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Worcester Highflow 400 BF Installation And Servicing Instructions

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See also: Instructions for Installation and Servicing , Installation and Servicing Manual
Highflow 400
ELECTRONIC BF
FLOOR STANDING COMBINATION APPLIANCE FOR CENTRAL
HEATING AND MAINS FED DOMESTIC HOT WATER
INSTALLATION AND

SERVICING INSTRUCTIONS

GC NUMBER NATURAL GAS
47 311 62
BOILER OUTPUT
Automatic Modulating Control
Domestic Hot Water and Central Heating
Minimum 8.8 kW DHW
11.0 kW CH
Maximum 24.0 kW
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

    Highflow 400 ELECTRONIC BF FLOOR STANDING COMBINATION APPLIANCE FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS GC NUMBER NATURAL GAS 47 311 62 BOILER OUTPUT Automatic Modulating Control Domestic Hot Water and Central Heating Minimum 8.8 kW DHW 11.0 kW CH Maximum 24.0 kW IMPORTANT: THIS APPLIANCE IS FOR USE WITH NATURAL GAS ONLY...

  • Page 2: Table Of Contents

    NOTE: As the dry weight of the appliance is 96kg, more than far as possible, the foreseeable situations which may arise. Contact one person will be required when moving the appliance. Worcester Heat Systems Technical Department, Telephone: 08705 266241, for advice on specific installations.
  • Page 3 2.6 FLUE 2.7 CONTROLS. The appliance has a balanced flue system. The electronic control system via the gas valve modulates the A terminal guard, Type E, GC No 393 547, is available from Tower heat input in response to the central heating and domestic hot Flue Components, Vale Rise, Tonbridge, TN9 1TB.
  • Page 4 A demand for hot water at a tap or shower will override individual outlets. For further information contact Worcester the central heating function for the period of the hot water 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 BOILER ADJUSTED FOR (10 minutes after lighting) G20 (Natural Gas) MAX. OUTPUT 24.0 MAX. INPUT (net) 26.8 BURNER PRESSURE mbar...
  • Page 6 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 15mm Copper Tube GAS INLET 22mm Copper Tube PRESSURE RELIEF VALVE DRAIN CONNECTION 15mm Copper Tube OVERALL CASING HEIGHT 860mm 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: Siting The Appliance

    5. Flue Terminal Position 4. Siting The Appliance 5.1 The flue must be installed as specified by BS 5440:Part 1and 4.1 THE APPLIANCE MAY BE INSTALLED IN ANY ROOM the building regulations. ALTHOUGH PARTICULAR ATTENTION IS DRAWN TO THE REQUIREMENTS OF THE CURRENT I.E.E. WIRING NOTE: Installations coming under the jurisdiction of Building REGULATIONS AND, IN SCOTLAND, THE ELECTRICAL Control should adhere to the increased clearances.

  • Page 9: Air Supply

    6. Air Supply 7a. Sealed System See Fig. 4 and 5. 6.1 The appliance does not require a separate vent for combustion air. 7a.1 The system must comply with the requirements of BS 6798 and BS 5449:1. 6.2 Installations in cupboards or compartments require 7a.2 The appliance must not be operated without the system permanent vents for cooling purposes, one at high level and one being full of water, properly vented and pressurised.

  • Page 10: 7B. Open Vent System

    appliance or above the highest point in the heating circuit, 7b. Open Vent Primary System whichever is the highest, is achieved. See Fig. 6. 8.4 The feed and vent pipe must rise continuously from the See Figs. 6 and 15. appliance to the feed and expansion cistern.

  • Page 11: Gas Supply

    electrical box, using a screw and cup washer. Ensure the earth 9. Gas Supply cable is longer than the other two cables so that it will not be taut, should the mains cable be pulled. Feed the mains cable through the top hole at the rear of the electrical box.

  • Page 12: Electrical

    Fig.9. Functional flow diagram. OUTPUTS INPUTS ELECTRONICS Convert AC to Low Voltage DC Fig. 11. Programmer connections. Fig. 10. Room/frost thermostats. Remove link To Programmer Neutral Switched central heating from programmer Live return Connector Switched hot Room thermostat X2 on water from programmer Live supply...

  • Page 13: Installing The Appliance

    11.2 FLUE PREPARATION 11. Installing The Appliance Having decided upon the most suitable position for the appliance the hole for the balanced flue assembly must now be The appliance is supplied suitable for fitting to a sealed system. If marked on the wall. it is to be fitted to an open vent system refer to paragraph 11.3 From the dimensions given in Fig.
  • Page 14 Apply the silicone sealant in a bead approximately 10mm (0.3 in) Sealed System diameter around the air duct spigot located on the rear of the Connect a 15mm copper drain pipe to the discharge connection inner casing. See Fig. 15. at the rear of the appliance.
  • 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. 1. Facia. 2. Control box. 3. Inner casing cover fixing screws (4). 4. Expansion vessel fixing screw. 5. Expansion vessel flexible hose. 6. Pressure gauge. 7. Expansion vessel hinge. 8.

  • Page 18: Commissioning The Appliance

    Pilot flame length 18-20mm Fig. 20. Pilot burner assembly. Pilot assembly Pilot head Pilot assembly fixing screws (2) Pilot gas pipe fixing nut Pilot gas pipe Spark electrode (secured by clip) Flame sense electrode Flame sense electrode fixing nut Spark electrode earth lead Fig.
  • Page 19 Check that the gas service and the electrical supply to the 2.5 bar when operating at the maximum central heating appliance are turned off. temperature, an extra expansion vessel must be fitted to the system as close to the appliance central heating return Raise the facia and control box into the Service Position.

  • Page 20: Instructions To The User

    13.3 Tell the user the Sealed System set pressure if applicable. burner and pilot will go out but sparking from the electrode will 13.4 Tell the user of the importance of regular servicing. Worcester continue. Carefully open the gas service cock and observe the Heat Systems Ltd offer a comprehensive maintenance contract.

  • Page 21: Replacement Of Parts

    openings in the compartment door or walls are clear. Refer to 14.3 SERVICING OF COMPONENTS Section 6, Air Supply. Clean the Burner Check the operation of the pressure relief valve. Reset the system Brush the blade tops and mixing tube with a soft brush and pressure if necessary.
  • Page 22 Fig. 23. Inner casing assembly. Water to water heat exchanger Safety Temperature Limiter CH (Primary) Sensor 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 Inner casing Pilot bracket and...
  • Page 23 CAUTION: Some water will remain in the expansion vessel, Tighten the union connections. Refit the access cover to the left pump, water diverter valve, water to water heat exchanger and hand side of the combustion chamber and replace the fibre gas to water heat exchanger.
  • Page 24 Discard the pilot burner. Fig. 25. Combustion chamber insulation. Fit a replacement pilot burner in the reverse order. Check the pilot burner settings and spark electrode gap are as shown in Fig. 23 and Section 12.4. Reassemble the appliance in the reverse order. 7.
  • Page 25 Fit a new sensor in the reverse order. The polarity of the Fig. 27. Pilot burner setting. connections is not important. Apply a smear of heat sink compound to the thermostat face. Reassemble the appliance in the reverse order 13. Water Filter Primary System. See Figs. 29 and 34. Check that the electricity supply to the appliance is turned off.
  • Page 26 Remove the pump electrical cover and disconnect the electrical Fig. 30. Hot water sensor. connections. Release the cable clamp and remove the cable. Withdraw the two securing clips from the pump body. Ease the Hot water outlet to pump forwards about 10mm off the “O” ring seals and remove taps from the appliance.
  • Page 27 Unplug the connector at the diverter valve. 22. Water to Water Heat Exchanger. See Figs. 34, 35, and 36. Using a pair of long nose pliers, remove the two clips securing the 6 mm copper pressure pipe, to the top left hand corner of the Check that the electricity supply to the appliance is turned off.
  • Page 28 Unscrew the union fitting below the cold water inlet valve To release the rear elbow reach under the water to water heat exchanger bracket and push in fully the flat plate clamp and remove the flow switch and water filter assembly. mechanism.
  • Page 29 Fig. 34. Water to water heat exchanger. Warning: There will be a small quantity of Note: Screw Nos. 1 2 , 5 6 7 8 , 11 12 unscrew two full turns – Do not remove. water remaining in the pipework and water- to-water heat exchanger.
  • Page 30 Fig. 35. 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 31 Remove and retain the brass stub connection and nut from the Fig. 37. Expansion vessel and flexible hose. manifold. Withdraw the by-pass adjuster retaining clip and unscrew the adjuster from the manifold retaining both items. Expansion Undo and remove the phial pocket securing clip screw and clip. Vessel Retain both the clip and screw.
  • Page 32 27. Pressure Gauge. See Fig. 16. Fig. 39. Flow turbine, Check that the electricity supply to the appliance is turned off. water filter and hot Remove the cabinet front panel, place the facia and control box water flow regulator. in the Service Position and lower the expansion vessel into the Service Position,as described in Section 14.2 a, b and c.
  • Page 33 Re-assemble the facia assembly in the reverse order ensuring that the control knobs are correctly aligned. 32. Facia Mounted Programmer. See Figs. 8 and 12. 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 Section 14.2 a and b.

  • Page 34: Operational Flow Diagrams

    16. Operational Flow Diagrams CENTRAL HEATING MODE 3 minute wait Gas valve OFF. 230V CH light ON. mains temperature Pump ON. 5°C above set supply to the Diverter valve point. temperature boiler. Frost thermostat and CH 4°C below control knob ON set point.
  • Page 35 TANK MODE Pump continues for 3 seconds. Pump pulse for 3 seconds if primary temperature is above 82°C. Tank 1°C above set point 230V Gas valve mains OFF. Primary supply to the temperature boiler. above 89°C. Maximum Tank 8°C heat input below set HW programme ON Ignition...

  • Page 36: Fault Finding

    17. Fault Finding Note: This fault-finding information is for guidance only. Worcester Heat Systems cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates three lights on the facia. These are used to show normal operating status. But as a secondary function, by flashing, they can also be used to help provide fault diagnostics.
  • Page 37 Is there a 230Vac Check electrical live supply across supply to boiler. connector X1 pins L&N? Transformer likely to Has fuse F1 blown? be faulty. Replace Has fuse F2 blown? control board. Likely to be caused by Likely to be caused by mains 230V parts external internal fault on control to the control board, e.g...
  • Page 38 Choose the appropriate catagory below. Suspect: Pilot flame only. All water cold in all Remove ignitor unit from gas Replace gas valve. operating modes. valve. Measure the resistance across the two outer pins on the gas valve. Is resistance between 6kohm and 9kohm? Replace ignitor unit.
  • Page 39 Is the gas supply connected and at the Rectify gas supply correct pressure? problem. Note: If gas supply has been interrupted it may take some time to purge gas to the pilot assembly. Is there a spark at the pilot Check links are fitted to assembly Is there 230Vac at...
  • Page 40 Visually inspect all three temperature sensors on Repair or replace the appliance (combustion faulty sensor or chamber cover needs to be wiring to it. removed to see the central heating / primary sensor). Are they electrically connected and look o.k. ? Remove 20 - way connector from control board.
  • Page 41 Storage tank has overheated. This is a serious fault. Call Service Engineer. Flue gas detected inside Is flue correctly boiler. Unblock/rectify installed and free of fault. blockages? Note 1: It is possible that during extreme weather conditions this fault may occur intermittently.

  • Page 42: Component Parts List

    18. Component Parts List GC No. Description Manufacturer’s Reference WHS Part No. 378 025 Burner NG Aeromatic AC23/053567 8 716 142 607 0 379 040 Burner Injector Injector 4.4mm diameter 8 716 156 337 0 Gas Valve SIT Sigma 8 716 102 995 0 379 562 Pilot Burner Honeywell Q38A2051...
  • Page 44 Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619 Technical Helpline: (0990) 266241 www.worcester-bosch.co.uk 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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