Worcester GREENSTAR HE combi Series Installation And Servicing Instructions Download Page 171

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7 181 465 347 (01.07)

Appendix

5.3

List of most important replacement parts

Component

Order no.

Remarks

Switchbox

PCB control
board

8 748 300 385

Transformer

8 747 201 358

Ignition lead

8 714 401 878

20-pin connector
lead assembly

8 714 401 912

Fuse

1 904 522 730

T 0,5 A

Fuse

1 904 522 740

T 1,6 A

Fuse

1 904 521 342

T 2,5 A

Code plug

included in

Conversion kit
G20 -> 31

7 710 149 050

ZWBR
8-30

Conversion kit
G31 -> G20

7 710 239 086

ZWBR
11- 30

Conversion kit
G20 -> G31

7 710 149 051

ZWBR
11 - 37

Conversion kit
G31 -> G20

7 710 239 087

ZWBR
14 - 37

Conversion kit
G20 -> G31

7 710 149 052

ZSBR
7-28

Conversion kit
G31 -> G20

7 710 239 088

ZSBR
11-28

Conversion kit
G20 -> G31

7 710 149 053

ZBR 8-35

Conversion kit
G31 -> G20

7 710 239 089

ZBR 11-35

Conversion kit
G20 -> G31

7 710 149 046

ZWBR
7-28

Conversion kit
G31 -> G20

7 710 239 082

ZWBR
11-35

Conversion kit
G20 -> G31

7 710 149 047

ZWBR
11-35

Conversion kit
G31 -> G20

7 710 239 083

ZWBR
14-35

Table 7

Heat exchanger

Temperature lim-
iter STB

8 729 000 144

110 °C

Flue gas temper-
ature limiter

8 729 000 144

Temperature
sensor, CH flow

8 714 500 054

NTC

Burner

Electrode
assembly

8 718 107 064

Gas valve

8 747 003 516

Gas valve

8 747 003 515

ZBR 11/
14..42A

Other components

Fan

8 717 204 325

Gas supply pipe

8 714 401 885

Textdisplay

8 747 208 081

Plate-type heat
exchanger

8 715 406 659

ZWBR
7/11-28 A.

Component

Order no.

Remarks

Table 7

Summary of Contents for GREENSTAR HE combi Series

Page 1: ...ctions GREENSTAR HE combi Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 577 00 10 ZWB 7 25 HE combi GC Number 47 311 73 ZWB 7 30 HE combi GC Number 47 3...

Page 2: ...g pump characteristic 27 6 2 Settings on the Bosch Heatronic 28 6 2 1 Operating the Bosch Heatronic 28 6 2 2 Selecting the pump control mode for central heating mode Service Function 2 2 28 6 2 3 Sett...

Page 3: ...ity of the appliance Health and safety B This appliance contains no asbestos products B There is no potential hazard due to the appliance being electrically unsafe B There are no substances used in th...

Page 4: ...ng 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 incorporatin...

Page 5: ...io frequency programmable room thermostat Timer Security kit 1 5 Casing dimensions Fig 1 13 Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System min 310 mm Alt...

Page 6: ...ting screw for min gas flow volume 88 3 way valve combi 98 DHW flow switch combi 102 Inspection window 120 Fixing points 221 1 Flue duct 221 2 Combustion air intake 226 Fan assembly 295 Appliance type...

Page 7: ...ombustion chamber 36 Temperature sensor in CH flow 43 CH flow 44 Hot water flow 45 Gas inlet 46 Cold water inlet 47 CH return 52 Solenoid valve 1 52 1 Solenoid valve 2 55 Filter 56 Gas valve CE 427 57...

Page 8: ...r 161 Link 226 Fan 300 Code plug 302 Earth connection 310 Temperature control for hot water 312 Fuse slow T 1 6 A 313 Fuse slow T 0 5 A 314 Connector for programmer 315 Terminal block for programmer 3...

Page 9: ...re bar 0 75 0 75 Total capacity l 10 10 Hot water specifications Hot water flow rate factory setting l min 8 8 Max hot water flow rate l min 14 14 Outlet temperature range C 40 60 40 60 Max permissibl...

Page 10: ...ure bar 0 75 0 75 Total capacity l 10 10 Hot water specifications Hot water flow rate factory setting l min 8 8 Max hot water flow rate l min 14 14 Outlet temperature range C 40 60 40 60 Max permissib...

Page 11: ...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 net Flues BS 5440 2 Flues and ventilation for g...

Page 12: ...ets 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 spra...

Page 13: ...ion 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...

Page 14: ...er to fig 1 and 16 B Mark the holes for the wall mounting frame onto the wall drill and plug the holes and screw the wall mounting frame to the wall with the screws provided Fig 8 B Screw the pre plum...

Page 15: ...ng the appliance B Remove packing taking care to observe the instruc tions on the packing B Lie the boiler on its back Removing the outer case B Turn the clips with a screwdriver 1 B Slide the outer c...

Page 16: ...to protect gas valve against damage from excessive pressure B Check gas supply pipe B Release the pressure on the gas supply pipe 3 9 Flue Systems The only flue systems that may be used are those sup...

Page 17: ...erminal Position kW input expressed in net Balanced flues room sealed Fanned draught A1 Directly below an opening air brick opening windows etc 300 mm B 1 Above an opening air brick opening window etc...

Page 18: ...g plates Extension kit comprises Air duct Flue duct Duct clamp Refer to fig 20 Instructions for fitting other flue systems are packed with the relevant flue kit Check that the position chosen for the...

Page 19: ...1600mm Flue Turret No Clamp Terminal Assembly Outer Wall Extension Duct 6 720 610 602 09 1O Clamp Flue Turret No Clamp Clamp Extension Duct Clamp Extension Duct Terminal Assembly Outer Wall 6 720 610...

Page 20: ...An inner wall sealing plate is provided which should be fitted to the ducts before assem bly Push the assembly through the wall and fix the turret to the appliance with the clamp Refer to fig 24 Fig 2...

Page 21: ...0 20 mm to BS6500 Table 6 Temperature rated 100 C Protection IPX4D External fuse 3 A 4 1 Connecting the appliance To gain access to the mains connection remove the drop down facia cover The drop down...

Page 22: ...t facility can only be isolated by actuating the ECO button 0 1 2 3 4 5 E 6 720 610 332 12 1R 13 14 10 12 8 9 5 7 L N N L LR S S 4130 14 1R 230 VRoom Thermostat Connections Ns Ls LR ST8 Ns Ls LR ST8 R...

Page 23: ...ating system should be flushed in accordance with the guidelines given in BS7593 1992 Treatment of water in domestic hot water systems Full instruc tions are supplied with proprietary cleansers sold f...

Page 24: ...Fig 31 The trap filling programme ensures that the condensa tion trap is filled after the appliance has been installed or after the appliance has been out of use for a long period or the mains supply...

Page 25: ...r supply pressure one full turn is equivalent to approximately 2 l min B To increase the flow rate max 14 l min turn screw on flow switch anti clockwise The outlet temperature will decrease relative t...

Page 26: ...button flashes B Press and hold the button until the display shows The appliance will then start up again and the display will show the central heating flow temperature If the button does not flash B...

Page 27: ...er Fig 35 B Rotate yellow button through 180 and replace dot facing inwards The CH flow temperature is no longer limited 6 1 3 Changing the heating pump characteristic The speed of the central heating...

Page 28: ...2 2 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 setti...

Page 29: ...compare with the fig ures specified for the code number displayed If fig ures do not match adjust the code number B Press and hold the and buttons simultane ously until the display shows The heating...

Page 30: ...e see page 16 refer to fig 13 B Switch on the appliance at the master switch I B Unscrew sealing plug from flue gas testing point 234 Refer to fig 41 B Insert testing probe about 135 mm into the flue...

Page 31: ...ode The display and the button will flash B Press and hold the button until the display shows B Reset the temperature controls and to their original positions The display will revert to the CH flow te...

Page 32: ...arts B Always renew seals and O rings removed during servicing or repair work B Use only the following types of grease Water valve WRc approved silicon based grease Unions approved sealant B To drain...

Page 33: ...flue gas see page 31 6 Check CO2 setting for min max gas air ratio see page 30 min max 7 Check gas and water systems for leaks see page 16 8 On combi models check hot water outlet temperature see page...

Page 34: ...aced Domestic hot water If the flow rate is too slow B remove the domestic hot water heat exchanger and replace or B descale with a descaling agent approved for use on stainless steel B Before removin...

Page 35: ...using a new seal and tighten screws to torque of approx 5 Nm Burner B Check that the gas cock is turned off and the master switch is in the OFF position B Remove the clips 1 and unscrew the two bolts...

Page 36: ...g 2 B Unscrew the two fixing screws and carefully remove the electrode assembly Refer to fig 50 B Clean the electrodes with a non metallic brush The spark gap should be 4 5 mm 0 5 mm B Replace and re...

Page 37: ...g 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...

Page 38: ...ack is available Part number 8 744 503 010 0 8 3 2 Fan Assembly Fig 61 B Switch off the appliance B Disconnect the appliance from the power supply B Undo lower pipe union on gas pipe 1 Refer to fig 61...

Page 39: ...d replace the pump head Fig 62 8 3 4 3 way diverter valve B Switch off the appliance B Disconnect appliance from the power supply B Turn off service cocks B Unplug connector from 3 way valve motor Ref...

Page 40: ...hot water circuit is drained B Release and pull off the connector B Unscrew the sensor 8 3 7 Gas Valve B Check that the gas cock is turned off B Lower the control panel Refer to fig 62 B Pull off the...

Page 41: ...e B Undo the union connection at the base of the vessel Refer to fig 2 B Unscrew the top and bottom fixing screws and remove the vessel B Set the pressure of the new vessel to that required by the sys...

Page 42: ...e top connection of the pump Refer to fig 62 B Undo the grey plastic cap next to the top pump con nection at the base of the heat exchanger B Unscrew and remove the condensate trap Refer to section 8...

Page 43: ...ped E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting lead E9 Safety temp limiter in CH flow has tripped Check system pressure check safety temp limiters check pump operation che...

Page 44: ...f valve 1 8 717 401 012 0 10 Electrode assembly 1 8 718 107 077 0 11 Electrode lead 1 8 714 401 999 0 12 Pump 1 8 717 204 384 0 13 Pressure gauge 1 8 717 208 079 0 14 Burner skin seal 1 8 711 004 168...

Page 45: ...3 33 7 80 21 8 22 0 38 5 90 24 5 24 8 43 3 100 27 2 27 5 48 1 Table 20 Propane Display code Heat output kW Heat input kW 40 10 9 11 0 50 13 6 13 8 60 16 3 16 5 70 19 1 19 3 80 21 8 22 0 90 24 5 24 8 1...

Page 46: ...ntil flow temperature is below set value Gas valve shuts Pump remains ON Demand ends Yes No NOTE The appliance controls can be set to one of 2 modes of operation 1 Comfort mode Full pre heat 2 ECO mod...

Page 47: ...Burner stabilises at start speed for 5 10 secs Fan speed reduces over 15 secs Gas valve closes Red light OFF Minimum heat input for 15min Boiler operates to match system load and CH control setting Bo...

Page 48: ...Appendix Appendix EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619...

Page 49: ...re Guide R 25 30 HE combi Condensing boiler R 28 HE system Condensing boiler 6 720 611 441 00 1O ZWB 7 25 R 25 HE GC Number 47 311 77 ZWB 7 30 R 30 HE GC Number 47 311 78 ZB 7 28 R 28 HE system GC Num...

Page 50: ...al Heating 14 3 4 Controlling Central Heating 14 3 5 R 25 30 Boilers Setting the Hot Water Temperature 15 3 6 Summer Mode Hot Water Only R 25 30 Appliances 16 3 7 Frost protection R 25 30 Appliances 1...

Page 51: ...Systems Ltd Offering a complete maintenance scheme to keep your boiler operating at peak condition and efficiency No wonder that more and more people are agreeing that when it is gas it has to be a W...

Page 52: ...This appliance must be installed only by a competent person to the requirements of IS 813 Make sure your installer hands you a certificate confirming com pliance with IS 813 and that you read carefull...

Page 53: ...smoke B Extinguish any naked flames B Call your gas company If you smell fumes from the appliance B Switch off appliance B Open windows and doors B Inform your heating engineer Fitting and modificati...

Page 54: ...afe B There are no substances used in the construction that are a potential hazard in relation to the COSHH Regulations Con trol of Substances Hazardous to Health Regulations 1988 Combustion Air Ambie...

Page 55: ...being heated at an even rate If the top of a radiator is at a lower temperature than the bottom then it should be vented by releasing air through the venting screw at the top of the radiator Ask your...

Page 56: ...itted They should conform to the requirements of BS2767 10 Showers bidets taps and mixing valves R 25 30 Boilers Standard hot and cold taps and mixing valves must be suitable for operating at mains pr...

Page 57: ...ance with the requirements of the local water com pany An isolating valve should be fitted to allow for servicing Alternatively the maximum temperature of the domestic hot water may be reset to about...

Page 58: ...171 Hot water 172 Gas isolation valve open 173 Cold water inlet 295 Identification sticker 310 Hot water temperature control R 25 30 317 Display 363 Indicator lamp for burner on 364 Indicator lamp for...

Page 59: ...e with direction of flow the cock is open Central heating system valves 170 B Using a spanner turn square nut until groove is in line with direction of flow see detail Groove at right angles to direct...

Page 60: ...er is below 1 bar when the system is cold top up the system with water until the pointer is 1 bar Your installer will have shown you how to do this B The maximum operating pressure of 2 5 bar at maxim...

Page 61: ...that the condensation trap is filled after the appliance has been installed or after the appliance has been out of use for a long period For that reason the appli ance remains at minimum heating outp...

Page 62: ...mperature heating setting E approx 75 C Max setting 88 C When the burner is lit the red indicator lamp is illuminated 3 4 Controlling Central Heating B Set room thermostat to the desired room temperat...

Page 63: ...y 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 t...

Page 64: ...e hot water is available 3 6 Summer Mode Hot Water Only R 25 30 Appliances With room thermostat B Turn temperature control on the appliance anti clockwise as far as the stop The central heating is now...

Page 65: ...ay shows The appliance will then start up again and the display will show the central heating flow temperature If the button does not flash B Switch the appliance off and then on again at the master s...

Page 66: ...ermo static radiator valves The central heating control on the boiler should be set to the max imum rated temperature of the central heating system or to posi tion E when the maximum central heating w...

Page 67: ...contact your installer or write to us 5 General Information Cleaning the Outer Case Wipe down the outer case with a damp cloth Do not use abrasive or caustic cleaning agents Appliance details If you e...

Page 68: ...perate at peak efficiency and performance it is essen tial that your boiler receives regular competent servicing and maintenance checks beyond the initial 2 year guarantee period If you would like to...

Page 69: ...Our Field Service Engineer finds no fault with the appliance see NOTE OR The cause of breakdown is misuse or with other parts of your plumbing heating system or with equipment not supplied by Worcest...

Page 70: ...sioned and where appropriate the first 2 year service has been carried out to the satisfaction of Worcester Heat Systems Limited when requested That any product or part thereof returned for servicing...

Page 71: ...y establishing a reference and permanent record for your boiler This will not affect your statutory rights in any way Important For your own record Model Serial number See identity label inside applia...

Page 72: ...he remote temperature control unit to the appropriate setting Hot water temperature ECO button lit Economy mode ECO button not lit Comfort mode Hot water only Fault Condition If the button flashes pre...

Page 73: ...ons GREENSTAR HE plus combi Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 598 00 1O ZWBR 7 30 HE plus GC Number 47 311 75 ZWBR 11 35 HE plus GC Number 4...

Page 74: ...programme 31 6 6 2 Hot water immediately 31 6 7 i Info 31 6 8 Settings 32 6 8 1 Heating if TR 2 is connected 32 6 8 2 Hot Water Storage Tank ZSBR models only 32 6 8 3 Service 32 6 9 Individual timer...

Page 75: ...ity of the appliance Health and safety B This appliance contains no asbestos products B There is no potential hazard due to the appliance being electrically unsafe B There are no substances used in th...

Page 76: ...n room size Natural gas models are low emission appliances Multifunction display Bosch Heatronic control system with integrated tex tdisplay for servicefunctions and faults 3 channel digital timer for...

Page 77: ...ons are sent with these kits Heating programmer Security kit 1 5 Casing dimensions Fig 1 13 Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System min 310 mm Alt...

Page 78: ...s flow volume 88 3 way valve combi 98 DHW flow switch combi 102 Inspection window 120 Fixing points 221 1 Flue duct 221 2 Combustion air intake 226 Fan assembly 295 Appliance type sticker 234 Testing...

Page 79: ...CH return 52 Solenoid valve 1 52 1 Solenoid valve 2 55 Filter 56 Gas valve CE 427 57 Main valve disc 61 Reset button 63 Adjustable gas flow restrictor 64 Adjusting screw for min gas flow volume 69 Con...

Page 80: ...A AC 230 V 153 Transformer 161 Link 226 Fan 300 Code plug 302 Earth connection 310 Temperature control for hot water 312 Fuse slow T 1 6 A 313 Fuse slow T 0 5 A 317 Digital display 328 Terminal block...

Page 81: ...capacity l 18 18 10 10 Hot water specifications Hot water flow rate factory setting l min 8 8 8 8 Max hot water flow rate l min 14 14 14 14 Outlet temperature range C 40 60 40 60 40 60 40 60 Max perm...

Page 82: ...ension Duct Length mm 1000 Table 4 ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM Overall Diameter of Duct mm 125 Max 13 m ZWBR 7 30 Max 10 m ZWBR 11 35 including turret Flue Terminal Duct Assembly mm 1030...

Page 83: ...for gas appliances of rated input not exceeding 70 kW net Flues BS 5440 2 Flues and ventilation for gas appliances of rated input not exceeding 70 kW net Air Supply BS 6891 Installation of low pressur...

Page 84: ...such as water meters or back flow pre vention valves capable of preventing the flow of expansion water must not be fitted unless sepa rate arrangements have been made A Zilmet Z160 expansion vessel i...

Page 85: ...egard to flammable building materials and fitted furniture The specified clearences must be maintained Cupboard Compartment The appliance can be installed in a cupboard compart ment need for airing cl...

Page 86: ...fer to fig 1 and 16 B Mark the holes for the wall mounting frame onto the wall drill and plug the holes and screw the wall mounting frame to the wall with the screws provided Fig 8 B Screw the pre plu...

Page 87: ...t least 2 5 3 7 Fitting the appliance B Remove packing taking care to observe the instruc tions on the packing B Lie the boiler on its back Removing the outer case B Remove retaining screw on left han...

Page 88: ...3 8 Checking the connections Water connections B Check that the O rings or seals are in place before tightening the connection B Turn on the service valves for central heating flow and return and fill...

Page 89: ...alternative flue systems are sent with the appropriate flue kit Systems are available to give a maximum horizontal length of 13 m ZWBR 7 30 and 10 m ZWBR 11 35 A vertical flue system upto a height of...

Page 90: ...rminal Position kW input expressed in net Balanced flues room sealed Fanned draught A1 Directly below an opening air brick opening windows etc 300 mm B 1 Above an opening air brick opening window etc...

Page 91: ...g plates Extension kit comprises Air duct Flue duct Duct clamp Refer to fig 20 Instructions for fitting other flue systems are packed with the relevant flue kit Check that the position chosen for the...

Page 92: ...1600mm Flue Turret No Clamp Terminal Assembly Outer Wall Extension Duct 6 720 610 602 09 1O Clamp Flue Turret No Clamp Clamp Extension Duct Clamp Extension Duct Terminal Assembly Outer Wall 6 720 610...

Page 93: ...NOTE An inner wall sealing plate is provided which should be fitted to the ducts before assem bly Push the assembly through the wall and fix the turret to the appliance with the clamp Refer to fig 24...

Page 94: ...0 20 mm to BS6500 Table 6 Temperature rated 100 C Protection IPX4D External fuse 3 A 4 1 Connecting the appliance To gain access to the mains connection remove the drop down facia cover The drop down...

Page 95: ...e If an external timer is used then the domestic hot water pre heat facility can only be isolated by actuating the ECO button 0 1 2 3 4 5 E 6 720 610 332 12 1R 13 14 10 12 8 9 5 7 L N N L LR S S 4130...

Page 96: ...ral heating system should be flushed in accordance with the guidelines given in BS7593 1992 Treatment of water in domestic hot water systems Full instruc tions are supplied with proprietary cleansers...

Page 97: ...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 he...

Page 98: ...approximately 2 l min B 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 B To reduce the...

Page 99: ...sh If the button flashes B Press and hold the button until the display shows The appliance will then start up again and the display will show the central heating flow temperature If the button does no...

Page 100: ...k function as an example B To start programming press any button e g The display lighting switches on and the main menu is displayed Fig 36 Main menu B Use the or button to move the cursor arrow on th...

Page 101: ...TENTION Delete all parameters in x seconds Once the reset has been completed the following message is displayed Please wait Initialising 6 3 Menu structure i The hours of service can not be reset to 0...

Page 102: ...omy or Frost protection switching on at the same times Saturday and Sunday Individual day of the week e g Thursday to have the relevant program always switching on at the specified time on that day of...

Page 103: ...for heating as described on page 30 6 6 2 Hot water immediately Hot water immediately ON Comfort mode is active for 2 hours Comfort mode is active for 2 hours normal auto matic program Hot water mode...

Page 104: ...selected from the third submenu Language Time correction LCD contrast Time correction B Press and hold the button about 5 seconds until the display shows Time correction and LCD contrast B Press or t...

Page 105: ...ed to those functions necessary for commissioning Displaying service functions All service functions are displayed B Press any button to activate the main menu B Press or button until the arrow cursor...

Page 106: ...to any level between min rated heat output and max rated heat output to limit it to the specific heat requirements The factory setting is the max rated heat output 100 B Look up heating output in kW a...

Page 107: ...ng probe about 135 mm into the flue gas testing point and seal testing point Fig 40 B On the text display unit select in the main menu Set tings Service Display service parameters B Press and hold the...

Page 108: ...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 B Remove sealing plug from combustion air testing point 234 1...

Page 109: ...To drain the appliance shut the system valves and open the pressure relief valve B Upon completion of any electrical work check for earth continuity correct polarisation and resistance to earth Repla...

Page 110: ...page 36 6 Check CO2 setting for min max gas air ratio see page 36 min max 7 Check gas and water systems for leaks see page 16 8 Check hot water outlet temperature see page 39 9 Check heat exchanger se...

Page 111: ...tainless steel B Before removing the heat exchanger shut the inlet valve and drain the hot water circuit B Use new seals when replacing the heat exchanger Fig 44 Primary Heat exchanger There is a spec...

Page 112: ...ws to torque of approx 5 Nm Burner B Check that the gas cock is turned off and the master switch is in the OFF position B Remove the clips 1 and unscrew the two bolts 2 Refer to fig 50 B Unscrew and r...

Page 113: ...bly taking care not to mislay the inspection window Diaphragm in mixer unit for ZWBR 7 30 HE plus B Open mixer unit 29 B Carefully withdraw diaphragm 443 from fan intake tube and check for soiling and...

Page 114: ...m does not retain the pressure the expan sion vessel and the heating system should be checked for leaks 9 3 Replacement of Parts Before changing any components check that the gas is turned off and tha...

Page 115: ...th connector 2 The earth connector has a positive clip fixing B Remove fixing screws attaching fan to the burner cover 3 B Remove fan together with gas pipe and mixer unit B Separate the fan from the...

Page 116: ...lve Fig 59 After refitting B Fill system bleed and re pressurise see Installation Instructions 9 3 5 3 way diverter valve motor B Switch off the appliance B Turn off the service cocks B Unplug connect...

Page 117: ...d in section 8 1 Fig 60 9 3 8 Domestic Hot Water Heat Exchanger B Refer to section 9 2 B Use new seals when fitting the new heat exchanger 9 3 9 Electrode assembly B Refer to section 9 2 B Use a new s...

Page 118: ...urner Refer to section 9 2 B Disconnect the sensors Refer to section 9 3 6 B Undo the central heating flow union B Undo the top connection of the pump Refer to fig 57 B Undo the grey plastic cap next...

Page 119: ...lead E9 Safety temp limiter in CH flow has tripped Check system pressure check safety temp limiters check pump operation check fuse on pcb bleed appliance EA Flame not detected Is gas cock turned on...

Page 120: ...Expansion vessel ZWBR 11 35 1 8 715 407 246 0 9 Relief valve 1 8 717 401 012 0 10 Electrode assembly 1 8 718 107 077 0 11 Electrode lead 1 8 714 401 999 0 12 Pump 1 8 717 204 350 0 13 Pressure gauge...

Page 121: ...20 7 36 1 80 23 4 23 6 41 3 90 26 3 26 6 46 5 100 29 2 29 5 51 6 Table 20 Propane Display code Heat output kW Heat input kW 40 11 7 11 8 50 14 6 14 8 60 17 5 17 7 70 20 4 20 7 80 23 4 23 6 90 26 3 26...

Page 122: ...until flow temperature is below set value Gas valve shuts Pump remains ON Demand ends Yes No NOTE The appliance controls can be set to one of 2 modes of operation 1 Comfort mode Full pre heat 2 ECO mo...

Page 123: ...Burner stabilises at start speed for 5 10 secs Fan speed reduces over 15 secs Gas valve closes Red light OFF Minimum heat input for 15min Boiler operates to match system load and CH control setting Bo...

Page 124: ...Appendix Appendix EXCELLENCE COMES AS STANDARD Worcester Heat Systems Limited Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619...

Page 125: ...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 ZW...

Page 126: ...1 Boiler failure codes indication 14 4 1 1 on the boiler 14 4 1 2 on the programmer optional accessory 14 4 2 Summary 14 4 2 1 Appliance faults 14 4 2 2 Faults that are not indicated on any display 14...

Page 127: ...ations 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 Signal words indicate the seriousness of the haz...

Page 128: ...ter Variable charac teristic pump Automatic vent Gas flow restrictor adju sting screw for CO2 max Gas valve adjusting screw for CO2 min Plate type heat exchanger ZWBR Hot water NTC sensor ZWBR CH flow...

Page 129: ...ress and hold the button for about 5 sec onds until the display shows shows Adjust service parameters and the first service function to be set e g 2 0 Operating mode If a fault has occurred the displa...

Page 130: ...5 1 5 Required flow temp 0 99 C 1 9 Module detection no module detected bus module 2 0 Operating mode normal Min Max normal 2 2 Pump switch mode 1 3 2 2 3 Stor tank charge output 0 100 100 2 4 Anti cy...

Page 131: ...ocked heat demand 4 4 Heat demand heating yes no Heat demand stor tank yes no 4 5 Heat demand hot water yes no Keep hot period yes no 4 6 Internal regulator blocked heat demand 5 0 Max output heating...

Page 132: ...off on on 7 3 Air purge mode off on autom deaktivat permanent on on autom deaktiv at off 7 4 Actual map pump step 1 8 7 5 Map pump load index 0 255 7 6 Map pump type 0 99 7 7 Output reduction off only...

Page 133: ...cording to the commands received from the programmer Min mode the appliance runs constantly at minimum output The text display shows MIn mode The 2 digit dis play alternates between the CH flow temper...

Page 134: ...ed with the appliance 3 5 Pump blocking time ZBR models only 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 the...

Page 135: ...an output dependent basic charge The heating output can be limited to any level between the min rated heat output and the max rated heat out put to suit the specific heat requirements The factory sett...

Page 136: ...ap heating is set to 0 Pump step adjustable This service function corresponds to the pump speed switch used on conventional heating pumps 7 2 Antiblock map pump not ZBR The appliance is supplied with...

Page 137: ...n 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 9 2 Hot water on demand The...

Page 138: ...ogrammer optional accessory A TW 2 remote control unit can also be connected to the text display module If other more functions are required another program mer must be connected Those programmers are...

Page 139: ...Programmer faults TR 2 Page Set room temperature not reached X 41 Set room temperature exceeded by large amount X 43 Set room temperature not reached 41 Temperature rises instead of falling X 43 Room...

Page 140: ...plete heat demand cycle until the appliance switches off If the fault is now cured the appliance will revert to nor mal operation and the fault finding process is complete Now simply re check the sett...

Page 141: ...ater leaks and repair as necessary B Top up system B Turn ON the appliance A1 2 no 2 2 Activate venting sequence B Activate menu option Show service parameters B Select 7 3 Aeration mode select settin...

Page 142: ...r 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 displa...

Page 143: ...appliance B Change hot water NTC sensor 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...

Page 144: ...Wiring between TR 2 and text display OK Terminal 3 on TR 2 connected to Terminal 3 on textdisplay Terminal 4 Terminal 4 etc yes B Turn ON the appliance 3 no B Rewire correctly as specified in the inst...

Page 145: ...3 1 no 4 3 Heat store NTC 1 B Unplug connector from PCB con trol board B Short circuit the connector using wire jumper After max 60 sec Display changes to temperature between 100 and 95 yes B Replace...

Page 146: ...elect 1 2 Code plug B Compare number displayed with that shown in Appendix No number or incorrect number last three digits displayed yes 2 no 4 3 Code plug loose incorrect or defec tive B Power OFF th...

Page 147: ...s B Power OFF the appliance B Replace fan lead B Turn ON the appliance C6 3 no 3 3 Fan defective yes B Power OFF the appliance B Plug the connection wire B Replace fan B Plug the connection wire B Tur...

Page 148: ...F 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 sen sor B Turn ON the appliance d3 4 no 4 4 Existing h...

Page 149: ...o 2 2 Heating outlet NTC sensor Temperature between 95 and 100 is displayed yes The CH flow NTC sensor is interrupted B Power OFF the appliance B Replace CH flow NTC sensor observe fitting instruction...

Page 150: ...trical connection B Turn ON the appliance B Press does appliance restart E9 3 no 3 3 Is lead disconnected from one both safety temperature limiters yes B Power OFF the appliance B Connect lead B Turn...

Page 151: ...rn ON the appliance B Press does appliance restart E9 6 no B Remount the fuse B Turn ON the appliance 6 The PCB control board is damaged B Power OFF the appliance B Disconnect the boiler electrical co...

Page 152: ...models does the building have a supply pres sure regulator yes B Check that it is fitted correctly and functioning properly and correct if necessary B Check supply pressure inform gas company if outs...

Page 153: ...start EA 10 8 Is condensation trap in condensing boiler blocked yes B Unscrew condensation trap and clean B Press does appliance restart EA 12 no 9 9 Check the gas valve B Power OFF the appliance B Un...

Page 154: ...ition electrode B Press does appliance restart EA 14 14 Ignition cable connector engaged in switchbox yes 15 no B Power OFF the appliance B Engage ignition cable connector in switchbox B Turn ON the a...

Page 155: ...pliance restart EA 18 18 Check if the 20 pin connector lead assembly is damaged B Power OFF the appliance B Change the 20 pin connector lead assembly B Turn ON the appliance B Press does appliance res...

Page 156: ...ice Further options Fault history Other faults apart from F0 dis played yes B Deal with fault s displayed as instructed in rele vant fault table s no 3 4 flashing yes B Press button B Initiate demand...

Page 157: ...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 does appliance restart F7...

Page 158: ...tion air 0 2 CO2 yes B Check flue and repair or replace if necessary B Press does appliance restart FA B Power OFF the appliance 4 no 4 4 The gas valve is damaged B Change the gas valve B Turn ON the...

Page 159: ...ug text display module con nector B Connecting lead between text dis play 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 R...

Page 160: ...ert appliance to correct gas type1 2 B Test gas supply pressure OK 1 yes 3 no B Decommission appliance B Notify gas company 3 Problem with flue B Check CO2 level in combustion air 0 2 CO2 yes B Check...

Page 161: ...as company 3 Problem with flue B Check CO2 level in combustion air 0 2 CO2 yes B Check flue and repair or replace if necessary no 4 4 Flue gas CO2 levels measured at min and max load do not match spec...

Page 162: ...r OFF the appliance Ignition poor 4 4 Ignition cable defective yes B Power OFF the appliance B Replace ignition cable B Turn ON the appliance B Press button B Power OFF the appliance Ignition poor 5 n...

Page 163: ...seal if necessary B Ensure seal is fitted in correct position 1 See installation instructions Ignition too harsh ignition poor Check Action Loose or broken contact on heat store NTC sensor Check Acti...

Page 164: ...etween 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...

Page 165: ...l on boiler set too low yes B Turn up CH flow temperature control no 3 3 Air in the heating system B Power OFF the appliance B Check appliance and system for water leaks and repair as necessary B Top...

Page 166: ...trol 4 no 4 4 Heat store connected via HSM yes 5 no 6 5 Is heat store temperature unreacha ble CH flow temperature control set too low yes B Turn up CH flow temperature control 6 no 6 6 Air in the hea...

Page 167: ...tion location1 3 no 3 3 B Turn down thermostatic valve s n 1 See installation instructions Temperature rises instead of falling Check Action Timer clock DT 2 incorrectly set B Check setting and correc...

Page 168: ...tore fails to heat up Check Action 1 with TR 2 CH flow temperature control on boiler set too low B Increase CH flow temperature control setting 2 Hot water temperature control on boiler set too low B...

Page 169: ...r NTC sensor Outside temperature C Measurement tolerance 10 Resistance 20 2 392 16 2 088 12 1 811 8 1 562 4 1 342 0 1 149 4 984 8 842 10 781 15 642 20 528 25 436 Table 5 Temperature C Measurement tole...

Page 170: ...161 Link 226 Fan 300 Code plug 302 Earth connection 310 Temperature control for hot water 312 Fuse slow T 1 6 A 313 Fuse slow T 0 5 A 317 Digital display 328 Terminal block for AC 230 V Mains supply 3...

Page 171: ...Conversion kit G31 G20 7 710 239 088 ZSBR 11 28 Conversion kit G20 G31 7 710 149 053 ZBR 8 35 Conversion kit G31 G20 7 710 239 089 ZBR 11 35 Conversion kit G20 G31 7 710 149 046 ZWBR 7 28 Conversion...

Page 172: ...h good corrosion inhibiting properties 20 40 Fernox Alphi 11 Anti freeze fluid with corrosion inhibitor also suit able for aluminium BASF Glythermin NF Anti freeze fluid based on ethylene glycol with...

Page 173: ...long periods of time In order to limit the damage the source of the contami nation must be located and sealed off If this is not pos sible the combustion air must be brought to the appliance from an u...

Page 174: ...7 181 465 347 01 07 50 Appendix...

Page 175: ...7 181 465 347 01 07 Appendix 51...

Page 176: ...Appendix...

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Worcester GREENSTAR HE combi Series, Installation And Servicing Instructions

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