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Worcester R 30 HE plus combi, Installation And Servicing Instructions, Page: 1 / 96

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Worcester R 30 HE plus combi Installation And Servicing Instructions Download Page 1

6 720 610 893-01.TD

Installation and Servicing Instructions

R 30/35/40 HE plus combi

Wall mounted condensing boiler for central heating and mains
fed domestic hot water

ZWBR  7-30 R 30 HE plus 

GC-Number: 41 311 79

ZWBR 11-35 R 35 HE plus 

GC-Number: 41 311 80

ZWBR 11-40 R 40 HE plus 

GC Number 41 311 81

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Summary of Contents for R 30 HE plus combi

Page 1: ...0 35 40 HE plus combi Wall mounted condensing boiler for central heating and mains fed domestic hot water ZWBR 7 30 R 30 HE plus GC Number 41 311 79 ZWBR 11 35 R 35 HE plus GC Number 41 311 80 ZWBR 11...

Page 2: ...water immediately 29 6 7 i Info 29 6 8 Settings 30 6 8 1 Heating if TR 2 is connected 30 6 8 2 Hot Water Storage Tank system models only 30 6 8 3 Service 30 6 9 Individual timer programmes 30 7 Indivi...

Page 3: ...f chemically aggressive substances e g halogenated hydrocarbons which contain chlorine or fluorine compounds This will prevent corrosion Instructions to the customer B Explain to the customer how the...

Page 4: ...mission appliances Multi function display Bosch Heatronic control system with integrated text display for service functions and faults 3 channel digital timer for one heating circuit Variable pump Aut...

Page 5: ...Temperature Controller 1 5 Casing dimensions Fig 1 13 Manifold assembly 101 Outer case 103 Facia cover X Standard Concentric Horizontal Flue System min 160 mm Alternative Concentric Flue System min 2...

Page 6: ...H flow 63 Adjustable gas flow restrictor 64 Adjusting 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 Combusti...

Page 7: ...s 46 Cold water inlet 47 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 Gas flow restrictor adjustable for max gas flow volume...

Page 8: ...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 f...

Page 9: ...ications Hot water flow rate 35 rise l min 12 1 12 1 14 6 14 6 16 4 16 4 Outlet temperature range C 40 60 40 60 40 60 40 60 40 60 40 60 Max permissible water supply pressure bar 10 10 10 10 10 10 Min...

Page 10: ...input not exceeding 70 kW net Flues BS 5440 2 Flues and ventilation for gas appliances of rated input not exceeding 70 kW net Air Supply BS 6891 Installation of low pressure gas pipework installation...

Page 11: ...ice at the point of the flexible hose connections Over rim bidets may be connected to the appliance pro vided that it is in accordance with the requirements of the local water company The outlet s sho...

Page 12: ...6 3 4 Siting the appliance Regulations concerning the Installation Site B Relevant national regulations must be complied with section 3 9 1 B Consult the installation instructions for details of min...

Page 13: ...the wall mounting frame to the wall with the screws provided B Mark the position of the flue duct hole if a rear flue is to be used Refer to fig 1 and 16 Fig 8 B Screw the pre plumbing manifold with...

Page 14: ...d with a downward slope of at least 2 5 3 7 Fitting the appliance Removing the outer case B Remove retaining screws 1 see Fig 13 B Slide the outer case upwards and forwards to remove 2 Fig 13 Boiler B...

Page 15: ...pipe 3 9 Flue Systems The only flue systems that may be used are those sup plied with the boiler The flue system must be installed in accordance with the requirements of BS5440 1 Standard 100 mm flue...

Page 16: ...I I boundary Q K H H A F J P Dimension Terminal position kW input expressed in net Balanced flues room sealed Fanned draught A1 Directly below an opening air brick opening windows etc 300 mm B1 Above...

Page 17: ...s for fitting other flue systems are packed with the relevant flue kit Check that the position chosen for the appliance is sat isfactory Refer to fig 16 Fig 16 Marking the position of a side flue open...

Page 18: ...assembly Measure the flue length L Refer to fig 21 22 Maximum 1600mm Clamp Flue Turret Terminal Assembly Outer Wall 6 720 610 599 00 TD Extension Duct Clamp Flue Turret Terminal Assembly Outer Wall 6...

Page 19: ...solvent free grease is lightly applied i e Silicone lubricant to the male end of the ducts NOTE An inner wall sealing plate is provided which should be fitted to the ducts before assem bly Push the a...

Page 20: ...electrical supply Water Protection IPX4D 4 1 Connecting the appliance To gain access to the mains connection remove the drop down facia cover The drop down cover is removed by lowering it to the hori...

Page 21: ...beneath the Text display page 8 fig 4 item 422 using a minimum 1mm cable to avoid incresing resistance between the terminals see Fig 29 Fig 29 4 3 Mains Voltage external controls connections Externall...

Page 22: ...tral 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...

Page 23: ...ap filling programme ensures that the condensa tion trap is filled after the appliance has been installed or after the appliance has been out of use for a long period or the mains supply has been inte...

Page 24: ...pproximately 2 l min B To increase the flow rate turn screw on flow switch anti clockwise The outlet temperature will decrease relative to the increase in the flow rate B To reduce the flow rate min 8...

Page 25: ...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 the left of the menu so that it points to the des...

Page 26: ...following message is displayed Please wait Initialising 6 3 Menu structure i The hours of service can not be reset to 0 C C C Submenu Main menu 1 2 3 Parameters to change select Page Time day holi da...

Page 27: ...Frost protection Same times for Monday to Friday Same times for Saturday and Sunday Different times for every day Setting switching times and operating mode B From the main menu select Heating and the...

Page 28: ...imer programme enabling Hot Water pre heat from 5 00am disabling Hot Water preheat from 10 00pm The ECO button must not be lit 6 7 i Info B Select Info from the main menu You can view the following in...

Page 29: ...the third submenu select Language B Press or to select the desired language Two other supplementary functions can be selected from the third submenu Language Time correction LCD contrast Time correcti...

Page 30: ...eneral description The text display module provides a convenient means of setting various appliance functions This description is limited to those functions necessary for commissioning Displaying serv...

Page 31: ...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 and correspon...

Page 32: ...ch I B Unscrew sealing plug from flue gas testing point 234 Refer to fig 40 B Insert testing probe about 135 mm into the flue gas testing point and seal testing point Fig 40 B On the text display unit...

Page 33: ...on B Remove testing probe from the flue gas testing point 234 and refit sealing plug B Re seal gas valve adjusting screw and gas flow restrictor B Replace the outer case by locating it on the top lugs...

Page 34: ...active The button will light up and the display shows the CH flow temperature B Remove sealing plug from flue gas testing point 234 fig 43 B Insert testing probe about 135 mm into the testing point an...

Page 35: ...stance to earth Replace the text display module or the Heatronic PCB If the text display module is replaced the service func tion settings are retained B The remaining settings have to be re entered I...

Page 36: ...page 34 6 Check CO2 setting for min max gas air ratio see page 32 min max 7 Check gas and water systems for leaks see page 15 8 Check hot water outlet temperature see page 37 9 Check heat exchanger se...

Page 37: ...anger and replace 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 s...

Page 38: ...ue 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 remove the...

Page 39: ...assembly taking care not to mislay the inspection window Diaphragm in mixer unit for 30 HE plus B Open mixer unit 29 B Carefully withdraw diaphragm 443 from fan intake tube and check for soiling and...

Page 40: ...ystem 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...

Page 41: ...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 pipe and mixer unit by t...

Page 42: ...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 43: ...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 44: ...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 45: ...connecting lead E9 Safety temp limiter in CH flow has tripped Check system pressure check safety temp lim iters check pump operation check fuse on pcb bleed appliance EA Flame not detected Is gas cock...

Page 46: ...lve 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 1 8 717 208 079 0 14 Burner skin seal 1 8 711 004 168 0 15...

Page 47: ...37 4 80 24 2 24 4 42 7 90 27 2 27 5 48 0 100 30 2 30 5 53 4 Table 20 Propane Display code Heat output kW Heat input kW 40 12 1 12 2 50 15 1 15 3 60 18 1 18 3 70 21 1 21 4 80 24 2 24 4 90 27 2 27 5 10...

Page 48: ...ter temperature is 8 C 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...

Page 49: ...mp ON Fan to start speed Gas valve opens Burner stabilises at start speed for 5 10 secs Fan speed reduces over 15 secs Fan min speed for 90 secs Boiler unused for long period Minimum heat input for 15...

Page 50: ...6 720 611 400 GB 03 11 50 Appendix...

Page 51: ...6 720 611 400 GB 03 11 Appendix 51...

Page 52: ...Appendix Appendix EXCELLENCE COMES AS STANDARD Worcester Bosch Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619...

Page 53: ...and Customer Care Guide R 30 35 40 HE combi plus Condensing boiler 6 720 610 598 00 2O ZWBR 7 30 R 30 GC Number 47 311 79 ZWBR 11 35 R 35 GC Number 47 311 80 ZWBR 11 40 R 40 GC Number 47 311 81 6 720...

Page 54: ...15 3 5 Combination Boilers Setting Hot Water Temperature 16 3 6 System boiler with Storage Tank 17 3 7 Summer Mode Hot Water Only Combi Appliances 18 3 8 Frost protection Combi Appliances 19 3 9 Faul...

Page 55: ...mediately System models 31 4 7 i Info 32 4 8 Settings 33 4 8 1 Heating if TR 2 is connected 33 4 8 2 Hot Water Storage Tank System boiler models only 33 4 8 3 Service 33 4 9 Individual timer programme...

Page 56: ...Worcester Heat 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 i...

Page 57: ...doors and windows B Do not operate any electrical switches B Do not smoke B Extinguish any naked flames B Call your gas company If you smell fumes from the appliance B Switch off appliance B Open wind...

Page 58: ...no potential hazard due to the appliance being electri cally unsafe B There are no substances used in the construction that are a potential hazard in relation to the COSHH Regulations Con trol of Subs...

Page 59: ...e 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 you...

Page 60: ...s Thermostatic radiator valves It is recommended that this type of valve is fitted to all the radiators except one usually the radiator where the room temperature con troller is fitted They should con...

Page 61: ...appliance will still operate in the central heating mode Use in hard water areas Combination Boilers In exceptionally hard water areas a device to prevent scale forma tion may be fitted Installation...

Page 62: ...598 GB 03 11 Do not allow the flue terminal fitted on the outside wall to become obstructed or damaged Pump The pump is a fully modulating type to which the parameters have been set by the manufacture...

Page 63: ...w and return 171 Hot water 172 Gas isolation valve open 173 Cold water inlet 295 Identification sticker 310 Hot water temperature control 317 Display 363 Indicator lamp for burner on 364 Indicator lam...

Page 64: ...ith direction of flow the cock is open Central heating system valves 170 B Using a spanner turn square nut until groove is in line with direction of flow see detail Groove at right angles to direction...

Page 65: ...ow 1 bar when the system is cold top up the system with water until the pointer is 1 bar Your installer will have shown you how to do this B The maximum operating pressure of 2 5 bar at maximum centra...

Page 66: ...res 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 o...

Page 67: ...etting E approx 75 C Max setting 88 C When the burner is lit the red indicator lamp is illuminated Fig 5 3 4 Controlling Central Heating B Set the timer to the correct time B Set room thermostat to th...

Page 68: ...on 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...

Page 69: ...e ECO mode button is lit Water is not heated up until hot water is drawn This means that there is a longer waiting period before hot water is available 3 6 System boiler with Storage Tank B Set the ho...

Page 70: ...e ECO mode button is lit In ECO mode the appliance switches between central heating mode and cylinder charging mode every 12 minutes 3 7 Summer Mode Hot Water Only Combi Appliances With room temperatu...

Page 71: ...ent of a fault occurring while the appliance is in operation The display and the text display then shows a fault code and the button may also flash If the button flashes B Press and hold the button un...

Page 72: ...odule has a power buffer period of about 10 hours during which it will run without the mains power supply After that period has elapsed the clock function shuts down but all other settings are retaine...

Page 73: ...erating modes may be displayed during commis sioning servicing etc The programming procedure is described in detail below using the clock function as an example B To start programming press any button...

Page 74: ...ime day B Confirm the selection by pressing the button The corresponding submenu is displayed Fig 11 Setting the hour When settings are being entered the setting to be altered is indi cated on the top...

Page 75: ...other buttons for 15 minutes 4 2 1 Deleting a setting Either over write the setting or press the button to delete it B Find the setting to be deleted B Press and release the button The display shows...

Page 76: ...ays Days holiday 25 Heating Heating program Day 1st operating mode 1st switching point 6th switching point 27 Set econ omy temp if TR2 is connected 5 30 C 28 Manual if TR2 is not con nected Automatic...

Page 77: ...ct Holidays B Enter the number of days holiday by pressing or max 99 days holiday After the set number of days the text display module automat Settings Heating Optimum Start Off On 33 Hot water System...

Page 78: ...mode early B In the Holidays submenu Press the button until the display shows 0 i The day on which you enter the days holiday counts as the first day of the holiday i e the unit starts the holiday pro...

Page 79: ...urday and Sunday Different times for every day Setting switching times and operating mode B From the main menu select Heating and then from the first submenu select Heating program B Select Monday Fri...

Page 80: ...o not wish to change can be skipped by pressing 4 5 2 Setting the Economy temperature if TR2 is con nected This option allows you to set the room temperature for Economy mode Off Economy This function...

Page 81: ...onstant on comfort and Constant off economy The manually selected operating mode starts immediately Constant off economy and Constant on comfort are auto matically reset at 00 00 midnight To cancel th...

Page 82: ...enabled from 5 00 am disabled from 10 00 pm The ECO button must not be lit Comfort mode System models with Storage Tank The basic settings pro vide a timer programme enable from 5 00 am disable from...

Page 83: ...ocked Released operating mode in the same way as for the switching points and modes for heating as described on page 27 4 6 2 Hot water immediately System models Hot water immediately ON Comfort mode...

Page 84: ...for CH flow Actual flow temp Actual CH flow temperature Required flow temp Required CH flow temperature Max HW temp Maximum permissible hot water out flow temperature Required HW temp Required hot wa...

Page 85: ...se up to six different times with temperatures see page 30 Hot water Only times During that times the Storage Tank will be charged to the chosen temperature B From the main menu select Settings and fr...

Page 86: ...ction 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 to select Time correction B Press the button The disp...

Page 87: ...d submenu select Operating times Fault history This option displays any faults that have occurred for the informa tion of the service engineer The first fault displayed may still be active Any other f...

Page 88: ...Operating mode Time Operating mode Time Operating mode Time Operating mode Time Monday Tuesday Wednesday Thursday Friday Saturday Sunday Enable disable hot water function Switching point 1 2 3 4 5 6 S...

Page 89: ...tem Desired room temperature exceeded by large amount Radiators are too hot Turn down ther mostatic valves Temperature rises instead of falling Clock is incor rectly set Check setting Room tempera tur...

Page 90: ...ermostatic 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 wa...

Page 91: ...e contact your installer or write to us 7 General Information Cleaning the Outer Case Wipe down the outer case with a damp cloth Do not use abrasive or caustic cleaning agents Appliance details If you...

Page 92: ...operate at peak efficiency and performance it is essen tial that your boiler receives regular competent servicing and maintenance checks beyond the initial 2 year guarantee period If you would like to...

Page 93: ...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 Worceste...

Page 94: ...ssioned 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 95: ...ice by establishing a reference and permanent record for your boiler This will not affect your statutory rights in any way Important For your own record Model Serial number See identity label inside a...

Page 96: ...ay Set switching times and operating mode within the text display Hot water temperature Combina tion boiler only ECO button lit Economy mode ECO button not lit Comfort mode Fault Condition Refer to pa...

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