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1. Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating l l Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres Has a primary water system filter been installed CENTRAL HEATING MODE measure and record Gas rate OR ft hr Burner operating pressure if applicable OR Gas inlet pressure mbar Central heating flow temperature Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard wate
2. 0 32 5 8 Finishing commissioning ES 2 Z ANORCESTER Bosch Group 6 SERVICING AND SPARES ceeeeeeeeees 34 6 1 Inspection and spares ccc e eee eee ee 34 6 1 1 Inspection c 40cc0sc2000200s0aeee00sseeeeaaars 34 6 1 2 Checking flue integrity 34 6 1 3 Component Access 0 cc cece cence 35 6 1 4 Fanpressuretest 0 cc cece cee eens 35 6 1 5 To Clean the Heat Exchanger 05 36 6 1 6 ToCleanthe Burner 36 6 1 7 To Check the Diaphragm in Burner Cover 37 6 1 8 Re assembly of the burner cover 37 6 1 9 ToCleanthe Condensate Trap 37 6 2 Settingtheair gasratio cee eee eee 38 6 3 Replacement of parts 39 6 4 SOM DAMS IIS ccc iscviwendvonwvaeneediadeerers 44 FAULT FINDING amp DIAGNOSIS 45 n Fault finding EE 45 1 2 Protection function external pump 45 7 3 Heating function 46 6 720 815 723 2015 05 7 WORCESTER Bosch Group 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1 1 Key to symbols Warnings Warnings in this document are identified by a warning triangle printed against a grey background Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken The following keywords are defined and can be used in this document e NOTE indicates a situation that could result in damage
3. Code Plug o SS CO 6720648547 15 2Wo CAUTION Isolate the mains gas supply before starting Fig 42 Electrical connections any work and observe all relevant safety precautions CAUTION Short circuit gt When connecting the cables ensure that no cable strands fall into the Heatronic 6 720 815 723 2015 05 21 INSTALLATION 4 8 PRE WIRED LINK SAFETY SOLENOID L SAFETY Ae SOLENOID ZE yvyeyeyey 230V EXTERNAL CONTROLS WIRING CENTRE re re zg Live Return CH TEMPERATURE CONTROL TRANSFORMER EXTERNAL PUMP A Neutral Live sr lll Fig A3 Wired components 28 Position of wired components Colour sequence DIAGNOSTIC INTERFACE FLAME SENSE ELECTRODE FLOW NTC FAN FLUE OVERHEAT STAT PUMP SUPPLY Eo Colour sequence F S cc ST2 ala ord sTeLellallell Fuse F1 slow 2 5 A AC 230 V Fuse F3 T 0 5A 250V TE Fuse F2 T 1 6A 250V QG CODE PLUG Z ANORCESTER Bosch Group SPARK ELECTRODES OVERHEAT STAT Yellow Orange f Orange 6 720 812 174 16 10 6 720 815 723 2015 05 Z ANORCESTER Bosch Group 5 COMMISSIONING 5 1 Pre commissioning checks CAUTION Isolate the mains gas supply before starting any work and observe all relevant safety precautions 1 Check that the service and water pipes are connected to the correct position on the manifold A CH flow 22mm B C
4. Fig 39 Plume redirection NOTICE Outlet position AN gt The flue terminal outlet position must follow those stated in the relevant appliance instruction manual When redirecting the flue discharge the outlet terminal must be at least 1500mm from any opening in the direction of the discharge to prevent combustion products from entering the building 29 Z ANORCESTER Bosch Group INSTALLATION IN S A Y N ECS IP U ri a 6720643895 119 1Wo Fig 40 Plume distance to opening Opening in building Flue discharge Plume deflector Minimum 1500mm from an opening in the building Table 19 Key to figure 40 GG NM e 4 6 CONDENSATE CONNECTION Never terminate or discharge into any open source including sink bath shower bidet toilet etc Any external condensate pipe work of excessive runs should be protected with weather resistant insulation to help prevent freezing Ensure that the condensate drain is 22 mm diameter plastic pipe It must fall at least 50 mm per metre towards the outlet An adaptor A in 22 mm pipe is contained in the fitting pack 26 4 7 ELECTRICAL CAUTION Isolate the mains gas supply before starting any work and observe all relevant safety precautions Danger of short circuit When connecting the cables ensure that no cable strands fall into the Heatronic Mains supply to the boiler must be through a fused D dou
5. 6 720 815 723 2015 05 INSTALLATION COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING REGULAR BOILER GREENSTAR CDi CLASSIC REGULAR P FOR OPEN VENTED AND SEALED CENTRAL HEATING SYSTEMS AND INDIRECT DOMESTIC HOT WATER THE APPLIANCE IS FOR USE WITH NATURAL GAS ORT PG Cat II 2H3P TYPE C13 amp C33 NATURAL GAS 30CDi Classic Regular TT GC Number 41 406 33 40CDi Classic Regular HIT GC Number 41 406 35 LIQUID PETROLEUM GAS 30CDi Classic Regular GC Number 41 406 34 40CDi Classic Regular TT GC Number 41 406 36 J enchma aT MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS ANNORCESTER Bosch Group CONTENTS CONTENTS 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 3 1 1 Key tosymbols ccc cece cece eee eens 3 1 2 Safety precautions 3 2 APPLIANCE INFORMATION seeeeeeeceees 5 2 1 General information 5 2 2 Technicaldata 0 cece cc cece ee eee ee 6 2 3 Product data on energy consumption 7 2 4 Layout amp components cece cee ee eee 8 3 PRE ANSTALLATION cases csecSasine erger gend 8 3 1 Cleaning primary systems 00 ccc eee eee 8 3 2 Mains supply 9 3 2 1 Electricalsupply 9 3 2 2 GdSSUDDY a Ee et En d 9 3 3 Water systems amp pipework 9 3 4 Condensate pipework 11 3 4 1 Internalconnections 1
6. 9 100mm minimum plastic pipe 10 Drainage holes 11 Limestone chippings 12 Bottom of sealed tube 13 Insulate and increase pipe size 14 Pipe work transition 15 External air break 16 Air gap 17 External rain water pipe into foul water 18 43mm 90 male female bend i Condensate trap of 75mm already incorporated into the boiler If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point or purpose designed soak away may be considered If this method is chosen then the following measures should be adopted gt UseaCondenseSure siphon to help prevent the condensate freezing gt The external run be kept as short as possible and not exceed three metres gt The pipe should be run internally as far as possible before going externally and the pipe diameter should be increased to 32mm before it passes through the wall to the exterior The pipe should be insulated using suitable waterproof and weather resistant insulation if not using a CondenseSure siphon gt Theexternal pipe should take the shortest and least exposed route to the discharge point and should fall as steeply as possible away from the boiler with no horizontal runs in which condensate might stand gt Theuse of fittings elbows etc should be kept to a minimum and any internal burrs on cut pipe work should be removed so that the internal pipe section is as smo
7. Fig 52 Fitting bottom panel 6 720 815 723 2015 05 33 SERVICING AND SPARES 6 SERVICING AND SPARES CAUTION Isolate the mains gas supply before starting any work and observe all relevant safety precautions check for gas tightness where relevant and carry out functional checks as described in commissioning Any O rings or gaskets that are disturbed during servicing must be replaced i NOTICE After replacement of any components always 6 1 Inspection and spares NOTICE Any service work must be carried out by a competent registered engineer such as British Gas or Gas Safe NOTICE CO CO Analyser gt Service work must NOT be attempted if a calibrated CO CO Analyser is NOT available e To ensure the continued efficient operation of the appliance it must be checked at regular intervals e The frequency of servicing will depend upon the particular installation conditions and usage However an annual service is recommended The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers 6 1 1 Inspection 1 Check that the terminal and the terminal guard if fitted are clear and undamaged 2 Ifthe appliance is in a compartment or cupboard check that the specified service space around the appliance is clear 3 Check all the joints and connections in the system and remake any that show signs of leakage Refill and re pressuri
8. again and the boiler will return to normal operation gt If left in the performance test mode the control will return to normal operation after 15 minutes gt Re seal the screw in the gas inlet pressure test point 5 6 2 Checking the gas rate gt The gas rate should be measured at the gas meter after 10 minutes operation at maximum See technical data section at the front of this manual gt Where a gas meter is not available e g L P G the CO CO must be checked to the units shown in the setting of the air gas ratio refer to section 6 2 gt If pressure and gas rate are satisfactory press the performance test button again and the boiler will return to normal operation f left in the performance test mode the control will return to normal operation after 15 minutes Close the gas isolation valve Remove the manometer Re seal the screw in the gas inlet pressure test point Open the gas isolation valve Ensure that there are no gas leaks Replace the outer case vvvvvyv 31 COMMISSIONING 5 7 CO AND COMBUSTION CHECKS The following combustion and flue integrity checks will be mandatory from April 2014 and these values must be recorded on the Benchmark check list at the back of this manual Once the gas rate and pressure have been confirmed as acceptable then the CO and combustion checks can be undertaken The flow chart is given for guidance the details of the checks are given in the following secti
9. Bottom panels APPLIANCE INFORMATION 2 2 TECHNICAL DATA Product type Heating Max rated heat input Max rated heat output net 40 30 C Max rated heat output net 50 30 C Max rated heat output net 80 60 C 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 Max flow temperature Max permissible operating pressure Gas flow rate Max 10 minutes from lighting Natural Gas G20 Propane Gas LPG Flue Flue Gas Temp 80 60 C rated min load Max Min Flue Gas Temp 40 30 C rated min load Max Min CO2 level at max rated heat output CO2 level at min rated heat output NOx class Condensate Max condensation rate OH value approx Electrical Electrical power supply voltage Frequency Max power consumption General Data SEDBUK Appliance protection rating Permissible ambient temperatures Nominal capacity of appliance Total boiler weight lift weight Packaged boiler weight SAP 2009 annual efficiency SAP 2005 seasonal efficiency SEDBUK Table 3 Technical data kW kW kW kW kW kW kW kW C bar m3 h kg h I h AC V Hz band CANVORCESTER Bosch Group NATURAL GAS 30CDi Classic 40CDi Classic Regular E Regular E 30 9 42 0 32 1 43 7 31 8 43 3 30 0 40 8 8 6 10 6 8 6 10 5 T T 9 4 8 0 9 8 nom 90 nom 90 25 2 5 32 4 4 76 58 87 58 55 33 58 35 9 6 SNI 9 0 9 1 5 5 2 1 Sf 4 8 4 8 230 2
10. Fig 20 Behind the boiler pipe run 6 720 815 723 2015 05 A WORCESTER Bosch Group 3 8 Flue options The Greenstar CDi Classic Regular PT has the option of three horizontal RSF 60 100 telescopic 60 100 longer telescopic and 80 125 telescopic flue systems and two vertical RSF 60 100 or 80 125 regular flue systems The systems have different maximum flue lengths for different boiler outputs and different plume management lengths For every extra 1000mm of plume management after the first 500mm the internal 60 100 flue length must be reduced by 700mm up toa maximum of 4500mm of plume management For example on a 30CDi Classic Regular IT if the plume management effective length was 1500mm the internal flue would be reduced to 5200mm Maximum horizontal flue lengths L Boiler model 100mm 125mm No Plume 500mm 4500mm No plume management of plume of plume management management management available 30CDi 7 900mm 5 900mm 3 100mm 18 500mm 40CDi 6 000mm 4 000mm 1 200mm 12 500mm Table 7 Maximum horizontal flue lengths Maximum vertical flue lengths Boiler model 100mmd 125mm 30CDi 9 400mm 18 500mm AOCDi 7 500mm 16 000mm Table 8 Maximum vertical flue lengths This page and the page opposite shows various flue options with the Straight flue lengths required to achieve the maximum flue length NOTICE 60 100 Flue systems gt Each 90 bend used is equivalent to 1 5 metres of straight flue gt Ea
11. suitable location onto a fixed rigid non combustible surface at least the same size as the boiler and capable of supporting the boiler weight NOTICE No surface protection is required against heat transfer from the boiler COMPARTMENTS Follow the requirements of BS6798 and BS5440 Part 2 and note e Minimum clearances must be maintained e An access door is required to install service and maintain the boiler and any ancillary equipment e Ifan airing cupboard is adapted to house a boiler then the airing spaces must be separated from the boiler compartment by a noncombustible partition The partition may be perforated if required by holes not exceeding 13 mm in diameter e f the appliance is fitted into a cupboard or a compartment is built around the appliance after installation then the compartment must be built or lined by a non combustible material BOILER CLEARANCES The diagram opposite shows the minimum space required to install and service the boiler VENTILATION This is aroom sealed appliance and does not require any air for combustion from inside the property The requirements of BS 6798 and BS 5440 regarding ventilation do not apply with the Greenstar CDi Regular DT boiler There is no need for ventilation openings to be provided in the compartment because of the low heat loss from the appliance casing if the clearances shown are maintained 13 PRE INSTALLATION Do not operate the appliance if the flue
12. 2 Loosen but do not remove the two screws A securing boiler casing at the bottom of the appliance 3 Pull upwards to release the clip B on top of the boiler 4 Pull case forward and remove 19 N Ss SC Kei isp N lt lt 0 CH CN N LO Fig 69 Removing outer case Adjusting boiler control to service position 1 Pull down the catch securing the control panel 2 Gently pull forward until it comes to rest in service position 6 720 815 723 2015 05 SERVICING AND SPARES 6 720 812 174 18 10 Fig 70 Service position Primary sensor gt Press retaining clip on plastic moulding and pull upwards until clear of pocket in heat exchanger gt Separate sensor from connector coat new sensor with heat conductive paste and replace Overheat thermostat gt Remove two electrical connectors from thermostat gt Unscrew the sensor Flue limit thermostat gt Remove electrical connections gt Unscrew thermostat from flue 39 Z NORCESTER SERVICING AND SPARES Bosch Group 7 GAS VALVE Isolate gas supply at boiler gas cock Pull out air inlet tube A Undo top gas connection B to gas valve Undo bottom gas connection C to gas valve Undo two securing screws D on the underside of casing Pull valve up and forward out of boiler Disconnect electrical connections Replace valve with new seals and check for gas soundness The valve will require setting foll
13. 5 Check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system water in accordance with the manufacturers instructions Fill via a WRAS approved filling loop to between 1 and 2 bar Vent all radiators retighten vents when complete Vent the primary side of the hot water tank For sealed systems re pressurise if necessary Set all controls to maximum Record the date when the inhibitor was added to the system on the guarantee card gt The concentration level of inhibitor in the system D should be checked every 12 months or sooner if system content is lost gt The addition of sealing agents to the system water is not recommended as this can cause problems with deposits left in the heat exchanger YYY ONO compatible with aluminium The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated Water treatment products Suitable water treatment products can be obtain from the following manufacturers FERNOX SENTINEL 0870 601 5000 www fernox com 0800 389 4670 www sentinel solutions net 5 6 Commissioning CHECKING GAS INLET PRESSURE The inlet pressure to the appliance must be checked using the following procedure SETTING THE BOILER TO MAXIMUM 1 Press performance test button 7 for ten seconds and set temperature control 6 t
14. CNCHIIGM Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 0330 123 9559 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 815 723 2015 05 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0330 1239779 LITERATURE 0330 1239119 TRAINING 0330 123 0166 SALES 0330 123 9669 ANWORCESTER Bosch Group
15. Work Regulations 1989 and any other local requirements EU Regulations No 811 2013 Energy Labelling British Standards Where no specific instruction is given reference should be made to the relevant British Standard codes of Practice BS7074 1 Code of practice for domestic and hot water supply BS68911 Installation of low pressure gas pipe work up to 28mm R1 BS5546 Installation of gas hot water supplies for domestic purposes EN12828 Central heating for domestic premises BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Flues BS5440 2 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Air Supply WORCESTER Bosch Group BS7593 Treatment of water in domestic hot water central heating systems BS6798 Installation of gas fired boilers of rated input up to 70kW net Irish Standards The relevant Irish standards should be followed including e ECTI National rules for electrical installations e S 813 2002 for Domestic Gas Installations LPG Installations An appliance using L P G must not be installed in a room or internal space below ground level unless one side of the building is open to the ground Timber framed building Where the boiler is to be fitted to a timber framed building the guidelines laid down inBS5440 Part 1 and IGE Gas Installations in Timber Frame Buildings should be adhered to Potable water
16. gt Assemble the washer spring spacer and castellated nut D refer to figure 64 onto the screws securing the burner cover to the heat exchanger gt Usinga 10mm spanner tighten the castellated nuts D securing the burner cover G to the heat exchanger until the spacers bottom out on the heat exchanger body The nut will stop turning at this point do not overtighten gt fnecessary back the nuts off slightly until the hole for the clip C is visible gt Insert the clips C and secure gt After re assembly check the air gas ratio and adjust if necessary Refer to section 6 2 Setting the air gas ratio 6 1 9 To Clean the Condensate Trap 1 Pull condensate hose out of the trap 2 Remove the trap from boiler gt Clean the trap and check that the connection to the heat exchanger is clear Fill the condensate trap with approximately 250 millilitres of water and refit in reverse order ASUS d lt gt A ASS lt lt 4 ZH lil ers dd Ax N SH Ny 6 720 812 174 24 10 Fig 67 Siphon removal 37 Z ANORCESTER SERVICING AND SPARES 6 2 Setting the air gas ratio NOTICE Air Gas ratio AN gt The setting of the gas ratio must be carried out by a competent person Setting the air gas ratio must not be attempted unless the person carrying out the operation is equipped with a combustion analyser conforming to BS 7927 and is co
17. in this mode for 15 minutes unless the performance test button is pressed again gt Pull the cover off and connect a manometer to the fan pressure test point gt After measurement replace test point cover 35 AANORCESTER SERVICING AND SPARES Bosch Group 2 Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade TI O fetes KS K EIS H Ni U N UI gt d em 6720648547 21 1Wo Fe A Fan pressure test point e Pressure readings in the black area will indicate that the heat exchanger requires attention cleaning e There is a special accessory kit available specifically designed for cleaning the heat exchanger Part number 7 719 001 996 FAN PRESSURE TEST Cee HeatEx ok gt NG Boilers Fig 61 40 CDi ER 3 Clean the heat exchanger from top to bottom using the brush 30CD eT i mbar i LPG Boilers 40CD C gt oC C gt A d V Vu S M 6720648547 26 1Wo l j mbar u Lg A0 Fan pressure readings 6 1 5 To Clean the Heat Exchanger gt Remove outer case and base panel and isolate the appliance from power Gs EE lt EE Ge E H N K 1 Remove the cleaning access cover B seal C and metal plate D securing it if present Fig 62 gt Refit the clean out cover plates in reverse order using a new seal C and tighten screws 6 1 6 To Clean the Burner 1 Remove cover panel A by removing th
18. overhang External flue joints must be sealed with suitable silicon to 25mm as long as the flue terminal is extended to clear any sealant overhang External flue joints must be sealed with suitable silicon 17 Flue clearance must be at least 300mm from the ground Terminal sealant guards must be fitted if the flue is less than 2 metres from the ground 3 1 500mm between a vertical flue terminal and a window or dormer or ifa EH could come into GE with the flue terminal window 18 600mm distance to a surface facing a terminal unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when 4 1 200mm between terminals facing each other y ener siting terminals in relation to surfaces facing a terminal 5 Vertical flue clearance 300mm adjacent to a boundary line 6 600mm distance to a boundary line unless it will cause a nuisance S Note BS 5440 Part 1 recommends that care is taken when siting terminal oe tallations i t t ded e Doun ars nstallations in car ports are not recommended 7 600mm minimum clearance from a skylight to a vertical flue a ne e HEEN ee Bea netop i E of a light well due to the build up of combustion 8 Vertical flue clearance 500mm to non combustible building an l products material and 1 500mm clearance to combustible building material P 9 300mm ab E O ab inged l t gt Dimensions from a flue terminal to a fanned air inlet i ee e to be determined by the ventilation equipment EE manuf
19. terminal fitted on the outside wall or roof is obstructed or damaged 170 210mm 1130 11 70mm i Minimum clearance to removable door RW Minimum clearance required for servicing ES Height for either 60 100 or 80 125 flue Table 6 Minimum clearances BATHROOMS Additional RCD Residual Current Device protection may be required Refer to the latest IET wiring regulations NOTICE Any switch or appliance control using 230 V mains electricity must not be able to be touched by a person using the bath or shower Electrical switches fused spur and socket outlets must not be situated in the bathroom BATHROOM INSTALLATIONS CH LO N N 2250mm i Radius 600mm 6720646608 124 3Wo Fig 19 Bathroom installations 14 ANORCESTER Bosch Group 3 7 PLUMBING MANIFOLD CONNECTIONS Heating System 22mm compression fittings Gas 22mm compression fittings Use the fittings supplied in the Hardware pack PREPLUMBING With the plumbing manifold installed pipe work can be installed to the valves on the manifold RUNNING PIPES BEHIND THE BOILER If the boiler pipes are to be run behind the appliance ensure that the pipes pass close to the wall as shown in the diagram opposite and within the pipe guide EI Fow 22r Am Return 22mm CoD H Mains Gas Supply 22mm 6720806548 03 1Wo
20. that the implement is used in such a way so that it may not cause personal injury All sharp objects must be covered or the blade retracted after use and put away ina Safe place 1 The upper carton cover 14 and support 13 are now removed with the components bottom panel 12 pre plumbing manifold with water and gas connections 11 hardware packs x2 4 and 5 documentation set 6 hanging bracket 3 2 Remove the flow 7 and return pipes 8 and 9 3 The boiler wall mounting plate 2 can now be pulled out Additional requirements for roof space installation e The boiler should be first unpacked before ascending ladder to loft space e Two sets of steps should be used e Two people should share the lifting of the boiler up to the loft hatch where the boiler is entered into the loft space tilted and slid on its back into the loft Once the appliance is removed from its packaging check the contents against the packing list NOTICE Before installing appliance ensure system has been cleaned as explained on page 8 6 720 815 723 2015 05 INSTALLATION Fig 24 Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 Carton Wall mounting plate Hardware pack 1 Hardware pack 2 Literature pack Flow pipe Return pipe 1 Return pipe 2 Pre plumbing manifold with water and gas connections Bottom panel Upper carton support polystyrene Carton cover ErP energy
21. 0 815 723 2015 05 INSTALLATION 21 AORCESTER Bosch Group INSTALLATION Do not use the frame as a handle Fig 28 4 4 Fitting the appliance boiler connections CAUTION Isolate the mains gas supply before starting AN any work and observe all relevant safety precautions GAS AND WATER CONNECTIONS e If there is greater than 600mm clearance below the appliance it is 6 720 815 725 11 10 Ee omy Ke possible to fit the flow and return pipes supplied with the boiler installed on the wall If clearance is less than 600 mm below the appliance it may be necessary to fit the flow and return pipes before 6 720 812 174 05 10 Fig 29 Fit washers hanging the appliance gt System pipes may be run vertically up behind the boiler or below it See Plumbing Manifold Section on page 14 If pipes require reducing in length this is best done D before they are fitted to the boiler A Flow 22mm C Return 22mm B Gas inlet 22mm 1 Fit the sealing washers before hanging boiler gt Remove the plastic strip from connections on boiler The accessibility to the pre plumbing manifold can be D improved by removing the condensate trap 22 2 Hang the boiler on to the hanging bracket The lugs pass through the rectangular holes in the boiler back panel Take care not to disturb the washers on the connections gt Lifting should be performed by 2 peo
22. 1 3 4 2 External connections ce eee eee 12 3 5 Boiler internal dran 13 3 6 Boilerlocation amp clearances 0000 13 3 7 Plumbing manifold 14 3 8 Flue options 15 3 9 Flueterminal positions 17 3 10 Plume management terminal positions 18 A INSTALLATION eeben 19 4 1 Unpacking wall frame and ancillary items 19 4 2 Wall mounting plate and flue opening 20 4 3 Unpacking the appliance 0000 21 4 4 Fitting the appliance boiler connections 22 4 5 Flue installation 0 ccc cece eee eee 24 4 5 1 60 100mm Telescopic flue kit 0 24 4 5 2 60mm Plume management kit 24 4 5 3 Adjusting the standard terminal length 24 4 5 4 Installing the standard flue 25 4 5 5 Flue terminal plume re direction 25 4 6 Condensate connection 0000 eee 26 4 7 Ee cocuutodusie now Ee 26 4 8 Position of wired components 05 28 5 COMMISSIONING ege ee ebe 29 5 1 Pre commissioning checks 000000 29 5 2 Condensate connection 0000 00 29 5 3 Fllmg Uesvstem cece eee 29 5 4 Starting the appliance 00 ee 30 5 9 Water treatment 30 5 6 Commissioning 30 5 6 1 Checking the gas inlet pressure 4 31 5 6 2 Checking the gasrate 0c eee 31 5 7 COandCombustionchecks
23. 30 50 50 approx OU approx 100 A A X4D X4D 0 50 0 50 35 3 5 39 5 39 5 48 48 89 2 89 2 90 2 90 1 L P G 30CDi Classic 40CDi Classic Regular FFP Regular E 30 9 42 0 32 1 43 7 31 8 43 3 30 0 40 8 12 4 15 7 12 3 15 5 11 0 13 9 11 5 14 5 nom 90 nom 90 2 5 2 5 2 4 3 3 76 58 87 58 55 33 58 35 11 5 11 5 10 5 10 5 5 5 2 3 7 4 8 4 8 230 230 50 50 approx OU approx 100 A A X4D X4D 0 50 0 50 3 5 3 5 39 5 39 5 48 48 90 2 90 2 92 1 92 0 6 720 815 723 2015 05 WORCESTER kao APPLIANCE INFORMATION 2 3 Product data on energy consumption The following product data satisfy the requirements of the EU Regulations No 811 2013 No 812 2013 No 813 2013 and No 814 2013 supplementing Directive 2010 30 EU Product data Symbol Unit 7738 100 245 7 738 100 235 7 738 100 232 7 738 100 234 Product type 30CDi Classic 30CDi Classic 40CDi Classic 40CDi Classic Regular P Regular LPG Beeular DI Regular PT LPG Condensing boiler Yes Yes EE RER a a o a y a Usehilefcienry OOOO Useful efficiency t30 eof rated heat outputand low temperature regime n 975 os 969 969 n standby mode tandby heat loss 0 048 0 048 0 048 0 048 missions of nitrogen oxides We Te ound power level indoors mem s s o o 1 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet Table A Product data for energy consumption 2 Low temperature m
24. 3895 30 1Wo Fig 35 Standard telescopic flue Reducing the standard terminal length 2 Remove securing screws 3 to detach the terminal assembly from the turret Slide terminal section 2 from the terminal assembly and discard To use terminal 1 without cutting remove the location lug 4 on the inner flue tube 5 and remove any burrs To reduce the terminal length further 3 Mark the length required for the terminal 6 as shown min 130mm and cut square taking care not to damage the tubes Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and prevent seal damage The aluminium tape is not required when reducing the terminal 6720643895 31 1Wo Fig 36 Reducing the standard terminal 6 720 815 723 2015 05 Z ANORCESTER Bosch Group 4 5 4 Installing the standard flue 1 Set the flue length to the distance required secure with screw and Seal joint with the aluminium tape supplied Slide the inner wall seal 1 onto the terminal 2 as shown If fitting from inside the building slide the outer wall seal 3 onto the terminal 2 as shown 6720644842 08 1Wo Fig 37 Telescopic flue 2 Remove the three screws 4 8 around the flue outlet 6 on the boiler See screw pack in boiler Check the boiler flue seal is correctly seated Apply silicone grease to the boiler flue seal 3 Position terminal 2 through the flue opening in the wall to the outside of the buil
25. All seals joints and compounds including flux and solder and components used as part of the secondary domestic water system must be approved by WRAS CH Water Artificially softened water must not be used to fill the central heating system 6 720 815 723 2015 05 Z ANORCESTER Bosch Group 2 APPLIANCE INFORMATION 2 1 General information Boiler features and checklist e Pre plumbed e Galvanised steel inner frame e Digital control system e Automatic ignition e Direct burner ignition electrodes e Built in frost protection e Built in fault finding diagnostics Automatic gas valve e Modulating combustion air fan with speed regulator e CH temperature sensor amp control e Pump anti seizure protection e Flue gas temperature sensor e Condensate siphonic trap Standard package Fig 1 Overall dimensions 6 720 815 723 2015 05 APPLIANCE INFORMATION fe e ee SCHER R WS 6 720 812 174 01 10 Fig 2 Standard package Key to Fig 1 and 2 1 2 3 4 5 6 7 8 9 10 11 Wall hung gas fired condensing regular boiler for central heating and domestic hot water Wall mounting plate with hanging bracket Hardware pack 1 Hardware pack 2 Literature pack Installation instructions User instructions Wall mounting template Flow pipe Return pipe 1 Return pipe 2 Pre plumbing manifold with water and gas connections ErP energy label
26. CHECKLIST or a certificate confirming compliance with IS 813 Eire only and the user manual with the owner or at the gas meter after installation or servicing Distance learning and training courses are available from Worcester The BENCHMARK CHECKLIST can be found in the back of this Installation manual Diameter Natural Gas Liquid Petroleum Gas Central Heating Domestic Hot Water Domestic Cold Water Pressure Relief Valve Negative Temperature Coefficient sensor Ingress Protection Residual Current Device R Thermostatic Radiator Valve CV Emergency Control Valve WRAS Water Regulations Advisory Scheme SEDBUK Seasonal Efficiency of Domestic Boilers in the U K Table 2 Abbreviations use in this manual 1 2 SAFETY PRECAUTIONS If you smell gas A gas leak could potentially cause an explosion If you smell gas observe the following rules gt Prevent flames or sparks Do not smoke use a lighter or strike matches Do not operate any electrical switches or unplug any equipment Do not use the telephone or ring doorbells Turn off the gas at the meter Open windows and doors Warn your neighbours and leave the building Prevent anyone from entering the building Well away from the building call the National Gas Emergency Service on 0800 111 999 BOILER OPERATION This boiler must only be operated by a responsible adult who has been instructed in understands and is aware of the boiler s operating conditions and
27. GC No H56 469 Electrodes 8 718 664 3010 GC No H22 458 Flue overheat thermostat 8 710 506 267 0 Bearing plate fan intake diaphragm 8 715 505 883 0 Flue sample plug air intake 8 16 111 2530 6 720 815 723 2015 05 WORCESTER Bosch Group FAULT FINDING amp DIAGNOSIS 7 FAULT FINDING amp DIAGNOSIS 7 1 Fault finding This fault finding information is for guidance only D Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to be competent a EARTH CONTINUITY ee ee b SHORT CIRCUIT CHECK The electronic control system for this boiler incorporates a blue central c POLARITY indicator This normally confirms the permanent mains supply but by d RESISTANCE TO EARTH flashing during a fault provides a guide to the cause as listed This fault finding system assumes that the appliance has been operating normally until the time of failure i e not a first installation error Display code Description Remedy b1 Code plug not detected Insert code plug correctly test and replace if necessary C6 Fan speed too low Check fan lead and connector and fan replace as necessary E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting lead E9 Safety temperature limiter in CH flow has tripped Check system pressure check safety temp limiters check pump operation check fuse on pcb bleed appliance EA Flame not detected Is gas cock turned on Check gas sup
28. H return 22mm C Gas inlet 22mm 2 Check the gas type specified on the identification plate F matches that of the gas supply Turn on the main gas supply check the gas pipe work connections and rectify any leaks 3 Check that the condensate pipe has been connected to the adapter NOTICE If the boiler is not to be commissioned immediately then after successfully completing all of the checks and any rectification work close the gas and water valves shut off the gas supply and electrically isolate the boiler 5 2 Condensate connection Never terminate or discharge into any open source including sink bath shower bidet toilet etc Any external condensate pipe work of excessive runs should be protected with weather resistant insulation to help prevent freezing gt Ensure that the condensate drain is 22mm diameter plastic pipe It must fall at least 52mm per metre towards the outlet D A 22mm adaptor pipe is contained in the fitting pack Refer to figure 44 condensate connection 1 Align the installation side plastic pipework through the pre plumbing manifold 2 Connect the installation side plastic pipework to the end of the condensate hose 3 Push the plastic pipework inside the condensate hose at least 25mm Ass T Wi EE lt lt 6 720 812 174 17 10 Fig 44 Condensate connection 6 720 815 723 2015 05 COM
29. MISSIONING 5 3 Filling the system 1 Ensure all system and boiler drain points are closed 2 For sealed systems fill the system using a WRAS approved filling loop to a pressure of 1 bar 3 Vent all radiators and primary side of the hot water cylinder 4 Refill the system up to 1 bar GAS SUPPLY gt Open gas cock on the boiler and purge the gas supply to the boiler ensuring that the room is well ventilated gt Test gas supply for soundness as described in BS 6891 29 COMMISSIONING 5 4 STARTING THE APPLIANCE NOTICE Never run the appliance when the appliance system is empty or partially filled SWITCHING THE APPLIANCE ON OFF 1 Turn on mains power supply gt Turn on any external controls gt Set the thermostatic radiator controls to maximum temperature gt Set the clock programmer to continuously ON and the room thermostat to maximum temperature 6720806548 14 1Wo Fig 45 Control panel 1 Display 2 Reset button 3 Not used 4 Not used 5 ON OFF and fault indicator Blue 6 Central heating temperature control 7 Performance test button 8 Service button 9 Burner indicator Green 10 ON OFF button gt Press button 10 and the power on indicator 5 illuminates BLUE After a few seconds the display will show the flow temperature 2 Turn the CH temperature control 6 to maximum The burner on indicator 9 illum
30. TING amp MODIFICATIONS Fitting the appliance and any controls to the appliance may only be carried out by acompetent engineer in accordance with the current Gas Safety Installation and Use Regulations Flue systems must not be modified in any way other than as described in the fitting instructions Any misuse or unauthorised modifications to the appliance flue or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any such actions excluding statutory rights SERVICING Advise the user to have the system serviced annually by a competent qualified Gas Safe registered engineer Approved spares must be used to help maintain the economy safety and reliability of the appliance IMPORTANT The service engineer must complete the Service Record on the Benchmark Checklist after each service INSTALLATION REGULATIONS Current Gas Safety Installation amp Use Regulations All gas appliances must be installed by a competent person in accordance with the above regulations Failure to install appliances correctly could lead to prosecution The appliance must be installed in accordance with and comply to the current Gas Safety Regulations IET Regulations Building Regulations England Building Standards Scotland Consolidation Building Regulations Wales Building Regulations Northern Ireland local water by laws Health amp Safety Document 635 The Electricity at
31. a description of the wiring box see proprietary D instructions gt Refer to manufacturers instructions when connecting external parts to the wiring centre Worcester Bosch Group cannot be held responsible for wiring errors 6 720 815 723 2015 05 Z ANORCESTER Bosch Group INSTALLATION The mains supply to the boiler must be fed through a fused double pole isolator situated adjacent to the appliance The isolator must have a contact separation of 3 mm minimum in all poles 8 External Pump ST2 gt Connect NEUTRAL wire to terminal Nz gt Connect LIVE wire to terminal Lz gt Connect EARTH wire to earth bracket E The system pump must be connected to the appliance control for the pump over run facility 9 Refit control panel cover gt Refit panel and secure with screws B gt Bring the control panel to its upper position and secure by sliding the EARTH NEUTRAL o white plastic clip up LIVE SWITCHED LIVE CONTROLS WIRING CENTRE Lr LsNs N ST10 SSG SaS ww STOSS ee Lr LsNs N By a em em em et e del em em em ef Q i d ST10 OH o 6720648547 43 2Wo
32. acturer 10 600mm diagonally to an opening door air vent or opening window l 11 300mn to an internal or external corner 12 2 000mm below a Velux window 600mm above or to either side of the Velux window 13 400mm from a pitched roof or 500mm in regions with heavy snow fall 14 500mm clearance to any vertical structure on a roof 600mm to room sealed flue or 1 500 to an open flue 15 200mm below eaves and 75mm below gutters pipe and drains 6 720 815 723 2015 05 17 ANORCESTER Bosch Group PRE INSTALLATION 3 10 Plume management terminal positions All measurements in millimetres Flue terminal guard 7 716 191 176 Plume re direction gt Flue Exhaust Outlet Air Intake oZ K NOTICE All measurements are the minimum clearances required The minimum length plume management length is 500mm to a maximum of 4500mm this includes two 90 bends Refer to section 3 8 and table 7 for further information on internal flue lengths Subsequent 45 bends 750mm and 90 1500mm For each metre 1000mm of plume management length the internal flue length is reduced by 700mm Refer to previous page for all concentric flue terminal positions unless the flue position is specified on the figure above Plume terminal positions Terminals must be positioned so to avoid combustion products entering the building Support the flue at approximately one metre intervals and at a change of direction use suitable bracket
33. ainst the wall in the desired position Secure wall mounting plate with four screws supplied with the boiler Do not fully fasten the lower two screws vvv iv A gt Mount the pre plumbing manifold on the two lower screws and secure the screws holes B AU Hanging e bracket holes A 6 720 812 174 21 10 Fig 26 Wall mounting plate and pre plumbing manifold 6 720 815 723 2015 05 Z ANORCESTER Bosch Group 4 3 UNPACKING THE APPLIANCE 1 o gt With the wall frame and ancillary items removed lay the carton A on its back Open the carton bottom flaps and fold under boiler Do not remove the packaging base Stand carton A with boiler upright on the packaging base B Remove outer carton A and place safely away from the working area Remove the protective wrapping C Lie the boiler on its back Remove the packaging base B and place safely away from the working area REMOVING OUTER CASE 8 9 Loosen but do not remove the two screws E securing boiler casing at the bottom of the appliance Release the clip F on top of the boiler and pull the case upwards 10 Remove the outer case 11 Remove the protective packaging G from the electrode assembly A B C D E F G Outer carton Packaging base Protective wrapping Appliance outer case Screws Clip Protective packaging electrodes 6720647361 10 1Wo 6 72
34. be used Ensure that the condensate drain pipe is connected down stream of the waste trap 6 720 815 723 2015 05 PRE INSTALLATION 6720644744 07 3Wo Fig 12 Disposal to a waste pipe CONDENSATE PUMP Where gravity discharge to an internal termination is not physically possible or where very long internal runs would be required to reach a suitable discharge point condensate should be removed using a proprietary condensate pump of a specification recommended by the boiler or condensate pump manufacturer The pump outlet pipe should discharge to a suitable internal foul water discharge point such as an internal soil and vent stack internal kitchen or bathroom waste pipe washing machine waste pipe etc A suitable permanent connection to the foul waste pipe should be used 6720644744 08 3Wo Fig 13 Condensate pump disposal 11 PRE INSTALLATION 3 4 2 External connections NOTICE Freezing conditions gt When the position of the boiler prevents internal routing we recommend installing a CondenseSure siphon to significantly reduce the risk of freezing Pipe work length should be kept to a minimum and the route as vertical as possible Weather proof insulation must be used if not using a CondenseSure siphon NOTICE Condensate waste gt Care should be taken when siting a soak away to avoid obstructing existing services Continued Key to condensate illustrations 8 PVCu strap on fitting
35. ble pole isolator situated adjacent to the appliance The isolator must have a contact separation of 3 mm minimum in all poles Access to electrical connections gt Remove boiler casing to access control panel 1 Press inthe centre of the white plastic clip securing the control panel Slide down to release and lower into the service position 2 Unscrew the three screws B on the back of the control panel and pull off the connections cover 3 Unclip cable clamp C 4 Cut off the tapered cable entry to fit cable diameter required 5 Turn cable retaining screw D anti clockwise Run cable over the main crossbar and through the cable clamp C ensuring there is ample cable to reach the connectors Turn the cable clamping screw D clockwise to secure the cable and replace the clamp C into control panel 6 Mains power 230 V connection ST10 pre mounted gt Separate the wires from the cable end and strip the wires back by 6mm gt Connect the LIVE wire to the terminal L Connect the NEUTRAL wire to the terminal N gt Connect the EARTH wire to the earth connector _L A Ensure that the Earth cable is longer than the others so that it pulls out last if the mains cable is snagged N External controls wiring box ST10 Remove the link Connect the wiring box LIVE supply to terminal LS Connect the wiring box LIVE return to terminal LR Connect the wiring box NEUTRAL to terminal NS vv vV Yy gt For
36. ch 45 bend used is equivalent to 0 75 metres of straight flue NOTICE 80 125 flue systems gt Each 90 bend used is equivalent to 2 metres of straight flue gt Each 45 bend used is equivalent to 1 metre of straight flue Telescopic horizontal flue Flue option 1 100mmd 125mm 30CDi 570mm 600mm 40CDi 570mm 600mm Table 9 Flue option 1 Horizontal extended flue Flue option 2 100mmd 125mm 30CDi 7 900mm 18 500mm 40CDi 6 000mm 12 500mm Table 10 Flue option 2 6 720 815 723 2015 05 PRE INSTALLATION Horizontal extended flue with 1x90 bends Flue option 3 100mm 125mmd 30CDi 6 400mm 16 500mm AOCDi 4 500mm 10 500mm Table 11 Flue option 3 Horizontal extended flue with 2x90 bends Flue option 4 100mmd 125mm 30CDi 4 900mm 14 500mm AOCDi 3 000mm 8 500mm Table 12 Flue option 4 High level horizontal extended flue Flue option 5 100mm 125mm 30CDi 7 900mm 18 500mm 40CDi 6 000mm 12 500mm Table 13 Flue option 5 High level horiz extended flue with 2x90 bends Flue option 6 100mm 125mmd 30CDi 6 400mm 16 500mm 40CDi 4 500mm 10 500mm Table 14 Flue option 6 High level horiz extended flue with 3x90 bends Flue option 7 100mmd 125mm 30CDi 4 900mm 14 500mm 40CDi 3 000mm 8 500mm Table 15 Flue option 7 Vertical balanced extended flue Flue option 8 100mmd 125mmd 30CDi 9 400mm 18 500mm AOCDi 7 500mm 16 000mm Table 16 Flue option 8 Vertical balanced extended flue with 2x90 bends Flue option 9 100
37. ding by the distance shown The flue terminal MUST be fitted with the TOP uppermost to allow the correct fit and use of the plume management system 4 Align the flue turret 5 to the boiler flue outlet 6 with flat 7 facing to the rear of the boiler Push the flue turret 5 straight down into the boiler flue outlet 6 For ease of assembly locate screw 8 first and then fit screws 4 to secure flue turret 5 If fitting from the outside of the building slide the outer wall seal 3 onto the terminal 2 as shown AN m d 6720647361 17 1Wo Fig 38 Fitting the flue 6 720 815 723 2015 05 INSTALLATION 4 5 5 Flue terminal plume re direction The flue discharge can be re directed allowing some plume redirection control alternatively acomplete plume management system can be fitted to the flue terminal RE DIRECTING THE FLUE DISCHARGE 1 Using a suitable tool release the clips 1 amp 2 the terminal end and rotate through 180 NOTICE DO NOT rotate the complete terminal assembly 1 Refit to the terminal ensuring that the clips 1 amp 2 are engaged and secure 2 Loosen screws 3 and rotate the entire outlet assembly to redirect the plume Tighten screws 3 to secure in the required position The flue terminal outlet has built in stops to limit rotation D for horizontal flues to allow condensate to run back into the boiler for safe disposal Do not attempt to force beyond the limit stops
38. e at the meter for natural gas and a maximum of 4mbar less than the pressure at the regulator for LPG 4 Set the central heating control to minimum This will make the boiler go to minimum power 5 Measure the CO3 it should now be at the figure for minimum output gt If not use a 4mm Allen key to adjust the min adjustment on the gas valve until correct gt Return to maximum and re check the CO3 If correct press and hold down the performance test button for two seconds the button will cease to be illuminated and the blue power indicator will be permanently illuminated Remove manometer and re seal inlet pressure point on gas valve Fit new plastic sealing cover onto the max adjuster Replace the brass screw over the min adjuster on the valve Re assemble and refit boiler case A vv vV Yy Bosch Group Inlet pressure test point Fig 68 Setting the Air Gas ratio 6720647361 48 1Wo 6 720 815 723 2015 05 Z ANORCESTER Bosch Group 6 3 Replacement of parts CAUTION Isolate the mains gas supply before starting AN any work and observe all relevant safety precautions functional checks as described in commissioning Any O rings or gaskets that are disturbed during servicing must be replaced NOTICE After replacement of any components always AN check for gas tightness where relevant and carry out Removing outer case 1 Remove bottom panel by pulling it forward and off
39. e boiler is fired up 9 Cover for external wiring connection 10 Control panel in service position 8 6 720 815 723 2015 05 ANORCESTER Bosch Group gt Run the boiler system at normal operating temperature as directed by the manufacturer of the flushing agent gt Drain and thoroughly flush the system to remove the flushing agent and debris gt It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances gt Close the drain cocks and refill with fresh water and a suitable inhibitor gt Vent any air from the boiler and system INHIBITOR Add a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the DWTA code of practice and manufacturer s guidelines WARNING Sealing agents gt The addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger Water treatment Suitable water treatment products can be obtain from the following manufacturers FERNOX 0870 601 5000 www fernox com SENTINEL 0800 389 4670 www sentinel solutions net 3 2 MAINS SUPPLY 3 2 1 Electrical supply e Supply 230V 50 Hz 140 Watts e Cable PVC insulated 0 75 mm2 24x 0 2 mm temperature rated to 90 C e External 3A fuse to BS1362 e The appliance must be earthed e This appliance must not be connected to a three phase su
40. e screws B gt Check that the boiler is completely isolated from the gas supply 6 720 812 175 30 10 Fig 60 Cleaning the heat exchanger 36 6 720 815 723 2015 05 Z ANORCESTER Bosch Group Q QQE 6 720 812 175 15 10 Fig 63 2 Remove the clips C and unscrew the two bolts D gt Unscrew and remove the two hexagon screws E securing the fan gt Slacken fully the rear securing bolt F gt Remove the burner cover plate G 6 720 812 175 16 10 Fig 64 Burner cover securing detail 3 Remove the burner H and clean components Do not use a wire brush 6 720 812 175 17 10 Fig 65 6 720 815 723 2015 05 SERVICING AND SPARES 6 1 7 To Check the Diaphragm in Burner Cover 4 Carefully withdraw diaphragm J from fan intake tube and check for soiling and splits gt Refit diaphragm J the correct way round into the fan intake tube OML 99 L9ELV90 TLI Fig 66 6 1 8 Re assembly of the burner cover NOTICE Burner gasket seal gt Always replace the burner gasket seal with a new when the joint has been disturbed gt Re assemble the burner in the reverse order using a new seal K gt Insert the burner cover under the rear securing bolt and tighten down
41. eans for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet 6 720 815 723 2015 05 7 WORCESTER PRE INSTALLATION Bosch Group 2 4 Layout amp components 11 Flow 12 Trap Siphon 13 Condensate hose 22 mm outlet connection 14 Inlet pressure test point 15 Gas valve 16 Air gas adjustment screw 17 Testing point for fan pressure 18 Fan 19 Primary sensor 20 Auto air vent 21 Removable top case for servicing 22 Blank plate 23 Display 24 Fault reset button 25 Notused 26 Not used 27 ON OFF and fault indicator blue 28 Temperature control 29 Performance test button 30 Service button 31 Burner indicator green 32 ON OFF button The diagram above shows the controls in the servicing position and excludes the outer case al ei gt LE ANg yy R Gh 8 SI A HU E ec S S SA Fase ais Q Sy 3 PRE INSTALLATION 3 1 Cleaning primary systems NOTICE gt All the following Pre Installation sections must be Ge FO Je read and requirements met before starting boiler or ee flue installations E 6 720 812 174 07 10 CAUTION gt ISOLATE THE MAINS SUPPLIES BEFORE STARTING Fig 3 Boiler layout and components The diagram shows the controls ANY WORK AND OBSERVE ALL RELEVANT SAFETY in the
42. ectrode assembly 14 Air gas manifold WARNING Air Gas manifold gt Do not remove the manifold unless a new gasket is available for re assembly 1 Remove cover panel A by removing screws B gt Check that the boiler is completely isolated from the gas supply Q QQE 6 720 812 175 15 10 Fig 78 Top panel 2 Remove clips C and unscrew the two bolts D gt Unscrew and remove the two hexagon screws E securing the fan gt Slacken the rear securing bolt F 42 Z ANORCESTER Bosch Group 6 720 812 175 16 10 Fig 79 Release air gas manifold 3 Remove air gas manifold 1 6 720 812 175 17 10 Fig GU Air gas manifold 4 Open air gas manifold 1 gt Carefully withdraw diaphragm J from fan intake tube and check for soiling and splits OMIL 99 L9ELV90 TLY Fig 81 Diaphragm 15 BURNER gt Remove the burner H gt Replace new burner in correct position 6 720 815 723 2015 05 Z ANORCESTER Bosch Group gt Refer to section 6 1 8 Re assembly of the burner cover gt Ensure that a new seal K is used refer to fig 81 6 720 812 175 29 10 Fig 82 Burner removal 16 Heat excha
43. effects vvvvyv Benchmark places f A responsibilities on both enc mar manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS KEY TO SYMBOLS AND SAFETY PRECAUTIONS their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot water Industry Council who manage and promote the scheme Visit centralheating co uk for more information HEALTH AND SAFETY The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations Control of Substances Hazardous to Health Regulations 1988 COMBUSTIBLE AND CORROSIVE MATERIALS Do not store or use any combustible materials paper thinners paints etc inside or within the vicinity of the boiler Chemically aggressive substances can corrode the appliance and invalidate any warranty FIT
44. from an opening in a car port on the same wall e g door or window leading into the dwelling 10 600mm distance to a surface facing a terminal unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal Note gt Installations in car ports are not recommended gt The flue cannot be lower than 1 000mm from the top of a light well due to the build up of combustion products gt Dimensions from a flue terminal to a fanned air inlet to be determined by the ventilation equipment manufacturer 6 720 815 723 2015 05 ANORCESTER Bosch Group 4 INSTALLATION NOTICE All the previous Pre Installation sections AN must be read and requirements met before starting boiler or flue installation 4 1 Unpacking wall frame and ancillary items LIFTING AND CARRYING PRECAUTIONS WARNING gt Lift only amanageable weight or ask for help When lifting the boiler bend the knees and keep the back straight and feet apart Do not lift and twist at the same time Lift and carry the boiler close to the body Wear protective clothing and gloves to protect from any sharp edges IMPORTANT HANDLING INSTRUCTIONS e tis advised that two people are used to carry the carton from the van to the point of delivery e Once the carton has been delivered the top of the carton is opened If a sharp implement is used make sure the carton is not pierced and
45. hen replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate AND CO Record At min rate Where Possible AND CO Comments Comments Signature SERVICE 03 Signature SERVICE 04 Engineer name Engineer name Company name Telephone No Company name Telephone No Gas safe register No At max rate CO ppm AND Record At min rate Where Possible CO ppm AND Comments CO CO Gas safe register No At max rate ppm AND Record At min rate Where Possible CO Comments ppm AND CO CO At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 07 Signature SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signatu
46. inates GREEN when the burner has lit The boiler runs for 15 minutes at minimum heating D output to fill the condensate trap the display K alternates between ll and the flow temperature This occurs every time the mains supply has been interrupted This could take longer than 15 minutes if high output is demanded 3 If the boiler fails to light the BLUE power indicator 5 and reset button 2 will flash alternately To reset press and hold the reset button 2 for 2 seconds The boiler will be reset RESET BOILER i CAUTION DO NOT PRESS POWER INDICATOR 5 TO 5 5 Water treatment NOTICE Debris from the system can damage the boiler AN and reduce efficiency Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty Ensure that the system has been cleaned as on 8 of these instructions FLUSHING Central Heating 1 Switch off the boiler gt Open all drain cocks and drain the system while the appliance is hot 2 Close drain cocks and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer s instructions 30 AANORCESTER Bosch Group 3 Run the boiler system at normal operating temperature for the time stated by the manufacturer of the flushing agent 4 Drain and thoroughly flush the system to remove the flushing agent and debris INHIBITOR Central Heating
47. ing the air gas ratio The setting of the gas ratio must be carried out by a competent person Setting the air gas ratio must not be attempted unless the person carrying out the operation is equipped with a combustion analyser conforming to BS 7927 and is competent in its use gt Remove electrical connector from fan gt Remove condensate trap see page 40 1 Undo the union connection A from the top of the gas valve gt Remove wire clip B from air gas adjustment assembly C then pull gas pipe down 2 Unscrew two screws D 3 Remove fan from boiler 4 Remove three screws retaining the air gas adjustment assembly E gt Reassemble with new fan assuring that seals are correctly fitted Fig 76 Fan assembly removal 4i SERVICING AND SPARES 13 Electrode assembly WARNING Electrode gasket gt Donotremove the electrode assembly unless a new gasket is available for re assembly Disconnect spark electrodes and flame sensor connection Remove two screws F Remove spark flame electrode assembly G from heat exchanger Inspect the spark flame electrode assembly and ceramics for signs of contamination or damage replace as necessary If necessary clean the spark flame electrode assembly with a plastic scouring pad gt Replace electrode gasket gt Re assemble with the new gasket and secure with the screws F removed earlier vv vV Yy vy 6 720 812 175 20 10 Fig 77 El
48. int of the system 6720644743 08 1Wo Fill point Fig 5 System fill System make up PRE INSTALLATION S AND Y PLAN SYSTEM NOTICE Bypass AN gt Generally a bypass is not necessary ona Y plan system as one of the ports is open to flow 1 Static head Minimum static head 250mm measured from the highest point in the heating system top surface of the appliance or the highest point in the heating system to the water level in the feed and expansion tank Heating vent 22mm minimum Primary cold feed 15mm minimum Diverter Zone valve Pump maximum power 90 Watts Automatic bypass Radiator valve Flow Lock shield valve Return Expansion vessel Pressure gauge 3 bar pressure relief valve 12 Stop cock Table5 Key to figures 7 8 9 amp 10 CO CO NI 0 AIJ N e e l NOTICE A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance system layout 6 720 812 174 12 10 6 720 812 174 11 10 Fig 7 Yplan 10 Z ANORCESTER Bosch Group 6 720 812 174 13 10 Fig 8 Sealed system new build system layouts The latest Part L1a regulation for new installations require separate zone controls for the central heating 6 720 812 174 10 10 6 720 812 174 09 10 Fig 10 Sealed system with two heating zones 6 720 815 723 2015 05 ANORCESTER Bosch Group 3 4 Condensate pipe work NOTICE AN gt Where a new or replacement boi
49. label 19 AANORCESTER INSTALLATION 4 2 Wall mounting plate and flue opening CAUTION Ensure there are no pipes electric cables damp proof courses or other hazards before drilling SAFETY All relevant safety precautions must be undertaken Protective clothing foot wear gloves and safety goggles must be worn as appropriate FIXING THE POSITION OF THE WALL MOUNTING PLATE e Fig 25 shows the relative positions of the flue and the fixing of the wall mounting plate including hanging bracket and pre plumbing manifold 6 720 812 175 27 10 Fig 25 Mounting template gt Fix the wall mounting template supplied with the literature pack to the wall gt Drill holes for wall mounting plate and pre plumbing manifold atleast one of the holes A atleast one of the holes B preferably use left hole holec hole D gt If required make a hole in wall for the flue pipe 20 Bosch Group FLUE OUTLET gt Followthe Fig 25 to mark the centre of the flue for rear outlet 3 or for side outlet 4 gt For the 60 100mm flue make a 125 mm diameter hole through the wall using a core drill or similar For flues using an optional weather collar fitted from inside the building make a 150 mm hole Clear away any debris Drill the hole preferably using acore drill Remove the mounting template Place the wall mounting plate with hanging bracket ag
50. ler is being installed access to an internal gravity discharge point should be one of the factors considered in determining boiler location gt The condensate pipe must be nominally 22mm plastic pipe gt The condensate pipe work must fall at least 52mm per metre towards the outlet and should take the shortest practicable route gt Ensure there are no blockages in the pipe run Key to condensate illustrations Condensate discharge from boiler Soil and vent stack Minimum 450mm and up to three storeys Visible air break at plug hole Sink or basin with integrated overflow 75mm sink waste trap Condensate pump Condensate trap of 75mm already incorporated into the boiler 1 SI OO Oil BRI CG NO Eh 3 4 1 Internal connections In order to minimise risk of freezing during prolonged cold spells the following methods of installing condensate drainage pipe should be adopted in order of priority Wherever possible the condensate drainage pipe should be routed and terminated so that the condensate drains away from the boiler under gravity to a suitable internal foul water discharge point such as an internal soil and vent stack A suitable permanent connection to the foul waste pipe should be used S oe CO P Ki N tT CO CH N N oO Fig 11 Disposal to soil vent stack Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe washing machine waste pipe etc can
51. m Minimum hole size for the condensate soak away must be D 400mm deep by 200Omm In situations where there are likely to be extremes of temperature or exposure the use of aproprietary trace heating system for external pipe work incorporating an external frost thermostat should be considered If such a system is used the requirement to use 32mm pipe does not apply However all other guidance above and the instructions for the trace heating system should be closely followed NOTICE Unheated internal areas gt Internal pipe runs in unheated areas such as lofts basements and garages should be treated as external runs X SS 500mm min 4 i d d LW E PN OU H e E Di f ES SHI d el E si i 6720644744 11 3Wo dl Kas ET AN V H N AN ibi N fe Bi J W 6720644744 12 3Wo Fig 17 Condensate pump to external disposal 6 720 815 723 2015 05 PRE INSTALLATION 3 5 Boiler internal drain The CDI Regular DT has the facility to drain the water direct from the boiler through the condensate pipe Fig 18 Drain tap positions If the boiler uses a Soakaway or a condensate pump gt Use an external drain point on the system to prevent excess system water being drawn through the soakaway or condensate pump 3 6 Boiler location amp clearances This boiler is only suitable for installing internally within a property at a
52. mmd 125mmd 30CDi 6 400mm 14 500mm 40CDi 4 500mm 12 000mm Table 17 Flue option 9 Vertical balanced extended flue with 2x45 bends Flue option 10 100mmd 125mm 30CDi 7 900mm 16 500mm 40CDi 6 000mm 14 000mm Table 18 Flue option 10 15 PRE INSTALLATION 350 mm 570 mm i 1 130 mm Min Pit 2C rog Sd 500 mm amp 300 mmf Flat roof Fig 21 16 Z ANORCESTER Bosch Group WW 6720643895 12 1Wo 6 720 815 723 2015 05 WORCESTER Bosch Group PRE INSTALLATION 3 9 Flue terminal positions All measurements in millimetres 52mm 104mm Fig 22 Flue terminal positions NOTICE gt All measurements are the minimum clearances required gt Terminals must be positioned so to avoid combustion products entering the building gt Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fittings flue brackets 100mm part number 7 716 191177 flue brackets 100mm x 6 part number 7 716 191 178 flue bracket 125mm part number 7 716 191 179 Key to illustration 16 The dimension below eaves balconies and car ports can be reduced 1 300mm adjacent to a boundary line to 25mm as long as the flue terminal is extended to clear any 2 The dimension below eaves balconies and car ports can be reduced
53. mpetent in its use Setting the CO When running in the performance test mode ensure the motorised valve s are open to avoid the boiler cycling during the commissioning operation 1 Connect manometer to inlet test point on the gas valve gt To adjust the CO it will be necessary to first operate the boiler at maximum output gt Press and hold down the performance test button for 10 seconds until illuminated 2 Turn central heating control to maximum the boiler will then go to maximum output The control will resume normal operation after 15 minutes or if the performance test button is pressed for over asecond 3 Using a flat blade screwdriver set the CO via the max adjuster referring to the table below CO should be measured 10 minutes after firing the D appliance CO setting CO setting Gas type maximum minimum Greenstar 30CDi Classic Regular Natural gas 9 6 0 4 9 0 0 4 LPG 11 5 0 4 10 5 0 4 Greenstar 40CDi Classic Regular Natural gas 9 7 0 4 9 1 0 4 LPG 11 5 0 4 10 5 0 4 NOTE When checking an existing appliance the tolerance is 0 4 lf checking after cleaning or component replacement or for adjustment when the reading is outside the tolerance given above then the tolerance is 0 2 CO less than 200 ppm 0 002 ratio gt Check CO is less than 200 ppm gt Measure the gas inlet pressure at the gas valve test point it should be amaximum of 2 5mbar less than the pressur
54. nces working GAS PRESSURE WITHIN THE SYSTEM Refer to the figure below for Natural Gas pressures The pressure at the boiler must not be less than the pressure read at the meter minus 1 mbar The pressure drop from the meter to the gas valve must not be more than 2 5 mbar for natural gas If the pressure drops are greater than shown in the figure below then this would indicate a problem with the pipe work or connections within the system Natural Gas Gas Control lt 2 5mbar difference 19 23 mbar 16 5 20 5 mbar Boiler inlet peal 1 5 mbar drop ee 18 22 mbar Fig 48 Natural gas pressures 6720644744 44 2Wo 6 720 815 723 2015 05 COMMISSIONING Refer to the figure below for L P G gas pressures The pressure at the boiler must not be less than the pressure read at the meter minus 2 5 mbar The pressure drop from the meter to the gas valve must not be more than Ambar for LPG lf the pressure drops are greater than shown in the figure below then this would indicate a problem with the pipe work or connections within the system Regulator Gas Control L P G lt 4 0mbar difference 32 45 mbar 28 41 mbar Boiler inlet ee BW 1 5 mbar drop 6720644744 45 2Wo 7 29 5 42 5 mbar Fig 49 L P G pressures NOTICE Do not continue commissioning until the correct gas pressure is achieved gt f pressure is satisfactory press the performance test button L
55. nd case seals Rectify where necessary Check CO and combustion ratio at minimum rate CO lt 350ppm CO CO ratio lt 0 004 CO lt 350ppm CO CO ratio lt 0 004 Set boiler to minimum rate Boiler is operating satisfactorily No further action is required 6720809056 01 1Wo 6 720 815 723 2015 05 Ay WORCESTER ibe Group COMMISSIONING 5 8 Finishing commissioning The boiler has been factory set so there should be no need to adjust combustion settings REPLACE OUTER CASING 1 Replace outer casing making sure that the securing points are properly located gt Press the clip A downwards to secure casing on top gt Retighten bottom two screws B l A e E e SE PER HS 2J S INSTALLING BOTTOM PANEL kwa DATI L 2 The bottom panel slides onto two ledges C either side of the boiler ES M frame gt Hold the panel up against the underside of the boiler and slide towards the rear until it is fully engaged HANDOVER gt Complete the Benchmark check list gt Open the fascia cover by pulling the centre top of the cover D gt Setup the controls and show the user how to operate all the controls shown in the User Guide gt Place the user guide into the tray E on the inside of the facia cover gt Ifthe appliance is unused and exposed to freezing conditions shut off all the mains supplies and drain the system and boiler lt Kaz Si gt mS Fig 51 Fitting outer case
56. nger gt Isolate flow and return valves and drain the boiler gt Remove condensate trap see page 40 gt Remove fan assembly see page 41 1 Remove plastic nut A from the base of the inner casing Fig 83 Heat exchanger removal 1 2 Remove screw at the top of the heat exchanger B gt Unscrew the flow pipe C 6 720 812 174 22 10 Fig 84 Heat exchanger removal 2 3 Undo flue connection D from sump E gt Pull flue pipe up gt Remove the heat exchanger 6 720 815 723 2015 05 SERVICING AND SPARES CA Tt ei ei 6 720 812 174 23 10 Fig 85 Heat exchanger removal 3 19 DRAIN TAP gt Remove clip G gt Unscrew nut H gt Replace drain tap Fig 86 Auto Air Vent removal 20 AUTO AIR VENT gt Ensure the appliance has been fully drained gt Unscrew air vent J and replace 43 SERVICING AND SPARES 6 4 Short parts list Table 21 44 Fan 8 717 204 453 0 GC No H26 536 Burner skin seal 8711004 1660 GC No E27 201 Temperature limit sensor 8 722 963 858 0 GC No H08 291 Control sensor primary 8 714500 087 0 GC No E7453 Control unit 8717 207 8330 Heat exchange inspection cover seal 8 710103 1530 Flue sample point 8716111 2520 Z ANORCESTER Bosch Group Burner 8 718 006 658 0 GC No E27 200 Gas valve 8 718 221 3470
57. nger telescopic flue without cutting and can be used with Condensfit Il flue extension components The terminal end of the standard telescopic flue can be further reduced to 130mn if necessary refer to the Flue Instruction manual supplied The plume deflector can be adjusted to redirect the flue discharge allowing some plume management control alternatively a complete plume management system can be fitted to the flue terminal Refer to the Flue Instruction manual supplied with the flue kit 350mm to 570mm Min 130mm cut length Fig 33 Telescopic flue 4 5 2 60mm Plume management kit Part Number 7 716 191 086 The plume management system connects to the terminal outlet of the Telescopic flue and must not be used with the flue terminal of the Standard Flue Kit The plume management system can be reduced by cutting min 500mm and can be used with plume management extension components 24 Z ANORCESTER Bosch Group 6720643895 30 1Wo Fig 34 60mm PLUME MANAGEMENT KIT 7 716 191 086 replaces the plume deflector in the 60 100mm telescopic flue terminal 4 5 3 ADJUSTING THE STANDARD TERMINAL LENGTH 1 Extend tube 1 by withdrawing from tube 2 to achieve the flue length required 350 570mm for the standard telescopic flue or 570 to 790mm for the longer telescopic flue Secure with screw provided and seal joint with the aluminium tape supplied e 570 mll lt 350 TEE 672064
58. o maximum e The performance test button 7 will illuminate continually 6720806548 14 1Wo Fig 46 Control panel 1 Display 2 Reset button 3 Not used 4 Not used 5 ON OFF and fault indicator Blue 6 Central heating temperature control 7 Performance test button 8 Service button 9 Burner indicator Green 10 ON OFF button 6 720 815 723 2015 05 Z ANORCESTER Bosch Group 5 6 1 Checking the gas inlet pressure The inlet pressure to the appliance must be checked using the following procedure NOTICE The combustion for the boiler is factory set AN No adjustment is required if the gas inlet pressure is correct MEASURING THE INLET PRESSURE 6720647361 58 1Wo Inlet pressure test point Fig 47 Inlet pressure test point gt Close gas isolation valve gt Slacken the screw in the inlet pressure test point and connect a manometer gt Open gas isolation valve gt Measure the pressure with the boiler running at maximum Press performance test button for more than ten seconds and set Central Heating temperature to maximum The performance test button will illuminate continually and the blue power indicator will pulse five times gt Check the gas supply working pressure at the gas valve conforms to values shown in figures 48 or 49 Ensure inlet pressure is satisfactory with all other gas applia
59. ons Checking flue integrity refer to section 6 1 2 page 34 Setting the air gas ratio refer to section 6 2 page 38 Zero the analyser in fresh air See notice Set boiler to maximum rate START HERE gt ON Flue integrity Z ANORCESTER Bosch Group NOTICE BEFORE CO AND COMBUSTION CHECKS Refer to section 5 6 1 and 5 6 2 to verify gas type gas inlet pressure and gas rate Visually check the integrity of the whole flue system and confirm that all the components are correctly assembled fixed and supported The flue gas analyser must be the correct type as specified in BS 7967 Before use the analyser must have been calibrated as specified by the manufacturer The installer must be competent in the use of the analyser Check and zero the analyser in fresh air as specified by the manufacturer The air gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester Bosch Group help line 0330 123 3366 test using analyser Verify flue integrity lt less than 2 greater than or equal to CO lt 350ppm CO CO ratio lt 0 004 Record values Do not adjust the gas valve Turn off boiler and call Worcester Bosch Group help line 0330 123 3366 Fig 50 Combustion check flow chart 32 Check all seals Check CO and combustion ratio at maximum rate around the burner internal flue seals a
60. oth as possible 12 Z ANORCESTER Bosch Group FITTING AN EXTERNAL AIR BREAK Refer to figure 14 when a rain water down pipe is used to dispose of condensate e An air break must be installed in the 43mm pipe work between the boiler condensate outlet and the drainpipe outside the property to avoid flooding during adverse weather conditions 6720644744 09 3Wo Fig 14 Disposal into a rainwater down pipe Condensate drainage pipe can be run above or below D ground Where the pipe terminates over an open drain or gully the pipe should terminate below the grating level but above water level in order to minimise wind chill at the open end The use of a drain cover such as those used to prevent blockage by leaves may offer further protection from wind chill Pipe drainage will be improved if the end is cut at 45 as opposed to a straight cut CH CH 7 lt Ki N ed Ki CO CH N N oO Fig 15 External disposal 6 720 815 723 2015 05 Z ANORCESTER Bosch Group CONDENSATE SOAK AWAY e The condensate drainage pipe may be run above or below the ground to the soak away The examples shown on this page run above ground e The soak away must use a 100mm plastic tube with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube The holes must face away from the house e The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400m
61. ow procedure Setting the gas air ratio in the gas conversion section vvvvvvv yv N DCN ES 6 720 812 174 25 10 Fig 72 Gas valve removal 8 Siphon condensate trap 1 Pull condensate pipe out of the adaptor 2 Remove trap from boiler gt Clean trap and check that the connection to the heat exchanger is clear gt Fill the condensate trap with approximately 1 4 litre of water and refit in reverse order 6 720 812 174 24 10 Fig 73 Siphon removal 6 720 812 174 20 10 Fig 71 Sensors 40 6 720 815 723 2015 05 Z ANORCESTER Bosch Group 9 ACCESS TO BOILER CONTROL COMPONENTS gt Remove 3 screws A and remove cover from control 10 PCB fuse gt Remove fuse B from the PCB and replace gt There is a spare fuse clipped into the cover 6720647361 35 2Wo Fig 7 4 Component and fuse access 11 PCB REMOVAL To gain access to the PCB gt Remove the five screws shown in the diagram below and remove the PCB cover ti EE Gas Ee S Gs A mh Eu V 6720647361 36 2Wo Fig 75 PCB access 6 720 815 723 2015 05 SERVICING AND SPARES 12 Fan assembly NOTICE Air Gas ratio gt After re assembly the combustion must be checked using the procedure in the section Sett
62. ple observing D all precautions for safe lifting of heavy objects gt Do not lift by the top case panel There are two handling holes in the inner casing left and right in the lower section of the appliance 6 720 815 723 2015 05 Z ANORCESTER Bosch Group H I I I I I I L U Do not lift by the top case panel Handling hole both sides 6 720 815 723 04 10 Fig 30 Hang the boiler 3 Lower the control panel into the service position by releasing the white catch on the retaining bracket 4 Make connections to the heating system gt Connect the gas supply to the boiler gas cock 22mm compression fitting N F Q vi Pe ei N Fig 31 Connections 6 720 815 723 2015 05 INSTALLATION 23 INSTALLATION 4 5 Flue installation HORIZONTAL FLUE 60 100mm diameter For vertical flues and 80 125mm horizontal flues please refer to separate Flue Kit instructions Apply silicone lubricant to the sealing surfaces of the flue components to ease assembly of flue components 6720647361 13 1Wo Fig 32 4 5 1 60 100mm Telescopic flue kit Standard telescopic flue 350 570mm part Number 7 716 191 082 Longer Telescopic flue 570 790mm part number 7 716191171 The standard telescopic flue terminal length can be reduced or extended to within 350 to 570 mm or 570 to 790mm for the lo
63. ply pressure power supply igniter electrode and lead ionisation sensing electrode and lead flue duct and CO2 level FO Internal error Check electrical connector contacts programmer inter face module ignition leads are not loose replace pcb if necessary F7 Flame detected even though appliance switched off Check electrode assembly dry pcb Flue clear FA Flame detected after gas shut off Check gas valve and wiring to gas valve Clean condensation trap and check electrode assembly Flue clear Fd Reset button pressed by mistake Press reset button again Table 22 PRELIMINARY CHECKS Preliminary electrical system checks are the first electrical checks to be carried out during a fault finding procedure On completion of the Service Fault Finding task which has required the breaking and remaking of electrical connections check A more detailed fault finding procedure is described in the Service Engineer s booklet 7 2 Protection function external pump Pump anti seize 6 720 815 723 2015 05 Pump runs for 5 seconds every 24 hours 6720648547 25 1Wo 45 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part w
64. pply e PXAD e Wiring must comply with the latest IET wiring regulations 3 2 2 Gas supply e Boilers using Natural Gas NG must be connected to a governed meter e Liquid Petroleum Gas LPG must be connected to a regulator e Installation and connection of the gas supply to the boiler must be in accordance with BS6891 Under no circumstance should be size of the gas supply pipe be less than 22 mm The meter or regulator and pipe work to the meter must be checked preferably by the gas supplier This is to ensure that the equipment is in good working order and can meet the gas flow and pressure requirements in addition to the demand from any other appliance being served 6 720 815 723 2015 05 PRE INSTALLATION 3 3 WATER SYSTEMS amp PIPE WORK PLASTIC PIPEWORK e Any plastic pipe work must have a polymeric barrier with 600 mm minimum length of copper or steel pipe connected to the boiler e Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 C The pipe work from the boiler to the blending valve must be in copper or steel protected from corrosion CONNECTIONS VALVES e Al system connections taps and mixing valves must be capable of sustaining a pressure up to 3 bar e Radiator valves should conform to BS2767 10 e Do not use galvanised pipes or radiators e All other valves should conform
65. r area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate m hr OR Burner operating pressure at maximum rate mbar OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at all outlets Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate CO ppm CO CO At min rate where possible CO ppm CO CO Record the following The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a 4
66. re SERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature 79 SHEATHING FUNCTION must be notified to Local Authority Building Control LABC either directly or through a e tent Person uilding Regulations Compliance Certificate will then be issued to the customer ompe s Scheme Heating and Hotwater Industry Council HHIC Signature penCchinan THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model
67. s and fittings Key to illustration 7 Internal external corners The air intake clearance can be reduced to 1 18 This feature allows some basic plume re direction options on a standard telescopic horizontal flue terminal 300mm minimum clearances to a opening e g window However the minimum clearances to an opening in the direction that the plume management is facing must be increased to 1 500mm Where the flue is less than 150mm to a drainpipe and plume re direction is used the deflector should not be directed towards the drainpipe 300mm adjacent to a boundary line Plume Management kit air intake can be reduced to 150mm providing the flue exhaust outlet is no less than 300mm adjacent toa boundary line 1 200mm between terminals facing each other 600mm distance to a boundary line unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminal in relation to boundary lines Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance Plume kits running horizontally must have a 10 fall back to the boiler for proper disposal of condensate For details on specific lengths see relevant boiler Technical amp Specification information 150mm providing the flue exhaust outlet has a 300mm clearance Clearances no less than 200mm from the lowest point of the balcony or overhang 1 200mm
68. se if applicable as described in Commissioning gt Operate the appliance and take note of any irregularities Call up the last fault stored by the Bosch Heatronic Service Function D Refer to Fault Finding for rectification procedures 34 Z ANORCESTER Bosch Group 6 1 2 Checking flue integrity The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points Flue gas sample point Air inlet sample point 2 Table 20 Key to figure 53 6720643895 67 1Wo Fig 53 Flue turret test points With the boiler case on and the boiler running at maximum output refer to paragraph SET THE BOILER TO MAXIMUM page 35 gt Ensure that the probe reaches the centre of the air intake adjust the cone on the probe so that it seals the sample point and correctly positions the end of the probe gt Insert the analyser probe into the air intake sample point gt Allow the readings to stabilise and check that 0 is equal to or greater than 20 6 CO is less than 0 2 gt Ifthe readings are outside these limits then this indicates that there is a problem with the flue system or combustion circuit e g missing or dislodged seals 6720809056 3 1Wo Fig 54 Flue integrity test 6 720 815 723 2015 05 AORCESTER Bosch Group 6 1 3 Component Access Removing outer case 1 Remove bottom panel by pulling it forward and off 2 Undo but do not remo
69. servicing position and excludes the outer case PRECAUTIONS NOTICE AN Debris from the system can damage the boiler and reduce efficiency Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty BEFORE CLEANING THE SYSTEM gt Ensure that the system and pipe work is in good working order gt Where possible keep the existing boiler circulating pump in place when flushing the system FOLLOW THE GUIDANCE OF BS7593 Treatment of water in domestic hot water central heating and also the flushing guidelines below ne ere NOTICE ARTIFICALLY SOFTENED WATER MUST NOT Fig 4 AN BE USED TO FILL THE CENTRAL HEATING SYSTEM 1 Ignition electrode and flame sense electrode 2 Heat exchanger FLUSHING THE SYSTEM 3 Overheat thermostat gt Fill the system with cold water and check for leaks 4 Access point for cleaning heat exchanger 5 Drain point gt Open all drain cocks and drain the system 6 Return gt Close drain cocks and add asuitable flushing agent compatible with 7 Gas connection 22 mm compression aluminium at the correct strength for the system conditions in 8 Drain hose accordance with the manufacturer s instructions The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated gt Circulate the flushing agent before th
70. to BS1010 e On new installations or extensions to existing systems where a radiator previously did not exist each radiator should be fitted with a TRV except the one fitted in the same room area as the room thermostat On boiler only replacement jobs it is recommended but not mandatory to fit a TRV on each radiator It is however a requirement for energy conservation purposes to recommend to the customer that a TRV is fitted to each radiator e Anautomatic bypass may be required downstream of the pump in order to maintain the minimum flow rate through the appliance e Anairventis required at the highest point on the system SEALED PRIMARY SYSTEM NOTICE Artificially softened water must not be used to N fill the central heating system The CH sealed system must be filled using a WRAS approved filling loop or comply with figure 5 for system fill An expansion vessel of a size suitable for the system must be fitted as close as possible to the appliance in the central heating return Also fit a pressure gauge a 3 bar pressure relief valve and stop cock fixed cylinder type or sealed system approved connection e Do not use galvanised pipes or radiators SYSTEM FILL SYSTEM FILL Heating Mains return supply Hose union SV s D Temporary hose CV Check Valve SV Stop Valve AA Auto Air vent CV Check Valve SYSTEM MAKE UP Heating return Make up AA 1000 mm 39 in above the highest po
71. to property or equipment e CAUTION indicates a situation that could result in minor to medium injury e WARNING indicates a situation that could result in severe injury or death e DANGER indicates a situation that will result in severe injury or death Important information This symbol indicates important information where there is no risk to people or property Additional symbols Symbol Explanation gt Step in an action sequence gt Cross reference to another part of the document List entry List entry second level SYMBOLS USED IN THIS MANUAL Domestic Hot Water Central Heating Hot Water Storage Cylinder Domestic Cold Water Supply Electrical Supply Gas Supply ZN CBJ i Table 1 Commonly used symbols 6 720 815 723 2015 05 KEY TO SYMBOLS AND SAFETY PRECAUTIONS PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION These instructions are applicable to the Worcester appliance model s stated on the front cover of this manual only and must not be used with any other make or model of appliance These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations This appliance must be installed by a GAS SAFE registered competent person Failure to install correctly could lead to prosecution If you are in any doubt contact the Worcester Technical help line 0330 123 3366 Please leave these instructions with the completed BENCHMARK
72. ve the 2 screws A securing boiler casing at the bottom of the appliance 3 Pull upwards to release the clip B on top of the boiler 4 Pull case forward and remove wi N gy oO isp KR kg Kei CH N N lt o Fig 55 Removing outer case 6 720 815 723 2015 05 SERVICING AND SPARES Adjusting boiler control to service position 1 Pull down the catch securing the control panel 2 Gently pull forward until it comes to rest in service position I STON W S Leg BA On Ee Le Jee e Zem ZB gwy A E ZF S ZT R y ff K SE W TONN ee A Tee Ale LE gt A 6 720 812 174 18 10 Fig 56 Service position 6 1 4 Fan pressure test This test is to determine if the heat cell requires cleaning attention SET THE BOILER TO MAXIMUM The boiler must operate at maximum output for the Fan D Pressure test and Flue Gas Analysis 6720806548 14 1Wo Fig 57 Control panel 1 Display 2 Reset button 3 Notused 4 Notused 5 ON OFF and fault indicator Blue 6 Central heating temperature control 7 Performance test button 8 Service button 9 Burner indicator Green 10 ON OFF button gt Press and HOLD performance test button 7 for 10 seconds and set Central Heating temperature to maximum The performance test button will illuminate continually The boiler will stay

- Worcester Bosch

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