Worcester GR4700iW C Installation And Maintenance Instructions Manual Download

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6 720 891 161 (2020/09) UK/IE

Installation and Maintenance Instructions

Gas-fired condensing combi appliance

Greenstar 4000

GR4700iW C

Summary of Contents for GR4700iW C

Page 1: ...6 720 891 161 2020 09 UK IE Installation and Maintenance Instructions Gas fired condensing combi appliance Greenstar 4000 GR4700iW C ...

Page 2: ...ret adaptor installation 38 5 5 Electrical connection 39 5 5 1 Cable preparations 40 5 5 2 Installer wiring connections 40 5 5 3 External controls Domestic installations 42 6 Commissioning 42 6 1 Pre Commissioning checks 42 6 2 Water treatment 42 6 2 1 Filling the appliance and adding Inhibitor 43 6 3 Starting the appliance 43 6 3 1 Control panel overview 43 6 3 2 Turning on the appliance 43 6 3 3...

Page 3: ...al Specifications Logs 83 13 1 Technical data 83 13 2 Energy consumption 86 13 2 1 Product data on energy consumption 86 13 3 Component resistance characteristics 88 13 3 1 Sensor values Flow temperature sensor 88 13 3 2 Sensor values DHW 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 Out...

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: ...ater 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 Installation of gas fired boilers of rated...

Page 8: ...en demonstrated by the CE marking You can ask for a copy of the declaration of conformity for this product For this see the contact address on the back cover of these instructions 3 3 Appliance type overview These appliances are for use with Natural Gas or LPG 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...

Page 9: ...outlet dimensions Table 3 Appliance and flue outlet dimensions Table 4 Pipe dimensions Description 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...

Page 10: ...enstar 4000 6 720 891 161 2020 09 10 3 6 Product overview Fig 3 Product overview 0010035123 001 1 2 3 4 6 8 7 5 9 14 18 19 12 13 10 11 36 35 34 32 33 31 29 30 28 25 24 20 26 27 37 9 35 3 32 34 2 26 25 27 14 23 17 16 15 22 21 ...

Page 11: ... and therefore contain small design differences Please refer to the relevant maintenance chapter for more detailed information Spare parts are fully interchangeable Part number Description 7 733 601 245 4000 SimpleSwitch flue adaptor 60 100 7 733 601 250 4000 Compact Pre piping kit 7 733 600 266 Greenstar System filter 22mm mini 7 733 600 236 Greenstar System filter 22mm 7 733 600 237 Greenstar Sy...

Page 12: ...m 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 copper or steel pipe connected to the appliance Primary system connections valves Do not use galvanised pipes or radiators All system connection...

Page 13: ...oint on the system top of the highest radiator Select a curve from the key below 1 5 System pressure should be set at 0 1 0 25 bar higher than the vessel pre charge Itmustbeatleasttotheminimumonapplianceswithananalogue gauge Minimum pressure settings may need to be adjusted to suit on appliances with a digital gauge in the applicable menu function Intelligent filling settings may need to be adjust...

Page 14: ... This appliance must not be connected to a three phase supply The wiring between the appliance and the electrical supply must comply with the latest IET wiring regulations that apply to wiring a fixed appliance for Class 1 equipment The correct type of RCD must be employed where additional protection is required that is suitable for a low energy DC modulating pump according to IET wiring regulatio...

Page 15: ...ould be sought Water mains pressure Minimum mains water pressure for maximum performance refer to section 13 1 Technical data Maximum mains fed water static pressure is 10 bar If necessary fit a pressure reducing valve NOTICE Non return back flow prevention devices including those associated with water meters fitted to the mains water supply can cause a pressure build up which could damage the boi...

Page 16: ... room Avoid the build up of dust NOTICE Damage to appliance Extreme temperatures may cause damage to the heating system Ensure the appliance location s ambient temperature 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 mon...

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 11 Appliance minimum clearances Table 11 Appliance minimum clearances 0010017086 0...

Page 18: ...bserved to any obstruction surface dark shaded areas figures 12 and 13 Fig 12 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 13 Reduced front maintenance clearances Front v...

Page 19: ...le 15 Table 15 Effective length of bends NOTICE Effective flue length of SimpleSwitch flue adaptor 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 l...

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 19 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 25 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 26 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 29 Fig 29 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 32 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 32 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 37 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 39 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: ...n 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 guidelin...

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 42 Removing the front casing Addition...

Page 35: ...appliance section 4 3 3 Appliance clearances Fig 43 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 throu...

Page 36: ...lianceduetofactorytesting External condensate pipework or internal pipe runs in unheated 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 For further ease of fitting an optional Vertical Pre piping Assembly kit...

Page 37: ...enstar Intelligent filling System install any other accessories to the mounting frame before continuing Ensure the sealing washers are fitted to the appropriate service valves before installing the appliance onto the mounting frame Ensurethatthecontrolpanelisinitsclosedpositionbeforeliftingthe appliance Preparing the service valves The bonded washer supplied is for the Gas connection only Fit the ...

Page 38: ...ows are aligned Fig 50 Siphon fitting 5 4 Flue turret adaptor installation NOTICE Flue installation Refer to the Flue Kit Installation instructions provided with your flue kit to correctly install the flue with this appliance Donotexceedthemaximumstraightlengthforahorizontalorvertical flue or a 60mm plume management system if used as stated in chapter 4 4 Telescopic flue Cutting the flue to an exa...

Page 39: ...cticable replacement appliances The mains electrical supply to the appliance must be through a fused double pole isolator Theisolatormusthavecontactseparationof3mmminimumbetween poles Any system connected to the appliance must not have a separate electrical supply Any additional components that are connected to the appliance that require 230 Volts must be connected to the same supply as the applia...

Page 40: ...ections Access to electrical connections Release side catches and lower control panel into the service position Loosen the retaining screw 1 Push in the tabs and open the cover Fig 55 Opening the cover Stepped cable grommets For splash water protection IP cut the stepped cable grommets to match the diameter of the cable Fig 56 Adapting the grommets to the cable diameter 1 Low voltage signal cables...

Page 41: ... DHW demand input pre heat time control External frost thermostat FS output frost thermostat supply FR input frost thermostat return No functionality not used 0010019905 002 0010036464 001 1 No functionality not used No functionality not used Symbol Function No functionality not used 4000 Combi DHW Pre heat Kit accessory Connect the 2 core cable supplied with the accessory Outdoor weather compensa...

Page 42: ...ks Check that the electrical connections of the appliance are correct Mains electrical supply 230V 50Hz Compliant earth connection Correct polarities External equipment and controls are wired in correctly Check that the flue is correctly fitted airtight free from any obstruction and the connections are secure Check that the condensate pipework is connected properly and that there are no leaks NOTI...

Page 43: ...s recommended that the mid position of the 3 way valve is used to fill drain the system Forinitialfill the boilerautomaticallyselectsthe mid positionwhenfirst powered up Ifpower is not yet connected the3 way valve willalso bein the mid position For future fills to set the 3 way valve to mid position Service menu Settings Special function 3 WV mid pos Yes The 3 way valve remains at the middle posit...

Page 44: ...appliance atmaximum rated output 2 Setthechimneysweepmodeandsettheapplianceatminimumrated output 6 4 1 Setting the appliance to maximum Maximum output mode A hot water outlet must be opened to prevent the appliance from shutting down due to high temperature during testing Press the ok key for 5 seconds until Chimney sweep is displayed Confirm you have read and understood the alert message press ok...

Page 45: ...echnical data section of this manual for the appliance 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...

Page 46: ...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 65 Com...

Page 47: ...ted The flue gas analysis performance of the appliance can be checked via the flue turret adaptor sample points Refer to figure 67 for the location of the flue gas sample point on flue turret adaptor Fig 67 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 c...

Page 48: ...ance 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 appliance system and building If the appliance is unused and exposed to freezing conditions safely isolate all the mains supplies and drain the system and appliance label accordingly Show the customer the location o...

Page 49: ...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 50: ...n HC1 configuration Pump config Heating Max heat output Standby time Anticyc temp off Anticycle temp on Hot water Turbine signal del DHW start del CH delay Man TD line TD Temperature Max TD duration Pump Pump range map Pump ctr mode Min output 4 Max output 4 Pump overrun Special function Ventilation func 3 WV mid pos Filling valve avail Autom filling Min Sys Pres Target Sys Pres Max refill time Ht...

Page 51: ...ting Fault history Service display 2 Hidden menu Reset Maintenance Landlord Demo mode Yes No 1 When theFunctionCheckmenuisenteredonlyBurner 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 52: ...nce commissioning System pressure Current system pressure in bar Hot water Max output Maximum domestic hot water output in kW DHW flow rate Current DHW flow rate in l min DHW act temp Current domestic hot water temperature in C Hot water temp Current domestic hot water temperature in C Inlet temp 1 1 Only available if DHW preheat kit is fitted Cold mains inlet temperature in C when DHW Pre heat Ki...

Page 53: ... changes in the water supply pressure from causing the burner to briefly operate although no water is drawn off DHW start del 0 50 s The delayconcernsheatingmodeinsystemsinwhichthe DHW outlet of the solar heated DHW cylinder is connected to the cold water inlet of a combi boiler DHW heating by the combi boiler will be suppressed so that solar system DHW will reach the DHW temperature sensor earlie...

Page 54: ...dle position for approx 15 minutes Filling valve avail Yes No If the intelligent filling link is installed then select Yes Selecting Yes activates the sub menus below Autom filling 1 Autom filling Yes No Min Sys Pres 0 6 0 7 0 8 bar Target Sys Pres 1 0 1 7 bar Max refill time 120 240 s Htg sys type Small Medium Large Reset refilling No Yes The automatic filling function ensures that the operating ...

Page 55: ...ater temperature Min boiler outp Minimum rated output increases up to 30 Minimum heat output depending on code plug Max 30 Heating curve Enable Yes No To turn this function on when connecting a weather sensor select Yes to enable The system control unit optimises this setting This service function activates a simple weather compensated controller with a linear heatingcurve Dependingontheon offinpu...

Page 56: ...ion Pump On Off Permanent pump operation 3 way valve Heating Hot water Permanent position of the 3 way valve Ionisat oscill On Off Check the ionisation measurement function at the flame HC1 pump 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 On Off Only available if a pump is co...

Page 57: ... 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 58: ...ed 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 69 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 70 Test nipple at the mixing device NOTICE Fan pressure test Theappliancemustbe...

Page 59: ...rminal guard if fitted are clear and undamaged Combustion testing must be carried out to BS 7967 by a competent person Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated Combustion Analyser conforming to BS EN 50379 and is competent in its use Flue gas analysis Ensure that the gas inlet pressure has been checked and is satisfactory Refit...

Page 60: ... 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 72 Remove the burner cover Refer to figure 73 Remove the non return valve bearing plate 1 Check for damage cracks or deformation and for contamination replace if required Ensure non return valve moves freely Fig 73 Non return valve bearing...

Page 61: ...tion aperture cover and remove with the seal Fig 76 Cleaning the heat exchanger Clean out residue and re fit the inspection aperture again Refer to figure 77 Rinse the heat exchanger with water from the top Fig 77 Rinse the heat exchanger with water Refer to figure 78 Re open inspection aperture and ensure no residue remains Close the inspection aperture once checked Fig 78 Checking the heat excha...

Page 62: ...p 4 figure 79 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 80 Remove the gasket on the top of the siphon Check the gasket for cracks deformation or breakage and replace if required Align t...

Page 63: ...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 82 and set the CO2 content for minimum rated output Fig 82 Setting the CO2 content above SIT valve below Honeywell valves 1 Gas valve NG 2 Gas valve LPG Re check settings at maxi...

Page 64: ...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 65: ...nger Disconnect the cable from the flue gas temperature limiter Remove the nut Fig 85 Separating components from the heat exchanger assembly Removing the heat exchanger assembly Refer to figure 86 Release the flue pipe clip Push the flue pipe up Remove the bracket screws Remove the heat exchanger assembly Fig 86 Removing the heat exchanger assembly 9 4 Checking the strainer in the cold water pipe ...

Page 66: ...tion 3 WVmid pos Yes The 3 way valve remains at the middle position for approx 15 minutes Detach the motor in the sequence shown Unplug the plug Remove the lock clip Turn the motor anti clockwise and pull it up and out Pull the motor up to disengage from ball head and remove Fig 89 Detaching the motor from the 3 way valve variant without screws Installing the motor Install the motor in the sequenc...

Page 67: ... it will be hard to pull it out again Install the motor in the sequence shown Lower the new motor from above and suspend it from the ball head Push the motor in and fasten it in place using 2 screws Connect the plug Fig 92 Installing the motor in the 3 way valve variant with screws 9 6 Removing the pump Unplug the electrical connections 4 Release the ratchet connection 1 between pump and heat exch...

Page 68: ...ce Remove the screw 2 Remove the plate heat exchanger 1 Fig 95 Removing the plate heat exchanger Install the new plate heat exchanger in reverse order Make sure that the lugs are fully inserted into the retaining points on the right 9 9 Replacing the expansion vessel Disconnect the pipe union nut 3 Slacken the screws on the clamps top 1 and bottom 2 of the expansion vessel Slide the expansion vess...

Page 69: ...ear view of pressure gauge connection From the front of the boiler 1 Release at least two of the retaining clips on the pressure gauge mount 2 Pull the pressure gauge forward and down to remove Fig 100 Front view of pressure gauge 9 13 Replacing the control unit Replacement control unit Thereplacementcontrolunitisnotsuppliedwithcodeplugordisplay cover panel These must be removed and refitted to th...

Page 70: ...cold water mains is turned on Ensure the primary system has adequate pressure system content for the system type Ensure there is gas to the appliance Are other 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 ...

Page 71: ...hermostat Check the high limit of the safety temperature limiter thermostat or the flue thermostat and the harness for continuity Check the flow temperature 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 ...

Page 72: ...5 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 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 f...

Page 73: ...r anti cycle mode Operating message is not a fault Anti cycle mode domestic hot water post heat function Following a domestic hot water demand the boiler runs for 30 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 aft...

Page 74: ...munication failure or wrong pump is fitted i e non ErP Check the pump communication wire is connected and has continuity Replace the pump for correct modulating pump 1021 B Cylinder charging or hot water temperature sensor faulty A 1021 error can only be cleared by powering the appliance off and back on again the hot watersensorhasbeenchangedifopenorshortcircuit orrefittedtothepipeifithasfallen of...

Page 75: ... back on Check the incoming mains voltage Check the polarity Replace the PCB 2908 V System fault boiler electronics basic controller Restart the appliance to see if the problem re occurs If the fault remains after resetting the burner controller PCB is defective and must be replaced 2910 V Fault in flue system Check the flue for obstructions and remove any found Check the flue integrity test Check...

Page 76: ... plug replace if necessary 2948 B No flame signal with low output Burner starts automatically after purging This can be caused by strong winds If this fault occurs frequently Check CO2 settings Check flue outlet position for effects of excessive wind pressure Check flue integrity 2949 B No flame signal with high output May be caused by strong winds or flue gas recirculation The burner starts autom...

Page 77: ...k isolation valves 2966 B Flowtemperatureriseinheatexchangertoo rapid System is not filled with water No water flow because CH system is closed No water flow because pump is not operating correctly Check pump is operating freely check voltage to pump Check the isolation valves Check for air locks in the system purge if required Check flow through appliance and system pressure 2967 B Thetemperature...

Page 78: ...pliance Other filling loop Vent the heating system and top up water until the target pressure is reached Pressure sensor Check the continuity down harness for the pressure sensor and replace if required Check the voltage at the pressure sensor and replace if required 2972 V Mains voltage too low Establish supply voltage of at least 196 VAC Replace control unit 3071 Comfort II RF Check the configur...

Page 79: ...layed ignition poor ignition Check the ignition transformer function for misfiring in the Function check menu Ignition test replace if required Check the gas type Check the gas supply pressure Check the power supply Check the electrodes with cable replace if required Check the flue system clean or repair if required Check the gas air ratio For natural gas check the external gas flow monitor replac...

Page 80: ... 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 81: ...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 82: ...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 mo...

Page 83: ...perature without additional accessories C 25 Central Heating 25 Maximum mains inlet pressure standing pressure PMW bar MPa 10 1 10 1 Minimum mains inlet pressure working for max flow bar MPa 1 2 0 12 1 0 1 Minimum mains inlet pressure working for operation bar MPa 0 2 0 02 0 2 0 02 Maximum DHW flow rate 40 C rise 15 3 l min 11 9 Maximum DHW flow rate 35 C rise for industry comparison l min 12 3 10...

Page 84: ...ange rated heat output 40 30 C kW 3 3 24 8 3 3 24 8 Maximum flow temperature C 82 82 Maximum flow temperature possible C 86 86 Maximum permissible operating pressure PMS bar MPa 2 5 0 25 2 5 0 25 Available pump head at 20 C system temperature rise m 2 2 Domestic Hot Water DHW Rated heat input DHW net QnW kW 29 4 24 5 Minimum heat input kW 3 2 3 2 Minimum required flow to activate DHW demand l min ...

Page 85: ...weight kg 41 4 41 1 Total appliance weight excluding packaging kg 34 9 34 6 Lift weight front panel removed kg 32 3 32 0 Lift weight front panel and expansion vessel removed kg 28 4 28 1 SEDBUK 2009 12 90 4 90 4 SEDBUK 2005 91 8 91 8 1 For minimum and maximum permissable pressure refer to Gas pressure within the system section 6 5 2 Propane butane mixture for fixed containers with capacity up to 1...

Page 86: ...mperature boilers 37 C and for other heaters 50 C return temperature at heater inlet P1 kW 8 1 8 1 Useful efficiency At rated heat output and high temperature regime 1 4 87 9 87 9 At 30 of rated heat output and low temperature regime 2 1 98 9 98 9 Auxiliary electricity consumption At full load elmax kW 0 039 0 039 At part load elmin kW 0 013 0 013 In standby mode PSB kW 0 002 0 002 Other items Sta...

Page 87: ... heaters 50 C return temperature at heater inlet P1 kW 8 1 8 1 Useful efficiency At rated heat output and high temperature regime 1 4 87 9 87 9 At 30 of rated heat output and low temperature regime 2 1 98 9 98 9 Auxiliary electricity consumption At full load elmax kW 0 039 0 039 At part load elmin kW 0 013 0 013 In standby mode PSB kW 0 002 0 002 Other items Standby heat loss Pstby kW 0 061 0 061 ...

Page 88: ...cessory 13 4 Code plug Table 42 Code plug Temperature C 10 Resistance 0 33 404 5 25 902 10 20 247 15 15 950 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 30 400 5 25 902 10 20 247 15 15 950 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...

Page 89: ...running faster to try and maintain the pressure differential When the TRVs start to close and the resistance of the CH system increases the pump speed reduces to maintain the pressure The setting 1 6 to be selected is dependent upon the resistance and heatloadoftheCHsystem Thehighertheseare thehigherthepressure constant 13 6 Setting values for output 13 6 1 Gas setting values GR4700iW 30 C Table 4...

Page 90: ... 4 3 3 3 2 21 15 11 2 2 2 13 2 17 16 15 14 13 9 9 8 10 11 12 7 6 5 4 3 3 2 1 18 30 18 5AF 22 28 4 8 3 24 29 23 25 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 12 7 20 10 1 19 230V 26 27 ...

Page 91: ...w temperature sensor at the heat exchanger assembly 13 DHW temperature sensor 14 Pressure sensor 15 Turbine 16 Pump control cable 17 3 way valve 18 Chassis earth 19 Fan earth 20 Cable between flue gas temperature limiter and heat exchanger assembly temperature limiter 21 Electrode set 22 Code plug 23 Display 24 Terminals for Installer connections 25 Connecting lead for Key accessory slot 26 Connec...

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 GR4700iW C, Installation And Maintenance Instructions Manual

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Summary of Contents for GR4700iW C

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