Installation - Worcester 24CDi Installation And Servicing Instructions

12. Installation

Read this section fully before starting the Installation.
12.1 General.
The appliance is supplied suitable for fitting to a sealed system. If
it is to be fitted to an open vent system refer to Section 9.
The flue must be installed in accordance with BS5440:1.
An optional wall spacing frame is available to allow pipework to
be run behind the boiler.
12.2 Unpacking and Appliance Preparation.
Remove all the packaging from the appliance.
Using the two M4 thread-forming screws supplied in the
hardware pack assemble the wall-plate cross members to the
pre-plumbed manifold. Refer to Fig 16.
12.3 Site Preparation
Check that the wall is sound, flat and will support the weight of
the appliance. Refer to Table 4.
Check that the position chosen for the appliance is in accordance
with the instructions given in Section 4 and 5.
Ensure that the plastic cover over the valves and 'O' rings is left
in place. The cover will protect the valves and 'O' rings against
the ingress of dirt and dust.
12.4 Fixing Holes and Flue Opening
Hold the wall-plate to the wall. Check that the plumbing manifold is level.
Mark the position of the fixing holes. Two at the top and two on
the plumbing manifold.
Mark the position of the appliance centre-line from the 'V'
formed by the wall-plate cross-member. Refer to Fig 16.
Mark a horizontal line across the top of the plumbing manifold.
Refer to Fig 16.
Rear Flue:
Draw a vertical line through the centre point marked on
the wall. Measure 820mm upwards from the horizontal
line marked on the wall along the vertical line and mark
the point. This is the rear flue hole centre point position.
Refer to Fig 16.
Side Flue:
Extend a line horizontally from the rear flue hole centre
point along the appropriate wall.
Measure 197 mm from the junction of the walls and mark
Fig. 16 . Fixing the wall mounting plate.
Boiler fixing studs
(2)
116
723
Pre-plumbing
manifold
99
425
Dimensions in mm
a vertical line. Extend horizontally the side flue line to
intersect the vertical line to give the position of the side
flue hole.
NOTE: If the optional wall spacing frame is used then the
197mm dimension should be increased by 35mm (see
instructions supplied with frame).
Check the position and alignment of the holes before
drilling the fixing holes (60mm deep for N
the flue holes Ø110 for external fitting and Ø150 for
internal fitting). Ensure that the flue hole is horizontal
through the wall. Refer to Fig 16.
12.5 Wall-mounting Plate and Manifold
Fit the plugs and fix the plate/manifold assembly to the wall.
Check that the assembly is properly aligned before tightening
the screws.
12.6 Gas and Water Pipes
Remove and discard the plastic cover protecting the valves and
'O' rings. Check that the 'O' rings are fitted and that they are
clean and lubricated.
Remove the gas cock, fix the appropriate fitting to connect to the
inlet pipe and replace.
Connect the water connections to the manifold. Refer to Fig 3.
Pre-plumbing is not advised if no movement in the pipework is
possible.
Pipework can only run horizontally outside the limits of the
casing. It is important that the pipes are not fixed near the
appliance using clips that put a strain on the connections.
Before the appliance is fitted to the wall the primary system and
the mains supply must be thoroughly flushed and treated in
accordance with the recommendations of BS7593:1992.
12.7 Install the Boiler
Slide the appliance onto the pre-plumbing manifold ensuring
that the three pegs are located correctly.
Secure with two M6 nuts and washers at the top and screw the
appliance to the manifold at the bottom using the three retaining
caps and M6 bolts. Refer to Fig 17.
Unscrew and discard the automatic air vent cap. Refer to Fig.18.
Lower the facia. Refer to Fig 12.
Fit a discharge pipe to the relief valve leading it away from any
electrics or where it may be a hazard. The pipe must not be less
than 15mm in diameter and must run continuously downwards
outside the appliance.
211
Wall fixing screws
(2)
820
Plumbing manifold
fixing screws
(4)
13
o
12 plugs) and
(232mm if the optional
space frame is fitted)