Worcester GREENSTAR HE combi Series Installation And Servicing Instructions
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Worcester GREENSTAR HE combi Series Installation And Servicing Instructions

Wall mounted condensing boiler for central heating and mains fed domestic hot water
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Installation and Servicing Instructions
GREENSTAR HE combi
Wall mounted condensing boiler for central heating and mains
fed domestic hot water
ZWB 7-25 HE combi
ZWB 7-30 HE combi
6 720 610 577-00.10
GC-Number: 47 311 73
GC-Number: 47 311 74

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  • Page 1 Installation and Servicing Instructions GREENSTAR HE combi Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 577-00.10 ZWB 7-25 HE combi GC-Number: 47 311 73 ZWB 7-30 HE combi GC-Number: 47 311 74...

  • Page 2: Table Of Contents

    Contents Contents 6.1.3 Changing the heating pump characteristic Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic 6.2.2 Selecting the pump control mode for central Safety precautions heating mode (Service Function 2.2) 6.2.3 Setting the anti-cycle time (Service Function 2.4) Symbols 6.2.4 Setting the maxim CH flow temperature (Service Function 2.5)

  • Page 3: Safety Precautions

    Safety precautions Safety precautions Symbols Safety instructions in this document If you smell gas are identified by a warning-triangle sym- B Turn off gas service cock at the meter. bol and are printed on a grey back- B Open windows and doors. ground.

  • Page 4: Details Of The Appliance

    Details of the appliance Details of the appliance Description of appliance • Wall-mounted appliance, siting not dependent on room size EC Declaration of Conformity • Natural gas models are low-emission appliances This appliance is in accordance with the applicable • Multifunction display requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility •...

  • Page 5: Accessories

    Details of the appliance Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues upto 4 m in length. • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths upto 13 m and vertical flue systems for flue lengths uto 15 m.

  • Page 6: Layout Of Appliance

    Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 18.1 6 720 610 576-02.2O Fig. 2 Heatronic control Inspection window Heat exchanger safety temperature limiter Fixing points Hot water NTC sensor 221.1 Flue duct Testing point for gas supply pressure 221.2 Combustion air intake Pressure gauge Fan assembly...

  • Page 7: Function

    Details of the appliance Function Fig. 3 Bosch Heatronic control Adjustable gas flow restrictor Temperature limiter, heat exchanger Adjusting screw for min. gas inlet flow volume Hot water NTC sensor Control valve Testing point for gas supply pressure Motor Pressure gauge 3-way valve Flue gas temperature limiter Venturi...

  • Page 8: Electrical Wiring Diagram

    Details of the appliance Electrical wiring diagram o - orange g - green bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 576-08.2O Fig.

  • Page 9: Technical Data Zwb

    Details of the appliance Technical data ZWB 7/11-25 ZWB 7-25 ZWB 11-25 Units Natural gas Propane Max. rated heat output net 40/30˚C central heating 29.1 29.1 Max. rated heat output net 50/30˚C central heating 28.8 28.8 Max. rated heat output net 80/60˚C central heating 27.2 27.2 Max.

  • Page 10: Technical Data Zwb 7/11-30

    Details of the appliance 1.10 Technical data ZWB 7/11-30 ZWB 7-30 ZWB 11-30 Units Natural gas Propane Max. rated heat output net 40/30˚C central heating 31.2 31.2 Max. rated heat output net 50/30˚C central heating 30.9 30.9 Max. rated heat output net 80/60˚C central heating 29.2 29.2 Max.

  • Page 11: Installation Regulations

    Installation regulations Condensate analysis, mg/l Domestic water performance Ammonium 1.2 Nickel 0.15 7-25 7-30 ≤ 0.01 Mercury ≤ 0.0001 Lead ≤ 0.001 Sulphate Domestic Tempera- 30 °C 13.2 13.9 Cadmium Water Flow ture Rise ≤ 0.005 Zinc ≤ 0.015 Chromium Rate l/min Tempera- 35 °C...

  • Page 12: Installation

    Installation Installation All types of single lever mixer taps and thermostatic mixer units suitable for a mains pressure of up to 10 bar can be used. B Always turn off the gas cock before car- The head of a loose-head shower must not be allowed rying out any work on components to fall within 25 mm of the top the bath to prevent the which carry gas.

  • Page 13: Siting The Appliance

    Installation If Thermostatic Radiator Valves are fitted then it is rec- pH value of the system water must be less than 8 ommended that the primary radiator is left open. or the appliance guarantee will be invalidated. Repeated venting probably indicates a leak and this A drain cock to BS2879 must be fitted to the lowest must be rectified to ensure the proper operation of the point of the system.

  • Page 14: Wall Mounting Frame Assembly

    Installation B Screw the pre-plumbing manifold with two screws to Wall mounting frame assembly the wall mounting frame. B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 7. Use the inner lugs on the top and bottom horizontal sections for the appliances that are 440 mm wide.

  • Page 15: Fitting The Appliance

    Installation Condensate Termination and Route External condensate pipework The condensate connection on the Greenstar appli- All Greenstar condensing boilers have within a ances is in 22 mm plastic. The pipe should be extended syphonic condensate trap. Rather than the condensate and run away from the appliance with a constant fall of constantly dripping into the discharge pipe, the con- 2.5 °...

  • Page 16: Checking The Connections

    B Take care not to disturb the washers on the connec- tions. The only flue systems that may be used are those sup- plied by Worcester Heat Systems. Connecting the flue duct The flue system must be installed in accordance with B Fit flue duct connector onto appliance flue spigot.

  • Page 17: Siting The Flue Terminal

    Installation 3.9.1 Siting the Flue Terminal lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which The flue must be installed in accordance with people have access then a guard must be fitted. The BS 5440:1 and the Building Regulations.

  • Page 18: Installation Of The Flue

    Installation 3.9.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm require exten- Terminal sion duct assemblies.
  • Page 19 Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp Extension Clamp Duct 6 720 610 602 - 09.1O Fig. 18 Flue with one extension Terminal Assembly Flue Turret Outer Wall Clamp Clamp Extension Extension Clamp Duct Duct 6 720 610 602 - 10.1O Fig.

  • Page 20: Flue Duct Preparation And Assembly

    Installation 3.9.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 21, 22. Outer Wall Flue Terminal Face Raised Ring locating the terminal relative to the outside wall face 6 720 610 576 - 20.1O NOTE: THE FLUE MUST BE INCLINED T O THE BOILER 6 720 610 602 - 12.1O Fig.

  • Page 21: Electrical Connections

    Electrical connections Electrical connections Connecting the appliance B Always disconnect the power supply to the appliance at the mains before carry- To gain access to the mains connection remove the ing out any work on the electrical sys- drop down facia cover. The drop down cover is tems and components.

  • Page 22: Mains Voltage External Controls Connections

    Electrical connections B Cut cable grommet to diameter of cable. Mains Voltage external controls connections NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Remove Link Motor 230 V R oom Thermostat Connections 230 V Pr ogrammer Connections Ns Ls L 230 V r oom thermos t at and...

  • Page 23: Commissioning

    Commissioning Commissioning 317 366 367 6 720 610 576-07.2O Fig. 30 Commissioning Pressure gauge Safety valve Automatic vent Never run the appliance when empty or Reset button unpressurised. Master switch Temperature control for central heating Service cocks on CH flow and return Hot water The operational CO level is set at the fac-...

  • Page 24: Switching The Appliance On/Off

    Commissioning B Before commissioning, the gas supply pres- Switching off the appliance sure must be checked at the gas supply pres- B Set the master switch to (0). sure test point (see page 6, fig. 2, item 7). The green indicator lamp goes out. Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or B Always disconnect the appliance from...

  • Page 25: Setting The Domestic Hot Water Temperature And Flow Rate

    Commissioning B To increase the flow rate (max. 14 l/min): Setting the domestic hot water turn screw on flow switch anti-clockwise (+). temperature and flow rate The outlet temperature will decrease relative to the 5.5.1 Domestic hot water temperature increase in the flow rate. B To reduce the flow rate (min.

  • Page 26: Fault Condition

    Commissioning Fault Condition A list of faults that may occur is given on page 43. In the unlikely event of a fault occuring while the appli- ance is in operation: The display then shows a fault code and the but- may also flash.

  • Page 27: Individual Settings

    Individual settings Individual settings B Rotate yellow button through 180° and replace (dot Mechanical settings facing inwards). 6.1.1 Checking the size of the expansion vessel The CH flow temperature is no longer limited. Maximum pressure at maximum CH flow temperature is Control setting CH flow temperature 2.5 bar.

  • Page 28: Settings On The Bosch Heatronic

    Individual settings Settings on the Bosch Heatronic 6.2.1 Operating the Bosch Heatronic Entering a setting The Bosch Heatronic enables easy setting and check- B To enter the setting for a function, turn the tempera- ing of a large number of appliance functions. ture control This description is limited to those functions required Storing a setting...

  • Page 29: Setting The Maxim Ch Flow Temperature (Service Function 2.5)

    Individual settings B Refer to the settings tables for heating and cylinder 6.2.4 Setting the maxim CH flow temperature (Service Function 2.5) charging output to obtain the relevant code for the desired heating output in kW (see page 45). The maximum CH flow temperature can be set to B Turn the temperature control between 35˚C and 88˚C (factory setting).

  • Page 30: Converting The Appliance To Different Gas Types

    Converting the appliance to different gas types Converting the appliance to different gas types The setting is factory sealed at maximum. Adjustment to Setting the gas/air ratio the rated heat input and min. heat input is not neces- The gas/air ratio may only be adjusted on the sary.

  • Page 31: Testing Combustion Air/Flue Gas At Set Heat Output

    Converting the appliance to different gas types B Turn the temperature control B Remove the seal from the gas valve adjusting screw until the display shows 2. (= max. rated heat output). (64) and adjust the CO level to the figure given in The display and the button will flash.

  • Page 32: Maintenance

    Maintenance Maintenance In “chimney sweep” mode, the appliance switches to max. rated heat output or the B Always disconnect the appliance from set heating output. You then have 15 min- the electrical power supply (fuse, circuit utes in which to measure the levels. After breaker) before carrying out any work that, the appliance switches back from on the electrical systems or compo-...

  • Page 33: Pre-Service Check List

    Maintenance Pre-Service Check List Date Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 34). Check ionisation current, Service Function 3.3, (see page 34). Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 36).

  • Page 34: Description Of Servicing Operations

    Maintenance Description of servicing operations Primary Heat exchanger There is a special accessory kit (no. 840) for cleaning The combustion performance must be checked before the heat exchanger, order no. 7 719 001 996. and after any servicing work on the combustion and burner components.
  • Page 35 Maintenance B Loosen any deposits in the heat exchanger from top Burner to bottom using the cleaning blade. Refer to fig. 52. B Check that the gas cock is turned off and the master switch is in the OFF position. B Remove the clips (1) and unscrew the two bolts (2).
  • Page 36 Maintenance Diaphragm in mixer unit Electrode assembly B Switch off the master switch. B Take care not to damage diaphragm (443) when removing and refitting it. B Pull off the leads from the electrodes. Refer to fig. 2. B Unscrew the two fixing screws and carefully remove B Open mixer unit (29).

  • Page 37: Replacement Of Parts

    Maintenance Heating system pressure Replacement of Parts Fill the system using the WRc approved Before changing any components check that the gas is filling loop. turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance.

  • Page 38: Fan Assembly

    Maintenance B Remove the pcb control board. 8.3.2 Fan Assembly Fig. 60 Fuses Fig. 61 B Remove the connections covers. Refer to fig. 25, B Switch off the appliance. B Disconnect the appliance from the power supply. The fuses are located adjacent to the mains connector B Undo lower pipe union on gas pipe (1.).

  • Page 39: Pump

    Maintenance 8.3.3 Pump 8.3.4 3-way diverter valve B Switch off the appliance. B Switch off the appliance. B Disconnect the appliance from the power supply. B Disconnect appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to B Turn off service cocks.

  • Page 40: Sensors

    Maintenance B Recheck the combustion performance as described 8.3.6 Sensors in section 7.1. B Check that the appliance is electrically isolated. Central Heating Flow Temperature Sensor – Item 36, fig. 2, 59 B Pull-off the connector. B Release the sensor clip and withdraw the sensor. B Apply heat transfer paste to the replacement sensor.

  • Page 41: Domestic Hot Water Heat Exchanger

    Maintenance 8.3.8 Domestic Hot Water Heat Exchanger 8.3.14 Flow switch B Refer to section 7.2. B Shut the mains water inlet valve and drain the domes- tic hot water circuit. B Use new seals when fitting the new heat exchanger. B Pull-off the connectors from the micro-switch.

  • Page 42: Primary Heat Exchanger

    Maintenance 8.3.15 Primary Heat Exchanger B Drain the appliance. B Check that the gas supply is turned off. B Check that the appliance is electrically isolated. B Remove the fan assembly complete with the gas/air tube and mixer assembly. Refer to section 8.3.2. B Remove the burner.

  • Page 43: Appendix

    Appendix Appendix Fault Codes More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346. Display code Description Remedy Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for circuit breaks/short circuits.

  • Page 44: Short Parts List

    Appendix Short parts list Description Qty GC Spare part number Sensor - Flue gas temp. 8 729 000 144 0 Sensor - CH flow temp. 8 714 500 087 0 Sensor - DHW flow temp. 8 714 500 054 0 Control board 8 748 300 418 0 Gas valve...

  • Page 45: Heating/Hot Water Output Settings

    Appendix Heating/hot water output settings Heating/hot water output settings ZWB 7-25 N.G. ZWB 11-25 L.P.G. Propane Natural gas G20 Display Display Heat output Heat Gas vol. flow code Heat output kW Heat input kW code input kW rate (l/min at = 80/60˚C) 10.9 11.0...

  • Page 46: Operational Flow Diagrams

    Appendix Operational Flow diagrams 9.7.1 Domestic hot water function Fig. 67 6 720 610 576 GB (03.02)

  • Page 47: Central Heating Function

    Appendix 9.7.2 Central heating function Fig. 68 6 720 610 576 GB (03.02)
  • Page 48 Appendix Appendix EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619...
  • Page 49 Users Instructions and Customer Care Guide R 25 & 30 HE combi Condensing boiler R 28 HE system Condensing boiler 6 720 611 441-00.1O ZWB 7-25 R 25 HE GC-Number: 47 311 77 ZWB 7-30 R 30 HE GC-Number: 47 311 78 ZB 7-28 R 28 HE system GC-Number: 41 311 62 GB/IE...
  • Page 50 Contents Contents Excellence comes as standard Safety precautions General notes Controls Operating the Appliance Preparation Switching the Appliance On/Off Switching on the Central Heating Controlling Central Heating R 25 & 30 Boilers: Setting the Hot Water Temperature 15 Summer Mode, Hot Water Only (R 25 &...

  • Page 51: Excellence Comes As Standard

    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 Heat Systems Ltd. - Offering a complete maintenance scheme to keep your boiler operating at peak condition and efficiency.
  • Page 52 Excellence comes as standard EIRE ONLY The CE mark to indicates manufacture to EU safety requirements. This appliance must be installed only by a competent person to the requirements of IS 813. Make sure your installer hands you a certificate confirming com- pliance with IS 813 and that you read carefully the instruction book suppplied with this appliance.

  • Page 53: Safety Precautions

    Safety precautions Safety precautions Gas Safety (Installation and Use) Regulations 1998 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.
  • Page 54 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 1988).

  • Page 55: General Notes

    General notes General notes To get the best from your appliance please read these instruc- tions carefully. Sealed heating systems The appliance is fitted to a sealed heating system which is pre- pressurised. Your installer will tell you of the minimum and maxi- mum pressure which must be indicated on the pressure gauge.
  • Page 56 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 10 mm Right-hand side 10 mm In Front 600 mm...
  • Page 57 General notes For further information contact Worcester Heat Systems Ltd. Technical Services Department. Hot and cold flow – R 25 & 30 Boilers The flow of water demanded from both hot and cold service out- lets is dependent upon the mains supply. It may not be possible in some installations to operate all outlets simultaneously.

  • Page 58: Controls

    Controls Controls 317 366 367 310 422 6 720 610 600-01.1O System Pressure gauge Reset button Master switch Central heating temperature control Service valves in CH flow and return Hot water Gas isolation valve (open) Cold water inlet Identification sticker Hot water temperature control (R 25 &...

  • Page 59: Operating The Appliance

    Operating the Appliance Operating the Appliance 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).
  • Page 60 Operating the Appliance Check the central heating system pressure B The pointer on the pressure gauge (8.1) should be about 1 bar. B If the pointer is below 1 bar (when the system is cold), top up the system with water until the pointer is 1 bar. Your installer will have shown you how to do this.

  • Page 61: Switching The Appliance On/Off

    Operating the Appliance 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 central heating flow temperature, when the appliance is oper- ating in the central heating mode. 6 720 610 333-04.1O If the display alternates between -II- and the cen- tral heating flow temperature, the trap filling pro-...

  • Page 62: Switching On The Central Heating

    Operating the Appliance Switching on the Central Heating B Turn the central heating 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. 6 720 610 333-05.1O Controlling Central Heating B Set room thermostat to the desired room temperature.

  • Page 63: R 25 & 30 Boilers: Setting The Hot Water Temperature

    Operating the Appliance R 25 & 30 Boilers: Setting the Hot Water Temperature Hot water temperature On R 25 & 30 models, the hot water temperature can be set to between approx. 40˚C and 60˚C using the temperature control The domestic hot water temperature is not shown on the display. 6 720 610 333-07.1O Control Setting Water Temperature...

  • Page 64: Summer Mode, Hot Water Only (R 25 & 30 Appliances)

    Operating the Appliance ECO mode with demand detection, button is lit The demand detection function enables maximum gas and water economy. Briefly turning a hot water tap on and then off again signals demand to the appliance which then heats up the water to the set temperature.

  • Page 65: Fault Condition

    The appliance will start up again and the central heating flow temperature will be displayed. If the fault remains and can not be cleared: B Call Worcester Heat Systems Ltd. for assistance, giving a description of the fault and, if possible, the fault code from the facia display.

  • Page 66: Tips On Saving Energy

    Tips on saving energy 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.

  • Page 67: General Information

    General Information Hot water A lower setting on the hot water temperature control can result in considerable energy savings. For R 25 & 30 appliances: The on-demand activation using the ECO-button makes possi- ble the maximum savings of gas and water. Now you know how to heat your home economically with the R 25 &...

  • Page 68: Maintaining Your Appliance

    2 year guarantee period. If you would like to know more about a Worcester Bosch service contract, please tick the appropriate box on your warranty regis- tration card.

  • Page 69: Fault Or Breakdown

    Fault or breakdown 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 occurring on this appliance.

  • Page 70: Your Guarantee

    Model, Serial Number, Date of Installation. • That Worcester Heat Systems Limited will not accept respon- sibility for damage caused by faulty installation, neglect, mis- use or accidental damage, the non observance of the instructions contained in the Installation and Users Instructions Leaflets.

  • Page 71: Guarantee Registration

    Check that the Benchmark “log-book” has been completed by your installer or service engineer. EXCELLENCE COMES AS STANDARD Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619 SERIAL NUMBER. Copy the number off the Guarantee Card.
  • Page 73 Installation and Servicing Instructions GREENSTAR HE plus combi Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 598-00.1O ZWBR 7-30 HE plus GC-Number: 47 311 75 ZWBR 11-35 HE plus GC-Number: 47 311 57...
  • Page 74 Contents Contents Hot water 6.6.1 Hot water programme 6.6.2 Hot water immediately i Info Settings Safety precautions 6.8.1 Heating (if TR 2 is connected) 6.8.2 Hot Water (Storage Tank, ZSBR models only) Symbols 6.8.3 Service Individual timer programmes Details of the appliance EC Declaration of Conformity Individual settings Standard package...

  • Page 75: Safety Precautions

    Safety precautions Safety precautions Symbols If you smell gas Safety instructions in this document B Turn off gas service cock at the meter. are identified by a warning-triangle sym- B Open windows and doors. bol and are printed on a grey back- B Do not operate any electrical switches.

  • Page 76: Details Of The Appliance

    Details of the appliance Details of the appliance Description of appliance • Wall-mounted appliance, siting not dependent on room size EC Declaration of Conformity • Natural gas models are low-emission appliances This appliance is in accordance with the applicable • Multifunction display requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility •...

  • Page 77: Accessories

    Details of the appliance Accessories • Standard horizontal flue kit at 100 mm outside diameter for flues upto 4 m in length. • Flue duct kits for horizontal (125 mm outside diameter) for flue lengths upto 10 m (ZWBR 11-35) or 13 m (ZWBR 7-30) and vertical flue systems for flue lengths 12 m (ZWBR 11-35) or 15m (ZWBR 7- 30).

  • Page 78: Layout Of Appliance

    Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 6 720 610 597 - 02.1O Fig. 2 Heatronic control Fixing points Heat exchanger safety temperature limiter 221.1 Flue duct Hot water NTC sensor 221.2 Combustion air intake Testing point for gas supply pressure Fan assembly Pressure gauge Appliance type sticker...

  • Page 79: Function

    Details of the appliance Function 234.1 ϑ 29.1 52.1 ϑ 6 720 610 597- 03.2O Fig. 3 Bosch Heatronic control Adjustable gas flow restrictor Temperature limiter, heat exchanger Adjusting screw for min. gas flow volume Hot water NTC sensor Control valve Testing point for gas supply pressure Motor Pressure gauge...

  • Page 80: Electrical Wiring Diagram

    Details of the appliance Electrical wiring diagram o - orange g - green bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 602 - 02.1O Fig.

  • Page 81: Technical Data

    Details of the appliance Technical data ZWBR 7-30 ZWBR 11-30 ZWBR 11-35 ZWBR 14-35 Units Natural gas Propane Natural gas Propane Max. rated heat output net 40/30˚C central heating 31.2 31.2 37.5 37.5 Max. rated heat output net 50/30˚C central heating 30.9 30.9 37.1...
  • Page 82 Details of the appliance Condensate analysis, mg/l Gas supply Ammonium 1.2 Nickel 0.15 Total length of gas supply pipe Pipe diameter ≤ 0.01 Mercury ≤ 0.0001 (metres) (mm) Lead ≤ 0.001 Sulphate Cadmium ≤ 0.005 Zinc ≤ 0.015 Chromium Gas discharge rate (m ≤...

  • Page 83: Installation Regulations

    Installation regulations Installation regulations Installation Gas Safety (Installation & Use) Regulations 1998: All B Always turn off the gas cock before car- gas appliances must be installed by a competent per- rying out any work on components son. Failure to install correctly could lead to prosecu- which carry gas.

  • Page 84: Domestic Hot Water

    Installation Domestic hot water A Zilmet Z160 expansion vessel is the preferred type. A thread sealant compatible with potable water must be Any regulations specified by the local water company used. The vessel should be connected into the cold must be observed. water mains inlet pipe as close as possible to the appli- The final 600 mm of the mains cold water connection to ance.

  • Page 85: Siting The Appliance

    Installation APPLIANCE Refer to Fig.1 Appliance water flow diagram A drain cock should be fitted at the lowest point of the heating circuit and the appliance WRAS approved filling loop Lockshield valve Central heating return Domestic Central heating flow hot water Radiator valve BS stop valve.

  • Page 86: Wall Mounting Frame Assembly

    Installation B Screw the pre-plumbing manifold with two screws to Wall mounting frame assembly the wall mounting frame. B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 7. Use the outer lugs on the top and bottom horizontal sec- tions for the appliances that are 512 mm wide.

  • Page 87: Fitting The Appliance

    Installation Condensate Termination and Route External condensate pipework The condensate connection on the Greenstar appli- All Greenstar condensing boilers have within a ances is in 22 mm plastic. The pipe should be extended syphonic condensate trap. Rather than the condensate and run away from the appliance with a constant fall of constantly dripping into the discharge pipe, the con- 2.5 °...

  • Page 88: Checking The Connections

    Installation B Lift off the top fixing lugs and slide case forwards and Connecting the flue duct remove (3.). B Fit flue duct connector onto appliance flue spigot. B Secure with the two screws supplied. Fig. 14 B For remaining installation of flue assembly, refer to the relevant installation instructions.

  • Page 89: Flue Systems

    Installation Flue Systems The only flue systems that may be used are those sup- plied by Worcester Heat Systems. The flue system must be installed in accordance with the requirements of BS5440:1. Standard 100 mm flue system The standard concentric flue system provides for a hor- izontal length of upto 4 m.

  • Page 90: Siting The Flue Terminal

    Installation 3.9.1 Siting the Flue Terminal The flue must be installed in accordance with lighting, activated by passive infra-red sensing heads. BS 5440:1 and the Building Regulations. Flue termi- If the terminal is less than 2 m above a surface to which nals in carports and under balconies are to be avoided.

  • Page 91: Installation Of The Flue

    Installation 3.9.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm require exten- Terminal sion duct assemblies.
  • Page 92 Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp Extension Clamp Duct 6 720 610 602 - 09.1O Fig. 18 Flue with one extension Terminal Assembly Flue Turret Outer Wall Clamp Clamp Extension Extension Clamp Duct Duct 6 720 610 602 - 10.1O Fig.

  • Page 93: Flue Duct Preparation And Assembly

    Installation 3.9.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 21, 22. Outer Wall Flue Terminal Face Raised Ring locating the terminal relative to the outside wall face 6 720 610 576 - 20.1O NOTE: THE FLUE MUST BE INCLINED T O THE BOILER 6 720 610 602 - 12.1O Fig.

  • Page 94: Electrical Connections

    Electrical connections Electrical connections Connecting the appliance B Always disconnect the power supply to the appliance at the mains before carry- To gain access to the mains connection remove the ing out any work on the electrical sys- drop down facia cover. The drop down cover is tems and components.

  • Page 95: Connecting Tr2 Room Thermostat

    Electrical connections B Cut cable grommet to diameter of cable. Mains Voltage external controls connections NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Remove Link Motor 230 V R oom Thermostat Connections 230 V Pr ogrammer Connections 230 V r oom thermos t at and Ns Ls L...

  • Page 96: Commissioning

    Commissioning Commissioning 317 366 367 6 720 610 597 - 05.1O Fig. 30 Pressure gauge Commissioning Safety valve Automatic vent Never run the appliance when empty or Reset button unpressurised. Master switch Temperature control for central heating Service cocks on CH flow and return Hot water The operational CO level is set at the fac-...

  • Page 97: Switching The Appliance On/Off

    Commissioning B Before commissioning, the gas supply pres- B Open automatic vent (27) and re-close after venting sure must be checked at the gas supply pres- (see page 24). sure test point (see page 6, fig. 2, item 7). Switching off the appliance Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or B Set the master switch to (0).

  • Page 98: Setting The Domestic Hot Water

    Commissioning B To increase the flow rate (max. 14 l/min): Setting the domestic hot water turn screw on flow switch anti-clockwise (+). temperature and flow rate The outlet temperature will decrease relative to the 5.5.1 Domestic hot water temperature increase in the flow rate. B To reduce the flow rate (min.

  • Page 99: Fault Condition

    Commissioning Fault Condition A list of faults that may occur is given on page 47. In the unlikely event of a fault occuring while the appli- ance is in operation: The display and the text display then show a fault code and the button may also flash.

  • Page 100: Text Display

    Text Display Text Display B To start programming, press any button, e. g. General Description The display lighting switches on and the main menu • The text display is used to display information about is displayed: the appliance and the system and to alter the set- tings displayed.

  • Page 101: Deleting A Setting

    Text Display B Confirm the setting by pressing the button. Menu structure B Use the button to set the day of the Submenu week. B Press the button to confirm the setting. The Main Parameters to menu change/select cursor then returns to the top line. Time/ Time/day - - Hours...

  • Page 102: Setting The Time/Day

    Text Display Setting the time/day Setting switching times and operating mode B From the main menu select Heating and then from 6.4.1 Setting the time and day the first submenu, select Heating program. For details of how to set the time and day, refer to B Select Monday - Friday, Saturday and Sunday or page 28.

  • Page 103: Manual Operating Mode (If Tr2 Is Not Connected)

    Text Display 6.5.3 Manual operating mode (if TR2 is not con- i Info nected) B Select Info from the main menu. For selecting an operating mode that is different from the one set in the heating programme (Automatic You can view the following information: mode).

  • Page 104: Heating (If Tr 2 Is Connected)

    Text Display B Press the Settings button. The display shows Change value. 6.8.1 Heating (if TR 2 is connected) B Press to set the number of seconds in 24 hours. Optimum Start B From the main menu, select Settings and from the Basic setting: “+ 0 s”...

  • Page 105: Individual Settings

    Individual settings Individual settings Mechanical settings Control setting CH flow temperature 7.1.1 Checking the size of the expansion vessel approx. 35˚C approx. 43˚C System Capacity – BS7074:1 approx. 51˚C Expansion Vessel Pressure ZWBR ZWBR approx. 59˚C and System Capacity 7-30 11-35 approx.

  • Page 106: Setting The Anti-Cycle Time (Service Function 2.4)

    Individual settings Setting service functions 7.2.3 Setting the maximum CH flow tempera- Only the service functions that can be set are displayed. ture (Service Function 2.5) The maximum CH flow temperature can be set to B Press any button to activate the main menu. between 35˚C and 88˚C (factory setting).
  • Page 107 Converting the appliance to different gas types Converting the appliance to different gas types B Insert testing probe about 135 mm into the flue gas The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not neces- testing point and seal testing point.

  • Page 108: Testing Combustion Air/Flue Gas At Set

    Converting the appliance to different gas types fully engaged. Check that the case is properly ZWBR 7-30 aligned with facia. Refer to fig. 13. reading reading B Secure by replacing the screw at the bottom left. at max. at min. Refer to fig.
  • Page 109 Maintenance 8.2.2 Testing CO and CO Maintenance B Press and hold the button until the display shows B Always disconnect the appliance from – –. the electrical power supply (fuse, circuit “Chimney sweep” mode is now active. breaker) before carrying out any work button will light up and the display shows the on the electrical systems or compo- CH flow temperature.

  • Page 110: Maintenance

    Maintenance Pre-Service Check List Date Call up the last fault stored by the text- display , (see page 32). Check ionisation current, Service Function 3.3, (see page 39). Perform visual check of air/flue duct. Visual check of diaphragm for soiling and splits (see page 41).

  • Page 111: Description Of Servicing Operations

    Maintenance Description of servicing operations Primary Heat exchanger There is a special accessory kit (no. 840) for cleaning The combustion performance must be checked before the heat exchanger, order no. 7 719 001 996. and after any servicing work on the combustion and burner components.
  • Page 112 Maintenance B Loosen any deposits in the heat exchanger from top Burner to bottom using the cleaning blade. Refer to fig. 47. B Check that the gas cock is turned off and the master switch is in the OFF position. B Remove the clips (1) and unscrew the two bolts (2).
  • Page 113 Maintenance B Seal the mixer unit (29). Condensation trap In order to prevent spillage of condensate the condensa- Diaphragm in mixer unit for ZWBR 11-35 HE plus tion trap should be completely removed, (see page 39 , fig. 46 ). B Remove fan and mixer unit assembly.

  • Page 114: Replacement Of Parts

    Maintenance Siphon Replacement of Parts B Unscrew the clip and disconnect the pipe to the Before changing any components check that the gas is siphon. turned off and that the appliance is electrically isolated. B Remove the yellow plug to drain the siphon. When necessary close the system valves and drain the appliance.

  • Page 115: Fan Assembly

    Maintenance B Remove the pcb control board. 9.3.2 Fan Assembly Fig. 56 Fuses Fig. 57 B Remove the connections covers. Refer to fig. 25, B Switch off the appliance. B Disconnect the appliance from the power supply. The fuses are located adjacent to the mains connector B Undo lower pipe union on gas pipe (1.).

  • Page 116: 3-Way Diverter Valve

    Maintenance B Remove 3-way valve. Alternatively B After removing the siphon release the four Allen screws and remove and replace the pump head. Fig. 59 After refitting: B Fill system, bleed and re-pressurise (see Installation Instructions). 9.3.5 3-way diverter valve motor Fig.

  • Page 117: Gas Valve

    Maintenance Domestic Hot Water Temperature Sensor – 9.3.8 Domestic Hot Water Heat Exchanger Item 6.1, fig. 2 B Refer to section 9.2. B Check that the inlet water valve is closed and the B Use new seals when fitting the new heat exchanger. domestic hot water circuit is drained.
  • Page 118 Maintenance B Transfer components, as necessary, to the new heat 9.3.14 Flow switch exchanger. B Shut the mains water inlet valve and drain the domes- B Ensure that all the seals are in place and all of the tic hot water circuit. connections are tight before re-commissioning the B Pull-off the connectors from the micro-switch.

  • Page 119: Appendix

    Appendix Appendix 10.1 Fault Codes More detailed fault finding procedures are described in the Service Booklet for the Engineer number 7 181 465 347. Display code Description Remedy pump has run dry Check system pressure, add water and bleed system as necessary Hot water NTC sensor defective.

  • Page 120: 10.2 Short Parts List

    Appendix 10.2 Short parts list Description Qty GC Spare part number Sensor - Flue gas temp. 8 729 000 144 0 Sensor - CH flow temp. 8 714 500 087 0 Sensor - DHW flow temp. 8 714 500 054 0 Control board 8 748 300 418 0 Gas valve ZWBR 7-30...

  • Page 121: 10.3 Heating/Hot Water Output Settings

    Appendix 10.3 Heating/hot water output settings 10.4 Heating/hot water output settings ZWBR 7-30 N.G. ZWBR 11-30 L.P.G Propane Natural gas G20 Display Heat output, Heat input, Display Heat output, Heat input, Gas vol. flow code code rate (l/min at = 80/60˚C) 11.7 11.8 15.5...

  • Page 122: 10.7 Operational Flow Diagrams

    Appendix 10.7 Operational Flow diagrams 10.7.1 Domestic hot water function Fig. 63 6 720 610 597 GB (03.02)

  • Page 123: 2Central Heating Function

    Appendix 10.7.2 Central heating function Fig. 64 6 720 610 597 GB (03.02)
  • Page 124 Appendix Appendix EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619...
  • Page 125 Service Booklet for the Engineer for Gas Condensing Boilers ZSBR 7-28 ICS1 GC-Number: 41 108 04 ZWBR 8-30 ICC2 GC-Number: 41 108 09 ZBR 8-35 ICS1 GC-Number: 41 108 05 ZWBR 11-37 ICC1 GC-Number: 41 108 10 ZWBR 7-28 HE plus GC-Number: 47 311 56 ZWBR 11-35 HE plus GC-Number: 47 311 57...
  • Page 126 Contents Contents Safety precautions Symbols Layout of Appliance (ZSBR/ZWBR) Operation Standard display Displaying service functions Setting service functions Resetting service functions to factory settings 5 2.4.1 Resetting service functions 0.0 to 4.9 to their factory settings (Reset 1): 2.4.2 Resetting service functions 0.0 to 9.9 to the factory setting (Reset 2): Boiler service functions Summary...

  • Page 127: Safety Precautions

    Safety precautions Safety precautions Symbols Safety instructions in this document Repairs are identified by a warning-triangle sym- B Repairs may only be carried out by an approved bol and are printed on a grey back- installer! ground. B Before carrying out any work on the appliance, switch it off at the master switch! Signal words indicate the seriousness of the hazard in B Even when the appliance is switched off at the mas-...

  • Page 128: Layout Of Appliance (Zsbr/Zwbr)

    Layout of Appliance (ZSBR/ZWBR) Layout of Appliance (ZSBR/ZWBR) Testing points: flue gas Fan fixing screws Automatic vent Burner fixing screws Fan connector Electrode assembly: Flame sensing electrode Mixer unit Ignition electro- Silencer CH flow NTC CH flow sensor Gas supply pipe Flue gas safety CH flow safety...

  • Page 129: Operation

    Operation Operation B Press the Instructions on the use of the text display module are button. given in the operating and installation instructions for The cursor is pointing to Display service the boiler. parameters. B Press and hold the button (for about 5 sec- onds) until the display shows shows Adjust service parameters and the first service function to be set, e.g.

  • Page 130: Boiler Service Functions

    Boiler service functions Boiler service functions Summary Range adjustable Reset Text display message Display from - to Value Last fault 00 - FF Clear only Flow temp. sensor 0 - 99 °C Hot water temp. sensor 0 - 99 °C Stor.
  • Page 131 Boiler service functions Range adjustable Reset Text display message Display from - to Value Link 8 - 9 open closed Link Ls-Lr open closed Stor. tank. therm.. (7-9) blocked heat demand Room therm. LSM blocked heat demand LSM release blocked heat demand Timer ch.
  • Page 132 Boiler service functions Range adjustable Reset Text display message Display from - to Value Cycle time (hot water) 0 - 60 min 0 min Duration (hot water) 0 - 30 min 1 min Pump map (heating) 0 Pump step adjustable 4 Prop.

  • Page 133: Explanation Of Service Functions

    Boiler service functions Explanation of service functions • Min mode: the appliance runs constantly at minimum output. 0.0 Last fault The text display shows MIn mode. The 2-digit dis- play alternates between the CH flow temperature The last fault can also be recalled for servicing pur- poses when the appliance is functioning correctly.
  • Page 134 Boiler service functions 2.7 Autom. anti-cycle mode 3.5 Pump blocking time (ZBR.. models only) If an outside-temperature controlled programmer is con- nected to the appliance, the anti-cycle time is adjusted Only applies if service function 3.4, Pump automatically. mode, is set to Pump mode 1 (external 3- Automatic adjustment of the anti-cycle time can be dis- way valve for heat store charging is con- abled.
  • Page 135 Boiler service functions Shows the status of channel 2 of the timer integrated in The heating output can be limited to any level between the text display module or the separate programmer. the min. rated heat output and the max. rated heat out- If that channel’s status is “Heat demand”, hot water put to suit the specific heat requirements.
  • Page 136 Boiler service functions If a stratified-charge tank is connected, it is useful to 7.2 Antiblock. map pump (not ZBR...) have the function activated. The appliance is supplied with this function activated. The delayed cut-in of the pump then prevents cold If the pump threatens to jam, an oscillating pump action water being pumped through the tank and cooling it is activated.
  • Page 137 Boiler service functions 8.5 Siphon fill program The trap filling programme ensures that the condensa- tion trap is filled when the appliance is first installed or after it has been shut down for a long period: The con- densation trap prevents flue gas escaping from the appliance into the room in which it is installed.

  • Page 138: Rectifying Faults

    Rectifying faults Rectifying faults Boiler failure codes indication Summary 4.1.1 ... on the boiler 4.2.1 Appliance faults In order to identify the specific boiler failure a two digit alphanumeric code is used. This allows a quick fault identification and solution. The text display shows the message Fault EA.
  • Page 139 Rectifying faults Appliance faults Loose or broken contact on heat store NTC sensor Specified CH flow tempera- ture from TA... programmer exceeded Table 3 Programmer faults Set room temperature not reached Set room temperature exceeded by large amount Set room temperature not reached Temperature rises instead of falling...

  • Page 140: How To Use The Fault Tables

    Rectifying faults How to use the fault tables If the fault is now cured, the appliance will revert to nor- The procedure is explained using the fault code EA as an example: mal operation and the fault-finding process is complete. Now simply re-check the setting of the two temperature The table heading shows the fault code and a general controls.

  • Page 141: Faults Indicated On Display

    Rectifying faults Faults indicated on display flashing. Controlled-characteristic pump has run dry Check Action B Power OFF the appliance. System pressure below 1.2 bar? yes: B Check appliance and system for water leaks and repair as necessary. B Top up system. B Turn ON the appliance.

  • Page 142: Appendix

    Rectifying faults flashing. Heat store NTC sensor 2 defective Check Action B Activate menu option B Is the connector for heat store NTC sensor 2 cor- yes: Show service parameters. roded , damaged or dirty? Replace affected components. B Select .4 Stor.tank temp.sensor2 .
  • Page 143 Rectifying faults flashing. Hot water NTC sensor defective Check Action B Activate menu option B Is the connector for hot water NTC sensor corro- yes: Show service parameters. , damaged or dirty? Replace affected com- ponents. B Select .2 Hot water temp.sensor . ↓2.
  • Page 144 Rectifying faults flashing. No correct electrical connection Check Action B Turn switch until it clicks into position. Mode selector switch is between two settings A8? ↓2. B Power OFF the appliance. B Turn ON the appliance. yes: Wiring between TR 2 and text- ↓3.
  • Page 145 Rectifying faults flashing. Heat store NTC sensor 1 not detected Check Action ↓2. Is lead for heat store NTC sensor yes: correctly routed, i.e. not through B Route connecting lead for heat store tempera- cable clamp? ture sensor as specified in installation instruc- tions.
  • Page 146 Rectifying faults flashing. Code plug not detected. Check Action B Power OFF the appliance. No fault or fault code FC displayed yes: on text display? B Fit code plug (correctly), making sure code number (see Appendix) is correct. B Turn ON the appliance. b1? ↓2.
  • Page 147 Rectifying faults flashing. Fan speed too low Check Action ↓2. Fan lead connector properly con- yes: nected? B Power OFF the appliance. B Plug in connector. B Turn ON the appliance. C6? ↓2. Fan lead defective? yes: B Power OFF the appliance. B Replace fan lead.
  • Page 148 Rectifying faults flashing. Wrong signal from pin 8-9. Check Action ↓2. Jumper 8 - 9 fitted correctly? yes: B Power OFF the appliance. B Fit jumper 8 - 9 correctly, tighten screw. B Turn ON the appliance. d3? ↓2. ↓3. B Turn ON the appliance.
  • Page 149 Rectifying faults flashing. The heating outlet NTC sensor is damaged. Check Action B Activate menu option yes: The heating outlet NTC sensor is in short circuit: Show service parameters. B Power OFF the appliance. B Select .1 Flow temp.sensor. B Replace CH flow NTC sensor; observe fitting Is a temperature between 0.
  • Page 150 Rectifying faults flashing. Safety temperature limiter has tripped. Check Action B Top up system. Is the heating pressure between 1 yes: and 2 bar? B Vent appliance. B Press , does appliance restart??? E9?↓2. ↓2. Is the pump blocked? yes: B Unblock the pump.
  • Page 151 Rectifying faults flashing. Safety temperature limiter has tripped. Check Action B Power OFF the appliance. B Change the fuse. yes: B Remove fuse SI 3 from appliance B Turn ON the appliance. PCB control board and test for B Press , does appliance restart??? continuity.
  • Page 152 Rectifying faults flashing. During operation: flame not detected Check Action ↓6. Is the flame present? yes: ↓2. ↓3. Is the gas cock open? yes: B Open the gas cock B Press , does appliance restart??? EA? ↓3. Is there air in the supply pipe? B Vent supply pipe.
  • Page 153 Rectifying faults flashing. During operation: flame not detected Check Action ↓7. Is the ground connection correct? yes: B Rewire correctly as specified in the installation instructions. B Press , does appliance restart??? EA? ↓7. ↓8. Two phase net: yes: Is there a resistor fitted between Pe B Power OFF the appliance.
  • Page 154 Rectifying faults flashing. During operation: flame not detected Check Action Is flue gas CO level incorrect B Adjust to correct level. yes: B Press , does appliance restart??? EA? ↓12. ↓12. ↓13. B Activate menu option Show serv- yes: ice parameters. ↓16.
  • Page 155 Rectifying faults flashing. During operation: flame not detected Check Action Electrode assembly defective? B Replace electrode assembly. yes: B Power OFF the appliance. B Turn ON the appliance. B Remove electrode assembly. B Press , does appliance restart??? Electrodes worn out? EA? ↓18.
  • Page 156 Rectifying faults (and possibly ) flashing. Internal failure Check Action B Activate menu option B Record figure displayed in service report. Show service parameters. ↓2. B Select 9.3 GFA-Asic-error. A message is displayed. B Select 5.2 GFA status / error. B Record figure displayed in service report.
  • Page 157 Rectifying faults flashing. Although appliance switches off, flame still detected Check Action B Power OFF the appliance. Electrode(s) dirty or defective. B Replace electrode assembly. B Turn ON the appliance. B Press , does appliance restart??? F7? ↓2. B Power OFF the appliance. B Dry PCB control board (e.g.
  • Page 158 Rectifying faults flashing. After appliance switches off flame is detected Check Action B Clean condensation trap discharge pipe. Is condensation trap in condensing yes: boiler blocked? B Press , does appliance restart??? FA? ↓2. ↓2. Electrodes faulty. B Replace electrode assembly. B Turn ON the appliance.
  • Page 159 Rectifying faults flashing. Text display module not detected Check Action B Power OFF the appliance. No fault or fault code FC displayed on text display? B Fit code plug (correctly), making sure code number is correct (see Appendix). B Turn ON the appliance. FC? ↓2.
  • Page 160 Rectifying faults Faults that are not displayed 4.5.1 Appliance faults Boiler indicates P1, P2, P3 at start-up and then restarts with P1.. Check Action B Turn ON the appliance. Fuse T 1.6 A (312) defective. yes: B Change the fuse. B Power OFF the appliance.
  • Page 161 Rectifying faults Flue gas levels incorrect, CO level too high Check Action ↓2. Does the gas supply type match the yes: specifications on the appliance iden- B Convert appliance to correct gas type tification plate? ↓3. B Test gas supply pressure , - OK? yes: B Decommission appliance.
  • Page 162 Rectifying faults Ignition too harsh, ignition poor Check Action ↓6. B Activate menu option yes: Show service parameters. ↓2. B Select 5.1 Permanent ignition. Continuous ignition OK? ↓3. Ignition lead connected to ignition yes: electrodes? B Connect cable to ignition electrode. B Press button Ignition poor? ↓3.

  • Page 163: Loose Or Broken Contact On Heat Store Ntc Sensor

    Rectifying faults Ignition too harsh, ignition poor Check Action ↓8. B Test gas supply pressure - OK?. yes: B Decommission appliance. B Notify gas company. Problem with flue? B Check flue and repair or replace if necessary. yes: B Check CO level in combustion Ignition poor? ↓8.

  • Page 164: Specified Ch Flow Temperature From Ta

    Rectifying faults Specified CH flow temperature from TA... programmer exceeded Check Action If outside-temperature controlled programmer (TA...) is connected to boiler: • The anti-cycle time is adjusted by the programmer to the suit the system. • The factory setting for the anti-cycle time (3 min.) and the heating mode hysteresis setting, if applicable, are deactivated.

  • Page 165: Programmer Faults

    Rectifying faults 4.5.2 Programmer faults Set room temperature not reached (TR 2) Check Action B Turn up thermostatic valve(s). Thermostatic valve(s) set too low? yes: ↓2. ↓2. CH flow temperature control on yes: B Turn up CH flow temperature control. boiler set too low? ↓3.

  • Page 166: Set Room Temperature Not Reached

    Rectifying faults Set room temperature not reached Check Action Thermostatic valve(s) set too low? yes: B Turn up thermostatic valve(s). ↓2. ↓2. Heating characteristic set too low? B Correct heating characteristic. yes: ↓3. ↓3. CH flow temperature control on B Turn up CH flow temperature control. yes: boiler set too low? ↓4.

  • Page 167: Set Room Temperature Exceeded By Large Amount

    Rectifying faults Set room temperature exceeded by large amount Check Action Do radiators get too hot? yes: TR 2: B Decrease setting of “Heating” control ↓2. ↓2. Bad choice of location for program- B Select better installation location yes: mer, e.g. outside wall, near window, ↓3.

  • Page 168: Heat Store Fails To Heat Up

    Rectifying faults Heat store fails to heat up Check Action with TR 2: B Increase CH flow temperature control setting. CH flow temperature control on boiler set too low. Hot water temperature control on B Increase hot water temperature control setting. boiler set too low 7 181 465 347 (01.07)
  • Page 169 Appendix Appendix NTC values 5.1.2 CH flow NTC sensor, heat store NTC sen- sor, constant hot water NTC sensor and 5.1.1 Outside temperature sensor hot water NTC sensor Outside temperature Temperature ( °C) ( °C) Measurement Resistance tolerance ± 10% ( Ω) Measurement Resistance...
  • Page 170 Appendix Electronic schemes o - orange bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 603 - 03.1O Fig. 2 Ignition transformer Temperature limiter, heat exchanger Code plug Flue gas temperature limiter...
  • Page 171 Appendix List of most important replacement parts Component Order no. Remarks Component Order no. Remarks Switchbox Heat exchanger PCB control 8 748 300 385 board Temperature lim- 8 729 000 144 110 °C iter STB Transformer 8 747 201 358 Flue gas temper- 8 729 000 144 Ignition lead...
  • Page 172 Appendix Approved corrosion inhibitors and anti-freeze fluids for central heating water Mixing concentra– tion % by Manufacturer Description Remarks weight With all anti-freeze fluids and corrosion inhibitors, it is extremely important to observe the manufacturer’s recom- mended concentration levels and to check the concentration regularly. In the case of anti-freeze fluids, it should be noted that the efficiency of fluid-to-fluid heat transfer diminishes as the anti-freeze concentration increases.
  • Page 173 Appendix Detecting corrosion by CFCs Halogenated hydrocarbons in the combustion air cause surface corrosion of the affected metal components. The combustion chamber and the boiler heating sur- faces (including stainless steel) are particularly suscep- tible to this type of attack as are the metal components in the flue socket, flue joints and the chimney.
  • Page 174 Appendix 7 181 465 347 (01.07)
  • Page 175 Appendix 7 181 465 347 (01.07)
  • Page 176 Appendix...

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