Greenstar ZWB 7 27 HE Combi 47 311 55

Installation and Servicing Instructions
Wall mounted condensing boiler for central heating and mains fed domestic hot water
GREENSTAR HE combi
6 720 610 577-00.10
ZWB 7-27 HE combi GC-Number: 47 311 55
6 720 610 576 GB (01.07) OSW
Contents
Contents
Safety precautions Symbols 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.9.1 3.9.2 3.9.3 4 4.1 4.2 5 5.1 5.2 5.3 5.4 5.5 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 Installation regulations Installation Important remarks Domestic hot water 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 3 3 4 4 4 4 5 5 6 7 8 9 11 11 11 12 12 13 14 14 15 16 16 17 18 20 6.2.1 Operating the Bosch Heatronic 6.2.2 Selecting the pump control mode for central heating mode (Service Function 2.2) 6.2.3 Setting the anti-cycle time (Service Function 2.4) 6.2.4 Setting the maxim CH flow temperature (Service Function 2.5) 6.2.5 Setting the switching difference (Service Function 2.6) 6.2.6 Setting the heating output (Service Function 5.0) 6.2.7 Constant hot water cycle time (Service Function 6.8) 6.3 Setting the gas/air ratio 7 Converting the appliance to different gas types 7.1 Setting the gas/air ratio 7.2 Testing combustion air/flue gas at set heat output 7.2.1 Testing the O2 or CO2 level in the combustion air 7.2.2 Testing CO and CO2 8 Maintenance 8.1 Pre-Service Check List 8.2 Description of servicing operations 8.3 Replacement of Parts 8.3.1 PCB control board and transformer 8.3.2 Fan Assembly 8.3.3 Pump 8.3.4 3-way diverter valve 8.3.5 3-way diverter valve motor 8.3.6 Sensors 8.3.7 Gas Valve 8.3.8 Domestic Hot Water Heat Exchanger 8.3.9 Electrode assembly 8.3.10Pressure gauge 8.3.11Expansion vessel 8.3.12Pressure Relief Valve 8.3.13Burner 8.3.14Flow switch 8.3.15Primary Heat Exchanger 9 9.1 9.2 9.3 9.4 9.5 9.5.1 9.5.2 Appendix Fault Codes Short parts list Heating/hot water output settings (N.G.) Heating/hot water output settings (L.P.G) Operational Flow diagrams Domestic hot water function Central heating function 27 27 27 28 28 28 28 28
29 29 31 31 31 32 33 34 37 37 38 38 39 39 39 40 40 40 40 40 40 40 41 41 42 42 43 44 44 45 45 46
Electrical connections 21 Connecting the appliance 21 Mains Voltage external controls connections 22 23 23 24 24 24 24 24 25 25 25 25 25 26 26 26 26 26 27
Commissioning Commissioning Switching the appliance on/off Switching on the central heating System controls Setting the domestic hot water temperature and flow rate 5.5.1 Domestic hot water temperature 5.5.2 Hot water flow rate 5.6 Summer mode (hot water only) 5.7 Frost protection 5.8 Pump anti-seize function 5.9 Fault Condition 6 6.1 6.1.1 6.1.2 6.1.3 6.2 Individual settings Mechanical settings Checking the size of the expansion vessel Setting the central heating flow temperature Changing the heating pump characteristic Settings on the Bosch Heatronic
6 720 610 576 GB (01.07)
Safety precautions
Safety precautions
If you smell gas y Turn off gas service cock at the meter. y Open windows and doors. y Do not operate any electrical switches. y Extinguish any naked flames. y Telephone your gas company. If you smell fumes from the appliance y Switch off appliance (see page 24). y Open windows and doors. Fitting and modifications y 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. y Flue systems must not be modified in any ways other than as described in the fitting instructions. y This appliance is for use on sealed primary systems only. Maintenance y The user is recommended: to have the system regularly serviced in order to ensure that it functions reliably and safely. y Use only original spare parts! Combustible materials y Do not store or use any combustible materials (paper, thinners, paints etc.) in the vicinity of the appliance. Health and safety y This appliance contains no asbestos products. y There is no potential hazard due to the appliance being electrically unsafe. y 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 y 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 y Explain to the customer how the appliance works and how to operate it. y Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it y These instructions are to be left with the user or at the Gas meter. y Important: These instructions apply in the UK only.
Symbols
Safety instructions in this document are identified by a warning-triangle symbol and are printed on a grey background. Notes containing important information are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.
6 720 610 576 GB (01.07)
Details of the appliance
1
1.1

EC Declaration of Conformity 1.3 Description of appliance
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 Category UK Appliance Type Table 1 CE-0085 BL 0507 II2H 3P C13, C33
Wall-mounted appliance, siting not dependent on room size Natural gas models are low-emission appliances Multifunction display Bosch Heatronic control system 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 Regulated speed fan Pre-mix burner Temperature control for central heating Temperature sensor in domestic hot water Safety temperature limiter in 24 V electrical circuit Three-speed central heating pump with automatic vent Relief valve, pressure gauge, expansion vessel Flue gas temperature limiter (105 C) Hot water priority circuit Motorised 3-way valve Plate-type heat exchange Condensate Trap.
1.2
Standard package
Gas condensing combination boiler for central heating and domestic hot water Wall mounting frame Clamp for securing flue duct kit Fixings (screws etc.) Set of documentation for appliance Pre-plumbing manifold Condensate drain pipe.
6 720 610 576 GB (01.07)
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 uto 15 m. Fitting instructions are sent with these kits. Heating programmer Timer Security kit.
1.5
Casing dimensions
min.
min.
Z Y
120
850
101 13 103
35 360 395 250
30
861
906
200
440
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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
6 720 610 576 GB (01.07)
1.6
Layout of appliance
120
221.1 221.2
349
234.1
234
226
20
102 32.1
29
36
271
43 9 63 358
415
416 27 419
64 7 355
18 423 18.1 418
6.1
15 8.1 88
295 417
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98 4
Fig. 2
4 6 6.1 7 8.1 9 15 18 18.1 20 27 29 32.1 36 43 63 64 88 98 Heatronic control Heat exchanger safety temperature limiter Hot water NTC sensor Testing point for gas supply pressure Pressure gauge Flue gas temperature limiter Relief valve Pump Pump speed selector switch 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 (combi) DHW flow switch (combi) 102 120 221.1 221.2 226 295 234 234.1 271 349 355 358 415 416 417 418 419 423 Inspection window Fixing points Flue duct 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 Plate-type domestic hot water heat exchanger Condensate trap Cover plate for cleaning access Condensate collector Clip for fixing outer case Data plate Hose from automatic vent Siphon
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1.7
Function
26 229 226 29 33 30
234.1
234
36
32
20 6
221 35
29.1
63 358
52.1
69 64
27 18 88 419 8.1 15
96 95 94 93 98
52 57 55
56
4
0
1
61
3 2 4
317
ECO
5 E
max max
355
90
6.1
91 97
423
M
84 47
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13
43
44
45
46
Fig. 3
4 6 6.1 7 8.1 9 13 15 18 20 26 27 29 29.1 30 32 33 35 36 43 44 45 46 47 52 52.1 55 56 57 61 Bosch Heatronic control Temperature limiter, heat exchanger Hot water NTC sensor 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 Hot water flow Gas inlet Cold water inlet CH return Solenoid valve 1 Solenoid valve 2 Filter Gas valve CE 427 Main valve disc Reset button 63 64 69 84 88 90 91 93 94 95 96 97 98 221 226 229 234 234.1 317 355 358 419 423 Adjustable gas flow restrictor Adjusting screw for min. gas inlet flow volume Control valve Motor 3-way valve Venturi Pressure relief valve Water flow regulator Diaphragm Pushrod with switch cam Microswitch Valve for hot water flow volume Water valve Flue duct Fan Inner casing Testing point for flue gas Testing point for combustion air Display Plate-type heat exchanger Condensate trap Hose from automatic vent Siphon
6 720 610 576 GB (01.07)
1.8
Electrical wiring diagram

o - orange g - green bl - black
33 364
4.1
r - red
p - purple
365
61
317
366
367
ECO
363
25 V
230 V
153
230V/AC
136
310 312 313 315

124 789
p p p
135
318
328
302
L N Ns Ls LR
151
84
161
328.1
300 314
M
96
6
o r r
g g
M
mains supply
M
226
52 52.1
18
56
o bl bl bl bl o
36
bl
6.1
32
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Fig. 4
4.1 6 6.1 9 18 32 33 36 52 52.1 56 61 84 96 135 136 151 153 Ignition transformer Temperature limiter, heat exchanger Hot water NTC sensor 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 Microswitch, hydraulic switch Master switch Temperature control for CH flow Fuse, slow 2.5 A, AC 230 V Transformer 161 226 300 302 310 312 313 314 315 317 318 328 328.1 363 364 365 366 367 Link Fan Code plug Earth connection Temperature control for hot water Fuse, slow T 1,6 A Fuse, slow T 0,5 A Connector for programmer Terminal block for programmer Digital display Connector for timer 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
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1.9
Technical data
Units Natural gas 29.1 28.8 27.2 27.5 8.4 8.3 7.4 7.6 27.2 27.5 2.9 2.1 20 0.75 10 8 14 40 - 60 10 0.2 12.4 67/55 43/32 80 9.5 9.2 5 90.6 2.3 4.8 230 50 101 36 X4D nom. 90 2.5 0 - 60 3.75 46 37 0.75 10 8 14 40 - 60 10 0.2 12.4 67/55 43/32 80 11.3 11.0 5 90.6 2.3 4.8 230 50 101 36 X4D nom. 90 2.5 0 - 60 3.75 46 Propane 29.1 28.8 27.2 27.5 11.6 11.4 10.5 10.8 27.2 27.5
kW Max. rated heat output net 40/30 C central heating kW Max. rated heat output net 50/30 C central heating kW Max. rated heat output net 80/60 C central heating Max. rated heat input net kW kW Min. rated heat output net 40/30 C kW Min. rated heat output net 50/30 C kW Min. rated heat output net 80/60 C Min. rated heat input net kW Max. rated heat output net, domestic hot water kW Max. rated heat input net, domestic hot water kW Maximum gas flow rate After 10 minutes from lighting Natural gas G20 (HiB = 9,5 kWh/m3) m3/h LPG (Hi = 12,8 kWh/kg) kg/h Gas supply pressure Natural gas G20 mbar LPG mbar Expansion vessel Charge pressure bar Total capacity l Hot water specifications Hot water flow rate (factory setting) l/min Max. hot water flow rate l/min Outlet temperature range C Max. permissible water supply pressure bar Min. inlet pressure bar Specific flow rate l/min Flue Flue gas temp. 80/60 C, rated/min. load C Flue gas temp. 40/30 C, rated/min. load C Residual delivery pressure (inc. pressure drop in air intake duct) Pa CO2 level at max. rated heat output % CO2 level at min. rated heat output % NOx-class SEDBUK figure, Band A % Condensate Max. condensation rate (tR = 30 C) l/h pH-value, approx. General Data Electrical power supply voltage AC ... V Frequency Hz Max. power consumption W Noise output level dB(A) Appliance protection rating IP Max. CH flow temperature C Max. permissible operating pressure (CH) bar Permissible ambient temperatures C Nominal capacity of appliance l Weight (excluding packing) kg
Table 2
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Condensate analysis, mg/l

Ammonium 1.2 Lead 0.01 Cadmium 0.001 Chromium 0.005 Halogenated hydrocarbons 0.002 Hydrocarbons 0.015 Copper 0.028 Nickel 0.15 Mercury 0.0001 Sulphate 1 Zinc 0.015 Tin 0.01 Vanadium 0.001 pH-value 4.8 Extension Duct Length - Fixed Extension Duct Length - Fixed Extension Duct Length Telescopic 100 750 Max. 4m Extension Duct Length Adjustable (Cut to length) mm mm mm 950 1950 265375 450 Extension Duct Length Extension Duct Length - Fixed mm mm 200 450 Max. 15 m VERTICAL 125 mm FLUE SYSTEM Overall Diameter of Duct Flue Terminal / Duct Assembly mm mm 125 1360
Table 3 Flue system

HORIZONTAL 100 mm Standard Overall Diameter of Duct Flue Terminal / Duct Assembly Length Extension Duct Length mm mm
mm
mm
1000
Table 6 Elbow - 90 Equivalent length 2 m Gas supply
Bend - 45 Equivalent length 1m
Table 4
ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM Overall Diameter of Duct Flue Terminal / Duct Assembly Extension Duct Length - Fixed Extension Duct Length - Fixed Extension Duct Length - Fixed Extension Duct Length - Fixed Extension Duct Length Telescopic Extension Duct Length Adjustable (Cut to length) mm mm mm mm mm mm mm 125
Total length of gas supply pipe (metres) 3 6 9
Pipe diameter (mm)
550 200
Gas discharge rate (m3/h) 8.7 5.8 12.0 4.6 9.4 22 28
450 950 1950 265375 200
Max. 13 m (including turret)
18.0
Table 7 Domestic water performance

Temperature Rise Domestic Water Flow Rate l/min Temperature Rise Temperature Rise Maximum Mains pressure Minimum Mains pressure 30 C 35 C 40 C bar bar
13.2 11.3 9.9 10.0 0.2
mm
Table 5
Table 8
10
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Installation regulations
Installation regulations
Installation
y Always turn off the gas cock before carrying out any work on components which carry gas.
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 BS 5449: Central Heating for Domestic Premises BS 5546: Installation of gas hot water supplies for domestic purposes BS 5440:1: Flues and ventilation for gas appliances of rated input not exceeding 70 kW (gross): Flues BS 5440:2: Flues and ventilation for gas appliances of rated input not exceeding 60 kW (gross): Air Supply BS 6891: Installation of low pressure gas pipework installations up to 28mm (R1). BS 7074:1: Code of practice for domestic heating and hot water supply. These instructions must be followed.
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
y Appliance should only be installed in sealed central heating systems. y To avoid gas formation in the system, galvanised radiators or pipes must not be used. y If a room thermostat is used: do not fit a thermostatic radiator valve on the radiator in the primary room. y Add a suitable anti-freeze fluid compatible with aluminium to the water in the central heating system. Suitable products are available from Betz-Dearborn Tel.: 0151 4209563 and Fernox Tel.: 01799 550811. y 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.
6 720 610 576 GB (01.07)
11
Installation
3.2
Domestic hot water
3.3
Sealed systems
Any regulations specified by the local water company must be observed. The final 600 mm of the mains cold water connection to the applaince should be made in copper tube only. The appliance is suitable for a mains supply having a maximum pressure of 10 bar. A pressure reducing valve must be fitted, if necessary. The hot water outlet temperature is set to be capable of achieving a maximum of 60 C. The maximum temperature and the frequency of the recharge of the heat store may be reset. The maximum water flow rate is factory set at 9.9 l/min to give temperature rise of 40 C. If a higher rise is required then the flow must be reduced at the tap and the discharge temperature will rise up to the maximum set figure. The temperature rise, upto the maximum set by the user, is automatically maintained by the modulation of the heat input. In winter, when the mains temperature is very low, the water flow, adjusted at the tap or shower, should be reduced to maintain the required delivery temperature. It is suggested that long pipe runs to taps or showers be insulated to prevent the rapid cooling of the water. All types of single lever mixer taps and thermostatic mixer units suitable for a mains pressure of up to 10 bar can be used. The head of a loose-head shower must not be allowed to fall within 25 mm of the top the bath to prevent the risk of water being drawn back into the mains. Alternatively the shower must be fitted with an anti-syphonage device at the point of the flexible hose connections. Over-rim bidets may be connected to the appliance provided that it is in accordance with the requirements of the local water company. The outlet(s) should be shrouded and unable to have any temporary hand held spray attached. No anti-syphonage arrangements are necessary. In exceptionally hard water areas a device to prevent scale formation may be fitted or, alternatively, the maximum temperature reset to about 45 C which may reduce the risk of scale formation. The installation of a scale inhibitor assembly should be in accordance with the requirements of the local water company. Artificially softened water must not be used. An isolating valve should be fitted to allow for servicing. Devices, such as water meters or back-flow prevention valves, capable of preventing the flow of expansion water must not be fitted unless separate arrangements have been made. A Zilmet Z160 expansion vessel is the preferred type. A thread sealant compatible with potable water must be used.
The appliance must not be operated without the system being full of water, properly vented and pressurised. The expansion vessel has a volume of 10 litres and is charged to a pressure of 0.75 bar. The water capacity of the system is shown in table 11, page 26. 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 2.65 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. The filling point must be at low level and arranged as shown in figs. 5 and 6. The pressure relief valve is set to operate at 3 bar. There must be no connection to the mains without the approval of the local water company. All connections in the system must be capable of withstanding a pressure of up to 3 bar and the radiator valves conform to the requirements of BS 2767:10. If Thermostatic Radiator Valves are fitted then it is recommended that one 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 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.
12
6 720 610 576 GB (01.07)
Installation
APPLIANCE Refer to Fig.1 Appliance water flow diagram
A drain cock should be fitted at the lowest point of the heating circuit and the appliance Lockshield valve
WRC approved filling loop
Central heating return Domestic hot water Domestic hot water Central heating flow
Radiator valve
BS stop valve. Fixed spindle type Water main
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Fig. 5
Sealed primary water system
Heating return
Non-return valve
Non-return valve Hose union Hose union Test cock Test cock Temporary hose
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Fig. 6
Sealed primary water system - filling method
3.4
Siting the appliance

Surface temperature The max. surface temperature of the casing and the flue is less than 85 C. This means that, no special safety precautions are required with regard to flammable building materials and fitted furniture. The specified clearences must be maintained. 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.
Regulations concerning the Installation Site y Relevant national regulations must be complied with section 3.9.1. y 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.
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13
Installation
3.5
Wall mounting frame assembly

y Screw the pre-plumbing manifold with two screws to the wall mounting frame.
y Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 7. Use the inner lugs on the top and bottom horizontal sections for the appliances that are 440 mm wide.
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Fig. 9
6 720 610 576-04.1O
Fig. 7 y Hold the wall-mounting frame against the wall ensuring that it is vertical. y Mark the position of the flue duct hole if a rear flue is to be used. Refer to fig. 1 and 15. y 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.
3.6
Pre-piping the system

200
171 43
112
172 47
50
35
120-130 260
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Fig. 10 Manifold
43 47 112 171 172
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CH flow CH return Gas cock Domestic hot water Cold water relief
Fig. 8
y A drain tap should be fitted at the lowest point of the central heating system. y WRc filling loop must be fitted.
14
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Installation
Condensate drain Prepare the condensate discharge system. Refer to fig. 11. The condensate drainage pipe should be a standard drain pipe material , i . e. PVC, PVC-U, ABS etc. and should be at least 22 mm in diameter. A siphon with a 75 mm condensate seal is fitted within the appliance. A connection to an internal drain is recommended. Any external drain pipe should be insulated to prevent freezing. The connection of a condensate pipe to a drain may be subject to local building regulations. For more information refer to the CIBSE Guide, BS5546 and the Building Regulations.
3.7
Fitting the appliance

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.
y Remove packing, taking care to observe the instructions on the packing. y Lie the boiler on its back. Removing the outer case
The outer case is secured against unauthorised removal by two clips (electrical safety). Always secure the outer case with those clips again after refitting.
y Turn the clips with a screwdriver (1.). y Slide the outer case upwards and then forwards to remove (2.). y Remove the plastic caps from the boiler connections.
2.
1.
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Fig. 11 Position of the condensate drain
6 720 610 332-07.1R
Fig. 12 Fixing the appliance y Fit the washers onto the gas and water connections. y Lift the boiler onto the wall-mounting frame. The lugs pass through the rectangular holes in the boiler back panel. y Take care not to disturb the washers on the connections.
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15
Installation
Connecting the flue duct y Fit flue duct connector onto appliance flue spigot. y Secure with the two screws supplied.
3.9
Flue Systems
The only flue systems that may be used are those supplied by Worcester Heat Systems. The flue system must be installed in accordance with the requirements of BS5440:1. Standard 100 mm flue system The standard concentric flue system provides for a horizontal length of upto 4 m. Full instructions for fitting this flue are in Subsection 3.9.2 Installation of the flue. Alternative 125 mm diameter flue systems Installation instructions for the alternative flue systems are sent with the appropriate flue kit. Systems are available to give a maximum horizontal length of 13 m. 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 2m for each 90 bend and 1 m for each 45 bend used. IMPORTANT: Any horizontal flue system fitted to a condensing boiler must incline towards the appliance at an angle of 3 % (30 mm per metre length) to prevent condensate dripping from the flue terminal. This means that the clearance above the appliance must be increased to match the duct length. Refer to fig. 1 on page 5.
1
2
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Fig. 13 y For remaining installation of flue assembly, refer to the relevant installation instructions.
3.8
Checking the connections
Water connections y Check that the O-rings or seals are in place before tightening the connection. y Turn on the service valves for central heating flow and return and fill the heating system through a WRC approved filling loop. y Check all seals and unions for leaks (testing pressure max. 3.0 bar as indicated by pressure gauge). y Turn on cold water service cock and fill hot water system (testing pressure max. 10 bar). y Check all connections for leaks. Gas supply pipe y Check that the seal is in place before tightening the connection. y Turn off gas cock to protect gas valve against damage from excessive pressure. y Check gas supply pipe. y Release the pressure on the gas supply pipe.
16
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Installation
3.9.1 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. 14 and table 9. The terminal will, at times, give out a plume of water vapour and consideration must be given to this when choosing a terminal position. Keep clear of security
lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which people have access then a guard must be fitted. The guard must be evenly spaced about the terminal with a space of 50 mm in each direction and fixed with plated screws. A guard Type K2 for the standard horizontal flue, can be obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
Fig. 14 Minimum dimensions of flue terminal positions (all types) (see fig. 14)
Dimension A1) B 1) C 1) D E F G H I J K L M N O P Q Terminal Position (kW input expressed in net) Directly below an opening, air brick, opening windows, etc. Above an opening, air brick, opening window, etc. Horizontally to an opening, air brick, opening window, etc. Below gutters, soil pipes or drain pipes Below eaves Below balconies or car port roof From a vertical drain pipe or soil pipe From an internal or external corner Above ground roof or balcony level From a surface facing the terminal From a terminal facing the terminal From an opening in the car port (e. g. door, window) into the dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the same wall From the wall on which the terminal is mounted From a vertical structure on the roof Above intersection with roof Balanced flues room sealed: Fanned draught 300 mm 300 mm 300 mm 75 mm 200 mm 200 mm 150 mm 300 mm 300 mm 600 mm 1200 mm 1200 mm 1500mm 300 mm Not applicable Not applicable Not applicable
Table 9
1) In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
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17
Installation
3.9.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm require extension duct assemblies. NOTE: Flue lengths between 650 mm and 730 mm cannot be accomodated. Refer to fig. 16, 17, 18. 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. 19. 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. 15.
Terminal Assembly Flue Turret Maximum 650 mm
Outer Wall No Clamp

6 720 610 602 - 08.1O
Fig. 16 Standard Flue

Centre line of flue/air duct Drilling point for flue duct opening
H
Centre line of flue opening and appliance Appliance
120
3% (30 mm/meter)
Top of the wall mounting frame
H Standard Horizontal Flue 158 mm Optional Horizontal Flue 121 mm
6 720 610 602 - 07.1O
Fig. 15 Marking the position of the side flue opening
18
6 720 610 576 GB (01.07)
Installation
Terminal Assembly Flue Turret Maximum 1600mm
No Clamp
Clamp Extension Duct

6 720 610 602 - 09.1O
Outer Wall
Fig. 17 Flue with one extension
Terminal Assembly Flue Turret
No Clamp
Clamp Extension Duct Extension Duct
Clamp
Outer Wall
6 720 610 602 - 10.1O
Fig. 18 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. 19 Flue components
6 720 610 576 GB (01.07)
19
Installation
3.9.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 20, 21.
Outer Wall Face Flue Terminal
120
Raised Ring locating the terminal relative to the outside wall face
6 720 610 576 - 20.1O
NOTE: THE FLUE MUST BE INCLINED T O THE 6 720 610 602 - 12.1O BOILER
Fig. 22 Flue terminal position Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must face downwards. The assembly will be made easier if a solvent free grease is lightly applied i.e Vaseline, to the male end of the ducts. NOTE: An inner wall sealing plate is provided which should be fitted to the ducts before assembly. Push the assembly through the wall and fix the turret to the appliance with the clamp. Refer to fig. 23.
Fig. 20 Flue length - rear
NOTE: THE FLUE MUST BE INCLINED T O THE 6 720 610 602 - 13.1O BOILER
Flue Turret Air and Flue Duct Entry into silicone rubber seals
Fig. 21 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-750 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. 22. Extension air duct - L-70mm, flue duct - L-50 mm. The measurement is from the formed end.
Clamp
Flue Socket on Boiler
6 720 610 602 - 14.1O
Fig. 23 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
6 720 610 576 GB (01.07)
Electrical connections
y Always disconnect the power supply to the appliance at the mains before carrying out any work on the electrical systems and components.
4.1
Connecting the appliance
All control and safety systems are built into the appliance. y Allow mains cable to protrude at least 50 cm from wall. y To make splash-water proof (IP): cut the cable grommet hole size to match diameter of cable, see fig. 26. It must be possible to isolate the appliance. The appliance must be earthed. The appliance must be connected to the mains through a 6 A double pole isolator with a contact separation 3 mm in all poles and supplying the appliance and controls only. The wiring must comply with the current requirements of the IEE Wiring Regulations and any local regulations which apply. 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.
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. y Pull out cover panel at the bottom and remove. Refer to fig. 24.
0 2 1
4 5
6 720 610 332-10.1R
Protection IPX4D External fuse 3 A.
Fig. 24 y Remove screw and slide terminal cover forwards to remove. Refer to fig. 25.
0
2 1
4 5
6 720 610 332 -11.1R
Fig. 25
6 720 610 576 GB (01.07)
21
y Cut cable grommet to diameter of cable.

3 2 1 E
4.2
Mains Voltage external controls connections
4 5
NOTE: Only double insulated controls not requiring an earth can be used
Ns Ls LR ST8
Switched Live
Ns Ls LR ST8
Switched Live
Neutral
Neutral
Remove Link
Live
Motor
8-9 5-7
230 V Room Thermostat Connections 230 V Programmer Connections 230 V room thermostat and Programmer Connections Ns Ls LR ST8
Series connection to be made safe
Live
Li ve
ed
6 720 610 332-12.1R

Neutral Live
Live
10-12
13-14
Sw
Fig. 26 y Feed cable through cable grommet and connect the mains supply cable, see fig. 27. y Secure cable in cable grommet by means of cable grip.
L N NS L S L R
it ch
Ne
ut
ra l
Motor
6 720 610 576 - 22.1O
Fig. 28
4130-14.1R
Fig. 27
22
6 720 610 576 GB (01.07)
Live
d
Sw itc he
Commissioning
Commissioning
136 365
61
317 366 367
358
27
419
ECO
364 363 135 295

E
8.1
310
15
170
171
172
173
170
6 720 610 576-07.1O
Fig. 29
8.1 15 27 61 135 136 170 171 172 173 295 310 317 358 363 364 365 366 367 419 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 on position) Cold water service cock Appliance type sticker Temperature control for hot water Multifunction display Condensate trap Indicator lamp for burner Indicator lamp for power supply Chimney sweep button Service button ECO button Hose from automatic vent
5.1
Commissioning
Never run the appliance when empty or unpressurised.
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 and Fernox Tel.: 01799 550811. Instructions for use are supplied with the these products. y Before commissioning, the gas supply pressure must be tested (see page 29).
6 720 610 576 GB (01.07)
23
Commissioning
y Unscrew the condensation trap (358) and pull out, fill with approx. 1/4 l of water and refit. Refer to fig. 29. y Adjust charge pressure of expansion vessel to static head of the central heating system (see page 26). y Open all system radiator valves. y Turn on service valves (170), fill central heating system to pressure of 1 - 2 bar through the WRc approved filling loop. Refer to fig. 29. y Vent radiators. y Refill heating system and set the pressure to 1 bar. y Turn on cold water service cock (173). Refer to fig. 29. y Check that the gas type specified on the identification plate matches that of the gas supply. y Turn on gas cock (172). Refer to fig. 29.
5.3
Switching on the central heating
The central heating flow temperature is adjustable between 35 C and 88 C. Refer to table 12, page 26. y 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 26). When the burner is alight, the red indicator lamp lights up.
5.2
Switching the appliance on/off
Switching on y 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. Fig. 31
6 720 610 333-05.1O
5.4
System controls
6 720 610 333-04.1O
Fig. 30
y Set room thermostat to the desired room temperature. y Set outside - temperature driven control unit, if fitted. Refer to the instructions with the control. y Set the thermostatic radiator valves to the desired settings.
If the display alternates between -II- and the central heating flow temperature, the trap filling programme is active.
5.5
Setting the domestic hot water temperature and flow rate
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. Switching off the appliance y Set the master switch to (0). The green indicator lamp goes out. The optional timer will continue running until the emergency supply is exhausted.
5.5.1 Domestic hot water temperature The hot water temperature can be set to between approx. 40 C and 60 C. This temperature is not shown on the display.
6 720 610 333-07.1O
Fig. 32 y Always disconnect the appliance from the power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or components.
24
6 720 610 576 GB (01.07)
Commissioning
Setting Turn fully anti-clockwise
Hot Water temperature approx. 40 C approx. 55 C approx. 60 C
5.6
Summer mode (hot water only)
With room thermostat y 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.
l
Turn fully clockwise Table 10
ECO button By pressing and holding the ECO button , until the display lights, you can switch between Comfort mode and Economy mode. Comfort mode: button is not lit (factory setting) The appliance is held constantly at the set temperature. This means that hot water is available almost instantaneously at the tap. Consequently the appliance will switch on at intervals, even if no hot water is being drawn. ECO mode with demand detection, button is lit The demand detection function enables maximum gas and water economy. Briefly turning a hot water tap on and then off again 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. 5.5.2 Hot water flow rate The flow rate is factory set to 8 l/min. Under standard conditions (2 bar) supply pressure, one full turn is equivalent to approximately 2 l/min. y To increase the flow rate (max. 14 l/min): turn screw on flow switch anti-clockwise (+). The outlet temperature will decrease relative to the increase in the flow rate. y To reduce the flow rate (min. 8 l/min): turn screw on flow switch clockwise (). The outlet temperature will increase relative to the decrease in the flow rate.
5.7
Frost protection
y Leave master switch switched on. If the appliance is to be left for long periods switch the central heating off: y Add a suitable anti-freeze fluid to the water in the central heating system. Suitable products are available from Betz-Dearborn Tel.: 0151 4209563 and Fernox Tel.: 01799 550811.
5.8
Pump anti-seize function

This function prevents the central heating pump seizing after long periods of 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 5 minutes.
5.9
Fault Condition
A list of faults that may occur is given on page 42.
In the unlikely event of a fault occuring while the appliance is in operation: The display then shows a fault code and the button may also flash. If the button flashes: y 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:
y 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.
6720 610 332-25.1O
Fig. 33
6 720 610 576 GB (01.07)
25
Individual settings
6
6.1
Individual settings
Mechanical settings
y Rotate yellow button through 180 and replace (dot facing inwards). The CH flow temperature is no longer limited. Control setting 1 2 3 4 5 E max Table 12 litres litres 82 46 6.1.3 Changing the heating pump characteristic The speed of the central heating pump can be altered on the pump terminal box. CH flow temperature approx. 35 C approx. 43 C approx. 51 C approx. 59 C approx. 67 C approx. 75 C approx. 88 C
6.1.1 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 11. System Capacity BS7074:1
Expansion Vessel Pressure and System Capacity
Expansion Vessel Expansion Vessel Charge Pressure System pressure and capacity Table 11 6.1.2 1 bar 1.5 bar
litres bar
10 0.75
i
H
(bar)
Setting the central heating flow temperature The central heating flow temperature can be set to between 35 C and 88 C.
At switch position 1, maximum output is not delivered if hot water mode is active. Position 1 must not be used on combi appliances.
0,7 0,6 0,5 0,4
With underfloor heating systems, observe the maximum permissible flow temperatures.
3 2
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. y Lift off the yellow button on the temperature control with a screwdriver.
0,3 0,2 0,1 0
200
400
600
800
1000 1200 1400 1600
Q (l/h)
6 720 610 576 - 23.1O
Fig. 35
1 2 3 H Q Pump characteristic for switch position 1 Pump characteristic for switch position 2 Pump characteristic for switch position 3 Residual delivery pressure Water circulation rate
6 720 610 332-27.1O
Fig. 34
26
6 720 610 576 GB (01.07)
Individual settings
6.2
Settings on the Bosch Heatronic

Entering a setting y To enter the setting for a function, turn the temperature control . Storing a setting y Level 1: press and hold the button until the display shows [ ]. y Level 2: press and hold the and buttons simultaneously until the display shows [ ]. After completing the settings y Reset the temperature controls original positions. 6.2.2
6 720 610 332-30.1O
6.2.1 Operating the Bosch Heatronic The Bosch Heatronic enables easy setting and checking of a large number of appliance functions. This description is limited to those functions required for commissioning. For a full description of all available functions, please refer to the Service booklet for the Engineer, number 7 181 465 346.
2 5 1
and
to their
Selecting the pump control mode for central heating mode (Service Function 2.2) If an outside temperature driven control unit is connected, pump control mode 3 is automatically activated
Fig. 36 Appliance controls

1 2 3 4 5 Service button Chimney sweep button Temperature control for central heating Temperature control for hot water Display
The choice of settings is as follows: Control Mode 1 For heating equipment without a control unit. The pump is controlled by the central heating flow temperature control. Control Mode 2 (factory setting) For heating systems with room thermostat. The central heating flow temperature control controls only the gas, the pump is not affected. The room thermostat controls both the gas and the pump. The pump and fan have an overrun time of between 15 s and 3 min. Control Mode 3 The pump is controlled by the outside temperature driven control unit. In summer mode, the pump operates only for hot water mode. 6.2.3 Setting the anti-cycle time (Service Function 2.4) This service function is only active if Service Function 2.7, automatic anti-cycle time, is 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).
Selecting service function:
Note the positions of the temperature controls and . After completing the settings, return the temperature controls to their original positions.
The service functions are subdivided into two levels: Level 1 comprises service functions up to function 4.9, while Level 2 consists of the service functions from 5.0 upwards. y To select a service function on Level 1: press and hold the button until the display shows . y To select a service function on Level 2: press and hold the buttons and simultaneously until the display shows = =. y Then turn the temperature control to select the required function. Service function Code no. Pump control mode 2.2 Anti-cycle time 2.4 Max. CH flow temperature 2.5 Switching difference 2.6 Max. heating output 5.0 Constant hot water cycle time 6.8 Table 13 The service function 5.0 may be reset. See page 27 27 28 28 28 28
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.
6 720 610 576 GB (01.07)
27
Individual settings
6.2.4
Setting the maxim CH flow temperature (Service Function 2.5) The maximum CH flow temperature can be set to between 35 C and 88 C (factory setting). 6.2.5 Setting the switching difference (Service Function 2.6) If the appliance is connected to an outside-temperature controlled programmer, the programmer sets the switching difference. It does not need to be set on the appliance.
y Refer to the settings tables for heating and cylinder charging output to obtain the relevant code for the desired heating output in kW (see page 44). y Turn the temperature control until the display shows the desired code number. The display and the and buttons will flash. y Measure the gas flow rate and compare with the figures specified for the code number displayed. If figures do not match, adjust the code number! y Press and hold the and buttons simultaneously until the display shows [ ]. The heating output is now stored.
The switching difference is the permissible divergence from the specified CH flow temperature. It can be set in increments of 1 K. The adjustment range is 1 to 30 K (is factory set to 0 K). The minimum CH flow temperature is 30 C.
6 720 610 332-52.1O
6.2.6
Setting the heating output (Service Function 5.0) 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.
Fig. 39 y Return the temperature controls and to their original positions. The display will revert to the CH flow temperate. 6.2.7 Constant hot water cycle time (Service Function 6.8) In Comfort mode ECO light off , the hot water inside the appliance is held constantly at the set temperature. For that reason, the appliance switches on if the water temperature falls below a certain temperature. In order to prevent it switching on and off too frequently, the constant hot water cycle time service function allows you to set the minimum period between switching off and on again. This function has no effect on normal demand for hot water and relates only to the constant hot water function in Comfort mode. The cycle time can be set to any period between 20 and 60 minutes (is factory set to 20 minutes).
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. y Press and hold the and buttons simultaneously until the display shows = =. The and buttons will light up.
6 720 610 332-50.1O
6.3
Setting the gas/air ratio
Fig. 37 y Turn the temperature control until the display shows 5.0. After a short delay, the display then shows the set heating output in percent.
Refer to section 7.1 for details of the method of setting the gas/air ratio.
6 720 610 332-51.1O
Fig. 38
28
6 720 610 576 GB (01.07)
Converting the appliance to different gas types

7.1 Setting the gas/air ratio
y Switch off the appliance at the master switch (O). y Remove the outer case (see page 15, refer to fig. 12). y Switch on the appliance at the master switch (I). y Unscrew sealing plug from flue gas testing point (234). Refer to fig. 40. y Insert testing probe about 135 mm into the flue gas testing point and seal testing point.
The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not necessary. 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. Checking the gas supply pressure y Check the gas supply pressure at the gas supply pressure testing point.
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.
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
234
6 720 610 332-57.1R
Model ZWB 7-27 HE combi ZWB 11-27 HE combi
For conversion from ... N.G to L.P.G L.P.G to N.G
Fig. 40 Order no. 7 710 149 044 7 710 239 080 y Press and hold button until the display shows . The button will light up.
Table 14 Instructions are sent with each conversion kit. Fig. 41
6 720 610 332-32.1O
y Turn the temperature control until the display shows 2.0 . After a short delay, the current operating mode setting will be displayed (0. = Normal mode).
6 720 610 332-60.1O
Fig. 42
6 720 610 576 GB (01.07)
29
y Turn the temperature control until the display shows 2. (= max. rated heat output). The display and the button will flash.
y Turn the temperature control anti-clockwise until the display shows 1. (= min. rated heat output). The display and the button will flash.
6 720 610 332-63.1O 6 720 610 332-61.1O
Fig. 45 y Measure the CO2 level. y Remove the seal from the gas valve adjusting screw (64) and adjust the CO2 level to the figure given in Table 15 for min. rated heat output.
Fig. 43 y Measure the CO2 level. y Prise off the seal on the gas flow restrictor. y Adjust the gas flow restrictor (63) to obtain the CO2 level given in Table 15. Refer to fig. 44.
63
6 720 610 332-64.1R
Fig. 46 y Measure the CO level. If the CO level is over 300 ppm, the gas volumetric flow rate is too high. Reduce the gas flow rate on the adjustable gas flow restrictor (63) until the CO level is below 100 ppm. y Re-adjust the CO2 level if necessary. y Recheck the levels at min. and max. rated heat output and re-adjust if necessary. y Turn the temperature control anti-clockwise as far as the stop so that the display shows 0. (= Normal operating mode). The display and the button will flash. y Press and hold the button until the display shows [ ]. y Reset the temperature controls and to their original positions. The display will revert to the CH flow temperature. y Remove testing probe from the flue gas testing point (234) and refit sealing plug. y Re-seal gas valve adjusting screw and gas flow restrictor. y Replace outer case and secure.
Fig. 44 CO2 reading at max. rated heat output 9.5 % 11.3 %
Gas Type Natural gas type H (23) LPG (propane) Table 15
CO2 reading at min. rated heat output 9.2 % 11.0 %
y Measure the CO level. If the CO level is over 300 ppm, the gas volumetric flow rate is too high. Reduce the gas flow rate on the adjustable gas flow restrictor (63) until the CO level is below 100 ppm. y Re-adjust the CO2 level if necessary.
30
6 720 610 576 GB (01.07)
7.2
7.2.1
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 %. 7.2.2 Testing CO and CO2 y 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.
y 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.
You have 15 minutes in which to measure the levels. After that, the appliance switches back from chimney sweep mode to normal mode.
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.
y Remove sealing plug from flue gas testing point (234, fig. 47). y Insert testing probe about 135 mm into the testing point and seal testing point. y CO- and CO2 levels. y Refit sealing plug. y Press and hold button until the display shows . The button will stop flashing and the display shows the CH flow temperature.
y Remove sealing plug from combustion air testing point (234.1, fig. 47). y Insert testing probe about 80 mm into the testing point and seal testing point.
234
234.1
6 720 610 332-65.1R
Fig. 47 y Measure O2 and CO2 levels. y Refit sealing plug. y Press and hold button until the display shows . The button will stop flashing and the display shows the CH flow temperature.
6 720 610 576 GB (01.07)
31
Maintenance
Maintenance
y Always disconnect the appliance from the electrical power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or components. y Always turn off the gas cock before carrying out any work on components which carry gas.
i i
There is a Service booklet for the Engineer, order no. 7 181 465 346, available to competent persons. All safety and control systems are monitored by the Bosch Heatronic. In the event of a component fault, the display shows a fault code.
y The User should be recommended to have the appliance serviced regularly by a competent person (see Maintenance Contract). y Use only genuine spare parts y Refer to the Spare Parts List when ordering spare parts. y Always renew seals and O-rings removed during servicing or repair work. y Use only the following types of grease: Water valve: WRc approved silicon based grease Unions: approved sealant. y To drain the appliance shut the system valves and open the pressure relief valve.
32
6 720 610 576 GB (01.07)
Maintenance
8.1
Pre-Service Check List

Date
Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 34). Check ionisation current, Service Function 3.3, (see page 34). Perform visual check of air/flue duct. Check gas supply pressure (see page 29). Test combustion air/flue gas (see page 31). Check CO2 setting for min./ max. (gas/air ratio) (see page 29). min. % max. % mbar
2 3 4 5 6
7 8 9
Check gas and water systems for leaks (see page 16). On combi models, check hot water outlet temperature (see page 34). Check heat exchanger (see page 34). mbar
10 Check burner (see page 35). 11 Clean condensation trap (see page 36). 12 Check charge pressure of mbar expansion vessel matches static head of heating system. 13 Check central heating system mbar pressure. 14 Check electrical wiring for damage. 15 Check heating programmer settings. 16 Check appliances that are part of the heating system Table 16
6 720 610 576 GB (01.07)
33
Maintenance
8.2
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 7.2. Check Last fault stored: y Select Service Function .0 (see page 27 Selecting service function). There is a list of the fault codes in the Appendix (see page 42. To delete Last fault stored: y Turn temperature control anti-clockwise as far as the stop. y Press and hold the button until the display shows [ ]. The last fault stored has now been deleted. Checking the ionisation current, Service Function 3.3 y Select Service Function 3.3 (see page 27 Selecting service function). 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. Domestic hot water If the flow rate is too slow: y remove the domestic hot water heat exchanger and replace, -ory descale with a descaling agent approved for use on stainless steel. y Before removing the heat exchanger shut the inlet valve and drain the hot water circuit. y Use new seals when replacing the heat exchanger.
Primary Heat exchanger There is a special accessory kit (no. 840) for cleaning the heat exchanger, order no. 7 719 001 996. y Check control pressure on the air - gas mixer unit at max. rated heat output using an electronic manometer.
6 720 610 332-69.1R
Fig. 49
The heat exchanger should only be cleaned if the control pressure is 2.2 mbar (depression) or less.
y Remove cleaning access cover (415, page 6) and the metal plate below it, if present. Refer to fig. 2. y Unscrew condensation trap and place suitable container underneath. Refer to fig. 50. y Remove the fan and the burner as described in the text headed Burner (see page 35).
6 720 610 332-72.1R
Fig. 50
7 181 465 330-06.1R
Fig. 48
34
6 720 610 576 GB (01.07)
Maintenance
y Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade. Refer to fig. 51.
Burner y Check that the gas cock is turned off and the master switch is in the OFF position. y Remove the clips (1) and unscrew the two bolts (2). Refer to fig. 54. y Unscrew and remove the two hexagon screws securing the fan (3). y Slacken fully the rear securing bolt (4). y Remove the burner coverplate.
4.
6 720 610 332-73.1R
Fig. 51 y Clean the heat exchanger from top to bottom using the brush. Refer to fig. 52.
2. 3. 1.
7 181 465 330-04.1R
Fig. 54 y Remove burner and clean components. Do not use a wire brush. Refer to fig. 55.
6 720 610 332-74.1R
Fig. 52 y Remove the fan and the burner (see section headed Burner) and flush the heat exchanger from the top. y Clean out the condensate collector and trap connection (with other end of brush).
1.
H 2O
2.
7 181 465 330-08.1R

6 720 610 332-75.1R
Fig. 53 y Refit the clean-out cover using a new seal and tighten screws to torque of approx. 5 Nm.
Fig. 55 y Re-assemble burner in reverse order using a new seal. y Adjust gas/air ratio. Refer to section 7.2.
6 720 610 576 GB (01.07)
35
Maintenance
Condensation trap In order to prevent spillage of condensate, the condensation trap should be completely removed, (see page 34, fig. 50). y Unscrew condensation trap and check connection to heat exchanger is clear. y Remove condensation trap cover and clean. y Fill condensation trap with approx. 1/4 l of water and refit. Electrode assembly y Switch off the master switch. y Pull off the leads from the electrodes. Refer to fig. 2. y Unscrew the two fixing screws and carefully remove the electrode assembly. Refer to fig. 49. y Clean the electrodes with a non-metallic brush. (The spark gap should be 4,5 mm 0,5 mm.) y Replace and re-connect the assembly taking care not to mislay the inspection window. Siphon y Unscrew the clip and disconnect the pipe to the siphon. y Remove the yellow plug to drain the siphon. y Unscrew the securing nut from beneath the side facia and remove the siphon. Refer to figure below. y Refit and prime the siphon.
Expansion vessel The expansion vessel should be checked once a year. y Depressurise appliance. y If necessary, adjust expansion vessel charge pressure to static head of the heating system. Heating system pressure
Fill the system using the WRc approved filling loop.
y The pointer on the pressure gauge should be 1 bar. y If the pointer is below 1 bar (when the system is cold), water should be added until the pointer is 1 bar again. y 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. y If the system does not retain the pressure, the expansion vessel and the heating system should be checked for leaks. Electrical wiring y Check the electrical wiring for physical damage and replace any damaged wires.
Condensate Drain
Siphon
6 720 610 602 - 16.1O
Fig. 56
36
6 720 610 576 GB (01.07)
Maintenance
8.3
Replacement of Parts
y Remove the pcb control board.
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. 8.3.1 PCB control board and transformer
y Switch off the appliance. y Disconnect appliance from the power supply. y Unplug all connectors from the control box (inc. keyed plug). Access is gained by removing the covers. Refer to fig. 24, 25. y Remove screw holding power connector earth lead and remove earth lead. y Remove two top fixing screws from the control box. Refer to fig. 57.
1
3 2 4
7 181 465 330-10.1R

3 2 1 E 4 5
1
3 2 4
Fig. 58 Fuses
7 181 465 329-02.1R
Fig. 57 y Lower the control box. y Unscrew earth lead. y Unscrew four fixing screws from cover plate. Refer to fig. 58. y Prise off cover plate. y Pull off transformer. y Remove pcb holder.
6 720 610 576 GB (01.07)
3 2 4
y Remove the connections covers. Refer to fig. 24, 25. The fuses are located adjacent to the mains connector block and connector ST18. Refer to fig. 4. Fuse, item 312, is only replaceable by removing the pcb. Spare fuses are fixed to the connections cover. A fuse pack is available: Part number 8 744 503 010 0.
37
Maintenance
8.3.2
Fan Assembly
8.3.3
Pump
3. 2.
4.
y Switch off the appliance. y Disconnect the appliance from the power supply. y Remove two switchbox fixing screws (1.). Refer to fig. 60. y Lower switchbox (2.). y Unscrew and remove the the siphon by releasing the jubilee clip. Refer to fig. 56. y Unscrew the pump union nuts (3.). Refer to fig. 60. y Carefully remove the pump and disconnect the leads. Alternatively y After removing the siphon release the four Allen screws and remove and replace the pump head.
3. 1.
Fig. 59 y Switch off the appliance. y Disconnect the appliance from the power supply. y Undo lower pipe union on gas pipe (1.). Refer to fig. 59. y Remove fan lead and earth connector (2.). The earth connector has a positive clip fixing. y Remove fixing screws attaching fan to the burner cover (3.). y Remove fan together with gas pipe and mixer unit. y Separate the fan from the pipe and mixer unit by twisting the mixer unit to release it (4.).
7 181 465 330-05.1R
1.
1.
2.
Fig. 60
38
6 720 610 576 GB (01.07)
Maintenance
8.3.4 y y y y y y y y y y
3-way diverter valve
8.3.6
Sensors
Switch off the appliance. Disconnect appliance from the power supply. Turn off service cocks. Unplug connector from 3-way valve motor. Refer to fig. 61. Pull out retaining clip. Remove motor. Disconnect the relief valve drain. Disconnect the pressure gauge. Undo pipe unions. Remove 3-way valve.
y Check that the appliance is electrically isolated. Central Heating Flow Temperature Sensor Item 36, fig. 2, 57 y Pull-off the connector. y Release the sensor clip and withdraw the sensor. y Apply heat transfer paste to the replacement sensor. Safety Temperature Limiter Item 6, fig. 2, 57 y Pull-off the connectors. y Unscrew the sensor. Flue Temperature Limiter Item 9, fig. 2, 57 y Pull-off the connectors. y Unscrew the sensor. Domestic Hot Water Temperature Sensor Item 6.1, fig. 2 y Check that the inlet water valve is closed and the domestic hot water circuit is drained. y Release and pull-off the connector. y Unscrew the sensor.
7 181 465 330-12.1R
Fig. 61 After refitting: y Fill system, bleed and re-pressurise (see Installation Instructions). 8.3.5 3-way diverter valve motor
y Switch off the appliance. y Turn off the service cocks. y Unplug connector from 3-way valve motor. Refer to fig. 61. y Pull out retaining clip. y Remove motor.
6 720 610 576 GB (01.07)
39
Maintenance
8.3.7
Gas Valve
8.3.8
Domestic Hot Water Heat Exchanger
y Check that the gas cock is turned off. y Lower the control panel. Refer to fig. 60. y Pull off the solenoid connections at the rear of the valve. y Undo the union, within the inner casing, securing the valve to the gas/air tube. Refer to fig. 59. y Remove the white plastic cap from the gas valve. y Release the gas inlet union at the manifold assembly. y Unscrew the two screws securing the gas valve assembly bracket to the back panel and withdraw the assembly. y Transfer the bracket and inlet pipe assembly to the new gas valve. y Check for gas soundness when the new gas valve has been fitted. y Recheck the combustion performance as described in section 7.1.
y Refer to section 7.2. y Use new seals when fitting the new heat exchanger. 8.3.9 Electrode assembly
y Refer to section 7.2. y Use a new seal if the existing seal is damaged. 8.3.10 Pressure gauge y Drain the appliance. y Lower the facia. Refer to fig. 60. y Twist the pressure gauge head anti-clockwise to release it from the casing. Refer to fig. 2. y Disconnect the capillary head from the rear of the diverter valve by withdrawing the clip and pulling out the head. Refer to fig. 61. 8.3.11 Expansion vessel y Drain the appliance. y Undo the union connection at the base of the vessel. Refer to fig. 2. y Unscrew the top and bottom fixing screws and remove the vessel. y Set the pressure of the new vessel to that required by the system. 8.3.12 Pressure Relief Valve y Drain the appliance. y Disconnect the drain pipe from the valve. Refer to fig. 29. y Pull-out the clip securing the valve. y Pull-out the valve. y Ensure that the replacement valve is fully entered before fitting the clip. 8.3.13 Burner y Refer to section 8.2.
6 720 610 602 - 04.1O
Fig. 62
40
6 720 610 576 GB (01.07)
Maintenance
8.3.14 Flow switch y Shut the mains water inlet valve and drain the domestic hot water circuit. y Pull-off the connectors from the micro-switch. y Unscrew the inlet and union connection and remove the assembly. y Reset the domestic hot water flow rate on the new assembly.
y Pull forward from the top and lift the heat exchanger from the casing. y Transfer components, as necessary, to the new heat exchanger. y Ensure that all the seals are in place and all of the connections are tight before re-commissioning the appliance.
OUTLET
INLET
6 720 610 602 - 05.10
Fig. 63 8.3.15 Primary Heat Exchanger y y y y y y y y Drain the appliance. Check that the gas supply is turned off. Check that the appliance is electrically isolated. Remove the fan assembly complete with the gas/air tube and mixer assembly. Refer to section 8.3.2. Remove the burner. Refer to section 8.2. Disconnect the sensors. Refer to section 8.3.6. Undo the central heating flow union. Undo the top connection of the pump. Refer to fig. 60.
6 720 610 602 - 06.10
Fig. 64
y Undo the grey plastic cap, next to the top pump connection at the base of the heat exchanger. y Unscrew and remove the condensate trap. Refer to section 8.2. y Unscrew and remove the two screws securing the heat exchanger top bracket to the rear panel. y Lift up the flue duct, item 271, refer to fig. 2.
6 720 610 576 GB (01.07)
41
Appendix
9
9.1
Appendix
Fault Codes
More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.
Display code A7
Description Hot water NTC sensor defective. Break in communication Module not detected. Keyed plug not detected. Fan speed too low. Jumper 8-9 not detected. CH flow NTC sensor defective Safety temp. limiter in CH flow has tripped.
Remedy Check hot water NTC sensor and connecting lead for circuit breaks/short circuits. Check connecting lead to programmer Check connecting lead between TA211E/TR212E and Heatronic Insert keyed plug correctly, test and replace if necessary. Check fan lead and connector, and fan; replace as necessary. Connector not connected, link missing, underfloor heating limiter tripped. Check CH flow NTC sensor and connecting lead. Check system pressure, check safety temp. limiters, check pump operation, check fuse on pcb, bleed appliance. 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. Check electrical connector contacts, programmer interface module ignition leads are not loose; replace pcb if necessary. Check electrode assembly, dry pcb. Flue clear? Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue clear? Press reset button again 24 V fuse blown. Replace fuse.
A8 AC
b1 C1 d3
E2 E9
EA
Flame not detected.
F0
Internal error.
F7 FA
Flame detected even though appliance switched off. Flame detected after gas shut off.
Fd P1, P2, P3, P1...
Reset button pressed by mistake. Please wait, initialisation in progress.
Table 17
42
6 720 610 576 GB (01.07)
Appendix
9.2
Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Short parts list

Description Sensor - Flue gas temp. Sensor - CH flow temp. Sensor - DHW flow temp. Control board Gas valve Fan assembly Fan washer Expansion vessel Relief valve Electrode assembly Electrode lead Pump Pressure gauge Burner skin seal Transformer - facia Flow switch 3-way diverter valve Heat exchanger washer Washerset Condenstaion Trap Fuseset Serviceset Water Valve Domestic Hot Water Heat Exchanger Primary heat exchanger Qty GC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Spare part number 8 729 000 144 0 8 714 500 087 0 8 714 500 054 0 8 748 300 418 0 8 747 003 516 0 8 717 204 373 0 8 729 000 183 0 8 715 407 236 0 8 717 401 012 0 8 718 107 077 0 8 714 401 999 0 8 717 204 477 0 8 717 208 079 0 8 711 004 168 0 8 747 201 358 0 8 717 002 110 0 8 717 010 062 0 8 710 103 153 0 8 710 103 154 0 8 744 503 010 0 8 710 503 031 0 8 715 406 659 0 8 715 406 615 0
Table 18
6 720 610 576 GB (01.07)
43
Appendix
9.3
Heating/hot water output settings (N.G.)

Natural gas G20
Display code 30 40 50 60 70 80 90 100
Heat output kW 8.2 10.9 13.6 16.3 19.1 21.8 24.5 27.2
Heat input kW 8.3 11.0 13.8 16.5 19.3 22.0 24.8 27.5
Gas vol. flow rate (l/min at tV/tR = 80/60 C) 14.4 19.3 24.1 28.9 33.7 38.5 43.3 48.1
Table 19
9.4
Heating/hot water output settings (L.P.G)

Propane
Display code 40 50 60 70 80 90 100
Heat output kW 10.9 13.6 16.3 19.1 21.8 24.5 27.2
Heat input kW 11.0 13.8 16.5 19.3 22.0 24.8 27.5
Table 20
44
6 720 610 576 GB (01.07)
9.5
9.5.1
Fig. 65
Ignition sequence Ignition spark 5 secs
6 720 610 576 GB (01.07)

Burner lights. Red light ON. Burner shut-down if primary temperature exceeds 94 C remains OFF until 78 C
Pump ON Diverter valve operates.
Fan to start speed. Gas valve opens.
Pre-heat satisfied.
Domestic hot water function
Operational Flow diagrams
Burner remains OFF until flow temperature is below set value. Gas valve shuts. Pump remains ON.
Over temperature shut-down if water temperature is 8C above set value.
** NOTE: The appliance controls can be set to one of 2 modes of operation. 1. Comfort mode Full pre-heat 2. ECO mode a) Operates as an instantaneous combination boiler. b) Demand Detection: a short demand (less than 5 seconds) switches the control to Comfort mode for 5 mins. Mini pre-heat. The Factory setting is Comfort mode.
. Pump ON Diverter valve operates. Demand ends. Fan to start speed. Gas valve opens. Heat input modulates to maintain the delivery temperature. Gas valve closes. Red light OFF. Fan runs for upto 3 mins. Pump runs for 30secs. Pre-heat mode.**
Mains switch ON.
Green light ON.
Pre-heat mode.**
Hot water demand.
Ignition sequence
Ignition spark for 5 seconds.
Burner lights. Red light ON.
Yes
No
Fan runs to purge gas from burner.
6 720 610 576 - 24.1O
Repeats 5 times before lock-out.
Appendix
45
46
Burner remains OFF until flow temperature is below set value. Gas valve shuts. Pump remains ON. Over temperature shut-down if water temperature is 5C above set value.
9.5.2
Fig. 66 Central heating function

CH demand. Pump ON Fan to start speed. Gas valve opens. Fan min. speed for 90 secs. Burner stabilises at start speed for 5-10 secs Fan speed reduces over 15 secs. Boiler unused for long period.*
Appendix
Mains switch ON.
Green light ON.
Yes
* Minimum heat input for 15min.
No
ce
Room thermostat and/or mains programmer or link ON AND Electronic facia programmer (if fitted) ON AND CH control knob ON.
Boiler operates to match system load and CH control setting.
Ignition sequence
Yes
CH demand satisfied.
Gas valve closes. Red light OFF.
Pump and Fan run for upto 3 mins.
No
* NOTE: The sequence ensures that the condensate siphon is not empty after long OFF periods. (More than 24 hours without a demand).
6 720 610 576 - 25.1O
6 720 610 576 GB (01.07)
Appendix
6 720 610 576 GB (01.07)
47
Appendix
EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624 Fax: (01905) 754619
Appendix
9.3

Natural gas G20
Display code 30 40 50 60 70 80 90 100
Heat output kW 8.2 10.9 13.6 16.3 19.1 21.8 24.5 27.2
Heatinput kW 8.3 11.0 13.8 16.5 19.3 22.0 24.8 27.5
Table 17
9.4

Propane
Display code 40 50 60 70 80 90 100
Heat output kW 10.9 13.6 16.3 19.1 21.8 24.5 27.2
Heat input kW 11.0 13.8 16.5 19.3 22.0 24.8 27.5
Table 18
42
6 720 610 596 GB (01.07)
9.5
9.5.1
Fig. 61
6 720 610 596 GB (01.07)
Central heating function
Mains switch ON. CH demand.
Green light ON.
Pump ON Fan to start speed. Gas valve opens. Fan min. speed for 90 secs.
Burner stabilises at start speed for 5-10 secs
Fan speed reduces over 15 secs.
Boiler unused for long period.*
Yes
No
ce
Ignition sequence
Yes
No
6 720 610 576 - 25.1O
Appendix
43
Appendix
AZB 800
Vertical Flue Gas Ducting 60/100 mm 7 719 001 884
120 1310 98.5 50 125

6 720 610 703-00.1O
535
for Gas Condensing Boilers: ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2
ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 11-35 HE plus
6 720 610 703 (01.07) OSW
125
Contents
Contents
Safety instructions Symbols 1 1.1 1.2 1.3 1.4 2 Use General Gas condensing boilers Combination with flue duct kits Standard specifications Fitting space requirements for gas condensing boiler Examples of installation of vertical flue duct with roof exit Straight flue ducting without elbows Straight flue ducting with two 45-elbows Straight flue ducting with two 90-elbows Flue ducting with more than two elbows Mounting Notes on fitting Roof-exit clearances Fitting the flue ducting 2 2 3 3 3 3 3
Safety instructions
Proper functioning of this product is only guaranteed if these installation instructions are correctly followed. Subject to alteration. Installation must be carried out by an approved installer. Installation of the boiler must be carried out in accordance with the appropriate installation instructions. If you smell fumes from the appliance B Switch off appliance. B Open windows and doors. B Inform your heating engineer. Fitting and modifications 4 B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance with 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.
3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3
5 5 5 6 7 8 8 8 9
Symbols
Notes are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.
6 720 610 703 (01.07)
Use
1
1.1
Use
General 1.4 Standard specifications
The installation of a gas condensing boiler must be in accordance with the relevant British Standard, the relevant Building Regulations and any local rules. The surface temperature of the fresh air duct is below 85C. Therefore no minimum distances to combustible building materials are necessary. The regulations can deviate, however, and might prescribe minimum distances to combustible materials. The flue gas accessory is part of CE approval when discharging flue gas. For this reason, only the original flue gas accessories may be used.
120
535
1.2
Gas condensing boilers
B4
The AZB 800 can be used in conjunction with the following gas condensing boilers: Gas condensing boilers ZWB 7-29 CC1 ZB 7-28 CS1
50 125
Prod.-ID-No.
98.5
ZSBR 7-28 ICS1 ZWBR 8-30 ICC2 ZBR 8-35 ICS1 CE 0085 BL 0507 ZWBR 11-37 ICC2 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 11-35 HE plus Table 1 Fig. 1
B4: B4.1:
B4.1
125
6 720 610 703-01.1O
Vertical Flue Gas Ducting AZB 800 Adapter 80/125 - 60/100
1.3
Combination with flue duct kits
The AZB 800 can be combined with the following flue duct kits: Flue duct kits AZB 802, elbow 90 AZB 803, elbow 45 AZB 804, extension 1000 mm Table 2
1310
6 720 610 703 (01.07)
Fitting space requirements for gas condensing boiler

B C ZSBR 7-28 ICS1 ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2 ZWBR 7-28 HE plus ZWBR 11-35 HE plus B C
ZWB 7-29 CC1 ZB 7-28 CS1 ZWB 7-27 HE combi ZB 7-27 HE system
440 mm
5 mm
512 mm
100 mm
Table 3
98.5
C
85 120
850
1150
360
77 835
6 720 610 703-02.1O
Fig. 2
Flat roof
835 98.5
C
85 957 120
850
360
B
6 720 610 703-03.1O
Fig. 3
Inclined roof
77
6 720 610 703 (01.07)
Examples of installation of vertical flue duct with roof exit
3
3.1

Straight flue ducting without elbows
Lmax
3.2
Straight flue ducting with two 45-elbows

Lmax
ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 11-35 HE plus
6.4 m
4.4 m
Table 4
Table 5
535
1310
1310
1000
B2
B2
B2 B4.1
1000
B6 B6
1000 71
B2 B4.1
6 720 610 703-04.1O
Fig. 4 Key to Fig. 4 and 5:

B2: B4: B6: AZB 804 AZB 800 AZB 803
1000
6 720 610 703-05.1O
Fig. 5
L
5
98.5
6 720 610 703 (01.07)
B4
535
120
120
B4
98.5
3.3

535
Lmax
120 1310
2.4 m
B4 B3
98.5 1000
Table 6
B3
1000
B2
B2
1000
535
120
1310
B2
B4.1
B4
6 720 610 703-07.1O
98.5 1000
Fig. 7
B2 B3
1000
140
B2 B4.1 B4
1000 98.5
6 720 610 703-06.1O
B2
1000
Fig. 6 Key to Fig. 6, 7 and 8:

B2: B3: B4: AZB 804 AZB 802 AZB 800
B2 B3
1000
B3
1000
B2
B2
B4.1
6 720 610 703-08.1O
Fig. 8
6 720 610 703 (01.07)
1310
B3
535
120
3.4
Flue ducting with more than two elbows
The equivalent pipe length, Le, is calculated from the sum of the straight lengths of the horizontal and vertical flue ducting (Lhoriz , Lvert ) and the equivalent lengths of the elbows. The equivalent length of every elbow fitted must be included. The overall equivalent pipe length must be less than the maximum equivalent pipe length: Le Le,max. For vertical flue ducting the following equivalent lengths apply: Equivalent lengths of additional elbows
90
Example: For a vertical flue system with a vertical length of 4 m and two 45-elbows, the equivalent pipe length is calculated as follows: Length/ Number Straight length Lvert Straight length Lhoriz Elbow 90 Elbow 45 4m x 0m x 0 x 2 x Sectional equivalent length 1 = 1 = 2m = 1m =
Total 4m 0m 0m 2m 6m 6.4 m o.k.
Vertical flue ducting
Equivalent pipe length Le Maximum equivalent overall pipe length Le,max Le Le,max
Boiler ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 11-35 HE plus Table 7 Pipe lengths
Le,max [m]
1545
[m]
[m]
Table 8 At 6 m, the equivalent pipe length is shorter than the maximum equivalent overall length of 6.4 m. This flue system is therefore acceptable. 6.4 2 1 Example: For a vertical flue system with a vertical length of 2 m, a horizontal length of 0.4 m and two 90-elbow, the equivalent pipe length is calculated as follows: Length/ Number Straight length Lvert Straight length Lhoriz Elbow 90 Elbow 45 2m x 0.4 m x 2 x 0 x Equivalent pipe length Le Maximum equivalent overall pipe length Le,max Le Le,max Sectional equivalent length 1 = 1 = 2m = 1m =
Le,max: maximum equivalent overall pipe length
Total 2m 0.4 m 4m 0m 6.4 m 6.4 m o.k.
Table 9 At 6.4 m, the equivalent pipe length is equal the maximum equivalent overall length of 6.4 m. This flue system is therefore acceptable (borderline case).
6 720 610 703 (01.07)
Mounting
4
4.1
Mounting
Notes on fitting
4.2.2 A Table 11 Inclined roof 400 mm, in areas with frequent heavy snow falls 500 mm 60, in areas with frequent heavy snow falls 50
The vertical flue duct AZB 800 can be extended at any point between the heat exchanger and the flue terminal assembly using the flue duct kits AZB 802, 803 or 804. For details of the maximum permissible flue pipe length, refer to the installation examples starting on page 5. The horizontal section of the vertical flue section should be fitted should be fitted with an upward incline of 3% (3 cm per metre) in the direction of flow of the flue gases. In damp rooms, the air pipe should be insulated.
4.2
4.2.1
Roof-exit clearances
Flat roof Combustible building material Non-combustible building material 500 mm
X Table 10
1500 mm
X
Fig. 10
6 720 610 489-13.1O
535
120
6 720 610 703-09.1O
Fig. 9
6 720 610 703 (01.07)
Mounting
4.3
Fitting the flue ducting
B Determine the length LV of the air pipe (refer to fig 4 - fig. 8).
B Slide the flue gas accessories, lightly twisting, into each other to the stop in the sleeve.
LV
B4
B4
6 720 610 489-014.1O
Fig. 11
B4: AZB 800
B Cut off the air pipe at a right angle, deburr the cut edges and clean. B Determine the length LA = LV +20 mm of the flue pipe.
B2
LA LV B4
B4.1
20
6 720 610 703-10.1O 6 720 610 703-11.1O
Fig. 12
B4: AZB 800
Fig. 13
B2: B4: AZB 804 AZB 800
B Cut off the flue pipe at a right angle, deburr the cut edges and clean. B Lightly grease the seals on the sleeves with a solventfree grease (e. g. Vaseline).
6 720 610 703 (01.07)
Mounting
10
6 720 610 703 (01.07)
Mounting
6 720 610 703 (01.07)
11
AZB 841
80/125 60/100 7 719 002 099
100 62
50
80 125
6 720 610 709-00.1O
ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2
6 720 610 709 (01.07) OSW
125
Important Notes
The appliance and its accessories may only be fitted by an approved installer. Please also observe the following: B This accessory kit should only be used in conjunction with the matching basic accessory kit AZB ... B When replacing, check compatibility of accessory kit. B Follow the installation instructions for the appliance and the accessories used. B Make sure air/flue duct lengths are within the permissible limits.
Combination with flue ducts

The adapter may be used with the 60/100 horizontal flue kit AZB 801/1, the 60/100 90 bend AZB 802 and the 60/100 extension duct AZB 804 to connect a short length of vertical flue pipe to the appliance before the horizontal assembly. Only one 90 bend may be used.
Maximum flue length

Maximum flue length under these conditions is 2 m. The straight vertical length must not be greater than the horizontal straight length.
Mounting
B Use a silicon based grease to ease the assembly of the adapter fully onto the boiler flue outlet.
6 720 610 709-01.1O
1.1
AZB 806/1
Horizontal Flue Gas Ducting 80/125 mm 7 719 002 071
110 40 82 127 125
105 80 135 1200 200

12
110
80 125
200
12
155
200
155
8x
155 155
6 720 610 613-00.1o
6 720 610 613 (01.06) OSW
200
AZB 806/1
6 720 610 613 (01.06)
AZB 806/1
Contents
Safety instructions Symbols 1 1.1 1.2 1.3 1.4 2 2.1 2.2 3 Use General Gas condensing boilers Combination with flue duct kits Standard specifications Flue pipe lengths General Equivalent pipe length Minimum Fitting space requirements for gas condensing boiler Examples of installation for outside wall (C13x) Straight flue duct Flue ducting with two 45-elbows Flue ducting with one 90-elbow Straight flue ducting with two 90-elbows Flue ducting with more than two elbows Mounting Notes on fitting Room-sealed air/flue ducting with exit through outside wall 3 3 4 4 4 4 5 6 6 6
Safety instructions
Proper functioning of this product is only guaranteed if these installation instructions are correctly followed. Subject to alteration. Installation must be carried out by an approved installer. Installation of the boiler must be carried out in accordance with the appropriate installation instructions. 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 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.
Symbols
4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 8 8 10 11 12 13 14 14 14
6 720 610 613 (01.06)
AZB 806/1
1
1.1
Use
General 1.2 Gas condensing boilers
The installation of a gas condensing boiler must be in accordance with the relevant British Standard, the relevant Building Regulations and any local rules. The surface temperature of the fresh air duct is below 85C. Therefore no minimum distances to combustible building materials are necessary. The regulations can deviate, however, and might prescribe minimum distances to combustible materials. Flue ducting to C13x: The flue gas accessory is part of CE approval when discharging flue gas according to C13x. For this reason, only the original flue gas accessories may be used.
The AZB 806/1 can be used in conjunction with the following gas condensing boilers: Gas condensing boilers ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWBR 8-30 ICC2 ZBR 8-35 ICS1 CE 0085 BL 0507 ZWBR 11-37 ICC2 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 11-35 HE plus Table 1 Prod.-ID-No.
1.3
The AZB 806/1 can be combined with the following flue duct kits: Flue duct kits AZB 807, elbow 90 AZB 808, extension 990 mm AZB 814, elbow 45 Table 2
6 720 610 613 (01.06)
AZB 806/1
1.4
Standard specifications
110 40 82 127 125
B1.1
105 80 135 1200 200 200
6 12
110
80 125
B1.3
155
155
8x
B1.5
155 155
200
B1.2
Fig. 1
B1.1: B1.2: B1.3: B1.5: Flue terminal assembly Cover plates Flue turret Screws and wall plugs
6 720 610 613-01.1o
200
6 12
6 720 610 613 (01.06)
AZB 806/1
2
2.1
Flue pipe lengths

General
Example: ZWB 7-29 CC1 For a horizontal flue system with a length of 5 m and two 45-elbows, the equivalent pipe length is calculated as follows: Sectional equivalent length 1 = 2m = 1m =
The sum of the straight vertical and horizontal pipe lengths (Lvert, Lhoriz) and the equivalent lengths of the elbows makes the equivalent length of the flue ducting, Le. This equivalent pipe length must be less than the maximum equivalent pipe length.
2.2
Equivalent pipe length

Straight length Lhoriz Elbow 90 Elbow 45
Length/ Number 5m x 0 x 2 x
Total 5m 0m 2m 7m 13 m o.k.
The equivalent pipe length, Le, is calculated from the sum of the straight lengths of the flue ducting (Lhoriz) and the equivalent lengths of the elbows. The flue turret (on gas condensing boiler) is included in the maximum lengths. The equivalent length of every additional elbow must be included. The overall equivalent pipe length must be less than the maximum equivalent pipe length: Le Le,max. For horizontal flue ducting to C13x the following equivalent lengths apply: Equivalent lengths of additional elbows
90
Equivalent pipe length Le Maximum equivalent length Le,max Le Le,max
Horizontal flue ducting to C13x
Boiler ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2 ZWBR 11-35 HE plus Table 3 Pipe lengths for C33x
Le,max [m]
1545
Table 4 At 7 m, the equivalent pipe length is shorter than the maximum equivalent overall length of 13 m. This flue system is therefore acceptable.
[m]
[m]
13 2 1
10
Le,max: maximum equivalent pipe length
6 720 610 613 (01.06)
AZB 806/1
Minimum Fitting space requirements for gas condensing boiler

440 mm
5 mm
512 mm
100 mm
Table 5
Wall thickness 15 - 24 cm 24 - 33 cm 33 - 42 cm 42 - 50 cm K 155 mm 160 mm 165 mm 170 mm
Table 6
125
250
3% incline
85 120 1038 961
850
360
835
6 720 610 613-02.1O
Fig. 2
77
K
7
6 720 610 613 (01.06)
AZB 806/1
4
4.1
Examples of installation for outside wall (C13x)

Straight flue duct (Fig. 3, Fig. 4, Fig. 5)
B C without extension L with extension
ZWB 7-29 CC1 ZB 7-28 CS1 ZWB 7-27 HE combi ZB 7-27 HE system ZSBR 7-28 ICS1 ZWBR 7-28 HE plus ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2 ZWBR 11-35 HE plus
440 mm
5 mm
13 m
995 mm 13 m 512 mm 100 mm 10 m
Table 7
265
B1.3
990
125
B2
B1.1
961
861
850
3% incline
125
160
B
6 720 610 613-03.1o
Fig. 3 Key to Fig. 3, Fig. 4 and Fig. 5:

B1: B2: AZB 806/1 AZB 808
>30
6 720 610 613 (01.06)
AZB 806/1
B1.1
265
B2
B1.3
125
120 120 120
990
B1.2
160
L
6 720 610 613-04.1o
Fig. 4
125
160 265
B1.2
B1.1 L C
120
110
B1.2
Fig. 5
360 395
6 720 610 613-05 .1o
360 395
6 720 610 613 (01.06)
AZB 806/1
4.2
Flue ducting with two 45-elbows

B C without extension L with extension
440 mm
5 mm
11 m
1150 mm 11 m 512 mm 100 mm 8m
Table 8
B2
265 165
B1.3
B1.1
125
120
230
990 1000 160
B1.2
B6 B6
360
Fig. 6
B1: B2: B6: AZB 806/1 AZB 808 AZB 814
10
6 720 610 613 (01.06)
395
6 720 610 613-06.1o
AZB 806/1
4.3
Flue ducting with one 90-elbow

B C without extension L with extension L = L1 + L2
440 mm
5 mm
11 m
170 mm 512 mm 100 mm
290 mm 11 m
8m
Table 9
125
160
B1.1 L2 C
265 990
B1.2
110
120 360
B3 B2 B
B1.3
L1
6 720 610 613-07.1o
Fig. 7
B1: B2: B3: AZB 806/1 AZB 808 AZB 807
395
6 720 610 613 (01.06)
11
AZB 806/1
4.4

B C L1 , L2 without extension with extension L = L1+L2+L3
440 mm
5 mm
9m
170 mm 512 mm 100 mm
290 mm 9m
6m
Table 10
L1
B1.1
120
B3
990
360
B2
990
B B2 L2
265
B1.1
125
B3 B1.2
Fig. 8
B1: B2: B3: AZB 806/1 AZB 808 AZB 807
160
L3
6 720 610 613-08.1o
12
395
6 720 610 613 (01.06)
AZB 806/1
4.5
The calculations for checking the flue duct situation are performed according to the rules explained in section 2. Example: ZWB 7-29 CC1 For a horizontal flue system with a length of 4 m, four 45-elbows and two 90-elbows, the equivalent pipe length is calculated as follows: Sectional equivalent length 1 = 2m = 1m =
Example: ZWBR 11-35 HE plus For a horizontal flue system with a length of 4 m, two 45-elbows and two 90-elbows, the equivalent pipe length is calculated as follows: Sectional equivalent length 1 = 2m = 1m =
Length/ Number Straight length Lhoriz Elbow 90 Elbow 45 4m x 2 x 2 x
Total 4m 4m 2m 10 m 10 m o.k.
Length/ Number Straight length Lhoriz Elbow 90 Elbow 45 4m x 2 x 4 x
Total 4m
Equivalent pipe length Le 4m 4m 12 m 13 m o.k. Maximum equivalent length Le,max Le Le,max
Equivalent pipe length Le Maximum equivalent length Le,max Le Le,max
Table 12 At 10 m, the equivalent pipe length is equal the maximum equivalent overall length of 10 m. This flue system is therefore acceptable (borderline case).
Table 11 At 12 m, the equivalent pipe length is shorter than the maximum equivalent overall length of 13 m. This flue system is therefore acceptable.
6 720 610 613 (01.06)
13
AZB 806/1
5
5.1
Mounting
Notes on fitting
B Calculate length of the flue terminal assembly (B1.1) taking account of the distance from the outside wall to the end of the flue pipe.
The horizontal flue duct (AZB 806/1) can be extended at any point between the heat exchanger and the flue terminal assembly (B1.1) using the flue duct kits AZB 807, 808 or 814. The maximum permissible flue/air duct length depends on the type of gas condensing boiler and the number of elbows in the air/flue pipe. For details of how to calculate it, refer to section 2, page 6 onwards. Every additional horizontal extension AZB 808 must be supported by a bracket with rubber band. The horizontal air/flue duct should be fitted with an upward incline of 3% (3 cm per metre) in the direction of flow of the flue gases. In damp rooms, the air pipe should be insulated.
265 160
125
B1.1 B1.2
6 720 610 488-14.1O
5.2
Room-sealed air/flue ducting with exit through outside wall

Fig. 10
B Apply a thin layer of solvent-free grease (e.g. Vaseline) to the seals on the joints. B Fit flue turret (B1.3) onto flue socket on boiler and push fully home, twisting the elbow slightly at the same time. B Secure the flue turret with the bracket supplied.
B Smooth off rough edges of cut end. B Calculate the required diameter of the hole in the wall according to the wall thickness (see minimum fitting space requirements, page 7 onwards). B Make the hole in the wall remembering to allow for the required 3% incline of the air/flue pipe. B Fit interior cover plate (B1.2) to the flue terminal assembly (B1.1).
If the flue/air ducting from a wall-mounted boiler has no forward offset, the cover plate (B1.2) will have to be trimmed.
6 720 610 613-09.1O
Fig. 9
14
6 720 610 613 (01.06)
AZB 806/1
B Pass flue terminal assembly (B1.1) through the hole in the wall and push into the end of the flue turret, twisting the pipe slightly as you do so. The air-intake slots on the flue terminal must face downwards. B Fit the external cover plate (B1.2) onto the flue terminal assembly (B1.1). B Mark and drill fixing holes for the two cover plates (B1.2). B Fix cover plates using screws and wall plugs (B1.5). B Fit protective grille into end of flue terminal (B1.1), compressing it slightly.
B1.2
3% incline
B1.2
Fig. 11
B1.1
B1.5
6 720 610 613-10.1o
6 720 610 613 (01.06)
15
AZB 808
80/125 mm 7 719 001 892
127 82
1000
990
40
B2
125
6 720 610 165-00.1O
6 720 610 165 (01.06) OSW
Important Notes
Symbols
B Lightly grease the seals on the sleeves with
a solvent-free grease (e. g. Vaseline) (Fig. 1.1).

B Slide the flue gas accessories, lightly
40
twisting, into each other to the stop in the sleeve (40 mm, Fig. 1.1).
6 720 610 165 (01.06)
360
B2
6 720 610 165-03.1O
2.2
40
40
6 720 610 363-01.1O
1.1
B2
40
B2
125
2.3
B2: AZB 808
6 720 610 165-04.1O
LV
LV 160 mm
6 720 610 165-02.1O
2.1
6 720 610 165 (01.06)
AZB 807
80/125 mm 7 719 001 891
110
40
110
40
B3
125
6 720 610 164-00.1O
6 720 610 164 (01.06) OSW
127
82
Important Notes
Symbols

40
6 720 610 164 (01.06)
360 180
B3
B3
6 720 610 164-02.1O
2.2
40
40
300
B3
6 720 610 363-01.1O
B2
1.1
B3
6 720 610 164-05.1O
2.3
B2 B3
LV 160
LV B3
6 720 610 164-01.1O
2.1
B2 X
B3
6 720 610 164-06.1O
3.1
B2: B3: AZB 808 AZB 807
6 720 610 164 (01.06)
LV /mm
990 800 600 400
B2
6 720 610 165-03.1O
3.4
160 300
AZB 808
500 700 900 1100
X /mm
1130
6 720 610 164-08.1O
3.2
B3
B2
B3
40
B2
6 720 610 164-07.1O
125
3.5
LV
LV 160 mm
3.3
6 720 610 165-02.1O
B2: B3:
AZB 808 AZB 807
AZB 814
80/125 mm 7 719 001 899
7 12
75 40
82
75
40
B6
45
6 720 610 170-00.2O
125
6 720 610 170 (01.06) OSW
Important Notes
Symbols

40
6 720 610 170 (01.06)
360
165
B6
=
B2
B6
6 720 610 170-03.1O
2.2
40
40
6 720 610 363-01.1O
1.1
LV 160
LV
B6 B6
80
B2
X B6 B6
3.1
B2: B6: AZB 808 AZB 814
6 720 610 170-04.1O
6 720 610 170-02.1O
2.1
6 720 610 170 (01.06)
L /mm 1000 800 600 400
B2
6 720 610 165-03.1O
160 AZB 808 0 100 200 165 300 400 500 600 X/mm 672
6 720 604 892-06.1O
3.4
B6 B2
3.2
B6
40
B2
6 720 610 170-05.1O
125
3.5
B2: B6: AZB 808 AZB 814
LV
LV 160 mm
3.3
6 720 610 165-02.1O
AZB 805/1
Vertical Flue Gas Ducting 80/125 mm 7 719 002 070
135
645
125
6 720 610 612-00.1O
1365
6 720 610 612 (01.06) OSW
Contents
Contents
Safety instructions Symbols 1 1.1 1.2 1.3 1.4 2 Use General Gas condensing boilers Combination with flue duct kits Standard specifications Fitting space requirements for gas condensing boiler Examples of installation of vertical flue duct with roof exit Straight flue ducting without elbows Straight flue ducting with two 45-elbows Straight flue ducting with two 90-elbows Flue ducting with more than two elbows Mounting Notes on fitting Roof-exit clearances Fitting the flue ducting 2 2 3 3 3 3 3
Safety instructions
Proper functioning of this product is only guaranteed if these installation instructions are correctly followed. Subject to alteration. Installation must be carried out by an approved installer. Installation of the boiler must be carried out in accordance with the appropriate installation instructions. 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 controls to the appliance may only be carried out by a competent engineer in accordance with 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.
3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3
5 5 5 6 7 8 8 8 9
Symbols
6 720 610 612 (01.06)
Use
1
1.1
Use
General 1.4 Standard specifications
The installation of a gas condensing boiler must be in accordance with the relevant British Standard, the relevant Building Regulations and any local rules. The surface temperature of the fresh air duct is below 85C. Therefore no minimum distances to combustible building materials are necessary. The regulations can deviate, however, and might prescribe minimum distances to combustible materials. Flue ducting to C33x: The flue gas accessory is part of CE approval when discharging flue gas according to C33x. For this reason, only the original flue gas accessories may be used.
135
1365
1.2
Gas condensing boilers
B4
The AZB 805/1 can be used in conjunction with the following gas condensing boilers: Gas condensing boilers ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWBR 8-30 ICC2
6 720 610 612-01.1O
Prod.-ID-No.
125
ZBR 8-35 ICS1 CE 0085 BL 0507 ZWBR 11-37 ICC2 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 11-35 HE plus Table 1
Fig. 1
B4: Vertical Flue Gas Ducting AZB 805/1
1.3
The AZB 805/1 can be combined with the following flue duct kits: Flue duct kits AZB 807, elbow 90 AZB 808, extension 990 mm AZB 814, elbow 45 Table 2
645
6 720 610 612 (01.06)

440 mm
5 mm
512 mm
100 mm
Table 3
125
C
85 120
850
1150
360
77 835
6 720 610 612-03.1O
Fig. 2
Flat roof
835 125
C
85 957 120
850
360
B
6 720 610 612-04.1O
Fig. 3
Inclined roof
77
6 720 610 612 (01.06)
3
3.1

Straight flue ducting without elbows
Lmax
3.2

Lmax
ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2 ZWBR 11-35 HE plus
15 m
13 m
12 m
10 m
Table 4
Table 5
645
1365
1365
990
B2
B2
B6 990 B2 B6
990 87
6 720 610 612-05.1O
B2
Fig. 4 Key to Fig. 4 and 5:

B2: B4: B6: AZB 808 AZB 805/1 AZB 814
6 720 610 612-06.1O
Fig. 5
990
L
5
125
6 720 610 612 (01.06)
B4
645
135
135
B4
125
3.3

645
Lmax
135 1365
B3
8m
125 990
B3
990
Table 6
B2
B2
990
645
135
B2
1365
B4
Fig. 7
6 720 610 612-08.1O
125 990
B3
645
B2
135 1365
B3
990 180
B2
B4
990
125
B2
990
6 720 610 612-07.1O
B2 B3
990
Fig. 6 Key to Fig. 6, 7 and 8:

B2: B3: B4: AZB 808 AZB 807 AZB 805/1
B3
990
B2 B2
6 720 610 612-09.1O
Fig. 8
6 720 610 612 (01.06)
11 m
B4
3.4
The equivalent pipe length, Le, is calculated from the sum of the straight lengths of the horizontal and vertical flue ducting (Lhoriz , Lvert ) and the equivalent lengths of the elbows. The equivalent length of every elbow fitted must be included. The overall equivalent pipe length must be less than the maximum equivalent pipe length: Le Le,max. For vertical flue ducting to C33x the following equivalent lengths apply: Equivalent lengths of additional elbows
90
Example: ZWB 7-29 CC1 For a vertical flue system with a vertical length of 4 m, a horizontal length of 0.5 m, four 45-elbows and two 90- elbows, the equivalent pipe length is calculated as follows: Length/ Number Straight length Lvert Straight length Lhoriz Elbow 90 Elbow 45 4m x 0.5 m x 2 x 4 x Sectional equivalent length 1 = 1 = 2m = 1m =
Total 4m 0.5 m 4m 4m 12.5 m 15 m o.k.
Vertical flue ducting to C33x
Boiler ZWB 7-29 CC1 ZB 7-28 CS1 ZSBR 7-28 ICS1 ZWB 7-27 HE combi ZB 7-27 HE system ZWBR 7-28 HE plus ZWBR 8-30 ICC2 ZBR 8-35 ICS1 ZWBR 11-37 ICC2 ZWBR 11-35 HE plus Table 7 Pipe lengths for C33x
Le,max [m]
1545
Equivalent pipe length Le Maximum equivalent overall pipe length Le,max Le Le,max
[m]
[m]
15 2 1
Table 8 At 12.5 m, the equivalent pipe length is shorter than the maximum equivalent overall length of 15 m. This flue system is therefore acceptable. Example: ZWBR 11-35 HE plus For a vertical flue system with a vertical length of 6 m, two 45-elbows and two 90-elbow, the equivalent pipe length is calculated as follows: Length/ Number Straight length Lvert Straight length Lhoriz Elbow 90 Elbow 45 6m x 0m x 2 x 2 x Equivalent pipe length Le Maximum equivalent overall pipe length Le,max Le Le,max Sectional equivalent length 1 = 1 = 2m = 1m =
12
Le,max: maximum equivalent overall pipe length
Total 6m 0m 4m 2m 12 m 12 m o.k.
Table 9 At 12 m, the equivalent pipe length is equal the maximum equivalent overall length of 12 m. This flue system is therefore acceptable (borderline case).
6 720 610 612 (01.06)
Mounting
4
4.1
Mounting
Notes on fitting
4.2.2 A Table 11 Inclined roof 400 mm, in areas with frequent heavy snow falls 500 mm 60, in areas with frequent heavy snow falls 50
The vertical flue duct (AZB 805/1) can be extended at any point between the heat exchanger and the flue terminal assembly (B4) using the flue duct kits AZB 807, 808 or 814. For details of the maximum permissible flue pipe length, refer to the installation examples starting on page 5. The vertical air/flue duct should be fitted with an upward incline of 3% (3 cm per metre) in the direction of flow of the flue gases. In damp rooms, the air pipe should be insulated.
4.2
4.2.1
Roof-exit clearances
Flat roof Combustible building material Non-combustible building material 500 mm
1500 mm
Table 10
X
6 720 610 489-13.1O
Fig. 10
645
135
6 720 610 612-10.1O
Fig. 9
6 720 610 612 (01.06)
Mounting
4.3
Fitting the flue ducting

B Slide the flue gas accessories, lightly twisting, into each other to the stop in the sleeve.
B Determine the length LV of the double pipe.
LV
B4
B4
6 720 610 489-014.1O
Fig. 11
B4: AZB 805/1
B Cut off the double pipe at a right angle, deburr the cut edges and clean. B Lightly grease the seals on the sleeves with a solventfree grease (e. g. Vaseline).
B2
6 720 610 612-11.1o
Fig. 12
B2: B4: AZB 808 AZB 805/1
6 720 610 612 (01.06)
Mounting
10
6 720 610 612 (01.06)
Mounting
6 720 610 612 (01.06)
11
DT1 DT2
6 720 610 367-00.1O
6 720 610 367 (00.12)
Contents
1 1.1 1.2 Details of Timer Technical Data Basic Settings 6 6 7
1
1.1
Details of Timer
Technical Data
Installation
3 3.1 3.2 3.3
Operation Button Functions Programming Time Display
7 7 8 9
Safety Instructions
y These instructions must be
Timer may only be fitted in appliances with Bosch Heatronic or Bosch Eurotronic Combination with programmer TA 211 E or room thermostat without its own timer is possible DT 1: single channel, Ch 1 (timer program with 3 timed periods each day for central heating) DT 2: two channels, Ch 1 (as DT 1) and Ch 2 (timer program with 3 timed periods each day for hot water). Dimensions Rated voltage Rated current Ambient temp. Power buffer Safety rating 91.7 x 74.,4 mm 18...27 V DC 10 mA 0... +60 C Approx. 12 hours IP X4
observed to ensure proper functioning of the timer. y The timer should only be fitted by an approved installer. y The timer must not be connected to the 230 V mains supply.
6 720 610 367 (00.12)
1.2
Basic Settings
3
3.1
Operation
Button Functions
Ch
Channel 1 Ch 1 Central heating, all days ON : 6:00 OFF : 22:00. Channel 2 Ch 2 Hot water, all days (DT 2 only) ON : 5:00 OFF : 22:00. No other timed periods are programmed (:).
Installation
y Switch off the central heating boiler. y Remove outer case if necessary. y Open control panel cover and
unhook if necessary.
y Press tab (g) and remove blank
Menu button (b): PROG: Time, Day Ch1 PROG: Timed periods, Channel 1 Ch2 PROG (DT 2 only): Timed periods, Channel 2 Ch1 PROG: Mode, Channel 1 CH2 PROG (DT 2 only): Mode, Channel 2 C (c): Clear (d): Move to next setting Set button (e) or (f): Press and release: changes setting by one unit Press and hold: changes setting continuously.
panel (h) (Fig. 2).

y Connect connector (k) to terminal (j)
on the main circuit board (ST 5).

y Insert timer in the space (i) and snap
into position at the top.

y Refit the boiler components previ-
ously removed.
6 720 610 367 (00.12)
DT1/DT2
3.2
Programming
3.2.1 Setting time and day

y Press
i
y Press
repeatedly until the display shows PROG. y The hour setting flashes: change hour by pressing or . y Press and release ; the minutes setting flashes: set minutes by pressing or . y Press and release ; the day setting flashes: set day by pressing or . (1 = Monday, 2 = Tuesday, etc.).
Ch
The timed periods can be set in increments of 10 minutes. The timed periods are sorted in ascending order.
Ch
Changing between summer and winter time: y Adjust the time as described. y Do not alter the timed periods. 3.2.2 Setting the timed periods Setting options: Max. 3 timed periods per day Same times for groups of days or different times for each day Possible day groupings: All days (1-7) Monday to Friday (1-5) Saturday and Sunday (6-7)
y y y y y
repeatedly until the display shows Ch1 PROG or Ch2 PROG (DT 2 only): All days are shown (1-7). Press or repeatedly until the desired day or group of days is shown. Press and release : the first ON time is displayed (e.g. 6:00). Set the ON time by pressing or . Press and release : the first OFF time is displayed (e.g. 22:00). Set the OFF time by pressing or . Press and release : the second ON time is displayed. Continue as with the first timed period.
6 720 610 367 (00.12)
DT1/DT2 3.2.3 Changing the Operating Mode

y Press
3.2.5 Completing Programming

y Press
repeatedly until the display shows Ch1 PROG or Ch2 PROG (DT 2 only). y Set mode by pressing or : ON: Central heating on (Ch 1)/ hot water on (Ch 2) OFF: Central heating off/Economy (Ch 1)/hot water off (Ch 2) AUTO: The timer switches the central heating (CH 1)/hot water (Ch 2) on and off according to the timed-period settings
Ch
repeatedly until the normal display (a) appears. -ory Do not press any buttons for 30 seconds.
Ch
3.3
Time Display
Time of day and timed periods are displayed either in 24-hour (default setting) or 12-hour format.
The time display format cannot be changed while programming.
3.2.4 Deleting Settings Deleting an individual timed period: y Select required timed period on the display (see chapter 3.2.2). y Briefly press and release C . Resetting the timer completely: y Press and hold C for approx. 15 seconds. To change the time display format: y Press and hold and simultaneously (for about 10 seconds). In 12-hour time format, the display also shows am (morning) or pm pm (afternoon) next to the time.
6 720 610 367 (00.12)
DT1/DT2
Appendix
b c d
6 720 610 367-01.1O
e f
g h i j k
Ch
6 720 610 367-02.1O
Bosch Heatronic
6 720 610 367 (00.12)
DT1/DT2
g h i j
ST5
Ch
k
3 Bosch Eurotronic
6 720 610 367-03.1O
6 720 610 367 (00.12)
I CH 1 1 2 3 4 5 6 7 I CH 2 1 2 3 4 5 6 7 ON OFF ON ON OFF ON
II OFF ON
III OFF
II OFF ON
III OFF
Room-temperature (economy/night) unit
TR 212 E
for boilers with Optimum Start-compatible Bosch Heatronic units
6 720 610 614-00.1R
Order no. 7 744 901 136
6 720 610 617 GB (01.05) OSW
Contents
Contents
Safety instructions Symbols 1 1.1 1.2 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5 Details of Unit Standard specifications Technical data Installation Fitting Electrical connections Operation Setting the room temperature for Off (Economy) mode (d) Setting the room temperature for On (Comfort) mode Selecting operating mode Frost protection Entering the heating programme General instructions Fault finding 3 3 4 4 4 5 5 6 7 7 7 7 7 7 8 9
4 5
6 720 610 617 GB (01.05) OSW
Safety instructions
Safety instructions
General B Follow the instructions in order to ensure that the unit functions correctly. B The TR 212 E should only be installed and commissioned by an approved installer. B Install and commission the boiler in accordance with the appropriate instructions. Usage B Only use the TR 212 E in conjunction with the gas central heating boilers specified. Make connections as shown in the wiring diagram. Electrics B Never connect the TR 212 E to the 230-V mains power supply. B Before fitting the TR 212 E: disconnect the boiler from the electricity power supply (230 V AC). B Do not install the TR 212 E in damp rooms.
Symbols
Safety instructions in this document are identified by a warning-triangle symbol and are printed on a grey background. 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.
Notes contain important information in cases where there is no risk of personal injury or damage to property.
6 720 610 617 GB (01.05) OSW
Details of Unit
Details of Unit
i
1.1
The TR 212 E may only be fitted in a boiler with an Optimum Startcompatible Bosch Heatronic unit and in conjunction with the TR 2 room thermostat and DT 2 fitted timer.
1.2
Technical data
approx. 5...30C III
Modulation range Enclosure class
Table 1 Technical data
Room-temperature (economy/night) unit TR 212 E.
6 720 610 617 GB (01.05) OSW
Installation
2
2.1
Installation
Fitting
Danger: Risk of electric shock! B Disconnect the central heating boiler from the power supply before fitting the programmer.
0
1
3 E 2
5
7
6 720 610 614-01.1R
1
4100-02.2/G
Fig. 4
Slide TR 212 E into the guide slots and push upwards until it locks into position.
Fig. 1
Remove flap
4 3 E 2 5
3
4100-03.2/G
Fig. 2
Remove screw and cover

ECO
6 720 610 614-02.1R
Fig. 5
Plug TR 212 E connector into socket (ST 9 TA module).
4 3 2
B Connect up the TR 2 (Fig. 6).

5 E
B Refit cover (Fig. 2) and flap (Fig. 1). Fitting accessory units B Fit accessory units for boilers without text display unit according to the statutory requirements and the installation instructions provided: TR 2 room thermostat DT 2 fitted timer 5
4
4100-04.2/G
Fig. 3
Withdraw blanking plate
6 720 610 617 GB (01.05) OSW
Installation
2.2
rying 230 V in order to prevent inductive interference (minimum separation 100 mm). B If there are external sources of inductive interference (e.g. high-power cables, overhead tram cables, transformer substations, radio and TV equipment, amateur radio equipment, microwaves, etc.): use screened cable.
B Connection from TR 212 E to TR 2: Use electrical cable that conforms at least to BS6500: up to 20 m cable length: 0.75 to 1.5 mm2 up to 30 m cable length: 1.0 to 1.5 mm2 over 30 m cable length: 1.5 mm2 B All low-voltage wiring (instrument wiring) should be routed separately from cables car-
Bosch Heatronic ST 1 TR 212 E
TR 2
1 3 4 A F
DT 2
ST 2
4(3)
F
F
3
3
4
4
3
3
4 A F
4 F
ST 5
ST 9 TA-Modul
6 720 610 614-03.1O
Fig. 6
6 720 610 617 GB (01.05) OSW
Operation
Operation
15 10
20 25 30C
6 720 610 614-04.1R
Fig. 7
d
Controls
Control for Off (Economy) mode; for setting the desired room temperature
3.3
Selecting operating mode
i
3.1
Set the CH flow temperature control on the heating boiler to the maximum required CH flow temperature.
B Select the desired operating mode on the TR 2 room thermostat (see TR 2 operating instructions).
3.4
Frost protection
There are three possible frost protection modes:
Setting the room temperature for Off (Economy) mode (d)
Frost protection while Off (Economy) mode is active (control (d) set to position ). Frost protection while On (Comfort) mode is active (control on TR 2 set to position ). Constant frost protection mode (mode selector switch on TR 2 set to position ). In all frost protection modes, the room in which the TR 2 is fitted is protected against frost. If the ambient temperature is above 5C, the heating (pump) remains switched off.
B Set the control (d) to the desired room temperature between (5C) and 30C. As soon as Off (Economy) mode calls for heat, the heating switches on and continues running until the set room temperature has been reached.
3.2
Setting the room temperature for On (Comfort) mode
B Set the desired room temperature for On (Comfort) mode on the TR 2 room thermostat (refer to operating instructions). As soon as the TR 2 calls for heat, the heating switches on and continues running until the set room temperature has been reached.
3.5
Entering the heating programme
B Enter the switching times for the heating programme on the DT 2 fitted timer (see timer operating instructions).
6 720 610 617 GB (01.05) OSW
General instructions
If the building is well insulated: the temperature may not drop as low as the set economy temperature. Nevertheless, you will still save energy because the heating will not switch on. In such cases, set the start time for Off (Economy) mode earlier. To air a room, do not leave windows constantly slightly open. This will result in continuous heat loss without significantly improving the quality of air in the room. Air the room for a short time, but thoroughly (windows fully open). While airing, turn off the thermostatic valve or set TR 2 to .
... and tips on saving energy: The temperature in the primary room (room in which TR 2 is fitted) serves as the reference for the entire heating system. For that reason, the radiators must be adjusted to balance the system. With manual valves, they should be preset. With thermostatic valves, they should be set to maximum and the adjustment made using the return unions. If the thermostatic valves in the primary room are not turned up to the maximum setting, they could restrict the supply of heat even though the TR 2 is calling for heat. Adjust the temperature in the remaining rooms by means of thermostatic valves. If the primary room is heated by external sources (e.g. sunshine, stove, etc.) the other rooms may not heat up adequately (central heating may not cut in). Save energy by reducing the room temperature during the day or at night: reducing the room temperature by 1 C: can achieve up to 5% energy savings. Energy-inefficient: allowing the temperature of rooms that are heated daily to fall below +15 C because the walls will become cold, the room temperature will have to be raised and thus more energy consumed than if an even temperature were maintained.
6 720 610 617 GB (01.05) OSW
Fault finding
Fault finding
Cause Thermostatic valve(s) in primary room set too low CH flow temperature control on boiler set too low Air trapped in heating system Remedy Turn up thermostatic valves to maximum or replace with manual valve(s) Turn up CH flow temperature control Bleed radiators and heating system Choose better installation site for TR 2
Problem Desired room temperature is not reached
Desired room temperature is exceeded by large amount Excessive fluctuations in room temperature Temperature rises instead of falling Room temperature too high in Off (Economy) mode
Bad choice of installation site for TR 2, e.g. on external wall, near window, in draught, ... Periodic effect of external source of heat on room, e.g. due to sunshine, lighting, TV, fire, etc. Time set incorrectly on timer
Choose better installation site for TR 2
Check time setting
Building stores heat well
Set Off (Economy) mode to start earlier
Incorrect or non- TR 2 wired incorrectly existent modulation
Check wiring conforms to wiring diagram and correct as necessary
6 720 610 617 GB (01.05) OSW
Fault finding
10
6 720 610 617 GB (01.05) OSW
Fault finding
6 720 610 617 GB (01.05) OSW
11
Fault finding
Room thermostat
TR 2
for boilers with Optimum Start-compatible Bosch Heatronic units
20
10
30
Order no. 7 744 901 137
6 720 610 616 GB (01.05) OSW
6 720 610 611-00.1R
Contents
Contents
Safety instructions Symbols 1 1.1 1.2 1.3 2 2.1 2.1.1 2.1.2 2.1.3 2.2 3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.2 3.3 3.4 3.5 4 5 Details of Unit Standard specifications Technical data Description of function Installation Fitting Installation position Fitting Fitting accessory units Electrical connections Operation Setting the operating mode (e) Automatic mode (basic setting) Constant On (Comfort) mode Constant Off (Economy) mode Constant Frost protection mode Setting the room temperature for On (Comfort) mode (f) Setting the room temperature for Off (Economy) mode Frost protection Entering the heating programme General instructions Fault finding 3 3 4 4 4 4 5 5 5 6 6 7 8 8 8 8 8 8 9 9 9 9 10 11
6 720 610 616 GB (01.05) OSW
Safety instructions
Safety instructions
General B Follow the instructions in order to ensure that the unit functions correctly. B The TR 2 should only be installed and commissioned by an approved installer. B Install and commission the boiler in accordance with the appropriate instructions. Usage B Only use the TR 2 in conjunction with the gas central heating boilers specified. Make connections as shown in the wiring diagram. Electrics B Never connect the TR 2 to the 230-V mains power supply. B Before fitting the TR 2: disconnect the boiler from the electricity power supply (230 V AC). B Do not install the TR 2 in damp rooms.
Symbols
6 720 610 616 GB (01.05) OSW
Details of Unit
Details of Unit
1.3
Description of function
i
1.1
The TR 2 may only be connected to a central heating boiler with an Optimum Start-compatible Bosch Heatronic unit.
The desired room temperature for On (Comfort) mode can be set to between (5C) and 30C using the control (f, Fig. 7). The built-in temperature sensor signals the current room temperature to the central heating boiler (if the boiler has a text display, the room temperature is displayed). Optimum Start This function is only active if the mode selector switch (e, Fig. 7) is set to Automatic mode . The following conditions must also be met: Central heating boiler has text display or Central heating boiler has room-temperature (economy /night)-unit TR 212 E fitted and timer DT 2.
TR 2 room thermostat Drilling template Quick operating instructions (inserted in right side of base).
The function can only be deactivated on boilers with text display (see boiler operating instructions). The Optimum Start function delays the time at which central On (Comfort) mode starts (according to the current and desired room temperatures). The desired room temperature is reached approx. 1 hour after the programmed heating on time. Example: If the room temperature has fallen 6C or more from the set position, the heating comes on straight away. If the temperature has fallen only 3C then the boiler is prevented from firing 30 minutes. The length of delay is therefore 10 minutes per degree below set temperature.
6 720 610 611-01.1R
Fig. 1
1.2
Technical data
82x82x42 mm approx. 5...30C 0... +40 C III IP 20
Height x Width x Depth Modulation range Permissible ambient temperature Enclosure class Enclosure rating
Table 1 Technical data
6 720 610 616 GB (01.05) OSW
Installation
2
2.1
Installation
Fitting
Danger: risk of electric shock! B Disconnect the central heating boiler from the power supply before making the electrical connections. Balance the radiator system by adjusting the radiator valves. If thermostatic valves are fitted in the primary room set to maximum. In that way, the primary room will heat up in the same way as the other rooms.
2.1.1
Installation position
The effectiveness with which the TR 2 is able to control the room temperature depends on where it is sited. Requirements for the installation site: The room in which it is fitted (= primary room) must be suitable for regulating the temperature of the heating system as a whole. Internal wall (if possible) out of the way of draughts and direct heat (the effects of piping, hollow walls, etc.). Unrestricted circulation of air through the vents on the top and bottom of the TR 2 (shaded area in Fig. 2 should be kept clear).
1,2 - 1,5m 0,6m
min. 0,3m
0,3m
2448-02.1/O
Fig. 2
Recommended installation site for TR 2
6 720 610 616 GB (01.05) OSW
Installation 2.1.2 Fitting B Make the electrical connections (refer to Section 2.2). B Refit top section (a). 2.1.3 Fitting accessory units
B Remove top section (a) of unit from base (b).

b
B Fit accessory units for boilers without text display unit according to the statutory requirements and the installation instructions provided:
a
Room-temperature (economy/night) unit TR 212 E timer DT 2.
6 720 610 611-02.1R
Fig. 3 B Turn base so that the terminal labelling is legible. B Fit base (b) to a standard mounting box or directly to the wall using the four screws (drilling template supplied).
6 mm
3,5 mm
6 720 610 611-04.1R
6 mm
Fig. 4
6 720 610 616 GB (01.05) OSW
Installation
2.2
TR 2
B Connection from TR 2 to boiler: Use electrical cable that conforms to BS 6500: up to 20 m cable length: 0.75 to 1.5 mm2 up to 30 m cable length: 1.0 to 1.5 mm2 over 30 m cable length: 1.5 mm2 B All low-voltage wiring (instrument wiring) should be routed separately from cables carrying 230 V in order to prevent inductive interference (minimum separation 100 mm). B If there are external sources of inductive interference (e.g. high-power cables, overhead tram cables, transformer substations, radio and TV equipment, amateur radio equipment, microwaves, etc.): use screened cable.
F
F
3
3
4
4
A F
Textdisplay
6 720 610 611-05.1R
Fig. 5
Connecting the TR 2 to the text display unit
Bosch Heatronic ST 1 TR 212 E
TR 2
1 3 4 A F
DT 2
ST 2
4(3)
F
F
3
3
4
4
3
3
4 A F
4 F
ST 5
ST 9 TA-Modul
6 720 610 614-03.1O
Fig. 6
Connecting the TR 2 to the TR 212 E. 7
6 720 610 616 GB (01.05) OSW
Operation
Operation
20
10
30
C
6 720 610 611-07.1R
Fig. 7
e f
Controls
Mode selector switch Control for On (Comfort) mode; for setting the desired room temperature
3.1.2
Constant On (Comfort) mode
i
3.1
3.1.1
Set the CH flow temperature control on the heating boiler to the maximum required CH flow temperature.
When the mode selector is set to position the TR 2 modulates continuously to the temperature set on the On (Comfort) heating mode control (f). The timer programme settings are ignored. 3.1.3 Constant Off (Economy) mode Use this function when you go to bed earlier than usual or if you are going to be be away from home for a while.
Setting the operating mode (e)

Automatic mode (basic setting)
Switches automatically between On (Comfort) and Off (Economy) modes according the timer programme. On (Comfort) (=Day): the TR 2 modulates to the temperature set on the heating mode control (f). Off (Economy) (= Night): the TR 2 modulates to the temperature set on the text display unit or TR 212 E room-temperature (economy/night) unit.
When the mode selector is set to position the TR 2 modulates continuously to the room temperature set on the text display unit or the TR 212 E room-temperature (economy/night) unit. The timer programme settings are ignored. 3.1.4 Constant Frost protection mode
When the mode selector is set to position the TR 2 modulates continuously to a room temperature of 5C. This provides protection against frost in the room in which the TR 2 is fitted. If the ambient room temperature is above 5C, the heating (pump) remains off.
6 720 610 616 GB (01.05) OSW
Operation The room temperature set on the heating mode control (f), text display unit or TR 212 E roomtemperature (economy/night) unit is ignored. The timer programme settings are ignored.
3.4
Frost protection
There are three possible frost protection modes: Continuous frost protection mode (mode selector switch (e) set to position ).
3.2
Setting the room temperature for On (Comfort) mode (f)
Frost protection while On (Comfort) mode is active (control (f) set to position ). Frost protection while Off (Economy) mode is active: Text display unit: Off (Economy) set to 5C. Room-temperature (economy/night) unit TR 212 E set to . In all frost protection modes, the room in which the TR 2 is fitted is protected against frost. If the ambient temperature is above 5C, the heating (pump) remains switched off.
B Set the control (f) to the desired room temperture between (5C) und 30C. As soon as the TR 2 calls for heat, the heating switches on and continues running until the set room temperature has been reached.
3.3
Setting the room temperature for Off (Economy) mode
If the heating boiler has a text display unit: B Set the desired room temperature for Off (Economy) mode on the text display unit (refer to boiler operating instructions). If the heating boiler does not have a text display unit: B Set the desired room temperature for Off (Economy) mode on the room-temperature (economy/night) unit TR 212 E (refer to operating instructions). As soon as Off (Economy) mode calls for heat, the heating switches on and continues running until the set room temperature has been reached.
3.5
Entering the heating programme
B Enter the switching times for the heating programme on the text display unit (see boiler operating instructions). -orB Enter the switching times for the heating programme on the fitted timer DT 2 (see timer operating instructions).
6 720 610 616 GB (01.05) OSW
If the building is well insulated: the temperature may not drop as low as the set economy temperature. Nevertheless, you will still save energy because the heating will not switch on. In such cases, set the start time for Off (Economy) mode earlier. To air a room, do not leave windows constantly slightly open. This will result in continuous heat loss without significantly improving the quality of air in the room. Air the room for a short time, but thoroughly (windows fully open). While airing, turn off the thermostatic valve or set TR 2 to .
... and tips on saving energy: The temperature in the primary room (room in which TR 2 is fitted) serves as the reference for the entire heating system. For that reason, the radiators must be adjusted to balance the system. With manual valves, they should be preset. With thermostatic valves, they should be set to maximum and the adjustment made using the return unions. If the thermostatic valves in the primary room are not turned up to the maximum setting, they could restrict the supply of heat even though the TR 2 is calling for heat. Adjust the temperature in the remaining rooms by means of thermostatic valves. If the primary room is heated by external sources (e.g. sunshine, stove, etc.) the other rooms may not heat up adequately (central heating may not cut in). Save energy by reducing the room temperature during the day or at night: reducing the room temperature by 1 C: can achieve up to 5% energy savings. Energy-inefficient: allowing the temperature of rooms that are heated daily to fall below +15 C because the walls will become cold, the room temperature will have to be raised and thus more energy consumed than if an even temperature were maintained.
10
6 720 610 616 GB (01.05) OSW
Fault finding
Fault finding
Cause Thermostatic valve(s) in primary room set too low CH flow temperature control on boiler set too low Air trapped in heating system Remedy Turn up thermostatic valves to maximum or replace with manual valve(s) Turn up CH flow temperature control Bleed radiators and heating system Choose better installation site (see Section 2.1.1).
Problem Desired room temperature is not reached
Desired room temperature is exceeded by large amount Excessive fluctuations in room temperature Temperature rises instead of falling Room temperature too high in Economy mode
Bad choice of installation site for TR 2, e.g. on external wall, near window, in draught, ... Periodic effect of external source of heat on room, e.g. due to sunshine, lighting, TV, fire, etc. Time set incorrectly on timer
Choose better installation site (see Section 2.1.1).
Check time setting
Building stores heat well
Set Off (Economy) mode to start earlier
Incorrect or non- TR 2 wired incorrectly existent modulation
Check wiring conforms to wiring diagram and correct as necessary
6 720 610 616 GB (01.05) OSW
11
Fault finding
Nr. 860
7 719 002 068
4.
>11 Nm
3. 2. 3. 1.
>11 Nm
6 720 610 619 (01.06) Gm
6 720 610 619-01.1R
14
Nr. 840
7 719 001 996
3
6 720 610 376-00.1R
6 720 610 376 (01.01) Ka
Nr. 840
6 720 610 376-01.1R
6 720 610 376-05.1R
2 ZBR...-42..
2.
H 2O
1.
1.
2.
6 720 610 376-02.1R
6 720 610 376-06.1R
7
~5 Nm
3
6 720 610 376-03.1R 6 720 610 376-07.1R
6 720 610 376-04.1R
AMENDMENT SHEET TO MEET THE REQUIREMENTS OF AMENDED BUILDING REGULATIONS DOCUMENT J

THE FIGURES, INFORMATION & DIAGRAMS INCLUDED IN THIS AMENDMENT SHEET SHOWN HERE & OVERLEAF SUPERSEDE THOSE GIVEN IN THE ACCOMPANYING LITERATURE TERMINAL POSITIONS
The following distances should be applied to the positioning of terminals in relation to other terminals and openings in dwellings.
NOTE: The dimensions given are for general guidance only. Other surrounding buildings or objects may affect the clearance of combustion products. An alternative flue terminal position should be sought when there is any possibility of a nuisance being caused by inadequate dispersal of flue products. Terminals should be positioned so as to avoid products of combustion entering into buildings. P
M Boundry M C.D. F J H E Boundry G A B
Window Flue outlet Terminal
K F F L
Terminal Position A B C D E F G H J K L M N O P Directly below an opening, air brick, window, etc . ...... ...................................... Horizontally to an opening, air brick, window, etc. .......................................... Below a gutter or sanitary pipe if combustible material protected. .............. Below a balcony, eaves, gutter or drainage without protection to combustible material. ...................................................................................... From vertical sanitary pipework.. ....................................................................... From an internal or external corner or boundry along side terminal. .......... Above ground or balcony level. .......................................................................... From a surface or boundry facing the terminal. .............................................. From a terminal facing the terminal. ................................................................. Vertically from a terminal on the same wall. ................................................... Horizontally from a terminal on the same wall. .............................................. Above an intersection with the roof. ................................................................. From a vertical structure on the side of the terminal...................................... Above a vertical structure less than 750mm from the side of the terminal. From a ridge terminal to a vertical structure on the roof................................
Open Flue
Minimum Distance (mm) Low-Level Vertical Discharge Balanced Flue 600 600 75 600 300 300 300 600 1200 1500 750 Not applicable Not applicable Not applicable Not applicable Not allowed '' '' '' '' '' '' '' '' '' 732 750 732 Not applicable
Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 600 750 600 1500
SYSTEM FILLING & MAKE UP FOR SEALED SYSTEM APPLIANCES

The system filling and make up diagram below supersedes the diagram in the Installation and Servicing Instructions.
Make up vessel Heating return Auto air vent Non return valve Stop cock Fill point
300 mm (12 in) min. above the highest point of the system.
Method 1
Method 2
Service booklet for the Engineer for Gas Condensing Boilers
6 720 610 333-00.1R
ZB 7-29 CC1 GC-Number: 47 108 05 ZB 7-28 CS1 GC-Number: 47 108 02 ZWB 7-27 HE combi GC-Number: 47 311 55 ZB 7-27 HE system GC-Number: 47 311 49
7 181 465 346 (01.07) OSW
Table of contents
Table of contents
Warnings Symbols 1 2 2.1 2.2 2.3 2.4 2.4.1 2.4.2 3 3.1 3.2 3.2.1 3.2.2 3.3 3.4 3.4.1 3.4.2 4 4.1 4.1.1 4.1.2 Layout of Appliance (system/combi) Bosch Heatronic board functions Temperature indication Boiler failure codes indication Special programme visualisation Boiler service functions First Service Level Secondary Service Level Failure identification procedure How to use the code tables Summary Appliance faults Faults that are not displayed Error codes on the display Faults that are not displayed Appliance faults Programmer faults 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 3 3 4 5 5 5 5 6 6 9 10 10 11 11 11 12 34 34 39 43 43 43
4.2 4.3 4.4 4.5
43 44 45 46 47
7 181 465 346 (01.07)
Warnings
Warnings
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! Instructions to the customer B Explain to the customer how the appliance works and how to operate it. B Advise the customer that he/she must not make any modifications to the appliance or carry out any repairs on it.
Symbols
Notes are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text
7 181 465 346 (01.07)
Layout of Appliance (system/combi)
Layout of Appliance (system/combi)
Fan fixing screws burner
Fan lead connector Fan Mixer unit Silencer
Burner fixing screws
Electrode assembly CH flow NTC sensor CH flow safety temperature limiter
CH flow Gas supply pipe Flue gas safety temp. limiter Gas flow restrictor: adjusting screw for CO2 (max)
Pump
Gas valve: adjusting screw for CO2 (min) Hot water NTC sensor 1 (combi)
7 181 465 346-01.1R
7 181 465 346 (01.07)
Bosch Heatronic board functions
2
2.1

Temperature indication
The appliance works continuously at the maximum power. B Press the button until the symbol appears on the display. The button is lighted. B Turn the temperature control until function 2.0 appears on the display. After about 5 seconds the display will show 2 for the maximum power. B Turn the temperature control completely anticlockwise until the display shows 0 . B Press the button until the symbol [ ] appears on the display. The display shows the heating outlet temperature. Display shows 45 -II- 45 (trap filling programme) The trap filling programme ensures that the condensation trap is filled after the appliance is first installed or if it has been switched off for a long period. The trap filling programme is activated if: 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 central heating or heat store calls for heat, the appliance is held at a low heat output for 15 minutes. The display shows -II- in alternation with the CH flow temperature. The factory setting is 1 (enabled). Warning: If the condensation trap is not filled with water, flue gas can escape! B The trap filling programme should only be disabled in order to carry out servicing work. B Always re-enable the trap filling programme after completing servicing work. To switch off the trap filling programme to carry out servicing work: B Press and hold the and buttons simultaneously until the display shows = =. The and buttons will light up. B Turn the temperature control until the display shows 8.5. After a short delay, the display then shows the trap filling programme setting (1. = Enabled).
On all models, the current CH flow temperature is displayed in central heating mode and hot water mode. The display range extends from 00 C to 99 C.
2.2
Boiler failure codes indication
In order to identify the specific boiler failure a two digit alphanumeric code is used. This allows a quick fault identification and solution. The failures can be divided into four basic typologies, as described: The appliance continues to work at a minimum function level (e. g. with error codes A5, A7, AC, Ad, CC). The appliance is locked until the failure is repaired (e. g. with error codes b1, C1, C4, C6, d1, E2). 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).
i
2.3
To unblock the appliance: B Press the unblock button until the digit appears on the display.
Special programme visualisation
The display shows for example 45 45 (continuous working at the minimum sanitary/heating power) The display shows alternatively the temperature and . The function is memorised in the Service mode. The appliance works continuously at the sanitary or heating minimum power. B Press the button until the symbol appears on the display. The button is lighted. B Turn the temperature control until function 2.0 appears on the display. After a short delay, the display shows 1 for minimum output. B Turn the temperature control completely anticlockwise until the display shows 0 . B Press the button until the symbol [ ] appears on the display. The display shows the heating outlet temperature. The display shows for example 55_ _55 (continuous working at the maximum power) The display shows alternatively the temperature and _ _. The function is memorised in the Service mode.
7 181 465 346 (01.07)
B Turn the temperature control shows 0. (= Disabled). The display and the and
until the display buttons will flash.
Display shows 00 (venting function) The first time the appliance is switched on, it automatically activates a one-off venting sequence in which the heating pump switches on and off at intervals for about 8 minutes. This function can be activated on Service Level 2, Service Code 7.3, if it is required at any other time.
B Press and hold the and buttons simultaneously until the display shows [ ]. The trap filling programme is now disabled. B Regulate the temperature control and the temperature control on the previously set positions. The display shows the heating outlet temperature.
2.4
2.4.1
Boiler service functions

First Service Level
Operating In order to change or check the values of the service functions: B Press the button until the symbol appears on the display. The button is lighted. B Turn the temperature control until the desired function number appears on the display. Once changed or checked the function value: B Press the button until the symbol [ ] appears on the display. The display shows the heating outlet temperature. Values that can be modified: B Regulate the temperature control and the temperature control on the previously set positions. In order to reset the main menu function values to their default values: B Power OFF the appliance. B Press the button and keep it pressed. butB Switch on the appliance, press and hold the ton until the display shows r1 followed by [ ].
Description .0 2.0 2.2 2.3 2.4 2.5 2.6 2.7 3.4 Table 1 1) 2) Show the last error code. Identification of the function mode (0 = normal, 1= min, 2 = max) Identification of the pump function mode Max. output in heat store heating mode Anti-cycle time1) Max. CH flow temperature Minimum hysteresis in heating mode (T) Activation of automatic anti-cycle time (0 = Disabled; 1 = Enabled) Pump mode
Display 0 - FF 0-2 1-3 28 - 99 0 - 15 min 35 - 88 C 0 - 30 K 0, 1 0-3
Reset Value Clear only 0 2 99 3 min 88 C 0K 1

2)
If appliance is used in conjunction with type TA... programmer, only effective if Service Code 2.7 is set to 0 (= "Disabled)! The reset value is dependent on the code plug.
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Values that can only be read:
Description .1 .2 .3 .4 1.2 1.4 Heating outlet temperature. Sanitary outlet temperature. Heat store NTC sensor (ZSB.) Constant hot water NTC sensor (ZWB.) Order no. for code plug: 8 714 411 XXX Temperature voltage signal (Terminal 2) from room thermostat (eg. TRQ 21, TR 100) Specified CH flow temperature from programmer Outside temperature from TA 211 E or room temperature from TR 212 E Status TR 2 (0 = Not present 1 = Frost protection 3 = Auto 4 = Day, Night 5=Error) Terminal 2 on programmer interface module Identification code for the external module: 0, 2, 4, 5 = no module connected, 3 = ADM, 6 = TA 211E, 53 = ADM, 56 = TR 212 E). Instantaneous power. Fan speed Quality of the ionisation signal: 0 = no ionisation, 1 = weak ionisation, 2 = medium ionisation, 3 = high ionisation. Software version
Display 0 - 99 C 0 - 99 C 0 - 99 C 0 - 99 C 0 - 255 5 - 22 VDC
Reset Value -
1.5 1.6
0 - 99 C -20 +30 C
1.7
0-4
1.8 1.9
0 - 24 VDC 0 - 8, 53, 56
2.9 3.0 3.3
0 - 99 % 0 - 105 0-3
3.6 Table 2
3x2 positions
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Values that can only be read - only left display digit: Display XY 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand
Description 3.9 External switch (points 8 - 9).
Reset Value -
4.1
External demand for heat via LSM
4.2
Programmable clock: 1st channel (Heating). Automatic pump shut OFF with RAM module (point 5) Heating demand.
4.3
4.4
4.5 Table 3
Sanitary demand.
Values that can only be read - only right display digit: Display XY 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand 0 = closed 1 = Heating demand
Description 3.9 4.0 External 2-point demand for heat via 230 V AC (Terminals Ls - Lr) Heat store demand for heat via heat store thermostat (Terminals 7-9) LSM Enable
Reset Value -
4.1
4.2
Programmable clock: 2nd channel (DHW Maintaining). Heating demand from TA 211 E
4.3
4.4
Heat store demand for heat via heat store NTC sensor Sanitary heat exchanger temperature maintaining.
4.5
4.6 Table 4
Anti-cycle time
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2.4.2
Secondary Service Level
Operation In order to change or check the values of the service functions: B Press buttons and simultaneously until the symbol = = appears on the display. The buttons and are lighted. B Turn the temperature control until the desired function number appears on the display. Once changed or checked the function value: B Press buttons and simultaneously until the symbol [ ] appears on the display. The display shows the heating outlet temperature. Values that can be modified: B Regulate the temperature control and the temperature control on the previously set positions. To reset all settings on Service Levels 1 and 2 to the factory setting: B Power OFF the appliance. B Press buttons them pressed. and simultaneously and keep
B Switch on appliance, press and hold the and buttons until the display shows r2 followed by [ ].
Description 5.0 5.1 Reduced max. heating output Continuous ignition (for testing ignition without gas) Increased min. heating and heat store charging output Starting speed option (if flame propagation is poor, set high starting speed) Pump deactivation in HW mode, ZW only. Cycle time for heat exchanger constant hot water function on ZW model. Constant hot water Venting function
Display 0 - 99 % and sealed 0 = off 1 = on 0 - 99 %
Reset Value 99 0
5.5
5.9 6.7 6.8
0 = First start at low speed; 1 = First start at high speed) 0 = off, 1 = on 0 - 60 min
1 0
6.9 7.3
0 - 30 min 0 = off, 1 = On for 8 cycles then permanently off (i.e. set to 0) 2 = on 0 = off 1 = on
3 1
8.5 Table 5
Trap filling programme
Values that can only be read:
Description 5.2 9.3 Table 6 Automatic gas igniter status and/or fault Automatic gas igniter Asic fault code
Display 00 - FF 00 - FF
Reset Value -
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Failure identification procedure
3
3.1

How to use the code tables
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. 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.
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. Once that has been done, you must check if (after the appliance has attempted to start up) the burner flame is visible. 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?) wasno, then you go to and answer Question 2, Is the gas cock turned on?. If the gas cock is turned
EA
and
flashing.
No flame ionisations signal Check Action

B Note the setting of the temperature controls and . 1. Is burner flame visible? yes: no: 2. Is the gas cock turned on? yes: no: 5. B Turn on the gas cock. B Press button EA? 3. Did the thermal security of the gas cock lock out? ... Is there a problem with the flue? B Check CO2 level in combustion air. > 0,2 % CO2? yes: no: Check flue and clean if necessary. .... yes: no: ... ... .
4. ... 5. ...
To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions. Table 7
10
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3.2
3.2.1
Summary
Appliance faults 3.2.2 Faults that are not displayed
ZWB ...A
ZWB ...A
X X X X X X
ZB ...A
ZB ...A
Page
Appliance faults
A5 A7 A8 AC Ad b1 C1 CC d3 E2 E9 EA F0 F7 FA Fd Table 8
Appliance faults
Excessive burner noise, rumbling noises Flue gas levels incorrect, CO level too high Ignition too harsh, ignition poor. Boiler indicates P1, P2, P3 at start-up and then restarts with P1,... Loose or broken contact on heat store NTC sensor Specified CH flow temperature from TA... programmer exceeded Table 9
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
12 13 14 15 17 18 19 20 21 23 24
X X X X
34 35 36 37
X X
38 38
TR 2 and TR 212 E
26 30 31 32 33 Programmer faults Set room temperature not reached. Set room temperature exceeded. Set room temperature not reached. Set room temperature exceeded by large amount. Excessive fluctuations in room temperature Temperature rises instead of falling Room temperature too high in Economy mode Incorrect or no modulation Heat store fails to heat up Table 10
TA 211E and DT 2 X X X X X X X
X X
39
40 41 41 41 42 42
X X X X
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Page
3.3
Error codes on the display
A5
1.
flashing.
Heat store NTC sensor 2 defective Check Action

B Note the setting of the temperature controls and . B Press button . yes: B Select service function .3 . Is a temperature between 0. and 5. displayed? no: 2. Heat store NTC: B Unplug the connector. B Short circuit the connector. Display changes to temperature between 100. and 95. yes: B Flue gas connector corroded1), damaged or dirty?. Change relative parts. 2. 3. B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change NTC sensor. B Plug the connection wire. B Reconnect the boiler electrical connection. B Turn ON the appliance. A5? 3. no: B Change the 20-pin connector lead assembly. 3. 3. Temperature between 95. and 99. is displayed. B Unplug the connector. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.? yes: B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change NTC sensor. B Plug the connection wire. B Reconnect the boiler electrical connection. B Turn ON the appliance. A5? 4. no: 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.? yes: 4. B Change the 20-pin connector lead assembly. 5. 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. 5. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
1) For notes, refer to Appendix
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A7
1.
flashing.
Hot water NTC sensor defective Check Action

B Note the setting of the temperature controls and . B Press button . yes: B Select service function .2 . Is a temperature between 0. and 5. displayed? no: 2. Hot water NTC sensor: B Unplug the connector. B Short circuit the connector. Display changes to temperature 99. yes: B Flue gas connector corroded1), damaged or dirty? Change relative parts. 2. 3. B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change NTC sensor. B Plug the connection wire. B Reconnect the boiler electrical connection. B Turn ON the appliance. A7? 3. no: B Change the 20-pin connector lead assembly. 3. 3. Temperature between 95. and 99. is displayed. B Unplug the connector. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.? yes: B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change NTC sensor. B Plug the connection wire. B Reconnect the boiler electrical connection. B Turn ON the appliance. A7? 4. no: 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.? yes: 4. B Change the 20-pin connector lead assembly. 5. 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. 5. 5. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
1) For notes, refer to Appendix
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13
A8
1.
flashing.
No correct electrical connection Check

TR 2 connected? yes: no:
Action
A8? 2. B Power OFF the appliance. B Connect TR 2. B Turn ON the appliance. A8? 2.
2.
Mode selector switch is between two settings B Power OFF the appliance. Wiring between TR 2 and TR 212 E OK? Terminal 3 on TR 2 connected to Terminal 3 on TR 212 E? Terminal 4... Terminal 4.... no: yes:
B Turn switch until it clicks into position. A8? 3. B Turn ON the appliance. 4. B Rewire correctly as specified in the installation instructions. B Turn ON the appliance. After 90 sec.: A8? 4.
3.
4.
TR 2 defective
B Power OFF the appliance. B Change TR 2. B Turn ON the appliance.
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AC
flashing.
Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.) Check Action
B Note the setting of the temperature controls and . 1. B Press button . yes: No modul detected. B Disconnect connecting lead between PCB control board and TA 211 E or TA 212 E. B Re-connect connecting lead. AC? 3. no: 2. Are 24 V DC cables routed alongside 230 V AC cables? yes: 2. B Ensure cable separation conforms to minimum requirements as per installation instructions and/ or use shielded cable. 3. B Power OFF the appliance. B Replace connecting lead between PCB control board and programmer interface module or TA 211 E. B Turn ON the appliance. AC? 4. 4. TA 211 E connected? yes: no: 5. B Select service function 1.6 . Outside temperature between -20 and +30 C is displayed. If the outside temperature is negative, the temperature is shown in alternation with the minus sign! If remote control installed: B Select service function 1.7 . Remote control status 0. is displayed . no: yes: no: 5. 8. 7. B Power OFF the appliance. B Replace outside temperature sensor. B Turn ON the appliance. AC? 7. yes: B Power OFF the appliance. B Plug the connection wire. B Turn ON the appliance. AC? 7. 7.
B Select service function 1.9 . Code 0., 2., 4., 5. is displayed.
no: 3. Connecting lead between PCB control board and TA 211 E or TA 212 E defective.
6.
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15
AC
7.
flashing.
Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.) Check
Remote control status still 0.? yes:
Action
B Power OFF the appliance. Remote control: B Replace top section. B Turn ON the appliance. AC? 8. no: 8. 9. B Power OFF the appliance. B Replace TR 2. B Turn ON the appliance. 9. 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. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
8.
B Select service function 1.6 . Room temperature between -20 and +30 C is displayed. If the roomtemperature is negative, the temperature is shown in alternation with the minus sign. The PCB control board is damaged.
yes: no:
9.
16
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Ad
flashing.
Heat store NTC sensor 1 not detected (ZB...). Check Action

B Note the setting of the temperature controls and . 1. Is connecting lead for heat store NTC sensor 1 correctly routed, i.e. not through cable grommet? yes: no: 2. B Route connecting lead for heat store temperature sensor as specified in installation instructions. Connector on end of NTC sensor lead: B Flue gas connector corroded1), damaged or dirty? Change relative parts. B Press button Ad? 3. no: 3. Heat store -NTC 1: B Unplug connector from PCB control board. B Short circuit the connector using wire jumper. After max. 60 sec: Display changes to temperature between 100. and 95. 4. Temperature between 99. and 95. is displayed. B Unplug the connector. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.? no: yes: 4. B Change NTC sensor. 4. B Change PCB control board. 4. .
2.
B Press button
yes:
B Select service function .3 . Is a temperature between 0. and 5. displayed?
yes: no:
B Change NTC sensor. 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. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
1)
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17
b1
1. 2.
flashing.
The Heatronic does not recognise the code key. Check Action
B Power OFF the appliance. Code plug loose, incorrect or defective. B Replace code plug, check code number is correct. B Turn ON the appliance. b1? 3. 3. 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.
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C1
1.
flashing.
Fan speed too low Check

Fan lead connector properly connected? yes: no:
Action
2. B Power OFF the appliance. B Plug in connector. B Turn ON the appliance. C1? 2.
2.
Fan lead defective?
yes:
B Power OFF the appliance. B Replace fan lead. B Turn ON the appliance. C1? 3.
no: 3. Fan defective? yes:
3. B Power OFF the appliance. B Plug the connection wire. B Replace fan. B Plug the connection wire. B Turn ON the appliance. C1? 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.
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CC
Check
1.
flashing.
Outside temperature NTC sensor not detected. (Boiler heating as if outside temperature is -20 C) Action
yes: no: 2. B Power OFF the appliance. B Connect outside temperature sensor to Terminals A and F on TA 211 E. B Turn ON the appliance. CC? 2. 2. B Power OFF the appliance. B Disconnect outside temperature sensor and test resistance R = or R = 0? B Change the external sensor. B Turn ON the appliance.
Outside temperature sensor AF2 connected to Terminals A and F on TA 211 E?
20
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d3
1.
flashing.
Wrong signal from pin 8-9 (open?). Check

B Turn ON the appliance. B Measure voltage between Terminal 4 and Terminal 8. 24 V DC? 2. Existing heat store thermostat connected to Terminals 7, 8 and 9? 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? 3. no: 3. Break in connecting lead? yes: 4. B Power OFF the appliance. B Plug the connection wire. B Turn ON the appliance. d3? 4. no: 4. Limiter for underfloor heating fitted external to appliance? Limiter for underfloor heating connected to LSM? yes: no: yes: no: 4. 5. 8. 6. B Power OFF the appliance. B Connect underfloor heating limiter to LSM. B Fit jumper across 8 - 9 on appliance and tighten screws. B Turn ON the appliance. d3? 6. 6. Has underfloor heating limiter tripped? yes: B Locate and eliminate cause. B Reset limiter. d3? 7. no: 7. Connecting lead disconnected? yes: 7. B Power OFF the appliance. B Plug in, repair or replace connecting lead. B Turn ON the appliance. d3? 8. no: 8. yes: no:
Action
2. 8.
5.
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21
d3
8.
flashing.
Wrong signal from pin 8-9 (open?). Check

Terminal block defective.
Action
B Power OFF the appliance. B Replace terminal block. B Turn ON the appliance. d3? 9.
9.
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.
22
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E2
flashing.
The heating outlet NTC sensor is damaged. Check Action

B Note the setting of the temperature controls and . 1. B Press button . yes: The heating outlet NTC sensor is in short circuit: 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? 2. no: 2. Temperature for heating outlet NTC sensor between 95. and 99. is displayed. yes: 2. 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. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
B Select service function .1 . Is a temperature between 0. and 5. displayed?
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E9
1.
and
flashing.
Safety temperature limiter has tripped. Check

Is the heating pressure between 1 and 2 bar? yes: no:
Action
2. B Top up system. B Vent appliance. B Press E9? 2. , does appliance restart???
2.
Is the pump blocked?
yes:
B Unblock the pump. If pump wont 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 E9? 3. , does appliance restart???
no: 3. Lead disconnected from safety temperature limiters? yes:
3. B Power OFF the appliance. B Connect lead. B Turn ON the appliance. B Press E9? 4. , does appliance restart???
no: 4. B Power OFF the appliance. B Unplug the connector from the cut-off device. B Measure the NTC electrical resistance. R = ? no: yes:
4. B Change the over heating cut-off device. B Connect flue gas safety temperature limiter lead. B Turn ON the appliance. B Press E9? 5. B Connect flue gas safety temperature limiter lead. B Turn ON the appliance. 5. , does appliance restart???
24
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E9
5.
and
flashing.

B Power OFF the appliance. B Disconnect lead to CH flow safety temperature limiter. B Measure the CH flow safety temperature limiter. R = ? no: yes:
Action
B Change CH flow safety temperature limiter. B Connect CH flow safety temperature limiter lead. B Turn ON the appliance. B Press E9? 6. B Connect CH flow safety temperature limiter lead. B Turn ON the appliance. 6. , does appliance restart???
6.
B Power OFF the appliance. B Remove fuse SI 3 from appliance PCB control board and test for continuity. R = ?
yes:
B Change the fuse. B Turn ON the appliance. B Press E9? 7. , does appliance restart???
no:
B Remount the fuse. B Turn ON the appliance. 7.
7.
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25
EA
and
flashing.
No flame ionisations signal Check Action

B Note the setting of the temperature controls and . 1. Is the flame present? yes: no: 2. Is the gas cock open? yes: no: 6. 2. 3. B Open the gas cock. B Press EA? 3. 3. Is there air in the supply pipe? yes: B Vent supply pipe. B Press EA? 4. no: 4. Did the thermal security of the gas cock lock out? yes: 4. B Reset security. B Press EA? 5. no: 5. Natural gas models: does the building have a supply pressure regulator? yes: 5. 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 EA? 6. no: LPG models: is the flow rate of the gas supply to the appliance correct? yes: no: 6. 6. 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 EA? 6. , does appliance restart??? , does appliance restart??? , does appliance restart??? , does appliance restart??? , does appliance restart???
26
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EA
6.
and
flashing.
No flame ionisations signal Check

Is the ground connection correct? yes: no:
Action
7. B Correct the electrical ground connection. B Press EA? 7. , does appliance restart???
7.
Two phase net: Is there a resistor fitted between Pe and N?
yes: no:
8. B Power OFF the appliance. B Disconnect the boiler electrical connection. B Insert a 2 M resistance between the ground and the N connection. B Reconnect the boiler electrical connection. B Turn ON the appliance. B Press EA? 10. , does appliance restart???
8.
Is the condensation trap blocked?
yes:
B Clean out condensation trap discharge pipe. B Press EA? 12. , does appliance restart???
no: 9. Check the gas valve? B Power OFF the appliance. B Unplug the connectors from the gas valve. B Measure the gas valve coils I and II electrical resistance. R = 164 40 ? no: yes:
9. B Reconnect the gas valve. B Turn ON the appliance. B Press EA? 10. B Change the gas valve. B Reconnect the gas valve. B Turn ON the appliance. B Press EA? 10. , does appliance restart??? , does appliance restart???
10.
Problem with flue? B Open up heat exchanger - is it dirty? B Check CO2 level in combustion air. > 0,2 % CO2?
yes:
B Check flue and clean if necessary. B Press EA? 11. , does appliance restart???
no:
11.
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27
EA
11.
and
flashing.

Is flue gas CO2 level incorrect1)? yes:
Action
B Adjust to correct level. B Press EA? 12. no: 12. B Press buttons 13. no: B Press buttons 16. yes: no: 14. B Connect cable to ignition electrode. B Press EA? 14. , does appliance restart??? and simultaneously. and simultaneously. , does appliance restart???
12.
B Press buttons neously.
and
simulta-
yes:
B Select service-function 5.1. Continuous ignition (without gas) OK? 13. Ignition lead connected to ignition electrodes?
14.
Ignition cable connector engaged in switchbox?
yes: no:
15. B Power OFF the appliance. B Engage ignition cable connector in switchbox. B Turn ON the appliance. B Press EA? 15. , does appliance restart???
15.
Is the ignition electrical wire damaged?
yes:
B Power OFF the appliance. B Change the ignition electrical wire. B Turn ON the appliance. B Press EA? 16. , does appliance restart???
no: 16. B Press button . yes: no:
16. 18. 17.
B Select service-function 3.3. Is the ionisation quality 2 or 3 ?
28
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EA
17.
and
flashing.

Electrode assembly defective? B Power OFF the appliance. B Remove electrode assembly. Electrodes worn out? yes:
Action
B Power OFF the appliance. B Replace electrode assembly. B Turn ON the appliance. B Press EA? 18. no: B Refit electrode assembly. B Turn ON the appliance. B Press EA? 18. , does appliance restart??? , does appliance restart???
18.
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 EA? B Power OFF the appliance. 19. , does appliance restart???
19.
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. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
1)
See installation instructions
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29
F0
(and possibly
) flashing.
Internal failure Check Action

B Note the setting of the temperature controls and . 1. B Press buttons neously. and simultaB Enter figure displayed in customer service record. 2.
B Select service function 9.3 . A service code is displayed. 2. B Select service function 5.2 . A service code is displayed. flashing? yes:
B Enter figure displayed in customer service record. 3. B Press button . B Initiate demand for heat by pressing button and then press again after 30 seconds to cancel. B Initiate two more demands for heat as above. F0? 4. 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. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
3.
4.
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F7
1.
and
flashing.
Although appliance switches off, flame still detected Check

Electrode(s) dirty or defective.
Action
B Power OFF the appliance. B Replace electrode assembly. B Turn ON the appliance. B Press F7? 2. , does appliance restart???
2.
B Power OFF the appliance. B Disconnect the boiler electrical connection. B Remove PCB control board. PCB control board damp?
yes:
B Dry PCB control board (e.g. with hair dryer). B Refit PCB control board. B Reconnect the boiler electrical connection. B Turn ON the appliance. B Press F7? 3. , does appliance restart???
no: 3. Problem with flue? B Check CO2 level in combustion air. > 0,2 % CO2? 4. The PCB control board is damaged. yes: no:
3. B Check flue and repair or replace if necessary. 4.
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31
FA
and
flashing.
Although appliance switches off, flame still detected Check Action

B Note the setting of the temperature controls and . B Power OFF the appliance. 1. Condensation trap blocked? yes: B Clean condensation trap discharge pipe. B Press FA? 2. no: 2. Electrodes faulty. 2. B Replace electrode assembly. B Turn ON the appliance. B Press FA? , does appliance restart??? , does appliance restart???
B Power OFF the appliance. 3. Problem with flue? B Check CO2 level in combustion air. > 0,2 % CO2? yes: B Check flue and repair or replace if necessary. B Press FA? 4. no: 4. The gas valve is damaged. 4. B Change the gas valve. B Turn ON the appliance. B Press FA? 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 FA? 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. , does appliance restart??? , does appliance restart??? , does appliance restart???
B Power OFF the appliance.
32
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Fd
Button
1.
and
flashing.
pressed without necessity Action

is flashing. B Press Fd? 2. , does appliance restart???
Check
Button
2.
B Disconnect the boiler electrical connection. B Change PCB control board. B Reconnect the boiler electrical connection. B Turn ON the appliance.
7 181 465 346 (01.07)
33
3.4
3.4.1
Faults that are not displayed

Appliance faults
Excessive burner noise, rumbling noises
Check
Action
B Note the setting of the temperature controls and .
1.
Does the gas supply type match the specifications on the appliance identification plate?
yes: no:
2. B Convert appliance to correct gas type1). 2.
2.
B Test gas supply pressure - OK?

1)
yes: no:
3. B Decommission appliance. B Notify gas company.
3.
Problem with flue? B Check CO2 level in combustion air. > 0,2 % CO2?
yes: no:
B Check flue and repair or replace if necessary. 3.
4.
Cascade: Is the appliance min. output high enough to open the shut-off device? Is appliances internal air/flue channel leaking or blocked? B Open up heat exchanger and inspect. B Remove silencer, flue duct and air flow limit. B Open trap and inspect. Air channels dirty/clogged, seals defective or not correctly fitted?
yes: no: yes:
5. B Increase min. output. B Repair or replace components. B Grease seal before fitting. B Make sure it is fitted in correct position. 6.
5.
no:
6.
Flue gas CO2 levels measured at min. and max. load do not match specified levels1). B Measure CO2 levels.
yes: no:
B Adjust CO2 levels1). B Power OFF the appliance. B Change the gas valve. B Turn ON the appliance.
7.
and
simulta-
B Set to 1 for high start-up speed.
B Select service-function 5.9. 0 is displayed.

1) See installation instructions
34
7 181 465 346 (01.07)
Flue gas levels incorrect, CO level too high
Check
1. Does the gas supply type match the specifications on the appliance identification plate? yes: no:
Action
2. B Convert appliance to correct gas type1). 2.
2.
B Test gas supply pressure - OK?
yes: no:
3.
yes: no:
4.
Flue gas CO2 levels measured at min. and max. load do not match specified levels? B Measure CO2 levels.
yes: no:
B Adjust CO2 levels. 5.
5.
Gas volumetric flow too high when CO2 level correctly set.
yes:
B Reduce gas volumetric flow rate by means of adjusting screw on gas valve and/or gas flow restrictor. B Check CO2 adjustment. 6. Change the gas valve.
no: 6.
7 181 465 346 (01.07)
35
Ignition too harsh, ignition poor
Check
Action
1.
and
simulta-
yes: no:
6. 2.
B Select service-function 5.1. Continuous ignition (without gas) OK? 2. Ignition lead connected to ignition electrodes?
yes: no:
3. B Connect cable to ignition electroden. B Press button Ignition poor? 3. .
3.
yes: no:
4. B Power OFF the appliance. B Engage ignition cable connector in switchbox. B Turn ON the appliance. B Press button Ignition poor? B Power OFF the appliance. 4. .
4.
Is the ignition electrical wire damaged?
yes:
B Power OFF the appliance. B Change the ignition electrical wire. B Turn ON the appliance. B Press button Ignition poor? B Power OFF the appliance. 5. .
no: 5. Electrode assembly defective? B Power OFF the appliance. B Remove electrode assembly. Electrodes worn out? no: yes:
5. B Replace electrode assembly. B Turn ON the appliance. B Press , does appliance restart??? Ignition poor? 6. B Refit electrode assembly. B Turn ON the appliance. B Press , does appliance restart??? Ignition poor? 6.
36
7 181 465 346 (01.07)
Check
6. Does the gas supply type match the specifications on the appliance identification plate? B Test gas supply pressure - OK? yes: no: yes: no:
Action
7. B Carry out gas type conversion as described in installation instructions. 8. B Decommission appliance. B Notify gas company.
7.
8.
yes:
no: yes: no:
9. B Adjust CO2-levels1). 10.
9.
Flue gas CO2 levels measured at min. and max. load do not match specified levels1). B Measure CO2 levels.
10.
Burner not correctly fitted or defective? B Remove burner. Cover fixings not tight or seal defective or not correctly fitted or burner defective!
B Replace burner and seal if necessary. B Ensure seal is fitted in correct position.
To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
Boiler indicates P1, P2, P3 at start-up and then restarts with P1..
Check
1. Fuse T 1,6 A (312) defective. yes:
Action
B Turn ON the appliance. B Change the fuse. B Power OFF the appliance. Start sequence not completed? 2. no: 2. B Change PCB control board.
2.
7 181 465 346 (01.07)
37
Loose or broken contact on heat store NTC sensor
Check
1. 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).
Action
B Record condition of appliance as found in customer service record. B Route cable as specified in installation instructions.
Specified CH flow temperature from TA... programmer exceeded
Check
Action
If outside-temperature controlled programmer (TA 211 E) 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 Press button . B Disable automatic anti-cycle time, i.e. change setting to 0.
B Select service-function 2.7. Read off status of automatic anticycle time (0 = Disabled, 1 = Enabled). 2. B Select service-function 2.4. Read off anti-cycle time setting (0 ... 15 min).
B Set anti-cycle time as required, e.g. factory setting 3 min. To return to normal function mode: B Press buttons and simultaneously. B Regulate the temperature control and the temperature control on the previously set positions.
38
7 181 465 346 (01.07)
3.4.2
Programmer faults
Set room temperature not reached (TR 2 and TR 212 E)
Check
1. Thermostatic valve(s) set too low? yes:
Action
B Turn up thermostatic valve(s). 2. no: 2. B Turn up CH flow temperature control. 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.
2.
CH flow temperature control on boiler set too low? Air in the heating system.
yes: no:
3.
1)
7 181 465 346 (01.07)
39
Set room temperature not reached (TA 211 E und DT 2)
Check
Action
B Turn up thermostatic valve(s). 2. no: 2. B Correct heating characteristic. 3. no: 3. B Turn up CH flow temperature control. 4. no: 4. B Turn up CH flow temperature control. 5. no: 5. 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.
2.
Heating characteristic set too low?
yes:
3.
CH flow temperature control on boiler set too low?
yes:
4.
Is heat store temperature unreachable (CH flow temperature control set too low)?
yes:
5.
Air in the heating system.
1)
40
7 181 465 346 (01.07)
Set room temperature exceeded by large amount
Check
1. Do radiators get too hot? yes:
Action
TR 2: B Decrease setting of Heating control TA 211 E: B Correct heating characteristic. 2. no: 2. B Select better installation location1). -orB Fit external room thermostat. 3. no: 3. B Turn down thermostatic valve(s).
2.
Bad choice of location for programmer, e.g. outside wall, near window, in draught, on hollow wall, etc.
yes:
3.
Excessive fluctuations in room temperature (TA 211 E)
Check
1. Periodic effect of external heat on room, e.g. from sunshine, lighting, TV, separate stove, fire, etc.
Action
B Eliminate external heat sources if possible.
Temperature rises instead of falling
Check
Timer clock (DT 2) incorrectly set
Action
B Check setting and correct as necessary.
7 181 465 346 (01.07)
41
Room temperature too high in Economy mode
Check
Building retains heat well yes:
Action
B Set economy temperature lower . or B Set to Frost Protection instead of Economy. or B Set start time for Frost protection/Economy earlier.
Incorrect or no modulation
Check
Programmer incorrectly wired
Action
B Check wiring against wiring diagram and correct as necessary.
42
7 181 465 346 (01.07)
Appendix
4
4.1
4.1.1
Appendix
NTC values
Outside temperature sensor 4.1.2 CH flow NTC sensor, heat store NTC sensor, constant hot water NTC sensor and hot water NTC sensor
Outside temperature ( C) Measurement tolerance 10%

-20 -16 -12 -8 -4 0 4 8 10 15 20 25 Table 11
Resistance ( )
2 392 2 088 1 811 1 562 1 342 1 149 984 842 781 642 528 436
Temperature ( C) Measurement tolerance 10%

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Table 12
Resistance ( )
14 772 11 981 9 786 8 047 6 653 5 523 4 608 3 856 3 243 2 744 2 332 1 990 1 704 1 464 1 262 1 093 950
7 181 465 346 (01.07)
43
Appendix
4.2
Electronic schemes
o - orange g - green bl - black
33 364
4.1
r - red
p - purple
365
61
317
366
367
ECO
363
25 V
230 V
153
230V/AC
136
310 312 313 315

124 789
p p p
135
318
328
302
L N Ns Ls LR
151
84
161
328.1
300 314
M
96
6
o r r
g g
M
mains supply
M
226
52 52.1
18
56
o bl bl bl bl o
36
bl
6.1
32
6 720 610 576-08.2O
4.1 6 6.1 6.3 18 32 33 36 52 52.1 56 61 84 96 135 136 151 153 161 226 300 302 310 312 313 314 315 317 318 328
Ignition transformer Heat exchanger overheat cut-out Flue gas NTC sensor Hot water sensor Central heating pump Flame sensing electrode Spark electrodes Temperature sensor in CH flow Safety gas valve 1 Safety gas valve 2 CE 428 gas valve Reset button Motor (ZWB/ZB) Microswitch, water switch (ZWB) Main power switch Heating outlet temperature potentiometer Fuse T 2,5 A, 230 V AC Transformer Bridge Fan Code key Ground electrical connection Sanitary outlet temperature potentiometer Fuse T 1,6 A, 24 V DC Fuse T 0,5 A, 5 V DC Strip connector for TA 211 E fitted programmer Terminal block for programmer Digital display Internal programmable clock connection 230 V AC connection
328.1 363 364 365 366 367
Bridge Flame presence led Electrical power led (0/I) Chimney cleaner button Technique service button ECO button
44
7 181 465 346 (01.07)
Appendix
4.3
List of most important replacement parts

Order no. Remarks Component Electrode assembly 8 748 300 385 Gas valve 8 747 201 358 8 714 401 999 8 714 402 087 8 714 402 086 1 904 552 730 1 904 552 740 1 904 521 342 8 744 503 010 8 717 207 514 8 717 207 513 with DT 2 without DT 2 ZB... ZWB... T 0,5 A T 1,6 A T 2,5 A Gas valve Other components Fan Gas supply pipe Plate-type heat exchanger Overflow trap Table 13 8 717 204 343 8 710 725 500 8 715 406 651 8 710 725 328 ZWB... 8 747 003 516 CE 427 Order no. 8 718 107 077 Remarks
Component Switchbox PCB control board Transformer Ignition lead 20-pin connector lead assembly 20-pin connector lead assembly Fuse Fuse Fuse Set of fuses Switchbox kpl. Switchbox kpl.
Code plug included in Conversion kit G20 -> G31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 Heat exchanger Temperature limiter Temperature sensor, CH flow Table 13 8 729 000 144 8 714 500 087 110 C NTC 7 710 149 048 7 710 239 084 7 710 149 049 7 710 239 085 7 710 149 044 7 710 239 080 7 710 149 045 7 710 239 081 ZWB 7/11-29 A ZWB 7/11-29 A ZB 7/11-28 A ZB 7/11-28 A ZWB 7/11-27 A ZWB 7/11-27 A ZB 7/11-27 A ZB 7/11-27 A
7 181 465 346 (01.07)
45
Appendix
4.4
Approved corrosion inhibitors and anti-freeze fluids for central heating water
Mixing concentra tion % by weight
Manufacturer
Description
Remarks
With all anti-freeze fluids and corrosion inhibitors, it is extremely important to observe the manufacturers 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 Hls Tyforop Chemie GmbH, Hamburg Schilling Chemie Ilexan E Tyfocor L Varidos FSK Anti-freeze fluid, equivalent to Antifrogen N. Anti-freeze fluid based on propylene glycol. Anti-freeze fluid based on ethylene glycol with good corrosion-inhibiting properties. Also suitable for aluminium. Anti-freeze fluid based on ethylene glycol with good corrosion-inhibiting properties. Anti-freeze fluid with corrosion inhibitor, also suitable for aluminium. Anti-freeze fluid based on ethylene glycol with good corrosion-inhibiting properties, also suitable for aluminium. Corrosion inhibitor Schilling Chemie Schilling Chemie Schilling Chemie Benckiser Wassertechnik Geminox, Frankreich Betz Dearborn, Belgien Fernox Cillit Wassertechnik Varidos KK Varidos 1+1 Varidos AP Randophos HS Universal Inibal Sentinel X 100 Copal Cillit-HS Combi Corrosion inhibitor Corrosion inhibitor Corrosion inhibitor, also suitable for aluminium. Corrosion inhibitor Corrosion inhibitor, suitable for aluminium. Corrosion inhibitor for hot water heating systems, also suitable for aluminium. Corrosion inhibitor, also suitable for aluminium. Corrosion inhibitor Other additives Fernox Fernox Restorer Superfloc Universal Cleanser Superconcentrate Central heating Protector Cleaning agent (for sludge removal), also suitable for aluminium. Reduces limescale precipitation, also suitable for aluminium. 1-2 1-2 1,1 1 0,5 0,5 1-2 1-2 20-62 25-80 22-55
Hoechst Fernox BASF
Antifrogen N Alphi-11 Glythermin NF
20-40
Tab. 14
46
7 181 465 346 (01.07)
Appendix
4.5
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 Perchloroethylene, trichloroethylene, methyl chloroform Trichloroethylene Aerosol propellants, hydrocarbons containing chlorine and fluorine (Freon) Perchloroethylene, methyl chloroform, trichloroethylene, methylene chloride, carbon tetrachloride, hydrochloric acid Various chlorinated hydrocarb Chlor-fluorinated hydrocarbons (Freons)
Degreasing baths Printers Hairdressers
Sources in the home Cleaning and degreasing agents
Hobby workshops Solvents and thinners Aerosol sprays Table 15
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47
Appendix
Appendix
9.3

Natural gas G20
Display code 30 40 50 60 70 80 90 100
Heat output kW 8.2 10.9 13.6 16.3 19.1 21.8 24.5 27.2
Heatinput kW 8.3 11.0 13.8 16.5 19.3 22.0 24.8 27.5
Table 17
9.4

Propane
Display code 40 50 60 70 80 90 100
Heat output kW 10.9 13.6 16.3 19.1 21.8 24.5 27.2
Heat input kW 11.0 13.8 16.5 19.3 22.0 24.8 27.5
Table 18
42
6 720 610 596 GB (01.07)
9.5
9.5.1
Fig. 61
6 720 610 596 GB (01.07)
Central heating function
Mains switch ON. CH demand.
Green light ON.
Pump ON Fan to start speed. Gas valve opens. Fan min. speed for 90 secs.
Burner stabilises at start speed for 5-10 secs
Fan speed reduces over 15 secs.
Boiler unused for long period.*
Yes
No
ce
Ignition sequence
Yes
No
6 720 610 576 - 25.1O
Appendix
43
Appendix
Appendix
10.3 Heating/hot water output settings ZWBR 7-28 N.G.

Natural gas G20 Display code 30 40 50 60 70 80 90 100 Heat output, kW 8.5 11.3 14.1 16.9 19.8 22.6 25.4 28.2 Heat input, kW 8.6 11.4 14.3 17.1 20.0 22.8 25.7 28.5 Gas vol. flow rate (l/min at tV/tR = 80/60 C) 15.0 20.0 24.9 29.9 34.9 39.9 44.9 49.9
Table 20
10.4 Heating/hot water output settings ZWBR 11-28 L.P.G

Propane Display code 40 50 60 70 80 90 100 Heat output, kW 11.3 14.1 16.9 19.8 22.6 25.4 28.2 Heat input, kW 11.4 14.3 17.1 20.0 22.8 25.7 28.5
Table 21
48
6 720 610 597 GB (01.07)
Appendix
10.5 Heating/hot water output settings ZWBR 11-35 N.G.

Natural gas G20 Display code 30 40 50 60 70 80 90 100 Heat output, kW 10.5 14.1 17.6 21.1 24.6 28.1 31.6 35.1 Heat input, kW 10.7 14.2 17.8 21.3 24.9 28.4 32.0 35.5 Gas vol. flow rate (l/min at tV/tR = 80/60 C) 18.6 24.9 31.1 37.3 43.5 49.7 55.9 62.1
Table 22
10.6 Heating/hot water output settings ZWBR 14-35 L.P.G

Propane Display code 40 50 60 70 80 90 100 Heat output, kW 14.1 17.6 21.1 24.6 28.1 31.6 35.1 Heat input , kW 14.2 17.8 21.3 24.9 28.4 32.0 35.5
Table 23
6 720 610 597 GB (01.07)
49
50
Ignition sequence Ignition spark 5 secs Burner lights. Red light ON. Burner shut-down if primary temperature exceeds 94 C remains OFF until 78 C Gas valve shuts. Pump remains ON. Over temperature shut-down if water temperature is 8C above set value.
Fig. 60
** NOTE: The appliance controls can be set to one of 2 modes of operation. 1. Comfort mode Full pre-heat 2. ECO mode a) Operates as an instantaneous combination boiler. b) Demand Detection: a short demand (less than 5 seconds) switches the control to Comfort mode for 5 mins. Mini pre-heat. The Factory setting is Comfort mode.
. Pump ON Diverter valve operates. Demand ends. Fan to start speed. Gas valve opens. Heat input modulates to maintain the delivery temperature. Gas valve closes. Red light OFF. Fan runs for upto 3 mins. Pump runs for 30secs. Pre-heat mode.** Burner lights. Red light ON.
Appendix
Pump ON Diverter valve operates.
Fan to start speed. Gas valve opens.
Pre-heat satisfied.
10.7.1 Domestic hot water function
10.7 Operational Flow diagrams
Burner remains OFF until flow temperature is below set value.
Mains switch ON.
Green light ON.
Pre-heat mode.**
Hot water demand.
Ignition sequence
Yes
No
6 720 610 576 - 24.1O
6 720 610 597 GB (01.07)
Fig. 61
10.7.2 Central heating function
6 720 610 597 GB (01.07)

CH demand. Pump ON Fan to start speed. Gas valve opens. Fan min. speed for 90 secs. Burner stabilises at start speed for 5-10 secs Fan speed reduces over 15 secs. Boiler unused for long period.*
Mains switch ON.
Green light ON.
Yes
No
ce
Ignition sequence
Yes
No
6 720 610 576 - 25.1O
Appendix
51
Appendix
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 ZWBR 7-28 HE plus GC-Number: 47 311 56 ZWBR 11-35 HE plus GC-Number: 47 311 57
7 181 465 347 (01.07) OSW
Contents
Contents
Safety precautions Symbols 1 2 2.1 2.2 2.3 2.4 2.4.1 Layout of Appliance (ZSBR/ZWBR) 3 3 4 5 5 5 5 5 5 5 6 6 9 14 14 14 14 14 14 14 16 17 36 36 41 45 45 45
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): 3 3.1 3.2 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 5 5.1 5.1.1 5.1.2 Boiler service functions Summary Explanation of service functions 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 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
5.2 5.3 5.4 5.5
45 46 47 48 49
7 181 465 347 (01.07)
Safety precautions
Safety precautions
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! 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).
Symbols
Notes are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text
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Layout of Appliance (ZSBR/ZWBR)
Layout of Appliance (ZSBR/ZWBR)

Testing points: flue gas air Fan fixing screws
Automatic vent
Burner fixing screws Fan connector Fan Mixer unit Electrode assembly: Flame sensing electrode Ignition electrodes
Silencer CH flow Gas supply pipe Flue gas safety temperature limiter Gas flow restrictor: adjusting screw for CO2 max. Gas valve: adjusting screw for CO2 min. Plate-type heat exchanger (ZWBR) Hot water NTC sensor (ZWBR) CH flow NTC sensor
CH flow safety temperature limiter Inspection opening
Variable-characteristic pump Change-over valve
Condensation trap
Change-over valve motor
Transformer Heatronic Water switch (ZSBR)
7 181 465 347 (01.07)
Operation
Operation
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 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. buttons to enter the
Instructions on the use of the text display module are given in the operating and installation instructions for the boiler.
b c
6 720 610 337-08.1R
Fig. 1
a b c d e f
Controls
Display Up or More button Down, or Less button Back button Nest button Delete button
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.
2.1
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).
2.4
2.4.1
Resetting service functions to factory settings

Resetting service functions 0.0 to 4.9 to their factory settings (Reset 1): and keep it pressed. but-
2.2
Displaying service functions
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 button to select Display service parameters. Service function 0.0, Last fault is displayed. B Press or current settings. B Press button to cycle through the
B Power OFF the appliance. B Press the button B Switch on the appliance, press and hold the ton until the display shows r1 followed by [ ] . 2.4.2
Resetting service functions 0.0 to 9.9 to the factory setting (Reset 2): and .
B Power OFF the appliance. B Simultaneously press and hold buttons B Switch on appliance, press and hold the and buttons until the display shows r2 followed by [ ] .
button to exit the menu.
2.3
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 button. B Press or button until the arrow cursor is pointing to Service.
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.
7 181 465 347 (01.07)
3
3.1

Summary
Range adjustable from - to Clear only Reset Value 0 -
Text display message 0.0 0.1 0.2 0.3 0.4 1.2 1.5 1.9 Last fault Flow temp. sensor Hot water temp. sensor Stor. tank temp. sensor1 Stor. tank temp. sensor2 Code plug 8714411 XXX Required flow temp. Module detection
Display 00 - FF 0 - 99 C 0 - 99 C 0 - 99 C 0 - 99 C 0 - 255 0 - 99 C no module detected bus module -
2.0
Operating mode
normal Min Max 1-3 0 - 100% 0 - 15 min 35 - 88 C 0 - 30 C on off -
normal
2.2 2.3 2.4 2.5 2.6 2.7
Pump switch mode Stor. tank charge output Anti-cycle mode Max. flow temperature Switch.diff.flow temperature Autom. anti-cycle mode
2 100 % 3 min 88 C 0 C on
2.9 3.0 3.3
Actual output Fan speed Ionisations current
0 - 100 % 0 - 255 U/s no low middle high -
3.4 3.5
Pump mode Pump blocking time
0-3 0 - 240 s in 15-s increments -
01) 0s
3.6 Table 1
Software version
BF 11.XX
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Text display message 3.9 Link 8 - 9
Display open closed open closed blocked heat demand blocked heat demand blocked heat demand blocked heat demand blocked heat demand yes no yes no yes no yes no blocked heat demand -
Range adjustable from - to -
Reset Value -
Link Ls-Lr
4.0
Stor. tank. therm.. (7-9)
4.1
Room therm. LSM
LSM release
4.2
Timer ch. 1 (heating)
Timer ch. 2 (hot wat.)
4.4
Heat demand (heating).
Heat demand (stor. tank).
4.5
Heat demand (hot water).
Keep hot period
4.6
Internal regulator
5.0 5.1
Max. output (heating) Permanent ignition
27 - 100% no yes 27 - 100 % on off low high off on
100 % no
5.2 5.5 5.8
GFA status / error Min. output Cyclic boiler starts
00h - FFh -
27 % on
5.9
Fan speed (start)
low
6.7 Table 1
Pump off (hot water).
off
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Text display message 6.8 6.9 7.0 Cycle time (hot water) Duration (hot water) Pump map (heating)
Display -
Range adjustable from - to 0 - 60 min 0 - 30 min 0 Pump step adjustable 1 Const. pressure high 2 Const. pressure middle 3 Const. pressure low 4 Prop.pressure high 5 Prop.pressure low 2-7 off on off on autom. deaktivat. permanent on
Reset Value 0 min 1 min 4 Prop. pressure high
7.1 7.2
Map pump step (heat.). Antiblock. map pump.
7 on
7.3
Air purge mode
on autom. deaktiv at./ off -
7.4 7.5 7.6 7.7
Actual map pump step Map pump load index Map pump type Output reduction
1-8 0 ... 255 0 .. 99 -
off only in only in heating mode heating only in hot water mode mode in heat./hot water mode. on, boiler min.output, on, adjust. min output, off on, boiler min. output on
8.5
Siphonfillprogram
9.2
Hot water on demand
off on -
9.3 Table 1 1)
GFA-Asic-error
00h - FFh
The reset value depends on the code plug.
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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. button to select yes.
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. 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.
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. 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. 0.4 Storage tank NTC 2 Stratified-charge tank (ST...S): The temperature measured by NTC sensor 2 at the top of the heat store is indicated. 1.2 Code plug The 10-digit part number of the code plug is indicated. The code plug determines the appliance functions. If the appliance is converted from natural gas to LPG or vice versa (using conversion kit) the code plug also has to be changed. 1.5 Desired flow temp. The CH flow temperature demanded by the text display module or a programmer connected to the bus module is displayed. 1.9 Module detection The text display module shows the modules detected by the appliance. 2.0 Operating mode There are 3 operating modes to choose from. Normal mode: the appliance operates according to the commands received from the programmer.
If an outside-temperature controlled heating programmer is used, no setting is required. The anti-cycle time is optimised by the programmer.
B Enter the anti-cycle time on the commissioning record enclosed with the appliance. 2.5 Max. flow temperature The maximum CH flow temperature can be set to between 35 C and 88 C (factory setting). 2.6 Switch diff. flow NTC
If an outside-temperature controlled 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.
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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. 3.3 Ionisation current 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. 3.4 Pump mode (ZBR.. models only) The possible settings are: Pump mode 1: if a heating pump and a 3-way valve for charging the heat store are connected. The 3-way valve is de-energised when the heat store circuit is open. Pump mode 2 (factory setting): if a circulation pump and a heat store charging pump are 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. 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). B The pump mode setting should be entered on the commissioning record enclosed with the appliance.
3.5 Pump blocking time (ZBR.. models only)
Only applies if service function 3.4, Pump mode, is set to Pump mode 1 (external 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 The version number of the software is displayed. 3.9 Jumper 8 - 9 / 3.9 Jumper Ls - Lr When supplied, the appliance has a jumper fitted across terminals 8-9 (= Heat demand). If that connection is opened (e.g. by a limiter for an underfloor heating system), heating mode is disabled. When supplied, the appliance has a jumper fitted across terminals Ls-Lr (= Heat demand). If that connection is opened (e.g. by an external 2-point programmer), heating mode is disabled. 4.0 Stor. tank therm. (7 - 9) 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. 4.1 Room therm. LSM/ 4.1 LSM release When supplied, a jumper is fitted across terminals LZ L1 on the LSM (= Heat demand). If that connection is opened (e.g. by a connected room thermostat), heating mode is disabled. LSM release shows the total number of all possible 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 channels status is Heat demand, heating mode will be activated according to the programmer commands.
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Shows the status of channel 2 of the timer integrated in the text display module or the separate programmer. If that channels status is Heat demand, hot water mode will be activated according to the programmer commands. 4.4 Heat demand (heating)/ Heat demand (stor. tank) (ZSBR.. only) Heat demand (heating) shows the heat demand status for the central heating system. If this channels status is Heat demand, heating mode will be activated according to the programmer commands. Heat demand (stor. tank) shows the heat demand status for charging the heat store. If this channels status is Heat demand, the heat store will be charged according to the commands from the heat store thermostat or NTC sensor. 4.5 Heat demand (hot water)/ Keep hot period (ZWBR... models only) Heat demand (hot water) shows the heat demand status for the hot water function. If this channels 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 channels 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.
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.
Even if the heating output is limited, the full rated heat output remains available for hot water or heat store charging.
The factory setting is maximum rated output display shows 100 %. 5.1 Permanent ignition This function allows permanent ignition without gas supply to be activated for the purposes of checking the ignition mechanism. 5.2 GFA status/error The status of the automatic ignition module integrated in the PCB control board is indicated. 5.5 Min. output The min. heat input is factory set, see technical data. The modulation range can be extended at the top end to suit the chimney conditions. 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.
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11
If a stratified-charge tank is connected, it is useful to have the function activated. The delayed cut-in of the pump then prevents cold water being pumped through the tank and cooling it down. 6.8 Cycle time (hot water) (ZWBR... only) The appliance is supplied with the hot water cycle time set to 3 minutes. The hot water cycle time 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 pump map indicates how the pump is controlled in heating mode. The pump switches between the various pump speeds so as to reproduce the characteristic curve selected. (The current setting can be viewed by means of service function 7.4.) Changing the pump characteristic can be helpful if a lower pressure difference will guarantee the necessary circulation on the basis of the system dimensions and pump characteristic (see installation instructions).
7.2 Antiblock. map pump (not ZBR...) The appliance is supplied with this function activated. If the pump threatens to jam, an oscillating pump action is activated. Afterwards, the required operating mode is continued. 7.3 Aeration mode (not ZBR...) The first time the appliance is switched on, a once-only venting function is activated. The heating pump then switches on and off at intervals. This sequence lasts about 8 minutes and the text display shows Aeration mode. The 2-digit display shows 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 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 currently active pump speed is displayed (see function 7.0). 7.5 Map pump load index (not ZBR...) The load index is displayed. 7.6 Map pump type (not ZBR...) The pump type code of the pump fitted is displayed. 7.7 Output reduction The appliance is supplied with this function activated. It prevents overload of the heat exchanger with high CH flow temperatures. The output of the burner is reduced according to the CH flow temperature, i.e. 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.
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. This service function corresponds to the pump speed switch used on conventional heating pumps.
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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.
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13
Rectifying faults
4
4.1
4.1.1
Rectifying faults
Boiler failure codes indication
... on the boiler
4.2
4.2.1
Summary
Appliance faults ZSBR ... A ZWBR ...A X X X X X X X X X X X X X X X ZWBR ...A X X X 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. 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. The failures can be divided into four basic typologies, as described: The appliance continues to work at a minimum function level (e. g. with error codes A5, A7, A8, AC, Ad, CC, FC). The appliance is locked until the failure is repaired (e. g. with error codes (b1, C1, d1, d3, E2, F0)). The appliance is locked, until the ON/OFF switch is turned (A1). 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).
Appliance faults A1 A5 A7 A8 Ad b1 C1 d3 E2 E9 EA F0 F7
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
17 18 19 20 21 22 23 24 25 26 28 32 33 34 35 35
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)
FA FC Fd 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. For more detailed information, refer to the installation instructions for the boiler and the installed programmer. 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.
ZSBR ... A
ZBR ... A
A TW 2 remote control unit can also be connected to the text display module.
Faults that are not indicated on any display
Appliance faults Excessive burner noise, rumbling noises Flue gas levels incorrect, CO level too high Ignition too harsh, ignition poor Boiler indicates P1, P2, P3 at start-up and then restarts with P1, ... Table 3
X X X X
X X X X
36 37 38 36
14
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Page
Page
In order to identify the specific boiler failure a two digit alphanumeric code is used. This allows a quick fault identification and solution.
Rectifying faults
ZSBR ... A
ZWBR ...A 41 43 41 43 43 43 44 Page
ZBR ... A
Appliance faults Loose or broken contact on heat store NTC sensor Specified CH flow temperature from TA... programmer exceeded Table 3 Programmer faults Set room temperature not reached Set room temperature exceeded by large amount Set room temperature not reached Temperature rises instead of falling Room temperature too high in Economy mode Incorrect or no modulation Heat store fails to heat up Table 4
X X
X X
39 40
X X
X X X
TR 2
Page
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15
Rectifying faults
4.3
How to use the fault tables

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.
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?) wasno, 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
1.
and
flashing.
Flame not detected Check

Is burner flame visible? yes: no: 2. Is the gas cock turned on? yes: no:
Action
5. 2. 3. B Turn on the gas cock. B Press EA? 3. , does appliance restart???
3.
Did the thermal security of the gas cock lock out? ... Is there a problem with the flue? B Check CO2 level in combustion air. > 0,2 % CO2?
yes: no:
B ... ...
4. 5.
yes: no:
B Check the flue. ....
...
...
16
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Rectifying faults
4.4
Faults indicated on display
A1
1.
flashing.
Controlled-characteristic pump has run dry Check

System pressure below 1.2 bar? yes:
Action
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. 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. 3.
2.
Activate venting sequence.
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)
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17
Rectifying faults
A5
1.
flashing.
Heat store NTC sensor 2 defective Check

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.? yes:
Action
B Is the connector for heat store NTC sensor 2 corroded1), damaged or dirty? Replace affected components. 2. no: yes: 3. 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. B Unplug the connector. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.?
yes:
B Power OFF the appliance. B Change heat store NTC sensor 2. B Plug the connection wire. B Turn ON the appliance. A7? 4.
no: 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.? yes: no:
4. B Change the 20-pin connector lead assembly. 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.
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Rectifying faults
A7
1.
flashing.
Hot water NTC sensor defective Check

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. 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.? no: yes:
Action
B Is the connector for hot water NTC sensor corroded1), damaged or dirty? Replace affected components. 2. no: yes: 3. B Power OFF the appliance. B Change hot water NTC sensor. B Plug the connection wire. B Turn ON the appliance. A7? 3. B Change the 20-pin connector lead assembly. 3.
3.
yes:
B Power OFF the appliance. B Change hot water NTC sensor. B Plug the connection wire. B Turn ON the appliance. A7? 4.
no: 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.? yes: no:
4. B Change the 20-pin connector lead assembly. 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.
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19
Rectifying faults
A8
1.
flashing.
No correct electrical connection Check

Mode selector switch is between two settings B Power OFF the appliance. Wiring between TR 2 and textdisplay OK? Terminal 3 on TR 2 connected to Terminal 3 on textdisplay ? Terminal 4 ... Terminal 4 .... etc. 3. Lead(s) defective. no: yes:
Action
B Turn switch until it clicks into position. A8? 2. B Turn ON the appliance. 3. B Rewire correctly as specified in the installation instructions. B Turn ON the appliance. after 90 sek.: A8? 3. B Check leads for continuity and replace as necessary. A8? 4.
2.
4.
TR 2 defective.
B Power OFF the appliance. B Change TR 2 . B Turn ON the appliance.
20
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Rectifying faults
Ad
1.
flashing.
Heat store NTC sensor 1 not detected Check

Is lead for heat store NTC sensor correctly routed, i.e. not through cable clamp? yes: no:
Action
2. B Route connecting lead for heat store temperature sensor as specified in installation instructions. Connector on end of NTC sensor lead: B Flue gas connector corroded1), damaged or dirty? Change relative parts. B Press button Ad? 3. no: 4. B Replace heat store NTC sensor 1. 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. yes: no: B Replace heat store NTC sensor 1. 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. .
2.
B Activate menu option Show service parameters. B Select .3 Stor.tank temp.sensor1 . Is a temperature between 0. and 5. displayed?
yes:
3.
Heat store -NTC 1: B Unplug connector from PCB control board. B Short circuit the connector using wire jumper. After max. 60 sec: Display changes to temperature between 100. and 95.
yes: no:
4.
1)
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21
Rectifying faults
b1
1.
flashing.
Code plug not detected. Check

No fault or fault code FC displayed on text display? yes:
Action
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. no: 2. 2. 4.
2.
B Activate menu option Show service parameters. B Select 1.2 Code plug. B Compare number displayed with that shown in Appendix. No number or incorrect number (last three digits) displayed.
yes: no:
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.
1)
For order no., refer to Appendix
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Rectifying faults
C1
1.
flashing.
Fan speed too low Check

Fan lead connector properly connected? yes: no:
Action
2. 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.
no: 3. Fan defective? yes:
3. 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.
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23
Rectifying faults
d3
1.
flashing.
Wrong signal from pin 8-9. Check

Jumper 8 - 9 fitted correctly? yes: no:
Action
2. 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. B Measure voltage between Terminal 4 and Terminal 8. 24 V DC?
yes: no:
3. 5.
3.
Heat store NTC sensor connected to terminals 7, 8 and 9?
yes:
B Power OFF the appliance. 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.
no: 4. Existing heat store thermostat connected to Terminals 7, 8 and 9? yes:
4. 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.
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Rectifying faults
E2
1.
flashing.
The heating outlet NTC sensor is damaged. Check

B Activate menu option Show service parameters. B Select .1 Flow temp.sensor. Is a temperature between 0. and 5. displayed? yes:
Action
The heating outlet NTC sensor is in short circuit: 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? 2. no: 2. 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. B Power OFF the appliance. B Change the 20-pin connector lead assembly. B Turn ON the appliance. E2? 4.
2.
Heating outlet NTC sensor: Temperature between 95. and 100. is displayed.
yes:
3.
4.
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25
Rectifying faults
E9
1.
and
flashing.

Is the heating pressure between 1 and 2 bar? yes:
Action
B Top up system. B Vent appliance. B Press E9?2. no: 2. B Unblock the pump. If pump wont 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 E9? 3. no: 3. B Power OFF the appliance. B Connect lead. B Turn ON the appliance. B Press E9? 4. no: 4. B Change the over heating cut-off device. B Connect flue gas safety temperature limiter lead. B Turn ON the appliance. B Press E9? 5. no: B Connect flue gas safety temperature limiter lead. B Turn ON the appliance. E9? 5. , does appliance restart??? , does appliance restart??? , does appliance restart??? , does appliance restart???
2.
Is the pump blocked?
yes:
3.
Is lead disconnected from one/both safety temperature limiters?
yes:
4.
B Power OFF the appliance. B Unplug the connector from the cut-off device. B Measure the NTC electrical resistance. R = ?
yes:
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Rectifying faults
E9
5.
and
flashing.

B Power OFF the appliance. B Remove fuse SI 3 from appliance PCB control board and test for continuity. R = ? no: yes:
Action
B Change the fuse. B Turn ON the appliance. B Press E9? 6. B Remount the fuse. B Turn ON the appliance. , does appliance restart???
6.
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27
Rectifying faults
EA
1.
and
flashing.
During operation: flame not detected Check

Is the flame present? yes: no: 2. Is the gas cock open? yes: no:
Action
6. 2. 3. B Open the gas cock B Press EA? 3. , does appliance restart???
3.
Is there air in the supply pipe?
yes:
B Vent supply pipe. B Press EA? 4. , does appliance restart???
no: 4. Did the thermical security of the gas cock lock out? yes:
4. B Reset security. B Press EA? 5. , does appliance restart???
no: 5. Natural gas models: does the building have a supply pressure regulator? yes:
5. 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 EA? 6. , does appliance restart???
no: LPG models: is the flow rate of the gas supply to the appliance correct? yes: no:
6. 6. 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 EA? 6. , does appliance restart???
28
7 181 465 347 (01.07)
Rectifying faults
EA
6.
and
flashing.

Is the ground connection correct? yes: no:
Action
7. B Rewire correctly as specified in the installation instructions. B Press EA? 7. , does appliance restart???
7.
Two phase net: Is there a resistor fitted between Pe and N?
yes: no:
8. 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 EA? 10. , does appliance restart???
8.
Is condensation trap in condensing boiler blocked?
yes:
B Unscrew condensation trap and clean. B Press EA? 12. , does appliance restart???
no: 9. Check the gas valve? B Power OFF the appliance. B Unplug the connectors from the gas valve. B Measure the gas valve coils I and II electrical resistance. R =164 40 ? no: yes:
9. B Reconnect the gas valve. B Turn ON the appliance. B Press EA? 10. B Change the gas valve. B Reconnect the gas valve. B Turn ON the appliance. B Press EA? 10. , does appliance restart??? , does appliance restart???
10.
Is flue blocked? B Check CO2 level in combustion air. > 0,2 % CO2?
yes:
B Check the flue. B Press EA? 11. , does appliance restart???
no:
11.
7 181 465 347 (01.07)
29
Rectifying faults
EA
11.
and
flashing.

Is flue gas CO2 level incorrect1) ? yes:
Action
B Adjust to correct level. B Press EA? 12. no: 12. 13. 16. , does appliance restart???
12.
B Activate menu option Show service parameters. B Select 5.1 Permanent ignition. Continuous ignition OK?
yes: no:
13.
Ignition lead connected to ignition electrodes?
yes: no:
14. B Connect cable to ignition electrode. B Press EA? 14. , does appliance restart???
14.
yes: no:
15. B Power OFF the appliance. B Engage ignition cable connector in switchbox. B Turn ON the appliance. B Press EA? 15. , does appliance restart???
15.
Ignition cable defective?
yes:
B Power OFF the appliance. B Replace ignition cable. B Turn ON the appliance. B Press EA? 16. , does appliance restart???
no: 16. B Select 3.3 Ionisation current. Measured ionisation current medium or high? yes: no:
16. 18. 17.
30
7 181 465 347 (01.07)
Rectifying faults
EA
17.
and
flashing.

Electrode assembly defective? B Power OFF the appliance. B Remove electrode assembly. Electrodes worn out? no: yes:
Action
B Replace electrode assembly. B Turn ON the appliance. B Press EA? 18. B Refit electrode assembly. B Turn ON the appliance. B Press EA? 18. , does appliance restart??? , does appliance restart???
18.
B Power OFF the appliance. B Change the 20-pin connector lead assembly. B Turn ON the appliance. B Press EA? 19. , does appliance restart???
19.
1)
7 181 465 347 (01.07)
31
Rectifying faults
F0
1.
(and possibly
) flashing.
Internal failure Check

B Activate menu option Show service parameters. B Select 9.3 GFA-Asic-error. A message is displayed. 2. 3. B Select 5.2 GFA status / error. A message is displayed. B Select Settings -> Service -> Further options -> Fault history. Other faults apart from F0 displayed? 4. flashing? yes: no: yes:
Action
B Record figure displayed in service report. 2.
B Record figure displayed in service report. B Deal with fault(s) displayed as instructed in relevant fault table(s) . 3. 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
1.
and
flashing.
Although appliance switches off, flame still detected Check

Electrode(s) dirty or defective.
Action
B Power OFF the appliance. B Replace electrode assembly. B Turn ON the appliance. B Press F7? 2. , does appliance restart???
2.
B Power OFF the appliance. B Disconnect the boiler electrical connection. B Remove PCB control board. PCB control board damp?
yes:
B Dry PCB control board (e.g. with hair dryer). B Refit PCB control board. B Reconnect the boiler electrical connection. B Press F7? 3. , does appliance restart???
no: 3. Is there a problem with the flue? B Check CO2 level in combustion air. > 0,2 % CO2? 4. The PCB control board is damaged. yes: no:
3. B Check flue and repair or replace if necessary. 4.
7 181 465 347 (01.07)
33
Rectifying faults
FA
1.
and
flashing.
After appliance switches off flame is detected Check

Is condensation trap in condensing boiler blocked? yes:
Action
B Clean condensation trap discharge pipe. B Press FA? 2. no: 2. B Replace electrode assembly. B Turn ON the appliance. B Press FA? B Power OFF the appliance. 3. , does appliance restart??? , does appliance restart???
2.
Electrodes faulty.
3.
yes:
B Check flue and repair or replace if necessary. B Press FA? B Power OFF the appliance. 4. , does appliance restart???
no: 4. The gas valve is damaged.
4. B Change the gas valve. B Turn ON the appliance. B Press FA? B Power OFF the appliance. 5. , does appliance restart???
5.
B Change the 20-pin connector lead assembly. B Turn ON the appliance. B Press FA? B Power OFF the appliance. 6. , does appliance restart???
6.
34
7 181 465 347 (01.07)
Rectifying faults
FC
1.
flashing.
Text display module not detected Check

No fault or fault code FC displayed on text display?
Action
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.
B Replace text display module.
Fd
1. 2.
and
flashing.
Reset button pressed inadvertently Check Action

B Press button The PCB control board is damaged. again.
7 181 465 347 (01.07)
35
Rectifying faults
4.5
4.5.1
Faults that are not displayed

Appliance faults
Boiler indicates P1, P2, P3 at start-up and then restarts with P1..
Check
1. Fuse T 1.6 A (312) defective. yes:
Action
B Turn ON the appliance. B Change the fuse. B Power OFF the appliance. Start sequence not completed? 2. no: 2. B Change PCB control board.
2.
Excessive burner noise, rumbling noises
Check
1. Does the gas supply type match the specifications on the appliance identification plate? B Test gas supply pressure - OK?1)? yes: no: yes: no:
Action
2. B Convert appliance to correct gas type1). 3. B Decommission appliance. B Notify gas company.
2.
3.
yes: no:
4.
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.
yes:
B Repair or replace components. B Grease seal before fitting, B Make sure it is fitted in correct position. 5. B Adjust CO2 levels. B Power OFF the appliance. B Change the gas valve. B Turn ON the appliance.
no: yes: no:
5.
1)
36
7 181 465 347 (01.07)
Rectifying faults
Flue gas levels incorrect, CO level too high
Check
1. Does the gas supply type match the specifications on the appliance identification plate? B Test gas supply pressure1), - OK? yes: no: yes: no:
Action
2. B Convert appliance to correct gas type1). 3. B Decommission appliance. B Notify gas company.
2.
3.
yes: no:
4.
Flue gas CO2 levels measured at min. and max. load do not match specified levels?1). B Measure CO2 levels.
yes: no:
B Adjust CO2 levels. 5.
5.
Gas volumetric flow too high when CO2 level correctly set1).
yes:
B Reduce gas volumetric flow rate by means of adjusting screw on gas valve and/or gas flow restrictor. B Check CO2 adjustment. 6. B Change the gas valve.
no: 6.
7 181 465 347 (01.07)
37
Rectifying faults
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? yes: no:
Action
6. 2.
yes: no:
3. B Connect cable to ignition electrode. B Press button Ignition poor? 3. .
3.
yes: no:
4. B Power OFF the appliance. B Engage ignition cable connector in switchbox. B Turn ON the appliance. B Press button Ignition poor? 4. . B Power OFF the appliance.
4.
Ignition cable defective?
yes:
B Power OFF the appliance. B Replace ignition cable. B Turn ON the appliance. B Press button Ignition poor? 5. . B Power OFF the appliance.
no: 5. Electrode assembly defective? B Power OFF the appliance. B Remove electrode assembly. Electrodes worn out? no: yes:
5. B Replace electrode assembly. B Turn ON the appliance. B Press , does appliance restart??? Ignition poor? 6. 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: no:
7. B Carry out gas type conversion as described in installation instructions. Ignition poor? 7.
38
7 181 465 347 (01.07)
Rectifying faults
Check
7. B Test gas supply pressure 1)- OK?. yes: no:
Action
8.
yes:
B Check flue and repair or replace if necessary. Ignition poor? 8.
no: yes: no:
9. B Adjust CO2 levels. 9.
9.
Flue gas CO2 levels measured at min. and max. load do not match specified levels. B Measure CO2 levels.
10.
Burner not correctly fitted or defective? B Remove burner. Cover fixings not tight or seal defective or not correctly fitted or burner defective.
B Replace burner and seal if necessary B Ensure seal is fitted in correct position.
1)
Loose or broken contact on heat store NTC sensor
Check
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).
Action
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
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).
Action
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 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) B Set anti-cycle time as required, e.g. factory setting 3 min. B Disable automatic anti-cycle time, i.e. change setting to 0.
40
7 181 465 347 (01.07)
Rectifying faults
4.5.2
Programmer faults
Set room temperature not reached (TR 2)
Check
Action
B Turn up thermostatic valve(s). 2. no: 2. B Turn up CH flow temperature control. 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.
2.
CH flow temperature control on boiler set too low? Air in the heating system.
yes: no:
3.
1)
7 181 465 347 (01.07)
41
Rectifying faults
Set room temperature not reached
Check
Action
B Turn up thermostatic valve(s). 2. no: 2. B Correct heating characteristic. 3. no: 3. B Turn up CH flow temperature control. 4. no: 4. 5. 6. B Turn up CH flow temperature control. 6. no: 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.
2.
Heating characteristic set too low?
yes:
3.
CH flow temperature control on boiler set too low?
yes:
4.
Heat store connected via HSM?
yes: no:
5.
Is heat store temperature unreachable (CH flow temperature control set too low)?
yes:
6.
Air in the heating system.
1)
42
7 181 465 347 (01.07)
Rectifying faults
Set room temperature exceeded by large amount
Check
1. Do radiators get too hot? yes:
Action
TR 2: B Decrease setting of Heating control 2. no: 2. B Select better installation location1). 3. no: 3. B Turn down thermostatic valve(s).n
2.
Bad choice of location for programmer, e.g. outside wall, near window, in draught, on hollow wall, etc.
yes:
3.
Temperature rises instead of falling
Check
Timer clock (DT 2) incorrectly set
Action
B Check setting and correct as necessary.
Room temperature too high in Economy mode
Check
Building retains heat well yes:
Action
B Set economy temperature lower. -orB Set earlier start time for Economy mode.
Incorrect or no modulation
Check
Programmer incorrectly wired
Action
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
1. with TR 2: CH flow temperature control on boiler set too low. Hot water temperature control on boiler set too low
Action
B Increase CH flow temperature control setting.
2.
B Increase hot water temperature control setting.
44
7 181 465 347 (01.07)
Appendix
5
5.1
5.1.1
Appendix
NTC values
Outside temperature sensor 5.1.2 CH flow NTC sensor, heat store NTC sensor, constant hot water NTC sensor and hot water NTC sensor
Outside temperature ( C) Measurement tolerance 10%

-20 -16 -12 -8 -4 0 4 8 10 15 20 25 Table 5
Resistance ( )
2 392 2 088 1 811 1 562 1 342 1 149 984 842 781 642 528 436
Temperature ( C) Measurement tolerance 10%

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Table 6
Resistance ( )
14 772 11 981 9 786 8 047 6 653 5 523 4 608 3 856 3 243 2 744 2 332 1 990 1 704 1 464 1 262 1 093 950
7 181 465 347 (01.07)
45
Appendix
5.2
Electronic schemes
o - orange
33 364
4.1
bl - black
367
ECO
r - red
p - purple
365
61
317
366
363
25 V
230 V
153
230V/AC
136
310 312 313
135
400
328
L N Ns Ls LR
151
124 789
302
161
328.1
300
p p p
84
3 4
18
6
r r
422
M
mains supply
226
o
52
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 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
46
7 181 465 347 (01.07)
Appendix
5.3
List of most important replacement parts Order no. Remarks Component Order no. Remarks
Component
Switchbox PCB control board Transformer Ignition lead 20-pin connector lead assembly Fuse Fuse Fuse
8 748 300 385 8 747 201 358 8 714 401 878 8 714 401 912
Heat exchanger Temperature limiter STB Flue gas temperature limiter Temperature sensor, CH flow 8 729 000 144 8 729 000 144 8 714 500 054 NTC 110 C
1 904 522 730 1 904 522 740 1 904 521 342
T 0,5 A T 1,6 A Burner T 2,5 A Electrode assembly 8 718 107 064
Code plug included in Conversion kit G20 -> 31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 Conversion kit G20 -> G31 Conversion kit G31 -> G20 7 710 149 050 7 710 239 086 7 710 149 051 7 710 239 087 7 710 149 052 7 710 239 088 7 710 149 053 7 710 239 089 7 710 149 046 7 710 239 082 7 710 149 047 7 710 239 083 ZWBR 8-30 ZWBR 11- 30
Gas valve Gas valve Gas valve Other components ZWBR 11 - 37 ZWBR 14 - 37 ZSBR 7-28 ZSBR 11-28 ZBR 8-35 ZBR 11-35 ZWBR 7-28 ZWBR 11-35 ZWBR 11-35 ZWBR 14-35 Table 7 Fan Gas supply pipe Textdisplay Plate-type heat exchanger 8 717 204 325 8 714 401 885 8 747 208 081 8 715 406 659 ZWBR 7/11-28 A. 8 747 003 516 8 747 003 515 ZBR 11/ 14..42A
Table 7
7 181 465 347 (01.07)
47
Appendix
5.4
Approved corrosion inhibitors and anti-freeze fluids for central heating water
Mixing concentra tion % by weight
Manufacturer
Description
Remarks
With all anti-freeze fluids and corrosion inhibitors, it is extremely important to observe the manufacturers 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 Hls Tyforop Chemie GmbH, Hamburg Schilling Chemie Ilexan E Tyfocor L Varidos FSK Anti-freeze fluid, equivalent to Antifrogen N. Anti-freeze fluid based on propylene glycol. Anti-freeze fluid based on ethylene glycol with good corrosion-inhibiting properties. Also suitable for aluminium. Anti-freeze fluid based on ethylene glycol with good corrosion-inhibiting properties. Anti-freeze fluid with corrosion inhibitor, also suitable for aluminium. Anti-freeze fluid based on ethylene glycol with good corrosion-inhibiting properties, also suitable for aluminium. 20-62 25-80 22-55
Hoechst Fernox BASF
Antifrogen N Alphi-11 Glythermin NF
20-40
Corrosion inhibitor Schilling Chemie Schilling Chemie Schilling Chemie Benckiser Wassertechnik Geminox, Frankreich Betz Dearborn, Belgien Fernox Cillit Wassertechnik Other additives Fernox Fernox Restorer Superfloc Universal Cleanser Superconcentrate Central heating Protector Cleaning agent (for sludge removal), also suitable for aluminium. Reduces limescale precipitation, also suitable for aluminium. 1-2 Varidos KK Varidos 1+1 Varidos AP Randophos HS Universal Inibal Sentinel X 100 Copal Cillit-HS Combi Corrosion inhibitor Corrosion inhibitor Corrosion inhibitor, also suitable for aluminium. Corrosion inhibitor Corrosion inhibitor, suitable for aluminium. Corrosion inhibitor for hot water heating systems, also suitable for aluminium. Corrosion inhibitor, also suitable for aluminium. Corrosion inhibitor 1-2 1,1 1 0,5 0,5 1-2 1-2
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 Perchloroethylene, trichloroethylene, methyl chloroform Trichloroethylene Aerosol propellants, hydrocarbons containing chlorine and fluorine (Freon)
Degreasing baths Printers Hairdressers
Sources in the home Cleaning and degreasing agents Perchloroethylene, methyl chloroform, trichloroethylene, methylene chloride, carbon tetrachloride, hydrochloric acid
Hobby workshops Solvents and thinners Aerosol sprays Table 9 Various chlorinated hydrocarb Chlor-fluorinated hydrocarbons (Freons)
7 181 465 347 (01.07)
49
Appendix
50
7 181 465 347 (01.07)
Appendix
7 181 465 347 (01.07)
51
Appendix
ADDENDUM SYSTEM BOILERS
28CS1 ZB 7-28, 28ICS1 ZSBR 7-28 and 35ICS1 ZBR 8-35
HE 27 ZB 7-27
ONLY COMPETENT PERSONNEL SHOULD ATTEMPT INSTALLATION
THESE INSTRUCTIONS SHOULD BE USED IN CONJUNCTION WITH THE INSTALLATION AND SERVICE MANUALS PROVIDED WITH THESE APPLIANCES
These appliances must NOT be used with a Honeywell mid-position Y plan diverter valve. The use of these valves will create a condition where the appliance operates without a demand for heat. These system diagrams replace the diagram on page 12. The wiring diagram replaces the diagram on page 22.
Fig. A. System layout if using built - in diverter valve. Fig. B. System layout if using external diverter valve.
Cylinder Return
APPLIANCE Heating Return LV RV RV LV Refer to Appliance Water Flow Diagram
APPLIANCE LV RV RV LV Heating Return Refer to Appliance Water Flow Diagram
Cylinder Return
Note: A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance
LV RV RV
LV
INDIRECT CYLINDER
LV RV RV
LV
INDIRECT CYLINDER
Heating Flow
Radiator Valve - Flow RV Lockshield Valve - Return LV
Safety Discharge Hot Water Flow Mains Cold Water BS Stop Valve Fixed Cylinder Type
Heating Flow
Safety Discharge Diverter Valve
Mains Cold Water
BS Stop Valve Fixed Cylinder Type
Room Stat
Tank Stat
Fig. C. System layout if using twin zone valves (S) plan.

RemotePre-wired Junction Box
INDIRECT CYLINDER
L out
Terminal Strip
E L N
LV RV RV
LV
External pump (DISCONNECT AND REMOVE)

Cylinder Return
Boiler/pump demand from junction box.
System Water Valve/s)
Timer
Permanent Mains supply (NOT ALLOWED)
Mains electrical supply to junction box (NO OTHER SUPPLY TO JUNCTION BOX ALLOWED) Outside of Boiler Inside of Boiler
APPLIANCE LV RV RV LV Heating Return Refer to Appliance Water Flow Diagram
Heating Flow
Hot Water Flow
Safety Discharge DHW Zone Valve
N NS L S L R
CH Zone Valve
Mains Cold Water BS Stop Valve Fixed Cylinder Type
MAINS ONLY
6 720 610 603 -04.1O
6 720 610 667 (01.06)
Hot Water Flow
Nr. 868
7 719 002 090
8 9 10 4 5 11 12 13
6 720 610 664 (01.07) GB Ka
GREENSTAR HE system, ZB 7-27 HE system ZB 7-28 CS1 ZSB 7-28 CS1
ZSB 7-27 HE system
6 720 610 664-00.1R
Nr. 868
Important Notes
English
The appliance and its accessories may only be fitted by a competent person. Please also observe the following: B Follow the installation instructions for the appliance and the accessories used.
1. 2.
6 720 610 497-03.1R
4
9
6 720 610 497-01.1R
2.
1. 3.
8 7 8
6 720 610 497-02.1R
6 720 610 497-04.1R
Only remove the plug and connect the additional cylinder flow pipe (as shown in figs. 1 and 2) if you wish to have a dedicated DHW flow pipe i.e. 2 flow pipes and 2 return pipes connecting to the boiler.
6 720 610 664 (01.07) GB
Nr. 868
4 10 5 6
6 720 610 497-05.1R
6 720 610 497-07.1R
8
0
115 Natural gas

8 2 3 6
116 LPG
6 720 610 497-06.1R
9 Connecting hot water cylinder
2 4 7 8 9
Position the sensor for the hot water cylinder according to the cylinder manufactures instruction.
6 720 610 664-02.1R
6 720 610 664 (01.07) GB

Greenstar ZWB 7 27 HE Combi 47 311 55

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Installation and Servicing Instructions

6 720 610 577-00.10

ZWB 7-27 HE combi GC-Number: 47 311 55

6 720 610 576 GB (01.07) OSW

6 720 610 576 GB (01.07)

6 720 610 576 GB (01.07)

Details of the appliance

Details of the appliance

6 720 610 576 GB (01.07)

Details of the appliance

6 720 610 601-01.1O

6 720 610 576 GB (01.07)

Details of the appliance

18 423 18.1 418

6 720 610 576 GB (01.07)

Details of the appliance

6 720 610 576 GB (01.07)

Details of the appliance

Electrical wiring diagram

310 312 313 315

6 720 610 576 GB (01.07)

Details of the appliance

6 720 610 576 GB (01.07)

Details of the appliance

Condensate analysis, mg/l

Table 3 Flue system

Table 6 Elbow - 90 Equivalent length 2 m Gas supply

Bend - 45 Equivalent length 1m

Total length of gas supply pipe (metres) 3 6 9

Pipe diameter (mm)

Gas discharge rate (m3/h) 8.7 5.8 12.0 4.6 9.4 22 28

450 950 1950 265375 200

Max. 13 m (including turret)

Table 7 Domestic water performance

13.2 11.3 9.9 10.0 0.2

6 720 610 576 GB (01.07)

6 720 610 576 GB (01.07)

Domestic hot water

6 720 610 576 GB (01.07)

APPLIANCE Refer to Fig.1 Appliance water flow diagram

WRC approved filling loop

BS stop valve. Fixed spindle type Water main

6 720 610 576 -09.1O

Sealed primary water system

6 720 610 576 - 10.1O

Sealed primary water system - filling method

Siting the appliance

6 720 610 576 GB (01.07)

Wall mounting frame assembly

6 720 610 576-11.1O

Pre-piping the system

6 720 610 576 GB (01.07)

Fitting the appliance

Fig. 11 Position of the condensate drain

6 720 610 332-07.1R

6 720 610 576 GB (01.07)

6 720 610 332-09.1R

Checking the connections

6 720 610 576 GB (01.07)

6 720 610 576 GB (01.07)

Terminal Assembly Flue Turret Maximum 650 mm

Outer Wall No Clamp