Datasheet | Bosch Greenstar 131 Technical data

ENGINEER‘S SERVICE BOOKLET

FLOOR MOUNTED & WALL HUNG RSF GAS FIRED CONDENSING BOILERS

GREENSTAR CDi RANGE

FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER

This Service booklet covers the following boiler ranges:

CDi Combi N.G.

CDi Combi L.P.G.

CDi System N.G.

CDi System L.P.G.

CDi Regular N.G.

CDi Regular L.P.G.

Highflow CDi N.G.

Highflow CDi L.P.G.

FS CDi Regular N.G.

FS CDi Regular L.P.G.

UK/IE

2

TABLE OF CONTENTS

TABLE OF CONTENTS

1 Explanation of symbols and safety precautions 3

1.1

Explanation of symbols . . . . . . . . . . . . . . . 3

1.2

Safety precautions . . . . . . . . . . . . . . . . . . 3

2 layout of boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1

CDi Combi boilers . . . . . . . . . . . . . . . . . . . 4

2.2

CDi System boilers . . . . . . . . . . . . . . . . . . 6

2.3

CDi regular boilers . . . . . . . . . . . . . . . . . . 8

2.4

Highflow CDi Combi boiler . . . . . . . . . . . 10

2.5

FS CDi Regular boilers . . . . . . . . . . . . . . 11

3 OPERATION - CDi . . . . . . . . . . . . . . . . . . . . . . . 12

3.1

Initialisation . . . . . . . . . . . . . . . . . . . . . . . 12

3.2

Display messages . . . . . . . . . . . . . . . . . . 12

3.3

Operating elements CDi (Wall hung) . . . 13

3.4

First service level . . . . . . . . . . . . . . . . . . 13

3.5

Second service level . . . . . . . . . . . . . . . . 13

3.6

Resetting service functions to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.7

Select max. or min. heat output . . . . . . . 14

3.8

Reset the appliance . . . . . . . . . . . . . . . . . 14

4 OPERATION - HIGHFLOW CDi and FS CDi

REGULAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1

Initialisation . . . . . . . . . . . . . . . . . . . . . . . 15

4.2

Display messages . . . . . . . . . . . . . . . . . . 15

4.3

Operating elements . . . . . . . . . . . . . . . . . 16

4.4

First service level . . . . . . . . . . . . . . . . . . 16

4.5

Second service level . . . . . . . . . . . . . . . . 16

4.6

Resetting service functions to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.7

Select max. or min. heat output . . . . . . . 17

4.8

Reset the appliance . . . . . . . . . . . . . . . . . 17

5 Boiler service functions - CDi Combi & System boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.1

First service level . . . . . . . . . . . . . . . . . . . 18

5.2

Second service level. . . . . . . . . . . . . . . . . 19

5.3

Explanation of service functions . . . . . . . 19

6 Boiler service functions CDi, Highflow CDi

& FS CDi Regular . . . . . . . . . . . . . . . . . . . . . . . . 23

6.1

First service level . . . . . . . . . . . . . . . . . . . 23

6.2

Second service level. . . . . . . . . . . . . . . . . 24

6.3

Explanation of service functions . . . . . . . 25

7 Rectifying faults . . . . . . . . . . . . . . . . . . . . . . . . 27

7.1

Indication of faults . . . . . . . . . . . . . . . . . 27

7.2

Summary . . . . . . . . . . . . . . . . . . . . . . . . . 27

7.3

Notes on using the fault code tables . . . . 28

7.4

Error codes on the display . . . . . . . . . . . 29

7.5

Faults that are not displayed . . . . . . . . . 52

8 Troubleshooting - FW 100 . . . . . . . . . . . . . . . . . 58

8.1

Troubleshooting using the display . . . . . . 58

8.2

Troubleshooting without the display . . . . 62

9 Troubleshooting - FR110 . . . . . . . . . . . . . . . . . . 63

9.1

Troubleshooting using the display . . . . . . 63

9.2

Troubleshooting without the display . . . . 67

10 Troubleshooting - RT10 . . . . . . . . . . . . . . . . . . . 68

11 Troubleshooting - TD 200 . . . . . . . . . . . . . . . . . 69

12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

12.1 NTC sensor values, CDi appliances . . . . . 71

12.2 CDi fan speeds . . . . . . . . . . . . . . . . . . . . 71

12.3 Highflow CDi &

FS CDi Regular fan speeds . . . . . . . . . . . .71

12.4 NTC sensor characteristics Highflow CDi & FS

CDi Regular appliances . . . . . . . . . . . . . . .72

12.5 Electrical wiring diagrams . . . . . . . . . . . . 73

12.6 Code plugs used with CDi appliances . . . 78

12.7 Code plugs used with Highflow CDi & FS CDi

Regular appliances . . . . . . . . . . . . . . . . . .78

12.8 Approved corrosion inhibitors and anti-freeze for central heating water . . . . . . . . . . . . .79

12.9 Possible sources of corrosive CFCs . . . . . 79

8 716 115 748 (2009/09)

EXPLANATION OF SYMBOLS AND SAFETY PRECAUTIONS

1 EXPLANATION OF SYMBOLS AND SAFETY PRECAUTIONS

1.1

EXPLANATION OF SYMBOLS

WARNING SYMBOLS

Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background.

Electrical hazards are identified by a lightning symbol surrounded by a warning triangle.

Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions.

•

NOTICE indicates possible damage to property or equipment, but where there is no risk of personal injury.

•

CAUTION indicates possible personal injury.

•

WARNING indicates possible severe personal injury.

•

DANGER indicates possible risk to life.

IMPORTANT INFORMATION

Notes contain important information in cases where there is no risk of personal injury or material losses and are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.

ADDITIONAL SYMBOLS

•

Symbol

B

Æ

–

Tab. 1

Meaning a step in an action sequence a reference to a related part in the document or to other related documents a list entry a list entry (second level)

1.2

SAFETY PRECAUTIONS

IF YOU SMELL GAS

B Do not smoke or strike matches

B Do not turn electrical switches on or off

B Put out naked flames

B Open doors and windows

B Keep people away from the affected area

B Turn off the control valve at the meter

B Call your gas company or

B Call 0800 111 999

BOILER OPERATION:

This appliance must only be operated by a responsible adult who has been instructed in, understands and is aware of the appliance‘s operating conditions and effects.

HEALTH AND SAFETY

The appliance contains no substances that contravene the COSHH Regulations (Control of Substances

Hazardous to Health regulations 1988).

COMBUSTIBLE AND CORROSIVE MATERIALS

Do not store or use any combustible materials (paper, thinners, paint etc.) inside or close to the appliance.

Chemically aggressive substances, such as halogenated hydrocarbons.

The presence of halogenated hydrocarbons in the combustion air causes surface corrosion on affected metals.

In order to limit the damage, the source of the air contamination must be located and sealed off. If this is not possible, the combustion air must be drawn from an alternative clean source.

FITTING AND MODIFICATION

Fitting the appliance and any controls to the appliance must only be carried out by a competent engineer in accordance with the current Gas Safety (installation and use) Regulations.

SERVICING

Advise the user to have the system serviced annually by a competent, qualified engineer, such as British gas or

Gas safe registered personnel, using approved spares.

This will help to maintain the economy, safety and reliability of the appliance.

8 716 115 748 (2009/09) 3

LAYOUT OF BOILER

2 LAYOUT OF BOILER

2.1

CDi COMBI BOILERS

6 72

0 611

927

-09.1

O

29

28

27

26

1

2

3

4

5

25

24

18

17

23

22

21

20

19

16

Fig. 1 CDi combi layout

13

14

15

9

10

11

12

7

8

5

6

3

4

1

2

Flame viewing window

Ignition electrode and flame sense electrode

Heat exchanger

Overheat thermostat

Access point for cleaning heat exchanger

Plate to plate DHW heat exchanger

Pump

System pressure gauge

Drain point

Mains cold water in

CH return

Charging link assembly

Gas inlet connection 22 mm compression

Cover for external wiring connections

Control panel in service position

4

15

14

13

8

9

10

11

12

6

7

16 Access cover for transformer & PCB

17 DHW out

18 CH flow

19 Trap / syphon outlet connection (22 mm plastic pipe)

20 Inlet pressure test point

21 Trap / syphon

22 Gas valve

23 DHW temperature sensor

24 Air / gas adjustment screw

25 Testing point for fan pressure

26 Fan

27 Primary sensor

28 Expansion vessel

29 Removable top case panel for servicing

8 716 115 748 (2009/09)

41

42

43


48

40

6

39

38

37

36

32

48

46

47

44

9

45

55

54

53

52

61

60

59

58

57

56

8 716 115 748 - 01.1Wo

49 50

51

Fig. 2 This diagram shows the compact hydraulics and controls with the mantel and fascia panel removed

6 Plate to plate DHW heat exchanger

9 Drain point

32 Pump, modulating

36 Flow turbine

37 Unused port

38 Return connection to boiler heat exchanger

39 Auto air vent

40 Flow connection from boiler heat exchanger

41 DHW sensor

42 CH flow connection to isolation valve

43 DHW out connection

44 Cold water in connection

45 CH return connection to isolation valve

46 Diverter valve housing

47 Pressure relief valve

48 Compact hydraulic mounting screw (2) to boiler

49 CH temperature control

50 Mains on/off indicator/diagnostic light (blue)

51 DHW temperature control

52 Central heating boost button

53 Service button

54 Burner on indicator light (green)

55 Master switch on/off

56 Holiday button

57 ECO button

58 Fault reset button

59 Display

60 System pressure gauge

61 Position for optional programmer

8 716 115 748 (2009/09) 5


2.2

CDi SYSTEM BOILERS

6 720

612 458-02.

1O

24

23

22

21

20

19

18

17

16

15

14

13

Fig. 3 CDi System layout

6

7

4

5

1

2

3

8

9

10

11

12


Ignition electrode and flame sensing electrode

Heat exchanger

Overheat thermostat


Pump


Drain point

Central Heating return

Gas inlet connection (22mm compression)



6

1

2

3

4

5

6

7

8

9

12

11

10

13 Access cover for transformer and PCB

14 Central Heating flow

15 Trap /Syphon outlet connector (22mm plastic pipe)

16 Inlet pressure test point

17 Trap / Syphon

18 Gas valve

19 Air / Gas adjustment screw

20 Test point for fan pressure

21 Fan

22 Primary sensor

23 Expansion vessel

24 Removable top panel for servicing

8 716 115 748 (2009/09)

36


25

26

35

34

33

27

28

29

30

25

31

32

49

48

47

46

45

37

38

39

40

41

44

43 42 8716115 748-04.1Wo

Fig. 4 This diagram shows the compact hydraulics and controls with the mantel and fascia panel removed

25 Compact hydraulic mounting screw (2) to boiler

26 Flow unit

27 Auto air vent

28 Return connection to boiler heat exchanger

29 Unused port

30 Pump

31 Pressure relief valve

32 Diverter valve housing

37

38

39

40

33 Central Heating return connection to service valve

34 Drain point

35 Internal bypass within plastic moulding

36 Central Heating flow connection to service valve


Display

Fault reset button

ECO button

41 Holiday button


43 Power ON/OFF indicator / diagnostic light (blue)

44 Central Heating temperature control

45 Position for option controller

46 Central heating boost button

47 Service button

48 Burner on indicator light (green)

49 Power ON/OFF switch

8 716 115 748 (2009/09) 7


2.3

CDi REGULAR BOILERS

23

22

21

20

19

18

17

16

15

14

6

7

8

9

13

10

12

11

8716115748-05.1Wo

Fig. 5 The diagram shows the controls in the service position with the mantle and fascia panel removed

1

2

3

4

5

8 8 716 115 748 (2009/09)


33

32

31

30

29 28

Fig. 6 Front of the control panel

28

29

30

31

24

25

26

27

32

33

20

21

22

23

16

17

18

19

12

13

14

15

8

9

10

11

6

7

4

5

1

2

3


Ignition electrode and flame sense electrode

Heat exchanger

Overheat thermostat


Condensate hose

Drain point

Trap / syphon outlet connection (22 mm plastic pipe)

CH return

Gas inlet connection 22 mm compression



Access cover for transformer & PCB

CH flow

Inlet pressure test point

Trap / syphon

Gas valve

Air / gas adjustment screw

Testing point for fan pressure

Fan

Primary sensor

Auto air vent

Removable top case panel for servicing

Display

Fault reset button

Non functional on CDi Regular

Holiday button

Mains On/off indicator/diagnostic light (blue)

CH temperature control

Central heating boost button

Service button

Burner on indicator light (green)

Master switch on/off

8716115748-02.1Wo

24

25

26

27

8 716 115 748 (2009/09) 9


2.4

HIGHFLOW CDi COMBI BOILER

3 4

5

1

2

6

7

8

31

30

29

28

27

26

9

10

11

12

13

14

15

25

23

24

22

21

20

19 18

16

8716115748-03.1Wo

Fig. 7 Highflow CDi boiler, controls in service position

44

43

42

41

32

33

34

35

36

8

9

10

11

12

13

6

7

4

5

1

2

3

40

39

Fig. 8 Highflow CDi control panel

38

8716115748-06.1Wo

Cover - installer module

Heat store

Pressure relief valve

Auto air vent

Flue gas sampling point

Primary sensor

Flue blanking plate

Fan

Ignition electrodes & flame sensing electrode

Heat exchanger

Heat exchanger access panel

Air/Gas adjustment screw

Expansion vessel

37

17

14 Gas valve

15 Condensate pump assembly

16 Circulating pump

17 Optional filling link

18 Runner wheels on mounting frame

19 CH return isolating valve

20 Mains water inlet isolating valve

21 Gas isolating valve

22 DHW outlet

23 CH flow isolating valve

24 DHW sensor

25 Boiler/tank drain & connection point for filling link

26 Flow turbine

27 Filling link isolating valve

28 DHW heat exchanger

29 Tank overheat thermostat

30 Tank temperature sensor

31 Control panel

32 Display

33 System pressure gauge

34 Reset button

35 ECO button

36 Not used


38 Position of optional controller

39 Mains ON/OFF indicator & fault diagnostic light (blue)

40 CH temperature control

41 CH boost button

42 Service button

43 Burner ON indicator light (green)

44 Master ON/OFF switch

10 8 716 115 748 (2009/09)


2.5

FS CDi REGULAR BOILERS

31

32

33 34

35 12

13

1

16

14

15

11

10

9

8

1

7 6

Fig. 9 FS CDi Regular boiler layout

6

7

4

5

1

2

3

Control panel

Display

Reset button

Service function only

Service function only

Mains ON/OFF indicator & fault diagnostic light (blue)

Temperature control

8

9

Boost button

Service button

10 Burner ON indicator light (green)

11 Master ON/OFF switch

12 Flue knock-out panel

13 Flue outlet blanking covers

14 Ignition electrodes & flame sensing electrode

15 Heat cell high limit thermostat

16 Inner case

17 Gas valve

18 Condensate syphon

19 Mounting frame

20 Return connector

21 Gas isolating valve

22 Flow connector

23 Runner wheel

24 Condensate pump assembly

25 Air/Gas adjustment screw (sealed)

26 Heat cell

27 Primary sensor

28 Flow pipe

29 Auto air vent

2

3

4

5

30

29

28

27

26

25

24

23

22

21

20

30 Heatronic III series control board

31 Data label

32 Flue gas sampling point

33 Combustion air modulating fan

34 Casing support strut

35 Left hand side panel

18

17

19

8716115748-07.1Wo

8 716 115 748 (2009/09) 11

OPERATION - CDI

3 OPERATION - CDi

3.1

INITIALISATION

When it is switched on, the appliance performs a selftest which takes about 10 seconds.

While the test is in progress, the display shows for the first two seconds . Additionally buttons and light up orange and the reset button lights up red.

Afterwards the display shows the CH flow temperature.

On completion of the test sequence the appliance is ready for operation.

3.2

Display messages

The 7-Segment-Display has following display messages

(table 2 and 3):

Displayed value Description digit, dot followed by letter

Service function

Error code letter followed by digit or letter two digits

U followed by

0..9

decimal value e.g. flow temperature decimal value;

100..109 will be displayed as U0..U9

one digit (long displayed) followed by two digits twice

(short displayed) two dashes followed by two digits twice decimal value (triple-digit); first digit will be displayed alternating with two last digits (e.g.: 1...69..69 for

169) code plug number; the value is displayed in

3 steps:

1. two dashes

2. two first digits

3. two last digits

(e.g.: -- 10 04) two letters followed by two digits twice version number; the value is displayed in

3 steps:

1. two first letters

2. two first digits

3. two last digits

(e.g.: CF 10 20)

Tab. 2 Display messages

Range

00..99

0..109

0..999

1000..

9999

Special messages Description

Key acknowledgement after pressing one button (except reset button)

Key acknowledgement after pressing two buttons simultaneously

Key acknowledgement after pressing button longer than 3 seconds (storage function)

The display shows alternatively the

CH flow temperature and . The appliance works continuously at the minimum power (see service function 2.F).


CH flow temperature and . The appliance works continuously at the maximum power (see service function 2.F).

Appliance is in Air purge mode, see service function 2.C.


CH flow temperature and . The

Syphon-fill programme is active. See service function 4.F


CH flow temperature and reminding that the next service is due. The burner service interval of

2324 hours has run out. See service function 5.F.


CH flow temperature and . The pump is blocked. See error E9.


CH flow temperature and . The gradient limitation is active. The primary temperature is rising too fast and the burner has switched off for 2 minutes. See error E9.

Tab. 3 Special display messages

12 8 716 115 748 (2009/09)

A

B

C

D

M L K

J

I

H

5

E G min

6 720 614 059-19.1 Wo

F

3.3

Operating elements CDi (Wall hung)

E

F

G

J

K

L

M

I

Fig. 10 CDi control panel

C

D

A

B

H

On/off button

Burner indicator (GREEN)

Service button (ORANGE)

Central heating boost button (ORANGE) (in service mode for displaying and storing values, for selection of max. or min. heat output)

Central heating temperature control

On/off and fault indicator (BLUE)

DHW temperature control

(Not used on Regular boilers)

(Not used on System boilers unless the option integral diverter valve is fitted)

Holiday button (GREEN) (in service mode for selecting downwards)

ECO button (GREEN) (in service mode for selecting upwards)

Reset button (RED)


Display

Cover or optional programmer

Modifications of appliance parameters only become active after saving.

3.4

First service level

3.4.1

Display the value of the service function

B Press the button for approximately 10 seconds

(the display shows ). When the button lights up orange, release it. In the display appears Digit.Letter e. g. 1.A.

B Press the eco button for going upwards or the button

for going downwards to select the service function.

B Press the button and release it. After releasing the button will light up orange. The display shows the value of the service function.

OPERATION - CDI

3.4.2

Set and store values in the service function

B Display the value of the service function.

B Press the eco button for going upwards or the button for going downwards to select the value.

B Press the button for longer than 3 seconds until appears on the display. After releasing, the button goes out and the value is stored. The first service level is active.

3.4.3

Exit service function/service level without storing

B Press the button to exit the service function without storing. After releasing the button goes out.

B Press the button to exit service level. After releasing the button goes out. The display shows the flow temperature.

3.5

Second service level

3.5.1

Display the value of the service function

B Press the button for approx.10 seconds (the display shows ). When the button will light up orange, release it.

B Press eco button and simultaneously for approximately 3 seconds (the display shows ) until in the display appears Digit.Letter e. g. 8.A.

B Press the eco button for going upwards or the button for going downwards to select the service function.


3.5.2

Set and store values in the service function



B Press the button longer than 3 seconds until appears on the display. After releasing the button goes out and the value is stored. The second service level is active.

3.5.3

Exit service function/service level without storing


First service level is active.

B Press eco button and simultaneously for approximately 3 seconds (the display shows ) in order to go to the first service level. Afterwards the display shows the last selected service function.

-or-

B Press the button to exit all service levels. After releasing, the button goes out.

8 716 115 748 (2009/09) 13

OPERATION - CDI

3.6

Resetting service functions to factory settings

To reset all settings on Service levels 1 and 2 to the factory settings:

B Display the value of the service function 8.E (second service level, value = 0) and store it. The appliance restarts with factory settings (see also section 3.1).

3.7

SELECT MAX. OR MIN. HEAT OUTPUT

B Press the button for approximately 10 seconds (the display shows ). When the button will light up orange, release it.

B Turn the CH control knob on the right and adjust maximum heat output (the display shows alternatively the CH flow temperature and ).

-or-

B Turn the CH control knob on the left and adjust minimum heat output (the display shows alternatively the CH flow temperature and ).

B Press the button to exit the function. After releasing the button goes out.

Maximum or minimum heat output is only active for 15 minutes. After this time the appliance changes to normal mode.

To ensure that the maximum 15 minutes is achieved, remove the diverter valve motor and run a hot water tap.

3.8

RESET THE APPLIANCE

B Press the reset button for 3 seconds and release.

After releasing button the appliance re-starts without parameter reset. (For a parameter reset see section 3.6).

14 8 716 115 748 (2009/09)

OPERATION - HIGHFLOW CDI AND FS CDI REGULAR

4 OPERATION - HIGHFLOW CDi and FS CDi REGULAR

4.1

INITIALISATION

When it is switched on, the appliance performs a selftest which takes about 10 seconds.

While the test is in progress, the display shows for the first two seconds . Additionally buttons and light up orange and the reset button lights up red.

Afterwards the display shows the CH flow temperature.

On completion of the test sequence the appliance is ready for operation.

4.2

Display messages

The 7-Segment-Display has following display messages

(table 2 and 3):

Displayed value Description digit, dot followed by letter letter followed by digit or letter two digits

Service function

Error code

U followed by

0..9

decimal value e.g. flow temperature decimal value;

100..109 will be displayed as U0..U9

one digit (long displayed) followed by two digits twice

(short displayed) two dashes followed by two digits twice two letters followed by two digits twice decimal value (tripledigit); first digit will be displayed alternating with two last digits (e.g.: 1...69..69 for

169) code plug number; the value is displayed in

3 steps:

1. two dashes

2. two first digits

3. two last digits

(e.g.: -- 10 04) version number; the value is displayed in

3 steps:

1. two first letters

2. two first digits

3. two last digits

(e.g.: CF 10 20)

Tab. 4 Display messages

Range

00..99

0..109

0..999

1000..

9999

Special messages Description

Key acknowledgement after pressing one button (except reset button)

Key acknowledgement after pressing two buttons simultaneously

Key acknowledgement after pressing button longer than 3 seconds (storage function)


CH flow temperature and . The appliance works continuously at the minimum power (see service function 2.F).


CH flow temperature and . The appliance works continuously at the maximum power (see service function 2.F).

Appliance is in Air purge mode, (see service function 2.C)


CH flow temperature and . The

Syphon-fill programme is active. See service function 4.F.

When the control is in internal heat bank demand and syphon fill is not active, then the seven segment display will alternate between the primary temperature and the tank demand symbol

Tab. 5 Special display messages

8 716 115 748 (2009/09) 15


A

B

C

D

M L K

J

I

H

5

E G min

6 720 614 059-19.1 Wo

F

4.3

Operating elements

K

L

I

J

M

G

H

E

F

Fig. 11 Highflow CDi control panel

C

D

A

B

On/off button

Burner indicator (GREEN)

Service mode button (ORANGE)

Central heating boost button (ORANGE) (in service mode for displaying and storing values, for selection of max. or min. heat output)

Central heating temperature control

On/off and fault indicator (BLUE)

DHW temperature control (Highflow only)

Holiday button (Service mode back button)

ECO button (GREEN) (Service mode, next button)

Reset button (RED)


Display

Cover or optional programmer

Modifications of appliance parameters only become active after saving.

4.4

First service level

4.4.1 Display the value of the service function

B Press the button for more than 10 seconds (the display shows ). When the button lights up orange, release it. In the display appears Digit.Letter e. g. 1.A.

B Press the eco button for going up (service next) or

button for going down (service previous) to select the service function.


4.4.2 Set and store values in service function



B Press the button longer than 4 seconds until appears on the display. After releasing the button goes out and the value is stored. The first service level is active.

4.4.3 Exit service function/service level without storing


B Press the button to exit service level. After releasing the button goes out. The display shows the flow temperature.

4.5

Second service level

4.5.1 Display the value of the service function

B Press the button for more than 10 seconds or (the display shows ). When the button will light up orange, release it.

B Press eco button and simultaneously for approximately 3 seconds (the display shows ) until in the display appears Digit.Letter e. g. 8.A.

B Press the eco button for going upwards or the button for going downwards to select the service function.


4.5.2 Set and store values in service function



B Press the button for longer than 4 seconds until

appears on the display. After releasing, the button goes out and the value is stored. The second service level is active.

16 8 716 115 748 (2009/09)

4.5.3 Exit service function/service level without storing


First service level is active.

B Press eco button and simultaneously for

3 seconds (the display shows ) in order to go to the first service level. Afterwards the display shows the last selected service function.

-or-

B Press the button to exit all service levels. After releasing the button goes out.

4.6

Resetting service functions to factory settings

To reset all settings on Service levels 1 and 2 to the factory settings:

B Display the value of the service function 8.E (second service level, value = 0) and store it. The appliance restarts with factory settings (see also section 3.1).

4.7

SELECT MAX. OR MIN. HEAT OUTPUT

B Press the button for approximately 10 seconds (the display shows ). When the button will light up orange, release it.

B Turn the CH control knob on the right and adjust maximum heat output (the display shows alternatively the CH flow temperature and ).

-or-

B Turn the CH control knob on the left and adjust minimum heat output (the display shows alternatively the CH flow temperature and ).

B Press the button to exit the function. After releasing the button goes out.

Maximum or minimum heat output is only active for 15 minutes. After this time the appliance changes to normal mode.

4.8

RESET THE APPLIANCE

B Press the reset button for 3 seconds and release.

After releasing button the appliance re-starts without parameter reset.

(For a parameter reset see section 3.6).


8 716 115 748 (2009/09) 17

BOILER SERVICE FUNCTIONS - CDI COMBI & SYSTEM BOILER

5 BOILER SERVICE FUNCTIONS - CDi COMBI & SYSTEM BOILER

5.1

FIRST SERVICE LEVEL (PRESSING THE BUTTON FOR APPROX. 10 SECONDS)

1.A

1.b

1.C

1.d

1.E

2.b

2.C

2.F

3.b

3.C

3.E

3.F

4.F

5.A

5.b

6.A

6.d

6.E

7.A

Description

Max. output (heating)

Display

*-U0

Range adjustable from - to/

Description min adjustable output - 100%

(not on 37 and 42 Combis) min adjustable output - 100% Max. output (hotwater - combi only) *-U0

Pump map (heating)

(wall hung combi & system only)

(see section 5.3.1, 1.C/1.d)

Map pump step (heat.)

(wall hung combi & system only)

00-05 0 Pump step adjustable

1 Constant pressure high

2 Constant. pressure middle

3 Constant pressure low

4 Proportional pressure high

5 Proportional pressure low

02-07 2-7

Pump switch mode

Max. flow temperature

Air purge mode

(burner keeps off while air purge mode is on)

Operating mode

Anti-cycle time

Anti-cycle flow temperature differential

Pre heat cycle time (hot water)

(combi only)

01-03

35-88

00-02

00-02

00-15

00-30

20-60

1 - 3

35 - 88 °C

0 off

1 on, automatic deactivation

(on for 8 minutes, then off)

2 permanent on

0 Normal

1 Minimal (for 15 min)

2 Maximal (for 15 min)

0 - 15 min

0-30 K

(Note: 1K =^ 1 °C)

20 - 60 min

Burner off after DHW demand (hot water) (combi only)

Syphon-fill programme

00-30

00-01

Reset service reminder

Fan over-run time

Last fault

Actual flow rate turbine (combi only)

Programmer input

Fault indicator LED on/off

00

01-18

00 - FF

00-99

00-11

00-01

Reset value (after parameter reset) depends on appliance type

U0

04

07

02

88 °C

01

00

03 min

10 K

20 min

0 - 30 min

(0 = 10sec)

0 off,

1 on, boiler min. output

0 must be stored in order to reset service reminder

01 min

01

00

1-18 (= 10 sec - 180 sec) 03 (30 sec) last fault code can be displayed 00

0-99 l/min

00, 01, 10, 11

(left digit: heating, right digit: hotwater) read only read only

0 off

1 on

Flashes in case of error even when its setting is off (0).

01

Tab. 6 CDi Service - first level

18 8 716 115 748 (2009/09)


5.2

SECOND SERVICE LEVEL (ENTER AT THE FIRST SERVICE LEVEL AND PRESS THE

ECO BUTTON AND SIMULTANEOUSLY FOR 3 SECONDS)

Description

8.A

Software version

8.b

Code plug number

8.C

GFA status (not applicable)

8.d

GFA error (not applicable)

8.E

Reset all parameters

8.F

Permanent ignition

9.A

Operation mode permanent

9.b

Actual fan speed

9.C

Actual heat output

9.d

9.E

Start fan speed

Turbine signal delay (combi only)

9.F

Pump over-run time (CH mode)

Tab. 7 CDi Service - second level

-

-

00

Display

CF ** **

-- ** **

00-01

00-02

*..** (Hz)

** (%)

45-55

02-08

00-03

-


Description

-

-

1000-4000; corresponds to digits 7 to 10 of order number for example: 8 714 411 062 0

0 (must be stored in order to set all parameters to factory settings)

0 = off

1 = on (Do not run for more than 2 minutes!)

0 normal

1 min

2 max

-

0-U0

45-55 Hz

2-8 [quarter seconds] (corresponds to 0.5-2 sec)

0-3 min

Reset Value

(after parameter reset) read only read only read only read only

00

00

00 read only read only

50 Hz

04 (corresponds to

1 sec)

03

5.3

EXPLANATION OF SERVICE FUNCTIONS

5.3.1

FIRST SERVICE LEVEL

1.A MAX. OUTPUT (HEATING)

The heating output can be set to any level between min. rated heat output and max rated heat output to limit it to the specific heat requirements.

Even if the heating output is limited, the full rated heat output remains available for hot water.

The factory setting is maximum rated output – it depends on appliance type.

1.B MAX. OUTPUT (HOTWATER - COMBI ONLY)

The hot water output can be set to any level between minimum rated hot water output and maximum rated hot water output to limit it to the specific hot water requirements.

The factory setting is maximum rated output – display shows U0.

1.C PUMP MAP (HEATING)

(COMBI & SYSTEM ONLY)

The appliance is supplied with this function set to

4 (Proportional pressure high). See pump characteristics below.

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.

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.

8 716 115 748 (2009/09) 19


In order to save as much energy as possible and to minimise the possibility of water circulation noise, a low characteristic should be chosen.

The pump map can be selected within:

•

0 (Pump step adjustable), see service function

1.d (Map pump step (heating))

•

1 (Constant pressure high)

•

2 (Constant pressure middle)

•

3 (Constant pressure low)

•

4 (Proportional pressure high)

•

5 (Proportional pressure low)

The factory setting is:

1.C Pump map (heating) 4 (Proportional pressure high)

H

(bar)

0,6

0,5

0,4

0,3

1

2

3

0,2

0,1

0

0 200 400 600

Fig. 12 Constant pressure

800 1000 1200 1400 1600

Q (l/h)

H

(bar)

0,6

0,5

0,4

0,3

0,2

0,1

4

5

0

0 200 400 600 800 1000 1200 1400 1600

Q (l/h)

Fig. 13 Proportional pressure

1-5 Characteristics

H Pressure

Q Water circulation rate

If this parameter is set to 0 then the pump speed set under function 1.d (Map pump step (heating)) is active.

1.D MAP PUMP STEP (HEATING)

(combi & system only)

This service function corresponds to the pump speed switch used on conventional heating pumps.

However, the setting is only active if function 1.C (Pump map (heating)), is set to 0.

The factory setting is:

1.d Map pump step (heating) 7

0,6

H

(bar)

0,5

0,4

0,3

0,2

2

3

4

5

6

7

0,1

0

0 200 400 600 800 1000 1200 1400 1600

Q (l/h)

6 720 612 126-45.1O

Fig. 14 Characteristics

2-7 Characteristics

H Pressure

Q Water circulation rate

20 8 716 115 748 (2009/09)

•

1.E PUMP SWITCH MODE

The choice of settings is as follows:

•

Control Mode 1

For heating equipment without a control unit.

The pump is controlled by the central heating flow temperature control.

•

Control Mode 2 (factory setting)

For heating systems with room thermostat.

The central heating flow temperature control controls only the gas, the pump is not affected. The room thermostat controls both the gas and the pump.

The pump and fan have an over-run time of between

15 s and 3 min.

•

Control Mode 3

Not applicable

2.B MAX. FLOW TEMPERATURE

The maximum CH flow temperature can be set to between 35 °C and 88 °C (factory setting). Even if the

CH flow temperature control is set higher, the setting entered for 2.b (Max. flow temperature) is not exceeded.

2.C AIR PURGE MODE

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.

The 2-digit display shows in alternation with the CH flow temperature.

The automatic vent will open during venting and then close once the venting sequence is complete.

The venting function can be activated manually after servicing.

If the venting function is set to “On” (with automatic deactivation), the function is set to “Off” once the sequence has been completed

2.F OPERATING MODE

There are 3 operating modes to choose from.

•

Normal mode: the appliance operates according to the commands received from the programmer. The display shows 0.

•

Minimum mode: the appliance runs constantly at minimum output.

The display shows 1. The 2-digit display alternates between the CH flow temperature and . After

15 min the minimal mode changes to normal mode.


• Maximum mode: the appliance runs constantly at maximum output.


15 min the maximal mode changes to normal mode.

3.B ANTI-CYCLE TIME

The anti-cycle time is factory set to 3 minutes.

The shortest possible anti-cycle time is 1 minute

(recommended for single-pipe and hot-air heating systems).

If the setting 0 is entered, the anti-cycle time is inactive.

B Enter the anti-cycle time on the commissioning record enclosed with the appliance.

3.C ANTI-CYCLE FLOW TEMPERATURE DIFFERENTIAL

The switching difference is the permissible differential from the specified CH flow temperature. It can be set in increments of 1 K. The adjustment range is 0 to 30 K (is factory set to 10 K). The minimum CH flow temperature is 35 °C.

Note: 1K =^ 1 °C.

B The switching difference setting should be entered on the commissioning record supplied with the appliance.

3.E CYCLE TIME (HOT WATER) (COMBI ONLY)

The appliance is supplied with the pre-heat cycle time set to 20 minutes.

After pre-heating or DHW demand, this function will stipulate the period of time before the next permissible pre-heat. This will prevent excessive pre-heat cycling.

3.F BURNER OFF AFTER DHW DEMAND (HOT WATER)

(COMBI ONLY)

The appliance is supplied with the hot water duration set to 1 minute.

The “hot water duration” time specifies how long, after hot water has been drawn, that the heating mode remains disabled.

8 716 115 748 (2009/09) 21


4.F SYPHON-FILL PROGRAMME

The syphon filling function ensures that the syphon trap is filled when the appliance is first installed or shut down for a long period. Flue gas is prevented from escaping into the room that the appliance is installed.

The syphon filling function is activated when:

• the appliance is switched on at the main 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 syphon filling programme remains active until the appliance has completed 15 minutes of operation at minimum output.

The 2-digit display alternates between and the CH flow temperature.

If the syphon is not filled, flue gas can escape!

B Only deactivate the syphon filling programme in order to carry out servicing work.

B Always re-activate trap filling programme once servicing is complete.

5.A RESET SERVICE REMINDER

The burner service interval of 2324 hours has run out.

After the service inspection store 0 for resetting the service interval.

5.B FAN OVER-RUN TIME

Set the time of fan over-run after a boiler demand.

6.A LAST FAULT

The last fault can also be recalled for servicing purposes when the appliance is functioning correctly.

6.D ACTUAL FLOW RATE TURBINE (COMBI ONLY)

The actual flow rate of the turbine is displayed.

6.E PROGRAMMER INPUT

Shows the status of channel 1 of the timer DT10/20.

Left digit is “Heat demand”, heating mode will be activated according to the programmer commands.

Shows the status of channel 2 of the timer DT20.

Right digit is “DHW demand”, hot water mode will be activated according to the programmer commands.

7.A FAULT INDICATOR LED ON/OFF

The fault indicator LED flashes in case of error even when its setting is off (0).

5.3.2

SECOND SERVICE LEVEL

8.A SOFTWARE VERSION

The version number of the software is displayed.

8.B CODE PLUG

The 4-digit part number of the code plug (digits no. 7 up to 10 of order no.) 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.

8.C GFA STATUS

(not applicable)

8.D GFA ERROR

(not applicable)

8.E RESET ALL PARAMETERS

Set all parameters to factory setting. See also section 3.6.

8.F PERMANENT IGNITION

This function allows permanent ignition without gas supply to be activated for the purposes of checking the ignition mechanism.

Do not run for more than 2 minutes!

9.A OPERATION MODE PERMANENT

Set a fixed operation mode even when boiler has been switched off.

9.B ACTUAL FAN SPEED

The current fan speed is displayed in Hertz (Hz).

9.C ACTUAL HEAT OUTPUT

The actual heat output of the appliance at the time viewed is displayed.

9.D START FAN SPEED

The actual start fan speed between 45 and 55 Hz is displayed in Hertz (Hz).

9.E TURBINE SIGNAL DELAY (COMBI ONLY)

Set a delay time relates to the beginning of DHW demand to avoid an undesired demand by water surge hammer.

9.F PUMP OVER-RUN TIME (CH MODE)

Set the time of pump over-run after the end of a heating demand.

22 8 716 115 748 (2009/09)

BOILER SERVICE FUNCTIONS CDI, HIGHFLOW CDI & FS CDI REGULAR

6 BOILER SERVICE FUNCTIONS CDi, HIGHFLOW CDi

& FS CDi REGULAR

6.1

FIRST SERVICE LEVEL (PRESSING THE BUTTON FOR APPROX. 10 SECONDS)

Reset Value

Description

1.A

Max. output (heating)

2.b

Max. flow temperature

2.C

Air purge mode

(burner keeps off while air purge mode is on)

2.F

Display

*-U0

35-88

00-02

00-02

3.b

Anti-cycle time 00-15

3.C

Anti-cycle flow temperature differential 00-30

3.F

4.F

Operating mode

Burner off after DHW demand (hot water) (combi only)

Syphon-fill programme

5.b

Fan over-run time

6.A

Last fault

6.d

6.E

Actual flow rate turbine (combi only)

Programmer input

00-30

00-01

01-18

00 - FF

00-99

00-11


Description min adjustable output - 100%

35 - 88 °C

0 off

1 on, automatic deactivation (on for 8 minutes, then off)

2 permanent on

0 Normal

1 Minimal (for 15 min)

2 Maximal (for 15 min)

0 - 15 min

0-30 K

(Note: 1K =^ 1 °C)

0 - 30 min

(0 = 10sec)

0 off,

1 on, boiler min. output

1-18 (= 10 sec - 180 sec) last fault code can be displayed

0-99 l/min

00, 01, 10, 11

(left digit: heating, right digit: hotwater)

(after parameter reset) depends on appliance type

88 °C

01

00

03 min

10 K

01 min

01

03 (30 sec)


Tab. 8 Highflow CDi & FS CDi Regular service - first level

8 716 115 748 (2009/09) 23


6.2

SECOND SERVICE LEVEL (ENTER AT THE FIRST SERVICE LEVEL AND PRESS THE

ECO BUTTON AND SIMULTANEOUSLY FOR 3 SECONDS)

8.A

8.b

8.E

Description

Software version

Code plug number.

Reset all parameters

Display

CF ** **

-- ** **

00

-


Description

1000-4000; corresponds to digits

7 to 10 of order number: for example: 8 714 411 062 0

0 (must be stored in order to set all parameters to factory settings)

8.F

9.A

Permanent ignition

Operation mode permanent

00-01

00-02

9.b

9.C

AA

AB

Actual fan speed

Actual heat output

Primary hot water temperature

Domestic hot water temperature

*..** (Hz)

** (%)

Tab. 9 Highflow CDi & FS CDi Regular service - second level

-

0-U0

0 = off

1 = on (Do not run for more than 2 minutes!)

0 normal

1 min

2 max

Reset Value

(after parameter reset) read only read only

00

00


24 8 716 115 748 (2009/09)


6.3

EXPLANATION OF SERVICE FUNCTIONS

6.3.1

FIRST SERVICE LEVEL

1.A MAX. OUTPUT (HEATING)

The heating output can be set to any level between minimum rated heat output and maximum rated heat output to limit it to the specific heat requirements.

Even if the heating output is limited, the full rated heat output remains available for hot water.

The factory setting is maximum rated output, depending on appliance type.

2.B MAX. FLOW TEMPERATURE

The maximum CH flow temperature can be set to between 35 °C and 88 °C (factory setting). Even if the

CH flow temperature control is set higher, the setting entered for 2.b (Max. flow temperature) is not exceeded.

2.C AIR PURGE MODE

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.


The automatic vent must be opened and then closed again once the venting sequence is complete.

3.B ANTI-CYCLE TIME

The anti-cycle time is factory set to 3 minutes.

The shortest possible anti-cycle time is 1 minute

(recommended for single-pipe and hot-air heating systems).

If the setting 0 is entered, the anti-cycle time is inactive.

B Enter the anti-cycle time on the commissioning record enclosed with the appliance.

3.C ANTI-CYCLE FLOW TEMPERATURE DIFFERENTIAL

The switching difference is the permissible differential from the specified CH flow temperature. It can be set in increments of 1 K. The adjustment range is 0 to 30 K (is factory set to 10 K). The minimum CH flow temperature is 35 °C.

Note: 1K =^ 1 °C.

The venting function can be activated manually after servicing.

•

If the venting function is set to “On” (with automatic deactivation), the function is set to “Off” once the sequence has been completed

2.F OPERATING MODE

There are 3 operating modes to choose from.

•

Normal mode: the appliance operates according to the commands received from the programmer. The display shows 0.

•

Minimal mode: the appliance runs constantly at minimum output.


15 min the minimal mode changes to normal mode.

•

Maximum mode: the appliance runs constantly at maximum output.


15 min the maximal mode changes to normal mode

B The switching difference setting should be entered on the commissioning record supplied with the appliance.

3.F BURNER OFF AFTER DHW DEMAND (HOT WATER)

(CDi COMBI & HIGHFLOW CDi ONLY)

The appliance is supplied with the hot water duration set to one minute.

The hot water duration time specifies how long, after hot water has been drawn, that the heating mode remains disabled.

4.F SYPHON-FILL PROGRAMME

If the syphon is not filled, flue gases can escape!

B Only deactivate the syphon filling program in order to carry out service work.

B Always re-activate syphon filling program once servicing is complete.

The syphon filling function ensures that the syphon trap is filled when the appliance is first installed or shut down for a long period. Flue gas is prevented from escaping into the room that the appliance is installed.

The syphon filling function is activated when:

• the appliance is switched on at the main switch

• the burner has not been in operation for at least

48 hours

• the appliance is switched from summer to winter mode

8 716 115 748 (2009/09) 25


The next time the heating or hot water system calls for heat, the appliance is held at minimum output for

15 minutes. The syphon filling programme remains active until the appliance has completed 15 minutes of operation at minimum output.


5.B FAN OVER-RUN TIME

Set the time of fan over-run after a boiler demand.

6.A LAST FAULT

The last fault can also be recalled for servicing purposes when the appliance is functioning correctly.

6.D ACTUAL FLOW RATE TURBINE (COMBI ONLY)

The actual flow rate of the turbine is displayed.

6.E PROGRAMMER INPUT

Shows the status of channel 1 of the timer DT10/20.

Left digit is “Heat demand”, heating mode will be activated according to the programmer commands.

Shows the status of channel 2 of the timer DT20.

Right digit is “DHW demand”, hot water mode will be activated according to the programmer commands.

6.3.2

SECOND SERVICE LEVEL

8.A SOFTWARE VERSION

The version number of the software is displayed.

8.B CODE PLUG

The 4-digit part number of the code plug (digits 7 to 10 of order number) 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.

8.C GFA STATUS

(not applicable)

8.D GFA ERROR

(not applicable)

8.E RESET ALL PARAMETERS

Set all parameters to factory setting. See also section 3.6.

8.F PERMANENT IGNITION

This function allows permanent ignition without gas supply to be activated for the purposes of checking the ignition mechanism.

Do not run for more than 2 minutes!

9.A OPERATION MODE PERMANENT

Set a fixed operation mode even when boiler has been switched off.

9.B ACTUAL FAN SPEED

The current fan speed is displayed in Hertz (Hz).

9.C ACTUAL HEAT OUTPUT

The actual heat output of the appliance at the time viewed is displayed.

26 8 716 115 748 (2009/09)

RECTIFYING FAULTS

7 RECTIFYING FAULTS

7.1

INDICATION OF FAULTS

Faults are indicated simultaneously by a letter code in the display and by flashing of the fault indicator LED.

This helps to identify and eliminate the cause of the fault quickly and reliably.

The fault codes displayed are grouped into four categories:

• Category 1:

The appliance is disabled until it has been switched off and then on again.

•

Category 2:

The appliance is disabled until the cause of the fault has been eliminated.

• Category 3:

The appliance continues to operate with limited function.

•

Category 4:

The appliance is disabled and locked (button reset and fault indicator LED are flashing) until the cause of the fault has been eliminated and the appliance unlocked

Unlocking the appliance:

B Press the reset button for 3 seconds and release it. After releasing the appliance re-starts. (See also section 3.1).

7.2

Summary

7.2.1

APPLIANCE FAULTS

F7

FA

Fd

Appliance faults

A1

A5

A6

A7

A8 b1

E2

E9

EA

F0

C6

CC d5 CDi HF & FS d6 CDi HF only 39

40

41

44

48

35

36

37

38

29

30

31

32

33

49

50

51

4

4

4

2/4

4

2

4

2

2

2

2

2

2

2

3

1

3

7.2.2

Faults that are not displayed

Appliance faults

Excessive burner noise, rumbling noises

Flow noises

Heating up of last radiators in system too slow

Flue gas levels incorrect, CO level too high

Ignition too harsh, ignition poor

Condensation in the flue pipe

Inadequate hot water outlet temperature (combi boiler)

Tab. 10 Undisplayed faults

50

50

51

51

52

53

54

CONDENSATE PUMP (Floor standing appliances)

- OPERATING LIGHTS AND FAULT CONDITIONS

Ready for operation = Steady green light

Fault = Steady red light

Pump running = Flashing green light

Operating lights

Green Red

Cause Solution

Off Off Mains power missing

Flashing Flashing Dry - run

(possible air in system)

On

On

Off

Insert plug

Check mains and fuse

Pump starts automatically after 1 minute

Flashing Pump blocked Inspect tank pump inlet remove dirt

On Level exceeds alarm level

Pressure hose / non return valve blocked (clean or unkink)

Flashing Pump blocked and alarm level exceeded

Inspect tank pump inlet remove dirt

Tab. 11 Condensate pump

Programmer faults

Set room temperature not reached

Set room temperature exceeded by a large amount (230V on/off room stat)

Excessive fluctuations in room temperature

Tab. 12 Programmer faults

Page

54

55

55

8 716 115 748 (2009/09) 27

28


7.3

NOTES ON USING THE FAULT CODE TABLES

The procedure is best described with the aid of an example:

•

Work through the table from top to bottom and from left to right.

•

First make a note of the present settings and restore them before leaving the appliance.

•

Read question 1. (Check column) and depending on the answer (yes or no) read the action required from the relevant box and carry out the instruction given; ignore the other answer. For example: if the burner flame is visible, follow the instructions for yes, i.e. go to 5.!

•

“go to 5” means go to number 5., ignoring the steps in between.

In this example: check the flue is clear by testing the

CO

2

level.

• If the appliance is locked (reset button and the fault indicator LED are flashing), press the reset button.

•

If the fault has been rectified, the appliance will then start up without indicating a fault and the fault isolation procedure is complete.

•

If the fault is still present after performing the reset action and, if necessary, restarting the appliance, move on to the next step in the fault isolation procedure.

•

If another fault code is displayed, work through the fault code table for that code

EA

and flashing.

Flame not detected

1.

Check

Is a burner flame visible?

2.

Is the gas cock turned on?

yes: no: yes: no: yes: no:

Action

↓ 5.

↓ 2.

Ø 5.

B Open the gas cock.

B Press button

.

EA? ↓3.

...

↓ ...

3.

Has the thermal cut-out on the gas cock tripped?

4. ...

...

5. ...

Problem with flue?

B Check CO air.

Is CO

2

level in combustion

2

level above 0,2 % ? yes: no:

Check flue.

↓ ...

6 720 612 126-01.1O

Fig. 15 Example of fault code table

8 716 115 748 (2009/09)


2.

3.

1.

7.4

ERROR CODES ON THE DISPLAY

A1 and fault indicator LED are flashing

Controlled characteristic pump has run dry

Check

System pressure below 1.2 bar yes:

Pump seized or sticking?

Audible bearing damage on pump no: yes: no: yes:

Action

B Power OFF the appliance

B Check appliance and system for water leaks and repair as necessary.

B Fill system, bleed and re-pressurise

(see Installation Instructions).

B Turn ON appliance

A1? go to 2 go to 2

Free/release pump go to 3

B Power OFF the appliance

B Disconnect the boiler electrical connection.

B Drain appliance.

B Change the pump (see Installation Instructions).

B Fill system, bleed and repressurise

(see Installation Instructions).

B Reconnect the boiler electrical connection.

B Turn ON the appliance.

4.

Activate venting sequence no: yes.

go to 4

B Select in the first service level, service function 2.C

(Air Purge mode - see page 25).

B Select the value 1 and store.

B Exit the service function.

B The boiler vents for eight minutes.

B Vent radiators manually.

Tab. 13 A1 Error codes

8 716 115 748 (2009/09) 29


3.

2.

1.

A5 and fault indicator LED are flashing. Appliance still available for heating demands.

Tank (Heat Bank) NTC sensor defective.

Check Action

Is the tank NTC sensor connection corroded, damaged or dirty?

yes:

B Power OFF the appliance.

B Disconnect the appliance electrical connection.

B Unplug the 20 pin connector from the PCB.

B Check the resistance across connections 5 and 6 on the cable side.

Does the value match the one in table 43?

no: yes: no:

Change relevant parts

A5? go to 2 go to 2

B Reconnect the appliance electrical connections.

B Turn ON the appliance

B Make a note of the altered service function settings.


B Disconnect the appliance electrical connections.

B Change the PCB control board.

B Reconnect the appliance.

B Turn the appliance ON.

B Restore the service setting noted previously.

go to 3

B Unplug the NTC sensor from the cable.

B Check the resistance of the NTC sensor.

Does the value match the one in table 43?

yes: B Change the 20 pin connector lead assembly.



no: B Change the NTC sensor.




30 8 716 115 748 (2009/09)


4

3

2.

1.

A6 and fault indicator LED are flashing. Appliance NOT available for demands.

External under floor heating thermostat defective.

Check Action yes: no:


B Disconnect the appliance electrical connection.

Check if the external under floor heating thermostat is connected on

ST8/8-9?

B Disconnect lead to thermostat.

Check the thermostat for continuity?

yes: go to 2

B Ensure that the link is securely connected to ST8/8-9

B Reconnect the appliance electrical connection.

B Power ON the appliance.

A6? go to 4 no:

B Reconnect lead to thermostat.

go to 3

B Change thermostat.

B Reconnect the lead to thermostat.



A6? go to 4

A6? go to 4 B Unplug the harness connector that connects the thermostat to the control board.

Check the harness for continuity?

yes

The control board is damaged.

no B Change or repair wiring to the thermostat.



A6? go to 4





B Disconnect the appliance electrical connections.

B Change the control board.



B Restore the service settings previously noted.


8 716 115 748 (2009/09) 31


1.

2.

3.

A7

and fault indicator LED are flashing.

(Boiler still produces hot water but at a lesser degree of accuracy over the temperature.)

Water NTC sensor defective.

Check

B Check if the water NTC connector corroded, damaged or dirty.

B Switch OFF the appliance.

B Disconnect the boiler power connection.

B Un-plug 20-pin connector from

PCB.

B Check resistance from connections 3 to 4 on the cable side. Does the value match the ones described in table 38, page 71?

B Un-plug NTC sensor from cable.

B Check resistance of NTC sensor.

Does the value match the ones described in table 38, page 71?


Action

B Change relative parts.

A7? go to 2 go to 2

B Connect the boiler electrical connection.

B Switch ON the appliance.

B Make a note of the altered service function settings (see table 6 on page 18) in order to keep the altered values.



B Change PCB control board.

B Reconnect the appliance power connection.


B Restore service settings previously noted.

go to 3

B Change the 20-pin connector lead assembly.



B Change NTC sensor.




32 8 716 115 748 (2009/09)


2.

3.

4

1.

A8


Bus communication to the programmer interrupted (set value not received)

Check Action

B Switch off the appliance.

B Disconnect the appliance power.

B Remove the upper section of the programmer mount and slide the programmer out of the wall mount.

B Check the wiring between the programmer and the appliance.

Are terminals B being used, the centre terminal must not be used for bus connections.

Check that terminals B are connected on the appliance and programmer.

B Is there continuity

Where multiple bus modules are installed:

B Check the wiring between bus modules and the branch box.

B Ensure that the B terminals are employed.



B Is there continuity yes: no: yes: no:

Where multiple bus modules are installed:

B Check the wiring between branch box and the programmer.

B Ensure that the B terminals are employed.


yes: no:


B Is there continuity

Has the programmer been replaced?

yes: no:

A8? go to 2

B Wire up or correct bus cable.

B Reconnect appliance power.

B Switch on appliance.

A8? go to 2

A8? go to 3

B Cable between bus module and branch box is defective.

B Repair or replace cable.



A8? go to 3

A8? go to 4

B Cable between the branch box and programme is defective.

B Repair or replace cable.



A8? go to 4

A8? go to 5

B Switch off appliance

B Disconnect electrical power

B Replace programmer

B Reconnect appliance power

B Switch on appliance

A8? go to 5


8 716 115 748 (2009/09) 33


6

5

A8


Bus communication to the programmer interrupted (set value not received)

Check Action

Has the bus module been replaced yes: no:

The PCB control board is faulty

A8? go to 6



B Replace bus module

B Reconnect appliance power


A8? go to 5

B Reconnect electrical power


B Make a note of the service function settings



B Change PCB control board

B Reconnect electrical power


B Restore service settings noted previously


34 8 716 115 748 (2009/09)


2.

1.

b1

and fault indicator LED are flashing

Code plug not detected.

Check

B Select in the second service level the service function 8.b (Code plug).

B Compare number displayed with that shown in Appendix (only digits no. 7 up to 10 of order no.).

No number or incorrect number displayed.


Code plug loose, incorrect or defective.

yes: no:

3.

The PCB is damaged.

Action go to 2 go to 3


B Fit code plug (correctly), making sure code number is correct (see Appendix).


b1? go to 3

B Make a note of the altered service function settings

(see table 6 on page 18) in order to keep the altered values.






B Restore service settings previously noted down.

Tab. 18 b1 Error codes

8 716 115 748 (2009/09) 35

36


1.

C6


Fan speed too low

Check

Fan cable connector correctly connected on fan?

yes: no:

2.

3.

4.

Check power supply to appliance, check supply with all electrical appliances on. Is the supply voltage within tolerance (230 V AC ± 10)?

Is fan cable defective?



B Measure the fan lead for continuity.

Is there continuity for each one of the cores?

Fan defective.

yes: no: yes: no: yes:

5.

The PCB is damaged.

Action go to 2


B Reconnect connector.


C6? go to 2 go to 3

B Switch off some electrical appliances. go to 3 go to 4

B Replace fan cable.



C6? go to 4



B Un-plug the connection wire.

B Replace fan.

B Push on the connection wire.



C6? go to 5









Tab. 19 C6 Error codes

8 716 115 748 (2009/09)


2.

1.

CC


Outside temperature sensor fault (open or short circuit)

Check Action


B Disconnect the boiler mains connection.

Are the outside temperature sensors connected to A and F on the printed circuit board.

yes no

B Power off the appliance.

At the outside temperature sensor cable connection, measure the resistance of the outside temperature sensor.

Does the value match that in table

44?

yes no

go to 2

B Connect the outside temperature sensors correctly to A and F on the PCB.

B Reconnect the boiler electrical mains

B Power ON the appliance

CC? go to 2 go to 3

B Replace the outside temperature sensors.

B Power ON the appliance

CC? go to 3

3.



B Disconnect the outside temperature sensors at connectors A and F on the PCB.

Check for continuity, is there continuity.

yes no

4.

The PCB control board is damaged.

CC? go to 4

B Replace the cable.

B Reconnect the boiler electrical mains connection.


CC? go to 4






B Change the control board PCB.




Tab. 20 CC Error codes

8 716 115 748 (2009/09) 37

38


1.

2.

3.

4.

d5

and fault indicator LED are flashing. (Boiler not available for demands)

Condensate float switch in condensate pump defective

Check Action



Check if condensate float switch is connected on PCB via ST19 4-5

B Disconnect plug on condensate pump.

Measure the float switch for continuity.

Is there continuity?

B unplug connector ST19.

Test harness for continuity.



yes no yes no yes no

go to 2

B Ensure that ST19 is plugged onto the PCB and the wires properly tightened on the terminal block.

B Reconnect the boiler electrical mains

B Power ON the appliance d5? go to 4

B Reconnect plug on condensate pump.

go to 3

B Change condensate pump.

B Reconnect condensate pump.


B Power ON the appliance d5? go to 4 d5? go to 4

B Change or fix wiring to condensate pump.



d5? go to 4










Tab. 21 d5 Error codes

8 716 115 748 (2009/09)


1.

2.

3.

4.

d6

and fault indicator LED are flashing. (Boiler not available for demands)

Tank overheat thermostat defective

Check Action



Check if thermostat is connected on PCB via ST9

B Disconnect lead on thermostat.

Measure the thermostat for continuity.


B unplug connector ST9.

Test harness for continuity.



yes no yes no yes no go to 2

B Ensure that ST9 is plugged onto the PCB.

B Reconnect the boiler electrical mains.

B Power ON the appliance d6? go to 4

B Reconnect lead on thermostat.

go to 3

B Change thermostat.

B Reconnect lead on thermostat.


B Power ON the appliance d6? go to 4 d6? go to 4

B Change or fix wiring to thermostat.



d6? go to 4










Tab. 22 d6 Error codes

8 716 115 748 (2009/09) 39


2.

1.

E2


Flow temperature NTC sensor defective.

Check

B Check if the flow temperature

NTC sensor connector is corroded, damaged or dirty.

yes: no: yes: B Switch OFF the appliance.


B Unplug 20-pin connector from

PCB.

B Check resistance from connections 8 to 9 on the cable side. Does the value match the ones described in table 38, page 71?

3.

B Un-plug NTC sensor from cable.

B Check resistance of NTC sensor.

Does the value match the ones described in table 38, page 71?


Tab. 23 E2 Error codes no: yes: no:

Action

B Change relative parts.

E2? go to 2 go to 2











go to 3



B Change the 20-pin connector lead assembly.



B Change NTC sensor.

40 8 716 115 748 (2009/09)


4.

5.

3.

1.

2.

E9

and button reset and fault indicator LED are flashing.

Safety temperature circuit has tripped.

Check Action

Type of CH system:

Is the appliance installed in a fully pumped sealed system?

Open vented CH system:

Is there enough water in the feed and expansion tank?

yes: no: yes: no: go to 3 go to 2 go to 4

B Top up system.

B Vent appliance.

B Press the reset button for 3 seconds and release it.

After releasing the appliance re-starts.

E9? go to 4 go to 4 Fully pumped sealed system:

Is the heating pressure between 1 and 2 bar (sealed systems)? yes: no:

Is the pump seized?

Lead disconnected from flue safety temperature limiter and/or CH flow safety temperature limiter?

yes: no: yes: no:

B Top up system.

B Vent appliance.



E9? go to 4

B Free/release the pump.

If pump won’t start:



B Drain appliance.

B Change the pump (see Installation Instructions).

B Fill system, vent and re-pressurise (see installation instructions).





E9? go to 5 go to 5


B Reconnect lead.




E9? go to 4 go to 4

Tab. 24 E9 Error codes

8 716 115 748 (2009/09) 41

42


9.

8.

7.

6.

E9



Check Action


B Un-plug the connector from the flue safety temperature limiter.

B Measure the flue safety temperature limiter for continuity.

Resistance small?

yes: no:

Connect flue gas safety temperature limiter lead.

go to 5

B Change the flue safety temperature limiter.

B Connect flue gas safety temperature limiter lead.




E9? go to 5

B Disconnect lead to CH flow safety temperature limiter.

B Measure the CH flow safety temperature limiter for continuity.

Resistance small?

yes: no:

Connect CH flow safety temperature limiter.

go to 6


B Unplug connector of harness that connects the limiters to PCB from control board. Test harness

(including the two limiters) for continuity.

Resistance small?

yes: no:

B Change CH flow safety temperature limiter.

B Connect CH flow safety temperature limiter.




E9? go to 6

Reconnect connector.

go to 7

Harness defective.

B Repair or replace the harness.





E9? go to 7


B Remove fuse SI 3 from appliance

PCB control board and test for continuity.


yes: no:

B Remount the fuse.



go to 8

B Change the fuse.





E9? go to 8


8 716 115 748 (2009/09)


E9



Check Action

10.

The PCB is damaged.

B Make a note of the altered service settings.








8 716 115 748 (2009/09) 43

44


1.

2.

3.

4.

EA

and RESET button and fault indicator LED are flashing.

During operation: flame not detected.

Check

Is a burner flame visible?

Is the gas cock turned on?

Is there air in the supply pipe?

Natural gas models: measure gas supply at gas valve. Is the pressure OK according to technical data?

LPG models: is the flow rate of the gas supply to the appliance correct?

yes: no: yes: no: yes: no: yes: no: yes: no:

Action go to 5 go to 2 go to 3

B Open the gas valve.



EA? go to 3

B Vent supply pipe.



EA? go to 4 go to 4

B Is correct code plug fitted? If not, fit correct code plug (see Appendix).



EA? go to 5

B Check working pressure at appliance to eliminate pipe work problems.

B Check pressure at the building supply pressure regulator, inform gas company if outside correct range.



EA? go to 5 go to 5

B Is there enough gas in the supply cylinder?

B Is there air in the supply pipe?

B Is the supply pressure OK? (if supply pressure outside correct range, inform gas supplier)



EA? go to 5

Tab. 25 EA Error codes

8 716 115 748 (2009/09)


6.

7.

8.

5.

EA



Check



Is the earth connection correct?

yes:

Is the condensate trap blocked?

Is diaphragm in air/gas manifold fitted correctly (see installation instructions)?

B Open air/gas manifold.

B Check diaphragm for correct orientation, soiling and splitting.

Is diaphragm OK?

no: yes: no: yes: no:

Check the gas valve.


B Un-plug the connectors from the gas valve.

B Measure the gas valve coils I and

II electrical resistance.

R = 164± 40 Ω?

B Remove gas valve and check inlet filter for blockage.

yes: no:

Action



EA? go to 6

B Correct the electrical connection.





EA? go to 6

B Clean out condensation trap discharge pipe.



EA? go to 7 go to 7

B Close air/gas manifold (see installation instructions).

go to 8

B Insert diaphragm in the fan intake tube as per installation instructions so that the flaps open upwards.


EA? go to 8

B Reconnect the connectors.




EA? go to 9

B Turn off gas valve.


B Change the gas valve.


B Reconnect the connectors.



B Check appliance for leaks.



EA? go to 9


8 716 115 748 (2009/09) 45

46

9.


EA



Check

Problem with flue?

B Check CO

2

level in combustion air in the flue (with outer casing fitted).

Is the CO

2

level above 0.2%?

B Perform a fan pressure test

(as described in the installation manual).

B Open up heat exchanger - is it dirty?

Is flue gas CO

2

level incorrect?

yes: no: yes:

Action

B Check flue installation for agreement with the instruction manual.

Then:



EA? go to 10 go to 10

10.

11.

12.

13.

14.

B Select in the second service level the service function 8.F

(Permanent ignition).


Check the permanent ignition at the electrodes (without gas). Is it OK?

no: yes: no:

Ignition cable connected to ignition electrodes?

yes: no:

Ignition cable connector engaged in control panel?

yes: no:

Is the ignition cable damaged?

yes: no:

B Adjust to correct level.





Exit the service function.

go to 12


Exit the service function.

go to 15 go to 13

B Reconnect lead.





B Engage ignition cable connector in control panel.




EA? go to 14


B Change the ignition cable.






8 716 115 748 (2009/09)


16.

17.

15.

EA



Check

Electrode assembly defective?


B Remove electrode assembly.

Electrode assembly burnt out or cracked?

yes:



B Check if the 20-pin connector lead assembly is damaged.

The PCB is damaged.

no:

Action

B Replace electrode assembly.




EA? go to 16

B Refit electrode assembly.




EA? go to 16

B Change the connector lead assembly.





EA? go to 17









8 716 115 748 (2009/09) 47


2.

1.

F0

and fault indicator LED (and possibly RESET button) are flashing.

Internal failure

Check Action

Button reset flashing?

yes:

The PCB is damaged.

no:



B Initiate demand for heat by pressing button for 10 seconds and then press again after 30 seconds to cancel.

B Initiate two more demands for heat as above.

F0? go to 2 go to 2








Tab. 26 F0 Error codes

48 8 716 115 748 (2009/09)


2.

3.

1.

F7


Although appliance switches off, flame still detected

Check Action

Electrode(s) dirty or defective?


B Remove electrode assembly and bracket and check for wear, deposits and mechanical damage.

yes:

Problem with flue?

B Check CO

2

level in combustion air in the flue

(with outer casing fitted).

Is CO

2

level above 0.2%?

The PCB is damaged.

no: yes: no:





F7? go to 2





F7 go to 2

There are flue gases in the combustion air.

B Check flue and repair or replace if necessary.

F7? go to 3 go to 3








Tab. 27 F7 Error codes

8 716 115 748 (2009/09) 49

50


2.

3.

4.

5.

1.

FA


After appliance switches off flame is detected

Check Action

Is the condensate trap blocked?

yes:




Electrode assembly burnt out?

Problem with flue?

B Check CO

2


Is CO

2

level above 0.2%?

Is the gas valve damaged?



B Check if the 20-pin connector lead assembly is damaged.

no: yes: no: yes: no: yes: no:


B Clean out condensate trap discharge pipe.




FA? go to 2 go to 2





FA? go to 3 go to 3

There are flue gases in the combustion air.

B Check flue, clean if necessary.



FA? go to 4 go to 4











FA? go to 5 go to 5

B Change the connector lead assembly.





FA? go to 6

Tab. 28 FA Error codes

8 716 115 748 (2009/09)


6.

FA


After appliance switches off flame is detected

Check Action

The PCB is damaged.








Tab. 28 FA Error codes

1.

2.

Fd


Reset button pressed inadvertently

Check

reset button flashing?

The PCB is damaged.

Action



Fd? go to 2

B Make a note of the altered service settings (see table 6 on page 18).







Tab. 29 Fd Error codes

8 716 115 748 (2009/09) 51


7.5

FAULTS THAT ARE NOT DISPLAYED

7.5.1

APPLIANCE FAULTS

Excessive burner noise, rumbling noises

1.

Check

Does the gas supply type match the specifications on the appliance type plate?

yes: no:

2.

B Test gas supply pressure - OK?

Does pressure match figure specified in installation instructions?

yes: no:

3.

4.

5.

Problem with flue?

B Check CO

2


Is CO

2

level above 0.2%?

Is appliance’s internal air/flue channel leaking or blocked?

B Check control pressure at test point as stated in installation instructions. If fan fails the test.

B Open up heat exchanger and inspect.

B Remove silencer, flue duct and air flow limit.

B Open trap and inspect.

Air channels dirty/clogged, seals defective or not correctly fitted?

B Measure CO

2

CO

2

levels.

levels in flue gas at min. and max. output do not match figures specified in installation instructions.


Action go to 2

B Convert appliance to correct gas type.

Rumbling noises? go to 2 go to 3

B De-commission appliance.

Natural gas models:

B Notify gas utility.

There is flue gas in the combustion air.



B Repair or replace components.

B Grease seal before fitting. Ensure it is fitted in correct position.


B Adjust CO

2

level as per installation instructions.







Flow noises

Check

1.

Pump map/pump step incorrect?

Action

Wall hung combi and system appliances:

B Set appropriate pump map/pump step (service function 1.C/1.d).

Conventional appliances:

B Set appropriate pump velocity on pump.

52 8 716 115 748 (2009/09)


Heating up of last radiators in system too slow

1.

Check

Pump map/pump step incorrect?

Action

Wall hung combi and system appliances:

B Set appropriate pump map/pump step (service function 1.C/1.d).

Conventional appliances:

B Set appropriate pump velocity on pump.

Flue gas levels incorrect, CO level too high

Check

1.


yes: no:

2.

3.

4.

5.



yes: no:

Problem with flue?

B Check CO

2


Is CO

2

level above 0.2%?

Flue gas CO

2

levels measured at min. and max. load do not match specified levels?

B Measure the CO

2

or O

2

level.

Gas rate too high when CO

2

level correctly set.

yes: no: yes: no: yes:

6.

no:

Action go to 2


Flue gas levels incorrect? go to 2

↓3.


Natural gas models:




Flue gas levels incorrect? go to 4 go to 4

B Adjust CO

2



B Reduce gas rate by means of adjusting screw on gas valve and/or gas flow restrictor.

B Check CO

2

adjustment.








8 716 115 748 (2009/09) 53


Ignition too harsh, ignition poor

Check

1.

B Select in the second service level the service function 8.F (Permanent ignition).


Check the permanent ignition at the electrodes (without gas). Is it

OK?

2.

3.

4.

5.

Ignition cable connected to ignition electrodes?

Ignition cable connector engaged in control panel?

Is the ignition cable damaged?




Electrode assembly burnt out?

yes: no: yes: no: yes: no: yes: no: yes: no:

6.


yes: no:

Action



go to 6



go to 2 go to 3

B Connect cable to ignition electrodes.



Ignition poor? go to 3 go to 4


B Engage ignition cable connector in control panel.




Ignition poor? go to 4


B Change the ignition cable.









Ignition poor? go to 6







ignition poor? go to 7

54 8 716 115 748 (2009/09)


Ignition too harsh, ignition poor

Check

7.



8.

9.

10.

yes: no:

Problem with flue?

B Check CO

2


Is CO

2

level above 0.2%?

Flue gas CO

2

levels measured at min. and max. load do not match specified levels?

B Measure the CO

2

or O

2

level.

Burner incorrectly fitted or defective?



B Remove burner.

Cover fittings loose

or seal defective or incorrectly fitted

or burner defective?


Action go to 8


In case of natural gas:





B Adjust CO

2



B Replace burner and seal if necessary.

B Ensure seal is fitted in correct position.




Condensation in the air box

Check

1.

Is diaphragm in air/gas manifold fitted correctly (see installation instructions)?

B Open air/gas manifold.

B Check diaphragm for correct orientation, soiling and splitting.

Action

B Fit diaphragm as per installation instructions or replace.


8 716 115 748 (2009/09) 55


Inadequate hot water outlet temperature (combi boiler)

Check

1.

yes: Does pump run?

B Ensure the pump is not in ECO mode (default after power ON and after reset).

B Un-plug connector from pump; is voltage between terminal 1 and terminal 3 on connector

230 V AC?

no:

2.

3.

Compare flow rate from boiler with showed flow rate in service function 6.d.

Are they equal?



B Un-plug connector from

Heatronic;



B Is voltage between terminal 1 and terminal 3 on Heatronic

230 V AC?


Action

B Try to start pump.

B If not successful, change pump.

go to 2 go to 3

B Change turbine.



B Change the lead assembly.



B Make a note of the altered service settings (see table 6 on page 18).







7.5.2

PROGRAMMER FAULTS

Set room temperature not reached (DT10/DT20)

1.

Check

Thermostatic valve(s) set too low?

yes:

2.

3.

4.

Set time periods for channel 1 at the timer DT10/20 correct?

Check the channel 1 at DT10/20 with the service function 6.E. Is the left digit set to 1?

CH flow temperature control on boiler set too low?

no: yes: no: yes: no: yes: no:

Action

B Turn up thermostatic valve(s).

go to 2 go to 2 go to 3

B Correct the time periods for channel 1.

go to 4

B Change DT10/20.

B Turn up CH flow temperature control.

go to 5 go to 5

56 8 716 115 748 (2009/09)


Set room temperature not reached (DT10/DT20)

5.

Check

Air in the heating system.

Action


B Check appliance and system for water leaks and repair as necessary.

B Top up system.


B Select in the first service level the service function

2.C (Air purge mode).



B The appliance vents itself for 8 minutes.

B Vent radiators manually.

Set room temperature exceeded by large amount

1.

Check

Do radiators get too hot?

yes:

2.

Bad choice of location for programmer, e.g. outside wall, near window, in draught, etc. no: yes:

3.

Excessive fluctuations in room temperature

1.

Check

Poor choice of location for roomstat e.g. outside wall, near window, in draught, on hollow wall, etc.

no:

Action

B Decrease setting of “Heating” control.

go to 2 go to 2

B Select better installation location.

or

B Fit external room thermostat.

go to 3 go to 3

B Turn down thermostatic valve(s).

Action

B Select better installation location.

8 716 115 748 (2009/09) 57

TROUBLESHOOTING - FW 100

8 TROUBLESHOOTING - FW 100

BUS device faults are indicated.

If the controller shows Fault 12, the cylinder temperature is so high that the cylinder High Limit

Thermal Cut-out has tripped.

B Reset the High Limit Thermal Cut-out.

8.1

TROUBLESHOOTING USING THE DISPLAY

The current fault is displayed on the controller:

9 12 h

15

2

1

3

B Identify the BUS device affected by the current fault.

The fault can only be rectified on the BUS device from which the fault originates.

4

3 24 h 21

6 720 613 462-17.1O

3

4

Fig. 16 Fault display

1

2

Fault number

BUS device which detected the fault and reported it to the controller

Description of fault

Code or additional information about fault

Information displayed (Æ Pos. 1, 3 and 4 in fig.16)

Text

Fault 01

BUS communication fault

Code Cause

200 Boiler no longer reporting.

Fault 02

Internal fault

201 Incorrect BUS subscriber con-

42 nected.

Code switch on IPM in intermedi-

Fault 02

Internal fault

Some parameters reset to factory settings due to EEPROM

Remedy

Check BUS device, BUS connection and repair circuit break if necessary.

Identify and replace incorrect BUS device.

Switch system off and correct coding.

43 ate position.

Coding switch position has been changed since initialisation phase.

100 ISM not responding.

Check BUS connection and repair circuit break if necessary.

205 Some parameters reset to default. Check parameter settings and readjust them as necessary. Replace faulty controller.

problem

Fault 02

Internal fault

FW 100 can no longer control the heating system!

Fault 03

Room temp sensor faulty

255

20

21

FW 100 can no longer control the heating system.

There is a circuit break on the room temperature sensor built into the

FW 100.

There is a short circuit on the room

Replace faulty controller.

Replace faulty controller.

temperature sensor built into the

FW 100.

Tab. 30

58 8 716 115 748 (2009/09)



Text

Fault 11

System configuration: new BUS device

Code Cause

131 New ISM detected.

132

New ISM detected. Power up all

ISMs simultaneously and start automatic system configuration.

Fault 12

System configuration: BUS device missing

ISM1 not detected. Check connection.

Fault 13

System configuration: BUS device changed or replaced

Check system configuration for

DHW or start automatic system configuration.

Fault 13

170

171

HLC has tripped or is faulty.

Check HLC.

Check solar parameter T2.

Is thermal disinfection active?

Check connection.

ISM1 no longer detected despite having been configured.

157 BUS device changed or replaced.

Check system configuration for domestic hot water system or start automatic system configuration.

158

159

Remedy

Power up all ISMs simultaneously and start automatic system configuration.

Check system configuration for heating circuit System configuration: BUS device changed or replaced

Check system configuration for heating circuit!

Fault 15

Outside temperature sensor not connected

30 Outside temperature sensor not recognised.

Check outside temperature sensor and remedy interruption, if necessary.

Outside temperature is not available.

Fault 19

Unable to save parameter settings

Fault 20

System configuration: invalid

Fault 29


Fault 30

Mixer temperature sensor faulty

Fault 33

Temperature sensors incorrectly connected

Fault 40

Temperature sensor T1 on collector group 1 faulty

Fault 41

Temperature sensor T2 at bottom of solar cylinder faulty

Tab. 30

202

193

202

7

22

101

BUS device is configured but not available at present.

Invalid coding in remote control for the heating circuit.


Mixer temperature sensor (MF) connected to IPM faulty.

A temperature sensor is connected to the IUM.

Short circuit on the sensor lead

(T

1

).

102 Break in the sensor lead (T

1

).

103 Short circuit on the sensor lead

(T

2

).


2

).

Check system layout, check system configuration, modify if necessary and set parameter again.

In combination with FW 100 only coding 1 is possible in the remote control.

Check system layout, check system configuration, modify if necessary and reset parameters on remote control.

Check mixer temperature sensor (MF) and replace if necessary.

Remove the temperature sensor and insert a coding plug if necessary.

Check temperature sensor (T replace if necessary.

Check temperature sensor (T replace if necessary.

1

2

) and

) and

8 716 115 748 (2009/09) 59



Text

Fault 50

Solar pump jammed or air in system

Fault 56

At least one pump/valve in manual mode

Tab. 30

Code Cause

121 Solar pump (SP) sticking due to

126

140 physical blockage.

Air in solar thermal system.

Fault 51

Incorrect temperature sensor type connected

Fault 52

Temperature sensors reversed

Fault 53

Temperature sensor fitted in wrong location

Fault 54

Temperature for thermal disinfection not reached in solar cylinder

122 Collector temperature sensor type used as cylinder temperature sensor (T

2

).

123 Cylinder temperature sensor type used as collector temperature sensor (T

1

)

127 Cylinder temperature sensor type used as collector temperature sensor (TA).

132 Temperature sensor type PTC 1000 used as cylinder temperature sensor (T

2

).

133 Temperature sensor type PTC 1000 used as collector temperature

124 Temperature sensors (T

1

and T

2

)

125

128 sensor (T

1

).

reversed.

Collector temperature sensor (T

1

) fitted on collector array inlet.

145 Maximum temperature for solar cylinder too low.

Delivery rate of disinfection pump

(PE) too low.

Fault 55

Solar system not yet commissioned temperature was reached in the solar cylinder.

146 Solar system is not yet in operation.

147

154

Thermal disinfection cancelled manually before the required

Pump (SP) in manual mode.

Pump (PE) operated manually.

Remedy

Unscrew and remove the slotted screw on the pump head and use a screwdriver to release the pump shaft.

Do NOT strike the pump shaft with the screwdriver.

Bleed solar system and top up with heat transfer fluid if necessary.

Use correct type of temperature sensor. Æ Technical data in ISM installation instructions.

Check the temperature sensors and swap the connections if necessary.

Fit collector temperature sensor (T

1

) close to collector array outlet.

Set maximum temperature for the solar cylinder higher Æ limit cylinder temperature, page 49.

Set higher pump speed on disinfection pump (PE) or, if possible, open flow restrictor more.

This is not a fault. Message is shown only for 5 minutes.

Fill, bleed and prepare the solar thermal system for commissioning according to its documentation. Then start up the solar system.

Reset parameters for pump or valve to

“Auto”.

60 8 716 115 748 (2009/09)



Text

Fault 59

Mass flow rate in solar system too high/low.

Code Cause

201 Mass flow rate in solar system for collector group 1 is too high.

202 Mass flow rate in solar system for collector group 1 is too low.

Remedy

Set mass flow in solar system correctly

(e.g. increase/decrease pump speed) and if necessary open or close flow restrictor more on solar station.

Guide figure: 20 - 40 kg/m 2 of collector area per hour.

Check setting for collector area, type and climate zone on Solar optimisation menu.

Tab. 30

8 716 115 748 (2009/09) 61


8.2

TROUBLESHOOTING WITHOUT THE DISPLAY

Fault

Required room temperature not achieved.

Excessive room temperature fluctuations.

Temperature rises instead of falling.

Room temperature too high during

“Economy” and/or

“Frost” mode.

Incorrect or no control.

Controller can only be set to automatic mode.

Domestic hot water cylinder does not heat up.

Cause

Thermostatic valve(s) set too low.

Minimum outside temperature setting too low.

Heating curve set too low.

Flow temperature controller on the boiler set too low.


Room temperature offset set incorrectly

Remedy

Set thermostatic valve(s) higher.

Adjust minimum outside temperature setting.

Heating up takes too long.

Flow temperature from boiler too low, radiators too cool.

Required room temperature greatly exceeded.

The boilers holiday function is active.

“Heating up speed” set too low.

Minimum outside temperature setting too low.

Radiators become too hot.

FW 100 installed in an unfavourable location, e.g. external wall, near windows, in a draught,

Room temperature offset set incorrectly

Adjust minimum outside temperature setting.

Set thermostatic valve(s) lower.

“Heating levels” for “Comfort” or ask your installer to correct heating curve.

Select a better location for FW 100 and ask your heating engineer to reposition it.

Temporary influence of external heat on the room, e.g. through solar radiation, lighting,

TV, fireplace etc.

Clock time incorrectly set.

Perform adjustment to room temperature sensor and correct Room temperature offset.

Increase “Room influence”.

Select a better location for FW 100.

Check time setting.

The building retains a lot of heat.

BUS connection or BUS subscriber faulty.

Mode selector faulty.

Domestic hot water temperature control on boiler set too low.


Domestic hot water programme fault.

Incorrect System configuration for domestic hot water system.

“Heating levels” for “Comfort” - Correct heating curve.

Set the flow temperature controller higher.

Reduce influence of solar optimisation if necessary.

Bleed radiators and vent the heating system.

Perform adjustment to room temperature sensor and correct Room temperature offset.

Deactivate the boilers holiday function.

Set “Heating up speed” e. g. to “Fast”.

Set an earlier switching time for “Economy” and/ or “Frost”.

Check the BUS connection against the wiring diagram and correct it if required.

Have FW 100 replaced by your installer.

Set domestic hot water temperature control higher.


Turn the flow temperature control on the boiler clockwise as far as it will go.

Check/correct programme.

Correct the configuration to match the domestic hot water system connected.

Tab. 31

62 8 716 115 748 (2009/09)

TROUBLESHOOTING - FR110

9 TROUBLESHOOTING - FR110

BUS device faults are indicated.

If the controller shows Fault 12, the cylinder temperature is so high that the cylinder High Limit

Thermal Cut-out has tripped.

B Reset the High Limit Thermal Cut-out.

9.1

TROUBLESHOOTING USING THE DISPLAY

The current fault is indicated on the controller:

9 12 h 15

1

6

3

18

2

B Identify the BUS device affected by the current fault.

The fault can only be rectified on the BUS device from which the fault originates.

4

3 24 h

21

8716115748-10.1Wo

3

4

Fig. 17 Fault display

1

2

Fault number

BUS device which detected the fault and reported it to the controller

Description of fault

Code or additional information about fault

Information displayed

(Æ items 1, 3 and 4 in Fig. 17 )

Text

Fault 01

BUS communication fault

Fault 02

Internal fault

Fault 02

Internal fault

Some parameters reset to factory settings due to EEPROM problem

Fault 02

Internal fault

FR110 can no longer control the CH system

Fault 03

Room temp sensor faulty

Code Cause

200 Boiler no longer reporting.

Remedy

Check BUS device, BUS connection and repair circuit break if necessary.

Identify and replace incorrect 201 Incorrect BUS subscriber connected.

BUS device.

40 Incorrect module type detected.

Replace IPM.

100 ISM not responding.

Check BUS connection and repair circuit break if necessary.

205 Some parameters reset to default. Check parameter settings and

255 FR 110 can no longer control the heating system.

readjust them as necessary.

Identify faulty controller and replace.


20

21

There is a circuit break on the room temperature sensor built into the FR 110.

There is a short circuit on the room temperature sensor built into the FR 110.


Tab. 32

8 716 115 748 (2009/09) 63



(Æ items 1, 3 and 4 in Fig. 17 )

Text

Fault 11

System configuration: new BUS device

New ISM detected. Power up all ISMs simultaneously and start automatic system configuration.

Fault 12

System configuration: BUS device missing

ISM1 not detected. Check connection.

Fault 13


Check system configuration for DHW or start automatic system configuration.

Fault 13


Check system configuration for heating circuit x and connections on IPM for heating circuit x.

Fault 14

System configuration: incompatible

BUS device

DHW controlled by boiler. IPM control of DHW has no effect.

Fault 14

System configuration: incompatible

BUS device

IPM for cylinder must be set to identification 3 or higher.

Fault 19


Code Cause

131

132

New ISM detected.

Remedy

Power up all ISMs simultaneously and start automatic system configuration.

170

171

HLC has tripped or is faulty.

Check HLC.

Check solar parameter T2

ISM1 no longer detected despite

Is thermal disinfection active?

Check connection.

having been configured.


Check system configuration for hot water system or start automatic system configuration.


Check system configuration for heating circuit x.

117 Incompatible BUS device:

118

119

Incompatible BUS device:

Identify incompatible BUS device and remove from the system.

Set IPM for cylinder to coding 3 or higher.

Fault 33

Temperature sensors incorrectly connected

Fault 40

Temperature sensor T1 on collector group 1 faulty

Fault 41

Temperature sensor T2 at bottom of solar cylinder faulty

Tab. 32

202

22

101


A temperature sensor is connected to the IUM.

Short circuit on the sensor lead

(T

1

).


1

).

103 Short circuit on the sensor lead

(T

2

).


2

).

Check system layout, check system configuration, modify if necessary and set parameter again.

Remove the temperature sensor and insert a coding plug if necessary.

Check temperature sensor (T

1

) and replace if necessary.

Check temperature sensor (T and replace if necessary.

2

)

64 8 716 115 748 (2009/09)



(Æ items 1, 3 and 4 in Fig. 17 )

Text

Fault 50

Solar pump jammed or air in system

Fault 51

Incorrect temperature sensor type connected

Fault 52

Temperature sensors reversed

Fault 53

Temperature sensor fitted in wrong location

Fault 54

Temperature for thermal disinfection not reached in solar cylinder

Fault 55

Solar system not yet commissioned

Fault 56

At least one pump/valve in manual mode

Code Cause

121 Solar pump (SP) sticking due to physical blockage.

Air in solar thermal system.

122 Collector temperature sensor type used as cylinder temperature sensor (T

2

).

123 Cylinder temperature sensor type used as collector temperature sensor (T

1

)

132 Temperature sensor type PTC

1000 used as cylinder temperature sensor (T

2

).

133 Temperature sensor type PTC

1000 used as collector temperature sensor (T

1

).

124 Temperature sensors (T

1

and T

2

) reversed.

Remedy

Unscrew and remove the slotted screw on the pump head and use a screwdriver to release the pump shaft. Do NOT strike the pump shaft with the screwdriver.

Bleed solar system and top up with heat transfer fluid if necessary.

Use correct type of temperature sensor. Æ Technical data in ISM installation instructions.

125 Collector temperature sensor (T

145 fitted on collector array inlet.

Maximum temperature for solar cylinder too low.

Delivery rate of disinfection pump

(PE) too low.

Thermal disinfection cancelled manually before the required temperature was reached in the solar cylinder.

146 Solar system is not yet in operation.

1

)

Check the temperature sensors and swap the connections if necessary.

Fit collector temperature sensor

(T

1

) close to collector array outlet.

Set higher maximum temperature for solar cylinder.

Æ Limiting cylinder temperature.

Set higher pump speed on disinfection pump (PE) or, if possible, open flow restrictor more.

This is not a fault. Message is shown only for 5 minutes.

147 Pump (SP) in manual mode.

Fill, bleed and prepare the solar thermal system for commissioning according to its documentation. Then start up the solar system.

Reset parameters for pump or valve to “Auto”.

Tab. 32

8 716 115 748 (2009/09) 65



(Æ items 1, 3 and 4 in Fig. 17 )

Text

Fault 59

Mass flow rate in solar system too high/ low.

Code Cause

201 Mass flow rate in solar system for collector group 1 is too high.

202 Mass flow rate in solar system for collector group 1 is too low.

Remedy

Set mass flow in solar system correctly (e.g. increase/ decrease pump speed) and if necessary open or close flow restrictor more on solar station.

Guide figure: 20 - 40 kg/m 2 of collector area per hour.

Check setting for collector area, type and climate zone on Solar optimisation menu.

Tab. 32

66 8 716 115 748 (2009/09)


9.2

TROUBLESHOOTING WITHOUT THE DISPLAY

Fault

Required room temperature not achieved.

Required room temperature greatly exceeded.

Excessive room temperature fluctuations.

Temperature rises instead of falling.

Room temperature too high during

“Economy” and/or

“Frost” mode.

Incorrect or no control.

Controller can only be set to automatic mode.

Hot water cylinder does not heat up.

Cause Remedy

Thermostatic valve(s) set too low.



Holiday key on the boiler enabled.

Radiators become too hot.

Set thermostatic valve(s) higher.

Set the flow temperature controller higher.


Bleed radiators and vent the heating system.

Disable the holiday key on the boiler.

Set thermostatic valve(s) lower.

Set Heating levels for “Comfort” lower.

Select a better location for FR 110 and reposition it.

FR 110 installed in an unfavourable location, e.g. external wall, near windows, in a draught,

Temporary influence of external heat on the room, e.g. through radiant energy from the sun, lighting, TV, fireplace etc.

Clock time incorrectly set.

Select a better location for FR 110 and reposition it.

Check time setting.

The building retains a lot of heat.

BUS connection or BUS subscriber faulty.

Mode selector faulty.

Set an earlier switching time for “Economy” and/or “Frost”.

Check the BUS connection against the wiring diagram and correct it if required.

Have FR 110 replaced by your heating engineer.

Heating on during the night.

Hot water temperature control on boiler set too low.


Hot water programme fault.

Incorrect System configuration for hot water system.

Heat-up optimisation starts the heating early so that the home reaches the desired room temperature by the set time.

Set hot water temperature control higher.


Turn the flow temperature control on the boiler clockwise as far as it will go.

Check/correct programme.

Correct the configuration to match the hot water system connected.

Set a later time for the desired room temperature.

Switch off heat-up optimisation.

Tab. 33

8 716 115 748 (2009/09) 67

TROUBLESHOOTING - RT10

10 TROUBLESHOOTING - RT10

In the event of a fault in the heating appliance, the display will show e.g.

A7 E.

In the event of a fault in the FW 100, the display will show e.g. 1A4 E.

Here the figure 1 stands for a fault in the FW 100 and the letter E for Error (= fault):

Display Cause

1A4 E Temperature sensor in the

FW 100 defective.

Remedy

Replace FW 100.

1A8 E TD 200 using the bus no longer responds.

Check bus connection and, if necessary, rectify interruption.

Heating appliance using the bus no longer responds.

Check bus connection and, if necessary, rectify interruption.

e.g.:

A7 E

...

Error display for the heating appliance.

Rectify the fault in accordance with the heating appliance documentation.

Tab. 34

Complaint Cause Remedy

Required temperature not reached

Thermostatic valve(s) in the room set to low

Open the thermostatic valve(s).

Flow temperature controller on the heating appliance set too low

Set flow temperature controller higher.

Required room temperature is greatly exceeded

Air lock in the heating system

Installation location of the

FW 100 not suitable, e.g. outer wall, proximity to window, draught, ...

Vent radiator and heating system.

Choose a better installation location move the FW 100.

Excessive room temperature fluctuations

Temporary effect of heat from other sources on the room, e.g. from sunshine, room lighting,

TV, fireplace etc.

Choose a better installation location and move the FW 100.

Temperature rise instead of fall

Time of day set incorrectly on the TD 200

Room temperature too high in low mode

Incorrect or no control

Building has high degree of heat storage

Select low mode earlier.

Bus connection defective for the devices using the bus

Check setting.

Check the bus connection and, if necessary, rectify according to the connection diagram.

Tab. 35

68 8 716 115 748 (2009/09)

TROUBLESHOOTING - TD 200

11 TROUBLESHOOTING - TD 200

Faults in the devices using the bus are displayed.

A fault in the heating appliance is shown in the display with corresponding help texts.

Display

TD 200 defect

Cause

Temperature sensor in the TD 200 defective

No Bus communication The TD 200 using the bus no longer responds.

Heating appliance using the bus no longer responds.

On/Off instead of

TD 200 not detected during commissioning. Set

Room temperature

Only Service modes are displayed, e.g.:

Service 1.A:

No error:

Service mode at heating appliance active.

and maximum central heating heatout.

The following appears each time the button is pressed:

Key lock is active.

press ok to go back

Key lock function is active...

No display Heating appliance is switched off.

A “YS Plan” is connected

Tab. 36

Remedy

Emergency mode:

The heating automatically goes into On / Off mode.

If Room temperature continues to be displayed during the standard display:

Set RT10 equipped? to No.

Check the bus connection and if necessary rectify the interruption.

Have TD 200 replaced by a professional.



Set RT10 equipped? to Yes.

Press the Service button on the heating appliance.

Deactivate key lock.

Switch on heating appliance.

No function for TD 200 possible.

8 716 115 748 (2009/09) 69

TROUBLESHOOTING - TD 200

Complaint

Required temperature not reached

Required room temperature is greatly exceeded

Excessive room temperature fluctuations

Temperature rise instead of fall

Room temperature too high in Economy mode

Incorrect or no control

Only Automatic mode can be set

Tab. 37

Cause

Thermostat valve(s) in the control room set to low

Flow temperature controller on the heating appliance set too low

Air lock in the heating system

Installation location of the TD 200 not suitable, e.g. outer wall, proximity to window, draught, ...

Temporary effect of heat from other sources on the room, e.g. from sunshine, room lighting, TV, fireplace etc.

Time of day incorrectly set

Building has high degree of heat storage

Bus connection defective for the devices using the bus

Operating switch defective

Remedy

Fully open the thermostat valve(s) or replace them with manual valve(s).

Set flow temperature controller higher.

Vent radiator and heating system.

Choose a better installation location for TD 200

(see Installation Instructions of the TD 200).

Choose a better installation location for TD 200

(see Installation Instructions of the TD 200).

Check setting.

Select Economy mode earlier.

Check the bus connection, if necessary, rectify according to the connection diagram.

Replace the TD200

70 8 716 115 748 (2009/09)

APPENDIX

12 APPENDIX

12.1 NTC SENSOR VALUES, CDi APPLIANCES

12.1.1 CH flow NTC sensor and hot water NTC sensor

70

75

80

85

50

55

60

65

30

35

40

45

Temperature ( °C)

Measurement tolerance ± 10%

20

25

Resistance ( Ω)

14 772

11 981

9 786

8 047

6 653

5 523

4 608

3 856

3 243

2 744

2 332

1 990

1 704

1 464

90

95

1 262

1 093

100 950

Tab. 38 Central heating flow & hot water sensors

12.2

CDi fan speeds

Appliance

27CDi N.G.

30CDi N.G.

37CDi N.G.

42CDi N.G.

27CDi L.P.G.

30CDi L.P.G.

37CDi L.P.G.

Fan speed ranges (Hz)

29 - 78

29 - 91

32 - 84

31 - 82

36 - 74

36 - 84

41 - 78

42CDi L.P.G.

30CDi Conventional N.G.

41 - 78

29 - 91

40CDi Conventional N.G.

29 - 91

30CDi Conventional L.P.G.

36 - 84

40CDi Conventional L.P.G.

36- 84

Tab. 39 CDi fan speed range

12.3 HIGHFLOW CDi &

FS CDi Regular fan speeds

APPLIANCE

SPEED RANGE

MIN - MAX (Hz)

HIGHFLOW 440CDi N.G.

36 - 96

HIGHFLOW 440CDi L.P.G.

40 - 93

HIGHFLOW 550CDi N.G.

36 - 111

HIGHFLOW 550CDi L.P.G.

36 - 108

FS 30CDi Regular N.G.


38 - 101

40 - 98



Tab. 40 Fan speed range

36 - 109

39 - 106

8 716 115 748 (2009/09) 71

APPENDIX

12.4 NTC SENSOR CHARACTERISTICS HIGHFLOW CDi & FS CDi REGULAR APPLIANCES

12.4.3 OUTDOOR NTC SENSOR CHARACTERISTIC

Description Characteristic

TABLE

Primary NTC

Domestic hot water NTC

Siemens NTC

Elmwood NTC

RESISTANCE ( Ω)

>= 4111

TEMPERATURE ( °C)

-40

Internal heat bank NTC Elmwood NTC

3669 -35

Outdoor NTC Outdoor NTC

3218

Tab. 41 Thermisters

-30

2775 -25

12.4.1 SIEMENS NTC SENSOR CHARACTERISTIC

TABLE

2360 -20

RESISTANCE ( Ω) TEMPERATURE ( °C)

1983 -15

>= 35975 0

1650 -10

22763 10

1363 -5

14772 20

1122 0

9786 30

922 5

6652 40

759 10

4607 50

624 15

3243 60

515 20

2332 70

427 25

1703 80

354 30

1261 90

296 35

<= 949 100

247 40

Tab. 42 Siemens thermisters

207 45

12.4.2 ELMWOOD NTC CHARACTERISTIC TABLE <= 174 50

RESISTANCE ( Ω)

33242

TEMPERATURE ( °C)

0

Tab. 44 Outdoor thermisters

12.4.4 FLOW TURBINE HORIZONTAL

19947 10

FREQUENCY (Hz) FLOW RATE (L/m)

12394 20

0 0

7947 30

7.7

1.5

5242 40

69.2

10

3548 50

104.1

15

2459 60

140.5

20

1740 70

176.4

25

1256 80

Tab. 45 Flow turbine

923 90

Tab. 43 Elmwood thermisters

72 8 716 115 748 (2009/09)

12.5 ELECTRICAL WIRING DIAGRAMS

12.5.1 CDi COMBI APPLIANCES

FAN

FLAME SENSE

ELECTRODE

Orange or Green

FLOW NTC

Orange

SPARK

ELECTRODES

HEAT

EXCHANGER

OVERHEAT

STAT

R e d

APPENDIX

FLUE

OVERHEAT

STAT

Red

SAFETY

SOLENOID

Black

Black

Orange

SAFETY

SOLENOID

DHW

SENSOR

PUMP

PUMP

CONTROL

White

Black

Purple

MAINS

SUPPLY

Earth

230 V ROOM STAT/

PROGRAMMER

Colour sequence

CH TEM-

PERATURE

CONTROL

SPARK

TRANSFORMER

ST5

L

R

Ls Ns N L

ST10

Fuse, slow

2.5 A, AC 230 V

PUMP

SUPPLY

ST4

DHW

TEMPERATURE

CONTROL

ST6

ST8

1

F

A

B

B

4

2

230 V

ST1

9V/25 V

230V/AC

DIAGNOSTIC

INTERFACE

Fig. 18 CDi combi electrical diagram

ST17

230 V EXTERNAL

FROST STAT

(OPTIONAL)

ST9

Fuse, slow T 0.5 A

Fuse, slow T1.6 A

ST18

CODE

PLUG

DIVERTER

VALVE

Red

Orange

Blue

Yellow

Green

Black

ST19

Red

Orange

Blue

Yellow

Green

Black

Black

Black

Black

Black

Red

Red

Orange or Green

Black

Black

Black

Orange

Orange

Orange

Orange

White

Black

Purple

FLOW

TURBINE

Black

6 720 612 485-01.1O

8 716 115 748 (2009/09) 73

APPENDIX

12.5.2 CDi SYSTEM APPLIANCES

FAN

FLAME SENSE

ELECTRODE

Orange

FLOW NTC

Orange

SPARK

ELECTRODES

HEAT

EXCHANGER

OVERHEAT

STAT

Red

FLUE

OVERHEAT

STAT

Red

SAFETY

SOLENOID

Black

Black

SAFETY

SOLENOID

PUMP

PUMP

CONTROL

White

Black

Purple

DIVERTER

VALVE

(Optional)

Red

Orange

Blue

Yellow

Green

Black

MAINS

SUPPLY

Earth

PUMP

SUPPLY

WIRING

CENTRE

CH TEM-

PERATURE

CONTROL

SPARK

TRANSFORMER

L

R

Ls Ns N

ST10

L

Colour sequence

ST5

ST4

Fuse, slow

2.5 A, AC 230 V

230 V EXTERNAL

FROST STAT

(OPTIONAL)

SENSOR FOR

DIVERTER

VALVE KIT

DHW

TEMPERATURE

CONTROL

ST6

1

F

A

B

B

4

2

ST8

ST17

ST19

ST9

Red

Orange

Blue

Yellow

Green

Black

Black

Black

Black

Black

Red

Red

Orange

9V/25 V

230 V

ST1

230V/AC

DIAGNOSTIC

INTERFACE

Fig. 19 CDi System electrical diagram

Fuse, slow T 0.5 A

Fuse, slow T1.6 A

ST18

CODE

PLUG

Orange

Orange

White

Black

Purple

74 8 716 115 748 (2009/09)

6 720 612 458-06.1O

12.5.3 CDi REGULAR APPLIANCES

FAN

FLAME SENSE

ELECTRODE

Orange

FLOW NTC

Orange

SPARK

ELECTRODES

HEAT

EXCHANGER

OVERHEAT

STAT

Red

APPENDIX

FLUE

OVERHEAT

STAT

Red

SAFETY

SOLENOID

Black

Black

SAFETY

SOLENOID

Earth

MAINS

SUPPLY

WIRING

CENTRE

Colour sequence

CH TEM-

PERATURE

CONTROL

SPARK

TRANSFORMER

ST5

L

R

Ls Ns N L

ST10

Fuse, slow

2.5 A, AC 230 V

PUMP SUPPLY

ST2

ST4 ST6

ST8

ST17

9V/25 V

230 V

EXTERNAL

PUMP 230V/AC

ST1

6 720 612 032-35.1O

Fig. 20 CDi Regular electrical diagram

DIAGNOSTIC

INTERFACE

8 716 115 748 (2009/09)

ST9

Fuse, slow T 0.5 A

Fuse, slow T1.6 A

ST18

CODE

PLUG

Black

Black

Black

Black

Red

Red

Orange

Orange

Orange

75

APPENDIX

12.5.4 HIGHFLOW CDi APPLIANCES

FAN

FLAME SENSE

ELECTRODE

Orange or Green

PRIMARY

FLOW NTC

Red

SPARK

ELECTRODES

PRIMARY

OVERHEAT

Orange

DHW

SENSOR

SAFETY

SOLENOID

SAFETY

SOLENOID

230V TWIN

PROGRAMMER

CH

DHW

230 V

Violet

Blue

9V/25 V

230V/AC

230 V

HW

INTER-

FACE

MAINS

SUPPLY

Earth

IGNITION

TRANSFORMER

*

ST5

L

R

Ls Ns N L

ST10

Fuse, slow

2.5 A, AC 230 V

ST1

DIAGNOSTIC

INTERFACE

Fig. 21 Highflow CDi electrical diagram

FLUE

OVERHEAT

Colour sequence

Orange

PUMP

TANK

OVERHEAT

FLOW

TURBINE

DIVERTER

VALVE

HIGH LEVEL

SENSOR

PUMP

SUPPLY

CONDENSATE

PUMP

ST4

ST6

EMS

BUS

ST25

1

F

A

B

B

4

2

ST19

OUTDOOR

TEMP NTC

ST8

*

ST15

ST17

* Prelinked

Blue

Blue

Violet

Violet

Orange

Orange

Green or Orange

ST9

Fuse, slow T 0.5 A

Fuse, slow T1.6 A

CODE

ST18

PLUG

Pink

Red

Red

8716115748-08.1Wo

76 8 716 115 748 (2009/09)

12.5.5 FS CDi APPLIANCES

FAN

FLAME SENSE

ELECTRODE

Orange or Green

PRIMARY

FLOW NTC

Red

SPARK

ELECTRODES

PRIMARY

OVERHEAT

O ra nge

APPENDIX

FLUE

OVERHEAT

Orange

SAFETY

SOLENOID

Violet

Blue

SAFETY

SOLENOID

EXTERNAL

WIRING CENTRE

Y or S PLAN

Earth

MAINS

SUPPLY

Colour sequence

IGNITION

TRANSFORMER

*

ST5

L

R

Ls Ns N L

ST10

Fuse, slow

2.5 A, AC 230 V

230 V

9V/25 V

230V/AC

ST1

DIAGNOSTIC

INTERFACE

Fig. 22 FS CDi electrical diagram

PUMP

EXTERNAL

PUMP

CONTROL

PUMP

SUPPLY

HIGH LEVEL

SENSOR

CONDENSATE

PUMP

ST25

ST6

EXTERNAL

STAT

*

ST8

1

F

A

B

B

4

2

ST19

* Prelinked

ST9

Fuse, slow T 0.5 A

Fuse, slow T1.6 A

CODE

PLUG

ST18

Blue

Blue

Violet

Violet

Orange

Orange

Green or Orange

Pink

Red

Red

8 716 115 748 (2009/09)

8716115748-09.1Wo

77

APPENDIX

12.6 CODE PLUGS USED WITH CDi

APPLIANCES

Order no.

Remarks Component

Code plug

27CDi N.G.

8 714 431 020 0 -

30CDi N.G.

37CDi N.G.

42CDi N.G.

27CDi L.P.G.

30CDi L.P.G.

37CDi L.P.G.

42CDi L.P.G.

30CDi system

N.G.

without diverter valve

30CDi system

L.P.G. without diverter valve

30CDi system

N.G. with diverter valve

30CDi system

L.P.G. with diverter valve

8 714 431 012 0

8 714 431 014 0 -

8 714 431 016 0

8 714 431 021 0 -

8 714 431 013 0

8 714 431 015 0 -

8 714 431 017 0

8 714 431 018 0

8 714 431 019 0

8 714 431 002 0

8 714 431 003 0

30CDi

Regular N.G.

40CDi

Regular N.G.

8 714 431 008 0

8 714 431 010 0

30CDi

Regular L.P.G.

8 714 431 009 0

40CDi

Regular L.P.G.

8 714 431 011 0

Tab. 46 CDi code plug part numbers

Mid position diverter valve systems and

Zone valves systems

12.7 CODE PLUGS USED WITH HIGHFLOW

CDi & FS CDi REGULAR APPLIANCES

Component

Code plug

Order no.

Highflow 440CDi

N.G.

8 714 431 700 0 -

Remarks

Highflow 440CDi

L.P.G..

8 714 431 701 0

Highflow 550CDi

N.G.

8 714 431 702 0 -

Highflow 550CDi

N.G.

8 714 431 703 0

8 714 431 704 0 FS 30CDi

Regular N.G.

FS 30CDi

Regular L.P.G.

8 714 431 705 0

FS 42CDi

Regular N.G.

8 714 431 706 0 -

FS 42CDi

Regular L.P.G.

8 714 431 707 0

Tab. 47 Highflow CDi & FS CDi Regular code plug part numbers

78 8 716 115 748 (2009/09)

12.8 APPROVED CORROSION INHIBITORS

AND ANTI-FREEZE FOR CENTRAL

HEATING WATER

CORROSION INHIBITOR

B Add a suitable* inhibitor (or combined inhibitor/antifreeze if the system is exposed to freezing conditions) to the heating system in accordance with the DWTA

Code of Practice and the manufacturers instructions.

*The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the appliance and any other materials/components within the system.

Manufacturer

Fernox 01799 550811

Sentinal 1800 882 373 fernox.com

sentinel-solutions.net

APPENDIX

12.9 POSSIBLE SOURCES OF CORROSIVE

CFCS

The presence of halogenated hydrocarbons in the combustion air causes surface corrosion on affected metals. Particularly susceptible is the combustion chamber and the heat exchanger surfaces (including stainless steel) as well as the metal components in the flue socket, flue pipe connections and in the chimney.

The halogen compounds present in the combustion air produce highly corrosive hydrochloric acid in the flame and in some cases - depending on the precise composition of the combustion air - hydrofluoric acid, both of which accumulate in the boiler and remain active over long periods.

In order to limit the damage, the source of the air contamination must be located and sealed off. If this is not possible, the combustion air must be drawn from an alternative clean source.

Halogens can occur in the following locations:

Commercial and industrial sources

Dry cleaners Trichloroethylene, tetrachloroethylene, fluorinated hydrocarbons

Degreasing baths Perchloroethylene, trichloroethylene, methyl chloroform

Printers Trichloroethylene

Hairdressers Aerosol spray propellants, hydrocarbons containing fluorine and chlorine (freons)

Sources in the home

Cleaning and degreasing agents

Perchloroethylene, methyl chloroform, trichloroethylene, methylene chloride, carbon tetrachloride, hydrochloric acid

Home workshops

Solvents and thinners

Spray cans

Various chlorinated hydrocarbons

Chlorofluorohydrocarbons

(freons)

8 716 115 748 (2009/09) 79

Dedicated to heating comfort

Worcester, Bosch Group

Cotswold Way, Warndon, Worcester WR4 9SW

Tel. 01905 754624 Fax. 01905 754619

Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.

www.worcester-bosch.co.uk

8 716 115 748

CONTACT INFORMATION

WORCESTER, BOSCH GROUP:

TECHNICAL: 08705 266241

SERVICE:

SERVICE (Eire):

08457 256206

01494 0099

SPARES:

LITERATURE:

TRAINING:

SALES:

01905 752571

01905 752556

01905 752526

01905 752640

WEBSITE: www.worcester-bosch.co.uk

Datasheet | Bosch Greenstar 131 Technical data

ENGINEER‘S SERVICE BOOKLET

FLOOR MOUNTED & WALL HUNG RSF GAS FIRED CONDENSING BOILERS

GREENSTAR CDi RANGE

FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER

CDi Combi N.G.

CDi Combi L.P.G.

CDi System N.G.

CDi System L.P.G.

CDi Regular N.G.

CDi Regular L.P.G.

Highflow CDi N.G.

Highflow CDi L.P.G.

FS CDi Regular N.G.

FS CDi Regular L.P.G.

UK/IE

TABLE OF CONTENTS

1 EXPLANATION OF SYMBOLS AND SAFETY PRECAUTIONS

2 LAYOUT OF BOILER

2.1

CDi COMBI BOILERS

2.4

HIGHFLOW CDi COMBI BOILER

3 OPERATION - CDi

3.2

Display messages

3.3

Operating elements CDi (Wall hung)

3.4

First service level

3.5

Second service level

4 OPERATION - HIGHFLOW CDi and FS CDi REGULAR

4.2

Display messages

4.3

Operating elements

5 BOILER SERVICE FUNCTIONS - CDi COMBI & SYSTEM BOILER

6 BOILER SERVICE FUNCTIONS CDi, HIGHFLOW CDi

& FS CDi REGULAR

7 RECTIFYING FAULTS

7.2

Summary

8 TROUBLESHOOTING - FW 100

9 TROUBLESHOOTING - FR110

10 TROUBLESHOOTING - RT10

11 TROUBLESHOOTING - TD 200

12 APPENDIX

12.2

CDi fan speeds

Dedicated to heating comfort

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Worcester

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30i System Compact

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GREENSTAR PLUS

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Greenstar CDi Highflow Combi (01.05.2015-13.07.2016)

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Greenstar FS 30CDi Regular

Table of contents