Worcester R29 Technical data

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Installation and Servicing Instructions

GREENSTAR 29 HE Conventional

Wall mounted condensing boiler

6 720 610 577-00.10

HE Conventional

GC-Number Natural Gas: 41 311 56

GC-Number LPG: 41 311 57

Contents

Contents

Safety precautions

Symbols

1 Details of the appliance

1.1

EC Declaration of Conformity

1.2

Standard package

1.3

Description of appliance

1.4

Accessories

1.5

Casing dimensions

1.6

Layout of appliance

1.7

Function

1.8

Electrical wiring diagram

1.9

Technical data

2 Installation regulations

3 Installation

3.1

Important remarks

3.2

System

3.3

Siting the appliance

3.4

Wall mounting frame assembly

3.5

Pre-piping the system

3.6

Fitting the appliance

3.7

Checking the connections

3.8

Flue Systems

3.8.1 Siting the Flue Terminal

3.8.2 Installation of the flue

3.8.3 Flue duct preparation and assembly

4 Electrical connections

4.1

Connecting the appliance

4.2

Wiring to your system

5 Commissioning

5.1

Commissioning

5.2

Switching the appliance on/off

5.3

Switching on the System

5.4

System controls

5.5

Frost protection

5.6

Fault Condition

10

14

14

15

16

11

11

11

13

16

17

18

20

21

21

22

23

23

24

24

24

24

25

3

3

6

7

5

5

8

9

4

4

4

4

6 Individual settings

6.1

Mechanical settings

6.1.1 Setting the boiler flow temperature

6.2

Settings on the Bosch Heatronic

6.2.1 Operating the Bosch Heatronic

6.2.2 Setting the anti-cycle time

(Service Function 2.4)

6.2.3 Setting the maximum flow temperature

(Service Function 2.5)

6.2.4 Setting the switching difference

(Service Function 2.6)

6.2.5 Setting the heating output

(Service Function 5.0)

6.3

Setting the gas/air ratio

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 O

2

or CO in the combustion air

2

level

7.2.2 Testing CO and CO

2

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 Sensors

8.3.4 Gas Valve

8.3.5 Electrode assembly

8.3.6 Pressure Relief Valve

8.3.7 Burner

8.3.8 Primary Heat Exchanger

37

38

38

38

32

33

34

37

39

39

39

39

9

9.1

9.2

9.3

9.4

9.5

Appendix

Fault Codes

Short parts list

Heating settings (N.G)

Heating settings (L.P.G)

Operational Flow diagram

26

26

26

26

26

27

27

27

27

28

40

40

41

41

41

42

2

6 720 611 137 GB (03.02)

Safety precautions

Safety precautions

B

B

B

B

If you smell gas

B Turn off gas service cock at the meter.

Open windows and doors.

Do not operate any electrical switches.

Extinguish any naked flames.

Telephone your gas company.

If you smell fumes from the appliance

B

Switch off appliance (see page 24).

B Open windows and doors.

Fitting and modifications

B Fitting of the appliance or any controls to the appli-

B ance may only be carried out by a competent engineer in accordance wth the Gas Safety (Installation and Use) Regulations.

Flue systems must not be modified in any ways other

B than as described in the fitting instructions.

This appliance is supplied for fitting to fully pumped, sealed and open vent systems only.

Maintenance

B The user is recommended: to have the system

B regularly serviced in order to ensure that it functions reliably and safely.

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

B

This appliance contains no asbestos products.

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).

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

B it.

These instructions are to be left with the user or at

B the Gas meter.

Important: These instructions apply in the UK only.

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.

3

6 720 611 137 GB (03.02)

Details of the appliance

1 Details of the appliance

1.1

EC Declaration of Conformity

This appliance is in accordance with the applicable requirements of the Gas Appliance Directive, Boiler

Efficiency Directive, Electromagnetic Compatibility

Directive and the Low Voltage Directive.

PIN CE-0085 BL 0507

Category

UK

Appliance Type

Table 1

II

2H 3P

C

13

, C

33

1.2

Standard package

• Gas condensing boiler

• Wall mounting frame

• Clamp for securing flue duct kit

• Fixings (screws etc.)

• Set of documentation for appliance

• Pre-plumbing manifold

• Condensate drain pipe.

1.3

Description of appliance

• Wall-mounted appliance, siting not dependent on room size

• Natural gas models are low-emission appliances

• Multifunction display

• Bosch Heatronic control system

• Automatic ignition

• Modulating control

• Full safety systems incorporating Bosch Heatronic with flame ionisation monitoring, solenoid valves and temperature sensors

• Concentric flue/air duct with testing point for

CO

2

/CO

• Regulated speed fan

• Pre-mix burner

• Temperature control for boiler flow

• Safety temperature limiter in 24 V electrical circuit

• Flue gas temperature limiter (105 °C)

• Condensate Trap

• Connecting possibility for 3 port or 2 x 2 port

motorised valve systems

• Suitable for fully pumped sealed and open vent systems.

4

6 720 611 137 GB (03.02)

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.

• Security kit.

1.5

Casing dimensions min.

5 * min.

5 *

Z

Y

X

600

*

120

Details of the appliance

101

103

440

35 360

395

*

Fig. 1

13

101

103

X

Y

Z

*

Wall mounting frame and Manifold assembly

Outer case

Facia cover

Standard Concentric Horizontal Flue System: (Ø 100 mm) min. 310 mm

Alternative Concentric Flue System: (Ø 125 mm) 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

200

13

6 720 610 601- 01.3O

6 720 611 137 GB (03.02)

5

Details of the appliance

1.6

Layout of appliance

221.1

221.2

226

27

29

271

43

9

63

358

64

4.4

7

361

295

417

Fig. 2

32.1

36

43

63

64

102

120

9

15

27

29

6

7

4

4.4

Heatronic control

Y-S-module

Heat exchanger safety temperature limiter

Testing point for gas supply pressure

Flue gas temperature limiter

Safety valve

Automatic air vent

Air gas Mixer unit

Electrode assembly

Temperature sensor in boiler flow

Flow pipe

Adjustable gas flow restrictor

Adjusting screw for min. gas flow volume

Inspection window

Fixing points

6

120

349

234.1

234

415

416

102

32.1

36

6

423

418

15

4

6 720 611 137-01.1 O

358

361

415

416

417

418

423

221.1

221.2

226

295

234

234.1

271

349

Flue duct

Combustion air intake

Fan assembly

Appliance type sticker

Testing point for combustion products

Testing point for combustion air

Flue duct

Cover plate for twin flue duct connection

Condensate trap

Drain valve

Cover plate for cleaning access

Condensate collector

Clip for fixing outer case

Data plate

Siphon

6 720 611 137 GB (03.02)

Details of the appliance

1.7

Function

27 229 226 29 33 30 234.1

234

4.4

443

29.1

36

ϑ

6

63

52.1

0

4 61 317

1

2

3

4

5

E max

ECO

57

7

69

64

56

358

15

52 55

361 43

Fig. 3

33

35

36

43

29

29.1

30

32

9

13

15

27

6

7

4

4.4

Bosch Heatronic control

Y-S-module

Temperature limiter, heat exchanger

Testing point for gas supply pressure

Flue gas temperature limiter

Manifold

Safety valve

Automatic air 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 boiler flow

Boiler flow

63

64

69

84

88

221

226

229

234

55

56

57

61

45

47

Gas inlet

Return

52 Solenoid valve 1

52.1

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

Motor (optional extra)

3-way valve (optional extra)

Flue duct

Fan

Inner casing

Testing point for flue gas

45 13 47

234.1

Testing point for combustion air

317 Display

358 Condensate trap

361 Drain valve

423 Siphon

443 Diaphragm

4

6 720 611 137-02.1O

32

221

35

9

6 720 611 137 GB (03.02)

7

Details of the appliance

1.8

Electrical wiring diagram

364

4.1

33

365 61 317 o - orange bl - black r - red

366 367

ECO

363

25 V

153

230V/AC

135

230 V

136

328

302

L N Ns Ls LR

151

310

312

313

1 2 4 7 8 9

161

300 mains supply

4.4

Fig. 4

32

33

36

52

6

9

4.1

4.4

Ignition transformer

Y-S-module

Temperature limiter, heat exchanger

Flue gas temperature limiter

Flame sensing electrode

Ignition electrode

Temperature sensor in primary flow

Solenoid valve 1

52.1

Solenoid valve 2

56 Gas valve CE 427

61 Reset button

135 Master switch

136 Temperature control for boiler flow

151 Fuse, slow 2.5 A, AC 230 V

153 Transformer

161 Link

226 Fan

M

226

9 6 r r

52 52.1

56 bl bl bl bl o o

36

32

6 720 611 137-03.1O

300

302

310

312

313

317

328

363

364

365

366

367

Code plug

Earth connection

Function control (Service only)

Fuse, slow T 1,6 A

Fuse, slow T 0,5 A

Digital display

Terminal block for AC 230 V Mains supply

Indicator lamp for burner

Indicator lamp for power supply

“Chimney sweep” button

Service button

No function

8

6 720 611 137 GB (03.02)

Details of the appliance

1.9

Technical data

Units Natural gas Propane

Max. rated heat output net 40/30˚C central heating

Max. rated heat output net 50/30˚C central heating

Max. rated heat output net 80/60˚C central heating

Max. rated heat input net

Min. rated heat output net 40/30˚C

Min. rated heat output net 50/30˚C

Min. rated heat output net 80/60˚C

Min. rated heat input net

Maximum gas flow rate - After 10 minutes from lighting

Natural Gas G20 (CVnet 34.02 MJ/m

3

) m

3

/h

LPG G31 (CVnet 88 MJ/m

3

) kg/h

Gas supply pressure

Natural Gas G20 (CVnet 34.02 MJ/m

3

)

LPG G31 (CVnet 88 MJ/m

3

) mbar mbar

Flue

Flue gas temp. 80/60˚C, rated/min. load

Flue gas temp. 40/30˚C, rated/min. load

Residual delivery pressure

(inc. pressure drop in air intake duct)

CO

CO

2

level at max. rated heat output

2

level at min. rated heat output

NO x

-class

SEDBUK figure, Band A

1)

Condensate

Max. condensation rate (t

R

= 30˚C)

˚C

˚C

Pa

%

%

% l/h kW kW kW

29.3

29.0

27.4

kW27.7

kW kW kW

8.4

8.3

7.4

kW7.6

2.9

-

20

-

67/55

43/32

80

9.2

8.8

5

90.7

2.3

29.3

29.0

27.4

27.7

11.6

11.4

10.5

10.8

-

2.1

-

37

67/55

43/32

80

10.8

10.5

5

90.7

2.3

pH-value, approx.

General Data

Electrical power supply voltage

Frequency

Max. power consumption

Noise output level

Appliance protection rating

Max. flow temperature

Minimum static head

Maximum static head

Permissible ambient temperatures

Nominal capacity of appliance

AC ... V

Hz

W43 dB(A)

IP

˚C m m

˚C l

4.8

230

50

36

X4D nom. 90

1.0

30.0

0 - 50

3.75

4.8

230

50

43

36

X4D nom. 90

1.0

30.0

0 - 50

3.75

Weight (excluding packing)

Table 2

1) kg 38 38

The value is used in the UK Government Standard Assessment Procedure (SAP) for the energy rating of dwellings. The test data from which it has been calculated have been certified by DVGW.

6 720 611 137 GB (03.02)

9

Installation regulations

Condensate analysis, mg/l

Ammonium

Lead

Cadmium

Chromium

Halogenated hydrocarbons

Hydrocarbons

Copper

1.2

Nickel

≤ 0.01

Mercury

0.001

Sulphate

≤ 0.005

Zinc

Tin

≤ 0.002

0.015

Vanadium

0.028

pH-value

Table 3

Flue system

HORIZONTAL 100 mm – Standard

Overall Diameter of Duct mm 100

0.15

≤ 0.0001

1

≤ 0.015

0.01

0.001

4.8

Flue Terminal / Duct

Assembly Length mm 600

Max.

4 m

Extension Duct Length

Table 4 mm 1000

VERTICAL 100 mm – Standard

Overall Diameter of Duct

Flue Terminal / Duct

Assembly mm 100 mm 600

Extension Duct Assembly

Table 5 mm 1000

ALTERNATIVE HORIZONTAL 125 mm FLUE

SYSTEM

Max.

6.4 m

(incl. flue assembly)

Overall Diameter of Duct

Extension Duct Length

Table 6 mm 125

Flue Terminal / Duct Assembly mm 1030 mm 1000

Max.

13 m

(inclu- ding turret)

VERTICAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125

Flue Terminal / Duct Assembly mm 1360

Extension Duct Length mm 1000

Table 7

Elbow - 90 ° Equivalent length 2 m

Bend - 45 ° Equivalent length 1m

Max.

15 m

Gas supply

Total length of gas supply pipe

(metres)

3 6 9

Gas discharge rate (m

3

/h)

Pipe diameter

(mm)

8.7

5.8

4.6

22

18.0

Table 8

12.0

9.4

28

2 Installation regulations

Gas Safety (Installation & Use) Regulations: 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

• 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).

• BS 6700: Domestic water supply (when relevant)

• BS 7671: Requirements for Electrical Installation.

These instructions must be followed.

10

6 720 611 137 GB (03.02)

Installation

3 Installation

B Always turn off the gas cock before carrying out any work on components which carry gas.

i

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.

3.1

Important remarks

B Appliance is prepared to be installed in fully pumped sealed and open vent 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. All system cleaners must be removed before adding any inhibitor.

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.

3.2

System

The system must comply with the requirements of

BS 6798 and BS 5449.

General

The appliance is only suitable for connection to indirect fully pumped sealed and open-vent systems. The minimum static head is 1.0 m and the maximum is 30m.

The controls must be wired to ensure that the boiler does not cycle when the electronically controlled zone valves are closed.

Note 1: An automatic by-pass is required if the controls i.e. 2-port valves, can result in the closure of the CH and

DHW circuits when the boiler is hot. If mechanically operated thermostatically controlled valves are fitted on all radiators then an automatic by-pass located at least

2m from the boiler is required.

Note 2: A by-pass is generally unnecessary on a system using a 3-way diverter valve as one port will be open to flow at all times. However if TRV's are used throughout then an automatic by-pass may be necessary. Refer to the current Building Regulations or the

Good Practise Guide 302 which lists all the above requirements.

Plastic pipes must not be directly connected to the appliance. A copper to plastic transition piece should be positioned a minimum of 600mm from the appliance.

Some plastice pipes are permeable to oxygen and must be avoided. a pipe with a polymer barrier should be used.

Sealed System

A sealed system must include an expansion vessel, pressure gauge and pressure relief valve set operate at

3bar - these are available as proprietary kits. The expansion vessel and fittings must be connected at the neutral point of the system on the entry to the pump. A pump and diverter valves are also required as appropri-

ate to the system. Refer to Fig. 5, 6, 7. The sealed sys-

tem must be filled through a WRAS approved filling kit.

Refer to Fig. 8. For system wiring please refer to Fig. 12

and the controls manufacturers details.

The appliance must not be operated without the system being full of water and correcetly pressurised.

All connections in the system must withstand a pressure of up to 3 bar. The system and appliance must be properly vented. Repeated venting loses water from the system and usually indicates that there is a leak. A drain cock to BS 2879 must be fitted to the lowest point of the system.

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 Super Concentrate or Sentinel 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.

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 BS 7593.

Domestic Hot Water

The appliance is NOT suitable for direct water supply.

Do not connect to a direct cylinder.

The appliance can be connected to any indirect cylinder i.e unvented or thermal store, and all the benefits of a "dry loft" can be realised. For more information contact Worcester Heat Systems Helpline 08705 266241.

Note: Indirect coil type or a direct cylinders with an immersion calorifier that is suitable for a pressure of

0.35 bar above the setting of the pressure relief valve may be used. Single feed indirect cylinders are

NOT suitable for sealed systems. Any connection to the mains water supply must conform to the relevant

Building and Water Regulations and be approved by the local water company.

11

6 720 611 137 GB (03.02)

Installation

Typical system layout if using Honeywell 'Y' plan

Feed and

Vent Cistern

Primary cold feed

(15mm min.)

S.H.

Domestic hot water cylinder

Heating vent

(22mm min.)

150mm max

Diverting valve

Boiler

Pump

Bypass or uncontrolled radiator

(if required)

Refer to system

notes.

S.H.

S.H. – Minimum static head 1.0m measured from the highest point in the heating system (top surface of the appliance or highest point in the heating system) to the water level in the feed and expansion tank

Radiator

N.B. A drain cock should be installed at the lowest point of the heating circuit

6 720 611 137 -26.1O

Fig. 5

Typical system layout if using Honeywell 'S' plan

Feed and

Vent Cistern

Primary cold feed

(15mm min.)

S.H.

Domestic hot water cylinder

Heating vent

(22mm min.)

Diverting valves

150mm max

Boiler

Pump

Bypass or uncontrolled radiator

Refer to system

notes.

Fig. 6

S.H.

S.H. – Minimum static head 1.0m measured from the highest point in the heating system (top surface of the appliance or highest point in the heating system) to the water level in the feed and expansion tank

Radiator

N.B. A drain cock should be installed at the lowest point of the heating circuit

6 720 611 137 - 27.1O

12

6 720 611 137 GB (03.02)

Installation

Fully pumped sealed system

Note:

A drain cock should be fitted at the lowest RV point of the heating circuit and beneath the appliance

LV

RV

LV

INDIRECT

CYLINDER

BOILER

LV LV

RV

RV

Pressure

Gauge

Expansion

Vessel

Relief

Valve

Bypass balancing valve or uncontrolled radiator with tw o lockshield valves

Radiator Valve - Flow RV

Lockshield Valve - Return LV

Mains Cold Water

BS

Stop Valve Fixed Cylinder Type or sealed systems - Approved connection

6 720 611 137 - 28.2O

Fig. 7

Sealed system filling and make up

Heating return

Non return valve

Non return valve Hose union

Test cock

Stop cock

Temporary hose

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.

Heating return

Auto air vent Non return valve

Make up vessel

Fill point

Stop cock

1000mm (39 in) above the highest point of the system.

6 720 611 137 - 29.1O

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. Refer to Fig. 1

for the required clearences around the appliance.

6 720 611 137 GB (03.02)

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

6 720 610 576-04.1O

Fig. 9

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.

Fig. 11

3.5

Pre-piping the system

200

112

43 47

50

Fig. 10

6 720 610 576-05.1O

260

6 720 611 137-04.1O

Fig. 12 Manifold

43

47

112

Primary flow

Primary return

Gas cock

B Remove the domestic hot water and cold water inlet valves from the manifold and discard.

B A drain tap should be fitted at the lowest point of the central heating system.

14

6 720 611 137 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

Siphon

Ø 22 min.

Sink

Boiler

No length restriction 75 min. trap

Ø 22 min.

Siphon

Use waterproof pipe work insulation in very exposed positions

The gradient of the discharge pipe should be 2.5

°

(40 mm/m) minimum

An internal waste system

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

An external waste system

External length of pipe 2m min.

Open end of pipe direct into gully, below ground but above water level.

Boiler

Ø 22 min.

No length restriction

75 min. trap

Internal soil and vent stack Sink

Boiler

No length restriction

Siphon

Ø 22 min.

75 min. trap

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

Invert

The rainwater system

The gradient of the discharge pipe should be 2.5

°

(40 mm/m) minimum

An external purpose made soakaway

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.

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:

• 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 °.

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”.

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

6 720 611 137 GB (03.02)

15

Installation

B Remove the plastic caps from the boiler connections.

2.

6 720 611 137-06.1O

Fig. 15

Fixing the appliance

B Fit the washers onto the gas and water connections.

B Lift the boiler onto the wall-mounting frame. The lugs pass through the rectangular holes in the boiler back panel.

B Take care not to disturb the washers on the connections.

Connecting the flue duct

B Fit flue duct connector onto appliance flue spigot.

B Secure with the two screws supplied.

1 .

1.

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.

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 boiler flow and return.

B Check all seals and unions for leaks.

Open vent systems: It is not necessary to connect a drain pipe to the pressure relief valve outlet as it is not operational.

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 by Worcester Heat Systems.

The flue system must be installed in accordance with the requirements of BS5440:1.

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 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 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.

16

6 720 611 137 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 9.

The terminal will, at times, give out a plume of water vapour and consideration must be given to this when choosing a terminal position. Keep clear of security lighting, activated by passive infra-red sensing heads.

If the terminal is less than 2 m above a surface to which people have access then a guard must be fitted. The guard must be evenly spaced about the terminal with a space of 50 mm in each direction and fixed with plated screws.

A guard Type 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)

M

N

O

P

Q

K

L

I

J

E

F

2)

G

H

Dimension

A

1)

B

1)

C

1)

D

Table 9

1)

2)

Terminal Position (kW input expressed in net)

Directly below an opening, air brick, opening windows, etc.

Above an opening, air brick, opening window, etc.

Horizontally to an opening, air brick, opening window, etc.

Below gutters, soil pipes or drain pipes

Below eaves

Below balconies or car port roof (lowest point)

Balanced flues room sealed: Fanned draught

300 mm

300 mm

300 mm

75 mm

200 mm

200 mm

From a vertical drain pipe or soil pipe

From an internal or external corner

Above ground roof or balcony level

From a surface facing the terminal

150 mm

300 mm

300 mm

600 mm

From a terminal facing the terminal 1200 mm

From an opening in the car port (e. g. door, window) into the dwelling Not recommended

Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall

1500mm

300 mm

From the wall on which the terminal is mounted

From a vertical structure on the roof

Above intersection with roof

Not applicable

Not applicable

Not applicable

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.

6 720 611 137 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 600 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 sat-

isfactory. Refer to fig. 18.

Flue

Turret

Fig. 19 Standard Flue

Maximum 650 mm

No

Clamp

Terminal

Assembly

Outer

Wall

6 720 610 602 - 08.1O

Centre line of flue/air duct

Centre line of flue opening and appliance

Appliance

H

Top of the wall mounting frame

120

Drilling point for flue duct opening

3 %

(30 mm/metre)

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

6 720 611 137 GB (03.02)

Installation

Terminal

Assembly

Flue

Turret

Maximum 1600mm

Outer

Wall

No

Clamp

Fig. 20 Flue with one extension

Extension

Duct

Clamp

6 720 610 602 - 09.1O

Terminal

Assembly

Flue

Turret

No

Clamp

Extension

Duct

Clamp

Fig. 21 Flue with extensions

Flue

Turret

Extension

Duct

Clamp

6 720 610 602 - 10.1O

Outer

Wall

Extension Air Duct

Duct Clamp

Extension Flue Duct

Terminal Assembly Wall Sealing Plates

6 720 610 602 - 11.1O

Fig. 22 Flue components

6 720 611 137 GB (03.02)

19

Installation

3.8.3

Flue duct preparation and assembly

Measure the flue length L. Refer to fig. 23, 24.

L

Outer

Wall

Face

Flue Terminal

120

NOTE: THE FLUE MUST BE INCLINED T O THE

BOILER

6 720 610 602 - 12.1O

Fig. 23 Flue length - rear

L

Raised Ring locating the terminal relative to the outside wall face

6 720 610 576 - 20.1O

Fig. 25 Flue terminal position

Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must 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

BOILER 6 720 610 602 - 13.1O

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 Turret

Air and

Flue Duct

Entry into silicone rubber seals

Flue Socket on Boiler 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

6 720 611 137 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.

All control and safety systems are built into the appliance.

B Allow mains cable to protrude at least 50 cm from wall.

B To make splash-water proof (IP): cut the cable grom-

met 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 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.

• Supply: 230 V ~ 50 Hz, 43 Watts

• Mains cable: PVC insulated 0.75 mm

2

(24 x 0.20 mm) to BS6500-Table 6.

Temperature rated 100˚C.

• Water protection IPX4D

• External fuse 3 A to BS 1362.

4.1

Connecting the appliance

To gain access to the mains connection remove the drop down facia cover. The drop down cover is removed by lowering it to the horizontal position and pushing firmly upwards at the rear of the supports to release the cover. Lift cover from the appliance.

After installation (or in the event of an electrical fault) the electrical system shall be checked for short circuits, fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.

B Pull out cover panel at the bottom and remove. Refer

to fig. 27.

B Remove screw and slide terminal cover forwards to

remove. Refer to fig. 28.

0

1

2

3 4

5

E

Fig. 28

B Cut cable grommet to diameter of cable.

0

3

4

1

2

5

E

6 720 611 137 -07.1O

8-9

5-7

10-12 13-14

6 720 611 137-08.1O

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.

L

R

0

1

2

3 4

5

E

4130-14.1R

Fig. 30

Fig. 27

6 720 611 137 GB (03.02)

6 720 611 137-09.1O

21

Electrical connections

4.2

Wiring to your system

Mains electrical supply: The boiler should be connected to the permanent mains supply as described in

section 4.1. This also provides the electrical supply to

the system.

Note: This must be the only electrical supply to the system. This ensures the safety of a single fused supply.

The boiler can only be wired to a remote system junction box.

Note: A pump is not built into the boiler and must be fitted externally.

The diagram shows the overall wiring details. A factory fitted cable is fitted between the boiler control panel and the Y-S-module. This module is designed to provide the correct voltage interface.

The other connector in the module must be used for wiring to the remote junction box as shown. It is the responsibility of the installer to connect all other system components i.e water valve/s, pump, programmer etc. to the proprietary junction box according to the instructions supplied with the box. Worcester Heat Systems cannot be held responsible for any incorrect wiring to these parts of the system.

If a room thermostat and/or frost thermostat is required, these must also be connected to the junction box according to the proprietary instructions.

Upon completion of the electrical connections check for earth continuity, correct polarisation and resistance to earth.

Note:

Y-S-Module Remote Junction Box

LS

NS

PE

DV

L

N

E (Earth)

Demand (Switched live)

Table 10

Fig. 31

Y-S-Module

LRLS NS PE PE DV LS NS

PRE-WIRED

HEATRONIC CONNECTOR

L N N S L S L R

CONTROL BOARD

INSIDE OF BOILER

MAINS 230V

LIVE SUPPLY

TO BOILER AND SYSTEM

REMOTE PRE-WIRED

JUNCTION BOX

OUTSIDE OF BOILER

Other connections to

Terminal Strip according to Proprietary instructions

MAINS SUPPLY

L N E

BOILER/PUMP

DEMAND

Terminal

Strip

This must be the only electrical supply to the

Junction Box

INSTALLATION

WIRING

PUMP

6 720 611 137-10.1O

22

6 720 611 137 GB (03.02)

Commissioning

5 Commissioning

27

364

135

295

361

136 365 61 317 366 367

ECO

358

E

363

310

170

172

Fig. 32

310

317

358

361

363

364

365

366

367

15

27

61

135

136

170

172

295

Safety valve

Automatic vent

Reset button

Master switch

Temperature control for central heating

Service cocks on flow and return

Gas cock (shown in on position)

Appliance type sticker

Function control (Service only)

Multifunction display

Condensate trap

Drain valve

Indicator lamp for burner

Indicator lamp for power supply

“Chimney sweep” button

Service button

No function

6 720 611 137 GB (03.02)

15

170

6 720 611 137-11.1O

5.1

Commissioning

Never run the appliance when empty or, with sealed systems, unpressurised.

i

The operational CO

2

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. The inhibitor must not be added until all the cleaner has been removed.

To drain the appliance shut the system valves and open the drain 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.

23

Commissioning

B Before commissioning, the gas supply pres- sure must be checked at the gas supply pres-

sure 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. 32.

B Open all system radiator valves.

B Turn on service valves (170), fill central heating system.

B Vent radiators.

B Check that the gas type specified on the identification plate matches that of the gas supply.

B Turn on gas cock (172). Refer to fig. 32.

B If a domestic hot water cylinder is fitted set the boiler temperature control and the hot water cylinder thermostat to 60 °C.

5.2

Switching the appliance on/off

Switching on

B Switch on the appliance at the master switch (I).

The indicator lamp shows green and the display will show the boiler flow temperature.

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 System

The boiler 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:

– Low-temperature heating: setting “E

(approx. 75˚C)

– Central heating systems for flow temperatures up to 88 °C: limited “max” setting for low-tempera-

ture operation (see page 26).

When the burner is alight, the red indicator lamp lights up.

6 720 610 333-04.1O

Fig. 33 i

If the display alternates between -II- and the boiler 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.

6 720 611 137-12.1O

Fig. 34

5.4

System controls

B Set room thermostat to the desired room temperature.

B Set the external time clock to the desired time periods.

B Set the thermostatic radiator valves to the desired settings.

5.5

Frost protection

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.

24

6 720 611 137 GB (03.02)

5.6

Fault Condition i

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:

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.

Commissioning

6 720 611 137 GB (03.02)

25

Individual settings

6 Individual settings

6.1

Mechanical settings

6.1.1

Setting the boiler flow temperature

The central heating flow temperature can be set to between 50˚C and 88˚C.

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.

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.

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.

2 5 1

6 720 611 137-13.1O

Fig. 35

B Rotate yellow button through 180° and replace (dot facing inwards).

The CH flow temperature is no longer limited.

Control setting CH flow temperature

3

4

1

2

5

E max

Table 11 approx. 50˚C approx. 55˚C approx. 60˚C approx. 65˚C approx. 70˚C approx. 75˚C approx. 88˚C

3

6 720 611 137-14.1O

4

Fig. 36 Appliance controls

3

4

1

2

5

Service button

“Chimney sweep” button

Temperature control for boiler flow

Function control

Display

Selecting service function: i

Note the positions of the temperature control. 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 flow temperature control to select the required function.

Service function

Anti-cycle time

Max. flow temperature

Switching difference

Max. heating output

Code no.

See page

2.4

2.5

2.6

5.0

Table 12

The service function 5.0 may be reset.

27

27

27

27

26

6 720 611 137 GB (03.02)

Individual settings

Entering a setting

B To enter the setting for a function, turn the function 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

B Reset the temperature control and the function control to their original positions.

6.2.2

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.

6.2.3

Setting the maximum flow temperature

(Service Function 2.5)

The maximum flow temperature can be set to between

35˚C and 88˚C (factory setting).

6.2.4

Setting the switching difference

(Service Function 2.6) i

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 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 flow temperature is

30˚C.

6.2.5

Setting the heating output

(Service Function 5.0)

The heating output can be set to any level between min. rated heat output and max rated heat output to limit it to the specific heat requirements.

i

The full rated heat output is still available for hot water or charging the hot water cylinder even if the heating output has been limited.

The factory setting is the max. rated heat output.

B 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.

6 720 611 137-15.1O

Fig. 37

B Turn the temperature control until the display shows

5.0.

After a short delay, the display then shows the set heating output in percent.

6 720 611 137-16.1O

Fig. 38

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 41).

B Turn the function control until the display shows the desired code number.

The display and the and buttons will flash.

27

6 720 611 137 GB (03.02)

Individual settings

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.

6.3

Setting the gas/air ratio

The appliance is set at the factory and adjustment is not necessary.

6 720 611 137-17.1O

Fig. 39

B Return the temperature control and the function control to their original positions.

The display will revert to the boiler flow temperature.

28

6 720 611 137 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.

7.1

Setting the gas/air ratio

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

• Appliances for natural gas type G20 are factory set to Wobbe-Index 15 kWh/m

3

and 20 mbar supply pressure and sealed.

The gas/air ratio may only be adjusted on the basis of a CO

2

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. 40.

B Insert testing probe about 135 mm into the flue gas testing point and seal testing point.

Conversion kits

Model

For conversion from ... Order no.

ZB 7-29 HE N.G to L.P.G

7 710 149 083

ZB 11-29 HE L.P.G to N.G

7 710 239 109

Table 13

• Instructions are sent with each conversion kit.

2 3 4

6 7 2 0 6 1 0 3 3 2 - 5 7 . 2 R

Fig. 40

B Press and hold button until the display shows – –.

The button will light up.

6 720 611 137-18.1O

Fig. 41

B Turn the temperature control until the display shows

2.0 .

After a short delay, the current operating mode setting will be displayed (0. = Normal mode).

Fig. 42

6 720 611 137-19.1O

29

6 720 611 137 GB (03.02)

Converting the appliance to different gas types

B Turn the function 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

6 720 611 137-20.1O

Fig. 43

B Measure the CO

2

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. 44.

63

6 720 610 332-64.1R

Fig. 44

Gas Type

Natural gas type

(G20)

LPG (G31)

(propane)

Table 14

CO

2

reading at max. rated heat output

9.2 %

10.8 %

CO

2

reading at min. rated heat output

8.8 %

10.5 %

B Turn the function control anti-clockwise until the display shows 1. (= min. rated heat output).

The display and the button will flash.

3928-74.1R

Fig. 46

B Recheck the levels at min. and max. rated heat output and re-adjust if necessary.

B Turn the function 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 control and the function control to their original positions.

The display will revert to the boiler 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.

6 720 611 137-21.1O

Fig. 45

B Measure the CO

2

level.

30

6 720 611 137 GB (03.02)

Converting the appliance to different gas types

7.2

Testing combustion air/flue gas at set heat output

7.2.1

Testing the O

2

or CO

2

level in the combustion air i

By testing the O

2

or CO

2

level in the combustion air the gas tightness of a type C

13 or C

O

33

flue system can be checked. The

2

level must not be less than 20,6 %.

The CO

2

level must not exceed 0,2 %.

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 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 flue gas testing point

(234, fig. 47).

B Insert testing probe about 135 mm into the testing point and seal testing point.

B CO- and CO

2

levels.

B Refit sealing plug.

B Press and hold button until the display shows – –.

The button will stop flashing and the display shows the boiler flow temperature.

B Remove sealing plug from combustion air testing

point (234.1, fig. 47).

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. 47

B Measure O

2

and CO

B Refit sealing plug.

2

levels.

B Press and hold button until the display shows – –.

The button will stop flashing and the display shows the boiler flow temperature.

31

6 720 611 137 GB (03.02)

Maintenance

8 Maintenance

B Always disconnect the appliance from the electrical power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or components.

B Always turn off the gas cock before carrying out any work on components which carry gas.

i

There is a special Service booklet for the

Engineer, order no. 7 181 465 346, available to competent persons.

i

All safety and control systems are monitored by the Bosch Heatronic. In the event of a component fault, the display shows a fault code.

B The User should be recommended to have the appliance serviced regularly by a competent person (see

Maintenance Contract).

B Use only genuine spare parts

B Refer to the Spare Parts List when ordering spare parts.

B Always renew seals and O-rings removed during servicing or repair work.

B Use only the following types of grease:

– Water valve: WRAS approved silicon based grease

– Unions: approved sealant.

B To drain the appliance shut the system valves and open the drain valve.

B Upon completion of any electrical work check for earth continuity, correct polarisation and resistance to earth.

32

6 720 611 137 GB (03.02)

8.1

Pre-Service Check List

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).

mbar 4 Check gas supply pressure

(see page 29).

5 Test combustion air/flue gas

(see page 31).

6 Check CO

2

setting for min./ max. (gas/air ratio)

(see page 29).

min. % max. %

7 Check gas and water systems for

leaks (see page 16).

8 Check heat exchanger

(see page 34).

mbar

9

Check burner (see page 35).

10 Clean condensation trap

(see page 35).

11 Check electrical wiring for damage.

12 Check heating programmer settings.

13 Check appliances that are part of the heating system.

Table 15

Date

6 720 611 137 GB (03.02)

Maintenance

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.

Check “Last fault stored”:

B Select Service Function .0 (see page 26 “Selecting

Service Function”).

There is a list of the fault codes in the Appendix (see

page 40.

To delete “Last fault stored”:

B Turn function 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

B Select Service Function 3.3 (see page 26 “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.

B Remove the fan and the burner as described in the

text headed “Burner” (see page 35).

6 720 610 332-72.1R

Fig. 49

B Loosen any deposits in the heat exchanger from top

to bottom using the cleaning blade. Refer to fig. 50.

6 720 610 332-73.1R

Fig. 50

B Clean the heat exchanger from top to bottom using

the brush. Refer to fig. 51.

6 720 610 332-69.1R

Fig. 48 i

The heat exchanger should only be cleaned if the control pressure is

2.2 mbar (depression) or less.

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 con-

tainer underneath. Refer to fig. 49.

6 720 610 332-74.1R

Fig. 51

B Flush the heat exchanger from the top. Refer to

fig. 52.

34

6 720 611 137 GB (03.02)

Maintenance

B Clean out the condensate collector and trap connection (with other end of brush).

6 720 610 332-75.2R

Fig. 52

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. 53.

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.

1.

2.

3.

4.

7 181 465 330-04.1R

Fig. 53

B Remove the burner skin and clean components. Do

not use a wire brush. Refer to fig. 54.

7 181 465 330-08.1R

Fig. 54

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. 49).

B Unscrew condensation trap and check connection to heat exchanger is clear.

B Remove condensation trap cover and clean.

B Fill condensation trap with approx. 1/4 l of water and refit.

Electrode assembly

B Switch off the master switch.

B Pull off the leads from the electrodes. Refer to fig. 2.

B Unscrew the two fixing screws and carefully remove

the electrode assembly. Refer to fig. 48.

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.

6 720 611 137 GB (03.02)

35

Maintenance

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.

B Refit and prime the siphon.

Condensate

Drain

Siphon

3.

443

29

1.

6 720 611 137 - 22. 1O

Fig. 56

Electrical wiring

B Check the electrical wiring for physical damage and replace any damaged wires.

2.

6 720 610 790-07.2R

Fig. 55

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.

36

6 720 611 137 GB (03.02)

Maintenance

8.3

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 cov-

ers. 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. 57.

B Remove the pcb control board.

2

4

1

3

2

4

1

3

1

2

3 4

5

E

2

4

1

3

6 720 611 137 - 23.1O

Fig. 57

B Lower the control box.

B Unscrew earth lead.

B Unscrew four fixing screws from cover plate. Refer to

fig. 58.

B Prise off cover plate.

B Pull off transformer.

B Remove pcb holder.

7 181 465 330-10.1R

Fig. 58

Fuses

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.

The external fuse must be to BS 1362.

6 720 611 137 GB (03.02)

37

Maintenance

8.3.2

Fan Assembly

3.

2.

4.

Flue Temperature Limiter – Item 9, fig. 2, 57

B Pull-off the connectors.

B Unscrew the sensor.

8.3.4

Gas Valve

B Check that the gas cock is turned off.

B Lower the control panel. Refer to fig. 60.

1.

1.

1.

7 181 465 330-05.1R

Fig. 59

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. 59.

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.).

8.3.3

Sensors

B Check that the appliance is electrically isolated.

Central Heating Flow Temperature Sensor –

Item 36, fig. 2, 57

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, 57

B Pull-off the connectors.

B Unscrew the sensor.

6 720 611 137- 25.1O

2.

Fig. 60

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. 59.

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.

38

6 720 611 137 GB (03.02)

6 720 610 602 - 04.1O

Fig. 61

8.3.5

Electrode assembly

B Refer to section 8.2.

B Use a new seal if the existing seal is damaged.

8.3.6

Pressure Relief Valve

B Drain the appliance.

B Disconnect the drain pipe from the valve. Refer to

fig. 32.

B Pull-out the clip securing the valve.

B Pull-out the valve.

B Ensure that the replacement valve is fully entered before fitting the clip.

8.3.7

Burner

B Refer to section 8.2.

Maintenance

8.3.8

Primary Heat Exchanger

B Drain the appliance.

B Check that the gas supply is turned off.

B Check that the appliance is electrically isolated.

B Remove the fan assembly complete with the gas/air

tube and mixer assembly. Refer to section 8.3.2.

B Remove the burner. Refer to section 8.2.

B Disconnect the sensors. Refer to section 8.3.3.

B Undo the central heating flow union.

B Undo the grey plastic cap at the base of the heat exchanger.

B Unscrew and remove the condensate trap. Refer to

section 8.2.

B Unscrew and remove the two screws securing the heat exchanger top bracket to the rear panel.

B Lift up the flue duct, item 271, refer to fig. 2.

B Pull forward from the top and lift the heat exchanger from the casing.

B Transfer components, as necessary, to the new heat exchanger.

B Ensure that all the seals are in place and all of the connections are tight before re-commissioning the appliance.

6 720 610 602 - 06.10

Fig. 62

6 720 611 137 GB (03.02)

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

A8

AC b1

C1 d3

E2

E9

EA

F0

F7

Description

Break in communication

Module not detected.

Keyed plug not detected.

Fan speed too low.

Jumper 8-9 not detected.

CH flow NTC sensor defective

Safety temp. limiter in CH flow has tripped.

Flame not detected.

Internal error.

Remedy

Check connecting lead to programmer

Check connecting lead between TA211E/

TR212E and Heatronic

Insert keyed plug correctly, test and replace if necessary.

Check fan lead and connector, and fan; replace as necessary.

Connector not connected, link missing, underfloor heating limiter tripped.

Check CH flow NTC sensor and connecting lead.

Check system pressure, check safety temp. limiters, check external pump operation, check fuse on pcb, bleed appliance.

Is gas cock turned on? Check gas supply pressure, power supply, igniter electrode and lead, ionisation sensing electrode and lead, flue duct and CO

2

level.

Check electrical connector contacts, programmer interface module ignition leads are not loose; replace pcb if necessary.

Check electrode assembly, dry pcb. Flue clear?

FA

Flame detected even though appliance switched off.

Flame detected after gas shut off.

Fd

P1, P2,

P3, P1...

Table 16

Reset button pressed by mistake.

Please wait, initialisation in progress.

Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue clear?

Press reset button again

24 V fuse blown. Replace fuse.

40

6 720 611 137 GB (03.02)

Appendix

Key

12

13

14

15

8

9

10

11

4

5

6

7

1

2

3

Table 17

9.2

Short parts list

Description Qty GC

Sensor - Flue gas temp.

Sensor - CH flow temp.

Control board

Gas valve

Fan assembly

Fan washer

Relief valve

Electrode assembly

Electrode lead

Burner skin seal

Transformer - facia

Heat exchanger washer 1

Washer set Condensation Trap 1

Fuse set

Primary heat exchanger

1

1

1

1

1

1

1

1

1

1

1

1

1

9.3

Heating settings (N.G)

Display code

30

40

50

60

70

80

90

100

Table 18

Heat output, kW

8.2

11.0

13.7

16.5

19.2

21.9

24,7

27.4

Heat input, kW

8.3

11.1

13.9

16.6

19.4

22.2

24.9

27.7

Natural gas G20

Gas vol. fl ow rate

(l/min at t

V

/t

R

= 80/60 C)

14.5

19.4

24.2

29.1

33.9

38.8

43.6

48.5

Spare part number

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

8 729 000 183 0

8 717 401 012 0

8 718 107 077 0

8 714 401 999 0

8 711 004 168 0

8 747 201 358 0

8 710 103 153 0

8 710 103 154 0

8 744 503 010 0

8 715 406 615 0

9.4

Heating settings (L.P.G)

Propane

50

60

70

80

Display code

40

90

100

Table 19

Heat output kW Heat input kW

11.0

11.1

13.7

16.5

13.9

16.6

19.2

21.9

24,7

27.4

19.4

22.2

24.9

27.7

6 720 611 137 GB (03.02)

41

Appendix

9.5

Operational Flow diagram

fo mp

Fig. 63

42

6 720 611 137 GB (03.02)

Appendix

6 720 611 137 GB (03.02)

43

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

R 29 / R 40 HE conventional Condensing boiler

6 720 611 441-00.1O

ZB 7-28 R 29 HE GC-Number: 41 311 60

ZB 11-40 R 40 HE GC-Number: 41 311 61

GB/IE

Contents

Contents

1

2

Excellence comes as standard

Safety precautions

General notes

Controls

3 Operating the Appliance

3.1

Preparation

3.2

Switching the Appliance On/Off

3.3

Switching on the System

3.4

Controlling

3.5

Setting the Hot Water Temperature of a Cylinder

3.6

Frost protection

3.7

Fault Condition

4

5

6

Tips on saving energy

General Information

Maintaining your appliance

7

8

Service

Fault or breakdown

9 Your Bosch guarantee

10 Guarantee registration

11 Operating Instructions Quick Reference

16

17

18

19

14

15

16

20

7

9

3

5

10

10

11

12

12

12

13

13

2 6 720 611 138 GB (04.05)

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 comes to gas, it has to be a Worcester Bosch 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 and is one of the methods of demonstrating compliance with the Building Regulations.

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.

6 720 611 138 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 6 720 611 138 GB (04.05)

6 720 611 138 GB (04.05)

Safety precautions

Safety precautions

Gas Safety (Installation and Use) Regulations

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.

B

B

B

B

B

If you smell gas:

B Turn off gas service cock at the meter.

Open all doors and windows.

Do not operate any electrical switches.

Do not smoke.

Extinguish any naked flames.

Call your gas company.

B

B

If you smell fumes from the appliance:

B Switch off appliance.

Open windows and doors.

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.

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).

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 6 720 611 138 GB (04.05)

General notes

1 General notes

To get the best from your appliance please read these instructions carefully.

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. An open vented system will re-fill automatically.

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. Contact Fernox or Sentinel for further details.

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.

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.

6 720 611 138 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 (Vertical Flue)

Above Flue Turret

Below

10 mm

10 mm

600 mm

200 mm

30 mm

200 mm

Table 1

Room thermostat

A room thermostat should be fitted to control the central heating.

Refer to the instructions supplied with the thermostat for information on siting and setting.

Thermostatic radiator valves

It is recommended that this type of valve is fitted to all the radiators. It is a requirement that they are fitted, at least, in the sleeping areas.They should conform to the requirements of BS2767:10.

Time Control

Separate time control of the space heating and the hot water system is required using a twin-channel programmer or two or more separate timers.

Cylinder Thermostat

A cylinder thermostat must be fitted to the cylinder which, when used with a motorised valve, will give close control of the water temperature.

8 6 720 611 138 GB (04.05)

Controls

2 Controls

136 365 61 317 366 367 363 310

ECO

364

135

295

E

170

172 170

61

135

136

170

172

295

310

317

363

364

365

366

367

Reset button

Master switch

Boiler temperature control

Service valves in boiler flow and return

Gas isolation valve (open)

Identification sticker

Function control (Service only)

Display

Indicator lamp for “burner on”

Indicator lamp for “off/on”

“Chimney sweep” button

Service button

No function

6 720 611 138-01.1O

6 720 611 138 GB (04.05) 9

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.

10

170

172

6 720 611 138-02.1O

6 720 611 138 GB (04.05)

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 primary flow temperature.

6 720 610 333-04.1O

i If the display alternates between -II and the boiler 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.

6 720 611 138 GB (04.05) 11

Operating the Appliance

3.3

Switching on the System

B Turn the temperature control to the desired level:

“ Min ” setting: 35˚C

Low-temperature heating: setting “

“ Max ” setting: 88˚C

E ” (approx. 75˚C)

When the burner is lit, the red indicator lamp is illuminated.

6 720 611 138-05.1O

3.4

Controlling

B

B

B

Set room thermostat to the desired room temperature.

Set the external time clock to the desired time periods.

Set the thermostatic radiator valves to the desired settings.

3.5

Setting the Hot Water Temperature of a

Cylinder

Hot water temperature

The hot water temperature can be set to between approx. 40˚C and 60˚C using the thermostat on the cylinder.

The domestic hot water temperature is not shown on the display.

12 6 720 611 138 GB (04.05)

Operating the Appliance

3.6

Frost protection

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.

3.7Fault 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 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 boiler 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 boiler flow temperature will be displayed.

If the fault remains and can not be cleared:

B Call your approved installer or Worcester Bosch Customer

Services for assistance, giving a description of the fault and, if possible, the fault code from the facia display.

6 720 611 138 GB (04.05) 13

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 temperature 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.

14 6 720 611 138 GB (04.05)

General Information

Hot water

A lower setting on the hot water cylinder thermostat can result in considerable energy savings.

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.

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 Services 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 “logbook” giving details of the boiler together with name, address and registration number. Have the “log-book” to hand when calling a Service Engineer.

6 720 611 138 GB (04.05) 15

Maintaining your appliance

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.

If you would like to know more about Worcester’s extended warranty options please tick the appropriate box on your warranty registration card.

7Service

If your R29/R40 should fail to operate correctly or requires servicing, please call Worcester Heat Systems on: 08457 256206.

16 6 720 611 138 GB (04.05)

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 i. e. the Benchmark “logbook”.

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. 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.

6 720 611 138 GB (04.05) 17

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 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.

18 6 720 611 138 GB (04.05)

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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Copy the number of the Guarantee Card: . . . . . . . . . . . . . . . . . . .

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.

6 720 611 138 GB (04.05) 19

Installation and Servicing Instructions

R29 & R40 HE conventional

Wall mounted condensing boiler for central heating

6 720 611 441-00.1O

ZB 7-28 R29 HE

GC-Number: 41 311 60

ZB 11-40 R40 HE

GC-Number: 41 311 61

GB/IE

Contents

Contents

Safety precautions

Symbols

1 Details of the appliance

1.1

EC Declaration of Conformity

1.2

Standard package

1.3

Description of appliance

1.4

Accessories

1.5

Casing dimensions

1.6

Layout of appliance

1.7

Function

1.8

Electrical wiring diagram

1.9

Technical data

2 Installation regulations

3 Installation

3.1

Important remarks

3.2

System

3.3

Siting the appliance

3.4

Wall mounting frame assembly

3.5

Pre-piping the system

3.6

Fitting the appliance

3.7

Checking the connections

3.8

Flue Systems

3.8.1 Siting the Flue Terminal

3.8.2 Installation of the flue

3.8.3 Flue duct preparation and assembly

4 Electrical connections

4.1

Connecting the appliance

4.2

Wiring to your system

5 Commissioning

5.1

Commissioning

5.2

Switching the appliance on/off

5.3

Switching on the Boiler

5.4

System controls

5.5

Frost protection

5.6

Fault Condition

23

23

24

24

24

25

25

14

14

15

16

11

11

11

13

16

17

18

20

3

3

8

9

5

5

6

7

4

4

4

4

6

6.1

Individual settings

Mechanical settings

6.1.1 Setting the boiler flow temperature

6.2

Settings on the Bosch Heatronic

6.2.1 Operating the Bosch Heatronic

6.2.2 Setting the anti-cycle time

(Service Function 2.4)

6.2.3 Setting the maximum boiler flow temperature

27

(Service Function 2.5)

6.2.4 Setting the switching difference

27

26

26

26

26

26

27 (Service Function 2.6)

6.2.5 Setting the heating output

(Service Function 5.0)

6.3

Setting the gas/air ratio

27

28

11

21

21

22

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 O

2

or CO

2

level in the combustion air

7.2.2 Testing CO and CO

2

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 Sensors

8.3.4 Gas Valve

8.3.5 Electrode assembly

8.3.6 Pressure Relief Valve

8.3.7 Burner

8.3.8 Primary Heat Exchanger

37

38

38

38

32

33

34

37

39

39

39

39

29

29

31

31

31

9

9.1

9.2

9.3

Appendix

Fault Codes

Short parts list

Heating/hot water output settings (N.G)

40

40

41

41

9.4

Heating/hot water output settings (L.P.G) 41

9.5

Operational Flow diagrams 42

9.5.1 Central heating function 42

2

6 720 611 445 GB (04.05)

Safety precautions

Safety precautions

B

B

B

If you smell gas

B Turn off gas service cock at the meter.

B Open windows and doors.

Do not operate any electrical switches.

Extinguish any naked flames.

Telephone your gas company.

If you smell fumes from the appliance

B

Switch off appliance (see page 24).

B Open windows and doors.

Fitting and modifications

B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance with the Gas Safety (Installation and Use) Regulations 1998.

B Flue systems must not be modified in any ways other than as described in the fitting instructions.

B This appliance is for use with fully pumped, sealed and open vent 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.

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

B

B

B

B

Two people should transfer the packaged appliance from the van to the point of installation

Open the top of the carton, remove and place the component tray and both side bars of the wall mounting frame to one side

Lie the packaged appliance on its back. (The back has “TRUCK HERE” printed on the carton)

One person firmly holds the packaging while the other straddles the boiler and slides it from the packaging

Two persons are then required to lift one end and stand the appliance upright with the flue at the top

B

B

Additional requirements for roof space installation

Two people should use two step ladders and share lifting the unpacked boiler up to the loft hatch

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.

3

6 720 611 445 GB (04.05)

Details of the appliance

1 Details of the appliance

1.1

EC Declaration of Conformity

This appliance is in accordance with the applicable requirements of the Gas Appliance Directive, Boiler

Efficiency Directive, Electromagnetic Compatibility

Directive and the Low Voltage Directive.

CE-0085 BL 0507 PIN

Category

UK

Appliance Type

Table 1

II

2H 3P

C

13

, C

33

1.2

Standard package

• Gas condensing boiler for central heating

• Wall mounting frame

• Fixings (screws etc.)

• Set of documentation for appliance

• Pre-plumbing manifold

• Condensate drain pipe.

1.3

Description of appliance

• Wall-mounted appliance

• Natural gas models are low-emission appliances

• Multi function display

• Bosch Heatronic control system

• Automatic ignition

• Modulating control

• Full safety systems incorporating Bosch Heatronic with flame ionisation monitoring, solenoid valves and temperature sensors

• Concentric flue/air duct with testing point for

CO

2

/CO

• Regulated speed fan

• Pre-mix burner

• Temperature control for boiler flow

• Safety temperature limiter in 24 V electrical circuit

• Flue gas temperature limiter (105 °C)

• Condensate Trap

• Connecting possibility for 3 port or 2 x 2 port motorised valve systems

• Suitable for fully pumped sealed and open vent systems.

4

6 720 611 445 GB (04.05)

1.4

Accessories

• Standard horizontal flue kit at 100 mm outside diameter for flues up to 4 m in length (3.5m for the R

40 HE).

• Flue duct kits for horizontal (125 mm outside diameter) for flue lengths up to 13m (R 29 HE ) or

10m (R 40 HE) and vertical flue systems for flue lengths up to 15 m (R 29 HE) or 12 m (R 40 HE). Fitting instructions are sent with these kits.

1.5

Casing dimensions min.

10 * min.

10

*

Z

Y

120

X

600

*

Details of the appliance

101

103

440

35 360

395

*

Fig. 1

13

101

103

X

Y

Z

*

Note:

Manifold assembly

Outer case

Facia cover

Standard Concentric Horizontal Flue System: min. 160 mm

Alternative Concentric Flue System: min. 220 mm

Standard Concentric Horizontal Flue System: 40 mm

Alternative Concentric Flue System: 70 mm

Standard Concentric Horizontal Flue System: 105 mm

Alternative Concentric Flue System: 130 mm

For servicing the appliance

Horizontal flue only: dimension X may need to increase due to the incline of the flue.

200

13

6 720 611 441- 01.1O

6 720 611 445 GB (04.05)

5

Details of the appliance

1.6

Layout of appliance

221.1

221.2

226

27

29

271

43

9

63

358

64

4.4

7

361

295

417

Fig. 2

32.1

36

43

63

64

102

9

15

27

29

6

7

4

4.4

Heatronic control

Y-S module

Heat exchanger safety temperature limiter

Testing point for gas supply pressure

Flue gas temperature limiter

Relief valve

Automatic air vent

Air gas Mixer unit

Electrode assembly

Temperature sensor in boiler flow

Flow pipe

Adjustable gas flow restrictor

Adjusting screw for min. gas flow volume

Inspection window

6

120

6 720 611 445-01.1O

120

221.1

221.2

226

295

271

358

361

415

416

417

423

Fixing points

Flue duct

Combustion air intake

Fan assembly

Appliance type sticker

Flue duct

Condensate trap

Drain valve

Cover plate for cleaning access

Condensate collector

Clip for fixing outer case

Siphon

4

423

15

415

416

102

32.1

36

6

6 720 611 445 GB (04.05)

Details of the appliance

1.7

Function

4.4

361

Fig. 3

63

64

69

221

226

55

56

57

61

45

47

52

52.1

33

35

36

43

29

29.1

30

32

9

13

15

27

6

7

4

4.4

Bosch Heatronic control

Y-S module

Temperature limiter, heat exchanger

Testing point for gas supply pressure

Flue gas temperature limiter

Manifold

Safety valve

Automatic air 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 boiler flow

Boiler flow

Gas inlet

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

Flue duct

Fan

6 720 611 445 GB (04.05)

6 720 611 445-02.1O

229

317

358

361

423

443

Inner casing

Display

Condensate trap

Drain valve

Siphon

Diaphragm

7

Details of the appliance

1.8

Electrical wiring diagram

364

4.1

33

365 61 317 o - orange bl - blac k r - red

366 367

ECO

363

25 V

153

230V/AC

135

230 V

136

328

302

L N Ns Ls LR

151

310

312

313

1 2 4 7 8 9

161

300 mains supply

4.4

M

226

9 6 r r

52 52.1

56 bl bl bl bl o o

36

32

6 720 611 445-03.1O

Fig. 4

52.1

56

61

135

136

151

153

161

32

33

36

52

6

9

4.1

4.4

Ignition transformer

Y-S module

Temperature limiter, heat exchanger

Flue gas temperature limiter

Flame sensing electrode

Ignition electrode

Temperature sensor in boiler flow

Solenoid valve 1

Solenoid valve 2

Gas valve CE 427

Reset button

Master switch

Temperature control for boiler flow

Fuse, slow 2.5 A, AC 230 V

Transformer

Link

226

300

Fan

Code plug

302 Earth connection

310 Function control (Service only)

312 Fuse, slow T 1,6 A

313 Fuse, slow T 0,5 A

328 Terminal block for AC 230 V Mains supply

363 Indicator lamp for burner

364 Indicator lamp for power supply

365 “Chimney sweep” button

366 Service button

367 No function

8

6 720 611 445 GB (04.05)

Details of the appliance

1.9

Technical data

Units

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

Max. rated heat input net

Min. rated heat output net 40/30˚C

Min. rated heat output net 50/30˚C

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 (CVnet 34.02 MJ/m

3

) m

3

/h

LPG (CVnet 88 MJ/m

3

) kg/h kW kW kw kW kW kW kW

Gas supply pressure

Natural gas G20 (CVnet 34.02 MJ/m

3

)

LPG (CVnet 88 MJ/m

3

)

Flue

Flue gas temp. 80/60˚C, rated/min. load

Flue gas temp. 40/30˚C, rated/min. load

Residual delivery pressure

(inc. pressure drop in air intake duct)

CO

2

CO

2

level at max. rated heat output

level at min. rated heat output

NO x

-class

SEDBUK figure

Condensate

Max. condensation rate (t

R

= 30˚C) pH-value, approx.

General Data

Electrical power supply voltage

Frequency

Max. power consumption

Noise output level

Appliance protection rating with blanking plate fitted

Max. boiler flow temperature

Max. permissible operating pressure (boiler)

Permissible ambient temperatures mbar mbar

˚C

˚C

Pa

%

%

Band l/h

Nominal capacity of appliance

Weight (excluding packaging)

Table 2

AC ... V

Hz

W dB(A)

IP

˚C bar

˚C l kg

R 29 HE

Natural gas

29.3

29.0

27.4

27.7

8.4

8.3

7.4

7.6

2.9

-

20

-

67/55

43/32

80

9.2

8.8

5

A

2.3

4.8

230

50

43

36

X4D nom. 90

3

0 - 50

3.75

43

-

2.1

-

37

67/55

43/32

80

10.8

10.5

5

A

2.3

4.8

230

50

43

36

X4D nom. 90

3

0 - 50

3.75

43

R 29 HE

Propane

29.3

29.0

27.4

27.7

11.6

11.4

10.5

10.8

R 40 HE

Natural gas

41.4

41.4

39.1

40

12.9

12.8

11.4

11.8

R 40 HE

Propane

41.4

41.4

39.1

40

16.2

16.1

14.3

14.8

4.2

20

-

87/58

65/43

100

9.2

9.2

5

A

3.5

4.8

230

50

113

42

X4D nom.90

3

0 - 50

3.75

43

-

3.2

-

37

87/58

65/43

100

10.8

10.8

5

A

3.5

4.8

230

50

113

42

X4D nom.90

3

0 - 50

3.75

43

6 720 611 445 GB (04.05)

9

Details of the appliance

Condensate analysis, mg/l

Ammonium

Lead

Cadmium

Chromium

Halogenated hydrocarbons

Hydrocarbons

1.2

Nickel

0.01

Mercury

≤ 0.001

Sulphate

0.005

Zinc

Tin

0.002

0.015

Vanadium

Copper

Table 3

0.028

pH-value

Flue system

0.15

0.0001

1

0.015

≤ 0.01

≤ 0.001

4.8

HORIZONTAL 100 mm – Standard FLUE SYSTEM

Overall Diameter of Duct mm

100

Flue Terminal / Duct

Assembly Length mm

600

Max.

R29 4m

R40 3.5m

(including turret)

Extension Duct Length

Table 4 mm

1000

VERTICAL 100mm FLUE SYSTEM

Overall Diameter of Duct mm 100

Flue Terminal / Duct

Assembly Length mm 1140

Table 5

HORIZONTAL 125 mm FLUE SYSTEM

Max. (Incl. terminal)

R29 6.4 m

R40 5.4 m

Overall Diameter of Duct

Flue Terminal / Duct

Assembly Length mm 125 mm 1030

Max.

R29 13m

R40 10m

(including turret)

Table 6

VERTICAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125 Max. (Incl. terminal)

R29 15 m

R40 12 m

Flue Terminal / Duct

Assembly Length mm 1365

Table 7

Elbow - 90 ° Equivalent length 2 m

Bend - 45 ° Equivalent length 1m

Gas supply

Total length of gas supply pipe

(metres)

3 6

Gas discharge rate (m

3

/h)

9

8.7

5.8

4.6

18.0

Table 8

12.0

9.4

Pipe diameter

(mm)

22

28

10

6 720 611 445 GB (04.05)

Installation regulations

2 Installation regulations

Gas Safety (Installation & Use) Regulations 1998: All gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution.

The manufacturers notes must not be taken, in any way, as overriding statutory obligations.

The appliance must be installed in accordance with the current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation), bye-laws of the local Water Company, Health and

Safety Document 635 (Electricity at Work Regulations

1989) and any other local requirements.

Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the installer to avoid any risk by using only quality approved branded fittings.

The relevant British Standards should be followed i.e.

• BS 6798: Specification for the installation of gas fired hot water boilers of rated input not exceeding

60kW

• BS 5449: Central Heating for Domestic Premises

• BS 5546: Installation of gas hot water supplies for domestic purposes

• BS 5440:1: Flues and ventilation for gas appliances of rated input not exceeding 70 kW (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 pipe work 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.

3 Installation

B Always turn off the gas cock before carrying out any work on components which carry gas.

i

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.

3.1

Important remarks

B Appliance should only be installed in fully pumped sealed and open vent central heating systems.

B To avoid gas formation in the system, galvanised radiators or pipes must not be used.

B Do not fit a thermostatic radiator valve on the radiator in the primary room where a room thermostat is used.

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.

3.2

System

The system must comply with the requirements of BS

6798 and BS 5449.

General

The appliance is only suitable for connection to indirect fully pumped sealed and open vented systems. The minimum static head is 1m and the maximum is 30m.

The controls must be wired to ensure that the boiler does not cycle when the electronically controlled zone valves are closed.

Note 1: An automatic bypass is required if the controls i.e. 2-port valves, can result in the closure of the CH and

DHW circuits when the boiler is hot. If mechanically operated thermostatic control valves are fitted on all radiators an automatic bypass is required, located at least 2m from the boiler.

Note 2: A bypass is not usually required for systems using a 3-way diverter valve (with one valve is open to flow at all times) unless TRV’s are used throughout the system. Refer to the current Building Regulations or the

Good Practice Guide 302 which lists all the above requirements.

Plastic pipes must not be directly connected to the appliance. A copper to plastic transition piece should be positioned a minimum of 600mm from the appliance.

11

6 720 611 445 GB (04.05)

Installation

Some plastics are permeable to oxygen and must be avoided, a pipe with a polymer barrier should be used.

Sealed System

A sealed system must include an expansion vessel, pressure gauge and pressure relief valve set to operate at 3 bar - these are available as proprietary kits. The expansion vessel and fittings must be connected at the neutral point of the system on the entry to the pump.

Suitable pump and diverter valves are also required.

Refer to Fig. 5 & Fig. 6. The sealed system must be filled

through a WRAS approved filling kit. Refer to Fig. 7.

The appliance must not be operated without the system being full of water and correctly pressurised.

All connections in the system must be able to withstand a pressure up to 3 bar. The system and appliance must be properly vented. Repeated venting loses water from the system and usually indicates a leak. A drain cock to

BS 2879 must be fitted to the lowest point on the system.

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 Super concentrate 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.

IMPORTANT: Check that no dirt is left in the water pipe work 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.

Domestic Hot Water

The appliance is NOT suitable for direct water supply.

Do not connect to a direct cylinder.

The appliance can be connected to any indirect cylinder i.e. unvented or thermal store to realise the benefits from a “dry loft”. For more information contact Worcester Heat Systems Helpline 08705 266241.

Note: Indirect coil type cylinders with an immersion calorifier suitable for a pressure of 0.35 bar above the setting of the pressure relief valve may be used. Single feed indirect cylinders are not suitable for sealed

systems. Any connection to the mains water supply must conform to the relevant Buildings and Water Regulations and be approved by the local water company.

FEED & VENT

CISTERN

HEATING

VENT

Minimum diameter

22mm.

PRIMARY

COLD FEED

Minimum diameter

15mm.

150mm max.

S.H.

DOMESTIC

HOT WATER

CYLINDER

S.H.

S.H. MINIMUM STATIC HEAD 1.0m MEASURED

FROM THE HIGHEST POINT IN THE HEATING

SYSTEM (TOP SURFACE OF THE APPLIANCE

OR HIGHEST POINT IN THE HEATING

SYSTEM) TO THE WATER LEVEL IN THE FEED

AND EXPANSION TANK.

RADIATOR RADIATOR

DIVERTER

VALVE

PUMP

RADIATOR RADIATOR

BOILER

TYPICAL OPEN VENTED SYSTEM

Fig. 5

DRAIN

COCK

6 720 611 445-04.1O

12

6 720 611 445 GB (04.05)

Installation

DOMESTIC

HOT WATER

CYLINDER

AUTOMATIC

AIR VENT

DIVERTER

VALVE

SAFETY

VALVE

PRESSURE

GAUGE

EXPANSION

VESSEL

BOILER

TYPICAL FULLY PUMPED SEALED SYSTEM

Fig. 6

TO SYSTEM

FILLING

DEVICE

PUMP

RADIATOR

RADIATOR

RADIATOR

RADIATOR

DRAIN

COCK

6 720 611 445-05.1O

6 720 611 400-14.1O

Fig. 7

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.

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.

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.

6 720 611 445 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. 8. 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

6 720 610 576-04.1O

Fig. 8

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 17.

Fig. 10

3.5

Pre-piping the system

200

43

171 112 172

47

50

35

Fig. 9

6 720 610 576-05.1O

120-130

260

6 720 610 576-06.1O

Fig. 11 Manifold

43

47

112

171

172

Boiler flow

Boiler return

Gas cock

Not used

Not used

B Remove valves 171 and 172 from manifold, see Fig.

11.

B A drain tap should be fitted at the lowest point of the central heating system.

14

6 720 611 445 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 with a constant fall of 2.5˚ or 45mm in every metre. See Fig. 13.

The condensate pipe can terminate into any of four areas:

Boiler

Siphon

Ø 22 min.

Boiler

Sink

Siphon

Ø 22 min.

No length restriction

Use waterproof pipe work insulation in very exposed positions

The gradient of the discharge pipe should be 2.5

°

(40 mm/m) minimum

An internal waste system

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

An external waste system

Open end of pipe direct into gully, below ground but above water level.

Boiler

Ø 22 min.

Internal soil and vent stack Sink

Boiler

Siphon

Ø 22 min.

No length restriction

No length restriction

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

Invert

The rainwater system

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. 12

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.

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 °.

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”.

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.).

6 720 611 400 - 27.1O

Fig. 13 Recommended route of the condensate drain

6 720 611 445 GB (04.05)

15

Installation

B Remove the plastic caps from the boiler connections.

2.

1.

6 720 611 441-05.1O

Fig. 14

Fixing the appliance

B Fit the washers onto the gas and water connections.

B Lift the boiler onto the wall-mounting frame. The lugs pass through the rectangular holes in the boiler back panel.

B Take care not to disturb the washers on the connections.

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 Flue Turret to

Boiler Sealing

Gasket

Appliance

Flue Socket

6 720 611 400-16.1O

Fig. 15

B For remaining installation of flue assembly, refer to the relevant installation instructions.

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 boiler flow and return.

B Check all seals and unions for leaks.

Open vent systems: It is not necessary to connect a drain pipe to the pressure relief valve outlet as it is not operational and should be blanked off.

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 by Worcester Heat Systems.

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 4m (R29) and 3.5m (R40). 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 13m (R29) and 10m (R40).

A vertical flue system up to a height of 15 m (12 m R40) 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

6 720 611 445 GB (04.05)

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. 16 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 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.

J

I

F

L

Q

Q

D, E

G

B

I

A

C

N

Q

H

H

M

N

N

M

K

6 720 611 400-25.1O

Fig. 16

Minimum dimensions of flue terminal positions (all types) (see fig. 16)

N

P

Q

I

J

K

L

2)

M

G

H

D

E

F

2)

Dimension

A

1)

B

1)

C

1)

Terminal position (kW input expressed in net)

Directly below an opening, air brick, opening windows, etc.

Above an opening, air brick, opening window, etc.

Horizontally to an opening, air brick, opening window, etc.

Below gutters, soil pipes or drain pipes

Below eaves

Below balconies or car port roof (lowest point)

From a vertical drain pipe or soil pipe

From an internal or external corner or

Above ground roof or balcony

From a surface or facing the terminal or boundary

From a terminal facing the terminal

From an opening in the car port (e. g. door, window) into the dwelling

Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall

From a vertical structure on the roof

Above intersection with roof

Balanced flues room sealed: Fanned draught

300 mm

300 mm

300 mm

75 mm

200 mm

200 mm

75 mm

300 mm

300 mm

600 mm

1200 mm

1200 mm

1500mm

300 mm

500 mm

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

6 720 611 445 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 4m (R29) & 3.5m (R40).

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

• Flue turret clamp

• Terminal assembly

• Wall sealing gasket and cover plate.

Refer to fig. 21.

Instructions for fitting other flue systems are packed with the relevant flue kit.

Check that the position chosen for the appliance is sat-

isfactory. Refer to fig. 17.

Flue

Turret

Maximum 730mm

Minimum 480mm

Outer

Wall

Clamp

Fig. 18 Standard Flue

Terminal

Assembly

6 720 611 400-18.1O

Centre line of flue/air duct H

Centre line of flue opening and appliance

Appliance

Top of wall mounting frame (not boiler)

120mm

Drilling point for flue duct opening

1,6

°

(30mm/metre)

Standard 100mm horizont al flue 0.5

°

(5mm/metre)

H = 40mm for the Standard 100mm Horizontal Flue

H = 70mm for the Optional 125mm Horizontal Flue

Fig. 17 Marking the position of the side flue opening.

Note: ensure there is adequate access to the air/flue sampling points in the flue turret.

18

6 720 611 445 GB (04.05)

Installation

Maximum 1700mm

Flue

Turret

Outer

Wall

Fig. 19 Flue with one extension

Flue

Turret

Clamp

Extension

Duct

Terminal

Assembly

6 720 611 400-19.1O

Outer

Wall

Clamp

Fig. 20 Flue with extensions

Flue

Turret

Extension

Duct

Clamp

Extension

Duct

Clamp

Terminal

Assembly

6 720 611 400-20.1O

Clamp Extension Flue Duct

Fig. 21 Flue components

Flue Terminal Wall Sealing Gasket

6 720 611 400-21.1O

6 720 611 445 GB (04.05)

19

Installation

3.8.3

Flue duct preparation and assembly

Measure the flue length L. Refer to fig. 22, 23.

L

Outer Wall Face

Flue Terminal

120

Fig. 22 Flue length - rear

L

6 720 611 400-22.1O

6 720 611 400-23.1O

Fig. 23 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. 22 & Fig. 23 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.

Wall Sealing Gasket

6 720 611 400-24.1O

Fig. 24 Flue terminal position

Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must be directed as per Fig. 24.

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. 25.

Flue Turret

Retaining

Screw Flue Turret to

Boiler Sealing

Gasket

Appliance

Flue Socket

6 720 611 400-16.1O

Fig. 25 Flue turret

Ensure that the turret is fully entered 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

6 720 611 445 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.

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. 28.

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.

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.

• 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.

B Pull out cover panel at the bottom and remove. Refer

to fig. 26.

0

1

2

3

4

5

E

B Remove screw and slide terminal cover forwards to remove. Refer to fig. 27.

0

1

2

3 4

5

E

Fig. 27

B Cut cable grommet to diameter of cable.

0

1

2

3

4

5

E

6 720 611 137 -07.1O

8-9

5-7

10-12 13-14

6 720 611 137-08.1O

Fig. 28

B Feed cable through cable grommet and connect the mains supply cable, see fig. 29.

B Secure cable in cable grommet by means of cable grip.

L

Fig. 29

Fig. 26

6 720 611 445 GB (04.05)

6 720 611 137-09.1O

21

Electrical connections

4.2

Wiring to your system

Mains electricity supply: The boiler should be connected to the permanent mains supply as described in

section 4.1 This also provides the electrical supply to

the system.

Note: This must be the only electrical supply to the system. This ensures the safety of a single

fused supply.

The boiler can only be wired to a remote system junction box.

Note: A pump is not built into the boiler and must be fitted externally.

The diagram shows the overall wiring details. A cable is fitted at the factory, between the boiler control panel and the Y-S module. This module is designed to provide the correct voltage interface.

The other connector in the module must be used for wiring to the remote junction box as shown. It is the responsibility of the installer to connect all other system components i.e. water valve/s, pump, programmer etc. to the proprietary junction box according to the instructions supplied with the box. Worcester Heat Systems cannot be held responsible for any incorrect wiring to these parts of the system.

If a room thermostat and/or frost thermostat is required, these must also be connected to the junction box according to the proprietary instructions.

Upon completion of the electrical connections check for earth continuity, correct polarisation and resistance to earth.

Note:

Y-S Module

LS

NS

PE

DV

Table 10

Remote Junction Box

L

N

E (Earth)

Demand (Switched Live)

INSIDE

OF BOILER

OUTSIDE

OF BOILER

Y-S-Module

LR LS NS PE PE DV LS NS

PRE-WIRED

CONTROL

BOARD

HEATRONIC CONNECTOR

L N N S L S L R

MAINS 230V

LIVE SUPPLY

TO BOILER AND

SYSTEM

INSTALLATION

WIRING

Other connections to

Terminal Strip according to Proprietary instructions

REMOTE PRE-WIRED

˜ JUNCTION BOX

Terminal

Strip

MAINS SUPPLY

L N E

BOILER/PUMP

˜DEMAND

PUMP

This must be the only electrical supply to the Junction Box

Fig. 30 Wiring to the Y-S module

6 720 611 445-06.1O

22

6 720 611 445 GB (04.05)

Commissioning

5 Commissioning

27

364

135

295

361

136 365 61 317 366 367

ECO

358

E

363

310

170

15

Fig. 31

310

317

358

361

363

364

365

366

367

15

27

61

135

136

170

172

295

Safety valve

Automatic vent

Reset button

Master switch

Temperature control for boiler

Service cocks on boiler flow and return

Gas cock (shown in on position)

Appliance type sticker

Function control (Service only)

Multi function display

Condensate trap

Drain valve

Indicator lamp for burner

Indicator lamp for power supply

“Chimney sweep” button

Service button

No function

172 170

6 720 611 137-11.1O

5.1

Commissioning

Never run the appliance when empty or unpressurised.

i

The operational CO

2

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. The inhibitor must not be added until all the cleaner has been removed.

23

6 720 611 445 GB (04.05)

Commissioning

To drain the appliance shut the system valves and open the drain valve.

Suitable flushing agents and inhibitors are available from Betz-Dearborn Tel: 0151-4209563 and Fernox

Tel: 01799-550811. Instructions for use are supplied with the these products.

B Before commissioning, the gas supply pres- sure must be checked at the gas supply pres-

sure 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. 31.

B Open all system radiator valves.

B Check the automatic air vent is open (27) see Fig. 31

B Turn on service valves (170), fill central heating system.

B Vent radiators.

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. 31.

B If a domestic hot water cylinder is fitted, set the hot water cylinder thermostat to 60˚C.

5.2

Switching the appliance on/off

Switching on

B Switch on the appliance at the master switch (I).

The indicator lamp shows green and the display will show the boiler flow temperature.

that reason, the appliance remains at minimum heating output for 15 minutes.

Switching off the appliance

B Set the master switch to (0).

The green indicator lamp goes out.

B 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 Boiler

The central heating flow temperature is adjustable between 50˚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:

– Low-temperature heating: setting “E

(approx. 75˚C)

– Central heating systems for flow temperatures up to 88 °C: limited “max” setting for low-tempera-

ture operation (see page 26).

When the burner is alight, the red indicator lamp lights up.

6 720 611 137-12.1O

Fig. 33

5.4

System controls

B Set room thermostat to the desired room temperature.

B Set time clock and the on/off periods. Refer to the instructions with the control.

B Set the thermostatic radiator valves to the desired settings.

6 720 610 333-04.1O

Fig. 32 i

If the display alternates between -II- and the boiler 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

24

6 720 611 445 GB (04.05)

5.5

Frost protection

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: 01799-

550811.

5.6

Fault Condition i

A list of faults that may occur is given on

page 40.

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 boiler 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 boiler flow temperature will be displayed.

Commissioning

25

6 720 611 445 GB (04.05)

Individual settings

6 Individual settings

6.1

Mechanical settings

6.1.1

Setting the boiler flow temperature

The central heating flow temperature can be set to between 50˚C and 88˚C.

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.

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.

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.

2 5 1

6 720 611 137-13.1O

Fig. 34

B Rotate yellow button through 180° and replace (dot facing inwards).

The boiler flow temperature is no longer limited.

Control setting boiler flow temperature

3

4

1

2

5

E max

Table 11 approx. 50˚C approx. 55˚C approx. 60˚C approx. 65˚C approx. 70˚C approx. 75˚C approx. 88˚C

3

6 720 611 137-14.1O

4

Fig. 35 Appliance controls

3

4

1

2

5

Service button

“Chimney sweep” button

Temperature control for boiler flow

Function control

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,

Level 2 consists of 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

Anti-cycle time

Max. boiler flow temperature

Switching difference

Max. heating output

Code no.

2.4

2.5

2.6

5.0

Table 12

The service function 5.0 may be reset.

See page

27

27

27

27

26

6 720 611 445 GB (04.05)

Individual settings

Entering a setting

B To enter the setting for a function, turn the function 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

B Reset the temperature controls and the function control to their original positions.

6.2.2

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).

6.2.3

Setting the maximum boiler flow temperature (Service Function 2.5)

The maximum flow temperature can be set to between

50˚C and 88˚C (factory setting).

6.2.4

Setting the switching difference

(Service Function 2.6) i

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 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). Minimum flow temperature is

30˚C.

6.2.5

Setting the heating output

(Service Function 5.0)

The heating output can be set to any level between min. rated heat output and max rated heat output to limit it to the specific heat requirements.

i

The full rated heat output is still available for hot water or charging the hot water cylinder even if the heating output has been limited.

The factory setting is the max. rated heat output.

B 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.

6 720 611 137-15.1O

Fig. 36

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.

6 720 611 137-16.1O

Fig. 37

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 41).

B Turn the function 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.

6 720 611 137-17.1O

Fig. 38

B Return the temperature controls and to their original positions.

The display will revert to the boiler flow temperate.

27

6 720 611 445 GB (04.05)

Individual settings

6.3

Setting the gas/air ratio

The appliance is set at the factory and adjustment to the

CO

2

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.

28

6 720 611 445 GB (04.05)

Converting the appliance to different gas types

7 Converting the appliance to different gas types

The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not necessary.

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

• 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

7.1

Setting the gas/air ratio

The gas/air ratio may only be adjusted on the basis of a CO

2

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. 14).

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. 39.

B Insert testing probe about 135 mm into the flue gas testing point and seal testing point.

234.1

Model

For conversion from ... Order no.

R 29 HE N.G to L.P.G

7 710 149 049

R 40 HE N.G to L.P.G

7 716 192 299

Table 13

• Instructions are sent with each conversion kit.

234

6 720 611 400-22.1O

Fig. 39

B Press and hold button until the display shows – –.

The button will light up.

6 720 611 137-18.1O

Fig. 40

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).

Fig. 41

6 720 611 137-19.1O

29

6 720 611 445 GB (04.05)

Converting the appliance to different gas types

B Turn the function 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

6 720 611 137-20.1O

Fig. 42

B Measure the CO

2

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. 43.

63

6 720 610 332-64.1R

Fig. 43

Gas Type

Natural gas type

G20

LPG G31

(propane)

Table 14

CO

2

reading at max. rated heat output

9.2 %

10.8 %

CO

2

reading at min. rated heat output

8.8 %

10.5 %

B Turn the temperature control anti-clockwise until the display shows 1. (= min. rated heat output).

The display and the button will flash.

3928-74.1R

Fig. 45

B Re check 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 function control to their original positions.

The display will revert to the boiler 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.

6 720 611 137-21.1O

Fig. 44

B Measure the CO

2

level.

30

6 720 611 445 GB (04.05)

Converting the appliance to different gas types

7.2

Testing combustion air/flue gas at set heat output

7.2.1

Testing the O

2

or CO

2

level in the combustion air i

By testing the O

2

or CO

2

level in the combustion air the gas tightness of a type C

13 or C

O

33

flue system can be checked. The

2

level must not be less than 20,6 %.

The CO

2

level must not exceed 0,2 %.

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 boiler 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 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 boiler 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. 46).

B Insert testing probe about 80 mm into the testing point and seal testing point.

B Remove sealing plug from flue gas testing point

(234, fig. 46).

B Insert testing probe about 135 mm into the testing point and seal testing point.

B Measure CO- and CO

2

levels.

B Refit sealing plug.

B Press and hold button until the display shows – –.

The button will stop flashing and the display shows the boiler flow temperature.

234.1

234

6 720 611 400-22.1O

Fig. 46

B Measure O

2

and CO

2

levels.

B Refit sealing plug.

B Press and hold button until the display shows – –.

The button will stop flashing and the display shows the boiler flow temperature.

31

6 720 611 445 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

There is a special Service booklet for the

Engineer, order no. 7-181-465-346, available to competent persons.

i

All safety and control systems are monitored by the Bosch Heatronic. In the event of a component fault, the display shows a fault code.

B The User should be recommended to have the appliance serviced regularly by a competent person (see

Maintenance Contract).

B Use only genuine spare parts

B Refer to the Spare Parts List when ordering spare parts.

B Always renew seals and O-rings removed during servicing or repair work.

B Use only the following types of grease:

– Water valve: WRAS approved silicon based grease

– Unions: approved sealant.

B To drain the appliance shut the system valves and open the drain valve.

B Upon completion of any electrical work check for earth continuity, correct polarisation and resistance to earth.

32

6 720 611 445 GB (04.05)

8.1

Pre-Service Check List

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).

mbar 4 Check gas supply pressure

(see page 29).

5 Test combustion air/flue gas

(see page 31).

6 Check CO

2

setting for min./ max. (gas/air ratio)

(see page 29).

min. %

8 Check heat exchanger

(see page 34).

max. %

7 Check gas and water systems for

leaks (see page 16).

mbar

9

Check burner (see page 35).

10 Clean condensation trap

(see page 35).

11 Check electrical wiring for damage.

12 Check heating programmer settings.

13 Check appliances that are part of the heating system.

Table 15

Date

6 720 611 445 GB (04.05)

Maintenance

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 7.1.

Check “Last fault stored”:

B Select Service Function .0 (see page 26 “Selecting

service function”).

There is a list of the fault codes in the Appendix (see

page 40).

To delete “Last fault stored”:

B Turn function 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

B Select Service Function 3.3 (see page 26 “Select-

ing 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.

B Unscrew condensation trap and place suitable container underneath. Refer to fig. 48.

B Remove the fan and the burner as described in the

text headed “Burner” (see page 35).

6 720 610 332-72.1R

Fig. 48

B Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade. Refer to fig. 49.

6 720 610 332-73.1R

Fig. 49

B Clean the heat exchanger from top to bottom using the brush. Refer to fig. 50.

6 720 610 332-69.1R

Fig. 47 i

The heat exchanger should only be cleaned if the control pressure is

4.2 mbar (R29 HE)

6.2 mbar (R40 HE)

(depression) or less.

B Remove cleaning access cover (415, page 6) and the metal plate below it, if present. Refer to fig. 2.

6 720 610 332-74.1R

Fig. 50

B Flush the heat exchanger from the top.

34

6 720 611 445 GB (04.05)

Maintenance

B Clean out the condensate collector and trap connection (with other end of brush).

6 720 610 332-75.2R

Fig. 51

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. 52.

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.

1.

2.

3.

4.

7 181 465 330-04.1R

Fig. 52

B Remove the burner skin and clean components. Do not use a wire brush. Refer to fig. 53.

7 181 465 330-08.2R

Fig. 53

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 34, fig. 48).

B Unscrew condensation trap and check connection to heat exchanger is clear.

B Remove condensation trap cover and clean.

B Fill condensation trap with approx. 1/4 l of water and refit.

Electrode assembly

B Switch off the master switch.

B Pull off the leads from the electrodes. Refer to fig. 2.

B Unscrew the two fixing screws and carefully remove

the electrode assembly. Refer to fig. 47.

B Clean the electrodes with a non-metallic brush. (The spark gap should be 4 mm ± 0.5 mm.)

B Replace and re-connect the assembly taking care not to mislay the inspection window.

6 720 611 445 GB (04.05)

35

Maintenance

Diaphragm in mixer unit

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.

B Refit and prime the siphon.

Condensate

Drain

Siphon

3.

1.

443

29

Drain

Plug

6 720 611 445 - 07. 1O

Fig. 55

Electrical wiring

B Check the electrical wiring for physical damage and replace any damaged wires.

2.

6 720 610 790-07.2R

Fig. 54

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 drain plug to drain the siphon.

B Unscrew the securing nut from beneath the side facia and remove the siphon. Refer to figure below.

36

6 720 611 445 GB (04.05)

Maintenance

8.3

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 cov-

ers. Refer to fig. 26, 27.

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. 56.

B Remove the pcb control board.

2

4

1

3

2

4

1

3

1

2

3 4

5

E

2

4

1

3

6 720 611 137 - 23.1O

Fig. 56

B Lower the control box.

B Unscrew earth lead.

B Unscrew four fixing screws from cover plate. Refer to fig. 57.

B Prise off cover plate.

B Pull off transformer.

B Remove pcb holder.

7 181 465 330-10.1R

Fig. 57

Fuses

B Remove the connections covers. Refer to fig. 26,

27.

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.

6 720 611 445 GB (04.05)

37

Maintenance

8.3.2

Fan Assembly

3.

8.3.4

Gas Valve

B Check that the gas cock is turned off.

B Lower the control panel. Refer to fig. 59.

2.

1.

1.

4.

1.

7 181 465 330-05 1R

Fig. 58

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. 58.

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.).

8.3.3

Sensors

B Check that the appliance is electrically isolated.

Central Heating Flow Temperature Sensor –

Item 36, fig. 2

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

B Pull-off the connectors.

B Unscrew the sensor.

Flue Temperature Limiter – Item 9, fig. 2

B Pull-off the connectors.

B Unscrew the sensor.

6 720 611 137- 25.1O

2.

Fig. 59

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. 58.

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.

38

6 720 611 445 GB (04.05)

6 720 610 602 - 04.1O

Fig. 60

8.3.5

Electrode assembly

B Refer to section 8.2.

B Use a new seal if the existing seal is damaged.

8.3.6

Pressure Relief Valve

B Drain the appliance.

B Disconnect the drain pipe from the valve. Refer to

fig. 31.

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.

8.3.7

Burner

B Refer to section 8.2.

8.3.8

Primary Heat Exchanger

B Drain the appliance.

B Check that the gas supply is turned off.

B Check that the appliance is electrically isolated.

B Remove the fan assembly complete with the gas/air

tube and mixer assembly. Refer to section 8.3.2.

B Remove the burner. Refer to section 8.2.

B Disconnect the sensors. Refer to section 8.3.3.

6 720 610 602 - 06.10

Fig. 61

6 720 611 445 GB (04.05)

Maintenance

B Undo the central heating flow union.

B Undo the grey plastic cap at the base of the heat exchanger.

B Unscrew and remove the condensate trap. Refer to

section 8.2.

B Unscrew and remove the two screws securing the heat exchanger top bracket to the rear panel.

B Lift up the flue duct, item 271, refer to fig. 2.

B Pull forward from the top and lift the heat exchanger from the casing.

B Transfer components, as necessary, to the new heat exchanger.

B Ensure that all the seals are in place and all of the connections are tight before re-commissioning the appliance.

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 b1

C1 d3

E2

E9

EA

F0

F7

FA

Fd

P1, P2,

P3, P1...

Table 16

Description Remedy

Code plug not detected.

Fan speed too low.

Jumper 8-9 not detected.

boiler flow NTC sensor defective

Safety temp. limiter in boiler flow has tripped.

Insert code plug correctly, test and replace if necessary.

Check fan lead and connector, and fan; replace as necessary.

Connector not connected, link missing, underfloor heating limiter tripped.

Check boiler flow NTC sensor and connecting lead.

Check system pressure, check safety temp. limiters, check pump operation, check fuse on pcb, bleed appliance.

Flame not detected.

Internal error.

Is gas cock turned on? Check gas supply pressure, power supply, igniter electrode and lead, ionisation sensing electrode and lead, flue duct and CO

2

level.

Check electrical connector contacts, programmer interface module ignition leads are not loose; replace pcb if necessary.

Flame detected even though appliance switched off.

Check electrode assembly, dry pcb. Flue clear?

Flame detected after gas shut off.

Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue clear?

Reset button pressed by mistake.

Please wait, initialisation in progress.

Press reset button again

24 V fuse blown. Replace fuse.

40

6 720 611 445 GB (04.05)

Appendix

9.2

Short parts list

Key

8

9

10

11

12

13

4

5

6

7

1

2

3

14

15

Table 17

Description

Sensor - Flue gas temp.

Sensor - boiler flow temp.

Control board

Gas valve

Fan assembly

Fan washer

Relief valve

Electrode assembly

Electrode lead

Burner skin seal

Transformer - facia

Heat exchanger washer

Washer set Condensation Trap

Fuse set

Primary heat exchanger

9.3

Heating/hot water output settings

(N.G)

60

70

80

90

30

40

50

100

Table 18

Display code

Heat output, kW

8.2

11.0

13.7

16.5

19.2

21.9

24,7

27.4

Heat input, kW

8.3

11.1

13.9

16.6

19.4

22.2

24.9

27.7

Natural gas G20

Gas vol. flow rate

(l/min at t

V

/t

R

= 80/60˚C)

14.5

19.4

24.2

29.1

33.9

38.8

43.6

48.5

Qty GC

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Spare part number

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

8 729 000 183 0

8 717 401 012 0

8 718 107 077 0

8 714 401 999 0

8 711 004 168 0

8 747 201 358 0

8 710 103 153 0

8 710 103 154 0

8 744 503 010 0

8 715 406 615 0

9.4

Heating/hot water output settings

(L.P.G)

Propane

60

70

80

90

100

Display code

40

50

Table 19

Heat output kW

11.0

13.7

16.5

19.2

21.9

24,7

27.4

Heat input kW

11.1

13.9

16.6

19.4

22.2

24.9

27.7

6 720 611 445 GB (04.05)

41

Appendix

9.5

Operational Flow diagrams

9.5.1

Central heating function

fo mp

Fig. 62

42

6 720 611 445 GB (04.05)

Appendix

6 720 611 445 GB (04.05)

43

EXCELLENCE COMES AS STANDARD

Manufactured exclusively for British Gas by The Bosch Group

Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.

Telephone: (01905) 754624 Fax: (01905) 754619

Users Instructions and

Customer Care Guide

R 29 / R 40 HE conventional Condensing boiler

6 720 611 441-00.1O

ZB 7-28 R 29 HE GC-Number: 41 311 60

ZB 11-40 R 40 HE GC-Number: 41 311 61

GB/IE

Contents

Contents

1

2

Excellence comes as standard

Safety precautions

General notes

Controls

3 Operating the Appliance

3.1

Preparation

3.2

Switching the Appliance On/Off

3.3

Switching on the System

3.4

Controlling

3.5

Setting the Hot Water Temperature of a Cylinder

3.6

Frost protection

3.7

Fault Condition

4

5

6

Tips on saving energy

General Information

Maintaining your appliance

7

8

Service

Fault or breakdown

9 Your Bosch guarantee

10 Guarantee registration

11 Operating Instructions Quick Reference

16

17

18

19

14

15

16

20

7

9

3

5

10

10

11

12

12

12

13

13

2 6 720 611 138 GB (04.05)

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 comes to gas, it has to be a Worcester Bosch 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 and is one of the methods of demonstrating compliance with the Building Regulations.

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.

6 720 611 138 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 6 720 611 138 GB (04.05)

6 720 611 138 GB (04.05)

Safety precautions

Safety precautions

Gas Safety (Installation and Use) Regulations

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.

B

B

B

B

B

If you smell gas:

B Turn off gas service cock at the meter.

Open all doors and windows.

Do not operate any electrical switches.

Do not smoke.

Extinguish any naked flames.

Call your gas company.

B

B

If you smell fumes from the appliance:

B Switch off appliance.

Open windows and doors.

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.

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).

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 6 720 611 138 GB (04.05)

General notes

1 General notes

To get the best from your appliance please read these instructions carefully.

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. An open vented system will re-fill automatically.

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. Contact Fernox or Sentinel for further details.

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.

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.

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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 (Vertical Flue)

Above Flue Turret

Below

10 mm

10 mm

600 mm

200 mm

30 mm

200 mm

Table 1

Room thermostat

A room thermostat should be fitted to control the central heating.

Refer to the instructions supplied with the thermostat for information on siting and setting.

Thermostatic radiator valves

It is recommended that this type of valve is fitted to all the radiators. It is a requirement that they are fitted, at least, in the sleeping areas.They should conform to the requirements of BS2767:10.

Time Control

Separate time control of the space heating and the hot water system is required using a twin-channel programmer or two or more separate timers.

Cylinder Thermostat

A cylinder thermostat must be fitted to the cylinder which, when used with a motorised valve, will give close control of the water temperature.

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Controls

2 Controls

136 365 61 317 366 367 363 310

ECO

364

135

295

E

170

172 170

61

135

136

170

172

295

310

317

363

364

365

366

367

Reset button

Master switch

Boiler temperature control

Service valves in boiler flow and return

Gas isolation valve (open)

Identification sticker

Function control (Service only)

Display

Indicator lamp for “burner on”

Indicator lamp for “off/on”

“Chimney sweep” button

Service button

No function

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6 720 611 138 GB (04.05) 9

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.

10

170

172

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6 720 611 138 GB (04.05)

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 primary flow temperature.

6 720 610 333-04.1O

i If the display alternates between -II and the boiler 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.

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Operating the Appliance

3.3

Switching on the System

B Turn the temperature control to the desired level:

“ Min ” setting: 35˚C

Low-temperature heating: setting “

“ Max ” setting: 88˚C

E ” (approx. 75˚C)

When the burner is lit, the red indicator lamp is illuminated.

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3.4

Controlling

B

B

B

Set room thermostat to the desired room temperature.

Set the external time clock to the desired time periods.

Set the thermostatic radiator valves to the desired settings.

3.5

Setting the Hot Water Temperature of a

Cylinder

Hot water temperature

The hot water temperature can be set to between approx. 40˚C and 60˚C using the thermostat on the cylinder.

The domestic hot water temperature is not shown on the display.

12 6 720 611 138 GB (04.05)

Operating the Appliance

3.6

Frost protection

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.

3.7Fault 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 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 boiler 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 boiler flow temperature will be displayed.

If the fault remains and can not be cleared:

B Call your approved installer or Worcester Bosch Customer

Services for assistance, giving a description of the fault and, if possible, the fault code from the facia display.

6 720 611 138 GB (04.05) 13

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 temperature 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.

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General Information

Hot water

A lower setting on the hot water cylinder thermostat can result in considerable energy savings.

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.

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 Services 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 “logbook” 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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Maintaining your appliance

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.

If you would like to know more about Worcester’s extended warranty options please tick the appropriate box on your warranty registration card.

7Service

If your R29/R40 should fail to operate correctly or requires servicing, please call Worcester Heat Systems on: 08457 256206.

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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 i. e. the Benchmark “logbook”.

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. 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.

6 720 611 138 GB (04.05) 17

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 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.

18 6 720 611 138 GB (04.05)

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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Copy the number of the Guarantee Card: . . . . . . . . . . . . . . . . . . .

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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Service booklet for the Engineer for Gas Condensing Boilers

6 720 610 577-00.10

ZWB 7-29 CC1

GC-Number: 47 108 05

ZB 7-28 CS1

GC-Number: 41 108 02

ZWB 7-27 HE combi

GC-Number: 47 311 55

ZWB 7-25 HE combi

GC-Number: 47 311 73

ZWB 7-30 HE combi

GC-Number: 47 311 74

ZB 7-27 HE system

GC-Number: 41 311 49

ZB 7-28 HE system

GC-Number: 41 311 58

Greenstar 29 HE Conventional

GC-Number: Natural Gas: 41 311 56; LPG: 41 311 57

Table of contents

Table of contents

Warnings

Symbols

1 Layout of Appliance

1.1

combi

1.2

system

2 Bosch Heatronic board functions

2.1

Initialisation

2.2

Temperature display

2.3

Indication of faults

2.4

Special programme visualisation

2.5

Boiler service functions

2.5.1 First Service Level

2.5.2 Secondary Service Level

3 Failure identification procedure

3.1

Notes on using the fault code tables

3.2

Summary

3.2.1 Appliance faults

3.2.2 Faults that are not displayed

3.3

Error codes on the display

3.4

Faults that are not displayed

3.4.1 Appliance faults

3.4.2 Programmer faults

4 Appendix

4.1

NTC values

4.1.1 Outside temperature sensor

4.1.2 CH flow NTC sensor, heat store

52

52

52

NTC sensor, constant hot water

NTC sensor and hot water NTC sensor

4.2

Electronic schemes

52

53

4.3

List of most important replacement parts 54

4.4

Approved corrosion inhibitors and anti-freeze fluids for central heating water

4.4.1 Frost protection

4.4.2 Sealing agents

4.5

Summary of BDH Information Sheet on Identifying Corrosion by CFCs

55

55

55

55

14

15

42

42

48

13

13

14

14

8

11

6

8

6

6

6

6

4

4

5

3

3

2

7 181 465 346 GB (03.02)

Warnings

Warnings

B

B

Repairs

B Repairs may only be carried out by an approved installer!

B Before carrying out any work on the appliance, switch it off at the master switch!

B Even when the appliance is switched off at the master switch, some components on the PCB control board inside the control box are still live. Therefore:

B Before carrying out any work on the electrical parts of the appliance fully disconnect it from the power supply (e. g. by means of fuse or circuit breaker)!

Flue ducting must not be modified in any way.

Use only original spare parts!

Instructions to the customer

B Explain to the customer how the appliance works and how to operate it.

B Advise the customer that he/she must not make any modifications to the appliance or carry out any repairs on it.

Symbols

Safety instructions in this document are identified by a warning-triangle symbol and are printed on a grey background.

Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions.

Caution indicates that minor damage to property could result.

Warning indicates that minor personal injury or serious damage to property could result.

Danger indicates that serious personal injury could result. In particularly serious cases, lives could be at risk.

i

Notes are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.

Notes contain important information in cases where there is no risk of personal injury or damage to property.

7 181 465 346 GB (03.02)

3

Layout of Appliance

1 Layout of Appliance

1.1

combi

221.1

221.2

27

226

20

29

271

43

9

63

358

64

7

355

6.1

295

417

Fig. 1

18.1

20

27

29

32.1

36

43

63

8.1

9

15

18

4

6

6.1

7

64

88

98

102

Heatronic control

Heat exchanger safety temperature limiter

Hot water NTC sensor

Testing point for gas supply pressure

Pressure gauge

Flue gas temperature limiter

Relief valve

Pump

Pump speed selector switch

Expansion vessel

Automatic air vent

Air gas Mixer unit

Electrode assembly

Temperature sensor in CH flow

CH flow

Adjustable gas flow restrictor

Adjusting screw for min. gas flow volume

3-way valve (combi)

DHW flow switch (combi)

Inspection window

4

120

349

234.1

234

102

32.1

36

6

415

416

18

423

18.1

418

15

8.1

88

98

4

6 720 610 576-02.2O

349

355

358

415

416

417

418

423

120

221.1

221.2

226

295

234

234.1

271

Fixing points

Flue duct

Combustion air intake

Fan assembly

Appliance type sticker

Testing point for combustion products

Testing point for combustion air

Flue duct

Cover plate for twin flue duct connection

Plate-type domestic hot water heat exchanger

Condensate trap

Cover plate for cleaning access

Condensate collector

Clip for fixing outer case

Data plate

Siphon

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Layout of Appliance

43

9

63

358

64

7

27

226

20

29

271

1.2

system

221.1

221.2

295

417

Fig. 2

36

43

63

64

20

27

29

32.1

4

6

7

8.1

9

15

18

18.1

102

120

221.1

221.2

226

295

234

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

Combustion air intake

Fan assembly

Appliance type sticker

Testing point for combustion products

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120

349

234.1

234

102

32.1

36

6

415

416

18

423

18.1

418

15

8.1

4

6 720 610 596-01.2O

234.1

271

349

358

415

416

417

418

423

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

5

6

Bosch Heatronic board functions

2 Bosch Heatronic board functions

2.1

Initialisation

When it is switched on, the appliance performs a selftest which takes about 5 seconds. While the test is in progress, the display shows the following sequence of codes:

P1 -> P2 -> P3 -> P4 -> P5 -> P6

On completion of the test sequence the appliance is ready for operation.

2.2

Temperature display

The display shows the current flow temperature in central heating and hot water modes. The display range extends from 00 ˚C to 99 ˚C.

If a service function requires the display of a temperature greater than 99 ˚C, the display alternates between initially showing the first digit and then the remaining two digits.

E.g.

: display showing 1.

followed by 69.

indicates

169˚C .

For outside temperatures, the display shows a minus sign followed by the negative temperature in alternation.

2.3

Indication of faults

Faults are indicated by a letter code. This helps to identify and eliminate the cause of the fault quickly and reliably.

The fault codes displayed are grouped into four categories:

Category 1:

The appliance is disabled until it has been switched off and then on again.

Category 2:

The appliance is disabled until the cause of the fault has been eliminated.

Category 3:

The appliance continues to operate with limited function.

Category 4:

The appliance is disabled and locked ( flashes) until the cause of the fault has been eliminated and the appliance unlocked.

i

Unlocking the appliance:

B Press and hold the display shows – – .

button until the

2.4

Special programme visualisation

The display shows for example 45

– –

45 (continuous working at the minimum sanitary/heating power)

The display shows alternatively the temperature and

– –

. The function is memorised in the Service mode.

• The appliance works continuously at the sanitary or heating minimum power.

B

B

B

B

Press the button until the symbol

– –

appears on the display.

The button is lighted.

Turn the temperature control until function 2.0

appears on the display.

After a short delay, the display shows 1 for minimum output.

Turn the temperature control completely anticlockwise until the display shows 0 .

Press the button until the symbol [ ] appears on the display.

The display shows the heating outlet temperature.

The display shows for example 55

– –

55

(continuous working at the maximum power)

The display shows alternatively the temperature and

– –

.

The function is memorised in the Service mode.

• The appliance works continuously at the maximum power.

B

B

B

B

Press the button until the symbol

– –

appears on the display.

The button is lighted.

Turn the temperature control until function 2.0

appears on the display.

After about 5 seconds the display will show 2 for the maximum power.

Turn the temperature control completely anticlockwise until the display shows 0 .

Press the button until the symbol [ ] appears on the display.

The display shows the heating outlet temperature.

Display shows 45 -II- 45 (trap filling programme)

The trap filling programme ensures that the condensation trap is filled after the appliance is first installed or if it has been switched off for a long period.

The trap filling programme is activated if:

• the appliance is switched on at the master switch

• the burner has not been in operation for at least 48 hours

• the appliance is switched from summer to winter mode.

7 181 465 346 GB (03.02)

The next time the central heating or heat store calls for heat, the appliance is held at a low heat output for 15 minutes. The display shows -II in alternation with the

CH flow temperature.The factory setting is 1 (enabled).

If the condensation trap is not filled with water, flue gas can escape!

B The trap filling programme should only be disabled in order to carry out servicing work.

B Always re-enable the trap filling programme after completing servicing work.

To switch off the trap filling programme to carry out servicing work:

B Press and hold the and buttons simultaneously until the display shows = = .

The and buttons will light up.

B Turn the temperature control until the display shows 8.5

.

After a short delay, the display then shows the trap filling programme setting ( 1.

= Enabled).

B Turn the temperature control until the display shows 0. (= Disabled).

The display and the and buttons will flash.

B Press and hold the and buttons simultaneously until the display shows [ ].

The trap filling programme is now disabled.

B Regulate the temperature control and the temperature control on the previously set positions.

The display shows the heating outlet temperature.

Display shows

0

0

(venting function)

The first time the appliance is switched on, it automatically activates a one-off venting sequence in which the heating pump switches on and off at intervals for about

8 minutes.

This function can be activated on Service Level 2, Service Code 7.3, if it is required at any other time.

Bosch Heatronic board functions

7 181 465 346 GB (03.02)

7

Bosch Heatronic board functions

2.5

Boiler service functions

2.5.1

First Service Level

Operating

In order to change or check the values of the service functions:

B Press the button until the symbol

– –

appears on the display.

The button is lighted.

B Turn the temperature control until the desired function number appears on the display.

Once changed or checked the function value:

Values that can be modified:

B Press the button until the symbol [ ] appears on the display.

The display shows the heating outlet temperature.

B Regulate the temperature control and the temperature control on the previously set positions.

In order to reset the main menu function values to their default values:

B Power OFF the appliance.

B Press the button and keep it pressed.

B Switch on the appliance, press and hold the button until the display shows r1 followed by [ ].

.0

2.0

2.2

2.3

2.4

Description

Show the last error code.

Identification of the function mode (0 = normal, 1= min, 2 = max)0 - 2

Identification of the pump function mode

Display

0 - FF

1 - 3

Reset Value

Clear only

0

2

Max. output in heat store heating mode

Anti-cycle time

1)

28 - 99

0 - 15 min

99

3 min

2.5

2.6

Max. CH flow temperature 35 - 88˚C 88˚C

Minimum hysteresis in heating mode (

T)0 - 30 K 0 K

Activation of automatic anti-cycle time (0 = Disabled; 1 = Enabled)0, 1 1 2.7

3.4

Pump mode 0 - 3 2)

Table 1 First Service Level; Values that can be modified

1)If appliance is used in conjunction with type TA... programmer, only effective if Service Code 2.7 is set to “0” (= "Disabled”)!

2)The reset value is dependent on the code plug.

8

7 181 465 346 GB (03.02)

Bosch Heatronic board functions

Values that can only be read:

.3

.4

.1

.2

1.2

1.4

1.5

1.6

1.7

1.8

1.9

2.9

3.0

3.3

3.6

Description

Heating outlet temperature.

Sanitary outlet temperature.

Table 2 First Service Level; Values that can only be read

Display

0 - 99˚C

0 - 99˚C

Heat store NTC sensor (ZSB.)0 - 99˚C

Constant hot water NTC sensor (ZWB.)0 - 99˚C

Order no. for code plug: 8 714 411 XXX 0 - 255

Temperature voltage signal (Terminal 2) from room thermostat

(eg. TRQ 21, TR 100)

Specified CH flow temperature from programmer

5 - 22 VDC

0 - 99˚C

-20 +30˚C -

-

Outside temperature from TA 211 E or room temperature from

TR 212 E

Status TR 2 (0 = Not present 1 = Frost protection 3 = Auto 4 = Day,

Night 5=Error)

0 - 4

-

-

Terminal 2 on programmer interface module

Identification code for the external module:

0, 2, 4, 5 = no module connected,

3 = ADM, 6 = TA 211E, 53 = ADM, 56 = TR 212 E).

Instantaneous power.

Fan speed

0 - 24 VDC -

0 - 8, 53,

56

-

0 - 99 %

0 - 105

0 - 3

-

-

Quality of the ionisation signal:

0 = no ionisation,

1 = weak ionisation,

2 = medium ionisation,

3 = high ionisation.

Software version 3 x 2 positions

-

-

-

-

-

-

Reset Value

7 181 465 346 GB (03.02)

9

Bosch Heatronic board functions

Values that can only be read - only left display digit:

3.9

4.1

Description

External switch (points 8 - 9).

External demand for heat via LSM

Display XY

0 = closed

1 = Heating demand

0 = closed

1 = Heating demand

0 = closed

1 = Heating demand

4.2

4.3

4.4

Programmable clock:

1st channel (Heating).

Automatic pump shut OFF with RAM module

(point 5)

Heating demand.

0 = closed

1 = Heating demand

0 = closed

1 = Heating demand

4.5

Sanitary demand.

0 = closed

1 = Heating demand

Table 3 First Service Level; Values that can only be read - only left display digit

Values that can only be read - only right display digit:

3.9

4.0

4.1

Description

External 2-point demand for heat via 230 V AC

(Terminals Ls - Lr)

Heat store demand for heat via heat store thermostat (Terminals 7-9)

LSM Enable

Display XY

0 = closed

1 = Heating demand

0 = closed

1 = Heating demand

0 = closed

1 = Heating demand

4.2

4.3

4.4

4.5

Programmable clock:

2nd channel (DHW – Maintaining).

Heating demand from TA 211 E

0 = closed

1 = Heating demand

0 = closed

1 = Heating demand

Heat store demand for heat via heat store NTC sensor

0 = closed

1 = Heating demand

Sanitary heat exchanger temperature maintaining.

0 = closed

1 = Heating demand

4.6

Anti-cycle time 0 = closed

1 = Heating demand

Table 4 First Service Level; Values that can only be read - only right display digit

-

-

-

-

-

-

Reset Value

-

-

-

-

-

-

-

-

Reset Value

10

7 181 465 346 GB (03.02)

Bosch Heatronic board functions

2.5.2

Secondary Service Level

Operation

In order to change or check the values of the service functions:

B Press buttons and simultaneously until the symbol = = appears on the display.

The buttons and are lighted.

B Turn the temperature control until the desired function number appears on the display.

Once changed or checked the function value:

Values that can be modified:

B Press buttons and simultaneously until the symbol [ ] appears on the display.

The display shows the heating outlet temperature.

B Regulate the temperature control perature control

and the tem-

on the previously set positions.

To reset all settings on Service Levels 1 and 2 to the factory setting:

B Power OFF the appliance.

B Press buttons and simultaneously and keep them pressed.

B Switch on appliance, press and hold the and buttons until the display shows r2 followed by [ ].

5.0

5.1

5.5

Description

Reduced max. heating output

Continuous ignition (for testing ignition without gas)

Increased min. heating and heat store charging output

Display

0 - 99 % and sealed

0 = off

1 = on

0 - 99 %

5.9

Starting speed option (if flame propagation is poor, set high starting speed)

Pump deactivation in HW mode, ZW only.

6.7

6.8 Cycle time for heat exchanger constant hot water function on ZW model.

6.9

7.3

Constant hot water

Venting function

0 = First start at low speed;

1 = First start at high speed)

0 = off, 1 = on

0 - 60 min

0 - 30 min

0 = off,

1 = On for 8 cycles then permanently off (i.e. set to 0)

2 = on

7.7

Temperature-dependent output reduction 0 = off;

1 = Heating on

2 = Hot water on

3 = Heating and hot water on

8.5

Trap filling programme

Table 5 Secondary Service Level; Values that can be modified

0 = off

1 = on

1

0

3

1

Reset Value

99

0

0

0

3

1

7 181 465 346 GB (03.02)

11

Bosch Heatronic board functions

Values that can only be read:

Description

Automatic gas igniter status and/or fault 5.2

9.3

Automatic gas igniter Asic fault code

Table 6 Secondary Service Level; Values that can only be read

Display

00 - FF

00 - FF -

-

Reset Value

12

7 181 465 346 GB (03.02)

Failure identification procedure

1.

2.

3 Failure identification procedure

3.1

Notes on using the fault code tables

The procedure is best described with the aid of an example:

• Work through the table from top to bottom and from left to right.

• First make a note of the present settings and restore them before leaving the appliance.

• Read question 1. (Check column)and depending on the answer (yes or no) read the action required from the relevant box and carry out the instruction given; ignore the other answer. For example: if the burner flame is visible, follow the instructions for yes, i.e.

5.!

5. means go to number 5., ignoring the steps in between.

EA

and flashing.

Flame not detected

Check

In this example: check the flue is clear by testing the CO

2

level.

• If the appliance is locked ( button is flashing), press the button. Important: after unlocking the appliance, always restart it (i.e. switch off and then on again). Only then is it possible to say whether or not the fault has been eliminated.

• If the fault has been rectified, the appliance will then start up without indicating a fault and the fault isolation procedure is complete.

• If the fault is still present after performing the action specified and, if necessary, restarting the appliance, move on to the next step in the fault isolation procedure.

• If another fault code is displayed, work through the fault code table for that code.

Is a burner flame visible?

Is the gas cock turned on?

yes: no: yes: no: yes: no:

Action

B Note the setting of the temperature controls and .

5.

2.

5.

B Open the gas cock.

B Press , restart the appliance.

EA?

3.

...

...

3.

Has the thermal cut-out on the gas cock tripped?

4. ...

...

5. ...

Problem with flue?

B Check CO

2

level in combustion air.

Is CO

2

level above 0,2 % ? yes: no:

Check flue.

...

Return to normal operation:

B Press the button until the symbol [ ] appears on the display.

B Regulate the temperature control and the temperature control on the previously set positions.

Table 7

13

7 181 465 346 GB (03.02)

Failure identification procedure

3.2

Summary

3.2.1

Appliance faults 3.2.2

Faults that are not displayed

Appliance faults

Ad b1

C1

CC

A5

A7

A8

AC d3

E2

E9

EA

F0

F7

FA

Fd

Table 8

4

4

4

4

4

2

2

4/

2

2

3

3

2

3

3

3

3

X

15

X

17

X X X

19

X X X

20

X

22

X X X

24

X X X

25

X X X

26

X X X

27

X X X

28

X X X

30

X X X

32

X X X

37

X X X

38

X X X

39

X X X

41

Appliance faults

Excessive burner noise, rumbling noises

Flue gas levels incorrect, CO level too high

Ignition too harsh, ignition poor.

Boiler indicates P1, P2, P3 at start-up and then restarts with P1,...

Loose or broken contact on heat store NTC sensor

Specified CH flow temperature from TA... programmer exceeded

Table 9

X X

42

X X

43

X X

44

X X

46

X X

46

X X

47

Programmer faults

Set room temperature not reached.

Set room temperature exceeded.

Set room temperature not reached.

Set room temperature exceeded by large amount.

Excessive fluctuations in room temperature

Temperature rises instead of falling

Room temperature too high in Economy mode

Incorrect or no modulation

Heat store fails to heat up

Table 10

X

X

X

X

X

X

48

X

X

X

X

X

X

X

49

50

50

51

50

51

14

7 181 465 346 GB (03.02)

Failure identification procedure

3.3

Error codes on the display

A5

flashing.

Heat store NTC sensor 2 defective

Check

1. B Press button .

B Select service function .3 .

Is a temperature between 0. and

5. displayed?

yes:

2.

no: yes: Heat store NTC:

B Unplug connector.

B Short circuit the connector.

Display changes to temperature between 99. and 95. no:

3.

4.

Temperature between 95. and 99. is displayed.

B Unplug connector.

After max. 60 sec.:

Does the displayed code change to a value between 0. and 5.?

yes: no: yes: B Unplug 20-pin connector from

PCB.

After max. 60 sec.:

Does the displayed code change to a value between 0. and 5.?

7 181 465 346 GB (03.02) no:

Action

B Note the setting of the temperature controls and .

B Flue gas connector corroded

1)

, damaged or dirty?. Change relative parts.

2.

3.

B Power OFF the appliance.

B Change NTC sensor.

B Plug the connection wire.

B Turn ON the appliance.

A5? ↓

3.

B Change the 20-pin connector lead assembly.

3.

B Power OFF the appliance.

B Change NTC sensor.

B Plug the connection wire.

B Turn ON the appliance.

A5?

4.

4.

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change the 20-pin connector lead assembly.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

5.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

15

Failure identification procedure

A5

flashing.

Heat store NTC sensor 2 defective

Check

5.

1)For notes, refer to Appendix

Action

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

16

7 181 465 346 GB (03.02)

Failure identification procedure

A7

flashing.

Hot water NTC sensor defective

Check

1. B Press button .

B Select service function .2 .

Is a temperature between 0. and

5. displayed?

yes:

2.

no: yes: Hot water NTC sensor:

B Unplug connector.

B Short circuit the connector.

Display changes to temperature 99.

3.

no:

Temperature between 95. and 99. is displayed.

B Unplug connector.

After max. 60 sec.:

Does the displayed code change to a value between 0. and 5.?

yes: no:

Action

B Note the setting of the temperature controls and .

B Flue gas connector corroded

1)

, damaged or dirty? Change relative parts.

2.

3.

B Power OFF the appliance.

B Drain the hot water circuit.

B Disconnect the boiler electrical connection.

B Change NTC sensor.

B Plug the connection wire.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

A7?

3.

B Change the 20-pin connector lead assembly.

3.

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change NTC sensor.

B Refill the hot water circuit.

B Check the built-in NTC sensor for leaks.

B Plug the connection wire.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

A7?

4.

4.

17

7 181 465 346 GB (03.02)

18

Failure identification procedure

5.

A7

flashing.

Hot water NTC sensor defective

4.

Check

B Unplug 20-pin connector from

PCB.

After max. 60 sec.:

Does the displayed code change to a value between 0. and 5.?

yes: no:

Action

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change the 20-pin connector lead assembly.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

5.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

5.

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

1)For notes, refer to Appendix

7 181 465 346 GB (03.02)

Failure identification procedure

A8

flashing.

No correct electrical connection

1.

Check

TR 2 connected?

2.

3.

Mode selector switch is between two settings

B Power OFF the appliance.

Wiring between TR 2 and TR 212 E

OK?

• Terminal 3 on TR 2 connected to

Terminal 3 on TR 212 E?

• Terminal 4... Terminal 4....

yes: no:

4.

TR 2 defective yes: no:

Action

A8?

2.

B Power OFF the appliance.

B Connect TR 2.

B Turn ON the appliance.

A8?

2.

B Turn switch until it clicks into position.

A8?

3.

B Turn ON the appliance.

4.

B Rewire correctly as specified in the installation instructions.

B Turn ON the appliance.

After 90 sec.:

A8?

4.

B Power OFF the appliance.

B Change TR 2.

B Turn ON the appliance.

19

7 181 465 346 GB (03.02)

20

Failure identification procedure

AC

flashing.

Module not detected.

(Constant CH flow temperature according to CH temperature control on boiler.)

Check Action

1.

2.

3.

4.

5.

6.

B Press button

B Select service function 1.9 .

Code 0., 2., 4., 5. is displayed.

Are 24 V DC cables routed alongside 230 V AC cables?

Connecting lead between PCB control board and TA 211 E or TA 212 E defective.

played .

.

TA 211 E connected?

B Select service function 1.6 .

Outside temperature between -20 and +30 ˚C is displayed.

Does temperature displayed match true outside temperature?

If remote control installed:

B Select service function 1.7 .

Remote control status 0. is disyes: no: yes: no: yes: no: yes: no: yes: no:

B Note the setting of the temperature controls and .

No modul detected.

B Disconnect connecting lead between PCB control board and TA 211 E or TA 212 E.

B Re-connect connecting lead.

AC? ↓

3.

↓ 2.

B Ensure cable separation conforms to minimum requirements as per installation instructions and/ or use shielded cable.

↓ 3.

B Power OFF the appliance.

B Replace connecting lead between PCB control board and programmer interface module or TA

211 E.

B Turn ON the appliance.

AC? ↓

4.

↓ 5.

↓ 8.

↓ 7.

B Power OFF the appliance.

B Replace outside temperature sensor.

B Turn ON the appliance.

AC? ↓

7.

B Power OFF the appliance.

B Plug the connection wire.

B Turn ON the appliance.

AC? ↓

7.

↓ 7.

7 181 465 346 GB (03.02)

Failure identification procedure

AC

flashing.

Module not detected.

(Constant CH flow temperature according to CH temperature control on boiler.)

7.

8.

Check

Remote control status still 0.?

The PCB control board is damaged.

yes: no:

Action

B Power OFF the appliance.

Remote control:

B Replace top section.

B Turn ON the appliance.

AC?

8.

8.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

21

7 181 465 346 GB (03.02)

22

Failure identification procedure

Ad

flashing.

Heat store NTC sensor 1 not detected (ZB...).

Check

1.

2.

Is connecting lead for heat store

NTC sensor 1 correctly routed, i.e.

not through cable grommet?

B Press button .

B Select service function .3 .

Is a temperature between 0. and

5. displayed?

yes: no: yes:

3.

Heat store -NTC 1:

B Unplug connector from PCB control board.

B Short circuit the connector using wire jumper.

After max. 60 sec:

Display changes to temperature between 99. and 95. no: yes: no:

Action

B Note the setting of the temperature controls and .

↓ 2.

B Route connecting lead for heat store temperature sensor as specified in installation instructions.

Is NTC sensor connector corroded, damaged or dirty?

B Power OFF the appliance.

B Change NTC sensor.

B Turn ON the appliance.

B Press button .

Ad?

3.

4.

B Power OFF the appliance.

B Change NTC sensor.

B Turn ON the appliance.

B Press button .

4.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

4.

7 181 465 346 GB (03.02)

Failure identification procedure

Ad

flashing.

Heat store NTC sensor 1 not detected (ZB...).

4.

Check

Temperature between 99. and 95. is displayed.

B Unplug connector.

After max. 60 sec.:

Does the displayed code change to a value between 0. and 5.?

yes: no:

Action

B Power OFF the appliance.

B Change NTC sensor.

B Turn ON the appliance.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

23

7 181 465 346 GB (03.02)

Failure identification procedure b1

flashing.

1.

2.

The Heatronic does not recognise the code key.

Check

Code plug loose, incorrect or defective.

3.

The PCB control board is damaged.

Action

B Power OFF the appliance.

B Replace code plug, check code number is correct.

B Turn ON the appliance.

b1?

3.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

24

7 181 465 346 GB (03.02)

Failure identification procedure

C1

flashing.

Fan speed too low

1.

Check

Fan lead connector properly connected?

yes: no:

2.

3.

4.

Is fan lead defective?

B Is impedance reading between the two connectors for one of the cores infinity?

yes:

Are the differential pressure switch contacts closed?

B Press button .

B Select service function 3.8 .

Is left digit of display showing 1?

Fan defective?

no: yes: no: yes:

5.

The PCB control board is damaged.

no:

Action

2.

B Power OFF the appliance.

B Plug in connector.

B Turn ON the appliance.

C1?

2.

B Power OFF the appliance.

B Replace fan lead.

B Turn ON the appliance.

C1?

3.

3.

4.

4.

B Power OFF the appliance.

B Plug the connection wire.

B Replace fan.

B Plug the connection wire.

B Turn ON the appliance.

C1?

5.

5.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

25

7 181 465 346 GB (03.02)

Failure identification procedure

2.

CC

flashing.

Outside temperature NTC sensor not detected.

(Boiler heating as if outside temperature is -20˚C)

1.

Check

Outside temperature sensor AF2 connected to Terminals A and F on

TA 211 E?

yes: no:

B Power OFF the appliance.

B Disconnect outside temperature sensor and test resistance

R =

or R = 0?

Action

2.

B Power OFF the appliance.

B Connect outside temperature sensor to Terminals A and F on TA 211 E.

B Turn ON the appliance.

CC?

2.

B Change the external sensor.

B Turn ON the appliance.

26

7 181 465 346 GB (03.02)

Failure identification procedure

3.

d3

flashing.

Wrong signal from pin 8-9 (open?).

1.

2.

Check

B Turn ON the appliance.

B Measure voltage between Terminal 4 and Terminal 8.

Voltage

24 V DC?

Existing heat store thermostat connected to Terminals 7, 8 and 9?

Break in connecting lead?

4.

The PCB control board is damaged.

yes: no: yes: no: yes: no:

Action

2.

3.

B Power OFF the appliance.

B Fix the additional bridge 8-9 in the right position and close the screws.

B Turn ON the appliance.

d3?

3.

4.

B Power OFF the appliance.

B Plug the connection wire.

B Turn ON the appliance.

d3?

4.

4.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

27

7 181 465 346 GB (03.02)

28

Failure identification procedure

E2

flashing.

The heating outlet NTC sensor is damaged.

Check

1.

2.

Temperature for heating outlet NTC sensor between 95. and 99. is displayed.

no: yes:

3.

4.

B Press button .

B Select service function .1 .

Is a temperature between 0. and

5. displayed?

Check if the 20-pin connector lead assembly is damaged.

The PCB control board is damaged.

yes: no:

Action

B Note the setting of the temperature controls and .

The heating outlet NTC sensor is in short circuit:

B Power OFF the appliance.

B Replace CH flow NTC sensor; observe fitting instructions for NTC sensor when doing so.

B Turn ON the appliance.

E2?

2.

2.

The CH flow NTC sensor is interrupted :

B Power OFF the appliance.

B Replace CH flow NTC sensor; observe fitting instructions for NTC sensor when doing so.

B Turn ON the appliance.

E2? ↓

3.

3.

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change the 20-pin connector lead assembly.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

E2? ↓

4.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

7 181 465 346 GB (03.02)

Failure identification procedure

E2

flashing.

The heating outlet NTC sensor is damaged.

Check Action

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

7 181 465 346 GB (03.02)

29

30

Failure identification procedure

E9

and flashing.

Safety temperature limiter has tripped.

1.

Check

Is the heating pressure between 1 and 2 bar?

yes: no:

2.

Is the pump blocked?

3.

Lead disconnected from safety temperature limiters?

no: yes:

4.

B Power OFF the appliance.

B Unplug the connector from the cut-off device.

B Measure the NTC electrical resist- ance.

R =

?

no: yes: no: yes:

Action

2.

B Top up system.

B Vent appliance.

B Press , restart the appliance.

E9? ↓

2.

B Unblock the pump.

If pump won’t start:

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change the pump.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Press , restart the appliance.

E9?

3.

3.

B Power OFF the appliance.

B Connect lead.

B Turn ON the appliance.

B Press , restart the appliance.

E9?

4.

4.

B Change the over heating cut-off device.

B Connect flue gas safety temperature limiter lead.

B Turn ON the appliance.

B Press , restart the appliance.

E9?

5.

B Connect flue gas safety temperature limiter lead.

B Turn ON the appliance.

5.

7 181 465 346 GB (03.02)

Failure identification procedure

E9

and flashing.

Safety temperature limiter has tripped.

5.

Check

Is lead disconnected from CH flow safety temp. limiter?

yes:

6.

B Power OFF the appliance.

B Disconnect lead to CH flow safety temperature limiter.

B Measure the CH flow safety temperature limiter.

R =

?

no: yes: no:

7.

8.

B Power OFF the appliance.

B Remove fuse SI 3 from appliance

PCB control board and test for continuity.

R =

?

yes:

The PCB control board is damaged.

no:

Action

B Power OFF the appliance.

B Reconnect lead.

B Turn ON the appliance.

B Press , restart the appliance.

6.

6.

B Change CH flow safety temperature limiter.

B Connect CH flow safety temperature limiter lead.

B Turn ON the appliance.

B Press , restart the appliance.

E9?

7.

B Connect CH flow safety temperature limiter lead.

B Turn ON the appliance.

7.

B Change the fuse.

B Turn ON the appliance.

B Press , restart the appliance.

E9?

8.

B Remount the fuse.

B Turn ON the appliance.

8.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

31

7 181 465 346 GB (03.02)

32

Failure identification procedure

EA

and flashing.

No flame ionisations signal

Check

1.

2.

3.

Is the flame present?

Is the gas cock open?

Is there air in the supply pipe?

4.

Did the thermal security of the gas cock lock out?

no: yes: no: yes: no: yes: no: yes:

Action

B Note the setting of the temperature controls and .

↓ 6.

↓ 2.

↓ 3.

B Open the gas cock.

B Press , restart the appliance.

EA?

3.

B Vent supply pipe.

B Press , restart the appliance.

EA?

4.

4.

B Reset security.

B Press , restart the appliance.

EA?

5.

5.

7 181 465 346 GB (03.02)

Failure identification procedure

EA

and flashing.

No flame ionisations signal

5.

Check

Natural gas models: does the building have a supply pressure regulator?

yes:

6.

7.

LPG models: is the flow rate of the gas supply to the appliance correct?

no: yes: no:

Is the ground connection correct?

Two phase net:

Is there a resistor fitted between Pe and N?

yes: no: yes: no:

Action

B Check that it is fitted correctly and functioning properly and correct if necessary.

B Check supply pressure, inform gas company if outside correct range.

B Is correct code plug fitted?

B Press , restart the appliance.

EA?

6.

6.

6.

B Is there enough gas in the supply cylinder?

B Is there air in the supply pipe?

B Is the solenoid valve in the "meter cabinet” opening?

B Is the supply pressure OK? (if the supply pressure is too high, check the pressure regulator in the “meter cabinet” and on the LPG supply cylinder).

B Press , restart the appliance.

EA?

6.

7.

B Correct the electrical ground connection.

B Press , restart the appliance.

EA?

7.

8.

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Insert a 2 M Ω

resistance between the ground and the N connection.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Press , restart the appliance.

EA?

11.

33

7 181 465 346 GB (03.02)

34

Failure identification procedure

9.

EA

and flashing.

No flame ionisations signal

8.

Check

Is diaphragm in the mixer unit correctly fitted and functional?

B Open mixer unit (29).

B Check diaphragm for correct orientation, soiling and splitting.

Is diaphragm OK?

Is the condensation trap blocked?

yes: no: yes:

10.

Check the gas valve?

B Power OFF the appliance.

B Unplug the connectors from the gas valve.

B Measure the gas valve coils I and

II electrical resistance.

R = 164 ± 40

?

no: yes: no:

11.

Problem with flue?

B Check CO

2

level in combustion air.

Is CO

2

level above 0,2 % ?

B Open up heat exchanger - is it dirty?

12.

Is flue gas CO

2

level incorrect

1)

?

yes: no: yes: no:

Action

B Close mixer unit.

9.

B Insert diaphragm in the fan intake duct as per installation instructions so that the flaps open upwards.

B Close mixer unit.

EA?

9.

B Clean out condensation trap discharge pipe.

B Press , restart the appliance.

EA? ↓

13.

↓ 10.

B Reconnect the gas valve.

B Turn ON the appliance.

B Press , restart the appliance.

EA?

11.

B Change the gas valve.

B Reconnect the gas valve.

B Turn ON the appliance.

B Press , restart the appliance.

EA?

11.

B Check flue and clean if necessary.

B Press , restart the appliance.

EA?

12.

12.

B Adjust to correct level.

B Press , restart the appliance.

EA?

13.

13.

7 181 465 346 GB (03.02)

Failure identification procedure

EA

and flashing.

No flame ionisations signal

Check

13.

B Press buttons and simultaneously.

B Select service-function 5.1.

Continuous ignition (without gas)

OK?

yes: no:

14.

Ignition lead connected to ignition electrodes?

yes: no:

15.

Ignition cable connector engaged in switchbox?

yes: no:

16.

Is the ignition electrical wire damaged?

17.

B Press button .

B Select service-function 3.3.

Is the ionisation quality 2. or 3. ?

18.

Electrode assembly defective?

B Power OFF the appliance.

B Remove electrode assembly.

Electrodes worn out?

yes: no: yes: no: yes: no:

Action

B Press buttons and simultaneously.

14.

B Press buttons and simultaneously.

↓ 17.

↓ 15.

B Connect cable to ignition electrode.

B Press , restart the appliance.

EA?

15.

16.

B Power OFF the appliance.

B Engage ignition cable connector in switchbox.

B Turn ON the appliance.

B Press , restart the appliance.

EA?

16.

B Power OFF the appliance.

B Change the ignition electrical wire.

B Turn ON the appliance.

B Press , restart the appliance.

EA?

17.

17.

19.

18.

B Replace electrode assembly.

B Turn ON the appliance.

B Press , restart the appliance.

EA?

19.

B Refit electrode assembly.

B Turn ON the appliance.

B Press , restart the appliance.

EA?

19.

35

7 181 465 346 GB (03.02)

36

Failure identification procedure

EA

and flashing.

No flame ionisations signal

Check

19.

Check if the 20-pin connector lead assembly is damaged.

20.

The PCB control board is damaged.

Action

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change the 20-pin connector lead assembly.

B Turn ON the appliance.

B Reconnect the boiler electrical connection.

B Press , restart the appliance.

EA?

B Power OFF the appliance.

20.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

1)See installation instructions

7 181 465 346 GB (03.02)

Failure identification procedure

F0

(and possibly ) flashing.

Internal failure

Check

1.

2.

3.

B Press buttons and simultaneously.

B Select service function 9.3 .

A service code is displayed.

B Select service function 5.2 .

A service code is displayed.

flashing?

yes:

4.

The PCB control board is damaged.

no:

Action

B Note the setting of the temperature controls and .

B Enter figure displayed in customer service record.

2.

B Enter figure displayed in customer service record.

3.

B Press button .

B Initiate demand for heat by pressing button and then press again after 30 seconds to cancel.

B Initiate two more demands for heat as above.

F0?

4.

4.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

37

7 181 465 346 GB (03.02)

38

Failure identification procedure

F7

and flashing.

Although appliance switches off, flame still detected

1.

Check

Electrode(s) dirty or defective.

2.

3.

4.

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Remove PCB control board.

PCB control board damp?

Problem with flue?

B Check CO

2

level in combustion air.

Is CO

2

level above 0,2 % ?

The PCB control board is damaged.

yes: no: yes: no:

Action

B Power OFF the appliance.

B Replace electrode assembly.

B Turn ON the appliance.

B Press , restart the appliance.

F7?

2.

B Dry PCB control board (e.g. with hair dryer).

B Look for point where damp is entering switchbox and seal as necessary (cable grommets properly fitted, ...?).

B Refit PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Press , restart the appliance.

F7?

3.

3.

B Check flue and repair or replace if necessary.

4.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

7 181 465 346 GB (03.02)

Failure identification procedure

FA

and flashing.

Although appliance switches off, flame still detected

Check Action

1.

2.

3.

4.

Condensation trap blocked?

Electrode assembly defective?

B Power OFF the appliance.

B Remove electrode assembly.

Electrode assembly burnt out?

Problem with flue?

B Check CO

2

level in combustion air.

Is CO

2

level above 0,2 % ?

The gas valve is damaged.

yes: no: yes: no: yes: no:

B Note the setting of the temperature controls and .

B Power OFF the appliance.

B Clean condensation trap discharge pipe.

B Press , restart the appliance.

FA?

2.

2.

B Replace electrode assembly.

B Turn ON the appliance.

B Press , restart the appliance.

FA?

B Power OFF the appliance.

3.

B Refit electrode assembly.

B Turn ON the appliance.

B Press , restart the appliance.

FA?

3.

B Check flue and repair or replace if necessary.

B Press , restart the appliance.

FA?

B Power OFF the appliance.

4.

4.

B Change the gas valve.

B Turn ON the appliance.

B Press , restart the appliance.

FA?

B Power OFF the appliance.

5.

39

7 181 465 346 GB (03.02)

40

Failure identification procedure

FA

and flashing.

Although appliance switches off, flame still detected

5.

Check

Check if the 20-pin connector lead assembly is damaged.

6.

The PCB control board is damaged.

Action

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change the 20-pin connector lead assembly.

B Turn ON the appliance.

B Reconnect the boiler electrical connection.

B Press , restart the appliance.

FA?

B Power OFF the appliance.

↓ 6.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

7 181 465 346 GB (03.02)

Failure identification procedure

Fd

and flashing.

Button pressed without necessity

Check

1.

Button is flashing.

2.

The PCB control board is damaged.

Action

B Press , restart the appliance.

Fd?

2.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

7 181 465 346 GB (03.02)

41

Failure identification procedure

3.4

Faults that are not displayed

3.4.1

Appliance faults

Excessive burner noise, rumbling noises

Check

1.

2.

3.

4.

Does the gas supply type match the specifications on the appliance identification plate?

B Test gas supply pressure - OK?

Does pressure match figure specified in installation instructions?

Problem with flue?

B Check CO

2

level in combustion air.

Is CO

2

level above 0,2 % ?

Cascade system:

Is the appliance min. output high enough to open the shut-off device?

yes: no: yes: no: yes: no: yes: no:

Action

B Note the setting of the temperature controls and .

↓ 2.

B Convert appliance to correct gas type.

↓ 2.

↓ 3.

B Decommission appliance.

For natural gas:

B Notify gas company.

B Check flue and repair or replace if necessary.

3.

5.

B Press buttons and simultaneously.

B Select Service Function 5.5 .

B Increase min. output.

B Repair or replace components.

B Grease seal before fitting.

B Make sure it is fitted in correct position.

6.

5.

6.

Is appliance’s internal air/flue channel leaking or blocked?

B Open up heat exchanger and inspect.

B Remove silencer, flue duct and air flow limit.

B Open trap and inspect.

Air channels dirty/clogged, seals defective or not correctly fitted?

B Measure CO

2

levels.

CO

2

levels in flue gas at min and max output do not match figures specified in installation instructions.

yes: no: yes: no:

B Adjust CO

2

level as per installation instructions.

B Turn off gas cock.

B Power OFF the appliance.

B Change the gas valve.

B Open the gas cock.

B Turn ON the appliance.

B Check appliance for leaks.

42

7 181 465 346 GB (03.02)

Failure identification procedure

Excessive burner noise, rumbling noises

7.

Check

B Press buttons and simultaneously.

B Select service-function 5.9.

0 is displayed.

Flue gas levels incorrect, CO level too high

Action

B Set to 1 for high start-up speed.

1.

Check

Does the gas supply type match the specifications on the appliance identification plate?

yes: no:

2.

B Test gas supply pressure - OK?

yes: no:

3.

4.

5.

Problem with flue?

B Check CO

2

level in combustion air.

Is CO

2

level above 0,2 % ?

Flue gas CO

2

levels measured at min. and max. load do not match specified levels?

B Measure CO

2

levels.

Gas volumetric flow too high when

CO

2

level correctly set.

yes: no: yes: no: yes: no:

6.

Action

2.

B Convert appliance to correct gas type.

2.

3.

B Decommission appliance.

B Notify gas company.

B Check flue and repair or replace if necessary.

4.

B Adjust CO

2

levels.

5.

B Reduce gas volumetric flow rate by means of adjusting screw on gas valve and/or gas flow restrictor.

B Check CO

2

adjustment.

6.

B Turn off gas cock.

B Power OFF the appliance.

B Change the gas valve.

B Open the gas cock.

B Turn ON the appliance.

B Check appliance for leaks.

7 181 465 346 GB (03.02)

43

Failure identification procedure

Ignition too harsh, ignition poor

Check

1.

2.

B Press buttons and simultaneously.

B Select service-function 5.1.

Continuous ignition (without gas)

OK?

Ignition lead connected to ignition electrodes?

yes: no: yes: no:

3.

4.

5.

Ignition cable connector engaged in switchbox?

Is the ignition electrical wire damaged?

Electrode assembly defective?

B Power OFF the appliance.

B Remove electrode assembly.

Electrodes worn out?

yes: no: yes: no: yes: no:

Action

B Note the setting of the temperature controls and .

↓ 6.

↓ 2.

3.

B Connect cable to ignition electrodes.

B Press button .

Ignition poor?

3.

4.

B Power OFF the appliance.

B Engage ignition cable connector in switchbox.

B Turn ON the appliance.

B Press button .

Ignition poor?

B Power OFF the appliance.

4.

B Power OFF the appliance.

B Change the ignition electrical wire.

B Turn ON the appliance.

B Press button .

Ignition poor?

B Power OFF the appliance.

5.

5.

B Replace electrode assembly.

B Turn ON the appliance.

B Press , restart the appliance.

Ignition poor?

6.

B Refit electrode assembly.

B Turn ON the appliance.

B Press , restart the appliance.

Ignition poor?

6.

44

7 181 465 346 GB (03.02)

Failure identification procedure

Ignition too harsh, ignition poor

6.

7.

Check

Does the gas supply type match the specifications on the appliance identification plate?

yes: no:

B Test gas supply pressure - OK?

yes: no:

8.

9.

Problem with flue?

B Check CO

2

level in combustion air.

Is CO

2

level above 0,2 % ?

Flue gas CO

2

levels measured at min. and max. load do not match specified levels.

B Measure CO

2

levels.

10.

Burner not correctly fitted or defective?

B Remove burner.

Cover fixings not tight or seal defective or not correctly fitted or burner defective!

yes: no: yes: no:

Action

7.

B Carry out gas type conversion as described in installation instructions.

8.

B Decommission appliance.

B Notify gas company.

B Check flue and repair or replace if necessary.

9.

9.

B Adjust CO

2

level as per installation instructions.

10.

B Replace burner and seal if necessary.

B Ensure seal is fitted in correct position.

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

7 181 465 346 GB (03.02)

45

Failure identification procedure

Loose or broken contact on heat store NTC sensor

1.

Check

Heat store NTC sensor lead is not fitted as described in the installation instructions (i.e. the cable does not pass through the cable grip in the switchbox).

Action

B Record condition of appliance as found in customer service record.

B Route cable as specified in installation instructions.

Boiler indicates P1, P2, P3 at start-up and then restarts with P1..

1.

2.

Check

Fuse T 1,6 A (312) defective.

The PCB control board is damaged.

yes: no:

Action

B Turn ON the appliance.

B Change the fuse.

B Power OFF the appliance.

Start sequence not completed?

2.

2.

B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary

Service Level; Values that can be modified" at page 11).

B Power OFF the appliance.

B Disconnect the boiler electrical connection.

B Change PCB control board.

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

B Restore service settings previously noted down.

46

7 181 465 346 GB (03.02)

Failure identification procedure

Specified CH flow temperature from TA... programmer exceeded

1.

2.

Check Action

B Note the setting of the temperature controls and .

If outside-temperature controlled programmer (TA...) is connected to boiler:

• The anti-cycle time is adjusted by the programmer to the suit the system.

• The factory setting for the anti-cycle time (3 min.) and the heating mode hysteresis setting, if applicable, are deactivated.

• In cyclic mode, the switching of the boiler on or off is subject to a time delay in order to prevent divergence between the average CH flow temperature and the specified CH flow temperature.

As a result (depending on the heat draw), the specified CH flow temperature is briefly exceeded.

In extreme cases, it can happen that the burner does not switch off until the maximum CH flow temperature is reached even though a lower CH flow temperature has been specified.

B Disable automatic anti-cycle time, i.e. change setting to 0.

B Press button .

B Select service-function 2.7.

Read off status of automatic anticycle time (0 = Disabled, 1 = Enabled).

B Select service-function 2.4.

Read off anti-cycle time setting

(0 ... 15 min).

B Set anti-cycle time as required, e.g. factory setting 3 min.

To return to normal function mode:

B Press buttons and simultaneously.

B Regulate the temperature control and the temperature control on the previously set positions.

Hot water has unpleasant odour or is dark colour

Check Action

This is generally caused by the formation of hydrogen sulphide by sulphate-reducing bacteria. Such bacteria are found in water which is very low in oxygen and live off the hydrogen produced by the anode.

1.

2.

B Clean the hot water cylinder.

B Replace the sacrificial anode.

B Heat cylinder to a temperature ≥

60˚C

B Replace magnesium sacrificial anode with impressed-current anode.

The conversion costs are payable by the operator!

7 181 465 346 GB (03.02)

47

Failure identification procedure

Condensation in the flue pipe

1.

Check

Is diaphragm in mixer unit fitted correctly (see installation instructions)?

B Open mixer unit (29).

B Check diaphragm for correct orientation, soiling and splitting.

3.4.2

Programmer faults

Set room temperature not reached (TR 2 and TR 212 E)

Action

B Fit diaphragm as per installation instructions or replace.

B Close mixer unit.

1.

Check

Thermostatic valve(s) set too low?

2.

3.

CH flow temperature control on boiler set too low?

Air in the heating system.

yes: no: yes: no:

Action

B Turn up thermostatic valve(s).

2.

2.

B Turn up CH flow temperature control.

3.

B Power OFF the appliance.

B Check appliance and system for water leaks and repair as necessary.

B Top up system.

B Select Service Function 7.3 .

Select 1 (on, automatically deactivated) and confirm.

B Vent appliance.

B Vent radiators.

B Turn ON the appliance.

48

7 181 465 346 GB (03.02)

Failure identification procedure

Set room temperature not reached (TA 211 E und DT 2)

1.

2.

3.

4.

5.

Check

Thermostatic valve(s) set too low?

yes:

Heating characteristic set too low?

no: yes:

CH flow temperature control on boiler set too low?

no: yes:

Is heat store temperature unreachable (CH flow temperature control set too low)?

no: yes: no:

Air in the heating system.

Action

B Turn up thermostatic valve(s).

2.

2.

B Correct heating characteristic.

3.

3.

B Turn up CH flow temperature control.

4.

4.

B Turn up CH flow temperature control.

5.

5.

B Power OFF the appliance.

B Check appliance and system for water leaks and repair as necessary.

B Top up system.

B Select Service Function 7.3 .

Select 1 (on, automatically deactivated) and confirm.

B Vent appliance

B Vent radiators.

B Turn ON the appliance.

7 181 465 346 GB (03.02)

49

Failure identification procedure

Set room temperature exceeded by large amount

1.

2.

Check

Do radiators get too hot?

Bad choice of location for programmer, e.g. outside wall, near window, in draught, on hollow wall, etc.

yes: no: yes: no:

3.

Excessive fluctuations in room temperature (TA 211 E)

Action

TR 2:

B Decrease setting of “Heating” control

TA 211 E:

B Correct heating characteristic.

2.

2.

B Select better installation location.

-or-

B Fit external room thermostat.

3.

3.

B Turn down thermostatic valve(s).

1.

2.

Check

Periodic effect of external heat on room, e.g. from sunshine, lighting, TV, separate stove, fire, etc.

yes: no:

Bad choice of location for programmer, e.g. outside wall, near window, in draught, on hollow wall, etc.

Room temperature too high in Economy mode

Action

B Eliminate external heat sources if possible.

2.

2.

B Select better installation location.

-or-

B Fit external room thermostat.

Check

Building retains heat well yes:

Action

B Set economy temperature lower .

or

B Set to Frost Protection instead of Economy.

or

B Set start time for Frost protection/Economy earlier.

50

7 181 465 346 GB (03.02)

Failure identification procedure

Temperature rises instead of falling

Check

Timer clock (DT 2) incorrectly set

Incorrect or no modulation

Check

Programmer incorrectly wired

Action

B Check setting and correct as necessary.

Action

B Check wiring against wiring diagram and correct as necessary.

7 181 465 346 GB (03.02)

51

Appendix

4 Appendix

4.1

NTC values

4.1.1

Outside temperature sensor

Outside temperature

(˚C)

Measurement tolerance

±±±±

10%

4

8

-4

0

-20

-16

-12

-8

10

15

20

25

Table 11

Resistance (

)

781

642

528

436

2 392

2 088

1 811

1 562

1 342

1 149

984

842

4.1.2

CH flow NTC sensor, heat store NTC sensor, constant hot water NTC sensor and hot water NTC sensor

Temperature (˚C)

Measurement tolerance

±±±±

10%

60

65

70

75

80

85

90

95

100

Table 12

40

45

50

55

20

25

30

35

Resistance (

3 243

2 744

2 332

1 990

1 704

1 464

1 262

1 093

950

14 772

11 981

9 786

8 047

6 653

5 523

4 608

3 856

)

52

7 181 465 346 GB (03.02)

Appendix

4.2

Electronic schemes

364

4.1

o - orange g - green bl - black r - red p - purple

33

365 61 317 366 367

ECO

363

25 V

153

230V/AC

135

230 V

328

302

L N Ns Ls LR

151

328.1

mains supply

136

M

18

M

226

18

32

33

36

4.1

6

6.1

6.3

Ignition transformer

Heat exchanger overheat cut-out

Flue gas NTC sensor

Hot water sensor

Central heating pump

Flame sensing electrode

Spark electrodes

Temperature sensor in CH flow

52 Safety gas valve 1

52.1 Safety gas valve 2

56

61

CE 428 gas valve

Reset button

84

96

Motor (ZWB/ZB)

Microswitch, water switch (ZWB)

135 Main power switch

136 Heating outlet temperature potentiometer

151 Fuse T 2,5 A, 230 V AC

153 Transformer

161 Bridge

226 Fan

300 Code key

302 Ground electrical connection

310 Sanitary outlet temperature potentiometer

312 Fuse T 1,6 A, 24 V DC

313 Fuse T 0,5 A, 5 V DC

314 Strip connector for TA 211 E fitted programmer

315 Terminal block for programmer

317 Digital display

318 Internal programmable clock connection

328 230 V AC connection

310

312

313

315

1 2 4 7 8 9

161

300

314

318

9 6 r r

52 52.1

56 bl bl bl bl

328.1 Bridge

363 Flame presence led

364 Electrical power led (0/I)

365 Chimney cleaner button

366 Technique service button

367 ECO button o o

36 bl

32 o

6.1

6 720 610 576-08.2O

o g g p p p

84

M

96

7 181 465 346 GB (03.02)

53

Appendix

4.3

List of most important replacement parts

Component Order no.

Remarks

Switchbox

PCB control board

Transformer

Ignition lead

8 748 300 385

8 747 201 358

8 714 401 999

8 714 402 087 ZB...

20-pin connector lead assembly

20-pin connector lead assembly

Fuse

Fuse

Fuse

Set of fuses

8 714 402 086 ZWB...

1 904 552 730 T 0,5 A

1 904 552 740 T 1,6 A

1 904 521 342 T 2,5 A

8 744 503 010

Switchbox kpl.

Switchbox kpl.

8 717 207 514 with DT 2

8 717 207 513 without DT 2

Code plug included in

Conversion kit

G20 -> G31

7 710 149 048 ZWB

7/11-29 A

Conversion kit

G31 -> G20

Conversion kit

G20 -> G31

Conversion kit

G31 -> G20

Conversion kit

G20 -> G31

Conversion kit

G31 -> G20

Conversion kit

G20 -> G31

Conversion kit

G31 -> G20

Heat exchanger

Temperature limiter

Table 13

7 710 239 084

7 710 149 049

7 710 239 085

7 710 149 044

7 710 239 080

7 710 149 045

7 710 239 081

ZWB

7/11-29 A

ZB

7/11-28 A

ZB

7/11-28 A

ZWB

7/11-27 A

ZWB

7/11-27 A

ZB

7/11-27 A

ZB

7/11-27 A

8 729 000 144 110˚C

Component Order no.

Remarks

Temperature sensor, CH flow

Electrode assembly

8 714 500 087

8 718 107 077

NTC

Gas valve

Gas valve

Other components

8 747 003 516 CE 427

Fan 8 717 204 343

Gas supply pipe 8 710 725 500

8 715 406 651 ZWB...

Plate-type heat exchanger

Overflow trap 8 710 725 328

8 715 505 801 Diaphragm in the mixer unit

Table 13

54

7 181 465 346 GB (03.02)

Appendix

4.4

Approved corrosion inhibitors and anti-freeze fluids for central heating water

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.

4.4.1

Frost protection

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 Tel.: 0121 378 0952.

4.4.2

Sealing agents

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.

4.5

Summary of BDH Information

Sheet on Identifying Corrosion by

CFCs

The presence of halogenated hydrocarbons in the combustion air causes surface corrosion on affected metals. Particularly susceptible is the combustion chamber and the heat exchanger surfaces (including stainless steel) as well as the metal components in the flue socket, flue pipe connections and in the chimney.

The halogen compounds present in the combustion air produce highly corrosive hydrochloric acid in the flame and in some cases - depending on the precise composition of the combustion air - hydrofluoric acid, both of which accumulate in the boiler and remain active over long periods.

In order to limit the damage, the source of the air contamination must be located and sealed off. If this is not possible, the combustion air must be drawn from an alternative clean source.

Halogens can occur in the following locations:

Commercial and industrial sources

Dry cleaners Trichloroethylene, tetrachloroethylene, fluorinated hydrocarbons

Degreasing baths Perchloroethylene, trichloroethylene, methyl chloroform

Printers

Hairdressers

Trichloroethylene

Aerosol spray propellants, hydrocarbons containing fluorine and chlorine (freons)

Sources in the home

Cleaning and degreasing agents

Perchloroethylene, methyl chloroform, trichloroethylene, methylene chloride, carbon tetrachloride, hydrochloric acid

Home workshops

Solvents and thinners

Spray cans

Various chlorinated hydrocarbons

Chlorofluorohydrocarbons

(freons)

Table 14

7 181 465 346 GB (03.02)

55

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