Worcester Highflow 400 RSF Installation And Servicing Instructions
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Worcester Highflow 400 RSF Installation And Servicing Instructions

Worcester Highflow 400 RSF Installation And Servicing Instructions

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

SERVICING INSTRUCTIONS

GC NUMBER 47 311 18
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 1994

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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 18 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 Domestic Hot Water Supply ........Page 13 General Information ............ Page 2 Electrical ..............Page 14 Data Tables ..............Page 5 Installing the Appliance ..........Page 16 Siting the Appliance ............ Page 8 Commissioning the Appliance ........Page 31 5a.
  • Page 3 To flue the appliance right, left or upwards 90° flue bends are individual outlets. For further information contact Worcester available as optional extras. Heat Systems Ltd. A maximum of three 90° flue bends are available for the flue 2.13 SAFETY CONSIDERATIONS.
  • Page 4 With the system at the temperature set by the Temperature HOT WATER AND CENTRAL HEATING MODE: Control Knob,on the facia, the burner will cycle to maintain The appliance will supply heat to the central heating system as output to the system. required.

  • Page 5: Data Tables

    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 Table 4 AVAILABLE PUMP HEAD TEMPERATURE RISE BOILER OUTPUT HEAD MIN. FLOW RATE ACROSS HEATING FLOW AND RETURN Btu/h Metres Feet L/min. Gal/Min. (30,000) 20.0 11.5 11.0 (37,000) 17.5 14.0 11°C (20°F) 13.0 (44,350) 16.0 17.0 HEATING 15.0 (51,200) 13.5 19.5 RANGE 17.0...
  • 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: Siting The Appliance

    Installation Service 4. Siting The Appliance Above the appliance 450 mm 10 mm In front 600 mm 600 mm 4.1 THE APPLIANCE MAY BE INSTALLED IN ANY ROOM ALTHOUGH PARTICULAR ATTENTION IS DRAWN TO THE Right side 5 mm 5 mm REQUIREMENTS OF THE CURRENT I.E.E.
  • Page 9 Fig. 5. Flue options. 90¡ flue bend Standard flue length Standard flue length 100 to 500mm 100 to 950mm Appliance Appliance Frame 1: Flue Option 1. Standard Horizontal Rear Flue. Frame 2: Flue Option 2. Standard Horizontal Side Flue. 90¡ flue bend Maximum flue length 3000mm Maximum flue length...

  • Page 10: 5C. Vertical Flue

    The following items are included in this flue kit: providing the total straight length does not exceed 2300 mm when measured from the appliance cabinet. See Fig. 5. Frame 6. 1 – Air duct 700 mm long (including fixing length inside appliance cabinet).

  • Page 11: Sealed System

    should be made in the central heating return as close to the 7. Sealed System appliance as possible. 7.9 The make-up vessel must be fitted with a non-return valve. See Fig. 6 and 7. 7.10 Repeated venting loses water from the system. It is essential that this water is replaced and the system pressure 7.1 The system must comply with the requirements of BS 6798 maintained.

  • Page 12: 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 a pipe must be fitted which See Fig.

  • Page 13: Domestic Hot Water Supply

    9.11 The supply of hot and cold mains water direct to a bidet is 9. Domestic Water Supply permitted, subject to local Water Company requirements, provided that the bidet is of the over-rim flushing type. The outlet(s) should be shrouded and unable to have any temporary 9.1 The final 600mm of the mains cold water connection to the hand held spray attached.

  • Page 14: Electrical

    anchorage, the current carrying conductors become taut before 10. Electrical the Earth conductor. For access refer to Section 14. 10.6 The wiring between the appliance and the electrical supply shall comply with current IEE Wiring Regulations, and any local Refer to Figs. 9, 10, 11 and 12. regulations which apply.
  • Page 15 Fig. 10. Functional flow diagram. Fig. 11. Room/frost thermostats and programmer. Fig. 12. External programmer connections. To External Programmer Room thermostat Switched live Switched central heating from Live Neutral programmer Connector X13 Connector Switched hot Remove link on control board X12 on water from programmer...

  • Page 16: Installing The Appliance

    Before continuing with the installation it will be necessary to 11. Installing The Appliance decide which flue option is suitable. Refer to Section 5b and Fig. 5. Having decided upon the most suitable flue option for the The appliance is supplied suitable for fitting to a sealed system. If installation, the position of the hole for the flue must now be it is to be fitted to an open vent system refer to paragraph 11.3 marked on the wall/walls.
  • Page 17 Mark the wall where the flue will terminate to suit the The position for the hole/holes for the flue should be marked on installation. the wall/walls. This is the Side Flue Extension centre point position. See Fig. 13. Drill the flue hole/holes 120 mm (4.5in.) diameter, ensure it is FLUE OPTION 8.
  • Page 18 11.3 FIXING THE APPLIANCE FOR ALL FLUE OPTIONS. When the appliance is flued to the rear ensure the flue position, located on the rear of the appliance, is directly in line with the To gain access to the appliance remove the cabinet front and top hole in the wall.
  • Page 19 Fig. 15. Discharge pipe connection for sealed Fig. 17. Central heating flow and return valves, system. by-pass adjustment, pressure relief and manual air vent. Cabinet side Central Heating panel Flow Valve Rear view of appliance Central Heating Return Valve Pressure relief drain connection Manual Air Vent...

  • Page 20: Applicable

    Withdraw the two securing clips from the pump body. Flue Flue Length or Flue Restrictor Option Total Straight Flue Size mm (dia.) East the pump forwards about 10mm off the “O” ring seals. It is Length (mm) not necessary to disconnect the electrical cable. The cable is sufficient to allow the pump head to rest on top of the appliance.
  • Page 21 Apply a smear silicone sealant around the inside of the air duct. the end of the air duct and flue terminal. See Fig. 24. Drill through the holes in the flue terminal into the air duct with Re-assembly the air duct over the flue duct, ensure the flue duct the drill provided.
  • Page 22 Fig. 20. Flue Option 3. Standard horizontal side flue. Flue Option 4. Extension horizontal side flue. Flue duct = (A + 284) mm Air duct = (A + 244) mm 90¡ flue bend Base outline of appliance marked on floor Distance from the side of the base outline of the appliance to the outside...
  • Page 23 Fit the flue adaptor to the air and flue ducts and assemble the Apply a smear of silicone sealant to the end of the air duct and flue system. Follow the procedure as described in Section 11.3 fix into the flue terminal using the screws provided. and 11.4 to fit the flue adaptor and assemble the flue system.
  • Page 24 The section of horizontal air and flue duct fitted adjacent to the The flue duct must fit correctly between the flue bends. The duct first flue bend will not require expanded ends. Cut off the is trapped between the flue bends and does not require fixing expanded ends from this section.
  • Page 25 ii) A flue restrictor ring may be required. Refer to Measure accurately the distance from the rear of the appliance, Section 11.3 to determine the size or whether previously marked on the floor, to the centre of the first 90° flue the restrictor is necessary.

  • Page 26: Applicable

    Continue the installation by following the procedure for the flue Facia Mounted Programmer (where applicable). option chosen. Refer to Section 11.5, 11.6.2, 11.6.3, 11.6.4, Remove the facia panel as described in Section 11.3. Refer to Fig. 14. 11.6.5, or 11.6.6. Unplug the Operating Switch connection at the control board .
  • Page 27 Fig. 24. Fixing the flue restrictor ring into the flue terminal. Air duct Flue Flue restrictor terminal ring. Refer to Section 11.3 for correct size Fit the flue restrictor ring into the flue terminal. Ensure the air duct is fully engaged in the flue ter- minal and the restrictor ring is located firmly between the end of the air duct and flue terminal.
  • Page 28 Fig. 27. Flue Option 6. Extension flue upwards and horizontal using a second 90° flue bend. The two flue lengths, when added Outside together, must not exceed 2300mm Second 90¡ flue bend wall Air duct = (B Ð 166) mm Flue duct = (B Ð...
  • Page 29 Fig. 29. Flue Option 8. Extension flue upwards and horizontal using a second and third 90° flue bend. The three lengths, when added Second 90¡ Outside wall together, must not exceed 1000mm flue bend Air duct = (B - 166) mm Flue duct = (B - 152) mm Air duct = (C - 58) mm Flue duct = (C - 14) mm...
  • Page 30 Fig. 31. Terminal assembly for internal Fig. 32. Duct and terminal assembly for fitting of the flue. internal fitting of the flue. Rubber sealing gasket Flue centring ring Flue terminal Seal Flue duct Flue terminal Duct assembly Air duct Clamping ring External wall Rubber sealing gasket...

  • Page 31: Commissioning The Appliance

    The appliance (as despatched) can accommodate a system 12. Commissioning The Appliance volume of about 104 litres. Refer to BS 7074 Part 1. If the system volume is in excess of that accommodated by the expansion vessel fitted to the appliance then an extra vessel must be fitted 12.1 The appliance is despatched with the controls set to as close as possible to the central heating return connection of provide a maximum output for domestic hot water of 24 kW...
  • Page 32 Worcester Heat Systems Service Department. Put the Operating switch (or Programmer) to OFF. Switch off the Should the appliance not light, check it is not in the overheat gas service cock and the electrical supply to the appliance.

  • Page 33: Instructions To The User

    Ease the flue hood forwards about 15 mm to clear the rear 13.4 Tell the user of the importance of regular servicing. location. Remove the flue hood off the heat exchanger and clear Worcester Heat Systems Ltd offer a comprehensive maintenance of the inner casing. See Fig. 35. contract.

  • Page 34: Replacement Of Parts

    Controls. that as much water as possible is drained from the appliance. Remove any dust or deposits using a soft brush. Take care not to CAUTION: Some water will remain in the expansion vessel, mishandle any component connections. pump, water diverter valve, water to water heat exchanger and gas to water heat exchanger.
  • Page 35 the heat exchanger clear of the inner casing. Remove the cabinet front panel, place the facia and control box in the Service Position, lower the expansion vessel into the WARNING: There will be a small quantity of water remaining in Service Position and remove the inner casing cover, as described the heat exchanger.
  • Page 36 Fig. 35. Inner casing assembly. Venturi connections Ð Fan assembly Water to water heat exchanger Securing clip Venturi housing Fan outlet located in fan Safety temperature outlet limiter thermostat Thermostat phial pocket Thermostat Fan electrical fixing Flexible pipes (2) connections (2) Automatic Fan assembly air vent...
  • Page 37 burner. Ease the pilot burner forwards sufficiently to allow a Carefully pull one end of the lead from the electrode and ease the suitable tool to support it. other end off the tag on the spark ignition sequence board. Remove the lead from the appliance and discard. The spark electrode is held in position with a clip.
  • Page 38 Remove the facia as described in Section 15.1. mounting bracket. Withdraw the thermostat threading the capillary through the slot in the rear of the control box and Remove the spring clip from the thermostat pocket located on discard. the front left hand side of the heatbank. NB.
  • Page 39 bracket located in the control box. of heat sink compound to the thermostat phial. Reassemble the appliance in the reverse order. Release the strain relief bush by compressing the loose section of the bush and carefully withdraw the leads from the 17.
  • Page 40 Using an approved jointing compound complying with Service Position, as described in Section 14.2 a, b and c. Remove BS5292 fit the female half of the brass union to the the facia as described in Section 15.1 . replacement gas valve inlet. Drain the heating circuit as described in Section 15.2 a.
  • Page 41 screws are correctly engaged. Replace the “O” ring seals and refit the manifold to the water to water heat exchanger support bracket. Retain the screws. See Fig. 47. the pressure pipe. Ensure the securing clips are fully engaged in the locating holes. Unscrew the flat faced union securing the manifold to the inner casing pipework.
  • Page 42 assembly to the support bracket with screw Nos.13 and 14. Fully replaced. tighten the screws fixing the “O” rings Nos. 11 and 12. See Figs. Re-assemble the circulating pump ensure the securing clips are 47 and 48. re-placed. Re-assemble the top manifold in the reverse order. Open the valves, fill and repressurise the system as described in Section 12.2.
  • Page 43 Reassemble the manifold in the reverse order using new “O” washers. Ensure the orientation of the hose fittings does not rings to replace any “O” rings which have been disturbed. Use cause twisting or crimping of the hose when the expansion new sealing washers where appropriate.
  • Page 44 Fig. 47. Water to water heat exchanger. Note: Screw Nos. 1 2 , 5 6 7 8 , 11 12 Warning: There will be a small quantity of water remaining in the pipework and water- unscrew two full turns Ð Do not remove. to-water heat exchanger.
  • Page 45 Fig. 48. 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 46 30. Flow Switch. See Figs. 9, 16, 52 and 53. Check that the electricity supply to the appliance is turned off. Check that the electricity supply to the appliance is turned off. Remove the cabinet front panel, place the facia and control box in the Service Position, as described in Remove the cabinet front panel, place the facia and control box in the Service Position and lower the expansion vessel into the...
  • Page 47 Disconnect the room thermostat and frost thermostat if fitted, Reassemble in the reverse order and ensure that : note the positions. i) the spark electrode lead is connected to the terminal at Disconnect the mains supply at the terminal strip located the top right hand corner of the ignition board.
  • Page 48 Fig. 54. Control box and thermostat Fig. 56. Neon indicator light bracket. connections. Thermostat capillaries Hot water thermostat Control box Connector Hot water high Standby limit thermostat (Amber) Heating thermostat Demand and clamping nut (Green) Clamping Mounting bracket Fixing screws Fig.

  • Page 49: 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. Domestic Hot Water Operational Flow Diagram (CH Selected Off) Standby Indicator Burner Hot Water Hot Water Hot Water Safety Automatic Heatbank...

  • Page 50: 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 51 Replace the Is there 230V at Is there 230V at Does the fan run? control board pin 1 of pin 2 of terminal X16? terminal X16? (Left black wire) (Right black wire) Hot water high limit stat has tripped. Investigate cause of overheating and/or replace Is there 230V at Is there 230V at...
  • Page 52 Can a pilot flame Turn on the gas supply, Is there a gas supply be seen? bleed the system and to the appliance? check the pressure Is the pilot injector free Replace the from blockage? injector Replace the gas valve Does the main Rectify Has the sparking...
  • Page 53 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 54 START OF CENTRAL HEATING TEST Before tests ensure pump has stopped Is there 230V at Replace the pin 4 of operating switch Set the operating switch terminal X12? (or programmer) (or programmer) (C.H.) to HEATING and WATER and turn the heating control stat and room Is there 230V at Is there 230V at...

  • Page 55: Component 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 8 716 142 438 0 378 819 Air Pressure Switch Honeywell C6065AH1038...
  • Page 56 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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