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Benchmark RD 532i, Installation And Servicing Instructions

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Benchmark RD 532i Installation And Servicing Instructions Download Page 6

6 720 611 449 GB (03.11)

6

Details of the appliance

1.6

Layout of appliance

Fig. 2

4

Heatronic control

6

Heat exchanger safety temperature limiter

7

Testing point for gas supply pressure

8.1

Pressure gauge

9

Flue gas temperature limiter

15

Relief valve

18

Pump

20

Expansion vessel

27

Automatic air vent

29

Air gas Mixer unit

32.1

Electrode assembly

36

Temperature sensor in CH flow

43

CH flow

63

Adjustable gas flow restrictor

64

Adjusting screw for min. gas flow volume

88

3-way valve 

102

Inspection window

120

Fixing points 

221.1

Flue duct

221.2

Combustion air intake

226

Fan assembly 

295

Appliance type sticker

271

Flue duct

349

Cover plate for twin flue duct connection

358

Condensae trap

396

Hose Condensate trap

400

Textdisplay

415

Cover plate for cleaning access

416

Condensate collector

418

Data plate

423

Siphon

6 720 610 603 - 02.1O

29

102

226

271

416

221.1

221.2

20

43

9

63

358

64

7

4

415

6

36

32.1

295

8.1

18

27

88

15

120

418

400

396

423

Summary of Contents for RD 532i

Page 1: ...6 720 610 893 01 TD Installation and Servicing Instructions RD 430i Wall mounted condensing boiler for central heating ZSBR 7 30 RD 430i GC Number 41 108 06 6 720 611 449 GB 03 11 TD...

Page 2: ...etting the Economy temperature TR2 connected 29 6 5 3 Manual operating mode TR2 not connected 30 6 6 Hot water 30 6 6 1 Hot water programme 30 6 6 2 Hot water immediately 30 6 7 i Info 30 6 8 Settings...

Page 3: ...f 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...

Page 4: ...ting not dependent on room size Natural gas models are low emission appliances Multifunction display Bosch Heatronic control system with integrated tex tdisplay for servicefunctions and faults 3 chann...

Page 5: ...g dimensions Fig 1 13 Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System min 160 mm Alternative Concentric Flue System min 250 mm Y Standard Concentric Horiz...

Page 6: ...H flow 43 CH flow 63 Adjustable gas flow restrictor 64 Adjusting screw for min gas flow volume 88 3 way valve 102 Inspection window 120 Fixing points 221 1 Flue duct 221 2 Combustion air intake 226 Fa...

Page 7: ...36 Temperature sensor in CH flow 43 CH flow 45 Gas 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 63 Adjustable gas flow restri...

Page 8: ...ansformer 161 Link 226 Fan 300 Code plug 302 Earth connection 310 Temperature control for hot water 312 Fuse slow T 1 6 A 313 Fuse slow T 0 5 A 317 Digital display 328 Terminal block for AC 230 V Main...

Page 9: ...J m3 mbar 20 LPG CVnet 88 MJ m3 mbar 37 Expansion vessel Charge pressure bar 0 75 0 75 Total capacity l 10 10 Flue Flue gas temp 80 60 C rated min load C 67 55 67 55 Flue gas temp 40 30 C rated min lo...

Page 10: ...ting for Domestic Premises BS 5546 Installation of gas hot water supplies for domestic purposes BS 5440 1 Flues and ventilation for gas appliances of rated input not exceeding 70 kW net Flues BS 5440...

Page 11: ...nce as possible The filling point must be at low level and arranged as shown in figs 5 and 6 The pressure relief valve is set to operate at 3 bar There must be no connection to the mains without the a...

Page 12: ...Fig 5 It is not recommended to use any external valves or con trollers in addition to the in built equipment Fig 6 RV LV LV RV RV RV LV LV INDIRECT CYLINDER APPLIANCE Refer to Appliance Water Flow Di...

Page 13: ...d fluorine compounds and are contained in some sol vents paints adhesives aerosol propellants and house hold cleaners for example Surface temperature The max surface temperature of the casing and the...

Page 14: ...ll mounting frame to the wall with the screws provided B Mark the position of the flue duct hole if a rear flue is to be used Refer to fig 1 and 16 Fig 8 B Screw the pre plumbing manifold with two scr...

Page 15: ...zontal runs and with a downward slope of at least 2 5 3 6 Fitting the appliance Removing the outer case B Remove retaining screws 1 see Fig 13 B Slide the outer case upwards and forwards to remove 2 F...

Page 16: ...sure on the gas supply pipe 3 8 Flue Systems The only flue systems that may be used are those sup plied with the boiler The flue system must be installed in accordance with the requirements of BS5440...

Page 17: ...I I boundary Q K H H A F J P 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 B1 Above...

Page 18: ...er flue systems are packed with the relevant flue kit Check that the position chosen for the appliance is sat isfactory Refer to fig 16 Fig 16 Marking the position of the side flue opening Note ensure...

Page 19: ...assembly Measure the flue length L Refer to fig 21 22 Maximum 1600mm Clamp Flue Turret Terminal Assembly Outer Wall 6 720 610 599 00 TD Extension Duct Clamp Flue Turret Terminal Assembly Outer Wall 6...

Page 20: ...solvent free grease is lightly applied i e Silicone lubricant to the male end of the ducts NOTE An inner wall sealing plate is provided which should be fitted to the ducts before assem bly Push the as...

Page 21: ...down facia cover The drop down cover is removed by lowering it to the horizontal position and pushing firmly upwards at the rear of the supports to release the cover Lift cover from the appliance Afte...

Page 22: ...ecting a Hot Water Cylinder The sensor for the connection is in the package of the appliance B Snap out plastic tongue B Insert cylinder NTC sensor lead B Plug connector into PCB Fig 29 Care must be t...

Page 23: ...m should be flushed in accordance with the guidelines given in BS7593 1992 Treatment of water in domestic hot water systems Full instructions are supplied with proprietary cleansers sold for this pur...

Page 24: ...at the condensa tion trap is filled after the appliance has been installed or after the appliance has been out of use for a long period or the mains supply has been interrupted For that reason the app...

Page 25: ...l 0151 4209563 Fernox Tel 01799 550811 and Salamander Tel 0121 378 0952 5 8 Pump anti seize function Every time the pump is switched off a timer is started If after 24 hours the pump has not run again...

Page 26: ...eated the House Address 8 Make the jumper JP1 on the ADM while powering up the appliance see Fig 35 Observe LED on ADM flashing The flashing rate is 0 5 Hz the ADM is now in House Address Acquisi tion...

Page 27: ...an example B To start programming press any button e g The display lighting switches on and the main menu is displayed Fig 37 Main menu B Use the or button to move the cursor arrow on the left of the...

Page 28: ...e following message is displayed Please wait Initialising 6 3 Menu structure i The hours of service can not be reset to 0 C C C Submenu Main menu 1 2 3 Parameters to change select Page Set hour day Se...

Page 29: ...t protection Same times for Monday to Friday Same times for Saturday and Sunday Different times for every day Setting switching times and operating mode B From the main menu select Heating and then fr...

Page 30: ...Hot water program B Set the days of the week Blocked Released operat ing mode in the same way as for the switching points and modes for heating as described on page 29 6 6 2 Hot water immediately Hot...

Page 31: ...from the third submenu Language Time correction LCD contrast Time correction B Press and hold the button about 5 seconds until the display shows Time correction and LCD contrast B Press or to select...

Page 32: ...eans of setting various appliance functions This description is limited to those functions necessary for commissioning Displaying service functions All service functions are displayed B Press any butt...

Page 33: ...ce Function 2 5 The maximum CH flow temperature can be set to between 35 C and 88 C factory setting 7 2 4 Setting the heating output Service Function 5 0 The heating output can be set to any level bet...

Page 34: ...play service parameters B Press and hold the button for about 5 sec onds until the display shows Adjust service parameters and the first service function to be set 2 0 Operating mode If a fault has oc...

Page 35: ...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 8 2 2 Testing CO and CO2 B Press and...

Page 36: ...istance to earth Replace the text display module or the Heatronic PCB If the text display module is replaced the service func tion settings are retained B The remaining settings have to be re entered...

Page 37: ...bustion air flue gas see page 35 6 Check CO2 setting for min max gas air ratio see page 35 min max 7 Check gas and water systems for leaks see page 16 8 Check heat exchanger see page 38 mbar 9 Check b...

Page 38: ...eck control pressure on the air gas mixer unit at max rated heat output using an electronic manome ter Fig 45 B Remove cleaning access cover 415 page 6 and the metal plate below it if present Refer to...

Page 39: ...erse order using a new seal B Adjust gas air ratio see page 34 Refer to section 8 2 Condensation trap In order to prevent spillage of condensate the conden sation trap should be completely removed see...

Page 40: ...n vessel charge pres sure to static head of the heating system Heating system pressure 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...

Page 41: ...o fig 25 26 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 54 Fig 54 B Lower the control box B Unscrew earth l...

Page 42: ...er switchbox 2 B Remove screw from underside of right hand plastic cover plate 3 B Pull cover plate forwards to remove 4 B Unscrew and remove the the siphon by releasing the jubilee clip Refer to fig...

Page 43: ...em 6 fig 2 54 B Pull off the connectors B Unscrew the sensor Flue Temperature Limiter Item 9 fig 2 54 B Pull off the connectors B Unscrew the sensor 9 3 7 Gas Valve B Check that the gas cock is turned...

Page 44: ...valve is fully entered before fitting the clip 9 3 12 Burner B Refer to section 9 2 9 3 13 Primary Heat Exchanger B Drain the appliance B Check that the gas supply is turned off B Check that the appli...

Page 45: ...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 elec...

Page 46: ...1 8 711 004 168 0 14 Transformer facia 1 8 747 201 358 0 15 Flow switch 1 8 717 002 110 0 16 3 way diverter valve 1 8 717 010 062 0 17 Heat exchanger washer 1 8 710 103 153 0 18 Washer set Condensati...

Page 47: ...ve set value Pump ON Fan to start speed Gas valve opens Burner stabilises at start speed for 5 10 secs Fan speed reduces over 15 secs Fan min speed for 90 secs Boiler unused for long period Minimum he...

Page 48: ...ppendix EXCELLENCE COMES AS STANDARD Manufactured exclusively for British Gas by The Bosch Group Bosch Group Worcester Heat Systems Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01...

Page 49: ...combi Condensing boiler RD 430i system Condensing boiler 6 720 610 598 00 2O ZWBR 7 32 RD 532i GC Number 47 108 10 ZWBR 11 37 RD 537i GC Number 47 108 11 ZWBR 11 42 RD 542i GC Number 47 108 12 System...

Page 50: ...15 3 5 Combination Boilers Setting Hot Water Temperature 16 3 6 System boiler with Storage Tank 17 3 7 Summer Mode Hot Water Only Combi Appliances 18 3 8 Frost protection Combi Appliances 19 3 9 Faul...

Page 51: ...diately System models 31 4 7 i Info 32 4 8 Settings 33 4 8 1 Heating if TR 2 is connected 33 4 8 2 Hot Water Storage Tank System boiler models only 33 4 8 3 Service 33 4 9 Individual timer programmes...

Page 52: ...And it s backed up by British Gas Offering a complete mainte nance scheme to keep your boiler operating at peak condition and efficiency No wonder that more and more people are agreeing that when it...

Page 53: ...ors and windows B Do not operate any electrical switches B Do not smoke B Extinguish any naked flames B Call your gas company If you smell fumes from the appliance B Switch off appliance B Open window...

Page 54: ...no potential hazard due to the appliance being electri cally unsafe B There are no substances used in the construction that are a potential hazard in relation to the COSHH Regulations Con trol of Subs...

Page 55: ...being heated at an even rate If the top of a radiator is at a lower temperature than the bottom then it should be vented by releasing air through the venting screw at the top of the radiator Ask your...

Page 56: ...ces Thermostatic radiator valves It is recommended that this type of valve is fitted to all the radiators except one usually the radiator where the room temperature con troller is fitted They should c...

Page 57: ...e will still operate in the central heating mode Use in hard water areas Combination Boilers In exceptionally hard water areas a device to prevent scale forma tion may be fitted Installation of a scal...

Page 58: ...604 GB 03 06 Do not allow the flue terminal fitted on the outside wall to become obstructed or damaged Pump The pump is a fully modulating type to which the parameters have been set by the manufacture...

Page 59: ...and return 171 Hot water 172 Gas isolation valve open 173 Cold water inlet 295 Identification sticker 310 Hot water temperature control 317 Display 363 Indicator lamp for burner on 364 Indicator lamp...

Page 60: ...ith direction of flow the cock is open Central heating system valves 170 B Using a spanner turn square nut until groove is in line with direction of flow see detail Groove at right angles to direction...

Page 61: ...1 bar when the system is cold top up the system with water until the pointer is 1 bar Your installer will have shown you how to do this B The maximum operating pressure of 2 5 bar at maximum central...

Page 62: ...res that the condensation trap is filled after the appliance has been installed or after the appliance has been out of use for a long period For that reason the appli ance remains at minimum heating o...

Page 63: ...ting E approx 75 C Max setting 88 C When the burner is lit the red indicator lamp is illuminated Fig 5 3 4 Controlling Central Heating B Set the timer to the correct time B Set room thermostat to the...

Page 64: ...on By pressing and holding the ECO button until the display lights you can switch between Comfort mode and Economy mode Comfort mode button is not lit factory setting The appliance is held constantly...

Page 65: ...ECO mode button is lit Water is not heated up until hot water is drawn This means that there is a longer waiting period before hot water is available 3 6 System boiler with Storage Tank B Set the hot...

Page 66: ...e ECO mode button is lit In ECO mode the appliance switches between central heating mode and cylinder charging mode every 12 minutes 3 7 Summer Mode Hot Water Only Combi Appliances With room temperatu...

Page 67: ...ely event of a fault occuring while the appliance is in operation The display and the text display then shows a fault code and the button may also flash If the button flashes B Press and hold the butt...

Page 68: ...odule has a power buffer period of about 10 hours during which it will run without the mains power supply After that period has elapsed the clock function shuts down but all other settings are retaine...

Page 69: ...rating modes may be displayed during commis sioning servicing etc The programming procedure is described in detail below using the clock function as an example B To start programming press any button...

Page 70: ...ime day B Confirm the selection by pressing the button The corresponding submenu is displayed Fig 11 Setting the hour When settings are being entered the setting to be altered is indi cated on the top...

Page 71: ...other buttons for 15 minutes 4 2 1 Deleting a setting Either overwrite the setting or press the button to delete it B Find the setting to be deleted B Press and release the button The display shows 4...

Page 72: ...ays Days holiday 25 Heating Heating program Day 1st operating mode 1st switching point 6th switching point 27 Set econ omy temp if TR2 is connected 5 30 C 28 Manual if TR2 is not con nected Automatic...

Page 73: ...Holidays B Enter the number of days holiday by pressing or max 99 days holiday After the set number of days the text display module automat Settings Heating Optimum Start Off On 33 Hot water System b...

Page 74: ...mode early B In the Holidays submenu Press the button until the display shows 0 i The day on which you enter the days holiday counts as the first day of the holiday i e the unit starts the holiday pro...

Page 75: ...rday and Sunday Different times for every day Setting switching times and operating mode B From the main menu select Heating and then from the first submenu select Heating program B Select Monday Frid...

Page 76: ...o not wish to change can be skipped by pressing 4 5 2 Setting the Economy temperature if TR2 is con nected This option allows you to set the room temperature for Economy mode Off Economy This function...

Page 77: ...stant on comfort and Constant off economy The manually selected operating mode starts immediately Constant off economy and Constant on comfort are auto matically reset at 00 00 midnight To cancel the...

Page 78: ...enabled from 5 00 am disabled from 10 00 pm The ECO button must not be lit Comfort mode System models with Storage Tank The basic settings pro vide a timer programme enable from 5 00 am disable from...

Page 79: ...cked Released operating mode in the same way as for the switching points and modes for heating as described on page 27 4 6 2 Hot water immediately System models Hot water immediately ON Comfort mode i...

Page 80: ...for CH flow Actual flow temp Actual CH flow temperature Required flow temp Required CH flow temperature Max HW temp Maximum permissible hot water out flow temperature Required HW temp Required hot wa...

Page 81: ...e up to six different times with temperatures see page 30 Hot water Only times During that times the Storage Tank will be charged to the choosed temperature B From the main menu select Settings and fr...

Page 82: ...ction LCD contrast Time correction B Press and hold the button about 5 seconds until the display shows Time correction and LCD contrast B Press or to select Time correction B Press the button The disp...

Page 83: ...submenu select Operating times Fault history This option displays any faults that have occurred for the informa tion of the service engineer The first fault displayed may still be active Any other fa...

Page 84: ...Operating mode Time Operating mode Time Operating mode Time Operating mode Time Monday Tuesday Wednesday Thursday Friday Saturday Sunday Enable disable hot water function Switching point 1 2 3 4 5 6 S...

Page 85: ...em Desired room temperature exceeded by large amount Radiators are too hot Turn down ther mostatic valves Temperature rises instead of falling Clock is incor rectly set Check setting Room tempera ture...

Page 86: ...ermostatic radiator valves The central heating control on the boiler should be set to the max imum rated temperature of the central heating system or to posi tion E when the maximum central heating wa...

Page 87: ...s please contact your installer or write to us 7 General Information Cleaning the Outer Case Wipe down the outer case with a damp cloth Do not use abrasive or caustic cleaning agents Appliance details...

Page 88: ...fe and to ensure it con tinues to operate at peak efficiency and performance it is essen tial that your boiler receives regular competent servicing and maintenance checks beyond the initial 2 year gua...

Page 89: ...OR Our Field Service Engineer finds no fault with the appliance see NOTE OR The cause of breakdown is misuse or with other parts of your plumbing heating system or with equipment not supplied by Worc...

Page 90: ...first 2 year service has been carried out to the satisfaction of Worcester Heat Systems Limited when requested That any product or part thereof returned for servicing under the guarantee any component...

Page 91: ...e and will assist us in maintaining an effective and efficient customer service by establishing a refer ence and permanent record for your boiler This will not affect your statutory rights in any way...

Page 92: ...ay Set switching times and operating mode within the text display Hot water temperaeture Combi nation boiler only ECO button lit Economy mode ECO button not lit Comfort mode Fault Condition Refer to p...

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