Bosch Worchester GREENSTAR ZWB 7-27 HE combi Installation And Servicing Instructions
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Bosch Worchester GREENSTAR ZWB 7-27 HE combi Installation And Servicing Instructions

Bosch Worchester GREENSTAR ZWB 7-27 HE combi Installation And Servicing Instructions

Wall mounted condensing boiler for central heating and mains fed domestic hot water
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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
ZWB 7-27 HE combi
GC-Number: 47 311 55

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Summary of Contents for Bosch Worchester GREENSTAR ZWB 7-27 HE combi

  • Page 1 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 ZWB 7-27 HE combi GC-Number: 47 311 55...

  • Page 2: Table Of Contents

    6.1.1 Checking the size of the expansion vessel Symbols 6.1.2 Setting the central heating flow temperature 26 6.1.3 Changing the heating pump characteristic Settings on the Bosch Heatronic Details of the appliance 6.2.1 Operating the Bosch Heatronic EC Declaration of Conformity 6.2.2 Selecting the pump control mode for central...

  • Page 3: Safety Precautions

    Safety precautions Safety precautions Symbols If you smell gas Safety instructions in this document are identified by a warning-triangle sym- B Turn off gas service cock at the meter. bol and are printed on a grey back- B Open windows and doors. ground.

  • Page 4: Details Of The Appliance

    • Bosch Heatronic control system • Automatic ignition Category 2H 3P • Modulating control • Full safety systems incorporating Bosch Heatronic Appliance Type with flame ionisation monitoring, solenoid valves and Table 1 temperature sensors • Concentric flue/air duct with testing point for Standard package •...

  • Page 5: Accessories

    Details of the appliance Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues upto 4 m in length. • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths upto 13 m and vertical flue systems for flue lengths uto 15 m.

  • Page 6: Layout Of Appliance

    Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 18.1 6 720 610 576-02.2O Fig. 2 Heatronic control Inspection window Heat exchanger safety temperature limiter Fixing points Hot water NTC sensor 221.1 Flue duct Testing point for gas supply pressure 221.2 Combustion air intake Pressure gauge...

  • Page 7: Function

    Details of the appliance Function Fig. 3 Bosch Heatronic control Adjustable gas flow restrictor Temperature limiter, heat exchanger Adjusting screw for min. gas inlet flow volume Hot water NTC sensor Control valve Testing point for gas supply pressure Motor Pressure gauge...

  • Page 8: Electrical Wiring Diagram

    Details of the appliance Electrical wiring diagram o - orange g - green bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 576-08.2O Fig.

  • Page 9: Technical Data

    Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30°C central heating 29.1 29.1 Max. rated heat output net 50/30°C central heating 28.8 28.8 Max. rated heat output net 80/60°C central heating 27.2 27.2 Max.
  • Page 10 Details of the appliance Condensate analysis, mg/l VERTICAL 125 mm FLUE SYSTEM Ammonium 1.2 Nickel 0.15 Overall Diameter of Duct Lead ≤ 0.01 Mercury ≤ 0.0001 Cadmium ≤ 0.001 Flue Terminal / Duct Assembly 1360 Sulphate 1 Chromium ≤ 0.005 Zinc ≤...

  • Page 11: Installation Regulations

    Installation regulations Installation regulations Installation Gas Safety (Installation & Use) Regulations 1998: All B Always turn off the gas cock before car- gas appliances must be installed by a competent per- rying out any work on components son. Failure to install correctly could lead to prosecu- which carry gas.

  • Page 12: Domestic Hot Water

    Installation Domestic hot water Sealed systems Any regulations specified by the local water company The appliance must not be operated without the system must be observed. being full of water, properly vented and pressurised. The final 600 mm of the mains cold water connection to The expansion vessel has a volume of 10 litres and is the applaince should be made in copper tube only.

  • Page 13: Siting The Appliance

    Installation APPLIANCE Refer to Fig.1 Appliance water flow diagram A drain cock should be fitted at the lowest point of the heating circuit and the appliance WRC approved filling loop Lockshield valve Central heating return Domestic Central heating flow hot water Radiator valve BS stop valve.

  • Page 14: Wall Mounting Frame Assembly

    Installation B Screw the pre-plumbing manifold with two screws to Wall mounting frame assembly the wall mounting frame. B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 7. Use the inner lugs on the top and bottom horizontal sections for the appliances that are 440 mm wide.

  • Page 15: Fitting The Appliance

    Installation Condensate drain Fitting the appliance Prepare the condensate discharge system. Refer to fig. 11. The condensate drainage pipe should be a Benchmark: For optimum performance standard drain pipe material , i . e. PVC, PVC-U, ABS after installation, this boiler and its asso- etc.

  • Page 16: Checking The Connections

    Installation Connecting the flue duct Flue Systems B Fit flue duct connector onto appliance flue spigot. The only flue systems that may be used are those sup- plied by Worcester Heat Systems. B Secure with the two screws supplied. The flue system must be installed in accordance with the requirements of BS5440:1.

  • Page 17: Siting The Flue Terminal

    Installation 3.9.1 Siting the Flue Terminal The flue must be installed in accordance with lighting, activated by passive infra-red sensing heads. BS 5440:1 and the Building Regulations. Flue terminals If the terminal is less than 2 m above a surface to which in carports and under balconies are to be avoided.

  • Page 18: Installation Of The Flue

    Installation 3.9.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm require exten- Terminal sion duct assemblies.
  • Page 19 Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp Extension Clamp Duct 6 720 610 602 - 09.1O Fig. 17 Flue with one extension Terminal Assembly Flue Turret Outer Wall Clamp Clamp Extension Extension Clamp Duct Duct 6 720 610 602 - 10.1O Fig.

  • Page 20: Flue Duct Preparation And Assembly

    Installation 3.9.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 20, 21. Outer Wall Flue Terminal Face Raised Ring locating the terminal relative to the outside wall face 6 720 610 576 - 20.1O NOTE: THE FLUE MUST BE INCLINED T O THE BOILER 6 720 610 602 - 12.1O Fig.

  • Page 21: Electrical Connections

    Electrical connections Electrical connections Connecting the appliance B Always disconnect the power supply to the appliance at the mains before carry- To gain access to the mains connection remove the ing out any work on the electrical sys- drop down facia cover. The drop down cover is tems and components.

  • Page 22: Mains Voltage External Controls Connections

    Electrical connections B Cut cable grommet to diameter of cable. Mains Voltage external controls connections NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Remove Link Motor 230 V R oom Thermostat Connections 230 V Pr ogrammer Connections Ns Ls L 230 V r oom thermos t at and...

  • Page 23: Commissioning

    Commissioning Commissioning 317 366 367 6 720 610 576-07.2O Fig. 29 Commissioning Pressure gauge Safety valve Automatic vent Never run the appliance when empty or Reset button unpressurised. Master switch Temperature control for central heating Service cocks on CH flow and return Benchmark Water Treatment: For optimum perform- Hot water Gas cock (shown in on position)

  • Page 24: Switching The Appliance On/Off

    Commissioning B Unscrew the condensation trap (358) and pull out, fill Switching on the central heating with approx. 1/4 l of water and refit. Refer to fig. 29. The central heating flow temperature is adjustable B Adjust charge pressure of expansion vessel to static between 35°C and 88°C.

  • Page 25: Hot Water Flow Rate

    Commissioning Summer mode (hot water only) Setting Hot Water temperature With room thermostat Turn fully anti-clockwise approx. 40°C B Turn temperature control on the appliance anti- approx. 55°C clockwise as far as the stop. Turn fully clockwise approx. 60°C The central heating is now turned off. The hot water function and the mains power supply for the heating Table 10 programmer and timer remain switched on.

  • Page 26: Individual Settings

    Individual settings Individual settings Mechanical settings B Rotate yellow button through 180° and replace (dot facing inwards). 6.1.1 Checking the size of the expansion vessel The CH flow temperature is no longer limited. Maximum pressure at maximum CH flow temperature is Control setting CH flow temperature 2.5 bar.

  • Page 27: Settings On The Bosch Heatronic

    Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic Entering a setting The Bosch Heatronic enables easy setting and check- B To enter the setting for a function, turn the tempera- ing of a large number of appliance functions. ture control...

  • Page 28: Setting The Maxim Ch Flow Temperature (Service Function 2.5)

    Individual settings B Refer to the settings tables for heating and cylinder 6.2.4 Setting the maxim CH flow temperature (Service Function 2.5) charging output to obtain the relevant code for the desired heating output in kW (see page 45). The maximum CH flow temperature can be set to B Turn the temperature control between 35°C and 88°C (factory setting).

  • Page 29: Converting The Appliance To Different Gas Types

    Converting the appliance to different gas types Converting the appliance to different gas types Setting the gas/air ratio The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not neces- B Switch off the appliance at the master switch (O). sary.
  • Page 30 Converting the appliance to different gas types B Turn the temperature control B Turn the temperature control until the display anti-clockwise until shows 2. the display shows 1. (= min. rated heat output). (= max. rated heat output). The display and the button will flash.

  • Page 31: Testing Combustion Air/Flue Gas At Set Heat Output

    Converting the appliance to different gas types Testing combustion air/flue gas at set heat output 7.2.1 Testing the O or CO level in the combus- 7.2.2 Testing CO and CO tion air B Press and hold the button until the display By testing the O or CO level in the com-...

  • Page 32: Maintenance

    7 181 465 346, available to competent persons. All safety and control systems are moni- tored by the Bosch Heatronic. In the event of a component fault, the display shows a fault code. B The User should be recommended to have the appli- ance serviced regularly by a competent person (see Maintenance Contract).

  • Page 33: Pre-Service Check List

    Maintenance Pre-Service Check List Date Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 34). Check ionisation current, Service Function 3.3, (see page 34). Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 36).

  • Page 34: Description Of Servicing Operations

    Maintenance Description of servicing operations The combustion performance must be checked before Primary Heat exchanger and after any servicing work on the combustion and There is a special accessory kit (no. 840) for cleaning burner components. Refer to section 7.2. the heat exchanger, order no.
  • Page 35 Maintenance B Loosen any deposits in the heat exchanger from top Burner to bottom using the cleaning blade. Refer to fig. 51. B Check that the gas cock is turned off and the master switch is in the OFF position. B Remove the clips (1) and unscrew the two bolts (2).
  • Page 36 Maintenance B Replace and re-connect the assembly taking care not Diaphragm in mixer unit to mislay the inspection window. B Take care not to damage diaphragm (443) when removing and refitting it. Siphon B Unscrew the clip and disconnect the pipe to the B Open mixer unit (29).
  • Page 37 Maintenance Expansion vessel The expansion vessel should be checked once a year. B Depressurise appliance. B If necessary, adjust expansion vessel charge pres- sure to static head of the heating system. Heating system pressure Fill the system using the WRc approved filling loop.

  • Page 38: Replacement Of Parts

    Maintenance B Remove the pcb control board. Replacement of Parts Before changing any components check that the gas is turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance. Refitting is a reverse of the procedure for removal using new seals or o-rings as appropriate.

  • Page 39: Fan Assembly

    Maintenance 8.3.2 Fan Assembly 8.3.3 Pump B Switch off the appliance. B Disconnect the appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to fig. 61. B Lower switchbox (2.). B Unscrew and remove the the siphon by releasing the jubilee clip.

  • Page 40: 3-Way Diverter Valve

    Maintenance 8.3.4 3-way diverter valve 8.3.6 Sensors B Switch off the appliance. B Check that the appliance is electrically isolated. B Disconnect appliance from the power supply. Central Heating Flow Temperature Sensor – B Turn off service cocks. Item 36, fig. 2, 58 B Unplug connector from 3-way valve motor.

  • Page 41: Gas Valve

    Maintenance 8.3.7 Gas Valve 8.3.8 Domestic Hot Water Heat Exchanger B Check that the gas cock is turned off. B Refer to section 7.2. B Lower the control panel. Refer to fig. 61. B Use new seals when fitting the new heat exchanger. B Pull off the solenoid connections at the rear of the 8.3.9 Electrode assembly...

  • Page 42: Flow Switch

    Maintenance B Pull forward from the top and lift the heat exchanger 8.3.14 Flow switch from the casing. B Shut the mains water inlet valve and drain the domes- B Transfer components, as necessary, to the new heat tic hot water circuit. exchanger.

  • Page 43: Appendix

    Appendix Appendix Fault Codes More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346. Display code Description Remedy Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for circuit breaks/short circuits.

  • Page 44: Short Parts List

    Appendix Short parts list Description Qty GC Spare part number Sensor - Flue gas temp. 8 729 000 144 0 Sensor - CH flow temp. 8 714 500 087 0 Sensor - DHW flow temp. 8 714 500 054 0 Control board 8 748 300 418 0 Gas valve...

  • Page 45: Heating/Hot Water Output Settings (N.g.)

    Appendix Heating/hot water output settings (N.G.) Natural gas G20 Display Heat output kW Heat input kW Gas vol. flow rate (l/min at t = 80/60°C) code 14.4 10.9 11.0 19.3 13.6 13.8 24. 1 16.3 16.5 28.9 19. 1 19.3 33.7 21.8 22.0...
  • Page 46 ** NOTE: The appliance controls can be set to one of Pump ON Fan to Ignition Diverter valve start speed. spark Ignition sequence 2 modes of operation. operates. Gas valve opens. 5 secs 1. “Comfort“ mode - Full pre-heat Burner shut-down if 2.
  • Page 47 Over temperature Burner remains OFF Gas valve shuts. shut-down if water until flow temperature Pump remains ON. temperature is 5°C is below set value. above set value. Room thermostat and/or mains Boiler programmer or operates to link ON Pump ON Burner Fan speed Boiler...
  • Page 48 Appendix Appendix EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619...

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