Worcester 7 733 600 377 Installation And Maintenance Instructions Manual Download

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Table of contents

Greenstar 4000 – 6 720 891 162 (2020/09)

Table of contents

Explanation of symbols and safety instructions . . . . . . . . . . . 4

1.1

Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2

General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4

Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1

Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . 8

3.3

Appliance type overview . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.4

Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.5

Pipework positions and flue outlet . . . . . . . . . . . . . . . . . 9

3.6

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.7

Standard accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.7.1 Appliance accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.7.2 Programmer/timer accessories. . . . . . . . . . . . . . . . . . . 11

Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1

System preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1.1 Artificially softened water . . . . . . . . . . . . . . . . . . . . . . . 12

4.1.2 Water systems and pipework . . . . . . . . . . . . . . . . . . . . 12

4.1.3 System layouts examples. . . . . . . . . . . . . . . . . . . . . . . . 13

4.1.4 System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2

Mains supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.3

Appliance location and clearances . . . . . . . . . . . . . . . . 16

4.3.1 Appliance location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3.2 Rooms containing a bath or shower . . . . . . . . . . . . . . . 17

4.3.3 Appliance clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.4

Flue systems considerations . . . . . . . . . . . . . . . . . . . . . 19

4.4.1 Flue length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4.2 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4.3 Plume management system. . . . . . . . . . . . . . . . . . . . . . 22

4.4.4 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.4.5 Plume re-direct and plume management terminal

positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.5

Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.5.1 Appliance siphonic condensate trap. . . . . . . . . . . . . . . 28

4.5.2 Condensate pipework . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.5.3 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.5.4 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.6

Pressure relief discharge . . . . . . . . . . . . . . . . . . . . . . . . 32

4.6.1 Pressure relief pipework . . . . . . . . . . . . . . . . . . . . . . . . 32

4.6.2 Alternative PRV connections - Combined PRV/

condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.7

Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 33

4.7.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1

Position the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1.1 Mounting frame fixing . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.2

Appliance connections . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.3

Hanging the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.4

Flue turret/adaptor installation . . . . . . . . . . . . . . . . . . . 39

5.5

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.5.1 Cable preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.5.2 Installer wiring connections . . . . . . . . . . . . . . . . . . . . . 41

5.5.3 External controls - Domestic installations . . . . . . . . . . 42

Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.1

Pre-Commissioning checks. . . . . . . . . . . . . . . . . . . . . . 43

6.2

Water treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.2.1 Filling the appliance and adding Inhibitor . . . . . . . . . . 43

6.3

Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.3.1 Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.3.2 Turning on the appliance . . . . . . . . . . . . . . . . . . . . . . . . 44

6.3.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.4

Chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.4.1 Setting the appliance to maximum . . . . . . . . . . . . . . . . 45

6.4.2 Setting the appliance to minimum . . . . . . . . . . . . . . . . 45

6.4.3 Exiting chimney sweep mode . . . . . . . . . . . . . . . . . . . . 45

6.5

Checking gas inlet pressure . . . . . . . . . . . . . . . . . . . . . 45

6.6

Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.7

Checking for gas leaks during operation . . . . . . . . . . . 46

6.8

CO and combustion check . . . . . . . . . . . . . . . . . . . . . . 47

6.9

Checking flue integrity. . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.10

Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.11

Finishing commissioning. . . . . . . . . . . . . . . . . . . . . . . . 49

6.11.1 Appliance/product guarantee . . . . . . . . . . . . . . . . . . . . 49

Settings in the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.1

Operating the service menu . . . . . . . . . . . . . . . . . . . . . 50

7.2

Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.2.1 Overview of the service menu. . . . . . . . . . . . . . . . . . . . 51

7.2.2 Benchmark and Info menu . . . . . . . . . . . . . . . . . . . . . . 53

7.2.3 Settings menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.2.4 Menu Function check. . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.2.5 Reset menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.2.6 Menu Demo mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.3

Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.1

Inspection and maintenance considerations . . . . . . . . 58

8.2

Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.3

Checking heat exchanger assembly . . . . . . . . . . . . . . . 59

8.4

Check working gas inlet pressure . . . . . . . . . . . . . . . . . 60

8.5

Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.6

Checking the flue integrity . . . . . . . . . . . . . . . . . . . . . . 60

8.7

Cleaning the siphon and heat exchanger . . . . . . . . . . . 60

8.7.1 Checking the electrodes and cleaning the heat

exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.7.2 Cleaning the condensate trap . . . . . . . . . . . . . . . . . . . . 63

8.8

Setting the air/gas ratio. . . . . . . . . . . . . . . . . . . . . . . . . 64

Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

9.1

Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

9.2

Draining the appliance. . . . . . . . . . . . . . . . . . . . . . . . . . 65

9.3

Removing the heat exchanger assembly . . . . . . . . . . . 66

9.4

Checking/replacing the motor of the 3-way valve
(appliances fitted with diverter valve accessory) . . . . 67

9.5

Removing the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9.6

Replacing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 68

9.7

Replacing the expansion vessel . . . . . . . . . . . . . . . . . . 68

Summary of Contents for 7 733 600 377

Page 1: ...6 720 891 162 2020 09 UK IE Installation and Maintenance Instructions Gas fired condensing system appliance Greenstar 4000 GR4700iW S ...

Page 2: ...5 5 Electrical connection 40 5 5 1 Cable preparations 40 5 5 2 Installer wiring connections 41 5 5 3 External controls Domestic installations 42 6 Commissioning 43 6 1 Pre Commissioning checks 43 6 2 Water treatment 43 6 2 1 Filling the appliance and adding Inhibitor 43 6 3 Starting the appliance 44 6 3 1 Control panel overview 44 6 3 2 Turning on the appliance 44 6 3 3 Operation 44 6 4 Chimney sw...

Page 3: ...hnical data 82 13 2 Energy consumption 84 13 2 1 Product data on energy consumption 84 13 3 Component resistance characteristics 88 13 3 1 Sensor values Flow temperature sensor 88 13 3 2 Sensor values Cylinder temperature sensor 88 13 3 3 Sensor values Flue overheat thermostat 88 13 3 4 Sensor values Heat exchanger assembly temperate limiter 88 13 3 5 Sensor values Outside temperature sensor 88 13...

Page 4: ...e 0330 123 3366 Distancelearningandtrainingcoursesareavailable from Worcester The BENCHMARK Commissioning Checklist can be found on page 92 of this Installation manual H Notices for the target group These installation instructions are intended for gas plumbing heating and electrical contractors All instructions must be observed Failure to comply with instructions may result in material damage and ...

Page 5: ...arn your neighbours and leave the building immediately Call an approved contractor Have any defects rectified H Installation and maintenance Installation and maintenance must only be carried out by a competent registered gas engineer such as a Gas Safe registered engineer or British Gas engineer Carryoutagastightnesstestaftercompletingwork on gas carrying components Only use original spares H Elec...

Page 6: ...OSHH Regulations Control of Substances Hazardous to Health Regulations 1988 H Combustion and corrosive materials Do not store or use any combustible materials paper thinners paintsetc insideorwithinthevicinityofthe appliance Chemically aggressive substances can corrode the appliance and invalidate any warranty H Fitting and modification Fittingtheapplianceandanycontrolstotheappliance may only be c...

Page 7: ...BS5546 Installation of gas hot water supplies for domestic purposes EN12828 Central heating for domestic premises BS5440 1 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Flues BS5440 2 Flues and ventilation for gas appliances of rated heating not exceeding 70kW net Air Supply BS7593 Treatment of water in domestic hot water central heating systems BS6798 Installati...

Page 8: ...he contact address on the back cover of these instructions 3 3 Appliance type overview These appliances are for use with Natural Gas or L P G Cat II 2H3P type C13 C33 C53 This document refers to the following appliance types Table 2 Type overview The name of the appliance consists of the following parts GR4700iW Type name 12 15 18 21 or 24 Heat output in kW S System appliance NG Gas type Natural G...

Page 9: ...tion Dimensions mm X Appliance width 400 Y Appliance height 724 1 1 724mm to middle of top panel 710mm side panel height Bottom panel is removable and not part of minimum clearance height requirements Z Appliance depth 310 W Flue centre from appliance left side 200 D Flue centre from rear of appliance 135 0010023464 001 1 2 3 4 5 6 7 Function From left case edge Diameter of pipe 1 Condensate Outle...

Page 10: ...ation Greenstar 4000 6 720 891 162 2020 09 10 3 6 Product overview Fig 3 Product overview 0010035359 001 1 2 3 4 6 8 7 5 9 12 13 16 17 11 15 14 10 30 29 28 26 27 25 23 24 22 20 18 33 9 29 3 25 28 2 31 33 32 13 21 19 ...

Page 11: ...Comfort II RF Weather compensation is available with the EasyControl without the need for a physical outdoor sensor however it can improve control accuracy for installations in isolated micro climates or highly sheltered locations such as valleys 1 These components are sourced from multiple suppliers and therefore contain small design differences Please refer to the relevant maintenance chapter fo...

Page 12: ...ipework Primary system plastic pipework Any plastic pipework must have a polymeric barrier complying with BS7921andinstalledtoBS5955with600mm minimum lengthof copper connected to the appliance Plastic pipework used for under floor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 C with 1000mm minimum length of copp...

Page 13: ... expansion is required If the dissected line is in are B then an additional expansion vessel must be installed Fig 4 Fig 5 Curves for the expansion vessel 1 Pre charge pressure 0 5 bar minimum 2 Pre charge pressure 0 75 bar 3 Pre charge pressure 1 0 bar 4 Pre charge pressure 1 2 bar 5 Pre charge pressure 1 3 bar A Operational capacity of the expansion vessel left of the relevant curve B Additional...

Page 14: ...cturer must be contacted for confirmation their product is suitable for the installation layout shown in figure 9 Although it is accepted common practice to install 2 port motorised valve in the primary flow pipe to the cylinder and wired to the dual thermostat supplied with the cylinder it is possible to use the integral diverter valve kit and not need the 2 port motorised valve to cut the flow o...

Page 15: ...onal equipment wired to the appliance must comply with the latest IET wiring regulations Appliance protection rating IPX4D When using a control Key product the boiler rating is maintained at IPX4D 4 2 2 Gas supply Appliances using Natural Gas NG must be connected to a governed meter Appliances using Liquid Petroleum Gas LPG must be connected to a regulator Installation and connection of the gas su...

Page 16: ...is above 0 C and below 50 C NOTICE Damage to system The heating system pipework can be damaged by frost if installed in an internal unheated area such as a loft basement or garage The appliance internal frost protection only monitors the system water temperature within the appliance to provide protection for the appliance Install afrost thermostat and pipe thermostat connected in series to protect...

Page 17: ... or property The appliance will overheat if the clearance space around the appliance is restricted by objects Donotrestrictthisspacewiththeadditionofcupboards shelvesetc next to or around the appliance Do not store any combustible materials on or next to the appliance such as clothes towels paper or plastic bags Fig 13 Appliance minimum clearances Table 11 Appliance minimum clearances 0010017086 0...

Page 18: ...bserved to any obstruction surface dark shaded areas figures 14 and 15 Fig 14 Reduced front maintenance clearances Side view A Appliance 1 Above appliance Same clearance required as for standard clearances of 60 100 flue or 80 125mm flue 2 In front of appliance Minimum 450mm 3 Bottom of appliance to the floor 1 000 1 500mm 4 Below appliance 186mm Fig 15 Reduced front maintenance clearances Front v...

Page 19: ...or The SimpleSwitch flue adaptor has an equivalent straight flue length Refer to table 16 Table 16 Effective length of SimpleSwitch flue adaptor 4 4 2 Flue options The systems have different maximum flue lengths refer to the following example flue options for those maximum flue lengths Horizontal high level flue assembly Fig 16 Horizontal flue option Flue length L initial bend included in length c...

Page 20: ...Maximum horizontal flue lengths minus the 90 bend equivalent straight flue length as stated in Table 15 Effective length of bends Horizontal flue with additional 90 elbows Fig 21 Horizontal flue option Flue length L adaptor bend included in length calculation Maximum flue length as stated in Maximum horizontal flue lengths minus 2 x 90 bends equivalent straight flue length as stated in Table 15 Ef...

Page 21: ...ngth as stated in Maximum vertical flue lengths Vertical balanced flue with 90 elbow offset Fig 27 Vertical flue option Flue length L Maximumfluelengthasstatedin Maximumverticalfluelengths minus 2 x 90 bends equivalent straight flue length as stated in Table 15 Effective length of bends Vertical balanced flue with 45 elbow offset Fig 28 Vertical flue option Flue length L Maximumfluelengthasstatedi...

Page 22: ...rizontal runs after an elbow can be 3 WARNING Minimum plume management length The minimum distance of 500mm must be maintained between air inlet and exhaust Do not terminate the plume management inside the terminal exclusion zone shaded area shown in figure 31 Fig 31 Terminal exclusion zone NOTICE Cutting the 500mm pipe The Plume management extension kit contains the components required for such a...

Page 23: ...The terminal must be at least 1 500mm from the opening or vent whensitedbelowthewindowor600mmwhensitedtoeitherside or above 7 400mm measured diagonally from a pitched roof or 500mm in regions with heavy snow fall 300mm measured vertically from the air intake to the closest intersection with the roof 8 1 200mm separation measured between a vertical flue and a horizontal flue terminal 9 Forthepurpos...

Page 24: ...KYLIGHT DORMER 1000 600 300 300 300 BELOW GROUND OPEN LIGHT WELL 15 2 2 1 1 1 200 25 100 16 25 100 10 300 600 BOUNDARIES 1 2 1 2 9 100 25 25 100 25 25 100 25 600 600 2000 OPENING OPPOSITE TOP BOUNDARY LINE 3 4 5 11 11 11 7 10 10 10 5 1 200 25 75 25 75 600 600 1000 1200 600 300 300 300 300 300 300 300 300 200 200 300 300 300 25 300 1500 1200 13 0010021442 004 5 300 150 8 300 TOP 17 18 ...

Page 25: ...ce If the terminal section is less than 150mm and has two screws securing it to the elbow the terminal section will not require a supporting bracket 11 300mm above below and either sideof an opening door air vent or opening window 12 Below ground level in an open lightwell The flue must be at least 600mm from the opposing surface and have at least 300mm clearance either side and below The flue ter...

Page 26: ...entric flue terminal positions unless the flue position is specified in figure 34 Plume re direct and plume management terminal positions Terminals must be positioned so to avoid combustion products entering the building Supporttheflueatapproximatelyonemetreintervalsandatachange of direction use suitable brackets and fittings Fig 34 Plume re direct and plume management terminal positions BOUNDARY ...

Page 27: ...anagementkittheairintakemeasurementcanbe reduced to 150mm providing the flue exhaust outlet has a 300mm clearance 11 Below balcony or overhang The air intake clearance can be reduced to 150mm providing the flue exhaust outlet has a 200mm clearance 12 1 200mm between terminals facing each other1 13 Internal externalcorners Theairintakeclearancecanbereduced to 150mm providing the flue exhaust outlet...

Page 28: ...o 20 minutes Resulting in Increased velocity and flow rate With less frequent siphonic actions per hour the condensate pipework is empty for longer Significantly reducing freezing potential for a 48 hour period at 15 C provided the installation parameters listed below are followed 4 5 2 Condensate pipework NOTICE General consideration Where a new or replacement appliance is being installed access ...

Page 29: ...6798 for more information on condensate disposal NOTICE Grey water recovery system Contamination of recovered water Condensate disposal shall not be allowed into a grey water recovery system that is intended for re use External disposal considerations NOTICE Freezing conditions Frozen condensate will block the condensate drain pipe and stop the appliance from running Pipe lengths should be kept to...

Page 30: ...h a wall 1 Internal face sealed 32mm pipe sealed to sleeve 2 40mm sleeve 3 External face sealed 32mm pipe sealed to sleeve 4 Insulation recessed into the wall 5 Condensate discharge pipe Good Practice The following guidance indicates the good practices that must be maintained for the Installation and Maintenance of a product Rain water down pipe with external air break Figure 39 Refer to following...

Page 31: ...d flooding adverse weather conditions which could prevent the condensate from discharging Minimum hole size for the condensate soak away must be 400mm deep by Ø 300mm Fig 41 Disposal to soak away 1 Condensate discharge from appliance 8 Pipework transition 9 Additional protection for transition through a wall page 30 11 External air break 15 100mm minimum Ø plastic pipe 16 Drainage holes 17 Limesto...

Page 32: ...other hazard preferably to an external drain or soak away The pipe 1 or 3 should be finished with a partial bend to face the external wall as shown to ensure safe discharge of hot water In all normal circumstances a PRV discharge pipe installation as described above sufficiently meets all but the most exceptional circumstances Where the PRV discharge pipe could be susceptible to damage vandalism f...

Page 33: ... then it is possibletousetheappliancewhilstcleaningthesystem Asystem filter must be fitted to the return to reduce the risk of contaminants entering the appliance Follow the guidance of BS7593 Inhibitor Add a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the DWTA code of practice and manufacturer s guid...

Page 34: ... the casing from damage during installation Thefrontcasingissecuredwithtwoscrewswhicharecriticaltomaintain the case seal and to prevent unauthorised removal electrical safety Always secure the casing with these screws Removing the front casing during unpacking Loosen the two screws 1 and lift the bottom of the casing clear of the screws Lift off the casing Fig 44 Removing the front casing Addition...

Page 35: ...ance clearances Fig 45 Wall mounting template 1 Side exit flue example 2 Rear exit flue example 3 Wall mounting template 4 Primary fixing points D 135mm Theappliancewallmountingtemplateshowstherelativepositionsofthe flue and the top and bottom fixings of the wall mounting frame Fix the wall mounting template 3 to the wall in the desired position Drill the holes 4 through the template for the prima...

Page 36: ...ed areas such as lofts basements and garages exposed to prolonged cold temperatures should be protected chapter 4 5 Plumbing manifold Further guidance on pipe routing can be found printed on the appliance template supplied with the appliance Forfurthereaseoffitting anoptionalVerticalPre pipingAssemblykit 7 733 601 250 is available comprising of pre formed copper CH and DHW pipes Fig 46 Connections...

Page 37: ... the wall frame Fig 48 PRV connection preparation 5 3 Hanging the appliance NOTICE Transport protection covers Remove any internal transport packaging and protection covers from the appliance where applicable Before hanging the appliance Install any accessories to the mounting frame before continuing Ensure the sealing washers are fitted to the appropriate service valves before installing the appl...

Page 38: ...service connectors before installing the appliance Refer to figure 51 Hangtheapplianceontothewallmountingframeutilisingthecentral mounting point at the top of the wall frame Fig 51 Hanging the appliance Connect the PRV discharge pipe on the hydraulic unit onto the PRV outlet pipework and tighten firmly Tighten the gas and water connections firmly Fitting the siphon WARNING Danger to life due to po...

Page 39: ...n use suitable brackets and fittings Flue bracket 100mm part number 7 716 191 177 Flue brackets 100mm x 6 part number 7 716 191 178 Flue bracket 125mm part number 7 716 191 179 Ensure the external wall seal is fitted and properly located in the groove provided on the terminal This seal must be installed in the groove unless the flue is extended beyond a gutter or balcony as shown in the installati...

Page 40: ...liance components can damage electrical cables Ensure all electrical cables are in the correct cable guides and away from hot appliance components Cable routing Route cables over the valve bracket avoiding any hot components Run power cables separately from signal cables Interference from powercablescaninducespuriousfaultsonsignalcables ensurethat thereisatleast100mmseparationbetweenpowerandsignal...

Page 41: ...th strain relief 1 Low voltage signal cables Guide the cable through the grommet Connect the cable to the terminal strip for external accessories 2 Power supply power cables Guide the cable through the grommet Connect the cable to the terminal strip for external accessories and the protective conductor PE to the rail Secure the cable on the strain relief Power supply power cables terminal strip Fi...

Page 42: ...al frost thermostat connections 4 The Live supply is terminal FS The Switch Live is terminal FR Fig 62 External controls connections example 1 230V mains supply to the appliance 2 230V supply from the appliance to the wiring centre 3 CH DHW Switch Live Demand from the external controls 4 External frost protection Live supply and Switch Live Demand Symbol Function Power supply power cable Pre wired...

Page 43: ...e DWTA code of practice and manufacturer s guidelines The pH value of the system water must be between 6 5 and 8 or the appliance warranty will be invalidated The inhibitor or combined inhibitor anti freeze must not cause damage to the materials within the appliance aluminium mild steel stainless steel copperandbrass andanyothermaterials componentswithinthe system Record the date when the inhibito...

Page 44: ...ng flow temperature adjustment Withunderfloorheatingsystemsobservethemaximumpermissibleflow temperature Press the key The set maximum flow temperature appears Pressthe or keystosetthedesiredmaximumflowtemperature The setting is saved automatically after two seconds Then the symbol is briefly displayed Hot watertemperatureadjustment onlyavailablewhenanoptional integral diverter valve kit is fitted ...

Page 45: ...ll continue to run in order to cool the heat exchanger Boiler status code 208 will be visible during this operation 6 5 Checking gas inlet pressure Measuring the inlet pressure Switch off the appliance and close the gas isolator Unscrew the screw on the test nipple for the gas supply pressure and connect a pressure gauge Fig 64 Checking the gas supply pressure above SIT valve below Honeywell valve...

Page 46: ...nce gas rates and CO CO2 ratios Where a gas meter is not available e g LPG the CO CO2 must be checked Gas rate must be checked with the appliance in service maximum output test mode Carry out gas rating as per the latest advice in the Gas Safety Installation and Use Regulations Ensureallothergasappliancesareisolatedwhencarryingoutthegas rate check on the appliance Setthechimneysweepmode and startu...

Page 47: ...e the analyser must have been calibrated as specifiedbythemanufacturer Theinstallermustbecompetentinthe use of the analyser Check and zero the analyser in fresh air as specified by the manufacturer The air gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester Bosch Group help line 0330 123 3366 Fig 67 Com...

Page 48: ...e flue turret adaptor sample points Refer to figure 69 for the location of the flue gas sample point on flue turret adaptor Fig 69 Combustion test 1 Flue gas sample point 2 Flue turret flue gas blank plug 3 Flue adaptor flue gas blank plug The CO and combustion ratio are checked In chimney sweep mode at maximum output In chimney sweep mode at minimum output Appliance to maximum output Set the appl...

Page 49: ... bosch co uk Ensure that all documentation is left with the appliance or homeowner Appliance documentation Controls documentation Any other equipment documentation that is connected to the appliance or system Appliance not in use If the appliance is not going to be used immediately and may be exposed to freezing conditions advise the customer of the precautions necessary to prevent damage to the a...

Page 50: ...ting the service menu Opening the service menu Press the key and the key simultaneously until the service menu appears Closing the service menu Press the key or the key or Press the d key Navigating through the menu To highlight a menu or a menu item press the key 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...

Page 51: ...onfiguration HC1 configuration Pump config Heating Max heat output Standby time Anticyc temp off Anticycle temp on Hot water Max output DHW circ pump Cycle circ pump TD Temperature Start TD Pump Pump range map Pump ctr mode Min output 4 Max output 4 Pump overrun Special function Ventilation func 3 WV mid pos Maintenance Maintenance type Without off Burner run time Boiler run time Service date 2 La...

Page 52: ...ing Fault history Service display 2 Hidden menu Reset Maintenance Landlord Demo mode Yes No 1 When theFunction CheckmenuisenteredonlyBurner willbevisibleforthefirst 10 seconds after this period of time the other components that can be tested willappearinthemenu ComponentssuchasHC1pump DHWcirculationpump and Solar pump will show if connected to the control board 2 Available when Maintenance has bee...

Page 53: ...Current outside temperature in C 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 Maximum domestic hot water output in kW DHW act temp 1 1 Menu item only visible if integral diverter kit is fitted Current domestic hot water temperature in C S Act temp cyl 1 Current d...

Page 54: ... temperature until the burner is switched off Anticycle temp on 15 5 2 K Thedifferencebetweenthecurrentflowtemperatureand the set flow temperature until the burner is switched on Hot water Max DHW output 50 100 Maximum power on hot water DHW circ pump Off On No functionality not used Cycle circ pump 1 x 3 minutes h 2 x 3 minutes h 3 x 3 minutes h 4 x 3 minutes h 5 x 3 minutes h 6 x 3 minutes h Per...

Page 55: ...te A contact telephone number Installer tel no is shown together withservicedisplay Thetenantshouldcallthisnumberto arrange a suitable maintenance date A second reminder appearsatthescheduleddate Iftheservicedisplayisnot reset by the service engineer the control unit limits the functions 14 days after the scheduled date Reduced functions are set at Maint reminder DHW reduced reduced comfort max 35...

Page 56: ...emp limit 0 5 10 C Temperature value for the system frost protection This service function is only available if the frost protection function was activated If the outside temperature does not exceed the frost threshold temperature thentheheatingpumpintheheatingcircuit switches on 1 Only available with installed Key Timer accessory Menu item Settings adjustment range Comment restriction ...

Page 57: ... water Permanent position of the 3 way valve Ionisat oscill On Off Check the ionisation measurement function at the flame HC1 pump 1 1 Components will show if connected to the control board On Off Only available if a pump is connected to the corresponding boiler control unit input Selecting On will permanently run the pump until switched off DHW circ pump 1 On Off Only available if a pump is conne...

Page 58: ... attempted if a calibrated CO CO2 analyser and manometer are not available WARNING Hot surfaces If the appliance has been operating components may be hot Ensure precautions are taken when working on the appliance CAUTION Annual maintenance checks Annual maintenance checks have to be conducted to ensure the continued safe and reliable operation of the boiler During each maintenance check the gas va...

Page 59: ...l and to prevent unauthorised removal electrical safety Always secure the casing with these screws Loosen the two screws 1 and pull the bottom of the casing forward Lift off the casing Fig 71 Removing the front casing 8 3 Checking heat exchanger assembly Remove the front casing Remove the cap from the test nipple and connect a pressure gauge Fig 72 Test nipple at the mixing device NOTICE Fan press...

Page 60: ...in the exhaust paths That the injector is clean AfterallcheckshavebeencompletedandtheCO2 isstilloutoftolerance then contact Worcester Bosch Group helpline 0330 123 3366 before making any adjustment to the gas valve 8 6 Checking the flue integrity NOTICE Check flue joints are secure the terminal and the terminal guard if fitted are clear and undamaged Combustion testing must be carried out to BS 79...

Page 61: ...w 1 on the mixing device Remove the fan with mixing device 4 Fig 73 Removing the fan with mixing unit Refer to figure 74 Pull off cables from the electrode set 2 Pull off cable 1 Remove M8 nut 3 Remove the burner cover 4 On re assembly to ensure a full gas tight seal tighten the M8 nut down firmly without over tightening Fig 74 Remove the burner cover Refer to figure 75 Remove the non return valve...

Page 62: ...tion aperture cover and remove with the seal Fig 78 Cleaning the heat exchanger Clean out residue and re fit the inspection aperture again Refer to figure 79 Rinse the heat exchanger with water from the top Fig 79 Rinse the heat exchanger with water Refer to figure 80 Re open inspection aperture and ensure no residue remains Close the inspection aperture once checked Fig 80 Checking the heat excha...

Page 63: ...p 4 figure 81 at the bottom and clean it Check dirt trap gasket for cracks deformation or breakage replace if required Refit the dirt trap and check that it is correctly seated Check that the opening to the heat exchanger is clear Replacing siphon gasket Refer to figure 82 Remove the gasket on the top of the siphon Check the gasket for cracks deformation or breakage and replace if required Align t...

Page 64: ...nutes after firing the appliance Adjusting the minimum rated output settings With the appliance in minimum rated output Remove the seal from the adjusting screw of the gas valve only gas valve is shown in the below Figure 84 and set the CO2 content for minimum rated output Fig 84 Setting the CO2 content above SIT valve below Honeywell valves 1 Gas valve NG 2 Gas valve LPG Re check settings at maxi...

Page 65: ...the guarantee if applicable and any warranty Acomprehensivelistofappliancesparescanbefoundonthewebsite www worcester bosch co uk spares 9 1 Component access Removing the front casing Thefrontcasingissecuredwithtwoscrewswhicharecriticaltomaintain the case seal and to prevent unauthorised removal electrical safety Always secure the casing with these screws Loosen the two screws 1 and pull the bottom...

Page 66: ...wn Release the clip Detach the flow connection Disconnect the cable from the heat exchanger temperature limiter Disconnect the in line connector from the flow temperature sensor on the heat exchanger Disconnect the cable from the flue gas temperature limiter Remove the nut Fig 87 Separating components from the heat exchanger assembly Removing the heat exchanger assembly Refer to figure 88 Release ...

Page 67: ...hing the motor from the 3 way valve variant without screws Installing the motor Install the motor in the sequence shown Align the motor with the ball head and push down to engage Turn the motor clockwise as far as it will go Refit the lock clip Connect the plug Fig 90 Installing the motor in the 3 way valve variant without screws 9 5 Removing the pump Unplug the electrical connections 4 Release th...

Page 68: ...expansion vessel in the reverse order 9 8 Replacing the PRV Unscrew the knurled nut of the PRV discharge pipe Disconnect the PRV discharge pipe prior to removing the PRV Remove the PRV in the sequence shown Release the clip Pull the PRV forward to release Fig 94 PRV removal Replace the PRV in the reverse order 9 9 Replacing the pressure sensor Pressure sensor is a wet pocket sensor therefore the a...

Page 69: ...t be removed and refitted to the replacement control unit Preparation before control unit removal Loosen the retaining screw and open the cover Remove connectors from the PCB on the both terminal strip sides Power supply power cables terminal strip 2 Low voltage signal cables terminal strip 3 Remove connector for the Key accessory slot 4 Remove code plug 5 Fig 98 Control unit removal preparations ...

Page 70: ...r gas appliances working gas cooker hob for example Has the credit run out on the gas pre payment meter NOTICE On completion of the Service Fault Finding task which has required the breaking and remaking of electrical connections check Earth continuity Short circuit check Polarity Resistance to earth 10 1 Operating and fault displays 10 1 1 General information Fault code indicates which fault is p...

Page 71: ...mperature to confirm actual temperature may have tripped out at lower temperature leading to a safety temperature limiter thermostat or the flue thermostat fault Check the system pressure and top up as required Check if air is trapped in the system and in the boiler Pump seized not running check the pump for failure or blockage Check if a blockage restriction within boiler pipework is restricting ...

Page 72: ... control unit 249 V System fault boiler electronics basic controller Reset appliance electronics factory reset Check the electrical connections on the board check for loose wires etc Replace the control unit 250 V System fault boiler electronics basic controller Reset appliance electronics factory reset Check the electrical connections on the board check for loose wires etc Replace the control uni...

Page 73: ... seconds or until the target temperature is met Diverter valve is held in the hot water position for a period of time If nodomestic hot water demand isrequested then check for false demands onthe cold water inlet 306 V Flame signal after closing the fuel supply Check the gas valve replace if required Check electrodes and connecting leads replace if required Replace the appliance electronics 353 O ...

Page 74: ... Reset the maintenance code via the reset menu 1017 W System pressure too low Top up system water and vent the system Checkthevoltagetothepressuresensorandthesignalbackfromthepressuresensor Replace the pressure sensor 1018 W Maintenance interval expired Carry out maintenance Reset the maintenance code via the reset menu 1019 W Incorrect pump type detected Pump communication failure or wrong pump i...

Page 75: ...ce if required Replace the flow temperature sensor Replace the PCB 1075 W Heat exchanger temp sensor short circuit Check the flow temperature sensor plug is connected Check the resistance of the flow temperature sensor and replace if required Check the continuity of harness and replace if required Replace the flow temperature sensor Replace the PCB 1076 W Heat exchanger temp sensor disconnected Ch...

Page 76: ...stem Check combustion air supply Check the heat exchanger on the flue gas side for deposits clean if necessary 2928 V Internal fault Restart appliance If the fault persists following a reset the burner control unit is faulty and must be replaced replace control unit 2931 V System fault boiler electronics basic controller Illegal instruction Restart appliance If the fault persists following a reset...

Page 77: ...2964 B Flow rate in heat exchanger too low Check the flow through the appliance and that the system is filled Check for air locks in the system and purge if required Check the heat exchanger sensor primary thermistor and the plug connected to the temperature sensor Check the resistance of the temperature sensor and replace if required Check the continuity of the harness and replace if required 296...

Page 78: ...lt code Fault category Fault text on the display description Remedy Appliance faults Remedy Combustion noises too loud rumbling noises Check the gas type Check the gas supply pressure Check the flue system clean or repair if required Check the gas air ratio Check the gas valve replace if required Flow noises Set the pump rate or pump characteristic map correctly and match to the maximum output Hea...

Page 79: ... normally set If the system is to be drained the boiler must be electrically isolated CAUTION If system pressure is repeatedly increasing even when the applianceisnotoperating youshouldfirstcheckthatthefillinglink is fully closed and confirm that it is not passing If radiators are also notheatingtothetopofthepanelsandrepeatedlyneedventing the heating system may be suffering from gassing This is an...

Page 80: ...arly drip The boiler is fine Check the CH system for leaks Check replace PRV YES NO YES NO YES The boiler is fine Check Expansion Vessel is sized correctly for the system Re pressurise the EV Is the Expansion Vessel pre charged higher than expected NO YES Is the Expansion Vessel pre charge too low NO YES YES NO The boiler is fine Confirm the filling link is closed and check that the Plate Heat Exc...

Page 81: ... minimize any potential harm to the environment and human health Furthermore recycling of electronic scrap helps preserve natural resources For additional information on the environmentally compatible disposal of old electrical and electronic appliances please contact the relevant local authorities your household waste disposal service or the retailer where you purchased the product You can find m...

Page 82: ...25 2 5 0 25 2 5 0 25 2 5 0 25 Available pump head at 20 C system temperature rise m 2 2 2 2 2 2 Flue Flue gas temperature 80 60 C rated min load C 71 57 71 57 68 57 68 57 65 57 65 57 Flue gas temperature 40 30 C rated min load C 50 30 50 30 47 30 47 30 45 30 45 30 CO2 level at max rated heat output after 10 minutes 9 4 10 8 9 4 10 8 9 4 10 8 CO2 level at min rated heat output after 10 minutes 8 6 ...

Page 83: ... 25 Available pump head at 20 C system temperature rise m 2 2 2 2 Flue Flue gas temperature 80 60 C rated min load C 63 57 63 57 62 57 62 57 Flue gas temperature 40 30 C rated min load C 41 30 41 30 38 30 38 30 CO2 level at max rated heat output after 10 minutes 9 4 10 8 9 4 10 8 CO2 level at min rated heat output after 10 minutes 8 6 10 2 8 6 10 2 NOx rating EN 15502 1 mg kWh 34 47 31 46 NOx Clas...

Page 84: ... output and high temperature regime 1 1 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 24 21 18 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 8 1 7 1 6 1 Useful effi...

Page 85: ... 1 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 15 12 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 5 1 4 0 Useful efficiency At rated heat output and high tempera...

Page 86: ... 1 1 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 24 21 18 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 8 1 7 1 6 1 Useful efficiency At rated heat output and hig...

Page 87: ...1 1 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet P4 kW 15 12 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 5 1 4 0 Useful efficiency At rated heat output and high temper...

Page 88: ...950 20 12 657 25 10 115 30 8 138 35 6 589 40 5 367 45 4 398 50 3 624 55 3 002 60 2 500 65 2 092 70 1 759 75 1 486 80 1 260 85 1 074 90 918 3 95 788 5 Temperature C 10 Resistance k 0 35 964 5 28 507 10 22 756 15 18 273 20 14 768 25 11 977 30 9 783 35 8 045 40 6 650 45 5 521 50 4 606 55 3 855 60 3 242 65 2 744 70 2 332 75 1 989 80 1 703 85 1 463 90 1 262 95 1 093 Normally closed thermostat Temperatu...

Page 89: ...sure bar Q Volumetric flow rate l hr Constant pressure If the constant pressure Pump range map 1 6 is chosen the differential pressure between the CH flow and return will be kept at the corresponding value When the CH system is cold and the radiator TRVs are fully open the pump will be running faster to try and maintain the pressure differential When the TRVs start to close and the resistance of t...

Page 90: ...13 14 15 3 4 3 3 2 19 11 2 15 14 13 9 9 8 10 11 12 7 6 5 4 3 3 2 1 16 27 16 5AF 20 25 4 8 22 21 23 DHW NTC PRESSURE SENSOR TURBINE PUMP CONTROL STEPPER MOTOR GAS VALVE OH STST RETURN IONISATION PROBE FAN EARTH GROUND OH STAT CH NTC GROUND CH NTC HEAT EXCHANGER CH NTC FLOW PIPE FAN CONTROL CABLE PUMP POWER FAN POWER SPARK IGNITOR POWER 2 7 18 10 1 17 26 230V 3 2 2 12 24 ...

Page 91: ...e sensor 14 Pump control cable 15 Connecting lead for 3 way valve from the diverter valve kit accessory 1 16 Chassis earth 17 Fan earth 18 Cable between flue gas temperature limiter and heat exchanger assembly temperature limiter 19 Electrode set 20 Code plug 21 Display 22 Terminals for Installer connections 23 Connecting lead for Key accessory slot 24 Connection for the cylinder sensor from the d...

Page 92: ... no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar C Central heating return temperature C System correctly balanced rebalanced Yes COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No Water scale reducer softener pre existing Fitted Not required Brand Product Yes No If yes DHW expansion vessel pre existing Fitted Not required...

Page 93: ...Yes Yes Yes No Yes Yes Yes Yes Yes Year 3 ________________________ ___________________ Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Year 4 ________________________ ___________________ Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Year 5 ________________________ ___________________ Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Year 6 ________________________ ...

Page 94: ... rate Were parts fitted Parts fitted Comments Signature OR Yes No m h ft h Where possible has a flue integrity check been undertaken in accordance with manufacturers instructions and readings are correct System inhibitor concentration has been checked and appropriate action taken in accordance with BS 7593 and boiler manufacturers instructions Telephone No Gas Safe registration No Company name Dat...

Page 95: ... rate Were parts fitted Parts fitted Comments Signature OR Yes No m h ft h Where possible has a flue integrity check been undertaken in accordance with manufacturers instructions and readings are correct System inhibitor concentration has been checked and appropriate action taken in accordance with BS 7593 and boiler manufacturers instructions Telephone No Gas Safe registration No Company name Dat...

Page 96: ... Kingdom Tel 0330 123 9559 worcester bosch co uk TECHNICAL SUPPORT 0330 123 3366 RENEWABLE SUPPORT 0330 123 9229 CONTROLS AND CONNECTIVITY TEAM 0330 123 3641 APPOINTMENTS 0330 123 9339 SPARES 0330 123 9779 LITERATURE 0330 123 9119 TRAINING 0330 123 0166 SALES 0330 123 9669 ...

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Worcester 7 733 600 377, Installation And Maintenance Instructions Manual

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