Worcester GR4700iW 21 S NG System Boiler Manuals

Manuals and User Guides for Worcester GR4700iW 21 S NG System Boiler. We have 1 Worcester GR4700iW 21 S NG System Boiler manual available for free PDF download: Installation And Maintenance Instructions Manual

Worcester GR4700iW 21 S NG Installation And Maintenance Instructions Manual (97 pages)

Gas-fired condensing system appliance

Brand: Worcester | Category: Boiler | Size: 22 MB

Table of Contents
2
Explanation of Symbols and Safety Instructions
4
Warnings
4
Intended Use
4
Misuse
4
If You Smell Gas
5
Electrical Work
5
Installation and Maintenance
5
Danger to Life from Carbon Monoxide
5
Servicing
6
Important Handling Instructions
6
Health and Safety
6
Installation Regulations
7
Water Supply
7
Scope of Delivery
8
Appliance Type Overview
8
Product Identification
9
Pipework Positions and Flue Outlet
9
Additional Type Plate
9
Pipe and Flue Outlet Dimensions
9
Product Overview
10
Standard Accessories
11
Appliance Accessories
11
Programmer/Timer Accessories
11
Bosch Easycontrol Smart Control System
11
Pre-Installation
12
System Preparation
12
Water Systems and Pipework
12
Primary System/Connections/Valves
12
System Layouts Examples
13
Checking the Size of the Expansion Vessel
13
Curves for the Expansion Vessel
13
Cylinder and Heating Zone
13
Optional Integral Diverter Valve Kit
14
3-Way Valve, Cylinder and Heating Zone
14
Example Layout - Internal Diverter Valve Kit
14
System Fill
15
Gas Supply
15
Pipe Sizing
15
Mains Supply
15
Liquid Petroleum Gas (LPG)
16
Appliance Location and Clearances
16
Rooms Containing a Bath or Shower
17
Appliance Minimum Clearances
17
Bathroom Installations
17
Appliance Clearances
17
Reduced Front Maintenance Minimum Clearances
18
Appliances in Compartments
18
Reduced Front Maintenance Clearances - Side View
18
Flue Systems Considerations
19
Flue System Bends
19
Flue Length
19
Flue Kit Part Numbers
19
Telescopic Horizontal Flue Assembly
20
Horizontal Flue Option
20
Horizontal Fixed Length Flue Assembly
20
Extended Horizontal Flue
20
Vertical Flue Option
21
Simpleswitch Flue Adaptor
21
Plume Management System
22
Terminal Exclusion Zone
22
Plume Management Bends
22
Horizontal Plume Management Runs
22
Vertical Flue Terminal Positions
23
Horizontal Flue Terminal Positions
24
Plume Re-Direct and Plume Management Terminal Positions
26
Condensate Discharge
28
Condensate Pipework - Unheated Internal Areas
28
Internal Connections
28
Soil Stack Connection
28
External Connections
29
Waste Pipe Connection
29
External Disposal Considerations
29
Additional Protection for Transition through a Wall
30
Disposal into Rain Water down Pipe
30
Disposal to Open Drain or Gully with Air Break
30
Condensate Soak Away Considerations
31
Condensate Soak Away with External Air Break
31
Disposal to Soak-Away
31
Cavity Wall Considerations
31
Pressure Relief Discharge
32
Pressure Relief Pipework
32
Through the Wall Lagging Example
32
Alternative PRV Connections - Combined Prv/Condensate
32
Cleaning Primary Systems
33
Flushing the System
33
Before Cleaning the System
33
Inhibitor
33
Installation
34
Additional Requirements for Roof Space Installations
34
Position the Appliance
34
Appliance Positioning
34
Mounting Frame Fixing
35
Wall Mounting Template
35
Appliance Connections
36
Connections on the Gas and Water Side
36
Condensate Discharge Connection Preparation
36
Plumbing Manifold
36
PRV Pre-Plumbing Connection Preparation
37
Preparing the Service Valves
37
Fitting the Sealing Washers
37
Hanging the Appliance
37
Preparing the Wall Frame
38
Fitting the Siphon
38
Wall Frame Preparation
38
Flue Turret/Adaptor Installation
39
Flue Turret/Adaptor Connection
39
Slope for Condensate Disposal
39
Electrical Connection
40
Cable Preparations
40
Installer Wiring Connections
41
Power Supply (Power Cables) Terminal Strip
41
Earth Rail Location
41
Stepped Cable Grommets
41
Power Supply (Power Cables) Connections
42
External Controls - Domestic Installations
42
Low Voltage (Signal Cables) Terminal Strip
42
Low Voltage (Signal Cables) Connections
42
Commissioning
43
Pre-Commissioning Checks
43
Filling the System - Sealed Systems
43
Filling the Appliance and Adding Inhibitor
43
Starting the Appliance
44
Control Panel Overview
44
Turning on the Appliance
44
Chimney Sweep Mode
44
Setting the Appliance to Maximum
45
Setting the Appliance to Minimum
45
Exiting Chimney Sweep Mode
45
Checking Gas Inlet Pressure
45
Checking the Gas Rate
46
Checking for Gas Leaks During Operation
46
Gas Supply Pressure Drop
46
Allowed Mbar Pressure Drop
46
CO and Combustion Check
47
Before CO and Combustion Checks
47
Commissioning Checks Flow Chart
47
Checking Flue Integrity
48
Flue Integrity Check Test Point
48
Flue Gas Analysis
48
Finishing Commissioning
49
Fitting the Front Casing
49
Benchmark Menu
49
Appliance Handover
49
Settings in the Service Menu
50
Operating the Service Menu
50
Changing the Setting Values
50
Exiting the Menu Item Without Saving Values
50
Service Menu
51
Overview of the Service Menu
51
Benchmark and Info Menu
53
Settings Menu
54
Menu Function Check
57
Thermal Disinfection
58
Inspection and Maintenance
58
Mains Supplies
58
Inspection and Maintenance Considerations
58
Maintenance Reminder Options
59
Checking Heat Exchanger Assembly
59
Maximum System Pressure
59
Natural Gas Appliances
59
Check Working Gas Inlet Pressure
60
Checking the Flue Integrity
60
Cleaning the Siphon and Heat Exchanger
60
Checking the Electrodes and Cleaning the Heat Exchanger
60
Removing the Fan with Mixing Unit
61
Non-Return Valve (Bearing Plate) in the Mixing Unit
61
Removing the Burner
61
Cleaning the Condensate Trap
63
Replacing the Gasket
63
Removing the Siphon
63
Setting the Air/Gas Ratio
64
Adjusting the Minimum Rated Output Settings
64
Adjusting the Maximum Rated Output Settings (LPG Appliances)
64
Replacement Parts
65
Draining the Appliance
65
Component Access
65
Removing the Front Casing
65
Removing the Heat Exchanger Assembly
66
Separating Components from the Heat Exchanger Assembly
66
Checking/Replacing the Motor of the 3-Way Valve
67
Removing the Pump
67
Replacing the Gas Valve
68
Replacing the PRV
68
Replacing the Expansion Vessel
68
Replacing the Pressure Sensor
68
Pressure Gauge Removal
69
Replacing the Control Unit
69
Control Unit Removal Preparations
69
Fault Finding and Diagnosis
70
Operating and Fault Displays
70
10.1.2 Operating/Fault Code Table
71
System Gassing
79
Environmental Protection and Disposal
81
Compostable Packaging
81
Data Protection Notice
81
Technical Specifications/Logs
82
Technical Data
82
Energy Consumption
84
Product Data on Energy Consumption
84
Component Resistance Characteristics
88
Sensor Values - Flue Overheat Thermostat
88
Sensor Values - Flow Temperature Sensor
88
Sensor Values - Cylinder Temperature Sensor
88
Pump Characteristic Map of the Heating Pump
89
Constant Pressure
89
Internal Wiring of the Appliance
90
Inspection and Maintenance Checklist
93

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Worcester GR4700iW 21 S NG Installation And Maintenance Instructions Manual (97 pages)

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