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Bosch Condens 7000 F Installation And Maintenance Instructions For The Contractor
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Bosch Condens 7000 F Installation And Maintenance Instructions For The Contractor

Gas-fired condensing boiler
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Installation and maintenance instructions for the contractor
Gas-fired condensing boiler
Condens 7000 F
GC7000F 75...300

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Summary of Contents for Bosch Condens 7000 F

  • Page 1 Installation and maintenance instructions for the contractor Gas-fired condensing boiler Condens 7000 F GC7000F 75...300...

  • Page 2: Table Of Contents

    7.9.2 Carrying out a flue gas test ..... . 27 2.9.1 Dimensions and connections Condens 7000 F ..8 7.10...

  • Page 3: Explanation Of Symbols And Safety Instructions

    Inspection and maintenance protocols ... . .64 ▶ Observe the safety instructions and warnings. ▶ Follow national and regional regulations, technical regulations and guidelines. ▶ Record all work carried out. Condens 7000 F – 6720871560 (2019/11)
  • Page 4 (volt free checkback signal to the boiler controller via failsafe limit switch). Provide for control of supply air flaps. ▶ Make sure the boiler installation location is frost- proof. Condens 7000 F – 6720871560 (2019/11)

  • Page 5: Product Information

    Scope of delivery The Condens 7000 F is delivered with a control unit, which is assigned ▶ The heating system must be installed and operated when ordering, in 2 packaging units.

  • Page 6: Product Overview

    For this, it makes the following functions available, including: 0010014182-001 Fig. 1 Condens 7000 F, 75...100 kW main components (shown: right-hand version; cleaning cover and flow and return are located on the right) Boiler front panel (2-part) Boiler casing Gas valve...
  • Page 7 Product Information 0010014184-001 Fig. 2 Condens 7000 F, 150...300 kW main components (shown: right-hand version; cleaning cover and flow and return are located on the right) Boiler front panel (2-part) Gas valve Gas burner with burner rod Control unit CC 8313 (optional)

  • Page 8: Dimensions And Specifications

    Product Information Dimensions and specifications 2.9.1 Dimensions and connections Condens 7000 F 8313 MX25 0010014185-002 Fig. 3 Dimensions and connections for Condens 7000 F, 75...100 kW (right and left-hand version; dimensions in mm) Condens 7000 F – 6720871560 (2019/11)
  • Page 9 MX25 DN200: min. 80 DN160: min. 50 max. 7 Ø 200 ±0,8 Ø 160 ±0,8 0010014186-002 Fig. 4 Dimensions and connections for Condens 7000 F, 150...300 kW (right and left-hand version; dimensions in mm) Condens 7000 F – 6720871560 (2019/11)
  • Page 10 1624 1624 1624 1624 1624 1624 1624 1624 1624 1624 1624 MX25 Height H 1470 1470 1470 1470 1470 1470 1470 1470 1470 1470 1470 1470 Height H Height H – – – – Condens 7000 F – 6720871560 (2019/11)

  • Page 11: Regulations

    ▶ Make sure that official requirements are complied with. ▶ Please note that in certain regions approvals may be required for the flue system and the connection of the condensate outlet to the public sewerage system. Condens 7000 F – 6720871560 (2019/11)

  • Page 12: Installation Location

    (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds). ▶ Keep the combustion air supply free of dust or use the “air filter” accessory set. 1) In addition to this, country-specific and local regulations must be observed. Condens 7000 F – 6720871560 (2019/11)

  • Page 13: Transporting The Boiler

    0010013902-001 Fig. 5 Guide of crane lifting gear on the frame 0010012540-001 Fig. 6 Transporting the boiler with crane (viewed from front left) Condens 7000 F – 6720871560 (2019/11)

  • Page 14: Lifting The Boiler Off The Pallet

    You can also use commercially available transport rollers. 0010013512-001 Fig. 9 Transporting the boiler on a furniture roller If the boiler is not to be brought into operation: ▶ Protect boiler from contamination. Dispose of packaging in an environmentally responsible manner. Condens 7000 F – 6720871560 (2019/11)

  • Page 15: Installation

    Fig. 11 Wall clearances at the installation location (left-hand version) Wall clearance [mm] Dimension minimum recommended 1000 – – 1000 1) This clearance depends on the flue system installed. Table 5 Recommended and minimum wall clearances Condens 7000 F – 6720871560 (2019/11)

  • Page 16: Levelling The Boiler

    ▶ Fill the siphon below the flue outlet with roughly 3 litres of water. 0010012545-001 Fig. 13 Installing the condensate hose 0010012543-001 Condensation catch pan Fig. 12 Levelling the boiler Connecting the condensate hose to the siphon connector Condens 7000 F – 6720871560 (2019/11)

  • Page 17: Establishing The Flue Gas Connection

    With boiler rating 150-300 kW: ▶ Remove factory-installed 90° flue bend. ▶ Plug the straight pipe section (accessory) onto the connector on the condensation catch pan and install the flue mechanically uncompressed. Condens 7000 F – 6720871560 (2019/11)

  • Page 18: Connecting The Air Supply (For Room Sealed Operation)

    2" female thread (DN50) ▶ In cascade arrangements, ensure that the boiler is equipped with a PN6 standard flange EN1092 (DN50) separate combustion air pipe. 200-300 PN6 standard flange EN1092 (DN65) Table 7 Water connection dimensions Condens 7000 F – 6720871560 (2019/11)

  • Page 19: Connecting The Flow

    ▶ Seal the pressure relief valve at the threaded connection of the heating flow using suitable sealants or supplied gaskets (Fig. 17). ▶ Fit the discharge pipe to the respective pressure relief valve according to local regulations. Condens 7000 F – 6720871560 (2019/11)
  • Page 20 Hexagon bolts Flat gasket Hexagon nuts O ring Discharge pipe connection 0010013914-001 Fig. 18 Safety set, 3 bar (illustration shows alternative installation setup) Manifold with taps and thermal insulation Twin nipple Extension Flow temperature sensor Condens 7000 F – 6720871560 (2019/11)

  • Page 21: Installing A Dhw Cylinder

    ▶ Once the heating system has been tested and no leaks have been found, set the correct operating pressure. ▶ Put all non-return valves at the operating position. ▶ Mark the minimum and maximum pressure on the pressure gauge when the system is cold. Condens 7000 F – 6720871560 (2019/11)

  • Page 22: Providing The Fuel Supply

    Fig. 22 Gas connection Expansion joint Gas isolator (here with thermally activated shut-off device) Pipe clip For higher gas supply pressures than shown in table 10, ( page 28), Bosch offers additional gas pressure governors as accessories. Condens 7000 F – 6720871560 (2019/11)

  • Page 23: Electrical Connection

    ▶ To install the control unit, observe the corresponding technical documentation. ▶ When making the electrical connections, refer to the connection diagrams for the individual devices and components (Chapter 17.4, page 59). Condens 7000 F – 6720871560 (2019/11)

  • Page 24: Commissioning

    The agent must be approved for gas tightness operating pressure of at least 1 bar. testing. ▶ Confirm in the commissioning report that the tightness test has been carried out. Condens 7000 F – 6720871560 (2019/11)

  • Page 25: Recording Gas Parameters

    [2]. 0010012477-002 Fig. 27 Updating the data plate If the connection is subject to mechanical stress, the gas pipe can be Boiler data plate removed to make disassembly easier. Label Condens 7000 F – 6720871560 (2019/11)

  • Page 26: Lpg Conversion

    100 kW Ø 6.80 boiler rating 150 kW Ø 8.50 200 kW Ø 10.30 250 kW Ø 11.30 300 kW Ø 12.10 Table 9 Gas characteristics and required gas flow restrictors (LPG) Condens 7000 F – 6720871560 (2019/11)

  • Page 27: Supply Air And Flue Gas Connection

    ▶ Wait 10-20 seconds and then measure the resulting gas supply pressure/static pressure at the test nipple for the gas supply pressure/static pressure. 0010030369-001 Fig. 29 Setting pin on the butterfly valve Position 1: damper closed Position 2: damper open Condens 7000 F – 6720871560 (2019/11)

  • Page 28: Checking The Gas/Air Ratio

    ▶ Remove the test hose. ▶ Carefully tighten the locking screw on the test nipple for gas supply pressure. For higher supply pressures than shown in tab. 10 Bosch offers 1)2) Country Gas group Supply pressure [mbar] additional gas pressure governors as accessories.

  • Page 29: Concluding The Flue Gas Test

    ▶ To test the ionisation current, observe the corresponding technical documentation for the control unit. 0010012499-001 Fig. 30 Recording measurements (boiler rating 150-300 kW) Test point at the condensation catch pan Flue gas temperature limiter (optional) Condens 7000 F – 6720871560 (2019/11)

  • Page 30: Checking Tightness During Operation

    ▶ Turn the unlocking screws on the top of the boiler clockwise using a suitable tool and lock the front panel [3]. ▶ Affix the clear pocket containing the technical documentation to the side panel of the boiler in a clearly visible location. Condens 7000 F – 6720871560 (2019/11)

  • Page 31: Environmental Protection And Disposal

    Environmental protection is a fundamental corporate strategy of the Bosch Group. The quality of our products, their economy and Offer your customer an annual maintenance and inspection contract, environmental safety are all of equal importance to us and all which is based on actual requirements.

  • Page 32: Detailed Overview Of Boiler Components

    [15] Burner control unit [16] EMC butterfly valve [17] Compensation line (blue) [18] Gas pipe [19] Offset setting, sealed [20] Air/gas ratio control valve [21] Valve check system [22] Ignition transformer [23] Gas pipe Condens 7000 F – 6720871560 (2019/11)

  • Page 33: 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 F – 6720871560 (2019/11)

  • Page 34: Carrying Out Gas Tightness Test

    ▶ Check tightness of the test nipples. If the read-off point for the test volume (Vtest) and pressure drop per minute lies within the "Train leaks" range (see Read-off example), you must carry out the test described below. Condens 7000 F – 6720871560 (2019/11)

  • Page 35: 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 F – 6720871560 (2019/11)
  • Page 36 ▶ Undo the union nut ( Fig. 41, [1]) of the gas supply pipe ( Fig. 41, [2]). 0010012555-001 Fig. 42 Air supply pipe Ventilation air collector Hinged pipe clip Supply air hose ▶ Remove 4 fixing nuts [1] on the flange of the mixture manifold. Condens 7000 F – 6720871560 (2019/11)
  • Page 37 Burner holder (with boiler rating 200-300 kW) Retaining cable (with boiler rating 200-300 kW) Fastening of retaining cable (with boiler rating 200-300 kW) 0010013925-001 Fig. 44 Burner in the service position (right-hand installation). Fixing nuts Factory-installed screws Condens 7000 F – 6720871560 (2019/11)

  • Page 38: Cleaning The Burner And Heat Exchanger

    ▶ Remove the cover. 0010013912-001 Fig. 50 Dirt trap following removal Dirt trap 0010012528-001 Fig. 48 Removing the cover of the condensation catch pan (illustration shows boiler size 150-300 kW) Cover of condensation catch pan Condens 7000 F – 6720871560 (2019/11)
  • Page 39 ▶ Screw the cleaning cover back on or wet clean the heat exchanger. ▶ Make sure the covers and gaskets are positioned correctly. ▶ Replace faulty gaskets, observe replacement intervals. 0010012575-001 Fig. 52 Removing the cleaning covers Cleaning cover Condens 7000 F – 6720871560 (2019/11)

  • Page 40: Inspecting The Burner Electrodes

    ▶ Observe information in Chapter 11.11, page 41 onwards. 11.10 Testing the differential pressure switch The differential pressure switch must be checked to ensure it is working correctly each time maintenance or an inspection is carried out (Chapter 16, page 54). Condens 7000 F – 6720871560 (2019/11)

  • Page 41: Replacing Components

    (boiler rating 75-100 kW) Hexagon nuts (4x) on the mixture manifold Electrical connections on the fan, boiler rating 75-100 kW Union nut on venturi, boiler rating 75-100 kW Plug-in connector, boiler rating 75-300 kW Condens 7000 F – 6720871560 (2019/11)

  • Page 42: Replacing Components According To The Service

    We recommend replacing the electrode block as part of annual maintenance. 0010012558-001 Fig. 61 Removing the fan (boiler rating 150-300 kW) Hexagon nuts (4x) on the venturi Hexagon nuts (4x) on the mixture manifold Condens 7000 F – 6720871560 (2019/11)

  • Page 43: Refitting Detached Parts

    ▶ Secure the flange of the gas connection again to the gas valve using 4 screws. 11.12.2 Refit the combustion air connector. ▶ With room sealed operation, plug the combustion air hose onto the adapter and secure with the hinged pipe clip (Chapter 5.7, page 18). Condens 7000 F – 6720871560 (2019/11)

  • Page 44: Emergency Operation

    6 720 801 303-02.1T Observe corresponding technical documentation for the control unit and Fig. 62 Clearing a fault on the burner control unit user interface. Reset button Condens 7000 F – 6720871560 (2019/11)

  • Page 45: 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 15 Operating codes Condens 7000 F – 6720871560 (2019/11)

  • Page 46: Service Displays

    (ISTB) for the flow intelligent high-limit safety temperature sensor/high-limit safety temperature for the flow of cut-out. 140 °C, and an ionisation ▶ Replace ignition/monitoring current is detected or the electrode. solenoid valves are open. Condens 7000 F – 6720871560 (2019/11)
  • Page 47 ▶ Reconnect any loose plugs. sensor. water temperature sensor. ▶ Replace the temperature sensor, if Check sensor readings against table. there are any deviations from the Check the voltage values at the table. sensor against the table. Condens 7000 F – 6720871560 (2019/11)
  • Page 48 Check whether the safety chain (terminal 17/18 control unit) has triggered. Condens 7000 F – 6720871560 (2019/11)
  • Page 49 Check the 230 V power supply to the ▶ Reset the burner control unit at the sequences (power switched off 5 times during control unit. reset button. supply the burner start. ▶ Rectify power supply problem. disconnection during burner start). Condens 7000 F – 6720871560 (2019/11)
  • Page 50 ▶ Check diverter module. Power cable damaged or faulty. ▶ Check the plug-in connection. ▶ Replace power cable if necessary. ▶ Replace external component if necessary. Faulty external component. Condens 7000 F – 6720871560 (2019/11)
  • Page 51 569 Water pressure Water pressure sensor Check connecting cable running to ▶ Rectify any short-circuits. sensor fault short-circuit (voltage water pressure sensor. ▶ Replace water pressure sensor. (short-circuit). < 0.5 V). Check water pressure sensor. Condens 7000 F – 6720871560 (2019/11)
  • Page 52 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 F – 6720871560 (2019/11)

  • Page 53: Status Indicator Of The Burner Control Unit

    ........................Off The burner control unit is not in operation Table 18 Display of the operating condition of the burner via the lighting of the reset button. Permanently   GREEN Condens 7000 F – 6720871560 (2019/11)

  • Page 54: Check Temperature Switch

    Fig. 67 Pull off plug (PWM signal) at fan (boiler rating 75-100 kW) PWM signal plug, boiler rating 75-100 kW 0010014360-001 Fig. 65 Measure the electrical resistance across the contacts of the temperature switch (temperature switch not ok) Condens 7000 F – 6720871560 (2019/11)

  • Page 55: Test The Differential Pressure Switch For Continuity At Zero Pressure

    ▶ Switch off the boiler at the control unit. ▶ Undo the union nut of the gas supply pipe at the flange on the air/gas ratio control valve (Fig. 41, page 36). Condens 7000 F – 6720871560 (2019/11)

  • Page 56: Appendix

    1 is at full load (positive pressure cascade) Flue system Temperature classification to be used min. T120 min. T120 min. T120 min. T120 min. T120 min. T120 for flue system in accordance with EN 1443 Condens 7000 F – 6720871560 (2019/11)
  • Page 57 (Chapter 7.11, page 28). 5) Satisfies NO class 6 in accordance with EN15502-1. Table 19 Technical Data Condens 7000 F – 6720871560 (2019/11)
  • Page 58 Table 21 Country-specific gas categories If the boiler is to be replaced in existing systems: ▶ Consult gas suppliers to ensure that the nominal gas pressure according to table , page 28 is adhered to. Condens 7000 F – 6720871560 (2019/11)

  • Page 59: Sensor Curves

    Table 22 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 F – 6720871560 (2019/11)

  • Page 60: Burner Control Unit

    [14] Control unit [15] Burner control unit With the boiler ratings 75-150 kW an interference suppression coil is connected in series between the power supply of the burner control unit and power supply of the fan. Condens 7000 F – 6720871560 (2019/11)

  • Page 61: Diagrammatic Representation Of Supply Air/Flue Gas Monitor And Gas Tightness

    Flue gas pressure limiter (must be manually unlocked) ] Compensation line connection (blue) ] Test cable connection for gas outlet pressure (white) ] Pressure compensation line komp ] Gas outlet pressure Pressure in flue system Flue gas Condens 7000 F – 6720871560 (2019/11)

  • Page 62: Conversion Of Vol.% Co2 Into Vol.% O2 For Burner Setting

    CO value (with the read-off example) 2max Read-off calculation: Default value: CO = 9.2 vol. – % Nominal value: CO = 12.0 vol. – % 2max Result: O = 4.9 vol. – % Condens 7000 F – 6720871560 (2019/11)

  • Page 63: System Commissioning Report

    • With LPG: measure upstream of the additional pressure regulator (only 75/100 kW) • With LPG: measure downstream of the additional pressure Full load: Partial regulator (only 75/100 kW) _________mbar load:_________ mbar Condens 7000 F – 6720871560 (2019/11)

  • Page 64: Inspection And Maintenance Protocols

    • With LPG: measure downstream of the additional pressure regulator (only 75/100 kW) Check the supply and extract air apertures are unobstructed and clean. Check tightness of flue gas connection and flue gas routing. • Check flue gas damper Condens 7000 F – 6720871560 (2019/11)
  • Page 65 If any condition requiring maintenance is identified in the course of the inspection, this work must be carried out as required. The requirements for replacement of gaskets are detailed in Chapter 11.11.3, page 42. Condens 7000 F – 6720871560 (2019/11)
  • Page 66 ________ °C ________ °C ________% _________% _________% _______% ________% _________% _________% _________% _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm _______ppm ________μA ________μA _______μA ________μA ________μA ________μA ________μA _______μA Table 26 Inspection and maintenance record Condens 7000 F – 6720871560 (2019/11)
  • Page 67 Confirmation that maintenance has been correctly carried out. Company stamp/signature Table 27 Date: ____________________ Date: ____________________ Date: ____________________ Date: ____________________ Date: ____________________ Company stamp/signature Company stamp/signature Company stamp/signature Company stamp/signature Company stamp/signature Table 28 Condens 7000 F – 6720871560 (2019/11)
  • Page 68 Bosch Thermotechnik GmbH Sophienstrasse 30-32 D-35576 Wetzlar www.bosch-industrial.com...

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Condens 7000 f seriesCondens gc7000f 75-3Condens gc7000f 100-3Condens gc7000f 150-4Condens gc7000f 200-5Condens gc7000f 250-6 ... Show all

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