Bosch Appliances Boiler 14 19CBI User Manual
9/14CBi, 14/19CBi, 19/24CBi  
WALL MOUNTED BOILERS FOR CENTRAL HEATING  
AND INDIRECT SUPPLY OF DOMESTIC HOT WATER  
INSTALLATION AND  
SERVICING INSTRUCTIONS  
Worcester supports the  
Benchmark code of practice  
This appliance is for use with Natural Gas or LPG (Cat II 2H3P).  
9/14CBi GC NUMBER 41 311 50 (N.G.)  
14/19CBi GC NUMBER 41 311 52 (N.G.)  
19/24CBi GC NUMBER 41 311 54 (N.G.)  
9/14CBi GC NUMBER 41 311 51 (LPG)  
14/19CBi GC NUMBER 41 311 53 (LPG)  
19/24CBi GC NUMBER 41 311 55 (LPG)  
APPLIANCE OUTPUTS  
9/14CBi N.G.  
14/19CBi N.G.  
19/24CBi N.G.  
Minimum 9.0 kW  
Maximum 14.0 kW  
Minimum 14.0 kW  
Maximum 19.1 kW  
Minimum 19.1 kW  
Maximum 23.5 kW  
9/14CBi LPG  
14/19CBi LPG  
19/24CBi LPG  
Minimum 10.0 kW  
Maximum 14.0 kW  
Minimum 14.0 kW  
Maximum 19.1 kW  
Minimum 19.1 kW  
Maximum 23.5 kW  
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.  
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working at a gauge pressure of at least 0.35bar above the relief  
valve setting if on a sealed system.  
Fig. 1. Water flow diagram.  
Where a storage system will not have a vent to atmosphere the  
installation must comply with Building Regulations and Water  
Company bye-laws. If connecting to an existing system the local  
authority should be informed.  
Pipes  
Return Flow  
2.7 Flue  
There are 3 fluing options available.  
(i)  
Rear Only Flue Kit.  
Flue can be fitted within  
the height of the casing from  
220mm to 375mm without  
cutting.  
The minimum length is  
100mm with cutting.  
No flue bends or extensions  
can be fitted to this system.  
Side view  
(ii)  
Multi-Directional Horizontal Flue Kit.  
Standard Flue Kit  
can be adjusted from  
425mm to 725mm without  
cutting.  
The minimum length is 250  
mm with cutting.  
Extended flue lengths upto  
Alternative position  
a
maximum of 2.5m  
of Flow and Return pipes  
(19/24CBi) and 3.0m (9/14  
and 14/19CBi) are available.  
NOTE: Flow pipe is at the rear  
in the alternative position.  
Flow Return  
Optional 45° and 90° flue  
bend kits are available  
NOTE: When using flue  
bends the maximum flue  
length is reduced (see  
Section 11.2.8).  
2.10 Operation  
Central Heating  
A demand for heat will ignite the burner. The temperature is  
controlled by the integral sensor. At the end of the demand the  
burner will go out and the pump will continue to run for up to 4  
minutes and the fan for 1 minute to dissipate the residual heat.  
Side view  
If access to the flue is a  
problem then this option  
combined with an internal  
flue fixing kit should be  
used.  
Domestic Hot Water:  
The supply of domestic hot water depends upon the type of hot  
water equipment installed and the control system.  
The use of unvented cylinders must be in accordance with the  
manufacturers instructions and relevant to British Standards.  
(iii) Vertical Flue Kit  
A vertical flue option is also available with flue lengths from  
1.1m (without cutting) to a maximum of 3.35m (19/24CBi) or  
4.1m (9/14 and 14/19CBi). Optional 45° and 90° bends are  
available with this option. NOTE: When using flue bends the flue  
length is reduced (see Section11.2.8).  
The boiler is despatched from the factory with the flow and  
return pipework prepared for top outlet connection.  
The pipework can be orientated to allow connection from the  
bottom by simply unplugging the bayonet style pushfit connec-  
tions.  
2.8 Controls  
A control knob adjusts the boiler temperature, switches the  
boiler ON or to STANDBY and acts as a lock-out reset.  
NOTE: When changing from a top connection to one at the bot-  
tom the pipe functions are reversed.  
Top flow pipe becomes the bottom return pipe.  
Top return pipe becomes the bottom flow pipe.  
2.9 Safety  
The appliance must not be operated with the inner casing cover removed.  
The gas and electricity supplies must be turned off before  
servicing or working on the appliance.  
The drain off point on the return pipe becomes an air vent if the  
pipes are reversed. In this case a drain point should be fitted  
close to the appliance.  
The casing is earthed through a push-on connector at the base.  
When the casing is refitted this connection MUST be remade.  
3
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3. Technical Data  
The data plate is fixed to the inner casing cover.  
Table 1.  
Factory set at maximum input  
NOMINAL BOILER RATINGS (10 Minutes After Lighting)  
APPLIANCE  
BURNER  
PRESSURE  
m bar.  
OUTPUT  
INPUT (Net)  
GAS RATE  
3
kW  
kW  
m /h  
14.00  
11.50  
9.00  
15.28  
12.70  
10.11  
20.57  
17.96  
15.38  
25.74  
23.35  
21.16  
15.28  
13.18  
11.17  
20.57  
17.96  
15.38  
25.74  
23.35  
21.16  
11.0  
7.3  
1.62  
1.41  
1.07  
2.18  
1.90  
1.63  
2.72  
2.47  
2.24  
0.63  
0.54  
0.45  
0.84  
0.73  
0.63  
1.05  
9/14CBi NG  
4.5  
14/19CBi NG  
19.05  
16.52  
14.00  
23.45  
21.25  
19.05  
14.00  
12.00  
10.00  
19.05  
16.52  
14.00  
23.45  
21.25  
19.05  
11.5  
8.5  
6.0  
12.0  
9.8  
7.8  
27.2  
20.4  
15.4  
25.4  
19.0  
13.9  
29.9  
24.6  
20.2  
19/24CBi NG  
9/14CBi LPG  
14/19CBi LPG  
19/24CBi LPG  
Table 2.  
0.96  
0.87  
Natural Gas: Net Input = Gross Input x 0.901  
Propane: Net Input = Gross Input x 0.921  
FLUE DETAILS  
HORIZONTAL FLUE  
mm  
110  
150  
425  
WALL HOLE DIAMETER  
EXTERNAL FIX  
INTERNAL FIX  
MINIMUM LENGTH  
MAXIMUM LENGTH  
MAXIMUM LENGTH  
MINIMUM LENGTH  
MAXIMUM LENGTH  
STANDARD TELESCOPIC FLUE KIT  
EXTENDED FLUE  
725  
2.5m (19/24CBi) or 3.0m (9/14 and 14/19CBi)  
INTERNAL FLUE - REAR ONLY WITHIN CABINET  
220  
375  
100  
FLUE ASSEMBLY DIAMETER  
VERTICAL FLUE  
MINIMUM LENGTH  
1100  
3.35m (19/24CBi) or 4.1m (9/14 and 14/19CBi)  
MAXIMUM LENGTH INCLUDING TERMINAL  
NOTE: FOR VERTICAL FLUE REFER TO A SEPARATE LEAFLET FOR INFORMATION  
Table 3 9/14CBi  
Table 3 14/19CBi  
HYDRAULIC RESISTANCE  
HYDRAULIC RESISTANCE  
FLOW/RETURN  
DIFFERENTIAL  
°C  
FLOW/RETURN  
DIFFERENTIAL  
°C  
BOILER OUTPUT RESISTANCE MIN. FLOW RATE  
BOILER OUTPUT RESISTANCE MIN. FLOW RATE  
kW  
Metres  
L/min.  
kW  
Metres  
L/min.  
0.06  
0.13  
0.28  
6.5  
20  
11  
11  
0.09  
0.26  
0.52  
10  
20  
11  
11  
9.0  
14.0  
11.7  
18.2  
18.2  
24.8  
14.0  
19 .05  
Table 3 19/24CBi  
NOTE: Pump is fitted externally  
HYDRAULIC RESISTANCE  
FLOW/RETURN  
DIFFERENTIAL  
°C  
BOILER OUTPUT RESISTANCE MIN. FLOW RATE  
kW  
Metres  
L/min.  
0.15  
0.52  
0.73  
13.7  
24.8  
30.5  
20  
11  
11  
19.05  
23.44  
4
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Table 4  
FLOW - COPPER TAILS  
MECHANICAL SPECIFICATIONS  
22mm  
RETURN - COPPER TAILS  
GAS INLET  
22mm  
15mm COMPRESSION  
600mm  
CASING HEIGHT  
CASING WIDTH  
CASING DEPTH  
WEIGHT - LIFT  
390mm  
260mm  
9/14CBi 28kg  
9/14CBi 41kg  
14/19 & 19/24CBi 33.5kg  
14/19 & 19/24CBi 47kg  
WEIGHT - PACKAGED  
Table 5  
PERFORMANCE SPECIFICATIONS  
9/14CBi 1.6 litres 14/19 & 19/24CBi 2.1 litres  
MINIMUM 1.2M MAXIMUM 30M  
82°C (nom)  
PRIMARY WATER CAPACITY  
STATIC HEAD  
MAXIMUM FLOW TEMPERATURE  
MAXIMUM CENTRAL HEATING SYSTEM OPERATING PRESSURE (Sealed System)  
2.5 bar  
MINIMUM CENTRAL HEATING SYSTEM SET PRESSURE  
OUTPUT TO CENTRAL HEATING  
(Sealed System)  
0.12 bar  
9/14CBi 9.0 - 14.0kw 14/19CBi 14.0 - 19.05kw 19/24CBi 19.05 - 23.45kw  
NOx CLASSIFICATION FOR CBi APPLIANCES  
SEDBUK NUMBER AND BAND*  
Class 1  
9/14CBi NG 78.5 D  
9/14CBi LPG 81.0 D  
14/19CBi NG 79.4 D  
14/19CBi LPG 81.7 D  
19/24CBi NG 78.4 D  
19/24CBi LPG 80.8 D  
* The value is used in the UK Government Standard Assesment Procedure (SAP) for the energy rating of dwellings. The test data from which it has been calculated  
have been certified by the GASTEC noified body.  
Table 6  
GAS SUPPLY SYSTEM - BASED ON NG (G20)  
TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres  
3
6
9
12  
3
MAXIMUMGAS DISCHARGERATE-PRESSUREDROP 1mbar. m /h PIPE DIAMETER mm  
8.7  
18.0  
5.8  
12.0  
4.6  
9.4  
3.9  
8.0  
22  
28  
GAS SUPPLY SYSTEM - BASED ON PROPANE (G31)  
TOTAL LENGTH OF GAS SUPPLY PIPE (COPPER) metres  
3
1.5  
8.0  
15.9  
6
9
12  
—
3.6  
7.2  
PIPE DIAMETER mm  
—
—
15  
22  
28  
5.2  
8.8  
4.2  
8.5  
Table 7  
CLEARANCES  
(mm)  
INSTALLATION  
SERVICE  
30  
ABOVE APPLIANCE - INTERNAL REAR FLUE  
30  
180  
600  
200  
5
ABOVE APPLIANCE - EXTERNAL FLUE TURRET  
IN FRONT OF APPLIANCE  
BENEATH APPLIANCE  
180  
600  
200  
5
RIGHT HAND SIDE  
LEFT HAND SIDE  
5
5 *  
**  
The appliance can be installed on the above clearance dimensions however, for improved access the following is suggested:  
* Improved access - 50mm is recommended  
** For improved access minimum clearance when fitted to an adjacent LHS wall is 100mm  
NOTE: It is possible to fit the appliance in an unventilated compartment. Refer to Section 6 for details.  
Table 8  
SEALED SYSTEM CAPACITY - 10 litre vessel  
TOTAL SYSTEM VOLUME litres  
INITIAL  
PRESSURE bar  
1.0  
INITIAL CHARGE PRESSURE bar  
0.5  
72  
39  
1.0  
92  
53  
1.5  
N/A  
64  
1.5  
5
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4. Siting The Appliance  
Fig. 3. Appliance pipework connections  
The appliance may be installed in any room subject 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.  
165mm  
FLOW  
RETURN  
If the appliance is installed in a room containing a bath or  
shower, any switch or appliance control using mains electricity  
must NOT be able to be touched by a person using the bath or  
shower.  
The appliance shall not be installed in a room or internal space  
below ground level when it is intended for use with LPG propane  
(G31). This does not preclude the installation into a room or  
space which are basements with respect to one side of the  
building but are open to the ground on the opposite side.  
The appliance is NOT suitable for external installation.  
The wall must be able to support the weight of the appliance.  
Refer to Table 4.  
The specified clearances must be available for installation and  
servicing. Refer to Table 7 and Fig.2.  
88mm 36mm  
25mm  
GAS  
The appliance can be installed in a cupboard/compartment to  
be used for airing clothes providing that the requirements of  
BS6798 and BS5440/2 are followed.  
The clearance between the front of the appliance and the  
cupboard/compartment door should be not less than 25mm for  
air circulation.  
Fig. 2. Appliance casing dimensions and  
required clearances.  
30mm*  
External  
flue turret  
150mm  
100mm  
30mm  
(Rear only flue)  
142mm  
Rear only flue  
36mm  
Rear only flue  
Side view  
Front view  
260mm  
600mm*  
390mm  
200mm*  
5mm*  
5mm*  
Fixing clip  
* Space required for installation and servicing. Refer to Table 7  
6
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5. Flue terminal positions  
6. Air Supply  
The flue system must be installed following the requirements of  
BS5440:1.  
The standard flue kit length is 425 - 725mm. Extension kits for  
flues up to 3.0m are available.  
A separate vent for combustion air is not required.  
The appliance can be fitted in a cupboard or compartment with  
no vents for cooling, but the minimum clearances must be  
increased to those given below. Refer to BS6798.  
A rear flue suitable for walls from 220 - 375mm thick is available  
which can be contained within the boiler casing.  
The terminal must not cause an obstruction nor the combustion  
products a nuisance.  
Note: the clearance at the front is to a removable panel, e.g. door.  
The user must be informed not to restrict the clearances by the  
addition of extra shelves etc and that flammable materials must  
not be stored in this compartment.  
If the terminal is less than 2m above a surface to which people  
have access then a guard must be fitted. The guard must be  
evenly spaced about the terminal and fixed with plated screws.  
A guard Type K2 can be obtained from Tower Flue Components,  
Vale Rise, Tonbridge, TN9 1TB.  
It is essential that products of combustion cannot re-enter the  
building. Refer to Fig 4.  
Above Appliance (when using Rear only Flue)  
30mm  
Above Appliance (when using  
horizontal flue) 180mm  
In front  
Below  
Right-hand side  
Left-hand side  
340mm  
200mm  
105mm  
105mm  
If the appliance is fitted in a cupboard or compartment with less  
clearance than those stated in the table above (minimum  
clearances are given in Section 4 Siting the Appliance) then  
permanent air vents for cooling are required, one at high level  
and one at low level. Both high and low level vents must  
communicate with the same room or must be on the same wall  
to outside air. The minimum requirements are:  
Model Position of vent  
Air from room Air from outside  
2
2
19/24CBi  
14/19CBi  
9/14CBi  
High  
Low  
High  
Low  
High  
Low  
255cm  
128cm  
2
2
255cm  
207cm  
128cm  
104cm  
2
2
2
2
207cm  
152cm  
104cm  
2
2
76cm  
2
2
152cm  
76cm  
Fig. 4. Siting of the flue terminal.  
If the boiler is fitted between kitchen units and a decorative  
door panel is fitted then the top and bottom of the space must  
be left open.  
*NOTE: A minimum of 75mm must be achieved  
where the terminal is near fusible or combustible  
material such as plastic drain pipes, guttering or a  
carport roof UNLESS suitable heat shields are  
provided.  
A
L
G
B,C  
K
L
D
K
F
F
HI  
A
G
M
F
J
E
TERMINAL POSITION  
MIN. DISTANCE  
TERMINAL POSITION  
MIN. DISTANCE  
A– directly below an openable window or  
I– From a terminal facing a terminal  
1200mm  
other opening e.g. air brick.  
300mm  
75mm  
25mm  
25mm  
25mm  
25mm  
300mm  
600mm  
J– From an opening in a car port (e.g. door  
B– Below gutters, soil pipes or drain pipes.*  
C– Below eaves.*  
D– Below balconies or car port roof.*  
E– From vertical drain pipes and soil pipes.*  
F– From internal or external corners.  
G– Above ground, roof or balcony level.  
H– From a surface facing a terminal.  
window) into dwelling.  
K– Vertically from a terminal on the same  
wall.  
L– Horizontally from a terminal on the same  
wall.  
1200mm  
1500mm  
300mm  
300mm  
M– From door, window or air vent.  
7
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7. System  
8. Domestic Hot Water  
The system must comply with requirements of BS6798 and  
BS5449.  
The appliance is NOT suitable for direct water supply.  
Do not connect to a direct cylinder.  
General:  
The CBi can be connected to any indirect cylinder, i.e unvented or  
thermal store, and all the benefits of a "dry loft" and mains  
pressure hot water can be realised. Contact The Worcester  
Technical Helpline. 08705 266241.  
The appliance is only suitable for connection to indirect fully  
pumped sealed and open vent systems. The minimum static  
head is 1.2m and the maximum is 30m.  
The pump MUST be wired to the boiler control to ensure that the  
pump-overrun function operates to prevent the risk of  
overheating and hence nuisance shutdown.  
The controls must be wired to ensure that the boiler does not  
cycle when electronically controlled zone valves are closed.  
A by-pass is required if the controls i.e. 2-port valves, can result  
in the closure of the CH and DHW circuits when the boiler is hot.  
If mechanically operated thermostatically controlled valves are  
fitted on all radiators then a by-pass located at least 2m from the  
boiler is required.  
Cylinder  
Indirect coil type or a direct cylinder with an immersion calorifier  
that is suitable for a pressure of 0.35bar above the setting of the  
pressure relief valve. Single feed indirect cylinders are NOT  
suitable for sealed systems. Any connection to the mains water  
supply must conform to the relevant Building and Water  
Regulations and be approved by the local Water company.  
A bypass is generally unecessary on a system using a 3 way diverter  
valve as one port will be open to flow at all times. This will be  
satisfactory for the pump overrun requirement. However if TRV's are  
used throughout then a bypass or open radiator may be necessary.  
Sealed System:  
A sealed system must include an expansion vessel, pressure  
relief valve and pressure gauge - these are available as  
proprietary kits, the sealed system expansion vessel and fittings  
must be connected at the neutral point of the system on the  
entry to the pump. A pump and diverter valves are also required  
as appropriate to the system. Refer to Fig 5,6,7.  
The sealed system must be filled through a WRc approved filling  
kit. Refer to Fig.8. The approved method for temporary  
connection for filling a closed circuit in a house can be found on  
Page 8.25. Fig R24-2a of the Water Regulation Guide and Water  
Bylaws 2000 Scotland.  
The appliance must not be operated without the system being  
full of water and correctly pressurised.  
All connections in the system must withstand a pressure of up to  
3 bar.  
The system and the appliance must be properly vented.  
Repeated venting loses water from the system and usually  
indicates that there is a leak.  
For system wiring please refer to  
Fig. 10. and the controls  
manufacturers details.  
Fig. 5. System layout if using Honeywell 'Y' plan  
Feed and  
Vent Cistern  
S.H. – Minimum static head 1.2m  
measured from the highest point in the  
heating system (top surface of the appliance  
S.H.  
or highest point in the heating system) to the  
Primary  
S.H.  
water level in the feed and expansion tank  
cold feed  
Domestic hot  
water cylinder  
(15mm min.)  
Heating vent  
(22mm min.)  
Diverting  
valve  
N.B. A drain cock should be  
installed at the lowest point of  
the heating circuit  
Pump  
Radiator  
Boiler  
Bypass or  
150mm max  
uncontrolled  
radiator  
(if required)  
8
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For system wiring please refer to  
Fig. 10. and the controls  
manufacturers details.  
Fig. 6. System layout if using Honeywell 'S' plan  
Feed and  
Vent Cistern  
S.H. – Minimum static head 1.2m  
measured from the highest point in the  
heating system (top surface of the appliance  
S.H.  
or highest point in the heating system) to the  
Primary  
S.H.  
water level in the feed and expansion tank  
cold feed  
Domestic hot  
water cylinder  
(15mm min.)  
Heating vent  
(22mm min.)  
Diverting  
valves  
N.B. A drain cock should be  
installed at the lowest point of  
the heating circuit  
Pump  
Radiator  
Boiler  
Bypass or  
uncontrolled  
radiator  
150mm max  
For system  
wiring  
Fig. 7. Fully pumped sealed system.  
please refer to  
Fig. 10. and the  
controls  
manufacturers  
Note:  
A drain cock  
INDIRECT  
CYLINDER  
details.  
LV  
LV  
should be fitted  
RV  
RV  
at the lowest  
point of the  
heating circuit  
and beneath  
the appliance  
APPLIANCE  
LV  
LV  
RV  
Pressure  
Gauge  
RV  
Bypass  
balancing valve or  
bathroom  
Expansion  
Vessel  
radiatior with two  
lockshield valves  
Relief  
Valve  
Radiator Valve - Flow RV  
Lockshield Valve - Return LV  
Mains Cold Water  
BS  
Stop Valve Fixed Cylinder Type or sealed systems - Approved connection  
Fig. 8. Sealed system filling and make-up.  
Make up  
vessel  
Auto  
Heating return  
air vent  
Non return  
valve  
Stop  
cock  
1200mm (48 in)  
above the highest  
point of the system.  
Fill point  
9
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10. Electrical  
9. Gas Supply  
The gas supplier must be contacted to check the suitability of  
the appliance for the local gas supply conditions before  
connecting the appliance.  
Mains Supply: 230V, 50 Hz, 125 watts.  
External Fuse: 5A (must be to BS1362).  
Internal Fuse: F1 4A (Spare supplied with appliance).  
IP Rating: IP 20.  
3
The 19/24CBi appliance requires a maximum of 2.72 m /h of  
3
natural gas (G20), 1.05 m /h propane (G31).  
The appliance must be earthed and it must be possible to  
completely isolate the appliance.  
3
The 14/19CBi appliance requires a maximum of 2.18 m /h of  
3
The mains cable must be 0.75mm2 (24 x 0.2mm) to  
BS6500 - Table 15 or 16  
natural gas (G20), 0.84 m /h propane (G31).  
3
The 9/14CBi appliance requires a maximum of 1.62 m /h of  
3
natural gas (G20), 0.63 m /h propane (G31). Refer to Table 1.  
Mains supply to the boiler and system wiring centre must be  
through a common fused double pole isolator situated adjacent  
to the appliance. The isolator must have a contact separation of  
3mm minimum in all poles. A single switched live cable should  
be wired into the boiler from the system wiring centre.  
The mains and pump cables must be fed through the mains lead  
bracket, secured through the cable clamp and connected to the  
connector plug. Refer to Fig. 9, 10 and 11.  
Frost protection of the boiler is provided on the control board.  
A frost thermostat should be considered where parts of the  
system are remote from the appliance. For any frost thermostat  
function, the boiler temperature control knob must not be set to  
the 'OFF' position. The frost thermostat must be fitted to the  
system junction box in accordance with the manufacturers  
instructions. Refer to Fig. 11.  
A natural gas appliance must be connected to a governed meter.  
The installation of the gas supply to the appliance must be in  
accordance with BS6891.  
The meter and the pipework to the appliance must be checked,  
preferably by the gas supplier, to ensure that a dynamic pressure  
of 20mbar for natural gas is available at the appliance  
[equivalent to about 19.0 mbar at the gas valve inlet pressure  
connection] and that the gas flow is adequate for all the installed  
gas appliances or a dynamic pressure of 37 mbar equivalent to  
36 mbar at gas valve inlet pressure connection on propane (G31).  
Safety Check: If there is an electrical fault after installation check  
for fuse failure, short circuits, incorrect polarity of connections,  
earth continuity or resistance to earth.  
Fig.9 . Mains electricity and controls  
10  
connections.  
11  
12  
13  
14  
9
1
2
8
7
Earth post detail.  
Note: Pump earth (top connection)  
Mains earth (bottom connection)  
3
4
5
6
Pump Earth  
Mains Earth  
9. Gas valve connection  
10. Mains lead bracket  
1. Base plate  
2. Control board  
3. Control knob  
4. Fuse 4A  
11. Spark electrode connection  
12. Air pressure switch, temperature sensor,  
overheat thermostat connection  
13. Fan connection  
5. External control connector block  
6. Earth post  
7. Cable clamp  
8. Internal earth connection  
14. Flame sense connection  
10  
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Fig.10. Boiler wiring diagram  
Polarity of these connections is not  
important.  
Fan  
*
Air pressure  
switch  
*
white  
NC  
grey  
NO  
brown  
COM  
Overheat  
Thermostat  
orange  
black  
*
Spark  
Electrode  
Flame  
Sense  
Electrode  
Temperature  
sensor  
*
Gas Valve  
X4  
1
1
X6  
X5  
X3  
X7  
1
Control Board  
blue  
X2  
brown  
earth  
Pump Live  
Pump Neutral  
Installer  
Connections  
X1  
Permanent Neutral  
Permanent Live  
User control  
potentiometer/switch  
Switched Live (Boiler Demand)  
3 pin header  
11  
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Fig.11 . System wiring diagram  
System components wired into terminal strip  
in accordance with component manufacturers instructions  
System  
wiring centre  
Boiler/pump  
demand from  
system wiring  
centre  
L switched  
Terminal strip  
Pump not to be  
connected to  
system wiring  
centre  
230V 50Hz  
(5A Fuse)  
E
N
L
Common isolator  
for wiring centre  
and boiler  
Pump  
(supplied from  
boiler only)  
Should be located  
adjacent to the  
boiler  
OUTSIDE OF BOILER  
INSIDE OF BOILER  
Cable clamp  
Control Board  
Pump L  
Pump N  
Permanent N  
Permanent L  
Switched L  
(Boiler Demand)  
X1  
Earth post  
12  
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Fig. 12a. Boiler Assembly 9/14CBi  
Shown set for Rear Only flue kit  
26  
18  
17  
20  
19  
21  
16  
22  
1
15  
2
14  
3
13  
25  
4
12  
11  
5
24  
23  
6
9
10  
7
8
1. Inner case  
14. Overheat thermostat  
15. Air pressure switch  
16. Flow pipe  
2. J bolts and wing nuts (2)  
3. Combustion chamber cover  
4. Burner  
17. Return pipe  
5. Burner fixing screw  
6. Control knob  
18. Combustion test point  
19. Sensing tubes  
7. Indicator lights  
20. Fan  
8. Base/controls fixing screw  
9. Cabinet fixing screw  
10. Gas valve  
21. Flue hood  
22. Inner case cover fixing points (4)  
23. Outer case earth tag  
24. Side cover plate  
25. Wire clip  
11. Spark electrode  
12. Burner injector  
13. Temperature sensor  
26. Pressure tube junction  
13  
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Fig. 12b. Boiler Assembly 14/19 and 19/24CBi  
Shown set for  
horizontal flue or vertical flue  
17  
18  
20  
21  
19  
16  
22  
23  
15  
1
2
14  
13  
3
27  
26  
4
12  
11  
5
25  
24  
6
10  
8
7
9
1. Inner case  
15. Air pressure switch  
16. Flow pipe  
2. J bolts and wing nuts (2)  
3. Combustion chamber cover  
4. Burner  
5. Burner fixing screw  
6. Control knob  
7. Indicator lights  
8. Base/controls fixing screw  
9. Cabinet fixing screw  
10. Gas valve  
11. Spark electrode  
12. Burner injector  
17. Return pipe  
18. Combustion test point  
19. Sensing tubes  
20. Fan  
21. Fan clamp (2 screws)  
22. Inner case cover fixing points (4)  
23. Flue hood  
24. Outer case earth tag  
25. Side cover plate  
26. Wire clip  
13. Temperature sensor  
14. Overheat thermostat  
27. Front baffle  
14  
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Fig. 13b . Flue and wall plate  
11. Installing The Appliance  
NOTE: READ THIS SECTION FULLY BEFORE COMMENCING THE  
INSTALLATION  
To install a boiler with a rear only flue refer to Section 11.1.  
To install a boiler with a  
to Section 11.2.  
telescopic horizontal flue kit refer  
To install a boiler with a vertical flue refer to Section 11.2. and the  
literature with the flue kit.  
11. Installation of the Boiler with a  
Rear Only Flue Kit  
Flue fixing position  
11.1 Unpacking the Boiler  
Check the contents against the packing list.  
Remove the wall mounting template, the mounting plate  
assembly and the external flue turret connector and restrictors.  
11.1.4 Flue Preparation  
11.1.2 Site Preparation  
(i)  
Drill the hole for the flue at 110mm diameter.  
Check that the correct position for the appliance has been chosen  
and that the wall is sound, flat and will support the weight of the  
appliance. Refer to Sections 4 & 5 and Tables 4 to 8.  
(ii)  
Fix the wall-mounting plate - do not fully tighten the  
screws.  
11.1.3 Fixing Holes and Flue Opening  
(iii) Measure the wall thickness L - Min 220mm, Max 375mm.  
If L is less than 220mm thick then it is necessary to cut  
the flue. To do this subtract L from 220 and cut all flue  
parts by this amount.  
Hold the template to the wall. Check that the template is level.  
Mark the position of the fixing holes and the flue opening. Refer to Fig 13.  
Mark the position of the bottom fixing point for a screw or  
optional security bolt.  
Ensure that the ducts are square and free from burrs.  
Always check dimensions before cutting.  
The minimum length L is 100mm with cutting.  
Fig. 13 . Fixing the wall mounting plate.  
(iv) Adjust the telescopic flue assembly to a length L+5mm  
and secure with the screw supplied. Refer to Fig. 14.  
(v)  
Apply the plastic tape onto the duct in contact with the  
wall (position shown in Fig. 14.).  
Centre line  
of boiler  
(vi) Remove the inner flue duct (with the fixing bar).  
(vii) Push the outer duct assembly through the wall mounting  
plate and wall. Tighten the wall mounting plate fixing  
screws after checking that the plate is level.  
Centre line  
of flue  
Fig. 14 . Flue assembly - Rear Only Flue Kit  
6
Fig. 13a . Wall plate  
4
36mm  
L + 5  
Top of  
boiler to  
centre of  
flue  
3
=142mm  
1
Tape  
2
5
Centre line of boiler  
Centre line of flue  
1. Telescopic flue assembly  
2. Terminal  
3. Flange  
4. Flue tube with fixing bar  
5. Indents  
6. Gasket - fitted to inner case  
15  
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Fig. 14a . Rear only flue assembly  
3
L + 5  
6
Tape  
2
4
1
5
1. Telescopic flue assembly  
2. Terminal assembly  
3. Flange / flue assembly  
4. Indents  
5. Wall mounting plate  
6. Flue tube with fixing bar  
11.1.6 Install the Boiler  
Fig. 14b . Rear of casing  
IMPORTANT: Thoroughly flush the system before connecting the  
boiler. Any system cleanser must be flushed from the system  
before adding any inhibitor.  
(i)  
Lift the boiler onto the wall mounting plate. See Fig. 15.  
(ii)  
Level the boiler using the two levelling feet at the base of the  
back panel.  
(iii) Fit the bottom fixing screw (or optional security screw).  
(iv) Connect the gas supply using the nut and olive supplied in the  
literature pack - details of the position are shown in Fig. 3.  
(v)  
Connect the flow and return pipes to the system. It is important  
that the flow and return pipes are not fixed near to the boiler  
using clips that put a strain on the connections.  
A drain point should be fitted close to the appliance if bottom  
connections are made.  
Always consider the possible need to disconnect and remove  
the boiler.  
Gasket  
11.1.7 Installation of Flue onto Boiler  
(i)  
Pull the flue into position so that the holes in the flange  
line up with those in the case  
NOTE: The correct rectangular flue restrictor must now be fitted  
11.1.5 Boiler Preparation  
when the boiler is on the wall.  
9/14CBi and 14/19CBi  
66 X 62 (Rectangular)  
19/24CBi  
77 X 62 (Rectangular)  
(i)  
Remove the appliance casing by releasing the screw at  
the centre base. Disconnect the earth connection at the base  
and lift off.  
(ii)  
From the inside, place the correct restrictor in position  
over the flue opening and using the screws provided, fix  
through the inner casing into the flue system.  
(ii)  
Release the four screws and remove the inner casing cover.  
(iii) Release the two wing-nuts and remove the combustion  
chamber front panel. The cover is located into notches at  
the base of the side plates. Leave the stainless steel baffles  
in place.  
(iii) Slide the inner flue duct with fixing bar into the flue.  
(iv) Slide the fluehood and fan assembly back into position  
engaging the fan outlet into the inner duct assembly  
and reconnect the fan electrical terminals (polarity is not  
important). Reconnect the pressure sensing tubes onto the  
junction pieces. See Fig. 16.  
(iv) Disconnect the fan electrical terminals and the sensing  
tube from the junction pieces. Slide the flue hood/fan  
assembly out of the boiler.  
(v)  
Ensure that the combustion chamber is slotted underneath  
the flue hood and re-assemble with the combustion  
chamber front and 'J' bolts.  
(v)  
From the literature pack take the self adhesive gasket  
and stick around the rear flue opening on the outside of  
the casing ensuring that the fixing holes are not blocked  
(see Fig. 14b).  
16  
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Fig. 15 . Fixing the appliance to the wall mounting plate.  
2
6
5
8
1
7
1. Telescopic flue assembly  
2. Wall mounting plate  
3
3. Fixing or security screw  
4. Levelling feet (2)  
5. Restrictor plate with rectangular hole  
6. Gasket  
7. Flue fixing screws  
8. Flue tube with fixing bar  
4
Fig. 16 . Fan/Flue hood Assembly with Rear Only Flue Kit  
5
NOTE: The polarity of wires is  
not important  
6
11  
9
—ve  
1
10  
1. Flue hood  
2. Fan  
+ve  
3. Sensing connection (+)  
4. Sensing connection (—)  
5. Top outlet sealing plate  
6. Fan lead clip  
+
7. Fan fixing screws (2)  
8. Pressure tube junction  
9. — ve pressure tube  
8
7
4 ( — )  
2
10. + ve pressure tube  
12  
(clear tube)  
11. — ve pressure tube extension  
12. + ve pressure tube extension  
3 (+)  
(red tube)  
17  
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11.1.8 Completion of the Installation  
Check that all the gas and water connections have been  
tightened.  
Fig.17 . Mains electricity and controls  
connections.  
10  
11  
12 13  
Lower the base plate/control panel. Refer to Fig. 17.  
The permanent mains and switched live supply to the boiler  
must come from the system junction box. Refer to Fig.11. A 4  
core cable is recommended.  
9
14  
1
Feed the 4 core cable and the pump cables through the bracket  
and secure in the cable clamp. Refer to Fig. 17.  
2
Fit all the supply and pump wires to the 5 way plug before fitting  
the plug to the socket on the board. This will avoid stress to the  
board when using a screwdriver. Refer to Fig.11. for the  
connections.  
8
7
Check that the cables cannot touch the inner casing.  
Test for gas soundness as described in BS6891.  
4
6
5
3
1. Base plate  
2. Control board  
3. Control knob  
4. Fuse 4A  
5. External control connector block  
6. Earth post  
7. Cable clamp  
9. Gas valve connection  
10. Mains lead bracket  
11. Spark electrode connection  
12. Air pressure switch,  
temperature sensor,  
overheat thermostat  
connection  
13. Fan connection  
14. Flame sense conection  
If the appliance is not commissioned immediately, refit the  
combustion cover, inner casing cover, base/controls assembly  
and the casing. Re-connect the earth connection at the base of  
the casing. Check that the gas and electricity services have been  
turned off.  
REFER NOW TO SECTION 12 - COMMISSIONING THE  
APPLIANCE  
8. Internal earth connection  
9. Gas valve connection  
11.2.4 Boiler Preparation  
11.2 Installation of the Boiler with a  
Telescopic Horizontal Flue Kit  
(i)  
Remove the appliance casing by releasing the screw at  
the centre base. Disconnect the earth connection at the base  
and lift off.  
11.2.1 Unpacking the Boiler  
Check the contents against the packing list.  
Remove the wall mounting template, the mounting plate  
assembly and the flue spigot and restrictors.  
The flue spigot is positioned within the boiler carton and not in  
the accessory pack.  
(ii)  
Release the four screws and remove the inner casing cover.  
(iii) Release the two wing-nuts and remove the combustion  
chamber front panel. The cover is located into notches at  
the base of the side plates. Leave the stainless steel baffles  
in place.  
11.2.2 Site Preparation  
(iv) Disconnect the fan electrical terminals and the sensing  
tube from the junction pieces. Slide the flue hood/fan  
assembly out of the boiler.  
Check that the correct position for the appliance has been chosen  
and that the wall is sound, flat and will support the weight of the  
appliance. Refer to Sections 4 & 5 and Tables 4 and 8.  
(v)  
Remove the blanking plate from the top of the inner  
casing and refit onto the rear flue opening ensuring a good  
seal.  
11.2.3 Fixing Holes and Flue Opening  
Hold the template to the wall. Check that the template is level.  
Mark the position of the fixing holes and the flue opening. Refer to Fig 13.  
Mark the position of the bottom fixing point for a screw or  
optional security bolt.  
(vi) From the literature pack take the self adhesive gasket  
and stick around the top flue opening on the outside of  
the casing ensuring that the fixing holes are not blocked  
(see Fig. 19).  
Drill the 5 fixing holes 60mm deep for the No.12 size plugs.  
(vii) Fix the spigot and the appropriate restrictor (if the flue is  
less than 1m in length) to the top of the inner casing. Refer  
to Fig. 19.  
Fig. 18. Fixing the wall mounting plate.  
The fixing screw hole on the spigot must be pointing to  
the front.  
Centre of boiler  
IMPORTANT:  
9/14CBi and 14/19CBi  
Ø72mm  
Top Exit Restrictors  
19/24CBi  
Ø79mm  
(viii) The boiler is supplied for flow and return connections at  
the top. If a bottom connection is required then pull out  
the clips, remove and invert the pipes. Refer to Fig. 1.  
NOTE: When changing the connections the pipe functions are  
reversed -  
Top flow becomes the bottom return  
Top return becomes bottom flow  
18  
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(iii) The method of installation of the flue system may be  
varied to suit the actual site conditions. The instructions  
for connecting and fixing the ducts must, however, be  
strictly followed.  
Fig.19. Flue turret fixing and combustion  
sensing point  
1
1
2
8
Remove all packing material from the flue components.  
7
The standard telescopic flue assembly is suitable for lengths  
from 425mm up to 725mm measured from the centre-line of the  
boiler flue outlet to the outer face of the wall. Refer to Fig. 17.  
1. Flue spigot fixing screws  
2. Flue spigot  
3. Restrictor ring (if required)  
4. Gasket  
5. Flue spigot fixing holes  
6. Combustion sensing  
point  
3
If the length needed is greater than 725mm then extension duct  
kit/s will be required - each kit extends the flue by 750mm up to  
a maximum of 2.5m (19/24CBi) or 3.0m (9/14 and 14/19CBi).  
See table below.  
4
5
7. Clamping ring  
8. Fixing screw hole  
EXTENSION  
MAXIMUM FLUE LENGTH mm  
1475  
6
1
2
3
3
2225  
2500 (19/24CBi)  
2975 (9/14 and 14/19CBi)  
(iv) Measure length L. Refer to Fig 20, 21, 22.  
(v)  
For installation of standard flue up to 750mm refer to  
Section 11.2.6.  
For installation of flue greater than 750mm refer to  
Section 11.2.7.  
11.2.5 Flue Preparation  
For installation of bend kits refer to Sections above and  
Section 11.2.8.  
(i)  
Drill the hole for the flue at Ø110mm unless the optional  
internal fitting kit (WHS part No. 7 716 191 019) is used in  
which case a Ø150mm hole is required.  
For installation of vertical adaptor refer to Section 11.2.9.  
For installation of internal fitting kit refer to Sections  
above and Section 11.2.10.  
(ii)  
Fix the wall mounting plate onto the wall. Ensure it is level  
before tightening the screws.  
Fig.20 . Extension Duct.  
Tape  
L
Turret  
assembly  
Terminal  
Fixing screws  
Fixing screw  
assembly  
Ducts of equal length  
Appliance casing  
Shorten first extension fitted  
to the turret assembly if more  
than one extension is fitted  
Fig.21. Flue duct length (side flue).  
Fig.22 . Flue duct length (rear flue).  
L
Tape  
L
Fixing  
screws  
Fixing  
screws  
Terminal  
assembly  
Flue  
Turret  
assembly  
Tape  
External  
wall face  
Rear face of appliance  
and face of mounting  
wall  
19  
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11.2.6  
Telescopic Horizontal Flue Kit up to  
750mm in Length  
11.2.8 Flue Bends  
90° and 45° directional bends are available. A maximum of two  
45° or 90° bends may be used in addition to the first bend on  
the flue turret.  
A 90° bend is equivalent to 750mm of straight duct.  
A 45° bend is equivalent to 375mm of straight duct.  
(i)  
The standard flue can be telescopically adjusted to any  
length between 425mm and 725mm.  
It will only be necessary to cut the standard assembly if  
L<425mm. Cut the flue turret assembly and the terminal  
assembly by the same amount i.e L=350 - remove 75mm  
from each assembly.  
Measure the lengths X and Y. Refer to Fig.23.  
The maximum value of X using the turret assembly only is  
506mm. Reduce the ducts to the appropriate length e.g. X =  
406mm, cut 100mm from the air duct and 120mm (to cover the  
entry into the 45° or 90° elbow) from the flue duct. Refer to  
Fig.24.  
The minimum length L is 250mm with cutting.  
General: Cut the ducts as necessary, ensuring that the ducts are  
square and free from burrs. Always check the dimensions before  
cutting.  
The final section, dimension Y, of the flue system must include a  
section of plain duct assembly i.e . an extension assembly with  
the sockets removed. Reduce the final section, including the  
terminal assembly, by the appropriate amount i.e. Air duct Y -  
81mm and the flue duct Y - 51mm. Refer to Fig.23.  
(i)  
Fix the flue assembly together using the self-tapping  
screws provided. Refer to Fig. 21, 22.  
(ii)  
Apply the plastic tape onto the duct in contact with the  
wall (see Fig. 21, 22).  
If an internal fitting kit is to be used refer now to Section 11.2.10  
otherwise refer to Section 11.2.11.  
If Y is smaller than425mm it will be necessary to cut the air and  
flue ducts of the extension to a plain length of 100mm and  
reduce the length of the terminal assembly e.g. Y=350mm -  
remove 75mm from the terminal assembly.  
11.2.7  
Telescopic Horizontal flue Kit  
Greater Than 750mm in Length  
If Y is between 425 and 725mm it is not necessary to cut the  
terminal assembly or use a second extension duct as the length  
can be set telescopically.  
If bends are to be used refer also to Section 11.2.8.  
(i)  
By adding extension duct kits to the standard flue kit it is  
not necessary to cut the extension ducts if  
If Y is greater than 725mm then two extension duct assemblies  
will be required, the first assembly being cut to length as plain  
tubes.  
L is between  
1175 - 1475mm (1 extension)  
1925 - 2225mm (2 extension)  
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  
terminal assembly.  
NOTE: The flue duct of the final extension must be 30mm longer  
than the air duct.  
(ii)  
However extension ducts need to be cut if  
L is between  
725 - 1175mm (1 extension)  
1475 - 1925mm (2 extension)  
2225 - 2500mm (3 extension) 19/24 CBi  
2225 - 2975mm (3 extension) 14/19 and 19/24CBi  
Each section must be connected to the previous section of the  
flue bend by fixing the flue ducts together and then similarly  
fixing the air ducts which engage the elbows.  
(iii) To shorten the duct the first extension only should be cut.  
To work out the length to be cut off:  
Fix the flue assembly together using the self tapping screws  
provided.  
(No. of extensions x 750) + 425 — L = length to be cut.  
NOTE: Extension duct measurements do not include the  
socketed end. Unless specifically instructed the socketed  
end must not be removed.  
Apply the plastic tape onto the duct in contact with the wall (see  
Fig. 23).  
If an internal fitting kit is to be used refer now to Section 11.2.10  
otherwise refer to Section 11.2.11.  
(iv) Fix the flue assembly together using the self tapping  
screws provided (see Fig. 20).  
(v)  
Apply the plastic tape onto the duct in contact with the  
wall (see Fig. 20).  
Tape  
If an internal fitting kit is to be used refer now to Section 11.2.10  
otherwise refer to Section 11.2.11.  
Fig. 23. Flue bends.  
Swaged ends  
Plain ends  
Y
Note: Connections to and from  
bend should be plain ended and  
the same length.  
X
20  
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Fig.26 . Terminal assembly for internal  
Fig. 24 - Elbow to Flue Turret  
Assembly.  
fitting of the flue.  
120mm  
100mm  
Tape  
5
1
Flue Turret  
4
3
2
Bend  
1. Flue centring ring  
2. Air duct  
3. Flue duct  
4. Rubber sealing gasket  
5. Flue Terminal  
11.2.9 Vertical Adaptor for Horizontal Flues  
An adapter is available for an initial short section of vertical flue.  
Refer to Fig. 25.  
Rubber sealing  
gasket  
Measure and cut the flue as described in Section 11.2.7.  
The first, vertical, section (equivalent to dimension X) is  
measured from the top of the boiler casing. Cut the vertical  
section of the extension duct to 167mm less than the measured  
distance. Do not remove the socketed ends.  
Flue terminal  
Clamping ring  
The minimum measured distance is 167mm.  
Seal the air duct to the turret using silicone sealant.  
11.2.11 Install the Boiler  
Fig.25 Vertical Adaptor  
IMPORTANT: Thoroughly flush the system before connecting the  
boiler. Any system cleanser must be fully flushed from the system  
before adding any inhibitor.  
Flue Duct  
(i)  
Lift the boiler onto the wall mounting plate. See Fig. 27.  
(ii)  
Level the boiler using the two levelling feet at the base of the  
back panel.  
Air Duct  
(iii) Fit the bottom fixing screw (or optional security screw).  
(iv) Connect the gas supply using the nut and olive supplied in the  
literature pack - details of the position are shown in Fig. 3.  
(v)  
Connect the flow and return pipes to the system. It is  
important that the flow and return pipes are not fixed  
near to the boiler using clips that put a strain on the  
connections.  
Clamping  
Adaptor  
ring  
A drain point should be fitted close to the appliance if bottom  
connections are made.  
Always consider the possible need to disconnect and remove  
the boiler.  
Fixing screw hole  
Flue Spigot  
Fig. 27 . Fixing the appliance to the wall  
mounting plate.  
11.2.10 Fitting of the Flue Assembly without access  
to the Terminal  
4
An internal flue fixing kit (WHS part No. 7 716 191 019) is  
available from Worcester, Bosch Group.  
NOTE: A larger diameter opening (Ø150mm) in the wall is  
required. Refer to Table 2.  
3
Prepare the flue assembly as described in Section 11.2.6 - 11.2.8.  
Fit the rubber sealing gasket centrally onto the terminal  
assembly and tighten the clamp. Refer to Fig. 26.  
Apply the plastic tape to the air duct in contact with the external  
brickwork.  
Appliance  
2
From inside push the assembly through the wall so that the  
gasket flange is against the outer face. Refer to Fig. 26.  
It may be necessary to adjust the legs of the flue centring ring.  
1. Levelling feet (2)  
2. Fixing or security  
screw  
3. Boiler support  
4. Wall plate  
1
21  
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Fig.29 . Flue Turret Fixing .  
11.2.12 Installation of Flue onto Boiler  
(i)  
Fit the clamping ring around the flue spigot but leave loose.  
From the inside push the assembly through the wall. Align  
the flue turret and push fully onto the spigot on the appliance.  
1
(ii)  
Slide the clamping ring into position so that the hole in  
the spigot lines up with the hole in the ring. Tighten the  
ring in this position. Through the fixing hole screw the self  
drilling screw into the flue (see Fig. 29).  
2
3
(iii) Remove the fan from the fan/fluehood assembly by  
removing the two fan flange fixing screws and also  
releasing the fan clamping bracket.  
4
1. Flue turret assembly  
2. Clamp  
3. Appliance  
4. Fixing screw hole  
(iv) Disconnect the two end lengths of the pressure sensing  
hoses up to and the connection joints (approx 150mm of  
hose). Both of these hoses should be discarded. Refer to  
Fig. 16.  
11.2.13 Completion of the Installation  
Check that all the gas and water connections have been  
tightened.  
(v)  
Slide the flue hood only back into the boiler facing the  
opposite way to before. Ensure that the flue hood hits the  
stops at the rear and the rear combustion chamber slots  
in underneath (see Fig. 28).  
Lower the base plate/control panel. Refer to Fig. 30.  
(vi) With the fluehood on the boiler refit the fan:  
The permanent mains and switched live supply to the boiler  
must come from the system junction box. Refer to Fig.11. A 4  
core cable is recommended.  
(a)  
(b)  
Remove the fan lead from the top clip.  
With the fan in close proximity to the fluehood re-  
attach the fan electrical terminals to the fan. The  
polarity of the connection to the fan motor is not  
important.  
Feed the 4 core cable and the pump cables through the bracket  
and secure in the cable clamp. Refer to Fig. 30.  
Fit all the supply and pump wires to the 5 way plug before fitting  
the plug to the socket on the board. This will avoid stress to the  
board when using a screwdriver. Refer to Fig.11. for the  
connections.  
(c)  
Refit the the fan onto the fluehood. The rear flange  
should slide into the clips at the rear of the flue hood.  
(d)  
The fan should then slide upwards into the flue  
outlet to enable the fan clamp to be fitted and  
tightened into position.  
Check that all the cables cannot touch the inner casing.  
Test for gas soundness as described in BS6891.  
(vii) Re-assemble the front combustion chamber with the 'j'  
bolts and replace inner case door.  
If the appliance is not commissioned immediately, refit the  
combustion cover, inner casing cover, base/controls assembly  
and the casing. Re-connect the earth connection at the base of  
the casing. Check that the gas and electricity services have been  
turned off.  
Fig. 28 . Fan/Flue hood Assembly with  
Flue Turret Kit  
REFER NOW TO SECTION 12 - COMMISSIONING THE  
APPLIANCE  
Fig. 30 . Mains electricity and controls  
connections.  
5
10  
11  
12 13  
9
14  
1
4 ( )  
(Clear tube)  
6
+
2
7
8
3 (+)  
(Red tube)  
7
6
4
5
3
1. Base plate  
2. Control board  
3. Control knob  
4. Fuse 4A  
5. External control connector block  
6. Earth post  
7. Cable clamp  
10. Mains lead bracket  
11. Spark electrode connection  
12. Air pressure switch,  
temperature sensor,  
1
2
overheat thermostat  
connection  
13. Fan connection  
14. Flame sense connection  
1. Flue hood  
2. Fan  
5. Flue turret  
6. Fan clamp  
3. Sensing connection (+)  
7. Fan clamp fixing screw  
8. Internal earth connection  
9. Gas valve connection  
4. Sensing connection (  
)
22  
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12. Commissioning The Appliance  
Fig. 31. Gas Valve.  
2
1
Cleansing and Inhibiting a Central Heating  
Installation in compliance with Benchmark  
It is accepted good practice in compliance with BS 7593, Pas 33 and  
Benchmark, to cleanse both an existing central heating system when  
fitting a replacement boiler, and when fitting a new central heating  
system. Then treat with a 'Corrosion Protector.'  
Worcester recommend only products from water treatment manu-  
facturers participating in Benchmark. These include:  
GAS  
INLET  
Fernox  
Sentinel  
Alpha-Fry Technologies  
Tandem House  
Marlowe Way  
Beddington Farm Road  
Croydon  
Betz Dearborn Ltd  
Foundry Lane  
Widnes  
4
6
Cheshire  
WA8 8UD  
1. Gas valve  
2. Solenoids  
3. Connector  
3
CRO 4XS  
Tel: 01799 521133  
5
4. Inlet pressure test point  
5. Burner pressure test point  
6. Burner pressure adjustment screw  
Tel: 0151 424 5351  
Please call either of the above for a specific cleansing method  
statement if so required. Below is a general guide for flushing,  
which we would advise you to follow along with the chemical  
manufacturers recommendations.  
The  
charge pressure of an expansion vessel is usually 0.5bar, which  
is equivalent to a static head of 5m [17ft].  
Fill up and commission the system in the normal way, i.e: flush  
at least once without firing the boiler to remove loose debris.  
The charge pressure must not be less than the static head at the  
point of connection. The expansion vessel must be charged to  
0.3bar less than the initial system design pressure.  
Note: 1bar = 10.2m = 33.5ft of water.  
Then add the cleansing agent, with regard to COSHH, this must  
be in the system for a minimum of 1 hour with the system at  
normal operating temperature. A longer period of time, up to 48  
hours, would be more beneficial to the cleansing process, espe-  
cially if heavy sludge deposits are suspected to be present (see  
water analysis kit).  
12.3 Set the System Pressure  
Fill the system initially until the pressure gauge is at 2.5bar and check for leaks.  
Release water through the drain cock until the required system  
pressure is obtained, up to a maximum of 1.5bar.  
Set the pointer on the pressure gauge to record the set system pressure.  
If the pressure indicated on the gauge is greater than 2.65bar  
when operating at the maximum central heating temperature,  
the expansion vessel is too small and a larger vessel must be fitted.  
The boiler with a 10 litre expansion vessel can accommodate a  
sealed system volume of about 90 litres. Refer to BS7074 Part 1,  
BS5449 and Table 9.  
Drain the system thoroughly at least twice to remove the cleans-  
ing agent and any debris/flux present. This is a crucial part of  
the cleansing process and must be done correctly. A TDS meter  
is recommended to ensure adequate flushing.  
Once you are sure that the system has been cleansed thoroughly,  
then add a mixed metal corrosion protector. This will protect  
against the formation of scale, corrosion and microbiological  
growths. A minimum of one treatment should be added per system.  
12.4 Clock/Programmer  
Any controls fitted to the system should be set up at this stage.  
The label that is supplied by the manufacturer with the corrosion  
protector treatment, shall be correctly filled in and attached to  
the boiler. Also, the instructions in the Benchmark logbook will  
be adhered to.  
12.5 Check that the gas and electricity supplies are turned off.  
Connect a pressure gauge to the burner pressure test point on  
the gas valve. Refer to Fig. 31.  
12.6 Light the Boiler  
Please note that the corrosion protector level should be checked  
on an annual basis. This is normally done at the time of the  
mandatory boiler service. Water analysis test kits and postal  
analysis services are available from water treatment suppliers for  
this purpose.  
Switch on the gas and electricity supply.  
Set the temperature control knob to maximum and any clocks or  
programmer to operate continuously.  
The gas supply pipe will be purged by the boiler.  
The control will work as follows:  
Failure to comply with these recommendations, may invalidate  
the boiler warranty. If any of the above is unclear, then please  
contact The Worcester Technical Services for further advice.  
(i)  
Pre-purge (air) for approximately 20 seconds.  
(ii) Spark and gas for approximately 5 seconds  
(iii) Purge (air) for approximately 10 seconds  
The boiler will attempt to light a maximum of 5 times before  
going to lockout. To reset the product turn the control knob  
fully anti-clockwise and back.  
12.1 Remove the outer casing by first loosening the base screw.  
Disconnect the earth and lift off the casing.  
Check that the electricity and gas supplies to the appliance are  
turned off and that all the water connections throughout the  
system are tight.  
NOTE: The burner pressure is factory set and may be reset to  
match the system requirements. If, after checking that the  
supply pressure is sufficient i.e. 19 mbar approx [NG] or 36 mbar  
approx [PROPANE] at the gas valve inlet pressure test point, the  
required pressure cannot be obtained then contact The  
Worcester Service Department Tel: 08705 266241.  
Reset the pressure as necessary by adjusting the screw on the  
gas valve. Refer to Table 1 and Fig.31.  
Open any system valves.  
Open all the radiator valves. Remove any air vent caps.  
If a sealed system has been installed then fill through a WRc  
approved filling kit to an initial pressure of 2.5bar.  
Check for water soundness throughout the system.  
Vent each radiator in turn.  
12.7 Domestic Hot Water  
Remove the cap from the pump and turn the shaft about half a  
turn. Replace the cap.  
Check that the relief valve (sealed system) operates by turning  
the knob anti-clockwise until it releases.  
Check that the cylinder thermostat, if fitted, is set to between 55°C  
and 60°C.  
Check that all external controls are calling for heat and that the  
flow pipe to the cylinder is hot after a short period.  
12.2 Set the Expansion Vessel Pressure - Sealed System  
23  
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12.8 Central Heating  
pressure falls.  
Check that the external controls are calling for heat to the heating  
circuit.  
13.5 Explain that regular servicing, of a maximum of 12 months  
between services, will maintain the safe and efficient operation  
and extend the life of the appliance. Worcester can offer a  
comprehensive maintenance contract.  
Check that all the radiators heat up evenly. If necessary carefully vent.  
12.9 Balance the system to give the correct temperature  
differential. Refer to Table 3. Refer to Section 7. for bypass  
requirements.  
13.6 Tell the user that any work on the appliance must only be  
carried out by a competent person.  
12.10 Set the room thermostat to minimum and check that the  
burner goes out. Reset the room thermostat and the burner will re-light.  
Turn off the gas service cock at the boiler. The burner will go out  
but, after a short pause, the appliance will make 5 attempts to  
restart sparking for 5 seconds and then 'lock-out'. After 60  
seconds carefully open the gas service cock at the boiler, operate  
the reset control and observe the burner re-light and follow the  
normal sequence of operation. Refer to Fig. 32.  
14. Inspection And Service  
14.1 The extent of the service will be determined by the  
operating condition of the appliance. It is the law that any  
service work is carried out by a competent person.  
14.2 Inspection  
Turn off the gas service cock at the boiler and the electricity  
supply to the appliance.  
Check that the terminal and the terminal guard, if fitted, are clear  
and undamaged.  
Drain the system while the appliance is hot.  
If the appliance is in a compartment or cupboard check that the  
specified clearances are clear. Refer to Table 7 and Section 6 Air  
Supply.  
Refill, vent and re-pressurise the system (Sealed System) adding a  
suitable proprietary inhibitor. Further information is available  
from Worcester Technical Information Dept, Telephone 08705  
266241.  
Check all the joints and connections in the system and remake  
any that show signs of leakage. Refill and re-pressurise (Sealed  
System) as described in Section 12 Commissioning.  
Operate the appliance and take note of any irregularities. Refer to  
Section 18-Fault Finding.  
12.11 Completion of Commissioning  
Disconnect the pressure gauge from the gas valve and tighten  
the test point screw.  
Restart the appliance and check for gas soundness around the  
test point screw.  
Check the combustion performance  
Lift off the cap from the sample point on the top of the boiler and  
connect the meter. Refer to Fig 30/30a.  
Fix the red arrow on the data plate to show the boiler setting. If  
the setting has been altered the adjustment screw should be re-  
sealed by a dab of paint to stop un-authorized adjustment.  
Refit the casing, reconnect the earth and tighten the clip.  
If the appliance is to be passed over to the user immediately  
then set any controls to the users requirements.  
With the appliance at maximum rate and stable expect readings  
of about:  
SHORT FLUE WITH  
RESTRICTOR PLATE  
FITTED  
LONG FLUE WITHOUT  
RESTRICTOR PLATE  
FITTED  
APPLIANCE  
2
2
CO  
CO  
CO  
CO  
If the appliance is to be left inoperative in frosty conditions then  
set a programmer, if fitted, to continuous and the appliance to  
operate at a low temperature under the control of a frost  
thermostat, if fitted, to protect remote parts of the system.  
The boiler has its own integral frost protection which will also  
protect a compact system.  
If there is any possibility of the appliance being left totally  
unused in freezing conditions then switch off the gas and  
electricity and drain the appliance and the system.  
0.003 - 0.007  
0.003 - 0.007  
0.002 - 0.005  
0.002 - 0.005  
0.008 - 0.012  
0.005 - 0.010  
7.2 - 8.1  
8.1 - 8.7  
6.6 - 7.5  
7.8 - 8.5  
7.1 - 7.7  
8.0 - 8.9  
0.002 - 0.005  
0.002 - 0.005  
0.002 - 0.005  
0.002 - 0.005  
0.008 - 0.012  
0.008 - 0.015  
6.0 - 6.8  
6.9 - 7.7  
5.6 - 6.5  
6.3 - 7.0  
7.0 - 7.8  
7.8 - 8.5  
9/14CBi NG  
LPG  
14/19CBi NG  
LPG  
19/24CBi NG  
LPG  
Refit the sample point cap after the test.  
Always test for gas soundness after the service has been  
completed.  
Complete the Benchmark Log-book.  
Disconnect the electrical supply at the mains and turn off the  
gas supply at the gas service cock on the appliance before  
starting any service procedures.  
13. Instructions To The User  
Fig. 32. User controls.  
14.3 Component Access  
Ensure that the gas and electricity supplies are isolated before  
accessing the following parts.  
Remove some or all of the following parts to gain access to the  
components.  
Outer Case. Loosen the screw and clip at the base, disconnect  
the earth tag, lift the case up and pull forwards.  
Base/Control Assembly. Remove the single screw and lower.  
Refer to Fig. 33a/b.  
Inner Case Door. Remove the four corner screws and lift the  
door off.  
1
2
3
4
Combustion Chamber Front Cover. Loosen the two wing-nuts  
and slide the 'J' bolts out of the slots. Pull the front cover  
forwards and upwards to remove from the boiler.  
NOTE: On the 9/14CBi the RHS bolt and clamping bracket must  
be removed.  
1. Boiler demand  
4. Temperature control knob/ ON-STANDBY/ Lock-out reset  
2. Burner ON  
3. Lock-out  
13.1 Hand over the User Booklet and the Benchmark  
Log-book and explain how to operate the appliance safely and  
efficiently.  
Fan - Rear Only Flue. Remove the combustion chamber front  
cover. Carefully pull off the electrical connections and the  
pressure tubes from the air flow detector. Slide out the fan and  
flue hood assembly. Ensure that the combustion chamber rear  
fits under the lip on the fluehood. To remove the fan, remove the  
two fixing screws and release the clamping bracket.  
13.3 Tell the user what to do if the appliance is not to be used in  
very cold conditions.  
13.4 Tell the user what to do if the system (Sealed System)  
24  
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Fan -  
Horizontal Flue. Remove the combustion  
14.4 Component Cleaning  
chamber cover. Carefully pull off the electrical connections and  
the tubes from the air flow detector. Loosen the two clamps to  
remove the fan . Refer to Fig 34.  
Do not use a brush with metal bristles to clean components.  
Clean the fan taking care not to block air flow detector.  
Clean the burner to ensure that the blades are clear. Do not use a  
metal probe to clean the injector.  
Flue Hood -  
Horizontal Flue. Remove the fan, see  
Clean the electrodes and check the alignment. Replace if there is  
any sign of deterioration.  
above. Remove the combustion chamber cover and withdraw  
the hood. When refitting ensure that the combustion front fits  
under the lip of the flue hood.  
Clean the heat exchanger from top and bottom after covering the  
burner injector. To clean the heat exchanger flueways remove the  
stainless steel baffles from the appliance - the rear combustion  
chamber cover can be tilted for better access. The front and rear  
flueways can be cleaned with a brush being careful to protect the  
rear combution chamber insulation. The inner flueway can be  
cleaned with a scraper.  
Burner Blade Assembly. Remove the combustion chamber  
cover. Undo the screw at the right hand end of the burner.  
Carefully pull-off the connections to the spark electrode. Slide the  
burner blade assembly off the injector and remove. Carefully pull  
off the flame sense electrode lead. Refer to Fig 33/33a.  
Check the combustion chamber insulation and replace if there is  
any sign of damage or deterioration. Refer to Section 15.4.11.  
Carefully refit any components removed and check that all  
screws are tight and the connections properly re-made with the  
appropriate gaskets/O-rings/seals.  
Re-commission, as necessary, for correct operation to the users  
requirements. Refer to Section 12 Commissioning.  
Control Board Cover. To gain access to the control board remove  
cover from the front clip, with a screwdriver (if necessary) and  
unclip from the rear of the controls tray.  
Fig. 33a. Inner Casing and control  
18  
9/14CBi  
17  
19  
16  
22  
20  
1
15  
21  
27  
26  
14  
13  
2
3
25  
4
12  
11  
5
6
24  
23  
10  
7
8
9
1. Inner case  
8. Base/controls fixing screw  
9. Cabinet fixing screw  
10. Gas valve  
15. Air pressure switch  
16. Flow pipe  
22. Inner case cover fixing points (4)  
23. Outer case earth tag  
24. Side cover plate  
2. J bolts and wing nuts (2)  
3. Combustion chamber cover  
4. Burner  
17. Return pipe  
18. Combustion test point  
19. Sensing tubes  
20. Fan  
11. Spark electrode  
25. Wire clip  
5. Burner fixing screw  
6. Control knob  
7. Indicator lights  
12. Burner injector  
13. Temperature sensor  
14. Overheat thermostat  
26. 9/14CBi clamping bracket  
27. Pressure tube junction  
21. Flue hood  
25  
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15.3 Draining the Appliance  
Isolate the appliance.  
15. Replacement Of Parts  
Important: Turn off the gas and electricity supplies and drain,  
where necessary, before replacing any components.  
Remove the casing. Refer to Section 14.3.  
Fit a tube to the drain connection from the system (top connection  
only) and open the tap. Refer to Fig 34. Close the tap when the flow  
has stopped.  
IMPORTANT: A small quantity of water will remain in some  
components. Protect any electrical components when removing  
items that might retain water.  
15.1 Always check for gas soundness where relevant and carry  
out functional checks as described in Section 12 Commissioning.  
Any O-ring, gasket or seal that appears damaged must be  
replaced.  
15.4 Component Replacement  
15.2 Component Access  
Refer to Section 14.3 Inspection and Servicing for access to  
components.  
Replace any components removed from the appliance in the  
reverse order using new gaskets/O-rings/sealant/heat transfer  
paste where necessary. Always check that any electrical  
connections are correctly made and that all screws are tight.  
Fig. 33b. Inner Casing and control  
14/19 and 19/24CBi  
17  
18  
20  
21  
19  
16  
22  
23  
1
15  
2
14  
13  
3
27  
26  
4
12  
11  
5
6
25  
24  
10  
8
9
7
1. Inner case  
8. Base/controls fixing screw  
9. Cabinet fixing screw  
10. Gas valve  
15. Air pressure switch  
16. Flow pipe  
22. Inner case cover fixing points (4)  
23. Flue hood  
2. J bolts and wing nuts (2)  
3. Combustion chamber cover  
4. Burner  
17. Return pipe  
24. Outer case earth tag  
25. Side cover plate  
26. Wire clip  
11. Spark electrode  
18. Combustion test point  
19. Sensing tubes  
20. Fan  
5. Burner fixing screw  
6. Control knob  
7. Indicator lights  
12. Burner injector  
13. Temperature sensor  
14. Overheat thermostat  
27. Front baffle  
21. Fan clamp (2 screws)  
26  
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Fig. 34 . Inner Casing - Gas and Electric  
Controls. 9/14CBi shown.  
17  
18  
16  
19  
20  
15  
21  
22  
23  
1
11  
14  
2
3
1. Inner casing  
13  
12  
2. J bolts and wing nuts (2)  
3. Combustion chamber cover  
4. Burner assembly  
5. Inner case cover fixing  
points (4)  
6. Base/control fixing point  
7. Gas valve  
8. Burner manifold fixing  
screws (4 + 4)  
11  
9. Burner manifold  
10. Drain point (top flow return)  
11. Flow and return pipe fixing clip  
12. Access panel  
13. Temperature sensor  
14. Overheat thermostat  
15. Casing support  
14  
10  
4
8
5
16. Return pipe  
17. Flow pipe  
18. Air pressure switch  
19. Combustion test point  
20. Air pressure switch fixing clip (4)  
21. Flue hood  
7
9
8
22. Fan  
6
23. Sensing tubes  
24. Outer case earth tag  
25. Side cover plate  
7
25  
24  
Fig. 35 . Base/Control Board Assembly  
2
3
1. Base/control assembly  
2. Base/control assembly fixing  
point  
10  
3. Gas valve  
4. Inner connections earth tag  
5. External controls earth post  
points (4)  
6. Cable clamp  
7. External controls connection  
8. Control knob  
9. Fuse  
10. Outer case earth tag  
NOTE: Control board cover not shown.  
6
1
4
7
9
8
5
27  
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Alter the red arrow if a new setting is made.  
The adjustment screw must be sealed by a dab of paint to stop  
unauthorized adjustment.  
15.4.1 Gas Valve  
NOTE: If the left hand clearance is >50mm then the gas valve  
can be replaced with the burner and combustion chamber cover  
in place by unscrewing the four extended screws at the manifold  
on the outside of the inner casing. The manifold gasket should be  
replaced if it is damaged or has deteriorated.  
Switch off the appliance, disconnect the pressure gauge and  
tighten the test point screw. Refer to Fig. 31.  
Check for gas soundness.  
Check that the gas supply is isolated.  
15.4.2 Spark Electrode  
Remove the inner casing cover, the combustion chamber cover  
and the burner blade assembly. Refer to Section 14.3.  
Unscrew and lower the base plate/control assembly.  
Unplug the electrical connection at the gas valve.  
Unscrew and remove the side plate adjacent to the manifold.  
Undo the four screws securing the gas cock to the valve. Take  
care not to damage the control panel.  
Remove the inner casing cover and the combustion chamber  
cover.  
Carefully pull off the leads at the electrodes. Remove the burner  
blade assembly. Refer to Section 14.3.  
Unscrew and remove the electrode assembly. Refer to Fig. 36 and 36a.  
15.4.3 Flame Sense Electrode  
Undo the four pozi-head screws to remove the gas valve and  
burner manifold assembly.  
Remove the inner casing cover and the combustion chamber  
cover.  
Undo the four pozi-head screws inside the casing to separate the gas  
valve from the manifold.  
Pull off the connections to the spark electrode. Carefully remove  
the burner blade assembly. Refer to Section 14.3.  
Carefully pull off the lead from the electrode.  
Unscrew and remove the electrode assembly. Refer to Fig. 36 and 36a.  
Ensure that the new electrode is at the correct height and  
position on the burner blade.  
Use new O-rings when replacing the valve.  
Set the Gas Valve:  
Connect a pressure gauge to the burner pressure test point on  
the valve. Refer to Fig. 31.  
Switch on the gas and electricity supplies. Check for gas  
soundness at the gas valve inlet.  
15.4.4 Burner Blade Assembly  
Refer to Section 12 Commissioning for the method of checking  
the pressures.  
Remove the inner casing cover and the combustion chamber cover.  
Remove the burner blade assembly. Refer to Section 14.3.  
Check for gas soundness at the gas valve outlet.  
Adjust the gas valve to obtain the required pressure. Refer to the  
data plate on the cabinet where required pressure will be indicated.  
Spark Electrode Gaps  
3
Fig. 36. Burner Blade Assembly 14/19 and  
19/24CBi  
4.1 0.2  
2.5  
Flame Sense Electrode Gap  
3.1 0.2  
1. Burner blade assembly  
2. Burner fixing screw  
3. Flame sense electrode  
4. Spark electrode  
5
4
5. Burner baffle (not removable from  
1
2
the burner  
Spark Electrode Position  
Fig. 36a . Burner Blade Assembly 9/14CBi  
Both Burners  
3
Flame Sense Electrode Position  
Both Burners  
4
5
1
2
28  
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15.4.5 Control Board  
15.4.6 Fan  
Lower the base plate/control assembly and carefully disconnect  
the plug-in connector and all the electrical connections. Refer to  
Fig. 35.  
Remove the inner casing and combustion chamber cover .  
Remove the fan as described in Section 14.3 Inspection and  
Servicing. The flue hood gasket should be replaced if it is  
damaged or has deteriorated.  
Release the five clips and lift out the control board. Refer to Fig. 35.  
Pull out and replace, if necessary, a failed fuse.  
Ensure that all the connections are correctly made to the new  
fan. Refer to Fig. 37 and 37a.  
Do not use any sealant on the fan/flue duct connection.  
The polarity of wires onto the fan is not important.  
Fig. 37 . Fan/Flue hood Assembly with  
Horizontal Flue  
5
4 ( )  
(clear tube)  
6
+
7
1. Flue hood  
3 (+)  
(red tube)  
2. Fan  
3. Sensing connection (+)  
4. Sensing connection (  
5. Flue turret  
6. Fan clamp  
7. Fan clamp fixing screw  
)
1
2
Fig. 37a . Fan/Flue hood Assembly with Rear Only Flue  
NOTE: The polarity of wires is  
not important  
5
6
1. Flue hood  
2. Fan  
3. Sensing connection (+)  
4. Sensing connection (—)  
5. Top outlet sealing plate  
6. Fan lead clip  
7. Fan fixing screws (2)  
8. Pressure tube junction  
9. — ve pressure tube  
9
—ve  
10. + ve pressure tube  
1
10  
+ve  
4 ( — )  
(clear tube)  
+
3 (+)  
(red tube)  
8
7
2
29  
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15.4.7 Air Flow Sensor  
15.4.10 Air Pressure Switch  
Remove the fan as described in 14.3. Unscrew and withdraw,  
through the fan outlet, the air flow sensor. Refer to Fig .38 and  
38a.  
Noting the position of each pressure tube carefully disconnect  
the tubes and electrical connections from the switch. Unclip and  
remove the switch if there is more than 50mm clearance. Refer  
to Fig.40.  
The detector is 'handed' - do not force it into place.  
If there is minimum clearance then remove the inner casing  
cover and release the two screws. Remove the air pressure  
switch and mounting bracket complete.  
Ensure that the connections are correctly made on the  
replacement switch. Red tube to the connection marked (+) and  
the clear tube to the connection marked ( —).  
Fig. 38 - 9/14CBi  
Fig. 38a - 14/19 and  
19/24CBi  
+
+
Fig. 40. Air Pressure Switch  
1
2
7
15.4.8 Temperature Sensor  
Remove the access panel to give improved access with minimum  
side clearance.  
Carefully pull-off the connections.  
Remove grommet.  
Pull off the clip and remove the sensor. Refer to Fig .39.  
When replacing component ensure heat sink compound is  
added around contact area.  
6
5
15.4.9 Overheat Thermostat  
Remove the access panel to give improved access with minimum  
side clearance.  
Carefully pull-off the connections.  
Remove grommet.  
Unscrew and remove the sensor (see above).  
When replacing component ensure heat sink compound is  
added around contact area.  
3
4
Fig. 39. Sensor and Overheat Thermostat  
6
1. Air pressure switch  
2. Fixing clips (4) - mounting bracket  
3. Sensing tube connection - clear to ' ' on fan  
4. Sensing tube connection - red to '+' on fan  
5. Electrical connection COM - brown  
6. Electrical connection NO - grey  
7. Electrical connection NC - white  
3
5
1
4
2
1. Sensor clip with grommet  
2. Temperature sensor  
3. Overheat thermostat  
4. Thermostat pocket  
5. Flow manifold  
6. Flow pipe  
7. Grommet  
7
30  
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15.4.11 Combustion Chamber Insulation  
The insulation pads are manufactured from a material in  
accordance with COSHH.  
Fig. 41. Heat Exchanger Baffles in Position  
on the Heat Exchanger  
Remove the casing, inner casing cover and combustion chamber  
cover.  
Front Insulation: Unscrew the clamp at the top of the  
combustion chamber cover to replace insulation.  
3
Side Insulation: Release the clip at the bottom and slide  
out the insulation.  
2
Rear Insulation: Remove the burner blade assembly and  
cover the burner injector.  
Remove the fan and flue hood assembly.  
Remove the side insulation pads.  
1
Unscrew the combustion chamber rear panel and lower.  
Cut the rear insulation board to remove it from the boiler.  
Cut the replacement board approximately 90mm from the  
top so that the joint will be behind the heat exchanger.  
Slide in the top section followed by the bottom section.  
Refer to Fig.37.  
On replacement ensure that the fixing screw returns  
through the hole in the rear bracket.  
15.4.12 Heat Exchanger  
Shut off the gas and electricity supplies.  
Drain the appliance.  
Protect the electrical components.  
NOTE: Some water will remain in the heat exchanger.  
Remove the casing, inner casing cover, combustion chamber  
cover, heat exchanger baffles, fan and flue hood assembly,  
burner blade assembly and the access plate at the left hand side  
of the inner casing.  
1
Pull off the leads from the sensor and overheat thermostats. Pull  
off the clip to remove the sensor and unscrew the overheat  
thermostat.  
1. Heat exchanger baffle  
2. Wire fixing clip  
3. Heat exchanger  
4. Flow and return manifolds  
Pull out the clips securing the flow and return pipes and remove  
them from the manifolds. It will be necessary to disconnect the  
pipes from the system adjacent to the boiler.  
4
Unscrew the slotted hex head screw at the base of the  
combustion chamber rear panel.  
Slide the panel upwards and unscrew the two screws exposed at  
the right and left hand sides at the rear.  
Unscrew the four hex head screws, two at each side, securing the  
steel side plates to the inner casing.  
Lower the combustion chamber rear panel by pulling the lower  
fixing point in front of the securing bracket.  
Unscrew the two M6 nuts whilst supporting the heat exchanger  
(the approximate weight is: 9/14CBi - 18kg, 14/19 and  
19/24CBi - 24kg).  
Lift out the heat exchanger assembly complete with side plates  
and manifolds. Take care as the combustion chamber rear panel  
is now unattached.  
Transfer the side plates to the new heat exchanger  
Fit the new heat exchanger in the reverse order.  
Re-commission the appliance. Refer to Section 12.  
31  
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(VI) Transfer the spark and flame electrode assemblies to the  
new burner blade assembly. Refer to Sections 15.4.2 - 4 for  
details of positions.  
16. Conversion Instructions  
These instructions should only be read if converting appliance  
from Natural Gas to LPG or vice versa.  
(VII) Fit the new burner blade assembly into the appliance not  
forgetting to re-connect the electrode leads.  
Only components supplied by Worcester, Bosch Group should be  
used.  
(VIII) Refit the combustion chamber front and inner case cover.  
(IX) Switch on the gas supply and open the gas cock at the  
appliance. Check for leaks at the gas valve inlet.  
Only competent persons should attempt the conversion.  
Conversion from Natural Gas to LPG should not be carried out  
on appliances installed in a room or internal space below  
ground level.  
(X)  
Refit the base control assembly.  
(XI) Recommission the appliance.  
Refer to Section 12. Commissioning for details.  
Adjust the burner setting pressure as required. Refer to  
Table 1 and Fig. 31.  
Turn off the gas and electricity supplies to the boiler.  
NOTE: Turning the control knob to off does not isolate the boiler.  
(XII) Fix the Red Arrow on the data plate to show the boiler  
setting. If the setting has been altered the adjustment  
screw should be resealed by a dab of paint to stop un-  
authorized adjustment.  
16.1 Conversion  
(I)  
Remove the outer casing by loosening the fixing screw at  
the base and lifting off. Refer to Fig. 12a/b.  
(II)  
Remove the inner casing door and combustion chamber  
front. Refer to Section 14.3.  
(XIII) If converting to an LPG boiler add LPG sticker to the casing  
door. If converting from LPG to NG then remove the LPG  
sticker from the casing door.  
(III) Lower the base/control assembly. Refer to Section 14.3.  
(IV) Remove the burner blade assemby. Refer to Section 14.3.  
(XIV) Refit the cabinet casing.  
(V)  
Unscrew and replace the burner injector and washer with  
the new one from the kit. Refer to Tables 9 and10.  
(XV) Complete the Benchmark checklist.  
Table 9.  
Conversion from LPG — NG  
9/14CBi  
14/19CBi  
19/24CBi  
7 716 192 271  
8 716 157 115 (4.3mm)  
8 716 101 994  
LPG — NG Kit No.  
Burner Injector  
Injector Washer  
7 716 192 269  
8 716 157 116 (3.4mm)  
8 716 101 994  
7 716 192 279  
8 716 103 168 (3.8mm)  
8 716 101 994  
Bunner Blade Assembly  
8 716 142 654  
8 716 142 653  
8 716 142 653  
Table 10. Conversion from NG — LPG  
9/14CBi  
14/19CBi  
7 716 192 277  
8 716 103 169 (2.5mm)  
8 716 101 994  
8 716 102 412  
ZK LAB 417  
19/24CBi  
7 716 192 272  
8 716 102 411 (2.7mm)  
8 716 101 994  
8 716 102 412  
ZK LAB 417  
NG — LPG Kit No.  
Burner Injector  
Injector Washer  
Bunner Blade Assembly  
LPG Label  
7 716 192 270  
8 716 102 407 (2.1mm)  
8 716 101 994  
8 716 102 408  
ZK LAB 147  
32  
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17. Short Parts List  
Key  
No.  
G.C. No.  
Part  
Manufacturer’s Reference  
Qty  
WHS  
Part No.  
1
2
3
E60-473  
E60-474  
E60-475  
Burner Assembly NG 9/14CBi  
Burner Assembly LPG 9/14CBi  
Burner Assembly NG 14/19, 19/24CBi  
Burner Assembly LPG 14/19, 19/24CBi  
Injector Burner 3.4mm NG 9/14CBi  
Injector Burner 2.1mm LPG 9/14CBi  
Injector Burner 3.8mm NG 14/19CBi  
Injector Burner 2.5mm LPG 14/19CBi  
Injector Burner 4.3mm NG 19/24CBi  
Injector Burner 2.7mm LPG 19/24CBi  
Gas Valve NG  
Air Pressure Switch 9/14, 14/19CBi  
Air Pressure Switch 19/24CBi  
Spark Electrode Assembly  
Sensor Electrode Assembly  
Spark Electrode Lead  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10  
1
1
8716121773 0  
87161032100  
8716121767 0  
87161032110  
8716157 116 0  
8716102407 0  
8716103168 0  
8716103169 0  
8716157 115 0  
87161024110  
8716156 769 0  
8716146 165 0  
8716146 163 0  
8716142 140 0  
8716142 139 0  
8716121805 0  
8716142 137 0  
8716121699 0  
8716121700 0  
7716101854 0  
7716101796 0  
8716146 332 0  
8716142 399 0  
8 716 142 302 0  
8 716 104 581 0  
8 716 104 582 0  
8716156 008 0  
8716101797 0  
8716101798 0  
4
E60-476  
5
6
7
8
E60-477  
E60-478  
E60 479  
E60-480  
E60-481  
E60-482  
E60-483  
E60-484  
E60-485  
E60-486  
E60-487  
E60-492  
E60-493  
375 696  
E60-498  
E60-499  
E60-500  
E60-503  
E60-504  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
Sensor Electrode Lead  
Heat Exchanger Assembly 9/14CBi  
Heat Exchanger Assembly 14/19, 19/24CBi  
Insulation Kit 9/14CBi  
Insulation Kit 14/19, 19/24CBi  
Control Board PCB  
Overheat Thermostat  
Primary/Domestic Thermister Sensor Kit  
FanAssembly 9/14CBi  
FanAssembly 14/19, 19/24CBi  
Fuse 4A Fast blow 20 X 5mm  
O-Ring Kit HT/Exchanger  
Gas Section Sealing Kit  
33  
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18. Operational Flow Diagram  
34  
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19. Fault Finding  
NOTE: This fault finding information is for guidance only. Worcester, Bosch Group cannot be held responsible for costs incurred by  
persons not deemed to be competent.  
The electronic control for this boiler incorporates three lights: Boiler demand, flame on and lockout.  
These form the basis for this fault finding guide.  
To use this guide, select box below which represents the light situation during your fault, then refer to the appropriate section.  
This guide assumes a component failure has occured following a period of normal running. It is not intended to solve installation errors.  
PRELIMINARY CHECKS  
Preliminary electrical system checks are the first electrical checks to be carried out during a fault-finding procedure. On completion of the  
Service/Fault-finding task which has required the breaking and remaking of electrical connections, check (a) EARTH CONTINUITY,  
(b) SHORT CIRCUIT CHECK, (c) POLARITY and (d) RESISTANCE TO EARTH.  
WARNING: In addition to the controls, the overheat thermostat and fan are connected directly to the permanent live supply. Under  
all circumstances remove the permanent live supply before touching these parts.  
LIGHT SITUATION DURING FAULT  
WITH A SYSTEM BOILER DEMAND AND USER CONTROL SET TO MAXIMUM:  
NO LIGHTS AT ALL  
FAULT POINT A  
DEMAND LIGHT ONLY  
FAULT POINT B  
FAULT POINT C  
BURNER LIGHT ONLY  
LOCKOUT LIGHT ON  
CONSTANTLY  
ON OR OFF  
ON OR OFF  
OFF  
OFF  
FAULT POINT D  
FAULT POINT E  
LOCKOUT LIGHT  
FLASHING  
OTHER FAULTS NOT COVERED BY ABOVE  
FAULT POINT F  
35  
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No boiler demand  
from the heating  
system. Investigate  
system.  
Gain access to the  
control board.  
No  
Is there 230V at connector  
X1 between pins SL & N?  
Yes  
Replace control board.  
NOTE: It is normal to see only a  
demand light if the boiler is hot  
and the burner has temporarily  
shut off.  
Ensure boiler is cool and user  
control set to maximum.  
Replace sensor  
or check  
cables to it.  
No permanent live  
supply to control  
board. Investigate  
electrical supply from  
external system.  
Gain access to the  
control board.  
No  
Is there 230V at connector  
X1 between pins  
'PERM LIVE' & 'N'?  
No  
Remove connector  
X5 and test  
resistance between  
the red and violet  
cables. Is the  
resistance between  
1 kohm and  
Yes  
Is there 230V  
across the fan  
terminals?  
WARNING:  
if NO, both fan  
terminals will  
be LIVE.  
Check fuse F1  
on the control  
board.  
No  
No  
Does the No  
pump  
run?  
No  
Create a new demand.  
Does the fan run?  
Has it blown?  
Yes  
30 kohm?  
Yes  
Yes  
Yes  
Replace fuse and  
investigate cause.  
Suggestions:  
Air pressure switch  
is stuck on.  
Yes  
Replace air pressure  
switch.  
connections to (or  
faults within) pump,  
fan, gas valve,  
Replace fan.  
system wiring,  
possible board fault.  
Fan cycles on & off.  
Is there any sign of  
blockage in the flue or  
air pressure tubes?  
No  
No  
Does the fan run  
continuously?  
Replace control board.  
Yes  
Yes  
Clear blockage.  
Air pressure switch not  
changing over. Check flue and  
air pressure sense tubes. Are  
they clear and not damaged?  
No  
Repair fault.  
Yes  
Replace air pressure switch.  
If this does not solve the  
problem check the venturi in  
the fan housing.  
36  
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Demand light has  
failed. Replace control  
board if it is  
Is the boiler in a very cold  
environment  
No  
i.e is the primary water  
temperature below 5°C?  
considered a problem.  
Yes  
Boiler is running in  
'Autofroststat' mode.  
Is the system fully  
water pressurised  
and is all air vented?  
No  
Rectify fault/leak.  
Yes  
The system should have a  
bypass fitted as described in  
Section 7. SYSTEM and Figs.  
5, 6 & 7. Is bypass fitted and  
correctly adjusted?  
No  
No  
Add or adjust system  
bypass.  
Yes  
Reset the lockout and create  
a boiler demand.  
Replace pump or  
check cables to it.  
With the boiler cool does  
the pump run?  
Yes  
Switch off mains supply.  
Remove boiler cover  
and inspect the  
No  
Refit sensor to  
manifold or add heat  
conductive paste.  
temperature sensor.  
Is it correctly fitted to the  
manifold with heat  
conductive paste on its  
surface?  
Yes  
Use a suitable  
implement to push  
switch to the 'normal'  
left position. The  
'heatstore' right position  
is for commercial  
Gain access to control board  
and inspect the slide switch  
at the front of the board.  
In normal domestic  
No  
No  
installation this switch  
should be in the left  
'normal' position.  
applications only.  
Yes  
Remove connector at X5.  
With boiler cool is there a  
short circuit between the  
orange & black cables?  
Replace overheat  
thermostat or check  
wiring to it.  
Yes  
Replace control board.  
37  
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No  
No  
Is the gas supply  
connected and at the  
correct pressure?  
Rectify gas supply  
problem.  
Yes  
Remove boiler casing.  
Reset and restart  
the boiler.  
TURN OFF GAS SUPPLY.  
Remove inner casing  
cover.  
Are the electrodes  
and gap and  
No  
No  
No  
Repair or replace  
spark electrode  
or HT leads.  
Can a flame be seen  
through the spyglass?  
Note: there is a 20  
second delay from fan  
on to spark.  
connections  
Reset and restart boiler.  
Does a spark occur  
across the electrodes?  
in good order?  
Yes  
Yes  
Replace control board.  
During spark period  
is there 216V D.C.  
across the pins at  
connector X2?  
Yes  
Yes  
Replace gas valve or  
check cable to it.  
TURN OFF GAS SUPPLY.  
Remove the combustion  
chamber cover. Is the  
sense (right) electrode  
and lead in good  
No  
Repair or replace  
flame sense  
or cable to it.  
condition and is gap  
correct?  
See Section 15.4.3  
Yes  
Replace control board.  
Note: It is not possible  
to reliably check the  
cross light performance  
of the burner.  
In the unlikely event of  
such a fault, investigate  
condition of flue,  
NOTE: Do not attempt to light the boiler  
with the combustion chamber cover  
removed.  
burner and injector.  
Also check polarity of  
mains voltage supply.  
38  
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Delivered primary water  
temperature always too hot.  
(Over 85°C)  
Check thermister  
sensor/heat conductive  
paste.  
Move control knob to lower  
setting.  
Replace control board.  
Such a fault is likely to be caused  
by one or more of the following:  
Low gas pressure  
Delivered primary water  
temperature appears too  
low with control knob set to  
maximum.  
Partially blocked flue  
Partially blocked heat exchanger  
Blocked/dirty burner  
Gas valve sticking  
(Less than 75°C)  
Control board fault  
Faulty themister  
39  
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40  
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BENCHMARK No.  
GAS BOILER COMMISSIONING CHECKLIST  
NOTIFICATION No.  
C O L L E C T I V E M A R K  
BOILER SERIAL No.  
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes  
TIME & TEMPERATURE CONTROLTO HEATING ROOM T/STAT& PROGRAMMER/TIMER  
TIME & TEMPERATURE CONTROLTO HOTWATER CYLINDER T/STAT& PROGRAMMER/TIMER  
PROGRAMMABLE ROOMSTAT  
COMBI BOILER  
HEATING ZONE VALVES  
FITTED  
FITTED  
FITTED  
FITTED  
NOT REQUIRED  
HOTWATER ZONE VALVES  
NOT REQUIRED  
THERMOSTATIC RADIATOR VALVES  
AUTOMATIC BYPASS TO SYSTEM  
NOT REQUIRED  
FOR ALL BOILERS CONFIRM THE FOLLOWING  
THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS?  
THE SYSTEM CLEANER USED  
THE INHIBITOR USED  
FOR THE CENTRALHEATING MODE, MEASURE & RECORD  
3
m3/hr  
N/A  
GAS RATE  
tf/hr  
BURNER OPERATING PRESSURE (IF APPLICABLE)  
CENTRALHEATING FLOW TEMPERATURE  
CENTRALHEATING RETURN TEMPERATURE  
mbar  
¡C  
¡C  
FOR COMBINATION BOILERS ONLY  
HAS AWATERSCALEREDUCERBEENFITTED?  
YES  
NO  
WHATTYPE OF SCALE REDUCER HAS BEEN FITTED?  
FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD  
3
m3/hr  
N/A  
GAS RATE  
tf/hr  
MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE)  
COLD WATER INLET TEMPERATURE  
HOTWATER OUTLETTEMPERATURE  
WATER FLOW RATE  
mbar  
¡C  
¡C  
lts/min  
FOR CONDENSING BOILERS ONLYCONFIRM THE FOLLOWING  
THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH  
THE MANUFACTURER S INSTRUCTIONS?  
YES  
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING  
THE HEATING AND HOTWATER SYSTEM COMPLIES  
WITH CURRENTBUILDING REGULATIONS  
THE APPLIANCE AND ASSOCIATED EQUIPMENTHAS BEEN INSTALLED AND COMMISSIONED  
INACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS  
IF REQUIRED BYTHE MANUFACTURER, HAVEYOU RECORDED ACO/CO2RATIO READING? N/A  
YES  
CO/CO2RATIO  
THE OPERATION OF THE APPLIANCE AND SYSTEM  
CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER  
THE MANUFACTURER S LITERATURE HAS BEEN LEFTWITH THE CUSTOMER  
COMMISSIONING ENG S NAME PRINT  
CORGI ID No.  
DATE  
SIGN  
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SERVICE INTERVAL RECORD  
It is recommended that your heating system is serviced regularly  
and that you complete the appropriate Service Interval Record Below.  
Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service  
as described in the boiler manufacturer sinstructions.Always use the manufacturer sspecifiedsparepartwhenreplacingallcontrols  
SERVICE 1 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
SERVICE 2 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
CORGI ID CARD SERIALNo.  
COMMENTS  
CORGI ID CARD SERIALNo.  
COMMENTS  
SIGNATURE  
SIGNATURE  
SERVICE 3 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
SERVICE 4 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
CORGI ID CARD SERIALNo.  
COMMENTS  
CORGI ID CARD SERIALNo.  
COMMENTS  
SIGNATURE  
SIGNATURE  
SERVICE 5 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
SERVICE 6 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
CORGI ID CARD SERIALNo.  
COMMENTS  
CORGI ID CARD SERIALNo.  
COMMENTS  
SIGNATURE  
SIGNATURE  
SERVICE 7 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
SERVICE 8 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
CORGI ID CARD SERIALNo.  
COMMENTS  
CORGI ID CARD SERIALNo.  
COMMENTS  
SIGNATURE  
SIGNATURE  
SERVICE 9 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
SERVICE 10 DATE  
ENGINEER NAME  
COMPANYNAME  
TEL No.  
CORGI ID CARD SERIALNo.  
COMMENTS  
CORGI ID CARD SERIALNo.  
COMMENTS  
SIGNATURE  
SIGNATURE  
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43  
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This manual is to be used in conjunction  
with the variant part number of the bar  
code below:  
www.worcester-bosch.co.uk  
Bosch Group  
Worcester, Bosch Group, Cotswold Way, Warndon, Worcester WR4 9SW.  
Telephone: 01905 754624. Fax: 01905 753130.  
Technical Helpline 08705 266241.  
Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Limited.  
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.  
All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.  
PUBLICATION 8 716 115 015a (02/08)  
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