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Electrical connection

Condens 7000 WP – 6721841195 (2022/01)

20

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].

Fig. 24 Positioning the connecting lead and cable conduit

7.5

Connecting the pump of the pump assembly

▶ Open the pump terminal unit.

▶ Use the right screwdriver for this.

Fig. 25 Opening the pump terminal unit

With pump assembly:

▶ Connect the 230 V mains cable [1] of the pump to the 3-pin plug.
▶ Connect the PWM signal cable [2] of the pump to the 2-pin plug.
▶ Guide both cables through the strain relief.
▶ Connect the pump terminal unit: fold the pump terminal unit up and

press horizontally until it snaps into place.

Without pump assembly:

When using pump types other than those available from Bosch as
accessories, the PWM signal cannot be used. The PWM connection in the
pump terminal unit is then not used. On/Off operation 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.

0010035234-002

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0010035232-002

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Содержание 7736 702 194

Страница 1: ...6721841195 2022 01 UK IE Installation and Maintenance Instructions Wall mounted gas condensing boilers Condens 7000 WP GC7000WP 50 23 GC7000WP 65 23 GC7000WP 85 23 GC7000WP 100 23 ...

Страница 2: ... the pump of the pump assembly 20 7 6 Connecting the 3 way valve 230 V accessory 21 7 7 Mounting the function module accessory 21 7 8 Fitting the plug if not preassembled 21 8 Commissioning 22 8 1 Commissioning the boiler 22 8 2 Setting the parameters 22 8 3 Setting options for air gas ratio control valve 23 8 4 Measuring the gas standing pressure static 23 8 5 Measuring the gas working pressure d...

Страница 3: ...ticHotWater heatinginclosed loopDHWand heating systems Any other use is considered inappropriate Anydamagethatmayresultisexcluded from liability H System malfunctions caused by third party equipment This heat source is designed for operation with our control units System malfunctions malfunctions and defects of system components resulting from the use of third party equipment are excluded from lia...

Страница 4: ...ighlight the following points in particular Point out that modifications or repairs may be carried out only by an approved contractor To ensure safe and environmentally compatible operation an annual inspection and also cleaning and maintenance as required must be carried out within the specified interval Point out the possible consequences material damage personalinjuryandpossibledangertolife of ...

Страница 5: ...t Table 2 Scope of delivery 2 9 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 seizing 2 10 Frost protection NOTICE Installation damage due to the effects of frost Theheatingsystemcouldfreezeduringahardfrostdueto mainsvoltage failure insufficient gas supply or appliance fault Install the boiler in ...

Страница 6: ...Condens 7000 WP 6721841195 2022 01 6 2 11 product overview Fig 1 GC7000WP with connection set on frame 0010030188 002 12 13 14 11 9 3 4 18 19 21 22 24 25 26 10 8 7 5 6 2 17 15 16 20 1 29 27 23 30 31 32 35 36 28 37 38 33 34 ...

Страница 7: ...uting 16 Test point for air supply 17 Appliance cover 18 Connection point for diagnosis tool 19 Fan 20 Burner cover 21 Igniter 22 Flow temperature sensor 93 C 23 Safety temperature monitor 105 C 24 High limit safety cut out 25 Pressure sensor 26 return temperature sensor 27 Type Plate 28 Condensate trap Connection set and frame accessories 29 Pump 30 Gas isolator 31 Expansion vessel connection 32 ...

Страница 8: ...ions Boiler on frame Fig 2 Dimensions on base frame mm Boiler against the wall Fig 3 Dimensions on the wall mm 0010030944 002 202 198 200 115 521 642 5 260 520 115 260 64 1690 12 53 191 0010031061 002 53 138 198 520 260 300 115 115 136 457 5 260 260 191 1120 298 100 199 ...

Страница 9: ...tlet 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 Distance from walls a...

Страница 10: ...he manufacturer When installing and operating the heating system observe the following requirements The local building regulations regarding installation conditions The local building regulations regarding the supply and exhaust air systems and the chimney connection Latest edition of the IEE Wiring regulations governing electrical connection to the mains power supply Regulations and standards reg...

Страница 11: ...icinity of the boiler NOTICE Boiler damage through contaminated combustion air or contaminated air in the vicinity of the boiler Never operate the boiler under dusty conditions or where the atmosphereiscontaminatedwithcorrosivesubstances Thesemight be for example paint shops hairdressing salons and agricultural operations involving the production of manure Never operate boilers in locations where ...

Страница 12: ...er temperature is sufficient to cover the heating load and also guarantee the service life of the boiler A higher maximum flow temperature may however be required for certain installations In these cases the chloride content of the 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 treatme...

Страница 13: ...all 2 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 in the frame using theadjustmentoption 1 Fully tighten the grub screw in the frame Fig 10 Align the boiler on the frame 001003...

Страница 14: ...ing rail Align 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 Theboilercanbeconnectedontheheatingandgassidein2 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 ...

Страница 15: ...g agent Mount the coupling two parts 2 Install the gas valve 3 Connect the gas line without stress to the gas valve Install a gas filer 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 wit...

Страница 16: ...rugated hose 4 Condensate trap 6 7 Connecting the condensate pipe NOTICE If the waste water 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 ...

Страница 17: ... the flow and return pipe Fig 18 p 17 6 8 1 Connecting the gas valve Connect the gas valve 6 4 p 14 6 8 2 Installing the pump Select the pump using the specifications as the basis Tab 15 2 p 47 Take the required volumetric flow rate into consideration Tab 15 4 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 Install ...

Страница 18: ...30 V AC 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 15 1 p 46 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 ex...

Страница 19: ... 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 7 7 p 21 Mains voltage Co...

Страница 20: ...he right screwdriver for this Fig 25 Opening the pump terminal unit With pump assembly Connect the 230 V mains cable 1 of the pump to the 3 pin plug Connect the PWM signal cable 2 of the pump to the 2 pin plug Guide both cables through the strain relief Connect the pump terminal unit fold the pump terminal unit up and press horizontally until it snaps into place Without pump assembly When using pu...

Страница 21: ...230 V 3 Neutral cable N 7 7 Mounting the function module accessory NOTICE EMC fault due to incorrect cable routing IfbuscablesandpowercablesareroutedinparallelthereisariskofEMC faults occurring Route bus cables and power supply cables separately 1 function module 3 can be installed in the oiler Carefullyreadtheinstructionsforthefunctionmodulewhencarrying out the installation Install the BUS cable ...

Страница 22: ...p 26 Adjust the parameters if required Make a note of which parameters have been modified in the commissioning report 15 7 p 50 Setting Maintenance type Withamaintenanceperiod of2years normaloperationisconsideredto be a maximum burner runtime of 4000 hours every 2 years During commissioning the anticipated burner runtime must be estimated in order to set the right Maintenance type During the initi...

Страница 23: ...ad Asthemeasurementistakenattheair gasratiocontrolvalveandnotthe gas valve the permissible gas working pressure may be reduced due to the pressure drop between the gas valve and air gas ratio control valve Example GC7000WP 100 to natural gas H G20 Permissible gas pre pressure min 17 mbar max 25 mbar Tab 24 p 48 Pressure drop between gas valve and air gas ratio control valve is 2 7 mbar Tab 10 Perm...

Страница 24: ...g system can release its heat Open the gas air ratio test port by turning the adjusting screw through 2 revolutions 8 3 p 23 Set the pressure gauge to 0 Connect the pressure gauge to the test port Open the menu Function check Burner Start Function check by setting the smallest possible value Check the measured value table 11 p 24 Only modify the gas air ratio if the measurement is outside the spec...

Страница 25: ... refilled this is a sign that the system is faulty and or leaking ensure required water quality according to the operator s log Inform operator about the required water quality and point out where the heating water must be refilled Inform the operator that he or she must not carry out any modifications or repairs Point out the possible consequences material damage personal injury or danger to life...

Страница 26: ... Siphon fill prog appears on the display Thesiphonfilling programisinterrupted whenthechimneysweep mode is called up 9 4 Settings in the service menu Many device functions can be set and checked in the service menu It includes Info viewing information Settings general and device specific settings Function check settings for function checks and start of function checks Reset restoring the factory s...

Страница 27: ...on Pump config Heating Max heat output Standby time Anticyc temp off Anticycle temp on Hot water Max DHW output DHW circ pump Cycle circ pump TD Temperature Start TD Stop TD Pump Pump ctr mode Min output Pump overrun Min Sys Pres Target Sys Pres Special function Ventilation func Siphon fill prog 3 WV mid pos Autom filling System Fill Min Sys Pres Target Sys Pres Max refill time Blocking time Max r...

Страница 28: ... 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...

Страница 29: ...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...

Страница 30: ...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...

Страница 31: ...eave the function switched on for a maximum of 2 minutes Fan On Off Permanent ignition Fan running without gas supply or ignition Pump On Off Permanent pump run internal or external pumps Cyl prim pump On Off Permanent pump operation of cylinder primary pump 3 way valve Heating Hot water Permanent position of the 3 way valve HC1 pump On Off PermanentHC1pumpoperation downstreamoflowloss header if H...

Страница 32: ... measuring devices and tools Pressure gauge with a measurement accuracy of 0 01 mbar Flue gas analysis measurement device Cleaning brush with plastic bristles Only install original spare parts Replace all loose gaskets when carrying out the work Inspection and maintenance interval To ensure the wall mounted gas condensing boiler works correctly and safely the following intervals must be adhered to...

Страница 33: ...aced 10 16 1 p 36 Make a note of the value inthe maintenance protocol 10 17 p 38 10 3 Remove the gas air unit Remove the plug from the fan Remove the gas hose between the air gas ratio control valve venturi nozzle Fig 35 Remove the gas hose 85 kW Remove the air intake pipe from the venturi nozzle Fig 36 Removing the air intake pipe Open the 4 snap fasteners on the burner cover Attention The snap f...

Страница 34: ...plastic bristles for cleaning Cover ignition unit 1 Remove loose dirt with a vacuum cleaner Loosen any other dirt with a brush and remove it with a vacuum cleaner Purge the heat exchanger with water 2 Fig 41 Cleaning the heat exchanger 10 6 Cleaning the siphon Remove the flexible hose and possibly the tee from the siphon Unscrew the union nut of the siphon in the boiler and completely screw open 1...

Страница 35: ... gas air ratio 8 7 p 24 Make anote ofthe valueinthe maintenance protocol 10 17 p 38 10 12 Measuring the ionisation current Read off the ionisation current on the display 8 8 p 24 Make anote ofthe valueinthe maintenance protocol 10 17 p 38 or If the value is less than 2 A replace the ignition and flame sense electrode 10 16 2 p 36 10 13 Check the flue gas backflow preventer If a positive pressure c...

Страница 36: ... both threaded bolts of the igniter 3 Nm Mount the plug of the igniter Start up the boiler Check the flue gas tightness of the removed parts Carry out a check by measuring the ionisation current 8 8 p 24 10 16 3 Replacing the flue gas temperature sensor The flue gas temperature sensor is equipped with a bayonet connection Switch off the appliance Turn the flue gas temperature sensoranticlockwise b...

Страница 37: ...s easily accessible 3 Remove the coding plug 4 Attach new coding plug Fig 47 Replacing the coding plug Mount the burner control unit again by following the above steps in reverse order Screw down the bracket of the burner control unit Close and secure the top panel Operate the appliance 10 16 5 Replacing the air gas ratio control valve Take the replacement interval of the air gas ratio control val...

Страница 38: ...ghtness and mechanical stability 5 Check the gas supply pressure mbar 6 Check the gas air ratio Pa 7 Check CO content ppm 8 Check CO2 content 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 Check non return valve 16 Check the pre charge pressure of the expansion vessel for the sta...

Страница 39: ...flue gas thermostat or heat exchanger maximal thermostat has activated Heating circuit 1 Check that the heating water is circulating correctly 2 Open the closed valve in the heating circuit 3 Top up water until the preset pressure is reached 4 Connect the plug to the heating block temperature limiter correctly 5 Check heating block temperature limiter replace if required Potable water circuit Chec...

Страница 40: ... and boiler identification 1 Check boiler identification module coding plug 2 Install valid combination of control device burner control unit 237 V System fault 1 Replace boiler identification module coding plug 2 Replace control device burner control unit 238 V Boiler electronics faulty Replace control device 242 263 V System fault boiler electronics basic controller 1 Remedy contact problem 2 If...

Страница 41: ...r replace it 3 Replace faulty EMS BUS node 1013 W Max combustion point reached 1 Carry out maintenance 2 Reset service display 1017 W System pressure too low 1 Top up water and vent the system 2 Check the pressure sensor replace if necessary 1018 W Maintenance interval expired 1 Carry out maintenance 2 Reset service display 1019 W Incorrect pump type detected 1 Check pump cabling 2 Check that the ...

Страница 42: ...920 V Fault in flame monitoring Check control device replace if necessary 2923 2926 V Boiler electr system fault 1 Check air gas ratio control valve cabling 2 Check air gas ratio control valve If the fault persists following a reset the control device or the air gas ratio control valve is faulty and must be replaced 2927 B No flame detected after ignition 1 Open the main shut off valve 2 Open the ...

Страница 43: ...ng block on the flue gas side 17 Check control device burner control unit replace if necessary 2952 V Internal fault when testing the ionisation signal 1 Perform reset 2 Replace control device burner control unit 2955 B Boiler does not support the parameters set for the hydraulic configuration Check hydraulic settings change if necessary Low loss header Internal DHW circuit cylinder charging circu...

Страница 44: ...lish supply voltage of at least 196 VAC 2 Replace burner control unit 3071 No communication with remote control 1 Check configuration 2 Check cabling Device faults Remedy Combustion noises too loud rumbling noises Check the gas type Check the gas supply pressure Check the flue system clean or repair as necessary Check the gas air ratio Check the air gas ratio control valve replace if required Flow...

Страница 45: ... return and recycling of old electronic appliances that apply in each country As electronic devices may contain hazardous substances it needs to be recycled responsibly in order to 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 ele...

Страница 46: ...lation pump 230VAC 19 Mains voltage 230VAC 20 EMS bus 21 Temperature sensor of low loss header 22 Storage cylinder temperature sensor 23 Outdoor ambient temperature sensor 24 External switching contact volt free 25 EMS bus 26 Volt free contact 27 Coding plug 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 ...

Страница 47: ...ction concentric air supply mm 110 160 Heating flow return pipe wall mounted gas condensing boiler inch G1 Gas connection wall mounted gas condensing boiler inch R1 Condensate drain flexible drain hose mm 24 Emission values in accordance with EN 13384 CO2 content with natural gas G20 partial load full load 8 4 9 3 8 4 9 3 8 2 9 1 8 1 9 1 CO2 content with natural gas G25 partial load full load 8 3 ...

Страница 48: ...G20 17 20 25 HU Aardgas H G20 17 20 25 DE LU NL PL Aardgas E G20 17 20 25 FR Bereik Es Aardgas E G20 17 20 25 FR Bereik Ei Aardgas E G20 20 25 30 BE Bereik Es Aardgas E G25 20 25 30 NL Aardgas K G25 3 20 25 30 DE Aardgas LL G25 18 20 25 DK NL NO SE Propaan L G31 25 30 35 AZ BA BE BG CH CZ ES FR GB GR IE PT IT MD PL RO RS TR PL SK Propaan L G31 25 37 45 AT AU BG CH DE ES EE HR HU LT LV LU NL SI SK ...

Страница 49: ... 52 Residual head of pump GC7000WP 50 15 6 Setting values for heating capacity Table 28 Setting values for heating capacity Unité GC7000 WP 50 GC7000 WP 65 GC7000 WP 85 GC7000 WP 100 Required volumetric flow rate at T 20 K l h 2200 3000 3600 4300 Max volumetric flow rate l h 5000 Resistance of boiler mbar 75 130 170 240 0010039392 001 0 100 200 300 400 500 600 700 800 0 500 1000 1500 2000 2500 300...

Страница 50: ...mbustion air at maximum rated output Notes regarding underpressure or overpressure operation Gas setting and flue gas test Set gas type Gas supply pressure 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 ...

Страница 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 ___________________...

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

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