Bosch Worcester 24CDi

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Summary

Fitting Instructions for New Plastic Flow Manifold

Initial Safety Precautions

Ensure electricity supply is off before starting work. Turn off cold water valve and drain.

Draining and Preparation

Turn off central heating valves, drain appliance, and remove existing manifold.

Filling Loop Assembly

Assemble the filling loop to the new plastic manifold using provided clip.

Manifold Installation

Insert filling loop inlet into diverter valve and attach new manifold with wire clip.

Final Reassembly

Reassemble diverter valve and manifold assembly to appliance.

Summary

Fitting Instructions for New Plastic Flow Manifold

Initial Safety Precautions

Ensure electricity supply is off before starting work. Turn off cold water valve and drain.

Draining and Preparation

Turn off central heating valves, drain appliance, and remove existing manifold.

Filling Loop Assembly

Assemble the filling loop to the new plastic manifold using provided clip.

Manifold Installation

Insert filling loop inlet into diverter valve and attach new manifold with wire clip.

Final Reassembly

Reassemble diverter valve and manifold assembly to appliance.

Overview

Function Description
Important Technical Specifications (Inferred from the document)
Usage Features (Related to the component's role)
Maintenance Features (Related to the component's role and installation)

This document provides fitting instructions for a new plastic flow manifold designed for specific Worcester Bosch boiler models: the 24CDi range, 28CDi, 35CDi II, and 26CDi Extra. These instructions are intended to be used in conjunction with the appliance's existing installation and service manual. The installation process is complex and should only be attempted by competent personnel to ensure safety and proper functioning of the appliance.

Function Description:

The flow manifold is a critical component within the boiler's hydraulic system, responsible for directing the flow of water for both the central heating and domestic hot water circuits. In these specific Worcester Bosch models, the manifold integrates with the diverter valve and the filling loop assembly. The diverter valve, in conjunction with the manifold, controls whether water is directed to the central heating system or to the domestic hot water heat exchanger. The filling loop assembly, which connects to the manifold, is used to top up the pressure in the central heating system when required. The replacement of the old plastic flow manifold with a new one is likely due to design improvements, material upgrades, or to address common failure points in older versions, ensuring better reliability and performance of the boiler. The new manifold design, as depicted in the diagrams, shows a more integrated assembly with connections for the central heating flow and return, cold water inlet, and the domestic hot water circuit via the diverter valve.

Important Technical Specifications (Inferred from the document):

Compatibility: Specifically designed for Worcester Bosch 24CDi range, 28CDi, 35CDi II, and 26CDi Extra boiler models. This indicates precise dimensional and functional compatibility with these particular boiler series.
Material: The component is explicitly referred to as a "new plastic flow manifold," suggesting it is constructed from a durable, heat-resistant plastic suitable for boiler applications. This choice of material is common in modern boiler components due to its resistance to corrosion, lighter weight, and potentially lower manufacturing cost compared to metal alternatives, while still meeting performance requirements.
Connections: The manifold features multiple connection points for various hydraulic circuits:
- Central Heating Flow and Return: These connections facilitate the circulation of water to and from the central heating system.
- Cold Water Inlet: This is where the main cold water supply enters the boiler, often before being directed to the domestic hot water circuit or for system filling.
- Diverter Valve Outlet Port: A crucial connection point where the manifold integrates with the diverter valve, allowing the boiler to switch between heating and hot water functions.
- Filling Loop Inlet: This connection point allows the filling loop assembly to be attached, enabling the user to repressurize the central heating system.
Sealing Mechanism: The instructions mention the use of an O-ring and retaining clips for secure assembly, particularly when connecting the filling loop assembly to the new manifold. This indicates a design that relies on robust sealing to prevent leaks under system pressure. Silicone grease is recommended for O-ring assembly, highlighting the importance of proper lubrication for a tight seal and ease of installation.
Clip Mechanism: Both small retaining clips (for the filling loop elbow) and a large wire clip (for securing the manifold to the diverter valve) are integral to the assembly. These clips are designed for quick and secure attachment, ensuring components remain in place during operation. The emphasis on ensuring the large wire clip is "aligned and fully entered" underscores the importance of correct installation for structural integrity and leak prevention.

Usage Features (Related to the component's role):

Integrated Design: The new manifold appears to offer a more streamlined or improved design compared to the "old plastic flow manifold" it replaces. This integration likely simplifies assembly and potentially reduces the number of individual components, which can enhance reliability.
Support for Dual Functionality: As part of the diverter valve assembly, the manifold is central to the boiler's ability to provide both central heating and domestic hot water on demand. Its design ensures efficient routing of water for these distinct functions.
Ease of Maintenance/Replacement (for technicians): While the installation requires competence, the design with clips and O-rings suggests that, for trained personnel, the component is designed for relatively straightforward replacement, facilitating boiler servicing and repair. The clear visual aids in the document further support this.
System Repressurization: The integrated filling loop connection is a key user-facing feature, allowing homeowners (or technicians) to easily top up the central heating system pressure when it drops, which is a common maintenance task.

Maintenance Features (Related to the component's role and installation):

Pre-Installation Safety: The instructions emphasize critical safety steps before any work begins: turning off the electricity supply, cold water inlet valve, and central heating flow/return valves, followed by draining the appliance. This highlights the importance of safety protocols when working with boiler components.
Component Removal and Disposal: The instructions detail the removal of the existing diverter valve and flow manifold, as well as the "plastic elbow and screws" and "support bracket," which are to be discarded. This indicates that the new manifold may not require these older support components or that they are integrated into the new design.
O-ring and Clip System: The use of O-rings and retaining clips simplifies assembly and disassembly for maintenance. The recommendation to apply silicone grease to the O-ring during assembly is a maintenance tip to ensure a good seal and prevent damage to the O-ring during installation.
Reference to Service Manual: The repeated instruction to refer to the "Installation and Servicing Instructions" for specific sections (e.g., "Replacement of Parts Section: Water Diverting Valve") underscores that this document is an addendum, not a standalone guide, and that comprehensive maintenance requires consulting the primary service manual. This ensures that technicians have access to all necessary information, including torque settings, specific component checks, and troubleshooting guides not covered in these specific fitting instructions.
Competent Personnel Requirement: The explicit statement "ONLY COMPETENT PERSONNEL SHOULD ATTEMPT INSTALLATION" is a crucial maintenance feature, as it ensures that individuals with the necessary training, knowledge, and tools perform the work, minimizing the risk of incorrect installation, damage to the appliance, or safety hazards. This also implies that specialized tools or diagnostic procedures might be required beyond simple component swapping.