Bosch ZSB18, Condens 5000W Installation And Servicing Instructions

Installation and Servicing Instructions

HYDRONIC GAS SYSTEM BOILER 18kW

BOSCH CONDENS 5000W

6720646195-00.1Wo

ZSB18 - 2A

6 720 646 195a (2010/11)

2 | Contents AU/NZ

6 720 646 195a (2010/11)

Contents

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

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

1.2 Safety precautions . . . . . . . . . . . . . . . . . . 4

2 Boiler information . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Technical data . . . . . . . . . . . . . . . . . . . . . 7

2.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Pre-installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Cleaning primary systems . . . . . . . . . . . . 11

3.2 Mains supply . . . . . . . . . . . . . . . . . . . . . . 12

3.2.1 Electrical supply . . . . . . . . . . . . . . . . . . . 12

3.2.2 Equipotential (earth) bonding . . . . . . . . 12

3.2.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . 12

3.3 Water system and pipe work . . . . . . . . . 13

3.4 Condensate pipe work . . . . . . . . . . . . . . 15

3.4.1 Internal connections . . . . . . . . . . . . . . . . 15

3.4.2 External connections . . . . . . . . . . . . . . . 16

3.5 Pressure relief drain line . . . . . . . . . . . . 17

3.6 Boiler location and clearances . . . . . . . . 18

3.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . 18

3.6.2 Servicing clearances

- Ventilated compartment . . . . . . . . . . . 18

3.6.3 Compartments . . . . . . . . . . . . . . . . . . . . 18

3.6.4 Boiler clearances

- Unventilated compartments . . . . . . . . 19

3.6.5 Installation clearances

- Unventilated compartments . . . . . . . . 19

3.7 Plumbing manifold . . . . . . . . . . . . . . . . . 20

3.7.1 Connections . . . . . . . . . . . . . . . . . . . . . . 20

3.8 Flue options . . . . . . . . . . . . . . . . . . . . . . 21

3.9 Flue terminal positions . . . . . . . . . . . . . . 23

3.10 Plume management terminal positions . 24

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 Unpacking wall frame & ancillary items . 25

4.2 Wall mounting template & flue opening . 26

4.3 Unpacking the boiler . . . . . . . . . . . . . . . . 27

4.4 Boiler connections . . . . . . . . . . . . . . . . . 28

4.5 Flue installation . . . . . . . . . . . . . . . . . . . 30

4.5.1 Measuring the flue (standard flue) . . . . . 30

4.5.2 Reducing the telescopic flue length . . . . 30

4.5.3 Installing the telescopic flue . . . . . . . . . . 31

4.5.4 Flue terminal plume re-direction . . . . . . 32

4.6 Condensate connection . . . . . . . . . . . . . 33

4.7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 34

5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1 Pre-commissioning checks . . . . . . . . . . . 36

5.2 Filling the system . . . . . . . . . . . . . . . . . . 37

5.3 Water treatment . . . . . . . . . . . . . . . . . . . 37

5.4 Starting the boiler . . . . . . . . . . . . . . . . . 38

5.5 Commissioning . . . . . . . . . . . . . . . . . . . 39

5.5.1 Checking the gas inlet pressure . . . . . . 39

5.5.2 Checking the gas rate . . . . . . . . . . . . . . 40

5.5.3 Domestic hot water: . . . . . . . . . . . . . . . 40

5.6 Finishing commissioning . . . . . . . . . . . . 41

5.6.1 Replace outer casing: . . . . . . . . . . . . . . 41

5.6.2 Fitting fascia flap . . . . . . . . . . . . . . . . . . 41

5.6.3 Installing bottom panel . . . . . . . . . . . . . 41

5.6.4 Handover . . . . . . . . . . . . . . . . . . . . . . . . 41

6 Service and spares . . . . . . . . . . . . . . . . . . . . . . 42

6.1 Inspection and service . . . . . . . . . . . . . 42

6.2 Check the gas inlet pressure . . . . . . . . . 43

6.3 Checking flue integrity . . . . . . . . . . . . . 43

6.4 Fan pressure test . . . . . . . . . . . . . . . . . 44

6.5 Flue gas analysis . . . . . . . . . . . . . . . . . . 45

6.6 Setting the air/gas ratio . . . . . . . . . . . . 46

6.6.1 Setting the CO/CO2 . . . . . . . . . . . . . . . 46

6.7 Cleaning the heat exchanger . . . . . . . . . 47

6.8 Replacement of parts . . . . . . . . . . . . . . 50

6.8.1 Removing outer case . . . . . . . . . . . . . . . 50

6.8.2 Primary sensor . . . . . . . . . . . . . . . . . . . 50

6.8.3 Overheat thermostat . . . . . . . . . . . . . . . 50

6.8.4 Flue overheat thermostat

(with grommet) . . . . . . . . . . . . . . . . . . . 51

6.8.5 Moving controls to service position . . . 51

6.8.6 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . 52

6.8.7 Air/gas manifold and fan assembly . . . . 52

6.8.8 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.8.9 Electrode assembly and burner . . . . . . . 54

6.8.10 Heat exchanger . . . . . . . . . . . . . . . . . . . 54

6.8.11 Access to boiler control components . . 56

6.8.12 PCB Fuse . . . . . . . . . . . . . . . . . . . . . . . . 56

6.8.13 Transformer/PCB . . . . . . . . . . . . . . . . . 56

6.8.14 Replacing controls . . . . . . . . . . . . . . . . 57

6.8.15 Syphon removal . . . . . . . . . . . . . . . . . . . 58

6.8.16 Diverter valve motor (If fitted) . . . . . . . 58

6.8.17 Diverter valve (If fitted) . . . . . . . . . . . . . 58

6.8.18 Auto air vent . . . . . . . . . . . . . . . . . . . . . 59

6.8.19 Pump head . . . . . . . . . . . . . . . . . . . . . . 59

6.8.20 Drain tap . . . . . . . . . . . . . . . . . . . . . . . . 59

6.8.21 Pressure gauge . . . . . . . . . . . . . . . . . . . 60

6.8.22 Hydraulic block removal . . . . . . . . . . . . 60

6.8.23 CH Pressure relief valve . . . . . . . . . . . . 61

6.8.24 Bypass valve . . . . . . . . . . . . . . . . . . . . . 61

6.8.25 Expansion vessel . . . . . . . . . . . . . . . . . . 61

6.9 Short parts list . . . . . . . . . . . . . . . . . . . 63

7 Fault finding and diagnosis . . . . . . . . . . . . . . . 64

7.1 Fault finding . . . . . . . . . . . . . . . . . . . . . 64

7.1.1 Circuit diagram . . . . . . . . . . . . . . . . . . . 67

7.2 Boiler function . . . . . . . . . . . . . . . . . . . . 68

7.3 Protection function . . . . . . . . . . . . . . . . 69

KEY TO SYMBOLS AND SAFETY PRECAUTIONS | 3AU/NZ

6 720 646 195a (2010/11)

1 KEY TO SYMBOLS AND SAFETY PRECAUTIONS

1.1 Explanation of symbols

Warning symbols

Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.

• NOTICE indicates possible damage to property or
equipment, but where there is no risk of injury.

• CAUTION indicates possible injury.

• WARNING indicates possible severe injury.

• DANGER indicates possible risk to life.

Important information

Additional symbols

SYMBOLS USED IN THIS MANUAL

PLEASE READ THESE INSTRUCTIONS CAREFULLY
BEFORE STARTING INSTALLATION.

This installation manual is only applicable to the model
of boiler stated on the front cover of this manual.

This boiler must be installed by an authorised person
only. Failure to install this boiler correctly could lead to
prosecution.

If you are in any doubt contact the Robert Bosch
technical hotline on:

1300 30 70 37 AU or 0800 54 33 52 NZ

Please leave these instructions, completed installation
checklist and user manual with the customer after
installing the boiler.

The checklist can be found in the back pages of this
manual.

Abbreviations used in this manual:

Safety instructions in this document are
framed and identified by a warning triangle
which is printed on a grey background.

Electrical hazards are identified by a
lightning symbol surrounded by a warning
triangle.

Notes contain important information in
cases where there is no risk of personal
injury or material losses and are identified
by the symbol shown on the left. They are
bordered by horizontal lines above and
below the text.

Symbol Meaning

B a step in an action sequence

Æ a reference to a related part in the

document or to other related documents

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

Tab. 1 Symbols

Domestic hot water

Central heating

Hot water storage cylinder

Domestic cold water supply

Electrical supply

Gas supply

Tab. 2 Commonly used symbols

ØDiameter

NG Natural gas

LPG Liquefied petroleum gas

CH Central heating

DHW Domestic hot water

PCB Printed circuit board

PRV Pressure relief valve

NTC Negative temperature coefficient (sensor)

IP Ingress protection

RCD Residual current device

TRV Thermostatic radiator valve

approx. Approximate

BSP British standard pipe

pH Potential hydrogen

PVC Poly vinyl chloride

RSF Room sealed flue

kPa kilo Pascals

Tab. 3 Abbreviations

4 | KEY TO SYMBOLS AND SAFETY PRECAUTIONS AU/NZ

6 720 646 195a (2010/11)

1.2 Safety precautions

If you smell gas:

B CALL THE FEDERAL GOVERNMENTS SAFETY

HOTLINE ON 13 17 92

B LPG BOILERS CALL THE SUPPLIER‘S NUMBER ON

THE SIDE OF THE LPG TANK/CYLINDER

B TURN OFF THE ECV (EMERGENCY CONTROL VALVE)

AT THE METER

B DO NOT TURN ELECTRICAL SWITCHES ON OR OFF

B DO NOT STRIKE MATCHES OR SMOKE

B PUT OUT NAKED FLAMES

B OPEN DOORS AND WINDOWS

B KEEP PEOPLE AWAY FROM THE AFFECTED AREA

Boiler operation

This boiler must only be operated by a responsible
adult who has been instructed in, understands, and is
aware of the boiler's operating conditions and effects.

Service checklist

The Service Checklist 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 authorised persons and meets the
requirements of the appropriate building regulations.
The service checklist can be used to demonstrate
compliance with building regulations and should be
provided to the customer for future reference.

Combustion and corrosive materials

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

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

Fittings and modifications

Fitting the boiler and any controls may only be carried
out by an authorised person.

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

Servicing

Advise the user to have the system serviced annually by
an authorised person. Approved spar es must be used to
help maintain the economy, safety and reliability of the
boiler.

Important

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

Installation regulations

All gas boilers must be installed by an authorised person
in accordance with AS 3000, AS 5601 and building
regulations of relevant states and territories.

Failure to install boilers correctly could lead to
prosecution.

Standards

Where no specific instruction is given, reference should
be made to the following standards:

• AS 5601 Gas Installations,

• AS 1596 LPG storage and handling,

• AS 4552 Gas fired water heaters for hot water supply

and/or central heating,

• AS/NZS 3000 Electrical Installations,

• AS1697 Installation and maintenance of steel pipe

systems for gas,

• AS 4032 Water supply - valves for the control of hot
water supply temperatures,

• AS 3498 Authorization requirements for plumbing
products - water heaters and hot-water storage tanks.

• AS 1910 Water supply - float control valves for use in
hot and cold water, AS 3500 National plumbing and
drainage code.

Liquefied petroleum gas

A boiler using LPG gas must not be installed in a room or
internal space below ground level unless one side of the
building is open to the ground.

KEY TO SYMBOLS AND SAFETY PRECAUTIONS | 5AU/NZ

6 720 646 195a (2010/11)

Boiler features and checklist

• Pre-wired and pre-plumbed

• Galvanised steel inner frame

• Digital control system

• Intelligent controls

• Automatic ignition

• Direct burner ignition electrodes

• Built-in frost protection

• Built-in fault finding diagnostics

• Modulating automatic gas valve

• Combustion air fan with speed regulator

• CH temperature sensor & control

• Pump anti-seizure protection

• Flue gas temperature sensor

• Condensate syphonic trap

• Temperature control

Check list

- Hardware literature pack:

Qty.

Installation instructions 1

User instructions 1

Warranty card 1

Sealing pack: 1

- Compression nut 22mm 3

- Compression ring 22mm 3

- Compression nut 15mm 3

- Compression ring 15mm 3

- Fibre washer 18.6 x 13.5 x 1.5 2

- Fibre washer 23.9 x 17.2 x 1.5 2

- Bonded washer 3/4“ for gas 1

Adapter, 22mm to R¾ 3

Adapter, 15mm to R½ 1

Syphon assembly 1

Warranty return envelope 1

Tab. 4 Checklist

6 | Boiler information AU/NZ

6 720 646 195a (2010/11)

2 Boiler information

2.1 Boiler

Fig. 1 Boiler carton contents

Standard package:

1 Hydronic system boiler 5 Fascia panel
2 Wall mounting frame 6Syphon assembly
3 Hardware literature pack (see checklist) 7 Metric to Imperial adapter pack
4 Bottom panel

2

4

3

5

* 710mm to top of case front

1

700mm*

400mm

330mm

Depth to wall

(When tted to wall frame)

6

6720646195-01.1Wo

7

Boiler information | 7AU/NZ

6 720 646 195a (2010/11)

2.2 Technical data

Description Natural gas

UNIT 18kW

Gas flow rate - Max. 10 minutes from lighting

Natural gas G20 MJ/h 73.84

Liquefied petroleum gas (LPG) kg/h -

Central heating

Maximum rated heat input (net) kW 18.48

Minimum heat input kW 5.54

Max. rated heat output 40/30 °C kW 19.28

Max. rated heat output 50/30 °C kW 19.11

Max. rated heat output 80/60 °C kW 18

Max. flow temperature °C 82

Max. flow temperature to cylinder (with integral optional diverter valve) °C 75

Max. permissible operating pressure kPa 250

Available pump head at 21 °C system temp. rise m 2.0

Flue

Flue gas temp. 80/60 °C, rated/min. load °C 70/60

Flue gas temp. 40/30 °C, rated/min. load °C 48/34

CO2 level at max. rated heat output (after 30 min) % 9.8

CO2 level at min. rated heat output (after 30 min) % 9.2

NOx class 4

Condensate

Maximum condensate rate l/h 1.5

pH value, approx. 4.8

Electrical

Electrical power supply voltage a.c. V 240

Frequency Hz 50

Maximum power consumption W 140

General data

Star Rating

Permissible ambient temperatures °C 0 - 50

Nominal capacity of boiler litre 3.9

Noise output level (Max central heating) dBA 42

Packaged boiler weight kg 41

Total boiler weight kg 37.5

Lift weight kg 27.1

Efficency

Tab. 5 Technical data Condens 5000

8 | Boiler information AU/NZ

6 720 646 195a (2010/11)

2.3 Layout

Fig. 2 Main boiler components

6720644743-02.1Wo

12

31

30

29

28

27

26

10

14

12

11

13

15

16

25

23

24

22

21

20

19

18

17

34

5

6

7

8

9

Boiler information | 9AU/NZ

6 720 646 195a (2010/11)

Fig. 3 Hydraulic block components

1 Expansion vessel 23 Hydraulic block mounting plate

2 Sensor - boiler flow 24 Left side hand-hold for lifting boiler

3 Removable panel - for servicing 25 Gas valve

4 Electrode assembly 26 Flue air pressure switch connection (not used)

5 Overheat thermostat 27 Fan

6 Securing nut - air/gas manifold clamp 28 Fan guard

7 Silicon tube - heat exchanger air vent 29 Manual vent point

8 Heat exchanger 30 Fan pressure test point

9 Flue over heat thermostat 31 Air/gas manifold

10 Access panel - heat exchanger/sump cleaning 32 Compact hydraulic - left mounting point

11 Right side hand-hold for lifting boiler 33 Flow connector from heat exchanger

12 Diverter valve assembly (body) 34 Expansion vessel hose connection point

13 Diverter valve actuator (stepper motor) 35 Auto air vent

14 Pump 36 Return connection to heat exchanger

15 Drain point 37 Flow turbine housing (not used)

16 CH return isolator 38 Unused port

17 System pressure gauge 39 Compact hydraulic - right mounting point

18 Control panel (in service position) 40 Pressure relief valve

19 Cover - external wiring connections 41 CH return connection to service valve

20 Cover - transformer and PCB 42 Internal by-pass

21 Gas inlet connection BSP ¾ inch thread 43 CH flow connection to service valve

22 CH flow isolator 44 Pressure gauge connection point

Tab. 6 Boiler components

6720644743-03.1Wo

32 33 23 3534 36 37

38

39

40

44

43

12

42 15 41

14

13

10 | Boiler information AU/NZ

6 720 646 195a (2010/11)

Fig. 4 Additional components

1 Burner ON indicator light (green) 9 PRV pipe connection point

2 Power ON/OFF indicator/fault diagnostic light (blue) 10 CH return isolator

3 Position for optional programmer 11 Gas inlet connection BSP ¾ inch thread

4 Reset button 12 CH flow isolator

5System pressure gauge 13 Condensate connection

6 ECO button (not used) 14 CH temperature control

7 DHW temperature control* 15 Service mode button

8 Boiler identification label

Tab. 7 Additional boiler components

6720644743-04.1Wo

123

45

6

15

14

91011

13

12

7

8

* The DHW temperature control is only
operational when the “optional internal
diverter valve” is fitted.

Pre-installation | 11AU/NZ

6 720 646 195a (2010/11)

3 Pre-installation

3.1 Cleaning primary systems

Before cleaning the system:

B Ensure the system and pipe work are in good working

order.

B Where possible keep the existing boiler/circulating

pump in place when flushing the system.

Flushing the system

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

compatible with aluminium at the correct strength
for the system conditions in accordance with the
manufacturer‘s instructions.

The pH value of the system water must be less than
8 or the boiler guarantee will be invalidated.

B Circulate the flushing agent before the boiler is fired

up.

B Run the boiler/system at normal operating

temperature as directed by the manufacturer of the
flushing agent.

B Drain and thoroughly flush the system to remove the

flushing agent and debris.

B It may be necessary to use a power flushing machine

to aid the cleansing procedure in some
circumstances.

B Close the drain points and refill with fresh water and

a suitable inhibitor.

B Vent any air from the boiler and system.

Inhibitor

Add a suitable inhibitor or combined inhibitor/anti­freeze, if the system is exposed to freezing conditions, to
the heating system in accordance with the
manufacturer‘s guidelines.

NOTE:

B All the following pre-installation sections

must be read and requirements met
before starting boiler or flue installations.

CAUTION:

B Isolate the mains supplies before starting

any work and observe all relevant safety
precautions.

NOTE:

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

NOTE: Artificially softened water must not
be used to fill the CH system.

WARNING: Sealing agents
B The addition of sealing agents to the

system water is not permitted as this may
block the heat exchanger.

12 | Pre-installation AU/NZ

6 720 646 195a (2010/11)

3.2 Mains supply

3.2.1 Electrical supply

• Supply: 240V - 50 Hz, 140 Watts

• Cable: PVC insulated 0.75 mm

2

(24 x 0.2 mm)

temperature rated to 90 °C.

• External 3A fuse.

• The boiler must be earthed.

• This boiler must not be connected to a three phase

supply.

• IPX4D.

• Wiring must comply with AS/NZS 3000 Electrical

Installations.

3.2.2 Equipotential (earth) bonding

Main equipotential bonding is carried at the origin of the
electrical installation.

Supplementary bonding is carried out in an area of
increased shock risk e.g. bathrooms.

Metal pipes can be used as bonding conductors if joints
are metal to metal and electrically continuous.

Wiring regulations require that extraneous conductive
parts must be connected to the main electrical earth.

The main bonding of incoming metallic services must be
as close as practical to their entry point, before any
branch pipe work and a maximum of 600mm from an
internal meter.

Earth bond conductors must be copper and the same
size as other earth bonding conductors and not be less
than 10mm

2

.

The earth bond conductors must be permanently fixed
to the metal pipes with clamps and labels in a visible
position to allow for inspection.

3.2.3 Gas supply

• Boilers using natural gas (NG) must be connected to
a governed meter.

• Liquefied petroleum gas (LPG) must be connected to
a regulator or governed meter.

• Installation and connection of the gas supply to the
boiler must be in accordance with AS 5601.

• Under no circumstance should the size of the gas
supply pipe be less than the inlet on the boiler.

• The meter or regulator 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 and demand from any other
appliance being served.

Pre-installation | 13AU/NZ

6 720 646 195a (2010/11)

3.3 Water system and pipe work

Plastic pipe work:

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

• Pl a s t i c pipe wor k us e d f o r underfl oor h e a ting must b e
correctly controlled with a thermostatic blending
valve limiting the temperature of the circuits to
approximately 50 °C.

Primary systems connections/valves:

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

• Bosch recommends that thermostatic radiator valves
(TRV’s) be used on all radiators within the sleeping
accommodation but not the radiator where the room
thermostat is sited. This must be fitted with lock­shield valves and left open.

• A drain point is required at the lowest part of the
system.

• An air vent is required at all the high points in the
system.

Sealed primary system:

• The CH sealed system must be filled using an
approved filling loop or comply with figure 5 for
system fill.

• Where the system volume is more than 100 litres or
exceeds 265 kPa at maximum heating temperature,
an extra expansion vessel (2) must be fitted as close
as possible to the boiler in the central heating return.

• Pressurise the extra expansion vessel (2) to the same
figure as the expansion vessel built into the boiler.

• Do not use galvanised pipes or radiators.

System fill

Fig. 5 System fill

Fig. 6 Additional expansion vessel

The boiler is equipped with an automatic

internal by-pass.

NOTE: Artificially softened water must not
be used to fill the CH system.

1 boiler expansion vessel - CH

2 Extra expansion vessel - CH return

3 Pressure relief discharge

Tab. 8 Key to fig. 5

SYSTEM FILL

CV = Check Valve
SV = Stop Valve

SV SV

Test point

Temporary hose

Hose union

CV

CV

Heating

return

Mains
supply

SYSTEM MAKE UP

AA = Auto Air vent
CV = Check Valve
SV = Stop Valve

SV

CV

AA

Make up

vessel

Heating

return

1000 mm (39 in)
above the highest
point of the system.

Fill point

6720644743-08.1Wo

1

2

3

6720644743-09.1Wo

14 | Pre-installation AU/NZ

6 720 646 195a (2010/11)

S and Y plan systems:

Optional diverter valve

This boiler is designed to operate on a sealed system
only and will require a second return pipe from the water
cylinder to the wall mounting frame.

S plan layout

Fig. 7 S plan

Y plan layout
with external diverter valve

Fig. 8 Y plan

System layout
with optional internal diverter valve
(not supplied with boiler)

Fig. 9 System layout

NOTE: The boiler is fitted with its own
internal bypass.

1 Diverter valve

2 Radiator valve (flow)

3 Lock shield valve (return)

4Bypass

Tab. 9

NOTE:

B A drain point should be fitted at the

lowest part of the heating circuit and
beneath the boiler.

3

2

1

4

M

M

6720644743-05.1Wo

3

2

1

M

6720644743-06.1Wo

Boiler flow

Cylinder return

Heating return

()

3

2

6720644743-07.1Wo

Pre-installation | 15AU/NZ

6 720 646 195a (2010/11)

3.4 Condensate pipe work

3.4.1 Internal connections

Where there is the possibility of freezing conditions and
In order to minimise the freezing risk during prolonged
cold spells, the following methods of installing
condensate drainage pipe should be adopted, in order of
priority.

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

A self sealing device should be incorporated in the
drainage path, if possible, in an upright position.
A tundish should be used as a suitable air gap just before
the self sealing device. The self sealing device can be
used on a gradient as long as it preceded by a vertically
mounted tundish.

Fig. 10 Disposal to soil vent stack - vertical position

Fig. 11 Disposal to soil vent stack - on gradient

Alternatively if the first option is not possible an internal
kitchen or bathroom waste pipe can be used.

Fig. 12 Disposal to a waste pipe

A washing machine waste pipe or bifurcated pipe etc.
can also be used.

Fig. 13 Bifurcated pipe disposal

NOTE:

BWhere a new or replacement boiler is being

installed and freezing conditions are
possible, access to an internal “gravity
discharge” point should be one of the
factors considered in determining boiler
location.

BThe condensate pipe must be a minimum of

40 mm Ø plastic pipe.

BThe condensate pipe work must fall at least

50 mm per metre towards the outlet and
should take the shortest practicable route.

BEnsure that there are no blockages in the

pipe run.

Key to condensate illustrations

1 Condensate discharge

2 Air gap (20mm)

3Tundish

4Self sealing device

5 Dishwasher connection

6Vent stack

20mm

1

40mm Ø

2
3

6

4

6720646195-18.1Wo

6720646195-19.1Wo

20mm

1

40mm Ø

40mm Ø

2
3

6

4

20mm

1

40mm Ø

40/50mm Ø

4

2
3

6720646195-16.1Wo

20mm

1

40/50mm Ø

4

2

5

3

6720646195-17.1Wo

16 | Pre-installation AU/NZ

6 720 646 195a (2010/11)

3.5 Pressure relief drain line

• The pressure relief valve and control valve shall be
fitted with a drain line that shall be of copper or other
suitable pipping and be of a diameter not smaller than
the nominal size of the valve outlet as per AS/NZS

3500.

• Drain line (1) should be finished with a partial bend,
near the outlet to face the external wall (as shown) to
help prevent freezing.

1. Pressure relief discharge pipe can be between 200
and 300mm above a paved area

2. Pressure relief discharge pipe can be between 75 and
300mm when discharging into a gravel pit of not less
than 100mm diameter.

Fig. 14 Pressure relief pipe work

NOTE:

B The PRV is a safety device for the boiler

and if activated may discharge boiling
water steam through the relief valve drain
line.

B Care should be taken when siting the

drain line so that it does not cause an
obstruction or discharge above a
window, entrance or other public access
where it could cause a hazard.

1 Paved area

2 Gravel pit not less than 100mmØ

Tab. 10 Key to fig 14

6720646195-20.1Wo

300mm

200mm

300mm

75m

m

1

2

Pre-installation | 17AU/NZ

6 720 646 195a (2010/11)

3.6 Boiler location and clearances

3.6.1 Installation

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

3.6.2 Servicing clearances ­ventilated compartment

Figure 15 shows the minimum space required to install
and service the boiler in a ventilated compartment.

• If a boiler is installed in a compartment with

clearances less than shown in the tables 14, 15, or 16
ventilation is required. Refer to table 11 for
ventilation requirements.

Fig. 15 Ventilated compartment

3.6.3 Compartments

• Minimum clearances must be maintained.

• An access door is required to install, service and

maintain the boiler and any ancillary equipment.

• If fitting the boiler into an airing cupboard use a non­combustible material to separate the boiler from the
airing space.
The material can be perforated up to a maximum hole
size of 13mm.

NOTE:

No surface protection is required against
heat transfer from the boiler

Vent position

To room or
internal space

Direct to
outside

High level Minimum free

area 122 cm

2

Minimum free
area 61 cm

2

Low level Minimum free

area 122 cm

2

Minimum free
area 61 cm

2

Tab. 11 Compartment ventilation

* Minimum clearance to removable door

** Minimum clearance required for servicing

Tab. 12 Minimum clearances

6720643895-121.1Wo

+ 30 mm

above elbow

930 mm 410 mm

25 mm*
600 mm**

5 mm

Using 100 mm
flue kit
1080 mm

Using 125 mm
flue kit
1100 mm

200 mm

5 mm

18 | Pre-installation AU/NZ

6 720 646 195a (2010/11)

3.6.4 Boiler clearances - Unventilated compartments

3.6.5 Installation clearances - unventilated compartments

The tables below show the options for the minimum space required to install and service the boiler inside an
unventilated compartment.

Tab. 13

CAUTION: Clearances

B Top and bottom clearances must not be reduced below the values shown in table 14 as they are the

minimum clearances required for servicing.

Unventilated compartment installation clearances (millimetres)

The suggested total unventilated compartment minimum clearances are:

Side Above Below Front (to removable door)

400 170 approx. (30 above the elbow) 200 100

Tab. 14 Minimum unventilated compartment clearances

If side clearances are reduced (millimetres)

If total side clearance is reduced to:

(combined left and right clearances

excluding the boiler)

Increase height clearances to (approx):

(combined top and bottom clearances

excluding the boiler)

OR Front clearance (to

removable door) must

be increased to:

350 441 129

300 523 161

250 617 200

200 717 243

150 856 295

100 1012 358

50 1202 434

Tab. 15 Reduced side clearances

If front clearance is reduced (millimetres)

If front clearance (to

removable door) is

reduced to:

Increase overall height clearances to approx:

(combined top and bottom clearances

excluding the boiler)

OR Increase total side clearance to:

(combined left and right

clearances excluding the boiler)

50 511 505

25 596 569

Tab. 16 Reduced front clearances

Pre-installation | 19AU/NZ

6 720 646 195a (2010/11)

3.7 Plumbing manifold

3.7.1 Connections

Use the fittings supplied in the hardware literature pack.

• If the boiler pipes are to be run behind the boiler
ensure that the pipes pass through the slot in the
white cardboard guide. This is fitted to the frame.

Fig. 16 Pipe dimensions

Fig. 17 Plumbing manifold

WARNING: If fitting an optional integral
diverter valve.

B Refer to the “optional integral diverter

valve” installation instructions.

Heating System ¾ inch BSP thread compression

fittings

Gas ¾ inch BSP thread

Tab. 17

Further guidance on pipe routing can be

found printed on the boiler template

(supplied).

12345

6720646195-07.1Wo

# Function

From left
case edge

Øof pipe
connections

1CH flow 70 mm ¾ BSP

2Gas 200 mm ¾ BSP

3CH return 330 mm ¾ BSP

4Condensate 35 mm 22mm

5 Pressure relief valve 367 mm ½ BSP

Tab. 18 Key to figures 16 & 17

1

2

3

4

5

1

2

3

6720644743-10.1Wo

20 | Pre-installation AU/NZ

6 720 646 195a (2010/11)

3.8 Flue options

The Condens 5000W series has the option of three
horizontal RSF (60/100 telescopic, 60/100 extended
telescopic and 80/125) flue systems and two vertical
RSF (60/100 or 80/125) flue systems:

The flue systems have different maximum flue lengths

The page opposite shows some possible flue
configurations.

Table 19 below shows the maximum straight length of
flue available to the installer after the effective lengths
of the bends have been taken into account from each
flue option on the page opposite.

NOTE: Effective flue lengths:

B each 90° bend used is equivalent to

2 metres of straight flue

B each 45° bend used is equivalent to

1 metre of straight flue

Maximum straight flue length
available (mm)

Flue type Boiler

i System

60/100 80/125

1 Telescopic horizontal flue assembly All 570 1,070

2 Horizontal flue extension All 4,600 13,000

3 Horizontal flue with 1 x 90° bend All 2,600 11,000

4 Horizontal flue with 2 x 90° bends All N/A 9,000

5 High level horizontal flue with 1 x 90° bend All 2,600 11,000

6 High level horizontal flue with 2 x 90° bends All N/A 9,000

7 High level horizontal flue with 3 x 90° bends All N/A 7,000

8 Vertical balanced flue assembly All 6,400 15,000

9 Vertical balanced flue with 2 x 90° bends All 2,400 11,000

10 Vertical balanced flue with 2 x 45° bends All 4,400 13,000

Tab. 19 Flue options

Pre-installation | 21AU/NZ

6 720 646 195a (2010/11)

350 mm - 570 mm

130 mm Min

Flat roof

300 mm

500 mm

Pitched

roof

2

3

4

5

6

10

9

8

7

1

6720643895-12.1Wo