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Bosch WORCESTER GREENSTAR 36LXi Installation, Commissioning And Servicing Instructions
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Bosch WORCESTER GREENSTAR 36LXi Installation, Commissioning And Servicing Instructions

Wall hung rsf gas fired condensing combination boiler
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INSTALLATION, COMMISSIONING AND SERVICING
INSTRUCTIONS
WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER
GREENSTAR 36LXi
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
The appliance is for use with Natural Gas or
L.P.G. (Cat II 2H3P type C13, C33 & C53)
Model
Natural Gas
36kW
Liquid Petroleum Gas
36kW
GC Number
47-406-30
47-406-31

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Summary of Contents for Bosch WORCESTER GREENSTAR 36LXi

  • Page 1 INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS WALL HUNG RSF GAS FIRED CONDENSING COMBINATION BOILER GREENSTAR 36LXi FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER The appliance is for use with Natural Gas or L.P.G. (Cat II 2H3P type C13, C33 & C53) Model GC Number Natural Gas...
  • Page 2 CONTENTS CONTENTS 5.7.3 Fitting the fascia flap ....44 KEY TO SYMBOLS & SAFETY INSTRUCTIONS . . 3 5.7.4 Installing bottom panel ....44 Explanation of symbols .
  • Page 3 KEY TO SYMBOLS AND SAFETY INSTRUCTIONS KEY TO SYMBOLS AND SAFETY INSTRUCTIONS EXPLANATION OF SYMBOLS PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. WARNING SYMBOLS These instructions are applicable to the Worcester Safety instructions in this document are appliance model(s) stated on the front cover of this framed and identified by a warning triangle manual only and must not be used with any other which is printed on a grey background.
  • Page 4 KEY TO SYMBOLS AND SAFETY INSTRUCTIONS SAFETY PRECAUTIONS FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance IF YOU SMELL GAS: may only be carried out by a competent engineer in accordance with the current Gas Safety (Installation and B CALL NATIONAL GAS EMERGENCY SERVICE ON Use) Regulations.
  • Page 5 KEY TO SYMBOLS AND SAFETY INSTRUCTIONS BRITISH STANDARDS BOILER FEATURES Where no specific instruction is given, reference should • High pressure die-cast aluminium heat exchanger be made to the relevant British Standard codes of • Low NOx emissions Practice. • Fixed gas valve settings BS7074:1 Code of practice for domestic and hot water •...
  • Page 6 APPLIANCE INFORMATION APPLIANCE INFORMATION APPLIANCE Depth to wall 280mm (When fitted to wall frame) 680mm* * 690mm to top of case front 390mm 6720646608-01.1Wo STANDARD PACKAGE – Consumer Guarantee Card 1. Wall hung gas-fired condensing combi boiler for – Guarantee Return Envelope central heating and domestic hot water –...
  • Page 7 APPLIANCE INFORMATION TECHNICAL DATA Natural gas DESCRIPTION LXi L.P.G. UNIT 36kW 36kW Domestic Hot Water Minimum heat input 7.15 7.15 Maximum rated heat output 35.5 35.5 Maximum rated heat input 36.7 36.7 Maximum mains inlet pressure (standing pressure) Minimum mains inlet pressure (working) for max. flow Minimum mains inlet pressure (working) for operation Domestic Hot Water temperature range °C...
  • Page 8 APPLIANCE INFORMATION LAYOUT 6720646608-02.1Wo 48 47 46 45 44 43 Fig. 1 Main boiler components 6 720 646 608 (2011/07)
  • Page 9 APPLIANCE INFORMATION Wall mounting frame Expansion vessel Flow temperature sensor (NTC) PRV connection Electrode assembly CH return isolating valve Maximum safety sensor (NTC) DCW mains isolating valve Auto air vent Gas isolating valve Aluminium Silicon Heat exchanger DHW outlet connection Flueway CH flow isolating valve Sump assembly...
  • Page 10 PRE-INSTALLATION PRE-INSTALLATION CLEANING PRIMARY SYSTEMS B Drain and thoroughly flush the system to remove the CAUTION: flushing agent and debris. B ISOLATE THE MAINS SUPPLIES BEFORE B It may be necessary to use a power flushing machine STARTING ANY WORK AND OBSERVE ALL to aid the cleansing procedure in some RELEVANT SAFETY PRECAUTIONS.
  • Page 11 PRE-INSTALLATION MAINS SUPPLY 3.2.1 ELECTRICAL SUPPLY 3.2.3 WATER SUPPLY • Supply: 230V - 50 Hz, 143 Watts WATER MAINS PRESSURE: • Cable: PVC insulated 0.75mm (24 x 0.2mm) • Minimum mains water pressure for maximum temperature rated to 90 °C. performance: 1.5 bar.
  • Page 12 PRE-INSTALLATION WATER SYSTEMS AND PIPE WORK PLASTIC PIPE WORK: SYSTEM FILL • Any plastic pipe work must have a polymeric barrier Mains Heating with 600mm (minimum) length of copper pipe before supply return being connected to the boiler. Hose union •...
  • Page 13 PRE-INSTALLATION CONDENSATE PIPE WORK Alternatively if the first option is not possible an internal NOTE: kitchen or bathroom waste pipe, washing machine B Where a new or replacement boiler is waste pipe etc. can be used. being installed, access to an internal Ensure that the condensate drain pipe is connected “gravity discharge”...
  • Page 14 PRE-INSTALLATION 3.4.2 EXTERNAL CONNECTIONS FITTING AN EXTERNAL AIR BREAK • Refer to figure 8 when a rain water down pipe is used NOTE: Freezing conditions to dispose of condensate. B Pipe work length should be kept to a • An air break must be installed in the 43mm pipe work, minimum and the route as vertical as between the boiler condensate outlet and the possible.
  • Page 15 PRE-INSTALLATION PRESSURE RELIEF PIPE WORK CONDENSATE SOAK AWAY • The condensate drainage pipe may be run above or NOTE: below the ground to the soak away. The examples shown on this page run above ground. B The pressure relief valve is a safety device •...
  • Page 16 PRE-INSTALLATION BOILER LOCATION AND CLEARANCES 3.6.1 INSTALLATION 3.6.4 BATHROOMS This boiler is only suitable for installing internally within A boiler fitted with a mechanical timer or RF mechanical a property at a suitable location onto a fixed, rigid timer (receiver) or FW100 controller may only be surface at least the same size as the boiler and capable installed outside the shaded area.
  • Page 17 PRE-INSTALLATION PLUMBING MANIFOLD 3.7.1 CONNECTIONS Heating System 22mm compression fittings 15mm compression fittings 22mm compression fittings Tab. 11 Use the fittings supplied in the Hardware literature pack. Further guidance on pipe routing can be found printed on the boiler template (supplied with the boiler).
  • Page 18 PRE-INSTALLATION FLUE OPTIONS NOTE: Effective flue lengths: CAUTION: Non accessible flue systems: B each 90° bend used is equivalent to B Where a flue system is not going to be 2 metres of straight flue accessible, provision must be made for B each 45°...
  • Page 19 PRE-INSTALLATION 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo 6 720 646 608 (2011/07)
  • Page 20 PRE-INSTALLATION FLUE TERMINAL POSITIONS All measurements in millimetres Dormer Window 1,500 Velux Window Drainpipe 1,200 1,500 Boundary Window 6720643895-13.2Wo Fig. 17 Flue terminal positions NOTE: B All measurements are the minimum clearances required. B Terminals must be positioned so to avoid combustion products entering the building. B Support the flue at approximately one metre intervals and at a change of direction, use suitable brackets and fittings (Flue brackets 100mm x 6 part number: 7 716 191 173, Flue bracket 125mm part number :7 716 191 174).
  • Page 21 PRE-INSTALLATION 3.10 PLUME MANAGEMENT TERMINAL POSITIONS All measurements in millimetres ±45° Plume management deflector: Flue Exhaust Outlet 180° Air Intake ±80° 1,200 Balcony Window Window Window Door Boundary Drainpipe 6720643895-14.1Wo Fig. 18 Plume terminal positions NOTE: B All measurements are the minimum clearances required. B Refer to figure 17 for all concentric flue terminal positions unless the flue position is specified on the figure above “Plume terminal positions”.
  • Page 22 INSTALLATION INSTALLATION IMPORTANT HANDLING INSTRUCTIONS: WARNING: All the previous “Pre- • It is advised that two people are used to carry the Installation” sections must be read and the carton from the van to the point of delivery. requirements met before starting boiler or flue installation.
  • Page 23 INSTALLATION WALL MOUNTING TEMPLATE & FLUE OPENING WARNING: BEFORE DRILLING ENSURE THAT THERE ARE NO PIPES, ELECTRICAL CABLES, DAMP PROOF COURSES OR OTHER HAZARDS . SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.
  • Page 24 INSTALLATION UNPACKING THE APPLIANCE 1. Remove outer carton (1) and place safely away from 3. Pull the bottom of the fascia forward and out to the working area. release the top of the control panel. 2. Remove the inner sleeve (2) leaving all other 4.
  • Page 25 INSTALLATION PRE-PLUMBING BOILER CONNECTIONS PLUMBING THE CONDENSATE DRAIN PIPE CAUTION: B Fit the condensate discharge pipe as close to the wall B Isolate the mains gas supply before as possible to ensure easy fitting of the boiler bottom starting any work and observe all relevant panel.
  • Page 26 INSTALLATION HANGING THE BOILER CAUTION: Lifting the boiler B There are two handling holes incorporated into the inner casing left and right in the lower section of the appliance. B Do not lift the boiler using the control panel as a hand hold. NOTE: Hanging the boiler B Remove the plastic strip fitted to pipes before hanging the boiler.
  • Page 27 INSTALLATION CONNECTING THE EXPANSION VESSEL CONNECTING THE SYPHON OUTLET To connect the expansion vessel to the hydraulic pump 1. Push the black rubber syphon discharge hose, onto manifold situated to the left of the pump: the wall frame connector, until fully engaged. 1.
  • Page 28 INSTALLATION FLUE INSTALLATION HORIZONTAL FLUE (60/100mm diameter) Extend tube (1) by withdrawing from tube (2) to achieve the flue length required, between 350 - 570mm or 570 to For vertical flues and 80/125mm horizontal flues, please 790mm if using the longer telescopic flue. refer to separate instructions supplied with the flue kit.
  • Page 29 INSTALLATION 4.6.3 INSTALLING THE TELESCOPIC FLUE: Refer to figure 39. B Fit the screws removed in step 1 to secure flue turret. 1. Set the flue length to the distance required, secure B If fitting the outer seal from outside the building, slide with screws provided.
  • Page 30 INSTALLATION 4.6.4 FLUE TERMINAL PLUME RE-DIRECTION: NOTE: Outlet position The flue discharge can be re-directed allowing some B The flue terminal outlet position must plume redirection control, alternatively, a complete follow those stated in the relevant plume management system can be fitted to the flue appliance instruction manual.
  • Page 31 INSTALLATION ELECTRICAL Low voltage connections CAUTION: Isolate the mains electrical supply before starting any work and observe all relevant safety precautions. The boiler is pre-fitted with a mains supply cable. Route the cable through the right hand side of the wall mounting frame. •...
  • Page 32 INSTALLATION 4.7.1 MOUNTING OPTIONAL PLUG-IN CONTROLS FITTING THE PROGRAMMER/TIMER CAUTION: Isolate the mains electrical supply before starting any work and When fitting EMS intelligent programmers, observe all relevant safety precautions. step 1 can be ignored. Refer the to Programmer/Timer manual for set up and operation of the unit.
  • Page 33 INSTALLATION 4.7.2 NEW COMPLETE SYSTEM INSTALLATIONS INTEGRATED TIMER AND TWO ZONES If a new complete heating system installation is in a new build property or is a first time installation in an existing Zone 1 Zone Valve property, heating systems must conform to current building regulations Part L1a.
  • Page 34 INSTALLATION 4.7.3 EXISTING INSTALLATIONS PROGRAMMABLE THERMOSTAT For boiler replacements on an existing system, it is not Programmable necessary to zone the upstairs and downstairs Thermostat separately, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat.
  • Page 35 COMMISSIONING COMMISSIONING PRE-COMMISSIONING CHECKS FILLING THE SYSTEM 1. Turn on the water main and open the system valves. CAUTION: ISOLATE THE MAINS 2. Open all radiator valves. ELECTRICITY SUPPLY BEFORE STARTING 3. Fill the system via a WRAS approved filling loop or the ANY WORK AND OBSERVE ALL RELEVANT optional Worcester Integral Filling Link accessory to 1 SAFETY PRECAUTIONS.
  • Page 36 COMMISSIONING WATER TREATMENT WATER TREATMENT NOTE: Suitable water treatment products can be obtained from B Artificially softened water must not be the following manufacturers: used to fill the central heating system. ENSURE THAT THE SYSTEM HAS BEEN CLEANED. FERNOX 01799 550811 REFER TO SECTION 3.1 OF THESE INSTRUCTIONS.
  • Page 37 COMMISSIONING STARTING THE APPLIANCE CAUTION: RUNNING THE APPLIANCE B Never run the appliance when the appliance/system is empty or partially filled. 12 13 Fig. 57 Control panel Switching the appliance on/off: Key to figure 57 B Turn on the mains power supply, initially the “Boiler Spanner/return button start up screens”...
  • Page 38 COMMISSIONING 5.4.1 BOILER START UP SCREENS SCREEN DISPLAY DESCRIPTION On initial start up, the following screens are displayed: All possible screen symbols This screen is displayed briefly during boiler start 1. All the symbols are displayed for approximately two up and shows all the seconds.
  • Page 39 COMMISSIONING STATUS CODES During normal boiler operation various Status codes can be displayed by pressing the button. The first screen of the Information menu displays the current Status code, this will change as the boiler runs through the various modes and sequences. These are not faults, but provide information concerning the current status of the boiler.
  • Page 40 COMMISSIONING 5.4.2 SELECTING SERVICE MENUS will display for three seconds to confirm the update of the new value. 1. Press and hold buttons together for one second, the display will show Menu 1. The same process is used for adjusting all Menus 1, 2, 3 and Test.
  • Page 41 COMMISSIONING 5.4.4 MENU 3 - BOILER MAXIMUM & MINIMUM LIMITS The menu shows the boiler's maximum limits. These can 3.1A Maximum The maximum heating be adjusted on this menu. heating output output in kW can be set Menu 3 cannot be factory re-set. here.
  • Page 42 COMMISSIONING COMMISSIONING B Measure the pressure with the boiler running at NOTE: The combustion settings on this gas- maximum. fired boiler have been checked, adjusted and – Press the button for at least five preset at the factory for operation on the gas seconds and boiler will ramp up to maximum type defined on the data plate.
  • Page 43 COMMISSIONING GAS PRESSURE WITHIN THE SYSTEM 5.5.3 GAS RATING TEST Refer to the figures below for natural gas or L.P.G gas B Ensure all other gas appliances are isolated. pressures. 1. Set the boiler to maximum output by pressing The working pressure at the boiler must not be less than button together for at least 5 seconds.
  • Page 44 COMMISSIONING FINISHING COMMISSIONING 5.7.1 REPLACING THE BOILER CASE: 5.7.3 FITTING THE FASCIA FLAP 1. Replace the boiler case. 1. Rotate the hinge to be in-line with the flap and present the flap assembly up to the fascia. 2. Make sure that the securing points on top of the case are properly located.
  • Page 45 B Have you advised the customer where they can find information on the Worcester, Bosch Group website. B Advise the customer that the varying external temperatures will affect the output of the boiler, especially the DHW.
  • Page 46 SERVICE AND SPARES SERVICE AND SPARES CHECKING THE GAS INLET CAUTION: Mains supplies: PRESSURE B Turn off the gas supply and isolate the electrical mains supply before starting NOTE: Gas inlet pressure any work on the appliance and observe all B Ensure that the gas pressure is relevant safety precautions.
  • Page 47 SERVICE AND SPARES CHECKING FLUE INTEGRITY COMPONENT ACCESS The integrity of the flue system and performance of the To gain access to the components, remove the outer boiler can be checked via the flue turret sample points. case: 1. Remove the two screws securing the control panel. Flue gas sample point 2.
  • Page 48 65°C or less, the If the boiler, after completing the above checks, fails the boiler will operate both the central heating fan pressure test then contact Worcester, Bosch Group and DHW circuits with the diverter valve in for advice.
  • Page 49 SERVICE AND SPARES FLUE GAS ANALYSIS B Check CO is less than 200ppm. NOTE: Combustion testing B Set the boiler to minimum power by pressing the B Combustion testing must be carried out down arrow button. by a competent person. Testing must not be attempted unless the person carrying –...
  • Page 50 SERVICE AND SPARES OFFSET PRESSURE 1. Set the boiler to maximum output by pressing the NOTE: Offset Pressure buttons for at least five seconds. B Checking the Offset pressure must be 2. Select minimum output using the down arrow key. carried out by a competent person.
  • Page 51 SERVICE AND SPARES CLEANING THE HEAT EXCHANGER NOTE: Burner gasket B Replace the burner gasket after cleaning the heat exchanger. There is an optional tool available to assist in cleaning the heat exchanger, part number 7 746 901 479 The following items will have to be removed to gain access to the heat exchanger for cleaning: B Lower the control panel into the service position.
  • Page 52 SERVICE AND SPARES 6.8.2 CLEANING THE SYPHON REFITTING THE SYPHON 1. Protect the controller from water ingress and B Fill syphon with 200 to 250 millilitres of water. disconnect the black discharge hose from the wall 1. Push the syphon up onto the sump assembly until it frame connector.
  • Page 53 SERVICE AND SPARES REPLACEMENT OF PARTS CAUTION: Mains supplies: B Turn off the gas supply and isolate the mains supplies before starting any work on the boiler and observe all relevant safety precautions. CAUTION: Component replacement: B After replacement of a gas related component, where a gasket or seal has been disturbed or replaced, check for gas tightness using a gas sniffer/analyser.
  • Page 54 SERVICE AND SPARES 6.9.3 SYPHON REMOVAL 6.9.5 MAXIMUM SAFETY SENSOR (NTC) 1. Disconnect the discharge hose from the wall frame B Disconnect the lead to the Maximum safety sensor. connector. 1. Remove the screw securing the sensor. 2. Rotate the syphon body clockwise to release the 2.
  • Page 55 SERVICE AND SPARES 6.9.7 AUTO AIR VENT B Tighten the bottom connection firmly with a suitable spanner. Ensure that the boiler has been fully drained. B Connect the top gas pipe. 1. Remove the spring clip completely. B Reconnect the electrical connector. 2.
  • Page 56 SERVICE AND SPARES COMBUSTION AIR INLET AND GAS PIPE DISCONNECTION 1. Rotate the combustion air inlet pipe anticlockwise to 5. Rotate the exhaust pipe clockwise. release from the fan assembly and pull away from the 6. Pull the fan assembly away from the mount, lift and fan.
  • Page 57 SERVICE AND SPARES 6.9.11 IGNITION TRANSFORMER 6.9.13 BURNER HOUSING, BURNER/ GASKET To remove the ignition transformer The front two bolts retaining the burner B Remove the combustion air inlet pipe. housing are NOT captive and will drop out B Ensure that the harness wires are disconnected from when the nuts are removed.
  • Page 58 SERVICE AND SPARES 6.9.14 HEAT EXCHANGER B Re-assemble in the reverse order. Before removal: B Isolate the electrical power to the boiler. B Drain the system. HEAT EXCHANGER DISCONNECTION 1. Undo the flow and return connections. 2. Pull both the flow and return pipes away from the heat exchanger.
  • Page 59 SERVICE AND SPARES 6.9.16 DHW TEMPERATURE SENSOR (NTC) 6.9.18 FLOW SENSOR, FLOW RESTRICTOR AND FILTER REMOVAL B Disconnect the electrical connector from the sensor. B Isolate the cold mains and ensure that the DHW B Unclip the sensor from the pipe. circuit is fully drained.
  • Page 60 SERVICE AND SPARES 6.9.20 PRESSURE GAUGE 6.9.22 DRAIN TAP B Ensure that the boiler is fully drained. B Ensure that the system is full drained down. B The drain tap rotates anticlockwise for a ¼ turn to 1. Remove the securing screw and plate. open.
  • Page 61 SERVICE AND SPARES 6.9.24 DHW PRESSURE RELIEF VALVE 6.9.26 HYDRAULIC BLOCK REMOVAL Before removal: Do not remove the hydraulic block assembly unless absolutely necessary. B Isolate the electrical power to the boiler. Before removal: B Drain the system. B Isolate the electrical power to the boiler. B Isolate the cold water mains.
  • Page 62 SERVICE AND SPARES 6.9.28 ACCESS TO BOILER CONTROL COMPONENTS 6.9.29 REPLACING THE CONTROL UNIT 1. Remove the three screws retaining the installer The control unit is supplied in a plastic access cover. housing. The complete unit must be replaced. 2. The access cover can now be removed with the flap. The HCM must be exchanged from old to the new control unit.
  • Page 63 SERVICE AND SPARES REMOVING THE CONTROL UNIT B Support the control unit and detach the control unit support strap. 1. Remove the plastic retaining clips at each hinge. 2. Release the two catches underneath the panel. 3. Hinge the control unit up to approximately a 45° angle.
  • Page 64 SERVICE AND SPARES 6.9.30 EXPANSION VESSEL B Disconnect the electrical supply and any external controls. The expansion vessel can be replaced with the boiler in B Disconnect the flue from the boiler. place if there is a side exit flue fitted and a minimum clearance of 450mm above the boiler casing.
  • Page 65 SERVICE AND SPARES 6.10 SHORT PARTS LIST Burner 8 718 Gas Valve 7 746 009 09A 0 8 718 600 04A 0 600 23B 0 Control Flue overheat Electrodes panel thermostat (including 8 718 686 (grommet type) gasket) 274 0 8 717 206 213 0 8 718 600 28A Spark generator...
  • Page 66 FAULT FINDING AND DIAGNOSIS FAULT FINDING AND DIAGNOSIS INTERNAL WIRING DIAGRAM Fan wiring: PRE WIRED LINK Live = Brown FLUE Neutral = Blue STAT SPARK ELECTRODES FLAME SENSE ELECTRODE FLOW MAX SAFETY NTC FLAME SENSE GROUND VALVE SAFETY SOLENOID Blue SAFETY Orange SOLENOID...
  • Page 69 FAULT FINDING AND DIAGNOSIS PROTECTION FUNCTION Fig. 129 Protection function 6 720 646 608 (2011/07)
  • Page 70 FAULT FINDING AND DIAGNOSIS INFORMATION AND SERVICE MENUS 7.5.1 SELECTING THE INFORMATION MENU Current status Every operation and mode of The Information Menu is a "read only" menu. Information the boiler has a related boiler about the boiler is displayed here, some of the values are status code.
  • Page 71 FAULT FINDING AND DIAGNOSIS 7.5.2 SELECTING SERVICE MENUS Time inputs This indicates the status of 1. Press and hold buttons together for one the optional fascia mounted second, the display will show Menu 1. controls: 0 = CH off, DHW off Double up or down arrows indicate that the menu can 1 = CH off, DHW on only be scrolled up or down, an up and down arrow...
  • Page 72 FAULT FINDING AND DIAGNOSIS 7.5.3 MENU 1 - SYSTEM PARAMETERS Not applicable for Greenstar LXi. 2.1A Maximum power Range rate the CH of the Initially Menu 1 will be displayed, but will contain no boiler. options. Adjustment in kW. The maximum is 24kW. Menu 1 options will appear on the display when the 2.1C Pump head...
  • Page 73 FAULT FINDING AND DIAGNOSIS 7.5.5 RESET TO FACTORY SETTINGS 2.9E Turbine signal Delay time set to ignore a delay temporary DHW demand. To reset any or all changes made in menu 2 back to the Maximum delay is three factory defaults setting: seconds which can be set in ¼...
  • Page 74 FAULT FINDING AND DIAGNOSIS 7.5.6 MENU 3 - BOILER MAXIMUM & MINIMUM LIMITS The menu shows the boiler's minimum and maximum 3.1A Maximum The maximum heating limits. Which can be adjusted in this menu. heating output output in kW can be set The boiler will revert to adjusted settings in Menu 3 here.
  • Page 75 FAULT FINDING AND DIAGNOSIS 7.5.7 USING THE TEST MENU TESTING THE COMPONENT This menu enables the testing of the functionality of B Select a component to test. components in an ON/OFF mode. B Press the button, the value 0 will flash. The duration of each test is limited to 30 seconds.
  • Page 76 FAULT FINDING AND DIAGNOSIS RESETTING THE TEST COMPONENT After completing the test: Test B Press the button, the value 1 will flash. Igniter test. The igniter will spark for a B Press the arrow button, the value will change to a Checking the maximum of 30 seconds.
  • Page 77 FAULT FINDING AND DIAGNOSIS 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. At the same time a (static) cause code will also be displayed.
  • Page 78 Ignition timing error Reset Flame not established during the first 4 seconds button ignition period. Internal error Call Worcester, Bosch Group technical helpline 0844 892 3366 Gas valve error Reset Leaking gas valve button 242 - 256 Internal error...
  • Page 79 FAULT FINDING AND DIAGNOSIS BLOCKING ERRORS Fault Cause code code Description Possible cause Pump stuck or running in air Little or no water in the system. Airflow stopped during operation Fan has stopped. Airflow present during last 24 hours Fan has been running continuously during the past 24 hours.
  • Page 80 FAULT FINDING AND DIAGNOSIS NOTES 6 720 646 608 (2011/07)
  • Page 81 FAULT FINDING AND DIAGNOSIS NOTES 6 720 646 608 (2011/07)
  • Page 82 Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 83 Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
  • Page 84 LITERATURE: 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 646 608 (2011/07)

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