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KEY TO SYMBOLS AND SAFETY PRECAUTIONS

AU/NZ

6 720 646 195a (2010/11)

1.2

Safety precautions

If you smell gas:

B

CALL

THE FEDERAL GOVERNMENTS SAFETY

HOTLINE ON 13 17 92

B

LPG BOILERS

CALL THE SUPPLIER‘S NUMBER ON

THE SIDE OF THE LPG TANK/CYLINDER

B

TURN OFF

THE ECV (EMERGENCY CONTROL VALVE)

AT THE METER

B

DO NOT

TURN ELECTRICAL SWITCHES ON OR OFF

B

DO NOT

STRIKE MATCHES OR SMOKE

B

PUT OUT NAKED FLAMES

B

OPEN DOORS AND WINDOWS

B

KEEP PEOPLE AWAY FROM THE AFFECTED AREA

Boiler operation
This boiler must only be operated by a responsible
adult who has been instructed in, understands, and is
aware of the boiler's operating conditions and effects.

Service checklist

The Service Checklist places responsibilities on both
manufacturers and installers. The purpose is to ensure
that customers are provided with the correct equipment
for their needs, that it is installed, commissioned and
serviced in accordance with the manufacturer's
instructions by authorised persons and meets the
requirements of the appropriate building regulations.
The service checklist can be used to demonstrate
compliance with building regulations and should be
provided to the customer for future reference.

Combustion and corrosive materials

Do not store or use any combustible materials (paper,
thinners, paints etc.) inside or within the vicinity of the
boiler.

Chemically aggressive substances can corrode the boiler
and invalidate any warranty.

Fittings and modifications

Fitting the boiler and any controls may only be carried
out by an authorised person.

Flue systems must not be modified in any way other than
as described in the fitting instructions. Any misuse or
unauthorised modifications to the boiler, flue or
associated components and systems could invalidate
the warranty. The manufacturer accepts no liability
arising from any such actions, excluding statutory rights.

Servicing

Advise the user to have the system serviced annually by
an authorised person. Approved spares must be used to
help maintain the economy, safety and reliability of the
boiler.

Important

The service engineer must complete the Service Record
at the rear of this manual after each service.

Installation regulations

All gas boilers must be installed by an authorised person
in accordance with AS 3000, AS 5601 and building
regulations of relevant states and territories.

Failure to install boilers correctly could lead to
prosecution.

Standards

Where no specific instruction is given, reference should
be made to the following standards:

•

AS 5601 Gas Installations,

•

AS 1596 LPG storage and handling,

•

AS 4552 Gas fired water heaters for hot water supply
and/or central heating,

•

AS/NZS 3000 Electrical Installations,

•

AS1697 Installation and maintenance of steel pipe
systems for gas,

•

AS 4032 Water supply - valves for the control of hot
water supply temperatures,

•

AS 3498 Authorization requirements for plumbing
products - water heaters and hot-water storage tanks.

•

AS 1910 Water supply - float control valves for use in
hot and cold water, AS 3500 National plumbing and
drainage code.

Liquefied petroleum gas

A boiler using LPG gas must not be installed in a room or
internal space below ground level unless one side of the
building is open to the ground.

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Содержание CONDENS 5000W

Страница 1: ...Installation and Servicing Instructions HYDRONIC GAS SYSTEM BOILER 18kW BOSCH CONDENS 5000W 6720646195 00 1Wo ZSB18 2A 6 720 646 195a 2010 11 ...

Страница 2: ...missioning checks 36 5 2 Filling the system 37 5 3 Water treatment 37 5 4 Starting the boiler 38 5 5 Commissioning 39 5 5 1 Checking the gas inlet pressure 39 5 5 2 Checking the gas rate 40 5 5 3 Domestic hot water 40 5 6 Finishing commissioning 41 5 6 1 Replace outer casing 41 5 6 2 Fitting fascia flap 41 5 6 3 Installing bottom panel 41 5 6 4 Handover 41 6 Service and spares 42 6 1 Inspection an...

Страница 3: ...he boiler The checklist can be found in the back pages of this manual Abbreviations used in this manual Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background Electrical hazards are identified by a lightning symbol surrounded by a warning triangle Notes contain important information in cases where there is no risk of personal inju...

Страница 4: ...rried out by an authorised person Flue systems must not be modified in any way other than as described in the fitting instructions Any misuse or unauthorised modifications to the boiler flue or associated components and systems could invalidate the warranty The manufacturer accepts no liability arising from any such actions excluding statutory rights Servicing Advise the user to have the system se...

Страница 5: ...n with speed regulator CH temperature sensor control Pump anti seizure protection Flue gas temperature sensor Condensate syphonic trap Temperature control Check list Hardware literature pack Qty Installation instructions 1 User instructions 1 Warranty card 1 Sealing pack 1 Compression nut 22mm 3 Compression ring 22mm 3 Compression nut 15mm 3 Compression ring 15mm 3 Fibre washer 18 6 x 13 5 x 1 5 2...

Страница 6: ...ents Standard package 1 Hydronic system boiler 5 Fascia panel 2 Wall mounting frame 6 Syphon assembly 3 Hardware literature pack see checklist 7 Metric to Imperial adapter pack 4 Bottom panel 2 4 3 5 710mm to top of case front 1 700mm 400mm 330mm Depth to wall When fitted to wall frame 6 6720646195 01 1Wo 7 ...

Страница 7: ...operating pressure kPa 250 Available pump head at 21 C system temp rise m 2 0 Flue Flue gas temp 80 60 C rated min load C 70 60 Flue gas temp 40 30 C rated min load C 48 34 CO2 level at max rated heat output after 30 min 9 8 CO2 level at min rated heat output after 30 min 9 2 NOx class 4 Condensate Maximum condensate rate l h 1 5 pH value approx 4 8 Electrical Electrical power supply voltage a c V...

Страница 8: ...8 Boiler information AU NZ 6 720 646 195a 2010 11 2 3 Layout Fig 2 Main boiler components 6720644743 02 1Wo 1 2 31 30 29 28 27 26 10 14 12 11 13 15 16 25 23 24 22 21 20 19 18 17 3 4 5 6 7 8 9 ...

Страница 9: ... 11 Right side hand hold for lifting boiler 33 Flow connector from heat exchanger 12 Diverter valve assembly body 34 Expansion vessel hose connection point 13 Diverter valve actuator stepper motor 35 Auto air vent 14 Pump 36 Return connection to heat exchanger 15 Drain point 37 Flow turbine housing not used 16 CH return isolator 38 Unused port 17 System pressure gauge 39 Compact hydraulic right mo...

Страница 10: ...rammer 11 Gas inlet connection BSP inch thread 4 Reset button 12 CH flow isolator 5 System pressure gauge 13 Condensate connection 6 ECO button not used 14 CH temperature control 7 DHW temperature control 15 Service mode button 8 Boiler identification label Tab 7 Additional boiler components 6720644743 04 1Wo 1 2 3 4 5 6 15 14 9 10 11 13 12 7 8 The DHW temperature control is only operational when ...

Страница 11: ...stem to remove the flushing agent and debris B It may be necessary to use a power flushing machine to aid the cleansing procedure in some circumstances B Close the drain points and refill with fresh water and a suitable inhibitor B Vent any air from the boiler and system Inhibitor Add a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heat...

Страница 12: ... services must be as close as practical to their entry point before any branch pipe work and a maximum of 600mm from an internal meter Earth bond conductors must be copper and the same size as other earth bonding conductors and not be less than 10mm2 The earth bond conductors must be permanently fixed to the metal pipes with clamps and labels in a visible position to allow for inspection 3 2 3 Gas...

Страница 13: ...stem The CH sealed system must be filled using an approved filling loop or comply with figure 5 for system fill Where the system volume is more than 100 litres or exceeds 265 kPa at maximum heating temperature an extra expansion vessel 2 must be fitted as close as possible to the boiler in the central heating return Pressurise the extra expansion vessel 2 to the same figure as the expansion vessel...

Страница 14: ...ternal diverter valve Fig 8 Y plan System layout with optional internal diverter valve not supplied with boiler Fig 9 System layout NOTE The boiler is fitted with its own internal bypass 1 Diverter valve 2 Radiator valve flow 3 Lock shield valve return 4 Bypass Tab 9 NOTE B A drain point should be fitted at the lowest part of the heating circuit and beneath the boiler 3 2 1 4 M M 6720644743 05 1Wo...

Страница 15: ...o soil vent stack vertical position Fig 11 Disposal to soil vent stack on gradient Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe can be used Fig 12 Disposal to a waste pipe A washing machine waste pipe or bifurcated pipe etc can also be used Fig 13 Bifurcated pipe disposal NOTE BWhere a new or replacement boiler is being installed and freezing conditi...

Страница 16: ...scharge pipe can be between 200 and 300mm above a paved area 2 Pressure relief discharge pipe can be between 75 and 300mm when discharging into a gravel pit of not less than 100mm diameter Fig 14 Pressure relief pipe work NOTE B The PRV is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain line B Care should be taken when siting the dra...

Страница 17: ... Compartments Minimum clearances must be maintained An access door is required to install service and maintain the boiler and any ancillary equipment If fitting the boiler into an airing cupboard use a non combustible material to separate the boiler from the airing space The material can be perforated up to a maximum hole size of 13mm NOTE No surface protection is required against heat transfer fr...

Страница 18: ...170 approx 30 above the elbow 200 100 Tab 14 Minimum unventilated compartment clearances If side clearances are reduced millimetres If total side clearance is reduced to combined left and right clearances excluding the boiler Increase height clearances to approx combined top and bottom clearances excluding the boiler OR Front clearance to removable door must be increased to 350 441 129 300 523 161...

Страница 19: ...RNING If fitting an optional integral diverter valve B Refer to the optional integral diverter valve installation instructions Heating System inch BSP thread compression fittings Gas inch BSP thread Tab 17 Further guidance on pipe routing can be found printed on the boiler template supplied 1 2 3 4 5 6720646195 07 1Wo Function From left case edge Ø of pipe connections 1 CH flow 70 mm BSP 2 Gas 200...

Страница 20: ...hs B each 90 bend used is equivalent to 2 metres of straight flue B each 45 bend used is equivalent to 1 metre of straight flue Maximum straight flue length available mm Flue type Boiler i System 60 100 80 125 1 Telescopic horizontal flue assembly All 570 1 070 2 Horizontal flue extension All 4 600 13 000 3 Horizontal flue with 1 x 90 bend All 2 600 11 000 4 Horizontal flue with 2 x 90 bends All N...

Страница 21: ...Pre installation 21 AU NZ 6 720 646 195a 2010 11 350 mm 570 mm 130 mm Min Flat roof 300 mm 500 mm Pitched roof 2 3 4 5 6 10 9 8 7 1 6720643895 12 1Wo ...

Страница 22: ...g the building NOTE Install a fire proof back board if installing on combustible surfaces The fixing method must be sufficient to hold the weight of the boiler Ref Item Min Clearance mm a Below eaves balconies and other projections Appliances over 50MJ h 300 b From the ground above a balcony or other surface 300 c From a return wall or external corner 300 d From a gas meter 1000 e From an electric...

Страница 23: ... safe place Care should be taken when lifting the boiler from the base and the proper technique for safe lifting of any heavy object should be strictly observed 1 Remove straps and open the top of the boiler packaging 2 Remove the wall mounting frame 1 and wall mounting template 2 and from the packaging 3 Remove the boiler bottom panel 5 front fascia 6 hardware literature pack 4 and syphon assembl...

Страница 24: ...lue is to be used a 125 mm Ø hole is required However if using the weather sealing collar by pushing it through from inside the property then a 150 mm diameter hole is required to accommodate this B The flue turret of the 100 mm flue has an in built 3 angle B If extensions are to be added then the complete flue must rise at an angle of 3 B The 125 mm Ø flue system will require the flue to rise at ...

Страница 25: ...r outer casing 5 to be removed B The inner sleeve 2 opens as shown in figure 23 B Remove the protective wrapping 4 1 Undo but do not remove the two screws at the bottom of the boiler 2 Undo the two screws at the top see fig 24 3 Remove the outer case 5 B Remove any packaging within the boiler and the packaging base 3 Fig 21 Remove outer carton Fig 22 Lay boiler down Fig 23 Remove packaging Fig 24 ...

Страница 26: ... B Fit sealing washers to service valves before hanging boiler B Fit the metric to imperial 15mm to R adapter 4 to the pressure relief valve connection 1 B Assemble the compression nut 3 and ring 2 onto the adapter 4 and fit to the PRV connection 1 Fig 26 Sealing washers 1 Pull the extended tab lever forward and down until there is no further travel Fig 27 PRV connection in the down position CAUTI...

Страница 27: ...on To connect the expansion vessel flexible pipe to the hydraulic manifold situated to the left of the pump B Remove and discard the plastic cap from the expansion vessel flexible pipe 1 Refer to figure 30 release the retaining clip 2 Remove and discard the orange plastic blanking plug from the pressure vessel connection at the hydraulic manifold Fig 30 Blanking plug 1 Refer to figure 31 and inser...

Страница 28: ... the flue length required between 350 570mm Secure with screw provided and seal joint with the aluminium tape supplied 4 5 2 Reducing the telescopic flue length The flue terminal must be fitted with the top label uppermost to allow the correct fit and use of the plume management system Fig 34 Reducing the standard terminal B Remove securing screws 3 to detach the terminal assembly from the turret ...

Страница 29: ...rret to the boiler flue outlet with flat facing 1 to the rear of the boiler The flue turret should be pushed straight down on to the boiler Fig 37 Aligning the turret B Fit the screws removed in step 1 to secure flue turret B If fitting the outer seal from outside the building slide the outer wall seal onto the terminal as shown Fig 38 Telescopic flue installation Additional notes and reminders En...

Страница 30: ... to opening NOTE Do not rotate the complete terminal assembly The flue terminal outlet has built in stops to limit rotation for horizontal fluing to allow condensate to run back into the boiler for safe disposal Do not attempt to force beyond the limit stops 1 2 1 3 2 3 1 80 180 6720643895 34 1Wo NOTE Outlet position B The flue terminal outlet position must follow those stated in the relevant boil...

Страница 31: ... clip is engaged in the top of the syphon Fig 44 Fitting syphon 3 Push the discharge hose onto the wall frame connector until fully engaged Maintenance Fig 45 There is no need to remove the syphon assembly for cleaning To drain debris from the syphon during the annual service B Release the clips and remove the drainage cap from the bottom of the syphon B Empty the debris and condensate from the sy...

Страница 32: ...ve the connections cover Fig 47 Removing the connection cover Fig 48 Electrical connector information CAUTION Isolate the mains electricity B Remove the plug from the mains socket to isolate the electrical supply before starting any work on the boiler and observe all relevant safety precautions The boiler is pre wired with a 1 metre mains supply cable A spare strain relief block is supplied in cas...

Страница 33: ...E B External diverter valve s and all other 240V parts are not supplied with the boiler B A fascia mounted programmer timer cannot be fitted unless optional integral diverter valve is used B Refer to manufacturers instructions when connecting external parts to the wiring centre B Robert Bosch cannot be held responsible for wiring errors B There is an option to fit an internal diverter valve This a...

Страница 34: ...e B Turn on the main gas supply check the gas pipe work connections and rectify any leaks B Check that the condensate pipe 1 has been connected to the syphon Fig 53 Syphon connection B Referring to figure 54 check pressure relief drain pipe 1 is correctly fitted and securely tightened Fig 54 Pressure relief drain pipe CAUTION Isolate the mains electricity supply before starting any work and observ...

Страница 35: ...s hot B Close drain points and add a suitable flushing agent at the correct strength for the system condition in accordance with the manufacturer s instructions B Run the boiler system at normal operating temperature for the time stated by the manufacturer of the flushing agent B Drain and thoroughly flush the system to remove the flushing agent and debris Inhibitor CH B Check drain points are clo...

Страница 36: ...he boiler fails to light the blue power indicator 5 and reset button 7 will flash To reset press and hold the reset button 7 for more than two seconds The boiler will be reset CAUTION Running the boiler B Never run the boiler when the system is empty or partially filled 1 2 3 4 5 6 7 8 9 6720643895 52 1Wo 1 Central heating temperature control 2 Burner indicator green 3 Service button 4 Cover or op...

Страница 37: ...cator will pulse five times B Check the gas supply working pressure at the gas valve conforms to values shown in Fig 58 Gas pressure within the system Refer to the figures below for natural gas pressures The pressure at the boiler must not be less than the pressure read at the meter minus 0 03 kPa If the pressure drops are greater than shown below then this would indicate a problem with the pipe w...

Страница 38: ...button again and the boiler will return to normal operation If left in the service mode the control will return to normal operation after 15 minutes B Close the gas isolation valve B Remove the manometer B Re seal the screw in the gas inlet pressure test point B Open the gas isolation valve B Ensure that there are no gas leaks B Replace the outer case 5 5 3 Domestic hot water Controlling the hot w...

Страница 39: ...lose the flap 5 6 3 Installing bottom panel B The bottom panel slides onto two ledges C either side of the boiler frame B Hold the panel up against the underside of the boiler and slide towards the rear until there is no more movement B Slide the panel forward until it is fully engaged Fig 60 Bottom panel installation 5 6 4 Handover B Complete the gas boiler commissioning checklist B Open the fasc...

Страница 40: ... the boiler and take note of any irregularities Refer to fault finding for rectification procedures Component access 1 Removing outer case Remove bottom panel by pushing it fully back and then pulling it forward and down to remove Undo and remove two screws 1 securing boiler casing at the top of the boiler Undo but do not remove the two screws 2 Pull case forward and remove Fig 61 Remove outer cas...

Страница 41: ...for more than 10 seconds 2 Set the CH temperature to maximum The service button will illuminate continually and the blue power indicator will pulse 5 times The boiler will stay in this mode for 15 minutes unless the service button is pressed again Fig 64 Set boiler to maximum Fan pressure Fig 65 Fan pressure test point B Remove the cover and connect a digital manometer to the fan pressure test poi...

Страница 42: ...ue gas sampling point as shown in the figure below B Run the boiler at maximum output for at least 10 minutes B Check the CO CO2 readings against the information in table 26 CO CO2 settings Fig 68 Combustion test If the boiler fails the combustion test check 1 Air intake for restriction 2 Diaphragm in the fan for correct operation 3 Cleanliness of the heat cell plus blockages in the condensate dis...

Страница 43: ...the CO is less than 200ppm B Return to maximum and re check the CO CO2 If correct press the service button the button will cease to be illuminated and the blue power indicator will be permanently illuminated B Re assemble and refit boiler case Fig 70 Gas valve adjustment NOTE Setting of the gas ratio must be carried out by an authorised person Setting of the gas ratio must not be attempted unless ...

Страница 44: ... by removing retaining screw Fig 73 Rotate air gas manifold NOTE Combustion testing B Combustion testing must be carried out by an authorised person Testing must not be attempted unless the person carrying out the combustion check is equipped with a combustion analyser and competent in its use NOTE CO CO2 checks B If the joint between the air gas manifold and heat exchanger is disturbed the sealin...

Страница 45: ...the condition of the electrodes and ceramics replace if necessary B Use a plastic scouring pad to clean the electrodes Baffle removal Refer to figure 75 1 Remove top baffle 2 Remove lower baffle Fig 75 Baffle removal NOTE Cleaning B Do not use wire wool to clean the electrodes 1 2 3 6720643895 61 1Wo If the lower baffle is stuck it may be necessary to use the baffle removal tool from the heat exch...

Страница 46: ...l and ensure that the seal is correctly fitted B Check the syphon unit is clean before refitting to boiler B Reassemble and check combustion as stated in setting the air gas ratio section on page 43 Fig 77 Cleaning heat exchanger Cleaning the syphon There is no need to remove the syphon to clean To drain debris from the syphon release the clips and remove the drainage cap from the bottom of the sy...

Страница 47: ... Remove two electrical connectors from thermostat 3 Slacken and remove fixing screw and thermostat 3 B When replacing ensure thermostat sits correctly on surface of the casting with the left hand side of thermostat sitting up against the shoulder Fig 79 Primary sensor and overheat thermostat CAUTION Turn off the gas supply and isolate the mains supplies before starting any work and observe all rel...

Страница 48: ... the sump B Retrieve the thermostat from the sump well Fig 81 Remove thermostat To replace push the thermostat and grommet gently back into the opening until contact with the locating ridge is felt 6 8 5 Moving controls to service position 1 Remove the screw securing control panel 2 Gently pull the panel forward Fig 82 Control panel to service position 6720643895 71 1Wo 2 1 6720643895 70 1Wo 1 To ...

Страница 49: ...ve wire clip from gas valve outlet then move gas pipe free from the gas valve see figure 83 Fig 85 Retaining plate B Undo the securing nut at the top of the heat exchanger and remove the retaining plate assembly 1 NOTE The valve will require setting follow procedure setting the air gas ratio 1 2 6720643895 72 1Wo 6720643895 73 1Wo 1 2 The following components require the air gas manifold and fan a...

Страница 50: ...fan ensuring seals are correctly fitted Fig 87 Dismantling the air gas manifold assembly Flap valve assembly There is no need to remove the mounting flange from the fan assembly just to gain access to the flap B Twist the mixing chamber clockwise to release from the mounting flange B Pull the mixing chamber off the mounting flange 1 Pull the rubber flap off the flap valve assembly B To replace the...

Страница 51: ...Remove syphon Refer to figure 90 1 Remove the clip from plastic elbow on the flow pipe 2 Move flow pipe away from heat exchanger Fig 90 Flow pipe removal Refer to figure 91 1 Remove the three screws securing the turret to the top of the boiler 2 Turn the upper exhaust connector clockwise to release from the hook 3 Move the upper exhaust connector down Fig 91 Upper exhaust assembly NOTE CO CO2 chec...

Страница 52: ...e sump Refer to figure 94 1 Lift the heat exchanger up to clear 2 Move the heat exchanger forward from the case Fig 94 Heat exchanger removal B Reassemble and check combustion as stated in the gas conversion section 6 6 6720643895 71 1Wo 2 1 2 1 3 6720644743 26 1Wo NOTE CO CO2 checks B If the joint between the air gas manifold and heat exchanger is disturbed the sealing gasket must be replaced B A...

Страница 53: ...taining the rear panel of the control 2 Remove the rear panel 3 Remove the transformer cover Fig 98 Transformer PCB access Refitting the control board cover B Ensure that all wires are fully within the control board B Align the front right hand corner of the cover with the front right hand corner of the control board B Align the rear right hand B Holding the cover level slide the cover onto the co...

Страница 54: ...he control support bracket to the left Fig 101 Release control panel Refer to figure 102 B Support the control and unclip control support cable 1 from the boiler frame B Remove the support cable and fit to the new control B Remove appropriate cable restraints from the new control box Fig 102 Release support cable B Fit control to the boiler B Re connect support cable 1 to the boiler and all electr...

Страница 55: ... from the diverter valve motor 1 Pull the motor assembly towards you The assembly will slide free from the valve B To fit the new diverter valve motor slide the body into the housing B Ensure that H section of the motor actuator is fitted correctly into valve body B Re connect the electrical connection B Re fit the protective cover if available Fig 104 Diverter valve and motor 6 8 17 Diverter valv...

Страница 56: ...107 Pump head removal B To refit follow the above in reverse 6 8 20 Drain tap B Ensure the boiler has been fully drained 1 Rotate the drain tap fully anticlockwise 2 Withdraw the drain tap from its housing Fig 108 Drain tap B To refit follow the above in reverse Ensure any seals that have been disturbed are renewed Removal of the syphon assembly will give access to the auto air vent Refer to page ...

Страница 57: ...pe to the plastic housing and remove the pipe B Release the spring clip securing the pressure gauge sensing head to the plastic housing and remove the sensing head B Release the locking devices that secure the two copper water pipes leading to the combustion chamber by squeezing the two tabs together and rotating anticlockwise viewed from above B Remove the rubber pipe connecting the sump and remo...

Страница 58: ...casing If a vertical flue is fitted then a similar clearance to one side of the flue is required If this clearance is not available then the boiler will need to be removed from the mounting frame to gain access to the expansion vessel Alternatively a second vessel of at least the capacity of seven litres can be fitted to the return from the heating system as close as possible to the boiler Expansi...

Страница 59: ...onnection to boiler at the service valves Fig 114 Removing expansion vessel from wall frame B Release the clip from expansion vessel connection to the pump manifold B Carefully lift the boiler off the mounting frame 1 Remove the expansion vessel retaining screw 2 Lift the expansion off the cross beam 3 Move the expansion vessel towards you to remove B Replace expansion vessel in the reverse order ...

Страница 60: ...635 0 Pump assembly 3 speed 8 716 106 355 0 Pressure gauge 8 718 224 344 0 By pass valve 8 716 106 434 0 Automatic air vent 8 716 106 445 0 Diverter valve motor 8 716 106 847 0 Control sensor primary 8 716 106 688 0 Diverter valve assembly 8 716 106 845 0 Expansion vessel 8 716 105 545 0 Pressure relief valve 8 716 106 431 0 High limit stat 8 707 206 196 0 Fusing element set 8 744 503 010 0 Contai...

Страница 61: ...y and d Resistance to earth This fault finding information is for guidance only Robert Bosch cannot be held responsible for costs incurred by incorrectly diagnosed faults Blue light indication Lockout reset button Fault Possible solution check Off Off No power at control board Permanent mains supply to boiler Fuse F1 2 5A or Fuse F3 0 5A Transformer primary coil below 60 Ω both secondary coil belo...

Страница 62: ...continuity B Otherwise replace control board Slow flash mostly on flashes off Flashing reset required Flue overheat B Heat exchanger baffles removed and not refitted Fast flash Off Volatile lockout Fan does not run B Temperature sensors Check condition and continuity of leads sensors B Fan 230V a c across the live purple and neutral brown B Fan lead Check continuity B Code plug Is code plug missin...

Страница 63: ...L Neutral Supply 230V WIRING CENTER JUNCTION BOX BOSCH 24V CONTROLS PLUG IN POINT NOT USED Live Supply Live Return Neutral Live Colour sequence Purple Purple Red Red Orange Orange 7 8 9 Colour sequence SL L N 230V AC 9V 25V PRE WIRED LINK EMS BUS contacts for FX controls not used B B 4 2 1 A F PUMP GAS VALVE SAFETY SOLENOID SAFETY SOLENOID FLAME SENSE ELECTRODE SPARK ELECTRODES OVERHEAT STAT FLUE ...

Страница 64: ...cond stabilisation period Fan modulation to achieve set temperature 40 82 C END OF BOILER DEMAND Gas valve OFF Pump run 3 minutes Fan run 30 seconds Over temperature shut down if water tempera ture is 5 C above set value Gas valve OFF Fan overrun 30 seconds 3 minute pump over run Spark ignition and gas 4 seconds NO YES Room thermostat and or mains programmer ON or link fitted at ST10 AND Facia mou...

Страница 65: ...ernal boiler temperature rises above 12 C Central heating demand switches off Pump switches off after a 3 minute overrun period Central heating demand is activated Pump runs for 3 minutes to dissipate heat from the boiler into the system End of boiler demand central heating or domestic hot water AUTOMATIC INTERNAL FROST FUNCTION PUMP OVERRUN FUNCTION A central heating demand activated pump runs no...

Страница 66: ...66 Fault finding and diagnosis AU NZ 6 720 646 195a 2010 11 Notes ...

Страница 67: ...Fault finding and diagnosis 67 AU NZ 6 720 646 195a 2010 11 Notes ...

Страница 68: ...ustralia Robert Bosch Australia Pty Ltd 1555 Centre Road CLAYTON Victoria 3168 Phone 1300 30 70 37 Fax 1300 30 70 38 www bosch com au hotwater New Zealand Phone 0800 4 bosch or 08 543 352 www bosch co nz ...

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