Worcester 440CDi Instruction Manual

UK/IEINSTRUCTION MANUALINSTALLATION COMMISSIONING & SERVICING8 716 115 219c (03.2010)THE APPLIANCE IS FOR USE WITHNATURAL GAS OR L.P.G. (Cat II 2H

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS8 716 115 219c (03.2010)8 716 115 219c (03.2010)8MAINS SUPPLIESMAINS SUPPLIESGAS SUPPLY:• Boi

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS8 716 115 219c (03.2010)9WATER SYSTEMS & PIPEWORKPRIMARY SYSTEM PLASTIC PIPEWORK:• Any pl

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS8 716 115 219c (03.2010)10WATER SYSTEMS & PIPEWORKFILLING PRIMARY SYSTEMS:• The CH sealed

Soil & vent stack22mmØminimum 450mm and up to 3 storeysInvertCondensate drainage pipe can be run above or below ground25mmBottom of tube sealedLi

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS128 716 115 219c (03.2010)PRESSURE RELIEF PIPEWORKABA• The pressure relief drain pipe (A) sho

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONSBOILER LOCATION & CLEARANCES8 716 115 219c (03.2010)13• This boiler is only suitable for

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONSBOILER LOCATION & CLEARANCES8 716 115 219c (03.2010)14BOILER LOCATION &CLEARANCES600m

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS8 716 115 219c (03.2010)15MOUNTING FRAME CONNECTIONSCONNECTIONS:Water: 22mm compression fitti

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS16TERMINAL OUTLET POSITIONS8 716 115 219c (03.2010)TERMINAL OUTLET POSITIONSKey to illustrati

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS17TERMINAL OUTLET POSITIONS8 716 115 219c (03.2010)Key to illustration1. 600 mm distance to

INSTALLATION & SERVICING INSTRUCTIONSCONTACT INFORMATIONINSTALLATION & SERVICING INSTRUCTIONSCONTACT INFORMATIONINSTALLATION & SERVICING I

The diagrams (opposite) show thecomponents used and the maximum fluelength for each configuration of Ø100mm andØ125mm flues.• Only straight flue secti

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS19UNPACKING THE BOILER8 716 115 219c (03.2010)IMPORTANT: All the previous Pre-Installation sectio

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS20MOUNTING FRAME FIXING &FLUE OPENING8 716 115 219c (03.2010)MOUNTING FRAME FIXING &FLU

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS21MOUNTING FRAME CONNECTIONS8 716 115 219c (03.2010)CAUTION: ISOLATE THE MAINS GASSUPPLY BEFORE S

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS22FLUE LENGTHSFLUE MEASURING & CUTTING8 716 115 219c (03.2010)HORIZONTAL FLUE:(60/100mm diame

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS23FLUE MEASURING & CUTTING8 716 115 219c (03.2010)Flue bends:1 Connecting flue bends increase

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS24FLUE MEASURING & CUTTING8 716 115 219c (03.2010)FLUE MEASURING & CUTTINGFLUE OUTLETS (L

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS25FLUE INSTALLATION8 716 115 219c (03.2010)FLUE INSTALLATION1 Remove retaining screw (A) to swin

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS26STANDARD FLUE INSTALLATION8 716 115 219c (03.2010)STANDARD FLUE INSTALLATIONTOP110mm3BKGFHEEGHJ

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS27EXTENDED FLUE INSTALLATION8 716 115 219c (03.2010)EXTENDED FLUE INSTALLATIONTOPM110mm10N869MKCB

INSTALLATION & SERVICING INSTRUCTIONSCONTENTSSAFETY &REGULATIONSFAULT FINDING& DIAGRAMSAPPLIANCEINFORMATIONPRE-INSTALLATIONINSTALLATIONCOM

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS28FLUE TERMINAL PLUME MANAGEMENT8 716 115 219c (03.2010)FLUE TERMINAL PLUMEMANAGEMENTThe flue dis

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONSCONDENSATE, GAS & WATERCONNECTIONS29CONDENSATE, GAS & WATER CONNECTIONS8 716 115 219c (03

INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS30PRESSURE RELIEF VALVE OUTLET8 716 115 219c (03.2010)PRESSURE RELIEF VALVEOUTLETFitting the pres

NOTE:The mains electrical supply to the boiler andsystem wiring centre must be common andthrough either a common fused double poleisolator or a fused

COMMISSIONINGINSTALLATION & SERVICING INSTRUCTIONS32PRE-COMMISIONING CHECKS8 716 115 219c (03.2010)PRE-COMMISIONING CHECKSCAUTION: ISOLATE THE MAI

COMMISSIONINGINSTALLATION & SERVICING INSTRUCTIONS33FILLING THE SYSTEM8 716 115 219c (03.2010)FILLING THE SYSTEM1 Turn on the water main and open

COMMISSIONINGINSTALLATION & SERVICING INSTRUCTIONS34WATER TREATMENT8 716 115 219c (03.2010)IMPORTANT: Debris from the system candamage the boiler

IMPORTANT: Never run the appliancewhen the appliance or system is emptyor unpressurised.Switching the appliance on/off:1 Turn on mains power supply. T

COMMISSIONINGINSTALLATION & SERVICING INSTRUCTIONS36FINISHING COMMISSIONING8 716 115 219c (03.2010)FINISHING COMMISSIONINGNOTE:At the time of comm

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS37INSPECTION & SERVICE8 716 115 219c (03.2010)INSPECTION & SERVICEIMPORTANT: Any

SAFETY PRECAUTIONS INSTALLATION REGULATIONSIF YOU SMELL GAS:DO NOT SMOKE OR STRIKE MATCHES.DO NOT TURN ELECTRICAL SWITCHES ON OR OFF.PUT OUT NAKED FLA

SERVICE INSPECTION:1 Grip the outer sides of the front panel(A) pull and lift away from retaining lugs(B).2 Remove retaining screw (C) to swingcontrol

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS39INSPECTION & SERVICE8 716 115 219c (03.2010)INSPECTION & SERVICEIf the Heat Ex

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS408 716 115 219c (03.2010)INSPECTION & SERVICEINSPECTION AND SERVICEBurner:NOTE: On

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS41REPLACEMENT PARTS8 716 115 219c (03.2010)REPLACEMENT PARTSIMPORTANT: Any service work

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS42REPLACEMENT PARTS8 716 115 219c (03.2010)Fan Assembly: Undo lower pipe union on gas pi

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS43REPLACEMENT PARTS8 716 115 219c (03.2010)REPLACEMENT PARTSSensors: Check that the appl

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS44REPLACEMENT PARTS8 716 115 219c (03.2010)REPLACEMENT PARTSDomestic hot water heat exch

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS8 716 115 219c (03.2010)45REPLACEMENT PARTSREPLACEMENT PARTSElectrode assembly: Switch o

SETTING THE AIR/GAS RATIOSERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS46SETTING THE GAS/AIR RATIO8 716 115 219c (03.2010)GAS TYPECO2

SERVICING& SPARESINSTALLATION & SERVICING INSTRUCTIONS47SHORT PARTS LIST8 716 115 219c (03.2010)SHORT PARTS LIST1a Burner skin seal:Part No. 8

APPLIANCEINFORMATIONINSTALLATION & SERVICING INSTRUCTIONS3GENERAL INFORMATIONGENERAL INFORMATION8 716 115 219c (03.2010)STANDARD PACKAGE:A - Floor

CONVERSIONKITSINSTALLATION & SERVICING INSTRUCTIONS48L.P.G. CONVERSION8 716 115 219c (03.2010)Change code plug:1 Release three screws (A) to remov

FAULT FINDING& DIAGRAMSINSTALLATION & SERVICING INSTRUCTIONS49ELECTRICAL WIRING DIAGRAM8 716 115 219c (03.2010)ELECTRICAL WIRING DIAGRAMT2.5 A

FAULT FINDING& DIAGRAMSINSTALLATION & SERVICING INSTRUCTIONS50CENTRAL HEATING FUNCTION8 716 115 219c (03.2010)CENTRAL HEATING FUNCTIONONEYSIAM

FAULT FINDING& DIAGRAMSINSTALLATION & SERVICING INSTRUCTIONS518 716 115 219c (03.2010)DHW FUNCTIONDHW FUNCTIONIAMNWSTI HCNOGREENLGITHNOONEYST

FAULT FINDING& DIAGRAMSINSTALLATION & SERVICING INSTRUCTIONS52FAULT FINDING8 716 115 219c (03.2010)NOTE ; This fault finding information is fo

CONTROLS Tick the appropriate boxesTime and Temperature Control to Heating Room Thermostat and Programmable Load/Weather Optimum Start Program

S ERVICE RECOR DIt is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.Service Provider

APPLIANCEINFORMATIONINSTALLATION & SERVICING INSTRUCTIONS4TECHNICAL DATA8 716 115 219c (03.2010)TECHNICAL DATACentral HeatingMax. rated heat outpu

Worcester, Bosch GroupCotswold Way, Warndon, Worcester WR4 9SWTel. 0844 892 9900 Fax. 01905 754619Worcester, Bosch Group is a brand name of Bosch The

APPLIANCEINFORMATIONINSTALLATION & SERVICING INSTRUCTIONS5LAYOUT & COMPONENTSLAYOUT & COMPONENTS8 716 115 219c (03.2010)The diagram opposi

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS6CLEANING PRIMARY SYSTEMSCLEANING PRIMARY SYSTEMSCAUTION: ISOLATE THE MAINS SUPPLIES BEFORE S

PRE-INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS8 716 115 219c (03.2010)7MAINS SUPPLIESMAINS SUPPLIESELECTRICAL SUPPLY:• Supply: 230V - 50Hz.