Bosch Appliances Boiler R 40 HE User Manual

Users Instructions and  
Customer Care Guide  
R 29 / R 40 HE conventional Condensing  
boiler  
6 720 610 577-01.10  
ZB 7-28 R 29 HE GC-Number: 41 311 60  
ZB 11-40 R 40 HE GC-Number: 41 311 61  
Excellence comes as standard  
Excellence comes as standard  
Thank you for purchasing a Worcester Greenstar condensing  
appliance.  
The Worcester Greenstar Series has been developed by the  
Bosch Group and the strictest quality control standards are  
demanded throughout every stage of production.  
Indeed, the Bosch Group have led the field in innovative appliance  
design and performance for many years.  
The result is that your new Greenstar appliance offers you the very  
best of everything – quality, efficiency, economical running costs,  
proven reliability and value for money.  
What’s more, you also have the assurance of our no nonsense  
2 year parts and labour guarantee.  
And it’s backed up by Worcester Care Call a complete mainte-  
nance scheme to keep your boiler operating at peak condition and  
efficiency.  
No wonder that more and more people are agreeing that when it  
comes to gas, it has to be a Worcester Bosch appliance.  
Benchmark  
The “Benchmark” initiative is the new code of practice to encour-  
age the correct installation, commissioning and servicing of  
domestic central heating boilers and system equipment.  
The “log-book” is a vital document that must be completed by the  
installer at the time of installation. It confirms that the boiler has  
been installed and commissioned according to the manufacturers  
instructions and is one of the methods of demonstrating  
compliance with the Building Regulations.  
Without the completion of the “log-book”, manufacturers may  
refuse to respond to a call–out from a householder, who will be  
advised that he or she must call back the installer, who has not ful-  
filled his obligations to record the information required by the ini-  
tiative.  
6 720 611 138 GB (03.11)  
3
Safety precautions  
Safety precautions  
Gas Safety (Installation and Use) Regulations  
It is the law that all gas appliances are installed by a competent  
person in accordance with the above regulations. Failure to install  
appliances correctly could lead to prosecution. It is in your inter-  
est, and that of safety, to ensure compliance with the law.  
If you smell gas:  
B Turn off gas service cock at the meter.  
B Open all doors and windows.  
B Do not operate any electrical switches.  
B Do not smoke.  
B Extinguish any naked flames.  
B Call your gas company.  
If you smell fumes from the appliance:  
B Switch off appliance.  
B Open windows and doors.  
B Inform your heating engineer.  
Fitting and modifications  
B Fitting of the appliance or any modifications to the appliance  
may only be carried out by a competent person.  
B Flue systems must not be modified in any way.  
Maintenance  
B We recommend that you take out a maintenance contract  
with a competent installer and have the appliance serviced at  
regular intervals.  
B Ensure that your Service Engineer uses only genuine spare  
parts!  
Combustible materials  
B Do not store or use any combustible materials (paper, thin-  
ners, paints etc.) in the vicinity of the appliance.  
4
6 720 611 138 GB (03.11)  
Safety precautions  
Health and safety  
B This appliance contains no asbestos products.  
B There is no potential hazard due to the appliance being electri-  
cally unsafe.  
B There are no substances used in the construction that are a  
potential hazard in relation to the COSHH Regulations (Con-  
trol of Substances Hazardous to Health Regulations).  
Combustion Air/Ambient Air  
B Keep combustion air/ambient air free of corrosive substances  
(e.g. halogenated hydrocarbons which contain chlorine or flu-  
orine compounds). In this way corrosion can be prevented.  
6 720 611 138 GB (03.11)  
5
General notes  
1
General notes  
To get the best from your appliance please read these instructions  
carefully.  
Central heating systems  
During the first few hours of operation of the central heating sys-  
tem, check that all radiators are being heated at an even rate. If the  
top of a radiator is at a lower temperature than the bottom then it  
should be vented by releasing air through the venting screw at the  
top of the radiator. Ask your installer to show you how this is done.  
Repeated venting will reduce the quantity of water in the system  
and this must be replenished for safe and satisfactory operation of  
the appliance. An open vented system will re-fill automatically.  
Should water leaks be found in the system or excessive venting is  
required then a service engineer must be contacted to inspect the  
installation and rectify any fault.  
Only additives that are compatible with aluminium may be used in  
the system. Any incompatible additive used will invalidate the  
guarantee. Contact Fernox or Sentinel for further details.  
Condensate drain  
This is a condensing appliance and the terminal will, at times, give  
out a plume of water vapour. This is quite normal.  
The appliance produces quantities of condense which is dis-  
charged regularly through the siphon.  
Ventilation  
This is a room sealed appliance and does not require any air for  
combustion from inside the house. If the appliance is fitted into a  
cupboard or a compartment is built around the appliance after  
installation then the compartment must be separated from the  
boiler space by a perforated non-combustible partition as  
described in BS6798.  
Notwithstanding the requirements of BS6798, there is no need  
for ventilation openings to be provided in the compartment  
because of the low heat loss from the casing.  
Do not allow the flue terminal fitted on the outside wall to become  
obstructed or damaged.  
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6 720 611 138 GB (03.11)  
General notes  
Clearances  
Your installer will have provided adequate space around the appli-  
ance for safety and servicing access. Do not restrict this space  
with the addition of cupboards, shelves etc. next to the appliance.  
Left-hand side  
Right-hand side  
In Front  
10 mm  
10 mm  
600 mm  
200 mm  
30 mm  
Above Casing (Vertical Flue)  
Above Flue Turret  
Below  
200 mm  
Table 1  
Room thermostat  
A room thermostat should be fitted to control the central heating.  
Refer to the instructions supplied with the thermostat for informa-  
tion on siting and setting.  
Thermostatic radiator valves  
It is recommended that this type of valve is fitted to all the radia-  
tors. It is a requirement that they are fitted, at least, in the sleeping  
areas.They should conform to the requirements of BS2767:10.  
Time Control  
Separate time control of the space heating and the hot water sys-  
tem is required using a twin-channel programmer or two or more  
separate timers.  
Cylinder Thermostat  
A cylinder thermostat must be fitted to the cylinder which, when  
used with a motorised valve, will give close control of the water  
temperature.  
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7
Controls  
2
Controls  
136 365 61 317 366 367 363 310  
ECO  
364  
135  
295  
E
170  
172  
170  
6 720 611 138-01.1O  
61  
Reset button  
135  
136  
170  
172  
295  
310  
317  
363  
364  
365  
366  
367  
Master switch  
Boiler temperature control  
Service valves in boiler flow and return  
Gas isolation valve (open)  
Identification sticker  
Function control (Service only)  
Display  
Indicator lamp for “burner on”  
Indicator lamp for “off/on”  
“Chimney sweep” button  
Service button  
No function  
8
6 720 611 138 GB (03.11)  
Operating the Appliance  
3
Operating the Appliance  
3.1 Preparation  
Turn on the gas cock (172).  
B Press in the handle and turn it anti-clockwise as far as the stop  
(when handle is in line with direction of flow, the cock is open).  
Central heating system valves (170)  
B Using a spanner, turn square nut until groove is in line with  
direction of flow (see detail).  
Groove at right angles to direction of flow = off.  
170  
172  
6 720 611 138-02.1O  
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9
Operating the Appliance  
3.2  
Switching the Appliance On/Off  
Switching on  
B Switch on the appliance at the master switch (I).  
The indicator lamp shows green and the display will show the  
primary flow temperature.  
6 720 610 333-04.1O  
If the display alternates between -II- and the boiler  
flow temperature, the trap filling programme is  
active.  
i
The trap filling programme ensures that the condensation trap is  
filled after the appliance has been installed or after the appliance  
has been out of use for a long period. For that reason, the appli-  
ance remains at minimum heating output for 15 minutes.  
Switching off  
B Switch off the appliance at the master switch (0).  
The green indicator lamp goes out.  
10  
6 720 611 138 GB (03.11)  
Operating the Appliance  
3.3 Switching on the System  
B Turn the temperature control to the desired level:  
– “Min” setting: 35°C  
– Low-temperature heating: setting “E” (approx. 75°C)  
– “Max” setting: 88°C  
When the burner is lit, the red indicator lamp is illuminated.  
6 720 611 138-05.1O  
3.4 Controlling  
B Set room thermostat to the desired room temperature.  
B Set the external time clock to the desired time periods.  
B Set the thermostatic radiator valves to the desired settings.  
3.5 Setting the Hot Water Temperature of a  
Cylinder  
Hot water temperature  
The hot water temperature can be set to between approx. 40°C  
and 60°C using the thermostat on the cylinder.  
The domestic hot water temperature is not shown on the display.  
6 720 611 138 GB (03.11)  
11  
Operating the Appliance  
3.6  
Frost protection  
B Leave master switch switched on.  
If the appliance is to be left for long periods switch the central  
heating off:  
B Add a suitable anti-freeze fluid to the water in the central heat-  
ing system.  
Suitable products are available from Betz-Dearborn Tel.: 0151  
4209563 and Fernox Tel.: 01799 550811.  
3.7  
Fault Condition  
In the unlikely event of a fault occuring while the appliance is in  
operation:  
The display then shows a fault code and the button  
flash.  
may also  
If the button  
flashes:  
B Press and hold the button  
until the display shows “– –”.  
The appliance will then start up again and the display will show  
the boiler flow temperature.  
If the button  
does not flash:  
B Switch the appliance off and then on again at the master  
switch.  
The appliance will start up again and the boiler flow tempera-  
ture will be displayed.  
If the fault remains and can not be cleared:  
B Call your approved installer or Worcester Bosch Customer  
Services for assistance, giving a description of the fault and, if  
possible, the fault code from the facia display.  
12  
6 720 611 138 GB (03.11)  
Tips on saving energy  
4
Tips on saving energy  
Heating economically  
The boiler is designed to provide a high level of comfort while  
keeping gas consumption and the resulting environmental effect  
as low as possible. The gas supply to the burner is controlled  
according to the level of demand for heat. The boiler continues to  
operate with a low flame if the demand for heat reduces. The tech-  
nical term for this process is modulating control. Modulating con-  
trol keeps temperature fluctuations small and provides even  
distribution of heat throughout the home. This means that the  
boiler may stay on for relatively long periods but will use less gas  
than an appliance that continually switches on and off.  
Central heating systems with room thermostats/thermo-  
static radiator valves  
The temperature control on the boiler should be set to the maxi-  
mum rated temperature of the central heating system or to posi-  
tion “E”, when the maximum central heating water temperature  
obtained is 75°C.  
The temperature can be set individually in each room (except pri-  
mary room with the room thermostat) using the thermostatic radi-  
ator valves. If you wish to have a lower temperature in the primary  
room than in the other rooms, leave the room thermostat at the set  
temperature and turn down the radiator using the radiator valve.  
Reduced-output operation  
Considerable fuel savings can be made by slightly reducing the  
room temperature. Lowering the temperature by 1 °C can bring  
about energy savings of up to 5 %. However, it is not advisable to  
allow the room temperature to fall below +15 °C. The room tem-  
perature for reduced-output mode can be set separately on the  
room thermostat. Instructions are given in the control unit operat-  
ing instructions.  
6 720 611 138 GB (03.11)  
13  
General Information  
Hot water  
A lower setting on the hot water cylinder thermostat can result in  
considerable energy savings.  
Now you know how to heat your home economically with the  
Greenstar gas condensing boiler. If you have any other questions,  
please contact your installer – or write to us.  
5
General Information  
Cleaning the Outer Case  
Wipe down the outer case with a damp cloth. Do not use abrasive  
or caustic cleaning agents.  
Appliance details  
If you ever need to call Customer Services it helps us a great deal  
if you can provide precise details of your appliance.  
The information is printed on the appliance identification plate/  
sticker (see page 8, item 295).  
Your installer will have completed the Benchmark “log-  
book” giving details of the boiler together with name,  
address and registration number. Have the “log-book” to  
hand when calling a Service Engineer.  
14  
6 720 611 138 GB (03.11)  
Maintaining your appliance  
6
Maintaining your appliance  
Your new Worcester Greenstar gas-fired appliance represents a  
long-term investment in a reliable, high quality product.  
In order to realise its maximum working life, and to ensure it con-  
tinues to operate at peak efficiency and performance, it is essen-  
tial that your boiler receives regular, competent servicing and  
maintenance checks beyond the initial 2 year guarantee period.  
If you would like to know more about Worcester’s extended war-  
ranty options please tick the appropriate box on your warranty reg-  
istration card.  
7
Service  
If your R29/R40 should fail to operate correctly or requires serv-  
icing, please call Worcester Heat Systems on: 08457 256206.  
6 720 611 138 GB (03.11)  
15  
Fault or breakdown  
8
Fault or breakdown  
This product is supported in the UK by Worcester Heat Systems  
Ltd. – part of the Bosch Group.  
A specialist factory trained field SERVICE ENGINEER is available  
to attend a breakdown or manufacturing fault occuring on this  
appliance.  
No charge will be made for parts and/or labour providing:  
An appliance fault is found and the appliance has been  
installed within the past 24 months. Reasonable evidence of  
this must be supplied on request i. e. the Benchmark “log-  
book”.  
2nd year warranty is dependent on annual servicing.  
A call-out charge will be made where:  
The appliance has been installed for over 24 months.  
OR  
Our Field Service Engineer finds no fault with the appliance  
(see NOTE).  
OR  
The cause of breakdown is misuse or with other parts of your  
plumbing/heating system, or with equipment not supplied by  
Worcester.  
NOTE: No appliance fault is found on over 30 % of all service call  
outs.  
If in doubt contact our Technical Helpline on 08705 266241.  
IN THE EVENT OF AN APPLIANCE FAULT OR BREAKDOWN  
please contact your Service Centre. Your service administrator  
will arrange for an engineer to call with the minimum of delay;  
under normal circumstances this will be within the period 1-3  
working days (excluding weekends) for priority breakdown situa-  
tions (no hot water and/or heating service).  
INVOICES FOR ATTENDANCE AND REPAIR WORK  
CARRIED OUT ON THIS APPLIANCE BY ANY THIRD  
PARTY WILL NOT BE ACCEPTED.  
16  
6 720 611 138 GB (03.11)  
Your Bosch guarantee  
9
Your Bosch guarantee  
This appliance is guaranteed against faulty material or workman-  
ship for a period of 24 calendar months from the date of installa-  
tion subject to the following conditions and exceptions.  
That during the currency of this guarantee any components of  
the unit which are proved to be faulty or defective in manufac-  
ture will be exchanged or repaired free of material charges and  
free of labour charges by Worcester Heat Systems Limited.  
That the householder may be asked to prove the date of instal-  
lation, that the appliance was correctly commissioned and,  
where appropriate, the first 2 year service has been carried out  
to the satisfaction of Worcester Heat Systems Limited when  
requested.  
That any product or part thereof returned for servicing under  
the guarantee must be accompanied by a claim stating the  
Model, Serial Number, Date of Installation.  
That Worcester Heat Systems Limited will not accept respon-  
sibility for damage caused by faulty installation, neglect, misuse  
or accidental damage, the non observance of the instructions  
contained in the Installation and Users Instructions Leaflets.  
That the appliance has been used only for normal domestic  
purposes for which it was designed.  
That this guarantee applies only to equipment purchased and  
used in Great Britain.  
This guarantee is given in addition to all your normal statutory  
rights.  
6 720 611 138 GB (03.11)  
17  
Guarantee registration  
10 Guarantee registration  
You should complete and return the postpaid Guarantee Regis-  
tration Card within 14 days of purchase.  
The card will register you as the owner of your new Worcester  
Greenstar appliance and will assist us in maintaining an effective  
and efficient customer service by establishing a reference and  
permanent record for your boiler.  
This will not affect your statutory rights in any way.  
Important:  
For your own record:  
Model  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Serial number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Copy the number of the Guarantee Card: . . . . . . . . . . . . . . . . . . .  
Type/size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Date of installation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Check that the Benchmark “log-book” has been completed by  
your installer or service engineer.  
18  
6 720 611 138 GB (03.11)  
11 Operating Instructions Quick Reference  
Switching on  
Controlling the system  
temperature  
Switching off  
Set room thermostat to desired tem-  
perature or the outside-temperature  
control unit to the appropriate setting.  
Fault Condition  
6 720 610 333-04.1O  
6 720 610 333-11.1O  
If the  
button flashes, press and  
Switching the system on  
hold-in to reset the appliance. Refer to  
page 12.  
6 720 611 138-05.1O  
EXCELLENCE COMES AS STANDARD  
Worcester Heat Systems Limited. Cotswold Way,  
Warndon, Worcester WR4 9SW.  
Telephone: (01905) 754624 Fax: (01905) 754619  

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