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British Gas - ICC2

1. 5 Appendix 5 1 NTC values 5 1 2 CH flow NTC sensor heat store NTC sen Sor constant hot water NTC sensor and 511 Outside temperature sensor hot water NTC sensor Outside temperature Temperature C C Measurement Resistance Measurement Resistance tolerance 10 Q tolerance 10 Q 20 14 772 20 2 392 25 11 981 16 2 088 30 9 786 12 1811 35 8 047 8 1562 40 6 653 4 1 342 45 5 523 0 1149 50 4 608 4 984 55 3 856 8 842 60 3 243 10 781 65 2 744 15 642 70 2 332 20 528 75 1 990 25 436 80 1 704 Table 5 85 1 464 90 1 262 95 1 093 100 950 Table 6 7 181 465 347 01 07 45 Appendix 5 2 Electronic schemes o orange bl black r red p purple 317 366 367 25 V 153 1 230V AC LL 6 720 610 603 03 10 Fig 2 4 1 Ignition transformer 226 Fan 6 Temperature limiter heat exchanger 300 Code plug 9 Flue gas temperature limiter 302 Earth connection 18 Pump 310 Temperature control for hot water 32 Flame sensing electrode 312 Fuse slow T 1 6 A 33 Ignition electrode 313 Fuse slow T 0 5 A 36 Temperature sensor in CH flow 317 Digital display 52 Solenoid valve 1 328 Terminal block for AC 230 V Mains supply 521 Solenoid valve 2 328 1 Link 56 Gas valve CE 427 363 Indicator lamp for burner 61 Reset button 364 Indi
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4. 7 Check gas and water systems for leaks see page 15 8 Check hot water outlet temperature see page 38 9 Check heat exchanger mbar see page 38 10 Check burner see page 39 11 Clean condensation trap see page 40 12 Check charge pressure of mbar expansion vessel matches static head of heating system 13 Check central heating system pressure 14 Check electrical wiring for damage 15 Check heating programmer settings in the textdisplay 16 Check appliances that are part of the heating system Table 17 6 720 610 602 GB 03 02 37 Maintenance 9 2 Description of servicing operations The combustion performance must be checked before and after any servicing work on the combustion and burner components Refer to section 8 2 Checking the ionisation current Service Function 3 3 Select Service Function 3 3 See page 31 Display ing Service Functions If the display shows 2 or 3 the ionisation current is OK If the display shows O or 1 the electrode assembly 32 1 page 6 must be cleaned or replaced Domestic hot water If the flow rate is too slow remove the domestic hot water heat exchanger and replace Or descale with a descaling agent approved for use on stainless steel Before removing the heat exchanger shut the inlet valve and drain the hot water circuit Use n
5. 7 181 465 347 01 07 51 NORCESTER Worcester Heat Systems Ltd Cotswold Way Warndon Worcester WR4 9SW Great Britain www thermotechnik com Users Instructions and Customer Care Guide RD 532i RD 537i RD 542i combi Condensing boiler RD 430i system Condensing boiler reme 6 720 610 598 00 20 ZWBR 7 32 RD 532i GC Number 47 108 10 ZWBR 11 37 RD 537i GC Number 47 108 11 ZWBR 11 42 RD 542i GC Number 47 108 12 System boiler 7 30 RD 430i GC Number 41 108 06 Benchmark 6 720 610 604 GB 03 06 OSW British Gas 2 Scottish Gas 2 Contents Contents Excellence comes as standard 4 Safety precautions 5 1 General notes 7 2 Controls 11 3 Operating the Appliance 12 3 1 Preparation 12 3 2 Switching the Appliance On Off 14 3 3 Switching on the Central Heating 15 3 4 Controlling Central Heating 15 3 5 Combination Boilers Setting Hot Water Temperature 16 3 6 System boiler with Storage Tank 17 3 7 Summer Mode Hot Water Only Combi Appliances 18 9 8 Frost protection Combi Appliances 19 3 9 Fault Condition 19 4 Text Display 20 41 General Description 20 4 2 Programming 20 4 2 1 Deleting a setting 23 4 2 2 Resetting all parameters to their original settings 23 4 8 Menu structure 24 4 4 Setting the time day 25 4 4 1 Setting the time and day 25 4 4 2 Holidays 25 4 5 Heating 27 2 6 720 610 604 GB 03 06 Contents 4 5
6. Unscrew the pump union nuts 5 Refer to fig 58 Carefully remove the pump and disconnect the leads 42 6 720 610 602 GB 03 02 Maintenance Alternatively After removing the siphon release the four Allen screws and remove and replace the pump head Fig 58 9 3 4 3 way diverter valve Switch off the appliance Disconnect appliance from the power supply gt Turn off service cocks gt Unplug connector from 3 way valve motor Refer to fig 59 Pull out retaining clip Remove motor Disconnect the relief valve drain Disconnect the pressure gauge by withdrawing the clip and pulling out the capillary head Undo pipe unions by withdrawing the clips gt Remove 3 way valve 7 181 465 330 12 1R Fig 59 After refitting Fill system bleed and re pressurise see Installation Instructions 9 3 5 3 way diverter valve motor Switch off the appliance Turn off the service cocks Unplug connector from 3 way valve motor Refer to fig 59 Pull out retaining clip Remove motor 9 3 6 Sensors Check that the appliance is electrically isolated Central Heating Flow Temperature Sensor Item 36 fig 2 55 Pull off the connector Release the sensor clip and withdraw the sensor Apply heat transfer paste to the replacement sensor Safety Temperature Limiter Item 6 fig 2 55 Pull off the
7. 44 4 The gas valve is damaged Change the gas valve Turn ON the appliance gt Press N does appliance restart FA Power OFF the appliance 45 5 Check if the 20 pin connector lead assembly is damaged Change the 20 pin connector lead assembly Turn ON the appliance gt Press N does appliance restart FA Power OFF the appliance 16 6 The PCB control board is damaged Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 34 7 181 465 347 01 07 Rectifying faults FC Text display module not detected Check Action 1 No fault or fault code FC displayed on text display Power OFF the appliance Fit code plug correctly making sure code number is correct see Appendix Turn ON the appliance FC 12 2 Unplug text display module con yes nector Connecting lead between text dis Plug in connector FC l3 play module and Heatronic OK no Replace text display module FC l3 3 Text display module defective Replace text display module F d and AN flashing Reset button pressed inadvertently Check Action Press button again v 2 The PCB control board is damaged Disconnect the boiler electrical conn
8. 29 water times and tempera ZSBR tures models Service Display 30 service param Further Lan English 30 options guage Francais Deutsch Time correction 30 LCD contrast 30 Operat 30 ing times Fault 30 history 27 6 720 610 602 GB 03 02 Text Display 6 4 Setting the time day 6 4 14 Setting the time and day For details of how to set the time and day refer to page 26 Changing winter and summer time Only adjust the clock Do not alter the switching points for heating econo my etc 6 4 2 Holidays In the Holiday programme the central heating runs in Economy mode and the hot water is switched off frost protection function remains active From the main menu select Time day holidays and from the first submenu select Holidays gt Enter the number of days holiday by pressing 497 max 99 days holiday After the set number of days the text display module automatically cancels Economy mode at midnight on the last day and returns to Automatic mode The day on which you enter the days holiday counts as the first day of the holiday i e the unit starts the holiday program immediately Only include the day on which you are return ing if you don t want the heating to return to the normal program on that day To cancel Holiday mode early In the Holidays submenu Press the 6 button until the display shows 0 6 5 Heating 6 5 1 Heating programme
9. Basic setting Automatic mode The appliance switches automatically between nor mal heating Economy mode and Frost protection mode according to the timer settings entered Basic setting Heating starts at 6 00 am Economy starts at 10 00 pm Setting options Maximum of six switching points per day with three different operating modes Heating Economy Frost protection Same times for Monday to Friday Same times for Saturday and Sunday Different times for every day Setting switching times and operating mode From the main menu select Heating and then from the first submenu select Heating program Select Monday Friday Saturday and Sunday or an individual day of the week Monday Friday to have Heating and Econ omy or Frost protection switching on at the same times every weekday Saturday Sunday to have Heating and Economy or Frost protection switching on at the same times Saturday and Sunday Individual day of the week e g Thursday to have the relevant program always switching on at the specified time on that day of the week i e Heating Economy or Frost protection at the same time every Thursday gt Press The display shows Set 1 operating mode gt Set the desired first operating mode Heating Econ omy or Frost protection gt Press gt The display shows Set 1 time period Setthe desired first time period gt Press Set
10. Hot water immediately ON Comfort mode is active for 2 hours Comfort mode is active for 2 hours normal automatic pro gram Hot water mode according to timer programme entered From the main menu select Hot water and then from the first submenu select Hot water immediately Press a V J to switch Hot water immediately on or off 6 720 610 604 GB 03 06 31 Text Display 4 7 i Info Select Info from the main menu You can view the following information Display text Description Room temperature if TR 2 connected Current temperature in the room where TR 2 is installed Required room temper ature if TR 2 connected Required temperature in room where TR 2 is installed Operating mode if TR 2 connected E g Heating Economy in Automatic mode or Economy Heating Frost protection in manual mode Max flow temp Maximum CH flow temperature set on the temperature control for CH flow Actual flow temp Actual CH flow temperature Required flow temp Required CH flow temperature Max HW temp Maximum permissible hot water out flow temperature Required HW temp Required hot water temperature Actual HW temp Actual hot water outflow temperature Storage Tank charge released or blocked Shows if hot water is released or blocked Storage Tank charge on or off or Storage Tank charge afterrunning Shows if hot w
11. 6 720 610 602 GB 03 02 29 Text Display 6 8 Settings 6 8 1 Heating if TR 2 is connected Optimum Start From the main menu select Settings and from the first submenu select Heating gt Press a C to switch Optimum Start on or off Basic setting ON 6 8 2 Hot Water Storage Tank ZSBR models only The text display can control the hot water either with Times and temperatures or only times Times and temperatures One can choose up to six different times with temperatures see page 29 Hot water Only times During that times the Storage Tank will be charged to the choosed temperature From the main menu select Settings and from the first submenu select hot water gt Press a or lt to switch Times and temperatures or only times Turn the hot water temperature control always higher than the temperature at the text display is choosen 6 8 3 Service Displaying service functions This option displays various current settings and sta tuses of the electrically controlled appliance and sys tem components for the benefit of the heating engineer Service parameters Language Available languages are English Francais French Deutsch German From the main menu select Settings from the first submenu select Service from the Second submenu select Further options and from the third submenu select Language Press or to select the desired langu
12. CC FC The appliance is locked until the failure is repaired g with error codes b1 C1 d1 d3 22 FO The appliance is locked until the ON OFF switch is turned A1 The boiler has shut down and locked out 4 flashes and remains so until the cause of the fault has been eliminated and the lock out cancelled e g E9 EA FO F7 FA Fd To unblock the appliance Press the unblock button until the digit appears on the display Once the appliance starts up success fully the fault disappears from the text display 4 1 2 onthe programmer optional accessory A TW 2 remote control unit can also be connected to the text display module If other more functions are required another program mer must be connected Those programmers are then controlled via the bus module BM1 For more detailed information refer to the installation instructions for the boiler and the installed programmer Faults on this programmer are indicated by text mes sages on the programmer display Once the fault has been put right the programmer reverts to its normal display 42 Summary 4 2 4 Appliance faults S TE x B SS Appliance faults mios A1 X X 17 A5 X 18 A7 X X X 19 A8 X X X 20 Ad X X X 21 b1 X X X 22 C1 X X X 23 d3 X X X 24 E2 X X X 25 E9 X X X 26 EA X X X 28 FO X X X 32 F7 X X X 33
13. Description Oty GC Spare part number Sensor Flue gas temp 8 729 000 144 0 Sensor CH flow temp 8 714 500 0870 Sensor DHW flow temp 8 714 500 0540 Control board pcb 8 748 300 418 0 Gas valve ZWBR 8 30 8 747 003 5160 Gas valve ZWBR 11 37 8 747 003 5150 Fan assembly 8 717 204 3250 Fan washer 8 729 000 183 0 Expansion vessel 8 715 407 246 0 Relief valve 8717 401 0120 10 Electrode assembly 1 8 718 107 0770 11 Electrode lead 1 8 714 401 999 0 12 Pump 1 8 717 204 4770 13 Pressure gauge 1 8 717 208 079 0 14 Burner skin seal 1 8 711 004 1680 15 Transformer facia 1 8 747 201 3580 16 Flow switch 1 8717 002 1100 17 3 way diverter valve 1 8 717 010 0620 18 Heat exchanger washer 1 8 710 103 1530 19 Washer set Condensation 1 8 710 103 1540 20 Fuse set 1 8 744 503 0100 21 Service set Water Valve 1 8 710 503 0310 22 Domestic Hot Water Heat 1 8 715 406 659 0 Exchanger 23 Text Display 1 8 747 208 103 0 24 Primary heat exchanger 1 8 715 406 615 0 25 Diaphragm 1 8 715 505 801 0 Table 19 6 720 610 602 GB 03 02 47 Appendix 10 3 Heating hot water output settings ZWBR 8 30 N G 10 5 Heating hot water output settings ZWBR 11 37 N G Natural gas G20 Natural gas G20 Display H
14. Refit sealing plug gt Press and hold Z button until the display shows The 29 button will stop flashing and the display shows the CH flow temperature 8 22 Testing CO and CO Press and hold the button until the display shows Chimney sweep mode is now active The amp button will light up and the display shows the CH flow temperature You have 15 minutes in which to measure the levels After that the appliance switch es back from chimney sweep mode to normal mode Remove sealing plug from flue gas testing point 234 fig 43 Insert testing probe about 135 mm into the testing point and seal testing point CO and CO levels Refit sealing plug Press and hold 4 button until the display shows The amp button will stop flashing and the display shows the CH flow temperature 6 720 610 602 GB 03 02 35 Maintenance 9 Maintenance Always disconnect the appliance from AN the electrical power supply fuse circuit breaker before carrying out any work on the electrical systems or components Always turn off the gas cock before car AN rying out any work on components which carry gas There is a Service booklet for the Engi neer order no 7 181 465 347 available to competent persons All safety and control systems are moni tored by the Bosch Heatronic In the event of a component fault the textdisplay shows a fault code The Use
15. 56 Prise off cover plate v Pull off transformer v Remove pcb holder 6 720 610 602 GB 03 02 41 Maintenance Remove the pcb control board Fig 56 Fuses Remove the connections covers Refer to fig 25 26 The fuses are located adjacent to the mains connector block and connector ST18 Refer to fig 4 Fuse item 312 is only replaceable by removing the pcb Spare fuses are fixed to the connections cover A fuse pack is available Part number 8 744 503 010 0 A 9 3 2 Fan Assembly 7 181 465 330 0518 Fig 57 Switch off the appliance Undo lower pipe union on gas pipe 1 Refer to fig 57 Remove fan lead and earth connector 2 The earth connector has a positive clip fixing Remove fixing screws attaching fan to the burner cover 3 Remove fan together with gas pipe and mixer unit Separate the fan from the pipe and mixer unit by twisting the mixer unit to release it 4 9 3 3 Pump Switch off the appliance Disconnect the appliance from the power supply Remove two switchbox fixing screws 1 Refer to fig 58 Lower switchbox 2 Remove screw from underside of right hand plastic cover plate 3 Pull cover plate forwards to remove 4 Unscrew and remove the the siphon by releasing the jubilee clip Refer to fig 54
16. Frost protection and constant frost pro tection modes can be set on the text dis play module If the appliance is to be left for long periods switch the central heating off Add a suitable anti freeze fluid to the water in the central heating system Suitable products are available from Betz Dearborn Tel 0151 4209563 and Fernox Tel 01799 550811 5 8 Pump anti seize function This function prevents the central heating pump seizing after long periods of inactiv ity Every time the pump is switched off a timer is started If after 24 hours the pump has not run again it is switched on for a period of 10 seconds 24 6 720 610 602 GB 03 02 Commissioning 5 9 Fault Condition A list of faults that may occur is given on page 46 In the unlikely event of a fault occuring while the appli ance is in operation The display and the textdisplay then show a fault code and the button 4 may also flash If the button 4 flashes Press and hold the button 4S until the display shows The appliance will then start up again and the display will show the central heating flow temperature If the button does not flash Switch the appliance off and then on again at the master switch The appliance will start up again and the central heat ing flow temperature will be displayed 6 720 610 602 GB 03 02 25 Text Display 6 Text Display 6 1 General Description The tex
17. parameters Press and hold the C button for about 5 sec onds until the display shows shows Adjust service parameters and the first service function to be set e g 2 0 Operating mode If a fault has occurred the display will show 0 0 and the last fault Press ha Or LS button until the desired service function is displayed Press the C button The first line of the display shows Change value gt Use the a buttons to enter the required setting Press the C button The text display shows ATTENTION Store set tings Press m or to select yes or Press to confirm your selection The text display shows Please wait and the serv ice function is then displayed with the new setting Press the 97 button until the next func tion you wish to change is displayed Or gt Press the 5 gt button to exit the menu 2 4 Resetting service functions to fac tory settings 241 Resetting service functions 0 0 to 4 9 to their factory settings Reset 1 Power OFF the appliance Press the button 2 and keep it pressed Switch on the appliance press and hold the 2 but ton until the display shows r1 followed by 1 2 4 2 Resetting service functions 0 0 to 9 9 to the factory setting Reset 2 Power OFF the appliance Simultaneously press and hold buttons 2 and gt Switch on appliance press and hold the 2 and bu
18. switchbox Power OFF the appliance Engage ignition cable connector in switchbox Turn ON the appliance Press does appliance restart EA 115 15 Ignition cable defective yes Power OFF the appliance Replace ignition cable Turn ON the appliance Press N does appliance restart EA 116 no 416 16 Select 3 3 lonisation current yes 418 Measured ionisation current medium no 417 or high 30 7 181 465 347 01 07 Rectifying faults EA and flashing During operation flame not detected Check Action 17 Electrode assembly defective yes Replace electrode assembly Power OFF the appliance Turn ON the appliance Remove electrode assembly gt Press N does appliance restart Electrodes worn out EA 118 no Refit electrode assembly Turn ON the appliance gt Press N does appliance restart EA 118 18 Check if the 20 pin connector lead Power OFF the appliance assembly is damaged Change the 20 pin connector lead assembly Turn ON the appliance gt Press N does appliance restart EA 419 19 The PCB control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 1 See installation instructions 7 18
19. up to 80 C flow temperature full burner output is permitted Above 80 C the burner output is reduced as flow temperature increases up to 90 C at which only minimum output is available even with maximum heat demand This function can be deactivated for hot water and or central heating mode 7 181 465 347 01 07 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 The trap filling programme is activated the appliance is switched on at the master switch the burner has not been in operation for at least 48 hours the appliance is switched from summer to winter mode The next time the heating or hot water system calls for heat the appliance is held at minimum output for 15 minutes The trap filling programme remains active until the appliance has completed 15 minutes of operation at minimum output The text display shows Siphon fill program and the 2 digit display alternates between ll and the CH flow temperature The factory setting is 1 activated Warning if the condensation trap is not filled flue gas can escape Only deactivate the trap filling program me in order to carry out servicing work Always re
20. 1 See installation instructions 42 7 181 465 347 01 07 Rectifying faults Set room temperature exceeded by large amount Check Action 1 Do radiators get too hot yes TR 2 Decrease setting of Heating control V2 no 42 2 Bad choice of location for program yes Select better installation location mer e g outside wall near window 13 in draught on hollow wall etc no V3 3 Turn down thermostatic valve s n 1 See installation instructions Temperature rises instead of falling Check Action Timer clock DT 2 incorrectly set Check setting and correct as necessary Room temperature too high in Economy mode Check Action Building retains heat well yes Set economy temperature lower Or Set earlier start time for Economy mode Incorrect or no modulation Check Action Programmer incorrectly wired Check wiring against wiring diagram and correct as necessary 7 181 465 347 01 07 43 Rectifying faults Heat store fails to heat up Check Action 1 with TR 2 CH flow temperature control on boiler set too low Increase CH flow temperature control setting 2 Hot water temperature control on boiler set too low Increase hot water temperature control setting 44 7 181 465 347 01 07 Appendix
21. 5 2 fig 30 Check that the gas type specified on the identifica tion plate matches that of the gas supply Turn on gas cock 172 Refer to fig 30 Switching the appliance on off Switching on 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 operating in the central heating mode If the display alternates between 11 and the central heating flow temperature the trap filling programme is active The trap filling programme ensures that the condensa tion trap is filled after the appliance has been installed or after the appliance has been out of use for a long period or the mains supply has been interrupted For that reason the appliance remains at minimum heating output for 15 minutes Open automatic vent 27 and re close after venting page 22 Switching off the appliance AN 5 3 Set the master switch to 0 The green indicator lamp goes out The optional timer will continue running until the emergency sup ply is exhausted Always disconnect the appliance from the power supply fuse circuit breaker before carrying out any work on the electrical systems or components Switching on the central heating The central heating flow temperature is adjustable between 35 C and 88 C Refer to table 12 page 31 Turn the temperature control to set the f
22. 61 9 3 15 Primary Heat Exchanger 6 720 610 602 06 10 Drain the appliance Check that the gas supply is turned off Fig 62 Check that the appliance is electrically isolated Remove the fan assembly complete with the gas air tube and mixer assembly Refer to section 9 3 2 Remove the burner Refer to section 9 2 Disconnect the sensors Refer to section 9 3 6 Undo the central heating flow union Undo the top connection of the pump Refer to fig 57 Undo the grey plastic cap next to the top pump con nection at the base of the heat exchanger Unscrew and remove the condensate trap Refer to section 9 2 Unscrew and remove the two screws securing the heat exchanger top bracket to the rear panel gt Lift up the flue duct item 271 refer to fig 2 Pull forward from the top and lift the heat exchanger from the casing 6 720 610 602 GB 03 02 45 Appendix 10 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 A1 pump has run dry Check system pressure add water and bleed system as necessary A7 Hot water NTC sensor defective Check hot water NTC sensor and connecting lead for circuit breaks short circuits A8 Break in communication Check connecting lead to TR2 b1 Keyed plug not det
23. 720 610 604 GB 03 06 33 Text Display Service parameters Language Available languages are English Fran ais French Deutsch German From the main menu select Settings from the first submenu select Service from the Second submenu select Further options and from the third submenu select Language Press a or 9 to select the desired language Two other supplementary functions can be selected from the third submenu Language Time correction LCD contrast Time correction Press and hold the C button about 5 seconds until the display shows Time correction and LCD contrast gt Press a or CJ to select Time correction gt Press the button The display shows Change value gt Press a or lt 7 to set the number of seconds in 24 hours Basic setting 0 s LCD contrast gt Press and hold the button about 5 seconds until the display shows Time correction and LCD contrast gt Press or lt to select LCD contrast gt Press the button The display shows Change value Press a 9 7 to adjust the LCD contrast Basic setting e g 47 Operating times This option shows the hours of service appliance burner and hot 34 6 720 610 604 GB 03 06 Text Display water since commissioning gt From the main menu select Settings from the first submenu select Service from the Second submenu select Further options and from the third su
24. ECO light off the hot water inside the appliance is held constantly at the set temperature For that reason the appliance switches on if the water temperature falls below a certain temperature In order to prevent it switching on and off too frequently the constant hot water cycle time service function allows you to set the minimum period between switching off and on again This function has no effect on normal demand for hot water and relates only to the constant hot water function in Comfort mode The cycle time can be set to any period between 20 and 60 minutes is factory set to 20 minutes 7 2 6 Variable pump settings Service Function 7 0 The pump speed varies automatically to match the water flow requirement of the system determined by the position of thermostatic radiater valves An automatic by pass must not be used The Service Function 7 0 is factory set to 4 which will accommodate the majority of heating systems Information on the re settings of this functions can be found in the Service Booklet for the Engineer number 7 181 465 347 7 3 Setting the gas air ratio The appliance is set at the factory and adjustment is not necessary 32 6 720 610 602 GB 03 02 Converting the appliance to different gas types 8 Converting the appliance to different gas types The setting is factory sealed at maximum Adjustment to the rated heat input and min heat input is not neces sary Checking the gas supply
25. Function 6 8 32 3 1 Important remarks 11 7 2 6 Variable pump settings 3 2 Domestic hot water 11 Service Function 7 0 32 3 3 Sealed systems 11 7 8 Setting the gas air ratio 32 3 4 Siting the appliance 12 3 5 Wall mounting frame assembly 13 3 6 Pre piping the system 13 8 Converting the appliance to different 3 7 Fitting the appliance 14 gas types 33 3 8 Checking the connections 15 81 Setting the gas air ratio 33 3 9 Flue Systems 15 8 2 Testing combustion air flue gas at set 3 9 1 Siting ihe Flue Terminal 16 heat output 35 3 9 2 Installation of the flue 17 8 2 1 Testing the or level 3 9 3 Flue duct preparation and assembly 19 in the combustion air 35 8 2 2 Testing CO and 35 4 Electrical connections 20 4 1 Connecting the appliance 20 9 Maintenance 36 4 2 Connecting TR2 Room thermostat 21 91 Pre Service Check List 37 4 3 Mains Voltage external controls connections 21 9 2 Description of servicing operations 38 9 3 Replacement of Parts 41 nee 9 3 1 PCB control board and transformer 41 5 Commissioning 22 9 3 2 Fan Assembly 42 5 1 Commissioning 22 9 3 3 Pump 49 5 2 Switching the appliance on off 23 934 3 way diverter valve 43 5 3 Switching on the central heating 23 935 3 e diverter v lve motor 43 5 4 System controls 23 936 Sensors 43 5 5 Setting the domestic hot water 937 Gas Valve 44 temperature and flow rate 24 9 3 8 Domestic Hot Water Heat Exchanger 44 5 5 1 Domestic hot water temperature 24 9 3 9 Electrode assembly 44 5 5 2 Ho
26. Turn ON the appliance between 100 and 95 4 Temperature between 95 100 is yes Replace heat store NTC sensor 1 displayed Power OFF the appliance Unplug the connector i After max 8D sec Disconnect the boiler electrical connection Does the displayed code change Change PCB control board to a value between 0 and 5 Reconnect the boiler electrical connection Turn ON the appliance 7 181 465 347 01 07 21 Rectifying faults b 1 flashing Code plug not detected Check Action 1 No fault or fault code FC displayed yes Power OFF the appliance on text display Fit code plug correctly making sure code number see Appendix is correct Turn ON the appliance b1 12 no 12 2 gt Activate menu option Show serv yes 42 ice parameters no 14 Select 1 2 Code plug Compare number displayed with that shown in Appendix No number or incorrect number last three digits displayed 3 Code plug loose incorrect or defec tive Power OFF the appliance Replace code plug is correct making sure code number Turn ON the appliance b1 l4 4 The PCB control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 1 For order no refe
27. and cold mains fed water can be supplied directly to an over rim flushing bidet subject to local water company requirements 8 6 720 610 604 GB 03 06 General notes With all mains fed systems the flow of water from individual taps will vary with the number of outlets operated simultaneously and the cold water mains supply pressure to the property Flow balancing using ball o fix type valves is recommended to avoid an excessive reduction in flow to individual outlets For further information contact British Gas Technical Services Department Hot and cold flow Combination 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 Water mains failure Combination Boilers If there is a failure of the mains water supply then no water will be available at a tap or shower until the mains supply is restored The appliance will still operate in the central heating mode Use in hard water areas Combination Boilers In exceptionally hard water areas a device to prevent scale forma tion may be fitted Installation of a scale inhibitor assembly should be in accordance with the requirements of the local water com pany An isolating valve should be fitted to allow for servicing Alternatively the maximum temperature of the domestic hot water may be reset to about 45 C which will reduce the r
28. and on again at the mas ter switch another demand for heat activating Min or Max mode or briefly switching to summer mode on the tempera ture control for CH flow 5 0 Max output heating Some gas suppliers demand an output dependent basic charge The heating output can be limited to any level between the min rated heat output and the max rated heat out put to suit the specific heat requirements Even if the heating output is limited the full rated heat output remains available for hot water or heat store charging The factory setting is maximum rated output display shows 100 5 1 Permanent ignition This function allows permanent ignition without gas supply to be activated for the purposes of checking the ignition mechanism 5 2 GFA status error The status of the automatic ignition module integrated in the PCB control board is indicated 5 5 Min output The min heat input is factory set see technical data The modulation range can be extended at the top end to suit the chimney conditions gt Refer to settings table for heating and heat store charging output for details of the min heat output in kW and the corresponding percentage see installa tion instructions for boiler Enter percentage on text display module and confirm Measure gas flow rate and compare with the figures quoted for the percentage shown If different correct the percentage figure Enter
29. display module has a power buffer period of about 10 hours during which it will run without the mains power supply After that period has elapsed the clock function shuts down but all other settings are retained 4 2 Programming S o Gm mA Gm 6 720 610 337 08 1R Fig 8 Controls Display Up More button Down Less button Back button Next button Delete button The standard display shows the following information Time Room temperature if TR 2 connected CH flow temperature 20 6 720 610 604 GB 03 06 Text Display Domestic Hot Water temperature System boiler if a Storage Tank is accorded Additional indication if a special programme is active x holidays Hot water immediately Constant on comfort if TR2 is not connected Constant off economy if TR2 is not connected Other special operating modes may be displayed during commis sioning servicing etc The programming procedure is described in detail below using the clock function as an example To start programming press any button e g gt The display lighting switches on and the main menu is dis played gt Timerdayzholidays Heating Hat water ilnfo Settings 6 720 610 598 04 20 Fig 9 Main menu gt Usethe 27 or lt button to move the cursor arrow on the left of the menu so that it points to the desired menu item In thi
30. flammable building materials and fitted furniture The specified clearences must be maintained 12 6 720 610 602 GB 03 02 Installation Cupboard Compartment The appliance can be installed in a cupboard compart ment need for airing clothes providing that the require ments of BS6798 and BS5440 2 are followed The low casing losses from the appliance eliminate the need for ventilation openings in the compartment 3 5 Wall mounting frame assembly Takethe 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 6 720 610 597 06 10 Fig 7 Hold the wall mounting frame against the wall ensur ing that it is vertical Markthe position of the flue duct hole if a rear flue is to be used Refer to fig 1 and 16 Mark the holes for the wall mounting frame onto the wall drill and plug the holes and screw the wall mounting frame to the wall with the screws provided T 4 c 6 720 610 597 07 10 Fig 8 Screw the pre plumbing manifold with two screws to the wall mounting frame 6 720 610 597 08 10 Fig 9 3 6 the system 200 6 720 610 576 06 10 Fig 10 Manifo
31. manually selected operating mode select the relevant menu and then press the button or select a different operating mode or set Holiday From the main menu select Heating and then from the first submenu Manual select required mode 6 6 Hot water General description Combi models only The basic settings provide a straightforward timer programme enabled from 5 00 am disabled from 10 00 pm The ECO button must not be lit Comfort mode ZSBR models with Storage Tank The basic settings provide a timer programme enable from 5 00 am disable from 10 00 pm With the menu Hot water see page 29 you can choose a timer tem perature programme with the basic settings 60 C from 5 00 am 10 C from 10 00 pm 6 1 Hot water programme Up to six switching points per day can be set There are two operating modes Blocked and Released From the main menu select Hot water and then from the first submenu select Hot water program Set the days of the week Blocked Released oper ating mode in the same way as for the switching points and modes for heating as described on page 28 6 2 Hot water immediately Hot water immediately ON Comfort mode is active for 2 hours Comfort mode is active for 2 hours normal auto matic program Hot water mode according to timer programme entered From the main menu select Hot water and then from the first submenu select Hot water immedi ately ately on or
32. of water vapour This is quite normal The appliance produces quantities of condense which is dis charged regularly through the siphon 6 720 610 604 GB 03 06 7 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 Above Casing Vert Flue 75 mm Above Flue Turret 30 mm Below 200 mm Table 1 Room thermostat A room temperature controller is may be fitted to control the cen tral heating Refer to the instructions supplied with the thermostat for information on siting and setting Cylinder thermostat System boilers The cylinder thermostat should be set to 60 C which will be sat isfactory for bathing washing in normal circumstances Thermostatic radiator valves It is recommended that this type of valve is fitted to all the radiators except one usually the radiator where the room temperature con troller is fitted They should conform to the requirements of BS2767 10 Showers bidets taps and mixing valves Combination Boilers Standard hot and cold taps and mixing valves must be suitable for operating at mains pressure Thermostatically controlled or pres sure equalising shower valves will guard against the flow of water at too high a temperature Hot
33. pressure gt Check the gas supply pressure at the gas supply pressure testing point Natural gas appliances must not be oper ated if the gas supply pressure is below 18 mbar or above 24 mbar LPG appliances must not be operated if the supply pressure is below or above 37 mbar Natural gas Appliances for natural gas type G20 are factory set to Wobbe Index 15 kWh m and 20 mbar supply pressure and sealed Conversion kits For conversion Model from Order no ZWBR 8 30 N G to L P G 7 710 149 050 ZWBR 11 30 L P G to N G 7 710 239 086 ZWBR 14 37 L P G to N G 7 710 239 087 ZWBR 11 37 N G to L P G 7 710 149 052 Table 14 Instructions are sent with each conversion kit 8 1 Setting the gas air ratio The gas air ratio may only be adjusted on the basis of a CO measurement at max heat output and min heat output using an electronic tester Switch off the appliance at the master switch O Remove the outer case see page 15 refer to fig 13 Switch on the appliance at the master switch I Unscrew sealing plug from flue gas testing point 234 Refer to fig 40 Insert testing probe about 135 mm into the flue gas testing point and seal testing point 6 720 610 332 57 2R Fig 40 v On the text display unit select in the main menu Set tings Service Display service parameters Press and hold the C button for about 5 sec onds unt
34. set ting s Temperature con trol for CH flow set too low Increase CH flow temperature con trol setting Air trapped in heating system Bleed radiators and heating sys tem Desired room temperature exceeded by large amount Radiators are too hot Turn down ther mostatic valves Temperature rises instead of falling Clock is incor rectly set Check setting Room tempera ture too high in Economy mode Building retains heat well Start Economy mode sooner No display or dis play unit does not respond Momentary power failure Switch off appli ance at master Switch wait a few seconds and Switch on again Storage Tank doesn t warm up Temperature con trol is too low Turn the tempera ture control to the desired tempera ture 6 720 610 604 GB 03 06 37 Tips on saving energy 6 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
35. 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 thermostatic radiator valves The central heating control on the boiler should be set to the max imum 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 9o However it is not advisable to allow any 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 38 6 720 610 604 GB 03 06 General Information Hot water A lower setting on the hot water temperature control can result in considerable energy savings For combi appliances The on demand activation using the ECO button makes possi ble the maximum savings of gas and water No
36. temperature controlled programmer TA is connected to boiler The anti cycle time is adjusted by the programmer to the suit the system e The factory setting for the anti cycle time 3 min and the heating mode hysteresis setting if applicable n cyclic mode the switching of the boiler on or off is subject to a time delay in order to prevent diver gence between the average CH flow temperature and the specified CH flow temperature As a result depending on the heat draw the specified CH flow temperature is briefly exceeded In extreme cases it can happen that the burner does not switch off until the maximum CH flow tempe rature is reached even though a lower CH flow temperature has been specified 1 Activate menu option Show service parameters Select 2 7 Autom anti cycle mode Read off status of automatic anti cycle time 0 Disabled 1 Enabled Disable automatic anti cycle time i e change setting to O 2 Select 2 4 Anti cycle mode Read off anti cycle time setting 0 15 min gt Set anti cycle time as required e g factory set ting 3 min 40 7 181 465 347 01 07 Rectifying faults 4 5 2 Programmer faults Set room temperature not reached TR 2 Check Action 1 Thermostatic valve s set too low yes Turn up thermostatic valve s 12 12 2 CH flow temperature control on yes gt Turn up CH flow temperature con
37. the following operating modes and time periods as described for the first gt If necessary select the next day and enter the oper ating modes and timer periods as described above If the settings for a particular day of the week are different from the settings for the other days then if Monday Friday or Saturday and Sunday is selected the display shows 1 i e there are no common switching points for those options Timer periods and operating modes are you do not wish to change can be skipped by pressing lt gt 6 5 2 Setting the Economy temperature if TR2 is connected This option allows you to set the room temperature for Economy mode Off Economy This function is only active if Automatic mode or Economy mode is set on the TR 2 room thermostat From the main menu select Heating and then from the first submenu select Set Economy temp gt Use the or lt button to set a temperature between 5 and 30 C 28 6 720 610 602 GB 03 02 Text Display 6 F 5 8 Manual operating mode if TR2 is not con nected or selecting an operating mode that is different from the one set in the heating programme Automatic mode You can choose between Automatic Constant on comfort and Constant off economy The manually selected operating mode starts imme diately Constant off economy and Constant on comfort are automatically reset at 00 00 midnight To cancel the
38. the use of the text display module are given in the operating and installation instructions for the boiler EO EEG 6 720 610 337 08 1R Fig 1 Controls Display Up or More button Down or Less button Back button Nest button Delete button 2 1 Standard display The text display shows the time the CH flow tempera ture and the measured outside temperature in plain English In addition the 2 digit display also shows the current CH flow temperature in Heating mode and Hot Water mode display range 00 C to 99 C 2 2 Displaying service functions Press any button to activate the main menu gt Press um or button until the arrow cursor is pointing to Settings Press the C button Press RF or lai button until the arrow cursor is pointing to Service Press the C button Press C button to select Display service parameters Service function 0 0 Last fault is displayed gt Press iv or e button to cycle through the current settings Press CSD button to exit the menu 2 3 Setting service functions Press any button to activate the main menu Taste or button until the arrow cursor is pointing to Settings Press the C button Press 7 or ee button until the arrow cursor is pointing to Service Press the C button The cursor is pointing to Display service
39. you move on to Step 5 1 5 The question asked in Step 5 is Is there a problem with the flue The flue must then be checked If the answer to the first question Is burner flame visi ble was no then you go to and answer Question 2 Is the gas cock turned on If the gas cock is turned off it must be turned on and the appliance reset To do SO you press the 4 button Restartthe appliance and run through a complete heat demand cycle until the appliance switches off If the fault is now cured the appliance will revert to nor mal operation and the fault finding process is complete Now simply re check the setting of the two temperature controls If the fault EA recurs during the heat demand cycle it will be shown on the display again In that case continue the fault finding procedure from Step 3 thermal cut out in gas cock as described above If a different fault code is displayed after the heat demand cycle find the appropriate section of the fault finding table and work through the procedure described step by step E A and A flashing Flame not detected Check Action 1 Is burner flame visible yes 15 no 12 2 Is the gas cock turned on yes 13 no gt Turn on the gas cock Press N does appliance restart EA 13 3 Did the thermal security of the gas yes cock lock out no diu 4 5 Is there a problem with the flue yes Check t
40. 000 Table 4 ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM Overall Diameter of Duct mm 125 Flue Terminal Duct Assembly mm 1030 Max 13 m ZWBR 8 30 Max 10 m ZWBR 11 37 including turret Table 5 VERTICAL 125 mm FLUE SYSTEM Overall Diameter of Duct mm 125 Flue Terminal Duct Assembly mm 1360 Max 15 m ZWBR 8 30 Max 12 m ZWBR 11 37 Table 6 Elbow 90 Equivalent length 2 m Bend 45 Equivalent length 1m ZWBR ZWBR 8 30 11 37 Domestic Tempera 30 C 14 6 18 0 Water Flow ture Rise Rate l min Tempera 35 C 12 5 15 4 ture Rise Tempera 40 C 11 0 13 5 ture Rise Maximum Mains pressure bar 10 0 10 0 Minimum Mains pressure bar 0 2 0 2 Table 8 2 Installation regulations Gas Safety Installation amp Use Regulations 1998 All gas appliances must be installed by a competent per son Failure to install correctly could lead to prosecu tion The manufacturers notes must not be taken in any way as overriding statutory obligations The appliance must be installed in accordance with the current IEE Wiring Regulations local Building Regula tions Building Standards Scotland Consolidation bye laws of the local Water Company Health and Safety Document 635 Electricity at Work Regulations 1989 and any other local requirements Product Liabil
41. 1 465 347 01 07 31 Rectifying faults Internal failure F Ny flashing Action 1 Activate menu option Show service parameters Select 9 3 GFA Asic error A message is displayed Record figure displayed in service report 12 2 Select 5 2 GFA status error A message is displayed Record figure displayed in service report 3 gt Select Settings gt Service gt yes Deal with fault s displayed as instructed in rele Further options gt Fault history vant fault table s Other faults apart from FO dis jn played 4 A flashing yes gt Press button N Initiate demand for heat by pressing the but ton and then cancel after 30 seconds by pressing the button again gt Initiate demand for heat twice more as described above FO 14 no 44 5 The control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 32 7 181 465 347 01 07 Rectifying faults F 7 and AN flashing Although appliance switches off flame still detected Check Action Electrode s dirty or defective Power OFF the appliance Replace electrode assembly Turn ON the appliance gt Press N does applianc
42. 1 Heating program 27 4 5 2 Setting the Economy temperature if TR2 is connected 28 4 5 3 Manual operating mode if TR2 is not connected 29 4 6 Hot water 30 4 6 1 Hot water program 31 4 6 2 Hot water immediately System models 31 4 7 ilnfo 32 4 8 Settings 33 4 8 1 Heating if TR 2 is connected 33 4 8 2 Hot Water Storage Tank System boiler models only 33 4 8 3 Service 33 4 9 Individual timer programmes 36 5 Fault finding 37 6 Tips on saving energy 38 7 General Information 39 8 Maintaining your appliance 40 9 Service 40 10 Fault or breakdown 41 11 Your guarantee 42 12 Guarantee registration 43 13 Operating Instructions Ouick Reference 44 6 720 610 604 GB 03 06 3 Excellence comes as standard Excellence comes as standard Thank you for purchasing an RD 532i RD 537i RD 542i RD 430i condensing appliance The RD 532i RD 537i RD 542i RD 430i Series has been devel oped by the Bosch Group and the strictest quality control stand ards 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 RD 532i RD 537i RD 542i RD 430i appliance offers you the very best of everything quality effi ciency 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 British Gas Offer
43. 15 10 X rM EE E L Fig 15 Minimum dimensions of flue terminal positions all types see fig 15 Dimension Terminal Position kW input expressed in net Balanced flues room sealed Fanned draught A Directly below an opening air brick opening windows etc 300 mm Above an opening air brick opening window etc 300 mm c Horizontally to an opening air brick opening window etc 300 mm D Below gutters soil pipes or drain pipes 75 mm E Below eaves 200 mm F 2 Below balconies or car port roof lowest point 200 mm G From a vertical drain pipe or soil pipe 150 mm H From an internal or external corner 300 mm Above ground roof or balcony level 300 mm J From a surface facing the terminal 600 mm K From a terminal facing the terminal 1200 mm L From an opening in the car port e g door window into the dwelling 1200 mm M Vertically from a terminal on the same wall 1500 mm N Horizontally from a terminal on the same wall 300 mm From the wall on which the terminal is mounted Not applicable P From a vertical structure on the roof Not applicable Q Above intersection with roof Not applicable Table 9 1 In addition the terminal should not be nearer than 150 mm fanned draught to an opening in the building fabric formed for the purpose of accommo dating a built in element such as a window frame 2 Not recommended 16 6 720 610 602 GB 03 02 Installation 3 9 2 Installation of the flue The standard 100 mm diameter horizontal flue sy
44. 2 Hot water temp sensor 12 Is a temperature between O and 5 displayed no 43 2 Disconnect connector for hot yes Power OFF the appliance water NTC sensor Change hot water NTC sensor Shortcircuit the 2 pin connector Plug the connection wire on the end of the 20 pin connector Turn ON the appliance lead assembly Display changes to temperature 7 413 between 100 and 95 no Change the 20 pin connector lead assembly 13 3 Temperature between 95 and 100 is yes Power OFF the appliance displayed Change hot water NTC sensor Unplug the connector Plug the connection wire lel mak ou Turn ON the appliance Does the displayed code change PP to a value between O and 5 A7 414 no 4 Unplug the 20 pin connectorlead yes Change the 20 pin connector lead assembly assembly from the Heatronic Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 1 For notes refer to Appendix 7 181 465 347 01 07 Rectifying faults AS No correct electrical connection Check Action Mode selector switch is between two settings gt Turn switch until it clicks into position A8 12 2 Power OFF the appliance yes Turn ON the appliance Wiring between TR 2
45. 26 27 229 226 29 335 30 634 0 234 ira V Vv A 13 43 44 45 46 47 6 720 610 597 03 20 Fig 3 4 Bosch Heatronic control 64 Adjusting screw for min gas flow volume 6 Temperature limiter heat exchanger 69 Control valve 6 1 Hot water NTC sensor 84 Motor 7 Testing point for gas supply pressure 88 3 way valve 8 1 Pressure gauge 90 Venturi 9 Flue gas temperature limiter 91 Pressure relief valve 13 Manifold 93 Water flow regulator 15 Safety valve 94 Diaphragm 18 Central heating pump 95 Pushrod with switch cam 20 Expansion vessel 96 Microswitch 26 Charging valve 97 Valve for hot water flow volume 27 Automatic vent 98 Water valve 29 Mixer unit 221 Flue duct 29 1 Bi metallic thermostat for combustion air compensation 226 Fan 30 Burner 229 Air box 32 Flame sensing electrode 234 Testing point for flue gas 33 Igniter electrode 234 1 Testing point for combustion air 35 Heat exchanger with cooled combustion chamber 317 Display 36 Temperature sensor in CH flow 355 Plate type heat exchanger 43 CH flow 358 Condensate trap 44 Hot water flow 400 45 Gas 423 Siphon 46 Cold water inlet 443 Diaphragm 47 CH return 52 Solenoid valve 1 521 Solenoid valve 2 55 Filter 56 Gas valv
46. 5 Table 7 Component Order no Remarks Heat exchanger Temperature lim 8 729 000 144 110 C iter STB Flue gas temper 8 729 000 144 ature limiter Temperature 8 714 500 054 NTC sensor CH flow Burner Electrode 8 718 107 064 assembly Gas valve Gas valve 8 747 003 516 Gas valve 8 747 003 515 ZBR 11 14 42A Other components Fan 8 717 204 325 Gas supply pipe 8 714 401 885 Textdisplay 8 747 208 081 Plate type heat 8 715 406 659 ZWBR exchanger 7 11 28 A Table 7 7 181 465 347 01 07 47 Appendix 5 4 Approved corrosion inhibitors and anti freeze fluids for central heating water Manufacturer Description Remarks Mixing concentra tion 9o by 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 Anti freeze fluid H ls llexan E Anti freeze fluid equivalent to Antifrogen N Tyforop Chemie Tyfocor L Anti freeze fluid based on propylene glycol 25 80 GmbH Hamburg Schilling Chemie Varidos FSK Anti freeze fluid based on ethylene glycol with 22 55 good corrosion inhibiting properties Als
47. 7 78 57 87 58 87 58 Flue gas temp 40 30 C rated min load C 58 35 58 35 65 43 65 43 Residual delivery pressure Pa 90 90 100 100 inc pressure drop in air intake duct CO level at max rated heat output 9 4 11 0 9 2 11 0 CO level at min rated heat output 9 2 11 0 9 2 11 0 NO class 5 5 5 5 SEDBUK figure Band A 90 3 90 3 90 3 90 3 pH value approx Electrical power supply voltage AC V 230 230 230 230 Frequency Hz 50 50 50 50 Max power consumption W 156 156 161 161 Noise output level dB A 39 39 41 41 Appliance protection rating IP X4D X4D X4D X4D Max CH flow temperature C nom 90 nom 90 nom 90 nom 90 Max permissible operating pressure CH bar 2 5 2 5 2 5 2 5 Permissible ambient temperatures C 0 50 0 50 0 50 0 50 Nominal capacity of appliance 3 75 3 75 3 75 3 75 Weight kg 53 53 53 53 Table 2 6 720 610 602 GB 03 02 Installation regulations Condensate analysis mg l Domestic water performance Ammonium 1 2 Nickel 0 15 Lead 0 01 Mercury lt 0 0001 Cadmium 0 001 Sulphate 1 Chromium 0 005 Zinc lt 0 015 Halogenated Tin 0 01 hydrocarbons lt 0 002 Hydrocarbons 0 015 Vanadium lt 0 001 Copper 0 028 pH value 4 8 Table 3 Flue system HORIZONTAL 100 mm Standard Overall Diameter of Duct mm 100 Flue Terminal Duct mm 600 Mat m Assembly Length Extension Duct Length mm 1
48. 9 Individual timer programmes Tables for your own timer programmes you find in the User Manual 30 6 720 610 602 GB 03 02 Individual settings 7 Individual settings 7 4 Mechanical settings 711 Checking the size of the expansion vessel Maximum pressure at maximum CH flow temperature is 2 5 bar If the pressure is greater than this then fit an extra expansion vessel Refer to table 11 System Capacity BS7074 1 Expansion Vessel Pressure and System Capacity Expansion Vessel litres 10 Expansion Vessel Charge bar 0 75 Pressure System 1 bar litres 82 pressure and capacity 1 5 bar litres 46 Table 11 7 1 2 Setting the central heating flow tempera ture The central heating flow temperature can be set to between 35 C and 88 C With underfloor heating systems observe the maximum permissible flow tempera tures Limited maximum setting for low temperature operation The temperature control is factory limited to setting E giving a maximum flow temperature of 75 C Adjustment of the heating output to the calculated heat demand is not required by the heating systems regula tions Removing the maximum setting limit For heating systems which require higher flow temper atures the maximum setting limit can be removed gt Lift off the yellow button on the temperature control Tit with a screwdriver 6 720 610 332 27 10 Fig 39 gt R
49. 99 7 7 Output reduction off only in only in heating mode heating only in hot water mode mode in heat hot water mode 8 5 Siphonfillprogram on boiler min output on on adjust min output boiler off min output 9 2 Hot water on demand off on on 9 3 GFA Asic error 00h FFh Table 1 1 The reset value depends on the code plug 8 7 181 465 347 01 07 Boiler service functions 3 2 Explanation of service functions 0 0 Last fault The last fault can also be recalled for servicing pur poses when the appliance is functioning correctly To delete the stored fault Delete fault no fault displayed Press the button Use the Sa or m button to select yes Press the C button list of the last 10 indicated faults is required for serv icing purposes look under Settings gt Service gt Fur ther options gt Fault history 0 1 Flow NTC The temperature measured by the NTC sensor on the CH flow pipe is indicated 0 2 Hot water NTC The temperature measured by the NTC sensor on the plate type heat exchanger outflow is indicated 0 3 Storage tank NTC 1 Indirectly heated heat store SO SK ST The temperature measured by NTC sensor 1 in the heat store is indicated Stratified charge tank ST S The temperature measured by NTC sensor 2 at the bot tom of the heat store is indicated 0 4 Storage tank NTC 2 Stratified charge tank ST S The temperature me
50. 992 A drain cock should be fitted at the lowest point of the heating circuit and the appliance Domestic hot water Central heating flow BS stop valve Fixed spindle type Water main Fig 5 Sealed primary water system Sealed system filling and make up Heating return Non return Non return valve valve Hose union Stop cock i piia Stop cock Test cock Temporary hose Fig 6 3 4 Siting the appliance Regulations concerning the Installation Site gt Relevant national regulations must be complied with section 3 9 1 gt Consultthe installation instructions for details of min imum clearances required Combustion air In order to prevent corrosion the combustion air must not contain any corrosive substances Radiator valve 6 720 610 576 09 30 Make up vessel Auto Heating return air vent Non return valve i Stop cock 1000mm 39 in above the highest Fill point point of the system 6 720 611 137 29 10 Substances classed as corrosion promoting include halogenated hydrocarbons which contain chlorine and fluorine compounds and are contained in some sol vents paints adhesives aerosol propellants and household cleaners for example Surface temperature The max surface temperature of the casing and the flue is less than 85 C This means that no special safety precautions are required with regard to
51. CO levels min and max load do not match no Power OFF the appliance Change the gas valve Turn ON the appliance 1 See installation instructions 36 7 181 465 347 01 07 Rectifying faults Flue gas levels incorrect CO level too high Check Action 1 Does the gas supply type match the yes 12 specifications on the appliance iden 6 1 tification plate no gt Convert appliance to correct gas type 2 Test gas supply pressure OK yes 13 no Decommission appliance Notify gas company 3 Problem with flue yes Check flue and repair or replace if necessary Check level in combustion ho 44 air gt 0 2 CO 4 Flue gas levels measured at yes Adjust CO levels min and max load do not match D specified levels no 9 Measure CO levels 5 Gas volumetric flow too high when yes Reduce gas volumetric flow rate by means of CO level correctly set adjusting screw on gas valve and or gas flow restrictor Check CO adjustment no le 6 Change the gas valve 1 See installation instructions 7 181 465 347 01 07 37 Rectifying faults Ignition too harsh ignition poor Check Action 1 Activate menu option yes le Show service parameters mee no 12 gt Select 5 1 Permanent ignition
52. Continuous ignition OK 2 Ignition lead connected to ignition yes 43 electrodes ne no Connect cable to ignition electrode gt Press button 3 Ignition poor 13 3 Ignition cable connector engaged in yes 4 switchbox Power OFF the appliance Engage ignition cable connector in switchbox Turn ON the appliance gt Press button Power OFF the appliance Ignition poor 44 4 Ignition cable defective yes Power OFF the appliance Replace ignition cable Turn ON the appliance gt Press button Ay Power OFF the appliance Ignition poor 45 no 45 5 Electrode assembly defective yes Replace electrode assembly Power OFF the appliance Turn ON the appliance Remove electrode assembly Press N does appliance restart Electrodes worn out Ignition poor 46 no gt Refit electrode assembly Turn ON the appliance gt Press N does appliance restart Ignition poor 46 6 Does the gas supply type match the yes 47 specifications on the appliance iden tification plate no Carry out gas type conversion as described in installation instructions Ignition poor 47 38 7 181 465 347 01 07 Rectifying faults Ignition too harsh ignition poor Check Action 7 Test gas supply pressure 1 yes 48 Decommission appliance Notify gas company 8 Problem with flue yes Check flue and repair
53. FA X X X 34 FC X X X 35 Fd X X X 35 Table 2 4 2 2 Faults that are not indicated on any dis play 4 4 lt x B 5 g Appliance faults mios 2 Excessive burner noise rum X X IX 36 bling noises Flue gas levels incorrect CO X X X 37 level too high Ignition too harsh ignition X X X 38 poor Boiler indicates P1 P2 P3 at X X X 36 start up and then restarts with P1 Table 3 7 181 465 347 01 07 Rectifying faults Appliance faults ZWBR Loose or broken contact on heat store NTC sensor x ZBR A x ZSBR A Specified CH flow tempera ture from TA programmer exceeded Table 3 Programmer faults Set room temperature not reached X TR2 Set room temperature exceeded by large amount Set room temperature not reached 41 Temperature rises instead of falling 43 Room temperature too high in Economy mode 43 Incorrect or no modulation 43 Heat store fails to heat up 44 Table 4 7 181 465 347 01 07 Rectifying faults 43 Howto use the fault tables The procedure is explained using the fault code EA as an example The table heading shows the fault code and a general description of the fault In the example shown you are instructed to note the current settings before going any further If you can see the flame answer to question is yes
54. Horizontal Flue System 105 mm Alternative Concentric Flue System 130 mm For servicing the appliance 6 720 610 602 GB 03 02 Details of the appliance 1 6 Layout of appliance N N 6 720 610 597 02 10 Fig 2 4 Heatronic control 120 Fixing points 6 Heat exchanger safety temperature limiter 221 1 Flue duct 6 1 Hot water NTC sensor 221 2 Combustion air intake 7 Testing point for gas supply pressure 226 Fan assembly 8 1 Pressure gauge 295 Appliance type sticker 9 Flue gas temperature limiter 234 Testing point for combustion products 15 Relief valve 234 1 Testing point for combustion air 18 Pump 271 Flue duct 20 Expansion vessel 349 Cover plate for twin flue duct connection 27 Automatic air vent 355 Plate type domestic hot water heat exchanger 29 Air gas Mixer unit 358 Condensate trap 321 Electrode assembly 396 Hose Condensate trap 36 Temperature sensor in CH flow 400 Textdisplay 43 CH flow 415 Cover plate for cleaning access 63 Adjustable gas flow restrictor 416 Condensate collector 64 Adjusting screw for min gas flow volume 418 Data plate 88 3 way valve combi 423 Siphon 98 DHW flow switch combi 102 Inspection window 6 6 720 610 602 GB 03 02 Details of the appliance 1 7 Function
55. Installation and Servicing Instructions s ICC2 combi e Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 598 0010 ZWBR 8 30 ICC2 GC Number 41 108 09 ZWBR 11 37 ICC2 GC Number 41 108 10 SET RST I benchmar gt British Gas Scottish Gas 0 6 720 610 602 GB 03 02 OSW Contents 6 6 Hot water 29 Contents 6 6 1 Hot water programme 29 6 6 2 Hot water immediately 29 _ ___ ___ _6 _6__ _ 6 7 ilnfo 29 Safety precautions 3 6 8 Settings 30 6 8 1 Heating if TR 2 is connected 30 6 8 2 Hot Water Storage Tank Symbols 3 ZSBR models only 30 6 8 3 Service _ 30 1 Details of the appliance 4 6 9 Individual timer programmes 30 1 1 EC Declaration of Conformity 4 1 2 Standard package 4 7 Individual settings 31 1 8 Description of appliance 4 7 1 Mechanical settings 31 1 4 Accessories 9 7 1 1 Checking the size of the expansion vessel 31 1 5 Casing dimensions 5 7 1 2 Setting the central heating flow temperature 31 1 6 Layout of appliance 6 7 2 Settings on the Bosch Heatronic 31 1 7 Function 7 7 2 1 General description 31 1 8 Electrical wiring diagram 8 7 2 2 Setting the anti cycle time 1 9 Technical data 9 Service Function 2 4 32 7 2 8 Setting the maximum CH flow temperature 2 Installation regulations 10 754 a NE 92 Service Function 5 0 32 7 2 5 Constant hot water cycle time 3 Installation 11 Service
56. Main menu gt Use the button to move the cursor arrow on the left of the menu so that it points to the desired menu item In this example the cursor is positioned next to the menu item Time day holidays gt Confirm the selection by pressing the C button The corresponding submenu is displayed Select l gt Time day Holidays Fig 37 Submenu Time day In the submenus the top line indicates what action is required The bottom line shows the previous menu level if appli cable see fig 38 gt Use the a or Y button to select Time day gt Confirm the selection by pressing the C gt gt button The corresponding submenu is displayed Hour gt mon Monday Timerday 6 720 610 598 06 20 Fig 38 Setting the hour When settings are being entered the setting to be altered is indicated on the top line In addition the set ting being altered is displayed with a dark background gt Use the 7 or Y button to set the hour Press and release to change the display by one unit at a time Press and hold to change the display rapidly gt Confirm the setting by pressing the button Use the 25 or Y button to set the minutes Confirm the setting by pressing the gt button Use the 5 or 77 button to set the day of the week v 26 6 720 610 602 GB 03 02 Text Display gt Pres
57. ON THIS APPLIANCE BY ANY THIRD PARTY WILL NOT BE ACCEPTED 6 720 610 604 GB 03 06 41 11 Your 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 any components of the unit which are proved to be faulty 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 Br
58. Plates 6 720 610 602 11 10 Fig 20 Flue Components 18 6 720 610 602 GB 03 02 Installation 3 9 3 Flue duct preparation and assembly Measure the flue length L Refer to fig 21 22 Outer Wall Face Flue Terminal Raised Ring locating the terminal relative to the outside wall face NOTE THE FLUE MUST BE INCLINED TO THE 8 720 610 578 2010 BOILER 6 720 610 602 12 10 Fig 21 Flue length rear Fig 23 Flue terminal position Assemble flue system completely Push the ducts fully together and clamp in the positions The slope of the terminal outlet must face downwards The assembly will be made easier if a solvent free grease is lightly applied i e Vaseline to the male end of the ducts NOTE An inner wall sealing plate is provided which should be fitted to the ducts before assem bly Push the assembly through the wall and fix the turret to the appliance with the clamp Refer to fig 24 NOTE THE FLUE MUST BE INCLINED T O THE BOILER 6 720 610 602 13 10 Flue Turret Fig 22 Flue length side Mark off the lengths shown onto the ducts and cut to 4 Air and length The cuts must be square and free from burrs ER Duct Terminal assembly outer air duct L 70 mm inner FUA flue duct L 50 mm The measurement is made from Clamp rubber seals the ridge at the terminal indicating the outer face of the wall Refer to fig 23 Extension air duct L 70mm
59. Pos 303 If lead has no connector replace heat store NTC sen sor Turn ON the appliance d3 44 no 14 4 Existing heat store thermostat con yes Power OFF the appliance nected to Terminals 7 8 and 9 Fixthe additional bridge 8 9 in the right position and close the screws Turn ON the appliance d3 15 no 45 5 The PCB control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 24 7 181 465 347 01 07 Rectifying faults E 2 flashing The heating outlet NTC sensor is damaged Check Action 1 Activate menu option yes The heating outlet NTC sensor is in short circuit Show service parameters Power OFF the appliance gt Select 1 Flow temp sensor Replace CH flow NTC sensor observe fitting Is a temperature between 0 and 5 instructions for NTC sensor when doing so 2 ON the appliance E2 12 no 2 2 Heating outlet NTC sensor yes The CH flow NTC sensor is interrupted Temperature between 95 and 100 is Power OFF the appliance displayed Replace CH flow NTC sensor observe fitting instructions for NTC sensor when doing so Turn ON the appliance E2 13 no 43 3 Check if the 20 pin connector lead assembly is damaged Power OFF the appliance Chang
60. These instructions are to be left with the user or at the Gas meter Important These instructions apply in the UK only Symbols Safety instructions in this document A are identified by a warning triangle sym bol and are printed on a grey back ground Notes containing important information are identified by the symbol shown on the left They are bordered by horizontal lines above and below the text 6 720 610 602 GB 03 02 Details of the appliance 1 Details of the appliance 1 1 EC Declaration of Conformity This appliance is in accordance with the applicable requirements of the Gas Appliance Directive Boiler Efficiency Directive Electromagnetic Compatibility Directive and the Low Voltage Directive PIN CE 0085 BL0507 Category UK ap Appliance Type C33 Table 1 1 2 Standard package Gas condensing combination boiler for central heat ing and domestic hot water Control panel cover Wall mounting frame Room thermostat TR2 Clamp for securing flue duct kit Fixings screws etc Set of documentation for appliance e Pre plumbing manifold e Condensate drain pipe Filling loop 1 3 Description of appliance Wall mounted appliance siting not dependent on room size Natural gas models are low emission appliances Multifunction display Bosch Heatronic control system with integrated tex tdisplay for servicefunctions and faults 3 channel digital timer fo
61. acia Refer to fig 58 Twist the pressure gauge head anti clockwise to release it from the casing Refer to fig 2 Disconnect the capillary head from the rear of the diverter valve by withdrawing the clip and pulling out the head Refer to fig 59 9 3 11 Expansion vessel Drain the appliance Undo the union connection at the base of the vessel Refer to fig 2 Unscrew the top and bottom fixing screws and remove the vessel gt Set the pressure of the new vessel to that required by the system 9 3 12 Pressure Relief Valve Drain the appliance Disconnect the drain pipe from the valve Refer to fig 30 Pull out the clip securing the valve Pull out the valve Ensure that the replacement valve is fully entered before fitting the clip 9 3 13 Burner Referto section 9 2 44 6 720 610 602 GB 03 02 Maintenance 9 3 14 Flow switch Transfer components as necessary to the new heat Shutthe mains water inlet valve and drain the domes eronanger tic hot water circuit Ensure that all the seals are in place and all of the connections are tight before re commissioning the gt Pull off the connectors from the micro switch appliance Unscrew the inlet and union connection and remove the assembly Reset the domestic hot water flow rate on the new assembly OUTLET TY Ppp 2 7 LN Ly y 6 720 610 602 05 10 Fig
62. activate trap filling program me once servicing is complete 9 2 Hot water on demand The appliance is supplied with this function activated This function relates to mode the button lights up The demand detection function enables maximum gas and water economy Briefly turning a hot water tap on and then off again sig nals demand to the appliance which then heats up the water to the set temperature Hot water is then available at short notice 9 3 GFA Asic error automatic ignition module extended messages The status of or an error message from the automatic ignition module integrated in the PCB control board is displayed 7 181 465 347 01 07 13 Rectifying faults 4 Rectifying faults 4 1 Boiler failure codes indication 4 1 4 onthe boiler 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 Please call service for example At the same time the fault code appears on the 2 digit display in this example EA You can view an explanatory description of the fault indi cated by going to Settings gt Service gt Service parameters in this example EA During operation Flame not detected The failures can be divided into four basic typologies as described The appliance continues to work at a minimum func tion level e g with error codes A5 A7 A8 AC Ad
63. activated The anti cycle time can be set to between 0 and 15 min utes is factory set to 3 minutes If the setting O is entered the anti cycle time is inactive The shortest possible anti cycle time is 1 minute rec ommended for single pipe and hot air heating systems If the appliance is connected to an out side temperature controlled heating pro grammer the anti cycle time does not need to be set on the appliance and is op timised by the programmer instead 7 2 3 Setting the maximum CH flow tempera ture Service Function 2 5 The maximum CH flow temperature can be set to between 35 C and 88 C factory setting 7 2 4 Setting the heating output Service Function 5 0 The heating output can be setto any level between min rated heat output and max rated heat output to limit it to the specific heat requirements The full rated heat output is still available for hot water or charging the hot water cyl inder even if the heating output has been limited The factory setting is the max rated heat output 100 Look up heating output in kW and corresponding code number on the settings tables for heating out put see page 48 Enter the code number on the text display module Measure the gas flow rate and compare with the fig ures specified for the code number shown If differ ent correct code number 7 2 5 Constant hot water cycle time Service Function 6 8 In Comfort mode
64. age Two other supplementary functions can be selected from the third submenu Language Time correction LCD contrast Time correction Press and hold the lt gt button about 5 seconds until the display shows Time correction and LCD contrast gt Press a or 97 to select Time correction Press the button The display shows Change value gt Press or to set the number of seconds in 24 hours Basic setting 0 s LCD contrast Press and hold the lt gt button about 5 seconds until the display shows Time correction and LCD contrast gt Press a or 7 to select LCD contrast gt Press the button The display shows Change value Press or lt 7 to adjust the LCD contrast Basic setting e g 47 Operating times This option shows the hours of service appliance burner and hot water since commissioning From the main menu select Settings from the first submenu select Service from the Second submenu select Further options and from the third submenu select Operating times Fault history This option displays any faults that have occurred for the information of the service engineer The first fault displayed may still be active Any other faults displayed are no longer active From the main menu select Settings from the first submenu select Service from the Second submenu select Further options and from the third submenu select Fault history 6
65. and text 13 display OK e Terminal 3 on TR 2 connected to no Rewire correctly as specified in the installation Terminal 3 on textdisplay instructions Terminal 4 Terminal 4 gt Tum ON the appliance etc after 90 sek A8 13 3 Lead s defective Checkleads for continuity and replace as necessary A8 l4 4 TR 2 defective Power OFF the appliance Change TR2 Turn ON the appliance 20 7 181 465 347 01 07 Rectifying faults Ad flashing Heat store NTC sensor 1 not detected Check Action 1 Is lead for heat store NTC sensor yes 42 correctly routed i e not through cable clamp no Route connecting lead for heat store tempera ture sensor as specified in installation instruc tions 2 Activate menu option yes Connector on end of NTC sensor lead Show service parameters Flue gas connector corroded damaged or Select dirty Change relative parts 3 Stor tank temp sensor1 Press button Is a temperature between 0 and 5 displayed Ad 13 no 14 3 Heat store NTC 1 yes Replace heat store NTC sensor 1 Unplug connector from PCB con Ho Power OFF the appliance trol board M Disconnect the boiler electrical connection Short circuit the connector using wire jumper Change PCB control board After max 60 sec Reconnect the boiler electrical connection Display changes to temperature gt
66. as Propane Max rated heat output net 40 30 C central heating kW 32 3 32 3 39 7 39 7 Max rated heat output net 50 30 C central heating kW 31 9 31 9 39 2 39 2 Max rated heat output net 80 60 C central heating kW 30 2 30 2 37 1 37 1 Max rated heat input net kW 30 5 30 5 37 5 37 5 Min rated heat output net 40 30 C kW 9 5 12 7 12 9 16 2 Min rated heat output net 50 30 C kW 9 4 12 6 12 8 16 1 Min rated heat output net 80 60 C kW 8 2 11 0 11 4 14 3 Min rated heat input net kW 8 8 11 8 11 8 14 8 Max rated heat output net domestic hot water kW 30 2 30 2 37 1 37 1 Max rated heat input net domestic hot water kW 30 5 30 5 37 5 37 5 Maximum gas flow rate After 10 minutes from lighting Natural gas G20 CVnet 34 02 MJ m m3 h 3 2 3 9 LPG CVnet 88 MJ m kg h 2 2 2 7 ply pressure Natural gas G20 CVnet 34 02 MJ m mbar 20 O D 2 o LPG CVnet 88 MJ m Expansion vessel Charge pressure mbar 0 75 0 75 0 75 0 75 Total capacity Hot water specifications 10 10 10 10 Hot water flow rate factory setting l min 8 8 8 8 Max hot water flow rate l min 14 0 14 0 14 0 14 0 Outlet temperature range C 40 60 40 60 40 60 40 60 Max permissible water supply pressure bar 10 10 10 10 Min inlet pressure bar 0 2 0 2 0 2 0 2 Specific flow rate l min 13 7 13 7 16 9 16 9 Max condensation rate tp 30 C Flue gas temp 80 60 C rated min load C 78 5
67. asured by NTC sensor 2 at the top of the heat store is indicated 1 2 Code plug The 10 digit part number of the code plug is indicated The code plug determines the appliance functions If the appliance is converted from natural gas to LPG or vice versa using conversion kit the code plug also has to be changed 1 5 Desired flow temp The CH flow temperature demanded by the text display module or a programmer connected to the bus module is displayed 1 9 Module detection The text display module shows the modules detected by the appliance 2 0 Operating mode There are 3 operating modes to choose from Normal mode the appliance operates according to the commands received from the programmer Min mode the appliance runs constantly at minimum output The text display shows MIn mode The 2 digit dis play alternates between the CH flow temperature and Max mode the appliance runs constantly at maxi mum output The text display shows Max mode The 2 digit dis play alternates between the CH flow temperature and 2 3 Stor tank charge outp The heat store charging output can be set to any level between the minimum and maximum rated heat output for hot water according to the heat transfer capacity of the heat store Enter the heat store charging output setting on the commissioning record enclosed with the appliance 2 4 Anti cycle mode This function is only active if service function 2 7 Auto matic anti cyc
68. ater is on or off or if the pump for the Storage Tank after running is on Boiler operat mode winter summer Indicates which mode the CH flow temperature control is set to Burner on off Indicates whether the burner is alight or not Pump on off Indicates whether the integral pump is switched on or off 32 6 720 610 604 GB 03 06 Text Display 48 Settings 4 81 Heating if TR 2 is connected Optimum Start gt From the main menu select Settings and from the first sub menu select Heating Press a or K J to switch Optimum Start on or off 4 8 2 Hot Water Storage Tank System boiler models only The text display can control the hot water either with Times and temperatures or only times Times and temperatures One can choose up to six different times with temperatures see page 30 Hot water Only times During that times the Storage Tank will be charged to the choosed temperature From the main menu select Settings and from the first sub menu select hot water Press a or lt 7 to switch Times and temperatures or only times Turn the hot water temperature control al ways higher than the temperature at the text display is choosen 4 8 3 Service Displaying service functions This option displays various current settings and statuses of the electrically controlled appliance and system components for the benefit of the heating engineer 6
69. ay Press The display shows Set 1 operating mode Setthe desired first operating mode Heating Economy or Frost protection Press The display shows Set 1 time period Setthe desired first time period gt Press Set the following operating modes and time peri ods as described for the first gt f necessary select the next day and enter the operating modes and timer periods as described above If the settings for a particular day of the week are different from the settings for the other days then if Monday Friday or Saturday and Sunday is selected the display shows for those options Timer periods and operating modes are you do not wish to change can be skipped by pressing C 4 5 2 Setting the Economy temperature if TR2 is con nected This option allows you to set the room temperature for Economy mode Off Economy This function is only active if Automatic mode or Economy mode is set on the TR 2 room thermostat gt From the main menu select Heating and then from the first submenu select Set Economy temp gt Use the 7 V button to set a temperature between 5 and 30 C 28 6 720 610 604 GB 03 06 Text Display 4 5 3 Manual operating mode if TR2 is not connected For selecting an operating mode that is different from the one set in the heating programme Automatic mode You can choose between Automatic Constant on comfort and Constant o
70. bmenu Parameters to e Main menu 1 2 3 change select amp Settings Heating Optimum Start Off On 33 Hot water x Only charging times 30 System times and temperatures boiler mod els Service Display 33 service param Further Language English 34 options Francais Deutsch Time correction 34 LCD contrast 34 Operating 34 times Fault 35 history 44 Setting the time day 4 4 1 Setting the time and day For details of how to set the time and day refer to page 21 Changing winter and summer time Only adjust the clock Do not alter the switching points for heating economy etc 4 4 2 Holidays In the Holiday programme the central heating runs in Economy mode and the hot water is switched off frost protection function remains active Fromthe main menu select Time day holidays and from the first submenu select Holidays Enter the number of days holiday by pressing a or 7 7 max 99 days holiday After the set number of days the text display module automat 6 720 610 604 GB 03 06 25 Text Display ically cancels Economy mode at midnight on the last day and returns to Automatic mode The day on which you enter the days holiday counts as the first day of the holiday i e the unit starts the holiday program immediately Only in clude the day on which you are returning if you don t want the heating to return to the normal pro gram
71. bmenu select Operating times Fault history This option displays any faults that have occurred for the informa tion of the service engineer The first fault displayed may still be active Any other faults displayed are no longer active gt From the main menu select Settings from the first submenu select Service from the Second submenu select Further options and from the third submenu select Fault history 6 720 610 604 GB 03 06 35 Text Display 4 9 Individual timer programmes Heating periods for central heating N gt Switching point Operating mode Operating mode Operating mode Operating mode Operating mode Operating mode Time Time Time Time Time Time Status Monday Tuesday Wednesday Thursday Friday Saturday Sunday Enable disable hot water function gt oa Switching point Operating mode Operating mode Operating mode Operating mode Operating mode Operating mode Time Time Time Time Time Time Status Monday Tuesday Wednesday Thursday Friday Saturday Sunday 36 6 720 610 604 GB 03 06 Fault finding 5 Fault finding Problem Cause Remedy Desired room temperature is not reached Thermostatic valve s set too low Increase thermo static valve
72. carried out by competent persons author ised by CORGI 3 1 Important remarks Appliance should only be installed in sealed central heating and hot water systems To avoid gas formation in the system galvanised radiators or pipes must not be used lfaroom thermostat is used do not fit a thermostatic radiator valve on the radiator in the primary room This appliance uses an automatically variable pump An auto bypass must not be fitted Adda suitable anti freeze fluid to the water in the central heating system Suitable products are available from Betz Dearborn Tel 0151 4209563 and Fernox Tel 01799 55081 1 In our experience the addition of sealing agents to the water in the central heating system can cause problems deposits in the heat exchanger For that reason we advise against their use 3 2 Domestic hot water Any regulations specified by the local water company must be observed The final 600 mm of the mains cold water connection to the applaince should be made in copper tube only The appliance is suitable for a mains supply having a maximum pressure of 10 bar A pressure reducing valve must be fitted if necessary The hot water outlet temperature is set to be capable of achieving a maximum of 60 C The maximum tempera ture and the frequency of the recharge of the heat store may be reset The water flow rate of 11 0 l min ZWBR 8 30 and 13 5 l min ZWBR 11 37 will give a temperat
73. cator lamp for power supply 84 Motor 3 way valve ZSBR 365 Chimney sweep button 135 Master switch 366 Service button 136 Temperature control for CH flow 367 ECO button 151 Fuse slow 2 5 A AC 230 V 400 Textdisplay 153 Transformer 422 Connecting TR2 161 Link 46 7 181 465 347 01 07 Appendix 5 3 List of most important replacement parts Component Order no Remarks Switchbox PCB control 8 748 300 385 board Transformer 8 747 201 358 Ignition lead 8 714 401 878 20 pinconnector 8 714 401 912 lead assembly Fuse 1 904 522 730 Fuse 1904522740 T1 6A Fuse 1904521342 T2 5A Code plug included in Conversion kit 7 710 149 050 ZWBR G20 gt 31 8 30 Conversion kit 7 710 239 086 ZWBR G31 gt G20 11 30 Conversion kit 7710149 051 ZWBR G20 gt G31 11 37 Conversion kit 7 710 239 087 ZWBR G31 gt G20 14 37 Conversion kit 7 710 149 052 ZSBR G20 gt G31 7 28 Conversion kit 7 710 239 088 ZSBR G31 gt G20 11 28 Conversion kit 7710 149 053 ZBR 8 35 G20 gt G31 Conversion kit 7 710 239 089 ZBR 11 35 G31 gt G20 Conversion kit 7 710 149 046 ZWBR G20 gt G31 7 28 Conversion kit 7 710 239 082 ZWBR G31 gt G20 11 35 Conversion kit 7 710 149 047 ZWBR G20 gt G31 11 35 Conversion kit 7 710 239 083 ZWBR G31 gt G20 14 3
74. connectors Unscrew the sensor Flue Temperature Limiter Item 9 fig 2 55 gt Pull off the connectors Unscrew the sensor 6 720 610 602 GB 03 02 43 Maintenance Domestic Hot Water Temperature Sensor Item 6 1 fig 2 Check that the inlet water valve is closed and the domestic hot water circuit is drained Release and pull off the connector Unscrew the sensor 9 3 7 Gas Valve v Check that the gas cock is turned off v Lower the control panel Refer to fig 58 Pull off the solenoid connections at the rear of the valve v Undo the union within the inner casing securing the valve to the gas air tube Refer to fig 57 Remove the white plastic cap from the gas valve Release the gas inlet union at the manifold assembly Unscrew the two screws securing the gas valve assembly bracket to the back panel and withdraw the assembly Transfer the bracket and inlet pipe assembly to the new gas valve Check for gas soundness when the new gas valve has been fitted Recheck the combustion performance as described in section 8 1 6 720 610 602 04 10 Fig 60 9 3 8 Domestic Hot Water Heat Exchanger Referto section 9 2 Use new seals when fitting the new heat exchanger 9 3 9 Electrode assembly Referto section 9 2 Use anew seal if the existing seal is damaged 9 3 10 Pressure gauge Drain the appliance Lower the f
75. ctly or requires servicing please call British Gas on 0845 9 60 50 40 40 6 720 610 604 GB 03 06 Fault or breakdown 10 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 A call out charge will be made where The appliance has been installed for over 24 months OR OurField 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 British Gas on 0845 9 60 50 40 IN THE EVENT OF AN APPLIANCE FAULT OR BREAKDOWN please contact your Service Centre see over 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 sit uations no hot water and or heating service INVOICES FOR ATTENDANCE AND REPAIR WORK CARRIED OUT
76. dividual settings Setting service functions Only the service functions that can be set are displayed Press any button to activate the main menu Press 7 or qum button until the arrow cursor is pointing to Settings Press the C gt button Press Pa button until the arrow cursor is pointing to Service Press the C gt button The cursor is pointing to Display service parame ters gt Press and hold the C button for about 5 sec onds until the display shows Adjust service parameters and the first service function to be set e g 2 0 Operating mode If a fault has occurred the display will show 0 0 and the last fault Press the ad or e button until the desired service function is displayed Press the C button The first line of the display shows Change value Usethe vd or f buttons to enter the required setting Press the C button The text display shows ATTENTION Store set tings gt Press V9 or a to select yes or no Press C to confirm your selection The text display shows Please wait and the service function is then displayed with the new set ting Press the vm or a button until the next func tion you wish to change is displayed Or gt Press the CSD button to exit the menu 7 2 2 Setting the anti cycle time Service Function 2 4 This service function is only active if Service Function 2 7 automatic anti cycle time is de
77. e CE 427 57 Main valve disc 61 Reset button 63 Adjustable gas flow restrictor 6 720 610 602 GB 03 02 7 Details of the appliance 1 8 Electrical wiring diagram g green bl black r red p purple 365 366 367 153 bl bi 32 6 720 610 602 02 10 4 4 1 Ignition transformer 365 Chimney sweep button 6 Temperature limiter heat exchanger 366 Service button 6 1 Hot water NTC sensor 367 ECO button 9 Flue gas temperature limiter 400 18 Pump 422 Connecting TR2 32 Flame sensing electrode 33 Ignition electrode 36 Temperature sensor in CH flow 52 Solenoid valve 1 521 Solenoid valve 2 56 Gas valve CE 427 61 Reset button 84 Motor 3 way valve 96 Microswitch hydraulic switch 135 Master switch 136 Temperature control for CH flow 151 Fuse slow 2 5 A AC 230 V 153 Transformer 161 Link 226 Fan 300 Code plug 302 Earth connection 310 Temperature control for hot water 312 Fuse slow T 1 6 A 313 Fuse slow T 0 5 A 317 Digital display 328 Terminal block for AC 230 V Mains supply 328 1 Link 363 Indicator lamp for burner 364 Indicator lamp for power supply 8 6 720 610 602 GB 03 02 Details of the appliance 1 9 Technical data ZWBR 8 30 ZWBR 11 30 ZWBR 11 37 ZWBR 14 37 Units Natural gas Propane Natural g
78. e Display from to Value 3 9 Link8 9 open closed Link Ls Lr open closed 4 0 Stor tank therm 7 9 blocked heat demand 4 1 Room therm LSM blocked heat demand LSM release blocked heat demand 4 2 Timer ch 1 heating blocked heat demand Timer ch 2 hot wat blocked heat demand 4 4 Heat demand heating yes no Heat demand stor tank yes no 4 5 Heat demand hot water yes no Keep hot period yes no 4 6 Internal regulator blocked heat demand 5 0 Max output heating 27 100 100 5 1 Permanent ignition no no yes 5 2 GFA status error OOh FFh 5 5 Min output 27 100 27 5 8 Cyclic boiler starts on on off 5 9 Fan speed start low low high 6 7 Pump off hot water off off on Table 1 7 181 465 347 01 07 Boiler service functions Range adjustable Reset Text display message Display from to Value 6 8 Cycle time hot water 0 60 min 0 min 6 9 Duration hot water 0 30 min 1 min 7 0 Pump map heating 0 Pump step adjustable 4 Prop 1 Const pressure high pres 2 Const pressure sure middle high 3 Const pressure low 4 Prop pressure high 5 Prop pressure low 7 1 Map pump step heat 2 7 7 7 2 Antiblock map pump off on on 7 3 Air purge mode off on on autom deaktivat autom permanent on deaktiv at off 7 4 Actual map pump step 1 8 7 5 Map pump load index 255 7 6 Map pump type 0
79. e pressure relief valve is set to operate at 3 bar There must be no connection to the mains without the approval of the local water company All connections in the system must be capable of withstanding a pressure 6 720 610 602 GB 03 02 11 Installation of up to 3 bar and the radiator valves conform to the requirements of BS2767 10 If Thermostatic Radiator Valves are fitted then it is rec ommended that the primary radiator is left open Repeated venting probably indicates a leak and this must be rectified to ensure the proper operation of the appliance No galvanised radiators or pipes must be used If any system water treatment is required then only products suitable for use with Aluminium shall be used i e Fernox Copal or Superconcen trate or Sentinal X100 in accordance with the APPLIANCE Refer to Fig 1 Appliance water flow diagram WRAS approved filling loop Central heating retum manufacturers instructions The use of any other substances will invalidate the guarantee The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated A drain cock to BS2879 must be fitted to the lowest point of the system IMPORTANT Check that no dirt is left in the water pipework as this could damage the appli ance Thoroughly flush the heating system and the mains water supply before fitting the appli ance to the wall in accordance with the recom mendations of BS7593 1
80. e restart F7 12 Power OFF the appliance yes Dry PCB control board e g with hair dryer Disconnect the boiler electrical Refit PCB control board connection Reconnect the boiler electrical connection Remove PCB control board gt Press N does appliance restart PCB control board damp F7 13 no 13 Is there a problem with the flue yes Check flue and repair or replace if necessary gt Check CO level in combustion nai air gt 0 2 CO The PCB control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 7 181 465 347 01 07 33 Rectifying faults FA and flashing After appliance switches off flame is detected Check Action 1 Is condensation trap in condensing boiler blocked yes Clean condensation trap discharge pipe gt Press N does appliance restart FA 12 no 12 2 Electrodes faulty Replace electrode assembly Turn ON the appliance gt Press N does appliance restart FA Power OFF the appliance 43 3 Problem with flue Check CO level in combustion air gt 0 2 96 CO yes Check flue and repair or replace if necessary gt Press N does appliance restart FA Power OFF the appliance 44
81. e setting and return to the previous menu Fig 9 page 22 or gt Do not press any other buttons for 15 minutes 4 2 1 Deleting a setting Either overwrite the setting or press the button to delete it gt Find the setting to be deleted Press and release the button The display shows 4 2 2 Resetting all parameters to their original settings The hours of service can not be reset to O Press and hold the button for more than 15 seconds After about 5 seconds the following message appears on the display ATTENTION Delete all parameters in x seconds Once the reset has been completed the following message is displayed Please wait Initialising 6 720 610 604 GB 03 06 23 Text Display 4 3 Menu structure Submenu Parameters to 2 Main menu 1 change select Ed Time day hol Time day Hours 25 idays Minutes Day of week Holidays Days holiday 25 Heating Heating Day 27 program 1st operating mode 1st switching point 6th switching point Set econ 5 30 28 temp if TR2 is connected Manual Automatic 29 if TR2 is Constant on not con comfort nected Constant off economy Hot water Hot water Day 31 program 1st operating mode 1st switching point 6th switching point Hot water Off On 31 immediately Info 32 24 6 720 610 604 GB 03 06 Text Display Su
82. e the 20 pin connector lead assembly Turn ON the appliance E2 J4 4 The PCB control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 7 181 465 347 01 07 25 Rectifying faults E 9 and AN flashing Safety temperature limiter has tripped Check Action 1 Is the heating pressure between 1 yes and 2 bar Top up system Vent appliance Press N does appliance restart E9742 no 15 2 Is the pump blocked yes Unblock the pump If pump won t start Power OFF the appliance Disconnect the boiler electrical connection Change the pump Reconnect the boiler electrical connection Turn ON the appliance gt Press N does appliance restart E9 13 no 43 3 Is lead disconnected from one both yes safety temperature limiters Power OFF the appliance Connect lead Turn ON the appliance Press 2 does appliance restart E9 14 no 44 4 Power OFF the appliance yes Unplug the connector from the cut off device Measure the NTC electrical resist ance Change the over heating cut off device Connect flue gas safety temperature limiter lead Turn ON the appliance gt Pres
83. eat Heat Gas vol flow rate Display Heat Heat Gas vol flow rate code output input l min at code output input l min at ty tg kW kW ty tg 80 60 C kW kW 80 60 C 30 9 1 9 2 16 0 30 11 1 11 3 19 7 40 12 1 12 2 21 4 40 14 9 15 0 26 3 50 15 1 15 3 26 7 50 18 6 18 8 32 8 60 18 1 18 3 32 0 60 22 3 22 5 39 4 70 21 1 21 4 37 4 70 26 0 26 3 45 9 80 24 2 24 4 42 7 80 29 7 30 0 52 5 90 27 2 27 5 48 0 90 33 4 33 8 59 1 100 30 2 30 5 53 4 100 37 1 37 5 65 6 Table 20 Table 22 10 4 Heating hot water output settings ZWBR 11 30 L P G 10 6 Heating hot water output settings ZWBR 14 37 L P G Propane Propane Display Display code Heat output kW Heat input kW code Heat output kW Heat input kW 40 12 1 12 2 40 14 9 15 0 50 15 1 15 3 50 18 6 18 8 60 18 1 18 3 60 22 3 22 5 70 21 1 21 4 70 26 0 26 3 80 24 2 24 4 80 29 7 30 0 90 27 2 27 5 90 33 4 33 8 100 30 2 30 5 100 37 1 37 5 Table 21 Table 23 48 6 720 610 602 GB 03 02 Appendix 10 7 Operational Flow diagrams 10 7 1 Domestic hot water function OV vc 945 019 022 9 609806 10 440 suni 1461 peu Suiu e seso o Jo Suni sey S Hues A024 941 IUIN G 01 y spuooes G 559 e
84. ected Insert keyed plug correctly test and replace if necessary C1 Fan speed too low Check fan lead and connector and fan replace as necessary d3 Jumper 8 9 not detected Connector not connected link missing under floor heating limiter tripped E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting lead E9 Safety temp limiter in CH flow has tripped Check system pressure check safety temp lim iters check pump operation check fuse on pcb bleed appliance EA Flame not detected Is gas cock turned on Check gas supply pres sure power supply igniter electrode and lead ionisation sensing electrode and lead flue duct and CO2 level FO Internal error Check electrical connector contacts program mer interface module ignition leads and bus module are not loose replace pcb or bus mod ule if necessary F7 Flame detected even though appliance Check electrode assembly dry pcb Flue clear switched off FA Flame detected after gas shut off Check gas valve and wiring to gas valve Clean condensation trap and check electrode assem bly Flue clear FC Textdisplay not detected Check connecting lead between Textdsiplay and Heatronic replace Textdisplay if necessary Fd Reset button pressed by mistake Press reset button again P1 P2 Please wait initialisation in progress 24 V fuse blown Replace fuse P3 P1 Table 18 46 6 720 610 602 GB 03 02 Appendix 10 2 Short parts list Key
85. ection Change PCB control board Reconnect the boiler electrical connection v v Turn ON the appliance 7 181 465 347 01 07 35 Rectifying faults 4 5 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 1 Fuse T 1 6 A 312 defective yes Turn ON the appliance Change the fuse Power OFF the appliance Start sequence not completed 12 no J2 2 The PCB control board is damaged Change PCB control board Excessive burner noise rumbling noises specified levels Measure CO levels Check Action 1 Does the gas supply type match the yes 12 specifications on the appliance iden 1 tification plate no Convert appliance to correct gas type 2 Test gas supply pressure OK yes 13 no Decommission appliance Notify gas company 3 Problem with flue yes Check flue and repair or replace if necessary Check CO level in combustion no Ip air gt 0 2 90 4 Remove silencer flue pipe and yes Repair or replace components mixer unit er Grease seal before fitting ls intorna Nue piper pinty 2d Make sure it is fitted in correct position clogged or are seals defective or incorrectly fitted no l5 5 Flue gas CO levels measured at yes Adjust
86. es 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 The presence of halogenated hydrocarbons in the com bustion air results in the production of highly caustic hydrochloric acid and depending on the composition of the combustion air hydrofluoric acid which build up inside the boiler and remain active over long periods of time In order to limit the damage the source of the contami nation must be located and sealed off If this is not pos sible the combustion air must be brought to the appliance from an unaffected area Halogens can occur in the following areas Industrial sources Dry cleaners Trichloroethylene tetrachlo roethylene fluorinated hydro carbons Degreasing baths Perchloroethylene trichlo roethylene methyl chloroform Printers Trichloroethylene Hairdressers Aerosol propellants hydrocar bons containing chlorine and fluorine Freon Sources in the home Cleaning and Perchloroethylene methyl degreasing agents chloroform trichloroethylene methylene chloride carbon tetrachloride hydrochloric acid Hobby workshops Solvents and thin Various chlorinated hydrocarb ners Aerosol sprays Chlor fluorinated hydrocar bons Freons Table 9 7 181 465 347 01 07 49 Appendix 50 7 181 465 347 01 07 Appendix
87. es the building have a supply pres sure regulator 5 Natural gas models yes Check that it is fitted correctly and functioning properly and correct if necessary Check supply pressure inform gas company if outside correct range Press N does appliance restart EA l6 no 46 models 16 is the flow rate of the gas supply to the appliance correct no gt 15 there enough gas in the supply cylinder gt Is there air in the supply pipe gt 15 the solenoid valve in the meter cabinet open ing 15 the supply pressure OK if the supply pres sure is too high check the pressure regulator in the meter cabinet and on the LPG supply cylin der gt Press N does appliance restart EA l6 28 7 181 465 347 01 07 Rectifying faults EA and flashing During operation flame not detected Check Action 6 Is the ground connection correct yes 47 Rewire correctly as specified in the installation instructions gt Press N does appliance restart EA 17 7 Two phase net yes 48 Is there a resistor fitted between Pe and N no Power OFF the appliance Disconnect the boiler electrical connection Insert resistance Order no 8 900 431 516 between the ground and the N connection Reconnect the boiler electrical connection Turn ON the applia
88. ew seals when replacing the heat exchanger 7 181 465 330 06 1R Fig 44 Primary Heat exchanger There is a special accessory kit no 840 for cleaning the heat exchanger order no 7 719 001 996 Check control pressure on the air gas mixer unit at max rated heat output using an electronic manome ter Fig 45 The heat exchanger should only be cleaned if the control pressure is 5 0 mbar ZWBR 8 30 4 5 mbar ZWBR 11 37 depression or less Remove cleaning access cover 415 page 6 and the metal plate below it if present Refer to fig 2 Unscrew condensation trap and place suitable con tainer underneath Refer to fig 46 Remove the fan and the burner as described in the text headed Burner see page 39 6 720 610 332 72 18 Fig 46 38 6 720 610 602 GB 03 02 Maintenance Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade Refer to fig 47 6 720 610 332 73 1R Fig 47 Clean the heat exchanger from top to bottom using the brush Refer to fig 48 6 720 610 332 74 1R Fig 48 Flush the heat exchanger from the top Refer to fig 49 gt Clean out the condensate collector and trap connec tion with other end of brush 6720 610 332 75 2R Fig 49 Refit the clean out cover using a new seal and
89. ff economy The manually selected operating mode starts immediately Constant off economy and Constant on comfort are auto matically reset at 00 00 midnight To cancel the manually selected operating mode select the relevant menu and then press the button or select a different operating mode or set Holiday From the main menu select Heating and then from the first submenu Manual select required mode 6 720 610 604 GB 03 06 29 Text Display 4 6 Hot water General description Combi models only The basic settings provide a straightfor ward timer programme enabled from 5 00 am disabled from 10 00 pm The ECO button must not be lit Comfort mode System models with Storage Tank The basic settings pro vide a timer programme enable from 5 00 am disable from 10 00 pm With the menu Hot water see page 33 you can choose a timer temperature programme with the basic set tings 60 C from 5 00 am 10 C from 10 00 pm 30 6 720 610 604 GB 03 06 Text Display 4 6 1 Hot water program Up to six switching points per day can be set There are two operating modes Blocked and Released From the main menu select Hot water and then from the first submenu select Hot water program Set the days of the week Blocked Released operating mode in the same way as for the switching points and modes for heating as described on page 27 6 2 Hot water immediately System models
90. flue duct L 50 mm The measurement is from the formed end Flue Socket AN on Boiler 6 720 610 602 14 10 Fig 24 Flue turret Ensure that the turret is fully entered into the socket on the boiler From the outside fix the outer wall plate to the terminal and after ensuring the duct is properly i nclined towards the boiler fix the plate to the wall If the terminal is within 2 m of the ground where there is access then an approved terminal guard must be fitted The guard must give a clearance of at least 50 mm around the terminal an be fixed with corrosion resistant Screws 6 720 610 602 GB 03 02 19 Electrical connections 4 Electrical connections Always disconnect the power supply to AN the appliance at the mains before carry ing out any work on the electrical sys tems and components All control and safety systems are built into the appli ance Allow mains cable to protrude at least 50 cm from wall To make splash water proof IP cut the cable grom met hole size to match diameter of cable see fig 27 It must be possible to isolate the appliance The appli ance must be earthed The appliance must be connected to the mains through a 6 A double pole isolator with a contact separation 3 mm in all poles and supplying the appliance and con trols only The wiring must comply with the current requirements of the IEE Wiring Regulations and any local regulations which apply Su
91. g of the appliance or any controls to the appli ance may only be carried out by a competent engi neer in accordance wth the Gias Safety Installation and Use Regulations 1998 Flue systems must not be modified in any ways other than as described in the fitting instructions This appliance is for use on sealed primary systems only Maintenance The user is recommended to have the system regularly serviced in order to ensure that it functions reliably and safely Use only original spare parts Combustible materials Do not store or use any combustible materials paper thinners paints etc in the vicinity of the appliance Health and safety This appliance contains no asbestos products There is no potential hazard due to the appliance being electrically unsafe There are no substances used in the construction that are a potential hazard in relation to the COSHH Regulations Control of Substances Hazardous to Health Regulations 1988 Combustion air Ambient atmosphere The combustion air ambient atmosphere should be kept free of chemically aggressive substances e g halogenated hydrocarbons which contain chlorine or fluorine compounds This will prevent corrosion Instructions to the customer Explain to the customer how the appliance works and how to operate it Advise the user that he she must not make any modi fications to the appliance or carry out any repairs on it
92. he flue gt Check CO level in combustion nai ll air gt 0 2 CO 16 7 181 465 347 01 07 Rectifying faults 4 4 Faults indicated on display A 1 flashing Controlled characteristic pump has run dry Check Action 1 System pressure below 1 2 bar yes Power OFF the appliance Check appliance and system for water leaks and repair as necessary Top up system Turn ON the appliance A1 12 no 42 2 Activate venting sequence gt Activate menu option Show service parameters Select 7 3 Aeration mode select setting On autom deactivat and confirm Vent appliance Vent radiators 43 3 Audible bearing damage on pump yes Power OFF the appliance Drain appliance Replace pump Top up system v ON the appliance 1 See installation instructions 7 181 465 347 01 07 Rectifying faults A 5 flashing Heat store NTC sensor 2 defective Check Action 1 Activate menu option yes Show service parameters gt Select gt 15 the connector for heat store NTC sensor 2 cor damaged or dirty Replace affected components 4 Stor tank temp sensor2 lo Is a temperature between 0 and 5 displayed no 43 2 Disconnect connector for heat yes Power OFF the appliance store NTC sensor 2 gt Short circuit the 2 pin connector on
93. iance 3 Operating the Appliance 3 1 Preparation Turn on the gas cock 172 Pressinthe 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 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 Cold water inlet valve 173 Turn handle so that it is in line with direction of flow When handle is at right angles to direction of flow the valve is closed 6 720 610 598 02 20 12 6 720 610 604 GB 03 06 Operating the Appliance Check the central heating system pressure gt The pointer on the pressure gauge 8 1 should be about 1 bar Ifthe 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 The maximum operating pressure of 2 5 bar at maximum central heating flow temperature must not be exceeded If the pressure increases to 3 bar then the relief valve 15 opens 6 720 610 598 03 20 6 720 610 604 GB 03 06 13 Operating the Appliance 3 2 Switching the Appliance On Off Switching on 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 i
94. il the display shows Adjust service parameters and the first service function to be set 2 0 Operating mode If a fault has occurred the display will show 0 0 and the last fault Press om or fae until the display shows 2 0 Operating mode normal Press the C button Press d or to select Max Measure the CO level Prise off the seal on the gas flow restrictor 6 720 610 602 GB 03 02 33 Converting the appliance to different gas types Adjust the gas flow restrictor 63 to obtain the CO level given in Table 15 Refer to fig 41 6 720 610 332 64 1R Fig 41 ZWBR 8 30 CO reading at max CO reading rated heat at min rated Gas Type output heat output Natural gas type 9 4 96 9 2 G20 LPG G31 11 0 11 0 propane Table 15 ZWEBER 11 37 CO reading at max and Gas Type min rated heat output Natural gas type 9 2 G20 LPG G31 11 0 propane Table 16 Press NC or to select Min Measure the CO level Remove the seal from the gas valve adjusting screw 64 and adjust the CO level to the figure given in Table 15 for min rated heat output Refer to Recheck the levels at min and max rated heat output and re adjust if necessary Press V until the display shows normal Press the C button The text display shows Store settings Press im to select yes Press the C button Remove test
95. ing 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 is gas it has to be a British Gas Scottish Gas Condensing appli ance 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 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 4 6 720 610 604 GB 03 06 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 If you smell gas gt Turn off gas service cock at the meter Open all doors and windows Do not operate any electrical switches Do not s
96. ing probe from the flue gas testing point 234 and refit sealing plug Re seal gas valve adjusting screw and gas flow restrictor Replace the outer case by locating it on the top lugs and pushing backwards until the bottom clips are fully engaged Check that the case is properly aligned with facia Refer to fig 13 Secure by replacing the screw at the bottom left Refer to fig 13 34 6 720 610 602 GB 03 02 Converting the appliance to different gas types 8 2 Testing combustion air flue gas at set heat output 8 2 1 Testing the O or CO level in the combustion air By testing the or level in the com bustion air the gas tightness of a type C535 flue system can be checked The level must not be less than 20 6 The CO level must not exceed 0 2 96 gt Press and hold the button until the display shows Chimney sweep mode is now active The 9 button will light up and the display shows the CH flow temperature In chimney sweep mode the appliance Switches to max rated heat output or the set heating output You then have 15 min utes in which to measure the levels After that the appliance switches back from chimney sweep mode to normal mode Remove sealing plug from combustion air testing point 234 1 fig 43 Insert testing probe about 80 mm into the testing point and seal testing point 6 720 610 332 65 2R Fig 43 gt Measure and CO levels
97. ions are supplied with proprietary cleansers sold for 400 PIU i this purpose If an inhibitor is to be used after flushing it should be used in accordance with the inhibitor man ufacturers instructions To drain the appliance shut the system valves and open the system drain point Suitable flushing agents and inhibitors are available from Betz Dearborn Tel 0151 4209563 Fernox Tel 01799 550811 and Salamander Tel 0121 378 0952 Instructions for use are supplied with the these products 22 6 720 610 602 GB 03 02 Commissioning Before commissioning the gas supply pres sure must be checked at the gas supply pres sure test point see page 6 fig 2 item 7 Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar LPG appliances must not be operated if the supply pressure is not 37 mbar at the inlet to the appliance Unscrew the condensation trap 358 and pull out fill with approx 1 4 of water and refit Refer to fig 30 Adjust charge pressure of expansion vessel to static head of the central heating system see page 31 Open all system radiator valves Turn on service valves 170 fill central heating sys tem to pressure of 1 2 bar through the WRAS approved filling loop Refer to fig 30 Vent radiators Refill heating system and set the pressure to 1 bar Turn on cold water service cock 173 Refer to
98. is set to O Pump step adjustable This service function corresponds to the pump speed Switch used on conventional heating pumps 7 2 Antiblock map pump not ZBR The appliance is supplied with this function activated If the pump threatens to jam an oscillating pump action is activated Afterwards the required operating mode is continued 7 3 Aeration mode not ZBR The first time the appliance is switched on a once only venting function is activated The heating pump then Switches on and off at intervals This sequence lasts about 8 minutes and the text display shows Aeration mode The 2 digit display shows in alternation with the CH flow temperature The automatic vent must be opened and then closed again once the venting sequence is complete The venting function can be activated manually after servicing Ifthe venting function is set to On autom deacti vat once the sequence has been completed 7 4 Actual map pump step not ZBR The currently active pump speed is displayed see func tion 7 0 7 5 Map pump load index not ZBR The load index is displayed 7 6 Map pump type not ZBR The pump type code of the pump fitted is displayed 7 7 Output reduction The appliance is supplied with this function activated It prevents overload of the heat exchanger with high CH flow temperatures The output of the burner is reduced according to the CH flow temperature i e
99. isk of scale formation in these hard water areas 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 BS 6798 Notwithstanding the requirements of BS 6798 there is no need for ventilation openings to be provided in the compartment because of the low heat loss from the casing 6 720 610 604 GB 03 06 9 General notes Do not allow the flue terminal fitted on the outside wall to become obstructed or damaged Pump The pump is a fully modulating type to which the parameters have been set by the manufacturer and must not be adjusted 10 6 720 610 604 GB 03 06 Controls 2 Fig 1 8 1 61 135 136 170 171 172 173 295 310 317 363 364 365 366 367 400 Controls 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 Display Indicator lamp for burner on Indicator lamp for off on Chimney sweep button Service button ECO button Text Display 6 720 610 604 GB 03 06 11 Operating the Appl
100. itain This guarantee is given in addition to all your normal statutory rights 42 6 720 610 604 GB 03 06 Guarantee registration 12 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 RD 532i RD 537i RD 542i RD 430i appliance and will assist us in maintaining an effective and efficient customer service by establishing a refer ence and permanent record for your boiler This will not affect your statutory rights in any way Important For your own record Model Check that the Benchmark log book has been completed by your installer or service engineer SERIAL NUMBER Copy the number off the Guarantee Card 6 720 610 604 GB 03 06 43 13 Operating Instruc tions Ouick Refer ence Switching on 6 720 610 333 04 10 Switching the central heating on F Sa S a 21 6 720 610 333 05 10 3 m Text Display Set switching times and operating mode within the text display Hot water temperaeture Combi nation boiler only 6 720 610 333 07 10 ECO button lit Economy mode ECO button not lit Comfort mode Fault Condition Refer to page 19 Switching off 6 720 610 333 11 10
101. ity regulations indicate that in certain cir cumstances the installer can be held responsible not only for mistakes on his part but also for damage result ing from the use of faulty materials We advise the installer to avoid any risk by using only quality approved branded fittings The relevant British Standards should be followed i e BS 6798 Specification for the installation of gas fired hot water boilers of rated input not exceeding 60kW BS 5449 Central Heating for Domestic Premises BS 5546 Installation of gas hot water supplies for domestic purposes Gas supply e BS 5440 1 Flues and ventilation for gas appliances of rated input not exceeding 70 kW net Flues pen ee pugascupplyipipe ja d BS 5440 2 Flues and ventilation for gas appliances mentee mm of rated input not exceeding 70 kW net Air 3 6 9 Supply BS 6891 Installation of low pressure gas pipework Gas discharge rate m h installations up to 28mm R1 8 7 5 8 4 6 22 BS 7074 1 Code of practice for domestic heating and hot water supply 18 0 12 0 9 4 28 BS 7671 Requirements for Electrical Installation Table 7 These instructions must be followed 10 6 720 610 602 GB 03 02 Installation 3 Installation Always turn off the gas cock before car rying out any work on components which carry gas Fixing of the appliance gas and flue con nections commissioning of the system and electrical connections may only be
102. ld 43 CH flow 47 CH return 112 Gas cock 171 Domestic hot water 172 Cold water relief Adrain tap should be fitted at the lowest point of the central heating system gt WRAS approved filling loop must be fitted 6 720 610 602 GB 03 02 Installation Condensate Termination and Route The condensate connection on the British Gas Bosch appliances is in 22 mm plastic The pipe should be extended and run away from the appliance with a con stant fall of 2 5 or 40 mm in every metre The condensate pipe can terminate into any of four areas Boiler 7 22 min Boiler Siphon 22 min Siphon Zi Open end of pipe i direct into gully Use waterproof pipe work insulation in very exposed below ground but positions above water level The gradient of the discharge pipe should be 2 5 40 mm m minimum An external waste system Boiler Boiler Internal soil vent stack i lo lengi 22 min nd venEstad Sink ce 7 Open end of pipe 22min direct into gully in tg die Fs min trap below ground but uid above water level The gradient of the discharge pipe should be 2 5 40 mm m minimum An external purpose made soakaway External length of pipe 2m min N No length restriction Ts min trap The gradient of the discharge pipe should be 2 5 40 mm m minimum OPen end of pipe direct into gully below ground but above water level An internal
103. le mode is disabled The anti cycle time is factory set to 3 minutes The shortest possible period is 1 minute recom mended for single pipe and hot air heating systems The setting O means that the anti cycle time is disabled If an outside temperature controlled heat ing programmer is used no setting is re quired The anti cycle time is optimised by the programmer Enterthe anti cycle time on the commissioning record enclosed with the appliance 2 5 Max flow temperature The maximum CH flow temperature can be set to between 35 C and 88 C factory setting 2 6 Switch diff flow NTC If an outside temperature controlled heat ing programmer is used no setting is re quired on the appliance The switching difference is the permissible deviation from the specified CH flow temperature It can be set in increments of 1 K The adjustment range is from O to 30 K factory setting O K The minimum CH flow tem perature is 30 C Disable anti cycle time setting O The switching difference setting should be entered on the commissioning record supplied with the appli ance 7 181 465 347 01 07 Boiler service functions 2 7 Autom anti cycle mode If an outside temperature controlled programmer is con nected to the appliance the anti cycle time is adjusted automatically Automatic adjustment of the anti cycle time can be dis abled This may be necessary in the case of unfavo
104. low tem perature to a level appropriate to the type of central heating system Underfloor heating e g setting 3 approx 50 C Low temperature heating setting E approx 75 C Central heating systems for flow temperatures up to 88 C limited max setting for low temperature operation see page 31 When the burner is alight the red indicator lamp lights up 6 720 610 333 05 10 Fig 32 5 4 gt System controls Set room thermostat to the desired room tempera ture Set outside temperature driven control unit if fitted Refer to the instructions with the control Set the thermostatic radiator valves to the desired settings 6 720 610 602 GB 03 02 23 Commissioning 5 5 Setting the domestic hot water temperature and flow rate 5 5 1 Domestic hot water temperature The hot water temperature can be set to between approx 40 C and 60 C This temperature is not shown on the display Setting Hot Water temperature Turn fully anti clockwise approx 40 C e approx 55 C Turn fully clockwise approx 60 C Table 10 ECO button By pressing and holding the ECO button until the display lights you can switch between Comfort mode and Economy mode Comfort mode button is not lit factory setting The appliance is held constantly at the set temperature This means that hot water is available almost instanta neously a
105. mer heating mode is disabled 4 0 Stor tank therm 7 9 When supplied the appliance has no jumper across ter minals 7 9 Disabled If that connection is closed e g by a heat store thermostat heat store charging is enabled 4 1 Room therm LSM 4 1 LSM release When supplied a jumper is fitted across terminals LZ L1 on the LSM Heat demand If that connection is opened e g by a connected room thermostat heating mode is disabled LSM release shows the total number of all possible ena ble signals connected via the LSM As soon as a mod ule connected to it e g mechanical limiter for underfloor heating limit switch on flue flap combustion air flap etc shuts off heating and hot water modes are disabled 4 2 Timer ch 1 heating 4 2 Timer ch 2 hot water Shows the status of channel 1 of the timer integrated in the text display module or the separate programmer If that channel s status is Heat demand heating mode will be activated according to the programmer com mands 7 181 465 347 01 07 Boiler service functions Shows the status of channel 2 of the timer integrated in the text display module or the separate programmer If that channel s status is Heat demand hot water mode will be activated according to the programmer commands 4 4 Heat demand heating Heat demand stor tank ZSBR only Heat demand heating shows the heat demand status for the central heating sys
106. min rated heat output on the commissioning record enclosed with the appliance 5 8 Cyclic boiler starts ZSBR 3 5 16 A only When supplied this function is activated on the above appliances and prevents start up problems caused by poor ignition characteristics A truncated start cycle is activated if the burner has not been in operation for more than 3 hours During a truncated start cycle the fan runs and the gas valve is opened long enough to completely fill the gas pipe with gas approx 1 2 seconds but the burner is not ignited This function is not required and can not be activated on any other models 6 7 Pump off hot water The appliance is supplied with this function activated i e there is a delay before the pump switches on in hot water mode This means that cold water comes out of the pipe to begin with followed by hot water once the pump switches on If the pump is set to switch on immediately Pump off function deactivated the hot water temperature rises gradually until the set temperature is reached 7 181 465 347 01 07 Boiler service functions If a stratified charge tank is connected it is useful to have the function activated The delayed cut in of the pump then prevents cold water being pumped through the tank and cooling it down 6 8 Cycle time hot water ZWBR only The appliance is supplied with the hot water cycle time set to 3 minutes The hot water cycle time s
107. moke Extinguish any naked flames Call your gas company If you smell fumes from the appliance Switch off appliance Open windows and doors Inform your heating engineer Fitting and modifications Fitting of the appliance or any modifications to the appliance may only be carried out by a competent person Flue systems must not be modified in any way Maintenance We recommend that you take out a maintenance contract with a competent installer and have the appliance serviced at regular intervals gt Ensure that your Service Engineer uses only genuine spare parts 6 720 610 604 GB 03 06 5 Safety precautions Combustible materials gt Do not store or use any combustible materials paper thin ners paints etc in the vicinity of the appliance Health and safety This appliance contains no asbestos products gt There is no potential hazard due to the appliance being electri cally unsafe There are no substances used in the construction that are potential hazard in relation to the COSHH Regulations Con trol of Substances Hazardous to Health Regulations 1988 Ventilation Air Ambient Air Keep ventilation 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 6 720 610 604 GB 03 06 General notes 1 General notes To get the bes
108. n A 60 C for normal operation Only use temperatures of up to 70 C tempo rarily for thermal disinfection purposes With the text display you can additional set hot water charging times or times and tempera tures Set the hot water temperature by means of the temperature control amp on the appliance 6 720 610 333 07 10 6 720 610 604 GB 03 06 17 Operating the Appliance Control Setting Water Temperature Anti clockwise limit approx 10 C frost protection approx 60 C Clockwise limit approx 70 C Table 3 ECO button Pressing and holding the ECO button until it lights up switches from Comfort mode to ECO mode Comfort mode ECO button is not lit factory setting In Comfort mode the hot water tank has priority The hot water cyl inder is first heated up to the set temperature The appliance then Switches to central heating mode ECO mode button is lit In ECO mode the appliance switches between central heating mode and oylinder charging mode every 12 minutes 3 7 Summer Mode Hot Water Only Combi Appliances With room temperature controller Turn temperature control Pit on the appliance anti clockwise as far as the stop The central heating is now turned off The hot water function and the mains power supply for the heating programmer and timer remain switched on 18 6 720 610 604 GB 03 06 Operating the Appliance 3 8 Fro
109. nce Press does appliance restart EA 410 8 Is condensation trap in condensing yes Unscrew condensation trap and clean boiler blocked Press N does appliance restart EA 112 no 49 9 Check the gas valve yes Reconnect the gas valve Power OFF the appliance Turn ON the appliance Unplug the connectors from the Press N does appliance restart gas valve EA 410 Measure the gas valve coils and electrical resistance no Change the gas valve R 164 40 07 Reconnect the gas valve Turn ON the appliance gt Press N does appliance restart EA 410 10 Is flue blocked yes gt Check the flue Check CO level in combustion gt Press N does appliance restart air gt 0 2 CO EA 411 no 411 7 181 465 347 01 07 29 Rectifying faults EA and A flashing During operation flame not detected Check Action 11 Is flue gas level incorrect yes Adjust to correct level Press N does appliance restart EA 112 no 442 12 Activate menu option Show serv yes 413 ice parameters ee no 416 Select 5 1 Permanent ignition Continuous ignition OK 13 Ignition lead connected to ignition yes 414 electrodes T no Connect cable to ignition electrode gt Press N does appliance restart EA 414 14 Ignition cable connector engaged in yes 415
110. ndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619 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 AANIORCESTER Bosch Group 7 181 465 347 01 07 OSW Contents Contents Safety precautions 3 Symbols 3 1 Layout of Appliance ZSBR ZWBR 4 2 Operation 5 2 1 Standard display 5 2 2 Displaying service functions 5 2 3 Setting service functions 5 2 4 Resetting service functions to factory settings 5 2 4 1 Resetting service functions 0 0 to 4 9 to their factory settings Reset 1 5 2 4 2 Resetting service functions 0 0 to 9 9 to the factory setting Reset 2 5 3 Boiler service functions 6 3 1 Summary 6 3 2 Explanation of service functions 9 4 Rectifying faults 14 41 Boiler failure codes indication 14 4 1 1 on the boiler 14 4 1 2 on the programmer optional accessory 14 4 2 Summary 14 4 2 1 Appliance faults 14 4 2 2 Faults that are not indicated on any display 14 4 3 to use the fault tables 16 4 4 Faults indicated on display 17 4 5 Faults that are not displayed 36 4 5 1 Appliance faults 36 4 5 2 Programmer faults 41 5 Appendix 45 51 NTC values 45 5 1 1 Outside temperature sensor 45 5 1 2 CH flow NTC sensor heat
111. ng temperature has priority up to 85 C The hydraulic configuration must be matched to this pump mode use of a mixer unit and hydraulic balancing The pump mode setting should be entered on the commissioning record enclosed with the appliance 3 5 Pump blocking time ZBR models only Only applies if service function 3 4 Pump mode is set to Pump mode 1 external 3 way valve for heat store charging is con nected Otherwise has no function If the system incorporates a 3 way valve external to the appliance the heating pump is disabled while the 3 way valve is being actuated therefore the blocking time of the heating pump should be 2 the actuation time of the 3 way valve The blocking time has an adjustment range of O to 16 with each increment equivalent to 15 seconds The adjustment range therefore equates to 0 to 240 sec onds Factory setting is 30 seconds Enterthe pump blocking time on the commissioning record enclosed with the appliance 3 6 Software version The version number of the software is displayed 3 9 Jumper 8 9 3 9 Jumper Ls Lr When supplied the appliance has a jumper fitted across terminals 8 9 Heat demand If that connec tion is opened e g by a limiter for an underfloor heating system heating mode is disabled When supplied the appliance has a jumper fitted across terminals Ls Lr Heat demand If that connec tion is opened e g by an external 2 point program
112. ngs or seals are in place before tightening the connection gt Turn on the service valves for central heating flow and return and fill the heating system through a WRAS approved filling loop Check all seals and unions for leaks testing pres sure max 3 0 bar as indicated by pressure gauge Turn on cold water service cock and fill hot water system testing pressure max 10 bar gt Check all connections for leaks Gas supply pipe gt Check that the seal is in place before tightening the connection Turn off gas cock to protect gas valve against dam age from excessive pressure Check gas supply pipe Release the pressure on the gas supply pipe 3 9 Flue Systems The only flue systems that may be used are those sup plied with the boiler 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 Full instructions for fitting this flue are in Subsection 3 9 2 Installation of the flue Alternative 125 mm diameter flue systems Installation instructions for the alternative flue systems are sent with the appropriate flue kit Systems are available to give a maximum horizontal length of 13 m ZWBR 8 30 and 10 m ZWBR 11 37 A vertical flue system upto a height of 15 m ZWBR 8 30 and 12 m ZWBR 11 37 is available 45 and 90 flue bends can be used wi
113. nit for ZWBR 8 30 ICC2 Take care not to damage diaphragm N 443 when removing and refitting it Open mixer unit 29 Carefully withdraw diaphragm 443 from fan intake tube and check for soiling and splits I 2 6 720 610 790 07 2R Fig 52 Carefully refit diaphragm 443 the correct way round into the fan intake tube The flaps of the diaphragm 443 must open upwards Seal the mixer unit 29 Diaphragm in mixer unit for ZWBR 11 37 ICC2 Remove fan and mixer unit assembly 6 720 610 910 63 1R Fig 53 Unscrew mixer unit 29 Remove sleeve Carefully remove diaphragm 443 and check for soiling and cracks v Refit diaphragm 443 taking care to ensure it is the correct way round The flaps of the diaphragm 443 must open upwards Refit mixer unit 29 and fan assembly 40 6 720 610 602 GB 03 02 Maintenance Siphon Unscrew the clip and disconnect the pipe to the siphon Remove the yellow plug to drain the siphon Unscrew the securing nut from beneath the side facia and remove the siphon Refer to figure below Refit and prime the siphon 6 720 610 602 16 10 Fig 54 Expansion vessel The expansion vessel should be checked once a year Depressurise appliance gt If necessary adjust expansion vessel charge pres sure to static head of the heating system Heating system pres
114. o suitable for aluminium Hoechst Antifrogen N Anti freeze fluid based on ethylene glycol with 20 40 good corrosion inhibiting properties Fernox Alphi 1 1 Anti freeze fluid with corrosion inhibitor also suit able for aluminium BASF Glythermin NF Anti freeze fluid based on ethylene glycol with 20 62 good corrosion inhibiting properties also suitable for aluminium Corrosion inhibitor Schilling Chemie Varidos KK Corrosion inhibitor 0 5 Schilling Chemie Varidos 1 1 Corrosion inhibitor 1 2 Schilling Chemie Varidos AP Corrosion inhibitor also suitable for aluminium 1 2 Benckiser Randophos HS Corrosion inhibitor Wassertechnik Universal Geminox Inibal Corrosion inhibitor suitable for aluminium 1 2 Frankreich Betz Dearborn Sentinel X 100 Corrosion inhibitor for hot water heating systems 1 1 Belgien also suitable for aluminium Fernox Copal Corrosion inhibitor also suitable for aluminium 1 Cillit Wassertechnik Cillit HS Combi Corrosion inhibitor 0 5 Other additives Fernox Restorer Superfloc Cleaning agent for sludge removal also suitable 1 2 Universal Cleanser for aluminium Fernox Superconcentrate Reduces limescale precipitation also suitable for Central heating aluminium Protector Table 8 48 7 181 465 347 01 07 Appendix 5 5 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 fac
115. off 6 7 ilnfo Select Info from the main menu gt Press 27 or amp J to switch Hot water immedi You can view the following information Display text Description Room tempera ture if TR 2 connected Current temperature in the room where TR 2 is installed Required room temperature if TR 2 connected Required temperature in room where TR 2 is installed Operating mode if TR 2 connected E g Heating Economy in Automatic mode or Economy Heating Frost protection in manual mode Max flow temp Maximum CH flow tempera ture set on the temperature control for CH flow Actual flow temp Actual CH flow temperature Required flow temp Required CH flow tempera ture Max HW temp Maximum permissible hot water outflow temperature Required HW Required hot water temper temp ature Actual HW temp Actual hot water outflow temperature Storage Tank Shows if hot water is charge released released or blocked or blocked Storage Tank Shows if hot water is on or charge on or off or Storage Tank charge afterrunning off or if the pump for the Storage Tank afterrunning is on Boiler operat mode winter summer Indicates which mode the CH flow temperature control is set to Burner on off Indicates whether the burner is alight or not Pump on off Indicates whether the inte gral pump is switched on or off
116. on that day To cancel Holiday mode early In the Holidays submenu Press the button until the display shows 0 26 6 720 610 604 GB 03 06 Text Display 4 5 Heating 4 5 1 Heating program Basic setting Automatic mode Theappliance switches automatically between normal heating Economy mode and Frost protection mode according to the timer settings entered Basic setting Heating starts at 6 00 am Economy starts at 10 00 pm Setting options Maximum of six switching points per day with three different operating modes Heating Economy Frost protection Same times for Monday to Friday Same times for Saturday and Sunday Different times for every day Setting switching times and operating mode From the main menu select Heating and then from the first submenu select Heating program Select Monday Friday Saturday and Sunday or an individual day of the week Monday Friday to have Heating and Economy or Frost protection switching on at the same times every weekday Saturday Sunday to have Heating and Economy or Frost protection switching on at the same times Saturday and Sunday Individual day of the week e g Thursday to have the rel evant program always switching on at the specified time on that day of the week i e Heating Economy or Frost protection at the same time every Thursday 6 720 610 604 GB 03 06 27 Text Displ
117. or replace if necessary gt oe CO level in combustion Ignition poor 48 gt 0 2 COs no 49 9 Flue gas CO levels measured yes gt Adjust levels min and max load do not match specified levels no 9 Measure CO levels 10 Burner not correctly fitted or defec Replace burner and seal if necessary tive Remove burner Cover fixings not tight or seal defective or not correctly fitted or burner defective Ensure seal is fitted in correct position 1 See installation instructions Loose or broken contact on heat store NTC sensor Check Action Heat store NTC sensor lead is not fit ted as described in the installation instructions i e the cable does not pass through the cable grip in the Switchbox Record condition of appliance as found in custo mer service record Route cable as specified in installation instruc tions Text display fails to respond no display or display incorrect Check Action Ignition lead is not fitted as specified in installation instructions i e the lead should be routed through the clip on the underside of the air box Route cable as specified in installation instruc tions 7 181 465 347 01 07 39 Rectifying faults Specified CH flow temperature from TA programmer exceeded Check Action are deactivated If outside
118. ormance AN after installation this boiler and its asso ciated central heating system must be flushed in accordance with the guide lines given in BS5793 1992 Treatment of water in domestic hot water central heating systems Remove packing taking care to observe the instruc tions on the packing Lie the boiler on its back Removing the outer case The outer case is secured against unau thorised removal by a retaining bracket electrical safety at the bottom left Always secure the outer case with this bracket again after refitting Remove retaining screw on left hand side 1 Press both catch levers backwards 2 14 6 720 610 602 GB 03 02 Installation Liftoffthe top fixing lugs and slide the case forwards and remove 3 2 1 oA 6 720 610 597 09 10 Fig 13 Fixing the appliance Fit the washers onto the gas and water connections gt Lift the boiler onto the wall mounting frame The lugs pass through the rectangular holes in the boiler back panel gt Take care not to disturb the washers on the connec tions Connecting the flue duct Fit flue duct connector onto appliance flue spigot Secure with the two screws supplied 6 720 610 332 09 2R Fig 14 gt For remaining installation of flue assembly refer to the relevant installation instructions 3 8 Checking the connections Water connections Check that the O ri
119. otate yellow button through 180 and replace dot facing inwards The CH flow temperature is no longer limited Control setting CH flow temperature 1 approx 35 C 2 approx 43 C 3 approx 51 C 4 approx 59 C 5 approx 67 C E approx 75 C max approx 88 C Table 12 7 2 Settings on the Bosch Heatronic 7 2 4 General description The text display module provides a convenient means of setting various appliance functions This description is limited to those functions necessary for commissioning see Service function Code no page Anti cycle time 2 4 32 Max CH flow temp 2 5 32 Max heating output 5 0 32 Constant hot water cycle 6 8 32 time Variable pump settings 7 0 32 Table 13 For a detailed description refer to Service Booklet for the Engineer 7 181 465 347 Displaying service functions All service functions are displayed Press any button to activate the main menu Press Sa or Ce button until the arrow cursor is pointing to Settings Press the C button Press Or fa y button until the arrow cursor is pointing to Service Press the C button gt Press the C button to select Display service parameters Service function 0 0 Last fault is displayed Pressthe a or fae button to cycle through the current settings gt Press the CSD button to exit the menu 6 720 610 602 GB 03 02 31 In
120. pecifies how long after hot water is drawn the pump continues to pump water through the internal hot water system 6 9 Duration hot water ZWBR only The appliance is supplied with the hot water duration set to 3 minutes The hot water duration specifies how long after hot water is drawn heating mode remains disabled 7 0 Pump map heating not ZBR The appliance is supplied with this function set to 4 Prop pressure high see pump characteristic boiler installation instructions The pump map indicates how the pump is controlled in heating mode The pump switches between the various pump speeds so as to reproduce the characteristic curve selected The current setting can be viewed by means of service function 7 4 Changing the pump characteristic can be helpful if a lower pressure difference will guarantee the necessary circulation on the basis of the system dimensions and pump characteristic see installation instructions In order to save as much energy as possi ble and to minimise the possibility of water circulation noise a low characteristic should be chosen If this parameter is set to O Pump step adjustable then the pump speed set under function 7 1 is active 7 1 Map pump step heat not ZBR The appliance is supplied with this function setto 1 see pump characteristic in boiler installation instructions However the setting is only active if function 7 0 Pump map heating
121. pply 230 V 50 Hz 140 Watts Mains cable PVC insulated 0 75 mm 24 x 0 20 mm to BS6500 Table 6 Temperature rated 100 C Protection IPX4D External fuse 3 A 4 1 Connecting the appliance To gain access to the mains connection remove the drop down facia cover The drop down cover is removed by lowering it to the horizontal position and pushing firmly upwards at the rear of the supports to release the cover Lift cover from the appliance After installation or in the event of an electrical fault the electrical system shall be checked for short circuits fuse failure incorrect polarity of connections earth con tinuity and resistance to earth Pull out cover panel at the bottom and remove Refer to fig 25 6 720 610 332 10 1R Fig 25 Remove screw and slide terminal cover forwards to remove Refer to fig 26 6 720 610 336 18 1R 20 6 720 610 602 GB 03 02 Electrical connections Cut cable grommet to diameter of cable 6 720 610 332 12 1R Fig 27 Feed cable through cable grommet and connect the mains supply cable see fig 28 Secure cable in cable grommet by means of cable grip 4130 14 1R Fig 28 4 2 Connecting TR2 Room thermostat The TR2 should be connected to terminals 3 4 and F beneath the Textdisplay page 8 fig 4 item 422 4 3 Mains Voltage external controls connections NOTE Only double insulated controls not req
122. r Temperature Hot water temperature On combi 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 10 Fig 6 Control Setting Water Temperature Anti clockwise limit approx 40 C e approx 55 C Clockwise limit approx 60 C Table 2 ECO button By pressing and holding the ECO button 0 until the display lights you can switch between Comfort mode and Economy mode Comfort mode button is not lit factory setting The appliance is held constantly at the set temperature This means that hot water is available almost instantaneously at the tap Consequently the appliance will switch on at intervals even if no hot water is being drawn 16 6 720 610 604 GB 03 06 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 Hot water is thus available in about 1 minute ECO mode button is lit Water is not heated up until hot water is drawn This means that there is a longer waiting period before hot water is available 3 6 System boiler with Storage Tank Do not set the temperature higher tha
123. r one heating circuit Variable pump Automatic ignition Modulating control Full safety systems incorporating Bosch Heatronic with flame ionisation monitoring solenoid valves and temperature sensors Concentric flue air duct with testing point for CO CO Regulated speed fan Pre mix burner Temperature control for central heating Temperature sensor in domestic hot water Safety temperature limiter in 24 V electrical circuit Relief valve pressure gauge expansion vessel Flue gas temperature limiter 105 C Hot water priority circuit Motorised 3 way valve Plate type heat exchange Condensate Trap 6 720 610 602 GB 03 02 Details of the appliance 1 4 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 37 or 13 m ZWBR 8 30 and vertical flue systems for flue lengths 12 m ZWBR 11 37 or 15m ZWBR 8 30 Fitting instructions are sent with these kits Heating programmer Security kit 1 5 Casing dimensions 6 720 610 602 01 30 Fig 1 13 Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System min 310 mm Alternative Concentric Flue System min 250 mm Y Standard Concentric Horizontal Flue System 158 mm Alternative Concentric Flue System 121 mm 2 Standard Concentric
124. r should be recommended to have the appli ance serviced regularly by a competent person Use only genuine spare parts Refer to the Spare Parts List when ordering spare parts Always renew seals and O rings removed during servicing or repair work Use only the following types of grease Water valve WRAS approved silicon based grease Unions approved sealant To drain the appliance shut the system valves and open the pressure relief valve Upon completion of any electrical work check for earth continuity correct polarisation and resistance to earth Replace the text display module or the Heatronic PCB lf t tio gt Ift he text display module is replaced the service func n settings are retained The remaining settings have to be re entered he Heatronic PCB is replaced Re enter the service function settings as recorded in the commissioning record 36 6 720 610 602 GB 03 02 Maintenance 9 1 Pre Service Check List Date 1 up the last fault stored by the text display see page 30 2 Check ionisation current Service Function 3 3 see page 38 3 Perform visual check of air flue duct Visual check of diaphragm for soiling and splits see page 40 4 Check gas supply pressure mbar see page 33 5 Test combustion air flue gas see page 35 6 Check setting for min min max gas air ratio see page 35 max 96
125. r to Appendix 22 7 181 465 347 01 07 Rectifying faults C 1 flashing Fan speed too low Check Action 1 Fan lead connector properly con nected yes 42 Power OFF the appliance Plug in connector Turn ON the appliance C6 l2 2 Fan lead defective yes Power OFF the appliance Replace fan lead Turn ON the appliance C6 43 no 43 3 Fan defective yes Power OFF the appliance Plug the connection wire Replace fan Plug the connection wire Turn ON the appliance C6 44 no 44 4 The control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 7 181 465 347 01 07 23 Rectifying faults Wrong signal from pin 8 9 Check Action 1 Jumper 8 9 fitted correctly yes 12 no Power OFF the appliance Fit jumper 8 9 correctly tighten screw Turn ON the appliance d3 12 2 gt Turn ON the appliance yes 43 Measure voltage between Termi fo l5 nal 4 and Terminal 8 24V DC 3 Heat store NTC sensor connected to yes Power OFF the appliance terminals 7 8 and 9 Plug heat store NTC sensor connector into PCB control board 303 page 46
126. roperty could result Warning indicates that minor personal injury or seri ous damage to property could result Danger indicates that serious personal injury could result In particularly serious cases lives could be at risk Notes are identified by the symbol shown on the left They are bordered by horizon tal lines above and below the text Notes contain important information in cases where there is no risk of personal injury or damage to property 7 181 465 347 01 07 Layout of Appl iance ZSBR ZWBR 1 Layo Automatic vent Fan connector Fan Mixer unit Silencer CH flow Gas supply pipe Flue gas safety temperature limiter Gas flow restrictor adju sting screw for CO max Gas valve adjusting screw for CO min ut of Appliance ZSBR ZWBR Testing points flue gas air Fan fixing Screws Burner fixing Screws Electrode assembly Flame sensing electrode Ignition electro des CH flow safety temperature limiter Inspection opening Variable charac teristic pump Plate type heat Change over exchanger valve ZWBR Hot water NTC sensor ZWBR Condensation trap Change over valve motor Transformer Water switch Heatronic ZSBR 4 7 181 465 347 01 07 Operation 2 Operation Instructions on
127. s N does appliance restart E9 15 no Connect flue gas safety temperature limiter lead gt Turn ON the appliance E9 15 26 7 181 465 347 01 07 Rectifying faults E 9 and flashing Safety temperature limiter has tripped Check Action 5 Power OFF the appliance yes Change the fuse Remove fuse SI 3 from appliance Turn ON the appliance PCB control board and test for gt Press N does appliance restart continuity E9 l6 Remount the fuse Turn ON the appliance 6 The PCB control board is damaged Power OFF the appliance Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection gt Turn ON the appliance 7 181 465 347 01 07 27 Rectifying faults EA and flashing During operation flame not detected Check Action 1 Is the flame present yes l6 no 12 2 Is the gas cock open yes 43 Open the gas cock gt Press N does appliance restart EA 43 3 Is there air in the supply pipe yes Vent supply pipe gt Press N does appliance restart EA 44 no 44 cock lock out 4 Did the thermical security of the gas yes Reset security Press N does appliance restart EA 45 no 45 do
128. s example the cursor is positioned next to the menu item Time day holidays 6 720 610 604 GB 03 06 21 Text Display gt Confirm the selection by pressing the 2 button The corresponding submenu is displayed Select gt Time day Holidays 6 720 610 598 05 20 Fig 10 Submenu Time day In the submenus the top line indicates what action is required The bottom line shows the previous menu level if applicable see Fig 10 gt Use the or 9 button to select Time day gt Confirm the selection by pressing the button The corresponding submenu is displayed Hour 4 gt mon Monday Time day 6 720 610 598 06 20 Fig 11 Setting the hour When settings are being entered the setting to be altered is indi cated on the top line In addition the setting being altered is dis played with a dark background gt Use the a or button to set the hour Press and release to change the display by one unit at a time Press and hold to change the display rapidly gt Confirm the setting by pressing the gt button 22 6 720 610 604 GB 03 06 Text Display Use the or 9 button to set the minutes Confirm the setting by pressing the button Use the or 77 button to set the day of the week Press the button to confirm the setting The cursor then returns to the top line vow or gt Press the CSD button to confirm th
129. s oper ating in the central heating mode 6720610 333 04 10 Fig 4 If the display alternates between Il and the cen tral heating flow temperature the trap filling pro gramme is active 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 Switch off the appliance at the master switch 0 The green indicator lamp goes out The optional timer will con tinue running until the emergency supply is exhausted 14 6 720 610 604 GB 03 06 Operating the Appliance 3 8 Switching on the Central Heating 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 10 Fig 5 3 4 Controlling Central Heating Setthe timer to the correct time Setroom thermostat to the desired room temperature Settemperature driven control unit if fitted Refer to the instructions with the control Setthe thermostatic radiator valves to the desired settings 6 720 610 604 GB 03 06 15 Operating the Appliance 3 5 Combination Boilers Setting the Hot Wate
130. s the C button to confirm the setting The 6 3 Menu structure cursor then returns to the top line Or Submenu gt Press the CSD button to confirm the setting and Main Parameters to return to the previous menu fig 37 page 26 menui 8 change seloct amp P 9 pag Time Hours 28 Or day holi Minutes Do not press any other buttons for 15 minutes days Day of week Holidays Days holiday 28 6 2 1 Deleting a setting Heating Heating Day 28 Either overwrite the setting or press the button to oe deu AUR 1st switching point delete it E Find the setting to be deleted Gth switching point Set econ 5 30 C 28 Press and release the C button omy The display shows temp if TR2 is 6 22 Resetting all parameters to their original con settings nected Manual Automatic 29 The hours of service can not be reset to O if TR2 is Constant on not con comfort nected Constant off economy Press and hold the C button for more than 15 sec Hot Hot Day 29 onds water water 1st operating mode After about 5 seconds the following message program 1st switching point appears on the display Late dnd pat ATTENTION Il Hot Off On 29 De ete all parameters water in x seconds immedi Once the reset has been completed the following ately message is displayed Info 29 Please wait Initialising Settings Heating Optimum Start Off 30 On Hot Only charging times
131. ssembly should be in accordance with the requirements of the local water company Artificially softened water must not be used to fill the central heat ing system An isolating valve should be fitted to allow for servicing Devices such as water meters or back flow pre vention valves capable of preventing the flow of expansion water must not be fitted unless sepa rate arrangements have been made A Zilmet Z160 expansion vessel is the preferred type A thread sealant compatible with potable water must be used The vessel should be connected into the cold water mains inlet pipe as close as possible to the appli ance 3 3 Sealed systems The appliance must not be operated without the system being full of water properly vented and pressurised The expansion vessel has a volume of 10 litres and is charged to a pressure of 0 75 bar The water capacity of the system is shown in table 11 page 31 greater capacity is required then an addi tional expansion vessel must be fitted into the system return as close to the appliance as possible The system pressure can be set up to a maximum of 1 5 bar with 1 bar being the normal setting If the system pressure is greater than 2 5 bar when the appliance is operating at maximum temperature then an additional expansion vessel must be fitted into the sys tem return as close to the appliance as possible The filling point must be at low level and arranged as shown in figs 5 and 6 Th
132. st protection Combi Appliances Leave master switch switched on If the appliance is to be left for long periods switch the central heating on and set the room temperature controller at 6 C gt 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 Fernox Tel 01799 550811 and Salamander Tel 0121 378 0952 3 9 Fault Condition In the unlikely event of a fault occuring while the appliance is in operation The display and the text display then shows a fault code and the button D may also flash If the button D flashes Press and hold the button D until the display shows The appliance will then start up again and the display will show the central heating flow temperature If the button D does not flash gt Switch the appliance off and then on again at the master switch The appliance will start up again and the central heating flow temperature will be displayed If the fault remains and can not be cleared Call British Gas for assistance giving a description of the fault and if possible the fault code from the facia display 6 720 610 604 GB 03 06 19 Text Display 4 Text Display 4 1 General Description The text display is used to display information about the appli ance and the system and to alter the settings displayed Once the appliance has been in operation for one day the text
133. stem 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 sion duct assemblies NOTE Flue lengths between 650 mm and 730 mm cannot be accomodated Refer to fig 17 18 19 Standard system comprise Flue turret Flue turret clamp Terminal assembly Wall sealing plates Extension kit comprises Air duct Flue duct Duct clamp Refer to fig 20 Instructions for fitting other flue systems are packed with the relevant flue kit Check that the position chosen for the appliance is sat isfactory Refer to fig 16 Drilling point for flue duct opening Centre line of flue air duct N Centre line of flue opening and appliance Appliance Standard Horizontal Flue 158 mm Optional Horizontal Flue 121 mm 6 720 610 602 07 20 Fig 16 Marking the position of the side flue opening Terminal Assembly Turret Maximum 650 mm 6 720 610 602 08 10 Fig 17 Standard Flue 6 720 610 602 GB 03 02 17 Installation Terminal Assembly Turret Maximum 1600mm Clamp Extension Duct 6 720 610 602 09 10 Fig 18 Flue with One Extension Terminal Assembly Flue Turret i Extension Clamp sees Dic 6 720 610 602 10 10 Fig 19 Flue with Extensions Duct Clamp H Flue Extension Air Duct Turret Extension Flue Duct Terminal Assembly Wall Sealing
134. store NTC sensor constant hot water NTC sensor and hot water NTC sensor 45 5 2 Electronic schemes 46 5 3 List of most important replacement parts 47 5 4 Approved corrosion inhibitors and anti freeze fluids for central heating water 48 5 5 Detecting corrosion by CFCs 49 2 7 181 465 347 01 07 Safety precautions Safety precautions Repairs Repairs may only be carried out by an approved installer Before carrying out any work on the appliance Switch it off at the master switch gt Even when the appliance is switched off at the mas ter switch some components on the PCB control board inside the control box are still live Therefore Before carrying out any work on the electrical parts of the appliance fully disconnect it from the power supply e g by means of fuse or circuit breaker Flue ducting must not be modified in any way Use only original spare parts Instructions to the customer Advise the customer that he she must not make any modifications to the appliance or carry out any repairs on it Draw attention to the need for an annual service or maintenance contract if applicable Symbols Safety instructions in this document IN are identified by a warning triangle sym bol and are printed on a grey back ground Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions Caution indicates that minor damage to p
135. sure Fill the system using the WRAS approved filling loop The pointer on the pressure gauge should be 1 bar If the pointer is below 1 bar when the system is cold water should be added until the pointer is 1 bar again Max pressure of 2 5 bar when the heating system water is at maximum temperature must not be exceeded If this pressure is exceeded then an extra expansion vessel must be fitted in the system return as close to the appliance as possible gt Ifthe system does not retain the pressure the expan sion vessel and the heating system should be checked for leaks 9 3 Replacement of Parts Before changing any components check that the gas is turned off and that the appliance is electrically isolated When necessary close the system valves and drain the appliance Refitting is a reverse of the procedure for removal using new seals or o rings as appropriate 9 3 1 PCB control board and transformer Switch off the appliance Disconnect appliance from the power supply v Unplug all connectors from the control box inc keyed plug Access is gained by removing the cov ers Refer to fig 25 26 Remove screw holding power connector earth lead and remove earth lead v v Remove two top fixing screws from the control box Refer to fig 55 7 181 465 330 09 1R Fig 55 Lower the control box Unscrew earth lead Unscrew four fixing screws from cover plate Refer to fig
136. t display is used to display information about the appliance and the system and to alter the set tings displayed Once the appliance has been in operation for one day the text display module has a power buffer period of about 10 hours during which it will run with out the mains power supply After that period has elapsed the clock function shuts down but all other settings are retained 6 2 Programming _ D O 6 720 610 337 08 1R Fig 35 Controls a Display b Up More button c Down Less button d Back button e Next button f Delete button The standard display shows the following information Time Room temperature if TR 2 connected CH flow temperature Domestic Hot Water temperature ZSBR if a Stor age Tank is accorded Additional indication if a special programme is active xholidays Hot water immediately Constant on comfort if TR2 is not connected Constant off economy if TR2 is not connected Other special operating modes may be displayed dur ing commissioning servicing etc The programming procedure is described in detail below using the clock function as an example To start programming press any button e g C The display lighting switches on and the main menu is displayed gt idays Heating Hat water i lnfo Settings 6 720 610 598 04 20 Fig 36
137. t from your appliance please read these instructions 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 Check regularly that the pressure is maintained and contact your installer or maintenance engineer if there is a permanent signifi cant drop in the pressure If the system loses pressure it should be repressurised and the cause of the fall investigated 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 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 Condensate drain This is a condensing appliance and the terminal will at times give out a plume
138. t the tap Consequently the appliance will switch on at intervals even if no hot water is being drawn 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 sig nals demand to the appliance which then heats up the water to the set temperature Hot water is thus available in about 1 minute ECO mode button is lit Water is not heated up until hot water is drawn This means that there is a longer waiting period before hot water is available 5 5 2 Hot water flow rate The flow rate is factory set to 8 l min Under standard conditions 2 bar supply pressure one full turn is equivalent to approximately 2 l min gt To increase the flow rate max 14 l min turn screw on flow switch anti clockwise The outlet temperature will decrease relative to the increase in the flow rate To reduce the flow rate min 8 l min turn screw on flow switch clockwise The outlet temperature will increase relative to the decrease in the flow rate 6720 610 332 25 10 5 6 Summer mode hot water only With room thermostat gt Turn temperature control on the appliance anti clockwise as far as the stop The central heating is now turned off The hot water function and the mains power supply for the heating programmer and timer remain switched on 5 7 Frost protection Leave master switch switched on
139. t water flow rate 24 9 3 10Pressure gauge 44 5 6 Summer mode hot water only 24 9311 44 9 7 Frost protection 24 9 3 12Pressure Relief Valve 44 5 8 Pump anti seize function 24 9 3 13Bumer 44 5 9 Fault Condition 25 9 3 14Flow switch 45 9 3 15Primary Heat Exchanger 45 6 Text Sp ey 26 6 1 General Description 26 10 Appendix 46 6 2 Programming 26 10 1 Fault Codes 46 6 2 1 Deleting a setting 27 10 2 Short parts list 47 6 2 2 Resetting all parameters to their 10 3 Heating hot water output settings original settings 27 ZWBR 8 30 N G 48 6 3 Menu structure 21 10 4 Heating hot water output settings 6 4 Setting the time day 28 ZWBR 11 30 LP G 48 6 4 1 Setting the time and day 28 10 5 Heating hot water output settings 6 4 2 Holidays 28 ZWBR 11 37 N G 48 6 5 Heating 28 10 6 water output settings 6 5 1 Heating EL 28 ZWBR 14 37 LP G 48 6 5 2 Setting the Economy temperature 10 7 Operational diagrams 49 653 28 10 7 1 Domestic hot water function 49 if TRU is not connected 29 10 7 2Central heating function 50 2 6 720 610 602 GB 03 02 Safety precautions Safety precautions If you smell gas Turn off gas service cock at the meter Open windows and doors Do not operate any electrical switches Extinguish any naked flames Telephone your gas company If you smell fumes from the appliance Switch off appliance see page 23 Open windows and doors Fitting and modifications Fittin
140. tem If this channel s status is Heat demand heating mode will be activated according to the programmer com mands Heat demand stor tank shows the heat demand sta tus for charging the heat store If this channel s status is Heat demand the heat store will be charged according to the commands from the heat store thermostat or NTC sensor 4 5 Heat demand hot water Keep hot period ZWBR models only Heat demand hot water shows the heat demand sta tus for the hot water function If this channel s status is Heat demand the hot water function operates according to the commands from the hot water NTC sensor Keep hot period shows the constant hot water circuit status of the heat exchanger ECO or Comfort mode If this channel s status is Heat demand Comfort mode is active If the status is Disabled ECO mode with demand detection is active 4 6 Internal regulator The boiler has an internal anti cycle function which pre vents the burner overheating if the heat output can not be dissipated even in Min mode The appliance will then switch off even when the system is calling for heat It will subsequently switch on again after 5 seconds in hot water mode after 30 seconds in heat store charging mode after O to 15 minutes in heating mode depending on the setting for service function 2 4 Anti cycle mode The anti cycle function is cancelled by switching the appliance off
141. th a correspond ing reduction in flue length of 2 m for each 90 bend and 1 m for each 45 bend used IMPORTANT Any horizontal flue system fitted to a condensing boiler must incline towards the appliance at an angle of 3 30 mm per metre length to prevent condensate dripping from the flue terminal This means that the clearance above the appliance must be increased to match the duct length Refer to fig 1 on page 5 6 720 610 602 GB 03 02 Installation 3 9 1 Siting the Flue Terminal The flue must be installed in accordance with BS 5440 1 and the Building Regulations Flue termi nals in carports and under balconies are to be avoided The terminal must be positioned so that it does not cause an obstruction nor the combustion products a nuisance See fig 15 and table 9 The terminal will at times give out a plume of water vapour and consideration must be given to this when choosing a terminal position Keep clear of security lighting activated by passive infra red sensing heads If the terminal is less than 2 m above a surface to which people have access then a guard must be fitted The guard must be evenly spaced about the terminal with a space of 50 mm in each direction and fixed with plated screws A guard Type K6 for the standard horizontal flue can be obtained from Tower Flue Components Vale Rise Ton bridge TN9 1TB 6 720 610 602
142. the end of the 20 pin connector lead assembly After max 60 sec Change heat store NTC sensor 2 Plug the connection wire Turn ON the appliance A7 13 Display changes to temperature between 100 and 95 no Change the 20 pin connector lead assembly 13 3 Temperature between 95 and 100 is yes Power OFF the appliance displayed Change heat store NTC sensor 2 Unplug the connector After max 60 sec Does the displayed code change Plug the connection wire gt Turn ON the appliance to a value between 0 and 5 A7 14 no 14 4 gt Unplug the 20 pin connector lead yes Change the 20 pin connector lead assembly assembly from the Heatronic no Power OFF the appliance After max 60 sec Does the displayed code change to a value between 0 and 5 Disconnect the boiler electrical connection Change PCB control board Reconnect the boiler electrical connection Turn ON the appliance 1 For notes refer to Appendix 7 181 465 347 01 07 Rectifying faults A 7 flashing Hot water NTC sensor defective After max 60 sec Does the displayed code change to a value between 0 and 5 Check Action 1 Activate menu option yes Is the connector for hot water NTC sensor corro Show service parameters ded damaged or dirty Replace affected com gt Select ponents
143. tighten screws to torque of approx 5 Nm Burner gt Check that the gas cock is turned off and the master switch is in the OFF position Remove the clips 1 and unscrew the two bolts 2 Refer to fig 50 Unscrew and remove the two hexagon screws secur ing the fan 3 Slacken fully the rear securing bolt 4 Remove the burner coverplate 1 1771 181 465 330 04 1R Remove the burner skin and clean components Do not use a wire brush Refer to fig 51 N Fig 51 AN 7 181 465 330 08 1R Re assemble burner in reverse order using a new seal Adjust gas air ratio Refer to section 8 2 6 720 610 602 GB 03 02 39 Maintenance Condensation trap In order to prevent spillage of condensate the conden sation trap should be completely removed see page 38 fig 46 Unscrew condensation trap and check connection to heat exchanger is clear Remove condensation trap cover and clean gt Fill condensation trap with approx 1 4 of water and refit Electrode assembly Switch off the master switch Pull off the leads from the electrodes Refer to fig 2 Unscrew the two fixing screws and carefully remove the electrode assembly Refer to fig 45 Clean the electrodes with a non metallic brush The spark gap should be 4 5 mm 0 5 mm Replace and re connect the assembly taking care not to mislay the inspection window Diaphragm in mixer u
144. trol boiler set too low no 13 3 Air in the heating system Power OFF the appliance Check appliance and system for water leaks and repair as necessary Top up system gt Activate menu option Show service parame ters Select 7 3 Aeration mode select setting On autom deactivat and confirm Vent appliance gt Vent radiators gt Turn ON the appliance 1 See installation instructions 7 181 465 347 01 07 41 Rectifying faults Set room temperature not reached Check Action 1 Thermostatic valve s set too low yes Turn up thermostatic valve s 42 no 42 2 Heating characteristic set too low yes Correct heating characteristic V3 no V3 3 CH flow temperature control on yes Turn up CH flow temperature control boiler set too low V4 4 Heat store connected via HSM yes 45 no 5 Is heat store temperature unreacha yes Turn up CH flow temperature control ble CH flow temperature control set too low 6 Air in the heating system Power OFF the appliance Check appliance and system for water leaks and repair as necessary Top up system gt Activate menu option Show service parame ters Select 7 3 Aeration mode select setting On autom deactivat and confirm Vent appliance Vent radiators Turn ON the appliance
145. ttons until the display shows r2 followed by 1 To reset all parameters except service settings set on the text display module Press and hold the C button until the settings are deleted 7 181 465 347 01 07 Boiler service functions 3 Boiler service functions 3 1 Summary Range adjustable Reset Text display message Display from to Value 0 0 Last fault 00 FF Clear only 0 0 1 Flow temp sensor 0 99 C 0 2 Hot water temp sensor 0 99 C 0 3 Stor tank temp sensor1 0 99 C 0 4 Stor tank temp sensor2 0 99 C 1 2 Code plug 8714411 XXX 0 255 1 5 Required flow temp 0 99 C 1 9 Module detection no module detected bus module 2 0 Operating mode normal normal Min Max 2 2 Pump switch mode 1 3 2 2 3 Stor tank charge output 0 100 100 2 4 Anti cycle mode 0 15 min 3 min 2 5 Max flow temperature 35 88 C 88 C 2 6 Switch diff flow temperature 0 30 C 0 C 2 7 Autom anti cycle mode on on off 2 9 Actual output 0 100 96 3 0 Fan speed 255 U s 3 3 lonisations current no low middle high 3 4 Pump mode 0 3 o 3 5 Pump blocking time 0 240s Os in 15 s increments 3 6 Software version BF 11 XX Table 1 6 7 181 465 347 01 07 Boiler service functions Range adjustable Reset Text display messag
146. uiring an earth can be used Programmer Connections Series connection to be made safe E 6 720 610 576 22 10 Fig 29 Note If an external timer is used then the domestic hot water pre heat facility can only be isolated by actuating the ECO button 6 720 610 602 GB 03 02 21 Commissioning 5 Commissioning 6 720 610 597 05 10 Fig 30 81 Pressure gauge 5 1 Commissioning 15 Safety valve 27 Automatic vent 61 Reset button Never run the appliance when empty or 135 Master switch AN unpressurised 136 Temperature control for central heating 170 Service cocks on CH flow and return 1 atomi dn oft position The operational level is set at the fac 173 Cold water service cock tory and no adjustment is necessary when 295 Appliance type sticker installing a natural gas fired appliance 310 Temperature control for hot water 317 Multifunction display Benchmark Water Treatment For optimum perform 358 Condensation trap 853 Indicator lamp for burner ance after installation this boiler and its associated cen 364 Indicator lamp for power supply tral heating system should be flushed in accordance 365 Chimney sweep button with the guidelines given in BS7593 1992 Treatment 366 Service button of water in domestic hot water systems Full instruc 267 ECO Dutton t
147. ura bly dimensioned heating systems If automatic adjustment of the anti cycle time is disa bled the length of the anti cycle time must be set under service function 2 4 If automatic adjustment of the anti cycle time has been disabled this should be entered on the com missioning record enclosed with the appliance 2 9 Actual output The actual output of the appliance at the time viewed is displayed 3 0 Fan speed The current fan speed is displayed 3 3 lonisation current The burner flame is monitored by measuring the ionisa tion current generated during combustion If no ionisa tion current is detected the gas valve shuts off This ensures that unburned gas does not escape 3 4 Pump mode ZBR models only The possible settings are Pump mode 1 if a heating pump and a 3 way valve for charging the heat store are connected The 3 way valve is de energised when the heat store circuit is open Pump mode 2 factory setting if a circulation pump and a heat store charging pump are con nected In ECO mode if the circulation pump and the heat store charging pump call for heat simultane ously the system alternates between 12 minutes heating and 12 minutes hot water Pump mode 3 if a circulation pump and a heat store charging pump are connected In ECO mode if the circulation pump and the heat store charging pump call for heat at the same time both pumps run simul taneously The heat store chargi
148. ure rise of 40 C If a higher rise is required then the flow must be reduced at the tap and the discharge temperature will rise up to the maximum set figure The temperature rise upto the maximum set by the user is automatically maintained by the modulation of the heat input In winter when the mains temperature is very low the water flow adjusted at the tap or shower should be reduced to maintain the required delivery temperature It is suggested that long pipe runs to taps or showers be insulated to prevent the rapid cooling of the water All types of single lever mixer taps and thermostatic mixer units suitable for a mains pressure of up to 10 bar can be used The head of a loose head shower must not be allowed to fall within 25 mm of the top the bath to prevent the risk of water being drawn back into the mains Alterna tively the shower must be fitted with an anti syphonage device at the point of the flexible hose connections Over rim bidets may be connected to the appliance provided that it is in accordance with the requirements of the local water company The outlet s should be shrouded and unable to have any temporary hand held spray attached No anti syphonage arrangements are necessary In exceptionally hard water areas a device to prevent scale formation may be fitted or alternatively the maxi mum temperature reset to about 45 C which may reduce the risk of scale formation The installation of a scale inhibitor a
149. w you know how to heat your home economically with the RD 532i RD 537i RD 542i RD 430i gas condensing boiler If you have any other questions please contact your installer or write to us 7 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 Service 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 11 item 295 Your installer will have completed the Benchmark log book giv ing details of the boiler together with name address and registra tion number Have the log book to hand when calling a Service Engineer 6 720 610 604 GB 03 06 39 Maintaining your appliance 8 Maintaining your appliance Your new RD 532i RD 537i RD 542i RD 430i gas fired appli ance 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 To arrange for a British Gas three star cover agreement please call 0845 9 60 50 40 9 Service If your RD 532i RD 537i RD 542i RD 430i appliance should fail to operate corre
150. waste system No length restriction The gradient of the discharge pipe Invert should be 2 5 40 mm m minimum The rainwater system 6 720 610 596 03 10 Fig 11 Whilst all of the above methods are acceptable it is always the best practice to terminate the condense pipe via an internal waste system This will eliminate the need for any external condensate pipe runs which can be susceptible to freezing in extreme weather 6 720 610 602 03 10 Fig 12 Position of the condensate drain External condensate pipework All British Gas Bosch condensing boilers have within a syphonic condensate trap Rather than the condensate constantly dripping into the discharge pipe the con densate is collected into a trap which releases it in 100 ml quantities This will help prevent freezing occurring If there is no alternative and the condensate pipe has to be externally run the following should be considered The pipe run should take the shortest practical route The pipework should be insulated with weather resistant insulation e The pipe should terminate as close as possible to the ground or drain whilst still allowing the condensate to safely disperse This would prevent wind blowing up the pipe The pipework should be installed with the minimum of horizontal runs and with a downward slope of at least 2 5 3 7 Fitting the appliance Benchmark For optimum perf

British Gas - ICC2

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