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Bosch Condens 8300i W Installation And Maintenance Instructions Manual

Wall mounted gas condensing boiler
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Installation and maintenance instructions for specialists
Wall mounted gas condensing boiler
Condens 8300i W
GC8300iW 35/40 C

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Summary of Contents for Bosch Condens 8300i W

  • Page 1 Installation and maintenance instructions for specialists Wall mounted gas condensing boiler Condens 8300i W GC8300iW 35/40 C...

  • Page 2: Table Of Contents

    Filling the appliance and adding Inhibitor... 23 9.21 Following inspection/maintenance....49 Condens 8300i W – 6721841531 (2022/10)
  • Page 3 Electrical Wiring .......60 13.8 Commissioning report for the appliance... .62 Condens 8300i W – 6721841531 (2022/10)

  • Page 4: Explanation Of Symbols And Safety Instructions

    ▶ Before touching live parts: Wait at least 5 minutes to discharge the liability. capacitors. Service work required to repair the damage will be invoiced. ▶ Observe the wiring diagrams of other system components as well. Condens 8300i W – 6721841531 (2022/10)

  • Page 5: Product Information

    The CE marking declares that the product complies with all the applicable EU legislation, which is stipulated by attaching this marking. The complete text of the Declaration of Conformity is available on the Internet: www.bosch-climate.com.au/ www.bosch-climate.co.nz. Condens 8300i W – 6721841531 (2022/10)

  • Page 6: Product Identification

    Wall thickness S K [mm] for Ø flue accessories [mm] Ø 60/100 Ø 80 Ø 80/125 15–24 cm 24–33 cm 33–42 cm 42–50 cm Table 2 Wall thickness S depending on the diameter of the flue accessories Condens 8300i W – 6721841531 (2022/10)
  • Page 7 With horizontal flue gas routing, the elbow must be kept in a free space of 100 mm. ≥ 5* ≥ 5* " " R1 " " " 0010041296-002 Fig. 3 Front view (mm) Recommended 100 mm Condens 8300i W – 6721841531 (2022/10)

  • Page 8: Product Overview

    Product Information Product overview 0010041047-001 Fig. 4 Product overview Condens 8300i W – 6721841531 (2022/10)

  • Page 9: Regulations

    EN 50201-2-1 Boilers for gaseous fuels - Part 2-1: Type C boilers and Type B2, B3 and B5 boilers with a rated heat input no greater than 1000 kW Table 4 Regulations, standards and guidelines Condens 8300i W – 6721841531 (2022/10)

  • Page 10: Flue Gas Routing

    CE approval. breathing air that pose a risk to life This is why we recommend using Bosch original accessories. ▶ Ensure that flue pipes and gaskets are not damaged. You can find designations and part numbers in the main catalogue.

  • Page 11: Inspection Apertures

    ▶ Observe country-specific requirements for the minimum clearances in relation to roof windows. ≥1 ≥1 < 1,5 > 1,5 0010034885-001 Fig. 6 Condens 8300i W – 6721841531 (2022/10)

  • Page 12: Horizontal Concentric Flue System

    ▶ Use only control units with suitable IP rating. Fig. 8 Vertical concentric flue system Allowed maximum length GC8300iW 35/40 C Accessory Ø Maximum pipe length L [mm] Ø 60/100 Ø 80/125 Table 7 Flue routing Condens 8300i W – 6721841531 (2022/10)

  • Page 13: Water System And Pipe Work

    • All system connections, taps and mixing valves must be capable of sustaining a pressure up to 3 bar (300 kPa). • Bosch recommends that thermostatic radiator valves (TRVs) be used Fig. 11 Additional expansion vessel on all radiators within the sleeping accommodation but not the Boiler expanison vessel - CH radiator where the room thermostat is sited.

  • Page 14: Condensate Pipe Work

    ▶ When using plastic pipes, use oxygen-tight pipework or create system separation by means of heat exchangers. 6720646195-19.1Wo Fig. 13 Disposal to soil vent stack - on gradient Condens 8300i W – 6721841531 (2022/10)

  • Page 15: Fill And Top-Up Water

    You can use the document search on our website to display this. You will find the address of the website on the back cover of these instructions. Corrosion inhibitor The following corrosion inhibitors are permitted: Designation Concentration Fernox see supplier information Sentinel see supplier information Table 9 Condens 8300i W – 6721841531 (2022/10)

  • Page 16: Installation

    ▶ Only use screws and rawl plugs that are suitable for the wall type and weight of the unit. Condens 8300i W – 6721841531 (2022/10)
  • Page 17 ▶ Affix an installation template (if available) to the wall. ▶ Check whether the screws and rawl plugs supplied with the device can be used. ▶ Drill suitable holes for the selected rawl plugs and screws. Condens 8300i W – 6721841531 (2022/10)

  • Page 18: Installing The Appliance

    ▶ Unlock the condensate trap and remove from appliance ( Fig. 9.17, p. 46) ▶ Check the positioning of the sealing washers on the pipe connections. ▶ Tighten the union nuts on the pipe connections starting with the CH return on the right. Condens 8300i W – 6721841531 (2022/10)

  • Page 19: Connecting The Flue Accessories

    ▶ Check tightness of all joints (test pressure: max. 150 mbar). ▶ Depressurise the system. 0010042916-001 Fig. 23 ▶ Align the seal [1] with the holes and stick it onto the housing of the appliance. Condens 8300i W – 6721841531 (2022/10)

  • Page 20: Electrical Connection

    ▶ Flip down the control device ( Fig. 25). 0010019569-002 Fig. 25 Opening the cover When the cover is open, there is access to the electrical connection of the control panel. Condens 8300i W – 6721841531 (2022/10)
  • Page 21 Mains power supply for the heating ▶ Set hydraulic configuration heating circuit 1 with service function 2-A3 to 2. pump (max. 100 W) downstream the low loss header in the heating circuit without mixer Without function Condens 8300i W – 6721841531 (2022/10)
  • Page 22 There is a replacement fuse on the inside of the cover. 230V-On/Off temperature controller ▶ Remove the jumper at L-LR and N-LR. 230V ▶ Connect the 230V-On/Off temperature controller. Table 12 Terminal strip for external accessories Condens 8300i W – 6721841531 (2022/10)

  • Page 23: Commissioning

    Filling the system - When initially filling the appliance, before power is applied, use the pressure gauge to set the system pressure. Once the appliance electrical pre commissioning is complete and the appliance is switched on refer to the digital pressure display on the appliance. Condens 8300i W – 6721841531 (2022/10)

  • Page 24: Adjusting The Operating Pressure Of The Heating System

    Save settings, Chimney sweeper key (Service Engineer function): press 5 seconds for chimney sweeper mode eco key: Hot water preheat selection Hot water key: Adjusting the hot water temperature Heating key: Heating mode on, set the maximum flow temperature Condens 8300i W – 6721841531 (2022/10)

  • Page 25: Turn On The Appliance

    Fig. 32 Removing the combustion cover During the siphon filling program, the symbol appears alternately with the flow temperature on the display. The siphon filling mode is interrupted when the chimney sweep mode is started. Condens 8300i W – 6721841531 (2022/10)

  • Page 26: Checking Gas Inlet Pressure

    ▶ Switch off the appliance, close the gas isolator, remove the pressure gauge and tighten the screw. NOTICE Do not continue commissioning until the correct gas pressure is achieved. Condens 8300i W – 6721841531 (2022/10)

  • Page 27: Checking For Gas Leaks During Operation

    Turn off boiler Boiler is operating and contact CO < 350ppm satisfactorily. Bosch help line CO/CO ratio No further action < 0.004 is required. 0010042279-001 Fig. 35 Commissioning checks flow chart Condens 8300i W – 6721841531 (2022/10)

  • Page 28: Checking Flue Integrity

    ▶ Refit the test point plugs after the test has been completed. The flue gas analysis performance of the appliance can be checked via the flue turret/adaptor sample points. Refer to figure 37 for the location of the flue gas sample point on flue turret/adaptor. Condens 8300i W – 6721841531 (2022/10)

  • Page 29: Finishing Commissioning

    ▶ Give the customer details of how to contact the installer/ gas emergency numbers. ▶ Show the customer how to safely isolate the appliance. ▶ Advise the customer where they can find information on the Bosch Group website www.bosch-climate.com.au/ www.bosch-climate.co.nz.

  • Page 30: Settings In The Service Menu

    Documenting the settings The label “Service menu settings” (scope of delivery) makes it easier to restore the individual settings following maintenance. ▶ Enter modified settings. ▶ Affix label to the device in a visible location. Condens 8300i W – 6721841531 (2022/10)

  • Page 31: Service Menu

    Setting only if heating circuit 1 is connected behind the low loss header without module. • 2: heating pump behind the low loss header connected to the device (PW2) Table 16 Menu 2: hydraulic settings Condens 8300i W – 6721841531 (2022/10)
  • Page 32 3-d6 Overrun time of the heating pump in • 1 … 2 … 60 minutes The pump overrun begins at the end of the heat heating mode demand by the heating controller. • 24 hours Table 17 Menu 3: Basic settings Condens 8300i W – 6721841531 (2022/10)
  • Page 33 If the outside temperature exceeds the set temperature limit, the heating is switched off (summer mode). If the outside temperature falls to at least 1 K ( °C) below the setting, the heating is switched back on (winter mode). Condens 8300i W – 6721841531 (2022/10)
  • Page 34 4-F1 Reset device to basic setting • NO: settings are retained • YES: device is reset to factory settings 4-F2 Reset service display • NO • YES Table 18 Menu 4: settings Condens 8300i W – 6721841531 (2022/10)
  • Page 35 • ON 0-A2 Set temperature in manual operation • OFF This service function is only available if service function 0-A1 is switched on. • 30 … 82 °C Table 21 Menu 0: manual operation Condens 8300i W – 6721841531 (2022/10)

  • Page 36: Thermal Disinfection

    ▶ Use heat conducting paste 8 719 918 658 0. reconnection. ▶ Use approved greases. HRisk of death from escaping flue gas! Escaping flue gas can cause poisoning. ▶ Check for leaks after working on flue gas-carrying components. Condens 8300i W – 6721841531 (2022/10)

  • Page 37: Checklist For Inspection And Maintenance

    ▶ Check and adjust the gas/air ratio. ▶ Affix the gas type label (included in the scope of delivery of the wall mounted boiler or gas type conversion set) to the wall mounted boiler next to the data plate. Condens 8300i W – 6721841531 (2022/10)

  • Page 38: Checking And, If Required, Adjusting The Gas/Air

    Liquid gas (LPG) Butane 11.9 11.2 Table 25 CO and O contents ▶ Measure the CO content. The CO content must be < 250 ppm. ▶ Set the minimum rated output. ▶ Measure the CO or O content. Condens 8300i W – 6721841531 (2022/10)
  • Page 39 ▶ Exit the chimney sweep mode. ▶ Enter the CO or O contents in the commissioning report ( Chapter 13.8, page 62). ▶ Remove the flue gas probe from the flue gas test port and refit the bung. Condens 8300i W – 6721841531 (2022/10)

  • Page 40: Check The Gas Supply Pressure

    ▶ If this is not possible: isolate the device on the gas side and notify the gas supplier. ▶ Set the chimney sweep mode and start up the device at minimum rated output. ▶ Exit the chimney sweep mode. Condens 8300i W – 6721841531 (2022/10)

  • Page 41: Tightness Test Of The Flue Gas Path

    ▶ Set the maximum rated output in chimney sweep mode. ▶ Measure the CO content. ▶ Press the OK key. The device returns to normal operation. ▶ Remove the flue gas probe. ▶ Re-install the bung. Condens 8300i W – 6721841531 (2022/10)

  • Page 42: Checking The Burner

    ▶ Reinstall the burner in reverse order, including a new gasket if required. ▶ Install the burner and the burner cover. ▶ Tighten the screw ([1], Fig. 47) on the burner cover with 5.5+0.5 Nm. Condens 8300i W – 6721841531 (2022/10)

  • Page 43: Checking The Non-Return Valve In The Mixing Device

    Checking the expansion vessel The expansion vessel must be checked every year. ▶ Depressurise the appliance. ▶ Adjust the pre-charge pressure of the expansion vessel to the static head of the heating system, if necessary. Condens 8300i W – 6721841531 (2022/10)

  • Page 44: Checking The Plate Heat Exchanger

    ▶ Attach cap to test port. ▶ Check the gas/air ratio. 0010031368-001 Fig. 54 Removing the plate heat exchanger ▶ Install the new plate heat exchanger in reverse order. ▶ Make sure that the label "bottom" is facing downwards. Condens 8300i W – 6721841531 (2022/10)

  • Page 45: Cleaning The Heat Exchanger Assembly

    ▶ Re-fit the cover to the heating block. Tighten the screws with 5.5 + 3 Nm. 0 010 007 128-001 Fig. 57 Cleaning the heating block with a brush ▶ Remove the burner ( chapter 9.9, page 42). Condens 8300i W – 6721841531 (2022/10)

  • Page 46: Cleaning The Condensate Trap

    ▶ Check the gasket for cracks, deformation or breakage and replace if required. 0010019159-002 Fig. 62 Pressing on the gasket ▶ Check the condensate hose and clean if required. ▶ Fill the condensate trap with approx. 250 ml water. Condens 8300i W – 6721841531 (2022/10)

  • Page 47: Adjusting The Operating Pressure Of The Heating System

    3. Remove the gas pipe. 0010007251-001 Fig. 66 Removing the gas control valve ▶ Install the air/gas ratio control valve in reverse order, and check the gas/air ratio. 0010017782-001 Fig. 64 Removing the gas pipe Condens 8300i W – 6721841531 (2022/10)

  • Page 48: Checking/Replacing The Motor Of The 3-Way Valve

    Fig. 68 Installing the motor in the 3-way valve (variant without screws) 0010027500-002 Fig. 67 Detaching the motor from the 3-way valve (variant without screws) ▶ Push the motor down. ▶ Turn the motor clockwise as far as it will go. Condens 8300i W – 6721841531 (2022/10)

  • Page 49: Following Inspection/Maintenance

    Following inspection/maintenance ▶ Re-tighten all the threaded connections that have been released. ▶ Restart the device ( page 24). ▶ Check tightness of all joints. ▶ Check the gas/air ratio. ▶ Fit the casing. Condens 8300i W – 6721841531 (2022/10)

  • Page 50: 10.1.2 Error Code Table

    12.Convert the flue system. 13.The interconnected combustion air supply is too low or the ventilation opening is too small. 14. Clean the heating block on the flue gas side. 15.Replace control device/burner control unit. Condens 8300i W – 6721841531 (2022/10)
  • Page 51 Replace control device. 242 - System fault boiler electronics / basic 1. Remedy contact problem. controller 2. If necessary, replace control device or boiler identification module/coding plug (Bosch contact customer service). Heat demand lower than energy supplied – Relay test was activated –...
  • Page 52 16.The interconnected room air supply is too small or the size of the ventilation opening is too small. 17.Clean the heating block on the flue gas side. 18.Check control device/burner control unit, replace if necessary. 2928 V Internal fault 1. Perform reset. 2. Replace control device/burner control unit. Condens 8300i W – 6721841531 (2022/10)
  • Page 53 1. Perform reset. 2. Replace control device/burner control unit. 2946 V Incorrect code plug detected Replace boiler identification module/coding plug (Bosch contact customer service). 2948 B No flame signal with low output Burner starts automatically after purging. If this fault occurs frequently, check CO setting.
  • Page 54 The lock is removed and the unit returns to normal operation. 3. Double-check the last 10 faults in the fault history to confirm the fault has been remedied Table 28 Indicators and fault displays Condens 8300i W – 6721841531 (2022/10)

  • Page 55: 10.1.3 Faults That Are Not Displayed

    If the system pressure in the heating system drops below 0.3 bar, the display shows the message LoPr alternating with the operating pressure. The heating system is then blocked. ▶ Fill the heating system. Condens 8300i W – 6721841531 (2022/10)

  • Page 56: Shutdown

    You can find more information here: www.weee.bosch-thermotechnology.com/ Batteries Batteries must not be disposed together with your household waste. Used batteries must be disposed of in local collection systems. Condens 8300i W – 6721841531 (2022/10)

  • Page 57: Technical Information And Reports

    EMC limit value class – Sound power level at P (as per NF EN 15036-1, NF EN ISO 9614- dB(A) 54.9 54.9 54.9 1 and AFNOR regulations RP247) Protection index Max. temperature setting °C Condens 8300i W – 6721841531 (2022/10)

  • Page 58: Ionisation Current

    Table 32 Outside temperature sensor (for weather-compensated controllers, accessory) Table 33 Flow temperature sensor 13.4 Coding plug Type Gas type Number GC8300iW 35/40 C Natural gas 20456 GC8300iW 35/40 C Liquid gas (LPG) 20457 Table 34 Coding plug Condens 8300i W – 6721841531 (2022/10)

  • Page 59: Pump Characteristic Map Of The Heating Pump

    20,4 21,0 21,4 22,0 22,5 23,0 23,5 24,0 24,5 25,0 25,5 26,0 26,5 27,0 27,6 28,0 28,6 29,0 29,6 30,0 30,6 31,0 31,6 32,0 32,7 33,0 33,7 33,7 34,4 Table 35 GC8300iW 35/40 C Condens 8300i W – 6721841531 (2022/10)

  • Page 60: Electrical Wiring

    Technical information and reports 13.7 Electrical Wiring ON/OFF 230V 230V 230V 11 18 12 8 0010041052-001 Fig. 72 Electrical Wiring Condens 8300i W – 6721841531 (2022/10)
  • Page 61 [14] Connection for the automatic filling device (accessory) [15] Display [16] Coding plug [17] Terminal strip for external accessories ( terminal assignment from page 22) [18] 3-way valve [19] Connecting lead with plug [20] On/Off-switch [21] Earth bar (PE) Condens 8300i W – 6721841531 (2022/10)

  • Page 62: Commissioning Report For The Appliance

     Low loss header, type:  Additional expansion vessel  Heating pump: Size/pre-charge pressure: Automatic air vent valve present?  Yes |  No  DHW cylinder/type/number/heating surface output:  System hydraulics checked, Notes: Condens 8300i W – 6721841531 (2022/10)
  • Page 63 ___________________________________________________________ Name of service engineer __________________________________________________________ Date, user's signature Affix the test report here. ____________________________________________________________ Date, system installer's signature Table 36 Commissioning report Condens 8300i W – 6721841531 (2022/10)
  • Page 64 Robert Bosch (Australia) Pty Ltd Thermotechnology Division 1555 Centre Road Clayton Victoria 3168 Australia Phone: 1300 30 70 37 Fax: 1300 30 70 38 www.bosch-climate.com.au New Zealand Phone: 0800 54 33 52 Fax: 0800 54 33 55 www.bosch-climate.co.nz...

This manual is also suitable for:

Gc8300iw 35cGc8300iw 40c

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