Worcester Highflow 400 BF Installation And Servicing Instructions
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Worcester Highflow 400 BF Installation And Servicing Instructions

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Bosch Group
Highflow 400
BF
FLOOR STANDING COMBINATION APPLIANCE FOR CENTRAL
HEATING AND MAINS FED DOMESTIC HOT WATER
INSTALLATION AND

SERVICING INSTRUCTIONS

GC NUMBER 47 311 19
BOILER OUTPUT
To Hot Water On/Off Control
Maximum 24.0 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) Regulations 1998

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  • Page 1: Servicing Instructions

    Bosch Group Highflow 400 FLOOR STANDING COMBINATION APPLIANCE FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS GC NUMBER 47 311 19 BOILER OUTPUT To Hot Water On/Off Control Maximum 24.0 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...

  • Page 2: Table Of Contents

    Contents Installation Requirements ........Page 2 Electrical ..............Page 11 Installing the Appliance ..........Page 13 General Information ..........Page 2 Technical Data ............Page 5 Commissioning the Appliance ........ Page 18 Instructions to the User ..........Page 20 Siting the Appliance ..........Page 6 Flue Terminal Position ..........
  • Page 3 2.7 PACKING 2.10 CONTROLS The appliance and flue components are packed in separate The electronic control system via the gas valve operates the heat cartons. input in response to the central heating and hot water 2.8 GENERAL INSTALLATION temperature settings. The appliance is supplied for connection to a sealed system but The Operating switch provides for the selection of hot water is suitable for use with an open system.
  • Page 4 Temperature Control Knob, the burner recommended to avoid an excessive reduction in flow to will light, pump will energise and the process will be repeated. individual outlets. For further information contact Worcester Hot Water and Central Heating mode: Heat Systems Ltd.

  • Page 5: Technical Data

    3. Technical Data See Fig. 2 and 3. The Data Plate is fixed to the top of the control box casing. Table 1 NOMINAL BOILER RATINGS (10 minutes after lighting the appliance) BURNER SETTING MODE OUTPUT INPUT GAS RATE PRESSURE Btu/h Btu/h m bar.

  • Page 6: Siting The Appliance

    Table 5: SPECIFICATIONS CENTRAL HEATING FLOW 22mm Copper Tube CENTRAL HEATING RETURN 22mm Copper Tube COLD WATER MAINS INLET 15mm Copper Tube DOMESTIC HOT WATER OUTLET 22mm Copper Tube GAS INLET 22mm Copper Tube PRESSURE RELIEF VALVE DRAIN CONNECTION 22mm Copper Tube OVERALL CASING HEIGHT 860mm (33.8 in.) OVERALL CASING WIDTH...
  • Page 7 Fig. 2. Appliance cabinet dimensions and minimum clearances required. Space required for installation 1200 Space required for Space required servicing for installation Space required Surface may be under fixed fixed after surface installation. A gap of 10mm is required above the appliance Side View Front View...

  • Page 8: Flue Terminal Position

    Fig. 4. Siting of the flue terminal. TERMINAL POSITION MIN. DISTANCE MINIMUM SITING DIMENSIONS FOR POSITIONING THE BALANCED A– Directly below an opening, air brick, window etc. 1500mm (60 in.) FLUE TERMINAL A1– Above an opening, air brick, window etc. 300mm (12 in.) A2–...

  • Page 9: Sealed System

    7.8 Water loss must be replaced. See Fig. 6. The connection 7. Sealed System should be made in the central heating return as close to the appliance as possible. 7.9 The make-up vessel must be fitted with a non-return valve. See Fig.

  • Page 10: Open Vent System

    8.4 The feed and vent pipe must rise continuously from the 8. Open Vent Primary System appliance to the feed and expansion cistern. 8.5 A safety valve is not required on an open vented system. With the safety valve left in position then a pipe must be fitted See Fig.

  • Page 11: Electrical

    current carrying conductor, so that if the cable slips in its 10. Electrical anchorage, the current carrying conductors become taut before the Earth conductor. For access refer to Section 14. 10.6 The wiring between the appliance and the electrical supply Refer to Figs.
  • Page 12 Fig. 9. Functional flow diagram. Fig. 10. Room/frost thermostats and programmer. Fig. 11. External programmer connections. To External Programmer Room thermostat Switched live Switched central heating from Live Neutral programmer Connector Connector X13 Switched hot Remove link on control board X12 on water from programmer...

  • Page 13: Installing The Appliance

    From the carton containing the flue kit (either standard or 11. Installing The Appliance extended) remove the flue terminal, flue duct, air duct and the package containing the following items :- 4 off - M5 Hex Head screws The appliance is supplied suitable for fitting to a sealed system. If 2 off - M5 Shakeproof Washers it is to be fitted to an open vent system refer to paragraph 11.3 4 off - No 8 wall plugs...
  • Page 14 To access the open vent connection remove the pump head. Unscrew and retain the four nuts and washers securing the Withdraw the two securing clips from the pump body. Ease the switch mounting plate to the facia. Remove the plate. Fit the pump forwards about 10mm off the “O”...
  • Page 15 Fig. 13. Balanced flue appliance wall preparation. Inside plaster 347 x 247 Wall thickness (W) Duct size to include any surface finish, inside or outside Outside rendering (if applied) Floor level Aperture cut through wall to accept balanced flue assembly. This Floor level dimension may vary depending on whether any floor covering is...
  • Page 16 Fig. 15. Arrangement of balanced flue and terminal. 10mm (0.4in.) diameter continuous seam of silicone sealant all Wall thickness around (see below) 230mm (9in.) minimum 610mm (24in.) maximum Raise control box Telescopic flue duct Tape joint Flue hood Flue hood fixing Telescopic screws air duct...
  • Page 17 Fig. 16. Layout of components with expansion vessel in service position. Facia Heatbank overheat Refer to figure 17 for thermostat reset button details of this area Mains cold water inlet Control Box valve Central heating return valve Central heating flow valve Inner casing fixing screws (4) Primary manual air vent Pressure relief valve...

  • Page 18: Commissioning The Appliance

    Fig. 20. Pilot burner assembly. Flame length 18-20mm Pilot assembly fixing screws Pilot head Pilot shield Spark electrode Pilot assembly Spark electrode location clip groove Spark electrode guide Pilot injector Spark electrode lead Fig. 21. Gas control valve adjustment. High/Low Retaining solenoid screw...
  • Page 19 Turn the room thermostat (if fitted) to maximum. the Hot Water mode. If the gas supply pressure is correct but the correct burner pressure is not achieved, contact Worcester Heat Set the Operating Switch (or Programmer) to OFF. Systems Service Department.

  • Page 20: Instructions To The User

    Fig. 12. for the position of the appliance drain point. 13.3 Tell the user the Sealed System set pressure if applicable. Refill, vent and re-pressurise (sealed systems) as described 13.4 Tell the user of the importance of regular servicing. Worcester previously. Heat Systems Ltd offer a comprehensive maintenance contract.

  • Page 21: Replacement Of Parts

    Check the system and remake any joints or fittings which show Clean the Pilot Bracket. signs of leakage. Refill, vent and re-pressurise sealed systems as Brush with a soft brush. Clean the pilot injector by rinsing it in described in Section 12. Commissioning. warm water.
  • Page 22 Fig. 22. Inner casing assembly. (Pilot shield not shown for clarity) Water to water heat exchanger Safety temperature limiter thermostat Fixing screws (2) Thermostat fixing Flue hood Automatic air vent Sealing grommets Gas to water Flue hood fixing heat-exchanger screws (2) Combustion chamber cover fixing screws (4) Combustion chamber cover...
  • Page 23 Any “O” ring which shows sign of damage must be replaced. The combustion chamber held in position with one screw. Unscrew “O” rings can be lubricated with a suitable lubricant (i.e. silicon the front and rear heat exchanger union connections. based grease or glycerin) which is non-reactive with the ethylene- Lift the heat exchanger off the right hand side of the combustion propylene nitrile “O”...
  • Page 24 6. Thermocouple. See Figs. 16, 20, 22 and 26. Check that the electricity supply to the appliance is turned off. Ensure the insulation pad fitted to the combustion chamber cover has the pilot observation hole correctly aligned. Remove the cabinet front panel, place the facia and control box in the Service Position, lower the expansion vessel into the Reassemble the appliance in the reverse order.
  • Page 25 Remove the combustion chamber cover as described in Section its mounting bracket. Retain the fixing screws. 14.2 f. Fit a new Piezo spark generator and reassemble the appliance in Unscrew the two screws securing the pilot burner to the main the reverse order.
  • Page 26 bracket. Withdraw the thermostat threading the capillary through Remove the cabinet front panel, place the facia and control box in the slot in the rear of the control box and discard. the Service Position, as described in Section 15.2.a. Fit a new thermostat and re-assemble in the reverse order. The NOTE: It is not necessary to drain the complete appliance.
  • Page 27 Remove the spring clip from the thermostat pocket located on supporting the domestic drain from the left hand side of the gas the front left hand side of the heatbank. valve. Retain bracket and screw. Note: There are two thermostat phials fitted in the pocket. The Disconnect the thermocouple from the gas valve and disengage Heat Bank Overheat Thermostat phial is located at the rear of the interrupter and thermostat lead.
  • Page 28 Service Position, as described in Section 14.2 a, b and c. the appliance. Do not allow the pump head to be suspended by the cable. Secure the pump head. Drain the heating circuit as described in Section 15.2 a. Pull off the Molex plug marked X7 “Diverter Valve” from the Remove the pump electrical cover and disconnect the control board located in the control box.
  • Page 29 strain relief bush. Replace the circulating pump as described in of the heating flow and return pipes and hot water outlet pipe. Section 15.3 - 20. Remove the manifold clear of the appliance and retain. Open the valves, fill and re-pressurise the system as described in Unscrew locating screws Nos.
  • Page 30 Fig. 33. Water to water heat exchanger. Note: Screw Nos. 1 2 , 5 6 7 8 , 11 12 Warning: There will be a small quantity of unscrew two full turns Ð Do not remove. water remaining in the pipework and water- to-water heat exchanger.
  • Page 31 Fig. 34. Water to water heat exchanger. WARNING: There will be a small quantity of water remaining in the pipework and water-to-water heat Domestic Ease water to water heat exchanger drain clip exchanger and bottom manifold out of support bracket and clear of appliance Move assembly upwards 10mm approx.

  • Page 32: Applicable

    and 10. Tighten screws Nos. 6, 7 and 8 and manifold union 25. Expansion Vessel. See Figs. 16 and 36. fitting. Check that the electricity supply to the appliance is turned off. Re-assemble the pump outlet pipe and re-fit the pump support Remove the cabinet front panel, place the facia and control box plate.
  • Page 33 Remove the cabinet front panel, place the facia and control box Remove the facia as described in Section 15.1. Unplug the Molex in the Service Position as described in Section 14.2 a, b and c. plug marked X1 “Flow Switch”, from the control board. Release the strain relief bush by compressing the loose section of the Drain the heating circuit as described in Section 15.2 a.
  • Page 34 Fig. 39. Control Box. Neon indicator lights connected to Control box Thermostat mounting bracket terminal X3 (marked ÒIndicatorsÓ). cooling fan Hot water Heating thermostat thermostat Control Control box cooling Hot water high limit thermostat. fan impeller Unscrew the central clamping nut Control board and remove from the control box.
  • Page 35 Unplug the neon connection at terminal X3 (marked “Indicators”) on the control board . Use an electrical screwdriver Fig. 40. Control box and thermostat to carefully push down through the locking clip slot to depress bracket. the locking clips and withdraw the appropriate leads of the failed neon.

  • Page 36: Operational Flow Diagrams

    16. Operational Flow Diagrams Note: The alpha references in these charts are to be used for cross-referencing when fault finding. See Section 17.

  • Page 38: Fault Finding

    This Fault Finding Chart is to be used in conjunction with the Operational Flow 17. Fault Finding Diagrams in Section 16. To find the fault, locate the point on the flow diagram at which the appliance has failed, e.g. letter B. Then read the corresponding section in the fault finding chart, e.g.
  • Page 39 Does the pilot flame Has the safety limit Is the pilot flame Check the pilot remain established? stat tripped? height 18-20mm? injector for blockage. Replace if necessary and ensure the pilot adjustment screw Is the primary water Wait for the is correctly set by temperature below screwing in fully...
  • Page 40 START OF DOMESTIC HOT WATER TEST Does the main Does the pilot Refer back to burner ignite? flame still exist? FAILURE AT POINT A Is there 230V at Is there 230V at Is there 230V at pin 1 of terminal X6? pin 1 of terminal X8? pin 1 of terminal X16? (Brown wire)
  • Page 41 Whether the pump stops immediately Set the operating switch or continues (or programmer) indefinitely the to OFF, and turn both control board will control knobs be at fault. anti-clockwise to OFF. Replace control board Does the pump continue to run for approx. 5 minutes? Is there 230V at Is there 230V at...
  • Page 42 START OF CENTRAL HEATING TEST Before tests ensure pump has stopped Is there 230V at Replace the Set the operating switch pin 4 of operating switch (or programmer) terminal X12? (or programmer) to HEATING and WATER (C.H.) and turn the heating control stat and room thermostat (if fitted) to Is there 230V at...
  • Page 43 Is there 230V Replace the Does the diverter valve at pin 3 control board operate? of terminal X7? Note: This failure would (Brown wire) prevent hot water at the flow outlet and the boiler would cycle on the heating control stat Replace the diverter valve END OF...

  • Page 44: Component Parts List

    18. Short Parts List GC No. Description Manufacturer’s Reference WHS Part No. 378 381 BF Burner Replacement Kit NG Aeromatic 8 716 142 606 0 379 040 Injector (4.4mm diameter) 8 716 156 337 0 299 324 Gas Valve Honeywell V4600Q2125 8 716 142 448 0 379 673 Pilot Burner...
  • Page 48 Bosch Group Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624. Fax: (01905) 754619. Technical Helpline: (0990) 266241 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.

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