Bosch Worchester GREENSTAR ZWB 7-27 HE combi Benutzerhandbuch

Installation and Servicing Instructions

GREENSTAR HE combi

Wall mounted condensing boiler for central heating and mains

fed domestic hot water

6 720 610 577-00.10

ZW 7-27 HE combi GC-Number: 47 311 55

6 720 610 576 GB (02.05) OSW

6 720 610 576 GB (02.05)

Contents

Safety precautions 3

Symbols 3

1 Details of the appliance 4

1.1 EC Declara ion of Conformi y 4

1.2 S andard package 4

1.3 Descrip ion of appliance 4

1.4 Accessories 5

1.5 Casing dimensions 5

1.6 Layou of appliance 6

1.7 Func ion 7

1.8 Elec rical wiring diagram 8

1.9 Technical da a 9

2 Installation regulations 11

3 Installation 11

3.1 Impor an remarks 11

3.2 Domes ic ho wa er 12

3.3 Sealed sys ems 12

3.4 Si ing he appliance 13

3.5 Wall moun ing frame assembly 14

3.6 Pre-piping he sys em 14

3.7 Fi ing he appliance 15

3.8 Checking he connec ions 16

3.9 Flue Sys ems 16

3.9.1 Si ing he Flue Terminal 17

3.9.2 Ins alla ion of he flue 18

3.9.3 Flue duc prepara ion and assembly 20

4 Electrical connections 21

4.1 Connec ing he appliance 21

4.2 Mains Vol age ex ernal con rols connec ions 22

5Commissioning 23

5.1 Commissioning 23

5.2 Swi ching he appliance on/off 24

5.3 Swi ching on he cen ral hea ing 24

5.4 Sys em con rols 24

5.5 Se ing he domes ic ho wa er

empera ure and flow ra e 24

5.5.1 Domes ic ho wa er empera ure 24

5.5.2 Ho wa er flow ra e 25

5.6 Summer mode (ho wa er only) 25

5.7 Fros pro ec ion 25

5.8 Pump an i-seize func ion 25

5.9 Faul Condi ion 25

6 Individual settings 26

6.1 Mechanical se ings 26

6.1.1 Checking he size of he expansion vessel 26

6.1.2 Se ing he cen ral hea ing flow empera ure 26

6.1.3 Changing he hea ing pump charac eris ic 26

6.2 Se ings on he Bosch Hea ronic 27

6.2.1 Opera ing he Bosch Hea ronic 27

6.2.2 Selec ing he pump con rol mode for cen ral

hea ing mode (Service Func ion 2.2) 27

6.2.3 Se ing he an i-cycle ime

(Service Func ion 2.4) 27

6.2.4 Se ing he maxim CH flow empera ure

(Service Func ion 2.5) 28

6.2.5 Se ing he swi ching difference

(Service Func ion 2.6) 28

6.2.6 Se ing he hea ing ou pu

(Service Func ion 5.0) 28

6.2.7 Cons an ho wa er cycle ime

(Service Func ion 6.8) 28

6.3 Se ing he gas/air ra io 28

7 Converting the appliance to different

gas types 29

7.1 Se ing he gas/air ra io 29

7.2 Tes ing combus ion air/flue gas a se

hea ou pu 31

7.2.1 Tes ing he O2 or CO2 level in he

combus ion air 31

7.2.2 Tes ing CO and CO2 31

8 Maintenance 32

8.1 Pre-Service Check Lis 33

8.2 Descrip ion of servicing opera ions 34

8.3 Replacemen of Par s 38

8.3.1 PCB con rol board and ransformer 38

8.3.2 Fan Assembly 39

8.3.3 Pump 39

8.3.4 3-way diver er valve 40

8.3.5 3-way diver er valve mo or 40

8.3.6 Sensors 40

8.3.7 Gas Valve 41

8.3.8 Domes ic Ho Wa er Hea Exchanger 41

8.3.9 Elec rode assembly 41

8.3.10Pressure gauge 41

8.3.11Expansion vessel 41

8.3.12Pressure Relief Valve 41

8.3.13Burner 41

8.3.14Flow swi ch 42

8.3.15Primary Hea Exchanger 42

9Appendix 43

9.1 Faul Codes 43

9.2 Shor par s lis 44

9.3 Hea ing/ho wa er ou pu se ings (N.G.) 45

9.4 Hea ing/ho wa er ou pu se ings (L.P.G) 45

9.5 Opera ional Flow diagrams 46

9.5.1 Domes ic ho wa er func ion 46

9.5.2 Cen ral hea ing func ion 47

6 720 610 576 GB (02.05)

Safety precautions

If you smell gas

BTurn off gas service cock a he me er.

BOpen windows and doors.

BDo no opera e any elec rical swi ches.

BEx inguish any naked flames.

BTelephone your gas company.

If you smell fumes from the appliance

BSwi ch off appliance (see page 24).

BOpen windows and doors.

Fitting and modifications

BFi ing of he appliance or any con rols o he appli-

ance may only be carried ou by a compe en engi-

neer in accordance w h he Gas Safe y (Ins alla ion

and Use) Regula ions 1998.

BFlue sys ems mus no be modified in any ways o her

han as described in he fi ing ins ruc ions.

BThis appliance is for use on sealed primary sys ems

only.

Maintenance

BThe user is recommended: o have he sys em

regularly serviced in order o ensure ha i func ions

reliably and safely.

BUse only original spare par s!

Combustible materials

BDo no s ore or use any combus ible ma erials

(paper, hinners, pain s e c.) in he vicini y of he

appliance.

Health and safety

BThis appliance con ains no asbes os produc s.

BThere is no po en ial hazard due o he appliance

being elec rically unsafe.

BThere are no subs ances used in he cons ruc ion

ha are a po en ial hazard in rela ion o he COSHH

Regula ions (Con rol of Subs ances Hazardous o

Heal h Regula ions 1988).

Combustion air/Ambient atmosphere

BThe combus ion air/ambien a mosphere should be

kep free of chemically aggressive subs ances (e.g.

halogena ed hydrocarbons which con ain chlorine or

fluorine compounds). This will preven corrosion.

Instructions to the customer

BExplain o he cus omer how he appliance works and

how o opera e i .

BAdvise he user ha he/she mus no make any modi-

fica ions o he appliance or carry ou any repairs on i

BThese ins ruc ions are o be lef wi h he user or a

he Gas me er.

BImpor an : These ins ruc ions apply in he UK only.

Symbols

Safety instructions in his documen

are iden ified by a warning- riangle sym-

bol and are prin ed on a grey back-

ground.

iNotes con aining impor an informa ion

are iden ified by he symbol shown on he

lef . They are bordered by horizon al lines

above and below he ex .

6 720 610 576 GB (02.05)

Details of the appliance

1 Details of the appliance

1.1 EC Declaration of Conformity

This appliance is in accordance wi h he applicable

requiremen s of he Gas Appliance Direc ive, Boiler Effi-

ciency Direc ive, Elec romagne ic Compa ibili y Direc-

ive and he Low Vol age Direc ive.

1.2 Standard package

• Gas condensing combina ion boiler for cen ral hea -

ing and domes ic ho wa er

• Wall moun ing frame

• Clamp for securing flue duc ki

• Fixings (screws e c.)

• Se of documen a ion for appliance

• Pre-plumbing manifold

• Condensa e drain pipe.

1.3 Description of appliance

• Wall-moun ed appliance, si ing no dependen on

room size

• Na ural gas models are low-emission appliances

• Mul ifunc ion display

• Bosch Hea ronic con rol sys em

• Au oma ic igni ion

• Modula ing con rol

• Full safe y sys ems incorpora ing Bosch Hea ronic

wi h flame ionisa ion moni oring, solenoid valves and

empera ure sensors

• Concen ric flue/air duc wi h es ing poin for

CO2/CO

• Regula ed speed fan

•Pre-mix burner

• Tempera ure con rol for cen ral hea ing

• Tempera ure sensor in domes ic ho wa er

• Safe y empera ure limi er in 24 V elec rical circui

• Three-speed cen ral hea ing pump wi h au oma ic

ven

• Relief valve, pressure gauge, expansion vessel

• Flue gas empera ure limi er (105 °C)

• Ho wa er priori y circui

• Mo orised 3-way valve

• Pla e- ype hea exchange

• Condensa e Trap.

PIN CE-0085 BL 0507

Category

UK II2H 3P

Appliance Type C13, C33

Table 1

6 720 610 576 GB (02.05)

Details of the appliance

1.4 Accessories

• S andard horizon al flue ki a 100 mm ou side

diame er for flues up o 4 m in leng h.

• Flue duc ki s for horizon al (125 mm ou side

diame er) for flue leng hs up o 13 m and ver ical flue

sys ems for flue leng hs u o 15 m. Fi ing ins ruc ions

are sen wi h hese ki s.

•Heaing programmer

•Timer

• Securi y ki .

1.5 Casing dimensions

Fig. 1

13 Manifold assembly

101 Ou er case

103 Facia cover

XS andard Concen ric Horizon al Flue Sys em: min. 310 mm

Al erna ive Concen ric Flue Sys em: min. 250 mm

YS andard Concen ric Horizon al Flue Sys em: 158 mm

Al erna ive Concen ric Flue Sys em: 121 mm

ZS andard Concen ric Horizon al Flue Sys em: 105 mm

Al erna ive Concen ric Flue Sys em: 130 mm

min.

850

440

395 250

360

861

906

200

6 720 610 601-01.1O

101

103

120

6 720 610 576 GB (02.05)

Details of the appliance

1.6 Layout of appliance

Fig. 2

4Hea ronic con rol

6Hea exchanger safe y empera ure limi er

6.1 Ho wa er NTC sensor

7Tes ing poin for gas supply pressure

8.1 Pressure gauge

Flue gas empera ure limi er

15 Relief valve

18 Pump

18.1 Pump speed selec or swi ch

20 Expansion vessel

27 Au oma ic air ven

2 Air gas Mixer uni

32.1 Elec rode assembly

36 Tempera ure sensor in CH flow

43 CH flow

63 Adjus able gas flow res ric or

64 Adjus ing screw for min. gas flow volume

88 3-way valve (combi)

8 DHW flow swi ch (combi)

102 Inspec ion window

120 Fixing poin s

221.1 Flue duc

221.2 Combus ion air in ake

226 Fan assembly

2 5 Appliance ype s icker

234 Tes ing poin for combus ion produc s

234.1 Tes ing poin for combus ion air

271 Flue duc

34 Cover pla e for win flue duc connec ion

355 Pla e- ype domes ic ho wa er hea exchanger

358 Condensa e rap

415 Cover pla e for cleaning access

416 Condensa e collec or

417 Clip for fixing ou er case

418 Da a pla e

423 Siphon

8.1

102

226

234.1

271

416

221.1

221.2

358

355

6.1

417

415

32.1

234

349

120

418

295

6 720 610 576-02.2O

18.1

423

6 720 610 576 GB (02.05)

Details of the appliance

1.7 Function

Fig. 3

4Bosch Hea ronic con rol

6Tempera ure limi er, hea exchanger

6.1 Ho wa er NTC sensor

7Tes ing poin for gas supply pressure

8.1 Pressure gauge

Flue gas empera ure limi er

13 Manifold

15 Safe y valve

18 Cen ral hea ing pump

20 Expansion vessel

26 Charging valve

27 Au oma ic ven

2 Mixer uni

2 .1 Bi-me allic hermos a for combus ion air compensa ion

30 Burner

32 Flame sensing elec rode

33 Igni er elec rode

35 Hea exchanger wi h cooled combus ion chamber

36 Tempera ure sensor in CH flow

43 CH flow

44 Ho wa er flow

45 Gas inle

46 Cold wa er inle

47 CH re urn

52 Solenoid valve 1

52.1 Solenoid valve 2

55 Fil er

56 Gas valve CE 427

57 Main valve disc

61 Rese bu on

63 Adjus able gas flow res ric or

64 Adjus ing screw for min. gas inle flow volume

6 Con rol valve

84 Mo or

88 3-way valve

0 Ven uri

1 Pressure relief valve

3 Wa er flow regula or

4 Diaphragm

5 Pushrod wi h swi ch cam

6 Microswi ch

7 Valve for ho wa er flow volume

8 Wa er valve

221 Flue duc

226 Fan

22 Inner casing

234 Tes ing poin for flue gas

234.1 Tes ing poin for combus ion air

317 Display

355 Pla e- ype hea exchanger

358 Condensa e rap

423 Siphon

443 Diaphragm

6 720 610 576 GB (02.05)

Details of the appliance

1.8 Electrical wiring diagram

Fig. 4

4.1 Igni ion ransformer

6Tempera ure limi er, hea exchanger

6.1 Ho wa er NTC sensor

Flue gas empera ure limi er

18 Pump

32 Flame sensing elec rode

33 Igni ion elec rode

36 Tempera ure sensor in CH flow

52 Solenoid valve 1

52.1 Solenoid valve 2

56 Gas valve CE 427

61 Rese bu on

84 Mo or, 3-way valve

6 Microswi ch, hydraulic swi ch

135 Mas er swi ch

136 Tempera ure con rol for CH flow

151 Fuse, slow 2.5 A, AC 230 V

153 Transformer

161 Link

226 Fan

300 Code plug

302 Ear h connec ion

310 Tempera ure con rol for ho wa er

312 Fuse, slow T 1,6 A

313 Fuse, slow T 0,5 A

314 Connec or for programmer

315 Terminal block for programmer

317 Digi al display

318 Connec or for imer

328 Terminal block for AC 230 V Mains supply

328.1 Link

363 Indica or lamp for burner

364 Indica or lamp for power supply

365 “Chimney sweep” bu on

366 Service bu on

367 ECO bu on

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

6.1

6 720 610 576-08.2O

mains supply

bl bl

o - orange g - green bl - black r - red p - purple

6 720 610 576 GB (02.05)

Details of the appliance

1.9 Technical data

Units Natural gas Propane

Max. ra ed hea ou pu ne 40/30°C cen ral hea ing

Max. ra ed hea ou pu ne 50/30°C cen ral hea ing

Max. ra ed hea ou pu ne 80/60°C cen ral hea ing

29.1

28.8

27.2

29.1

28.8

27.2

Max. ra ed hea inpu ne kW 27.5 27.5

Min. ra ed hea ou pu ne 40/30°C

Min. ra ed hea ou pu ne 50/30°C

Min. ra ed hea ou pu ne 80/60°C

8.4

8.3

7.4

11.6

11.4

10.5

Min. ra ed hea inpu ne kW 7.6 10.8

Max. ra ed hea ou pu ne , domes ic ho wa er kW 27.2 27.2

Max. ra ed hea inpu ne , domes ic ho wa er kW 27.5 27.5

Maximum gas flow rate – After 10 minutes from lighting

Na ural gas G20 (His = 9,5 kWh/m3)m

3/h 2.9 -

LPG (Hi = 12,9 kWh/kg) kg/h - 2.1

Gas supply pressure

Na ural gas G20 mbar 20 -

LPG mbar - 37

Expansion vessel

Charge pressure bar 0.75 0.75

To al capaci y l 10 10

Hot water specifications

Ho wa er flow ra e (fac ory se ing) l/min 8 8

Max. ho wa er flow ra e l/min 14 14

Ou le empera ure range °C 40 - 60 40 - 60

Max. permissible wa er supply pressure bar 10 10

Min. inle pressure bar 0.2 0.2

Specific flow ra e l/min 12.4 12.4

Flue

Flue gas emp. 80/60°C, ra ed/min. load °C 67/55 67/55

Flue gas emp. 40/30°C, ra ed/min. load °C 43/32 43/32

Residual delivery pressure

(inc. pressure drop in air in ake duc ) Pa 80 80

CO2 level a max. ra ed hea ou pu

CO2 level a min. ra ed hea ou pu

9.5

9.2

11.3

11.0

NOx-class 5 5

SEDBUK figure, Band A % 90.6 90.6

Condensate

Max. condensa ion ra e ( R = 30°C) l/h 2.3 2.3

pH-value, approx. 4.8 4.8

General Data

Elec rical power supply vol age AC ... V 230 230

Frequency Hz 50 50

Max. power consump ion W 101 101

Noise ou pu level dB(A) 36 36

Appliance pro ec ion ra ing IP X4D X4D

Max. CH flow empera ure °C nom. 90 nom. 90

Max. permissible opera ing pressure (CH) bar 2.5 2.5

Permissible ambien empera ures °C 0 - 60 0 - 60

Nominal capaci y of appliance l 3.75 3.75

Weigh (excluding packing) kg 46 46

Table 2

6 720 610 576 GB (02.05)

Details of the appliance

Condensate analysis, mg/l

Flue system

Elbow - 90 ° Bend - 45 °

Equivalen leng h 2 m Equivalen leng h 1m

Gas supply

Domestic water performance

Ammonium 1.2 Nickel 0.15

Lead ≤ 0.01 Mercury ≤ 0.0001

Cadmium ≤ 0.001 Sulpha e 1

Chromium ≤ 0.005 Zinc ≤ 0.015

Halogena ed

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 Diame er of Duc mm 100

Max.

Flue Terminal / Duc Assem-

bly Leng h

mm 750

Ex ension Duc Leng h mm 1000

Table 4

ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM

Overall Diame er of Duc mm 125

Max.

13 m

(inclu-

ding

urre )

Flue Terminal / Duc Assembly mm 550

Ex ension Duc Leng h - Fixed mm 200

Ex ension Duc Leng h - Fixed mm 450

Ex ension Duc Leng h - Fixed mm 950

Ex ension Duc Leng h - Fixed mm 1950

Ex ension Duc Leng h -

Telescopic

mm 265-

375

Ex ension Duc Leng h - Adjus a-

ble (Cu o leng h)

mm 200

Table 5

VERTICAL 125 mm FLUE SYSTEM

Overall Diame er of Duc mm 125

Max.

15 m

Flue Terminal / Duc Assembly mm 1360

Ex ension Duc Leng h mm 200

Ex ension Duc Leng h - Fixed mm 450

Ex ension Duc Leng h - Fixed mm 950

Ex ension Duc Leng h - Fixed mm 1950

Ex ension Duc Leng h - Tele-

scopic

mm 265-

375

Ex ension Duc Leng h -

Adjus able (Cu o leng h)

mm 450

Table 6

Total length of gas supply pipe

(metres)

Pipe diameter

(mm)

369

Gas discharge ra e (m3/h)

8.7 5.8 4.6 22

18.0 12.0 9.4 28

Table 7

Domes ic

Wa er Flow

Ra e l/min

Tempera ure

Rise

30 °C 13.2

Tempera ure

Rise

35 °C 11.3

Tempera ure

Rise

40 °C 9.9

Maximum Mains pressure bar 10.0

Minimum Mains pressure bar 0.2

Table 8

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