BOSCH Condens 7000 WP Wall Mounted Gas Condensing Boilers Instruction Manual

Condens 7000 WP Wall Mounted Gas Condensing Boilers

Installation and Maintenance Instructions
Wall mounted gas condensing boilers Condens 7000 WP
GC7000WP 50 23, GC7000WP 65 23, GC7000WP 85 23, GC7000WP 100 23

6721841195 (2022/01) UK/IE

Table of contents

Table of contents

1 Explanation of symbols and safety instructions . . . . . . . . . . . 3 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 3

2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Product data for energy consumption . . . . . . . . . . . . . . 4 2.3 About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.4 Appliance types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.5 Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.6 Conversion of gas type. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.7 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.8 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.9 Pump test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.10 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.11 product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.12 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.13 Minimum clearance from walls . . . . . . . . . . . . . . . . . . . . 9 2.14 Flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . 9 2.15 Opening and closing the front panel of the
appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 Notes on installation and operation . . . . . . . . . . . . . . . 10 3.2 Regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Flue gas routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Preconditions for installation. . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.1 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.2 Important notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.3 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 5.3.1 Water conditioning and treatment . . . . . . . . . . . . . . . . 12 5.4 Maximum flow temperature. . . . . . . . . . . . . . . . . . . . . . 12

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.1 6.2 6.3 6.4 6.5 6.5.1 6.5.2 6.6

Unpacking the floor standing boiler . . . . . . . . . . . . . . . 12 Checking the gas type . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Setting up the floor standing boiler. . . . . . . . . . . . . . . . 12 Connecting on the heating and gas side . . . . . . . . . . . . 14 Mounting the connection set (accessories) . . . . . . . . . 14 Installing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mounting the connection set . . . . . . . . . . . . . . . . . . . . . 15 Mounting the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.7 Connecting the condensate pipe . . . . . . . . . . . . . . . . . 16

6.8 Connecting heating pipes (without connection set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.8.1 Connecting the gas valve . . . . . . . . . . . . . . . . . . . . . . . . 17

6.8.2 6.9 6.10 6.11

Installing the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installing the low loss header . . . . . . . . . . . . . . . . . . . . 17 Connecting an expansion vessel . . . . . . . . . . . . . . . . . . 18 Installing the insulation (accessory) . . . . . . . . . . . . . . . 18

7 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7.1 Handling printed circuit boards. . . . . . . . . . . . . . . . . . . 18 7.2 Opening the top cover . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.3 Overview of plug-in strip . . . . . . . . . . . . . . . . . . . . . . . . 19 7.4 Connecting electrical components . . . . . . . . . . . . . . . . 20 7.5 Connecting the pump of the pump assembly. . . . . . . . 20 7.6 Connecting the 3-way valve 230 V (accessory). . . . . . 21 7.7 Mounting the function module (accessory) . . . . . . . . . 21 7.8 Fitting the plug (if not preassembled) . . . . . . . . . . . . . 21

8 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.1 Commissioning the floor standing boiler . . . . . . . . . . . 22 8.2 Setting the parameters . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.3 Setting options for air/gas ratio control valve . . . . . . . 23 8.4 Measuring the gas standing pressure (static) . . . . . . . 23 8.5 Measuring the gas working pressure (dynamic) . . . . . 23 8.6 Measuring of CO2 and CO (full load) . . . . . . . . . . . . . . 24 8.7 Measuring the gas/air ratio (minimum load) . . . . . . . . 24 8.8 Reading off the ionisation current . . . . . . . . . . . . . . . . 24 8.9 Check the (flue) gas tightness . . . . . . . . . . . . . . . . . . . 25 8.10 Check the function of the floor standing boiler . . . . . . 25 8.11 Completion work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 8.12 Instructing the operator . . . . . . . . . . . . . . . . . . . . . . . . 25

9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9.1 Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 25

9.2 9.3 9.4 9.4.1 9.4.2 9.4.3

Switching on the device . . . . . . . . . . . . . . . . . . . . . . . . 25 Siphon filling program . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Settings in the service menu . . . . . . . . . . . . . . . . . . . . . 26 Operating the service menu . . . . . . . . . . . . . . . . . . . . . 26 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

10 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 32 10.1 Important notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 10.2 General work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 10.3 Remove the gas-air unit . . . . . . . . . . . . . . . . . . . . . . . . . 33 10.4 Clean the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 10.5 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 34 10.6 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 10.7 Cleaning the condensation catch pan . . . . . . . . . . . . . 35 10.8 Resetting the Maintenance type . . . . . . . . . . . . . . . . . . 35 10.9 Measuring the gas pressure . . . . . . . . . . . . . . . . . . . . . 35 10.10 Measuring of CO and CO2 . . . . . . . . . . . . . . . . . . . . . . . 35 10.11 Measuring the gas/air ratio . . . . . . . . . . . . . . . . . . . . . . 35 10.12 Measuring the ionisation current . . . . . . . . . . . . . . . . . 35 10.13 Check the flue gas backflow preventer. . . . . . . . . . . . . 35 10.14 Check the (flue) gas tightness . . . . . . . . . . . . . . . . . . . 35 10.15 Check for correct operation . . . . . . . . . . . . . . . . . . . . . 35 10.16 Replacing components . . . . . . . . . . . . . . . . . . . . . . . . . 36 10.16.1 Replacement interval for components . . . . . . . . . . . . 36 10.16.2 Inserting the igniter . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 10.16.3 Replacing the flue gas temperature sensor. . . . . . . . . 36 10.16.4 Replacing the coding plug . . . . . . . . . . . . . . . . . . . . . . 37 10.16.5 Replacing the air/gas ratio control valve . . . . . . . . . . . 37 10.17 Inspection and maintenance protocol (checklist) . . . . 38

11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 11.1 Operating and fault displays . . . . . . . . . . . . . . . . . . . . . 39 11.1.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 11.1.2 Fault code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Condens 7000 WP ­ 6721841195 (2022/01)

11.1.3 Faults that are not displayed . . . . . . . . . . . . . . . . . . . . .44 12 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
12.1 Standard decommissioning . . . . . . . . . . . . . . . . . . . . . .45 12.2 Decommissioning when there is a risk of frost . . . . . . .45 13 Environmental protection and disposal . . . . . . . . . . . . . . . . .45
14 Data Protection Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
15 Technical information and reports. . . . . . . . . . . . . . . . . . . . . .46 15.1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 15.2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . .47 15.3 Data relating to the gas. . . . . . . . . . . . . . . . . . . . . . . . . .48 15.4 Hydraulic resistances . . . . . . . . . . . . . . . . . . . . . . . . . . .49 15.5 Residual head of pumps . . . . . . . . . . . . . . . . . . . . . . . . .49 15.6 Setting values for heating capacity . . . . . . . . . . . . . . . .49 15.7 Commissioning report for the appliance. . . . . . . . . . . .50
1 Explanation of symbols and safety instructions
1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing danger are not taken. The following signal words are defined and can be used in this document:
DANGER DANGER indicates that severe or life-threatening personal injury will occur.
WARNING WARNING indicates that severe to life-threatening personal injury may occur.
CAUTION CAUTION indicates that minor to medium personal injury may occur.
NOTICE NOTICE indicates that material damage may occur.
Important information
The info symbol indicates important information where there is no risk to people or property.
1.2 General safety instructions
H Notices for the target group These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with

Explanation of symbols and safety instructions
instructions may result in material damage and personal injury, including danger to life. Read the installation, service and commissioning
instructions (heat source, heating controller, pumps, etc.) before installation. Observe the safety instructions and warnings. Follow national and regional regulations, technical regulations and guidelines. Record all work carried out.
H Determined use The product may only be used for the heating of central heating water in a sealed system and for DHW (Domestic Hot Water) heating in closed-loop DHW and heating systems. Any other use is considered inappropriate. Any damage that may result is excluded from liability.
H System malfunctions caused by third-party equipment
This heat source is designed for operation with our control units.
System malfunctions, malfunctions and defects of system components resulting from the use of thirdparty equipment are excluded from liability.
Service work required to repair the damage will be invoiced.
H If you smell gas A gas leak could potentially cause an explosion. If you smell gas, observe the following rules:
Prevent flames or sparks: ­ Do not smoke, use a lighter or strike matches. ­ Do not operate any electrical switches or unplug any equipment. ­ Do not use the telephone or ring doorbells.
Turn off the gas at the meter or regulator. Open windows and doors. Warn your neighbours and leave the building. Prevent anyone from entering the building. Move well away from the building: call the National
Gas Emergency Service on 0800 111 999. L.P.G. boilers: Call the supplier’s number on the
side of the gas tank.
H Danger to life from poisoning by flue gas There is a danger to life from escaping flue gas.
Ensure that flues and gaskets are not damaged.

Condens 7000 WP ­ 6721841195 (2022/01)

3

Product Information
H Danger of death from poisoning by flue gas due to inadequate combustion
Danger of death due to flue gas leak. If flues are damaged or leaking, or if you smell flue gas, observe the following rules.
Close the fuel infeed. Open doors and windows. If necessary, warn all residents and leave the
building. Prevent third parties from entering the building. Rectify any damage to the flue gas pipe
immediately. Check the combustion air supply. Do not cover or reduce the size of ventilation
openings in doors, windows and walls. Ensure that there is adequate combustion air
supply, including for any appliances installed at a later date, e.g. extractor fans, kitchen fans or air conditioning units that discharge air to the outside. Never operate the device if there is insufficient combustion air supply.
H Combustion/room air Keep the combustion/ambient air free of corrosive
substances (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds). This will help to prevent corrosion. Keep the combustion air supply free of dust.
H Installation, commissioning and maintenance Installation, commissioning and maintenance may be performed only by an approved contractor.
In the case of open flue operation: ensure that the installation location meets the ventilation requirements.
Do not repair, manipulate or deactivate safetyrelevant components.
Only install original spare parts. Check for gas tightness after working on gas-
carrying components.
H Handover to the user When handing over, brief the owner in the operation of the heating system and about the operating conditions.
Explain operation ­ with particular emphasis on all safety-related actions.
Highlight the following points in particular: ­ Point out that modifications or repairs may be carried out only by an approved contractor. ­ To ensure safe and environmentally compatible operation, an annual inspection, and also

cleaning and maintenance as required, must be carried out within the specified interval. Point out the possible consequences (material damage, personal injury and possible danger to life) of not carrying out inspection, cleaning and maintenance correctly, or omitting it altogether. Draw attention to the dangers associated with carbon monoxide (CO) and recommend the use of CO detectors. Hand over the installation and operating instructions to the user for safekeeping.
H Inspection and maintenance interval To ensure the wall mounted gas condensing boiler works correctly and safely, the following intervals must be adhered to: · Inspection: annually, · Maintenance: every 2 years or following a burner
runtime of 4000 hours (depending on which occurs first).
2 Product Information
2.1 Declaration of conformity The design and operating characteristics of this product comply with the European and national requirements.
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: worcester-bosch.co.uk.
2.2 Product data for energy consumption The product data on energy consumption can be found in the operating instructions for the user.
2.3 About these instructions
Figures used The figures in these instructions serve to provide general notices regarding correct operation. The figures used serve to provide general notices regarding correct operation. These figures may slightly deviate from the actual situation.
Product types mentioned These instructions describe all product types of the GC7000WP. Availability may vary depending on the country.

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Condens 7000 WP ­ 6721841195 (2022/01)

2.4 Appliance types

Appliance type: GC7000WP 50 23 GC7000WP 65 23 GC7000WP 85 23 GC7000WP 100 23 Table 1 Appliance types

Country UK, IE UK, IE UK, IE UK, IE

Part No. 7736 702 194 7736 702 195 7736 702 196 7736 702 197

The wall mounted boiler designation comprises the following:
· Condens 7000 WP: product name; · GC7000WP 50… GC7000WP 100: product type; · 50 … 100: heating capacity in kW; · 23: gas type.

2.5 Type Plate
The data plate contains information on the appliance output, registration data and serial number of the product. The data plate is on the underside of the wall mounted boiler on the right next to the gas connection ( Fig. 1, p. 6).

2.6 Conversion of gas type This floor standing boiler is suitable for the gas categories specified on the data plate.
If conversion of the floor standing boiler to a different gas category is allowed, this is specified in the gas data ( § 15.3, p. 48).

2.7 Accessories A wide range of accessories is available for this appliance.
Contact the manufacturer for more information. You will find the relevant addresses on the back of this document.

2.8 Scope of delivery A range of accessories is supplied with the GC7000WP.
Check the heating system is intact on delivery. Check that all package contents are present.

Packaging unit 1 (boiler)

Component · Wall-mounted boiler

Packaging
Cardboard box

2 (accessories)

· Mounting rail

Cardboard

· Fixing materials

box

· Siphon

· Condensate drain hose

· Plug (if not pre-

assembled)

· Rotary joint + gasket (2x)

· Documentation

Table 2 Scope of delivery

2.9 Pump test.
The pump starts automatically for 10 seconds every 24 hours if it is not in use for a longer period. This procedure prevents the pump from seizing.

Product Information
2.10 Frost protection
NOTICE Installation damage due to the effects of frost. The heating system could freeze during a hard frost due to: mains voltage failure, insufficient gas supply or appliance fault. Install the boiler in a frost-proof room. Drain the entire heating system if it is to be shut down for a longer
period.
The boiler is equipped with integral frost protection. This means that an external frost protection safeguard for the boiler does not have to be installed. The frost protection switches the boiler on at a boiler temperature of 7 °C and switches it off at a boiler temperature of 15 °C. This frost protection does not protect the heating system against frost.

Condens 7000 WP ­ 6721841195 (2022/01)

5

Product Information 2.11 product overview
14 13 12 11 10 9 8 7 6 5 4
3 2 1 38 37 28 36 35
Fig. 1 GC7000WP with connection set on frame
6

15 16 17 18
19 20 21
22 23 24 25 26
27 29 30 31 32 33 34
0010030188-002
Condens 7000 WP ­ 6721841195 (2022/01)

Floor standing condensing boiler: [1] Pump assembly [2] Gas line [3] Drain pan [4] heat exchanger [5] Snap fastener [6] Automatic air vent valve [7] CO2 adjusting screw1) [8] Air intake pipe [9] Venturi nozzle [10] Air/gas ratio control valve [11] Remote control [12] On/off switch [13] Flue gas temperature sensor [14] Connector [15] Test point for flue gas routing [16] Test point for air supply [17] Appliance cover [18] Connection point for diagnosis tool [19] Fan [20] Burner cover [21] Igniter [22] Flow temperature sensor (93 °C) [23] Safety temperature monitor (105 °C) [24] High limit safety cut-out [25] Pressure sensor [26] return temperature sensor [27] Type Plate [28] Condensate trap Connection set and frame (accessories): [29] Pump [30] Gas isolator [31] Expansion vessel connection [32] Fill and drain valve [33] Service valve return [34] Base frame [35] Adjustment fixture [36] Service valve flow [37] Pressure gauge [38] Water pressure relief valve

1. Reproduced: GC7000WP 100
   Condens 7000 WP ­ 6721841195 (2022/01)

Product Information 7

Product Information
2.12 Dimensions Floor standing boiler on frame

Floor standing boiler against the wall

64

53

115
520 115

521 200

115 520
115
260 300

53

457.5 136

202 198 199
138 198

1120

1690 ± 12

298 > 100

191

260

642,5 260

191

260

260

Fig. 2 Dimensions on base frame [mm]

0010030944-002

Fig. 3 Dimensions on the wall [mm]

0010031061-002

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Condens 7000 WP ­ 6721841195 (2022/01)

2.13 Minimum clearance from walls
With a horizontal flue gas connection, make sure the electronic components inside the floor standing boiler at the top remain accessible when placing an elbow directly on the flue outlet adapter. After fitting the flue bend, check whether the top cover of the
appliance is easy to remove ( § 7.2, p. 18). There must be a clearance of at least 100 mm directly above the bend
at the floor standing boiler.
23
1

100

B

A

K

5,2 % S

(52 mm/1 m)

136

Product Information

Flue gas routing

A [mm] B [mm]

Ø 110 mm Connection adapter with elbow, 165 A + 0.5*K

Ø 110/ 160 mm

horizontal flue outlet.

179 A + 0.5*K

Ø 110 mm Connection adapter, vertical –

0

Ø 110/ 160 mm

flue outlet

–

0

Table 4 Clearance A and B depending on flue outlet

Determine the minimum clearance above the floor standing boiler.

Add dimension B from Table 4 to the height of the top of the floor standing boiler.
With a horizontal flue outlet: ­ Add 52 mm to dimension B for every meter of horizontal flue outlet. ­ In this case also take the diameter of the collar into consideration.
With a vertical flue outlet: ­ Maintain a clearance of at least 100 mm above the floor standing boiler to allow the electronic components to be accessed and worked on.
Minimum space required for the floor standing boiler.

Provide an unobstructed space of at least 100 cm for the floor standing boiler to allow maintenance and other work to be carried out.
Distance from walls at sides.

Maintain a clearance of at least 5 mm on the weather side of the floor standing boiler.

1120

5*

5*

C

0010040879-001

Fig. 4 Side view [mm] [1] Horizontal flue outlet [2] Collar [3] Vertical flue outlet
A Clearance from top of floor standing boiler – hard borehole B Clearance from top of floor standing boiler – upper side of
borehole C Depth of floor standing boiler: 365 mm K Diameter of borehole S Wall thickness

Wall thickness S K [mm] for Ø flue outlet [mm]

Ø 110/160

Ø 110

15 – 24 cm

190

140

24 – 33 cm

195

145

33 – 42 cm

200

150

42 – 50 cm

205

155

Table 3 Diameter of borehole K

Condens 7000 WP ­ 6721841195 (2022/01)

260 300
520
0010033512-001
Fig. 5 Front view [mm] 2.14 Flue gas temperature sensor The floor standing boiler is manufactured with a flue outlet sensor as standard ( Fig. 1, p. 6). The flue gas temperature sensor protects the floor standing boiler and flue system from high flue gas temperatures by setting back the boiler load (downward modulation).
9

Regulations 2.15 Opening and closing the front panel of the appliance The floor standing boiler has a rotary lock. Use the designated tool when opening and closing the front panel
(ideally a flat-bladed screwdriver). Opening the front panel Turn the locking screw a quarter turn [1]. Tilt the front cover forwards and remove [2 + 3]. Closing the front panel Insert the locating pins on the front cover into the centring holes [4] in the frame. Squeeze the front cover shut at the position of the locking screw.

NOTICE
Risk of system damage due to differing operating conditions! Faults may arise if the specified operating conditions are disregarded. Where there is serious disregard for the stated operating conditions, individual components or the boiler itself may be destroyed. Observe the binding information on the data plate.
3.1 Notes on installation and operation
Use only genuine spare parts from the manufacturer. The manufacturer can assume no liability for damage caused by spare parts not supplied by the manufacturer.
When installing and operating the heating system, observe the following requirements: · The local building regulations regarding installation conditions. · The local building regulations regarding the supply and exhaust air
systems, and the chimney connection. · Latest edition of the IEE Wiring regulations governing electrical
connection to the mains power supply · Regulations and standards regarding the safety equipment in water-
filled heating systems. 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.
3.2 Regulations In order to ensure installation and operation of the product in accordance with the regulations, please observe all the applicable national and regional regulations as well as all technical rules and guidelines. The document 6720807972 contains information about the applicable regulations. You can use the document search on our website to display this. You will find the address of the website on the back of these instructions.

3. 4
   Fig. 6 Opening the front panel

4 Flue gas routing
A supplement for flue gas routing is included with this product. This document describes the flue gas accessories, flue gas classifications and corresponding flue lengths. Install the flue system as described in the supplied documentation.
0010030538-001

3 Regulations
DANGER Failure to comply with instructions may result in material damage and personal injury, including danger to life! Comply with all instructions.

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Condens 7000 WP ­ 6721841195 (2022/01)

5 Preconditions for installation
DANGER Danger to life from explosion! An increased and permanent ammonia concentration may lead to stress corrosion cracking on brass (e.g.gas valves, union nuts). As a result, there is a risk of explosion from gas escaping. Do not use wall mounted gas boilers in rooms where there is an
increased or permanent ammoniac concentration (e.g. livestock stables or storage room for fertilisers). If contact with ammonia is unavoidable, make sure that there are no brass parts installed in the system.
CAUTION Personal injury due to lifting incorrectly. Due to the weight and dimensions of the wall mounted boiler, take
adequate measures to transport the wall mounted boiler safely in the installation room. The packaged floor standing boiler should ideally be transported to the installation room on a sack truck or trolley.
NOTICE The appliance may be damaged if lifted incorrectly. Not all parts of the boiler are suitable for lifting and carrying. To lift the floor standing boiler correctly, handles are attached to the underside. Use these handles to move the floor standing boiler [1]. Hold the boiler at the side and base and not at the basic controller or
flue connection.
1
1

Preconditions for installation
5.1 Installation location
NOTICE
Frost damage! Install the heating system in a frost-free room.
DANGER Risk of fire through flammable materials or liquids. Never store flammable materials or liquids in the immediate vicinity
of the boiler.
NOTICE
Boiler damage through contaminated combustion air or contaminated air in the vicinity of the boiler! Never operate the boiler under dusty conditions or where the
atmosphere is contaminated with corrosive substances. These might be, for example, paint shops, hairdressing salons and agricultural operations involving the production of manure. Never operate boilers in locations where trichloroethene, halogenated hydrocarbons or other corrosive chemical substances are used or stored. Certain adhesives, solvents, cleaning agents and paints, for example, contain these substances. Choose or prepare a suitable installation location.
5.2 Important notices The wall mounted boiler must not be operated in open heating systems (oxygen permeation). The heating system must then be converted to a sealed system according to EN12828 or a system separation must be installed: Mount a separation (a plate heat exchanger for example) between the
floor standing boiler and the heating system.
When plastic pipes are used in the heating system If plastic pipes are used in the heating system, in an underfloor heating system for example: Use plastic pipes with oxygen diffusion resistance to DIN 4726/
4729 -or Mount a separation (a plate heat exchanger for example) between the
floor standing boiler and the heating system.
When using a room thermostat/room temperature-dependent controller Do not mount thermostatic radiator valves in the reference room.
Surface temperature The maximum surface temperature of the appliance is below 85 °C. Therefore no special safety measures are required to protect flammable materials and fitted furniture. Country-specific regulations must be observed.

Fig. 7 Position of handle recesses

0010034260-002

Condens 7000 WP ­ 6721841195 (2022/01)

11

Installation
5.3 Water quality Unsuitable or contaminated heating and tap water can lead to faults in the floor standing boiler and can damage the heat exchanger or DHW supply among other things due to sludge formation, corrosion or calcification. Please get in touch with the manufacturer if you require additional information on the water quality. You will find the relevant addresses on the back of this document. Using the supplied “Water quality operator’s log” determine the water
volume Vmax: If the amount of fill and top-up water is already greater than the calculated water volume Vmax: Use the water treatment as specified in the “Water quality operator’s
log”. If the amount of fill and top-up water is less than the calculated water volume Vmax: Purge and clean the heating system if required. Only use untreated potable water. Do not use chemical additives (e.g. inhibitors or agents that increase
or reduce the pH), apart from as specified in § 5.3.1.
5.3.1 Water conditioning and treatment
NOTICE
Damage to appliance due to sealing agent in the heating water. Addition of sealing agent to the heating water is not permitted.

Conditioned water is water that has been softened or desalinated and to which no chemicals have been added. Treated water is unconditioned or conditioned water to which chemicals have been added.

The following water conditioning and water treatment measures have been approved for use by Bosch:

Application
Demineralisation
Inhibitor/antifreeze Antifreeze Table 5 Additives

Product name
Demineralisation/ desalination with mixed bed cartridges
Fernox Alphi 11 Noburst AL

Max. concentration [%] In accordance with the supplied “Manual for water quality”
40
40

For information on concentrations and applications, contact the supplier of the additive.

5.4 Maximum flow temperature

NOTICE
Too much chloride in the heating water can damage the appliance.
If the chloride content in the heating water exceeds 150 ppm, the floor standing boiler may be damaged if the heating water temperature is higher than 80 °C. If the maximum flow temperature is set higher than 80 °C, the water treatment must be adapted in order to reduce the chloride content.
If the chloride content is more than 150 ppm, carry out a water treatment as described in the supplied “Manual for water quality”.

The boiler is supplied with a set maximum flow temperature of 80 °C as standard. Under standard conditions, this maximum boiler temperature

is sufficient to cover the heating load and also guarantee the service life of the floor standing boiler. A higher maximum flow temperature may however be required for certain installations. In these cases, the chloride content of the heating water must be checked and reduced if necessary. With the chloride content of the heating water. If the chloride content is more than 150 ppm, perform water
treatment as described in the supplied “Manual for water quality”. Set the maximum flow temperature to the required value ( § 9.4.2,
p. 26). Contact the manufacturer for more information. You will find the
relevant addresses on the back of this document.
6 Installation
WARNING Risk of explosion Close the gas valve before working on gas-carrying components. After completing the work, check the tightness of all gas-carrying
components.
6.1 Unpacking the floor standing boiler
The packaging material is fully recyclable. Dispose of the boiler packaging after installing the floor standing
boiler at a recycling point.
Remove the outer packaging by setting the boiler upright and pulling it up and off.
Avoid damaging the connections on the boiler at the top and bottom. Cover the flue outlet adapter of the floor standing boiler during
assembly.
6.2 Checking the gas type Check whether the gas type to be connected to the appliance
corresponds to the gas type specified on the data plate. ( § 2.11, p. 6 ).
6.3 Setting up the floor standing boiler The floor standing boiler can be installed in two ways: · Installation on a frame (accessory). · Installation on the wall. To make full use of the modular design of the system, it is advisable to install the boiler in combination with the frame.
Installation on the frame (accessory)
WARNING Physical injury due to tipping of the boiler. The frame must be securely attached to the floor or wall so that the boiler cannot tip over. Use fixing materials that are suitable for the subsurface or wall and
offer a sufficient hold. Fasten the frame to the floor with the bracket (included). If drilling in the floor is not permitted fasten the frame to the wall.
Mount the cross bars [1] to the stands [2]. Secure the cross bars with the brackets [3] (included). Place the frame at the required location in the installation room.

12

Condens 7000 WP ­ 6721841195 (2022/01)

Set up the frame so the marking [4] points forwards.
4

Installation
2

1 2

1 3

3

3

3

3

3

3 0010033904-001
Fig. 8 Installing the frame
[1] Cross bar [2] Stand [3] Angle [4] Marking
Fasten the brackets [1] to the frame. Fasten the brackets to the floor [3]. -or Fasten the frame to the wall [2]. As the boiler subsequently needs to be adjusted, do not fully tighten
the screw.

0010039423-001
Fig. 9 Secure the frame to the wall or floor
Push the floor standing boiler onto the frame. The floor standing boiler is secured to the frame at the rear. If it has been secured correctly a “click” will be audible.
Align the floor standing in the frame using the adjustment option. [1]. Fully tighten the grub screw in the frame.

Condens 7000 WP ­ 6721841195 (2022/01)

1

1

Fig. 10 Align the floor standing boiler on the frame

0010030947-001

13

Installation

Assembly on the wall

NOTICE
If the boiler may be damaged if attached incorrectly.
Use suitable fixing materials for the condition of the masonry and weight of the floor standing boiler. The fixing materials provided are only suitable for installation on concrete walls.
Only use fixing materials that are suitable for the construction which will be supporting the floor standing boiler.

Check whether the wall has sufficient load-bearing capacity based on the dimensions and weight of the floor standing boiler. ( § 15.2, p. 47).
Mount a fastening structure if required.
Only use fixing materials that are suitable for the structure to which the floor standing boiler is to be attached. ( Tab. 6).

Wall type Concrete Solid lime sandstone Others

Fixing materials See scope of delivery
Not included: to be decided by the installer.

Minimum load [N] 10001) Per fixing point.

1. The load applies for tensile and shear loads.

Table 6 Specification of the fixing materials
Determine the position of the floor standing boiler on the wall. Mark the boreholes using the enclosed mounting rail [1]. Install the mounting rail on the wall using a spirit level to make sure it
is level [2 + 3 + 4].

Fig. 11 Installing the mounting rail on a concrete wall Hook the floor standing boiler into the mounting rail.

10011604-001

Align the floor standing boiler using a spirit level and adjusting screw on the rear.

Fig. 12 Aligning the floor standing boiler on the wall

0010030948-001

6.4 Connecting on the heating and gas side
The floor standing boiler can be connected on the heating and gas side in 2 ways: · using a connection set (accessory, § 6.5, p. 14), · without connection set ( § 6.8, S. 16).

6.5 Mounting the connection set (accessories)

NOTICE
Installation damage due to incorrect excess pressure of the safety valve.
The connection set must be equipped with a safety valve.
Check whether the excess pressure of the safety valve is suitable for the required operating pressure and the components in the heating system.
Replace the pre-installed safety valve with a safety valve with a suitable excess pressure (accessory).

The following components have been incorporated into the connection set: · Gas valve; · Service shut-off valves; · Pressure gauge · Safety valve; · Pump; · Fill and drain valve.
These components can be found in the overview drawing ( § 2.11, p. 6).

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Condens 7000 WP ­ 6721841195 (2022/01)

6.5.1 Installing the gas valve
WARNING If the sealing is not carried out correctly gas may escape. The thread of the gas connection under the floor standing boiler must not be roughened. This could cause gas to escape. Comply with the country-specific regulations and standards in
relation to the sealing agent used.

NOTICE
Boiler damage due to dirt. Pollution in old gas lines, including rust, can damage the air/gas ratio control valve or block the gas supply. Install a gas filter in the gas line in accordance with the specifications
if required.
Seal the gas connection [1] using an approved sealing agent. Mount the coupling (two parts) [2]. Install the gas valve [3]. Connect the gas line without stress to the gas valve. Install a gas filer in the gas line if required.

1. Fig. 14 Mount the flow/return connection Screw down the bracket with the screws [1]. Fully tighten all rotary joints [2].

Installation
2. 3.
0010041394-001

1 2

2 2
2

3
0010033907-002
Fig. 13 Installing the gas valve [1] Gas connection [2] Two-part coupling [3] Gas isolator 6.5.2 Mounting the connection set Mount the flow connection with the flat gasket [1]. Mount the pump with the flat gasket [2]. Mount the return connection with the flat gasket [3]. Tighten the rotary joints handtight.

1
0010041395-001
Fig. 15 Mount the brackets Connect the flow and return line to the connection set, making sure
they are free of stress. The minimum diameter of the flow and return line must be 1½” (Ø 35 mm).

Condens 7000 WP ­ 6721841195 (2022/01)

15

Installation
6.6 Mounting the siphon Fill the boiler siphon with water. Mount the boiler siphon [1] with gasket [2]. Check whether the neck of the siphon is properly connected to the
condensation catch pan. Tighten the union nut hand tight [4].
4.
4
3.
1 2

2 2

1
0010033908-003
Fig. 16 Mounting the boiler siphon With pump assembly Mount the tee [1] between the diaphragm safety valve and the
siphon. Connect the hose [2] from the automatic air vent valve to the tee [1]. Do not insert the hose into the tee by more than 10 cm. Shorten the hose if required. Install the corrugated hose [3]. Without pump assembly Mount the corrugated hose [3] directly on the siphon [4]. Connect the hose [2] from the automatic air vent valve to the waste
water system.

3

Fig. 17 Mounting the air vent valve hose
[1] T-piece [2] Air vent valve hose [3] Corrugated hose [4] Condensate trap
6.7 Connecting the condensate pipe

0010033906-002

NOTICE
If the waste water pipe is blocked, this can damage the boiler.
A blockage in the waste water pipe can prevent the removal of condensate from the boiler if the condensate drain line is permanently connected to the waste water pipe.
Make sure that the connection between the condensate pipes of the floor standing boiler and the waste water pipe connection is unobstructed.

Use a waste water pipe made of plastic material with a diameter of at least Ø 40 mm to remove the condensate.
Install a siphon in the waste water pipe. Install horizontal pipe sections so they slope towards the downpipe.
The maximum length of the horizontal pipe section in this case is 5 m. Fill siphon in the waste water pipe.
6.8 Connecting heating pipes (without connection set)

NOTICE
If the operating pressure is too high, this can damage the boiler. Install a diaphragm safety valve between the floor standing boiler and
the service shut-off valve.

16

Condens 7000 WP ­ 6721841195 (2022/01)

Installation

NOTICE
Damage to appliance due to incorrect connection of safety equipment. When using service valves, all safety equipment must remain in operation when the service valves are closed. Mount the connection for the expansion vessel and safety valve
directly under the boiler and above the service valves. ( Fig. 18, p. 17).
NOTICE
Appliance fault due to insufficient cooling. If the boiler is installed on a frame, the internal overtemperature protection of the pump may be triggered if the cooling is insufficient when an On/Off pump was selected. When using insulating parts, ensure sufficient ventilation by not
mounting the rear panel.
Connect the flow and return pipe without stress to the floor standing boiler.
The diameter of the flow and return pipe must be no less than 1 ½” (Ø 35 mm).
To make maintenance work easier: Install a service valve in the flow and return pipe ( Fig. 18, p. 17).
6.8.1 Connecting the gas valve Connect the gas valve ( § 6.4, p. 14).
6.8.2 Installing the pump Select the pump using the specifications as the basis ( Tab. 15.2,
p. 47). Take the required volumetric flow rate into consideration ( Tab.
15.4, p. 49). If a low loss header is not used: Select a pump with a residual head of at least 200 mbar at the
required volumetric flow rate. Install the pump [6] in the return line [5].

1

5

7

2

46

8

3

3

9

3

3

0010018400-003
Fig. 18 Connection of heating water pipes
[1] Flow line [2] Water pressure relief valve [3] Service valve [4] Gas isolator [5] Return line [6] Pump [7] Fill and drain valve [8] Expansion Vessel [9] Dirt trap
6.9 Installing the low loss header If the remaining head is insufficient at the required volumetric flow rate, a low loss header [1] must be set up.
Check the specifications to find out whether it is necessary to set up a low loss header ( § 15.4, p. 49).

2

1

34

Condens 7000 WP ­ 6721841195 (2022/01)

Fig. 19 Setup with low loss header
[1] Low-loss header [2] Expansion Vessel [3] Pump [4] Service valve [5] Differential pressure regulator

5

4

0010018401-003

17

Electrical connection
6.10 Connecting an expansion vessel
For the boiler and the system to function correctly, the right expansion vessel must be selected. Determine the size and pre-charge pressure of the expansion vessel
by referring to EN 12828.
Remove the cap from the connection point [1]. Connect the connecting pipework of the expansion vessel to the
connection point.

7.1 Handling printed circuit boards Printed circuit boards with control electronics are very sensitive to electrostatic discharge (ESD). To prevent damage to the components, exercise utmost caution.
CAUTION Damage due to electrostatic charge! Wear an earthed wristband when handling unenclosed PCBs.

1. 0010034327-001
   Fig. 20 Connecting an expansion vessel
   6.11 Installing the insulation (accessory) Insulating parts are available for the connection set of this floor standing boiler. If the floor standing boiler is placed on the base frame, the insulation consists of several panels. In the case of wall-mounted installation, the insulation consists of 1 piece which is fastened underneath the floor standing boiler. For more information, refer to worcester-bosch.co.uk or you will find
   the relevant addresses on the rear of this document.
   7 Electrical connection
   CAUTION Electric shock. Disconnect the floor standing boiler from the power supply before
   working on electrical parts.
   NOTICE Electrical short circuit due to incorrect cabling. Only use original cables if they need to be replaced. All 230 VAC connections in the floor standing boiler must be
   established using the cable type H05VV-F 3 x 0.75 mm2 or NYM-J 3 x 1.5 mm2. All 24 VAC connections in the floor standing boiler must be established using a 2-wire power cable with 0.4 ­ 0.8 mm2 crosssection.

6 720 614 366-24.1I
Fig. 21 Wrist strap The damage is not normally immediately apparent. A PCB may function perfectly during commissioning and problems often only arise later on. Charged objects are only a problem if they are in the vicinity of the electronics. Before starting work, ensure a safe distance of at least 1 m from foam rubber, protective film and other packaging materials, clothing made of synthetic fibres (e.g. fleece pullovers) and similar items. An earthed wrist strap offers good ESD protection when working with electronics. This wrist strap must be worn when opening the screened metallic bag/packaging or prior to exposing a fitted PCB. The wrist strap must be worn until the PCB has been placed inside its screened packaging or has been connected inside the closed control cabinet. Replaced PCBs that are returned must be handled in this way. 7.2 Opening the top cover The burner control unit and terminal strip for electrical components are located under the top cover. Open the top cover by unfastening the retaining screws [1].
1
2.

It must be possible to reach mains plug and therefore also the socket (230 V AC, 50 Hz) at all times for commissioning of the floor standing boiler. The socket must be earthed.
When establishing the electrical connection, also refer to the documentation of the accessory to be connected and the wiring diagram (§ 15.1, p. 46).
18

Fig. 22 Opening the top cover

0010033907-002

Condens 7000 WP ­ 6721841195 (2022/01)

7.3 Overview of plug-in strip

I1

BUS

I3

T1

TW1

T0

BUS

120/230 VAC

PW2

Electrical connection

120/230 VAC

PW1

Fig. 23 Overview of plug-in strip

Symbol

Function

Description

On/Off temperature control (volt free) Connect an On/Off temperature control. Request for heat via volt-free contact, closed = on, open = off.

0010034531-001

Modulation-controlled control unit and Connect modulating temperature controller (EMS bus).

BUS

EMS-BUS

21

External switching contact (volt free). This connection is short-circuited as standard.

If it is necessary to connect several safety components, e.g. a condensate pump and a thermal cut out for the underfloor heating system, they must be connected in series. If a break occurs due to one of the safety components, the heating load to the boiler is interrupted.

Remove short circuit.
Connect safety components (in series). Attention! 230 V components must only be connected via a relay.

outside temperature sensor

Connect the outside temperature sensor.

Storage cylinder temperature sensor Connect cylinder temperature sensor.

BUS
120/230 VAC
PW2 120/230 VAC
PW1

Temperature sensor of low loss header Connect the temperature sensor of a low loss header. Set the use of the low loss header in the service menu: Settings

Hydraulics > Low-loss header.

Function modules

Connect the Bus cable of the function module. If installed in the boiler, install the function module as described in the instructions ( §
7.7, p. 21).

Mains voltage
Circulating pump Mains voltage Cylinder primary pump

Connect the 230 V power supply for the function module. -or Connect the 3-way valve according to the instructions ( § 7.6, p. 21). Attention! The total power consumption of the connected components must not exceed 725 W. If a DHW circulation line is used, a sanitary pump can be connected. Connect the 230 V power supply for the sanitary pump.
Mains plug 230 VAC Connect the mains plug, if not pre-assembled ( § 7.8, p. 21).
Connect the cylinder pump. -or Connect the 3-way valve according to the instructions ( § 7.6, p. 21).

Fine-wire fuse of the burner control unit There is a replacement fuse under the cover flap on the burner control unit.

Table 7 Plug-in strip symbols

Condens 7000 WP ­ 6721841195 (2022/01)

19

Electrical connection
7.4 Connecting electrical components All cables from electrical components outside the boiler that are connected to the plug-in strip must be routed to the inside via the strain relief. Connect the connecting leads of the components to the plug-in strip
without tension. Route the connecting lead through the strain relief. Position the cable conduit [1].

Use the right screwdriver for this.

1

0010035234-002
Fig. 24 Positioning the connecting lead and cable conduit 7.5 Connecting the pump of the pump assembly Open the pump terminal unit.

0010035232-002

Fig. 25 Opening the pump terminal unit
With pump assembly: Connect the 230 V mains cable [1] of the pump to the 3-pin plug. Connect the PWM signal cable [2] of the pump to the 2-pin plug. Guide both cables through the strain relief. Connect the pump terminal unit: fold the pump terminal unit up and
press horizontally until it snaps into place.
Without pump assembly:

When using pump types other than those available from Bosch as accessories, the PWM signal cannot be used. The PWM connection in the pump terminal unit is then not used. On/Off operation applies for these pumps.
Connect the 230 V mains cable of the pump to the 3-pin plug [1]. Guide the 230 V mains voltage cable through the strain relief.

20

Condens 7000 WP ­ 6721841195 (2022/01)

Close the pump terminal box: fold the pump terminal box up and press horizontally until it snaps into place.
12
0010034673-001
Fig. 26 Connecting the pump [1] 230 V cable [2] PWM signal cable 7.6 Connecting the 3-way valve 230 V (accessory)

Electrical connection
7.7 Mounting the function module (accessory)
NOTICE EMC fault due to incorrect cable routing. If bus cables and power cables are routed in parallel there is a risk of EMC faults occurring. Route bus cables and power supply cables separately.
1 function module [3] can be installed in the floor standing boiler. Carefully read the instructions for the function module when carrying
out the installation. Install the BUS cable on the plug [1] according to the specified cable
routing. Install the 230 V power supply cable on the plug [2] according to the
specified cable routing.

1

BUS

120/230 VAC

2

A 3-way valve can only be connected to the plug-in strip of the floor standing boiler if the output of the floor standing boiler is 100 kW.
An appropriate accessory 230 V 3-way valve can be connected to the plug-in strip. Use the plug for the boiler pump for this [B]. Carefully read the instructions for the 230 V 3-way valve. Connect the neutral wire (N) to the plug [A]. Connect the phase wire (L), switching neutral wire (N) and earth wire
to the plug [B].

A

120/230 VAC

PW2

120/230 VAC

PW1

B

3
0010036034-002
Fig. 28 Mounting the function module [1] BUS system connection EMS [2] 230 V mains voltage cable [3] Function modules 7.8 Fitting the plug (if not preassembled) Fit the plug to the power cable of the floor standing boiler.

65 43 211

M
Fig. 27 Connection diagram for 230 V 3-way valve [1] Phase cable L, continuous 230 V [2] Phase cable L, discontinuous 230 V [3] Neutral cable N

0010035147-001

1
2
3
Fig. 29 Fitting the plug [1] Neutral conductor N (blue) [2] Protective conductor (green/yellow) [3] Phase L (brown)

0010018427-001

Condens 7000 WP ­ 6721841195 (2022/01)

21

Commissioning
8 Commissioning
WARNING Escaping gas. After completing the work, check the tightness of all gas-carrying
components.
CAUTION Flue gas spillage. Check the tightness of all flue gas routing parts once the work is
complete.
Complete the commissioning report during the commissioning procedure ( § 15.7, p. 50).
8.1 Commissioning the floor standing boiler
NOTICE
Risk of boiler damage due to unsuitable fill water. Check the chloride content of the fill water, if the maximum heating
water temperature is set higher than 80 °C ( § 5.4, p. 12). Check whether the fill water satisfies the water quality requirements
( § 5.3, p. 12).
The boiler starts as soon as the operating pressure exceeds 0.8 bar. If the operating pressure is lower than 0.2 bar, the appliance no longer goes into operation.
Open all radiator valves. Check whether the service shut-off valves of the connection sets are
open. Use an appropriate filling method in line with Water Regulations. (
§ 2.11, p. 6). Fill the heating system to a pressure of 2 bar and close the filling
valve. Vent the radiators. Fill the heating system again to a pressure of 2 bar. Open the gas cock. Venting the gas line. Operate the appliance. Start up the floor standing boiler.
8.2 Setting the parameters Different parameters can be set in the settings menu so the floor standing boiler can be adapted to the heating system. Go through the parameters in the menu Settings ( § 9.4, p. 26). Adjust the parameters if required. Make a note of which parameters have been modified in the
commissioning report ( § 15.7, p. 50).
Setting Maintenance type With a maintenance period of 2 years, normal operation is considered to be a maximum burner runtime of 4000 hours (every 2 years). During commissioning, the anticipated burner runtime must be estimated in order to set the right Maintenance type. During the initial inspection or maintenance the burner runtime can be read out via the service menu and the burner runtime Maintenance type modified if required. Open the menu Maintenance > Maintenance type. Based on the operation, estimate whether the maximum burner
runtime of 4000 hours will be exceeded in 2 years.

If the maximum burner runtime of 4000 hours in 2 years is likely to be exceeded:
Set Burner run time to 4000 hours.
If the maximum burner runtime is likely to be less than 4000 hours:
Set Boiler run time to 24 months. -or Set Service date: 24 months after installation date.

Setting Maintenance Burner run

type

time

Standard operation 4000 hours

Boiler run time
24 months

Table 8 Maintenance interval parameters

Service date
Date: 24 months after installation

Setting Min. boiler outp. If the boiler is installed in a positive pressure cascade system, the minimum load must be increased.
Open the menu Limit values > Min. boiler outp.. Increase the setting Min. boiler outp. ( table 9).

Appliance type:

Factory [%]

Raised value with positive pressure
cascade
[%]

GC7000WP 50

28

36

GC7000WP 65

20

26

GC7000WP 85

24

28

GC7000WP 100

20

23

Table 9 Setting the Min. boiler outp. with positive pressure cascade systems

22

Condens 7000 WP ­ 6721841195 (2022/01)

8.3 Setting options for air/gas ratio control valve Different air/gas ratio control valves are used depending on the rating of the floor standing boiler. The positions of the various test ports and adjusting screws vary accordingly.
Overview of air/gas ratio control valve GC7000WP 50, GC7000WP 65

2 34

1

0010034262-001
Fig. 30 Overview of test ports and adjusting screws 70 kW [1] Adjusting screw CO2/O2 [2] Gas pre-charge pressure test port [3] Gas/air ratio test port [4] Gas/air ratio adjusting screw Overview of air/gas ratio control valve GC7000WP 85, GC7000WP 100
2 34
5
1
0010034263-001
Fig. 31 Overview of test ports and adjusting screws 85 kW [1] Adjusting screw CO2/O2 [2] Gas pre-charge pressure test port [3] Gas/air ratio test port [4] Gas/air ratio adjusting screw [5] Without function 8.4 Measuring the gas standing pressure (static) The gas standing pressure must be stable to guarantee correct operation of the boiler. The measurement is carried out when the floor standing boiler is switched off.

Commissioning

Switch off the appliance. Remove the front panel. Open the gas standing pressure test port by turning the adjusting
screw through 2 revolutions ( § 8.3, p. 23). Set the pressure gauge to “0”. Connect the pressure gauge to the test port. Measure the static gas standing pressure. Make a note of the value in the commissioning report ( § 15.7,
p. 50). Close the inlet pressure test port.

8.5 Measuring the gas working pressure (dynamic) The gas working pressure must be stable to guarantee correct operation of the boiler. The measurement is performed at full load.
As the measurement is taken at the air/gas ratio control valve and not the gas valve, the permissible gas working pressure may be reduced due to the pressure drop between the gas valve and air/gas ratio control valve.
Example: GC7000WP 100 to natural gas H, G20. · Permissible gas pre-pressure: min. 17 mbar ­ max. 25 mbar (
Tab. 24, p. 48). · Pressure drop between gas valve and air/gas ratio control valve is
2.7 mbar ( Tab. 10).
Permissible limit values on the air/gas ratio control valve:
Min. 17 mbar ­ 2.7 mbar = 14.3 mbar. Max. 25 mbar ­ 2.7 mbar = 22.3 mbar.

Max. pressure drop for each gas type [mbar]

Type

G20

G25 / G25.3

GC7000WP 50

1.5

2.0

GC7000WP 65

2.5

2.8

GC7000WP 85

2.6

3.3

GC7000WP 100

2.7

3.7

Table 10 Pressure drop between gas valve and air/gas ratio control valve

Calculate the permissible minimum and maximum gas pre-pressure. Switch off the appliance. Remove the front panel. Open the gas inlet pressure test port by turning the adjusting screw
through 2 revolutions ( § 8.3, S. 23). Set the pressure gauge to”0″. Connect the pressure gauge to the test port. Make sure the heating system can release its heat. Operate the appliance. Open the menu Function check > Burner. Start the Function check by setting the value to 100%. Check whether the measured value lies within the calculated limit
values.

If the measured value lies outside the calculated limit values, do not commission the boiler. The cause must be established and the fault rectified. If this is not possible, shut off the gas supply to the system and contact the gas supplier.
Make a note of the measured value [mBar] after 1 minute in the commissioning report ( § 15.7, p. 50).
Deactivate Function check. Close the working pressure test port.

Condens 7000 WP ­ 6721841195 (2022/01)

23

Commissioning
8.6 Measuring of CO2 and CO (full load)
The CO content in the flue gases must be less than 250 ppm (0.025 % by volume) during combustion without excess air. If the CO content exceeds 250 ppm, this will be due to pollution of the burner, malfunction of the burner or recirculation of the flue gases. Switch off the appliance. Remove the plug on the test point for flue gas [1].
12

0010034264-002

Fig. 32 Remove the plug on the flue outlet

[1] Test point for flue gas [2] Test point for air supply
Make sure that the floor standing boiler can release its heat. Insert the lance of the flue gas analyser 10 cm into the test point. Operate the appliance. Open the menu Function check > Burner. Start the Function check by setting the value to 100%. Measure the CO content. Determine and eliminate the cause of the potentially high CO content. Make a note of the CO content in the commissioning report ( §
15.7, p. 50). Measure the CO2 percentage. Check the measured value ( table 11, p. 24). Only modify the CO2 level if the measurement is outside the specified
range. Make a note of the measured CO2 slevel in the commissioning report
( § 15.7, p. 50). Deactivate Function check. Remove the flue gas analyser. Fit the plug on the test point for flue gas.
Setting data

Appliance type: Gas type

GC7000WP 50

Natural gas H (G20)
Natural gas L (G25)
Propane L (G31)

CO2 percentage
[%] 9.3 ± 0.3
9.1 ± 0.3
10.0 ± 0.3

Gas/air ratio [Pa] -5 ± 4

Appliance type: Gas type
GC7000WP 65 Natural gas H (G20)
Natural gas L (G25)
Propane L (G31)
GC7000WP 85 Natural gas H (G20)
Natural gas L (G25)
Propane L (G31)
GC7000WP 100 Natural gas H (G20)
Natural gas L (G25)
Propane L (G31)
Table 11 Setting data

CO2 percentage
[%] 9.3 ± 0.3 9.1 ± 0.3 10.0 ± 0.3 9.1 ± 0.3 9.1 ± 0.3 10.0 ± 0.3 9.1 ± 0.3 9.1 ± 0.3 10.0 ± 0.3

Gas/air ratio [Pa] -5 ± 4
-5 ± 4
-5 ± 4

8.7 Measuring the gas/air ratio (minimum load)
Switch off the appliance.
Make sure the heating system can release its heat.
Open the gas/air ratio test port by turning the adjusting screw through 2 revolutions ( § 8.3, p. 23).
Set the pressure gauge to “0”.
Connect the pressure gauge to the test port. Open the menu Function check > Burner. Start Function check by setting the smallest possible value. Check the measured value ( table 11, p. 24). Only modify the gas/air ratio if the measurement is outside the
specified range. The gas/air ratio adjusting screw is underneath the cover.
Make a note of the measured value [Pa] in the commissioning report ( § 15.7, p. 50).
Deactivate Function check. Close with the gas/air ratio test port.

8.8 Reading off the ionisation current Open the menu Function check > Burner. Start Function check by setting the smallest possible value. Open the menu Info > Ionisation current.
Reading off the ionisation current.

The ionisation current must be at least 2 A. If the value is lower, check the gas/air ratio and the igniter.
Make a note of the value that has been read off [A] in the commissioning report ( § 15.7, p. 50).
Deactivate Function check.

24

Condens 7000 WP ­ 6721841195 (2022/01)

8.9 Check the (flue) gas tightness
NOTICE
Damage to wall mounted boiler due to short circuit. Cover plugs, cables and components when using gas leak detection
spray.
Make sure that the floor standing boiler can release its heat. Operate the appliance. Open the menu Function check > Burner. Start the Function check by setting the value to 50%. Check all gas-carrying components using an approved leak detecting
agent or device. Check the tightness and installation/brackets of the flue system.

Operation
Draw attention to the dangers associated with carbon monoxide (CO) and recommend the use of CO detectors.
Hand over the technical documents to the operator.
9 Operation
9.1 Control panel overview
9 1
8

2

7

3

0010034659-001
Fig. 33 Inspecting the gas path
Determine and rectify the cause of a possible leak. Deactivate Function check.
8.10 Check the function of the floor standing boiler Freeze the connected control and check whether the floor standing
boiler starts burning after several minutes to support the boiler operation. If applicable: open a DHW tap, check the DHW temperature and draw-off quantity.
8.11 Completion work Mount the front cover. Complete the commissioning report ( § 15.7, p. 50).
8.12 Instructing the operator Familiarise the user with the heating system and operation of the
floor standing boiler. Point out to the operator that if heating water frequently needs to be
refilled this is a sign that the system is faulty and/or leaking (ensure required water quality according to the operator’s log). Inform operator about the required water quality and point out where the heating water must be refilled. Inform the operator that he or she must not carry out any modifications or repairs. Point out the possible consequences (material damage, personal injury or danger to life) of not carrying out inspection, cleaning and maintenance correctly, or omitting it altogether.

6

54

0010033251-001

Fig. 34 Control panel

[1] Display [2] and keys [3] Heating water pressure display [4] d key [5] OK key [6] Menu key [7] Hot water key [8] Heating key [9] Burner display

See the operating instructions for a description of the user menus.
9.2 Switching on the device Switch on the appliance at the On/Off switch ( Fig. 2.11, page 6). Set the language the first time the device is turned on. To scroll through the languages, press the or key. To select the desired language, press the OK key.

When the display shows Siphon fill. prog., the trap filling program is active. The condensate trap in the appliance is filled ( Chapter 9.3,
page 26).

Condens 7000 WP ­ 6721841195 (2022/01)

25

Operation
9.3 Siphon filling program The siphon filling program is activated automatically, manually by the installer on the device or on the controller. Before starting, fill the condensate siphon ( Page 16). The siphon filling program is activated in the service menu under > Settings > Special function > Siphon fill. prog.. While the siphon filling program is active, access to the Hot water menu, the Heating menu and the service menu is possible. The siphon filling program is activated automatically in the following cases: · The device is switched on using the On/Off switch. · The burner was not in use for at least 28 days. · After conversion from summer to winter mode. The next time there is a heat demand for heating, the device is held at low thermal output for 15 minutes. The siphon filling program remains active until the device has completed 15 minutes of operation with increased min. capacity. During the siphon filling program, Siphon fill. prog. appears on the display. The siphon filling program is interrupted when the chimney sweep mode is called up.
9.4 Settings in the service menu Many device functions can be set and checked in the service menu. It includes: · Info: viewing information · Settings: general and device-specific settings · Function check: settings for function checks and start of function
checks · Reset: restoring the factory settings, resetting the maintenance
intervals
9.4.1 Operating the service menu
Opening the service menu Press the DHW key and the Heating key simultaneously until the
service menu appears.
Closing the service menu Press the DHW key or the Heating key. -or Press the d key. Navigating through the menu To highlight a menu or a menu item, press the key or the key. Press the OK key.
The menu or the menu item is displayed. To return to the next higher menu level, press the d key. Changing the setting values Select the menu item with the OK key. To select the desired value, press the or the key. Press the OK key.
The new value is saved.
Exiting the menu item without saving values Press the d key.
The value is not saved.
9.4.2 Service menu
26

Condens 7000 WP ­ 6721841195 (2022/01)

Overview of the service menu
Info
­ Current status ­ Current fault ­ Fault history ­ Boiler
­ Max. heat output ­ Flow temp. ­ Set flow temp. ­ Low-loss hdr.tmp ­ Act. burner mod. ­ Burner output ­ Ionisation current ­ Pump mod. ­ Outside temp. ­ Burner starts ­ Hours run ­ System pressure ­ Hot water ­ Max. output ­ DHW flow rate ­ DHW act. temp. ­ Hot water temp. ­ Inlet temp. ­ DHW set temp. ­ Autom. filling ­ System pressure ­ No. of refills ­ Last refill dur. ­ Refilling active ­ System ­ Contr.device ver. ­ Progr. unit ver. ­ Code plug no. ­ Code plug ver. ­ Solar ­ Collector temp. ­ Cyl.temp.bottom ­ Collector pump ­ Solar fault
Settings
­ Hydraulics ­ Low-loss header ­ DHW configuration ­ HC1 configuration ­ Pump config.
­ Heating ­ Max. heat output ­ Standby time ­ Anticyc. temp. off ­ Anticycle temp. on
­ Hot water ­ Max. DHW output ­ DHW circ. pump ­ Cycle circ. pump ­ TD- Temperature ­ Start TD ­ Stop TD
Condens 7000 WP ­ 6721841195 (2022/01)

­ Pump ­ Pump ctr. mode ­ Min. output ­ Pump overrun ­ Min. Sys. Pres. ­ Target Sys. Pres.
­ Special function ­ Ventilation func. ­ Siphon fill. prog. ­ 3-WV mid. pos. ­ Autom. filling ­ System Fill ­ Min. Sys. Pres. ­ Target Sys. Pres. ­ Max. refill time ­ Blocking time ­ Max. refills ­ Reset refilling
­ Maintenance ­ Maintenance type ­ Without ­ Burner run time ­ Boiler run time ­ Service date1)
­ Limit values ­ Max. flow temp. ­ Max. DHW temp. ­ Min. boiler outp.
­ Heating curve ­ Enable ­ Htg. curve base ­ Htg. curve end ­ Summer mode ­ Frost prot. ­ Frost temp. limit
Function check
­ Activate test ­ Burner ­ Ignition ­ Fan ­ Pump ­ Cyl. prim. pump ­ 3-way valve ­ HC1 pump ­ DHW circ. pump ­ Ionisat.oscill.
Reset
­ Default setting ­ Service display ­ Fault history
Demo mode
­ Yes ­ No

1. With heating controller

Operation 27

Operation
Menu Info
Meu item Current status Current fault Fault history Boiler
Max. heat output Flow temp. Set flow temp. HEx temperature Low-loss hdr.tmp Return temp. Heating mod. Act. burner mod. Burner output Ionisation current Pump mod. Outside temp. HC1 pump Burner starts Hours run System pressure Hot water Max. output DHW act. temp. Act.DHWtmp.cyl. DHW set temp. System Progr. unit ver. Contr.device ver. SW sub-ver. Code plug no. Code plug ver.
Table 12 Menu Info

Settings/adjustment range ­ ­ ­
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­
­ ­ ­ ­
­ ­ ­ ­

Remark/restriction Tab. 11.1.2, page 39 Tab. 11.1.2, page 39
Internal appliance temperature
Temperature in low loss header Current return temperature in °C
Current burner modulation Current burner output in kW Current ionisation current in A
Current outside temperature in °C Own pump installed downstream of low loss header Number of burner starts since commissioning Run time of the system since commissioning Current operating pressure in bar
Current water temperature in the cylinder DHW temperature setting value
Software version of the control unit Software version of the control device Software subversion of the control device Coding plug number Coding plug version

28

Condens 7000 WP ­ 6721841195 (2022/01)

Settings menu

Operation

The factory settings are highlighted in the following table.

Meu item Hydraulics
Low-loss header
DHW configuration
HC1 configuration Pump config. Heating Max. heat output

Settings/adjustment range
· Off · NTC on device
· NTC on module
· NTC off
· Not installed · 3-way valve installed · Cyl. prim. pump inst. after low loss hdr. · Cyl. primary pump installed · Not installed · Dedicated pump inst. after low loss hdr. · Heating pump
· 50 100%

Standby time
Anticyc. temp. off Anticycle temp. on Hot water Max. DHW output DHW circ. pump Cycle circ. pump
TD-Temperature Start TD Stop TD Pump Pump ctr. mode

· 5 … 10 … 60 min
· 2 … 6 … 15 K
· -15 -6 … 2 K
· 50 100% · Off · On · 1 x 3 minutes/h · 2 x 3 minutes/h · 3 x 3 minutes/h · 4 x 3 minutes/h · 5 x 3 minutes/h · 6 x 3 minutes/h · Permanent · 60 70 … 80 °C · Start now? · Cancel now?
· Energy saving · Heat demand

Min. output

· 10 … 100 %

Remark/restriction
Connection of temperature sensor on the low loss header · Low loss header not installed in the system · Low loss header installed, temperature sensor
connected to wall mounted boiler · Low loss header installed, temperature sensor
connected to heating circuit module · Low loss header installed, but no temperature sensor
connected
Maximum released heat output [%]. On natural gas devices: Measure the gas rate. Compare the measurement obtained with the setting
tables ( Chapter 15.6, page 49). Correct deviations. The time interval specifies the minimum waiting time between switching on the burner and switching it on again. The difference between the current flow temperature and the set flow temperature until the burner is switched off. The difference between the current flow temperature and the set flow temperature until the burner is switched on.
Maximum approved DHW output [%].
The DHW circulation pump goes into operation 1 … 6 times per hour for 3 minutes, or into continuous operation.
DHW temperature during thermal disinfection. Start thermal disinfection. Cancel thermal disinfection.
· Save energy: intelligent shutdown of heat pump for heating systems with weather-compensated controller. The heating pump is only switched on if required.
· With heat demand: the flow temperature controller switches the heating pump. If there is heat energy demand, the heating pump starts up with the burner.
Pump output at minimum heat output. Only available if Pump range map is set to 0.

Condens 7000 WP ­ 6721841195 (2022/01)

29

Operation Meu item
Max. output Pump block time Pump overrun Ventilation func.
Siphon fill. prog.
3-WV mid. pos. Min. Sys. Pres. Target Sys. Pres. Maintenance Maintenance type
Limit values Max. flow temp. Max. DHW temp. Min. boiler outp.
Heating curve Enable
Htg. curve base Htg. curve end
30

Settings/adjustment range · 10 … 100 % · 0 … 24 × 10 seconds · 1 2 … 60 min, 24 h · Off · Auto · On · Off (only permitted when maintenance is in
progress) · On, boiler min. · On, heating min.
· No · Yes · 0.6 0.8 bar · 1.0 … 1.3 … 1.7 bar

Remark/restriction
Pump output at maximum heat output. Only available if Pump range map is set to 0.
The internal pump is locked until the external 3-way valve has reached its end position.
Overrun time of the heating pump: pump overrun begins when heat demand ends.
The venting function can be switched on after maintenance work.
During ventilation, the following appears in the info area of the standard display Ventilation func.
The siphon filling program is activated in the following cases: · Once the device is switched on using the On/Off
switch · Once the burner was not in operation for at least
28 days · Once the operating mode is switched from summer to
winter mode · Once the factory settings of the device have been
restored
The next time there is a heat demand for heating, the appliance is held at low heat output for 15 minutes. The siphon filling program remains active until the device was in operation with low heat output for 15 minutes.
When the trap filling program is running, the following appears in the info area of the standard display Siphon fill. prog.
The function ensures that the system is fully drained and that the motor can be easily removed. The 3-way valve remains at the middle position for approx. 15 minutes.

· Without
· Burner run time: 1000 … 6000 h · Service date1)
· Boiler run time: 1 … 72 months

· 30 … 85 °C

Limits the adjustment range for the flow temperature.

· 35 … 60 … 80 °C · 14 … 50%

Limits the adjustment range for the domestic hot water temperature.
Minimum heat output. Minimum setting value may vary depending on appliance output.

· Yes · No
· 20 … 90 °C
· 20 … 90 °C

When connecting a weather-compensated control unit, no adjustment at the device is required. The system control unit optimises this setting. This service function activates a simple, weather-compensated controller with a linear heating curve. Depending on the on/off input, the heating is switched on or off.
This is only displayed if the control unit was activated. This can be used to set the base point of the heating curve, which corresponds to an outside temperature of +20 °C.
This is only displayed if the control unit was activated. This can be used to set the base point of the heating curve, which corresponds to an outside temperature of 10 °C.

Condens 7000 WP ­ 6721841195 (2022/01)

Meu item Summer mode
Frost prot. Frost temp. limit

Settings/adjustment range · 0 … 16 … 30 °C
· Yes · No · 0 … 5 … 10 °C

1. With heating controller
   Table 13 Settings menu Menu Function check Meu item Activate test
   Burner
   Ignition

Settings/adjustment range
· Off …100 %
· On · Off

Fan
Pump Cyl. prim. pump 3-way valve HC1 pump DHW circ. pump Ionisat.oscill. Table 14 Menu Function check Menu Reset Meu item Default setting
Service display Fault history

· On · Off · On · Off · On · Off · Heating · Hot water · On · Off · On · Off · On · Off
Settings/adjustment range Restore?
Reset? Delete?

Table 15 Menu Reset Menu Demo mode Menu item Demo mode
Table 16 Menu Demo mode

Settings/adjustment range · Yes · No

Condens 7000 WP ­ 6721841195 (2022/01)

Operation
Remark/restriction This is only displayed if the control unit was activated. This can be used to set the outside temperature threshold at which the heating system switches to summer mode.
Temperature value for the system frost protection. This service function is only available if the frost protection function was activated. If the outside temperature does not exceed the frost threshold temperature, then the heating pump in the heating circuit switches on.
Remark/restriction
This service function enables you to test the burner by adjusting the appliance output. Permanent ignition. Testing the ignition by means of permanent ignition without gas supply. To prevent damage to the ignition transformer: leave
the function switched on for a maximum of 2 minutes. Permanent ignition. Fan running without gas supply or ignition. Permanent pump run (internal or external pumps).
Permanent pump operation of cylinder primary pump
Permanent position of the 3-way valve.
Permanent HC1 pumpoperation (downstream of low loss header), if HC1 pump is installed. Permanent DHW circulation pump.
Check the ionisation measurement function at the flame.
Remark/restriction All settings of the heat source, and the control unit if applicable, are reset to the respective default setting. The system needs to be re-commissioned following this reset. Resetting the maintenance Reset the maintenance first. The fault history of the heat generator, and control unit if applicable, is deleted. If currently a fault is present, it is immediately entered again.
Remark/restriction To exit Demo mode: switch the device off and back on
at the ON/OFF switch.
31

Inspection and maintenance
9.4.3 Thermal disinfection To prevent hot water from becoming contaminated by bacteria such as legionella, we recommend thermal disinfection after long downtimes.
CAUTION Risk of scalding. During thermal disinfection, discharging unmixed hot water can cause serious scalding. Only use the maximum adjustable hot water temperature for thermal
disinfection. Inform occupants of the premises of the risk of scalding. Perform thermal disinfection outside of the normal operating times. Do not discharge DHW unmixed.
Proper thermal disinfection involves the DHW system including the draw-off points. Set the thermal disinfection in the hot water program of the heating
controller ( heating controller operating instructions). Close DHW draw-off points. Set any DHW circulation pump to continuous operation. Wait until the maximum temperature is reached. Open all DHW draw-off points, from the nearest to the one furthest
away, and draw off hot water until hot water at a minimum of 70 °C has flown from all draw-off points for at least 3 minutes. Restore the original settings.
10 Inspection and maintenance
WARNING Risk of explosion Close the gas valve before working on gas-carrying components. After completing the work, check the tightness of all gas-carrying
components.
CAUTION Flue gas poisoning Check the tightness of all flue gas routing parts once the work is
complete.
CAUTION Electric shock Avoid contact with the burner control unit, fan or pump when
measuring and adjusting the floor standing boiler. These are 230 V parts. Switch off the floor standing boiler before working on electrical parts.
CAUTION Malfunctioning safety sensors The function of the safety sensors in the installation room (such as CO, CO2, and gas detectors) must be regularly checked. Check the function of relevant safety sensors during inspection or
maintenance. You can read about how to perform the check in the instructions for
the safety sensor. Defects at relevant safety sensors must be rectified immediately.

10.1 Important notices You will need the following measuring devices and tools:
· Pressure gauge with a measurement accuracy of 0.01 mbar. · Flue gas analysis measurement device. · Cleaning brush with plastic bristles.
Only install original spare parts. Replace all loose gaskets when carrying out the work.
Inspection and maintenance interval To ensure the wall mounted gas condensing boiler works correctly and safely, the following intervals must be adhered to: · Inspection: annually, · Maintenance: every 2 years or following a burner runtime of 4000
hours (depending on which occurs first).
The following tasks must be performed when carrying out an inspection or maintenance:

General work
Cleaning
Check measurements

§ 10.2 § 10.3 to § 10.8 § 10.9 to § 10.15

Inspection
–

Maintenan ce

Table 17 Work to be carried out

10.2 General work The following work is not described in any further detail in this document. It must, nevertheless, still be carried out:
Check the general condition of the heating system. Visual inspection and function check of the heating system. Check the supply air and flue gas routing for function and safety. Check all gas and water pipes for signs of corrosion. Replace any corroded pipes. Check the pre-charge pressure of the expansion vessel. Check the concentration of any antifreeze/additives that may be used
in the system fill/top-up water annually. If necessary, check installed water treatment cartridges
(in the backfeed section) to ensure they are functioning correctly and for wear. During commissioning and the annual inspection, check all regulating, control and safety equipment for correct function and, where applicable, for correct settings.
Reading out Hours run The number of Hours run that have elapsed since initial commissioning is displayed in the menu. The number of Hours run specifies whether:
· Components need to be replaced as a preventative measure. · The Maintenance type needs to be modified.
Open the menu Info > Boiler > Hours run. Read out the number of Hours run. Check based on the value read out whether components need to be
replaced ( § 10.16.1, p. 36). Make a note of the value in the maintenance protocol ( § 10.17, p.
38). Establish the difference between the value most recently read out
and the previous value from the maintenance protocol. Check the setting Maintenance type based on this difference and
adjust if required ( § 8.2, p. 22).

32

Condens 7000 WP ­ 6721841195 (2022/01)

Reading out Burner starts The number of Burner starts that have elapsed since initial commissioning is displayed in the menu. The number of Burner starts specifies whether:
· Components need to be replaced as a preventative measure.
Open the menu Info > Boiler > Burner starts. Read out the number of Burner starts. Check based on the value read out whether components need to be
replaced ( § 10.16.1, p. 36). Make a note of the value in the maintenance protocol ( § 10.17, p.
38).
10.3 Remove the gas-air unit Remove the plug from the fan. Remove the gas hose between the air/gas ratio control valve venturi
nozzle.

Inspection and maintenance
Open the 4 snap fasteners on the burner cover. Attention! The snap fasteners are under tension.

0010028689-001
Fig. 37 Open the snap fasteners Remove the gas-air unit together with the burner cover.

70 kW
Fig. 35 Remove the gas hose 85 kW Remove the air intake pipe from the venturi nozzle.

0010028685-001

0010031062-001
Fig. 38 Remove the gas-air unit together with the burner cover.

Fig. 36 Removing the air intake pipe

0010029890-001

Condens 7000 WP ­ 6721841195 (2022/01)

33

Inspection and maintenance
10.4 Clean the burner Removing the burner gasket.

Purge the heat exchanger with water [2].
2. 1.

Fig. 39 Removing the burner gasket Removing the burner.

0010035719-001

0010035230-001
Fig. 41 Cleaning the heat exchanger 10.6 Cleaning the siphon Remove the flexible hose, and possibly the tee, from the siphon. Unscrew the union nut of the siphon in the floor standing boiler and
completely screw open [1]. Remove siphon [2].

0010035717-001
Fig. 40 Removing the burner Check the burner and gas distributor plate for pollution and cracking. Clean the burner with compressed air or a soft brush if necessary.
10.5 Cleaning the heat exchanger
NOTICE Risk of damage to the heat exchanger due to improper cleaning. Do not use chemical agents to clean the heat exchanger. Only use one brush with plastic bristles for cleaning.
Cover ignition unit [1]. Remove loose dirt with a vacuum cleaner. Loosen any other dirt with a brush and remove it with a vacuum
cleaner.

0010040938-001
Fig. 42 Remove the boiler siphon
Flush the siphon. Fill the siphon completely with water. Reattach the siphon. Check whether the neck of the siphon is properly connected to the
condensation catch pan. Tighten the union nut hand tight.

34

Condens 7000 WP ­ 6721841195 (2022/01)

10.7 Cleaning the condensation catch pan If the siphon is soiled, check and clean the condensation catch pan as necessary. Open the 2 quick-release fasteners.
2.

1. 0010035238-001
   Fig. 43 Open the snap fasteners of the condensation catch pan Remove the condensation catch pan.
   0010035239-001
   Fig. 44 Remove the condensation catch pan. Clean the condensation catch pan. Insert new gasket in the condensation catch pan. Place the condensation catch pan under the heat exchanger. Push the condensation catch pan so it rests seamlessly against the
   exchanger. Close the snap fasteners. Reassemble all parts in reverse order. Start up the floor standing boiler. 10.8 Resetting the Maintenance type Resetting the set Maintenance type starts the new maintenance interval. Open the menu Reset ( table 15, p. 31). Reset the parameter Service display. 10.9 Measuring the gas pressure Measure the gas working pressure ( § 8.5, p. 23).

Inspection and maintenance
Make a note of the value in the maintenance protocol ( § 10.17, p. 38).
10.10 Measuring of CO and CO2 Measure the CO content and the CO2 percentage ( § 8.6, p. 24). Make a note of the values in the maintenance protocol ( § 10.17,
p. 38).
10.11 Measuring the gas/air ratio Measure the gas/air ratio ( § 8.7, p. 24). Make a note of the value in the maintenance protocol ( § 10.17, p.
38).
10.12 Measuring the ionisation current Read off the ionisation current on the display ( § 8.8, p. 24). Make a note of the value in the maintenance protocol ( § 10.17, p.
38). -or If the value is less than 2 A: replace the ignition and flame sense
electrode ( § 10.16.2, p. 36).
10.13 Check the flue gas backflow preventer If a positive pressure cascade system has been mounted on the floor standing boiler, the backflow preventer must be checked.
Open the inspection aperture via the backflow preventer. Check the backflow preventer for wear, damage or pollution and
replace if necessary. Fill the backflow preventer with water if necessary. Close the inspection aperture of the backflow preventer.
10.14 Check the (flue) gas tightness Check the tightness of all gas-carrying components ( § 8.9, p.
25). Visually inspect the supply air and flue gas routing and check for
tightness and correct installation/brackets. Check whether the siphon is filled with water and fill if required ( §
10.6, p. 34).
10.15 Check for correct operation Check the tightness of all couplings. Check the operating pressure and top up if required.
In doing so, take the water quality into consideration ( § 5.3, p. 12). Check the settings of the floor standing boiler ( § 9.4.2, p. 26). Complete the inspection and maintenance protocol ( § 10.17, p. 38). Close the front panel.

Condens 7000 WP ­ 6721841195 (2022/01)

35

Inspection and maintenance

10.16 Replacing components

10.16.1 Replacement interval for components
The following components must be replaced after expiry of the specified service life.

Replace according to specification, depending on what occurs first.

Service life

Burner Burner starts runtime

Component

[Year] [Hours] [Number]

Gaskets and O-rings Remove gaskets and always replace O-rings.

Ignition and flame sense electrode

2

4000

25,000

Burner gasket

2

4000

—

Gasket of condensate

2

4000

—

catch pan

Air/gas ratio control

10

—

500,000

valve

Gas hose

10

20,000

–1)

1. When replacing the air/gas ratio control valve it is advisable also to replace the gas hose.

Table 18 Replacement interval for each component

Document replacement of components in the maintenance protocol ( § 15.7, p. 50).

10.16.2 Inserting the igniter

NOTICE
Damage to the appliance by applying an excessively high torque when tightening the screws.
The threaded bolts of the ignition unit are mounted in an aluminium heat exchanger. Using a graphite seal ensures tightness when tightening the threaded bolts hand-tight (using hand tools). Tighten both threaded bolts of the igniter (3 Nm).

Take the replacement interval of the air/gas ratio control valve into account. Replace the igniter, depending on the service life ( Tab. 18, p.
36).
Switch off the appliance. Undo both threaded bolts [1] of the igniter.

Remove igniter [3] and seal [2].
3 Nm 1
3 2
0010034708-002
Fig. 45 Inserting the igniter Detach connections from the igniter. Clean the contact surface on the heat exchanger. Position the new seal and igniter. Tighten both threaded bolts of the igniter (3 Nm). Mount the plug of the igniter. Start up the floor standing boiler. Check the flue gas tightness of the removed parts. Carry out a check by measuring the ionisation current ( § 8.8, p.
24). 10.16.3 Replacing the flue gas temperature sensor The flue gas temperature sensor is equipped with a bayonet connection. Switch off the appliance. Turn the flue gas temperature sensor anticlockwise by a quarter turn. Take the flue gas temperature sensor out of the flue pipe. Detach the plug from the flue gas temperature sensor. Fit the new O-ring on the new flue gas temperature sensor before
inserting it. Connect the plug at the new sensor. Insert the flue gas temperature sensor with the cam [1] pointing to
the right in the flue pipe. Turn the flue gas temperature sensor clockwise by a quarter turn.

36

Condens 7000 WP ­ 6721841195 (2022/01)

Operate the appliance.

Inspection and maintenance
Mount the burner control unit again by following the above steps in reverse order.
Screw down the bracket of the burner control unit. Close and secure the top panel. Operate the appliance. 10.16.5 Replacing the air/gas ratio control valve

1

Fig. 46 Replacing the flue gas temperature sensor 10.16.4 Replacing the coding plug

0010036539-001

NOTICE
Damage due to electrostatic charge Printed circuit boards in electronic components are susceptible to electrostatic charge (ESD).
Wear an earthed wrist strap when working on electronic components ( § 7.1, p. 18).

Switch off the appliance. Open the top appliance cover ( § 7.2, p. 18). Detach the bracket of the burner control unit [1]. Push the burner control unit to the left [2]. Lift the front of the burner control unit so the coding plug is easily
accessible [3]. Remove the coding plug [4]. Attach new coding plug.

Take the replacement interval of the air/gas ratio control valve into account.
If the air/gas ratio control valve is defective or depending on the service life, replace it ( table 18, page 36).
Switch off the appliance. Close gas isolator. Follow the replacement instructions provided when replacing the air/
gas ratio control valve. Open the gas cock. Operate the appliance. Check the tightness of all gas-carrying components.

Fig. 47 Replacing the coding plug

0010035231-001

Condens 7000 WP ­ 6721841195 (2022/01)

37

Inspection and maintenance

10.17 Inspection and maintenance protocol (checklist) Date

1

Call up the last fault saved in the service menu.

2

Call up the burner starts in the service

menu.

3

Call up the operating hours in the service

menu.

4

Inspect the flue system visually to make sure it has been

installed correctly. If there are any noticeable problems,

ensure tightness and mechanical stability.

5

Check the gas supply pressure.

mbar

6

Check the gas/air ratio.

Pa

7

Check CO content.

ppm

8

Check CO2 content.

%

9

Check tightness on the gas and water side.

10 Check the electrodes.

11 Check the burner.

12 Check the heating block.

13 Check ionisation current.

A

14 Clean dirt trap.

15 Check non-return valve.

16 Check the pre-charge pressure of the

bar

expansion vessel for the static head of the

heating system.

17 Check the heating system pressure.

bar

18 Check the sacrificial anode of the cylinder. mA

19 Check the electrical wiring for damage.

20 Check settings of the heating control.

21

Reset maintenance.

Table 19 Inspection and maintenance record

38

Condens 7000 WP ­ 6721841195 (2022/01)

11 Troubleshooting
11.1 Operating and fault displays
11.1.1 General information · Fault code: indicates which fault is present. · Fault category: indicates what kind of fault is present and its effects.
Fault category O (operating code) Operating codes indicate the operating conditions in normal operation.
Fault category B (blocking faults) Blocking faults result in the heating system being shut down temporarily. The heating system restarts automatically as soon as the blocking fault is removed.
11.1.2 Fault code table
Fault text on the display, description Remedy

Troubleshooting
Fault category V (locking faults) Locking faults result in the heating system being shut down, and the system can only be restarted after a reset. Press the and keys, until Reset is displayed.
The appliance resumes operation. If a fault persists: Rectify the fault according to 10.1.2 Fault code table
Fault category W (service displays) Service displays indicate that a maintenance or repair has to be carried out. The device is still in operation. If the service display has been caused by a defect, under certain circumstances, it may continue running with restricted functions.

Fault code Fault category

200 O 201 O 202 O 203 O 204 O 208 O 214 V 224 V
227 V
228 V

Boiler in heating mode Boiler in hot water mode Boiler in anti-cycle mode Boiler in standby, no heat energy demand Current prim. water temp. higher than set val. Chimney sweep demand Fan shut down during safety time Maximal flue gas thermostat or heat exchanger maximal thermostat has activated
No flame signal after ignition
Flame signal without flame present

­ ­ ­ ­ ­
­ 1. Check the plug on the fan. 2. Check the connecting lead to the fan. Heating circuit:
1. Check that the heating water is circulating correctly. 2. Open the closed valve in the heating circuit. 3. Top up water until the preset pressure is reached. 4. Connect the plug to the heating block temperature limiter correctly. 5. Check heating block temperature limiter, replace if required.
Potable water circuit:
Check that the potable water in the cylinder circuit is circulating correctly.

1. Open the main shut-off valve. 2. Open the device shut-off valve. 3. Interrupt the power supply of the appliance and check the gas line. 4. Check the supply pressure of the gas line. 5. Check that the burner is working correctly, adjust burner if necessary. 6. Check CO2 content of combustion air, adjust if necessary. 7. Establish protective conductor connection (PE) in the control device. 8. Carry out function check for ignition. 9. Carry out function check for ionisation. 10.Connect the plug for the ionisation and ignition sections correctly. 11.Connect the plug for the air/gas ratio control valve correctly. 12.Check condensate pipes. 13. Check flue gas side of heat exchanger for pollution. 14.Check flame sense electrode, replace if necessary. 15.Check ignition electrode, replace if necessary. 16.Check ignition electrode connecting lead, replace if necessary. 17.Check flame sense electrode connecting lead, replace if necessary. 18.Check air/gas ratio control valve, replace if necessary. 19.Check control device/burner control unit, replace if necessary. 1. Check ionisation cable, replace if necessary. 2. Check electrode set, replace if necessary. 3. Replace the control device.

Condens 7000 WP ­ 6721841195 (2022/01)

39

Troubleshooting Fault text on the display, description Remedy

Fault code Fault category

229 B
232 B
233 V 234 V 235 V 237 V 238 V 242 – V 263 265 O 268 O 269 V 273 B 281 B 306 V 316 V 317 V 318 V

Flame failed during burner operation

1. Open the main shut-off valve.

2. Open the device shut-off valve.

3. Shut down the device and check the gas line.

4. Signal evaluation on printed circuit board defective.

5. Replace flame sense electrode.

6. Establish protective conductor connection (PE) in the control device.

7. Replace ignition cable.

8. Replace the connecting lead to the flame sense electrode.

9. Replace air/gas ratio control valve.

10.Set the burner correctly or replace the burner nozzles.

11.Set the burner at minimum rated load.

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.

Boiler locked by external switching contact 1. Connect the plug for the external switching contact.

2. Install jumper/check condensate pump according to manufacturer’s specifications.

3. Adapt switching point of the external temperature switch to the system.

4. Replace connecting lead to the external temperature switch.

5. Replace external temperature switch.

Boiler identification module or device electronics faulty

1. Install boiler identification module/coding plug. 2. Connect plug to boiler identification module/coding plug.

3. Replace boiler identification module/coding plug (Bosch contact customer service).

Gas valve electrical fault

1. Replace connecting lead and reset once replacement is complete.

2. Replace air/gas ratio control valve and reset once replacement is complete.

Conflicting versions of boiler electr. and 1. Check boiler identification module/coding plug.

boiler identification

2. Install valid combination of control device/burner control unit.

System fault

1. Replace boiler identification module/coding plug.

2. Replace control device/burner control unit.

Boiler electronics faulty

Replace control device.

System fault boiler electronics / basic controller

1. Remedy contact problem. 2. If necessary, replace control device or boiler identification module/coding plug (Bosch
contact customer service).

Heat demand lower than energy supplied ­

Component test activated

­

Flame monitoring

Replace control device/burner control unit.

Operation interrupted following 24 hours of The fan and burner start automatically after the safety check. continuous operation

Pump stuck or running in air

1. Check whether the pump is blocked, unblock or replace if necessary.

2. Ensure that the heating water can circulate correctly.

3. Vent the pump.

Flame signal after closing the fuel supply 1. Replace the air/gas ratio control valve.

2. Replace the ionisation cable.

3. Replace the control device/burner control unit.

Flue gas temp. too high during sensor test 1. Replace flue gas temperature sensor.

2. Replace the connecting lead to the flue gas temperature sensor.

3. Replace the control device/burner control unit.

Short-circuit at flue gas temp. sensor

1. Replace flue gas temperature sensor.

2. Replace the connecting lead to the flue gas temperature sensor.

3. Replace the control device/burner control unit.

Flue gas temperature sensor interrupted 1. Connect the plug to the flue gas temperature sensor.

2. Check the connecting lead to the flue gas temperature sensor.

3. Replace flue gas temperature sensor.

4. Replace the control device/burner control unit.

40

Condens 7000 WP ­ 6721841195 (2022/01)

Fault code Fault category

Fault text on the display, description Remedy

Troubleshooting

349 B
357 O 358 O 360 V 362 V 363 V 811 A
815 W 1010 O 1013 W 1017 W 1018 W 1019 W 1022 W
1023 1025 W
1037 W
1065 W

Difference between flow and return temperature too high

1. Open the shut-off valves. 2. If the water pressure is too low, top up with water and vent the system.

3. Open a thermostat valve.

4. Replace flow or return sensor if required.

5. Replace the pump if required.

Ventilation program

­

Anti-seizing functn. active

­

System fault boiler electronics / basic controller

1. Install boiler identification module/coding plug. 2. Connect plug to boiler identification module/coding plug.

3. Replace boiler identification module/coding plug (Bosch contact customer service).

Boiler identification module or boiler electronics faulty

Replace boiler identification module/coding plug (Bosch contact customer service).

System fault boiler electronics / basic controller

Replace control device/burner control unit.

Hot water heating: thermal disinfection failed

1. If water is being drawn constantly, take action to stop this. 2. Position the DHW temperature sensor correctly.

3. Check that there is contact between the DHW cylinder temperature sensor and the cylinder.

4. Vent the cylinder circuit.

5. Set DHW heating to “priority”.

6. Check plate heat exchanger for calcification.

7. Check sizing of DHW circulation line and heat loss.

Low loss header temp. sensor faulty

1. Check hydraulic configuration, correct if necessary.

2. Check sensor for breaks or short circuits, replace if necessary.

No communication via EMS BUS connection 1. Rectify wiring fault and switch the control unit off and on again.

2. Repair the BUS cable or replace it.

3. Replace faulty EMS-BUS node.

Max. combustion point reached

1. Carry out maintenance.

2. Reset service display.

System pressure too low

1. Top up water and vent the system.

2. Check the pressure sensor, replace if necessary.

Maintenance interval expired

1. Carry out maintenance.

2. Reset service display.

Incorrect pump type detected

1. Check pump cabling.

2. Check that the correct heating pump type is in the appliance, replace if necessary.

Cylinder temp. sensor faulty or contact problems

1. Connect the plug to the temperature sensor correctly. 2. Connect the plug to the control device correctly.

3. Check the temperature sensor, replace if necessary.

4. Check temperature sensor connecting lead, replace if necessary.

Maximum run time including standby time 1. Carry out maintenance.

reached

2. Reset service display.

Return temp. sensor is faulty

1. Connect the plug to the return temperature sensor correctly.

2. Replace return temperature sensor.

3. Replace connecting lead to return temperature sensor.

4. Replace control device.

Outside temp. sensor faulty – heating back- 1. If an outside temperature sensor is not desired. Select the room temperature-

up operation active

dependent configuration in the control device.

2. If there is no continuity, rectify the fault.

3. Clean corroded terminals in the outside sensor housing.

4. If values do not match, replace the sensor.

5. If the sensor values matched, but the voltage values do not match, replace the control unit.

System pressure sensor faulty or not connected

1. Connect the plug to the pressure sensor correctly. 2. Check pressure sensor connecting lead, replace if necessary.

3. Check the pressure sensor, replace if necessary.

Condens 7000 WP ­ 6721841195 (2022/01)

41

Troubleshooting Fault text on the display, description Remedy

Fault code Fault category

1068 W
1070 1071 1072 1074 1075 W 1076 W 2085 V 2908 V 2910 V 2914 – V 2916 2920 V 2923- V 2926 2927 B
2928 V 2931 V 2940 V

Outside temp. sensor or lambda probe faulty.

1. Connect the plug to the temperature sensor correctly. 2. Connect the plug to the control device correctly.

3. Attach the temperature sensor correctly.

4. Check the temperature sensor, replace if necessary.

5. Check temperature sensor connecting lead, replace if necessary.

Maintenance is due on <dd.mm.yyyy>

­

please call your service engineer

Maintenance is now due please call your ­ service engineer

Maintenance is overdue please call your ­ service engineer

No signal from flow temperature sensor ­

Heat exchanger temp sensor short circuit 1. Connect the plug to the temperature sensor correctly.

2. Check the temperature sensor, replace if necessary.

3. Check temperature sensor connecting lead, replace if necessary.

Heat exchanger temp sensor disconnected 1. Connect the plug to the temperature sensor correctly.

2. Check the temperature sensor, replace if necessary.

3. Check temperature sensor connecting lead, replace if necessary.

Internal fault

1. Unlock.

2. Disconnect power from the system for 30 seconds.

3. Replace the burner control unit.

System fault boiler electronics / basic controller

If the fault persists following a reset, the burner control unit is faulty and must be replaced.

Fault in flue system

1. Install the flue system.

2. Remove any deposits from the flue system.

Boiler electr. system fault

If the fault persists following a reset, the control device is faulty and must be replaced.

Fault in flame monitoring Boiler electr. system fault No flame detected after ignition
Internal fault System fault boiler electronics / basic controller System fault burner control unit

Check control device, replace if necessary. 1. Check air/gas ratio control valve cabling. 2. Check air/gas ratio control valve.
If the fault persists following a reset, the control device or the air/gas ratio control valve is faulty and must be replaced. 1. Open the main shut-off valve. 2. Open the device shut-off valve. 3. Interrupt the power supply of the appliance and check the gas line. 4. Carry out function check for ignition. 5. Carry out function check for ionisation. 6. Connect the plug for the ionisation and ignition sections correctly. 7. Establish protective conductor connection (PE) in the control device. 8. Check flame sense electrode, replace if necessary. 9. Check ignition electrode, replace if necessary. 10.Check ignition electrode connecting lead, replace if necessary. 11.Replace the connecting lead to the flame sense electrode. 12.Set the burner correctly/replace the burner nozzles. 13.Set the burner at minimum rated load. 14.Check air/gas ratio control valve, replace if necessary. 15.Check the flue system and repair if necessary. 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. 1. Perform reset. 2. Replace control device/burner control unit. 1. Perform reset. 2. Replace control device/burner control unit. 1. Perform reset. 2. Replace control device/burner control unit.

42

Condens 7000 WP ­ 6721841195 (2022/01)

Fault code Fault category

Fault text on the display, description Remedy

Troubleshooting

2946 V 2948 B 2949 B 2950 B 2951 V
2952 V 2955 B
2956 O 2957 V 2961 V 2962 2963 B
2964 2965 B

Incorrect code plug detected No flame signal with low output
No flame signal with high output

Replace boiler identification module/coding plug (Bosch contact customer service).
Burner starts automatically after purging. If this fault occurs frequently, check CO2 setting. The burner is automatically restarted following purging.

1. Check burner gaskets, replace if required.

2. Reduce output.

No flame signal following starting procedure Burner starts automatically after purging. Set gas/air ratio correctly.

Loss of flame too many times

1. Open the main shut-off valve.

2. Open the device shut-off valve.

3. Interrupt the power supply of the appliance and check the gas line.

4. Carry out function check for ionisation.

5. Connect the plug for the ionisation and ignition sections correctly.

6. Establish protective conductor connection (PE) in the control device.

7. Check flame sense electrode, replace if necessary.

8. Check ignition electrode, replace if necessary.

9. Check ignition electrode connecting lead, replace if necessary.

10.Check flame sense electrode connecting lead, replace if necessary.

11.Set the burner correctly/replace the burner nozzles.

12.Set the burner at minimum rated load.

13.Check air/gas ratio control valve, replace if necessary.

14.Check the flue system and repair if necessary.

15.The interconnected room air supply is too small or the size of the ventilation opening is too small.

16.Clean the heating block on the flue gas side.

17.Check control device/burner control unit, replace if necessary.

Internal fault when testing the ionisation 1. Perform reset.

signal

2. Replace control device/burner control unit.

Boiler does not support the parameters set Check hydraulic settings, change if necessary.

for the hydraulic configuration

· Low-loss header

· Internal DHW circuit (cylinder charging circuit)

· Heating circuit 1

· Heating pump in appliance

Hydraulic configuration at the boiler

­

activated

Boiler electr. system fault

1. Reset control device / burner control unit.

2. Reconnect electrical connections at control device / burner control unit correctly.

3. Replace the control device/burner control unit.

No fan signal available

1. Check fan and connecting lead.

2. Check mains voltage.

The heat exchanger sensor or both supply and heat exchanger sensors are defect
Flow rate in heat exchanger too low Flow temperature too high

1. Connect the plug to the temperature sensor correctly. 2. Connect the plug to the control device correctly. 3. Attach the temperature sensor correctly. 4. Check the temperature sensor, replace if necessary. 5. Check temperature sensor connecting lead, replace if necessary. ­ 1. Ensure that the heating circulation is working correctly. 2. Check pump setting, adjust to match heating system if necessary. 3. Connect the plug to the temperature sensor correctly. 4. Connect the plug to the control device correctly. 5. Attach the temperature sensor correctly. 6. Check the temperature sensor, replace if necessary. 7. Check temperature sensor connecting lead, replace if necessary.

Condens 7000 WP ­ 6721841195 (2022/01)

43

Troubleshooting Fault text on the display, description Remedy

Fault code Fault category

2966 B

Flow temperature rise in heat exchanger too 1. Ensure that the heating circulation is working correctly.

rapid

2. Check pump setting, adjust to match heating system if necessary.

3. Connect the plug to the temperature sensor correctly.

4. Connect the plug to the control device correctly.

5. Attach the temperature sensor correctly.

6. Check the temperature sensor, replace if necessary.

7. Check temperature sensor connecting lead, replace if necessary.

2967

The temperature difference between supply ­ temperature sensor and temperature sensor at heat exchanger is too large

2968

Refilling system pressure

­

2970

Pressure drop in heating system too rapid ­

2971 B System pressure too low

1. Vent the heating system.

2. Check the heating system for tightness.

3. Top up water until the target pressure is reached.

4. Check the pressure sensor, replace if necessary.

5. Check the pressure sensor cable, replace if necessary.

2972

Mains voltage too low

1. Establish supply voltage of at least 196 VAC.

2. Replace burner control unit.

3071

No communication with remote control 1. Check configuration.

2. Check cabling.

Table 20 Indicators and fault displays

11.1.3 Faults that are not displayed

Device faults Combustion noises too loud, rumbling noises
Flow noises Heat-up takes too long. Flue gas values incorrect, CO content too high.
Violent ignition, poor ignition.
No function, the display remains dark. Table 21 Faults that are not shown on the display

Remedy Check the gas type. Check the gas supply pressure. Check the flue system, clean or repair as necessary. Check the gas/air ratio. Check the air/gas ratio control valve, replace if required.
Set the pump rate or pump characteristic map correctly and match to the maximum output.
Set the pump rate or pump characteristic map correctly and match to the maximum output.
Check the gas type. Check the gas supply pressure. Check the flue system, clean or repair as necessary. Check the gas/air ratio. Check the air/gas ratio control valve, replace if required.
Check the ignition transformer with service function t01 for misfiring, replace if required.
Check the gas type. Check the gas supply pressure. Check the power supply. Check the electrodes with cable, replace if required. Check the flue system, clean or repair as necessary. Check the gas/air ratio. For natural gas: check the external gas flow monitor, replace if required. Check the burner, replace if required. Check the air/gas ratio control valve, replace if required.
Check the electrical wiring for damage. Replace defective cables. Check the fuse, replace if required.

Fault display: System pressure too low
If the system pressure in the heating system falls below the minimum pressure that has been set, the display shows the message LoPr => L0.X

bar. The system pressure is too low. Fill the heating system.

44

Condens 7000 WP ­ 6721841195 (2022/01)

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.
12 Shutdown
12.1 Standard decommissioning Switch off the floor standing boiler via the on/off switch ( § 2.11,
p. 6). Close gas isolator. Close the service valves.
12.2 Decommissioning when there is a risk of frost If the floor standing boiler remains switched off. Set the pump overrun time to 24 hours ( § , p. 29). Make sure that a sufficient flow rate is possible at all radiators.
If the floor standing boiler is switched off: Switch off the floor standing boiler via the on/off switch ( § 2.11,
p. 6). Drain the entire heating system. If installed, drain the entire potable water system.
13 Environmental protection and 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. We use the best possible technology and materials for protecting the environment taking account of economic considerations.
Packaging Where packaging is concerned, we participate in country-specific recycling processes that ensure optimum recycling. All of our packaging materials are environmentally compatible and can be recycled.
Used appliances Used appliances contain valuable materials that can be recycled. The various assemblies can be easily dismantled. Synthetic materials are marked accordingly. Assemblies can therefore be sorted by composition and passed on for recycling or disposal.
Old electrical and electronic appliances This symbol means that the product must not be disposed of with other waste, and instead must be taken to the waste collection points for treatment, collection, recycling and disposal.
The symbol is valid in countries where waste electrical and electronic equipment regulations apply, e.g. “European Directive 2012/ 19/EC on old electronic and electrical appliances”. These regulations define the framework for the return and recycling of old electronic appliances that apply in each country.
As electronic devices may contain hazardous substances, it needs to be recycled responsibly in order to minimize any potential harm to the environment and human health. Furthermore, recycling of electronic scrap helps preserve natural resources.
For additional information on the environmentally compatible disposal of old electrical and electronic appliances, please contact the relevant local authorities, your household waste disposal service or the retailer where you purchased the product.

You can find more information here: www.weee.bosch-thermotechnology.com/

Shutdown

14 Data Protection Notice
We, Bosch Thermotechnology Ltd., Cotswold Way, Warndon, Worcester WR4 9SW, United Kingdom process product and installation information, technical and connection data, communication data, product registration and client history data to provide product functionality (art. 6 (1) sentence 1 (b) GDPR), to fulfil our duty of product surveillance and for product safety and security reasons (art. 6 (1) sentence 1 (f) GDPR), to safeguard our rights in connection with warranty and product registration questions (art. 6 (1) sentence 1 (f) GDPR) and to analyze the distribution of our products and to provide individualized information and offers related to the product (art. 6 (1) sentence 1 (f) GDPR). To provide services such as sales and marketing services, contract management, payment handling, programming, data hosting and hotline services we can commission and transfer data to external service providers and/or Bosch affiliated enterprises. In some cases, but only if appropriate data protection is ensured, personal data might be transferred to recipients located outside of the European Economic Area. Further information are provided on request. 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 situation or where personal data are processed for direct marketing purposes, at any time to processing of your personal data which is based on art. 6 (1) sentence 1 (f) GDPR. To exercise your rights, please contact us via privacy.ttgb@bosch.com To find further information, please follow the QR-Code.

Condens 7000 WP ­ 6721841195 (2022/01)

45

Technical information and reports
15 Technical information and reports
15.1 Wiring Diagram

2

3 45

P
C13 C12 C11 C7 C6 C5 C4 C3 C2 C1

1

HMI

A8 A7 A6 A5 A4 A3 A2 A1

6 7 8 9 10 11

D17 D14 D16 D14 D13

PE D11 D4 D14 D1 D2

12

PE 13 14

PE

2(N) 1(L)
E7 E6 E5 P1 P2 E2 E1
PE

NL

PE

F6 F5

A B 1 8 8

1 17

C

1 17

D

1

7

E

16

F

1

27
5678 1234 R4 R3 R2 R1

R1 4

G HJ K

L M NP

Q

1

8

1

41

41

61

41

61

41

5

1

4

J4 J3 J2 J1 K2 K1 K6 K5

J

L3 L4 L2 L1

J1 J2

12 3 4 5 6 7 8

I1

BUS

I3

T1

9 10 11 12 13 14 15 16

TW1

T0

BUS

P

P1 P2 M3 M4

PE

PE

PM

P4 P5 M1M2

PE

PE

Q1Q2Q3Q4

120/230 VAC

PW2

120/230 VAC

PW1

1234

26 25 24 23

22 21 20

Fig. 48 Wiring Diagram
[1] Control panel, HMI 700 [2] PWM signal, pump [3] Pressure sensor [4] Return temperature sensor [5] Flue gas temperature sensor [6] Safety temperature sensor [7] flow temperature sensor [8] High limit safety cut-out STB, heat exchanger [9] Maximum temperature limiter STB [10] Monitoring electrode [11] Air/gas ratio control valve [12] Fan [13] Ignition and flame sense electrode [14] Boiler circulation pump 230Vac [15] On/off switch [16] Cylinder primary pump 230VAC
46

19 18

16

15

17

0010034254-002

[17] Mains plug 230VAC [18] DHW circulation pump 230VAC [19] Mains voltage 230VAC [20] EMS-bus
[21] Temperature sensor of low loss header
[22] Storage cylinder temperature sensor
[23] Outdoor ambient temperature sensor
[24] External switching contact, volt free
[25] EMS-bus
[26] Volt-free contact
[27] Coding plug

Condens 7000 WP ­ 6721841195 (2022/01)

Technical information and reports

15.2 Technical Specifications

Condens 7000 WP GC7000WP
General information Rated heat output (50/30 °C) [Pn cond] Rated heat output (80/60 °C) [Pn] Rated thermal load G20, G25, G25.3 (UW) [Qn (Hi)] Rated thermal load G31 (UW) [Qn (Hi)] Efficiency (37/30 °C) partial load 30% in accordance with EN 15502 Efficiency (80/60 °C) full load Standby loss in accordance with EN 15502. Standard efficiency of heating curve (75/60 °C) Standard efficiency of heating curve (40/30 °C) Pump overrun IP classification [IP rating] Appliance class in accordance with EN 15502. Product ID no. Temperature classification in accordance with EN 14471. Appliance fuse Mains voltage, frequency [U] Power input (without pump),
standby / partial load / full load Maximum possible installation altitude of boiler Permissible ambient temperature Maximum flow temperature [Tmax] Maximum permissible water pressure [PMS] Maximum condensate accumulation rate Connections Flue gas connection/concentric air supply Heating flow/return pipe (wall mounted gas condensing boiler) Gas connection (wall mounted gas condensing boiler) Condensate drain (flexible drain hose) Emission values in accordance with EN 13384 CO2 content with natural gas G20, partial load/full load CO2 content with natural gas G25, partial load/full load CO2 content with natural gas G25.3, partial load/full load CO2 content with propane G31, partial load/full load O2 content with natural gas G25.3, partial load/full load O2 content with propane G31, partial load/full load CO output G20 at full load (n = 1) Standard emission factor (EN15502) CO Standard emission factor (EN15502) NOx G20 (average) NOx class Flue gas mass flow rate at min./max. rated heat output Flue gas temperature at 80/60 °C, partial load/full load Flue gas temperature at 50/30 °C, partial load/full load Differential pressure gas/air (with partial load) Flue gas class for LAS (Germany only) Fan discharge pressure Residual head of fan (pmax) DN110/185, B23p, partial load/full load DN110/185, with overpressure flap, B23p, partial load/full load DN110/160, Cx3x, partial load/full load DN110-110, Cx3x, partial load/full load Dimensions and weight

GC7000WP 50 GC7000WP 65 GC7000WP 85 GC7000WP 100

Unit

kW

14.3 ­ 49.9 14.3 ­ 69.5 20.8 ­ 84.5 20.8 ­ 99.5

kW

13.0 ­ 46.5 13.0 ­ 62.6 18.9 ­ 80.0 19.0 ­ 94.5

kW

13.3 ­ 47.5 13.3 ­ 64.3 19.3 ­ 82.0 19.3 ­ 96.5

kW

13.3 ­ 47.5 13.3 ­ 64.3 19.3 ­ 82.0 19.3 ­ 96.5

%

108.4

108.7

109.1

108.7

%

98.5

98.9

98.7

98.6

%

0.24

0.18

0.14

0.12

%

106.0

106.9

106.7

106.8

%

109.7

110.4

110.2

110.3

min

2

IP X0D

B23(p), B53(p), C13(x), C33(x), C43(x), C53(x), C63(x), C83(x), C93(x) CE- 0085DL0480

T120

230 V, 5AF

230 V, 50 Hz

W

2 / 8 / 31

2 / 8 / 65

2 / 10 / 88 2 / 10 / 133

m

°C

°C

bar

l/h

6.0

1200

0 – 40

85

6

7.6

9.3

11.0

mm

110/160

inch

G1½

inch

R1

mm

24

% % % % % % ppm mg/m3 mg/kWh

8.4 / 9.3 8.3 / 9.1 8.4 / 9.1 9.5 / 10.0 5.7 / 4.4 6.5 / 5.7
31 2.7 25

g/s

6.5/21.6

°C

56 / 59

°C

32 / 39

Pa

8.4 / 9.3

8.2 / 9.1

8.4 / 9.1

8.2 / 9.1

8.4 / 9.1

8.2 / 9.1

9.5 / 10.0

9.1 / 10.0

5.7 / 4.4

6.1 / 4.4

6.5 / 5.7

7.1 / 5.7

63

70

10.8

17.2

34

34

6

6.5/29.2

9.8/38.0

56 / 61

56 / 66

32 / 43

34 / 50

-5

G61

8.1 / 9.1 8.1 / 9.1 8.1 / 9.1 9.0 / 10.0 6.3 / 4.4 7.3 / 5.7
81 23.4 38
9.8/44.7 56 / 73 34 / 53

Pa

71

130

162

226

Pa

50 / 83

50 / 148

50 / 177

50 / 241

Pa

41 / 41

50 / 100

50 / 108

50 / 148

Pa

50 / 71

50 / 130

50 / 162

50 / 226

Pa

50 / 71

50 / 130

50 / 162

50 / 226

Condens 7000 WP ­ 6721841195 (2022/01)

47

Technical information and reports

Condens 7000 WP GC7000WP

Height x Width x Length

mm

Weight

kg

Connection set

Heating flow pipe

inch

Heating return pipe

inch

Gas line

inch

Power input Wilo-Para STG 25/8, min./max.

W

Power input Wilo-Stratos Para 25/1-8,

W

min./max.

Table 22 Technical Specifications

15.3 Data relating to the gas Gas consumption

Maximum gas consumption [ m³/h]

Gas type

GC7000 GC7000 GC7000 GC7000 WP 50 WP 65 WP 85 WP 100

Natural gas E, H, Es (G20)

5.03 6.80 8.68 10.21

Natural gas LL, L, Ei, (G25)

5.85 7.91 10.09 11.88

Natural gas K (G25.3)

XX

XX

XX

XX

Propane 3P (G31)

1.94 2.62 3.34 3.93

Table 23 Gas consumption

Gasaansluitdruk

Land

Gasfamilie Gasaansluitdruk [mbar] Min.1) Nom. Max.

AT, AU, AZ, BA, BG, BY, CH, Aardgas H, 17 20 25

CZ, DK, EE, ES, GB, GR, HR,

G20

IE, IT, KZ, LT, LV, MD, NO, PT,

RO, RS, RU, SE, SI, SK, TR, UA

HU

Aardgas H, 17 20 25

G20

DE, LU, NL, PL

Aardgas E, 17 20 25 G20

FR

Bereik Es 17 20 25

Aardgas E

(G20)

FR

Bereik Ei 20 25 30

Aardgas E

(G20)

BE

Bereik Es 20 25 30

Aardgas E

(G25)

NL

Aardgas K, 20 25 30

G25.3

DE

Aardgas LL, 18 20 25

G25

DK, NL, NO, SE

Propaan L, 25 30 35 G31

AZ, BA, BE, BG, CH, CZ, ES, Propaan L, 25 37 45 FR, GB, GR, IE, PT, IT, MD, PL, G31 RO, RS, TR, PL, SK

AT, AU, BG, CH, DE, ES, EE, Propaan L, 42,5 50 57,5 HR, HU, LT, LV, LU, NL, SI, SK, G31 RS, UA

GC7000WP 50 GC7000WP 65 GC7000WP 85
1120 x 520 x 457 74

GC7000WP 100

4 / 74

G1½ G1½ G 1
27 / 138

1. De minimale gasvoordruk gemeten op het gasregelblok waarbij de maximale belasting van het cv-toestel gewaarborgd blijft is 10 mbar.

Table 24 Gasaansluitdrukken

Natural gas

Country

Standard Gas Gas type gas category
pressure [mbar]

DE

20

2ELL 2E, G20

DE

25

2ELL 2LL, G25

AT, AU AZ, BA, BG, BY, 20 CH, CZ, DK, EE, ES, GB, GR, HR, IE, IT, KZ, LT, LV, MD, NO, PT, RO, RS, RU, SE, SI, SK, TR, UA

2H 2H, G20

FR

20/25

2Es 2Es, G20

FR

20/26

2EI 2Ei, G20

BE

20/25 2E

2Es,

G20/G25

LU, PL

20

2E 2E, G20

NL

20

2E 2E, G20

HU

25

2H 2H, G20

NL

25

2K

2K,

G25.3

Table 25 Natural gas

Default setting [mbar] 20 25 20
20 -20
20 -25 25

Propane

Country

Standard Gas Gas Conversion gas category type required
pressure [mbar]

DK, NO, SE

30

3P G31

Yes

AZ, BA, BE, FR, GB, GR, 37 IE, IT, MD, PL, PT, RO, TR

3P G31

Yes

AT, DE, EE, HR, HU, LT, 50 LU, LV, RS, SI, UA

3P G31

Yes

NL

30, 50 3P G31

Yes

BG, CH, CZ, ES, RS, SK 37, 50 3P G31

Yes

Table 26 Propane

48

Condens 7000 WP ­ 6721841195 (2022/01)

15.4 Hydraulic resistances

Unité GC7000 GC7000 GC7000 GC7000 WP 50 WP 65 WP 85 WP 100

Required

l/h 2200 3000 3600 4300

volumetric flow

rate at T = 20 K

Max. volumetric l/h flow rate

5000

Resistance of floor standing boiler

mbar 75 130 170 240

Table 27 Hydraulic resistances

15.5 Residual head of pumps

Changing the pump output The standard setting for the pump output is sufficient under normal conditions or with the heating circuit distributor. With a measured T of more than 20 K an adjustment of the pump output is desirable.
Increase the pump output until T is 20 K ( § 9.4, 26). -or Reduce the installation resistance by installing a low loss header.

[mbar]

800

1

4

700

5

600

2

6

500

400

300

200
3 100

00

500 1000 1500 2000 2500 3000 3500 4000 4500 5000

[l/h]

0010039392-001

Fig. 49 Residual head of pump GC7000WP 100

Legend next to pump graphics:
[1] Maximum adjustable discharge head of pump [2] Standard setting of discharge head [3] Minimum pump discharge head [4] Resistance of heat exchanger + connection + non-return valve [5] Resistance of heat exchanger + connection set [6] Resistance of heat exchanger

[mbar]

800

1

4

700

5

600

6

500

400

2

300

200
3 100

00

500 1000 1500 2000 2500 3000 3500 4000 4500 5000

[l/h]

0010039391-001

Fig. 50 Residual head of pump GC7000WP 85

Technical information and reports

[mbar]

800

4

700

5

600

6

500 400

21

300

200
3 100

00

500 1000 1500 2000 2500 3000 3500 4000 4500 5000

[l/h]

0010039390-001

Fig. 51 Residual head of pump GC7000WP 65

[mbar]

800

4

700

5

600

6

500

1

400

300

2

200
3 100

00

500 1000 1500 2000 2500 3000 3500 4000 4500 5000

[l/h]

0010039389-001

Fig. 52 Residual head of pump GC7000WP 50

15.6 Setting values for heating capacity

Power

Display

Display

Display

Display

GC7000WP GC7000WP GC7000WP GC7000WP

50

65

85

100

[kW] [%] [%] [%] [%]

13

28

20

—

—

20

40

28

24

20

25

50

36

29

25

30

60

43

35

30

35

70

50

41

35

40

80

57

47

40

45

90

64

53

45

50

100

71

59

50

55

—

79

65

55

60

—

86

71

60

65

—

93

76

65

70

—

100

82

70

75

—

—

88

75

80

—

—

94

80

85

—

90

—

95

—

100

—

—

100

85

—

—

90

—

—

95

—

—

100

Table 28 Setting values for heating capacity

Condens 7000 WP ­ 6721841195 (2022/01)

49

Technical information and reports
15.7 Commissioning report for the appliance Customer/system user: Surname, first name Telephone/fax System installer:

Street, house number Postcode, town

Order number:

Appliance type:

(Complete a separate report for every appliance!)

Serial number:

Date of commissioning:

Individual appliance | Cascade, number of devices: ……

Installation location: Cellar | Attic | Other:

Ventilation apertures: Number: ……, Size: approx.

cm2

Flue gas routing:

Twin pipe system | LAS | Duct | Separate pipe routing

Plastic | Aluminium | Stainless steel

Total length: approx. …… m | Elbow 87°: …… pce | Elbow 15 – 45°: …… pce

Leak check of the flue with a countercurrent: Yes | No

CO2 value in the combustion air at maximum rated output:

%

O2 value in the combustion air at maximum rated output:

%

Notes regarding underpressure or overpressure operation:

Gas setting and flue gas test: Set gas type: Gas supply pressure: Set maximum rated output: Gas flow rate at maximum rated output: Net calorific value HiB: CO2 at maximum rated output: O2 at maximum rated output: CO at maximum rated output:
Flue gas temperature at maximum rated output: Maximum measured flow temperature: System Hydraulic: Low loss header, type: Heating pump:

mbar kW l/min
kWh/m3 % % ppm mg/kWh °C
°C

DHW cylinder/type/number/heating surface output: System hydraulics checked, Notes:

Gas static supply pressure: Set minimum rated output: Gas flow rate at minimum rated output:
CO2 at minimum rated output: O2 at minimum rated output: CO at minimum rated output:
Flue gas temperature at minimum rated output: Minimum measured flow temperature:

mbar kW l/min
% % ppm mg/kWh °C
°C

Additional expansion vessel Size/pre-charge pressure: Automatic air vent valve present? Yes | No

50

Condens 7000 WP ­ 6721841195 (2022/01)

Changed service functions Read off the changed service functions and enter the values here.

Technical information and reports

Label with “settings in the service menu” filled out and affixed.

Heating controls:

Weather-compensated control

Room temperature-dependent control

Remote control × …… pce., heating circuit(s) coding:

Room temperature-dependent control × …… pce., heating circuit(s) coding:

Module × …… pce., heating circuit(s) coding:

Miscellaneous:

Heating controls set, Notes:

Changed settings for the heating controls documented in the operating/installation instructions for the control unit

The following work has been carried out:

Electrical connections checked, Notes:

Condensate trap filled

Carry out a combustion air/flue gas test

Function check carried out

Leak test carried out on the gas and water sides

Commissioning includes checking the setting values, a visual leak test on the appliance and a function check of both the device and its control. The system installer conducts a test of the heating system.

The system named above has been checked to the extent described.

The documents have been handed over to the user. The user has been made aware of the safety instructions and operation of the abovementioned wall mounted boiler, including accessories. Attention has been drawn to the requirement for regular maintenance of the above-mentioned heating system.

___ Name of service engineer

__ Date, user’s signature Affix the test report here.

____ Date, system installer’s signature
Table 29 Commissioning report

Condens 7000 WP ­ 6721841195 (2022/01)

51

Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau
www.bosch-thermotechnology.com

References

• New Boilers | Worcester Bosch
• Home | Bosch Home Comfort
• WEEE Electronic Waste | Bosch Home Comfort Group

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