Benchmark ZB 7-28 R 28 HE Installation And Servicing Instructions

Text of Benchmark ZB 7-28 R 28 HE User Guide:

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 44 Appendix 9.5 Operational Flow diagrams 9.5.1 Central heating function Fig. 67 6 72 0 61 1 4 4 3 -04.1O Yes No Yes No Mains switch ON. Green light ON. Room thermostat and/or mains programmer or link ON AND Electronic facia programmer (if fitted) ON AND CH control knob ON. CH demand. Burner remains OFF until flow temperature is below set value. Gas valve shuts. Pump remains ON. Over temperature shut down if water temperature is 5∞C above set value. Pump ON Fan to start speed. Gas valve opens. Burner stabilises at start speed for 5-10 secs Fan speed reduces over 15 secs. Fan min. speed for 90 secs. Bo

• 6 720 611 443 GB (05.04) Installation 15 Condensate Termination and Route The appliance has a built-in syphonic condensate trap eliminating the need for external traps. Connect to the 22mm plastic drain pipe and extend the pipe run away from the control panel and appliance witha constant fall of 2.5° or 45mm in every metre. See fig. 14. The condensate pipe can ter

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) Maintenance 41 8.3.9 Pressure gauge B Drain the appliance. B Lower the facia. Refer to fig. 63. B Twist the pressure gauge head anti-clockwise to release it from the casing. Refer to fig. 2. B Disconnect the capillary head from the rear by with- drawing the clip and pulling out the head. Refer to fig. 57. 8.3.10 Expansion vessel B Drain the appliance. B Undo the union connection at the base of the vessel. Refer to fig. 2. B Unscrew the top and bottom fixing screws and remove the vessel. B Set the pressure of the new vessel to that required by the system

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 34 Maintenance 8.1 Pre-Service Check List Date 1 Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 35). 2 Check ionisation current, Service Function 3.3, (see page 35). 3 Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 37). 4 Check gas supply pressure (see page 30). mbar 5 Test combustion air/flue gas (see page 32). 6 Check CO 2 setting for min./ max. (gas/air ratio) (see page 30). min. % max. % 7 Check gas and water systems for leaks (see page 16). 8 Check heat exchanger (see page 35). mbar 9 Check burner (see page 36). 10 Clean condensation

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 24 Commissioning 5 Commissioning Fig. 33 8.1 Pressure gauge 15 Safety valve 27 Automatic vent 61 Reset button 135 Master switch 136 Temperature control for central heating 170 Service cocks on CH flow and return 171 Optional cylinder flow (used only with motorised valve) 172 Gas cock (shown in on position) 173 Optional cylinder return (used only with motorised valve) 295 Appliance type sticker 310 Temperature control for hot water 317 Multi function display 358 Condensate trap 363 Indicator lamp for burner 364 Indicator lamp for power supply 365 “Chimney sweep” button 366 Service button 367 ECO button 5.1 Co

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) Installation 11 3 Installation 3.1 Important remarks B Appliance should only be installed in sealed central heating systems. B To avoid gas formation in the system, galvanised radi- ators or pipes must not be used. B If a room thermostat is used: do not fit a thermostatic radiator valve on the radiator in the primary room. B Add a suitable anti-freeze fluid compatible with alu- minium to the water in the central heating system. Suitable products are available from Betz-Dearborn Tel.: 0151 4209563, Fernox Tel.: 01799 550811 and Salamander Tel: 0121 378 0952. B In our experience, the addition of sealing agents to the water in the central heating sys

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) Commissioning 25 B Before commissioning, the gas supply pres- sure must be checked at the gas supply pres- sure test point (see page 6, fig. 2, item 7). Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar. LPG appliances must not be operated if the supply pressure is not 37 mbar at the inlet to the appliance. B Unscrew the condensation trap (358) and pull out, fill with approx. 1/4 l of water and refit. Refer to fig. 33. B Adjust charge pressure of expansion vessel to static head of the central heating system (see page 27). B Open all system radiator valves. B Check automatic air vent is open (27) f

• 6 720 611 443 GB (05.04) Converting the appliance to different gas types 31 B Turn the temperature control until the display shows 2. (= max. rated heat output). The display and the button will flash. Fig. 46 B Measure the CO 2 level. B Prise off the seal on the gas flow restrictor. B Adjust the gas flow restrictor (63) to obtain the CO 2 level given in

• 6 720 611 443 GB (05.04) 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. • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths up to 13 m and vertical flue systems for flue lengths up to 15 m. Fitting instruc- tions are sent with these kits. • Heating

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) Installation 17 3.8.1 Siting the Flue Terminal The flue must be installed in accordance with BS 5440:1 and the Building Regulations. Flue terminals in carports and under balconies are to be avoided. The terminal must be positioned so that it does not cause an obstruction nor the combustion products a nuisance. See fig. 17 and table 9. The terminal will, at times, give out a plume of water vapour and consideration must be given to this when choosing a terminal position. Keep clear of security lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which people have access then a guard must be f

• 6 720 611 443 GB (05.04) 12 Installation Fig. 5 System layout if using optional built-in diverter valve (This must be used in conjunction with an integral programmer, Night Set Back Module and TR2 Optimising Room Thermostat) Fig. 6 System layout if using external diverter valve (excludes using a Honeywell ‘Y’ plan valve). RV LV LV RV RV RV LV LV INDIRECT CYLINDER APPLIANCE Refer to

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 16 Installation Fixing the appliance B Fit the washers onto the gas and water connections. B Lift the boiler onto the wall-mounting frame. The lugs pass through the rectangular holes in the boiler back panel. B Take care not to disturb the washers on the connec- tions. Connecting the flue assembly B Fit flue duct connector onto appliance flue spigot. B Secure with screws pre-fitted to flue outlet on boiler unless additional screws are provided with flue sys- tem. Fig. 16 B For remaining installation of flue assembly, refer to the relevant installation instructions. 3.7 Checking the connections Water connections B Check that the O-rings or s

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) Maintenance 39 8.3.2 Fan Assembly Fig. 62 B Switch off the appliance. B Disconnect the appliance from the power supply. B Undo lower pipe union on gas pipe (1.). Refer to fig. 62. B Remove fan lead and earth connector (2.). The earth connector has a positive clip fixing. B Remove fixing screws attaching fan to the burner cover (3.). B Remove fan together with gas pipe and mixer unit. B Separate the fan from the pipe and mixer unit by twisting the mixer unit to release it (4.). 8.3.3 Pump B Switch off the appliance. B Disconnect appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to fig. 63. B Lower switchbox

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) Details of the appliance 9 1.9 Technical data Units Natural gas 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 29.3 29.0 27.4 29.3 29.0 27.4 Max. rated heat input net kW 27.7 27.7 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 Min. rated heat input net kW 7.6 10.8 Maximum gas flow rate – After 10 minutes from lighting Natural gas G20 (CVnet 34.02 MJ/m 3 )m 3 /h 2.9 - LPG (CVnet 88 MJ/m 3 )kg/h-2.1 Gas supply pressure Natural gas

• 6 720 611 443 GB (05.04) Individual settings 29 6.2.5 Setting the switching difference (Service Function 2.6) The switching difference is the permissible divergence from the specified CH flow temperature. It can be set in increments of 1°C. The adjustment range is 1 to 30°C (is factory set to 0°C). The minimum CH flow temper- ature is 30°C. 6.2.6 Setting the heating

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 14 Installation 3.4 Wall mounting frame assembly B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 9. Use the inner lugs on the top and bottom horizontal sec- tions. Fig. 9 B Hold the wall-mounting frame against the wall ensur- ing that it is vertical. B Mark the holes for the wall mounting frame onto the wall, drill and plug the holes and screw the wall mounting frame to the wall with the screws provided. B Mark the position of the

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 30 Converting the appliance to different gas types 7 Converting the appliance to different gas types The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not neces- sary. Checking the gas supply pressure B Check the gas supply pressure at the gas supply pressure testing point. Natural gas • Appliances for natural gas type G20 are factory set to Wobbe-Index 15 kWh/m 3 and 20 mbar supply pressure and sealed. Conversion kits • Instructions are sent with each conversion kit. 7.1 Setting the gas/air ratio The gas/air ratio may only be adjusted

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 26 Commissioning 5.5 Appliances with optional plug-in diverter valve: Setting hot water temperature B Set the hot water temperature by means of the tem- perature control on the appliance. Fig. 36 ECO button Pressing and holding the ECO button switches from Comfort mode to ECO-mode. Comfort mode, ECO button is not lit (factory set- ting) Comfort mode the hot water tank has priority. The hot water cylinder is first heated up to the set temperature. The appliance then switches to central heating mode. ECO mode, button is lit In ECO mode the appliance switches between central heating mode and cylinder charging mode every 12 minut

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 22 Electrical connections B Secure cable in cable grommet by means of cable grip. Fig. 30 4.2 Wiring to your system The boiler is fitted with an internal pump and there are two recommended ways of connecting a system, exter- nal 230v or internal 24v depending on the choice of diverter valve(s). 4.2.1 External 230v Non-supplied parts required: external 230v conven- tional terminal block or wiring centre, pre-wired to the 230v diverter valve(s) and all other 230v system com- ponents. Note: Honeywell and Siemens Y plan valves require a capacitor to be wired across the switch wire and neu- tral o

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 38 Maintenance 8.3 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. 8.3.1 PCB control board and transformer B Switch off the appliance. B Disconnect appliance from the power supply. B Unplug all connectors from the control box (inc. keyed plug). Access is gai

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) 8 Details of the appliance 1.8 Electrical wiring diagram Fig. 4 4.1 Ignition transformer 6 Temperature limiter, heat exchanger 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 Diverter valve motor (optional extra) 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 F

• Benchmark ZB 7-28 R 28 HE, 6 720 611 443 GB (05.04) Details of the appliance 7 1.7 Function (with optional extra motorised valve) Fig. 3 4 Bosch Heatronic control 6 Temperature limiter, heat exchanger 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

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