GREENSTAR HIGHFLOW 440CDi &

INSTRUCTION MANUAL
INSTALLATION COMMISSIONING & SERVICING
FLOOR STANDING RSF GAS-FIRED CONDENSING COMBINATION
BOILER
GREENSTAR
HIGHFLOW 440CDi & 550CDi
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C93)
NATURAL GAS:
GREENSTAR HIGHFLOW 440CDi GC NUMBER 47-406-24
GREENSTAR HIGHFLOW 550CDi GC NUMBER 47-406-25
LIQUID PETROLEUM GAS:
GREENSTAR HIGHFLOW 440CDi GC NUMBER 47-406-26
GREENSTAR HIGHFLOW 550CDi GC NUMBER 47-406-27
UK/IE
8 716 115 219c (03.2010)
CONTACT INFORMATION
WORCESTER, BOSCH GROUP:
RECEPTION:
0844 892 9900
MAIN FAX:
01905 754619
TECHNICAL:
0844 892 3366
SERVICE:
0844 892 3000
SPARES:
01905 752571
LITERATURE:
0844 892 9800
TRAINING:
01905 752526
SALES:
01905 752640
WEBSITE:
worcester-bosch.co.uk
INSTALLATION & SERVICING INSTRUCTIONS
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE PRODUCT MODEL(S) STATED ON
THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY
OTHER MAKE OR MODEL OF APPLIANCE.
THE INSTRUCTIONS APPLY IN THE UK/IE ONLY AND MUST BE FOLLOWED EXCEPT
FOR ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT REGISTERED ENGINEER,
SUCH AS A BRITISH GAS OR OTHER GAS SAFE REGISTERED PERSONNEL.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL SUPPORT
WATER TREATMENT:
FERNOX 01799 550811
fernox.com
SENTINEL 0800 389 4670
sentinel-solutions.net
HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER,
PART OF THE BOSCH GROUP.
PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED
BENCHMARK LOG BOOK (AT THE BACK OF THIS MANUAL) OR A CERTIFICATE
CONFIRMING COMPLIANCE WITH IS 813 (EIRE ONLY) WITH THE USER OR AT
FLUE TERMINAL GUARDS:
THE GAS METER AFTER INSTALLATION OR SERVICING.
TOWER FLUE COMPONENTS
COMMERCIAL INSTALLATION:
VALE RISE, TONBRIDGE, TN9 1TB
IF INSTALLING A GROUP OF APPLIANCES TOGETHER, ON COMMERCIAL PREMISES,
TEL: 01732 351680
THAT TOTALS MORE THAN 70KW, THEN THE APPLIANCES MUST BE INSTALLED IN
tfc-group.co.uk
ACCORDANCE WITH THE REQUIREMENTS OF IGE/UP/10 THEREFORE A COMMERCIAL
GAS QUALIFICATION WILL BE REQUIRED.
ABBREVIATIONS:
Ø
Diameter
NG
Natural Gas
IMPORTANT HANDLING INSTRUCTIONS:
LPG
Liquid Petroleum Gas
It is advised that at least two people are
involved in the transfer of the packaged
appliance from the van to the point of
installation.
A suitable truck should be used.
The boiler is secured to a wooden board with
screws. It is advised that no attempt should
be made to move the packaged appliance
without the use of a suitable truck.
Before removing the carton it is advised that
the top flaps are opened and the ancillary
items removed and set to one side.
The carton can now be lifted off the boiler.
Remove the plastic bag protecting the boiler
surfaces and place safely away from the
working area.
Remove the boiler (complete with board) from
the pallet before removing the securing screws.
The boiler is mounted on small wheels and
can now be slid off the board and guided into
the installation position.
Care should be taken not to damage any
panels.
Two people are required to move the appliance
from the board into the installation position.
CH
Central Heating
DHW
Domestic Hot Water
TRV
Thermostatic Radiator Valve
IP
Ingress Protection
RS
Room sealed flue
N/A
Not allowed
SEDBUK Seasonal Efficiency for Domestic Boilers in the United Kingdom
SYMBOLS USED IN THIS MANUAL:
Domestic hot water
Programmer ON CH only
Central heating
Programmer ON DHW only
Room thermostat
Programmer ON CH and DHW
Frost thermostat
Cold water main supply
Wait time period
Electricity supply
Programmer/timer OFF
Fuel supply
GENERAL HANDLING GUIDELINES:
• Lift only a manageable weight, or ask for help.
• When lifting, bend the knees, and keep the
back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry items close to the body
• Wear protective clothing and gloves to
protect from any sharp edges
Store the appliance in a dry area prior to
installation.
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
SAFETY &
REGULATIONS
CONTENTS
SAFETY & REGULATIONS
SAFETY PRECAUTIONS
2
INSTALLATION REGULATIONS
2
GENERAL INFORMATION
3
TECHNICAL DATA
4
LAYOUT & COMPONENTS
5
APPLIANCE
INFORMATION
APPLIANCE INFORMATION
PRE-INSTALLATION
6
MAINS SUPPLIES
7
WATER SYSTEMS & PIPEWORK
9
CONDENSATE PIPEWORK
11
PRESSURE RELIEF PIPEWORK
12
BOILER LOCATION & CLEARANCES
13
MOUNTING FRAME CONNECTIONS
14
TERMINAL OUTLET POSITIONS
17
ROOM SEALED FLUE OPTIONS
18
PREINSTALLATION
CLEANING PRIMARY SYSTEMS
19
MOUNTING FRAME FIXING / FLUE OPENING
20
MOUNTING FRAME CONNECTIONS
21
FLUE LENGTHS/FLUE MEASURING & CUTTING
22
FLUE MEASURING & CUTTING
23
FLUE INSTALLATION
25
STANDARD FLUE INSTALLATION
26
EXTENDED FLUE INSTALLATION
27
FLUE TERMINAL PLUME MANAGEMENT
28
CONDENSATE, GAS & WATER CONNECTIONS
29
PRESSURE RELIEF VALVE OUTLET
30
ELECTRICAL
31
COMMISSIONING
UNPACKING THE BOILER
INSTALLATION
INSTALLATION
PRE-COMMISSIONING CHECKS
32
FILLING THE SYSTEM
33
WATER TREATMENT
34
STARTING THE APPLIANCE
35
FINISHING COMMISSIONING
36
SERVICING
& SPARES
COMMISSIONING
SERVICING & SPARES
37
REPLACEMENT OF PARTS
41
SETTING THE GAS/AIR RATIO
46
SHORT PARTS LIST
47
CONVERSION
KITS
INSPECTION AND SERVICE
CONVERSION KITS
48
FAULT FINDING
& DIAGRAMS
L.P.G. CONVERSION
FAULT FINDING & DIAGRAMS
ELECTRICAL WIRING DIAGRAM
49
CENTRAL HEATING FUNCTION
50
DHW FUNCTION
51
FAULT FINDING
52
BENCHMARK LOG BOOK AT REAR OF MANUAL
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
CONTENTS
1
SAFETY &
REGULATIONS
SAFETY PRECAUTIONS
INSTALLATION REGULATIONS
IF YOU SMELL GAS:
Failure to install appliances correctly could
lead to prosecution.
DO NOT SMOKE OR STRIKE MATCHES.
DO NOT TURN ELECTRICAL SWITCHES ON OR OFF.
This appliance must be installed by a
competent registered engineer, such as British
Gas or other GAS SAFE registered personnel,
in accordance with, and comply to, the
current: Gas Safety (Installation & Use)
Regulations 1998, IEE Regulations, Building
Regulations, Building Standards (Scotland)
(Consolidation), Building Regulations
(Northern Ireland), local water by-laws, Health
& Safety Document 635 (The Electricity at
Work Regulations 1989), IS 813 (Eire) and
any other local requirements.
PUT OUT NAKED FLAMES.
OPEN DOORS AND WINDOWS.
KEEP PEOPLE AWAY FROM THE AREA AFFECTED.
TURN OFF THE CONTROL VALVE AT THE METER.
CALL YOUR GAS COMPANY.
-ORCALL 0800 111 999 NATIONAL GRID EMERGENCY SERVICES.
BOILER OPERATION:
This boiler must only be operated by a responsible adult who has been instructed
in, understands and is aware of the boiler’s operating conditions and effects.
The relevant Standards should be followed,
including:
BS7074:1 : Code of practice for domestic
heating and hot water supply
BS6891 : Installation of low pressure gas
pipework up to 32mm (R11/4)
BENCHMARK:
Benchmark places responsibilities on both manufacturers and installers. The purpose
is to ensure that customers are provided with the correct equipment for their needs,
that it is installed, commissioned and serviced in accordance with the manufacturer’s
instructions by competent persons and that it meets the requirements of the appropriate
Building Regulations. The Benchmark Checklist can be used to demonstrate compliance
with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in
accordance with the Benchmark Code of Practice which is available from the Heating
and Hotwater Industry Council who manage and promote the scheme.
Visit www.centralheating.co.uk for more information.
IMPORTANT: The completed Benchmark Log Book will be required in the event of
any warranty work and may be required by the local Building Control
Inspector.
HEALTH & SAFETY:
The appliance contains no asbestos and no substances have been used in the
construction process that contravene the COSHH Regulations (Control of Substances
Hazardous to Health Regulations 1988). Where applicable, the CE mark indicates
compliance with relative EU Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside
or within the vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances, which
can corrode the appliance and invalidate any warranty.
FITTING & MODIFICATIONS:
BS EN:12828 : Central heating for domestic
premises
BS5440:1 : Flues and ventilation for gas
appliances of rated heating not exceeding
70kW (net) : Flues
BS5440:2 : Flues and ventilation for gas
appliances of rated heating not exceeding
70kW (net) : Air Supply
BS7593 : Treatment of water in domestic hot
water central heating systems
BS6798 : Installation of gas fired boilers of
rated input up to 70kW (net)
Where no specific instruction is given,
reference should be made to the relevant
codes of Practice.
L.P.G. Installation:
An appliance using L.P.G. must not be installed
in a room or internal space below ground
level unless one side of the building is open
to the ground.
Timber framed buildings:
Where the boiler is to be fitted to a timber
framed building the guidelines laid down in
BS5440: Part 1 and IGE "Gas Installations in
Timber Frame Buildings” should be adhered
to.
Fitting the appliance and any controls to the appliance may only be carried out by
a competent engineer in accordance with these instructions and the relevant Installation
Regulations.
IMPORTANT:
Flue systems must not be modified in any way other than as described in the fitting
instructions.
Artificially softened water must not be used
to fill the central heating system.
Any misuse or unauthorised modifications to the appliance, flue or associated
components and systems could invalidate the warranty. The manufacturer accepts
no liability arising from any such actions, excluding statutory rights.
SERVICING:
Advise the user to have the system regularly serviced by a competent, qualified
engineer (such as British Gas or other GAS SAFE registered personnel) using approved
spares, to help maintain the economy, safety and reliability of the appliance.
IMPORTANT - The service engineer must complete the Service Record in the
Benchmark Log Book after each service.
2
SAFETY PRECAUTIONS &
INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
GENERAL INFORMATION
STANDARD PACKAGE:
A - Floor standing gas fired combination
boiler for central heating and domestic
hot water.
C - Literature pack.
D - Condensate waste pipe & non-return valve
A
SPECIFICATIONS:
APPLIANCE
INFORMATION
B - Mounting frame complete with preplumbing manifold assembly.
Pre-wired and pre-plumbed.
Galvanised steel inner frame.
Bosch Heatronic control system.
Automatic ignition.
850mm
Direct burner ignition electrodes.
Built-in frost thermostat.
Built-in fault finding diagnostics.
Modulating automatic gas valve.
Combustion air fan with speed regulator.
CH temperature sensor & control.
DHW flow sensor & temperature control.
Integral water circulating pump with antiseizure protection.
Sealed primary system & pressure gauge
display.
Pressure relief valve.
600mm
600mm
Flue gas temperature limiter.
Plate-type DHW heat exchanger.
Condensate trap & pump.
B
D
C
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
GENERAL INFORMATION
3
TECHNICAL DATA
DESCRIPTION
UNITS
Natural Gas
L.P.G
440CDi
550CDi
440CDi
550CDi
APPLIANCE
INFORMATION
Central Heating
Max. rated heat output net 40/30°C
kW
31.2
32.8
31.2
32.8
Max. rated heat output net 50/30°C
kW
30.9
32.5
30.9
32.5
30.6
Max. rated heat output net 80/60°C
kW
29.2
30.6
29.2
Max. rated heat input net
kW
29.6
31
29.6
31
Min. rated heat output net 40/30°C
kW
8.4
11
11.6
13.4
Min. rated heat output net 50/30°C
kW
8.3
10.9
11.4
13.2
Min. rated heat output net 80/60°C
kW
7.4
9.7
10.5
12.1
Min. rated heat input net
kW
7.6
10
10.8
12.5
Max. flow temperature
°C
88
88
88
88
Max. permissible operating pressure
bar
2.5
2.5
2.5
2.5
kW
29.6
41.5
29.5
41.5
Max. rated heat output
kW
29.5
41.1
29.2
41.1
Minimum flow rate to start
l/min
2.3
2.8
2.3
2.8
bar
1.5
-
1.5
-
-
1.7
Domestic Hot Water
Max. rated heat input net
Minimum pressure for max flow rate 20 l/min (±15%)
Minimum pressure for max flow rate 25 l/min (±15%)
bar
-
1.7
Specific rate - 30°C rise - heat store hot
ltr/min
20 for 10 min.
25 for 10 min.
Specific rate - 30°C rise - heat store off
ltr/min
14
19.6
14
19.6
mins
13
13
13
13
Natural Gas G20
m2/h
3.1
4.4
Propane Gas (LPG)
kg/h
-
Natural Gas G20
mb
20
LPG (Propane) Gas G31
mb
-
Flue Gas Temp. 80/60°C, rated min. load
°C
67/55
Flue Gas Temp. 40/30°C, rated min. load
°C
CO2 level at max. rated heat output
%
Time to heat tank 15°C to 65°C
20 for 10 min. 25 for 10 min.
Gas flow rate - Max. 10 minutes from lighting
2.3
3.2
Gas supply pressure
20
37
37
67/55
67/55
67/55
43/32
43/32
43/32
43/32
9.4
9.4
10.8
10.8
%
8.6
9.0
10.4
10.4
class
5
5
5
5
Flue
CO2 level at min. rated heat output
NOx - classification
Condensate
Max. condensation rate
l/h
pH value, approx.
2.7
3.7
2.7
3.7
4.8
4.8
4.8
4.8
Electrical
Electrical power supply voltage
AC...V
230
230
230
230
Frequency
Hz
50
50
50
50
Max. power consumption
W
164
206
164
206
Charge Pressure
bar
0.75
0.75
0.75
0.75
Total Capacity
Itr
12
12
12
12
SEDBUK (Band A)
%
90.8
90.8
92.2
92.2
Appliance protection rating
IP
x4D
x4D
x4D
x4D
Expansion Vessel
General Data
Appliance protection rating (with mechanical timer fitted into fascia)
IP
20
20
20
20
Permissable ambient temperatures
°C
0 - 50
0 - 50
0 - 50
0 -50
Nominal capacity of appliance
Itr
51
51
51
51
Noise output level (at maximum CH output)
Weight (excluding packaging)
4
TECHNICAL DATA
dB(A)
37
37
37
37
kg
112
112
112
112
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
LAYOUT & COMPONENTS
The diagram opposite shows the controls in
the servicing position and excludes the outer
case, inner covers and wiring.
1 CONTROL PANEL
2 MASTER SWITCH FOR ON/OFF
F
4 SERVICE BUTTON
D
5 CENTRAL HEATING BOOST BUTTON
C
6 DISPLAY
7 RESET BUTTON
B
8 ECO BUTTON
A
9 NOT USED
APPLIANCE
INFORMATION
3 BURNER ON INDICATOR LIGHT (GREEN)
E
10 CH TEMPERATURE CONTROL
1
6
2
13
3
7
4
8
5
9
10
12
11
14
42
39
41 40
38
43
1
37
36
15 16
35
11 MAINS ON/OFF INDICATOR & FAULT
DIAGNOSTIC LIGHT
12 DHW TEMPERATURE CONTROL
13 SYSTEM PRESSURE GAUGE
14 POSITION FOR OPTIONAL PROGRAMMER
15 TANK TEMPERATURE SENSOR
16 TANK OVERHEAT THERMOSTAT
17 DHW HEAT EXCHANGER
18 FILLING LOOP ISOLATION VALVE
19 WATER FLOW SENSOR TURBINE
20 BOILER/TANK DRAIN & CONNECTION POINT
FOR FILLING LOOP
21 DHW FLOW SENSOR
22 CH FLOW ISOLATION VALVE
23 DHW OUTLET
24 GAS ISOLATION VALVE
25 MAINS WATER INLET ISOLATION VALVE
26 CH RETURN ISOLATION VALVE
27 RUNNER WHEEL ON MOUNTING FRAME
28 OPTIONAL FILLING LINK WITH PRESSURE
GAUGE: PART NO: 7 716 192 599
29 CIRCULATING PUMP
30 CONDENSATE PUMP ASSEMBLY
31 GAS VALVE
32 EXPANSION VESSEL
33 AIR/GAS ADJUSTMENT SCREW (SEALED)
34 HEAT CELL
35 CH FLOW TEE PIECE
36 GAS BURNER/SPARK ELECTRODES
37 COMBUSTION AIR MODULATING FAN
38 FLUE BLANKING PLATES
39 CASING SUPPORT STRUT
40 CASE ‘KNOCK-OUT’ PANEL-FLUE
41 AUTO AIR VENT
42 SYSTEM PRESSURE RELIEF VALVE
43 HEAT STORE
34
33
17
32
18
31
19
30
20
29
21
22 23
24
25 26
27
100mmØ HORIZONTAL FLUE COMPONENTS
(Kit Part No. 7 716 191 155)
A - 93° ELBOW
B - ADAPTOR
C - CONNECTOR
D - INNER WALL FLUE COLLAR
E - TELESCOPIC TERMINAL ASSEMBLY
F - OUTER WALL FLUE COLLAR
FLUE KITS:
Vertical 100mmØ
Vertical 125mmØ
Horizontal 125mmØ
Plume management kit
Part No. 7716191156
Part No. 7716191158
Part No. 7716191157
Part No. 7716191086
28
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
LAYOUT & COMPONENTS
5
CLEANING PRIMARY SYSTEMS
IMPORTANT: All the following pre-installation sections must be read and
requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT:
Debris from the system can damage the
boiler and reduce efficiency. Failure to
comply with the guidelines for the use
of water treatment with the appliance
will invalidate the appliance warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK ARE
IN GOOD WORKING ORDER.
PREINSTALLATION
USE THE EXISTING BOILER/CIRCULATING
PUMP WHERE POSSIBLE OR USE A POWER
FLUSHING MACHINE TO AID THE CLEANSING
PROCEDURE BEFORE INSTALLING A NEW
BOILER.
CLEANING THE PRIMARY SYSTEM
IMPORTANT: ARTIFICIALLY SOFTENED
WATER MUST NOT BE USED
TO FILL THE CENTRAL
HEATING SYSTEM.
Fill the system with cold mains water to
the recommended pressure and check for
leaks.
Open all drain cocks and drain the system.
Close drain cocks and add a suitable
flushing agent at the correct strength for
the system condition in accordance with
the manufacturer's instructions.
Circulate the flushing agent before the
boiler is fired up.
Run the boiler and system at normal
operating temperature in accordance with
the manufacturer's instructions.
Drain and thoroughly flush the system to
remove the flushing agent and any debris.
6
CLEANING PRIMARY SYSTEMS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
MAINS SUPPLIES
ELECTRICAL SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm2 (24 x
0.2mm) temperature rated to 90°C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• Wiring between the appliance and the
electrical supply must comply with IEE
wiring regulations and any local regulations
which may apply for fixed wiring to a
stationary appliance.
• Any system connected to the boiler must
not have a separate electricity supply.
WATER SUPPLY:
• Connections to the water supply must not
be made without the authority of the local
water company.
PREINSTALLATION
• It must be possible to isolate the appliance
from the electric supply with at least a
3mm contact separation in both poles
supplying the appliance.
• The appliance cold water supply should
be the first connection off the water main
where possible.
Water Mains Pressure:
• Minimum dynamic mains water pressure
1.2 bar for maximum performance.
• Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 192 105
B - Water Main supply pipe
C - Non-return valve
D - Boiler
D
A
B
C
IMPORTANT: Non-return, back flow
prevention devices (including those
associated with water meters) fitted to
the mains water supply can cause a
pressure build up which could damage
the boiler and other household
appliances.
• Where the water main supply has a nonreturn, back flow prevention valve fitted,
a mini expansion vessel (A) should be
connected to the mains water inlet pipe
(B) between the non-return valve (C) and
the boiler (D) as shown opposite.
Use in hard water areas:
Normally there is no need for water treatment
to prevent scale formation as the maximum
temperature of the heat exchanger is limited
by the electronic control circuit.
In areas where the temporary water hardness
exceeds 200ppm, consideration may need to
be given to the fitting of a scale prevention
device. In such circumstances, the advice of
the local water authority should be sought.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
MAINS SUPPLIES
7
MAINS SUPPLIES
GAS SUPPLY:
• Boilers using NG must be connected to a
governed meter.
• LPG boilers must be connected to a
regulator.
• Installation and connection of the gas
supply to the boiler must be in accordance
with BS6891.
• Under no circumstances should the
diameter of the gas supply pipe be less
than that of the appliance inlet connection.
PREINSTALLATION
• The meter or regulator and pipework to
the boiler must be checked, preferably by
the gas supplier to ensure it is in good
working order and can meet the gas flow
and pressure requirements in addition to
the demand from any other appliance being
served.
8
MAINS SUPPLIES
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
WATER SYSTEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
• Any plastic pipework must have a polymeric
barrier with 600mm (minimum) length of
copper connected to the boiler.
• Plastic pipework used for underfloor
heating must be correctly controlled with
a thermostatic blending valve limiting the
temperature of the circuits to approx. 50°C.
The pipework from the boiler to the
blending valve must be in copper.
PRIMARY
SYSTEM/CONNECTIONS/VALVES:
• All system connections, taps and mixing
valves must be capable of sustaining a
pressure of 3 bar.
• Radiator valves should conform to
BS2767:10.
• All other valves should conform to BS1010.
PREINSTALLATION
• Do not use galvanised pipes or radiators.
• On new installations TRV’s must be used
on all radiators except the radiator where
the room thermostat is sited, this must be
fitted with lockshield valves and left open.
All installations should have TRV's fitted
to radiators within the sleeping
accommodation.
• Drain cocks are required at all the lowest
points on the system.
• Air vents are required at all high points on
the system.
TYPICAL SEALED SYSTEM:
R
T
R
L
T
SEALED PRIMARY SYSTEM:
• Where the system volume is more than
100 litres or exceeds 2.5bar at maximum
heating temperature an extra expansion
vessel (B) must be fitted as close as
possible to the appliance in the central
heating return.
L
A
R
R
• Pressurise the extra expansion vessel (B)
to the same figure as the expansion vessel
built into the appliance - REFER TO
TECHNICAL DATA TABLE.
B
T
P
L
T
L
C
D
A - Appliance expansion vessel
B - Extra expansion vessel
C - Automatic bypass valve
D - Drain cock
L - Lockshield valve
P - Pressure relief discharge
R - Radiators
T - TRV
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
D
NOTICE:
It is advisable to install an automatic
by-pass (C) externally to the boiler,
between the heating flow and return pipe
work, to accept any excess pressure and
flow from the circulating pump.
This is particularly relevant when the
heating system load reduces due to TRVs
etc.
This will also enable the installation to
comply with the building regulations and
the Domestic Heating Compliance guide
requirements.
WATER SYSTEMS & PIPEWORK
9
WATER SYSTEMS & PIPEWORK
FILLING PRIMARY SYSTEMS:
Water main
supply
Heating return
Hose
return
Stop
cock
Temporary
hose
Non
return
valve
Non
return
valve
Test cock
• The CH sealed system must be filled using
a WRAS approved filling loop or comply
with the diagram opposite for system fill.
• The filling point must be at low level and
must never be a permanent direct fixing
to the mains water supply.
Stop
cock
SHOWERS/BIDETS:
• If a shower head can be immersed in water
or comes closer than 25mm from the top
edge of a bath or shower tray spill over
level then an anti-siphon device must be
fitted to the shower hose.
PREINSTALLATION
• Bidets with direct hot & cold mains water
can be used (with the approval of the local
water authority) and must be the over rim
flushing type with shrouded outlets to
prevent the fitting of hand held sprays.
DOMESTIC HOT WATER:
• Taps and mixing valves must be capable
of sustaining a pressure up to 10 bar.
• Hot water temperature and flow rate are
affected by the size and insulation of
pipework making up the distribution system
and are controlled by the hot water tap
and the water main inlet pressure. A mixing
valve can be fitted if a more permanent
setting is required.
• If using more than one outlet at once
causes water flow starvation, fit flow
balancing valves or Ball-O-Fix valves to the
appropriate outlets.
10
WATER SYSTEMS & PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
CONDENSATE PIPEWORK
IMPORTANT:
Visible air break
at plug hole
• Ensure there are no
blockages in the pipe run
100mm
siting a soak-away to avoid
obstructing existing services
Insulation or
increase pipe size
22mmØ
plastic pipe
• Condensate waste must not
Open end of
condensate drainage
pipe directly into gully
below grating but
above water level
75 mm
min.
-
75mm sink
waste trap
22mmØ
Soil & vent stack
Condensing
Boiler
minimum
450mm
and up to
3 storeys
Invert
22mmØ condensate
drainage pipe, max external
length 3 metres
Insulation or
increase pipe size
500mm min.
Condensate drainage pipe can be
run above or below ground
CONDENSATE PIPEWORK:
• The condensate pipe must be a minimum of
22mm Ø plastic pipe.
• The condensate pipework must fall at
least 50 mm per metre towards the outlet
and should take the shortest practicable
route.
• The pipework must follow one of the options
shown opposite or discharge directly into a
vent stack min. 450mm above pipe invert or
into a gully below ground but above the water
level.
• Wherever possible the condensate
discharge pipe work should be routed and
terminated internally. Should this not be
possible, and the only available route is
external, the following conditions should be
observed:
External pipe work
-
Pipe work length should be kept to a
minimum and the route as vertical as
possible.
-
Where pipe work is subjected to
extreme cold or wind chill, a weather
proof insulation should be used.
Alternatively the condensate pipework
could be increased to a minimum
diameter of 32mm without the
requirement to insulate.he pipe run
25mm
Diameter 100mm
min. plastic tube
Condensate soakaway
The condensate drainage pipe may be run
above or below the ground to the soakaway.
Bottom of
tube sealed
Limestone
chippings
be terminated into a septic
tank or cesspit
PREINSTALLATION
Condensing
Boiler
• Care should be taken when
Sink with
integral
overflow
Drainage holes
The example shown opposite runs above
ground level.
Hole depth
400mm min.
by 300 Ø
The soakaway must use a 100mm diameter
plastic tube with two rows of three 12 mm
holes on 25 mm centres and 50 mm from
the bottom of the tube. The holes must face
away from the house.
The tube must be surrounded by at least
100 mm of limestone chippings ot a depth
of 400mm.
22 mm Ø plastic condensate
drainage pipe running
through the external wall
External rain water
pipe into foul water
External
air break
Condensing
Boiler
Air gap
Insulation or
increase pipe size
43 mm 90°
M & F bend
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
68 mm Ø PVC-u
strap on fitting
Fitting an external air break
Use the situation opposite when a rain water
down pipe is used to dispose of condensate
and the down pipe goes directly into an
existing sewer that carries both rainwater
and foul water.
An air break must be installed in the
32/43mm pipework, between the boiler
condensate outlet and the drainpipe, outside
the property, to avoid flooding during
adverse weather conditions.
CONDENSATE
PIPEWORK
11
PRESSURE RELIEF PIPEWORK
IMPORTANT: Debris from the system
can damage the boiler and reduce
efficiency. Failure to comply with the
guidelines for the use of water treatment
with the appliance will invalidate the
appliance warranty.
• The pressure relief drain pipe (A) should
be at least 15mm diameter copper pipe
and run downwards away from the boiler
and discharge away from any electrics or
other hazard, preferably to an external
drain or soakaway.
PREINSTALLATION
A
• Pipe (A) should be finished with a partial
bend, near the outlet to face the external
wall(as shown) to help prevent freezing.
A -
Drain pipe.
B -
Outside wall.
B
A
12
PRESSURE RELIEF PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
BOILER LOCATION &
CLEARANCES
• This boiler is only suitable for installing
internally within a property at a suitable
location onto a fixed rigid non-combustible
surface at least the same size as the boiler
and capable of supporting the boiler weight.
1: INSTALLATION CLEARANCES
1200mm
610mm
600mm
• THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
5mm
COMMERCIAL INSTALLATION:
5mm
2: SERVICE / VENTED
600mm
CUPBOARD CLEARANCES
1200mm
610mm
15mm
• If installing more than one appliance in a
modular or cascade arrangement in a
commercial premises, that total more than
70kW, then additional ventilation is needed to
comply with the Dangerous Substances and
Explosive Atmospheres Regulations (DSEAR).
Compartments:
Follow the requirements of BS6798 and
BS5440 Part 2 and note:
865mm
5mm
3: UNVENTED
COMPARTMENT CLEARANCES
800mm
250mm*
• An access door is required to install, service
and maintain the boiler and any ancillary
equipment.
• If fitting the boiler into an airing cupboard
use a non-combustible perforated material
(maximum hole sizes of 13mm) to separate
the boiler from the airing space.
800mm
1: INSTALLATION CLEARANCES:
50mm
900mm
• Minimum clearances must be maintained.
5mm
600mm
PREINSTALLATION
1450mm
• The boiler is not suitable for external installation
unless a suitable enclosure is provided.
Diagram '1' shows the minimum space
required to install the boiler only.
100mm**
2: SERVICE CLEARANCES:
100mm**
Diagram '2' opposite shows the minimum
space required to service the boiler only.
25mm to an removable door.
200mm*
3: UNVENTED COMPARTMENT
CLEARANCES:
Diagram '3' shows the minimum space
required to install and service the boiler inside
an unvented compartment.
*Space required for unvented areas with a
removable door or panel.
**This space can be reduced to 50mm for one
side only as long as both the side clearances
add up to the total of both the side
measurements shown or more.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
BOILER LOCATION & CLEARANCES
13
BOILER LOCATION &
CLEARANCES
4: AIRING CUPBOARD
CLEARANCES
625mm
800mm
4: AIRING CUPBOARD CLEARANCES:
Diagram 'd' opposite shows the minimum
space required to install and service the boiler
within an airing cupboard.
5: VENTING COMPARTMENTS:
1050mm
25mm
PREINSTALLATION
5: VENTING
COMPARTMENTS
If the clearances are less than those stated
for options '3' & '4' (above) then ventilation
must be provided as described in BS 5440.
200mm
A minimum of 2 air vents (C) of equal size must
be fitted, one at low level and another at high
level on the same wall using the same air for
circulation.
100mm
25mm
100mm
Minimum free area required for venting:
For area directly from outside:
440CDi 155cm2 per vent.
550CDi 220cm2 per vent.
B
For air from internal space/room:
440CDi 310cm2 per vent.
C
550CDi 440cm2 per vent.
D
600mm
600mm
6: BATHROOMS:
750mm
1
1
2250mm
Electrical switches, fused spurs and socket
outlets must not be situated in the bathroom.
2250mm
2
2
IMPORTANT:
Any switch or appliance control using mains
electricity must not be within reach of a
person using the bath or shower.
A boiler fitted with a non-mechanical timer or
with no timer can be installed in zone 2 or
outside the shaded area.
A boiler with a mechanical timer or RF
mechanical timer with a room thermostat
must only installed outside the shaded area.
Additional RCD (Residual Current Device)
protection may be required.
600mm
Refer to the latest IEE wiring regulations.
750mm
1
2250mm
1
2
2250mm
2
600mm radius
14
BOILER LOCATION & CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
MOUNTING FRAME
CONNECTIONS
CONNECTIONS:
Water: 22mm compression fittings
Gas: 22mm compression fitting.
PRE-PLUMBING:
• With the mounting frame (A) installed,
pipework can be connected to the valves
on the plumbing manifold.
• The system can be filled (without the
boiler being connected) using an optional
charging link assembly (B).
• The boiler can be installed at a later date.
RUNNING PIPES BEHIND THE BOILER:
• The frame should sit against the wall (not
the skirting board) with enough room for
the pipework.
PREINSTALLATION
• The valves can be closed enabling the
DHW and CH systems to be tested.
• Do not cross a pipe over another.
• The area around a rear flue outlet must
be avoided.
A
B (Optional)
C
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
MOUNTING FRAME CONNECTIONS
15
TERMINAL OUTLET POSITIONS
All measurements in millimetres
300
6
Dormer
Window
500
25
5
7
14
400
8
10
PREINSTALLATION
25
1,500
Velux Window
9
11
200
Drainpipe
300
25
4
3
500
600
500
300
1,200
12
13
1,500
300
2
Boundary
Window
300
15
600
1 300
NOTE:
All measurements are the minimum clearances required.
Terminals must be positioned so to avoid combustion
products entering the building.
Key to illustration
1. Flue clearance must be at least 300mm from the ground.
Terminal guards must be fitted if the flue is less than 2 metres
from the ground or if a person could come into contact with
the flue terminal.
8. 400mm from a pitched roof or in regions with heavy snow fall
500mm.
9. The flue cannot be lower than 1,000mm from the top of a light
well due to the build up of combustion products.
2. 600mm distance to a boundary, unless it will cause a nuisance.
BS 5440: Part 1 recommends that care is taken when siting
terminals in relation to boundaries.
10. 2,000mm below a Velux window, 600mm above or to either
side of the Velux window.
3. 600mm minimum clearance from a skylight to a vertical flue.
11. 200mm below eaves and 75mm below gutters, pipes and
drains.
4. Vertical flue clearance 500mm to non-combustible building
material, and 1,500mm clearance to combustible building
material.
12. 1,200mm between terminals facing each other.
13. 300mm to an internal or external corner.
5. The dimension below eaves, gutters,pipes and drains can
be reduced to 25 mm, as long as the flue terminal is extended
to clear any overhang. Any external flue joints must be sealed
with suitable silicon sealent.
6. 500mm clearance to any vertical structure on a roof, 600mm
to room sealed flue or 1,500mm to an open flue.
7. 1,500mm between a vertical flue terminal and a window or
dormer window.
16
TERMINAL OUTLET POSITIONS
14. The dimension below eaves, balconies and car ports can
be reduced to 25 mm, as long as the flue terminal is extended
to clear any overhang. Installations in car ports are not
recommended. Any external flue joints must be sealed
with suitable silicon sealent.
15. 300mm above, below and either side of an opening door,
air vent or opening window.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
PLUME MANAGEMENT KIT POSITIONS
All measurements in millimetres
Plume management deflector:
180°
Flue Exhaust
Outlet
Air Intake
8
PREINSTALLATION
7
3
200
300
200
2
1,200
Balcony
4
150
200
600
1
200
25
300
150
Window
300
Window
300
200 5
Window
Door
Boundary
25
150
150
150
6
Drainpipe
NOTE:
All measurements are the minimum clearances required.
Terminals must be positioned so to avoid combustion
products entering the building.
Key to illustration
1. 600 mm distance to a boundary, unless it will cause a nuisance.
BS 5440: Part 1 recomends that care is taken when siting
terminals in relation to boundaries.
2. Internal/external corners the air intake can be reduced
to150mm providing the flue exhaust outlet has a 300mm
clearance.
3. The flue cannot be lower than 1,000mm from the top of the
light well due to the build up of combustion products.
4. 1,200mm between air intake and facing terminal.
5. Clearance no less than 200mm from the lowest point of the
balcony or overhang, installations in car ports are not
recommended.
6. 1,200mm from an opening in a car port on the same wall
i.e. door or window leading into dwelling. 600mm to a surface
facing a terminal.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
7. Using a Plume Management Kit the air intake measurement
can be reduced to 150mm providing the flue exhaust outlet
has a 300mm clearance.
Plume kits running horizontally must have a 10 degree fall
back to the boiler for proper disposal of condensate.
For details on specific lengths see relevant boiler Technical &
Specification manual.
8. This allows some basic plume options on a standard telescopic
horizontal flue terminal. 300mm minimum clearances to a
opening e.g. window.
However the minimum clearance to an opening in the direction
to which the plume is directed in, should be increased to
1,500mm.
Where the flue is less than 150mm to a drain pipe & the plume
deflector is used it should not be directed towards it.
TERMINAL OUTLET POSITIONS
17
ROOM SEALED FLUE OPTIONS
L= Ø100mm 140 - 530mm
L= Ø125mm 350 - 1200mm
L= Ø125mm 9000mm
The diagrams (opposite) show the
components used and the maximum flue
length for each configuration of Ø100mm and
Ø125mm flues.
L
L
A
Min.
120mm
A
B
Ø125mm x8
C
• Only straight flue sections can be reduced
in length by cutting.
• The Ø100mm horizontal flue terminal can
be fitted from inside or outside the
building.
C
IMPORTANT:
All horizontal sections must rise away
from the boiler by 52mm per metre (3°)
to allow the condensate to drain back
to the boiler.
L= Ø100mm 310 - 4000mm
L= Ø125mm 350 - 13000mm
PREINSTALLATION
L
A
B
L= Ø125mm 7000mm
Ø100mm x4
Ø125mm x12
A
L
C
D
A
Min.
120mm
B
Ø125mm x6
L= Ø100mm 2000mm
L= Ø125mm 11000mm
E
B
A - Horizontal terminal
B - Straight flue extension
C
A
C
C
C - Flue bend 90°
D - Flue bend 45°
L
E - Vertical Terminal
B
Ø100mm x2
Ø125mm x10
Calculating the flue length:
Measure the total flue length (L) required,
noting that the maximum straight flue length
including the terminal is:
C
Horizontal Ø60/100mm: 4000mm
Horizontal Ø80/125mm: 13000mm
L= Ø100mm 4400mm L
L= Ø125mm 13000mm
Vertical Ø60/100mm: 6400mm
Vertical Ø80/125mm: 15000mm
D
L=Ø100mm 2000mm
L=Ø125mm 11000mm
E
A
L
Min.
120mm
D
B
Ø100mm x4
Ø125mm x12
B
Ø100mm x2
Ø125mm x10
Then reduce the total straight flue length for
each extra flue bend (excluding the flue elbow)
by:
2000mm for 90°
1000mm for 45°
Flue Extension lengths:
D
Horizontal & Vertical Ø60/100mm: 950mm
D
Horizontal & Vertical Ø80/125mm: 950mm
Flue Terminal lengths:
Horizontal Ø60/100mm: 530mm
L=Ø100mm 2400mm
L=Ø125mm 11000mm
L= Ø125mm 9000mm
A
Vertical Ø60/100mm: 1140mm
L
C
E
C
B
Ø125mm x8
C
18
Horizontal Ø80/125mm: 1200mm
L
C
ROOM SEALED FLUE OPTIONS
Min.
120mm
Vertical Ø80/125mm: 1365mm
B
Ø100mm x2
Ø125mm x10
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
IMPORTANT: All the previous Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
UNPACKING THE BOILER
Take care not to damage the boiler panels or
the floor and note that the boiler may contain
some water due to factory testing.
Unpacking:
2
1
1
Undo the ties securing the carton to the
pallet
If a sharp implement is used, care must be
taken not to pierce the carton or cause injury.
A
B
C
2
Before removing the carton it is advised
that the top flaps are opened and the
ancillary items (A, B, C & D) are removed
and set to one side.
3
The carton can now be lifted off the
boiler.
Remove the plastic bag protecting the
boiler surfaces and place safely away from
the working area.
D
Remove 2 screws at the rear of the board
securing the board to the pallet.
Grip the outer sides of the front panel
pull and lift away from retaining lugs.
Remove securing screw, at the front of
the boiler, from the pallet.
Remove remaining screws, at the rear of
the boiler, from the pallet.
The boiler is mounted on small wheels
and two people are recommended to move
the boiler from the board taking care not
to damage the panels or the floor.
INSTALLATION
Slide the boiler and board off the pallet.
4
5
Remove the rubber plug (E) from the
boiler pipework by pulling down.
At all times the correct method for handling
heavy objects should be strictly observed.
3
GENERAL HANDLING GUIDELINES:
Lift only a manageable weight, or ask for
help.
When lifting, bend the knees, and keep
the back straight and feet apart.
Do not lift and twist at the same time.
Lift and carry items close to the body
Wear protective clothing and gloves to
protect from any sharp edges
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
A - Mounting frame
B - Installation pack
C - Literature pack
D - Condensate waste pipe & non-return
valve
4
E
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
UNPACKING THE BOILER
19
All dimensions in mm
F
D
D
A
B
MOUNTING FRAME FIXING &
FLUE OPENING
CAUTION: Ensure there are no pipes,
electric cables, damp proof course or other
hazards before drilling.
B
SAFETY:
112
65
98.5
65
65
81
20
All relevant safety precautions must be
undertaken. Protective clothing, footwear,
gloves and safety goggles must be worn as
appropriate.
MOUNTING FRAME/PIPEWORK POSITIONS:
A - Mounting frame.
B - Manifold connections.
C - Mounting frame fixing point.
38mm
D - Wall.
E - Gas and water pipework (not supplied).
INSTALLATION
B
C
D
F - Boiler.
E
FIXING THE MOUNTING FRAME:
Position the mounting frame (A) on the
floor against the wall with manifold
connections (B) facing away from the wall
(D) ensuring there is enough space for the
pipework (E).
A
Allow the minimum space from each side
of the frame (A) for the boiler overhang (F)
and minimum service clearance, as shown.
X
Y
Ensure the mounting frame is level and
mark fixing points (C).
Z
Secure mounting frame (A) to the floor
using appropriate fixings (not supplied).
Clear any debris from the site.
FLUE OPENING:
Follow the diagram opposite to mark the
centre of the flue (1, & 2) for rear opening,
(2 & 3) for side opening or (1 & 4) for top
opening.
Measurements shown include the minimum
service clearances.
4
123
Y
Cover the mounting frame manifold
assembly (A) to protect the manifold
connections.
1
3
X
NOTE: All horizontal flue sections must rise away
from the boiler by 52mm per meter to
ensure that condensate flows back into
the boiler for safe discharge via the
condensate waste pipe.
123
Make an opening (X or Z) through the wall
using a core drill or similar at a size relative
to the wall thickness as shown below:
267
343
Z
2
+13
743*
Wall
Flue opening Flue opening
thickness
60/100mmØ 80/125mmØ
150 - 240mm
127mmØ
152mmØ
240 - 330mm
127mmØ
152mmØ
330 - 420mm
127mmØ
162mmØ
420 - 500mm
140mmØ
162mmØ
Where the flue terminal can only be fitted
from inside the building, increase the opening
to 150mmØ to allow the optional weather
collar to fit through the opening for 60/100
flue.
Clear away any debris.
20
MOUNTING FRAME FIXING &
FLUE OPENING
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
MOUNTING FRAME
CONNECTIONS
CAUTION: ISOLATE THE MAINS GAS
SUPPLY BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
GAS AND WATER CONNECTIONS:
Ensure all pipework is clean and each
pipe is in the correct position as shown
opposite.
Push in each pipe in turn and tighten the
fitting to secure.
A - CH flow (22mm)
B - DHW flow (22mm)
C - Gas inlet (22mm)
D - Mains water inlet (22mm)
E - CH return (22mm)
INSTALLATION
F - Mounting frame.
F
A
B
C
D
E
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
MOUNTING FRAME CONNECTIONS
21
FLUE LENGTHS
HORIZONTAL FLUE:
1
(60/100mm diameter)
L
For vertical flues and 80/125mmØ horizontal
flues, please refer to separate Flue manuals.
Ø60/100mm HORIZONTAL TELESCOPIC
FLUE LENGTHS:
The maximum effective straight flue lengths
(L) are stated opposite for the relevant
appliance and must not be exceeded.
1
EFFECTIVE MAXIMUM STRAIGHT FLUE
LENGTHS for Ø60/100mm Telescopic flue:
Measure the total straight length (L)
along the flue route, then add the following
to length (L) to check the maximum flue
length is not exceeded:
L max.
2000mm for each extra 90° bend.
440CDi
4000mm
1000mm for each extra 45° bend.
550CDi
4000mm
INSTALLATION
Appliance description
FLUE MEASURING & CUTTING
Do not exceed the maximum straight
length for a horizontal Ø60/100mm flue
or a Ø60mm plume management system
(if used) as stated in this Instruction
Manual or Flue Manual.
All dimensions in mm.
1 Example with one extension tube:
L
CUT LENGTH WITH ONE
EXTENSION = L - 410mm
10
400
110
Cutting the flue to an exact measure is not
normally required as the telescopic flue terminal
allows for adjustment.
1
B
A
C
E
D
Measure the flue length (L) from the
boiler inner case (A) along the flue route
to the outside wall (D).
Note, the terminal end projects beyond the
outside wall by the distance shown opposite.
A - Boiler inner case.
B - Flue connector.
C - Flue extension tube socket.
D - Outside wall.
E - Aluminium tape over terminal screwed
joint.
22
FLUE LENGTHS
FLUE MEASURING & CUTTING
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
FLUE MEASURING & CUTTING
1
Flue bends:
1
950mm
1145mm
Connecting flue bends increases the
effective pipe length and an allowance
must be made for the different connectors.
The example opposite shows dimensions
for two 90° bends connected to a standard
flue extension.
Adjusting the standard terminal length:
2
2
530mm
Extend tube (A) by withdrawing from
tube (B) to achieve the flue length required,
310- 530mm.
Secure with screw provided and seal
joint with the aluminium tape supplied.
310mm
Reducing the standard terminal length:
3
Remove securing screws (C) to detach
the terminal assembly from the connector.
A
B
To use terminal (A) without cutting
remove the location lug (D) on the inner
flue tube (E) and remove any burrs.
To reduce the terminal length further:
4
3
Mark the length required for the terminal
(A) as shown (min. 130mm) and cut square,
taking care not to damage the tubes.
Remove any burrs and chamfer the outer
edge of the tubes to assist ease of
connection and prevent seal damage.
C
INSTALLATION
Slide terminal section (B) from the
terminal assembly and discard.
NOTE: The aluminium tape is not required
when reducing the terminal.
A
B
Reducing extended flue tube length:
D
E
Only cut flue extension & not flue terminal.
5
Mark flue extension (F) to the required
distance measuring from the socket end
and cut square taking care not to damage
the tubes.
Remove any burrs and chamfer the outer
edge of the tubes to assist ease of
connection and prevent seal damage.
4
A
130mm
MIN
Required distance
5
G
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
FLUE MEASURING & CUTTING
23
FLUE MEASURING & CUTTING
FLUE OUTLETS (L or P):
P
L
1
2
L
3
Remove seal (B) from flue adaptor (A).
Cut square to mark, as shown, deburr
and clean.
Replace seal (B).
2
L
INSTALLATION
1
A
B
3
2
P
1
A
B
3
B
24
FLUE MEASURING & CUTTING
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
FLUE INSTALLATION
D
1
2
Remove retaining screw (A) to swing
control panel assembly (B) outwards to
its full extent.
Remove screws (C) from inside of casing.
Lift front of top panel (D) to release.
Pull forwards to disengage rear retainer
(E), then lift panel (D) away from boiler.
3
H
E
4
C
Pull clip (F) outwards to release the
expansion vessel(G).
Swing expansion vessel (G) outwards.
2
B
1
Note: for easier access to the inner case, the
expansion vessel can be unhooked (by removing
the retaining screw on the hinge) lowered and
moved to the side. Take care not to overstretch
the flexible pipe connections.
5
A
I
5
F
Release four screws (H) to remove the
inner case cover ( I ).
INSTALLATION
3
G
A
A
B
1
C
E
D
CONVERT FROM REAR FLUE OUTLET:
The boiler is supplied ready to fit a rear flue
outlet. To flue from the sides or top of the boiler,
follow the procedure below:
1
Remove and discard the required side or
top 'knock-out' panel (A) from the outer
casing (B).
2
Remove the flue outlet blanking plate
comprising: cover (D) and gasket (E) from
the inner casing (C) by removing the three
screws (F).
3
Refit the outlet blanking plate over
the rear flue outlet.
2
F
B
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
A
FLUE INSTALLATION
25
STANDARD FLUE INSTALLATION
1
NOTE: to ease assembly of the flue components,
grease seals lightly with the solvent-free grease
supplied.
B
Check all the seals are seated properly in the grooves
provided and are in good condition.
All flue joints must be sealed to prevent leakage of
condensate and flue products.
Installing the standard flue:
2
1
Set the flue terminal (B) to the distance
required, secure with screw and seal joint
with the aluminium tape supplied.
2
Slide the inner wall seal (C) onto the
terminal (B) as shown.
If fitting from inside the building; slide
the outer wall seal (K) onto terminal (B).
B
C
3
A
TOP
TOP
The flue terminal (B) MUST be fitted
with the label marked 'TOP' uppermost
to allow the correct fit and use of the
plume management system.
B
INSTALLATION
K
If fitting from the outside of the building;
slide the outer wall seal (K) onto terminal
(B) to fit against the outer wall and then
pull back to create a seal.
A
C
4
3
Roll the boiler into position on the floor
mounting frame.
Position connector (A) with the label
marked ‘TOP’ uppermost to align with the
three holes in the boiler inner casing (E).
110
mm
TOP
4
Position terminal (B) through the flue
opening in the wall to the outside of the
building by the distance shown and then
pull back to create a seal.
Secure using three hexagonal bolts (F).
A
5
Push-fit adaptor (G) into elbow (H) until
secured by the clip.
6
Slide adaptor (G) into the inner flue tube
of terminal (B) and push elbow (H) into
flue outlet (J) until secured by the retaining
clips ensuring a good seal is made.
F
E
G
5
Clip
H
6
G
H
E
J
26
STANDARD FLUE INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
2m
EXTENDED FLUE INSTALLATION
1m
52mm
NOTE: to ease assembly of the flue components,
grease seals lightly with the solvent-free grease
supplied.
104mm
Check all the seals are seated properly in the grooves
provided and are in good condition.
TOP
D
B
C
All flue joints must be sealed to prevent leakage of
condensate and flue products.
A
1
TOP
All horizontal flue sections must rise by
at least 52mm for each metre away from
the boiler to ensure that condensate
flows back into the boiler for safe
discharge via the condensate waste pipe.
3
A
D
2
Installing an extended flue:
4
Secure connector (A) to flue extension
(B) using two screws (D).
3
Support the weight of flue extension (B)
and position connector (A) with label
marked ‘TOP’ uppermost to align with the
three holes in the boiler inner casing (E).
4
Push-fit adaptor (G) into elbow (H) until
secured by the clip.
5
Push-fit the adaptor (G) into the inner
flue extension (B) and push elbow (H) into
flue outlet (J) until secured by the retaining
clips.
6
Slide a support clamp (C) (not supplied)
onto additional flue extensions (B).
5
Secure using three hexagonal bolts (F).
G
H
H
B
E
Working from the boiler, fit the
extension/s with support clamp/s as
required, to take the weight of the flue.
J
Drill two holes (180° apart if possible)
through the outer flue tube of each
extension taking care NOT to drill the inner
flue tube and secure with screws (K) as
shown.
K
6
7
B
C
Slide the inner wall seal (L) onto terminal
(N).
If fitting from inside the building; slide
the outer wall seal (M) onto terminal (N)
as shown.
K
B
C
7
N
9
L
M
8
Position terminal assembly (N) through
the flue opening in the wall to the outside
of the building by the distance shown and
then pull back to create a seal..
9
Fit terminal assembly (N) into the last
extension (B).
The flue terminal (N) MUST be fitted
with the label 'TOP' uppermost to allow
the correct fit and use of the plume
management system.
TOP
Drill the outer flue tubes and fix with
screws (K).
M
8
B
Slide a support clamp (C) (not supplied)
onto a flue extension (B) as shown.
2
E
G
Clip
1
INSTALLATION
B
F
10
10 If fitting from the outside of the building;
slide the outer wall seal (M) onto terminal
(N).
K
110m
m
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
EXTENDED FLUE INSTALLATION
27
FLUE TERMINAL PLUME
MANAGEMENT
The flue discharge can be redirected allowing
some plume management control, alternatively,
a complete plume management system can be
fitted to the flue terminal.
2
A
Redirecting the flue discharge:
Important: should you wish to use the
plume deflector please use the additional
grease enclosed to ensure that an
adequate seal is retained.
1
1
Remove screws (A) and terminal end (B).
2
Spread the extra grease supplied into
the groove that runs around the terminal
outlet (C) to ensure a good seal is retained.
3
Rotate the detached end section (B) to
plume deflecting position, as shown and
refit using screws (A).
4
Loosen screws (D) and rotate the terminal
end (B & C) to redirect the plume.
B
C
DO NOT rotate the complete flue terminal
assembly.
INSTALLATION
A
Retighten screws (D) to secure in the
required position.
NOTE: the flue terminal outlet has built-in
stops to limit rotation for horizontal fluing
to allow condensate to run back into the
boiler for safe disposal. Do not attempt to
force beyond the limit stops.
3
B
±80°
4
D
28
C B
FLUE TERMINAL PLUME MANAGEMENT
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
CONDENSATE, GAS & WATER
CONNECTIONS
CONDENSATE CONNECTION:
H
The condensate pump (G) fills up and
periodically discharges through the flexible
condensate pipe (H) between 200mm to
4500mm from floor level. After this point the
condensate flows, due to gravity, down the
21.5mm plastic pipe to the outlet.
Max. 4500mm
Fit the bayonet connector on the end of
the condensate waste pipe to the
condensate pump. Push down and rotate
clockwise until the connector is locked.
Route and secure condensate waste pipe
(H) with clips supplied to prevent kinking
or restriction.
Min. 200mm
Cut off any excess pipe (H).
Fit the condensate waste pipe (H) to
adaptor (K) and secure with clip (J).
G
Connect adaptor (K) to 21.5mm plastic
pipe and terminate into an internal waste
trap.
Never terminate or discharge into any
open source, including; sink, bath, shower,
bidet, toilet etc.
H
J
Note: Any external condensate pipework
should be protected with weather resistant
insulation to help prevent freezing.
K
The flexible pipe supplied can only be
used inside the property.
INSTALLATION
(See Pre-Installation section for condensate
pipework running from the adaptor (K) to
the discharge outlet).
CAUTION: ISOLATE THE MAINS GAS AND
WATER SUPPLY BEFORE STARTING ANY
WORK AND OBSERVE ALL RELEVANT
SAFETY PRECAUTIONS.
GAS AND WATER CONNECTIONS:
Remove the transit bung (L) from the gas
& water connections (A, B, C, D & E) on
the boiler and mounting frame.
H
Note: that surplus water may be present due
to factory testing.
Ensure the area is clear of debris and
manoeuvre the boiler rear wheels onto the
outer rails of the mounting frame (F).
F
Take care when moving the boiler to
position the front wheels onto the rails
and align the gas/water connections and
the flue.
M
Secure boiler to mounting frame (F) with
screw (M)
F
Place the 5 larger valve sealing washers
(shown shaded) onto valves A, B, C, D &
E.
Ensure all pipework is clean.
A
B
L
C
Tighten the compression fittings to
secure:
A - CH flow (22mm).
D
E
B - DHW flow (22mm).
C - Gas inlet (22mm).
D - Mains water inlet (22mm).
E - CH return (22mm).
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
CONDENSATE, GAS & WATER CONNECTIONS
29
PRESSURE RELIEF VALVE
OUTLET
A
B
Fitting the pressure relief valve drain pipe:
Connect a length of 15mm copper pipe
(A) to the P.R.V drain pipe (B).
C
The P.R.V drain pipe (B) should be at least
15mm diameter and run down away from
any electrics or other hazard.
IMPORTANT: The pressure relief valve
is a safety device for the boiler and if
activated may discharge boiling water
or steam through the P.R.V drain pipe.
Auto air vent:
INSTALLATION
Remove the auto air vent cap (C) and
discard.
C
30
PRESSURE RELIEF VALVE OUTLET
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
ELECTRICAL
1
CAUTION: ISOLATE THE MAINS
ELECTRICITY SUPPLY BEFORE STARTING
ANY WORK AND OBSERVE ALL RELEVANT
SAFETY PRECAUTIONS
2
NOTE:
The mains electrical supply to the boiler and
system wiring centre must be common and
through either a common fused double pole
isolator or a fused three pin plug and
unswitched socket.
A
B
The isolator shall be situated next to the
boiler for new systems and, where
practicable, replacement boilers.
EARTH = E
The isolator must have a contact separation
of 3mm minimum between all poles. Any
system connected to the boiler must not
have a separate electrical supply.
LIVE = L
NEUTRAL = N
SWITCHED LIVE = S
8
External fuse 3 Amps.
7
FROST
THERMOSTAT
AND
/OR
3
6
When stripping wires ensure copper strands
do not fall into the control box.
Access to electrical connections:
3
S
L
ST6
N L S
ST10
N NS LS LR
F R F S NP L P
1 Remove screw (A) and swing the control
panel into the service position.
2 Remove the three screws (B) in the control
panel and remove the connections cover.
3 Unclip cable clamp (C).
C
4 Cut off the tapered cable entry to suit the
cable diameter.
6
4
5 Unscrew cable retaining screw (D).
Run the cable through the cable clamp (C)
ensuring there is ample cable to reach the
connectors. Tighten the cable retaining
screw D to secure the cable and replace
clamp C into the control panel.
230 V
ST10
D
L
N NS LS LR
L
5
INSTALLATION
Remove boiler casing to access control panel.
E
6 Mains power 230 Volt connection ST10:
N
Separate wires from cable end and strip
to 6mm
Connect LIVE wire to terminal L
D
Connect NEUTRAL wire to terminal N
Connect EARTH wire to connector
NOTE: Make the EARTH wire longer so that
if the cable is snagged, the EARTH
wire is the last to be pulled out.
7 Optional frost thermostat connection ST6:
Connect frost thermostat supply wire to
terminal Fs
Connect frost thermostat return wire to
terminal FR
8 230V room thermostat and/or external timer
ST10:
ST10
Remove link
Connect room thermostat LIVE supply to
terminal Ls
Connect room thermostat LIVE return to
terminal LR
6 720 614562-04.1O
Connect room thermostat NEUTRAL to
terminal Ns
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
9 Refit all panels
Refer to manufacturers instructions when
connecting external parts to the wiring centre.
Worcester, Bosch Group cannot be held
responsible for wiring errors.
ELECTRICAL
31
PRE-COMMISIONING CHECKS
CAUTION: ISOLATE THE MAINS SUPPLIES
BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
2
1
Check that the service and water pipes
are connected to the correct valve on the
manifold;
A - CH flow (22mm)
B - DHW flow (22mm)
C - Gas inlet (22mm)
D - Mains water inlet (22mm)
3
E - CH return (22mm)
2
Check the gas type specified on the
identification plate matches that of the
gas supply.
Turn on the main gas supply, check the
gas pipework, connections and rectify any
leaks.
COMMISSIONING
4
3
Check the flue is correctly fitted and the
connections are secure.
4
Check the condensate pipework is
correctly fitted and connected.
5
Check the CH circulating pump is set to
3.
Note: The CH circulating heating pump is preset
to number '3' and should not be altered.
IMPORTANT: If the boiler is not to be
commissioned immediately then:
after successfully completing all of the
checks and any rectification work, shut
off the gas supply and electrically isolate
the boiler.
Complete the installation part of the
Guarantee Registration Card.
1
32
A
B
C
D
PRE-COMMISIONING CHECKS
E
5
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
FILLING THE SYSTEM
1
2
3
Turn on the water main and open the
system valves (align slot vertically).
Open all radiator valves.
Unscrew the tank drain cap and connect
the integral filling loop between the Flow
valve and the Tank drain valve.
Open the flow and tank drain valves.
Fill the system to a pressure up to 2 bar.
Close the flow valve.
4
Vent all radiators, retighten the vent when
completed.
Check the system and correct any leaks.
5
The boiler integral expansion vessel is
pre-charged to 0.75bar (equal to a static
head of 7.5m (22ft)). A Schraeder type
valve is fitted to the expansion vessel to
allow for pressure adjustment if required.
6
7
Briefly open the pressure relief valve to
test its operation.
Close the tank drain valve.
Disconnect the integral filling loop.
Connect a suitable hose to the tank drain
ensuring safe disposal of the discharge.
Open the tank drain valve to reduce the
system pressure to the system pressure
required, then close.
COMMISSIONING
If an extra expansion vessel is fitted to the
central heating return, adjust this to the
same pressure as the appliance internal
expansion tank, refer to separate instructions
with the extra expansion vessel.
System pressure and capacity:
1 bar 82 litres.
1.5 bar 46 litres.
Rotate the adjustable pointer on the
pressure gauge to record the set system
pressure.
Disconnect the hose from the tank drain.
Refit tank drain cap.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
FILLING THE SYSTEM
33
WATER TREATMENT
IMPORTANT: Debris from the system can
damage the boiler and reduce efficiency.
Failure to comply with the guidelines for
the use of water treatment with the
appliance will invalidate the appliance
warranty.
FLUSHING (Central Heating):
Switch off the boiler.
Open vented systems only: turn off the
water to the system header tank.
Open all radiator valves/drain cocks and
drain the system while the appliance is
hot.
Close drain cocks.
Add a suitable flushing agent and refill
the system at the correct strength for the
system condition in accordance with the
manufacturer's instructions.
Run the boiler/system at normal operating
temperature for the time stated by the
flushing agent manufacturer.
Drain and thoroughly flush the system to
remove the flushing agent and debris.
INHIBITOR (Central Heating):
Check drain cocks are closed and all
radiator valves are open.
COMMISSIONING
Add a suitable* inhibitor, (or combined
inhibitor/anti-freeze if the system is
exposed to freezing conditions) to the
heating system in accordance with the
manufacturers instructions.
The inhibitor or combined inhibitor/antifreeze must not cause damage to the
materials within the boiler (aluminium,
stainless steel, copper and brass) and any
other materials/components within the
system.
Open vented systems only: turn on the
water to the system header tank and allow
the system to fill.
Sealed systems only: fill the system to
between 1 and 2 bar via a WRAS approved
filling loop.
Vent the boiler and all radiators; retighten
vents when complete.
Record the date when the inhibitor was
added to the system on the guarantee card.
NOTE:
The concentration level of inhibitor in the system
should be checked every 12 months or sooner
if system content is lost.
The addition of sealing agents to the system
water is not recommended as this can cause
problems with deposits left in the heat
exchanger.
* compatible with aluminium. The pH
value of the system water must be less
than 8 or the appliance guarantee will
be invalidated.
34
WATER TREATMENT
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
K
A
I
D
E
F
H
L
M
STARTING THE APPLIANCE
IMPORTANT: Never run the appliance
when the appliance or system is empty
or unpressurised.
Switching the appliance on/off:
1
Turn on mains power supply.
Turn on any external controls.
Set the TRV controls to maximum.
C
Set the clock/programmer to continuously ON
and the room thermostat to maximum
temperature.
G
B
J
A - MASTER SWITCH FOR ON/OFF
2
Press button (A) and the power on indicator (B)
illuminates blue.
3
Turn the temperature control (C) to maximum.
The burner on indicator (D) illuminates green
when the burner has lit.
B - MAINS ON/OFF INDICATOR + FAULT DIAGNOSTIC LIGHT
C - CENTRAL HEATING TEMPERATURE CONTROL
E - FAULT RESET BUTTON
Note: The boiler runs for 15 minutes at minimum heating
output to fill the condensate trap. This occurs every
time the mains supply has been interrupted.
F - SERVICE BUTTON
4
D - BURNER ON INDICATOR LIGHT (GREEN)
G - DOMESTIC HOT WATER TEMPERATURE CONTROL
To reset the boiler, press and hold the reset
button (E) for 2 seconds.
H - ECO BUTTON (DOMESTIC HOT WATER PRE-HEAT ON/OFF)
I - SYSTEM PRESSURE GAUGE
CAUTION: DO NOT PRESS THE POWER
INDICATOR (B) TO RESET THE BOILER.
J - POSITION FOR OPTIONAL PROGRAMMER
K - DISPLAY
L - CENTRAL HEATING BOOST BUTTON
THE COMBUSTION FOR THE APPLIANCE IS FACTORY
SET.
NO ADJUSTMENT IS REQUIRED IF THE GAS INLET
PRESSURE IS CORRECT.
M - NOT USED
The inlet pressure to the appliance must be checked
using the following procedure:
2
SETTING THE BOILER TO MAXIMUM:
Press boost button (L) for ten seconds and set
temperature to maximum.
The boost button will illuminate continually.
MEASURING THE INLET PRESSURE:
Slacken the screw in the inlet pressure test point
and connect a manometer.
B
COMMISSIONING
CHECKING THE GAS INLET PRESSURE:
A
1
If the boiler fails to light, the blue power indicator
(B) and reset button (E) will flash alternately.
Measure the pressure with the boiler running at
maximum.
Check the gas supply working pressure at the
gas valve inlet point:
3
N.G. minimum 17-19 mbar, nominal 18 mbar
L.P.G. 35-39 mbar, nominal 37 mbar
The gas rate should be measured at the gas meter
after 10 minutes operation at maximum. See
Technical Data section at the front of this manual.
D
(L.P.G.) where a gas meter is not available the
CO/CO2 must be checked to units shown in
“Setting the air/gas ratio” section.
Ensure inlet pressure is satisfactory with all other
gas appliances working.
C
Replace controls cover.
NOTE: this boiler is designed with a differential
of 20° C across the heating system.
4
IMPORTANT: Do not continue
commissioning until the correct gas inlet
pressure is achieved.
E
If pressure is satisfactory press the boost button
again and the boiler will return to normal
operation.
If left in service mode the control will return to
normal operation after 15 minutes.
B
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
Reseal the screw in the gas inlet pressure test
point.
STARTING THE APPLIANCE
35
FINISHING COMMISSIONING
A
NOTE:
At the time of commissioning, complete all
relevant sections of the Benchmark Checklist
located on the inside back pages of this
document.
1
B
1
Engage top panel (A) onto rear retainers
(B) and lower front of panel into position.
Secure with screws (C).
2
C
Swing control panel assembly (D) into
the boiler.
Secure with screw (E).
3
2
D
Locate bottom corners of the front panel
(F) into retainers (G).
Push top of door to engage clips.
E
COMMISSIONING
3
G
F
HANDOVER:
Complete the Benchmark log book at the
rear of the manual.
Set up the controls and show the user how
to operate all the controls shown in the
User Guide.
Instruct the customer how to repressurise
the system.
If the appliance is unused and exposed to
freezing conditions, advise the customer
of the precautions necessary to prevent
damage to the boiler, system and building.
In the event of the appliance being
inoperative, isolate the boiler and drain
the system and boiler.
36
FINISHING COMMISSIONING
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES
BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY
IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR
GAS TIGHTNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS
DESCRIBED IN COMMISSIONING. ANY O-RING OR GASKET THAT APPEARS
DAMAGED MUST BE REPLACED.
INSPECTION & SERVICE
IMPORTANT: Any service work must be
carried out by competent registered
engineers, such as British Gas or other
GAS SAFE registered personnel.
NOTE: After servicing, complete the relevant
Service Interval Record section of
the Benchmark Checklist located on
the inside back pages of this
document.
NOTE: A service must NOT be attempted
if a CO/CO2 analyser is NOT
available.
• To ensure the continued efficient operation
of the appliance it must be checked at
regular intervals.
• The frequency of servicing will depend
upon the particular installation conditions
and usage however, an annual service is
recommended.
• The extent of the service required by the
appliance is determined by the operating
condition of the appliance when tested by
fully qualified engineers.
SERVICE FUNCTION:
Setting boiler to maximum:
Note: when running in the heating boost mode,
the boiler will operate both the Central Heating
and DHW circuits. This is to allow sufficient
time for setting procedure.
It will be necessary to run water through the
DHW circuit to ensure that the boiler will not
cycle on low heating demands.
A
I
D
E
F
H
Press and HOLD central heating boost
button (L) for 10 seconds and set Central
Heating temperature to maximum.
L
M
The central heating boost button will
illuminate continually.
C
G
B
The boiler will stay in this mode for 15
minutes unless the central heating boost
button is pressed again.
SERVICING
& SPARES
K
J
A - MASTER SWITCH FOR ON/OFF
B - MAINS ON/OFF INDICATOR + FAULT DIAGNOSTIC LIGHT
C - CENTRAL HEATING TEMPERATURE CONTROL
D - BURNER ON INDICATOR LIGHT (GREEN)
E - FAULT RESET BUTTON
F - SERVICE BUTTON
G - DOMESTIC HOT WATER TEMPERATURE CONTROL
H - ECO BUTTON (DOMESTIC HOT WATER PRE-HEAT ON/OFF)
I - SYSTEM PRESSURE GAUGE
J - POSITION FOR OPTIONAL PROGRAMMER
K - DISPLAY
L - CENTRAL HEATING BOOST BUTTON
M - NOT USED
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
INSPECTION & SERVICE
37
INSPECTION & SERVICE
SERVICE INSPECTION:
J
1
Grip the outer sides of the front panel
(A) pull and lift away from retaining lugs
(B).
2
Remove retaining screw (C) to swing
control panel assembly (D) outwards to
its full extent.
3
Pull clip (E) outwards to release
expansion vessel (F).
G
D
H
C
4
2
Swing expansion vessel (F) outwards.
Note: for easier access to the inner case, the
expansion vessel can be unhooked (by
removing the retaining screw on the hinge)
lowered and moved to the side. Take care
not to overstretch the flexible pipe
connections.
5
5
4
3
B
E
Release four screws (G) to remove the
inner case cover (H).
Connect a manometer to the fan pressure
test point (see step 1 in figure on next
page).
After measurement replace test point
cover.
Pressure readings will be negative, refer
to chart below.
FAN PRESSURE TEST
Clean Heat Ex.
Heat Ex. ok
NG Boilers
1
- 5.2
HF 550 CDi:
- 4.1
HF 440 CDi:
-1
F
-2
-3
-4
mbar
-6
LPG Boilers
- 5.2
HF 550 CDi:
- 4.1
HF 440 CDi:
A
-5
-1
-2
-3
-4
mbar
-5
-6
SERVICING
& SPARES
Pressure readings in the black area indicate
that the heat exchanger requires cleaning.
Check that the terminal and terminal guard,
if fitted, are clear and undamaged.
If the appliance is in a compartment or
cupboard check that the specified service
space around the appliance is clear.
See 'Boiler Location & Clearances' under the
Pre-Installation section for compartment
clearances.
Check all the joints and connections in the
system and remake any that show signs of
leakage. Refill and re-pressurise the system.
See 'Filling the System' and 'Water Treatment'
under the Commissioning section.
Operate the appliance and take note of
any irregularities. Call up the last fault
stored by the Bosch Heatronic, Service
Function '6A'.
Refer to 'Fault Finding' under the Fault Finding
& Diagrams section for display codes and
rectification procedures.
38
INSPECTION & SERVICE
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
IMPORTANT: AFTER COMPLETING THE APPLIANCE SERVICE THE CO/CO2 MUST BE
CHECKED AND SET TO THE LIMITS IN THE SECTION “AIR/GAS RATIO”.
INSPECTION & SERVICE
If the Heat Exchanger requires cleaning:
An accessory kit is available (No. 840)
specifically designed for cleaning the heat
exchanger. If required order 7 719 001 996.
2
Remove the cleaning access cover (B),
seal (C) and metal plate (D) securing it, if
present.
3
Unscrew the condensation trap cap and
place a suitable container underneath.
NOTE: Use a new seal when reassembling.
4
Loosen any deposits in the heat exchanger
from top to bottom using the cleaning
blade.
Clean the heat exchanger from top to
bottom using the brush.
Refit the “clean out” access cover in
reverse order using a new seal (C), hand
tighten screws and then use a spanner to
tighten a further half turn.
1
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
To Remove Condensate pump:
Disengage condensate pipe from
condensate pump.
Remove condensate pump from base
panel.
Fan pressure
test point
2
After servicing the heat exchanger, fill
the condensate trap with approximately
250 millilitres of water and refit in reverse
order.
SERVICING
& SPARES
3
B
C
D
4
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
INSPECTION & SERVICE
39
INSPECTION AND SERVICE
Burner:
NOTE: On re-assembly, replace the seal
Check that the boiler is completely isolated
from the gas supply.
C
1
A
Remove the clips (A) and unscrew the
castellated nuts (B).
Remove springs.
Unscrew and remove the two hexagon
screws (C) securing the fan.
D
Slacken fully the rear securing bolt (D).
E
F
B
D
G
Remove the burner cover plate (E).
2
Remove the burner (F) and clean the
components.
Do not use a wire brush.
Re-assemble burner in reverse order using
a new seal (G).
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
For sealed systems only:
Max pressure:
When the heating system water is at
maximum temperature, 2.5 bar must not
be exceeded. If this pressure is exceeded
then an extra expansion vessel must be
fitted into the system return as close as
possible to the appliance.
If the system does not retain the pressure,
the expansion vessel and the heating
system should be checked for leaks.
B
Electrical wiring:
Check the electrical wiring for physical
damage and replace any damaged wires.
To check the diaphragm in burner cover:
SERVICING
& SPARES
Carefully withdraw diaphragm from fan
intake tube and check for soiling and splits.
Carefully refit diaphragm the correct way
round into the fan intake tube.
Note: The flaps of the diaphragm must
open upwards.
Re- assemble burner in reverse order using
a new seal.
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
To clean the condensate trap:
F
Remove pipe from condensate pump.
Remove screw retaining trap (F) and push
trap downwards until clear.
Remove trap from boiler along with pipe
to condensate pump.
40
INSPECTION & SERVICE
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS ELECTRICAL
SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
DRAIN THE BOILER/SYSTEM WHERE NECESSARY AND PROTECT ANY ELECTRICS
FROM WATER INGRESS DURING COMPONENT REPLACEMENT.
IMPORTANT: Refit or replace any components removed from the appliance in the
reverse order using new gaskets/'O' rings/sealant/heat transfer paste where
necessary.
Any 'O' ring or gasket that appears damaged must be replaced. Always check that
any electrical connections are correctly made and that all screws are tight.
AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR GAS
TIGHTNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS
DESCRIBED IN THE COMMISSIONING SECTION.
REPLACEMENT PARTS
IMPORTANT: Any service work must be
carried out by competent registered
engineers, such as British Gas or other
GAS SAFE registered personnel.
IMPORTANT: After re-assembly the
combustion must be checked using the
procedure in the section “Setting the
air/gas ratio”. Measurement and setting
of the gas ratio must not be attempted
unless the person is equipped with a
combustion analyser conforming to
BS 7927 and is competent in its use.
DRAINING THE APPLIANCE:
Turn off the system heating flow and
return stop cocks - external to boiler.
Using a suitable hose, attach one end
to the drain tap on the boiler return
elbow and lead the other end of the
hose to an external drain point.
Fully open the drain tap on the boiler
return elbow.
Close the drain tap when the flow from
the appliance has stopped and remove
the hose.
A
NOTE:
A small quantity of water may remain in some
components even after the appliance has been
drained. Protect any electrical components
when removing items from the water circuits.
B
PCB CONTROL BOARD & TRANSFORMER:
Access to boiler control components
Spare Fuse order
T1.6A
Remove screws (A) to release the cover
from the controller.
L250V F2
Remove the fuse (B) and replace with
a spare that are clipped on the inside
of the controller cover.
Transformer / PCB
T2.5A L250V F1
T500mA L250V F3
Disconnect all electrical connections
from the control.
Remove the screws (C) retaining the rear
panel of the control and remove the
panel.
SERVICING
& SPARES
PCB Fuse
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
C
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
REPLACEMENT PARTS
41
NOTE: A SERVICE TO THE FAN ASSEMBLY AND FLAP VALVE MUST NOT BE ATTEMPTED
IF A CO/CO2 ANALYSER IS NOT AVAILABLE.
REPLACEMENT PARTS
Fan Assembly:
Undo lower pipe union on gas pipe (E).
Remove fan lead and earth connector.
The earth connector has a positive clip fixing.
A
B
Remove fixing screws attaching fan (A)
to the burner cover (B).
Remove fan (A) with gas pipe (E) and
mixer unit (D).
Twist mixer unit (D) with gas pipe (E) to
separate from fan (A).
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
C
Flap Valve:
Undo lower pipe union on gas pipe (E).
Remove pipe (E) by pushing upwards
and to the rear.
Twist mixer unit (D) with gas pipe (E) to
separate from fan (A).
Remove flap valve (F) from within fan
intake (A) and replace.
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
F
D
J
H
G
NOTE: Ensure the flap valve is fitted correctly
with rubber flap upwards.
Condensate pump:
Disconnect electrical connections in
control box, see wiring schematic in the
‘Fault finding & Diagrams’ section.
Remove 15mm flexible tube (H) from pump
by rotating anti-clockwise and pulling up.
Remove black flexible pipe (J) from
condensate tank. Take care as there may
be condensate remaining in the pipe.
Carefully remove the condensate pump
(G) from the boiler and pour any excess
condensate into a suitable container for
safe disposal.
E
Diverter valve motor
SERVICING
& SPARES
N
M
Ensure that the appliance is in service
mode (there is no need to drain the
appliance).
Disconnect the electrical connector (K)
from the diverter valve motor (L).
Pull the motor (L) towards you, the
assembly will slide free from the valve.
To refit, follow the reverse of above.
NOTE: In case of problems when refitting the
motor: connect the electrical connector to
the motor and switch the appliance on. When
the motor goes into the middle position the
motor can be fitted without difficulty.
L
Diverter valve
K
Ensure that the appliance has been fully
drained.
Disconnect the electrical connector (K)
from the diverter valve motor (L).
Undo the two screws holding the valve
actuator body to the plastic housing (N).
Remove the motor and valve actuator
body from the diverter valve.
Withdraw the valve actuator from the
diverter valve.
To refit assemble in reverse, ensuring
that the valve actuator is properly seated
on the two lugs of the actuator body.
42
REPLACEMENT PARTS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
REPLACEMENT PARTS
Sensors:
Check that the appliance is electrically
isolated.
Central heating flow temperature sensor
(A):
Remove the connector.
Release the sensor clip and withdraw
the sensor.
A
Apply heat transfer paste to the
replacement sensor.
B
Drain the system first:
Safety temperature limiter (B):
Remove the connectors.
Unscrew the sensor.
Tank sensor (C):
Remove screws retaining plastic cover.
Remove cover and disconnect 2 electrical
connections.
Unscrew 2 hexagon studs.
Replace sensor coating surface with paste
supplied.
C
Re-assemble.
D
Tank overheat thermostat (D):
Remove screws retaining plastic cover.
Remove cover and disconnect 2 electrical
connections.
E
Unscrew 2 hexagon studs.
F
Replace sensor coating surface with paste
supplied.
Re-assemble.
E
Shut off mains water at inlet valve and
drain DHW circuit.
Disconnect inline connector.
Remove 2 retaining clips (F).
Remove flow sensor assembly (E).
Remove brass housing with flow regulator
(G) from sensor.
SERVICING
& SPARES
Flow sensor/flow regulator assembly (E):
G
Re-assemble ensuring that retaining clips
are correctly positioned.
H
Flue Temperature limiter (H):
Remove the connector.
Unscrew the sensor.
Domestic hot water temperature sensor
(J):
J
Release and pull-off the connector.
Unscrew the bracket.
Replace sensor coating surface with paste
supplied.
Re-assemble.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
REPLACEMENT PARTS
43
REPLACEMENT PARTS
Domestic hot water heat exchanger:
Before removing the heat exchanger, close
the inlet valves, drain the hot water circuits
and tank.
A
The pipe (A) may be removed between the
flow sensor outlet and the plate heat exchanger
to improve access to the rear connections.
Undo the two screws securing the plastic
housing to the heat exchanger.
Remove the heat exchanger.
To refit, follow the above in reverse. Ensure
any seals that have been disturbed are
replaced.
Pressure gauge:
Drain the appliance.
Unscrew connection to the pressure relief valve.
Remove 2 screws from rear of control
panel and remove pressure gauge.
B
Replace sealing washer and replace
pressure gauge.
Expansion vessel:
Drain the appliance.
Move control panel into service position.
Remove locking screw (C) from vessel
bracket.
Hinge pressure vessel out and lift from
brackets.
C
Undo the union connection at the top of
the vessel.
E
D
Set the pressure of the new vessel to that
required by the system.
Pressure relief valve:
F
Drain the appliance.
Disconnect drain pipe from valve (D)
Undo nut retaining valve to flow pipe.
Undo nut connecting pressure gauge.
Remove valve.
Replace sealing washer and fit a new valve.
Condensate trap:
SERVICING
& SPARES
Move control and pressure vessel into
service position.
Remove inner case door.
Remove condensate pump.
Remove access panel (E) at the base of
the inner casing.
1
Remove screw retaining trap (F) and push
trap downwards until clear.
Remove trap from boiler along with pipe
to condensate pump.
2
Gas valve:
Check that the gas cock is turned off.
Remove condensate pump.
1
Undo the union, within the inner casing,
securing the valve to the gas/air tube.
2
Remove the black rubber tube from the
gas valve (G).
G
4
3
Release the gas inlet union at the inlet.
4
Remove the solenoid connections at the
side of the gas valve.
3
Transfer the inlet pipe assembly to the
new gas valve.
Check for gas tightness when the new gas
valve has been fitted.
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
44
REPLACEMENT PARTS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
REPLACEMENT PARTS
Electrode assembly:
Switch off the master switch.
Isolate appliance from the power supply.
Move control panel into service position.
Release 4 screws to remove inner case
door.
Remove the leads from the electrodes.
Unscrew the two fixing screws (B) and
carefully remove the electrode assembly (A).
Replace and re-connect the assembly
taking care not to mislay the inspection
window.
D
E
C
F
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
Burner:
NOTE: On re-assembly, replace the seal
Check that the gas cock is turned off and
the master switch is in the OFF position.
G
Isolate appliance from the power supply.
Remove the clips (C) and unscrew the
two bolts (L).
H
Remove springs.
Unscrew and remove the 2 hexagon
screws (D) securing the fan.
Slacken fully the rear securing nut (E).
Remove the burner coverplate (F).
Remove the burner skin (G).
Re-assemble the new burner in reverse
order, inspect the new seal (H) for damage
and replace if necessary.
A
L
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
Primary heat exchanger:
Isolate appliance from the power supply.
Drain down appliance.
Move control and pressure vessel into
service position. To improve access, remove
the pressure vessel.
J
Remove inner case door.
SERVICING
& SPARES
Turn off all isolation valves.
B
Remove fan assembly, burner, gas mixing
tube.
K
Disconnect and remove sensors
connected to heat exchanger.
Remove condensate trap.
Remove internal flue elbow and tube
from boiler sump.
Disconnect return pipe union (J) at the
base of the boiler heat exchanger.
Disconnect flow pipe connection.
Remove plastic nut (K) from the base of
the inner casing.
Remove heat exchanger from inner casing.
Ensure heat conductive paste is used on
sensors when refitting.
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
REPLACEMENT PARTS
45
SETTING THE AIR/GAS RATIO
1
IMPORTANT: The appliance is set at the
factory and adjustment to the CO2
settings (air/gas 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.
A
The air/gas ratio may only be adjusted on
the basis of a CO2 measurement at
maximum and minimum heat output using
an electronic tester.
Setting the gas ratio MUST ONLY be
carried out by a competent person
equipped with a combustion analyser
conforming to BS 7927 and competent in
its use.
2
B
Remove cap [J] on the “flue gas sample
point”, as shown in the figure on page 38,
and connect a flue gas combustion
analyser. Replace the cap after use.
1
Greenstar Highflow 440CDi
C
GAS TYPE
3
Natural Gas
Type H (G20)
CO2 setting
maximum.
CO2 setting
minimum.
9.4 ±0.5%
8.6 ±0.5%
LPG (propane)
10.8 ±0.5%
(G31)
10.4 ±0.5%
Measure the inlet pressure, it should be
between 17 - 19mbar (nominally 18 mbar)
for Natural Gas and between 35 - 39mbar
(nominally 37mbar) for LPG.
2 To adjust the CO2 it will be necessary to
first operate the boiler at maximum output.
Press and hold down the boost button
(B) for 10 seconds.
Greenstar Highflow 550CDi
D
GAS TYPE
Natural Gas
Type H (G20)
CO2 setting
maximum.
CO2 setting
minimum.
9.4 ±0.5%
9.0 ±0.5%
LPG (propane)
10.8 ±0.5%
(G31)
10.4 ±0.5%
Turn temperature control (C) to
maximum, the boiler will then go to
maximum output.
Note: the control will resume normal
operation after 15 minutes or if the
boost button (B) is pressed for more
than 1 second.
SERVICING
& SPARES
3
4
Connect manometer to the inlet pressure
point (A) on the gas valve.
Remove plastic cap and using a flat
bladed screwdriver, set the CO2 via adjuster
(D) referring the table opposite.
Note: CO2 should be measured 10 minutes
after firing the boiler.
Check the CO is less than 200ppm.
C
4
Turn the temperature control (C) to
minimum. This will make the boiler go to
minimum output.
5
Measure the CO2 it should now be at the
figure for minimum output shown on the
table opposite. If not, remove cap and
adjust (E) on the gas valve until correct.
Check the CO is less than 200ppm.
5
E
Turn temperature control to maximum
output and recheck the CO2. If correct,
hold down the boost button (B) for two
seconds, the boiler should return to normal
operating mode with the blue power
indicator permanently illuminated.
Remove manometer and re-seal the inlet
pressure point on the gas valve.
Fit a new plastic sealing cover to outlet
adjuster (D) and replace the cap on the
gas valve.
46
SETTING THE GAS/AIR RATIO
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
SHORT PARTS LIST
1a
2
3
1a Burner skin seal:
1b
Part No. 8 711 004 168 0 (GC No. E27 201)
1b Burner:
Part No. 8 718 006 658 0 (GC No. E27 200)
2 Fan assembly:
440CDi:
Part No. 8 717 204 410 0 (GC No. H66 918)
4
5
6
550CDi:
7
Part No. 8 717 204 453 0 (GC No. H26 536)
3 Circulating Pump assembly:
Part No. 8 718 681 477 0 (GC No. H66 929)
4 Diverter valve assembly:
Part No. 8 716 106 845 0 (GC No. H02 533)
5 Diverter valve motor:
Part No. 8 716 106 847 0 (GC No. H02 534)
6 Flow sensor:
Part No. 8 717 002 132 0 (GC No. H21 232)
7 Flow regulator:
8
9
10
11
12
440CDi Type E 20 litre Beige:
Part No. 8 717 002 135 0 (GC No. H21 235)
550CDi Type E 25 litre light grey:
Part No. 8 718 681 198 0 (GC No. H66 928)
8 Temperature sensor primary:
Part No. 8 714 500 087 0 (GC No. E74 536)
9 Temperature limit (Flue or heat exchanger):
Part No. 8 722 963 858 0 (GC No. H08 291)
13
14
15
10 Thermistor sensor (DHW):
Part No. 8 716 142 302 0 (GC No. 375 696)
11 Thermister sensor (tank):
Part No. 8 716 142 319 0 (GC No. 379 785)
12 Overheat thermostat (Tank):
Part No. 8 716 103 217 0 (GC No. E82 394)
13 Heat exchanger:
Part No. 8 716 108 212 0 (GC No. H22 465)
550CDi:
Part No. 8 718 680 648 0 (GC No. H66 931)
16
17
18
19
14 Gas valve:
Part No. 8 718 221 347 0 (GC No. H56 469)
SERVICING
& SPARES
440CDi:
15 Condensing Pump:
Part No. 8 716 114 077 (GC No. H66 921)
16 Pressure relief valve:
Part No. 8 716 142 416 0 (GC No. 386 789)
17 Pressure gauge:
Part No. 8 718 680 742 0 (GC No. H66 930)
20
21
18 Auto air vent:
Part No. 8 716 140 500 0 (GC No. E00 717)
19 Electrodes:
Part No. 8 718 107 087 0 (GC No. E74 535)
20 Expansion vessel:
Part No. 8 715 407 288 0 (GC No. H21 242)
21 Control board:
Part No. 8 748 300 606 0 (GC No. H66 923)
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
SHORT PARTS LIST
47
L.P.G. CONVERSION
Change code plug:
1
Release three screws (A) to remove cover
(B).
2
Remove and dispose of the existing code
plug (C).
C
Replace with new conversion code plug.
2
N.G. code plug number:
440CDi 1700
550CDi 1702
L.P.G. code plug number:
B
440CDi 1701
550CDi 1703
Refit panel (B) and secure with three
screws (A).
1
Change gas pipe:
A
4
Rotate gas pipe (D) anti-clockwise, pull
upwards and remove gas pipe.
5
Replace with new conversion gas pipe
(E), push downwards and rotate clockwise
to lock into position.
Conversion label:
3
Replace existing label with new
conversion label.
D
b
Adjust the CO2 level:
After re-assembly check CO/CO2 levels
as described in the section “Setting the
air/gas ratio”.
a
c
CONVERSION
KITS
4
b
E
a
c
48
L.P.G. CONVERSION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
ELECTRICAL WIRING DIAGRAM
PRE WIRED LINK
DIAGNOSTIC
INTERFACE
CODE PLUG
230V HW interface
(Installer Module)
ST1
located to the right
of the control panel
ST18
Fuse F2, T 1.6A, L250V
Red
Yellow
230V/AC
White
Fuse F3, T 0.5 A, L250V
Pink
NO
9V
C
NC
WORCESTER 24V CONTROLS
OPTION, PLUG IN POINT
(under blanking cover on fascia)
ST9
Orange
Violet
EMS BUS contacts
(for FX controls)
Blue
Red
Orange
Blue
Yellow
Green
Black
ST17
SPARK
TRANSFORMER
Fuse F1, slow
T2.5 A, H 230 V
9
*
8
7
EXTERNAL
FROST STAT
(OPTIONAL)
ST10
ST8
LP NP FS FR
Wall plate contacts
(for FX controls)
N NS LS LR
ST5
ST4
Neutral
Live
DHW TEMPERATURE
CONTROL
L
Live
ST6
Neutral
F
A
1
2
4
B
B
*
CH TEMPERATURE
CONTROL
Colour sequence
Earth
B B
MAINS
SUPPLY
PUMP SUPPLY
Outside sensor
(FW 100)
NC
Colour sequence
NO
CH
DHW
External 230V twin
channel programmer
option
C
External volt free
programmer option
(used with MT10 timer)
FAN
FLAME SENSE
ELECTRODE
SPARK
ELECTRODES
FLOW NTC
OVERHEAT
STAT
TANK
SENSOR
TANK
OVERHEAT
FLUE
OVERHEAT
STAT
PUMP
FLOW
TURBINE
GAS
VALVE
FAULT FINDING
& DIAGRAMS
Green
Red
Yellow
Black
25V
DIVERTER
VALVE
SAFETY
SOLENOID
SAFETY
SOLENOID
DHW
SENSOR
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
HIGH LEVEL
SENSOR
CONDENSATE
PUMP
ELECTRICAL WIRING DIAGRAM
49
*
50
FAULT FINDING
& DIAGRAMS
CENTRAL HEATING FUNCTION
Burner remans OFF
until flow temperature
is below set value.
MAI N
SWITCH
ON
GREEN
LIG HT
ON
CE NTRAL
H EATI NG
DE MAN D
Fan to start
speed.
Gas valve
open.
Ignition
spark 5
second
(max).
Over temperature
shut-down if water
temperature is 5°C
above set value.
Gas valve shuts.
Pump remains ON.
BURNER
LIT?
YE S
RED
LIG HT
ON
Burner
stabilises
at start
speed for
5 - 10
seconds.
Fan
reduces
over
15
seconds.
Boiler
unused
for long
period?
NO
Boiler
operates
to match
system load and
CH control
setting.
YE S
NO
Pump ON.
Diverter valve
to
CH position.
Fan min.
speed
for
90
seconds
NO
LOCKOUT
Minimum
heat input
for
15 min.
Fan run to
purge gas
from burner.
CH demand
satisfied.
Gas valve closes.
Red light OFF.
Pump and Fan run
for up to 3 mins.
CENTRAL HEATING FUNCTION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
YE S
5th
Attempt?
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
Gas valve OFF
until
temperature drops
to
set level.
Hot water demand
(overrides all other
demands).
MAI N
SWITCH
ON
GREEN
LIG HT
ON
Ignition sequence.
Delivered
temperature
too high.
Modulate fan
(heat input) to
maintain delivered
temperature set
by user control
(45° - 65°C).
Pump ON.
Diverter valve to
Hot Water position.
Tank demand
(overrides central
heating demand).
Ignition sequence.
NO
Modulate fan
(heat input) to
charge tank to
temperature set
by user control
(65° - 75°C).
Check tank
temperature.
Is it still near
set point?
YE S
GAS
VALVE
OFF
Continue fan
40 secs.
Continue pump
15 secs.
Tank satisfied.
DHW FUNCTION
Minimum heat
imput
until 50°C
if boiler unused
for long period.
DHW FUNCTION
51
FAULT FINDING
& DIAGRAMS
End of demand.
FAULT FINDING
BOILER - FAULTS AND CONDITIONS
NOTE ; This fault finding information is for
guidance only. Worcester Bosch cannot be held
responsible for costs incurred by persons not
deemed to be competent.
Display code:
Fault description
Check, repair/replace as necessary
A5
Tank NTC defect
Check tank NTC sensor and leads,
measure resistance across NTC
(33.5kΩ- 500Ω)
A7
DHW NTC defect
Check DHW NTC sensor and leads,
measure resistance across NTC
(33.5kΩ- 500Ω)
A8
EMS communication error
Check all electrical connections,
replace control board.
b1
Code plug not detected
Insert code plug correctly, test and
replace as necessary.
b2, b3, b4, b5,
b6
Data error
Replace control board.
b7
Burner control error
Replace control board.
C6
Fan defect
Check fan, lead, and connector,
replace as necessary.
D3
External temp limiter
Connect terminals 8 & 9 on ST8.
D5
Condensate overflow
See condensate pump table.
D6
Internal heat bank overflow
Check system pressure, tank, over heat
thermostat, and pump operation
EA
Flame not detected
Check gas is present, ignition electrodes
and harness, flame sense electrode and
harness, and operation of gas valve.
Replace as necessary.
The electronic control system for this boiler
incorporates a blue central indicator. This
normally confirms the permanent mains supply,
but, by flashing during a fault, provides a guide
to the cause as listed.
This fault finding system assumes that the
appliance has been operating normally until the
time of failure (i.e. not a first time installation
error).
Preliminary checks:
Preliminary electrical system checks are the
first electrical checks to be carried out during
a fault finding procedure.
On completion of the Service/Fault finding
task which has required the breaking and
remaking of electrical connections, check:
E2
Primary NTC defect
Check primary NTC sensor and leads,
resistance across NTC should be between
36k to 1kΩ
E9
OH stat tripped
Check system pressure, over heat thermostat, and pump operation.
Replace as necessary
F0
Internal error
Check all electrical connections, replace
board as necessary.
F1
ROM error check
Check all electrical connections, replace
board as necessary.
F7
Flame detected after appliance
shut off
Check flame sense electrode and harness,
and control board for signs of water
damage. Replace a s necessary
FA
a) EARTH CONTINUITY
b) SHORT CIRCUIT CHECK
c) POLARITY
d) RESISTANCE TO EARTH.
Flame detected after gas shut off Check flame sense electrode and harness,
and control board for signs of water
damage. Check gas valve operation.
Replace a s necessary
Fd
Reset button pressed
Press reset button again
CONDENSATE PUMP - OPERATING LAMPS AND FAULT CONDITIONS
Ready for operation
Fault
Pump running
FAULT FINDING
& DIAGRAMS
Operating lamps
52
=
=
=
Steady green light
Red light
Flashing green light
Cause
Solution
Green
Red
Off
Off
Mains plug not plugged in
Power failure
Insert plug
Check mains and fuse
Flashing
Flashing
Dry-run
(poss. air in pump)
Pump restarts automatically
after one minute
On
Flashing
Pump blocked
Visual inspection of the pump inlet
in the tank and removal or
rinsing out of dirt/foreign bodies
On
On
Level exceeds alarm level
Pressure hose / non-return valve
blocked (clean or remove kink
if applicable)
Off
Flashing
Pump blocked and
alarm level exceeded
Visual inspection of the pump inlet
in the tank and removal or
rinsing out of dirt/foreign bodies
FAULT FINDING
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
GAS BOILER COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Customer Name
Telephone Number
Address
Boiler Make and Model
Boiler Serial Number
Commissioned by (print name)
CORGI ID Number
Company Name
Telephone Number
Company Address
Commissioning Date
To be completed by the customer on receipt of a Building Regulations Compliance Certificate*:
Building Regulations Notification Number (if applicable)
CONTROLS Tick the appropriate boxes
Time and Temperature Control to Heating
Room Thermostat and
Programmer/Timer
Programmable
Room Thermostat
Time and Temperature Control to Hot Water
Load/Weather
Compensation
Optimum Start
Control
Cylinder Thermostat and Programmer/Timer
Combination Boiler
Heating Zone Valves
Fitted
Not Required
Hot Water Zone Valves
Fitted
Not Required
Thermostatic Radiator Valves
Fitted
Not Required
Automatic Bypass to System
Fitted
Not Required
Boiler Interlock
Provided
ALL SYSTEMS
The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions
Yes
What system cleaner was used?
What inhibitor was used?
litres
Quantity
CENTRAL HEATING MODE Measure and Record:
Gas Rate
m3/hr
OR
Burner Operating Pressure (if applicable)
mbar
OR
ft3/hr
Gas Inlet Pressure
mbar
Central Heating Flow Temperature
°C
Central Heating Return Temperature
°C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)?
Yes
No
If yes, has a water scale reducer been fitted?
Yes
No
What type of scale reducer has been fitted?
DOMESTIC HOT WATER MODE Measure and Record:
Gas Rate
m3/hr
OR
Burner Operating Pressure (at maximum rate)
mbar
OR
ft3/hr
Gas Inlet Pressure (at maximum rate)
mbar
Cold Water Inlet Temperature
°C
Hot water has been checked at all outlets
Yes
Temperature
°C
l/min
Water Flow Rate
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798
Yes
ALL INSTALLATIONS
If required by the manufacturer, record the following
CO2
%
OR
CO
ppm
The heating and hot water system complies with the appropriate Building Regulations
OR CO/CO2 Ratio
Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions
Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer
Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Yes
Commissioning Engineer’s Signature
Customer’s Signature
(To confirm satisfactory demonstration and receipt of manufacturer’s literature)
*All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.
A Building Regulations Compliance Certificate will then be issued to the customer.
©Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.
Service Provider
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s
instructions.
Always use the manufacturer’s specified spare part when replacing controls.
SERVICE 1
SERVICE 2
Date
Energy Efficiency Checklist completed?
Yes
No
Date
Energy Efficiency Checklist completed?
Engineer Name
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
SERVICE 3
SERVICE 4
Date
Energy Efficiency Checklist completed?
Yes
No
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
SERVICE 5
SERVICE 6
Date
Yes
No
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
SERVICE 8
Date
Energy Efficiency Checklist completed?
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
SERVICE 9
No
Yes
No
Yes
No
Yes
No
Date
Engineer Name
SERVICE 10 Date
Date
Energy Efficiency Checklist completed?
Yes
Date
Energy Efficiency Checklist completed?
Engineer Name
SERVICE 7
No
Date
Energy Efficiency Checklist completed?
Engineer Name
Energy Efficiency Checklist completed?
Yes
Yes
No
Energy Efficiency Checklist completed?
Engineer Name
Engineer Name
Company Name
Company Name
Telephone Number
Telephone Number
CORGI ID Number
CORGI ID Number
Comments
Comments
Signature
Signature
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW
Tel. 0844 892 9900 Fax. 01905 754619
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
worcester-bosch.co.uk
8 716 115 219c (03.2010)