Worcester | ZB 7-28 HE system | Technical data | Worcester ZB 7-28 HE system Technical data

Worcester ZB 7-28 HE system Technical data
Installation and Servicing Instructions
R 28 HE system
Wall mounted condensing boiler for central heating
6 720 610 577-01.10
6 720 611 443 GB (03.11) TD
ZB 7-28 R 28 HE System GC Number: 41 311 62
Contents
Contents
Safety precautions
3
6.1.3
6.2
6.2.1
6.2.2
6.2.3
Symbols
3
6.2.4
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Details of the appliance
EC Declaration of Conformity
Standard package
Description of appliance
Accessories
Casing dimensions
Layout of appliance
Function (with optional extra motorised valve)
Electrical wiring diagram
Technical data
2
Installation regulations
10
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
Installation
Important remarks
Sealed systems
Siting the appliance
Wall mounting frame assembly
Pre-piping the system
Fitting the appliance
Checking the connections
Flue Systems
Siting the Flue Terminal
Installation of the flue
Flue duct preparation and assembly
11
11
11
13
14
14
15
17
17
18
19
20
4
4.1
4.2
4.3
4.3.1
Electrical connections
22
Connecting the appliance
22
Mains Voltage external controls connections 23
Wiring to your system
23
Pre-wired Remote S Plan
23
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
Commissioning
24
Commissioning
24
Switching the appliance on/off
25
Switching on the central heating
25
System controls
25
Appliances with optional plug-in diverter valve:
Setting hot water temperature
26
Frost protection
26
Pump anti-seize function
26
Fault Condition
26
6
6.1
6.1.1
6.1.2
Individual settings
Mechanical settings
Checking the size of the expansion vessel
Setting the central heating flow temperature
2
4
4
4
4
5
5
6
7
8
9
6.2.5
6.2.6
6.3
Changing the heating pump characteristic
Settings on the Bosch Heatronic
Operating the Bosch Heatronic
Selecting the pump control mode for central
heating mode (Service Function 2.2)
Setting the anti-cycle time
(Service Function 2.4)
Setting the maximum CH flow temperature
(Service Function 2.5)
Setting the switching difference
(Service Function 2.6)
Setting the heating out
Setting the gas/air ratio
27
28
28
28
28
28
29
29
29
7
Converting the appliance to different gas
types
30
7.1 Setting the gas/air ratio
30
7.2 Testing combustion air/flue gas at set heat output
32
7.2.1 Testing the O2 or CO2 level in the combustion
air
32
7.2.2 Testing CO and CO2
32
8
Maintenance
8.1 Pre-Service Check List
8.2 Description of servicing operations
8.3 Replacement of Parts
8.3.1 PCB control board and transformer
8.3.2 Fan Assembly
8.3.3 Pump
8.3.4 Optional 3-way diverter valve
8.3.5 3-way diverter valve motor
8.3.6 Sensors
8.3.7 Gas Valve
8.3.8 Electrode assembly
8.3.9 Pressure gauge
8.3.10Expansion vessel
8.3.11Pressure Relief Valve
8.3.12Burner
8.3.13Primary Heat Exchanger
33
34
35
38
38
39
39
39
40
40
40
40
41
41
41
41
41
9
9.1
9.2
9.3
9.4
9.5
9.5.1
42
42
43
43
43
44
44
Appendix
Fault Codes
Short parts list
Heating/hot water output settings (N.G)
Heating/hot water output settings (L.P.G)
Operational Flow diagrams
Central heating function
27
27
27
27
6 720 611 443 GB (03.11)
Safety precautions
Safety precautions
If you smell gas
B Turn off gas service cock at the meter.
B Open windows and doors.
B Do not operate any electrical switches.
B Extinguish any naked flames.
B Telephone your gas company.
If you smell fumes from the appliance
B Switch off appliance (see page 24).
B Open windows and doors.
Fitting and modifications
B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance with the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use on sealed primary systems only.
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
Unpacking
IMPORTANT HANDLING INSTRUCTIONS
B Two people should transfer the packaged appliance
from the van to the point of installation
B Open the top of the carton, remove and place the
component tray and both side bars of the wall mounting frame to one side
B Lie the packaged appliance on its back. (The back
has “TRUCK HERE” printed on the carton)
B One person firmly holds the packaging while the
other straddles the boiler and slides it from the packaging
B Two persons are then required to lift one end and
stand the appliance upright with the flue at the top
Additional requirements for roof space installation
B Two people should use two step ladders and share
lifting the unpacked boiler up to the loft hatch
B Where the boiler enters the loft space, tilt and slide
the boiler on its back to the point of installation
Check the contents against the packing list.
Symbols
B Use only original spare parts!
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance
being electrically unsafe.
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.
B There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
B The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Explain to the customer how the appliance works and
how to operate it.
B Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it.
B These instructions are to be left with the user or at
the Gas meter.
B Important: These instructions apply in the UK only.
6 720 611 443 GB (03.11)
3
Details of the appliance
1
1.1
Details of the appliance
1.3
EC Declaration of Conformity
• Wall-mounted appliance, siting not dependent on
room size
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.
Description of appliance
• Natural gas models are low-emission appliances
• Multi function display
• Bosch Heatronic control system
• Automatic ignition
CE-0085 BL 0507
• Modulating control
Category
UK
II2H 3P
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
Appliance Type
C13, C33
PIN
Table 1
• Concentric flue/air duct with testing point for
CO2/CO
• Regulated speed fan
1.2
Standard package
• Pre-mix burner
• Temperature control for central heating
• Gas condensing boiler for central heating
• Safety temperature limiter in 24 V electrical circuit
• Wall mounting frame
• Three-speed central heating pump
• Fixings (screws etc.)
• Set of documentation for appliance
• Relief valve, pressure gauge, expansion vessel, automatic air vent
• Pre-plumbing manifold
• Flue gas temperature limiter (105 °C)
• Condensate drain pipe.
• Condensate Trap
• Connecting possibility for S-Plan System.
4
6 720 611 443 GB (03.11)
Details of the appliance
1.4
Accessories
• Standard horizontal flue kit at 100 mm outside
diameter for flues up to 4 m in length.
• Flue duct kits for horizontal (125 mm outside
diameter) for flue lengths up to 13 m and vertical flue
systems for flue lengths up to 13.7 m. Fitting instructions are sent with these kits.
• Heating programmers
• Timer
• Motorised valve is available as an optional extra. If
this option is used then an integral programmer,
Night Set Back Module and TR2 Optimising Room
Thermostat will be required.
1.5
Casing dimensions
min
min
10*
10*
Z
600*
X
Y
850
850
120
101
13
103
30
200
35
360
395
*
200
440
6 720 610 601- 01.4O
Fig. 1
13
101
103
X
Manifold assembly
Outer case
Facia cover
Standard Concentric Horizontal Flue System: min. 160 mm
Alternative Concentric Flue System: min. 220 mm
Y
Standard Concentric Horizontal Flue System: 40mm
Alternative Concentric Flue System: 70mm
Z
Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
*
For servicing the appliance
Note: Horizontal flue only: dimension X may need to increase due
to the incline of the flue.
6 720 611 443 GB (03.11)
5
Details of the appliance
1.6
Layout of appliance
120
221.1
221.2
27
226
20
102
32.1
29
36
271
6
415
43
9
63
416
358
18
64
423
7
18.1
418
15
8.1
295
4
417
6 720 610 599 - 00.TD
Fig. 2
4
6
7
8.1
9
15
18
18.1
20
27
29
32.1
36
43
63
64
102
120
221.1
6
Heatronic control
Heat exchanger safety temperature limiter
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Relief valve
Pump
Pump speed selector switch
Expansion vessel
Automatic air vent
Air gas Mixer unit
Electrode assembly
Temperature sensor in CH flow
CH flow
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
Inspection window
Fixing points
Flue duct
221.2
226
295
271
358
415
416
417
418
423
Combustion air intake
Fan assembly
Appliance type sticker
Flue duct
Condensate trap
Cover plate for cleaning access
Condensate collector
Clip for fixing outer case
Data plate
Siphon
6 720 611 443 GB (03.11)
Details of the appliance
1.7
Function (with optional extra motorised valve)
Fig. 3
4
6
7
8.1
9
13
15
18
20
26
27
29
29.1
30
32
33
35
36
43
45
47
52
52.1
55
56
57
61
63
64
69
Bosch Heatronic control
Temperature limiter, heat exchanger
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Manifold
Safety valve
Central heating pump
Expansion vessel
Charging valve
Automatic vent
Mixer unit
Bi-metallic thermostat for combustion air compensation
Burner
Flame sensing electrode
Igniter electrode
Heat exchanger with cooled combustion chamber
Temperature sensor in CH flow
CH flow
Gas inlet
CH return
Solenoid valve 1
Solenoid valve 2
Filter
Gas valve CE 427
Main valve disc
Reset button
Adjustable gas flow restrictor
Adjusting screw for min. gas inlet flow volume
Control valve
6 720 611 443 GB (03.11)
71
72
84
88
221
226
229
317
358
423
443
Storage water heater outflow (only with optional motorised
valve)
Storage water heater return (only with optional motorised
valve)
Motor (optional extra)
3-way valve (optional extra)
Flue duct
Fan
Inner casing
Display
Condensate trap
Siphon
Diaphragm
7
Details of the appliance
1.8
Electrical wiring diagram
o - orange
bl - black
r - red
33
365
364
61
366
363
367
ECO
4.1
25 V
153
30V/AC
230 V
310
136
135
2
312
328
302
313
151
318
124 789
L N Ns Ls LR
161
p
p
300 314
p
84
M
328.1
9
M
6
M
r
r
mains supply
18
o
226
52
52.1
56
o
bl
bl
bl
bl
36
32
6 720 610 601-02.2O
Fig. 4
4.1
6
9
18
32
33
36
52
52.1
56
61
84
135
136
151
153
161
226
300
302
310
312
313
314
318
328
328.1
363
8
Ignition transformer
Temperature limiter, heat exchanger
Flue gas temperature limiter
Pump
Flame sensing electrode
Ignition electrode
Temperature sensor in CH flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Diverter valve motor (optional extra)
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
Link
Fan
Code plug
Earth connection
Temperature control for hot water
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Connector for Night Set Back Module TA212E
Connector for integral programmer
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
364
365
366
367
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
6 720 611 443 GB (03.11)
Details of the appliance
1.9
Technical data
Units
Natural gas
Propane
Max. rated heat output net 40/30°C central heating
Max. rated heat output net 50/30°C central heating
Max. rated heat output net 80/60°C central heating
kW
kW
kW
29.3
29.0
27.4
29.3
29.0
27.4
Max. rated heat input net
kW
27.7
27.7
Min. rated heat output net 40/30°C
Min. rated heat output net 50/30°C
Min. rated heat output net 80/60°C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
Min. rated heat input net
kW
7.6
10.8
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (CVnet 34.02 MJ/m3)
m3/h
2.9
-
LPG (CVnet 88 MJ/m3)
kg/h
-
2.1
mbar
20
-
mbar
-
37
bar
0.75
0.75
l
10
10
Flue gas temp. 80/60°C, rated/min. load
°C
67/55
67/55
Flue gas temp. 40/30°C, rated/min. load
°C
43/32
43/32
Residual delivery pressure
(inc. pressure drop in air intake duct)
Pa
80
80
CO2 level at max. rated heat output
CO2 level at min. rated heat output
%
%
9.2
8.8
10.8
10.5
5
5
Band
A
A
l/h
2.3
2.3
4.8
4.8
AC ... V
230
230
Frequency
Hz
50
50
Max. power consumption
W
102
102
Gas supply pressure
Natural gas G20 (CVnet 34.02 MJ/m3)
3
LPG (CVnet 88 MJ/m )
Expansion vessel
Charge pressure
Total capacity
Flue
NOx-class
SEDBUK figure
Condensate
Max. condensation rate (tR = 30°C)
pH-value, approx.
General Data
Electrical power supply voltage
Noise output level
dB(A)
36
36
Appliance protection rating with blanking plate fitted
IP
X4D
X4D
Max. CH flow temperature
°C
nom. 90
nom. 90
Max. permissible operating pressure (CH)
bar
3
3
Permissible ambient temperatures
°C
0 - 50
0 - 50
Nominal capacity of appliance
l
3.75
3.75
Weight (excluding packaging)
kg
43
43
Table 2
6 720 611 443 GB (03.11)
9
Installation regulations
Gas supply
Condensate analysis, mg/l
Ammonium
1.2
≤ 0.01
Lead
Nickel
0.15
≤ 0.0001
Mercury
Cadmium
≤ 0.001
Sulphate
Chromium
≤ 0.005
Zinc
≤ 0.015
Tin
≤ 0.01
Halogenated
hydrocarbons
≤ 0.002
Hydrocarbons
0.015
Vanadium
Copper
0.028
pH-value
1
Total length of gas supply pipe
(metres)
3
9
Gas discharge rate (m3/h)
8.7
5.8
4.6
22
18.0
12.0
9.4
28
≤ 0.001
4.8
Table 3
Table 8
Flue system
2
HORIZONTAL 100 mm – Standard FLUE SYSTEM
Overall Diameter of Duct
mm
100
Flue Terminal / Duct
Assembly Length
mm
600
Extension Duct Length
mm
1000
Max.
4m
Table 4
HORIZONTAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1030
Max.
13 m
(including
turret)
Table 5
VERTICAL 100 mm FLUE SYSTEM
Overall Diameter of Duct
mm
100
Flue Terminal / Duct Assembly
mm
1140
Excl.
terminal
Max.
5m
Table 6
Installation regulations
Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.
• BS 6798: Specification for the installation of gas
fired hot water boilers of rated input not exceeding
60kW
• BS 5449: Central Heating for Domestic Premises
• BS 5546: Installation of gas hot water supplies for
domestic purposes
• BS 5440:1: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Flues
VERTICAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1365
Table 7
Elbow - 90 ° Equivalent length 2 m
Bend - 45 ° Equivalent length 1m
6
Pipe diameter
(mm)
Excl.
terminal
Max.
13.7 m
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28 mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply
• BS 7671: Requirements for Electrical Installation.
These instructions must be followed.
10
6 720 611 443 GB (03.11)
Installation
3
Installation
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
3.1
Fixing of the appliance, gas and flue connections, commissioning of the system
and electrical connections may only be
carried out by competent persons authorised by CORGI.
Important remarks
B Appliance should only be installed in sealed central
heating systems.
3.2
Sealed systems
The appliance must not be operated without the system
being full of water, properly vented and pressurised.
The expansion vessel has a volume of 10 litres and is
charged to a pressure of 0.75 bar.
The water capacity of the system is shown in table 12,
page 27. If a greater capacity is required then an additional expansion vessel must be fitted into the system
return as close to the appliance as possible. The system
pressure can be set up to a maximum of 1.5 bar with 1
bar being the normal setting.
If the system pressure is greater than 2.5 bar when the
appliance is operating at maximum temperature then an
additional expansion vessel must be fitted into the system return as close to the appliance as possible.
B To avoid gas formation in the system, galvanised radiators or pipes must not be used.
The filling point must be at low level and arranged as
shown in fig. 8.
B If a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.
The pressure relief valve is set to operate at 3 bar.
B Add a suitable anti-freeze fluid compatible with aluminium to the water in the central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563, Fernox Tel.: 01799 550811
and Salamander Tel: 0121 378 0952.
B In our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.
There must be no connection to the mains without the
approval of the local water company. All connections in
the system must be capable of withstanding a pressure
of up to 3 bar and the radiator valves conform to the
requirements of BS 2767:10.
Fit Thermostatic Radiator Valves to radiators in the
sleeping accommodation and not to the radiator where
the room thermostat is sited, this must be left open.
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
No galvanised radiators or pipes must be used.
If any system water treatment is required then
only products suitable for use with Aluminium
shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the
manufacturers instructions. The use of any other
substances will invalidate the guarantee. The pH
value of the system water must be less than 8 or
the appliance guarantee will be invalidated.
Suitable products are available from Betz-Dearborn Tel:
0151-4209563 and Fernox Tel: 01799-550811.
A drain cock to BS2879 must be fitted to the lowest
point of the system.
IMPORTANT: Check that no dirt is left in the
water pipework as this could damage the appliance. Thoroughly flush the heating system and
the mains water supply before fitting the appliance to the wall in accordance with the recommendations of BS7593:1992.
6 720 611 443 GB (03.11)
11
Installation
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Heating Return
APPLIANCE
LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
6 720 610 601-04.1O
Cylinder Return
RV
Heating Flow
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Hot Water Flow
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
System layout if using optional built-in diverter valve (This must be used in conjunction with an integral
programmer, Night Set Back Module and TR2 Optimising Room Thermostat)
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
Diverter
Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
Fig. 6
12
6 720 610 601-05.1O
APPLIANCE
LV
Hot Water Flow
Cylinder Return
RV
Heating Return
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Heating Flow
Fig. 5
System layout if using external diverter valve (excludes using a Honeywell ‘Y’ plan valve).
6 720 611 443 GB (03.11)
Installation
LV
RV
INDIRECT
CYLINDER
LV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
CH
Zone
Valve
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
DHW Zone Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
6 720 610 601-06.1O
RV
Heating Return
LV
Hot Water Flow
APPLIANCE
LV
RV
Fig. 7
Cylinder Return
RV
Heating Flow
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
System layout if using twin zone valves (S) plan
Fig. 8
3.3
Siting the appliance
Surface temperature
B Consult the installation instructions for details of minimum clearances required.
The max. surface temperature of the casing and the flue
is less than 85 °C.
This means that, no special safety precautions are
required with regard to flammable building materials
and fitted furniture. The specified clearances must be
maintained.
Combustion air
Cupboard/Compartment
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS 6798 and BS 5440:2 are followed. The
low casing losses from the appliance eliminate the need
for ventilation openings in the compartment.
Regulations concerning the Installation Site
B Relevant national regulations must be complied with
section 3.8.1.
Substances classed as corrosion-promoting include
halogenated hydrocarbons which contain chlorine and
fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and household cleaners, for example.
6 720 611 443 GB (03.11)
13
Installation
3.4
Wall mounting frame assembly
B Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 9. Use
the inner lugs on the top and bottom horizontal sections.
B Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
6 720 610 576-11.1O
Fig. 11
6 720 610 576-04.1O
3.5
Pre-piping the system
Fig. 9
200
B Hold the wall-mounting frame against the wall ensuring that it is vertical.
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 18.
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 12 Manifold
43
47
112
171
172
6 720 610 576-05.1O
Fig. 10
14
CH flow
CH return
Gas cock
Optional cylinder flow (used only with motorised valve)
Optional cylinder return (used only with motorised valve)
B A drain tap should be fitted at the lowest point of the
central heating system.
B WRAS approved filling loop must be fitted.
6 720 611 443 GB (03.11)
Installation
Condensate Termination and Route
The appliance has a built-in syphonic condensate trap
eliminating the need for external traps. Connect to the
22mm plastic drain pipe and extend the pipe run away
from the control panel and appliance witha constant fall
of 2.5° or 25mm in every metre. See fig. 14.
The condensate pipe can terminate into any of four
areas:
External condensate pipework
The syphonic condensate trap collects condensate into
a trap which releases it in 100 ml quantities. This helps
to prevent the discharge from freezing.
If there is no alternative and the condensate pipe has to
be externally run, the following should be considered:
• The pipe run should take the shortest practical route.
• The pipework should be insulated with weather
resistant insulation.
Boiler
Boiler
Ø 22 min.
Sink
Siphon
No length
restriction
Siphon
Ø 22 min.
75 min. trap
Open end of pipe
direct into gully,
below ground but
above water level.
Use waterproof pipe work
insulation in very exposed
positions
The gradient of the discharge pipe
should be 2.5¡ (40 mm/m) minimum
Open end of pipe direct
into gully, below ground
but above water level
An internal waste system
• The pipework should be installed with the minimum
of horizontal runs and with a downward slope of at
least 2.5 °.
The gradient of the discharge pipe should be
2.5¡ (40 mm/m) minimum
An external waste system
Boiler
Boiler
Internal soil
and vent stack
Ø 22 min.
No length
restriction
Sink
Siphon
Ø 22 min.
75 min. trap
The gradient of the discharge pipe
should be 2.5¡ (40 mm/m) minimum
75 min. trap
450 min.
No length
restriction
• The pipe should terminate as close as possible to the
ground or drain, whilst still allowing the condensate
to safely disperse. This would prevent wind blowing
up the pipe.
Invert
The rainwater system
3.6
Open end of pipe
direct into gully,
below ground but
above water level
Benchmark: For optimum performance
after installation, this boiler and its associated central heating system must be
flushed in accordance with the guidelines given in BS5793:1992 “Treatment
of water in domestic hot water central
heating systems”.
The gradient of the discharge pipe
should be 2.5¡ (40 mm/m) minimum
An external purpose made soakaway
6 720 610 596 -03.2TD
Fig. 13
Whilst all of the above methods are acceptable it is
always the best practice to terminate the condense pipe
via an internal waste system.This will eliminate the need
for any external condensate pipe runs which can be susceptible to freezing in extreme weather.
Fitting the appliance
Removing the outer case
i
The outer case is secured against unauthorised removal by two screws (electrical
safety). Always secure the outer case with
those screws again after refitting.
B Remove retaining screws (1.).
B Slide the outer case upwards and then forwards to
remove (2.).
B Remove the plastic caps from the boiler connections.
2
6 720 610 602 - 04.1O
Fig. 14 Recommended route of the condensate drain
1
Fig. 15
6 720 611 443 GB (03.11)
15
Installation
Fixing the appliance
3.7
B Fit the washers onto the gas and water connections.
Water connections
B Lift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
B Take care not to disturb the washers on the connections.
Connecting the flue assembly
B Fit flue duct connector onto appliance flue spigot.
B Secure with the screws supplied.
Checking the connections
B Check that the O-rings or seals are in place before
tightening the connection.
B Turn on the service valves for central heating flow
and return and fill the heating system through a
WRAS approved filling loop.
B Check all seals and unions for leaks (testing pressure
max. 3.0 bar as indicated by pressure gauge).
B Check all connections for leaks.
Gas supply pipe
B Check that the seal is in place before tightening the
connection.
Flue Turret
B Turn off gas cock to protect gas valve against damage from excessive pressure.
Flue seal
B Check gas supply pipe.
Retaining
Screw
Appliance
Flue Socket
Flue Turret to
Boiler Sealing
Gasket
6 720 610 599 - 01.TD
Fig. 16
B For remaining installation of flue assembly, refer to
the relevant installation instructions.
B Release the pressure on the gas supply pipe.
3.8
Flue Systems
The only flue systems that may be used are those supplied with the boiler.
The flue system must be installed in accordance with
the requirements of BS 5440:1.
Standard 100 mm flue system
The standard concentric flue system provides for a horizontal length of up to 4 m. Full instructions for fitting this
flue are in Subsection 3.8.2 “Installation of the flue”.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue
systems are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13 m.
A vertical flue system up to a height of 13.7 metres is
available.
45° and 90° flue bends can be used with a corresponding reduction in flue length of 2 m for each 90° bend and
1 m for each 45° bend used.
IMPORTANT: Any horizontal flue system fitted to a
condensing boiler must incline from the appliance at an
angle of 3° (30 mm per metre length) to prevent condensate dripping from the flue terminal.
Note, the standard 100mm horizontal flue requires only
a 0.5° incline from the boiler as the inner exhaust pipe is
inclined at 2.5° inside the outer pipe.
This means that the clearance above the appliance must be increased to match the duct length.
Refer to fig. 1 on page 5.
16
6 720 611 443 GB (03.11)
Installation
3.8.1
lighting, activated by passive infra-red sensing heads.
If the terminal is less than 2 m above a surface to which
people have access then a guard must be fitted. The
guard must be evenly spaced about the terminal with a
space of 50 mm in each direction and fixed with plated
screws.
A guard Type K6 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
Siting the Flue Terminal
The flue must be installed in accordance with
BS 5440:1 and the Building Regulations. Flue terminals
in carports and under balconies are to be avoided.
The terminal must be positioned so that it does not
cause an obstruction nor the combustion products a
nuisance. See fig. 17 and table 9.
The terminal will, at times, give out a plume of water
vapour and consideration must be given to this when
choosing a terminal position. Keep clear of security
P
Q
boundary
Q
I
D,E
Q
B
H
C
F
J
N
A
L
G
M
H
I
H
K
Fig. 17
Minimum dimensions of flue terminal positions (all types) (see fig. 17)
Dimension
Terminal Position (kW input expressed in net)
A1)
Directly below an opening, air brick, opening windows, etc.
B
1)
Balanced flues room sealed: Fanned draught
300 mm
Above an opening, air brick, opening window, etc.
300 mm
C1)
Horizontally to an opening, air brick, opening window, etc.
300 mm
D
Below gutters, soil pipes or drain pipes
E
Below eaves
200 mm
F
Below balconies or car port roof (lowest point)
Not recommended
G
From a vertical drain pipe or soil pipe
H
From an internal or external corner or to a boundary alongside the
terminal
300 mm
I
Above ground roof or balcony level
300 mm
J
From a surface or boundary facing the terminal
1200 mm
K
From a terminal facing the terminal
2000 mm
L
From an opening in the car port (e. g. door, window) into the dwelling
Not recommended
M
Vertically from a terminal on the same wall
1500mm
N
Horizontally from a terminal on the same wall
300 mm
75 mm
75 mm
P
From a vertical structure on the roof
500 mm
Q
Above intersection with roof
300 mm
Table 9
1)
In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
6 720 611 443 GB (03.11)
17
Installation
3.8.2
Installation of the flue
The standard 100 mm diameter horizontal flue system is
suitable for lengths up to 4 m.
Flues up to 650 mm do not require an extension duct
assembly.
Flues between 1600 mm and 4000 mm require extension duct assemblies.
NOTE: Flue lengths between 650 mm and 730 mm
cannot be accommodated. Refer to fig. 19, 20, 21.
Flue
Turret
Standard 100mm system comprise:
• Flue turret
Maximum 650mm
Outer
Wall
Minimum 100mm
• Flue turret clamp
• Terminal assembly
Clamp
• Wall sealing gasket and cover plate.
Terminal
Assembly
6 720 610 599 - 01.TD
Refer to fig. 22.
Instructions for fitting other flue systems are packed
with the relevant flue kit.
Check that the position chosen for the appliance is satisfactory. Refer to fig. 18.
Centre line of
flue/air duct
H
Fig. 19 Standard Flue
m
120m
3°
Top of wall
mounting
frame (not
boiler)
Appliance
Drilling
point for
flue duct
opening
H = 40mm for the Standard 100mm Horizontal Flue
H = 70mm for the Optional 125mm Horizontal Flue
6 720 610 602-08.3O
Centre
line of
flue
opening
and
appliance
(30mm/metre)
Standard 100mm
horizontal flue 0.5°
(5mm/metre)
Fig. 18 Marking the position of a side flue opening.
Note: ensure ther is adequate access to the
air/flue sampling points in the flue turret.
18
6 720 611 443 GB (03.11)
Installation
Maximum 1600mm
Outer
Wall
Flue
Turret
Extension
Duct
Clamp
Terminal
Assembly
6 720 610 599 - 00.TD
Fig. 20 Flue with one extension
Outer
Wall
Flue
Turret
Clamp
Extension
Duct
Clamp
Extension
Duct
Clamp
Terminal
Assembly
6 720 610 599 - 01.TD
Fig. 21 Flue with extensions
Flue
Turret
Clamp
Flue Terminal
Extension Flue Duct
Wall Sealing Gasket
6 720 610 599 - 01.TD
Fig. 22 Flue components
3.8.3
Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 23, 24.
6 720 611 443 GB (03.11)
19
Installation
The assembly will be made easier if a solvent free
grease is lightly applied i.e Silicone lubricant, to the
male end of the ducts.
L
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assembly.
Push the assembly through the wall and fix the turret to
the appliance using the screws provided. Refer to fig.
26.
120
6 720 610 599 - 01.TD
Flue Turret
Fig. 23 Flue length - rear
Flue seal
L
Retaining
Screw
Appliance
Flue Socket
Flue Turret to
Boiler Sealing
Gasket
6 720 610 599 - 01.TD
Fig. 26 Flue turret
6 720 610 599 - 01.TD
Fig. 24 Flue length - side
Measure ‘L’ from the end of the metal section of the flue
terminal to the centre of the flue outlet on the boiler as
shown in Fig. 23 & Fig. 24 and deduct 90mm from that
measurement.
Ensure that the turret is fully secured to the socket on
the boiler.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal and fixed with corrosion resistant
screws.
Cut both inner and outer flue pipe square at the opposite end to the terminal without creasing the tubes.
Remove any burrs before fitting the terminal to the turret.
Outer Wall Face
Flue Terminal
Wall Sealing Gasket
6 720 610 599-00.TD
Fig. 25 Flue terminal position
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must be directed as per Fig. 25.
20
6 720 611 443 GB (03.11)
Electrical connections
4
Electrical connections
B Always disconnect the power supply to
the appliance at the mains before carrying out any work on the electrical systems and components.
B Pull out cover panel at the bottom and remove. Refer
to fig. 27.
3
0
4
2
5
1
E
All control and safety systems are built into the appliance.
B Allow mains cable to protrude at least 50 cm from
wall.
B To maintain the splash-proof (IP) design: cut the
cable grommet hole size to match the diameter of the
cable, see fig. 29.
B The appliance must be earthed.
B It must be possible to completely isolate the appliance with at least 3mm contact separation in both
poles.
6 720 610 332-10.1R
Fig. 27
B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 28.
3
0
The wiring between the appliance and the electrical
supply shall comply with current IEE Wiring Regulations
(and any local regulations which apply) for fixed wiring
to a stationary appliance.
4
2
5
1
E
• Supply: 230 V ~ 50 Hz, 150 Watts
• External fuse 3 A
• The system connected to the boiler must NOT have
a separate electrical supply
• Water Protection IPX4D (with fascia blanking plate
fitted or IP20 without blanking plate).
4.1
Connecting the appliance
To gain access to the mains connection remove the
drop down facia cover. The drop down cover is
removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
release the cover. Lift cover from the appliance.
6 720 610 332 -11.1R
Fig. 28
B Cut cable grommet to diameter of cable.
3
0
2
4
5
1
E
After installation (or in the event of an electrical fault) the
electrical system shall be checked for short circuits,
fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.
8-9
5-7
10-12
13-14
6 720 610 332-12.1R
Fig. 29
B Feed cable through cable grommet and connect the
mains supply cable, see fig. 30.
6 720 611 443 GB (03.11)
21
Electrical connections
B Secure cable in cable grommet by means of cable
grip.
L
N NS
4.2
Wiring to your system
The boiler is fitted with an internal pump and there are
two recommended ways of connecting a system, external 230v or internal 24v depending on the choice of
diverter valve(s).
4.2.1
External 230v
Non-supplied parts required: external 230v conventional terminal block or wiring centre, pre-wired to the
230v diverter valve(s) and all other 230v system components.
Note: Honeywell and Siemens Y plan valves require a
Fig. 30
capacitor in the external wiring block or wiring centre
to avoid any feedback problems, if there is no other
alternative, please contact Worcester Bosch helpline
08705 266241 for further details.
• See section 4.1 to gain access to the boiler mains
wiring centre
• Remove the connecting link from Ls and Lr terminals
and connect the system to the boiler as shown in
Fig. 31
Permanent
Mains supply
(NOT ALLOWED)
System
Water
Valve/s
Room Stat
Tank Stat
Timer
• Any other components (including frost thermostats)
cannot be connected to the boiler and should
instead be connected to the external terminal block
or wiring centre in accordance with the manufacturers proprietary instructions. No liability is accepted
arising from or by any wiring external to the boiler.
Remote Pre-wired
Junction Box
Terminal Strip
L out
E L N
External pump
(DISCONNECT
AND REMOVE)
Boiler/pump
demand from
junction box.
Mains electrical supply to junction box
(NO OTHER SUPPLY TO
JUNCTION BOX ALLOWED)
OUTSIDE OF BOILER
INSIDE OF BOILER
L
N NS L S L R
MAINS ONLY
6 720 610 603 -05.TD
Fig. 31 External 230v connections
22
6 720 611 443 GB (03.11)
Commissioning
4.2.2
Internal 24v
Non-supplied Worcester Bosch parts required:
• See section 4.1 to gain access to the boiler mains
wiring centre
Description
Part Number
• Keep the link connecting the Ls and Lr terminals
24v Diverter valve (including
tank NTC)
7 719 002 090
• Refer to instructions supplied with each part
TR2 room thermostat
7 774 901 137
• Externally wired frost protection is not required as
this is provided by the boiler’s internal frost thermostat and the TR2 room thermostat.
Night set back module
7 744 901 136
Twin channel programmer
7 716 192 032
Table 10
5
Commissioning
27
136 365
61
317 366 367
358
ECO
364
363
135
8.1
E
310
295
15
170
171
172
173
170
6 720 610 576-07.2O
Fig. 32
8.1
15
27
61
135
136
170
171
172
173
295
310
317
358
363
Pressure gauge
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for central heating
Service cocks on CH flow and return
Optional cylinder flow (used only with motorised valve)
Gas cock (shown in on position)
Optional cylinder return (used only with motorised valve)
Appliance type sticker
Temperature control for hot water
Multi function display
Condensate trap
Indicator lamp for burner
6 720 611 443 GB (03.11)
364
365
366
367
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
23
Commissioning
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
i
The operational CO2 level is set at the factory and no adjustment is necessary when
installing a natural gas fired appliance.
Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance
with the guidelines given in BS 7593:1992 - Treatment
of water in domestic hot water systems. Full instructions
are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should
be used in accordance with the inhibitor manufacturers
instructions.
To drain the appliance shut the system valves and open
the system drain point.
Suitable flushing agents and inhibitors are available
from Betz-Dearborn Tel: 0151-4209563 and Fernox
Tel: 01799-550811. Instructions for use are supplied
with the these products.
B Before commissioning, the gas supply pressure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7).
Natural gas appliances must not be operated if
the gas supply pressure is below 18 mbar or
above 24 mbar. LPG appliances must not be
operated if the supply pressure is not 37 mbar
at the inlet to the appliance.
5.2
Switching the appliance on/off
Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the central heating flow temperature, when the
appliance is operating in the central heating mode.
6 720 610 333-04.1O
Fig. 33
i
If the display alternates between -II- and
the central heating flow temperature, the
trap filling programme is active.
The trap filling programme ensures that the condensation trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
Switching off the appliance
B Set the master switch to (0).
The green indicator lamp goes out.
B Unscrew the condensation trap (358) and pull out, fill
with approx. 1/4 l of water and refit. Refer to fig. 32.
B Always disconnect the appliance from
the power supply (fuse, circuit breaker)
before carrying out any work on the
electrical systems or components.
B Adjust charge pressure of expansion vessel to static
head of the central heating system (see page 27).
B Open all system radiator valves.
B Check automatic air vent is open (27) fig. 32
5.3
B Turn on service valves (170), fill central heating system to pressure of 1 - 2 bar through the WRAS
approved filling loop. Refer to fig. 32.
The central heating flow temperature is adjustable
between 35°C and 88°C. Refer to table 13, page 27.
B Vent radiators.
B Refill heating system and set the pressure to 1 bar.
B Turn on cold water service cock (173). Refer to
fig. 32.
B Check that the gas type specified on the identification plate matches that of the gas supply.
B Turn on gas cock (172). Refer to fig. 32.
24
Switching on the central heating
B Turn the temperature control
to set the flow temperature to a level appropriate to the type of central
heating system:
– Underfloor heating: e.g. setting “3”
(approx. 50°C)
– Low-temperature heating: setting “E”
(approx. 75°C)
6 720 611 443 GB (03.11)
Commissioning
– Central heating systems for flow temperatures up
to 88 °C: limited “max” setting for low-temperature
operation (see page 27).
When the burner is alight, the red indicator lamp
lights up.
6 720 610 333-05.1O
Fig. 34
5.4
System controls
B Set room thermostat to the desired room temperature.
B Set room temperature controller, if fitted. Refer to the
instructions with the control.
B Set the thermostatic radiator valves to the desired
settings.
6 720 611 443 GB (03.11)
25
Commissioning
5.5
Appliances with optional plug-in
diverter valve: Setting hot water
temperature
B Do not set the temperature higher than
60°C for normal operation.
B Only use temperatures of up to 70°C
temporarily for thermal disinfection purposes.
B Set the hot water temperature by means of the temperature control
on the appliance.
5.6
The appliance has an in-built frost protection device
which is generally suitable for most applications.
B Leave master switch switched on.
If the appliance is to be left for long periods switch the
central heating off:
B Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel: 0151-4209563 and Fernox Tel: 01799550811.
5.7
i
6 720 610 333-07.1O
Pump anti-seize function
This function prevents the central heating
pump seizing after long periods of inactivity.
Every time the pump is switched off, a timer is started.
If after 24 hours the pump has not run again, it is
switched on for a period of 5 minutes.
Fig. 35
Control Setting
Water Temperature
Anti-clockwise limit
approx. 10°C
(frost protection)
approx. 60°C
Clockwise limit
Frost protection
approx. 70°C
5.8
i
Fault Condition
A list of faults that may occur is given on
page 42.
Table 11
In the unlikely event of a fault occurring while the appliance is in operation:
ECO button
The display then shows a fault code and the button
may also flash.
Pressing and holding the ECO button
Comfort mode to ECO-mode.
switches from
Comfort mode, ECO button is not lit (factory setting)
Comfort mode the hot water tank has priority. The hot
water cylinder is first heated up to the set temperature.
The appliance then switches to central heating mode.
ECO mode, button is lit
In ECO mode the appliance switches between central
heating mode and cylinder charging mode every
12 minutes.
26
If the button
flashes:
B Press and hold the button
until the display shows
“– –”.
The appliance will then start up again and the display
will show the central heating flow temperature.
If the button
does not flash:
B Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the central heating flow temperature will be displayed.
6 720 611 443 GB (03.11)
Individual settings
6
Individual settings
6.1
Mechanical settings
6.1.1
Checking the size of the expansion vessel
Maximum pressure at maximum CH flow temperature is
2.5 bar. If the pressure is greater than this then fit an
extra expansion vessel. Refer to table 12.
System Capacity – BS 7074:1
Expansion Vessel Pressure and System Capacity
Expansion Vessel
litres
10
Expansion Vessel
Charge Pressure
bar
0.75
System
pressure
and
capacity
B Rotate yellow button through 180° and replace (dot
facing inwards).
The CH flow temperature is no longer limited.
Control setting
CH flow temperature
1
2
3
4
5
E
max
approx. 50°C
approx. 55°C
approx. 60°C
approx. 65°C
approx. 70°C
approx. 75°C
approx. 88°C
Table 13
1 bar
litres
82
6.1.3
1.5 bar
litres
46
The speed of the central heating pump can be altered
on the pump terminal box.
i
Table 12
6.1.2
Setting the central heating flow temperature
The central heating flow temperature can be set to
between 50°C and 88°C.
Changing the heating pump characteristic
H
At switch position 1, maximum output is
not delivered if hot water mode is active.
Position 1 must not be used on combi appliances.
0,7
(bar)
i
With underfloor heating systems, observe
the maximum permissible flow temperatures.
0,6
0,5
Limited maximum setting for low-temperature
operation
0,4
The temperature control is factory limited to setting E,
giving a maximum flow temperature of 75°C.
0,3
3
2
0,2
Adjustment of the heating output to the calculated heat
demand is not required by the heating systems regulations.
1
0,1
0
Removing the maximum setting limit
0
200
400
600
800
1000 1200 1400 1600
Q (l/h)
For heating systems which require higher flow temperatures, the maximum setting limit can be removed.
B Lift off the yellow button on the temperature control
with a screwdriver.
6 720 610 576-23.2O
Fig. 37
1
2
3
H
Q
Pump characteristic for switch position 1
Pump characteristic for switch position 2
Pump characteristic for switch position 3
Residual delivery pressure
Water circulation rate
6 720 610 332-27.1O
Fig. 36
6 720 611 443 GB (03.11)
27
Individual settings
6.2
Settings on the Bosch Heatronic
Entering a setting
6.2.1
Operating the Bosch Heatronic
B To enter the setting for a function, turn the temperature control
.
The Bosch Heatronic enables easy setting and checking of a large number of appliance functions.
Storing a setting
This description is limited to those functions required
for commissioning.
B Level 1: press and hold the
play shows [ ].
For a full description of all available functions, please
refer to the Service booklet for the Engineer, order no.
7-181-465-346.
B Level 2: press and hold the
and
buttons simultaneously until the display shows [ ].
5
2
After completing the settings
1
B Reset the temperature controls
original positions.
6.2.2
i
6 720 610 332-30.1O
4
3
Fig. 38 Appliance controls
1
2
3
4
5
Service button
“Chimney sweep” button
Temperature control for central heating
Temperature control for hot water
Display
The service functions are subdivided into two levels:
Level 1 comprises service functions up to function 4.9,
while Level 2 consists of the service functions from 5.0
upwards.
B To select a service function on Level 1: press and
hold the
button until the display shows – –.
B To select a service function on Level 2: press and
hold the buttons
and
simultaneously until the
display shows = =.
B Then turn the
temperature control to select the
required function.
Service function
Code no.
See page
Pump control mode
Anti-cycle time
Max. CH flow
temperature
2.2
2.4
28
28
Switching difference
Max. heating output
to their
Selecting the pump control mode for central heating mode (Service Function 2.2)
If an room temperature controller unit is
connected, pump control mode 3 is automatically activated
• Control Mode 1
For heating equipment without a control unit.
The pump is controlled by the central heating flow
temperature control.
Note the positions of the temperature controls
and
. After completing the settings, return the temperature controls to
their original positions.
2.5
2.6
5.0
and
The choice of settings is as follows:
Selecting service function:
i
button until the dis-
• Control Mode 2 (factory setting)
For heating systems with room thermostat.
The central heating flow temperature control controls
only the gas, the pump is not affected. The room thermostat controls both the gas and the pump.
The pump and fan have an overrun time of between
15 s and 3 min.
• Control Mode 3
The pump is controlled by the room temperature controller unit. In summer mode, the pump operates only
for hot water mode.
6.2.3
Setting the anti-cycle time
(Service Function 2.4)
This service function is only active if Service Function
2.7, automatic anti-cycle time, is deactivated.
The anti-cycle time can be set to between 0 and 15 minutes (is factory set to 3 minutes).
If the setting 0 is entered, the anti-cycle time is inactive.
The shortest possible anti-cycle time is 1 minute (recommended for single-pipe and hot-air heating systems).
28
6.2.4
29
29
The maximum CH flow temperature can be set to
between 35°C and 88°C (factory setting).
Setting the maximum CH flow temperature (Service Function 2.5)
Table 14
The service function 5.0 may be reset.
28
6 720 611 443 GB (03.11)
Individual settings
6.2.5
i
Setting the switching difference
(Service Function 2.6)
If the appliance is connected to an outside-temperature controlled programmer,
the programmer sets the switching difference.
It does not need to be set on the appliance.
The switching difference is the permissible divergence
from the specified CH flow temperature. It can be set in
increments of 1°C. The adjustment range is 1 to 30°C
(is factory set to 0°C). The minimum CH flow temperature is 30°C.
6.2.6
Setting the heating output
(Service Function 5.0)
The heating output can be set to any level between min.
rated heat output and max rated heat output to limit it to
the specific heat requirements.
The factory setting is the max. rated heat output.
B Set the room thermostat and thermostatic radiator
valves to max. temperature.
B Press and hold the
and
buttons simultaneously until the display shows [ ].
The heating output is now stored.
6 720 610 332-52.1O
Fig. 41
B Return the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperate.
6.3
Setting the gas/air ratio
The appliance is set at the factory and adjustment to the
CO2 settings (gas/air ratio) is only required where the
appliance has been stripped down and assembled or if
the fan, burner or gas valve are replaced or the appliance has been converted to a different gas type, see
section 7.
B Press and hold the
and
buttons simultaneously until the display shows = =.
The
and
buttons will light up.
6 720 610 332-50.1O
Fig. 39
B Turn the temperature control
until the display
shows 5.0.
After a short delay, the display then shows the set
heating output in percent.
6 720 610 332-51.1O
Fig. 40
B Refer to the settings tables for heating and cylinder
charging output to obtain the relevant code for the
desired heating output in kW (see page 43).
B Turn the temperature control
until the display
shows the desired code number.
The display and the
and
buttons will flash.
B Measure the gas flow rate and compare with the figures specified for the code number displayed. If figures do not match, adjust the code number!
6 720 611 443 GB (03.11)
29
Converting the appliance to different gas types
7
Converting the appliance to different gas types
The setting is factory sealed at maximum. Adjustment to
the rated heat input and min. heat input is not necessary.
Checking the gas supply pressure
B Check the gas supply pressure at the gas supply
pressure testing point.
i
Natural gas appliances must not be operated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is below or above
37 mbar.
Natural gas
7.1
Setting the gas/air ratio
The gas/air ratio may only be adjusted on the
basis of a CO2 measurement at max. heat output
and min. heat output using an electronic tester.
B Switch off the appliance at the master switch (O).
B Remove the outer case (see page 15, refer to
fig. 15).
B Switch on the appliance at the master switch (I).
B Set room thermostat to maximum temperature.
B Open thermostatic radiator valves.
B Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 42.
B Insert testing probe about 135 mm into the flue gas
testing point and seal testing point.
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m 3 and 20 mbar supply
pressure and sealed.
234
6 720 610 599 - 01.TD
Fig. 42
B Press and hold
button until the display shows – –.
The
button will light up.
6 720 610 332-32.1O
Fig. 43
B Turn the temperature control
until the display
shows 2.0 .
After a short delay, the current operating mode setting will be displayed (0. = Normal mode).
6 720 610 332-60.1O
Fig. 44
30
6 720 611 443 GB (03.11)
Converting the appliance to different gas types
B Turn the temperature control
until the display
shows 2. (= max. rated heat output).
The display and the
button will flash.
B Remove the seal from the gas valve adjusting
screw (64) and adjust the CO2 level to the figure
given in Table 15 for min. rated heat output.
64
6 720 610 332-61.1O
Fig. 45
B Measure the CO2 level.
B Prise off the seal on the gas flow restrictor.
B Adjust the gas flow restrictor (63) to obtain the CO2
level given in Table 15. Refer to fig. 46.
3928-74.1R
Fig. 48
B Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
B Turn the temperature control
anti-clockwise as
far as the stop so that the display shows 0.
(= Normal operating mode).
The display and the
button will flash.
63
B Press and hold the
shows [ ].
6 720 610 332-64.1R
button until the display
B Reset the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperature.
B Remove testing probe from the flue gas testing
point (234) and refit sealing plug.
Fig. 46
Gas Type
Natural gas type
G20
LPG G31
(propane)
CO2 reading
at max.
rated heat
output
CO2 reading
at min. rated
heat output
9.2 %
8.8 %
10.8 %
10.5 %
B Re-seal gas valve adjusting screw and gas flow
restrictor.
B Replace outer case and secure.
B Set room thermostat and thermostatic radiator valves
to the desired temperature.
Table 15
B Turn the temperature control
anti-clockwise until
the display shows 1. (= min. rated heat output).
The display and the
button will flash.
6 720 610 332-63.1O
Fig. 47
B Measure the CO2 level.
6 720 611 443 GB (03.11)
31
Converting the appliance to different gas types
7.2
Testing combustion air/flue gas at set heat output
7.2.1
Testing the O2 or CO2 level in the combustion air
i
By testing the O 2 or CO2 level in the combustion air the gas tightness of a type C 13
or C33 flue system can be checked. The
O2 level must not be less than 20,6 %.
The CO2 level must not exceed 0,2 %.
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
In “chimney sweep” mode, the appliance
switches to max. rated heat output or the
set heating output. You then have 15 minutes in which to measure the levels. After
that, the appliance switches back from
“chimney sweep” mode to normal mode.
B Remove sealing plug from combustion air testing
point (234.1, Fig. 49).
7.2.2
Testing CO and CO2
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
You have 15 minutes in which to measure
the levels. After that, the appliance switches back from “chimney sweep” mode to
normal mode.
B Remove sealing plug from flue gas testing point
(234, fig. 49).
B Insert testing probe about 135 mm into the testing
point and seal testing point.
B CO- and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
B Insert testing probe about 80 mm into the testing
point and seal testing point.
234.1
234
6 720 610 599 - 01.TD
Fig. 49
B Measure O2 and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
32
6 720 611 443 GB (03.11)
Maintenance
8
Maintenance
B Always disconnect the appliance from
the electrical power supply (fuse, circuit
breaker) before carrying out any work on
the electrical systems or components.
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
There is a special Service booklet for the
Engineer, order no. 7-181-465-346, available to competent persons.
i
All safety and control systems are monitored by the Bosch Heatronic. In the event
of a component fault, the display shows a
fault code.
B The User should be recommended to have the appliance serviced regularly by a competent person (see
Maintenance Contract).
B Use only genuine spare parts
B Refer to the Spare Parts List when ordering spare
parts.
B Always renew seals and O-rings removed during
servicing or repair work.
B Use only the following types of grease:
– Water valve: WRAS approved silicon based
grease
– Unions: approved sealant.
B To drain the appliance shut the system valves and
open the pressure relief valve.
B To drain the appliance shut the system valves and
open the pressure relief valve.
B Upon completion of any electrical work check for
earth continuity, correct polarisation and resistance
to earth.
6 720 611 443 GB (03.11)
33
Maintenance
8.1
Pre-Service Check List
Date
1
Call up the last fault stored by the
Bosch Heatronic, Service Function .0,
(see page 35).
2
Check ionisation current, Service
Function 3.3, (see page 35).
3
Perform visual check of air/flue
duct.Visual check of diaphragm for
soiling and splits (see page 37).
4
Check gas supply pressure
(see page 30).
5
Test combustion air/flue gas
(see page 32).
6
Check CO 2 setting for min./
max. (gas/air ratio)
(see page 30).
mbar
min. %
max. %
7
Check gas and water systems for
leaks (see page 16).
8
Check heat exchanger
(see page 35).
9
Check burner (see page 36).
mbar
10 Clean condensation trap
(see page 36).
11 Check charge pressure of
mbar
expansion vessel matches
static head of heating system.
12 Check central heating system mbar
pressure.
13 Check electrical wiring for damage.
14 Check heating programmer settings.
15 Check appliances that are part of
the heating system.
Table 16
34
6 720 611 443 GB (03.11)
Maintenance
8.2
Description of servicing operations
The combustion performance must be checked before
and after any servicing work on the combustion and
burner components. Refer to section 7.1.
B Remove the fan and the burner as described in the
text headed “Burner” (see page 36).
Check “Last fault stored”:
B Select Service Function .0 (see page 28 “Selecting
service function”).
There is a list of the fault codes in the Appendix (see
page 42).
To delete “Last fault stored”:
B Turn temperature control
the stop.
anti-clockwise as far as
B Press and hold the
button until the display
shows [ ].
The last fault stored has now been deleted.
Checking the ionisation current,
Service Function 3.3
6 720 610 332-72.1R
Fig. 51
B Loosen any deposits in the heat exchanger from top
to bottom using the cleaning blade. Refer to fig. 52.
B Select Service Function 3.3 (see page 28 “Selecting service function”).
If the display shows 2 or 3, the ionisation current is OK.
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced.
Primary Heat exchanger
There is a special accessory kit (no. 840) for cleaning
the heat exchanger, order no. 7 719 001 996.
B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manometer.
6 720 610 332-73.1R
Fig. 52
B Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 53.
6 720 610 332-69.1R
Fig. 50
6 720 610 332-74.1R
i
The heat exchanger should only be
cleaned if the control pressure is
4.2 mbar (depression) or less.
Fig. 53
B Flush the heat exchanger from the top. Refer to
fig. 54.
B Remove cleaning access cover (415, page 6) and
the metal plate below it, if present. Refer to fig. 2.
B Unscrew condensation trap and place suitable container underneath. Refer to fig. 51.
6 720 611 443 GB (03.11)
35
Maintenance
B Clean out the condensate collector and trap connection (with other end of brush).
6 720 610 332-75.2R
Fig. 54
B Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
Burner
B Check that the gas cock is turned off and the master
switch is in the OFF position.
B Remove the clips (1.) and unscrew the two bolts (2.).
Refer to fig. 55.
B Unscrew and remove the two hexagon screws securing the fan (3.).
7 181 465 330-09.2R
Fig. 56
B Re-assemble burner in reverse order inspect seal for
damage and replace if necessary.
B Adjust gas/air ratio. Refer to section 7.2.
B Slacken fully the rear securing bolt (4.).
Condensation trap
B Remove the burner coverplate.
In order to prevent spillage of condensate, the condensation trap should be completely removed, (see
page 35, fig. 51).
4.
B Unscrew condensation trap and check connection to
heat exchanger is clear.
B Remove condensation trap cover and clean.
2.
B Fill condensation trap with approx. 1/4 l of water and
refit.
3.
1.
Electrode assembly
B Switch off the master switch.
B Pull off the leads from the electrodes. Refer to fig. 2.
Fig. 55
B Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 50.
B Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 56.
B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4 mm ± 1 mm.)
7 181 465 330-04.1R
B Replace and re-connect the assembly taking care not
to mislay the inspection window.
36
6 720 611 443 GB (03.11)
Maintenance
Siphon
Diaphragm in mixer unit
B Take care not to damage diaphragm
(443) when removing and refitting it.
B Unscrew the clip and disconnect the pipe to the
siphon.
B Remove the drain plug to drain the siphon.
B Open mixer unit (29).
B Carefully withdraw diaphragm (443) from fan intake
tube and check for soiling and splits.
3.
B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
B Refit and prime the siphon.
443
Condensate
Drain
29
Siphon
Drain Plug
1.
Fig. 58
Expansion vessel
The expansion vessel should be checked once a year.
2.
B Depressurise appliance.
6 720 610 790-07.2R
Fig. 57
B Carefully refit diaphragm (443) the correct way round
into the fan intake tube.
i
The flaps of the diaphragm (443) must
open upwards.
B Seal the mixer unit (29).
B If necessary, adjust expansion vessel charge pressure to static head of the heating system.
Heating system pressure
i
Fill the system using the WRAS approved
filling loop.
B The pointer on the pressure gauge should be 1 bar.
B If the pointer is below 1 bar (when the system is
cold), water should be added until the pointer is
1 bar again.
B Max. pressure of 2.5 bar when the heating system
water is at maximum temperature must not be
exceeded. If this pressure is exceeded then an extra
expansion vessel must be fitted in the system return
as close to the appliance as possible.
B If the system does not retain the pressure, the expansion vessel and the heating system should be
checked for leaks.
Electrical wiring
B Check the electrical wiring for physical damage and
replace any damaged wires.
6 720 611 443 GB (03.11)
37
Maintenance
8.3
B Remove the pcb control board.
Replacement of Parts
Before changing any components check that the gas is
turned off and that the appliance is electrically isolated.
When necessary close the system valves and drain the
appliance.
Refitting is a reverse of the procedure for removal using
new seals or o-rings as appropriate.
8.3.1
PCB control board and transformer
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the covers. Refer to fig. 27, 28.
B Remove screw holding power connector earth lead
and remove earth lead.
B Remove two top fixing screws from the control box.
Refer to fig. 62.
1
3
2 4
3
1
7 181 465 330-10.1R
4
1
3
2 4
2
5
Fig. 60
E
Fuses
1
7 181 465 329-02.1R
3
2 4
Fig. 59
B Remove the connections covers. Refer to fig. 27,
28.
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
B Lower the control box.
Fuse, item 312, is only replaceable by removing the
pcb.
B Unscrew earth lead.
Spare fuses are fixed to the connections cover.
B Unscrew four fixing screws from cover plate. Refer to
fig. 63.
A fuse pack is available: Part number 8 744 503 010 0.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.
38
6 720 611 443 GB (03.11)
Maintenance
8.3.2
Fan Assembly
8.3.3
3.
Pump
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Remove two switchbox fixing screws (1.). Refer to
fig. 62.
2.
B Lower switchbox (2.).
B Unscrew and remove the siphon by releasing the
jubilee clip. Refer to fig. 58.
B Unscrew the pump union nuts (3). Refer to fig. 62.
4.
B Carefully remove the pump and disconnect the leads.
Alternatively
B After removing the siphon release the four Allen
screws and remove and replace the pump head.
3.
1.
7 181 465 330-05.1R
Fig. 61
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 61.
B Remove fan lead and earth connector (2.). The earth
connector has a positive clip fixing.
1.
1.
B Remove fixing screws attaching fan to the burner
cover (3.).
B Remove fan together with gas pipe and mixer unit.
B Separate the fan from the pipe and mixer unit by
twisting the mixer unit to release it (4.).
2.
Fig. 62
8.3.4
Optional 3-way diverter valve
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Turn off service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 63.
B Pull out retaining clip.
B Remove motor.
B Disconnect the relief valve drain.
B Disconnect the pressure gauge by withdrawing the
clip and pulling out the capillary head.
B Undo pipe unions by withdrawing the clips.
6 720 611 443 GB (03.11)
39
Maintenance
B Remove 3-way valve.
8.3.7
Gas Valve
B Check that the gas cock is turned off.
B Lower the control panel. Refer to fig. 62.
B Pull off the solenoid connections at the rear of the
valve.
B Undo the union, within the inner casing, securing the
valve to the gas/air tube. Refer to fig. 61.
B Remove the white plastic cap from the gas valve.
B Release the gas inlet union at the manifold assembly.
B Unscrew the two screws securing the gas valve
assembly bracket to the back panel and withdraw the
assembly.
B Transfer the bracket and inlet pipe assembly to the
new gas valve.
B Check for gas soundness when the new gas valve
has been fitted.
B Recheck the combustion performance as described
in section 7.1.
7 181 465 330-12.1R
Fig. 63
After refitting:
B Fill system, bleed and re-pressurise
(see Installation Instructions).
8.3.5
3-way diverter valve motor
B Switch off the appliance.
B Turn off the service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 63.
B Pull out retaining clip.
B Remove motor.
8.3.6
Sensors
B Check that the appliance is electrically isolated.
Central Heating Flow Temperature Sensor –
Item 36, fig. 2, 62
B Pull-off the connector.
B Release the sensor clip and withdraw the sensor.
B Apply heat transfer paste to the replacement sensor.
Safety Temperature Limiter – Item 6, fig. 2, 62
B Pull-off the connectors.
B Unscrew the sensor.
Flue Temperature Limiter – Item 9, fig. 2, 62
B Pull-off the connectors.
B Unscrew the sensor.
6 720 610 602 - 04.1O
Fig. 64
8.3.8
Electrode assembly
B Refer to section 8.2.
B Use a new seal if the existing seal is damaged.
40
6 720 611 443 GB (03.11)
Maintenance
8.3.9
Pressure gauge
B Drain the appliance.
B Lower the facia. Refer to fig. 62.
B Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
appliance.
B Twist the pressure gauge head anti-clockwise to
release it from the casing. Refer to fig. 2.
B Disconnect the capillary head from the rear by withdrawing the clip and pulling out the head. Refer to
fig. 57.
8.3.10 Expansion vessel
B Drain the appliance.
B Undo the union connection at the base of the vessel.
Refer to fig. 2.
B Unscrew the top and bottom fixing screws and
remove the vessel.
B Set the pressure of the new vessel to that required by
the system.
8.3.11 Pressure Relief Valve
B Drain the appliance.
B Disconnect the drain pipe from the valve. Refer to
fig. 32.
B Pull-out the clip securing the valve.
B Pull-out the valve.
B Ensure that the replacement valve is fully entered
before fitting the clip.
8.3.12 Burner
B Refer to section 8.2.
8.3.13 Primary Heat Exchanger
B Drain the appliance.
B Check that the gas supply is turned off.
6 720 610 602 - 06.10
Fig. 65
B Check that the appliance is electrically isolated.
B Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 8.3.2.
B Remove the burner. Refer to section 8.2.
B Disconnect the sensors. Refer to section 8.3.6.
B Undo the central heating flow union.
B Undo the top connection of the pump. Refer to
fig. 57.
B Undo the grey plastic cap, next to the top pump connection at the base of the heat exchanger.
B Unscrew and remove the condensate trap. Refer to
section 8.2.
B Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
B Lift up the flue duct, item 271, refer to fig. 2.
B Pull forward from the top and lift the heat exchanger
from the casing.
B Transfer components, as necessary, to the new heat
exchanger.
6 720 611 443 GB (03.11)
41
Appendix
9
Appendix
9.1
Fault Codes
More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.
Display
code
Description
Remedy
A8
Break in communication
Check connecting lead to programmer
AC
Module not detected.
Check connecting lead between TA211E/TR212E
and Heatronic
b1
Code plug not detected.
Insert code plug correctly, test and replace if necessary.
C1
Fan speed too low.
Check fan lead and connector, and fan; replace as
necessary.
d3
Jumper 8-9 not detected.
Connector not connected, link missing, underfloor
heating limiter tripped.
E2
CH flow NTC sensor defective
Check CH flow NTC sensor and connecting lead.
E9
Safety temp. limiter in CH flow has tripped.
Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA
Flame not detected.
Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0
Internal error.
Check electrical connector contacts, programmer
interface module ignition leads are not loose; replace
pcb if necessary.
F7
Flame detected even though appliance switched off.
Check electrode assembly, dry pcb. Flue clear?
FA
Flame detected after gas shut off.
Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue
clear?
Fd
Reset button pressed by mistake.
Press reset button again
P1, P2, P3,
P1...
Please wait, initialisation in progress.
24 V fuse blown. Replace fuse.
Table 17
42
6 720 611 443 GB (03.11)
Appendix
9.2
Short parts list
Key
Description
Qty GC
Spare part number
1
Sensor - Flue gas temp.
1
8 722 963 858 0
2
Sensor - CH flow temp.
1
8 714 500 087 0
3
Control board
1
8 748 300 395 0
4
Gas valve
1
8 747 003 508 0
5
Fan assembly
1
8 717 204 373 0
6
Fan washer
1
8 729 000 183 0
7
Expansion vessel
1
8 715 407 236 0
8
Relief valve
1
8 717 401 012 0
9
Electrode assembly
1
8 718 107 077 0
10
Electrode lead
1
8 714 401 999 0
11
Pump
1
8 717 204 384 0
12
Pressure gauge
1
8 717 208 079 0
13
Burner skin seal
1
8 711 004 168 0
14
Transformer - facia
1
8 747 201 358 0
15
Heat exchanger washer
1
8 710 103 153 0
16
Washer set Condensation Trap
1
8 710 103 154 0
17
Fuse set
1
8 744 503 010 0
18
Primary heat exchanger
1
8 715 406 615 0
Table 18
9.3
Heating/hot water output settings
(N.G)
9.4
Heating/hot water output settings
(L.P.G)
Propane
Natural gas G20
Display
code
Heat
output,
kW
Heat
input,
kW
Gas vol. flow rate
(l/min at
tV/tR = 80/60°C)
Display
code
Heat output kW
Heat input kW
40
11.0
11.1
30
8.2
8.3
14.5
50
13.7
13.9
40
11.0
11.1
19.4
60
16.5
16.6
50
13.7
13.9
24.2
70
19.2
19.4
60
16.5
16.6
29.1
80
21.9
22.2
70
19.2
19.4
33.9
90
24,7
24.9
80
21.9
22.2
38.8
100
27.4
27.7
90
24,7
24.9
43.6
100
27.4
27.7
48.5
Table 20
Table 19
6 720 611 443 GB (03.11)
43
Fan speed
reduces
over 15
secs.
Fan min.
speed for
90 secs.
Boiler
unused
for long
period.*
Yes
*Minimum
heat
input for
15min.
No
Ignition sequence
Ignition spark for
5 seconds.
Burner lights. Red
light ON.
Yes
CH demand
satisfied.
Gas valve closes.
Red light OFF.
Pump and Fan
run for up to 3
mins.
No
6 720 611 443 GB (03.11)
Repeats 5 times
(N.G.) or 3 times
(L.P.G.) before
lock-out.
Fan runs to
purge gas from
burner.
* NOTE: The sequence ensures that the condensate siphon is not empty
after long OFF periods. (More than 24 hours without a demand).
6 720 610 576 - 26.TD
Appendix
Burner
stabilises at
start speed for
5-10 secs
Pump ON Fan to
start speed. Gas
valve opens.
Operational Flow diagrams
CH
demand.
9.5
Green
light
ON.
Boiler
operates to
match
system load
and CH
control
setting.
Central heating function
Mains
switch
ON.
Room
thermostat
and/or mains
programmer or
link ON AND
Electronic facia
programmer (if
fitted) ON AND
CH control
knob ON.
Over temperature
shut down if water
temperature is 5°C
above set value.
Gas valve shuts.
Pump remains ON.
9.5.1
Fig. 66
44
Burner remains OFF
until flow temperature
is below set value.
Appendix
6 720 611 443 GB (03.11)
45
Appendix
46
6 720 611 443 GB (03.11)
Appendix
6 720 611 443 GB (03.11)
47
Appendix
EXCELLENCE COMES AS STANDARD
Worcester Bosch, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
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