Worcester 35CDi Installation And Servicing Instructions
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Worcester 35CDi Installation And Servicing Instructions

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See also: Installation, Commissioning & Servicing Instructions , Instructions for Using
35
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.)
Natural Gas
Domestic
Hot Water
Minimum
9.0 kW
Maximum
35.17 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.
Supplied By www.heating spares.co Tel. 0161 620 6677
CDi
35CDi
GC NUMBER 47 311 40 (L.P.G.)
CE 97/0086
APPLIANCE OUTPUTS
Central
Domestic
Heating
Hot Water
9.0 kW
12.9 kW
25.0 kW
35.17 kW
LPG (Propane)
Central
Heating
12.9 kW
25.0 kW

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  • Page 1: Servicing Instructions

    WALL MOUNTED COMBINATION BOILER FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS 35CDi 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.)

  • Page 2: Table Of Contents

    Contact casing losses, there is no need for the cooling ventilation Worcester Heat Systems Technical Department, Telephone: 0990 openings in the compartment. The spaces specified for servicing 266241, for advice on specific installations.
  • Page 3 2.5 Flue Fig. 1. Facia Controls 2.5.1. The flue can be to the right, left or rear. 2.5.2. The flue terminal, on the outside wall, must not be obstructed or damaged. 2.5.3. A terminal guard, Type K2 - GC 393 553, is available from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB 2.5.4.

  • Page 4: Technical Data

    3. Technical Data Table 1. NOMINAL BOILER RATINGS (10 Minutes After Lighting) BOILER ADJUSTED FOR G20 (Natural Gas) BURNER SETTING OUTPUT INPUT (Net) GAS RATE PRESSURE Btu/h Btu/h m bar. in. wg. 30,700 11.42 38,900 1.19 41.98 25.0 85,300 28.52 97,300 2.97 104.8...
  • Page 5 Table 5 PERFORMANCE SPECIFICATIONS PRIMARY WATER CAPACITY 3.0 litres MAXIMUM MAINS INLET PRESSURE 10 bar MINIMUM MAINS INLET PRESSURE (working) for max. hot water flow 1.3 bar MINIMUM MAINS INLET PRESSURE (working) to operate appliance 0.8 bar MAXIMUM CENTRAL HEATING FLOW TEMPERATURE 82°C nom MAXIMUM CENTRAL HEATING SYSTEM SET PRESSURE 1.5 bar...

  • Page 6: Siting The Appliance

    Fig. 3. Casing Dimension and Clearances 4. Siting the Appliance 4.1. The appliance may be installed in any room but refer to the requirements of the current IEE regulations and, in Scotland, the relevant electrical provisions of the Building Regulations with respect to the installation of appliances in rooms containing baths or showers.

  • Page 7: Air Supply

    5.3. The terminal must not cause an obstruction nor the combustion products a nuisance. Fig 6 - Sealed system 5.4. Under some climatic conditions the terminal might steam. Positions where this might be a nuisance should be avoided. Combustion products must not enter the roof space. 5.5.

  • Page 8: Domestic Hot Water

    8. Domestic Hot Water Fig 8 - System Make Up 8.1. If necessary reference should be made to the local water company before connecting the appliance. 8.2. Devices which would prevent the flow of expansion water must not be fitted unless separate arrangements have been made.
  • Page 9 Fig 9 - Mains Electrical Connection be considered where parts of the system are remote from the appliance. Refer to Worcester Heat Systems Technical Department for more information - Tel: 0990 266241. 10.11. A radio frequency room thermostat is available for use with the appliance.
  • Page 10 Fig 13 - Pictorial Wiring Diagram 2 Red 2 Orange Black White 6 Wires from Green Bottom Green 1. Spark Generator Boiler 2. 6 Way In-Line Connector 3. 2 Way In-Line Connector 4. Gas Valve 5. Flow Switch 6. DHW Sensor 7.
  • Page 11 Fig 14 - Functional Wiring Diagram Flame Demand Demand Detect Spark Indicator Indicator Indicator Electrodes Mains Indicator Green Electronics Spark Indicators Fuse F2 Regulator Valve (1.25A Slow) Main Valve Main Valve Transformer Pump Control Board MAIN CONTROL BOARD Fuse F1 Convert AC to low Flow Switch ST 12 Pin L...
  • Page 12 Fig 17- Front View of Appliance (control panel removed) 1. Fan & Flow Sensor 4-Fig 57 2. Fan Connections 3. Combustion Products 2-Fig 23 1-Fig 22 28-Fig 55 Test Point 27-Fig 55 4. Overheat Thermostat 5. Air Pressure Switch 5-Fig 61 6.

  • Page 13: Installation

    Fig 19- Side Flue Opening Position 11. Installation 11.1. General. 11.1.1. The appliance is suitable for sealed systems only. 11.1.2. The flue must be installed in accordance with BS5440:1. 11.2. Unpacking and appliance preparation 11.2.1. Remove the appliance from its packing and lay it on its back.
  • Page 14 Fig 21-Casing and Control Panel Fixing Screws Fig 22- Fan and Air Flow Sensor Fixing Negative 1.Transport Bracket and Bottom Panel Fixing Screws 2. Inner Casing Positive Fixing Screws 3. Control Panel Fixing Screws 1. Electrical connections 5. Air Flow Sensor 2.
  • Page 15 11.7.6. Check that the gas and water valves are closed. Refer to Fig 26-Service Valve Operation Fig 26. 11.7.7. Lift the appliance onto the wall mounting plate/manifold assembly ensuring that the connections fully enter the manifold fittings after it is supported at the top. COLD 11.7.8.
  • Page 16 11.8.3. Mark and cut the air and flue ducts to length. Always Fig 32-Flue Terminal and Duct Assembly check the dimensions before cutting. Do not cut the drilled or the expanded ends of the ducts. Make the cuts square and smooth. 11.8.4 Assemble the air and flue ducts and the terminal assembly as shown in the diagrams.

  • Page 17: Commissioning

    1. Auto Air Vent Fig 35-Auto Air Vent Fig 34-Air Duct into Clamp 2. Cap 3. Primary (CH) 1. Boiler Casing Sensor - Behind the 2. Air Duct Auto Air Vent Clamp 4. Flue Hood Assembly 5. Flue Hood Clamp 3.
  • Page 18 12.6. Remove the cap from the front of each pump and turn the Fig 38-Pumps exposed shaft about half a turn using a flat bladed screw driver. 1. Central Heating Replace the caps. Refer to Fig 38. Pump 12.7. Set the system pressure by filling the system until a 2.

  • Page 19: User Information

    14.4.3 Clean the electrodes. Replace if there is any deterioration 13.4 Tell the user of the importance of regular servicing. of an electrode. Worcester Heat Systems Ltd. offer a comprehensive maintenance 14.4.4 Clean the burner manifold. Inspect the burner manifold and contract.

  • Page 20: Replacement Of Parts

    Fig 42-Flue Hood Fixing Fig 45-Burner Assembly 1. Burner Blade Assembly 5. Manifold Support Bracket Fixing Screw (2) 6. Burner Blade Locating 2. Burner Blade Assembly Screw 3. Burner Location Slot 7. Manifold Fixing Screw 1. Clamp Location 3. Flue Hood 4.
  • Page 21 Replace any components removed from the appliance in the 15.4.2. Spark Electrode reverse order using new gaskets/O-rings/sealant where Remove the inner casing cover. necessary. Always check that any electrical connections are Carefully pull off the leads at the electrode assembly. Unscrew correctly made and that all screws are tight.
  • Page 22 15.4.9. Inlet Water Filter Fig 49-Domestic Hot Water Control Assembly Drain the hot water circuit. Refer to 15.3.2. Remove the bottom panel. Lower the facia. Disconnect the inlet water pipe at the manifold and the flow switch. Remove the filter. Ensure that the new filter is correctly aligned.
  • Page 23 15.4.17. CH Sensor Fig 52-Control Panel Fixing Remove the inner casing cover. Carefully pull off the connections and release the clip to remove the sensor. Apply heat transfer paste to the face of the new sensor. Refer to Fig 55. Note: If a left-hand flue is fitted then it is easier to remove the sensor and clip before pulling off the connections 15.4.18.
  • Page 24 Use new seals and gaskets where necessary. Refill and pressurise Fig 56-Domestic Hot Water Sensor as described in Section 12.4-8 - Commissioning. Refer to Fig 59. 15.4.23. Auto Air Vent Remove the inner casing cover. Drain the primary system. Refer to 15.3.1. Unscrew and remove the auto air vent.
  • Page 25 Fig 59-Domestic Hot Water Heat Exchanger Fig 60-Primary Heat Exchanger Fixing 1. Fixing Clip (2) 2. Domestic Hot Water Heat Exchanger 3. Cold Water Inlet 4. O-Ring 5. Domestic Hot Water Flow 1. Fixing Clip (2) 5. O-Ring 2. Clip Locating Channel 6.

  • Page 26: Short Parts List

    Furigas 8 716 142 643 0 E02-891 Burner E19 - LPG Furigas 8 716 192 224 0 E02-838 Insulation Pack Worcester 299-506 Pressure Gauge 4 Bar Dark Grey Cewal 8 716 142 300 0 397-677 Pressure Relief Valve Caleffi 8 716 142 416 0...

  • Page 27: Operational Flow Diagrams

    17. Operational Flow Diagrams Room CENTRAL HEATING FUNCTION thermostat and/or mains programmer (or link) On Electronic MAIN SWITCH Green Light facia programmer (if fitted) On ST13 link In CH control knob On CH light On. Two minute Pump On. minimum Modulate gas Pump Fan high...
  • Page 28 OVERRUN FUNCTION If heat Run pump demand has until primary occured in last drops to 30 minutes 80°C Within four minutes of last hot water demand primary temperature If heat If primary above 80°C Run pump demand has Run pump for temperature until primary 2 seconds...

  • Page 29: Fault Finding

    With individual or groups of lights being permanently off, on or Note: This information is for guidance only. Worcester Heat flashing, every normal fault can be identified. Systems cannot be held responsible for costs incurred by per- sons not deemed to be competent.
  • Page 30 Is the facia on/off switch turned on? Turn switch on. `(Clockwise) Is there a 230V AC live supply across Check electrical Terminal ST12 pins L supply to boiler. and N Replace control board Has fuse F1 blown? (Section 15.4.11) Replace fuse and investigate cause. Suggestions: Cable damage, connections to (or faults within) pump, fan, external 230V controls, transformer or board.
  • Page 31 Separate the 2 way in-line Remove multiway With a hot water tap connector to flowswitch connector from board Replace fully open, does the (fitted to boiler side position ST16. With Flow Switch boiler ignite and panel). With tap still open, tap still open is there appear to run is there continuity across...
  • Page 32 Is the gas supply Rectify gas supply connected and at the problem. correct pressure? Remove front panel. Remove inner cover. Repair or replace Reset and restart the Reset and restart the Are the electrodes and electrodes boiler. Can a flame be boiler.
  • Page 33 Is the multiway connector at board position ST16 pushed Push fully home. fully home on to the board? Remove multiway connector from board Separate 6 way in-line position ST16. Test Is there continuity connector and check resistance across from contacts 17 and continuity of red wires contacts 17 and 18 18 to DHW sensor?
  • Page 34 Does this fault only Remove fan connector occur in CH or DHW from board position mode? ST1 and restart boiler in the fault mode. After 5 seconds is there mains 230V Replace control board. from the left (N) track (Section 15.4.11). at ST1 and right (L) track if DHW mode? Centre (L) track if CH...
  • Page 35 Light indication during fault not Control board is likely covered by above to be wet or damaged details. or malfunctioning. Check for wet board or connections. Dry and re-use or replace control board. (Section 15.4.11). Hot water sensor Hot water could be off or poorly temperature always fixed to pipe.
  • Page 36 This manual is to be used in conjunction with the variant part number of the bar code below: 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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