British Gas - ICS1 - free boiler manuals

Installation and Servicing Instructions
ICS1
Wall mounted condensing boiler for central heating
6 720 610 598-00.1O
6 720 610 603 GB (03.02) OSW
ZSBR 7-28 ICS1 GC-Number: 41 108 04
Contents
Contents
Safety precautions
3
Symbols
3
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Details of the appliance
EC Declaration of Conformity
Standard package
Description of appliance
Accessories
Casing dimensions
Layout of appliance
Function
Electrical wiring diagram
Technical data
4
4
4
4
5
5
6
7
8
9
2
Installation regulations
10
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
Installation
Important remarks
Sealed systems
Siting the appliance
Wall mounting frame assembly
Pre-piping the system
Fitting the appliance
Checking the connections
Flue Systems
Siting the Flue Terminal
Installation of the flue
Flue duct preparation and assembly
11
11
11
13
14
14
15
16
16
17
18
20
4
4.1
4.2
4.3
4.4
Electrical connections
Connecting the appliance
Connecting TR2 Room thermostat
Mains Voltage external controls connections
Connecting a Hot Water Cylinder
21
21
22
22
22
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6
6.1
6.2
6.2.1
6.2.2
6.3
6.4
6.4.1
6.4.2
6.5
6.5.1
6.5.2
2
Commissioning
Commissioning
Switching the appliance on/off
Switching on the central heating
System controls
ZSBR-Appliances with Storage Tank:
Setting hot water temperature
Summer mode, hot water only (ZSBR)
Frost protection
Pump anti-seize function
Fault Condition
Text Display
General Description
Programming
Deleting a setting
Resetting all parameters to their
original settings
Menu structure
Setting the time/day
Setting the time and day
Holidays
Heating
Heating programme
Setting the Economy temperature
(if TR2 is connected)
23
23
24
24
24
25
25
25
25
25
26
26
26
27
27
27
28
28
28
28
28
28
6.5.3 Manual operating mode
(if TR2 is not connected)
6.6 Hot water
6.6.1 Hot water programme
6.6.2 Hot water immediately
6.7 i Info
6.8 Settings
6.8.1 Heating (if TR 2 is connected)
6.8.2 Hot Water (Storage Tank,
ZSBR models only)
6.8.3 Service
6.9 Individual timer programmes
7
7.1
7.1.1
7.1.2
7.2
7.2.1
7.2.2
Individual settings
Mechanical settings
Checking the size of the expansion vessel
Setting the central heating flow temperature
Settings on the Bosch Heatronic
General description
Setting the anti-cycle time
(Service Function 2.4)
7.2.3 Setting the maximum CH flow temperature
(Service Function 2.5)
7.2.4 Setting the heating output
(Service Function 5.0)
7.2.5 Variable pump settings
(Service Function 7.0)
7.3 Setting the gas/air ratio
29
29
29
29
29
30
30
30
30
30
31
31
31
31
31
31
32
32
32
32
32
8
Converting the appliance to
different gas types
8.1 Setting the gas/air ratio
8.2 Testing combustion air/flue gas at
set heat output
8.2.1 Testing the O2 or CO2 level in the
combustion air
8.2.2 Testing CO and CO2
35
35
9
Maintenance
9.1 Pre-Service Check List
9.2 Description of servicing operations
9.3 Replacement of Parts
9.3.1 PCB control board and transformer
9.3.2 Fan Assembly
9.3.3 Pump
9.3.4 3-way diverter valve
9.3.5 3-way diverter valve motor
9.3.6 Sensors
9.3.7 Gas Valve
9.3.8 Electrode assembly
9.3.9 Pressure gauge
9.3.10Expansion vessel
9.3.11Pressure Relief Valve
9.3.12Burner
9.3.13Primary Heat Exchanger
36
37
38
41
41
42
42
42
43
43
43
44
44
44
44
44
44
10
10.1
10.2
10.3
45
45
46
Appendix
Fault Codes
Short parts list
Heating/hot water output settings
ZSBR 7-28 N.G.
10.4 Heating/hot water output settings
ZSBR 11-28 L.P.G
10.5 Operational Flow diagrams
10.5.1Central heating function
33
33
35
46
46
47
47
6 720 610 603 GB (03.02)
Safety precautions
Safety precautions
Symbols
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
If you smell gas
B Turn off gas service cock at the meter.
B Open windows and doors.
B Do not operate any electrical switches.
B Extinguish any naked flames.
B Telephone your gas company.
If you smell fumes from the appliance
B Switch off appliance (see page 24).
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.
B Open windows and doors.
Fitting and modifications
B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance wth the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use on sealed primary systems only.
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
B Use only original spare parts!
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance
being electrically unsafe.
B There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
B The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Explain to the customer how the appliance works and
how to operate it.
B Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it.
B These instructions are to be left with the user or at
the Gas meter.
B Important: These instructions apply in the UK only.
6 720 610 603 GB (03.02)
3
Details of the appliance
1
1.1
Details of the appliance
1.3
EC Declaration of Conformity
• Wall-mounted appliance, siting not dependent on
room size
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.
PIN
CE-0085 BL0507
Category
UK
II2H 3P
Appliance Type
C13, C33
Table 1
1.2
Standard package
Description of appliance
• Natural gas models are low-emission appliances
• Multifunction display
• Bosch Heatronic control system with integrated textdisplay for servicefunctions and faults
• 3-channel - digital timer for one heating circuit
• Variable pump
• Automatic ignition
• Modulating control
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
• Concentric flue/air duct with testing point for
CO2/CO
• Gas condensing boiler for central heating and
domestic hot water
• Regulated speed fan
• Control panel cover
• Temperature control for central heating
• Wall mounting frame
• Safety temperature limiter in 24 V electrical circuit
• Clamp for securing flue duct kit
• Relief valve, pressure gauge, expansion vessel
• Fixings (screws etc.)
• Flue gas temperature limiter (105 °C)
• Set of documentation for appliance
• Hot water priority circuit
• Pre-plumbing manifold
• Motorised 3-way valve
• Condensate drain pipe
• Condensate Trap.
• Pre-mix burner
• Filling loop
• Room thermostat TR2
• Sensor for Hot Water Cylinder.
4
6 720 610 603 GB (03.02)
Details of the appliance
1.4
Accessories
• Standard horizontal flue kit at 100 mm outside
diameter for flues upto 4 m in length.
• Flue duct kits for horizontal (125 mm outside
diameter) for flue lengths upto 13 m and vertical flue
systems for flue lengths 15 m. Fitting instructions are
sent with these kits.
• Heating programmer,
• Security kit.
1.5
Casing dimensions
min.
min.
5*
5*
Z
Y
600*
X
906
850
861
120
101
13
103
30
200
512
360
395
*
200
35
6 720 610 602 - 01.3O
Fig. 1
13
101
103
X
Y
Z
*
Manifold assembly
Outer case
Facia cover
Standard Concentric Horizontal Flue System: min. 310 mm
Alternative Concentric Flue System: min. 250 mm
Standard Concentric Horizontal Flue System: 158 mm
Alternative Concentric Flue System: 121 mm
Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
For servicing the appliance
6 720 610 603 GB (03.02)
5
Details of the appliance
1.6
Layout of appliance
120
221.1
349
221.2
234.1
234
27
226
20
102
32.1
29
36
271
6
415
43
9
63
416
358
396
64
18
7
423
418
15
8.1
88
400
295
4
6 720 610 603 - 01.1O
Fig. 2
4
6
7
8.1
9
15
18
20
27
29
32.1
36
43
63
64
88
102
120
221.1
6
Heatronic control
Heat exchanger safety temperature limiter
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Relief valve
Pump
Expansion vessel
Automatic air vent
Air gas Mixer unit
Electrode assembly
Temperature sensor in CH flow
CH flow
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
3-way valve
Inspection window
Fixing points
Flue duct
221.2
226
295
234
234.1
271
349
358
396
400
415
416
418
423
Combustion air intake
Fan assembly
Appliance type sticker
Testing point for combustion products
Testing point for combustion air
Flue duct
Cover plate for twin flue duct connection
Condensae trap
Hose Condensate trap
Textdisplay
Cover plate for cleaning access
Condensate collector
Data plate
Siphon
6 720 610 603 GB (03.02)
Details of the appliance
1.7
Function
26
27
229
226
33
29
30
234.1
234
36
32
ϑ
20
221
6
35
29.1
9
63
52.1
69
64
56
57
317
61
4
358
7
52
400
18
88
55
8.1
ECO
3
0
2
1
4
5
15
E
max
423
max
M
84
13
43
71
45
72
47
6 720 610 603 - 02.2O
Fig. 3
4
6
7
8.1
9
13
15
18
20
26
27
29
29.1
30
32
33
35
36
43
45
47
52
52.1
55
56
57
61
63
64
69
Bosch Heatronic control
Temperature limiter, heat exchanger
Testing point for gas supply pressure
Pressure gauge
Flue gas temperature limiter
Manifold
Safety valve
Central heating pump
Expansion vessel
Charging valve
Automatic vent
Mixer unit
Bi-metallic thermostat for combustion air compensation
Burner
Flame sensing electrode
Igniter electrode
Heat exchanger with cooled combustion chamber
Temperature sensor in CH flow
CH flow
Gas
CH return
Solenoid valve 1
Solenoid valve 2
Filter
Gas valve CE 427
Main valve disc
Reset button
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
Control valve
6 720 610 603 GB (03.02)
71
72
84
88
221
226
229
234
234.1
317
358
400
423
443
Storage water heater outflow
Storage water heater return
Motor
3-way valve
Flue duct
Fan
Air box
Testing point for flue gas
Testing point for combustion air
Display
Condensation trap
Textdisplay
Siphon
Diaphragm
7
Details of the appliance
1.8
Electrical wiring diagram
o - orange
bl - black
r - red
p - purple
33
365
364
61
317
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
310
136
400
135
312
328
313
151
124 789
p
p
L N Ns Ls LR
302
161
300
p
84
3 4
F
M
328.1
9
18
M
M
422
6
226
r
r
mains supply
52
o
52.1
56
o
bl
bl
bl
bl
36
bl
32
6 720 610 603 - 03.1O
Fig. 4
4.1
6
9
18
32
33
36
52
52.1
56
61
84
135
136
151
153
161
226
300
302
310
312
313
317
328
328.1
363
8
Ignition transformer
Temperature limiter, heat exchanger
Flue gas temperature limiter
Pump
Flame sensing electrode
Ignition electrode
Temperature sensor in CH flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Motor, 3-way valve
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
Link
Fan
Code plug
Earth connection
Temperature control for hot water
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Digital display
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
364
365
366
367
400
422
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
Textdisplay
Connecting TR2
6 720 610 603 GB (03.02)
Details of the appliance
1.9
Technical data
Units
ZSBR 7-28
Natural gas
ZSBR 11-28
Propane
Max. rated heat output net 40/30°C central heating
Max. rated heat output net 50/30°C central heating
Max. rated heat output net 80/60°C central heating
kW
kW
kW
29.3
29.0
27.4
29.3
29.0
27.4
Max. rated heat input net
kW
27.7
27.7
Min. rated heat output net 40/30°C
Min. rated heat output net 50/30°C
Min. rated heat output net 80/60°C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
Min. rated heat input net
kW
7.6
10.8
m3/h
2.9
-
kg/h
-
2.1
mbar
20
-
mbar
-
37
bar
0.75
0.75
l
18
18
Flue gas temp. 80/60°C, rated/min. load
°C
67/55
67/55
Flue gas temp. 40/30°C, rated/min. load
°C
43/32
43/32
Residual delivery pressure
(inc. pressure drop in air intake duct)
Pa
80
80
CO2 level at max. rated heat output
CO2 level at min. rated heat output
%
%
9.2
8.8
10.8
10.5
5
5
%
90.7
90.7
l/h
2.3
2.3
4.8
4.8
AC ... V
230
230
Frequency
Hz
50
50
Max. power consumption
W
121
121
dB(A)
36
36
Appliance protection rating
IP
X4D
X4D
Max. CH flow temperature
°C
nom. 90
nom. 90
Max. permissible operating pressure (CH)
bar
2.5
2.5
Permissible ambient temperatures
°C
0 - 50
0 - 50
l
3.75
3.75
kg
50
50
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (CVnet 34.02 MJ/m3)
3
LPG (CVnet 88 MJ/m )
Gas supply pressure
Natural gas G20 (CVnet 34.02 MJ/m3)
3
LPG (CVnet 88 MJ/m )
Expansion vessel
Charge pressure
Total capacity
Flue
NOx-class
SEDBUK figure, Band A
Condensate
Max. condensation rate (tR = 30°C)
pH-value, approx.
General Data
Electrical power supply voltage
Noise output level
Nominal capacity of appliance
Weight
Table 2
6 720 610 603 GB (03.02)
9
Installation regulations
2
Condensate analysis, mg/l
Ammonium
1.2
Nickel
0.15
≤ 0.01
Mercury
Cadmium
≤ 0.001
Sulphate
Chromium
≤ 0.005
Zinc
≤ 0.015
Halogenated
hydrocarbons
Tin
≤ 0.002
≤ 0.01
Hydrocarbons
0.015
Vanadium
Copper
0.028
pH-value
Lead
≤ 0.0001
1
≤ 0.001
4.8
Table 3
Flue system
HORIZONTAL 100 mm – Standard
Overall Diameter of Duct
mm
100
Flue Terminal / Duct
Assembly Length
mm
600
Extension Duct Length
mm
1000
Max.
4m
Installation regulations
Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.
• BS 6798: Specification for the installation of gas
fired hot water boilers of rated input not exceeding
60kW
Table 4
• BS 5449: Central Heating for Domestic Premises
ALTERNATIVE HORIZONTAL 125 mm FLUE
SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1030
• BS 5546: Installation of gas hot water supplies for
domestic purposes
Max.
13 m
(including
turret)
Table 5
• BS 5440:1: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Flues
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28 mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply
VERTICAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct Assembly
mm
1360
Max.
15 m
• BS 7671: Requirements for Electrical Installation.
These instructions must be followed.
Table 6
Elbow - 90 ° Equivalent length 2 m
Bend - 45 ° Equivalent length 1m
Gas supply
Total length of gas supply pipe
(metres)
3
6
Pipe diameter
(mm)
9
Gas discharge rate (m3/h)
8.7
5.8
4.6
22
18.0
12.0
9.4
28
Table 7
10
6 720 610 603 GB (03.02)
Installation
3
Installation
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
3.1
Fixing of the appliance, gas and flue connections, commissioning of the system
and electrical connections may only be
carried out by competent persons authorised by CORGI.
Important remarks
B Appliance should only be installed in sealed central
heating and hot water systems.
3.2
Sealed systems
The appliance must not be operated without the system
being full of water, properly vented and pressurised.
The expansion vessel has a volume of 10 litres and is
charged to a pressure of 0.75 bar.
The water capacity of the system is shown in table 10,
page 31. If a greater capacity is required then an additional expansion vessel must be fitted into the system
return as close to the appliance as possible. The system
pressure can be set up to a maximum of 1.5 bar with
1 bar being the normal setting.
If the system pressure is greater than 2.5 bar when the
appliance is operating at maximum temperature then an
additional expansion vessel must be fitted into the system return as close to the appliance as possible.
B To avoid gas formation in the system, galvanised radiators or pipes must not be used.
The filling point must be at low level and arranged as
shown in figs. 5 and 8.
B If a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.
The pressure relief valve is set to operate at 3 bar.
B This appliance uses an automatically variable pump.
An auto-bypass must not be fitted.
B Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
B In our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.
There must be no connection to the mains without the
approval of the local water company. All connections in
the system must be capable of withstanding a pressure
of up to 3 bar and the radiator valves conform to the
requirements of BS2767:10.
If Thermostatic Radiator Valves are fitted then it is recommended that the primary radiator is left open.
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
No galvanised radiators or pipes must be used.
If any system water treatment is required then
only products suitable for use with Aluminium
shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the
manufacturers instructions. The use of any other
substances will invalidate the guarantee. The pH
value of the system water must be less than 8 or
the appliance guarantee will be invalidated.
A drain cock to BS2879 must be fitted to the lowest
point of the system.
IMPORTANT: Check that no dirt is left in the
water pipework as this could damage the appliance. Thoroughly flush the heating system and
the mains water supply before fitting the appliance to the wall in accordance with the recommendations of BS7593:1992.
6 720 610 603 GB (03.02)
11
Installation
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Heating Return
APPLIANCE
LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
6 720 610 601-04.1O
Cylinder Return
RV
Heating Flow
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Hot Water Flow
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
System layout if using built-in diverter valve
LV
RV
INDIRECT
CYLINDER
LV
RV
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Refer to
Appliance
Water
Flow
Diagram
Safety Discharge
Diverter
Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
Fig. 6
12
6 720 610 601-05.1O
APPLIANCE
LV
Hot Water Flow
Cylinder Return
RV
Heating Return
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Heating Flow
Fig. 5
System layout if using external diverter valve
6 720 610 603 GB (03.02)
Installation
LV
RV
INDIRECT
CYLINDER
LV
RV
Radiator Valve - Flow
RV
Lockshield Valve - Return LV
Refer to
Appliance
Water
Flow
Diagram
Heating Return
Heating Flow
RV
CH
Zone
Valve
Safety Discharge
DHW Zone Valve
Mains Cold Water
BS
Stop Valve Fixed Cylinder Type
6 720 610 601-06.1O
LV
Hot Water Flow
APPLIANCE
LV
RV
Fig. 7
Cylinder Return
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
System layout if using twin zone valves (S) plan
Sealed system filling and make up
Make up
vessel
Heating return
Heating return
Auto
air vent
Non return Non return
valve
valve
Hose union
Stop
cock
Stop cock
Test cock
Temporary hose
Non return
valve
1000mm (39 in)
above the highest
point of the system.
Fill point
6 720 611 137 - 29.1O
Fig. 8
3.3
Siting the appliance
Regulations concerning the Installation Site
Surface temperature
B Relevant national regulations must be complied with
section 3.8.1.
The max. surface temperature of the casing and the flue
is less than 85 °C.
This means that, no special safety precautions are
required with regard to flammable building materials
and fitted furniture. The specified clearences must be
maintained.
B Consult the installation instructions for details of minimum clearances required.
Combustion air
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
Substances classed as corrosion-promoting include
halogenated hydrocarbons which contain chlorine and
fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and household cleaners, for example.
6 720 610 603 GB (03.02)
Cupboard/Compartment
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS6798 and BS5440:2 are followed. The low
casing losses from the appliance eliminate the need for
ventilation openings in the compartment.
13
Installation
3.4
Wall mounting frame assembly
B Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 9. Use
the outer lugs on the top and bottom horizontal sections for the appliances that are 512 mm wide.
B Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
6 720 610 597-08.1O
Fig. 11
6 720 610 597-06.1O
3.5
Pre-piping the system
Fig. 9
B Hold the wall-mounting frame against the wall ensuring that it is vertical.
200
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 18.
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 12 Manifold
43
47
112
171
172
6 720 610 597-07.1O
Fig. 10
CH flow
CH return
Gas cock
Domestic hot water
Cold water relief
B A drain tap should be fitted at the lowest point of the
central heating system.
B WRAS filling loop must be fitted.
14
6 720 610 603 GB (03.02)
Installation
Condensate Termination and Route
External condensate pipework
The condensate connection on the British Gas/Bosch
appliances is in 22 mm plastic. The pipe should be
extended and run away from the appliance with a constant fall of 2.5 ° or 40 mm in every metre.
All the British Gas/Bosch condensing boilers have
within a syphonic condensate trap. Rather than the condensate constantly dripping into the discharge pipe, the
condensate is collected into a trap which releases it in
100 ml quantities.
This will help prevent freezing occurring.
The condensate pipe can terminate into any of four
areas:
If there is no alternative and the condensate pipe has to
be externally run, the following should be considered:
Boiler
Boiler
Ø 22 min.
No length
restriction
• The pipe run should take the shortest practical route.
Sink
Siphon
External length of
pipe 2m min.
Siphon
Ø 22 min.
75 min. trap
Open end of pipe
direct into gully,
below ground but
above water level.
Use waterproof pipe work
insulation in very exposed
positions
The gradient of the discharge pipe
should be 2.5° (40 mm/m) minimum
Open end of pipe direct
into gully, below ground
but above water level
An internal waste system
An external waste system
Boiler
Ø 22 min.
Internal soil
and vent stack
No length
restriction
Sink
Siphon
Ø 22 min.
75 min. trap
75 min. trap
450 min.
No length
restriction
• The pipe should terminate as close as possible to the
ground or drain, whilst still allowing the condensate
to safely disperse. This would prevent wind blowing
up the pipe.
The gradient of the discharge pipe should be
2.5° (40 mm/m) minimum
Boiler
The gradient of the discharge pipe Invert
should be 2.5° (40 mm/m) minimum
The rainwater system
• The pipework should be insulated with weather
resistant insulation.
Open end of pipe
direct into gully,
below ground but
above water level
The gradient of the discharge pipe
should be 2.5° (40 mm/m) minimum
• The pipework should be installed with the minimum
of horizontal runs and with a downward slope of at
least 2.5 °.
3.6
Fitting the appliance
An external purpose made soakaway
Benchmark: For optimum performance
after installation, this boiler and its associated central heating system must be
flushed in accordance with the guidelines given in BS5793:1992 “Treatment
of water in domestic hot water central
heating systems”.
6 720 610 596 -03.1O
Fig. 13
Whilst all of the above methods are acceptable it is
always the best practice to terminate the condense pipe
via an internal waste system.This will eliminate the need
for any external condensate pipe runs which can be susceptible to freezing in extreme weather.
B Remove packing, taking care to observe the instructions on the packing.
B Lie the boiler on its back.
Removing the outer case
i
The outer case is secured against unauthorised removal by a retaining bracket
(electrical safety) at the bottom left.
Always secure the outer case with this
bracket again after refitting.
B Remove retaining screw on left hand side (1.).
B Press both catch levers backwards (2.).
6 720 610 602 - 03.1O
Fig. 14 Position of the condensate drain
6 720 610 603 GB (03.02)
15
Installation
B Lift off the top fixing lugs and slide the case forwards
and remove (3.).
3.7
Checking the connections
Water connections
B Check that the O-rings or seals are in place before
tightening the connection.
B Turn on the service valves for central heating flow
and return and fill the heating system through a
WRAS approved filling loop.
B Check all seals and unions for leaks (testing pressure
max. 3.0 bar as indicated by pressure gauge).
B Turn on cold water service cock and fill hot water system (testing pressure max. 10 bar).
3.
B Check all connections for leaks.
Gas supply pipe
B Check that the seal is in place before tightening the
connection.
B Turn off gas cock to protect gas valve against damage from excessive pressure.
2.
2.
1.
6 720 610 597 -09.1O
Fig. 15
Fixing the appliance
B Fit the washers onto the gas and water connections.
B Lift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
B Take care not to disturb the washers on the connections.
Connecting the flue duct
B Fit flue duct connector onto appliance flue spigot.
B Secure with the two screws supplied.
B Check gas supply pipe.
B Release the pressure on the gas supply pipe.
3.8
Flue Systems
The only flue systems that may be used are those supplied with the boiler.
The flue system must be installed in accordance with
the requirements of BS5440:1.
Standard 100 mm flue system
The standard concentric flue system provides for a horizontal length of upto 4 m. Full instructions for fitting this
flue are in Subsection 3.8.2 “Installation of the flue”.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue systems
are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13 m.
A vertical flue system upto a height of 15 metres is available.
45° and 90° flue bends can be used with a corresponding reduction in flue length of 2 m for each 90° bend
and 1 m for each 45° bend used.
1 .
1
2
3
4
2 .
6 7 2 0 6 1 0 3 3 2 -0 9 .2 R
IMPORTANT: Any horizontal flue system fitted to a
condensing boiler must incline towards the appliance at
an angle of 3 % (30 mm per metre length) to prevent
condensate dripping from the flue terminal. This
means that the clearance above the appliance
must be increased to match the duct length.
Refer to fig. 1 on page 5.
Fig. 16
B For remaining installation of flue assembly, refer to
the relevant installation instructions.
16
6 720 610 603 GB (03.02)
Installation
3.8.1
Siting the Flue Terminal
The flue must be installed in accordance with
BS 5440:1 and the Building Regulations. Flue terminals
in carports and under balconies are to be avoided.
The terminal must be positioned so that it does not
cause an obstruction nor the combustion products a
nuisance. See fig. 17 and table 8.
The terminal will, at times, give out a plume of water
vapour and consideration must be given to this when
choosing a terminal position. Keep clear of security
lighting, activated by passive infra-red sensing heads.
If the terminal is less than 2 m above a surface to which
people have access then a guard must be fitted. The
guard must be evenly spaced about the terminal with a
space of 50 mm in each direction and fixed with plated
screws.
A guard Type K6 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
Fig. 17
Minimum dimensions of flue terminal positions (all types) (see fig. 17)
Dimension Terminal Position (kW input expressed in net)
Balanced flues room sealed: Fanned draught
A1)
Directly below an opening, air brick, opening windows, etc.
300 mm
B 1)
Above an opening, air brick, opening window, etc.
300 mm
C 1)
Horizontally to an opening, air brick, opening window, etc.
300 mm
D
Below gutters, soil pipes or drain pipes
E
Below eaves
F 2)
Below balconies or car port roof (lowest point)
200 mm
G
From a vertical drain pipe or soil pipe
150 mm
H
From an internal or external corner
300 mm
I
Above ground roof or balcony level
300 mm
J
From a surface facing the terminal
600 mm
K
From a terminal facing the terminal
1200 mm
L
From an opening in the car port (e. g. door, window) into the dwelling
1200 mm
M
Vertically from a terminal on the same wall
1500 mm
N
Horizontally from a terminal on the same wall
O
From the wall on which the terminal is mounted
Not applicable
P
From a vertical structure on the roof
Not applicable
Q
Above intersection with roof
Not applicable
75 mm
200 mm
300 mm
Table 8
1)
2)
In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
Not recommended.
6 720 610 603 GB (03.02)
17
Installation
3.8.2
Installation of the flue
The standard 100 mm diameter horizontal flue system is
suitable for lengths upto 4 m.
Flues upto 650 mm do not require an extension duct
assembly.
Flues between 1600 mm and 4000 mm require extension duct assemblies.
NOTE: Flue lengths between 650 mm and 730 mm
cannot be accomodated. Refer to fig. 19, 20, 21.
Standard system comprise: Flue turret - Flue turret
clamp - Terminal assembly - Wall sealing - plates.
Extension kit comprises: Air duct - Flue duct - Duct
clamp. Refer to fig. 22.
Instructions for fitting other flue systems are packed
with the relevant flue kit.
Check that the position chosen for the appliance is satisfactory Refer to fig. 18.
Terminal
Assembly
Flue
Turret
Maximum 650 mm
Outer
Wall
No
Clamp
6 720 610 602 - 08.1O
Fig. 19 Standard Flue
Drilling point for
flue duct opening
Centre line of
flue/air duct
H
Centre
line of
flue
opening
and
appliance
120
3%
(30 mm/metre)
Top of the
wall
mounting
frame
Appliance
H
Standard Horizontal Flue 158 mm
Optional Horizontal Flue 121 mm
6 720 610 602-07.2O
Fig. 18 Marking the position of the side flue opening
18
6 720 610 603 GB (03.02)
Installation
Terminal
Assembly
Flue
Turret
Maximum 1600mm
Outer
Wall
Clamp
No
Clamp
Extension
Duct
6 720 610 602 - 09.1O
Fig. 20 Flue with One Extension
Terminal
Assembly
Flue
Turret
No
Clamp
Outer
Wall
Clamp
Clamp
Extension
Duct
Extension
Duct
6 720 610 602 - 10.1O
Fig. 21 Flue with extensions
Duct Clamp
Flue
Turret
Extension Air Duct
Extension Flue Duct
Terminal Assembly
Wall Sealing Plates
6 720 610 602 - 11.1O
Fig. 22 Flue Components
6 720 610 603 GB (03.02)
19
Installation
3.8.3
Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 23, 24.
Outer
Wall
Face
Flue Terminal
L
Raised Ring
locating the
terminal relative
to the outside
wall face
120
6 720 610 576 - 20.1O
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 12.1O
BOILER
Fig. 23 Flue length - rear
Fig. 25 Flue terminal position
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must face downwards.
L
The assembly will be made easier if a solvent free
grease is lightly applied i.e Vaseline, to the male end of
the ducts.
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assembly.
Push the assembly through the wall and fix the turret to
the appliance with the clamp. Refer to fig. 26.
NOTE: THE FLUE MUST BE INCLINED T O THE
6 720 610 602 - 13.1O
BOILER
Flue Turret
Fig. 24 Flue length - side
Mark off the lengths shown onto the ducts and cut to
length. The cuts must be square and free from burrs.
Terminal assembly outer (air) duct - L- 70 mm, inner
(flue) duct - L- 50 mm.The measurement is made from
the ridge at the terminal indicating the outer face of the
wall. Refer to fig. 25.
Extension air duct - L- 70mm, flue duct - L- 50 mm.
The measurement is from the formed end.
Clamp
Flue Socket
on Boiler
Air and
Flue Duct
Entry into
silicone
rubber seals
6 720 610 602 - 14.1O
Fig. 26 Flue turret
Ensure that the turret is fully entered into the socket on
the boiler. From the outside fix the outer wall plate to the
terminal and, after ensuring the duct is properly i nclined
towards the boiler, fix the plate to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal an be fixed with corrosion resistant
screws.
20
6 720 610 603 GB (03.02)
Electrical connections
4
Electrical connections
B Always disconnect the power supply to
the appliance at the mains before carrying out any work on the electrical systems and components.
All control and safety systems are built into the appliance.
B Allow mains cable to protrude at least 50 cm from
wall.
B To make splash-water proof (IP): cut the cable grommet hole size to match diameter of cable, see fig. 29.
It must be possible to isolate the appliance. The appliance must be earthed.
4.1
Connecting the appliance
To gain access to the mains connection remove the
drop down facia cover. The drop down cover is
removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
release the cover. Lift cover from the appliance.
After installation (or in the event of an electrical fault) the
electrical system shall be checked for short circuits,
fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.
B Pull out cover panel at the bottom and remove. Refer
to fig. 27.
3
0
4
2
The appliance must be connected to the mains through
a 6 A double pole isolator with a contact separation
3 mm in all poles and supplying the appliance and controls only. The wiring must comply with the current
requirements of the IEE Wiring Regulations and any
local regulations which apply.
5
1
E
• Supply: 230 V ~ 50 Hz, 140 Watts
•
Mains cable: PVC insulated 0.75 mm2
(24 x 0.20 mm) to BS6500-Table 6.
Temperature rated 100°C.
• Protection IPX4D
• External fuse 3 A.
6 720 610 332-10.1R
Fig. 27
B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 28.
3
0
2
4
5
1
E
6 720 610 336 -18.1R
Fig. 28
6 720 610 603 GB (03.02)
21
Electrical connections
B Cut cable grommet to diameter of cable.
Mains Voltage external controls
connections
4
NOTE: Only double insulated controls not requiring an earth can be used
5
Ns Ls LR
Ns Ls LR
1
E
ST8
Remove Link
Neutral
Switched Live
Neutral
Live
ST8
Switched Live
2
Live
3
0
4.3
Motor
230 V Room Thermostat Connections
230 V Programmer Connections
8-9
230 V room thermostat and
Programmer Connections
Ns Ls LR
ST8
ed
it ch
Sw
Live
Neutral
ve
ra
l
Li
ut
Live
Ne
d
6 720 610 332-12.1R
he
13-14
itc
10-12
Series
connection
to be made
safe
Sw
Live
5-7
Fig. 29
B Feed cable through cable grommet and connect the
mains supply cable, see fig. 30.
B Secure cable in cable grommet by means of cable
grip.
L
Motor
6 720 610 576 - 22.1O
Fig. 31
4.4
N NS L S L R
Connecting a Hot Water Cylinder
The sensor for the connection is in the package of the
appliance.
B Snap out plastic tongue.
B Insert cylinder NTC sensor lead.
4130-14.1R
B Plug connector into PCB.
1 2 4 7 8 9
Fig. 30
4.2
Connecting TR2 Room thermostat
The TR2 should be connected to terminals 3, 4 and F
beneath the Textdisplay, page 8, Fig. 4, Pos. 422.
4151-48.10R
Fig. 32
i
22
Position the sensor for the Hot Water
Cylinder according to the cylinder manufacturers instruction.
6 720 610 603 GB (03.02)
Commissioning
5
Commissioning
27
136 365
61
317 366 367
358
ECO
363
310
400
364
8.1
135
E
295
15
170
nn
.
171
172
173
170
6 720 610 597 - 05.1O
Fig. 33
8.1
15
27
61
135
136
170
171
172
173
295
310
317
358
363
364
365
366
367
400
Pressure gauge
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for central heating
Service cocks on CH flow and return
Hot water
Gas cock (shown in off position)
Cold water service cock
Appliance type sticker
Temperature control for hot water
Multifunction display
Condensation trap
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
Textdisplay
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
i
The operational CO2 level is set at the factory and no adjustment is necessary when
installing a natural gas fired appliance.
Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance
with the guidelines given in BS7593:1992 - Treatment
of water in domestic hot water systems. Full instructions
are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should
be used in accordance with the inhibitor manufacturers
instructions.
To drain the appliance shut the system valves and open
the pressure relief valve.
Suitable flushing agents and inhibitors are available
from Betz/Dearborn Tel.: 0151 4209563, Fernox Tel.:
01799 550811 and Salamander Tel.: 0121 378 0952.
Instructions for use are supplied with the these
products.
6 720 610 603 GB (03.02)
23
Commissioning
B Before commissioning, the gas supply pressure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7).
Natural gas appliances must not be operated if
the gas supply pressure is below 18 mbar or
above 24 mbar. LPG appliances must not be
operated if the supply pressure is not 37 mbar
at the inlet to the appliance.
Switching off the appliance
B Set the master switch to (0).
The green indicator lamp goes out. The optional timer
will continue running until the emergency supply is
exhausted.
B Always disconnect the appliance from
the power supply (fuse, circuit breaker)
before carrying out any work on the
electrical systems or components.
B Unscrew the condensation trap (358) and pull out, fill
with approx. 1/4 l of water and refit. Refer to fig. 33.
B Adjust charge pressure of expansion vessel to static
head of the central heating system (see page 31).
B Open all system radiator valves.
B Turn on service valves (170), fill central heating system to pressure of 1 - 2 bar through the WRAS
approved filling loop. Refer to fig. 33.
B Vent radiators.
B Refill heating system and set the pressure to 1 bar.
B Turn on cold water service cock (173). Refer to
fig. 33.
B Check that the gas type specified on the identification plate matches that of the gas supply.
B Turn on gas cock (172). Refer to fig. 33.
5.2
Switching the appliance on/off
Switching on
5.3
Switching on the central heating
The central heating flow temperature is adjustable
between 35°C and 88°C (refer to tables 11, page 31).
B Turn the temperature control
to set the flow temperature to a level appropriate to the type of central
heating system:
– Underfloor heating: e.g. setting “3”
(approx. 50°C)
– Low-temperature heating: setting “E”
(approx. 75°C)
– Central heating systems for flow temperatures up
to 88 °C: limited “max” setting for low-temperature
operation (see page 31).
When the burner is alight, the red indicator lamp
lights up.
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the central heating flow temperature, when the
appliance is operating in the central heating mode.
6 720 610 333-05.1O
Fig. 35
5.4
6 720 610 333-04.1O
Fig. 34
i
System controls
B Set room thermostat to the desired room temperature.
B Set outside- temperature driven control unit, if fitted.
Refer to the instructions with the control.
If the display alternates between -II- and
the central heating flow temperature, the
trap filling programme is active.
B Set the thermostatic radiator valves to the desired
settings.
The trap filling programme ensures that the condensation trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
B Open automatic vent (27) and re-close after venting
(page 23).
24
6 720 610 603 GB (03.02)
Commissioning
5.5
ZSBR-Appliances with Storage
Tank: Setting hot water temperature
B Do not set the temperature higher than
60°C for normal operation.
B Only use temperatures of up to 70°C
temporarily for thermal disinfection purposes.
i
With the text display you can additional
set hot water charging times or times and
temperatures.
B Set the hot water temperature by means of the temperature control
on the appliance.
5.6
Summer mode, hot water only
(ZSBR)
With room thermostat
B Turn temperature control
on the appliance anticlockwise as far as the stop.
The central heating is now turned off. The hot water
function and the mains power supply for the heating
programmer and timer remain switched on.
5.7
Frost protection
B Leave master switch switched on.
i
Frost protection and constant frost protection modes can be set on the text display module.
If the appliance is to be left for long periods switch the
central heating off:
6 720 610 333-07.1O
B Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.
Fig. 36
5.8
Control Setting
Water Temperature
Anti-clockwise limit
approx. 10°C
(frost protection)
approx. 60°C
Clockwise limit
approx. 70°C
i
Pump anti-seize function
This function prevents the central heating
pump seizing after long periods of inactivity.
Every time the pump is switched off, a timer is started.
If after 24 hours the pump has not run again, it is
switched on for a period of 10 seconds.
Table 9
ECO button
Pressing and holding the ECO button , until it lights
up switches from Comfort mode to ECO-mode.
Comfort mode, ECO button is not lit (factory setting)
Comfort mode the hot water tank has priority. The hot
water cylinder is first heated up to the set temperature.
The appliance then switches to central heating mode.
5.9
i
Fault Condition
A list of faults that may occur is given on
page 45.
In the unlikely event of a fault occuring while the appliance is in operation:
The display and the textdisplay then show a fault code
and the button
may also flash.
ECO mode, button is lit
If the button
In ECO mode the appliance switches between central
heating mode and cylinder charging mode every 12
minutes.
B Press and hold the button
until the display shows
“– –”.
The appliance will then start up again and the display
will show the central heating flow temperature.
If the button
flashes:
does not flash:
B Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the central heating flow temperature will be displayed.
6 720 610 603 GB (03.02)
25
Text Display
B To start programming, press any button, e. g.
.
The display lighting switches on and the main menu
is displayed:
6
Text Display
6.1
General Description
T
• The text display is used to display information about
the appliance and the system and to alter the settings
displayed.
• Once the appliance has been in operation for one
day, the text display module has a power buffer
period of about 10 hours during which it will run without the mains power supply. After that period has
elapsed, the clock function shuts down but all other
settings are retained.
6.2
Programming
/holidays
6 720 610 598-04.2O
Fig. 38 Main menu
B Use the
or
button to move the cursor
arrow on the left of the menu so that it points to the
desired menu item.
In this example, the cursor is positioned next to the
menu item Time/day/holidays.
B Confirm the selection by pressing the
button.
The corresponding submenu is displayed:
a
T
b
c
C
6 720 610 598-05.2O
6 720 610 337-08.1R
f
e
d
Fig. 37 Controls
a
b
c
d
e
f
Display
“Up”/“More” button
“Down”/“Less” button
“Back” button
“Next” button
“Delete” button
The standard display shows the following information:
• Time
• Room temperature (if TR 2 connected)
Fig. 39 Submenu: Time/day
In the submenus, the top line indicates what action is
required.
The bottom line shows the previous menu level, if applicable (see Fig. 40.
B Use the
or
button to select Time/day.
B Confirm the selection by pressing the
button.
The corresponding submenu is displayed:
H
• CH flow temperature
• Domestic Hot Water temperature (ZSBR if a Storage
Tank is accorded).
Additional indication if a special programme is active:
• x holidays
T
6 720 610 598-06.2O
Fig. 40 Setting the hour
• Constant on (comfort, if TR2 is not connected)
When settings are being entered, the setting to be
altered is indicated on the top line. In addition, the setting being altered is displayed with a dark background.
• Constant off (economy, if TR2 is not connected).
B Use the
• Hot water immediately
Other special operating modes may be displayed during commissioning, servicing, etc.
The programming procedure is described in detail
below using the clock function as an example:
or
button to set the hour.
– Press and release to change the display by one
unit at a time
– Press and hold to change the display rapidly
B Confirm the setting by pressing the
B Use the
or
button to set the minutes.
B Confirm the setting by pressing the
B Use the
week.
26
or
button.
button.
button to set the day of the
6 720 610 603 GB (03.02)
Text Display
B Press the
button to confirm the setting. The
cursor then returns to the top line.
6.3
Menu structure
B Press the
button to confirm the setting and
return to the previous menu (Fig. 39 page 26).
Main
menu
-or-
Set
Set
hour/day hour/day
B Do not press any other buttons for 15 minutes.
6.2.1
Deleting a setting
Heating
Either overwrite the setting or press the C button to
delete it.
1.
2.
3.
-
6.2.2
i
Resetting all parameters to their original
settings
The hours of service can not be reset to 0.
B Press and hold the C button for more than 15 seconds.
After about 5 seconds, the following message
appears on the display:
ATTENTION
Delete all parameters
in x seconds
Once the reset has been completed, the following
message is displayed:
Please wait... Initialising
6 720 610 603 GB (03.02)
Hot
water
Info
- Hours
- Minutes
- Day of week
28
Holidays -
-
Days holiday
28
Heating
program
-
-
- Day
- 1st operating mode
- 1st switching point
...
- 6th switching point
28
Set econ- omy
temp.
(if TR2 is
connected)
-
5...30°C
28
Manual
(if TR2 is
not connected)
-
- Automatic
- Constant on
(comfort)
- Constant off
(economy)
29
Hot
water
program
-
-
- Day
- 1st operating mode
- 1st switching point
...
- 6th switching point
29
Hot
water
immediately
-
-
Off/On
29
-
B Find the setting to be deleted.
B Press and release the C button.
The display shows --:--
Parameters to
change/select
Page
Submenu
-or-
-
-
-
29
Settings Heating
-
-
Optimum Start Off/
On
30
Hot
water
(ZSBRmodels)
-
-
Only charging times/
times and temperatures
29
Service
Display service
param.
-
30
Further Lanoptions guage
-English/
-Français/
-Deutsch
30
-Time correction
-LCD contrast
30
30
Operat- ing
times
30
Fault
history
30
-
27
Text Display
6.4
Setting the time/day
Setting switching times and operating mode
6.4.1
Setting the time and day
B From the main menu select Heating and then from
the first submenu, select Heating program.
For details of how to set the time and day, refer to
page 26.
i
6.4.2
Changing winter and summer time:
B Only adjust the clock! Do not alter the
switching points (for heating, economy,
etc.).
Holidays
In the Holiday programme, the central heating runs in
Economy mode and the hot water is switched off (frost
protection function remains active).
B From the main menu, select Time/day/holidays,
and from the first submenu select Holidays.
B Enter the number of days holiday by pressing
or
(max. 99 days holiday).
After the set number of days, the text display module
automatically cancels Economy mode at midnight on
the last day and returns to Automatic mode.
B Select Monday - Friday, Saturday and Sunday or
an individual day of the week.
– Monday - Friday: to have “Heating” and “Economy” or “Frost protection” switching on at the
same times every weekday.
– Saturday - Sunday: to have “Heating” and
“Economy” or “Frost protection” switching on at
the same times Saturday and Sunday.
– Individual day of the week (e. g. Thursday): to
have the relevant program always switching on at
the specified time on that day of the week, i.e.
“Heating”, “Economy” or “Frost protection” at the
same time every Thursday.
B Press
mode.
. The display shows Set 1. operating
B Set the desired first operating mode (Heating, Economy or Frost protection).
B Press
. The display shows Set 1. time period.
B Set the desired first time period.
i
The day on which you enter the days holiday counts as the first day of the holiday,
i.e. the unit starts the holiday program immediately. Only include the day on which
you are returning if you don’t want the
heating to return to the normal program on
that day!
To cancel Holiday mode early:
B Press
. Set the following operating modes and
time periods as described for the first.
B If necessary: select the next day and enter the operating modes and timer periods as described above.
i
B In the Holidays submenu:
Press the C button until the display shows 0 .
6.5
Heating
6.5.1
Heating programme
Basic setting (Automatic mode)
• The appliance switches automatically between normal heating, Economy mode and Frost protection
mode according to the timer settings entered.
• Basic setting:
– Heating starts at 6:00 am
– Economy starts at 10:00 pm
Setting options
• Maximum of six switching points per day with three
different operating modes (Heating, Economy, Frost
protection).
If the settings for a particular day of the
week are different from the settings for the
other days, then if Monday - Friday or
Saturday and Sunday is selected, the
display shows
--:--, i.e. there are no common switching
points for those options.
Timer periods and operating modes are you do not wish
to change can be skipped by pressing
.
6.5.2
Setting the Economy temperature (if TR2
is connected)
This option allows you to set the room temperature for
Economy mode (Off (Economy)).
This function is only active if:
• Automatic mode or Economy mode is set on the TR
2 room thermostat.
B From the main menu, select Heating and then from
the first submenu, select Set Economy temp..
B Use the
or
button to set a temperature
between 5 and 30 °C.
• Same times for Monday to Friday.
• Same times for Saturday and Sunday.
• Different times for every day.
28
6 720 610 603 GB (03.02)
Text Display
6.5.3
Manual operating mode (if TR2 is not connected)
For selecting an operating mode that is different from
the one set in the heating programme (Automatic
mode).
6.7
i Info
B Select Info from the main menu.
You can view the following information:
Display text
Description
Room temperature
(if TR 2 connected)
Current temperature in the
room where TR 2 is installed
Required room
temperature
(if TR 2 connected)
Required temperature in
room where TR 2 is installed
Operating mode
(if TR 2 connected)
E. g. Heating, Economy in
Automatic mode
or
Economy, Heating, Frost
protection in manual mode
Max. flow temp.
Maximum CH flow temperature set on the temperature
control for CH flow
Actual flow temp.
Actual CH flow temperature
• ZSBR models (with Storage Tank): The basic
settings provide a timer programme: enable from
5:00 am, disable from 10:00 pm. With the menu Hot
water (see page 30) you can choose a timer-/temperature programme with the basic settings: 60°C
from 5:00 am, 10°C from 10:00 pm.
Required flow
temp.
Required CH flow temperature
Max HW temp.
Maximum permissible hot
water outflow temperature
Required HW
temp.
Required hot water temperature
6.6.1
Actual HW temp.
Actual hot water outflow
temperature
Storage Tank
charge released
or blocked
Shows, if hot water is
released or blocked
Storage Tank
charge on or off
or Storage Tank
charge afterrunning
Shows, if hot water is on or
off, or if the pump for the
Storage Tank afterrunning is
on
Boiler operat.
mode
winter/ summer
Indicates which mode the
CH flow temperature control
is set to
Burner on/off
Indicates whether the burner
is alight or not
Pump on/off
Indicates whether the integral pump is switched on or
off
• You can choose between Automatic, Constant on
(comfort) and Constant off (economy).
• The manually selected operating mode starts immediately.
• Constant off (economy) and Constant on (comfort)
are automatically reset at 00.00 (midnight).
• To cancel the manually selected operating mode:
– select the relevant menu and then press the C
button,
– or select a different operating mode,
– or set Holiday.
B From the main menu select Heating and then from
the first submenu Manual select required mode.
6.6
Hot water
General description
Hot water programme
• Up to six switching points per day can be set.
• There are two operating modes: Blocked and
Released.
B From the main menu, select Hot water and then
from the first submenu, select Hot water program.
B Set the days of the week, Blocked/Released (operating mode) in the same way as for the switching points
and modes for heating as described on page 28.
6.6.2
Hot water immediately
• Hot water immediately ON:
– Comfort mode is active for 2 hours.
• Comfort mode is active for 2 hours: normal automatic program (Hot water mode according to timer
programme entered).
B From the main menu, select Hot water and then
from the first submenu, select Hot water immediately.
B Press
or
ately on or off.
to switch Hot water immedi-
6 720 610 603 GB (03.02)
29
Text Display
6.8
Settings
B Press the
value.
6.8.1
Heating (if TR 2 is connected)
B Press
or
24 hours.
Optimum Start
B From the main menu, select Settings and from the
first submenu, select Heating.
B Press
or
to switch Optimum Start on or off.
Basic setting: “ON”
6.8.2
Hot Water (Storage Tank, ZSBR models
only)
The text display can control the hot water either with
Times and temperatures or only times.
button. The display shows Change
to set the number of seconds in
Basic setting: “+ 0 s”
LCD contrast:
B Press and hold the
button (about 5 seconds)
until the display shows Time correction and LCD
contrast.
B Press
or
B Press the
value.
B Press
to select LCD contrast.
button. The display shows Change
or
to adjust the LCD contrast.
• Times and temperatures: One can choose up to
six different times with temperatures, see page 29
“Hot water”.
Basic setting: e. g. “47”
• Only times: During that times the Storage Tank will
be charged to the choosed temperature.
Operating times
This option shows the hours of service (appliance,
burner and hot water) since commissioning.
B From the main menu, select Settings and from the
first submenu select hot water.
B Press
or
or only times.
Turn the hot water temperature control
always higher than the temperature at the
text display is choosen.
i
6.8.3
to switch Times and temperatures
Service
B From the main menu, select Settings, from the first
submenu select Service, from the Second submenu
select Further options, and from the third submenu
select Operating times.
Fault history
This option displays any faults that have occurred for
the information of the service engineer. The first fault
displayed may still be active. Any other faults displayed
are no longer active.
This option displays various current settings and statuses of the electrically controlled appliance and system
components for the benefit of the heating engineer.
B From the main menu, select Settings, from the first
submenu select Service, from the Second submenu
select Further options, and from the third submenu
select Fault history.
Service parameters
6.9
Language
Available languages are: English, Français (French),
Deutsch (German).
Tables for your own timer programmes you find in the
User Manual.
Displaying service functions
Individual timer programmes
B From the main menu, select Settings, from the first
submenu select Service, from the Second submenu
select Further options, and from the third submenu
select Language.
B Press
or
to select the desired language.
Two other supplementary functions can be selected
from the third submenu Language:
• Time correction
• LCD contrast.
Time correction:
B Press and hold the
button (about 5 seconds)
until the display shows Time correction and LCD
contrast.
B Press
30
or
to select Time correction.
6 720 610 603 GB (03.02)
Individual settings
7
Individual settings
7.1
Mechanical settings
7.1.1
Checking the size of the expansion vessel
Maximum pressure at maximum CH flow temperature is
2.5 bar. If the pressure is greater than this then fit an
extra expansion vessel. Refer to table 10.
System Capacity – BS7074:1
Expansion Vessel Pressure and System
Capacity
Control setting
CH flow temperature
1
2
3
4
5
E
max
approx. 35°C
approx. 43°C
approx. 51°C
approx. 59°C
approx. 67°C
approx. 75°C
approx. 88°C
Table 11
Expansion Vessel
litres
Expansion Vessel Charge
Pressure
System
pressure and
capacity
18
7.2
Settings on the Bosch Heatronic
General description
bar
0.75
7.2.1
1 bar
litres
147
The text display module provides a convenient means of
setting various appliance functions.
1.5 bar
litres
82
This description is limited to those functions necessary
for commissioning.
Table 10
7.1.2
Setting the central heating flow temperature
The central heating flow temperature can be set to
between 35°C and 88°C.
i
With underfloor heating systems, observe
the maximum permissible flow temperatures.
Limited maximum setting for low-temperature
operation
The temperature control is factory limited to setting E,
giving a maximum flow temperature of 75°C.
Adjustment of the heating output to the calculated heat
demand is not required by the heating systems regulations.
Removing the maximum setting limit
For heating systems which require higher flow temperatures, the maximum setting limit can be removed.
B Lift off the yellow button on the temperature control
with a screwdriver.
Service function
Code no.
see
page
Anti-cycle time
2.4
32
Max. CH flow temp.
2.5
32
Max. heating output
5.0
32
Variable pump settings
7.0
32
Table 12
i
For a detailed description, refer to Service
Booklet for the Engineer 7 181 465 347.
Displaying service functions
All service functions are displayed.
B Press any button to activate the main menu.
B Press
or
button until the arrow cursor is
pointing to Settings.
B Press the
button.
B Press
or
button until the arrow cursor is
pointing to Service.
B Press the
button.
B Press the
button to select Display service
parameters.
Service function 0.0, Last fault is displayed.
B Press the
or
current settings.
B Press the
6 720 610 332-27.1O
Fig. 41
B Rotate yellow button through 180° and replace (dot
facing inwards).
The CH flow temperature is no longer limited.
6 720 610 603 GB (03.02)
button to cycle through the
button to exit the menu.
Setting service functions
Only the service functions that can be set are displayed.
B Press any button to activate the main menu.
31
Individual settings
B Press
or
button until the arrow cursor is
pointing to Settings.
7.2.4
B Press the
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.
button.
B Press
oder
button until the arrow cursor
is pointing to Service.
B Press the
button.
The cursor is pointing to Display service parameters.
B Press and hold the
button (for about 5 seconds) until the display shows Adjust service
parameters and the first service function to be set,
e.g. 2.0, Operating mode. If a fault has occurred,
the display will show 0.0 and the last fault.
B Press the
or
button until the desired
service function is displayed.
B Press the
button.
The first line of the display shows Change value.
B Use the
setting.
or
buttons to enter the required
B Press the
button.
The text display shows ATTENTION Store settings?.
B Press
or
to select yes or no.
B Press
to confirm your selection.
The text display shows Please wait ... ..., and the
service function is then displayed with the new setting.
B Press the
or
button until the next function you wish to change is displayed.
-orB Press the
7.2.2
button to exit the menu.
Setting the anti-cycle time
(Service Function 2.4)
i
Setting the heating output
(Service Function 5.0)
The full rated heat output is still available
for hot water or charging the hot water cylinder even if the heating output has been
limited.
The factory setting is the max. rated heat output, 100 %.
B Look up heating output in kW and corresponding
code number on the settings tables for heating output (see page 46).
B Enter the code number on the text display module.
B Measure the gas flow rate and compare with the figures specified for the code number shown. If different, correct code number.
7.2.5
Variable pump settings
(Service Function 7.0)
The pump speed varies automatically to match the
water flow requirement of the system determined by the
position of thermostatic radiater valves. An automatic
by-pass must not be used.
The Service Function 7.0 is factory set to 4 which will
accommodate the majority of heating systems.
Information on the re-settings of this functions can be
found in the Service Booklet for the Engineer
number 7 181 465 347.
7.3
Setting the gas/air ratio
The appliance is set at the factory and adjustment is not
necessary.
This service function is only active if Service Function
2.7, automatic anti-cycle time, is deactivated.
The anti-cycle time can be set to between 0 and 15 minutes (is factory set to 3 minutes).
If the setting 0 is entered, the anti-cycle time is inactive.
The shortest possible anti-cycle time is 1 minute (recommended for single-pipe and hot-air heating systems).
i
7.2.3
If the appliance is connected to an outside-temperature controlled heating programmer, the anti-cycle time does not
need to be set on the appliance and is optimised by the programmer instead.
Setting the maximum CH flow temperature (Service Function 2.5)
The maximum CH flow temperature can be set to
between 35°C and 88°C (factory setting).
32
6 720 610 603 GB (03.02)
Converting the appliance to different gas types
8
Converting the appliance to different gas types
The setting is factory sealed at maximum. Adjustment to
the rated heat input and min. heat input is not necessary.
Checking the gas supply pressure
B Check the gas supply pressure at the gas supply
pressure testing point.
i
Natural gas appliances must not be operated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is below or above
37 mbar.
8.1
Setting the gas/air ratio
The gas/air ratio may only be adjusted on the
basis of a CO2 measurement at max. heat output
and min. heat output using an electronic tester.
B Switch off the appliance at the master switch (O).
B Remove the outer case (see page 16, refer to
fig. 15).
B Switch on the appliance at the master switch (I).
B Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 42.
B Insert testing probe about 135 mm into the flue gas
testing point and seal testing point.
Natural gas
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m3 and 20 mbar supply
pressure and sealed.
Conversion kits
2 3 4
Model
For conversion
from ...
Order no.
ZSBR 7-28
N.G to L.P.G
7 710 149 052
ZSBR 11-28
L.P.G to N.G
7 710 239 088
6 7 2 0 6 1 0 3 3 2 -5 7 .2 R
Table 13
Fig. 42
• Instructions are sent with each conversion kit.
B On the text display unit, select in the main menu Settings, Service, Display service parameters.
B Press and hold the
button (for about 5 seconds) until the display shows Adjust service
parameters and the first service function to be set,
2.0 Operating mode. If a fault has occurred, the
display will show 0.0 and the last fault.
B Press
or
until the display shows 2.0
Operating mode normal.
B Press the
B Press
button.
or
to select Max.
B Measure the CO2 level.
B Prise off the seal on the gas flow restrictor.
6 720 610 603 GB (03.02)
33
Converting the appliance to different gas types
B Adjust the gas flow restrictor (63) to obtain the CO2
level given in Table 14. Refer to fig. 43.
B Remove testing probe from the flue gas testing
point (234) and refit sealing plug.
B Re-seal gas valve adjusting screw and gas flow
restrictor.
B Replace the outer case by locating it on the top lugs
and pushing backwards until the bottom clips are
fully engaged. Check that the case is properly
aligned with facia. Refer to fig. 15.
63
B Secure by replacing the screw at the bottom left.
Refer to fig. 15.
6 720 610 332-64.1R
Fig. 43
ZSBR 7-28
Gas Type
Natural gas type
G20
LPG G31
(propane)
CO2 reading
at max.
rated heat
output
CO2 reading
at min.
rated heat
output
9.2 %
8.8 %
10.8 %
10.5 %
Table 14
B Press
or
to select Min.
B Measure the CO2 level.
B Remove the seal from the gas valve adjusting screw
(64) and adjust the CO2 level to the figure given in
Table 14 for min. rated heat output. Refer to fig. 44.
64
3928-74.1R
Fig. 44
B Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
B Press
normal.
or
until the display shows
B Press the
button. The text display shows
Store settings.
B Press
B Press the
34
to select yes.
button.
6 720 610 603 GB (03.02)
Converting the appliance to different gas types
8.2
8.2.1
i
Testing combustion air/flue gas at
set heat output
Testing the O2 or CO2 level in the
combustion air
By testing the O2 or CO2 level in the combustion air the gas tightness of a type C13
or C33 flue system can be checked. The
O2 level must not be less than 20,6 %.
The CO2 level must not exceed 0,2 %.
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
In “chimney sweep” mode, the appliance
switches to max. rated heat output or the
set heating output. You then have 15 minutes in which to measure the levels. After
that, the appliance switches back from
“chimney sweep” mode to normal mode.
8.2.2
Testing CO and CO2
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
CH flow temperature.
i
You have 15 minutes in which to measure
the levels. After that, the appliance switches back from “chimney sweep” mode to
normal mode.
B Remove sealing plug from flue gas testing point
(234, fig. 45).
B Insert testing probe about 135 mm into the testing
point and seal testing point.
B CO- and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
B Remove sealing plug from combustion air testing
point (234.1, fig. 45).
B Insert testing probe about 80 mm into the testing
point and seal testing point.
2 3 4
2 3 4 .1
6 7 2 0 6 1 0 3 3 2 -6 5 .2 R
Fig. 45
B Measure O2 and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the CH flow temperature.
6 720 610 603 GB (03.02)
35
Maintenance
9
Maintenance
B Always disconnect the appliance from
the electrical power supply (fuse, circuit
breaker) before carrying out any work on
the electrical systems or components.
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
There is a Service booklet for the Engineer, order no. 7 181 465 347, available
to competent persons.
i
All safety and control systems are monitored by the Bosch Heatronic. In the event
of a component fault, the textdisplay
shows a fault code.
B The User should be recommended to have the appliance serviced regularly by a competent person.
B Use only genuine spare parts
B Refer to the Spare Parts List when ordering spare
parts.
B Always renew seals and O-rings removed during
servicing or repair work.
B Use only the following types of grease:
– Water valve: WRAS approved silicon based
grease
– Unions: approved sealant.
B To drain the appliance shut the system valves and
open the pressure relief valve.
B Upon completion of any electrical work check for
earth continuity, correct polarisation and resistance
to earth.
Replace the text display module or the Heatronic
PCB
If the text display module is replaced, the service function settings are retained.
B The remaining settings have to be re-entered.
If the Heatronic PCB is replaced:
B Re-enter the service function settings as recorded in
the commissioning record.
36
6 720 610 603 GB (03.02)
Maintenance
9.1
Pre-Service Check List
Date
1
Call up the last fault stored by the textdisplay , (see page 30).
2
Check ionisation current, Service
Function 3.3, (see page 38).
3
Perform visual check of air/flue duct.
Visual check of diaphragm for soiling
and splits (see page 40).
4
Check gas supply pressure
(see page 33).
5
Test combustion air/flue gas
(see page 35).
6
Check CO2 setting for min./
max. (gas/air ratio)
(see page 35).
mbar
min. %
max. %
7
Check gas and water systems for
leaks (see page 16).
8
Check heat exchanger
(see page 38).
9
Check burner (see page 39).
mbar
10 Clean condensation trap
(see page 39).
11 Check charge pressure of
mbar
expansion vessel matches
static head of heating system.
12 Check central heating system mbar
pressure.
13 Check electrical wiring for damage.
14 Check heating programmer settings in
the textdisplay.
15 Check appliances that are part of
the heating system.
Table 15
6 720 610 603 GB (03.02)
37
Maintenance
9.2
Description of servicing operations
The combustion performance must be checked before
and after any servicing work on the combustion and
burner components. Refer to section 8.2.
B Remove the fan and the burner as described in the
text headed “Burner” (see page 39).
Checking the ionisation current,
Service Function 3.3
B Select Service Function 3.3. (See page 31 “Displaying Service Functions”)
If the display shows 2 or 3, the ionisation current is OK.
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced.
Primary Heat exchanger
There is a special accessory kit (no. 840) for cleaning
the heat exchanger, order no. 7 719 001 996.
B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manometer.
6 720 610 332-72.1R
Fig. 47
B Loosen any deposits in the heat exchanger from top
to bottom using the cleaning blade. Refer to fig. 48.
6 720 610 332-73.1R
6 720 610 332-69.1R
B Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 49.
Fig. 46
i
Fig. 48
The heat exchanger should only be
cleaned if the control pressure is
2.2 mbar (depression) or less.
B Remove cleaning access cover (415, page 6) and
the metal plate below it, if present. Refer to fig. 2.
B Unscrew condensation trap and place suitable container underneath. Refer to fig. 47.
6 720 610 332-74.1R
Fig. 49
B Flush the heat exchanger from the top. Refer to
fig. 50.
38
6 720 610 603 GB (03.02)
Maintenance
B Clean out the condensate collector and trap connection (with other end of brush).
6 720 610 332-75.2R
Fig. 50
B Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
Burner
B Check that the gas cock is turned off and the master
switch is in the OFF position.
B Remove the clips (1.) and unscrew the two bolts (2.).
Refer to fig. 51.
B Unscrew and remove the two hexagon screws securing the fan (3.).
B Slacken fully the rear securing bolt (4.).
B Remove the burner coverplate.
7 181 465 330-08.2R
Fig. 52
B Re-assemble burner in reverse order using a new
seal.
B Adjust gas/air ratio (see page 33). Refer to
section 8.2.
Condensation trap
4.
In order to prevent spillage of condensate the condensation trap should be completely removed, (see
page 38, fig. 47).
B Unscrew condensation trap and check connection to
heat exchanger is clear.
2.
B Remove condensation trap cover and clean.
3.
B Fill condensation trap with approx. 1/4 l of water and
refit.
1.
Electrode assembly
B Switch off the master switch.
7 181 465 330-04.1R
Fig. 51
B Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 52.
B Pull off the leads from the electrodes. Refer to fig. 2.
B Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 46.
B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4,5 mm ± 0,5 mm.)
B Replace and re-connect the assembly taking care not
to mislay the inspection window.
6 720 610 603 GB (03.02)
39
Maintenance
Diaphragm in mixer unit
B Refit and prime the siphon.
B Take care not to damage diaphragm
(443) when removing and refitting it.
B Open mixer unit (29).
Condensate
Drain
B Carefully withdraw diaphragm (443) from fan intake
tube and check for soiling and splits.
Siphon
3.
443
29
6 720 610 602 - 16.1O
Fig. 54
1.
Expansion vessel
The expansion vessel should be checked once a year.
B Depressurise appliance.
B If necessary, adjust expansion vessel charge pressure to static head of the heating system.
2.
6 720 610 790-07.2R
Fig. 53
B Carefully refit diaphragm (443) the correct way round
into the fan intake tube.
i
The flaps of the diaphragm (443) must
open upwards.
B Seal the mixer unit (29).
Siphon
B Unscrew the clip and disconnect the pipe to the
siphon.
B Remove the yellow plug to drain the siphon.
B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
40
Heating system pressure
i
Fill the system using the WRAS approved
filling loop.
B The pointer on the pressure gauge should be 1 bar.
B If the pointer is below 1 bar (when the system is
cold), water should be added until the pointer is
1 bar again.
B Max. pressure of 2.5 bar when the heating system
water is at maximum temperature must not be
exceeded. If this pressure is exceeded then an extra
expansion vessel must be fitted in the system return
as close to the appliance as possible.
B If the system does not retain the pressure, the expansion vessel and the heating system should be
checked for leaks.
6 720 610 603 GB (03.02)
Maintenance
9.3
B Remove the pcb control board.
Replacement of Parts
Before changing any components check that the gas is
turned off and that the appliance is electrically isolated.
When necessary close the system valves and drain the
appliance.
Refitting is a reverse of the procedure for removal using
new seals or o-rings as appropriate.
9.3.1
PCB control board and transformer
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the covers. Refer to fig. 27, 28.
B Remove screw holding power connector earth lead
and remove earth lead.
B Remove two top fixing screws from the control box.
Refer to fig. 55.
1
3
2 4
3
4
7 181 465 330-10.1R
1
3
2 4
2
5
Fig. 56
1
E
Fuses
1
7 181 465 330-09.1R
3
2 4
B Remove the connections covers. Refer to fig. 27,
28.
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
Fig. 55
Fuse, item 312, is only replaceable by removing the
pcb.
B Lower the control box.
Spare fuses are fixed to the connections cover.
B Unscrew earth lead.
A fuse pack is available: Part number 8 744 503 010 0.
B Unscrew four fixing screws from cover plate. Refer to
fig. 56.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.
6 720 610 603 GB (03.02)
41
Maintenance
9.3.2
Fan Assembly
9.3.3
3.
Pump
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Remove two switchbox fixing screws (1.). Refer to
fig. 58.
2.
B Lower switchbox (2.).
B Remove screw from underside of right-hand plastic
cover plate (3.).
B Pull cover plate forwards to remove (4.).
4.
B Unscrew and remove the the siphon by releasing the
jubilee clip. Refer to fig. 54.
B Unscrew the pump union nuts (5.). Refer to fig. 58.
B Carefully remove the pump and disconnect the leads.
Alternatively
B After removing the siphon release the four Allen
screws and remove and replace the pump head.
1.
5.
7 181 465 330-05.1R
Fig. 57
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Remove fan lead and earth connector (2.). The earth
connector has a positive clip fixing.
B Remove fixing screws attaching fan to the burner
cover (3.).
7 181 465 330-03.1R
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 57.
1.
1.
B Remove fan together with gas pipe and mixer unit.
B Separate the fan from the pipe and mixer unit by
twisting the mixer unit to release it (4.).
3.
2.
4.
Fig. 58
9.3.4
3-way diverter valve
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Turn off service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 59.
B Pull out retaining clip.
B Remove motor.
B Disconnect the relief valve drain.
B Disconnect the pressure gauge by withdrawing the
clip and pulling out the capillary head.
42
6 720 610 603 GB (03.02)
Maintenance
B Undo pipe unions by withdrawing the clips.
9.3.7
B Remove 3-way valve.
B Check that the gas cock is turned off.
Gas Valve
B Lower the control panel. Refer to fig. 58.
B Pull off the solenoid connections at the rear of the
valve.
B Undo the union, within the inner casing, securing the
valve to the gas/air tube. Refer to fig. 57.
B Remove the white plastic cap from the gas valve.
B Release the gas inlet union at the manifold assembly.
B Unscrew the two screws securing the gas valve
assembly bracket to the back panel and withdraw the
assembly.
B Transfer the bracket and inlet pipe assembly to the
new gas valve.
B Check for gas soundness when the new gas valve
has been fitted.
B Recheck the combustion performance as described
in section 8.1.
7 181 465 330-12.1R
Fig. 59
After refitting:
B Fill system, bleed and re-pressurise
(see Installation Instructions).
9.3.5
3-way diverter valve motor
B Switch off the appliance.
B Turn off the service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 59.
B Pull out retaining clip.
B Remove motor.
9.3.6
Sensors
B Check that the appliance is electrically isolated.
Central Heating Flow Temperature Sensor –
Item 36, fig. 2, 55
B Pull-off the connector.
B Release the sensor clip and withdraw the sensor.
B Apply heat transfer paste to the replacement sensor.
Safety Temperature Limiter – Item 6, fig. 2, 55
B Pull-off the connectors.
6 720 610 602 - 04.1O
B Unscrew the sensor.
Flue Temperature Limiter – Item 9, fig. 2, 55
Fig. 60
B Pull-off the connectors.
B Unscrew the sensor.
6 720 610 603 GB (03.02)
43
Maintenance
9.3.8
Electrode assembly
B Refer to section 9.2.
B Use a new seal if the existing seal is damaged.
9.3.9
Pressure gauge
B Drain the appliance.
B Lower the facia. Refer to fig. 58.
B Pull forward from the top and lift the heat exchanger
from the casing.
B Transfer components, as necessary, to the new heat
exchanger.
B Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
appliance.
B Twist the pressure gauge head anti-clockwise to
release it from the casing. Refer to fig. 2.
B Disconnect the capillary head from the rear of the
diverter valve by withdrawing the clip and pulling out
the head. Refer to fig. 59.
9.3.10 Expansion vessel
B Drain the appliance.
B Undo the union connection at the base of the vessel.
Refer to fig. 2.
B Unscrew the top and bottom fixing screws and
remove the vessel.
B Set the pressure of the new vessel to that required by
the system.
9.3.11 Pressure Relief Valve
B Drain the appliance.
B Disconnect the drain pipe from the valve. Refer to
fig. 33.
B Pull-out the clip securing the valve.
B Pull-out the valve.
B Ensure that the replacement valve is fully entered
before fitting the clip.
9.3.12 Burner
B Refer to section 9.2.
9.3.13 Primary Heat Exchanger
B Drain the appliance.
B Check that the gas supply is turned off.
6 720 610 602 - 06.10
Fig. 61
B Check that the appliance is electrically isolated.
B Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 9.3.2.
B Remove the burner. Refer to section 9.2.
B Disconnect the sensors. Refer to section 9.3.6.
B Undo the central heating flow union.
B Undo the top connection of the pump. Refer to
fig. 57.
B Undo the grey plastic cap, next to the top pump connection at the base of the heat exchanger.
B Unscrew and remove the condensate trap. Refer to
section 9.2.
B Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
B Lift up the flue duct, item 271, refer to fig. 2.
44
6 720 610 603 GB (03.02)
Appendix
10
Appendix
10.1 Fault Codes
More detailed fault finding procedures are described in the Service Booklet for the Engineer number 7 181 465 347.
Display
code
Description
Remedy
A1
Pump has run dry
Check system pressure, add water and bleed system
as necessary
A8
Break in communication
Check connecting lead to TR2
b1
Keyed plug not detected.
Insert keyed plug correctly, test and replace if necessary.
C1
Fan speed too low.
Check fan lead and connector, and fan; replace as
necessary.
d3
Jumper 8-9 not detected.
Connector not connected, link missing, underfloor
heating limiter tripped.
E2
CH flow NTC sensor defective
Check CH flow NTC sensor and connecting lead.
E9
Safety temp. limiter in CH flow has tripped.
Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA
Flame not detected.
Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0
Internal error.
Check electrical connector contacts, programmer
interface module ignition leads and bus module are
not loose; replace pcb or bus module if necessary.
F7
Flame detected even though appliance switched off.
Check electrode assembly, dry pcb. Flue clear?
FA
Flame detected after gas shut off.
Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue
clear?
FC
Textdisplay not detected.
Check connecting lead between Textdisplay and
Heatronic, change Textdisplay
Fd
Reset button pressed by mistake.
Press reset button again
P1, P2,
P3, P1...
Please wait, initialisation in progress.
24 V fuse blown. Replace fuse.
Table 16
6 720 610 603 GB (03.02)
45
Appendix
10.2 Short parts list
Key
Description
Qty GC
Spare part number
1
Sensor - Flue gas temp.
1
8 729 000 144 0
2
Sensor - CH flow temp.
1
8 714 500 087 0
3
Control board
1
8 748 300 418 0
4
Gas valve
1
8 747 003 516 0
5
Fan assembly
1
8 717 204 373 0
6
Fan washer
1
8 729 000 183 0
7
Expansion vessel
1
8 715 407 236 0
8
Relief valve
1
8 717 401 012 0
9
Electrode assembly
1
8 718 107 077 0
10
Electrode lead
1
8 714 401 999 0
11
Pump
1
8 717 204 477 0
12
Pressure gauge
1
8 717 208 079 0
13
Burner skin seal
1
8 711 004 168 0
14
Transformer - facia
1
8 747 201 358 0
15
Flow switch
1
8 717 002 110 0
16
3-way diverter valve
1
8 717 010 062 0
17
Heat exchanger washer
1
8 710 103 153 0
18
Washer set Condensation Trap
1
8 710 103 154 0
19
Fuse set
1
8 744 503 010 0
20
Service set Water Valve
1
8 710 503 031 0
21
Text Display
1
8 747 208 103 0
22
Primary heat exchanger
1
8 715 406 615 0
23
Diaphragm
1
8 715 505 801 0
Table 17
10.3 Heating/hot water output settings
ZSBR 7-28 N.G.
10.4 Heating/hot water output settings
ZSBR 11-28 L.P.G
Propane
Natural gas G20
Heat
output,
kW
Heat
input,
kW
Gas vol. flow rate
(l/min at
tV/tR = 80/60°C)
Display
code
Heat output kW
Heat input kW
40
11.0
11.1
30
8.2
8.3
14.5
50
13.7
13.9
40
11.0
11.1
19.4
60
16.4
16.6
50
13.7
13.9
24.2
70
19.2
19.4
60
16.4
16.6
29.1
80
21.9
22.2
70
19.2
19.4
33.9
90
24.7
24.9
80
21.9
22.2
38.8
100
27.4
27.7
90
24.7
24.9
43.6
100
27.4
27.7
48.5
Display
code
Table 19
Table 18
46
6 720 610 603 GB (03.02)
Mains
switch
ON.
6 720 610 603 GB (03.02)
Repeats 5 times
before lock-out.
Green
light
ON.
CH
demand.
Ignition spark for
5 seconds.
Ignition sequence
Room thermostat
and/or mains
programmer or
link ON
AND
Electronic facia
programmer
(if fitted) ON
AND
CH control knob
ON.
Fan runs to purge
gas from burner.
No
Burner lights.
Red light ON.
Pump ON
Fan to
start speed.
Gas valve opens.
Yes
Burner remains OFF
until flow temperature
is below set value.
Fan speed
reduces
over 15
secs.
CH demand
satisfied.
Fan min.
speed for
90 secs.
Yes
Gas valve
closes.
Red light
OFF.
No
Boiler
unused for
long
period.*
*
Minimum
heat input
for 15min.
Over temperature
shut-down if water
temperature is 5°C
above set value.
Pump and Fan
run for upto
3 mins.
Boiler
operates to
match
system load
and CH
control
setting.
6 720 610 576 - 25.1O
* NOTE: The sequence ensures that the condensate siphon is not empty
after long OFF periods. (More than 24 hours without a demand).
ce
Burner
stabilises at
start speed
for 5-10 secs
Gas valve shuts.
Pump remains ON.
Appendix
10.5 Operational Flow diagrams
10.5.1 Central heating function
Fig. 62
47
Appendix
EXCELLENCE COMES AS STANDARD
Manufactured exclusively for British Gas by The Bosch Group
Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619
Service Booklet for the Engineer
for Gas Condensing Boilers
6 720 610 333-00.1R
ZSBR 7-28 ICS1 GC-Number: 41 108 04
ZWBR 8-30 ICC2 GC-Number: 41 108 09
ZBR 8-35 ICS1 GC-Number: 41 108 05
ZWBR 11-37 ICC1 GC-Number: 41 108 10
7 181 465 347 (01.07) OSW
ZWBR 7-28 HE plus GC-Number: 47 311 56
ZWBR 11-35 HE plus GC-Number: 47 311 57
Contents
Contents
Safety precautions
3
Symbols
3
1
4
Layout of Appliance (ZSBR/ZWBR)
2
2.1
2.2
2.3
2.4
2.4.1
Operation
Standard display
Displaying service functions
Setting service functions
Resetting service functions to factory settings
Resetting service functions 0.0 to 4.9 to their
factory settings (Reset 1):
2.4.2 Resetting service functions 0.0 to 9.9 to the
factory setting (Reset 2):
5
5
5
5
5
3
3.1
3.2
Boiler service functions
Summary
Explanation of service functions
6
6
9
4
4.1
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.3
4.4
4.5
4.5.1
4.5.2
Rectifying faults
Boiler failure codes indication
... on the boiler
... on the programmer (optional accessory)
Summary
Appliance faults
Faults that are not indicated on any display
How to use the fault tables
Faults indicated on display
Faults that are not displayed
Appliance faults
Programmer faults
14
14
14
14
14
14
14
16
17
36
36
41
5
5.1
5.1.1
5.1.2
Appendix
NTC values
Outside temperature sensor
CH flow NTC sensor, heat store NTC
sensor, constant hot water NTC sensor
and hot water NTC sensor
Electronic schemes
List of most important replacement parts
Approved corrosion inhibitors and
anti-freeze fluids for central heating water
Detecting corrosion by CFCs
45
45
45
5.2
5.3
5.4
5.5
2
5
5
45
46
47
48
49
7 181 465 347 (01.07)
Safety precautions
Safety precautions
Symbols
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
Repairs
B Repairs may only be carried out by an approved
installer!
B Before carrying out any work on the appliance,
switch it off at the master switch!
B Even when the appliance is switched off at the master switch, some components on the PCB control
board inside the control box are still live.
Therefore:
B Before carrying out any work on the electrical parts
of the appliance fully disconnect it from the power
supply (e. g. by means of fuse or circuit breaker)!
B Flue ducting must not be modified in any way.
B Use only original spare parts!
Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
• Caution indicates that minor damage to property
could result.
• Warning indicates that minor personal injury or serious damage to property could result.
• Danger indicates that serious personal injury could
result. In particularly serious cases, lives could be at
risk.
Instructions to the customer
B Advise the customer that he/she must not make any
modifications to the appliance or carry out any
repairs on it.
B Draw attention to the need for an annual service (or
maintenance contract if applicable).
7 181 465 347 (01.07)
i
Notes are identified by the symbol shown
on the left. They are bordered by horizontal lines above and below the text
Notes contain important information in cases where
there is no risk of personal injury or damage to property.
3
Layout of Appliance (ZSBR/ZWBR)
1
Layout of Appliance (ZSBR/ZWBR)
Testing points:
flue gas
air
Fan fixing
screws
Automatic vent
Burner fixing
screws
Fan connector
Electrode
assembly:
Flame sensing
electrode
Ignition electrodes
Fan
Mixer unit
Silencer
CH flow NTC
sensor
CH flow
Gas supply
pipe
Flue gas safety
temperature
limiter
Gas flow
restrictor: adjusting screw for
CO2 max.
CH flow safety
temperature
limiter
Inspection
opening
Gas valve:
adjusting
screw for CO2
min.
Variable-characteristic pump
Plate-type heat
exchanger
(ZWBR)
Change-over
valve
Hot water NTC
sensor (ZWBR)
Condensation
trap
Change-over
valve motor
Transformer
Heatronic
4
Water switch
(ZSBR)
7 181 465 347 (01.07)
Operation
2
Operation
Instructions on the use of the text display module are
given in the operating and installation instructions for
the boiler.
a
b
c
C
6 720 610 337-08.1R
e
f
Fig. 1
a
b
c
d
e
f
2.1
B Press and hold the
button (for about 5 seconds) until the display shows shows Adjust service
parameters and the first service function to be set,
e.g. 2.0, Operating mode. If a fault has occurred, the
display will show 0.0 and the last fault.
B Press
or
button until the desired service
function is displayed.
B Press the
button.
The first line of the display shows Change value.
B Use the
and
required setting.
d
Controls
Display
“Up” or “More” button
“Down”, or “Less” button
“Back” button
“Nest” button
“Delete” button
Standard display
The text display shows the time, the CH flow temperature and the measured outside temperature in plain
English.
In addition, the 2-digit display also shows the current
CH flow temperature in Heating mode and Hot Water
mode (display range 00 °C to 99 °C).
2.2
B Press the
button.
The cursor is pointing to Display service
parameters.
Displaying service functions
buttons to enter the
B Press the
button.
The text display shows ATTENTION Store settings?.
B Press
or
to select yes or no.
B Press
to confirm your selection.
The text display shows Please wait ..., and the service function is then displayed with the new setting.
B Press the
or
button until the next function you wish to change is displayed.
-orB Press the
button to exit the menu.
2.4
Resetting service functions to factory settings
2.4.1
Resetting service functions 0.0 to 4.9 to
their factory settings (Reset 1):
B Press any button to activate the main menu.
B Press
or
button until the arrow cursor is
pointing to Settings.
B Power OFF the appliance.
B Press the
B Switch on the appliance, press and hold the
ton until the
display shows r1 followed by [ ] .
button.
B Press
or
button until the arrow cursor is
pointing to Service .
B Press the
button.
B Press
button to select Display service
parameters.
Service function 0.0, Last fault is displayed.
B Press
or
current settings.
B Press
2.3
button to cycle through the
button to exit the menu.
Setting service functions
B Press any button to activate the main menu.
B Taste
or
button until the arrow cursor is
pointing to Settings.
B Press the
B Press the button
2.4.2
and keep it pressed.
but-
Resetting service functions 0.0 to 9.9 to
the factory setting (Reset 2):
B Power OFF the appliance.
B Simultaneously press and hold buttons
and
.
B Switch on appliance, press and hold the
and
buttons until the display shows r2 followed by [ ] .
i
To reset all parameters (except service
settings) set on the text display module):
B Press and hold the C button until the
settings are deleted.
button.
B Press
or
button until the arrow cursor is
pointing to Service.
7 181 465 347 (01.07)
5
Boiler service functions
3
Boiler service functions
3.1
Summary
Text display message
Display
Range adjustable
from - to
Reset
Value
0.0
Last fault
00 - FF
Clear only
0
0.1
Flow temp. sensor
0 - 99 °C
-
-
0.2
Hot water temp. sensor
0 - 99 °C
-
-
0.3
Stor. tank temp. sensor1
0 - 99 °C
-
-
0.4
Stor. tank temp. sensor2
0 - 99 °C
-
-
1.2
Code plug 8714411 XXX
0 - 255
-
-
1.5
Required flow temp.
0 - 99 °C
-
-
1.9
Module detection
no module detected
bus module
-
-
2.0
Operating mode
-
normal
Min
Max
normal
2.2
Pump switch mode
-
1-3
2
2.3
Stor. tank charge output
-
0 - 100%
100 %
2.4
Anti-cycle mode
-
0 - 15 min
3 min
2.5
Max. flow temperature
-
35 - 88 °C
88 °C
2.6
Switch.diff.flow temperature
-
0 - 30 °C
0 °C
2.7
Autom. anti-cycle mode
-
on
off
on
2.9
Actual output
0 - 100 %
-
-
3.0
Fan speed
0 - 255 U/s
-
-
3.3
Ionisations current
no
low
middle
high
-
-
3.4
Pump mode
-
0-3
01)
3.5
Pump blocking time
-
0 - 240 s
in 15-s increments
0s
3.6
Software version
BF 11.XX
-
-
Table 1
6
7 181 465 347 (01.07)
Boiler service functions
Range adjustable
from - to
Reset
Value
open
closed
-
-
Link Ls-Lr
open
closed
-
-
4.0
Stor. tank. therm.. (7-9)
blocked
heat demand
-
-
4.1
Room therm. LSM
blocked
heat demand
-
-
LSM release
blocked
heat demand
-
-
Timer ch. 1 (heating)
blocked
heat demand
-
-
Timer ch. 2 (hot wat.)
blocked
heat demand
-
-
Heat demand (heating).
yes
no
-
-
Heat demand (stor. tank).
yes
no
-
-
Heat demand (hot water).
yes
no
-
-
Keep hot period
yes
no
-
-
4.6
Internal regulator
blocked
heat demand
-
-
5.0
Max. output (heating)
-
27 - 100%
100 %
5.1
Permanent ignition
-
no
yes
no
5.2
GFA status / error
00h - FFh
-
-
5.5
Min. output
-
27 - 100 %
27 %
5.8
Cyclic boiler starts
-
on
off
on
5.9
Fan speed (start)
-
low
high
low
6.7
Pump off (hot water).
-
off
on
off
3.9
4.2
4.4
4.5
Text display message
Display
Link 8 - 9
Table 1
7 181 465 347 (01.07)
7
Boiler service functions
Text display message
Display
Range adjustable
from - to
Reset
Value
6.8
Cycle time (hot water)
-
0 - 60 min
0 min
6.9
Duration (hot water)
-
0 - 30 min
1 min
7.0
Pump map (heating)
-
0 Pump step adjustable
1 Const. pressure high
2 Const. pressure
middle
3 Const. pressure low
4 Prop.pressure high
5 Prop.pressure low
4 Prop.
pressure
high
7.1
Map pump step (heat.).
-
2-7
7
7.2
Antiblock. map pump.
-
off
on
on
7.3
Air purge mode
-
off
on autom. deaktivat.
permanent on
on
autom.
deaktiv
at./ off
7.4
Actual map pump step
1-8
-
-
7.5
Map pump load index
0 ... 255
-
-
7.6
Map pump type
0 .. 99
-
-
7.7
Output reduction
-
off
only in
only in heating mode
heating
only in hot water mode
mode
in heat./hot water mode.
8.5
Siphonfillprogram
-
on, boiler min.output,
on, adjust. min output,
off
on,
boiler
min.
output
9.2
Hot water on demand
-
off
on
on
9.3
GFA-Asic-error
00h - FFh
-
-
Table 1
1)
8
The reset value depends on the code plug.
7 181 465 347 (01.07)
Boiler service functions
3.2
Explanation of service functions
0.0 Last fault
The last fault can also be recalled for servicing purposes when the appliance is functioning correctly.
To delete the stored fault:
B Delete fault (no fault displayed).
B Press the
B Use the
B Press the
button.
or
button to select yes.
button.
If a list of the last 10 indicated faults is required for servicing purposes, look under Settings -> Service -> Further options -> Fault history.
0.1 Flow NTC
The temperature measured by the NTC sensor on the
CH flow pipe is indicated.
0.2 Hot water NTC
The temperature measured by the NTC sensor on the
plate-type heat exchanger outflow is indicated.
• Min mode: the appliance runs constantly at minimum
output.
The text display shows MIn mode. The 2-digit display alternates between the CH flow temperature
and – – .
• Max mode: the appliance runs constantly at maximum output.
The text display shows Max mode. The 2-digit display alternates between the CH flow temperature
and – –.
2.3 Stor. tank charge outp
The heat store charging output can be set to any level
between the minimum and maximum rated heat output
for hot water according to the heat transfer capacity of
the heat store.
B Enter the heat store charging output setting on the
commissioning record enclosed with the appliance.
2.4 Anti-cycle mode
This function is only active if service function 2.7 Automatic anti-cycle mode is disabled.
The anti-cycle time is factory set to 3 minutes.
0.3 Storage tank NTC 1
Indirectly heated heat store (SO..., SK..., ST...):
The temperature measured by NTC sensor 1 in the heat
store is indicated.
Stratified-charge tank (ST...S):
The temperature measured by NTC sensor 2 at the bottom of the heat store is indicated.
The shortest possible period is 1 minute (recommended for single-pipe and hot-air heating systems).
The setting 0 means that the anti-cycle time is disabled.
i
0.4 Storage tank NTC 2
If an outside-temperature controlled heating programmer is used, no setting is required.
The anti-cycle time is optimised by the
programmer.
Stratified-charge tank (ST...S):
The temperature measured by NTC sensor 2 at the top
of the heat store is indicated.
B Enter the anti-cycle time on the commissioning
record enclosed with the appliance.
1.2 Code plug
2.5 Max. flow temperature
The 10-digit part number of the code plug is indicated.
The maximum CH flow temperature can be set to
between 35 °C and 88 °C (factory setting).
The code plug determines the appliance functions. If
the appliance is converted from natural gas to LPG or
vice versa (using conversion kit) the code plug also has
to be changed.
1.5 Desired flow temp.
The CH flow temperature demanded by the text display
module or a programmer connected to the bus module
is displayed.
1.9 Module detection
The text display module shows the modules detected
by the appliance.
2.0 Operating mode
There are 3 operating modes to choose from.
• Normal mode: the appliance operates according to
the commands received from the programmer.
7 181 465 347 (01.07)
2.6 Switch diff. flow NTC
i
If an outside-temperature controlled heating programmer is used, no setting is required on the appliance.
The switching difference is the permissible deviation
from the specified CH flow temperature. It can be set in
increments of 1 K. The adjustment range is from 0 to
30 K (factory setting: 0 K). The minimum CH flow temperature is 30 °C.
B Disable anti-cycle time (setting 0).
B The switching difference setting should be entered
on the commissioning record supplied with the appliance.
9
Boiler service functions
2.7 Autom. anti-cycle mode
If an outside-temperature controlled programmer is connected to the appliance, the anti-cycle time is adjusted
automatically.
Automatic adjustment of the anti-cycle time can be disabled. This may be necessary in the case of unfavourably dimensioned heating systems.
If automatic adjustment of the anti-cycle time is disabled, the length of the anti-cycle time must be set under
service function 2.4.
B If automatic adjustment of the anti-cycle time has
been disabled, this should be entered on the commissioning record enclosed with the appliance.
2.9 Actual output
The actual output of the appliance at the time viewed is
displayed.
3.0 Fan speed
The current fan speed is displayed.
3.5 Pump blocking time
(ZBR.. models only)
i
Only applies if service function 3.4, Pump
mode, is set to Pump mode 1 (external 3way valve for heat store charging is connected). Otherwise has no function.
If the system incorporates a 3-way valve external to the
appliance, the heating pump is disabled while the 3-way
valve is being actuated. therefore, the blocking time of
the heating pump should be ≥ the actuation time of the
3-way valve.
The blocking time has an adjustment range of 0 to 16,
with each increment equivalent to 15 seconds. The
adjustment range therefore equates to 0 to 240 seconds.
Factory setting is 30 seconds.
B Enter the pump blocking time on the commissioning
record enclosed with the appliance.
3.6 Software version
3.3 Ionisation current
The version number of the software is displayed.
The burner flame is monitored by measuring the ionisation current generated during combustion. If no ionisation current is detected, the gas valve shuts off. This
ensures that unburned gas does not escape.
3.9 Jumper 8 - 9 /
3.9 Jumper Ls - Lr
The possible settings are:
When supplied, the appliance has a jumper fitted
across terminals 8-9 (= Heat demand). If that connection is opened (e.g. by a limiter for an underfloor heating
system), heating mode is disabled.
• Pump mode 1: if a heating pump and a 3-way valve
for charging the heat store are connected.
The 3-way valve is de-energised when the heat store
circuit is open.
When supplied, the appliance has a jumper fitted
across terminals Ls-Lr (= Heat demand). If that connection is opened (e.g. by an external 2-point programmer),
heating mode is disabled.
• Pump mode 2 (factory setting): if a circulation
pump and a heat store charging pump are connected. In ECO mode, if the circulation pump and the
heat store charging pump call for heat simultaneously, the system alternates between 12 minutes
heating and 12 minutes hot water.
4.0 Stor. tank therm. (7 - 9)
• Pump mode 3: if a circulation pump and a heat store
charging pump are connected. In ECO mode, if the
circulation pump and the heat store charging pump
call for heat at the same time, both pumps run simultaneously. The heat store charging temperature has
priority (up to 85 °C). The hydraulic configuration
must be matched to this pump mode (use of a mixer
unit and hydraulic balancing).
4.1 Room therm. LSM/ 4.1 LSM release
3.4 Pump mode (ZBR.. models only)
B The pump mode setting should be entered on the
commissioning record enclosed with the appliance.
When supplied, the appliance has no jumper across terminals 7- 9 (= Disabled). If that connection is closed
(e.g. by a heat store thermostat) heat store charging is
enabled.
When supplied, a jumper is fitted across terminals LZ L1 on the LSM (= Heat demand). If that connection is
opened (e.g. by a connected room thermostat), heating
mode is disabled.
LSM release shows the total number of all possible enable signals connected via the LSM. As soon as a module connected to it (e.g. mechanical limiter for
underfloor heating, limit switch on flue flap, combustion
air flap, etc.) shuts off, heating and hot water modes are
disabled.
4.2 Timer ch. 1 (heating)/ 4.2 Timer ch. 2
(hot water)
Shows the status of channel 1 of the timer integrated in
the text display module or the separate programmer.
If that channel’s status is “Heat demand”, heating mode
will be activated according to the programmer commands.
10
7 181 465 347 (01.07)
Boiler service functions
Shows the status of channel 2 of the timer integrated in
the text display module or the separate programmer.
If that channel’s status is “Heat demand”, hot water
mode will be activated according to the programmer
commands.
4.4 Heat demand (heating)/
Heat demand (stor. tank) (ZSBR.. only)
The heating output can be limited to any level between
the min. rated heat output and the max. rated heat output to suit the specific heat requirements.
i
Even if the heating output is limited, the full
rated heat output remains available for hot
water or heat store charging.
Heat demand (heating) shows the heat demand status
for the central heating system.
The factory setting is maximum rated output – display
shows “100 %”.
If this channel’s status is “Heat demand”, heating mode
will be activated according to the programmer commands.
5.1 Permanent ignition
Heat demand (stor. tank) shows the heat demand status for charging the heat store.
This function allows permanent ignition without gas
supply to be activated for the purposes of checking the
ignition mechanism.
If this channel’s status is “Heat demand”, the heat store
will be charged according to the commands from the
heat store thermostat or NTC sensor.
5.2 GFA status/error
4.5 Heat demand (hot water)/
Keep hot period (ZWBR... models only)
5.5 Min. output
Heat demand (hot water) shows the heat demand status for the hot water function.
If this channel’s status is “Heat demand”, the hot water
function operates according to the commands from the
hot water NTC sensor.
Keep hot period shows the constant hot water circuit
status of the heat exchanger (ECO or Comfort mode).
If this channel’s status is “Heat demand”, Comfort mode
is active. If the status is “Disabled”, ECO mode with
demand detection is active.
4.6 Internal regulator
The boiler has an internal anti-cycle function which prevents the burner overheating if the heat output can not
be dissipated even in Min mode. The appliance will then
switch off even when the system is calling for heat.
It will subsequently switch on again
• after 5 seconds in hot water mode
• after 30 seconds in heat store charging mode
• after 0 to 15 minutes in heating mode (depending on
the setting for service function 2.4 Anti-cycle mode).
The anti-cycle function is cancelled by
• switching the appliance off and on again at the master switch,
• another demand for heat,
• activating Min or Max mode
• or briefly switching to summer mode on the temperature control for CH flow.
5.0 Max. output (heating)
Some gas suppliers demand an output-dependent
basic charge.
7 181 465 347 (01.07)
The status of the automatic ignition module integrated
in the PCB control board is indicated.
The min. heat input is factory set, see technical data.
The modulation range can be extended at the top end
to suit the chimney conditions.
B Refer to settings table for heating and heat store
charging output for details of the min. heat output in
kW and the corresponding percentage (see installation instructions for boiler).
B Enter percentage on text display module and confirm.
B Measure gas flow rate and compare with the figures
quoted for the percentage shown. If different, correct
the percentage figure!
B Enter min. rated heat output on the commissioning
record enclosed with the appliance.
5.8 Cyclic boiler starts (ZSBR 3/5-16 A... only)
When supplied, this function is activated on the above
appliances and prevents start-up problems caused by
poor ignition characteristics.
A truncated start cycle is activated if the burner has not
been in operation for more than 3 hours.
During a truncated start cycle, the fan runs and the gas
valve is opened long enough to completely fill the gas
pipe with gas (approx. 1 - 2 seconds) but the burner is
not ignited.
This function is not required, and can not be activated,
on any other models.
6.7 Pump off (hot water)
The appliance is supplied with this function activated,
i.e. there is a delay before the pump switches on in hot
water mode. This means that cold water comes out of
the pipe to begin with, followed by hot water once the
pump switches on.
If the pump is set to switch on immediately (Pump off
function deactivated), the hot water temperature rises
gradually until the set temperature is reached.
11
Boiler service functions
If a stratified-charge tank is connected, it is useful to
have the function activated.
7.2 Antiblock. map pump (not ZBR...)
The delayed cut-in of the pump then prevents cold
water being pumped through the tank and cooling it
down.
If the pump threatens to jam, an oscillating pump action
is activated. Afterwards, the required operating mode is
continued.
6.8 Cycle time (hot water) (ZWBR... only)
7.3 Aeration mode (not ZBR...)
The appliance is supplied with the hot water cycle time
set to 3 minutes.
The first time the appliance is switched on, a once-only
venting function is activated. The heating pump then
switches on and off at intervals. This sequence lasts
about 8 minutes and the text display shows “Aeration
mode”. The 2-digit display shows “oo” in alternation with
the CH flow temperature. The automatic vent must be
opened and then closed again once the venting
sequence is complete.
The hot water cycle time specifies how long after hot
water is drawn the pump continues to pump water
through the internal hot water system.
6.9 Duration (hot water) (ZWBR... only)
The appliance is supplied with the hot water duration
set to 3 minutes.
The hot water duration specifies how long after hot
water is drawn heating mode remains disabled.
7.0 Pump map (heating) (not ZBR...)
The appliance is supplied with this function set to
“4 Prop. pressure high”(see pump characteristic in
boiler installation instructions).
The appliance is supplied with this function activated.
i
The venting function can be activated
manually after servicing.
• If the venting function is set to “On, autom. deactivat.”, once the sequence has been completed.
7.4 Actual map pump step (not ZBR...)
The pump map indicates how the pump is controlled in
heating mode. The pump switches between the various
pump speeds so as to reproduce the characteristic
curve selected. (The current setting can be viewed by
means of service function 7.4.)
The currently active pump speed is displayed (see function 7.0).
Changing the pump characteristic can be helpful if a
lower pressure difference will guarantee the necessary
circulation on the basis of the system dimensions and
pump characteristic (see installation instructions).
7.6 Map pump type (not ZBR...)
i
In order to save as much energy as possible and to minimise the possibility of water
circulation noise, a low characteristic
should be chosen.
If this parameter is set to “0 Pump step adjustable”, then
the pump speed set under function 7.1 is active.
7.1 Map pump step (heat.) (not ZBR...)
The appliance is supplied with this function set to 1 (see
pump characteristic in boiler installation instructions).
However, the setting is only active if function 7.0, Pump
map (heating), is set to “0 Pump step adjustable”.
7.5 Map pump load index (not ZBR...)
The load index is displayed.
The pump type code of the pump fitted is displayed.
7.7 Output reduction
The appliance is supplied with this function activated. It
prevents overload of the heat exchanger with high CH
flow temperatures.
The output of the burner is reduced according to the
CH flow temperature, i.e. up to 80 °C flow temperature,
full burner output is permitted. Above 80 °C, the burner
output is reduced as flow temperature increases up to
90 °C at which only minimum output is available (even
with maximum heat demand).
This function can be deactivated for hot water and/or
central heating mode.
This service function corresponds to the pump speed
switch used on conventional heating pumps.
12
7 181 465 347 (01.07)
Boiler service functions
8.5 Siphon fill program
The trap filling programme ensures that the condensation trap is filled when the appliance is first installed or
after it has been shut down for a long period: The condensation trap prevents flue gas escaping from the
appliance into the room in which it is installed.
The trap filling programme is activated:
• the appliance is switched on at the master switch
• the burner has not been in operation for at least 48
hours
• the appliance is switched from summer to winter
mode.
The next time the heating or hot water system calls for
heat, the appliance is held at minimum output for 15
minutes. The trap filling programme remains active until
the appliance has completed 15 minutes of operation at
minimum output.
The text display shows “Siphon fill program” and the
2-digit display alternates between „-II-“ and the CH flow
temperature.
The factory setting is „1“ (activated).
Warning: if the condensation trap is not
filled, flue gas can escape!
B Only deactivate the trap filling programme in order to carry out servicing work.
B Always re-activate trap filling programme once servicing is complete.
9.2 Hot water on demand
The appliance is supplied with this function activated.
This function relates to mode, the
button lights up.
The demand detection function enables maximum gas
and water economy.
Briefly turning a hot water tap on and then off again signals demand to the appliance which then heats up the
water to the set temperature.
Hot water is then available at short notice.
9.3 GFA-Asic error (automatic ignition module,
extended messages)
The status of, or an error message from the automatic
ignition module integrated in the PCB control board is
displayed.
7 181 465 347 (01.07)
13
Rectifying faults
4
Rectifying faults
4.1
Boiler failure codes indication
4.2
Summary
4.1.1
... on the boiler
4.2.1
Appliance faults
Appliance faults
ZWBR ...A
Page
A1
X
X
17
You can view an explanatory description of the fault indicated by going to Settings -> Service -> Service
parameters, in this example: EA: During operation:
Flame not detected.
A5
X
ZBR ... A
The text display shows the message Fault EA. Please
call service, for example. At the same time, the fault
code appears on the 2-digit display, in this example: EA.
ZSBR ... A
In order to identify the specific boiler failure a two digit
alphanumeric code is used. This allows a quick fault
identification and solution.
18
A7
X
X
X
19
A8
X
X
X
20
Ad
X
X
X
21
• The appliance continues to work at a minimum function level (e. g. with error codes A5, A7, A8, AC, Ad,
CC, FC).
b1
X
X
X
22
C1
X
X
X
23
• The appliance is locked until the failure is repaired
(e. g. with error codes (b1, C1, d1, d3, E2, F0)).
d3
X
X
X
24
• The appliance is locked, until the ON/OFF switch is
turned (A1).
E2
X
X
X
25
E9
X
X
X
26
EA
X
X
X
28
F0
X
X
X
32
F7
X
X
X
33
FA
X
X
X
34
FC
X
X
X
35
Fd
X
X
X
35
The failures can be divided into four basic typologies, as
described:
• The boiler has shut down and locked out ( flashes)
and remains so until the cause of the fault has been
eliminated and the lock-out cancelled (e.g. E9, EA,
F0, F7, FA,Fd).
i
4.1.2
To unblock the appliance:
B Press the unblock button
until the
digit – – appears on the display.
Once the appliance starts up successfully, the fault disappears from the text
display.
... on the programmer (optional accessory)
Table 2
4.2.2
If other/more functions are required, another programmer must be connected. Those programmers are then
controlled via the bus module BM1.
Appliance faults
ZBR ... A
ZSBR ... A
ZWBR ...A
Page
A TW 2 remote control unit can also be connected to
the text display module.
Faults that are not indicated on any display
For more detailed information, refer to the installation
instructions for the boiler and the installed programmer.
Excessive burner noise, rumbling noises
X
X
X
36
Flue gas levels incorrect, CO
level too high
X
X
X
37
Ignition too harsh, ignition
poor
X
X
X
38
Boiler indicates P1, P2, P3 at
start-up and then restarts
with P1, ...
X
X
X
36
Faults on this programmer are indicated by text messages on the programmer display.
Once the fault has been put right, the programmer
reverts to its normal display.
Table 3
14
7 181 465 347 (01.07)
X
X
39
Specified CH flow temperature from TA... programmer
exceeded
X
X
40
Page
ZSBR ... A
Loose or broken contact on
heat store NTC sensor
Appliance faults
ZWBR ...A
ZBR ... A
Rectifying faults
Page
Programmer faults
TR 2
Table 3
Set room temperature not
reached
X
41
Set room temperature
exceeded by large amount
X
43
Set room temperature not
reached
41
Temperature rises instead of
falling
X
43
Room temperature too high in
Economy mode
X
43
Incorrect or no modulation
X
43
Heat store fails to heat up
44
Table 4
7 181 465 347 (01.07)
15
Rectifying faults
4.3
How to use the fault tables
The procedure is explained using the fault code
EA as an example:
The table heading shows the fault code and a general
description of the fault.
In the example shown, you are instructed to note the
current settings before going any further. If you can see
the flame (answer to question is “yes”) you move on to
Step 5. (↓ 5.). The question asked in Step 5 is “Is there
a problem with the flue”. The flue must then be checked.
If the answer to the first question (“Is burner flame visible?”) was“no””, then you go to and answer Question 2,
“Is the gas cock turned on?”. If the gas cock is turned
off, it must be turned on and the appliance reset. To do
so, you press the
button. Restart the appliance and
run through a complete heat-demand cycle until the
appliance switches off.
EA
and
If the fault is now cured, the appliance will revert to normal operation and the fault-finding process is complete.
Now simply re-check the setting of the two temperature
controls.
If the fault EA recurs during the heat-demand cycle, it
will be shown on the display again. In that case continue
the fault finding procedure from Step 3 (thermal cut-out
in gas cock) as described above.
If a different fault code is displayed after the heatdemand cycle, find the appropriate section of the fault
finding table and work through the procedure described
step by step.
flashing.
Flame not detected
Check
1.
2.
Is burner flame visible?
Is the gas cock turned on?
Action
yes:
↓5.
no:
↓2.
yes:
↓3.
no:
B Turn on the gas cock.
B Press
, does appliance restart???
EA? ↓3.
3.
Did the thermal security of the gas
cock lock out?
4.
...
5.
Is there a problem with the flue?
B Check CO2 level in combustion
air.
> 0,2 % CO2?
...
16
yes:
B ...
no:
↓ ...
yes:
B Check the flue.
no:
↓ ....
...
7 181 465 347 (01.07)
Rectifying faults
4.4
Faults indicated on display
A1
flashing.
Controlled-characteristic pump has run dry
Check
1.
System pressure below 1.2 bar?
Action
yes:
B Power OFF the appliance.
B Check appliance and system for water leaks and
repair as necessary.
B Top up system.
B Turn ON the appliance.
A1? ↓2.
no:
2.
↓2.
B Activate menu option Show service parameters.
Activate venting sequence.
B Select 7.3 Aeration mode select setting On,
autom. deactivat. and confirm.
B Vent appliance1).
B Vent radiators.
↓3.
3.
Audible bearing damage on pump?
yes:
B Power OFF the appliance.
B Drain appliance.
B Replace pump.
B Top up system.
B Turn ON the appliance.
1)
See installation instructions
7 181 465 347 (01.07)
17
Rectifying faults
A5
flashing.
Heat store NTC sensor 2 defective
Check
1.
B Activate menu option
Show service parameters.
B Select
.4 Stor.tank temp.sensor2 .
Is a temperature between 0. and 5.
displayed?
2.
B Disconnect connector for heat
store NTC sensor 2.
B Short-circuit the 2-pin connector
on the end of the 20-pin connector
lead assembly.
After max. 60 sec:
Display changes to temperature
between 100. and 95.?
Action
yes:
B Is the connector for heat store NTC sensor 2 corroded1), damaged or dirty? Replace affected
components.
↓2.
no:
↓3.
yes:
B Power OFF the appliance.
B Change heat store NTC sensor 2.
B Plug the connection wire.
B Turn ON the appliance.
A7? ↓3.
no:
B Change the 20-pin connector lead assembly.
↓3.
3.
Temperature between 95. and 100. is
displayed.
yes:
B Change heat store NTC sensor 2.
B Unplug the connector.
After max. 60 sec.:
Does the displayed code change
to a value between 0. and 5.?
4.
B Unplug the 20-pin connector lead
assembly from the Heatronic.
After max. 60 sec.:
Does the displayed code change
to a value between 0. and 5.?
B Power OFF the appliance.
B Plug the connection wire.
B Turn ON the appliance.
A7? ↓4.
no:
↓4.
yes:
B Change the 20-pin connector lead assembly.
no:
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
1)
18
For notes, refer to Appendix.
7 181 465 347 (01.07)
Rectifying faults
A7
flashing.
Hot water NTC sensor defective
Check
1.
B Activate menu option
Show service parameters.
B Select
.2 Hot water temp.sensor .
Is a temperature between 0. and 5.
displayed?
2.
B Disconnect connector for hot
water NTC sensor.
Action
yes:
B Is the connector for hot water NTC sensor corroded1), damaged or dirty? Replace affected components.
↓2.
no:
↓3.
yes:
B Power OFF the appliance.
B Change hot water NTC sensor.
B Short-circuit the 2-pin connector
on the end of the 20-pin connector
lead assembly.
Display changes to temperature
between 100. and 95.?
B Plug the connection wire.
B Turn ON the appliance.
A7? ↓3.
no:
B Change the 20-pin connector lead assembly.
↓3.
3.
Temperature between 95. and 100. is
displayed.
yes:
B Change hot water NTC sensor.
B Unplug the connector.
After max. 60 sec.:
Does the displayed code change
to a value between 0. and 5.?
4.
B Unplug the 20-pin connector lead
assembly from the Heatronic.
After max. 60 sec.:
Does the displayed code change
to a value between 0. and 5.?
B Power OFF the appliance.
B Plug the connection wire.
B Turn ON the appliance.
A7? ↓4.
no:
↓4.
yes:
B Change the 20-pin connector lead assembly.
no:
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
1)
For notes, refer to Appendix.
7 181 465 347 (01.07)
19
Rectifying faults
A8
flashing.
No correct electrical connection
1.
2.
Check
Action
Mode selector switch is between two
settings
B Turn switch until it clicks into position.
B Power OFF the appliance.
A8? ↓2.
yes:
Wiring between TR 2 and textdisplay OK?
• Terminal 3 on TR 2 connected to
Terminal 3 on textdisplay ?
• Terminal 4 ... Terminal 4 ....
3.
B Turn ON the appliance.
↓3.
no:
B Rewire correctly as specified in the installation
instructions.
B Turn ON the appliance.
etc.
after 90 sek.:
A8? ↓3.
Lead(s) defective.
B Check leads for continuity and replace as
necessary.
A8? ↓4.
4.
TR 2 defective.
B Power OFF the appliance.
B Change TR 2 .
B Turn ON the appliance.
20
7 181 465 347 (01.07)
Rectifying faults
Ad
flashing.
Heat store NTC sensor 1 not detected
Check
1.
2.
Action
Is lead for heat store NTC sensor
correctly routed, i.e. not through
cable clamp?
yes:
↓2.
no:
B Route connecting lead for heat store temperature sensor as specified in installation instructions.
B Activate menu option
Show service parameters.
yes:
Connector on end of NTC sensor lead:
B Flue gas connector corroded1), damaged or
dirty? Change relative parts.
B Select
.3 Stor.tank temp.sensor1 .
Is a temperature between 0. and 5.
displayed?
3.
B Press button
Ad? ↓3.
no:
↓4.
Heat store -NTC 1:
yes:
B Replace heat store NTC sensor 1.
B Unplug connector from PCB control board.
no:
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Short circuit the connector using
wire jumper.
After max. 60 sec:
Display changes to temperature
between 100. and 95.
4.
.
Temperature between 95. and 100. is
displayed.
B Unplug the connector.
After max. 60 sec.:
Does the displayed code change
to a value between 0. and 5.?
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
yes:
B Replace heat store NTC sensor 1.
no:
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
1)
7 181 465 347 (01.07)
21
Rectifying faults
b1
flashing.
Code plug not detected.
Check
1.
No fault or fault code FC displayed
on text display?
Action
yes:
B Power OFF the appliance.
B Fit code plug (correctly), making sure code
number (see Appendix) is correct.
B Turn ON the appliance.
b1? ↓2.
2.
B Activate menu option Show service parameters.
B Select 1.2 Code plug.
no:
↓2.
yes:
↓2.
no:
↓4.
B Compare number displayed with
that shown in Appendix.
No number or incorrect number
(last three digits) displayed.
3.
Code plug loose, incorrect or defective.
B Power OFF the appliance.
B Replace code plug1), making sure code number
is correct.
B Turn ON the appliance.
b1? ↓4.
4.
The PCB control board is damaged.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
1)
22
For order no., refer to Appendix
7 181 465 347 (01.07)
Rectifying faults
C1
flashing.
Fan speed too low
Check
1.
Fan lead connector properly connected?
Action
yes:
↓2.
no:
B Power OFF the appliance.
B Plug in connector.
B Turn ON the appliance.
C6? ↓2.
2.
Fan lead defective?
yes:
B Power OFF the appliance.
B Replace fan lead.
B Turn ON the appliance.
C6? ↓3.
3.
Fan defective?
no:
↓3.
yes:
B Power OFF the appliance.
B Plug the connection wire.
B Replace fan.
B Plug the connection wire.
B Turn ON the appliance.
C6? ↓4.
no:
4.
The PCB control board is damaged.
↓4.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
7 181 465 347 (01.07)
23
Rectifying faults
d3
flashing.
Wrong signal from pin 8-9.
Check
1.
Jumper 8 - 9 fitted correctly?
Action
yes:
↓2.
no:
B Power OFF the appliance.
B Fit jumper 8 - 9 correctly, tighten screw.
B Turn ON the appliance.
d3? ↓2.
2.
B Turn ON the appliance.
yes:
↓3.
B Measure voltage between Terminal 4 and Terminal 8.
no:
↓5.
yes:
B Power OFF the appliance.
24 V DC?
3.
Heat store NTC sensor connected to
terminals 7, 8 and 9?
B Plug heat store NTC sensor connector into PCB
control board (303, page 46, Pos. 303). If lead
has no connector: replace heat store NTC sensor.
B Turn ON the appliance.
d3? ↓4.
4.
Existing heat store thermostat connected to Terminals 7, 8 and 9?
no:
↓4.
yes:
B Power OFF the appliance.
B Fix the additional bridge 8-9 in the right position
and close the screws.
B Turn ON the appliance.
d3? ↓5.
no:
5.
The PCB control board is damaged.
↓5.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
24
7 181 465 347 (01.07)
Rectifying faults
E2
flashing.
The heating outlet NTC sensor is damaged.
Check
1.
B Activate menu option
Show service parameters.
Action
yes:
The heating outlet NTC sensor is in short circuit:
B Power OFF the appliance.
B Select .1 Flow temp.sensor.
Is a temperature between 0. and 5.
displayed?
B Replace CH flow NTC sensor; observe fitting
instructions for NTC sensor when doing so.
B Turn ON the appliance.
E2? ↓2.
2.
Heating outlet NTC sensor:
Temperature between 95. and 100. is
displayed.
no:
↓ 2.
yes:
The CH flow NTC sensor is interrupted:
B Power OFF the appliance.
B Replace CH flow NTC sensor; observe fitting
instructions for NTC sensor when doing so.
B Turn ON the appliance.
E2? ↓3.
no:
3.
Check if the 20-pin connector lead
assembly is damaged.
↓3.
B Power OFF the appliance.
B Change the 20-pin connector lead assembly.
B Turn ON the appliance.
E2? ↓4.
4.
The PCB control board is damaged.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
7 181 465 347 (01.07)
25
Rectifying faults
E9
and
flashing.
Safety temperature limiter has tripped.
Check
1.
Is the heating pressure between 1
and 2 bar?
Action
yes:
B Top up system.
B Vent appliance.
B Press
, does appliance restart???
E9?↓2.
2.
Is the pump blocked?
no:
↓2.
yes:
B Unblock the pump.
If pump won’t start:
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change the pump.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
B Press
, does appliance restart???
E9? ↓3.
3.
Is lead disconnected from one/both
safety temperature limiters?
no:
↓3.
yes:
B Power OFF the appliance.
B Connect lead.
B Turn ON the appliance.
B Press
, does appliance restart???
E9? ↓4.
4.
B Power OFF the appliance.
no:
↓4.
yes:
B Change the over heating cut-off device.
B Unplug the connector from the
cut-off device.
B Connect flue gas safety temperature limiter lead.
B Measure the NTC electrical resistance.
B Press
B Turn ON the appliance.
, does appliance restart???
E9? ↓5.
R = ∞?
no:
B Connect flue gas safety temperature limiter lead.
B Turn ON the appliance.
E9? ↓5.
26
7 181 465 347 (01.07)
Rectifying faults
E9
and
flashing.
Safety temperature limiter has tripped.
Check
5.
B Power OFF the appliance.
Action
yes:
B Remove fuse SI 3 from appliance
PCB control board and test for
continuity.
B Change the fuse.
B Turn ON the appliance.
B Press
, does appliance restart???
E9? ↓6.
R = ∞?
no:
B Remount the fuse.
B Turn ON the appliance.
6.
The PCB control board is damaged.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
7 181 465 347 (01.07)
27
Rectifying faults
EA
and
flashing.
During operation: flame not detected
Check
1.
2.
Is the flame present?
Is the gas cock open?
Action
yes:
↓6.
no:
↓2.
yes:
↓3.
no:
B Open the gas cock
B Press
, does appliance restart???
EA? ↓3.
3.
Is there air in the supply pipe?
yes:
B Vent supply pipe.
B Press
, does appliance restart???
EA? ↓4.
4.
Did the thermical security of the gas
cock lock out?
no:
↓4.
yes:
B Reset security.
B Press
, does appliance restart???
EA? ↓5.
5.
Natural gas models:
does the building have a supply pressure regulator?
no:
↓5.
yes:
B Check that it is fitted correctly and functioning
properly and correct if necessary.
B Check supply pressure, inform gas company if
outside correct range.
B Press
, does appliance restart???
EA? ↓6.
LPG models:
is the flow rate of the gas supply to
the appliance correct?
no:
↓6.
yes:
↓6.
no:
B Is there enough gas in the supply cylinder?
B Is there air in the supply pipe?
B Is the solenoid valve in the “meter cabinet” opening?
B Is the supply pressure OK? (if the supply pressure is too high, check the pressure regulator in
the “meter cabinet” and on the LPG supply cylinder).
B Press
, does appliance restart???
EA? ↓6.
28
7 181 465 347 (01.07)
Rectifying faults
EA
and
flashing.
During operation: flame not detected
Check
6.
Is the ground connection correct?
Action
yes:
↓7.
no:
B Rewire correctly as specified in the installation
instructions.
B Press
, does appliance restart???
EA? ↓7.
7.
Two phase net:
Is there a resistor fitted between Pe
and N?
yes:
↓8.
no:
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Insert resistance (Order no. 8 900 431 516)
between the ground and the N connection.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
B Press
, does appliance restart???
EA? ↓10.
8.
Is condensation trap in condensing
boiler blocked?
yes:
B Unscrew condensation trap and clean.
B Press
, does appliance restart???
EA? ↓12.
9.
Check the gas valve?
no:
↓9.
yes:
B Reconnect the gas valve.
B Power OFF the appliance.
B Turn ON the appliance.
B Unplug the connectors from the
gas valve.
B Press
B Measure the gas valve coils I and
II electrical resistance.
R =164 ± 40 Ω?
, does appliance restart???
EA? ↓10.
no:
B Change the gas valve.
B Reconnect the gas valve.
B Turn ON the appliance.
B Press
, does appliance restart???
EA? ↓10.
10.
Is flue blocked?
yes:
B Check CO2 level in combustion
air.
> 0,2 % CO2?
B Press
, does appliance restart???
EA? ↓11.
no:
7 181 465 347 (01.07)
B Check the flue.
↓11.
29
Rectifying faults
EA
and
flashing.
During operation: flame not detected
Check
11.
Is flue gas CO2 level incorrect1) ?
Action
yes:
B Adjust to correct level.
B Press
, does appliance restart???
EA? ↓12.
12.
B Activate menu option Show service parameters.
B Select 5.1 Permanent ignition.
no:
↓12.
yes:
↓13.
no:
↓16.
yes:
↓14.
no:
B Connect cable to ignition electrode.
Continuous ignition OK?
13.
Ignition lead connected to ignition
electrodes?
B Press
, does appliance restart???
EA? ↓14.
14.
Ignition cable connector engaged in
switchbox?
yes:
↓15.
no:
B Power OFF the appliance.
B Engage ignition cable connector in switchbox.
B Turn ON the appliance.
B Press
, does appliance restart???
EA? ↓15.
15.
Ignition cable defective?
yes:
B Power OFF the appliance.
B Replace ignition cable.
B Turn ON the appliance.
B Press
, does appliance restart???
EA? ↓16.
16.
30
no:
↓16.
B Select 3.3 Ionisation current.
yes:
↓18.
Measured ionisation current medium
or high?
no:
↓17.
7 181 465 347 (01.07)
Rectifying faults
EA
and
flashing.
During operation: flame not detected
Check
17.
Electrode assembly defective?
Action
yes:
B Replace electrode assembly.
B Power OFF the appliance.
B Turn ON the appliance.
B Remove electrode assembly.
Electrodes worn out?
B Press
, does appliance restart???
EA? ↓18.
no:
B Refit electrode assembly.
B Turn ON the appliance.
B Press
, does appliance restart???
EA? ↓18.
18.
Check if the 20-pin connector lead
assembly is damaged.
B Power OFF the appliance.
B Change the 20-pin connector lead assembly.
B Turn ON the appliance.
B Press
, does appliance restart???
EA? ↓19.
19.
The PCB control board is damaged.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
1)
See installation instructions
7 181 465 347 (01.07)
31
Rectifying faults
F0
(and possibly
) flashing.
Internal failure
1.
Check
Action
B Activate menu option
Show service parameters.
B Record figure displayed in service report.
↓2.
B Select 9.3 GFA-Asic-error.
A message is displayed.
2.
B Select 5.2 GFA status / error.
A message is displayed.
3.
B Select Settings -> Service ->
Further options -> Fault history.
Other faults apart from F0 displayed?
4.
flashing?
B Record figure displayed in service report.
yes:
B Deal with fault(s) displayed as instructed in relevant fault table(s) .
no:
↓3.
yes:
B Press button
.
B Initiate demand for heat by pressing the
. button and then cancel after 30 seconds by pressing
the button again.
B Initiate demand for heat twice more as described
above.
F0? ↓4.
no:
5.
The PCB control board is damaged.
↓4.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
32
7 181 465 347 (01.07)
Rectifying faults
F7
and
flashing.
Although appliance switches off, flame still detected
1.
Check
Action
Electrode(s) dirty or defective.
B Power OFF the appliance.
B Replace electrode assembly.
B Turn ON the appliance.
B Press
, does appliance restart???
F7? ↓2.
2.
B Power OFF the appliance.
yes:
B Refit PCB control board.
B Remove PCB control board.
B Press
B Reconnect the boiler electrical connection.
PCB control board damp?
3.
Is there a problem with the flue?
B Check CO2 level in combustion
air.
> 0,2 % CO2?
4.
B Dry PCB control board (e.g. with hair dryer).
B Disconnect the boiler electrical
connection.
The PCB control board is damaged.
, does appliance restart???
F7? ↓3.
no:
↓3.
yes:
B Check flue and repair or replace if necessary.
no:
↓4.
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
7 181 465 347 (01.07)
33
Rectifying faults
FA
and
flashing.
After appliance switches off flame is detected
Check
1.
Is condensation trap in condensing
boiler blocked?
Action
yes:
B Clean condensation trap discharge pipe.
B Press
, does appliance restart???
FA? ↓2.
no:
2.
↓2.
B Replace electrode assembly.
Electrodes faulty.
B Turn ON the appliance.
B Press
, does appliance restart???
FA?
B Power OFF the appliance.
↓3.
3.
Problem with flue?
yes:
B Check CO2 level in combustion
air.
> 0,2 % CO2?
B Check flue and repair or replace if necessary.
B Press
, does appliance restart???
FA?
B Power OFF the appliance.
↓4.
no:
4.
The gas valve is damaged.
↓4.
B Change the gas valve.
B Turn ON the appliance.
B Press
, does appliance restart???
FA?
B Power OFF the appliance.
↓5.
5.
Check if the 20-pin connector lead
assembly is damaged.
B Change the 20-pin connector lead assembly.
B Turn ON the appliance.
B Press
, does appliance restart???
FA?
B Power OFF the appliance.
↓6.
6.
The PCB control board is damaged.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
34
7 181 465 347 (01.07)
Rectifying faults
FC
flashing.
Text display module not detected
1.
Check
Action
No fault or fault code FC displayed
on text display?
B Power OFF the appliance.
B Fit code plug (correctly), making sure code
number is correct (see Appendix).
B Turn ON the appliance.
FC? ↓2.
2.
B Unplug text display module connector.
B Connecting lead between text display module and Heatronic OK.?
yes:
B Plug in connector.
FC? ↓3.
no:
B Replace text display module.
FC? ↓3.
3.
Text display module defective.
Fd
and
B Replace text display module.
flashing.
Reset button pressed inadvertently
Check
B Press button
1.
2.
Action
The PCB control board is damaged.
again.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Turn ON the appliance.
7 181 465 347 (01.07)
35
Rectifying faults
4.5
Faults that are not displayed
4.5.1
Appliance faults
Boiler indicates P1, P2, P3 at start-up and then restarts with P1..
Check
1.
Fuse T 1.6 A (312) defective.
Action
yes:
B Turn ON the appliance.
B Change the fuse.
B Power OFF the appliance.
Start sequence not completed? ↓2.
no:
2.
↓2.
B Change PCB control board.
The PCB control board is damaged.
Excessive burner noise, rumbling noises
Check
1.
2.
Action
Does the gas supply type match the
specifications on the appliance identification plate?
yes:
↓2.
no:
B Convert appliance to correct gas type1).
B Test gas supply pressure - OK?1)?
yes:
↓3.
no:
B Decommission appliance.
B Notify gas company.
3.
Problem with flue?
B Check CO2 level in combustion
air.
> 0,2 % CO2?
4.
5.
B Remove silencer, flue pipe and
mixer unit.
Is internal flue pipe/silencer dirty or
clogged or are seals defective or
incorrectly fitted?
Flue gas CO2 levels measured at
min. and max. load do not match
specified levels1).
B Measure CO2 levels.
1)
36
yes:
B Check flue and repair or replace if necessary.
no:
↓4.
yes:
B Repair or replace components.
B Grease seal before fitting,
B Make sure it is fitted in correct position.
no:
↓5.
yes:
B Adjust CO2 levels.
no:
B Power OFF the appliance.
B Change the gas valve.
B Turn ON the appliance.
See installation instructions
7 181 465 347 (01.07)
Rectifying faults
Flue gas levels incorrect, CO level too high
Check
1.
2.
Action
Does the gas supply type match the
specifications on the appliance identification plate?
yes:
↓2.
no:
B Convert appliance to correct gas type1).
B Test gas supply pressure1), - OK?
yes:
↓3.
no:
B Decommission appliance.
B Notify gas company.
3.
Problem with flue?
B Check CO2 level in combustion
air.
> 0,2 % CO2?
4.
Flue gas CO2 levels measured at
min. and max. load do not match
specified levels?1).
yes:
B Check flue and repair or replace if necessary.
no:
↓4.
yes:
B Adjust CO2 levels.
no:
↓5.
yes:
B Reduce gas volumetric flow rate by means of
adjusting screw on gas valve and/or gas flow
restrictor.
B Measure CO2 levels.
5.
Gas volumetric flow too high when
CO2 level correctly set1).
B Check CO2 adjustment.
no:
B Change the gas valve.
6.
1)
↓6.
See installation instructions
7 181 465 347 (01.07)
37
Rectifying faults
Ignition too harsh, ignition poor
Check
1.
B Activate menu option
Show service parameters.
B Select 5.1 Permanent ignition.
Continuous ignition OK?
2.
Ignition lead connected to ignition
electrodes?
Action
yes:
↓6.
no:
↓2.
yes:
↓3.
no:
B Connect cable to ignition electrode.
B Press button
.
Ignition poor? ↓3.
3.
Ignition cable connector engaged in
switchbox?
yes:
↓4.
no:
B Power OFF the appliance.
B Engage ignition cable connector in switchbox.
B Turn ON the appliance.
B Press button
.
B Power OFF the appliance.
Ignition poor? ↓4.
4.
Ignition cable defective?
yes:
B Power OFF the appliance.
B Replace ignition cable.
B Turn ON the appliance.
B Press button
.
B Power OFF the appliance.
Ignition poor? ↓5.
5.
Electrode assembly defective?
no:
↓5.
yes:
B Replace electrode assembly.
B Power OFF the appliance.
B Turn ON the appliance.
B Remove electrode assembly.
Electrodes worn out?
B Press
, does appliance restart???
Ignition poor? ↓6.
no:
B Refit electrode assembly.
B Turn ON the appliance.
B Press
, does appliance restart???
Ignition poor? ↓6.
6.
Does the gas supply type match the
specifications on the appliance identification plate?
yes:
↓7.
no:
B Carry out gas type conversion as described in
installation instructions.
Ignition poor? ↓7.
38
7 181 465 347 (01.07)
Rectifying faults
Ignition too harsh, ignition poor
Check
7.
B Test gas supply pressure 1)- OK?.
Action
yes:
↓8.
no:
B Decommission appliance.
B Notify gas company.
8.
Problem with flue?
B Check CO2 level in combustion
air.
> 0,2 % CO2?
9.
Flue gas CO2 levels measured at
min. and max. load do not match
specified levels.
yes:
B Check flue and repair or replace if necessary.
Ignition poor? ↓8.
no:
↓9.
yes:
B Adjust CO2 levels.
no:
↓9.
B Measure CO2 levels.
10.
Burner not correctly fitted or defective?
B Replace burner and seal if necessary
B Ensure seal is fitted in correct position.
B Remove burner.
Cover fixings not tight
or
seal defective or not correctly fitted
or
burner defective.
1)
See installation instructions
Loose or broken contact on heat store NTC sensor
Check
Action
Heat store NTC sensor lead is not fitted as described in the installation
instructions (i.e. the cable does not
pass through the cable grip in the
switchbox).
B Record condition of appliance as found in customer service record.
B Route cable as specified in installation instructions.
Text display fails to respond, no display or display incorrect
Check
Action
Ignition lead is not fitted as specified
in installation instructions (i.e. the
lead should be routed through the
clip on the underside of the air box).
B Route cable as specified in installation instructions.
7 181 465 347 (01.07)
39
Rectifying faults
Specified CH flow temperature from TA... programmer exceeded
Check
Action
If outside-temperature controlled programmer (TA...) is connected to boiler:
• The anti-cycle time is adjusted by the programmer to the suit the system.
• The factory setting for the anti-cycle time (3 min.) and the heating mode hysteresis setting, if applicable,
are deactivated.
• In cyclic mode, the switching of the boiler on or off is subject to a time delay in order to prevent divergence between the average CH flow temperature and the specified CH flow temperature.
As a result (depending on the heat draw), the specified CH flow temperature is briefly exceeded.
In extreme cases, it can happen that the burner does not switch off until the maximum CH flow temperature is reached even though a lower CH flow temperature has been specified.
1.
B Activate menu option
Show service parameters.
B Disable automatic anti-cycle time, i.e. change
setting to 0.
B Select 2.7 Autom. anti-cycle
mode.
Read off status of automatic anticycle time (0 = Disabled,
1 = Enabled)
2.
B Select 2.4 Anti-cycle mode.
Read off anti-cycle time setting ( 0 ...
15 min)
40
B Set anti-cycle time as required, e.g. factory setting 3 min.
7 181 465 347 (01.07)
Rectifying faults
4.5.2
Programmer faults
Set room temperature not reached (TR 2)
Check
1.
Thermostatic valve(s) set too low?
Action
yes:
B Turn up thermostatic valve(s).
↓2.
2.
3.
CH flow temperature control on
boiler set too low?
Air in the heating system.
no:
↓2.
yes:
B Turn up CH flow temperature control.
no:
↓3.
B Power OFF the appliance.
B Check appliance and system for water leaks and
repair as necessary.
B Top up system.
B Activate menu option Show service parameters.
B Select 7.3 Aeration mode , select setting On,
autom. deactivat. and confirm.
B Vent appliance1).
B Vent radiators.
B Turn ON the appliance.
1)
See installation instructions
7 181 465 347 (01.07)
41
Rectifying faults
Set room temperature not reached
Check
1.
Thermostatic valve(s) set too low?
Action
yes:
B Turn up thermostatic valve(s).
↓2.
2.
Heating characteristic set too low?
no:
↓2.
yes:
B Correct heating characteristic.
↓3.
3.
4.
5.
CH flow temperature control on
boiler set too low?
Heat store connected via HSM?
Is heat store temperature unreachable (CH flow temperature control set
too low)?
no:
↓3.
yes:
B Turn up CH flow temperature control.
↓4.
no:
↓4.
yes:
↓5.
no:
↓6.
yes:
B Turn up CH flow temperature control.
↓6.
no:
6.
Air in the heating system.
↓6.
B Power OFF the appliance.
B Check appliance and system for water leaks and
repair as necessary.
B Top up system.
B Activate menu option Show service parameters.
B Select 7.3 Aeration mode , select setting On,
autom. deactivat. and confirm.
B Vent appliance1).
B Vent radiators.
B Turn ON the appliance.
1)
42
See installation instructions
7 181 465 347 (01.07)
Rectifying faults
Set room temperature exceeded by large amount
Check
1.
Do radiators get too hot?
Action
yes:
TR 2:
B Decrease setting of “Heating” control
↓2.
2.
Bad choice of location for programmer, e.g. outside wall, near window,
in draught, on hollow wall, etc.
no:
↓2.
yes:
B Select better installation location1).
↓3.
no:
B Turn down thermostatic valve(s).n
3.
1)
↓3.
See installation instructions
Temperature rises instead of falling
Check
Action
Timer clock (DT 2) incorrectly set
B Check setting and correct as necessary.
Room temperature too high in Economy mode
Check
Building retains heat well
Action
yes:
B Set economy temperature lower.
-orB Set earlier start time for Economy mode.
Incorrect or no modulation
Check
Action
Programmer incorrectly wired
B Check wiring against wiring diagram and correct
as necessary.
7 181 465 347 (01.07)
43
Rectifying faults
Heat store fails to heat up
Check
Action
1.
with TR 2:
CH flow temperature control on
boiler set too low.
B Increase CH flow temperature control setting.
2.
Hot water temperature control on
boiler set too low
B Increase hot water temperature control setting.
44
7 181 465 347 (01.07)
Appendix
5
Appendix
5.1
NTC values
5.1.1
Outside temperature sensor
5.1.2
Outside temperature
( °C)
Measurement
tolerance ± 10%
Resistance
( Ω)
-20
2 392
-16
2 088
-12
1 811
-8
1 562
-4
1 342
0
1 149
4
984
8
842
10
781
15
642
20
528
25
436
CH flow NTC sensor, heat store NTC sensor, constant hot water NTC sensor and
hot water NTC sensor
Temperature ( °C)
Measurement
tolerance ± 10%
Resistance
( Ω)
20
14 772
25
11 981
30
9 786
35
8 047
40
6 653
45
5 523
50
4 608
55
3 856
60
3 243
65
2 744
70
2 332
75
1 990
80
1 704
85
1 464
90
1 262
95
1 093
100
950
Table 5
Table 6
7 181 465 347 (01.07)
45
Appendix
5.2
Electronic schemes
o - orange
bl - black
r - red
p - purple
33
365
364
61
317
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
310
136
400
135
312
328
313
151
124 789
p
p
L N Ns Ls LR
302
161
300
p
84
3 4
F
M
328.1
9
18
M
M
422
6
226
r
r
mains supply
52
o
52.1
56
o
bl
bl
bl
bl
36
bl
32
6 720 610 603 - 03.1O
Fig. 2
4.1
6
9
18
32
33
36
52
52.1
56
61
84
135
136
151
153
161
46
Ignition transformer
Temperature limiter, heat exchanger
Flue gas temperature limiter
Pump
Flame sensing electrode
Ignition electrode
Temperature sensor in CH flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Motor, 3-way valve (ZSBR)
Master switch
Temperature control for CH flow
Fuse, slow 2.5 A, AC 230 V
Transformer
Link
226
300
302
310
312
313
317
328
328.1
363
364
365
366
367
400
422
Fan
Code plug
Earth connection
Temperature control for hot water
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Digital display
Terminal block for AC 230 V Mains supply
Link
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
ECO button
Textdisplay
Connecting TR2
7 181 465 347 (01.07)
Appendix
5.3
List of most important replacement parts
Component
Order no.
Remarks
Component
Order no.
Remarks
110 °C
Switchbox
PCB control
board
8 748 300 385
Heat exchanger
8 747 201 358
Temperature limiter STB
8 729 000 144
Transformer
Ignition lead
8 714 401 878
Flue gas temperature limiter
8 729 000 144
20-pin connector
lead assembly
8 714 401 912
Temperature
sensor, CH flow
8 714 500 054
Fuse
1 904 522 730
T 0,5 A
Fuse
1 904 522 740
T 1,6 A
Fuse
1 904 521 342
T 2,5 A
NTC
Burner
Electrode
assembly
Code plug included in
8 718 107 064
Gas valve
Conversion kit
G20 -> 31
7 710 149 050
ZWBR
8-30
Conversion kit
G31 -> G20
7 710 239 086
ZWBR
11- 30
Conversion kit
G20 -> G31
7 710 149 051
ZWBR
11 - 37
Conversion kit
G31 -> G20
7 710 239 087
ZWBR
14 - 37
Conversion kit
G20 -> G31
7 710 149 052
ZSBR
7-28
Conversion kit
G31 -> G20
7 710 239 088
ZSBR
11-28
Conversion kit
G20 -> G31
7 710 149 053
ZBR 8-35
Conversion kit
G31 -> G20
7 710 239 089
ZBR 11-35
Conversion kit
G20 -> G31
7 710 149 046
ZWBR
7-28
Conversion kit
G31 -> G20
7 710 239 082
ZWBR
11-35
Conversion kit
G20 -> G31
7 710 149 047
ZWBR
11-35
Conversion kit
G31 -> G20
7 710 239 083
ZWBR
14-35
Gas valve
8 747 003 516
Gas valve
8 747 003 515
ZBR 11/
14..42A
Other components
Fan
8 717 204 325
Gas supply pipe
8 714 401 885
Textdisplay
8 747 208 081
Plate-type heat
exchanger
8 715 406 659
ZWBR
7/11-28 A.
Table 7
Table 7
7 181 465 347 (01.07)
47
Appendix
5.4
Approved corrosion inhibitors and anti-freeze fluids for central heating water
Manufacturer
Description
Mixing
concentra–
tion % by
weight
Remarks
With all anti-freeze fluids and corrosion inhibitors, it is extremely important to observe the manufacturer’s recommended concentration levels and to check the concentration regularly.
In the case of anti-freeze fluids, it should be noted that the efficiency of fluid-to-fluid heat transfer diminishes as
the anti-freeze concentration increases.
Anti-freeze fluid
Hüls
Ilexan E
Anti-freeze fluid, equivalent to Antifrogen N.
Tyforop Chemie
GmbH, Hamburg
Tyfocor L
Anti-freeze fluid based on propylene glycol.
25-80
Schilling Chemie
Varidos FSK
Anti-freeze fluid based on ethylene glycol with
good corrosion-inhibiting properties. Also suitable
for aluminium.
22-55
Hoechst
Antifrogen N
Anti-freeze fluid based on ethylene glycol with
good corrosion-inhibiting properties.
20-40
Fernox
Alphi-11
Anti-freeze fluid with corrosion inhibitor, also suitable for aluminium.
BASF
Glythermin NF
Anti-freeze fluid based on ethylene glycol with
good corrosion-inhibiting properties, also suitable
for aluminium.
20-62
Schilling Chemie
Varidos KK
Corrosion inhibitor
0,5
Schilling Chemie
Varidos 1+1
Corrosion inhibitor
1-2
Schilling Chemie
Varidos AP
Corrosion inhibitor, also suitable for aluminium.
1-2
Benckiser
Wassertechnik
Randophos HS
Universal
Corrosion inhibitor
Geminox,
Frankreich
Inibal
Corrosion inhibitor, suitable for aluminium.
1-2
Betz Dearborn,
Belgien
Sentinel X 100
Corrosion inhibitor for hot water heating systems,
also suitable for aluminium.
1,1
Fernox
Copal
Corrosion inhibitor, also suitable for aluminium.
1
Cillit Wassertechnik
Cillit-HS Combi
Corrosion inhibitor
0,5
Fernox
Restorer Superfloc
Universal Cleanser
Cleaning agent (for sludge removal), also suitable
for aluminium.
1-2
Fernox
Superconcentrate
Central heating
Protector
Reduces limescale precipitation, also suitable for
aluminium.
Corrosion inhibitor
Other additives
Table 8
48
7 181 465 347 (01.07)
Appendix
5.5
Detecting corrosion by CFCs
Halogenated hydrocarbons in the combustion air cause
surface corrosion of the affected metal components.
The combustion chamber and the boiler heating surfaces (including stainless steel) are particularly susceptible to this type of attack as are the metal components
in the flue socket, flue joints and the chimney.
The presence of halogenated hydrocarbons in the combustion air results in the production of highly caustic
hydrochloric acid and - depending on the composition
of the combustion air - hydrofluoric acid which build up
inside the boiler and remain active over long periods of
time.
In order to limit the damage, the source of the contamination must be located and sealed off. If this is not possible, the combustion air must be brought to the
appliance from an unaffected area.
Halogens can occur in the following areas:
Industrial sources
Dry cleaners
Trichloroethylene, tetrachloroethylene, fluorinated hydrocarbons
Degreasing baths
Perchloroethylene, trichloroethylene, methyl chloroform
Printers
Trichloroethylene
Hairdressers
Aerosol propellants, hydrocarbons containing chlorine and
fluorine (Freon)
Sources in the home
Cleaning and
degreasing agents
Perchloroethylene, methyl
chloroform, trichloroethylene,
methylene chloride, carbon
tetrachloride, hydrochloric
acid
Hobby workshops
Solvents and thinners
Various chlorinated hydrocarb
Aerosol sprays
Chlor-fluorinated hydrocarbons (Freons)
Table 9
7 181 465 347 (01.07)
49
Appendix
50
7 181 465 347 (01.07)
Appendix
7 181 465 347 (01.07)
51
Appendix
Users Instructions and
Customer Care Guide
RD 532i/RD 537i/RD 542i combi Condensing boiler
RD 430i system Condensing boiler
6 720 610 598 - 00.2O
6 720 610 604 GB (03.06) OSW
ZWBR 7-32 RD 532i GC-Number: 47 108 10
ZWBR 11-37 RD 537i GC-Number: 47 108 11
ZWBR 11-42 RD 542i GC-Number: 47 108 12
System boiler 7-30 RD 430i GC-Number: 41 108 06
Contents
Contents
Excellence comes as standard
4
Safety precautions
5
1
General notes
7
2
Controls
11
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Operating the Appliance
Preparation
Switching the Appliance On/Off
Switching on the Central Heating
Controlling Central Heating
Combination Boilers: Setting Hot Water Temperature
System boiler with Storage Tank
Summer Mode, Hot Water Only (Combi Appliances)
Frost protection (Combi Appliances)
Fault Condition
12
12
14
15
15
16
17
18
19
19
4
4.1
4.2
4.2.1
4.2.2
4.3
4.4
4.4.1
4.4.2
4.5
Text Display
General Description
Programming
Deleting a setting
Resetting all parameters to their original settings
Menu structure
Setting the time/day
Setting the time and day
Holidays
Heating
20
20
20
23
23
24
25
25
25
27
2
6 720 610 604 GB (03.06)
Contents
4.5.1
4.5.2
4.5.3
4.6
4.6.1
4.6.2
4.7
4.8
4.8.1
4.8.2
4.8.3
4.9
Heating program
27
Setting the Economy temperature (if TR2 is connected) 28
Manual operating mode (if TR2 is not connected)
29
Hot water
30
Hot water program
31
Hot water immediately (System models)
31
i Info
32
Settings
33
Heating (if TR 2 is connected)
33
Hot Water (Storage Tank, System boiler models only) 33
Service
33
Individual timer programmes
36
5
Fault finding
37
6
Tips on saving energy
38
7
General Information
39
8
Maintaining your appliance
40
9
Service
40
10
Fault or breakdown
41
11
Your guarantee
42
12
Guarantee registration
43
13
Operating Instructions Quick Reference
44
6 720 610 604 GB (03.06)
3
Excellence comes as standard
Excellence comes as standard
Thank you for purchasing an RD 532i/RD 537i/RD 542i /RD 430i
condensing appliance.
The RD 532i/RD 537i/RD 542i /RD 430i Series has been developed by the Bosch Group and the strictest quality control standards are demanded throughout every stage of production.
Indeed, the Bosch Group have led the field in innovative appliance
design and performance for many years.
The result is that your new RD 532i/RD 537i/RD 542i /RD 430i
appliance offers you the very best of everything – quality, efficiency, economical running costs, proven reliability and value for
money.
What’s more, you also have the assurance of our no nonsense
2 year parts and labour guarantee.
And it’s backed up by British Gas - Offering a complete maintenance scheme to keep your boiler operating at peak condition and
efficiency.
No wonder that more and more people are agreeing that when it
is gas, it has to be a British Gas/Scottish Gas Condensing appliance.
Benchmark
The “Benchmark” initiative is the new code of practice to encourage the correct installation, commissioning and servicing of
domestic central heating boilers and system equipment.
The “log-book” is a vital document that must be completed by the
installer at the time of installation. It confirms that the boiler has
been installed and commissioned according to the manufacturers
instructions.
Without the completion of the “log-book”, manufacturers may
refuse to respond to a call–out from a householder, who will be
advised that he or she must call back the installer, who has not fulfilled his obligations to record the information required by the initiative.
4
6 720 610 604 GB (03.06)
Safety precautions
Safety precautions
Gas Safety (Installation and Use) Regulations 1998
It is the law that all gas appliances are installed by a competent
person in accordance with the above regulations. Failure to install
appliances correctly could lead to prosecution. It is in your interest, and that of safety, to ensure compliance with the law.
If you smell gas:
B Turn off gas service cock at the meter.
B Open all doors and windows.
B Do not operate any electrical switches.
B Do not smoke.
B Extinguish any naked flames.
B Call your gas company.
If you smell fumes from the appliance:
B Switch off appliance.
B Open windows and doors.
B Inform your heating engineer.
Fitting and modifications
B Fitting of the appliance or any modifications to the appliance
may only be carried out by a competent person.
B Flue systems must not be modified in any way.
Maintenance
B We recommend that you take out a maintenance contract
with a competent installer and have the appliance serviced at
regular intervals.
B Ensure that your Service Engineer uses only genuine spare
parts!
6 720 610 604 GB (03.06)
5
Safety precautions
Combustible materials
B Do not store or use any combustible materials (paper, thinners, paints etc.) in the vicinity of the appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance being electrically unsafe.
B There are no substances used in the construction that are a
potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).
Ventilation Air/Ambient Air
B Keep ventilation air/ambient air free of corrosive substances
(e. g. halogenated hydrocarbons which contain chlorine or fluorine compounds). In this way corrosion can be prevented.
6
6 720 610 604 GB (03.06)
General notes
1
General notes
To get the best from your appliance please read these instructions
carefully.
Sealed heating systems
The appliance is fitted to a sealed heating system which is prepressurised. Your installer will tell you of the minimum and maximum pressure which must be indicated on the pressure gauge.
Check regularly that the pressure is maintained and contact your
installer or maintenance engineer if there is a permanent significant drop in the pressure. If the system loses pressure it should
be repressurised and the cause of the fall investigated.
Central heating systems
During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. If the
top of a radiator is at a lower temperature than the bottom then it
should be vented by releasing air through the venting screw at the
top of the radiator. Ask your installer to show you how this is done.
Repeated venting will reduce the quantity of water in the system
and this must be replenished for safe and satisfactory operation
of the appliance.
Should water leaks be found in the system or excessive venting is
required then a service engineer must be contacted to inspect the
installation and rectify any fault.
Only additives that are compatible with aluminium may be used in
the system. Any incompatible additive used will invalidate the
guarantee.
Condensate drain
This is a condensing appliance and the terminal will, at times, give
out a plume of water vapour. This is quite normal.
The appliance produces quantities of condense which is discharged regularly through the siphon.
6 720 610 604 GB (03.06)
7
General notes
Clearances
Your installer will have provided adequate space around the appliance for safety and servicing access. Do not restrict this space
with the addition of cupboards, shelves etc. next to the appliance.
Left-hand side
Right-hand side
In Front
Above Casing (Vert. Flue)
Above Flue Turret
Below
10 mm
10 mm
600 mm
75 mm
30 mm
200 mm
Table 1
Room thermostat
A room temperature controller is may be fitted to control the central heating. Refer to the instructions supplied with the thermostat
for information on siting and setting.
Cylinder thermostat - System boilers
The cylinder thermostat should be set to 60°C which will be satisfactory for bathing/washing in normal circumstances.
Thermostatic radiator valves
It is recommended that this type of valve is fitted to all the radiators
except one, usually the radiator where the room temperature controller is fitted. They should conform to the requirements of
BS2767:10.
Showers, bidets, taps and mixing valves – Combination
Boilers
Standard hot and cold taps and mixing valves must be suitable for
operating at mains pressure. Thermostatically controlled or pressure equalising shower valves will guard against the flow of water
at too high a temperature.
Hot and cold mains fed water can be supplied directly to an overrim flushing bidet subject to local water company requirements.
8
6 720 610 604 GB (03.06)
General notes
With all mains fed systems the flow of water from individual taps
will vary with the number of outlets operated simultaneously and
the cold water mains supply pressure to the property.
Flow balancing using “ball-o-fix” type valves is recommended to
avoid an excessive reduction in flow to individual outlets.
For further information contact British Gas Technical Services
Department.
Hot and cold flow – Combination Boilers
The flow of water demanded from both hot and cold service outlets is dependent upon the mains supply, it may not be possible in
some installations to operate all outlets simultaneously.
Water mains failure – Combination Boilers
If there is a failure of the mains water supply then no water will be
available at a tap or shower until the mains supply is restored. The
appliance will still operate in the central heating mode.
Use in hard water areas – Combination Boilers
In exceptionally hard water areas a device to prevent scale formation may be fitted. Installation of a scale inhibitor assembly should
be in accordance with the requirements of the local water company. An isolating valve should be fitted to allow for servicing.
Alternatively the maximum temperature of the domestic hot water
may be reset to about 45 °C which will reduce the risk of scale
formation in these hard water areas.
Ventilation
This is a room sealed appliance and does not require any air for
combustion from inside the house. If the appliance is fitted into a
cupboard or a compartment is built around the appliance after
installation then the compartment must be separated from the
boiler space by a perforated non-combustible partition as
described in BS 6798.
Notwithstanding the requirements of BS 6798, there is no need
for ventilation openings to be provided in the compartment
because of the low heat loss from the casing.
6 720 610 604 GB (03.06)
9
General notes
Do not allow the flue terminal fitted on the outside wall to become
obstructed or damaged.
Pump
The pump is a fully modulating type to which the parameters have
been set by the manufacturer and must not be adjusted.
10
6 720 610 604 GB (03.06)
Controls
2
Controls
136 365 61 317 366 367 363 310 400
ECO
364
8.1
135
295
170
171
172
173
170
6 720 610 598 - 01.2O
Fig. 1
8.1
61
135
136
170
171
172
173
295
310
317
363
364
365
366
367
400
System Pressure gauge
Reset button
Master switch
Central heating temperature control
Service valves in CH flow and return
Hot water
Gas isolation valve (open)
Cold water inlet
Identification sticker
Hot water temperature control
Display
Indicator lamp for “burner on”
Indicator lamp for “off/on”
“Chimney sweep” button
Service button
“ECO” button
Text Display
6 720 610 604 GB (03.06)
11
Operating the Appliance
3
Operating the Appliance
3.1
Preparation
Turn on the gas cock (172).
B Press in the handle and turn it anti-clockwise as far as the stop
(when handle is in line with direction of flow, the cock is open).
Central heating system valves (170)
B Using a spanner, turn square nut until groove is in line with
direction of flow (see detail).
Groove at right angles to direction of flow = off.
Cold water inlet valve (173)
B Turn handle so that it is in line with direction of flow.
When handle is at right angles to direction of flow, the valve is
closed.
170
172
173
6 720 610 598-02.2O
Fig. 2
12
6 720 610 604 GB (03.06)
Operating the Appliance
Check the central heating system pressure
B The pointer on the pressure gauge (8.1) should be about 1 bar.
B If the pointer is below 1 bar (when the system is cold), top up
the system with water until the pointer is 1 bar. Your installer
will have shown you how to do this.
B The maximum operating pressure of 2.5 bar at maximum
central heating flow temperature must not be exceeded. If the
pressure increases to 3 bar then the relief valve (15) opens.
2
3
1
4
0
bar
8.1
15
170
171
172
173
170
6 720 610 598 - 03.2O
Fig. 3
6 720 610 604 GB (03.06)
13
Operating the Appliance
3.2
Switching the Appliance On/Off
Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will show the
central heating flow temperature, when the appliance is operating in the central heating mode.
6 720 610 333-04.1O
Fig. 4
i
If the display alternates between -II- and the central heating flow temperature, the trap filling programme is active.
The trap filling programme ensures that the condensation trap is
filled after the appliance has been installed or after the appliance
has been out of use for a long period. For that reason, the appliance remains at minimum heating output for 15 minutes.
Switching off
B Switch off the appliance at the master switch (0).
The green indicator lamp goes out. The optional timer will continue running until the emergency supply is exhausted.
14
6 720 610 604 GB (03.06)
Operating the Appliance
3.3
Switching on the Central Heating
B Turn the central heating temperature control
level:
to the desired
– “Min” setting: 35°C
– Low-temperature heating: setting “E” (approx. 75°C)
– “Max” setting: 88°C
When the burner is lit, the red indicator lamp is illuminated.
6 720 610 333-05.1O
Fig. 5
3.4
Controlling Central Heating
B Set the timer to the correct time.
B Set room thermostat to the desired room temperature.
B Set temperature driven control unit, if fitted. Refer to the
instructions with the control.
B Set the thermostatic radiator valves to the desired settings.
6 720 610 604 GB (03.06)
15
Operating the Appliance
3.5
Combination Boilers: Setting the Hot Water
Temperature
Hot water temperature
On combi models, the hot water temperature can be set to
between approx. 40°C and 60°C using the temperature
control
.
The domestic hot water temperature is not shown on the display.
6 720 610 333-07.1O
Fig. 6
Control Setting
Water Temperature
Anti-clockwise limit
approx. 40°C
approx. 55°C
Clockwise limit
approx. 60°C
Table 2
“ECO” button
By pressing and holding the “ECO” button
, until the display
lights, you can switch between Comfort mode and Economy
mode.
Comfort mode: button is not lit (factory setting)
The appliance is held constantly at the set temperature. This
means that hot water is available almost instantaneously at the
tap. Consequently the appliance will switch on at intervals, even if
no hot water is being drawn.
16
6 720 610 604 GB (03.06)
Operating the Appliance
ECO mode with demand detection, button is lit
The demand detection function enables maximum gas and water
economy.
Briefly turning a hot water tap on and then off again signals
demand to the appliance which then heats up the water to the set
temperature.
Hot water is thus available in about 1 minute.
ECO mode, button is lit
Water is not heated up until hot water is drawn. This means that
there is a longer waiting period before hot water is available.
3.6
System boiler with Storage Tank
B Do not set the temperature higher than
60°C for normal operation.
B Only use temperatures of up to 70°C temporarily for thermal disinfection purposes.
i
With the text display you can additional set hot
water charging times or times and temperatures.
B Set the hot water temperature by means of the temperature
control
on the appliance.
6 720 610 333-07.1O
Fig. 7
6 720 610 604 GB (03.06)
17
Operating the Appliance
Control Setting
Water Temperature
Anti-clockwise limit
approx. 10°C
(frost protection)
l
approx. 60°C
Clockwise limit
approx. 70°C
Table 3
ECO button
Pressing and holding the ECO button
, until it lights up
switches from Comfort mode to ECO-mode.
Comfort mode, ECO button is not lit (factory setting)
In Comfort mode the hot water tank has priority. The hot water cylinder is first heated up to the set temperature. The appliance then
switches to central heating mode.
ECO mode, button is lit
In ECO mode the appliance switches between central heating
mode and cylinder charging mode every 12 minutes.
3.7
Summer Mode, Hot Water Only
(Combi Appliances)
With room temperature controller
B Turn temperature control
on the appliance anti-clockwise
as far as the stop.
The central heating is now turned off. The hot water function
and the mains power supply for the heating programmer and
timer remain switched on.
18
6 720 610 604 GB (03.06)
Operating the Appliance
3.8
Frost protection (Combi Appliances)
B Leave master switch switched on.
If the appliance is to be left for long periods switch the central
heating on and set the room temperature controller at 6°C.
B Add a suitable anti-freeze fluid to the water in the central heating system.
Suitable products are available from Betz-Dearborn Tel.: 0151
4209563, Fernox Tel.: 01799 550811 and Salamander Tel.:
0121 378 0952.
3.9
Fault Condition
In the unlikely event of a fault occuring while the appliance is in
operation:
The display and the text display then shows a fault code and the
button
may also flash.
If the button
flashes:
B Press and hold the button
until the display shows “– –”.
The appliance will then start up again and the display will show
the central heating flow temperature.
If the button
does not flash:
B Switch the appliance off and then on again at the master
switch.
The appliance will start up again and the central heating flow
temperature will be displayed.
If the fault remains and can not be cleared:
B Call British Gas for assistance, giving a description of the fault
and, if possible, the fault code from the facia display.
6 720 610 604 GB (03.06)
19
Text Display
4
Text Display
4.1
General Description
• The text display is used to display information about the appliance and the system and to alter the settings displayed.
• Once the appliance has been in operation for one day, the text
display module has a power buffer period of about 10 hours
during which it will run without the mains power supply. After
that period has elapsed, the clock function shuts down but all
other settings are retained.
4.2
Programming
a
b
c
C
6 720 610 337-08.1R
f
Fig. 8
a
b
c
d
e
f
e
d
Controls
Display
“Up”/“More” button
“Down”/“Less” button
“Back” button
“Next” button
“Delete” button
The standard display shows the following information:
• Time
• Room temperature (if TR 2 connected)
• CH flow temperature
20
6 720 610 604 GB (03.06)
Text Display
• Domestic Hot Water temperature (System boiler if a Storage
Tank is accorded).
Additional indication if a special programme is active:
• x holidays
• Hot water immediately
• Constant on (comfort, if TR2 is not connected)
• Constant off (economy, if TR2 is not connected).
Other special operating modes may be displayed during commissioning, servicing, etc.
The programming procedure is described in detail below using
the clock function as an example:
B To start programming, press any button, e. g.
.
The display lighting switches on and the main menu is displayed:
T
/holidays
6 720 610 598-04.2O
Fig. 9
Main menu
B Use the
or
button to move the cursor arrow on the
left of the menu so that it points to the desired menu item.
In this example, the cursor is positioned next to the menu item
Time/day/holidays.
6 720 610 604 GB (03.06)
21
Text Display
B Confirm the selection by pressing the
The corresponding submenu is displayed:
button.
T
6 720 610 598-05.2O
Fig. 10
Submenu: Time/day
In the submenus, the top line indicates what action is required.
The bottom line shows the previous menu level, if applicable (see
Fig. 10).
B Use the
or
button to select Time/day.
B Confirm the selection by pressing the
The corresponding submenu is displayed:
button.
H
T
6 720 610 598-06.2O
Fig. 11
Setting the hour
When settings are being entered, the setting to be altered is indicated on the top line. In addition, the setting being altered is displayed with a dark background.
B Use the
or
button to set the hour.
– Press and release to change the display by one unit at a
time
– Press and hold to change the display rapidly
B Confirm the setting by pressing the
22
button.
6 720 610 604 GB (03.06)
Text Display
B Use the
or
button to set the minutes.
B Confirm the setting by pressing the
B Use the
or
button.
button to set the day of the week.
B Press the
button to confirm the setting. The cursor then
returns to the top line.
-orB Press the
button to confirm the setting and return to the
previous menu (Fig. 9 page 22).
-orB Do not press any other buttons for 15 minutes.
4.2.1
Deleting a setting
Either overwrite the setting or press the C button to delete it.
B Find the setting to be deleted.
B Press and release the C button.
The display shows --:-4.2.2
i
Resetting all parameters to their original settings
The hours of service can not be reset to 0.
B Press and hold the C button for more than 15 seconds.
After about 5 seconds, the following message appears on the
display:
ATTENTION
Delete all parameters
in x seconds
Once the reset has been completed, the following message is
displayed:
Please wait... Initialising
6 720 610 604 GB (03.06)
23
Text Display
4.3
Menu structure
Main menu 1.
Time/day/hol- Time/day
idays
Heating
Hot water
Info
24
2.
-
3.
-
-
-
Set econ- omy temp.
(if TR2 is
connected)
Manual
(if TR2 is
not connected)
-
Hot water
program
-
-
Hot water immediately
-
Holidays
Heating
program
-
Parameters to
change/select
- Hours
- Minutes
- Day of week
Days holiday
- Day
- 1st operating mode
- 1st switching point
...
- 6th switching point
5...30°C
Page
Submenu
25
25
27
28
29
-
- Automatic
- Constant on
(comfort)
- Constant off
(economy)
- Day
- 1st operating mode
- 1st switching point
...
- 6th switching point
Off/On
-
-
32
31
31
6 720 610 604 GB (03.06)
Text Display
Main menu
Settings
1.
Heating
Hot water
(System
boiler-models)
Service
Page
Submenu
2.
-
3.
-
Parameters to
change/select
Optimum Start Off/On 33
Only charging times/
30
times and temperatures
Display
service
param.
Further
options
-
-
33
Language
-English/
-Français/
-Deutsch
-Time correction
-LCD contrast
-
34
-
35
Operating
times
Fault
history
4.4
Setting the time/day
4.4.1
Setting the time and day
34
34
34
For details of how to set the time and day, refer to page 21.
i
4.4.2
Changing winter and summer time:
B Only adjust the clock! Do not alter the switching
points (for heating, economy, etc.).
Holidays
In the Holiday programme, the central heating runs in Economy
mode and the hot water is switched off (frost protection function
remains active).
B From the main menu, select Time/day/holidays, and from the
first submenu select Holidays.
B Enter the number of days holiday by pressing
or
(max. 99 days holiday).
After the set number of days, the text display module automat-
6 720 610 604 GB (03.06)
25
Text Display
ically cancels Economy mode at midnight on the last day and
returns to Automatic mode.
i
The day on which you enter the days holiday
counts as the first day of the holiday, i.e. the unit
starts the holiday program immediately. Only include the day on which you are returning if you
don’t want the heating to return to the normal program on that day!
To cancel Holiday mode early:
B In the Holidays submenu:
Press the C button until the display shows 0 .
26
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Text Display
4.5
Heating
4.5.1
Heating program
Basic setting (Automatic mode)
• The appliance switches automatically between normal heating,
Economy mode and Frost protection mode according to the
timer settings entered.
• Basic setting:
– Heating starts at 6:00 am
– Economy starts at 10:00 pm
Setting options
• Maximum of six switching points per day with three different
operating modes (Heating, Economy, Frost protection).
• Same times for Monday to Friday.
• Same times for Saturday and Sunday.
• Different times for every day.
Setting switching times and operating mode
B From the main menu select Heating and then from the first
submenu, select Heating program.
B Select Monday - Friday, Saturday and Sunday or an individual
day of the week.
– Monday - Friday: to have “Heating” and “Economy” or
“Frost protection” switching on at the same times every
weekday.
– Saturday - Sunday: to have “Heating” and “Economy” or
“Frost protection” switching on at the same times Saturday
and Sunday.
– Individual day of the week (e. g. Thursday): to have the relevant program always switching on at the specified time on
that day of the week, i.e. “Heating”, “Economy” or “Frost
protection” at the same time every Thursday.
6 720 610 604 GB (03.06)
27
Text Display
B Press
. The display shows Set 1. operating mode.
B Set the desired first operating mode (Heating, Economy or
Frost protection).
B Press
. The display shows Set 1. time period.
B Set the desired first time period.
B Press
. Set the following operating modes and time periods as described for the first.
B If necessary: select the next day and enter the operating
modes and timer periods as described above.
i
If the settings for a particular day of the week
are different from the settings for the other
days, then if Monday -Friday or Saturday
and Sunday is selected, the display shows
--:--, i.e. there are no common switching points
for those options.
Timer periods and operating modes are you do not wish to
change can be skipped by pressing
.
4.5.2
Setting the Economy temperature (if TR2 is connected)
This option allows you to set the room temperature for Economy
mode (Off (Economy)).
This function is only active if:
• Automatic mode or Economy mode is set on the TR 2 room
thermostat.
B From the main menu, select Heating and then from the first
submenu, select Set Economy temp..
B Use the
and 30 °C.
28
or
button to set a temperature between 5
6 720 610 604 GB (03.06)
Text Display
4.5.3
Manual operating mode (if TR2 is not connected)
For selecting an operating mode that is different from the one set
in the heating programme (Automatic mode).
• You can choose between Automatic, Constant on (comfort)
and Constant off (economy).
• The manually selected operating mode starts immediately.
• Constant off (economy) and Constant on (comfort) are automatically reset at 00.00 (midnight).
• To cancel the manually selected operating mode:
– select the relevant menu and then press the C button,
– or select a different operating mode,
– or set Holiday.
B From the main menu select Heating and then from the first
submenu Manual select required mode.
6 720 610 604 GB (03.06)
29
Text Display
4.6
Hot water
General description
• Combi models only: The basic settings provide a straightforward timer programme: enabled from 5:00 am, disabled from
10:00 pm. The ECO button must not be lit (Comfort mode).
• System models (with Storage Tank): The basic settings provide a timer programme: enable from 5:00 am, disable from
10:00 pm. With the menu Hot water (see page 33) you can
choose a timer-/temperature programme with the basic settings: 60°C from 5:00 am, 10°C from 10:00 pm.
30
6 720 610 604 GB (03.06)
Text Display
4.6.1
Hot water program
• Up to six switching points per day can be set.
• There are two operating modes: Blocked and Released.
B From the main menu, select Hot water and then from the first
submenu, select Hot water program.
B Set the days of the week, Blocked/Released (operating mode)
in the same way as for the switching points and modes for
heating as described on page 27.
4.6.2
Hot water immediately (System models)
• Hot water immediately ON:
– Comfort mode is active for 2 hours.
• Comfort mode is active for 2 hours: normal automatic program (Hot water mode according to timer programme
entered).
B From the main menu, select Hot water and then from the first
submenu, select Hot water immediately.
B Press
or
6 720 610 604 GB (03.06)
to switch Hot water immediately on or off.
31
Text Display
4.7
i Info
B Select Info from the main menu.
You can view the following information:
Display text
Description
Room temperature
(if TR 2 connected)
Current temperature in the room
where TR 2 is installed
Required room temperature (if TR 2 connected)
Required temperature in room where
TR 2 is installed
Operating mode
(if TR 2 connected)
E. g. Heating, Economy in Automatic
mode
or
Economy, Heating, Frost protection in
manual mode
Max. flow temp.
Maximum CH flow temperature set on
the temperature control for CH flow
Actual flow temp.
Actual CH flow temperature
Required flow temp.
Required CH flow temperature
Max HW temp.
Maximum permissible hot water outflow temperature
Required HW temp.
Required hot water temperature
Actual HW temp.
Actual hot water outflow temperature
Storage Tank charge
released or blocked
Shows, if hot water is released or
blocked
Storage Tank charge on
or off or Storage Tank
charge afterrunning
Shows, if hot water is on or off, or if
the pump for the Storage Tank afterrunning is on
Boiler operat. mode
winter/ summer
Indicates which mode the CH flow
temperature control is set to
Burner on/off
Indicates whether the burner is alight
or not
Pump on/off
Indicates whether the integral pump is
switched on or off
32
6 720 610 604 GB (03.06)
Text Display
4.8
Settings
4.8.1
Heating (if TR 2 is connected)
Optimum Start
B From the main menu, select Settings and from the first submenu, select Heating.
B Press
4.8.2
or
to switch Optimum Start on or off.
Hot Water (Storage Tank, System boiler models only)
The text display can control the hot water either with Times and
temperatures or only times.
• Times and temperatures: One can choose up to six different
times with temperatures, see page 30 “Hot water”.
• Only times: During that times the Storage Tank will be
charged to the choosed temperature.
B From the main menu, select Settings and from the first submenu select hot water.
B Press
times.
i
4.8.3
or
to switch Times and temperatures or only
Turn the hot water temperature control
always higher than the temperature at the text
display is choosen.
Service
Displaying service functions
This option displays various current settings and statuses of the
electrically controlled appliance and system components for the
benefit of the heating engineer.
6 720 610 604 GB (03.06)
33
Text Display
Service parameters
Language
Available languages are: English, Français (French), Deutsch
(German).
B From the main menu, select Settings, from the first submenu
select Service, from the Second submenu select Further
options, and from the third submenu select Language.
B Press
or
to select the desired language.
Two other supplementary functions can be selected from the third
submenu Language:
• Time correction
• LCD contrast.
Time correction:
B Press and hold the
button (about 5 seconds) until the
display shows Time correction and LCD contrast.
B Press
or
B Press the
B Press
to select Time correction.
button. The display shows Change value.
or
to set the number of seconds in 24 hours.
Basic setting: “+ 0 s”
LCD contrast:
B Press and hold the
button (about 5 seconds) until the
display shows Time correction and LCD contrast.
B Press
or
B Press the
B Press
to select LCD contrast.
button. The display shows Change value.
or
to adjust the LCD contrast.
Basic setting: e. g. “47”
Operating times
This option shows the hours of service (appliance, burner and hot
34
6 720 610 604 GB (03.06)
Text Display
water) since commissioning.
B From the main menu, select Settings, from the first submenu
select Service, from the Second submenu select Further
options, and from the third submenu select Operating times.
Fault history
This option displays any faults that have occurred for the information of the service engineer. The first fault displayed may still be
active. Any other faults displayed are no longer active.
B From the main menu, select Settings, from the first submenu
select Service, from the Second submenu select Further
options, and from the third submenu select Fault history.
6 720 610 604 GB (03.06)
35
Text Display
4.9
Individual timer programmes
Heating periods for central heating
Time
Operating mode
6.
Time
Operating mode
Time
5.
Operating mode
4.
Time
Operating mode
3.
Time
Operating mode
2.
Time
Status
1.
Operating mode
Switching point
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Enable/disable hot water function
Time
Operating mode
6.
Time
Operating mode
Time
5.
Operating mode
4.
Time
Operating mode
3.
Time
Operating mode
2.
Time
Status
1.
Operating mode
Switching point
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
36
6 720 610 604 GB (03.06)
Fault finding
5
Fault finding
Problem
Cause
Remedy
Desired room
temperature is not
reached
Thermostatic
valve(s) set too
low
Increase thermostatic valve setting(s)
Temperature control for CH flow
set too low
Increase CH flow
temperature control setting
Air trapped in
heating system
Bleed radiators
and heating system
Desired room
temperature
exceeded by large
amount
Radiators are too
hot
Turn down thermostatic valves
Temperature rises
instead
of falling
Clock is incorrectly set
Check setting
Room temperature too high in
Economy mode
Building retains
heat well
Start Economy
mode sooner
No display or display unit does not
respond
Momentary power
failure
Switch off appliance at master
switch, wait a few
seconds and
switch on again
Storage Tank
doesn’t warm up
Temperature control is too low
Turn the temperature control to the
desired temperature
6 720 610 604 GB (03.06)
37
Tips on saving energy
6
Tips on saving energy
Heating economically
The boiler is designed to provide a high level of comfort while
keeping gas consumption and the resulting environmental effect
as low as possible. The gas supply to the burner is controlled
according to the level of demand for heat. The boiler continues to
operate with a low flame if the demand for heat reduces. The technical term for this process is modulating control. Modulating control keeps temperature fluctuations small and provides even
distribution of heat throughout the home. This means that the
boiler may stay on for relatively long periods but will use less gas
than an appliance that continually switches on and off.
Central heating systems with room thermostats/thermostatic
radiator valves
The central heating control on the boiler should be set to the maximum rated temperature of the central heating system or to position “E”, when the maximum central heating water temperature
obtained is 75°C.
The temperature can be set individually in each room (except primary room with the room thermostat) using the thermostatic radiator valves. If you wish to have a lower temperature in the primary
room than in the other rooms, leave the room thermostat at the set
temperature and turn down the radiator using the radiator valve.
Reduced-output operation
Considerable fuel savings can be made by slightly reducing the
room temperature. Lowering the temperature by 1 °C can bring
about energy savings of up to 5 %. However, it is not advisable to
allow any room temperature to fall below +15 °C. The room temperature for reduced-output mode can be set separately on the
room thermostat. Instructions are given in the control unit operating instructions.
38
6 720 610 604 GB (03.06)
General Information
Hot water
A lower setting on the hot water temperature control can result in
considerable energy savings.
For combi appliances:
The on-demand activation using the ECO-button makes possible the maximum savings of gas and water.
Now you know how to heat your home economically with the RD
532i/RD 537i/RD 542i /RD 430i gas condensing boiler. If you
have any other questions, please contact your installer – or write
to us.
7
General Information
Cleaning the Outer Case
Wipe down the outer case with a damp cloth. Do not use abrasive
or caustic cleaning agents.
Appliance details
If you ever need to call Customer Service it helps us a great deal
if you can provide precise details of your appliance.
The information is printed on the appliance identification plate/
sticker (see page 11, item 295).
Your installer will have completed the Benchmark “log-book” giving details of the boiler together with name, address and registration number. Have the “log-book” to hand when calling a Service
Engineer.
6 720 610 604 GB (03.06)
39
Maintaining your appliance
8
Maintaining your appliance
Your new RD 532i/RD 537i/RD 542i /RD 430i gas-fired appliance represents a long-term investment in a reliable, high quality
product.
In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, it is essential that your boiler receives regular, competent servicing and
maintenance checks beyond the initial 2 year guarantee period.
To arrange for a British Gas three star cover agreement please
call 0845 9 60 50 40.
9
Service
If your RD 532i/RD 537i/RD 542i /RD 430i appliance should fail
to operate correctly or requires servicing please call British Gas
on: 0845 9 60 50 40.
40
6 720 610 604 GB (03.06)
Fault or breakdown
10
Fault or breakdown
This product is supported in the UK by Worcester Heat Systems
Ltd. – part of the Bosch Group.
A specialist factory trained field SERVICE ENGINEER is available
to attend a breakdown or manufacturing fault occuring on this
appliance.
No charge will be made for parts and/or labour providing:
• An appliance fault is found and the appliance has been
installed within the past 24 months. Reasonable evidence of
this must be supplied on request.
A call-out charge will be made where:
• The appliance has been installed for over 24 months.
OR
• Our Field Service Engineer finds no fault with the appliance
(see NOTE).
OR
• The cause of breakdown is misuse or with other parts of your
plumbing/heating system, or with equipment not supplied by
Worcester.
NOTE: No appliance fault is found on over 30 % of all service call
outs.
If in doubt contact our British Gas on 0845 9 60 50 40.
IN THE EVENT OF AN APPLIANCE FAULT OR BREAKDOWN
please contact your Service Centre (see over). Your service
administrator will arrange for an engineer to call with the minimum
of delay; under normal circumstances this will be within the period
1-3 working days (excluding weekends) for priority breakdown situations (no hot water and/or heating service).
INVOICES FOR ATTENDANCE AND REPAIR WORK CARRIED
OUT ON THIS APPLIANCE BY ANY THIRD PARTY WILL NOT
BE ACCEPTED.
6 720 610 604 GB (03.06)
41
Your guarantee
11
Your guarantee
This appliance is guaranteed against faulty material or workmanship for a period of 24 calendar months from the date of installation subject to the following conditions and exceptions.
• That during the currency of this guarantee any components of
the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and
free of labour charges by Worcester Heat Systems Limited.
• That the householder may be asked to prove the date of installation, that the appliance was correctly commissioned and,
where appropriate, the first 2 year service has been carried out
to the satisfaction of Worcester Heat Systems Limited when
requested.
• That any product or part thereof returned for servicing under
the guarantee any components of the unit which are proved to
be faulty guarantee must be accompanied by a claim stating
the Model, Serial Number, Date of Installation.
• That Worcester Heat Systems Limited will not accept responsibility for damage caused by faulty installation, neglect, misuse
or accidental damage, the non observance of the instructions
contained in the Installation and Users Instructions Leaflets.
• That the appliance has been used only for normal domestic
purposes for which it was designed.
• That this guarantee applies only to equipment purchased and
used in Great Britain.
This guarantee is given in addition to all your normal statutory
rights.
42
6 720 610 604 GB (03.06)
Guarantee registration
12
Guarantee registration
You should complete and return the postpaid Guarantee Registration Card within 14 days of purchase.
The card will register you as the owner of your new RD 532i/RD
537i/RD 542i /RD 430i appliance and will assist us in maintaining
an effective and efficient customer service by establishing a reference and permanent record for your boiler.
This will not affect your statutory rights in any way.
Important:
For your own record:
Model
.......................................................................................................................
Serial number:.............................................................................................
(See identity label inside appliance casing)
Type/size:.....................................................................................................
Date of installation:....................................................................................
Check that the Benchmark “log-book” has been completed by
your installer or service engineer.
SERIAL NUMBER. Copy the number off the Guarantee Card.
6 720 610 604 GB (03.06)
43
13
Operating Instructions Quick Reference
Switching on
6 720 610 333-04.1O
Switching the central heating on
6 720 610 333-05.1O
Text Display
Set switching times and operating
mode within the text display.
Hot water temperaeture – Combination boiler only
6 720 610 333-07.1O
“ECO”-button lit –
Economy mode.
“ECO”-button not lit –
Comfort mode
Refer to page 19.
Fault Condition
Switching off
6 720 610 333-11.1O