Benchmark RD 532 combi Installation And Servicing
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Benchmark RD 532 combi Installation And Servicing

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Installation and Servicing Instructions
RD 532 combi
Wall mounted condensing boiler for central heating and mains
fed domestic hot water
6 720 610 577-01.10
ZWB 7-32 RD 532
GC-Number: 41 108 13

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  • Page 1 Installation and Servicing Instructions RD 532 combi Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 577-01.10 ZWB 7-32 RD 532 GC-Number: 41 108 13...

  • Page 2: Table Of Contents

    Contents Contents Mechanical settings 6.1.1 Checking the size of the expansion vessel 6.1.2 Setting the central heating flow temperature 28 6.1.3 Changing the heating pump characteristic Safety precautions Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic 6.2.2 Setting the anti-cycle time Symbols (Service Function 2.4) 6.2.3 Setting the maximum CH flow temperature...

  • Page 3: Safety Precautions

    Safety precautions Unpacking Safety precautions IMPORTANT HANDLING INSTRUCTIONS If you smell gas B Two people should transfer the packaged appliance B Turn off gas service cock at the meter. from the van to the point of installation B Open windows and doors. B Open the top of the carton, remove and place the B Do not operate any electrical switches.

  • 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 • Night Set Back module • TR2 room controllers. • Standard horizontal flue kit at 100 mm outside diameter for flues up to 4 m in length. NOTE: Where a timer, other than the Twin Channel Dig- ital, is used, the Hot Water Pre-Heat facility can only be •...

  • Page 6: Layout Of Appliance

    Details of the appliance Layout of appliance 221.1 221.2 32.1 18.1 6 720 610 599-00.TD Fig. 2 Heatronic control Inspection window Heat exchanger safety temperature limiter Fixing points Hot water NTC sensor 221.1 Flue duct Testing point for gas supply pressure 221.2 Combustion air intake Pressure gauge Fan assembly...

  • Page 7: Function

    Details of the appliance Function ϑ 29.1 52.1 66.1 ϑ 6 720 610 599-08.2O Fig. 3 Bosch Heatronic control Adjustable gas flow restrictor Temperature limiter, heat exchanger Adjusting screw for min. gas inlet flow volume Hot water NTC sensor Control valve Testing point for gas supply pressure Motor Pressure gauge...

  • Page 8: Electrical Wiring Diagram

    Details of the appliance Electrical wiring diagram o - orange g - green bl - black r - red p - purple 25 V 230 V 230V/ 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 599-07.2O Fig.

  • Page 9: Technical Data

    Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30°C central heating 34.3 34.3 Max. rated heat output net 50/30°C central heating 34.0 34.0 Max. rated heat output net 80/60°C central heating 32.2 32.3 Max.
  • Page 10 Details of the appliance Condensate analysis, mg/l Gas supply Ammonium Nickel 0.15 Total length of gas supply pipe Pipe diameter ≤ 0.01 ≤ 0.0001 (metres) (mm) Lead Mercury ≤ 0.001 Cadmium Sulphate ≤ 0.005 ≤ 0.015 Chromium Zinc Gas discharge rate (m ≤...

  • Page 11: Installation Regulations

    Installation regulations Installation regulations Gas Safety (Installation & Use) Regulations 1998: All gas appliances must be installed by a competent per- son. Failure to install correctly could lead to prosecu- tion. The manufacturers notes must not be taken, in any way, as overriding statutory obligations.

  • Page 12: Installation

    Installation Installation A water flow rate of 11.7 l/min will give a temperature rise of 40°C. If a higher rise is required then the flow must be reduced at the tap and the discharge tempera- B Always turn off the gas cock before car- ture will rise up to the maximum set figure.

  • Page 13: Siting The Appliance

    Installation The water capacity of the system is shown in table 12, return as close to the appliance as possible. The system page 28. If a greater capacity is required then an addi- pressure can be set up to a maximum of 1.5 bar with 1 tional expansion vessel must be fitted into the system bar being the normal setting.

  • 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. 7. Use the inner lugs on the top and bottom horizontal sec- tions.

  • Page 15: Fitting The Appliance

    75 min. trap below ground but 75 min. trap 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 3.9.1 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 3.9.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths up to 4 m. Flues up to 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm require exten- sion duct assemblies.

  • Page 19: Flue Duct Preparation And Assembly

    Installation Maximum 1600mm Outer Wall Flue Turret Extension Terminal Clamp Duct Assembly 6 720 610 599 - 00.TD Fig. 18 Flue with one extension Outer Flue Wall Turret Extension Extension Terminal Clamp Clamp Clamp Duct Duct Assembly 6 720 610 599 - 01.TD Fig.
  • Page 20 Installation Outer Wall Face Flue Terminal Wall Sealing Gasket 6 720 610 599 - 01.TD 6 720 610 599-00.TD Fig. 21 Flue length - rear Fig. 23 Flue terminal position Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must face downwards.

  • Page 21: Electrical Connections

    Electrical connections B Remove screw and slide terminal cover forwards to Electrical connections remove. Refer to fig. 26. 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: Mains Voltage External Controls Connections

    Electrical connections Mains Voltage external controls connections NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Rem ove Link Motor 230 V Room Thermostat Connections 230 V Pr ogrammer Connections Ns Ls L External wiring Switched Live and connector...

  • Page 23: 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 24: Switching The Appliance On/Off

    Commissioning Instructions for use are supplied with the these that reason, the appliance remains at minimum heating products. output for 15 minutes. 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).

  • Page 25: Setting The Domestic Hot Water Temperature And Flow Rate

    Commissioning B To reduce the flow rate (min. 8 l/min): Setting the domestic hot water turn screw on flow switch clockwise (–). temperature and flow rate The outlet temperature will increase relative to the 5.5.1 Domestic hot water temperature decrease in the flow rate. The hot water temperature can be set to between approx.

  • Page 26: Fault Condition

    Commissioning Fault Condition A list of faults that may occur is given on page 44. In the unlikely event of a fault occurring while the appli- ance is in operation: The display then shows a fault code and the button may also flash.

  • Page 27: 5.10 Appliance Data Monitoring

    Commissioning 5.10 Appliance Data Monitoring 8. Make the jumper JP1 on the ADM while powering up the appliance, see Fig. 36. If an external Gateway module is fitted then the Observe LED on ADM flashing. The flashing rate is operating system must be commissioned at this 0.5 Hz, the ADM is now in “House Address Acquisi- stage.

  • Page 28: Individual Settings

    Individual settings B Rotate yellow button through 180° and replace (dot Individual settings facing inwards). The CH flow temperature is no longer limited. Mechanical settings Control setting CH flow temperature 6.1.1 Checking the size of the expansion vessel approx. 35°C Maximum pressure at maximum CH flow temperature is approx.

  • Page 29: 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 30: Constant Hot Water Cycle Time (Service Function 6.8)

    Individual settings B Press and hold the buttons simultane- you to set the minimum period between switching off ously until the display shows = =. and on again. This function has no effect on normal buttons will light up. demand for hot water and relates only to the constant hot water function in Comfort mode.

  • Page 31: Converting The Appliance To Different Gas Types

    Converting the appliance to different gas types Converting the appliance to Setting the gas/air ratio The gas/air ratio may only be adjusted on the different gas types basis of a CO measurement at max. heat output and min. heat output using an electronic tester. The setting is factory sealed at maximum.
  • Page 32 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 33: Testing Combustion Air/Flue Gas At Set Heat Output

    Converting the appliance to different gas types Testing combustion air/flue gas at You have 15 minutes in which to measure set heat output the levels. After that, the appliance switch- es back from “chimney sweep” mode to 7.2.1 Testing the O or CO level in the combus- normal mode.

  • Page 34: 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 35: 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 36). Check ionisation current, Service Function 3.3, (see page 36). Perform visual check of air/flue duct. Visual check of diaphragm for soiling and splits (see page 38).

  • Page 36: Description Of Servicing Operations

    Maintenance Description of servicing operations Primary Heat exchanger There is a special accessory kit (no. 840) for cleaning The combustion performance must be checked before the heat exchanger, order no. 7 719 001 996. and after any servicing work on the combustion and burner components.
  • Page 37 Maintenance B Loosen any deposits in the heat exchanger from top Burner to bottom using the cleaning blade. Refer to fig. 54. 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).
  • Page 38 Maintenance B Clean the electrodes with a non-metallic brush. (The Diaphragm in mixer unit spark gap should be 4,5 mm ± 0,5 mm.) B Take care not to damage diaphragm B Replace and re-connect the assembly taking care not (443) when removing and refitting it. to mislay the inspection window.

  • Page 39: Replacement Of Parts

    Maintenance B Remove the pcb control board. Electrical wiring B Check the electrical wiring for physical damage and replace any damaged wires. 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.

  • Page 40: Fan Assembly

    Maintenance 8.3.2 Fan Assembly 8.3.3 Pump B Switch off the appliance. B Disconnect the appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to fig. 64. B Lower switchbox (2.). B Unscrew and remove the the siphon by releasing the jubilee clip.

  • Page 41: Diverter Valve

    Maintenance 8.3.4 Diverter valve 8.3.6 Sensors B Switch off the appliance. B Check that the appliance is electrically isolated. B Disconnect appliance from the power supply. Central Heating Flow Temperature Sensor – B Turn off service cocks. Item 36, fig. 2, 61 B Unplug connector from 3-way valve motor.

  • Page 42: Gas Valve

    Maintenance 8.3.7 Gas Valve 8.3.8 Domestic Hot Water Heat Exchanger B Check that the gas cock is turned off. B Refer to section 8.2. B Lower the control panel. Refer to fig. 64. B Use new seals when fitting the new heat exchanger. B Pull off the solenoid connections at the rear of the 8.3.9 Electrode assembly...

  • Page 43: 14Flow Switch

    Maintenance B Transfer components, as necessary, to the new heat 8.3.14 Flow switch exchanger. B Shut the mains water inlet valve and drain the domes- B Ensure that all the seals are in place and all of the tic hot water circuit. connections are tight before re-commissioning the B Pull-off the connectors from the micro-switch.

  • Page 44: 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 Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for circuit breaks/short circuits.

  • Page 45: 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 Sensor - DHW flow temp. 8 714 500 054 0 Control board 8 748 300 495 0 Gas valve...

  • Page 46: Heating/Hot Water Output Settings (N.g)

    Appendix Heating/hot water output settings (N.G) Natural gas G20 Display Heat Heat Gas vol. flow rate code output kW input kW (l/min at t 80/60°C) 15.5 11.7 11.8 20.7 14.6 14.8 25.8 17.5 17.7 31.0 20.4 20.7 36.1 23.4 23.6 41.3 26.3 26.6...

  • Page 47: Operational Flow Diagrams

    Appendix Operational Flow diagrams 9.5.1 Domestic hot water function Fig. 69 6 720 611 451 GB (03.11)

  • Page 48: Central Heating Function

    Appendix Appendix 9.5.2 Central heating function EXCELLENCE COMES AS STANDARD Manufactured exclusively for British Gas by The Bosch Group Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619 Fig. 70...
  • Page 49 Appendix 6 720 611 451 GB (03.11)
  • Page 50 Appendix 6 720 611 451 GB (03.11)
  • Page 51 Appendix 6 720 611 451 GB (03.11)
  • Page 52 Appendix 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. Telephone: (01905) 754624 Fax: (01905) 754619...
  • Page 53 Users Instructions and Customer Care Guide RD 532 Condensing boiler RD 428 Condensing boiler 6 720 610 577-01.10 ZWB 7-32 RD 532 GC-Number: 41 108 13 ZB 7-28 RD 428 GC-Number: 41 108 07...
  • Page 54 Contents Contents Excellence comes as standard Safety precautions General notes Controls Operating the Appliance Preparation Switching the Appliance On/Off Switching on the Central Heating Controlling Central Heating RD 532 Boilers: Setting the Hot Water Temperature Summer Mode, Hot Water Only (RD 532 Appliances) Frost protection (RD 532 Appliances) Fault Condition...
  • Page 55 Contents Fault or breakdown Your Bosch guarantee Guarantee registration Operating Instructions Quick Reference 6 720 610 600 GB (03.06)

  • Page 56: Excellence Comes As Standard

    British Gas/Scottish Gas Condensing appli- ance. Benchmark The “Benchmark” initiative is the new code of practice to encour- age the correct installation, commissioning and servicing of domestic central heating boilers and system equipment.

  • Page 57: Safety Precautions

    Safety precautions Safety precautions Gas Safety (Installation and Use) Regulations 1998 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 inter- est, and that of safety, to ensure compliance with the law.

  • Page 58: General Notes

    General notes Combustible materials B Do not store or use any combustible materials (paper, thin- ners, paints etc.) in the vicinity of the appliance. Health and safety B This appliance contains no asbestos products. B There is no potential hazard due to the appliance being electri- cally unsafe.
  • Page 59 General notes Repeated venting will reduce the quantity of water in the system and this must be replenished for safe and satisfactory operation of the appliance. Should water leaks be found in the system or excessive venting is required then a service engineer must be contacted to inspect the installation and rectify any fault.
  • Page 60 General notes Thermostatic radiator valves It is recommended that this type of valve is fitted to all the radiators except one, usually radiator where the room thermostat is fitted. They should conform to the requirements of BS2767:10. Showers, bidets, taps and mixing valves – RD 532 Boilers Standard hot and cold taps and mixing valves must be suitable for operating at mains pressure.
  • Page 61 General notes Alternatively the maximum temperature of the domestic hot water may be reset to about 45 °C which will reduce the risk of scale formation in these hard water areas. Ventilation This is a room sealed appliance and does not require any air for combustion from inside the house.

  • Page 62: Controls

    Controls Controls 317 366 367 310 422 6 720 610 600-01.1O System Pressure gauge Reset button Master switch Central heating temperature control Service valves in CH flow and return Hot water Gas isolation valve (open) Cold water inlet Identification sticker Hot water temperature control (RD 532) Display Indicator lamp for “burner on”...

  • Page 63: Operating The Appliance

    Operating the Appliance Operating the Appliance 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).
  • Page 64 Operating the Appliance Cold water inlet valve (173) B Turn handle so that it is in line with direction of flow. When handle is at right angles to direction of flow, the valve is closed. 6 720 610 577-02.1O Check the central heating system pressure B The pointer on the pressure gauge (8.1) should be about 1 bar.
  • Page 65 Operating the Appliance B The maximum operating pressure of 2.5 bar at maximum central heating flow temperature must not be exceeded. If the pressure increases to 3 bar then the relief valve (15) opens. 6 720 610 600-03.1O 6 720 610 600 GB (03.06)

  • Page 66: Switching The Appliance On/Off

    Operating the Appliance 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 central heating flow temperature, when the appliance is oper- ating in the central heating mode. 6 720 610 333-04.1O If the display alternates between -II-...

  • Page 67: Switching On The Central Heating

    Operating the Appliance Switching on the Central Heating B Turn the central heating 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. 6 720 610 333-05.1O Controlling Central Heating B Set room thermostat to the desired room temperature.
  • Page 68 Operating the Appliance 6 720 610 333-07.1O Control Setting Water Temperature Anti-clockwise limit approx. 40°C approx. 55°C Clockwise limit approx. 60°C Table 2 “ECO” button By pressing and holding the “ECO” button , until the display lights, you can switch between Comfort mode and Economy mode.

  • Page 69: Summer Mode, Hot Water Only (Rd 532 Appliances)

    Operating the Appliance Summer Mode, Hot Water Only (RD 532 Appliances) With room thermostat B Turn temperature control on the appliance anti-clockwise as far as the stop. The central heating is now turned off. The hot water function and the mains power supply for the heating programmer and timer remain switched on.

  • Page 70: Frost Protection (Rd 532 Appliances)

    Operating the Appliance Frost protection (RD 532 Appliances) 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 heat- ing system.

  • Page 71: Tips On Saving Energy

    Tips on saving energy 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 con-trolled according to the level of demand for heat.
  • Page 72 Tips on saving energy Hot water A lower setting on the hot water temperature control can result in considerable energy savings. For RD 532 appliances: The on-demand activation using the ECO-button makes possi- ble the maximum savings of gas and water. Now you know how to heat your home economically with the RD 532/RD 428 gas condensing boiler.

  • Page 73: General Information

    The information is printed on the appliance identification plate/ sticker (see page 10, item 295). Your installer will have completed the Benchmark “log-book” giv- ing details of the boiler together with name, address and registra- tion number. Have the “log-book” to hand when calling a Service Engineer.

  • Page 74: Service

    Service Service If your RD 532/RD 428 appliance should fail to operate correctly or requires servicing please call British Gas on: 0845 9 60 50 40. 6 720 610 600 GB (03.06)
  • Page 75 Fault or breakdown 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.
  • Page 76 Your guarantee Your guarantee This appliance is guaranteed against faulty material or workman- ship for a period of 24 calendar months from the date of installa- tion 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 manufac- ture will be exchanged or repaired free of material charges and free of labour charges by Worcester Heat Systems Limited.
  • Page 77 Serial number:..................(See identity label inside appliance casing) Type/size:....................Date of installation:................Check that the Benchmark “log-book” has been completed by your installer or service engineer. EXCELLENCE COMES AS STANDARD Manufactured exclusively for British Gas by The Bosch Group Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.
  • Page 78 Guarantee registration Notice 6 720 610 600 GB (03.06)
  • Page 80 EXCELLENCE COMES AS STANDARD Manufactured exclusively for British Gas by The Bosch Group Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619...

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Zwb 7-32 rd 532

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