WORCESTER BOSCH GreenStar 35 HE Combi Installation And Servicing Instructions

6 720 610 893-01.TD Installation and Servicing Instructions R 30/35/40 HE plus combi Wall mounted condensing boiler for central heating and mains fed domestic hot water ZWBR 7-30 R 30 HE plus GC-Number: 41 311 79 ZWBR 11-35 R 35 HE plus GC-Number: 41 311 80 ZWBR 11-40 R 40 HE plus GC Number 41 311 81 6 720 611 400 GB (03.11) TD

6 720 611 400 GB (03.11) Contents 2 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 10 3 Installation 11 3.1 Important remarks 11 3.2 Domestic hot water 11 3.3 Sealed systems 11 3.4 Siting the appliance 12 3.5 Wall mounting frame assembly 13 3.6 Pre-piping the system 13 3.7 Fitting the appliance 14 3.8 Checking the connections 15 3.9 Flue Systems 15 3.9.1 Siting the Flue Terminal 16 3.9.2 Installation of the flue 17 3.9.3 Flue duct preparation and assembly 19 4 Electrical connections 20 4.1 Connecting the appliance 20 4.2 Connecting TR2 Room thermostat 21 4.3 Mains Voltage external controls connections 21 5 Commissioning 22 5.1 Commissioning 22 5.2 Switching the appliance on/off 23 5.3 Switching on the central heating 23 5.4 System controls 23 5.5 Setting the domestic hot water temperature and flow rate 24 5.5.1 Domestic hot water temperature 24 5.5.2 Hot water flow rate 24 5.6 Summer mode (hot water only) 24 5.7 Frost protection 24 5.8 Pump anti-seize function 24 5.9 Fault Condition 25 6 Text Display 26 6.1 General Description 26 6.2 Programming 26 6.2.1 Deleting a setting 27 6.2.2 Resetting all parameters to their original settings 27 6.3 Menu structure 27 6.4 Setting the time/day 28 6.4.1 Setting the time and day 28 6.4.2 Holidays 28 6.5 Heating 28 6.5.1 Heating programme 28 6.5.2 Setting Economy temperature (TR2 connected) 28 6.5.3 Manual operating mode (TR2 not connected) 29 6.6 Hot water 29 6.6.1 Hot water programme 29 6.6.2 Hot water immediately 29 6.7 i Info 29 6.8 Settings 30 6.8.1 Heating (if TR 2 is connected) 30 6.8.2 Hot Water (Storage Tank, system models only) 30 6.8.3 Service 30 6.9 Individual timer programmes 30 7 Individual settings 31 7.1 Mechanical settings 31 7.1.1 Checking the size of the expansion vessel 31 7.1.2 Setting the central heating flow temperature 31 7.2 Settings on the Bosch Heatronic 31 7.2.1 General description 31 7.2.2 Setting the anti-cycle time (Service Function 2.4) 32 7.2.3 Setting the maximum CH flow temperature (Service Function 2.5) 32 7.2.4 Setting the heating output (Service Function 5.0) 32 7.2.5 Constant hot water cycle time (Service Function 6.8) 32 7.2.6 Variable pump settings (Service Function 7.0) 32 7.3 Setting the gas/air ratio 32 8 Converting the appliance to different gas types 33 8.1 Setting the gas/air ratio 33 8.2 Testing combustion air/flue gas at set heat output 35 8.2.1 Testing the O2 or CO2 level in the combustion air 35 8.2.2 Testing CO and CO2 35 9 Maintenance 36 9.1 Pre-Service Check List 37 9.2 Description of servicing operations 38 9.3 Replacement of Parts 41 9.3.1 PCB control board and transformer 41 9.3.2 Fan Assembly 42 9.3.3 Pump 42 9.3.4 3-way diverter valve 43 9.3.5 3-way diverter valve motor 43 9.3.6 Sensors 43 9.3.7 Gas Valve 44 9.3.8 Domestic Hot Water Heat Exchanger 44 9.3.9 Electrode assembly 44 9.3.10 Pressure gauge 44 9.3.11 Expansion vessel 44 9.3.12 Pressure Relief Valve 44 9.3.13 Burner 44 9.3.14 Flow switch 45 9.3.15 Primary Heat Exchanger 45 10 Appendix 46 10.1 Fault Codes 46 10.2 Short parts list 47 10.3 Heating/hot water output settings R 30 HE N.G. 48 10.4 Heating/hot water output settings R 30 HE L.P.G 48 10.5 Heating/hot water output settings R 35 HE N.G. 48 10.6 Heating/hot water output settings R 35 HE L.P.G 48 10.7 Operational Flow diagrams 49 10.7.1 Domestic hot water function 49 10.7.2 Central heating function 5010.7.2Central heating function 50

6 720 611 400 GB (03.11) Safety precautions 3 Safety precautions If you smell gas B Turn off gas service cock at the meter. B Open windows and doors. B Do not operate any electrical switches. B Extinguish any naked flames. B Telephone your gas company. If you smell fumes from the appliance B Switch off appliance (see page 23). B Open windows and doors. Fitting and modifications B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engi- neer in accordance with the Gas Safety (Installation and Use) Regulations 1998. B Flue systems must not be modified in any ways other than as described in the fitting instructions. B This appliance is for use on sealed primary systems only. Maintenance B The user is recommended: to have the system regularly serviced in order to ensure that it functions reliably and safely. B Use only original spare parts! Combustible materials B Do not store or use any combustible materials (paper, thinners, paints etc.) in the vicinity of the appliance. Health and safety B This appliance contains no asbestos products. B There is no potential hazard due to the appliance being electrically unsafe. B 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 B 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 B Explain to the customer how the appliance works and how to operate it. B Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it. B These instructions are to be left with the user or at the Gas meter. B Important: These instructions apply in the UK only. Unpacking IMPORTANT HANDLING INSTRUCTIONS B Two people should transfer the packaged appliance from the van to the point of installation B Open the top of the carton, remove and place the component tray and both side bars of the wall mounting frame to one side B Lie the packaged appliance on its back. (The back has “TRUCK HERE” printed on the carton) B One person firmly holds the packaging while the other straddles the boiler and slides it from the packaging B Two persons are then required to lift one end and stand the appliance upright with the flue at the top Additional requirements for roof space installation B Two people should use two step ladders and share lifting the unpacked boiler up to the loft hatch B Where the boiler enters the loft space, tilt and slide the boiler on its back to the point of installation Check the contents against the packing list. Symbols Safety instructions in this document are identified by a warning-triangle symbol and are printed on a grey back- ground. i Notes containing important information are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.

6 720 611 400 GB (03.11) 4 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 and domestic hot water • Control panel cover • Wall mounting frame • Fixings (screws etc.) • Set of documentation for appliance • Pre-plumbing manifold • Condensate drain pipe • Filling loop. 1.3 Description of appliance • Wall-mounted appliance. • Natural gas models are low-emission appliances • Multi function display • Bosch Heatronic control system with integrated text display for service functions and faults • 3-channel - digital timer for one heating circuit • Variable pump • 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 2 /CO • Regulated speed fan • Pre-mix burner • Temperature control for central heating • Temperature sensor in domestic hot water • Safety temperature limiter in 24 V electrical circuit • Relief valve, pressure gauge, expansion vessel, Auto air vent • Flue gas temperature limiter (105 °C) • Hot water priority circuit • Motorised 3-way valve • Plate-type heat exchange • Condensate Trap. PIN CE-0085 BL0507 Category UK II 2H 3P Appliance Type C 13 , C 33 Table 1

6 720 611 400 GB (03.11) Details of the appliance 5 1.4 Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues up to 4 m in length (3.5m for the R 40 HE). • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths up to 13m or 10m (R 35 & 40 HE) and vertical flue systems for flue lengths up to 13.7m or 10.7m (R 35 & 40 HE). Fitting instructions are sent with these kits. • TR2 Room Temperature Controller.. 1.5 Casing dimensions Fig. 1 13 Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System: min. 160 mm Alternative Concentric Flue System: min. 220 mm Y Standard Concentric Horizontal Flue System: 40 mm Alternative Concentric Flue System: 70 mm Z Standard Concentric Horizontal Flue System: 105 mm Alternative Concentric Flue System: 130 mm * For servicing the appliance Note: Horizontal flue only: dimension X may need to increase due to the incline of the flue. 6 720 610 599 - 01.TD 200 30 13 395 360 850 35 X 120 Y Z 200 * * 600 min . 10* min . 440 850 101 103 10*

6 720 611 400 GB (03.11) 6 Details of the appliance 1.6 Layout of appliance Fig. 2 4 Heatronic control 6 Heat exchanger safety temperature limiter 6.1 Hot water NTC sensor 7 Testing point for gas supply pressure 8.1 Pressure gauge 9 Flue gas temperature limiter 15 Relief valve 18 Pump 20 Expansion vessel 27 Automatic air vent 29 Air gas Mixer unit 32.1 Electrode assembly 36 Temperature sensor in CH flow 43 CH flow 63 Adjustable gas flow restrictor 64 Adjusting screw for min. gas flow volume 88 3-way valve (combi) 98 DHW flow switch (combi) 102 Inspection window 120 Fixing points 221.1 Flue duct 221.2 Combustion air intake 226 Fan assembly 295 Appliance type sticker 271 Flue duct 355 Plate-type domestic hot water heat exchanger 358 Condensate trap 396 Hose Condensate trap 400 Text display 415 Cover plate for cleaning access 416 Condensate collector 418 Data plate 423 Siphon 6 720 610 599 - 00.TD 29 98 102 226 271 416 20 43 9 63 358 64 7 355 6.1 4 415 6 36 32.1 295 8.1 18 27 88 15 120 418 400 396 423 221.1 221.2

6 720 611 400 GB (03.11) Details of the appliance 7 1.7 Function Fig. 3 4 Bosch Heatronic control 6 Temperature limiter, heat exchanger 6.1 Hot water NTC sensor 7 Testing point for gas supply pressure 8.1 Pressure gauge 9 Flue 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 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 Gas flow restrictor, adjustable for max. gas flow volume 64 Adjusting screw for min. gas flow volume 69 Control valve 84 Motor 88 3-way valve 90 Venturi 91 Pressure relief valve 93 Water flow regulator 94 Diaphragm 95 Pushrod with switch cam 96 Microswitch 97 Valve for hot water flow volume 98 Water valve 221 Flue duct 226 Fan 229 Air box 317 Display 355 Plate-type heat exchanger 358 Condensate trap 400 Text display 423 Siphon 443 Diaphragm 6 720 610 597- 03.2O 42 3 J 33 29 30 226 229 26 6 36 29.1 63 15 45 47 20 43 44 46 13 8.1 84 90 97 98 93 94 95 96 91 69 64 57 52.1 56 52 55 7 355 M 358 18 88 max max 1 2 3 4 5 E ECO 0 317 61 4 400 32 9 35 221 J 27 6.1

6 720 611 400 GB (03.11) 8 Details of the appliance 1.8 Electrical wiring diagram Fig. 4 4.1 Ignition transformer 6 Temperature limiter, heat exchanger 6.1 Hot water NTC sensor 9 Flue 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 84 Motor, 3-way valve 96 Microswitch, hydraulic switch 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 317 Digital display 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 400 Text display 422 Connecting TR2 6 9 32 33 36 52.1 52 56 61 230 V 135 25 V 230V/AC 153 136 151 124 789 161 M 226 300 LN Ls Ns 328 LR 302 310 312 313 317 363 364 365 366 ECO 367 4.1 328.1 6.1 18 84 96 M 400 4 3 F M 6 720 610 602 - 02.1O mains supply 422 o - orange g - green bl - black r - red p - purple r r bl bl bl bl bl o o o o g g p p p

6 720 611 400 GB (03.11) Details of the appliance 9 1.9 Technical data Units R 30 HE NG R 30 HE Propane R 35 HEi NG R 35 HE Propane R 40 HE NG R 40 HE 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 kW kW kW 31.2 30.9 29.2 31.2 30.9 29.2 37.5 37.1 35.1 37.5 37.1 35.1 41.4 41.4 41.4 41.4 39.1 39.1 Max. rated heat input net kW 29.5 29.5 35.5 35.5 40.0 40.0 Min. rated heat output net 40/30°C Min. rated heat output net 50/30°C Min. rated heat output net 80/60°C kW kW kW 8.4 8.3 7.4 11.6 11.4 10.5 12.9 12.8 11.4 16.2 16.1 14.3 12.9 16.2 12.8 16.1 11.4 14.3 Min. rated heat input net kW 7.6 10.8 11.8 14.8 11.8 14.8 Max. rated heat output net, domestic hot water kW 29.2 29.2 35.1 35.1 39.1 39.1 Max. rated heat input net, domestic hot water kW 29.5 29.5 35.5 35.5 40 40 Maximum gas flow rate – After 10 minutes from lighting Natural gas G20 (CVnet 34.02 MJ/m 3 ) m 3 /h 3.1 3.7 4.2 LPG (CVnet 88 MJ/m 3 ) kg/h 2.3 3.2 Gas supply pressure Natural gas G20 (CVnet 34.02 MJ/m 3 ) mbar 20 - 20 - 20 - LPG (CVnet 88 MJ/m 3 ) mbar - 37 - 37 - 37 Expansion vessel Charge pressure bar 0.75 0.75 0.75 0.75 0.75 0.75 Total capacity l 10 10 10 10 10 10 Hot water specifications Hot water flow rate @ 35° rise l/min 12.1 12.1 14.6 14.6 16.4 16.4 Outlet temperature range °C 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 Max. permissible water supply pressure bar 10 10 10 10 10 10 Min. inlet pressure for maximum flow rate bar 1.2 1.2 1.2 1.2 1.2 1.2 Specific flow rate @ 30°C l/min 13.3 13.3 16.0 16.0 18.0 18.0 Flue Flue gas temp. 80/60°C, rated/min. load °C 67/55 67/55 87/58 87/58 87/58 87/58 Flue gas temp. 40/30°C, rated/min. load °C 43/32 43/32 65/43 65/43 65/43 65/43 Residual delivery pressure (inc. pressure drop in air intake duct) Pa 80 80 100 100 100 100 CO 2 level at max. rated heat output CO 2 level at min. rated heat output % % 9.2 8.8 10.8 10.5 9.2 9.2 11.0 11.0 9.2 9.2 10.8 10.8 NO x -class 5 5 5 5 5 5 SEDBUK figure Band A A A A A A Condensate Max. condensation rate (t R = 30°C) l/h 2.5 2.5 3.0 3.0 3.5 3.5 pH-value, approx. pH 4.8 4.8 4.8 4.8 4.8 4.8 General Data Electrical power supply voltage AC ... V 230 230 230 230 230 230 Frequency Hz 50 50 50 50 50 50 Max. power consumption W 125 125 152 152 183 183 Noise output level dB(A) 37 37 40 40 42 42 Appliance protection rating IP X4D X4D X4D X4D X4D X4D Max. CH flow temperature °C nom. 90 nom. 90 nom. 90 nom. 90 nom. 90 nom.90 Max. permissible operating pressure (CH) bar 2.5 2.5 2.5 2.5 2.5 2.5 Permissible ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 0 - 50 Nominal capacity of appliance l 3.75 3.75 3.75 3.75 3.75 3.75 Weight (excluding packaging) kg 46 46 46 46 46 46 Table 2

6 720 611 400 GB (03.11) 10 Installation regulations Condensate analysis, mg/l Flue system Elbow - 90 ° Equivalent length 2 m Bend - 45 ° Equivalent length 1m Gas supply Domestic water performance 2 Installation regulations Gas Safety (Installation & Use) Regulations 1998: All gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecu- tion. The manufacturers notes must not be taken, in any way, as overriding statutory obligations. The appliance must be installed in accordance with the current IEE Wiring Regulations, local Building Regula- tions, Building Standards (Scotland) (Consolidation), bye-laws of the local Water Company, Health and Safety Document 635 (Electricity at Work Regulations 1989) and any other local requirements. Product Liability regulations indicate that, in certain cir- cumstances, the installer can be held responsible, not only for mistakes on his part but also for damage result- ing from the use of faulty materials. We advise the installer to avoid any risk by using only quality approved branded fittings. The relevant British Standards should be followed i.e. • BS 6798: Specification for the installation of gas fired hot water boilers of rated input not exceeding 60kW • BS 5449: Central Heating for Domestic Premises • BS 5546: Installation of gas hot water supplies for domestic purposes • BS 5440:1: Flues and ventilation for gas appliances of rated input not exceeding 70 kW (net): Flues • BS 5440:2: Flues and ventilation for gas appliances of rated input not exceeding 70 kW (net): Air Supply • BS 6891: Installation of low pressure gas pipework installations up to 28mm (R1). • BS 7074:1: Code of practice for domestic heating and hot water supply • BS 7671: Requirements for Electrical Installation. These instructions must be followed. 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 FLUE SYSTEM Overall Diameter of Duct mm 100 Max. 4 m (R30 & 35 HE) Max 3.5m (R40 HE) Flue Terminal / Duct Assembly Length mm 600 Extension Duct Length mm 1000 Table 4 HORIZONTAL 125 mm FLUE SYSTEM Overall Diameter of Duct mm 125 Max. 13 m (R30HE) Max. 10m (R35 & 40 HE) Flue Terminal / Duct Assembly mm 1030 Table 5 VERTICAL 100mm FLUE SYSTEM Overall Dia. of Duct mm 100 Excl. terminal: Max. 6.4m (R30 & 35 HE) Max. 5.5m (R40HE) Flue Terminal / Duct Assembly Length mm 1140 Table 6 VERTICAL 125 mm FLUE SYSTEM Overall Dia. of Duct mm 125 Excl. terminal: Max. 13.7 m (R30HE) Max. 10.7 m (R35 & 40HE) Flue Terminal / Duct Assembly mm 1365 Table 7 Total length of gas supply pipe (metres) Pipe diameter (mm) 3 6 9 Gas discharge rate (m 3 /h) 8.7 5.8 4.6 22 18.0 12.0 9.4 28 Table 8 R 30 HE R 35 HE R 40 HE Domestic Water Flow Rate l/min Tempera- ture Rise 30 °C 14.2 17.0 19.2 Tempera- ture Rise 35 °C 12.1 14.6 16.4 Tempera- ture Rise 40 °C 10.6 12.8 14.4 Maximum Mains pressure bar 10.0 10.0 10 Minimum Mains pressure bar 0.2 0.2 0.2 Table 9

WORCESTER BOSCH GreenStar 35 HE Combi Installation And Servicing Instructions

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