Worcester GREENSTAR 30 HE Technical data

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Worcester GREENSTAR 30 HE Technical data | Manualzz
Installation and Servicing Instructions
GREENSTAR HE system
Wall mounted condensing boiler for central heating
6 720 610 577-00.10
6 720 610 596 GB (01.07) OSW
ZB 7-27 HE system GC-Number: 41 311 49
Contents
Contents
Safety precautions
3
Symbols
3
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
4
4
4
4
5
5
6
7
8
9
2
Details of the appliance
EC Declaration of Conformity
Standard package
Description of appliance
Accessories
Casing dimensions
Layout of appliance
Function
Electrical wiring diagram
Technical data
Installation regulations
11
6
6.1
6.1.1
6.1.2
6.1.3
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
Installation
Important remarks
Sealed systems
Siting the appliance
Wall mounting frame assembly
Pre-piping the system
Fitting the appliance
Checking the connections
Flue Systems
Siting the Flue Terminal
Installation of the flue
Flue duct preparation and assembly
11
11
11
12
13
13
14
15
15
16
17
19
4
4.1
4.2
4.3
4.3.1
Electrical connections
Connecting the appliance
Mains Voltage external controls connections
Wiring to your system
Pre-wired Remote Y Plan or S Plan
20
20
21
22
22
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Commissioning
Commissioning
Switching the appliance on/off
Switching on the central heating
System controls
Frost protection
Pump anti-seize function
Fault Condition
23
23
24
24
24
24
25
25
2
Individual settings
Mechanical settings
Checking the size of the expansion vessel
Setting the central heating flow temperature
Changing the heating pump characteristic
Settings on the Bosch Heatronic
Operating the Bosch Heatronic
Selecting the pump control mode for
central heating mode (Service Function 2.2)
Setting the anti-cycle time
(Service Function 2.4)
Setting the maxim CH flow temperature
(Service Function 2.5)
Setting the switching difference
(Service Function 2.6)
Setting the heating output
(Service Function 5.0)
Setting the gas/air ratio
26
26
26
26
26
27
27
27
27
28
28
28
28
7
Converting the appliance to
different gas types
7.1 Setting the gas/air ratio
7.2 Testing combustion air/flue gas
at set heat output
7.2.1 Testing the O2 or CO2 level in
the combustion air
7.2.2 Testing CO and CO2
31
31
8
Maintenance
8.1 Pre-Service Check List
8.2 Description of servicing operations
8.3 Replacement of Parts
8.3.1 PCB control board and transformer
8.3.2 Fan Assembly
8.3.3 Pump
8.3.4 Sensors
8.3.5 Gas Valve
8.3.6 Electrode assembly
8.3.7 Pressure gauge
8.3.8 Expansion vessel
8.3.9 Pressure Relief Valve
8.3.10Burner
8.3.11Primary Heat Exchanger
32
33
34
36
36
37
38
38
38
39
39
39
39
39
39
9
9.1
9.2
9.3
9.4
9.5
9.5.1
40
40
41
42
42
43
43
Appendix
Fault Codes
Short parts list
Heating/hot water output settings (N.G.)
Heating/hot water output settings (L.P.G)
Operational Flow diagrams
Central heating function
29
29
31
6 720 610 596 GB (01.07)
Safety precautions
Safety precautions
If you smell gas
y Turn off gas service cock at the meter.
y Open windows and doors.
y Do not operate any electrical switches.
y Extinguish any naked flames.
y Telephone your gas company.
If you smell fumes from the appliance
y Switch off appliance (see page 24).
y Open windows and doors.
Symbols
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.
Fitting and modifications
y Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance wth the Gas Safety (Installation
and Use) Regulations 1998.
y Flue systems must not be modified in any ways other
than as described in the fitting instructions.
y This appliance is for use on sealed primary systems
only.
Maintenance
y The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
y Use only original spare parts!
Combustible materials
y Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
y This appliance contains no asbestos products.
y There is no potential hazard due to the appliance
being electrically unsafe.
y There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
y The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
y Explain to the customer how the appliance works and
how to operate it.
y Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it
y These instructions are to be left with the user or at
the Gas meter.
y Important: These instructions apply in the UK only.
6 720 610 596 GB (01.07)
3
Details of the appliance
1
Details of the appliance
1.1
EC Declaration of Conformity
1.3
Description of appliance
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.
• Wall-mounted appliance, siting not dependent on
room size
PIN
CE-0085 BL 0507
• Bosch Heatronic control system
Category
UK
II2H 3P
• Modulating control
Appliance Type
C13, C33
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
Standard package
• Gas condensing combination boiler for central
heating
• Wall mounting frame
• Clamp for securing flue duct kit
• Fixings (screws etc.)
• Set of documentation for appliance
• Pre-plumbing manifold
• Condensate drain pipe.
• Multifunction display
• Automatic ignition
Table 1
1.2
• Natural gas models are low-emission appliances
• Concentric flue/air duct with testing point for
CO2/CO
• Regulated speed fan
• Pre-mix burner
• Temperature control for central heating
• Safety temperature limiter in 24 V electrical circuit
• Three-speed central heating pump with automatic
vent
• Relief valve, pressure gauge, expansion vessel
• Flue gas temperature limiter (105 °C)
• Condensate Trap
• Connecting possibility for Y-Plan or S-Plan System.
4
6 720 610 596 GB (01.07)
Details of the appliance
1.6
Layout of appliance
120
221.1
349
221.2
234.1
234
226
20
102
32.1
29
36
271
6
415
43
9
63
416
27
358
419
18
64
423
7
18.1
418
15
8.1
295
4
417
6 720 610 596-01.1O
Fig. 2
4
6
7
8.1
9
15
18
18.1
20
27
29
32.1
36
43
63
64
102
120
221.1
6
Heatronic control
Heat exchanger safety temperature limiter
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Relief valve
Pump
Pump speed selector switch
Expansion vessel
Automatic air vent
Air gas Mixer unit
Electrode assembly
Temperature sensor in CH flow
CH flow
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
Inspection window
Fixing points
Flue duct
221.2
226
295
234
234.1
271
349
358
415
416
417
418
419
423
Combustion air intake
Fan assembly
Appliance type sticker
Testing point for combustion products
Testing point for combustion air
Flue duct
Cover plate for twin flue duct connection
Condensate trap
Cover plate for cleaning access
Condensate collector
Clip for fixing outer case
Data plate
Hose from automatic vent
Siphon
6 720 610 596 GB (01.07)
Details of the appliance
1.7
Function
26
226
229
30
33
29
36
234.1
234
32
ϑ
20
221
6
35
29.1
9
63
358
52.1
69
27
64
18
56
52
419
57
317
61
4
7
55
8.1
15
ECO
3
0
2
1
4
5
423
E
max
max
13
43
47
45
6 720 610 596-02.1O
Fig. 3
4
6
7
8.1
9
13
15
18
20
26
27
29
29.1
30
32
33
35
36
43
44
45
46
47
52
52.1
55
56
57
61
63
Bosch Heatronic control
Temperature limiter, heat exchanger
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Manifold
Safety valve
Central heating pump
Expansion vessel
Charging valve
Automatic vent
Mixer unit
Bi-metallic thermostat for combustion air compensation
Burner
Flame sensing electrode
Igniter electrode
Heat exchanger with cooled combustion chamber
Temperature sensor in CH flow
CH flow
Hot water flow
Gas inlet
Cold water inlet
CH return
Solenoid valve 1
Solenoid valve 2
Filter
Gas valve CE 427
Main valve disc
Reset button
Adjustable gas flow restrictor
6 720 610 596 GB (01.07)
64
69
221
226
229
234
234.1
317
358
419
423
Adjusting screw for min. gas inlet flow volume
Control valve
Flue duct
Fan
Inner casing
Testing point for flue gas
Testing point for combustion air
Display
Condensate trap
Hose from automatic vent
Siphon
7
Details of the appliance
1.8
Electrical wiring diagram
o - orange
bl - black
r - red
33
365
364
61
317
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
310
136
135
312
328
302
313
151
318
315
124 789
L N Ns Ls LR
161
300 314
328.1
9
M
6
M
r
r
mains supply
18
o
226
52
52.1
56
o
bl
bl
bl
bl
36
32
6 720 610 601-02.1O
Fig. 4
4.1
6
9
18
32
33
36
52
52.1
56
61
135
136
151
153
8
Ignition transformer
Temperature limiter, heat exchanger
Flue gas temperature limiter
Pump
Flame sensing electrode
Ignition electrode
Temperature sensor in CH flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
161
226
300
302
310
312
313
314
315
317
318
328
328.1
363
364
365
366
367
Link
Fan
Code plug
Earth connection
Temperature control for hot water
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Connector for programmer TA212E
Terminal block for programmer
Digital display
Connector for timer
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
6 720 610 596 GB (01.07)
Details of the appliance
1.9
Technical data
Units
kW
Max. rated heat output net 40/30 °C central heating
kW
Max. rated heat output net 50/30 °C central heating
kW
Max. rated heat output net 80/60 °C central heating
Max. rated heat input net
kW
kW
Min. rated heat output net 40/30 °C
kW
Min. rated heat output net 50/30 °C
kW
Min. rated heat output net 80/60 °C
Min. rated heat input net
kW
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (HiB = 9,5 kWh/m3)
m3/h
LPG (Hi = 12,8 kWh/kg)
kg/h
Gas supply pressure
Natural gas G20
mbar
LPG
mbar
Expansion vessel
Charge pressure
bar
Total capacity
l
Flue
Flue gas temp. 80/60 °C, rated/min. load
°C
Flue gas temp. 40/30 °C, rated/min. load
°C
Residual delivery pressure
(inc. pressure drop in air intake duct)
Pa
CO2 level at max. rated heat output
%
CO2 level at min. rated heat output
%
NOx-class
SEDBUK figure, Band A
%
Condensate
Max. condensation rate (tR = 30 °C)
l/h
pH-value, approx.
General Data
Electrical power supply voltage
AC ... V
Frequency
Hz
Max. power consumption
W
Noise output level
dB(A)
Appliance protection rating
IP
Max. CH flow temperature
°C
Max. permissible operating pressure (CH)
bar
Permissible ambient temperatures
°C
Nominal capacity of appliance
l
Weight (excluding packing)
kg
Natural gas
Propane
29.1
28.8
27.2
27.5
8.4
8.3
7.4
7.6
29.1
28.8
27.2
27.5
11.6
11.4
10.5
10.8
2.9
2.1
20
-
37
0.75
10
0.75
10
67/55
43/32
67/55
43/32
80
9.5
9.2
5
90.6
80
11.3
11.0
5
90.6
2.3
4.8
2.3
4.8
230
50
101
36
X4D
nom. 90
2.5
0 - 60
3.75
46
230
50
101
36
X4D
nom. 90
2.5
0 - 60
3.75
46
Table 2
6 720 610 596 GB (01.07)
9
Details of the appliance
Condensate analysis, mg/l
VERTICAL 125 mm FLUE SYSTEM
Ammonium 1.2
Nickel 0.15
Lead ≤ 0.01
Mercury ≤ 0.0001
Overall Diameter of Duct
mm
125
Cadmium ≤ 0.001
Sulphate 1
Flue Terminal / Duct Assembly
mm
1360
Chromium ≤ 0.005
Zinc ≤ 0.015
Halogenated
hydrocarbons ≤ 0.002
Tin ≤ 0.01
Extension Duct Length
mm
200
Extension Duct Length - Fixed
mm
450
Hydrocarbons 0.015
Vanadium ≤ 0.001
Copper 0.028
pH-value 4.8
Extension Duct Length - Fixed
mm
950
Table 3
Extension Duct Length - Fixed
mm
1950
Flue system
Extension Duct Length Telescopic
mm
265375
Extension Duct Length Adjustable (Cut to length)
mm
450
HORIZONTAL 100 mm – Standard
Overall Diameter of Duct
mm
100
Flue Terminal / Duct
Assembly Length
mm
750
Extension Duct Length
mm
Max.
4m
1000
Table 6
Elbow - 90 °
Equivalent length 2 m
Max.
15 m
Bend - 45 °
Equivalent length 1m
Gas supply
Table 4
ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
550
Extension Duct Length - Fixed
mm
200
Extension Duct Length - Fixed
mm
450
Extension Duct Length - Fixed
mm
950
Extension Duct Length - Fixed
mm
1950
Extension Duct Length Telescopic
mm
265375
Extension Duct Length Adjustable (Cut to length)
mm
200
Total length of gas supply pipe
(metres)
3
6
Pipe diameter
(mm)
9
Gas discharge rate (m3/h)
Max.
13 m
(including
turret)
8.7
5.8
4.6
22
18.0
12.0
9.4
28
Table 7
Table 5
10
6 720 610 596 GB (01.07)
Installation regulations
2
Installation regulations
Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.
• BS 6798: Specification for the installation of gas
fired hot water boilers of rated input not exceeding
60kW
• BS 5449: Central Heating for Domestic Premises
• BS 5546: Installation of gas hot water supplies for
domestic purposes
• BS 5440:1: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (gross): Flues
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 60 kW (gross): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply.
These instructions must be followed.
6 720 610 596 GB (01.07)
3
Installation
y Always turn off the gas cock before carrying out any work on components
which carry gas.
i
3.1
Fixing of the appliance, gas and flue connections, commissioning of the system
and electrical connections may only be
carried out by competent persons authorised by CORGI.
Important remarks
y Appliance should only be installed in sealed central
heating systems.
y To avoid gas formation in the system, galvanised radiators or pipes must not be used.
y If a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.
y Add a suitable anti-freeze fluid compatible with aluminium to the water in the central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
y In our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.
3.2
Sealed systems
The appliance must not be operated without the system
being full of water, properly vented and pressurised.
The expansion vessel has a volume of 10 litres and is
charged to a pressure of 0.75 bar.
The water capacity of the system is shown in table 9,
page 26. If a greater capacity is required then an additional expansion vessel must be fitted into the system
return as close to the appliance as possible. The system
pressure can be set up to a maximum of 1.5 bar with 1
bar being the normal setting.
If the system pressure is greater than 2.5 bar when the
appliance is operating at maximum temperature then an
additional expansion vessel must be fitted into the system return as close to the appliance as possible.
The filling point must be at low level and arranged as
shown in figs. 5 and 6.
The pressure relief valve is set to operate at 3 bar.
There must be no connection to the mains without the
approval of the local water company. All connections in
the system must be capable of withstanding a pressure
of up to 3 bar and the radiator valves conform to the
requirements of BS 2767:10.
If Thermostatic Radiator Valves are fitted then it is recommended that one radiator is left open.
11
Installation
system water must be less than 8 or the
appliance guarantee will be invalidated.
A drain cock to BS2879 must be fitted to the lowest
point of the system.
IMPORTANT: Check that no dirt is left in the
water pipework as this could damage the
appliance. Thoroughly flush the heating system
and the mains water supply before fitting the
appliance to the wall in accordance with the
recommendations of BS7593:1992.
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
No galvanised radiators or pipes must be used.
If any system water treatment is required then
only products suitable for use with Aluminium
shall be used i.e Fernox- Copal or Sentinal X100,
in accordance with the manufacturers
instructions. The use of any other substances will
invalidate the guarantee. The pH value of the
APPLIANCE
Refer to Fig.1
Appliance
water flow
diagram
A drain cock should be fitted at
the lowest point of the heating
circuit and the appliance
WRC approved
filling loop
Lockshield
valve
Central heating return
Domestic
hot water
Central heating flow
Domestic
hot water
Fig. 5
Radiator
valve
BS stop valve.
Fixed spindle type
Water
main
6 720 610 576 -09.1O
Sealed primary water system
Heating
return
Non-return
valve
Non-return
valve
Hose
union
Hose
union
Test
cock
Test
cock
Temporary hose
6 720 610 576 - 10.1O
Fig. 6
Sealed primary water system - filling method
3.3
Siting the appliance
Regulations concerning the Installation Site
y Relevant national regulations must be complied with
section 3.8.1.
y Consult the installation instructions for details of minimum clearances required.
Combustion air
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
Substances classed as corrosion-promoting include
halogenated hydrocarbons which contain chlorine and
12
fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and household cleaners, for example.
Surface temperature
The max. surface temperature of the casing and the flue
is less than 85 °C.
This means that, no special safety precautions are
required with regard to flammable building materials
and fitted furniture. The specified clearences must be
maintained.
6 720 610 596 GB (01.07)
Installation
Cupboard/Compartment
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS6798 and BS5440:2 are followed. The low
casing losses from the appliance eliminate the need for
ventilation openings in the compartment.
3.4
y Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
Wall mounting frame assembly
y Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 7. Use
the inner lugs on the top and bottom horizontal sections for the appliances that are 440 mm wide.
6 720 610 576-11.1O
Fig. 9
3.5
Pre-piping the system
200
6 720 610 576-04.1O
Fig. 7
y Hold the wall-mounting frame against the wall ensuring that it is vertical.
y Mark the postion of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 15.
y Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 10 Manifold
43
47
112
171
172
CH flow
CH return
Gas cock
Domestic hot water
Cold water relief
y A drain tap should be fitted at the lowest point of the
central heating system.
y WRc filling loop must be fitted.
6 720 610 576-05.1O
Fig. 8
6 720 610 596 GB (01.07)
13
Installation
Condensate drain
Prepare the condensate discharge system. Refer to
fig. 11. The condensate drainage pipe should be a
standard drain pipe material , i . e. PVC, PVC-U, ABS
etc. and should be at least 22 mm in diameter.
A siphon with a 75 mm condensate seal is fitted within
the appliance.
A connection to an internal drain is recommended.
Any external drain pipe should be insulated to prevent
freezing.
The connection of a condensate pipe to a drain may be
subject to local building regulations.
For more information refer to the CIBSE Guide,
BS5546 and the Building Regulations.
3.6
Fitting the appliance
Benchmark: For optimum performance
after installation, this boiler and its associated central heating system must be
flushed in accordance with the guidelines given in BS5793:1992 “Treatment
of water in domestic hot water central
heating systems”.
y Remove packing, taking care to observe the instructions on the packing.
y Lie the boiler on its back.
Removing the outer case
The outer case is secured against unauthorised removal by two clips (electrical
safety).
Always secure the outer case with those
clips again after refitting.
i
y Turn the clips with a screwdriver (1.).
y Slide the outer case upwards and then forwards to
remove (2.).
y Remove the plastic caps from the boiler connections.
2.
1.
6 720 610 602 - 03.1O
Fig. 11 Position of the condensate drain
6 720 610 332-07.1R
Fig. 12
Fixing the appliance
y Fit the washers onto the gas and water connections.
y Lift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
y Take care not to disturb the washers on the connections.
14
6 720 610 596 GB (01.07)
Installation
Connecting the flue duct
3.8
y Fit flue duct connector onto appliance flue spigot.
y Secure with the two screws supplied.
The only flue systems that may be used are those supplied by Worcester Heat Systems.
The flue system must be installed in accordance with
the requirements of BS5440:1.
1
2
Standard 100 mm flue system
The standard concentric flue system provides for a horizontal length of upto 4 m. Full instructions for fitting this
flue are in Subsection 3.8.2 “Installation of the flue”.
3
4
6 720 610 332-09.1R
Fig. 13
y For remaining installation of flue assembly, refer to
the relevant installation instructions.
3.7
Flue Systems
Checking the connections
Water connections
y Check that the O-rings or seals are in place before
tightening the connection.
y Turn on the service valves for central heating flow
and return and fill the heating system through a WRC
approved filling loop.
y Check all seals and unions for leaks (testing pressure
max. 3.0 bar as indicated by pressure gauge).
y Turn on cold water service cock and fill hot water system (testing pressure max. 10 bar).
y Check all connections for leaks.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue systems
are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13 m.
A vertical flue system upto a height of 15 metres is available.
45° and 90° flue bends can be used with a corresponding reduction in flue length of 2m for each 90° bend and
1 m for each 45° bend used.
IMPORTANT: Any horizontal flue system fitted to a
condensing boiler must incline towards the appliance at
an angle of 3 % (30 mm per metre length) to prevent
condensate dripping from the flue terminal. This
means that the clearance above the appliance
must be increased to match the duct length.
Refer to fig. 1 on page 5.
Gas supply pipe
y Check that the seal is in place before tightening the
connection.
y Turn off gas cock to protect gas valve against
damage from excessive pressure.
y Check gas supply pipe.
y Release the pressure on the gas supply pipe.
6 720 610 596 GB (01.07)
15
Installation
3.8.1 Siting the Flue Terminal
The flue must be installed in accordance with
BS 5440:1 and the Building Regulations. Flue terminals
in carports and under balconies are to be avoided.
The terminal must be positioned so that it does not
cause an obstruction nor the combustion products a
nuisance. See fig. 14 and table 8.
The terminal will, at times, give out a plume of water
vapour and consideration must be given to this when
choosing a terminal position. Keep clear of security
lighting, activated by passive infra-red sensing heads.
If the terminal is less than 2 m above a surface to which
people have access then a guard must be fitted. The
guard must be evenly spaced about the terminal with a
space of 50 mm in each direction and fixed with plated
screws.
A guard Type K2 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
Fig. 14
Minimum dimensions of flue terminal positions (all types) (see fig. 14)
Dimension
Terminal Position (kW input expressed in net)
A1)
Balanced flues room sealed: Fanned draught
Directly below an opening, air brick, opening windows, etc.
B 1)
Above an opening, air brick, opening window, etc.
300 mm
C 1)
Horizontally to an opening, air brick, opening window, etc.
300 mm
D
Below gutters, soil pipes or drain pipes
E
Below eaves
300 mm
75 mm
200 mm
F
Below balconies or car port roof
200 mm
G
From a vertical drain pipe or soil pipe
150 mm
H
From an internal or external corner
300 mm
I
Above ground roof or balcony level
300 mm
J
From a surface facing the terminal
600 mm
K
From a terminal facing the terminal
1200 mm
L
From an opening in the car port (e. g. door, window) into the dwelling
1200 mm
M
Vertically from a terminal on the same wall
1500mm
N
Horizontally from a terminal on the same wall
O
From the wall on which the terminal is mounted
P
From a vertical structure on the roof
Not applicable
Q
Above intersection with roof
Not applicable
300 mm
Not applicable
Table 8
1)
16
In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
6 720 610 596 GB (01.07)
Installation
3.8.2 Installation of the flue
The standard 100 mm diameter horizontal flue system is
suitable for lengths upto 4 m.
Flues upto 650 mm do not require an extension duct
assembly.
Flues between 1600 mm and 4000 mm require extension duct assemblies.
NOTE: Flue lengths between 650 mm and 730 mm
cannot be accomodated. Refer to fig. 16, 17, 18.
Standard system comprise: Flue turret - Flue turret
clamp - Terminal assembly - Wall sealing - plates.
Extension kit comprises: Air duct - Flue duct - Duct
clamp. Refer to fig. 19.
Instructions for fitting other flue systems are packed
with the relevant flue kit.
Check that the position chosen for the appliance is satisfactory. Refer to fig. 15.
Terminal
Assembly
Flue
Turret
Maximum 650 mm
Outer
Wall
No
Clamp
6 720 610 602 - 08.1O
Fig. 16 Standard Flue
Drilling point for
flue duct opening
Centre line of
flue/air duct
H
Centre
line of
flue
opening
and
appliance
120
3%
(30 mm/meter)
Top of the
wall
mounting
frame
Appliance
H
Standard Horizontal Flue 158 mm
Optional Horizontal Flue 121 mm
6 720 610 602 - 07.1O
Fig. 15 Marking the position of the side flue opening
6 720 610 596 GB (01.07)
17
Installation
Terminal
Assembly
Flue
Turret
Maximum 1600mm
Outer
Wall
Clamp
No
Clamp
Extension
Duct
6 720 610 602 - 09.1O
Fig. 17 Flue with one extension
Terminal
Assembly
Flue
Turret
No
Clamp
Outer
Wall
Clamp
Clamp
Extension
Duct
Extension
Duct
6 720 610 602 - 10.1O
Fig. 18 Flue with extensions
Duct Clamp
Flue
Turret
Extension Air Duct
Extension Flue Duct
Terminal Assembly
Wall Sealing Plates
6 720 610 602 - 11.1O
Fig. 19 Flue components
18
6 720 610 596 GB (01.07)
Installation
3.8.3 Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 20, 21.
Outer
Wall
Face
Flue Terminal
L
Raised Ring
locating the
terminal relative
to the outside
wall face
120
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 12.1O
BOILER
Fig. 20 Flue length - rear
L
6 720 610 576 - 20.1O
Fig. 22 Flue terminal position
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must face downwards.
The assembly will be made easier if a solvent free
grease is lightly applied i.e Vaseline, to the male end of
the ducts.
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assembly.
Push the assembly through the wall and fix the turret to
the appliance with the clamp. Refer to fig. 23.
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 13.1O
BOILER
Flue Turret
Fig. 21 Flue length - side
Mark off the lengths shown onto the ducts and cut to
length. The cuts must be square and free from burrs.
Terminal assembly outer (air) duct - L-750 mm, inner
(flue) duct - L- 50 mm.The measurement is made from
the ridge at the terminal indicating the outer face of the
wall. Refer to fig. 22.
Extension air duct - L-70mm, flue duct - L-50 mm.
The measurement is from the formed end.
Clamp
Flue Socket
on Boiler
Air and
Flue Duct
Entry into
silicone
rubber seals
6 720 610 602 - 14.1O
Fig. 23 Flue turret
Ensure that the turret is fully entered into the socket on
the boiler. From the outside fix the outer wall plate to the
terminal and, after ensuring the duct is properly i nclined
towards the boiler, fix the plate to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal an be fixed with corrosion resistant
screws.
6 720 610 596 GB (01.07)
19
Electrical connections
4
Electrical connections
y Always disconnect the power supply to
the appliance at the mains before carrying out any work on the electrical systems and components.
All control and safety systems are built into the appliance.
y Allow mains cable to protrude at least 50 cm from
wall.
y To make splash-water proof (IP): cut the cable grommet hole size to match diameter of cable, see Fig. 26.
It must be possible to isolate the appliance. The appliance must be earthed.
The appliance must be connected to the mains through
a 6 A double pole isolator with a contact separation
3 mm in all poles and supplying the appliance and controls only. The wiring must comply with the current
requirements of the IEE Wiring Regulations and any
local regulations which apply.
4.1
Connecting the appliance
To gain access to the mains connection remove the
drop down facia cover. The drop down cover is
removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
release the cover. Lift cover from the appliance.
After installation (or in the event of an electrical fault) the
electrical system shall be checked for short circuits,
fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.
y Pull out cover panel at the bottom and remove. Refer
to fig. 24.
3
0
4
2
5
1
E
• Supply: 230 V ~ 50 Hz, 140 Watts
• Mains cable: PVC insulated 0.75 mm2
(24 x 0.20 mm) to BS6500-Table 6.
Temperature rated 100 °C.
6 720 610 332-10.1R
• Protection IPX4D
Fig. 24
• External fuse 3 A.
y Remove screw and slide terminal cover forwards to
remove. Refer to fig. 25.
3
0
2
4
5
1
E
6 720 610 332 -11.1R
Fig. 25
20
6 720 610 596 GB (01.07)
Electrical connections
y Cut cable grommet to diameter of cable.
3
0
4.2
Mains Voltage external controls
connections
4
2
5
1
NOTE: Only double insulated controls not requiring an earth can be used
E
Ns Ls LR
Ns Ls LR
ST8
Motor
230 V Room Thermostat Connections
5-7
230 V Programmer Connections
230 V room thermostat and
Programmer Connections
13-14
Ns Ls LR
ST8
ed
it ch
Sw
Live
Live
ve
ra
l
Li
ut
d
Ne
he
y Feed cable through cable grommet and connect the
mains supply cable, see Fig. 27.
itc
Fig. 26
Series
connection
to be made
safe
Sw
Live
6 720 610 332-12.1R
Neutral
10-12
Motor
y Secure cable in cable grommet by means of cable
grip.
L
Switched Live
Neutral
Remove Link
Live
Switched Live
Neutral
8-9
Live
ST8
6 720 610 576 - 22.1O
Fig. 28
N NS L S L R
4130-14.1R
Fig. 27
6 720 610 596 GB (01.07)
21
System
Water
Valve/s)
The following diagrams show the wiring options for your
system. Any other combinations of wiring are not recommended as it would increase complexity of the system. Please also follow wiring instructions of any
proprietary system. Worcester Heat Systems cannot be
held responsible for any incorrect wiring external from
the boiler.
Mains electrical supply: The boiler should be connected
to the mains supply as described in Section 4.1. This
also provides the electrical supply to the system. Note:
In all cases this must be the only electrical supply
to the system. This ensures the safety of a single
fused supply.
Pump: The boiler is fitted with an internal pump. Any
other system pump must be disconnected and
removed.
These diagrams show connection details of two popular
proprietary systems (Honeywell and Siebe, formerly
ACL ), for systems from other manufacturers instructions or contact Worcester Technical Service 0990
266241 for assistance.
Room Stat
Wiring to your system
Timer
4.3
Tank Stat
Electrical connections
Permanent
Mains supply
(NOT ALLOWED)
RemotePre-wired
Junction Box
L out
External pump
(DISCONNECT
AND REMOVE)
Boiler/pump
demand from
junction box.
Terminal Strip
E L N
Mains electrical supply to junction box
(NO OTHER SUPPLY TO
JUNCTION BOX ALLOWED)
Outside of Boiler
Inside of Boiler
L
N NS L S L R
6 720 610 603 -04.1O
Fig. 29
4.3.1 Pre-wired Remote Y Plan or S Plan
If the system is fully pre-wired at a juction box remotely
from the boiler, it can be easily connected back to the
Worcester System Boiler.
Drop down the facia and gain access to the boiler wiring centre as described in section 4.1.
Connect the junction box as shown (see fig. 29)
Important notes:
• Observe wiring details given in Section .
• Remove the pre-fitted link from LS and LR.
• If a room thermostat is required, it can be wired to the
remote junction box according to the proprietary
instructions.
• If a frost thermostat is required, it can be wired to the
remote junction box.
22
6 720 610 596 GB (01.07)
Commissioning
5
Commissioning
136 365
61
317 366 367
358
27
ECO
419
364
363
135
8.1
E
310
295
15
170
171
172
173
170
6 720 610 576-07.1O
Fig. 30
8.1
15
27
61
135
136
170
171
172
173
295
310
317
358
363
364
365
366
367
419
Pressure gauge
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for central heating
Service cocks on CH flow and return
Hot water
Gas cock (shown in on position)
Cold water service cock
Appliance type sticker
Temperature control for hot water
Multifunction display
Condensate trap
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
Hose from automatic vent
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance
with the guidelines given in BS7593:1992 - Treatment
of water in domestic hot water systems. Full instructions
are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should
be used in accordance with the inhibitor manufacturers
instructions.
To drain the appliance shut the system valves and open
the pressure relief valve.
Suitable flushing agents and inhibitors are available
from Betz/Dearborn Tel.: 0151 4209563 and Fernox
Tel.: 01799 550811. Instructions for use are supplied
with the these products.
y Before commissioning, the gas supply pressure must
be tested (see page 29).
6 720 610 596 GB (01.07)
23
Commissioning
y Unscrew the condensation trap (358) and pull out, fill
with approx. 1/4 l of water and refit. Refer to fig. 30.
y Adjust charge pressure of expansion vessel to static
head of the central heating system (see page 26).
y Open all system radiator valves.
y Turn on service valves (170), fill central heating system to pressure of 1 - 2 bar through the WRc
approved filling loop. Refer to fig. 30.
y Vent radiators.
y Refill heating system and set the pressure to 1 bar.
y Turn on cold water service cock (173). Refer to
fig. 30.
y Check that the gas type specified on the identification plate matches that of the gas supply.
y Turn on gas cock (172). Refer to fig. 30.
5.2
5.3
Switching on the central heating
The central heating flow temperature is adjustable
between 35 °C and 88 °C. Refer to table 10, page 26.
y Turn the temperature control
to set the flow temperature to a level appropriate to the type of central
heating system:
– Underfloor heating: e.g. setting “3”
(approx. 50 °C)
– Low-temperature heating: setting “E”
(approx. 75 °C)
– Central heating systems for flow temperatures up
to 88 °C: limited “max” setting for low-temperature
operation (see page 26).
When the burner is alight, the red indicator lamp
lights up.
Switching the appliance on/off
Switching on
y Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the central heating flow temperature, when the
appliance is operating in the central heating mode.
6 720 610 333-05.1O
Fig. 32
5.4
6 720 610 333-04.1O
Fig. 31
i
If the display alternates between -II- and
the central heating flow temperature, the
trap filling programme is active.
The trap filling programme ensures that the condensation trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
Switching off the appliance
y Set the master switch to (0).
The green indicator lamp goes out. The optional timer
will continue running until the emergency supply is
exhausted.
System controls
y Set room thermostat to the desired room temperature.
y Set outside - temperature driven control unit, if fitted.
Refer to the instructions with the control.
y Set the thermostatic radiator valves to the desired
settings.
5.5
Frost protection
Frost protection is only guaranteed from the external
room temperature thermostat.
y Leave master switch switched on.
If the appliance is to be left for long periods switch the
central heating off:
y Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
y Always disconnect the appliance from
the power supply (fuse, circuit breaker)
before carrying out any work on the
electrical systems or components.
24
6 720 610 596 GB (01.07)
Commissioning
5.6
i
Pump anti-seize function
This function prevents the central heating
pump seizing after long periods of inactivity.
Every time the pump is switched off, a timer is started.
If after 24 hours the pump has not run again, it is
switched on for a period of 5 minutes.
5.7
i
Fault Condition
A list of faults that may occur is given on
page 40.
In the unlikely event of a fault occuring while the appliance is in operation:
The display then shows a fault code and the button
may also flash.
If the button
flashes:
y Press and hold the button
until the display shows
„– –“.
The appliance will then start up again and the display
will show the central heating flow temperature.
If the button
does not flash:
y Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the central heating flow temperature will be displayed.
6 720 610 596 GB (01.07)
25
Individual settings
6
Individual settings
6.1
Mechanical settings
6.1.1 Checking the size of the expansion vessel
Maximum pressure at maximum CH flow temperature is
2.5 bar. If the pressure is greater than this then fit an
extra expansion vessel. Refer to table 9.
System Capacity – BS7074:1
Expansion Vessel Pressure and System Capacity
Expansion Vessel
litres
10
Expansion Vessel
Charge Pressure
bar
System
pressure
and
capacity
1 bar
litres
82
1.5 bar
litres
46
0.75
y Rotate yellow button through 180° and replace (dot
facing inwards).
The CH flow temperature is no longer limited.
Control setting
CH flow temperature
1
2
3
4
5
E
max
approx. 50 °C
approx. 55 °C
approx. 60 °C
approx. 65 °C
approx. 70 °C
approx. 75 °C
approx. 88 °C
Table 10
6.1.3 Changing the heating pump characteristic
The speed of the central heating pump can be altered
on the pump terminal box.
At switch position 1, maximum output is
not delivered if hot water mode is active.
Position 1 must not be used on combi appliances.
i
Table 9
6.1.2
Setting the central heating flow temperature
The central heating flow temperature can be set to
between 50 °C and 88 °C.
i
H
0,7
(bar)
0,6
With underfloor heating systems, observe
the maximum permissible flow temperatures.
0,5
2
0,3
y Lift off the yellow button on the temperature control
with a screwdriver.
1
0,2
0,1
0
Removing the maximum setting limit
For heating systems which require higher flow temperatures, the maximum setting limit can be removed.
3
0,4
Limited maximum setting for low-temperature
operation
The temperature control is factory limited to setting E,
giving a maximum flow temperature of 75 °C.
Adjustment of the heating output to the calculated heat
demand is not required by the heating systems regulations.
0
200
400
600
800
1000 1200 1400 1600
Q (l/h)
6 720 610 576 - 23.1O
Fig. 34
1
2
3
H
Q
Pump characteristic for switch position 1
Pump characteristic for switch position 2
Pump characteristic for switch position 3
Residual delivery pressure
Water circulation rate
6 720 610 332-27.1O
Fig. 33
26
6 720 610 596 GB (01.07)
Individual settings
6.2
Settings on the Bosch Heatronic
6.2.1 Operating the Bosch Heatronic
The Bosch Heatronic enables easy setting and checking of a large number of appliance functions.
This description is limited to those functions required
for commissioning.
For a full description of all available functions, please
refer to the Service booklet for the Engineer, order no.
7 181 465 346.
5
2
1
Entering a setting
y To enter the setting for a function, turn the temperature control
.
Storing a setting
y Level 1: press and hold the
button until the display shows [ ].
y Level 2: press and hold the
and
buttons simultaneously until the display shows [ ].
After completing the settings
y Reset the temperature controls
original positions.
6.2.2
6 720 610 332-30.1O
4
3
Fig. 35 Appliance controls
1
2
3
4
5
i
Service button
“Chimney sweep” button
Temperature control for central heating
Temperature control for hot water
Display
Note the positions of the temperature controls
and
. After completing the settings, return the temperature controls to
their original positions.
The service functions are subdivided into two levels:
Level 1 comprises service functions up to function 4.9,
while Level 2 consists of the service functions from 5.0
upwards.
y To select a service function on Level 1: press and
hold the
button until the display shows – –.
y To select a service function on Level 2: press and
hold the buttons
and
simultaneously until the
display shows = =.
y Then turn the
temperature control to select the
required function.
Service function
Code no.
Pump control mode
2.2
Anti-cycle time
2.4
Max. CH flow
temperature
2.5
Switching difference
2.6
Max. heating output
5.0
Table 11
The service function 5.0 may be reset.
6 720 610 596 GB (01.07)
to their
Selecting the pump control mode for central heating mode (Service Function 2.2)
If an outside temperature driven control
unit is connected, pump control mode 3 is
automatically activated
The choice of settings is as follows:
Selecting service function:
i
and
See page
27
27
28
28
28
• Control Mode 1
For heating equipment without a control unit.
The pump is controlled by the central heating flow
temperature control.
• Control Mode 2 (factory setting)
For heating systems with room thermostat.
The central heating flow temperature control controls
only the gas, the pump is not affected. The room thermostat controls both the gas and the pump.
The pump and fan have an overrun time of between
15 s and 3 min.
• Control Mode 3
The pump is controlled by the outside temperature
driven control unit. In summer mode, the pump operates only for hot water mode.
6.2.3
Setting the anti-cycle time
(Service Function 2.4)
This service function is only active if Service Function
2.7, automatic anti-cycle time, is deactivated.
The anti-cycle time can be set to between 0 and 15 minutes (is factory set to 3 minutes).
If the setting 0 is entered, the anti-cycle time is inactive.
The shortest possible anti-cycle time is 1 minute (recommended for single-pipe and hot-air heating systems).
i
If the appliance is connected to an outside-temperature controlled heating programmer, the anti-cycle time does not
need to be set on the appliance and is optimised by the programmer instead.
27
Individual settings
6.2.4
Setting the maxim CH flow temperature
(Service Function 2.5)
The maximum CH flow temperature can be set to
between 35 °C and 88 °C (factory setting).
6.2.5
i
Setting the switching difference
(Service Function 2.6)
If the appliance is connected to an outside-temperature controlled programmer,
the programmer sets the switching difference.
It does not need to be set on the appliance.
The switching difference is the permissible divergence
from the specified CH flow temperature. It can be set in
increments of 1 K. The adjustment range is 1 to 30 K (is
factory set to 0 K). The minimum CH flow temperature
is 30 °C.
6.2.6
Setting the heating output
(Service Function 5.0)
The heating output can be set to any level between min.
rated heat output and max rated heat output to limit it to
the specific heat requirements.
i
y Turn the temperature control
until the display
shows 5.0.
After a short delay, the display then shows the set
heating output in percent.
6 720 610 332-51.1O
Fig. 37
y Refer to the settings tables for heating and cylinder
charging output to obtain the relevant code for the
desired heating output in kW (see page 42).
y Turn the temperature control
until the display
shows the desired code number.
The display and the
and
buttons will flash.
y Measure the gas flow rate and compare with the figures specified for the code number displayed. If figures do not match, adjust the code number!
y Press and hold the
and
buttons simultaneously until the display shows [ ].
The heating output is now stored.
The full rated heat output is still available
for hot water or charging the hot water cylinder even if the heating output has been
limited.
The factory setting is the max. rated heat output.
y Set the room thermostat and thermostatic radiator
valves to max. temperature.
y Press and hold the
and
buttons simultaneously until the display shows = =.
The
and
buttons will light up.
6 720 610 332-52.1O
Fig. 38
y Return the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperate.
6.3
Setting the gas/air ratio
Refer to section 7.1 for details of the method of setting
the gas/air ratio.
6 720 610 332-50.1O
Fig. 36
28
6 720 610 596 GB (01.07)
Converting the appliance to different gas types
7
Converting the appliance to different gas types
The setting is factory sealed at maximum. Adjustment to
the rated heat input and min. heat input is not necessary.
The gas/air ratio may only be adjusted on the
basis of a CO2 measurement at max. heat output
and min. heat output using an electronic tester.
Checking the gas supply pressure
y Check the gas supply pressure at the gas supply
pressure testing point.
i
Natural gas appliances must not be operated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is not 37 mbar.
7.1
Setting the gas/air ratio
y Switch off the appliance at the master switch (O).
y Remove the outer case (see page 14, refer to
fig. 12).
y Switch on the appliance at the master switch (I).
y Set room thermostat to maximum temperature.
y Open thermostatic radiator valves.
y Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 39.
y Insert testing probe about 135 mm into the flue gas
testing point and seal testing point.
Natural gas
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m3 and 20 mbar supply
pressure and sealed.
234
Conversion kits
Model
For conversion
from ...
Order no.
6 720 610 332-57.1R
ZB 7-27 HE
N.G to L.P.G
7 710 149 045
Fig. 39
ZB 11-27 HE
L.P.G to N.G
7 710 239 081
y Press and hold
button until the display shows – –.
The
button will light up.
Table 12
• Instructions are sent with each conversion kit.
6 720 610 332-32.1O
Fig. 40
y Turn the temperature control
until the display
shows 2.0 .
After a short delay, the current operating mode setting will be displayed ( (0. = Normal mode).
6 720 610 332-60.1O
Fig. 41
6 720 610 596 GB (01.07)
29
Converting the appliance to different gas types
y Turn the temperature control
until the display
shows 2.
(= max. rated heat output).
The display and the
button will flash.
y Turn the temperature control
anti-clockwise until
the display shows 1. (= min. rated heat output).
The display and the
button will flash.
6 720 610 332-63.1O
Fig. 44
6 720 610 332-61.1O
Fig. 42
y Measure the CO2 level.
y Prise off the seal on the gas flow restrictor.
y Adjust the gas flow restrictor (63) to obtain the CO2
level given in Table 13. Refer to fig. 43.
y Measure the CO2 level.
y Remove the seal from the gas valve adjusting
screw (64) and adjust the CO2 level to the figure
given in Table 13 for min. rated heat output.
63
6 720 610 332-64.1R
Fig. 43
Gas Type
Natural gas type
H (23)
LPG
(propane)
Table 13
CO2 reading
at max.
rated heat
output
CO2 reading
at min. rated
heat output
9.5 %
9.2 %
11.3 %
11.0 %
y Measure the CO level.
If the CO level is over 300 ppm, the gas volumetric
flow rate is too high. Reduce the gas flow rate on the
adjustable gas flow restrictor (63) until the CO level
is below 100 ppm.
y Re-adjust the CO2 level if necessary.
30
Fig. 45
y Measure the CO level.
If the CO level is over 300 ppm, the gas volumetric
flow rate is too high. Reduce the gas flow rate on the
adjustable gas flow restrictor (63) until the CO level
is below 100 ppm.
y Re-adjust the CO2 level if necessary.
y Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
y Turn the temperature control
anti-clockwise as
far as the stop so that the display shows 0.
(= Normal operating mode).
The display and the
button will flash.
y Press and hold the
button until the display
shows [ ].
y Reset the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperature.
y Remove testing probe from the flue gas testing
point (234) and refit sealing plug.
y Re-seal gas valve adjusting screw and gas flow
restrictor.
y Replace outer case and secure.
y Set room thermostat and thermostatic radiator valves
to the desired temperature.
6 720 610 596 GB (01.07)
Converting the appliance to different gas types
7.2
Testing combustion air/flue gas at set heat output
7.2.1
Testing the O2 or CO2 level in the combustion air
i
By testing the O2 or CO2 level in the combustion air the gas tightness of a type C13
or C33 flue system can be checked. The
O2 level must not be less than 20,6 %.
The CO2 level must not exceed 0,2 %.
y Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
In “chimney sweep” mode, the appliance
switches to max. rated heat output or the
set heating output. You then have 15 minutes in which to measure the levels. After
that, the appliance switches back from
“chimney sweep” mode to normal mode.
y Remove sealing plug from combustion air testing
point (234.1, fig. 46).
y Insert testing probe about 80 mm into the testing
point and seal testing point.
7.2.2
Testing CO and CO2
y Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
You have 15 minutes in which to measure
the levels. After that, the appliance switches back from “chimney sweep” mode to
normal mode.
y Remove sealing plug from flue gas testing point
(234, fig. 46).
y Insert testing probe about 135 mm into the testing
point and seal testing point.
y CO- and CO2 levels.
y Refit sealing plug.
y Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
234
234.1
6 720 610 332-65.1R
Fig. 46
y Measure O2 and CO2 levels.
y Refit sealing plug.
y Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
6 720 610 596 GB (01.07)
31
Maintenance
8
Maintenance
y Always disconnect the appliance from
the electrical power supply (fuse, circuit
breaker) before carrying out any work on
the electrical systems or components.
y Always turn off the gas cock before carrying out any work on components
which carry gas.
i
i
There is a special Service booklet for the
Engineer, order no. 7 181 465 346, available to competent persons.
All safety and control systems are monitored by the Bosch Heatronic. In the event
of a component fault, the display shows a
fault code.
y The User should be recommended to have the appliance serviced regularly by a competent person (see
Maintenance Contract).
y Use only genuine spare parts
y Refer to the Spare Parts List when ordering spare
parts.
y Always renew seals and O-rings removed during
servicing or repair work.
y Use only the following types of grease:
– Water valve: WRc approved silicon based grease
– Unions: approved sealant.
y To drain the appliance shut the system valves and
open the pressure relief valve.
32
6 720 610 596 GB (01.07)
Maintenance
8.1
Pre-Service Check List
Date
1
Call up the last fault stored by the
Bosch Heatronic, Service Function .0,
(see page 34).
2
Check ionisation current, Service
Function 3.3, (see page 34).
3
Perform visual check of air/flue duct.
4
Check gas supply pressure
(see page 29).
5
Test combustion air/flue gas
(see page 31).
6
Check CO2 setting for min./
max. (gas/air ratio)
(see page 29).
mbar
min. %
max. %
7
Check gas and water systems for
leaks (see page 15).
8
Check heat exchanger
(see page 34).
9
Check burner (see page 35).
mbar
10 Clean condensation trap
(see page 35).
11 Check charge pressure of
mbar
expansion vessel matches
static head of heating system.
12 Check central heating system mbar
pressure.
13 Check electrical wiring for damage.
14 Check heating programmer settings.
15 Check appliances that are part of
the heating system
Table 14
6 720 610 596 GB (01.07)
33
Maintenance
8.2
Description of servicing operations
The combustion performance must be checked before
and after any servicing work on the combustion and
burner components. Refer to section 7.2.
y Remove the fan and the burner as described in the
text headed “Burner” (see page 35).
Check “Last fault stored”:
y Select Service Function .0 (see page 27 “Selecting
Service Function”).
There is a list of the fault codes in the Appendix (see
page 40.
To delete “Last fault stored”:
y Turn temperature control
anti-clockwise as far as
the stop.
y Press and hold the
button until the display
shows [ ].
The last fault stored has now been deleted.
Checking the ionisation current,
Service Function 3.3
6 720 610 332-72.1R
Fig. 48
y Loosen any deposits in the heat exchanger from top
to bottom using the cleaning blade. Refer to fig. 49.
y Select Service Function 3.3 (see page 27 “Selecting
Service Function”).
If the display shows 2 or 3, the ionisation current is OK.
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced.
Primary Heat exchanger
There is a special accessory kit (no. 840) for cleaning
the heat exchanger, order no. 7 719 001 996.
y Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manometer.
6 720 610 332-73.1R
Fig. 49
y Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 50.
6 720 610 332-69.1R
Fig. 47
6 720 610 332-74.1R
i
The heat exchanger should only be
cleaned if the control pressure is
2.2 mbar (depression) or less.
Fig. 50
y Remove cleaning access cover (415, page 6) and
the metal plate below it, if present. Refer to fig. 2.
y Unscrew condensation trap and place suitable container underneath. Refer to fig. 48.
34
6 720 610 596 GB (01.07)
Maintenance
y Flush the heat exchanger from the top. Refer to
fig. 51.
y Clean out the condensate collector and trap connection (with other end of brush).
y Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 53.
1.
H 2O
2.
6 720 610 332-75.1R
Fig. 51
y Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
Burner
y Check that the gas cock is turned off and the master
switch is in the OFF position.
y Remove the clips (1) and unscrew the two bolts (2).
Refer to fig. 52.
y Unscrew and remove the two hexagon screws securing the fan (3).
y Slacken fully the rear securing bolt (4).
y Remove the burner coverplate.
4.
2.
3.
1.
7 181 465 330-08.1R
Fig. 53
y Re-assemble burner in reverse order using a new
seal.
y Adjust gas/air ratio. Refer to section 7.2.
Condensation trap
In order to prevent spillage of condensate, the condensation trap should be completely removed, (see
page 34, fig. 48).
y Unscrew condensation trap and check connection to
heat exchanger is clear.
y Remove condensation trap cover and clean.
y Fill condensation trap with approx. 1/4 l of water and
refit.
Electrode assembly
7 181 465 330-04.1R
Fig. 52
6 720 610 596 GB (01.07)
y Switch off the master switch.
y Pull off the leads from the electrodes. Refer to fig. 2.
y Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 47.
y Clean the electrodes with a non-metallic brush. (The
spark gap should be 4,5 mm ± 0,5 mm.)
y Replace and re-connect the assembly taking care not
to mislay the inspection window.
35
Maintenance
Siphon
8.3
Replacement of Parts
y Unscrew the clip and disconnect the pipe to the
siphon.
y Remove the yellow plug to drain the siphon.
y Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
y Refit and prime the siphon.
Before changing any components check that the gas is
turned off and that the appliance is electrically isolated.
When necessary close the system valves and drain the
appliance.
Refitting is a reverse of the procedure for removal using
new seals or o-rings as appropriate.
8.3.1
PCB control board and transformer
y Switch off the appliance.
y Disconnect appliance from the power supply.
y Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the covers. Refer to fig. 24, 25.
y Remove screw holding power connector earth lead
and remove earth lead.
y Remove two top fixing screws from the control box.
Refer to fig. 55.
Condensate
Drain
Siphon
1
3
2 4
6 720 610 602 - 16.1O
3
4
1
3
2 4
2
5
1
E
Fig. 54
1
7 181 465 329-02.1R
3
2 4
Expansion vessel
The expansion vessel should be checked once a year.
y Depressurise appliance.
y If necessary, adjust expansion vessel charge pressure to static head of the heating system.
Fig. 55
Heating system pressure
i
Fill the system using the WRc approved
filling loop.
y The pointer on the pressure gauge should be 1 bar.
y If the pointer is below 1 bar (when the system is
cold), water should be added until the pointer is
1 bar again.
y Max. pressure of 2.5 bar when the heating system
water is at maximum temperature must not be
exceeded. If this pressure is exceeded then an extra
expansion vessel must be fitted in the system return
as close to the appliance as possible.
y If the system does not retain the pressure, the expansion vessel and the heating system should be
checked for leaks.
Electrical wiring
y Check the electrical wiring for physical damage and
replace any damaged wires.
36
6 720 610 596 GB (01.07)
Maintenance
y Lower the control box.
y Unscrew earth lead.
y Unscrew four fixing screws from cover plate. Refer to
fig. 56.
y Prise off cover plate.
y Pull off transformer.
y Remove pcb holder.
y Remove the pcb control board.
8.3.2
Fan Assembly
3.
2.
4.
1.
7 181 465 330-05.1R
Fig. 57
7 181 465 330-10.1R
Fig. 56
Fuses
y Remove the connections covers. Refer to fig. 24,
25.
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
Fuse, item 312, is only replaceable by removing the
pcb.
Spare fuses are fixed to the connections cover.
A fuse pack is available: Part number 8 744 503 010 0.
6 720 610 596 GB (01.07)
y Switch off the appliance.
y Disconnect the appliance from the power supply.
y Undo lower pipe union on gas pipe (1.). Refer to
fig. 57.
y Remove fan lead and earth connector (2.). The earth
connector has a positive clip fixing.
y Remove fixing screws attaching fan to the burner
cover (3.).
y Remove fan together with gas pipe and mixer unit.
y Separate the fan from the pipe and mixer unit by
twisting the mixer unit to release it (4.).
37
Maintenance
8.3.3
Flue Temperature Limiter – Item 9, fig. 2, 55
Pump
y Switch off the appliance.
y Disconnect the appliance from the power supply.
y Remove two switchbox fixing screws (1.). Refer to
fig. 58.
y Lower switchbox (2.).
y Unscrew and remove the siphon by releasing the
jubilee clip. Refer to fig. 54.
y Unscrew the pump union nuts (3.). Refer to fig. 58.
y Carefully remove the pump and disconnect the leads.
Alternatively
y After removing the siphon release the four Allen
screws and remove and replace the pump head.
3.
y Pull-off the connectors.
y Unscrew the sensor.
8.3.5
Gas Valve
y Check that the gas cock is turned off.
y Lower the control panel. Refer to fig. 58.
y Pull off the solenoid connections at the rear of the
valve.
y Undo the union, within the inner casing, securing the
valve to the gas/air tube. Refer to fig. 57.
y Remove the white plastic cap from the gas valve.
y Release the gas inlet union at the manifold assembly.
y Unscrew the two screws securing the gas valve
assembly bracket to the back panel and withdraw the
assembly.
y Transfer the bracket and inlet pipe assembly to the
new gas valve.
y Check for gas soundness when the new gas valve
has been fitted.
y Recheck the combustion performance as described
in section 7.1.
1.
1.
2.
Fig. 58
8.3.4
Sensors
y Check that the appliance is electrically isolated.
Central Heating Flow Temperature Sensor –
Item 36, fig. 2, 55
y Pull-off the connector.
y Release the sensor clip and withdraw the sensor.
y Apply heat transfer paste to the replacement sensor.
Safety Temperature Limiter – Item 6, fig. 2, 55
y Pull-off the connectors.
y Unscrew the sensor.
38
6 720 610 602 - 04.1O
Fig. 59
6 720 610 596 GB (01.07)
Maintenance
8.3.6
Electrode assembly
y Refer to section 8.2.
y Use a new seal if the existing seal is damaged.
8.3.7
Pressure gauge
y Drain the appliance.
y Lower the facia. Refer to fig. 58.
y Twist the pressure gauge head anti-clockwise to
release it from the casing. Refer to fig. 2.
y Disconnect the capillary head from the rear by withdrawing the clip and pulling out the head.
8.3.8
y Pull forward from the top and lift the heat exchanger
from the casing.
y Transfer components, as necessary, to the new heat
exchanger.
y Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
appliance.
Expansion vessel
y Drain the appliance.
y Undo the union connection at the base of the vessel.
Refer to fig. 2.
y Unscrew the top and bottom fixing screws and
remove the vessel.
y Set the pressure of the new vessel to that required by
the system.
8.3.9
Pressure Relief Valve
y Drain the appliance.
y Disconnect the drain pipe from the valve. Refer to
fig. 30.
y Pull-out the clip securing the valve.
y Pull-out the valve.
y Ensure that the replacement valve is fully entered
before fitting the clip.
8.3.10 Burner
y Refer to section 8.2.
8.3.11 Primary Heat Exchanger
y
y
y
y
y
y
y
y
Drain the appliance.
Check that the gas supply is turned off.
Check that the appliance is electrically isolated.
Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 8.3.2.
Remove the burner. Refer to section 8.2.
Disconnect the sensors. Refer to section 8.3.4.
Undo the central heating flow union.
Undo the top connection of the pump. Refer to
fig. 58.
6 720 610 602 - 06.10
Fig. 60
y Undo the grey plastic cap, next to the top pump connection at the base of the heat exchanger.
y Unscrew and remove the condensate trap. Refer to
section 8.2.
y Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
y Lift up the flue duct, item 271, refer to fig. 2.
6 720 610 596 GB (01.07)
39
Appendix
9
Appendix
9.1
Fault Codes
More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.
Display
code
Description
Remedy
A8
Break in communication
Check connecting lead to programmer
AC
Module not detected.
Check connecting lead between TA211E/TR212E
and Heatronic
b1
Keyed plug not detected.
Insert keyed plug correctly, test and replace if necessary.
C1
Fan speed too low.
Check fan lead and connector, and fan; replace as
necessary.
d3
Jumper 8-9 not detected.
Connector not connected, link missing, underfloor
heating limiter tripped.
E2
CH flow NTC sensor defective
Check CH flow NTC sensor and connecting lead.
E9
Safety temp. limiter in CH flow has tripped.
Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA
Flame not detected.
Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0
Internal error.
Check electrical connector contacts, programmer
interface module ignition leads are not loose; replace
pcb if necessary.
F7
Flame detected even though appliance switched off.
Check electrode assembly, dry pcb. Flue clear?
FA
Flame detected after gas shut off.
Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue
clear?
Fd
Reset button pressed by mistake.
Press reset button again
P1, P2, P3,
P1...
Please wait, initialisation in progress.
24 V fuse blown. Replace fuse.
Table 15
40
6 720 610 596 GB (01.07)
Appendix
9.2
Short parts list
Key
Description
Qty GC
Spare part number
1
Sensor - Flue gas temp.
1
8 729 000 144 0
2
Sensor - CH flow temp.
1
8 714 500 087 0
3
Control board
1
8 748 300 418 0
4
Gas valve
1
8 747 003 516 0
5
Fan assembly
1
8 717 204 373 0
6
Fan washer
1
8 729 000 183 0
7
Expansion vessel
1
8 715 407 236 0
8
Relief valve
1
8 717 401 012 0
9
Electrode assembly
1
8 718 107 077 0
10
Electrode lead
1
8 714 401 999 0
11
Pump
1
8 717 204 477 0
12
Pressure gauge
1
8 717 208 079 0
13
Burner skin seal
1
8 711 004 168 0
14
Transformer - facia
1
8 747 201 358 0
15
Heat exchanger washer
1
8 710 103 153 0
16
Washerset Condenstaion Trap
1
8 710 103 154 0
17
Fuseset
1
8 744 503 010 0
18
Primary heat exchanger
1
8 715 406 615 0
Table 16
6 720 610 596 GB (01.07)
41
Appendix
9.3
Heating/hot water output settings (N.G.)
Natural gas G20
Display
code
Heat output kW
Heatinput kW
Gas vol. flow rate
(l/min at tV/tR = 80/60 °C)
30
8.2
8.3
14.4
40
10.9
11.0
19.3
50
13.6
13.8
24.1
60
16.3
16.5
28.9
70
19.1
19.3
33.7
80
21.8
22.0
38.5
90
24.5
24.8
43.3
100
27.2
27.5
48.1
Table 17
9.4
Heating/hot water output settings (L.P.G)
Propane
Display
code
Heat output kW
Heat input kW
40
10.9
11.0
50
13.6
13.8
60
16.3
16.5
70
19.1
19.3
80
21.8
22.0
90
24.5
24.8
100
27.2
27.5
Table 18
42
6 720 610 596 GB (01.07)
Mains
switch
ON.
6 720 610 596 GB (01.07)
Fan runs to purge
gas from burner.
No
Yes
CH demand
satisfied.
Fan min.
speed for
90 secs.
Yes
Gas valve
closes.
Red light
OFF.
No
Boiler
unused for
long
period.*
*
Minimum
heat input
for 15min.
Pump and Fan
run for upto
3 mins.
6 720 610 576 - 25.1O
* NOTE: The sequence ensures that the condensate siphon is not empty
after long OFF periods. (More than 24 hours without a demand).
Fan speed
reduces
over 15
secs.
Central heating function
Burner lights.
Red light ON.
ce
Burner
stabilises at
start speed
for 5-10 secs
Boiler
operates to
match
system load
and CH
control
setting.
9.5.1
Ignition spark for
5 seconds.
Pump ON
Fan to
start speed.
Gas valve opens.
Over temperature
shut-down if water
temperature is 5°C
above set value.
Operational Flow diagrams
Ignition sequence
CH
demand.
Gas valve shuts.
Pump remains ON.
9.5
Repeats 5 times
before lock-out.
Green
light
ON.
Room thermostat
and/or mains
programmer or
link ON
AND
Electronic facia
programmer
(if fitted) ON
AND
CH control knob
ON.
Burner remains OFF
until flow temperature
is below set value.
Appendix
Fig. 61
43
Appendix
EXCELLENCE COMES AS STANDARD
Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
Users Instructions and
Customer Care Guide
Greenstar HE combi Condensing boiler
Greenstar HE system Condensing boiler
6 720 610 577-00.10
6 720 610 577 GB (01.07) OSW
ZWB 7-27 HE combi GC-Number: 47 311 55
ZB 7-27 HE system GC-Number: 41 311 49
Contents
Contents
Excellence comes as standard
3
Safety precautions
4
1
General notes
6
2
Controls
9
3
3.1
3.2
3.3
3.4
3.5
10
10
12
13
13
3.7
3.8
Operating the Appliance
Preparation
Switching the Appliance On/Off
Switching on the Central Heating
Controlling Central Heating
Combination Boilers:
Setting the Hot Water Temperature
Summer Mode, Hot Water Only
(Combi Appliances)
Frost protection (Combi Appliances)
Fault Condition
4
Tips on saving energy
17
5
General Information
19
6
Maintaining your appliance
19
7
Service centres
20
8
Fault or breakdown
21
9
Your Bosch Greenstar guarantee
22
10
Guarantee registration
23
11
Operating Instructions Quick Reference
24
3.6
2
14
15
15
16
6 720 610 577 GB (01.07)
Excellence comes as standard
Excellence comes as standard
Thank you for purchasing a Worcester Greenstar condensing
appliance.
The Worcester Greenstar Series has been developed by the
Bosch Group and the strictest quality control standards are
demanded throughout every stage of production.
Indeed, the Bosch Group have led the field in innovative appliance design and performance for many years.
The result is that your new Greenstar appliance offers you the very
best of everything – quality, efficiency, economical running costs,
proven reliability and value for money.
What’s more, you also have the assurance of our no nonsense
2 year parts and labour guarantee.
And it’s backed up by Worcester Care Call a complete maintenance scheme to keep your boiler operating at peak condition and
efficiency.
No wonder that more and more people are agreeing that when it
is gas, it has to be a Worcester Condensing appliance.
Benchmark
The “Benchmark” initiative is the new code of practice to encourage the correct installation, commissioning and servicing of
domestic central heating boilers and system equipment.
The “log-book” is a vital document that must be completed by the
installer at the time of installation. It confirms that the boiler has
been installed and commissioned according to the manufacturers
instructions.
Without the completion of the “log-book”, manufacturers may
refuse to respond to a call–out from a householder, who will be
advised that he or she must call back the installer, who has not fulfilled his obligations to record the information required by the initiative.
6 720 610 577 GB (01.07)
3
Safety precautions
Safety precautions
Gas Safety (Installation and Use) Regulations 1998
It is the law that all gas appliances are installed by a competent
person in accordance with the above regulations. Failure to install
appliances correctly could lead to prosecution. It is in your interest, and that of safety, to ensure compliance with the law.
If you smell gas:
y
Turn off gas service cock at the meter.
y
Open all doors and windows.
y
Do not operate any electrical switches.
y
Do not smoke.
y
Extinguish any naked flames.
y
Call your gas company.
If you smell fumes from the appliance:
y
Switch off appliance.
y
Open windows and doors.
y
Inform your heating engineer.
Fitting and modifications
y
Fitting of the appliance or any modifications to the appliance
may only be carried out by a competent person.
y
Flue systems must not be modified in any way.
Maintenance
y
We recommend that you take out a maintenance contract
with a competent installer and have the appliance serviced at
regular intervals.
y
4
Ensure that your Service Engineer uses only genuine spare
parts!
6 720 610 577 GB (01.07)
Safety precautions
Combustible materials
y
Do not store or use any combustible materials (paper, thinners, paints etc.) in the vicinity of the appliance.
Health and safety
y
This appliance contains no asbestos products.
y
There is no potential hazard due to the appliance being electrically unsafe.
y
There are no substances used in the construction that are a
potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).
Combustion Air/Ambient Air
y
Keep combustion air/ambient air free of corrosive substances
(e.g. halogenated hydrocarbons which contain chlorine or fluorine compounds). In this way corrosion can be prevented.
6 720 610 577 GB (01.07)
5
General notes
1
General notes
To get the best from your appliance please read these instructions carefully.
Sealed heating systems
The appliance is fitted to a sealed heating system which is prepressurised. Your installer will tell you of the minimum and maximum pressure which must be indicated on the pressure gauge.
Check regularly that the pressure is maintained and contact your
installer or maintenance engineer if there is a permanent significant drop in the pressure. If the system loses pressure it should
be repressurised and the cause of the fall investigated.
Central heating systems
During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. If
the top of a radiator is at a lower temperature than the bottom then
it should be vented by releasing air through the venting screw at
the top of the radiator. Ask your installer to show you how this is
done. Repeated venting will reduce the quantity of water in the
system and this must be replenished for safe and satisfactory
operation of the appliance.
Should water leaks be found in the system or excessive venting is
required then a service engineer must be contacted to inspect the
installation and rectify any fault.
Only additives that are compatible with aluminium may be used in
the system. Any incompatible additive used will invalidate the
guarantee.
Condensate drain
This is a condensing appliance and the terminal will, at times, give
out a plume of water vapour. This is quite normal.
The appliance produces quantities of condense which is discharged regularly through the siphon.
6
6 720 610 577 GB (01.07)
General notes
Clearances
Your installer will have provided adequate space around the appliance for safety and servicing access. Do not restrict this space
with the addition of cupboards, shelves etc. next to the appliance.
Left-hand side
Right-hand side
5 mm
5 mm
In Front
600 mm
Above Casing (Vert. Flue)
75 mm
Above Flue Turret
30 mm
Below
250 mm
Table 1
Room thermostat
A room thermostat with volt free contacts (i.e. battery operated)
may be fitted to control the central heating. Refer to the instructions
supplied with the thermostat for information on siting and setting. A
programmable thermostat may also be used with this appliance to
provide additional timed control of the central heating.
Thermostatic radiator valves
It is recommended that this type of valve is fitted to all the radiators except one, usually the bathroom radiator. They should conform to the requirements of BS2767:10.
Showers, bidets, taps and mixing valves – Combination Boilers
Standard hot and cold taps and mixing valves must be suitable for
operating at mains pressure. Thermostatically controlled or pressure equalising shower valves will guard against the flow of water
at too high a temperature.
Hot and cold mains fed water can be supplied directly to an overrim flushing bidet subject to local water company requirements.
With all mains fed systems the flow of water from individual taps
will vary with the number of outlets operated simultaneously and
the cold water mains supply pressure to the property.
6 720 610 577 GB (01.07)
7
General notes
Flow balancing using “ball-o-fix” type valves is recommended to
avoid an excessive reduction in flow to individual outlets.
For further information contact Worcester Heat Systems Technical Services Department.
Hot and cold flow – Combination Boilers
The flow of water demanded from both hot and cold service outlets is dependent upon the mains supply, it may not be possible
in some installations to operate all outlets simultaneously.
Water mains failure – Combination Boilers
If there is a failure of the mains water supply then no water will be
available at a tap or shower until the mains supply is restored. The
appliance will still operate in the central heating mode.
Use in hard water areas – Combination Boilers
In exceptionally hard water areas a device to prevent scale formation may be fitted. Installation of a scale inhibitor assembly should
be in accordance with the requirements of the local water company. An isolating valve should be fitted to allow for servicing.
Alternatively the maximum temperature of the domestic hot water
may be reset to about 45 °C which will reduce the risk of scale
formation in these hard water areas.
Ventilation
This is a room sealed appliance and does not require any air for
combustion from inside the house. If the appliance is fitted into a
cupboard or a compartment is built around the appliance after
installation then the compartment must be separated from the
boiler space by a perforated non-combustible partition as
described in BS6798:87.
Notwithstanding the requirements of BS6798:87, there is no
need for ventilation openings to be provided in the compartment
because of the low heat loss from the casing.
Do not allow the flue terminal fitted on the outside wall to become
obstructed or damaged.
Pump
The pump will have been set by the manufacturer and must not be
manually re-adjusted.
8
6 720 610 577 GB (01.07)
Controls
2
Controls
136 365
61
317 366 367 363 310
ECO
364
8.1
135
E
295
170
171
172
173
170
6 720 610 577-01.1O
8.1
61
135
136
170
171
172
173
295
310
317
363
364
365
366
367
System Pressure gauge
Reset button
Master switch
Central heating temperature control
Service valves in CH flow and return
Hot water
Gas isolation valve (open)
Cold water inlet
Identification sticker
Hot water temperature control (combi)
Display
Indicator lamp for “burner on”
Indicator lamp for “off/on”
“Chimney sweep” button
Service button
“ECO” button
6 720 610 577 GB (01.07)
9
Operating the Appliance
3
Operating the Appliance
3.1
Preparation
Turn on the gas cock (172).
y Press in the handle and turn it anti-clockwise as far as the stop
(when handle is in line with direction of flow, the cock is open).
Central heating system valves (170)
y Using a spanner, turn square nut until groove is in line with
direction of flow (see detail).
Groove at right angles to direction of flow = off.
Cold water inlet valve (173)
y
Turn handle so that it is in line with direction of flow.
When handle is at right angles to direction of flow, the valve is
closed.
170
172
173
6 720 610 577-02.1O
10
6 720 610 577 GB (01.07)
Operating the Appliance
Check the central heating system pressure
y
The pointer on the pressure gauge (8.1) should be about
1 bar.
y
If the pointer is below 1 bar (when the system is cold), top up
the system with water until the pointer is 1 bar. Your installer
will have shown you how to do this.
y
The maximum operating pressure of 2.5 bar at maximum
central heating flow temperature must not be exceeded. If the
pressure increases to 3 bar then the relief valve (15) opens.
2
3
1
4
0
bar
8.1
15
6 720 610 577-03.1O
6 720 610 577 GB (01.07)
11
Operating the Appliance
3.2
Switching the Appliance On/Off
Switching on
y
Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will show the
central heating flow temperature, when the appliance is operating in the central heating mode.
6 720 610 333-04.1O
i
If the display alternates between -II- and the central heating flow temperature, the trap filling programme is active.
The trap filling programme ensures that the condensation trap is
filled after the appliance has been installed or after the appliance
has been out of use for a long period. For that reason, the appliance remains at minimum heating output for 15 minutes.
Switching off
y
12
Switch off the appliance at the master switch (0).
The green indicator lamp goes out. The optional timer will continue running until the emergency supply is exhausted.
6 720 610 577 GB (01.07)
Operating the Appliance
3.3
y
Switching on the Central Heating
Turn the central heating temperature control
level:
to the desired
– “Min” setting: 35 °C
– Low-temperature heating: setting “E” (approx. 75 °C)
– “Max” setting: 88 °C
When the burner is lit, the red indicator lamp is illuminated.
6 720 610 333-05.1O
3.4
Controlling Central Heating
y
Set room thermostat to the desired room temperature.
y
Set outside- temperature driven control unit, if fitted. Refer to
the instructions with the control.
y
Set the thermostatic radiator valves to the desired settings.
6 720 610 577 GB (01.07)
13
Operating the Appliance
3.5
Combination Boilers: Setting the Hot
Water Temperature
Hot water temperature
On combi models, the hot water temperature can be set to
between approx. 40 °C and 60 °C using the temperature
control
.
The domestic hot water temperature is not shown on the display.
6 720 610 333-07.1O
Control Setting
Water Temperature
Anti-clockwise limit
approx. 40 °C
l
approx. 55 °C
Clockwise limit
approx. 60 °C
Table 2
“ECO” button
By pressing and holding the “ECO” button
, until the display
lights, you can switch between Comfort mode and Economy
mode.
Comfort mode: button is not lit (factory setting)
The appliance is held constantly at the set temperature. This
means that hot water is available almost instantaneously at the
tap. Consequently the appliance will switch on at intervals, even if
no hot water is being drawn.
14
6 720 610 577 GB (01.07)
Operating the Appliance
ECO mode with demand detection, button is lit
The demand detection function enables maximum gas and water
economy.
Briefly turning a hot water tap on and then off again signals
demand to the appliance which then heats up the water to the set
temperature.
Hot water is thus available in about 1 minute.
ECO mode, button is lit
Water is not heated up until hot water is drawn. This means that
there is a longer waiting period before hot water is available.
3.6
Summer Mode, Hot Water Only
(Combi Appliances)
With room thermostat
y
Turn temperature control
on the appliance anti-clockwise
as far as the stop.
The central heating is now turned off. The hot water function
and the mains power supply for the heating programmer and
timer remain switched on.
3.7
y
Frost protection (Combi Appliances)
Leave master switch switched on.
If the appliance is to be left for long periods switch the central
heating off:
y
Add a suitable anti-freeze fluid to the water in the central heating system.
Suitable products are available from Betz-Dearborn Tel.: 0151
4209563 and Fernox Tel.: 01799 550811.
6 720 610 577 GB (01.07)
15
Operating the Appliance
3.8
Fault Condition
In the unlikely event of a fault occuring while the appliance is in
operation:
The display then shows a fault code and the button
flash.
If the button
y
flashes:
Press and hold the button
until the display shows “– –”.
The appliance will then start up again and the display will show
the central heating flow temperature.
If the button
y
may also
does not flash:
Switch the appliance off and then on again at the master
switch.
The appliance will start up again and the central heating flow
temperature will be displayed.
If the fault remains and can not be cleared:
y
16
Call your approved installer or Greenstar Customer Service for
assistance, giving a description of the fault and, if possible, the
fault code from the facia display.
6 720 610 577 GB (01.07)
Tips on saving energy
4
Tips on saving energy
Heating economically
The boiler is designed to provide a high level of comfort while
keeping gas consumption and the resulting environmental effect
as low as possible. The gas supply to the burner is con-trolled
according to the level of demand for heat. The boiler con-tinues to
operate with a low flame if the demand for heat reduces. The technical term for this process is modulating control. Modulating control keeps temperature fluctuations small and provides even
distribution of heat throughout the home. This means that the
boiler may stay on for relatively long periods but will use less gas
than an appliance that continually switches on and off.
Central heating systems with room thermostats/thermostatic radiator valves
The central heating control on the boiler should be set to the maximum rated temperature of the central heating system or to position “E”, when the maximum central heating water temperature
obtained is 75 °C.
The temperature can be set individually in each room (except primary room with the room thermostat) using the thermostatic radiator valves. If you wish to have a lower temperature in the primary
room than in the other rooms, leave the room thermostat at the set
temperature and turn down the radiator using the radiator valve.
Reduced-output operation
Considerable fuel savings can be made by slightly reducing the
room temperature. Lowering the temperature by 1 °C can bring
about energy savings of up to 5 %. However, it is not advisable to
allow the room temperature to fall below +15 °C. The room temperature for reduced-output mode can be set separately on the
room thermostat. Instructions are given in the control unit operating instructions.
6 720 610 577 GB (01.07)
17
Tips on saving energy
Hot water
A lower setting on the hot water temperature control can result in
considerable energy savings.
For combi appliances:
The on-demand activation using the ECO-button makes possible the maximum savings of gas and water.
Now you know how to heat your home economically with the
Greenstar gas condensing boiler. If you have any other questions,
please contact your installer – or write to us.
18
6 720 610 577 GB (01.07)
General Information
5
General Information
Cleaning the Outer Case
Wipe down the outer case with a damp cloth. Do not use abrasive
or caustic cleaning agents.
Appliance details
If you ever need to call Greenstar Customer Service it helps us a
great deal if you can provide precise details of your appliance.
The information is printed on the appliance identification plate/
sticker (see page 9, item 295).
Your installer will have completed the Benchmark “log-book”
giving details of the boiler together with name, address and registration number. Have the “log-book” to hand when calling a
Service Engineer.
6
Maintaining your appliance
Your new Worcester Greenstar gas-fired appliance represents a
long-term investment in a reliable, high quality product.
In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is essential that your boiler receives regular, competent servicing and
maintenance checks beyond the initial 2 year guarantee period.
Regular service contracts can be arranged with your installer –
however if you have difficulty making a satisfactory arrangement
simply contact Worcester Heat Systems on 08705 256206 for
help.
If you would like to know more about Worcester’s extended warranty options please tick the appropriate box on your warranty registration card.
6 720 610 577 GB (01.07)
19
Service centres
7
Service centres
Region
Telephone
Scotland
NW
North West
Hours
(Mon-Fr)
(Sat)
(01625)
614308
8.00 am
TO
6.00 pm
08705
256206
W Western
Operating
Hours
(01506)
441687
Sc
E Eastern
Fax
Operating
8.30 am
TO
1.00 pm
(01905)
757536
SE South
SW South
Table 3
We have Service Centres situated throughout the country.
If you have a service request simply call our local rate number
above and your request will be routed to your Regional
Service Centre.
20
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Fault or breakdown
8
Fault or breakdown
This product is supported in the UK by Worcester Heat Systems
Ltd. – part of the Bosch Group.
A specialist factory trained field SERVICE ENGINEER is available
to attend a breakdown or manufacturing fault occuring on this
appliance.
No charge will be made for parts and/or labour providing:
• An appliance fault is found and the appliance has been
installed within the past 24 months. Reasonable evidence of
this must be supplied on request.
• 2nd year warranty is dependent on annual servicing.
A call-out charge will be made where:
• The appliance has been installed for over 24 months.
OR
• Our Field Service Engineer finds no fault with the appliance
(see NOTE).
OR
• The cause of breakdown is misuse or with other parts of your
plumbing/heating system, or with equipment not supplied by
Worcester.
NOTE: No appliance fault is found on over 30 % of all service call
outs.
If in doubt contact our Technical Helpline on 08705 266241.
IN THE EVENT OF AN APPLIANCE FAULT OR BREAKDOWN
please contact your Service Centre (see over). Your service
administrator will arrange for an engineer to call with the minimum
of delay; under normal circumstances this will be within the period
1-3 working days (excluding weekends) for priority breakdown situations (no hot water and/or heating service).
INVOICES FOR ATTENDANCE AND REPAIR WORK CARRIED
OUT ON THIS APPLIANCE BY ANY THIRD PARTY WILL NOT
BE ACCEPTED.
6 720 610 577 GB (01.07)
21
Your Bosch guarantee
9
Your Bosch guarantee
This appliance is guaranteed against faulty material or workmanship for a period of 24 calendar months from the date of installation subject to the following conditions and exceptions.
• That during the currency of this guarantee any components of
the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and
free of labour charges by Worcester Heat Systems Limited.
• That the householder may be asked to prove the date of installation, that the appliance was correctly commissioned and,
where appropriate, the first 2 year service has been carried out
to the satisfaction of Worcester Heat Systems Limited when
requested.
• That any product or part thereof returned for servicing under
the guarantee any components of the unit which are proved to
be faulty guarantee must be accompanied by a claim stating
the Model, Serial Number, Date of Installation.
• That Worcester Heat Systems Limited will not accept responsibility for damage caused by faulty installation, neglect, misuse or accidental damage, the non observance of the
instructions contained in the Installation and Users Instructions
Leaflets.
• That the appliance has been used only for normal domestic
purposes for which it was designed.
• That this guarantee applies only to equipment purchased and
used in Great Britain.
This guarantee is given in addition to all your normal statutory
rights.
22
6 720 610 577 GB (01.07)
Guarantee registration
10
Guarantee registration
You should complete and return the postpaid Guarantee Registration Card within 14 days of purchase.
The card will register you as the owner of your new Worcester
Greenstar appliance and will assist us in maintaining an effective
and efficient customer service by establishing a reference and
permanent record for your boiler.
This will not affect your statutory rights in any way.
Important:
For your own record:
Model
......................................................................................................................
Serial number:..........................................................................................
(See identity label inside appliance casing)
Type/size:...................................................................................................
Date of installation:................................................................................
Check that the Benchmark “log-book” has been completed by
your installer or service engineer.
EXCELLENCE COMES AS STANDARD
Worcester Heat Systems Limited. Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
SERIAL NUMBER. Copy the number of the Guarantee Card.
6 720 610 577 GB (01.07)
23
11
“ECO”-button not lit –
Comfort mode
“ECO”-button lit –
Economy mode.
6 720 610 333-07.1O
Hot water temperature
6 720 610 333-09.1O
6 720 610 333-11.1O
Switching off
If the
button flashes, press and
hold-in to reset the appliance. Refer to
page 16.
Fault Condition
Hot water only
Operating Instructions Quick Reference
Switching on
6 720 610 333-04.1O
Switching the central heating on
6 720 610 333-05.1O
Controlling the central heating
Set room thermostat to desired temperature or the outside-temperature
control unit to the appropriate setting.
Installation and Servicing Instructions
GREENSTAR HE system
Wall mounted condensing boiler for central heating
6 720 610 577-00.10
6 720 610 596 GB (03.02) OSW
ZB 7-28 HE system
GC-Number: 41 311 58
Contents
Contents
Safety precautions
3
Symbols
3
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
4
4
4
4
5
5
6
7
8
9
Details of the appliance
EC Declaration of Conformity
Standard package
Description of appliance
Accessories
Casing dimensions
Layout of appliance
Function
Electrical wiring diagram
Technical data
6
6.1
6.1.1
6.1.2
6.1.3
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
2
Installation regulations
10
6.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
Installation
Important remarks
Sealed systems
Siting the appliance
Wall mounting frame assembly
Pre-piping the system
Fitting the appliance
Checking the connections
Flue Systems
Siting the Flue Terminal
Installation of the flue
Flue duct preparation and assembly
11
11
11
13
14
14
15
16
16
17
18
20
7
4
4.1
4.2
4.3
4.3.1
Electrical connections
Connecting the appliance
Mains Voltage external controls connections
Wiring to your system
Pre-wired Remote S Plan
21
21
22
22
22
5
5.1
5.2
5.3
5.4
5.5
Commissioning
Commissioning
Switching the appliance on/off
Switching on the central heating
System controls
Appliances with optional plug-in diverter
valve: Setting hot water temperature
Frost protection
Pump anti-seize function
Fault Condition
23
23
24
24
24
5.6
5.7
5.8
2
25
25
25
25
Individual settings
Mechanical settings
Checking the size of the expansion vessel
Setting the central heating flow temperature
Changing the heating pump characteristic
Settings on the Bosch Heatronic
Operating the Bosch Heatronic
Selecting the pump control mode for central
heating mode (Service Function 2.2)
Setting the anti-cycle time
(Service Function 2.4)
Setting the maxim CH flow temperature
(Service Function 2.5)
Setting the switching difference
(Service Function 2.6)
Setting the heating output
(Service Function 5.0)
Setting the gas/air ratio
Converting the appliance to different
gas types
7.1 Setting the gas/air ratio
7.2 Testing combustion air/flue gas at set
heat output
7.2.1 Testing the O2 or CO2 level in the
combustion air
7.2.2 Testing CO and CO 2
26
26
26
26
26
27
27
27
27
28
28
28
28
29
29
31
31
31
8
Maintenance
8.1 Pre-Service Check List
8.2 Description of servicing operations
8.3 Replacement of Parts
8.3.1 PCB control board and transformer
8.3.2 Fan Assembly
8.3.3 Pump
8.3.4 3-way diverter valve
8.3.5 3-way diverter valve motor
8.3.6 Sensors
8.3.7 Gas Valve
8.3.8 Electrode assembly
8.3.9 Pressure gauge
8.3.10Expansion vessel
8.3.11Pressure Relief Valve
8.3.12Burner
8.3.13Primary Heat Exchanger
32
33
34
37
37
38
38
38
39
39
39
39
40
40
40
40
40
9
9.1
9.2
9.3
9.4
9.5
9.5.1
41
41
42
42
42
43
43
Appendix
Fault Codes
Short parts list
Heating/hot water output settings (N.G.)
Heating/hot water output settings (L.P.G)
Operational Flow diagrams
Central heating function
6 720 610 596 GB (03.02)
Safety precautions
Safety precautions
If you smell gas
B Turn off gas service cock at the meter.
B Open windows and doors.
B Do not operate any electrical switches.
B Extinguish any naked flames.
B Telephone your gas company.
If you smell fumes from the appliance
B Switch off appliance (see page 24).
B Open windows and doors.
Symbols
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.
Fitting and modifications
B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance wth the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use on sealed primary systems
only.
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
B Use only original spare parts!
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance
being electrically unsafe.
B There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
B The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Explain to the customer how the appliance works
and how to operate it.
B Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on
it.
B These instructions are to be left with the user or at
the Gas meter.
B Important: These instructions apply in the UK only.
6 720 610 596 GB (03.02)
3
Details of the appliance
1
1.1
Details of the appliance
1.3
EC Declaration of Conformity
• Wall-mounted appliance, siting not dependent on
room size
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler
Efficiency Directive, Electromagnetic Compatibility
Directive and the Low Voltage Directive.
Description of appliance
• Natural gas models are low-emission appliances
• Multifunction display
• Bosch Heatronic control system
• Automatic ignition
CE-0085 BL 0507
• Modulating control
Category
UK
II2H 3P
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
Appliance Type
C13, C33
PIN
Table 1
• Concentric flue/air duct with testing point for
CO2/CO
• Regulated speed fan
1.2
Standard package
• Gas condensing boiler for central
heating
• Pre-mix burner
• Temperature control for central heating
• Safety temperature limiter in 24 V electrical circuit
• Wall mounting frame
• Three-speed central heating pump with automatic
vent
• Clamp for securing flue duct kit
• Relief valve, pressure gauge, expansion vessel
• Fixings (screws etc.)
• Flue gas temperature limiter (105 °C)
• Set of documentation for appliance
• Condensate Trap
• Pre-plumbing manifold
• Connecting possibility for S-Plan System.
• Condensate drain pipe.
4
6 720 610 596 GB (03.02)
Details of the appliance
1.4
Accessories
• Standard horizontal flue kit at 100 mm outside
diameter for flues upto 4 m in length.
• Flue duct kits for horizontal (125 mm outside
diameter) for flue lengths upto 13 m and vertical flue
systems for flue lengths upto 15 m. Fitting instructions are sent with these kits.
• Heating programmer
• Timer
• Security kit
• Motorised valve is available as an optional extra. If
this option is used then the DT2, TR2 Optimising
Room Thermostat and the Night Set Back Module
will be required.
1.5
Casing dimensions
min.
min.
5*
5*
Z
Y
600*
X
906
861
850
120
101
13
103
30
200
35
360
395
*
200
440
6 720 610 601- 01.3O
Fig. 1
13
101
103
X
Y
Z
*
Manifold assembly
Outer case
Facia cover
Standard Concentric Horizontal Flue System: min. 310 mm
Alternative Concentric Flue System: min. 250 mm
Standard Concentric Horizontal Flue System: 158 mm
Alternative Concentric Flue System: 121 mm
Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
For servicing the appliance
6 720 610 596 GB (03.02)
5
Details of the appliance
1.6
Layout of appliance
120
221.1
349
221.2
234.1
234
27
226
20
102
32.1
29
36
271
6
415
43
9
63
416
358
18
64
423
7
18.1
418
15
8.1
295
4
417
6 720 610 596-01.2O
Fig. 2
4
6
7
8.1
9
15
18
18.1
20
27
29
32.1
36
43
63
64
102
120
221.1
6
Heatronic control
Heat exchanger safety temperature limiter
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Relief valve
Pump
Pump speed selector switch
Expansion vessel
Automatic air vent
Air gas Mixer unit
Electrode assembly
Temperature sensor in CH flow
CH flow
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
Inspection window
Fixing points
Flue duct
221.2
226
295
234
234.1
271
349
358
415
416
417
418
423
Combustion air intake
Fan assembly
Appliance type sticker
Testing point for combustion products
Testing point for combustion air
Flue duct
Cover plate for twin flue duct connection
Condensate trap
Cover plate for cleaning access
Condensate collector
Clip for fixing outer case
Data plate
Siphon
6 720 610 596 GB (03.02)
Details of the appliance
1.7
Function
Fig. 3
4
6
7
8.1
9
13
15
18
20
26
27
29
29.1
30
32
33
35
36
43
45
47
52
52.1
55
56
57
61
63
64
69
Bosch Heatronic control
Temperature limiter, heat exchanger
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Manifold
Safety valve
Central heating pump
Expansion vessel
Charging valve
Automatic vent
Mixer unit
Bi-metallic thermostat for combustion air compensation
Burner
Flame sensing electrode
Igniter electrode
Heat exchanger with cooled combustion chamber
Temperature sensor in CH flow
CH flow
Gas inlet
CH return
Solenoid valve 1
Solenoid valve 2
Filter
Gas valve CE 427
Main valve disc
Reset button
Adjustable gas flow restrictor
Adjusting screw for min. gas inlet flow volume
Control valve
6 720 610 596 GB (03.02)
71
72
84
88
221
226
229
234
234.1
317
358
423
443
Storage water heater outflow (only with motorised valve)
Storage water heater return (only with motorised valve)
Motor (optional extra)
3-way valve (optional extra)
Flue duct
Fan
Inner casing
Testing point for flue gas
Testing point for combustion air
Display
Condensate trap
Siphon
Diaphragm
7
Details of the appliance
1.8
Electrical wiring diagram
o - orange
bl - black
r - red
33
365
364
61
317
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
310
136
135
312
328
302
313
151
318
315
124 789
L N Ns Ls LR
161
p
p
300 314
p
84
M
328.1
9
M
6
M
r
r
mains supply
18
o
226
52
52.1
56
o
bl
bl
bl
bl
36
32
6 720 610 601-02.2O
Fig. 4
4.1
6
9
18
32
33
36
52
52.1
56
61
84
135
136
151
153
8
Ignition transformer
Temperature limiter, heat exchanger
Flue gas temperature limiter
Pump
Flame sensing electrode
Ignition electrode
Temperature sensor in CH flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Motor (optional extra)
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
161
226
300
302
310
312
313
314
315
317
318
328
328.1
363
364
365
366
367
Link
Fan
Code plug
Earth connection
Temperature control for hot water
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Connector for programmer TA212E
Terminal block for programmer
Digital display
Connector for timer
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
6 720 610 596 GB (03.02)
Details of the appliance
1.9
Technical data
Units
Natural gas
Propane
kW
kW
kW
29.1
28.8
27.2
29.1
28.8
27.2
Max. rated heat input net
kW
27.5
27.5
Min. rated heat output net 40/30˚C
Min. rated heat output net 50/30˚C
Min. rated heat output net 80/60˚C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
Min. rated heat input net
kW
7.6
10.8
Max. rated heat output net 40/30˚C central heating
Max. rated heat output net 50/30˚C central heating
Max. rated heat output net 80/60˚C central heating
Maximum gas flow rate - After 10 minutes from lighting
Natural gas G20 (CVnet 34.02 MJ/m3)
m3/h
2.9
-
LPG (CVnet 88 MJ/m3)
kg/h
-
2.1
Natural gas G20 (CVnet 34.02 MJ/m3)
mbar
20
-
LPG (CVnet 88 MJ/m3)
mbar
-
37
bar
0.75
0.75
l
10
10
Flue gas temp. 80/60˚C, rated/min. load
˚C
67/55
67/55
Flue gas temp. 40/30˚C, rated/min. load
˚C
43/32
43/32
Residual delivery pressure
(inc. pressure drop in air intake duct)
Pa
80
80
CO2 level at max. rated heat output
CO2 level at min. rated heat output
%
%
9.2
8.8
10.8
10.5
5
5
%
90.7
90.7
l/h
2.3
2.3
4.8
4.8
230
230
Gas supply pressure
Expansion vessel
Charge pressure
Total capacity
Flue
NOx-class
SEDBUK figure, Band A
Condensate
Max. condensation rate (tR = 30˚C)
pH-value, approx.
General Data
Electrical power supply voltage
AC ... V
Frequency
Hz
50
50
Max. power consumption
W
101
101
dB(A)
36
36
Noise output level
Appliance protection rating
IP
X4D
X4D
Max. CH flow temperature
˚C
nom. 90
nom. 90
Max. permissible operating pressure (CH)
bar
2.5
2.5
Permissible ambient temperatures
˚C
0 - 50
0 - 50
l
3.75
3.75
kg
46
46
Nominal capacity of appliance
Weight (excluding packing)
Table 2
6 720 610 596 GB (03.02)
9
Installation regulations
2
Condensate analysis, mg/l
Ammonium
1.2
Nickel
0.15
≤ 0.01
Mercury
Cadmium
≤ 0.001
Sulphate
Chromium
≤ 0.005
Zinc
≤ 0.015
Halogenated
hydrocarbons
≤ 0.002
Tin
≤ 0.01
Hydrocarbons
0.015
Vanadium
Copper
0.028
pH-value
Lead
≤ 0.0001
1
≤ 0.001
4.8
Table 3
Flue system
HORIZONTAL 100 mm – Standard
Overall Diameter of Duct
mm
100
Flue Terminal / Duct
Assembly Length
mm
600
Extension Duct Length
mm
1000
Max.
4m
Installation regulations
Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.
• BS 6798: Specification for the installation of gas
fired hot water boilers of rated input not exceeding
60kW
Table 4
• BS 5449: Central Heating for Domestic Premises
ALTERNATIVE HORIZONTAL 125 mm FLUE
SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1030
• BS 5546: Installation of gas hot water supplies for
domestic purposes
Max.
13 m
(including
turret)
Table 5
• BS 5440:1: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Flues
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28mm (R1).
VERTICAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1360
Max.
15 m
• BS 7074:1: Code of practice for domestic heating
and hot water supply
• BS 7671: Requirements for Electrical Installation.
These instructions must be followed.
Table 6
Elbow - 90 ° Equivalent length 2 m
Bend - 45 ° Equivalent length 1m
Gas supply
Total length of gas supply pipe
(metres)
3
6
Pipe diameter
(mm)
9
Gas discharge rate (m3/h)
8.7
5.8
4.6
22
18.0
12.0
9.4
28
Table 7
10
6 720 610 596 GB (03.02)
Installation
3
Installation
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
3.1
Fixing of the appliance, gas and flue connections, commissioning of the system
and electrical connections may only be
carried out by competent persons authorised by CORGI.
Important remarks
B Appliance should only be installed in sealed central
heating systems.
B To avoid gas formation in the system, galvanised
radiators or pipes must not be used.
B If a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.
B Add a suitable anti-freeze fluid compatible with aluminium to the water in the central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
B In our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.
6 720 610 596 GB (03.02)
3.2
Sealed systems
The appliance must not be operated without the system
being full of water, properly vented and pressurised.
The expansion vessel has a volume of 10 litres and is
charged to a pressure of 0.75 bar.
The water capacity of the system is shown in table 10,
page 26. If a greater capacity is required then an additional expansion vessel must be fitted into the system
return as close to the appliance as possible. The system
pressure can be set up to a maximum of 1.5 bar with 1
bar being the normal setting.
If the system pressure is greater than 2.5 bar when the
appliance is operating at maximum temperature then an
additional expansion vessel must be fitted into the system return as close to the appliance as possible.
The filling point must be at low level and arranged as
shown in figs. 5 and 8.
The pressure relief valve is set to operate at 3 bar.
There must be no connection to the mains without the
approval of the local water company. All connections in
the system must be capable of withstanding a pressure
of up to 3 bar and the radiator valves conform to the
requirements of BS 2767:10.
If Thermostatic Radiator Valves are fitted then it is recommended that primary radiator is left open.
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
No galvanised radiators or pipes must be used.
If any system water treatment is required then
only products suitable for use with Aluminium
shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the
manufacturers instructions. The use of any other
substances will invalidate the guarantee. The pH
value of the system water must be less than 8 or
the appliance guarantee will be invalidated.
A drain cock to BS2879 must be fitted to the lowest
point of the system.
IMPORTANT: Check that no dirt is left in the
water pipework as this could damage the appliance. Thoroughly flush the heating system and
the mains water supply before fitting the appliance to the wall in accordance with the recommendations of BS7593:1992.
11
Installation
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Heating Return
APPLIANCE
LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
6 720 610 601-04.1O
Cylinder Return
RV
Heating Flow
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Hot Water Flow
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
System layout if using built-in diverter valve
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
Diverter
Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
Fig. 6
12
6 720 610 601-05.1O
APPLIANCE
LV
Hot Water Flow
Cylinder Return
RV
Heating Return
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Heating Flow
Fig. 5
System layout if using external diverter valve
6 720 610 596 GB (03.02)
Installation
LV
RV
INDIRECT
CYLINDER
LV
RV
Refer to
Appliance
Water
Flow
Diagram
Heating Return
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Heating Flow
RV
CH
Zone
Valve
Safety Discharge
DHW Zone Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
6 720 610 601-06.1O
LV
Hot Water Flow
APPLIANCE
LV
RV
Fig. 7
Cylinder Return
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
System layout if using twin zone valves (S) plan
Sealed system filling and make up
Make up
vessel
Heating return
Heating return
Auto
air vent
Non return Non return
valve
valve
Hose union
Stop
cock
Stop cock
Test cock
Temporary hose
Non return
valve
Fill point
1000mm (39 in)
above the highest
point of the system.
6 720 611 137 - 29.1O
Fig. 8
3.3
Siting the appliance
Regulations concerning the Installation Site
B Relevant national regulations must be complied with
section 3.8.1.
B Consult the installation instructions for details of minimum clearances required.
Combustion air
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
Substances classed as corrosion-promoting include
halogenated hydrocarbons which contain chlorine and
fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and
household cleaners, for example.
6 720 610 596 GB (03.02)
Surface temperature
The max. surface temperature of the casing and the flue
is less than 85 °C.
This means that, no special safety precautions are
required with regard to flammable building materials
and fitted furniture. The specified clearences must be
maintained.
Cupboard/Compartment
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS6798 and BS5440:2 are followed. The low
casing losses from the appliance eliminate the need for
ventilation openings in the compartment.
13
Installation
3.4
Wall mounting frame assembly
B Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 9. Use
the inner lugs on the top and bottom horizontal sections for the appliances that are 440 mm wide.
B Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
6 720 610 576-11.1O
Fig. 11
6 720 610 576-04.1O
Fig. 9
3.5
Pre-piping the system
B Hold the wall-mounting frame against the wall ensuring that it is vertical.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 18.
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
200
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 12 Manifold
43
47
112
171
172
6 720 610 576-05.1O
Fig. 10
14
CH flow
CH return
Gas cock
Optional cylinder flow (used only with motorised valve)
Optional cylinder return (used only with motorised valve)
B A drain tap should be fitted at the lowest point of the
central heating system.
B WRAS approved filling loop must be fitted.
6 720 610 596 GB (03.02)
Installation
Condensate Termination and Route
The condensate connection on the Greenstar appliances is in 22 mm plastic. The pipe should be extended
and run away from the appliance with a constant fall of
2.5 ° or 40 mm in every metre.
The condensate pipe can terminate into any of four
areas:
Boiler
Boiler
Ø 22 min.
No length
restriction
• The pipe run should take the shortest practical route.
Sink
Siphon
External length of
pipe 2m min.
Siphon
Ø 22 min.
75 min. trap
Open end of pipe
direct into gully,
below ground but
above water level.
Use waterproof pipe work
insulation in very exposed
positions
The gradient of the discharge pipe
should be 2.5° (40 mm/m) minimum
Open end of pipe direct
into gully, below ground
but above water level
An internal waste system
An external waste system
Boiler
Ø 22 min.
Internal soil
and vent stack
No length
restriction
Sink
Siphon
Ø 22 min.
75 min. trap
75 min. trap
450 min.
No length
restriction
The gradient of the discharge pipe Invert
should be 2.5° (40 mm/m) minimum
The rainwater system
• The pipework should be insulated with weather
resistant insulation.
• The pipe should terminate as close as possible to the
ground or drain, whilst still allowing the condensate
to safely disperse. This would prevent wind blowing
up the pipe.
The gradient of the discharge pipe should be
2.5° (40 mm/m) minimum
Boiler
External condensate pipework
All Greenstar condensing boilers have within a
syphonic condensate trap. Rather than the condensate
constantly dripping into the discharge pipe, the condensate is collected into a trap which releases it in
100 ml quantities.
This will help prevent freezing occurring.
If there is no alternative and the condensate pipe has to
be externally run, the following should be considered:
Open end of pipe
direct into gully,
below ground but
above water level
The gradient of the discharge pipe
should be 2.5° (40 mm/m) minimum
• The pipework should be installed with the minimum
of horizontal runs and with a downward slope of at
least 2.5 °.
3.6
Fitting the appliance
An external purpose made soakaway
Benchmark: For optimum performance after installation, this boiler and its
associated central heating system must
be flushed in accordance with the
guidelines given in BS5793:1992
“Treatment of water in domestic hot water central heating systems”.
6 720 610 596 -03.1O
Fig. 13
Whilst all of the above methods are acceptable it is
always the best practice to terminate the condense
pipe via an internal waste system.This will eliminate the
need for any external condensate pipe runs which can
be susceptible to freezing in extreme weather.
B Remove packing, taking care to observe the instructions on the packing.
B Lie the boiler on its back.
Removing the outer case
i
The outer case is secured against unauthorised removal by two clips (electrical
safety).
Always secure the outer case with those
clips again after refitting.
B Turn the clips with a screwdriver (1.).
B Slide the outer case upwards and then forwards to
remove (2.).
6 720 610 602 - 03.1O
Fig. 14 Position of the condensate drain
6 720 610 596 GB (03.02)
15
Installation
B Remove the plastic caps from the boiler connections.
3.7
Checking the connections
Water connections
B Check that the O-rings or seals are in place before
tightening the connection.
B Turn on the service valves for central heating flow
and return and fill the heating system through a
WRAS approved filling loop.
B Check all seals and unions for leaks (testing pressure max. 3.0 bar as indicated by pressure gauge).
B Check all connections for leaks.
2.
1.
Gas supply pipe
6 720 610 332-07.1R
Fig. 15
B Check that the seal is in place before tightening the
connection.
B Turn off gas cock to protect gas valve against damage from excessive pressure.
B Check gas supply pipe.
B Release the pressure on the gas supply pipe.
Fixing the appliance
B Fit the washers onto the gas and water connections.
3.8
B Lift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
B Take care not to disturb the washers on the connections.
The only flue systems that may be used are those supplied by Worcester Heat Systems.
The flue system must be installed in accordance with
the requirements of BS5440:1.
Connecting the flue duct
B Fit flue duct connector onto appliance flue spigot.
B Secure with the two screws supplied.
1
3
4
2 .
6 7 2 0 6 1 0 3 3 2 -0 9 .2 R
Fig. 16
B For remaining installation of flue assembly, refer to
the relevant installation instructions.
16
Standard 100 mm flue system
The standard concentric flue system provides for a horizontal length of upto 4 m. Full instructions for fitting this
flue are in Subsection 3.8.2 “Installation of the flue”.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue
systems are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13 m.
A vertical flue system upto a height of 15 metres is available.
45° and 90° flue bends can be used with a corresponding reduction in flue length of 2m for each 90° bend and
1 m for each 45° bend used.
1 .
2
Flue Systems
IMPORTANT: Any horizontal flue system fitted to a
condensing boiler must incline towards the appliance at
an angle of 3 % (30 mm per metre length) to prevent
condensate dripping from the flue terminal. This
means that the clearance above the appliance
must be increased to match the duct length.
Refer to fig. 1 on page 5.
6 720 610 596 GB (03.02)
Installation
3.8.1 Siting the Flue Terminal
The flue must be installed in accordance with
BS 5440:1 and the Building Regulations. Flue terminals in carports and under balconies are to be avoided.
The terminal must be positioned so that it does not
cause an obstruction nor the combustion products a
nuisance. See fig. 17 and table 8.
The terminal will, at times, give out a plume of water
vapour and consideration must be given to this when
choosing a terminal position. Keep clear of security
lighting, activated by passive infra-red sensing heads.
If the terminal is less than 2 m above a surface to which
people have access then a guard must be fitted. The
guard must be evenly spaced about the terminal with a
space of 50 mm in each direction and fixed with plated
screws.
A guard Type K6 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
Fig. 17
Minimum dimensions of flue terminal positions (all types) (see fig. 17)
Dimension
A
1)
B 1)
C
1)
Terminal Position (kW input expressed in net)
Balanced flues room sealed: Fanned draught
Directly below an opening, air brick, opening windows, etc.
300 mm
Above an opening, air brick, opening window, etc.
300 mm
Horizontally to an opening, air brick, opening window, etc.
300 mm
D
Below gutters, soil pipes or drain pipes
75 mm
E
Below eaves
200 mm
F 2)
Below balconies or car port roof (lowest point)
200 mm
G
From a vertical drain pipe or soil pipe
150 mm
H
From an internal or external corner
300 mm
I
Above ground roof or balcony level
300 mm
J
From a surface facing the terminal
600 mm
K
From a terminal facing the terminal
1200 mm
L
From an opening in the car port (e. g. door, window) into the dwelling
1200 mm
M
Vertically from a terminal on the same wall
1500mm
N
Horizontally from a terminal on the same wall
O
From the wall on which the terminal is mounted
Not applicable
300 mm
P
From a vertical structure on the roof
Not applicable
Q
Above intersection with roof
Not applicable
Table 8
1)
2)
In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
Not recommended.
6 720 610 596 GB (03.02)
17
Installation
3.8.2 Installation of the flue
The standard 100 mm diameter horizontal flue system
is suitable for lengths upto 4 m.
Flues upto 650 mm do not require an extension duct
assembly.
Flues between 1600 mm and 4000 mm require extension duct assemblies.
NOTE: Flue lengths between 650 mm and 730 mm
cannot be accomodated. Refer to fig. 19, 20, 21.
Standard system comprise: Flue turret - Flue turret
clamp - Terminal assembly - Wall sealing - plates.
Extension kit comprises: Air duct - Flue duct - Duct
clamp. Refer to fig. 22.
Instructions for fitting other flue systems are packed
with the relevant flue kit.
Check that the position chosen for the appliance is satisfactory. Refer to fig. 18.
Terminal
Assembly
Flue
Turret
Maximum 650 mm
Outer
Wall
No
Clamp
6 720 610 602 - 08.1O
Fig. 19 Standard Flue
Drilling point for
flue duct opening
Centre line of
flue/air duct
H
Centre
line of
flue
opening
and
appliance
120
3%
(30 mm/metre)
Top of the
wall
mounting
frame
Appliance
H
Standard Horizontal Flue 158 mm
Optional Horizontal Flue 121 mm
6 720 610 602-07.2O
Fig. 18 Marking the position of the side flue opening
18
6 720 610 596 GB (03.02)
Installation
Terminal
Assembly
Flue
Turret
Maximum 1600mm
Outer
Wall
Clamp
No
Clamp
Extension
Duct
6 720 610 602 - 09.1O
Fig. 20 Flue with one extension
Terminal
Assembly
Flue
Turret
No
Clamp
Outer
Wall
Clamp
Clamp
Extension
Duct
Extension
Duct
6 720 610 602 - 10.1O
Fig. 21 Flue with extensions
Duct Clamp
Flue
Turret
Extension Air Duct
Extension Flue Duct
Terminal Assembly
Wall Sealing Plates
6 720 610 602 - 11.1O
Fig. 22 Flue components
6 720 610 596 GB (03.02)
19
Installation
3.8.3 Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 23, 24.
Outer
Wall
Face
Flue Terminal
L
Raised Ring
locating the
terminal relative
to the outside
wall face
120
6 720 610 576 - 20.1O
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 12.1O
BOILER
Fig. 23 Flue length - rear
Fig. 25 Flue terminal position
L
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must face downwards.
The assembly will be made easier if a solvent free
grease is lightly applied i.e Vaseline, to the male end of
the ducts.
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assembly.
Push the assembly through the wall and fix the turret to
the appliance with the clamp. Refer to fig. 26.
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 13.1O
BOILER
Flue Turret
Fig. 24 Flue length - side
Mark off the lengths shown onto the ducts and cut to
length. The cuts must be square and free from burrs.
Terminal assembly outer (air) duct - L- 70 mm, inner
(flue) duct - L- 50 mm.The measurement is made from
the ridge at the terminal indicating the outer face of the
wall. Refer to fig. 25.
Extension air duct - L- 70mm, flue duct - L- 50 mm.
The measurement is from the formed end.
Clamp
Flue Socket
on Boiler
Air and
Flue Duct
Entry into
silicone
rubber seals
6 720 610 602 - 14.1O
Fig. 26 Flue turret
Ensure that the turret is fully entered into the socket on
the boiler. From the outside fix the outer wall plate to the
terminal and, after ensuring the duct is properly i nclined
towards the boiler, fix the plate to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal an be fixed with corrosion resistant
screws.
20
6 720 610 596 GB (03.02)
Electrical connections
4
Electrical connections
B Always disconnect the power supply to
the appliance at the mains before carrying out any work on the electrical systems and components.
B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 28.
3
0
4
2
5
1
All control and safety systems are built into the appliance.
E
B Allow mains cable to protrude at least 50 cm from
wall.
B To make splash-water proof (IP): cut the cable grommet hole size to match diameter of cable, see Fig. 29.
It must be possible to isolate the appliance. The appliance must be earthed.
The appliance must be connected to the mains through
a 6 A double pole isolator with a contact separation
3 mm in all poles and supplying the appliance and controls only. The wiring must comply with the current
requirements of the IEE Wiring Regulations and any
local regulations which apply.
6 720 610 332 -11.1R
Fig. 28
B Cut cable grommet to diameter of cable.
3
0
4
2
5
1
E
• Supply: 230 V ~ 50 Hz, 140 Watts
• Mains cable: PVC insulated 0.75 mm 2
(24 x 0.20 mm) to BS6500-Table 6.
Temperature rated 100˚C.
• Protection IPX4D
• External fuse 3 A.
4.1
8-9
5-7
Connecting the appliance
To gain access to the mains connection remove the
drop down facia cover. The drop down cover is
removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
release the cover. Lift cover from the appliance.
After installation (or in the event of an electrical fault) the
electrical system shall be checked for short circuits,
fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.
10-12
3
2
6 720 610 332-12.1R
Fig. 29
B Feed cable through cable grommet and connect the
mains supply cable, see Fig. 30.
B Secure cable in cable grommet by means of cable
grip.
B Pull out cover panel at the bottom and remove. Refer
to fig. 27.
0
13-14
L
N NS L S L R
4
5
1
E
4130-14.1R
6 720 610 332-10.1R
Fig. 30
Fig. 27
6 720 610 596 GB (03.02)
21
Electrical connections
Mains Voltage external controls
connections
NOTE: Only double insulated controls not requiring an earth can be used
Ns Ls LR
ST8
Switched Live
• Observe wiring details given in Section.
• Remove the pre-fitted link from L S and LR.
Motor
230 V Room Thermostat Connections
230 V Programmer Connections
Ns Ls LR
ST8
ed
it ch
Timer
Sw
Live
ve
ra
l
Li
ut
d
Ne
he
Live
itc
Neutral
Series
connection
to be made
safe
Sw
Live
230 V room thermostat and
Programmer Connections
• If a room thermostat is required, it can be wired to the
remote junction box according to the proprietary
instructions.
• If a frost thermostat is required, it can be wired to the
remote junction box.
System
Water
Valve/s)
Neutral
Remove Link
Live
Switched Live
Neutral
Live
ST8
Room Stat
Ns Ls LR
4.3.1 Pre-wired Remote S Plan
If the system is fully pre-wired at a juction box remotely
from the boiler, it can be easily connected back to the
Worcester System Boiler.
Drop down the facia and gain access to the boiler wiring centre as described in section 4.1.
Connect the junction box as shown (see fig. 32)
Important notes:
Tank Stat
4.2
Permanent
Mains supply
(NOT ALLOWED)
RemotePre-wired
Junction Box
Motor
6 720 610 576 - 22.1O
L out
Fig. 31
4.3
Wiring to your system
External pump
(DISCONNECT
AND REMOVE)
Terminal Strip
Boiler/pump
demand from
junction box.
E L N
Mains electrical supply to junction box
(NO OTHER SUPPLY TO
JUNCTION BOX ALLOWED)
Outside of Boiler
The following diagrams show the wiring options for your
system. Any other combinations of wiring are not recommended as it would increase complexity of the system. Please also follow wiring instructions of any
proprietary system. Worcester Heat Systems cannot
be held responsible for any incorrect wiring external
from the boiler.
Mains electrical supply: The boiler should be connected
to the mains supply as described in Section 4.1. This
also provides the electrical supply to the system. Note:
In all cases this must be the only electrical supply
to the system. This ensures the safety of a single
fused supply.
Pump: The boiler is fitted with an internal pump.
These diagrams show connection details of two popular proprietary systems (Honeywell and Siebe, formerly
ACL ), for systems from other manufacturers instructions or contact Worcester Technical Service 08705
266241 for assistance.
Upon completion of the electrical connections check
for earth continuity, correct polarisation and resistance
to earth.
22
Inside of Boiler
L
N NS L S L R
MAINS ONLY
6 720 610 603 -04.2O
Fig. 32
6 720 610 596 GB (03.02)
Commissioning
5
Commissioning
27
136 365
61
317 366 367
358
ECO
364
363
135
8.1
E
310
295
15
170
171
172
173
170
6 720 610 576-07.2O
Fig. 33
8.1
15
27
61
135
136
170
171
172
173
295
310
317
358
363
364
365
366
367
Pressure gauge
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for central heating
Service cocks on CH flow and return
Optional cylinder flow (used only with motorised valve)
Gas cock (shown in on position)
Optional cylinder return (used only with motorised valve)
Appliance type sticker
Temperature control for hot water
Multifunction display
Condensate trap
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
6 720 610 596 GB (03.02)
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
i
The operational CO2 level is set at the factory and no adjustment is necessary when
installing a natural gas fired appliance.
Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance
with the guidelines given in BS7593:1992 - Treatment
of water in domestic hot water systems. Full instructions are supplied with proprietary cleansers sold for
this purpose. If an inhibitor is to be used after flushing,
it should be used in accordance with the inhibitor manufacturers instructions.
To drain the appliance shut the system valves and open
the system drain point.
Suitable flushing agents and inhibitors are available
from Betz/Dearborn Tel.: 0151 4209563 and Fernox
Tel.: 01799 550811. Instructions for use are supplied
with the these products.
23
Commissioning
B Before commissioning, the gas supply pressure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7).
Natural gas appliances must not be operated if
the gas supply pressure is below 18 mbar or
above 24 mbar. LPG appliances must not be
operated if the supply pressure is not 37 mbar
at the inlet to the appliance.
B Unscrew the condensation trap (358) and pull out,
fill with approx. 1/4 l of water and refit. Refer to
fig. 33.
B Adjust charge pressure of expansion vessel to static
head of the central heating system (see page 26).
B Open all system radiator valves.
B Turn on service valves (170), fill central heating system to pressure of 1 - 2 bar through the WRAS
approved filling loop. Refer to fig. 33.
B Vent radiators.
B Refill heating system and set the pressure to 1 bar.
B Turn on cold water service cock (173). Refer to
fig. 33.
B Check that the gas type specified on the identification plate matches that of the gas supply.
B Turn on gas cock (172). Refer to fig. 33.
5.2
Switching off the appliance
B Set the master switch to (0).
The green indicator lamp goes out.
B Always disconnect the appliance from
the power supply (fuse, circuit breaker)
before carrying out any work on the
electrical systems or components.
5.3
Switching on the central heating
The central heating flow temperature is adjustable
between 35˚C and 88˚C. Refer to table 11, page 26.
B Turn the temperature control
to set the flow temperature to a level appropriate to the type of central
heating system:
– Underfloor heating: e.g. setting “3”
(approx. 50˚C)
– Low-temperature heating: setting “E”
(approx. 75˚C)
– Central heating systems for flow temperatures up
to 88 °C: limited “max” setting for low-temperature
operation (see page 26).
When the burner is alight, the red indicator lamp
lights up.
Switching the appliance on/off
Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the central heating flow temperature, when the
appliance is operating in the central heating mode.
6 720 610 333-05.1O
Fig. 35
5.4
6 720 610 333-04.1O
Fig. 34
i
System controls
B Set room thermostat to the desired room temperature.
B Set outside - temperature driven control unit, if fitted.
Refer to the instructions with the control.
B Set the thermostatic radiator valves to the desired
settings.
If the display alternates between -II- and
the central heating flow temperature, the
trap filling programme is active.
The trap filling programme ensures that the condensation trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
24
6 720 610 596 GB (03.02)
Commissioning
5.5
Appliances with optional plug-in
diverter valve: Setting hot water
temperature
B Do not set the temperature higher than
60˚C for normal operation.
B Only use temperatures of up to 70˚C
temporarily for thermal disinfection purposes.
B Set the hot water temperature by means of the temperature control
on the appliance.
5.6
Frost protection is only guaranteed from the external
room temperature thermostat.
B Leave master switch switched on.
If the appliance is to be left for long periods switch the
central heating off:
B Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
5.7
i
6 720 610 333-07.1O
Control Setting
Water Temperature
Anti-clockwise limit
approx. 10˚C
(frost protection)
approx. 60˚C
Clockwise limit
approx. 70˚C
Table 9
ECO button
Pressing and holding the ECO button
Comfort mode to ECO-mode.
switches from
Comfort mode, ECO button is not lit (factory setting)
Comfort mode the hot water tank has priority. The hot
water cylinder is first heated up to the set temperature.
The appliance then switches to central heating mode.
ECO mode, button is lit
In ECO mode the appliance switches between central
heating mode and cylinder charging mode every 12
minutes.
6 720 610 596 GB (03.02)
Pump anti-seize function
This function prevents the central heating
pump seizing after long periods of
inactivity.
Every time the pump is switched off, a timer is started.
If after 24 hours the pump has not run again, it is
switched on for a period of 5 minutes.
Fig. 36
Frost protection
5.8
i
Fault Condition
A list of faults that may occur is given on
page 41.
In the unlikely event of a fault occuring while the appliance is in operation:
The display then shows a fault code and the button
may also flash.
If the button
flashes:
B Press and hold the button
until the display shows
“– –”.
The appliance will then start up again and the display
will show the central heating flow temperature.
If the button
does not flash:
B Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the central heating flow temperature will be displayed.
25
Individual settings
6
Individual settings
6.1
Mechanical settings
6.1.1 Checking the size of the expansion vessel
Maximum pressure at maximum CH flow temperature is
2.5 bar. If the pressure is greater than this then fit an
extra expansion vessel. Refer to table 10.
System Capacity – BS7074:1
Expansion Vessel Pressure and System Capacity
Expansion Vessel
litres
10
Expansion Vessel
Charge Pressure
bar
0.75
System
pressure
and
capacity
B Rotate yellow button through 180° and replace (dot
facing inwards).
The CH flow temperature is no longer limited.
Control setting
CH flow temperature
1
2
3
4
5
E
max
approx. 50˚C
approx. 55˚C
approx. 60˚C
approx. 65˚C
approx. 70˚C
approx. 75˚C
approx. 88˚C
Table 11
1 bar
litres
82
1.5 bar
litres
46
6.1.3 Changing the heating pump characteristic
The speed of the central heating pump can be altered
on the pump terminal box.
Table 10
Setting the central heating flow temperature
The central heating flow temperature can be set to
between 50˚C and 88˚C.
i
6.1.2
i
With underfloor heating systems, observe
the maximum permissible flow temperatures.
H
0,7
(bar)
0,6
0,5
Limited maximum setting for low-temperature
operation
The temperature control is factory limited to setting E,
giving a maximum flow temperature of 75˚C.
Adjustment of the heating output to the calculated heat
demand is not required by the heating systems regulations.
3
0,4
2
0,3
0,2
1
0,1
Removing the maximum setting limit
For heating systems which require higher flow temperatures, the maximum setting limit can be removed.
B Lift off the yellow button on the temperature control
with a screwdriver.
At switch position 1, maximum output is
not delivered if hot water mode is active.
Position 1 must not be used on combi appliances.
0
0
200
400
600
800
1000 1200 1400 1600
Q (l/h)
6 720 610 576-23.2O
Fig. 38
1
2
3
H
Q
Pump characteristic for switch position 1
Pump characteristic for switch position 2
Pump characteristic for switch position 3
Residual delivery pressure
Water circulation rate
6 720 610 332-27.1O
Fig. 37
26
6 720 610 596 GB (03.02)
Individual settings
6.2
Settings on the Bosch Heatronic
6.2.1 Operating the Bosch Heatronic
The Bosch Heatronic enables easy setting and checking of a large number of appliance functions.
This description is limited to those functions required
for commissioning.
For a full description of all available functions, please
refer to the Service booklet for the Engineer, order no.
7 181 465 346.
5
2
Storing a setting
B Level 1: press and hold the
button until the display shows [ ].
B Level 2: press and hold the
and
buttons simultaneously until the display shows [ ].
After completing the settings
B Reset the temperature controls
original positions.
6.2.2
1
i
Service button
“Chimney sweep” button
Temperature control for central heating
Temperature control for hot water
Display
Selecting service function:
i
Note the positions of the temperature
controls
and
. After completing the
settings, return the temperature controls
to their original positions.
The service functions are subdivided into two levels:
Level 1 comprises service functions up to function 4.9,
while Level 2 consists of the service functions from 5.0
upwards.
B To select a service function on Level 1: press and
hold the
button until the display shows – –.
B To select a service function on Level 2: press and
hold the buttons
and
simultaneously until the
display shows = =.
B Then turn the
temperature control to select the
required function.
Service function
Code no.
Pump control mode
2.2
Anti-cycle time
2.4
Max. CH flow
temperature
2.5
Switching difference
2.6
Max. heating output
5.0
Table 12
The service function 5.0 may be reset.
Selecting the pump control mode for central heating mode (Service Function 2.2)
If an outside temperature driven control
unit is connected, pump control mode 3 is
automatically activated
• Control Mode 1
For heating equipment without a control unit.
The pump is controlled by the central heating flow
temperature control.
Fig. 39 Appliance controls
1
2
3
4
5
to their
The choice of settings is as follows:
6 720 610 332-30.1O
4
3
and
See page
27
27
28
28
28
• Control Mode 2 (factory setting)
For heating systems with room thermostat.
The central heating flow temperature control controls
only the gas, the pump is not affected. The room thermostat controls both the gas and the pump.
The pump and fan have an overrun time of between
15 s and 3 min.
• Control Mode 3
The pump is controlled by the outside temperature
driven control unit. In summer mode, the pump operates only for hot water mode.
6.2.3
Setting the anti-cycle time
(Service Function 2.4)
This service function is only active if Service Function
2.7, automatic anti-cycle time, is deactivated.
The anti-cycle time can be set to between 0 and 15 minutes (is factory set to 3 minutes).
If the setting 0 is entered, the anti-cycle time is inactive.
The shortest possible anti-cycle time is 1 minute (recommended for single-pipe and hot-air heating systems).
i
If the appliance is connected to an outside-temperature controlled heating programmer, the anti-cycle time does not
need to be set on the appliance and is optimised by the programmer instead.
Entering a setting
B To enter the setting for a function, turn the temperature control
.
6 720 610 596 GB (03.02)
27
Individual settings
6.2.4
Setting the maxim CH flow temperature
(Service Function 2.5)
The maximum CH flow temperature can be set to
between 35˚C and 88˚C (factory setting).
6.2.5
i
Setting the switching difference
(Service Function 2.6)
If the appliance is connected to an outside-temperature controlled programmer,
the programmer sets the switching difference.
It does not need to be set on the appliance.
The switching difference is the permissible divergence
from the specified CH flow temperature. It can be set in
increments of 1 K. The adjustment range is 1 to 30 K (is
factory set to 0 K). The minimum CH flow temperature
is 30˚C.
6.2.6
Setting the heating output
(Service Function 5.0)
The heating output can be set to any level between min.
rated heat output and max rated heat output to limit it to
the specific heat requirements.
i
B Turn the temperature control
until the display
shows 5.0.
After a short delay, the display then shows the set
heating output in percent.
6 720 610 332-51.1O
Fig. 41
B Refer to the settings tables for heating and cylinder
charging output to obtain the relevant code for the
desired heating output in kW (see page 42).
B Turn the temperature control
until the display
shows the desired code number.
The display and the
and
buttons will flash.
B Measure the gas flow rate and compare with the figures specified for the code number displayed. If figures do not match, adjust the code number!
B Press and hold the
and
buttons simultaneously until the display shows [ ].
The heating output is now stored.
The full rated heat output is still available
for hot water or charging the hot water cylinder even if the heating output has been
limited.
The factory setting is the max. rated heat output.
B Set the room thermostat and thermostatic radiator
valves to max. temperature.
B Press and hold the
and
buttons simultaneously until the display shows = =.
The
and
buttons will light up.
6 720 610 332-52.1O
Fig. 42
B Return the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperate.
6.3
Setting the gas/air ratio
The appliance is set at the factory and adjustment is not
necessary.
6 720 610 332-50.1O
Fig. 40
28
6 720 610 596 GB (03.02)
Converting the appliance to different gas types
7
Converting the appliance to different gas types
The setting is factory sealed at maximum. Adjustment to
the rated heat input and min. heat input is not necessary.
Checking the gas supply pressure
B Check the gas supply pressure at the gas supply
pressure testing point.
i
Natural gas appliances must not be operated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is below or above
37 mbar.
Natural gas
7.1
Setting the gas/air ratio
The gas/air ratio may only be adjusted on the
basis of a CO2 measurement at max. heat output
and min. heat output using an electronic tester.
B Switch off the appliance at the master switch (O).
B Remove the outer case (see page 16, refer to
fig. 15).
B Switch on the appliance at the master switch (I).
B Set room thermostat to maximum temperature.
B Open thermostatic radiator valves.
B Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 43.
B Insert testing probe about 135 mm into the flue gas
testing point and seal testing point.
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m 3 and 20 mbar supply
pressure and sealed.
Conversion kits
Model
For conversion
from ...
Order no.
ZB 7-28 HE
N.G to L.P.G
7 710 149 045
ZB 11-28 HE
L.P.G to N.G
7 710 239 081
2 3 4
Table 13
• Instructions are sent with each conversion kit.
6 7 2 0 6 1 0 3 3 2 -5 7 .2 R
Fig. 43
B Press and hold
button until the display shows – –.
The
button will light up.
6 720 610 332-32.1O
Fig. 44
B Turn the temperature control
until the display
shows 2.0 .
After a short delay, the current operating mode setting will be displayed 0. (= Normal mode).
6 720 610 332-60.1O
Fig. 45
6 720 610 596 GB (03.02)
29
Converting the appliance to different gas types
B Turn the temperature control
until the display
shows 2. (= max. rated heat output).
The display and the
button will flash.
B Remove the seal from the gas valve adjusting
screw (64) and adjust the CO 2 level to the figure
given in Table 14 for min. rated heat output.
64
6 720 610 332-61.1O
Fig. 46
B Measure the CO2 level.
B Prise off the seal on the gas flow restrictor.
B Adjust the gas flow restrictor (63) to obtain the CO 2
level given in Table 14. Refer to fig. 47.
3928-74.1R
Fig. 49
63
6 720 610 332-64.1R
Fig. 47
Gas Type
Natural gas type
G20
LPG G31
(propane)
Table 14
CO2 reading
at max.
rated heat
output
CO2 reading
at min. rated
heat output
9.2 %
8.8 %
10.8 %
10.5 %
B Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
B Turn the temperature control
anti-clockwise as
far as the stop so that the display shows 0.
(= Normal operating mode).
The display and the
button will flash.
B Press and hold the
button until the display
shows [ ].
B Reset the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperature.
B Remove testing probe from the flue gas testing
point (234) and refit sealing plug.
B Re-seal gas valve adjusting screw and gas flow
restrictor.
B Replace outer case and secure.
B Set room thermostat and thermostatic radiator valves
to the desired temperature.
B Turn the temperature control
anti-clockwise until
the display shows 1. (= min. rated heat output).
The display and the
button will flash.
6 720 610 332-63.1O
Fig. 48
B Measure the CO2 level.
30
6 720 610 596 GB (03.02)
Converting the appliance to different gas types
7.2
7.2.1
i
Testing combustion air/flue gas at
set heat output
Testing the O2 or CO2 level in the combustion air
By testing the O2 or CO2 level in the combustion air the gas tightness of a type C 13
or C33 flue system can be checked. The
O2 level must not be less than 20,6 %.
The CO2 level must not exceed 0,2 %.
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
In “chimney sweep” mode, the appliance
switches to max. rated heat output or the
set heating output. You then have 15 minutes in which to measure the levels. After
that, the appliance switches back from
“chimney sweep” mode to normal mode.
7.2.2
Testing CO and CO 2
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
You have 15 minutes in which to measure
the levels. After that, the appliance switches back from “chimney sweep” mode to
normal mode.
B Remove sealing plug from flue gas testing point
(234, fig. 50).
B Insert testing probe about 135 mm into the testing
point and seal testing point.
B CO- and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
B Remove sealing plug from combustion air testing
point (234.1, fig. 50).
B Insert testing probe about 80 mm into the testing
point and seal testing point.
2 3 4
2 3 4 .1
6 7 2 0 6 1 0 3 3 2 -6 5 .2 R
Fig. 50
B Measure O2 and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
6 720 610 596 GB (03.02)
31
Maintenance
8
Maintenance
B Always disconnect the appliance from
the electrical power supply (fuse, circuit
breaker) before carrying out any work
on the electrical systems or components.
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
i
There is a special Service booklet for the
Engineer, order no. 7 181 465 346, available to competent persons.
All safety and control systems are monitored by the Bosch Heatronic. In the event
of a component fault, the display shows a
fault code.
B The User should be recommended to have the appliance serviced regularly by a competent person (see
Maintenance Contract).
B Use only genuine spare parts
B Refer to the Spare Parts List when ordering spare
parts.
B Always renew seals and O-rings removed during
servicing or repair work.
B Use only the following types of grease:
– Water valve: WRAS approved silicon based
grease
– Unions: approved sealant.
B To drain the appliance shut the system valves and
open the pressure relief valve.
B Upon completion of any electrical work check for
earth continuity, correct polarisation and resistance
to earth.
32
6 720 610 596 GB (03.02)
Maintenance
8.1
Pre-Service Check List
Date
1
Call up the last fault stored by the
Bosch Heatronic, Service Function .0,
(see page 34).
2
Check ionisation current, Service
Function 3.3, (see page 34).
3
Perform visual check of air/flue
duct.Visual check of diaphragm for
soiling and splits (see page 36).
4
Check gas supply pressure
(see page 29).
5
Test combustion air/flue gas
(see page 31).
6
Check CO2 setting for min./
max. (gas/air ratio)
(see page 29).
mbar
min. %
max. %
7
Check gas and water systems for
leaks (see page 16).
8
Check heat exchanger
(see page 34).
9
Check burner (see page 35).
mbar
10 Clean condensation trap
(see page 35).
mbar
11 Check charge pressure of
expansion vessel matches
static head of heating system.
12 Check central heating system mbar
pressure.
13 Check electrical wiring for damage.
14 Check heating programmer settings.
15 Check appliances that are part of
the heating system.
Table 15
6 720 610 596 GB (03.02)
33
Maintenance
8.2
Description of servicing operations
The combustion performance must be checked before
and after any servicing work on the combustion and
burner components. Refer to section 7.2.
B Remove the fan and the burner as described in the
text headed “Burner” (see page 35).
Check “Last fault stored”:
B Select Service Function .0 (see page 27 “Selecting
Service Function”).
There is a list of the fault codes in the Appendix (see
page 41.
To delete “Last fault stored”:
B Turn temperature control
anti-clockwise as far as
the stop.
B Press and hold the
button until the display
shows [ ].
The last fault stored has now been deleted.
Checking the ionisation current,
Service Function 3.3
6 720 610 332-72.1R
Fig. 52
B Loosen any deposits in the heat exchanger from top
to bottom using the cleaning blade. Refer to fig. 53.
B Select Service Function 3.3 (see page 27 “Selecting
Service Function”).
If the display shows 2 or 3, the ionisation current is OK.
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced.
Primary Heat exchanger
There is a special accessory kit (no. 840) for cleaning
the heat exchanger, order no. 7 719 001 996.
B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manometer.
6 720 610 332-73.1R
Fig. 53
B Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 54.
6 720 610 332-69.1R
Fig. 51
6 720 610 332-74.1R
i
The heat exchanger should only be
cleaned if the control pressure is
2.2 mbar (depression) or less.
Fig. 54
B Remove cleaning access cover (415, page 6) and
the metal plate below it, if present. Refer to fig. 2.
B Unscrew condensation trap and place suitable container underneath. Refer to fig. 52.
34
6 720 610 596 GB (03.02)
Maintenance
B Flush the heat exchanger from the top. Refer to
fig. 55.
B Clean out the condensate collector and trap connection (with other end of brush).
B Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 57.
6 720 610 332-75.2R
Fig. 55
B Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
Burner
B Check that the gas cock is turned off and the master
switch is in the OFF position.
B Remove the clips (1) and unscrew the two bolts (2).
Refer to fig. 56.
B Unscrew and remove the two hexagon screws securing the fan (3).
B Slacken fully the rear securing bolt (4).
B Remove the burner coverplate.
4.
2.
3.
1.
7 181 465 330-08.1R
Fig. 57
B Re-assemble burner in reverse order using a new
seal.
B Adjust gas/air ratio. Refer to section 7.2.
Condensation trap
In order to prevent spillage of condensate, the condensation trap should be completely removed, (see
page 34, fig. 52).
B Unscrew condensation trap and check connection
to heat exchanger is clear.
B Remove condensation trap cover and clean.
B Fill condensation trap with approx. 1/4 l of water and
refit.
Electrode assembly
7 181 465 330-04.1R
Fig. 56
6 720 610 596 GB (03.02)
B Switch off the master switch.
B Pull off the leads from the electrodes. Refer to fig. 2.
B Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 51.
B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4,5 mm ± 0,5 mm.)
B Replace and re-connect the assembly taking care
not to mislay the inspection window.
35
Maintenance
B Refit and prime the siphon.
Diaphragm in mixer unit
B Take care not to damage diaphragm
(443) when removing and refitting it.
B Open mixer unit (29).
B Carefully withdraw diaphragm (443) from fan intake
tube and check for soiling and splits.
Condensate
Drain
Siphon
3.
443
29
6 720 610 602 - 16.1O
Fig. 59
1.
Expansion vessel
The expansion vessel should be checked once a year.
B Depressurise appliance.
B If necessary, adjust expansion vessel charge pressure to static head of the heating system.
2.
Heating system pressure
6 720 610 790-07.2R
Fig. 58
B Carefully refit diaphragm (443) the correct way
round into the fan intake tube.
i
The flaps of the diaphragm (443) must
open upwards.
B Seal the mixer unit (29).
Siphon
B Unscrew the clip and disconnect the pipe to the
siphon.
B Remove the yellow plug to drain the siphon.
B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
i
Fill the system using the WRAS approved
filling loop.
B The pointer on the pressure gauge should be 1 bar.
B If the pointer is below 1 bar (when the system is
cold), water should be added until the pointer is
1 bar again.
B Max. pressure of 2.5 bar when the heating system
water is at maximum temperature must not be
exceeded. If this pressure is exceeded then an extra
expansion vessel must be fitted in the system return
as close to the appliance as possible.
B If the system does not retain the pressure, the expansion vessel and the heating system should be
checked for leaks.
Electrical wiring
B Check the electrical wiring for physical damage and
replace any damaged wires.
36
6 720 610 596 GB (03.02)
Maintenance
8.3
B Remove the pcb control board.
Replacement of Parts
Before changing any components check that the gas is
turned off and that the appliance is electrically isolated.
When necessary close the system valves and drain the
appliance.
Refitting is a reverse of the procedure for removal using
new seals or o-rings as appropriate.
8.3.1
PCB control board and transformer
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the covers. Refer to fig. 27, 28.
B Remove screw holding power connector earth lead
and remove earth lead.
B Remove two top fixing screws from the control box.
Refer to fig. 60.
1
3
2 4
3
4
7 181 465 330-10.1R
1
3
2 4
2
5
Fig. 61
1
E
Fuses
1
7 181 465 329-02.1R
3
2 4
Fig. 60
B Lower the control box.
B Unscrew earth lead.
B Unscrew four fixing screws from cover plate. Refer to
fig. 61.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.
6 720 610 596 GB (03.02)
B Remove the connections covers. Refer to fig. 27,
28.
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
Fuse, item 312, is only replaceable by removing the
pcb.
Spare fuses are fixed to the connections cover.
A fuse pack is available: Part number 8 744 503 010 0.
37
Maintenance
8.3.2
Fan Assembly
8.3.3
3.
2.
4.
Pump
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Remove two switchbox fixing screws (1.). Refer to
fig. 63.
B Lower switchbox (2.).
B Unscrew and remove the siphon by releasing the
jubilee clip. Refer to fig. 59.
B Unscrew the pump union nuts (3.). Refer to fig. 63.
B Carefully remove the pump and disconnect the
leads.
Alternatively
B After removing the siphon release the four Allen
screws and remove and replace the pump head.
3.
1.
7 181 465 330-05.1R
Fig. 62
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 62.
B Remove fan lead and earth connector (2.). The earth
connector has a positive clip fixing.
B Remove fixing screws attaching fan to the burner
cover (3.).
B Remove fan together with gas pipe and mixer unit.
B Separate the fan from the pipe and mixer unit by
twisting the mixer unit to release it (4.).
1.
1.
2.
Fig. 63
8.3.4
B
B
B
B
B
B
B
B
B
38
3-way diverter valve
Switch off the appliance.
Disconnect appliance from the power supply.
Turn off service cocks.
Unplug connector from 3-way valve motor. Refer to
fig. 64.
Pull out retaining clip.
Remove motor.
Disconnect the relief valve drain.
Disconnect the pressure gauge by withdrawing the
clip and pulling out the capillary head.
Undo pipe unions by withdrawing the clips.
6 720 610 596 GB (03.02)
Maintenance
B Remove 3-way valve.
8.3.7
Gas Valve
B Check that the gas cock is turned off.
B Lower the control panel. Refer to fig. 63.
B Pull off the solenoid connections at the rear of the
valve.
B Undo the union, within the inner casing, securing the
valve to the gas/air tube. Refer to fig. 62.
B Remove the white plastic cap from the gas valve.
B Release the gas inlet union at the manifold assembly.
B Unscrew the two screws securing the gas valve
assembly bracket to the back panel and withdraw the
assembly.
B Transfer the bracket and inlet pipe assembly to the
new gas valve.
B Check for gas soundness when the new gas valve
has been fitted.
B Recheck the combustion performance as described
in section 7.1.
7 181 465 330-12.1R
Fig. 64
After refitting:
B Fill system, bleed and re-pressurise
(see Installation Instructions).
8.3.5
3-way diverter valve motor
B Switch off the appliance.
B Turn off the service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 64.
B Pull out retaining clip.
B Remove motor.
8.3.6
Sensors
B Check that the appliance is electrically isolated.
Central Heating Flow Temperature Sensor –
Item 36, fig. 2, 60
B Pull-off the connector.
B Release the sensor clip and withdraw the sensor.
B Apply heat transfer paste to the replacement sensor.
Safety Temperature Limiter – Item 6, fig. 2, 60
B Pull-off the connectors.
B Unscrew the sensor.
Flue Temperature Limiter – Item 9, fig. 2, 60
B Pull-off the connectors.
B Unscrew the sensor.
6 720 610 602 - 04.1O
Fig. 65
8.3.8
Electrode assembly
B Refer to section 8.2.
B Use a new seal if the existing seal is damaged.
6 720 610 596 GB (03.02)
39
Maintenance
8.3.9
Pressure gauge
B Drain the appliance.
B Lower the facia. Refer to fig. 63.
B Twist the pressure gauge head anti-clockwise to
release it from the casing. Refer to fig. 2.
B Disconnect the capillary head from the rear by withdrawing the clip and pulling out the head.
8.3.10 Expansion vessel
B Drain the appliance.
B Undo the union connection at the base of the vessel.
Refer to fig. 2.
B Unscrew the top and bottom fixing screws and
remove the vessel.
8.3.11 Pressure Relief Valve
B Drain the appliance.
B Disconnect the drain pipe from the valve. Refer to
fig. 33.
B Pull-out the clip securing the valve.
B Pull-out the valve.
B Ensure that the replacement valve is fully entered
before fitting the clip.
8.3.12 Burner
B Refer to section 8.2.
8.3.13 Primary Heat Exchanger
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Drain the appliance.
Check that the gas supply is turned off.
Check that the appliance is electrically isolated.
Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 8.3.2.
Remove the burner. Refer to section 8.2.
Disconnect the sensors. Refer to section 8.3.6.
Undo the central heating flow union.
Undo the top connection of the pump. Refer to
fig. 63.
Undo the grey plastic cap, next to the top pump connection at the base of the heat exchanger.
Unscrew and remove the condensate trap. Refer to
section 8.2.
Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
Lift up the flue duct, item 271, refer to fig. 2.
Pull forward from the top and lift the heat exchanger
from the casing.
Transfer components, as necessary, to the new heat
exchanger.
Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
appliance.
40
6 720 610 602 - 06.10
Fig. 66
6 720 610 596 GB (03.02)
Appendix
9
Appendix
9.1
Fault Codes
More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.
Display
code
Description
Remedy
A8
Break in communication
Check connecting lead to programmer.
AC
Module not detected.
Check connecting lead between TA211E/TR212E
and Heatronic.
b1
Keyed plug not detected.
Insert keyed plug correctly, test and replace if necessary.
C1
Fan speed too low.
Check fan lead and connector, and fan; replace as
necessary.
d3
Jumper 8-9 not detected.
Connector not connected, link missing, underfloor
heating limiter tripped.
E2
CH flow NTC sensor defective
Check CH flow NTC sensor and connecting lead.
E9
Safety temp. limiter in CH flow has tripped.
Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA
Flame not detected.
Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0
Internal error.
Check electrical connector contacts, programmer
interface module ignition leads are not loose; replace
pcb if necessary.
F7
Flame detected even though appliance switched off.
Check electrode assembly, dry pcb. Flue clear?
FA
Flame detected after gas shut off.
Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue
clear?
Fd
Reset button pressed by mistake.
Press reset button again.
P1, P2,
P3, P1...
Please wait, initialisation in progress.
24 V fuse blown. Replace fuse.
Table 16
6 720 610 596 GB (03.02)
41
Appendix
9.2
Short parts list
Key
Description
Qty GC
Spare part number
1
2
3
4
5
Sensor - Flue gas temp.
Sensor - CH flow temp.
Control board
Gas valve
Fan assembly
1
1
1
1
1
8 729 000 144 0
8 714 500 087 0
8 748 300 418 0
8 747 003 516 0
8 717 204 373 0
6
7
8
9
10
11
12
13
14
15
16
Fan washer
Expansion vessel
Relief valve
Electrode assembly
Electrode lead
Pump
Pressure gauge
Burner skin seal
Transformer - facia
Heat exchanger washer
Washer set Condensation Trap
1
1
1
1
1
1
1
1
1
1
1
8 729 000 183 0
8 715 407 236 0
8 717 401 012 0
8 718 107 077 0
8 714 401 999 0
8 717 204 384 0
8 717 208 079 0
8 711 004 168 0
8 747 201 358 0
8 710 103 153 0
8 710 103 154 0
17
18
Fuse set
Primary heat exchanger
1
1
8 744 503 010 0
8 715 406 615 0
Table 17
9.3
Heating/hot water output settings (N.G.)
Natural gas G20
Display
code
Heat output kW
Heatinput kW
Gas vol. flow rate
(l/min at tV/tR = 80/60˚C)
30
8.2
8.3
14.4
40
10.9
11.0
19.3
50
13.6
13.8
24.1
60
16.3
16.5
28.9
70
19.1
19.3
33.7
80
21.8
22.0
38.5
90
24.5
24.8
43.3
100
27.2
27.5
48.1
Table 18
9.4
Heating/hot water output settings (L.P.G)
Propane
Display
code
Heat output kW
Heat input kW
40
10.9
11.0
50
13.6
13.8
60
16.3
16.5
70
19.1
19.3
80
21.8
22.0
90
24.5
24.8
100
27.2
27.5
Table 19
42
6 720 610 596 GB (03.02)
Mains
switch
ON.
6 720 610 596 GB (03.02)
Fan runs to purge
gas from burner.
No
Yes
Gas valve
closes.
Red light
OFF.
No
Yes
*
Minimum
heat input
for 15min.
Pump and Fan
run for upto
3 mins.
Boiler
operates to
match
system load
and CH
control
setting.
6 720 610 576 - 25.1O
* NOTE: The sequence ensures that the condensate siphon is not empty
after long OFF periods. (More than 24 hours without a demand).
CH demand
satisfied.
Fan min.
speed for
90 secs.
Boiler
unused for
long
period.*
Central heating function
Burner lights.
Red light ON.
Fan speed
reduces
over 15
secs.
9.5.1
Ignition spark for
5 seconds.
ce
Burner
stabilises at
start speed
for 5-10 secs
Over temperature
shut-down if water
temperature is 5°C
above set value.
Operational Flow diagrams
Ignition sequence
CH
demand.
Pump ON
Fan to
start speed.
Gas valve opens.
Gas valve shuts.
Pump remains ON.
9.5
Repeats 5 times
before lock-out.
Green
light
ON.
Room thermostat
and/or mains
programmer or
link ON
AND
Electronic facia
programmer
(if fitted) ON
AND
CH control knob
ON.
Burner remains OFF
until flow temperature
is below set value.
Appendix
Fig. 67
43
Appendix
EXCELLENCE COMES AS STANDARD
Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
Installation and Servicing Instructions
R 28 HE system
Wall mounted condensing boiler for central heating
6 720 611 441-00.1O
ZB 7-28 R 28 HE System GC Number: 41 311 62
6 720 611 443 GB (04.05) OSW
GB/IE
Contents
Contents
Safety precautions
3
Symbols
3
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Details of the appliance
EC Declaration of Conformity
Standard package
Description of appliance
Accessories
Casing dimensions
Layout of appliance
Function (with optional extra motorised valve)
Electrical wiring diagram
Technical data
4
4
4
4
5
5
6
7
8
9
2
Installation regulations
10
6.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
Installation
Important remarks
Sealed systems
Siting the appliance
Wall mounting frame assembly
Pre-piping the system
Fitting the appliance
Checking the connections
Flue Systems
Siting the Flue Terminal
Installation of the flue
Flue duct preparation and assembly
11
11
11
13
14
14
15
16
16
17
18
20
7
4
4.1
4.2
4.2.1
4.2.2
Electrical connections
Connecting the appliance
Wiring to your system
External 230v
Internal 24v
21
21
22
22
23
5
5.1
5.2
5.3
5.4
5.5
Commissioning
Commissioning
Switching the appliance on/off
Switching on the central heating
System controls
Appliances with optional plug-in diverter
valve: Setting hot water temperature
Frost protection
Pump anti-seize function
Fault Condition
24
24
25
25
25
5.6
5.7
5.8
2
26
26
26
26
6
6.1
6.1.1
6.1.2
6.1.3
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
Individual settings
Mechanical settings
Checking the size of the expansion vessel
Setting the central heating flow temperature
Changing the heating pump characteristic
Settings on the Bosch Heatronic
Operating the Bosch Heatronic
Selecting the pump control mode for central
heating mode (Service Function 2.2)
Setting the anti-cycle time
(Service Function 2.4)
Setting the maximum CH flow temperature
(Service Function 2.5)
Setting the switching difference
(Service Function 2.6)
Setting the heating output
(Service Function 5.0)
Setting the gas/air ratio
27
27
27
27
27
28
28
28
28
28
29
29
29
Converting the appliance to
different gas types
7.1 Setting the gas/air ratio
7.2 Testing combustion air/flue gas at set
heat output
7.2.1 Testing the O2 or CO2 level in the
combustion air
7.2.2 Testing CO and CO2
32
32
8
Maintenance
8.1 Pre-Service Check List
8.2 Description of servicing operations
8.3 Replacement of Parts
8.3.1 PCB control board and transformer
8.3.2 Fan Assembly
8.3.3 Pump
8.3.4 Optional 3-way diverter valve
8.3.5 3-way diverter valve motor
8.3.6 Sensors
8.3.7 Gas Valve
8.3.8 Electrode assembly
8.3.9 Pressure gauge
8.3.10Expansion vessel
8.3.11Pressure Relief Valve
8.3.12Burner
8.3.13Primary Heat Exchanger
33
34
35
38
38
39
39
39
40
40
40
40
41
41
41
41
41
9
9.1
9.2
9.3
9.4
9.5
9.5.1
42
42
43
43
43
44
44
Appendix
Fault Codes
Short parts list
Heating/hot water output settings (N.G)
Heating/hot water output settings (L.P.G)
Operational Flow diagrams
Central heating function
30
30
32
6 720 611 443 GB (04.05)
Safety precautions
Safety precautions
If you smell gas
B Turn off gas service cock at the meter.
B Open windows and doors.
B Do not operate any electrical switches.
B Extinguish any naked flames.
B Telephone your gas company.
If you smell fumes from the appliance
B Switch off appliance (see page 25).
B Open windows and doors.
Fitting and modifications
B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance with the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use on sealed primary systems only.
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
B Use only original spare parts!
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance
being electrically unsafe.
B There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
B The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
EIRE ONLY
The CE mark to indicates manufacture to EU safety
requirements.
This appliance must be installed only by a competent
person to the requirements of IS 813.
Make sure your installer hands you a certificate confirming compliance with IS 813 and that you read carefully
the instruction book suppplied with this appliance.
Keep the instruction book and compliance certificate
for future reference.
Unpacking
IMPORTANT HANDLING INSTRUCTIONS
B Two people should transfer the packaged appliance
from the van to the point of installation
B Open the top of the carton, remove and place the
component tray and both side bars of the wall mounting frame to one side
B Lie the packaged appliance on its back. (The back
has “TRUCK HERE” printed on the carton)
B One person firmly holds the packaging while the
other straddles the boiler and slides it from the packaging
B Two persons are then required to lift one end and
stand the appliance upright with the flue at the top
Additional requirements for roof space installation
B Two people should use two step ladders and share
lifting the unpacked boiler up to the loft hatch
B Where the boiler enters the loft space, tilt and slide
the boiler on its back to the point of installation
Check the contents against the packing list.
Symbols
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.
Instructions to the customer
B Explain to the customer how the appliance works
and how to operate it.
B Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it.
B These instructions are to be left with the user or at
the Gas meter.
B Important: These instructions apply in the UK only.
6 720 611 443 GB (04.05)
3
Details of the appliance
1
1.1
Details of the appliance
1.3
EC Declaration of Conformity
• Wall-mounted appliance, siting not dependent on
room size
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler
Efficiency Directive, Electromagnetic Compatibility
Directive and the Low Voltage Directive.
Description of appliance
• Natural gas models are low-emission appliances
• Multi function display
• Bosch Heatronic control system
• Automatic ignition
CE-0085 BL 0507
• Modulating control
Category
UK
II2H 3P
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
Appliance Type
C13, C33
PIN
Table 1
• Concentric flue/air duct with testing point for
CO2/CO
• Regulated speed fan
1.2
Standard package
• Pre-mix burner
• Temperature control for central heating
• Gas condensing boiler for central heating
• Safety temperature limiter in 24 V electrical circuit
• Wall mounting frame
• Three-speed central heating pump
• Fixings (screws etc.)
• Set of documentation for appliance
• Relief valve, pressure gauge, expansion vessel, automatic air vent
• Pre-plumbing manifold
• Flue gas temperature limiter (105 °C)
• Condensate drain pipe.
• Condensate Trap
• Connecting possibility for S-Plan System.
4
6 720 611 443 GB (04.05)
Details of the appliance
1.4
Accessories
• Standard horizontal flue kit at 100 mm outside
diameter for flues up to 4 m in length.
• Flue duct kits for horizontal (125 mm outside
diameter) for flue lengths up to 13 m and vertical flue
systems for flue lengths up to 15 m. Fitting instructions are sent with these kits.
• Heating programmers
• Timer
• Motorised valve is available as an optional extra. If
this option is used then an integral programmer,
Night Set Back Module and TR2 Optimising Room
Thermostat will be required.
1.5
Casing dimensions
min.
min.
10*
10*
Z
600*
X
Y
850
873
120
101
13
103
30
200
35
360
395
*
200
440
6 720 611 441- 01.1O
Fig. 1
13
101
103
X
Manifold assembly
Outer case
Facia cover
Standard Concentric Horizontal Flue System: min. 160 mm
Alternative Concentric Flue System: min. 220 mm
Y
Standard Concentric Horizontal Flue System: 40mm
Alternative Concentric Flue System: 70mm
Z
Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
*
For servicing the appliance
Note: Horizontal flue only: dimension X may need to increase due to
the incline of the flue.
6 720 611 443 GB (04.05)
5
Details of the appliance
1.6
Layout of appliance
120
221.1
221.2
27
226
20
102
32.1
29
36
271
6
415
43
9
63
416
358
.TD
18
64
423
7
18.1
418
15
8.1
295
4
417
6 720 611 443-01.1O
Fig. 2
4
6
7
8.1
9
15
18
18.1
20
27
29
32.1
36
43
63
64
102
120
6
Heatronic control
Heat exchanger safety temperature limiter
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Relief valve
Pump
Pump speed selector switch
Expansion vessel
Automatic air vent
Air gas Mixer unit
Electrode assembly
Temperature sensor in CH flow
CH flow
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
Inspection window
Fixing points
221.1
221.2
226
295
271
358
415
416
417
418
423
Flue duct
Combustion air intake
Fan assembly
Appliance type sticker
Flue duct
Condensate trap
Cover plate for cleaning access
Condensate collector
Clip for fixing outer case
Data plate
Siphon
6 720 611 443 GB (04.05)
Details of the appliance
1.7
Function (with optional extra motorised valve)
6 720 611 443 -02.1O
Fig. 3
4
6
7
8.1
9
13
15
18
20
26
27
29
29.1
30
32
33
35
36
43
45
47
52
52.1
55
56
57
61
63
64
69
Bosch Heatronic control
Temperature limiter, heat exchanger
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Manifold
Safety valve
Central heating pump
Expansion vessel
Charging valve
Automatic vent
Mixer unit
Bi-metallic thermostat for combustion air compensation
Burner
Flame sensing electrode
Igniter electrode
Heat exchanger with cooled combustion chamber
Temperature sensor in CH flow
CH flow
Gas inlet
CH return
Solenoid valve 1
Solenoid valve 2
Filter
Gas valve CE 427
Main valve disc
Reset button
Adjustable gas flow restrictor
Adjusting screw for min. gas inlet flow volume
Control valve
6 720 611 443 GB (04.05)
71
72
84
88
221
226
229
317
358
423
443
Storage water heater outflow (only with optional motorised
valve)
Storage water heater return (only with optional motorised
valve)
Motor (optional extra)
3-way valve (optional extra)
Flue duct
Fan
Inner casing
Display
Condensate trap
Siphon
Diaphragm
7
Details of the appliance
1.8
Electrical wiring diagram
o - orange
bl - black
r - red
33
365
364
61
317
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
310
136
135
312
328
302
313
151
318
315
124 789
L N Ns Ls LR
161
p
p
300 314
p
84
M
328.1
9
M
6
M
r
r
mains supply
18
o
226
52
52.1
56
o
bl
bl
bl
bl
36
32
6 720 610 601-02.2O
Fig. 4
4.1
6
9
18
32
33
36
52
52.1
56
61
84
135
136
151
153
161
226
300
302
310
312
313
314
318
328
328.1
363
364
8
Ignition transformer
Temperature limiter, heat exchanger
Flue gas temperature limiter
Pump
Flame sensing electrode
Ignition electrode
Temperature sensor in CH flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Diverter valve motor (optional extra)
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
Link
Fan
Code plug
Earth connection
Temperature control for hot water
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Connector for Night Set Back Module TA212E
Connector for integral programmer
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
Indicator lamp for power supply
365
366
367
“Chimney sweep” button
Service button
ECO button
6 720 611 443 GB (04.05)
Details of the appliance
1.9
Technical data
Units
Natural gas
Propane
kW
kW
kW
29.3
29.0
27.4
29.3
29.0
27.4
Max. rated heat input net
kW
27.7
27.7
Min. rated heat output net 40/30˚C
Min. rated heat output net 50/30˚C
Min. rated heat output net 80/60˚C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
Min. rated heat input net
kW
7.6
10.8
Max. rated heat output net 40/30˚C central heating
Max. rated heat output net 50/30˚C central heating
Max. rated heat output net 80/60˚C central heating
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (CVnet 34.02 MJ/m3)
m3/h
2.9
-
MJ/m3)
kg/h
-
2.1
Natural gas G20 (CVnet 34.02 MJ/m3)
mbar
20
-
MJ/m3)
mbar
-
37
bar
0.75
0.75
l
10
10
Flue gas temp. 80/60˚C, rated/min. load
˚C
67/55
67/55
Flue gas temp. 40/30˚C, rated/min. load
˚C
43/32
43/32
Residual delivery pressure
(inc. pressure drop in air intake duct)
Pa
80
80
CO2 level at max. rated heat output
CO2 level at min. rated heat output
%
%
9.2
8.8
10.8
10.5
5
5
Band
A
A
l/h
2.3
2.3
4.8
4.8
230
230
LPG (CVnet 88
Gas supply pressure
LPG (CVnet 88
Expansion vessel
Charge pressure
Total capacity
Flue
NOx-class
SEDBUK figure
Condensate
Max. condensation rate (tR = 30˚C)
pH-value, approx.
General Data
Electrical power supply voltage
AC ... V
Frequency
Hz
50
50
Max. power consumption
W
102
102
dB(A)
36
36
IP
X4D
X4D
Max. CH flow temperature
˚C
nom. 90
nom. 90
Max. permissible operating pressure (CH)
bar
3
3
Permissible ambient temperatures
˚C
0 - 50
0 - 50
Nominal capacity of appliance
l
3.75
3.75
Weight (excluding packaging)
kg
43
43
Noise output level
Appliance protection rating with blanking plate fitted
Table 2
6 720 611 443 GB (04.05)
9
Installation regulations
Condensate analysis, mg/l
Ammonium
1.2
Gas supply
Nickel
0.15
≤ 0.01
Mercury
Cadmium
≤ 0.001
Sulphate
Chromium
≤ 0.005
Zinc
≤ 0.015
Tin
≤ 0.01
Lead
Halogenated
hydrocarbons
≤ 0.002
Hydrocarbons
0.015
Vanadium
Copper
0.028
pH-value
≤ 0.0001
1
Total length of gas supply pipe
(metres)
3
9
Gas discharge rate (m3/h)
8.7
5.8
4.6
22
18.0
12.0
9.4
28
≤ 0.001
4.8
Table 3
Table 8
Flue system
2
HORIZONTAL 100 mm – Standard FLUE SYSTEM
Overall Diameter of Duct
mm
100
Flue Terminal / Duct
Assembly Length
mm
600
Extension Duct Length
mm
1000
Max.
4m
Table 4
HORIZONTAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1030
Max.
13 m
(including
turret)
Table 5
VERTICAL 100 mm FLUE SYSTEM
Overall Diameter of Duct
mm
100
Flue Terminal / Duct Assembly
mm
1140
Incl.
terminal
Max.
6.4m
Table 6
Installation regulations
Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.
• BS 6798: Specification for the installation of gas
fired hot water boilers of rated input not exceeding
60kW
• BS 5449: Central Heating for Domestic Premises
• BS 5546: Installation of gas hot water supplies for
domestic purposes
• BS 5440:1: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Flues
VERTICAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1365
Table 7
Elbow - 90 ° Equivalent length 2 m
Bend - 45 ° Equivalent length 1m
6
Pipe diameter
(mm)
Incl.
terminal
Max.
15 m
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28 mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply
• BS 7671: Requirements for Electrical Installation.
These instructions must be followed.
10
6 720 611 443 GB (04.05)
Installation
3
Installation
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
3.1
Fixing of the appliance, gas and flue connections, commissioning of the system
and electrical connections may only be
carried out by competent persons authorised by CORGI.
Important remarks
B Appliance should only be installed in sealed central
heating systems.
B To avoid gas formation in the system, galvanised
radiators or pipes must not be used.
B If a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.
B Add a suitable anti-freeze fluid compatible with aluminium to the water in the central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563, Fernox Tel.: 01799 550811
and Salamander Tel: 0121 378 0952.
B In our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.
6 720 611 443 GB (04.05)
3.2
Sealed systems
The appliance must not be operated without the system
being full of water, properly vented and pressurised.
The expansion vessel has a volume of 10 litres and is
charged to a pressure of 0.75 bar.
The water capacity of the system is shown in table 12,
page 27. If a greater capacity is required then an additional expansion vessel must be fitted into the system
return as close to the appliance as possible. The system
pressure can be set up to a maximum of 1.5 bar with 1
bar being the normal setting.
If the system pressure is greater than 2.5 bar when the
appliance is operating at maximum temperature then an
additional expansion vessel must be fitted into the system return as close to the appliance as possible.
The filling point must be at low level and arranged as
shown in fig. 8.
The pressure relief valve is set to operate at 3 bar.
There must be no connection to the mains without the
approval of the local water company. All connections in
the system must be capable of withstanding a pressure
of up to 3 bar and the radiator valves conform to the
requirements of BS 2767:10.
Fit Thermostatic Radiator Valves to radiators in the
sleeping accommodation and not to the radiator where
the room thermostat is sited, this must be left open.
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
No galvanised radiators or pipes must be used.
If any system water treatment is required then
only products suitable for use with Aluminium
shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the
manufacturers instructions. The use of any other
substances will invalidate the guarantee. The pH
value of the system water must be less than 8 or
the appliance guarantee will be invalidated.
Suitable products are available from Betz-Dearborn Tel:
0151-4209563 and Fernox Tel: 01799-550811.
A drain cock to BS2879 must be fitted to the lowest
point of the system.
IMPORTANT: Check that no dirt is left in the
water pipework as this could damage the appliance. Thoroughly flush the heating system and
the mains water supply before fitting the appliance to the wall in accordance with the recommendations of BS7593:1992.
11
Installation
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Heating Return
APPLIANCE
LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
6 720 610 601-04.1O
Cylinder Return
RV
Heating Flow
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Hot Water Flow
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
System layout if using optional built-in diverter valve (This must be used in conjunction with an integral
programmer, Night Set Back Module and TR2 Optimising Room Thermostat)
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
Diverter
Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
Fig. 6
12
6 720 610 601-05.1O
APPLIANCE
LV
Hot Water Flow
Cylinder Return
RV
Heating Return
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Heating Flow
Fig. 5
System layout if using external diverter valve (excludes using a Honeywell ‘Y’ plan valve).
6 720 611 443 GB (04.05)
Installation
LV
RV
INDIRECT
CYLINDER
LV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
CH
Zone
Valve
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
DHW Zone Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
6 720 610 601-06.1O
RV
Heating Return
LV
Hot Water Flow
APPLIANCE
LV
RV
Fig. 7
Cylinder Return
RV
Heating Flow
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
System layout if using twin zone valves (S) plan
6 720 611 400-14.1O
Fig. 8
3.3
Siting the appliance
Regulations concerning the Installation Site
B Relevant national regulations must be complied with
section 3.8.1.
B Consult the installation instructions for details of minimum clearances required.
Cupboard/Compartment
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS 6798 and BS 5440:2 are followed. The
low casing losses from the appliance eliminate the need
for ventilation openings in the compartment.
Combustion air
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
Substances classed as corrosion-promoting include
halogenated hydrocarbons which contain chlorine and
fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and
household cleaners, for example.
Surface temperature
The max. surface temperature of the casing and the flue
is less than 85 °C.
This means that, no special safety precautions are
required with regard to flammable building materials
and fitted furniture. The specified clearances must be
maintained.
6 720 611 443 GB (04.05)
13
Installation
3.4
Wall mounting frame assembly
B Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 9. Use
the inner lugs on the top and bottom horizontal sections.
B Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
6 720 610 576-11.1O
Fig. 11
6 720 610 576-04.1O
Fig. 9
3.5
Pre-piping the system
200
B Hold the wall-mounting frame against the wall ensuring that it is vertical.
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 18.
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 12 Manifold
43
47
112
171
172
6 720 610 576-05.1O
Fig. 10
14
CH flow
CH return
Gas cock
Optional cylinder flow (used only with motorised valve)
Optional cylinder return (used only with motorised valve)
B A drain tap should be fitted at the lowest point of the
central heating system.
B WRAS approved filling loop must be fitted.
6 720 611 443 GB (04.05)
Installation
Condensate Termination and Route
The appliance has a built-in syphonic condensate trap
eliminating the need for external traps. Connect to the
22mm plastic drain pipe and extend the pipe run away
from the control panel and appliance witha constant fall
of 2.5˚ or 45mm in every metre. See fig. 14.
The condensate pipe can terminate into any of four
areas:
Boiler
Boiler
Ø 22 min.
Sink
Siphon
Siphon
Ø 22 min.
No length
restriction
Open end of pipe
direct into gully,
below ground but
above water level.
Use waterproof pipe work
insulation in very exposed
positions
The gradient of the discharge pipe
should be 2.5° (40 mm/m) minimum
Open end of pipe direct
into gully, below ground
but above water level
An internal waste system
External condensate pipework
The syphonic condensate trap collects condensate into
a trap which releases it in 100 ml quantities. This helps
to prevent the discharge from freezing.
If there is no alternative and the condensate pipe has to
be externally run, the following should be considered:
• The pipe run should take the shortest practical route.
• The pipework should be insulated with weather
resistant insulation.
• The pipe should terminate as close as possible to the
ground or drain, whilst still allowing the condensate
to safely disperse. This would prevent wind blowing
up the pipe.
• The pipework should be installed with the minimum
of horizontal runs and with a downward slope of at
least 2.5 °.
The gradient of the discharge pipe should be
2.5° (40 mm/m) minimum
An external waste system
Boiler
Boiler
Ø 22 min.
Internal soil
and vent stack
No length
restriction
Sink
Siphon
The gradient of the discharge pipe Invert
should be 2.5° (40 mm/m) minimum
The rainwater system
3.6
Open end of pipe
direct into gully,
below ground but
above water level
Ø 22 min.
450 min.
No length
restriction
Benchmark: For optimum performance
after installation, this boiler and its associated central heating system must be
flushed in accordance with the guidelines given in BS5793:1992 “Treatment
of water in domestic hot water central
heating systems”.
The gradient of the discharge pipe
should be 2.5° (40 mm/m) minimum
An external purpose made soakaway
6 720 611 400-15.1O
Fig. 13
Whilst all of the above methods are acceptable it is
always the best practice to terminate the condense
pipe via an internal waste system.This will eliminate the
need for any external condensate pipe runs which can
be susceptible to freezing in extreme weather.
Fitting the appliance
Removing the outer case
i
The outer case is secured against unauthorised removal by two screws (electrical
safety). Always secure the outer case with
those screws again after refitting.
B Remove retaining screws (1.).
B Slide the outer case upwards and then forwards to
remove (2.).
B Remove the plastic caps from the boiler connections.
2.
1.
6 720 611 400 - 27.1O
Fig. 14 Recommended route of the condensate drain
6 720 611 441-05.1O
Fig. 15
6 720 611 443 GB (04.05)
15
Installation
Fixing the appliance
3.7
B Fit the washers onto the gas and water connections.
B Lift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
B Take care not to disturb the washers on the connections.
Water connections
Connecting the flue assembly
B Fit flue duct connector onto appliance flue spigot.
B Secure with screws pre-fitted to flue outlet on boiler
unless additional screws are provided with flue system.
Flue Turret
Retaining
Screw
Appliance
Flue Socket
Flue Turret to
Boiler Sealing
Gasket
6 720 611 400-16.1O
Fig. 16
B For remaining installation of flue assembly, refer to
the relevant installation instructions.
Checking the connections
B Check that the O-rings or seals are in place before
tightening the connection.
B Turn on the service valves for central heating flow
and return and fill the heating system through a
WRAS approved filling loop.
B Check all seals and unions for leaks (testing pressure max. 3.0 bar as indicated by pressure gauge).
B Check all connections for leaks.
Gas supply pipe
B Check that the seal is in place before tightening the
connection.
B Turn off gas cock to protect gas valve against damage from excessive pressure.
B Check gas supply pipe.
B Release the pressure on the gas supply pipe.
3.8
Flue Systems
The only flue systems that may be used are those supplied with the boiler.
The flue system must be installed in accordance with
the requirements of BS 5440:1.
Standard 100 mm flue system
The standard concentric flue system provides for a horizontal length of up to 4 m. Full instructions for fitting
this flue are in Subsection 3.8.2 “Installation of the
flue”.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue
systems are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13 m.
A vertical flue system up to a height of 15 metres is
available.
45° and 90° flue bends can be used with a corresponding reduction in flue length of 2 m for each 90° bend
and 1 m for each 45° bend used.
IMPORTANT: Any horizontal flue system fitted to a
condensing boiler must incline from the appliance at an
angle of 1,6˚ (30 mm per metre length) to prevent condensate dripping from the flue terminal.
Note, the standard 100mm horizontal flue requires only
a 0.5˚ incline from the boiler as the inner exhaust pipe
is inclined at 2.5˚ inside the outer pipe.
This means that the clearance above the appliance must be increased to match the duct length.
Refer to fig. 1 on page 5.
16
6 720 611 443 GB (04.05)
Installation
lighting, activated by passive infra-red sensing heads.
If the terminal is less than 2 m above a surface to which
people have access then a guard must be fitted. The
guard must be evenly spaced about the terminal with a
space of 50 mm in each direction and fixed with plated
screws.
A guard Type K6 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
3.8.1 Siting the Flue Terminal
The flue must be installed in accordance with
BS 5440:1 and the Building Regulations. Flue terminals in carports and under balconies are to be avoided.
The terminal must be positioned so that it does not
cause an obstruction nor the combustion products a
nuisance. See fig. 17 and table 9.
The terminal will, at times, give out a plume of water
vapour and consideration must be given to this when
choosing a terminal position. Keep clear of security
P
Q
Q
D,E
I
J
N
Q
B
F
M
C
N
N
L
G
A
I
K
H
H
M
6 720 611 400-25.1O
Fig. 17
Minimum dimensions of flue terminal positions (all types) (see fig. 17)
Dimension
A
1)
Terminal position (kW input expressed in net)
Directly below an opening, air brick, opening windows, etc.
Balanced flues room sealed: Fanned draught
300 mm
B1)
Above an opening, air brick, opening window, etc.
300 mm
C1)
Horizontally to an opening, air brick, opening window, etc.
300 mm
D
Below gutters, soil pipes or drain pipes
E
Below eaves
200 mm
F2)
Below balconies or car port roof (lowest point)
200 mm
G
From a vertical drain pipe or soil pipe
75 mm
H
From an internal or external corner or
300 mm
I
Above ground roof or balcony
300 mm
75 mm
J
From a surface or facing the terminal or boundary
K
From a terminal facing the terminal
1200 mm
600 mm
L 2)
From an opening in the car port (e. g. door, window) into the dwelling
1200 mm
M
Vertically from a terminal on the same wall
1500mm
N
Horizontally from a terminal on the same wall
300 mm
P
From a vertical structure on the roof
500 mm
Q
Above intersection with roof
300 mm
Table 9
1)
2)
In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
Not recommended
6 720 611 443 GB (04.05)
17
Installation
3.8.2 Installation of the flue
The standard 100 mm diameter horizontal flue system
is suitable for lengths up to 4 m.
Flues up to 730 mm do not require an extension duct
assembly.
Flues between 1700 mm and 4000 mm require extension duct assemblies.
Standard 100mm system comprise:
Flue
Turret
Maximum 730mm
Outer
Wall
Minimum 480mm
Clamp
Terminal
Assembly
6 720 611 400-18.1O
• Flue turret
Fig. 19 Standard Flue
• Flue turret clamp
• Terminal assembly
• Wall sealing gasket and cover plate.
Refer to fig. 22.
Instructions for fitting other flue systems are packed
with the relevant flue kit.
Check that the position chosen for the appliance is satisfactory. Refer to fig. 18.
Centre line of
flue/air duct
m
120m
H
1,6°
Appliance
Top of wall
mounting
frame (not
boiler)
Drilling
point for
flue duct
opening
H = 40mm for the Standard 100mm Horizontal Flue
H = 70mm for the Optional 125mm Horizontal Flue
6 720 611 400-17.1O
Centre
line of
flue
opening
and
appliance
(30mm/metre)
Standard 100mm
horizont al flue 0.5°
(5mm/metre)
Fig. 18 Marking the position of a side flue opening.
Note: ensure ther is adequate access to the
air/flue sampling points in the flue turret.
18
6 720 611 443 GB (04.05)
Installation
Maximum 1700mm
Outer
Wall
Flue
Turret
Terminal
Assembly
Extension
Duct
Clamp
6 720 611 400-19.1O
Fig. 20 Flue with one extension
Outer
Wall
Flue
Turret
Clamp
Extension
Duct
Clamp
Extension
Duct
Clamp
Terminal
Assembly
6 720 611 400-20.1O
Fig. 21 Flue with extensions
Flue
Turret
Clamp
Flue Terminal
Extension Flue Duct
Wall Sealing Gasket
6 720 611 400-21.1O
Fig. 22 Flue components
6 720 611 443 GB (04.05)
19
Installation
3.8.3 Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 23, 24.
Outer Wall Face
Flue Terminal
L
120
Wall Sealing Gasket
6 720 611 400-22.1O
Fig. 23 Flue length - rear
6 720 611 400-24.1O
Fig. 25 Flue terminal position
L
6 720 611 400-23.1O
Fig. 24 Flue length - side
Measure ‘L’ from the end of the metal section of the flue
terminal to the centre of the flue outlet on the boiler as
shown in Fig. 23 & Fig. 24 and deduct 90mm from that
measurement.
Cut both inner and outer flue pipe square at the opposite end to the terminal without creasing the tubes.
Remove any burrs before fitting the terminal to the turret.
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must be directed as per Fig. 25.
The assembly will be made easier if a solvent free
grease is lightly applied i.e Silicone lubricant, to the
male end of the ducts.
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assembly.
Push the assembly through the wall and fix the turret to
the appliance using the screws prefitted to the boiler
flue outlet. Refer to fig. 26.
Flue Turret
Retaining
Screw
Appliance
Flue Socket
Flue Turret to
Boiler Sealing
Gasket
6 720 611 400-16.1O
Fig. 26 Flue turret
Ensure that the turret is fully secured to the socket on
the boiler.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal and fixed with corrosion resistant
screws.
20
6 720 611 443 GB (04.05)
Electrical connections
4
Electrical connections
B Always disconnect the power supply to
the appliance at the mains before carrying out any work on the electrical systems and components.
B Pull out cover panel at the bottom and remove. Refer
to fig. 27.
3
0
4
2
5
1
E
All control and safety systems are built into the appliance.
B Allow mains cable to protrude at least 50 cm from
wall.
B To maintain the splash-proof (IP) design: cut the
cable grommet hole size to match the diameter of the
cable, see fig. 29.
B The appliance must be earthed.
B It must be possible to completely isolate the appliance with at least 3mm contact separation in both
poles.
6 720 610 332-10.1R
Fig. 27
B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 28.
The wiring between the appliance and the electrical
supply shall comply with current IEE Wiring Regulations (and any local regulations which apply) for fixed
wiring to a stationary appliance.
3
0
4
2
5
1
E
• Supply: 230 V ~ 50 Hz, 150 Watts
• External fuse 3 A
• The system connected to the boiler must NOT have
a separate electrical supply
• Water Protection IPX4D (with fascia blanking plate
fitted or IP20 without blanking plate).
4.1
Connecting the appliance
To gain access to the mains connection remove the
drop down facia cover. The drop down cover is
removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
release the cover. Lift cover from the appliance.
After installation (or in the event of an electrical fault) the
electrical system shall be checked for short circuits,
fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.
6 720 610 332 -11.1R
Fig. 28
B Cut cable grommet to diameter of cable.
3
0
2
4
5
1
E
8-9
5-7
10-12
13-14
6 720 610 332-12.1R
Fig. 29
B Feed cable through cable grommet and connect the
mains supply cable, see fig. 30.
6 720 611 443 GB (04.05)
21
Electrical connections
ZONE VALVE
DHW
BLUE
MOTOR
MOTOR
BROWN
CYLINDER
STAT.
1
1
2
3
4
5
6
ORANGE
ROOM STAT.
2 1 3
ORANGE
G/YELLOW
G/YELLOW
BROWN
GREY
N NS L
BLUE
L
ZONE VALVE
HTG
GREY
B Secure cable in cable grommet by means of cable
grip.
C
7
8
9
10
TIME
CONTROLLER
Fig. 30
N L
HW HTG
4.2
Wiring to your system
The boiler is fitted with an internal pump and there are
two recommended ways of connecting a system, external 230v or internal 24v depending on the choice of
diverter valve(s).
4.2.1 External 230v
Non-supplied parts required: external 230v conventional terminal block or wiring centre, pre-wired to the
230v diverter valve(s) and all other 230v system components.
Note: Honeywell and Siemens Y plan valves require a
capacitor to be wired across the switch wire and neutral of the external wiring centre or across the LS and
NS terminals on the boiler. The capacitor required is a
0.47 microfarad capacitor 275 vac class X2 type. This
can be obtained from an electronics wholesalers such
as Farnell Tel. 0870 1200 202. The Farnell part
number for this capacitor is 869-491.
L
N NS L S L R
6 720 611 443-03.1O
• See section 4.1 to gain access to the boiler mains
wiring centre
• Remove the connecting link from LS and LR terminals
and connect the system to the boiler. Two typical
examples of this are shown in Fig. 31 and Fig. 32.
Fig. 31 A typical example of external 230v connection
using 2 zone valves
• Any other components (including frost thermostats)
cannot be connected to the boiler and should
instead be connected to the external terminal block
or wiring centre in accordance with the manufacturers proprietary instructions. No liability is accepted
arising from or by any wiring external to the boiler.
22
6 720 611 443 GB (04.05)
Electrical connections
BLUE
G/YELLOW
MID
POSITION
ZONE
VALVE
ROOM STAT.
ORANGE
GREY
WHITE
CYLINDER
STAT.
1
N L SW
C 2
1
2
3
4
5
6
7
8
9
10
4.2.2 Internal 24v
Non-supplied Worcester Bosch parts required:
Description
Part Number
24v Diverter valve (including
tank NTC)
7 719 002 090
TR2 room thermostat
7 774 901 137
Night set back module
7 744 901 136
Twin channel programmer
7 716 192 032
Table 10
L
N
HW ON
HW OFF
• See section 4.1 to gain access to the boiler mains
wiring centre
• Keep the link connecting the LS and LR terminals
TIME
CONTROLLER
• Refer to instructions supplied with each part
• Externally wired frost protection is not required as
this is provided by the boiler’s internal frost thermostat and the TR2 room thermostat.
L
N NS L S L R
6 720 611 443-05.1O
Fig. 32 A typical example of external 230v connection
using a mid-position zone valve
6 720 611 443 GB (04.05)
23
Commissioning
5
Commissioning
27
136 365
61
317 366 367
358
ECO
364
363
135
8.1
E
310
295
15
170
171
172
173
170
6 720 610 576-07.2O
Fig. 33
8.1
15
27
61
135
136
170
171
172
173
295
310
317
358
363
364
365
366
367
24
Pressure gauge
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for central heating
Service cocks on CH flow and return
Optional cylinder flow (used only with motorised valve)
Gas cock (shown in on position)
Optional cylinder return (used only with motorised valve)
Appliance type sticker
Temperature control for hot water
Multi function display
Condensate trap
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
i
The operational CO2 level is set at the factory and no adjustment is necessary when
installing a natural gas fired appliance.
Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance
with the guidelines given in BS 7593:1992 - Treatment
of water in domestic hot water systems. Full instructions are supplied with proprietary cleansers sold for
this purpose. If an inhibitor is to be used after flushing,
it should be used in accordance with the inhibitor manufacturers instructions.
To drain the appliance shut the system valves and open
the system drain point.
Suitable flushing agents and inhibitors are available
from Betz-Dearborn Tel: 0151-4209563 and Fernox
Tel: 01799-550811. Instructions for use are supplied
with the these products.
6 720 611 443 GB (04.05)
Commissioning
B Before commissioning, the gas supply pressure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7).
Natural gas appliances must not be operated if
the gas supply pressure is below 18 mbar or
above 24 mbar. LPG appliances must not be
operated if the supply pressure is not 37 mbar
at the inlet to the appliance.
B Unscrew the condensation trap (358) and pull out,
fill with approx. 1/4 l of water and refit. Refer to
fig. 33.
B Adjust charge pressure of expansion vessel to static
head of the central heating system (see page 27).
B Open all system radiator valves.
B Check automatic air vent is open (27) fig. 33
B Turn on service valves (170), fill central heating system to pressure of 1 - 2 bar through the WRAS
approved filling loop. Refer to fig. 33.
B Vent radiators.
B Refill heating system and set the pressure to 1 bar.
B Turn on cold water service cock (173). Refer to
fig. 33.
B Check that the gas type specified on the identification plate matches that of the gas supply.
B Turn on gas cock (172). Refer to fig. 33.
5.2
Switching off the appliance
B Set the master switch to (0).
The green indicator lamp goes out.
B Always disconnect the appliance from
the power supply (fuse, circuit breaker)
before carrying out any work on the
electrical systems or components.
5.3
Switching on the central heating
The central heating flow temperature is adjustable
between 35˚C and 88˚C. Refer to table 13, page 27.
B Turn the temperature control
to set the flow temperature to a level appropriate to the type of central
heating system:
– Underfloor heating: e.g. setting “3”
(approx. 50˚C)
– Low-temperature heating: setting “E”
(approx. 75˚C)
– Central heating systems for flow temperatures up
to 88 °C: limited “max” setting for low-temperature
operation (see page 27).
When the burner is alight, the red indicator lamp
lights up.
Switching the appliance on/off
Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the central heating flow temperature, when the
appliance is operating in the central heating mode.
6 720 610 333-05.1O
Fig. 35
5.4
6 720 610 333-04.1O
System controls
B Set room thermostat to the desired room temperature.
B Set room temperature controller, if fitted. Refer to the
instructions with the control.
B Set the thermostatic radiator valves to the desired
settings.
Fig. 34
i
If the display alternates between -II- and
the central heating flow temperature, the
trap filling programme is active.
The trap filling programme ensures that the condensation trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
6 720 611 443 GB (04.05)
25
Commissioning
5.5
Appliances with optional plug-in
diverter valve: Setting hot water
temperature
B Do not set the temperature higher than
60˚C for normal operation.
B Only use temperatures of up to 70˚C
temporarily for thermal disinfection purposes.
B Set the hot water temperature by means of the temperature control
on the appliance.
5.6
The appliance has an in-built frost protection device
which is generally suitable for most applications.
B Leave master switch switched on.
If the appliance is to be left for long periods switch the
central heating off:
B Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel: 0151-4209563 and Fernox Tel: 01799550811.
5.7
i
6 720 610 333-07.1O
Control Setting
Water Temperature
Anti-clockwise limit
approx. 10˚C
(frost protection)
approx. 60˚C
Clockwise limit
approx. 70˚C
Table 11
ECO button
Pressing and holding the ECO button
Comfort mode to ECO-mode.
switches from
Comfort mode, ECO button is not lit (factory setting)
Comfort mode the hot water tank has priority. The hot
water cylinder is first heated up to the set temperature.
The appliance then switches to central heating mode.
ECO mode, button is lit
In ECO mode the appliance switches between central
heating mode and cylinder charging mode every
12 minutes.
26
Pump anti-seize function
This function prevents the central heating
pump seizing after long periods of inactivity.
Every time the pump is switched off, a timer is started.
If after 24 hours the pump has not run again, it is
switched on for a period of 5 minutes.
Fig. 36
Frost protection
5.8
i
Fault Condition
A list of faults that may occur is given on
page 42.
In the unlikely event of a fault occurring while the appliance is in operation:
The display then shows a fault code and the button
may also flash.
If the button
flashes:
B Press and hold the button
until the display shows
“– –”.
The appliance will then start up again and the display
will show the central heating flow temperature.
If the button
does not flash:
B Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the central heating flow temperature will be displayed.
6 720 611 443 GB (04.05)
Individual settings
6
Individual settings
6.1
Mechanical settings
6.1.1 Checking the size of the expansion vessel
Maximum pressure at maximum CH flow temperature is
2.5 bar. If the pressure is greater than this then fit an
extra expansion vessel. Refer to table 12.
System Capacity – BS 7074:1
Expansion Vessel Pressure and System Capacity
Expansion Vessel
litres
10
Expansion Vessel
Charge Pressure
bar
0.75
System
pressure
and
capacity
B Rotate yellow button through 180° and replace (dot
facing inwards).
The CH flow temperature is no longer limited.
Control setting
CH flow temperature
1
2
3
4
5
E
max
approx. 50˚C
approx. 55˚C
approx. 60˚C
approx. 65˚C
approx. 70˚C
approx. 75˚C
approx. 88˚C
Table 13
1 bar
litres
82
1.5 bar
litres
46
6.1.3 Changing the heating pump characteristic
The speed of the central heating pump can be altered
on the pump terminal box.
Setting the central heating flow temperature
The central heating flow temperature can be set to
between 50˚C and 88˚C.
At switch position 1, maximum output is
not delivered if hot water mode is active.
Position 1 must not be used on combi appliances.
i
Table 12
6.1.2
H
0,7
(bar)
i
With underfloor heating systems, observe
the maximum permissible flow temperatures.
0,6
0,5
Limited maximum setting for low-temperature
operation
The temperature control is factory limited to setting E,
giving a maximum flow temperature of 75˚C.
Adjustment of the heating output to the calculated heat
demand is not required by the heating systems regulations.
0,4
Removing the maximum setting limit
For heating systems which require higher flow temperatures, the maximum setting limit can be removed.
0
B Lift off the yellow button on the temperature control
with a screwdriver.
3
2
0,3
0,2
1
0,1
0
200
400
600
800
1000 1200 1400 1600
Q (l/h)
6 720 610 576-23.2O
Fig. 38
1
2
3
H
Q
Pump characteristic for switch position 1
Pump characteristic for switch position 2
Pump characteristic for switch position 3
Residual delivery pressure
Water circulation rate
6 720 610 332-27.1O
Fig. 37
6 720 611 443 GB (04.05)
27
Individual settings
6.2
Settings on the Bosch Heatronic
6.2.1 Operating the Bosch Heatronic
The Bosch Heatronic enables easy setting and checking of a large number of appliance functions.
This description is limited to those functions required
for commissioning.
For a full description of all available functions, please
refer to the Service booklet for the Engineer, order no.
7-181-465-346.
5
2
Entering a setting
B To enter the setting for a function, turn the temperature control
.
Storing a setting
B Level 1: press and hold the
button until the display shows [ ].
B Level 2: press and hold the
and
buttons simultaneously until the display shows [ ].
After completing the settings
1
B Reset the temperature controls
original positions.
6.2.2
6 720 610 332-30.1O
i
4
3
Fig. 39 Appliance controls
1
2
3
4
5
Service button
“Chimney sweep” button
Temperature control for central heating
Temperature control for hot water
Display
The service functions are subdivided into two levels:
Level 1 comprises service functions up to function 4.9,
while Level 2 consists of the service functions from 5.0
upwards.
B To select a service function on Level 1: press and
hold the
button until the display shows – –.
B To select a service function on Level 2: press and
hold the buttons
and
simultaneously until the
display shows = =.
B Then turn the
temperature control to select the
required function.
Code no.
2.2
2.4
Switching difference
Max. heating output
Table 14
The service function 5.0 may be reset.
28
See page
28
28
28
2.5
2.6
5.0
Selecting the pump control mode for central heating mode (Service Function 2.2)
If an room temperature controller unit is
connected, pump control mode 3 is automatically activated
• Control Mode 1
For heating equipment without a control unit.
The pump is controlled by the central heating flow
temperature control.
Note the positions of the temperature controls
and
. After completing the settings, return the temperature controls to
their original positions.
Service function
Pump control mode
Anti-cycle time
Max. CH flow
temperature
to their
The choice of settings is as follows:
Selecting service function:
i
and
29
29
• Control Mode 2 (factory setting)
For heating systems with room thermostat.
The central heating flow temperature control controls
only the gas, the pump is not affected. The room thermostat controls both the gas and the pump.
The pump and fan have an overrun time of between
15 s and 3 min.
• Control Mode 3
The pump is controlled by the room temperature
controller unit. In summer mode, the pump operates
only for hot water mode.
6.2.3
Setting the anti-cycle time
(Service Function 2.4)
This service function is only active if Service Function
2.7, automatic anti-cycle time, is deactivated.
The anti-cycle time can be set to between 0 and 15 minutes (is factory set to 3 minutes).
If the setting 0 is entered, the anti-cycle time is inactive.
The shortest possible anti-cycle time is 1 minute (recommended for single-pipe and hot-air heating systems).
6.2.4
Setting the maximum CH flow temperature (Service Function 2.5)
The maximum CH flow temperature can be set to
between 35˚C and 88˚C (factory setting).
6 720 611 443 GB (04.05)
Individual settings
6.2.5
i
Setting the switching difference
(Service Function 2.6)
If the appliance is connected to an outside-temperature controlled programmer,
the programmer sets the switching difference.
It does not need to be set on the appliance.
The switching difference is the permissible divergence
from the specified CH flow temperature. It can be set in
increments of 1˚C. The adjustment range is 1 to 30˚C
(is factory set to 0˚C). The minimum CH flow temperature is 30˚C.
Setting the heating output
(Service Function 5.0)
The heating output can be set to any level between min.
rated heat output and max rated heat output to limit it to
the specific heat requirements.
The factory setting is the max. rated heat output.
B Press and hold the
and
buttons simultaneously until the display shows [ ].
The heating output is now stored.
6 720 610 332-52.1O
Fig. 42
B Return the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperate.
6.2.6
B Set the room thermostat and thermostatic radiator
valves to max. temperature.
B Press and hold the
and
buttons simultaneously until the display shows = =.
The
and
buttons will light up.
6.3
Setting the gas/air ratio
The appliance is set at the factory and adjustment to the
CO2 settings (gas/air ratio) is only required where the
appliance has been stripped down and assembled or if
the fan, burner or gas valve are replaced or the appliance has been converted to a different gas type, see
section 7.
6 720 610 332-50.1O
Fig. 40
B Turn the temperature control
until the display
shows 5.0.
After a short delay, the display then shows the set
heating output in percent.
6 720 610 332-51.1O
Fig. 41
B Refer to the settings tables for heating and cylinder
charging output to obtain the relevant code for the
desired heating output in kW (see page 43).
B Turn the temperature control
until the display
shows the desired code number.
The display and the
and
buttons will flash.
B Measure the gas flow rate and compare with the figures specified for the code number displayed. If figures do not match, adjust the code number!
6 720 611 443 GB (04.05)
29
Converting the appliance to different gas types
7
Converting the appliance to different gas types
The setting is factory sealed at maximum. Adjustment to
the rated heat input and min. heat input is not necessary.
Checking the gas supply pressure
B Check the gas supply pressure at the gas supply
pressure testing point.
i
Natural gas appliances must not be operated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is below or above
37 mbar.
Natural gas
7.1
Setting the gas/air ratio
The gas/air ratio may only be adjusted on the
basis of a CO2 measurement at max. heat output
and min. heat output using an electronic tester.
B Switch off the appliance at the master switch (O).
B Remove the outer case (see page 15, refer to
fig. 15).
B Switch on the appliance at the master switch (I).
B Set room thermostat to maximum temperature.
B Open thermostatic radiator valves.
B Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 43.
B Insert testing probe about 135 mm into the flue gas
testing point and seal testing point.
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m 3 and 20 mbar supply
pressure and sealed.
234.1
Conversion kits
Model
For conversion
from ...
Order no.
R 28 HE
N.G to L.P.G
7 710 149 049
Table 15
• Instructions are sent with each conversion kit.
234
6 720 611 400-22.1O
Fig. 43
B Press and hold
button until the display shows – –.
The
button will light up.
6 720 610 332-32.1O
Fig. 44
B Turn the temperature control
until the display
shows 2.0 .
After a short delay, the current operating mode setting will be displayed (0. = Normal mode).
6 720 610 332-60.1O
Fig. 45
30
6 720 611 443 GB (04.05)
Converting the appliance to different gas types
B Turn the temperature control
until the display
shows 2. (= max. rated heat output).
The display and the
button will flash.
B Remove the seal from the gas valve adjusting
screw (64) and adjust the CO 2 level to the figure
given in Table 16 for min. rated heat output.
64
6 720 610 332-61.1O
Fig. 46
B Measure the CO2 level.
B Prise off the seal on the gas flow restrictor.
B Adjust the gas flow restrictor (63) to obtain the CO 2
level given in Table 16. Refer to fig. 47.
63
6 720 610 332-64.1R
Fig. 47
Gas Type
Natural gas type
G20
LPG G31
(propane)
Table 16
CO2 reading
at max.
rated heat
output
CO2 reading
at min. rated
heat output
9.2 %
8.8 %
10.8 %
10.5 %
3928-74.1R
Fig. 49
B Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
B Turn the temperature control
anti-clockwise as
far as the stop so that the display shows 0.
(= Normal operating mode).
The display and the
button will flash.
B Press and hold the
button until the display
shows [ ].
B Reset the temperature controls
and
to their
original positions.
The display will revert to the CH flow temperature.
B Remove testing probe from the flue gas testing
point (234) and refit sealing plug.
B Re-seal gas valve adjusting screw and gas flow
restrictor.
B Replace outer case and secure.
B Set room thermostat and thermostatic radiator valves
to the desired temperature.
B Turn the temperature control
anti-clockwise until
the display shows 1. (= min. rated heat output).
The display and the
button will flash.
6 720 610 332-63.1O
Fig. 48
B Measure the CO2 level.
6 720 611 443 GB (04.05)
31
Converting the appliance to different gas types
7.2
Testing combustion air/flue gas at set heat output
7.2.1
Testing the O2 or CO2 level in the combustion air
i
By testing the O2 or CO2 level in the combustion air the gas tightness of a type C13
or C33 flue system can be checked. The
O2 level must not be less than 20,6 %.
The CO2 level must not exceed 0,2 %.
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
In “chimney sweep” mode, the appliance
switches to max. rated heat output or the
set heating output. You then have 15 minutes in which to measure the levels. After
that, the appliance switches back from
“chimney sweep” mode to normal mode.
B Remove sealing plug from combustion air testing
point (234.1, Fig. 50).
B Insert testing probe about 80 mm into the testing
point and seal testing point.
7.2.2
Testing CO and CO 2
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
You have 15 minutes in which to measure
the levels. After that, the appliance switches back from “chimney sweep” mode to
normal mode.
B Remove sealing plug from flue gas testing point
(234, fig. 50).
B Insert testing probe about 135 mm into the testing
point and seal testing point.
B CO- and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
234.1
234
6 720 611 400-22.1O
Fig. 50
B Measure O2 and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
32
6 720 611 443 GB (04.05)
Maintenance
8
Maintenance
B Always disconnect the appliance from
the electrical power supply (fuse, circuit
breaker) before carrying out any work on
the electrical systems or components.
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
i
There is a special Service booklet for the
Engineer, order no. 7-181-465-346, available to competent persons.
All safety and control systems are monitored by the Bosch Heatronic. In the event
of a component fault, the display shows a
fault code.
B The User should be recommended to have the appliance serviced regularly by a competent person (see
Maintenance Contract).
B Use only genuine spare parts
B Refer to the Spare Parts List when ordering spare
parts.
B Always renew seals and O-rings removed during
servicing or repair work.
B Use only the following types of grease:
– Water valve: WRAS approved silicon based
grease
– Unions: approved sealant.
B To drain the appliance shut the system valves and
open the pressure relief valve.
B To drain the appliance shut the system valves and
open the pressure relief valve.
B Upon completion of any electrical work check for
earth continuity, correct polarisation and resistance
to earth.
6 720 611 443 GB (04.05)
33
Maintenance
8.1
Pre-Service Check List
Date
1
Call up the last fault stored by the
Bosch Heatronic, Service Function .0,
(see page 35).
2
Check ionisation current, Service
Function 3.3, (see page 35).
3
Perform visual check of air/flue
duct.Visual check of diaphragm for
soiling and splits (see page 37).
4
Check gas supply pressure
(see page 30).
5
Test combustion air/flue gas
(see page 32).
6
Check CO2 setting for min./
max. (gas/air ratio)
(see page 30).
mbar
min. %
max. %
7
Check gas and water systems for
leaks (see page 16).
8
Check heat exchanger
(see page 35).
9
Check burner (see page 36).
mbar
10 Clean condensation trap
(see page 36).
11 Check charge pressure of
mbar
expansion vessel matches
static head of heating system.
12 Check central heating system mbar
pressure.
13 Check electrical wiring for damage.
14 Check heating programmer settings.
15 Check appliances that are part of
the heating system.
Table 17
34
6 720 611 443 GB (04.05)
Maintenance
8.2
Description of servicing operations
The combustion performance must be checked before
and after any servicing work on the combustion and
burner components. Refer to section 7.1.
B Remove the fan and the burner as described in the
text headed “Burner” (see page 36).
Check “Last fault stored”:
B Select Service Function .0 (see page 28 “Selecting
service function”).
There is a list of the fault codes in the Appendix (see
page 42).
To delete “Last fault stored”:
B Turn temperature control
anti-clockwise as far as
the stop.
B Press and hold the
button until the display
shows [ ].
The last fault stored has now been deleted.
Checking the ionisation current,
Service Function 3.3
6 720 610 332-72.1R
Fig. 52
B Loosen any deposits in the heat exchanger from top
to bottom using the cleaning blade. Refer to fig. 53.
B Select Service Function 3.3 (see page 28 “Selecting service function”).
If the display shows 2 or 3, the ionisation current is OK.
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced.
Primary Heat exchanger
There is a special accessory kit (no. 840) for cleaning
the heat exchanger, order no. 7 719 001 996.
B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manometer.
6 720 610 332-73.1R
Fig. 53
B Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 54.
6 720 610 332-69.1R
Fig. 51
6 720 610 332-74.1R
i
The heat exchanger should only be
cleaned if the control pressure is
4.2 mbar (depression) or less.
Fig. 54
B Flush the heat exchanger from the top. Refer to
fig. 55.
B Remove cleaning access cover (415, page 6) and
the metal plate below it, if present. Refer to fig. 2.
B Unscrew condensation trap and place suitable container underneath. Refer to fig. 52.
6 720 611 443 GB (04.05)
35
Maintenance
B Clean out the condensate collector and trap connection (with other end of brush).
6 720 610 332-75.2R
Fig. 55
B Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
Burner
B Check that the gas cock is turned off and the master
switch is in the OFF position.
B Remove the clips (1.) and unscrew the two bolts (2.).
Refer to fig. 56.
B Unscrew and remove the two hexagon screws securing the fan (3.).
B Slacken fully the rear securing bolt (4.).
B Remove the burner coverplate.
4.
2.
3.
1.
Fig. 57
B Re-assemble burner in reverse order inspect seal for
damage and replace if necessary.
B Adjust gas/air ratio. Refer to section 7.2.
Condensation trap
In order to prevent spillage of condensate, the condensation trap should be completely removed, (see
page 35, fig. 52).
B Unscrew condensation trap and check connection
to heat exchanger is clear.
B Remove condensation trap cover and clean.
B Fill condensation trap with approx. 1/4 l of water and
refit.
Electrode assembly
7 181 465 330-04.1R
Fig. 56
B Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 57.
36
7 181 465 330-08.2R
B Switch off the master switch.
B Pull off the leads from the electrodes. Refer to fig. 2.
B Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 51.
B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4 mm ± 1 mm.)
B Replace and re-connect the assembly taking care
not to mislay the inspection window.
6 720 611 443 GB (04.05)
Maintenance
Siphon
Diaphragm in mixer unit
B Take care not to damage diaphragm
(443) when removing and refitting it.
B Open mixer unit (29).
B Carefully withdraw diaphragm (443) from fan intake
tube and check for soiling and splits.
3.
B Unscrew the clip and disconnect the pipe to the
siphon.
B Remove the drain plug to drain the siphon.
B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
B Refit and prime the siphon.
443
Condensate
Drain
29
Siphon
Drain Plug
1.
6 720 611 441-07.1O
Fig. 59
Expansion vessel
The expansion vessel should be checked once a year.
2.
6 720 610 790-07.2R
Fig. 58
B Carefully refit diaphragm (443) the correct way
round into the fan intake tube.
i
The flaps of the diaphragm (443) must
open upwards.
B Seal the mixer unit (29).
B Depressurise appliance.
B If necessary, adjust expansion vessel charge pressure to static head of the heating system.
Heating system pressure
i
Fill the system using the WRAS approved
filling loop.
B The pointer on the pressure gauge should be 1 bar.
B If the pointer is below 1 bar (when the system is
cold), water should be added until the pointer is
1 bar again.
B Max. pressure of 2.5 bar when the heating system
water is at maximum temperature must not be
exceeded. If this pressure is exceeded then an extra
expansion vessel must be fitted in the system return
as close to the appliance as possible.
B If the system does not retain the pressure, the expansion vessel and the heating system should be
checked for leaks.
Electrical wiring
B Check the electrical wiring for physical damage and
replace any damaged wires.
6 720 611 443 GB (04.05)
37
Maintenance
8.3
B Remove the pcb control board.
Replacement of Parts
Before changing any components check that the gas is
turned off and that the appliance is electrically isolated.
When necessary close the system valves and drain the
appliance.
Refitting is a reverse of the procedure for removal using
new seals or o-rings as appropriate.
8.3.1
PCB control board and transformer
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the covers. Refer to fig. 27, 28.
B Remove screw holding power connector earth lead
and remove earth lead.
B Remove two top fixing screws from the control box.
Refer to fig. 63.
1
3
2 4
7 181 465 330-10.1R
3
4
1
3
2 4
2
5
Fig. 61
1
E
Fuses
1
7 181 465 329-02.1R
3
2 4
Fig. 60
B Lower the control box.
B Unscrew earth lead.
B Unscrew four fixing screws from cover plate. Refer to
fig. 64.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.
38
B Remove the connections covers. Refer to fig. 27,
28.
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
Fuse, item 312, is only replaceable by removing the
pcb.
Spare fuses are fixed to the connections cover.
A fuse pack is available: Part number 8 744 503 010 0.
6 720 611 443 GB (04.05)
Maintenance
8.3.2
Fan Assembly
8.3.3
3.
Pump
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Remove two switchbox fixing screws (1.). Refer to
fig. 63.
B Lower switchbox (2.).
2.
B Unscrew and remove the siphon by releasing the
jubilee clip. Refer to fig. 59.
B Unscrew the pump union nuts (3). Refer to fig. 63.
B Carefully remove the pump and disconnect the
leads.
4.
Alternatively
B After removing the siphon release the four Allen
screws and remove and replace the pump head.
3.
1.
7 181 465 330-05.1R
Fig. 62
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 62.
B Remove fan lead and earth connector (2.). The earth
connector has a positive clip fixing.
B Remove fixing screws attaching fan to the burner
cover (3.).
B Remove fan together with gas pipe and mixer unit.
B Separate the fan from the pipe and mixer unit by
twisting the mixer unit to release it (4.).
1.
1.
2.
Fig. 63
8.3.4
B
B
B
B
B
B
B
B
B
6 720 611 443 GB (04.05)
Optional 3-way diverter valve
Switch off the appliance.
Disconnect appliance from the power supply.
Turn off service cocks.
Unplug connector from 3-way valve motor. Refer to
fig. 64.
Pull out retaining clip.
Remove motor.
Disconnect the relief valve drain.
Disconnect the pressure gauge by withdrawing the
clip and pulling out the capillary head.
Undo pipe unions by withdrawing the clips.
39
Maintenance
B Remove 3-way valve.
8.3.7
Gas Valve
B Check that the gas cock is turned off.
B Lower the control panel. Refer to fig. 63.
B Pull off the solenoid connections at the rear of the
valve.
B Undo the union, within the inner casing, securing the
valve to the gas/air tube. Refer to fig. 62.
B Remove the white plastic cap from the gas valve.
B Release the gas inlet union at the manifold assembly.
B Unscrew the two screws securing the gas valve
assembly bracket to the back panel and withdraw the
assembly.
B Transfer the bracket and inlet pipe assembly to the
new gas valve.
B Check for gas soundness when the new gas valve
has been fitted.
B Recheck the combustion performance as described
in section 7.1.
7 181 465 330-12.1R
Fig. 64
After refitting:
B Fill system, bleed and re-pressurise
(see Installation Instructions).
8.3.5
3-way diverter valve motor
B Switch off the appliance.
B Turn off the service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 64.
B Pull out retaining clip.
B Remove motor.
8.3.6
Sensors
B Check that the appliance is electrically isolated.
Central Heating Flow Temperature Sensor –
Item 36, fig. 2, 63
B Pull-off the connector.
B Release the sensor clip and withdraw the sensor.
B Apply heat transfer paste to the replacement sensor.
Safety Temperature Limiter – Item 6, fig. 2, 63
B Pull-off the connectors.
B Unscrew the sensor.
Flue Temperature Limiter – Item 9, fig. 2, 63
B Pull-off the connectors.
B Unscrew the sensor.
6 720 610 602 - 04.1O
Fig. 65
8.3.8
Electrode assembly
B Refer to section 8.2.
B Use a new seal if the existing seal is damaged.
40
6 720 611 443 GB (04.05)
Maintenance
8.3.9
Pressure gauge
B Drain the appliance.
B Lower the facia. Refer to fig. 63.
B Twist the pressure gauge head anti-clockwise to
release it from the casing. Refer to fig. 2.
B Disconnect the capillary head from the rear by withdrawing the clip and pulling out the head. Refer to
fig. 57.
B Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
appliance.
8.3.10 Expansion vessel
B Drain the appliance.
B Undo the union connection at the base of the vessel.
Refer to fig. 2.
B Unscrew the top and bottom fixing screws and
remove the vessel.
B Set the pressure of the new vessel to that required
by the system.
8.3.11 Pressure Relief Valve
B Drain the appliance.
B Disconnect the drain pipe from the valve. Refer to
fig. 33.
B Pull-out the clip securing the valve.
B Pull-out the valve.
B Ensure that the replacement valve is fully entered
before fitting the clip.
8.3.12 Burner
B Refer to section 8.2.
8.3.13 Primary Heat Exchanger
6 720 610 602 - 06.10
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Drain the appliance.
Check that the gas supply is turned off.
Check that the appliance is electrically isolated.
Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 8.3.2.
Remove the burner. Refer to section 8.2.
Disconnect the sensors. Refer to section 8.3.6.
Undo the central heating flow union.
Undo the top connection of the pump. Refer to
fig. 57.
Undo the grey plastic cap, next to the top pump connection at the base of the heat exchanger.
Unscrew and remove the condensate trap. Refer to
section 8.2.
Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
Lift up the flue duct, item 271, refer to fig. 2.
Pull forward from the top and lift the heat exchanger
from the casing.
Transfer components, as necessary, to the new heat
exchanger.
6 720 611 443 GB (04.05)
Fig. 66
41
Appendix
9
Appendix
9.1
Fault Codes
More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.
Display
code
Description
Remedy
A8
Break in communication
Check connecting lead to programmer
AC
Module not detected.
Check connecting lead between TA211E/TR212E
and Heatronic
b1
Code plug not detected.
Insert code plug correctly, test and replace if necessary.
C1
Fan speed too low.
Check fan lead and connector, and fan; replace as
necessary.
d3
Jumper 8-9 not detected.
Connector not connected, link missing, underfloor
heating limiter tripped.
E2
CH flow NTC sensor defective
Check CH flow NTC sensor and connecting lead.
E9
Safety temp. limiter in CH flow has tripped.
Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA
Flame not detected.
Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0
Internal error.
Check electrical connector contacts, programmer
interface module ignition leads are not loose; replace
pcb if necessary.
F7
Flame detected even though appliance switched off.
Check electrode assembly, dry pcb. Flue clear?
FA
Flame detected after gas shut off.
Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue
clear?
Fd
Reset button pressed by mistake.
Press reset button again
P1, P2,
P3, P1...
Please wait, initialisation in progress.
24 V fuse blown. Replace fuse.
Table 18
42
6 720 611 443 GB (04.05)
Appendix
9.2
Short parts list
Key
Description
Qty GC
Spare part number
1
Sensor - Flue gas temp.
1
8 722 963 858 0
2
Sensor - CH flow temp.
1
8 714 500 087 0
3
Control board
1
8 748 300 395 0
4
Gas valve
1
8 747 003 508 0
5
Fan assembly
1
8 717 204 373 0
6
Fan washer
1
8 729 000 183 0
7
Expansion vessel
1
8 715 407 236 0
8
Relief valve
1
8 717 401 012 0
9
Electrode assembly
1
8 718 107 077 0
10
Electrode lead
1
8 714 401 999 0
11
Pump
1
8 717 204 384 0
12
Pressure gauge
1
8 717 208 079 0
13
Burner skin seal
1
8 711 004 168 0
14
Transformer - facia
1
8 747 201 358 0
15
Heat exchanger washer
1
8 710 103 153 0
16
Washer set Condensation Trap
1
8 710 103 154 0
17
Fuse set
1
8 744 503 010 0
18
Primary heat exchanger
1
8 715 406 615 0
Table 19
9.3
Heating/hot water output settings
(N.G)
9.4
Heating/hot water output settings
(L.P.G)
Propane
Natural gas G20
Display
code
Heat
output,
kW
Heat
input,
kW
Gas vol. flow rate
(l/min at
tV/tR = 80/60˚C)
Display
code
Heat output kW
Heat input kW
40
11.0
11.1
30
8.2
8.3
14.5
50
13.7
13.9
40
11.0
11.1
19.4
60
16.5
16.6
50
13.7
13.9
24.2
70
19.2
19.4
60
16.5
16.6
29.1
80
21.9
22.2
70
19.2
19.4
33.9
90
24,7
24.9
80
21.9
22.2
38.8
100
27.4
27.7
90
24,7
24.9
43.6
100
27.4
27.7
48.5
Table 21
Table 20
6 720 611 443 GB (04.05)
43
Mains
switch
ON.
44
Fan runs to
purge gas from
burner.
No
Yes
CH demand
satisfied.
Fan min.
speed for
90 secs.
Yes
*Minimum
heat
input for
15min.
Gas valve closes.
Red light OFF.
No
Boiler
unused
for long
period.*
Pump and Fan
run for up to 3
mins.
* NOTE: The sequence ensures that the condensate siphon is not empty
after long OFF periods. (More than 24 hours without a demand).
Fan speed
reduces
over 15
secs.
Central heating function
Burner lights. Red
light ON.
Burner
stabilises at
start speed for
5-10 secs
Boiler
operates to
match
system load
and CH
control
setting.
9.5.1
Ignition spark for
5 seconds.
Pump ON Fan to
start speed. Gas
valve opens.
Over temperature
shut down if water
temperature is 5∞C
above set value.
Operational Flow diagrams
Ignition sequence
CH
demand.
Gas valve shuts.
Pump remains ON.
9.5
Repeats 5 times
(N.G.) or 3 times
(L.P.G.) before
lock-out.
Green
light
ON.
Room
thermostat
and/or mains
programmer or
link ON AND
Electronic facia
programmer (if
fitted) ON AND
CH control
knob ON.
Burner remains OFF
until flow temperature
is below set value.
Appendix
6 720 611 443 -04.1O
Fig. 67
6 720 611 443 GB (04.05)
Appendix
6 720 611 443 GB (04.05)
45
Appendix
46
6 720 611 443 GB (04.05)
Appendix
6 720 611 443 GB (04.05)
47
Appendix
EXCELLENCE COMES AS STANDARD
Worcester Bosch, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
Users Instructions and
Customer Care Guide
R 25 & 30 HE combi Condensing boiler
R 28 HE system Condensing boiler
6 720 611 441-00.1O
ZWB 7-25 R 25 HE GC-Number: 47 311 77
ZWB 7-30 R 30 HE GC-Number: 47 311 78
ZB 7-28 R 28 HE system GC-Number: 41 311 62
6 720 610 577 GB (04.05) OSW
GB/IE
Contents
Contents
Excellence comes as standard
3
Safety precautions
5
1
General notes
7
2
Controls
10
3
3.1
3.2
3.3
3.4
3.5
3.6
11
11
13
14
14
15
3.7
3.8
Operating the Appliance
Preparation
Switching the Appliance On/Off
Switching on the Central Heating
Controlling Central Heating
R 25 & 30 Boilers: Setting the Hot Water Temperature
Summer Mode, Hot Water Only
(R 25 & 30 Appliances)
Frost protection (R 25 & 30 Appliances)
Fault Condition
4
Tips on saving energy
18
5
General Information
19
6
Maintaining your appliance
20
7
Service
20
8
Fault or breakdown
21
9
Your guarantee
22
10
Guarantee registration
23
11
Operating Instructions Quick Reference
24
2
16
16
17
6 720 610 577 GB (04.05)
Excellence comes as standard
Excellence comes as standard
Thank you for purchasing an R 25 & 30/R 28 condensing appliance.
The R 25 & 30/R 28 Series has been developed by the Bosch
Group and the strictest quality control standards are demanded
throughout every stage of production.
Indeed, the Bosch Group have led the field in innovative appliance
design and performance for many years.
The result is that your new R 25 & 30/R 28 appliance offers you
the very best of everything – quality, efficiency, economical running costs, proven reliability and value for money.
What’s more, you also have the assurance of our no nonsense
2 year parts and labour guarantee.
And it’s backed up by Worcester Heat Systems Ltd. - Offering a
complete maintenance scheme to keep your boiler operating at
peak condition and efficiency.
No wonder that more and more people are agreeing that when it
is gas, it has to be a Worcester Heat Systems Ltd. Condensing
appliance.
Benchmark
The “Benchmark” initiative is the new code of practice to encourage the correct installation, commissioning and servicing of
domestic central heating boilers and system equipment.
The “log-book” is a vital document that must be completed by the
installer at the time of installation. It confirms that the boiler has
been installed and commissioned according to the manufacturers’ instructions.
Without the completion of the “log-book”, manufacturers may
refuse to respond to a call–out from a householder, who will be
advised that he or she must call back the installer, who has not fulfilled his obligations to record the information required by the initiative.
6 720 610 577 GB (04.05)
3
Excellence comes as standard
EIRE ONLY
The CE mark to indicates manufacture to EU safety requirements.
This appliance must be installed only by a competent person to
the requirements of IS 813.
Make sure your installer hands you a certificate confirming compliance with IS 813 and that you read carefully the instruction
book suppplied with this appliance.
Keep the instruction book and compliance certificate for future
reference.
4
6 720 610 577 GB (04.05)
Safety precautions
Safety precautions
Gas Safety (Installation and Use) Regulations 1998
It is the law that all gas appliances are installed by a competent
person in accordance with the above regulations. Failure to install
appliances correctly could lead to prosecution. It is in your interest, and that of safety, to ensure compliance with the law.
If you smell gas:
B Turn off gas service cock at the meter.
B Open all doors and windows.
B Do not operate any electrical switches.
B Do not smoke.
B Extinguish any naked flames.
B Call your gas company.
If you smell fumes from the appliance:
B Switch off appliance.
B Open windows and doors.
B Inform your heating engineer.
Fitting and modifications
B Fitting of the appliance or any modifications to the appliance
may only be carried out by a competent person.
B Flue systems must not be modified in any way.
Maintenance
B We recommend that you take out a maintenance contract
with a competent installer and have the appliance serviced at
regular intervals.
B Ensure that your Service Engineer uses only genuine spare
parts!
Combustible materials
B Do not store or use any combustible materials (paper, thinners, paints etc.) in the vicinity of the appliance.
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5
Safety precautions
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance being electrically unsafe.
B There are no substances used in the construction that are a
potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).
Combustion Air/Ambient Air
B Keep combustion air/ambient air free of corrosive substances
(e.g. halogenated hydrocarbons which contain chlorine or fluorine compounds). In this way corrosion can be prevented.
6
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General notes
1
General notes
To get the best from your appliance please read these instructions carefully.
Sealed heating systems
The appliance is fitted to a sealed heating system which is prepressurised. Your installer will tell you of the minimum and maximum pressure which must be indicated on the pressure gauge.
Check regularly that the pressure is maintained and contact your
installer or maintenance engineer if there is a permanent significant drop in the pressure. If the system loses pressure it should
be repressurised and the cause of the fall investigated.
Central heating systems
During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. If the
top of a radiator is at a lower temperature than the bottom then it
should be vented by releasing air through the venting screw at the
top of the radiator. Ask your installer to show you how this is done.
Repeated venting will reduce the quantity of water in the system
and this must be replenished for safe and satisfactory operation of
the appliance.
Should water leaks be found in the system or excessive venting is
required then a service engineer must be contacted to inspect the
installation and rectify any fault.
Only additives that are compatible with aluminium may be used in
the system. Any incompatible additive used will invalidate the
guarantee.
Condensate drain
This is a condensing appliance and the terminal will, at times, give
out a plume of water vapour. This is quite normal.
The appliance produces quantities of condensate which is discharged regularly through the siphon.
6 720 610 577 GB (04.05)
7
General notes
Clearances
Your installer will have provided adequate space around the appliance for safety and servicing access. Do not restrict this space
with the addition of cupboards, shelves etc. next to the appliance.
Left-hand side
Right-hand side
In Front
Above Casing (Vert. Flue)
Above Flue Turret
Below
10 mm
10 mm
600 mm
200 mm
30 mm
200 mm
Table 1
Room thermostat
A room thermostat may be fitted to control the central heating.
Refer to the instructions supplied with the thermostat for information on siting and setting. A programmable thermostat may also
be used with this appliance to provide additional timed control of
the central heating.
Thermostatic radiator valves
It is recommended that this type of valve is fitted to all the radiators except one, usually a radiator where the room thermostat is
fitted. They should conform to the requirements of BS2767:10.
Showers, bidets, taps and mixing valves – R 25 & 30
Boilers
Standard hot and cold taps and mixing valves must be suitable for
operating at mains pressure. Thermostatically controlled or pressure equalising shower valves will guard against the flow of water
at too high a temperature.
Hot and cold mains fed water can be supplied directly to an overrim flushing bidet subject to local water company requirements.
With all mains fed systems the flow of water from individual taps
will vary with the number of outlets operated simultaneously and
the cold water mains supply pressure to the property.
Flow balancing using “ball-o-fix” type valves is recommended to
avoid an excessive reduction in flow to individual outlets.
8
6 720 610 577 GB (04.05)
General notes
For further information contact Worcester Heat Systems Ltd.
Technical Services Department.
Hot and cold flow – R 25 & 30 Boilers
The flow of water demanded from both hot and cold service outlets is dependent upon the mains supply. It may not be possible
in some installations to operate all outlets simultaneously.
Water mains failure – R 25 & 30 Boilers
If there is a failure of the mains water supply then no water will be
available at a tap or shower until the mains supply is restored. The
appliance will still operate in the central heating mode.
Use in hard water areas – R 25 & 30 Boilers
In exceptionally hard water areas a device to prevent scale formation may be fitted. Installation of a scale inhibitor assembly should
be in accordance with the requirements of the local water company. An isolating valve should be fitted to allow for servicing.
Alternatively the maximum temperature of the domestic hot water
may be reset to about 45 °C which will reduce the risk of scale
formation in these hard water areas.
Ventilation
This is a room sealed appliance and does not require any air for
combustion from inside the house. If the appliance is fitted into a
cupboard or a compartment is built around the appliance after
installation then the compartment must be separated from the
boiler space by a perforated non-combustible partition as
described in BS6798.
Notwithstanding the requirements of BS6798, there is no need
for ventilation openings to be provided in the compartment
because of the low heat loss from the casing.
Do not allow the flue terminal fitted on the outside wall to become
obstructed or damaged.
Pump
The pump will have been set by the manufacturer and must not be
manually re-adjusted.
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9
Controls
2
Controls
136 365
61
317 366 367 363 310 422
ECO
364
8.1
135
E
CH
C
295
170
171
172
173
170
6 720 610 600-01.1O
8.1
61
135
136
170
171
172
173
295
310
317
363
364
365
366
367
422
10
System Pressure gauge
Reset button
Master switch
Central heating temperature control
Service valves in CH flow and return
Hot water
Gas isolation valve (open)
Cold water inlet
Identification sticker
Hot water temperature control (R 25 & 30)
Display
Indicator lamp for “burner on”
Indicator lamp for “off/on”
“Chimney sweep” button
Service button
“ECO” button
Optional timer
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Operating the Appliance
3
Operating the Appliance
3.1
Preparation
Turn on the gas cock (172).
B Press in the handle and turn it anti-clockwise as far as the stop
(when handle is in line with direction of flow, the cock is open).
Central heating system valves (170)
B Using a spanner, turn square nut until groove is in line with
direction of flow (see detail).
Groove at right angles to direction of flow = off.
Cold water inlet valve (173)
B Turn handle so that it is in line with direction of flow.
When handle is at right angles to direction of flow, the valve is
closed.
170
172
173
6 720 610 577-02.1O
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11
Operating the Appliance
Check the central heating system pressure
B The pointer on the pressure gauge (8.1) should be about
1 bar.
B If the pointer is below 1 bar (when the system is cold), top up
the system with water until the pointer is 1 bar. Your installer
will have shown you how to do this.
B The maximum operating pressure of 2.5 bar at maximum
central heating flow temperature must not be exceeded. If the
pressure increases to 3 bar then the relief valve (15) opens.
2
3
1
4
0
bar
8.1
CH
C
15
6 720 610 600-03.1O
12
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Operating the Appliance
3.2
Switching the Appliance On/Off
Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will show the
central heating flow temperature, when the appliance is operating in the central heating mode.
6 720 610 333-04.1O
i
If the display alternates between -II- and the central heating flow temperature, the trap filling programme is active.
The trap filling programme ensures that the condensation trap is
filled after the appliance has been installed or after the appliance
has been out of use for a long period. For that reason, the appliance remains at minimum heating output for 15 minutes.
Switching off
B Switch off the appliance at the master switch (0).
The green indicator lamp goes out. The optional timer will continue running until the emergency supply is exhausted.
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13
Operating the Appliance
3.3
Switching on the Central Heating
B Turn the central heating temperature control
level:
to the desired
– “Min” setting: 35˚C
– Low-temperature heating: setting “E” (approx. 75˚C)
– “Max” setting: 88˚C
When the burner is lit, the red indicator lamp is illuminated.
6 720 610 333-05.1O
3.4
Controlling Central Heating
B Set room thermostat to the desired room temperature.
B Set room temperature controller unit, if fitted. Refer to the
instructions with the control.
B Set the thermostatic radiator valves to the desired settings.
14
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Operating the Appliance
3.5
R 25 & 30 Boilers: Setting the Hot Water
Temperature
Hot water temperature
On R 25 & 30 models, the hot water temperature can be set to
between approx. 40˚C and 60˚C using the temperature
control
.
The domestic hot water temperature is not shown on the display.
6 720 610 333-07.1O
Control Setting
Water Temperature
Anti-clockwise limit
approx. 40˚C
approx. 55˚C
Clockwise limit
approx. 60˚C
Table 2
“ECO” button
By pressing and holding the “ECO” button
, until the display
lights, you can switch between Comfort mode and Economy
mode.
Comfort mode: button is not lit (factory setting)
The appliance is held constantly at the set temperature. This
means that hot water is available almost instantaneously at the
tap. Consequently the appliance will switch on at intervals, even if
no hot water is being drawn.
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15
Operating the Appliance
ECO mode with demand detection, button is lit
The demand detection function enables maximum gas and water
economy.
Briefly turning a hot water tap on and then off again signals
demand to the appliance which then heats up the water to the set
temperature.
Hot water is thus available in about 1 minute.
ECO mode, button is lit
Water is not heated up until hot water is drawn. This means that
there is a longer waiting period before hot water is available.
3.6
Summer Mode, Hot Water Only
(R 25 & 30 Appliances)
With room thermostat
B Turn temperature control
on the appliance anti-clockwise
as far as the stop.
The central heating is now turned off. The hot water function
and the mains power supply for the heating programmer and
timer remain switched on.
3.7
Frost protection (R 25 & 30 Appliances)
B Leave master switch switched on.
If the appliance is to be left for long periods switch the central
heating off:
B Add a suitable anti-freeze fluid to the water in the central heating system.
Suitable products are available from Betz-Dearborn Tel.: 0151
4209563, Fernox Tel.: 01799 550811 and Salamander on
0121 378 0952.
16
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Operating the Appliance
3.8
Fault Condition
In the unlikely event of a fault occurring while the appliance is in
operation:
The display then shows a fault code and the button
flash.
If the button
may also
flashes:
B Press and hold the button
until the display shows “– –”.
The appliance will then start up again and the display will show
the central heating flow temperature.
If the button
does not flash:
B Switch the appliance off and then on again at the master
switch.
The appliance will start up again and the central heating flow
temperature will be displayed.
If the fault remains and can not be cleared:
B Call Worcester Heat Systems Ltd. for assistance, giving a
description of the fault and, if possible, the fault code from the
facia display.
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17
Tips on saving energy
4
Tips on saving energy
Heating economically
The boiler is designed to provide a high level of comfort while
keeping gas consumption and the resulting environmental effect
as low as possible. The gas supply to the burner is controlled
according to the level of demand for heat. The boiler continues to
operate with a low flame if the demand for heat reduces. The technical term for this process is modulating control. Modulating control keeps temperature fluctuations small and provides even
distribution of heat throughout the home. This means that the
boiler may stay on for relatively long periods but will use less gas
than an appliance that continually switches on and off.
Central heating systems with room thermostats/thermostatic radiator valves
The central heating control on the boiler should be set to the maximum rated temperature of the central heating system or to position “E”, when the maximum central heating water temperature
obtained is 75˚C.
The temperature can be set individually in each room (except primary room with the room thermostat) using the thermostatic radiator valves. If you wish to have a lower temperature in the primary
room than in the other rooms, leave the room thermostat at the set
temperature and turn down the radiator using the radiator valve.
Reduced-output operation
Considerable fuel savings can be made by slightly reducing the
room temperature. Lowering the temperature by 1°C can bring
about energy savings of up to 5%. However, it is not advisable to
allow the room temperature to fall below +15°C. The room temperature for reduced-output mode can be set separately on the
room thermostat. Instructions are given in the control unit operating instructions.
18
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General Information
Hot water
A lower setting on the hot water temperature control can result in
considerable energy savings.
For R 25 & 30 appliances:
The on-demand activation using the ECO-button makes possible the maximum savings of gas and water.
Now you know how to heat your home economically with the R 25
& 30/R 28 gas condensing boiler. If you have any other questions,
please contact your installer – or write to us.
5
General Information
Cleaning the Outer Case
Wipe down the outer case with a damp cloth. Do not use abrasive
or caustic cleaning agents.
Appliance details
If you ever need to call Customer Service it helps us a great deal
if you can provide precise details of your appliance.
The information is printed on the appliance identification plate/
sticker (see page 10, item 295).
Your installer will have completed the Benchmark “log-book” giving details of the boiler together with name, address and registration number. Have the “log-book” to hand when calling a Service
Engineer.
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19
Maintaining your appliance
6
Maintaining your appliance
Your new R 25 & 30/R 28 gas-fired appliance represents a longterm investment in a reliable, high quality product.
In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is essential that your boiler receives regular, competent servicing and
maintenance checks beyond the initial 2 year guarantee period.
If you would like to know more about a Worcester Bosch service
contract, please tick the appropriate box on your warranty registration card.
7
Service
If your R 25 & 30/R 28 appliance should fail to operate correctly
or requires servicing please call Worcester Heat Systems Ltd. on:
08457 256 206.
20
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Fault or breakdown
8
Fault or breakdown
This product is supported in the UK by Worcester Heat Systems
Ltd. – part of the Bosch Group.
A specialist factory trained field SERVICE ENGINEER is available
to attend a breakdown or manufacturing fault occurring on this
appliance.
No charge will be made for parts and/or labour providing:
• An appliance fault is found and the appliance has been
installed within the past 24 months. Reasonable evidence of
this must be supplied on request.
A call-out charge will be made where:
• The appliance has been installed for over 24 months.
OR
• Our Field Service Engineer finds no fault with the appliance
(see NOTE).
OR
• The cause of breakdown is misuse or with other parts of your
plumbing/heating system, or with equipment not supplied by
Worcester.
NOTE: No appliance fault is found on over 30 % of all service call
outs.
If in doubt contact our Worcester Heat Systems Ltd. on 08705
266241.
IN THE EVENT OF AN APPLIANCE FAULT OR BREAKDOWN please contact your Service Centre. Your service administrator will arrange for an engineer to call with the minimum of
delay; under normal circumstances this will be within the period
1-3 working days (excluding weekends) for priority breakdown situations (no hot water and/or heating service).
INVOICES FOR ATTENDANCE AND REPAIR WORK CARRIED OUT ON THIS APPLIANCE BY ANY THIRD PARTY
WILL NOT BE ACCEPTED.
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21
Your guarantee
9
Your guarantee
This appliance is guaranteed against faulty material or workmanship for a period of 24 calendar months from the date of installation subject to the following conditions and exceptions.
• That during the currency of this guarantee any components of
the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and
free of labour charges by Worcester Heat Systems Limited.
• That the householder may be asked to prove the date of installation, that the appliance was correctly commissioned and,
where appropriate, the first 2 year service has been carried out
to the satisfaction of Worcester Heat Systems Limited when
requested.
• That any product or part thereof returned for servicing under
the guarantee must be accompanied by a claim stating the
Model, Serial Number, Date of Installation.
• That Worcester Heat Systems Limited will not accept responsibility for damage caused by faulty installation, neglect, misuse or accidental damage, the non observance of the
instructions contained in the Installation and Users Instructions
Leaflets.
• That the appliance has been used only for normal domestic
purposes for which it was designed.
• That this guarantee applies only to equipment purchased and
used in Great Britain.
This guarantee is given in addition to all your normal statutory
rights.
22
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Guarantee registration
10
Guarantee registration
You should complete and return the postpaid Guarantee Registration Card within 14 days of purchase.
The card will register you as the owner of your new appliance and
will assist us in maintaining an effective and efficient customer
service by establishing a reference and permanent record for your
boiler.
This will not affect your statutory rights in any way.
Important:
For your own record:
Model
......................................................................................................................
Serial number:..........................................................................................
(See identity label inside appliance casing)
Type/size:...................................................................................................
Date of installation:................................................................................
Check that the Benchmark “log-book” has been completed by
your installer or service engineer.
EXCELLENCE COMES AS STANDARD
Worcester Heat Systems, Cotswold Way, Warndon,
Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
SERIAL NUMBER. Copy the number off the Guarantee Card.
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23
11
6 720 610 333-09.1O
Hot water only
“ECO”-button not lit –
Comfort mode
“ECO”-button lit –
Economy mode.
6 720 610 333-07.1O
Hot water temperature
Operating Instructions Quick Reference
Switching on
6 720 610 333-04.1O
Switching the central heating on
6 720 610 333-05.1O
Controlling the central heating
Set room thermostat to desired temperature or the remote temperature
control unit to the appropriate setting.
Fault Condition
If the
button flashes, press and
hold-in to reset the appliance. Refer
to page 17.
Switching off
6 720 610 333-11.1O

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