Benchmark CS1 User guide

Installation and Servicing Instructions
CS1
Wall mounted condensing boiler for central heating
6 720 610 577-00.10
ZB 7-28 CS1 GC-Number: 41 108 02
6 720 610 601 GB (03.02) OSW

6 720 610 601 GB (03.02)
2
Contents
Contents
Safety recautions 3
Symbols 3
1 Details of the a liance 4
1.1 EC Declaration of Conformity 4
1.2 Standard package 4
1.3 Description of appliance 4
1.4 Accessories 5
1.5 Casing dimensions 5
1.6 Layo t of appliance 6
1.7 F nction (with optional extra motorised valve) 7
1.8 Electrical wiring diagram 8
1.9 Technical data 9
2 Installation regulations 10
3 Installation 11
3.1 Important remarks 11
3.2 Sealed systems 11
3.3 Siting the appliance 13
3.4 Wall mo nting frame assembly 14
3.5 Pre-piping the system 14
3.6 Fitting the appliance 15
3.7 Checking the connections 16
3.8 Fl e Systems 16
3.8.1 Siting the Fl e Terminal 17
3.8.2 Installation of the fl e 18
3.8.3 Fl e d ct preparation and assembly 20
4 Electrical connections 21
4.1 Connecting the appliance 21
4.2 Mains Voltage external controls connections 22
4.3 Wiring to yo r system 22
4.3.1 Pre-wired Remote S Plan 22
5 Commissioning 23
5.1 Commissioning 23
5.2 Switching the appliance on/off 24
5.3 Switching on the central heating 24
5.4 System controls 24
5.5 Appliances with optional pl g-in
diverter valve: Setting hot water temperat re 25
5.6 Frost protection 25
5.7 P mp anti-seize f nction 25
5.8 Fa lt Condition 25
6 Individual settings 26
6.1 Mechanical settings 26
6.1.1 Checking the size of the expansion vessel 26
6.1.2 Setting the central heating flow temperat re 26
6.1.3 Changing the heating p mp characteristic 26
6.2 Settings on the Bosch Heatronic 27
6.2.1 Operating the Bosch Heatronic 27
6.2.2 Selecting the p mp control mode for central
heating mode (Service F nction 2.2) 27
6.2.3 Setting the anti-cycle time
(Service F nction 2.4) 27
6.2.4 Setting the maxim CH flow temperat re
(Service F nction 2.5) 28
6.2.5 Setting the switching difference
(Service F nction 2.6) 28
6.2.6 Setting the heating o tp t
(Service F nction 5.0) 28
6.3 Setting the gas/air ratio 28
7 Converting the a liance to
different gas ty es 29
7.1 Setting the gas/air ratio 29
7.2 Testing comb stion air/fl e gas at set
heat o tp t 31
7.2.1 Testing the O
2
or CO
2
level in the
comb stion air 31
7.2.2 Testing CO and CO
2
31
8 Maintenance 32
8.1 Pre-Service Check List 33
8.2 Description of servicing operations 34
8.3 Replacement of Parts 37
8.3.1 PCB control board and transformer 37
8.3.2 Fan Assembly 38
8.3.3 P mp 38
8.3.4 3-way diverter valve 38
8.3.5 3-way diverter valve motor 39
8.3.6 Sensors 39
8.3.7 Gas Valve 39
8.3.8 Electrode assembly 39
8.3.9 Press re ga ge 40
8.3.10Expansion vessel 40
8.3.11Press re Relief Valve 40
8.3.12B rner 40
8.3.13Primary Heat Exchanger 40
9 A endix 41
9.1 Fa lt Codes 41
9.2 Short parts list 42
9.3 Heating/hot water o tp t settings (N.G) 42
9.4 Heating/hot water o tp t settings (L.P.G) 42
9.5 Operational Flow diagrams 43
9.5.1 Central heating f nction 43

6 720 610 601 GB (03.02)
Safety recautions
3
Safety recautions
If you smell gas
B Turn off g s service cock t the meter.
B Open windows nd doors.
B Do not oper te ny electric l switches.
B Extinguish ny n ked fl mes.
B Telephone your g s comp ny.
If you smell fumes from the a liance
B Switch off ppli nce (see p ge 24).
B Open windows nd doors.
Fitting and modifications
B Fitting of the ppli nce or ny controls to the ppli-
nce m y only be c rried out by competent engi-
neer in ccord nce with the G s S fety (Inst ll tion
nd Use) Regul tions 1998.
B Flue systems must not be modified in ny w ys other
th n s described in the fitting instructions.
B This ppli nce is for use on se led prim ry systems only.
Maintenance
B The user is recommended: to h ve the system
regul rly serviced in order to ensure th t it functions
reli bly nd s fely.
B Use only origin l sp re p rts!
Combustible materials
B Do not store or use ny combustible m teri ls
(p per, thinners, p ints etc.) in the vicinity of the
ppli nce.
Health and safety
B This ppli nce cont ins no sbestos products.
B There is no potenti l h z rd due to the ppli nce
being electric lly uns fe.
B There re no subst nces used in the construction
th t re potenti l h z rd in rel tion to the COSHH
Regul tions (Control of Subst nces H z rdous to
He lth Regul tions 1988).
Combustion air/Ambient atmos here
B The combustion ir/ mbient tmosphere should be
kept free of chemic lly ggressive subst nces (e.g.
h logen ted hydroc rbons which cont in chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Expl in to the customer how the ppli nce works
nd how to oper te it.
B Advise the user th t he/she must not m ke ny modi-
fic tions to the ppli nce or c rry out ny rep irs on it.
B These instructions re to be left with the user or t
the G s meter.
B Import nt: These instructions pply in the UK only.
Symbols
Safety instructions in this doc ment
are identified by a warning-triangle sym-
bol and are printed on a grey back-
gro nd.
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.

6 720 610 601 GB (03.02)
4
Details of the a liance
1 Details of the a liance
1.1 EC Declaration of Conformity
This ppli nce is in ccord nce with the pplic ble
requirements of the G s Appli nce Directive, Boiler
Efficiency Directive, Electrom gnetic Comp tibility
Directive nd the Low Volt ge Directive.
1.2 Standard ackage
• G s condensing boiler for centr l he ting
• W ll mounting fr me
• Cl mp for securing flue duct kit
• Fixings (screws etc.)
• Set of document tion for ppli nce
• Pre-plumbing m nifold
• Condens te dr in pipe.
1.3 Descri tion of a liance
• W ll-mounted ppli nce, siting not dependent on
room size
• N tur l g s models re low-emission ppli nces
• Multifunction displ y
• Bosch He tronic control system
• Autom tic ignition
• Modul ting control
• Full s fety systems incorpor ting Bosch He tronic
with fl me ionis tion monitoring, solenoid v lves nd
temper ture sensors
• Concentric flue/ ir duct with testing point for
CO
2
/CO
• Regul ted speed f n
• Pre-mix burner
• Temper ture control for centr l he ting
• S fety temper ture limiter in 24 V electric l circuit
• Three-speed centr l he ting pump with utom tic
vent
• Relief v lve, pressure g uge, exp nsion vessel
• Flue g s temper ture limiter (105 °C)
• Condens te Tr p
• Connecting possibility for S-Pl n System.
PIN CE-0085 BL 0507
Category
UK II
2H 3P
A liance Ty e C
13
, C
33
Table 1

6 720 610 601 GB (03.02)
Details of the a liance
5
1.4 Accessories
• St nd rd horizont l flue kit t 100 mm outside
di meter for flues upto 4 m in length.
• Flue duct kits for horizont l (125 mm outside
di meter) for flue lengths upto 13 m nd vertic l flue
systems for flue lengths upto 15 m. Fitting instruc-
tions re sent with these kits.
• He ting progr mmers
• Timer
• Security kit
• Motorised v lve is v il ble s n option l extr . If
this option is used then the DT2, TR2 Optimising
Room Thermost t nd the Night Set B ck Module
will be required.
1.5 Casing dimensions
Fig. 1
13 M nifold ssembly
101 Outer c se
103 F ci cover
X St nd rd Concentric Horizont l Flue System: min. 310 mm
Altern tive Concentric Flue System: min. 250 mm
Y St nd rd Concentric Horizont l Flue System: 158 mm
Altern tive Concentric Flue System: 121 mm
Z St nd rd Concentric Horizont l Flue System: 105 mm
Altern tive Concentric Flue System: 130 mm
*
For servicing the ppli nce
min.
5
min.
5
850
440 395
200
360
861
906
200
30
6 720 610 601- 01.3O
101
103
35
X
13
Y
120
600
Z
**
*
*

6 720 610 601 GB (03.02)
6
Details of the a liance
1.6 Layout of a liance
Fig. 2
4 He tronic control
6 He t exch nger s fety temper ture limiter
7 Testing point for g s supply pressure
8.1 Pressure g uge
9 Flue g s temper ture limiter
15 Relief v lve
18 Pump
18.1 Pump speed selector switch
20 Exp nsion vessel
27 Autom tic ir vent
29 Air g s Mixer unit
32.1 Electrode ssembly
36 Temper ture sensor in CH flow
43 CH flow
63 Adjust ble g s flow restrictor
64 Adjusting screw for min. g s flow volume
102 Inspection window
120 Fixing points
221.1 Flue duct
221.2 Combustion ir int ke
226 F n ssembly
295 Appli nce type sticker
234 Testing point for combustion products
234.1 Testing point for combustion ir
271 Flue duct
349 Cover pl te for twin flue duct connection
358 Condens te tr p
415 Cover pl te for cle ning ccess
416 Condens te collector
417 Clip for fixing outer c se
418 D t pl te
423 Siphon
8.1
29
102
226
234.1
271
416
221.1
221.2
20
43
9
63
358
64
7
417
15
4
18
415
6
36
32.1
234
349
120
418
295
6 720 610 596-01.2O
18.1
423
27

6 720 610 601 GB (03.02)
Details of the a liance
7
1.7 Function (with o tional extra motorised valve)
Fig. 3
4 Bosch He tronic control
6 Temper ture limiter, he t exch nger
7 Testing point for g s supply pressure
8.1 Pressure g uge
9 Flue g s temper ture limiter
13 M nifold
15 S fety v lve
18 Centr l he ting pump
20 Exp nsion vessel
26 Ch rging v lve
27 Autom tic vent
29 Mixer unit
29.1 Bi-met llic thermost t for combustion ir compens tion
30 Burner
32 Fl me sensing electrode
33 Igniter electrode
35 He t exch nger with cooled combustion ch mber
36 Temper ture sensor in CH flow
43 CH flow
45 G s inlet
47 CH return
52 Solenoid v lve 1
52.1 Solenoid v lve 2
55 Filter
56 G s v lve CE 427
57 M in v lve disc
61 Reset button
63 Adjust ble g s flow restrictor
64 Adjusting screw for min. g s inlet flow volume
69 Control v lve
71 Stor ge w ter he ter outflow (only with motorised v lve)
72 Stor ge w ter he ter return (only with motorised v lve)
84 Motor (option l extr )
88 3-w y v lve (option l extr )
221 Flue duct
226 F n
229 Inner c sing
234 Testing point for flue g s
234.1 Testing point for combustion ir
317 Displ y
358 Condens te tr p
423 Siphon
443 Di phr gm

6 720 610 601 GB (03.02)
8
Details of the a liance
1.8 Electrical wiring diagram
Fig. 4
4.1 Ignition tr nsformer
6Temper ture limiter, he t exch nger
9Flue g s temper ture limiter
18 Pump
32 Fl me sensing electrode
33 Ignition electrode
36 Temper ture sensor in CH flow
52 Solenoid v lve 1
52.1 Solenoid v lve 2
56 G s v lve CE 427
61 Reset button
84 Motor (option l extr )
135 M ster switch
136 Temper ture control for CH flow
151 Fuse, slow 2.5 A, AC 230 V
153 Tr nsformer
161 Link
226 F n
300 Code plug
302 E rth connection
310 Temper ture control for hot w ter
312 Fuse, slow T 1,6 A
313 Fuse, slow T 0,5 A
314 Connector for progr mmer TA212E
315 Termin l block for progr mmer
317 Digit l displ y
318 Connector for timer
328 Termin l block for AC 230 V M ins supply
328.1 Link
363 Indic tor l mp for burner
364 Indic tor l mp for power supply
365 “Chimney sweep” button
366 Service button
367 ECO button
6
9
32
33
36
52.1
52
56
61
230 V
135
25 V
230V/AC
153 136
151 124789
315
161
M
226
300
LNLs
Ns
328
LR
302
310
312
313
314
317
318
363
364 365 366
ECO
367
4.1
328.1
M
18
6 720 610 601-02.2O
mains supply
r
r
bl
bl
bl
bl
o
o
o - orange bl - black r - red
84
M
p
p
p

6 720 610 601 GB (03.02)
Details of the a liance
9
1.9 Technical data
Units Natural gas Pro ane
M x. r ted he t output net 40/30˚C centr l he ting
M x. r ted he t output net 50/30˚C centr l he ting
M x. r ted he t output net 80/60˚C centr l he ting
kW
kW
kW
29.3
29.0
27.4
29.3
29.0
27.4
M x. r ted he t input net kW 27.7 27.7
Min. r ted he t output net 40/30˚C
Min. r ted he t output net 50/30˚C
Min. r ted he t output net 80/60˚C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
Min. r ted he t input net kW 7.6 10.8
Maximum gas flow rate – After 10 minutes from lighting
N tur l g s G20 (CVnet 34.02 MJ/m3)m
3/h 2.9 -
LPG (CVnet 88 MJ/m3) kg/h - 2.1
Gas su ly ressure
N tur l g s G20 (CVnet 34.02 MJ/m3) mb r 20 -
LPG (CVnet 88 MJ/m3) mb r - 37
Ex ansion vessel
Ch rge pressure b r 0.75 0.75
Tot l c p city l 10 10
Flue
Flue g s temp. 80/60˚C, r ted/min. lo d ˚C 67/55 67/55
Flue g s temp. 40/30˚C, r ted/min. lo d ˚C 43/32 43/32
Residu l delivery pressure
(inc. pressure drop in ir int ke duct) P 80 80
CO2 level t m x. r ted he t output
CO2 level t min. r ted he t output
%
%
9.2
8.8
10.8
10.5
NOx-cl ss 5 5
SEDBUK figure, B nd A % 90.7 90.7
Condensate
M x. condens tion r te (tR = 30˚C) l/h 2.3 2.3
pH-v lue, pprox. 4.8 4.8
General Data
Electric l power supply volt ge AC ... V 230 230
Frequency Hz 50 50
M x. power consumption W 101 101
Noise output level dB(A) 36 36
Appli nce protection r ting IP X4D X4D
M x. CH flow temper ture ˚C nom. 90 nom. 90
M x. permissible oper ting pressure (CH) b r 2.5 2.5
Permissible mbient temper tures ˚C 0 - 50 0 - 50
Nomin l c p city of ppli nce l 3.75 3.75
Weight (excluding p cking) kg 46 46
Table 2

6 720 610 601 GB (03.02)
10
Installation regulations
Condensate analysis, mg/l
Flue system
Elbow - 90 ° Equiv lent length 2 m
Bend - 45 ° Equiv lent length 1m
Gas su ly
2 Installation regulations
G s S fety (Inst ll tion & Use) Regul tions 1998: All
g s ppli nces must be inst lled by competent per-
son. F ilure to inst ll correctly could le d to prosecu-
tion.
The m nuf cturers notes must not be t ken, in ny w y,
s overriding st tutory oblig tions.
The ppli nce must be inst lled in ccord nce with the
current IEE Wiring Regul tions, loc l Building Regul -
tions, Building St nd rds (Scotl nd) (Consolid tion),
bye-l ws of the loc l W ter Comp ny, He lth nd
S fety Document 635 (Electricity t Work Regul tions
1989) nd ny other loc l requirements.
Product Li bility regul tions indic te th t, in cert in cir-
cumst nces, the inst ller c n be held responsible, not
only for mist kes on his p rt but lso for d m ge result-
ing from the use of f ulty m teri ls. We dvise the
inst ller to void ny risk by using only qu lity pproved
br nded fittings.
The relev nt British St nd rds should be followed i.e.
• BS 6798: Specific tion for the inst ll tion of g s
fired hot w ter boilers of r ted input not exceeding
60kW
• BS 5449: Centr l He ting for Domestic Premises
• BS 5546: Inst ll tion of g s hot w ter supplies for
domestic purposes
• BS 5440:1: Flues nd ventil tion for g s ppli nces
of r ted input not exceeding 70 kW (net): Flues
• BS 5440:2: Flues nd ventil tion for g s ppli nces
of r ted input not exceeding 70 kW (net): Air
Supply
• BS 6891: Inst ll tion of low pressure g s pipework
inst ll tions up to 28 mm (R1).
• BS 7074:1: Code of pr ctice for domestic he ting
nd hot w ter supply
• BS 7671: Requirements for Electric l Inst ll tion.
These instructions must be followed.
Ammonium 1.2 Nickel 0.15
Le d ≤ 0.01 Mercury ≤ 0.0001
C dmium ≤ 0.001 Sulph te 1
Chromium ≤ 0.005 Zinc ≤ 0.015
H logen ted
hydroc rbons ≤ 0.002
Tin ≤ 0.01
Hydroc rbons 0.015 V n dium ≤ 0.001
Copper 0.028 pH-v lue 4.8
Table 3
HORIZONTAL 100 mm – Standard
Over ll Di meter of Duct mm 100
M x.
4 m
Flue Termin l / Duct
Assembly Length
mm 600
Extension Duct Length mm 1000
Table 4
ALTERNATIVE HORIZONTAL 125 mm FLUE
SYSTEM
Over ll Di meter of Duct mm 125 M x.
13 m
(inclu-
ding
turret)
Flue Termin l / Duct Assembly mm 1030
Table 5
VERTICAL 125 mm FLUE SYSTEM
Over ll Di meter of Duct mm 125 M x.
15 m
Flue Termin l / Duct Assembly mm 1360
Table 6
Total length of gas su ly i e
(metres)
Pi e diameter
(mm)
369
G s disch rge r te (m3/h)
8.7 5.8 4.6 22
18.0 12.0 9.4 28
Table 7