Bosch Appliances 28i junior, 24i junior manual 31.1, 31.2, 32.1 32.2, 32.3

Page 52

SERVICING

& SPARES

51

REPLACEMENT OF PARTS

31.1

 

 

 

31. Bypass valve

 

 

 

Remove the Hydraulic block from the boiler

 

 

 

(See Removing the Hydraulic Block).

 

 

 

31.1 Remove the two spring clips at either end of

 

 

 

the copper bypass pipe.

 

 

 

Undo the screw securing the left hand

 

 

31.2

plastic housing to the heat exchanger

 

 

Move the housing to the left to free up the

 

 

 

 

 

 

one end of the pipe.

 

 

 

Remove the pipe from the right hand housing

 

 

 

to reveal the bypass valve

 

 

 

31.2 Using a pair of pliers, pull out the bypass

 

 

 

valve (A) from the housing

 

 

 

To refit, follow the above in reverse. Ensure

 

 

 

any seals that have been disturbed are

 

 

 

renewed.

 

 

 

32. Expansion vessel

 

A

 

The expansion vessel can be replaced with the

 

 

 

boiler in position if there is a side exit flue fitted

 

 

 

and there is a minimum clearance of 340mm

 

 

 

above the boiler casing. If vertical flue is fitted

 

 

 

then a similar clearance to one side and the flue

 

 

 

is required.

32.1

32.2

 

If clearance is not available, the boiler will need to

 

be removed from the mounting frame to gain

 

 

 

access to the expansion vessel.

 

 

 

Alternatively a second vessel of at least the

 

 

 

capacity of 7lts can be fitted to the return from

 

 

 

the heating system as close as possible to the

 

 

 

boiler.

 

 

 

Expansion vessel replacement

 

 

 

(Boiler in place)

 

 

 

Isolate mains power from the boiler.

 

 

 

Place the controls in service position.

 

32.3

 

Isolate the boiler from the heating system

 

 

(and cylinder return if internal diverter valve is

 

 

 

fitted) using service valves.

 

 

 

Drain boiler.

 

 

 

32.1 Remove clip from expansion vessel

 

 

 

connection.

 

 

 

32.2 Remove screw retaining the vessel to the top

 

 

 

of the boiler casing.

 

 

 

32.3 Pull the vessel up and out over the flue

 

 

 

system or to one side if fitted with a vertical

 

 

 

flue.

 

 

 

Remove the flexible hose from the expansion

 

 

 

vessel and fit to the replacement vessel

 

 

 

using a new seal. Ensure that the connection

 

 

 

to the boiler will be pointing to the right hand

 

 

 

side of the appliance when fitted.

 

 

 

Reassemble expansion vessel into boiler and

 

 

 

connect flexible pipe to boiler.

 

 

 

Removing boiler

 

 

 

Isolate electrical supply.

 

 

 

Isolate system and gas connections at the

 

 

 

service valves.

 

 

 

Drain boiler.

 

 

 

Disconnect electrical supply and any external

 

 

 

controls.

 

 

 

Disconnect flue connection from the boiler.

 

 

 

Undo connection to boiler at the service valves.

 

 

 

Remove clip from expansion vessel

 

 

 

connection to the boiler.

 

 

 

Gently raise the boiler off the mounting frame.

 

 

 

Replace expansion vessel and refit the boiler

 

 

 

to the mounting frame.

 

 

 

Follow the commissioning procedure in this

 

 

 

manual.

REPLACEMENT OF PARTS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR 24 i junior/28 i junior 8 716 107 336b (11/05)

Image 52
Contents Appliance is for USE with Natural GAS or L.P.G. Cat II 2H3P Type C13 & C33Natural GAS Liquid Petroleum GASContact Information Installation & Servicing Instructions Installation & Servicing InstructionsContents Safety Precautions Installation RegulationsSpecifications General InformationGeneral Information Standard PackageTechnical Data Technical DataLayout & Components Layout & ComponentsGAS Inlet Connection 22mm Compression Trap / SyphonLayout & Components Cleaning Primary Systems Cleaning Primary SystemsCleaning the Primary System Open all drain cocks and drainMains Supply Mains SupplyWater Systems & Pipework Water Systems & PipeworkCondensate Pipework Condensate PipeworkPressure Relief Pipework Pressure Relief PipeworkVentilation Free Compartments Installation Clearances Servicing Clearances Vented CompartmentBoiler Location Clearances Boiler Location & ClearancesBoiler Location BathroomsPlumbing Manifold Plumbing ManifoldConnections Heating System 22mm compression fittingsFlue Terminal Positions Flue Terminal PositionsDrwg Terminal Position Distance From a terminal facing the terminal 1200mmFlue Options Flue OptionsUnpacking Wall Frame Ancillary Items Ancillary ItemsImportant Handling Instructions Unpacking Wall FrameWall Mounting Template Flue Opening Wall Mounting Plate Flue OpeningUnpacking the Appliance Unpacking the ApplianceBoiler Connections Boiler ConnectionsGAS and Water Connections Flue Installation Flue Installation189mm 93mm Edge of case 200mm 250mm min Turret Clamp FlueAddition of Flue Bends Assembling the Flue Fitting the FlueFitting the Elbow Additional Notes and RemindersCondensate Connection Condensate ConnectionCondensate Connection Electrics ElectricsPosition of Wired Components Position of Wired ComponentsChecks PRE-COMMISSIONINGPRE-COMMISSIONING Checks Filling the System Filling the SystemStarting the Appliance Switching the appliance on/offStarting the Appliance Water Treatment KEYWater Treatment Commissioning CommissioningInstalling Bottom Panel Finishing CommissioningFinishing Commissioning Replace Outer CasingInspection and Service Inspection and ServiceInspection Component Access Adjusting boiler control to Service positionRemoving outer case Primary Heat ExchangerSetting Boiler to Maximum Boiler will stay in this mode forTo maximum AgainTo Clean the Heat Exchanger Inspection and Service Small Tab Replacement of Parts Replacement of PartsPrimary sensor Overheat thermostatMoving boiler control to service position Gas adjusterGas valve SiphonPCB fuse Access to boiler control componentsTransformer / PCB 12.1 12.212.3 Replacing control14.4 13.2 13.314.2 15.3 15.1 15.218.4 18.1 18.2 18.3 19.1 20.121.1 21.2 22.1 22.223.1 23.2 24.125.1 26.1 26.228.1 28.2 27.1Hydraulic Block 27.229.1 29.230.1 Plastic protection device31.1 31.232.1 32.2 32.333.3 33.4Short Parts List 1112 1415 1718 2021 2324G. Conversion Code plugsCode plug G. ConversionFault Finding Fault FindingCentral Heating Function Ignition SequenceCentral Heating Function Preheat and DHW Function Preheat and DHW FunctionProtection Function Protection FunctionGAS Boiler Commissioning Checklist Service Interval Record Excellence Comes AS Standard Bonded Washer 3/4
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28i junior, 24i junior specifications

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