Bosch Condens 2000F30 Regular, Condens 2000F16 Regular, Condens 3000F30 System, Condens 2000F42 Regular, Condens 3000F16 System Installation, Commissioning And Servicing Instruction Manual
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)
Contents
Condens – 6720816930 (2015/04)
2
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
Key to symbols and safety precautions
Condens – 6720816930 (2015/04)
3
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
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
1
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
1
2
3
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
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
1
6
2
3*
4
6720809859-10.1Wo
123*4
466
394
61
78 111
141 253
Ø80
Ø125
98
130
162
193
5
83
59
900 - 930
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
2
14
16
12
10
11
15
9
8
7
6
21
5
18
20
19
43
6720809859-12.1Wo
13
17
1
22
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
1
11
3
4
2
9
7
56
8
10
6720809859-08.1Wo
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
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,
C
33X, C43X, C53X, C63X,
C
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
2E
G20/25 20 B
23, B33, C13X, C33X,
C
43X, C53X, C83X, C93X
Belgium BE 37 Cat II
3P
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
3
Natural gas 2H
11.4 to 15.2 kWh/m
3
Natural gas 2E
9.5 to 12.5 kWh/m
3
Natural gas 2LL
20.2 to 24.3 kWh/m
3
LPG 3B/P
20.2 to 21.4 kWh/m
3
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)
1
2
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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)
1
2
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0
50
100
150
200
250
300
350
400
450
500
550
600
0 300 600 900 1200 1500 1800 2100
P (mbar)
F (litres/h)
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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
20
1
2
19
15
14
13
12
10
11
18
17
16
9
8
7
6
25
5
24
22
23
21
43
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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
1
13
9
3
4
2
11
7
56
8
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10
Appliance information | 13
6 720 ... ... (YYYY/MM)Product Name
2.14 System 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 in power output due to altitude
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
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
1
2
3
4
5
6
7
8
0 500 1000 1500 2000
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1
2
APH ( m wg)
FR (l/hr)
Pump (m wg)
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
s
% 9393929393
Energy efficiency class – – A A A A A
Useful heat output
At rated heat output and high temperature regime
1)
1) High temperature regime means 60 °C return temperature at heater inlet and 80 °C feed temperature at heater outlet.
P
4
kW 15.3 30.1 38.1 15.3 30.1
At 30 % of rated heat output and low temperature
regime
2)
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).
P
1
kW 3.5 7 9.4 3.5 7
Useful efficiency
At rated heat output & high temperature regime 1)
4
% 88.2 88.2 88.2 88.2 88.2
At 30 % of rated heat output & low temperature
regime
2)
1
% 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
SB
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
HE
kWh - - - - Sound power level, indoors L
WA
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
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
xx
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
xx
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.
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
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61
78 111
Ø125
5
83
59
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
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1
6720809859-09.1Wo
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2
3
4
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
1
2
6720809859-94.1Wo
A
B
C
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
x4
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