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Bosch RD 529 Installation And Servicing Instruction
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Bosch RD 529 Installation And Servicing Instruction

Wall mounted condensing boiler for central heating and mains fed domestic hot water
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Installation and Servicing Instructions
RD 529
Wall mounted condensing boiler for central heating and mains
fed domestic hot water
6 720 610 577-00.10
RD 529 GC-Number: 47 108 09

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Summary of Contents for Bosch RD 529

  • Page 1 Installation and Servicing Instructions RD 529 Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 577-00.10 RD 529 GC-Number: 47 108 09...
  • Page 2 Safety precautions 6.1.2 Setting the central heating flow temperature 29 6.1.3 Changing the heating pump characteristic Symbols Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic Details of the appliance 6.2.2 Selecting the pump control mode for central EC Declaration of Conformity heating mode (Service Function 2.2)
  • Page 3 Safety precautions Safety precautions IMPORTANT HANDLING INSTRUCTIONS B It is advised that two people are used to carry the carton from the van to the point of installation. If you smell gas B Once the outer carton has been removed and the B Turn off gas service cock at the meter.
  • Page 4 • Appliance Data Monitoring (ADM) system • Automatic ignition CE-0085 BL 0507 • Modulating control Category • Full safety systems incorporating Bosch Heatronic 2H 3P with flame ionisation monitoring, solenoid valves and Appliance Type temperature sensors • Concentric flue/air duct with testing point for Table 1 •...
  • Page 5 Details of the appliance 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.
  • Page 6 Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 18.1 6 720 611 223-01.1O 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...
  • Page 7 ϑ 29.1 52.1 ϑ 6 720 611 223-02.1O Fig. 3 Bosch Heatronic control Reset button Temperature limiter, heat exchanger Adjustable gas flow restrictor Hot water NTC sensor Adjusting screw for min. gas inlet flow volume Testing point for gas supply pressure...
  • Page 8 Details of the appliance Electrical wiring diagram o - orange g - green bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 611 223-03.1O Fig.
  • Page 9 Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30°C central heating 31.2 31.2 Max. rated heat output net 50/30°C central heating 30.9 30.9 Max. rated heat output net 80/60°C central heating 29.2 29.2 Max.
  • Page 10 Details of the appliance Condensate analysis, mg/l Gas supply Ammonium 1.2 Nickel 0.15 Total length of gas supply Pipe diame- ≤ 0.01 Mercury ≤ 0.0001 pipe (metres) ter (mm) Lead ≤ 0.001 Sulphate Cadmium ≤ 0.005 Zinc ≤ 0.015 Chromium Gas discharge rate (m ≤...
  • Page 11 Installation regulations Installation regulations Installation Gas Safety (Installation & Use) Regulations 1998: All B 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 Installation Domestic hot water Sealed systems Any regulations specified by the local water company The appliance must not be operated without the system must be observed. being full of water, properly vented and pressurised. The final 600 mm of the mains cold water connection to The approved method for temporary connection for fill- the applaince should be made in copper tube only.
  • Page 13 Installation APPLIANCE Refer to Fig.1 Appliance water flow diagram A drain cock should be fitted at the lowest point of the heating circuit and the appliance WRC approved filling loop Lockshield valve Central heating return Domestic Central heating flow hot water Radiator valve BS stop valve.
  • Page 14 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 for the appliances that are 440 mm wide.
  • Page 15 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 16 Installation Connecting the flue duct Flue Systems B Fit flue duct connector onto appliance flue spigot. The only flue systems that may be used are those sup- plied by Worcester Heat Systems. B Secure with the two screws supplied. The flue system must be installed in accordance with the requirements of BS5440:1.
  • Page 17 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 3.9.2 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 exten- Terminal sion duct assemblies.
  • Page 19 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 20 Installation 3.9.3 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 6 720 610 576 - 20.1O NOTE: THE FLUE MUST BE INCLINED T O THE BOILER 6 720 610 602 - 12.1O Fig.
  • Page 21 Electrical connections Electrical connections Connecting the appliance To gain access to the mains connection remove the B Always disconnect the power supply to drop down facia cover. The drop down cover is the appliance at the mains before carry- removed by lowering it to the horizontal position and ing out any work on the electrical sys- pushing firmly upwards at the rear of the supports to tems and components.
  • Page 22 Electrical connections B Cut cable grommet to diameter of cable. Mains Voltage external controls connections B Ensure that the existing connections to Ls and Ns are maintained when fitting external con- trols. NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Remove Link...
  • Page 23 Commissioning Commissioning 317 366 367 422 2 6 720 610 599-04.2O Fig. 29 Commissioning Pressure gauge Safety valve Automatic vent Never run the appliance when empty or, Reset button with sealed systems, unpressurised. Master switch Temperature control for central heating Service cocks on CH flow and return Benchmark Water Treatment: For optimum perform- Hot water...
  • Page 24 Commissioning B Unscrew the condensation trap (358) and pull out, fill Appliance Data Monitoring with approx. 1/4 l of water and refit. Refer to fig. 29. If the external Gateway module is fitted then the operat- B Adjust charge pressure of expansion vessel to static ing system must be commissioned at this stage.
  • Page 25 Commissioning 8. Make the jumper JP1 on the ADM while powering up Switching on the central heating the appliance. The central heating flow temperature is adjustable Observe LED on ADM flashing. The flashing rate is between 35°C and 88°C. Refer to table 15, page 29. 0.5 Hz, the ADM is now in “House Address Acquisi- tion mode”.
  • Page 26 Commissioning Setting the domestic hot water 5.6.2 Hot water flow rate temperature and flow rate The flow rate is factory set to 8 l/min. Under standard conditions (2 bar) supply pressure, one 5.6.1 Domestic hot water temperature full turn is equivalent to approximately 2 l/min. The hot water temperature can be set to between B To increase the flow rate (max.
  • Page 27 Commissioning 5.10 Fault Condition 5.11.1 Basic Settings Channel 1 – CH 1 – Central heating, all days A list of faults that may occur is given on • ON : 6:00 page 46. • OFF : 22:00. Channel 2 – CH 2 – Hot water, all days In the unlikely event of a fault occuring while the appli- ance is in operation: •...
  • Page 28 Commissioning 5.11.9 Time Display The timed periods can be set in Time of day and timed periods are displayed either in increments of 10 minutes. 24-hour (default setting) or 12-hour format. The timed periods are sorted in ascending order. The time display format cannot be changed while programming.
  • Page 29 Individual settings Individual settings Mechanical settings B 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 30 Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic Entering a setting The Bosch Heatronic enables easy setting and check- B To enter the setting for a function, turn the tempera- ing of a large number of appliance functions. ture control...
  • Page 31 Individual settings B Refer to the settings tables for heating and cylinder 6.2.4 Setting the maxim CH flow temperature (Service Function 2.5) charging output to obtain the relevant code for the desired heating output in kW (see page 47). The maximum CH flow temperature can be set to B Turn the temperature control between 35°C and 88°C (factory setting).
  • Page 32 Model from ... Order no. B Press and hold button until the display shows – –. button will light up. RD 529 N.G to L.P.G 7 710 149 048 L.P.G to N.G 7 710 239 084 Table 17 • Instructions are sent with each conversion kit.
  • Page 33 Converting the appliance to different gas types B Turn the temperature control B Turn the temperature control until the display 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 34 Converting the appliance to different gas types Testing combustion air/flue gas at 7.2.2 Testing CO and CO set heat output B Press and hold the button until the display shows – –. 7.2.1 Testing the O or CO level in the combus- “Chimney sweep”...
  • Page 35 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. The appliance data monitoring system (ADM), if fitted, will transmit the condition of the appliance to British Gas.
  • Page 36 Maintenance Pre-Service Check List Date Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 37). Check ionisation current, Service Function 3.3, (see page 37). Perform visual check of air/flue duct. Visual check of diaphragm for soiling and splits (see page 39).
  • Page 37 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 38 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 39 Maintenance B Replace and re-connect the assembly taking care not Diaphragm in mixer unit to mislay the inspection window. B Take care not to damage diaphragm (443) when removing and refitting it. Siphon B Unscrew the clip and disconnect the pipe to the B Open mixer unit (29).
  • Page 40 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 41 Maintenance ADM module 8.3.2 Fan Assembly B Remove the connections covers. Refer to fig. 24, 25. B Slide the module cover (1) out of the control box. B Disconnect the connector (3) from the main pcb con- trol board. B Disconnect the electrical leads (4 and 5) from the module.
  • Page 42 Maintenance 8.3.3 Pump 8.3.4 3-way diverter valve B Switch off the appliance. B Switch off the appliance. B Disconnect the appliance from the power supply. B Disconnect appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to B Turn off service cocks.
  • Page 43 Maintenance 8.3.5 3-way diverter valve motor 8.3.7 Gas Valve B Switch off the appliance. B Check that the gas cock is turned off. B Turn off the service cocks. B Lower the control panel. Refer to fig. 65. B Unplug connector from 3-way valve motor. Refer to B Pull off the solenoid connections at the rear of the fig.
  • Page 44 Maintenance 8.3.8 Domestic Hot Water Heat Exchanger 8.3.14 Flow switch B Refer to section 8.2. B Shut the mains water inlet valve and drain the domes- tic hot water circuit. B Use new seals when fitting the new heat exchanger. B Pull-off the connectors from the micro-switch.
  • Page 45 Maintenance 8.3.15 Primary Heat Exchanger B Drain the appliance. B Check that the gas supply is turned off. B Check that the appliance is electrically isolated. B Remove the fan assembly complete with the gas/air tube and mixer assembly. Refer to section 8.3.2. B Remove the burner.
  • Page 46 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. Break in communication Check connecting lead to programmer ADM module not detected.
  • Page 47 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 Sensor - DHW flow temp. 8 714 500 054 0 Control board 8 748 300 418 0 Gas valve...
  • Page 48 Appendix Operational Flow diagrams 9.5.1 Domestic hot water function Fig. 70 6 720 611 223 GB (02.08)
  • Page 49 Appendix 9.5.2 Central heating function Fig. 71 6 720 611 223 GB (02.08)
  • Page 50 Appendix 6 720 611 223 GB (02.08)
  • Page 51 Appendix 6 720 611 223 GB (02.08)
  • 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...