Installation and Servicing Instructions GREENSTAR HE plus combi

Transcription

1 Installaton and Servcng Instructons GREENSTAR HE plus comb Wall mounted condensng boler for central heatng and mans fed domestc hot water O ZWBR 7-30 HE plus GC-Number: ZWBR HE plus GC-Number: OSW

2 Contents Contents Safety precautons 3 Symbols 3 1 Detals of the applance EC Declaraton of Conformty Standard package Descrpton of applance Accessores Casng dmensons Layout of applance Functon Electrcal wrng dagram Techncal data 9 2 Installaton regulatons 11 3 Installaton Important remarks Domestc hot water Sealed systems Stng the applance Wall mountng frame assembly Pre-ppng the system Fttng the applance Checkng the connectons Flue Systems Stng the Flue Termnal Installaton of the flue Flue duct preparaton and assembly 21 4 Electrcal connectons Connectng the applance Connectng TR2 Room thermostat Mans Voltage external controls connectons 23 5 Commssonng Commssonng Swtchng the applance on/off Swtchng on the central heatng System controls Settng the domestc hot water temperature and flow rate Domestc hot water temperature Hot water flow rate Summer mode (hot water only) Frost protecton Pump ant-seze functon Fault Condton 27 6 Text Dsplay General Descrpton Programmng Deletng a settng Resettng all parameters to ther orgnal settngs Menu structure Settng the tme/day Settng the tme and day Holdays Heatng Heatng programme Settng the Economy temperature (f TR2 s connected) Manual operatng mode (f TR2 s not connected) Hot water Hot water programme Hot water mmedately Info Settngs Heatng (f TR 2 s connected) Hot Water (Storage Tank, ZSBR models only) Servce Indvdual tmer programmes 32 7 Indvdual settngs Mechancal settngs Checkng the sze of the expanson vessel Settng the central heatng flow temperature Settngs on the Bosch Heatronc General descrpton Settng the ant-cycle tme (Servce Functon 2.4) Settng the maxmum CH flow temperature (Servce Functon 2.5) Settng the heatng output (Servce Functon 5.0) Constant hot water cycle tme (Servce Functon 6.8) Varable pump settngs (Servce Functon 7.0) Settng the gas/ar rato 34 8 Convertng the applance to dfferent gas types Settng the gas/ar rato Testng combuston ar/flue gas at set heat output Testng the O 2 or CO 2 level n the combuston ar Testng CO and CO Mantenance Pre-Servce Check Lst Descrpton of servcng operatons Replacement of Parts PCB control board and transformer Fan Assembly Pump way dverter valve way dverter valve motor Sensors Gas Valve Domestc Hot Water Heat Exchanger Electrode assembly Pressure gauge Expanson vessel Pressure Relef Valve Burner Flow swtch Prmary Heat Exchanger Appendx Fault Codes Short parts lst Heatng/hot water output settngs ZWBR 7-30 N.G Heatng/hot water output settngs ZWBR L.P.G Heatng/hot water output settngs ZWBR N.G Heatng/hot water output settngs ZWBR L.P.G Operatonal Flow dagrams Domestc hot water functon Central heatng functon 51 2

3 Safety precautons Safety precautons If you smell gas B Turn off gas servce cock at the meter. B Open wndows and doors. B Do not operate any electrcal swtches. B Extngush any naked flames. B Telephone your gas company. If you smell fumes from the applance B Swtch off applance (see page 25). B Open wndows and doors. Symbols Safety nstructons n ths document are dentfed by a warnng-trangle symbol and are prnted on a grey background. Notes contanng mportant nformaton are dentfed by the symbol shown on the left. They are bordered by horzontal lnes above and below the text. Fttng and modfcatons B Fttng of the applance or any controls to the applance may only be carred out by a competent engneer n accordance wth the Gas Safety (Installaton and Use) Regulatons B Flue systems must not be modfed n any ways other than as descrbed n the fttng nstructons. B Ths applance s for use on sealed prmary systems only. Mantenance B The user s recommended: to have the system regularly servced n order to ensure that t functons relably and safely. B Use only orgnal spare parts! Combustble materals B Do not store or use any combustble materals (paper, thnners, pants etc.) n the vcnty of the applance. Health and safety B Ths applance contans no asbestos products. B There s no potental hazard due to the applance beng electrcally unsafe. B There are no substances used n the constructon that are a potental hazard n relaton to the COSHH Regulatons (Control of Substances Hazardous to Health Regulatons 1988). Combuston ar/ambent atmosphere B The combuston ar/ambent atmosphere should be kept free of chemcally aggressve substances (e.g. halogenated hydrocarbons whch contan chlorne or fluorne compounds). Ths wll prevent corroson. Instructons to the customer B Explan to the customer how the applance works and how to operate t. B Advse the user that he/she must not make any modfcatons to the applance or carry out any repars on t. B These nstructons are to be left wth the user or at the Gas meter. B Important: These nstructons apply n the UK only. 3

4 Detals of the applance 1 Detals of the applance 1.1 EC Declaraton of Conformty Ths applance s n accordance wth the applcable requrements of the Gas Applance Drectve, Boler Effcency Drectve, Electromagnetc Compatblty Drectve and the Low Voltage Drectve. PIN Category UK 1.2 Standard package CE-0085 BL0507 II 2H 3P Applance Type C 13, C 33 Table 1 Gas condensng combnaton boler for central heatng and domestc hot water Control panel cover Wall mountng frame Clamp for securng flue duct kt Fxngs (screws etc.) Set of documentaton for applance Pre-plumbng manfold Condensate dran ppe Fllng loop. 1.3 Descrpton of applance Wall-mounted applance, stng not dependent on room sze Natural gas models are low-emsson applances Multfuncton dsplay Bosch Heatronc control system wth ntegrated textdsplay for servcefunctons and faults 3-channel - dgtal tmer for one heatng crcut varable pump Automatc gnton Modulatng control Full safety systems ncorporatng Bosch Heatronc wth flame onsaton montorng, solenod valves and temperature sensors Concentrc flue/ar duct wth testng pont for CO 2 /CO Regulated speed fan Pre-mx burner Temperature control for central heatng Temperature sensor n domestc hot water Safety temperature lmter n 24 V electrcal crcut Relef valve, pressure gauge, expanson vessel Flue gas temperature lmter (105 C) Hot water prorty crcut Motorsed 3-way valve Plate-type heat exchange Condensate Trap. 4

5 Detals of the applance 1.4 Accessores Standard horzontal flue kt at 100 mm outsde dameter for flues upto 4 m n length. Flue duct kts for horzontal (125 mm outsde dameter) for flue lengths upto 10 m (ZWBR 11-35) or 13 m (ZWBR 7-30) and vertcal flue systems for flue lengths 12 m (ZWBR 11-35) or 15m (ZWBR 7-30). Fttng nstructons are sent wth these kts. Heatng programmer Securty kt. 1.5 Casng dmensons mn. mn. 5* 5* Z Y X 600* * O Fg Manfold assembly 101 Outer case 103 Faca cover X Standard Concentrc Horzontal Flue System: mn. 310 mm Alternatve Concentrc Flue System: mn. 250 mm Y Standard Concentrc Horzontal Flue System: 158 mm Alternatve Concentrc Flue System: 121 mm Z Standard Concentrc Horzontal Flue System: 105 mm Alternatve Concentrc Flue System: 130 mm * For servcng the applance 5

6 Detals of the applance 1.6 Layout of applance Fg. 2 4 Heatronc control 6 Heat exchanger safety temperature lmter 6.1 Hot water NTC sensor 7 Testng pont for gas supply pressure 8.1 Pressure gauge 9 Flue gas temperature lmter 15 Relef valve 18 Pump 20 Expanson vessel 27 Automatc ar vent 29 Ar gas Mxer unt 32.1 Electrode assembly 36 Temperature sensor n CH flow 43 CH flow 63 Adjustable gas flow restrctor 64 Adjustng screw for mn. gas flow volume 88 3-way valve (comb) 98 DHW flow swtch (comb) 102 Inspecton wndow O Fxng ponts Flue duct Combuston ar ntake 226 Fan assembly 295 Applance type stcker 234 Testng pont for combuston products Testng pont for combuston ar 271 Flue duct 349 Cover plate for twn flue duct connecton 355 Plate-type domestc hot water heat exchanger 358 Condensate trap 396 Hose Condensate trap 400 Textdsplay 415 Cover plate for cleanng access 416 Condensate collector 418 Data plate 423 Sphon

7 Detals of the applance 1.7 Functon ϑ ECO E max max ϑ M O Fg. 3 4 Bosch Heatronc control 6 Temperature lmter, heat exchanger 6.1 Hot water NTC sensor 7 Testng pont for gas supply pressure 8.1 Pressure gauge 9 Flue gas temperature lmter 13 Manfold 15 Safety valve 18 Central heatng pump 20 Expanson vessel 26 Chargng valve 27 Automatc vent 29 Mxer unt 29.1 B-metallc thermostat for combuston ar compensaton 30 Burner 32 Flame sensng electrode 33 Ignter electrode 35 Heat exchanger wth cooled combuston chamber 36 Temperature sensor n CH flow 43 CH flow 44 Hot water flow 45 Gas 46 Cold water nlet 47 CH return 52 Solenod valve Solenod valve 2 55 Flter 56 Gas valve CE Man valve dsc 61 Reset button 63 Adjustable gas flow restrctor 64 Adjustng screw for mn. gas flow volume 69 Control valve 84 Motor 88 3-way valve 90 Ventur 91 Pressure relef valve 93 Water flow regulator 94 Daphragm 95 Pushrod wth swtch cam 96 Mcroswtch 97 Valve for hot water flow volume 98 Water valve 221 Flue duct 226 Fan 229 Ar box 234 Testng pont for flue gas Testng pont for combuston ar 317 Dsplay 355 Plate-type heat exchanger 358 Condensate trap 400 Textdsplay 423 Sphon 443 Daphragm 7

8 Detals of the applance 1.8 Electrcal wrng dagram o - orange g - green bl - black r - red p - purple ECO 25 V 230 V V/AC L N Ns Ls LR p p p 84 M 3 4 F mans supply M M r r o g g o o bl bl bl bl bl o O Fg Ignton transformer 6 Temperature lmter, heat exchanger 6.1 Hot water NTC sensor 9 Flue gas temperature lmter 18 Pump 32 Flame sensng electrode 33 Ignton electrode 36 Temperature sensor n CH flow 52 Solenod valve Solenod valve 2 56 Gas valve CE Reset button 84 Motor, 3-way valve 96 Mcroswtch, hydraulc swtch 135 Master swtch 136 Temperature control for CH flow 151 Fuse, slow 2.5 A, AC 230 V 153 Transformer 161 Lnk 226 Fan 300 Code plug 302 Earth connecton 310 Temperature control for hot water 312 Fuse, slow T 1,6 A 313 Fuse, slow T 0,5 A 317 Dgtal dsplay 328 Termnal block for AC 230 V Mans supply Lnk 363 Indcator lamp for burner 364 Indcator lamp for power supply 365 Chmney sweep button 366 Servce button 367 ECO button 400 Textdsplay 422 Connectng TR2 8

9 Detals of the applance 1.9 Techncal data Unts ZWBR 7-30 Natural gas ZWBR Propane ZWBR Natural gas ZWBR Propane Max. rated heat output net 40/30 C central heatng Max. rated heat output net 50/30 C central heatng Max. rated heat output net 80/60 C central heatng kw kw kw Max. rated heat nput net kw Mn. rated heat output net 40/30 C Mn. rated heat output net 50/30 C Mn. rated heat output net 80/60 C kw kw kw Mn. rated heat nput net kw Max. rated heat output net, domestc hot water kw Max. rated heat nput net, domestc hot water kw Maxmum gas flow rate After 10 mnutes from lghtng Natural gas G20 (CVnet MJ/m 3 ) m 3 /h LPG (CVnet 88 MJ/m 3 ) kg/h Gas supply pressure Natural gas G20 (CVnet MJ/m 3 ) mbar LPG (CVnet 88 MJ/m 3 ) mbar Expanson vessel Charge pressure bar Total capacty l Hot water specfcatons Hot water flow rate (factory settng) l/mn Max. hot water flow rate l/mn Outlet temperature range C Max. permssble water supply pressure bar Mn. nlet pressure bar Specfc flow rate l/mn Flue Flue gas temp. 80/60 C, rated/mn. load C 67/55 67/55 87/58 87/58 Flue gas temp. 40/30 C, rated/mn. load C 43/32 43/32 65/43 65/43 Resdual delvery pressure (nc. pressure drop n ar ntake duct) Pa CO 2 level at max. rated heat output CO 2 level at mn. rated heat output % % NO x -class SEDBUK fgure, Band A % Condensate Max. condensaton rate (t R = 30 C) l/h ph-value, approx General Data Electrcal power supply voltage AC... V Frequency Hz Max. power consumpton W Nose output level db(a) Applance protecton ratng IP X4D X4D X4D X4D Max. CH flow temperature C nom. 90 nom. 90 nom. 90 nom. 90 Max. permssble operatng pressure (CH) bar Permssble ambent temperatures C Nomnal capacty of applance l Weght kg Table

10 Detals of the applance Condensate analyss, mg/l Ammonum 1.2 Nckel 0.15 Lead 0.01 Mercury Gas supply Total length of gas supply ppe (metres) Ppe dameter (mm) Cadmum Sulphate 1 Chromum Znc Halogenated hydrocarbons Flue system Tn 0.01 Hydrocarbons Vanadum Copper ph-value 4.8 Table 3 HORIZONTAL 100 mm Standard Gas dscharge rate (m 3 /h) Table 7 Domestc water performance ZWBR 7-28 ZWBR Overall Dameter of Duct mm 100 Flue Termnal / Duct Assembly Length mm 600 Extenson Duct Length mm 1000 Max. 4 m Domestc Water Flow Rate l/mn Temperature Rse Temperature Rse 30 C C Table 4 Temperature Rse 40 C ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM Overall Dameter of Duct mm 125 Max. 13 m (ZWBR 7-30) Flue Termnal / Duct Assembly mm 1030 Max. 10 m (ZWBR 11-35) Maxmum Mans pressure bar Mnmum Mans pressure bar Table 8 ncludng turret Table 5 VERTICAL 125 mm FLUE SYSTEM Overall Dametter of Duct mm 125 Max. 15 m (ZWBR 7-30) Flue Termnal / Duct Assembly mm 1360 Max. 12 m (ZWBR 11-35) Table 6 Elbow - 90 Equvalent length 2 m Bend - 45 Equvalent length 1m 10

11 Installaton regulatons 2 Installaton regulatons Gas Safety (Installaton & Use) Regulatons 1998: All gas applances must be nstalled by a competent person. Falure to nstall correctly could lead to prosecuton. The manufacturers notes must not be taken, n any way, as overrdng statutory oblgatons. The applance must be nstalled n accordance wth the current IEE Wrng Regulatons, local Buldng Regulatons, Buldng Standards (Scotland) (Consoldaton), bye-laws of the local Water Company, Health and Safety Document 635 (Electrcty at Work Regulatons 1989) and any other local requrements. Product Lablty regulatons ndcate that, n certan crcumstances, the nstaller can be held responsble, not only for mstakes on hs part but also for damage resultng from the use of faulty materals. We advse the nstaller to avod any rsk by usng only qualty approved branded fttngs. The relevant Brtsh Standards should be followed.e. BS 6798: Specfcaton for the nstallaton of gas fred hot water bolers of rated nput not exceedng 60kW BS 5449: Central Heatng for Domestc Premses BS 5546: Installaton of gas hot water supples for domestc purposes BS 5440:1: Flues and ventlaton for gas applances of rated nput not exceedng 70 kw (net): Flues BS 5440:2: Flues and ventlaton for gas applances of rated nput not exceedng 70 kw (net): Ar Supply BS 6891: Installaton of low pressure gas ppework nstallatons up to 28mm (R1). BS 7074:1: Code of practce for domestc heatng and hot water supply BS 7671: Requrements for Electrcal Installaton. 3 Installaton B Always turn off the gas cock before carryng out any work on components whch carry gas. Fxng of the applance, gas and flue connectons, commssonng of the system and electrcal connectons may only be carred out by competent persons authorsed by CORGI. 3.1 Important remarks B Applance should only be nstalled n sealed central heatng and hot water systems. B To avod gas formaton n the system, galvansed radators or ppes must not be used. B If a room thermostat s used: do not ft a thermostatc radator valve on the radator n the prmary room. B Ths applance uses an automatcally varable pump. An auto-bypass must not be ftted. B Add a sutable ant-freeze flud to the water n the central heatng system. Sutable products are avalable from Betz-Dearborn Tel.: and Fernox Tel.: B In our experence, the addton of sealng agents to the water n the central heatng system can cause problems (deposts n the heat exchanger). For that reason we advse aganst ther use. These nstructons must be followed. 11

12 Installaton 3.2 Domestc hot water Any regulatons specfed by the local water company must be observed. The fnal 600 mm of the mans cold water connecton to the applance should be made n copper tube only. The applance s sutable for a mans supply havng a maxmum pressure of 10 bar. A pressure reducng valve must be ftted, f necessary. The hot water outlet temperature s set to be capable of achevng a maxmum of 60 C. The maxmum temperature and the frequency of the recharge of the heat store may be reset. The water flow rate of 10.3 l/mn (ZWBR 7-30) and 12.8 l/mn (ZWBR 11-35) wll gve temperature rse of 40 C. If a hgher rse s requred then the flow must be reduced at the tap and the dscharge temperature wll rse up to the maxmum set fgure. The temperature rse, upto the maxmum set by the user, s automatcally mantaned by the modulaton of the heat nput. In wnter, when the mans temperature s very low, the water flow, adjusted at the tap or shower, should be reduced to mantan the requred delvery temperature. It s suggested that long ppe runs to taps or showers be nsulated to prevent the rapd coolng of the water. All types of sngle lever mxer taps and thermostatc mxer unts sutable for a mans pressure of up to 10 bar can be used. The head of a loose-head shower must not be allowed to fall wthn 25 mm of the top the bath to prevent the rsk of water beng drawn back nto the mans. Alternatvely the shower must be ftted wth an ant-syphonage devce at the pont of the flexble hose connectons. Over-rm bdets may be connected to the applance provded that t s n accordance wth the requrements of the local water company. The outlet(s) should be shrouded and unable to have any temporary hand held spray attached. No ant-syphonage arrangements are necessary. In exceptonally hard water areas a devce to prevent scale formaton may be ftted or, alternatvely, the maxmum temperature reset to about 45 C whch may reduce the rsk of scale formaton. The nstallaton of a scale nhbtor assembly should be n accordance wth the requrements of the local water company. Artfcally softened water must not be used to fll the central heatng system. An solatng valve should be ftted to allow for servcng. Devces, such as water meters or back-flow preventon valves, capable of preventng the flow of expanson water must not be ftted unless separate arrangements have been made. A Zlmet Z160 expanson vessel s the preferred type. A thread sealant compatble wth potable water must be used. The vessel should be connected nto the cold water mans nlet ppe as close as possble to the applance. 3.3 Sealed systems The applance must not be operated wthout the system beng full of water, properly vented and pressursed. The expanson vessel has a volume of 10 ltres (ZWBR 11-35) or 18 ltres (ZWBR 7-30) and s charged to a pressure of 0.75 bar. The water capacty of the system s shown n table 11, page 33. If a greater capacty s requred then an addtonal expanson vessel must be ftted nto the system return as close to the applance as possble. The system pressure can be set up to a maxmum of 1.5 bar wth 1 bar beng the normal settng. If the system pressure s greater than 2.5 bar when the applance s operatng at maxmum temperature then an addtonal expanson vessel must be ftted nto the system return as close to the applance as possble. The fllng pont must be at low level and arranged as shown n fgs. 5 and 6. The pressure relef valve s set to operate at 3 bar. There must be no connecton to the mans wthout the approval of the local water company. All connectons n the system must be capable of wthstandng a pressure of up to 3 bar and the radator valves conform to the requrements of BS 2767:10. If Thermostatc Radator Valves are ftted then t s recommended that the prmary radator s left open. Repeated ventng probably ndcates a leak and ths must be rectfed to ensure the proper operaton of the applance. No galvansed radators or ppes must be used. If any system water treatment s requred then only products sutable for use wth Alumnum shall be used.e Fernox- Copal or Superconcentrate or Sentnal X100, n accordance wth the manufacturers nstructons. The use of any other substances wll nvaldate the guarantee. The ph value of the system water must be less than 8 or the applance guarantee wll be nvaldated. A dran cock to BS 2879 must be ftted to the lowest pont of the system. IMPORTANT: Check that no drt s left n the water ppework as ths could damage the applance. Thoroughly flush the heatng system and the mans water supply before fttng the applance to the wall n accordance wth the recommendatons of BS7593:

13 Installaton APPLIANCE Refer to Fg.1 Applance water flow dagram WRAS approved fllng loop Central heatng return A dran cock should be ftted at the lowest pont of the heatng crcut and the applance Locksheld valve Domestc hot water Central heatng flow BS stop valve. Fxed spndle type Water man Radator valve O Fg. 5 Sealed prmary water system Sealed system fllng and make up Heatng return Non return valve Non return valve Hose unon Heatng return Auto ar vent Non return valve Make up vessel Test cock Temporary hose Stop cock Stop cock Fll pont 1000mm (39 n) above the hghest pont of the system O Fg Stng the applance Regulatons concernng the Installaton Ste B Relevant natonal regulatons must be compled wth secton B Consult the nstallaton nstructons for detals of mnmum clearances requred. Combuston ar In order to prevent corroson, the combuston ar must not contan any corrosve substances. Substances classed as corroson-promotng nclude halogenated hydrocarbons whch contan chlorne and fluorne compounds and are contaned n some solvents, pants, adhesves, aerosol propellants and household cleaners, for example. Surface temperature The max. surface temperature of the casng and the flue s less than 85 C. Ths means that, no specal safety precautons are requred wth regard to flammable buldng materals and ftted furnture. The specfed clearences must be mantaned. Cupboard/Compartment The applance can be nstalled n a cupboard/compartment need for arng clothes provdng that the requrements of BS 6798 and BS 5440:2 are followed. The low casng losses from the applance elmnate the need for ventlaton openngs n the compartment. 13

14 Installaton 3.5 Wall mountng frame assembly B Take the wall mountng frame out of the package and screw together wth 6 screws as shown n fg. 7. Use the outer lugs on the top and bottom horzontal sectons for the applances that are 512 mm wde. B Screw the pre-plumbng manfold wth two screws to the wall mountng frame O Fg O Fg. 7 B Hold the wall-mountng frame aganst the wall ensurng that t s vertcal. B Mark the poston of the flue duct hole f a rear flue s to be used. Refer to fg. 1 and 16. B Mark the holes for the wall mountng frame onto the wall, drll and plug the holes and screw the wall mountng frame to the wall wth the screws provded. 3.6 Pre-ppng the system O Fg O Fg. 10 Manfold 43 CH flow 47 CH return 112 Gas cock 171 Domestc hot water 172 Cold water relef B A dran tap should be ftted at the lowest pont of the central heatng system. B WRAS approved fllng loop must be ftted. 14

15 Installaton Condensate Termnaton and Route The condensate connecton on the Greenstar applances s n 22 mm plastc. The ppe should be extended and run away from the applance wth a constant fall of 2.5 or 40 mm n every metre. The condensate ppe can termnate nto any of four areas: Boler Sphon No length restrcton No length restrcton Ø 22 mn. 75 mn. trap Ø 22 mn. Snk The gradent of the dscharge ppe should be 2.5 (40 mm/m) mnmum An nternal waste system Boler 75 mn. trap The gradent of the dscharge ppe Invert should be 2.5 (40 mm/m) mnmum The ranwater system Open end of ppe drect nto gully, below ground but above water level Internal sol and vent stack 450 mn. Ø 22 mn. Fg. 11 Whlst all of the above methods are acceptable t s always the best practce to termnate the condense ppe va an nternal waste system.ths wll elmnate the need for any external condensate ppe runs whch can be susceptble to freezng n extreme weather. Boler Sphon Use waterproof ppe work nsulaton n very exposed postons The gradent of the dscharge ppe should be 2.5 (40 mm/m) mnmum An external waste system Snk Boler Sphon Ø 22 mn. No length restrcton 75 mn. trap The gradent of the dscharge ppe should be 2.5 (40 mm/m) mnmum External length of ppe 2m mn. Open end of ppe drect nto gully, below ground but above water level. Open end of ppe drect nto gully, below ground but above water level An external purpose made soakaway O External condensate ppework All Greenstar condensng bolers have wthn a syphonc condensate trap. Rather than the condensate constantly drppng nto the dscharge ppe, the condensate s collected nto a trap whch releases t n 100 ml quanttes. Ths wll help prevent freezng occurrng. If there s no alternatve and the condensate ppe has to be externally run, the followng should be consdered: The ppe run should take the shortest practcal route. The ppework should be nsulated wth weather resstant nsulaton. The ppe should termnate as close as possble to the ground or dran, whlst stll allowng the condensate to safely dsperse.ths would prevent wnd blowng up the ppe. The ppework should be nstalled wth the mnmum of horzontal runs and wth a downward slope of at least Fttng the applance Benchmark: For optmum performance after nstallaton, ths boler and ts assocated central heatng system must be flushed n accordance wth the gudelnes gven n BS5793:1992 Treatment of water n domestc hot water central heatng systems. B Remove packng, takng care to observe the nstructons on the packng. B Le the boler on ts back. Removng the outer case The outer case s secured aganst unauthorsed removal by a retanng bracket (electrcal safety) at the bottom left. Always secure the outer case wth ths bracket agan after refttng. B Remove retanng screw on left hand sde (1.). B Press both catch levers backwards (2.). Fg. 12 Poston of the condensate dran O 15

16 "! Installaton B Lft off the top fxng lugs and slde case forwards and remove (3.). Connectng the flue duct B Ft flue duct connector onto applance flue spgot. B Secure wth the two screws suppled. 3. $ % $!! ' 4 Fg O Fxng the applance B Ft the washers onto the gas and water connectons. B Lft the boler onto the wall-mountng frame. The lugs pass through the rectangular holes n the boler back panel. B Take care not to dsturb the washers on the connectons. Fg. 14 B For remanng nstallaton of flue assembly, refer to the relevant nstallaton nstructons. 3.8 Checkng the connectons Water connectons B Check that the O-rngs or seals are n place before tghtenng the connecton. B Turn on the servce valves for central heatng flow and return and fll the heatng system through a WRAS approved fllng loop. B Check all seals and unons for leaks (testng pressure max. 3.0 bar as ndcated by pressure gauge). B Turn on cold water servce cock and fll hot water system (testng pressure max. 10 bar). B Check all connectons for leaks. Gas supply ppe B Check that the seal s n place before tghtenng the connecton. B Turn off gas cock to protect gas valve aganst damage from excessve pressure. B Check gas supply ppe. B Release the pressure on the gas supply ppe. 16

17 Installaton 3.9 Flue Systems The only flue systems that may be used are those suppled by Worcester Heat Systems. The flue system must be nstalled n accordance wth the requrements of BS5440:1. Standard 100 mm flue system The standard concentrc flue system provdes for a horzontal length of upto 4 m. Full nstructons for fttng ths flue are n Subsecton Installaton of the flue. Alternatve 125 mm dameter flue systems Installaton nstructons for the alternatve flue systems are sent wth the approprate flue kt. Systems are avalable to gve a maxmum horzontal length of 13 m (ZWBR 7-30) and 10 m (ZWBR 11-35). A vertcal flue system upto a heght of 15 m (ZWBR 7-30) and 12 m (ZWBR 11-35) s avalable. 45 and 90 flue bends can be used wth a correspondng reducton n flue length of 2 m for each 90 bend and 1 m for each 45 bend used. IMPORTANT: Any horzontal flue system ftted to a condensng boler must nclne towards the applance at an angle of 3 % (30 mm per metre length) to prevent condensate drppng from the flue termnal. Ths means that the clearance above the applance must be ncreased to match the duct length. Refer to fg. 1 on page 5. 17

18 Installaton Stng the Flue Termnal The flue must be nstalled n accordance wth BS 5440:1 and the Buldng Regulatons. Flue termnals n carports and under balcones are to be avoded. The termnal must be postoned so that t does not cause an obstructon nor the combuston products a nusance. See fg. 15 and table 9. The termnal wll, at tmes, gve out a plume of water vapour and consderaton must be gven to ths when choosng a termnal poston. Keep clear of securty lghtng, actvated by passve nfra-red sensng heads. If the termnal s less than 2 m above a surface to whch people have access then a guard must be ftted. The guard must be evenly spaced about the termnal wth a space of 50 mm n each drecton and fxed wth plated screws. A guard Type K6 for the standard horzontal flue, can be obtaned from Tower Flue Components, Vale Rse, Tonbrdge TN9 1TB. Fg. 15 Mnmum dmensons of flue termnal postons (all types) (see fg. 15) Dmenson Termnal Poston (kw nput expressed n net) Balanced flues room sealed: Fanned draught A 1) Drectly below an openng, ar brck, openng wndows, etc. 300 mm B 1) Above an openng, ar brck, openng wndow, etc. 300 mm C 1) Horzontally to an openng, ar brck, openng wndow, etc. 300 mm D Below gutters, sol ppes or dran ppes 75 mm E Below eaves 200 mm F 2) Below balcones or car port roof (lowest pont) 200 mm G From a vertcal dran ppe or sol ppe 150 mm H From an nternal or external corner 300 mm I Above ground roof or balcony level 300 mm J From a surface facng the termnal 600 mm K From a termnal facng the termnal 1200 mm L From an openng n the car port (e. g. door, wndow) nto the dwellng 1200 mm M Vertcally from a termnal on the same wall 1500 mm N Horzontally from a termnal on the same wall 300 mm O From the wall on whch the termnal s mounted Not applcable P From a vertcal structure on the roof Not applcable Q Above ntersecton wth roof Not applcable Table 9 1) In addton, the termnal should not be nearer than 150 mm (fanned draught) to an openng n the buldng fabrc formed for the purpose of accommodatng a bult-n element such as a wndow frame. 2) Not recommended. 18

19 Installaton Installaton of the flue The standard 100 mm dameter horzontal flue system s sutable for lengths upto 4 m. Flues upto 650 mm do not requre an extenson duct assembly. Flues between 1600 mm and 4000 mm requre extenson duct assembles. NOTE: Flue lengths between 650 mm and 730 mm cannot be accomodated. Refer to fg. 17, 18, 19. Flue Turret Maxmum 650 mm Termnal Assembly Standard system comprse: Flue turret - Flue turret clamp - Termnal assembly - Wall sealng - plates. Extenson kt comprses: Ar duct - Flue duct - Duct clamp. Refer to fg. 20. Instructons for fttng other flue systems are packed wth the relevant flue kt. Check that the poston chosen for the applance s satsfactory Refer to fg. 16. No Clamp Outer Wall O Fg. 17 Standard Flue Centre lne of flue/ar duct Drllng pont for flue duct openng Centre lne of flue openng and applance Applance H Top of the wall mountng frame % (30 mm/metre) H Standard Horzontal Flue 158 mm Optonal Horzontal Flue 121 mm O Fg. 16 Markng the poston of the sde flue openng 19

20 Installaton Flue Turret Maxmum 1600mm Termnal Assembly No Clamp Extenson Duct Clamp Outer Wall O Fg. 18 Flue wth one extenson Flue Turret Termnal Assembly No Clamp Extenson Duct Clamp Extenson Duct Clamp O Outer Wall Fg. 19 Flue wth extensons Duct Clamp Flue Turret Extenson Ar Duct Extenson Flue Duct Termnal Assembly Wall Sealng Plates O Fg. 20 Flue components 20

21 Installaton Flue duct preparaton and assembly Measure the flue length L. Refer to fg. 21, 22. L Outer Wall Face Flue Termnal 120 Rased Rng locatng the termnal relatve to the outsde wall face NOTE: THE FLUE MUST BE INCLINED T O THE BOILER Fg. 21 Flue length - rear L O O Fg. 23 Flue termnal poston Assemble flue system completely. Push the ducts fully together and clamp n the postons. The slope of the termnal outlet must face downwards. The assembly wll be made easer f a solvent free grease s lghtly appled.e Vaselne, to the male end of the ducts. NOTE: An nner wall sealng plate s provded whch should be ftted to the ducts before assembly. Push the assembly through the wall and fx the turret to the applance wth the clamp. Refer to fg. 24. NOTE: THE FLUE MUST BE INCLINED T O THE BOILER O Fg. 22 Flue length - sde Mark off the lengths shown onto the ducts and cut to length. The cuts must be square and free from burrs. Termnal assembly outer (ar) duct - L- 70 mm, nner (flue) duct - L- 50 mm.the measurement s made from the rdge at the termnal ndcatng the outer face of the wall. Refer to fg. 23. Extenson ar duct - L- 70mm, flue duct - L- 50 mm. The measurement s from the formed end. Clamp Flue Turret Ar and Flue Duct Entry nto slcone rubber seals Flue Socket on Boler O Fg. 24 Ensure that the turret s fully entered nto the socket on the boler. From the outsde fx the outer wall plate to the termnal and, after ensurng the duct s properly nclned towards the boler, fx the plate to the wall. If the termnal s wthn 2 m of the ground where there s access then an approved termnal guard must be ftted. The guard must gve a clearance of at least 50 mm around the termnal an be fxed wth corroson resstant screws. 21

22 Electrcal connectons 4 Electrcal connectons B Always dsconnect the power supply to the applance at the mans before carryng out any work on the electrcal systems and components. All control and safety systems are bult nto the applance. B Allow mans cable to protrude at least 50 cm from wall. B To make splash-water proof (IP): cut the cable grommet hole sze to match dameter of cable, see fg. 27. It must be possble to solate the applance. The applance must be earthed. The applance must be connected to the mans through a 6 A double pole solator wth a contact separaton 3 mm n all poles and supplyng the applance and controls only. The wrng must comply wth the current requrements of the IEE Wrng Regulatons and any local regulatons whch apply. Supply: 230 V ~ 50 Hz, 140 Watts Mans cable: PVC nsulated 0.75 mm 2 (24 x 0.20 mm) to BS6500-Table 6. Temperature rated 100 C. Protecton IPX4D External fuse 3 A. 4.1 Connectng the applance To gan access to the mans connecton remove the drop down faca cover. The drop down cover s removed by lowerng t to the horzontal poston and pushng frmly upwards at the rear of the supports to release the cover. Lft cover from the applance. After nstallaton (or n the event of an electrcal fault) the electrcal system shall be checked for short crcuts, fuse falure, ncorrect polarty of connectons, earth contnuty and resstance to earth. B Pull out cover panel at the bottom and remove. Refer to fg. 25. Fg. 25 B Remove screw and slde termnal cover forwards to remove. Refer to fg. 26. Fg

23 Electrcal connectons B Cut cable grommet to dameter of cable. 4.3 Mans Voltage external controls connectons NOTE: Only double nsulated controls not requrng an earth can be used Ns Ls LR Ns Ls LR ST8 ST8 Neutral Lve Swtched Lve Remove Lnk Neutral Lve Swtched Lve Fg. 27 B Feed cable through cable grommet and connect the mans supply cable, see fg. 28. B Secure cable n cable grommet by means of cable grp. 230 V Room Thermostat Connectons 230 V room thermostat and Programmer Connectons Ns Ls Neutral Lve Motor Motor 230 V Programmer Connectons Fg. 29 Note: If an external tmer s used then the domestc hot water pre-heat faclty can only be solated by actuatng the ECO-button. LR Swtched Lve ST8 Swtched Lve Neutral Lve Seres connecton to be made safe O Fg Connectng TR2 Room thermostat The TR2 should be connected to termnals 3, 4 and F beneath the Textdsplay, page 8, fg. 4, tem

24 Commssonng 5 Commssonng ECO E nn Fg Pressure gauge 15 Safety valve 27 Automatc vent 61 Reset button 135 Master swtch 136 Temperature control for central heatng 170 Servce cocks on CH flow and return 171 Hot water 172 Gas cock (shown n off poston) 173 Cold water servce cock 295 Applance type stcker 310 Temperature control for hot water 317 Multfuncton dsplay 358 Condensaton trap 363 Indcator lamp for burner 364 Indcator lamp for power supply 365 Chmney sweep button 366 Servce button 367 ECO button 400 Textdsplay 5.1 Commssonng O Never run the applance when empty or unpressursed. The operatonal CO 2 level s set at the factory and no adjustment s necessary when nstallng a natural gas fred applance. Benchmark Water Treatment: For optmum performance after nstallaton, ths boler and ts assocated central heatng system should be flushed n accordance wth the gudelnes gven n BS7593: Treatment of water n domestc hot water systems. Full nstructons are suppled wth propretary cleansers sold for ths purpose. If an nhbtor s to be used after flushng, t should be used n accordance wth the nhbtor manufacturers nstructons. To dran the applance shut the system valves and open the system dran pont. Sutable flushng agents and nhbtors are avalable from Betz/Dearborn Tel.: and Fernox Tel.: Instructons for use are suppled wth the these products. 24

25 Commssonng B Before commssonng, the gas supply pressure must be checked at the gas supply pressure test pont (see page 6, fg. 2, tem 7). Natural gas applances must not be operated f the gas supply pressure s below 18 mbar or above 24 mbar. LPG applances must not be operated f the supply pressure s not 37 mbar at the nlet to the applance. B Unscrew the condensaton trap (358) and pull out, fll wth approx. 1/4 l of water and reft. Refer to fg. 30. B Adjust charge pressure of expanson vessel to statc head of the central heatng system (see page 33). B Open all system radator valves. B Turn on servce valves (170), fll central heatng system to pressure of 1-2 bar through the WRAS approved fllng loop. Refer to fg. 30. B Vent radators. B Refll heatng system and set the pressure to 1 bar. B Turn on cold water servce cock (173). Refer to fg. 30. B Check that the gas type specfed on the dentfcaton plate matches that of the gas supply. B Turn on gas cock (172). Refer to fg Swtchng the applance on/off Swtchng on B Swtch on the applance at the master swtch (I). The ndcator lamp shows green and the dsplay wll show the central heatng flow temperature, when the applance s operatng n the central heatng mode. B Open automatc vent (27) and re-close after ventng (see page 24). Swtchng off the applance B Set the master swtch to (0). The green ndcator lamp goes out. The optonal tmer wll contnue runnng untl the emergency supply s exhausted. B Always dsconnect the applance from the power supply (fuse, crcut breaker) before carryng out any work on the electrcal systems or components. 5.3 Swtchng on the central heatng The central heatng flow temperature s adjustable between 35 C and 88 C. Refer to table 12, page 33. B Turn the temperature control to set the flow temperature to a level approprate to the type of central heatng system: Underfloor heatng: e.g. settng 3 (approx. 50 C) Low-temperature heatng: settng E (approx. 75 C) Central heatng systems for flow temperatures up to 88 C: lmted max settng for low-temperature operaton (see page 33). When the burner s alght, the red ndcator lamp lghts up. Fg O Fg O If the dsplay alternates between -II- and the central heatng flow temperature, the trap fllng programme s actve. 5.4 System controls B Set room thermostat to the desred room temperature. B Set outsde- temperature drven control unt, f ftted. Refer to the nstructons wth the control. B Set the thermostatc radator valves to the desred settngs. The trap fllng programme ensures that the condensaton trap s flled after the applance has been nstalled or after the applance has been out of use for a long perod or the mans supply has been nterrupted. For that reason, the applance remans at mnmum heatng output for 15 mnutes. 25

26 Commssonng 5.5 Settng the domestc hot water temperature and flow rate Domestc hot water temperature The hot water temperature can be set to between approx. 40 C and 60 C. Ths temperature s not shown on the dsplay. B To ncrease the flow rate (max. 14 l/mn): turn screw on flow swtch ant-clockwse (+). The outlet temperature wll decrease relatve to the ncrease n the flow rate. B To reduce the flow rate (mn. 8 l/mn): turn screw on flow swtch clockwse ( ). The outlet temperature wll ncrease relatve to the decrease n the flow rate. Fg O Settng Hot Water temperature Turn fully ant-clockwse approx. 40 C approx. 55 C Turn fully clockwse approx. 60 C Table 10 ECO button By pressng and holdng the ECO button, untl the dsplay lghts, you can swtch between Comfort mode and Economy mode. Comfort mode: button s not lt (factory settng) The applance s held constantly at the set temperature. Ths means that hot water s avalable almost nstantaneously at the tap. Consequently the applance wll swtch on at ntervals, even f no hot water s beng drawn. ECO mode wth demand detecton, button s lt The demand detecton functon enables maxmum gas and water economy. Brefly turnng a hot water tap on and then off agan sgnals demand to the applance whch then heats up the water to the set temperature. Hot water s thus avalable n about 1 mnute. ECO mode, button s lt Water s not heated up untl hot water s drawn. Ths means that there s a longer watng perod before hot water s avalable Hot water flow rate The flow rate s factory set to 8 l/mn. Under standard condtons (2 bar) supply pressure, one full turn s equvalent to approxmately 2 l/mn. Fg Summer mode (hot water only) Wth room thermostat B Turn temperature control on the applance antclockwse as far as the stop. The central heatng s now turned off. The hot water functon and the mans power supply for the heatng programmer and tmer reman swtched on. 5.7 Frost protecton B Leave master swtch swtched on. If the applance s to be left for long perods swtch the central heatng off: B Add a sutable ant-freeze flud to the water n the central heatng system. Sutable products are avalable from Betz-Dearborn Tel.: and Fernox Tel.: Pump ant-seze functon O Frost protecton and constant frost protecton modes can be set on the text dsplay module. Ths functon prevents the central heatng pump sezng after long perods of nactvty. Every tme the pump s swtched off, a tmer s started. If after 24 hours the pump has not run agan, t s swtched on for a perod of 10 seconds. 26

27 Commssonng 5.9 Fault Condton A lst of faults that may occur s gven on page 47. In the unlkely event of a fault occurng whle the applance s n operaton: The dsplay and the text dsplay then show a fault code and the button may also flash. If the button flashes: B Press and hold the button untl the dsplay shows. The applance wll then start up agan and the dsplay wll show the central heatng flow temperature. If the button does not flash: B Swtch the applance off and then on agan at the master swtch. The applance wll start up agan and the central heatng flow temperature wll be dsplayed. 27

28 Text Dsplay 6 Text Dsplay 6.1 General Descrpton The text dsplay s used to dsplay nformaton about the applance and the system and to alter the settngs dsplayed. Once the applance has been n operaton for one day, the text dsplay module has a power buffer perod of about 10 hours durng whch t wll run wthout the mans power supply. After that perod has elapsed, the clock functon shuts down but all other settngs are retaned. 6.2 Programmng B To start programmng, press any button, e. g.. The dsplay lghtng swtches on and the man menu s dsplayed: T /holdays O Fg. 36 Man menu B Use the or button to move the cursor arrow on the left of the menu so that t ponts to the desred menu tem. In ths example, the cursor s postoned next to the menu tem Tme/day/holdays. B Confrm the selecton by pressng the button. The correspondng submenu s dsplayed: T Fg. 35 Controls a b c d e f Dsplay Up / More button Down / Less button Back button Next button Delete button The standard dsplay shows the followng nformaton: Tme Room temperature (f TR 2 connected) CH flow temperature. Addtonal ndcaton f a specal programme s actve: x holdays Hot water mmedately Constant on (comfort, f TR2 s not connected) Constant off (economy, f TR2 s not connected). Other specal operatng modes may be dsplayed durng commssonng, servcng, etc. The programmng procedure s descrbed n detal below usng the clock functon as an example: Fg. 37 Submenu: Tme/day In the submenus, the top lne ndcates what acton s requred. The bottom lne shows the prevous menu level, f applcable (see Fg. 38). B Use the or button to select Tme/day. B Confrm the selecton by pressng the button. The correspondng submenu s dsplayed: H T O O Fg. 38 Settng the hour When settngs are beng entered, the settng to be altered s ndcated on the top lne. In addton, the settng beng altered s dsplayed wth a dark background. B Use the or button to set the hour. Press and release to change the dsplay by one unt at a tme Press and hold to change the dsplay rapdly B Confrm the settng by pressng the button. B Use the or button to set the mnutes. 28

29 Text Dsplay B Confrm the settng by pressng the button. B Use the or button to set the day of the week. B Press the button to confrm the settng. The cursor then returns to the top lne. -or- B Press the button to confrm the settng and return to the prevous menu (Fg. 37 page 28). -or- B Do not press any other buttons for 15 mnutes Deletng a settng Ether overwrte the settng or press the delete t. B Fnd the settng to be deleted. B Press and release the button. The dsplay shows --:-- button to Resettng all parameters to ther orgnal settngs. The hours of servce can not be reset to 0. B Press and hold the button for more than 15 seconds. After about 5 seconds, the followng message appears on the dsplay: ATTENTION Delete all parameters n x seconds Once the reset has been completed, the followng message s dsplayed: Please wat... Intalsng 6.3 Menu structure Submenu Man menu Tme/ day/holdays Heatng Hot water Parameters to change/select Tme/day Hours - Mnutes - Day of week Page Holdays - - Days holday 30 Heatng program Set economy temp. (f TR2 s connected) Manual (f TR2 s not connected) Hot water program Day - 1st operatng mode - 1st swtchng pont th swtchng pont C Automatc - Constant on (comfort) - Constant off (economy) Day - 1st operatng mode - 1st swtchng pont th swtchng pont Off/On 31 Info Settngs Heatng - - Optmum Start Off/ 32 On Servce Dsplay servce param Further optons -Englsh/ -Franças/ -Deutsch Hot water mmedately Language -Tme correcton -LCD contrast Operatng tmes Fault hstory

30 Text Dsplay 6.4 Settng the tme/day Settng the tme and day For detals of how to set the tme and day, refer to page Holdays In the Holday programme, the central heatng runs n Economy mode and the hot water s swtched off (frost protecton functon remans actve). B From the man menu, select Tme/day/holdays, and from the frst submenu select Holdays. B Enter the number of days holday by pressng or (max. 99 days holday). After the set number of days, the text dsplay module automatcally cancels Economy mode at mdnght on the last day and returns to Automatc mode. Changng wnter and summer tme: B Only adjust the clock! Do not alter the swtchng ponts (for heatng, economy, etc.). The day on whch you enter the days holday counts as the frst day of the holday,.e. the unt starts the holday program mmedately. Only nclude the day on whch you are returnng f you don t want the heatng to return to the normal program on that day! To cancel Holday mode early: B In the Holdays submenu: Press the button untl the dsplay shows Heatng Heatng programme Basc settng (Automatc mode) The applance swtches automatcally between normal heatng, Economy mode and Frost protecton mode accordng to the tmer settngs entered. Basc settng: Heatng starts at 6:00 am Economy starts at 10:00 pm Settng optons Maxmum of sx swtchng ponts per day wth three dfferent operatng modes (Heatng, Economy, Frost protecton). Same tmes for Monday to Frday. Same tmes for Saturday and Sunday. Dfferent tmes for every day. Settng swtchng tmes and operatng mode B From the man menu select Heatng and then from the frst submenu, select Heatng program. B Select Monday - Frday, Saturday and Sunday or an ndvdual day of the week. Monday - Frday: to have Heatng and Economy or Frost protecton swtchng on at the same tmes every weekday. Saturday - Sunday: to have Heatng and Economy or Frost protecton swtchng on at the same tmes Saturday and Sunday. Indvdual day of the week (e. g. Thursday): to have the relevant program always swtchng on at the specfed tme on that day of the week,.e. Heatng, Economy or Frost protecton at the same tme every Thursday. B Press. The dsplay shows Set 1. operatng mode. B Set the desred frst operatng mode (Heatng, Economy or Frost protecton). B Press. The dsplay shows Set 1. tme perod. B Set the desred frst tme perod. B Press. Set the followng operatng modes and tme perods as descrbed for the frst. B If necessary: select the next day and enter the operatng modes and tmer perods as descrbed above. If the settngs for a partcular day of the week are dfferent from the settngs for the other days, then f Monday - Frday or Saturday and Sunday s selected, the dsplay shows --:--,.e. there are no common swtchng ponts for those optons. Tmer perods and operatng modes are you do not wsh to change can be skpped by pressng Settng the Economy temperature (f TR2 s connected) Ths opton allows you to set the room temperature for Economy mode (Off (Economy)). Ths functon s only actve f: Automatc mode or Economy mode s set on the TR2 room thermostat. B From the man menu, select Heatng and then from the frst submenu, select Set Economy temp.. B Use the or button to set a temperature between 5 and 30 C. 30