Information on safe isolation can be found in the ▶ Worcester Bosch offer flue gas systems which are Health and Safety Executive guidance HSG85. suitable for use with the appliance. It is the – Using test equipment approved to GS38 to...
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Explanation of symbols and safety instructions H Handover to the user H Combustion and corrosive materials When handing over, instruct the user how to operate Do not store or use any combustible materials (paper, the heating system and inform the user about its thinners, paints etc.) inside or within the vicinity of the operating conditions.
Regulations Irish Standards Regulations The current relevant Irish standards should be followed, including: • ECTI Installation regulations – National rules for electrical installations Current Gas Safety (Installation and Use) Regulations: • IS 813 All gas appliances must be installed by a competent, registered gas –...
Product Information Scope of delivery Product Information Appliance features • Aluminium-silicon heat exchanger, which has an extra-large surface area for enhanced heat exchanger efficiency. • NOx emissions 39mg/kWh. • Direct burner ignition. • Zero pressure governor gas valve with fully modulating fan. •...
Product Information Product identification Function From left Diameter of pipe case edge Data plate 3 DHW Outlet 133mm 15mm The data plate includes the product performance information, approval data and serial number. The data plate location can be found in the •...
Actual consumption is likely to be less. [32] Flow temperature sensor Table 6 Control accessories [33] Schrader valve [34] Expansion vessel Bosch EasyControl smart control system [35] Fan Part number Description [36] Air-gas manifold with non-return valve 7 736 701 341...
Pre-Installation • Hot water temperature and flow rate are affected by the size and Pre-Installation insulation of pipe work making up the distribution system and are controlled by the hot water tap and the water main inlet pressure. A NOTICE: mixing valve can be fitted if a more permanent temperature setting is required.
Pre-Installation Sealed primary system - 2 x central heating zones: T[°C] • Requirement for new builds if the floor area of a property is over 150m 600 700 V[l] Fig. 7 Separated heating zones 0010016558-002 Appliance Fig. 5 Curves for the expansion vessel Zone valves Pre-charge pressure 0.5 bar (minimum) 4.1.4...
Pre-Installation Mains supply Natural Gas (NG): Discharge rates for copper tube with 1mbar differential pressure 4.2.1 Electrical supply between the ends for Natural Gas. • Supply: 230V AC - 50 Hz • This appliance must not be connected to a three phase supply. Discharge rates for Natural Gas (m /hr) with straight horizontal copper tube...
Pre-Installation Water mains pressure: DANGER: • Minimum mains water pressure, for maximum performance refer to section 13.1 "Technical data". Danger from explosive and flammable materials: • Maximum mains fed water static pressure 10 bar. Storage of explosive and flammable materials. If necessary fit a pressure reducing valve.
Pre-Installation 4.3.2 Rooms containing a bath or shower CAUTION: Risk of electric shock ▶ Any switch or appliance control using mains electricity must not be within reach of a person using the bath or shower. • In all cases the installation must be in accordance with the latest amendments to the latest edition of the IET Wiring Regulations (BS7671).
▶ If this is not possible, bends should be viewable from both directions. – 60/100 = 202 - 603mm – 80/125 = N/A Telescopic horizontal flue assembly Refer to the manual supplied with the Worcester, Bosch Group flue kit for complete installation instructions. 60/100 mm [A] 350 mm - 570 mm...
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Pre-Installation Extended horizontal flue High level horizontal flue with additional 90° elbow Fig. 15 Horizontal flue option • Flue length [L] (adaptor bend included in length calculation) Fig. 19 Horizontal flue option – Maximum flue length as stated in "Horizontal maximum flue lengths".
Pre-Installation Vertical balanced flue with 90° elbow offset NOTICE: Plume management length: ▶ The plume management length must be a minimum of 500mm and must not exceed the maximum straight length for a horizontal Ø 60/ 100mm flue with a 60mm plume management system as stated previously.
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Pre-Installation Vertical flue terminal positions RIDGE VENT RIDGE FLUE 1500 1500 1500 1500 2000 1500 1200 1500 BOUNDARY LINE BOUNDARIES Fig. 26 Vertical flue terminal positions Key to figure 26: centre line of any adjacent routes or waterways e.g. paths, streets, rights of way, canals, rivers or railways.
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Pre-Installation Key to figure 27: 200mm below eaves and 75mm below gutters, pipe and drains. The dimension below eaves, gutters, pipes and drains can be reduced to 25mm, as long as the flue terminal is extended by 100mm past any overhang. The telescopic flue joint must be sealed with suitable silicone sealant if it is external to the building.
Pre-Installation 4.4.5 Plume re-direct and plume management terminal positions NOTICE: ▶ All measurements are the minimum clearances required. Maximum and minimum plume management lengths: ▶ Refer to “Horizontal flue terminal positions” for all concentric flue ▶ A minimum distance of 500mm must be maintained between the terminal positions unless the flue position is specified in figure 28 plume management outlet and the flue air intake.
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Pre-Installation Key to figure 28 - Plume re-direction terminal positions: The exhaust terminal can also be routed though the roof of the carport providing 25mm clearance is provided around the flue This feature allows some basic plume re-direction options on a pipe to any flammable material and that it extends at least 300mm standard telescopic horizontal flue terminal.
Pre-Installation Condensate discharge 4.5.2 Condensate production When the appliance is in operation it can produce between 1 to 2 litres of condensation per hour. Full details on condensate discharge. This discharge is a constant drip feed during the production of condensate and does not release in frequent large volume discharges ▶...
Pre-Installation Waste pipe connection 4.5.4 External connections Figure 30 NOTICE: Alternatively if the first option is not possible an internal kitchen, Risk of condensate discharge freezing bathroom or washing machine waste pipe etc. can be used. Ensure that the condensate drain pipe is connected “down stream” of ▶...
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Pre-Installation ▶ The use of fittings, elbows etc. should be kept to a minimum and any internal burrs on cut pipe work should be removed so that the internal pipe section is as smooth as possible. ▶ All external pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut.
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Pre-Installation Condensate soak away considerations 400mm min. Before deciding to use a purpose-made soak away the history of the 25mm min. locality and the ability of the surrounding area to disperse the condensate should be taken into account, e.g. areas prone to flooding 500mm min.
Pre-Installation Minimum Standard • The pipe [1 or 3] should be finished with a partial bend, near the outlet to face the external wall (as shown) to help prevent freezing. ▶ The following guidance indicates the minimum standards that must •...
▶ The Building Services Compliance Guide recommends that a primary water cleanser is fitted to the system. FERNOX 0870 601 5000 ▶ Worcester Bosch recommend fitting a filter that will help remove both www.fernox.com magnetite and non-magnetic debris. SENTINEL 0800 389 4670 Worcester offers varies filters that helps remove both magnetite and www.sentinel-solutions.net...
Installation Installation Appliance positioning NOTICE: ▶ Ensure the appliance is mounted onto a flat, fixed rigid surface Risk of damage to appliance or accessories. capable of supporting the appliance weight. ▶ All the previous pre-installation sections must be read and ▶...
Installation Rear flue outlet [2]. NOTICE: ▶ Mark centre line of flue to be used; the external diameter of the hole can also be marked if required. Appliance - hydraulic connections ▶ If extensions are to be added then the complete flue must rise at an ▶...
Installation Fitting the hose to the condensate trap Installing pipework ▶ Take the cap off the drain on the condensate trap. DANGER: ▶ Fit the condensate hose on the condensate trap. Contaminated heating water can damage the appliance! Residue in the pipe work can damage the appliance. ▶...
Installation Connect condensate discharge pipe Flue turret/adaptor installation ▶ Connect the condensate discharge pipe to the appliance condensate NOTICE: hose outlet connection. Flue installation ▶ Refer to the Flue Kit Installation instructions provided with your flue kit to correctly install the flue with this appliance. ▶...
Installation ▶ The three replacement retaining screws [4] supplied with the adaptor kit are used to secure the vertical adaptor [B]. Electrical considerations: ▶ All electrical work must be carried out by a competent and authorised person. ▶ All work must comply with the current IET Wiring Regulations. ▶...
Installation 5.5.1 Installer connections External accessories terminal strip Symbol Function Component access ▶ Release catch and hinge open the control panel into the service Outside temperature sensor or ON/OFF temperature position. controller. (link factory fitted) The outside temperature sensor for the user interface is connected to the device.
Commissioning 5.5.3 Key (accessories) Description of the LED displays Example Constant green: No fault, normal operating condition. Key is supplied with Comfort+ II RF are pre-paired. LED Off: No fault, power-saving mode or appliance without power. Installing the Key Table 17 LED status Installing the Key will enable time and temperature control for the Commissioning appliance.
▶ In cases where all attempts to find a system micro leak have failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. ▶ Refer to Scope of delivery to check if an filling link is supplied with the appliance.
Commissioning Circulation pump Starting the appliance Controller module overview NOTICE: Damage to appliance or system! Running the appliance: ▶ Never run the appliance when the appliance/system is empty or partially filled. 6.4.1 Control panel overview Fig. 51 Overview Operation/fault indicator Constant speed mode indicator Constant pressure (p-c) mode indicator Self modulating (p-v) mode indicator...
Commissioning 6.4.2 Screen display 6.4.3 Switching on the device The appliance is vented after initial power-up. This involves the heating pump switching on and off at intervals (for approx. 4 minutes). and the flow temperature appear alternately in the display. ▶...
Commissioning 6.4.6 Setting the heating control device 6.5.3 Exiting chimney sweep mode To exit the chimney sweep mode: ▶ Press the ok button and the appliance will return to normal operation. Observe the operating instructions of the heating controller. This shows –...
Commissioning Gas pressure within the system Maximum output mode The appliance must be running at maximum output rate when ▶ A hot water outlet can be opened to prevent the appliance from performing the gas rate check, ( chapter 6.5.1). shutting down due to high temperature during testing.
▶ Check and zero the analyser in fresh air as specified by the manufacturer. ▶ The air/gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366. Zero the analyser ≥ 20.6% START...
Commissioning 6.10 Checking flue integrity 6.11 Flue gas analysis NOTICE: Combustion testing Flue integrity check ▶ Combustion testing must be carried out by a competent qualified ▶ The combustion casing must be fitted whilst this test is carried out. person. Testing must not be attempted unless the person carrying ▶...
▶ Show the customer how to safely isolate the appliance. ▶ Advise the customer where they can find information on the Worcester, Bosch Group website www.worcester-bosch.co.uk. ▶ Ensure that all documentation, is left with the appliance or homeowner.
Shutdown Shutdown Settings in the service menu Many appliance functions can be set and checked in the service menu. It Setting frost protection includes: • Menu 1: information menu NOTICE: • Menu 2: not used in UK/IE Risk of damage to the system from frost! •...
Settings in the service menu Service functions overview 8.2.1 Menu 1 ▶ Press the ( key and * key at the same time until L.1 appears. ▶ To confirm the selection: press OK key. ▶ Selecting and setting the service function. Service function Unit Further information...
Settings in the service menu 8.2.3 Menu 3 ▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key until L.3 is displayed. The basic settings are depicted as highlighted in the following table. ▶...
Settings in the service menu 8.2.4 Menu 4 ▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key until L.4 is displayed. The basic settings are depicted as highlighted in the following table. ▶...
Settings in the service menu Service function Settings/adjustment range Remark/restriction 4-b5 Device frost protection • OFF: switched off This service function is only available if service function 4-b1 is activated. • ON: switched on The device frost protection function switches the burner and heating pump on when the outside temperature falls below 5 °C.
Settings in the service menu 8.2.6 Menu 6 ▶ Press the ( key and * key at the same time until L.1 appears. ▶ Press arrow key until L.6 is displayed. The basic settings are depicted as highlighted in the following table. ▶...
Inspection and maintenance ▶ When it is frequently necessary to add water to maintain pressure in Inspection and maintenance the installation, even though no leaks have been discovered, perform an expansion vessel check. DANGER: ▶ Check that the condensate system is not obstructed, clean and refill the condensate siphon.
After all checks have been completed and the CO is still out of tolerance ▶ Clean the heat exchanger with a suitable cleaning tool, refer to then contact Worcester, Bosch Group helpline 0330 123 3366. cleaning section. ▶ Re-check the fan pressure readings.
Inspection and maintenance Checking the flue integrity 4. Remove the fan with mixing device. NOTICE: ▶ Check flue joints are secure, the terminal and the terminal guard, if fitted are clear and undamaged. ▶ Combustion testing must be carried out by a competent person. Testing must not be attempted unless the person carrying out the combustion check is equipped with a calibrated Flue Gas Analyser conforming to BS 7967 and is competent in its use.
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Inspection and maintenance ▶ Remove the non-return valve. ▶ Remove the top baffle using the lifting device. ▶ Check the non-return valve for contamination and cracks. 0010015934-001 Fig. 64 Non-return valve in the mixing device 0010002794-002 1. Remove the gasket. 2.
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Inspection and maintenance ▶ Clean both baffles. ▶ Refit the baffles. ▶ Clean the heating block with the brush: ▶ Remove the condensate trap and place a suitable container underneath. – by rotating in both directions ▶ Rinse the heat exchanger with water from the top. –...
Inspection and maintenance 9.8.2 Cleaning the siphon 1. Unscrew the cleaning cap. 2. Check the gasket for cracks, deformation or breakage and replace if Cleaning the condensate trap required. 3. Clean the condensate trap, and check that the aperture towards the WARNING: heat exchanger is clear.
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Inspection and maintenance ▶ Align the gasket correctly with the condensate trap. ▶ Replace the condensate trap and check for tightness. ▶ Check the condensate hose and clean if required. ▶ Grease the hose during assembly and check tightness of connection. 0010019151-001 Fig.
With the appliance in minimum rated output. ▶ Remove the seal from the adjusting screw of the gas valve (only gas Only use Worcester, Bosch Group original spare parts with this valve is shown in the below Figure 77) and set the CO...
Replacement parts 10.1 Component access 10.3 Checking the strainer in the cold water pipe 1. Remove the clip. Removing the front casing 2. Pull out the pressure relief valve. The front casing is secured with two screws to prevent unauthorised removal (electrical safety).
Replacement parts 10.4 Checking the plate heat exchanger 10.7 Removing the gas valve If the DHW output is insufficient: ▶ Close gas isolator. ▶ Check the strainer in the cold water pipe for contamination. ▶ Unplug the plug. ▶ Remove the plate heat exchanger and replace if necessary. ▶...
Replacement parts 10.8 Removing the pump 10.10 Removing the motor of the diverter valve ▶ Unplug the electrical plug [5]. ▶ Removing the automatic air vent valve ▶ Disconnect nut connection [1] between pump and heatcell. ▶ Removing the motor of the diverter valve: ▶...
Replacement parts 10.11 Removing the heat exchanger 10.12 Replacing the control unit ▶ Remove the fan, gas hose and mixing device ( Chapter , page 53). 1. Remove the clip. The devices are delivered without code plug. 2. Detach the flow pipe. ▶...
Fault finding and diagnosis 10.13 Reattaching the casing on the side NOTICE: ▶ Align the side panel so that the underside can be guided along the On completion of the Service/Fault-Finding task which has required the flange. breaking and remaking of electrical connections, check: ▶...
Fault finding and diagnosis 11.2 Table of operation and fault displays Description Remedy The device is in central heating mode. – The appliance is in DHW mode. – The appliance is in optimised switching mode: – the interval for restarting the burner has not yet expired (...
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Fault finding and diagnosis Description Remedy Flame lost during burner operation. ▶ Check the main shut-off valve, open if necessary. ▶ Check the appliance isolation valve, open if necessary. ▶ Measure the gas supply pressure at the rated heat input. If necessary, shut down the appliance and check the gas line.
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Fault finding and diagnosis Description Remedy Air feed failed during operating phase. ▶ Reconnect the fan plug properly, perform reset. ▶ Replace fan. ▶ Mains voltage must correspond to the default value. ▶ Remove any blockages in the flue system. ▶...
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Fault finding and diagnosis Description Remedy System fault, burner control unit. ▶ Reset appliance - factory reset. ▶ If the fault persists following a reset, the burner control unit is faulty and must be replaced. – DHW temperature has not increased for 2 hours. ▶ Prevent water from escaping. ▶...
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Fault finding and diagnosis Description Remedy 1076 R No signal from heat exchanger temperature ▶ Check plug, connect correctly. limiter. ▶ Check heat exchanger temperature limiter, replace if required. ▶ Check connecting lead for breaks, replace if required. ▶ Check and replace the appliance electronics. 2051 –...
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Fault finding and diagnosis Description Remedy 2927 B No flame detected during ignition. ▶ Check the main shut-off valve, open if necessary. ▶ Check the appliance isolation valve, open if necessary. ▶ Measure the gas supply pressure at the rated heat input. If necessary, shut down the appliance and check the gas line.
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Fault finding and diagnosis Description Remedy 2953 B No flame signal with low output. The burner starts automatically after cleaning (purge).Possible cause high winds. ▶ If the fault occurs repeatedly, check the settings of the CO values. ▶ Check Flue integrity. ▶...
Fault finding and diagnosis 11.4 Faults that are not displayed Appliance faults Remedy Combustion noises too loud; rumbling noises ▶ Check the gas type. ▶ Check the gas supply pressure. ▶ Check the flue system; clean or repair if required. ▶...
Environmental protection/disposal Environmental protection/disposal Environmental protection is a fundamental corporate strategy of the Bosch Group. The quality of our products, their economy and environmental safety are all of equal importance to us and all environmental protection legislation and regulations are strictly observed.
Technical Specifications/Logs Worcester 2000 7 736 902 027 7 736 902 028 Description Unit 25kW N.G. 30kW N.G. Lift weight (without front panel) 33.4 33.4 SEDBUK 2009 89.1 89.1 1) For minimum and maximum permissable pressure refer to “Gas pressure within the system”, section 6.6. 2) The Gas Rate provided assumes the accepted NG averaged calorific value of 34-9 MJ/m net.
Technical Specifications/Logs 13.5 Setting values for output The maximum rated heat output can be reduced to up to 50 % of the output range (service function 3-b1). The minimum rated heat output can be increased to up to 50 % of the output range (service function 5-A3).
GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Time, temperature control and boiler interlock provided for central heating and hot water Boiler Plus requirements (tick the appropriate box(s)) Weather compensation...
SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
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SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’...
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