Bosch Condens 7000 WP Installation And Maintenance Instructions Manual Download Page 19 | Manualshive

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Electrical connection

19

Condens 7000 WP – 6721842519 (2022/03)

7.3

Overview of plug-in strip

Fig. 23 Overview of plug-in strip

Table 6 Plug-in strip symbols

7.4

Connecting electrical components

All cables from electrical components outside the boiler that are
connected to the plug-in strip must be routed to the inside via the strain
relief.

▶ Connect the connecting leads of the components to the plug-in strip

without tension.

▶ Route the connecting lead through the strain relief.

▶ Position the cable conduit [1].

Symbol

Function

Description

On/Off temperature control (volt free) ▶ Connect an On/Off temperature control. (do not connect 230V directly to these

terminals)

Modulation-controlled control unit and
EMS BUS

▶ Connect modulating temperature controller (EMS bus).

External safety interlock contact (volt
free). This connection contains a link as
standard.

If it is necessary to connect several safety components, e.g. a condensate pump and a
thermal cut out for the underfloor heating system, they must be connected in series. If one
of the safety components are interrupted, the heating load to the wall mounted boiler is
interrupted.

▶ Remove wire link.
▶ Connect safety components (in series).

Attention!

230 V components must only be connected via a relay.

Outside temperature sensor

▶ Connect the outside temperature sensor.

Storage cylinder temperature sensor

▶ Connect cylinder temperature sensor.

Temperature sensor of low loss header ▶ Connect the temperature sensor of a low loss header.

▶ Set the use of the low loss header in the service menu: Settings

>

Hydraulics

>

Low-loss

header.

Function modules

▶ Connect the Bus cable of the function module.
▶ If installed in the boiler, install the function module as described in the instructions (



§

Mains voltage

▶ Connect the 230 V power supply for the function module.

Attention!

The total power consumption of the connected components must not exceed

725 W.

Hot water circulation pump

If a DHW circulation line is used, a secondary circulation pump can be connected.

▶ Connect to the secondary circulation pump.

Mains voltage

Mains plug 230 V

AC

▶ Connect the mains plug, if not pre-assembled (



§ 7.8, p. 21).

Cylinder pump

▶ Connect the cylinder primary pump.

Fine-wire fuse of the burner control unit There is a replacement fuse under the cover flap on the burner control unit.

0010034531-001

120/230 VAC

PW1

PW2

120/230 VAC

I1

I3

T1

BUS

BUS

TW1

T0

BUS

2

1

BUS

120/230 VAC

PW2

120/230 VAC

PW1

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Summary of Contents for Condens 7000 WP

Page 1: ...6721842519 2022 03 GB IE Installation and maintenance instructions for specialists Wall mounted gas condensing boilers Condens 7000 WP GC7000WP 125 23 GC7000WP 145 23 ...

Page 2: ...ve 230 V accessory 20 7 7 Mounting the function module accessory 20 7 8 Fitting the plug if not preassembled 21 8 Commissioning 21 8 1 Commissioning the boiler 21 8 2 Setting the parameters 21 8 3 Air gas ratio control valve switch off options 22 8 4 Measuring the gas standing pressure static 22 8 5 Measuring the gas dynamic working pressure 22 8 6 Measure CO2 and CO 22 8 7 Measure the of the heat...

Page 3: ... material damage and personal injury including danger to life Read the installation service and commissioning instructions heat source heating controller pumps etc before installation Observe the safety instructions and warnings Follow national and regional regulations technical regulations and guidelines Record all work carried out H Determined use The product may only be used in a domestic situa...

Page 4: ... or fluorine compounds This will help to prevent corrosion Keep the combustion air supply free of dust H Installation commissioning and maintenance Installation commissioning and maintenance may be performed only by an approved contractor In the case of open flue operation ensure that the installation location meets the ventilation requirements Do not repair manipulate or deactivate safety relevan...

Page 5: ...dtherelevant addresses on the back of this document 2 6 Scope of delivery A range of accessories is supplied with the GC7000WP Check the heating system is intact on delivery Check that all package contents are present Table 1 Scope of delivery 2 7 Pump test The pump starts automatically for 10 seconds every 24 hours if it is not in use for a longer period This procedure prevents the pump from seiz...

Page 6: ...ondens 7000 WP 6721842519 2022 03 6 2 9 product overview Fig 1 GC7000WP with connection set on frame 0010039414 001 14 10 7 11 6 36 39 38 37 30 35 34 33 31 32 28 13 12 8 9 2 4 1 5 3 16 15 17 19 21 26 27 22 20 24 18 23 25 29 ...

Page 7: ...adaptor 15 Test point for flue gas routing 16 Test point for air supply 17 Upper panel 18 Connection point for diagnosis tool 19 Automatic air vent 20 Internal flue gas routing 21 Gas air mixing pipe 22 Safety temperature sensor 23 CO2 adjusting screw 24 Fan 25 Venturi nozzle 26 Gas hose 27 Air gas ratio control valve 28 Pressure compensation hose 29 Data plate 30 Condensate trap Connection set an...

Page 8: ...10 Dimensions Boiler on frame Fig 2 Dimensions on base frame mm Boiler against the wall Fig 3 Dimensions on the wall mm 0010039235 001 260 260 191 202 198 115 64 200 651 520 115 1690 12 53 260 260 191 115 136 587 5 520 115 53 138 198 1120 100 309 0010039236 001 ...

Page 9: ...orizontal flue outlet In this case also take the diameter of the collar into consideration With a vertical flue outlet Maintain a clearance of at least 100 mm above the boiler to allow the electronic components to be accessed and worked on Minimum space required for the boiler Provide an unobstructed space of at least 100 cm for the boiler to allow maintenance and other work to be carried out Mini...

Page 10: ...of the IEE Wiring regulations governing electrical connection to the mains power supply Regulations and standards regarding the safety equipment in water filled heating systems For guidance see the ICOM water treatment guide for commercial heating systems Make sure that the regional approvals required for the flue system and condensate connection to the public sewage system have been obtained 3 2 ...

Page 11: ... The boiler may only be operated up to a maximum installation altitude of 1200 m above sea level Table 15 technical data see 46 NOTICE The boiler may be operated with combustion air up to a certain maximum temperature Themaximumtemperatureofthecombustionairmustnotexceed35 C Table 15 technical data see 46 5 2 Important notices The boiler must not be operated in open heating systems open vented syst...

Page 12: ...heating water must be checked and reduced if necessary With the chloride content of the heating water If the chloride content is more than 150 ppm perform water treatment as described in the supplied Manual for water quality Set the maximum flow temperature to the required value 9 4 p 25 Contact the manufacturer for more information You will find the relevant addresses on the back of this document...

Page 13: ... As the boiler subsequently needs to be adjusted do not fully tighten the screw Fig 9 Secure the frame to the wall or floor Push the boiler onto the frame The boiler is secured to the frame at the rear If it has been secured correctly a click will be audible Align the boiler in the frame using the adjustment option 1 Fully tighten the grub screw in the frame Fig 10 Align the boiler on the frame 00...

Page 14: ...gn the boiler using a spirit level and adjusting screw on the rear Fig 12 Aligning the boiler on the wall 6 4 Connecting on the heating and gas side The boiler can be connected on the heating and gas side in 2 ways using a connection set accessory 6 5 p 14 without connection set 6 8 S 16 6 5 Mounting the connection set accessories NOTICE Installation damage due to incorrect excess pressure of the ...

Page 15: ...hout stress to the gas valve Install a gas filter in the gas line if required Fig 13 Installing the gas valve 1 Gas connection 2 Two part coupling 3 Gas isolator 6 5 2 Mounting the connection set Mount the flow connection with the flat gasket 1 Mount the pump with the flat gasket 2 Mount the return connection with the flat gasket 3 Tighten the rotary joints handtight Fig 14 Mount the flow return c...

Page 16: ...ter pipe is blocked this can damage the boiler A blockage in the waste water pipe can prevent the removal of condensate from the boiler if the condensate drain line is permanently connected to the waste water pipe Make sure that the connection between the condensate pipes of the boiler and the waste water pipe connection is unobstructed Use a waste water pipe made of plastic material with a diamet...

Page 17: ... the flow and return pipe Fig 18 p 17 6 8 1 Connecting the gas valve Connect the gas valve 6 5 1 p 15 6 8 2 Installing the pump Select the pump using the specifications as the basis Tab 16 3 p 49 Take the required volumetric flow rate into consideration Tab 16 3 p 49 If a low loss header is not used Select a pump with a residual head of at least 200 mbar at the required volumetric flow rate Instal...

Page 18: ...C 50 Hz at all times for commissioning of the boiler The socket must be earthed When establishing the electrical connection also refer to the documentation of the accessory to be connected and the wiring diagram 16 1 p 47 7 1 Handling printed circuit boards Printed circuit boards with control electronics are very sensitive to electrostatic discharge ESD To prevent damage to the components exercise...

Page 19: ...boiler is interrupted Remove wire link Connect safety components in series Attention 230 V components must only be connected via a relay Outside temperature sensor Connect the outside temperature sensor Storage cylinder temperature sensor Connect cylinder temperature sensor Temperature sensor of low loss header Connect the temperature sensor of a low loss header Set the use of the low loss header ...

Page 20: ...applies for these pumps Connect the 230 V mains cable of the pump to the 3 pin plug 1 Guide the 230 V mains voltage cable through the strain relief Close the pump terminal box fold the pump terminal box up and press horizontally until it snaps into place Fig 26 Connecting the pump 1 230 V cable 2 PWM signal cable 7 6 Connecting the 3 way valve 230 V accessory A 3 way valve can only be connected to...

Page 21: ...ssure of 2 bar and close the filling valve Vent the radiators Fill the heating system again to a pressure of 2 bar Open the gas cock Venting the gas line Operate the appliance Start up the boiler 8 2 Setting the parameters Differentparameterscanbesetinthesettingsmenu so theboilercan be adapted to the heating system Go through the parameters in the menu Settings 9 4 p 25 Adjust the parameters if re...

Page 22: ...s ratio control valve Min 17 mbar 2 4 mbar 14 6 mbar Max 25 mbar 2 4 mbar 22 6 mbar Table 8 Pressure drop between gas valve and air gas ratio control valve Calculate the permissible minimum and maximum gas pre pressure Switch off the appliance Remove the front panel Open the gas pre charge pressure test port by turning the adjusting screw through 2 revolutions 8 3 S 22 Set the pressure gauge to 0 ...

Page 23: ...R0 During the subsequent inspection or maintenance the measurement RX should be used as an indication of the contamination Switch off the appliance Remove the front panel Removethecoverofthecondensationcatchpan Fig 38 p 34 Open the gas air ratio test port by turning the adjusting screw through 2 revolutions 8 3 p 22 Set the pressure gauge to 0 Connect the pressure gauge to the gas air ratio test p...

Page 24: ...y or omitting it altogether Drawattentiontothedangersassociatedwithcarbonmonoxide CO and recommend the use of CO detectors Hand over the technical documents to the operator 9 Operation 9 1 Control panel overview Fig 32 Control panel 1 Display 2 and keys 3 Heating water pressure display 4 d key 5 OK key 6 Menu key 7 Hot water key 8 Heating key 9 Burner display See the operating instructions for a d...

Page 25: ...ey or the key Press the OK key The menu or the menu item is displayed To return to the next higher menu level press the d key Changing the setting values Select the menu item with the OK key To select the desired value press the or the key Press the OK key The new value is saved Exiting the menu item without saving values Press the d key The value is not saved Overview of the service menu Info Cur...

Page 26: ... run time Service date1 Limit values Max flow temp Max DHW temp Min boiler outp Heating curve Enable Htg curve base Htg curve end Summer mode Frost prot Frost temp limit Function check Activate test Burner Ignition Fan Pump Cyl prim pump 3 way valve HC1 pump DHW circ pump Ionisat oscill Reset Default setting Service display Fault history Demo mode Yes No 1 With heating controller ...

Page 27: ... Ionisation current Current ionisation current in μA Pump mod Outside temp Current outside temperature in C HC1 pump Own pump installed downstream of low loss header Burner starts Number of burner starts since commissioning Hours run Run time of the system since commissioning System pressure Current operating pressure in bar Hot water Max output DHW act temp Act DHWtmp cyl Current water temperatur...

Page 28: ...ting time between switching on the burner and switching it on again Anticyc temp off 2 6 15 K Thedifferencebetweenthecurrentflowtemperatureand the set flow temperature until the burner is switched off Anticycle temp on 15 6 2 K Thedifferencebetweenthecurrentflowtemperatureand the set flow temperature until the burner is switched on Hot water Max DHW output 50 100 Maximum approved DHW output DHW ci...

Page 29: ...o area of the standard display Siphon fill prog 3 WV mid pos No Yes The function ensures that the system is fully drained and that the motor can be easily removed The 3 way valve remains at the middle position for approx 15 minutes Min Sys Pres 0 6 0 8 bar Target Sys Pres 1 0 1 3 1 7 bar Maintenance Maintenance type Without Burner run time 1000 6000 h Service date1 Boiler run time 1 72 months Limi...

Page 30: ...riction Activate test Burner Off 100 This service function enables you to test the burner by adjusting the appliance output Ignition On Off Permanent ignition Testing the ignition by means of permanent ignition without gas supply To prevent damage to the ignition transformer leave the function switched on for a maximum of 2 minutes Fan On Off Permanent ignition Fan running without gas supply or ig...

Page 31: ...boiler before working on electrical parts CAUTION Malfunctioning safety sensors The function of the safety sensors in the installation room such as CO CO2 and gas detectors must be regularly checked Check the function of relevant safety sensors during inspection or maintenance You can read about how to perform the check in the instructions for the safety sensor Defects at relevant safety sensors m...

Page 32: ... the value read out whether components need to be replaced 10 16 1 p 36 Make a note of the valuein the maintenance protocol 10 17 p 38 Establish the difference between the value most recently read out and the previous value from the maintenance protocol Check the setting Maintenance type based on this difference and adjust if required 8 2 p 21 Reading out Burner starts The number of Burner starts ...

Page 33: ...Contact with a hard brush or a vacuum cleaner may damage the surface of the burner Clean the burner only using compressed air Clean the burner using compressed air 10 5 Cleaning the heat exchanger NOTICE Risk of damage to the heat exchanger due to improper cleaning Do not use chemical agents to clean the heat exchanger Only use brushes with plastic bristles for cleaning Remove loose dirt with a va...

Page 34: ...k whether the neck of the siphon is properly connected to the condensation catch pan Tighten the union nut hand tight 10 8 Installing the gas air unit Clean the contact surfaces of the heat exchanger Reinsert the burner back into the heat exchanger When reinserting observe the position of the centring axis 1 Tighten the screws 3 Nm 2 Fig 40 Installing of the burner Install the new burner gasket 1 ...

Page 35: ...ascal Pa Attention During the measurement the air resistance is displayed as negative value Stop the Function check Close the gas air ratio test port Reattach the cover of the condensation catch pan 10 9 3 Assess the air resistance R For the assessment of the air resistance above the heat exchanger the following applies R0 Rx R The maximum decrease in the air resistance R differs depending on the ...

Page 36: ...ts in the maintenance protocol 10 17 p 38 10 16 2 Replacement of the ionisation and ignition electrode NOTICE Damage to the appliance by applying an excessively high torque when tightening the screws The screws of the ionisation and ignition electrode are installed in an aluminiumheatexchanger Usingagraphitesealensurestightnesswhen tightening the screws hand tight using hand tools Tighten the 4 sc...

Page 37: ...ible to electrostatic charge ESD Wearanearthedwriststrapwhenworkingonelectroniccomponents 7 1 p 18 Switch off the appliance Open the top appliance cover 7 2 p 18 Detach the bracket of the burner control unit 1 Push the burner control unit to the left 2 Lift the front of the burner control unit so the coding plug is easily accessible 3 Remove the coding plug 4 Attach new coding plug Fig 46 Replacin...

Page 38: ...ity 5 Check the gas supply pressure mbar 6 Check CO content ppm 7 Check CO2 content full load 8 Check CO2 content low load 9 Check tightness on the gas and water side 10 Check the electrodes 11 Check the burner 12 Check the heating block 13 Check ionisation current A 14 Clean dirt trap 15 Resistance of heat exchanger Pa 16 Check non return valve 17 Check the pre charge pressure of the expansion ve...

Page 39: ...edeviceisstillinoperation Iftheservicedisplayhasbeencaused by a defect under certain circumstances it may continue running with restricted functions 11 1 2 Fault code table R7 R8 R9 R10 R11 R12 R13 R14 R15 Inspection or maintenance Measurement RX R0 RX R Fault code Fault category Fault text on the display description Remedy 200 O Boiler in heating mode 201 O Boiler in hot water mode 202 O Boiler i...

Page 40: ...ting lead to the flame sense electrode 9 Replace air gas ratio control valve 10 Set the burner correctly or replace the burner nozzles 11 Set the burner at minimum rated load 12 Convert the flue system 13 The interconnected combustion air supply is too low or the ventilation opening is too small 14 Clean the heating block on the flue gas side 15 Replace control device burner control unit 232 B Boi...

Page 41: ... O Anti seizing functn active 360 V System fault boiler electronics basic controller 1 Install boiler identification module coding plug 2 Connect plug to boiler identification module coding plug 3 Replace boiler identification module coding plug Bosch contact customer service 362 V Boiler identification module or boiler electronics faulty Replace boiler identification module coding plug Bosch cont...

Page 42: ...ensor correctly 4 Check the temperature sensor replace if necessary 5 Check temperature sensor connecting lead replace if necessary 1070 Maintenance is due on dd mm yyyy please call your service engineer 1071 Maintenance is now due please call your service engineer 1072 Maintenance is overdue please call your service engineer 1074 No signal from flow temperature sensor 1075 W Heat exchanger temp s...

Page 43: ...cation module coding plug Bosch contact customer service 2948 B No flame signal with low output Burner starts automatically after purging If this fault occurs frequently check CO2 setting 2949 B No flame signal with high output The burner is automatically restarted following purging 1 Check burner gaskets replace if required 2 Reduce output 2950 B No flame signal following starting procedure Burne...

Page 44: ...rectly 6 Check the temperature sensor replace if necessary 7 Check temperature sensor connecting lead replace if necessary 2966 B Flowtemperatureriseinheatexchangertoo rapid 1 Ensure that the heating circulation is working correctly 2 Check pump setting adjust to match heating system if necessary 3 Connect the plug to the temperature sensor correctly 4 Connect the plug to the control device correc...

Page 45: ...e and instead must be taken to the waste collection points for treatment collection recycling and disposal The symbol is valid in countries where waste electrical and electronic equipment regulations apply e g European Directive 2012 19 EC on old electronic and electrical appliances These regulations define the framework for the return and recycling of old electronic appliances that apply in each ...

Page 46: ...Rated heat input G31 Qn Hi kW 24 5 118 1 24 5 140 1 Efficiency 37 30 C partial load 30 in accordance with EN 15502 109 3 109 6 Efficiency 80 60 C full load 99 0 99 1 Standby loss in accordance with EN 15502 0 12 0 15 Standard efficiency of heating curve 75 60 C 107 2 107 3 Standard efficiency of heating curve 40 30 C 110 4 110 6 Pump overrun min 2 2 IP classification IP rating IP X0D Appliance cla...

Page 47: ...2 min max W 12 300 12 300 Condens 7000 WP GC7000WP GC7000WP 125 GC7000WP 145 0010034254 002 A B C D E F R G H J K L M N Q P 1 8 1 4 1 4 1 6 1 4 1 4 1 6 4 1 1 5 8 1 1 8 17 17 1 7 1 6 1 1 A8 A7 A6 A5 A4 A3 A2 A1 HMI 1 4 1 5 2 6 3 7 4 8 R4 R3 R2 R1 C13 C12 C11 C7 C6 C5 P C4 C3 C2 C1 D17D14 D16D14 D13 D11 D14 D4 D1 D2 E7 E6 E5 P1 P2 E2 2 N 1 L E1 PE PE 120 230 VAC PW1 1 2 3 4 Q1Q2Q3Q4 M1M2 M J P PE E ...

Page 48: ...A BG BY CH CZ DK EE ES GB GR HR IE IT KZ LT LV MD NO PT RO RS RU SE SI SK TR UA Natural gas H G20 17 20 25 HU Natural gas H G20 17 20 25 DE LU NL PL Natural gas E G20 17 20 25 Fr Sub group Es Natural gas E G20 17 20 25 Fr Sub group Ei Natural gas E G20 20 25 30 BE Sub group Es Natural gas E G25 20 25 30 NL Natural gas L G25 20 25 30 NL Aardgas K G25 3 20 25 30 DE NaturalgasLL G25 18 20 25 DK NL NO...

Page 49: ...tance of heat exchanger 16 5 Setting values for heating capacity Table 30 Setting values for heating capacity 16 6 Commissioning report for the appliance Unit GC7000WP 125 GC7000WP 145 Required volumetric flow rate at T 20 K l h 5300 6300 Max volumetric flow rate l h 7000 Resistance of the boiler mbar 312 430 0010041018 002 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 1000 2000 3000 4000...

Page 50: ...e mbar Gas static supply pressure mbar Set maximum rated output kW Set minimum rated output kW Gas flow rate at maximum rated output l min Gas flow rate at minimum rated output l min Net calorific value HiB kWh m3 CO2 at maximum rated output CO2 at minimum rated output O2 at maximum rated output O2 at minimum rated output CO at maximum rated output ppm mg kWh CO at minimum rated output ppm mg kWh ...

Page 51: ...rry out a combustion air flue gas test Function check carried out Leak test carried out on the gas and water sides Commissioning includes checking the setting values a visual leak test on the appliance and a function check of both the device and its control The system installer conducts a test of the heating system The system named above has been checked to the extent described ___________________...

Page 52: ...Bosch Thermotechnik GmbH Junkersstrasse 20 24 D 73249 Wernau www bosch thermotechnology com ...

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