Académique Documents
Professionnel Documents
Culture Documents
Contents
Contents
Safety precautions
Symbols
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
4
4
4
4
5
5
6
7
8
9
Installation regulations
6.5.3
6.6
6.6.1
6.6.2
6.7
6.8
6.8.1
6.8.2
6.8.3
6.9
29
29
29
29
29
30
30
30
30
30
Individual settings
31
7.1
7.1.1
7.1.2
7.2
7.2.1
7.2.2
Mechanical settings
31
Checking the size of the expansion vessel
31
Setting the central heating flow temperature
31
Settings on the Bosch Heatronic
31
General description
31
Setting the anti-cycle time
(Service Function 2.4)
32
Setting the maximum CH flow temperature (Service
Function 2.5)
32
Setting the heating output
(Service Function 5.0)
32
Constant hot water cycle time
(Service Function 6.8)
32
Variable pump settings
(Service Function 7.0)
32
Setting the gas/air ratio
32
7.2.3
7.2.4
10
7.2.5
Installation
11
7.2.6
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.9.1
3.9.2
3.9.3
Important remarks
Domestic hot water
Sealed systems
Siting the appliance
Wall mounting frame assembly
Pre-piping the system
Fitting the appliance
Checking the connections
Flue Systems
Siting the Flue Terminal
Installation of the flue
Flue duct preparation and assembly
11
11
11
12
13
13
14
15
15
16
17
19
7.3
Electrical connections
20
4.1
4.2
4.3
20
21
21
Commissioning
22
5.1
5.2
5.3
5.4
5.5
Commissioning
22
Switching the appliance on/off
23
Switching on the central heating
23
System controls
23
Setting the domestic hot water temperature and flow
rate
24
5.5.1 Domestic hot water temperature
24
5.5.2 Hot water flow rate
24
5.6
Summer mode (hot water only)
24
5.7
Frost protection
24
5.8
Pump anti-seize function
24
5.9
Fault Condition
25
Text Display
26
6.1
6.2
6.2.1
6.2.2
6.3
6.4
6.4.1
6.4.2
6.5
6.5.1
6.5.2
General Description
Programming
Deleting a setting
Resetting all parameters to their original settings
Menu structure
Setting the time/day
Setting the time and day
Holidays
Heating
Heating programme
Setting Economy temperature (TR2 connected)
26
26
27
27
27
28
28
28
28
28
28
8
Converting the appliance to different
gas types
33
8.1
8.2
8.2.1
8.2.2
Maintenance
36
9.1
Pre-Service Check List
9.2
Description of servicing operations
9.3
Replacement of Parts
9.3.1 PCB control board and transformer
9.3.2 Fan Assembly
9.3.3 Pump
9.3.4 3-way diverter valve
9.3.5 3-way diverter valve motor
9.3.6 Sensors
9.3.7 Gas Valve
9.3.8 Domestic Hot Water Heat Exchanger
9.3.9 Electrode assembly
9.3.10 Pressure gauge
9.3.11 Expansion vessel
9.3.12 Pressure Relief Valve
9.3.13 Burner
9.3.14 Flow switch
9.3.15 Primary Heat Exchanger
37
38
41
41
42
42
43
43
43
44
44
44
44
44
44
44
45
45
10
46
Appendix
function
50
Safety precautions
Safety precautions
If you smell gas
B Turn off gas service cock at the meter.
B Open windows and doors.
B Do not operate any electrical switches.
B Extinguish any naked flames.
B Telephone your gas company.
If you smell fumes from the appliance
B Switch off appliance (see page 23).
B Open windows and doors.
Fitting and modifications
B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance with the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use on sealed primary systems only.
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
Unpacking
IMPORTANT HANDLING INSTRUCTIONS
B Two people should transfer the packaged appliance
from the van to the point of installation
B Open the top of the carton, remove and place the
component tray and both side bars of the wall mounting frame to one side
B Lie the packaged appliance on its back. (The back
has TRUCK HERE printed on the carton)
B One person firmly holds the packaging while the
other straddles the boiler and slides it from the packaging
B Two persons are then required to lift one end and
stand the appliance upright with the flue at the top
Additional requirements for roof space installation
B Two people should use two step ladders and share
lifting the unpacked boiler up to the loft hatch
B Where the boiler enters the loft space, tilt and slide
the boiler on its back to the point of installation
Check the contents against the packing list.
Symbols
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance
being electrically unsafe.
1.3
Description of appliance
Wall-mounted appliance.
1.1
EC Declaration of Conformity
CE-0085 BL0507
Category UK
II2H 3P
Appliance Type
C13, C 33
Table 1
1.2
Standard package
Gas condensing combination boiler for central heating and domestic hot water
Pre-plumbing manifold
Condensate drain pipe
Filling loop.
1.4
Accessories
1.5
Casing dimensions
min .
min .
10*
10*
600 *
850
850
120
101
13
103
30
200
440
360
395
200
35
Fig. 1
13
101
103
X
Y
Z
Manifold assembly
Outer case
Facia cover
Standard Concentric Horizontal Flue System: min. 160 mm
Alternative Concentric Flue System: min. 220 mm
Standard Concentric Horizontal Flue System: 40 mm
Alternative Concentric Flue System: 70 mm
Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
For servicing the appliance
1.6
Layout of appliance
120
221.1
221.2
27
226
20
102
32.1
29
36
271
415
43
9
63
416
358
396
64
18
7
423
418
355
6.1
15
8.1
88
400
295
4
98
6 720 610 599 - 00.TD
Fig. 2
4
6
6.1
7
8.1
9
15
18
20
27
29
32.1
36
43
63
64
88
98
102
Heatronic control
Heat exchanger safety temperature limiter
Hot water NTC sensor
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Relief valve
Pump
Expansion vessel
Automatic air vent
Air gas Mixer unit
Electrode assembly
Temperature sensor in CH flow
CH flow
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
3-way valve (combi)
DHW flow switch (combi)
Inspection window
120
221.1
221.2
226
295
271
355
358
396
400
415
416
418
423
Fixing points
Flue duct
Combustion air intake
Fan assembly
Appliance type sticker
Flue duct
Plate-type domestic hot water heat exchanger
Condensate trap
Hose Condensate trap
Text display
Cover plate for cleaning access
Condensate collector
Data plate
Siphon
1.7
Function
26
27
29
226
229
33
30
36
32
J
20
221
6
35
29.1
63
52.1
69
64
52
56
317
61
400
358
55
355
18
88
57
8.1
ECO
3
2
1
4
5
96
95
90
E
max
6.1
J
43
44
97
98
46
45
42
3
93
91
13
15
94
max
84
47
Fig. 3
4
6
6.1
7
8.1
9
13
15
18
20
26
27
29
29.1
30
32
33
35
36
43
44
45
46
47
52
52.1
55
56
57
61
63
64
69
84
88
90
91
93
94
95
96
97
98
221
226
229
317
355
358
400
423
443
1.8
bl - black
r - red
p - purple
33
365
364
61
317
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
310
136
400
135
312
328
313
151
124 789
p
p
p
L N Ns Ls LR
302
300
161
84
3 4
96
328.1
18
422
226
o
o
r
r
mains supply
52
52.1
56
o
bl
bl
bl
bl
36
bl
6.1
32
Fig. 4
4.1
6
6.1
9
18
32
33
36
52
52.1
56
61
84
96
135
136
151
153
161
226
300
302
310
312
313
317
328
328.1
363
364
Ignition transformer
Temperature limiter, heat exchanger
Hot water NTC sensor
Flue gas temperature limiter
Pump
Flame sensing electrode
Ignition electrode
Temperature sensor in CH flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Motor, 3-way valve
Microswitch, hydraulic switch
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
Link
Fan
Code plug
Earth connection
Temperature control for hot water
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Digital display
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
Indicator lamp for power supply
365
366
367
400
422
1.9
Technical data
Units
R 30 HE R 30 HE R 35 HEi R 35 HE R 40 HE R 40 HE
NG
Propane
NG
Propane
NG
Propane
kW
kW
kW
31.2
30.9
29.2
31.2
30.9
29.2
37.5
37.1
35.1
37.5
37.1
35.1
kW
kW
kW
kW
29.5
8.4
8.3
7.4
29.5
11.6
11.4
10.5
35.5
12.9
12.8
11.4
35.5
16.2
16.1
14.3
7.6
29.2
29.5
10.8
29.2
29.5
11.8
35.1
35.5
14.8
35.1
35.5
41.4
41.4
39.1
40.0
12.9
12.8
11.4
11.8
39.1
40
41.4
41.4
39.1
40.0
16.2
16.1
14.3
14.8
39.1
40
3.1
MJ/m3)
m3/h
kg/h
mbar
20
20
20
MJ/m3)
mbar
37
37
37
bar
l
0.75
10
0.75
10
0.75
10
0.75
10
0.75
10
0.75
10
l/min
C
bar
bar
l/min
12.1
40 - 60
10
1.2
13.3
12.1
40 - 60
10
1.2
13.3
14.6
40 - 60
10
1.2
16.0
14.6
40 - 60
10
1.2
16.0
16.4
40 - 60
10
1.2
18.0
16.4
40 - 60
10
1.2
18.0
C
C
Pa
67/55
43/32
80
67/55
43/32
80
87/58
65/43
100
87/58
65/43
100
87/58
65/43
100
87/58
65/43
100
%
%
9.2
8.8
10.8
10.5
9.2
9.2
11.0
11.0
9.2
9.2
10.8
10.8
5
A
5
A
3.5
4.8
3.5
4.8
LPG (CVnet 88
Gas supply pressure
LPG (CVnet 88
Expansion vessel
Charge pressure
Total capacity
Hot water specifications
Hot water flow rate @ 35 rise
Outlet temperature range
Max. permissible water supply pressure
Min. inlet pressure for maximum flow rate
Specific flow rate @ 30C
Flue
Flue gas temp. 80/60C, rated/min. load
Flue gas temp. 40/30C, rated/min. load
Residual delivery pressure (inc. pressure drop in air
intake duct)
CO2 level at max. rated heat output
CO2 level at min. rated heat output
NOx-class
SEDBUK figure
Condensate
Max. condensation rate (tR = 30C)
pH-value, approx.
General Data
Electrical power supply voltage
Frequency
Max. power consumption
Noise output level
Appliance protection rating
Max. CH flow temperature
Max. permissible operating pressure (CH)
Permissible ambient temperatures
Nominal capacity of appliance
Weight (excluding packaging)
Band
3.7
4.2
2.3
3.2
l/h
2.5
2.5
3.0
3.0
pH
4.8
4.8
4.8
4.8
AC ... V
Hz
W
dB(A)
IP
C
bar
C
l
kg
230
50
125
37
X4D
nom. 90
2.5
0 - 50
3.75
46
230
230
230
230
50
50
50
50
125
152
152
183
37
40
40
42
X4D
X4D
X4D
X4D
nom. 90 nom. 90 nom. 90 nom. 90
2.5
2.5
2.5
2.5
0 - 50
0 - 50
0 - 50
0 - 50
3.75
3.75
3.75
3.75
46
46
46
46
230
50
183
42
X4D
nom.90
2.5
0 - 50
3.75
46
Table 2
Installation regulations
1.2
Nickel
0.01
Lead
Mercury
Cadmium
0.001
Sulphate
Chromium
0.005
Zinc
0.015
Halogenated
hydrocarbons
Tin
0.002
0.01
Hydrocarbons
0.015
Vanadium
Copper
0.028
pH-value
R 30
HE
R 35
HE
R 40
HE
Temperature Rise
30 C
14.2
17.0
19.2
Temperature Rise
35 C
12.1
14.6
16.4
Temperature Rise
40 C
10.6
12.8
14.4
bar
10.0
10.0
10
bar
0.2
0.2
0.2
Domestic
Water Flow
Rate l/min
0.001
4.8
Table 3
Flue system
HORIZONTAL 100 mm Standard FLUE SYSTEM
Table 9
mm 100
mm 600
mm 1000
Max. 4 m
(R30 & 35 HE)
Max 3.5m
(R40 HE)
Table 4
HORIZONTAL 125 mm FLUE SYSTEM
Overall Diameter of Duct mm
Flue Terminal / Duct
Assembly
125
Max. 13 m
(R30HE)
1030 Max. 10m (R35 &
40 HE)
mm
Table 5
VERTICAL 100mm FLUE SYSTEM
Overall Dia. of Duct
mm
100
mm
1140
Excl. terminal:
Max. 6.4m (R30
& 35 HE)
Max. 5.5m
(R40HE)
Table 6
VERTICAL 125 mm FLUE SYSTEM
Overall Dia. of Duct
mm
125
mm
1365
Table 7
Elbow - 90 Equivalent length 2 m
Bend - 45 Equivalent length 1m
Pipe diameter
(mm)
5.8
4.6
22
18.0
12.0
9.4
28
10
3/h)
Table 8
Installation regulations
Gas supply
Total length of gas supply pipe
(metres)
Installation
Installation
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
3.1
Fixing of the appliance, gas and flue connections, commissioning of the system
and electrical connections may only be
carried out by competent persons authorised by CORGI.
Important remarks
3.2
3.3
Sealed systems
11
Installation
requirements of BS2767:10.
Fit Thermostatic Radiator Valves to radiators in the
sleeping accommodation and not to the radiator where
the room thermostat is sited, this must be left open.
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
No galvanised radiators or pipes must be used.
If any system water treatment is required then
only products suitable for use with Aluminium
shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the
manufacturers instructions. The use of any other
APPLIANCE
Refer to
Appliance
Water Flow
Diagram
Radiator valve
Lockshield valve
WRC
approved
filling loop
Fig. 5
Fig. 6
3.4
12
Surface temperature
The max. surface temperature of the casing and the flue
is less than 85 C.
This means that, no special safety precautions are
required with regard to flammable building materials
and fitted furniture. The specified clearances must be
maintained.
Cupboard/Compartment
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS6798 and BS5440:2 are followed. The low
casing losses from the appliance eliminate the need for
ventilation openings in the compartment.
Installation
3.5
Fig. 9
6 720 610 597-06.1O
Fig. 7
3.6
B Hold the wall-mounting frame against the wall ensuring that it is vertical.
200
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 16.
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 10 Manifold
43
47
112
171
172
6 720 610 597-07.1O
Fig. 8
CH flow
CH return
Gas cock
Domestic hot water
Cold water relief
13
Installation
Boiler
Boiler
22 min.
Sink
Siphon
No length
restriction
Siphon
22 min.
75 min. trap
Boiler
Boiler
Internal soil
and vent stack
22 min.
Siphon
22 min.
75 min. trap
Invert
75 min. trap
450 min.
No length
restriction
3.7
No length
restriction
Sink
Fig. 11
Whilst all of the above methods are acceptable it is
always the best practice to terminate the condense pipe
via an internal waste system.This will eliminate the need
for any external condensate pipe runs which can be susceptible to freezing in extreme weather.
Fig. 13
Fig. 12 Recommended route of the condensate drain
14
Installation
The standard concentric flue system provides for a horizontal length of up to 4m (3.5m R 40 HE). Full instructions for fitting this flue are in Subsection 3.9.2
Installation of the flue.
Flue Turret
Flue seal
Retaining
Screw
Appliance
Flue Socket
Flue Turret to
Boiler Sealing
Gasket
Fig. 14
B For remaining installation of flue assembly, refer to
the relevant installation instructions.
3.8
Water connections
B Check that the O-rings or seals are in place before
tightening the connection.
B Turn on the service valves for central heating flow
and return and fill the heating system through a
WRAS approved filling loop.
B Check all seals and unions for leaks (testing pressure
max. 3.0 bar as indicated by pressure gauge).
B Turn on cold water service cock and fill hot water system (testing pressure max. 10 bar).
B Check all connections for leaks.
Gas supply pipe
B Check that the seal is in place before tightening the
connection.
B Turn off gas cock to protect gas valve against damage from excessive pressure.
B Check gas supply pipe.
B Release the pressure on the gas supply pipe.
3.9
Flue Systems
The only flue systems that may be used are those supplied with the boiler.
15
Installation
3.9.1
boundary
Q
D,E
Q
B
H
N
A
L
M
H
I
H
K
Fig. 15
Minimum dimensions of flue terminal positions (all types) (see fig. 15)
Dimension
A1)
300 mm
1)
300 mm
C1)
300 mm
Below eaves
200 mm
Not recommended
300 mm
300 mm
2000 mm
From an opening in the car port (e. g. door, window) into the dwelling
Not recommended
1500mm
300 mm
500 mm
300 mm
75 mm
75 mm
1200 mm
Table 10
1)
16
In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
Installation
3.9.2
Flue turret
Flue turret clamp
Maximum 650mm
Outer
Wall
Minimum 100mm
Terminal assembly
Wall sealing gasket and cover plate.
Refer to fig. 20
Clamp
Centre line of
flue/air duct
Terminal
Assembly
6 720 610 599 - 01.TD
m
120m
Top of wall
mounting
frame (not
boiler)
Appliance
(30mm/metre)
Standard 100mm
horizontal flue 0.5
(5mm/metre)
Drilling
point for
flue duct
opening
Centre
line of
flue
opening
and
appliance
17
Installation
Maximum 1600mm
Outer
Wall
Flue
Turret
Extension
Duct
Clamp
Terminal
Assembly
6 720 610 599 - 00.TD
Outer
Wall
Flue
Turret
Clamp
Extension
Duct
Clamp
Extension
Duct
Clamp
Terminal
Assembly
6 720 610 599 - 01.TD
Flue
Turret
Clamp
Flue Terminal
18
Installation
Flue Terminal
120
Push the assembly through the wall and fix the turret to
the appliance with the screws provided. Refer to fig. 24.
Flue Turret
Flue seal
Retaining
Screw
Appliance
Flue Socket
Flue Turret to
Boiler Sealing
Gasket
19
Electrical connections
Electrical connections
B Always disconnect the power supply to
the appliance at the mains before carrying out any work on the electrical systems and components.
4.1
Fig. 25
B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 26.
3
2
1
4
5
E
Fig. 26
20
Electrical connections
4.3
8-9
5-7
10-12
13-14
Fig. 27
B Feed cable through cable grommet and connect the
mains supply cable, see fig. 28.
B Secure cable in cable grommet by means of cable
grip.
L
N NS L
Fig. 28
4.2
TR2
F 3 4
3 4 A F
TEXT DISPLAY
Fig. 29
21
Commissioning
Commissioning
27
136 365
61
358
ECO
363
310
400
364
8.1
135
295
15
170
nn
.
171
172
173
170
6 720 610 597 - 05.1O
Fig. 30
8.1
15
27
61
135
136
170
171
172
173
295
310
317
358
363
364
365
366
367
400
Pressure gauge
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for central heating
Service cocks on CH flow and return
Hot water
Gas cock (shown in off position)
Cold water service cock
Appliance type sticker
Temperature control for hot water
Multi function display
Condensation trap
Indicator lamp for burner
Indicator lamp for power supply
Chimney sweep button
Service button
ECO button
Text display
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
The operational CO2 level is set at the factory and no adjustment is necessary when
installing a natural gas fired appliance.
Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance
with the guidelines given in BS7593:1992 - Treatment
of water in domestic hot water systems. Full instructions
are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should
be used in accordance with the inhibitor manufacturers
instructions.
To drain the appliance shut the system valves and open
the system drain point.
Suitable flushing agents and inhibitors are available
from Betz-Dearborn Tel: 0151-4209563 and Fernox
Tel: 01799-550811. Instructions for use are supplied
with the these products.
22
Commissioning
B Before commissioning, the gas supply pressure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7).
Natural gas appliances must not be operated if
the gas supply pressure is below 18 mbar or
above 24 mbar. LPG appliances must not be
operated if the supply pressure is not 37 mbar
at the inlet to the appliance.
5.2
5.3
Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the central heating flow temperature, when the
appliance is operating in the central heating mode.
6 720 610 333-05.1O
Fig. 32
5.4
6 720 610 333-04.1O
Fig. 31
System controls
The trap filling programme ensures that the condensation trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
23
Commissioning
5.5
5.5.1
Fig. 34
Fig. 33
5.6
Setting
approx. 40C
approx. 55C
approx. 60C
Table 11
ECO button
By pressing and holding the ECO button , until the
display lights, you can switch between Comfort mode
and Economy mode.
5.7
Frost protection
Frost protection and constant frost protection modes can be set on the text display module.
5.8
24
Text Display
Text Display
6.1
General Description
6.2
Programming
/holidays
T
b
c
Fig. 35 Controls
a
b
c
d
e
f
Display
Up/More button
Down/Less button
Back button
Next button
Delete button
or
CH flow temperature.
Additional indication if a special programme is active:
x holidays
B Use the
or
or
or
button.
button.
25
Text Display
B Press the
button to confirm the setting. The
cursor then returns to the top line.
6.3
B Press the
button to confirm the setting and
return to the previous menu (fig. 37 page 25).
-orB Do not press any other buttons for 15 minutes.
Deleting a setting
Main
menu
Heating
26
2.
Time/day Time/
day/holidays
6.2.2
1.
Hot
water
Info
3.
-
Parameters to
change/select
Page
Submenu
-or-
6.2.1
Menu structure
- Hours
- Minutes
- Day of week
27
27
Holidays -
Days holiday
Heating
program
27
- Day
- 1st operating mode
- 1st switching point
...
- 6th switching point
5...30C
28
Manual
(if TR2 is
not connected)
- Automatic
- Constant on
(comfort)
- Constant off
(economy)
28
Hot
water
program
29
- Day
- 1st operating mode
- 1st switching point
...
- 6th switching point
Hot
water
immediately
Off/On
29
28
Settings Heating
29
Hot
water
(ZSBRmodels)
28
Service
Display service
param.
29
-English/
-Franais/
-Deutsch
29
-Time correction
-LCD contrast
29
29
Operat- ing
times
29
Fault
history
29
Text Display
6.4
6.4.1
i
6.4.2
6.5
Heating
6.5.1
Heating programme
Comfort Mode:
With TR2 Room thermostat fitted:
Central heating is on. House will be heated to temperature set on TR2.
Without TR2 Room thermostat fitted:
Central heating is on. Primary water is heated to temperature set at (radiator symbol) dial.
B Set the desired first operating mode (Comfort, Economy or Frost protection).
B Press
Economy Mode:
With TR2 Room thermostat fitted:
Central heating is on. House will be heated to temperature set on Economy mode of Text Display.
Without TR2 Room thermostat fitted:
Central heating will be off.
Frost protection:
Central heating is off. Boiler will only fire if sensor registers temperatures below 5C.
27
Text Display
6.5.2
6.7
i Info
Description
Room temperature
(if TR 2 connected)
Required room
temperature
(if TR 2 connected)
Required temperature in
room where TR 2 is installed
Operating mode
(if TR 2 connected)
E. g. Heating, Economy in
Automatic mode
or
Economy, Heating, Frost
protection in manual mode
Required flow
temp.
Max HW temp.
Required HW
temp.
Actual HW temp.
6.6
Storage Tank
charge released
or blocked
Storage Tank
charge on or off
or Storage Tank
charge
afterrunning
Boiler operat.
mode
winter/ summer
Burner on/off
Pump on/off
Hot water
General description
Combi models only: The basic settings provide a
straightforward timer programme:
enabling Hot Water pre-heat from 5:00am
disabling Hot Water preheat from 10:00pm.
The ECO button must not be lit.
28
Text Display
6.8
Settings
Time correction:
6.8.1
Optimum Start
B Press
B Press the
value.
B Press
or
24 hours.
or
or
Basic setting: + 0 s
LCD contrast:
Basic setting: ON
6.8.2
B Press
The text display can control the hot water either with
Times and temperatures or only times.
or
B Press the
value.
B Press
or
Basic setting: e. g. 47
Operating times
This option shows the hours of service (appliance,
burner and hot water) since commissioning.
i
6.8.3
Service
This option displays various current settings and statuses of the electrically controlled appliance and system
components for the benefit of the heating engineer.
Service parameters
6.9
Language
Available languages are: English, Franais (French),
Deutsch (German).
or
29
Individual settings
Individual settings
7.1
Mechanical settings
7.1.1
Control setting
CH flow temperature
1
2
3
4
5
E
max
approx. 35C
approx. 43C
approx. 51C
approx. 59C
approx. 67C
approx. 75C
approx. 88C
Expansion Vessel
litres
10
Table 13
bar
0.75
7.2
1 bar
litres
82
7.2.1
General description
1.5 bar
litres
46
System
pressure and
capacity
Table 12
7.1.2
Service function
Code no.
see
page
Anti-cycle time
2.4
31
2.5
31
5.0
31
6.8
31
7.0
31
Table 14
button.
B Press
or
button until the arrow cursor is
pointing to Service.
6 720 610 332-27.1O
Fig. 39
B Rotate yellow button through 180 and replace (dot
facing inwards).
The CH flow temperature is no longer limited.
B Press the
B Press the
button to select Display service
parameters.
Service function 0.0, Last fault is displayed.
B Press the
or
current settings.
B Press the
30
button.
Individual settings
7.2.4
button.
B Press
oder
button until the arrow cursor
is pointing to Service.
B Press the
button.
The cursor is pointing to Display service parameters.
B Press and hold the
button (for about 5 seconds) until the display shows Adjust service
parameters and the first service function to be set,
e.g. 2.0, Operating mode. If a fault has occurred,
the display will show 0.0 and the last fault.
B Press the
or
button until the desired
service function is displayed.
B Press the
button.
The first line of the display shows Change value.
7.2.5
B Use the
setting.
or
B Press the
button.
The text display shows ATTENTION Store settings?.
B Press
or
B Press
to confirm your selection.
The text display shows Please wait ... ..., and the
service function is then displayed with the new setting.
B Press the
or
button until the next function you wish to change is displayed.
B Press the
7.2.2
-or-
7.3
31
Natural gas appliances must not be operated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is below or above
37 mbar.
8.1
Natural gas
Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m 3 and 20 mbar supply
pressure and sealed.
234
Fig. 40
B On the text display unit, select in the main menu Settings, Service, Display service parameters.
B Press and hold the
button (for about 5 seconds) until the display shows Adjust service
parameters and the first service function to be set,
2.0 Operating mode. If a fault has occurred, the
display will show 0.0 and the last fault.
B Press
or
until the display shows 2.0
Operating mode normal.
B Press the
B Press
button.
or
to select Max.
32
B Press
normal.
or
B Press the
button. The text display shows
Store settings.
63
B Press
B Press the
to select yes.
button.
Fig. 41
R 30 HE
Gas Type
Natural gas type
G20
LPG G31
(propane)
CO2 reading
at max. rated
heat output
CO2 reading
at min. rated
heat output
9.2 %
8.8 %
10.8 %
10.5 %
Table 15
R 35 & 40 HE
CO2 reading at max. and min.
rated heat output
Gas Type
Natural gas type
G20
LPG G31
(propane)
9.2 %
10.8 %
Table 16
B Press
or
to select Min.
64
3928-74.1R
Fig. 42
B Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
33
8.2
8.2.1
By testing the O 2 or CO2 level in the combustion air the gas tightness of a type C 13,
C33 flue system can be checked. The
O2 level must not be less than 20,6 %.
The CO2 level must not exceed 0,2 %.
8.2.2
234.1
234
Fig. 43
B Measure O2 and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows .
The
button will stop flashing and the display
shows the CH flow temperature.
34
Maintenance
Maintenance
B Always disconnect the appliance from
the electrical power supply (fuse, circuit
breaker) before carrying out any work on
the electrical systems or components.
B Always turn off the gas cock before carrying out any work on components
which carry gas.
There is a Service booklet for the Engineer, order no. 7-181-465-349, available
to competent persons.
All safety and control systems are monitored by the Bosch Heatronic. In the event
of a component fault, the text display
shows a fault code.
B The User should be recommended to have the appliance serviced regularly by a competent person.
B Use only genuine spare parts
B Refer to the Spare Parts List when ordering spare
parts.
B Always renew seals and O-rings removed during
servicing or repair work.
B Use only the following types of grease:
Water valve: WRAS approved silicon based
grease
Unions: approved sealant.
B To drain the appliance shut the system valves and
open the pressure relief valve.
B Upon completion of any electrical work check for
earth continuity, correct polarisation and resistance
to earth.
Replace the text display module or the Heatronic
PCB
If the text display module is replaced, the service function settings are retained.
B The remaining settings have to be re-entered.
If the Heatronic PCB is replaced:
B Re-enter the service function settings as recorded in
the commissioning record.
35
Maintenance
9.1
mbar
min. %
max. %
mbar
36
Maintenance
9.2
Fig. 45
Fig. 44
Primary Heat exchanger
Fig. 46
37
Maintenance
Burner
B Check that the gas cock is turned off and the master
switch is in the OFF position
B Remove the clips (1) and unscrew the two bolts (2).
Refer to fig. 50.
B Unscrew and remove the two hexagon screws securing the fan (3).
B Slacken fully the rear securing bolt (4).
B Remove the burner coverplate.
4.
6 720 610 332-73.1R
2.
Fig. 47
B Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 48.
3.
1.
Fig. 50
B Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 51.
Fig. 48
B Flush the heat exchanger from the top. Refer to
fig. 49.
B Clean out the condensate collector and trap connection (with other end of brush).
Fig. 49
B Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
38
Fig. 51
B Re-assemble burner in reverse order, inspect seal for
damage and replace if necessary.
B Adjust gas/air ratio. Refer to section 8.2.
Maintenance
Condensation trap
In order to prevent spillage of condensate the condensation trap should be completely removed, (see
page 37, fig. 46).
B Unscrew condensation trap and check connection to
heat exchanger is clear.
B Remove condensation trap cover and clean.
B Fill condensation trap with approx. 1/4 l of water and
refit.
Electrode assembly
B Switch off the master switch.
B Pull off the leads from the electrodes. Refer to fig. 2.
2.
4.
1.
5.
443
3.
29
Fig. 53
B Unscrew mixer unit (29).
3.
443
29
1.
B Remove sleeve.
B Carefully remove diaphragm (443) and check for soiling and cracks.
B Refit diaphragm (443) taking care to ensure it is the
correct way round.
2.
6 720 610 790-07.2R
Fig. 52
B Carefully refit diaphragm (443) the correct way round
into the fan intake tube.
39
Maintenance
Siphon
9.3
Replacement of Parts
Condensate
Drain
Siphon
Drain Plug
1
3
2 4
Fig. 54
Expansion vessel
3
2 4
5
E
3
2 4
B Depressurise appliance.
B If necessary, adjust expansion vessel charge pressure to static head of the heating system.
Heating system pressure
Fig. 55
B Lower the control box.
B Unscrew earth lead.
B Unscrew four fixing screws from cover plate. Refer to
fig. 56.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.
B If the system does not retain the pressure, the expansion vessel and the heating system should be
checked for leaks.
40
Maintenance
9.3.2
Fan Assembly
3.
2.
4.
Fig. 56
Fuses
B Remove the connections covers. Refer to fig. 25,
26.
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
Fuse, item 312, is only replaceable by removing the
pcb.
1.
Fig. 57
B Switch off the appliance.
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 57.
B Remove fan lead and earth connector (2.). The earth
connector has a positive clip fixing.
Pump
41
Maintenance
Alternatively
B After removing the siphon release the four Allen
screws and remove and replace the pump head.
1.
1.
2.
3.
5.
4.
Fig. 59
After refitting:
B Fill system, bleed and re-pressurise
(see Installation Instructions).
9.3.5
Fig. 58
9.3.4
Sensors
42
Maintenance
9.3.8
9.3.9
9.3.7
Gas Valve
Electrode assembly
Fig. 60
43
Maintenance
OUTLET
INLET
6 720 610 602 - 05.10
Fig. 61
9.3.15 Primary Heat Exchanger
B Drain the appliance.
B Check that the gas supply is turned off.
Fig. 62
44
Appendix
10
Appendix
Description
Remedy
A1
A7
A8
Break in communication
b1
C1
d3
E2
E9
Check system pressure, check safety temp. limiters, check pump operation, check fuse on pcb,
bleed appliance.
EA
Is gas cock turned on? Check gas supply pressure, power supply, igniter electrode and lead,
ionisation sensing electrode and lead, flue duct
and CO2 level.
F0
Internal error.
Check electrical connector contacts, programmer interface module ignition leads are not
loose; replace pcb if necessary.
F7
FA
FC
Fd
P1, P2,
P3, P1...
Table 18
45
Appendix
Description
Qty GC
5.1
Fan assembly
Fan washer
Expansion vessel
Relief valve
10
Electrode assembly
11
Electrode lead
12
Pump
13
Pressure gauge
14
15
Transformer - facia
16
Flow switch
17
18
19
20
Fuse set
21
22
23
Text Display
24
25
Diaphragm
Table 19
46
Appendix
Display
code
Heat
output,
kW
Heat
input,
kW
Display
code
Heat
output,
kW
Heat
input,
kW
30
9.1
9.2
16.0
30
11.1
11.3
19.7
40
12.1
12.2
21.4
40
14.9
15.0
26.3
50
15.1
15.3
26.7
50
18.6
18.8
32.8
60
18.1
18.3
32.0
60
22.3
22.5
39.4
70
21.1
21.4
37.4
70
26.0
26.3
45.9
80
24.2
24.4
42.7
80
29.7
30.0
52.5
90
27.2
27.5
48.0
90
33.4
33.8
59.1
100
30.2
30.5
53.4
100
37.1
37.5
65.6
Table 20
Table 22
Propane
Propane
Display
code
Heat output kW
Heat input kW
Display
code
Heat output, kW
Heat input, kW
40
12.1
12.2
40
14.9
15.0
50
15.1
15.3
50
18.6
18.8
60
18.1
18.3
60
22.3
22.5
70
21.1
21.4
70
26.0
26.3
80
24.2
24.4
80
29.7
30.0
90
27.2
27.5
90
33.4
33.8
100
30.2
30.5
100
37.1
37.5
Table 21
Table 23
47
Mains
switch
ON.
Green
light
ON.
Pre-heat
mode.**
Hot
water
demand.
Burner shut-down if
primary temperature
exceeds 94C remains
OFF until 78C
Burner lights.
Red light ON.
Pump ON
Diverter valve
operates.
Fan to start
speed. Gas valve
opens.
Over temperature
shut down if water
temperature is 8C
above set value.
Heat input
modulates to
maintain the
delivery
temperature.
** NOTE:
The appliance controls can be set to one of 2
modes of operation.
1. Comfort mode Full pre-heat
2. ECO mode a) Operates as an instantaneous combination boiler.
b) Demand Detection: a short demand (less than 5
seconds) switches the control to Comfort mode
for 5 mins. Mini pre-heat. The Factory setting is
Comfort mode.
Demand
ends.
Gas valve
closes. Red
light OFF.
Ignition sequence
Ignition
spark
5 secs
Burner lights.
Red light ON.
Yes
No
6 720 611 400 GB (03.11)
Repeats 5 times
(N.G.) or 3 times
(L.P.G.) before
lock-out.
Pre-heat
mode.**
Appendix
Pre-heat satisfied.
Ignition sequence
Ignition
spark
5 secs
Fan to start
speed.Gas
valve opens.
Fig. 63
48
Pump ON
Diverter valve
operates.
Mains
switch
ON.
Green
light
ON.
Room
thermostat
and/or mains
programmer or
link ON AND
Electronic facia
programmer (if
fitted) ON AND
CH control
knob ON.
CH
demand.
Burner
stabilises at
start speed for
5-10 secs
Pump ON Fan to
start speed. Gas
valve opens.
Over temperature
shut down if water
temperature is 5C
above set value.
Fan speed
reduces
over 15
secs.
Fan min.
speed for
90 secs.
Boiler
unused
for long
period.*
Yes
*Minimum
heat
input for
15min.
No
Boiler
operates to
match
system load
and CH
control
setting.
Fig. 64
Ignition sequence
Yes
CH demand
satisfied.
No
Repeats 5 times
(N.G.) or 3 times
(L.P.G.) before
lock-out.
Fan runs to
purge gas from
burner.
* NOTE: The sequence ensures that the condensate siphon is not empty
after long OFF periods. (More than 24 hours without a demand).
Appendix
49
Appendix
50
Appendix
51
Appendix