Bosch Condens 7000 FP Installation And Service Instructions Manual
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Bosch Condens 7000 FP Installation And Service Instructions Manual

Bosch Condens 7000 FP Installation And Service Instructions Manual

Floor standing gas condensing boiler
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Installation and Service Instructions for Specialists
Floor standing gas condensing boiler
Condens 7000 FP
GC7000FP 350...500
0010042168-001
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Summary of Contents for Bosch Condens 7000 FP

  • Page 1 Installation and Service Instructions for Specialists Floor standing gas condensing boiler Condens 7000 FP GC7000FP 350...500 0010042168-001...

  • Page 2: Table Of Contents

    7.8.1 Switching on the boiler at the control unit ..29 2.9.1 Dimensions and connections Condens 7000 FP..8 7.8.2 Carrying out a flue gas test ..... . 29 Regulations .
  • Page 3 17.4.2 Burner control unit ......70 17.4.3 Diagrammatic representation of supply air/flue gas monitor and gas tightness ....71 Condens 7000 FP – 6721846699 (2022/12)

  • Page 4: Explanation Of Symbols And Safety Instructions

    In doing so, observe the regulations ( chapter 3). ▶ Do not repair, manipulate or bypass safety equipment. ▶ Observe all relevant instructions for system components, accessories and spare parts. Condens 7000 FP – 6721846699 (2022/12)

  • Page 5: Product Information

    Scope of delivery there is a risk of explosion from gas escaping. The Condens 7000 FP is delivered with a control unit, which is assigned ▶ Do not use wall mounted gas boilers in rooms where there is an when ordering, in 2 packaging units.

  • Page 6: Accessories

    Refer to the Technical product brochure for a complete overview of all 2.8.1 Product description available accessories. The main components of the Condens 7000 FP are: • Control unit The following accessories are available from your local sales office: • Boiler block •...
  • Page 7 Product Information 0010042180-001 Fig. 1 Condens 7000 FP, 350...500 kW main components (shown: right-hand version; cleaning cover and flow and return are located on the right) Boiler front panel (2-part) Air/gas ratio control valve Control unit CC83xx (optional) Regelgerät MX25 (optional)

  • Page 8: Dimensions And Specifications

    Dimensions and connections Condens 7000 FP MX25 8313 DN200: min. 80 DN160: min. 50 max. 7 Ø 250 ±0,8 0010042181-002 Fig. 2 Dimensions and connections for Condens 7000 FP, 350...500 kW (right and left-hand version; dimensions in mm) Condens 7000 FP – 6721846699 (2022/12)
  • Page 9 (DN20) (DN20) (DN20) (DN20) (DN20) (DN20) Height 1822 1822 1822 1822 1822 1822 83xx Height 1724 1724 1724 1724 1724 1724 MX25 1) Right-hand version 2) Left-hand version Table 3 Measurements and connection dimensions Condens 7000 FP – 6721846699 (2022/12)

  • Page 10: Regulations

    For guidance see the ICOM water treatment guide for commercial heating systems. • Make sure that the regional approvals required for the flue system and condensate connection to the public sewage system have been obtained. Condens 7000 FP – 6721846699 (2022/12)

  • Page 11: Quality Of The Heating Water

    The following applies for open-flue mode: ▶ Provide a combustion air opening that complies with the minimum size specified in table 4 1) In addition to this, country-specific and local regulations must be observed. Condens 7000 FP – 6721846699 (2022/12)

  • Page 12: Transporting The Boiler

    Remove the air hose to the top 0010036119-001 Fig. 3 Transport the floor standing boiler with pallet truck (example for illustration purposes) 0010041667-001 Pallet truck Fig. 5 Turn the inlet duct of the fan downwards Condens 7000 FP – 6721846699 (2022/12)
  • Page 13 11.7 for the Figs. 50 and 51. 6x screws ▶ Remove the 4 screws on the holding plate of the burner base Supporting plate for air hose (Fig. 10, [2]). Plug on differential pressure sensor Plug for solenoid valve Condens 7000 FP – 6721846699 (2022/12)

  • Page 14: Transporting The Boiler By Crane

    ▶ Remove the front and rear wooden crate (do not remove the upper wooden frame) ▶ Check the screws of the transport timber for a secure seat. 0010041669-001 Fig. 11 Remove the burner base Condens 7000 FP – 6721846699 (2022/12)

  • Page 15: Lifting The Floor Standing Boiler Off The Pallet

    4 – 6) and lift the boiler far enough so that the second partial pallet purposes) can be removed. ▶ Once the boiler is located at the final installation location, screw in the 4 boiler feet to the traverses on the side (Fig. 16). Condens 7000 FP – 6721846699 (2022/12)

  • Page 16: Transporting The Boiler On Rollers

    ▶ Position the pipes approx. 400 mm apart on the floor. purposes) ▶ Lift the floor standing boiler onto the lengths of pipe and carefully roll Transport rollers it to the boiler room. Transport timber Commercially-available transport rollers can be used. Condens 7000 FP – 6721846699 (2022/12)

  • Page 17: Installation

    0010012544-001 Fig. 19 Wall clearances at the installation location (right-hand version) DANGER Risk of fire through flammable materials or liquids. ▶ Never store flammable materials or liquids in the immediate vicinity of the boiler. Condens 7000 FP – 6721846699 (2022/12)

  • Page 18: Levelling The Floor Standing Boiler

    ▶ Attach the condensate hose to the condensate drain [5] and secure with hose clamps. ▶ Insert the condensate drain with condensate hose through the siphon bracket from behind and secure with the lock nut (not shown). Condens 7000 FP – 6721846699 (2022/12)

  • Page 19: Installing The Condensate Neutraliser

    ▶ Wear protective gloves. ▶ Fill the siphon below the flue outlet with roughly 3 litres of water. Centrocerin must be used as a lubricating paste when installing the flue system on the connector. Condens 7000 FP – 6721846699 (2022/12)
  • Page 20 The boiler must not be connected to any combined flue system with motorised motor systems (e.g. combined heat and power unit). 0010041192-001 Fig. 24 Mount the flue pipe vertically Flue gas routing upwards Flue pipe vertical (Fig. 24) 2x screws 2x nuts Condens 7000 FP – 6721846699 (2022/12)

  • Page 21: Connecting The Air Supply (For Balanced Flue Operation)

    To avoid condensate formation in the combustion air pipe (inside and Boiler size [kW] Connection outside), insulate the combustion air pipe. 350 – 500 DN100, PN6 standard flange EN1092 Table 8 Water connection sizes Condens 7000 FP – 6721846699 (2022/12)

  • Page 22: Connecting The Flow

    ▶ Observe the installation instructions for the accessories. ▶ Remove the drain valve mounted on the return (Fig. 27) ▶ Unscrew the 2” reduction. ▶ Mount accessory set with gasket (tightening torque: 35 Nm). Condens 7000 FP – 6721846699 (2022/12)

  • Page 23: Installing The Dhw Cylinder

    2x maximum pressure limiter Flat gasket Flat gasket For higher gas supply pressures than shown in table 10 ( page 29), Connector pipe 2” Bosch offers additional gas pressure governors as accessories. O-ring Flow connector Condens 7000 FP – 6721846699 (2022/12)

  • Page 24: Filling The Heating System And Checking For Leaks

    We recommend that the hood supply air cover [2] is installed before routing the electric cable. 6 720 615 876-59.2T Fig. 30 Pressure gauge for sealed systems Red needle Pressure gauge needle Green marking Condens 7000 FP – 6721846699 (2022/12)

  • Page 25: Electrical Connection

    ▶ Document connection and services in the inspection and ▶ Route all cables through the cable conduits to the control unit and maintenance record. connect them as shown in the connection diagram. Condens 7000 FP – 6721846699 (2022/12)

  • Page 26: Commissioning

    ▶ Burners contaminated during building work must be cleaned before commissioning. ▶ Inspect flue and combustion air pipe (with room sealed operation) and combustion air supply and ventilation openings ( Chapter 5.6, page 19). Condens 7000 FP – 6721846699 (2022/12)

  • Page 27: Checking For Leaks

    Chapter 17.6, page 72). If the boiler is to be replaced in existing systems: ▶ Consult gas suppliers to ensure that the nominal gas pressure according to table 10, page 29 is adhered to. Condens 7000 FP – 6721846699 (2022/12)

  • Page 28: Venting The Gas Line

    ▶ Check whether the flue gas connection complies with the applicable regulations ( Chapter 5.6, page 19). ▶ Have any faults rectified immediately. 0010042283-001 Fig. 34 Venting the gas line Test nipple for measuring the gas supply pressure and for venting Condens 7000 FP – 6721846699 (2022/12)

  • Page 29: Checking The Flue Gas Damper (Scope Of Delivery Of Flue Gas Cascade Set)

    To check the gas pressure regulator or the gas static pressure in the gas necessary, supply each boiler or consumer via a separate pressure installation: regulator. ▶ Shut down the burner from full load. Condens 7000 FP – 6721846699 (2022/12)

  • Page 30: Check And Adjust The Gas/Air Ratio

    Commissioning ▶ Identify and eliminate the fault. For higher supply pressures than shown in table 10, Bosch offers additional gas pressure regulators as accessories. 7.10 Check and adjust the gas/air ratio The deviation between the measures CO value in full load and partial load must not be greater than 0.5% CO...

  • Page 31: Check The Co2 Adjustment At Full Load ? ( At Least 70%)

    7.14.1 Checking the ionisation current (flame current) ▶ To test the ionisation current, observe the corresponding technical documentation for the control unit. 1) (lf) = air-free Condens 7000 FP – 6721846699 (2022/12)

  • Page 32: Checking Tightness During Operation

    ▶ If necessary, install the top flue gas cover [8]. ▶ First hook the side panels [6] at the rear into the bottom rail, lift slightly and hook in at the top. With the rear fold, place over the rear panel. Condens 7000 FP – 6721846699 (2022/12)

  • Page 33: 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 7000 FP – 6721846699 (2022/12)

  • Page 34: Inspection And Maintenance

    ▶ Remove the fixing screws on the top of the floor standing boiler and remove the upper boiler front panel. ▶ To do this, slightly raise the lower boiler front panel and remove it towards the front. Condens 7000 FP – 6721846699 (2022/12)

  • Page 35: Detailed Overview Of Boiler Components

    -white gas line) [13] Valve check system [14] Air/gas ratio control valve [15] Relay box [16] Test cable for gas outlet pressure (transparent gas line) [17] Compensation line (blue) X View without gas pipe Condens 7000 FP – 6721846699 (2022/12)
  • Page 36 Fig. 42 Detail overview of the components, side view right side (shown: without combustion air inlet hose, gas pipe and thermal insulation 500 kW rating) Gas pressure test nipple with temperature switch Flow temperature sensor Flue gas pressure limiter Water pressure sensor Return temperature sensor Condens 7000 FP – 6721846699 (2022/12)

  • Page 37: General Work

    15 x 1 18 x 1 22 x 1 28 x 1.5 35 x 1.5 45 x 1.5 – – – Table 13 Pipework volume (V ) in litres, subject to pipe length and diameter pipe Condens 7000 FP – 6721846699 (2022/12)

  • Page 38: Carrying Out Gas Tightness Test

    (V test ▶ Remove the hose. ▶ After completing the measurements, retighten the locking screw of the test nipple. ▶ Check tightness of the test nipples. Condens 7000 FP – 6721846699 (2022/12)

  • Page 39: Checking The Heating System Operating Pressure

    ▶ Observe all country-specific regulations and standards regarding the prevention of drinking water contamination. ▶ Water should be topped up via WRAS approved filling method. ▶ Vent the heating system via the radiator air vent valves. ▶ Check the operating pressure again. Condens 7000 FP – 6721846699 (2022/12)
  • Page 40 ▶ Remove the hoses on the differential pressure sensor (Fig. 52). Fig. 50 Pull the burner back Mixture manifold ▶ Install the insertion aid. When delivered, the insertion aid is attached on the upper cover plate (Fig. 51). Condens 7000 FP – 6721846699 (2022/12)
  • Page 41 ▶ Remove the 4 screws on the flange of the gas pipe (Fig. 52). ▶ Remove the O-ring on the guide pins of the burner sled (Fig. 52). ▶ Unplug the plug on the fan (Fig. 53). Condens 7000 FP – 6721846699 (2022/12)

  • Page 42: Burner In Maintenance Position

    Ventilation air collector Temperature switch / burner controller connecting cable Application of lubricating paste on the guide pins facilitates pulling the burner forwards. 0010046217-001 Fig. 55 Undo the plug, hoses and gas supply pipe Condens 7000 FP – 6721846699 (2022/12)

  • Page 43: Cleaning The Burner And Heat Exchanger

    0010012553-001 Fig. 58 Removing the siphon Siphon Condensation catch pan outlet ▶ Remove the screws from the cover of the condensation catch pan. 0010036923-001 Fig. 57 Pull the burner back Mixture manifold Condens 7000 FP – 6721846699 (2022/12)
  • Page 44 (service side), which depends on whether the boiler is a right or left- hand version. ▶ Remove the clips [1] on the thermal insulation. ▶ Remove the thermal insulation [2] from the heat exchanger. 0010013911-001 Fig. 60 View of condensation catch pan without cover Dirt trap Condens 7000 FP – 6721846699 (2022/12)
  • Page 45 ▶ To avoid injury, wear protective gloves when cleaning the boiler using on in pairs according to the tightening diagram. cleaning blades (accessories). ▶ Clean the heat exchanger hot gas flues horizontally and diagonally using the cleaning blade. Condens 7000 FP – 6721846699 (2022/12)

  • Page 46: Inspecting The Burner Electrodes

    ▶ Replace the electrode. ▶ Check the gaps between the electrodes and compare them with those shown in Fig. 68. 0010012529-001 Fig. 67 Wet cleaning the heat exchanger Condens 7000 FP – 6721846699 (2022/12)

  • Page 47: Testing The Differential Pressure Switch

    ▶ Connect the hose lines as shown in the connection diagram ratio control valve. (Chapterl 17.4.3, page 71). ▶ Remove filter cassette [1] and insert a new one. ▶ Make sure the hose lines are not buckled or trapped. Condens 7000 FP – 6721846699 (2022/12)

  • Page 48: Removing The Fan

    ▶ Replace components relevant for safety in case of increased wear or when reaching the service life at the latest. ▶ For replacement, use only new and undamaged original spare parts. Condens 7000 FP – 6721846699 (2022/12)

  • Page 49: Refitting Detached Parts

    ▶ Use only lubricating paste which has been released by the manufacturer of the flue gas system. DANGER Danger to life through escaping gases! ▶ Always replace the electrode block gasket when replacing electrodes. ▶ Generally, replace damaged gaskets or ones that appear aged. Condens 7000 FP – 6721846699 (2022/12)

  • Page 50: Fitting The Fan

    In doing so, take care that the gasket in the slide is not damaged and check the correct fit in the groove (if necessary, check the correct fit using a torch). ▶ Screw in the screws on the mixture manifold / slide (maximum tightening torque: 15,5±10%). Condens 7000 FP – 6721846699 (2022/12)

  • Page 51: Fitting The Gas Line To The Gas Valve

    2. 2. 2. OFF 1000 1000 200m 200m 200m 200m 1. 1. 1. 200K 20K 1K 2. 2. 2. 0010048145-001 Fig. 78 Measure the ionisation current (flame current) Ionisation cable plug Condens 7000 FP – 6721846699 (2022/12)

  • Page 52: Completing Inspection And Maintenance

    In emergency operation, faults can only be cleared via the reset button carrying components. on the burner control unit. Resetting is only possible if a locking fault is present. ▶ Press the reset button to clear the fault. Condens 7000 FP – 6721846699 (2022/12)

  • Page 53: Recognising The Operating Condition And Clearing

    Observe corresponding technical documentation for the control unit and user interface. 0010041073-001 Fig. 80 Pressure monitor position; view from the right and left side Pressure switch Combustion chamber test cable (DN8: colour black) Connection line with plug Condens 7000 FP – 6721846699 (2022/12)

  • Page 54: Calling Up The Fault History

    Calling up the fault history The fault history is called up in different ways, depending on the control unit used or the user interface installed. Observe corresponding technical documentation for the control unit and user interface. Condens 7000 FP – 6721846699 (2022/12)

  • Page 55: Operating And Fault Displays

    The control unit sets the heat – If external blocking is not required, externally via the terminal requirement to the burner a jumper must be fitted to the EV control unit to 0. terminals. Table 16 Operating codes Condens 7000 FP – 6721846699 (2022/12)

  • Page 56: Service Displays

    (ISTB) for the flow the intelligent high-limit temperature sensor/high-limit safety temperature for safety cut-out. the flow of 140 °C and ▶ Replace ignition/monitoring an ionisation current is electrode. detected or the solenoid valves are open. Condens 7000 FP – 6721846699 (2022/12)
  • Page 57 ▶ Reconnect any loose plugs. Check sensor readings against table. temperature sensor. ▶ Replace the temperature sensor, Check the voltage values at the if there are any deviations from sensor against the table. the table. Condens 7000 FP – 6721846699 (2022/12)
  • Page 58 Check whether the safety chain (terminal 17/18 control unit) has triggered. Condens 7000 FP – 6721846699 (2022/12)
  • Page 59 Check the 230 V power supply to the ▶ Reset the burner control unit at sequences (power was switched off 5 control unit. the reset button. supply times during the burner ▶ Rectify power supply problem. disconnection start. during burner start). Condens 7000 FP – 6721846699 (2022/12)
  • Page 60 If it is, replace the filter. ▶ Test the differential pressure switch (Chapter 16, page 65). ▶ Replace the gas filter if necessary. ▶ Replace the air/gas ratio control valve if necessary. Condens 7000 FP – 6721846699 (2022/12)
  • Page 61 ▶ If the connecting lead, contacts circuit in the sensor Check resistance values of and resistance values are all OK, lead. temperature sensor against table. replace the control unit. Temperature sensor is defective Condens 7000 FP – 6721846699 (2022/12)
  • Page 62 ▶ If the connecting lead, contacts and resistance values are all OK, Check resistance values of replace the burner control unit. temperature sensor against table. Burner control unit defective. Condens 7000 FP – 6721846699 (2022/12)
  • Page 63 Check sensor readings against table. ▶ Replace temperature sensor if there are discrepancies. Burner control unit defective. ▶ If the connecting lead, contacts and resistance values are all OK, replace the burner control unit. Condens 7000 FP – 6721846699 (2022/12)

  • Page 64: Status Indicator Of The Burner Control Unit

    ........................Off The burner control unit is not in operation Table 19 Display of the operating condition of the burner via the lighting of the reset button. Permanently   GREEN Condens 7000 FP – 6721846699 (2022/12)

  • Page 65: Check Temperature Switch

    If no value, or a resistance of > 1 ohm, is displayed ( Fig. 87), 200m 200m replace the differential pressure switch. 200K 20K 1K 0010037281-001 Fig. 84 Measure the electrical resistance across the contacts of the temperature switch (temperature switch not ok) Condens 7000 FP – 6721846699 (2022/12)

  • Page 66: Testing The Differential Pressure Switch For Continuity

    ▶ Following replacement, plug in (PWM signal) [1] plug at fan. > 1 OFF 1000 1000 200m 200m 200m 200m 200K 20K 1K 0010037305-001 Fig. 89 Measure the electrical resistance across the contacts of the differential pressure switch (differential pressure switch not Condens 7000 FP – 6721846699 (2022/12)

  • Page 67: Appendix

    Pressure classification to be used for connecting piece in accordance with EN 1443 P1 with additional mechanical impact stability up to 5000 Pa Condensate resistance classification to be used for flue system in accordance with EN 1443 Condens 7000 FP – 6721846699 (2022/12)
  • Page 68 10.38 kWh/m 9.79 kWh/m 10.69 kWh/m [kW] 31.8 36.9 36.9 36.1 36.3 42.2 42.2 41.3 45.4 52.8 52.7 51.6 Table 21 Gas throughput (relative to 15 °C gas temperature and 1013 mbar air pressure) Condens 7000 FP – 6721846699 (2022/12)

  • Page 69: Sensor Curves

    Table 23 Resistance values 2 similar temperature sensors (twin sensors), which are installed in a single sensor casing, are used as boiler water temperature sensors. All temperature sensors in the boiler have the same sensor curve. Condens 7000 FP – 6721846699 (2022/12)

  • Page 70: Hydraulic Resistance

    Boiler water temperature sensor [10] Temperature switch [11] Valve check system (closed during operation) [12] Differential pressure switch (closed during operation) [13] Flue gas pressure limiter (always closed) [14] Control unit [15] Burner control unit Condens 7000 FP – 6721846699 (2022/12)

  • Page 71: Setting

    – % from your gas supplier. 2 max If the specified values for CO and CO are listed in the following 2 max table, the corresponding O value can be read off directly from the table. Condens 7000 FP – 6721846699 (2022/12)

  • Page 72: System Commissioning Report

    Check tightness of gas line. • Venting the gas line. Establish operating pressure on water side. Check air intake and outlet openings and flue gas connection. 28 Check device equipment. Starting up the control unit and the burner. Condens 7000 FP – 6721846699 (2022/12)

  • Page 73: Inspection And Maintenance Protocols

    (observe the manufacturer's instructions and the details in Concentration:________% Concentration:_________% the operator's log). Check the heating system water pressure. • Pre-charge pressure of the expansion vessel ( expansion vessel installation instructions) Condens 7000 FP – 6721846699 (2022/12)
  • Page 74 Check that the control unit is set correctly in – line with demand (see documents for the control unit). Final check of servicing work – Document replacement of components: – Which components were replaced? Condens 7000 FP – 6721846699 (2022/12)
  • Page 75 _________% _______% _______________ _______________ _______________ _______________ _______________ _______________ _______________ _______________ ppm | mg/kWh ppm | mg/kWh ppm | mg/kWh ppm | mg/kWh ppm | mg/kWh ppm | mg/kWh ppm | mg/kWh ppm | mg/kWh Condens 7000 FP – 6721846699 (2022/12)
  • Page 76 Clean the condensation catch pan. Replace the mixture manifold gasket (O-ring). Carry out a function check. Replace components according to the service life. Confirmation that maintenance has been correctly carried out. Company stamp/signature Table 28 Condens 7000 FP – 6721846699 (2022/12)

  • Page 77: Data Protection Notice

    You can contact our Data Protection Officer under: Data Protection Officer, Information Security and Privacy (C/ISP), Robert Bosch GmbH, Postfach 30 02 20, 70442 Stuttgart, GERMANY. You have the right to object, on grounds relating to your particular...
  • Page 80 Bosch Thermotechnik GmbH GB Importer: Junkersstrasse 20-24 Bosch Thermotechnology Ltd. 73249 Wernau, Germany Cotswold Way, Warndon www.bosch-thermotechnology.com Worcester WR4 9SW, United Kingdom...

This manual is also suitable for:

Gc7000fp 350Gc7000fp 400Gc7000fp 500

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