Bosch Condens 2000F16 Regular boiler Installation, Commissioning And Servicing Instruction Manual Download Page 61

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FAULT FINDING AND DIAGNOSTICS

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Summary of Contents for Condens 2000F16 Regular boiler

Page 1: ...allation Commissioning and Servicing Instruction manual Floor standing gas fired condensing appliance Condens 6720809859 00 1W o 2000F16 30 42 Regular boiler 3000F 16 30 System boiler 6 720 816 930 2015 04 ...

Page 2: ...Water treatment 25 7 4 Starting the appliance 25 7 5 Checking gas inlet pressure 26 7 5 1 Measuring the inlet pressure 26 7 5 2 Checking the gas rate 26 7 6 Finishing commissioning 26 7 7 Commissioning checklist 27 8 Thermal disinfection 28 8 1 Perform thermal disinfection 28 8 2 Thermal disinfection for system with a hot water tank 28 9 Operating the appliance 29 9 1 Controls overview 29 9 2 Scre...

Page 3: ...ty of the appliance Chemically aggressive substances can corrode the appliance and invalidate any warranty Fitting and modification Fluesystemsmustnotbemodifiedinanywayotherthanasdescribedin the fitting instructions any misuse or unauthorised modifications to the appliance flue or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any...

Page 4: ...s heat only gas fired condensing boilers with an integrated circulating pump and optional 3 way valve for the connection of the hot water tank KBR units heat only gas fired condensing boilers without a circulating pump or optional three way valve for use in systems where this is provided externally 2 5 1 Electrical supply Supply 230V 50 Hz External Quick blow 3A fuse The appliance must be earthed ...

Page 5: ...Not used on the regular boiler 4 Hot water return 1 5 Condensate outlet 6 80 125 Flue outlet System boiler 1 Heating and DHW flow 1 2 Gas 3 4 3 DHW return 1 only if optional diverter valve kit is fitted 4 Heating return 1 5 Condensate outlet 6 80 125 Flue outlet 1 6 2 3 4 6720809859 10 1Wo 1 2 3 4 466 394 61 78 111 141 253 Ø80 Ø125 98 130 162 193 5 83 59 900 930 ...

Page 6: ...lame sense electrode 7 Electrode assembly 8 Flow temperature sensor 9 High limit thermostat 10 Heat exchanger inspection cover 11 Condensate pan 12 Pressure relief valve 13 Drain cock 14 Condensate trap 15 Gas valve 16 Flue overheat thermostat 17 Air Intake pipes 30 and 42kW boilers only 18 Manual vent 19 Pre mix chamber 20 Spark generator 21 Fan 22 Combustion chamber cover 2 14 16 12 10 11 15 9 8...

Page 7: ...4 1 Appliance terminal connector block 2 Mains supply 3 Heat control module HCM 4 Spark generator 5 Spark electrodes 6 Flame sense electrode 7 High limit thermostat 8 Flow temperature sensor 9 Flue overheat thermostat 10 Gas valve 11 Fan L1 N L2 N N 1 11 3 4 2 9 7 5 6 8 10 6720809859 08 1Wo ...

Page 8: ...erating pressure bar 3 00 Gas flow rate Max 10 minutes from lighting Natural Gas G20 m3 h 1 66 3 28 4 05 Natural Gas G25 m3h 1 54 3 17 3 92 Propane Gas G31 kg h 0 61 1 27 1 65 Gas supply pressure Natural Gas G20 mbar 20 20 20 Natural Gas G25 mbar 25 25 25 Propane Gas G31 mbar 37 37 37 Flue Flue Gas Temp 80 60 C max min C 67 55 67 55 67 55 67 55 77 55 77 55 67 55 67 55 77 55 Flue Gas Temp 40 30 C m...

Page 9: ...ory Factorysetting gasfamily gas group and test gas Factory setting rated gas pressure mbar Installation type Natural gas LPG Austria AT 20 50 Cat II 2H 3P G20 20 B23 B23P B33 C13X C33X C43X C53X C63X C83X C93X France FR 20 37 Cat II 2E SI 3P G20 20 Italy IT 20 37 Cat II 2H 3B P G20 20 Czech Republic CZ 20 37 Cat II 2H 3B P G20 20 Russia RU 13 37 Cat II 2H 3B P G20 20 Poland PO 20 37 Cat II 2H 3P ...

Page 10: ...in the system versus system flow Fig 7 p mbar Pressure loss in millibars F litres h Re circulated quantity of water in litres per hour 75 80 85 90 95 100 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 kW A Metres 1 2 6720809859 76 1Wo 0 50 100 150 200 250 300 350 400 450 500 550 600 0 300 600 900 1200 1500 1800 2100 P mbar F litres h 6720809859 88 1Wo ...

Page 11: ...rature sensor 9 High limit thermostat 10 Heat exchanger inspection cover 11 Condensate pan 12 Auto air vent 13 Diverter valve assembly only with option accessory kit 14 Pump 15 Drain cock 16 Pressure relief valve 17 Condensate trap 18 Gas valve 19 Flue overheat thermostat 20 Air Intake pipes 30 and 42kW boilers only 21 Manual vent 22 Mixing device 23 Spark generator 24 Flue exhaust 25 Fan 26 Combu...

Page 12: ... block 2 Mains electrical supply connector 3 Heat control module HCM 4 Spark generator 5 Spark electrodes 6 Flame sense electrode 7 High limit thermostat 8 Flow temperature sensor 9 Diverter valve connection 10 Pump 11 Flue overheat thermostat 12 Gas valve 13 Fan L1 N L2 N N 1 13 9 3 4 2 11 7 5 6 8 6720809859 07 1Wo 12 10 ...

Page 13: ...issible operating pressure bar 3 00 Gas flow rate Max 10 minutes from lighting Natural Gas G20 m3 h 1 66 3 28 Natural Gas G25 m3 h 1 54 3 17 Propane Gas G31 kg h 0 61 1 27 Gas supply pressure Natural Gas G20 mbar 20 20 Natural Gas G25 mbar 25 25 Propane Gas G31 mbar 37 37 Flue Flue Gas Temp 80 60 C max min C 67 55 67 55 67 55 67 55 67 55 67 55 Flue Gas Temp 40 30 C max min C 43 25 43 25 43 25 43 2...

Page 14: ...ion Product Name 6 720 YYYY MM Pumphead versus Flow rate Fig 10 APH Available pump head FR Flow rate 1 Actual data 2 Extrapolated data 0 1 2 3 4 5 6 7 8 0 500 1000 1500 2000 6720809859 87 1Wo 1 2 APH m wg FR l hr Pump m wg ...

Page 15: ...emperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 15 3 30 1 38 1 15 3 30 1 At 30 of rated heat output and low temperature regime 2 2 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet P1 kW 3 5 7 9 4 3 5 7 Useful efficiency At rated heat output high temperature regime 1 4 88 2 88...

Page 16: ...umentation supplied with the flue gas system 3 5 Room air dependent operation The boiler primarily operates as a room air sealed unit however the boiler can be operated as a room air dependant unit if required Provide sufficient boiler room ventilation when operating the appliance room air dependent Do not obstruct or block any ventilation openings Ventilation openings must always be kept clear 3 ...

Page 17: ...lue installations CAUTION MAINS POWER ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS NOTICE Protect the boiler Debris from the system can damage the boiler and reduce efficiency Failure to comply with guidelines for the use of water treatment with the appliance will invalidate the appliance warranty WARNING Sealing agents The addition of sealing age...

Page 18: ...Release the hose clamp 1 Remove the screw retaining the trap 2 Pull the trap down to remove the trap from boiler Pour 250ml of clean water into the top of the trap Re fit the trap to the boiler Fig 12 Condensate trap Installcondensateneutralisationsystems optionalaccessory inline with the installation instructions Ensure that the condensate pipework leading away from the appliance falls away towar...

Page 19: ...CE Boiler start up All the previous Pre Installation sections must be read and requirements met before starting boiler or flue installation NOTICE Boiler handling At all times the correct method for handling heavy objects should be strictly observed Take care not to damage the boiler panels or floor The boiler may contain water due to factory testing Store the boiler in a dry area prior to install...

Page 20: ... access to the pipe work Do not cross a pipe over another Fig 17 Pipe Connections System boiler 1 Heating and DHW flow 1 2 Gas 3 4 3 System boiler DHW return 1 only if optional diverter valve kit is fitted Regular boiler Not used 4 Heating return 1 5 Condensate outlet NOTICE Damage caused by insufficient load bearing or unsuitability of the boiler room floor Ensure the floor area is suitable for i...

Page 21: ... inspection Voids containing concealed flues must have at least one inspection hatch no less than 300mm square Fluejointswithinthevoidmustnotbemorethan1 5 metres from the edge of the inspection hatch Inspection hatches should be located at changes of direction Ifthisisnotpossible bendsshouldbeviewablefrom both directions NOTICE Effective flue lengths each 90 bend used is equivalent to 2 0 metres o...

Page 22: ...3 RSF flue Fig 20 C93 RSF flue L1 Ø110 Ø 80 Ø 80 125 6720809859 83 1Wo A C33 1m L Boiler output kW L max metres L1 max metres Equivalent length 93 flue elbow metres Equivalent length 15 and 45 flue elbow metres 16 13 3 2 1 30 13 3 2 1 42 13 3 2 1 Table 11 L1 Ø 80 L Ø 80 125 A 6720809859 84 1Wo 1m C93 L ...

Page 23: ...22 Flexible B33 flue L1 Ø 80 A Ø 80 125 1m 6720809859 85 1Wo L B33 Boiler output kW L max metres L1 max metres Equivalent length 93 flue elbow metres Equivalent length 15 and 45 flue elbow metres 16 13 3 2 1 30 13 3 2 1 42 13 3 2 1 Table 12 Ø 80 125 A Ø 80 6720809859 86 1Wo L1 L 1m B33 ...

Page 24: ... power cables can induce spurious faults on signal cables ensure that there is at least 300mm separation from each other CAUTION ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS Allelectricalworkmustbecarriedoutbyacompetent and authorised person Allworkmustbeinlinewithcountryspecificandlocal standard and regulations The isolator must have co...

Page 25: ...5 Check the condensate pipe work is correctly fitted and connected 6 Refit cover onto the bottom clips and secure with the ball catches 7 2 Filling the system and checking for leaks Check the heating system for leaks to avoid problems during commissioning and operation Ensure good ventilation ensure all isolating valves in the heating circuits and radiation temperature regulating valves are fully ...

Page 26: ...ows the appliance temperature Fig 32 Main power switch NOTICE Damage to property from overpressure during pressure tests Pressure control and safety devices may be damaged by excessive pressure After filling the system pressure test to the release pressure of the safety valve NOTICE Damagecausedbycracksfromthermalshock Crackscanoccurwhentopingupawarmheatingsystem with cold mains water The boiler c...

Page 27: ... minutes operation at maximum See technical data section at the front of this manual Where a gas meter is not available e g L P G the CO CO2 must be checked to the units shown in section Setting the air gas ratio If pressure and gas rate are satisfactory press the button and the boiler will return to normal operation If left in the Chimney sweep mode the control will return to normal operation aft...

Page 28: ... 9 Measure and record gas supply pressure mbar 10 Measure flue gas values and record Full load Partial load Flue gas pressure Pa Flue gas temperature gross tA C Air temperature tL C Flue gas temperature net tA tL C CO2 or O2 content Vol Flue gas losses qA CO content air free ppm Supply air CO2 or O2 content when operating room sealed Vol 11 Check for leaks during operation 12 Functional tests Meas...

Page 29: ...iler and working your way to the furthest outlet Set the circulation pump and control system back to normal operation Thermal disinfection via built in controller The Thermal disinfection is perform via the built in controller and is automatically started and ended Turn off all hot water taps Warn the occupants about the potential for scalding Set any other pumps for continuous operation Activate ...

Page 30: ... required 5 Chimney sweep mode 6 Fault alert 7 Service mode 6 7 Maintenance mode 8 Burner on 9 Temperature units C 10 Confirmation 11 Scroll up or down through the sub menus 12 Alphanumeric display e g Temperature 13 Text display 14 Heating mode off 15 Heating mode on 9 3 Appliance on off switch Initial switch on To switch on use the main appliance on off switch on the control panel The display li...

Page 31: ...ress the button The display shows the flashing maximum flow temperature and the Heating mode symbol is displayed Fig 40 Maximum flow temperature Press the or button to set the desired maximum flow temperature Press ok to save the setting The tick symbol is displayed briefly to confirm that the setting has been saved Fig 41 Setting the maximum flow temperature The controller has a pump anti seize f...

Page 32: ...hen switches back into heating mode 9 5 2 Setting the DHW temperature DHW or Eco mode section 9 5 Press the button The set DHW temperature flashes Fig 44 Pressthe or button toselectthedesiredDHWtemperature set between 40 and 60 C Press the ok button to save the setting The tick symbol is displayed briefly to confirm that the setting has been saved Fig 45 9 6 Control unit setting Some of the featur...

Page 33: ...bol flashing Press the ok button to save the setting The tick symbol is displayed briefly to confirm the setting For more information refer to the control system manual 9 8 Setting frost protection Heating system frost protection Set the maximum flow temperature to 30 C Section 9 4 2 or turn the appliance off Drain the heating system down For more information please refer to the control system man...

Page 34: ...cription can be found at the beginning of each section about the various menus To access the various menus see Menu info see section 10 2 2 Menu 1 see section 10 2 3 Menu 2 see section 10 2 4 Menu 3 see section 10 2 5 Test menu see section 10 2 6 Press the or button to scroll the menu area The text line 10 displays the service function and the alphanumeric display 2 shows the value of this service...

Page 35: ... in real time i12 DHW temperature The hot water set temperature i13 Temp at the storage tank temp sensor only with attached hot water tank i15 Current outside temperature Only displayed when an external temperature sensor system is connected i16 Actual system pump modulation Display in of pump modulation system boiler only i17 Current heating Displayin ofmaximumratedheatoutput in heating mode 1 1 ...

Page 36: ...ot water tank connected 8 Hot water tank connected Default setting is 0 Service function Possible settings Table 20 Menu 2 2 2J Storage priority Possible settings 0 Storage priority the storage tank is heated to temperature first and then the boiler switches to heating mode 1 When heat is required by the storage tank the boiler alternates between heating and hot water every ten minutes Default is ...

Page 37: ...ins at the end of heat demand Possible settings are 0 to 60 Follow up time in minutes 1 minute increments 24H follow up time 24 hours Default setting is 3 minutes 2 9L Hot water cylinder thermal disinfection This feature enables the storage cylinder to be heated to 70 C Possible settings are 0 Thermal disinfection is not active 1 Thermal disinfection active Default setting is 0 not active Thermal ...

Page 38: ...he sample point and correctly positions the end of the probe Allow the readings to stabilise and check that O2 is equal to or greater than 20 6 Service function Possible settings 3 1A Upper limit of maximum heating power for 2 1A This service feature allows the servicetechnician thesettingforthe maximum heat output service function 2 1A limit Default setting is the maximum rated output 3 1b Upper ...

Page 39: ...bustionchambercoverand remove to gain access to the components Fig 52 Component access 10 4 1 Control panel Service position To lower the control panel into the service position remove one top screw 1 from each side of the mounting bracket loosen the bottom screws slightly and pivot the panel forward The control panel is supported at approximately 100 Fig 53 Control panel to the service position 1...

Page 40: ...e taken switch the boiler off Remove the combustion air intake pipe Disconnect the manometer and replace the test point cover Replace the combustion air intake pipe 10 7 Flue gas analysis Combustion test Connect the flue gas analyser to the flue gas sampling point 1 as shown in the figure below Ensure that the probe reaches the centre of the flue gas exhaust adjust the cone on the probe so that it...

Page 41: ...clockwise to increase the setting Set the boiler to minimum output MeasuretheCO2 value itshouldbeatthefigureforminimumoutput shown in table 23 It not remove the brass dust cap 3 from the minimum adjuster Using a 4mm Allen key to adjust the minimum setting 4 on the gas valve until it is correct turn clockwise to increase and anti clockwise to decrease the setting Return the boiler to maximum output...

Page 42: ...uds Unscrew and remove the two hexagon headed nuts 4 securing the fan Remove the nut 5 from the rear stud 6 Remove the burner head 7 2 Remove the burner and clean the components Do not use a wire brush Fig 61 1 Clips 2 Castellated nuts 3 Washers Springs 4 Hex head nuts 5 Rear nut 6 Spacer Re assembly of the burner cover Re assemble the burner in reverse order using a new seal 8 Insert the burner c...

Page 43: ...an intake Carefully withdraw the flap valve from fan intake tube and check for soiling and splits clean or replace as required Take care when refitting the flap valve the flaps must open upwards into the fan in take tube After re assembly check CO CO2 levels as described in the section Setting the air gas ratio To clean the condensate trap Refer to figure 70 on page 49 to remove the trap Remove th...

Page 44: ...el pressure Check the operating pressure 4 Isolate the boiler and check the burner and heat exchanger for contamination 5 condensate trap 6 ignition system 7 Check the gas supply 8 Check the flue intake and exhaust and connections 9 Record readings Flue gas pressure Flue gas temperature gross tA Air temperature tL Flue gas temperature net tA tL CO2 or O2 content Flue gas losses qA CO content air f...

Page 45: ...n a state is detected the maintenance requires these operations must be carried out as required Full Load Partial load Full load Partial load Full load Partial load Full load Partial load 1 2 3 4 5 6 7 8 9 10 11 12 13 Table 25 Inspection and Service checklist continued ...

Page 46: ...m 2 Clean burner and heat exchanger 3 Replace burner gasket 4 Replace electrode set c 5 Clean condensate trap siphon 6 Functional check Confirm correct inspection Company stamp date signature Table 26 Date Date Date Date 1 2 3 4 5 6 Confirm correct inspection Company stamp date signature Table 27 Demand dependent maintenance ...

Page 47: ...y the mounting bracket Fig 64 Control panel to the service position CAUTION Mains supplies Turn off the gas supply and isolate the mains electrical supply before starting any work and observer all relevant safety precautions Draintheboiler systemwherenecessaryandprotect any electrical equipment from water ingress during component replacement NOTICE Gaskets Refit or replace any components removed f...

Page 48: ...ead and earth connector The earth connector has a positive clip fixing Remove fixing screws 2 attaching fan to the burner cover 3 Remove fan 4 and mixer unit 5 Twist mixer unit 5 to separate from the fan assembly 4 After re assembly check that the CO CO2 levels are as described in the section Setting the air gas ratio Fig 67 Fan removal 42kW version shown Flap Valve Refer to figure 68 Onallmodels ...

Page 49: ...y until the pipe clears the valve connection Pull the pipe towards you away from the gas valve and slide the pipe out of the mixer unit Remove the solenoid connections 2 at the side of the gas valve Remove the two screws 3 securing the gas valve to the chassis Release the gas inlet union 4 at the valve inlet under the inner casing Remove the gas valve Transfer the inlet pipe assembly to the new ga...

Page 50: ... page 42 After re assembly check that the CO CO2 levels as described in the section Setting the air gas ratio Primary heat exchanger Isolate the appliance from the power supply Turn off all the isolation valves Drain down the appliance Move the control panel into the service position refer to section 10 4 1 Remove the inner case door Remove the fan assembly gas mixing tube refer to section 11 1 2 ...

Page 51: ...r analyser DANGER Poisoning Check for gas tightness using a gas sniffer analyser on gas and flue components DANGER Electric shock Before working on the electrical components disconnect the electrical mains 230 V ac and secure against unintentional re connection 1 2 3 6 720 619 605 33 1O WARNING Scalding Hot water can cause serious burns Drain the appliance before working on water carrying parts NO...

Page 52: ... temperature too high 317 A3 Flue gas sensor shorted 318 E9 Flue gas sensor disconnected Status codes Fault codes 321 Self test of flue gas supervision 322 Code error 323 A8 EMS communication error 324 DHW NTC defect 325 DHW NTC not correctly installed 326 Storage NTC defect 327 Reset key stuck or short circuit 328 Internal error 329 CE No pressure variation detected after switching pump 332 E5 Su...

Page 53: ...during normal operation Displays the last diagnostic code with boiler status code i3 Maximum shared heating Setting of service function 2 1A i4 Maximum shared power Hot water Setting of service function 2 1b i7 Flow temperature The actual control system supply temperature required Table 28 Information menu 6720809859 53 1Wo C F i 1 203 1 2 C F Info i8 Ionisation current When the burner is running ...

Page 54: ...2 This menu lists the boiler parameters which can be adjusted in this menu Tomodifysetting selectthedesiredmenuoption refertotable 30 and press the ok button the option will flash Adjusttheparameterusingtheplusandminusarrowbuttonsandpress the ok button to confirm A will display for three seconds to confirm the update of the new value Ifthesettingisconfirmedpleaserecordthesavedvalueintheemptybox ne...

Page 55: ...mum DHW output Adjust the heat output in kW Compare the gas flow rate with the data table 5 8 In case of any deviations correct the setting 2 1C Pump head selection The pump speed and modulation behaviour is controlled by this setting to always modulate based on the burner power 0 Pump modulates depending on burner power Setting fixed to always be 0 2 1E Pump energy saving mode 4 mode ON 5 mode OF...

Page 56: ... here The output can be down rated Note When maximum boiler output is required for CO CO2 testing this parameter is ignored and full power is delivered for the duration of the test 3 1b Upper limit of the maximum power hot water for 2 1b This service feature allows the servicetechnicianthesettingforthe maximum heating hot water service function 2 1b limit Default setting is the maximum heat output...

Page 57: ...be up to 10 seconds after the button is pressed before the selected component responds t1 Igniter test Checking the igniter spark The igniter will spark for a maximum of 30 seconds The spark will be audible if the igniter is OK t2 Fan test Checking the basic fan operation The fan will run for a maximum of 30 seconds If the fan is OK then the fan will be heard running t3 Pump test Checking the basi...

Page 58: ...after a defined period of time Reset button Fan not running or airflow blocked D1 240 Return sensor error Reset button Sensor wet or damaged the boiler will block for 300 seconds before this condition 241 Return sensor error Reset button Sensor disconnected or damaged the boiler will block for 300 seconds before this condition 286 Return temperature too high Reset button Boiler overheat E2 222 Flo...

Page 59: ...ds before going to Locking error table 33 D4 271 Temperature difference between flow and safety sensors exceeds limit The temperature of the primary flow and the safety sensor on the primary heat exchanger should be within 15 C of each other E9 224 MAX thermostat activated Flue gas thermostat overheat 276 Flow temperature exceeds 95 C Primary overheat boiler waits for temperature to reduce if not ...

Page 60: ...60 FAULT FINDING AND DIAGNOSTICS Product Name 6 720 YYYY MM ...

Page 61: ...FAULT FINDING AND DIAGNOSTICS 61 6 720 YYYY MM Product Name ...

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