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Summary of Contents for Bosch Condens 2000F30 Regular boiler
- Page 1 Floor-standing gas-fired condensing appliance Condens 2000F16, 30, 42 Regular boiler/3000F 16, 30 System boiler Installation, Commissioning and Servicing Instruction manual...
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Page 2: Table Of Contents
Contents Contents 7.5.1 Measuring the inlet pressure ....26 Key to symbols and safety precautions ....3 7.5.2 Checking the gas rate . -
Page 3: Key To Symbols And Safety Precautions
Key to symbols and safety precautions Please read these instructions carefully before starting installation. KEY TO SYMBOLS AND SAFETY PRECAUTIONS Ø Diameter Equal to or less than Key to symbols Equal to or greater than Warnings < Less than Warnings in this document are identified by a warning >... -
Page 4: Appliance Information
3-way valve for the connection of the hot • Galvanised steel inner frame water tank. • Bosch EMS control system • Automatic ignition KBR units, heat only, gas-fired condensing boilers without a circulating pump or optional three way valve, for use in systems where this is •... -
Page 5: Dimensions And Description
Appliance information | 5 Dimensions and description Ø80 Ø125 61 78 98 130 162 193 Fig. 2 Pipe work connector location Regular boiler: Hot water flow (1”) Gas (3/4”) [3*] Not used on the regular boiler Hot water return (1”) Condensate outlet 80/125 Flue outlet System boiler:... -
Page 6: Regular Boiler Layout And Components
6 | Appliance information Regular boiler layout and components Fig. 3 Component layout KBR Legend to figure 3: Flue connector [18] Manual vent ON/OFF switch [19] Pre-mix chamber Display [20] Spark generator Pressure gauge [21] Fan Combustion chamber cover mounting bracket x 4 [22] Combustion chamber cover Flame sense electrode Electrode assembly... -
Page 7: Regular Boiler Wiring Diagram
Appliance information | 7 Regular boiler wiring diagram Fig. 4 Appliance terminal connector block High limit thermostat Mains supply Flow temperature sensor Heat control module (HCM) Flue overheat thermostat Spark generator [10] Gas valve Spark electrodes [11] Fan Flame sense electrode Product Name 6 720 ... -
Page 8: Regular Boiler Technical Data
8 | Appliance information Regular boiler Technical data All the technical data quoted in the table below refer to an appliance tested at sea level. Power outputs are reduced due to altitude, refer to figures 5 and 6 for the percentage reduction power output due to altitude DESCRIPTION Units Natural Gas... -
Page 9: Gas Type And Installation Type
Appliance information | 9 2.10 Gas type and installation type Rated gas pressure (mbar) Factory setting (gas family, Factory setting rated Country Natural gas category gas group and test gas) gas pressure (mbar) Installation type Austria Cat II 2H 3P 23P, 13X, France... - Page 10 10 | Appliance information Output power reduce on LPG boilers due to altitude 100% 1000 1250 1500 1750 2000 2250 2500 2750 3000 A (Metres) 6720809859-76.1Wo Fig. 6 Output reduction due to altitude for LPG Pressure loss in the system versus system flow 1200 1500 1800...
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Page 11: System Boiler Layout And Components
Appliance information | 11 2.12 System boiler layout and components Fig. 8 Component layout KSBR Legend to figure 5: Flue connector [18] Gas valve ON/OFF switch [19] Flue overheat thermostat Display [20] Air Intake pipes (30 and 42kW boilers only) Pressure gauge [21] Manual vent Combustion chamber cover mounting bracket x 4... -
Page 12: System Boiler Wiring Diagram
12 | Appliance information 2.13 System boiler wiring diagram Fig. 9 Appliance terminal connector block Flow temperature sensor Mains electrical supply connector Diverter valve connection Heat control module (HCM) [10] Pump Spark generator [11] Flue overheat thermostat Spark electrodes [12] Gas valve Flame sense electrode [13] Fan High limit thermostat... -
Page 13: System Boiler Technical Data
Appliance information | 13 2.14 System boiler Technical data All the technical data quoted in the table below refer to an appliance tested at sea level. Power outputs are reduced due to altitude, refer to figures 5 and 6 for the percentage reduction in power output due to altitude DESCRIPTION Units Natural Gas... - Page 14 14 | Appliance information Pumphead versus Flow rate Pump (m wg) 1000 1500 2000 FR (l/hr) 6720809859-87.1Wo Fig. 10 [APH] Available pump head [FR] Flow rate Actual data Extrapolated data 6 720 ..(YYYY/MM) Product Name...
- Page 15 Appliance information | 15 2.15 Energy efficiency The following product data satisfy the requirements of the EU Regulations No. 811/2013, No. 812/2013, No. 813/2013 and No. 814/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7731600026 7731600027 7731600028 7731600029 7713600030 Product type –...
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Page 16: Regulations
16 | Regulations Room air dependent operation Regulations The boiler primarily operates as a “room air sealed” unit, however the boiler can be operated as a “room air dependant” unit, if required. The boiler is designed to operated in conformity with the following requirements: Provide sufficient boiler room ventilation when operating the appliance •... -
Page 17: Pre-Installation
Pre-installation | 17 Service interval Ø125 NOTICE: Damage to the system caused by a lack of or insufficient cleaning and servicing. ▶ Get the heating system inspected at least annually by an authorised heating engineer ▶ Carry out a service as required. Carry out any repairs immediately to avoid any damage to the system Pre-installation Cleaning primary systems... -
Page 18: Expansion Vessel And Drain Valve
18 | Pre-installation 4.2.2 Expansion vessel and drain valve Connect an expansion vessel EN12828 requires and expansion vessel to be installed with the boiler. ▶ Install an expansion vessel in the return to the pump Fill and drain connections EN1717 requires a filling of the heating system with drinking water only via a fixed connection between water supply and heating circuit. -
Page 19: Installation | 19
INSTALLATION | 19 NOTICE: Damage from overheating. INSTALLATION Excessive ambient temperatures may cause damage to the heating system. NOTICE: Boiler start up ▶ Ensure the ambient temperature is above 0 °C and ▶ All the previous Pre-Installation sections must be below 35 °C read and requirements met before starting boiler or flue installation. -
Page 20: Positioning The Appliance
20 | INSTALLATION 5.2.2 Positioning the appliance The boiler must be adjusted to be level. This ensures air can escape from the heat exchanger and condensate drains freely. NOTICE: Damage caused by insufficient load bearing or unsuitability of the boiler room floor ▶... -
Page 21: Flue Options
INSTALLATION | 21 Gas connections DANGER: Risk to life from explosion of flammable gases ▶ Work on components in contact with gas must only be carried out by a competent and authorised 120 mm person. ▶ Comply with national and local standards and regulations ▶... -
Page 22: Vertical Flues
22 | INSTALLATION Vertical flues Room sealed flues C33 and C93 Ø 80 Ø110 Ø 80 > 1m > 1m 6720809859-84.1Wo 6720809859-83.1Wo Fig. 20 C93 RSF flue Fig. 19 C33 RSF flue Boiler Equivalent Equivalent length output L max L1 max length 93 °... - Page 23 INSTALLATION | 23 Open flues B33 Ø 80 Ø 80 > 1m > 1m 6720809859-85.1Wo 6720809859-86.1Wo Fig. 21 Rigid B33 flue Fig. 22 Flexible B33 flue Boiler Equivalent Equivalent length output L max L1 max length 93 ° flue 15 ° and 45 ° flue (kW) (metres) (metres)
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Page 24: Electrical
24 | ELECTRICAL Access to electrical connections: ELECTRICAL ▶ Access to all wiring connections are via the Installer access cover at the bottom front of the control panel. No access is required to other DANGER: Risk of fire from hot boiler components. parts of the control board. -
Page 25: Commissioning
COMMISSIONING | 25 Cable retainer clamps COMMISSIONING ▶ Unclip the cable clamp [1}. ▶ Cut off the tapered cable entry [2] to suit the cable diameter. Pre-Commissioning checks CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. -
Page 26: Water Treatment
26 | COMMISSIONING Starting the appliance NOTICE: Damage to property from overpressure during pressure tests! Pressure, control and safety devices may be damaged by excessive pressure. ▶ After filling the system pressure test to the release pressure of the safety valve NOTICE: Damage caused by cracks from thermal shock! Cracks can occur when toping up a warm heating system with cold mains water. -
Page 27: Checking Gas Inlet Pressure
COMMISSIONING | 27 Setting the boiler to maximum output Gas type min.pressure (mbar) max. pressure (mbar) 3. Press the button together with the button to enter the “Chimney sweep mode” , the display shows the current flow temperature and flashes the percentage heat output in the alphanumeric display. - Page 28 28 | COMMISSIONING Commissioning Page Unit Values Comment Fill the heating system and check for leaks Record gas values kWh/m Wobbe index Calorific value Check gas supply for leaks Bleed gas supply Pressurise the heating system and record the value ...
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Page 29: Thermal Disinfection
THERMAL DISINFECTION | 29 THERMAL DISINFECTION Perform thermal disinfection General To prevent Legionella bacterial contamination of the hot water system, we recommend that a thermal disinfection is performed after a long period of inactivity. Some control systems have a preset programmed time interval for thermal disinfection to be performed, see the operating instructions for your control system. -
Page 30: Operating The Appliance
30 | Operating the appliance OPERATING THE APPLIANCE This manual only applies to the appliances listed on the front cover. Screen display Depending on the control system fitted some function may be different. The following option control systems can be used: •... -
Page 31: Heating Mode
Operating the appliance | 31 Switching the appliance off 9.4.2 Set the maximum flow temperature ▶ To switch off: use the main appliance on/off switch on the control The maximum flow temperature can be set between 30 °C and 82 °C panel. -
Page 32: Setting The Dhw
32 | Operating the appliance Setting the DHW 9.5.2 Setting the DHW temperature ▶ DHW or Eco mode, ( section 9.5). 9.5.1 DHW on/off – Press the button. ▶ Press the button repeatedly until the symbol or the The set DHW temperature flashes. flashing is displayed. -
Page 33: Summer Mode On/Off
Operating the appliance | 33 Summer mode ON/OFF In the Summer mode the heating is turned off but the power to the appliance and control system are maintained and the DHW mode is on. NOTICE: Risk of freezing. In summer mode only the frost protection devices are active. -
Page 34: Servicing And Spares
34 | Servicing and spares 10.2 Service function SERVICING AND SPARES The Service menu provides you with service functions for editing and testing of many of the appliance’s functions. CAUTION: Mains supplies: The service menu is divided into five sub-menus: ▶... -
Page 35: Selecting The Information Menu
Servicing and spares | 35 10.2.2 Selecting the Information menu ▶ Press the ok button to confirm your selection. The Information Menu is a “read only”menu. Information about the boiler ▶ Press the + or - buttons to scroll through the menu area. is displayed here, some of the values are updated in real time to give the Service function Possible settings... - Page 36 36 | Servicing and spares Service function Possible settings Service function Possible settings 2.1E Pump energy saving The pump is automatically adjusted by 2.2J Storage priority Possible settings: the control system. mode • 0: - Storage priority; the storage • 4: ON - heating systems with tank is heated to temperature first and then the boiler switches to weather-compensated modulate...
- Page 37 Servicing and spares | 37 Service function Possible settings Service function Possible settings 2.5F Service reminder When this function is set on the control 2.CE Circulation pump Active only with activated circulation system, this service is not displayed. starts pump (service function 2.CL). Possible settings are: This service feature allows you to set how often the circulation pump is...
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Page 38: Selecting Menu 3
38 | Servicing and spares 10.2.5 Selecting menu 3 Service functions Possible settings To display a service function in this menu: Pump test. The pump will run for a maximum of Press the button and the ok button simultaneously until in the text 45 seconds. -
Page 39: Service Inspection - Component Access
Servicing and spares | 39 – CO is less than 0.2% ▶ If the readings are outside these limits then this indicates that there is a problem with the flue system or combustion circuit, e.g. missing or dislodged seals 6720809859-23.1Wo Fig. -
Page 40: Fan Pressure Test
40 | Servicing and spares ▶ The pressure will read negative, refer to the chart in figure 56 below. minimum pressure maximum pressure Gas type (mbar) (mbar) FAN PRESSURE TEST Clean the Heat Ex. Heat Ex. ok NG Boilers - 5.2 16kW: - 5.3 30kW:... -
Page 41: Setting The Air/Gas Ratio
Servicing and spares | 41 ▶ Press the button together with the button to enter the 10.8 Setting the air/gas ratio “Chimney sweep mode” , the display shows the current flow If the CO maximum or minimum value are incorrect, the gas valve can be temperature and flashes the percentage heat output in the adjusted as follows: alphanumeric display. -
Page 42: Cleaning The Heat Exchanger
42 | Servicing and spares ▶ gas way for leaks or obstructions To clean the burner ▶ the condition of burner, WARNING: Burner After all checks have been and the CO is still out of tolerance then the ▶ Do not remove the burner unless a new gasket is gas valve must be replaced. - Page 43 Servicing and spares | 43 Fig. 62 Burner removal Clip Castellated nuts Washers/Springs Rear nut Spacer and washer Burner head Seal Rear stud [10] Burner [11] Front studs For sealed systems only: Electrical wiring ▶ Check the electrical wiring for physical damage and replace any damaged wires.
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Page 44: Inspection And Servicing Checklist
44 | Servicing and spares 10.10 Inspection and servicing checklist The inspection and maintenance records also serve as a master copy. ▶ Sign and date the completed inspection record. Inspection and servicing Page Full load Partial load Full load Partial load ... - Page 45 Servicing and spares | 45 If the inspection, a state is detected, the maintenance requires, these operations must be carried out as required. Full Load Partial load Full load Partial load Full load Partial load Full load Partial load ...
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Page 46: Demand Dependant Maintenance
46 | Servicing and spares 10.11 Demand dependant maintenance Page Date Date Turn off heating system Clean burner and heat exchanger Replace burner gasket Replace electrode set Clean condensate trap/siphon ... -
Page 47: Replacement Parts
REPLACEMENT PARTS | 47 REPLACEMENT PARTS 11.1 Replacement parts CAUTION: Mains supplies ▶ Turn off the gas supply and isolate the mains electrical supply before starting any work and observer all relevant safety precautions. ▶ Drain the boiler/system where necessary and protect any electrical equipment from water ingress during component replacement. -
Page 48: Fan Assembly
48 | REPLACEMENT PARTS Fuse ▶ Release the three screws [1] securing the installer cover. ▶ The spare fuse [2] is located in the inside of the right hand corner of the cover. ▶ The fuse holder [3] is located at the top left hand corner of the terminal block. -
Page 49: Sensors
REPLACEMENT PARTS | 49 11.1.3 Sensors 11.1.5 Gas Valve ▶ Check that the appliance is electrically isolated. ▶ Check that the gas cock is turned off. ▶ Remove the air intake pipes, if fitted, pull down from the mixer Flow temperature sensor [1]: assembly to remove. -
Page 50: Primary Heat Exchanger
50 | REPLACEMENT PARTS 11.1.6 Primary Heat Exchanger Electrode assembly: ▶ Switch off the master switch. ▶ Isolate the appliance from the power supply. ▶ Move the control panel into the service position, refer to section 10.4.1. ▶ Release the four screws to remove the inner case door. ▶... -
Page 51: Status Codes And Faults
FAULT FINDING AND DIAGNOSTICS | 51 WARNING: Scalding! FAULT FINDING AND DIAGNOSTICS Hot water can cause serious burns. 12.1 Status codes and faults ▶ Drain the appliance before working on water- The controller monitors all safety, regulation and control components. carrying parts. - Page 52 Self-test of flue gas supervision Return sensor shorted Code error Return sensor disconnected EMS communication error 242 to Internal error call Bosch technical help-line DHW-NTC defect DHW-NTC not correctly installed Internal error - replace control board Storage-NTC defect 258 &...
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Page 53: Selecting The Information Menu
FAULT FINDING AND DIAGNOSTICS | 53 12.3.1 Selecting the information menu Service functions Comments The Information Menu is a "read only" menu. Information about the boiler Ionisation current When the burner is running: is displayed here, some of the values are updated in real time to give the •... -
Page 54: Selecting Service Menus
54 | FAULT FINDING AND DIAGNOSTICS 12.3.2 Selecting service menus Service function Possible settings 1. Press and hold and ok buttons together for one second, the 1.W1 Weather compensation 0 = off, display will show Menu 1. 1 = on Double up or down arrows indicate that the menu can only be scrolled up 1.W2 Weather compensation, point A @ -10 °C °C (default 90 °C) -
Page 55: Reset To Factory Settings
FAULT FINDING AND DIAGNOSTICS | 55 12.3.5 Reset to factory settings Para Parameter Description Updated To reset any or all changes made in menu 2 back to the factory defaults value setting: 2.1A Maximum power Range rate the CH of the boiler. Adjustment in kW. -
Page 56: Using The Test Menu
56 | FAULT FINDING AND DIAGNOSTICS 12.3.7 Using the test menu This menu enables the testing of the functionality of components in an ON/OFF mode.The duration of each test is up to 60 seconds. 1. Select menu TEST via the plus and minus buttons. °C 2. - Page 57 FAULT FINDING AND DIAGNOSTICS | 57 Testing the component ▶ Select a component to test. ▶ Press the ok button, the value 0 will flash. ▶ Use the plus button to change the value to a flashing 1. °C ▶ Press ok to confirm the change, the value 1 will stop flashing and a will displayed for 3 seconds.
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Page 58: Fault Codes
58 | FAULT FINDING AND DIAGNOSTICS 12.4 FAULT CODES Should a fault develop with this boiler (or the system), the boiler will enter a locking or blocking condition, and fault code information will be generated as described in this section. Locking error The boiler display will flash a warning triangle and fault code. - Page 59 FAULT FINDING AND DIAGNOSTICS | 59 Fault Cause codes codes Description Reset type Possible cause 237 - 242 - Internal error Call your Technical help line Sensor test failed Reset button On power up all safety sensors are checked. Check has failed. Recycle time error Reset button After the burner has stopped, the recycle mode purges gas from the...
- Page 60 60 | FAULT FINDING AND DIAGNOSTICS 6 720 ..(YYYY/MM) Product Name...
- Page 61 FAULT FINDING AND DIAGNOSTICS | 61 Product Name 6 720 ..(YYYY/MM)
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