6.5.3 Manual operating mode (TR2 not connected) 30 Safety precautions Hot water 6.6.1 Hot water programme 6.6.2 Hot water immediately Symbols i Info Settings 6.8.1 Heating (if TR 2 is connected) Details of the appliance 6.8.2 Hot Water Storage Tank EC Declaration of Conformity 6.8.3 Service Standard package...
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.
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 • Multifunction display requirements of the Gas Appliance Directive, Boiler Effi- ciency Directive, Electromagnetic Compatibility Direc- •...
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 13.7 m.
Details of the appliance Layout of appliance 221.1 221.2 32.1 6 720 610 603 - 02.1O 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 Flue duct Flue gas temperature limiter...
Details of the appliance Function 29.1 52.1 6 720 610 603 - 03.2O Fig. 3 Bosch Heatronic control Storage water heater outflow Temperature limiter, heat exchanger Storage water heater return Testing point for gas supply pressure Motor Pressure gauge 3-way valve Flue gas temperature limiter Flue duct Manifold...
Details of the appliance Electrical wiring diagram o - orange bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 603 - 03.1O Fig.
Details of the appliance Technical data Units RD 430i Natural gas RD 430i 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.
Installation Installation Sealed systems The appliance must not be operated without the system B Always turn off the gas cock before car- being full of water, properly vented and pressurised. rying out any work on components The expansion vessel has a volume of 10 litres and is which carry gas.
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Installation Note: INDIRECT A drain cock CYLINDER should be fitted at the lowest point of the heating circuit and beneath APPLIANCE the appliance Refer to Appliance Water Flow Diagram Radiator Valve - Flow Safety Discharge Lockshield Valve - Return LV Hot Water Flow Mains Cold Water Stop Valve Fixed Cylinder Type...
Installation Siting the appliance Regulations concerning the Installation Site Surface temperature The max. surface temperature of the casing and the flue B Relevant national regulations must be complied with is less than 85 °C. section 3.8.1. This means that, no special safety precautions are B Consult the installation instructions for details of min- required with regard to flammable building materials imum clearances required.
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.
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¡...
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.
Installation 3.8.1 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.
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.
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Installation Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must be directed as per Fig. 23. The assembly will be made easier if a solvent free grease is lightly applied i.e Silicone lubricant, to the male end of the ducts.
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.
Electrical connections Connecting TR2 Room thermostat The TR2 should be connected to terminals 3, 4 and F beneath the Textdisplay, page 8, Fig. 4, Pos. 422. Mains Voltage external controls connections Please note, that the in-built supplied controls and text display timer prevent and negate the need for any fur- ther external controls.
Appliance type sticker Temperature control for hot water Multifunction display Benchmark Water Treatment: For optimum perform- Condensation trap ance after installation, this boiler and its associated cen- Indicator lamp for burner tral heating system should be flushed in accordance...
Commissioning B Before commissioning, the gas supply pres- B Open automatic vent (27) and re-close after venting sure must be checked at the gas supply pres- (page 23). sure test point (see page 6, fig. 2, item 7). Switching off the appliance Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or B Set the master switch to (0).
Commissioning Appliances with Storage Tank: Summer mode, hot water only Setting hot water temperature With room thermostat B Turn temperature control on the appliance anti- B Do not set the temperature higher than clockwise as far as the stop. 60°C for normal operation. The central heating is now turned off.
Commissioning 5.10 Appliance Data Monitoring 8. Make the jumper JP1 on the ADM while powering up the appliance, see Fig. 35. If the 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.
Text Display B To start programming, press any button, e. g. Text Display The display lighting switches on and the main menu is displayed: General Description /holidays • The text display is used to display information about the appliance and the system and to alter the settings displayed.
Text Display B Press the button to confirm the setting. The Menu structure cursor then returns to the top line. Submenu -or- B Press the button to confirm the setting and Main Parameters to menu change/select return to the previous menu (Fig. 38 page 27). - Hours -or- hour/day...
Text Display Setting the time/day Basic setting (Automatic mode) • The appliance switches automatically between nor- 6.4.1 Setting the time and day mal heating, Economy mode and Frost protection For details of how to set the time and day, refer to mode according to the timer settings entered.
Text Display 6.5.2 Setting the Economy temperature (if TR2 • Comfort mode is active for 2 hours: normal auto- is connected) matic program (Hot water mode according to timer programme entered). This option allows you to set the room temperature for Economy mode (Off (Economy)).
Text Display B Press Settings to set the number of seconds in 24 hours. 6.8.1 Heating (if TR 2 is connected) Basic setting: “+ 0 s” Optimum Start LCD contrast: B From the main menu, select Settings and from the B Press and hold the button (about 5 seconds) first submenu, select Heating.
Individual settings Individual settings Mechanical settings B Rotate yellow button through 180° and replace (dot facing inwards). 7.1.1 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.
Individual settings B Press any button to activate the main menu. 7.2.4 Setting the heating output (Service Function 5.0) B Press button until the arrow cursor is pointing to Settings. The heating output can be set to any level between min. rated heat output and max rated heat output to limit it to B Press the button.
Converting the appliance to different gas types Converting the appliance to different gas types The setting is factory sealed at maximum. Adjustment to Operating mode normal. the rated heat input and min. heat input is not neces- B Press the button.
Converting the appliance to different gas types B Press until the display shows normal. 234.1 B Press the button. The text display shows Store settings. B Press to select yes. B Press the button. B Remove testing probe from the flue gas testing point (234) and refit sealing plug.
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.
Maintenance Pre-Service Check List Date Call up the last fault stored by the text- display , (see page 31). Check ionisation current, Service Function 3.3, (see page 38). Perform visual check of air/flue duct. Visual check of diaphragm for soiling and splits (see page 40).
Maintenance B Remove the fan and the burner as described in the Description of servicing operations text headed “Burner” (see page 39). The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 8.2. Checking the ionisation current, Service Function 3.3 B Select Service Function 3.3.
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Maintenance B Clean out the condensate collector and trap connec- tion (with other end of brush). 6 720 610 332-75.2R Fig. 49 B Refit the clean-out cover using a new seal and tighten screws to torque of approx. 5 Nm. Burner B Check that the gas cock is turned off and the master 7 181 465 330-09.2R...
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Maintenance B Refit and prime the siphon. Diaphragm in mixer unit B Take care not to damage diaphragm (443) when removing and refitting it. B Open mixer unit (29). B Carefully withdraw diaphragm (443) from fan intake tube and check for soiling and splits. Condensate Drain Siphon...
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.
Maintenance 9.3.2 Fan Assembly 9.3.3 Pump B Switch off the appliance. B Disconnect the appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to fig. 57. B Lower switchbox (2.). B Remove screw from underside of right-hand plastic cover plate (3.).
Maintenance B Undo pipe unions by withdrawing the clips. 9.3.7 Gas Valve B Remove 3-way valve. B Check that the gas cock is turned off. B Lower the control panel. Refer to fig. 57. B Pull off the solenoid connections at the rear of the valve.
Maintenance B Pull forward from the top and lift the heat exchanger 9.3.8 Electrode assembly from the casing. B Refer to section 9.2. B Transfer components, as necessary, to the new heat B Use a new seal if the existing seal is damaged. exchanger.
Appendix Appendix 10.1 Fault Codes More detailed fault finding procedures are described in the Service Booklet for the Engineer number 7 181 465 347. Display code Description Remedy Pump has run dry Check system pressure, add water and bleed system as necessary Break in communication Check connecting lead to TR2...
Appendix 10.5 Operational Flow diagrams 10.5.1 Central heating function Fig. 61 6 720 611 449 GB (03.11)
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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...
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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 Combination Boilers: Setting Hot Water Temperature System boiler with Storage Tank Summer Mode, Hot Water Only (Combi Appliances) Frost protection (Combi Appliances) Fault Condition Text Display...
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Contents 4.5.1 Heating program 4.5.2 Setting the Economy temperature (if TR2 is connected) 28 4.5.3 Manual operating mode (if TR2 is not connected) Hot water 4.6.1 Hot water program 4.6.2 Hot water immediately (System models) i Info Settings 4.8.1 Heating (if TR 2 is connected) 4.8.2 Hot Water (Storage Tank, System boiler models only) 4.8.3 Service Individual timer programmes...
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.
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.
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Safety precautions 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.
General notes General notes To get the best from your appliance please read these instructions carefully. Sealed heating systems The appliance is fitted to a sealed heating system which is pre- pressurised. Your installer will tell you of the minimum and maxi- mum pressure which must be indicated on the pressure gauge.
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General notes Clearances Your installer will have provided adequate space around the appli- ance for safety and servicing access. Do not restrict this space with the addition of cupboards, shelves etc. next to the appliance. Left-hand side 10 mm Right-hand side 10 mm In Front 600 mm...
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General notes With all mains fed systems the flow of water from individual taps will vary with the number of outlets operated simultaneously and the cold water mains supply pressure to the property. Flow balancing using “ball-o-fix” type valves is recommended to avoid an excessive reduction in flow to individual outlets.
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General notes Do not allow the flue terminal fitted on the outside wall to become obstructed or damaged. Pump The pump is a fully modulating type to which the parameters have been set by the manufacturer and must not be adjusted. 6 720 610 604 GB (03.06)
Controls Controls 61 317 366 367 6 720 610 598 - 01.2O Fig. 1 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 Display...
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).
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Operating the Appliance Check the central heating system pressure B The pointer on the pressure gauge (8.1) should be about 1 bar. B If the pointer is below 1 bar (when the system is cold), top up the system with water until the pointer is 1 bar. Your installer will have shown you how to do this.
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 Fig.
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 Fig.
Operating the Appliance Combination Boilers: Setting the Hot Water Temperature Hot water temperature On combi models, the hot water temperature can be set to between approx. 40°C and 60°C using the temperature control The domestic hot water temperature is not shown on the display. 6 720 610 333-07.1O Fig.
Operating the Appliance ECO mode with demand detection, button is lit The demand detection function enables maximum gas and water economy. Briefly turning a hot water tap on and then off again signals demand to the appliance which then heats up the water to the set temperature.
Operating the Appliance Control Setting Water Temperature Anti-clockwise limit approx. 10°C (frost protection) approx. 60°C Clockwise limit approx. 70°C Table 3 ECO button Pressing and holding the ECO button , until it lights up switches from Comfort mode to ECO-mode. Comfort mode, ECO button is not lit (factory setting) In Comfort mode the hot water tank has priority.
Operating the Appliance Frost protection (Combi Appliances) B Leave master switch switched on. If the appliance is to be left for long periods switch the central heating on and set the room temperature controller at 6°C. B Add a suitable anti-freeze fluid to the water in the central heat- ing system.
Text Display Text Display General Description • The text display is used to display information about the appli- ance and the system and to alter the settings displayed. • Once the appliance has been in operation for one day, the text display module has a power buffer period of about 10 hours during which it will run without the mains power supply.
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Text Display • Domestic Hot Water temperature (System boiler if a Storage Tank is accorded). Additional indication if a special programme is active: • x holidays • Hot water immediately • Constant on (comfort, if TR2 is not connected) • Constant off (economy, if TR2 is not connected). Other special operating modes may be displayed during commis- sioning, servicing, etc.
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Text Display B Confirm the selection by pressing the button. The corresponding submenu is displayed: 6 720 610 598-05.2O Fig. 10 Submenu: Time/day In the submenus, the top line indicates what action is required. The bottom line shows the previous menu level, if applicable (see Fig.
Text Display B Use the button to set the minutes. B Confirm the setting by pressing the button. B Use the button to set the day of the week. B Press the button to confirm the setting. The cursor then returns to the top line.
Text Display Menu structure Submenu Parameters to Main menu 1. change/select Time/day/hol- Time/day - Hours idays - Minutes - Day of week Holidays Days holiday Heating Heating - Day program - 1st operating mode - 1st switching point - 6th switching point Set econ- 5...30°C omy temp.
Text Display Submenu Parameters to Main menu change/select Settings Heating Optimum Start Off/On Hot water Only charging times/ (System times and temperatures boiler-mod- els) Service Display service param. Further Language -English/ options -Français/ -Deutsch -Time correction -LCD contrast Operating times Fault history Setting the time/day...
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Text Display ically cancels Economy mode at midnight on the last day and returns to Automatic mode. The day on which you enter the days holiday counts as the first day of the holiday, i.e. the unit starts the holiday program immediately. Only in- clude the day on which you are returning if you don’t want the heating to return to the normal pro- gram on that day!
Text Display Heating 4.5.1 Heating program Basic setting (Automatic mode) • The appliance switches automatically between normal heating, Economy mode and Frost protection mode according to the timer settings entered. • Basic setting: – Heating starts at 6:00 am – Economy starts at 10:00 pm Setting options •...
Text Display B Press . The display shows Set 1. operating mode. B Set the desired first operating mode (Heating, Economy or Frost protection). B Press . The display shows Set 1. time period. B Set the desired first time period. B Press .
Text Display 4.5.3 Manual operating mode (if TR2 is not connected) For selecting an operating mode that is different from the one set in the heating programme (Automatic mode). • You can choose between Automatic, Constant on (comfort) and Constant off (economy). •...
Text Display Hot water General description • Combi models only: The basic settings provide a straightfor- ward timer programme: enabled from 5:00 am, disabled from 10:00 pm. The ECO button must not be lit (Comfort mode). • System models (with Storage Tank): The basic settings pro- vide a timer programme: enable from 5:00 am, disable from 10:00 pm.
Text Display 4.6.1 Hot water program • Up to six switching points per day can be set. • There are two operating modes: Blocked and Released. B From the main menu, select Hot water and then from the first submenu, select Hot water program. B Set the days of the week, Blocked/Released (operating mode) in the same way as for the switching points and modes for heating as described on page 27.
Text Display i Info B Select Info from the main menu. You can view the following information: Display text Description Room temperature Current temperature in the room (if TR 2 connected) where TR 2 is installed Required room temper- Required temperature in room where ature (if TR 2 connected) TR 2 is installed Operating mode...
Text Display Settings 4.8.1 Heating (if TR 2 is connected) Optimum Start B From the main menu, select Settings and from the first sub- menu, select Heating. B Press to switch Optimum Start on or off. 4.8.2 Hot Water (Storage Tank, System boiler models only) The text display can control the hot water either with Times and temperatures or only times.
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Text Display Service parameters Language Available languages are: English, Français (French), Deutsch (German). B From the main menu, select Settings, from the first submenu select Service, from the Second submenu select Further options, and from the third submenu select Language. B Press to select the desired language.
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Text Display water) since commissioning. B From the main menu, select Settings, from the first submenu select Service, from the Second submenu select Further options, and from the third submenu select Operating times. Fault history This option displays any faults that have occurred for the informa- tion of the service engineer.
Text Display Individual timer programmes Heating periods for central heating Switching point Status Monday Tuesday Wednesday Thursday Friday Saturday Sunday Enable/disable hot water function Switching point Status Monday Tuesday Wednesday Thursday Friday Saturday Sunday 6 720 610 604 GB (03.06)
Fault finding Fault finding Problem Cause Remedy Desired room Thermostatic Increase thermo- temperature is not valve(s) set too static valve set- reached ting(s) Temperature con- Increase CH flow trol for CH flow temperature con- set too low trol setting Air trapped in Bleed radiators heating system and heating sys-...
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 controlled according to the level of demand for heat.
The information is printed on the appliance identification plate/ sticker (see page 11, 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.
Maintaining your appliance Maintaining your appliance Your new RD 532i/RD 537i/RD 542i /RD 430i gas-fired appli- ance represents a long-term investment in a reliable, high quality product. In order to realise its maximum working life, and to ensure it con- tinues to operate at peak efficiency and performance, it is essen- tial that your boiler receives regular, competent servicing and maintenance checks beyond the initial 2 year guarantee period.
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.
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.
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. SERIAL NUMBER. Copy the number off the Guarantee Card. 6 720 610 604 GB (03.06)