Bosch Condens 7000 WP User manual

6721842519 (2022/03) GB/IE
Installation and maintenance instructions for specialists
Wall mounted gas condensing boilers
Condens 7000 WP
GC7000WP 125 23, GC7000WP 145 23

Table of contents
Condens 7000 WP – 6721842519 (2022/03)
2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Product data for energy consumption . . . . . . . . . . . . . . 5
2.2 About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Conversion of gas type. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.7 Pump test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.8 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.9 product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.10 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.11 Minimum clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.12 Flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . 9
2.13 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. . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Important notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3.1 Water conditioning and treatment . . . . . . . . . . . . . . . . 12
5.4 Maximum flow temperature. . . . . . . . . . . . . . . . . . . . . . 12
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 Unpacking the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Checking the gas type . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3 Setting up the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.4 Connecting on the heating and gas side . . . . . . . . . . . . 14
6.5 Mounting the connection set (accessories) . . . . . . . . . 14
6.5.1 Installing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5.2 Mounting the connection set. . . . . . . . . . . . . . . . . . . . . 15
6.6 Mounting the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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 Installing the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.9 Installing the low loss header . . . . . . . . . . . . . . . . . . . . 17
6.10 Connecting an expansion vessel . . . . . . . . . . . . . . . . . . 18
6.11 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 . . . . . . . . . . . . . . . . 19
7.5 Connecting the pump of the pump assembly. . . . . . . . 20
7.6 Connecting the 3-way valve 230 V (accessory). . . . . . 20
7.7 Mounting the function module (accessory) . . . . . . . . . 20
7.8 Fitting the plug (if not preassembled) . . . . . . . . . . . . . 21
8 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Commissioning the boiler . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Setting the parameters . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.3 Air/gas ratio control valve switch-off options. . . . . . . . 22
8.4 Measuring the gas standing pressure (static) . . . . . . . 22
8.5 Measuring the gas dynamic working pressure . . . . . . . 22
8.6 Measure CO2 and CO . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.7 Measure the of the heat exchanger air resistance
[R0] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.8 Reading off the ionisation current . . . . . . . . . . . . . . . . 23
8.9 Check the (flue) gas tightness . . . . . . . . . . . . . . . . . . . 23
8.10 Check the function of the boiler . . . . . . . . . . . . . . . . . . 24
8.11 Completion work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.12 Instructing the operator . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.1 Control panel overview . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.2 Switching on the device . . . . . . . . . . . . . . . . . . . . . . . . 24
9.3 Siphon filling program . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.4 Settings in the service menu. . . . . . . . . . . . . . . . . . . . . 25
9.4.1 Operating the service menu . . . . . . . . . . . . . . . . . . . . . 25
9.4.2 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.4.3 Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.1 Important notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.2 General work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.3 Remove the gas-air unit . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.4 Clean the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.5 Cleaning the heat exchanger. . . . . . . . . . . . . . . . . . . . . 33
10.6 Cleaning the condensation catch pan . . . . . . . . . . . . . 33
10.7 Cleaning the siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.8 Installing the gas-air unit. . . . . . . . . . . . . . . . . . . . . . . . 34
10.9 Measure the heat exchanger air resistance [Rx] . . . . . 35
10.9.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.9.2 Measure the air resistance [Rx] . . . . . . . . . . . . . . . . . . 35
10.9.3 Assess the air resistance [RD] . . . . . . . . . . . . . . . . . . . 35
10.10 Resetting the Maintenance type . . . . . . . . . . . . . . . . . . 36
10.11 Measuring the gas pressure . . . . . . . . . . . . . . . . . . . . . 36
10.12 Measuring of CO and CO2. . . . . . . . . . . . . . . . . . . . . . . 36
10.13 Measuring the ionisation current . . . . . . . . . . . . . . . . . 36
10.14 Check the (flue) gas tightness . . . . . . . . . . . . . . . . . . . 36
10.15 Check for correct operation . . . . . . . . . . . . . . . . . . . . . 36
10.16 Replacing components . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.16.1 Replacement interval for components . . . . . . . . . . . . 36
10.16.2 Replacement of the ionisation and ignition
electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.16.3 Replacement of the gas/air check valve . . . . . . . . . . . 37
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
10.18 Air resistance measurement report . . . . . . . . . . . . . . . 38

Table of contents
3
Condens 7000 WP – 6721842519 (2022/03)
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 indicatesimportant information where there is no risk to
people or property.
1.2 General safety instructions
HNotices 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
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.
HDetermined use
The product may only be used in a domestic situation
for the heating of central heating water and for DHW
heating in closed-loop DHW and heating systems.
Any other use is considered inappropriate. Any
damage that may result from misuse is excluded from
liability.
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
11.1 Operating and fault displays . . . . . . . . . . . . . . . . . . . . .39
11.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
11.1.2 Fault code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
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 data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
16 Technical information and reports. . . . . . . . . . . . . . . . . . . . . .47
16.1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
16.2 Data relating to the gas. . . . . . . . . . . . . . . . . . . . . . . . . .48
16.3 Hydraulic resistances . . . . . . . . . . . . . . . . . . . . . . . . . . .49
16.4 Residual head of pumps. . . . . . . . . . . . . . . . . . . . . . . . .49
16.5 Setting values for heating capacity . . . . . . . . . . . . . . . .49
16.6 Commissioning report for the appliance. . . . . . . . . . . .49

Explanation of symbols and safety instructions
Condens 7000 WP – 6721842519 (2022/03)
4
HSystem 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 third-
party equipment are excluded from liability.
Service work required to repair the damage will be
invoiced.
HDanger 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.
HDanger 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.
HCombustion/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.
HInstallation, 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 safety-
relevant components.
▶ Only install original spare parts.
▶ Check for gas tightness after working on gas-
carrying components.
HHandover 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 tolife)
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.
HInspection 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).

Product Information
5
Condens 7000 WP – 6721842519 (2022/03)
2ProductInformation
2.1 Product data for energy consumption
The product data on energy consumption can be found in the operating
instructions for the user.
2.2 About these instructions
Figures used
The figures in these instructions 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.
2.3 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).
2.4 Conversion of gas type
This boiler is suitable for the gas categories specified on the data plate.
If conversion of the boiler to a different gas category is allowed, this is
specified in the gas data (§ 16.2, p. 48).
2.5 Accessories
A wide range of accessories is available for this appliance.
Contact the manufacturer formore information. You will find the relevant
addresses on the back of this document.
2.6 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.
Table 1 Scope of delivery
2.7 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.
2.8 Frost protection
NOTICE
Installation damage due to the effects of frost.
The heating systemcould freeze duringa 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.
Packaging unit Component Packaging
1 (boiler) • Wall-mounted boiler Cardboard
box
2 (accessories) • Mounting rail
• Fixing materials
•Siphon
• Condensate drain hose
• Plug (if not pre-
assembled)
• Rotary joint + gasket (2x)
• Documentation
Cardboard
box

Product Information
Condens 7000 WP – 6721842519 (2022/03)
6
2.9 product overview
Fig. 1 GC7000WP with connection set on frame
0010039414-001
14
10
7
11
6
36
39
38
37
30
35
34
33
31
32
28
13
12
8
9
2
4
1
5
3
16
15
17
19
21
26
27
22
20
24
18
23
25
29

Product Information
7
Condens 7000 WP – 6721842519 (2022/03)
Condensing boiler:
[1] Air intake pipe
[2] Cover of condensation catch pan
[3] Temperature sensor for flue gas routing
[4] Pressure sensor
[5] Return temperature sensor
[6] Transformer
[7] heat exchanger
[8] Ignition electrode
[9] Ionisation electrode
[10] Safety temperature monitor (105 °C)
[11] Flow temperature sensor (93 °C)
[12] Control unit
[13] On/off switch
[14] Flue gas routing adaptor
[15] Test point for flue gas routing
[16] Test point for air supply
[17] Upper panel
[18] Connection point for diagnosis tool
[19] Automatic air vent
[20] Internal flue gas routing
[21] Gas-air mixing pipe
[22] Safety temperature sensor
[23] CO2adjusting screw
[24] Fan
[25] Venturi nozzle
[26] Gas hose
[27] Air/gas ratio control valve
[28] Pressure compensation hose
[29] Data plate
[30] Condensate trap
Connection set and frame (accessories):
[31] Gas isolator
[32] Pump
[33] Expansion vessel connecting point
[34] Service valve return
[35] Floor frame
[36] Adjustment fixture
[37] Service valve flow
[38] Pressure gauge
[39] Water pressure relief valve

Product Information
Condens 7000 WP – 6721842519 (2022/03)
8
2.10 Dimensions
Boiler on frame
Fig. 2 Dimensions on base frame [mm]
Boiler against the wall
Fig. 3 Dimensions on the wall [mm]
0010039235-001
260
260191
202 198
115
64
200
651520
115
1690 ± 12
53
260
260
191
115
136
587,5520
115
53
138 198
1120 > 100309
0010039236-001

Product Information
9
Condens 7000 WP – 6721842519 (2022/03)
2.11 Minimum clearance
With a horizontal flue outlet, make sure the electronic components
inside the boiler at the top remain accessible when placing an elbow
directly on the flue outlet adapter.
▶ After fitting the flue bend, check whether the upper panel of the
appliance is easy to remove (§ 7.2, p. 18).
▶ There must be a clearance of at least 100 mm directly above the flue
bend at the boiler.
Fig. 4 Side view [mm]
[1] Horizontal flue outlet
[2] Collar
[3] Vertical flue outlet
A Clearance from top of the boiler - center of hole
B Clearance from top of the boiler - upper side of hole
C Depth of the boiler - 587,5 mm
K Diameter of hole
S Wall thickness
Table 2 Diameter of core drilled hole K
Table 3 Clearance A and B depending on flue outlet
Calculate the minimum clearance above the boiler.
▶ Add dimension B from Table 3 to the height of the top of the 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 boiler to allow
the electronic components to be accessed and worked on.
Minimum space required for the boiler.
▶ Provide an unobstructed space of at least 100 cm for the boiler to
allow maintenance and other work to be carried out.
Minimum space required next to the boiler.
▶ Maintain an area of at least 5 mm on the either side of the boiler.
Fig. 5 Front view [mm]
2.12 Flue gas temperature sensor
The boiler is manufactured with a flue outlet sensor as standard (Fig.
1, p. 6).
The flue gas temperature sensor protects the boiler and flue system from
high flue gas temperatures by reducing the boiler load (downward
modulation).
Wall thickness S K [mm] for Ø flue outlet [mm]
Ø 110/160 Ø110
15 - 24 cm 190 140
24 - 33 cm 195 145
33 - 42 cm 200 150
42 - 50 cm 205 155
0010040879-001
3
2
1
≥100
A
B
1120
C
S
K
(52 mm/1 m)
5,2 %
136
Flue exhaust A [mm] B [mm]
Ø 110 mm Connection adapter with
elbow, horizontal flue outlet.
165 A + 0.5*K
Ø 110/160 mm 179 A + 0.5*K
Ø 110 mm Connection adapter, vertical
flue outlet
-0
Ø 110/160 mm - 0
0010033512-001
≥ 5* ≥ 5*
520
260
300

Regulations
Condens 7000 WP – 6721842519 (2022/03)
10
2.13 Opening and closing the front panel of the appliance
The 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.
Fig. 6 Opening the front panel
3Regulations
DANGER
Failure to comply with instructions may result in material damage
and personal injury, including danger to life!
▶ Comply with all instructions.
NOTICE
System damage due to differing operating conditions!
Faults may arise when deviating from the specified operating operating
conditions. Individual components or the boiler may be destroyed if
there are deviations.
▶ 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.
4Fluegasrouting
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.
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.
▶Donotusewallmountedgasboilers 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.
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Condens 7000 WP – 6721842519 (2022/03)
CAUTION
Personal injury due to lifting incorrectly.
▶ Due to the weight and dimensions of the boiler, take adequate
measures to transport the wall mounted boiler safely in the
installation room.
▶ The packaged 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
boiler correctly, handles are attached to the underside.
▶ Use these handles to move the boiler [1].
▶ Hold the boiler at the side and base and not at the basic controller or
flue connection.
Fig. 7 Position of handle recesses
5.1 Installation location
DANGER
Risk of fire through flammable materials or liquids.
▶ Never store flammable materials or liquids in the immediate vicinity
of the boiler.
NOTICE
Frost damage!
▶ Install the heating system in a frost-free room.
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.
NOTICE
The boiler may only be operated up to a maximum installation
altitude of 1200 m above sea level!
▶Table 15 (technical data), see 46.
NOTICE
The boiler may be operated with combustion air up to a certain
maximum temperature!
The maximum temperature of the combustion air must not exceed 35 °C.
▶Table 15 (technical data), see 46.
5.2 Important notices
The boiler must not be operated in open heating systems (open vented
systems that could lead to oxygen ingress). 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
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
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.
5.3 Water quality
Unsuitable or contaminated heating and tap water can lead to faults in
the 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 qualityoperator's log” determine the water
volume Vmax:
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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:
Table 4 Additives
▶ 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 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 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,
p. 25).
▶ 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 boiler
The packaging material is fully recyclable.
▶ Dispose of the boiler packaging after installing the 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 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. (§ 2.9, p.
6).
6.3 Setting up the boiler
The 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.
Application Product name Max.
concentration
[%]
Demineralisation Demineralisation/
desalination with mixed
bed cartridges
In accordance with
the supplied
"Manual for water
quality"
Inhibitor/antifreeze Fernox Alphi 11 40
Antifreeze Noburst AL 40

Installation
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Condens 7000 WP – 6721842519 (2022/03)
▶ Set up the frame so the marking [4] points forwards.
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.
Fig. 9 Secure the frame to the wall or floor
▶ Push the boiler onto the frame.
The boiler is secured to the frame at the rear. If it has been secured
correctly a "click" will be audible.
▶ Align the boiler in the frame using the adjustment option. [1].
▶ Fully tighten the grub screw in the frame.
Fig. 10 Align the boiler on the frame
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Assembly on the wall
NOTICE
The boiler may be damaged if attached incorrectly.
Use suitable fixing materials for the condition of the masonry and weight
of the 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 boiler.
▶ Check whether the wall has sufficient load-bearing capacity based on
the dimensions and weight of the boiler. (§ 16, p. 47).
▶ Mount a fastening structure if required.
▶ Only use fixing materials that are suitable for the structure to which
the boiler is to be attached. (Tab. 5).
Table 5 Specification of the fixing materials
▶ Determine the position of the 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
▶Hooktheboilerintothe mounting rail.
▶ Align the boiler using a spirit level and adjusting screw on the rear.
Fig. 12 Aligning the boiler on the wall
6.4 Connecting on the heating and gas side
The 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
•Safetyvalve;
•Pump;
• Fill and drain valve.
These components can be found in the overview drawing (§ 2.9, p.
6).
Wall type Fixing materials Minimum load [N]
Concrete See scope of delivery ≥ 20001) Per fixing
point.
1) The load applies for tensile and shear loads.
Solid lime sandstone
Others Not included: to be
decided by the installer.
4.
3.
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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 filter in the gas line if required.
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.
Fig. 14 Mount the flow/return connection
▶ Screw down the bracket with the screws [1].
▶ Fully tighten all rotary joints [2].
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).
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.
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▶ Tighten the union nut hand tight [4].
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.
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
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
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 boiler and the service
shut-off valve.
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Condens 7000 WP – 6721842519 (2022/03)
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 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
▶Connectthegasvalve(§ 6.5.1, p. 15).
6.8.2 Installing the pump
▶ Select the pump using the specifications as the basis (Tab. 16.3,
p. 49).
▶ Take the required volumetric flow rate into consideration (Tab.
16.3, 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].
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 (§ 16.3, p. 49).
Fig. 19 Setup with low loss header
[1] Low-loss header
[2] Expansion Vessel
[3] Pump
[4] Service valve
[5] Differential pressure regulator
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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.
Fig. 20 Connecting an expansion vessel
6.11 Installing the insulation (accessory)
Insulating parts are available for the connection set of this boiler.
If the 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 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 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 boiler must be established using the
cable type H05VV-F 3 x 0.75 mm2or NYM-J 3 x 1.5 mm2.
▶ All 24 VAC connections in the boiler must be established using a 2-
wire power cable with 0.4 – 0.8 mm2cross-section.
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 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 (§ 16.1, p. 47).
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.
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].
Fig. 22 Opening the top cover
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Condens 7000 WP – 6721842519 (2022/03)
7.3 Overview of plug-in strip
Fig. 23 Overview of plug-in strip
Table 6 Plug-in strip symbols
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].
Symbol Function Description
On/Off temperature control (volt free) ▶ Connect an On/Off temperature control. (do not connect 230V directly to these
terminals)
Modulation-controlled control unit and
EMS BUS
▶ Connect modulating temperature controller (EMS bus).
External safety interlock contact (volt
free). This connection contains a link 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 one
of the safety components are interrupted, the heating load to the wall mounted boiler is
interrupted.
▶ Remove wire link.
▶ 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.
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. 20).
Mains voltage ▶ Connect the 230 V power supply for the function module.
Attention! The total power consumption of the connected components must not exceed
725 W.
Hot water circulation pump If a DHW circulation line is used, a secondary circulation pump can be connected.
▶ Connect to the secondary circulation pump.
Mains voltage Mains plug 230 VAC
▶ Connect the mains plug, if not pre-assembled (§ 7.8, p. 21).
Cylinder pump ▶ Connect the cylinder primary pump.
Fine-wire fuse of the burner control unit There is a replacement fuse under the cover flap on the burner control unit.
0010034531-001
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PW2
120/230 VAC
I1 I3 T1
BUS
BUS
TW1 T0
BUS
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Fig. 24 Positioning the connecting lead and cable conduit
7.5 Connecting the pump of the pump assembly
▶ Open the pump terminal unit.
▶ Use the right screwdriver for this.
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.
▶ Close the pump terminal box: fold the pump terminal box up and
press horizontally until it snaps into place.
Fig. 26 Connecting the pump
[1] 230 V cable
[2] PWM signal cable
7.6 Connecting the 3-way valve 230 V (accessory)
A 3-way valve can only be connected to the plug-in strip of the boiler if
the output of the boiler is ≤ 100 kW.
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 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.
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