Flue duct C Ð 14 mm Air duct B Ð 166 mm Flue duct B Ð 152 mm Second 90 flue bend Outside wall Appliance B 210mm minimum C Fig 25 Flue Option 5 Extension horizontal flue using a second 90 flue bend Flue elbow and air duct fixing screws Flue elbow and air duct fixing screws Fixing scre...

Page 28: ...tion 6 Extension flue upwards and horizontal using a second 90 flue bend Appliance First 90 flue bend Second 90 flue bend Third 90 flue bend Outside wall 210mm minimum 210mm minimum Air duct B 166 mm Flue duct B 152 mm Air duct B 166 mm Flue duct B 152 mm Air duct C 58 mm Flue duct C 14 mm The three lengths when added together must not exceed 1000mm B B C Fig 28 Flue Option 7 Extension flue horizo...

Page 29: ... upwards and horizontal using a second and third 90 flue bend Appliance Horizontal section of flue duct before the first 90 flue bend First 90 flue bend D 105mm minimum Air duct D 82 mm Flue duct D 80 mm A flue adaptor must be fitted before the horizontal section of flue duct Total length of straight flue including this section must not exceed the length stated in the flue option chosen Appliance ...

Page 30: ...ap See below Burner setting pressure test point High Low solenoid B A C Retaining screw 230v electrical supply plug to High Low solenoid A Ð Adjustment for domestic hot water High gas pressure setting B Ð Adjustment for heating Low gas pressure setting C Ð Plastic cap Fig 33 Gas control valve adjustment Duct assembly Air duct Flue duct Rubber sealing gasket Flue terminal Flue centring ring Seal Ex...

Page 31: ...e is in excess of that accommodated by the expansion vessel fitted to the appliance then an extra vessel must be fitted as close as possible to the central heating return connection of the appliance Any extra vessel fitted must be pressurised to the same figure as the integral vessel If the expansion vessel fails then the specified replacement must be fitted 12 3 PROGRAMMER Any programmer fitted t...

Page 32: ...al times to ensure correct gas pressures Replace the plastic cap C e If the Heating Low Gas Pressure has been changed set the indicator arrow on the data plate to the new setting Balance the system so that the required temperature difference across the heating flow and return pipes is obtained See Section 3 Table 4 Adjust the by pass valve until the same temperature difference is obtained See Fig ...

Page 33: ...h 90 into the Service Position Lodge in the Service Position on the outer locations See Fig 14 c Expansion Vessel Unscrew one screw securing the expansion vessel support bracket to the right hand side panel Lower the vessel gently until resting on the floor See Fig 16 d Inner Casing Cover Repeat operations a b and c Unscrew the four screws securing the cover to the inner casing and lift off See Fi...

Page 34: ...onents Place a towel or cloth beneath the component to absorb the excess system water The water will be contaminated and any absorbent material used must be destroyed or washed thoroughly after any component has been replaced a Appliance Heatbank and Heating Circuit Turn off the central heating flow and return valves at the appliance using a flat blade screwdriver See Fig 17 Fit a tube to the drai...

Page 35: ...nd control box in the Service Position lower the expansion vessel into the Service Position and remove the inner casing cover as described in Section 14 2 a b c and d Remove the combustion chamber cover and main burner assembly as described in Sections 14 2 g and h Discard the burner Fit a replacement main burner in the reverse order Ensure the main burner is fitted correctly on the main burner in...

Page 36: ...water heat exchanger Inner casing Burner assembly Inner casing flexible pressure connection Burner assembly fixing screws 2 Spark electrode Spark electrode Pilot pipe Spark electrode lead Pilot tube sealing grommet Pilot pipe union nut Sealing cover and fixing screw Pilot bracket and fixing screws 2 Fan electrical connections 2 Thermostat fixing Fan assembly Flue hood Fan assembly fixing screws 2 ...

Page 37: ...ve the cabinet front panel place the facia and control box in the Service Position lower the expansion vessel into the Service Position and remove the inner casing cover as described in Section 14 2 a b c and d Remove the combustion chamber cover as described in Sections 14 2 g Unscrew the two screws securing the pilot burner to the main burner Ease the pilot burner forwards sufficiently to allow ...

Page 38: ...gage the spindle from the mounting bracket Withdraw the thermostat threading the capillary through the slot in the rear of the control box and discard Fit a new thermostat and re assemble in the reverse order Apply a smear of heat sink compound to the thermostat phial The capillary of the replacement thermostat must be uncoiled to assist its passage through the control box opening Ensure the capil...

Page 39: ...mpound to the thermostat phial Reassemble the appliance in the reverse order 17 Air Flow Pressure Switch See Figs 9 35 43 and 53 Check that the electricity supply to the appliance is turned off Remove the cabinet front panel and place the facia and control box in the Service Position as described in Section 14 2 a and b Remove the facia as described in Section 15 1 Carefully pull off the suction t...

Page 40: ...It is not necessary to disconnect the electrical cable The cable length is sufficient to allow the pump head to rest on top of the appliance Do not allow the pump head to be suspended by the cable Secure the pump head Pull off the Molex plug marked X7 Diverter Valve from the control board located in the control box Release the strain relief bush by compressing the loose section of the bush and car...

Page 41: ... Nos 6 7 and 8 in the top manifold two full turns Unscrew and remove screws Nos 9 and 10 securing the manifold to the water to water heat exchanger support bracket Retain the screws See Fig 47 Unscrew the flat faced union securing the manifold to the inner casing pipework See Fig 47 Remove the sealing washer and discard See Fig 47 Ease the manifold assembly downwards 10 mm approx until clear of th...

Page 42: ... facia and control box in the Service Position and lower the expansion vessel into the Service Position as described in Section 14 2 a b and c Drain the heating and hot water circuit as described in Section 15 2 Refer to Section 15 3 22 and remove the Top Manifold commencing from the instruction WARNING The weight of the water to water heat exchanger is 2 kg approx A quantity of water will remain ...

Page 43: ...sing new sealing washers Ensure the orientation of the hose fittings does not cause twisting or crimping of the hose when the expansion vessel is repositioned in the boiler Open the valves fill and repressurise the system as described in Section 12 2 Reassemble the appliance in the reverse order 27 Pressure Relief Valve See Figs 16 and 51 Check that the electricity supply to the appliance is turne...

Page 44: ...ipe downwards 10mm into slip joint in bottom manifold Ease pipe to the left to clear top manifold Ease pipe upwards 10mm approx to clear top manifold and remove ÒOÓ ring seal Slip joint Heating return pipe ÒOÓ ring seal Water to water heat exchanger Slip joint Drain pipe securing clip Bottom manifold Front view of water to water heat exchanger with manifolds in position and fixing screws numbered ...

Page 45: ...p manifold Water to water heat exchanger Water to water heat exchanger Locate raised section of hole into the water to water heat exchange port Replace the ÒOÓ ring seals in the top and bottom manifold Ensure they are positioned in the locations provided IMPORTANT Before the water diverter valve is re assembled ensure the domestic drain pipe and clip are fitted to the bottom manifold Refer to Fig ...

Page 46: ...s described in Section 15 2 b Undo the flat faced union below the flow switch Ease the pipework sideways sufficiently to clear the flow switch Remove the sealing washer and discard The water flow regulator is located in the union fitting It may be necessary to prise the regulator from its housing Remove and discard Fit a new flow regulator small diameter section first Reassemble in the reverse ord...

Page 47: ...ectors are fitted to the correct terminals Connectors are not interchangeable and will only fit the terminals from which they were removed Refer to the wiring diagram Fig 9 Reassemble the facia in the reverse order 37 Facia Mounted Programmer See Fig 9 and 16 Check that the electricity supply to the appliance is turned off Remove the cabinet front panel place the facia and control box in the Servi...

Page 48: ...t Thermostat capillaries Mounting bracket Fixing screws Clamping nut Control box Fig 54 Control box and thermostat bracket Locking clip Connector Neon Lead Locking clip slot Plug Fig 55 Neon indicator light plugs Connector Standby Amber Demand Green X3 Fig 56 Neon indicator light connections ...

Page 49: ...Sparking Wait Pump Fan On Wait Pump Fan On Wait Pump On NORMAL TRIPPED H B C D E I A G F NORMAL NORMAL Domestic Hot Water Operational Flow Diagram CH Selected Off Central Heating Operational Flow Diagram HW Selected Off and Water Flow Switch off 16 Operational Flow Diagrams Note The alpha references in these charts are to be used for cross referencing when fault finding See Section 17 Frost Thermo...

Page 50: ...l and external electrical components Repair fault and replace fuse Heatbank Overheat Stat has tripped Investigate reason reset stat Check the mains electrical supply and external wiring Is there 230V at X11 pin 4 L Switch on the mains electrical supply Is the Standby Indicator illuminated Refer to Section FAILURE AT POINT A or FAILURE AT POINT J STANDBY INDICATOR DOES NOT ILLUMINATE Is there 230V ...

Page 51: ... Check harness and repair or replace Replace the fan Gain access to the fan Is there 230V across the fan terminals Brown and yellow wires Check and replace the air sensing tubes or replace the air pressure switch Replace the Ignition board Is there a 230V supply at pin L1 at terminal CN2 Grey wire Check for faults on the electrode lead and electrode and repair as necessary Does sparking occur Does...

Page 52: ...not solved replace cable to gas valve centre solenoid Replace the control board Check the gas supply to the appliance Check for blockages to the burner or replace the gas valve Rectify incorrect wiring Replace the Ignition board If problem persists check earth connections Live and Neutral supply could be reversed Check connections to both boards and electrical spur Is it correct Check condition of...

Page 53: ... immediately or continues indefinitely the control board will be at fault Replace control board Replace demand indicator Replace the control board Replace the flow switch Replace the control board Replace the control board Is there 230V at pin 1 of terminal X1 Blue wire Is there 230V at pin 3 of terminal X1 Brown wire Is there approx 90V at pin 5 of terminal X3 DEM Note Lamp is not driven directly...

Page 54: ...LURE AT POINT M FAILURE AT POINT N YES YES YES Is there 230V at pin 4 of terminal X12 C H Replace the operating switch or programmer Replace the control board Replace the control board Replace room thermostat or insert optional link Set the operating switch or programmer to HEATING and WATER and turn the heating control stat and room thermostat if fitted to maximum but keep the hot water control s...

Page 55: ...oard Pump Over run Pactrol 1 8 716 146 312 0 19 299 330 Thermal Store Thermostat BBA Ranco LM7 P5079 1 8 716 142 338 0 20 299 331 Safety Temperature Limiter Ranco LM8 P2041 1 8 716 142 339 0 21 173 051 CH Thermostat Ranco K36 P1332 1 8 716 142 341 0 22 173 052 HW Thermostat Ranco K36 P1333 1 8 716 142 340 0 23 299 333 HW Limit Thermostat Elmwood 1 8 716 120 817 0 25 386 778 Operating Switch Arrow ...

Page 56: ...nged 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 PUBLICATION 8 716 145 068f 01 2000 Bosch Group Worcester Heat Systems Limited Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619 Technical Helpline 0990 266241 ...