Benchmark CS1 Benutzerhandbuch

Installation and Servicing Instructions

CS1

Wall mounted condensing boiler for central heating

6 720 610 577-00.10

ZB 7-28 CS1

GC-Number: 41 108 02

6 720 610 601 GB (03.02) OSW

6 720 610 601 GB (03.02)

Contents

Safety recautions 3

Symbols 3

1 Details of the a liance 4

1.1 EC Declaration of Conformity 4

1.2 Standard package 4

1.3 Description of appliance 4

1.4 Accessories 5

1.5 Casing dimensions 5

1.6 Layo t of appliance 6

1.7 F nction (with optional extra motorised valve) 7

1.8 Electrical wiring diagram 8

1.9 Technical data 9

2 Installation regulations 10

3 Installation 11

3.1 Important remarks 11

3.2 Sealed systems 11

3.3 Siting the appliance 13

3.4 Wall mo nting frame assembly 14

3.5 Pre-piping the system 14

3.6 Fitting the appliance 15

3.7 Checking the connections 16

3.8 Fl e Systems 16

3.8.1 Siting the Fl e Terminal 17

3.8.2 Installation of the fl e 18

3.8.3 Fl e d ct preparation and assembly 20

4 Electrical connections 21

4.1 Connecting the appliance 21

4.2 Mains Voltage external controls connections 22

4.3 Wiring to yo r system 22

4.3.1 Pre-wired Remote S Plan 22

5 Commissioning 23

5.1 Commissioning 23

5.2 Switching the appliance on/off 24

5.3 Switching on the central heating 24

5.4 System controls 24

5.5 Appliances with optional pl g-in

diverter valve: Setting hot water temperat re 25

5.6 Frost protection 25

5.7 P mp anti-seize f nction 25

5.8 Fa lt Condition 25

6 Individual settings 26

6.1 Mechanical settings 26

6.1.1 Checking the size of the expansion vessel 26

6.1.2 Setting the central heating flow temperat re 26

6.1.3 Changing the heating p mp characteristic 26

6.2 Settings on the Bosch Heatronic 27

6.2.1 Operating the Bosch Heatronic 27

6.2.2 Selecting the p mp control mode for central

heating mode (Service F nction 2.2) 27

6.2.3 Setting the anti-cycle time

(Service F nction 2.4) 27

6.2.4 Setting the maxim CH flow temperat re

(Service F nction 2.5) 28

6.2.5 Setting the switching difference

(Service F nction 2.6) 28

6.2.6 Setting the heating o tp t

(Service F nction 5.0) 28

6.3 Setting the gas/air ratio 28

7 Converting the a liance to

different gas ty es 29

7.1 Setting the gas/air ratio 29

7.2 Testing comb stion air/fl e gas at set

heat o tp t 31

7.2.1 Testing the O

or CO

level in the

comb stion air 31

7.2.2 Testing CO and CO

8 Maintenance 32

8.1 Pre-Service Check List 33

8.2 Description of servicing operations 34

8.3 Replacement of Parts 37

8.3.1 PCB control board and transformer 37

8.3.2 Fan Assembly 38

8.3.3 P mp 38

8.3.4 3-way diverter valve 38

8.3.5 3-way diverter valve motor 39

8.3.6 Sensors 39

8.3.7 Gas Valve 39

8.3.8 Electrode assembly 39

8.3.9 Press re ga ge 40

8.3.10Expansion vessel 40

8.3.11Press re Relief Valve 40

8.3.12B rner 40

8.3.13Primary Heat Exchanger 40

9 A endix 41

9.1 Fa lt Codes 41

9.2 Short parts list 42

9.3 Heating/hot water o tp t settings (N.G) 42

9.4 Heating/hot water o tp t settings (L.P.G) 42

9.5 Operational Flow diagrams 43

9.5.1 Central heating f nction 43

6 720 610 601 GB (03.02)

Safety recautions

If you smell gas

Turn off g s service cock t the meter.

Open windows nd doors.

Do not oper te ny electric l switches.

Extinguish ny n ked fl mes.

Telephone your g s comp ny.

If you smell fumes from the a liance

Switch off ppli nce (see p ge 24).

Open windows nd doors.

Fitting and modifications

Fitting of the ppli nce or ny controls to the ppli-

nce m y only be c rried out by competent engi-

neer in ccord nce with the G s S fety (Inst ll tion

nd Use) Regul tions 1998.

Flue systems must not be modified in ny w ys other

th n s described in the fitting instructions.

This ppli nce is for use on se led prim ry systems only.

Maintenance

The user is recommended:

to h ve the system

regul rly serviced in order to ensure th t it functions

reli bly nd s fely.

Use only origin l sp re p rts!

Combustible materials

Do not store or use ny combustible m teri ls

(p per, thinners, p ints etc.) in the vicinity of the

ppli nce.

Health and safety

This ppli nce cont ins no sbestos products.

There is no potenti l h z rd due to the ppli nce

being electric lly uns fe.

There re no subst nces used in the construction

th t re potenti l h z rd in rel tion to the COSHH

Regul tions (Control of Subst nces H z rdous to

He lth Regul tions 1988).

Combustion air/Ambient atmos here

The combustion ir/ mbient tmosphere should be

kept free of chemic lly ggressive subst nces (e.g.

h logen ted hydroc rbons which cont in chlorine or

fluorine compounds). This will prevent corrosion.

Instructions to the customer

Expl in to the customer how the ppli nce works

nd how to oper te it.

Advise the user th t he/she must not m ke ny modi-

fic tions to the ppli nce or c rry out ny rep irs on it.

These instructions re to be left with the user or t

the G s meter.

Import nt: These instructions pply in the UK only.

Symbols

Safety instructions

in this doc ment

are identified by a warning-triangle sym-

bol and are printed on a grey back-

gro nd.

Notes

containing important information

are identified by the symbol shown on the

left. They are bordered by horizontal lines

above and below the text.

6 720 610 601 GB (03.02)

Details of the a liance

1 Details of the a liance

1.1 EC Declaration of Conformity

This ppli nce is in ccord nce with the pplic ble

requirements of the G s Appli nce Directive, Boiler

Efficiency Directive, Electrom gnetic Comp tibility

Directive nd the Low Volt ge Directive.

1.2 Standard ackage

• G s condensing boiler for centr l he ting

• W ll mounting fr me

• Cl mp for securing flue duct kit

• Fixings (screws etc.)

• Set of document tion for ppli nce

• Pre-plumbing m nifold

• Condens te dr in pipe.

1.3 Descri tion of a liance

• W ll-mounted ppli nce, siting not dependent on

room size

• N tur l g s models re low-emission ppli nces

• Multifunction displ y

• Bosch He tronic control system

• Autom tic ignition

• Modul ting control

• Full s fety systems incorpor ting Bosch He tronic

with fl me ionis tion monitoring, solenoid v lves nd

temper ture sensors

• Concentric flue/ ir duct with testing point for

/CO

• Regul ted speed f n

• Pre-mix burner

• Temper ture control for centr l he ting

• S fety temper ture limiter in 24 V electric l circuit

• Three-speed centr l he ting pump with utom tic

vent

• Relief v lve, pressure g uge, exp nsion vessel

• Flue g s temper ture limiter (105 °C)

• Condens te Tr p

• Connecting possibility for S-Pl n System.

CE-0085 BL 0507

Category

2H 3P

A liance Ty e

, C

Table 1

6 720 610 601 GB (03.02)

Details of the a liance

1.4 Accessories

• St nd rd horizont l flue kit t 100 mm outside

di meter for flues upto 4 m in length.

• Flue duct kits for horizont l (125 mm outside

di meter) for flue lengths upto 13 m nd vertic l flue

systems for flue lengths upto 15 m. Fitting instruc-

tions re sent with these kits.

• He ting progr mmers

• Timer

• Security kit

• Motorised v lve is v il ble s n option l extr . If

this option is used then the DT2, TR2 Optimising

Room Thermost t nd the Night Set B ck Module

will be required.

1.5 Casing dimensions

Fig. 1

M nifold ssembly

101

Outer c se

103

F ci cover

St nd rd Concentric Horizont l Flue System: min. 310 mm

Altern tive Concentric Flue System: min. 250 mm

St nd rd Concentric Horizont l Flue System: 158 mm

Altern tive Concentric Flue System: 121 mm

St nd rd Concentric Horizont l Flue System: 105 mm

Altern tive Concentric Flue System: 130 mm

For servicing the ppli nce

min.

850

440 395

200

360

861

906

200

6 720 610 601- 01.3O

101

103

120

600

6 720 610 601 GB (03.02)

Details of the a liance

1.6 Layout of a liance

Fig. 2

He tronic control

He t exch nger s fety temper ture limiter

Testing point for g s supply pressure

8.1

Pressure g uge

Flue g s temper ture limiter

Relief v lve

Pump

18.1

Pump speed selector switch

Exp nsion vessel

Autom tic ir vent

Air g s Mixer unit

32.1

Electrode ssembly

Temper ture sensor in CH flow

CH flow

Adjust ble g s flow restrictor

Adjusting screw for min. g s flow volume

102

Inspection window

120

Fixing points

221.1

Flue duct

221.2

Combustion ir int ke

226

F n ssembly

295

Appli nce type sticker

234

Testing point for combustion products

234.1

Testing point for combustion ir

271

Flue duct

349

Cover pl te for twin flue duct connection

358

Condens te tr p

415

Cover pl te for cle ning ccess

416

Condens te collector

417

Clip for fixing outer c se

418

D t pl te

423

Siphon

8.1

102

226

234.1

271

416

221.1

221.2

358

417

415

32.1

234

349

120

418

295

6 720 610 596-01.2O

18.1

423

6 720 610 601 GB (03.02)

Details of the a liance

1.7 Function (with o tional extra motorised valve)

Fig. 3

Bosch He tronic control

Temper ture limiter, he t exch nger

Testing point for g s supply pressure

8.1

Pressure g uge

Flue g s temper ture limiter

M nifold

S fety v lve

Centr l he ting pump

20 Exp nsion vessel

26 Ch rging v lve

27 Autom tic vent

29 Mixer unit

29.1 Bi-met llic thermost t for combustion ir compens tion

30 Burner

32 Fl me sensing electrode

33 Igniter electrode

35 He t exch nger with cooled combustion ch mber

36 Temper ture sensor in CH flow

43 CH flow

45 G s inlet

47 CH return

52 Solenoid v lve 1

52.1 Solenoid v lve 2

55 Filter

56 G s v lve CE 427

57 M in v lve disc

61 Reset button

63 Adjust ble g s flow restrictor

64 Adjusting screw for min. g s inlet flow volume

69 Control v lve

71 Stor ge w ter he ter outflow (only with motorised v lve)

72 Stor ge w ter he ter return (only with motorised v lve)

84 Motor (option l extr )

88 3-w y v lve (option l extr )

221 Flue duct

226 F n

229 Inner c sing

234 Testing point for flue g s

234.1 Testing point for combustion ir

317 Displ y

358 Condens te tr p

423 Siphon

443 Di phr gm

6 720 610 601 GB (03.02)

Details of the a liance

1.8 Electrical wiring diagram

Fig. 4

4.1 Ignition tr nsformer

6Temper ture limiter, he t exch nger

9Flue g s temper ture limiter

18 Pump

32 Fl me sensing electrode

33 Ignition electrode

36 Temper ture sensor in CH flow

52 Solenoid v lve 1

52.1 Solenoid v lve 2

56 G s v lve CE 427

61 Reset button

84 Motor (option l extr )

135 M ster switch

136 Temper ture control for CH flow

151 Fuse, slow 2.5 A, AC 230 V

153 Tr nsformer

161 Link

226 F n

300 Code plug

302 E rth connection

310 Temper ture control for hot w ter

312 Fuse, slow T 1,6 A

313 Fuse, slow T 0,5 A

314 Connector for progr mmer TA212E

315 Termin l block for progr mmer

317 Digit l displ y

318 Connector for timer

328 Termin l block for AC 230 V M ins supply

328.1 Link

363 Indic tor l mp for burner

364 Indic tor l mp for power supply

365 “Chimney sweep” button

366 Service button

367 ECO button

52.1

230 V

135

25 V

230V/AC

153 136

151 124789

315

161

226

300

LNLs

328

302

310

312

313

314

317

318

363

364 365 366

ECO

367

4.1

328.1

6 720 610 601-02.2O

mains supply

o - orange bl - black r - red

6 720 610 601 GB (03.02)

Details of the a liance

1.9 Technical data

Units Natural gas Pro ane

M x. r ted he t output net 40/30˚C centr l he ting

M x. r ted he t output net 50/30˚C centr l he ting

M x. r ted he t output net 80/60˚C centr l he ting

29.3

29.0

27.4

29.3

29.0

27.4

M x. r ted he t input net kW 27.7 27.7

Min. r ted he t output net 40/30˚C

Min. r ted he t output net 50/30˚C

Min. r ted he t output net 80/60˚C

8.4

8.3

7.4

11.6

11.4

10.5

Min. r ted he t input net kW 7.6 10.8

Maximum gas flow rate – After 10 minutes from lighting

N tur l g s G20 (CVnet 34.02 MJ/m3)m

3/h 2.9 -

LPG (CVnet 88 MJ/m3) kg/h - 2.1

Gas su ly ressure

N tur l g s G20 (CVnet 34.02 MJ/m3) mb r 20 -

LPG (CVnet 88 MJ/m3) mb r - 37

Ex ansion vessel

Ch rge pressure b r 0.75 0.75

Tot l c p city l 10 10

Flue

Flue g s temp. 80/60˚C, r ted/min. lo d ˚C 67/55 67/55

Flue g s temp. 40/30˚C, r ted/min. lo d ˚C 43/32 43/32

Residu l delivery pressure

(inc. pressure drop in ir int ke duct) P 80 80

CO2 level t m x. r ted he t output

CO2 level t min. r ted he t output

9.2

8.8

10.8

10.5

NOx-cl ss 5 5

SEDBUK figure, B nd A % 90.7 90.7

Condensate

M x. condens tion r te (tR = 30˚C) l/h 2.3 2.3

pH-v lue, pprox. 4.8 4.8

General Data

Electric l power supply volt ge AC ... V 230 230

Frequency Hz 50 50

M x. power consumption W 101 101

Noise output level dB(A) 36 36

Appli nce protection r ting IP X4D X4D

M x. CH flow temper ture ˚C nom. 90 nom. 90

M x. permissible oper ting pressure (CH) b r 2.5 2.5

Permissible mbient temper tures ˚C 0 - 50 0 - 50

Nomin l c p city of ppli nce l 3.75 3.75

Weight (excluding p cking) kg 46 46

Table 2

6 720 610 601 GB (03.02)

Installation regulations

Condensate analysis, mg/l

Flue system

Elbow - 90 ° Equiv lent length 2 m

Bend - 45 ° Equiv lent length 1m

Gas su ly

2 Installation regulations

G s S fety (Inst ll tion & Use) Regul tions 1998: All

g s ppli nces must be inst lled by competent per-

son. F ilure to inst ll correctly could le d to prosecu-

tion.

The m nuf cturers notes must not be t ken, in ny w y,

s overriding st tutory oblig tions.

The ppli nce must be inst lled in ccord nce with the

current IEE Wiring Regul tions, loc l Building Regul -

tions, Building St nd rds (Scotl nd) (Consolid tion),

bye-l ws of the loc l W ter Comp ny, He lth nd

S fety Document 635 (Electricity t Work Regul tions

1989) nd ny other loc l requirements.

Product Li bility regul tions indic te th t, in cert in cir-

cumst nces, the inst ller c n be held responsible, not

only for mist kes on his p rt but lso for d m ge result-

ing from the use of f ulty m teri ls. We dvise the

inst ller to void ny risk by using only qu lity pproved

br nded fittings.

The relev nt British St nd rds should be followed i.e.

• BS 6798: Specific tion for the inst ll tion of g s

fired hot w ter boilers of r ted input not exceeding

60kW

• BS 5449: Centr l He ting for Domestic Premises

• BS 5546: Inst ll tion of g s hot w ter supplies for

domestic purposes

• BS 5440:1: Flues nd ventil tion for g s ppli nces

of r ted input not exceeding 70 kW (net): Flues

• BS 5440:2: Flues nd ventil tion for g s ppli nces

of r ted input not exceeding 70 kW (net): Air

Supply

• BS 6891: Inst ll tion of low pressure g s pipework

inst ll tions up to 28 mm (R1).

• BS 7074:1: Code of pr ctice for domestic he ting

nd hot w ter supply

• BS 7671: Requirements for Electric l Inst ll tion.

These instructions must be followed.

Ammonium 1.2 Nickel 0.15

Le d ≤ 0.01 Mercury ≤ 0.0001

C dmium ≤ 0.001 Sulph te 1

Chromium ≤ 0.005 Zinc ≤ 0.015

H logen ted

hydroc rbons ≤ 0.002

Tin ≤ 0.01

Hydroc rbons 0.015 V n dium ≤ 0.001

Copper 0.028 pH-v lue 4.8

Table 3

HORIZONTAL 100 mm – Standard

Over ll Di meter of Duct mm 100

M x.

4 m

Flue Termin l / Duct

Assembly Length

mm 600

Extension Duct Length mm 1000

Table 4

ALTERNATIVE HORIZONTAL 125 mm FLUE

SYSTEM

Over ll Di meter of Duct mm 125 M x.

13 m

(inclu-

ding

turret)

Flue Termin l / Duct Assembly mm 1030

Table 5

VERTICAL 125 mm FLUE SYSTEM

Over ll Di meter of Duct mm 125 M x.

15 m

Flue Termin l / Duct Assembly mm 1360

Table 6

Total length of gas su ly i e

(metres)

Pi e diameter

(mm)

369

G s disch rge r te (m3/h)

8.7 5.8 4.6 22

18.0 12.0 9.4 28

Table 7

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