Related Manuals for Benchmark ZB 7-28 R 28 HE
Summary of Contents for Benchmark ZB 7-28 R 28 HE
-
Page 1: Installation And Servicing Instructions
Installation and Servicing Instructions R 28 HE system Wall mounted condensing boiler for central heating 6 720 611 441-00.1O ZB 7-28 R 28 HE System GC Number: 41 311 62 GB/IE... -
Page 2: Table Of Contents
Contents Contents Safety precautions Individual settings Mechanical settings 6.1.1 Checking the size of the expansion vessel Symbols 6.1.2 Setting the central heating flow temperature 27 6.1.3 Changing the heating pump characteristic Settings on the Bosch Heatronic Details of the appliance 6.2.1 Operating the Bosch Heatronic EC Declaration of Conformity 6.2.2 Selecting the pump control mode for central... -
Page 3: Safety Precautions
Safety precautions Safety precautions EIRE ONLY The CE mark to indicates manufacture to EU safety requirements. If you smell gas This appliance must be installed only by a competent B Turn off gas service cock at the meter. person to the requirements of IS 813. B Open windows and doors. -
Page 4: Details Of The Appliance
Details of the appliance Details of the appliance Description of appliance • Wall-mounted appliance, siting not dependent on room size EC Declaration of Conformity • Natural gas models are low-emission appliances This appliance is in accordance with the applicable • Multi function display requirements of the Gas Appliance Directive, Boiler Effi- ciency Directive, Electromagnetic Compatibility Direc- •... -
Page 5: Accessories
Details of the appliance Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues up to 4 m in length. • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths up to 13 m and vertical flue systems for flue lengths up to 15 m. -
Page 6: Layout Of Appliance
Details of the appliance Layout of appliance 221.1 221.2 32.1 18.1 6 720 611 443-01.1O Fig. 2 Heatronic control 221.1 Flue duct Heat exchanger safety temperature limiter 221.2 Combustion air intake Testing point for gas supply pressure Fan assembly Pressure gauge Appliance type sticker Flue gas temperature limiter Flue duct... -
Page 7: Function (With Optional Extra Motorised Valve)
Details of the appliance Function (with optional extra motorised valve) 6 720 611 443 -02.1O Fig. 3 Bosch Heatronic control Storage water heater outflow (only with optional motorised Temperature limiter, heat exchanger valve) Testing point for gas supply pressure Storage water heater return (only with optional motorised Pressure gauge valve) Flue gas temperature limiter... -
Page 8: Electrical Wiring Diagram
Details of the appliance Electrical wiring diagram o - orange bl - black r - red 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 601-02.2O Fig. 4 Ignition transformer “Chimney sweep” button Temperature limiter, heat exchanger Service button Flue gas temperature limiter... -
Page 9: Technical Data
Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30°C central heating 29.3 29.3 Max. rated heat output net 50/30°C central heating 29.0 29.0 Max. rated heat output net 80/60°C central heating 27.4 27.4 Max. -
Page 10: Installation Regulations
Installation regulations Condensate analysis, mg/l Gas supply Ammonium 1.2 Nickel 0.15 Total length of gas supply pipe Pipe diameter ≤ 0.01 Mercury ≤ 0.0001 (metres) (mm) Lead ≤ 0.001 Sulphate Cadmium ≤ 0.005 Zinc ≤ 0.015 Chromium Gas discharge rate (m ≤... -
Page 11: Installation
Installation Installation Sealed systems The appliance must not be operated without the system B Always turn off the gas cock before car- being full of water, properly vented and pressurised. rying out any work on components The expansion vessel has a volume of 10 litres and is which carry gas. - Page 12 Installation Note: INDIRECT A drain cock CYLINDER should be fitted at the lowest point of the heating circuit and beneath APPLIANCE the appliance Refer to Appliance Water Flow Diagram Radiator Valve - Flow Safety Discharge Lockshield Valve - Return LV Hot Water Flow Mains Cold Water Stop Valve Fixed Cylinder Type...
-
Page 13: Siting The Appliance
Installation Note: INDIRECT A drain cock CYLINDER should be fitted at the lowest point of the heating circuit and beneath APPLIANCE the appliance Refer to Appliance Water Flow Diagram Radiator Valve - Flow Safety Discharge Lockshield Valve - Return LV DHW Zone Valve Zone Mains Cold Water... -
Page 14: Wall Mounting Frame Assembly
Installation B Screw the pre-plumbing manifold with two screws to Wall mounting frame assembly the wall mounting frame. 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 sec- tions. -
Page 15: Fitting The Appliance
Ø 22 min. No length below ground but restriction above water level Benchmark: For optimum performance after installation, this boiler and its asso- The gradient of the discharge pipe The gradient of the discharge pipe Invert should be 2.5° (40 mm/m) minimum should be 2.5°... -
Page 16: Checking The Connections
Installation Fixing the appliance Checking the connections B Fit the washers onto the gas and water connections. Water connections B Lift the boiler onto the wall-mounting frame. The lugs B Check that the O-rings or seals are in place before pass through the rectangular holes in the boiler back tightening the connection. -
Page 17: Siting The Flue Terminal
Installation 3.8.1 Siting the Flue Terminal lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which The flue must be installed in accordance with people have access then a guard must be fitted. The BS 5440:1 and the Building Regulations. -
Page 18: Installation Of The Flue
Installation 3.8.2 Installation of the flue The standard 100 mm diameter horizontal flue system is Outer suitable for lengths up to 4 m. Flue Maximum 730mm Wall Turret Flues up to 730 mm do not require an extension duct Minimum 480mm assembly. - Page 19 Installation Maximum 1700mm Outer Wall Flue Turret Extension Terminal Clamp Duct Assembly 6 720 611 400-19.1O Fig. 20 Flue with one extension Outer Flue Wall Turret Extension Extension Terminal Clamp Clamp Clamp Duct Duct Assembly 6 720 611 400-20.1O Fig. 21 Flue with extensions Flue Turret Clamp...
-
Page 20: Flue Duct Preparation And Assembly
Installation 3.8.3 Flue duct preparation and assembly Outer Wall Face Measure the flue length L. Refer to fig. 23, 24. Flue Terminal Wall Sealing Gasket 6 720 611 400-22.1O Fig. 23 Flue length - rear 6 720 611 400-24.1O Fig. 25 Flue terminal position Assemble flue system completely. -
Page 21: Electrical Connections
Electrical connections B Pull out cover panel at the bottom and remove. Refer Electrical connections to fig. 27. B Always disconnect the power supply to the appliance at the mains before carry- ing out any work on the electrical sys- tems and components. -
Page 22: Wiring To Your System
Electrical connections B Secure cable in cable grommet by means of cable ZONE VALVE ZONE VALVE grip. BLUE N N L MOTOR MOTOR G/YELLOW ROOM STAT. CYLINDER 2 1 3 STAT. TIME CONTROLLER Fig. 30 HW HTG Wiring to your system The boiler is fitted with an internal pump and there are two recommended ways of connecting a system, exter- nal 230v or internal 24v depending on the choice of... -
Page 23: Internal 24V
Electrical connections 4.2.2 Internal 24v BLUE Non-supplied Worcester Bosch parts required: POSITION G/YELLOW WHITE ZONE VALVE Description Part Number 24v Diverter valve (including 7 719 002 090 tank NTC) ROOM STAT. CYLINDER STAT. N L SW TR2 room thermostat 7 774 901 137 Night set back module 7 744 901 136 Twin channel programmer... -
Page 24: Commissioning
Appliance type sticker Temperature control for hot water Multi function display Benchmark Water Treatment: For optimum perform- Condensate trap ance after installation, this boiler and its associated cen- Indicator lamp for burner tral heating system should be flushed in accordance... -
Page 25: Switching The Appliance On/Off
Commissioning B Before commissioning, the gas supply pres- Switching off the appliance sure must be checked at the gas supply pres- B Set the master switch to (0). sure test point (see page 6, fig. 2, item 7). The green indicator lamp goes out. Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or B Always disconnect the appliance from... -
Page 26: Appliances With Optional Plug-In Diverter Valve: Setting Hot Water Temperature
Commissioning Appliances with optional plug-in Frost protection diverter valve: Setting hot water The appliance has an in-built frost protection device temperature which is generally suitable for most applications. B Leave master switch switched on. B Do not set the temperature higher than 60°C for normal operation. -
Page 27: Individual Settings
Individual settings Individual settings B Rotate yellow button through 180° and replace (dot Mechanical settings facing inwards). 6.1.1 Checking the size of the expansion vessel The CH flow temperature is no longer limited. Maximum pressure at maximum CH flow temperature is Control setting CH flow temperature 2.5 bar. -
Page 28: Settings On The Bosch Heatronic
Individual settings Settings on the Bosch Heatronic Entering a setting B To enter the setting for a function, turn the tempera- 6.2.1 Operating the Bosch Heatronic ture control The Bosch Heatronic enables easy setting and check- ing of a large number of appliance functions. Storing a setting This description is limited to those functions required B Level 1: press and hold the... -
Page 29: Setting The Switching Difference (Service Function 2.6)
Individual settings B Press and hold the 6.2.5 Setting the switching difference buttons simultane- (Service Function 2.6) ously until the display shows [ ]. The heating output is now stored. If the appliance is connected to an out- side-temperature controlled programmer, the programmer sets the switching differ- ence. -
Page 30: Converting The Appliance To Different Gas Types
Converting the appliance to different gas types Converting the appliance to different gas types Setting the gas/air ratio The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not neces- The gas/air ratio may only be adjusted on the sary. - Page 31 Converting the appliance to different gas types B Turn the temperature control B Remove the seal from the gas valve adjusting until the display shows 2. (= max. rated heat output). screw (64) and adjust the CO level to the figure The display and the button will flash.
-
Page 32: Testing Combustion Air/Flue Gas At Set Heat Output
Converting the appliance to different gas types Testing combustion air/flue gas at set heat output 7.2.1 Testing the O or CO level in the combus- 7.2.2 Testing CO and CO tion air B Press and hold the button until the display By testing the O or CO level in the com-... -
Page 33: Maintenance
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 car- rying out any work on components which carry gas. -
Page 34: Pre-Service Check List
Maintenance Pre-Service Check List Date Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 35). Check ionisation current, Service Function 3.3, (see page 35). Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 37). -
Page 35: Description Of Servicing Operations
Maintenance B Remove the fan and the burner as described in the Description of servicing operations text headed “Burner” (see page 36). The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.1. Check “Last fault stored”: B Select Service Function .0 (see page 28 “Selecting service function”). - Page 36 Maintenance B Clean out the condensate collector and trap connec- tion (with other end of brush). 6 720 610 332-75.2R Fig. 55 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 7 181 465 330-08.2R...
- Page 37 Maintenance Diaphragm in mixer unit Siphon B Unscrew the clip and disconnect the pipe to the B Take care not to damage diaphragm siphon. (443) when removing and refitting it. B Remove the drain plug to drain the siphon. B Unscrew the securing nut from beneath the side B Open mixer unit (29).
-
Page 38: Replacement Of Parts
Maintenance 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. -
Page 39: Fan Assembly
Maintenance 8.3.2 Fan Assembly 8.3.3 Pump B Switch off the appliance. B Disconnect appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to fig. 63. B Lower switchbox (2.). B Unscrew and remove the siphon by releasing the jubilee clip. -
Page 40: 3-Way Diverter Valve Motor
Maintenance B Remove 3-way valve. 8.3.7 Gas Valve B Check that the gas cock is turned off. B Lower the control panel. Refer to fig. 63. B Pull off the solenoid connections at the rear of the valve. B Undo the union, within the inner casing, securing the valve to the gas/air tube. -
Page 41: Pressure Gauge
Maintenance B Ensure that all the seals are in place and all of the 8.3.9 Pressure gauge connections are tight before re-commissioning the B Drain the appliance. appliance. B Lower the facia. Refer to fig. 63. B Twist the pressure gauge head anti-clockwise to release it from the casing. -
Page 42: Appendix
Appendix Appendix 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 Break in communication Check connecting lead to programmer Module not detected. Check connecting lead between TA211E/TR212E and Heatronic Code plug not detected. -
Page 43: Short Parts List
Appendix Short parts list Description Qty GC Spare part number Sensor - Flue gas temp. 8 722 963 858 0 Sensor - CH flow temp. 8 714 500 087 0 Control board 8 748 300 395 0 Gas valve 8 747 003 508 0 Fan assembly 8 717 204 373 0 Fan washer... - Page 44 Over temperature Burner remains OFF Gas valve shuts. shut down if water until flow temperature Pump remains ON. temperature is 5∞C is below set value. above set value. Room thermostat Boiler and/or mains operates to programmer or Burner Fan speed Fan min.
- Page 45 Appendix 6 720 611 443 GB (05.04)
- Page 46 Appendix 6 720 611 443 GB (05.04)
- Page 47 Appendix 6 720 611 443 GB (05.04)
- Page 48 Appendix Appendix Worcester, Bosch Group Cotswold W ay, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd.
Need help?
Do you have a question about the ZB 7-28 R 28 HE and is the answer not in the manual?
Questions and answers