Installation and Servicing Instructions GREENSTAR 29 HE Conventional Wall mounted condensing boiler 6 720 610 577-00.10 6 720 611 137 GB (03.
Contents Contents Safety precautions 3 Symbols 3 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 Details of the appliance EC Declaration of Conformity Standard package Description of appliance Accessories Casing dimensions Layout of appliance Function Electrical wiring diagram Technical data 6 6.1 6.1.1 6.2 6.2.1 6.2.
Safety precautions Safety precautions Symbols Safety instructions in this document are identified by a warning-triangle symbol and are printed on a grey background. 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 24). B Open windows and doors.
Details of the appliance 1 1.1 Details of the appliance 1.3 EC Declaration of Conformity • Wall-mounted appliance, siting not dependent on room size This appliance is in accordance with the applicable requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.
Details of the appliance 1.4 Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues upto 4 m in length. • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths upto 13 m and vertical flue systems for flue lengths upto 15 m. Fitting instructions are sent with these kits. • Security kit. 1.5 Casing dimensions min. min. 5* 5* Z Y 600* X 906 861 850 120 101 13 103 30 200 35 360 395 * 200 440 6 720 610 601- 01.3O Fig.
Details of the appliance 1.6 Layout of appliance 120 221.1 349 221.2 234.1 234 226 102 27 32.1 29 36 271 6 415 43 9 63 416 358 64 423 4.4 7 418 15 361 295 4 417 6 720 611 137-01.1 O Fig. 2 4 4.4 6 7 9 15 27 29 32.
Details of the appliance 1.7 Function 27 226 229 33 29 30 234.1 234 36 32 ϑ 443 221 4.4 6 35 29.1 9 63 52.1 317 61 4 69 64 3 0 2 1 358 56 ECO 4 57 5 15 7 E max 52 55 4 361 43 45 13 47 6 720 611 137-02.1O Fig. 3 4 4.4 6 7 9 13 15 27 29 29.1 30 32 33 35 36 43 45 47 52 52.
Details of the appliance 1.8 Electrical wiring diagram o - orange bl - black r - red 33 365 364 61 317 366 363 367 ECO 4.1 25 V 230 V 153 230V/AC 136 310 135 312 328 302 313 151 124 789 L N Ns Ls LR 161 300 9 6 M r r mains supply o 226 52 4.4 52.1 56 o bl bl bl bl 36 32 6 720 611 137-03.1O Fig. 4 4.1 4.4 6 9 32 33 36 52 52.
Details of the appliance 1.9 Technical data Units Natural gas Propane Max. rated heat output net 40/30˚C central heating Max. rated heat output net 50/30˚C central heating Max. rated heat output net 80/60˚C central heating kW kW kW 29.3 29.0 27.4 29.3 29.0 27.4 Max. rated heat input net kW 27.7 27.7 Min. rated heat output net 40/30˚C Min. rated heat output net 50/30˚C Min. rated heat output net 80/60˚C kW kW kW 8.4 8.3 7.4 11.6 11.4 10.5 Min. rated heat input net kW 7.6 10.8 m3/h 2.
Installation regulations Condensate analysis, mg/l Ammonium 1.2 Gas supply Nickel 0.15 ≤ 0.01 Mercury Cadmium ≤ 0.001 Sulphate Chromium ≤ 0.005 Zinc ≤ 0.015 Halogenated hydrocarbons ≤ 0.002 Tin ≤ 0.01 Hydrocarbons 0.015 Vanadium Copper 0.028 pH-value Lead ≤ 0.0001 Pipe diameter (mm) 1 ≤ 0.001 3 6 9 Gas discharge rate (m3/h) 8.7 5.8 4.6 22 18.0 12.0 9.4 28 4.
Installation 3 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 B Appliance is prepared to be installed in fully pumped sealed and open vent central heating systems. B To avoid gas formation in the system, galvanised radiators or pipes must not be used.
Installation Typical system layout if using Honeywell 'Y' plan Feed and Vent Cistern S.H. Primary cold feed (15mm min.) S.H. Domestic hot water cylinder S.H. – Minimum static head 1.0m measured from the highest point in the heating system (top surface of the appliance or highest point in the heating system) to the water level in the feed and expansion tank Heating vent (22mm min.) Diverting valve 150mm max Pump Boiler N.B.
Installation Fully pumped sealed system Note: A drain cock should be fitted at the lowest RV point of the heating circuit and beneath the appliance INDIRECT CYLINDER LV LV BOILER LV LV Pressure Gauge RV Bypass balancing valve or uncontrolled radiator with tw o lockshield valves Radiator Valve - Flow RV Lockshield Valve - Return LV Heating Flow Expansion Vessel Relief Valve Hot Water Flow RV Cylinder Return Heating Return RV Mains Cold Water BS Stop Valve Fixed Cylinder Type or sealed sy
Installation 3.4 Wall mounting frame assembly B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 9. Use the inner lugs on the top and bottom horizontal sections for the appliances that are 440 mm wide. B Screw the pre-plumbing manifold with two screws to the wall mounting frame. 6 720 610 576-11.1O Fig. 11 6 720 610 576-04.1O Fig. 9 3.5 Pre-piping the system B Hold the wall-mounting frame against the wall ensuring that it is vertical.
Installation Condensate Termination and Route The condensate connection on the Greenstar appliances is in 22 mm plastic. The pipe should be extended and run away from the appliance with a constant fall of 2.5 ° or 40 mm in every metre. The condensate pipe can terminate into any of four areas: Boiler Boiler Ø 22 min. Sink Siphon No length restriction External length of pipe 2m min. Siphon Ø 22 min. 75 min. trap Open end of pipe direct into gully, below ground but above water level.
Installation B Remove the plastic caps from the boiler connections. 3.7 Checking the connections Water connections B Check that the O-rings or seals are in place before tightening the connection. B Turn on the service valves for boiler flow and return. B Check all seals and unions for leaks. 2. Open vent systems: It is not necessary to connect a drain pipe to the pressure relief valve outlet as it is not operational. Gas supply pipe 1. 6 720 611 137-06.
Installation 3.8.1 Siting the Flue Terminal The flue must be installed in accordance with BS 5440:1 and the Building Regulations. Flue terminals in carports and under balconies are to be avoided. The terminal must be positioned so that it does not cause an obstruction nor the combustion products a nuisance. See fig. 17 and table 9. The terminal will, at times, give out a plume of water vapour and consideration must be given to this when choosing a terminal position.
Installation 3.8.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 600 mm and 4000 mm require extension duct assemblies. NOTE: Flue lengths between 650 mm and 730 mm cannot be accomodated. Refer to fig. 19, 20, 21. Standard system comprise: Flue turret - Flue turret clamp - Terminal assembly - Wall sealing - plates.
Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp No Clamp Extension Duct 6 720 610 602 - 09.1O Fig. 20 Flue with one extension Terminal Assembly Flue Turret No Clamp Outer Wall Clamp Clamp Extension Duct Extension Duct 6 720 610 602 - 10.1O Fig. 21 Flue with extensions Duct Clamp Flue Turret Extension Air Duct Extension Flue Duct Terminal Assembly Wall Sealing Plates 6 720 610 602 - 11.1O Fig. 22 Flue components 6 720 611 137 GB (03.
Installation 3.8.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 23, 24. Outer Wall Face Flue Terminal L Raised Ring locating the terminal relative to the outside wall face 120 NOTE: THE FLUE MUST BE INCLINED T O THE 6 720 610 602 - 12.1O BOILER Fig. 23 Flue length - rear 6 720 610 576 - 20.1O Fig. 25 Flue terminal position L Assemble flue system completely. Push the ducts fully together and clamp in the positions.
Electrical connections 4 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. B Remove screw and slide terminal cover forwards to remove. Refer to fig. 28. 3 0 4 2 All control and safety systems are built into the appliance. 5 1 E B Allow mains cable to protrude at least 50 cm from wall. B To make splash-water proof (IP): cut the cable grommet hole size to match diameter of cable, see Fig.
Electrical connections Wiring to your system Y-S-Module Remote Junction Box LS L NS N PE E (Earth) DV Demand (Switched live) Y-S-Module LRLS NS PE PE DV LS NS PRE-WIRED INSTALLATION WIRING HEATRONIC CONNECTOR L CONTROL BOARD N NS LS LR MAINS 230V LIVE SUPPLY TO BOILER AND SYSTEM Frost Stat OUTSIDE OF BOILER Other connections to Terminal Strip according to Proprietary instructions Room Stat REMOTE PRE-WIRED JUNCTION BOX System Water Valve INSIDE OF BOILER Tank Stat Mains electrical
Commissioning 5 Commissioning 27 136 365 61 317 366 367 358 ECO 364 363 135 E 310 295 15 361 170 172 170 6 720 611 137-11.1O Fig.
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. B Unscrew the condensation trap (358) and pull out, fill with approx. 1/4 l of water and refit. Refer to fig. 32. B Open all system radiator valves.
Commissioning 5.6 i Fault Condition A list of faults that may occur is given on page 40. In the unlikely event of a fault occuring while the appliance is in operation: The display then shows a fault code and the button may also flash. If the button flashes: B Press and hold the button until the display shows “– –”. The appliance will then start up again and the display will show the central heating flow temperature.
Individual settings 6 Individual settings 6.1 Mechanical settings 6.1.1 Setting the boiler flow temperature The central heating flow temperature can be set to between 50˚C and 88˚C. Limited maximum setting for low-temperature operation The temperature control is factory limited to setting E, giving a maximum flow temperature of 75˚C. Adjustment of the heating output to the calculated heat demand is not required by the heating systems regulations. 6.2 Settings on the Bosch Heatronic 6.2.
Individual settings Entering a setting B To enter the setting for a function, turn the function control. Storing a setting B Level 1: press and hold the button until the display shows [ ]. B Level 2: press and hold the and buttons simultaneously until the display shows [ ]. 6.2.5 Setting the heating output (Service Function 5.0) The heating output can be set to any level between min. rated heat output and max rated heat output to limit it to the specific heat requirements.
Individual settings B Measure the gas flow rate and compare with the figures specified for the code number displayed. If figures do not match, adjust the code number! B Press and hold the and buttons simultaneously until the display shows [ ]. The heating output is now stored. 6.3 Setting the gas/air ratio The appliance is set at the factory and adjustment is not necessary. 6 720 611 137-17.1O Fig. 39 B Return the temperature control and the function control to their original positions.
Converting the appliance to different gas types 7 Converting the appliance to different gas types The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not necessary. Checking the gas supply pressure B Check the gas supply pressure at the gas supply pressure testing point. i Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar.
Converting the appliance to different gas types B Turn the function control until the display shows 2. (= max. rated heat output). The display and the button will flash. B Remove the seal from the gas valve adjusting screw (64) and adjust the CO 2 level to the figure given in Table 14 for min. rated heat output. 64 6 720 611 137-20.1O Fig. 43 B Measure the CO2 level. B Prise off the seal on the gas flow restrictor. B Adjust the gas flow restrictor (63) to obtain the CO 2 level given in Table 14.
Converting the appliance to different gas types 7.2 Testing combustion air/flue gas at set heat output 7.2.1 Testing the O2 or CO2 level in the combustion air i By testing the O2 or CO2 level in the combustion air the gas tightness of a type C 13 or C33 flue system can be checked. The O2 level must not be less than 20,6 %. The CO2 level must not exceed 0,2 %. B Press and hold the button until the display shows – –. “Chimney sweep” mode is now active.
Maintenance 8 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. i i There is a special Service booklet for the Engineer, order no. 7 181 465 346, available to competent persons. All safety and control systems are monitored by the Bosch Heatronic.
Maintenance 8.1 Pre-Service Check List Date 1 Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 34). 2 Check ionisation current, Service Function 3.3, (see page 34). 3 Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 36). 4 Check gas supply pressure (see page 29). 5 Test combustion air/flue gas (see page 31). 6 Check CO2 setting for min./ max. (gas/air ratio) (see page 29). mbar min. % max.
Maintenance 8.2 Description of servicing operations The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.2. B Remove the fan and the burner as described in the text headed “Burner” (see page 35). Check “Last fault stored”: B Select Service Function .0 (see page 26 “Selecting Service Function”). There is a list of the fault codes in the Appendix (see page 40.
Maintenance B Clean out the condensate collector and trap connection (with other end of brush). 6 720 610 332-75.2R Fig. 52 B Refit the clean-out cover using a new seal and tighten screws to torque of approx. 5 Nm. 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. 53. B Unscrew and remove the two hexagon screws securing the fan (3). B Slacken fully the rear securing bolt (4).
Maintenance B Refit and prime the siphon. Diaphragm in mixer unit B Take care not to damage diaphragm (443) when removing and refitting it. B Open mixer unit (29). B Carefully withdraw diaphragm (443) from fan intake tube and check for soiling and splits. Condensate Drain Siphon 3. 443 29 6 720 611 137 - 22.1O Fig. 56 Electrical wiring 1. B Check the electrical wiring for physical damage and replace any damaged wires. 2. 6 720 610 790-07.2R Fig.
Maintenance 8.3 B Remove the pcb control board. Replacement of Parts Before changing any components check that the gas is turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance. Refitting is a reverse of the procedure for removal using new seals or o-rings as appropriate. 8.3.1 PCB control board and transformer B Switch off the appliance. B Disconnect appliance from the power supply. B Unplug all connectors from the control box (inc.
Maintenance 8.3.2 Fan Assembly Flue Temperature Limiter – Item 9, fig. 2, 57 3. B Pull-off the connectors. B Unscrew the sensor. 8.3.4 2. Gas Valve B Check that the gas cock is turned off. B Lower the control panel. Refer to fig. 60. 1. 4. 1. 6 720 611 137- 25.1O 2. Fig. 60 1. 7 181 465 330-05.1R Fig. 59 B Switch off the appliance. B Disconnect the appliance from the power supply. B Undo lower pipe union on gas pipe (1.). Refer to fig. 59. B Remove fan lead and earth connector (2.).
Maintenance 8.3.8 B B B B B B B B B B B B B B Primary Heat Exchanger Drain the appliance. Check that the gas supply is turned off. Check that the appliance is electrically isolated. Remove the fan assembly complete with the gas/air tube and mixer assembly. Refer to section 8.3.2. Remove the burner. Refer to section 8.2. Disconnect the sensors. Refer to section 8.3.3. Undo the central heating flow union. Undo the grey plastic cap at the base of the heat exchanger. Unscrew and remove the condensate trap.
Appendix 9 Appendix 9.1 Fault Codes More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346. Display code Description Remedy A8 Break in communication Check connecting lead to programmer AC Module not detected. Check connecting lead between TA211E/ TR212E and Heatronic b1 Keyed plug not detected. Insert keyed plug correctly, test and replace if necessary. C1 Fan speed too low.
Appendix 9.2 Short parts list Key Description Qty GC Spare part number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Sensor - Flue gas temp. Sensor - CH flow temp.
Mains switch ON. 42 Heat demand. Ignition spark for 5 seconds. Ignition sequence Temperature control knob ON. Fan runs to purge gas from burner. No Burner lights. Red light ON. External Pump ON Fan to start speed. Gas valve opens. Yes Fan min. speed for 90 secs. Heat demand satisfied. Fan speed reduces over 15 secs. Yes Gas valve closes. Red light OFF. No Boiler unused for long period.* * Minimum heat input for 15min. Over temperature shut-down if water temperature is 5°C above set value.
Appendix 6 720 611 137 GB (03.
EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW.
Users Instructions and Customer Care Guide R 29 / R 40 HE conventional Condensing boiler 6 720 611 441-00.1O 6 720 611 138 GB (04.
Contents Contents Excellence comes as standard 3 Safety precautions 5 1 General notes 7 2 Controls 9 3 3.1 3.2 3.3 3.4 3.5 3.6 3.
Excellence comes as standard Excellence comes as standard Thank you for purchasing a Worcester Greenstar condensing appliance. The Worcester Greenstar Series has been developed by the Bosch Group and the strictest quality control standards are demanded throughout every stage of production. Indeed, the Bosch Group have led the field in innovative appliance design and performance for many years.
Excellence comes as standard EIRE ONLY The CE mark to indicates manufacture to EU safety requirements. This appliance must be installed only by a competent person to the requirements of IS 813. Make sure your installer hands you a certificate confirming compliance with IS 813 and that you read carefully the instruction book suppplied with this appliance. Keep the instruction book and compliance certificate for future reference. 4 6 720 611 138 GB (04.
Safety precautions Safety precautions Gas Safety (Installation and Use) Regulations It is the law that all gas appliances are installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your interest, and that of safety, to ensure compliance with the law. If you smell gas: B Turn off gas service cock at the meter. B Open all doors and windows. B Do not operate any electrical switches. B Do not smoke.
Safety precautions Health and safety B This appliance contains no asbestos products. B There is no potential hazard due to the appliance being electrically unsafe. B There are no substances used in the construction that are a potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations). Combustion Air/Ambient Air B Keep combustion air/ambient air free of corrosive substances (e.g. halogenated hydrocarbons which contain chlorine or fluorine compounds).
General notes 1 General notes To get the best from your appliance please read these instructions carefully. Central heating systems During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. If the top of a radiator is at a lower temperature than the bottom then it should be vented by releasing air through the venting screw at the top of the radiator. Ask your installer to show you how this is done.
General notes Clearances Your installer will have provided adequate space around the appliance for safety and servicing access. Do not restrict this space with the addition of cupboards, shelves etc. next to the appliance. Left-hand side Right-hand side In Front Above Casing (Vertical Flue) Above Flue Turret Below 10 mm 10 mm 600 mm 200 mm 30 mm 200 mm Table 1 Room thermostat A room thermostat should be fitted to control the central heating.
Controls 2 Controls 136 365 61 317 366 367 363 310 ECO 364 135 E 295 170 172 170 6 720 611 138-01.1O 61 135 136 170 172 295 310 317 363 364 365 366 367 Reset button Master switch Boiler temperature control Service valves in boiler flow and return Gas isolation valve (open) Identification sticker Function control (Service only) Display Indicator lamp for “burner on” Indicator lamp for “off/on” “Chimney sweep” button Service button No function 6 720 611 138 GB (04.
Operating the Appliance 3 Operating the Appliance 3.1 Preparation Turn on the gas cock (172). B Press in the handle and turn it anti-clockwise as far as the stop (when handle is in line with direction of flow, the cock is open). Central heating system valves (170) B Using a spanner, turn square nut until groove is in line with direction of flow (see detail). Groove at right angles to direction of flow = off. 170 172 6 720 611 138-02.1O 10 6 720 611 138 GB (04.
Operating the Appliance 3.2 Switching the Appliance On/Off Switching on B Switch on the appliance at the master switch (I). The indicator lamp shows green and the display will show the primary flow temperature. 6 720 610 333-04.1O i If the display alternates between -II- and the boiler flow temperature, the trap filling programme is active.
Operating the Appliance 3.3 Switching on the System B Turn the temperature control to the desired level: – “Min” setting: 35˚C – Low-temperature heating: setting “E” (approx. 75˚C) – “Max” setting: 88˚C When the burner is lit, the red indicator lamp is illuminated. 6 720 611 138-05.1O 3.4 Controlling B Set room thermostat to the desired room temperature. B Set the external time clock to the desired time periods. B Set the thermostatic radiator valves to the desired settings. 3.
Operating the Appliance 3.6 Frost protection B Leave master switch switched on. If the appliance is to be left for long periods switch the central heating off: B Add a suitable anti-freeze fluid to the water in the central heating system. Suitable products are available from Betz-Dearborn Tel.: 0151 4209563 and Fernox Tel.: 01799 550811. 3.7 Fault Condition In the unlikely event of a fault occuring while the appliance is in operation: The display then shows a fault code and the button flash.
Tips on saving energy 4 Tips on saving energy Heating economically The boiler is designed to provide a high level of comfort while keeping gas consumption and the resulting environmental effect as low as possible. The gas supply to the burner is controlled according to the level of demand for heat. The boiler continues to operate with a low flame if the demand for heat reduces. The technical term for this process is modulating control.
General Information Hot water A lower setting on the hot water cylinder thermostat can result in considerable energy savings. Now you know how to heat your home economically with the Greenstar gas condensing boiler. If you have any other questions, please contact your installer – or write to us. 5 General Information Cleaning the Outer Case Wipe down the outer case with a damp cloth. Do not use abrasive or caustic cleaning agents.
Maintaining your appliance 6 Maintaining your appliance Your new Worcester Greenstar gas-fired appliance represents a long-term investment in a reliable, high quality product. In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is essential that your boiler receives regular, competent servicing and maintenance checks beyond the initial 2 year guarantee period.
Fault or breakdown 8 Fault or breakdown This product is supported in the UK by Worcester Heat Systems Ltd. – part of the Bosch Group. A specialist factory trained field SERVICE ENGINEER is available to attend a breakdown or manufacturing fault occuring on this appliance. No charge will be made for parts and/or labour providing: • An appliance fault is found and the appliance has been installed within the past 24 months. Reasonable evidence of this must be supplied on request i. e.
Your Bosch guarantee 9 Your Bosch guarantee This appliance is guaranteed against faulty material or workmanship for a period of 24 calendar months from the date of installation subject to the following conditions and exceptions. • That during the currency of this guarantee any components of the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and free of labour charges by Worcester Heat Systems Limited.
Guarantee registration 10 Guarantee registration You should complete and return the postpaid Guarantee Registration Card within 14 days of purchase. The card will register you as the owner of your new Worcester Greenstar appliance and will assist us in maintaining an effective and efficient customer service by establishing a reference and permanent record for your boiler. This will not affect your statutory rights in any way. Important: For your own record: Model .........................................
11 If the button flashes, press and hold-in to reset the appliance. Refer to page 13. Fault Condition Set room thermostat to desired temperature or the outside-temperature control unit to the appropriate setting. Controlling the system temperature 6 720 610 333-11.1O Switching off Operating Instructions Quick Reference Switching on 6 720 610 333-04.1O Switching the system on 6 720 611 138-05.
Installation and Servicing Instructions R29 & R40 HE conventional Wall mounted condensing boiler for central heating 6 720 611 441-00.1O ZB 7-28 R29 HE GC-Number: 41 311 60 ZB 11-40 R40 HE GC-Number: 41 311 61 6 720 611 445 GB (04.
Contents Contents Safety precautions 3 Symbols 3 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 Details of the appliance EC Declaration of Conformity Standard package Description of appliance Accessories Casing dimensions Layout of appliance Function Electrical wiring diagram Technical data 6 6.1 6.1.1 6.2 6.2.1 6.2.
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 24). B Open windows and doors.
Details of the appliance 1 Details of the appliance 1.3 Description of appliance • Wall-mounted appliance 1.1 EC Declaration of Conformity • Natural gas models are low-emission appliances This appliance is in accordance with the applicable requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.
Details of the appliance 1.4 Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues up to 4 m in length (3.5m for the R 40 HE). • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths up to 13m (R 29 HE ) or 10m (R 40 HE) and vertical flue systems for flue lengths up to 15 m (R 29 HE) or 12 m (R 40 HE). Fitting instructions are sent with these kits. 1.5 Casing dimensions min. min.
Details of the appliance 1.6 Layout of appliance 120 221.1 221.2 226 102 27 32.1 29 36 271 6 415 43 9 63 416 358 64 423 4.4 7 15 361 295 4 417 6 720 611 445-01.1O Fig. 2 4 4.4 6 7 9 15 27 29 32.
Details of the appliance 1.7 Function 4.4 361 6 720 611 445-02.1O Fig. 3 4 4.4 6 7 9 13 15 27 29 29.1 30 32 33 35 36 43 45 47 52 52.
Details of the appliance 1.8 Electrical wiring diagram o - orange bl - black r - red 33 365 364 61 317 366 363 367 ECO 4.1 25 V 153 230V/AC 230 V 136 310 135 312 328 302 313 151 12 4 789 L N Ns Ls LR 161 300 9 6 M r r mains supply o 226 52 52.1 4.4 56 o bl bl bl bl 36 32 6 720 611 445-03.1O Fig. 4 4.1 4.4 6 9 32 33 36 52 52.
Details of the appliance 1.9 Technical data Units R 29 HE Natural gas R 29 HE Propane R 40 HE Natural gas R 40 HE Propane kW kW kw 29.3 29.0 27.4 29.3 29.0 27.4 41.4 41.4 39.1 41.4 41.4 39.1 Max. rated heat input net kW 27.7 27.7 40 40 Min. rated heat output net 40/30˚C Min. rated heat output net 50/30˚C Min. rated heat output net 80/60˚C kW kW kW 8.4 8.3 7.4 11.6 11.4 10.5 12.9 12.8 11.4 16.2 16.1 14.3 Min. rated heat input net kW 7.6 10.8 11.8 14.8 4.2 - Max.
Details of the appliance Gas supply Condensate analysis, mg/l Ammonium 1.2 Nickel 0.15 ≤ 0.01 Mercury Cadmium ≤ 0.001 Sulphate Chromium ≤ 0.005 Zinc ≤ 0.015 Tin ≤ 0.01 Lead Halogenated hydrocarbons ≤ 0.002 Hydrocarbons 0.015 Vanadium Copper 0.028 pH-value ≤ 0.0001 1 Total length of gas supply pipe (metres) 3 6 Pipe diameter (mm) 9 Gas discharge rate (m3/h) 8.7 5.8 4.6 22 18.0 12.0 9.4 28 ≤ 0.001 4.
Installation regulations 2 Installation regulations Gas Safety (Installation & Use) Regulations 1998: All gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution. The manufacturers notes must not be taken, in any way, as overriding statutory obligations.
Installation Some plastics are permeable to oxygen and must be avoided, a pipe with a polymer barrier should be used. Sealed System A sealed system must include an expansion vessel, pressure gauge and pressure relief valve set to operate at 3 bar - these are available as proprietary kits. The expansion vessel and fittings must be connected at the neutral point of the system on the entry to the pump. Suitable pump and diverter valves are also required. Refer to Fig. 5 & Fig. 6.
Installation AUTOMATIC AIR VENT DOMESTIC HOT WATER CYLINDER RADIATOR RADIATOR RADIATOR RADIATOR DIVERTER VALVE SAFETY VALVE PRESSURE GAUGE PUMP EXPANSION VESSEL BOILER TO SYSTEM FILLING DEVICE DRAIN COCK TYPICAL FULLY PUMPED SEALED SYSTEM 6 720 611 445-05.1O Fig. 6 6 720 611 400-14.1O Fig. 7 3.3 Siting the appliance Regulations concerning the Installation Site B Relevant national regulations must be complied with section 3.8.1.
Installation 3.4 Wall mounting frame assembly B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 8. Use the inner lugs on the top and bottom horizontal sections. B Screw the pre-plumbing manifold with two screws to the wall mounting frame. 6 720 610 576-11.1O Fig. 10 6 720 610 576-04.1O Fig. 8 3.5 Pre-piping the system 200 B Hold the wall-mounting frame against the wall ensuring that it is vertical.
Installation Condensate Termination and Route The appliance has a built-in syphonic condensate trap eliminating the need for external traps. Connect to the 22mm plastic drain pipe and extend the pipe run away from the control panel and appliance with a constant fall of 2.5˚ or 45mm in every metre. See Fig. 13. The condensate pipe can terminate into any of four areas: Boiler Boiler Ø 22 min. Sink Siphon Siphon Ø 22 min.
Installation B Remove the plastic caps from the boiler connections. 3.7 Checking the connections Water connections B Check that the O-rings or seals are in place before tightening the connection. B Turn on the service valves for boiler flow and return. B Check all seals and unions for leaks. 2. Open vent systems: It is not necessary to connect a drain pipe to the pressure relief valve outlet as it is not operational and should be blanked off. Gas supply pipe 1. 6 720 611 441-05.1O Fig.
Installation lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which people have access then a guard must be fitted. The guard must be evenly spaced about the terminal with a space of 50 mm in each direction and fixed with plated screws. A guard Type K6 for the standard horizontal flue, can be obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB. 3.8.
Installation 3.8.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths up to 4m (R29) & 3.5m (R40). Flues up to 730 mm do not require an extension duct assembly. Flues between 1700 mm and 4000 mm require extension duct assemblies. Standard 100mm system comprise: Flue Turret Maximum 730mm Outer Wall Minimum 480mm Clamp Terminal Assembly 6 720 611 400-18.1O • Flue turret Fig.
Installation Maximum 1700mm Outer Wall Flue Turret Terminal Assembly Extension Duct Clamp 6 720 611 400-19.1O Fig. 19 Flue with one extension Outer Wall Flue Turret Clamp Extension Duct Clamp Extension Duct Clamp Terminal Assembly 6 720 611 400-20.1O Fig. 20 Flue with extensions Flue Turret Clamp Flue Terminal Extension Flue Duct Wall Sealing Gasket 6 720 611 400-21.1O Fig. 21 Flue components 6 720 611 445 GB (04.
Installation 3.8.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 22, 23. Outer Wall Face Flue Terminal L 120 Wall Sealing Gasket 6 720 611 400-22.1O Fig. 22 Flue length - rear 6 720 611 400-24.1O Fig. 24 Flue terminal position L Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must be directed as per Fig. 24. The assembly will be made easier if a solvent free grease is lightly applied i.
Electrical connections 4 Electrical connections B Remove screw and slide terminal cover forwards to remove. Refer to fig. 27. B Always disconnect the power supply to the appliance at the mains before carrying out any work on the electrical systems and components. 3 0 4 2 5 1 E All control and safety systems are built into the appliance. B Allow mains cable to protrude at least 50 cm from wall.
Electrical connections Wiring to your system L NS N PE E (Earth) DV Demand (Switched Live) HEATRONIC CONNECTOR L CONTROL BOARD N NS LS LR MAINS 230V LIVE SUPPLY TO BOILER AND SYSTEM INSIDE OF BOILER INSTALLATION WIRING OUTSIDE OF BOILER Other connections to Terminal Strip according to Proprietary instructions REMOTE PRE-WIRED ˜ JUNCTION BOX MAINS SUPPLY L N E System Water Valve(s) LS PRE-WIRED Frost Stat Remote Junction Box LR LS NS PE PE DV LS NS Room Stat Y-S Module Y-S-Module
Commissioning 5 Commissioning 27 136 365 61 317 366 367 358 ECO 364 363 135 E 310 295 15 361 170 170 172 6 720 611 137-11.1O Fig.
Commissioning To drain the appliance shut the system valves and open the drain valve. 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. 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.
Commissioning 5.5 Frost protection The appliance has an in-built frost protection device which is generally suitable for most applications. B Leave master switch switched on. If the appliance is to be left for long periods switch the central heating off: B Add a suitable anti-freeze fluid to the water in the central heating system. Suitable products are available from Betz-Dearborn Tel: 0151-4209563 and Fernox Tel: 01799550811. 5.6 i Fault Condition A list of faults that may occur is given on page 40.
Individual settings 6 Individual settings 6.1 Mechanical settings 6.1.1 Setting the boiler flow temperature The central heating flow temperature can be set to between 50˚C and 88˚C. Limited maximum setting for low-temperature operation The temperature control is factory limited to setting E, giving a maximum flow temperature of 75˚C. Adjustment of the heating output to the calculated heat demand is not required by the heating systems regulations. 6.2 Settings on the Bosch Heatronic 6.2.
Individual settings Entering a setting B To enter the setting for a function, turn the function control. B Press and hold the and buttons simultaneously until the display shows = =. The and buttons will light up. Storing a setting B Level 1: press and hold the button until the display shows [ ]. B Level 2: press and hold the and buttons simultaneously until the display shows [ ]. 6 720 611 137-15.1O After completing the settings B Reset the temperature controls control to their original positions.
Individual settings 6.3 Setting the gas/air ratio The appliance is set at the factory and adjustment to the CO2 settings (gas/air ratio) is only required where the appliance has been stripped down and assembled or if the fan, burner or gas valve are replaced or the appliance has been converted to a different gas type, see section 7. 28 6 720 611 445 GB (04.
Converting the appliance to different gas types 7 Converting the appliance to different gas types The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not necessary. Checking the gas supply pressure B Check the gas supply pressure at the gas supply pressure testing point. i Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar.
Converting the appliance to different gas types B Turn the function control until the display shows 2. (= max. rated heat output). The display and the button will flash. B Remove the seal from the gas valve adjusting screw (64) and adjust the CO 2 level to the figure given in Table 14 for min. rated heat output. 64 6 720 611 137-20.1O Fig. 42 B Measure the CO2 level. B Prise off the seal on the gas flow restrictor. B Adjust the gas flow restrictor (63) to obtain the CO 2 level given in Table 14.
Converting the appliance to different gas types 7.2 Testing combustion air/flue gas at set heat output 7.2.1 Testing the O2 or CO2 level in the combustion air i By testing the O2 or CO2 level in the combustion air the gas tightness of a type C13 or C33 flue system can be checked. The O2 level must not be less than 20,6 %. The CO2 level must not exceed 0,2 %. B Press and hold the button until the display shows – –. “Chimney sweep” mode is now active.
Maintenance 8 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. i i There is a special Service booklet for the Engineer, order no. 7-181-465-346, available to competent persons. All safety and control systems are monitored by the Bosch Heatronic.
Maintenance 8.1 Pre-Service Check List Date 1 Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 34). 2 Check ionisation current, Service Function 3.3, (see page 34). 3 Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 36). 4 Check gas supply pressure (see page 29). 5 Test combustion air/flue gas (see page 31). 6 Check CO2 setting for min./ max. (gas/air ratio) (see page 29). mbar min. % max.
Maintenance 8.2 Description of servicing operations The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.1. B Unscrew condensation trap and place suitable container underneath. Refer to fig. 48. B Remove the fan and the burner as described in the text headed “Burner” (see page 35). Check “Last fault stored”: B Select Service Function .0 (see page 26 “Selecting service function”).
Maintenance B Clean out the condensate collector and trap connection (with other end of brush). 6 720 610 332-75.2R Fig. 51 B Refit the clean-out cover using a new seal and tighten screws to torque of approx. 5 Nm. 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. 52. B Unscrew and remove the two hexagon screws securing the fan (3.). B Slacken fully the rear securing bolt (4.).
Maintenance B Refit and prime the siphon. Diaphragm in mixer unit Take care not to damage diaphragm (443) when removing and refitting it. B Open mixer unit (29). B Carefully withdraw diaphragm (443) from fan intake tube and check for soiling and splits. Condensate Drain Siphon 3. Drain Plug 443 29 6 720 611 445 - 07.1O Fig. 55 Electrical wiring 1. B Check the electrical wiring for physical damage and replace any damaged wires. 2. 6 720 610 790-07.2R Fig.
Maintenance 8.3 B Remove the pcb control board. Replacement of Parts Before changing any components check that the gas is turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance. Refitting is a reverse of the procedure for removal using new seals or o-rings as appropriate. 8.3.1 PCB control board and transformer B Switch off the appliance. B Disconnect appliance from the power supply. B Unplug all connectors from the control box (inc.
Maintenance 8.3.2 Fan Assembly 8.3.4 3. Gas Valve B Check that the gas cock is turned off. B Lower the control panel. Refer to fig. 59. 2. 1. 1. 4. 6 720 611 137- 25.1O 2. Fig. 59 1. 7 181 465 330-05 1R Fig. 58 B Switch off the appliance. B Disconnect the appliance from the power supply. B Undo lower pipe union on gas pipe (1.). Refer to fig. 58. B Remove fan lead and earth connector (2.). The earth connector has a positive clip fixing.
Maintenance B Undo the central heating flow union. B Undo the grey plastic cap at the base of the heat exchanger. B Unscrew and remove the condensate trap. Refer to section 8.2. B Unscrew and remove the two screws securing the heat exchanger top bracket to the rear panel. B Lift up the flue duct, item 271, refer to fig. 2. B Pull forward from the top and lift the heat exchanger from the casing. B Transfer components, as necessary, to the new heat exchanger.
Appendix 9 Appendix 9.1 Fault Codes More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346. Display code Description Remedy b1 Code plug not detected. Insert code plug correctly, test and replace if necessary. C1 Fan speed too low. Check fan lead and connector, and fan; replace as necessary. d3 Jumper 8-9 not detected. Connector not connected, link missing, underfloor heating limiter tripped.
Appendix 9.2 Short parts list Key Description Qty GC Spare part number 1 Sensor - Flue gas temp. 1 8 729 000 144 0 2 Sensor - boiler flow temp.
Mains switch ON. 42 Heat demand. Fan runs to purge gas from burner. No Burner lights. Red light ON. Yes Gas valve closes. Red light OFF. No Yes * Minimum heat input for 15min. External Pump and Fan run for upto 3 mins. Boiler operates to match system load and temperature control setting. 6 720 611 137 - 24.1O * NOTE: The sequence ensures that the condensate siphon is not empty after long OFF periods. (More than 24 hours without a demand). Heat demand satisfied. Fan min. speed for 90 secs.
Appendix 6 720 611 445 GB (04.
Appendix EXCELLENCE COMES AS STANDARD Manufactured exclusively for British Gas by The Bosch Group Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.
Users Instructions and Customer Care Guide R 29 / R 40 HE conventional Condensing boiler 6 720 611 441-00.1O 6 720 611 138 GB (04.
Contents Contents Excellence comes as standard 3 Safety precautions 5 1 General notes 7 2 Controls 9 3 3.1 3.2 3.3 3.4 3.5 3.6 3.
Excellence comes as standard Excellence comes as standard Thank you for purchasing a Worcester Greenstar condensing appliance. The Worcester Greenstar Series has been developed by the Bosch Group and the strictest quality control standards are demanded throughout every stage of production. Indeed, the Bosch Group have led the field in innovative appliance design and performance for many years.
Excellence comes as standard EIRE ONLY The CE mark to indicates manufacture to EU safety requirements. This appliance must be installed only by a competent person to the requirements of IS 813. Make sure your installer hands you a certificate confirming compliance with IS 813 and that you read carefully the instruction book suppplied with this appliance. Keep the instruction book and compliance certificate for future reference. 4 6 720 611 138 GB (04.
Safety precautions Safety precautions Gas Safety (Installation and Use) Regulations It is the law that all gas appliances are installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your interest, and that of safety, to ensure compliance with the law. If you smell gas: B Turn off gas service cock at the meter. B Open all doors and windows. B Do not operate any electrical switches. B Do not smoke.
Safety precautions Health and safety B This appliance contains no asbestos products. B There is no potential hazard due to the appliance being electrically unsafe. B There are no substances used in the construction that are a potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations). Combustion Air/Ambient Air B Keep combustion air/ambient air free of corrosive substances (e.g. halogenated hydrocarbons which contain chlorine or fluorine compounds).
General notes 1 General notes To get the best from your appliance please read these instructions carefully. Central heating systems During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. If the top of a radiator is at a lower temperature than the bottom then it should be vented by releasing air through the venting screw at the top of the radiator. Ask your installer to show you how this is done.
General notes Clearances Your installer will have provided adequate space around the appliance for safety and servicing access. Do not restrict this space with the addition of cupboards, shelves etc. next to the appliance. Left-hand side Right-hand side In Front Above Casing (Vertical Flue) Above Flue Turret Below 10 mm 10 mm 600 mm 200 mm 30 mm 200 mm Table 1 Room thermostat A room thermostat should be fitted to control the central heating.
Controls 2 Controls 136 365 61 317 366 367 363 310 ECO 364 135 E 295 170 172 170 6 720 611 138-01.1O 61 135 136 170 172 295 310 317 363 364 365 366 367 Reset button Master switch Boiler temperature control Service valves in boiler flow and return Gas isolation valve (open) Identification sticker Function control (Service only) Display Indicator lamp for “burner on” Indicator lamp for “off/on” “Chimney sweep” button Service button No function 6 720 611 138 GB (04.
Operating the Appliance 3 Operating the Appliance 3.1 Preparation Turn on the gas cock (172). B Press in the handle and turn it anti-clockwise as far as the stop (when handle is in line with direction of flow, the cock is open). Central heating system valves (170) B Using a spanner, turn square nut until groove is in line with direction of flow (see detail). Groove at right angles to direction of flow = off. 170 172 6 720 611 138-02.1O 10 6 720 611 138 GB (04.
Operating the Appliance 3.2 Switching the Appliance On/Off Switching on B Switch on the appliance at the master switch (I). The indicator lamp shows green and the display will show the primary flow temperature. 6 720 610 333-04.1O i If the display alternates between -II- and the boiler flow temperature, the trap filling programme is active.
Operating the Appliance 3.3 Switching on the System B Turn the temperature control to the desired level: – “Min” setting: 35˚C – Low-temperature heating: setting “E” (approx. 75˚C) – “Max” setting: 88˚C When the burner is lit, the red indicator lamp is illuminated. 6 720 611 138-05.1O 3.4 Controlling B Set room thermostat to the desired room temperature. B Set the external time clock to the desired time periods. B Set the thermostatic radiator valves to the desired settings. 3.
Operating the Appliance 3.6 Frost protection B Leave master switch switched on. If the appliance is to be left for long periods switch the central heating off: B Add a suitable anti-freeze fluid to the water in the central heating system. Suitable products are available from Betz-Dearborn Tel.: 0151 4209563 and Fernox Tel.: 01799 550811. 3.7 Fault Condition In the unlikely event of a fault occuring while the appliance is in operation: The display then shows a fault code and the button flash.
Tips on saving energy 4 Tips on saving energy Heating economically The boiler is designed to provide a high level of comfort while keeping gas consumption and the resulting environmental effect as low as possible. The gas supply to the burner is controlled according to the level of demand for heat. The boiler continues to operate with a low flame if the demand for heat reduces. The technical term for this process is modulating control.
General Information Hot water A lower setting on the hot water cylinder thermostat can result in considerable energy savings. Now you know how to heat your home economically with the Greenstar gas condensing boiler. If you have any other questions, please contact your installer – or write to us. 5 General Information Cleaning the Outer Case Wipe down the outer case with a damp cloth. Do not use abrasive or caustic cleaning agents.
Maintaining your appliance 6 Maintaining your appliance Your new Worcester Greenstar gas-fired appliance represents a long-term investment in a reliable, high quality product. In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is essential that your boiler receives regular, competent servicing and maintenance checks beyond the initial 2 year guarantee period.
Fault or breakdown 8 Fault or breakdown This product is supported in the UK by Worcester Heat Systems Ltd. – part of the Bosch Group. A specialist factory trained field SERVICE ENGINEER is available to attend a breakdown or manufacturing fault occuring on this appliance. No charge will be made for parts and/or labour providing: • An appliance fault is found and the appliance has been installed within the past 24 months. Reasonable evidence of this must be supplied on request i. e.
Your Bosch guarantee 9 Your Bosch guarantee This appliance is guaranteed against faulty material or workmanship for a period of 24 calendar months from the date of installation subject to the following conditions and exceptions. • That during the currency of this guarantee any components of the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and free of labour charges by Worcester Heat Systems Limited.
Guarantee registration 10 Guarantee registration You should complete and return the postpaid Guarantee Registration Card within 14 days of purchase. The card will register you as the owner of your new Worcester Greenstar appliance and will assist us in maintaining an effective and efficient customer service by establishing a reference and permanent record for your boiler. This will not affect your statutory rights in any way. Important: For your own record: Model .........................................
11 If the button flashes, press and hold-in to reset the appliance. Refer to page 13. Fault Condition Set room thermostat to desired temperature or the outside-temperature control unit to the appropriate setting. Controlling the system temperature 6 720 610 333-11.1O Switching off Operating Instructions Quick Reference Switching on 6 720 610 333-04.1O Switching the system on 6 720 611 138-05.
Service booklet for the Engineer for Gas Condensing Boilers 6 720 610 577-00.10 7 181 465 346 GB (03.
Table of contents Table of contents Warnings 3 Symbols 3 1 1.1 1.2 Layout of Appliance combi system 4 4 5 2 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 Bosch Heatronic board functions Initialisation Temperature display Indication of faults Special programme visualisation Boiler service functions First Service Level Secondary Service Level 6 6 6 6 6 8 8 11 3 3.1 3.2 3.2.1 3.2.2 3.3 3.4 3.4.1 3.4.
Warnings Warnings Repairs B Repairs may only be carried out by an approved installer! B Before carrying out any work on the appliance, switch it off at the master switch! B Even when the appliance is switched off at the master switch, some components on the PCB control board inside the control box are still live. Therefore: B Before carrying out any work on the electrical parts of the appliance fully disconnect it from the power supply (e. g.
Layout of Appliance 1 Layout of Appliance 1.1 combi 120 221.1 349 221.2 234.1 234 27 226 20 102 32.1 29 36 271 6 415 43 9 63 416 358 18 64 423 7 18.1 355 418 6.1 15 8.1 88 295 98 417 4 6 720 610 576-02.2O Fig. 1 4 6 6.1 7 8.1 9 15 18 18.1 20 27 29 32.
Layout of Appliance 1.2 system 120 221.1 349 221.2 234.1 234 27 226 20 102 32.1 29 36 271 6 415 43 9 63 416 358 18 64 423 7 18.1 418 15 8.1 295 4 417 6 720 610 596-01.2O Fig. 2 4 6 7 8.1 9 15 18 18.1 20 27 29 32.1 36 43 63 64 102 120 221.1 221.
Bosch Heatronic board functions 2 Bosch Heatronic board functions 2.1 Initialisation When it is switched on, the appliance performs a selftest which takes about 5 seconds. While the test is in progress, the display shows the following sequence of codes: P1 -> P2 -> P3 -> P4 -> P5 -> P6 On completion of the test sequence the appliance is ready for operation. 2.2 Temperature display 2.
Bosch Heatronic board functions The next time the central heating or heat store calls for heat, the appliance is held at a low heat output for 15 minutes. The display shows -II- in alternation with the CH flow temperature.The factory setting is 1 (enabled). If the condensation trap is not filled with water, flue gas can escape! B The trap filling programme should only be disabled in order to carry out servicing work. B Always re-enable the trap filling programme after completing servicing work.
Bosch Heatronic board functions 2.5 Boiler service functions 2.5.1 First Service Level Operating In order to change or check the values of the service functions: B Press the button until the symbol – – appears on the display. The button is lighted. B Turn the temperature control until the desired function number appears on the display. Once changed or checked the function value: B Press the button until the symbol [ ] appears on the display. The display shows the heating outlet temperature.
Bosch Heatronic board functions Values that can only be read: Description Display Reset Value .1 Heating outlet temperature. 0 - 99˚C - .2 Sanitary outlet temperature. 0 - 99˚C - .3 Heat store NTC sensor (ZSB.) 0 - 99˚C .4 Constant hot water NTC sensor (ZWB.) 0 - 99˚C - 1.2 Order no. for code plug: 8 714 411 XXX 0 - 255 - 1.4 Temperature voltage signal (Terminal 2) from room thermostat (eg. TRQ 21, TR 100) 5 - 22 VDC - 1.
Bosch Heatronic board functions Values that can only be read - only left display digit: Description Display XY Reset Value 3.9 External switch (points 8 - 9). 0 = closed 1 = Heating demand - 4.1 External demand for heat via LSM 0 = closed 1 = Heating demand - 4.2 Programmable clock: 1st channel (Heating). 0 = closed 1 = Heating demand - 4.3 Automatic pump shut OFF with RAM module (point 5) 0 = closed 1 = Heating demand - 4.4 Heating demand. 0 = closed 1 = Heating demand - 4.
Bosch Heatronic board functions 2.5.2 Secondary Service Level Operation In order to change or check the values of the service functions: B Press buttons and simultaneously until the symbol = = appears on the display. The buttons and are lighted. B Turn the temperature control until the desired function number appears on the display. Once changed or checked the function value: B Press buttons and simultaneously until the symbol [ ] appears on the display. The display shows the heating outlet temperature.
Bosch Heatronic board functions Values that can only be read: Description Display Reset Value 5.2 Automatic gas igniter status and/or fault 00 - FF - 9.3 Automatic gas igniter Asic fault code 00 - FF - Table 6 Secondary Service Level; Values that can only be read 12 7 181 465 346 GB (03.
Failure identification procedure 3 Failure identification procedure 3.1 Notes on using the fault code tables In this example: check the flue is clear by testing the CO2 level. The procedure is best described with the aid of an example: • Work through the table from top to bottom and from left to right. • First make a note of the present settings and restore them before leaving the appliance. • Read question 1.
Failure identification procedure ZWB ...A Page X X 42 Flue gas levels incorrect, CO level too high X X 43 3 X 17 Ignition too harsh, ignition poor. X X 44 A8 3 X X X 19 Boiler indicates P1, P2, P3 at start-up and then restarts with P1,...
Failure identification procedure 3.3 Error codes on the display A5 flashing. Heat store NTC sensor 2 defective Check Action B Note the setting of the temperature controls and 1. B Press button . yes: B Select service function .3 . Is a temperature between 0. and 5. displayed? 2. Heat store NTC: B Unplug connector. B Short circuit the connector. Display changes to temperature between 99. and 95. . B Flue gas connector corroded 1), damaged or dirty?. Change relative parts. ↓2. no: ↓3.
Failure identification procedure A5 flashing. Heat store NTC sensor 2 defective Check 5. Action To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions. 1) 16 For notes, refer to Appendix 7 181 465 346 GB (03.
Failure identification procedure A7 flashing. Hot water NTC sensor defective Check Action B Note the setting of the temperature controls and 1. B Press button . yes: B Select service function .2 . Is a temperature between 0. and 5. displayed? 2. Hot water NTC sensor: B Unplug connector. B Short circuit the connector. Display changes to temperature 99. . B Flue gas connector corroded 1), damaged or dirty? Change relative parts. ↓2. no: ↓3. yes: B B B B B B B Power OFF the appliance.
Failure identification procedure A7 flashing. Hot water NTC sensor defective Check 4. B Unplug 20-pin connector from PCB. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.? Action yes: B B B B B Power OFF the appliance. Disconnect the boiler electrical connection. Change the 20-pin connector lead assembly. Reconnect the boiler electrical connection. Turn ON the appliance. ↓5.
Failure identification procedure A8 flashing. No correct electrical connection Check 1. TR 2 connected? Action yes: A8? ↓2. no: B Power OFF the appliance. B Connect TR 2. B Turn ON the appliance. A8? ↓2. 2. 3. B Turn switch until it clicks into position. Mode selector switch is between two settings A8? ↓3. B Power OFF the appliance. Wiring between TR 2 and TR 212 E OK? yes: • Terminal 3 on TR 2 connected to Terminal 3 on TR 212 E? no: • Terminal 4... Terminal 4....
Failure identification procedure AC flashing. Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.) Check Action B Note the setting of the temperature controls and 1. B Press button . yes: B Select service function 1.9 . Code 0., 2., 4., 5. is displayed. . No modul detected. B Disconnect connecting lead between PCB control board and TA 211 E or TA 212 E. B Re-connect connecting lead. AC? ↓3. 2. 3.
Failure identification procedure AC flashing. Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.) Check 7. Remote control status still 0.? Action yes: B Power OFF the appliance. Remote control: B Replace top section. B Turn ON the appliance. AC? ↓8. no: 8. The PCB control board is damaged. ↓8.
Failure identification procedure Ad flashing. Heat store NTC sensor 1 not detected (ZB...). Check Action B Note the setting of the temperature controls and 1. 2. . Is connecting lead for heat store NTC sensor 1 correctly routed, i.e. not through cable grommet? yes: ↓2. no: B Route connecting lead for heat store temperature sensor as specified in installation instructions. B Press button yes: Is NTC sensor connector corroded, damaged or dirty? B Power OFF the appliance. B Change NTC sensor.
Failure identification procedure Ad flashing. Heat store NTC sensor 1 not detected (ZB...). Check 4. Temperature between 99. and 95. is displayed. B Unplug connector. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.? Action yes: B Power OFF the appliance. B Change NTC sensor. B Turn ON the appliance.
Failure identification procedure b1 flashing. The Heatronic does not recognise the code key. Check B Power OFF the appliance. 1. 2. Action Code plug loose, incorrect or defective. B Replace code plug, check code number is correct. B Turn ON the appliance. b1? ↓3. 3. 24 The PCB control board is damaged.
Failure identification procedure C1 flashing. Fan speed too low Check 1. Action Fan lead connector properly connected? yes: ↓2. no: B Power OFF the appliance. B Plug in connector. B Turn ON the appliance. C1? ↓2. 2. 3. Is fan lead defective? B Is impedance reading between the two connectors for one of the cores infinity? Are the differential pressure switch contacts closed? B Press button . yes: B Power OFF the appliance. B Replace fan lead. B Turn ON the appliance. C1? ↓3. no: ↓3.
Failure identification procedure CC flashing. Outside temperature NTC sensor not detected. (Boiler heating as if outside temperature is -20˚C) Check 1. Outside temperature sensor AF2 connected to Terminals A and F on TA 211 E? Action yes: ↓2. no: B Power OFF the appliance. B Connect outside temperature sensor to Terminals A and F on TA 211 E. B Turn ON the appliance. CC? ↓2. 2. 26 B Power OFF the appliance.
Failure identification procedure d3 flashing. Wrong signal from pin 8-9 (open?). Check 1. 2. Action B Turn ON the appliance. B Measure voltage between Terminal 4 and Terminal 8. Voltage ≅ 24 V DC? yes: ↓2. no: ↓3. Existing heat store thermostat connected to Terminals 7, 8 and 9? yes: B Power OFF the appliance. B Fix the additional bridge 8-9 in the right position and close the screws. B Turn ON the appliance. d3? ↓3. 3. Break in connecting lead? no: ↓4. yes: B Power OFF the appliance.
Failure identification procedure E2 flashing. The heating outlet NTC sensor is damaged. Check Action B Note the setting of the temperature controls and 1. B Press button . yes: B Select service function .1 . Is a temperature between 0. and 5. displayed? . The heating outlet NTC sensor is in short circuit: B Power OFF the appliance. B Replace CH flow NTC sensor; observe fitting instructions for NTC sensor when doing so. B Turn ON the appliance. E2? ↓2. 2.
Failure identification procedure E2 flashing. The heating outlet NTC sensor is damaged. Check Action To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions. 7 181 465 346 GB (03.
Failure identification procedure E9 and flashing. Safety temperature limiter has tripped. Check 1. Is the heating pressure between 1 and 2 bar? Action yes: ↓2. no: B Top up system. B Vent appliance. B Press , restart the appliance. E9? ↓2. 2. Is the pump blocked? yes: B Unblock the pump. If pump won’t start: B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change the pump. B Reconnect the boiler electrical connection. B Turn ON the appliance.
Failure identification procedure E9 and flashing. Safety temperature limiter has tripped. Check 5. Is lead disconnected from CH flow safety temp. limiter? Action yes: B Power OFF the appliance. B Reconnect lead. B Turn ON the appliance. B Press , restart the appliance. ↓6. 6. B Power OFF the appliance. B Disconnect lead to CH flow safety temperature limiter. B Measure the CH flow safety temperature limiter. R = ∞? no: ↓6. yes: B Change CH flow safety temperature limiter.
Failure identification procedure EA and flashing. No flame ionisations signal Check Action B Note the setting of the temperature controls and 1. 2. Is the flame present? Is the gas cock open? . yes: ↓6. no: ↓2. yes: ↓3. no: B Open the gas cock. B Press , restart the appliance. EA? ↓3. 3. Is there air in the supply pipe? yes: B Vent supply pipe. B Press , restart the appliance. EA? ↓4. 4. Did the thermal security of the gas cock lock out? no: ↓4. yes: B Reset security.
Failure identification procedure EA and flashing. No flame ionisations signal Check 5. Natural gas models: does the building have a supply pressure regulator? Action yes: B Check that it is fitted correctly and functioning properly and correct if necessary. B Check supply pressure, inform gas company if outside correct range. B Is correct code plug fitted? B Press , restart the appliance. EA? ↓6. LPG models: is the flow rate of the gas supply to the appliance correct? no: ↓6. yes: ↓6.
Failure identification procedure EA and flashing. No flame ionisations signal Check 8. Is diaphragm in the mixer unit correctly fitted and functional? B Open mixer unit (29). B Check diaphragm for correct orientation, soiling and splitting. Is diaphragm OK? Action yes: B Close mixer unit. ↓9. no: B Insert diaphragm in the fan intake duct as per installation instructions so that the flaps open upwards. B Close mixer unit. EA? ↓9. 9.
Failure identification procedure EA and flashing. No flame ionisations signal Check 13. 14. Action B Press buttons and simultaneously. B Select service-function 5.1. Continuous ignition (without gas) OK? yes: Ignition lead connected to ignition electrodes? yes: ↓15. no: B Connect cable to ignition electrode. B Press buttons and simultaneously. and simultaneously. ↓14. no: B Press buttons ↓17. B Press , restart the appliance. EA? ↓15. 15.
Failure identification procedure EA and flashing. No flame ionisations signal 19. Check Action Check if the 20-pin connector lead assembly is damaged. B B B B B Power OFF the appliance. Disconnect the boiler electrical connection. Change the 20-pin connector lead assembly. Turn ON the appliance. Reconnect the boiler electrical connection. B Press , restart the appliance. EA? B Power OFF the appliance. ↓20. 20. The PCB control board is damaged.
Failure identification procedure F0 (and possibly ) flashing. Internal failure Check Action B Note the setting of the temperature controls and 1. 2. 3. . B Press buttons and simultaneously. B Select service function 9.3 . A service code is displayed. B Enter figure displayed in customer service record. B Select service function 5.2 . A service code is displayed. B Enter figure displayed in customer service record. flashing? ↓2. ↓3. yes: B Press button .
Failure identification procedure F7 and flashing. Although appliance switches off, flame still detected 1. Check Action Electrode(s) dirty or defective. B Power OFF the appliance. B Replace electrode assembly. B Turn ON the appliance. B Press , restart the appliance. F7? ↓2. 2. B Power OFF the appliance. B Disconnect the boiler electrical connection. B Remove PCB control board. PCB control board damp? yes: B Dry PCB control board (e.g. with hair dryer).
Failure identification procedure FA and flashing. Although appliance switches off, flame still detected Check Action B Note the setting of the temperature controls and . B Power OFF the appliance. 1. Condensation trap blocked? yes: B Clean condensation trap discharge pipe. B Press , restart the appliance. FA? ↓2. 2. Electrode assembly defective? B Power OFF the appliance. B Remove electrode assembly. Electrode assembly burnt out? no: ↓2. yes: B Replace electrode assembly.
Failure identification procedure FA and flashing. Although appliance switches off, flame still detected 5. Check Action Check if the 20-pin connector lead assembly is damaged. B B B B B Power OFF the appliance. Disconnect the boiler electrical connection. Change the 20-pin connector lead assembly. Turn ON the appliance. Reconnect the boiler electrical connection. B Press , restart the appliance. FA? B Power OFF the appliance. ↓6. 6. 40 The PCB control board is damaged.
Failure identification procedure Fd Button and flashing. pressed without necessity Check 1. Button Action is flashing. B Press , restart the appliance. Fd? ↓2. 2. The PCB control board is damaged. 7 181 465 346 GB (03.02) B Make a note of the altered service settings (see table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11). B Power OFF the appliance. B Disconnect the boiler electrical connection.
Failure identification procedure 3.4 Faults that are not displayed 3.4.1 Appliance faults Excessive burner noise, rumbling noises Check Action B Note the setting of the temperature controls and 1. Does the gas supply type match the specifications on the appliance identification plate? . yes: ↓2. no: B Convert appliance to correct gas type. ↓2. 2. 3. 4. B Test gas supply pressure - OK? Does pressure match figure specified in installation instructions? yes: ↓3.
Failure identification procedure Excessive burner noise, rumbling noises 7. Check Action B Press buttons and simultaneously. B Select service-function 5.9. 0 is displayed. B Set to 1 for high start-up speed. Flue gas levels incorrect, CO level too high Check 1. Does the gas supply type match the specifications on the appliance identification plate? Action yes: ↓2. no: B Convert appliance to correct gas type. ↓2. 2. 3. 4. 5. yes: ↓3. no: B Decommission appliance. B Notify gas company.
Failure identification procedure Ignition too harsh, ignition poor Check Action B Note the setting of the temperature controls and 1. 2. . B Press buttons and simultaneously. B Select service-function 5.1. Continuous ignition (without gas) OK? yes: ↓6. no: ↓2. Ignition lead connected to ignition electrodes? yes: ↓3. no: B Connect cable to ignition electrodes. B Press button . Ignition poor? ↓3. 3. Ignition cable connector engaged in switchbox? yes: ↓4. no: B Power OFF the appliance.
Failure identification procedure Ignition too harsh, ignition poor Check 6. 7. 8. 9. Action Does the gas supply type match the specifications on the appliance identification plate? yes: ↓7. no: B Carry out gas type conversion as described in installation instructions. B Test gas supply pressure - OK? yes: ↓8. no: B Decommission appliance. B Notify gas company. Problem with flue? B Check CO2 level in combustion air.
Failure identification procedure Loose or broken contact on heat store NTC sensor 1. Check Action Heat store NTC sensor lead is not fitted as described in the installation instructions (i.e. the cable does not pass through the cable grip in the switchbox). B Record condition of appliance as found in customer service record. B Route cable as specified in installation instructions. Boiler indicates P1, P2, P3 at start-up and then restarts with P1.. Check 1. Fuse T 1,6 A (312) defective.
Failure identification procedure Specified CH flow temperature from TA... programmer exceeded Check Action B Note the setting of the temperature controls and . If outside-temperature controlled programmer (TA...) is connected to boiler: • The anti-cycle time is adjusted by the programmer to the suit the system. • The factory setting for the anti-cycle time (3 min.) and the heating mode hysteresis setting, if applicable, are deactivated.
Failure identification procedure Condensation in the flue pipe 1. 3.4.2 Check Action Is diaphragm in mixer unit fitted correctly (see installation instructions)? B Open mixer unit (29). B Check diaphragm for correct orientation, soiling and splitting. B Fit diaphragm as per installation instructions or replace. B Close mixer unit. Programmer faults Set room temperature not reached (TR 2 and TR 212 E) Check 1. Thermostatic valve(s) set too low? Action yes: B Turn up thermostatic valve(s). ↓2.
Failure identification procedure Set room temperature not reached (TA 211 E und DT 2) Check 1. Thermostatic valve(s) set too low? Action yes: B Turn up thermostatic valve(s). ↓2. 2. Heating characteristic set too low? no: ↓2. yes: B Correct heating characteristic. ↓3. 3. 4. CH flow temperature control on boiler set too low? Is heat store temperature unreachable (CH flow temperature control set too low)? no: ↓3. yes: B Turn up CH flow temperature control. ↓4. no: ↓4.
Failure identification procedure Set room temperature exceeded by large amount Check 1. Do radiators get too hot? Action yes: TR 2: B Decrease setting of “Heating” control TA 211 E: B Correct heating characteristic. ↓2. 2. Bad choice of location for programmer, e.g. outside wall, near window, in draught, on hollow wall, etc. no: ↓2. yes: B Select better installation location. -orB Fit external room thermostat. ↓3. no: ↓3. B Turn down thermostatic valve(s). 3.
Failure identification procedure Temperature rises instead of falling Check Action Timer clock (DT 2) incorrectly set B Check setting and correct as necessary. Incorrect or no modulation Check Action Programmer incorrectly wired B Check wiring against wiring diagram and correct as necessary. 7 181 465 346 GB (03.
Appendix 4 Appendix 4.1 NTC values 4.1.1 Outside temperature sensor 4.1.
Appendix 4.2 Electronic schemes o - orange g - green bl - black r - red p - purple 33 365 364 61 317 366 363 367 ECO 4.1 25 V 153 230V/AC 230 V 310 136 135 312 328 302 313 151 318 315 124 789 L N Ns Ls LR 161 p p p 300 314 84 M 96 328.1 9 M mains supply 18 g 6 M g o r r o 226 52 52.1 56 o o bl bl bl bl 36 bl 6.1 32 6 720 610 576-08.2O 4.1 6 6.1 6.3 18 32 33 36 52 52.
Appendix 4.3 List of most important replacement parts Component Order no. Remarks Switchbox PCB control board 8 748 300 385 Transformer 8 747 201 358 Ignition lead 8 714 401 999 20-pin connector lead assembly 8 714 402 087 20-pin connector lead assembly 8 714 402 086 Fuse 1 904 552 730 T 0,5 A Fuse 1 904 552 740 T 1,6 A Fuse 1 904 521 342 T 2,5 A Set of fuses 8 744 503 010 Switchbox kpl. 8 717 207 514 with DT 2 Switchbox kpl. 8 717 207 513 without DT 2 Component Order no.
Appendix 4.4 Approved corrosion inhibitors and anti-freeze fluids for central heating water 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 substances will invalidate the guarantee. The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated. 4.4.
