Benchmark RD 532i, RD 537i, RD 542i combi Installation And Servicing Instructions

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Page 1

6 720 610 893-01.TD

Installation and Servicing Instructions

RD 532i/RD 537i/RD 542i combi

Wall mounted condensing boiler for central heating and mains fed domestic hot water

ZWBR 7-32 RD 532i GC-Number: 41 108 10 ZWBR 11-37 RD 537i GC-Number: 41 108 11 ZWBR 11-42 RD 542i GC Number: 41 108 12

6 720 611 447 GB (03.11) TD

Page 2

6 720 611 447 GB (03.11)

Contents

Safety precautions 3

Symbols 3

1 Details of the appliance 4

1.1 EC Declaration of Conformity 4

1.2 Standard package 4

1.3 Description of appliance 4

1.4 Accessories 5

1.5 Casing dimensions 5

1.6 Layout of appliance 6

1.7 Function 7

1.8 Electrical wiring diagram 8

1.9 Technical data 9

2 Installation regulations 10

3 Installation 11

3.1 Important remarks 11

3.2 Domestic hot water 11

3.3 Sealed systems 11

3.4 Siting the appliance 12

3.5 Wall mounting frame assembly 13

3.6 Pre-piping the system 13

3.7 Fitting the appliance 14

3.8 Checking the connections 15

3.9 Flue Systems 15

3.9.1 Siting the Flue Terminal 16

3.9.2 Installation of the flue 17

3.9.3 Flue duct preparation and assembly 18

4 Electrical connections 20

4.1 Connecting the appliance 20

4.2 Connecting a TR2 Room Thermostat 21

4.3 Mains Voltage external controls connections 21

5 Commissioning 22

5.1 Commissioning 22

5.2 Switching the appliance on/off 23

5.3 Switching on the central heating 23

5.4 System controls 23

5.5 Setting the domestic hot water temperature and flow rate 24

5.5.1 Domestic hot water temperature 24

5.5.2 Hot water flow rate 24

5.6 Summer mode (hot water only) 24

5.7 Frost protection 24

5.8 Pump anti-seize function 24

5.9 Fault Condition 25

5.10 Appliance Data Monitoring 25

6Text Display 26

6.1 General Description 26

6.2 Programming 26

6.2.1 Deleting a setting 27

6.2.2 Resetting all parameters to their original settings 27

6.3 Menu structure 27

6.4 Setting the time/day 28

6.4.1 Setting the time and day 28

6.4.2 Holidays 28

6.5 Heating 28

6.5.1 Heating programme 28

6.5.2 Setting the Economy temp (TR2 connected) 29

6.5.3 Manual operating mode (TR2 not connected) 29

6.6 Hot water 29

6.7 i Info 29

6.8 Settings 30

6.8.1 Heating (if TR 2 is connected) 30

6.8.2 Hot Water (Storage Tank, system models only) 30

6.8.3 Service 30

6.9 Individual timer programmes 30

7 Individual settings 31

7.1 Mechanical settings 31

7.1.1 Checking the size of the expansion vessel 31

7.1.2 Setting the central heating flow temperature 31

7.2 Settings on the Bosch Heatronic 31

7.2.1 General description 31

7.2.2 Setting the anti-cycle time (Service Function 2.4) 32

7.2.3 Setting the maximum CH flow temperature (Service Function 2.5) 32

7.2.4 Setting the heating output (Service Function 5.0) 32

7.2.5 Constant hot water cycle time (Service Function 6.8) 32

7.2.6 Variable pump settings (Service Function 7.0) 32

7.3 Setting the gas/air ratio 32

8 Converting the appliance to different gas types 33

8.1 Setting the gas/air ratio 33

8.2 Test combustion air/flue gas at set heat output 35

8.2.1 Test the O2 or CO2 level in the combustion air 35

8.2.2 Testing CO and CO2 35

9 Maintenance 36

9.1 Pre-Service Check List 37

9.2 Description of servicing operations 38

9.3 Replacement of Parts 41

9.3.1 PCB control board and transformer 41

9.3.2 Fan Assembly 42

9.3.3 Pump 42

9.3.4 3-way diverter valve 43

9.3.5 3-way diverter valve motor 43

9.3.6 Sensors 43

9.3.7 Gas Valve 44

9.3.8 Domestic Hot Water Heat Exchanger 44

9.3.9 Electrode assembly 44

9.3.10 Pressure gauge 44

9.3.11 Expansion vessel 44

9.3.12 Pressure Relief Valve 44

9.3.13 Burner 44

9.3.14 Flow switch 45

9.3.15 Primary Heat Exchanger 45

10 Appendix 46

10.1 Fault Codes 46

10.2 Short parts list 47

10.3 Heating/DHW output settings RD532i N.G. 48

10.4 Heating/DHW output settings RD532i L.P.G 48

10.5 Heating/DHW output settings RD537i N.G. 48

10.6 Heating/DHW output settings RD537i L.P.G 48

10.7 Operational Flow diagrams 49

10.7.1 Domestic hot water function 49

10.7.2 Central heating function 50

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6 720 611 447 GB (03.11)

Safety precautions

If you smell gas

B 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 appliance

B Switch off appliance (see page 23).

B Open windows and doors.

Fitting and modifications

B Fitting of the appliance or any controls to the appli-

ance may only be carried out by a competent engineer in accordance with the Gas Safety (Installation and Use) Regulations 1998.

B Flue systems must not be modified in any ways other

than as described in the fitting instructions.

B This appliance is for use on sealed primary systems only.

Maintenance

B The user is recommended: to have the system

regularly serviced in order to ensure that it functions reliably and safely.

B Use only original spare parts!

Combustible materials

B Do not store or use any combustible materials

(paper, thinners, paints etc.) in the vicinity of the appliance.

Health and safety

B This appliance contains no asbestos products. B There is no potential hazard due to the appliance

being electrically unsafe.

B There are no substances used in the construction

that are a potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).

Combustion air/Ambient atmosphere

B The combustion air/ambient atmosphere should be

kept free of chemically aggressive substances (e.g. halogenated hydrocarbons which contain chlorine or fluorine compounds). This will prevent corrosion.

Instructions to the customer

B Explain to the customer how the appliance works and

how to operate it.

B Advise the user that he/she must not make any modi-

fications to the appliance or carry out any repairs on it.

B These instructions are to be left with the user or at

the Gas meter.

B Important: These instructions apply in the UK only.

Unpacking

IMPORTANT HANDLING INSTRUCTIONS

B Two people should transfer the packaged appliance

from the van to the point of installation

B Open the top of the carton, remove and place the

component tray and both side bars of the wall mounting frame to one side

B Lie the packaged appliance on its back. (The back

has “TRUCK HERE” printed on the carton)

B One person firmly holds the packaging while the

other straddles the boiler and slides it from the packaging

B Two persons are then required to lift one end and

stand the appliance upright with the flue at the top

Additional requirements for roof space installation

B Two people should use two step ladders and share

lifting the unpacked boiler up to the loft hatch

B Where the boiler enters the loft space, tilt and slide

the boiler on its back to the point of installation

Check the contents against the packing list.

Symbols

Safety instructions in this document are identified by a warning-triangle symbol and are printed on a grey background.

Notes containing important information are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.

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6 720 611 447 GB (03.11)

Details of the appliance

1 Details of the appliance

1.1 EC Declaration of Conformity

This appliance is in accordance with the applicable requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.

1.2 Standard package

• Gas condensing combination boiler for central heating and domestic hot water

• Control panel cover

• Wall mounting frame

• Room thermostat TR2

• Fixings (screws etc.)

• Set of documentation for appliance

• Pre-plumbing manifold

• Condensate drain pipe

• Filling loop.

1.3 Description of appliance

• Wall-mounted appliance, siting not dependent on room size

• Natural gas models are low-emission appliances

• Multi function display

• Bosch Heatronic control system with integrated text display for service functions and faults

• 3-channel - digital timer for one heating circuit

• Variable pump

• Automatic ignition

• Modulating control

• Full safety systems incorporating Bosch Heatronic with flame ionisation monitoring, solenoid valves and temperature sensors

• Concentric flue/air duct with testing point for CO

/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, Auto air vent

• Flue gas temperature limiter (105 °C)

• Hot water priority circuit

• Motorised 3-way valve

• Plate-type heat exchange

• Condensate Trap.

PIN CE-0085 BL0507

Category UK II

2H 3P

Appliance Type C13, C

Table 1

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6 720 611 447 GB (03.11)

Details of the appliance

1.4 Accessories

• Standard horizontal flue kit at 100 mm outside diameter for flues up to 4 m in length (3.5m for the R 40 HE).

• Flue duct kits for horizontal (125 mm outside diameter) for flue lengths up to 13m or 10m (RD537i & RD542i) and vertical flue systems for flue lengths up to 13.7m or 10.7m (RD537i & RD542i). Fitting instructions are sent with these kits.

1.5 Casing dimensions

Fig. 1

13 Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System: min. 160 mm

Alternative Concentric Flue System: min. 220 mm

Y Standard Concentric Horizontal Flue System: 40 mm

Alternative Concentric Flue System: 70 mm

Z Standard Concentric Horizontal Flue System: 105 mm

Alternative Concentric Flue System: 130 mm

* For servicing the appliance

Note: Horizontal flue only: dimension X may need to increase due

to the incline of the flue.

6 720 610 599 - 01.TD

200

395

360

850

120

200

600

in .

10*

in .

440

850

101

103

10*

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6 720 611 447 GB (03.11)

Details of the appliance

1.6 Layout of appliance

Fig. 2

4 Heatronic control 6 Heat exchanger safety temperature limiter

6.1 Hot water NTC sensor 7 Testing point for gas supply pressure

8.1 Pressure gauge 9 Flue gas temperature limiter 15 Relief valve 18 Pump 20 Expansion vessel 27 Automatic air vent 29 Air gas Mixer unit

32.1 Electrode assembly 36 Temperature sensor in CH flow 43 CH flow 63 Adjustable gas flow restrictor 64 Adjusting screw for min. gas flow volume 88 3-way valve (combi) 98 DHW flow switch (combi) 102 Inspection window

120 Fixing points

221.1 Flue duct

221.2 Co mbustion air intake 226 Fan assembly 295 Appliance type sticker 271 Flue duct 355 Plate-type domestic hot water heat exchanger 358 Condensate trap 396 Hose Condensate trap 400 Text display 415 Cover plate for cleaning access 416 Condensate collector 418 Data plate 423 Siphon

6 720 610 599 - 00.TD

102

226

271

416

358

355

6.1

415

32.1

295

8.1

120

418

400

396

423

221.1

221.2

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6 720 611 447 GB (03.11)

Details of the appliance

1.7 Function

Fig. 3

4 Bosch Heatronic control 6 Temperature limiter, heat exchanger

6.1 Hot water NTC sensor

7 Testing point for gas supply pressure

8.1 Pressure gauge

9 Flue gas temperature limiter 13 Manifold 15 Safety valve 18 Central heating pump 20 Expansion vessel 26 Charging valve 27 Automatic vent 29 Mixer unit

29.1 Bi-metallic thermostat for combustion air compensation

30 Burner 32 Flame sensing electrode 33 Igniter electrode 35 Heat exchanger with cooled combustion chamber 36 Temperature sensor in CH flow 43 CH flow 44 Hot water flow 45 Gas 46 Cold water inlet 47 CH return 52 Solenoid valve 1

52.1 Solenoid valve 2

55 Filter 56 Gas valve CE 427 57 Main valve disc 61 Reset button 63 Gas flow restrictor, adjustable for max. gas flow volume

64 Adjusting screw for min. gas flow volume 69 Control valve 84 Motor 88 3-way valve 90 Venturi 91 Pressure relief valve 93 Water flow regulator 94 Diaphragm 95 Pushrod with switch cam 96 Microswitch 97 Valve for hot water flow volume 98 Water valve 221 Flue duct 226 Fan 229 Air box 317 Display 355 Plate-type heat exchanger 358 Condensate trap 400 Text display 423 Siphon 443 Diaphragm

6 720 610 597-

03.2O

42 3

332930

226

229

29.1

45 47

8.1

52.1

355

358

max

ECO

317

400

221

6.1

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6 720 611 447 GB (03.11)

Details of the appliance

1.8 Electrical wiring diagram

Fig. 4

4.1 Ignition transformer 6 Temperature limiter, heat exchanger

6.1 Hot water NTC sensor 9 Flue gas temperature limiter 18 Pump 32 Flame sensing electrode 33 Ignition electrode 36 Temperature sensor in CH flow 52 Solenoid valve 1

52.1 Solenoid valve 2 56 Gas valve CE 427 61 Reset button 84 Motor, 3-way valve 96 M icroswitch, hydraulic switch 135 Master switch 136 Temperature control for CH flow 151 Fuse, slow 2.5 A, AC 230 V 153 Transformer 161 Link 226 Fan 300 Code plug 302 E arth connection 310 Temperature control for hot water 312 Fuse, slow T 1,6 A 313 Fuse, slow T 0,5 A 317 Digital display 328 Terminal block for AC 230 V Mains supply

328.1 Link 363 Indicator lamp for burner 364 Indicator lamp for power supply

365 “Chimney sweep” button 366 Service button 367 ECO button 400 Text display 422 Connecting TR2

52.1

230 V

135

25 V

230V/AC

153

136

151

1247

161

226

300

NLsNs

328

302

310

312

313

317

363

364

365

366

ECO

367

4.1

328.1

6.1

400

43F

6 720 610 602 - 02.1O

mains supply

422

o - orange g - green bl - black r - red p - purple

r r

bl bl bl

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6 720 611 447 GB (03.11)

Details of the appliance

1.9 Technical data

Units

RD 532iNGRD 532i

Propane

RD 537iNGRD 537i

Propane

RD 542i NGRD 542i

Propane

Max. rated heat output net 40/30 °C central heating Max. rated heat output net 50/30 °C central heating Max. rated heat output net 80/60 °C central heating

kW kW kW

34.3

34.0

32.2

34.3

34.0

32.3

39.7

39.2

37.1

39.7

39.2

37.1

41.4 41.4

39.1 39.1 Max. rated heat input net kW 32.5 32.5 37.5 37.5 40.0 40.0 Min. rated heat output net 40/30°C Min. rated heat output net 50/30°C

Min. rated heat output net 80/60°C

kW kW kW

8.4

8.3

7. 4

11. 6

11. 4 10 .5

12.9

12.8

11. 4

16. 2 16 .1

14 . 3

12.9 16.2

12.8 16.1

11.4 14.3 Min. rated heat input net kW 7.6 10.8 11.8 14.8 11.8 14.8 Max. rated heat output net, domestic hot water kW 32.2 32.2 37.1 37.1 39.1 39.1 Max. rated heat input net, domestic hot water kW 32.5 32.5 37.5 37.5 40 40 Maximum gas flow rate – After 10 minutes from lighting

Natural gas G20 (CVnet 34.02 MJ/m3)m

3.4 3.9

4.2

LPG (CVnet 88 MJ/m

)

kg/h 2.5 2.7

Gas supply pressure

Natural gas G20 (CVnet 34.02 MJ/m3)

mbar 20 - 20 -

20 -

LPG (CVnet 88 MJ/m

)

mbar - 37 - 37

-37

Expansion vessel

Charge pressure bar 0.75 0.75 0.75 0.75 0.75 0.75 Total capacity l 10 10 10 10 10 10 Hot water specifications Hot water flow rate @35°C rise l/min 12.5 12.5 14.5 14.5 15.5 15.5 Outlet temperature range °C 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 Max. permissible water supply pressure bar 10 10 10 10 10 10 Min. inlet pressure for maximum flow rate bar 1.2 1.2 1.2 1.2 1.2 1.2 Specific flow rate @ 30°C l/min 14.6 14.6 16.9 16.9 18.0 18.0 Flue Flue gas temp. 80/60°C, rated/min. load °C 67/55 67/55 87/58 87/58 87/58 87/58 Flue gas temp. 40/30°C, rated/min. load °C 43/32 43/32 65/43 65/43 65/43 65/43 Residual delivery pressure (inc. pressure drop in air intake duct)

Pa 80 80 100 100 100 100

level at max. rated heat output

level at min. rated heat output

% %

9.2

8.8

10 .8

10.5

9.2

11. 0

9.2

11.0

-class 5 5 5 5

SEDBUK figure BandA AAAAA

Condensate

Max. condensation rate (tR = 30°C) l/h 2.8 2.8 3.2 3.2

3.5 3.5

pH-value, approx. pH 4.8 4.8 4.8 4.8 4.8 4.8

General Data

Electrical power supply voltage AC ... V 230 230 230 230 230 230 Frequency Hz50 5050505050 Max. power consumption W 130 130 162 162 183 183 Noise output level dB(A) 37 37 41 41 42 42 Appliance protection rating IP X4D X4D X4D X4D X4D X4D Max. CH flow temperature °C nom. 90 nom. 90 nom. 90 nom. 90 nom. 90 nom.90 Max. permissible operating pressure (CH) bar 2.5 2.5 2.5 2.5 2.5 2.5 Permissible ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 Nominal capacity of appliance l 3.75 3.75 3.75 3.75 3.75 3.75 Weight (excluding packaging) kg 46 46 46 46 46 46

Table 2

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6 720 611 447 GB (03.11)

Installation regulations

Condensate analysis, mg/l

Flue system

Elbow - 90 ° Equivalent length 2 m Bend - 45 ° Equivalent length 1m

Gas supply

Domestic water performance

2 Installation regulations

Gas Safety (Installation & Use) Regulations 1998: All gas 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 the current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation), bye-laws of the local Water Company, Health and Safety Document 635 (Electricity at Work Regulations

1989) and any other local requirements. Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the installer to avoid any risk by using only quality approved branded fittings. The relevant British Standards should be followed i.e.

• BS 6798: Specification for the installation of gas fired hot water boilers of rated input not exceeding 60kW

• BS 5449: Central Heating for Domestic Premises

• BS 5546: Installation of gas hot water supplies for domestic purposes

• BS 5440:1: Flues and ventilation for gas appliances of rated input not exceeding 70 kW (net): Flues

• BS 5440:2: Flues and ventilation for gas appliances of rated input not exceeding 70 kW (net): Air Supply

• BS 6891: Installation of low pressure gas pipework installations up to 28mm (R1).

• BS 7074:1: Code of practice for domestic heating and hot water supply

• BS 7671: Requirements for Electrical Installation.

These instructions must be followed.

Ammonium 1.2 Nickel 0.15 Lead ≤ 0.01 Mercury ≤ 0.0001 Cadmium ≤ 0.001 Sulphate 1 Chromium ≤ 0.005 Zinc ≤ 0.015

Halogenated hydrocarbons ≤ 0.002

Tin ≤ 0.01

Hydrocarbons 0.015 Vanadium ≤ 0.001

Copper 0.028 pH-value 4.8

Table 3

HORIZONTAL 100 mm – Standard FLUE SYSTEM

Overall Diameter of Duct mm 100

Max. 4 m (RD532i/537i) Max 3.5m (RD542i)

Flue Terminal / Duct Assembly Length

mm 600

Extension Duct Length mm 1000

Table 4

HORIZONTAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125 Max. 13 m

(RD532i) Max. 10m (RD537i/542i)

Flue Terminal / Duct Assembly

mm 1030

Table 5

VERTICAL 100mm FLUE SYSTEM

Overall Dia. of Duct mm 100 Excl. terminal:

Max. 6.4m (RD532i/537i) Max. 5.5m (RD542i)

Flue Terminal / Duct Assembly Length

mm 1140

Table 6

VERTICAL 125 mm FLUE SYSTEM

Overall Dia. of Duct mm 125 Excl. terminal: Max.

13.7 m (RD532i) Max. 10.7 m (RD537i/542i)

Flue Terminal / Duct Assembly

mm 1365

Table 7

Total length of gas supply pipe (metres)

Pipe diameter (mm)

369

Gas discharge rate (m

/h)

8.7 5.8 4.6 22

18 .0 12 . 0 9 .4 2 8

Table 8

R 30 HER 35 HER 40

Domestic Water Flow Rate l/min

Te mp e ra ture Rise

30 °C 14.2 17.0

19.2

Te mp e ra ture Rise

35 ° C 12 .1 14 . 6

16.4

Te mp e ra ture Rise

40 ° C 10 . 6 12 .8

14.4

Maximum Mains pressure bar 10.0 10.0

Minimum Mains pressure bar 0.2 0.2

0.2

Table 9

Page 11

6 720 611 447 GB (03.11)

Installation

3 Installation

3.1 Important remarks

B Appliance should only be installed in sealed central

heating and hot water systems.

B To avoid gas formation in the system, galvanised radi-

ators or pipes must not be used.

B If a room thermostat is used: do not fit a thermostatic

radiator 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 the

central heating system. Suitable products are available from Betz-Dearborn Tel: 0151-4209563, Fernox Tel: 01799-550811 and Salamandor on 0121 378 0952.

B In our experience, the addition of sealing agents to

the water in the central heating system can cause problems (deposits in the heat exchanger). For that reason we advise against their use.

3.2 Domestic hot water

Any regulations specified by the local water company must be observed.

The final 600 mm of the mains cold water connection to the appliance should be made in copper tube only.

The appliance is suitable for a mains supply having a maximum pressure of 10 bar. A pressure reducing valve must be fitted, if necessary.

The hot water outlet temperature is set to be capable of achieving a maximum of 60°C. The maximum temperature and the frequency of the recharge of the heat store may be reset.

The water flow rate of 11.0 l/min (RD532i), 12.7 l/min (RD537i) and 13.5 l/min (RD542i) will give a temperature rise of 40°C. If a higher rise is required then the flow must be reduced at the tap and the discharge temperature will rise up to the maximum set figure.

The temperature rise, up to the maximum set by the user, is automatically maintained by the modulation of the heat input. In winter, when the mains temperature is very low, the water flow, adjusted at the tap or shower, should be reduced to maintain the required delivery temperature.

It is suggested that long pipe runs to taps or showers

be insulated to prevent the rapid cooling of the water.

All types of single lever mixer taps and thermostatic mixer units suitable for a mains pressure of up to 10 bar can be used.

The head of a loose-head shower must not be allowed to fall within 25 mm of the top the bath to prevent the risk of water being drawn back into the mains. Alternatively the shower must be fitted with an anti-syphonage device at the point of the flexible hose connections.

Over-rim bidets may be connected to the appliance provided that it is in accordance with the requirements of the local water company. The outlet(s) should be shrouded and unable to have any temporary hand held spray attached. No anti-syphonage arrangements are necessary.

In exceptionally hard water areas a device to prevent scale formation may be fitted or, alternatively, the maximum temperature reset to about 45°C which may reduce the risk of scale formation. The installation of a scale inhibitor assembly should be in accordance with the requirements of the local water company. Artificially softened water must not be used to fill the central heating system. An isolating valve should be fitted to allow for servicing.

Devices, such as water meters or back-flow prevention valves, capable of preventing the flow of expansion water must not be fitted unless separate arrangements have been made.

A Zilmet Z160 expansion vessel is the preferred type. A thread sealant compatible with potable water must be used. The vessel should be connected into the cold water mains inlet pipe as close as possible to the appliance.

3.3 Sealed systems

The appliance must not be operated without the system being full of water, properly vented and pressurised.

The expansion vessel has a volume of 10 litres and is charged to a pressure of 0.75 bar.

The water capacity of the system is shown in table 12, page 31. If a greater capacity is required then an additional expansion vessel must be fitted into the system return as close to the appliance as possible. The system pressure can be set up to a maximum of 1.5 bar with 1 bar being the normal setting.

If the system pressure is greater than 2.5 bar when the appliance is operating at maximum temperature then an additional expansion vessel must be fitted into the system return as close to the appliance as possible.

The filling point must be at low level and arranged as shown 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 the

approval of the local water company. All connections in the system must be capable of withstanding a pressure of up to 3 bar and the radiator valves conform to the

B Always turn off the gas cock before car-

rying out any work on components which carry gas.

Fixing of the appliance, gas and flue connections, commissioning of the system and electrical connections may only be carried out by competent persons authorised by CORGI.

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6 720 611 447 GB (03.11)

Installation

requirements of BS2767:10.

Fit Thermostatic Radiator Valves to radiators in the sleeping accommodation and not to the radiator where the room thermostat is sited, this must be left open.

Repeated venting probably indicates a leak and this must be rectified to ensure the proper operation of the appliance.

No galvanised radiators or pipes must be used.

If any system water treatment is required then only products suitable for use with Aluminium shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the manufacturers instructions. The use of any other substances will invalidate the guarantee. The pH

value of the system water must be less than 8 or the appliance guarantee will be invalidated.

Suitable products are available from Betz-Dearborn Tel: 0151-4209563, Fernox Tel: 01799-550811 and Salamandor on 0121 378 0952.

A drain cock to BS2879 must be fitted to the lowest point of the system.

IMPORTANT: Check that no dirt is left in the water pipework as this could damage the appliance. Thoroughly flush the heating system and the mains water supply before fitting the appliance to the wall in accordance with the recommendations of BS7593:1992.

Fig. 5 Sealed primary water system

Fig. 6

3.4 Siting the appliance

Regulations concerning the Installation Site

B Relevant national regulations must be complied with

section 3.9.1.

B Consult the installation instructions for details of min-

imum clearances required.

Combustion air

In order to prevent corrosion, the combustion air must not contain any corrosive substances.

Substances classed as corrosion-promoting include halogenated hydrocarbons which contain chlorine and fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and household cleaners, for example.

Surface temperature

The max. surface temperature of the casing and the flue is less than 85 °C. This means that, no special safety precautions are required with regard to flammable building materials and fitted furniture. The specified clearances must be maintained.

Cupboard/Compartment

The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS6798 and BS5440:2 are followed. The low casing losses from the appliance eliminate the need for ventilation openings in the compartment.

6 720 610 576 -09.3O

APPLIANCE

A drain cock should be fitted at the lowest point of the heating circuit and the appliance

WRC approved filling loop

Domestic hot water

BS stop valve Fixed spindle type.

Water main

Refer to

Appliance

Water Flow

Diagram

Lockshield valve

Radiator valve

Central heating return

Central heating flow

Page 13

6 720 611 447 GB (03.11)

Installation

3.5 Wall mounting frame assembly

B Take the wall mounting frame out of the package and

screw together with 6 screws as shown in fig. 7. Use the inner lugs on the top and bottom horizontal sections.

Fig. 7

B Hold the wall-mounting frame against the wall ensur-

ing that it is vertical.

B Mark the holes for the wall mounting frame onto the

wall, drill and plug the holes and screw the wall mounting frame to the wall with the screws provided.

B Mark the position of the flue duct hole if a rear flue is

to be used. Refer to fig. 1 and 16.

Fig. 8

B Screw the pre-plumbing manifold with two screws to

the wall mounting frame.

Fig. 9

3.6 Pre-piping the system

Fig. 10 Manifold

43 CH flow 47 CH return 112 Gas cock 171 Domestic hot water 172 Cold water relief

B A drain tap should be fitted at the lowest point of the

central heating system.

B WRAS approved filling loop must be fitted.

6 720 610 597-06.1O

6 720 610 597-07.1O

6 720 610 597-08.1O

200

260

6 720 610 576-06.1O

120-130

4743

172112

171

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6 720 611 447 GB (03.11)

Installation

Condensate Termination and Route

The appliance has a built-in syphonic condensate trap eliminating the need for external traps. Connect to the 22mm plastic drain pipe and extend the pipe run away from the control panel and appliance witha constant fall of 2.5° or 25mm in every metre. See Fig. 12

The condensate pipe can terminate into any of four areas:

Fig. 11

Whilst all of the above methods are acceptable it is always the best practice to terminate the condense pipe via an internal waste system.This will eliminate the need for any external condensate pipe runs which can be susceptible to freezing in extreme weather.

Fig. 12 Recommended route of the condensate drain

External condensate pipework

The syphonic condensate trap collects condensate into a trap which releases it in 100 ml quantities. This helps to prevent the discharge from freezing.

If there is no alternative and the condensate pipe has to be externally run, the following should be considered:

• The pipe run should take the shortest practical route.

• The pipework should be insulated with weather resistant insulation.

• The pipe should terminate as close as possible to the ground or drain, whilst still allowing the condensate to safely disperse. This would prevent wind blowing up the pipe.

• The pipework should be installed with the minimum of horizontal runs and with a downward slope of at least 2.5 °.

3.7 Fitting the appliance

Removing the outer case

B Remove retaining screws (1), see Fig. 13.

B Slide the outer case upwards and forwards to

remove (2).

Fig. 13

Boiler

Sink

Ø 22 min.

Siphon

75 min. trap

Invert

No length restriction

Internal soil and vent stack

The gradient of the discharge pipe should be 2.5¡ (40 mm/m) minimum

An internal waste system

An external waste system

The rainwater system

An external purpose made soakaway

The gradient of the discharge pipe should be

2.5¡ (40 mm/m) minimum

Use waterproof pipe work insulation in very exposed positions

Open end of pipe direct into gully, below ground but above water level.

Open end of pipe direct into gully, below ground but above water level

75 min. trap

450 min.

Siphon

75 min. trap

Boiler

6 720 610 596 -03.2TD

Boiler

Sink

6 720 610 602 - 04.1O

Benchmark: For optimum performance after installation, this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS5793:1992 “Treatment of water in domestic hot water central heating systems”.

The outer case is secured against unauthorised removal by a retaining bracket (electrical safety) at the bottom left. Always secure the outer case with this bracket again after refitting.

6 720 610 597 -10.T

Page 15

6 720 611 447 GB (03.11)

Installation

Fixing the appliance

B Fit the washers onto the gas and water connections.

B Lift the boiler onto the wall-mounting frame. The lugs

pass through the rectangular holes in the boiler back panel.

B Take care not to disturb the washers on the connec-

tions.

Connecting the flue duct

B Fit flue duct connector onto boiler flue socket.

B Secure with the screws supplied.

Fig. 14

B For remaining installation of flue assembly, refer to

the relevant installation instructions.

3.8 Checking the connections

Water connections

B Check that the O-rings or seals are in place before

tightening the connection.

B Turn on the service valves for central heating flow

and return and fill the heating system through a WRAS approved filling loop.

B Check all seals and unions for leaks (testing pressure

max. 3.0 bar as indicated by pressure gauge).

B Turn on cold water service cock and fill hot water sys-

tem (testing pressure max. 10 bar).

B Check all connections for leaks.

Gas supply pipe

B Check that the seal is in place before tightening the

connection.

B Turn off gas cock to protect gas valve against dam-

age from excessive pressure.

B Check gas supply pipe.

B Release the pressure on the gas supply pipe.

3.9 Flue Systems

The only flue systems that may be used are those supplied with the boiler.

The flue system must be installed in accordance with the requirements of BS5440:1.

Standard 100 mm flue system

The standard concentric flue system provides for a horizontal length of up to 4m (3.5m RD542i). Full instructions for fitting this flue are in Subsection 3.9.2 “Installation of the flue”.

Alternative 125 mm diameter flue systems

Installation instructions for the alternative flue systems are sent with the appropriate flue kit.

Systems are available for a maximum horizontal length of 13m (RD532i),10m (RD537i/542i).

A vertical flue system up to a height of 13.7 m (RD532i) and10.7 m (RD537i/542i) is available.

45° and 90° flue bends can be used with a reduction in flue length of 2 m for each 90° bend and 1 m for each 45° bend used.

IMPORTANT: Any horizontal flue system fitted to a condensing boiler must incline from the appliance at an angle of 3° (30 mm per metre length) to prevent condensate dripping from the flue terminal.

Note, the standard 100mm horizontal flue requires only a 0.5° incline from the boiler as the inner exhaust pipe is inclined at 2.5° inside the outer pipe.

This means that the clearance above the appli-

ance must be increased to match the duct length. Refer to fig. 1 on page 5.

Retaining Screw

Flue Turret to Boiler Sealing Gasket

Flue Turret

6 720 610 599 - 01.TD

Appliance Flue Socket

Flue seal

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6 720 611 447 GB (03.11)

Installation

3.9.1 Siting the Flue Terminal

The flue must be installed in accordance with BS 5440:1 and the Building Regulations. Flue terminals in carports and under balconies are to be avoided. The terminal must be positioned so that it does not cause an obstruction nor the combustion products a nuisance. See fig. 15 and table 10. The terminal will, at times, give out a plume of water vapour and consideration must be given to this when choosing a terminal position. Keep clear of security

lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which people have access then a guard must be fitted. The guard must be evenly spaced about the terminal with a space of 50 mm in each direction and fixed with plated screws. A guard Type K6 for the standard horizontal flue, can be obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.

Fig. 15

Minimum dimensions of flue terminal positions (all types) (see fig. 15)

D,E

boundary

Dimension Term inal position (kW input expressed in net) Balanced flues room sealed: Fanned draught

Directly below an opening, air brick, opening windows, etc. 300 mm

Above an opening, air brick, opening window, etc. 300 mm

Horizontally to an opening, air brick, opening window, etc. 300 mm

D Below gutters, soil pipes or drain pipes 75 mm

E Below eaves 200 mm

F Below balconies or car port roof (lowest point) Not recommended

G From a vertical drain pipe or soil pipe 75 mm

H From an internal or external corner or to a boundary alongside the terminal 300 mm

I Above ground roof or balcony level 300 mm

J From a surface or boundary facing the terminal 1200 mm

K From a terminal facing the terminal 2000 mm

L From an opening in the car port (e. g. door, window) into the dwelling Not recommended

M Vertically from a terminal on the same wall 1500mm

N Horizontally from a terminal on the same wall 300 mm

P From a vertical structure on the roof 500 mm

Q Above intersection with roof 300 mm

Table 10

1) In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.

Page 17

6 720 611 447 GB (03.11)

Installation

3.9.2 Installation of the flue

The standard 100 mm diameter horizontal flue system is suitable for lengths up to 4m (3.5m RD542i). Flues up to 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm (3500 mm RD542i) require extension duct assemblies. NOTE: Flue lengths between 650 mm and 730 mm cannot 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. 20

Instructions for fitting other flue systems are packed with the relevant flue kit. Check that the position chosen for the appliance is satisfactory. Refer to fig. 16.

Fig. 16 Marking the position of a side flue opening.

Note: ensure there is adequate access to the air/flue sampling points in the flue turret.

Fig. 17 Standard Flue

Centre line of flue/air duct

Centre line of flue opening and appliance Drilling

point for flue duct opening

H = 40mm for the Standard 100mm Horizontal Flue H = 70mm for the Optional 125mm Horizontal Flue

3°

(30mm/metre)

Standard 100mm

horizontal flue 0.5°

(5mm/metre)

Top of wall mounting frame (not boiler)

Appliance

120

6 720 610 602-08.3O

Maximum 650mm

Clamp

Flue Turret

Terminal Assembly

Outer Wall

6 720 610 599 - 01.TD

Minimum 100mm

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6 720 611 447 GB (03.11)

Installation

Fig. 18 Flue with One Extension

Fig. 19 Flue with Extensions

Fig. 20 Flue Components

3.9.3 Flue duct preparation and assembly

Measure the flue length L. Refer to fig. 21, 22.

Maximum 1600mm

Clamp

Flue

Turret

Terminal Assembly

Outer Wa l l

6 720 610 599 - 00.TD

Extension Duct

Clamp

Flue Turret

Terminal Assembly

Outer Wall

6 720 610 599 - 01.TD

Extension Duct

ClampClamp

Clamp

Flue Turret

Extension Flue Duct

Flue Terminal Wall Sealing Gasket

6 720 610 599 - 01.TD

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6 720 611 447 GB (03.11)

Installation

Fig. 21 Flue length - rear

Fig. 22 Flue length - side

Measure ‘L’ from the end of the metal section of the flue terminal to the centre of the flue outlet on the boiler as shown in Fig. 21 & Fig. 22 and deduct 90mm from that measurement.

Cut both inner and outer flue pipe square at the opposite end to the terminal without creasing the tubes.

Remove any burrs before fitting the terminal to the turret.

Fig. 23 Flue terminal position

Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must be directed as per Fig. 23.

The assembly will be made easier if a solvent free grease is lightly applied i.e Silicone lubricant, to the male end of the ducts.

NOTE: An inner wall sealing plate is provided which should be fitted to the ducts before assembly.

Push the assembly through the wall and fix the turret to the appliance with the screws provided. Refer to fig. 24.

Fig. 24 Flue turret

Ensure that the turret is fully secured to the socket on the boiler.

If the terminal is within 2 m of the ground where there is access then an approved terminal guard must be fitted. The guard must give a clearance of at least 50 mm around the terminal and fixed with corrosion resistant screws.

120

6 720 610 599 - 01.TD

6 720 610 599-00.TD

Outer Wall Face

Flue Terminal

Wall Sealing Gasket

Retaining Screw

Flue Turret to Boiler Sealing Gasket

Flue Turret

6 720 610 599 - 01.TD

Appliance Flue Socket

Flue seal

Page 20

6 720 611 447 GB (03.11)

Electrical connections

4 Electrical connections

B Allow mains cable to protrude at least 50 cm from

wall.

B To maintain the splash-proof (IP) design: cut the

cable grommet hole size to match the diameter of the cable, see fig. 27.

B The appliance must be earthed. B It must be possible to completely isolate the appli-

ance with at least 3mm contact separation in both poles.

The wiring between the appliance and the electrical supply shall comply with current IEE Wiring Regulations (and any local regulations which apply) for fixed wiring to a stationary appliance.

• Supply: 230 V ~ 50 Hz, 150 Watts

• External fuse 3 A

• The system connected to the boiler must NOT have

a separate electrical supply

• Water Protection IPX4D.

4.1 Connecting the appliance

To gain access to the mains connection remove the drop down facia cover. The drop down cover is removed by lowering it to the horizontal position and pushing firmly upwards at the rear of the supports to release the cover. Lift cover from the appliance.

After installation (or in the event of an electrical fault) the electrical system shall be checked for short circuits, fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.

B Pull out cover panel at the bottom and remove. Refer

to fig. 25.

Fig. 25

B Remove screw and slide terminal cover forwards to

remove. Refer to fig. 26.

Fig. 26

B Always disconnect the power supply to

the appliance at the mains before carrying out any work on the electrical systems and components.

6 720 610 332-10.1R

6 720 610 336 -18.1R

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6 720 611 447 GB (03.11)

Electrical connections

B Cut cable grommet to diameter of cable.

Fig. 27

B Feed cable through cable grommet and connect the

mains supply cable, see fig. 28.

B Secure cable in cable grommet by means of cable

grip.

Fig. 28

4.2 Connecting a TR2 Room Thermostat (accessory)

Connect the TR2 to terminals 3, 4 and F beneath the Text display (page 8, fig. 4, item 422) using a minimum 1mm cable to avoid incresing resistance between the terminals, see Fig. 29

Fig. 29

4.3 Mains Voltage external controls connections

Externally wired controls are not required; the boiler has a built-in text display programmer and frost protection. The TR2 room thermostat provides additional frost protection and compliance to Part L of the Building Regulations.

6 720 610 332-12.1R

13-14

10-12

8-9

5-7

TEXT DISPLAY

F34

4AF3

TR2

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6 720 611 447 GB (03.11)

Commissioning

5 Commissioning

Fig. 30

8.1 Pressure gauge 15 Safety valve 27 Automatic vent 61 Reset button 135 Master switch 136 T emperature control for central heating 170 Service cocks on CH flow and return 171 Hot water 172 Gas cock (shown in off position) 173 Cold water service cock 295 Appliance type sticker 310 Temperature control for hot water 317 Multi function display 358 Condensation trap 363 Indicator lamp for burner 364 Indicator lamp for power supply 365 “Chimney sweep” button 366 Service button 367 ECO button 400 Text display

5.1 Commissioning

Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance with the guidelines given in BS7593:1992 - Treatment of water in domestic hot water systems. Full instructions are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should be used in accordance with the inhibitor manufacturers instructions.

To drain the appliance shut the system valves and open the system drain point.

Suitable flushing agents and inhibitors are available from Betz-Dearborn Tel: 0151-4209563, Fernox Tel: 01799-550811 and Salamandor on 0121 378 0952. Instructions for use are supplied with the these products.

ECO

364

135

295

8.1

365

317 366 367

310

136

363

400

358

6 720 610 597 - 05.1O

170

171

173

170

172

Never run the appliance when empty or unpressurised.

The operational CO2 level is set at the factory and no adjustment is necessary when installing a natural gas fired appliance.

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6 720 611 447 GB (03.11)

Commissioning

B Before commissioning, the gas supply pres-

sure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7). Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar. LPG appliances must not be operated if the supply pressure is not 37 mbar at the inlet to the appliance.

B Unscrew the condensation trap (358) and pull out, fill

with approx. 1/4 l of water and refit. Refer to fig. 30.

B Adjust charge pressure of expansion vessel to static

head of the central heating system (see page 31).

B Open all system radiator valves. B Check automatic air vent is open, item 27, see fig 30

B Turn on service valves (170), fill central heating sys-

tem to pressure of 1 - 2 bar through the WRAS approved 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 to

fig. 30.

B Check that the gas type specified on the identifica-

tion plate matches that of the gas supply.

B Turn on gas cock (172). Refer to fig. 30.

5.2 Switching the appliance on/off

Switching on

B Switch on the appliance at the master switch (I).

The indicator lamp shows green and the display will show the central heating flow temperature, when the appliance is operating in the central heating mode.

Fig. 31

The trap filling programme ensures that the condensation trap is filled after the appliance has been installed or after the appliance has been out of use for a long period or the mains supply has been interrupted. For that reason, the appliance remains at minimum heating output for 15 minutes.

Switching off the appliance

B Set the master switch to (0).

The green indicator lamp goes out. The optional timer will continue running until the emergency supply is exhausted.

5.3 Switching on the central heating

The central heating flow temperature is adjustable between 35 °C and 88 °C. Refer to table 13, page 31.

B Turn the temperature control to set the flow tem-

perature to a level appropriate to the type of central heating system:

– Underfloor heating: e.g. setting “3”

(approx. 50 °C)

– Low-temperature heating: setting “E”

(approx. 75 °C)

– Central heating systems for flow temperatures up

to 88 °C: limited “max” setting for low-temperature operation (see page 31).

When the burner is alight, the red indicator lamp lights up.

Fig. 32

5.4 System controls

B Set room temperature thermostat/controller (if fitted).

Refer to the instructions with the control.

B Set the thermostatic radiator valves to the desired

settings.

If the display alternates between -II- and the central heating flow temperature, the trap filling programme is active.

6 720 610 333-04.1O

B Always disconnect the appliance from

the power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or components.

6 720 610 333-05.1O

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Commissioning

5.5 Setting the domestic hot water temperature and flow rate

5.5.1 Domestic hot water temperature

The hot water temperature can be set to between approx. 40 °C and 60 °C.

This temperature is not shown on the display.

Fig. 33

“ECO” button

By pressing and holding the “ECO” button , until the display lights, you can switch between Comfort mode and 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 instantaneously at the tap. Consequently the appliance will switch on at intervals, even if no hot water is being drawn.

ECO mode with demand detection, button is lit

The demand detection function enables maximum gas and water economy. Briefly turning a hot water tap on and then off again signals demand to the appliance which then heats up the water to the set temperature. Hot water is thus available in about 1 minute.

ECO mode, button is lit

Water is not heated up until hot water is drawn. This means that there is a longer waiting period before hot water is available.

5.5.2 Hot water flow rate

Adjust the flow rate according to model.

Under standard conditions (2 bar) supply pressure, one full 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 the increase in the flow rate.

B To reduce the flow rate (min. 8 l/min):

turn screw on flow switch clockwise (–). The outlet temperature will increase relative to the decrease in the flow rate.

Fig. 34

5.6 Summer mode (hot water only)

With room thermostat

B Turn temperature control on the appliance anti-

clockwise as far as the stop. The central heating is now turned off. The hot water function and the mains power supply for the heating programmer and timer remain switched on.

5.7 Frost protection

B Leave master switch switched on.

If the appliance is to be left for long periods switch the central heating off:

B Add a suitable anti-freeze fluid to the water in the

central heating system. Suitable products are available from Betz-Dearborn Tel: 0151-4209563 and Fernox Tel: 01799-

550811.

5.8 Pump anti-seize function

Every time the pump is switched off, (after a CH demand) a timer is started. If after 24 hours the pump has not run again, it is switched on for a period of 10 seconds.

Setting Hot Water temperature

Turn fully anti-clockwise approx. 40 °C



approx. 55°C

Turn fully clockwise approx. 60°C

Table 11

6 720 610 333-07.1O

Frost protection and constant frost protection modes can be set on the text display module.

This function prevents the central heating pump seizing after long periods of inactivity.

6720 610 332-25.1O

Page 25

6 720 611 447 GB (03.11)

Commissioning

5.9 Fault Condition

In the unlikely event of a fault occuring while the appliance is in operation:

The display and the textdisplay then show a fault code and the button may also flash.

If the button flashes:

B Press and hold the button until the display shows

“––”. The appliance will then start up again and the display will show the central heating flow temperature.

If the button does not flash:

B Switch the appliance off and then on again at the

master switch. The appliance will start up again and the central heating flow temperature will be displayed.

5.10 Appliance Data Monitoring

If an external Gateway module is fitted then the operating system must be commissioned at this stage.

Commissioning of ADM and Gateway Check if Gateway is plugged into the telephone line and

mains.

1. Remove the cover from the gateway.

2. Unplug the power connector from the side of the gateway.

3. Reconnect the power to the gateway. Press and hold SW1 and SW2 within 5 seconds of powering up, see Fig. 35.

4. Observe 2 distinct clicks from the relays on the gateway.

Fig. 35 Gateway Module - switches and LED’s

5. Release the switches. Note only the RED LED is ON. The Gateway is now reset.

6. Press SW1. Observe 0.5 Hz flashing of GREEN LED. The gateway is now in “House Address Creation mode”. This lasts for approx. 1 minute.

7. Wait until GREEN LED flashes 3 seconds ON and 1 second OFF. The gateway has now Created the House Address.

8. Make the jumper JP1 on the ADM while powering up the appliance, see Fig. 36. Observe LED on ADM flashing. The flashing rate is

0.5 Hz, the ADM is now in “House Address Acquisi-

tion mode”.

Fig. 36 ADM - switches and LED’s

9. Return to the gateway and press SW1. Observe GREEN LED through the side of the box "House

Address Distribution mode”

10.After 100 seconds from step 8 observe ADM LED flashing at 2 Hz.

11.After 60 seconds from step 9 observe GREEN LED on gateway is ON.

12. The ADM will now cause the gateway to dial into BG. A click of the relay will be heard from the gateway at each end of the dialling in.

13.Now power down the Heatronic, remove JP1, replace all covers and power up again. The system is now set up.

A list of faults that may occur is given on page 46.

SW1

LED’s

Red Yellow Green

SW2

“House Address Acquisition mode” on the ADM and “House Address Distribution mode” on the gateway must overlap. Note the times are as follows, the ADM will stay in “House Address Acquisition mode” for 100 seconds and the gateway will stay in and “House Address Distribution mode” for 60 seconds.

JP1

LED

SENSOR

Page 26

6 720 611 447 GB (03.11)

Text Display

6Text Display

6.1 General Description

• The text display is used to display information about the appliance and the system and to alter the settings displayed.

• Once the appliance has been in operation for one day, the text display module has a power buffer period of about 10 hours during which it will run without the mains power supply. After that period has elapsed, the clock function shuts down but all other settings are retained.

6.2 Programming

Fig. 37 Controls

a Display b “Up”/“More” button c “Down”/“Less” button d “Back” button e “Next” button f “Delete” button

The 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 during commissioning, servicing, etc.

The programming procedure is described in detail below using the clock function as an example:

B To start programming, press any button, e. g. .

The display lighting switches on and the main menu is displayed:

Fig. 38 Main menu

B Use the or button to move the cursor

arrow on the left of the menu so that it points to the desired menu item. In this example, the cursor is positioned next to the menu item Time/day/holidays.

B Confirm the selection by pressing the button.

The corresponding submenu is displayed:

Fig. 39 Submenu: Time/day

In the submenus, the top line indicates what action is required. The bottom line shows the previous menu level, if applicable (see fig. 40).

B Use the or button to select Time/day. B Confirm the selection by pressing the button.

The corresponding submenu is displayed:

Fig. 40 Setting the hour

When settings are being entered, the setting to be altered is indicated on the top line. In addition, the setting being altered is displayed with a dark background.

B Use the or button to set the hour.

– Press and release to change the display by one

unit at a time

– Press and hold to change the display rapidly

B 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 the

week.

6 720 610 337-08.1R

6 720 610 598-04.2O

/holidays

6 720 610 598-05.2O

6 720 610 598-06.2O

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6 720 611 447 GB (03.11)

Text Display

B Press the button to confirm the setting. The

cursor then returns to the top line.

-or-

B Press the button to confirm the setting and

return to the previous menu (fig. 39 page 26).

-or-

B Do not press any other buttons for 15 minutes.

6.2.1 Deleting a setting

Either overwrite the setting or press the button to delete it.

B Find the setting to be deleted. B Press and release the button.

The display shows --:--

6.2.2 Resetting all parameters to their original settings

B Press and hold the button for more than 15 sec-

onds. After about 5 seconds, the following message appears on the display:

ATTENTION Delete all parameters in x seconds

Once the reset has been completed, the following message is displayed:

Please wait... Initialising

6.3 Menu structure

The hours of service can not be reset to 0.

Submenu

Main menu

1. 2. 3.

Parameters to change/select

Page

Time/ day/holidays

Time/day--- Hours

- Minutes

- Day of week

Holidays--Days holiday 28

Heating Heating

program

--- Day

- 1st operating mode

- 1st switching point ...

- 6th switching point

Set economy temp. (if TR2 is connected)

--5...30°C 29

Manual (if TR2 is not connected)

- - - Automatic

- Constant on (comfort)

- Constant off (economy)

Hot water

Hot water program

--- Day

- 1st operating mode

- 1st switching point

...

- 6th switching point

Hot water immediately

--Off/On 29

Info- --- 29 Settings Heating - - Optimum Start Off/On30

Hot water (ZSBRmodels)

--Only charging times/ times and temperatures

Service Display

service param.

-- 30

Further options

Language

-English/

-Français/

-Deutsch

-Time correction

-LCD contrast

30 30

Operating times

-30

Fault history

-30

Page 28

6 720 611 447 GB (03.11)

Text Display

6.4 Setting the time/day

6.4.1 Setting the time and day

For details of how to set the time and day, refer to page 26.

6.4.2 Holidays

In the Holiday programme, the central heating runs in Economy mode and the hot water is switched off (frost protection 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 module automatically cancels Economy mode at midnight on the last day and returns to Automatic mode.

To cancel Holiday mode early:

B In the Holidays submenu:

Press the button until the display shows 0 .

6.5 Heating

6.5.1 Heating programme

Comfort Mode:

• With TR2 Room thermostat fitted: Central heating is on. House will be heated to temperature set on TR2.

• Without TR2 Room thermostat fitted: Central heating is on. Primary water is heated to temperature set at (radiator symbol) dial.

Economy Mode:

• With TR2 Room thermostat fitted: Central heating is on. House will be heated to temperature set 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 registers temperatures below 5°C.

Basic setting (Automatic mode)

• The appliance switches automatically between normal heating, Economy mode and Frost protection mode according to the timer settings entered.

•Basic setting: – Heating (Comfort)starts at 6:00 am – Economy starts at 10:00 pm

Setting options

• Maximum of six switching points per day with three different operating modes (Comfort, Economy, Frost protection).

• Same times for Monday to Friday.

• Same times for Saturday and Sunday.

• Different times for every day.

Setting switching times and operating mode

B From the main menu select Heating and then from

the first submenu, select Heating program.

B Select Monday - Friday, Saturday and Sunday or

an individual day of the week. – Monday - Friday: to have “Comfort” and “Econ-

omy” or “Frost protection” switching on at the same times every weekday.

– Saturday - Sunday: to have “Comfort” and

“Economy” or “Frost protection” switching on at the same times Saturday and Sunday.

– Individual day of the week (e. g. Thursday): to

have the relevant program always switching on at the specified time on that day of the week, i.e. “Comfort”, “Economy” or “Frost protection” at the same time every Thursday.

B Press . The display shows Set 1. operating

mode.

B Set the desired first operating mode (Comfort, Econ-

omy or 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 and

time periods as described for the first.

B If necessary: select the next day and enter the oper-

ating modes and timer periods as described above.

Timer periods and operating modes are you do not wish to change can be skipped by pressing .

Changing winter and summer time:

B Only adjust the clock! Do not alter the

switching points (for heating, economy, etc.).

The day on which you enter the days holiday counts as the first day of the holiday, i.e. the unit starts the holiday program immediately. Only include the day on which you are returning if you don’t want the heating to return to the normal program on that day!

If the settings for a particular day of the week are different from the settings for the other days, then if Monday - Friday or Saturday and Sunday is selected, the display shows

--:--, i.e. there are no common switching points for those options.

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6 720 611 447 GB (03.11)

Text Display

6.5.2 Setting the Economy temperature (if TR2 is connected)

This option allows you to set the room temperature for Economy mode (Off (Economy)).

This function is only active if:

• Automatic mode or Economy mode is set on the TR2

room thermostat.

B From the main menu, select Heating and then from

the first submenu, select Set Economy temp..

B Use the or button to set a temperature

between 5 and 30 °C.

6.5.3 Manual operating mode (if TR2 is not connected)

For selecting an operating mode that is different from the one set in the heating programme (Automatic mode).

• You can choose between Automatic, Constant on

(comfort) and Constant off (economy).

• The manually selected operating mode starts imme-

diately.

• 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.

B From the main menu select Heating and then from

the first submenu Manual select required mode.

6.6 Hot water

General description

• Combi models only: The basic settings provide a straightforward timer programme: enabling Hot Water pre-heat from 5:00am disabling Hot Water preheat from 10:00pm. The ECO button must not be lit.

6.7 i Info

B Select Info from the main menu.

You can view the following information:

Display text Description

Room temperature

(if TR 2 connected)

Current temperature in the room where TR 2 is installed

Required room temperature

(if TR 2 connected)

Required temperature in room where TR 2 is installed

Operating mode

(if TR 2 connected)

E. g. Heating, Economy in Automatic mode or Economy, Heating, Frost protection in manual mode

Max. flow temp. Maximum CH flow tempera-

ture set on the temperature control for CH flow

Actual flow temp. Actual CH flow temperature

Required flow temp.

Required CH flow temperature

Max HW temp. Maximum permissible hot

water outflow temperature

Required HW temp.

Required hot water temperature

Actual HW temp. Actual hot water outflow

temperature

Storage Tank charge released or blocked

Shows, if hot water is released or blocked

Storage Tank charge on or off or Storage Tank charge afterrunning

Shows, if hot water is on or off, or if the pump for the Storage Tank afterrunning is on

Boiler operat. mode winter/ summer

Indicates which mode the CH flow temperature control is set to

Burner on/off Indicates whether the burner

is alight or not

Pump on/off Indicates whether the inte-

gral pump is switched on or off

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6 720 611 447 GB (03.11)

Text Display

6.8 Settings

6.8.1 Heating (if TR 2 is connected)

Optimum Start

If the optimum start facility is used: Set the heating ON time to 1 hour before the house

needs to be at the required temperature.

The boiler will start in heating mode at the optimum time, which could be at any time during that hour.

B From the main menu, select Settings and from the

first submenu, select Heating.

B Press or to switch Optimum Start on or off.

Basic setting: “ON”

6.8.2 Hot Water (Storage Tank, system models only)

The text display can control the hot water either with Times and temperatures or only times.

• Times and temperatures: One can choose up to

six different times with temperatures, see page 29 “Hot water”.

• Only times: During that times the Storage Tank will

be charged to the chosen temperature.

B From the main menu, select Settings and from the

first submenu select hot water.

B Press or to switch Times and temperatures

or only times.

6.8.3 Service

Displaying service functions

This option displays various current settings and statuses of the electrically controlled appliance and system components for the benefit of the heating engineer.

Service parameters

Language Available languages are: English, Français (French), Deutsch (German).

B From the main menu, select Settings, from the first

submenu select Service, from the Second submenu select Further options, and from the third submenu select Language.

B Press or to select the desired language.

Two other supplementary functions can be selected from the third submenu Language:

• Time correction

•LCD contrast.

Time correction:

B Press and hold the button (about 5 seconds)

until the display shows Time correction and LCD contrast.

B Press or to select Time correction.

B Press the button. The display shows Change

value.

B Press or to set the number of seconds in

24 hours.

Basic setting: “+ 0 s”

LCD contrast:

B Press and hold the button (about 5 seconds)

until the display shows Time correction and LCD contrast.

B Press or to select LCD contrast.

B Press the button. The display shows Change

value.

B Press or to adjust the LCD contrast.

Basic setting: e. g. “47”

Operating times This option shows the hours of service (appliance, burner and hot water) since commissioning.

B From the main menu, select Settings, from the first

submenu select Service, from the Second submenu select Further options, and from the third submenu select Operating times.

Fault history This option displays any faults that have occurred for the information of the service engineer. The first fault displayed may still be active. Any other faults displayed are no longer active.

B From the main menu, select Settings, from the first

submenu select Service, from the Second submenu select Further options, and from the third submenu select Fault history.

6.9 Individual timer programmes

Tables for your own timer programmes you find in the User Manual.

Turn the hot water temperature control always higher than the temperature at the text display is chosen.

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6 720 611 447 GB (03.11)

Individual settings

7 Individual settings

7.1 Mechanical settings

7.1.1 Checking the size of the expansion vessel

Maximum pressure at maximum CH flow temperature is

2.5 bar. If the pressure is greater than this then fit an extra expansion vessel. Refer to table 12.

System Capacity – BS7074:1

7.1.2 Setting the central heating flow temperature

The central heating flow temperature can be set to between 35 °C and 88°C.

Limited maximum setting for low-temperature operation

The temperature control is factory limited to setting E, giving a maximum flow temperature of 75°C.

Adjustment of the heating output to the calculated heat demand is not required by the heating systems regulations.

Removing the maximum setting limit

For heating systems which require higher flow temperatures, the maximum setting limit can be removed.

B Lift off the yellow button on the temperature control

with a screwdriver.

Fig. 41

B Rotate yellow button through 180° and replace (dot

facing inwards). The CH flow temperature is no longer limited.

7.2 Settings on the Bosch Heatronic

7.2.1 General description

The text display module provides a convenient means of setting various appliance functions.

This description is limited to those functions necessary for commissioning.

Displaying service functions

All service functions are displayed.

B Press any button to activate the main menu.

B Press or button until the arrow cursor is

pointing to Settings.

B Press the button.

B Press or button until the arrow cursor is

pointing to Service.

B Press the button.

B Press the button to select Display service

parameters. Service function 0.0, Last fault is displayed.

B Press the or button to cycle through the

current settings.

B Press the button to exit the menu.

Expansion Vessel Pressure and System Capacity

Expansion Vessel litres 10

Expansion Vessel Charge Pressure

bar 0.75

System pressure and capacity

1 bar litres 82

1.5 bar litres 46

Table 12

6 720 610 332-27.1O

Control setting CH flow temperature

1approx. 35°C 2approx. 43°C 3approx. 51°C 4approx. 59°C 5approx. 67°C

E approx. 75 °C

max approx. 88°C

Table 13

Service function Code no.

see page

Anti-cycle time 2.4 32

Max. CH flow temp. 2.5 32

Max. heating output 5.0 32

Constant hot water cycletime

6.8 32

Variable pump settings 7. 0 32

Table 14

For a detailed description, refer to Service Booklet for the Engineer 7 181 465 347.

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6 720 611 447 GB (03.11)

Individual settings

Setting service functions

Only 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 is

pointing to Settings.

B Press the button. B Press oder button until the arrow cursor

is pointing to Service.

B Press the button.

The cursor is pointing to Display service parame- ters.

B Press and hold the button (for about 5 sec-

onds) until the display shows Adjust service parameters 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 desired

service function is displayed.

B Press the button.

The first line of the display shows Change value.

B Use the or buttons to enter the required

setting.

B Press the button.

The text display shows ATTENTION Store set- tings?.

B Press or to select yes or no. B Press to confirm your selection.

The text display shows Please wait ... ..., and the

service function is then displayed with the new setting.

B Press the or button until the next func-

tion you 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 Function

2.7, 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 (recommended for 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 to between 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 to the specific heat requirements.

The factory setting is the max. rated heat output, 100 %.

B Look up heating output in kW and corresponding

code number on the settings tables for heating output (see page 48).

B Enter the code number on the text display module.

B Measure the gas flow rate and compare with the fig-

ures specified 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 inside the appliance is held constantly at the set temperature. For that reason, the appliance switches on if the water temperature falls below a certain temperature. In order to prevent it switching on and off too frequently, the constant hot water cycle time service function allows you to set the minimum period between switching off and on again. This function has no effect on normal demand for hot water and relates only to the constant hot water function in Comfort mode.

The cycle time can be set to any period between 20 and 60 minutes (is factory set to 20 minutes).

7.2.6 Variable pump settings (Service Function 7.0)

The pump speed varies automatically to match the water flow requirement of the system determined by the position of thermostatic radiator valves. An automatic by-pass must not be used.

The Service Function 7.0 is factory set to 4 which will accommodate the majority of heating systems.

Information on the re-settings of this functions can be found in the Service Booklet for the Engineer number 7-181-465-349.

7.3 Setting the gas/air ratio

The appliance is set at the factory and adjustment to the CO

settings (gas/air ratio) is only required where the appliance has been stripped down and assembled or if the fan, burner or gas valve are replaced or the appliance has been converted to a different gas type, see section 8.

The full rated heat output is still available for hot water or charging the hot water cylinder even if the heating output has been limited.

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6 720 611 447 GB (03.11)

Converting the appliance to different gas types

8 Converting the appliance to different gas types

The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not necessary.

Checking the gas supply pressure

B Check the gas supply pressure at the gas supply

pressure testing point.

Natural gas

•Appliances for natural gas type G20 are factory set to Wobbe-Index 15 kWh/m

and 20 mbar supply

pressure and sealed.

8.1 Setting the gas/air ratio

The gas/air ratio may only be adjusted on the basis of a CO

measurement at max. heat output

and 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 to

fig. 13).

B Switch on the appliance at the master switch (I).

B Unscrew sealing plug from flue gas testing

point (234). Refer to fig. 42.

B Insert testing probe about 135 mm into the flue gas

testing point and seal testing point.

Fig. 42

B On the text display unit, select in the main menu Set-

tings, Service, Display service parameters.

B Press and hold the button (for about 5 sec-

onds) until the display shows Adjust service

parameters and the first service function to be set,

2.0 Operating mode. If a fault has occurred, the

display will show 0.0 and the last fault.

B Press or until the display shows 2.0

Operating mode normal.

B Press the button.

B Press or to select Max. B Measure the CO

level.

B Prise off the seal on the gas flow restrictor. B Adjust the gas flow restrictor (63) to obtain the CO

level given in Table 15. Refer to fig. 43

Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar. LPG appliances must not be operated if the supply pressure is below or above 37 mbar.

6 720 610 599 - 01.TD

234

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6 720 611 447 GB (03.11)

Converting the appliance to different gas types

Fig. 43

B Press or to select Min.

B Measure the CO

level.

B Remove the seal from the gas valve adjusting

screw (64) and adjust the CO

level to the figure given in Table 15 for min. rated heat output. Refer to fig. 44.

Fig. 44

B Recheck the levels at min. and max. rated heat output

and re-adjust if necessary.

B Press or until the display shows

normal.

B Press the button. The text display shows

Store settings.

B Press to select yes.

B Press the button. B Remove testing probe from the flue gas testing

point (234) and refit sealing plug.

B Re-seal gas valve adjusting screw and gas flow

restrictor.

B Replace the outer case by locating it on the top lugs

and pushing backwards until the bottom clips are fully engaged. Check that the case is properly aligned with facia. Refer to fig. 13.

B Secure by replacing the screw at the bottom left.

Refer to fig. 13.

RD532i

Gas Type

CO2 reading at max. rated heat output

CO2 reading at min. rated heat output

Natural gas type G20

9.2 % 8.8 %

LPG G31 (propane)

10.8 % 10.5 %

Table 15

RD537i/542i

Gas Type

CO2 reading at max. and min. rated heat output

Natural gas type G20

9.2 %

LPG G31 (propane)

10. 8 %

Table 16

6 720 610 332-64.1R

3928-74.1R

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Converting the appliance to different gas types

8.2 Testing combustion air/flue gas at set heat output

8.2.1 Testing the O2 or CO2 level in the combustion air

B Press and hold the button until the display

shows ––. “Chimney sweep” mode is now active. The button will light up and the display shows the CH flow temperature.

B Remove sealing plug from combustion air testing

point (234.1, fig. 45).

B Insert testing probe about 80 mm into the testing

point and seal testing point.

Fig. 45

B Measure O

and CO2 levels.

B Refit sealing plug.

B Press and hold button until the display shows ––.

The button will stop flashing and the display shows the CH flow temperature.

8.2.2 Testing CO and CO

B Press and hold the button until the display

shows ––. “Chimney sweep” mode is now active. The button will light up and the display shows the CH flow temperature.

B Remove sealing plug from flue gas testing point

(234, fig. 45).

B Insert testing probe about 135 mm into the testing

point and seal testing point.

B CO- and CO

levels.

B Refit sealing plug. B Press and hold button until the display shows ––.

The button will stop flashing and the display shows the CH flow temperature.

By testing the O2 or CO2 level in the combustion air the gas tightness of a type C

flue system can be checked. The

level must not be less than 20,6 %.

The CO

level must not exceed 0,2 %.

In “chimney sweep” mode, the appliance switches to max. rated heat output or the set heating output. You then have 15 minutes in which to measure the levels. After that, the appliance switches back from “chimney sweep” mode to normal mode.

6 720 610 599 - 01.TD

234.1

234

You have 15 minutes in which to measure the levels. After that, the appliance switches back from “chimney sweep” mode to normal mode.

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6 720 611 447 GB (03.11)

Maintenance

9 Maintenance

B The User should be recommended to have the appli-

ance serviced regularly by a competent person.

B Use only genuine spare parts

B Refer to the Spare Parts List when ordering spare

parts.

B Always renew seals and O-rings removed during

servicing or repair work.

B Use only the following types of grease:

– Water valve: WRAS approved silicon based

grease

– Unions: approved sealant.

B To drain the appliance shut the system valves and

open the pressure relief valve.

B Upon completion of any electrical work check for

earth continuity, correct polarisation and resistance to earth.

Replace the text display module or the Heatronic PCB

If the text display module is replaced, the service function settings 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 in

the commissioning record.

B Always disconnect the appliance from

the electrical power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or components.

B Always turn off the gas cock before car-

rying out any work on components which carry gas.

There is a Service booklet for the Engineer, order no. 7-181-465-349, available to competent persons.

All safety and control systems are monitored by the Bosch Heatronic. In the event of a component fault, the text display shows a fault code.

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6 720 611 447 GB (03.11)

Maintenance

9.1 Pre-Service Check List

Date

1 Call up the last fault stored by the text

display, (see page 30).

2 Check ionisation current, Service

Function 3.3, (see page 38).

3 Perform visual check of air/flue duct.

Visual check of diaphragm for soiling and splits (see page 40).

4 Check gas supply pressure

(see page 33).

mbar

5 Test combustion air/flue gas

(see page 35).

6 Check CO

setting for min./

max. (gas/air ratio) (see page 33).

min. %

max. %

7 Check gas and water systems for

leaks (see page 15).

8 Check hot water outlet temperature

(see page 38).

9 Check heat exchanger

(see page 38).

mbar

10 Check burner (see page 39).

11 Clean condensation trap

(see page 40).

12 Check charge pressure of

expansion vessel matches static head of heating system.

mbar

13 Check central heating system

pressure.

mbar

14 Check electrical wiring for damage.

15 Check heating programmer settings in

the text display.

16 Check appliances that are part of

the heating system.

Table 17

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6 720 611 447 GB (03.11)

Maintenance

9.2 Description of servicing operations

The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 8.2.

Checking the ionisation current, Service Function 3.3

B Select Service Function 3.3. (See page 31 “Display-

ing Service Functions”)

If the display shows ‘Meduim’ or ‘High’ while the boiler is firing, the ionisation current is OK. If the display shows ‘No’ or ‘Low’ while the boiler is firing, the electrode assembly (32.1, page 6) must be cleaned or replaced.

Domestic hot water

If, after checking the dynamic pressure, the flow rate is too slow:

B remove the domestic hot water heat exchanger and

replace,

B Before removing the heat exchanger shut the inlet

valve and drain the hot water circuit.

B Use new seals when replacing the heat exchanger.

Fig. 46

Primary Heat exchanger

There is a special accessory kit (no. 840) for cleaning the heat exchanger, order no. 7 719 001 996.

B Check control pressure on the air - gas mixer unit at

max. rated heat output using an electronic manometer.

Fig. 47

B Remove cleaning access cover (415, page 6) and

the metal plate below it, if present. Refer to fig. 2.

B Unscrew condensation trap and place suitable con-

tainer underneath. Refer to fig. 48.

B Remove the fan and the burner as described in the

text headed “Burner” (see page 39).

Fig. 48

7 181 465 330-06.1R

The heat exchanger should only be cleaned if the control pressure is

5.2 mbar (RD532i)

5.3 mbar (RD537i)

6.2 mbar (RD542i)

(depression) or less.

6 720 610 332-69.1R

6 720 610 332-72.1R

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6 720 611 447 GB (03.11)

Maintenance

B Loosen any deposits in the heat exchanger from top

to bottom using the cleaning blade. Refer to fig. 49.

Fig. 49

B Clean the heat exchanger from top to bottom using

the brush. Refer to fig. 50.

Fig. 50

B Flush the heat exchanger from the top. Refer to

fig. 51.

B Clean out the condensate collector and trap connec-

tion (with other end of brush).

Fig. 51

B Refit the clean-out cover using a new seal and

tighten screws to torque of approx. 5 Nm.

Burner

B Check that the gas cock is turned off and the master

switch is in the OFF position

B Remove the clips (1) and unscrew the two bolts (2).

Refer to fig. 52.

B Unscrew and remove the two hexagon screws secur-

ing the fan (3).

B Slacken fully the rear securing bolt (4). B Remove the burner coverplate.

Fig. 52

B Remove the burner skin and clean components. Do

not use a wire brush. Refer to fig. 53.

Fig. 53

B Re-assemble burner in reverse order, inspect seal for

damage and replace if necessary.

B Adjust gas/air ratio. Refer to section 8.2.

6 720 610 332-73.1R

6 720 610 332-74.1R

6 720 610 332-75.2

7 181 465 330-04.1R

7 181 465 330-09.2R

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6 720 611 447 GB (03.11)

Maintenance

Condensation trap

In order to prevent spillage of condensate the condensation trap should be completely removed, (see page 38, fig. 48).

B Unscrew condensation trap and check connection to

heat exchanger is clear.

B Remove condensation trap cover and clean.

B Fill condensation trap with approx. 1/4 l of water and

refit.

Electrode assembly

B 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 remove

the electrode assembly. Refer to fig. 47.

B Clean the electrodes with a non-metallic brush. (The

spark gap should be 4,5 mm ± 0,5 mm.)

B Replace and re-connect the assembly taking care not

to mislay the inspection window.

Diaphragm in mixer unit for RD532i

B Open mixer unit (29).

B Carefully withdraw diaphragm (443) from fan intake

tube and check for soiling and splits.

Fig. 54

B Carefully refit diaphragm (443) the correct way round

into the fan intake tube.

B Seal the mixer unit (29).

Diaphragm in mixer unit for RD537i/542i

B Remove fan and mixer unit assembly.

Fig. 55

B Unscrew mixer unit (29). B Remove sleeve.

B Carefully remove diaphragm (443) and check for soil-

ing and cracks.

B Refit diaphragm (443) taking care to ensure it is the

correct way round.

B Refit mixer unit (29) and fan assembly.

B Take care not to damage diaphragm

(443) when removing and refitting it.

6 720 610 790-07.2R

The flaps of the diaphragm (443) must open upwards.

443

6 720 610 910-63.1R

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6 720 611 447 GB (03.11)

Maintenance

Siphon

B Unscrew the clip and disconnect the pipe to the

siphon.

B Remove the drain plug to drain the siphon. B Unscrew the securing nut from beneath the side

facia and remove the siphon. Refer to figure below.

B Refit and prime the siphon.

Fig. 56

Expansion vessel

The expansion vessel should be checked once a year.

B Depressurise appliance.

B If necessary, adjust expansion vessel charge pres-

sure to static head of the heating system.

Heating system pressure

B The pointer on the pressure gauge should be 1 bar.

B If the pointer is below 1 bar (when the system is

cold), water should be added until the pointer is 1 bar again.

B Max. pressure of 2.5 bar when the heating system

water is at maximum temperature must not be exceeded. If this pressure is exceeded then an extra expansion vessel must be fitted in the system return as close to the appliance as possible.

B If the system does not retain the pressure, the expan-

sion vessel and the heating system should be checked for leaks.

9.3 Replacement of Parts

Before changing any components check that the gas is turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance.

Refitting is a reverse of the procedure for removal using new seals or o-rings as appropriate.

9.3.1 PCB control board and transformer

B 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 lead

and remove earth lead.

B Remove two top fixing screws from the control box.

Refer to fig. 57.

Fig. 57

B Lower the control box.

B Unscrew earth lead. B Unscrew four fixing screws from cover plate. Refer to

fig. 58.

B Prise off cover plate. B Pull off transformer.

B Remove pcb holder.

Fill the system using the WRAS approved filling loop.

Condensate Drain

Siphon

Drain Plug

181 465 330-09.1R

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6 720 611 447 GB (03.11)

Maintenance

B Remove the pcb control board.

Fig. 58

Fuses

B Remove the connections covers. Refer to fig. 25,

26.

The fuses are located adjacent to the mains connector block and connector ST18. Refer to fig. 4.

Fuse, item 312, is only replaceable by removing the pcb.

Spare fuses are fixed to the connections cover. A fuse pack is available: Part number 8 744 503 010 0.

9.3.2 Fan Assembly

Fig. 59

B Switch off the appliance. B Undo lower pipe union on gas pipe (1.). Refer to

fig. 59.

B Remove fan lead and earth connector (2.). The earth

connector has a positive clip fixing.

B Remove fixing screws attaching fan to the burner

cover (3.).

B Remove fan together with gas pipe and mixer unit. B Separate the fan from the pipe and mixer unit by

twisting the mixer unit to release it (4.).

9.3.3 Pump

B Switch off the appliance. B Disconnect the appliance from the power supply.

B Remove two switch box fixing screws (1.). Refer to

fig. 60.

B Lower switchbacks (2.).

B Remove screw from underside of right-hand plastic

cover plate (3.).

B Pull cover plate forwards to remove (4.).

B Unscrew and remove the siphon by releasing the

jubilee clip. Refer to fig. 56.

B Unscrew the pump union nuts (5.). Refer to fig. 60.

B Carefully remove the pump and disconnect the leads.

7 181 465 330-10.1

7 181 465 330-05.1R

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6 720 611 447 GB (03.11)

Maintenance

Alternatively

B After removing the siphon release the four Allen

screws and remove and replace the pump head.

Fig. 60

9.3.4 3-way diverter valve

B 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 to

fig. 61.

B Pull out retaining clip.

B Remove motor. B Disconnect the relief valve drain.

B Disconnect the pressure gauge by withdrawing the

clip and pulling out the capillary head.

B Undo pipe unions by withdrawing the clips.

B Remove 3-way valve.

Fig. 61

After refitting:

B Fill system, bleed and re-pressurise

(see Installation Instructions).

9.3.5 3-way diverter valve motor

B Switch off the appliance. B Turn off the service cocks.

B Unplug connector from 3-way valve motor. Refer to

fig. 61.

B Pull out retaining clip.

B Remove motor.

9.3.6 Sensors

B Check that the appliance is electrically isolated.

Central Heating Flow Temperature Sensor – Item 36, fig. 2, 57

B 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, 57

B Pull-off the connectors. B Unscrew the sensor.

Flue Temperature Limiter – Item 9, fig. 2, 57

B Pull-off the connectors. B Unscrew the sensor.

7 181 465 330-03.1R

7 181 465 330-12.1

Page 44

6 720 611 447 GB (03.11)

Maintenance

Domestic Hot Water Temperature Sensor – Item 6.1, fig. 2

B Check that the inlet water valve is closed and the

domestic hot water circuit is drained.

B Release and pull-off the connector. B Unscrew the sensor.

9.3.7 Gas Valve

B Check that the gas cock is turned off.

B Lower the control panel. Refer to fig. 60. B Pull off the solenoid connections at the rear of the

valve.

B Undo the union, within the inner casing, securing the

valve to the gas/air tube. Refer to fig. 59.

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 valve

assembly bracket to the back panel and withdraw the assembly.

B Transfer the bracket and inlet pipe assembly to the

new gas valve.

B Check for gas soundness when the new gas valve

has been fitted.

B Recheck the combustion performance as described

in section 8.1.

Fig. 62

9.3.8 Domestic Hot Water Heat Exchanger

B Refer to section 9.2.

B Use new seals when fitting the new heat exchanger.

9.3.9 Electrode assembly

B Refer to section 9.2. B Use a new seal if the existing seal is damaged.

9.3.10 Pressure gauge

B Drain the appliance. B Lower the facia. Refer to fig. 60.

B Twist the pressure gauge head anti-clockwise to

release it from the casing. Refer to fig. 2.

B Disconnect the capillary head from the rear of the

diverter valve by withdrawing the clip and pulling out the head. Refer to fig. 61.

9.3.11 Expansion vessel

B 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 and

remove the vessel.

B Set the pressure of the new vessel to that required by

the system.

9.3.12 Pressure Relief Valve

B Drain the appliance.

B Disconnect the drain pipe from the valve. Refer to

fig. 30.

B Pull-out the clip securing the valve.

B Pull-out the valve. B Ensure that the replacement valve is fully entered

before fitting the clip.

9.3.13 Burner

B Refer to section 9.2.

6 720 610 602 - 04.1O

Page 45

6 720 611 447 GB (03.11)

Maintenance

9.3.14 Flow switch

B Shut the mains water inlet valve and drain the domes-

tic hot water circuit.

B Pull-off the connectors from the micro-switch. B Unscrew the inlet and union connection and remove

the assembly.

B Reset the domestic hot water flow rate on the new

assembly.

Fig. 63

9.3.15 Primary Heat Exchanger

B Drain the appliance. B Check that the gas supply is turned off.

B Check that the appliance is electrically isolated. B Remove the fan assembly complete with the gas/air

tube and mixer assembly. Refer to section 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 to

fig. 57.

B Undo the grey plastic cap, next to the top pump con-

nection at the base of the heat exchanger.

B Unscrew and remove the condensate trap. Refer to

section 9.2.

B Unscrew and remove the two screws securing the

heat 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 exchanger

from the casing.

B Transfer components, as necessary, to the new heat

exchanger.

B Ensure that all the seals are in place and all of the

connections are tight before re-commissioning the appliance.

Fig. 64

6 720 610 602 - 05.10

INLET

OUTLET

6 720 610 602 - 06.10

Page 46

6 720 611 447 GB (03.11)

Appendix

10 Appendix

10.1 Fault Codes

More detailed fault finding procedures are described in the Service Booklet for the Engineer number 7 181 465 347.

Display code

Description Remedy

A1 pump has run dry Check system pressure, add water and bleed

system as necessary

A7 Hot water NTC sensor defective. Check hot water NTC sensor and connecting

lead for circuit breaks/short circuits.

A8 Break in communication Check connecting lead to TR2

b1 Code plug not detected. Insert code plug correctly, test and replace if

necessary.

C1 Fan speed too low. Check fan lead and connector, and fan; replace

as necessary.

d3 Jumper 8-9 not detected. Connector not connected, link missing, under-

floor heating limiter tripped.

E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting

lead.

E9 Safety temp. limiter in CH flow has tripped. Check system pressure, check safety temp. lim-

iters, check pump operation, check fuse on pcb, bleed appliance.

EA Flame not detected. Is gas cock turned on? Check gas supply pres-

sure, power supply, igniter electrode and lead, ionisation sensing electrode and lead, flue duct and CO2 level.

F0 Internal error. Check electrical connector contacts, program-

mer interface module ignition leads are not loose; replace pcb if necessary.

F7 Flame detected even though appliance

switched off.

Check electrode assembly, dry pcb. Flue clear?

FA Flame detected after gas shut off. Check gas valve and wiring to gas valve. Clean

condensation trap and check electrode assembly. Flue clear?

FC Text display not detected. Check connecting lead between Text display

and Heatronic, replace Text display if necessary

Fd Reset button pressed by mistake. Press reset button again

P1, P2, P3, P1...

Please wait, initialisation in progress. 24 V fuse blown. Replace fuse.

Table 18

Page 47

6 720 611 447 GB (03.11)

Appendix

10.2 Short parts list

Key Description Qty GC Spare part number

1 Sensor - Flue gas temp. 1 8 722 963 858 0

2 Sensor - CH flow temp. 1 8 714 500 087 0

3 Sensor - DHW flow temp. 1 8 714 500 054 0

4 Control board pcb 1 8 748 300 495 0

5 Gas valve ZWBR 8-30 1 8 747 003 516 0

5.1 Gas valve ZWBR 11-37 1 8 747 003 515 0

6 Fan assembly 1 8 717 204 325 0

7 Fan washer 1 8 729 000 183 0

8 Expansion vessel 1 8 715 407 246 0

9 Relief valve 1 8 717 401 012 0

10 Electrode assembly 1 8 718 107 077 0

11 Electrode lead 1 8 714 401 999 0

12 Pump 1 8 717 204 350 0

13 Pressure gauge 1 8 717 208 079 0

14 Burner skin seal 1 8 711 004 168 0

15 Transformer - facia 1 8 747 201 358 0

16 Flow switch 1 8 717 002 110 0

17 3-way diverter valve 1 8 717 010 062 0

18 Heat exchanger washer 1 8 710 103 153 0

19 Washer set Condensation

Tr ap

1 8 710 10 3 15 4 0

20 Fuse set 1 8 744 503 010 0

21 Service set Water Valve 1 8 710 503 031 0

22 Domestic Hot Water Heat

Exchanger

1 8 715 406 659 0

23 Text Display 1 8 747 208 103 0

24 Primary heat exchanger 1 8 715 406 615 0

25 Diaphragm 1 8 715 505 801 0

Table 19

Page 48

6 720 611 447 GB (03.11)

Appendix

10.3 Heating/hot water output settings RD532i N.G.

10.4 Heating/hot water output settings RD532i L.P.G

10.5 Heating/hot water output settings RD537i N.G.

10.6 Heating/hot water output settings RD537i L.P.G

Natural gas G20

Display code

Heat output, kW

Heat input, kW

Gas vol. flow rate (l/min at t

V/tR

= 80/60°C)

30 9.1 9.2 16.0

40 12.1 12.2 21.4

50 15.1 15.3 26.7

60 18.1 18.3 32.0

70 21.1 21.4 37.4

80 24.2 24.4 42.7

90 27.2 27.5 48.0

100 30.2 30.5 53.4

Table 20

Propane

Display code

Heat output kW Heat input kW

40 12.1 12.2

50 15.1 15.3

60 18.1 18.3

70 21.1 21.4

80 24.2 24.4

90 27.2 27.5

100 30.2 30.5

Table 21

Natural gas G20

Display code

Heat output, kW

Heat input, kW

Gas vol. flow rate (l/min at t

V/tR

80/60°C)

30 11.1 11.3 19.7

40 14.9 15.0 26.3

50 18.6 18.8 32.8

60 22.3 22.5 39.4

70 26.0 26.3 45.9

80 29.7 30.0 52.5

90 33.4 33.8 59.1

100 37.1 37.5 65.6

Table 22

Propane

Display code

Heat output, kW Heat input, kW

40 14.9 15.0

50 18.6 18.8

60 22.3 22.5

70 26.0 26.3

80 29.7 30.0

90 33.4 33.8

100 37.1 37.5

Table 23

Page 49

6 720 611 447 GB (03.11)

Appendix

10.7 Operational Flow diagrams

10.7.1 Domestic hot water function

Fig. 65

6 720 610 576 - 25.TD

Repeats 5 times

(N.G.) or 3 times

(L.P.G.) before

lock-out.

Ye s

Pump ON

Diverter valve

operates.

Fan to start

speed.Gas

valve opens.

Ignition sequence

Ignition

spark

5 secs

Pre-heat satisfied.

Burner lights.

Red light ON.

Burner shut-down if

primary temperature

exceeds 94°C remains

OFF until 78°C

Burner remains OFF

until flow

temperature is below

set value.

Gas valve shuts.

Pump remains ON.

Over temperature

shut down if water

temperature is 8°C

above set value.

** NOTE:

The appliance controls can be set to one of 2

modes of operation.

1. “Comfort“ mode -

Full pre-heat

2. “ECO“ mode -

a) Operates as an instantaneous combination boiler.

b) Demand Detection: a short demand (less than 5

seconds) switches the control to “Comfort“ mode

for 5 mins. Mini pre-heat. The Factory setting is

“Comfort“ mode.

Mains

switch

ON.

Green

light

ON.

Pre-heat

mode.**

Hot

water

demand.

Pump ON

Diverter valve

operates.

Fan to start

speed. Gas valve

opens.

Heat input

modulates to

maintain the

delivery

temperature.

Demand

ends.

Gas valve

closes. Red

light OFF.

Fan runs for

up to 3 mins.

Pump runs for

30secs.

Pre-heat

mode.**

Ignition sequence

Ignition

spark

5 secs

Burner lights.

Red light ON.

Fan runs to purge

gas from burner.

Page 50

6 720 611 447 GB (03.11)

Appendix

10.7.2 Central heating function

Fig. 66

6 720 610 576 - 26.TD

Ye s

Mains

switch

ON.

Green

light

ON.

Room

thermostat

and/or mains

programmer or

link ON AND

Electronic facia

programmer (if

fitted) ON AND

CH control

knob ON.

demand.

Burner remains OFF

until flow temperature

is below set value.

Gas valve shuts.

Pump remains ON.

Over temperature

shut down if water

temperature is 5°C

above set value.

Pump ON Fan to

start speed. Gas

valve opens.

Burner

stabilises at

start speed for

5-10 secs

Fan speed

reduces

over 15

secs.

Fan min.

speed for

90 secs.

Boiler

unused

for long

period.*

*Minimum

heat

input for

15min.

Boiler

operates to

match

system load

and CH

control

setting.

Ignition sequence

Ignition spark for

5 seconds.

Burner lights. Red

light ON.

Repeats 5 times

(N.G.) or 3 times

(L.P.G.) before

lock-out.

Fan runs to

purge gas from

burner.

CH demand

satisfied.

Gas valve closes.

Red light OFF.

Pump and Fan

run for up to 3

mins.

* NOTE: The sequence ensures that the condensate siphon is not empty

after long

OFF

periods. (More than 24 hours without a demand).

Page 51

6 720 611 447 GB (03.11)

Appendix

Page 52

AppendixAppendix

EXCELLENCE COMES AS STANDARD

Manufactured exclusively for British Gas by The Bosch Group

Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.

Telephone: (01905) 754624 Fax: (01905) 754619

Page 53

Users Instructions and Customer Care Guide

RD 532i/RD 537i/RD 542i combi Condensing boiler RD 430i system Condensing boiler

6 720 610 598 - 00.2O

ZWBR 7-32 RD 532i GC-Number: 47 108 10 ZWBR 11-37 RD 537i GC-Number: 47 108 11 ZWBR 11-42 RD 542i GC-Number: 47 108 12

System boiler 7-30 RD 430i GC-Number: 41 108 06

6 720 610 604 GB (03.06) OSW

Page 54

Contents

Excellence comes as standard 4

Safety precautions 5

1 General notes 7

2 Controls 11

3 Operating the Appliance 12

3.1 Preparation 12

3.2 Switching the Appliance On/Off 14

3.3 Switching on the Central Heating 15

3.4 Controlling Central Heating 15

3.5 Combination Boilers: Setting Hot Water Temperature 16

3.6 System boiler with Storage Tank 17

3.7 Summer Mode, Hot Water Only (Combi Appliances) 18

3.8 Frost protection (Combi Appliances) 19

3.9 Fault Condition 19

4 Text Display 20

4.1 General Description 20

4.2 Programming 20

4.2.1 Deleting a setting 23

4.2.2 Resetting all parameters to their original settings 23

4.3 Menu structure 24

4.4 Setting the time/day 25

4.4.1 Setting the time and day 25

4.4.2 Holidays 25

4.5 Heating 27

6 720 610 604 GB (03.06)

Page 55

Contents

4.5.1 Heating program 27

4.5.2 Setting the Economy temperature (if TR2 is connected) 28

4.5.3 Manual operating mode (if TR2 is not connected) 29

4.6 Hot water 30

4.6.1 Hot water program 31

4.6.2 Hot water immediately (System models) 31

4.7 i Info 32

4.8 Settings 33

4.8.1 Heating (if TR 2 is connected) 33

4.8.2 Hot Water (Storage Tank, System boiler models only) 33

4.8.3 Service 33

4.9 Individual timer programmes 36

5Fault finding 37

6 Tips on saving energy 38

7 General Information 39

8 Maintaining your appliance 40

9Service 40

10 Fault or breakdown 41

11 Your guarantee 42

12 Guarantee registration 43

13 Operating Instructions Quick Reference 44

6 720 610 604 GB (03.06)

Page 56

Excellence comes as standard

Thank you for purchasing an RD 532i/RD 537i/RD 542i /RD 430i condensing appliance. The RD 532i/RD 537i/RD 542i /RD 430i Series has been developed by the Bosch Group and the strictest quality control standards are demanded throughout every stage of production. Indeed, the Bosch Group have led the field in innovative appliance design and performance for many years. The result is that your new RD 532i/RD 537i/RD 542i /RD 430i appliance offers you the very best of everything – quality, efficiency, economical running costs, proven reliability and value for money. What’s more, you also have the assurance of our no nonsense 2 year parts and labour guarantee. And it’s backed up by British Gas - Offering a complete maintenance scheme to keep your boiler operating at peak condition and efficiency. No wonder that more and more people are agreeing that when it is gas, it has to be a British Gas/Scottish Gas Condensing appliance.

Benchmark

The “Benchmark” initiative is the new code of practice to encourage the correct installation, commissioning and servicing of domestic central heating boilers and system equipment.

The “log-book” is a vital document that must be completed by the installer at the time of installation. It confirms that the boiler has been installed and commissioned according to the manufacturers instructions.

Without the completion of the “log-book”, manufacturers may refuse to respond to a call–out from a householder, who will be advised that he or she must call back the installer, who has not fulfilled his obligations to record the information required by the initiative.

6 720 610 604 GB (03.06)

Page 57

Safety precautions

Gas Safety (Installation and Use) Regulations 1998

It is the law that all gas appliances are installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your interest, and that of safety, to ensure compliance with the law.

If you smell gas:

B Turn off gas service cock at the meter.

B Open all doors and windows.

B Do not operate any electrical switches.

B Do not smoke.

B Extinguish any naked flames.

B Call your gas company.

If you smell fumes from the appliance:

B Switch off appliance.

B Open windows and doors.

B Inform your heating engineer.

Fitting and modifications

B Fitting of the appliance or any modifications to the appliance

may only be carried out by a competent person.

B Flue systems must not be modified in any way.

Maintenance

B We recommend that you take out a maintenance contract

with a competent installer and have the appliance serviced at regular intervals.

B Ensure that your Service Engineer uses only genuine spare

parts!

6 720 610 604 GB (03.06)

Page 58

Safety precautions

Combustible materials

B Do not store or use any combustible materials (paper, thin-

ners, paints etc.) in the vicinity of the appliance.

Health and safety

B This appliance contains no asbestos products.

B There is no potential hazard due to the appliance being electri-

cally unsafe.

B There are no substances used in the construction that are a

potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).

Ventilation Air/Ambient Air

B Keep ventilation air/ambient air free of corrosive substances

(e. g. halogenated hydrocarbons which contain chlorine or fluorine compounds). In this way corrosion can be prevented.

6 720 610 604 GB (03.06)

Page 59

General notes

1 General notes

To get the best from your appliance please read these instructions carefully.

Sealed heating systems

The appliance is fitted to a sealed heating system which is prepressurised. Your installer will tell you of the minimum and maximum pressure which must be indicated on the pressure gauge.

Check regularly that the pressure is maintained and contact your installer or maintenance engineer if there is a permanent significant drop in the pressure. If the system loses pressure it should be repressurised and the cause of the fall investigated.

Central heating systems

During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. If the top of a radiator is at a lower temperature than the bottom then it should be vented by releasing air through the venting screw at the top of the radiator. Ask your installer to show you how this is done. Repeated venting will reduce the quantity of water in the system and this must be replenished for safe and satisfactory operation of the appliance.

Should water leaks be found in the system or excessive venting is required then a service engineer must be contacted to inspect the installation and rectify any fault.

Only additives that are compatible with aluminium may be used in the system. Any incompatible additive used will invalidate the guarantee.

Condensate drain

This is a condensing appliance and the terminal will, at times, give out a plume of water vapour. This is quite normal.

The appliance produces quantities of condense which is discharged regularly through the siphon.

6 720 610 604 GB (03.06)

Page 60

General notes

Clearances

Your installer will have provided adequate space around the appliance for safety and servicing access. Do not restrict this space with the addition of cupboards, shelves etc. next to the appliance.

Left-hand side 10 mm Right-hand side 10 mm In Front 600 mm Above Casing (Vert. Flue) 75 mm Above Flue Turret 30 mm Below 200 mm

Table 1

Room thermostat

A room temperature controller is may be fitted to control the central heating. Refer to the instructions supplied with the thermostat for information on siting and setting.

Cylinder thermostat - System boilers

The cylinder thermostat should be set to 60°C which will be satisfactory for bathing/washing in normal circumstances.

Thermostatic radiator valves

It is recommended that this type of valve is fitted to all the radiators except one, usually the radiator where the room temperature controller is fitted. They should conform to the requirements of BS2767:10.

Showers, bidets, taps and mixing valves – Combination Boilers

Standard hot and cold taps and mixing valves must be suitable for operating at mains pressure. Thermostatically controlled or pressure equalising shower valves will guard against the flow of water at too high a temperature.

Hot and cold mains fed water can be supplied directly to an overrim flushing bidet subject to local water company requirements.

6 720 610 604 GB (03.06)

Page 61

General notes

With all mains fed systems the flow of water from individual taps will vary with the number of outlets operated simultaneously and the cold water mains supply pressure to the property. Flow balancing using “ball-o-fix” type valves is recommended to avoid an excessive reduction in flow to individual outlets.

For further information contact British Gas Technical Services Department.

Hot and cold flow – Combination Boilers

The flow of water demanded from both hot and cold service outlets is dependent upon the mains supply, it may not be possible in some installations to operate all outlets simultaneously.

Water mains failure – Combination Boilers

If there is a failure of the mains water supply then no water will be available at a tap or shower until the mains supply is restored. The appliance will still operate in the central heating mode.

Use in hard water areas – Combination Boilers

In exceptionally hard water areas a device to prevent scale formation may be fitted. Installation of a scale inhibitor assembly should be in accordance with the requirements of the local water company. An isolating valve should be fitted to allow for servicing.

Alternatively the maximum temperature of the domestic hot water may be reset to about 45 °C which will reduce the risk of scale formation in these hard water areas.

Ventilation

This is a room sealed appliance and does not require any air for combustion from inside the house. If the appliance is fitted into a cupboard or a compartment is built around the appliance after installation then the compartment must be separated from the boiler space by a perforated non-combustible partition as described in BS 6798.

Notwithstanding the requirements of BS 6798, there is no need for ventilation openings to be provided in the compartment because of the low heat loss from the casing.

6 720 610 604 GB (03.06)

Page 62

General notes

Do not allow the flue terminal fitted on the outside wall to become obstructed or damaged.

Pump

The pump is a fully modulating type to which the parameters have been set by the manufacturer and must not be adjusted.

6 720 610 604 GB (03.06)

Page 63

2 Controls

Controls

364

135 295

365136

170

171

317 366 367

ECO

172

310363

173

400

8.1

170

6 720 610 598 - 01.2O

Fig. 1

8.1 System Pressure gauge 61 Reset button 135 Master switch 136 Central heating temperature control 170 Service valves in CH flow and return 171 Hot water 172 Gas isolation valve (open) 173 Cold water inlet 295 Identification sticker 310 Hot water temperature control 317 Display 363 Indicator lamp for “burner on” 364 Indicator lamp for “off/on” 365 “Chimney sweep” button 366 Service button 367 “ECO” button 400 Text Display

6 720 610 604 GB (03.06)

Page 64

Operating the Appliance

3 Operating the Appliance

3.1 Preparation

Turn on the gas cock (172).

B Press in the handle and turn it anti-clo ckwise as far as the stop

(when handle is in line with direction of flow, the cock is open).

Central heating system valves (170)

B Using a spanner, turn square nut until groove is in line with

direction of flow (see detail). Groove at right angles to direction of flow = off.

Cold water inlet valve (173)

B Turn handle so that it is in line with direction of flow.

When handle is at right angles to direction of flow, the valve is closed.

170

172

173

Fig. 2

6 720 610 598-02.2O

6 720 610 604 GB (03.06)

Page 65

Operating the Appliance

Check the central heating system pressure

B The pointer on the pressure gauge (8.1) should be about 1 bar.

B If the pointer is below 1 bar (when the system is cold), top up

the system with water until the pointer is 1 bar. Your installer will have shown you how to do this.

B The maximum operating pressure of 2.5 bar at maximum

central heating flow temperature must not be exceeded. If the pressure increases to 3 bar then the relief valve (15) opens.

170

171

172

bar

8.1

173

170

6 720 610 598 - 03.2O

Fig. 3

6 720 610 604 GB (03.06)

Page 66

Operating the Appliance

3.2 Switching the Appliance On/Off

Switching on

B Switch on the appliance at the master switch (I).

The indicator lamp shows green and the display will show the central heating flow temperature, when the appliance is operating in the central heating mode.

6 720 610 333-04.1O

Fig. 4

If the display alternates between -II- and the cen-

The trap filling programme ensures that the condensation trap is filled after the appliance has been installed or after the appliance has been out of use for a long period. For that reason, the appliance remains at minimum heating output for 15 minutes.

Switching off

B Switch off the appliance at the master switch (0).

The green indicator lamp goes out. The optional timer will continue running until the emergency supply is exhausted.

tral heating flow temperature, the trap filling programme is active.

6 720 610 604 GB (03.06)

Page 67

Operating the Appliance

3.3 Switching on the Central Heating

B Turn the central heating temperature control to the desired

level:

–“Min” setting: 35°C – Low-temperature heating: setting “E” (approx. 75°C) –“Max” setting: 88°C When the burner is lit, the red indicator lamp is illuminated.

6 720 610 333-05.1O

Fig. 5

3.4 Controlling Central Heating

B Set the timer to the correct time.

B Set room thermostat to the desired room temperature.

B Set temperature driven control unit, if fitted. Refer to the

instructions with the control.

B Set the thermostatic radiator valves to the desired settings.

6 720 610 604 GB (03.06)

Page 68

Operating the Appliance

3.5 Combination Boilers: Setting the Hot Water Temperature

Hot water temperature

On combi models, the hot water temperature can be set to between approx. 40°C and 60°C using the temperature control .

The domestic hot water temperature is not shown on the display.

6 720 610 333-07.1O

Fig. 6

Control Setting Water Temperature

Anti-clockwise limit approx. 40°C



approx. 55°C

Clockwise limit approx. 60 °C

Table 2

“ECO” button

By pressing and holding the “ECO” button , until the display lights, you can switch between Comfort mode and Economy

mode.

Comfort mode: button is not lit (factory setting)

6 720 610 604 GB (03.06)

Page 69

Operating the Appliance

ECO mode with demand detection, button is lit

ECO mode, button is lit

Water is not heated up until hot water is drawn. This means that there is a longer waiting period before hot water is available.

3.6 System boiler with Storage Tank

B Do not set the temperature higher than

60°C for normal operation.

B Only use temperatures of up to 70 °C tempo-

rarily for thermal disinfection purposes.

With the text display you can additional set hot

B Set the hot water temperature by means of the temperature

control on the appliance.

water charging times or times and temperatures.

Fig. 7

6 720 610 604 GB (03.06)

6 720 610 333-07.1O

Page 70

Operating the Appliance

Control Setting Water Temperature

Anti-clockwise limit approx. 10°C

(frost protection)

l approx. 60°C

Clockwise limit approx. 70°C

Table 3

ECO button

Pressing and holding the ECO button , until it lights up switches from Comfort mode to ECO-mode.

Comfort mode, ECO button is not lit (factory setting)

In Comfort mode the hot water tank has priority. The hot water cylinder is first heated up to the set temperature. The appliance then switches to central heating mode.

ECO mode, button is lit

In ECO mode the appliance switches between central heating mode and cylinder charging mode every 12 minutes.

3.7 Summer Mode, Hot Water Only (Combi Appliances)

With room temperature controller

B Turn temperature control on the appliance anti-clockwise

as far as the stop. The central heating is now turned off. The hot water function and the mains power supply for the heating programmer and timer remain switched on.

6 720 610 604 GB (03.06)

Page 71

Operating the Appliance

3.8 Frost protection (Combi Appliances)

B Leave master switch switched on.

If the appliance is to be left for long periods switch the central heating on and set the room temperature controller at 6°C.

B Add a suitable anti-freeze fluid to the water in the central heat-

ing system. Suitable products are available from Betz-Dearborn Tel.: 0151 4209563, Fernox Tel.: 01799 550811 and Salamander Tel.: 0121 378 0952.

3.9 Fault Condition

In the unlikely event of a fault occuring while the appliance is in operation:

The display and the text display then shows a fault code and the button may also flash.

If the button flashes:

B Press and hold the button until the display shows “––”.

The appliance will then start up again and the display will show the central heating flow temperature.

If the button does not flash:

B Switch the appliance off and then on again at the master

switch. The appliance will start up again and the central heating flow temperature will be displayed.

If the fault remains and can not be cleared:

B Call British Gas for assistance, giving a description of the fault

and, if possible, the fault code from the facia display.

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Text Display

4Text Display

4.1 General Description

• The text display is used to display information about the appli-

ance and the system and to alter the settings displayed.

• Once the appliance has been in operation for one day, the text

display module has a power buffer period of about 10 hours during which it will run without the mains power supply. After that period has elapsed, the clock function shuts down but all other settings are retained.

4.2 Programming

b c

6 720 610 337-08.1R

Fig. 8 Controls

a Display b “Up”/“More” button c “Down”/“Less” button d “Back” button e “Next” button f “Delete” button

The standard display shows the following information:

•Time

• Room temperature (if TR 2 connected)

• CH flow temperature

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Text Display

• Domestic Hot Water temperature (System boiler if a Storage Tank is accorded).

Additional indication if a special programme is active:

•x holidays

• Hot water immediately

• Constant on (comfort, if TR2 is not connected)

• Constant off (economy, if TR2 is not connected).

Other special operating modes may be displayed during commissioning, servicing, etc.

The programming procedure is described in detail below using the clock function as an example:

B To start programming, press any button, e. g. .

The display lighting switches on and the main menu is displayed:

/holidays

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Fig. 9 Main menu

B Use the or button to move the cursor arrow on the

left of the menu so that it points to the desired menu item. In this example, the cursor is positioned next to the menu item Time/day/holidays.

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Text Display

B Confirm the selection by pressing the button.

The corresponding submenu is displayed:

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Fig. 10 Submenu: Time/day

In the submenus, the top line indicates what action is required. The bottom line shows the previous menu level, if applicable (see Fig. 10).

B Use the or button to select Time/day.

B Confirm the selection by pressing the button.

The corresponding submenu is displayed:

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Fig. 11 Setting the hour

When settings are being entered, the setting to be altered is indicated on the top line. In addition, the setting being altered is displayed with a dark background.

B Use the or button to set the hour.

– Press and release to change the display by one unit at a

time

– Press and hold to change the display rapidly

B Confirm the setting by pressing the button.

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Text Display

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 the week.

B Press the button to confirm the setting. The cursor then

returns to the top line.

-or-

B Press the button to confirm the setting and return to the

previous menu (Fig. 9 page 22).

-or-

B Do not press any other buttons for 15 minutes.

4.2.1 Deleting a setting

Either overwrite the setting or press the button to delete it.

B Find the setting to be deleted.

B Press and release the button.

The display shows --:--

4.2.2 Resetting all parameters to their original settings

The 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 message appears on the display:

ATTENTION Delete all parameters in x seconds

Once the reset has been completed, the following message is

displayed: Please wait... Initialising

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4.3 Menu structure

Submenu

Parameters to

Main menu 1. 2. 3.

Time/day/holidays

Heating Heating

Hot water Hot water

Info---- 32

Time/day - - - Hours

Holidays - - Days holiday 25

--- Day

program

Set economy temp. (if TR2 is connected) Manual (if TR2 is not connected)

program

Hot water immediately

- - 5...30°C 28

- - - Automatic

--- Day

- - Off/On 31

change/select

- Minutes

- Day of week

- 1st operating mode

- 1st switching point ...

- 6th switching point

- Constant on (comfort)

- Constant off (economy)

- 1st operating mode

- 1st switching point

...

- 6th switching point

Page

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Text Display

Submenu

Parameters to

Main menu 1. 2. 3.

Settings Heating - - Optimum Start Off/On 33

Hot water (System boiler-models)

Service Display

- - Only charging times/

-- 33 service param.

Further options

Language -English/

Operating times Fault history

change/select

times and temperatures

-Français/

-Deutsch

-Time correction

-LCD contrast

-34

-35

34 34

Page

4.4 Setting the time/day

4.4.1 Setting the time and day

For details of how to set the time and day, refer to page 21.

Changing winter and summer time:

B Only adjust the clock! Do not alter the switching

points (for heating, economy, etc.).

4.4.2 Holidays

In the Holiday programme, the central heating runs in Economy mode and the hot water is switched off (frost protection 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 module automat-

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Text Display

ically cancels Economy mode at midnight on the last day and returns to Automatic mode.

The day on which you enter the days holiday

To cancel Holiday mode early: B In the Holidays submenu:

counts as the first day of the holiday, i.e. the unit starts the holiday program immediately. Only include the day on which you are returning if you don’t want the heating to return to the normal program on that day!

Press the button until the display shows 0 .

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4.5 Heating

4.5.1 Heating program

Basic setting (Automatic mode)

• The appliance switches automatically between normal heating, Economy mode and Frost protection mode according to the timer settings entered.

• Basic setting: – Heating starts at 6:00 am – Economy starts at 10:00 pm

Setting options

• Maximum of six switching points per day with three different operating modes (Heating, Economy, Frost protection).

• Same times for Monday to Friday.

• Same times for Saturday and Sunday.

• Different times for every day.

Setting switching times and operating mode

B From the main menu select Heating and then from the first

submenu, select Heating program.

B Select Monday - Friday, Saturday and Sunday or an individual

day of the week. – Monday - Friday: to have “Heating” and “Economy” or

“Frost protection” switching on at the same times every weekday.

– Saturday - Sunday: to have “Heating” and “Economy” or

“Frost protection” switching on at the same times Saturday and Sunday.

– Individual day of the week (e. g. Thursday): to have the rel-

evant program always switching on at the specified time on that day of the week, i.e. “Heating”, “Economy” or “Frost protection” at the same time every Thursday.

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B Press . The display shows Set 1. operating mode.

B Set the desired first operating mode (Heating, Economy or

Frost protection).

B Press . The display shows Set 1. time period.

B Set the desired first time period.

B Press . Set the following operating modes and time peri-

ods as described for the first.

B If necessary: select the next day and enter the operating

modes and timer periods as described above.

If the settings for a particular day of the week

are different from the settings for the other days, then if Monday -Friday or Saturday

and Sunday is selected, the display shows

--:--, i.e. there are no common switching points

for those options.

Timer periods and operating modes are you do not wish to change can be skipped by pressing .

4.5.2 Setting the Economy temperature (if TR2 is connected)

This option allows you to set the room temperature for Economy mode (Off (Economy)).

This function is only active if:

• Automatic mode or Economy mode is set on the TR 2 room

thermostat.

B From the main menu, select Heating and then from the first

submenu, select Set Economy temp..

B Use the or button to set a temperature between 5

and 30 °C.

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Text Display

4.5.3 Manual operating mode (if TR2 is not connected)

For selecting an operating mode that is different from the one set in the heating programme (Automatic mode).

• You can choose between Automatic, Constant on (comfort) and Constant off (economy).

• 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.

B From the main menu select Heating and then from the first

submenu Manual select required mode.

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4.6 Hot water

General description

• Combi models only: The basic settings provide a straightfor-

ward timer programme: enabled from 5:00 am, disabled from 10:00 pm. The ECO button must not be lit (Comfort mode).

• System models (with Storage Tank): The basic settings pro-

vide a timer programme: enable from 5:00 am, disable from 10:00 pm. With the menu Hot water (see page 33) you can choose a timer-/temperature programme with the basic settings: 60°C from 5:00 am, 10°C from 10:00 pm.

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4.6.1 Hot water program

• Up to six switching points per day can be set.

• There are two operating modes: Blocked and Released.

B From the main menu, select Hot water and then from the first

submenu, select Hot water program.

B Set the days of the week, Blocked/Released (operating mode)

in the same way as for the switching points and modes for heating as described on page 27.

4.6.2 Hot water immediately (System models)

• Hot water immediately ON: – Comfort mode is active for 2 hours.

• Comfort mode is active for 2 hours: normal automatic pro- gram (Hot water mode according to timer programme entered).

B From the main menu, select Hot water and then from the first

submenu, select Hot water immediately.

B Press or to switch Hot water immediately on or off.

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4.7 i Info

B Select Info from the main menu.

You can view the following information:

Display text Description

Room temperature

(if TR 2 connected)

Required room temperature (if TR 2 connected)

Operating mode

(if TR 2 connected)

Max. flow temp. Maximum CH flow temperature set on

Actual flow temp. Actual CH flow temperature

Required flow temp. Required CH flow temperature

Max HW temp. Maximum permissible hot water out-

Required HW temp. Required hot water temperature

Current temperature in the room where TR 2 is installed

Required temperature in room where TR 2 is installed

E. g. Heating, Economy in Automatic mode or Economy, Heating, Frost protection in manual mode

the temperature control for CH flow

flow temperature

Actual HW temp. Actual hot water outflow temperature

Storage Tank charge released or blocked

Storage Tank charge on or off or Storage Tank charge afterrunning

Boiler operat. mode winter/ summer

Burner on/off Indicates whether the burner is alight

Pump on/off Indicates whether the integral pump is

Shows, if hot water is released or blocked

Shows, if hot water is on or off, or if the pump for the Storage Tank afterrunning is on

Indicates which mode the CH flow temperature control is set to

or not

switched on or off

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4.8 Settings

4.8.1 Heating (if TR 2 is connected)

Optimum Start

B From the main menu, select Settings and from the first sub-

menu, select Heating.

B Press or to switch Optimum Start on or off.

4.8.2 Hot Water (Storage Tank, System boiler models only)

The text display can control the hot water either with Times and temperatures or only times.

• Times and temperatures: One can choose up to six different times with temperatures, see page 30 “Hot water”.

• Only times: During that times the Storage Tank will be charged to the choosed temperature.

B From the main menu, select Settings and from the first sub-

menu select hot water.

B Press or to switch Times and temperatures or only

times.

Turn the hot water temperature control al-

4.8.3 Service

Displaying service functions

This option displays various current settings and statuses of the electrically controlled appliance and system components for the benefit of the heating engineer.

ways higher than the temperature at the text display is choosen.

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Service parameters

Language Available languages are: English, Français (French), Deutsch (German).

B From the main menu, select Settings, from the first submenu

select Service, from the Second submenu select Further options, and from the third submenu select Language.

B Press or to select the desired language.

Two other supplementary functions can be selected from the third submenu Language:

• Time correction

•LCD contrast.

Time correction:

B Press and hold the button (about 5 seconds) until the

display shows Time correction and LCD contrast.

B Press or to select Time correction.

B Press the button. The display shows Change value.

B Press or to set the number of seconds in 24 hours.

Basic setting: “+ 0 s”

LCD contrast:

B Press and hold the button (about 5 seconds) until the

display shows Time correction and LCD contrast.

B Press or to select LCD contrast. B Press the button. The display shows Change value. B Press or to adjust the LCD contrast.

Basic setting: e. g. “47”

Operating times This option shows the hours of service (appliance, burner and hot

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Text Display

water) since commissioning.

B From the main menu, select Settings, from the first submenu

select Service, from the Second submenu select Further options, and from the third submenu select Operating times.

B From the main menu, select Settings, from the first submenu

select Service, from the Second submenu select Further options, and from the third submenu select Fault history.

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Text Display

4.9 Individual timer programmes

Heating periods for central heating

Switching point 1. 2. 3. 4. 5. 6.

Status

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Sunday

Enable/disable hot water function

Switching point 1. 2. 3. 4. 5. 6.

Operating mode

Time

Operating mode

Time

Operating mode

Time

Operating mode

Time

Operating mode

Time

Operating mode

Time

Status

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Sunday

Operating mode

Time

Operating mode

Time

Operating mode

Time

Operating mode

Time

Operating mode

Time

Operating mode

Time

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5 Fault finding

Problem Cause Remedy

Fault finding

Desired room temperature is not reached

Desired room temperature exceeded by large amount

Temperature rises instead

Thermostatic valve(s) set too low

Temperature control for CH flow set too low

Air trapped in heating system

Radiators are too hot

Clock is incorrectly set

Increase thermostatic valve setting(s)

Increase CH flow temperature control setting

Bleed radiators and heating system

Turn down thermostatic valves

Check setting

of falling

Room temperature too high in Economy mode

No display or display unit does not respond

Storage Tank doesn’t warm up

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Building retains heat well

Momentary power failure

Temperature control is too low

Start Economy mode sooner

Switch off appliance at master switch, wait a few seconds and switch on again

Turn the temperature control to the desired temperature

Page 90

Tips on saving energy

6 Tips on saving energy

Heating economically

The boiler is designed to provide a high level of comfort while keeping gas consumption and the resulting environmental effect as low as possible. The gas supply to the burner is controlled according to the level of demand for heat. The boiler continues to operate with a low flame if the demand for heat reduces. The technical term for this process is modulating control. Modulating control keeps temperature fluctuations small and provides even distribution of heat throughout the home. This means that the boiler may stay on for relatively long periods but will use less gas than an appliance that continually switches on and off.

Central heating systems with room thermostats/thermostatic radiator valves

The central heating control on the boiler should be set to the maximum rated temperature of the central heating system or to position “E”, when the maximum central heating water temperature obtained is 75°C. The temperature can be set individually in each room (except primary room with the room thermostat) using the thermostatic radiator valves. If you wish to have a lower temperature in the primary room than in the other rooms, leave the room thermostat at the set temperature and turn down the radiator using the radiator valve.

Reduced-output operation

Considerable fuel savings can be made by slightly reducing the room temperature. Lowering the temperature by 1 °C can bring about energy savings of up to 5 %. However, it is not advisable to allow any room temperature to fall below +15 °C. The room temperature for reduced-output mode can be set separately on the room thermostat. Instructions are given in the control unit operating instructions.

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General Information

Hot water

A lower setting on the hot water temperature control can result in considerable energy savings.

For combi appliances: The on-demand activation using the ECO-button makes possi- ble the maximum savings of gas and water.

Now you know how to heat your home economically with the RD 532i/RD 537i/RD 542i /RD 430i gas condensing boiler. If you have any other questions, please contact your installer – or write to us.

7 General Information

Cleaning the Outer Case

Wipe down the outer case with a damp cloth. Do not use abrasive or caustic cleaning agents.

Appliance details

If you ever need to call Customer Service it helps us a great deal if you can provide precise details of your appliance.

The information is printed on the appliance identification plate/ sticker (see page 11, item 295).

Your installer will have completed the Benchmark “log-book” giving details of the boiler together with name, address and registration number. Have the “log-book” to hand when calling a Service Engineer.

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Maintaining your appliance

8 Maintaining your appliance

Your new RD 532i/RD 537i/RD 542i /RD 430i gas-fired appliance represents a long-term investment in a reliable, high quality product.

In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is essential that your boiler receives regular, competent servicing and maintenance checks beyond the initial 2 year guarantee period.

To arrange for a British Gas three star cover agreement please call 08459605040.

9 Service

If your RD 532i/RD 537i/RD 542i /RD 430i appliance should fail to operate correctly or requires servicing please call British Gas on: 08459605040.

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Fault or breakdown

10 Fault or breakdown

This product is supported in the UK by Worcester Heat Systems Ltd. – part of the Bosch Group.

A specialist factory trained field SERVICE ENGINEER is available to attend a breakdown or manufacturing fault occuring on this appliance.

No charge will be made for parts and/or labour providing:

• An appliance fault is found and the appliance has been installed within the past 24 months. Reasonable evidence of this must be supplied on request.

A call-out charge will be made where:

• The appliance has been installed for over 24 months.

• Our Field Service Engineer finds no fault with the appliance (see NOTE).

• The cause of breakdown is misuse or with other parts of your plumbing/heating system, or with equipment not supplied by Worcester.

NOTE: No appliance fault is found on over 30 % of all service call outs.

If in doubt contact our British Gas on 0845 9 60 50 40.

IN THE EVENT OF AN APPLIANCE FAULT OR BREAKDOWN please contact your Service Centre (see over). Your service administrator will arrange for an engineer to call with the minimum of delay; under normal circumstances this will be within the period 1-3 working days (excluding weekends) for priority breakdown situations (no hot water and/or heating service).

INVOICES FOR ATTENDANCE AND REPAIR WORK CARRIED OUT ON THIS APPLIANCE BY ANY THIRD PARTY WILL NOT BE ACCEPTED.

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Your guarantee

11 Your guarantee

This appliance is guaranteed against faulty material or workmanship for a period of 24 calendar months from the date of installation subject to the following conditions and exceptions.

• That during the currency of this guarantee any components of the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and free of labour charges by Worcester Heat Systems Limited.

• That the householder may be asked to prove the date of installation, that the appliance was correctly commissioned and, where appropriate, the first 2 year service has been carried out to the satisfaction of Worcester Heat Systems Limited when requested.

• That any product or part thereof returned for servicing under the guarantee any components of the unit which are proved to be faulty guarantee must be accompanied by a claim stating the Model, Serial Number, Date of Installation.

• That Worcester Heat Systems Limited will not accept responsibility for damage caused by faulty installation, neglect, misuse or accidental damage, the non observance of the instructions contained in the Installation and Users Instructions Leaflets.

• That the appliance has been used only for normal domestic purposes for which it was designed.

• That this guarantee applies only to equipment purchased and used in Great Britain.

This guarantee is given in addition to all your normal statutory rights.

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Guarantee registration

12 Guarantee registration

You should complete and return the postpaid Guarantee Registration Card within 14 days of purchase.

The card will register you as the owner of your new RD 532i/RD 537i/RD 542i /RD 430i appliance and will assist us in maintaining an effective and efficient customer service by establishing a reference and permanent record for your boiler.

This will not affect your statutory rights in any way.

Important:

For your own record:

Model

.......................................................................................................................

Serial number:.............................................................................................

(See identity label inside appliance casing)

Type/size:.....................................................................................................

Date of installation:....................................................................................

Check that the Benchmark “log-book” has been completed by your installer or service engineer.

SERIAL NUMBER. Copy the number off the Guarantee Card.

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6 720 610 333-05.1O

Comfort mode

tions Quick Refer-

13 Operating Instruc-

Text Display

Set switching times and operating

Switching the central heating on

Switching on

ence

6 720 610 333-04.1O

mode within the text display.

Hot water temperaeture – Combi-

“ECO”-button lit –

Economy mode.

“ECO”-button not lit –

nation boiler only

6 720 610 333-07.1O

6 720 610 333-11.1O

Switching off

Fault Condition

Refer to page 19.

Page 97

Users Instructions and Customer Care Guide

RD 532 Condensing boiler RD 428 Condensing boiler

720 610 577- 01.10

ZWB 7-32 RD 532 GC-Number: 41 108 13 ZB 7-28 RD 428 GC-Number: 41 108 07

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Page 98

Contents

Excellence comes as standard 4

Safety precautions 5

1 General notes 6

2Controls 10

3 Operating the Appliance 11

3.1 Preparation 11

3.2 Switching the Appliance On/Off 14

3.3 Switching on the Central Heating 15

3.4 Controlling Central Heating 15

3.5 RD 532 Boilers: Setting the Hot Water Temperature 15

3.6 Summer Mode, Hot Water Only

(RD 532 Appliances) 17

3.7 Frost protection (RD 532 Appliances) 18

3.8 Fault Condition 18

4 Tips on saving energy 19

5 General Information 21

6 Maintaining your appliance 21

7 Service 22

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Contents

8 Fault or breakdown 23

9 Your Bosch guarantee 24

10 Guarantee registration 25

11 Operating Instructions Quick Reference 27

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Excellence comes as standard

Thank you for purchasing an RD 532/RD 428 condensing appliance. The RD 532/RD 428 Series has been developed by the Bosch Group and the strictest quality control standards are demanded throughout every stage of production. Indeed, the Bosch Group have led the field in innovative appliance design and performance for many years. The result is that your new RD 532/RD 428 appliance offers you the very best of everything – quality, efficiency, economical running costs, proven reliability and value for money. What’s more, you also have the assurance of our no nonsense 2 year parts and labour guarantee. And it’s backed up by British Gas - Offering a complete maintenance scheme to keep your boiler operating at peak condition and efficiency. No wonder that more and more people are agreeing that when it is gas, it has to be a British Gas/Scottish Gas Condensing appliance.

Benchmark

The “Benchmark” initiative is the new code of practice to encourage the correct installation, commissioning and servicing of domestic central heating boilers and system equipment.

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