GREENSTAR HE combi - Worcester, Bosch Group

GREENSTAR HE combi - Worcester, Bosch Group
Installation and Servicing Instructions
GREENSTAR HE combi
Wall mounted condensing boiler for central heating and mains
fed domestic hot water
6 720 610 577-00.10
6 720 610 576 GB (02.05) OSW
ZWB 7-27 HE combi GC-Number: 47 311 55
Contents
Contents
Safety precautions
3
Symbols
3
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
4
4
4
4
5
5
6
7
8
9
2
Details of the appliance
EC Declaration of Conformity
Standard package
Description of appliance
Accessories
Casing dimensions
Layout of appliance
Function
Electrical wiring diagram
Technical data
Installation regulations
11
6
6.1
6.1.1
6.1.2
6.1.3
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
6.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.9.1
3.9.2
3.9.3
Installation
Important remarks
Domestic hot water
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
4
4.1
4.2
Electrical connections
21
Connecting the appliance
21
Mains Voltage external controls connections 22
5
5.1
5.2
5.3
5.4
5.5
23
23
24
24
24
Commissioning
Commissioning
Switching the appliance on/off
Switching on the central heating
System controls
Setting the domestic hot water
temperature and flow rate
5.5.1 Domestic hot water temperature
5.5.2 Hot water flow rate
5.6 Summer mode (hot water only)
5.7 Frost protection
5.8 Pump anti-seize function
5.9 Fault Condition
2
11
11
12
12
13
14
14
15
16
16
17
18
20
24
24
25
25
25
25
25
Individual settings
Mechanical settings
Checking the size of the expansion vessel
Setting the central heating flow temperature
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 maxim CH flow temperature
(Service Function 2.5)
Setting the switching difference
(Service Function 2.6)
Setting the heating output
(Service Function 5.0)
Constant hot water cycle time
(Service Function 6.8)
Setting the gas/air ratio
26
26
26
26
26
27
27
27
27
28
28
28
28
28
7
Converting the appliance to different
gas types
7.1 Setting the gas/air ratio
7.2 Testing combustion air/flue gas at set
heat output
7.2.1 Testing the O2 or CO2 level in the
combustion air
7.2.2 Testing CO and CO2
31
31
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 3-way diverter valve
8.3.5 3-way diverter valve motor
8.3.6 Sensors
8.3.7 Gas Valve
8.3.8 Domestic Hot Water Heat Exchanger
8.3.9 Electrode assembly
8.3.10Pressure gauge
8.3.11Expansion vessel
8.3.12Pressure Relief Valve
8.3.13Burner
8.3.14Flow switch
8.3.15Primary Heat Exchanger
32
33
34
38
38
39
39
40
40
40
41
41
41
41
41
41
41
42
42
9
9.1
9.2
9.3
9.4
9.5
9.5.1
9.5.2
43
43
44
45
45
46
46
47
Appendix
Fault Codes
Short parts list
Heating/hot water output settings (N.G.)
Heating/hot water output settings (L.P.G)
Operational Flow diagrams
Domestic hot water function
Central heating function
29
29
31
6 720 610 576 GB (02.05)
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.
Symbols
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
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.
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 wth 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.
B Use only original spare parts!
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.
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.
6 720 610 576 GB (02.05)
3
Details of the appliance
1
Details of the appliance
1.1
EC Declaration of Conformity
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.
1.3
Description of appliance
• Wall-mounted appliance, siting not dependent on
room size
• Natural gas models are low-emission appliances
• Multifunction display
PIN
CE-0085 BL 0507
Category
UK
II2H 3P
• Modulating control
Appliance Type
C13, C33
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
• Automatic ignition
Table 1
1.2
Standard package
• Gas condensing combination boiler for central heating and domestic hot water
• Wall mounting frame
• Clamp for securing flue duct kit
• Fixings (screws etc.)
• Set of documentation for appliance
• Pre-plumbing manifold
• Condensate drain pipe.
• Bosch Heatronic control system
• Concentric flue/air duct with testing point for
CO2/CO
• Regulated speed fan
• Pre-mix burner
• Temperature control for central heating
• Temperature sensor in domestic hot water
• Safety temperature limiter in 24 V electrical circuit
• Three-speed central heating pump with automatic
vent
• Relief valve, pressure gauge, expansion vessel
• Flue gas temperature limiter (105 °C)
• Hot water priority circuit
• Motorised 3-way valve
• Plate-type heat exchange
• Condensate Trap.
4
6 720 610 576 GB (02.05)
Details of the appliance
1.4
Accessories
• Standard horizontal flue kit at 100 mm outside
diameter for flues upto 4 m in length.
• Flue duct kits for horizontal (125 mm outside
diameter) for flue lengths upto 13 m and vertical flue
systems for flue lengths uto 15 m. Fitting instructions
are sent with these kits.
• Heating programmer
• Timer
• Security kit.
1.5
Casing dimensions
min.
min.
5
5
Z
Y
X
906
861
850
120
101
13
103
30
200
440
35
360
395
250
6 720 610 601-01.1O
Fig. 1
13
101
103
X
Y
Z
Manifold assembly
Outer case
Facia cover
Standard Concentric Horizontal Flue System: min. 310 mm
Alternative Concentric Flue System: min. 250 mm
Standard Concentric Horizontal Flue System: 158 mm
Alternative Concentric Flue System: 121 mm
Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
6 720 610 576 GB (02.05)
5
Details of the appliance
1.6
Layout of appliance
120
221.1
349
221.2
234.1
234
27
226
20
102
32.1
29
36
271
6
415
43
9
63
416
358
18
64
423
7
18.1
355
418
6.1
15
8.1
88
295
98
417
4
6 720 610 576-02.2O
Fig. 2
4
6
6.1
7
8.1
9
15
18
18.1
20
27
29
32.1
36
43
63
64
88
98
6
Heatronic control
Heat exchanger safety temperature limiter
Hot water NTC sensor
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
3-way valve (combi)
DHW flow switch (combi)
102
120
221.1
221.2
226
295
234
234.1
271
349
355
358
415
416
417
418
423
Inspection window
Fixing points
Flue duct
Combustion air intake
Fan assembly
Appliance type sticker
Testing point for combustion products
Testing point for combustion air
Flue duct
Cover plate for twin flue duct connection
Plate-type domestic hot water heat exchanger
Condensate trap
Cover plate for cleaning access
Condensate collector
Clip for fixing outer case
Data plate
Siphon
6 720 610 576 GB (02.05)
Details of the appliance
1.7
Function
Fig. 3
4
6
6.1
7
8.1
9
13
15
18
20
26
27
29
29.1
30
32
33
35
36
43
44
45
46
47
52
52.1
55
56
57
61
Bosch Heatronic control
Temperature limiter, heat exchanger
Hot water NTC sensor
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
Hot water flow
Gas inlet
Cold water inlet
CH return
Solenoid valve 1
Solenoid valve 2
Filter
Gas valve CE 427
Main valve disc
Reset button
6 720 610 576 GB (02.05)
63
64
69
84
88
90
91
93
94
95
96
97
98
221
226
229
234
234.1
317
355
358
423
443
Adjustable gas flow restrictor
Adjusting screw for min. gas inlet flow volume
Control valve
Motor
3-way valve
Venturi
Pressure relief valve
Water flow regulator
Diaphragm
Pushrod with switch cam
Microswitch
Valve for hot water flow volume
Water valve
Flue duct
Fan
Inner casing
Testing point for flue gas
Testing point for combustion air
Display
Plate-type heat exchanger
Condensate trap
Siphon
Diaphragm
7
Details of the appliance
1.8
Electrical wiring diagram
o - orange g - green bl - black
r - red
p - purple
33
365
364
61
317
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
310
136
135
312
328
302
313
151
318
315
124 789
L N Ns Ls LR
161
p
p
p
300 314
84
M
96
328.1
9
M
mains supply
18
g
6
M
g
o
r
r
o
226
52
52.1
56
o
o
bl
bl
bl
bl
36
bl
6.1
32
6 720 610 576-08.2O
Fig. 4
4.1
6
6.1
9
18
32
33
36
52
52.1
56
61
84
96
135
136
151
153
8
Ignition transformer
Temperature limiter, heat exchanger
Hot water NTC sensor
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
Motor, 3-way valve
Microswitch, hydraulic switch
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
161
226
300
302
310
312
313
314
315
317
318
328
328.1
363
364
365
366
367
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 programmer
Terminal block for programmer
Digital display
Connector for timer
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
6 720 610 576 GB (02.05)
Details of the appliance
1.9
Technical data
Units
Max. rated heat output net 40/30°C central heating
kW
Max. rated heat output net 50/30°C central heating
kW
Max. rated heat output net 80/60°C central heating
kW
Max. rated heat input net
kW
Min. rated heat output net 40/30°C
kW
Min. rated heat output net 50/30°C
kW
Min. rated heat output net 80/60°C
kW
Min. rated heat input net
kW
Max. rated heat output net, domestic hot water
kW
Max. rated heat input net, domestic hot water
kW
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (His = 9,5 kWh/m3)
m3/h
LPG (Hi = 12,9 kWh/kg)
kg/h
Gas supply pressure
Natural gas G20
mbar
LPG
mbar
Expansion vessel
Charge pressure
bar
Total capacity
l
Hot water specifications
Hot water flow rate (factory setting)
l/min
Max. hot water flow rate
l/min
Outlet temperature range
°C
Max. permissible water supply pressure
bar
Min. inlet pressure
bar
Specific flow rate
l/min
Flue
Flue gas temp. 80/60°C, rated/min. load
°C
Flue gas temp. 40/30°C, rated/min. load
°C
Residual delivery pressure
(inc. pressure drop in air intake duct)
Pa
CO2 level at max. rated heat output
%
%
CO2 level at min. rated heat output
NOx-class
SEDBUK figure, Band A
%
Condensate
Max. condensation rate (tR = 30°C)
l/h
pH-value, approx.
General Data
Electrical power supply voltage
AC ... V
Frequency
Hz
Max. power consumption
W
Noise output level
dB(A)
Appliance protection rating
IP
Max. CH flow temperature
°C
Max. permissible operating pressure (CH)
bar
Permissible ambient temperatures
°C
Nominal capacity of appliance
l
Weight (excluding packing)
kg
Natural gas
Propane
29.1
28.8
27.2
27.5
8.4
8.3
7.4
7.6
27.2
27.5
29.1
28.8
27.2
27.5
11.6
11.4
10.5
10.8
27.2
27.5
2.9
-
2.1
20
-
37
0.75
10
0.75
10
8
14
40 - 60
10
0.2
12.4
8
14
40 - 60
10
0.2
12.4
67/55
43/32
67/55
43/32
80
9.5
9.2
5
90.6
80
11.3
11.0
5
90.6
2.3
4.8
2.3
4.8
230
50
101
36
X4D
nom. 90
2.5
0 - 60
3.75
46
230
50
101
36
X4D
nom. 90
2.5
0 - 60
3.75
46
Table 2
6 720 610 576 GB (02.05)
9
Details of the appliance
Condensate analysis, mg/l
VERTICAL 125 mm FLUE SYSTEM
Ammonium 1.2
Nickel 0.15
Lead ≤ 0.01
Mercury ≤ 0.0001
Overall Diameter of Duct
mm
125
Cadmium ≤ 0.001
Sulphate 1
Flue Terminal / Duct Assembly
mm
1360
Chromium ≤ 0.005
Zinc ≤ 0.015
Extension Duct Length
mm
200
Halogenated
hydrocarbons ≤ 0.002
Tin ≤ 0.01
Extension Duct Length - Fixed
mm
450
Hydrocarbons 0.015
Vanadium ≤ 0.001
Extension Duct Length - Fixed
mm
950
Copper 0.028
pH-value 4.8
Extension Duct Length - Fixed
mm
1950
Extension Duct Length - Telescopic
mm
265375
Extension Duct Length Adjustable (Cut to length)
mm
450
Table 3
Flue system
HORIZONTAL 100 mm – Standard
Overall Diameter of Duct
mm
100
Flue Terminal / Duct Assembly Length
mm
750
Extension Duct Length
mm
1000
Max.
4m
Max.
15 m
Table 6
Elbow - 90 ° Bend - 45 °
Equivalent length 2 m Equivalent length 1m
Gas supply
Total length of gas supply pipe
(metres)
Table 4
ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
550
Extension Duct Length - Fixed
mm
200
Extension Duct Length - Fixed
mm
450
Extension Duct Length - Fixed
mm
950
Extension Duct Length - Fixed
mm
1950
Extension Duct Length Telescopic
mm
265375
Extension Duct Length - Adjustable (Cut to length)
mm
200
3
6
Pipe diameter
(mm)
9
Gas discharge rate (m3/h)
Max.
13 m
(including
turret)
8.7
5.8
4.6
22
18.0
12.0
9.4
28
Table 7
Domestic water performance
Temperature
Rise
30 °C
13.2
Temperature
Rise
35 °C
11.3
Temperature
Rise
40 °C
9.9
Maximum Mains pressure
bar
10.0
Minimum Mains pressure
bar
0.2
Domestic
Water Flow
Rate l/min
Table 5
Table 8
10
6 720 610 576 GB (02.05)
Installation regulations
2
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 (gross): Flues
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.
B To avoid gas formation in the system, galvanised radiators or pipes must not be used.
B If a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.
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 and Fernox Tel.: 01799
550811.
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.
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 60 kW (gross): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply.
These instructions must be followed.
6 720 610 576 GB (02.05)
11
Installation
3.2
Domestic hot water
3.3
Sealed systems
Any regulations specified by the local water company
must be observed.
The appliance must not be operated without the system
being full of water, properly vented and pressurised.
The final 600 mm of the mains cold water connection to
the applaince should be made in copper tube only.
The expansion vessel has a volume of 10 litres and is
charged to a pressure of 0.75 bar.
The appliance is suitable for a mains supply having a
maximum pressure of 10 bar. A pressure reducing valve
must be fitted, if necessary.
The water capacity of the system is shown in table 11,
page 26. 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.
The hot water outlet temperature is set to be capable of
achieving a maximum of 60°C. The maximum temperature and the frequency of the recharge of the heat store
may be reset.
The maximum water flow rate is factory set at 9.9 l/min
to give temperature rise of 40°C. If a higher rise is
required then the flow must be reduced at the tap and
the discharge temperature will rise up to the maximum
set figure.
If the system pressure is greater than 2.65 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.
The filling point must be at low level and arranged as
shown in figs. 5 and 6.
The temperature rise, upto the maximum set by the user,
is automatically maintained by the modulation of the
heat input. In winter, when the mains temperature is very
low, the water flow, adjusted at the tap or shower,
should be reduced to maintain the required delivery
temperature.
The pressure relief valve is set to operate at 3 bar.
It is suggested that long pipe runs to taps or showers
be insulated to prevent the rapid cooling of the water.
If Thermostatic Radiator Valves are fitted then it is recommended that one radiator is left open.
All types of single lever mixer taps and thermostatic
mixer units suitable for a mains pressure of up to 10 bar
can be used.
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
The head of a loose-head shower must not be allowed
to fall within 25 mm of the top the bath to prevent the
risk of water being drawn back into the mains. Alternatively the shower must be fitted with an anti-syphonage
device at the point of the flexible hose connections.
No galvanised radiators or pipes must be used.
Over-rim bidets may be connected to the appliance provided that it is in accordance with the requirements of
the local water company. The outlet(s) should be
shrouded and unable to have any temporary hand held
spray attached. No anti-syphonage arrangements are
necessary.
In exceptionally hard water areas a device to prevent
scale formation may be fitted or, alternatively, the maximum temperature reset to about 45°C which may
reduce the risk of scale formation. The installation of a
scale inhibitor assembly should be in accordance with
the requirements of the local water company. Artificially
softened water must not be used to fill the central heating system. An isolating valve should be fitted to allow
for servicing.
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.
If any system water treatment is required then only
products suitable for use with Aluminium shall be
used i.e Fernox- Copal 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.
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.
Devices, such as water meters or back-flow prevention valves, capable of preventing the flow of expansion water must not be fitted unless separate
arrangements have been made.
A Zilmet Z160 expansion vessel is the preferred type. A
thread sealant compatible with potable water must be
used.
12
6 720 610 576 GB (02.05)
Installation
APPLIANCE
Refer to Fig.1
Appliance
water flow
diagram
A drain cock should be fitted at
the lowest point of the heating
circuit and the appliance
WRC approved
filling loop
Lockshield
valve
Central heating return
Domestic
hot water
Central heating flow
Radiator
valve
BS stop valve.
Fixed spindle type
Water
main
Fig. 5
6 720 610 576 -09.2O
Sealed primary water system
Heating
return
Non-return
valve
Non-return
valve
Hose
union
Hose
union
Test
cock
Test
cock
Temporary hose
6 720 610 576 - 10.1O
Fig. 6
Sealed primary water system - filling method
3.4
Siting the appliance
Regulations concerning the Installation Site
Surface temperature
B Relevant national regulations must be complied with
section 3.9.1.
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 clearences must be
maintained.
B Consult the installation instructions for details of minimum clearances required.
Combustion air
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
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.
6 720 610 576 GB (02.05)
Cupboard/Compartment
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS6798 and BS5440:2 are followed. The low
casing losses from the appliance eliminate the need for
ventilation openings in the compartment.
13
Installation
3.5
Wall mounting frame assembly
B Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 7. Use
the inner lugs on the top and bottom horizontal
sections for the appliances that are 440 mm wide.
B Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
6 720 610 576-11.1O
Fig. 9
6 720 610 576-04.1O
3.6
Pre-piping the system
Fig. 7
200
B Hold the wall-mounting frame against the wall
ensuring that it is vertical.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 15.
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.
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 10 Manifold
43
47
112
171
172
6 720 610 576-05.1O
Fig. 8
14
CH flow
CH return
Gas cock
Domestic hot water
Cold water relief
B A drain tap should be fitted at the lowest point of the
central heating system.
B WRc filling loop must be fitted.
6 720 610 576 GB (02.05)
Installation
3.7
Condensate drain
Fitting the appliance
Prepare the condensate discharge system. Refer to
fig. 11. The condensate drainage pipe should be a
standard drain pipe material , i . e. PVC, PVC-U, ABS
etc. and should be at least 22 mm in diameter.
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”.
A siphon with a 75 mm condensate seal is fitted within
the appliance.
A connection to an internal drain is recommended.
Any external drain pipe should be insulated to prevent
freezing.
The connection of a condensate pipe to a drain may be
subject to local building regulations.
For more information refer to the CIBSE Guide,
BS5546 and the Building Regulations.
B Remove packing, taking care to observe the instructions on the packing.
B Lie the boiler on its back.
Removing the outer case
The outer case is secured against unauthorised removal by two clips (electrical
safety).
Always secure the outer case with those
clips again after refitting.
i
B Turn the clips with a screwdriver (1.).
B Slide the outer case upwards and then forwards to
remove (2.).
B Remove the plastic caps from the boiler connections.
2.
1.
6 720 610 602 - 03.1O
Fig. 11 Position of the condensate drain
6 720 610 332-07.1R
Fig. 12
Fixing the appliance
B Fit the washers onto the gas and 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.
6 720 610 576 GB (02.05)
15
Installation
Connecting the flue duct
3.9
B Fit flue duct connector onto appliance flue spigot.
The only flue systems that may be used are those supplied by Worcester Heat Systems.
The flue system must be installed in accordance with
the requirements of BS5440:1.
B Secure with the two screws supplied.
Flue Systems
Standard 100 mm flue system
1
2
The standard concentric flue system provides for a horizontal length of upto 4 m. Full instructions for fitting this
flue are in Subsection 3.9.2 “Installation of the flue”.
3
4
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.
6 720 610 332-09.1R
Fig. 13
B For remaining installation of flue assembly, refer to
the relevant installation instructions.
3.8
A vertical flue system upto a height of 15 metres is available.
45° and 90° flue bends can be used with a corresponding reduction in flue length of 2m for each 90° bend and
1 m for each 45° bend used.
Checking the connections
Water 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 WRC
approved filling loop.
IMPORTANT: Any horizontal flue system fitted to a condensing boiler must incline towards the appliance at an
angle of 3 % (30 mm per metre length) to prevent condensate dripping from the flue terminal. This means
that the clearance above the appliance must be
increased to match the duct length.
Refer to fig. 1 on page 5.
B Check all seals and unions for leaks (testing pressure
max. 3.0 bar as indicated by pressure gauge).
B Turn on cold water service cock and fill hot water system (testing pressure max. 10 bar).
B Check all connections for leaks.
Gas supply pipe
B Check that the seal is in place before tightening the
connection.
B Turn off gas cock to protect gas valve against
damage from excessive pressure.
B Check gas supply pipe.
B Release the pressure on the gas supply pipe.
16
6 720 610 576 GB (02.05)
Installation
3.9.1 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. 14 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
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 K2 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
Fig. 14
Minimum dimensions of flue terminal positions (all types) (see fig. 14)
Dimension
Terminal Position (kW input expressed in net)
A1)
Balanced flues room sealed: Fanned draught
Directly below an opening, air brick, opening windows, etc.
300 mm
B
1)
Above an opening, air brick, opening window, etc.
300 mm
C
1)
Horizontally to an opening, air brick, opening window, etc.
300 mm
D
Below gutters, soil pipes or drain pipes
E
Below eaves
200 mm
75 mm
F
Below balconies or car port roof
200 mm
G
From a vertical drain pipe or soil pipe
150 mm
H
From an internal or external corner
300 mm
I
Above ground roof or balcony level
300 mm
J
From a surface facing the terminal
600 mm
K
From a terminal facing the terminal
1200 mm
L
From an opening in the car port (e. g. door, window) into the dwelling
1200 mm
M
Vertically from a terminal on the same wall
1500mm
N
Horizontally from a terminal on the same wall
O
From the wall on which the terminal is mounted
Not applicable
P
From a vertical structure on the roof
Not applicable
Q
Above intersection with roof
Not applicable
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.
6 720 610 576 GB (02.05)
17
Installation
3.9.2
Installation of the flue
The standard 100 mm diameter horizontal flue system is
suitable for lengths upto 4 m.
Flues upto 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 accomodated. Refer to fig. 16, 17, 18.
Standard system comprise: Flue turret - Flue turret
clamp - Terminal assembly - Wall sealing - plates.
Extension kit comprises: Air duct - Flue duct - Duct
clamp. Refer to fig. 19.
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. 15.
Terminal
Assembly
Flue
Turret
Maximum 650 mm
Outer
Wall
No
Clamp
6 720 610 602 - 08.1O
Fig. 16 Standard Flue
Drilling point for
flue duct opening
Centre line of
flue/air duct
H
Centre
line of
flue
opening
and
appliance
120
3%
(30 mm/meter)
Top of the
wall
mounting
frame
Appliance
H
Standard Horizontal Flue 158 mm
Optional Horizontal Flue 121 mm
6 720 610 602 - 07.1O
Fig. 15 Marking the position of the side flue opening
18
6 720 610 576 GB (02.05)
Installation
Terminal
Assembly
Flue
Turret
Maximum 1600mm
Outer
Wall
Clamp
No
Clamp
Extension
Duct
6 720 610 602 - 09.1O
Fig. 17 Flue with one extension
Terminal
Assembly
Flue
Turret
No
Clamp
Outer
Wall
Clamp
Clamp
Extension
Duct
Extension
Duct
6 720 610 602 - 10.1O
Fig. 18 Flue with extensions
Duct Clamp
Flue
Turret
Extension Air Duct
Extension Flue Duct
Terminal Assembly
Wall Sealing Plates
6 720 610 602 - 11.1O
Fig. 19 Flue components
6 720 610 576 GB (02.05)
19
Installation
3.9.3
Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 20, 21.
Outer
Wall
Face
Flue Terminal
L
Raised Ring
locating the
terminal relative
to the outside
wall face
120
6 720 610 576 - 20.1O
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 12.1O
BOILER
Fig. 20 Flue length - rear
Fig. 22 Flue terminal position
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must face downwards.
L
The assembly will be made easier if a solvent free
grease is lightly applied i.e Vaseline, to the male end of
the ducts.
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 with the clamp. Refer to fig. 23.
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 13.1O
BOILER
Flue Turret
Fig. 21 Flue length - side
Mark off the lengths shown onto the ducts and cut to
length. The cuts must be square and free from burrs.
Terminal assembly outer (air) duct - L-70 mm, inner
(flue) duct - L- 50 mm.The measurement is made from
the ridge at the terminal indicating the outer face of the
wall. Refer to fig. 22.
Extension air duct - L-70mm, flue duct - L-50 mm.
The measurement is from the formed end.
Clamp
Flue Socket
on Boiler
Air and
Flue Duct
Entry into
silicone
rubber seals
6 720 610 602 - 14.1O
Fig. 23 Flue turret
Ensure that the turret is fully entered into the socket on
the boiler. From the outside fix the outer wall plate to the
terminal and, after ensuring the duct is properly i nclined
towards the boiler, fix the plate to the wall.
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 an be fixed with corrosion resistant
screws.
20
6 720 610 576 GB (02.05)
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.
All control and safety systems are built into the appliance.
B Allow mains cable to protrude at least 50 cm from
wall.
B To make splash-water proof (IP): cut the cable grommet hole size to match diameter of cable, see fig. 26.
It must be possible to isolate the appliance. The appliance must be earthed.
The appliance must be connected to the mains through
a 6 A double pole isolator with a contact separation
3 mm in all poles and supplying the appliance and controls only. The wiring must comply with the current
requirements of the IEE Wiring Regulations and any
local regulations which apply.
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.
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.
B Pull out cover panel at the bottom and remove. Refer
to fig. 24.
3
0
4
2
5
1
E
• Supply: 230 V ~ 50 Hz, 140 Watts
• Mains cable: PVC insulated 0.75 mm2
(24 x 0.20 mm) to BS6500-Table 6.
Temperature rated 100°C.
6 720 610 332-10.1R
• Protection IPX4D
Fig. 24
• External fuse 3 A.
B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 25.
3
0
2
1
4
5
E
6 720 610 332 -11.1R
Fig. 25
6 720 610 576 GB (02.05)
21
Electrical connections
B Cut cable grommet to diameter of cable.
Mains Voltage external controls
connections
4
NOTE: Only double insulated controls not requiring an earth can be used
5
Ns Ls LR
Ns Ls LR
E
ST8
Switched Live
Neutral
Live
ST8
Remove Link
Neutral
1
Switched Live
2
Live
3
0
4.2
Motor
230 V Room Thermostat Connections
230 V Programmer Connections
8-9
230 V room thermostat and
Programmer Connections
Ns Ls LR
ST8
ed
it ch
Sw
Live
Neutral
ve
ra
l
Li
ut
Live
Ne
d
6 720 610 332-12.1R
he
13-14
itc
10-12
Series
connection
to be made
safe
Sw
Live
5-7
Fig. 26
B Feed cable through cable grommet and connect the
mains supply cable, see fig. 27.
B Secure cable in cable grommet by means of cable
grip.
L
Motor
6 720 610 576 - 22.1O
Fig. 28
N NS L S L R
4130-14.1R
Fig. 27
22
6 720 610 576 GB (02.05)
Commissioning
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. 29
8.1
15
27
61
135
136
170
171
172
173
295
310
317
358
363
364
365
366
367
Pressure gauge
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for central heating
Service cocks on CH flow and return
Hot water
Gas cock (shown in on position)
Cold water service cock
Appliance type sticker
Temperature control for hot water
Multifunction display
Condensate trap
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
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 BS7593:1992 - 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 pressure relief valve.
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 tested (see page 29).
6 720 610 576 GB (02.05)
23
Commissioning
B Unscrew the condensation trap (358) and pull out, fill
with approx. 1/4 l of water and refit. Refer to fig. 29.
B Adjust charge pressure of expansion vessel to static
head of the central heating system (see page 26).
B Open all system radiator valves.
B Turn on service valves (170), fill central heating system to pressure of 1 - 2 bar through the WRc
approved filling loop. Refer to fig. 29.
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. 29.
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. 29.
5.2
5.3
Switching on the central heating
The central heating flow temperature is adjustable
between 35°C and 88°C. Refer to table 12, page 26.
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)
– Central heating systems for flow temperatures up
to 88 °C: limited “max” setting for low-temperature
operation (see page 26).
When the burner is alight, the red indicator lamp
lights up.
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.
6 720 610 333-05.1O
Fig. 31
5.4
System controls
B Set room thermostat to the desired room temperature.
6 720 610 333-04.1O
Fig. 30
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.
B Set outside - temperature driven control unit, if fitted.
Refer to the instructions with the control.
B Set the thermostatic radiator valves to the desired
settings.
5.5
Setting the domestic hot water
temperature and flow rate
5.5.1
Domestic hot water temperature
The hot water temperature can be set to between
approx. 40 °C and 60 °C.
This temperature is not shown on the display.
Switching off the appliance
B Set the master switch to (0).
The green indicator lamp goes out.
B Always disconnect the appliance from
the power supply (fuse, circuit breaker)
before carrying out any work on the
electrical systems or components.
24
6 720 610 333-07.1O
Fig. 32
6 720 610 576 GB (02.05)
Commissioning
5.6
Summer mode (hot water only)
Setting
Hot Water temperature
Turn fully anti-clockwise
approx. 40°C
With room thermostat
approx. 55°C
B Turn temperature control
on the appliance anticlockwise as far as the stop.
The central heating is now turned off. The hot water
function and the mains power supply for the heating
programmer and timer remain switched on.
Turn fully clockwise
approx. 60°C
Table 10
“ECO” button
By pressing and holding the “ECO” button
until the
display lights, you can switch between Comfort mode
and Economy mode.
5.7
Comfort mode: button is not lit (factory setting)
If the appliance is to be left for long periods switch the
central heating off:
The appliance is held constantly at the set temperature.
This means that hot water is available almost instantaneously at the tap. Consequently the appliance will
switch on at intervals, even if no hot water is being
drawn.
ECO mode with demand detection, button is lit
Frost protection
B Leave master switch switched on.
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.: 01799
550811.
The demand detection function enables maximum gas
and water economy.
Briefly turning a hot water tap on and then off again signals demand to the appliance which then heats up the
water to the set temperature.
Hot water is thus available in about 1 minute.
5.8
ECO mode, button is lit
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.
Water is not heated up until hot water is drawn. This
means that there is a longer waiting period before hot
water is available.
5.5.2
i
5.9
Pump anti-seize function
This function prevents the central heating
pump seizing after long periods of inactivity.
Fault Condition
Hot water flow rate
The flow rate is factory set to 8 l/min.
Under standard conditions (2 bar) supply pressure, one
full turn is equivalent to approximately 2 l/min.
i
A list of faults that may occur is given on
page 43.
B To increase the flow rate (max. 14 l/min):
turn screw on flow switch anti-clockwise (+).
The outlet temperature will decrease relative to the
increase in the flow rate.
In the unlikely event of a fault occuring while the appliance is in operation:
B To reduce the flow rate (min. 8 l/min):
turn screw on flow switch clockwise (–).
The outlet temperature will increase relative to the
decrease in the flow rate.
If the button
The display then shows a fault code and the button
may also flash.
-
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.
6720 610 332-25.1O
Fig. 33
6 720 610 576 GB (02.05)
25
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 11.
System Capacity – BS7074:1
Expansion Vessel Pressure and System Capacity
Expansion Vessel
litres
10
Expansion Vessel
Charge Pressure
bar
0.75
System
pressure
and
capacity
1 bar
litres
82
1.5 bar
litres
46
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. 35°C
approx. 43°C
approx. 51°C
approx. 59°C
approx. 67°C
approx. 75°C
approx. 88°C
Table 12
6.1.3
The speed of the central heating pump can be altered
on the pump terminal box.
Table 11
6.1.2
The central heating flow temperature can be set to
between 35°C and 88°C.
i
At switch position 1, maximum output is
not delivered if hot water mode is active.
Position 1 must not be used on combi appliances.
i
Setting the central heating flow temperature
With underfloor heating systems, observe
the maximum permissible flow temperatures.
Changing the heating pump characteristic
H
0,7
(bar)
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
Adjustment of the heating output to the calculated heat
demand is not required by the heating systems regulations.
2
0,2
1
0,1
Removing the maximum setting limit
0
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.
3
0
200
400
600
800
1000 1200 1400 1600
Q (l/h)
6 720 610 576-23.2O
Fig. 35
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. 34
26
6 720 610 576 GB (02.05)
Individual settings
6.2
Settings on the Bosch Heatronic
6.2.1
Operating the Bosch Heatronic
Entering a setting
The Bosch Heatronic enables easy setting and checking of a large number of appliance functions.
B To enter the setting for a function, turn the temperature control
.
This description is limited to those functions required
for commissioning.
Storing a setting
For a full description of all available functions, please
refer to the Service booklet for the Engineer,
number 7 181 465 346.
5
2
1
B Level 1: press and hold the
play shows [ ].
button until the dis-
B Level 2: press and hold the
and buttons simultaneously until the display shows [ ].
After completing the settings
B Reset the temperature controls
original positions.
6.2.2
6 720 610 332-30.1O
4
3
Fig. 36 Appliance controls
1
2
3
4
5
i
Service button
“Chimney sweep” button
Temperature control for central heating
Temperature control for hot water
Display
Note the positions of the temperature controls
and
. After completing the settings, return the temperature controls to
their original positions.
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
Switching difference
Max. heating output
Constant hot water
cycle time
2.2
2.4
27
27
2.5
2.6
5.0
28
28
28
6.8
28
Table 13
The service function 5.0 may be reset.
6 720 610 576 GB (02.05)
to their
Selecting the pump control mode for central heating mode (Service Function 2.2)
If an outside temperature driven control
unit is connected, pump control mode 3 is
automatically activated
The choice of settings is as follows:
Selecting service function:
i
and
• Control Mode 1
For heating equipment without a control unit.
The pump is controlled by the central heating flow
temperature control.
• 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 outside temperature
driven control 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).
i
If the appliance is connected to an outside-temperature controlled heating programmer, the anti-cycle time does not
need to be set on the appliance and is optimised by the programmer instead.
27
Individual settings
6.2.4
Setting the maxim CH flow temperature
(Service Function 2.5)
The maximum CH flow temperature can be set to
between 35°C and 88°C (factory setting).
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.
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 45).
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!
B Press and hold the
and
buttons simultaneously until the display shows [ ].
The heating output is now stored.
The switching difference is the permissible divergence
from the specified CH flow temperature. It can be set in
increments of 1 K. The adjustment range is 1 to 30 K (is
factory set to 0 K). The minimum CH flow temperature
is 30°C.
6 720 610 332-52.1O
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.
i
The full rated heat output is still available
for hot water or charging the hot water cylinder even if the heating output has been
limited.
The factory setting is the max. rated heat output.
B Press and hold the
and
buttons simultaneously until the display shows = =.
The
and
buttons will light up.
Fig. 39
B Return the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperate.
6.2.7
Constant hot water cycle time
(Service Function 6.8)
In Comfort mode “ECO light off” , the hot water inside
the appliance is held constantly at the set temperature.
For that reason, the appliance switches on if the water
temperature falls below a certain temperature. In order
to prevent it switching on and off too frequently, the
constant hot water cycle time service function allows
you to set the minimum period between switching off
and on again. This function has no effect on normal
demand for hot water and relates only to the constant
hot water function in Comfort mode.
The cycle time can be set to any period between 20 and
60 minutes (is factory set to 20 minutes).
6 720 610 332-50.1O
Fig. 37
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.
6.3
Setting the gas/air ratio
Refer to section 7.1 for details of the method of setting
the gas/air ratio.
6 720 610 332-51.1O
Fig. 38
28
6 720 610 576 GB (02.05)
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.
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 Remove the outer case (see page 15, refer to
fig. 12).
B Switch off the appliance at the master switch (O).
B Switch on the appliance at the master switch (I).
Checking the gas supply pressure
B Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 40.
B Check the gas supply pressure at the gas supply
pressure testing point.
B Insert testing probe about 135 mm into the flue gas
testing point and seal 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 not 37 mbar.
Natural gas
234
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m3 and 20 mbar supply
pressure and sealed.
Conversion kits
6 720 610 332-57.1R
For conversion
from ...
Order no.
ZWB 7-27
HE combi
N.G to L.P.G
7 710 149 044
ZWB 11-27
HE combi
L.P.G to N.G
7 710 239 080
Model
Fig. 40
B Press and hold
button until the display shows – –.
The
button will light up.
Table 14
• Instructions are sent with each conversion kit.
6 720 610 332-32.1O
Fig. 41
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. 42
6 720 610 576 GB (02.05)
29
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 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. 45
6 720 610 332-61.1O
Fig. 43
B Measure the CO2 level.
B Measure the CO2 level.
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.
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. 44.
63
6 720 610 332-64.1R
Fig. 44
Gas Type
Natural gas type
H (23)
LPG
(propane)
Fig. 46
CO2 reading
at max.
rated heat
output
CO2 reading
at min. rated
heat output
B Measure the CO level.
If the CO level is over 300 ppm, the gas volumetric
flow rate is too high. Reduce the gas flow rate on the
adjustable gas flow restrictor (63) until the CO level
is below 100 ppm.
9.5 %
9.2 %
B Re-adjust the CO2 level if necessary.
11.3 %
11.0 %
B Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
Table 15
B Measure the CO level.
If the CO level is over 300 ppm, the gas volumetric
flow rate is too high. Reduce the gas flow rate on the
adjustable gas flow restrictor (63) until the CO level
is below 100 ppm.
B Re-adjust the CO2 level 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.
B Press and hold the
shows [ ].
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.
B Re-seal gas valve adjusting screw and gas flow
restrictor.
B Replace outer case and secure.
30
6 720 610 576 GB (02.05)
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 O2 or CO2 level in the combustion air the gas tightness of a type C13
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. 47).
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. 47).
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
234.1
6 720 610 332-65.1R
Fig. 47
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.
6 720 610 576 GB (02.05)
31
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 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: WRc approved silicon based grease
– Unions: approved sealant.
B To drain the appliance shut the system valves and
open the pressure relief valve.
32
6 720 610 576 GB (02.05)
Maintenance
8.1
Pre-Service Check List
Date
1
Call up the last fault stored by the
Bosch Heatronic, Service Function .0,
(see page 34).
2
Check ionisation current, Service
Function 3.3, (see page 34).
3
Perform visual check of air/flue
duct.Visual check of diaphragm for
soiling and splits (see page 36).
4
Check gas supply pressure
(see page 29).
5
Test combustion air/flue gas
(see page 31).
6
Check CO2 setting for min./
max. (gas/air ratio)
(see page 29).
mbar
min. %
max. %
7
Check gas and water systems for
leaks (see page 16).
8
On combi models, check hot water
outlet temperature (see page 34).
9
Check heat exchanger
(see page 34).
mbar
10 Check burner (see page 35).
11 Clean condensation trap
(see page 36).
mbar
12 Check charge pressure of
expansion vessel matches
static head of heating system.
13 Check central heating system mbar
pressure.
14 Check electrical wiring for damage.
15 Check heating programmer settings.
16 Check appliances that are part of
the heating system
Table 16
6 720 610 576 GB (02.05)
33
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 7.2.
Primary Heat exchanger
Check “Last fault stored”:
B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manometer.
B Select Service Function .0 (see page 27 “Selecting
service function”).
There is a special accessory kit (no. 840) for cleaning
the heat exchanger, order no. 7 719 001 996.
There is a list of the fault codes in the Appendix (see
page 43.
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
B Select Service Function 3.3 (see page 27 “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.
Domestic hot water
6 720 610 332-69.1R
Fig. 49
i
The heat exchanger should only be
cleaned if the control pressure is
2.2 mbar (depression) or less.
If the flow rate is too slow:
B Remove cleaning access cover (415, page 6) and
the metal plate below it, if present. Refer to fig. 2.
B remove the domestic hot water heat exchanger and
replace,
B Unscrew condensation trap and place suitable container underneath. Refer to fig. 50.
-or-
B Remove the fan and the burner as described in the
text headed “Burner” (see page 35).
B descale with a descaling agent approved for use on
stainless steel.
B Before removing the heat exchanger shut the inlet
valve and drain the hot water circuit.
B Use new seals when replacing the heat exchanger.
6 720 610 332-72.1R
Fig. 50
7 181 465 330-06.1R
Fig. 48
34
6 720 610 576 GB (02.05)
Maintenance
B Loosen any deposits in the heat exchanger from top
to bottom using the cleaning blade. Refer to fig. 51.
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. 54.
B Unscrew and remove the two hexagon screws securing the fan (3).
B Slacken fully the rear securing bolt (4).
B Remove the burner coverplate.
4.
6 720 610 332-73.1R
2.
Fig. 51
B Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 52.
3.
1.
7 181 465 330-04.1R
Fig. 54
B Remove burner and clean components. Do not use a
wire brush. Refer to fig. 55.
6 720 610 332-74.1R
Fig. 52
B Remove the fan and the burner (see section headed
“Burner”) and flush the heat exchanger from the top.
B Clean out the condensate collector and trap connection (with other end of brush).
H 2O
1.
2.
7 181 465 330-08.1R
6 720 610 332-75.1R
Fig. 53
B Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
Fig. 55
B Re-assemble burner in reverse order using a new
seal.
B Adjust gas/air ratio. Refer to section 7.2.
6 720 610 576 GB (02.05)
35
Maintenance
Diaphragm in mixer unit
B Take care not to damage diaphragm
(443) when removing and refitting it.
B Replace and re-connect the assembly taking care not
to mislay the inspection window.
Siphon
B Open mixer unit (29).
B Unscrew the clip and disconnect the pipe to the
siphon.
B Carefully withdraw diaphragm (443) from fan intake
tube and check for soiling and splits.
B Remove the yellow plug to drain the siphon.
B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
B Refit and prime the siphon.
3.
Condensate
Drain
443
Siphon
1.
29
6 720 610 602 - 16.1O
2.
6 720 610 790 - 07.1O
Fig. 56
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).
Condensation trap
In order to prevent spillage of condensate, the condensation trap should be completely removed, (see
page 34, fig. 50).
B Unscrew condensation trap and check connection to
heat exchanger is clear.
B Remove condensation trap cover and clean.
B Fill condensation trap with approx. 1/4 l of water and
refit.
Electrode assembly
B Switch off the master switch.
B Pull off the leads from the electrodes. Refer to fig. 2.
B Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 49.
B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4,5 mm ± 0,5 mm.)
36
6 720 610 576 GB (02.05)
Maintenance
Expansion vessel
The expansion vessel should be checked once a year.
B Depressurise appliance.
B If necessary, adjust expansion vessel charge pressure to static head of the heating system.
Heating system pressure
i
Fill the system using the WRc 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.
6 720 610 576 GB (02.05)
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. 24, 25.
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. 58.
1
3
2 4
3
1
4
7 181 465 330-10.1R
1
3
2 4
2
5
Fig. 59
E
Fuses
1
7 181 465 329-02.1R
3
2 4
Fig. 58
B Remove the connections covers. Refer to fig. 24,
25.
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. 59.
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
6 720 610 576 GB (02.05)
Maintenance
8.3.2
Fan Assembly
8.3.3
3.
Pump
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Remove two switchbox fixing screws (1.). Refer to
fig. 61.
2.
B Lower switchbox (2.).
B Unscrew and remove the the siphon by releasing the
jubilee clip. Refer to fig. 57.
B Unscrew the pump union nuts (3.). Refer to fig. 61.
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. 60
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. 60.
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.).
6 720 610 576 GB (02.05)
2.
Fig. 61
39
Maintenance
8.3.4
3-way diverter valve
8.3.6
B Switch off the appliance.
Sensors
B Check that the appliance is electrically isolated.
B Disconnect appliance from the power supply.
B Turn off service cocks.
Central Heating Flow Temperature Sensor –
Item 36, fig. 2, 58
B Unplug connector from 3-way valve motor. Refer to
fig. 62.
B Pull-off the connector.
B Pull out retaining clip.
B Release the sensor clip and withdraw the sensor.
B Apply heat transfer paste to the replacement sensor.
B Remove motor.
B Disconnect the relief valve drain.
Safety Temperature Limiter – Item 6, fig. 2, 58
B Disconnect the pressure gauge.
B Pull-off the connectors.
B Undo pipe unions.
B Unscrew the sensor.
B Remove 3-way valve.
Flue Temperature Limiter – Item 9, fig. 2, 58
B Pull-off the connectors.
B Unscrew the sensor.
Domestic Hot Water Temperature Sensor –
Item 6.1, fig. 2
B Check that the inlet water valve is closed and the
domestic hot water circuit is drained.
B Release and pull-off the connector.
B Unscrew the sensor.
7 181 465 330-12.1R
Fig. 62
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. 62.
B Pull out retaining clip.
B Remove motor.
40
6 720 610 576 GB (02.05)
Maintenance
8.3.7
Gas Valve
8.3.8
Domestic Hot Water Heat Exchanger
B Check that the gas cock is turned off.
B Refer to section 7.2.
B Lower the control panel. Refer to fig. 61.
B Use new seals when fitting the new heat exchanger.
B Pull off the solenoid connections at the rear of the
valve.
8.3.9
Electrode assembly
B Undo the union, within the inner casing, securing the
valve to the gas/air tube. Refer to fig. 60.
B Refer to section 7.2.
B Remove the white plastic cap from the gas valve.
8.3.10 Pressure gauge
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.
B Use a new seal if the existing seal is damaged.
B Drain the appliance.
B Lower the facia. Refer to fig. 61.
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 of the
diverter valve by withdrawing the clip and pulling out
the head. Refer to fig. 62.
8.3.11 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.
8.3.12 Pressure Relief Valve
B Drain the appliance.
B Disconnect the drain pipe from the valve. Refer to
fig. 29.
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.
8.3.13 Burner
B Refer to section 8.2.
6 720 610 602 - 04.1O
Fig. 63
6 720 610 576 GB (02.05)
41
Maintenance
8.3.14 Flow switch
B Shut the mains water inlet valve and drain the domestic hot water circuit.
B Pull-off the connectors from the micro-switch.
B Unscrew the inlet and union connection and remove
the assembly.
B Reset the domestic hot water flow rate on the new
assembly.
B Pull forward from the top and lift the heat exchanger
from the casing.
B Transfer components, as necessary, to the new heat
exchanger.
B Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
appliance.
OUTLET
INLET
6 720 610 602 - 05.10
Fig. 64
8.3.15 Primary Heat Exchanger
B Drain the appliance.
B Check that the gas supply is turned off.
B Check that the appliance is electrically isolated.
6 720 610 602 - 06.10
Fig. 65
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. 61.
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.
42
6 720 610 576 GB (02.05)
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
A7
Hot water NTC sensor defective.
Check hot water NTC sensor and connecting lead for
circuit breaks/short circuits.
A8
Break in communication
Check connecting lead to programmer
AC
Module not detected.
Check connecting lead between TA211E/TR212E
and Heatronic
b1
Keyed plug not detected.
Insert keyed 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
6 720 610 576 GB (02.05)
43
Appendix
9.2
Short parts list
Key
Description
Qty GC
Spare part number
1
Sensor - Flue gas temp.
1
8 729 000 144 0
2
Sensor - CH flow temp.
1
8 714 500 087 0
3
Sensor - DHW flow temp.
1
8 714 500 054 0
4
Control board
1
8 748 300 418 0
5
Gas valve
1
8 747 003 516 0
6
Fan assembly
1
8 717 204 373 0
7
Fan washer
1
8 729 000 183 0
8
Expansion vessel
1
8 715 407 236 0
9
Relief valve
1
8 717 401 012 0
10
Electrode assembly
1
8 718 107 077 0
11
Electrode lead
1
8 714 401 999 0
12
Pump
1
8 717 204 477 0
13
Pressure gauge
1
8 717 208 079 0
14
Burner skin seal
1
8 711 004 168 0
15
Transformer - facia
1
8 747 201 358 0
16
Flow switch
1
8 717 002 110 0
17
3-way diverter valve
1
8 717 010 062 0
18
Heat exchanger washer
1
8 710 103 153 0
19
Washerset Condenstaion Trap
1
8 710 103 154 0
20
Fuseset
1
8 744 503 010 0
21
Serviceset Water Valve
1
8 710 503 031 0
22
Domestic Hot Water
Heat Exchanger
1
8 715 406 659 0
23
Primary heat exchanger
1
8 715 406 615 0
Table 18
44
6 720 610 576 GB (02.05)
Appendix
9.3
Heating/hot water output settings (N.G.)
Natural gas G20
Display
code
Heat output kW
Heat input kW
Gas vol. flow rate (l/min at tV/tR = 80/60°C)
30
8.2
8.3
14.4
40
10.9
11.0
19.3
50
13.6
13.8
24.1
60
16.3
16.5
28.9
70
19.1
19.3
33.7
80
21.8
22.0
38.5
90
24.5
24.8
43.3
100
27.2
27.5
48.1
Table 19
9.4
Heating/hot water output settings (L.P.G)
Propane
Display
code
Heat output kW
Heat input kW
40
10.9
11.0
50
13.6
13.8
60
16.3
16.5
70
19.1
19.3
80
21.8
22.0
90
24.5
24.8
100
27.2
27.5
Table 20
6 720 610 576 GB (02.05)
45
Burner remains OFF
until flow temperature
is below set value.
Over temperature
shut-down if water
temperature is 8°C
above set value.
Gas valve shuts.
Pump remains ON.
.
Mains
switch
ON.
Green
light
ON.
Pre-heat
mode.**
Hot
water
demand.
Pump ON
Diverter valve
operates.
Fan to
start speed.
Gas valve opens.
Heat input
modulates to
maintain the
delivery
temperature.
Demand
ends.
Gas valve
closes.
Red light
OFF.
Ignition sequence
Ignition spark for
5 seconds.
Burner lights.
Red light ON.
Yes
No
Repeats 5 times
before lock-out.
Fan runs to purge
gas from burner.
6 720 610 576 - 24.1O
Fan runs for
upto 3 mins.
Pump runs
for 30secs.
Pre-heat
mode.**
Appendix
Burner lights.
Red light ON.
Operational Flow diagrams
Burner shut-down if
primary temperature
exceeds 94 °C remains
OFF until 78 °C
** NOTE:
The appliance controls can be set to one of
2 modes of operation.
1. “Comfort“ mode Full pre-heat
2. “ECO“ mode a) Operates as an instantaneous combination
boiler.
b) Demand Detection: a short demand (less
than 5 seconds) switches the control to
“Comfort“ mode for 5 mins. Mini pre-heat.
The Factory setting is “Comfort“ mode.
9.5
Pre-heat satisfied.
Ignition sequence
Ignition
spark
5 secs
Domestic hot water function
Fan to
start speed.
Gas valve opens.
9.5.1
Fig. 66
46
Pump ON
Diverter valve
operates.
6 720 610 576 GB (02.05)
9.5.2
Fig. 67
Mains
switch
ON.
Green
light
ON.
Room thermostat
and/or mains
programmer or
link ON
AND
Electronic facia
programmer
(if fitted) ON
AND
CH control knob
ON.
CH
demand.
Pump ON
Fan to
start speed.
Gas valve opens.
Over temperature
shut-down if water
temperature is 5°C
above set value.
Gas valve shuts.
Pump remains ON.
Burner
stabilises at
start speed
for 5-10 secs
Fan speed
reduces
over 15
secs.
Fan min.
speed for
90 secs.
Boiler
unused for
long
period.*
Yes
*
Minimum
heat input
for 15min.
No
Boiler
operates to
match
system load
and CH
control
setting.
Central heating function
6 720 610 576 GB (02.05)
Burner remains OFF
until flow temperature
is below set value.
ce
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 upto
3 mins.
No
Repeats 5 times
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 - 25.1O
Appendix
47
Appendix
EXCELLENCE COMES AS STANDARD
Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising