Installation and Servicing Instructions

GREENSTAR HE combi
Wall mounted condensing boiler for central heating and mains
fed domestic hot water

6 720 610 577-00.10

ZWB 7-27 HE combi GC-Number: 47 311 55

6 720 610 576 GB (02.05) OSW
Contents

Contents

Safety precautions 3 6 Individual settings 26

6.1 Mechanical settings 26
6.1.1 Checking the size of the expansion vessel 26
Symbols 3 6.1.2 Setting the central heating flow temperature 26
6.1.3 Changing the heating pump characteristic 26
6.2 Settings on the Bosch Heatronic 27
1 Details of the appliance 4 6.2.1 Operating the Bosch Heatronic 27
1.1 EC Declaration of Conformity 4 6.2.2 Selecting the pump control mode for central
1.2 Standard package 4 heating mode (Service Function 2.2) 27
1.3 Description of appliance 4 6.2.3 Setting the anti-cycle time
1.4 Accessories 5 (Service Function 2.4) 27
1.5 Casing dimensions 5 6.2.4 Setting the maxim CH flow temperature
1.6 Layout of appliance 6 (Service Function 2.5) 28
1.7 Function 7 6.2.5 Setting the switching difference
1.8 Electrical wiring diagram 8 (Service Function 2.6) 28
1.9 Technical data 9 6.2.6 Setting the heating output
(Service Function 5.0) 28
6.2.7 Constant hot water cycle time
2 Installation regulations 11 (Service Function 6.8) 28
6.3 Setting the gas/air ratio 28
3 Installation 11
3.1 Important remarks 11 7 Converting the appliance to different
3.2 Domestic hot water 12 gas types 29
3.3 Sealed systems 12 7.1 Setting the gas/air ratio 29
3.4 Siting the appliance 13 7.2 Testing combustion air/flue gas at set
3.5 Wall mounting frame assembly 14 heat output 31
3.6 Pre-piping the system 14 7.2.1 Testing the O2 or CO2 level in the
3.7 Fitting the appliance 15 combustion air 31
3.8 Checking the connections 16 7.2.2 Testing CO and CO2 31
3.9 Flue Systems 16
3.9.1 Siting the Flue Terminal 17
3.9.2 Installation of the flue 18 8 Maintenance 32
3.9.3 Flue duct preparation and assembly 20 8.1 Pre-Service Check List 33
8.2 Description of servicing operations 34
8.3 Replacement of Parts 38
4 Electrical connections 21 8.3.1 PCB control board and transformer 38
4.1 Connecting the appliance 21 8.3.2 Fan Assembly 39
4.2 Mains Voltage external controls connections 22 8.3.3 Pump 39
8.3.4 3-way diverter valve 40
8.3.5 3-way diverter valve motor 40
5 Commissioning 23
8.3.6 Sensors 40
5.1 Commissioning 23
8.3.7 Gas Valve 41
5.2 Switching the appliance on/off 24
8.3.8 Domestic Hot Water Heat Exchanger 41
5.3 Switching on the central heating 24
8.3.9 Electrode assembly 41
5.4 System controls 24
8.3.10Pressure gauge 41
5.5 Setting the domestic hot water
8.3.11Expansion vessel 41
temperature and flow rate 24
8.3.12Pressure Relief Valve 41
5.5.1 Domestic hot water temperature 24
8.3.13Burner 41
5.5.2 Hot water flow rate 25
8.3.14Flow switch 42
5.6 Summer mode (hot water only) 25
8.3.15Primary Heat Exchanger 42
5.7 Frost protection 25
5.8 Pump anti-seize function 25
5.9 Fault Condition 25 9 Appendix 43
9.1 Fault Codes 43
9.2 Short parts list 44
9.3 Heating/hot water output settings (N.G.) 45
9.4 Heating/hot water output settings (L.P.G) 45
9.5 Operational Flow diagrams 46
9.5.1 Domestic hot water function 46
9.5.2 Central heating function 47

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 Safety precautions

Safety precautions Symbols

If you smell gas Safety instructions in this document
B Turn off gas service cock at the meter. are identified by a warning-triangle sym-
B Open windows and doors. bol and are printed on a grey back-
ground.
B Do not operate any electrical switches.
B Extinguish any naked flames.
Notes containing important information
B Telephone your gas company.
If you smell fumes from the appliance
i are identified by the symbol shown on the
left. They are bordered by horizontal lines
B Switch off appliance (see page 24). above and below the text.
B Open windows and doors.
Fitting and modifications
B Fitting of the appliance or any controls to the appli-
ance may only be carried out by a competent engi-
neer in accordance wth the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use on sealed primary systems
only.
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
B Use only original spare parts!
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance
being electrically unsafe.
B There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
B The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Explain to the customer how the appliance works and
how to operate it.
B Advise the user that he/she must not make any modi-
fications to the appliance or carry out any repairs on it
B These instructions are to be left with the user or at
the Gas meter.
B Important: These instructions apply in the UK only.

6 720 610 576 GB (02.05) 3

Details of the appliance

1 Details of the appliance

1.1 EC Declaration of Conformity 1.3 Description of appliance

This appliance is in accordance with the applicable • Wall-mounted appliance, siting not dependent on
requirements of the Gas Appliance Directive, Boiler Effi- room size
ciency Directive, Electromagnetic Compatibility Direc- • Natural gas models are low-emission appliances
tive and the Low Voltage Directive.
• Multifunction display
PIN CE-0085 BL 0507 • Bosch Heatronic control system
Category • Automatic ignition
UK II2H 3P • Modulating control
Appliance Type C13, C33 • Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
Table 1 temperature sensors
• Concentric flue/air duct with testing point for
CO2/CO
1.2 Standard package
• Regulated speed fan
• Gas condensing combination boiler for central heat-
• Pre-mix burner
ing and domestic hot water
• Temperature control for central heating
• Wall mounting frame
• Temperature sensor in domestic hot water
• Clamp for securing flue duct kit
• Safety temperature limiter in 24 V electrical circuit
• Fixings (screws etc.)
• Three-speed central heating pump with automatic
• Set of documentation for appliance
vent
• Pre-plumbing manifold
• Relief valve, pressure gauge, expansion vessel
• Condensate drain pipe.
• Flue gas temperature limiter (105 °C)
• Hot water priority circuit
• Motorised 3-way valve
• Plate-type heat exchange
• Condensate Trap.

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 Details of the appliance

1.4 Accessories
• Standard horizontal flue kit at 100 mm outside
diameter for flues upto 4 m in length.
• Flue duct kits for horizontal (125 mm outside
diameter) for flue lengths upto 13 m and vertical flue
systems for flue lengths uto 15 m. Fitting instructions
are sent with these kits.
• Heating programmer
• Timer
• Security kit.

1.5 Casing dimensions

min. min.
Z
5 5
Y X

120

906
850

861

101
13
103 200
30

35 360
440
395 250

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Fig. 1
13 Manifold assembly
101 Outer case
103 Facia cover
X Standard Concentric Horizontal Flue System: min. 310 mm
Alternative Concentric Flue System: min. 250 mm
Y Standard Concentric Horizontal Flue System: 158 mm
Alternative Concentric Flue System: 121 mm
Z Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm

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Details of the appliance

1.6 Layout of appliance

120
221.1

221.2 349
234.1
234

27

226

20 102

32.1
29
36

271 6

415
43

9
63
416

358

18
64
423
7 18.1
355
418
6.1 15
8.1
88
295 98
417 4

6 720 610 576-02.2O

Fig. 2
4 Heatronic control 102 Inspection window
6 Heat exchanger safety temperature limiter 120 Fixing points
6.1 Hot water NTC sensor 221.1 Flue duct
7 Testing point for gas supply pressure 221.2 Combustion air intake
8.1 Pressure gauge 226 Fan assembly
9 Flue gas temperature limiter 295 Appliance type sticker
15 Relief valve 234 Testing point for combustion products
18 Pump 234.1 Testing point for combustion air
18.1 Pump speed selector switch 271 Flue duct
20 Expansion vessel 349 Cover plate for twin flue duct connection
27 Automatic air vent 355 Plate-type domestic hot water heat exchanger
29 Air gas Mixer unit 358 Condensate trap
32.1 Electrode assembly 415 Cover plate for cleaning access
36 Temperature sensor in CH flow 416 Condensate collector
43 CH flow 417 Clip for fixing outer case
63 Adjustable gas flow restrictor 418 Data plate
64 Adjusting screw for min. gas flow volume 423 Siphon
88 3-way valve (combi)
98 DHW flow switch (combi)

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 Details of the appliance

1.7 Function

Fig. 3
4 Bosch Heatronic control 63 Adjustable gas flow restrictor
6 Temperature limiter, heat exchanger 64 Adjusting screw for min. gas inlet flow volume
6.1 Hot water NTC sensor 69 Control valve
7 Testing point for gas supply pressure 84 Motor
8.1 Pressure gauge 88 3-way valve
9 Flue gas temperature limiter 90 Venturi
13 Manifold 91 Pressure relief valve
15 Safety valve 93 Water flow regulator
18 Central heating pump 94 Diaphragm
20 Expansion vessel 95 Pushrod with switch cam
26 Charging valve 96 Microswitch
27 Automatic vent 97 Valve for hot water flow volume
29 Mixer unit 98 Water valve
29.1 Bi-metallic thermostat for combustion air compensation 221 Flue duct
30 Burner 226 Fan
32 Flame sensing electrode 229 Inner casing
33 Igniter electrode 234 Testing point for flue gas
35 Heat exchanger with cooled combustion chamber 234.1 Testing point for combustion air
36 Temperature sensor in CH flow 317 Display
43 CH flow 355 Plate-type heat exchanger
44 Hot water flow 358 Condensate trap
45 Gas inlet 423 Siphon
46 Cold water inlet 443 Diaphragm
47 CH return
52 Solenoid valve 1
52.1 Solenoid valve 2
55 Filter
56 Gas valve CE 427
57 Main valve disc
61 Reset button

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Details of the appliance

1.8 Electrical wiring diagram

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

33
364 365 61 317 366 367 363
ECO

4.1

25 V
230 V
153 136 310
135
230V/AC
312 318

315
313 124 789
328 151 84
p

302
L N Ns Ls LR
300 314
p
p M
161
96
328.1
g
9 6 g

M M o

r
r o
mains supply 18 226
52 52.1

56
o o

bl
36 6.1
bl
bl
bl bl
32

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Fig. 4
4.1 Ignition transformer 161 Link
6 Temperature limiter, heat exchanger 226 Fan
6.1 Hot water NTC sensor 300 Code plug
9 Flue gas temperature limiter 302 Earth connection
18 Pump 310 Temperature control for hot water
32 Flame sensing electrode 312 Fuse, slow T 1,6 A
33 Ignition electrode 313 Fuse, slow T 0,5 A
36 Temperature sensor in CH flow 314 Connector for programmer
52 Solenoid valve 1 315 Terminal block for programmer
52.1 Solenoid valve 2 317 Digital display
56 Gas valve CE 427 318 Connector for timer
61 Reset button 328 Terminal block for AC 230 V Mains supply
84 Motor, 3-way valve 328.1 Link
96 Microswitch, hydraulic switch 363 Indicator lamp for burner
135 Master switch 364 Indicator lamp for power supply
136 Temperature control for CH flow 365 “Chimney sweep” button
151 Fuse, slow 2.5 A, AC 230 V 366 Service button
153 Transformer 367 ECO button

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 Details of the appliance

1.9 Technical data

Units Natural gas Propane

Max. rated heat output net 40/30°C central heating kW 29.1 29.1
Max. rated heat output net 50/30°C central heating kW 28.8 28.8
Max. rated heat output net 80/60°C central heating kW 27.2 27.2
Max. rated heat input net kW 27.5 27.5
Min. rated heat output net 40/30°C kW 8.4 11.6
Min. rated heat output net 50/30°C kW 8.3 11.4
Min. rated heat output net 80/60°C kW 7.4 10.5
Min. rated heat input net kW 7.6 10.8
Max. rated heat output net, domestic hot water kW 27.2 27.2
Max. rated heat input net, domestic hot water kW 27.5 27.5
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (His = 9,5 kWh/m3) m3/h 2.9 -
LPG (Hi = 12,9 kWh/kg) kg/h - 2.1
Gas supply pressure
Natural gas G20 mbar 20 -
LPG mbar - 37
Expansion vessel
Charge pressure bar 0.75 0.75
Total capacity l 10 10
Hot water specifications
Hot water flow rate (factory setting) l/min 8 8
Max. hot water flow rate l/min 14 14
Outlet temperature range °C 40 - 60 40 - 60
Max. permissible water supply pressure bar 10 10
Min. inlet pressure bar 0.2 0.2
Specific flow rate l/min 12.4 12.4
Flue
Flue gas temp. 80/60°C, rated/min. load °C 67/55 67/55
Flue gas temp. 40/30°C, rated/min. load °C 43/32 43/32
Residual delivery pressure
(inc. pressure drop in air intake duct) Pa 80 80
CO2 level at max. rated heat output % 9.5 11.3
CO2 level at min. rated heat output % 9.2 11.0
NOx-class 5 5
SEDBUK figure, Band A % 90.6 90.6
Condensate
Max. condensation rate (tR = 30°C) l/h 2.3 2.3
pH-value, approx. 4.8 4.8
General Data
Electrical power supply voltage AC ... V 230 230
Frequency Hz 50 50
Max. power consumption W 101 101
Noise output level dB(A) 36 36
Appliance protection rating IP X4D X4D
Max. CH flow temperature °C nom. 90 nom. 90
Max. permissible operating pressure (CH) bar 2.5 2.5
Permissible ambient temperatures °C 0 - 60 0 - 60
Nominal capacity of appliance l 3.75 3.75
Weight (excluding packing) kg 46 46
Table 2

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Details of the appliance

Condensate analysis, mg/l

VERTICAL 125 mm FLUE SYSTEM
Ammonium 1.2 Nickel 0.15
Lead ≤ 0.01 Mercury ≤ 0.0001 Overall Diameter of Duct mm 125

Cadmium ≤ 0.001 Sulphate 1 Flue Terminal / Duct Assembly mm 1360

Chromium ≤ 0.005 Zinc ≤ 0.015 Extension Duct Length mm 200

Halogenated Tin ≤ 0.01 Extension Duct Length - Fixed mm 450
hydrocarbons ≤ 0.002
Extension Duct Length - Fixed mm 950 Max.
Hydrocarbons 0.015 Vanadium ≤ 0.001 15 m
Extension Duct Length - Fixed mm 1950
Copper 0.028 pH-value 4.8
Table 3 Extension Duct Length - Tele- mm 265-
scopic 375
Flue system
Extension Duct Length - mm 450
HORIZONTAL 100 mm – Standard Adjustable (Cut to length)
Table 6
Overall Diameter of Duct mm 100
Elbow - 90 ° Bend - 45 °
Flue Terminal / Duct Assem- mm 750 Max. Equivalent length 2 m Equivalent length 1m
bly Length 4m
Gas supply
Extension Duct Length mm 1000
Total length of gas supply pipe Pipe diameter
Table 4
(metres) (mm)
ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM
3 6 9
Overall Diameter of Duct mm 125
Gas discharge rate (m3/h)
Flue Terminal / Duct Assembly mm 550
8.7 5.8 4.6 22
Extension Duct Length - Fixed mm 200
18.0 12.0 9.4 28
Extension Duct Length - Fixed mm 450 Max.
13 m Table 7
Extension Duct Length - Fixed mm 950 (inclu- Domestic water performance
ding
Extension Duct Length - Fixed mm 1950 turret) Temperature 30 °C 13.2
Rise
Extension Duct Length - mm 265-
Telescopic 375 Domestic
Temperature 35 °C 11.3
Water Flow
Rise
Extension Duct Length - Adjusta- mm 200 Rate l/min
ble (Cut to length) Temperature 40 °C 9.9
Rise
Table 5
Maximum Mains pressure bar 10.0
Minimum Mains pressure bar 0.2
Table 8

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 Installation regulations

2 Installation regulations 3 Installation

Gas Safety (Installation & Use) Regulations 1998: All B Always turn off the gas cock before car-
gas appliances must be installed by a competent per- rying out any work on components
son. Failure to install correctly could lead to prosecu- which carry gas.
tion.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations. Fixing of the appliance, gas and flue con-
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regula-
i nections, commissioning of the system
and electrical connections may only be
tions, Building Standards (Scotland) (Consolidation), carried out by competent persons author-
bye-laws of the local Water Company, Health and ised by CORGI.
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements. 3.1 Important remarks
Product Liability regulations indicate that, in certain cir-
cumstances, the installer can be held responsible, not B Appliance should only be installed in sealed central
only for mistakes on his part but also for damage result- heating systems.
ing from the use of faulty materials. We advise the B To avoid gas formation in the system, galvanised radi-
installer to avoid any risk by using only quality approved ators or pipes must not be used.
branded fittings. B If a room thermostat is used: do not fit a thermostatic
The relevant British Standards should be followed i.e. radiator valve on the radiator in the primary room.
• BS 6798: Specification for the installation of gas B Add a suitable anti-freeze fluid compatible with alu-
fired hot water boilers of rated input not exceeding minium to the water in the central heating system.
60kW Suitable products are available from Betz-Dearborn
• BS 5449: Central Heating for Domestic Premises Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
• BS 5546: Installation of gas hot water supplies for
domestic purposes B In our experience, the addition of sealing agents to
the water in the central heating system can cause
• BS 5440:1: Flues and ventilation for gas appliances
problems (deposits in the heat exchanger). For that
of rated input not exceeding 70 kW (gross): Flues
reason we advise against their use.
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 60 kW (gross): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply.
These instructions must be followed.

6 720 610 576 GB (02.05) 11

Installation

3.2 Domestic hot water 3.3 Sealed systems

Any regulations specified by the local water company The appliance must not be operated without the system
must be observed. being full of water, properly vented and pressurised.
The final 600 mm of the mains cold water connection to The expansion vessel has a volume of 10 litres and is
the applaince should be made in copper tube only. charged to a pressure of 0.75 bar.
The appliance is suitable for a mains supply having a The water capacity of the system is shown in table 11,
maximum pressure of 10 bar. A pressure reducing valve page 26. If a greater capacity is required then an addi-
must be fitted, if necessary. tional expansion vessel must be fitted into the system
The hot water outlet temperature is set to be capable of return as close to the appliance as possible. The system
achieving a maximum of 60°C. The maximum tempera- pressure can be set up to a maximum of 1.5 bar with 1
ture and the frequency of the recharge of the heat store bar being the normal setting.
may be reset. If the system pressure is greater than 2.65 bar when the
The maximum water flow rate is factory set at 9.9 l/min appliance is operating at maximum temperature then an
to give temperature rise of 40°C. If a higher rise is additional expansion vessel must be fitted into the sys-
required then the flow must be reduced at the tap and tem return as close to the appliance as possible.
the discharge temperature will rise up to the maximum The filling point must be at low level and arranged as
set figure. shown in figs. 5 and 6.
The temperature rise, upto the maximum set by the user, The pressure relief valve is set to operate at 3 bar.
is automatically maintained by the modulation of the There must be no connection to the mains without the
heat input. In winter, when the mains temperature is very approval of the local water company. All connections in
low, the water flow, adjusted at the tap or shower, the system must be capable of withstanding a pressure
should be reduced to maintain the required delivery of up to 3 bar and the radiator valves conform to the
temperature. requirements of BS 2767:10.
It is suggested that long pipe runs to taps or showers If Thermostatic Radiator Valves are fitted then it is rec-
be insulated to prevent the rapid cooling of the water. ommended that one radiator is left open.
All types of single lever mixer taps and thermostatic Repeated venting probably indicates a leak and this
mixer units suitable for a mains pressure of up to 10 bar must be rectified to ensure the proper operation of the
can be used. appliance.
The head of a loose-head shower must not be allowed No galvanised radiators or pipes must be used.
to fall within 25 mm of the top the bath to prevent the
If any system water treatment is required then only
risk of water being drawn back into the mains. Alterna-
products suitable for use with Aluminium shall be
tively the shower must be fitted with an anti-syphonage
used i.e Fernox- Copal or Sentinal X100, in
device at the point of the flexible hose connections.
accordance with the manufacturers instructions.
Over-rim bidets may be connected to the appliance pro- The use of any other substances will invalidate the
vided that it is in accordance with the requirements of guarantee. The pH value of the system water must
the local water company. The outlet(s) should be be less than 8 or the appliance guarantee will be
shrouded and unable to have any temporary hand held invalidated.
spray attached. No anti-syphonage arrangements are
A drain cock to BS2879 must be fitted to the lowest
necessary.
point of the system.
In exceptionally hard water areas a device to prevent
IMPORTANT: Check that no dirt is left in the water
scale formation may be fitted or, alternatively, the maxi-
pipework as this could damage the appliance.
mum temperature reset to about 45°C which may
Thoroughly flush the heating system and the mains
reduce the risk of scale formation. The installation of a
water supply before fitting the appliance to the wall
scale inhibitor assembly should be in accordance with
in accordance with the recommendations of
the requirements of the local water company. Artificially
BS7593:1992.
softened water must not be used to fill the central heat-
ing system. An isolating valve should be fitted to allow
for servicing.
Devices, such as water meters or back-flow preven-
tion valves, capable of preventing the flow of expan-
sion water must not be fitted unless separate
arrangements have been made.
A Zilmet Z160 expansion vessel is the preferred type. A
thread sealant compatible with potable water must be
used.

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 Installation

APPLIANCE

Refer to Fig.1
Appliance
water flow
diagram A drain cock should be fitted at
the lowest point of the heating
circuit and the appliance
WRC approved
filling loop Lockshield
valve

Central heating return

Domestic
hot water Central heating flow
Radiator
valve

BS stop valve.
Fixed spindle type
Water
6 720 610 576 -09.2O
main

Fig. 5 Sealed primary water system

Heating Non-return Non-return

return valve valve

Hose Hose
union union

Test
cock

Test
Temporary hose
cock

6 720 610 576 - 10.1O

Fig. 6 Sealed primary water system - filling method

3.4 Siting the appliance

Regulations concerning the Installation Site Surface temperature
B Relevant national regulations must be complied with The max. surface temperature of the casing and the flue
section 3.9.1. is less than 85 °C.
This means that, no special safety precautions are
B Consult the installation instructions for details of min-
required with regard to flammable building materials
imum clearances required.
and fitted furniture. The specified clearences must be
Combustion air maintained.
In order to prevent corrosion, the combustion air must Cupboard/Compartment
not contain any corrosive substances.
The appliance can be installed in a cupboard/compart-
Substances classed as corrosion-promoting include ment need for airing clothes providing that the require-
halogenated hydrocarbons which contain chlorine and ments of BS6798 and BS5440:2 are followed. The low
fluorine compounds and are contained in some sol- casing losses from the appliance eliminate the need for
vents, paints, adhesives, aerosol propellants and house- ventilation openings in the compartment.
hold cleaners, for example.

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Installation

3.5 Wall mounting frame assembly B Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
B Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 7. Use
the inner lugs on the top and bottom horizontal
sections for the appliances that are 440 mm wide.

6 720 610 576-11.1O

Fig. 9

6 720 610 576-04.1O 3.6 Pre-piping the system

Fig. 7
200
B Hold the wall-mounting frame against the wall
ensuring that it is vertical.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 15.
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided. 171 112 172
43 47

50 35

120-130
260
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Fig. 10 Manifold
43 CH flow
47 CH return
112 Gas cock
171 Domestic hot water
172 Cold water relief

B A drain tap should be fitted at the lowest point of the

central heating system.
6 720 610 576-05.1O
B WRc filling loop must be fitted.
Fig. 8

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 Installation

Condensate drain 3.7 Fitting the appliance

Prepare the condensate discharge system. Refer to
fig. 11. The condensate drainage pipe should be a Benchmark: For optimum performance
standard drain pipe material , i . e. PVC, PVC-U, ABS after installation, this boiler and its asso-
etc. and should be at least 22 mm in diameter. ciated central heating system must be
A siphon with a 75 mm condensate seal is fitted within flushed in accordance with the guide-
the appliance. lines given in BS5793:1992 “Treatment
A connection to an internal drain is recommended. of water in domestic hot water central
heating systems”.
Any external drain pipe should be insulated to prevent
freezing.
B Remove packing, taking care to observe the instruc-
The connection of a condensate pipe to a drain may be tions on the packing.
subject to local building regulations.
B Lie the boiler on its back.
For more information refer to the CIBSE Guide,
BS5546 and the Building Regulations. Removing the outer case
The outer case is secured against unau-
i thorised removal by two clips (electrical
safety).
Always secure the outer case with those
clips again after refitting.

B Turn the clips with a screwdriver (1.).

B Slide the outer case upwards and then forwards to
remove (2.).
B Remove the plastic caps from the boiler connections.

2.

1.
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Fig. 11 Position of the condensate drain

6 720 610 332-07.1R

Fig. 12

Fixing the appliance

B Fit the washers onto the gas and water connections.
B Lift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
B Take care not to disturb the washers on the connec-
tions.

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Installation

Connecting the flue duct 3.9 Flue Systems

B Fit flue duct connector onto appliance flue spigot. The only flue systems that may be used are those sup-
B Secure with the two screws supplied. plied by Worcester Heat Systems.
The flue system must be installed in accordance with
the requirements of BS5440:1.

Standard 100 mm flue system

The standard concentric flue system provides for a hor-
izontal length of upto 4 m. Full instructions for fitting this
2
4
1
3
flue are in Subsection 3.9.2 “Installation of the flue”.

Alternative 125 mm diameter flue systems

Installation instructions for the alternative flue systems
are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13 m.
6 720 610 332-09.1R
A vertical flue system upto a height of 15 metres is avail-
Fig. 13 able.
B For remaining installation of flue assembly, refer to 45° and 90° flue bends can be used with a correspond-
the relevant installation instructions. ing reduction in flue length of 2m for each 90° bend and
1 m for each 45° bend used.
3.8 Checking the connections
IMPORTANT: Any horizontal flue system fitted to a con-
Water connections densing boiler must incline towards the appliance at an
B Check that the O-rings or seals are in place before angle of 3 % (30 mm per metre length) to prevent con-
tightening the connection. densate dripping from the flue terminal. This means
that the clearance above the appliance must be
B Turn on the service valves for central heating flow
increased to match the duct length.
and return and fill the heating system through a WRC
Refer to fig. 1 on page 5.
approved filling loop.
B Check all seals and unions for leaks (testing pressure
max. 3.0 bar as indicated by pressure gauge).
B Turn on cold water service cock and fill hot water sys-
tem (testing pressure max. 10 bar).
B Check all connections for leaks.

Gas supply pipe

B Check that the seal is in place before tightening the
connection.
B Turn off gas cock to protect gas valve against
damage from excessive pressure.
B Check gas supply pipe.
B Release the pressure on the gas supply pipe.

16 6 720 610 576 GB (02.05)

 Installation

3.9.1 Siting the Flue Terminal

The flue must be installed in accordance with lighting, activated by passive infra-red sensing heads.
BS 5440:1 and the Building Regulations. Flue terminals If the terminal is less than 2 m above a surface to which
in carports and under balconies are to be avoided. people have access then a guard must be fitted. The
The terminal must be positioned so that it does not guard must be evenly spaced about the terminal with a
cause an obstruction nor the combustion products a space of 50 mm in each direction and fixed with plated
nuisance. See fig. 14 and table 9. screws.
The terminal will, at times, give out a plume of water A guard Type K2 for the standard horizontal flue, can be
vapour and consideration must be given to this when obtained from Tower Flue Components, Vale Rise, Ton-
choosing a terminal position. Keep clear of security bridge TN9 1TB.

Fig. 14

Minimum dimensions of flue terminal positions (all types) (see fig. 14)
Dimension Terminal Position (kW input expressed in net) Balanced flues room sealed: Fanned draught

A1) Directly below an opening, air brick, opening windows, etc. 300 mm

B 1) Above an opening, air brick, opening window, etc. 300 mm

C 1) Horizontally to an opening, air brick, opening window, etc. 300 mm

D Below gutters, soil pipes or drain pipes 75 mm

E Below eaves 200 mm
F Below balconies or car port roof 200 mm
G From a vertical drain pipe or soil pipe 150 mm
H From an internal or external corner 300 mm
I Above ground roof or balcony level 300 mm
J From a surface facing the terminal 600 mm
K From a terminal facing the terminal 1200 mm
L From an opening in the car port (e. g. door, window) into the dwelling 1200 mm
M Vertically from a terminal on the same wall 1500mm
N Horizontally from a terminal on the same wall 300 mm
O From the wall on which the terminal is mounted Not applicable
P From a vertical structure on the roof Not applicable
Q Above intersection with roof Not applicable

Table 9
1) In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the pur-
pose of accommodating a built-in element such as a window frame.

6 720 610 576 GB (02.05) 17

Installation

3.9.2 Installation of the flue

The standard 100 mm diameter horizontal flue system is
suitable for lengths upto 4 m.
Flues upto 650 mm do not require an extension duct
assembly.
Flues between 1600 mm and 4000 mm require exten- Terminal
sion duct assemblies. Assembly
NOTE: Flue lengths between 650 mm and 730 mm Flue
cannot be accomodated. Refer to fig. 16, 17, 18. Turret Maximum 650 mm

Standard system comprise: Flue turret - Flue turret

clamp - Terminal assembly - Wall sealing - plates.
Extension kit comprises: Air duct - Flue duct - Duct Outer
Wall
clamp. Refer to fig. 19. No
Clamp
Instructions for fitting other flue systems are packed 6 720 610 602 - 08.1O
with the relevant flue kit.
Check that the position chosen for the appliance is sat-
isfactory Refer to fig. 15.

Fig. 16 Standard Flue

Centre line of Drilling point for

flue/air duct flue duct opening

H 3%
120
Centre (30 mm/meter)
line of
flue Top of the
opening wall
and mounting
appliance frame
Appliance

H
Standard Horizontal Flue 158 mm
6 720 610 602 - 07.1O
Optional Horizontal Flue 121 mm

Fig. 15 Marking the position of the side flue opening

18 6 720 610 576 GB (02.05)

 Installation

Terminal
Assembly
Flue
Turret Maximum 1600mm

Outer
Wall
No Clamp
Clamp Extension
Duct

6 720 610 602 - 09.1O

Fig. 17 Flue with one extension

Terminal
Assembly
Flue
Turret

Outer
Clamp Wall
Clamp
No
Clamp Extension Extension
Duct Duct
6 720 610 602 - 10.1O

Fig. 18 Flue with extensions

Duct Clamp
Flue Extension Air Duct
Turret

Extension Flue Duct

Terminal Assembly Wall Sealing Plates

6 720 610 602 - 11.1O

Fig. 19 Flue components

6 720 610 576 GB (02.05) 19

Installation

3.9.3 Flue duct preparation and assembly

Measure the flue length L. Refer to fig. 20, 21.
Outer
Wall
Flue Terminal
Face

Raised Ring
locating the
terminal relative
120 to the outside
wall face

6 720 610 576 - 20.1O

NOTE: THE FLUE MUST BE INCLINED T O THE
BOILER 6 720 610 602 - 12.1O

Fig. 20 Flue length - rear Fig. 22 Flue terminal position

Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must face downwards.
The assembly will be made easier if a solvent free
L grease is lightly applied i.e Vaseline, to the male end of
the ducts.
NOTE: An inner wall sealing plate is provided which
should be fitted to the ducts before assembly.
Push the assembly through the wall and fix the turret to
the appliance with the clamp. Refer to fig. 23.

NOTE: THE FLUE MUST BE INCLINED T O THE

BOILER 6 720 610 602 - 13.1O
Flue Turret

Fig. 21 Flue length - side

Air and
Mark off the lengths shown onto the ducts and cut to Flue Duct
length. The cuts must be square and free from burrs. Entry into
silicone
Terminal assembly outer (air) duct - L-70 mm, inner Clamp rubber seals
(flue) duct - L- 50 mm.The measurement is made from
the ridge at the terminal indicating the outer face of the
wall. Refer to fig. 22.
Extension air duct - L-70mm, flue duct - L-50 mm.
The measurement is from the formed end.
Flue Socket
on Boiler 6 720 610 602 - 14.1O

Fig. 23 Flue turret

Ensure that the turret is fully entered into the socket on
the boiler. From the outside fix the outer wall plate to the
terminal and, after ensuring the duct is properly i nclined
towards the boiler, fix the plate to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal an be fixed with corrosion resistant
screws.

20 6 720 610 576 GB (02.05)

 Electrical connections

4 Electrical connections
B Always disconnect the power supply to
4.1 Connecting the appliance
the appliance at the mains before carry- To gain access to the mains connection remove the
ing out any work on the electrical sys- drop down facia cover. The drop down cover is
tems and components. removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
All control and safety systems are built into the appli- release the cover. Lift cover from the appliance.
ance. After installation (or in the event of an electrical fault) the
B Allow mains cable to protrude at least 50 cm from electrical system shall be checked for short circuits,
wall. fuse failure, incorrect polarity of connections, earth con-
B To make splash-water proof (IP): cut the cable grom- tinuity and resistance to earth.
met hole size to match diameter of cable, see fig. 26. B Pull out cover panel at the bottom and remove. Refer
to fig. 24.
It must be possible to isolate the appliance. The appli-
ance must be earthed.
The appliance must be connected to the mains through 0 3 4
2
a 6 A double pole isolator with a contact separation 5

1
3 mm in all poles and supplying the appliance and con- E

trols only. The wiring must comply with the current

requirements of the IEE Wiring Regulations and any
local regulations which apply.
• Supply: 230 V ~ 50 Hz, 140 Watts
• Mains cable: PVC insulated 0.75 mm2
(24 x 0.20 mm) to BS6500-Table 6.
Temperature rated 100°C.
6 720 610 332-10.1R
• Protection IPX4D Fig. 24
• External fuse 3 A. B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 25.

0 3 4
2
5

1
E

6 720 610 332 -11.1R

Fig. 25

6 720 610 576 GB (02.05) 21

Electrical connections

B Cut cable grommet to diameter of cable. 4.2 Mains Voltage external controls
connections
0 3 4
2 NOTE: Only double insulated controls not requiring an earth can be used
5

1 Ns Ls LR Ns Ls LR
E ST8
ST8

Switched Live
Switched Live
Remove Link

Neutral
Neutral

Live
Live
Motor
230 V Room Thermostat Connections
230 V Programmer Connections
8-9
230 V room thermostat and Ns Ls LR
5-7 Programmer Connections ST8
Series
connection

Live
to be made

Sw
10-12 13-14

ed

itc
Neutral
safe

it ch

he
Ne
6 720 610 332-12.1R

Live
d
ut

Live

Sw
ra

Li
l

ve
Fig. 26
B Feed cable through cable grommet and connect the Motor
mains supply cable, see fig. 27. 6 720 610 576 - 22.1O

B Secure cable in cable grommet by means of cable Fig. 28

grip.

L N NS L S L R

4130-14.1R

Fig. 27

22 6 720 610 576 GB (02.05)

 Commissioning

5 Commissioning

27

136 365 61 317 366 367 358

ECO

364
363 8.1
135 E
310
295 15

170

171 172 173 170

6 720 610 576-07.2O

Fig. 29
8.1 Pressure gauge 5.1 Commissioning
15 Safety valve
27 Automatic vent
61 Reset button Never run the appliance when empty or
135 Master switch unpressurised.
136 Temperature control for central heating
170 Service cocks on CH flow and return
171 Hot water Benchmark Water Treatment: For optimum perform-
172 Gas cock (shown in on position) ance after installation, this boiler and its associated cen-
173 Cold water service cock tral heating system should be flushed in accordance
295 Appliance type sticker
310 Temperature control for hot water
with the guidelines given in BS7593:1992 - Treatment
317 Multifunction display of water in domestic hot water systems. Full instructions
358 Condensate trap are supplied with proprietary cleansers sold for this pur-
363 Indicator lamp for burner pose. If an inhibitor is to be used after flushing, it should
364 Indicator lamp for power supply be used in accordance with the inhibitor manufacturers
365 “Chimney sweep” button
366 Service button
instructions.
367 ECO button To drain the appliance shut the system valves and open
the pressure relief valve.
Suitable flushing agents and inhibitors are available
from Betz/Dearborn Tel.: 0151 4209563 and Fernox
Tel.: 01799 550811. Instructions for use are supplied
with the these products.
B Before commissioning, the gas supply pressure must
be tested (see page 29).

6 720 610 576 GB (02.05) 23

Commissioning

B Unscrew the condensation trap (358) and pull out, fill 5.3 Switching on the central heating
with approx. 1/4 l of water and refit. Refer to fig. 29.
The central heating flow temperature is adjustable
B Adjust charge pressure of expansion vessel to static between 35°C and 88°C. Refer to table 12, page 26.
head of the central heating system (see page 26).
B Open all system radiator valves. B Turn the temperature control to set the flow tem-
perature to a level appropriate to the type of central
B Turn on service valves (170), fill central heating sys- heating system:
tem to pressure of 1 - 2 bar through the WRc
approved filling loop. Refer to fig. 29. – Underfloor heating: e.g. setting “3”
(approx. 50°C)
B Vent radiators.
– Low-temperature heating: setting “E”
B Refill heating system and set the pressure to 1 bar. (approx. 75°C)
B Turn on cold water service cock (173). Refer to – Central heating systems for flow temperatures up
fig. 29. to 88 °C: limited “max” setting for low-temperature
B Check that the gas type specified on the identifica- operation (see page 26).
tion plate matches that of the gas supply. When the burner is alight, the red indicator lamp
B Turn on gas cock (172). Refer to fig. 29. lights up.

5.2 Switching the appliance on/off

Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the central heating flow temperature, when the
appliance is operating in the central heating mode. 6 720 610 333-05.1O

Fig. 31

5.4 System controls

B Set room thermostat to the desired room tempera-
ture.
B Set outside - temperature driven control unit, if fitted.
Refer to the instructions with the control.
6 720 610 333-04.1O
B Set the thermostatic radiator valves to the desired
Fig. 30 settings.

If the display alternates between -II- and 5.5 Setting the domestic hot water
i the central heating flow temperature, the
trap filling programme is active.
temperature and flow rate
5.5.1 Domestic hot water temperature
The trap filling programme ensures that the condensa- The hot water temperature can be set to between
tion trap is filled after the appliance has been installed approx. 40 °C and 60 °C.
or after the appliance has been out of use for a long This temperature is not shown on the display.
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.

Switching off the appliance

B Set the master switch to (0).
The green indicator lamp goes out.
6 720 610 333-07.1O
B Always disconnect the appliance from
the power supply (fuse, circuit breaker) Fig. 32
before carrying out any work on the
electrical systems or components.

24 6 720 610 576 GB (02.05)

 Commissioning

Setting Hot Water temperature

5.6 Summer mode (hot water only)

Turn fully anti-clockwise approx. 40°C With room thermostat

approx. 55°C B Turn temperature control on the appliance anti-

clockwise as far as the stop.
Turn fully clockwise approx. 60°C The central heating is now turned off. The hot water
Table 10 function and the mains power supply for the heating
programmer and timer remain switched on.
“ECO” button
By pressing and holding the “ECO” button until the 5.7 Frost protection
display lights, you can switch between Comfort mode
and Economy mode. B Leave master switch switched on.

Comfort mode: button is not lit (factory setting) If the appliance is to be left for long periods switch the
central heating off:
The appliance is held constantly at the set temperature.
This means that hot water is available almost instanta- B Add a suitable anti-freeze fluid to the water in the
neously at the tap. Consequently the appliance will central heating system.
switch on at intervals, even if no hot water is being Suitable products are available from Betz-Dearborn
drawn. Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
ECO mode with demand detection, button is lit
The demand detection function enables maximum gas
5.8 Pump anti-seize function
and water economy.
Briefly turning a hot water tap on and then off again sig-
This function prevents the central heating
nals demand to the appliance which then heats up the
water to the set temperature. i pump seizing after long periods of inactiv-
ity.
Hot water is thus available in about 1 minute.

ECO mode, button is lit Every time the pump is switched off, a timer is started.
If after 24 hours the pump has not run again, it is
Water is not heated up until hot water is drawn. This
switched on for a period of 5 minutes.
means that there is a longer waiting period before hot
water is available.
5.9 Fault Condition
5.5.2 Hot water flow rate
The flow rate is factory set to 8 l/min. A list of faults that may occur is given on
Under standard conditions (2 bar) supply pressure, one
full turn is equivalent to approximately 2 l/min.
i page 43.

B To increase the flow rate (max. 14 l/min): In the unlikely event of a fault occuring while the appli-
turn screw on flow switch anti-clockwise (+). ance is in operation:
The outlet temperature will decrease relative to the The display then shows a fault code and the button -
increase in the flow rate. may also flash.
B To reduce the flow rate (min. 8 l/min): If the button flashes:
turn screw on flow switch clockwise (–).
B Press and hold the button until the display shows
The outlet temperature will increase relative to the
“– –”.
decrease in the flow rate.
The appliance will then start up again and the display
will show the central heating flow temperature.
If the button does not flash:
B Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the central heat-
ing flow temperature will be displayed.

6720 610 332-25.1O

Fig. 33

6 720 610 576 GB (02.05) 25

Individual settings

6 Individual settings

6.1 Mechanical settings B Rotate yellow button through 180° and replace (dot
facing inwards).
6.1.1 Checking the size of the expansion vessel The CH flow temperature is no longer limited.
Maximum pressure at maximum CH flow temperature is
2.5 bar. If the pressure is greater than this then fit an Control setting CH flow temperature
extra expansion vessel. Refer to table 11. 1 approx. 35°C
System Capacity – BS7074:1 2 approx. 43°C
3 approx. 51°C
Expansion Vessel Pressure and System Capacity 4 approx. 59°C
5 approx. 67°C
Expansion Vessel litres 10
E approx. 75°C
Expansion Vessel bar 0.75 max approx. 88°C
Charge Pressure
Table 12
System 1 bar litres 82
6.1.3 Changing the heating pump characteristic
pressure
and 1.5 bar litres 46 The speed of the central heating pump can be altered
capacity on the pump terminal box.

Table 11 At switch position 1, maximum output is

6.1.2 Setting the central heating flow tempera- i not delivered if hot water mode is active.
Position 1 must not be used on combi ap-
ture
pliances.
The central heating flow temperature can be set to
between 35°C and 88°C.
0,7
H
With underfloor heating systems, observe (bar)

i the maximum permissible flow tempera-

tures.
0,6

0,5
3
Limited maximum setting for low-temperature
operation 0,4

The temperature control is factory limited to setting E, 2

0,3
giving a maximum flow temperature of 75°C.
Adjustment of the heating output to the calculated heat 0,2
demand is not required by the heating systems regula-
1
tions. 0,1

Removing the maximum setting limit

0
For heating systems which require higher flow tempera- 0 200 400 600 800 1000 1200 1400 1600
tures, the maximum setting limit can be removed. Q (l/h)
6 720 610 576-23.2O
B Lift off the yellow button on the temperature control
with a screwdriver. Fig. 35
1 Pump characteristic for switch position 1
2 Pump characteristic for switch position 2
3 Pump characteristic for switch position 3
H Residual delivery pressure
Q Water circulation rate

6 720 610 332-27.1O

Fig. 34

26 6 720 610 576 GB (02.05)

 Individual settings

6.2 Settings on the Bosch Heatronic

6.2.1 Operating the Bosch Heatronic Entering a setting
The Bosch Heatronic enables easy setting and check- B To enter the setting for a function, turn the tempera-
ing of a large number of appliance functions. ture control .
This description is limited to those functions required
for commissioning. Storing a setting
For a full description of all available functions, please B Level 1: press and hold the button until the dis-
refer to the Service booklet for the Engineer, play shows [ ].
number 7 181 465 346. B Level 2: press and hold the and buttons simul-
taneously until the display shows [ ].
2 5 1
After completing the settings
B Reset the temperature controls and to their
original positions.

6.2.2 Selecting the pump control mode for cen-

6 720 610 332-30.1O

3 4 tral heating mode (Service Function 2.2)

Fig. 36 Appliance controls If an outside temperature driven control

1
2
Service button
“Chimney sweep” button
i unit is connected, pump control mode 3 is
automatically activated
3 Temperature control for central heating
4 Temperature control for hot water The choice of settings is as follows:
5 Display
• Control Mode 1
Selecting service function: For heating equipment without a control unit.
The pump is controlled by the central heating flow
Note the positions of the temperature con- temperature control.
i trols and . After completing the set-
tings, return the temperature controls to • Control Mode 2 (factory setting)
their original positions. For heating systems with room thermostat.
The central heating flow temperature control controls
The service functions are subdivided into two levels: only the gas, the pump is not affected. The room ther-
Level 1 comprises service functions up to function 4.9, mostat controls both the gas and the pump.
while Level 2 consists of the service functions from 5.0 The pump and fan have an overrun time of between
upwards. 15 s and 3 min.
B To select a service function on Level 1: press and • Control Mode 3
hold the button until the display shows – –. The pump is controlled by the outside temperature
B To select a service function on Level 2: press and driven control unit. In summer mode, the pump oper-
hold the buttons and simultaneously until the ates only for hot water mode.
display shows = =. 6.2.3 Setting the anti-cycle time
B Then turn the temperature control to select the (Service Function 2.4)
required function. This service function is only active if Service Function
2.7, automatic anti-cycle time, is deactivated.
Service function Code no. See page The anti-cycle time can be set to between 0 and 15 min-
Pump control mode 2.2 27 utes (is factory set to 3 minutes).
Anti-cycle time 2.4 27 If the setting 0 is entered, the anti-cycle time is inactive.
Max. CH flow
The shortest possible anti-cycle time is 1 minute (rec-
temperature 2.5 28
ommended for single-pipe and hot-air heating systems).
Switching difference 2.6 28
Max. heating output 5.0 28 If the appliance is connected to an out-
Constant hot water
cycle time 6.8 28
i side-temperature controlled heating pro-
grammer, the anti-cycle time does not
Table 13 need to be set on the appliance and is op-
timised by the programmer instead.
The service function 5.0 may be reset.

6 720 610 576 GB (02.05) 27

Individual settings

6.2.4 Setting the maxim CH flow temperature B Refer to the settings tables for heating and cylinder
(Service Function 2.5) charging output to obtain the relevant code for the
The maximum CH flow temperature can be set to desired heating output in kW (see page 45).
between 35°C and 88°C (factory setting). B Turn the temperature control until the display
shows the desired code number.
6.2.5 Setting the switching difference The display and the and buttons will flash.
(Service Function 2.6)
B Measure the gas flow rate and compare with the fig-
If the appliance is connected to an out- ures specified for the code number displayed. If fig-
i side-temperature controlled programmer,
the programmer sets the switching differ-
ures do not match, adjust the code number!
B Press and hold the and buttons simultane-
ence. ously until the display shows [ ].
It does not need to be set on the appli- The heating output is now stored.
ance.

The switching difference is the permissible divergence

from the specified CH flow temperature. It can be set in
increments of 1 K. The adjustment range is 1 to 30 K (is
factory set to 0 K). The minimum CH flow temperature
is 30°C.
6 720 610 332-52.1O

6.2.6 Setting the heating output

Fig. 39
(Service Function 5.0)
B Return the temperature controls and to their
The heating output can be set to any level between min.
original positions.
rated heat output and max rated heat output to limit it to
The display will revert to the CH flow temperate.
the specific heat requirements.
6.2.7 Constant hot water cycle time
The full rated heat output is still available
i for hot water or charging the hot water cyl-
inder even if the heating output has been
(Service Function 6.8)
In Comfort mode “ECO light off” , the hot water inside
limited. the appliance is held constantly at the set temperature.
For that reason, the appliance switches on if the water
The factory setting is the max. rated heat output. temperature falls below a certain temperature. In order
to prevent it switching on and off too frequently, the
B Press and hold the and buttons simultane- constant hot water cycle time service function allows
ously until the display shows = =. you to set the minimum period between switching off
The and buttons will light up. and on again. This function has no effect on normal
demand for hot water and relates only to the constant
hot water function in Comfort mode.
The cycle time can be set to any period between 20 and
60 minutes (is factory set to 20 minutes).

6 720 610 332-50.1O

6.3 Setting the gas/air ratio
Fig. 37 Refer to section 7.1 for details of the method of setting
the gas/air ratio.
B Turn the temperature control until the display
shows 5.0.
After a short delay, the display then shows the set
heating output in percent.

6 720 610 332-51.1O

Fig. 38

28 6 720 610 576 GB (02.05)

 Converting the appliance to different gas types

7 Converting the appliance to different gas types

The setting is factory sealed at maximum. Adjustment to 7.1 Setting the gas/air ratio
the rated heat input and min. heat input is not neces-
sary. B Switch off the appliance at the master switch (O).
The gas/air ratio may only be adjusted on the basis B Remove the outer case (see page 15, refer to
of a CO2 measurement at max. heat output and min. fig. 12).
heat output using an electronic tester. B Switch on the appliance at the master switch (I).
B Unscrew sealing plug from flue gas testing
Checking the gas supply pressure
point (234). Refer to fig. 40.
B Check the gas supply pressure at the gas supply B Insert testing probe about 135 mm into the flue gas
pressure testing point. testing point and seal testing point.

Natural gas appliances must not be oper-

i ated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is not 37 mbar.

Natural gas
234
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m3 and 20 mbar supply
pressure and sealed.

Conversion kits
6 720 610 332-57.1R

For conversion Fig. 40

Model from ... Order no.
B Press and hold button until the display shows – –.
ZWB 7-27 N.G to L.P.G 7 710 149 044 The button will light up.
HE combi

ZWB 11-27 L.P.G to N.G 7 710 239 080

HE combi
Table 14
• Instructions are sent with each conversion kit. 6 720 610 332-32.1O

Fig. 41
B Turn the temperature control until the display
shows 2.0 .
After a short delay, the current operating mode set-
ting will be displayed (0. = Normal mode).

6 720 610 332-60.1O

Fig. 42

6 720 610 576 GB (02.05) 29

Converting the appliance to different gas types

B Turn the temperature control until the display B Turn the temperature control anti-clockwise until
shows 2. the display shows 1. (= min. rated heat output).
(= max. rated heat output). The display and the button will flash.
The display and the button will flash.

6 720 610 332-63.1O

6 720 610 332-61.1O

Fig. 45
Fig. 43 B Measure the CO2 level.
B Measure the CO2 level. B Remove the seal from the gas valve adjusting screw
B Prise off the seal on the gas flow restrictor. (64) and adjust the CO2 level to the figure given in
B Adjust the gas flow restrictor (63) to obtain the CO2 Table 15 for min. rated heat output.
level given in Table 15. Refer to fig. 44.

63

6 720 610 332-64.1R

Fig. 44 Fig. 46
B Measure the CO level.
CO2 reading If the CO level is over 300 ppm, the gas volumetric
at max. CO2 reading flow rate is too high. Reduce the gas flow rate on the
rated heat at min. rated adjustable gas flow restrictor (63) until the CO level
Gas Type output heat output is below 100 ppm.
Natural gas type 9.5 % 9.2 % B Re-adjust the CO2 level if necessary.
H (23) B Recheck the levels at min. and max. rated heat output
LPG 11.3 % 11.0 % and re-adjust if necessary.
(propane) B Turn the temperature control anti-clockwise as
Table 15 far as the stop so that the display shows 0.
B Measure the CO level. (= Normal operating mode).
If the CO level is over 300 ppm, the gas volumetric The display and the button will flash.
flow rate is too high. Reduce the gas flow rate on the B Press and hold the button until the display
adjustable gas flow restrictor (63) until the CO level shows [ ].
is below 100 ppm. B Reset the temperature controls and to their
B Re-adjust the CO2 level if necessary. original positions.
The display will revert to the CH flow temperature.
B Remove testing probe from the flue gas testing point
(234) and refit sealing plug.
B Re-seal gas valve adjusting screw and gas flow
restrictor.
B Replace outer case and secure.

30 6 720 610 576 GB (02.05)

 Converting the appliance to different gas types

7.2 Testing combustion air/flue gas at set heat output

7.2.1 Testing the O2 or CO2 level in the combus- 7.2.2 Testing CO and CO2
tion air
B Press and hold the button until the display
By testing the O2 or CO2 level in the com- shows – –.
i bustion air the gas tightness of a type C13
or C33 flue system can be checked. The
“Chimney sweep” mode is now active.
The button will light up and the display shows the
O2 level must not be less than 20,6 %. CH flow temperature.
The CO2 level must not exceed 0,2 %.
You have 15 minutes in which to measure
B Press and hold the button until the display i the levels. After that, the appliance switch-
es back from “chimney sweep” mode to
shows – –.
normal mode.
“Chimney sweep” mode is now active.
The button will light up and the display shows the
B Remove sealing plug from flue gas testing point
CH flow temperature.
(234, fig. 47).
In “chimney sweep” mode, the appliance B Insert testing probe about 135 mm into the testing
i switches to max. rated heat output or the
set heating output. You then have 15 min-
point and seal testing point.

utes in which to measure the levels. After B CO- and CO2 levels.
that, the appliance switches back from B Refit sealing plug.
“chimney sweep” mode to normal mode. B Press and hold button until the display shows – –.
The button will stop flashing and the display
B Remove sealing plug from combustion air testing shows the CH flow temperature.
point (234.1, fig. 47).
B Insert testing probe about 80 mm into the testing
point and seal testing point.

234
234.1

6 720 610 332-65.1R

Fig. 47
B Measure O2 and CO2 levels.
B Refit sealing plug.
B Press and hold button until the display shows – –.
The button will stop flashing and the display
shows the CH flow temperature.

6 720 610 576 GB (02.05) 31

Maintenance

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

B Always turn off the gas cock before car-

rying out any work on components
which carry gas.

There is a Service booklet for the Engi-

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

All safety and control systems are moni-

i tored by the Bosch Heatronic. In the event
of a component fault, the display shows a
fault code.

B The User should be recommended to have the appli-

ance serviced regularly by a competent person (see
Maintenance Contract).
B Use only genuine spare parts
B Refer to the Spare Parts List when ordering spare
parts.
B Always renew seals and O-rings removed during
servicing or repair work.
B Use only the following types of grease:
– Water valve: WRc approved silicon based grease
– Unions: approved sealant.
B To drain the appliance shut the system valves and
open the pressure relief valve.

32 6 720 610 576 GB (02.05)

 Maintenance

8.1 Pre-Service Check List

Date

1 Call up the last fault stored by the

Bosch Heatronic, Service Function .0,
(see page 34).

2 Check ionisation current, Service

Function 3.3, (see page 34).

3 Perform visual check of air/flue

duct.Visual check of diaphragm for
soiling and splits (see page 36).

4 Check gas supply pressure mbar

(see page 29).

5 Test combustion air/flue gas

(see page 31).

6 Check CO2 setting for min./ min. %

max. (gas/air ratio)
(see page 29). max. %

7 Check gas and water systems for

leaks (see page 16).

8 On combi models, check hot water

outlet temperature (see page 34).

9 Check heat exchanger mbar

(see page 34).

10 Check burner (see page 35).

11 Clean condensation trap

(see page 36).

12 Check charge pressure of mbar

expansion vessel matches
static head of heating system.

13 Check central heating system mbar

pressure.

14 Check electrical wiring for damage.

15 Check heating programmer settings.

16 Check appliances that are part of

the heating system
Table 16

6 720 610 576 GB (02.05) 33

Maintenance

8.2 Description of servicing operations

The combustion performance must be checked before Primary Heat exchanger
and after any servicing work on the combustion and There is a special accessory kit (no. 840) for cleaning
burner components. Refer to section 7.2. the heat exchanger, order no. 7 719 001 996.
Check “Last fault stored”: B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manome-
B Select Service Function .0 (see page 27 “Selecting
ter.
service function”).

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

page 43.
To delete “Last fault stored”:
B Turn temperature control anti-clockwise as far as
the stop.
B Press and hold the button until the display
shows [ ].
The last fault stored has now been deleted.

Checking the ionisation current,

Service Function 3.3
6 720 610 332-69.1R
B Select Service Function 3.3 (see page 27 “Selecting
Fig. 49
service function”).

If the display shows 2 or 3, the ionisation current is OK. The heat exchanger should only be
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced.
i cleaned if the control pressure is
2.2 mbar (depression) or less.
Domestic hot water B Remove cleaning access cover (415, page 6) and
If the flow rate is too slow: the metal plate below it, if present. Refer to fig. 2.
B remove the domestic hot water heat exchanger and B Unscrew condensation trap and place suitable con-
replace, tainer underneath. Refer to fig. 50.
-or- B Remove the fan and the burner as described in the
B descale with a descaling agent approved for use on text headed “Burner” (see page 35).
stainless steel.
B Before removing the heat exchanger shut the inlet
valve and drain the hot water circuit.
B Use new seals when replacing the heat exchanger.

6 720 610 332-72.1R

Fig. 50

7 181 465 330-06.1R

Fig. 48

34 6 720 610 576 GB (02.05)

 Maintenance

B Loosen any deposits in the heat exchanger from top Burner

to bottom using the cleaning blade. Refer to fig. 51.
B Check that the gas cock is turned off and the master
switch is in the OFF position.
B Remove the clips (1) and unscrew the two bolts (2).
Refer to fig. 54.
B Unscrew and remove the two hexagon screws secur-
ing the fan (3).
B Slacken fully the rear securing bolt (4).
B Remove the burner coverplate.

4.
6 720 610 332-73.1R

Fig. 51 2.
B Clean the heat exchanger from top to bottom using 3.
the brush. Refer to fig. 52. 1.

7 181 465 330-04.1R

Fig. 54
B Remove burner and clean components. Do not use a
wire brush. Refer to fig. 55.

6 720 610 332-74.1R

Fig. 52
B Remove the fan and the burner (see section headed
“Burner”) and flush the heat exchanger from the top.
B Clean out the condensate collector and trap connec-
tion (with other end of brush).

1.
H 2O

2.

7 181 465 330-08.1R

6 720 610 332-75.1R

Fig. 55
Fig. 53
B Refit the clean-out cover using a new seal and B Re-assemble burner in reverse order using a new
tighten screws to torque of approx. 5 Nm. seal.
B Adjust gas/air ratio. Refer to section 7.2.

6 720 610 576 GB (02.05) 35

Maintenance

Diaphragm in mixer unit B Replace and re-connect the assembly taking care not
to mislay the inspection window.
B Take care not to damage diaphragm
(443) when removing and refitting it. Siphon
B Unscrew the clip and disconnect the pipe to the
B Open mixer unit (29). siphon.
B Carefully withdraw diaphragm (443) from fan intake B Remove the yellow plug to drain the siphon.
tube and check for soiling and splits. B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
B Refit and prime the siphon.

3.
443 Condensate
Drain

Siphon

1.

29

6 720 610 602 - 16.1O

2.
6 720 610 790 - 07.1O

Fig. 56 Fig. 57
B Carefully refit diaphragm (443) the correct way round
into the fan intake tube.

The flaps of the diaphragm (443) must

i open upwards.

B Seal the mixer unit (29).

Condensation trap
In order to prevent spillage of condensate, the conden-
sation trap should be completely removed, (see
page 34, fig. 50).
B Unscrew condensation trap and check connection to
heat exchanger is clear.
B Remove condensation trap cover and clean.
B Fill condensation trap with approx. 1/4 l of water and
refit.

Electrode assembly
B Switch off the master switch.
B Pull off the leads from the electrodes. Refer to fig. 2.
B Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 49.
B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4,5 mm ± 0,5 mm.)

36 6 720 610 576 GB (02.05)

 Maintenance

Expansion vessel
The expansion vessel should be checked once a year.
B Depressurise appliance.
B If necessary, adjust expansion vessel charge pres-
sure to static head of the heating system.

Heating system pressure

Fill the system using the WRc approved
i filling loop.

B The pointer on the pressure gauge should be 1 bar.

B If the pointer is below 1 bar (when the system is
cold), water should be added until the pointer is
1 bar again.
B Max. pressure of 2.5 bar when the heating system
water is at maximum temperature must not be
exceeded. If this pressure is exceeded then an extra
expansion vessel must be fitted in the system return
as close to the appliance as possible.
B If the system does not retain the pressure, the expan-
sion vessel and the heating system should be
checked for leaks.

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

6 720 610 576 GB (02.05) 37

Maintenance

8.3 Replacement of Parts B Remove the pcb control board.

Before changing any components check that the gas is
turned off and that the appliance is electrically isolated.
When necessary close the system valves and drain the
appliance.
Refitting is a reverse of the procedure for removal using
new seals or o-rings as appropriate.

8.3.1 PCB control board and transformer

B Switch off the appliance.
B Disconnect appliance from the power supply.
B Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the
covers. Refer to fig. 24, 25.
B Remove screw holding power connector earth lead
and remove earth lead.
B Remove two top fixing screws from the control box.
Refer to fig. 58.

1
3
2 4

3 4 1
7 181 465 330-10.1R
3

2
2 4

1
E
Fig. 59

1
Fuses
3
2 4

7 181 465 329-02.1R

B Remove the connections covers. Refer to fig. 24,

25.

The fuses are located adjacent to the mains connector

block and connector ST18. Refer to fig. 4.
Fig. 58
Fuse, item 312, is only replaceable by removing the
B Lower the control box. pcb.
B Unscrew earth lead. Spare fuses are fixed to the connections cover.
B Unscrew four fixing screws from cover plate. Refer to A fuse pack is available: Part number 8 744 503 010 0.
fig. 59.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.

38 6 720 610 576 GB (02.05)

 Maintenance

8.3.2 Fan Assembly 8.3.3 Pump

B Switch off the appliance.
3. B Disconnect the appliance from the power supply.
B Remove two switchbox fixing screws (1.). Refer to
fig. 61.
2. B Lower switchbox (2.).
B Unscrew and remove the the siphon by releasing the
jubilee clip. Refer to fig. 57.
B Unscrew the pump union nuts (3.). Refer to fig. 61.
4. B Carefully remove the pump and disconnect the leads.

Alternatively
B After removing the siphon release the four Allen
screws and remove and replace the pump head.

3.

1. 7 181 465 330-05.1R

Fig. 60
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 60. 1.
B Remove fan lead and earth connector (2.). The earth 1.
connector has a positive clip fixing.
B Remove fixing screws attaching fan to the burner
cover (3.).
B Remove fan together with gas pipe and mixer unit.
B Separate the fan from the pipe and mixer unit by 2.
twisting the mixer unit to release it (4.). Fig. 61

6 720 610 576 GB (02.05) 39

Maintenance

8.3.4 3-way diverter valve 8.3.6 Sensors

B Switch off the appliance. B Check that the appliance is electrically isolated.
B Disconnect appliance from the power supply. Central Heating Flow Temperature Sensor –
B Turn off service cocks. Item 36, fig. 2, 58
B Unplug connector from 3-way valve motor. Refer to B Pull-off the connector.
fig. 62.
B Release the sensor clip and withdraw the sensor.
B Pull out retaining clip.
B Apply heat transfer paste to the replacement sensor.
B Remove motor.
B Disconnect the relief valve drain. Safety Temperature Limiter – Item 6, fig. 2, 58
B Disconnect the pressure gauge. B Pull-off the connectors.
B Undo pipe unions. B Unscrew the sensor.
B Remove 3-way valve.
Flue Temperature Limiter – Item 9, fig. 2, 58
B Pull-off the connectors.
B Unscrew the sensor.

Domestic Hot Water Temperature Sensor –

Item 6.1, fig. 2
B Check that the inlet water valve is closed and the
domestic hot water circuit is drained.
B Release and pull-off the connector.
B Unscrew the sensor.

7 181 465 330-12.1R

Fig. 62

After refitting:
B Fill system, bleed and re-pressurise
(see Installation Instructions).

8.3.5 3-way diverter valve motor

B Switch off the appliance.
B Turn off the service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 62.
B Pull out retaining clip.
B Remove motor.

40 6 720 610 576 GB (02.05)

 Maintenance

8.3.7 Gas Valve 8.3.8 Domestic Hot Water Heat Exchanger

B Check that the gas cock is turned off. B Refer to section 7.2.
B Lower the control panel. Refer to fig. 61. B Use new seals when fitting the new heat exchanger.
B Pull off the solenoid connections at the rear of the 8.3.9 Electrode assembly
valve.
B Undo the union, within the inner casing, securing the B Refer to section 7.2.
valve to the gas/air tube. Refer to fig. 60. B Use a new seal if the existing seal is damaged.
B Remove the white plastic cap from the gas valve. 8.3.10 Pressure gauge
B Release the gas inlet union at the manifold assembly.
B Drain the appliance.
B Unscrew the two screws securing the gas valve
B Lower the facia. Refer to fig. 61.
assembly bracket to the back panel and withdraw the
assembly. B Twist the pressure gauge head anti-clockwise to
release it from the casing. Refer to fig. 2.
B Transfer the bracket and inlet pipe assembly to the
new gas valve. B Disconnect the capillary head from the rear of the
diverter valve by withdrawing the clip and pulling out
B Check for gas soundness when the new gas valve
the head. Refer to fig. 62.
has been fitted.
B Recheck the combustion performance as described 8.3.11 Expansion vessel
in section 7.1.
B Drain the appliance.
B Undo the union connection at the base of the vessel.
Refer to fig. 2.
B Unscrew the top and bottom fixing screws and
remove the vessel.
B Set the pressure of the new vessel to that required by
the system.

8.3.12 Pressure Relief Valve

B Drain the appliance.
B Disconnect the drain pipe from the valve. Refer to
fig. 29.
B Pull-out the clip securing the valve.
B Pull-out the valve.
B Ensure that the replacement valve is fully entered
before fitting the clip.

8.3.13 Burner
B Refer to section 8.2.

6 720 610 602 - 04.1O

Fig. 63

6 720 610 576 GB (02.05) 41

Maintenance

8.3.14 Flow switch B Pull forward from the top and lift the heat exchanger
from the casing.
B Shut the mains water inlet valve and drain the domes-
tic hot water circuit. B Transfer components, as necessary, to the new heat
exchanger.
B Pull-off the connectors from the micro-switch.
B Ensure that all the seals are in place and all of the
B Unscrew the inlet and union connection and remove
connections are tight before re-commissioning the
the assembly.
appliance.
B Reset the domestic hot water flow rate on the new
assembly.

OUTLET

INLET

6 720 610 602 - 05.10

Fig. 64

8.3.15 Primary Heat Exchanger

B Drain the appliance. 6 720 610 602 - 06.10

B Check that the gas supply is turned off.

Fig. 65
B Check that the appliance is electrically isolated.
B Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 8.3.2.
B Remove the burner. Refer to section 8.2.
B Disconnect the sensors. Refer to section 8.3.6.
B Undo the central heating flow union.
B Undo the top connection of the pump. Refer to
fig. 61.
B Undo the grey plastic cap, next to the top pump con-
nection at the base of the heat exchanger.
B Unscrew and remove the condensate trap. Refer to
section 8.2.
B Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
B Lift up the flue duct, item 271, refer to fig. 2.

42 6 720 610 576 GB (02.05)

 Appendix

9 Appendix

9.1 Fault Codes

More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.

Display
code Description Remedy

A7 Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for
circuit breaks/short circuits.
A8 Break in communication Check connecting lead to programmer
AC Module not detected. Check connecting lead between TA211E/TR212E
and Heatronic
b1 Keyed plug not detected. Insert keyed plug correctly, test and replace if neces-
sary.
C1 Fan speed too low. Check fan lead and connector, and fan; replace as
necessary.
d3 Jumper 8-9 not detected. Connector not connected, link missing, underfloor
heating limiter tripped.
E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting lead.
E9 Safety temp. limiter in CH flow has tripped. Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA Flame not detected. Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0 Internal error. Check electrical connector contacts, programmer
interface module ignition leads are not loose; replace
pcb if necessary.
F7 Flame detected even though appliance switched off. Check electrode assembly, dry pcb. Flue clear?
FA Flame detected after gas shut off. Check gas valve and wiring to gas valve. Clean con-
densation trap and check electrode assembly. Flue
clear?
Fd Reset button pressed by mistake. Press reset button again
P1, P2, P3, Please wait, initialisation in progress. 24 V fuse blown. Replace fuse.
P1...
Table 17

6 720 610 576 GB (02.05) 43

Appendix

9.2 Short parts list

Key Description Qty GC Spare part number

1 Sensor - Flue gas temp. 1 8 729 000 144 0

2 Sensor - CH flow temp. 1 8 714 500 087 0
3 Sensor - DHW flow temp. 1 8 714 500 054 0
4 Control board 1 8 748 300 418 0
5 Gas valve 1 8 747 003 516 0
6 Fan assembly 1 8 717 204 373 0
7 Fan washer 1 8 729 000 183 0
8 Expansion vessel 1 8 715 407 236 0
9 Relief valve 1 8 717 401 012 0
10 Electrode assembly 1 8 718 107 077 0
11 Electrode lead 1 8 714 401 999 0
12 Pump 1 8 717 204 477 0
13 Pressure gauge 1 8 717 208 079 0
14 Burner skin seal 1 8 711 004 168 0
15 Transformer - facia 1 8 747 201 358 0
16 Flow switch 1 8 717 002 110 0
17 3-way diverter valve 1 8 717 010 062 0
18 Heat exchanger washer 1 8 710 103 153 0
19 Washerset Condenstaion Trap 1 8 710 103 154 0
20 Fuseset 1 8 744 503 010 0
21 Serviceset Water Valve 1 8 710 503 031 0
22 Domestic Hot Water 1 8 715 406 659 0
Heat Exchanger
23 Primary heat exchanger 1 8 715 406 615 0
Table 18

44 6 720 610 576 GB (02.05)

 Appendix

9.3 Heating/hot water output settings (N.G.)

Natural gas G20

Display Heat output kW Heat input kW Gas vol. flow rate (l/min at tV/tR = 80/60°C)
code
30 8.2 8.3 14.4
40 10.9 11.0 19.3
50 13.6 13.8 24.1
60 16.3 16.5 28.9
70 19.1 19.3 33.7
80 21.8 22.0 38.5
90 24.5 24.8 43.3
100 27.2 27.5 48.1
Table 19

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

Propane
Display
code Heat output kW Heat input kW
40 10.9 11.0
50 13.6 13.8
60 16.3 16.5
70 19.1 19.3
80 21.8 22.0
90 24.5 24.8
100 27.2 27.5
Table 20

6 720 610 576 GB (02.05) 45

 46

Fig. 66

9.5.1

9.5

Appendix
** NOTE:
The appliance controls can be set to one of

Operational Flow diagrams

Domestic hot water function
Pump ON Fan to Ignition
Diverter valve start speed. Ignition sequence spark
operates. Gas valve opens. 5 secs
2 modes of operation.
1. “Comfort“ mode -
Full pre-heat
Burner shut-down if 2. “ECO“ mode -
primary temperature
Pre-heat satisfied.
Burner lights. exceeds 94 °C remains
a) Operates as an instantaneous combination
Red light ON. OFF until 78 °C boiler.
b) Demand Detection: a short demand (less
Over temperature
than 5 seconds) switches the control to
Burner remains OFF “Comfort“ mode for 5 mins. Mini pre-heat.
Gas valve shuts. shut-down if water
until flow temperature
Pump remains ON. temperature is 8°C The Factory setting is “Comfort“ mode.
is below set value.
above set value.

.
Heat input
Gas valve Fan runs for
Mains Green Hot Pump ON Fan to modulates to
Pre-heat Demand closes. upto 3 mins. Pre-heat
switch light water Diverter valve start speed. maintain the
mode.** ends. Red light Pump runs mode.**
ON. ON. demand. operates. Gas valve opens. delivery
OFF. for 30secs.
temperature.

Ignition sequence

Ignition spark for Burner lights. Yes

5 seconds. Red light ON.

No

Repeats 5 times Fan runs to purge

before lock-out. gas from burner.
6 720 610 576 - 24.1O
6 720 610 576 GB (02.05)
6 720 610 576 GB (02.05)

Fig. 67

9.5.2
Over temperature
Burner remains OFF
Gas valve shuts. shut-down if water

Central heating function

until flow temperature
Pump remains ON. temperature is 5°C
is below set value.
above set value.

Room thermostat
and/or mains
programmer or Boiler
link ON operates to
Mains Green AND CH
Pump ON
Fan to
Burner
stabilises at
Fan speed
reduces
Fan min.
Boiler
unused for
Yes *
Minimum
match
switch light Electronic facia speed for system load
demand. start speed. start speed over 15 long heat input
ON. ON. programmer 90 secs. and CH
Gas valve opens. for 5-10 secs secs. period.* for 15min.
(if fitted) ON control
AND setting.
CH control knob
No
ON. ce

Ignition sequence

Gas valve
Pump and Fan
Ignition spark for Burner lights. Yes CH demand closes.
run for upto
5 seconds. Red light ON. satisfied. Red light
3 mins.
OFF.

No

Repeats 5 times Fan runs to purge * NOTE: The sequence ensures that the condensate siphon is not empty
before lock-out. gas from burner. after long OFF periods. (More than 24 hours without a demand).

6 720 610 576 - 25.1O

Appendix
47
Appendix

EXCELLENCE COMES AS STANDARD

Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619