R 30/35/40 HE plus combi - Heatingspares247.com

Installation and Servicing InstructionsR 30/35/40 HE plus combiWall mounted condensing boiler for central heating and mainsfed domestic hot water6 720 610 893-01.TDZWBR 7-30 R 30 HE plus GC-Number: 41 311 79ZWBR 11-35 R 35 HE plus GC-Number: 41 311 80ZWBR 11-40 R 40 HE plus GC Number 41 311 816 720 611 400 GB (03.11) TD

ContentsContentsSafety precautions 3Symbols 31 Details of the appliance 41.1 EC Declaration of Conformity 41.2 Standard package 41.3 Description of appliance 41.4 Accessories 51.5 Casing dimensions 51.6 Layout of appliance 61.7 Function 71.8 Electrical wiring diagram 81.9 Technical data 92 Installation regulations 103 Installation 113.1 Important remarks 113.2 Domestic hot water 113.3 Sealed systems 113.4 Siting the appliance 123.5 Wall mounting frame assembly 133.6 Pre-piping the system 133.7 Fitting the appliance 143.8 Checking the connections 153.9 Flue Systems 153.9.1 Siting the Flue Terminal 163.9.2 Installation of the flue 173.9.3 Flue duct preparation and assembly 194 Electrical connections 204.1 Connecting the appliance 204.2 Connecting TR2 Room thermostat 214.3 Mains Voltage external controls connections 215 Commissioning 225.1 Commissioning 225.2 Switching the appliance on/off 235.3 Switching on the central heating 235.4 System controls 235.5 Setting the domestic hot water temperature and flowrate 245.5.1 Domestic hot water temperature 245.5.2 Hot water flow rate 245.6 Summer mode (hot water only) 245.7 Frost protection 245.8 Pump anti-seize function 245.9 Fault Condition 256 Text Display 266.1 General Description 266.2 Programming 266.2.1 Deleting a setting 276.2.2 Resetting all parameters to their original settings 276.3 Menu structure 276.4 Setting the time/day 286.4.1 Setting the time and day 286.4.2 Holidays 286.5 Heating 286.5.1 Heating programme 286.5.2 Setting Economy temperature (TR2 connected) 286.5.3 Manual operating mode (TR2 not connected) 296.6 Hot water 296.6.1 Hot water programme 296.6.2 Hot water immediately 296.7 i Info 296.8 Settings 306.8.1 Heating (if TR 2 is connected) 306.8.2 Hot Water (Storage Tank, system models only) 306.8.3 Service 306.9 Individual timer programmes 307 Individual settings 317.1 Mechanical settings 317.1.1 Checking the size of the expansion vessel 317.1.2 Setting the central heating flow temperature 317.2 Settings on the Bosch Heatronic 317.2.1 General description 317.2.2 Setting the anti-cycle time(Service Function 2.4) 327.2.3 Setting the maximum CH flow temperature (ServiceFunction 2.5) 327.2.4 Setting the heating output(Service Function 5.0) 327.2.5 Constant hot water cycle time(Service Function 6.8) 327.2.6 Variable pump settings(Service Function 7.0) 327.3 Setting the gas/air ratio 328 Converting the appliance to differentgas types 338.1 Setting the gas/air ratio 338.2 Testing combustion air/flue gas at set heat output 358.2.1 Testing the O2 or CO2 level in the combustion air 358.2.2 Testing CO and CO2 359 Maintenance 369.1 Pre-Service Check List 379.2 Description of servicing operations 389.3 Replacement of Parts 419.3.1 PCB control board and transformer 419.3.2 Fan Assembly 429.3.3 Pump 429.3.4 3-way diverter valve 439.3.5 3-way diverter valve motor 439.3.6 Sensors 439.3.7 Gas Valve 449.3.8 Domestic Hot Water Heat Exchanger 449.3.9 Electrode assembly 449.3.10 Pressure gauge 449.3.11 Expansion vessel 449.3.12 Pressure Relief Valve 449.3.13 Burner 449.3.14 Flow switch 459.3.15 Primary Heat Exchanger 4510 Appendix 4610.1 Fault Codes 4610.2 Short parts list 4710.3 Heating/hot water output settings R 30 HE N.G. 4810.4 Heating/hot water output settings R 30 HE L.P.G 4810.5 Heating/hot water output settings R 35 HE N.G. 4810.6 Heating/hot water output settings R 35 HE L.P.G 4810.7 Operational Flow diagrams 4910.7.1 Domestic hot water function 4910.7.2 Central heating function 5010.7.2Central heatingfunction 506 720 611 400 GB (03.11)2

Safety precautionsSafety precautionsIf you smell gasB Turn off gas service cock at the meter.B Open windows and doors.B Do not operate any electrical switches.B Extinguish any naked flames.B Telephone your gas company.If you smell fumes from the applianceB Switch off appliance (see page 23).B Open windows and doors.Fitting and modificationsB Fitting of the appliance or any controls to the appliancemay only be carried out by a competent engineerin accordance with the Gas Safety (Installationand Use) Regulations 1998.B Flue systems must not be modified in any ways otherthan as described in the fitting instructions.B This appliance is for use on sealed primary systems only.MaintenanceB The user is recommended: to have the systemregularly serviced in order to ensure that it functionsreliably and safely.B Use only original spare parts!Combustible materialsB Do not store or use any combustible materials(paper, thinners, paints etc.) in the vicinity of theappliance.Health and safetyB This appliance contains no asbestos products.B There is no potential hazard due to the appliancebeing electrically unsafe.B There are no substances used in the constructionthat are a potential hazard in relation to the COSHHRegulations (Control of Substances Hazardous toHealth Regulations 1988).UnpackingIMPORTANT HANDLING INSTRUCTIONSB Two people should transfer the packaged appliancefrom the van to the point of installationB Open the top of the carton, remove and place thecomponent tray and both side bars of the wall mountingframe to one sideB Lie the packaged appliance on its back. (The backhas “TRUCK HERE” printed on the carton)B One person firmly holds the packaging while theother straddles the boiler and slides it from the packagingB Two persons are then required to lift one end andstand the appliance upright with the flue at the topAdditional requirements for roof space installationB Two people should use two step ladders and sharelifting the unpacked boiler up to the loft hatchB Where the boiler enters the loft space, tilt and slidethe boiler on its back to the point of installationCheck the contents against the packing list.SymbolsiSafety instructions in this documentare identified by a warning-triangle symboland are printed on a grey background.Notes containing important informationare identified by the symbol shown on theleft. They are bordered by horizontal linesabove and below the text.Combustion air/Ambient atmosphereB The combustion air/ambient atmosphere should bekept free of chemically aggressive substances (e.g.halogenated hydrocarbons which contain chlorine orfluorine compounds). This will prevent corrosion.Instructions to the customerB Explain to the customer how the appliance works andhow to operate it.B Advise the user that he/she must not make any modificationsto the appliance or carry out any repairs on it.B These instructions are to be left with the user or atthe Gas meter.B Important: These instructions apply in the UK only.6 720 611 400 GB (03.11)3

Details of the appliance1 Details of the appliance1.1 EC Declaration of ConformityThis appliance is in accordance with the applicablerequirements of the Gas Appliance Directive, Boiler EfficiencyDirective, Electromagnetic Compatibility Directiveand the Low Voltage Directive.PINCategory UK1.2 Standard packageCE-0085 BL0507II 2H 3PAppliance Type C 13 , C 33Table 1• Gas condensing combination boiler for central heatingand domestic hot water• Control panel cover• Wall mounting frame• Fixings (screws etc.)• Set of documentation for appliance• Pre-plumbing manifold• Condensate drain pipe• Filling loop.1.3 Description of appliance• Wall-mounted appliance.• Natural gas models are low-emission appliances• Multi function display• Bosch Heatronic control system with integrated textdisplay for service functions and faults• 3-channel - digital timer for one heating circuit• Variable pump• Automatic ignition• Modulating control• Full safety systems incorporating Bosch Heatronicwith flame ionisation monitoring, solenoid valves andtemperature sensors• Concentric flue/air duct with testing point forCO 2 /CO• Regulated speed fan• Pre-mix burner• Temperature control for central heating• Temperature sensor in domestic hot water• Safety temperature limiter in 24 V electrical circuit• Relief valve, pressure gauge, expansion vessel, Autoair vent• Flue gas temperature limiter (105 °C)• Hot water priority circuit• Motorised 3-way valve• Plate-type heat exchange• Condensate Trap.46 720 611 400 GB (03.11)

Details of the appliance1.4 Accessories• Standard horizontal flue kit at 100 mm outsidediameter for flues up to 4 m in length (3.5m for the R40 HE).• Flue duct kits for horizontal (125 mm outsidediameter) for flue lengths up to 13m or 10m (R 35 &40 HE) and vertical flue systems for flue lengths upto 13.7m or 10.7m (R 35 & 40 HE). Fitting instructionsare sent with these kits.• TR2 Room Temperature Controller..1.5 Casing dimensionsmin .10*min .10*ZYX600*1208508501011310320044035360395*200306 720 610 599 - 01.TDFig. 113 Manifold assembly101 Outer case103 Facia coverX Standard Concentric Horizontal Flue System: min. 160 mmAlternative Concentric Flue System: min. 220 mmY Standard Concentric Horizontal Flue System: 40 mmAlternative Concentric Flue System: 70 mmZ Standard Concentric Horizontal Flue System: 105 mmAlternative Concentric Flue System: 130 mm* For servicing the applianceNote:Horizontal flue only: dimension X may need to increase dueto the incline of the flue.6 720 611 400 GB (03.11)5

Details of the appliance1.6 Layout of appliance221.1120221.227226202910232.1362716434159633586474183556.12954Fig. 24 Heatronic control6 Heat exchanger safety temperature limiter6.1 Hot water NTC sensor7 Testing point for gas supply pressure8.1 Pressure gauge9 Flue gas temperature limiter15 Relief valve18 Pump20 Expansion vessel27 Automatic air vent29 Air gas Mixer unit32.1 Electrode assembly36 Temperature sensor in CH flow43 CH flow63 Adjustable gas flow restrictor64 Adjusting screw for min. gas flow volume88 3-way valve (combi)98 DHW flow switch (combi)102 Inspection window6 720 610 599 - 00.TD4163968.1120 Fixing points221.1 Flue duct221.2 Combustion air intake226 Fan assembly295 Appliance type sticker271 Flue duct355 Plate-type domestic hot water heat exchanger358 Condensate trap396 Hose Condensate trap400 Text display415 Cover plate for cleaning access416 Condensate collector418 Data plate423 Siphon1842315884009866 720 611 400 GB (03.11)

Details of the appliance1.7 Function262722922629 33 303632J2022163529.196352.1694 61 317400ECO3 40251Emaxmax3556.1J5255909157764569695949397 9888M84158.1183584231343 44 45 46 476 720 610 597-03.2OFig. 34 Bosch Heatronic control6 Temperature limiter, heat exchanger6.1 Hot water NTC sensor7 Testing point for gas supply pressure8.1 Pressure gauge9 Flue gas temperature limiter13 Manifold15 Safety valve18 Central heating pump20 Expansion vessel26 Charging valve27 Automatic vent29 Mixer unit29.1 Bi-metallic thermostat for combustion air compensation30 Burner32 Flame sensing electrode33 Igniter electrode35 Heat exchanger with cooled combustion chamber36 Temperature sensor in CH flow43 CH flow44 Hot water flow45 Gas46 Cold water inlet47 CH return52 Solenoid valve 152.1 Solenoid valve 255 Filter56 Gas valve CE 42757 Main valve disc61 Reset button63 Gas flow restrictor, adjustable for max. gas flow volume64 Adjusting screw for min. gas flow volume69 Control valve84 Motor88 3-way valve90 Venturi91 Pressure relief valve93 Water flow regulator94 Diaphragm95 Pushrod with switch cam96 Microswitch97 Valve for hot water flow volume98 Water valve221 Flue duct226 Fan229 Air box317 Display355 Plate-type heat exchanger358 Condensate trap400 Text display423 Siphon443 Diaphragm6 720 611 400 GB (03.11)7

Details of the appliance1.8 Electrical wiring diagramo - orange g - green bl - black r - red p - purple33364 365 61 317 366 367 3634.1ECO25 V230 V153 136135230V/AC310312400302328 151L N Ns Ls LR313124 7 89161300ppp84M3 4 Fmains supply328.118MM 22696rroggoo964225252.156blblblblblo36326.16 720 610 602 - 02.1OFig. 44.1 Ignition transformer6 Temperature limiter, heat exchanger6.1 Hot water NTC sensor9 Flue gas temperature limiter18 Pump32 Flame sensing electrode33 Ignition electrode36 Temperature sensor in CH flow52 Solenoid valve 152.1 Solenoid valve 256 Gas valve CE 42761 Reset button84 Motor, 3-way valve96 Microswitch, hydraulic switch135 Master switch136 Temperature control for CH flow151 Fuse, slow 2.5 A, AC 230 V153 Transformer161 Link226 Fan300 Code plug302 Earth connection310 Temperature control for hot water312 Fuse, slow T 1,6 A313 Fuse, slow T 0,5 A317 Digital display328 Terminal block for AC 230 V Mains supply328.1 Link363 Indicator lamp for burner364 Indicator lamp for power supply365 “Chimney sweep” button366 Service button367 ECO button400 Text display422 Connecting TR286 720 611 400 GB (03.11)

Details of the appliance1.9 Technical dataUnitsR 30 HENGR 30 HEPropaneR 35 HEiNGR 35 HEPropaneR 40 HENGR 40 HEPropaneMax. rated heat output net 40/30°C central heating kW 31.2 31.2 37.5 37.5 41.4 41.4Max. rated heat output net 50/30°C central heating kW 30.9 30.9 37.1 37.1 41.4 41.4Max. rated heat output net 80/60°C central heating kW 29.2 29.2 35.1 35.1 39.1 39.1Max. rated heat input net kW 29.5 29.5 35.5 35.5 40.0 40.0Min. rated heat output net 40/30°CMin. rated heat output net 50/30°CMin. rated heat output net 80/60°CkWkWkW8.48.37.411.611.410.512.912.811.416.216.114.312.9 16.212.8 16.111.4 14.3Min. rated heat input net kW 7.6 10.8 11.8 14.8 11.8 14.8Max. rated heat output net, domestic hot water kW 29.2 29.2 35.1 35.1 39.1 39.1Max. rated heat input net, domestic hot water kW 29.5 29.5 35.5 35.5 40 40Maximum gas flow rate – After 10 minutes from lightingNatural gas G20 (CVnet 34.02 MJ/m 3 ) m 3 /h 3.1 3.7 4.2LPG (CVnet 88 MJ/m 3 ) kg/h 2.3 3.2Gas supply pressureNatural gas G20 (CVnet 34.02 MJ/m 3 ) mbar 20 - 20 - 20 -LPG (CVnet 88 MJ/m 3 ) mbar - 37 - 37 - 37Expansion vesselCharge pressure bar 0.75 0.75 0.75 0.75 0.75 0.75Total capacity l 10 10 10 10 10 10Hot water specificationsHot water flow rate @ 35° rise l/min 12.1 12.1 14.6 14.6 16.4 16.4Outlet temperature range °C 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60Max. permissible water supply pressure bar 10 10 10 10 10 10Min. inlet pressure for maximum flow rate bar 1.2 1.2 1.2 1.2 1.2 1.2Specific flow rate @ 30°C l/min 13.3 13.3 16.0 16.0 18.0 18.0FlueFlue gas temp. 80/60°C, rated/min. load °C 67/55 67/55 87/58 87/58 87/58 87/58Flue gas temp. 40/30°C, rated/min. load °C 43/32 43/32 65/43 65/43 65/43 65/43Residual delivery pressure (inc. pressure drop in air Pa 80 80 100 100 100 100intake duct)CO 2 level at max. rated heat output% 9.2 10.8 9.2 11.0 9.2 10.8CO 2 level at min. rated heat output% 8.8 10.5 9.2 11.0 9.2 10.8NO x -class 5 5 5 5 5 5SEDBUK figure Band A A A A A ACondensateMax. condensation rate (t R = 30°C) l/h 2.5 2.5 3.0 3.0 3.5 3.5pH-value, approx. pH 4.8 4.8 4.8 4.8 4.8 4.8General DataElectrical power supply voltage AC ... V 230 230 230 230 230 230Frequency Hz 50 50 50 50 50 50Max. power consumption W 125 125 152 152 183 183Noise output level dB(A) 37 37 40 40 42 42Appliance protection rating IP X4D X4D X4D X4D X4D X4DMax. CH flow temperature °C nom. 90 nom. 90 nom. 90 nom. 90 nom. 90 nom.90Max. permissible operating pressure (CH) bar 2.5 2.5 2.5 2.5 2.5 2.5Permissible ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50Nominal capacity of appliance l 3.75 3.75 3.75 3.75 3.75 3.75Weight (excluding packaging) kg 46 46 46 46 46 46Table 26 720 611 400 GB (03.11)9

Installation regulationsCondensate analysis, mg/lAmmonium 1.2 Nickel 0.15Lead ≤ 0.01 Mercury ≤ 0.0001Cadmium ≤ 0.001 Sulphate 1Chromium ≤ 0.005 Zinc ≤ 0.015HalogenatedTin ≤ 0.01hydrocarbons ≤ 0.002Hydrocarbons 0.015 Vanadium ≤ 0.001Copper 0.028 pH-value 4.8Table 3Flue systemHORIZONTAL 100 mm – Standard FLUE SYSTEMOverall Diameter of Duct mm 100Flue Terminal / DuctAssembly LengthTable 7Elbow - 90 ° Equivalent length 2 mBend - 45 ° Equivalent length 1mGas supplymm 600Extension Duct Length mm 1000Table 4HORIZONTAL 125 mm FLUE SYSTEMMax. 4 m(R30 & 35 HE)Max 3.5m(R40 HE)Overall Diameter of Duct mm 125 Max. 13 mFlue Terminal / DuctAssemblyTable 5mm 1030VERTICAL 100mm FLUE SYSTEM(R30HE)Max. 10m (R35 &40 HE)Overall Dia. of Duct mm 100 Excl. terminal:Max. 6.4m (R30Flue Terminal / DuctAssembly LengthTable 6mm 1140VERTICAL 125 mm FLUE SYSTEM& 35 HE)Max. 5.5m(R40HE)Overall Dia. of Duct mm 125 Excl. terminal: Max.13.7 m (R30HE)Flue Terminal / Ductmm 1365 Max. 10.7 mAssembly(R35 & 40HE)Total length of gas supply pipe(metres)3 6 9Gas discharge rate (m 3 /h)8.7 5.8 4.6 2218.0 12.0 9.4 28Table 8Pipe diameter(mm)Domestic water performanceDomesticWater FlowRate l/minTemperatureRiseTemperatureRiseTemperatureRiseR 30HE2 Installation regulationsGas Safety (Installation & Use) Regulations 1998: Allgas appliances must be installed by a competent person.Failure to install correctly could lead to prosecution.The manufacturers notes must not be taken, in any way,as overriding statutory obligations.The appliance must be installed in accordance with thecurrent IEE Wiring Regulations, local Building Regulations,Building Standards (Scotland) (Consolidation),bye-laws of the local Water Company, Health andSafety Document 635 (Electricity at Work Regulations1989) and any other local requirements.Product Liability regulations indicate that, in certain circumstances,the installer can be held responsible, notonly for mistakes on his part but also for damage resultingfrom the use of faulty materials. We advise theinstaller to avoid any risk by using only quality approvedbranded fittings.The relevant British Standards should be followed i.e.• BS 6798: Specification for the installation of gasfired hot water boilers of rated input not exceeding60kW• BS 5449: Central Heating for Domestic Premises• BS 5546: Installation of gas hot water supplies fordomestic purposes• BS 5440:1: Flues and ventilation for gas appliancesof rated input not exceeding 70 kW (net): Flues• BS 5440:2: Flues and ventilation for gas appliancesof rated input not exceeding 70 kW (net): AirSupply• BS 6891: Installation of low pressure gas pipeworkinstallations up to 28mm (R1).• BS 7074:1: Code of practice for domestic heatingand hot water supply• BS 7671: Requirements for Electrical Installation.These instructions must be followed.R 35HER 40HE30 °C 14.2 17.0 19.235 °C 12.1 14.6 16.440 °C 10.6 12.8 14.4Maximum Mains pressure bar 10.0 10.0 10Minimum Mains pressure bar 0.2 0.2 0.2Table 9106 720 611 400 GB (03.11)

Installation3 InstallationiB Always turn off the gas cock before carryingout any work on componentswhich carry gas.Fixing of the appliance, gas and flue connections,commissioning of the systemand electrical connections may only becarried out by competent persons authorisedby CORGI.3.1 Important remarksB Appliance should only be installed in sealed centralheating and hot water systems.B To avoid gas formation in the system, galvanised radiatorsor pipes must not be used.B If a room thermostat is used: do not fit a thermostaticradiator valve on the radiator in the primary room.B This appliance uses an automatically variable pump.An auto-bypass must not be fitted.B Add a suitable anti-freeze fluid to the water in thecentral heating system.Suitable products are available from Betz-DearbornTel: 0151-4209563 and Fernox Tel: 01799-550811.B In our experience, the addition of sealing agents tothe water in the central heating system can causeproblems (deposits in the heat exchanger). For thatreason we advise against their use.3.2 Domestic hot waterAny regulations specified by the local water companymust be observed.The final 600 mm of the mains cold water connection tothe appliance should be made in copper tube only.The appliance is suitable for a mains supply having amaximum pressure of 10 bar. A pressure reducing valvemust be fitted, if necessary.The hot water outlet temperature is set to be capable ofachieving a maximum of 60°C. The maximum temperatureand the frequency of the recharge of the heat storemay be reset.The water flow rate of 10.6 l/min (R 30 HE), 12.8 l/min(R 35 HE) and 14.4 l/min (R 40 HE) will give a temperaturerise of 40°C. If a higher rise is required then theflow must be reduced at the tap and the discharge temperaturewill rise up to the maximum set figure.The temperature rise, up to the maximum set by theuser, is automatically maintained by the modulation ofthe heat input. In winter, when the mains temperature isvery low, the water flow, adjusted at the tap or shower,should be reduced to maintain the required deliverytemperature.It is suggested that long pipe runs to taps or showersbe insulated to prevent the rapid cooling of the water.All types of single lever mixer taps and thermostaticmixer units suitable for a mains pressure of up to 10 barcan be used.The head of a loose-head shower must not be allowedto fall within 25 mm of the top the bath to prevent therisk of water being drawn back into the mains. Alternativelythe shower must be fitted with an anti-syphonagedevice at the point of the flexible hose connections.Over-rim bidets may be connected to the appliance providedthat it is in accordance with the requirements ofthe local water company. The outlet(s) should beshrouded and unable to have any temporary hand heldspray attached. No anti-syphonage arrangements arenecessary.In exceptionally hard water areas a device to preventscale formation may be fitted or, alternatively, the maximumtemperature reset to about 45°C which mayreduce the risk of scale formation. The installation of ascale inhibitor assembly should be in accordance withthe requirements of the local water company. Artificiallysoftened water must not be used to fill the central heatingsystem. An isolating valve should be fitted to allowfor servicing.Devices, such as water meters or back-flow preventionvalves, capable of preventing the flow ofexpansion water must not be fitted unless separatearrangements have been made.A Zilmet Z160 expansion vessel is the preferred type. Athread sealant compatible with potable water must beused. The vessel should be connected into the coldwater mains inlet pipe as close as possible to the appliance.3.3 Sealed systemsThe appliance must not be operated without the systembeing full of water, properly vented and pressurised.The expansion vessel has a volume of 10 litres and ischarged to a pressure of 0.75 bar.The water capacity of the system is shown in table 12,page 30. If a greater capacity is required then an additionalexpansion vessel must be fitted into the systemreturn as close to the appliance as possible. The systempressure can be set up to a maximum of 1.5 bar with1bar being the normal setting.If the system pressure is greater than 2.5 bar when theappliance is operating at maximum temperature then anadditional expansion vessel must be fitted into the systemreturn as close to the appliance as possible.The filling point must be at low level and arranged asshown in figs. 5 and 6.The pressure relief valve is set to operate at 3 bar.There must be no connection to the mains without theapproval of the local water company. All connections inthe system must be capable of withstanding a pressureof up to 3 bar and the radiator valves conform to the6 720 611 400 GB (03.11)11

Installationrequirements of BS2767:10.Fit Thermostatic Radiator Valves to radiators in thesleeping accommodation and not to the radiator wherethe room thermostat is sited, this must be left open.Repeated venting probably indicates a leak and thismust be rectified to ensure the proper operation of theappliance.No galvanised radiators or pipes must be used.If any system water treatment is required thenonly products suitable for use with Aluminiumshall be used i.e Fernox- Copal or Superconcentrateor Sentinal X100, in accordance with themanufacturers instructions. The use of any othersubstances will invalidate the guarantee. The pHvalue of the system water must be less than 8 orthe appliance guarantee will be invalidated.Suitable products are available from Betz-Dearborn Tel:0151-4209563 and Fernox Tel: 01799-550811.A drain cock to BS2879 must be fitted to the lowestpoint of the system.IMPORTANT: Check that no dirt is left in thewater pipework as this could damage the appliance.Thoroughly flush the heating system andthe mains water supply before fitting the applianceto the wall in accordance with the recommendationsof BS7593:1992.APPLIANCERefer toApplianceWater FlowDiagramWRCapprovedfilling loopRadiator valveLockshield valveCentral heating returnCentral heating flowDomestichot waterBS stop valveFixed spindle type.Water mainA drain cock should be fitted at the lowest point of theheating circuit and the appliance6 720 610 576 -09.3OFig. 5Sealed primary water systemFig. 63.4 Siting the applianceRegulations concerning the Installation SiteB Relevant national regulations must be complied withsection 3.9.1.B Consult the installation instructions for details of minimumclearances required.Combustion airIn order to prevent corrosion, the combustion air mustnot contain any corrosive substances.Substances classed as corrosion-promoting includehalogenated hydrocarbons which contain chlorine andfluorine compounds and are contained in some solvents,paints, adhesives, aerosol propellants and householdcleaners, for example.Surface temperatureThe max. surface temperature of the casing and the flueis less than 85 °C.This means that, no special safety precautions arerequired with regard to flammable building materialsand fitted furniture. The specified clearances must bemaintained.Cupboard/CompartmentThe appliance can be installed in a cupboard/compartmentneed for airing clothes providing that the requirementsof BS6798 and BS5440:2 are followed. The lowcasing losses from the appliance eliminate the need forventilation openings in the compartment.126 720 611 400 GB (03.11)

Installation3.5 Wall mounting frame assemblyB Take the wall mounting frame out of the package andscrew together with 6 screws as shown in fig. 7. Usethe inner lugs on the top and bottom horizontal sections.B Screw the pre-plumbing manifold with two screws tothe wall mounting frame.6 720 610 597-08.1O6 720 610 597-06.1OFig. 7B Hold the wall-mounting frame against the wall ensuringthat it is vertical.B Mark the holes for the wall mounting frame onto thewall, drill and plug the holes and screw the wallmounting frame to the wall with the screws provided.B Mark the position of the flue duct hole if a rear flue isto be used. Refer to fig. 1 and 16.Fig. 93.6 Pre-piping the system200171 112 17243475035Fig. 86 720 610 597-07.1OFig. 10 Manifold43 CH flow47 CH return112 Gas cock171 Domestic hot water172 Cold water relief120-1302606 720 610 576-06.1OB A drain tap should be fitted at the lowest point of thecentral heating system.B WRAS approved filling loop must be fitted.6 720 611 400 GB (03.11)13

InstallationCondensate Termination and RouteThe appliance has a built-in syphonic condensate trapeliminating the need for external traps. Connect to the22mm plastic drain pipe and extend the pipe run awayfrom the control panel and appliance witha constant fallof 2.5° or 25mm in every metre. See Fig. 12The condensate pipe can terminate into any of fourareas:BoilerSiphonNo lengthrestrictionØ 22 min.75 min. trapThe gradient of the discharge pipeshould be 2.5¡ (40 mm/m) minimumSinkAn internal waste systemOpen end of pipe directinto gully, below groundbut above water levelØ 22 min.BoilerSiphonUse waterproof pipe workinsulation in very exposedpositionsThe gradient of the discharge pipe should be2.5¡ (40 mm/m) minimumAn external waste systemOpen end of pipedirect into gully,below ground butabove water level.External condensate pipeworkThe syphonic condensate trap collects condensate intoa trap which releases it in 100 ml quantities. This helpsto prevent the discharge from freezing.If there is no alternative and the condensate pipe has tobe externally run, the following should be considered:• The pipe run should take the shortest practical route.• The pipework should be insulated with weatherresistant insulation.• The pipe should terminate as close as possible to theground or drain, whilst still allowing the condensateto safely disperse. This would prevent wind blowingup the pipe.• The pipework should be installed with the minimumof horizontal runs and with a downward slope of atleast 2.5 °.BoilerØ 22 min.Internal soiland vent stackSinkBoilerNo lengthrestriction3.7 Fitting the applianceNo lengthrestriction75 min. trapThe gradient of the discharge pipeshould be 2.5¡ (40 mm/m) minimumThe rainwater systemInvert450 min.Ø 22 min.The gradient of the discharge pipeshould be 2.5¡ (40 mm/m) minimumOpen end of pipedirect into gully,below ground butabove water levelAn external purpose made soakawayFig. 11Whilst all of the above methods are acceptable it isalways the best practice to terminate the condense pipevia an internal waste system.This will eliminate the needfor any external condensate pipe runs which can be susceptibleto freezing in extreme weather.Siphon75 min. trap6 720 610 596 -03.2TDRemoving the outer caseiBenchmark: For optimum performanceafter installation, this boiler and its associatedcentral heating system must beflushed in accordance with the guidelinesgiven in BS5793:1992 “Treatmentof water in domestic hot water centralheating systems”.The outer case is secured against unauthorisedremoval by a retaining bracket(electrical safety) at the bottom left. Alwayssecure the outer case with thisbracket again after refitting.B Remove retaining screws (1), see Fig. 13.B Slide the outer case upwards and forwards toremove (2).2.6 720 610 602 - 04.1O16 720 610 597 -10.TDFig. 12 Recommended route of the condensate drainFig. 13146 720 611 400 GB (03.11)

InstallationFixing the applianceB Fit the washers onto the gas and water connections.B Lift the boiler onto the wall-mounting frame. The lugspass through the rectangular holes in the boiler backpanel.B Take care not to disturb the washers on the connections.Connecting the flue ductB Fit flue duct connector onto boiler flue socket.B Secure with the screws supplied.Flue TurretFlue sealRetainingScrewApplianceFlue SocketFig. 14B For remaining installation of flue assembly, refer tothe relevant installation instructions.3.8 Checking the connectionsFlue Turret toBoiler SealingGasket6 720 610 599 - 01.TDThe flue system must be installed in accordance withthe requirements of BS5440:1.Standard 100 mm flue systemThe standard concentric flue system provides for a horizontallength of up to 4m (3.5m R 40 HE). Full instructionsfor fitting this flue are in Subsection 3.9.2“Installation of the flue”.Alternative 125 mm diameter flue systemsInstallation instructions for the alternative flue systemsare sent with the appropriate flue kit.Systems are available for a maximum horizontal lengthof 13m (R 30 HE),10m (R 35 & 40 HE).A vertical flue system up to a height of 13.7 m (R 30 HE)and10.7 m (R 35 & 40 HE) is available.45° and 90° flue bends can be used with a reduction influe length of 2 m for each 90° bend and 1 m for each45° bend used.IMPORTANT: Any horizontal flue system fitted to acondensing boiler must incline from the appliance at anangle of 3° (30 mm per metre length) to prevent condensatedripping from the flue terminal.Note, the standard 100mm horizontal flue requires onlya 0.5° incline from the boiler as the inner exhaust pipe isinclined at 2.5° inside the outer pipe.This means that the clearance above the appliancemust be increased to match the duct length.Refer to fig. 1 on page 5.Water connectionsB Check that the O-rings or seals are in place beforetightening the connection.B Turn on the service valves for central heating flowand return and fill the heating system through aWRAS approved filling loop.B Check all seals and unions for leaks (testing pressuremax. 3.0 bar as indicated by pressure gauge).B Turn on cold water service cock and fill hot water system(testing pressure max. 10 bar).B Check all connections for leaks.Gas supply pipeB Check that the seal is in place before tightening theconnection.B Turn off gas cock to protect gas valve against damagefrom excessive pressure.B Check gas supply pipe.B Release the pressure on the gas supply pipe.3.9 Flue SystemsThe only flue systems that may be used are those suppliedwith the boiler.6 720 611 400 GB (03.11)15

Installation3.9.1 Siting the Flue TerminalThe flue must be installed in accordance withBS 5440:1 and the Building Regulations. Flue terminalsin carports and under balconies are to be avoided.The terminal must be positioned so that it does notcause an obstruction nor the combustion products anuisance. See fig. 15 and table 10.The terminal will, at times, give out a plume of watervapour and consideration must be given to this whenchoosing a terminal position. Keep clear of securitylighting, activated by passive infra-red sensing heads.If the terminal is less than 2 m above a surface to whichpeople have access then a guard must be fitted. Theguard must be evenly spaced about the terminal with aspace of 50 mm in each direction and fixed with platedscrews.A guard Type K6 for the standard horizontal flue, can beobtained from Tower Flue Components, Vale Rise, TonbridgeTN9 1TB.PQboundaryIQD,EQBJHLFGACHMNIHKFig. 15Minimum dimensions of flue terminal positions (all types) (see fig. 15)Dimension Terminal position (kW input expressed in net) Balanced flues room sealed: Fanned draughtA 1) Directly below an opening, air brick, opening windows, etc. 300 mmB 1) Above an opening, air brick, opening window, etc. 300 mmC 1) Horizontally to an opening, air brick, opening window, etc. 300 mmD Below gutters, soil pipes or drain pipes 75 mmE Below eaves 200 mmF Below balconies or car port roof (lowest point) Not recommendedG From a vertical drain pipe or soil pipe 75 mmH From an internal or external corner or to a boundary alongside the terminal 300 mmI Above ground roof or balcony level 300 mmJ From a surface or boundary facing the terminal 1200 mmK From a terminal facing the terminal 2000 mmL From an opening in the car port (e. g. door, window) into the dwelling Not recommendedM Vertically from a terminal on the same wall 1500mmN Horizontally from a terminal on the same wall 300 mmP From a vertical structure on the roof 500 mmQ Above intersection with roof 300 mmTable 101) In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purposeof accommodating a built-in element such as a window frame.166 720 611 400 GB (03.11)

Installation3.9.2 Installation of the flueThe standard 100 mm diameter horizontal flue system issuitable for lengths up to 4m (3.5m R40 HE).Flues up to 650 mm do not require an extension ductassembly.Flues between 1600 mm and 4000 mm (3500 mm R40 HE) require extension duct assemblies.NOTE: Flue lengths between 650 mm and 730 mmcannot be accommodated. Refer to fig. 17, 18, 19.Standard 100m system comprise:• Flue turret• Flue turret clamp• Terminal assembly• Wall sealing gasket and cover plate.Refer to fig. 20Instructions for fitting other flue systems are packedwith the relevant flue kit.Check that the position chosen for the appliance is satisfactory.Refer to fig. 16.FlueTurretFig. 17 Standard FlueMaximum 650mmMinimum 100mmClampTerminalAssemblyOuterWall6 720 610 599 - 01.TDCentre line offlue/air ductH120mmCentreline offlueopeningandapplianceApplianceTop of wallmountingframe (notboiler)Drillingpoint forflue ductopeningH = 40mm for the Standard 100mm Horizontal FlueH = 70mm for the Optional 125mm Horizontal Flue3°(30mm/metre)Standard 100mmhorizontal flue 0.5°(5mm/metre)Fig. 16 Marking the position of a side flue opening.Note: ensure there is adequate access to theair/flue sampling points in the flue turret.6 720 610 602-08.3O6 720 611 400 GB (03.11)17

InstallationFlueTurretMaximum 1600mmOuterWallClampExtensionDuctTerminalAssembly6 720 610 599 - 00.TDFig. 18 Flue with One ExtensionFlueTurretOuterWallClampExtensionDuctClampExtensionDuctClampTerminalAssembly6 720 610 599 - 01.TDFig. 19 Flue with ExtensionsFlueTurretClampExtension Flue DuctFlue TerminalWall Sealing Gasket6 720 610 599 - 01.TDFig. 20 Flue Components3.9.3 Flue duct preparation and assemblyMeasure the flue length L. Refer to fig. 21, 22.186 720 611 400 GB (03.11)

InstallationLOuter Wall FaceFlue Terminal120Wall Sealing Gasket6 720 610 599 - 01.TDFig. 21 Flue length - rearL6 720 610 599-00.TDFig. 23 Flue terminal positionAssemble flue system completely. Push the ducts fullytogether and clamp in the positions. The slope of theterminal outlet must be directed as per Fig. 23.The assembly will be made easier if a solvent freegrease is lightly applied i.e Silicone lubricant, to themale end of the ducts.NOTE: An inner wall sealing plate is providedwhich should be fitted to the ducts before assembly.Push the assembly through the wall and fix the turret tothe appliance with the screws provided. Refer to fig. 24.Flue TurretFig. 22 Flue length - side6 720 610 599 - 01.TDFlue sealMeasure ‘L’ from the end of the metal section of the flueterminal to the centre of the flue outlet on the boiler asshown in Fig. 21 & Fig. 22 and deduct 90mm from thatmeasurement.Cut both inner and outer flue pipe square at the oppositeend to the terminal without creasing the tubes.RetainingScrewApplianceFlue SocketFlue Turret toBoiler SealingGasket6 720 610 599 - 01.TDRemove any burrs before fitting the terminal to the turret.Fig. 24 Flue turretEnsure that the turret is fully secured to the socket onthe boiler.If the terminal is within 2 m of the ground where there isaccess then an approved terminal guard must be fitted.The guard must give a clearance of at least 50 mmaround the terminal and fixed with corrosion resistantscrews.6 720 611 400 GB (03.11)19

Electrical connections4 Electrical connectionsB Always disconnect the power supply tothe appliance at the mains before carryingout any work on the electrical systemsand components.B Allow mains cable to protrude at least 50 cm fromwall.B To maintain the splash-proof (IP) design: cut thecable grommet hole size to match the diameter of thecable, see fig. 27.B The appliance must be earthed.B It must be possible to completely isolate the appliancewith at least 3mm contact separation in bothpoles.The wiring between the appliance and the electricalsupply shall comply with current IEE Wiring Regulations(and any local regulations which apply) for fixed wiringto a stationary appliance.• Supply: 230 V ~ 50 Hz, 150 Watts• External fuse 3 A• The system connected to the boiler must NOT havea separate electrical supply• Water Protection IPX4D.4.1 Connecting the applianceTo gain access to the mains connection remove thedrop down facia cover. The drop down cover isremoved by lowering it to the horizontal position andpushing firmly upwards at the rear of the supports torelease the cover. Lift cover from the appliance.After installation (or in the event of an electrical fault) theelectrical system shall be checked for short circuits,fuse failure, incorrect polarity of connections, earth continuityand resistance to earth.B Pull out cover panel at the bottom and remove. Referto fig. 25.Fig. 25B Remove screw and slide terminal cover forwards toremove. Refer to fig. 26.Fig. 26206 720 611 400 GB (03.11)

Electrical connectionsB Cut cable grommet to diameter of cable. 4.3 Mains Voltage external controlsconnectionsExternally wired controls are not required; the boiler hasa built-in text display programmer and frost protection.The TR2 room thermostat (not supplied) provides additionalfrost protection and compliance to Part L of theBuilding Regulations.Fig. 27B Feed cable through cable grommet and connect themains supply cable, see fig. 28.B Secure cable in cable grommet by means of cablegrip.L N N S LFig. 284.2 Connecting a TR2 Room Thermostat(accessory)Connect the TR2 to terminals 3, 4 and F beneath theText display (page 8, fig. 4, item 422) using a minimum1mm cable to avoid incresing resistance between theterminals, see Fig. 29TR2F 3 434 A FTEXT DISPLAYFig. 296 720 611 400 GB (03.11)21

Commissioning5 Commissioning27136365 61 317 366 367358ECO364135E363 310 4008.129515170nn.171 172 173 170Fig. 308.1 Pressure gauge15 Safety valve27 Automatic vent61 Reset button135 Master switch136 Temperature control for central heating170 Service cocks on CH flow and return171 Hot water172 Gas cock (shown in off position)173 Cold water service cock295 Appliance type sticker310 Temperature control for hot water317 Multi function display358 Condensation trap363 Indicator lamp for burner364 Indicator lamp for power supply365 “Chimney sweep” button366 Service button367 ECO button400 Text display5.1 Commissioningi6 720 610 597 - 05.1ONever run the appliance when empty orunpressurised.The operational CO 2 level is set at the factoryand no adjustment is necessary wheninstalling a natural gas fired appliance.Benchmark Water Treatment: For optimum performanceafter installation, this boiler and its associated centralheating system should be flushed in accordancewith the guidelines given in BS7593:1992 - Treatmentof water in domestic hot water systems. Full instructionsare supplied with proprietary cleansers sold for this purpose.If an inhibitor is to be used after flushing, it shouldbe used in accordance with the inhibitor manufacturersinstructions.To drain the appliance shut the system valves and openthe system drain point.Suitable flushing agents and inhibitors are availablefrom Betz-Dearborn Tel: 0151-4209563 and FernoxTel: 01799-550811. Instructions for use are suppliedwith the these products.226 720 611 400 GB (03.11)

CommissioningB Before commissioning, the gas supply pressuremust be checked at the gas supply pressuretest point (see page 6, fig. 2, item 7).Natural gas appliances must not be operated ifthe gas supply pressure is below 18 mbar orabove 24 mbar. LPG appliances must not beoperated if the supply pressure is not 37 mbarat the inlet to the appliance.B Unscrew the condensation trap (358) and pull out, fillwith approx. 1/4 l of water and refit. Refer to fig. 30.B Adjust charge pressure of expansion vessel to statichead of the central heating system (see page 30).B Open all system radiator valves.B Check automatic air vent is open, item 27, see fig 30B Turn on service valves (170), fill central heating systemto pressure of 1 - 2 bar through the WRASapproved filling loop. Refer to fig. 30.B Vent radiators.B Refill heating system and set the pressure to 1 bar.B Turn on cold water service cock (173). Refer tofig. 30.B Check that the gas type specified on the identificationplate matches that of the gas supply.B Turn on gas cock (172). Refer to fig. 30.5.2 Switching the appliance on/offSwitching off the applianceB Set the master switch to (0).The green indicator lamp goes out. The optional timerwill continue running until the emergency supply isexhausted.B Always disconnect the appliance fromthe power supply (fuse, circuit breaker)before carrying out any work on theelectrical systems or components.5.3 Switching on the central heatingThe central heating flow temperature is adjustablebetween 35°C and 88°C. Refer to table 13, page 30.B Turn the temperature control to set the flow temperatureto a level appropriate to the type of centralheating system:– Underfloor heating: e.g. setting “3”(approx. 50°C)– Low-temperature heating: setting “E”(approx. 75°C)– Central heating systems for flow temperatures upto 88 °C: limited “max” setting for low-temperatureoperation (see page 30).When the burner is alight, the red indicator lamplights up.Switching onB Switch on the appliance at the master switch (I).The indicator lamp shows green and the display willshow the central heating flow temperature, when theappliance is operating in the central heating mode.Fig. 326 720 610 333-05.1OFig. 31i6 720 610 333-04.1OIf the display alternates between -II- andthe central heating flow temperature, thetrap filling programme is active.5.4 System controlsB Set room thermostat (if fitted) to the desired roomtemperature.B Set room temperature controller (TR2), if fitted. Referto the instructions with the control.B Set the thermostatic radiator valves to the desiredsettings.The trap filling programme ensures that the condensationtrap is filled after the appliance has been installedor after the appliance has been out of use for a longperiod or the mains supply has been interrupted. Forthat reason, the appliance remains at minimum heatingoutput for 15 minutes.6 720 611 400 GB (03.11)23

Commissioning5.5 Setting the domestic hot watertemperature and flow rate5.5.1 Domestic hot water temperatureThe hot water temperature can be set to betweenapprox. 40 °C and 60 °C.This temperature is not shown on the display.B To reduce the flow rate (min. 8 l/min):turn screw on flow switch clockwise (–).The outlet temperature will increase relative to thedecrease in the flow rate.Fig. 336 720 610 333-07.1OSetting Hot Water temperatureTurn fully anti-clockwise approx. 40°Capprox. 55°CTurn fully clockwise approx. 60°CTable 11“ECO” buttonBy pressing and holding the “ECO” button , until thedisplay lights, you can switch between Comfort modeand Economy mode.Comfort mode: button is not lit (factory setting)The appliance is held constantly at the set temperature.This means that hot water is available almost instantaneouslyat the tap. Consequently the appliance willswitch on at intervals, even if no hot water is beingdrawn.ECO mode with demand detection, button is litThe demand detection function enables maximum gasand water economy.Briefly turning a hot water tap on and then off again signalsdemand to the appliance which then heats up thewater to the set temperature.Hot water is thus available in about 1 minute.ECO mode, button is litWater is not heated up until hot water is drawn. Thismeans that there is a longer waiting period before hotwater is available.5.5.2 Hot water flow rateAdjust the flow rate according to model.Under standard conditions (2 bar) supply pressure, onefull turn is equivalent to approximately 2 l/min.B To increase the flow rate:turn screw on flow switch anti-clockwise (+).The outlet temperature will decrease relative to theincrease in the flow rate.Fig. 345.6 Summer mode (hot water only)With room thermostatB Turn temperature control on the appliance anticlockwiseas far as the stop.The central heating is now turned off. The hot waterfunction and the mains power supply for the heatingprogrammer and timer remain switched on.5.7 Frost protectionB Leave master switch switched on.iIf the appliance is to be left for long periods switch thecentral heating off:B Add a suitable anti-freeze fluid to the water in thecentral heating system.Suitable products are available from Betz-DearbornTel: 0151-4209563 and Fernox Tel: 01799-550811.5.8 Pump anti-seize functioni6720 610 332-25.1OFrost protection and constant frost protectionmodes can be set on the text displaymodule.This function prevents the central heatingpump seizing after long periods of inactivity.Every time the pump is switched off, (after a CHdemand) a timer is started. If after 24 hours the pumphas not run again, it is switched on for a period of 10seconds.246 720 611 400 GB (03.11)

Text Display6 Text Display6.1 General Description• The text display is used to display information aboutthe appliance and the system and to alter the settingsdisplayed.• Once the appliance has been in operation for oneday, the text display module has a power bufferperiod of about 10 hours during which it will run withoutthe mains power supply. After that period haselapsed, the clock function shuts down but all othersettings are retained.6.2 ProgrammingB To start programming, press any button, e. g. .The display lighting switches on and the main menuis displayed:TFig. 36 Main menuB Use the or button to move the cursorarrow on the left of the menu so that it points to thedesired menu item.In this example, the cursor is positioned next to themenu item Time/day/holidays.B Confirm the selection by pressing the button.The corresponding submenu is displayed:T/holidays6 720 610 598-04.2O6 720 610 598-05.2OFig. 35 Controlsabcdef Display“Up”/“More” button“Down”/“Less” button“Back” button“Next” button“Delete” buttonThe standard display shows the following information:• Time• Room temperature (if TR 2 connected)• CH flow temperature.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 duringcommissioning, servicing, etc.The programming procedure is described in detailbelow using the clock function as an example:Fig. 37 Submenu: Time/dayIn the submenus, the top line indicates what action isrequired.The bottom line shows the previous menu level, if applicable(see fig. 38).B Use the or button to select Time/day.B Confirm the selection by pressing the button.The corresponding submenu is displayed:HT6 720 610 598-06.2OFig. 38 Setting the hourWhen settings are being entered, the setting to bealtered is indicated on the top line. In addition, the settingbeing altered is displayed with a dark background.B Use the or button to set the hour.– Press and release to change the display by oneunit at a time– Press and hold to change the display rapidlyB Confirm the setting by pressing the button.B Use the or button to set the minutes.B Confirm the setting by pressing the button.B Use the or button to set the day of theweek.6 720 611 400 GB (03.11)25

Text DisplayB Press the button to confirm the setting. Thecursor then returns to the top line.-or-B Press the button to confirm the setting andreturn to the previous menu (fig. 37 page 25).-or-B Do not press any other buttons for 15 minutes.6.2.1 Deleting a settingEither overwrite the setting or press the delete it.B Find the setting to be deleted.B Press and release the button.The display shows --:--button to6.2.2 Resetting all parameters to their originalsettingsiThe hours of service can not be reset to 0.B Press and hold the button for more than 15 seconds.After about 5 seconds, the following messageappears on the display:ATTENTIONDelete all parametersin x secondsOnce the reset has been completed, the followingmessage is displayed:Please wait... Initialising6.3 Menu structureSubmenuMainmenu 1. 2. 3.Time/day/holidaysHeatingHotwaterParameters tochange/selectTime/day - - - Hours- Minutes- Day of weekHolidays - - Days holiday 27HeatingprogramSet economytemp.(if TR2 isconnected)Manual(if TR2 isnot connected)HotwaterprogramHotwaterimmediately- - - Day- 1st operating mode- 1st switching point...- 6th switching pointPage2727- - 5...30°C 28- - - Automatic- Constant on(comfort)- Constant off(economy)- - - Day- 1st operating mode- 1st switching point...- 6th switching point2829- - Off/On 29Info - - - - 28Settings Heating - - Optimum Start Off/ 29OnHotwater(ZSBRmodels)ServiceDisplayserviceparam.Furtheroptions28- - 29-English/-Français/-Deutsch- - Only charging times/times and temperaturesLanguage-Time correction-LCD contrastOperatingtimesFaulthistory292929- 29- 29266 720 611 400 GB (03.11)

Text Display6.4 Setting the time/day6.4.1 Setting the time and dayFor details of how to set the time and day, refer topage 25.i6.4.2 HolidaysIn the Holiday programme, the central heating runs inEconomy mode and the hot water is switched off (frostprotection function remains active).B From the main menu, select Time/day/holidays,and from the first submenu select Holidays.B Enter the number of days holiday by pressing or(max. 99 days holiday).After the set number of days, the text display moduleautomatically cancels Economy mode at midnight onthe last day and returns to Automatic mode.iChanging winter and summer time:B Only adjust the clock! Do not alter theswitching points (for heating, economy,etc.).The day on which you enter the days holidaycounts as the first day of the holiday, i.e. theunit starts the holiday program immediately.Only include the day on which you are returningif you don’t want the heating to return tothe normal program on that day!To cancel Holiday mode early:B In the Holidays submenu:Press the button until the display shows 0 .6.5 Heating6.5.1 Heating programmeComfort Mode:• With TR2 Room thermostat fitted:Central heating is on. House will be heated to temperatureset on TR2.• Without TR2 Room thermostat fitted:Central heating is on. Primary water is heated to temperatureset at (radiator symbol) dial.Economy Mode:• With TR2 Room thermostat fitted:Central heating is on. House will be heated to temperatureset on ‘’Economy mode’’ of Text Display.• Without TR2 Room thermostat fitted:Central heating will be off.Frost protection:Central heating is off. Boiler will only fire if sensor registerstemperatures below 5°C.Basic setting (Automatic mode)• The appliance switches automatically between normalheating, Economy mode and Frost protectionmode according to the timer settings entered.• Basic setting:– Heating (Comfort)starts at 6:00 am– Economy starts at 10:00 pmSetting options• Maximum of six switching points per day with threedifferent operating modes (Comfort, Economy, Frostprotection).• Same times for Monday to Friday.• Same times for Saturday and Sunday.• Different times for every day.Setting switching times and operating modeB From the main menu select Heating and then fromthe first submenu, select Heating program.B Select Monday - Friday, Saturday and Sunday oran individual day of the week.– Monday - Friday: to have “Comfort” and “Economy”or “Frost protection” switching on at thesame times every weekday.– Saturday - Sunday: to have “Comfort” and“Economy” or “Frost protection” switching on atthe same times Saturday and Sunday.– Individual day of the week (e. g. Thursday): tohave the relevant program always switching on atthe specified time on that day of the week, i.e.“Comfort”, “Economy” or “Frost protection” at thesame time every Thursday.B Press . The display shows Set 1. operatingmode.B Set the desired first operating mode (Comfort, Economyor Frost protection).B Press . The display shows Set 1. time period.B Set the desired first time period.B Press . Set the following operating modes andtime periods as described for the first.B If necessary: select the next day and enter the operatingmodes and timer periods as described above.iIf the settings for a particular day of theweek are different from the settings for theother days, then if Monday - Friday orSaturday and Sunday is selected, thedisplay shows--:--, i.e. there are no common switchingpoints for those options.Timer periods and operating modes are you do not wishto change can be skipped by pressing .6 720 611 400 GB (03.11)27

Text Display6.5.2 Setting the Economy temperature (if TR2is connected)This option allows you to set the room temperature forEconomy mode (Off (Economy)).This function is only active if:• Automatic mode or Economy mode is set on the TR2room thermostat.B From the main menu, select Heating and then fromthe first submenu, select Set Economy temp..B Use the or button to set a temperaturebetween 5 and 30 °C.6.5.3 Manual operating mode (if TR2 is not connected)For selecting an operating mode that is different fromthe one set in the heating programme (Automaticmode).• You can choose between Automatic, Constant on(comfort) and Constant off (economy).• The manually selected operating mode starts immediately.• Constant off (economy) and Constant on (comfort)are automatically reset at 00.00 (midnight).• To cancel the manually selected operating mode:– select the relevant menu and then press the button,– or select a different operating mode,– or set Holiday.6.7 i InfoB Select Info from the main menu.You can view the following information:Display textRoom temperature(if TR 2 connected)Required roomtemperature(if TR 2 connected)Operating mode(if TR 2 connected)Max. flow temp.Actual flow temp.Required flowtemp.Max HW temp.Required HWtemp.DescriptionCurrent temperature in theroom where TR 2 is installedRequired temperature inroom where TR 2 is installedE. g. Heating, Economy inAutomatic modeorEconomy, Heating, Frostprotection in manual modeMaximum CH flow temperatureset on the temperaturecontrol for CH flowActual CH flow temperatureRequired CH flow temperatureMaximum permissible hotwater outflow temperatureRequired hot water temperatureB From the main menu select Heating and then fromthe first submenu Manual select required mode.6.6 Hot waterGeneral description• Combi models only: The basic settings provide astraightforward timer programme:enabling Hot Water pre-heat from 5:00amdisabling Hot Water preheat from 10:00pm.The ECO button must not be lit.Actual HW temp.Storage Tankcharge releasedor blockedStorage Tankcharge on or offor Storage TankchargeafterrunningBoiler operat.modewinter/ summerBurner on/offPump on/offActual hot water outflowtemperatureShows, if hot water isreleased or blockedShows, if hot water is on oroff, or if the pump for theStorage Tank afterrunning isonIndicates which mode theCH flow temperature controlis set toIndicates whether the burneris alight or notIndicates whether the integralpump is switched on oroff286 720 611 400 GB (03.11)

Text Display6.8 Settings6.8.1 Heating (if TR 2 is connected)Optimum StartIf the optimum start facility is used:Set the heating ON time to 1 hour before the houseneeds to be at the required temperature.The boiler will start in heating mode at the optimumtime, which could be at any time during that hour.B From the main menu, select Settings and from thefirst submenu, select Heating.B Press or to switch Optimum Start on or off.Basic setting: “ON”6.8.2 Hot Water (Storage Tank, system modelsonly)The text display can control the hot water either withTimes and temperatures or only times.• Times and temperatures: One can choose up tosix different times with temperatures, see page 28“Hot water”.• Only times: During that times the Storage Tank willbe charged to the chosen temperature.B From the main menu, select Settings and from thefirst submenu select hot water.B Press or to switch Times and temperaturesor only times.i6.8.3 ServiceTurn the hot water temperature controlalways higher than the temperature at thetext display is chosen.Displaying service functionsThis option displays various current settings and statusesof the electrically controlled appliance and systemcomponents for the benefit of the heating engineer.Service parametersLanguageAvailable languages are: English, Français (French),Deutsch (German).B From the main menu, select Settings, from the firstsubmenu select Service, from the Second submenuselect Further options, and from the third submenuselect Language.B Press or to select the desired language.Time correction:B Press and hold the button (about 5 seconds)until the display shows Time correction and LCDcontrast.B Press or to select Time correction.B Press the button. The display shows Changevalue.B Press or to set the number of seconds in24 hours.Basic setting: “+ 0 s”LCD contrast:B Press and hold the button (about 5 seconds)until the display shows Time correction and LCDcontrast.B Press or to select LCD contrast.B Press the button. The display shows Changevalue.B Press or to adjust the LCD contrast.Basic setting: e. g. “47”Operating timesThis option shows the hours of service (appliance,burner and hot water) since commissioning.B From the main menu, select Settings, from the firstsubmenu select Service, from the Second submenuselect Further options, and from the third submenuselect Operating times.Fault historyThis option displays any faults that have occurred forthe information of the service engineer. The first faultdisplayed may still be active. Any other faults displayedare no longer active.B From the main menu, select Settings, from the firstsubmenu select Service, from the Second submenuselect Further options, and from the third submenuselect Fault history.6.9 Individual timer programmesTables for your own timer programmes you find in theUser Manual.Two other supplementary functions can be selectedfrom the third submenu Language:• Time correction• LCD contrast.6 720 611 400 GB (03.11)29

Individual settings7 Individual settings7.1 Mechanical settings7.1.1 Checking the size of the expansion vesselMaximum pressure at maximum CH flow temperature is2.5 bar. If the pressure is greater than this then fit anextra expansion vessel. Refer to table 12.System Capacity – BS7074:1Expansion Vessel Pressure and System CapacityExpansion Vessel litres 10Expansion Vessel ChargePressureSystempressure andcapacityTable 12bar 0.751 bar litres 821.5 bar litres 467.1.2 Setting the central heating flow temperatureThe central heating flow temperature can be set tobetween 35°C and 88°C.Limited maximum setting for low-temperatureoperationThe temperature control is factory limited to setting E,giving a maximum flow temperature of 75°C.Adjustment of the heating output to the calculated heatdemand is not required by the heating systems regulations.Removing the maximum setting limitFor heating systems which require higher flow temperatures,the maximum setting limit can be removed.B Lift off the yellow button on the temperature controlwith a screwdriver.6 720 610 332-27.1OFig. 39B Rotate yellow button through 180° and replace (dotfacing inwards).The CH flow temperature is no longer limited.Control setting CH flow temperature1 approx. 35°C2 approx. 43°C3 approx. 51°C4 approx. 59°C5 approx. 67°CE approx. 75°Cmax approx. 88°CTable 137.2 Settings on the Bosch Heatronic7.2.1 General descriptionThe text display module provides a convenient means ofsetting various appliance functions.This description is limited to those functions necessaryfor commissioning.Service functionCode no.Displaying service functionsAll service functions are displayed.seepageAnti-cycle time 2.4 31Max. CH flow temp. 2.5 31Max. heating output 5.0 31Constant hot water cycletime6.8 31Variable pump settings 7.0 31Table 14iFor a detailed description, refer to ServiceBooklet for the Engineer 7 181 465 347.B Press any button to activate the main menu.B Press or button until the arrow cursor ispointing to Settings.B Press the button.B Press or button until the arrow cursor ispointing to Service.B Press the button.B Press the button to select Display serviceparameters.Service function 0.0, Last fault is displayed.B Press the or button to cycle through thecurrent settings.B Press the button to exit the menu.306 720 611 400 GB (03.11)

Individual settingsSetting service functionsOnly the service functions that can be set are displayed.B Press any button to activate the main menu.B Press or button until the arrow cursor ispointing to Settings.B Press the button.B Press oder button until the arrow cursoris pointing to Service.B Press the button.The cursor is pointing to Display service parameters.B Press and hold the button (for about 5 seconds)until the display shows Adjust serviceparameters and the first service function to be set,e.g. 2.0, Operating mode. If a fault has occurred,the display will show 0.0 and the last fault.B Press the or button until the desiredservice function is displayed.B Press the button.The first line of the display shows Change value.B Use the or buttons to enter the requiredsetting.B Press the button.The text display shows ATTENTION Store settings?.B Press or to select yes or no.B Press to confirm your selection.The text display shows Please wait ... ..., and theservice function is then displayed with the new setting.B Press the or button until the next functionyou wish to change is displayed.-or-B Press the button to exit the menu.7.2.2 Setting the anti-cycle time(Service Function 2.4)This service function is only active if Service Function2.7, automatic anti-cycle time, is deactivated.The anti-cycle time can be set to between 0 and 15 minutes(is factory set to 3 minutes).If the setting 0 is entered, the anti-cycle time is inactive.The shortest possible anti-cycle time is 1 minute (recommendedfor single-pipe and hot-air heating systems).7.2.3 Setting the maximum CH flow temperature(Service Function 2.5)The maximum CH flow temperature can be set tobetween 35°C and 88°C (factory setting).7.2.4 Setting the heating output(Service Function 5.0)The heating output can be set to any level between min.rated heat output and max rated heat output to limit it tothe specific heat requirements.iThe full rated heat output is still availablefor hot water or charging the hot water cylindereven if the heating output has beenlimited.The factory setting is the max. rated heat output, 100 %.B Look up heating output in kW and correspondingcode number on the settings tables for heating output(see page 47).B Enter the code number on the text display module.B Measure the gas flow rate and compare with the figuresspecified for the code number shown. If different,correct code number.7.2.5 Constant hot water cycle time(Service Function 6.8)In Comfort mode “ECO light off”, the hot water insidethe appliance is held constantly at the set temperature.For that reason, the appliance switches on if the watertemperature falls below a certain temperature. In orderto prevent it switching on and off too frequently, theconstant hot water cycle time service function allowsyou to set the minimum period between switching offand on again. This function has no effect on normaldemand for hot water and relates only to the constanthot water function in Comfort mode.The cycle time can be set to any period between 20 and60 minutes (is factory set to 20 minutes).7.2.6 Variable pump settings(Service Function 7.0)The pump speed varies automatically to match thewater flow requirement of the system determined by theposition of thermostatic radiator valves. An automaticby-pass must not be used.The Service Function 7.0 is factory set to 4 which willaccommodate the majority of heating systems.Information on the re-settings of this functions can befound in the Service Booklet for the Engineernumber 7-181-465-349.7.3 Setting the gas/air ratioThe appliance is set at the factory and adjustment to theCO 2 settings (gas/air ratio) is only required where theappliance has been stripped down and assembled or ifthe fan, burner or gas valve are replaced or the appliancehas been converted to a different gas type, seesection 8.6 720 611 400 GB (03.11)31

Converting the appliance to different gas types8 Converting the appliance to different gas typesThe setting is factory sealed at maximum. Adjustment tothe rated heat input and min. heat input is not necessary.Checking the gas supply pressureB Check the gas supply pressure at the gas supplypressure testing point.iNatural gas appliances must not be operatedif the gas supply pressure is below18 mbar or above 24 mbar.LPG appliances must not be operated ifthe supply pressure is below or above37 mbar.8.1 Setting the gas/air ratioThe gas/air ratio may only be adjusted on thebasis of a CO 2 measurement at max. heat outputand min. heat output using an electronic tester.B Switch off the appliance at the master switch (O).B Remove the outer case (see page 14, refer tofig. 13).B Switch on the appliance at the master switch (I).B Unscrew sealing plug from flue gas testingpoint (234). Refer to fig. 40.B Insert testing probe about 135 mm into the flue gastesting point and seal testing point.Natural gas• Appliances for natural gas type G20 are factory setto Wobbe-Index 15 kWh/m 3 and 20 mbar supplypressure and sealed.2346 720 610 599 - 01.TDFig. 40B On the text display unit, select in the main menu Settings,Service, Display service parameters.B Press and hold the button (for about 5 seconds)until the display shows Adjust serviceparameters and the first service function to be set,2.0 Operating mode. If a fault has occurred, thedisplay will show 0.0 and the last fault.B Press or until the display shows 2.0Operating mode normal.B Press the button.B Press or to select Max.B Measure the CO 2 level.B Prise off the seal on the gas flow restrictor.B Adjust the gas flow restrictor (63) to obtain the CO 2level given in Table 15. Refer to fig. 41326 720 611 400 GB (03.11)

Converting the appliance to different gas typesFig. 41R 30 HEGas TypeNatural gas typeG20LPG G31(propane)Table 15R 35 & 40 HEGas TypeNatural gas typeG20LPG G31(propane)Table 16CO 2 readingat max. ratedheat output9.2 % 8.8 %CO 2 readingat min. ratedheat output10.8 % 10.5 %CO 2 reading at max. and min.rated heat output9.2 %10.8 %B Press or to select Min.B Measure the CO 2 level.B Remove the seal from the gas valve adjustingscrew (64) and adjust the CO 2 level to the figuregiven in Table 15 for min. rated heat output. Refer tofig. 42.B Press or until the display showsnormal.B Press the button. The text display showsStore settings.B Press to select yes.B Press the button.B Remove testing probe from the flue gas testingpoint (234) and refit sealing plug.B Re-seal gas valve adjusting screw and gas flowrestrictor.B Replace the outer case by locating it on the top lugsand pushing backwards until the bottom clips arefully engaged. Check that the case is properlyaligned with facia. Refer to fig. 13.B Secure by replacing the screw at the bottom left.Refer to fig. 13.643928-74.1RFig. 42B Recheck the levels at min. and max. rated heat outputand re-adjust if necessary.6 720 611 400 GB (03.11)33

Converting the appliance to different gas types8.2 Testing combustion air/flue gas at set heat output8.2.1 Testing the O 2 or CO 2 level in thecombustion airiB Press and hold the button until the displayshows ––.“Chimney sweep” mode is now active.The button will light up and the display shows theCH flow temperature.iBy testing the O 2 or CO 2 level in the combustionair the gas tightness of a type C 13 ,C 33 flue system can be checked. TheO 2 level must not be less than 20,6 %.The CO 2 level must not exceed 0,2 %.In “chimney sweep” mode, the applianceswitches to max. rated heat output or theset heating output. You then have 15 minutesin which to measure the levels. Afterthat, the appliance switches back from“chimney sweep” mode to normal mode.B Remove sealing plug from combustion air testingpoint (234.1, fig. 43).B Insert testing probe about 80 mm into the testingpoint and seal testing point.8.2.2 Testing CO and CO 2B Press and hold the button until the displayshows ––.“Chimney sweep” mode is now active.The button will light up and the display shows theCH flow temperature.iYou have 15 minutes in which to measurethe levels. After that, the appliance switchesback from “chimney sweep” mode tonormal mode.B Remove sealing plug from flue gas testing point(234, fig. 43).B Insert testing probe about 135 mm into the testingpoint and seal testing point.B CO- and CO 2 levels.B Refit sealing plug.B Press and hold button until the display shows ––.The button will stop flashing and the displayshows the CH flow temperature.234.12346 720 610 599 - 01.TDFig. 43B Measure O 2 and CO 2 levels.B Refit sealing plug.B Press and hold button until the display shows ––.The button will stop flashing and the displayshows the CH flow temperature.346 720 611 400 GB (03.11)

Maintenance9 MaintenanceB Always disconnect the appliance fromthe electrical power supply (fuse, circuitbreaker) before carrying out any work onthe electrical systems or components.B Always turn off the gas cock before carryingout any work on componentswhich carry gas.iiThere is a Service booklet for the Engineer,order no. 7-181-465-349, availableto competent persons.All safety and control systems are monitoredby the Bosch Heatronic. In the eventof a component fault, the text displayshows a fault code.B The User should be recommended to have the applianceserviced regularly by a competent person.B Use only genuine spare partsB Refer to the Spare Parts List when ordering spareparts.B Always renew seals and O-rings removed duringservicing or repair work.B Use only the following types of grease:– Water valve: WRAS approved silicon basedgrease– Unions: approved sealant.B To drain the appliance shut the system valves andopen the pressure relief valve.B Upon completion of any electrical work check forearth continuity, correct polarisation and resistanceto earth.Replace the text display module or the HeatronicPCBIf the text display module is replaced, the service functionsettings are retained.B The remaining settings have to be re-entered.If the Heatronic PCB is replaced:B Re-enter the service function settings as recorded inthe commissioning record.6 720 611 400 GB (03.11)35

Maintenance9.1 Pre-Service Check ListDate1 Call up the last fault stored by the textdisplay, (see page 29).2 Check ionisation current, ServiceFunction 3.3, (see page 37).3 Perform visual check of air/flue duct.Visual check of diaphragm for soilingand splits (see page 39).4 Check gas supply pressure(see page 32).mbar5 Test combustion air/flue gas(see page 34).6 Check CO 2 setting for min./max. (gas/air ratio)(see page 32).min. %max. %7 Check gas and water systems forleaks (see page 15).8 Check hot water outlet temperature(see page 37).9 Check heat exchanger(see page 37).mbar10 Check burner (see page 38).11 Clean condensation trap(see page 39).12 Check charge pressure ofexpansion vessel matchesstatic head of heating system.mbar13 Check central heating systempressure.mbar14 Check electrical wiring for damage.15 Check heating programmer settings inthe text display.16 Check appliances that are part ofthe heating system.Table 17366 720 611 400 GB (03.11)

Maintenance9.2 Description of servicing operationsThe combustion performance must be checked beforeand after any servicing work on the combustion andburner components. Refer to section 8.2.B Check control pressure on the air - gas mixer unit atmax. rated heat output using an electronic manometer.Checking the ionisation current,Service Function 3.3B Select Service Function 3.3. (See page 30 “DisplayingService Functions”)If the display shows ‘Meduim’ or ‘High’ while the boileris firing, the ionisation current is OK. If the displayshows ‘No’ or ‘Low’ while the boiler is firing, the electrodeassembly (32.1, page 6) must be cleaned orreplaced.Domestic hot waterIf, after checking the dynamic pressure, the flow rate istoo slow:B remove the domestic hot water heat exchanger andreplace,B Before removing the heat exchanger shut the inletvalve and drain the hot water circuit.B Use new seals when replacing the heat exchanger.Fig. 45iThe heat exchanger should only becleaned if the control pressure is5.2 mbar (R30 HE plus)5.3 mbar (R35 HE plus)6.2 mbar (R40 HE plus)(depression) or less.B Remove cleaning access cover (415, page 6) andthe metal plate below it, if present. Refer to fig. 2.B Unscrew condensation trap and place suitable containerunderneath. Refer to fig. 46.B Remove the fan and the burner as described in thetext headed “Burner” (see page 38).Fig. 44Primary Heat exchangerThere is a special accessory kit (no. 840) for cleaningthe heat exchanger, order no. 7 719 001 996.Fig. 466 720 611 400 GB (03.11)37

MaintenanceB Loosen any deposits in the heat exchanger from topto bottom using the cleaning blade. Refer to fig. 47.BurnerB Check that the gas cock is turned off and the masterswitch is in the OFF positionB Remove the clips (1) and unscrew the two bolts (2).Refer to fig. 50.B Unscrew and remove the two hexagon screws securingthe fan (3).B Slacken fully the rear securing bolt (4).B Remove the burner coverplate.Fig. 47B Clean the heat exchanger from top to bottom usingthe brush. Refer to fig. 48.Fig. 50B Remove the burner skin and clean components. Donot use a wire brush. Refer to fig. 51.Fig. 48B Flush the heat exchanger from the top. Refer tofig. 49.B Clean out the condensate collector and trap connection(with other end of brush).7 181 465 330-09.2R6 720 610 332-75.2RFig. 49B Refit the clean-out cover using a new seal andtighten screws to torque of approx. 5 Nm.Fig. 51B Re-assemble burner in reverse order, inspect seal fordamage and replace if necessary.B Adjust gas/air ratio. Refer to section 8.2.386 720 611 400 GB (03.11)

MaintenanceCondensation trapIn order to prevent spillage of condensate the condensationtrap should be completely removed, (seepage 37, fig. 46).B Unscrew condensation trap and check connection toheat exchanger is clear.B Remove condensation trap cover and clean.B Fill condensation trap with approx. 1/4 l of water andrefit.iThe flaps of the diaphragm (443) mustopen upwards.B Seal the mixer unit (29).Diaphragm in mixer unit for 35 & 40 HE plusB Remove fan and mixer unit assembly.Electrode assemblyB Switch off the master switch.B Pull off the leads from the electrodes. Refer to fig. 2.B Unscrew the two fixing screws and carefully removethe electrode assembly. Refer to fig. 45.B Clean the electrodes with a non-metallic brush. (Thespark gap should be 4,5 mm ± 0,5 mm.)B Replace and re-connect the assembly taking care notto mislay the inspection window.Diaphragm in mixer unit for 30 HE plusB Take care not to damage diaphragm(443) when removing and refitting it.B Open mixer unit (29).B Carefully withdraw diaphragm (443) from fan intaketube and check for soiling and splits.4433.294.5.2.1.6 720 610 910-63.1R3.44329Fig. 53B Unscrew mixer unit (29).B Remove sleeve.B Carefully remove diaphragm (443) and check for soilingand cracks.B Refit diaphragm (443) taking care to ensure it is thecorrect way round.1.iThe flaps of the diaphragm (443) mustopen upwards.B Refit mixer unit (29) and fan assembly.2.6 720 610 790-07.2RFig. 52B Carefully refit diaphragm (443) the correct way roundinto the fan intake tube.6 720 611 400 GB (03.11)39

MaintenanceSiphonB Unscrew the clip and disconnect the pipe to thesiphon.B Remove the drain plug to drain the siphon.B Unscrew the securing nut from beneath the sidefacia and remove the siphon. Refer to figure below.B Refit and prime the siphon.CondensateDrainSiphon9.3 Replacement of PartsBefore changing any components check that the gas isturned off and that the appliance is electrically isolated.When necessary close the system valves and drain theappliance.Refitting is a reverse of the procedure for removal usingnew seals or o-rings as appropriate.9.3.1 PCB control board and transformerB Switch off the appliance.B Disconnect appliance from the power supply.B Unplug all connectors from the control box (inc.keyed plug). Access is gained by removing the covers.Refer to fig. 25, 26.B Remove screw holding power connector earth leadand remove earth lead.B Remove two top fixing screws from the control box.Refer to fig. 55.Drain PlugFig. 54Expansion vesselThe expansion vessel should be checked once a year.B Depressurise appliance.B If necessary, adjust expansion vessel charge pressureto static head of the heating system.Heating system pressureiFill the system using the WRAS approvedfilling loop.B The pointer on the pressure gauge should be 1 bar.B If the pointer is below 1 bar (when the system iscold), water should be added until the pointer is1 bar again.B Max. pressure of 2.5 bar when the heating systemwater is at maximum temperature must not beexceeded. If this pressure is exceeded then an extraexpansion vessel must be fitted in the system returnas close to the appliance as possible.B If the system does not retain the pressure, the expansionvessel and the heating system should bechecked for leaks.Fig. 55B Lower the control box.B Unscrew earth lead.B Unscrew four fixing screws from cover plate. Refer tofig. 56.B Prise off cover plate.B Pull off transformer.B Remove pcb holder.406 720 611 400 GB (03.11)

MaintenanceB Remove the pcb control board.9.3.2 Fan AssemblyFig. 56FusesB Remove the connections covers. Refer to fig. 25,26.The fuses are located adjacent to the mains connectorblock and connector ST18. Refer to fig. 4.Fuse, item 312, is only replaceable by removing thepcb.Spare fuses are fixed to the connections cover.A fuse pack is available: Part number 8 744 503 010 0.Fig. 57B Switch off the appliance.B Undo lower pipe union on gas pipe (1.). Refer tofig. 57.B Remove fan lead and earth connector (2.). The earthconnector has a positive clip fixing.B Remove fixing screws attaching fan to the burnercover (3.).B Remove fan together with gas pipe and mixer unit.B Separate the fan from the pipe and mixer unit bytwisting the mixer unit to release it (4.).9.3.3 PumpB Switch off the appliance.B Disconnect the appliance from the power supply.B Remove two switch box fixing screws (1.). Refer tofig. 58.B Lower switchbacks (2.).B Remove screw from underside of right-hand plasticcover plate (3.).B Pull cover plate forwards to remove (4.).B Unscrew and remove the siphon by releasing thejubilee clip. Refer to fig. 54.B Unscrew the pump union nuts (5.). Refer to fig. 58.B Carefully remove the pump and disconnect the leads.6 720 611 400 GB (03.11)41

MaintenanceAlternativelyB Remove 3-way valve.B After removing the siphon release the four Allenscrews and remove and replace the pump head.Fig. 59After refitting:B Fill system, bleed and re-pressurise(see Installation Instructions).Fig. 589.3.4 3-way diverter valveB Switch off the appliance.B Disconnect appliance from the power supply.B Turn off service cocks.B Unplug connector from 3-way valve motor. Refer tofig. 59.B Pull out retaining clip.B Remove motor.B Disconnect the relief valve drain.B Disconnect the pressure gauge by withdrawing theclip and pulling out the capillary head.B Undo pipe unions by withdrawing the clips.9.3.5 3-way diverter valve motorB Switch off the appliance.B Turn off the service cocks.B Unplug connector from 3-way valve motor. Refer tofig. 59.B Pull out retaining clip.B Remove motor.9.3.6 SensorsB Check that the appliance is electrically isolated.Central Heating Flow Temperature Sensor –Item 36, fig. 2, 55B Pull-off the connector.B Release the sensor clip and withdraw the sensor.B Apply heat transfer paste to the replacement sensor.Safety Temperature Limiter – Item 6, fig. 2, 55B Pull-off the connectors.B Unscrew the sensor.Flue Temperature Limiter – Item 9, fig. 2, 55B Pull-off the connectors.B Unscrew the sensor.426 720 611 400 GB (03.11)

MaintenanceDomestic Hot Water Temperature Sensor –Item 6.1, fig. 2B Check that the inlet water valve is closed and thedomestic hot water circuit is drained.B Release and pull-off the connector.B Unscrew the sensor.9.3.7 Gas ValveB Check that the gas cock is turned off.B Lower the control panel. Refer to fig. 58.B Pull off the solenoid connections at the rear of thevalve.B Undo the union, within the inner casing, securing thevalve to the gas/air tube. Refer to fig. 57.B Remove the white plastic cap from the gas valve.B Release the gas inlet union at the manifold assembly.B Unscrew the two screws securing the gas valveassembly bracket to the back panel and withdraw theassembly.B Transfer the bracket and inlet pipe assembly to thenew gas valve.B Check for gas soundness when the new gas valvehas been fitted.B Recheck the combustion performance as describedin section 8.1.9.3.8 Domestic Hot Water Heat ExchangerB Refer to section 9.2.B Use new seals when fitting the new heat exchanger.9.3.9 Electrode assemblyB Refer to section 9.2.B Use a new seal if the existing seal is damaged.9.3.10 Pressure gaugeB Drain the appliance.B Lower the facia. Refer to fig. 58.B Twist the pressure gauge head anti-clockwise torelease it from the casing. Refer to fig. 2.B Disconnect the capillary head from the rear of thediverter valve by withdrawing the clip and pulling outthe head. Refer to fig. 59.9.3.11 Expansion vesselB Drain the appliance.B Undo the union connection at the base of the vessel.Refer to fig. 2.B Unscrew the top and bottom fixing screws andremove the vessel.B Set the pressure of the new vessel to that required bythe system.9.3.12 Pressure Relief ValveB Drain the appliance.B Disconnect the drain pipe from the valve. Refer tofig. 30.B Pull-out the clip securing the valve.B Pull-out the valve.B Ensure that the replacement valve is fully enteredbefore fitting the clip.9.3.13 BurnerB Refer to section 9.2.6 720 610 602 - 04.1OFig. 606 720 611 400 GB (03.11)43

Maintenance9.3.14 Flow switchB Shut the mains water inlet valve and drain the domestichot water circuit.B Pull-off the connectors from the micro-switch.B Unscrew the inlet and union connection and removethe assembly.B Reset the domestic hot water flow rate on the newassembly.B Transfer components, as necessary, to the new heatexchanger.B Ensure that all the seals are in place and all of theconnections are tight before re-commissioning theappliance.OUTLETINLET6 720 610 602 - 05.10Fig. 619.3.15 Primary Heat ExchangerB 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/airtube and mixer assembly. Refer to section 9.3.2.B Remove the burner. Refer to section 9.2.B Disconnect the sensors. Refer to section 9.3.6.B Undo the central heating flow union.B Undo the top connection of the pump. Refer tofig. 57.B Undo the grey plastic cap, next to the top pump connectionat the base of the heat exchanger.B Unscrew and remove the condensate trap. Refer tosection 9.2.B Unscrew and remove the two screws securing theheat exchanger top bracket to the rear panel.B Lift up the flue duct, item 271, refer to fig. 2.B Pull forward from the top and lift the heat exchangerfrom the casing.6 720 610 602 - 06.10Fig. 62446 720 611 400 GB (03.11)

Appendix10 Appendix10.1 Fault CodesMore detailed fault finding procedures are described in the Service Booklet for the Engineer number 7 181 465 347.Displaycode Description RemedyA1 pump has run dry Check system pressure, add water and bleedsystem as necessaryA7 Hot water NTC sensor defective. Check hot water NTC sensor and connectinglead for circuit breaks/short circuits.A8 Break in communication Check connecting lead to TR2b1 Code plug not detected. Insert code plug correctly, test and replace ifnecessary.C1 Fan speed too low. Check fan lead and connector, and fan; replaceas necessary.d3 Jumper 8-9 not detected. Connector not connected, link missing, underfloorheating limiter tripped.E2 CH flow NTC sensor defective Check CH flow NTC sensor and connectinglead.E9 Safety temp. limiter in CH flow has tripped. Check system pressure, check safety temp. limiters,check pump operation, check fuse on pcb,bleed appliance.EA Flame not detected. Is gas cock turned on? Check gas supply pressure,power supply, igniter electrode and lead,ionisation sensing electrode and lead, flue ductand CO2 level.F0 Internal error. Check electrical connector contacts, programmerinterface module ignition leads are notloose; replace pcb if necessary.F7Flame detected even though applianceswitched off.Check electrode assembly, dry pcb. Flue clear?FA Flame detected after gas shut off. Check gas valve and wiring to gas valve. Cleancondensation trap and check electrode assembly.Flue clear?FC Text display not detected. Check connecting lead between Text displayand Heatronic, replace Text display if necessaryFd Reset button pressed by mistake. Press reset button againP1, P2,P3, P1...Table 18Please wait, initialisation in progress.24 V fuse blown. Replace fuse.6 720 611 400 GB (03.11)45

Appendix10.2 Short parts listKey Description Qty GC Spare part number1 Sensor - Flue gas temp. 1 8 722 963 858 02 Sensor - CH flow temp. 1 8 714 500 087 03 Sensor - DHW flow temp. 1 8 714 500 054 04 Control board pcb 1 8 748 300 495 05 Gas valve ZWBR 8-30 1 8 747 003 516 05.1 Gas valve ZWBR 11-37 1 8 747 003 515 06 Fan assembly 1 8 717 204 325 07 Fan washer 1 8 729 000 183 08 Expansion vessel 1 8 715 407 246 09 Relief valve 1 8 717 401 012 010 Electrode assembly 1 8 718 107 077 011 Electrode lead 1 8 714 401 999 012 Pump 1 8 717 204 350 013 Pressure gauge 1 8 717 208 079 014 Burner skin seal 1 8 711 004 168 015 Transformer - facia 1 8 747 201 358 016 Flow switch 1 8 717 002 110 017 3-way diverter valve 1 8 717 010 062 018 Heat exchanger washer 1 8 710 103 153 019 Washer set CondensationTrap1 8 710 103 154 020 Fuse set 1 8 744 503 010 021 Service set Water Valve 1 8 710 503 031 022 Domestic Hot Water HeatExchanger1 8 715 406 659 023 Text Display 1 8 747 208 103 024 Primary heat exchanger 1 8 715 406 615 025 Diaphragm 1 8 715 505 801 0Table 19466 720 611 400 GB (03.11)

Appendix10.3 Heating/hot water output settingsR 30 HE N.G.Natural gas G2010.5 Heating/hot water output settingsR 35 HE N.G.Natural gas G20DisplaycodeHeatoutput,kWHeatinput,kWGas vol. flow rate(l/min att V /t R = 80/60°C)DisplaycodeHeatoutput,kWHeatinput,kWGas vol. flow rate(l/min at t V /t R =80/60°C)30 9.1 9.2 16.040 12.1 12.2 21.450 15.1 15.3 26.760 18.1 18.3 32.070 21.1 21.4 37.480 24.2 24.4 42.790 27.2 27.5 48.0100 30.2 30.5 53.4Table 2010.4 Heating/hot water output settingsR 30 HE L.P.GPropaneDisplaycode Heat output kW Heat input kW40 12.1 12.250 15.1 15.360 18.1 18.370 21.1 21.480 24.2 24.490 27.2 27.5100 30.2 30.5Table 2130 11.1 11.3 19.740 14.9 15.0 26.350 18.6 18.8 32.860 22.3 22.5 39.470 26.0 26.3 45.980 29.7 30.0 52.590 33.4 33.8 59.1100 37.1 37.5 65.6Table 2210.6 Heating/hot water output settingsR 35 HE L.P.GPropaneDisplaycode Heat output, kW Heat input, kW40 14.9 15.050 18.6 18.860 22.3 22.570 26.0 26.380 29.7 30.090 33.4 33.8100 37.1 37.5Table 236 720 611 400 GB (03.11)47

48Fig. 63Pump ONDiverter valveoperates.Fan to startspeed.Gasvalve opens.Pre-heat satisfied.Burner remains OFFuntil flowtemperature is belowset value.Ignition sequenceBurner lights.Red light ON.Ignitionspark5 secsGas valve shuts.Pump remains ON.Burner shut-down ifprimary temperatureexceeds 94°C remainsOFF until 78°COver temperatureshut down if watertemperature is 8°Cabove set value.** NOTE:The appliance controls can be set to one of 2modes of operation.1. “Comfort“ mode -Full pre-heat2. “ECO“ mode -a) Operates as an instantaneous combination boiler.b) Demand Detection: a short demand (less than 5seconds) switches the control to “Comfort“ modefor 5 mins. Mini pre-heat. The Factory setting is“Comfort“ mode.10.7.1 Domestic hot water function10.7 Operational Flow diagramsAppendixMainsswitchON.GreenlightON.Pre-heatmode.**Hotwaterdemand.Pump ONDiverter valveoperates.Fan to startspeed. Gas valveopens.Heat inputmodulates tomaintain thedeliverytemperature.Demandends.Gas valvecloses. Redlight OFF.Fan runs forup to 3 mins.Pump runs for30secs.Pre-heatmode.**Ignition sequenceIgnitionspark5 secsBurner lights.Red light ON.YesNo6 720 611 400 GB (03.11)Repeats 5 times(N.G.) or 3 times(L.P.G.) beforelock-out.Fan runs to purgegas from burner.6 720 610 576 - 25.TD

6 720 611 400 GB (03.11)Fig. 64MainsswitchON.GreenlightON.Roomthermostatand/or mainsprogrammer orlink ON ANDElectronic faciaprogrammer (iffitted) ON ANDCH controlknob ON.CHdemand.Burner remains OFFuntil flow temperatureis below set value.Pump ON Fan tostart speed. Gasvalve opens.Burnerstabilises atstart speed for5-10 secsGas valve shuts.Pump remains ON.Fan speedreducesover 15secs.Fan min.speed for90 secs.Boilerunusedfor longperiod.*NoOver temperatureshut down if watertemperature is 5°Cabove set value.Yes*Minimumheatinput for15min.Boileroperates tomatchsystem loadand CHcontrolsetting.10.7.2 Central heating functionIgnition sequenceIgnition spark for5 seconds.Burner lights. Redlight ON.YesCH demandsatisfied.Gas valve closes.Red light OFF.Pump and Fanrun for up to 3mins.NoRepeats 5 times(N.G.) or 3 times(L.P.G.) beforelock-out.Fan runs topurge gas fromburner.* NOTE: The sequence ensures that the condensate siphon is not emptyafter long OFF periods. (More than 24 hours without a demand).496 720 610 576 - 26.TDAppendix

Appendix506 720 611 400 GB (03.11)

Appendix6 720 611 400 GB (03.11)51

AppendixEXCELLENCE COMES AS STANDARDWorcester Bosch, Cotswold Way, Warndon, Worcester WR4 9SW.Telephone: (01905) 754624 Fax: (01905) 754619