Related Manuals for Bosch WORCESTER GREENSTAR HE ZB 7-27
Summary of Contents for Bosch WORCESTER GREENSTAR HE ZB 7-27
- Page 1 Installation and Servicing Instructions GREENSTAR HE system Wall mounted condensing boiler for central heating 6 720 610 577-00.10 ZB 7-27 HE system GC-Number: 41 311 49...
-
Page 2: Table Of Contents
Symbols 6.1.2 Setting the central heating flow temperature 26 6.1.3 Changing the heating pump characteristic Details of the appliance Settings on the Bosch Heatronic EC Declaration of Conformity 6.2.1 Operating the Bosch Heatronic Standard package 6.2.2 Selecting the pump control mode for Description of appliance central heating mode (Service Function 2.2) 27... -
Page 3: Safety Precautions
Safety precautions Safety precautions Symbols Safety instructions in this document If you smell gas are identified by a warning-triangle sym- y Turn off gas service cock at the meter. bol and are printed on a grey back- y Open windows and doors. ground. -
Page 4: Details Of The Appliance
• Bosch Heatronic control system • Automatic ignition Category • Modulating control 2H 3P • Full safety systems incorporating Bosch Heatronic Appliance Type with flame ionisation monitoring, solenoid valves and Table 1 temperature sensors • Concentric flue/air duct with testing point for Standard package •... -
Page 6: Layout Of Appliance
Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 18.1 6 720 610 596-01.1O Fig. 2 Heatronic control 221.2 Combustion air intake Heat exchanger safety temperature limiter Fan assembly Testing point for gas supply pressure Appliance type sticker Pressure gauge Testing point for combustion products Flue gas temperature limiter... -
Page 7: Function
Function 234.1 ϑ 29.1 52.1 6 720 610 596-02.1O Fig. 3 Bosch Heatronic control Adjusting screw for min. gas inlet flow volume Temperature limiter, heat exchanger Control valve Testing point for gas supply pressure Flue duct Pressure gauge 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 6 720 610 601-02.1O Fig. 4 Ignition transformer Link Temperature limiter, heat exchanger Flue gas temperature limiter Code plug... -
Page 9: Technical Data
Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30 °C central heating 29.1 29.1 Max. rated heat output net 50/30 °C central heating 28.8 28.8 Max. rated heat output net 80/60 °C central heating 27.2 27.2 Max. - Page 10 Details of the appliance Condensate analysis, mg/l VERTICAL 125 mm FLUE SYSTEM Ammonium 1.2 Nickel 0.15 Lead ≤ 0.01 Mercury ≤ 0.0001 Overall Diameter of Duct Cadmium ≤ 0.001 Sulphate 1 Flue Terminal / Duct Assembly 1360 Chromium ≤ 0.005 Zinc ≤...
-
Page 11: Installation Regulations
Installation regulations Installation regulations Installation Gas Safety (Installation & Use) Regulations 1998: All y Always turn off the gas cock before car- gas appliances must be installed by a competent per- rying out any work on components son. Failure to install correctly could lead to prosecu- which carry gas. -
Page 12: Siting The Appliance
Installation Repeated venting probably indicates a leak and this system water must be less than 8 or the must be rectified to ensure the proper operation of the appliance guarantee will be invalidated. appliance. A drain cock to BS2879 must be fitted to the lowest No galvanised radiators or pipes must be used. -
Page 13: Wall Mounting Frame Assembly
Installation Cupboard/Compartment y Screw the pre-plumbing manifold with two screws to the wall mounting frame. The appliance can be installed in a cupboard/compart- ment need for airing clothes providing that the require- ments of BS6798 and BS5440:2 are followed. The low casing losses from the appliance eliminate the need for ventilation openings in the compartment. -
Page 14: Fitting The Appliance
Installation Condensate drain Fitting the appliance Prepare the condensate discharge system. Refer to fig. 11. The condensate drainage pipe should be a Benchmark: For optimum performance standard drain pipe material , i . e. PVC, PVC-U, ABS after installation, this boiler and its asso- etc. -
Page 15: Checking The Connections
Installation Connecting the flue duct Flue Systems y Fit flue duct connector onto appliance flue spigot. The only flue systems that may be used are those sup- plied by Worcester Heat Systems. y Secure with the two screws supplied. The flue system must be installed in accordance with the requirements of BS5440:1. -
Page 16: Siting The Flue Terminal
Installation 3.8.1 Siting the Flue Terminal The flue must be installed in accordance with lighting, activated by passive infra-red sensing heads. BS 5440:1 and the Building Regulations. Flue terminals If the terminal is less than 2 m above a surface to which in carports and under balconies are to be avoided. -
Page 17: Installation Of The Flue
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 1600 mm and 4000 mm require exten- sion duct assemblies. - Page 18 Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp Extension Clamp Duct 6 720 610 602 - 09.1O Fig. 17 Flue with one extension Terminal Assembly Flue Turret Outer Wall Clamp Clamp Extension Extension Clamp Duct Duct 6 720 610 602 - 10.1O Fig.
-
Page 19: Flue Duct Preparation And Assembly
Installation 3.8.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 20, 21. Outer Wall Flue Terminal Face Raised Ring locating the terminal relative to the outside wall face NOTE: THE FLUE MUST BE INCLINED T O THE 6 720 610 576 - 20.1O BOILER 6 720 610 602 - 12.1O... -
Page 20: Electrical Connections
Electrical connections Electrical connections Connecting the appliance y Always disconnect the power supply to the appliance at the mains before carry- To gain access to the mains connection remove the ing out any work on the electrical sys- drop down facia cover. The drop down cover is tems and components. -
Page 21: Mains Voltage External Controls Connections
Electrical connections y Cut cable grommet to diameter of cable. Mains Voltage external controls connections NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Remove Link Motor 230 V R oom Thermostat Connections 230 V Pr ogrammer Connections 230 V r oom thermos t at and Ns Ls L... -
Page 22: Wiring To Your System
Electrical connections Wiring to your system Permanent Mains supply (NOT ALLOWED) The following diagrams show the wiring options for your system. Any other combinations of wiring are not rec- RemotePre-wired Junction Box ommended as it would increase complexity of the sys- tem. -
Page 23: Commissioning
Commissioning Commissioning 317 366 367 6 720 610 576-07.1O Fig. 30 Commissioning Pressure gauge Safety valve Automatic vent Never run the appliance when empty or Reset button unpressurised. Master switch Temperature control for central heating Service cocks on CH flow and return Benchmark Water Treatment: For optimum perform- Hot water Gas cock (shown in on position) -
Page 24: Switching The Appliance On/Off
Commissioning y Unscrew the condensation trap (358) and pull out, fill Switching on the central heating with approx. 1/4 l of water and refit. Refer to fig. 30. The central heating flow temperature is adjustable y Adjust charge pressure of expansion vessel to static between 35 °C and 88 °C. -
Page 25: Pump Anti-Seize Function
Commissioning Pump anti-seize function This function prevents the central heating pump seizing after long periods of inactiv- ity. Every time the pump is switched off, a timer is started. If after 24 hours the pump has not run again, it is switched on for a period of 5 minutes. -
Page 26: Individual Settings
Individual settings Individual settings Mechanical settings y Rotate yellow button through 180° and replace (dot 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 27: Settings On The Bosch Heatronic
Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic Entering a setting The Bosch Heatronic enables easy setting and check- y To enter the setting for a function, turn the tempera- ing of a large number of appliance functions. ture control... -
Page 28: Setting The Maxim Ch Flow Temperature (Service Function 2.5)
Individual settings 6.2.4 Setting the maxim CH flow temperature y Turn the temperature control until the display (Service Function 2.5) shows 5.0. After a short delay, the display then shows the set The maximum CH flow temperature can be set to heating output in percent. -
Page 29: Converting The Appliance To Different Gas Types
Converting the appliance to different gas types Converting the appliance to different gas types The setting is factory sealed at maximum. Adjustment to Setting the gas/air ratio the rated heat input and min. heat input is not neces- y Switch off the appliance at the master switch (O). sary. - Page 30 Converting the appliance to different gas types y Turn the temperature control until the display y Turn the temperature control anti-clockwise until shows 2. the display shows 1. (= min. rated heat output). (= max. rated heat output). The display and the button will flash.
-
Page 31: 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 y Press and hold the button until the display By testing the O or CO level in the com-... -
Page 32: Maintenance
Engineer, order no. 7 181 465 346, avail- able to competent persons. All safety and control systems are moni- tored by the Bosch Heatronic. In the event of a component fault, the display shows a fault code. y The User should be recommended to have the appli- ance serviced regularly by a competent person (see Maintenance Contract). -
Page 33: 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 34). Check ionisation current, Service Function 3.3, (see page 34). Perform visual check of air/flue duct. Check gas supply pressure mbar (see page 29). -
Page 34: Description Of Servicing Operations
Maintenance Description of servicing operations y Remove the fan and the burner as described in the text headed “Burner” (see page 35). The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.2. Check “Last fault stored”: y Select Service Function .0 (see page 27 “Selecting Service Function”). - Page 35 Maintenance y Flush the heat exchanger from the top. Refer to y Remove the burner skin and clean components. Do fig. 51. not use a wire brush. Refer to fig. 53. y Clean out the condensate collector and trap connec- tion (with other end of brush).
-
Page 36: Replacement Of Parts
Maintenance Siphon Replacement of Parts y Unscrew the clip and disconnect the pipe to the Before changing any components check that the gas is siphon. turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the y Remove the yellow plug to drain the siphon. -
Page 37: Fan Assembly
Maintenance y Lower the control box. 8.3.2 Fan Assembly y Unscrew earth lead. y Unscrew four fixing screws from cover plate. Refer to fig. 56. y Prise off cover plate. y Pull off transformer. y Remove pcb holder. y Remove the pcb control board. Fig. -
Page 38: Pump
Maintenance 8.3.3 Pump Flue Temperature Limiter – Item 9, fig. 2, 55 y Switch off the appliance. y Pull-off the connectors. y Disconnect the appliance from the power supply. y Unscrew the sensor. y Remove two switchbox fixing screws (1.). Refer to 8.3.5 Gas Valve fig. -
Page 39: Electrode Assembly
Maintenance 8.3.6 Electrode assembly y Pull forward from the top and lift the heat exchanger from the casing. y Refer to section 8.2. y Transfer components, as necessary, to the new heat y Use a new seal if the existing seal is damaged. exchanger. -
Page 40: 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 Keyed plug not detected. -
Page 41: Short Parts List
Appendix Short parts list Description Qty GC Spare part number Sensor - Flue gas temp. 8 729 000 144 0 Sensor - CH flow temp. 8 714 500 087 0 Control board 8 748 300 418 0 Gas valve 8 747 003 516 0 Fan assembly 8 717 204 373 0 Fan washer... -
Page 42: Heating/Hot Water Output Settings (N.g.)
Appendix Heating/hot water output settings (N.G.) Natural gas G20 Display Heat output kW Heatinput kW Gas vol. flow rate code (l/min at t = 80/60 °C) 14.4 10.9 11.0 19.3 13.6 13.8 24.1 16.3 16.5 28.9 19.1 19.3 33.7 21.8 22.0 38.5 24.5... -
Page 43: Operational Flow Diagrams
Appendix Operational Flow diagrams 9.5.1 Central heating function Fig. 61 6 720 610 596 GB (01.07) - Page 44 Appendix Appendix EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619...