Bosch WORCESTER GREENSTAR HE ZB 7-27 Bedienungsanleitung

Installation and Servicing Instructions

GREENSTAR HE system

Wall mounted condensing boiler for central heating

6 720 610 577-00.10

ZB 7-27 HE system

GC-Number: 41 311 49

6 720 610 596 GB (01.07) OSW

6 720 610 596 GB (01.07)

Contents

Safety precautions 3

Symbols 3

1 Details of the appliance 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 Layout of appliance 6

1.7 Function 7

1.8 Electrical wiring diagram 8

1.9 Technical data 9

2 Installation regulations 11

3 Installation 11

3.1 Important remarks 11

3.2 Sealed systems 11

3.3 Siting the appliance 12

3.4 Wall mounting frame assembly 13

3.5 Pre-piping the system 13

3.6 Fitting the appliance 14

3.7 Checking the connections 15

3.8 Flue Systems 15

3.8.1 Siting the Flue Terminal 16

3.8.2 Installation of the flue 17

3.8.3 Flue duct preparation and assembly 19

4 Electrical connections 20

4.1 Connecting the appliance 20

4.2 Mains Voltage external controls connections 21

4.3 Wiring to your system 22

4.3.1 Pre-wired Remote Y Plan or 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 Frost protection 24

5.6 Pump anti-seize function 25

5.7 Fault 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 temperature 26

6.1.3 Changing the heating pump characteristic 26

6.2 Settings on the Bosch Heatronic 27

6.2.1 Operating the Bosch Heatronic 27

6.2.2 Selecting the pump control mode for

central heating mode (Service Function 2.2) 27

6.2.3 Setting the anti-cycle time

(Service Function 2.4) 27

6.2.4 Setting the maxim CH flow temperature

(Service Function 2.5) 28

6.2.5 Setting the switching difference

(Service Function 2.6) 28

6.2.6 Setting the heating output

(Service Function 5.0) 28

6.3 Setting the gas/air ratio 28

7 Converting the appliance to

different gas types 29

7.1 Setting the gas/air ratio 29

7.2 Testing combustion air/flue gas

at set heat output 31

7.2.1 Testing the O

or CO

level in

the combustion 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 36

8.3.1 PCB control board and transformer 36

8.3.2 Fan Assembly 37

8.3.3 Pump 38

8.3.4 Sensors 38

8.3.5 Gas Valve 38

8.3.6 Electrode assembly 39

8.3.7 Pressure gauge 39

8.3.8 Expansion vessel 39

8.3.9 Pressure Relief Valve 39

8.3.10Burner 39

8.3.11Primary Heat Exchanger 39

9 Appendix 40

9.1 Fault Codes 40

9.2 Short parts list 41

9.3 Heating/hot water output settings (N.G.) 42

9.4 Heating/hot water output settings (L.P.G) 42

9.5 Operational Flow diagrams 43

9.5.1 Central heating function 43

6 720 610 596 GB (01.07)

Safety precautions

If you smell gas

Turn off gas service cock at the meter.

Open windows and doors.

Do not operate any electrical switches.

Extinguish any naked flames.

Telephone your gas company.

If you smell fumes from the appliance

Switch off appliance (see page 24).

Open windows and doors.

Fitting and modifications

Fitting of the appliance or any controls to the appli-

ance may only be carried out by a competent engi-

neer in accordance wth the Gas Safety (Installation

and Use) Regulations 1998.

Flue systems must not be modified in any ways other

than as described in the fitting instructions.

This appliance is for use on sealed primary systems

only.

Maintenance

The user is recommended:

to have the system

regularly serviced in order to ensure that it functions

reliably and safely.

Use only original spare parts!

Combustible materials

Do not store or use any combustible materials

(paper, thinners, paints etc.) in the vicinity of the

appliance.

Health and safety

This appliance contains no asbestos products.

There is no potential hazard due to the appliance

being electrically unsafe.

There are no substances used in the construction

that are a potential hazard in relation to the COSHH

Regulations (Control of Substances Hazardous to

Health Regulations 1988).

Combustion air/Ambient atmosphere

The combustion air/ambient atmosphere should be

kept free of chemically aggressive substances (e.g.

halogenated hydrocarbons which contain chlorine or

fluorine compounds). This will prevent corrosion.

Instructions to the customer

Explain to the customer how the appliance works and

how to operate it.

Advise the user that he/she must not make any modi-

fications to the appliance or carry out any repairs on it

These instructions are to be left with the user or at

the Gas meter.

Important: These instructions apply in the UK only.

Symbols

Safety instructions

in this document

are identified by a warning-triangle sym-

bol and are printed on a grey back-

ground.

Notes

containing important information

are identified by the symbol shown on the

left. They are bordered by horizontal lines

above and below the text.

6 720 610 596 GB (01.07)

Details of the appliance

1 Details of the appliance

1.1 EC Declaration of Conformity

This appliance is in accordance with the applicable

requirements of the Gas Appliance Directive, Boiler Effi-

ciency Directive, Electromagnetic Compatibility Direc-

tive and the Low Voltage Directive.

1.2 Standard package

• Gas condensing combination boiler for central

heating

• Wall mounting frame

• Clamp for securing flue duct kit

• Fixings (screws etc.)

• Set of documentation for appliance

• Pre-plumbing manifold

• Condensate drain pipe.

1.3 Description of appliance

• Wall-mounted appliance, siting not dependent on

room size

• Natural gas models are low-emission appliances

• Multifunction display

• Bosch Heatronic control system

• Automatic ignition

• Modulating control

• Full safety systems incorporating Bosch Heatronic

with flame ionisation monitoring, solenoid valves and

temperature sensors

• Concentric flue/air duct with testing point for

/CO

• Regulated speed fan

• Pre-mix burner

• Temperature control for central heating

• Safety temperature limiter in 24 V electrical circuit

• Three-speed central heating pump with automatic

vent

• Relief valve, pressure gauge, expansion vessel

• Flue gas temperature limiter (105 °C)

• Condensate Trap

• Connecting possibility for Y-Plan or S-Plan System.

CE-0085 BL 0507

Category

2H 3P

Appliance Type

, C

Table 1

6 720 610 596 GB (01.07)

Details of the appliance

1.6 Layout of appliance

Fig. 2

Heatronic control

Heat exchanger safety temperature limiter

Testing point for gas supply pressure

8.1

Pressure gauge

Flue gas temperature limiter

Relief valve

Pump

18.1

Pump speed selector switch

Expansion vessel

Automatic air vent

Air gas Mixer unit

32.1

Electrode assembly

Temperature sensor in CH flow

CH flow

Adjustable gas flow restrictor

Adjusting screw for min. gas flow volume

102

Inspection window

120

Fixing points

221.1

Flue duct

221.2

Combustion air intake

226

Fan assembly

295

Appliance type sticker

234

Testing point for combustion products

234.1

Testing point for combustion air

271

Flue duct

349

Cover plate for twin flue duct connection

358

Condensate trap

415

Cover plate for cleaning access

416

Condensate collector

417

Clip for fixing outer case

418

Data plate

419

Hose from automatic vent

423

Siphon

8.1

102

226

234.1

271

416

221.1

221.2

358

417

415

32.1

234

349

120

418

295

419

6 720 610 596-01.1O

18.1

423

6 720 610 596 GB (01.07)

Details of the appliance

1.7 Function

Fig. 3

4Bosch Heatronic control

6Temperature limiter, heat exchanger

7Testing point for gas supply pressure

8.1 Pressure gauge

9Flue gas temperature limiter

13 Manifold

15 Safety valve

18 Central heating pump

20 Expansion vessel

26 Charging valve

27 Automatic vent

29 Mixer unit

29.1 Bi-metallic thermostat for combustion air compensation

30 Burner

32 Flame sensing electrode

33 Igniter electrode

35 Heat exchanger with cooled combustion chamber

36 Temperature sensor in CH flow

43 CH flow

44 Hot water flow

45 Gas inlet

46 Cold water inlet

47 CH return

52 Solenoid valve 1

52.1 Solenoid valve 2

55 Filter

56 Gas valve CE 427

57 Main valve disc

61 Reset button

63 Adjustable gas flow restrictor

64 Adjusting screw for min. gas inlet flow volume

69 Control valve

221 Flue duct

226 Fan

229 Inner casing

234 Testing point for flue gas

234.1 Testing point for combustion air

317 Display

358 Condensate trap

419 Hose from automatic vent

423 Siphon

29 30

226

229 234

234.1

221

29.1

45 47

8.1

52.1

55 7

317

max

345

ECO

358

419

423

6 720 610 596-02.1O

6 720 610 596 GB (01.07)

Details of the appliance

1.8 Electrical wiring diagram

Fig. 4

4.1 Ignition transformer

6Temperature limiter, heat exchanger

9Flue gas temperature limiter

18 Pump

32 Flame sensing electrode

33 Ignition electrode

36 Temperature sensor in CH flow

52 Solenoid valve 1

52.1 Solenoid valve 2

56 Gas valve CE 427

61 Reset button

135 Master switch

136 Temperature control for CH flow

151 Fuse, slow 2.5 A, AC 230 V

153 Transformer

161 Link

226 Fan

300 Code plug

302 Earth connection

310 Temperature control for hot water

312 Fuse, slow T 1,6 A

313 Fuse, slow T 0,5 A

314 Connector for programmer TA212E

315 Terminal block for programmer

317 Digital display

318 Connector for timer

328 Terminal block for AC 230 V Mains supply

328.1 Link

363 Indicator lamp for burner

364 Indicator lamp 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

6 720 610 601-02.1O

mains supply

o - orange bl - black r - red

6 720 610 596 GB (01.07)

Details of the appliance

1.9 Technical data

Units Natural gas Propane

Max. rated heat output net 40/30 °C central heating

Max. rated heat output net 50/30 °C central heating

Max. rated heat output net 80/60 °C central heating

29.1

28.8

27.2

29.1

28.8

27.2

Max. rated heat input net kW 27.5 27.5

Min. rated heat output net 40/30 °C

Min. rated heat output net 50/30 °C

Min. rated heat output net 80/60 °C

8.4

8.3

7.4

11.6

11.4

10.5

Min. rated heat input net kW 7.6 10.8

Maximum gas flow rate – After 10 minutes from lighting

Natural gas G20 (HiB = 9,5 kWh/m3)m

3/h 2.9

LPG (Hi= 12,8 kWh/kg) kg/h 2.1

Gas supply pressure

Natural gas G20 mbar 20 -

LPG mbar - 37

Expansion vessel

Charge pressure bar 0.75 0.75

Total capacity l 10 10

Flue

Flue gas temp. 80/60 °C, rated/min. load °C 67/55 67/55

Flue gas temp. 40/30 °C, rated/min. load °C 43/32 43/32

Residual delivery pressure

(inc. pressure drop in air intake duct) Pa 80 80

CO2level at max. rated heat output

CO2level at min. rated heat output

9.5

9.2

11.3

11.0

NOx-class 5 5

SEDBUK figure, Band A % 90.6 90.6

Condensate

Max. condensation rate (tR= 30 °C) l/h 2.3 2.3

pH-value, approx. 4.8 4.8

General Data

Electrical power supply voltage AC ... V 230 230

Frequency Hz 50 50

Max. power consumption W 101 101

Noise output level dB(A) 36 36

Appliance protection rating IP X4D X4D

Max. CH flow temperature °C nom. 90 nom. 90

Max. permissible operating pressure (CH) bar 2.5 2.5

Permissible ambient temperatures °C 0 - 60 0 - 60

Nominal capacity of appliance l 3.75 3.75

Weight (excluding packing) kg 46 46

Table 2

6 720 610 596 GB (01.07)

Details of the appliance

Condensate analysis, mg/l

Flue system

Elbow - 90 ° Bend - 45 °

Equivalent length 2 m Equivalent length 1m

Gas supply

Ammonium 1.2 Nickel 0.15

Lead ≤0.01 Mercury ≤0.0001

Cadmium ≤0.001 Sulphate 1

Chromium ≤0.005 Zinc ≤0.015

Halogenated

hydrocarbons ≤0.002

Tin ≤0.01

Hydrocarbons 0.015 Vanadium ≤0.001

Copper 0.028 pH-value 4.8

Table 3

HORIZONTAL 100 mm – Standard

Overall Diameter of Duct mm 100

Max.

4 m

Flue Terminal / Duct

Assembly Length

mm 750

Extension Duct Length mm 1000

Table 4

ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125

Max.

13 m

(inclu-

ding

turret)

Flue Terminal / Duct Assembly mm 550

Extension Duct Length - Fixed mm 200

Extension Duct Length - Fixed mm 450

Extension Duct Length - Fixed mm 950

Extension Duct Length - Fixed mm 1950

Extension Duct Length -

Telescopic

mm 265-

375

Extension Duct Length -

Adjustable (Cut to length)

mm 200

Table 5

VERTICAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125

Max.

15 m

Flue Terminal / Duct Assembly mm 1360

Extension Duct Length mm 200

Extension Duct Length - Fixed mm 450

Extension Duct Length - Fixed mm 950

Extension Duct Length - Fixed mm 1950

Extension Duct Length -

Telescopic

mm 265-

375

Extension Duct Length -

Adjustable (Cut to length)

mm 450

Table 6

Total length of gas supply pipe

(metres)

Pipe diameter

(mm)

369

Gas discharge rate (m3/h)

8.7 5.8 4.6 22

18.0 12.0 9.4 28

Table 7

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