Bosch Worcester 2000, Worcester GC2000iW C, Worcester GC2000iW 30 C NG, Worcester GC2000iW 25 C NG Installation And Maintenance Instructions Manual

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Installation and Maintenance Instructions

Gas-fired condensing combi appliance

Worcester 2000

GC2000iW C

6 721 814 551 (2019/09) UK/IE

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Table of contents

1 Explanation of symbols and safety instructions . . . . . . . . . . . 3

1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4

2 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4 Appliance type overview . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.6 Pipe work positions and flue outlet. . . . . . . . . . . . . . . . . 8

3.7 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.8 Product data for energy consumption. . . . . . . . . . . . . . 10

3.9 Standard accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.9.1 Appliance accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.9.2 Programmer/timer accessories. . . . . . . . . . . . . . . . . . . 10

4 Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1 System preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1.1 Artificially softened water . . . . . . . . . . . . . . . . . . . . . . . 11

4.1.2 Water systems and pipe work . . . . . . . . . . . . . . . . . . . . 11

4.1.3 System layouts examples. . . . . . . . . . . . . . . . . . . . . . . . 12

4.1.4 System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2 Mains supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2.2 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2.3 Water supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 Appliance location and clearances . . . . . . . . . . . . . . . . 14

4.3.1 Appliance location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.3.2 Rooms containing a bath or shower . . . . . . . . . . . . . . . 15

4.3.3 Appliance clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.4 Flue systems considerations . . . . . . . . . . . . . . . . . . . . . 16

4.4.1 Flue length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4.2 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4.3 Plume management system. . . . . . . . . . . . . . . . . . . . . . 18

4.4.4 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.4.5 Plume re-direct and plume management terminal

positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.5 Condensate discharge . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.1 Condensate pipe work. . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.2 Condensate production . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.3 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.4 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.6 Pressure relief discharge. . . . . . . . . . . . . . . . . . . . . . . . 28

4.6.1 Pressure relief pipe work. . . . . . . . . . . . . . . . . . . . . . . . 28

4.6.2 Alternative PRV connections - Combined PRV/

condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.7 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . . 29

4.7.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.1 Position the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.1.1 Mounting bracket fixing . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2 Appliance connections . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.3 Hanging the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4 Flue turret/adaptor installation. . . . . . . . . . . . . . . . . . . 33

5.5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.5.1 Installer connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.5.2 Cable preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.5.3 Key (accessories). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.1 Pre-Commissioning checks . . . . . . . . . . . . . . . . . . . . . . 36

6.2 Water treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.2.1 Filling the appliance and adding Inhibitor. . . . . . . . . . . 37

6.3 Circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.4 Starting the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.4.1 Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.4.2 Screen display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4.3 Switching on the device. . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4.4 Setting the flow temperature. . . . . . . . . . . . . . . . . . . . . 39

6.4.5 Setting the DHW heating . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4.6 Setting the heating control device . . . . . . . . . . . . . . . . 40

6.4.7 After commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.4.8 Setting summer mode . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.5 Chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.5.1 Setting the appliance to maximum . . . . . . . . . . . . . . . . 40

6.5.2 Setting the appliance to minimum . . . . . . . . . . . . . . . . 40

6.5.3 Exiting chimney sweep mode . . . . . . . . . . . . . . . . . . . . 40

6.6 Checking gas inlet pressure. . . . . . . . . . . . . . . . . . . . . . 40

6.7 Checking the gas rate. . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.8 Checking for gas leaks during operation. . . . . . . . . . . . 41

6.9 CO and combustion check. . . . . . . . . . . . . . . . . . . . . . . 42

6.10 Checking flue integrity. . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.11 Flue gas analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.12 Finishing commissioning . . . . . . . . . . . . . . . . . . . . . . . . 44

6.12.1 Fitting the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.12.2 Appliance/product guarantee . . . . . . . . . . . . . . . . . . . . 44

7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.1 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2 Anti-seize protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8 Settings in the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8.1 Operating the service menu . . . . . . . . . . . . . . . . . . . . . 45

8.2 Service functions overview . . . . . . . . . . . . . . . . . . . . . . 46

8.2.1 Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8.2.2 Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8.2.3 Menu 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8.2.4 Menu 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8.2.5 Menu 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.2.6 Menu 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.2.7 Menu 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.1 Inspection and maintenance considerations . . . . . . . . 51

9.2 Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.2.1 Calling up the last fault saved . . . . . . . . . . . . . . . . . . . . 51

9.3 Component access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

9.4.1 Checking heating block . . . . . . . . . . . . . . . . . . . . . . . . . 52

9.5 Check working gas inlet pressure . . . . . . . . . . . . . . . . . 52

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Table of contents

9.6 Flue gas analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

9.7 Checking the flue integrity . . . . . . . . . . . . . . . . . . . . . . . 53

9.8 Cleaning the siphon and heat exchanger . . . . . . . . . . .53

9.8.1 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . .53

9.8.2 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

9.9 Setting the air/gas ratio . . . . . . . . . . . . . . . . . . . . . . . . .58

10 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

10.1 Component access. . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

10.2 Draining the appliance . . . . . . . . . . . . . . . . . . . . . . . . . .59

10.3 Checking the strainer in the cold water pipe. . . . . . . . .59

10.4 Checking the plate heat exchanger . . . . . . . . . . . . . . . .60

10.5 Checking the expansion vessel . . . . . . . . . . . . . . . . . . .60

10.6 Adjusting the operating pressure of the heating

system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

10.7 Removing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . .60

10.8 Removing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.9 Removing the automatic air vent valve . . . . . . . . . . . . .61

10.10 Removing the motor of the diverter valve . . . . . . . . . . .61

10.11 Removing the heat exchanger . . . . . . . . . . . . . . . . . . . . 62

10.12 Replacing the control unit . . . . . . . . . . . . . . . . . . . . . . .62

10.13 Reattaching the casing on the side . . . . . . . . . . . . . . . .63

11 Fault finding and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

11.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

11.2 Table of operation and fault displays. . . . . . . . . . . . . . .64

11.3 Pump operation and diagnosis . . . . . . . . . . . . . . . . . . .71

11.4 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . . 72

12 Environmental protection/disposal. . . . . . . . . . . . . . . . . . . . .73

13 Technical Specifications/Logs . . . . . . . . . . . . . . . . . . . . . . . . .74

13.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

13.2 Component resistance characteristics . . . . . . . . . . . . .75

13.2.1 Sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

13.3 Heating curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

13.4 Internal wiring of the appliance . . . . . . . . . . . . . . . . . . .76

13.4.1 Electircal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

13.5 Setting values for output . . . . . . . . . . . . . . . . . . . . . . . .77

13.5.1 Gas setting values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

13.6 Gas Boiler System Commissioning Checklist and

Warranty Validation Record . . . . . . . . . . . . . . . . . . . . . .78

13.7 Inspection and maintenance checklist . . . . . . . . . . . . .79

13.8 Service and Interim Boiler Work Record . . . . . . . . . . . .80

1 Explanation of symbols and safety instructions

1.1 Explanation of symbols

Warnings

In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken.

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

DANGER:

DANGER indicates that severe or life-threatening personal injury will

occur.

WARNING:

WARNING indicates that severe to life-threatening personal injury may

occur.

CAUTION:

CAUTION indicates that minor to medium personal injury may occur.

NOTICE:

NOTICE indicates that material damage may occur.

Important information

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

Additional symbols

Symbol Meaning

▶ a step in an action sequence  a reference to a related part in the document

• a list entry – a list entry (second level)

Table 1

Worcester 2000 – 6 721 814 551 (2019/09)

Explanation of symbols and safety instructions

1.2 General safety instructions

H Please read these instructions carefully before

starting installation.

• These instructions are applicable to the Worcester appliance model(s) stated on the front cover of this manual only and must not be used with any other make or model of appliance.

• These instructions apply in the UK and Ireland only and must be followed except for any statutory obligations.

• This appliance must be installed by a competent registered gas engineer, such as a Gas Safe registered engineer including a British Gas engineer. Failure to install correctly could lead to prosecution.

• If you are in any doubt, contact the Worcester, Bosch Group help line (0330 123 3366).

• Distance learning and training courses are available from Worcester.

• The BENCHMARK Commissioning Checklist can be found on page 78 of this Installation manual.

H Notices for the target group

These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life.

▶ Read the installation instructions (heat source,

heating controller, etc.) before installation.

▶ Observe the safety instructions and warnings. ▶ Follow national and regional regulations, technical

regulations and guidelines.

▶ Record all work carried out.

H Intended use

The appliance may only be used for heating water or domestic hot water in domestic properties.

▶ Observe the details on the data plate and the

specifications (installation manual) to ensure correct use of this appliance.

▶ Worcester Bosch offer flue gas systems which are

suitable for use with the appliance. It is the responsibility of the designer/installer of the flue to ensure this flue gas system operates correctly and in a safe manner.

H 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. ▶ Move well away from the building: call the National

Gas Emergency Service on 0800 111 999. ▶ L.P.G. boilers: Call the supplier’s number on the

side of the gas tank.

H Risk to life from carbon monoxide poisoning There is a risk to life from escaping flue gases

▶ Do not modify the flue gas system. ▶ Ensure that flue pipes and gaskets are undamaged.

If flue pipes are damaged or leaking:

▶ Turn off and isolate the appliance. ▶ Open windows and doors. ▶ If necessary, leave the building and warn your

neighbours. ▶ Prevent anyone from entering the building. ▶ Rectify any damage to the flue system immediately.

H Installation and maintenance

Installation and maintenance must only be carried out by a competent registered gas engineer, such as Gas Safe registered engineer or British Gas engineer.

▶ Carry out a gas tightness test after completing work

on gas-carrying components. ▶ Only use original spares.

H Electrical work

Electrical work must only be carried out by a qualified electrician:

▶ Before starting electrical work;

– Ensure that the electricity supply is safely

Isolated and secured to prevent inadvertent reconnection. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

– Using test equipment approved to GS38 to

confirm that the electricity supply is disconnected.

▶ Refer to the manufacturer’s information when

installing non Worcester components and systems

to the Worcester appliance.

Worcester 2000 – 6 721 814 551 (2019/09)

Explanation of symbols and safety instructions

H Handover to the user

When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions.

▶ Explain how to operate the heating system and draw

the user's attention to any safety relevant action.

▶ Explain that modifications and repairs must only be

performed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer.

▶ Leave the installation instructions with the

completed Benchmark Checklist (or a certificate confirming compliance with IS 813, Eire only) and the operating instructions with the user or at the gas meter.

H Servicing

Advise the user to have the system serviced annually by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer. Approved spares must be used to help maintain the efficiency, safety and reliability of the appliance.

H Benchmark Service Record

The service engineer must complete the Benchmark Service Record at the back of this manual after each service.

Benchmark places responsibilities on both manufacturers and installers.

The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer's instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot water Industry Council who manage and promote the scheme. Visit hhic.org.uk for more information.

H 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.

H Fitting and modification

Fitting the appliance and any controls to the appliance

may only be carried out by a competent engineer in

accordance with the current Gas Safety (Installation

and Use) Regulations.

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.

H General manual handling guidelines

▶ Only remove packaging at the time of the final

installation.

▶ Always use Health and Safety guidance for manual

handling of an appliance. – Never lift or carry more than the safe guidance

limit on your own.

– Always use appropriate methods and equipment

when lifting/carrying an appliance. ▶ Never lift or carry packages by the shipping straps. ▶ During handling and unpacking, wear safety gloves

to prevent injuries to your hands through sharpedged appliance components.

▶ Dispose of packing materials appropriately.

H Important handling instructions

Care should be taken when transporting, lifting and carrying the appliance.

▶ Use a means of transport suitable for handling

appliances (e.g. sack truck with strap, stair climbing or step trolley).

▶ When handling appliances, secure them against a

fall. ▶ Let only trained personnel undertake the handling. ▶ The correct method for handling heavy objects

should be strictly observed, at all times.

H Health and safety

The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).

Worcester 2000 – 6 721 814 551 (2019/09)

Regulations

2 Regulations

Installation regulations

Current Gas Safety (Installation and Use) Regulations:

All gas appliances must be installed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer in accordance with the current regulations. Failure to install appliances correctly could lead to prosecution.

The appliance must be installed in accordance with, and comply to, the current:

Gas Safety Regulations, IET Regulations, Building Regulations, Building Standards (Scotland) (Consolidation),

Building Regulations (Northern Ireland), local water by-laws,

Health and Safety Document 635 (The Electricity at Work Regulations

1989) and any other local requirements.

EU Regulations No. 811/2013 - Energy Labelling.

Building Regulations Part L1A 2013 - new dwellings

If the installation is in a new build property or it is a first time installation in an existing property, the heating systems must conform to current building regulations Part L1A.

The exception to this are single storey, open plan dwellings where the living area is more than 70% of the total usable floor area. Then this type of dwelling can be controlled as one zone.

An alternative would be individual electronically controlled TRVs.

For dwellings with a floor area over 150m temperature control for each zone is required. It is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators except the area where the room thermostat is sited.

, separate time and

Irish Standards

The current relevant Irish standards should be followed, including:

• ECTI – National rules for electrical installations

• IS 813 – Domestic Gas Installations

Timber framed buildings

Where the appliance is to be fitted to a timber framed building the guidelines laid down in BS5440: Part 1 and IGE “Gas Installations in Timber Frame Buildings” should be adhered to.

Potable water

All seals, joints and compounds (including flux and solder) and components used as part of the secondary domestic water system must be approved by WRAS.

CH Water

Salt based artificially softened water must not be used to fill the central heating system.

Building Regulations Part L1B 2010 - existing dwellings

For appliance replacements on an existing system, it is not necessary to zone the upstairs and downstairs separately, compliance with the zone requirements can be achieved by a single room thermostat or programmable room thermostat.

While the system is drained down, it is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators except the area where the room thermostat is sited.

British Standards

Where no specific instruction is given, reference should be made to the relevant British Standard codes of Practice.

• BS7074:1 – Code of practice for domestic and hot water supply

• BS6891 – Installation of low pressure gas pipe work up to 28mm (R1)

• BS5546 – Installation of gas hot water supplies for domestic purposes

• EN12828 – Central heating for domestic premises

• BS5440:1 – Flues and ventilation for gas appliances of rated heating not

exceeding 70kW (net): Flues

• BS5440:2 – Flues and ventilation for gas appliances of rated heating not

exceeding 70kW (net): Air Supply

• BS7593 – Treatment of water in domestic hot water central heating systems

• BS6798 – Installation of gas fired boilers of rated input up to 70kW (net)

• BS7671 – IET Wiring Regulations

Worcester 2000 – 6 721 814 551 (2019/09)

Product Information

3 Product Information

Appliance features

• Aluminium-silicon heat exchanger, which has an extra-large surface

area for enhanced heat exchanger efficiency.

• NOx emissions 39mg/kWh.

• Direct burner ignition.

• Zero pressure governor gas valve with fully modulating fan.

• Display for appliance status and access to diagnostics, system and

commissioning parameters.

• 1 hour memory retention after power interruption.

• Low electrical power consumption during operation and stand-by

modes.

• Modulating pump.

• Condensing in CH and DHW modes.

• Two star Hot Water Comfort measured to EN13203 Part 1 in comfort

mode with DHW pre-heat ON.

• Eco mode, to use gas on demand.

• Plate type DHW heat exchanger.

• Galvanised steel wall mounting bracket.

• Only Worcester controls, see accessories list for available controls.

– Worcester Comfort+ II RF control included with every 2000

boiler.

• Condensfit II flue systems 60/100 and 80/125 mm allows plume re-

direction.

• Condensfit II flue systems 60/100 allows the ability to attach plume

management kit.

• Front accessible components for maintenance.

3.1 Misuse

Appliance must be used as per the intended use statement. Operation outside the parameters of the intended use is considered misuse and could cause harm to people and damage to property.

Accessories should be as per accessories list. Minimum operational parameters are included in this document.

Using the appliance outside of its intended use may also invalidate the manufacturer's guarantee.

3.2 Scope of delivery

Fig. 1

[1] Wall mounted gas-fired condensing combi appliance. [2] Wall mounting bracket. [3] Fittings pack. [4] Condensate hose connector. [5] Valves set. [6] Compression fitting adapters set. [7] Literature pack:

– Installation and Maintenance Instructions, – User Instructions,

– Wall mounting template. [8] Guarantee card [9] ErP labels and system fiche. [10] Comfort+ II RF controller and Key

3.3 Declaration of Conformity

The design and operation of this product comply with European Directives and the supplementary national requirements. Conformity has been demonstrated by the CE marking.

You can ask for a copy of the declaration of conformity for this product. For this see the contact address on the back cover of these instructions.

0010029387-001

Worcester 2000 – 6 721 814 551 (2019/09)

3.4 Appliance type overview

This appliance are for use with:

• Natural Gas (Cat.II 2H type C13, C33 & C53)

This document refers to the following appliance types:

Appliance type Part number Gas Council number

GC2000iW 25 C NG 7 736 902 027 47-800-25 GC2000iW 30 C NG 7 736 902 028 47-800-24

Table 2 Type overview

The name of the appliance consists of the following parts:

• GC2000iW: Type name

• 25 or 30: Hot water output in kW

• C: Combi appliance

• NG: Gas type (Natural Gas)

Product Information

3.5 Product identification

Data plate

The data plate includes the product performance information, approval data and serial number. The data plate location can be found in the product overview.

Additional type plate

The product name and the most important product data are shown on the additional data plate. The additional type plate can be found on the outside of the product in an easily accessible location.

3.6 Pipe work positions and flue outlet

# Function From left

case edge

3 DHW Outlet 133mm 15mm

4 PRV Discharge 172.5mm 15mm

5 Gas 200mm 22mm

6 DCW Inlet 267mm 15mm

7 CH Return 332mm 22mm

Table 4 Pipe dimensions

For servicing purposes, keep condensate and pressure release valve discharge pipes away from other hydraulic components.

Diameter of pipe

• Compression fitting (via adaptor)

• Fittings not supplied

• Compression fitting (via adaptor)

Fig. 2 Pipe and flue outlet dimensions

Description Dimensions (mm)

X Appliance width 400 Y Appliance height 724 Z Appliance depth 300 W Flue centre from appliance left side 200 D Flue centre from rear of appliance 125

Table 3 Appliance and flue outlet dimensions

# Function From left

1 Condensate Outlet 60mm 22mm

2 CH Flow 68mm 22mm

Diameter of pipe

case edge

• Rubber push fit connection

• Compression fitting (via adaptor)

0010029389-001

Worcester 2000 – 6 721 814 551 (2019/09)

3.7 Product overview

Product Information

Fig. 3 Product overview

Worcester 2000 – 6 721 814 551 (2019/09)

0010029397-001

Product Information

Legend to figure 3:

[1] Inspection aperture [2] Flue connection [3] Heating block temperature limiter [4] Electrode set [5] Ignition transformer [6] Control pressure test point [7] Gas-air mixing chamber [8] Heating block [9] Gas valve [10] Condensate sump [11] Cover for inspection aperture [12] Diverter valve motor [13] Diverter valve [14] Automatic air vent [15] Heating pump [16] Pump speed adjuster and LED indicator [17] Pressure relief valve (heating circuit) [18] Plate heat exchanger [19] KEY accessory housing (wireless gateway) [20] Pressure gauge [21] Position for code plug (KIM) [22] Control unit [23] DHW temperature sensor [24] Pressure switch [25] Flow turbine [26] Fuse (replacement) [27] Condensate trap [28] Data plate [29] Condensate trap locking mechanism [30] Gas supply pressure test point [31] Flue gas temperature limiter [32] Flow temperature sensor [33] Schrader valve [34] Expansion vessel [35] Fan [36] Air-gas manifold with non-return valve [37] Heating flow [38] Flow temperature sensor at heating [39] Bracket [40] Combustion air intake

3.8 Product data for energy consumption

The product data on energy consumption can be found in the operating instructions for the user.

3.9 Standard accessories

3.9.1 Appliance accessories

Part number Description

7 716 192 746 Worcester CondenseSure 7 733 600 236 Greenstar System filter (22mm) 7 733 600 237 Greenstar System filter (28mm) 7 733 600 266 Greenstar System filter mini (22mm) 7 733 600 476 Greenstar Brass system filter (22mm) 7 716 192 610 Worcester keyless filling link 7 733 600 091 Heat exchanger cleaning kit

Table 5 Appliance accessories

3.9.2 Programmer/timer accessories

The programmers/timers listed can be used with the appliances stated on the front of this manual.

Part number Description

7 738 112 324 Comfort +II RF (programmable room

thermostat)

7 738 111 064 Sense II weather compensation controller

1) Preheat time control available

2) Landlord function is not compatible with the Worcester 2000

3) Power and gas consumption will not display accurately on the Comfort+ II RF. The electricity consumption for both CH and DHW assumes the pump is running at 100% speed permanently. As a result the indicated consumption will be the highest possible. Actual consumption is likely to be less.

Table 6 Control accessories

Bosch EasyControl smart control system

Part number Description

7 736 701 341 EasyControl (white) 7 736 701 392 EasyControl (black) 7 736 701 555 EasyControl TRV set (white) 7 736 701 556 EasyControl TRV set (black)

Table 7 EasyControl accessories

1) 2)3)

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4 Pre-Installation

NOTICE:

Risk of damage to system or appliance!

Before installation

▶ All the following Pre-Installation sections must be read and

requirements met before starting appliance or flue installations.

4.1 System preparation

4.1.1 Artificially softened water

It is possible to have an ion exchange water softener fitted to the cold water system of the property. However, the appliance requires an untreated cold water connection taken from the mains supply, before the water softener, to the primary water filling point of the heating system.

Alternatively there are water softening/treatment appliances that do not adjust or alter the pH levels of the water. With these appliances it may not be necessary to provide an untreated water by-pass to the primary water filling point of the heat system.

NOTICE:

▶ Salt based softened water must not be used to fill the central heating

system.

4.1.2 Water systems and pipe work

Primary system plastic pipework:

• Any plastic pipe work must have a polymeric barrier, complying with BS 7921 and installed to BS 5955 with 600mm (minimum) length of copper connected to the appliance.

• 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 with 1000mm (minimum) length of copper or steel pipe connected to the appliance.

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.

• Radiator valves should conform to BS 2767:10.

• All other valves should conform to BS 1010.

• It is best practice to fit Thermostatic Radiator Valves (TRV's) to all radiators, except the area where the room thermostat is sited which must be fitted with lockshield valves that are left open.

• The circulating pump speed is fixed therefore as system

circulation can be significantly adjusted or stopped by TRV's or zone valves, a system bypass must be installed to give at least a 3 metre circuit when activated.

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

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

Showers/Bidets:

• If a shower head can be immersed in water or comes closer than 25mm from the top edge of a bath or shower tray spill-over level then an anti-siphon appliance must be fitted to the shower hose.

• Bidets with direct hot and cold mains water can be used (with the approval of the local water authority) and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays.

Hot water:

• Taps and mixing valves must be capable of sustaining a pressure up to 10 bar.

Pre-Installation

• Hot water temperature and flow rate are affected by the size and insulation of pipe work making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A mixing valve can be fitted if a more permanent temperature setting is required.

• If using more than one outlet at once causes water flow starvation, fit flow balancing valves or Ball-O-Fix valves to the appropriate outlets.

Primary system considerations - Combi & System appliances Sealed system

• The CH sealed system must be filled using a WRAS approved filling loop or comply with examples in 4.1.4 "System fill" section.

• Where the system volume is more than 100 litres or exceeds 2.5 bar at maximum heating temperature an additional expansion vessel [2] must be fitted as close as possible to the appliance in the central heating return.

• Pressurise the extra expansion vessel [2] to the same value as the built-in expansion vessel - refer to the Technical data page.

0010021117-001

Fig. 4 Additional expansion vessel

[1] Appliance expansion vessel [2] Additional expansion vessel [3] Pressure relief discharge [4] Heating return [5] Heating flow

Checking the size of the expansion vessel

To determine whether an additional expansion vessel is required: Follow the steps below:

▶ Calculate the total system volume (litres).

– Plot a line vertically on the chart ( Fig. 5).

▶ Determine the central heating maximum operating flow temperature.

– Plot a line horizontally on the chart ( Fig. 5).

▶ Determine the pre-charge in the expansion vessel based on static

head, 1 meter = 0.1 bar. – Static head should be measured between the expansion vessel

and the highest point on the system (top of the highest radiator). ▶ Select a curve from the key below (1-5). ▶ System pressure should be set at 0.1 - 0.25 bar higher than the

vessel pre-charge. – It must be at least to the minimum on appliances with an analogue

gauge.

– Minimum pressure settings may need to be adjusted to suit on,

appliances with a digital gauge, in the applicable menu function.

– Intelligent filling settings may need to be adjusted to suit on,

appliances with the automatic filling accessory, in the applicable

menu function.

If the dissected lines are in area A then no additional expansion is required.

If the dissected line is in are B then an additional expansion vessel must be installed ( Fig. 4).

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Pre-Installation

T[°C]

Sealed primary system - 2 x central heating zones:

• Requirement for new builds if the floor area of a property is over 150m

0 100 200 300 400 500

Fig. 5 Curves for the expansion vessel

1 Pre-charge pressure 0.5 bar (minimum) 2 Pre-charge pressure 0.75 bar 3 Pre-charge pressure 1.0 bar 4 Pre-charge pressure 1.2 bar 5 Pre-charge pressure 1.3 bar A Operational capacity of the expansion vessel (left of the relevant

curve) B Additional expansion vessel required (right of the relevant curve) T Maximum operating temperature [ °C] V Total System Volume [l]

The default pre-charge pressure for the appliance is 0.75 bar

600 700

V[l]

0010016558-002

Fig. 7 Separated heating zones

[1] Appliance [2] Zone valves

4.1.4 System fill

Integral filling link

• An optional filling link accessory is available to fill the system. – Refer to filling link instructions for fitting and operation.

Filling primary sealed systems

NOTICE:

Filling the primary sealed system

The system must not be filled with salt based softened water.

▶ Ensure the primary water filling point uses an untreated cold water

connection from the mains supply, before a water softener.

0010021228-002

4.1.3 System layouts examples

Sealed primary system - Single central heating circuit:

Typical primary system example

Fig. 6 Single central heating circuit example

[1] Appliance

0010021227-002

• Filling the system must comply with one of the following methods shown.

• The filling point must be at low level and must never be a permanent connection to the mains water supply.

• Filling loops must be WRAS approved.

• If the external filling link is sited away from the appliance, then a pressure gauge should be installed at the filling point.

External filling loop

3 3

Fig. 8 External filling loop system fill example

[1] Cold mains inlet pipe [2] Stop valve [3] Check valve [4] Test point [5] Hose union [6] Central heating flow pipe

0010012942-001

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Pre-Installation

4.2 Mains supply

4.2.1 Electrical supply

• Supply: 230V AC - 50 Hz

• This appliance must not be connected to a three phase supply.

• The wiring between the appliance and the electrical supply must comply with the latest IET wiring regulations that apply to wiring a fixed appliance for Class 1 equipment.

• The correct type of RCD must be employed where additional protection is required that is suitable for a low energy DC modulating pump according to IET wiring regulations.

• External 3 A fuse to BS1362.

• The appliance must be earthed.

• Cable: PVC insulated 0.75mm 90 °C, to BS EN50525.

• Any additional components that are connected to the appliance with mains electrical supply must not have a separate supply.

• Additional equipment wired to the appliance must comply with the latest IET wiring regulations.

• Appliance protection rating - IPX4D

4.2.2 Gas supply

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

• Installation and connection of the gas supply to the appliance must be in accordance with the latest version of BS6891.

• Gas pipe sizing should be calculated to ensure no more than the permitted mbar drop between the meter to the appliance inlet. ( chapter 6).

• The meter and pipe work to the meter must be checked, preferably 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.

Pipe sizing (NG)

Gas pipe work:

▶ Gas installation pipe work must be designed to ensure the pressure

loss between the meter outlet (NG)  table 20 ”Allowed mbar pressure drop”.

Basic pipe sizing calculation

(24 x 0.2mm) temperature rated to

Natural Gas (NG):

Discharge rates for copper tube with 1mbar differential pressure between the ends for Natural Gas.

Discharge rates for Natural Gas (m3/hr)

with straight horizontal copper tube

Pipe Pipe Size (mm)

Length (m) 15 22 28 35

2.9 8.7 18 32 6 1.9 5.8 12 22 9

1.5 4.6 9.4 17

12 Discharge 1.3 3.9 8 15 15

m3/hr 1.1 3.4 7 13 20 0.95 2.9 5.9 11 25

0.92 2.5 5.2 9.5

30 0.88 2.3 4.7 8.5

Table 8 Natural Gas

Natural Gas:

▶ When using this table to estimate the gas flow rate in pipe work of a

known length, the effective length will be increased by 0.5m for each 90° elbow and tee fitted and by 0.3m for each 90° bend.

4.2.3 Water supply

Use in hard water areas:

Normally there is no need for water treatment to prevent scale formation as the maximum temperature of the HW heat exchanger is limited by the electronic control.

In areas where temporary water hardness exceeds 200ppm, consideration may need to be given to the fitting of a scale prevention appliance. In such circumstances, the advice of the local water authority should be sought.

Keyless filling link accessory

Minimum static pressure.

▶ A minimum static pressure of 1.75bar is recommended for correct

operation of the Keyless filling link.

Basic pipe sizing calculation.

▶ This method is only a guide - for more complex design please

refer to latest version of BS6891 and training given in ACS.

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Pre-Installation

Water mains pressure:

• Minimum mains water pressure, for maximum performance refer to section 13.1 "Technical data".

• Maximum mains fed water static pressure 10 bar. If necessary fit a pressure reducing valve.

NOTICE:

Non return, back flow prevention appliances (including those associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage the appliance and other household appliances.

NOTICE:

Non return valves in the cold water feed system.

If a non return valve is fitted on the mains inlet, then pressure can increase significantly over normal standing pressure when the appliance carries out a HW preheat or due to fast acting valves closing on other appliances/outlets.

▶ To ensure water pressure stays at a level that will not damage the

appliance or other household appliances, we would recommend that a 3bar pressure reducing valve and mini expansion vessel are fitted.

• Where the mains water supply has a non-return, back flow prevention valve fitted, a mini expansion vessel [3] should be connected to the mains water inlet pipe [1] between the non-return valve [2] and the appliance[4] as shown below.

3 4

0010015563-001

DANGER:

Danger from explosive and flammable materials:

Storage of explosive and flammable materials.

▶ Do not store flammable materials (paper, curtains, clothing, primer,

paint, …) in proximity to the appliance.

NOTICE:

Damage to appliance:

Contaminated combustion air.

▶ Do not use any cleaners containing chlorine or hydrogen halide (i.e.

spray cans, primers, cleaners, paint and glue). ▶ Do not store or use these substances in the appliance, room. ▶ Avoid the build up of dust.

NOTICE:

Damage to appliance:

Extreme temperatures may cause damage to the heating system.

▶ Ensure the appliance location’s ambient temperature is above 0 °C

and below 50°C.

NOTICE:

Damage to system:

The heating system pipe work can be damaged by frost if installed in an internal unheated area, such as a loft, basement or garage. The appliance internal frost protection only monitors the system water temperature within the appliance to provide protection for the appliance.

▶ No system frost protection available. ▶ The system pipe work in the internal unheated area should be

insulated. ▶ If the appliance is to be shut down for an extended period, drain the

central heating system.

Fig. 9 Mini expansion vessel location

[1] Mains water inlet pipe [2] Non-return valve [3] Mini expansion vessel - part no. 7 716 192 105 [4] Appliance

4.3 Appliance location and clearances

4.3.1 Appliance location

• Follow local regulations for the location within the property that the appliance is to be installed.

• This appliance is only suitable for installing internally within a property at a suitable location onto a flat, fixed rigid surface capable of supporting the appliance weight.

• The appliance is not suitable for external installation.

• Protect installation area against dust and moisture.

• Provide fresh air.

No surface protection is required against heat transfer from the appliance

The appliance must be installed where:

▶ The area is well lit, allowing to clearly see the appliance to carry out

any work or checks.

▶ An engineer can gain clear and safe access to work on the product or

component, including making adequate provision for visual inspection of flues in voids.

▶ The homeowner can gain clear and safe access to the controls, check,

top up or reset the appliance.

▶ Roof space installations must fully conform to BS 5410 part 1: roof

space installations.

▶ Products in roof spaces must have permanent fixed lighting, a

permanent fixed retractable ladder and a fixed floor area sufficient to allow access for normal use and servicing around the product and between and the access hatch. We would also recommend that a remote pressure gauge and filling loop are sited where the customer can gain easy access for checking and topping up.

Worcester 2000 – 6 721 814 551 (2019/09)

4.3.2 Rooms containing a bath or shower

CAUTION:

Risk of electric shock

▶ Any switch or appliance control using mains electricity must not be

within reach of a person using the bath or shower.

• In all cases the installation must be in accordance with the latest

amendments to the latest edition of the IET Wiring Regulations (BS7671).

• Check the IP rating of any control units to be used on this appliance.

• Circuit breaking devices should be used in accordance with the

regulations.

• Figure 10 is for guidance only.

600mm

Pre-Installation

600mm

2250mm

0010017086-001

Fig. 10 Bathroom installations

[1] Zone 1 [2] Zone 2 [2*] Without the end wall, zone 2 must extend 600mm from the bath [A] 600mm radius from the bath or shower

• Appliance protection rating - IPX4D

4.3.3 Appliance clearances

Appliance clearances

• The following details covering the installation, service and

maintenance clearances for the appliance.

CAUTION:

Risk of damage to appliance or property

The appliance will overheat if the clearance space around the appliance is restricted by objects.

▶ Do not restrict this space with the addition of cupboards, shelves etc.

next to or around the appliance.

▶ Do not store any combustible materials on or next to the appliance,

such as clothes, towels, paper or plastic bags.

Fig. 11 Appliance minimum clearances

Minimum clearances

Description Dimensions (mm)

X Appliance width 400 Y Appliance height 724

2250mm

Z Appliance depth 300

Installation/Maintenance

1 Overall clearance height 1115/1155 2 Overall clearance depth 850 3 In front of appliance 600 4 Overall clearance width 410 5 Above the appliance 191/231 6 Either side of appliance 5 7 Below the appliance 200 8 Compartment depth 320 9 Appliance to removable door 20

1) Height for either 60/100 flue or 80/125 flue

Table 9 Appliance minimum clearances

Appliances in compartments

Follow the latest requirements of BS6798 and BS5440 and note:

• Minimum clearances must be maintained.

• An access door is required to install, service and maintain the appliance and any ancillary equipment.

• If the appliance is installed in an unventilated airing/storage cupboard, there is no requirement to make a partition between the appliance and the storage space as long as the minimum clearances around the appliance are maintained.

0010012940-001

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Pre-Installation

4.4 Flue systems considerations

WARNING:

Flue systems

Possible flue gas escape

▶ Use Worcester, Bosch Group approved Condensfit II flue systems

only, no other manufacturer’s flue have been tested or approved for use with Worcester, Bosch Group appliances.

CAUTION:

Concealed flue systems:

▶ Where a flue system is going to be concealed, 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.

Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions.

Flue kit part numbers

Part number Flue Ø Description

7 716 191 082 60/100 Telescopic horizontal flue kit 7 716 191 171 60/100 Extended telescopic horizontal flue kit 7 733 600 048 60/100 Horizontal high level telescopic flue kit 7 719 003 702 80/125 Telescopic horizontal flue kit 7 719 002 430 60/100 Vertical balanced flue kit 7 719 002 431 80/125 Vertical balanced flue kit

Table 10 Flue kit assembly part numbers

4.4.1 Flue length

Horizontal maximum flue lengths

Flue length [L] Flue length [L]

Appliance 60/100 80/125

GC2000iW 25 C 9,000mm 12,000mm GC2000iW 30 C 9,000mm 12,000mm

Table 11 Maximum flue lengths - Horizontal flues

Effective flue length

Bend 60/100 80/125

45° 1m 1m 90° 2m 2m

Table 13 Effective length of bends

4.4.2 Flue options

The systems have different maximum flue lengths, refer to the following example flue options for those maximum flue lengths.

Horizontal high level flue assembly

60/100 mm

383 mm - 603 mm

130 mm Min

0010015190-001

Fig. 12 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – 60/100 = 202 - 603mm – 80/125 = N/A

Telescopic horizontal flue assembly

60/100 mm

[A] 350 mm - 570 mm [B] 570 mm - 790 mm

130 mm Min

0010015191-001

Fig. 13 Horizontal flue option

Telescopic horizontal flue assembly [A]

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 180 - 570mm – 80/125 = 405 - 600mm

Extended telescopic horizontal flue assembly [B]

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 570 - 790mm – 80/125 = N/A

Horizontal fixed length flue assembly

Vertical maximum flue lengths

Flue length [L] Flue length [L]

Appliance 60/100 80/125

GC2000iW 25 C 12,000mm 15,000mm GC2000iW 30 C 12,000mm 15,000mm

Table 12 Maximum flue lengths - Vertical flues

Flue system bends

NOTICE:

Effective flue lengths of bends:

Each bend used has an equivalent straight flue length.

▶ Refer to the table 13.

1050 mm

330 mm Min

0010015192-001

Fig. 14 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – 60/100 = 330 - 1,050mm – 80/125 = N/A

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Pre-Installation

Extended horizontal flue

0010015193-001

Fig. 15 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths".

Horizontal flue with additional 90° elbow

0010015194-001

Fig. 16 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus the 90° bend equivalent straight flue length as stated in Table 13 "Effective length of bends".

Horizontal flue with additional 90° elbows

High level horizontal flue with additional 90° elbow

0010015197-001

Fig. 19 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus the 90° bend equivalent straight flue length as stated in Table 13 "Effective length of bends".

High level horizontal flue with additional 90° elbows

0010015198-001

Fig. 20 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus 2 x 90° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

0010015195-001

Fig. 17 Horizontal flue option

• Flue length [L] (adaptor bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths" minus 2 x 90° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

High level horizontal flue

Fig. 18 Horizontal flue option

• Flue length [L] (initial bend included in length calculation) – Maximum flue length as stated in "Horizontal maximum flue

lengths".

Vertical balanced flue assembly

= 300 mm

B = 500 mm

0010015199-001

Fig. 21 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue

lengths".

0010015196-001

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Pre-Installation

Vertical balanced flue with 90° elbow offset

= 300 mm

B = 500 mm

0010015200-001

Fig. 22 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue lengths"

minus 2 x 90° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

Vertical balanced flue with 45° elbow offset

NOTICE:

Plume management length:

▶ The plume management length must be a minimum of 500mm and

must not exceed the maximum straight length for a horizontal Ø 60/ 100mm flue with a 60mm plume management system as stated previously.

Horizontal plume management runs

▶ The initial horizontal run from the terminal elbow must have a

minimum 10° fall back, (stop tabs in the elbow prevent less than 10°) to the appliance for proper disposal of condensate.

▶ Any further horizontal runs after an elbow can be 3°.

WARNING:

Minimum plume management length:

The minimum distance of 500mm must be maintained between air inlet and exhaust.

▶ Do not terminate the plume management inside the terminal

exclusion zone (shaded area) shown in figure 25.

= 300 mm

B = 500 mm

0010015201-001

Fig. 23 Vertical flue option

• Flue length [L] – Maximum flue length as stated in "Vertical maximum flue lengths"

minus 2 x 45° bends equivalent straight flue length as stated in Table 13 "Effective length of bends".

4.4.3 Plume management system

For every extra 1,000mm of plume management after the first 500mm, the internal 60/100 flue length must be reduced by 700mm, up to a maximum of 4,500mm of plume management.

2,800

2,100

1,400

[mm]

Fig. 24 Reduction to flue length as plume length increases graph

[1] Reduction to flue length [mm] (maximum reduction 2,800mm) [2] Plume length [mm] (maximum plume length 4,500mm)

700

500 1,500 2,500 3,500 4,500

[mm]

0010023114-001

±80°

0010013548-001

Fig. 25 Terminal exclusion zone

NOTICE:

Cutting the 500mm pipe

▶ The Plume management extension kit contains the components

required for such a configuration.

4.4.4 Flue terminal positions

CAUTION:

Flue terminal positions

▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products

entering the building.

Worcester 2000 – 6 721 814 551 (2019/09)

Vertical flue terminal positions

Pre-Installation

1/2

1500

RIDGE FLUERIDGE VENT

600

BOUNDARY LINE

BOUNDARIES

1500

300

500

1200

300

1500

600

300

1500

500

600

400

300

400

600

500

2000

600

1500

Fig. 26 Vertical flue terminal positions

Key to figure 26:

[1] 1,500mm measured between a vertical flue terminal and an

opening or vented window. 500mm measured horizontally between a vertical flue terminal and an opening or vented window providing the flue terminal is at least 300mm above the opening.

[2] Minimum clearance to an additional flue, 600mm to a room

sealed flue or 1,500mm to an open flue.

[3] 300mm clearance from a vertical flue terminal adjacent to a

boundary line, unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting a terminal in relation to boundary lines.

[4] 600mm minimum clearance measured from an opening or vented

skylight to a vertical flue terminal. If the terminal is within 1,500mm of the opening or vented skylight then it must be at least 300mm above the opening.

[5] 500mm clearance measured horizontally from a vertical flue to a

vertical structure. Not required if the terminal is 300mm above the structure.

[6] The flue must not penetrate the roof in the shaded area.

The terminal must be at least 1,500mm from the opening or vent when sited below the window or 600mm when sited to either side or above.

[7] 400mm measured diagonally from a pitched roof or 500mm in

regions with heavy snow fall. 300mm measured vertically from the air intake to the closest intersection with the roof.

[8] 1,200mm separation measured between a vertical flue and a

horizontal flue terminal.

[9] For the purpose of determining suitable flue terminal positions for

gas appliances, the boundary can be considered to extend to the

0010021441-002

centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways.

[10] 1,500mm measured between a vertical flue terminal and an

opening or vented window. 500mm measured horizontally between a vertical flue terminal and an opening or vented window providing the flue terminal is at least 300mm above the opening.

Note:

▶ Where a vertical flue terminates in an area that is enclosed on 3 sides,

the flue must be no more than 1,000mm below the lowest roof line. You must ensure that all clearances are maintained and that products of combustion disperse safely from the area.

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Pre-Installation

Horizontal flue terminal positions

300

1500

300

BOUNDARY LINE

OPENING OPPOSITE

2000

300

600

TOP

600

SKYLIGHTDORMA

600

1500

600

200

300

200

300

600

300

600

300

1200

1000

300

1200

BOUNDARY LINE

200

1/2

100

BOUNDARIES

Fig. 27 Horizontal flue terminal positions

200

BELOW GROUND OPEN LIGHT WELL

<1000

300

100

600

300150

100

300

0010021442-002

Worcester 2000 – 6 721 814 551 (2019/09)

Key to figure 27:

[1] 200mm below eaves and 75mm below gutters, pipe and drains. [2] The dimension below eaves, gutters, pipes and drains can be

reduced to 25mm, as long as the flue terminal is extended by 100mm past any overhang. The telescopic flue joint must be sealed with suitable silicone sealant if it is external to the building.

[3] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[4] 1,200mm separation measured between terminals facing each

other.

[5] 600mm distance to a surface or boundary line facing a terminal,

unless it will cause a nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[6] The terminal must be at least 1,500mm from the opening or vent

when sited below the window or 600mm when sited to either side or above.

[7] 600mm diagonally to an opening door, air vent or opening

window.

[8] 1,200mm separation measured between a vertical flue and a

horizontal flue terminal.

[9] For the purpose of determining suitable flue terminal positions for

gas appliances, the boundary can be considered to extend to the centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways.

[10] 300mm to an internal or external corner. 300mm above a

surface, such as the ground/ floor level or roof surface. * If the terminal section is less than 150mm and has two screws securing it to the elbow, the terminal section will not require a supporting bracket.

[11] 300mm above, below and either side of an opening door, air vent

or opening window.

[12] Below ground level in an open lightwell. The flue must be at least

600mm from the opposing surface and have at least 300mm clearance either side and below. The flue terminal must be no more than 1,000mm from the top of the lightwell.

[13] Flues should clear any LPG storage by 1,000mm horizontally and

300mm above.

[14] Proximity of flue duct outlet to boundaries, 2,000mm distance to

an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

[15] 300mm from an opening or vented window, 150mm to a fixed

unvented window.

[16] The dimension below eaves, balconies and car ports can be

reduced to 25mm, as long as the flue terminal is extended to clear any overhang. The telescopic flue joint of the terminal must be sealed with suitable silicon sealant if it is external to the building.

Pre-Installation

Note:

▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000mm from the top of a light well

due to the build up of combustion products.

▶ Dimensions from a flue terminal to a fanned air inlet to be determined

by the ventilation equipment manufacturer.

▶ A flue terminal guard shall be fitted whenever a terminal or air inlet is

fitted less than 2,000mm above ground, above a balcony or above a flat roof to which people have access.

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Pre-Installation

4.4.5 Plume re-direct and plume management terminal positions

Maximum and minimum plume management lengths:

▶ A minimum distance of 500mm must be maintained between the

plume management outlet and the flue air intake.

▶ The maximum plume management length is 4.5 metres for the

appliances detailed on the front of this manual.

▶ The 45° bend is equivalent to 0.75 metres of straight plume

management and the 90° bend is equivalent to 1.5 metres.

NOTICE:

▶ All measurements are the minimum clearances required. ▶ Refer to “Horizontal flue terminal positions” for all concentric flue

terminal positions unless the flue position is specified in figure 28 “Plume re-direct and plume management terminal positions”.

▶ Terminals must be positioned so to avoid combustion products

entering the building.

▶ Support the flue at approximately one metre intervals and at a change

of direction, use suitable brackets and fittings.

180°

±80°

200

300

200

300

150

300

600

BOUNDARY LINE

300

150

BOUNDARY LINE

TOP

200

1200

±45°

2000

600

EXCLUSION ZONE

OPENING

OPPOSITE

300

TOP

±80°

600

300

BOUNDARY LINE

600

300

150

1,500

150

300

1500

300

≥140

≥5

EXCLUSION ZONE

150

100

200

600

300

100

≥5

EXCLUSION ZONE

300

150

TOP

300

150

FLUE TERMINAL GUARD

7 716 191 176

0010021676-001

Fig. 28 Plume re-direct and plume management terminal positions

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Pre-Installation

Key to figure 28 - Plume re-direction terminal positions:

[1] This feature allows some basic plume re-direction options on a

standard telescopic horizontal flue terminal. 300mm minimum clearances to a opening e.g. window. However the minimum clearances to an opening in the direction that the plume management is facing, must be increased to 1,500mm. Where the flue is less than 150mm to a drainpipe and plume redirection is used the deflector should not be directed towards the drainpipe.

[2] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[3] Where the flow of products of combustion is not at right angles to

the boundary, the 600mm dimension may be measured in the direction of flow as long as the terminal is not less than 300mm from the boundary.

[4] When redirecting the flue discharge the terminal end must be at

least 1,500mm from any opening in the direction of the discharge to prevent combustion products from entering the building.

Key to figure 28 - Plume management terminal positions:

[5] 600mm distance facing a surface or a boundary line, unless it will

cause a nuisance. BS 5440:Part 1 recommends that care is taken when siting a terminal in relation to surfaces or boundary lines.

[6] Proximity of flue duct outlet to boundaries, 2000mm distance to

an opening in adjacent building facing a terminal. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to boundary lines.

[7] 300mm adjacent to a boundary line, unless it will cause a

nuisance. BS 5440: Part 1 recommends that care is taken when siting terminal in relation to surfaces or boundary lines.

[8] 300mm distance from a boundary line to the air intake as long as

the exhaust terminal faces away from the boundary line. The exhaust terminal must have a minimum 300mm clearance to a surface below and there must be at least 600mm clearance when measured horizontally in a straight line from the exhaust terminal to any other surface.

[9] Plume Management kit air intake can be reduced to 150mm

providing the flue exhaust outlet is no less than 300mm adjacent to a boundary line.

[10] Above, below and either side of an opening door, air vent or

opening window. Using a Plume Management kit the air intake measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance.

[11] Below balcony or overhang. The air intake clearance can be

reduced to 150mm providing the flue exhaust outlet has a 200mm clearance.

[12] 1,200mm between terminals facing each other

[13] Internal/external corners. The air intake clearance can be reduced

to 150mm providing the flue exhaust outlet has a 300mm clearance.

[14] Clearances no less than 200mm from the lowest point of the

balcony or overhang.

[15] If a plume management kit is installed within the confines of a

carport or other covered, partially enclosed extension, then the exhaust terminal must be positioned at least 1200mm away from any opening into the building which is sited within the footprint of the carport. If the exhaust terminal is extended at least 300mm beyond the footprint of the carport then the distance from the terminal to an opening within the carport can be reduced to 600mm.

The exhaust terminal can also be routed though the roof of the carport providing 25mm clearance is provided around the flue pipe to any flammable material and that it extends at least 300mm above the roof. The air intake must have a minimum 150mm clearance to any opening in the building in order to ensure the integrity of the structure is maintained. If the exhaust terminates within the footprint of the carport then the carport must have at least 2 sides completely open. If the exhaust terminates at least 300mm beyond the footprint of the carport then the carport must have at least one completely open side. The exhaust terminal must be positioned to ensure that plume will not cause nuisance or damage to vehicles and that minimum clear distances in front of the terminal will not be impeded by vehicles.

Note:

▶ Installations in car ports are not recommended. ▶ The flue cannot be lower than 1,000mm from the top of a light well

due to the build up of combustion products.

▶ Dimensions from a flue terminal to a fanned air inlet to be determined

by the ventilation equipment manufacturer.

▶ Plume kits running horizontally must have at least a 3° fall back to the

appliance for proper disposal of condensate, except or the initial horizontal run from the terminal. The initial plume kit horizontal run will have at least a 10° fall back to the appliance, due to the terminal elbow design, for proper disposal of the condensate.

1) 600mm in case two plume management kits are used on opposing terminals.

Each terminal should use a minimum length of 500mm plume management.

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Pre-Installation

4.5 Condensate discharge

Full details on condensate discharge.

▶ Follow the latest version of BS6798 and HHIC guidance.

For correct installation and trouble free operation of the appliance the following advice should be followed:

1. It is a requirement that the condensate drain is installed

internally.

2. If external disposal is the only means of condensate discharge, then the CondenseSure siphon or a condensate pump must be fitted.

3. All condensate pipe work must ‘fall’ from the appliance by a minimum of 3° (52mm per metre) to ensure adequate condensate flow.

4. The pipe work route must allow air to be supplied back to the appliance for correct operation.

5. Connection to a rainwater down pipe must include an air break.

Also:

• Assessment of the risk of the condensate pipe freezing must be carried out and appropriate precautions taken where necessary. This must take into account the specific site conditions.

• The condensate pipe work connected to the condensate drain outlet on the appliance should have a minimum internal diameter (ID) of 19mm.

• Keep external pipe work as short as possible. Further precautions against freezing must be taken if external pipe runs exceed 3m.

• External pipe work should have a minimum internal diameter (ID) of 30mm.

• Minimise the number of bends and connectors.

• Remove burrs after cutting pipe.

• Remove surplus solvent from the interior of the pipe.

• The condensate pipe work shall be run in standard drainpipe material, e.g. poly(vinyl chloride) (PVC), unplasticised (vinyl chloride) (PVC-U), acrylonitrilebutadiene.styrene (ABS), polypropylene (PP) or chlorinated poly(vinyl chloride) (PVC.C).

4.5.1 Condensate pipe work

NOTICE:

General consideration

▶ Where a new or replacement appliance is being installed, access to

an internal “gravity discharge” point should be one of the factors considered in determining appliance location.

▶ Condensate pipe connection at the appliance:

The condensate pipe must have a nominally outside diameter of 22mm plastic pipe.

▶ Ensure there are no blockages in the pipe run. ▶ Ensure that the discharge method for the installation can effectively

handle the condensate waste from the appliance.

4.5.2 Condensate production

When the appliance is in operation it can produce between 1 to 2 litres of condensation per hour.

This discharge is a constant drip feed during the production of condensate and does not release in frequent large volume discharges repeatedly.

4.5.3 Internal connections

Good Practice

▶ The following guidance indicates the good practices that must be

maintained for the Installation and Maintenance of a product.

Soil stack connection

 Figure 29

In order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted.

Wherever possible, the condensate drainage pipe should be routed and terminated so that the condensate drains away from the appliance under gravity to a suitable internal foul water discharge point such as an internal soil and vent stack. A suitable permanent connection to the foul waste pipe should be used.

0010012746-001

Fig. 29 Disposal to soil vent stack

[1] Condensate discharge from appliance [2] Soil and vent stack [3] Minimum 450mm and up to 3 storeys

NOTICE:

Unheated internal areas.

The condensate discharge may freeze in areas during prolonged cold temperatures.

▶ Internal pipe runs in unheated areas such as lofts, basements and

garages should be treated as external runs and consideration should be given to using a CondenseSure siphon.

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Pre-Installation

Waste pipe connection

 Figure 30

Alternatively if the first option is not possible an internal kitchen, bathroom or washing machine waste pipe etc. can be used. Ensure that the condensate drain pipe is connected “down stream” of the waste trap and that the condensate drain enters into the top of the pipe using a swept tee.

75mm

min.

75mm

Max.

min.

0010012767-001

Fig. 30 Waste pipe disposal

[1] Condensate discharge from appliance [5] Visible air break at plug hole [6] 75mm sink waste trap

Condensate pump

 Figure 31

Where direct connection to a “gravity discharge” pipe work is not physically possible, or where very long internal runs would be required to reach a suitable discharge point, condensate should be removed using a proprietary condensate pump, of a specification recommended by the condensate pump manufacturer.

• The pump outlet should discharge to a suitable “gravity discharge”

outlet. – The condensate then flows, by gravity, through the 22mm plastic

pipe to the condensate discharge point.

Fig. 31 Condensate pump example

[1] Condensate discharge from appliance [7] Condensate pump [8] Pipe work transition [C] Gravity discharge pipe work

Proprietary condensate pump

▶ Ensure minimum and maximum pump lifting heights are followed as

per condensate pump manufacturers instructions.

Min.

0010023656-001

4.5.4 External connections

NOTICE:

Risk of condensate discharge freezing

▶ No external disposal of condensate unless the CondenseSure

siphon or a condensate pump is fitted.

NOTICE:

Rainwater down pipe or external drain disposal

Untreated condensate must not be allowed to flow into streams or rivers

▶ A rainwater down pipe or an external drain shall only be used for

condensate disposal if the down pipe or external drain is connected to a combined foul and rainwater drainage system

▶ Refer to BS 6798 for more information on condensate disposal

NOTICE:

Grey water recovery system

Contamination of recovered water

▶ Condensate disposal shall not be allowed into a grey water recovery

system that is intended for re-use

External disposal considerations

NOTICE:

Freezing conditions

Frozen condensate will block the condensate drain pipe and stop the appliance from running

▶ Pipe lengths should be kept to a minimum and the routed as vertically

as possible.

NOTICE:

Condensate waste disposal

▶ Care should be taken when siting a soak-away to avoid causing

damage to existing services and building footings.

If no other discharge method is possible then the use of an externally run condensate drainage pipe terminating at a suitable foul water discharge point, or purpose-designed soak away, may be considered. If this method is chosen then the following measures should be adopted:

▶ A CondensSure external siphon accessory (part number:

7716192746) or third party condensate pump must be used.

▶ The external run be kept as short as possible and ideally should not

exceed three metres. Additional precaution against freezing must be taken if the external pipe run does exceed three metres.

▶ The pipe should be run internally as far as possible before going

externally and the pipe diameter should be increased to a minimum internal diameter (ID) of 30mm before it passes through the wall to the exterior. The pipe should be insulated externally using suitable waterproof and weather resistant insulation.

▶ The hole through the wall for the condensate pipe should be sealed to

the building fabric on the internal and external face using a suitable building material.

▶ The external pipe should take the shortest and least exposed route to

the discharge point, and should "fall" as steeply as possible away from the appliance, with no horizontal runs in which condensate might stand.

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Pre-Installation

▶ The use of fittings, elbows etc. should be kept to a minimum and any

internal burrs on cut pipe work should be removed so that the internal pipe section is as smooth as possible.

▶ All external pipe drainage will be improved if the end is cut at 45° as

opposed to a straight cut.

▶ In situations where there are likely to be extremes of temperature or

exposure, the use of a proprietary trace-heating system for external pipe work, incorporating an external frost thermostat, should be considered. All other guidance above and the instructions for the trace heating system, should be closely followed.

▶ As well as trace heating, other methods for protecting pipe work that

are run externally should be considered to prevent freezing during prolonged periods.

– Insulation materials can be used, these should be of class “O”

grade with an outer coating that is weather proof and have a UV resistant finish. A minimum of 19mm thick insulation is recommended for 32mm external pipes.

– The use of a drain cover (such as those to prevent leaf blockage)

may offer further protection from wind chill.

– An air break on the external pipe work can reduce the risk of the

appliance being inoperable due to the blocking and backing up of the condensate.

Good Practice

▶ The following guidance indicates the good practices that must be

maintained for the Installation and Maintenance of a product.

Rain water down pipe with external air break

 Figure 32

• Refer to following example to dispose of condensate to a rain water down pipe.

• An air break or rain water hopper must be utilised, between the appliance condensate outlet and the drainpipe, outside the property, to avoid flooding of the appliance should the downpipe become obstructed.

0010012784-002

Fig. 32 Disposal into rain water down pipe

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size [10] External rain water pipe to foul water [11] External air break [12] Air gap [13] Strap-on fitting [14] 43mm 90° male/female bend [20] Rain water hopper

Open drain or gully

 Figure 33

Where the pipe terminates over an open drain or gully:

• Refer to following example to dispose of condensate to an open drain or gully.

• The pipe should terminate below the grating level, but above water level, in order to minimise “wind chill” at the open end.

• The use of a drain cover (such as those used to prevent blockage by leaves) may offer further protection from wind chill.

Fig. 33 Disposal to open drain or gully

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size

Worcester 2000 – 6 721 814 551 (2019/09)

25mm min.

0010023655-002

Condensate soak away considerations

Before deciding to use a purpose-made soak away the history of the locality and the ability of the surrounding area to disperse the condensate should be taken into account, e.g. areas prone to flooding and ground with a high clay content can result in poor drainage with an increased risk of water logging or freezing causing the condensate pipe to become obstructed by water or ice and the boiler to shut down,

Although it is possible to increase the size of the soak away and the area with limestone chippings in clay soil areas, if the clay content is high and prevents effective dispersal of the condensate then a soak away may not be a suitable means of condensate disposal and an alternative method should be used.

Pre-Installation

400mm min.

25mm min.

500mm min.

10mm min.

Condensate soak away with external air break

 Figure 34

• Refer to following example to dispose of condensate to a soak away.

• The condensate soak away must be sited at least 500mm away from building footings.

• The condensate drainage pipe may be run above or below the ground to the soak away. The following example shows drainage pipe run above ground.

• The soak away must use a minimum of a 100mm Ø plastic tube with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube. The holes must face away from the house.

• The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm.

• An air break must be installed in the external pipe work as shown to avoid an airlock during ground flooding/adverse weather conditions which could prevent the condensate from discharging.

Minimum hole size for the condensate soak away must be 400mm deep by Ø 300mm.

Fig. 34 Disposal to soak-away

[1] Condensate discharge from appliance [8] Pipe work transition [9] Insulate and increase pipe size [11] External air break [12] Air gap (minimum 10mm) [15] 100mm minimum Ø plastic pipe [16] Drainage holes [17] Limestone chippings [18] Bottom of sealed tube [19] Increase size of soak away size and the area with limestone

chippings if in clay soil area. Not recommended for high clay soil areas.

0010012788-002

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Pre-Installation

Minimum Standard

▶ The following guidance indicates the minimum standards that must

be maintained for the Installation and Maintenance of a product.

Appliances with condensate pump, CondenseSure accessory or have trace heating fitted.

The need to insulate the pipe work through the wall is not normally required for appliances with a condensate pump or CondenseSure/ trace heating fitted for external runs under three metres.

Trace heating fitted:

• Check with trace heating manufactures instructions for additional requirements.

Condensate pump or CondenseSure fitted to the appliance:

• External pipe work exceeding three metres in length or installation with increased risk of freezing due to environmental factors:

– Additional protection of insulating the entire run of external pipe

work [5] should be carried out, with a recess in the external face allowing better insulation protection coverage [4] as it transitions to the outside of the building.

– The hole through the wall must be sealed to the building fabric on

the internal [1] and external [3] face using a suitable building material, (use a 40mm sleeve [2] to pass the condensate discharge through and then seal the internal and external faces).

• The pipe [1 or 3] should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing.

• In all normal circumstances a PRV discharge pipe installation as described above is suffice to meet all but the most exceptional circumstances.

– Where the PRV discharge pipe could be susceptible to damage,

vandalism, freezing etc that could cause either a blockage or restriction in the ability to discharge safely then a tundish should be considered. The tundish should be sited in a position where damage to the property or occupants cannot occur from any spillage or discharge.

0010026770-001

Fig. 35 Additional protection for transition through wall

[1] Internal face sealed (32mm pipe sealed to sleeve) [2] 40mm sleeve [3] External face sealed (32mm pipe sealed to sleeve) [4] Insulation recessed into the wall [5] Condensate discharge pipe

4.6 Pressure relief discharge

4.6.1 Pressure relief pipe work

CAUTION:

Scalding risk from hot water or steam!

▶ The pressure relief valve (PRV) is an appliance safety device and may

discharge hot water or steam when activated.

▶ The outlet pipe should be sited in such a way that it does not cause a

hazard or an obstruction when discharging, for example above a window, entrance door or other public access way.

• The pressure relief discharge pipe [1 or 3] should be run in at least 15mm diameter copper pipe or pipe made of a material that will withstand PRV discharge temperatures and pressures and which complies with BS 5254 or BS EN 1451.

• Plastic pipe work must be properly supported with a maximum of 300mm between supports to prevent sagging and run downwards away from the appliance.

• The pressure relief should discharge away from any electrical or other hazard, preferably to an external drain or soak-away.

6720818077-38.1Wo

Fig. 36 Pressure relief pipe work

[1] Discharge pipe (turned back onto external wall example) [2] Outside wall [3] Discharge pipe (into drain or gully example) [4] External drain

4.6.2 Alternative PRV connections - Combined PRV/condensate

The PRV or a combined PRV/ condensate discharge can be connected into a suitable internal waste system, the installer must ensure that all the pipe work, including the waste pipe, is capable of withstanding PRV temperatures and pressures.

Connection to a waste water pipe is possible by using either:

• A shielded tundish with non-return valve can be used to discharge upstream of a trap (there must not be a trap directly in the PRV discharge pipe without a tundish.

• A PRV can discharge directly into a suitable waste pipe downstream of a trap. Connections must be on top of the pipe to ensure they do not block. A Hotun (or similar) can be fitted for visual indication if desired but is not necessary.

The guidance of BS 6798 sections 6.3.5 and 6.4.3.2a must be followed.

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Pre-Installation

4.7 Cleaning primary systems

NOTICE:

Risk of damage to system or appliance!

Debris from the system can damage the appliance and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee and contravene the Building Regulations.

▶ It is a requirement of the Building Services Compliance Guide which

is a second tier document to the Building Regulations to flush and inhibit the primary water system in accordance with BS 7593.

▶ The Building Services Compliance Guide recommends that a primary

water cleanser is fitted to the system.

▶ Worcester Bosch recommend fitting a filter that will help remove both

magnetite and non-magnetic debris. Worcester offers varies filters that helps remove both magnetite and non-magnetic debris; see accessories list for available options.

NOTICE:

Risk of damage to system or appliance!

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

▶ Salt based, artificially softened water MUST NOT be used to fill the

system

WARNING:

Sealing agents

▶ In cases where all attempts to find a micro leak have failed,

Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

Water treatment products

Suitable water treatment products can be obtained from the following manufacturers:

ADEY 01242 546717

www.adey.com

FERNOX 0870 601 5000

www.fernox.com

SENTINEL 0800 389 4670

www.sentinel-solutions.net

Table 14

4.7.1 Flushing the system

Flushing the system using existing appliance/circulating pump or new appliance.

New appliances

▶ A new appliance must only be used to assist the cleaning of a newly

installed system.

NOTICE:

Sealing agents

Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger.

▶ Heating systems may lose small amounts of water over time. In cases

where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

Before cleaning the system:

▶ Ensure that the system and pipe work is in good working order. ▶ Where possible keep the existing appliance/circulating pump in

place when flushing the system before installing the new appliance. Alternatively use an after market power flushing system or similar to remove magnetite and other debris from the central heating system.

– Even new central heating systems contain contaminants that

need to be removed before treating the system with inhibitor/antifreeze.

– When an appliance is installed onto a new system then it is

possible to use the appliance whilst cleaning the system. A system filter must be fitted to the return to reduce the risk of contaminants entering the appliance.

▶ Follow the guidance of BS7593.

Inhibitor

Add a suitable inhibitor or combined inhibitor/anti-freeze, if the system is exposed to freezing conditions, to the heating system in accordance with the DWTA code of practice and manufacturer‘s guidelines.

Products approved to the BuildCert standard are deemed as compatible with the components and equipment within the appliance and system.

▶ Fill the system with cold water and check for leaks. ▶ Open all drain cocks and drain the system. ▶ Close drain cocks and add a suitable flushing agent compatible with

aluminium at the correct strength for the system conditions in

accordance with the manufacturer‘s instructions. ▶ Mark the position of the lockshield valves and open them fully. ▶ Fully open all TRVs. ▶ Circulate the flushing agent before the appliance is fired up. ▶ Run the appliance/system at normal operating temperature as

directed by the manufacturer of the flushing agent. ▶ Drain and thoroughly flush the system to remove the flushing agent

and debris. Do not drain the system through the PRV of new

appliances. ▶ It may be necessary to use a power flushing machine to aid the

cleansing procedure in some circumstances. ▶ Close the drain cocks and manual air vents. ▶ Existing appliance/circulating pump if continuing to use before

new appliance is installed.

– Add a suitable inhibitor to the system in accordance with the

manufacturers instructions.

– Fill the system to between 1 and 1.5 bar via a WRAS approved

filling loop.

– Vent any air from the appliance and system. ▶ New appliance.

– Once the new appliance has been installed follow the guidance in

Filling the appliance and adding inhibitor section.

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Installation

5 Installation

NOTICE:

Risk of damage to appliance or accessories.

▶ All the previous pre-installation sections must be read and

requirements met before starting the appliance or flue installations.

CAUTION:

Risk of injury through incorrect lifting and carrying!

▶ Only lift a manageable weight, or ask for help. ▶ Bend the knees and keep the back straight with feet apart, when

lifting or putting down heavy objects. ▶ DO NOT lift and twist at the same time. ▶ Lift and carry object close to the body.

Appliance on site

▶ Check contents of delivery are undamaged. ▶ Remove the appliance from its packaging check the contents against

the scope of delivery. ▶ Once the appliance is unpacked the installation can commence.

Important handling instructions

• It is advised that two people are used to carry the carton from the van

to the point of delivery.

• Once the car ton has been delivered, the outer carton is removed first.

Care should be taken when releasing the straps. If a sharp implement

is used make sure the outer carton is not pierced and that the

implement is used in such a way so that it may not cause personal

injury.

• All sharp objects must be covered or the blade retracted after use and

put away in a safe place. Care should be taken when lifting the

appliance from the base and the proper technique for safe lifting of

any heavy object should be strictly observed.

Additional requirements for roof space installations

• The unpacked appliance can now be moved into the loft space

• Two sets of steps should be used.

• Two people should share the lifting of the appliance up to the loft

hatch, tilt and slid on its back into the loft space.

• Ensure that the roof space has permanent fixed lighting, a permanent

fixed retractable ladder and a fixed floor area, from the hatch to the

appliance installation point. This will allow access for installation,

normal use and servicing.

Appliance positioning

▶ Ensure the appliance is mounted onto a flat, fixed rigid surface

capable of supporting the appliance weight.

▶ Ensure all aspects of the installation are considered when positioning

the appliance, flue run and discharge, condensate disposal, PRV discharge etc.

WARNING:

Damage to property!

Damage caused by drilling into pipes, electrical cables, damp proof course or other hazards.

▶ Before drilling ensure that there are no obstructions or other hazards.

NOTICE:

Damage to appliance!

Residue, metal shavings, and contaminants in the system pipe work can damage the appliance.

▶ Flush the system pipe work thoroughly to remove all residue. ▶ Follow the instructions with respect to cleaning primary systems.

Running pipes to the appliance.

• The area around a rear flue outlet must be avoided.

5.1.1 Mounting bracket fixing

Wall mounting template

▶ The wall mounting template has been sized to allow for the minimum

clearances around the appliance, ( section 4.3.3 "Appliance clearances").

 figure 37

The appliance wall mounting template shows the relative positions of the flue and the top fixings of the wall mounting bracket.

▶ Fix the wall mounting template [3] to the wall in the desired position. ▶ Drill the holes [4] through the template for the primary fixing points

as indicated on the template. – Additional fixing points for the appliance will be indicated on the

wall mounting template.

Flue outlet position.

The appliance wall mounting template has the flue centre lines for the following flue systems:

• 60/100mm

• 80/125mm

Before installing the appliance, ensure that the system has been cleaned

5.1 Position the appliance

WARNING:

▶ Ensure the mains gas supply is isolated before starting any work

and follow all relevant safety precautions.

Flue turret adapter

▶ The flue turret adaptor has an in-built 3° angle giving the flue

assembly the rise from the appliance to ensure the condensate flows back to the appliance.

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Installation

Rear flue outlet [2].

▶ Mark centre line of flue to be used; the external diameter of the hole

can also be marked if required.

▶ If extensions are to be added then the complete flue must rise at an

angle of 3° from the appliance.

Side flue outlet [1].

▶ Mark from the centre line of the wall mounting template to the wall

which the flue will pass through.

▶ Allow for a rise of 52mm per metre length of flue, to give a 3° angle.

Example hole size.

• If a 60/100mm diameter flue is to be used, a 125mm diameter hole is required.

• If using the weather sealing collar by pushing it through from inside the property, then a 150mm diameter hole is required to accommodate this.

Flue outlet position marked and ready to drill hole.

▶ Drill hole using a core drill or similar. ▶ Clear any debris from the site.

Appliance fixings and flue outlet drilled and ready.

▶ Remove the wall mounting template.

NOTICE:

Appliance - hydraulic connections

▶ Ensure all water pipe work, to be connected, are isolated/drained

and follow all relevant safety precautions.

▶ Be careful of plastic components when using a naked flame on pipe

work.

Surplus water may be present inside the appliance due to factory testing.

External condensate pipe work or internal pipe runs in unheated areas such as lofts, basements and garages exposed to prolonged cold temperatures should be protected  chapter 4.5.

Connection sets fitting Installing the connection sets

Refer to figure 38. ▶ Ensure the sealing washers are fitted in the connection sets before

installing the connection sets.

0010029478-001

Fig. 37 Wall mounting template

1 Side exit flue example 2 Rear exit flue example 3 Wall mounting template 4 Primary fixing points D 125mm

5.2 Appliance connections

WARNING:

Appliance - gas connection

▶ Ensure the mains gas supply is isolated before starting any work

and follow all relevant safety precautions.

12 3 45

Fig. 38 Fitting the connection sets

Description # From left case edge # From wall

CH flow 1 68mm 6 60mm DHW outlet 2 133mm 7 30mm Gas 3 200mm 7 30mm DCW Inlet 4 267mm 7 30mm CH return 5 332mm 6 60mm

Table 15

▶ Connect the heating, domestic water and gas pipe work to the

respective compression adaptor on the connection sets.

##########-001

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Installation

Fitting the hose to the condensate trap

▶ Take the cap off the drain on the condensate trap. ▶ Fit the condensate hose on the condensate trap.

0010016232-002

Fig. 39 Fitting the hose to the condensate trap

▶ Only route the condensate hose with a slope and connect it to the

drain line.

▶ Check tightness of connection at condensate trap.

5.3 Hanging the appliance

NOTICE:

Transport protection covers

▶ Remove the internal transport packaging and protection covers from

the appliance where applicable.

Installing pipework

DANGER:

Contaminated heating water can damage the appliance!

Residue in the pipe work can damage the appliance.

▶ Flush the pipe work before installing the appliance.

▶ Determine internal diameter for the gas supply. ▶ All pipe connections in the heating system must be able to withstand

a pressure of 3 bar, and 10 bar in the DHW circuit. ▶ Install service valves and gas isolator. ▶ To fill and drain the heating system, install a drain valve at the lowest

point of the system. ▶ Install the Pressure Relief Valve discharge pipe to the latest advice in

BS6798. ▶ Always route discharge pipes with a continuous fall.

Appliance connections

NOTICE:

Commissioning without water damages the appliance!

▶ Only operate the appliance when filled with water.

Removing the front casing

The front casing is secured with two screws to prevent unauthorised removal (electrical safety).

▶ Always secure the casing with these screws.

▶ Loosen the two screws [1] and pull the bottom of the casing forward. ▶ Lift off the casing.

0010029675-001

Fig. 40 Removing the front casing

765321

Fig. 41 Connections on the gas and water side

[1] Condensate hose connection [2] CH flow valve [3] DHW outlet connection [4] PRV tail connection (heating circuit) [5] Gas isolator [6] Cold Mains inlet valve [7] CH return valve [8] Connections for keyless filling link accessory

▶ Connect the CH flow pipe to the appliance 22mm compression

connection. ▶ Connect the CH return pipe to the appliance 22mm compression

connection. ▶ Connect the gas supply to the appliance gas cock 22mm

compression connection. ▶ Connect the Cold Mains inlet to the appliance 15mm compression

connection. ▶ Connect the DHW outlet to the appliance 15mm compression

connection.

0010029708-001

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Installation

Connect condensate discharge pipe

▶ Connect the condensate discharge pipe to the appliance condensate

hose outlet connection.

0010029707-001

Fig. 42 Connecting to the condensate outlet connection

[1] Condensate hose outlet connection [2] Condensate discharge pipe

Connect PRV discharge pipe

CAUTION:

Risk of damage to appliance!

Only use compression fitting when connecting to the PRV tail.

▶ Do not solder to the PRV tail connection.

▶ Connect the PRV discharge pipe to the appliance PRV tail via

compression fitting (not supplied).

5.4 Flue turret/adaptor installation

NOTICE:

Flue installation

▶ Refer to the Flue Kit Installation instructions provided with your flue

kit to correctly install the flue with this appliance.

▶ Do not exceed the maximum straight length for a horizontal or vertical

flue or a 60mm plume management system (if used) as stated in the relevant Installation and Maintenance Instructions manual or addendum.

Telescopic flue

▶ Cutting the flue to an exact measurement is not required as the

telescopic flue terminal can allow for some adjustment.

Apply silicone lubricant to sealing surfaces, to ease assembly of flue

components.

Refer to the manual supplied with the flue kit for complete installation

instructions.

▶ For plume management effective lengths and the effective flue

lengths,  chapter 4.4.

Additional notes and reminders:

• Ensure that all cut lengths are square and free from burrs.

• Ensure that the flue and seals are not damaged.

• The flue is sealed when assembled correctly, the components are pushed fully home and secured.

• The flue rises from the appliance at an angle of 3° or 52mm per metre length.

• Support the flue at each flue extension joint and at each change of direction, use suitable brackets and fittings:

– Flue bracket 100mm part number: 7 716 191 177. – Flue brackets 100mm x 6 part number: 7 716 191 178. – Flue bracket 125mm part number: 7 716 191 179.

Fig. 43 Connecting to the PRV tail connection

[1] PRV tail connection

0010029713-001

2,000mm

1,000mm

104mm52mm

Fig. 44 Slope for condensate disposal

Refer to figure 45. ▶ Remove the three inner flue tube retaining screws [1].

– The inner tube will be held in place in the appliance.

▶ Check the appliance flue seal [2] is correctly seated and apply

silicone grease.

Flue turret [A] fitting ▶ Align the flue turret [A] to the appliance flue outlet with flat facing [3]

to the rear of the appliance. – This should be pushed straight down, on to the appliance.

▶ The three inner flue tube retaining screws [1] are, re-used to secure

the flue turret [A].

Vertical adaptor [B] fitting ▶ Align the vertical adaptor [B] to the appliance flue outlet with flat

facing [3] to the rear of the appliance. – This should be pushed straight down, on to the appliance.

0010013472-001

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Installation

▶ The three replacement retaining screws [4] supplied with the

adaptor kit are used to secure the vertical adaptor [B].

Electrical considerations:

▶ All electrical work must be carried out by a competent and authorised

person. ▶ All work must comply with the current IET Wiring Regulations. ▶ The isolator shall be situated next to the appliance for new systems

and, where practicable, replacement appliances. ▶ The mains electrical supply to the appliance must be through a fused

double pole isolator. ▶ The isolator must have contact separation of 3mm minimum between

poles. Any system connected to the appliance must not have a

separate electrical supply. ▶ Any additional components that are connected to the appliance that

require 230 Volts must be connected to the same supply as the

appliance. ▶ The correct type of RCD must be employed where additional

protection is required that is suitable for a low energy DC modulating

pump according to IET wiring regulations. ▶ External fuse 3 Amps. ▶ When stripping the wires, ensure copper strands do not fall into the

control box.

0010023595-001

Fig. 45 Flue turret/adaptor connection

5.5 Electrical connection

DANGER:

Risk of electric shock!

▶ Isolate electrical components from the power supply (230 V AC)

(fuse, circuit breaker) and secure against unintentional reconnection before carrying out any work. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

▶ Check for zero potential before proceeding with work, using test

equipment approved to GS38 to confirm that the electricity supply is disconnected.

NOTICE:

Risk of damage from hot appliance components.

Hot appliance components can damage electrical cables.

▶ Ensure all electrical cables are in the correct cable guides and away

from hot appliance components.

NOTICE:

Risk of damage to control board!

Mains/230V damage to low voltage control board.

▶ Do not connect mains/230V to the control board other than

power supply cable provided with the appliance.

▶ Time and temperature controls are low voltage.

Use Comfort+ II RF provided or approved controller listed in 3.9.2

"Programmer/timer accessories".

Cable routing

▶ Route cables through support guides and retaining clips. ▶ Run power cables separately from signal cables. Interference from

power cables can induce spurious faults on signal cables, ensure that

there is at least 100mm separation from each other. ▶ Ensure the cables are of sufficient length to allow the control box to

be moved to the service position.

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Installation

5.5.1 Installer connections

Component access

▶ Release catch and hinge open the control panel into the service

position.

0010022207-001

Fig. 46 Moving control panel into service position

Connect external accessories

▶ Release the latches using a thin bladed screwdriver. Arrows on the

electrical cover indicate the position where the screw driver must be inserted to release the catches.

▶ Open the rear cover.

External accessories terminal strip

Symbol Function

Outside temperature sensor or ON/OFF temperature controller. (link factory fitted)

The outside temperature sensor for the user interface is connected to the device.

▶ Connect the outside temperature sensor. ON/OFF temperature controller

No functionality; not used No functionality; not used

(link factory fitted)

External user interface/external module with 2-wire BUS.

BUS

230V

Fuse

5AF

▶ Connect communication cable. Mains connection (power cable)

Fuse

Table 16 Terminal strip for external accessories

5.5.2 Cable preparations

NOTICE:

Damage to control unit!

Small pieces of wire can cause shorts and damage to electronics.

▶ When stripping wires always ensure copper strands do not fall into

the control box.

0010029486-001

Fig. 47 Open the cover

▶ For splash protection (IP): Cut the strain relief according to the

diameter of the cable.

Fig. 48 Cable feed

▶ Guide the cable through the strain relief. ▶ Connect the cable to the terminal block for external accessories. ▶ Secure the cable to the strain relief.

0010029485-001

Low voltage (signal cables), example  figure 49

6-8mm

0-30V

26-30mm

Fig. 49 Low voltage (signal cables) preparation

0010012956-001

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Commissioning

5.5.3 Key (accessories)

Key is supplied with Comfort+ II RF are pre-paired.

Installing the Key

Installing the Key will enable time and temperature control for the appliance. For Pairing refer to the compatible control manual.

Always turn off the power to the appliance before installing Key (accessories).

▶ If installing an EasyControl please ensure that the EasyControl Key is

also purchased and installed. Follow EasyControl setup before inserting Key into Key housing.

▶ Plug Key [2] into Key housing [1].

Fig. 50 Installing the Key

▶ The lever [3] of the locking mechanism is located on the right hand

side of the Key housing. Ensure that it is in its Open position before pulling lever [2] towards front.

▶ Turn on the power.

LED [1] starts blinking green.

▶ Wait until LED is constantly yellow.

Key LED status

The LED [1] on the Key displays different states with flashing or constant colours.

Description of the LED displays Example

Flashing red:

Fault, e.g. no communication between the Key and appliance:

▶ Install the key again, restore the last functioning status.

Flashing yellow:

No fault, user please wait.

Flashing green:

No fault, initialisation process is running.

Constant red:

Temporary fault: ▶ Wait for normal operating condition to be resumed.

Constant yellow:

▶ Keys with touch-sensitive indicator: Press touch-

sensitive indicator on key to start pairing.

Description of the LED displays Example

Constant green:

No fault, normal operating condition.

LED Off:

No fault, power-saving mode or appliance without power.

Table 17 LED status

6 Commissioning

6.1 Pre-Commissioning checks

DANGER:

Risk of electric shock!

▶ Isolate electrical components from the power supply (230 V AC)

(fuse, circuit breaker) and secure against unintentional re-

connection before carrying out any work.

Information on safe isolation can be found in the Health and Safety

Executive guidance HSG85. ▶ Check for zero potential before proceeding with work, using test

equipment approved to GS38 to confirm that the electricity supply is

disconnected.

Checks before commissioning: ▶ Check that the service and water pipes are connected correctly. ▶ Check the gas type specified on the identification plate matches that

of the gas supply and that the gas supply is properly purged. ▶ Check that the appliance is filled with water and under pressure (1.5

bar) and that there are no leaks. ▶ Check that the electrical connections of the appliance are correct:

0010029386-001

– Mains electrical supply - 230V, 50Hz

– Compliant earth connection

– Correct polarities.

– External equipment and controls are wired in correctly. ▶ Check that the flue is correctly fitted, airtight, free from any

obstruction and the connections are secure. ▶ Check that the condensate pipe work is connected properly and that

there are no leaks.

NOTICE:

If the appliance is not to be commissioned immediately then, after successfully completing all of the checks and any rectification work:

▶ Isolate the electricity supply. ▶ Isolate the gas supply. ▶ Close the shut-off valve for the cold water inlet. ▶ Close the water shut-off valves to the appliance. ▶ Label appropriately.

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Commissioning

6.2 Water treatment

Primary system flushing (Central Heating) Ensure that the system has been cleaned:

• Following the guidance of BS 7593: – Code of Practice for treatment of water in hot water central

heating systems.

• Overview available in Pre-installation, Cleaning primary systems section.

Inhibitor (Central Heating):

Add a suitable inhibitor that is compatible with aluminium (or combined inhibitor/anti-freeze, if the system is exposed to freezing conditions), to the heating system in accordance with the DWTA code of practice and manufacturer‘s guidelines.

The pH value of the system water must be between 6.5 and 8 or the appliance warranty will be invalidated.

The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the appliance (aluminium, mild steel, stainless steel, copper and brass) and any other materials/components within the system.

▶ Record the date when the inhibitor was added to the system on the

guarantee card.

▶ The concentration level of inhibitor in the system should be checked

every 12 months or sooner if system content is lost.

NOTICE:

Sealing agents

Normally the addition of sealing agents to the system water is not permitted as this can cause problems with deposits left in the heat exchanger.

▶ In cases where all attempts to find a system micro leak have failed,

Worcester, Bosch Group supports the use of Fernox F4 leak sealer.

6.2.1 Filling the appliance and adding Inhibitor

Before pressurising the system.

The appliance integral expansion vessel is pre-charged to 0.75 bar (equal to a static head of 7.5m (24.6ft)). A Schrader type valve is fitted to the expansion vessel to allow for pressure adjustment if required.

▶ If an extra expansion vessel is fitted to the central heating system,

ensure that it is set to the same pressure as the appliance internal expansion vessel, refer to separate instructions supplied with the extra expansion vessel.

Filling the system - Sealed systems

NOTICE:

▶ Salt based softened water must not be used to fill the central heating

system.

▶ Check drain cocks and manual air vents are closed and all radiator

valves are open. Add a suitable inhibitor or combined inhibitor/antifreeze, if the system is exposed to freezing conditions, to the heating

system water in accordance with the manufacturers instructions. ▶ Turn on the water main and open the system valves. ▶ Fill the system to between 1 and 1.5 bar via a WRAS approved filling

loop or one of the filling link accessories.

– Refer to filling link accessory instructions for operation and use. ▶ The Automatic Air Vent will release any air trapped in the appliance. ▶ Manually vent all radiators, tighten when completed and check the

system for any leaks and correct if required. ▶ Top up the system pressure if the pressure drops below 1 bar. ▶ Isolate and remove filling loop connections to the system.

– Refer to Integrated filling link accessory instructions for any

further actions required after filling the system.

An optional filling link is available as an accessory. This can be used to fill the system.

▶ Refer to Scope of delivery to check if an filling link is supplied with the

appliance.

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Keyless filling link

▶ An additional 0.75bar static mains pressure is required above

required system pressure to ensure the effective operation of the

keyless filling link accessory.

Adjusting the operating pressure of the heating system

Display on the pressure gauge

1 bar Minimum charge pressure (when system is cold) 1 - 1.5 bar Optimal charge pressure 3 bar Maximum charge pressure at maximum heating

water temperature must not be exceeded (pressure relief valve opens).

Table 18

If the indicator is below 1 bar when the system is cold: ▶ Top up the water until the indicator is between 1 bar and 1.5 bar

again.

If pressure is not being maintained: ▶ Check tightness of expansion vessel and heating system.

Commissioning

6.3 Circulation pump

Controller module overview

8 7 6 5

Fig. 51 Overview

[1] Operation/fault indicator [2] Constant speed mode indicator [3] Constant pressure (p-c) mode indicator [4] Self modulating (p-v) mode indicator [5] Pump curve 3 selection indicator [6] Pump curve 2 selection indicator [7] Pump curve 1 selection indicator [8] Selection button

Default setting

▶ Constant speed mode - curve III

Selection button

The circulating pump must be left in factory default setting (Constant speed mode - curve III) to ensure hot water performance.

6.4 Starting the appliance

NOTICE:

Damage to appliance or system!

Running the appliance:

▶ Never run the appliance when the appliance/system is empty or

partially filled.

6.4.1 Control panel overview

0010029670-001

2 3 4 5 6 7 8 9

Fig. 52

[1] Display [2] (key: Heating mode on/off, set the maximum flow temperature [3] * key: Hot water mode, adjusting the hot water temperature [4] eco key: Toggle economy mode (pre-heat off) [5] ok key: Save settings, Chimney sweeper key: press 5 seconds for

chimney sweep mode

[6] " key: Return/back [7]  key: To navigate through menus and decrease settings [8]  key: To navigate through menus and increase settings [9] Pressure gauge

0010029487-001

To return to the default factory setting, should there be an instance where an alternative setting is entered, please follow this advice:

▶Press

– Select constant speed control mode. – Select pump curve III.

For additional pump functions: ▶ Press and hold to:

– Activate the pump venting function (press for 3 seconds). – Activate manual restart (press for 5 seconds). – Lock/unlock button (press for 8 seconds).

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Commissioning

6.4.2 Screen display

21 3 4 5 6

10 9

Fig. 53 Screen display

Key Explanation

[1] Digital display

• Displays a temperature or appliance status/diagnostic code.

[2] Central heating (CH)

• ( Heating mode On

• ] Heating mode Off

[3] Fault indicator

• Displays during a fault condition.

[4] Burner operation

• Displays when the appliance is firing during a CH/DHW mode.

[5] Internet connected (accessory)

• Displays when compatible controller is connected to the appliance (not used).

[6] Radio link connected (accessory)

• Displays when compatible controller is connected to the appliance.

[7] Chimney sweep mode

• Displays during service when the appliance is set to maximum or minimum output.

[8] Service mode

• Displays when a qualified service engineer is in the service menus.

[9] Eco mode active

• Displays when in Economy mode (DHW Pre-heat/comfort function is turned off)

[10] Domestic hot water (DHW)

• * Hot water mode On

Table 19

8 7

0010016015-003

6.4.3 Switching on the device

The appliance is vented after initial power-up. This involves the heating pump switching on and off at intervals (for approx. 4 minutes).

and the flow temperature appear alternately in the display.

▶ Open automatic air vent valve.

Automatic siphon fill mode will begin when the appliance is first powered-up. When the flow temperature and the symbol appear alternately on the display, the siphon filling program is active.

6.4.4 Setting the flow temperature

The maximum flow temperature can be adjusted between 30 °C and 82 °C. The current flow temperature is shown on the display.

▶ Press the ( key.

The set maximum flow temperature is displayed.

▶ Press arrow key  or  to set the required maximum flow

temperature.

▶ Press the OK key to save. Otherwise the setting will be saved

automatically after 3 seconds. The display shows the current flow temperature.

The ( symbol flashes in the display in heating mode. The B symbol also appears if the burner is active.

6.4.5 Setting the DHW heating

Set DHW temperature

DHW temperature: ▶ Press the * key.

The set DHW temperature is displayed. ▶ Press arrow key  or  to set the required DHW temperature ▶ Press the OK key to save. Otherwise the setting will be saved

automatically after 3 seconds.

The display shows the current flow temperature. The * symbol flashes in the display in DHW mode. The B symbol also

appears if the burner is active.

Setting comfort mode or ECO mode

In comfort mode, the appliance is continually maintained at the set temperature ( service function 3-CA). This means there will be a short delay when drawing DHW. However, the device will switch on even if no DHW is being drawn.

In ECO mode, heating-up to the set temperature begins as soon as the DHW is being drawn.

In Eco mode, to reduce water usage:

▶ Briefly open and close the DHW tap.

The water is heated once to the set temperature.

Worcester 2000 – 6 721 814 551 (2019/09)

▶ To set ECO mode: press the eco key until eco appears in the display. ▶ To return to comfort mode: press the eco key until eco vanishes from

the display.

Commissioning

6.4.6 Setting the heating control device

Observe the operating instructions of the heating controller. This shows you:

▶ how to set the room temperature. ▶ how to heat economically and save energy.

6.4.7 After commissioning

▶ Complete commissioning report ( page 78).

6.4.8 Setting summer mode

The heating pump and consequently the heating are switched off in summer mode. The DHW supply and also the power supply for heating controls and timer remain active.

NOTICE:

Risk of the system freezing.

Frost protection is not available in summer mode.

▶ If there is a risk of frost, exit summer mode ( Chapter 7.1).

To activate summer mode: ▶ Press the ( key. ▶ Keep pressing the arrow key  until appears in the display. ▶ Press the OK key to save. Otherwise the setting will be saved

automatically after 3 seconds. ] is permanently displayed.

Further notices can be found in the operating instructions for the heating control.

6.5.3 Exiting chimney sweep mode

To exit the chimney sweep mode:

▶ Press the ok button and the appliance will return to normal operation.

– If left in the chimney sweep mode the control will return to normal

operation after 30 minutes.

6.6 Checking gas inlet pressure

Measuring the inlet pressure

▶ Switch off the appliance and close the gas isolator. ▶ Unscrew the screw on the test nipple for the gas supply pressure and

connect a pressure gauge.

6.5 Chimney sweep mode

You have 30 minutes to take your measurements or to check or adjust the appliance settings. After this time the appliance returns to normal operation.

Whilst the appliance is in chimney sweep mode, the chimney sweep symbol ( C ) will be displayed on the screen.

6.5.1 Setting the appliance to maximum

Maximum output mode

▶ A hot water outlet can be opened to prevent the appliance from

shutting down due to high temperature during testing.

▶ Press the ok button for at least 5 seconds.

– The appliance enters chimney sweep mode and automatically

enters maximum output.

– The display shows the maximum percentage of the power 100%

alternating with the flow temperature.

– The appliance will ramp up to maximum output in approximately

30 to 35 seconds.

6.5.2 Setting the appliance to minimum

Whilst the appliance is already in chimney sweep mode - maximum output.

▶ Press the  button to set the appliance to minimum output.

– The display shows the minimum percentage of the power

alternating with the flow temperature.

– The appliance will take approximately 30 to 35 seconds to ramp

down to minimum output.

– Allow the appliance to stabilise at minimum output.

T10

0010027680-001

Fig. 54 Checking the gas supply pressure

▶ Open the gas isolator and switch on the appliance. ▶ Ensure that there is heat transfer by opening the radiator valves. ▶ Set the appliance running at maximum output in chimney sweep

mode ( 6.5 "Chimney sweep mode").

▶ Check the required gas supply pressure according to following

section "Gas pressure within the system".

Commissioning must not take place outside of the permissible pressure range.

▶ Identify the cause and rectify the fault. ▶ If this is not possible: isolate the device on the gas side and notify the

gas supplier.

▶ Exit the chimney sweep mode. ▶ Switch off the device, close the gas isolator, remove the pressure

gauge and tighten the screw.

▶ Refit the casing.

Worcester 2000 – 6 721 814 551 (2019/09)

Gas pressure within the system

The appliance must be running at maximum output rate when performing the gas rate check, ( chapter 6.5.1).

Combi appliances

▶ Running a hot water tap does not guarantee the boiler will operate at

maximum output throughout the test.

Refer to the figures below for Natural Gas gas pressures.

The pressure drop from the meter to the gas valve inlet test point must not be more than the values stated in table 20.

If the pressure drops are greater than shown in table 20, then this would indicate a problem with the pipe work or connections within the system.

NOTICE:

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

Gas

Type

Meter Across

pipe

work

Appliance

inlet

Across

appliance

[A]

Gas valve

inlet test point [B]

Allowed mbar pressure drop

NG 19 - 23 1 18 - 22 1.5 16.5 - 20.5

mbar range

Table 20 Allowed mbar pressure drop

Gas supply pressure drop

Commissioning

Maximum output mode

▶ A hot water outlet can be opened to prevent the appliance from

shutting down due to high temperature during testing.

▶ Ensure all other gas appliances are isolated. ▶ Press the ok button until the C symbol appears on the display.

The display shows the maximum percentage of the power 100%

alternating with the flow temperature. ▶ Ensure that the appliance has stabilised at maximum output. ▶ If pressure and gas rate are satisfactory press the ok button and the

appliance will return to normal operation.

– If left in the service 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.

6.8 Checking for gas leaks during operation

▶ Use an approved gas leak detector to check all connections for

possible leaks. The product must be certified as a gas leak testing agent.

▶ Do not allow the product to come into contact with the electrical

wiring.

Meter

19 - 23 mbar

1.0 mbar drop

Natural Gas

Appliance inlet

18 - 22 mbar

Across appliance

drop [A]

Gas Control

valve

Inlet test point [B]

0010012820-001

Fig. 55 Natural Gas pressures

[A] Pressure loss across the appliance [B] Pressure reading at inlet test point

6.7 Checking the gas rate

▶ The gas rate should be measured at the gas meter after the appliance

has been operating for a minimum of 10 minutes at maximum output.

▶ Refer to Technical data section of this manual for the appliance gas

rates and CO/CO

▶ Gas rate must be checked with the appliance in service, maximum

output test mode.

▶ Carry out Gas rating procedures as described in current edition of the

“Essential Gas Safety”.

▶ Ensure all other gas appliances are isolated when carrying out the gas

rate check on the appliance.

ratios.

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Commissioning

6.9 CO and combustion check

The following combustion and flue integrity checks are mandatory and these values must be recorded on the Benchmark checklist, at the end of these instructions.

Once the gas rate and pressure have been confirmed as acceptable then the CO and combustion checks can be undertaken.

The flow chart is given for guidance, the details of the checks are given in the following sections:

• Checking flue integrity, ( 6.10 "Checking flue integrity")

• Flue gas analysis, ( 6.11 "Flue gas analysis")

START

HERE

Set boiler to

maximum rate.

Zero the analyser

in fresh air.

See notice above

NOTICE:

Before CO and combustion checks:

▶ Verify the appliance is connected to the correct gas type. ▶ Ensure the appliance is supplied with the correct gas inlet pressure

and gas rate as specified previously in the Commissioning section.

▶ Visually check the integrity of the whole flue system and confirm that

all the components are correctly assembled, fixed and supported.

▶ The flue gas analyser must be the correct type as specified in BS

7967. Before use the analyser must have been calibrated as specified by the manufacturer. The installer must be competent in the use of the analyser.

▶ Check and zero the analyser in fresh air as specified by the

manufacturer.

▶ The air/gas ratio valve is factory set and must not be adjusted during

commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366.

Flue integrity test

using analyser

O2 ≥ 20.6%

< 0.2%

Yes

= less than

≥

Record values.

Do not adjust the gas valve.

greater than or equal to

O2 ≥ 20.6%

CO < 350ppm

CO/CO

ratio

< 0.004

Yes

< 0.2%

Yes

Verify flue integrity

Check all seals around the burner, internal flue seals,

and case seals.

Rectify where necessary.

Check CO and combustion

ratio at minimum rate

Check CO and

combustion ratio

at maximum rate

CO < 350ppm

CO/CO

ratio

< 0.004

Yes

Set boiler to

minimum rate.

Turn off boiler and

call Worcester, Bosch

Group help line.

0330 123 3366

Fig. 56 Commissioning checks flow chart

CO < 350ppm

CO/CO

ratio

< 0.004

Boiler is operating

Yes

satisfactorily.

No further action

is required.

0010023581-002

Worcester 2000 – 6 721 814 551 (2019/09)

Commissioning

6.10 Checking flue integrity

Flue integrity check

▶ The combustion casing must be fitted whilst this test is carried out. ▶ Refit the test point plugs after the test has been completed.

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

Air inlet sample point location on flue turret/adaptor.

0010015568-001

Fig. 57 Flue integrity check test point

[1] Air inlet sample point [2] Flue turret air inlet blank plug (with retaining ring) [3] Flue adaptor air inlet blank plug

▶ With the appliance combustion casing on and the appliance running

at maximum output in chimney sweep mode ( 6.5 "Chimney sweep mode"), remove the blanking plug [2 or 3] for the air inlet

sample point [1]. ▶ Insert the analyser probe into the air inlet sample point [1]. ▶ Allow the readings to stabilise and check that:

–O

is equal to, or greater than 20.6%

–CO

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.

6.11 Flue gas analysis

NOTICE:

Combustion testing

▶ Combustion testing must be carried out by a competent qualified

person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated Flue Gas Analyser conforming to BS 7967 and is competent in its use.

Flue gas analysis

▶ Ensure that the gas inlet pressure has been checked and is

satisfactory.

▶ Refit the test point plugs after the test has been completed.

The flue gas analysis performance of the appliance can be checked via the flue turret/adaptor sample points.

Refer to figure 58 for the location of the flue gas sample point on flue turret/adaptor.

0010015569-001

Fig. 58 Combustion test

[1] Flue gas sample point [2] Flue turret flue gas blank plug [3] Flue adaptor flue gas blank plug

The CO and combustion ratio are checked;

• In chimney sweep mode at maximum output.

• In chimney sweep mode at minimum output.

Appliance to maximum output

▶ Set the appliance running at maximum output in chimney sweep

mode( 6.5 "Chimney sweep mode").

Appliance to minimum output

▶ Set the appliance running at minimum output in chimney sweep

mode( 6.5 "Chimney sweep mode"). – Allow the appliance to stabilise at minimum output.

Measuring the CO and combustion ratio.

▶ Remove the blanking plug [2 or 3] for the flue gas sample point [1]. ▶ Insert the analyser probe into the flue gas sample point [1].

– 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.

▶ Check the CO and combustion readings.

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Commissioning

6.12 Finishing commissioning

6.12.1 Fitting the front panel

▶ Fit the front panel making sure that the securing points are properly

located. – Lift the front panel onto the locating bracket on the top of the

appliance. – Push the bottom of the panel into position and tighten the bottom

two screws [1].

Fig. 59 Fitting the front panel

At the time of commissioning, complete all relevant sections of the Benchmark Checklist located at the end of this chapter.

0010029396-001

Appliance handover:

▶ Complete the Benchmark Gas Boiler Commissioning Checklist. ▶ Set up the appliance controls and show the customer how to operate

all the control unit/s for central heating operation. – Also show where in the appliance/controls documentation where

this information can be found.

▶ Where applicable, instruct the customer on:

– how to check the system pressure and re-pressurise if necessary. – how to set the TRVs.

– how to reset the appliance. ▶ Show the customer the fault finding section in the User Instructions. ▶ Show the customer where the serial number/appliance information is

located, they will need this information if they call in with a problem

(Benchmark Commissioning checklist on page 78 contains all

relevant appliance information). ▶ Give the customer details of how to contact the installer/ gas

emergency numbers. ▶ Show the customer how to safely isolate the appliance. ▶ Advise the customer where they can find information on the

Worcester, Bosch Group website www.worcester-bosch.co.uk. ▶ Ensure that all documentation, is left with the appliance or

homeowner.

– Appliance documentation.

– Controls documentation.

– Any other equipment documentation that is connected to the

appliance or system.

▶ Appliance not in use

– If the appliance is not going to be used immediately and may be

exposed to freezing conditions, advise the customer of the precautions necessary to prevent damage to the appliance, system and building.

– If the appliance is unused and exposed to freezing conditions,

safely isolate all the mains supplies and drain the system and appliance, label accordingly.

▶ Show the customer the location of the condensate pipe run in

unheated or external areas that may be at risk of freezing during

prolonged cold spells. ▶ User recommendation: Arrange an inspection/maintenance

contract with an approved heating contractor.

6.12.2 Appliance/product guarantee

This appliance/product has a guarantee against faulty materials or workmanship for a period from the date of installation subject to the terms and conditions.

For full terms and conditions, please visit:

www.worcester-bosch.co.uk/guarantee-terms-and-conditions

Guarantee registration

Your appliance/product carries a guarantee against faulty material or manufacture subject to Terms and Conditions.

To read the full Terms & Conditions please visit us on-line at www.worcester-bosch.co.uk/guarantee.

Your statutory rights are not affected by the manufacturer’s guarantee

Worcester 2000 – 6 721 814 551 (2019/09)

Shutdown

7 Shutdown

7.1 Setting frost protection

NOTICE:

Risk of damage to the system from frost!

The heating system can freeze up after a prolonged period (e.g. during a power failure, switching off the power supply, faulty fuel supply, boiler fault etc.).

▶ Ensure that the heating system is in constant use (particularly when

there is a risk of frost).

Frost protection for the heating system:

Always follow the latest advice in BS7593 for system frost protection.

Frost protection for the heating system is only ensured if the heating pump is operational and is pumping heating water through the entire system.

▶ Leave the heating switched on. ▶ Set the time control to constant ON and set the room thermostat to

12 °C.

-or- If you want to leave the appliance switched off:

▶ Mix Worcester-approved anti-freeze into the heating water ( Water

treatment products, page 29) and drain the DHW circuit.

For further information, see the heating controller operating instructions.

Appliance frost protection:

The appliance frost protection function switches the burner and heating pump on when the appliance temperature falls below 5 °C. This prevents the appliance from freezing.

8 Settings in the service menu

Many appliance functions can be set and checked in the service menu. It

includes:

• Menu 1: information menu

• Menu 2: not used in UK/IE

• Menu 3: factory settings

• Menu 4: special features

• Menu 5: limit values

• Menu 6: function checks

• Menu 0: manual operation

8.1 Operating the service menu

Selecting and setting the service function

If a key is not pressed for 30 minutes, the system exits the selected

service function automatically.

▶ To select a service function, press arrow key  or .

The display shows the service function.

▶ To confirm the selection: press OK key.

The current setting starts to flash. ▶ To change the setting: press arrow key  or . ▶ To save: press OK key.

-or-

▶ If you do not want to save the setting: press " key.

The value currently set is displayed. ▶ Press the " key.

The service function is displayed. ▶Press " key again.

The higher level menu is displayed. ▶Press " key again.

The device reverts to normal operation.

7.2 Anti-seize protection

This function prevents the heating pump and the diverter valve seizing up following long periods of inactivity. The anti-seizing function remains active during standby mode.

The pump is briefly activated automatically after 24 hours of inactivity.

Documenting the settings

▶ Record the change the settings in the commissioning report

( Section 13.6).

Settings in the service menu

Many appliance functions can be set and checked in the service menu.

Opening the service menu

▶ Press the DHW key and the Heating key simultaneously until the

service menu appears.

Closing the service menu

▶ Press the DHW key or the Heating key.

-or-

▶ Press the " key.

Navigating through the menu

▶ To highlight a menu or a menu item, press the  key or the key. ▶Press OK key.

The menu or the menu item is displayed. ▶ To return to the next higher menu level, press the " key.

Changing the settings values

▶ Select the menu item with the OK key. ▶ To select the desired value, press the  key or the key.

The new value will be saved after 5s or after pressing the OK key.

Exiting the menu item without saving values

▶ Press the " key.

The value is not saved.

Worcester 2000 – 6 721 814 551 (2019/09)

Settings in the service menu

8.2 Service functions overview

8.2.1 Menu 1

▶ Press the ( key and * key at the same time until L.1 appears. ▶ To confirm the selection: press OK key. ▶ Selecting and setting the service function.

Service function Unit Further information

1-A1 Current operating status Status code,  Section 11.2 1-A2 Current fault Error code,  Section 11.2 1-A3 Upper limit of the maximum heat output % The maximum heat output can be decreased via the service function

3-b1.

1-A4 Upper limit of the maximum DHW output % The maximum DHW output can be decreased via the service

function 3-C1. 1-A5 Temperature at flow temperature sensor °C – 1-A6 Set flow temperature °C – 1-b2 Current turbine flow rate l/min – 1-b3 Current DHW temperature °C – 1-b4 Current DHW outlet temperature °C – 1-b5 Current temperature at the cylinder °C – 1-b7 Set DHW temperature °C – 1-b8 Current thermal output as a % of the maximum rated heat output

in heating mode

1-C1 Ionisation current A • While the burner is operating: ≥ 2 A = OK, < 2 A = faulty

1-C2 Current pump output as % of rated pump output – 1-C4 Current outside temperature with outside temperature sensor

connected 1-C5 Temperature at the solar buffer cylinder °C Only displayed when a solar module is connected. 1-C6 Operating pressure bar – 1-d1 Collector temperature °C Only displayed when a solar module is connected. 1-d2 Temperature at the solar buffer cylinder (bottom) °C Only displayed when a solar module is connected. 1-d3 Solar pump % Only displayed when a solar module is connected. 1-d4 Solar unit fault Only displayed when a solar module is connected.

1-E1 Software version of the control panel (main version) – 1-E2 Software version of the control panel (secondary version) – 1-E3 Coding plug number – 1-E4 Coding plug version – 1-EA Software version of device electronics (main version) – 1-Eb Software version of device electronics (secondary version) –

Table 21 Menu 1: display of information

% During DHW heating, values greater than 100 % may be displayed.

• While the burner is switched off: < 2 A = OK, ≥ 2 A = faulty

°C –

Error code

8.2.2 Menu 2

▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key  until L.2 is displayed.

The basic settings are depicted as highlighted in the following table. ▶ To confirm the selection: press OK key. ▶ Selecting and setting the service function.

Service function Settings/adjustment range Remark/restriction

2-A1 Low-loss header • 0: no low loss header installed

• 1: (not available)

This setting defines where the sensor of the low loss header is connected.

• 2: low loss header connected to the module

Table 22 Menu 2: hydraulic settings

Worcester 2000 – 6 721 814 551 (2019/09)

Settings in the service menu

8.2.3 Menu 3

▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key  until L.3 is displayed.

The basic settings are depicted as highlighted in the following table. ▶ To confirm the selection: press OK key. ▶ Selecting and setting the service function.

Service function Settings/adjustment range Remark/restriction

3-b1 Maximum approved heat output • GC2000iW 25 C : 50 … 80 %

• GC2000iW 30 C : 50 … 68 %

▶ Set heat output in percent. ▶ Measure gas flow rate. ▶ Compare measured result with the setting

tables ( page 77). Correct the setting in the case of any deviation.

3-b2 Time interval between stopping and

starting the burner in heating mode

• 3 … 10 … 60 minutes The time interval specifies the minimum waiting time between switching on the burner and switching it on again.

If a weather-compensated heating controller is connected, this setting is optimised by the heating controller.

3-b3 Temperature interval for switching the

burner off and back on

• -15 … -6 … -2 K ( °C) The difference between the current flow temperature and the set flow temperature until the burner is switched on.

If a weather-compensated heating controller is connected, this setting is optimised by the heating controller.

3-C1 Maximum released DHW output • 50 … 100 % On natural gas devices:

▶ Set heat output in percent. ▶ Measure gas flow rate. ▶ Compare measured result with the setting

tables ( page 77). Correct the setting in the case of any deviation.

3-C4 Turbine signal delay • 2 … 16 × 0.25 seconds The delay prevents sudden changes in the water

supply pressure from causing the burner to briefly operate although no water is drawn off.

3-C5 Delay of DHW mode (solar mode) • 0 (not active) ... 50 seconds DHW mode will be suppressed until the DHW

temperature sensor detects that the water preheated by solar energy has reached the desired DHW temperature.

▶ Set the DHW mode delay according to the

system conditions.

3-C6 Time interval between stopping and

restarting the burner for DHW heating

• 0 … 30 minutes After DHW is drawn off, the DHW heating remains disabled for this period.

(only in comfort mode and summer mode)

3-C8 Thermal disinfection up to draw-off

point

• OFF: switched off

• ON: switched on

If too much water is drawn off, the required temperature may not be reached.

▶ Only draw off enough water to allow the DHW

temperature of 70 °C to be reached.

▶ Perform thermal disinfection

( Instructions for the user).

3-CA DHW mode • 0: comfort mode, the device is continually kept at

the set temperature.

• 1: ECO mode, only heat-up to the selected

temperature when hot water is being drawn.

Short waiting time in comfort mode, when domestic hot water is extracted. The device therefore switches on, even if no domestic hot water is extracted.

• 2: (not available)

• 3: (not available)

3-d6 Overrun time of the heating pump in

heating mode

• 1 … 3 … 60 minutes

• 61: 24 hours

The pump overrun begins at the end of the heat demand by the heating controller.

Table 23 Menu 3: factory settings

Worcester 2000 – 6 721 814 551 (2019/09)

Settings in the service menu

8.2.4 Menu 4

▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key  until L.4 is displayed.

The basic settings are depicted as highlighted in the following table. ▶ To confirm the selection: press OK key. ▶ Selecting and setting the service function.

Service function Settings/adjustment range Remark/restriction

4-A1 Venting function • 0: switched off

• 1: automatic (Ventilation is carried out once. At the end of ventilation, the setting reverts to the “Deactivated” status.)

The venting function can be switched on after maintenance work.

During ventilation, the symbol and flow temperature appear alternately in the display.

• 2: permanently switched off (The setting is retained until the operation mode changes.)

4-A2 Siphon filling program • 0: switched off (only permissible during

maintenance)

• 1: switched on with minimum power

• 2: switched on with minimum heat output

The siphon filling program is activated in the following cases:

• The device is switched on at the On/Off switch.

• The burner was not in operation for at least 28 days.

• The operating mode is switched from summer to winter mode.

The next time there is a heat demand in heating or cylinder mode, the heat output of the device is kept low for 15 minutes.

The symbol and flow temperature appear alternately in the display for the duration of the siphon filling program.

4-A4 Service display • 0: switched off

• 1: acc. to hours run

• 3: acc. to elapsed time

4-A5 Inspection interval according to hours

run

• 10 … 60 x 100 hours This service function is only available if service function 4-A4 is activated. (=01)

After this interval has expired, the display indicates that an inspection is due via the service display 1018.

4-A6 Inspection interval according to elapsed

time

• 1 … 72 months This service function is only available if service function 4-A4 is activated. (=03)

After this interval has expired, the display indicates that an inspection is due via the service display 1018.

4-b1 Device-internal weather-compensated

control

• OFF: not active

• ON: active

This service function is only available if an outside temperature sensor is detected in the system.

This service function is no longer available when a weather-compensated control unit with EMS connection is connected.

4-b2 Outside temperature limit for automatic

changeover between summer and winter mode.

• 0 ... 16 ... 30 °C This service function is only available if service function 4-b1 is activated.

If the outside temperature exceeds the set temperature limit, the heating is switched off (summer mode). If the outside temperature falls to at least 1 K ( °C) below the setting, the heating is switched back on (winter mode).

4-b3 End point of the heating curve for

weather-compensated control

• 20 ... 90 °C This service function is only available if service function 4-b1 is activated.

Set flow temperature for an outside temperature of – 10 °C ( heating curve, page 75).

4-b4 Base point of the heating curve for

weather-compensated control

• 20 ... 90 °C This service function is only available if service function 4-b1 is activated.

Set flow temperature for an outside temperature of + 20 °C ( heating curve, page 75).

Worcester 2000 – 6 721 814 551 (2019/09)

Service function Settings/adjustment range Remark/restriction

4-b5 Device frost protection • OFF: switched off

• ON: switched on

This service function is only available if service function 4-b1 is activated.

The device frost protection function switches the burner and heating pump on when the outside temperature falls below 5 °C. This prevents the wall mounted boiler freezing.

4-b6 Temperature value for the system frost

protection

• 0 ... 5 ... 10 °C This service function is only available if the frost protection function (service function 4-b1) was activated.

If the outside temperature does not exceed the frost threshold temperature, then the heating pump in the heating circuit switches on (system frost protection).

4-E1 LCD backlighting • OFF: backlighting switches off 2 minutes after

the last time a key was pressed

• ON: backlighting permanently on

4-E2 Unit of temperature • °C

• °F

4-F1 Reset device to basic setting • YES: device is reset to factory settings 4-F2 Reset the fault display • NO: fault is retained

• YES: fault is reset

Table 24 Menu 4: settings

Settings in the service menu

8.2.5 Menu 5

▶ Press the ( key and * key at the same time, until L.A is displayed. ▶ Keep pressing the arrow key , until L.5 is displayed. ▶ To confirm the selection: Press the OK key.

The basic settings are depicted as highlighted in the following table.

▶ These settings will not be reset during a factory reset.

▶ Select and set the service function.

Service function L.5 Settings/adjustment range Remark/restriction

5-A1 Maximum flow temperature • 30 … 82 °C Limits the adjustment range for the flow

temperature.

5-A2 Maximum DHW temperature • 35...60 ... 80 °C Limits the adjustment range for the hot water (not

applicable on combination appliances.).

5-A3 Minimum boiler output (heating and

DHW)

• GC2000iW 25 C : 19 ... 49%

• GC2000iW 30 C : 16 ... 49%

Minimum heat output.

Table 25 Menu 5: Limit values

Worcester 2000 – 6 721 814 551 (2019/09)

Settings in the service menu

8.2.6 Menu 6

▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key  until L.6 is displayed.

The basic settings are depicted as highlighted in the following table. ▶ To confirm the selection: press OK key. ▶ Selecting and setting the service function.

Service function Settings/adjustment range Remark/restriction

6-t1 Permanent ignition • OFF: switched off

• ON: switched on

Testing the ignition by means of permanent ignition without gas supply.

▶ To prevent damage to the ignition

transformer: Leave the function switched on

for a maximum of 2 minutes. 6-t2 Permanent fan operation • 0 … 100 % Fan running without gas supply or ignition. 6-t3 Permanent pump operation (heating

• 0 … 100 % If a value >0 is set, the pump runs with 100 %.

pump)

6-t5 3-way valve permanently in the DHW

heating position

• 0: heating

• 1: DHW

• 2: (not available)

6-tA Ionisation oscillator • OFF: switched off

• ON: switched on

6-tb Burner test • 0 … 100 % The burner test is ended by resetting the setting

value to 0, or by exiting L.5.

Table 26 Menu 6: function checks

8.2.7 Menu 0

▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key  until L.0 is displayed.

The basic settings are depicted as highlighted in the following table. ▶ To confirm the selection: press OK key. ▶ Selecting and setting the service function.

Service function Settings/adjustment range Remark/restriction

0-A1 Manual operation • OFF: switched off

• ON: switched on

0-A2 Set temperature in manual operation • 30 … 60 ... 82 °C

Table 27 Menu 0

Worcester 2000 – 6 721 814 551 (2019/09)

9 Inspection and maintenance

DANGER:

Risk of electric shock!

▶ Isolate electrical components from the power supply (230 V AC)

(fuse, circuit breaker) and secure against unintentional reconnection before carrying out any work. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85.

▶ Check for zero potential before proceeding with work, using test

equipment approved to GS38 to confirm that the electricity supply is disconnected.

CAUTION:

Mains supplies:

▶ Safely isolate both the gas and electrical supply before starting any

work on the appliance and observe all relevant safety precautions.

NOTICE:

Personnel and equipment

▶ Any service work must carried out by competent registered

engineers.

▶ Service work must not be attempted if a calibrated CO/CO

and manometer are not available.

WARNING:

Hot surfaces!

If the appliance has been operating components may be hot.

▶ Ensure precautions are taken when working on the appliance.

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.  Flue gas analysis.

analyser

Inspection and maintenance

▶ When it is frequently necessary to add water to maintain pressure in

the installation, even though no leaks have been discovered, perform an expansion vessel check.

▶ Check that the condensate system is not obstructed, clean and refill

the condensate siphon.

▶ If the appliance is in a compartment or cupboard check that the

specified clearances around the appliance is clear.

▶ Check that the flue system is unobstructed and undamaged, clean/

replace as necessary. – If fitted ensure the flue terminal guard is also unobstructed and

undamaged.

▶ Operate the appliance and take note of any irregularities.

– Refer to the fault finding pages for rectification procedure.

Maximum system pressure

▶ 2.5 bar must not be exceeded when the heating system water is at

maximum temperature. If this pressure is exceeded then an additional expansion vessel must be fitted into the system return as close as possible to the appliance.

▶ If the system does not retain the pressure, the pressure relief valve

(PRV) and the heating system should be checked for leaks.

9.2 Service functions

9.2.1 Calling up the last fault saved

An overview of the faults can be found from page 63.

▶ Select service function 1-A2 ( Chapter 8.2 from page 46).

9.3 Component access

Removing the front casing

The front casing is secured with two screws to prevent unauthorised removal (electrical safety).

▶ Always secure the casing with these screws.

▶ Loosen the two screws [1] and pull the bottom of the casing forward. ▶ Lift off the casing.

9.1 Inspection and maintenance considerations

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

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

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

• After each service, the ser vice interval record sheet at the rear of this manual, must be completed.

See the following instructions for detail of some of the service requirements:

▶ Check all joints and connections in the system and remake any that

show signs of leakage. Refill and re-pressurise if applicable as described in the commissioning section.

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Fig. 60 Removing the front casing

0010029675-001

Inspection and maintenance

9.4 Fan pressure test

NOTICE:

Fan pressure test

▶ The appliance must be running at maximum output in chimney sweep

mode for the fan pressure test, ( Setting the appliance to maximum).

This test is to determine if the heat exchanger requires cleaning or additional actions.

Fan pressure test reading.

▶ The pressure reading will be in negative values.

9.4.1 Checking heating block

▶ Remove the front casing. ▶ Remove the cap from the test nipple, and connect a pressure gauge.

▶ Disconnect the digital manometer and replace the test point cover. ▶ Replace the combustion air intake pipe after completing pressure

check.

9.5 Check working gas inlet pressure

NOTICE:

Gas inlet pressure

▶ Do not continue with the other checks if the correct gas inlet pressure

can not be achieved.

▶ Check the gas supply working pressures in the system conform to the

readings shown in the table shown in section 6.6 "Checking gas inlet pressure".

9.6 Flue gas analysis

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 flue gas analyser conforming to BS 7967 and is competent in its use.

0010015926-001

Fig. 61 Test nipple at the mixing device

Appliance fan pressure test values Natural Gas appliances

Appliance

Cleaning required No cleaning required

output

Value

30kW 0 mbar  -4.7 mbar -4.8 mbar  -12 mbar 25kW

0 mbar  -3.2 mbar -3.3 mbar  -12 mbar

Table 28 Natural Gas values

If the manometer reading is within tolerance, in the white area of the table values.

▶ The heat exchanger/exhaust path/siphon does not require attention.

If the manometer reading is out of tolerance, in the shaded area of the table values then carry out the following checks.

▶ Check that the siphon is not restricted or blocked. ▶ Check the exhaust paths for restrictions. ▶ Clean the heat exchanger with a suitable cleaning tool, refer to

cleaning section.

▶ Re-check the fan pressure readings.

If the appliance, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice.

▶ Switch the appliance off after completing pressure check.

Flue gas analysis

▶ Ensure that the gas inlet pressure has been checked and is

satisfactory.

▶ Refit the test point plugs after the test has been completed.

▶ Set the appliance to maximum and minimum output in chimney

sweep mode ( 6.5 "Chimney sweep mode") for the flue gas analysis checks.

▶ Check that the readings conform to those given in the following

tables. In addition to CO and CO/CO maximum and minimum CO

ratio checks also check the

percentage reading.

Appliance combustion contents settings

CO2 Reading CO Reading O2 Reading

Natural Gas - Maximum rated Output

Between 9.0 and 10.8% <250ppm 4.0 % Natural Gas - Minimum rated Output A minimum of 0.6 lower than the

<250ppm 5.5 %

maximum reading taken but above 8.2%

1) Should be measured 10 minutes after firing the appliance

Table 29 CO2 and O2 settings

If the CO

is out of tolerance then please check:

▶ The gas inlet pressure. ▶ The gas rate. ▶ The fan test pressure. ▶ The flue and air intake, plus any possible blockages in the condensate

disposal. ▶ The condition of burner. ▶ For leaks or obstructions in the exhaust paths. ▶ That the injector is clean.

After all checks have been completed and the CO

is still out of tolerance

then contact Worcester, Bosch Group helpline 0330 123 3366.

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Inspection and maintenance

9.7 Checking the flue integrity

NOTICE:

▶ Check flue joints are secure, the terminal and the terminal guard, if

fitted are clear and undamaged.

▶ 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 Flue Gas Analyser conforming to BS 7967 and is competent in its use.

Flue gas analysis

▶ Ensure that the gas inlet pressure has been checked and is

satisfactory.

▶ Refit the test point plugs after the test has been completed.

▶ Refer to section 6.10 "Checking flue integrity" and check that the

readings conform to those given, confirming flue system and combustion circuit are ok.

9.8 Cleaning the siphon and heat exchanger

WARNING:

Gaskets and seals - gas related components

▶ Burner/electrode assembly gasket must be replaced if disturbed ▶ Other gaskets/seals must be checked and replaced where necessary ▶ Do not attempt the cleaning procedure unless new gaskets and seals

are available.

9.8.1 Cleaning the heat exchanger

4. Remove the fan with mixing device.

0010016229-002

Fig. 62 Removing the fan with mixing device

▶ Pull off cable from the ignition and flame sense electrode.

▶ Remove the burner cover.

There is an optional tool available to assist in cleaning the heat exchanger, part number 7 733 600 091.

Checking the electrodes and cleaning the heat exchanger

CAUTION:

Risk of burns due to hot surfaces!

Individual components of the appliance can become very hot even after being shut down for a long time.

▶ Before working on the appliance: Allow the appliance to cool down. ▶ If necessary, wear protective gloves.

1. Unplug plug from the fan.

2. Remove the gas hose from the venturi nozzle.

3. Remove the screw on the mixing device.

To ensure full tightness when assembling the burner once the

maintenance is complete, tighten the M8 nut as far as it will go.

0010015927-002

Fig. 63 Remove the burner cover

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Inspection and maintenance

▶ Remove the non-return valve. ▶ Check the non-return valve for contamination and cracks.

Fig. 64 Non-return valve in the mixing device

1. Remove the gasket.

2. Remove electrode set and check electrodes for contamination, clean or replace, if required.

3. Remove the burner.

0010015934-001

▶ Remove the top baffle using the lifting device.

0010002794-002

Fig. 66 Remove the top baffle

▶ Remove the bottom baffle using the lifting device.

Fig. 65 Removing the burner

0010015929-003

0010002795-002

Fig. 67 Removing the bottom baffle

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Inspection and maintenance

▶ Clean both baffles. ▶ Clean the heating block with the brush:

– by rotating in both directions – from top to bottom up to the catch

▶ Remove the screws from the cover of the inspection aperture and

remove the cover.

0010015928-002

Fig. 68 Cleaning the heat exchanger

▶ Vacuum out residue and close the inspection aperture again. ▶ The heat exchanger can be inspected for residue with the aid of a

torch and mirror.

▶ Refit the baffles. ▶ Remove the condensate trap and place a suitable container

underneath.

▶ Rinse the heat exchanger with water from the top.

0010002797-002

Fig. 70 Purge the heat exchanger with water

▶ Reopen inspection aperture and clean the condensation catch pan

and condensate connection.

NOTICE:

Material damage due to hot flue gas!

Hot flue gas can leak through defective gaskets, damage the devices and endanger safe operation.

▶ Each time the burner is opened, replace the burner gasket

( Fig. 65, item [1]) and all other gaskets affected by the measure.

▶ Ensure that the gaskets are seated exactly.

▶ Check and adjust if required the gas/air ratio.

NOTICE:

Material damage due to chemicals!

Using chemicals during purging, cleaning the drain or carrying out maintenance can damage the EPDM rubber materials. This can cause exhaust gas to escape during operation.

▶ Do not use chemicals to purge the heating block.

Fig. 69 Checking the heat exchanger for residue

Worcester 2000 – 6 721 814 551 (2019/09)

On completion of the heat exchanger cleaning and reassembly, perform the fan pressure test.

0010002838-002

Inspection and maintenance

9.8.2 Cleaning the siphon

Cleaning the condensate trap

WARNING:

Danger to life due to poisoning!

If the condensate trap is not filled, poisonous flue gas can escape.

▶ Only turn off the trap filling program during maintenance, and turn it

back on at the end of maintenance.

▶ Make sure that the condensate drains off properly.

Damage resulting from an insufficiently cleaned siphon are excluded from the warranty.

▶ Clean the siphon regularly.

1. Remove the hose on the left of the condensate trap.

2. Actuate the locking lever at the bottom to release the siphon.

3. Pull the condensate trap down to remove it and drain it.

1. Unscrew the cleaning cap.

2. Check the gasket for cracks, deformation or breakage and replace if required.

3. Clean the condensate trap, and check that the aperture towards the heat exchanger is clear.

4. Insert a new gasket if required.

5. Tighten the cleaning cap up to the locking position.

Fig. 71 Removing the condensate trap

0010021752-001

Fig. 72 Cleaning the condensate trap

▶ Remove and check the gasket for cracks, deformation or breakage

and replace if required.

0010017273 -001

0010017274-001

Fig. 73 Removing the gasket on the top of the condensate trap

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Inspection and maintenance

▶ Align the gasket correctly with the condensate trap.

0010019151-001

Fig. 74 Aligning the gasket with the condensate trap

▶ Push on the gasket in the sequence shown.

When the gasket is correctly inserted, the pin is visible in the recess and is flush with the top edge of the gasket.

▶ Replace the condensate trap and check for tightness. ▶ Check the condensate hose and clean if required. ▶ Grease the hose during assembly and check tightness of connection.

Fig. 75 Pressing on the gasket

0010021780-001

Fig. 76 Inserting the condensate trap

▶ Fill the condensate trap with approximately 150 ml water.

0010019159-001

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Replacement parts

9.9 Setting the air/gas ratio

NOTICE:

Setting the air/gas ratio

▶ The air/gas ratio is factory set and should not need to be adjusted. If

found to be out of tolerance and when all other possible causes have been checked, please contact the Worcester Bosch Group helpline 0330 123 3366.

NOTICE:

Combustion testing

▶ The checking of the air/gas ratio must be carried out by a competent

registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer.

▶ Checking of the air/gas ratio must not be attempted unless the

person carrying out the test is equipped with a flue gas analyser conforming to BS7927 and is competent in its use.

All CO/CO2 readings must be taken with the combustion chamber cover ON. Adjustments can only be made with the cover off.

CO2 should be measured 10 minutes after firing the appliance.

Adjusting the minimum rated output settings

With the appliance in minimum rated output. ▶ Remove the seal from the adjusting screw of the gas valve (only gas

valve is shown in the below Figure 77) and set the CO for minimum rated output.

or O2 content

▶ Re-check settings at maximum and minimum rated output and re-

adjust if required.

▶ Seal the gas valve minimum adjustment. ▶ Exit the chimney sweep mode. ▶ Enter the CO

contents in the servicing record.

10 Replacement parts

WARNING:

Mains supplies - Isolate the appliance

▶ Turn off the gas supply and isolate the mains electrical supply before

starting any work and observe all relevant safety precautions.

▶ Drain the appliance/system where necessary and protect any

electrical equipment from water ingress during component replacement.

WARNING:

Component replacement:

▶ After replacement of a gas carrying component, where a gasket or

seal has been disturbed or replaced, check for gas tightness using a gas sniffer/leak detection fluid.

▶ On re-assembly check all affected seals for cracks, hardness and

deterioration.  If damaged or in any doubt the seal must be replaced.

▶ Also after re-assembly, carry out the following checks:

 Fan pressure.  Flue gas analysis.

Only use Worcester, Bosch Group original spare parts with this appliance. Non Worcester, Bosch Group original spare parts will invalidate the guarantee (if applicable) and any warranty.

▶ A comprehensive list of appliance spares can be found on the website

www.worcester-bosch.co.uk/spares

4mm

T40

Fig. 77 Setting the CO

Honeywell valve)

or O2 content (above: SIT valve, below:

0010027678-001

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Replacement parts

10.1 Component access

Removing the front casing

The front casing is secured with two screws to prevent unauthorised removal (electrical safety).

▶ Always secure the casing with these screws.

▶ Loosen the two screws [1] and pull the bottom of the casing forward. ▶ Lift off the casing.

0010029675-001

Fig. 78 Removing the front casing

10.3 Checking the strainer in the cold water pipe

1. Remove the clip.

2. Pull out the pressure relief valve.

0010006637-002

Fig. 80 Remove the pressure relief valve (heating circuit)

1. Remove the clip.

2. Pull out the insert.

3. Check strainer for contamination.

10.2 Draining the appliance

NOTICE:

Risk of water damage to appliance or property!

Damage from disconnecting water pathways which may have retained some water.

▶ Take care after draining the appliance to protect equipment/property

from residual water content within components.

Many of the tasks in this section require that the appliance be isolated and drained. This will be indicated in the manual if required.

Refer to figure 79. ▶ Open the drain plug using a 8mm hex key; use a suitable container to

collect any water.

8mm

2.3.

0010006636-002

Fig. 81 Checking the strainer in the cold water pipe

Fig. 79 Drain point

Worcester 2000 – 6 721 814 551 (2019/09)

0010029499-001

Replacement parts

10.4 Checking the plate heat exchanger

If the DHW output is insufficient: ▶ Check the strainer in the cold water pipe for contamination. ▶ Remove the plate heat exchanger and replace if necessary.

1. Remove the screw.

2. Remove the plate heat exchanger.

0010005834-002

Fig. 82 Removing the plate heat exchanger

10.5 Checking the expansion vessel

The expansion vessel must be checked every year.

▶ If necessary, adjust the expansion vessel pre-charge pressure to the

static head of the heating system.

10.6 Adjusting the operating pressure of the heating system

Display on the pressure gauge

1 bar Minimum charge pressure (when system is cold) 1 - 1.5 bar Optimal charge pressure 3 bar Maximum charge pressure at maximum heating

water temperature must not be exceeded (pressure relief valve opens).

Table 30

If the indicator is below 1 bar when the system is cold: ▶ Top up the water until the indicator is between 1 bar and 1.5 bar

again.

If pressure is not being maintained: ▶ Check tightness of expansion vessel and heating system.

10.7 Removing the gas valve

▶ Close gas isolator. ▶ Unplug the plug. ▶ Undo the union nut on the top of the gas valve. ▶ Pull off the gas hose and pressure reducer. ▶ Undo the union nut on the bottom of the gas valve.

0010015948-002

Fig. 83 Pull of the plug and undo the union nuts

▶ Remove 2 screws and take off gas valve.

0010015949-001

Fig. 84 Removing the gas valve

▶ Install the gas valve in reverse order, and check the gas/air ratio.

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Replacement parts

10.8 Removing the pump

▶ Unplug the electrical plug [5]. ▶ Disconnect nut connection [1] between pump and heatcell. ▶ Remove clip [3] between diverter valve manifold and pump

assembly.

▶ Remove 2 x T20 (Torx) screws [4] from the bottom plate of the

appliance.

▶ Remove pump assembly [2].

0010029657-001

Fig. 85 Removing the pump

10.9 Removing the automatic air vent valve

1. Remove the clip.

2. Pull out the automatic air vent valve.

10.10 Removing the motor of the diverter valve

▶ Removing the automatic air vent valve ▶ Removing the motor of the diverter valve:

1. Undo clip.

2. Remove the motor of the diverter valve.

0010006640-003

Fig. 87 Removing the motor of the diverter valve

▶ Press the cable retaining clip and remove the plug.

Fig. 86 Removing the automatic air vent valve

0010006638-003

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Replacement parts

10.11 Removing the heat exchanger

▶ Remove the fan, gas hose and mixing device ( Chapter , page 53).

1. Remove the clip.

2. Detach the flow pipe.

3. Disconnect the cable from the flow temperature sensor on the heat

exchanger.

4. Disconnect the cable from the flue gas temperature limiter.

5. Remove the nut.

10.12 Replacing the control unit

The devices are delivered without code plug.

▶ When replacing the control unit, ensure the code plug supplied is

used.

▶ Flip the electronics panel down (Fig. 46 page 35). ▶ Replace the control unit.

0010017283-002

Fig. 90 Replacing the control unit

▶ Open the cover on the enclosure of the appliance electronics. ▶ Insert the code plug.

Fig. 88 Detach the flow pipe and disconnect the cable

1. Unclip the flue pipe.

2. Push the flue pipe up.

3. Remove the heat exchanger.

0010015950-002

0010017275-001

Fig. 91 Inserting the code plug

Fig. 89 Removing the heat exchanger

0010015951-002

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Fault finding and diagnosis

10.13 Reattaching the casing on the side

▶ Align the side panel so that the underside can be guided along the

flange. ▶ Push the side panel towards the rear. ▶ Tighten the fixing screws.

NOTICE:

On completion of the Service/Fault-Finding task which has required the breaking and remaking of electrical connections, check:

▶ Earth continuity, ▶ Short circuit check, ▶ Polarity ▶ Resistance to earth.

11.1 General information

Indicators (fault category O)

Indicators signal operating conditions during normal operation.

Indicators can be read out with the service function 1-A1.

Non-blocking faults (fault category R)

The heating system remains in operation with non-blocking faults. The H symbol is shown on the display.

0010019239-001

Fig. 92 Attaching the side panel

11 Fault finding and diagnosis

This fault finding information is for guidance only. Worcester cannot be held responsible for costs incurred by persons not deemed to be competent.

This fault finding system assumes that the appliance has been operating normally until the time of failure (i.e. not a first time installation error).

Basic checks

• Ensure that there is 230V power supply and the polarity is correct to

the appliance.

• Ensure that the appliance settings and functionality is correct.

• Ensure the CH/DHW programmer/timer is functioning.

• Ensure the room thermostat is functioning.

• Ensure the cylinder thermostat (if fitted) is functioning.

• Ensure the cold water mains is turned on.

• Ensure the primary system has adequate pressure/system content

for the system type.

• Ensure there is gas to the appliance.

– Are other gas appliances working, gas cooker/hob for example?

– Has the credit run out on the gas pre-payment meter?

0010016301-001

Fig. 93 Example: non-blocking fault

Resetting a non-blocking fault ▶ Press the " key until the H and ! symbols are displayed.

The fault code with the smallest number is displayed. ▶ To select a fault code: press arrow key  or . ▶ To delete the fault code: press the OK key. ▶ Follow the same procedure to delete further fault codes.

Blocking faults (fault category B)

Blocking faults result in the heating system being shut down temporarily. The heating system restarts automatically as soon as the blocking fault is removed.

The fault code of a blocking fault can be read out with the service function 1-A2.

Fault category V: locking faults

Locking faults result in the heating system being shut down, and the system can only be restarted after a reset.

The fault code of a locking fault flashes together with the H on the display.

▶ Turn the power to the boiler off and on again.

-or-

▶ Press the arrow keys  and  at the same time until the symbols H

and ! disappear.

The device resumes operation. The flow temperature is displayed.

If a fault persists: ▶ Check PCB, replace if required. ▶ Adjust the service functions as directed on the “Settings in the

service menu” label.

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Fault finding and diagnosis

11.2 Table of operation and fault displays

Description Remedy

Fault

code

Fault

category

200 O The device is in central heating mode. – 201 O The appliance is in DHW mode. – 202 O The appliance is in optimised switching mode:

the interval for restarting the burner has not yet expired ( service function 3-b2).

203 O The appliance is on standby, there is no heat

demand.

204 O The current flow temperature is higher than the

set flow temperature. The burner has been switched off.

207 – Operating pressure too low. ▶ Fill and vent the system, check the system for leaks.

208 O The appliance is in chimney sweep mode.

Chimney sweep mode is deactivated automatically after 30 minutes.

212 – Temperature increase for safety or flow

temperature sensor too fast.

214 V The fan stops during the safety time. ▶ Check fan, replace if necessary.

215 V Fan too fast. ▶ Replace fan.

224 224BV

227

Flue gas temperature limiter or heat exchanger temperature limiter has tripped.

No flame detected. After the 5th ignition attempt, the blocking fault becomes a locking fault.

227BV

228 V Flame signal is present although burner is

switched off.

–

▶ Replace pressure sensor if necessary. –

▶ Open the shut-off valves.

▶ Check mains voltage.

▶ Mains voltage must correspond to the default value. ▶ Check PCB and fan harness, replace if necessary.

If the blocking fault persists for a prolonged period, it becomes a locking fault.

▶ Check position of isolation valve in heating circuit, open if required. ▶ Check water pressure, if necessary top up until the preset pressure is reached. ▶ Check the temperature limiter and connecting lead of the heat exchanger for

breaks, replace if required.

▶ Check the flue gas temperature limiter and the connecting lead for breaks, replace

if required.

▶ Vent appliance with service function 4-A1 ( page 48).

▶ Check whether the gas isolator is open. ▶ Check the gas supply pressure. ▶ Check ionisation signal. ▶ Check the power supply. ▶ Check the electrodes with cable, replace if required. ▶ Check the flue system, clean or repair if required. ▶ Check gas/air ratio, adjust if necessary. ▶ Clean heat exchanger. ▶ Check the gas valve, replace if required. ▶ Check burner setting, correct if necessary.

▶ Check if there is a flame present. ▶ Check electrodes and connecting leads, replace if required. ▶ Check the gas valve, replace if required. ▶ Check appliance electronics, replace if necessary.

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Fault finding and diagnosis

Description Remedy

Fault

code

Fault

category

229 B Flame lost during burner operation. ▶ Check the main shut-off valve, open if necessary.

▶ Check the appliance isolation valve, open if necessary. ▶ Measure the gas supply pressure at the rated heat input. If necessary, shut down

the appliance and check the gas line. ▶ Check flame sense electrode and connecting lead, replace if required. ▶ Check venturi/injector for potential blockage. ▶ Measure the ionisation current. ▶ Check the protective conductor connection in the control unit. ▶ Check the ignition cable for damage, replace if necessary. ▶ Check functionality of gas valve and replace if necessary. ▶ Check burner setting value at rated heat input. ▶ Check burner setting value at the lowest output. ▶ Check flue system. ▶ Check combustion air supply. ▶ Check the heat exchanger on the flue gas side for deposits, clean if necessary.

232 B Heat source locked by external switching

contact.

▶ Connect the plug for the external switching contact. ▶ Install jumper/check condensate pump according to manufacturer's

specifications. ▶ Adapt switching point of the external temperature switch to the system. ▶ Replace connecting lead to the external temperature switch. ▶ Replace external temperature switch.

233 V Fault in code plug or appliance electronics. ▶ Check whether code plug is installed.

▶ Check appliance electronics, replace if necessary.

234 V Electrical fault in gas valve. ▶ Check the connecting lead, replace if required.

▶ Check the gas valve, replace if required.

235 V Version conflict between appliance electronics

and code plug.

▶ Check software version of appliance electronics and code plug. ▶ Replace appliance electronics or code plug.

237 V System fault. ▶ Check and replace code plug.

▶ Check and replace the appliance electronics.

238 V appliance electronics faulty. ▶ Check and replace the appliance electronics. 242 V System fault, appliance electronics. ▶ Reset control appliance / burner control unit - factory reset.

▶ Reconnect electrical connections at control unit / burner control unit correctly. ▶ Replace the control unit/burner control unit.

244 V System fault, appliance electronics / basic

controller.

▶ Reset control unit / burner control unit - factory reset. ▶ Reconnect electrical connections at control unit / burner control unit correctly. ▶ Replace the control unit/burner control unit.

246

– Internal burner control fault. ▶ Reset burner control - factory reset. 247 257

245

System fault, appliance electronics. ▶ Reset appliance electronics - factory reset.

249

V 250

V 251

V 252

V 253

V 254

V 256 V System fault, appliance electronics / basic

controller.

▶ Check electrical connections of burner control. ▶ Replace burner control.

▶ Check electrical connections. ▶ Replace the appliance electronics.

▶ Reset control unit / burner control unit - factory reset. ▶ Reconnect electrical connections at control unit / burner control unit correctly. ▶ Replace the control unit/burner control unit.

258 V Internal fault in control unit. ▶ Reset control unit - factory reset.

▶ Reconnect electrical connections at control unit correctly. ▶ Replace control unit.

259

System fault, appliance electronics. ▶ Reset appliance electronics - factory reset. 262 263

V V

▶ Check electrical connections. ▶ Replace the appliance electronics.

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Fault finding and diagnosis

Description Remedy

Fault

code

Fault

category

264 B Air feed failed during operating phase. ▶ Reconnect the fan plug properly, perform reset.

▶ Replace fan. ▶ Mains voltage must correspond to the default value. ▶ Remove any blockages in the flue system. ▶ Check venturi/injector for potential blockage.

265 BC Heat energy demand lower than energy

–

supplied. 268 – Component test mode. Not applicable, is status message. 269 V Flame monitoring. ▶ Reset appliance electronics - factory reset.

▶ Replace the appliance electronics. ▶ Check flame sense electrodes and connections.

▶ Check earth connections. 270 BC The heat source has started up. – 273 O Operation interrupted: safety inspection

–

following 24 hours of continuous operation. 275 O Test code plug detected. – 281 – Pump stuck or running dry. ▶ Replace the pump.

▶ Vent the system. ▶ Check operating pressure. ▶ Check low pressure switch. ▶ Check pump connections (hydraulic and electrical).

305 BC Boiler cannot start temporarily following DHW

System appliance only.

priority. 306 V After switching gas off: Flame is detected. ▶ Check the gas valve, replace if required.

▶ Check electrodes and connecting leads, replace if required.

▶ Replace the appliance electronics. 323 – Control communication fault. – 328 V Mains voltage briefly interrupted. ▶ Check for voltage interruption between electrical wiring system of the building and

the appliance.

341 B Heat source temperature increase too rapid. ▶ Open isolation valves.

▶ Connect plug to pump.

▶ Replace pump.

▶ Ensure circulating pump is set on Constant speed mode - curve III. 342 BC Temperature increase in DHW mode too rapid. ▶ If the water pressure is too low, top up with water and vent the system.

▶ Open service valves in the cylinder charging circuit.

▶ Replace the diverter valve / cylinder primary pump. 350 B Flow temperature sensor short circuit. ▶ Check and replace flow temperature sensor and harness  Section 13.2.1.

▶ Check and replace the connecting lead to the flow temperature sensor.

▶ Check and replace control unit/burner control unit. 351 B Flow temperature sensor failure. ▶ Connect the plug to the flow temperature sensor.

▶ Check and replace flow temperature sensor and harness  Section 13.2.1.

▶ Check and replace the connecting lead to the flow temperature sensor.

▶ Check and replace control unit/burner control unit. 356 B Supply voltage for heat source too low. ▶ Establish supply voltage of at least 196 VAC. 357 BC Venting program – 358 BC Active anti-seizing function. Blocking protection for the heating pump and diverter valve active 360 V Incorrect code plug. ▶ Check code plug, replace if necessary. 362 V Service code plug detected. ▶ Check code plug, replace if necessary. 363 V System fault, appliance electronics: fault when

testing the ionisation signal.

▶ Check earthing connections.

▶ Reset appliance electronics, replace if necessary. 364 V Solenoid valve EV2 leaking. ▶ Check the gas valve, replace if required.

▶ Check electrodes and connecting leads, replace if required.

▶ Check and replace the appliance electronics. 365 V Solenoid valve EV1 leaking. ▶ Check the gas valve, replace if required.

▶ Check electrodes and connecting leads, replace if required.

▶ Check and replace the appliance electronics.

Worcester 2000 – 6 721 814 551 (2019/09)

Fault finding and diagnosis

Description Remedy

Fault

code

Fault

category

604 V System fault, burner control unit. ▶ Reset appliance - factory reset.

▶ If the fault persists following a reset, the burner control unit is faulty and must be

replaced.

810 – DHW temperature has not increased for 2 hours. ▶ Prevent water from escaping.

▶ Position DHW temperature sensor correctly. ▶ If no voltage can be measured, then the MC10 control panel is faulty and must be

replaced.

▶ If power is being supplied to the DHW cylinder charge pump but it is still not

running, it is faulty and must be replaced.

▶ If power cannot be supplied to the DHW cylinder charge pump, then there is a

problem in the cable between the control panel and pump. Check screw terminals and cables.

▶ If current is not being supplied to the 3-way valve, there is a problem in the cable

between the control panel and valve. Check screw terminals and cables.

▶ If current is being supplied to the 3-way valve but it is still not working, the valve is

faulty and must be replaced.

▶ If a voltage of approx. 230 V is measured at the terminals and the pump is not

running, the pump is faulty and must be replaced. ▶ Eliminate all faults in the cables. Vent if necessary. ▶ Replace the pump if there are any deviations whatsoever. ▶ Set the DHW heating to “Priority”. ▶ If readings are different to the values in the table, replace the sensor.

815 R Faulty low loss header temperature sensor. ▶ Check the sensor port.

▶ Check the temperature sensor for incorrect installation position or breakage.

1013 R Maximum combustion point reached. ▶ Check plausibility of displayed cylinder temperature.

▶ Check plug-in connectors and cable harness for contact. ▶ Replace cylinder temperature sensor.

1014 – Ionisation current is too low. – 1017 R Water pressure too low. ▶ Check water pressure, if necessary top up until the preset pressure is reached.

▶ Check pressure sensor, replace if required.

1018 W Service time expired. ▶ Carry out maintenance. 1021 R DHW temperature sensor faulty. ▶ Check plug, connect correctly.

▶ Check installation position of temperature sensor, mount correctly if required. ▶ Check temperature sensor, replace if necessary ( Tab. 36, page 75). ▶ Check connecting lead for breaks or short circuits, replace if required. ▶ Check and replace the appliance electronics.

1022 – DHW temperature sensor is faulty. – 1023 R Maximum operation time including standby is

▶ Perform inspection.

reached.

1065 R Pressure sensor faulty or not connected. ▶ Check plug, connect correctly.

▶ Check pressure sensor, replace if required. ▶ Check connecting lead for breaks or short circuits, replace if required. ▶ Check and replace the appliance electronics.

1068 R Outside temperature sensor faulty. ▶ Remedy contact problem.

▶ Replace the sensor.

1073 R Flow temperature sensor short circuit. ▶ Check flow temperature sensor, replace if necessary.

▶ Check connecting lead for short circuits, replace if required. ▶ Check and replace the appliance electronics.

1074 R No signal from the flow temperature sensor. ▶ Check plug, connect correctly.

▶ Check flow temperature sensor, replace if necessary. ▶ Check connecting lead for breaks, replace if required. ▶ Check and replace the appliance electronics.

1075 R Short circuit in heat exchanger temperature

limiter.

▶ Check heat exchanger temperature limiter, replace if required. ▶ Check connecting lead for short circuits, replace if required. ▶ Check and replace the appliance electronics.

Worcester 2000 – 6 721 814 551 (2019/09)

Fault finding and diagnosis

Description Remedy

Fault

code

Fault

category

1076 R No signal from heat exchanger temperature

limiter.

▶ Check plug, connect correctly. ▶ Check heat exchanger temperature limiter, replace if required. ▶ Check connecting lead for breaks, replace if required. ▶ Check and replace the appliance electronics.

2051 – Internal fault. ▶ Disconnect power from the system for 30 seconds.

▶ Check and replace control unit. ▶ Notify customer service.

2085 2908VV

Internal fault in burner control unit. ▶ Reset appliance.

▶ If the fault persists following a reset, the burner control unit is faulty and must be

replaced.

2909 – System fault, appliance electronics / basic

controller

▶ If the fault persists following a reset, the burner control unit or Key (including

interconnecting leads) is faulty and must be replaced.

2910 V Fault in flue system. ▶ Check whether a flue system is connected, install if required.

▶ Check for unobstructed cross-section of flue system, remove deposits if required. 2911 – Calibration failed. ▶ Replace faulty component. 2912 – No flame signal during calibration. ▶ Replace faulty component. 2913 – Flame signal too low during calibration. ▶ Check and replace flame sense electrodes (and interconnecting leads). 2914 – System fault, appliance electronics. ▶ If the fault persists following a reset, the appliance control unit is faulty and must

be replaced.

2915 V System fault, appliance electronics. ▶ Reset appliance.

▶ If the fault persists following a reset, the control unit is faulty and must be replaced. 2916 V System fault, appliance electronics. ▶ Reset appliance.

▶ Trigger heat demand.

▶ End heat demand.

If the fault persists, the control unit is defective and must be replaced.

2917 V No flame signal when checking the combustion

control.

▶ Disconnect power and then reconnect.

▶ Trigger heat demand.

▶ Wait 5 minutes.

▶ If the fault re-occurs within that time, reset the appliance without disconnecting

the supply voltage. This triggers a calibration of the ionisation circuits.

▶ If the fault is still present after the calibration, the control unit is faulty and must be

replaced. 2918 – Fault in the flue. ▶ Clean the siphon and drain water out of the appliance (gas side). 2920 V Flame monitoring fault. ▶ Check electrodes and connecting leads, replace if required.

▶ Check earthing connections. ▶ Check appliance electronics, replace if necessary.

2921 B The appliance is in test mode ( Menu 5,

–

page 49). 2922 – Internal burner control fault. ▶ Check and replace control unit. 2923

2924VV

System fault, appliance electronics. ▶ Reset appliance - factory reset.

▶ If the fault persists following a reset, the appliance electronics are faulty and must

be replaced.

2925 2926VV

System fault, appliance electronics. ▶ Check the gas valve, replace if required.

▶ Check appliance electronics, replace if necessary.

Worcester 2000 – 6 721 814 551 (2019/09)

Fault finding and diagnosis

Description Remedy

Fault

code

Fault

category

2927 B No flame detected during ignition. ▶ Check the main shut-off valve, open if necessary.

▶ Check the appliance isolation valve, open if necessary. ▶ Measure the gas supply pressure at the rated heat input. If necessary, shut down

2932 – Internal fault. ▶ Restart the appliance.

Internal fault in burner control unit. ▶ Reset appliance - factory reset.

2928

2930 2931 2940

V V

▶ If the fault persists following a reset, the burner control unit is faulty and must be

replaced.

2941 B Insufficient flow rate in heat source. ▶ Check plug of flow temperature sensor, connect correctly if required.

▶ Check flow temperature sensor, replace if necessary. ▶ Check pump for blockage, clear if required. ▶ Check pump settings, correct if required. ▶ Check water pressure, if necessary top up until the preset pressure is reached.

2942 – No fan speed feedback. ▶ Connect plug for speed control to the fan.

▶ Connect plug for power supply to the fan. ▶ Check fan harness. ▶ Check and replace control unit.

2943 – Mains voltage too low. ▶ Establish supply voltage of at least 196 VAC. 2945 V Too many short heat demands in a short time. ▶ Reset appliance - factory reset.

▶ Increase restart blocking time. ▶ Make sure that at least one thermostatic valve is open. ▶ Check and replace faulty heating pump. ▶ Check diverter valve functionality, replace if necessary.

2946 V Incorrect code plug. ▶ Check code plug, replace if necessary. 2947 R Anti-seizing function is activated. The function stops automatically. 2948 B No flame signal with low output. The burner restarts automatically after purging.

▶ Check CO

settings.

2949 B No flame signal with high output. The burner restarts automatically after purging.

▶ Check burner gaskets, replace if required. ▶ Check CO

settings.

2950 B No flame signal following starting procedure. ▶ Check CO2 settings, adjust if necessary.

▶ Check Burner and heat exchanger gaskets ▶ Check gas pressure during burning at full load ▶ Burner restarts automatically after purging

2951 V Loss of flame too frequent. ▶ Refer to the blocking error(s) that lead to this locking error. Check the fault history

on appliance. ▶ Possible purging of gas pipe incomplete. ▶ Could also indicate a wide variety of issues such as pipework undersized or gas

pressure dropping off, incorrectly routed condense drains, incorrectly sited flues,

incorrectly wired etc.

2952 V Internal fault when testing the ionisation signal. ▶ Restart appliance to see if problem re-occurs.

▶ If the fault remains after resetting, the burner controller (PCB) is defective

Worcester 2000 – 6 721 814 551 (2019/09)

Fault finding and diagnosis

Description Remedy

Fault

code

Fault

category

2953 B No flame signal with low output. The burner starts automatically after cleaning (purge).Possible cause high winds.

▶ If the fault occurs repeatedly, check the settings of the CO

values.

▶ Check Flue integrity. ▶ Check flue terminal.

2954 B No flame signal with high output. Burner restarts automatically after purging.

▶ Check and replace burner gaskets. ▶ Reduce burner load. ▶ If the fault occurs repeatedly, check the settings of the CO

values.

▶ Check Flue integrity. ▶ Check flue terminal.

2955 B The heat source does not support the specified

parameters for the hydraulic configuration.

2956 O Hydraulic configuration at the heat source is

▶ Check hydraulic configuration, correct if necessary. ▶ Check menu L2, default setting 0 required.

–

activated.

2957 2958VV

System fault, appliance electronics. ▶ Reset appliance electronics.

▶ Check electrical connections. ▶ Check and replace the control unit.

2959

System fault, appliance electronics. ▶ Check and replace the control unit and code plug.

2960BB 2961

2962VV

No signal from fan. ▶ Check mains voltage to fan.

▶ Check fan harness for continuity, replace if required. ▶ Check the Pulse width modulation (PWM). ▶ Check and replace the fan. ▶ Check and replace the PCB.

2963 R The signal from the heat exchanger temperature

limiter and flow temperature sensor is outside the permissible range.

▶ Check flow through appliance and system is filled. ▶ Check for air locks in the system. Purge if required. ▶ Check Heat exchanger sensor (primary thermistor) and plug connected to stat. ▶ Check resistance of stat. Replace if required. ▶ Check continuity of harness. Replace if required.

2964 B Insufficient flow rate in heat exchanger. ▶ Supply sensor is not assembled on the supply pipe.

▶ Supply sensor does not make proper contact to the supply pipe. ▶ System is not filled with water. ▶ No water flow, because CH system is closed. ▶ No water flow, because pump is not operating correctly.

2965 B Flow temperature too high. ▶ Check flow through appliance and system pressure.

▶ Check for air locks in the system. Purge if required. ▶ Check isolation valves.

2966 B Flow temperature increase in heat exchanger

too rapid.

▶ Check flow through appliance and system pressure. ▶ Check for air locks in the system. Purge if required. ▶ Check isolation valves. ▶ Check pump is operating freely, check voltage to pump

2967 B Temperature differential between flow

temperature sensor and heat exchanger temperature limiter is too great.

▶ Check flow through appliance and system filled. ▶ Check for air locks in the system. Purge if required. ▶ Check isolation valves. ▶ Check pump is operating, check voltage to pump. ▶ Check heat exchanger sensor and flow sensor are making contact with the pipe

work.

▶ Check heat exchanger sensor and resistance of stat. replace if required.

▶ Check continuity of harness. Replace if required. 2968 – Refilling of system in progress. Not applicable in the UK/IE 2969 – Maximum number of refills reached. Not applicable in the UK/IE 2971 V Operating pressure too low. ▶ Vent the heating system.

▶ Check water pressure, if necessary top up the system pressure.

▶ Check pressure sensor, replace if required. 2972 V Mains voltage too low. ▶ Check mains supply voltage on appliance L and N connections.

Worcester 2000 – 6 721 814 551 (2019/09)

Description Remedy

Fault

code

Fault

category

2973 – System fault, appliance electronics / basic

controller

▶ Perform reset - factory reset. ▶ Check and replace control unit.

2974 – Internal error ▶ Restart the appliance and check if fault remains.

▶ Check and replace control unit.

Table 31 Indicators and fault displays

11.3 Pump operation and diagnosis

The operation/fault indicator ( ) will indicate the status of the pump including any errors detected.

LED colour Description Diagnostic Potential cause Remedy

Green continuous

Green/Red blinking

Red - blinking Abnormal running mode

Red - continuous Pump stopped The pump has stopped due to

No LED No power supply No voltage on electronics • Pump is not connected to mains

Table 32 Pump operation and diagnosis

Normal operation Pump runs as expected Normal operation --

Warning mode (pump operating in an abnormal condition, no risk for the

The pump is running but sent a warning message.

• Dry run: – The pump is operating

without water.

pump functionality).

• Overload of motor: – Friction due to particles and

/or impeller blocked with debris and /or too high viscosity.

• Generator operation: – The pump rotor is driven by

an external flow.

(pump stopped but still functioning).

The pump has stopped due to external failure.

The pump will restart itself after the disappearance of the external failure.

• Under or Over voltage: – Mains supply voltage

U<160V or U>280V.

• Overload of motor: – Friction due to particles and/

or impeller blocked with debris and/or too high viscosity.

• Over speed: – The pump rotor is driven by

an external flow above the maximum allowed value.

• Over current: – Abnormal current exceeding

the limit.

• Module over temperature: – Temperature inside the

motor is too high.

• Turbine mode: – The pump is driven by

external flow (>1200l/h) in opposite direction of its flow.

• Faulty electronic module and/or

permanent failure.

faulty motor.

supply

• Faulty LED ▶ Check if pump is running.

• Faulty electronics ▶ Replace pump.

▶ Check appliance system

pressure and top up as required.

▶ Check installation water quality,

clean system if debris is present.

▶ The pump will operate normally

when the external flow will be stopped.

▶ Check mains voltage supply to

pump: 160V < U < 280V.

▶ Check installation water quality,

clean system if debris.

▶ Ensure that there is no other

external flow (additional secondary pump running) on the system.

▶ Check for leakage on appliance.

▶ Check for evidence of dry

running, low system pressure and ambient temperature.

▶ Ensure that the external flow is

less than 1200l/h.

▶ Restart the appliance and wait

30 seconds before switching back ON.

▶ Replace pump if LED is still red

after power restart.

▶ Check cable connection and

supply to pump.

Fault finding and diagnosis

Worcester 2000 – 6 721 814 551 (2019/09)

Fault finding and diagnosis

11.4 Faults that are not displayed

Appliance faults Remedy

Combustion noises too loud; rumbling noises ▶ Check the gas type.

▶ Check the gas supply pressure. ▶ Check the flue system; clean or repair if required. ▶ Check the gas/air ratio. ▶ Check the ratio control valve; replace if required. ▶ Check condense drain is clear. ▶ Check fan depression.

Flow noises ▶ Set the pump rate or pump characteristic map correctly and match to the maximum

output.

Heat-up takes too long. ▶ Set the pump rate or pump characteristic map correctly and match to the maximum

output. ▶ Check system is balanced. ▶ Check anti-cycle time.

Flue gas values incorrect; CO content too high. ▶ Check the gas type.

▶ Check the gas supply pressure. ▶ Check the flue system; clean or repair if required. ▶ Check the gas/air ratio. ▶ Check the ratio control valve; replace if required.

Delayed ignition, poor ignition. ▶ Check the ignition transformer function for misfiring in Menu 6, replace if required.

▶ Check the gas type. ▶ Check the gas supply pressure. ▶ Check operation of meter governor. ▶ Check the power supply. ▶ Check the electrodes; replace if required. ▶ Check the flue system; clean or repair if required. ▶ Check the gas/air ratio. ▶ Check the burner, replace if required. ▶ Check the air/gas ratio control valve; replace if required.

Condensate in air box ▶ Check the non-return valve in the air/gas manifold, replace if required. No hot water. ▶ Check the turbine, replace if required.

▶ Check diverter valve ▶ Check for cross-piping.

DHW volume is not reached. ▶ Check the plate heat exchanger.

▶ Check flow device. ▶ Check silencer body.

No function, the display remains dark. ▶ Check the electrical wiring for damage.

▶ Replace defective cables. ▶ Check the fuse, replace if required.

Table 33 Faults that are not shown on the display

Worcester 2000 – 6 721 814 551 (2019/09)

12 Environmental protection/disposal

Environmental protection is a fundamental corporate strategy of the Bosch Group. The quality of our products, their economy and environmental safety are all of equal importance to us and all environmental protection legislation and regulations are strictly observed. We use the best possible technology and materials for protecting the environment taking account of economic considerations.

Packaging

Where packaging is concerned, we participate in country-specific recycling processes that ensure optimum recycling. All of our packaging materials are environmentally compatible and can be recycled.

Used appliances

Used appliances contain valuable materials that can be recycled. The various assemblies can be easily dismantled. Synthetic materials are marked accordingly. Assemblies can therefore be sorted by composition and passed on for recycling or disposal.

Old electrical and electronic appliances

This symbol indicates that the product must not be disposed of with other waste, but be taken to the waste collection centers for treatment, collection, recycling and disposal procedure.

The symbol applies to countries with electronic waste regulations, for example the European Waste Electrical and Electronic Equipment Directive 2012/19/EU. These regulations determine the framework for the return and recycling of used electronic appliances as applicable within each country.

As electronic equipment may contain hazardous substances, it needs to be recycled responsibly in order to minimize any potential harm to the environment and human health. Furthermore, recycling of your electronic waste will help to conserve natural resources.

For additional information on the environmentally safe disposal of electrical and electronic equipment, please contact the relevant local authorities, your household waste disposal service or the retailer where you purchased the product.

For additional information, please visit: www.weee.bosch-thermotechnology.com/

Environmental protection/disposal

Batteries

Batteries must not be disposed together with your household waste. Used batteries must be disposed of in local collection systems.

Worcester 2000 – 6 721 814 551 (2019/09)

Technical Specifications/Logs

13 Technical Specifications/Logs

13.1 Technical data

Technical data table - Worcester 2000

Worcester 2000 7 736 902 027 7 736 902 028 Description Unit 25kW N.G. 30kW N.G.

Gas flow maximum rate - 10 minutes from lighting

Gas inlet pressure (nominal) Natural gas

Central Heating (CH)

Maximum rated heat input (net) (Q Maximum rated heat output 40/30 °C kW 21.4 21.4 Maximum rated heat output 50/30 °C (P Maximum rated heat output 80/60 °C (P Minimum rated heat input (net) (Q Minimum rated heat output 40/30 °C kW 5.3 5.3 Minimum rated heat output 50/30 °C (P Minimum rated heat output 80/60 °C (P Maximum flow temperature °C 86 86 Maximum flow temperature possible °C 82 82 Maximum permissible operating pressure (PMS) bar 3.0 3.0 Available pump head at 20 °C system temperature rise m 2 2

Domestic Hot Water (DHW)

Minimum heat input kW 4.9 4.9 Maximum rated heat input (net) (QnW) kW 25.5 30 Maximum rated heat output (PnW) kW 25.0 29.5 Maximum mains inlet pressure (standing pressure PMW) bar 10 10 Minimum mains inlet pressure (working) for max. flow bar 1.5 1.5 Minimum mains inlet pressure (working) for operation bar 0.3 0.3 Minimum required flow to activate DHW demand l/min 2.5 2.5 DHW temperature range °C 35 - 60 35 - 60 Maximum cold water inlet temperature °C 23 23 Maximum DHW flow rate - 35 °C rise ± 15% Maximum DHW flow rate - 40 °C rise ± 15% l/min 9 10.8

Flue

Flue gas temperature max. load DHW demand °C 70 75 Flue gas temperature 80/60 °C, rated/min. load °C 66/58 66/58 Flue gas temperature 40/30 °C, rated/min. load °C 48/35 48/35 CO2 level at max. rated heat output (after 10 minutes) % 9.6 9.6 CO2 level at min. rated heat output (after 10 minutes) % 8.6 8.6 NOx Class  6 6 NOx rating (EN 15502-1) mg/kWh 39 39

Condensate

Maximum condensate rate l/h 1.7 1.7 pH value, approx.  4.8 4.8

Electrical

Electrical power supply voltage a.c. V 230 230 Frequency Hz 50 50 Maximum power consumption (running) W 90 110 Maximum power consumption (stand-by) W 3 3 Energy efficiency index (EEI) heating pump  ≤ 0.2 ≤ 0.2

General data

Expansion vessel capacity l 6 6 Expansion vessel pre-charge pressure bar 0.75 0.75 Appliance protection rating Permissible ambient temperature short-term/long-term °C 0-50/40 0-50/40 Nominal capacity of the appliance l 7 7 Total package weight kg 40 40 Total appliance weight (excluding packaging) kg 36 36

mbar 20.0 20.0 m3/h 2.60 3.05

) kW 20.4 20.4

max

) kW 21.2 21.2

cond, max

) kW 20.0 20.0

max

) kW 4.9 4.9

min

) kW 5.3 5.3

cond, min

) kW 4.8 4.8

min

l/min 10 12

IP X4D X4D

Worcester 2000 – 6 721 814 551 (2019/09)

Technical Specifications/Logs

Worcester 2000 7 736 902 027 7 736 902 028 Description Unit 25kW N.G. 30kW N.G.

Lift weight (without front panel) kg 33.4 33.4 SEDBUK 2009 % 89.1 89.1

1) For minimum and maximum permissable pressure refer to “Gas pressure within the system”, section 6.6.

2) The Gas Rate provided assumes the accepted NG averaged calorific value of 34-9 MJ/m

3) Appliances are fitted with a flow regulator set to achieve a 35°C temperature rise. A 40°C temperature rise is possible at lower flow rates.

4) Protection rating may change depending on the control unit/s used on this appliance.

net.

Table 34 Technical data Worcester 2000

13.2 Component resistance characteristics

13.2.1 Sensor values

Temperature [°C ± 10%] Resistance []

0 33 404 5 25 902 10 20 247 15 15 950 20 12 657 25 10 115 30 8 138 35 6 589 40 5 367 45 4 398 50 3 624 55 3 002 60 2 500 65 2 092 70 1 759 75 1 486 80 1 260 85 1 074 90 918 95 788 100 680

Table 35 Flow temperature sensor

Temperature [°C] Resistance []

0 33 242 10 19 947 20 12 394 30 7 947 40 5 242 50 3 548 60 2 459 70 1 740 80 1 256 90 923

Table 36 DHW temperature sensor

Temperature [°C] Resistance []

-40 ≥ 4 111

-30 3 218

-20 2 360

-10 1 650 0 1 122 10 759 20 515 30 354 40 247 50 ≤ 174

Table 37 Outside temperature sensor (for weather-compensated

controllers, accessory)

13.3 Heating curve

VT/°C

max

+20

Fig. 94 Heating curve

A End point (at the outside temperature – 10 °C) AT Outdoor ambient temperature B Base point (at the outside temperature + 20 °C) max Maximum flow temperature pA Flow temperature at the end point of the heating curve pB Flow temperature at the foot point of the heating curve S Automatic heating switch-off (summer mode) VT Supply temperature

-10

0 010 005 905-001

AT/°C

Worcester 2000 – 6 721 814 551 (2019/09)

Technical Specifications/Logs

13.4 Internal wiring of the appliance

13.4.1 Electircal wiring

13 14 15

230V

Fig. 95 Electrical wiring

Legend to figure 95:

[1] Fuse [2] Mains cable [3] Earth connections [4] DHW temperature sensor [5] Low water pressure switch [6] Flow limiter cartridge [7] Diverter valve [8] Exhaust gas temperature limiter [9] Gas valve [10] Flow temperature sensor [11] Fan

N L

5AF

TW1

BUS

0010029492-001

[12] Heat exchanger flow temperature sensor [13] Earth connection [14] Ignition electrode [15] Flame sense electrode [16] Heat exchanger high limit stat [17] Ignition transformer [18] Pump [19] Low voltage I/Os for controls [20] Code plug interface - Not used

Worcester 2000 – 6 721 814 551 (2019/09)

13.5 Setting values for output

The maximum rated heat output can be reduced to up to 50 % of the output range (service function 3-b1).

The minimum rated heat output can be increased to up to 50 % of the output range (service function 5-A3).

13.5.1 Gas setting values

GC2000iW 25 C

Technical Specifications/Logs

Display

percentage %

Heat Output

[kW]

Heat input

[kW]

80 20.0 20.40 35.0 75 18.7 19.13 32.8 70 17.5 17.85 30.6 65 16.2 16.58 28.4 60 15.0 15.30 26.3 55 13.7 14.03 24.1 50 12.5 12.75 21.9 45 11.2 11.48 19.7 40 10.0 10.20 17.5 35 8.7 8.93 15.3 30 7.5 7.65 13.1 25 6.2 6.38 10.9 20 5.0 5.10 8.8 19 4.8 4.92 8.4

Table 38 GC2000iW 25 C

GC2000iW 30 C

Display

percentage %

Heat Output

[kW]

Heat input

[kW]

68 20.0 20.4 35.0 65 19.1 19.5 33.5 60 17.6 18.0 30.9 55 16.2 16.5 28.3 50 14.7 15.0 25.7 45 13.2 13.5 23.2 40 11.7 12.0 20.6 35 10.3 10.5 18.0 30 8.8 9.0 15.4 25 7.3 7.5 12.9 20 5.9 6.0 10.3 16 4.8 4.92 8.4

Table 39 GC2000iW 30 C

Gas flow rate [l/min]

Worcester 2000 – 6 721 814 551 (2019/09)

GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME): Gas Safe registration number:

Company name: Telephone number:

Company email: Company address:

Commissioning date:

Heating and hot water system complies with the appropriate Building Regulations? Yes

Time, temperature control and boiler interlock provided for central heating and hot water Yes

Boiler Plus requirements (tick the appropriate box(s))

Boiler Plus option chosen for combination boiler in ENGLAND

Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination boiler

Zone valves pre-existing Fitted Not required

Thermostatic radiator valves pre-existing Fitted Not required

Automatic bypass to system pre-existing Fitted Not required

pre-existing Fitted Not required

Water quality

What system cleaner was used? Brand: Product:

What inhibitor was used? Brand: Product:

pre-existing Fitted Not required

CENTRAL HEATING MODE measure and record (as appropriate)

Gas rate (for combination boilers complete DHW mode gas rate) m3/hr or ft3/hr

Central heating output left at factory settings? Yes No

If no, what is the maximum central heating output selected? kW

Dynamic gas inlet pressure mbar

Central heating return temperature °C

System correctly balanced/rebalanced? Yes

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)? Yes No

Water scale reducer/softener pre-existing Fitted Not required

Brand: Product:

If yes- DHW expansion vessel pre-existing Fitted Not required

Pressure reducing valve pre-existing Fitted Not required

DOMESTIC HOT WATER MODE Measure and record

Gas rate m3/hr or ft3/hr

Dynamic gas inlet pressure at maximum rate mbar

Cold water inlet temperature °C

Hot water has been checked at all outlets Yes Temperature °C

CONDENSATE DISPOSAL

The condensate drain has been installed in accordance with the manufacturers’ instructions and/or BS5546/BS6798 Yes

Point of termination Internal External (only where internal termination impractical)

Method of disposal Gravity Pumped

ALL INSTALLATIONS

At max rate: CO ppm CO

Record the following

At min rate (where possible) CO ppm CO

The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes

The manufacturers’ literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s signature

Customer’s signature

Weather compensation Smart thermostat with automisation and optimisation

Load compensation Flue Gas Heat Recovery

instructions Yes

Yes No

% CO/CO

instructions, and readings are correct? Yes

Ratio

°C

www.centralheating.co.uk

Technical Specifications/Logs

13.7 Inspection and maintenance checklist

Gas Safe Engineers Signature

________________________ ___________________

Gas Safe registration number

Appliance left to customer settings

Yes 

4.8

4.7

4.6

4.5

4.4

4.3

4.2

Gas Safe/Benchmark documentation updated

Check flue integrity

Fit casing

Check flame failure appliance

Gas rate appliance at maximum output in test mode

Check combustion settings: Min/Max test modes

Flue gas analysis

Correct working gas inlet pressure

Check and clean syphon

was cleaning required?

Yes 

No 

Yes 

No 

Yes 

No 

Yes 

4.1

Check Fan pressure test

Appliance performance checks:

Internal visual inspection

Check for signs of leaking, corrosion and distress

Yes 

Visual Inspection:-

Check compliance of appliance, system and components

Check appliance operation (CH & DHW) and fault history

Date:

Inspection and maintenance checklist

Yes 

Year 1

Yes 

Year 2

Yes 

Year 3

________________________ ___________________

Yes 

No 

Yes 

Year 4

Year 5

Year 6

Year 7

Year 8

Year 9

Year 10

Year 11

Year 12

Year 13

________________________ ___________________

Table 40 Inspection and maintenance checklist

Worcester 2000 – 6 721 814 551 (2019/09)

Yes 

No 

Yes 

Year 14

Year 15

SERVICE & INTERIM BOILER WORK RECORD

It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed.

Service provider

When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’ specified spare parts.

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

CO/CO

Date:

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

*A System inhibitor efficacy test is required on every annual service in accordance with the manufacturers’ instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

CO/CO

Date:

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

CO/CO

Date:

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

CO/CO

Date:

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

CO/CO

Date:

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

Max rate CO ppm %%CO/CO

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate:

Were parts fitted?

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

Comments:

Signature:

: Gas Safe registration No:

COMin rate

m³/h ft³/h

delete as appropriate

* All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.

Company name:

ppm

Yes No

delete as appropriate

CO/CO

www.centralheating.co.uk

Date:

yes

yes n/a

SERVICE & INTERIM BOILER WORK RECORD

Service provider

When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’ specified spare parts.

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

CO/CO

Date:

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

CO/CO

Date:

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

CO/CO

Date:

SERVICE/INTERIM WORK ON BOILER

ppm

Company name:

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

delete as appropriate

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

CO/CO

Date:

SERVICE/INTERIM WORK ON BOILER

ppm

Company name:

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

delete as appropriate

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

: Gas Safe registration No:

Max rate CO ppm %%CO/CO

COMin rate

Company name:

ppm

delete as appropriate

CO/CO

Date:

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’

yes

instructions, and readings are correct?”

Gas rate:

Were parts fitted?

m³/h ft³/h

delete as appropriate

Yes No

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593

yes n/a

and boiler manufacturers’ instructions. *

Comments:

Signature:

SERVICE/INTERIM WORK ON BOILER

Engineer name:

Telephone N

Max rate CO ppm %%CO/CO

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate:

Were parts fitted?

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

Comments:

Signature:

: Gas Safe registration No:

COMin rate

m³/h ft³/h

delete as appropriate

Company name:

ppm

Yes No

delete as appropriate

CO/CO

www.centralheating.co.uk

Date:

yes

yes n/a

TECHNICAL SUPPORT: 0330 123 3366

RENEWABLE SUPPORT: 0330 123 9229

CONTROLS AND CONNECTIVITY TEAM: 0330 123 3641 APPOINTMENTS: 0330 123 9339

SPARES: 0330 123 9779

LITERATURE: 0330 123 9119

TRAINING: 0330 123 0166

SALES: 0330 123 9669

Bosch Thermotechnology Ltd. Cotswold Way, Warndon Worcester WR4 9SW United Kingdom Tel. 0330 123 9559 worcester-bosch.co.uk

Bosch Worcester 2000, Worcester GC2000iW C, Worcester GC2000iW 30 C NG, Worcester GC2000iW 25 C NG Installation And Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual