Worcester C1 Installation And Servicing Instructions
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Worcester C1 Installation And Servicing Instructions

Wall mounted combination boiler for central heating and mains fed domestic hot water
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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.
Minimum
Maximum
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.
C1
0
I
GC NUMBER 47 311 53 (N.G.)
APPLIANCE OUTPUTS
Natural Gas
Domestic
Central Heating
8.5 kW
8.5 kW
28.0 kW
28.0 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 This appliance is for use with Natural Gas. GC NUMBER 47 311 53 (N.G.) APPLIANCE OUTPUTS Natural Gas Domestic Central Heating Minimum 8.5 kW 8.5 kW Maximum 28.0 kW...

  • Page 2: Table Of Contents

    Contents 1. Installation Regulations ......Page 2 9. Gas Supply ........Page 9 2.
  • Page 3 Domestic Hot Water Fig. 1. Facia controls A demand for hot water will ignite the burner. The burner pressure will immediately rise to maximum. Central Heating Domestic Hot Burner At the end of the demand the fan will continue to run for 35 Indicator Water Indicator Operation Light...

  • Page 4: Technical Data

    3. Technical Data The data plate is fixed to the inner casing cover. Table 1. NOMINAL BOILER RATINGS (10 Minutes After Lighting) BOILER ADJUSTED FOR G20 (Natural Gas) BURNER OUTPUT INPUT (Net) GAS RATE PRESSURE m bar. 10.5 1.12 28.0 31.1 14.1 3.38...
  • Page 5 Table 5 PERFORMANCE SPECIFICATIONS PRIMARY WATER CAPACITY litres MAXIMUM MAINS INLET PRESSURE MINIMUM MAINS INLET PRESSURE (WORKING) FOR MAXIMUM FLOW MINIMUM MAINS INLET PRESSURE (WORKING) FOR OPERATION DOMESTIC HOT WATER TEMPERATURE RANGE °C 40 - 62 MAXIMUM CENTRAL HEATING FLOW TEMPERATURE °C 82 (nom) MAXIMUM CENTRAL HEATING SYSTEM SET PRESSURE...

  • Page 6: Siting The Appliance

    4. Siting The Appliance Fig. 3. Appliance casing dimensions and required clearances (front view). 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: Flue Terminal Positions

    5. Flue terminal positions 6. Air Supply The flue system must be installed following the requirements of 6.1 The appliance does not require a separate vent for BS5440: 1. combustion air. Standard flue kit length is 330 - 725mm (as measured from the 6.2 The appliance can be fitted in a cupboard with no vents for centre of the flue turret) with extension kits for flues up to cooling but the minimum clearances must be increased to those...

  • Page 8: Sealed System

    The system and the appliance must be properly vented. 7. Sealed System Repeated venting loses water from the system, which must be replaced. The make-up connection must be close to the The system must comply with requirements of BS6798 and appliance in the heating return pipe through an approved non- BS5449 and must not be operated without being full of water return valve.

  • Page 9: Domestic Hot Water

    9. Gas Supply 8. Domestic Hot Water It may be necessary to contact the local Water Company before The appliance requires a maximum of 3.38 m /h of natural gas connecting the appliance. (G20) . Refer to Table 7. Devices, which would prevent the flow of expansion water, must A natural gas appliance must be connected to a governed meter.
  • Page 10 Fig. 11. Wiring diagram. Overheat cut-off device CH sensor (front of heat exchanger) Flame sense electrode Spark electrode Gas valve Flow Pump switch Main Main Spark transformer DHW sensor Control Board ST16 ST12 ST15 Link pink 2 blue 2 yellow Mains in 2 green 2 brown...
  • Page 11 Fig. 12. Functional flow diagram. Outputs Inputs DHW control knob CH Control knob Electronics/ microprocessor CH pressure adjust pot (Safety Low Voltage) Gas valve mode switch Reset button Convert AC to low voltage electronics Electronics Pump Electronics...

  • Page 12: Installation

    Fig 13 - Replacement internal fuses Fig.14 . Mains electricity connections. Bottom Left Hand Side - Facia NOTE: Check the size of the fuse before fitting ST12 Live N LS 230V Brown Neutral Blue Earth External control Green/Yellow Mains lead Strain relief clamp 1.
  • Page 13 Fig.16 . Manifold assembly Fig.18. Inner case and facia fixing Fixing screws Position of the cabinet Wall fixing screw Frame Wall Fibre Frame Washer Inner case cover Facia panel fixing screws Flow Flow Cold Inlet Return Facia All dimensions in mm 11.7 Install the Boiler Remove the cabinet by unscrewing the screw at the top front and releasing the sides.
  • Page 14 11.9 Measure and Cut the Ducts. General: Cut the ducts as necessary, ensuring that the ducts are Fig.20. Standard flue assembly square and free from burrs. Always check the dimensions before cutting. Measure the distance L. Refer to Fig. 22 and 23. The standard flue can be telescopically adjusted to any length Terminal assembly...
  • Page 15 Fig.24 . Flue Turret Fixing Fig.23. Flue duct length - rear Terminal assembly Flue turret assembly 1. Flue turret assembly 2. Clamp 3. Appliance 4. Fixing Screw NOTE: Extension duct measurements do not include the Fig.25 . Terminal assembly for internal socketed end.
  • Page 16 Fig.26. Flue bends Y-162 Plain tube If more than two extension ducts are needed in any section to achieve the required length then the final section of the assembly must not be less than 325mm without cutting the Fig.27 - Elbow to Flue Turret 120mm terminal assembly.
  • Page 17 Cover panel Fig.29. Facia connections cover Fig.30. Programmer cover Facia Controls connections cover Programmer connections Facia Fixing screw Facia bottom panel (clip-on) Fig 32 - Mains Voltage External Controls Connections NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Fig.31.

  • Page 18: Commissioning

    Fig. 35. Pump venting. 12. Commissioning The Appliance 12.1 Remove the appliance cabinet by removing the screw at the top centre of the cabinet. Pump Check that the electrical supply and the gas supply to the appliance are turned off and that all the water connections throughout the system are tight.
  • Page 19 Remove the clip-on facia bottom cover and the controls necessary for the central heating potentiometer to be adjusted to connections cover. Refer to Fig 29. change the burner pressure. If adjustment is required then the Slide down the access panel to display the mode switch and the adjusting tool is used to alter the setting of the potentiometer.

  • Page 20: Instructions To The User

    Refit the cabinet. starting any service procedures. If the appliance is to be passed over to the user immediately Always test for gas soundness after the service has been then set the controls to the users requirements. completed. If the appliance is to be left inoperative in frosty conditions then 14.3 Component Access set the programmer, if fitted, to off.
  • Page 21 Fig.41. Inner case components Flue spigot Inner casing Combustion products test point (front cap) Fan assembly Flue hood Overheat thermostat (at rear) Combustion chamber/flue hood fixing screws Primary sensor Heat exchanger Combustion Combustion chamber fixing chamber fixing screw screw Combustion chamber Burner Burner...

  • Page 22: Replacement Of Parts

    Fig.43. Flue hood Fig.42. Fan assembly Fan assembly Flue hood fixing screws Fan assembly fixing screws Air flow sensing tube Flue hood Air flow sensing tube (red) Flue hood Flue hood/Heat exchanger guide Fig.44. Burner assembly Burner blade Spark electrode assembly assembly Flame sense electrode...
  • Page 23 Fig.45 . Lower casing - gas and water Gas Valve controls. Pump connection Air flow switch Expansion vessel con- nection Water flow switch Pump Red tube (+ve) Pump connection Clear tube (-ve) Pressure gauge Relief valve Earth Boiler drain connection connection Transformer Facia assembly...
  • Page 24 Fig.48. Combustion Chamber Insulation. Fig.50. Pressure Gauge capillary fixing Pressure gauge capillary fixing clip Insulation panel-front Boiler drain ON/OFF Combustion chamber assembly Boiler drain Fixing tube screws connection (tube attached) Relief valve Pressure gauge Relief valve Insulation capillary fixing clip panel-side Do not omit the O-ring from the pressure capillary when fitting the replacement gauge.
  • Page 25 15.4.8 Flow Switch 15.4.10 Control Board Drain the DHW circuit as described in 15.3 preceding. Remove the facia bottom panel and carefully disconnect all the Remove the cabinet and lower the facia panel. electrical connections. Refer to Fig 33. Carefully pull off the connections from the micro-switch. Undo Remove the cabinet and lower the facia panel as described in the two union connections on the valve and remove the valve.
  • Page 26 15.4.11 Transformer Do not omit the heat transfer paste when fitting the replacement Remove the cabinet and lower the facia panel as described in sensor. Section 14, Inspection and Servicing. 15.4.16 Overheat Thermostat Unscrew the four screws and remove the metal cover. Refer to Fig Remove the cabinet and the inner casing.
  • Page 27 15.4.18 Pump Fig.60. Primary heat exchanger Check that the primary circuit has been fully drained as described in 15.3 preceding. Release the water connections and remove the pump. Refer to Heat Exchanger Fig 45. Disconnect and transfer the electrical connections to the new Central heating return Central heating flow pump.

  • Page 28: Short Parts List

    16. Short Parts List G.C. No. Part Manufacturer’s Reference Part No. E27-572 Flow Switch Prettl 8 717 002 122 0 E27-578 Water Filter Prettl 8 716 148 410 0 E27-580 Pressure Relief Valve Altechnic 8 716 156 764 0 E27-582 Pump Grundfos 59896603...

  • Page 30: Operational Flow Diagram

    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 Two minute CH light On. minimum Modulate gas Pump On.
  • Page 31 OVERRUN FUNCTION If primary temp above 80° fan If primary rises Fan overrun runs until temp above 85° fan END DHW function active below 80°C DEMAND runs until temp for 3 minutes (35 seconds falls below 80° minimum) If primary temp below 80°...

  • Page 32: Fault Finding

    19. 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 four 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 33 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 15.4.10) Replace fuse and investigate cause. Suggestions: Cable damage, connections to (or faults within) pump, fan, external 230V controls, transformer or board.
  • Page 34 With CH control knob fully clockwise, does There is no heat Is there 230V AC the boiler ignite and demand. Check room across terminal ST8 appear to run thermostat or mains pins LR and N? normally in central programmer (or link). heating mode? Red diode is Is there a link at...
  • Page 35 Replace control board. Is the boiler in a very (Section 15.4.10). cold environment (less Note: A damp board than 5°C)? could cause this fault. Boiler is running in “Autofrost stat” mode. See Section 17. Is the boiler fully Rectify fault. water pressurised and is all air vented? Repair or replace...
  • Page 36 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 spark electrode boiler. Can a flame be boiler.
  • Page 37 Is the multiway connector at board position ST16 pushed Push fully home fully home on to the board? Check the DHW sensor. Is it correctly Re-fix sensor onto pipe fitted onto the pipe with heat conductive paste between the pipe and sensor? Remove multiway connector from board position ST16.
  • Page 38 Turn off boiler. Is there Does the fan run Remove the fan continuity across the before the fault connector from board C and NO terminals of occurs? position ST1 and the air pressure switch restart the boiler. Is (where green wires are Replace control board.
  • Page 39 The gas valve mode Turn to 'NORM' switch (concealed by position the facia side panel) is not set correctly 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.
  • Page 40 This manual is to be used in conjunction with the variant part number of the bar code below: Manufactured exclusively for British Gas by Worcester Heat Systems Limited (Bosch Group), Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624. Fax: (01905) 754619. Technical Helpline 08705 266241.
  • Page 41 G.C. NUMBER : 47 311 53 USER INSTRUCTIONS & CUSTOMER CARE GUIDE...
  • Page 42 The result is that your new C1 appliance offers you the very best of everything - quality, efficiency, economical running costs, proven reliability and value for money.

  • Page 43: General Description

    WARNING: This appliance must be earthed and protected by a 3 amp fuse. ELECTRICITY SUPPLY: 230V ~ 50Hz IMPORTANT: To get the best from your C1 appliance please read these instructions carefully. NOTE: In the event of a fault the appliance should not be used until the fault has been corrected by a competent person.
  • Page 44 The flow is limited within the appliance to give a hot water delivery rate to a maximum of 10.0 (±15%) litres/minute (2.0 gallons/ minute). Hot Water and Central Heating mode: When a demand is made for heating by the system controls (i.e. a programmer or room thermostat).

  • Page 45: General Notes

    GENERAL NOTES CENTRAL HEATING SYSTEM During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. Should the upper area of a radiator be at a lower temperature than the base of the radiator, it should be vented by releasing air through the venting screw at the top of each radiator.

  • Page 46: Room Thermostat

    CLEARANCES Your installer will have provided adequate Left-hand side space around the appliance Right-hand side for safety and servicing. Do not restrict this space by In Front the addition of cupboards, Above the casing shelves etc. close to the Below appliance.

  • Page 47: Use In Hard Water Areas

    USE IN HARD WATER AREAS Normally there is no need for scale protection. However, in areas of exceptionally hard water supply it is recommended that an In-Line scale inhibitor be fitted. Installation should be strictly in accordance with the requirements of the local Water Company. An isolating valve to facilitate servicing should be incorporated.

  • Page 48: Domestic Hot Water Temperature

    OPERATION OF CONTROLS The appliance is fitted with the following controls: OPERATING SWITCH In the ‘0’ position there is no mains electricity to the control board. In the ‘I’ position mains electricity is connected to the control board. CENTRAL HEATING TEMPERATURE CONTROL The position of this knob will determine the temperature of the water delivered to the radiators between fully clockwise and anti-...

  • Page 49: Indicator Lights

    INDICATOR LIGHTS Mains electricity indicator: OFF : No mains electricity to the contol board ON : Mains electricity is connected to the appliance Central heating demand indicator: OFF : No demand for heat to the central heating circuit ON : Central heating or autofrost demand FLASHING SLOW : Ignition lockout (once per second) FLASHING FAST : Appliance fault (other than ignition...

  • Page 50: Electricity Supply

    TO LIGHT AND STOP THE APPLIANCE TO LIGHT THE APPLIANCE Check that the water valves to the central heating circuit are open. On sealed systems check that the grey needle on the pressure gauge is not below the required pressure. Switch on the mains electricity.
  • Page 51 The appliance can be reset by pressing the reset button and holding in for 5 seconds when the appliance has cooled. IGNITION LOCKOUT The appliance will enter a lockout condition in the event of the burner failing to ignite. If the burner fails to light after 5 attempts the electricity supply to the gas valve will be interrupted.
  • Page 52 APPLIANCE FAILS TO OPERATE If your C1 appliance should fail to operate correctly, please call British Gas on: 0845 9 60 50 40 IMPORTANT Do not touch or adjust any sealed component...
  • Page 53 MAINTAINING YOUR APPLIANCE Your new C1 gas-fired appliance represents a long-term investment in a reliable, high quality product. In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is...
  • Page 55 YOUR C1 GUARANTEE This appliance is guaranteed against faulty materials or workmanship for a period of twelve calendar months from the date of installation subject to the following conditions and exceptions. 1. That during the currency of this guarantee must be accompanied by...

  • Page 56: Guarantee Registration

    You should complete and return the postpaid Guarantee Registration Card within 14 days of purchase. The card will register you as the owner of your new C1 appliance and, while this will not affect your statutory rights in any way, it will assist us to maintain an effective and efficient customer service by establishing a reference and permanent record for your boiler.

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