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Worcester_Highflow_Installation

1. 300 lt gt 150 Fig 18 Plume terminal positions D Maximum and minimum plume management lengths gt Aminimum distance of 500mm must be maintained between the plume management outlet and the flue air intake The maximum plume management length is 4 5 metres for the appliances detailed on the front of this manual The 45 bend is equivalent to 0 75 metres of straight plume management and the 90 bendis equivalent to 1 5 metres NOTICE gt All measurements are the minimum clearances required 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 brackets and fittings gt Key to illustration 1 This feature allows some basic plume re direction options ona 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 50
2. 6720648665 15 1Wo Fig 50 Internal filling loop gt The boiler integral expansion vessel is pre charged to 0 7 5bar equal to a static head of 7 5m 22ft A Schraeder type valve is fitted to the expansion vessel to allow for pressure adjustment if required If an extra expansion vessel is fitted to the central heating return adjust this to the same pressure as the appliance internal expansion tank refer to separate instructions with the extra expansion vessel 32 6 720815 062 2015 05 CAWORCESTER Bosch Group 5 3 Water treatment NOTICE 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 NOTICE N gt ARTIFICIALLY SOFTENED WATER MUST NOT BE USED TO FILL THE CENTRAL HEATING SYSTEM ENSURE THAT THE SYSTEM HAS BEEN CLEANED AS ON PAGE 10 OF THESE INSTRUCTIONS FLUSHING Central Heating gt Switch off the boiler gt Open all radiator valves drain cocks and drain the system while the appliance is hot gt Close drain cocks gt Add a suitable flushing agent and refill the system at the correct strength for the system condition in accordance with the manufacturer s instructions gt Run the boiler system at normal operating temperature for the time stated by the flushing agent manufacturer gt Drain
3. 30 4 8 Electrical wod ENEE E RENE W EA 30 5 COMMISSIONING cece cence cece ceees 32 5 1 Pre commissioning check 32 5 2 Filling the system 32 53 Water treatment 33 5 4 Starting the appliance 00 c eee 33 5 5 Checking gas inlet pressure 34 5 5 1 Measuring theinlet pressure 34 5 5 2 Checking the gasrate ccc cece e eee 35 5 6 CO and combustion check 35 5 7 Finishing commissioning 37 2 6 720 815 062 2015 05 4 WORCESTER Bosch Group 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 1 1 Key to symbols Warnings These instructions are applicable to the Worcester appliance model s 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 nottaken The following keywords are defined and can be used in this document NOTICE indicates a situation that could result in damage to property or equipment CAUTION indicates a situation that could result in minor to medium injury WARNING indicates a situation that could result in severe injury or death DANGER indicates a situation that will result in severe injury or death Important information KEY TO SYMBOLS AND SAFETY PRECAUTIONS PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTI
4. Fig 81 Condensate pump indicator lights FAULT FINDING and DIAGRAMS 6720648568 52 1Wo CONDENSATE PUMP OPERATING LAMPS AND FAULT CONDITIONS Ready for operation Steady green light Fault Red light Pump running Flashing green light Operating lamps Cause Solution Green Red Off Off Mains plug not pluggedin Insert plug Power failure Check mains and fuse Flashing Flashing Dry run Pump restarts automatically poss airin pump after one minute On Flashing Pump blocked Visual inspection of the pump inlet in the tank and removal or rinsing out of dirt foreign bodies On On Level exceeds alarm level Pressure hose non return valve blocked clean or remove kink if applicable Off Flashing Pump blocked and Visual inspection of the pump inlet in the tank and removal or rinsing out of dirt alarm level exceeded foreign bodies Table 26 6 720 815 062 2015 05 53 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 when replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe re
5. NOTICE Protect the boiler gt 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 gt It is recommended that a primary water cleanser is fitted to the system Worcester offers a filter that helps remove both magnetite and non magnetic debris Part number 7 716 192 609 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 NOTICE ARTIFICALLY SOFTENED WATER MUST NOT N BE USED TO FILL THE CENTRAL HEATING SYSTEM FLUSHING THE SYSTEM gt Fill the system with cold water and check for leaks Open all drain cocks and drain the system gt Close drain cocks and add a suitable flushing agent compatible with aluminium at the correct strength for the system conditions in 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 the boiler is fired up gt Run the boiler system at normal operating temperature as directed by the manufacturer of the flushing agent gt
6. The flue terminal MUST be fitted with the TOP label uppermost to allow the correct fit and use of the plume management system 1 Remove securing screws from horizontal flue connector 1 to detach the terminal assembly 2 Slide terminal section 2 from the terminal assembly and discard 3 To use terminal 3 without cutting remove the location lug 4 figure 28 on the inner flue tube 5 figure 28 and remove any burrs 24 6 720 815 062 2015 05 CAVORCESTER Bosch Group INSTALLATION 1 FLUE OUTLETS A p Depending on the flue exit point from the boiler it may be necessary to i AM N reduce the length of the adaptor the details can be found in figure 31 2 1 page 25 and figure 32 page 26 MU D W Flue configuration and adapter required 2 1 Vertical Unmodified adapter c GZ 2 Left exit 93 bend and shortened adapter A 2 3 Right exit 93 bend and long adapter a NE 4 Rear exit 93 bend and shortened adapter Table 21 3 6720646219 07 1Wo Fig 27 Reducing the telescopic terminal To reduce the telescopic flue length further 1 gt Mark the length required for the terminal as shown in figure 28 min 130mm and cut square taking care not to damage the tubes gt 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 O 6720646219 08 1Wo
7. From standard telescopic flue p 265 mm gt Fig 30 Flue exit options Cutting the flue adaptor The flue adaptor must be cut to suit all horizontal fluing configurations 1 Remove seal from flue adaptor 6 M 672064621943 iWo 2 Cut square to mark as shown deburr and clean Fig 28 Further reduction 3 Replace seal REDUCING EXTENsion FLUE TUBE LENGTH D A 220mm short extension is available gt Mark the extension tube to the required distance measuring from the socketend and cut the tube square taking care not to damage the tubes gt Remove any burrs and chamfer the outer edge of the tubes to ease the connection and prevent damage to the seals 4 A A 6720646219 10 1Wo SS Fig 31 Long adapter for horizontal flue 6720644842 07 1Wo Fig 29 Cutting an extension tube 6 720 815 062 2015 05 25 INSTALLATION Fig 32 Short adaptor horizontal flue CONVERT FROM REAR FLUE OUTLET The boiler is supplied ready to fit a rear flue outlet To flue from the sides or top of the boiler follow the procedure below 1 Remove the required side or top knock out panel from the outer casing 2 Undue the three screws 3 Remove the flue outlet blanking plate comprising the cover and gasket from the inner casing 4 Refit the outlet blanking plate over the rear flue outlet making sure it seals 5 Secure the blanking plate cover and gasket with the three
8. 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 All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer Heating and Hotwater Industry Council HHIC Signature penchman 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 Boiler serial number Commissio
9. 6720648568 35 1Wo Fig 63 Fan control pressure test 38 6 720815 062 2015 05 CANORCESTER Bosch Group NOTICE Fan pressure test A gt The boiler must be run at maximum output for the fan pressure test With the combustion air intake pipe fitted and the boiler running at maximum output measure the fan pressure gt The pressure will read negative refer to the chart in figure 64 below FAN PRESSURE TEST NG Boilers HF 550CDi Tey gt HF 44000 Qs gt motoobooanolnoatnaknobnonaknatnoknanalnatnalnni 0 1 2 3 A 5 6 7 8 mbar LPG Boilers HF 550CDi ery gt HF 440CDi ERT gt 6720648665 21 1Wo mbar Fig 64 Fan control pressure readings gt Ifthe manometer reading is in the white area of the chart the heat exchanger exhaust path siphon does not require attention gt Ifthe manometer reading is in the black area of the chart then carry out the following checks Check that the siphon is not blocked Check the exhaust paths for restrictions Clean the heat exchanger with a suitable cleaning tool refer to section 6 7 Cleaning the heat exchanger gt Re check the fan pressure readings If the boiler after completing the above checks fails the fan pressure test then contact Worcester Bosch Group for advice gt After the measurements are taken switch the boiler off gt Remove the combustion air intake pipe gt Disconnect the manometer and replace the
10. gt Undo the lower pipe union on gas pipe E gt Remove the fan lead and earth connector The earth connector has a positive clip fixing Remove the fixing screws attaching fan A to the burner cover B Remove the fan A with gas pipe E and mixer unit D Twist the mixer unit D with gas pipe E to separate from fan A After re assembly check that the CO CO levels are as described in the section Setting the air gas ratio vvv v Flap Valve gt Undo the lower pipe union on gas pipe E gt Remove the pipe E by pushing upwards and to the rear gt Twist the mixer unit D with gas pipe E to separate from fan A gt Remove the flap valve F from within fan intake A and replace gt After re assembly check that the CO CO levels are as described in the section Setting the air gas ratio Ensure the flap valve is fitted correctly with rubber flap i upwards SERVICING and SPARES Fig 72 Fan assembly Condensate pump gt Disconnect electrical connections in control box see wiring schematic in the Fault finding and Diagrams section gt Remove 15mm flexible tube H from pump by rotating anti clockwise and pulling up 6720648568 39 1Wo Remove black flexible pipe J from condensate tank Take care as there maybe condensate remaining in the pipe gt Carefully remove the condensate pump G from the boiler and pour any excess condensate into
11. 6720648665 03 1Wo 3 4 Condensate pipe work NOTICE gt Whereanewor replacement boiler 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 Condensate pump within 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 trap of 75mm already incorporated into the boiler Table 12 NI OD Oo BY OG MO re CANORCESTER Bosch Group 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 internal kitchen or bathroom waste pipe washing machine waste pipe etc A suitable permanent connection to the foul waste
12. Mounting frame fixing and flue opening WARNING Damage to property Damage caused by drilling into pipes electrical cables damp proof course or other hazards gt Before drilling ensure that there are no obstructions Safety All relevant safety precautions must be undertaken Protective clothing footwear gloves and safety goggles must be worn as appropriate STARTING ANY WORK AND OBSERVE ALL RELEVANT CAUTION ISOLATE THE MAINS GAS SUPPLY BEFORE N SAFETY PRECAUTIONS Running pipes behind the boiler The frame should sit against the wall not the skirting board with enough room for the pipe work Do not cross a pipe over another The area around a rear flue outlet must be avoided GAS AND WATER CONNECTIONS gt Ensure all pipe work is clean and each pipe is in the correct position as shown opposite gt Push in each pipe in turn and tighten the fitting to secure gt MJ 1 40m N oom Ja L en I 6720648665 09 1Wo Fig 20 Pipe locations 1 Mounting frame A CH flow 22mm B DHW flow 22mm C Gas inlet 22mm D Mains water inlet 22mm E CH return 22mm CANORCESTER Bosch Group Fixing the mounting frame gt Position the mounting frame A on the floor against the wall with manifold connections B facing away from the wall D ensuring there is enough space for the pipe work E gt Allow the minimum space from
13. 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 gt 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 competentin the use of the analyser Check and zero the analyser in fresh air as specified by the manufacturer gt 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 COMMISSIONING 6 720 815 062 2015 05 35 CANORCESTER COMMISSIONING Bosch Group Zero the analyser in Nd Bra Flue integrity test See notice using analyser Set boiler to START HERE maximum rate lt less than Check CO and 2 greater than combustion ratio or equal to at maximum rate Check all seals around the burner CO lt 350ppm internal flue seals CO lt 350ppm CO CO ratio and case seals CO CO ratio lt 0 004 Rectify where lt 0 004 necessary Record values Do not adjust the gas valve Check CO and combustion ratio Set boiler to at minimum rate minimum rate Turn off boiler and FSE Boiler is operating call Worcester Bosch CO lt 350ppm satisfactori
14. 6 part number 7 716 191 178 flue bracket 125mm part number 7 716 191 179 NOTICE N 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 Key to illustration 1 300mm adjacent to a boundary line 2 The dimension below eaves gutters pipes and drains can be reduced to 25mm as long as the flue terminal is extended to clear any overhang External flue joints must be sealed with suitable silicon sealant 3 1 500mm between a vertical flue terminal and a window or dormer window 4 1 200mm between terminals facing each other 5 Vertical flue clearance 300mm adjacent 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 6 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 7 600mm minimum clearance from a skylight to a vertical flue 8 Vertical flue clearance 500mm to non combustible building material and 1 500mm clearance to combustible building material 9 300mm above below and either side of an opening door air vent or opening window 10 600mm diagonally to an opening door air vent or openi
15. Drain and thoroughly flush the system to remove the flushing agent and debris gt tmay 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 N 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 gt In cases where all attempts to find a micro leak have failed Worcester Bosch Group supports the use of Fernox F4 leak sealer 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 Table 10 Artificially softened water It is possible to have an ion exchange water softener fitted to the cold water system ofthe property However the boiler requires an untreated cold water connection taken from the mains supply before the water softener to the primary water filling point of the heating system Alternatively there are water softening treatment devices that do not adjust or alter th
16. EM 0H NO 1HOII N1dd9D puewap HD Jo Aqpuejs ul Jajlog 6 720 815 062 2015 05 50 WORCESTER Bosch Group FAULT FINDING and DIAGRAMS 7 4 Protection function AUTOMATIC INTERNAL FROST FUNCTION Internal boiler temperature between 8 C amp 5 C Internal boiler Pump switches off Pump runs temperature after a 3 minute rises above 9 C overrun period Boiler automatic frost function monitors internal boiler primary temperature Internal boiler Central heating temperature demand switches rises above 12 C off Internal boiler temperature below 5 C Central heating demand is activated Pump switches off after pump overrun period PUMP OVERRUN FUNCTION End of boiler demand Pump runs upto 3 minutes central heating preheat to dissipate heat from or domestic hot water the boiler into the system PUMP ANTISEIZE FUNCTION No central heating Pump runs 5 seconds A central heating demand demand after every 24hrs from activated pump runs a 24hr period last time pump ran normally 6720648665 36 1Wo 6 720 815 062 2015 05 51 FAULT FINDING and DIAGRAMS 7 5 Fault finding 4 WORCESTER Bosch Group deemed to be competent Dm gt This fault finding information is for guidance only Worcester Bosch cannot be held responsible for costs incurred by persons not gt Theelectronic control system for this boiler incorporates a blue central indicator This normally
17. Heat exchanger 440 CDi Heat exchanger 550 CDi Gas valve 87161082120 8 7186806480 87182213470 GCNo H22 465 GC No H66 931 GC No H56 469 Condensate pump 87161140770 GCNo H66 921 Pressure relief valve 87161424160 GC No 386 789 Pressure gauge 8 718680 7420 GC No H66 930 Auto air vent 8 716 140 5000 GC No E00 717 Set of electrodes including seal 8 718 664 3010 Expansion vessel 8715 407 2880 GC No H21 242 Control unit 8 737 703 1960 Table 24 6 720 815 062 2015 05 47 FAULT FINDING and DIAGRAMS CANORCESTER Bosch Group 7 7 1 PRE WIRED LINK Red Yellow Black Green Orange Violet Blue Black Green Yellow Blue Orange Red Electrical wiring diagram am FAULT FINDING and DIAGRAMS CODE PLUG ST18 Fuse F2 T 1 6A L250V Fuse F3 T 0 5 A L250V Wall plate contacts for FX controls Terrace Ll ST1 230V ST9 WORCESTER 24V CONTROLS OPTION PLUG IN POINT under blanking cover on fascia 0000 EMS BUS contacts oo i i N for FX controls ST17 EXTERNAL FROST STAT SPARK OPTIONAL Fuse F1 slow gt 12 5 A H 230 V TRANSFORMER off RE Or z I I ST8 o J F apem STE A LP NP FSFR era ST5 2 4 Satz B Ge DHW TEMPERATURE I CH TEMPERATURE CONTROL S Colour sequence CONTROL 3 B
18. below 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 ay NN py 2 N N 6720648568 10 1Wo Fig 8 External disposal Continued Key to condensate illustrations 15 100mm minimum plastic pipe 16 Drainage holes ili Limestone chippings 18 Bottom of sealed tube Table 14 6 720 815 062 2015 05 13 PRE INSTALLATION CONDENSATE SOAK AWAY Thecondensate drainage pipe may be run above or below the ground to the soak away The examples shown on this page run above ground 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 The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm CANORCESTER Bosch Group 3 5 Pressure relief pipe work NOTICE 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 Minimum
19. by children without supervision vvvvyv 6 720 815 062 2015 05 KEY TO SYMBOLS AND SAFETY PRECAUTIONS Benchmark places ibiliti both DERCHMAI ech installers THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and 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 COMBUSTION AND CORROSIVE MATERIALS Do not store or use any combustible materials paper thinners paints etc inside or within the vicinity of the appliance Chemically aggressive substances can corrode the appliance and inv
20. confirms the permanent mains supply but by flashing during a fault provides a guide to the cause as listed gt This fault finding system assumes that the appliance has been operating normally until the time of failure i e not a first time installation error BOILER FAULTS AND CONDITIONS Display code Fault description Check repair replace as necessary Al Pump dry run detection Check the system pressure refill if necessary or Pump is running in air A5 Tank NTC defect Check tank NTC sensor and leads measure resistance across NTC 33 5k Q 500 Q AT DHW NTC defect Check DHW NTC sensor and leads measure resistance across NTC 33 5k Q 500 Q A8 EMS communication error Check electrical connections of EMS controls if fitted connections on the control board replace control board b1 Code plug not detected Insert code plug correctly test and replace as necessary b2 b3 b4 Data error Replace control board b5 b6 b7 Burner control error Replace control board C6 Fan defect Check fan lead and connector replace as necessary D3 External temp limiter Check plug connector ST8 link missing damaged between 8 amp 9 on ST8 D5 Condensate pump failure See condensate pump table D6 Internal heat bank overflow Check system pressure tank over heat thermostat and leads and pump operation EA Flame not detected Check gas is present and working gas pressure igni
21. door 3 UNVENTED COMPARTMENT CLEARANCES boiler only 610mm izomm Ta a 15mm NE A 7 ii el m E 1 o e e 600mm i Yy i 25mm NU 6720648568 12 1Wo The dimensions below show the minimum space required to install and service the boiler inside an unvented compartment Space required for unvented areas with a removable door or panel This space can be reduced to 50mm for one side only as long as both the side clearances add up to the total of both the side measurements shown or more 800mm 900mm Fig 13 Unvented compartment clearances 800mm 100mm Zi 6720648568 13 1Wo 6 720 815 062 2015 05 15 PRE INSTALLATION 4 AIRING CUPBOARD CLEARANCES The dimensions below show the minimum space required to install and service the boiler within an airing cupboard 625mm 800mm 1050mm 3 3 6720648568 14 1Wo Fig 14 Airing cupboard clearances 5 VENTING COMPARTMENTS If the clearances are less than those stated for options 3 amp 4 above then ventilation must be provided as described in BS 5440 Aminimum of 2 air vents C of equal size must be fitted one at low level and another at high level on the same wall using the same air for circulation Fig 15 Venting compartments z 6720648568 15 1Wo Minimum free area required for venting For area directly from outside 440CD
22. down Assemble the washers spring B2 and castellated nut B1 on to the studs B to secure the burner cover to the heat exchanger Using a 10mm spanner tighten the castellated nuts B until the burner cover bottoms out on the heat exchanger The nuts will stop turning at this point do not overtighten If necessary back the nuts off slightly until the hole for the clip A is visible Insert the clips A and secure After re assembly check that the CO CO levels are as described in the section Setting the air gas ratio 6720648568 37 1Wo Fig 68 Burner removal Electrical wiring gt Check the electrical wiring for physical damage and replace any damaged wires To check the flap valve in the fan intake gt gt gt Refer to page 43 for access to the fan intake Carefully withdraw the flap valve from fan intake tube and check for soiling and splits clean or replace as required Take care when refitting the flap valve the flaps must open upwards into the fan in take tube After re assembly check CO CO2 levels as described in the section Setting the air gas ratio 6 720 815 062 2015 05 41 SERVICING and SPARES To clean the condensate trap gt Remove condensate pump refer to page 41 gt Remove screw retaining trap 1 gt Swing retainer 2 to release the condensate trap gt Remove trap 3 from boiler 6720648665 41 1Wo Fig 69 Condensate trap access 6 8 R
23. each side of the frame A for the boiler overhang F and minimum service clearance as shown gt Ensure the mounting frame is level and mark fixing points C gt Secure mounting frame A to the floor using appropriate fittings not supplied gt Clear any debris from the site Fig 21 Pipe positioning 6720648665 08 1Wo A Mounting frame B Manifold connections C Mounting frame fixing point D Wall E Gas and water pipe work not supplied F Boiler Flue opening gt Follow the figure 22 page 23 to mark the centre of the flue 1 amp 2 for rear opening 2 amp 3 for side opening or 1 amp 4 for top opening Measurements shown include the minimum service clearances Allhorizontal flue sections must rise away from the boiler D by 52mm per metre to ensure that condensate flows back into the boiler for safe discharge via the condensate waste pipe gt Cover the mounting frame manifold assembly A figure 21 page 22 to protect the manifold connections gt Make an opening X or Z through the wall using a core drill or similar at a size relative to the wall thickness as shown below Flue opening Flue opening Wall thickness 60 100mm9 80 125mm9 150 240mm 127mm 152mm0 240 330mm 127mm 152mm0 330 420mm 127mm 162mm0 420 500mm 140mm0 162mm0 Table 17 Where the flue terminal can only be fitted from inside the b
24. hole size for the condensate soak away must be 400mm deep by 300mm In situations where there are likely to be extremes of temperature or exposure the use of a proprietary 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 400mm min 25mm min 500mm min lt lt lt __ _ _ _ gt 6720648568 09 1Wo Fig 9 Soak away The pressure relief drain pipe 1 should be at least 15 mm diameter copper pipe and run downwards away from the boiler and discharge away from any electrical or other hazard preferably to an external drain or soakaway Pipe 3 should be finished with a partial bend near the outlet to face the external wall as shown to help prevent freezing SH 6720646608 123 1Wo Fig 10 Pressure relief pipe work 2 Outside wall 1 3 Drain pipe 4 Externa
25. of any irregularities Call up the last fault stored by the Bosch Heatronic Service Function 6A Refer to Fault Finding on page for rectification procedures w E Max pressure gt When the heating system water is at maximum temperature 2 5 bar must not be exceeded If this pressure is exceeded then an extra expansion vessel must be fitted into the system return as close as possible to the appliance gt Ifthe system does not retain the pressure the expansion vessel and the heating system should be checked for leaks 6 720 815 062 2015 05 37 CANORCESTER Bosch Group SERVICING and SPARES 6 2 Service function Setting boiler to maximum gt Whenrunning in the heating boost mode the boiler D will operate both the Central Heating and DHW circuits This is to allow sufficient time for setting procedure gt It willbe necessary to run water through the DHW circuit to ensure that the boiler will not cycle on low heating demands 6 3 Service inspection Grip the outer sides of the front panel A pull and lift away from retaining lugs B Remove retaining screw C to swing control panel assembly D outwards to its full extent Pull clip E outwards to release expansion vessel F Swing expansion vessel F outwards gt Press and HOLD central heating boost button L for 10 seconds and set Central Heating temperature to maximum The central heating boost button will illu
26. outer wall The flue terminal MUST be fitted with the TOP D uppermost to allow the correct fit and use of the plume management system WDE y 6720646219 13 1Wo Fig 34 Telescopic flue fitting 1 Roll the boiler into position on the floor mounting frame Position connector 1 with TOP uppermost to align with the three holes in the boiler inner casing 2 Secure the connector 1 to the boiler case using 3 hexagonal bolts 26 6 720815 062 2015 05 WORCESTER Bosch Group INSTALLATION TOP j 6720646219 17 1Wo 6720646219 15 2Wo Fig 35 Fitting flue outlet Fig 37 Fitting the adaptor elbow assembly Adapter elbow assembly 1 Push fit the adapter into the elbow until secured with the clip Horizontal low level flue exit 1 For horizontal low level side entry flues 2 Secure the flue adapter from inside the boiler case with the three hexagonal screws provided 6720646219 16 1Wo Fig 36 Adaptor elbow assembly Fitting the adapter elbow assembly 1 Slide the adaptor into the inner flue tube of the terminal 2 Slide the elbow into the flue outlet 1 ensuring that the clips 2 secure the elbow into position 6720646219 22 1Wo Fig 38 Side flue fitting 6 720 815 062 2015 05 27 INSTALLATION 1 Slide the adaptor into the inner flue tube of terminal as shown in figure 39 2 Push the elbow into flue outlet until secured wi
27. screws Go 6720646219 12 1Wo Fig 33 Converting from rear to side flue outlet ANORCESTER Bosch Group 4 4 Standard flue installation To ease assembly of the flue components grease seals lightly with the solvent free grease supplied gt Checkall the seals are seated properly in the grooves provided and are in good condition gt All flue joints must be sealed to prevent leakage of condensate and flue products DH gt When using a 100mm diameter flue a 125mm diameter hole through the wall is required However if installing the flue from inside the property and fitting the weather sealing collar before the flue is pushed through the hole then a 150mm diameter hole is required The flue connector for the 100mm flue has an in built 3 angle If extensions are to be added then the complete flue must rise at an angle of 3 or 52mm for every metre of flue length Drill the hole using a suitable core drill vv Set the flue terminal to the distance required secure with screw Seal the joint with the aluminium tape supplied Slide the inner wall seal onto the terminal as shown If fitting from inside the building slide the outer wall seal onto terminal 4 Position terminal through the flue opening in the wall to the outside of the building by the distance shown If fitting from the outside of the building slide the outer wall seal onto terminal to fit against the
28. system is not going to be accessible N provision must be made for service and inspection gt Voids containing concealed flues must have at least one inspection hatch no less than 300mm square gt Flue joints within the void must not be more than 1 5 metres from the edge of the inspection hatch gt Inspection hatches should be located at changes of direction gt Ifthisis not possible bends should be viewable from both directions Part number Flue Description 7716 191 155 60 100 Telescopic horizontal flue assembly 7716 191 157 80 125 Telescopic horizontal flue assembly 7716191 156 60 100 Vertical flue assembly 7716191 158 80 125 Vertical flue assembly gt each 45 bend used is equivalent to 0 75 metre of straight flue Plume management kits are available for the 60 100 horizontal flue system Part number 7 716 191 086 Refer to the manual supplied with the Plume Management kits for complete installation instructions NOTICE Effective flue lengths gt each 90 bend used is equivalent to 1 5 metres of straight flue ondensfit FLOOR Maximum total flue Highflow CDi boilers length L mm FLUE TYPE 60 100 80 125 1 Telescopic horizontal flue assembly 1401 530 350 1 200 2 Horizontal flue extension 4 000 13 000 3 Horizontal flue with 1 x 90 bend 2 000 11 000 4 Horizontal flue with 2x90 bends N A 9 000 5 High level horizontal flue 2 000 11 000
29. the electrode set and gasket gt Re assemble with the new gasket and secure with the screws B removed earlier gt After re assembly check that the CO CO levels as described in the section Setting the air gas ratio vvvvvy v 6 720 815 062 2015 05 45 SERVICING and SPARES Burner WARNING Burner A gt Do not remove the burner unless a new gasket is available for re assembly vv vvvvvvvy Check that the gas cock is turned off and the master switch is in the OFF position Isolate the appliance from the power supply Remove the clips C1 castellated nuts C and springs C3 from the studs C Unscrew and remove the 2 hexagon screws D securing the fan Remove nut and washer E1 from the rear stud E Remove the burner cover plate F Remove the burner G Re assemble the new burner in reverse order Replace the burner seal H with a new one Refer to the section Re assembly of the burner cover on page 41 After re assembly check that the CO CO levels as described in the section Setting the air gas ratio Primary heat exchanger vvvvvvvvvy vvvvyv Isolate the appliance from the power supply Turn off all the isolation valves Drain down the appliance Move the control and pressure vessel into service position Remove the inner case door Remove the fan assembly burner gas mixing tube Disconnect and remove the sensors connected to heat exchange
30. 0mm 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 4 7 8 9 1 200mm between terminals facing each other 5 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 at least a 3 fall back to the boiler for proper disposal of condensate except or the initial horizontal run from the terminal refer to note opposite For details on specific lengths see relevant boiler Technical and Specification information Internal external corners The air intake clearance can be reduced to 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 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 ta
31. 15 bar 1 5 1 5 Minimum pressure for max flow rate 25 l min 15 bar 1 7 1 7 Specific rate 30 C rise heat store hot ltr min 20for10 min 25for1Omin 20for1Omin 25 for 10 min Specific rate 30 C rise heat store off Itr min 14 19 6 14 19 6 Time to heat tank 15 C to 65 C mins 13 13 13 13 Gas flow rate Max 10 minutes from lighting Natural Gas G20 m2 h 3 1 4 4 Propane Gas LPG kg h 2 3 3 2 Gas supply pressure Natural Gas G20 mb 20 20 LPG Propane Gas G31 mb 37 37 Flue Flue Gas Temp 80 60 C rated min load C 67 55 67 55 67 55 67 55 Flue Gas Temp 40 30 C rated min load C 43 32 43 32 43 32 43 32 CO2 level at max rated heat output 9 4 9 4 10 8 10 8 CO2 level at min rated heat output 8 6 9 0 10 4 10 4 NOx classification class 5 5 5 5 Condensate Max condensation rate I h 2 7 3 7 2 7 3 7 pH value approx 4 8 4 8 4 8 4 8 Electrical Electrical power supply voltage AC V 230 230 230 230 Frequency Hz 50 50 50 50 Max power consumption W 164 206 164 206 Expansion Vessel Charge Pressure bar 0 75 0 75 0 75 0 75 Total Capacity ltr 12 12 12 12 General Data SAP 2009 annual efficiency 89 2 89 2 90 2 90 2 SAP 2005 seasonal efficiency SEDBUK 90 8 90 8 92 2 92 2 Appliance protection rating IP x4D x4D x4D x4D Appliance protection rating with mechanical timer MT1ORF or IP 20 20 20 20 FW100 fitted into fascia Permissible ambient temperatures C 0 50 0 50 0 50 0 50 Nominal capacity of appliance ltr 51 51 51 51 Noise ou
32. 3 Sound power level indoors Lwa dB A 53 53 52 52 Additional data for combination heaters Declared load profile XL XL XL XL Daily electricity consumption Qelec kWh 0 350 0 350 0 357 0 357 Annual electricity consumption AEC kWh 77 77 79 79 Daily fuel consumption Qtuet kWh 27 356 27 356 28 047 28 047 Annual fuel consumption AFC GJ 1 672 1 672 1 714 1 714 Water heating energy efficiency Nwh 72 72 71 71 Water heating energy efficiency class B B B B Table 8 Product data for energy consumption 1 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet 2 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet 6 720 815 062 2015 05 CANORCESTER Bosch Group APPLIANCE INFORMATION 2 4 Layout and components ZS E IT THS E iii Dine a E f L Gi UA N 6 720 815 062 02 10 8 6 720815 062 2015 05 4 WORCESTER Bosch Group APPLIANCE INFORMATION 1 CONTROL PANEL 23 DHW OUTLET 2 MASTER SWITCH FOR ON OFF 24 GAS ISOLATION VALVE 3 BURNER ON INDICATOR LIGHT GREEN 25 MAINS WATER IN
33. 5 Table 23 CO CO settings 6 7 Cleaning heat exchanger NOTICE COMBUSTION TESTING gt Combustion testing must be carried out by a competent person Testing must not be attempted unless the person carrying out the combustion check is equipped with a Combustion Analyser conforming to BS 7927 and is competent in its use NOTICE CO CO CHECKS gt Ifthe joint between the Air Gas manifold and heat exchanger is disturbed the sealing gasket must be replaced gt After completing the service of the appliance the CO CO must be checked and set to the limits shown in Setting the air gas ratio on page 40 WARNING Cleaning access cover A gt Do not remove the cover unless a new gasket is available for re assembly If the heat exchanger requires cleaning Anaccessory kit is available No 840 specifically designed for cleaning the heat exchanger If required order 7 719 001 996 2 Remove the cleaning access cover B seal C and metal plate D securing it if present 3 Unscrew the condensation trap cap and place a suitable container underneath D Use a new seal when reassembling 4 Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade gt Clean the heat exchanger from top to bottom using the brush gt Refit the clean out access cover in reverse order using a new seal C hand tighten screws and then use a spanner to tighten a further half
34. 6 el I DZ JI ER J Fig 51 Fascia guide A Master switch for ON OFF B Mains ON OFF indicator fault diagnostic light C Central heating temperature control D Burner on indicator light green E Fault reset button F Service button G Domestic hot water temperature control H ECO button domestic hot water pre heat ON OFF I System pressure gauge J Position for optional programmer K Display L Central heating boost button M Notused Switching the appliance on off NOTICE Never run the appliance when the appliance or N system is empty or unpressurised 1 Turn on mains power supply 6720648568 28 1Wo Fig 52 Fused double pole isolator gt Turm on any external controls gt Set the TRV controls to maximum gt Set the clock programmer to continuously ON and the room thermostat to maximum temperature 2 Press button A and the power on indicator B illuminates blue A 2 at 400 EA CH Nd A A ML I Bo Fig 53 Turning on the appliance 6720648665 17 1Wo 3 Turn the temperature control C to maximum The burner on indicator D illuminates green when the burner has lit 6 720 815 062 2015 05 33 COMMISSIONING CANORCESTER Bosch Group The boiler runs for 15 minutes at minimum heating output to fill the condensate trap This occurs every time the mains supp
35. 6 High level horizontal flue with 2 x 90 N A 9 000 bends 7 High level horizontal flue with 3 x 90 N A 7 000 bends Vertical balanced flue assembly 6 400 15 000 9 Vertical balanced fluewith2x90 2 400 11 000 bends 10 Vertical balanced flue with 2x45 4 400 13 000 bends Table 15 Flue options 1 The flue is cut to a minimum of 130mm the flue connector adds the additional 10mm The flue systems have different maximum flue lengths The next page shows various fluing options Refer to the Flue options in table 15 for the straight flue lengths required to achieve the maximum flue length Table 16 Flue options 18 6 720 815 062 2015 05 CANORCESTER Bosch Group 350 mm 570 mm The JM b H 1 Uu Gm Da ragasa 00 mm 300 mm PRE INSTALLATION 6720648568 17 1Wo 6 720 815 062 2015 05 PRE INSTALLATION 3 9 Plume management terminal positions All measurements in millimetres CANORCESTER Bosch Group Plume re direction IE lt 3 Outlet Flue Exhaust Air Intake Flue terminal guard 7 716 191 176
36. 9 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 1Code of practice for domestic and hot water supply BS6891 Installation of low pressure gas pipe work up to 28mm R1 BS5546lnstallation of gas hot water supplies for domestic purposes CANORCESTER Bosch Group EN12828 Central heating for domestic premises BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 7 OkW net Flues BS5440 2Flues and ventilation for gas appliances of rated heating not exceeding 7 OkW net Air Supply BS7593Treatment 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 ECTI National rules for electrical installations 1 813 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 in BS5440 Part 1 and IGE Gas Installations in Timber Frame Buildings should be adhered to Potable water All seals joints and compounds including flux
37. ANT SAFETY PRECAUTIONS NOTICE COMPONENTS gt After replacement of any components always check for gas tightness where relevant and carry out functional checks as described in Commissioning Damaged O rings or gaskets must be replaced Gas Safe registered personnel NOTICE SERVICE MUST NOT BE ATTEMPTED IF A CO CO ANALYSER IS NOT AVAILABLE gt After servicing complete the relevant Service Interval Record section of he Benchmark Checklist located on the inside back pages of this document NOTICE Service work must be carried out by a N competent registered engineer such as British Gas or To ensure the continued efficient operation of the appliance it must be checked at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage however an annual service is recommended The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers Inspection 1 Check that the terminal and the terminal guard if fitted are clear and undamaged 2 If the appliance is in a compartment or cupboard check that the specified service space around the appliance is clear Check all the joints and connections in the system and remake any that show signs of leakage Refill and re pressurise if applicable as described in Commissioning Operate the appliance and take note
38. B PUMP SUPPLY el Outside sensor FW 100 ei Colour sequence gt External volt free FAN programmer option used with MT10 timer 230V HW interface Installer Module located to the right of the control panel MAINS L SUPPLY Fig 80 TANK SENSOR TANK OVERHEAT FLOW TURBINE c l Zil SOLENOID f SOLENOID Ze FLAME SENSE SPARK ELECTRODE ELECTRODES FLOW NTC OVERHE T STAT DIVERTER PUMP VALVE SAFETY SAFETY HIGH LEVEL SENSOR CONDENSATE PUMP External 230V twin channel programmer option 6 720 815 062 29 10 48 6 720815 062 2015 05 FAULT FINDING and DIAGRAMS Bosch Group CAVORCESTER Central heating function 7 2 OZ vE Z90 S18 9022 9 anjen yes sAoge s sInjelsdwe seynuw 0 dn soy _ 440 M I Gay paysyes un uey pue dund Sasojd NJea SEO puewep HO saynulw GL 10 jndu jesy wnuruiw SAA spuooes Dumes spuooes 0L G o U09 HD ponad 06 KE 10 _ pue peo uajs s Buo 104 lt Joy lt j wun lt pasds peu o ON pesnun poads Zeen yes je sajeiado Jajlog um ue KR sasijiqeis Jellog i Jeuung J8 EM JI UMOp JNUsS aunyesadwia I8A0 NO sulewes dund SINUS AJLA ses au
39. EMS The boiler comes with an internal fitted filling loop system and can be used to fill the system The CH sealed system must be filled using a WRAS approved filling loop or comply with the diagram below for system fill externally fitted The filling point must be at low level and must never be a permanent direct fixing to the mains water supply SYSTEM FILL External option Heating Mains return supply Hose union SV Temporary hose CV Check Valve SV Stop Valve Fig 4 External filling option SHOWERS BIDETS Ifa shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill over level then an anti siphon device must befitted to the shower hose Bidets with direct hot and cold mains water can be used with the approval of the local water authority and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays DOMESTIC HOT WATER Taps and mixing valves must be capable of sustaining a pressure up to 10 bar Hot water temperature and flow rate are affected by the size and insulation of pipe work making up the distribution system and are controlled by the hot water tap and the water main inlet pressure A mixing valve can be fitted if a more permanent setting is required fusing more than one outlet at once causes water flow starvation fit flow balancing valves or Ball O Fix valves to the appropriate outlets
40. Fig 1 1 2 3 4 5 6 goo 00mm 850mm 6720648665 01 20 Standard package Floor standing gas fired combination boiler for central heating and domestic hot water Mounting frame complete with pre plumbing manifold assembly Literature pack Installation pack Condensate waste pipe and non return valve ErP energy label 6 720 815 062 2015 05 APPLIANCE INFORMATION 2 2 Technical data WORCESTER Bosch Group DESCRIPTION UNITS Natural Gas L P G 440CDi EE 550CDi EP 440CDi EP 550CDi EP Central Heating Max rated heat output net 40 30 C kW SZ 32 8 312 32 8 Max rated heat output net 50 30 C kW 30 9 32 5 30 9 32 5 Max rated heat output net 80 60 C kw 29 2 30 6 29 2 30 6 Max rated heat input net kW 29 6 31 29 6 31 Min rated heat output net 40 30 C kW 8 4 11 11 6 13 4 Min rated heat output net 50 30 C kW 8 3 10 9 11 4 13 2 Min rated heat output net 80 60 C kW 7 4 9 7 10 5 12 1 Min rated heat input net kw 7 6 10 10 8 12 5 Max flow temperature C 88 88 88 88 Max permissible operating pressure bar 235 2 5 2 5 2 5 Domestic Hot Water Max rated heat input net kW 29 6 41 5 29 5 41 5 Max rated heat output kW 29 5 41 1 29 2 41 1 Minimum flow rate to start l min 2 3 2 8 2 3 2 8 Minimum pressure for max flow rate 20 l min
41. Gas pressure within the system The boiler must be running at maximum output rate when performing the gas rate check Refer to the figures below for natural gas or L P G gas pressures The pressure at the boiler must not be less than the pressure read at the meter minus 1 mbar for Natural Gas 2 5 mbar for L P G The pressure drop from the meter to the gas valve must not be more than 2 5 mbar for Natural Gas 4 mbar for L P G If the pressure drops are greater than shown below then this would indicate a problem with the pipe work or connections within the system Meter Natural Gas ceca lt 2 5mbar difference 19 23 mbar l 16 5 20 5 mbar Boiler inlet 1 mbar i il 1 5 mbar drop ps2 p drop 18 22 mbar 6 720 815 062 44 10 Fig 57 Natural gas pressures lt Equal to or less than Regulator Gas Control L P G valu lt 4 0mbar difference i 28 41 mbar Boiler inlet 2 5 mbar lt a 1 5 mbar drop s drop e 29 5 42 5 mbar Fig 58 L P G pressures NOTICE Do not continue commissioning until the correct gas pressure is achieved 6 720 815 062 45 10 34 6 720 815 062 2015 05 CAWORCESTER Bosch Group gt If pressure is satisfactory press the Central heating boost button L again and the boiler will return to normal operation gt If left in the central heating boost mode t
42. Installation Commissioning and Servicing Instructions Floor standing RSF gas fired condensing combination boiler Greenstar Highflow 440CDi DT amp 550CDi P s fed domestic hot water The appliances are for use with Natural Gas or L P G Cat II 2H3P type C13 C33 amp C53 Natural Gas 440CDi EP GC number 47 406 85 550CDi EP GC number 47 406 87 gt L P G 440CDi EP GC number 47 406 86 550CDi EP GC number 47 406 88 6720648665 00 1Wo THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 4 NORCESTER Bosch Group 6 720815 062 2015 05 WORCESTER Contents Bosch Group Contents 1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS 3 6 SERVICING and SPARES 37 1 1 Key to Symbols td oO ELA Ol ences 3 6 1 Inspection and service 37 1 2 Safety precautions 3 6 2 Service function 0 cece 38 6 3 Service inspection 0 ccc eee cece 38 6 4 Fan pressure test 38 2 APPLIANCE INFORMATION ececececeees 5 6 5 Fluegasanalysis 0eccceeeeeeeeeeeees 39 2 1 General information 5 6 6 Settingtheair gasratio 1 40 2 2 Technical data wee ostoi dok EE PGA 6 6 7 Cleaning heatexchanger 40 2 3 Product data on energy consumption 7 6 8 Deplacement parts 42 2 4 Layoutand components 1 1 8 6 9 Sbhotpartslet nonno annann na
43. LET ISOLATION VALVE 4 SERVICE BUTTON 26 CH RETURN ISOLATION VALVE 5 CENTRAL HEATING BOOST BUTTON 27 RUNNER WHEEL ON MOUNTING FRAME 6 DISPLAY 28 INSTALLER MODULE PROTECTIVE COVER 7 RESET BUTTON 29 LOW ENERGY CIRCULATING PUMP 8 ECO BUTTON 30 CONDENSATE PUMP ASSEMBLY 9 NOT USED 31 GAS VALVE 10 CH TEMPERATURE CONTROL 32 EXPANSION VESSEL 11 MAINS ON OFF INDICATOR amp FAULT DIAGNOSTIC LIGHT 33 AIR GAS ADJUSTMENT SCREW SEALED 12 DHW TEMPERATURE CONTROL 34 HEAT CELL 13 SYSTEM PRESSURE GAUGE 35 CH FLOW TEE PIECE 14 POSITION FOR OPTIONAL PROGRAMMER 36 GAS BURNER SPARK ELECTRODES 15 TANK TEMPERATURE SENSOR 37 COMBUSTION AIR MODULATING FAN 16 TANK OVERHEAT THERMOSTAT 38 FLUE BLANKING PLATES 17 DHW HEAT EXCHANGER 39 CASING SUPPORT STRUT 18 FILLING LOOP ISOLATION VALVE 40 CASE KNOCK OUT PANEL FLUE 19 WATER FLOW SENSOR TURBINE 41 AUTO AIR VENT 20 BOILER TANK DRAIN amp CONNECTION POINT FOR FILLING LOOP 42 SYSTEM PRESSURE RELIEF VALVE 21 DHW TEMPERATURE SENSOR 43 HEAT STORE 22 CH FLOW ISOLATION VALVE Table 9 6 720 815 062 2015 05 PRE INSTALLATION 4 WORCESTER Bosch Group 3 PRE INSTALLATION 3 1 Cleaning primary systems NOTICE Before installation gt Allthe following Pre Installation sections must be read and requirements met before starting boiler or flue installations CAUTION MAINS POWER gt ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS gt
44. Maximum mains fed water pressure 10 bar If necessary fit a pressure reducing valve NOTICE Non return flow back prevention devices including those associated with water meters fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances Where the mains water supply has a non return flow back prevention valve fitted a mini expansion vessel 1 should be connected to the mains water inlet pipe 2 between the non return valve 3 and the boiler 4 as shown below 6720643895 04 1Wo Fig 2 Mains water pressure Mini expansion vessel part no 7 716 102 105 Mains water inlet pipe Non return valve RB wW N HH Boiler Table 11 USE IN HARD WATER AREAS Normally there is no need for water treatment to prevent scale formation asthe maximum temperature of the HW heat exchanger is limited by the electronic control In areas where temporary water hardness exceeds 200ppm consideration may need to be given to the fitting of a scale prevention device In such circumstances the advice of the local water authority should be sought PRE INSTALLATION 3 3 Water systems and pipe work PRIMARY SYSTEM PLASTIC PIPEWORK Any plastic pipe work must have a polymeric barrier with 600mm minimum length of copper connected to the boiler Plastic pipe work used for under floor heating must be correctly controlled with a thermostatic blending va
45. NG INSTALLATION 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 helpline 0330 123 3366 Please leave these instructions with the completed BENCHMARK 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 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 Table 1 SYMBOLS USED IN THIS MANUAL Domestic Hot Water Installation manual Table 3 0 Diameter NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot Water DCW Domestic Cold Water PRV Pressure Relief Valve NTC Negative Temperature Coefficient sensor IP Ingress Protection RCD R
46. a suitable container for safe disposal Fig 73 Condensate pump 6720648568 43 1Wo 6 720 815 062 2015 05 43 SERVICING and SPARES Diverter valve motor gt Ensure that the appliance is in service mode there is no need to drain the appliance gt Disconnect the electrical connector K from diverter valve motor L gt Pull the motor L to you the assembly will slide free from the valve gt Torefit follow the reverse of above In case of problems when refitting the motor connect D the electrical connector to the motor and switch the appliance on When the motor goes into the middle position the motor can be fitted without difficulty Diverter valve gt Ensure that the appliance has been fully drained gt Disconnect the electrical connector K from diverter valve motor L gt Undo the two screws holding the valve actuator body to the plastic housing N gt Remove the motor and valve actuator body from the diverter valve gt Withdraw the valve actuator from the diverter valve gt Torefit assemble in reverse ensuring that the valve actuator is properly seated on the two lugs of the actuator body O RO yi NN 6 720 815 062 25 10 Fig 74 Diverter valve Sensors gt Check that the appliance is electrically isolated Central heating flow temperature sensor A gt Remove the connector gt Release the sensor clip and withdraw the sensor gt Apply heat t
47. ale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate OR Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at all outlets Yes 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 U en Amar COLLECTIVE MARK Competent Persons Scheme A Building Regulations Compliance Cert
48. alidate any warranty FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance may only be carried out by a competent 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 and 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 IEE Regulations Building Regulations Building Standards Scotland Consolidation Building Regulations Northern Ireland local water by laws Health and Safety Document 635 The Electricity at Work Regulations 198
49. ana 47 3 PRE INSTALLATION Z 10 FAULT FINDING and DIAGRAMS ecccceee 48 3 1 Cleaning primary systems 10 7 1 Electrical wiringdiagram 48 3 2 Mains sun 0 0s esses ee ee ee ee et et ees 10 7 2 Central heating function 49 3 2 1 Electricalsupply 10 7 3 DIW FU EEN 50 3 2 2 Gas Supply 0 esse eee teeter eet eters 10 7 4 Protection function SKS RANNER EEN 51 3 2 3 Water supply 0 sees eee ee et ee teeter ees 11 7 5 Faultfinding o on 52 3 3 Water systems and pipe Work 11 7 6 Condensate pump Indicator lights 53 3 4 Condensate pipe work 12 3 4 1 Internalconnections aaaa aaa aaa eee 12 3 4 2 External connections eec cece eae 13 3 5 Pressure relief pipe work 14 3 6 Boiler location and clearances 15 3 7 Flue terminal positions 17 3 8 Flue 6PUONS wawa EE Ae 18 3 9 Plume management terminal positions 20 d INSTALLATION 2 00 aa 0 NEE 21 4 1 Unpacking the boiler aaaaaaaaa112 21 4 2 Mounting frame fixing and flue opening 22 4 3 Flue measuring and cutting 1 1 23 4 3 1 Flueextensionexample 24 4 4 Standard flue installation 005 26 4 5 Flue terminal plume re direction 28 4 6 Condensate gas and water connections 29 4 7 Pressure relief valve outlet
50. 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 6 720 815 062 2015 05 CAWORCESTER Bosch Group 2 APPLIANCE INFORMATION 2 1 General information BOILER FEATURES AND CHECKLIST Pre wired and pre plumbed Galvanised steel inner frame Digital control system FX Intelligent controls Automatic ignition Direct burner ignition electrodes Built in frost protection Built in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor and control Pump anti seizure protection Flue gas temperature sensor Condensate trap and pump DHW flow sensor and temperature control Plate type DHW heat exchanger CHECK LIST LITERATURE PACK Qty Greenstar 440CDi EP amp 550CDi EP Installation 1 Commissioning and Servicing Instructions Users Instructions 1 Table 5 Literature pack checklist CHECK LIST INSTALLATION PACK Qty Sealing Pack Compression Nut 22mm Compression Ring 22mm Compression Nut 15mm Compression Ring 15mm Fibre Washer 18 6 x 13 5 x 1 5 Fibre Washer 23 9x 17 2 x 1 5 e NINI ojl ojoj wje Bonded Washer 3 4 Table 6 Installation pack checklist APPLIANCE INFORMATION STANDARD PACKAGE
51. and thoroughly flush the system to remove the flushing agent and debris INHIBITOR Central Heating gt Check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor compatible with aluminium or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system water in accordance with the manufacturers instructions The pH value of the system water must be less than 8 or the appliance warrantee will be invalidated D gt Fill the system to between 1 and 1 5 bar via the supplied internal WRAS approved filling loop figure 50 page 32 gt Vent the boiler and all radiators retighten vents when complete gt Record the date when the inhibitor was added to the system on the guarantee card NOTICE gt The concentration of inhibitor in the system 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 gt Incases where all attempts to find a micro leak have failed Worcester Bosch Group supports the use of Fernox F4 leak sealer COMMISSIONING 5 4 Starting the appliance K A Aa O Ee fl M eg d Met 188 E D Ar A o Delat E E Je 0 R eet H Ces Ra NM Lesch RY Ss
52. anger close the mains water inlet isolation valve and drain the hot water circuit Close the CH isolating valves and drain the appliance The pipe A may be removed between the flow sensor outlet and the plate heat exchanger to improve access to the rear connections gt Undo the two screws securing the plastic housing to the heat exchanger gt Remove the heat exchanger gt Torefit follow the above in reverse Ensure any seals that have been disturbed are replaced 44 6 720 815 062 2015 05 WORCESTER Bosch Group SERVICING and SPARES Pressure gauge gt Remove the trap 3 from boiler gt Drain the appliance gt Unplug the connection to the pressure relief valve gt Remove the two screws from rear of control panel and remove pressure gauge 4 gt Replace the O ring and replace pressure gauge _ mS Expansion vessel Drain the appliance Move the control panel into service position Remove the locking screw C from vessel bracket Hinge the pressure vessel out and lift from brackets Undo the union connection at the top of the vessel Set the pressure of the new vessel to that required by the system vvvvvyv 6720648665 41 1Wo Pressure relief valve Drain the appliance Fig 77 Condensate trap access Disconnect the drain pipe from valve D Undo the nut retaining valve to flow pipe Undo the nut connecting pressure gauge Remove the valve Replace the sealing washer and f
53. e is a safety device for N the boiler and if activated may discharge boiling water or steam through the P R V drain pipe Auto air vent gt Remove the auto air vent cap C and discard 6 720 815 062 11 10 Fig 44 PRV amp AAV 4 8 Electrical BEFORE STARTING ANY WORK AND OBSERVE ALL CAUTION ISOLATE THE MAINS ELECTRICITY SUPPLY RELEVANT SAFETY PRECAUTIONS CANORCESTER Bosch Group gt The mains electrical supply to the boiler and system D wiring centre must be common and through either a common fused double pole isolator or a fused three pin plug and unswitched socket gt The isolator shall be sited next to the boiler for new systems and where practicable replacement boilers gt The isolator must have a contact separation of 3mm minimum between all poles Any system connected to the boiler must not have a separate electrical supply gt External fuse 3 Amps gt When stripping wires ensure copper strands do not fall into the control box Access to electrical connections Remove boiler casing to access control panel 1 Remove screw A and swing the control panel into the service position 6 720 815 062 12 10 Fig 45 Control box in service position 2 Remove the three screws B in the control panel and remove the connections cover gt Remove the screw C and rem
54. e pH levels of the water With these devices it may not be necessary to provide an untreated water by pass to the primary water filling point of the heat system 3 2 Mains supply 3 2 1 Electrical supply Supply 230V 50 Hz 140 Watts Cable PVC insulated 0 75 mm2 24 x0 2 mm temperature rated to 90 C External 3A fuse to BS1362 The appliance must be earthed This appliance must not be connected to a three phase supply IPX4D NOTICE This is reduced to IP20 if the following mechanical timers are fitted 7 716 192 036 or 7 716 192 037 or clip in weather compensating controller Wiring must comply with the latest IEE wiring regulations 3 2 2 Gas supply Boilers using Natural Gas NG must be connected to a governed meter Liquid Petroleum Gas LPG must be connected to a regulator 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 10 6 720 815 062 2015 05 CANORCESTER Bosch Group 3 2 3 Water supply WATER MAINS PRESSURE Minimum mains water pressure 1 7 bar for maximum performance
55. eplacement parts CAUTION N gt TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS ELECTRICAL SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS gt DRAIN THE BOILER SYSTEM WHERE NECESSARY AND PROTECT ANY ELECTRICS FROM WATER INGRESS DURING COMPONENT REPLACEMENT NOTICE gt Refit or replace any components removed from the appliance in the reverse order using new gaskets O rings sealant heat transfer paste where necessary gt Any OT ring or gasket that appears damaged must be replaced Always check that any electrical connections are correctly made and that all screws are tight AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR GAS TIGHTNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS DESCRIBED IN THE COMMISSIONING SECTION NOTICE gt Any service work must be carried out by competent registered engineers such as British Gas or other GAS SAFE registered personnel gt After re assembly the combustion must be checked using the procedure in the section Setting the air gas ratio Measurement and setting of the gas ratio must not be attempted unless the person is equipped with a combustion analyser conforming to BS 7927 and is competent in its use CAVORCESTER Bosch Group DRAINING THE APPLIANCE gt Turn off the system heating flow and return isolation valves external to boiler 1 Unscrew the tank drain cap from the drain tank valve A 2 C
56. esidual Current Device TRV Thermostatic Radiator Valve ECV Emergency Control Valve WRAS Water Regulations Advisory Scheme SEDBUK Seasonal Efficiency of Domestic Boilers in the UK Central Heating Hot Water Storage Cylinder Domestic Cold Water Supply Electrical Supply Gas Supply NOE Table 2 Commonly used symbols Table 4 Abbreviations use in this manual 1 2 Safety precautions If you smell gas Agas leak could potentially cause an explosion If you smell gas observe the following rules gt Prevent flames or sparks Donotsmoke use a lighter or strike matches Do not operate any electrical switches or unplug any equipment Donotuse the telephone or ring doorbells Turn off the gas at the meter or regulator 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 gt L P G boilers Call the supplier s number on the side of the gas tank BOILER OPERATION This appliance can be used by children aged from 8 years and above and persons with reduced physical sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in asafe way and understand the hazards involved Children shall not play with the appliance Cleaning and user maintenance shall not be made
57. etermination 1 Flue adaptor stop point L Effective length of the flue system R Actual length of the flue sections L 10 R E Extension flue length T Telescopic flue length FLUE BENDS NOTICE EFFECTIVE LENGTH Each flue bend is rated as a certain straight length of flue refer to table 20 page 24 below The effective length of each bendis added to the straight length of flue Adding bends to the flue system reduces the actual flue length available The effective length of the flue must not exceed that stated in the relevant appliance Installation commissioning and service manual CANORCESTER Bosch Group Effective length in millimetres Bend HF 440 550 CDi FP amp FS 30 42 CDi EP 90 2000 45 1000 Table 20 Effective length of bends 90 BENDS Figure 25 shows the actual length added by a 90 bend when used in either orientation 6720644842 04 2Wo Fig 25 90 Bend offset dimensions aDJUSTING THE TELESCOPIC FLUE LENGTH i LED mm gt lt 310 mm gt 6720646219 06 2Wo Fig 26 Standard telescopic flue Extend tube 1 by withdrawing from tube 2 to achieve the flue length required between 310 530mm Secure with screw provided and seal joint with the aluminium tape supplied REDUCING THE TELESCOPIC FLUE LENGTH Ensure that the TOP label of both sections are aligned D before securing the two parts at the required length
58. gister No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Com Signature SERVICE 03 Signature SERVICE 04 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 SERVICE 05 Signature SERVICE 06 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 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 SERVICE 09 Signature SERVICE 10 Engineer name Engineer name
59. he control will return to normal operation after 15 minutes gt Re seal the screw in the gas inlet pressure test point 5 5 2 Checking the gas rate gt The gas rate should be measured at the gas meter after 10 minutes operation at maximum refer to technical data in section 2 2 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 the air gas ratio gt refer to section 6 6 gt f pressure and gas rate are satisfactory press the service button again and the boiler will return to normal operation If leftin the service 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 vvvvvy 5 6 CO and combustion check 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 sections e Checking flue integrity Flue gas analysis refer to section 6 5 page 37 NOTICE Before CO and combustion checks gt Refer to section 5 5 1 and 5 5
60. i EP 155cm 550CDi EP 220cm For air from internal space room 440CDi EP 310cm 550CDi EP 440cm CAWORCESTER Bosch Group 6 BATHROOMS NOTICE Any switch or appliance control using mains N electricity must not be within reach of a person usingthe bath or shower A boiler fitted with a mechanical RF mechanical timer or a clip in weather compensating controller may only installed outside the shaded area A boiler fitted with any other timer or blanking panel can be installed in zone 2 Additional RCD Residual Current Device protection may be required Refer to the latest IEE wiring regulations 800mm E E D N N 2250mm 6720646608 124 3Wo Fig 16 Bathroom installations 16 6 720 815 062 2015 05 CANORCESTER Bosch Group 3 7 Flue terminal positions All measurements in millimetres gt 600 500 PRE INSTALLATION gt gt TT 300_300 O 6 LL 4 BA 300 Fig 17 Flue terminal positions flue bracket 100mm part number 7 716 191 177 flue brackets 100mm x
61. ificate 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 720815 062 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0330 123 9779 LITERATURE 0330 123 9119 TRAINING 0330 123 0166 SALES 0330 123 9669 4 NORCESTER Bosch Group
62. ischarge Terminal end Minimum 1500mm from an opening in the building Table 22 Key to figure 41 RB wW N re 28 6 720 815 062 2015 05 CAVORCESTER Bosch Group 4 6 Condensate gas and water connections CONDENSATE CONNECTION The condensate pump G fills up and periodically discharges through the flexible condensate pipe H between 200mm to 4500mm from floor level After this point the condensate flows due to gravity down the 21 5mm plastic pipe to the outlet gt Fitthe bayonet connector on the end of the condensate waste pipe to the condensate pump Push down and rotate clockwise until the connector is locked gt Route and secure condensate waste pipe H with clips supplied to prevent kinking or restriction gt Cut off any excess pipe H gt Fitthe condensate waste pipe H to adaptor K and secure with clip J gt Connect adaptor K to 21 5mm plastic pipe and terminate into an internal waste trap 7 Max 4500mm __ Min 200mm Y 6720648665 39 1Wo Fig 42 Condensate connection See Pre Installation section for condensate pipe work running from the adaptor K to the discharge outlet Never terminate or discharge into any open source including sink bath shower bidet toilet etc gt Any external condensate pipe work should be protected with weather resistant insulation to help prevent freezing gt The flexible pipe supplied can o
63. it a new valve Gas valve gt Check that the gas cock is turned off gt Remove the condensate pump vvvvvyv 1 Undo the union within the inner casing securing the valve to the gas air tube Remove the black rubber tube from the gas valve G Release the gas inlet union at the inlet Remove the solenoid connections at the side of the gas valve Check for gas tightness when the new gas valve has been fitted After re assembly check CO CO2 levels as described in the section Setting the air gas ratio 2 3 4 gt Transfer the inlet pipe assembly to the new gas valve gt gt 6 720 815 062 27 10 Fig 76 Replacement parts 6720648568 47 1Wo Condensate trap gt Move the control panel and pressure vessel into service position gt Remove the inner case door Fig 78 Gas valve gt Remove the condensate pump refer to page 43 Electrode assembly and heatshield gt Remove the screw retaining trap 1 Switch EEN gt Swing the retainer 2 to release the condensate trap Isolate the appliance from the power supply Move the control panel into service position Release the 4 screws to remove inner case door Remove the leads from the electrodes Unscrew the two fixing screws B and carefully remove the electrode assembly A Inspect the spark flame electrode assembly and ceramics for signs of contamination or damage replace as necessary gt Replace
64. ken when siting terminals in relation to surfaces facing a terminal D 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 Dimensions from a flue terminal to a fanned air inlet to be determined by the ventilation equipment manufacturer The initial plume kit horizontal run will have at least a 10 fall back to the boiler due to the terminal elbow design for proper disposal of the condensate 20 6 720 815 062 2015 05 CANORCESTER Bosch Group 4 INSTALLATION CAUTION ROOF SPACE N gt THIS BOILER IS NOT SUITABLE FOR ROOF SPACE INSTALLATION NOTICE Boiler start up N gt Allthe previous Pre Installation sections must be read and requirements met before starting boiler or flue installation 4 1 Unpacking the boiler NOTICE BOILER HANDLING gt Atalltimes the correct method for handling heavy objects should be strictly observed gt Take care not to damage the boiler panels or the floor gt The boiler may contain some water due to factory testing gt Store the boiler ina dry area prior to installation Unpacking 1 N v E v Undo the ties securing the carton to the pallet If a sharp implement is used care must be taken not to pierce the carton or cause injury Before removing the carton itis advised that the top fla
65. l drain 14 6 720815 062 2015 05 CAVORCESTER Bosch Group 3 6 Boiler location and clearances This boiler is only suitable for installing internally within a property at a Suitable location onto a fixed rigid non combustible surface at least the same size as the boiler and capable of supporting the boiler weight The boiler is not suitable for external installation unless a suitable enclosure is provided COMMERCIAL INSTALLATION Ifinstalling more than one appliance in a modular or cascade arrangement in a commercial premises that total more than 70kW then additional ventilation is needed to comply with the Dangerous Substances and Explosive Atmospheres Regulations DSEAR Compartments Follow the requirements of BS6798 and BS5440 Part 2 and note Minimum clearances must be maintained An access door is required to install service and maintain the boiler and any ancillary equipment If fitting the boiler into an airing cupboard use a non combustible perforated material maximum hole sizes of 13 mm to separate the boiler from the airing space 1 INSTALLATION CLEARANCES The dimensions below are the minimum space required to install the boiler only 1450mm 5 3 I 6720648568 11 1Wo Fig 11 Installation clearances PRE INSTALLATION 2 SERVICE CLEARANCES The dimensions below are the minimum space required to service the Fig 12 Service clearances 25mm to a removable
66. lve limiting the temperature of the circuits to approximately 50 C The pipe work from the boiler to the blending valve must be in copper PRIMARY SYSTEM CONNECTIONS VALVES Do not use galvanised pipes or radiators Allsystem connections taps and mixing valves must be capable of sustaining a pressure of 3 bar Radiator valves should conform to BS2767 10 All other valves should conform to BS1010 On newinstallations TRV s should be used on all radiators except the radiator where the room thermostat is sited this must befitted with lock shield valves and left open All installations should have TRV s fitted to radiators within the sleeping accommodation Drain cocks are required at all the lowest points on the system Air vents are required at all high points on the system SEALED PRIMARY SYSTEM Where the system volume is more than 100 litres or exceeds 2 5 bar at maximum heating temperature an extra expansion vessel 2 must be fitted as close as possible to the appliance in the central heating return Pressurise the extra expansion vessel 2 to the same figure as the expansion vessel built into the appliance REFER TO TECHNICAL DATA TABLE Ill pte all li 6720648665 04 20 Fig 3 Typical sealed system 1 Appliance expansion vessel 2 Extra expansion vessel 3 Pressure relief discharge 4 Drain cock 5 Radiators 6 720 815 062 2015 05 11 PRE INSTALLATION FILLING PRIMARY SYST
67. ly Group help line CO CO ratio i No further action 0330 123 3366 lt 0 004 is required 6720809056 01 1Wo Fig 59 Commissioning checks 36 6 720 815 062 2015 05 CANORCESTER Bosch Group 5 7 Finishing commissioning SERVICING and SPARES At the time of commissioning complete all relevant sections of the Benchmark Checklist located on the inside back pages of this document 6 SERVICING and SPARES 6 1 Inspection and service 1 Engage top panel A onto rear retainers B and lower front of panel into position Secure with screws C Swing control panel assembly D into the boiler Secure with screw E Locate bottom corners of the front panel F into retainers G vo YN y Push top of door to engage clips 6720648665 20 1Wo Fig 60 Finishing commissioning HANDOVER gt Complete the Benchmark log book at the rear of the manual gt Setup the controls and show the user how to operate all the controls shown in the User Guide gt Instruct the customer how to repressurise the system gt Ifthe appliance is unused and exposed to freezing conditions advise the customer of the precautions necessary to prevent damage to the boiler system and building In the event of the appliance being inoperative isolate the boiler and drain the system and boiler CAUTION TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEV
68. ly has been interrupted Ensure inlet pressure is satisfactory with all other gas appliances working 6720648665 18 1Wo Fig 54 Operating the boiler 4 Ifthe boiler fails to light the blue power indicator B and reset button E will flash alternately gt Toreset the boiler press and hold the reset button E for 2 seconds 4 a M eO do 400 2 6720648665 19 1Wo Fig 55 Boiler reset CAUTION DO NOT PRESS THE POWER INDICATOR B N TO RESET THE BOILER 5 5 Checking gas inlet pressure 5 5 1 Measuring the inlet pressure The inlet pressure to the appliance must be checked using the following procedure 6720648568 41 1Wo Fig 56 Inlet test point gt Close gas isolation valve gt Slacken the screw in the inlet pressure test point and connect a manometer Open gas isolation valve gt Measure the pressure with the boiler running at maximum Press Central heating boost button L for more than ten seconds and set Central Heating temperature to maximum The Central heating boost button L 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 figure or figure
69. ment is not normally required as the telescopic flue terminal can allow for some adjustment 6 720 815 062 22 10 Fig 23 Access for flue connection Maximum effective flue lengths L max mm HF 440 550 CDi EP amp FS 30 42 CDi EP 4000 Table 18 Maximum flue lengths Flue Length guide Flue length range mm Number of extensions 1401 265 None 310 530 None 530 750 None 750 1260 1 1260 1480 1 1480 2210 2 2210 2430 2 2430 3160 3 3160 3380 3 3380 4000 4 Table 19 Flue extension guidance up to 4000mm 1 The flue is cut to a minimum of 130mm the flue connector adds the additional 10mm 6 720 815 062 2015 05 23 INSTALLATION 4 3 1 Flue extension example The terminal end projects beyond the outside wall by the D distance shown in fig 24 The flue adaptor sits flush against the outside of the inner casing 1 Measure the flue length L from the inner face of the flue adapter along the route of the flue system to the face of the outside wall 2 Select the required number of extensions and bends to achieve the require flue run 3 If the flue requires cutting Set the telescopic flue length to 400mm Secure the joint with the screw and tape provided Subtract 400mm from the measured flue length L to determine the amount to be cut of an extension 6720648665 38 1Wo Fig 24 Flue length d
70. minate continually The boiler will stay in this mode for 15 minutes unless the central heating boost button is pressed again K A at fl A WEJ LO D ht do saa e k F c a S xX ARA g _ A CO g Fig 61 Fascia guide A MASTER SWITCH FOR ON OFF B MAINS ON OFF INDICATOR FAULT DIAGNOSTIC LIGHT BLUE C CENTRAL HEATING TEMPERATURE CONTROL D BURNER ON INDICATOR LIGHT GREEN E FAULT RESET BUTTON F SERVICE BUTTON G DOMESTIC HOT WATER TEMPERATURE CONTROL H ECO BUTTON DOMESTIC HOT WATER PRE HEAT ON OFF I SYSTEM PRESSURE GAUGE J POSITION FOR OPTIONAL PROGRAMMER K DISPLAY L BOOST BUTTON SERVICE ONLY M NOTUSED For easier access to the inner case the expansion vessel can be unhooked by removing the retaining screw on the hinge lowered and moved to the side Take care not to overstretch the flexible pipe connections En 5 Release four screws G to remove the inner case cover H D d G 6 720 815 062 22 10 Fig 62 Access for servicing 6 4 Fan pressure test gt Connecta manometer to the fan pressure test point 1 gt Setthe boiler to maximum output gt After measurement replace test point cover Pressure readings will be negative refer to chart below f x L EE IA ep NEK Ne DA Fan pressure test point
71. ned 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 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 What system cleaner was used What inhibitor was used Quantity Has a primary water system filter been installed CENTRAL HEATING MODE measure and record Gas rate OR Burner operating pressure if applicable OR Gas inlet pressure Central heating flow temperature Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water sc
72. ng window 11 300mm 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 16 The dimension below eaves balconies and car ports can be reduced to 25mm as long as the flue terminal is extended to clear any overhang External flue joints must be sealed with suitable silicon sealant 17 Flue clearance must be at least 300mm from the ground Terminal guards must be fitted if the flue is less than 2 metres from the ground or if a person could come into contact with the flue terminal 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 siting terminals in relation to surfaces facing a terminal D 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 6 720 815 062 2015 05 17 PRE INSTALLATION 3 8 Flue options 4 WORCESTER Bosch Group CAUTION Non accessible flue systems gt Wherea flue
73. nly be used inside the property CAUTION ISOLATE THE MAINS GAS AND WATER SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS INSTALLATION GAS AND WATER CONNECTIONS gt Remove the transit bung L from the gas and water connections A B C D amp E onthe boiler and mounting frame D Surplus water may be present due to factory testing gt Ensure the area is clear of debris and manoeuvre the boiler rear wheels onto the outer rails of the mounting frame F gt Take care when moving the boiler to position the front wheels onto the rails and align the gas water connections and the flue gt Secure boiler to mounting frame F with screw M gt Place the 5 larger valve sealing washers shown shaded onto valves A B C D amp E gt Ensure all pipe work is clean gt Tighten up the flat sealing connections to secure A CH flow 22mm B DHW flow 22mm C Gas inlet 22mm D Mains water inlet E CH return 22mm bonded washer 22mm 6 720 815 062 10 10 Fig 43 Connections 6 720 815 062 2015 05 29 INSTALLATION 4 7 Pressure relief valve outlet Fitting the pressure relief valve drain pipe gt Connecta length of 15mm copper pipe A to the PRV drain pipe B The PRV drain pipe B should be at least 15mm diameter and run down away from any electrical or other hazard NOTICE The pressure relief valv
74. nq wo SJA a T 1NOY901 uoqisod SA EA Je U8AIQ NO dwnd seb abind 0 und UE ON xew usdo spuooes SAJEA SES peds lt pesds uous Ups 0 ued a OL anjen jes Mojaq S aNY naQ ONILVSH IVHdLNH9 enjeleduwe MOY un 440 Sue saung NO 1H9IT N4349 Aqpue s Ul iejlog 49 6 720 815 062 2015 05 Bosch Group CANORCESTER FAULT FINDING and DIAGRAMS DHW function 7 3 OLSE 290 S18 OZZ 9 Spuodes CL dwund enuquo9 Spuo28S 0y UEL anujuoD poysies Yue AAO AATWA SVv9 SIA julod jes Jeeu usual eInieleduwe ue YOBYD ponad Duo JO pasnun 1elloq Jl 905 Dun Indu yeoy wnwuIN D G2 59 ojuoo 1esn Aq jes ainyesodwe 0 yue sBleyo o ndu jesy ue 8 EJNPOIN ON puewsp jo pug wg agouenbes uous lt 0 59 St JOujU09 1esn Aq es ainjesoduwa lt pa snljsp ulejurewu o yndu yeay UEL ayejnpoyy puewep HO sapiIsA0 lt puew p yueL NO dung uonisod JO JE JOH 0 SA EA JOLSAIG 440 dund gouenbeas uous yBiy 00 gt olnieleduwej palsnijaq ue JOS 0 sdoup eJnjeJeduwea gun 440 SNE seg spuewep Jeujo UE sepulsno puewap 18
75. ns and rectify any leaks 3 Check the flue is correctly fitted and the connections are secure 4 Check the condensate pipe work is correctly fitted and connected the checks and any rectification work gt Close the gas valve gt Close the water shut off valve gt Isolate the gas supply gt Isolate the electricity supply gt Label appropriately NOTICE If the boiler is not to be commissioned N immediately then after successfully completing all of 6 720 815 062 14 10 Fig 49 Pre commissioning checks CAWORCESTER Bosch Group 5 2 Filling the system RB w XS Jo gg gg o Pull the upper edges of the front panel forwards Lift front panel Turn on the water main and open the system valves align slot vertically Open all radiator valves Unscrew the tank drain cap from the Tank drain valve Connect the integral filling loop from the Flow valve A using the hose B to the Tank drain valve C Open the flow and tank drain valves Fill the system to a pressure up to 1 5 bar Close the flow valve Close the tank drain valve Disconnect the integral filling loop Refit tank drain cap The Automatic Air Vent will release any air trapped in the boiler Vent all radiators retighten the vent when completed Check the system and correct any leaks
76. onnect the hose connection and nut supplied with boiler literature pack 3 Using a suitable hose attach one end to the drain tap on the boiler return elbow and lead the other end of the hose to an external drain point 4 Fully open the drain tap B on the drain tank valve A gt Close the drain tap when the flow from the appliance has stopped and remove the hose 6720648665 33 1Wo Fig 70 Draining the boiler Asmall quantity of water may remain in some D components even after the appliance has been drained Protect any electrical components when removing items from the water circuits PCB CONTROL BOARD Access to boiler control components gt Remove the screws A to release the cover from the controller PCB Fuse gt Remove the fuse B and replace with a spare that are clipped on the inside of the controller cover PCB gt Disconnect all electrical connections from the control gt Remove the screws C retaining the rear panel of the control and remove the panel gt After re assembly check CO CO2 levels as described in the section Setting the air gas ratio 42 6 720 815 062 2015 05 CAVORCESTER Bosch Group Spare Fuse order T1 6A L250V F2 _ T25A H250VF1 T500mA L250V F3 6720648665 24 1Wo Fig 71 PCB Fan Assembly MUST NOT BE ATTEMPTED IF A CO CO2 ANALYSER IS D ASERVICE TO THE FAN ASSEMBLY AND FLAP VALVE NOT AVAILABLE
77. ove installer module cover D gt Remove Installer module plastic cover E 6720648665 13 1Wo Fig 46 Electrical connections access 3 Unclip cable clamp F 4 Cut off the tapered cable entry to suit the cable diameter 30 6 720 815 062 2015 05 CANORCESTER Bosch Group 5 Unscrew cable retaining screw G Run the cable through the cable INSTALLATION ei clamp F ensuring there is ample cable to reach the connectors 6 Tighten the cable retaining screw G to secure the cable and replace clamp F into the control panel i Gesper V EEN el oaazaz022 N_Ns Ls LR 6720648665 31 1Wo FROST x THERMOSTAT Fig 47 Cable retainers 7 Mains power 230 Volt connection ST10 Separate wires from cable end and strip to 6mm Connect LIVE wire to terminal L SIT ste Connect NEUTRAL wire to terminal N 4 EES Connect EARTH wire to connector Make the EARTH wire longer so that if the cable is D Fig 48 PCB connections gt gt gt gt ener snagged the EARTH wire is the last to be pulled out Optional fro
78. pipe should be used 14 za Fig 5 Disposal to soil vent stack 6720648568 06 1Wo Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe washing machine waste pipe etc can be used Ensure that the condensate drain pipe is connected down stream of the waste trap 22mm dz POJ zel 14 EA 7 Fig 6 Disposal to a waste pipe 6720648568 07 1Wo 12 6 720815 062 2015 05 CANORCESTER Bosch Group 3 4 2 External connections NOTICE Freezing conditions gt When the position of the boiler prevents internal routing we recommend installing a CodenseSure siphon to significantly reduce the risk of freezing gt Pipe work length should be kept to a minimum and the route as vertical as possible gt Weather proof insulation must be used gt Care should be taken when siting a soak away to avoid obstructing existing services f NOTICE Condensate waste Continued Key to condensate illustrations CO Pipe work transition 9 Insulate and increase pipe size 10 External rain water pipe into foul water 11 External air break 12 Air gap 13 PVCu strap on fitting 14 43mm 90 male female bend Table 13 Ifno other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point or purpo
79. ps are opened and the ancillary items A B C amp D are removed and set to one side The carton can now be lifted off the boiler Remove the plastic bag protecting the boiler surfaces and place safely away from the working area Remove the two screws at the rear of the board securing the board to the pallet Grip the outer sides of the front panel pull and lift away from retaining lugs Remove securing screw at the front of the boiler from the pallet Remove remaining screws at the rear of the boiler from the pallet The boiler is mounted on small wheels and two people are recommended to move the boiler from the board taking care not to damage the panels or the floor gt Slide the boiler off the pallet Remove the rubber plug E from the boiler pipe work by pulling down GENERAL HANDLING GUIDELINES gt gt gt Lift only a manageable weight or ask for help When lifting bend the knees and keep the back straight and feet apart Do not lift and twist at the same time Lift and carry items close to the body Wear protective clothing and gloves to protect from any sharp edges INSTALLATION Fig 19 Unpacking A Mounting frame B Installation pack C Literature pack D Condensate waste pipe and non return valve E ErP energy label 6 720 815 062 0710 6 720 815 062 2015 05 21 INSTALLATION 4 2
80. r Remove the condensate trap Remove the internal flue elbow and tube from boiler sump Disconnect the return pipe union J at the base of the boiler heat exchanger Remove the plastic nut K from the base of the inner casing Remove the heat exchanger from inner casing Ensure that heat conductive paste is used on sensors when refitting Check the seals and replace if necessary After re assembly check that the CO CO levels as described in the section Setting the air gas ratio Fig 79 Primary heat exchanger CANORCESTER Bosch Group 6720648568 46 1Wo 46 6 720 815 062 2015 05 CANORCESTER Bosch Group SERVICING and SPARES 6 9 Short parts list Burner Burner seal Fan 440 CDi 8 718 006 658 0 8711004 1680 8717 204 3730 GC No E27 200 GC No E27 201 GC No E74 539 Fan 550 CDi 8716 116 0670 GC No N A Pump 8716117 455 GC No J25 460 Diverter valve assembly 8716 106 8450 GC No H02 533 Diverter valve motor 8716 106 8470 CG No H02 534 Flow turbine 8717 002 1320 GC No H21 232 Flow regulator 440 CDi 20 litre beige 8717 002 1350 GC No H21 235 Flow regulator 550 CDi 25 Flow NTC Limit NTC flue heat litre light grey 8 714 500 087 0 exchanger 8718681 1980 GCNo E74536 8 722 963 8580 GC No H66 928 GC No H08 291 DHW NTC Tank NTC Tank OH NTC ee 8716 142 3020 8716 142 3190 8716 103 2170 10 GC No 375 696 GC No 379 785 GC No E82 394
81. ransfer paste to the replacement sensor Safety temperature limiter B gt Remove the connectors gt Unscrew the sensor Tank sensor C gt Remove the screws retaining plastic cover CANORCESTER Bosch Group gt Remove the cover and disconnect the two electrical connections gt Unscrew 2 hexagon studs gt Replace the sensor coating surface with paste supplied gt Re assemble Tank overheat thermostat D Remove the screws retaining plastic cover Remove the cover and disconnect 2 electrical connections Unscrew the two hexagon studs Replace the sensor coating surface with paste supplied Re assemble vvvvyv Flow sensor flow regulator assembly E Shut off the mains water at inlet valve and drain DHW circuit Disconnect the in line connector Remove the two retaining clips F Remove the flow sensor assembly E Remove the brass housing with flow regulator G from sensor Re assemble ensuring that retaining clips are correctly positioned vvvvvy Flue Temperature limiter H gt Remove the connector gt Unscrew the sensor Domestic hot water temperature sensor J gt Release and pull off the electrical connectors gt Unscrew the bracket gt Replace the sensor coating surface with paste supplied gt Re assemble 6 720 815 062 26 10 Fig 75 Domestic hot water heat exchanger gt Before removing the heat exch
82. se 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 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 The use 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 smooth as possible PRE INSTALLATION FITTING AN EXTERNAL AIR BREAK Refer to figure 7 when a rain water down pipe is used to dispose of condensate 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 7 La 11 p 12 ae SS kl 13 6720648568 08 1Wo Fig 7 Disposal into a rainwater down pipe Condensate drainage pipe can be run above or
83. st thermostat connection ST6 Connect frost thermostat supply wire to terminal Fs Connect frost thermostat return wire to terminal FR 230V room thermostat and or external timer ST10 Remove link Connect room thermostat LIVE supply to terminal Ls Connect room thermostat LIVE return to terminal LR Connect room thermostat NEUTRAL to terminal Ns 10 Installer module for DHW timing gt Connect external timer NEUTRAL to top terminal gt Connect external timer DHW ON to bottom terminal gt Refit all panels SZ vg gg O vv o Refer to manufacturers instructions when connecting external parts to the boiler Worcester Bosch Group cannot be held responsible for wiring errors S d S d d EECH LC Vtt YES SSS EARTH LIVE O NEUTRAL SWITCHED LIVE 6720648665 30 2Wo 6 720 815 062 2015 05 31 COMMISSIONING 5 COMMISSIONING 5 1 Pre commissioning checks CAUTION Isolate the mains supplies before starting any N work and observe all relevant safety pre cautions 1 Check that the service and water pipes are connected to the correct valve on the manifold A CH flow 22mm B DHW flow 22mm C Gas inlet 22mm D Mains water inlet 22mm E CH return 22mm 2 Checkthe gastype specified on the identification plate matches that of the gas supply gt Turn onthe main gas supply check the gas pipe work connectio
84. temperature control C to maximum the boiler will then go to maximum output The control will resume normal operation after 15 minutes or if the boost button B is pressed for more than 1 second gt Remove plastic cap and using a flat bladed screwdriver set the CO3 via adjuster D referring the table 23 gt Check the CO is less than 200ppm Min adjustment S CE i 6720648568 42 1Wo Fig 66 Setting air gas ratio gt Turn the temperature control C to minimum This will make the boiler go to minimum output gt Measure the CO it should now be at the figure for minimum output shown on the table 23 If not remove cap and adjust E on the gas valve until correct gt Check the CO is less than 200ppm gt Turn temperature control to maximum output and recheck the CO If correct hold down the boost button B for two seconds the boiler should return to normal operating mode with the blue power indicator permanently illuminated gt Remove manometer and re seal the inlet pressure point on the gas valve gt Fit anew plastic sealing cover to outlet adjuster D and replace the cap on the gas valve CANORCESTER Bosch Group GAS TYPE CO setting max CO setting min Greenstar HF 440CDi PE Natural Gas 9 4 0 5 8 6 0 5 LPG propane 10 8 0 5 10 4 0 5 Greenstar HF 550CDi EP Natural Gas 9 4 0 5 9 0 0 5 LPG propane 10 8 0 5 10 4 0
85. test point cover gt Replace the combustion air intake pipe SERVICING and SPARES 6 5 Flue gas analysis Ensure that the gas inlet pressure is correct before continuing refer to section 5 5 1 Combustion test gt Remove cap on the flue gas sample point as shown below and connect a flue gas combustion analyser Replace the cap after use gt Run the boiler at maximum output for at least 10 minutes gt Check the CO CO readings against the information in table 23 CO CO settings on page 40 Flue gas sample point 6720648665 32 1Wo Fig 65 Flue integrity test If the boiler fails the combustion test check 1 Air intake for restriction 2 Diaphragm in the fan for correct operation 3 Cleanliness of the heat cell plus blockages in the condensate disposal 6 720 815 062 2015 05 39 SERVICING and SPARES 6 6 Setting the air gas ratio NOTICE THE SETTING OF THE GAS RATIO MUST BE CARRIED OUT BY A COMPETENT PERSON SETTING OF THE GAS RATIO MUST NOT BE ATTEMPTED UNLESS THE PERSON CARRYING OUT THE TEST IS EQUIPPED WITH A COMBUSTION ANALYSER CONFORMING TO BS 7927 AND IS COMPETENT IN ITS USE gt Refer to section 5 5 1 and ensure that the gas inlet pressure is correct before continuing gt Toadjust the CO CO it will be necessary to first operate the boiler at maximum output gt Press and hold down the boost button B for 10 seconds gt Turn
86. th the retaining clips 2 ensuring a good seal is made 6720646219 23 1Wo Fig 39 Fitting the adaptor elbow 4 5 Flue terminal plume re direction The flue discharge can be re directed to allow some plume redirection control Alternatively a complete plume management system can be fitted to the flue terminal Re directing the flue discharge NOTICE DO NOT ROTATE THE COMPLETE FLUE TERMINAL ASSEMBLY gt The flue terminal outlet has built in stops to limit rotation for horizontal fluing This allows condensate to run back to the boiler for safe disposal Do not attempt to force beyond the limit stops 1 Using a suitable tool unclip the end of the terminal 2 Rotate the end by 180 and refit the terminal end ensuring to engage the clips to secure 3 Loosen the screws securing the entire outlet assembly and rotate by 80 to the desired position and re secure the assembly CANORCESTER Bosch Group 6720643895 34 1Wo Fig 40 Plume redirection NOTICE OUTLET POSITIONS gt The flue terminal outlet position must follow those stated in figure 17 When redirecting the flue discharge the terminal end must be at least 1500mm from any opening in the direction of the discharge to prevent combustion products from entering the building as shown Fig 41 Plume distance to opening Opening in building Flue d
87. tion electrodes and harness flame sense electrode and harness and operation of gas valve Replace as necessary E2 Primary NTC defect Check primary NTC sensor and leads resistance across NTC should be between 36k to 1k Q E9 OH stat tripped Check system pressure over heat thermostat and pump operation Check fuse T1 6A slow blow replace as necessary FO Internal error Check all electrical connections replace board as necessary F1 ROM error check Check all electrical connections replace board as necessary F7 Flame detected after appliance shut off Check flame sense electrode and harness and control board for signs of water damage Replace as necessary FA Flame detected after gas shut off Check flame sense electrode and harness and control board for signs of water damage Check gas valve operation Replace as necessary Fd Reset button pressed Press reset button again Table 25 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 EARTH CONTINUITY SHORT CIRCUIT CHECK b c POLARITY d RESISTANCE TO EARTH 52 6 720815 062 2015 05 WORCESTER Bosch Group 7 6 Condensate pump Indicator lights The condensate pump has indicator lights A which show operation status or a fault condition
88. tput level at maximum CH output dB A 37 37 37 37 Weight excluding packaging kg 112 112 112 112 Table 7 6 6 720 815 062 2015 05 WORCESTER Bosch Group APPLIANCE INFORMATION 2 3 Product data on energy consumption The following product data satisfy the requirements of the EU Regulations No 811 2013 and No 812 2013 supplementing Directive 2010 30 EU Product data Symbol Unit 7 738 100 589 7 738 100 591 7 738 100 590 7 738 100 592 Product type 440CDiEP 550CDiEP LPG 440CDiEP 550CDi EP LPG Condensing boiler Yes Yes Yes Yes Combination heater Yes Yes Yes Yes Rated heat output Prated kW 30 30 31 31 Seasonal space heating energy efficiency Ns 92 92 92 92 Energy efficiency class A A A A Useful heat output At rated heat output and high temperature regime 1 Py kW 29 6 29 6 31 0 31 0 At 30 of rated heat output and low temperature regime P kW 9 6 9 6 10 0 10 0 Useful efficiency At rated heat output and high temperature regime 1 Na 88 5 88 5 88 5 88 5 At 30 of rated heat output and low temperature regime 2 n4 97 1 97 1 97 1 97 1 Auxiliary electricity consumption At full load el max kW 0 041 0 041 0 042 0 042 At part load Elmin kW 0 018 0 018 0 018 0 018 In standby mode Pop kw 0 004 0 004 0 004 0 004 Other items Standby heat loss Pat kW 0 053 0 053 0 053 0 053 Emissions of nitrogen oxides NOx mg kWh 23 23 23 2
89. turn gt After re assembly check that the CO CO levels are as described in the section Setting the air gas ratio 40 6 720 815 062 2015 05 CAWORCESTER Bosch Group To remove the condensate pump gt Disengage the condensate pipe from the condensate pump gt Remove the condensate pump from the base panel gt After servicing the heat exchanger fill the condensate trap with approximately 250 millilitres of water and refit in reverse order 6 720 815 062 23 10 Fig 67 Cleaning heat exchanger To clean the burner WARNING Burner A gt Do not remove the burner unless a new gasket is available for re assembly gt Check that the boiler is completely isolated from the gas supply 1 Remove the clips A castellated nuts B1 and springs B2 from the studs B gt Unscrew and remove the two hexagon headed screws C securing the fan Remove nut D1 from the rear stud D Remove the burner cover plate E 2 Remove the burner F and clean the components Do not use a wire brush SERVICING and SPARES Re assembly of the burner cover NOTICE Burner gasket seal N gt Always replace the burner seal with a new one when the joint has been disturbed Re assemble the burner in reverse order using a new seal G Insert the burner cover under the rear securing bolt and tighten
90. uilding increase the opening to 150mm9 to allow the optional weather collar to fit through the opening for 60 100 flue gt Clear away any debris All dimensions in millimetres 22 6 720 815 062 2015 05 CAWORCESTER Bosch Group INSTALLATION Access to combustion chamber for flue installation X y LU aw 1 Grip the outer sides of the front panel A pull and lift away from Z Z retaining lugs B 2 Remove retaining screw C to swing control panel assembly D outwards to its full extent 3 Pull clip E outwards to release expansion vessel F 4 Swing expansion vessel F outwards For easier access to the inner case the expansion vessel 4 can be unhooked by removing the retaining screw on RZE lt A the hinge lowered and moved to the side Take care not my 123 R to overstretch the flexible pi ti m Y SAR A pipe connections es Spee ree 1 ees ee 5 Release four screws G to remove the inner case cover H Es De D G x M123 _343 gt 267 re ane za Ee 5 a SZ KA C SK i 6720648665 37 1Wo r4 iwo 1 Fig 22 Boiler flue outlet positions 4 3 Flue measuring and cutting NOTICE FLUE LENGTH N gt Do not exceed the maximum straight length for a horizontal 60 100mm flue ora 60mm plume management system if used as stated in the relevant Installation Commissioning and Servicing Instructions manual or addendum Cutting the flue to an exact measure

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