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Worcester 28CDi RSF User Manual

Worcester 28CDi RSF
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28CDi RSF
WALL MOUNTED COMBINATION BOILER FOR CENTRAL HEATING
AND MAINS FED DOMESTIC HOT WATER
INSTALLATION AND
SERVICING INSTRUCTIONS
GC NUMBER 47 311 34 (N.G.)
GC NUMBER 47 311 35 (L.P.G.)
BOILER OUTPUT
Automatic Modulating Control
To Domestic Hot Water To Central Heating
Minimum 9.0 kW 9.0 kW
Maximum 28.0 kW 24.0 kW
IMPORTANT: 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) Regulations 1994
Bosch Group
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Worcester 28CDi RSF Specifications

General IconGeneral
Model28CDi RSF
CategoryBoiler
Output28 kW
Fuel TypeNatural Gas
Efficiency RatingA
MountingWall-mounted
Max. Central Heating Output24 kW
Max. DHW Output28 kW
Efficiency90%
Hot Water Flow Rate11.4 L/min
Max Working Pressure3 bar

Summary

Installation Regulations

Gas Safety Regulations Compliance

Ensure installation adheres to Gas Safety (Installation and Use) Regulations.

Manufacturer Notes vs Statutory Obligations

Manufacturer's instructions do not override statutory obligations.

Compliance with British Standards

Installation must comply with relevant British Standards and building regulations.

Conforming to Other Standards

Installation should meet other relevant British Standards for optimal performance.

Seeking Installation Advice

Contact manufacturer for specific installation advice when needed.

General Information

External Installation Prohibition

The appliance is not suitable for external installation.

Appliance Output Specifications

Appliance controls set for maximum output of 28 kW (DHW) and 24 kW (CH).

Ignition System

Features direct burner ignition; no pilot light is used.

Principal Appliance Components

Overview of key components like heat exchangers, controls, and vessel.

Electrical Supply Requirements

Specifies mains supply voltage, frequency, and fuse ratings.

Gas Supply Verification

Check data plate for correct gas supply (Natural Gas or Propane).

Appliance Packing Details

Appliance and flue components are packed separately.

General Installation Requirements

Appliance for sealed/open vent systems, ventilation, clearances.

Flue System Specifications

Details on flue type, lengths, and terminal guard.

Appliance Controls Explained

Modulating controls, ON/OFF switch, temperature controls, programmer options.

System Notes and Recommendations

Flushing, pipework, pressure, drain cock, relief valve discharge.

Taps, Showers, Bidets and Mixing Valves

Requirements for water fixtures and flow balancing.

Safety Considerations for Operation

Do not operate without water, with cover removed, or without power off.

Appliance Operation Modes

How the appliance operates for DHW and Central Heating.

Technical Data

Nominal Boiler Ratings

Boiler output and input ratings for Natural Gas and Propane.

Flue Details and Dimensions

Specifications for flue wall hole diameter and lengths.

Available Pump Head Data

Pump head, flow rate, and temperature rise for different boiler outputs.

General Specifications

Details on fittings, dimensions, weight, pressure, and temperature.

Siting The Appliance

Installation Location Requirements

Room installation, electrical safety near baths/showers.

Wall Protection and Support

No special wall protection needed; wall must support appliance weight.

Installation and Servicing Clearances

Required clearances for installation and servicing are detailed.

Cupboard Installation Guidelines

Guidelines for fitting in a clothes cupboard, adhering to standards.

Compartment Ventilation and Clearances

Compartment requirements, including no vents if clearances are met.

Combustible Surface Clearances

Minimum distance from combustible surfaces to appliance casing.

Cupboard Door to Cabinet Clearance

Minimum distance between cupboard door and cabinet front.

LPG Installation Restrictions

LPG installation prohibition in rooms below ground level.

Siting The Flue Terminal

Flue Installation Standards

Flue installation must comply with BS 5440:Part 1.

Flue Terminal Placement

Avoid obstructions and nuisance from discharge.

Protection from Gutters and Eaves

Install aluminum shield if terminal is near plastic gutters/eaves.

Flue Terminal Guards

Guards are required for terminals less than 2m above accessible surfaces.

Siting to Avoid Steam Nuisance

Avoid siting where terminal steam could cause a nuisance.

Combustion Products and Roof Voids

Prevent combustion products from entering ventilated roof voids.

Air Supply Requirements

Combustion Air Source

Appliance does not require a separate vent for combustion air.

Cupboard Installation Airflow

Clearances for cupboard installation without vents.

Required Ventilation for Compartments

Ventilation openings for cooling in compartments with reduced clearances.

Minimum Free Air Area

Specifies minimum free areas for air vents based on location.

Sealed Primary Systems

System Compliance Requirements

Systems must comply with BS 6798 and BS 5449.

System Operation Prerequisites

Appliance must not operate without a full, vented, and pressurized system.

Pressure Relief Valve Operation

PRV operates at 3 bar; discharge must be safe.

Pressure Gauge Function

Pressure gauge indicates system pressure that must be maintained.

Expansion Vessel Capacity

10-litre expansion vessel for static head of 5 metres.

System Volume and Pressure Adjustment

Accommodates ~83 litres; charge pressure can be increased.

System Filling Link

Appliance includes a system filling link for adding water.

Replenishing Water Loss

Water loss from the system must be replaced.

Filling the System Procedure

Step-by-step guide to filling the system using the filling key.

Maintaining System Pressure

Repeated venting loses water; pressure must be maintained.

Mains Water Connection Authority

Mains water connections require local Water Company authority.

Pump Setting

The pump is set at maximum and must not be adjusted.

Connection Pressure Resistance

System connections must withstand up to 3 bar pressure.

Radiator Valve Standards

Radiator valves must conform to BS 2767:10.

Other Valve Standards

Other valves used should conform to BS 1010.

Open Vent Primary Systems

Pipework Sizing for Open Vent Systems

Pipework sizing based on Section 3, Table 4.

Feed and Expansion Cistern Arrangement

Cistern arrangement for minimum static head requirement.

Feed and Vent Pipe Specifications

Feed and vent pipe diameter and continuous rise requirement.

Pressure Relief Valve Exclusion

A pressure relief valve is not required on an open vented system.

Air Venting and Dissipation

Air expelled via feed/vent or dissipated into the system.

Pump Setting

The pump is set to maximum and must not be reset.

DHW Operation Before CH Connection

Requirements for DHW operation before central heating connection.

Domestic Hot Water (DHW) System

General DHW Requirements

General requirements for DHW system, consult local water company.

Mains Cold Water Inlet

Requirements for cold water inlet and expansion vessel connection.

Cold Water Connection Material

Final 600mm of cold water connection must be copper.

Maximum Mains Pressure

Appliance suitable for mains pressure up to 10 bar.

Mains Supply Isolating Valve

Appliance is fitted with a mains supply isolating valve.

Maximum DHW Flow Rate

Specifies the maximum domestic hot water flow rate.

Adjusting DHW Flow Rate

Reduced flow rate may be needed in winter for desired temperature.

Pipe Insulation for DHW

Suggests insulating long pipe runs to prevent rapid cooling.

Tap and Mixing Valve Compatibility

Taps and mixing valves must suit mains pressure and temperature.

Shower Valve Recommendations

Thermostatic or pressure equalising shower valves recommended.

Shower Head Positioning

Shower head position to prevent immersion in bath water.

Bidet Installation Requirements

Requirements for direct supply to bidets, including shrouded outlets.

Scale Prevention for DHW

Scale accumulation is unlikely; treatment optional if needed.

Electrical Requirements

Mains Supply Specifications

Details on voltage, frequency, power consumption, and fuses.

Appliance Isolation

Requirement for complete isolation of the appliance.

Connection Alternatives

Acceptable methods for connecting mains electricity supply.

Earthing Requirements

The appliance must be properly earthed.

Mains Cable Specifications

Details on the type and size of the mains cable.

Wiring Compliance

Wiring must comply with IEE Regulations and local rules.

Thermostat and Programmer Connections

Wiring for room thermostats and external programmers.

Optional Facia Programmers

Information on optional facia-mounted programmer kits.

External Time Switch/Programmer

Option to fit a time switch or programmer externally.

Internal Frost Thermostat

Boiler has an internal frost thermostat for protection.

Post-Installation Electrical Safety Check

Checks for short circuits, polarity, earth continuity, resistance.

Installation Procedures

Flue Options and Lengths

Details on standard and extension flue lengths and bends.

Wall Mounting Plate Installation

Instructions for fixing the wall mounting plate.

Appliance Mounting to Wall Plate

Steps for securing the appliance to the wall mounting plate.

Flue Turret and Air Vent Fixing

Procedure for fixing the flue turret and automatic air vent.

General Fitting Procedures

Component Checks and Wall Plate Assembly

Checks for appliance components and wall plate assembly.

Air and Flue Duct Preparation

Instructions for preparing and assembling air and flue ducts.

External Duct Assembly Fitting

Steps for fitting the duct assembly externally to the appliance.

Internal Duct Assembly Fitting

Internal Flue and Duct Assembly

Instructions for fitting the duct assembly internally.

Fitting Flue Bends

Flue Bend Installation Guidance

Guidance on fitting flue bends and calculating equivalent lengths.

Final Installation Checks

Connection and System Pressure Checks

Final checks on connections, electrical supply, and system pressure.

Commissioning Procedures

Commissioning Summary

Overview of appliance settings and system checks before commissioning.

System Preparation for Commissioning

Steps to prepare the appliance and system for commissioning.

Pressure Relief Valve Test

Procedure to test the pressure relief valve operation.

Expansion Vessel Pressure Setting

Setting the correct charge pressure for the expansion vessel.

System Pressure Setting

Filling the system and setting the initial system pressure.

Appliance Operation Checks

Programmer Setup

Setting up any fitted programmer according to its instructions.

Burner Pressure Setting

Procedures for setting burner pressure for different modes.

Domestic Hot Water Operation Check

Checks for ignition and operation during hot water demand.

Central Heating Operation Check

Checks for heating output, radiator heating, and system balancing.

DHW and CH Combined Operation

Testing combined operation and hot water priority.

Commissioning Completion

Final checks, tightening screws, gas soundness, and user handover.

Instructions for the User

Appliance Operation Handover

Instruct the user on appliance operation and provide leaflet.

Frost Protection Advice

Advise the user on actions if the heating system is unused in frost.

Sealed System Pressure Information

Inform the user about the sealed system's set pressure.

Importance of Regular Servicing

Emphasize the need for regular servicing and maintenance contracts.

Setting User Controls

Set the system controls according to the user's specific requirements.

Programmer Settings for DHW

Suggest settings for external programmers for domestic hot water.

Inspection and Servicing

Routine Servicing Schedule

Appliance requires checking and servicing at regular intervals, ideally annually.

Pre-Service Inspection Checks

Checks for flue terminal, compartment vents, and system leaks.

Flue Gas Measurement Procedure

Steps for measuring flue gases under constant output conditions.

Appliance Dismantling for Service

Steps to dismantle the appliance for component access.

Component Servicing

Cleaning Fan, Burner, and Heat Exchanger

Cleaning procedures for the fan, burner, heat exchanger, and insulation.

Post-Service Appliance Testing

Testing gas soundness and appliance operation after servicing.

Replacement of Parts

Important Notes for Part Replacement

Switch off supplies, check soundness and function after replacement.

Component Access for Replacement

Information on accessing components for replacement.

Appliance Draining Procedure

Steps for draining the central heating and DHW circuits.

Component Replacement Steps

Procedures for replacing specific components like the automatic air vent.

Component Replacement Procedures

Air Flow Pressure Switch Replacement

Steps to replace the air flow pressure switch.

Fan Assembly Replacement

Procedure for removing and replacing the fan assembly.

Overheat Thermostat Replacement

Steps to replace the overheat thermostat.

Gas to Water Heat Exchanger Replacement

Procedure for replacing the gas to water heat exchanger.

Combustion Chamber Insulation Replacement

Replacing fibre insulation pads in the combustion chamber.

Burner Assembly Replacement

Steps for replacing the burner assembly.

Burner Injector Replacement

Procedure for replacing the burner injector.

Spark Electrode Assembly Replacement

Steps to replace the spark electrode assembly and set the gap.

Flame Sensor Replacement

Procedure for replacing the flame sensor and setting the gap.

Gas Valve Replacement and Setting

Replacing the gas valve and setting burner pressures.

Component Replacement Procedures (Cont.)

Central Heating Sensor Replacement

Steps to replace the central heating sensor.

Domestic Hot Water Sensor Replacement

Steps to replace the domestic hot water sensor.

Circulating Pump Replacement

Procedure for replacing the circulating pump.

Expansion Vessel Replacement

Steps to replace the expansion vessel.

Pressure Relief Valve Replacement

Procedure for replacing the pressure relief valve.

Water Diverting Valve Micro Switch Replacement

Replacing the micro switch assembly on the water diverting valve.

Water Diverting Valve Replacement

Steps to replace the water diverting valve.

Water to Water Heat Exchanger Replacement

Procedure for replacing the water to water heat exchanger.

DHW Flow Restrictor Replacement

Steps to replace the domestic hot water flow restrictor.

Pressure Gauge Replacement

Procedure for replacing the pressure gauge.

Control Board Replacement

Steps to replace the control board.

Filling Loop Replacement

Procedure for replacing the filling loop assembly.

Transformer Replacement

Steps to replace the transformer.

Short Parts List

Operational Flow Diagrams

Central Heating Function Flow Diagram

Illustrates the sequence of operations for central heating.

Domestic Hot Water Function Flow Diagram

Illustrates the sequence of operations for domestic hot water.

Overrun Function Flow Diagram

Illustrates the sequence of operations for the overrun function.

Autofrost Function Flow Diagram

Illustrates the sequence of operations for the autofrost function.

Fault Finding Guide

Fault Finding Light Situations

Overview of light patterns indicating faults.

Fail Point A: No Lights

Troubleshooting steps when no lights are displayed.

Fail Point B: No Red Lights

Troubleshooting steps when only green light works.

Fail Point C: No Green Light

Troubleshooting steps when red lights work but no green.

Fail Point D: No Light (Other Lights Work)

Troubleshooting steps when one light is out.

Fail Point E: Light on Constant

Troubleshooting steps for constant light indication.

Fail Point F: Two Lights Flashing Slowly

Troubleshooting steps for two lights flashing slowly.

Fail Point G: Flashing Slow

Troubleshooting steps for slow flashing lights.

Fail Point H: Flashing Fast

Troubleshooting steps for fast flashing lights.

Fail Point I: Flashing Fast (Specific Pattern)

Troubleshooting steps for specific flashing patterns.

Fail Point J: Flashing Fast (Sequence)

Troubleshooting steps for sequence-dependent flashing faults.

Fail Point K: Other Faults

Troubleshooting for faults not covered by specific light patterns.

Preliminary Electrical Checks

Electrical Checks for Fault Finding

Essential electrical checks before and after fault finding.

Fail Point Troubleshooting Flowcharts

Fail Point A Troubleshooting Flow

Diagnostic flowchart for Fail Point A.

Fail Point B Troubleshooting Flow

Diagnostic flowchart for Fail Point B.

Fail Point C Troubleshooting Flow

Diagnostic flowchart for Fail Point C.

Fail Point D Troubleshooting Flow

Diagnostic flowchart for Fail Point D.

Fail Point E Troubleshooting Flow

Diagnostic flowchart for Fail Point E.

Fail Point F Troubleshooting Flow

Diagnostic flowchart for Fail Point F.

Fail Point G "Primary Overheat" Troubleshooting

Diagnostic flowchart for primary overheat faults.

Fail Point H "Burner Lockout" Troubleshooting

Diagnostic flowchart for burner lockout faults.

Fail Point I "Sensor Fault" Troubleshooting

Diagnostic flowchart for sensor faults.

Fail Point J "Air Pressure Fault" Troubleshooting

Diagnostic flowchart for air pressure faults.

Fail Point K Troubleshooting

Diagnostic flowchart for other or unspecified faults.

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