Bosch Condens 2000F30 Regular, Condens 2000F16 Regular, Condens 3000F30 System, Condens 2000F42 Regular, Condens 3000F16 System Installation, Commissioning And Servicing Instruction Manual

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Page 1

Installation, Commissioning and Servicing Instruction manual

Floor-standing gas-fired condensing appliance

Condens

6720809859-00.1Wo

2000F16, 30, 42 Regular boiler/3000F 16, 30 System boiler

6 720 816 930 (2015/04)

Page 2

Contents

Condens – 6720816930 (2015/04)

Contents

1 Key to symbols and safety precautions . . . . . . . . . . . . . . . . . . . 3

1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Legislation and regulations . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Appliance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.4 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.5 Type overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.5.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.5.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.6 Dimensions and description . . . . . . . . . . . . . . . . . . . . . . . 5

2.7 Regular boiler layout and components . . . . . . . . . . . . . . . 6

2.8 Regular boiler wiring diagram . . . . . . . . . . . . . . . . . . . . . . 7

2.9 Regular boiler Technical data . . . . . . . . . . . . . . . . . . . . . . 8

2.10 Gas type and installation type . . . . . . . . . . . . . . . . . . . . . 9

2.11 Output power reduction due to altitude . . . . . . . . . . . . . . 9

2.12 System boiler layout and components . . . . . . . . . . . . . 11

2.13 System boiler wiring diagram . . . . . . . . . . . . . . . . . . . . 12

2.14 System boiler Technical data . . . . . . . . . . . . . . . . . . . . 13

3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 Country specific regulations . . . . . . . . . . . . . . . . . . . . . 15

3.2 Approvals and notifications . . . . . . . . . . . . . . . . . . . . . 15

3.3 Quality of the heating water . . . . . . . . . . . . . . . . . . . . . 15

3.4 Connection to combustion air and flue gas systems . . 15

3.5 Room air dependent operation . . . . . . . . . . . . . . . . . . . 15

3.6 Flue gas systems type Bxx . . . . . . . . . . . . . . . . . . . . . . 15

3.7 Flue gas systems type Cxx . . . . . . . . . . . . . . . . . . . . . . 15

3.8 Combustion air quality . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.10 Inspection, service and maintenance . . . . . . . . . . . . . 16

4 Pre-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 16

4.2 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2.1 Connecting flow and return . . . . . . . . . . . . . . . . . . . . . 16

4.2.2 Expansion vessel and drain valve . . . . . . . . . . . . . . . . . 17

4.3 Water systems and pipework . . . . . . . . . . . . . . . . . . . . 17

4.4 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.4.1 To remove the condensate trap . . . . . . . . . . . . . . . . . . 17

4.5 Boiler location and clearances . . . . . . . . . . . . . . . . . . . 17

4.5.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.5.2 Installations and servicing clearances: . . . . . . . . . . . . 17

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.1 Unpacking the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.2 Boiler room requirements . . . . . . . . . . . . . . . . . . . . . . . 18

5.2.1 Installing the levelling feet . . . . . . . . . . . . . . . . . . . . . . 18

5.2.2 Positioning the appliance . . . . . . . . . . . . . . . . . . . . . . . 19

5.3 Mounting the boiler and flue opening . . . . . . . . . . . . . . 19

5.4 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.5 Vertical flues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . 24

7.2 Filling the system and checking for leaks . . . . . . . . . . . 24

7.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.5 Checking gas inlet pressure . . . . . . . . . . . . . . . . . . . . . 26

7.5.1 Measuring the inlet pressure . . . . . . . . . . . . . . . . . . . . 26

7.5.2 Checking the gas rate . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.6 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . 26

7.7 Commissioning checklist . . . . . . . . . . . . . . . . . . . . . . . 27

8 Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.1 Perform thermal disinfection . . . . . . . . . . . . . . . . . . . . 28

8.2 Thermal disinfection for system with a hot water tank 28

9 Operating the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

9.1 Controls overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

9.2 Screen display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

9.3 Appliance on/off switch . . . . . . . . . . . . . . . . . . . . . . . . 29

9.4 Heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

9.4.1 Heating mode on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

9.4.2 Set the maximum flow temperature . . . . . . . . . . . . . . . 30

9.5 Setting the DHW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

9.5.1 DHW on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

9.5.2 Setting the DHW temperature . . . . . . . . . . . . . . . . . . . 31

9.6 Control unit setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

9.7 Summer mode ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . 32

9.8 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . 32

10 Servicing and spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

10.1 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . 33

10.2 Service function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

10.2.1 Selecting service menus . . . . . . . . . . . . . . . . . . . . . . . . 33

10.2.2 Selecting the Information menu . . . . . . . . . . . . . . . . . . 34

10.2.3 Selecting menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

10.2.4 Selecting menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

10.2.5 Selecting menu 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

10.2.6 Selecting the Test menu . . . . . . . . . . . . . . . . . . . . . . . . 36

10.2.7 Setting the boiler to maximum output . . . . . . . . . . . . . 37

10.3 Flue integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10.4 Service inspection - Component access . . . . . . . . . . . 37

10.4.1 Control panel - Service position . . . . . . . . . . . . . . . . . . 38

10.5 Checking the gas inlet pressure . . . . . . . . . . . . . . . . . . 38

10.6 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

10.7 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

10.8 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . 40

10.9 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . 40

10.10 Inspection and servicing checklist . . . . . . . . . . . . . . . . 42

10.11 Demand dependant maintenance . . . . . . . . . . . . . . . . 44

11 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.1 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.1.1 Access to components . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.1.2 Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

11.1.3 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

11.1.4 To remove the condensate trap . . . . . . . . . . . . . . . . . . 47

11.1.5 Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

11.1.6 Primary Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . 48

12 Fault finding and dianostics . . . . . . . . . . . . . . . . . . . . . . . . . . 49

12.1 Status codes and faults . . . . . . . . . . . . . . . . . . . . . . . . . 49

12.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

12.3 Information and service menus . . . . . . . . . . . . . . . . . . 49

12.3.1 Selecting the information menu . . . . . . . . . . . . . . . . . . 51

12.3.2 Selecting service menus . . . . . . . . . . . . . . . . . . . . . . . . 52

12.3.3 Menu 1 - System parameters . . . . . . . . . . . . . . . . . . . . 52

12.3.4 Menu 2 - Boiler parameters . . . . . . . . . . . . . . . . . . . . . 52

12.3.5 Reset to factory settings . . . . . . . . . . . . . . . . . . . . . . . . 53

12.3.6 Menu 3 - Boiler maximum & minimum limits . . . . . . . . 53

12.3.7 Using the test menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

12.4 Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Page 3

Key to symbols and safety precautions

Condens – 6720816930 (2015/04)

1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS

1.1 Key to symbols

Warnings

The following keywords are defined and can be used in this document:

• NOTICE indicates a situation that could result in damage to property or equipment.

• CAUTION indicates a situation that could result in minor to medium injury.

• WARNING indicates a situation that could result in severe injury or death.

• DANGER indicates a situation that will result in severe injury or death.

Appliance operation:

This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.

Important information

Additional symbols

Symbols used in the manual

Please read these instructions carefully before starting installation.

If you smell gas

A gas leak could potentially cause an explosion. If you smell gas, observe the following rules.

▶ Prevent flames or sparks:

– Do not smoke, use a lighter or strike matches. – Do not operate any electrical switches or unplug any equipment.

– Do not use the telephone or ring doorbells. ▶ Turn off the gas at the meter or regulator. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Well away from the building, call the Emergency Services. ▶ L.P.G. boilers: Call the supplier’s number on the side of the gas tank.

Combustion and corrosive materials

Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the appliance.

Chemically aggressive substances can corrode the appliance and invalidate any warranty.

Fitting and modification

Flue systems must not be modified in any way other than as described in the fitting instructions. any misuse or unauthorised modifications to the appliance, flue or associated components and systems could invalidate the warranty. The manufacturer accepts no liability arising from any such actions, excluding statutory rights.

Servicing

Advise the user to have the system serviced annually by a competent registered engineer. Approved spares must be used to help maintain the economy, safety, and reliability.

Central heating water

Artificially softened water must not be used to fill the central heating system.

1.2 Legislation and regulations

Installation regulations

The appliance must be installed by a competent person in accordance with all the legislation and regulations that are in force at the time of installation, paying particular attention to any provisions or regulations made by the local authorities.

Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken.

This symbol indicates important information where there is no risk to people or property.

Symbol Explanation

▶ Step in an action sequence  Cross-reference to another part of the document

• List entry – List entry (second level)

Domestic Hot Water

Central Heating

Hot Water Storage Cylinder

Domestic Cold Water Supply

Gas Supply

Ø Diameter

 Equal to or less than  Equal to or greater than

< Less than > Greater than NG Natural Gas LPG Liquid Petroleum Gas CH Central Heating DHW Domestic Hot Water DCW Domestic Cold Water PRV Pressure Relief Valve NTC Negative Temperature Coefficient (sensor) IP Ingress Protection RCD Residual Current Device TRV Thermostatic Radiator Valve

Table 1 Abbreviations use in this manual

Page 4

4 | Appliance information

Product Name6 720 ... ... (YYYY/MM)

2 Appliance information

2.1 General information

Boiler features and checklist

• Pre-wired and pre-plumbed

• Galvanised steel inner frame

• Bosch EMS control system

• Automatic ignition

• Direct burner ignition electrodes

• Built-in frost protection

• Built-in fault finding diagnostics

• Modulating automatic gas valve

• Combustion air fan with speed regulator

• CH temperature sensor and control

• Flue gas overheat sensor

Fig. 1 Standard package

2.2 Intended use

These appliances may only be used in a closed loop hot water central heating system. Any other purpose is considered improper use. Any damage resulting from misuse is excluded from the manufacturer’s guarantee. The commercial or industrial use of the appliance to produce process heat is not permitted. Only use genuine gas from official gas suppliers. Ensure the appliance is operated within the limits on the data label and parameters in this manual.

2.3 Declaration of conformity

This product, in design and operation, conforms to the European Directives and supplementary national requirements. Compliance is demonstrated by the CE marking. You can request the declaration of conformity of the product. To do so, send your request to the address on the back of the manual. The appliances meet the requirements for gas-fired condensing boilers in terms of energy saving regulations.

The appliances are tested according to EN 677.

2.4 Type plate

The type label contains information on device performance, the registration data and the serial number.

2.5 Type overview

KSBR units, heat only gas-fired condensing boilers with an integrated circulating pump and optional 3-way valve for the connection of the hot water tank.

KBR units, heat only, gas-fired condensing boilers without a circulating pump or optional three way valve, for use in systems where this is provided externally.

2.5.1 Electrical supply

• Supply: 230V - 50 Hz

• External “Quick blow” 3A fuse

• The appliance must be earthed

• IPX4D

• The wiring between the appliance and the electrical supply must comply with the latest IEE wiring regulations that apply to wiring a to a fixed appliance

• Any system connected to the appliance must not have a separate electrical supply

2.5.2 Gas supply

• Boilers using Natural Gas (NG) must be connected to a governed meter.

• Liquid Petroleum Gas (LPG) must be connected to a regulator.

• Installation and connection of the gas supply to the boiler must be in accordance with country and local regulations.

• Under no circumstance should be size of the gas supply pipe be less than DN20.

• The meter or regulator and pipe work to the meter must be checked, by the gas supplier. This is to ensure that the equipment is in good working order and can meet the gas flow and pressure requirements, in addition to the demand from any other appliance being served.

CHECK LIST - LITERATURE PACK: Qty.

1 Installation, Commissioning and Servicing Instructions 1

Users Instructions

Table 2 Literature pack - checklist

CHECK LIST - INSTALLATION PACK: Qty.

2 PRV discharge pipe 1 3 Levelling feet 4

Table 3 Installation pack - checklist

6720809859-47.1Wo

K Floor standing appliance S Built-in circulation pump & optional 3 way diverter valve B Condensing technology R Modulating burner 16 output up to 16 kiloWatts 30 output up to 30 kiloWatts 42 output up to 42 kilowatts

Table 4 Appliance designation

Page 5

Appliance information | 5

6 720 ... ... (YYYY/MM)Product Name

2.6 Dimensions and description

Fig. 2 Pipe work connector location

Regular boiler:

[1] Hot water flow (1”) [2] Gas (3/4”) [3*] Not used on the regular boiler [4] Hot water return (1”) [5] Condensate outlet [6] 80/125 Flue outlet

System boiler:

[1] Heating and DHW flow (1”) [2] Gas (3/4”) [3*] DHW return (1”) (only if optional diverter valve kit is fitted) [4] Heating return (1”) [5] Condensate outlet [6] 80/125 Flue outlet

6720809859-10.1Wo

123*4

466

394

78 111

141 253

Ø80

Ø125

130

162

193

900 - 930

Page 6

6 | Appliance information

Product Name6 720 ... ... (YYYY/MM)

2.7 Regular boiler layout and components

Fig. 3 Component layout KBR

Legend to figure 3:

[1] Flue connector [2] ON/OFF switch [3] Display [4] Pressure gauge [5] Combustion chamber cover mounting bracket x 4 [6] Flame sense electrode [7] Electrode assembly [8] Flow temperature sensor [9] High limit thermostat [10] Heat exchanger inspection cover [11] Condensate pan [12] Pressure relief valve [13] Drain cock [14] Condensate trap [15] Gas valve [16] Flue overheat thermostat [17] Air Intake pipes (30 and 42kW boilers only)

[18] Manual vent [19] Pre-mix chamber [20] Spark generator [21] Fan [22] Combustion chamber cover

6720809859-12.1Wo

Page 7

Appliance information | 7

6 720 ... ... (YYYY/MM)Product Name

2.8 Regular boiler wiring diagram

Fig. 4

[1] Appliance terminal connector block [2] Mains supply [3] Heat control module (HCM) [4] Spark generator [5] Spark electrodes [6] Flame sense electrode

[7] High limit thermostat [8] Flow temperature sensor [9] Flue overheat thermostat [10] Gas valve [11] Fan

L1 N L2 N N

6720809859-08.1Wo

Page 8

8 | Appliance information

Product Name6 720 ... ... (YYYY/MM)

2.9 Regular boiler Technical data

All the technical data quoted in the table below refer to an appliance tested at sea level. Power outputs are reduced due to altitude, refer to figures 5 and 6 for the percentage reduction power output due to altitude

DESCRIPTION Units Natural Gas Propane

16kW 30kW 42kW 16kW 30kW 42kW

Central Heating G20 G25 G20 G25 G20 G25 G31 G31 G31

Input/Output

Max. rated heat output net 50/30°C kW 17.00 13.90 31.70 26.00 39.80 32.60 15.80 31.70 41.00 Max. rated heat output net 80/60°C kW 15.30 12.60 30.10 24.67 38.10 31.20 14.60 30.10 38.40 Max. rated heat input net kW 16.00 13.10 30.90 25.30 39.00 32.00 16.00 30.90 39.00 Min. rated heat output net 50/30°C kW 3.80 3.10 8.00 6.60 10.10 8.30 6.40 11.52 13.50 Min. rated heat output net 80/60°C kW 3.50 2.90 7.00 5.60 9.40 7.70 5.70 10.20 12.50 Min. rated heat input net kW 3.70 3.10 8.00 6.60 10.30 8.40 6.30 10.80 13.50 Max. flow temperature °C 82 Max. permissible operating pressure bar 3.00

Gas flow rate - Max. 10 minutes from lighting

Natural Gas G20 m3/h 1.66 3.28 4.05 Natural Gas G25 m3h 1.54 3.17 3.92 Propane Gas G31 kg/h 0.61 1.27 1.65 Gas supply pressure Natural Gas G20 mbar 20 20 20 Natural Gas G25 mbar 25 25 25 Propane Gas G31 mbar 37 37 37

Flue

Flue Gas Temp. 80/60°C, max/min °C 67/55 67/55 67/55 67/55 77/55 77/55 67/55 67/55 77/55 Flue Gas Temp. 40/30°C, max/min °C 43/25 43/25 43/25 43/25 43/25 43/25 43/25 43/22 43/25 CO2 level at max. rated heat output % 9.4 7.4 9.4 7.4 9.4 7.5 10.8 10.8 10.9 CO2 level at min. rated heat output % 8.6 6.9 8.6 6.9 9.4 7.4 10.4 10.4 10.8 NOx - classification class 555555555

Exhaust gas flow rate

Maximum g/s 6.8 6.8 13.3 13.3 17.2 17.2 6.7 12.8 16.2 Minimum g/s 1.7 1.7 3.4 3.4 4.1 4.1 2.6 6.2 7.9 Condensate Max. condensation rate l/h 3.7 pH value, approx. 4.8

Electrical

Electrical power supply voltage AC...V 230 Frequency Hz 50 Max. power consumption (excluding external pumps) W 28 28 48 48 68 68 27 48 66

General Data

Appliance protection rating IP X4D Permissible ambient temperatures °C -20 to +50 Nominal water capacity of appliance Itr 3.75 Weight (excluding packaging) kg 52

Table 5 Appliance technical data KBR

Page 9

Appliance information | 9

6 720 ... ... (YYYY/MM)Product Name

2.10 Gas type and installation type

2.11 Output power reduction due to altitude

The graph in figure 5 below applies to all boiler sizes using natural gas, and the graph in figure 6 below applies to all boiler sizes using LPG. The power output of the boilers quoted in tables 5 and 8 are reduced due to the altitude of the installation, refer to the graphs below for the percentage output reduction.

Output power reduce on natural gas boilers due to altitude

Fig. 5 Output reduction due to altitude for natural gas

[1] Percentage output at elevation [2] Percentage estimated output at elevation [A] Altitude in metres [kW(%)] Percentage kiloWatt output

Country

Rated gas pressure (mbar)

Gas

category

Factory setting (gas family,

gas group and test gas)

Factory setting rated

gas pressure (mbar)

Installation typeNatural gas LPG

Austria AT 20 50 Cat II

2H 3P

G20 20 B

23, B23P, B33, C13X,

33X, C43X, C53X, C63X,

83X, C93X

France FR 20 37 Cat II

2E SI 3P

G20 20

Italy IT 20 37 Cat II

2H 3B/P

G20 20

Czech Republic CZ 20 37 Cat II

2H 3B/P

G20 20

Russia RU 13 37 Cat II

2H 3B/P

G20 20

Poland PO 20 37 Cat II

2H 3P

G20 20

Belgium BE 20/25 Cat II

G20/25 20 B

23, B33, C13X, C33X,

43X, C53X, C83X, C93X

Belgium BE 37 Cat II

G31 37

Table 6 Gas type and installations per country

Wobbe index (WS) (15C) gas group Gas group

12.5 to 15.2 kWh/m

Natural gas 2H

11.4 to 15.2 kWh/m

Natural gas 2E

9.5 to 12.5 kWh/m

Natural gas 2LL

20.2 to 24.3 kWh/m

LPG 3B/P

20.2 to 21.4 kWh/m

LPG 3P

Table 7 Test gas disclosures with code and gas group (EN437)

75%

80%

85%

90%

95%

100%

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000

kW (%)

A (Metres)

6720809859-75.1Wo

Page 10

10 | Appliance information

Product Name6 720 ... ... (YYYY/MM)

Output power reduce on LPG boilers due to altitude

Fig. 6 Output reduction due to altitude for LPG

Pressure loss in the system versus system flow

Fig. 7

[p( mbar)]Pressure loss in millibars [F (litres/h)]Re-circulated quantity of water in litres per hour

75%

80%

85%

90%

95%

100%

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000

kW (%)

A (Metres)

6720809859-76.1Wo

100

150

200

250

300

350

400

450

500

550

600

0 300 600 900 1200 1500 1800 2100



P (mbar)

F (litres/h)

6720809859-88.1Wo

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Appliance information | 11

6 720 ... ... (YYYY/MM)Product Name

2.12 System boiler layout and components

Fig. 8 Component layout KSBR

Legend to figure 5:

[1] Flue connector [2] ON/OFF switch [3] Display [4] Pressure gauge [5] Combustion chamber cover mounting bracket x 4 [6] Flame sense electrode [7] Electrode assembly [8] Flow temperature sensor [9] High limit thermostat [10] Heat exchanger inspection cover [11] Condensate pan [12] Auto air vent [13] Diverter valve assembly (only with option accessory kit) [14] Pump [15] Drain cock [16] Pressure relief valve [17] Condensate trap

[18] Gas valve [19] Flue overheat thermostat [20] Air Intake pipes (30 and 42kW boilers only) [21] Manual vent [22] Mixing device [23] Spark generator [24] Flue exhaust [25] Fan [26] Combustion chamber cover

6720809859-11.1Wo

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12 | Appliance information

Product Name6 720 ... ... (YYYY/MM)

2.13 System boiler wiring diagram

Fig. 9

[1] Appliance terminal connector block [2] Mains electrical supply connector [3] Heat control module (HCM) [4] Spark generator [5] Spark electrodes [6] Flame sense electrode [7] High limit thermostat

[8] Flow temperature sensor [9] Diverter valve connection [10] Pump [11] Flue overheat thermostat [12] Gas valve [13] Fan

L1 N L2 N N

6720809859-07.1Wo

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Appliance information | 13

6 720 ... ... (YYYY/MM)Product Name

2.14 System boiler Technical data

DESCRIPTION Units Natural Gas Propane

16kW 30kW 16kW 30kW

Central Heating G20 G25 G20 G25 G31 G31

Input/Output

Max. rated heat output net 50/30°C kW 17.00 13.90 31.70 26.00 15.80 31.70 Max. rated heat output net 80/60°C kW 15.30 12.60 30.10 24.67 14.60 30.10 Max. rated heat input net kW 16.00 13.10 30.90 25.30 16.00 30.90 Min. rated heat output net 50/30°C kW 3.80 3.10 8.00 6.60 6.40 11.52 Min. rated heat output net 80/60°C kW 3.50 2.90 7.00 5.60 5.70 10.20 Min. rated heat input net kW 3.70 3.10 8.00 6.60 6.30 10.80 Max. flow temperature °C 82 Max. permissible operating pressure bar 3.00

Gas flow rate - Max. 10 minutes from lighting

Natural Gas G20 m3/h 1.66 3.28 Natural Gas G25 m3/h 1.54 3.17 Propane Gas G31 kg/h 0.61 1.27 Gas supply pressure Natural Gas G20 mbar 20 20 Natural Gas G25 mbar 25 25 Propane Gas G31 mbar 37 37

Flue

Flue Gas Temp. 80/60°C, max/min °C 67/55 67/55 67/55 67/55 67/55 67/55 Flue Gas Temp. 40/30°C, max/min °C 43/25 43/25 43/25 43/25 43/25 43/25 CO2 level at max. rated heat output % 9.4 7.4 9.4 7.4 10.8 10.8 CO2 level at min. rated heat output % 8.6 6.9 8.6 6.9 10.4 10.4 NOx - classification class 5

Exhaust gas flow rate

Maximum g/s 6.8 6.8 13.3 13.3 6.7 12.8 Minimum g/s 1.7 1.7 3.4 3.4 2.6 6.2 Condensate Max. condensation rate l/h 3.7 pH value, approx. 4.8

Electrical

Electrical power supply voltage AC...V 230 Frequency Hz 50 Max. power consumption (including pump) W 97 97 116 116 95 116

General Data

Appliance protection rating IP X4D Permissible ambient temperatures °C -20 to +50 Nominal water capacity of appliance Itr 3.75 Weight (excluding packaging) kg 54

Table 8 Appliance technical data KSBR

Page 14

14 | Appliance information

Product Name6 720 ... ... (YYYY/MM)

Pumphead versus Flow rate

Fig. 10

[APH] Available pump head [FR] Flow rate [1] Actual data [2] Extrapolated data

0 500 1000 1500 2000

6720809859-87.1Wo

APH ( m wg)

FR (l/hr)

Pump (m wg)

Page 15

Appliance information | 15

6 720 ... ... (YYYY/MM)Product Name

2.15 Energy efficiency

The following product data satisfy the requirements of the EU Regulations No. 811/2013, No. 812/2013, No. 813/2013 and No. 814/2013 supplementing Directive 2010/30/EU.

Product data Symbol Unit 7731600026 7731600027 7731600028 7731600029 7713600030

Product type – – Condens

2000F 16 NG

Condens

2000F 30 NG

Condens

2000F 42 NG

Condens

3000F16 NG

Condens

3000F 30 NG Condensing boiler – – Yes Yes Yes Yes Yes Low temperature boiler – – No No No No No B1 boiler – – No No No No No Cogeneration space heater (CHP) – – No No No No No Combination heater – – No No No No No Rated heat output P

rated

kW 16 30.9 39 16 30.9

Seasonal space heating energy efficiency 

% 9393929393

Energy efficiency class – – A A A A A

Useful heat output

At rated heat output and high temperature regime

1) High temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.

kW 15.3 30.1 38.1 15.3 30.1

At 30 % of rated heat output and low temperature regime

2) Low temperature means for condensing boilers 30 °C, for low-temperature boilers 37 °C and for other heaters 50 °C return temperature (at heater inlet).

kW 3.5 7 9.4 3.5 7

Useful efficiency

At rated heat output & high temperature regime 1)

% 88.2 88.2 88.2 88.2 88.2

At 30 % of rated heat output & low temperature regime



% 98.9 97.6 97 98.7 97.6

Auxiliary electricity consumption

At full load el

max

kW 0.028 0.048 0.068 0.097 0.116

At part load el

min

kW 0.015 0.015 0.016 0.049 0.054

In standby mode P

kW 0.0016 0.0016 0.0016 0.0016 0.0016

Other items

Standby heat loss P

stby

kW 0.059 0.059 0.059 0.076 0.076

Ignition burner power consumption P

ign

kW00000 Emissions of nitrogen oxides NOx mg/kWh 32 29 27 32 29 Annual energy consumption Q

kWh - - - - Sound power level, indoors L

dB(A) 47.9 54.9 52.6 47.9 52.6

Table 9 Product data for energy consumption according to the EU regulations no. 813/2013 and no. 813/2013

Page 16

16 | Regulations

Product Name6 720 ... ... (YYYY/MM)

3 Regulations

The boiler is designed to operated in conformity with the following requirements:

• EN 677, EN 483, EN 15502

• EN 437

• Gas appliance directive 2009/142/EG

• Efficiency directive 92/42/EWG

• EMV directive 2004/108/EG

• Low voltage directive 2006/95/EG

3.1 Country specific regulations

For installation and operation, please refer to country specific standards and regulations. Critical are:

• Local standards and regulations for siting the appliance

• Local standards and regulations for combustion air supply, ventilation and connection to a flue gas system

• Regulations for connection to an electrical mains supply

• Regulations of the gas supplier for connecting a gas appliance onto the local distribution network

• Standards and regulations for safety equipment on wet heating systems

3.2 Approvals and notifications

• The installation of a gas boiler must be declared to, and approved by the gas supplier.

• Please note, local regulations may require third party approval when connecting to a flue gas system or drain condensate into the local sewage system

• Where required, inform local representative (i.e. chimney sweeper) before installing the boiler

3.3 Quality of the heating water

Use water to drinking water quality when filling and toping up the heating system.

Unsuitable or contaminated water can lead to problems or damage of the heat exchanger and water supply caused by i.e. sludge, corrosion and scale build up. Apply the following steps: ▶ Thoroughly flush the system before filling ▶ Water from wells and springs are not suitable as fill water ▶ Consider the total volume of scale introduced into the heating system

over its lifetime, by fill and top up water, and protect it against damage with that in mind

▶ For systems with a volume 50litres/kW (i.e. when using buffer

vessels) the water must be treated. An approved solution is the full removal of salts from the fill and top up water, achieving a conductivity of  10

μsiemens/cm (= 10μS/cm).

Instead of a the water treatment solution you could install a means of system separation (i.e. plate heat exchanger) directly after the boiler.

▶ Please contact the manufacturer of the appliance for additional

inhibitors and anti freezes. Always refer to the manufacturer's advice for filling and continuous maintenance when using these solutions.

3.4 Connection to combustion air and flue gas systems

• Always refer to the latest version of the applicable local standards and regulations

• Further information about combustion air supply and connection to flue gas systems can be found in chapter 5 in this manual.

• Also refer to the documentation supplied with the flue gas system.

3.5 Room air dependent operation

The boiler primarily operates as a “room air sealed” unit, however the boiler can be operated as a “room air dependant” unit, if required.

Provide sufficient boiler room ventilation when operating the appliance room air dependent ▶ Do not obstruct or block any ventilation openings ▶ Ventilation openings must always be kept clear

3.6 Flue gas systems type B

Type B flue gas systems take combustion air from the boiler room. Flue gas exits the appliance via the flue gas system. Special regulations apply for installations of this type - comply with these requirements. Sufficient combustion air must be available.

3.7 Flue gas systems type C

Type C flue gas systems take combustion air from outside the building. Flue gas exits the appliance via the flue gas system to the outside. To ensure this, the combustion chamber door is air tight. Therefore always ensure the combustion chamber door is closed when operating the appliance room air sealed.

• Refer to the installation instructions of the flue gas system when installing the appliance

3.8 Combustion air quality

To avoid corrosion, combustion air must be free from aggressive substances (hydrogen halide, chlorines and fluorine).

3.9 Disposal

• Dispose any part of the heating system via an authorised facility

3.10 Inspection, service and maintenance

The heating system should be service regularly for the following reasons:

• To achieve and maintain a high efficiency and low fuel consumption

• To ensure operational safety

• To keep combustion clean and emissions low

Water quality is an important factor to increase the efficiency, safety, reliability and availability of your heating system.

DANGER: Risk to life from flue gas poisoning. Insufficient combustion air supply can lead to flue gas escaping. ▶ Ensure combustion air supply ▶ Supply and extract vents in doors, windows and

walls must not be closed off or reduced in size.

▶ Ensure a sufficient combustion air supply, also with

equipment installed afterwards: i.e. kitchen extract fans and air conditioning units extracting air to the outside

▶ Do not operate the appliance if combustion air

supply is insufficient.

NOTICE: Damage to boiler from contaminated combustion air and contaminated air in the vicinity of the appliance! ▶ Never operate the boiler in an dusty and chemically

aggressive environment i.e. spray painting, hair dressing and farming facilities

▶ Never operate the boiler in places where using or

storing trichlorethane, hydrogen halide and other aggressive chemical substances. These substances can be contained in spray cans, various glues, primers, paints and cleaning substances. In this case always install the appliance room air sealed in a hermetically sealed plant room with ventilation directly to the outside.

Page 17

Pre-installation | 17

6 720 ... ... (YYYY/MM)Product Name

Service interval

4 Pre-installation

4.1 Cleaning primary systems

4.2 Hydraulic connections

4.2.1 Connecting flow and return

Fig. 11 Pipe work connector location

Regular boiler:

[1] Hot water flow (1”) [2] Gas (3/4”) [3*] Not use on the Regular boiler [4] Hot water return (1”) [5] Condensate outlet

System boiler:

[1] Heating and DHW flow (1”) [2] Gas (3/4”) [3*] DHW return (1”) (only if optional diverter valve kit is fitted) [4] Heating return (1”) [5] Condensate outlet

NOTICE: Damage to the system caused by a lack of or insufficient cleaning and servicing. ▶ Get the heating system inspected at least annually by

an authorised heating engineer

▶ Carry out a service as required. Carry out any repairs

immediately to avoid any damage to the system

NOTICE: Before installation ▶ All the following Pre-Installation sections must be

read and requirements met before starting boiler or flue installations.

CAUTION: MAINS POWER ▶ ISOLATE THE MAINS SUPPLIES BEFORE STARTING

ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

NOTICE: Protect the boiler ▶ Debris from the system can damage the boiler and

reduce efficiency.Failure to comply with guidelines for the use of water treatment with the appliance will invalidate the appliance warranty.

WARNING: Sealing agents ▶ The addition of sealing agents to the system water is

not permitted, this can cause problems with deposits left in the heat exchanger.

NOTICE: Damage to property caused by leaking connections: ▶ Ensure the pipes are installed without mechanical

strain onto the appliance connections

▶ Refurbish seals when loosening or removing

connection joints ▶ Check gaskets and connections for signs of damage ▶ We recommend the installation of a line strainer in

the system return to protect the heating system ▶ Fit isolating valves before and after the line strainer

to allow for servicing

Fit isolation valves in the flow and return to allow servicing of the appliance

6720809859-10.1Wo

123*4

78 111

Ø125

Page 18

18 | Pre-installation

Product Name6 720 ... ... (YYYY/MM)

4.2.2 Expansion vessel and drain valve

Connect an expansion vessel

EN12828 requires and expansion vessel to be installed with the boiler. ▶ Install an expansion vessel in the return to the pump

Fill and drain connections

EN1717 requires a filling of the heating system with drinking water only via a fixed connection between water supply and heating circuit.

▶ Fit an external filling link between the DCW and CH Flow on the

appliance

4.3 Water systems and pipework

Primary system plastic pipework

• Any plastic pipe work must have a polymeric barrier with 600mm (minimum) length of copper connected to the boiler.

• Plastic pipe work used for under floor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50°C. The pipe work from the boiler to the blending valve must be in copper.

Primary system/connections/valves:

• Do not use galvanised pipes or radiators.

• All system connections, taps and mixing valves must be capable of sustaining a pressure of 3 bar.

• Drain cocks are required at all the lowest points on the system.

• Air vents are required at all high points on the system.

4.4 Condensate drain

Ensure that the condensate trap has at least 250ml of clean water in it before the boiler is run.

If the flue has not been fitted yet, the water can be poured down the inner flue pipe. If the flue has already been fitted, the condensate trap will have to be removed and filled.

4.4.1 To remove the condensate trap

▶ Release the hose clamp [1] ▶ Remove the screw retaining the trap [2] ▶ Pull the trap down to remove the trap from boiler ▶ Pour 250ml of clean water into the top of the trap ▶ Re-fit the trap to the boiler

Fig. 12 Condensate trap

▶ Install condensate neutralisation systems (optional accessory) in line

with the installation instructions

▶ Ensure that the condensate pipework leading away from the

appliance falls away towards the drainage point

▶ Connect into the sewage system based on national and local

standards and regulations

4.5 Boiler location and clearances

4.5.1 Installation

• This boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid non-combustible surface at least the same size as the boiler and capable of supporting the boiler weight.

• The boiler is not suitable for external installation unless a suitable enclosure is provided.

4.5.2 Installations and servicing clearances:

The dimensions below are the minimum space required to install, service and perform maintenance on the boiler only.

Fig. 13 Installation clearances

[1] 1900mm [2] 2500mm [3] 2000mm [4] 70mm

DANGER: Danger to life by poisoning from escaping flue gas. Flue gas can escape if condensate trap is not filled with water or connections are not sealing properly. ▶ Fill the siphon with water

NOTICE: Additional advice on draining condensate ▶ Any condensate in the appliance and the flue gas

system must be drained in an appropriate manner (flue gas system must have sufficient fall towards the appliance)

▶ Comply with country specific standards and

regulations when connecting the condensate into the sewage system

▶ Comply with local regulations

Condensate neutralisation systems are available as an accessory.

6720809859-77.1Wo

6720809859-09.1Wo

Page 19

INSTALLATION | 19

6 720 ... ... (YYYY/MM)Product Name

5 INSTALLATION

5.1 Unpacking the boiler

Unpacking:

1. Undo the ties securing the carton If a sharp implement is used, care must be taken not to pierce the carton or cause injury.

2. Before removing the carton it is advised that the top flaps are opened and the ancillary items (A, B, & C) are removed and set to one side.

3. The carton can now be lifted off the boiler.

▶ Remove the plastic bag protecting the boiler surfaces and place

safely away from the working area.

General handling guidelines:

▶ Lift only a manageable weight, or ask for help. ▶ When lifting, bend the knees, and keep the back straight and feet

apart.

▶ Do not lift and twist at the same time. Lift and carry items close to the

body

▶ Wear protective clothing and gloves to protect from any sharp edges

Fig. 14 Unpacking

[A] Literature pack [B] PRV disposal pipe [C] Levelling feet x4

5.2 Boiler room requirements

5.2.1 Installing the levelling feet

▶ Screw a levelling nut onto the threaded shaft of each of the feet ▶ Screw the threaded shaft into the base of the boiler at each corner as

indicated in figure 15 ▶ Adjust the feet to be approximately the same length ▶ Level the boiler as described in section 5.2.2

Fig. 15 Fitting the feet

NOTICE: Boiler start up

▶ All the previous Pre-Installation sections must be

read and requirements met before starting boiler or flue installation.

NOTICE: Boiler handling

▶ At all times the correct method for handling heavy

objects should be strictly observed. ▶ Take care not to damage the boiler panels or floor. ▶ The boiler may contain water due to factory testing ▶ Store the boiler in a dry area prior to installation

DANGER: Explosive and flammable materials ▶ Do not store flammable materials (paper, curtains,

clothing, primer, paint, …) in proximity to the boiler

NOTICE: Damage to the appliance from contaminated combustion air ▶ Do not use any cleaners containing chlorine or

hydrogen halide (i.e. spray cans, primers, cleaners,

paint and glue) ▶ Don’t store or use these substances in the boiler

room ▶ Avoid the build up of dust

6720809859-94.1Wo

NOTICE: Damage from overheating. Excessive ambient temperatures may cause damage to the heating system. ▶ Ensure the ambient temperature is above 0 °C and

below 35 °C

NOTICE: Frost damage to the appliance ▶ Fit the boiler in a frost free room

CAUTION: Toppling hazard Boiler will topple over if tilted passed 45 ° ▶ Tilt the boiler to no more than 40 ° ▶ Take care when tilting the boiler to fit levelling feet,

ideally two people are required to safely fit the feet.

NOTICE: Damage to boiler ▶ Do not lie the boiler down to fit the levelling feet

6720809850-95.1Wo





<40

Page 20

20 | INSTALLATION

Product Name6 720 ... ... (YYYY/MM)

5.2.2 Positioning the appliance

The boiler must be adjusted to be level. This ensures air can escape from the heat exchanger and condensate drains freely.

▶ Place boiler in its final location ▶ Release the locknuts on the boiler feet ▶ Adjust the boiler feet until the boiler is level vertically and

horizontally, check using a spirit level

▶ Secure in position with the locknuts

Fig. 16 Levelling the boiler

5.3 Mounting the boiler and flue opening

Safety

All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.

Running pipes behind the boiler

• The boiler should sit at least 70mm from the rear wall to allow enough room for access to the pipe work.

• Do not cross a pipe over another.

Fig. 17 Pipe Connections

System boiler:

[1] Heating and DHW flow (1”) [2] Gas (3/4”) [3*] System boiler - DHW return (1”)

(only if optional diverter valve kit is fitted)

Regular boiler - Not used [4] Heating return (1”) [5] Condensate outlet

NOTICE: Damage caused by insufficient load bearing or unsuitability of the boiler room floor ▶ Ensure the floor area is suitable for installing a boiler

and can take the “wet weight” of the appliance.

NOTICE: Damaged caused by mechanical strain on the hydraulic and flue gas connections when adjusting the position of the appliance. ▶ Do not apply any strain the connections when

adjusting the boiler position

CAUTION: Isolate the mains gas supply before starting any work and follow all relevant safety precautions.

6720809859-79.1Wo

6720809859-48.1Wo

394

Ø80

Ø125

466

130

162

193

900 - 930

78 111

141253

Page 21

INSTALLATION | 21

6 720 ... ... (YYYY/MM)Product Name

Gas connections

Flue opening

5.4 Flue options

Fig. 18 Flue options

DANGER: Risk to life from explosion of flammable gases ▶ Work on components in contact with gas must only

be carried out by a competent and authorised person.

▶ Comply with national and local standards and

regulations

▶ Only use approved methods of making gas tight

connections

Surplus water may be present due to factory testing.

Any horizontal flue sections must rise away from the boiler by 52mm per metre to ensure that condensate flows back into the boiler for safe discharge via the condensate waste pipe.

CAUTION: Non accessible flue systems: ▶ Where a flue system is not going to be accessible,

provision must be made for service and inspection.

▶ Voids containing concealed flues must have at least

one inspection hatch no less than 300mm square.

▶ Flue joints within the void must not be more than 1.5

metres from the edge of the inspection hatch.

▶ Inspection hatches should be located at changes of

direction.

▶ If this is not possible, bends should be viewable from

both directions.

NOTICE: Effective flue lengths: ▶ each 90 ° bend used is equivalent to 2.0 metres of

straight flue

▶ each 45 ° bend used is equivalent to 1.0 metre of

straight flue

Maximum total flue length L (mm)

Flue type

1 High level horizontal flue 11 000 2 High level horizontal flue with 2 x 90 ° bends 9 000 3 High level horizontal flue with 3 x 90 ° bends 7 000 4 Vertical balanced flue assembly 15 000 5 Vertical balanced flue with 2 x 90 ° bends 11 000 6 Vertical balanced flue with 2 x 45 ° bends 13 000

Table 10 Flue options

120 mm

6720809859-82.1Wo

Flat roof

300 mm

500 mm

Pitched

roof

120 mm

Page 22

22 | INSTALLATION

Product Name6 720 ... ... (YYYY/MM)

5.5 Vertical flues

Room sealed flues C33 and C93

Fig. 19 C33 RSF flue

Fig. 20 C93 RSF flue

Ø110

Ø 80

Ø 80/125

6720809859-83.1Wo

C33

> 1m

Boiler output (kW)

L max (metres)

L1 max (metres)

Equivalent length 93 ° flue elbow (metres)

Equivalent length 15 ° and 45 ° flue elbow (metres)

16 13 3 2 1 30 13 3 2 1 42 13 3 2 1

Table 11

Ø 80

Ø 80/125

6720809859-84.1Wo

> 1m

C93

Page 23

INSTALLATION | 23

6 720 ... ... (YYYY/MM)Product Name

Open flues B33

Fig. 21 Rigid B33 flue Fig. 22 Flexible B33 flue

Ø 80

Ø 80/125

> 1m

6720809859-85.1Wo

B33

Boiler output (kW)

L max (metres)

L1 max (metres)

Equivalent length 93 ° flue elbow (metres)

Equivalent length 15 ° and 45 ° flue elbow (metres)

16 13 3 2 1 30 13 3 2 1 42 13 3 2 1

Table 12

Ø 80/125

Ø 80

6720809859-86.1Wo

> 1m

B33

Page 24

24 | ELECTRICAL

Product Name6 720 ... ... (YYYY/MM)

6 ELECTRICAL

6.1 Electrical

Access to the electrical connections: Remove the boiler front panel to gain access to electrical connections. ▶ Pull the top corners of the front panel away from the case until the

ball catches are released.

▶ Lift the panel off the lower brackets and set the panel safely aside.

Fig. 23 Electrical connections access

Access to electrical connections:

▶ Access to all wiring connections are via the Installer access cover at

the bottom front of the control panel. No access is required to other parts of the control board.

▶ Release the three screws in the connections cover and remove the

cover.

Fig. 24

[1] Mains voltage connections [2] Low voltage connections [3] Cable retainers

Fig. 25 Mains voltage connections

Fig. 26 Low voltage connections

DANGER: Risk of fire from hot boiler components. Hot boiler components can damage electrical cables. ▶ Ensure all electrical cables are in the correct cable

guides and away from hot boiler components

Run power cables separately from signal cables. Interference from power cables can induce spurious faults on signal cables, ensure that there is at least 300mm separation from each other.

CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS

▶ All electrical work must be carried out by a competent

and authorised person.

▶ All work must be in line with country specific and local

standard and regulations.

▶ The isolator must have contact separation of 3mm

minimum between poles. Any system connected to

the boiler must not have a separate electrical supply. ▶ External fuse 3 Amps. ▶ When stripping the wires ensure copper strands do

not fall into the control box.

6720809859-18.1Wo

Mains voltage terminal strip

1 External frost thermostat 2 230 V A.C. switched live inputs 3 230 V A.C. mains output 4 DHW charge pump 5 DHW circulation pump 6 CH circulation pump 7 Boiler 230 V A.C. mains supply

Table 13 Key to figure 25

Low voltage terminal strip

8 Input for external demand 9 EMS bus connections 10 External cut off switch (supplied with factory fitted link) 11 Outside sensor 12 DHW cylinder sensor 13 Low Loss Header sensor

Table 14 Key to figure 26

6720809859-16.1Wo

6720809859-15.1Wo

230V IN

230V OUT

FRFSLR

3 4

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EMS

Page 25

COMMISSIONING | 25

6 720 ... ... (YYYY/MM)Product Name

Cable retainer clamps

▶ Unclip the cable clamp [1}. ▶ Cut off the tapered cable entry [2] to suit the cable diameter.

Fig. 27 Cable entry

▶ Unscrew the cable retaining screw [3}.

Run the cable [4] through the cable clamp ensuring there is ample cable to reach the connectors.

▶ Tighten the cable retaining screw [3] to secure the cable and replace

clamp into the control panel.

Fig. 28 Cable retainers

7 COMMISSIONING

7.1 Pre-Commissioning checks

1. Check that the service and water pipes are connected to the correct points on the back of the boiler; 1 - CH flow (1”) 2 - Gas inlet (3/4”) 3* - DHW return (1”) System boiler with optional diverter valve kit only 4 - CH return (1”) 5 - Condensate out

Fig. 29 Pre-commissioning checks

2. Check all system and boiler drain points are closed.

3. Check the gas type specified on the identification plate matches that of the gas supply.

▶ Turn on the main gas supply and purge the gas supply to the boiler

ensuring that the room is well ventilated.

▶ Test the gas supply for tightness.

4. Check the flue is correctly fitted and the connections are secure.

5. Check the condensate pipe work is correctly fitted and connected.

6. Refit cover onto the bottom clips and secure with the ball catches.

7.2 Filling the system and checking for leaks

Check the heating system for leaks to avoid problems during commissioning and operation.

• Ensure good ventilation, ensure all isolating valves in the heating circuits and radiation temperature regulating valves are fully open

• Open all automatic air vents

≥ 5mm

6720809529-92.1Wo

36-40mm

26-30mm

6-8mm



6720809529-92.1Wo

CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.

NOTICE: If the boiler is not commissioned immediately then, after successfully completing all of the checks and any rectification work, shut off the gas supply and electrically isolate the boiler.

NOTICE: Damage due to the ingress of air into the system ▶ The appliance is only suitable for installation and

operation on pumped, sealed and pressurised heating systems in line with EN12828.

▶ Do not connect onto gravity and/or open vented

systems

CAUTION: Risk to health from contaminated drinking water: ▶ Comply with country specific standards and

regulations for avoiding contamination of drinking water

▶ In Europe, also comply with EN 1717

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26 | COMMISSIONING

Product Name6 720 ... ... (YYYY/MM)

▶ Open all the system and radiator valves. ▶ Turn on the water main stop cock.

Sealed System

1. Monitor the pressure gauge on the control panel of the appliance

2. Slowly fill the system via the external filling link

3. Set the pressure between 1 and 1.5 bar pressure.

Fig. 30 Setting the system pressure

▶ Close the external filling valve ▶ Check the pipe work and connections for leaks and rectify as

necessary ▶ Vent all radiators, retighten when completed. If the test pressure drops off as a result of the air bleeding: ▶ Top up with domestic cold mains water ▶ Complete pressure test based on the local requirements Once the pressure test is completed and no leaks are present: ▶ Set correct working pressure

7.3 Water treatment

7.4 Starting the appliance

Fig. 31

[1] Main on/off switch [2] Diagnostic port (Service engineers only) [3] DHW button [4] Heating button [5] Display [6] Minus button [7] Plus button [8] ok button [9] Back button [10] Pressure gauge [11] Service button [12] Reset button [13] Summer/Winter mode button

Switching the appliance on/off:

1. Turn on the mains power supply. ▶ Turn on any external controls. ▶ Set the TRV controls to maximum. ▶ Set the clock or programmer, if fitted, to continuously ON and the

room thermostat to maximum temperature.

2. Switch on the appliance with the ON/OFF switch on the control panel. The display lights up and initially shows the appliance temperature.

Fig. 32 Main power switch

NOTICE: Damage to property from overpressure during pressure tests! Pressure, control and safety devices may be damaged by excessive pressure. ▶ After filling the system pressure test to the release

pressure of the safety valve

NOTICE: Damage caused by cracks from thermal shock! Cracks can occur when toping up a warm heating system with cold mains water. The boiler could start leaking. ▶ Only fill and top up the heating system when cold

(maximum flow temperature 40 °C)

▶ Comply with the requirements for water quality

Have a fixed connection between mains water supply and filling point in line with EN 1717. Fit the appropriate safety device.

NOTICE: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty.

NOTICE:

▶ The quality of the system water must be checked

regularly. Please contact the appliance manufacturer for further guidance.

▶ The addition of sealing agents to the system water is

not recommended as this can cause problems with deposits left in the heat exchanger.

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Min

1 bar

1.5 bar

Max

NOTICE: Never run the appliance when the appliance or system is empty or unpressurised.

The condensate trap fill program starts each time the appliance is turned on. The appliance runs at minimum output for about 15 minutes to fill the condensate trap. The symbol . flashes until 15 minutes of burner operation has been completed.

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Setting the boiler to maximum output

3. Press the / button together with the button to enter the “Chimney sweep mode” , the display shows the current flow temperature and flashes the percentage heat output in the alphanumeric display. The burner symbol will be shown in the display. Press the + or - buttons until the required percentage output is displayed. Set the output to 100% initially.

Fig. 33 Operating the boiler

4. If the boiler fails to light, press the reset button until the reset line of text displays. The device goes back into operation and the flow temperature is displayed.

5. Press the button at any time to return to normal operation.

7.5 Checking gas inlet pressure

7.5.1 Measuring the inlet pressure

▶ Remove the front panel  figure 23 ▶ Remove the combustion chamber cover.

The inlet pressure to the appliance must be checked using the following procedure:

Fig. 34 Inlet test point

▶ Close gas isolation valve. ▶ Slacken the screw in the inlet pressure test point and connect a

manometer.

▶ Open gas isolation valve. ▶ Measure the pressure with the boiler running at maximum output.

▶ Check the gas supply working pressure at the gas valve conforms to

values shown in table 15.

Gas pressure within the system

If the gas pressure, for your gas type, is below the minimum shown in table 15, then this would indicate a problem with the pipe work or connections within the system.

▶ If pressure is satisfactory press the button and the boiler will

return to normal operation.

▶ If left in the central heating boost mode the control will return to

normal operation after 30 minutes.

▶ Re-seal the screw in the gas inlet pressure test point.

7.5.2 Checking the gas rate

▶ The gas rate should be measured at the gas meter after 10 minutes

operation at maximum. See technical data section at the front of this manual.

▶ Where a gas meter is not available (e.g. L.P.G.) the CO/CO

must be

checked to the units shown in section “Setting the air/gas ratio”.

▶ If pressure and gas rate are satisfactory press the button and the

boiler will return to normal operation. – If left in the “Chimney sweep” mode the control will return to

normal operation after 30 minutes. ▶ Close the gas isolation valve. ▶ Remove the manometer. ▶ Re-seal the screw in the gas inlet pressure test point. ▶ Open the gas isolation valve. ▶ Ensure that there are no gas leaks. ▶ Replace the outer case.

7.6 Finishing commissioning

1. Refit and secure the inner combustion chamber cover with the four

screws removed earlier.

2. Locate the lower edge of the front panel onto the brackets and

engage ball catches into the receptors in each side panel.

HANDOVER:

▶ Complete the Commissioning checklist supplied. ▶ Set up the controls and show the user how to operate all the controls

shown in the User Guide. ▶ If appropriate instruct the customer how to repressurise the system. ▶ If the appliance is unused and exposed to freezing conditions, advise

the customer of the precautions necessary to prevent damage to the

boiler, system and building.

In the event of the appliance being inoperative, isolate the boiler and

drain the system and boiler.

7.7 Commissioning checklist

▶ After commissioning, confirm work carried out, enter values, sign

and date to complete.

The boiler will run at maximum output for 30 minutes before switching back to normal operation.

Ensure inlet pressure is satisfactory with all other gas appliances working.

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Gas type min.pressure (mbar) max. pressure (mbar)

G20 17 25 G25 22 30 G31 25 45

Table 15 Gas pressure range

NOTICE:

Do not continue commissioning until the correct gas pressure is achieved.

At the time of commissioning, complete all relevant sections of the Commissioning Checklist supplied.

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28 | COMMISSIONING

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Commissioning Page Unit Values Comment

1 Fill the heating system and check for leaks



2 Record gas values

Wobbe index Calorific value

kWh/m

3 Check gas supply for leaks



Bleed gas supply



4 Pressurise the heating system and record the value bar

5 Check the flue inlet and exhaust, and connections



7 Set the gas type, if required

8 Commission burner and controls



9 Measure and record gas supply pressure mbar

10 Measure flue gas values and record Full load Partial load

- Flue gas pressure Pa

- Flue gas temperature (gross) t

°C

- Air temperature t

°C

- Flue gas temperature (net) tA - t

°C

- CO2 or O2 content Vol. %

- Flue gas losses q

- CO content (air free) ppm

- Supply air CO2 or O2 content when operating room sealed Vol. %

11 Check for leaks during operation



12 Functional tests

Measure ionisation current

13 Refit casing panels



14 Inform homeowner and hand over documentation



15 Correct installation by approved installer Signature

16 Homeowner Signature

Table 16 Commissioning checklist

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8 THERMAL DISINFECTION

8.1 Perform thermal disinfection

General

To prevent Legionella bacterial contamination of the hot water system, we recommend that a thermal disinfection is performed after a long period of inactivity.

Some control systems have a preset programmed time interval for thermal disinfection to be performed, see the operating instructions for your control system.

Thermal disinfection treats the entire hot water system including the extraction points.

8.2 Thermal disinfection for system with a hot water tank

Thermal disinfection via external controller

The thermal disinfection is in this case is performed via the external controller, refer to the controller operating instructions

▶ Turn off all the hot water taps. ▶ Warn the occupants about the potential for scalding. ▶ Set any other pumps for continuous operation. ▶ Activate the Thermal disinfection at the maximum temperature via

the controller. ▶ Wait until the maximum temperature is reached. ▶ Run each hot water taps for at least 3 minutes at 70 °C, starting at the

one nearest to the boiler and working your way to the furthest outlet ▶ Set the circulation pump and control system back to normal

operation.

Thermal disinfection via built in controller

The Thermal disinfection is perform via the built-in controller and is automatically started and ended.

▶ Turn off all hot water taps ▶ Warn the occupants about the potential for scalding ▶ Set any other pumps for continuous operation ▶ Activate the thermal disinfection via the service function 2.9L see

table 20 on page 35 ▶ Wait until the maximum temperature is reached ▶ Run each hot water tap for at least 3 minutes at 70 °C, starting at the

tap nearest to the boiler and working your way to the furthest tap ▶ Set the other circulation pump back to normal operation ▶ Thermal disinfection is completed after the water was maintained at

70 °C for 35 minutes

To interrupt thermal disinfection

▶ Turn the device off and on again. The appliance returns to normal into operation and the flow temperature

is displayed.

WARNING: Risk of scalding Hot water can cause serious burns

▶ Perform thermal disinfection outside normal hot

water use times.

Drawing off hot water at too high a rate may mean that the required temperature can not be achieved. ▶ Draw off only as much water as the appliance can

supply constantly at the disinfection temperature of 70 ° C.

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30 | Operating the appliance

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9 OPERATING THE APPLIANCE

This manual only applies to the appliances listed on the front cover. Depending on the control system fitted some function may be different.

The following option control systems can be used:

• EMS externally mounted programmer

9.1 Controls overview

Fig. 35

9.2 Screen display

Fig. 36 Display symbols

[1] DHW mode off [2] DHW mode on [3] Solar mode (not used on this appliance) [4] Weather compensation (External sensor required) [5] Chimney sweep mode [6] Fault alert [7] Service mode [6 + 7] Maintenance mode [8] Burner on [9] Temperature units °C [10] Confirmation [11] Scroll up or down through the sub menus [12] Alphanumeric display (e.g. Temperature) [13] Text display [14] Heating mode off [15] Heating mode on

9.3 Appliance on/off switch

Initial switch on

▶ To switch on, use the main appliance on/off switch on the control

panel. The display lights up and initially shows the appliance temperature.

Fig. 37 Main power switch

For more information refer to the manual of that controller or programmer.

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The condensate trap fill program starts each time the appliance is turn on. The appliance runs at minimum output for about 15 minutes to fill the condensate trap. The symbol . flashes until 15 minutes of burner operation have been completed.

13 121415

2 3 4 876 95

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Switching the appliance off

▶ To switch off: use the main appliance on/off switch on the control

panel. The display goes blank. ▶ If the appliance is to be taken out of service for a while: Check the

anti-freeze ( Section 9.8).

9.4 Heating mode

9.4.1 Heating mode on/off

▶ Press the Heating mode button repeatedly until the display

shows the Heating mode on symbol or the Heating mode off

symbol flashing.

Fig. 38 Heating display

▶ Press the + or – button to select Heating mode on or off:

– =Heating mode on

– = Heating mode off

▶ Press the ok button to save the setting.

The tick symbol will be displayed briefly.

Fig. 39 Heating mode display

The burner symbol is displayed when the there is a heating

demand.

9.4.2 Set the maximum flow temperature

The maximum flow temperature can be set between 30 °C and 82 °C

The current flow temperature appears on the display.

When in the Heating mode: ▶ Press the button.

The display shows the flashing maximum flow temperature and the Heating mode symbol is displayed.

Fig. 40 Maximum flow temperature

▶ Press the + or – button to set the desired maximum flow

temperature.

▶ Press ok to save the setting.

The tick symbol is displayed briefly to confirm that the setting has been saved.

Fig. 41 Setting the maximum flow temperature

The controller has a pump anti-seize function for when the pump is inactive for a long period of time, the pump is run periodically to prevent it seizing. If the controller is turned off, then this function is inactive.

NOTICE: Risk of the system freezing When the heating is turned off, only the appliance is protected from frost. ▶ Check the anti-freeze if there is at risk of freezing

( Page 33).

No heating will occur if the Heating mode has been set to off.

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1) The maximum value can be reduced by the service technician.

For under-floor heating be aware of the maximum flow temperature.

Flow temperature (approx.)

Example

50 °C Under-floor 75 °C Radiators 82 °C Convection

Table 17 Maximum flow temperatures

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9.5 Setting the DHW

9.5.1 DHW on/off

▶ Press the button repeatedly until the symbol or the

flashing is displayed.

Fig. 42 DHW display

▶ Press + or – button to set the desired hot water use:

– = DHW mode

– + Eco = Eco mode

– = DHW mode off

▶ Press ok to save the setting.

The tick symbol is displayed briefly to confirm that the setting has been saved.

Fig. 43 Eco mode setting

The burner symbol is displayed when there is a DHW demand.

DHW or Eco mode?

• DHW mode If the temperature in the hot water tank falls by more than 5 K (° C) below the set temperature, the hot water tank is heated back up to the set temperature. The control then switches back into heating mode.

• Eco mode If the temperature in the hot water tank falls by more than 10 K (° C) below the set temperature, the hot water tank is heated back up to the set temperature. The control then switches back into heating mode.

9.5.2 Setting the DHW temperature

▶ DHW or Eco mode, ( section 9.5).

– Press the button.

The set DHW temperature flashes.

Fig. 44

▶ Press the + or – button, to select the desired DHW temperature, set

between 40 and 60 °C.

▶ Press the ok button to save the setting.

The tick symbol is displayed briefly, to confirm that the setting has been saved.

Fig. 45

9.6 Control unit setting

Some of the features described in this section change when connected to another control unit (e.g. FW100), some of those features are:

• communication with the control unit and base controller

• setting parameters

No hot water will be available if the DHW mode has been set to off.

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It is recommend that the temperature is set to at least 55 °C to prevent bacterial contamination, such as Legionella.

Control unit instructions The instructions will show you how to: ▶ set the mode and the heating curve using feedback

from an outside temperature sensor. ▶ set the room temperature. ▶ heat economically and save energy.

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9.7 Summer mode ON/OFF

In the Summer mode the heating is turned off but the power to the appliance and control system are maintained and the DHW mode is on.

Summer mode switch: ▶ Press the / button repeatedly until the display shows the

symbol flashing.

Fig. 46

▶ Press the ok button to save the setting.

The tick symbol is displayed briefly to confirm the setting.

Fig. 47

Summer mode setting: ▶ Press the / button repeatedly until the display shows the

symbol flashing.

▶ Press the ok button to save the setting.

The tick symbol is displayed briefly to confirm the setting.

For more information, refer to the control system manual.

9.8 Setting frost protection

Heating system frost protection:

▶ Set the maximum flow temperature to 30 °C ( Section 9.4.2).

-or- turn the appliance off: ▶ Drain the heating system down.

For more information please refer to the control system manual. Cylinder frost protection: Even when the DHW mode is switched off the cylinder is protected

against frost damage. ▶ Set the DHW mode to off( Section 9.5.1).

NOTICE: Risk of freezing. In summer mode only the frost protection devices are active. ▶ Frost protection ( Page 33).

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34 | Servicing and spares

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10 SERVICING AND SPARES

10.1 Inspection and service

• To ensure the continued efficient operation of the appliance it must be checked at regular intervals.

• The frequency of servicing will depend upon the particular installation conditions and usage however, an annual service is recommended.

• The extent of the service required by the appliance is determined by the operating condition of the appliance when tested by fully qualified engineers.

Inspection

1. Check that the terminal and the terminal guard, if fitted, are clear and

undamaged.

2. Check all the joints and connections in the system and remake any

that show signs of leakage. Refill and re-pressurise if applicable as described in Commissioning.

3. Operate the appliance and take note of any irregularities. Call up the

last fault stored by the controller, Service Function ‘i2’. Refer to Fault Finding on page for rectification procedures.

10.2 Service function

The Service menu provides you with service functions for editing and testing of many of the appliance’s functions. The service menu is divided into five sub-menus:

• Info menu for reading out values

• Menu 1, for setting service functions of the first level

• Menu 2, for setting service functions of the second level

• Menu 3, for setting service functions of the third level

• Test menu for manually adjusting device functions for test purposes

Fig. 48

[1] Mode symbol, either Heating or DHW [2] Alphanumeric display [3] Service symbol [4] Plus button (scroll up) [5] ok button (confirm selection, store value) [6] Back button (leave the service function without saving) [7] Minus button (scroll down) [8] Scroll function indicators [9] Service button [10] Text line

10.2.1 Selecting service menus

The description can be found at the beginning of each section about the various menus.

To access the various menus see: ▶ Menu info (see section 10.2.2)

▶ Menu 1 (see section 10.2.3) ▶ Menu 2 (see section 10.2.4) ▶ Menu 3 (see section 10.2.5) ▶ Test menu (see section 10.2.6)

Press the + or - button to scroll the menu area.

The text line [10] displays the service function and the alphanumeric display [2] shows the value of this service function.

Setting the value: ▶ Press the ok button, in the service function, to change the value. ▶ The value flashes in the alphanumeric display. ▶ Press the + or - button to select the desired value. ▶ Press the ok button again to save the setting. After successfully storing the changed value, a tick symbol will appear momentarily in the display. The control will automatically exit the service level after 15 minutes of inactivity.

CAUTION: Mains supplies: ▶ Turn off the gas supply and isolate the electrical

mains supply before starting any work on the appliance and observe all relevant safety precautions.

CAUTION: Component replacement: ▶ After replacement of a gas related component,

where a gasket or seal has been disturbed or replaced, check for gas tightness using a gas sniffer/ analyser.

▶ Also after re-assembly, carry out the following

checks: Fan pressure in section 10.6, Flue gas analysis in section 10.7.

NOTICE: Service work ▶ Service work must be carried out by a competent

registered engineer!

NOTICE: CO/CO2 ANALYSER ▶ Service work must not be attempted if a calibrated

CO/CO

analyser and manometer is not available.

NOTICE: Any service work must be carried out by qualified, competent and registered engineers.

▶ After servicing, complete the relevant Service

Interval Record.

▶ A service must NOT be attempted if a CO/CO

analyser is NOT available.

An up and down arrow combination means you can scroll up and down through the menu.

A double up or double down arrow means you can only scroll up or down through the menu.

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10.2.2 Selecting the Information menu

The Information Menu is a “read only”menu. Information about the boiler is displayed here, some of the values are updated in real time to give the current status of the boiler. The menu backlight turns off after 30 seconds of inactivity and all menus time-out after two minutes of inactivity and the display returns to the normal operation display. Double up or down arrows indicate that the menu can only be scrolled up or down, an up and down arrow combination indicates position in the menu where options can be scrolled either up or down. To enter Information menu: ▶ Press the button ▶ Press the + or - buttons to scroll through the Information menu

10.2.3 Selecting menu 1

To display a service function in this menu: ▶ Press the button and the ok button simultaneously until in the

text line Menu 1 is displayed.

▶ Press the ok button to confirm your selection. ▶ Press the + or - buttons to scroll through the menu area.

10.2.4 Selecting menu 2

To display a service function in this menu: ▶ Press the button and the ok button simultaneously until in the

text line Menu 1 is displayed. ▶ Select menu 2 with the + button. ▶ Press the ok button to confirm your selection. ▶ Press the + or - buttons to scroll through the menu area.

Service functions Comments

i1 Current operating

state

Every operation and mode of the boiler has a related boiler status code. The boiler status code is displayed on the screen as a three figure number. Refer to Status code table on page 51

i2 Operating code for

the last error

This can be viewed during normal operation. Displays the last diagnostic code with boiler status code.

i3 Maximum shared

heating

Setting of service function 2.1A

i4 Maximum shared

power (Hot water)

Setting of service function 2.1b

i7 Flow temperature The actual control system supply

temperature required

i8 Ionisation current When the burner is running:

• 2 micro Amp = OK

• < 2 micro Amp = faulty With burner off:

• < 2 micro Amp = OK

• 2 micro Amp = faulty

i9 Temperature at

temperature flow sensor

This is the actual temperature from the main heat exchanger displayed in real

time. i12 DHW temperature The hot water set temperature i13 Temp. at the storage

tank temp. sensor

only with attached hot water tank

i15 Current outside

temperature

Only displayed when an external

temperature sensor system is connected. i16 Actual system pump

modulation

Display in % of pump modulation (system

boiler only) i17 Current heating Display in % of maximum rated heat output

in heating mode

1) During the water heating, values greater that 100% are displayed in menu 1

i18 Current fan speed Display in revolutions per second (Hz) i20 Software version

circuit board 1

Firmware version of the main control

board. i21 Software version

circuit board 2

Firmware version of the fascia control

display board i22 Code plug number The last three digits of the code plug

(HCM) are displayed i23 HCM version Version of the code plug (HCM) is

displayed

Table 18 Information menu

Service function Possible settings

1.W1 Weather compensation 0 = off, 1 = on

1.W2 Weather compensation, point A @ -10 °C °C (default 90 °C)

1.W3 Weather compensation, point B @ 20 °C °C (default 20 °C)

1.W4 Weather compensation, Automatic

Winter/Summer switch point

°C (default 16 °C)

1.W5 System frost protection 0 = off, 1 = on

1.W6 System frost protection temperature °C (default 5 °C)

1.7d Open shunt sensor input 0 = None, 1 = at the boiler, 2 = at the module

Table 19 Menu 1

Service function Possible settings

2.1A Maximum heat

output

Some gas utilities require a performance-based basic price. The heat output can be limited to between the minimum rated output and maximum rated output for specific heating requirements. Default setting is the maximum rated output. ▶ Adjust the heat output in kW. ▶ Compare the gas flow rate with the

data tables 5 & 8. In case of any deviations, correct the setting.

2.1b Maximum DHW

performance

The heat output can be limited to between the minimum rated output and maximum rated output for specific heating requirements.

Default setting is the maximum DHW output. ▶ Adjust the heat output in kW. ▶ Compare the gas flow rate with the

data table 5 & 8. In case of any deviations, correct the setting.

2.1C Pump head selection The pump speed and modulation

behaviour is controlled by this setting to always modulate based on the burner power.

0: Pump modulates depending on burner power

Setting fixed to always be 0

Table 20 Menu 2

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2.1E Pump energy saving mode

The pump is automatically adjusted by the control system.

• 4: ON - heating systems with weather-compensated modulate the pump down. The pump is only switched on when needed.

• 5: OFF - The flow temperature controller controls the pump. When heat is required the pump and burner are turned on.

Default setting is 5

2.1F Hydraulic system configuration

System configuration, allows you to specify which components in the heating system. Possible settings are: 0: Central Heating pump and 3-way valve (internal) 1: Central Heating pump (internal) and three-way valve (external) 2: Central Heating pump (internal) and storage tank charging pump (external) Default is 0 for a System boiler Default is 2 for a Regular boiler

2.1L Pump operating mode

Allows the setup of systems with or without a low loss header:

0: Pump operates as a heating circuit pump

1: Pump operates as a boiler circuit pump

Default is 0

2.2A Pump blocking time for an external 3-way diverter valve

The internal pump is blocked until the external three-way diverter valve has reached its end position. Setting range 0 - 6 × 10 seconds. Default setting is 0 (seconds).

2.2C Air purge mode This feature can be selected to purge

the system and boiler of air. 0 = off, 1 = auto 2 = on continuously Default is 1 As long as the venting function is active, the icon blinks.

2.2d Thermal disinfection This service feature enables the

heating of hot water at 70 °C. Heating occurs only while water is drawn. Possible settings are:

• 0: Thermal disinfection is not active

• 1. Thermal disinfection active basic setting is 0 (not active)

Thermal disinfection is not displayed ▶ set it back to 0 after thermal

disinfection service function.

2.2H Hot water system When connecting a storage tank temperature sensor to the boiler, the function must be enabled. Possible settings are:

• 0: No hot water tank connected

• 8: Hot water tank connected Default setting is 0

Service function Possible settings

Table 20 Menu 2

2.2J Storage priority Possible settings:

• 0: - Storage priority; the storage tank is heated to temperature first and then the boiler switches to heating mode

• 1: - When heat is required by the storage tank, the boiler alternates between heating and hot water every ten minutes.

Default is 0

2.3b Anti-fast cycle time for CH

This sets the amount of time between stop and starts of the main heat exchanger burner. When connecting a weathercompensated control system, no adjustment to the unit is required. The control system optimises this setting. Setting range: 3 to 45 minutes. Default setting is 10 minutes.

2.3C Anti fast cycle flow temperature hysteresis (negative tolerance only)

This sets the temperature drop before the burner re-starts, 6 K is the default. This is used in conjunction with the Anti fast cycle time. When connecting a weathercompensated control system, no adjustment to the unit is required. The control system optimises this setting. The temperature interval determines how much the flow temperature must drop below the desired flow temperature until the drop is interpreted as a demand for heat. It can be set in steps of 1 K. The temperature interval can be set from 0 to 30 K. The default setting is 6 K.

2.4F Siphon fill program The siphon fill program ensures that

the condensate siphon is filled after installation or after the boiler has been switched off. The siphon fill program is activated when:

• the power is turned on

• the burner was not in operation for at least 28 days

• when the boiler is switched from summer into winter mode at the next heat demand.

The siphon fill program remains in effect for 15 minutes at low heat output. Possible settings are:

• 1: siphon fill program with low heat output

• 0:. Siphon fill program is off (for service use only)

Default is 1 The icon blinks, when the siphon fill program is active. ▶ Set back to 1 after the

maintenance service function.

Service function Possible settings

Table 20 Menu 2

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2.5F Service reminder When this function is set on the control system, this service is not displayed. Possible settings are:

• 0: not active

• 1-72, 1 to 72 months can be set

and after the expiry of this period, the display shows the a service is required.

Default is 0

2.7b 3-way valve in the

middle position

After saving the value 1, the 3-way valve moves to the centre position. The complete emptying of the water in the system can be ensured allowing the removal of the heat exchanger. After 15 minutes, the value 0 is restored automatically. The middle position of 3-way valve is not displayed.

2.7E Screed drying

function

This function only provided heat for screed drying, the appliance does not function as a central heating boiler, no other settings are possible: 0: off 1: heating only on the device or controller setting, i.e. all other heat requirements are locked. Default is 0 As long as the screed drying function is active, the text line shows 7E

2.9F CH Pump delay time The CH pump delay time begins at the end of heat demand. Possible settings are:

• 0 to 60: Follow-up time in minutes

(1-minute increments)

• 24H: follow-up time 24 hours. Default setting is 3 minutes.

2.9L Hot water cylinder

thermal disinfection

This feature enables the storage cylinder to be heated to 70 °C. Possible settings are:

• 0: Thermal disinfection is not active

• 1: Thermal disinfection active Default setting is 0 (not active). Thermal disinfection is not displayed. The water is maintained at 70 °C for 35 minutes, to complete the thermal disinfection.

Service function Possible settings

Table 20 Menu 2

2.CE Circulation pump starts

Active only with activated circulation pump (service function 2.CL). This service feature allows you to set how often the circulation pump is running in an hour for 3 minutes. Possible settings are: 1: 3 minutes on, 57 minutes off. 2: 3 minutes on, 27 minutes off. 3: 3 minutes on, 17 minutes off.

4. 3 minutes on, 12 minutes off. 5: 3 minutes on, 9 minutes off. 6: 3 minutes on, 7 minutes off. 7: Permanently on Default setting is 2

2.CL Circulation pump This service function a connected

circulation pump is activated. Possible settings are:

• 0: not active circulation pump

• 1: Circulation pump active Default setting is 0

Service function Possible settings

Table 20 Menu 2

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38 | Servicing and spares

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10.2.5 Selecting menu 3

To display a service function in this menu: Press the button and the ok button simultaneously until in the text

line Menu 1 is displayed. Select Menu 3 with the + button. Press the button and the ok button simultaneously until in the text

line the first service function is displayed 3.xx. Press the + or - buttons to scroll the through menu area.

10.2.6 Selecting the Test menu

To display a service function in this menu: Press the button and the ok button simultaneously until in the text

line Menu 1 is displayed. Select the Test menu with the + button. Press the ok button to confirm your selection. Press the + or - buttons to scroll through the menu area.

10.2.7 Setting the boiler to maximum output

4. Press the / button together with the button to enter the “Chimney sweep mode”, the display shows the current flow temperature and flashes the percentage heat output in the alphanumeric display. The burner symbol will be shown in the display. Press the + or - buttons until the required percentage output is displayed. Set the output to 100% initially.

Fig. 49 Operating the boiler

5. If the boiler fails to light, press the reset button until the reset line of text displays. The device goes back into operation and the flow temperature is displayed.

6. Press the button at any time to return to normal operation.

10.3 Flue integrity

The integrity of the flue system and performance of the boiler can be checked via the flue turret sample points.

Fig. 50 Flue turret

[1] Flue gas sample point [2] Air inlet sample point

With the boiler case on and the boiler running at maximum output (refer to section “Setting the boiler to maximum”).

▶ Insert the analyser probe into the air intake sample point [2]. ▶ Ensure that the probe reaches the centre of the air intake, adjust the

cone on the probe so that it seals the sample point and correctly positions the end of the probe.

▶ Allow the readings to stabilise and check that:

–O

is equal to, or greater than 20.6%.

Service function Possible settings

3.1A Upper limit of maximum heating power for 2.1A

This service feature allows the service technician, the setting for the maximum heat output (service function 2.1A) limit. Default setting is the maximum rated output.

3.1b Upper limit of the maximum power (hot water) for 2.1b

This service feature allows the service technician the setting for the maximum heating (hot water, service function 2.1b) limit. Default setting is the maximum heat output hot water.

3.2b Upper limit of the flow temperature

The maximum flow temperature can be adjusted between 30 °C and 82 °C. It limits the setting at the operating level Default:. 82 °C

3.3b Minimum nominal heat output (heating and hot water)

The heating and hot water output can be set as a percentage to any value between the minimum and maximum rated output. Default setting is the minimum nominal heat output (heating and hot water), it is depending on the device.

Table 21 Menu 3

Service functions Possible settings

t01 Igniter test

Checking the igniter spark

The igniter will spark without gas supply for a maximum of 2 minutes, otherwise the ignition transformer will be damaged. The spark will be audible if the igniter is OK. Possible settings are: 0 = off 1 = on - default is 0

t02 Fan test

Checking the fan operation

The fan will run without gas supply or ignition. Possible settings are: 0 = off 1 = on - default is 0

Table 22 Test menu

t03 Pump test.

Checking the pump operation.

(internal and external pumps)

The pump will run for a maximum of 45 seconds. If the pump is OK then the pump will be heard running. Possible settings are: 0 = pump off 1 = pump on - default is 0

t04 Checking the internal

3-way diverter valve

Possible settings are: 0 = off 1 = on - DHW - default is 0

The boiler will run at maximum output for 30 minutes before switching back to normal operation.

Service functions Possible settings

Table 22 Test menu

6 720 619 605-16.1O

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Servicing and spares | 39

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– CO2 is less than 0.2%

▶ If the readings are outside these limits then this indicates that there

is a problem with the flue system or combustion circuit, e.g. missing or dislodged seals

Fig. 51 Flue integrity test

10.4 Service inspection - Component access

Remove the boiler front panel to gain access to components. ▶ Pull the top corners of the front panel away from the case until the

ball catches are released. ▶ Lift the panel off the two lower brackets and set the panel aside. ▶ Lower the control panel into the service position. ▶ Remove the four screws securing the combustion chamber cover and

remove to gain access to the components.

Fig. 52 Component access

10.4.1 Control panel - Service position

To lower the control panel into the service position, remove one top screw [1] from each side of the mounting bracket, loosen the bottom screws slightly and pivot the panel forward. The control panel is supported at approximately 100 °.

Fig. 53 Control panel to the service position

10.5 CHECKING THE GAS INLET PRESSURE

▶ Refer to section 7.5 and check that the gas working pressures in the

system conform to within the figures shown below:

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NOTICE: Gas inlet pressure ▶ Ensure that the gas pressure is satisfactory with all

other gas appliances working.

▶ Do not continue with the other checks if the correct

gas pressure can not be achieved.

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10.6 Fan pressure test

▶ Remove the bung from the fan pressure test point

Fig. 54 Fan pressure test point and cover

▶ Connect a manometer to the fan pressure test point, (1). ▶ Set the boiler to maximum output. ▶ After measurement replace test point cover.

Fig. 55 Fan control pressure test

With the combustion air intake pipe fitted and the boiler running at maximum output, measure the fan pressure:

▶ The pressure will read negative, refer to the chart in figure 56 below.

Fig. 56 Fan control pressure readings

▶ If the manometer reading is in the white area of the chart the heat

exchanger/exhaust path/trap does not require attention.

▶ If the manometer reading is in the black area of the chart then carry

out the following checks: – Check that the condensate trap is not blocked. – Check the exhaust paths for restrictions. – Clean the heat exchanger with a suitable cleaning tool, refer to

section 10.9 - Cleaning the heat exchanger ▶ Re-check the fan pressure readings. If the boiler, after completing the above checks, fails the fan pressure

test then contact your technical help-line for advice. ▶ After the measurements are taken switch the boiler off.

▶ Remove the combustion air intake pipe. ▶ Disconnect the manometer and replace the test point cover. ▶ Replace the combustion air intake pipe.

10.7 Flue gas analysis

Combustion test

▶ Connect the flue gas analyser to the flue gas sampling point (1) as

shown in the figure below.

▶ Ensure that the probe reaches the centre of the flue gas exhaust,

adjust the cone on the probe so that it seals the sample point and correctly positions the end of the probe.

Fig. 57 Flue turret

[1] Flue gas sample point [2] Air inlet sample point

Gas type

minimum pressure

(mbar)

maximum pressure

(mbar)

G20 17 25 G25 22 30 G31 25 45

NOTICE: Fan pressure test ▶ The boiler must be run at maximum output for the

fan pressure test.

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NOTICE: Combustion testing ▶ Combustion testing must be carried out by a

competent person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated Combustion Analyser conforming to BS 7927 and is competent in its use.

NOTICE: Gas inlet pressure ▶ Ensure that the gas inlet pressure has been checked

and is satisfactory, refer to section 7.5

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FAN PRESSURE TEST

Clean the Heat Ex.

Heat Ex. ok

-6

-5

-4

-3

-2-1

-8

-7

mbar

NG Boilers

42kW:

30kW:

16kW:

- 4.8

- 5.3

- 5.2

-6

-5

-4

-3

-2-1

-8

-7

mbar

LPG Boilers

42kW:

30kW:

16kW:

- 5.3

- 5.6

- 4.7

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▶ Press the / button together with the button to enter the

“Chimney sweep mode” , the display shows the current flow temperature and flashes the percentage heat output in the alphanumeric display. The burner symbol will be shown in the display. Press the + or - buttons until the required percentage output is displayed. Set the output to 100% initially. – The boiler will ramp up to maximum output in approximately

30 to 35 seconds. ▶ Run the boiler at maximum output for at least 10 minutes. ▶ Check the CO/CO

readings against the information in table 23.

Fig. 58

▶ Check CO is less than 200ppm. ▶ Set the boiler to minimum power.

– The boiler will take 30 to 35 seconds to ramp down to minimum

output.

– Allow the boiler to stabilise at minimum output.

▶ Check the CO/CO

readings against the information in table 23. ▶ Check that the CO is less than 200ppm. ▶ Return the boiler to maximum and re-check the CO/CO

– The boiler will take approximately 30 to 35 seconds to ramp up to

maximum output.

– Allow the boiler to stabilise at maximum output.

▶ If correct, press the button and the boiler will return to normal

operation.

▶ Re-assemble and refit boiler case.

10.8 Setting the air/gas ratio

If the CO2 maximum or minimum value are incorrect, the gas valve can be adjusted as follows: ▶ Set the boiler to maximum output

▶ Remove the plastic dust cover [1] ▶ Using a flat blade screwdriver adjust the maximum CO

setting [2] with reference to table 23, turn clockwise to reduce or anti-clockwise to increase the setting.

▶ Set the boiler to minimum output ▶ Measure the CO

value, it should be at the figure for minimum output

shown in table 23

▶ It not, remove the brass dust cap [3] from the minimum adjuster ▶ Using a 4mm Allen key to adjust the minimum setting [4] on the gas

valve until it is correct, turn clockwise to increase and anti-clockwise to decrease the setting

▶ Return the boiler to maximum output and check the CO

value ▶ If this is correct, then return the boiler to normal operation ▶ Remove the manometer from the flue gas sample point ▶ Replace the flue gas sample point cap ▶ Replace the brass dust [3] cover on the minimum adjuster [4] ▶ Fit a new plastic dust cover [1] on the maximum adjuster [2]

Fig. 59 CO

adjustment

[1] Maximum adjuster plastic dust cover [2] Maximum adjustment [3] Minimum adjuster brass dust cover [4] Minimum adjustment

If the CO

is still out of tolerance then please check the: ▶ gas inlet pressure ▶ gas rate ▶ fan pressure ▶ flue and air intake, plus any blockages in the condensate disposal

NOTICE: Minimum CO

▶ The minimum CO2 reading must be at least 0.1 lower

that the maximum CO

reading.

GAS TYPE

CO2 max % setting CO2 min % setting

G20 Natural Gas (42kW) 9.5 (+0.4/ -0.0) 9.4 (+0.4/ -0.0) G20 Natural Gas (16 & 32kW) 9.4 (+0.4/ -0.0) 8.6 (+0.4/ -0.0) G25 Natural gas (42kW) 7.6 (+0.4/ -0.0) 7.5 (+0.4/ -0.0) G25 Natural Gas (16 & 32kW) 7.5 (+0.4/ -0.0) 6.9 (+0.4/ -0.0) G31 LPG (42kW) 10.9 (+0.4/ -0.0) 10.8 (+0.4/ -0.0) G31 LPG (16 & 32kW) 10.8 (+0.4/ -0.0) 10.5 (+0.4/ -0.0) CO - less than 200 ppm (0.002 ratio)

Table 23 CO/CO

settings

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The control will return to normal operation after 30 minutes or press the button.

The CO2 should be measured 10 minutes after setting the boiler to maximum

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▶ gas way for leaks or obstructions ▶ the condition of burner, After all checks have been and the CO

is still out of tolerance then the

gas valve must be replaced.

10.9 Cleaning the heat exchanger

If the Heat Exchanger requires cleaning:

An accessory kit is available (No. 840) specifically designed for cleaning the heat exchanger. If required order 7 719 001 996.

1. Remove the cleaning access cover [1], seal [2] and metal plate [3] securing it, if present.

2. Unscrew the condensation trap cap and place a suitable container underneath.

3. Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade [4].

▶ Clean the heat exchanger from top to bottom using the brush [5]. ▶ Refit the “cleaning” access cover in reverse order using a new seal

[2], hand tighten screws and then use a spanner to tighten a further half turn.

▶ After re-assembly check that the CO/CO

levels are as described in

the section “Setting the air/gas ratio”.

Fig. 60 Cleaning the heat exchanger

[1] Inspection cover [2] Inspection cover seal [3] Back plate (if fitted) [4] Cleaning blade [5] Cleaning brush

To clean the burner

▶ Check that the boiler is completely isolated from the gas supply.

1. Remove the clips [1], castellated nuts [2] and springs [3] from the studs.

▶ Unscrew and remove the two hexagon headed nuts [4] securing the

fan.

▶ Remove the nut [5] from the rear stud [6].

Remove the burner head [7].

2. Remove the burner and clean the components.

Do not use a wire brush.

Fig. 61

[1] Clips [2] Castellated nuts [3] Washers/Springs [4] Hex head nuts [5] Rear nut [6] Spacer

Re-assembly of the burner cover

▶ Re-assemble the burner in reverse order using a new seal [8]. ▶ Insert the burner cover under the rear securing bolt and tighten

down.

▶ Assemble the washers/ spring [3], and castellated nut [2], refer to

figure 62, on to the studs [11] to secure the burner cover to the heat exchanger.

▶ Using a 10mm spanner, tighten the castellated nuts [2] until the

burner cover bottoms out on the heat exchanger.

▶ The nuts will stop turning at this point, do not overtighten. ▶ If necessary, back the nuts off slightly until the hole for the clip [1] is

visible.

▶ Insert the clips [1] and secure. ▶ After re-assembly check that the CO/CO

levels are as described in

the section “Setting the air/gas ratio”.

WARNING: Cleaning access cover ▶ Do not remove the cover unless a new gasket is

available for re-assembly.

NOTICE: After completing the appliance service the CO/CO

must be checked and set to the limits in the

section “AIR/GAS RATIO”.

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WARNING: Burner ▶ Do not remove the burner unless a new gasket is

available for re-assembly.

NOTICE: Burner gasket seal ▶ Always replace the burner seal with a new one when

the joint has been disturbed.

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Fig. 62 Burner removal

[1] Clip [2] Castellated nuts [3] Washers/Springs [5] Rear nut [6] Spacer and washer [7] Burner head [8] Seal [9] Rear stud [10] Burner [11] Front studs

For sealed systems only:

Electrical wiring

▶ Check the electrical wiring for physical damage and replace any

damaged wires.

To check the flap valve in the fan intake

▶ Refer to page 48 for access to the fan intake. ▶ Carefully withdraw the flap valve from fan intake tube and check for

soiling and splits, clean or replace as required.

▶ Take care when refitting the flap valve, the flaps must open upwards

into the fan in take tube.

▶ After re-assembly check CO/CO

levels as described in the section

“Setting the air/gas ratio”.

To clean the condensate trap

Refer to figure 70 on page 49 to remove the trap ▶ Remove the condensate pipe [1]

▶ Remove the screw retaining the trap [2] ▶ Pull the trap down to remove from the boiler ▶ Remove the bottom cap [3] and empty the condensate and flush out

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10.10 Inspection and servicing checklist

The inspection and maintenance records also serve as a master copy. ▶ Sign and date the completed inspection record.

Inspection and servicing Page Full load Partial load Full load Partial load

1 Visual and functional check of the heating system

 

2 Check gas and water bearing components for:

- Leaks

 

- Visible corrosion

 

- Deterioration or damage

 

3 Check the system water pressure

 

Check the expansion vessel pressure Check the operating pressure

4 Isolate the boiler and check:

- the burner and heat exchanger for contamination 5 - condensate trap 6 - ignition system 7 Check the gas supply 8 Check the flue intake and exhaust, and connections

 

9 Record readings:

- Flue gas pressure

- Flue gas temperature (gross) t

- Air temperature t

- Flue gas temperature (net) tA - t

- CO2 or O2 content

- Flue gas losses q

- CO content (air free) 10 Carry out functional test

- Check and record ionisation current 11 Check for water leaks during operation c



12 Check the controller settings (refer to controller manual)

 

13 Final checks

 

Confirm correct inspection

Company stamp / date / signature

Table 24 Inspection and service checklist

Page 45

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6 720 ... ... (YYYY/MM)Product Name

If the inspection, a state is detected, the maintenance requires, these operations must be carried out as required.

Full Load Partial load Full load Partial load Full load Partial load Full load Partial load

  

        

 

4 5 6 7 8

 

Table 25 Inspection and Service checklist continued

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Product Name6 720 ... ... (YYYY/MM)

10.11 Demand dependant maintenance

Page Date Date

1 Turn off heating system

 

2 Clean burner and heat exchanger

 

3 Replace burner gasket

 

4 Replace electrode set



5 Clean condensate trap/siphon

 

6 Functional check

 

Confirm correct inspection

Company stamp / date / signature

Table 26

Date Date Date Date

 

Confirm correct inspection

Company stamp / date / signature

Table 27 Demand dependent maintenance

Page 47

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11 REPLACEMENT PARTS

11.1 Replacement parts

Draining the appliance:

▶ Turn off the system heating flow and return stop cocks - external to

boiler.

▶ Using a suitable hose, attach one end to the drain tap on the boiler

return elbow and lead the other end of the hose to an external drain

point. ▶ Fully open the drain tap on the boiler return elbow. ▶ Close the drain tap when the flow from the appliance has stopped

and remove the hose.

11.1.1 Access to components

Remove the boiler front panel to gain access to components. ▶ Pull the top corners of the front panel away from the case until the

ball catches are released. ▶ Lift the panel off the two lower brackets and set the panel safely

aside. ▶ Lower the control panel into the service position. ▶ Remove the four bolts securing the combustion chamber cover and

remove to gain access to the components.

Fig. 63 Component access

Control panel access

To lower the control panel into the service position, remove top screw [1] from each side of the mounting bracket, loosen the bottom screws slightly and pivot the panel forward. The control panel will be supported at approximately 100 ° by the mounting bracket.

Fig. 64 Control panel to the service position

CAUTION: Mains supplies ▶ Turn off the gas supply and isolate the mains

electrical supply before starting any work and observer all relevant safety precautions.

▶ Drain the boiler/system where necessary and protect

any electrical equipment from water ingress during component replacement.

NOTICE: Gaskets ▶ Refit or replace any components removed from the

appliance in the reverse order using new gaskets/'O' rings/sealant/heat transfer paste where necessary.

▶ Any 'O' ring or gasket that appears damaged must be

replaced. Always check that any electrical connections are correctly made and that all screws are tight.

NOTICE: REPLACEMENT OF COMPONENTS ▶ ALWAYS CHECK FOR GAS TIGHTNESS WHERE

RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS DESCRIBED IN THE COMMISSIONING SECTION

NOTICE: Service

▶ Any service work must be carried out by a competent

registered engineer.

▶ After re-assembly the combustion must be checked

using the procedure in the section “Setting the air/ gas ratio”. Measurement and setting of the gas ratio must not be attempted unless the person is equipped with a calibrated combustion analyser and is competent in its use.

A small quantity of water may remain in some components even after the appliance has been drained. Protect any electrical components when removing items from the water circuits.

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Fuse

▶ Release the three screws [1] securing the installer cover. ▶ The spare fuse [2] is located in the inside of the right hand corner of

the cover.

▶ The fuse holder [3] is located at the top left hand corner of the

terminal block.

Fig. 65

PCB access

▶ Unclip the covers [1] and [2]. ▶ Disconnect all electrical connections from the control. ▶ Remove the screws [3] retaining the rear panel of the control and

remove the panel.

▶ After re-assembly check that the CO/CO

levels are as described in

the section “Setting the air/gas ratio”.

Fig. 66

11.1.2 Fan assembly

Refer to figure 67 On all models, except the 16kW versions, the air intake pipes will have to

be removed: ▶ Remove the air intake pipes from the mixing chamber, pull down to

disengage and remove.

▶ Undo lower pipe union on gas pipe [1]. ▶ Push the pipe [6] up into the mixer assembly [5] until the pipe clears

the valve connection.

▶ Pull the pipe [6] towards you, away from the gas valve and slide the

pipe out of the mixer unit.

▶ Remove fan lead and earth connector.

The earth connector has a positive clip fixing.

▶ Remove fixing screws [2] attaching fan to the burner cover [3]. ▶ Remove fan [4] and mixer unit [5]. ▶ Twist mixer unit [5] to separate from the fan (assembly [4]. ▶ After re-assembly check that the CO/CO

levels are as described in

the section “Setting the air/gas ratio”.

Fig. 67 Fan removal - 42kW version shown

Flap Valve:

Refer to figure 68 On all models, except the 16kW versions, the air intake pipes will have to be removed: ▶ Remove the air intake pipes from the mixing chamber, pull down to

disengage and remove. ▶ Undo the lower pipe union on the gas pipe [1]. ▶ Push the pipe [6] up into the mixer assembly [5] until the pipe clears

the valve connection. ▶ Pull the pipe [6] towards you, away from the gas valve and slide the

pipe out of the mixer unit. ▶ Twist mixer unit [5] to separate from the fan assembly[4]. ▶ Remove flap valve [7] from within fan assembly [4] and replace.

▶ After re-assembly check that the CO/CO

levels are as described in

the section “Setting the air/gas ratio”.

Fig. 68 Flap valve removal

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Ensure the flap valve is fitted correctly with rubber flap upwards.

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11.1.3 Sensors

▶ Check that the appliance is electrically isolated.

Flow temperature sensor [1]:

▶ Remove the connector. ▶ Release the sensor clip and withdraw the sensor. ▶ Apply heat transfer paste to the replacement sensor.

Safety temperature limiter [2]:

▶ Remove the connectors. ▶ Unscrew the sensor.

Flue Temperature limiter [3]:

▶ Remove the connector. ▶ Using a small terminal screwdriver, prise the sensor and grommet

from the plastic housing. Take care not to damage the plastic housing.

Fig. 69 Sensors

11.1.4 To remove the condensate trap

▶ Release the hose clamp [1] ▶ Remove the screw retaining the trap [2] ▶ Pull the trap down to remove the trap from boiler ▶ Remove the end cap [3] and empty the condensate into a suitable

container

Fig. 70 Condensate trap

11.1.5 Gas Valve

▶ Check that the gas cock is turned off.

▶ Remove the air intake pipes, if fitted, pull down from the mixer

assembly to remove. ▶ Undo the union on top of the gas valve [1], within the inner casing. ▶ Push the pipe up into the mixer assembly until the pipe clears the

valve connection. ▶ Pull the pipe towards you, away from the gas valve and slide the pipe

out of the mixer unit. ▶ Remove the solenoid connections [2] at the side of the gas valve. ▶ Remove the two screws [3] securing the gas valve to the chassis ▶ Release the gas inlet union [4] at the valve inlet under the inner

casing. ▶ Remove the gas valve. ▶ Transfer the inlet pipe assembly to the new gas valve. ▶ Insert the end of the gas pipe into the mixer unit. ▶ Ensure that the bonded washer is in good condition, replace if

necessary, and fit between the gas valve and gas union. ▶ Locate the bottom of the gas valve onto the gas inlet union [4] and

hand tighten. ▶ Refit the screws the screws [3], removed earlier, to secure the gas

valve to the chassis. ▶ Tighten the gas union with the appropriately sized spanner ▶ Refit the air intake pipes, if required, push up into the mixer unit. ▶ Reconnect the solenoid plug onto the side of the gas valve. ▶ Check for gas tightness when the new gas valve has been fitted. ▶ Re-check the combustion performance. ▶ After re-assembly check the CO/CO

levels are as described in the

section “Setting the air/gas ratio”.

Fig. 71 Gas valve

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11.1.6 Primary Heat Exchanger Electrode assembly:

▶ Switch off the master switch. ▶ Isolate the appliance from the power supply. ▶ Move the control panel into the service position, refer to

section 10.4.1. ▶ Release the four screws to remove the inner case door. ▶ Remove the leads from the electrodes. ▶ Unscrew the two fixing screws [2] and remove the electrode

assembly [1], that includes the gasket [3] and heatshield [4]. ▶ Replace and re-connect the assembly taking care not to mislay the

inspection window. ▶ After re-assembly check that the CO/CO

levels as described in the

section “Setting the air/gas ratio”.

Burner:

▶ Check that the gas cock is turned off and the master switch is in the

OFF position. ▶ Isolate the appliance from the power supply. ▶ Remove the clips, castellated nuts and springs [5] from the studs

[6]. ▶ Unscrew and remove the two hexagon screws [7] securing the fan. ▶ Remove nut and washer [8] from the rear stud [9]. ▶ Remove the burner cover plate [10]. ▶ Remove the burner [11]. ▶ Re-assemble the new burner in reverse order. ▶ Replace the burner seal [12] with a new one. ▶ Refer to the section “Re - assembly of the burner cover” on page 42. ▶ After re-assembly check that the CO/CO

levels as described in the

section “Setting the air/gas ratio”

Primary heat exchanger:

▶ Isolate the appliance from the power supply. ▶ Turn off all the isolation valves. ▶ Drain down the appliance. ▶ Move the control panel into the service position, refer to

section 10.4.1. ▶ Remove the inner case door. ▶ Remove the fan assembly, gas mixing tube, refer to section 11.1.2. ▶ Disconnect and remove the sensors connected to heat exchanger,

refer to section 11.1.3. ▶ Remove the condensate trap, refer to section 11.1.4. ▶ Remove the internal flue elbow [13] and tube from the boiler sump. ▶ Disconnect the return pipe union clip [14] at the base of the boiler

heat exchanger and disconnect the pipe. ▶ Remove the plastic nut [15] from the base of the inner casing. ▶ Disconnect the flow pipe [16] at the union on the heat exchanger. ▶ Remove the heat exchanger from the inner casing. ▶ Ensure that heat conductive paste is used on the sensors when

refitting. ▶ Check the seals and replace if necessary. ▶ After re-assembly check that the CO/CO

levels are as described in

the section “Setting the air/gas ratio”.

Fig. 72 Primary heat exchanger

Fig. 73 Primary heat exchanger removal

WARNING: Burner ▶ Do not remove the burner unless a new gasket is

available for re-assembly.

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6720809859-41.1Wo

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12 FAULT FINDING AND DIAGNOSTICS

12.1 Status codes and faults

The controller monitors all safety, regulation and control components.

Each operating state of the device is supported by a unique status code,

each fault by a fault code.

Detailed troubleshooting is possible using the following tables.

The operation and fault displays are shown as follows:

• Status codes, these show operating states during normal operation – Status codes can be read during operation using the info menu

(service function i01)

• Blocking faults cause a temporary shutdown of the appliance. The appliance restarts as soon as the blocking fault has been removed or rectified. – Display of blocking faults are with error code and status code

appears on the screen.

• Locking faults are system errors which cause the appliance to shutdown. The appliance will only restart after a manual intervention or a reset. – Locking errors are with error codes and status code flash on the

display.

Fig. 74

[1] Alphanumeric fault code [2] Service menu function [3] Status/cause code

12.2 Troubleshooting

12.3 INFORMATION AND SERVICE MENUS

STATUS CODES

During normal boiler operation various Status codes can be displayed by pressing the button.

The first screen of the Information menu displays the current Status code, this will change as the boiler runs through the various modes and sequences. These are not always faults, but just provide information concerning the current status of the boiler.

DANGER: Explosion! ▶ Turn the gas supply off before working on gas related

components.

▶ After replacing gas components, seals and gaskets

check for gas tightness using a gas sniffer/analyser.

DANGER: Poisoning! ▶ Check for gas tightness using a gas sniffer/analyser

on gas and flue components.

DANGER: Electric shock! ▶ Before working on the electrical components

disconnect the electrical mains (230 V ac) and secure against unintentional re-connection.

2 3

6 720 619 605-33.1O

WARNING: Scalding! Hot water can cause serious burns.

▶ Drain the appliance before working on water-

carrying parts.

NOTICE: Water leaks Water can damage the controller.

▶ Protect from water leaks by covering the controller.

Status codes

Fault codes

200 CH System is being heated 201 DHW system is being heated 202 Anti rapid cycle mode 203 System stand by 204 System waiting, primary flow temperature above

setpoint 205 Waiting for airflow 207 CE System pressure too low 208 Test mode active due chimney switch 210 E9 Flue-gas thermostat activated 211 TTB opened (thermal kickback device) 212 Safety or flow temperature rises too fast 213 D4 Temperature difference between supply and return

exceeding limit 214 C7 Fan not running 215 C6 Fan running too fast 216 C6 Fan running too slow 217 C7 No airflow after defined period of time 218 E5 Flow temperature too high 219 E9 Safety sensor temperature too high 220 E9 Safety sensor shorted 221 E9 Safety sensor disconnected 222 E2 Flow sensor shorted 223 E2 Flow sensor disconnected 224 E9 MAX thermostat activated 225 Difference between flow and safety exceeding limit

(bi-sensor only) 227 EA No ionisation detected after ignition 228 F7 Ionisation current detected before burner-start 229 EA Loss of ionisation signal during operation 230 EA Ionisation signal out of bounds 231 FD Mains power error - electrical power interruption 232 D3 external cut-off switch activated 233 9U HCM problem 234 EA Gas valve coil disconnected 237 C4 Airflow present during last 24 hours - fan running

continuously 238 F0 Gas valve error

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52 | FAULT FINDING AND DIAGNOSTICS

Product Name6 720 ... ... (YYYY/MM)

239 F0 Watchdog relay error 240 D1 Return sensor shorted 241 D1 Return sensor disconnected 242 to

256

F0 Internal error call Bosch technical help-line

257 b7 Internal error - replace control board 258 &

259

F0 Internal error call Bosch technical help-line

260 No temperature rise after burner start 261 EA First Safety timing error 262 &

263

F0 Internal error call Bosch technical help-line

264 C1 Airflow stopped during operation 265 Stand-by mode forced due to energy transfer limit 266 CE No pressure variation detected after switching pump 267 F0 Watchdog time out error 268 Component test mode 269 EA Ignition device activated too long 270 Power up mode 271 D4 Temperature difference between flow and safety

sensor exceeding limit 272 F0 Internal error 273 C4 Airflow present during last 24 hours 274 Ionisation signal present during last 24 hours 276 E9 Flow temperature exceeded 95° 277 E9 Safety sensor temperature exceeded 95° 278 F0 Sensor test failed 279 F0 AD converter error, unstable measurement 280 F0 Recycle timing error 281 A1 Pump stuck or running in air 282 H5 No feedback from pump 283 Burner starting 284 Gas valve(s) opened, first safety time started 285 E9 Return temperature exceeded 95°C 286 D1 Return temperature too high 287 F0 Ionisation sensor shorted 288 CF Water pressure sensor not connected or short-circuit

to supply 289 CF Water pressure sensor not connected or short-circuit

to ground 290 F0 AD converter reference error 305 Anti fast cycle mode 306 FA Ionisation detected after burner stop 307 Pump stuck 308 Pump running in air 309 CH & DHW system are being heated 310 CUS communication error 311 CUS locked 312 CUS blocked 313 CUS reported error condition 314 Mains disconnected during super lockout 315 Several times lack of water flow 316 E9 Flue gas sensor temperature too high 317 A3 Flue gas sensor shorted 318 E9 Flue gas sensor disconnected

Status codes

Fault codes

321 Self-test of flue gas supervision 322 Code error 323 A8 EMS communication error 324 DHW-NTC defect 325 DHW-NTC not correctly installed 326 Storage-NTC defect 327 Reset-key stuck or short-circuit 328 Internal error 329 CE No pressure variation detected after switching pump 332 E5 Supply sensor exceeded 110°C 333 Start temporarily not allowed due to flow error on CH 338 F0 Too many short burner starts without confirmation of

water flow 341 D4 CH: supply and/or return temperatures rising too fast 342 D4 HW: supply temperature rising too fast 343 ED CH: flue gas temperature rising but supply

temperature not 344 ED HW: flue gas temperature rising but supply

temperature not 345 EF Supply and/or return temperatures do not change

after burner start 346 EC Flue gas temperature rising too fast 347 E3 Return temperature higher than supply temperature

(some time after burner start) 348 EE HW: supply temperature too hot 349 EF CH: Boil Detect, large delta T despite minimum

burner load 350 E2 Flow sensor shorted 351 'E2' Flow sensor

disconnected 353 -- Burn temporarily blocked due to no 20 minute

continuous OFF time in last 24 hours. 354 Overpressure setting erased 357 Primary Heat Exchanger air venting program active -

approximately 100 seconds 358 Three way valve kick 359 DHW outlet temperature too hot 364 FA Gas valve EV2 leak test failed 365 Fb Gas valve EV1 leak test failed 372 Temporarily ignoring CH requests to limit

temperatures of the appliance components 373 8C SuperLock caused by too frequent thermostat

overheat detections during burning 374 8C SuperLock caused by too frequent ionisation loss

during burning 375 E4 Preheat sensor on DHW inlet Short Circuit 376 E4 Preheat sensor on DHW Inlet Open Circuit 380 Inlet temperature greater than DHW Outlet Set point 800 CC Outdoor sensor defect 808 A7 Domestic hot water sensor defect 810 Domestic hot water remains cold 828 Water pressure sensor defect

Status codes

Fault codes

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12.3.1 Selecting the information menu

The Information Menu is a "read only" menu. Information about the boiler is displayed here, some of the values are updated in real time to give the current status of the boiler.

All menus time-out after two minutes and the display returns to the normal operation display, the display backlight turns off after another 30 seconds.

Double up or down arrows indicate that the menu can only be scrolled up or down, an up and down arrow combination indicates position in the menu where options can be scrolled either up or down.

To enter Information menu:

1. Press the button to enter the information menu. ▶ A three figure boiler status code will be displayed along side the

information menu number. Refer to status code table on page 51 for a description of the boiler status codes.

2. Use the plus and minus buttons to scroll through the menu items. ▶ Press the button again to exit the Information menu.

Fig. 75 Accessing the Information menu

Service functions Comments

i1 Current operating

state

Every operation and mode of the boiler has a related boiler status code. The boiler status code is displayed on the screen as a three figure number. Refer to Status code table on page 51

i2 Operating code for

the last error

This can be viewed during normal operation. Displays the last diagnostic code with boiler status code.

i3 Maximum shared

heating

Setting of service function 2.1A

i4 Maximum shared

power (Hot water)

Setting of service function 2.1b

i7 Flow temperature The actual control system supply

temperature required

Table 28 Information menu

6720809859-53.1Wo

°C

°F

i 1 203

°C

°F

Info

i8 Ionisation current When the burner is running:

• 2 micro Amp = OK

• < 2 micro Amp = faulty With burner off:

• < 2 micro Amp = OK

• 2 micro Amp = faulty

i9 Temperature at

temperature flow sensor

This is the actual temperature from the main heat exchanger displayed in real

time. i12 DHW temperature The hot water set temperature i13 Temp. at the storage

tank temp. sensor

only with attached hot water tank

i15 Current outside

temperature

Only displayed when an external

temperature sensor system is connected. i16 Actual system pump

modulation

Display in % of pump modulation (system

boiler only) i17 Current heating Display in % of maximum rated heat output

in heating mode

i18 Current fan speed Display in revolutions per second (Hz) i20 Software version

circuit board 1

Firmware version of the main control

board. i21 Software version

circuit board 2

Firmware version of the fascia control

display board i22 Code plug number The last three digits of the code plug

(HCM) are displayed i23 HCM version Version of the code plug (HCM) is

displayed

1) During the water heating, values greater that 100% are displayed in menu 1

Service functions Comments

Table 28 Information menu

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12.3.2 Selecting service menus

1. Press and hold and ok buttons together for one second, the display will show Menu 1.

Double up or down arrows indicate that the menu can only be scrolled up or down, an up and down arrow combination indicates position in the menu where options can be scrolled either up or down.

2. Scroll up and down through the menus with the plus and minus buttons on the right hand side of display.

Fig. 76 Service menu selection

12.3.3 Selecting menu 1

To display a service function in this menu: ▶ Press the button and the ok button simultaneously until in the

text line Menu 1 is displayed.

▶ Press the ok button to confirm your selection. ▶ Press the + or - buttons to scroll through the menu area.

12.3.4 Menu 2 - Boiler parameters

1. Select Menu 2 via the plus and minus buttons.

2. Press and hold the ok button for one second to enter Menu 2. This menu lists the boiler parameters, which can be adjusted in this

menu. To modify setting, select the desired menu option (refer to table 30) and

press the ok button, the option will flash. Adjust the parameter using the plus and minus arrow buttons and press

the ok button to confirm. A will display for three seconds to confirm the

update of the new value. If the setting is confirmed please record the saved value in the empty box

next to the relevant setting in Table 30. The same process is used for adjusting all Menus 1, 2, 3 and Test.

Fig. 77 Menu 2 selection

6720809859-54.1Wo

°C

°F

Menu 1

°C

°F

Menu 1

°C

°F

Menu 2

°C

°F

Menu 3

°C

°F

Test

°C

°F

Eco

Service function Possible settings

1.W1 Weather compensation 0 = off, 1 = on

1.W2 Weather compensation, point A @ -10 °C °C (default 90 °C)

1.W3 Weather compensation, point B @ 20 °C °C (default 20 °C)

1.W4 Weather compensation, Automatic

Winter/Summer switch point

°C (default 16 °C)

1.W5 System frost protection 0 = off, 1 = on

1.W6 System frost protection temperature °C (default 5 °C)

1.7d Open shunt sensor input 0 = None, 1 = at the boiler, 2 = at the module

Table 29 Menu 1

6720809859-55.1Wo

°C

°F

°C

°F

Menu 2

2.2C

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12.3.5 Reset to factory settings

To reset any or all changes made in menu 2 back to the factory defaults setting:

1. Press and hold the , ok and plus button for at lest five seconds. The screen will then display code 8E with the spanner symbol.

2. Press the reset button and “Reset” will be displayed with the tick symbol for three seconds. After three seconds the screen will revert to the normal operation screen.

Fig. 78 Reset sequence

12.3.6 Menu 3 - Boiler maximum & minimum limits

The menu shows the boiler's minimum and maximum limits. Which can be adjusted in this menu.

The boiler will revert to adjusted settings in Menu 3 following a power interruption.

Menu 3 cannot be factory re-set.

1. Select menu 3 via the plus and minus scroll buttons.

2. Press and hold the ok button for at least 5 seconds to enter Menu 3.

To modify setting, select desired menu option (refer to table 31) via the plus and minus buttons and press the OK button, the option will flash.

Adjust the parameters using the plus and minus buttons and press the ok button to confirm.

A symbol will be displayed for three seconds to confirm the update of the new value.

Para No.

Parameter Description Updated

value

2.1A Maximum power CHRange rate the CH of the boiler. Adjustment in kW.

2.1b Maximum DHW

performance

The heat output can be limited to between the minimum rated output and maximum rated output for specific heating requirements.

Default setting is the maximum DHW output. ▶ Adjust the heat output in

kW.

▶ Compare the gas flow rate

with the data table 5 & 8. In case of any deviations, correct the setting.

2.1C Pump head

selection

The pump speed and modulation behaviour is controlled by this setting to always modulate based on the burner power.

0: Pump modulates depending on burner power

Setting fixed to always be 0

2.1E Pump energy

saving mode

4 = mode ON, 5 = mode OFF

2.2C Air purge mode This feature can be selected to purge the system and boiler of air. 0 = off, 1 = auto, 2 = on

2.3B Anti fast cycle time

for CH

This sets the amount of time between stop and starts of the main heat exchanger. The default is 10 minutes, the range is 3 to 45 minutes.

2.3C Anti fast cycle flow

temperature hysteresis (negative tolerance only)

This sets the temperature drop before the burner re-starts, 6 K is the default. This is used in conjunction with the “Anti fast cycle time” The range is from 2 to 15K in 1K steps.

2.5F Service reminder

time

Between 1 and 72 months can be set

2.9F Pump post purge

time for CH

The default pump overrun time is 3 minutes. This can set between 3 and 30 minutes. The actual time will be affected by the Pump Energy Saving mode.

2.9L Hot water cylinder

thermal disinfection

This feature enables the storage cylinder to be heated to 70 °C. Possible settings are:

• 0: Thermal disinfection is

not active

• 1: Thermal disinfection

active Default setting is 0 (not active). Thermal disinfection is not displayed. The water is maintained at 75 °C for 35 minutes, to complete the thermal disinfection.

Table 30 Menu 2 parameters

NOTICE: Menu 3 ▶ Any changes made in Menu 3 are not reset via these

actions.

°C

Eco

°C

°F

°C

°F

Reset

°C

°F

Eco

reset

6720809859-56.1Wo

≈

5 s

≈

3 s

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Fig. 79 Menu 3 selection

12.3.7 Using the test menu

This menu enables the testing of the functionality of components in an ON/OFF mode.The duration of each test is up to 60 seconds.

1. Select menu TEST via the plus and minus buttons.

2. Press the ok button for one second to enter TEST.

Fig. 80 Selecting test menu

Selecting a test component

Refer to table 32 and use the plus and minus buttons to scroll through the various test options.

Fig. 81 Scroll through test options

3.1A Maximum heating output

The maximum heating output in kW can be set here. The output can be down rated. Note: When maximum boiler output is required for CO/CO

testing, this parameter is ignored and full power is delivered for the duration of the test.

3.1b Upper limit of the maximum power (hot water) for 2.1b

This service feature allows the service technician the setting for the maximum heating (hot water, service function 2.1b) limit. Default setting is the maximum heat output hot water.

3.2B Maximum flow temperature

This limits the upper flow temperature of the central heating knob. Which is 82 °C as a maximum. This can be down rated.

3.3D Minimum boiler power for both heating and hot water.

This sets the minimum output, for example 3kW.

Table 31 Menu 3 parameters

6720809859-57.1Wo

°C

°F

°C

°F

Menu 3

3.3D kW

6720809859-58.1Wo

°C

°F

°C

°F

Test 1

t01

6720809859-59.1Wo

°C

°F

t01

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Testing the component

▶ Select a component to test. ▶ Press the ok button, the value 0 will flash. ▶ Use the plus button to change the value to a flashing 1. ▶ Press ok to confirm the change, the value 1 will stop flashing and a

will displayed for 3 seconds.

The test will run for 30 to 60 seconds unless the value is changed back to 0 before that time, the test may take 10 seconds to start.

Fig. 82 Testing component

Resetting the test component

After completing the test: ▶ Press the ok button, the value 1 will flash.

▶ Press the minus arrow button, the value will change to a flashing 0. ▶ Press ok to confirm the change, a will display for 3 seconds.

Fig. 83 Resetting test

°C

°F

°C

°F

t01

°C

°F

t01

6720809859-60.1Wo

Test

Note that it could be up to 10 seconds after the button is pressed before the selected component responds.

t1 Igniter test.

Checking the igniter spark.

The igniter will spark for a maximum of 30 seconds. The spark will be audible if the igniter is OK.

t2 Fan test.

Checking the basic fan operation.

The fan will run for a maximum of 30 seconds. If the fan is OK then the fan will be heard running.

t3 Pump test.

Checking the basic pump operation.

The pump will run for a maximum of 45 seconds. If the pump is OK then the pump will be heard running.

t4 Three way valve test.

Test the operation of the diverter valve.

When 1 is selected via the test menu the diverter valve will move to the DHW position. When 0 is selected the valve will move to CH position.

t6 Ionisation oscillator test.

Tests the flame detection circuit.

Ionisation circuit is switched on. An A.C. voltage of approximately 150 Volts can be measured between the ionisation probe and earth.

Table 32 Test menu

°C

°F

°C

°F

t01

°C

°F

t01

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12.4 FAULT CODES

Should a fault develop with this boiler (or the system), the boiler will enter a locking or blocking condition, and fault code information will be generated as described in this section.

Locking errors

Locking error The boiler display will flash a warning triangle and fault code. At the same time a (static) cause code will also be displayed.

Manual intervention is required following clearance of the fault: ▶ Press the reset button on the boiler fascia

Blocking error The boiler will stop operating with no fault data displayed. The cause code, in the info menu, is accessed by pressing the

spanner/return button. The condition will clear automatically when the associated fault clears e.g. waiting for an area to cool.

In some cases a blocking error has a defined time duration prior to changing to a locking condition. Fault code Alpha numeric number indicating the fault group Cause code Three digit number. During a blocking error (or normal operating status) it is not displayed, but accessed in the info menu via

the spanner/return button. During a locking error the cause code flashes on the display.

Fault codes

Cause codes

Description Reset type Possible cause

9U 233 HCM (Heat Control Module) Reset button Problem with the code plug b7 257 Internal error Replace control board. C6 215 Fan problem Reset button Fan running too fast

216

Fan problem Reset button Fan running too slow

C7 214 Fan problem Reset button Fan not running

217

No airflow after a defined period of time Reset button Fan not running or airflow blocked

D1 240 Return sensor error Reset button Sensor wet or damaged (the boiler will block for 300 seconds before

this condition).

241

Return sensor error Reset button Sensor disconnected or damaged (the boiler will block for 300

seconds before this condition).

286

Return temperature too high Reset button Boiler overheat

E2 222 Flow sensor short circuit Reset button Flow sensor shorted or damaged.

223

Flow sensor open circuit Reset button Flow sensor disconnected or damaged.

E5 218 Flow temperature too high Reset button Primary flow sensor overheated

332

Primary flow sensor has exceeded 110 °C

Reset button Primary flow sensor overheated

E9 219 Safety sensor temperature too high Reset button The main heat exchanger has overheated.

Maximum temperature 105C °

220

Safety sensor short circuit Reset button Maximum temperature sensor on the main heat exchanger has failed.

221

Safety sensor open circuit Reset button Maximum temperature sensor on the main heat exchanger has not

been recognised.

224

Max temperature thermostat activated Reset button Flue gas thermostat overheat

EA 227 No flame detected after ignition Reset button Failure of five ignition attempts. The boiler waits 30 seconds before

another attempt is made.

229

Loss of flame signal during operation Reset button An established flame has been extinguished.

This could be caused by:

• moisture in the sump, due to a blocked sump/condensate trap.

• a strong wind into the flue.

234

Gas valve error Reset button Gas valve coil disconnected

261

Ignition timing error Reset button Flame not established during the first 4 seconds ignition period.

Table 33 Locking fault and cause code listing

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FAULT FINDING AND DIAGNOSTICS | 59

6 720 ... ... (YYYY/MM)Product Name

Blocking errors

F0 237 -

239

242 -

256 258 259 262 263 267 272 279 290

Internal error Call your Technical help line

278 Sensor test failed Reset button On power up all safety sensors are checked.

Check has failed.

280 Recycle time error Reset button After the burner has stopped, the recycle mode purges gas from the

heat exchanger before attempting to burn again. The software has 3.1 seconds to intervene before the boiler goes into this fault condition.

338 Too many short burner starts without

confirmation

Reset button There is an error where the pump is not detecting water.

F7 228 Flame error Reset button False flame. Flame detected before burner start.

328 Internal error Replace control board FA 306 False flame error Reset button Flame detected after burner stop FD 231 Mains power error Reset button Electrical power interruption. FA 364 Gas valve EV2 leak test failed Reset button Gas valve leak. Fb 365 Gas valve EV1 leak test failed Reset button Gas valve leak.

Fault code

Cause code

Description Possible cause

A1 281 Pump stuck or running in air Little or no water in the system. C1 264 Airflow stopped during operation Fan has stopped. C4 273 Airflow present during last 24 hours Fan has been running continuously during the past 24 hours. D1 240 Return sensor short circuit Wet sensor. Blocking for 300 seconds before going to Locking error ( table 33).

241

Return sensor disconnected Blocking for 300 seconds before going to Locking error ( table 33).

D4 271 Temperature difference between flow and

safety sensors exceeds limit

The temperature of the primary flow and the safety sensor on the primary heat exchanger should be within 15 °C of each other.

E9 224 MAX thermostat activated Flue gas thermostat overheat.

276

Flow temperature exceeds 95 °C Primary overheat - boiler waits for temperature to reduce; if not it becomes a

Locking error.

277

Safety temperature exceeds 95 °C Main heat exchanger safety sensor overheat - boiler will wait for the temperature to

reduce; if not it becomes a Locking error 219.

285

Return temperature exceeds 95 °C The boiler will stop the burn and wait to see if it cools down. If after 2 seconds

there is an increase in temperature the boiler will go to Locking error 286.

EA 227 No ionisation detected after ignition No flame is detected. The boiler will block during 4 attempts before going to

Locking fault.

EF 349 Central heating, boil detect.

Large delta T despite minimum burner.

The boiler is operating at minimum burner load and there is a greater than 18°C Flow & Return temperature difference.

No code

212 Safety or flow temperature rises too fast Air lock or reduced water content.

213

Temperature difference between supply and return exceeding limit

Air lock or reduced water content.

260

No temperature rise after burner starts Sensor disconnected or no water content.

380

Inlet DHW temperature higher than the DHW outlet temperature.

The output is blocked until the inlet temperature drops below the output temperature.

Table 34 Blocking codes

Fault codes

Cause codes

Description Reset type Possible cause

Table 33 Locking fault and cause code listing

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