EasyManua.ls Logo

Bosch WORCESTER 35CDi User Manual

Bosch WORCESTER 35CDi
36 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
35CDi
WALL MOUNTED COMBINATION BOILER FOR CENTRAL HEATING
AND MAINS FED DOMESTIC HOT WATER
INSTALLATION AND
SERVICING INSTRUCTIONS
This appliance is for use with Natural Gas or LPG (Cat II 2H3P).
GC NUMBER 47 311 39 (N.G.) GC NUMBER 47 311 40 (L.P.G.)
CE 97/0086
APPLIANCE OUTPUTS
Natural Gas LPG (Propane)
Domestic Central Domestic Central
Hot Water Heating Hot Water Heating
Minimum 9.0 kW 9.0 kW 12.9 kW 12.9 kW
Maximum 35.17 kW 25.0 kW 35.17 kW 25.0 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.
Bosch Group
35CDi
Question and Answer IconNeed help?

Do you have a question about the Bosch WORCESTER 35CDi and is the answer not in the manual?

Bosch WORCESTER 35CDi Specifications

General IconGeneral
ModelWORCESTER 35CDi
TypeCombi Boiler
Output35 kW
Flow Rate14.3 l/min
Fuel TypeNatural Gas
MountingWall Mounted
Domestic Hot Water Output35 kW
ErP Heating EfficiencyA
ErP Water Heating EfficiencyA
Warranty5 years
Dimensions760mm x 440mm x 360mm
Hot Water Flow Rate14.3 l/min

Summary

Installation Regulations

Gas Safety (Installation & Use) Regulations

Legal requirement for competent installation under Gas Safety Regulations.

Installation Requirements

Installation must comply with IEE, Building Regs, and local bye-laws.

Installation Standards

Follows BS standards for boilers, heating, flues, ventilation, and gas pipework.

LPG Installation Requirements

LPG appliances not to be installed below ground level, except for basements open to the ground.

Introduction to the Appliance

General Information

Appliance outputs, hot water flow rate, and mains pressure suitability.

Electrical Supply Specifications

Specifies voltage, frequency, load, and fuse ratings.

Gas Supply Requirements

Required gas flow rates and inlet pressures for Natural Gas and LPG.

Installation Guidelines

Indoor installation, sealed systems only, servicing clearances, and compartment requirements.

Flue System Requirements

Flue positions, terminal requirements, and guard availability.

Controls and System Setup

Appliance Controls Overview

Details on on/off knobs, temperature controls, and programmer connections.

System Requirements

System flushing, pressure resistance, drain cock, and air vent requirements.

Ancillary Water Fittings

Suitability of taps, mixing valves, and shower valves for system.

Safety Features

Covers inner casing, power isolation, low pressure cut-off, overheat protection, and pump seizure.

Operational Modes

Describes central heating and domestic hot water operation sequences.

Technical Data and Specifications

Nominal Boiler Ratings Table

Boiler output, input, burner setting pressure, and gas rate for NG and LPG.

Flue Details Table

Specifications for horizontal flue types, diameters, and lengths.

Pump Head Data Table

Pump head, flow rate, and differential for different boiler outputs.

Mechanical Specifications Table

Details pipe connections, casing dimensions, and weights.

Performance Specifications and Clearances

Performance Specifications Table

Max mains pressure, DHW flow rate, outputs, and temperature ranges.

Clearances for Installation and Service Table

Required clearances above, in front, beneath, and to the sides of the appliance.

Appliance Siting and Flue Requirements

Siting the Appliance

Guidelines for appliance location, including room requirements and bathroom safety.

External Installation Prohibition

The appliance is explicitly not suitable for external installation.

Flue Terminal Positions

Requirements for flue terminal placement and minimum distances.

System and Air Supply Requirements

Flue Terminal Safety Requirements

Terminal must not cause obstruction, nuisance, or be too close to gutters/eaves.

Air Supply Guidelines

No separate vent required; clearance for air movement is necessary.

Sealed System Compliance

System must comply with BS6798/BS5449; must be full and pressurised.

Expansion Vessel and Pressure

Details on expansion vessel capacity, pressure settings, and high-pressure requirements.

System Pressure Switch Function

Appliance stops if system pressure falls below 0.45 bar.

Domestic Hot Water and Gas Supply

Domestic Hot Water Operation

DHW pressure suitability, flow rates, and temperature control.

Gas Supply Specifications

Required gas flow rates and inlet pressures for Natural Gas and LPG.

Electrical Supply and Connections

Mains supply details, earthing, isolation, and cable connection requirements.

Electrical Connections and Controls

External Frost Thermostat Use

Guidance on using an external frost thermostat for remote system parts.

Mains Electrical Connection Diagram

Diagram illustrating mains connection to the appliance.

Electrical Connections Identification

Identification of terminals for mains, thermostat, and pump connections.

External Controls Wiring

Wiring diagrams for connecting room thermostats and programmers.

Wiring Diagrams and Fuse Replacement

Pictorial Wiring Diagram

Visual representation of the appliance's internal wiring and components.

Replacement Fuses Location

Identification and location of fuses F1 and F2 for replacement.

Programmer Connection Diagram

Diagram showing how to connect an external programmer to the appliance.

Functional Wiring Diagram and Facia Panel

Functional Wiring Diagram Overview

Diagram illustrating the appliance's functional electrical pathways.

Facia Panel Control Identification

Identification of controls on the facia panel like reset button and temperature knobs.

Appliance Component Identification

Front View of Appliance Components

Identification of key components visible from the front panel.

Key Component Locations

Highlights specific components like sensors, pumps, valves, and electrodes.

Installation Procedures - Part 1

General Installation Guidelines

Appliance suitability for sealed systems and flue installation compliance.

Unpacking and Site Preparation

Steps for unpacking, preparing the site, and checking wall suitability.

Fixing Plate and Flue Opening

Marking and drilling fixing holes and flue duct opening using templates.

Gas and Water Pipe Connections

Guidance on connecting gas and water pipes, including pipe routing.

Installation Procedures - Part 2

Pipework and Component Handling

Guidelines for pipework, cabinet removal, and fan/duct connections.

Fan and Air Flow Sensor Fixing

Details on fixing the fan assembly and air flow sensor.

Air Duct Clamp Assembly

Instructions for fitting the air duct clamp assembly.

Installation Procedures - Part 3

Duct Measurement and Cutting

Measuring and cutting air and flue ducts to the correct length.

Relief Valve Discharge Pipe

Fitting the discharge pipe to the relief valve safely.

Draining the Appliance

Procedures for draining the primary system and DHW circuit.

Duct Installation and Completion

Duct Cutting and Assembly

Marking, cutting, and assembling air and flue ducts.

Internal Flue Fixing

Steps for internally fixing air and flue ducts using sealing collars.

Fan Refitting and Connections

Refitting the fan and reconnecting tubes and electrical connections.

External Duct Fixing

Steps for externally fixing air and flue ducts through the wall.

Installation Completion and Commissioning Prep

Fan Refitting and Wall Finishing

Refitting fan, making good walls, and replacing covers.

Final Checks and Gas Soundness

Checking connections, fitting controls, and performing gas soundness test.

Facia Panel Controls Identification

Identification of facia panel indicators like reset button and pressure gauge.

Appliance Commissioning Procedures

System Flushing and Filling

Procedures for flushing and filling DHW and CH systems.

Pressure Setting and Checks

Setting system pressure, expansion vessel charge, and burner pressure.

Burner and Pump Operation Checks

Verifying burner ignition, CH/DHW operation, and pump function.

Commissioning Completion and User Handover

System Balancing and Testing

Balancing the system, checking thermostat, and completing final tests.

User Information Handover

Explaining operation, safety, and maintenance to the user.

Inspection and Servicing Guidelines

Procedures for inspecting components, checking combustion, and accessing parts.

Component Access and Cleaning for Servicing

Component Replacement Safety

Turn off gas/electricity before component replacement; check post-replacement.

Appliance Draining Procedures

Steps for draining the primary heating system and DHW circuit.

Component Identification for Servicing

Diagrams showing location of components like burner, electrodes, and flue hood.

Component Replacement Procedures

Gas Valve and Electrode Replacement

Steps for replacing gas valve, spark electrode, and flame sensing electrode.

Burner, Manifold, and Insulation Replacement

Procedures for replacing burner assembly, manifold, and combustion chamber insulation.

Pressure Gauge and Relief Valve Replacement

Steps for replacing the pressure gauge and relief valve.

Component Replacement - Water and Electrical

Flow Switch and Pressure Switch Replacement

Steps for replacing the flow switch and system pressure switch.

Control Board and Transformer Replacement

Procedures for replacing the main control board and transformer.

Fan and Air Flow Detector Replacement

Steps for replacing the fan and air flow detector.

Component Replacement - Sensors and Pumps

CH and DHW Sensor Replacement

Steps for replacing the central heating and domestic hot water sensors.

Overheat Thermostat and Pump Replacement

Procedures for replacing overheat thermostat and CH/DHW pumps.

Expansion Vessel and Heat Exchanger Replacement

Steps for replacing the expansion vessel and DHW heat exchanger.

Component Replacement - Air, Heat Exchanger, and Pumps

Auto Air Vent and Heat Exchanger Replacement

Steps for replacing the auto air vent and primary gas to water heat exchanger.

Sensor and Thermostat Identification

Diagrams for Domestic Hot Water Sensor, Overheat Thermostat, and CH Sensor.

Component Replacement - Air Pressure Switch and Heat Exchangers

Air Pressure Switch Replacement

Steps for replacing the air pressure switch.

Heat Exchanger Fixing Details

Diagrams showing fixing methods for DHW and Primary Heat Exchangers.

Air Flow Switch Identification

Diagram identifying the air flow switch and its connections.

Short Parts List

Gas Supply Components

List of gas valves and burner parts.

Ignition and Sensing Components

List of electrodes and ignition leads.

Pressure and Safety Components

List of pressure gauges, relief valves, and pressure switches.

Water Flow and Pump Components

List of pumps, flow regulators, sensors, and heat exchangers.

Control and Electrical Components

List of control boards, transformers, fans, and fuses.

Ancillary Components

List of filters, gaskets, and insulation packs.

Operational Flow Diagrams

Central Heating Function Diagram

Flow diagram illustrating the central heating operation sequence.

Domestic Hot Water Function Diagram

Flow diagram illustrating the domestic hot water operation sequence.

Appliance Operational Logic

Overrun Function Logic

Diagram showing pump and fan overrun logic after demand.

Autofrostat Function Logic

Diagram illustrating the frost protection logic.

Fault Finding Guide

Preliminary Checks and Indicator Status

Initial checks, indicator light meanings, and fault point identification.

Fault Finding Chart and Actions

Table linking indicator faults to causes and recommended actions.

Troubleshooting Specific Fault Points

Fail Point A, B, and C Diagnostics

Troubleshooting steps for faults related to power supply, fuses, and diodes.

Fail Point D Diagnostics

Troubleshooting steps for faults related to CH controls, ST8 supply, ST13 link, and programmer.

Troubleshooting Specific Fault Points (Continued)

Fail Point E and G Diagnostics

Troubleshooting for hot water operation, flow switch, and primary overheat faults.

Fail Point F Diagnostics

Troubleshooting for cold environments, autofrostat mode, and pump output faults.

Troubleshooting Burner Lockout and Sensor Faults

Fail Point H: Burner Lockout Troubleshooting

Steps for diagnosing burner lockout due to gas supply, electrodes, or flame sensor.

Fail Point I: Sensor Fault Troubleshooting

Steps for diagnosing sensor faults related to connections and resistance.

Troubleshooting Pressure and Control Faults

Fail Point J: Air or Water Pressure Faults

Diagnosing faults related to water pressure, fan operation, and air pressure switch.

Troubleshooting Temperature and Gas Pressure Faults

Fail Point K: Temperature and Pressure Issues

Diagnosing faults like high hot water temperature or low gas pressure.

Related product manuals