Worcester ZSBR 7-30 RD 430i system Service Booklet Download Page 1

Page: 1 / 56

Supplied By www.heating spares.co Tel. 0161 620 6677

Service booklet for the Engineer

for Gas Condensing Boilers

6 720 611 400-00.1O

ZWBR 7-30 R 30 HE plus combi

GC-Number: 41 311 79

ZWBR 11-35 R 35 HE plus combi

GC-Number: 41 311 80

ZWBR 11-40 R 40 HE plus combi

GC-Number: 41 311 81

ZSBR 7-30 RD 430i system

GC-Number: 41 108 06

ZWBR 7-32 RD 532i combi

GC-Number: 41 108 10

ZWBR 11-37 RD 537i combi

GC-Number: 41 108 11

ZWBR 11-42 RD 542i combi

GC-Number: 41 108 12

7 181 465 347 (05.01)

OSW

Summary of Contents for ZSBR 7-30 RD 430i system

Page 1: ...R 30 HE plus combi GC Number 41 311 79 ZWBR 11 35 R 35 HE plus combi GC Number 41 311 80 ZWBR 11 40 R 40 HE plus combi GC Number 41 311 81 ZSBR 7 30 RD 430i system GC Number 41 108 06 ZWBR 7 32 RD 532...

Page 2: ...e not displayed 16 4 3 Notes on using the fault code tables 17 4 4 Error codes on the display 18 4 5 Faults that are not displayed 36 4 5 1 Appliance faults 36 4 5 2 Programmer faults 43 5 Replacement...

Page 3: ...ot 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 Signal words indicate the ser...

Page 4: ...ensor in CH flow 43 CH flow 63 Adjustable gas flow restrictor 64 Adjusting screw for min gas inlet flow volume 88 3 way valve 98 DHW flow switch combi 102 Inspection window 120 Fixing points 221 1 Flu...

Page 5: ...On completion of the test sequence the appliance is ready for operation 2 2 Standard display The text display shows the time the CH flow tempera ture and the room temperature of TR2 location if fitted...

Page 6: ...ed setting B Press the button The text display shows A T T E N T I O N Store settings B Press or to select yes or no B Press to confirm your selection The text display shows Please wait and the serv i...

Page 7: ...k temp sensor2 not applicable 1 2 Code plug 8714411 XXX 0 255 1 4 Voltage at terminal 2 not applicable 1 5 Required flow temp for CH 0 99 C 1 8 Power set by module not applicable 1 9 Module detection...

Page 8: ...applicable 4 2 Timer ch 1 heating blocked heat demand Timer ch 2 hot wat blocked heat demand 4 4 Heat demand heating yes no Heat demand stor tank system boiler yes no 4 5 Heat demand hot water yes no...

Page 9: ...step heat 2 7 7 7 2 Antiblock map pump off on on 7 3 Air purge mode burner keeps off while air purge mode is on off on autom deactivat permanent on off 7 4 Actual map pump step 2 7 7 5 Map pump load...

Page 10: ...ni mum output The text display shows MIn mode The 2 digit dis play alternates between the CH flow temperature and Max mode the appliance runs constantly at maxi mum output The text display shows Max m...

Page 11: ...is displayed 3 9 Link 8 9 3 9 Link Ls Lr When supplied the appliance has a link fitted across terminals 8 9 Heat demand If that connection is opened e g by a limiter for an underfloor heating sys tem...

Page 12: ...n air fan can be increased where problems with excessive flue lengths may interfere with ignition Areas with variable wind conditions may also benefit from this facility 6 6 Thermostore satisfied not...

Page 13: ...setting is only active if function 7 0 Pump map heating is set to Pump step adjustable The factory setting is 7 1 Map pump step heat 7 Fig 5 Caracteristics 2 7 Caracteristics H Pressure Q Water circu...

Page 14: ...that the condensa tion trap is filled when the appliance is first installed or after it has been shut down for a long period The con densation trap prevents flue gas escaping from the appliance into...

Page 15: ...to four catego ries Category 1 The appliance is disabled until it has been switched off and then on again Category 2 The appliance is disabled until the cause of the fault has been eliminated Category...

Page 16: ...t odour or is dark colour system boiler X 41 Text display fails to respond no display or display incorrect X X 41 Condensation in the flue pipe X X 41 Inadequate hot water outlet tem perature combi bo...

Page 17: ...heck the flue is clear by testing the CO2 level If the appliance is locked button is flashing press the button If the fault has been rectified the appliance will then start up without indicating a fau...

Page 18: ...rise see Installa tion Instructions B Turn ON the appliance A1 2 no 2 2 Audible bearing damage on pump yes B Power OFF the appliance B Disconnect the boiler electrical connection B Drain appliance B C...

Page 19: ...ide Does the value match the ones described in table 7 page 50 yes B Make a note of the altered service function set tings see table 1 on page 7 in order to keep the altered values B Power OFF the app...

Page 20: ...ance 2 2 B Check continuity on wiring to TR 2 Is there continuity yes 3 no B Replace or repair wiring and or connections B Turn ON the appliance After 90 sec A8 B Power OFF the appliance 3 3 B Check r...

Page 21: ...DHW cylinder NTC con nector from PCB control board B Check resistance from connec tions 3 to 4 on the cable side Does the value match the ones described in table 7 page 50 yes B Make a note of the al...

Page 22: ...number displayed with that shown in Appendix No number or incorrect number last three digits displayed yes 3 no 4 3 Code plug loose incorrect or defec tive B Power OFF the appliance B Fit code plug c...

Page 23: ...Power OFF the appliance B Replace fan lead B Turn ON the appliance C1 3 3 Fan defective yes B Power OFF the appliance B Unplug the connection wire B Replace fan B Plug the connection wire B Turn ON th...

Page 24: ...appliance d3 3 no 3 3 Terminal block defective B Power OFF the appliance B Disconnect the boiler electrical connection B Replace terminal strip B Reconnect the boiler electrical connection B Turn ON...

Page 25: ...8 to 9 on the cable side Does the value match the ones described in table 7 page 50 yes B Make a note of the altered service function set tings see table 1 on page 7 in order to keep the altered valu...

Page 26: ...d re pressurise see Installa tion Instructions B Reconnect the boiler electrical connection B Turn ON the appliance B Press restart the appliance E9 3 no 3 3 Lead disconnected from safety tem perature...

Page 27: ...ce B Press restart the appliance E9 7 no B Connect CH flow safety temperature limiter B Turn ON the appliance 7 7 B Power OFF the appliance B Remove fuse SI 3 from appliance PCB control board and test...

Page 28: ...ck supply pressure inform gas company if outside correct range B Is correct code plug fitted B Press restart the appliance EA 5 no 5 LPG models is the flow rate of the gas supply to the appliance corr...

Page 29: ...as cock B Reconnect the boiler electrical connection B Reconnect the connectors B Turn ON the appliance B Check appliance for leaks B Press restart the appliance EA 9 9 Problem with flue B Open up hea...

Page 30: ...e appliance B Engage ignition cable connector in switchbox B Turn ON the appliance B Press restart the appliance EA 14 14 Is the ignition electrical wire damaged yes B Power OFF the appliance B Change...

Page 31: ...B Press restart the appliance EA 18 18 The PCB control board is damaged B Make a note of the altered service settings see table 1 on page 7 B Power OFF the appliance B Disconnect the boiler electrica...

Page 32: ...t Settings Further options Service Display service param Other faults apart from F0 dis played yes B Deal with fault s displayed as instructed in rele vant fault table s no 4 4 flashing yes B Press bu...

Page 33: ...7 2 2 Problem with flue B Check CO2 level in combustion air Is CO2 level above 0 2 yes B Check flue and repair or replace if necessary no 3 3 The PCB control board is damaged B Make a note of the alte...

Page 34: ...gas cock B Reconnect the boiler electrical connection B Turn ON the appliance B Check appliance for leaks B Press restart the appliance FA 5 5 Check if the 20 pin connector lead assembly is damaged B...

Page 35: ...etween 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 Replace text display module Fdand flashing Reset butto...

Page 36: ...page 7 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 B Restore service setting...

Page 37: ...rrectly fitted yes B Repair or replace components B Grease seal before fitting Make sure it is fitted in correct position Rumbling noises 5 no 5 5 B Measure CO2 levels CO2 levels in flue gas at min an...

Page 38: ...h flue B Check CO2 level in combustion air Is CO2 level above 0 2 yes B Check flue and repair or replace if necessary Flue gas levels incorrect 4 no 4 4 Flue gas CO2 levels measured at min and max loa...

Page 39: ...connector in switchbox B Turn ON the appliance B Press button Ignition poor 4 4 Is the ignition electrical wire damaged yes B Power OFF the appliance B Change the ignition electrical wire B Turn ON t...

Page 40: ...nstructions Ignition poor 10 no 10 10 Burner not correctly fitted or defec tive B Power OFF the appliance B Turn off gas cock B Remove burner Cover fixings not tight or seal defective or not correctly...

Page 41: ...m sacrificial anode with impressed current anode The conversion costs are payable by the opera tor Text display fails to respond no display or display incorrect Check Action Ignition lead is not fitte...

Page 42: ...etween terminal 1 and terminal 3 230 V AC yes B Power OFF the appliance B Disconnect the boiler electrical connection B Change the 20 pin connector lead assembly B Reconnect the boiler electrical conn...

Page 43: ...liance B Check appliance and system for water leaks and repair as necessary B Top up system B Turn ON the appliance B Activate menu option Show service parame ters B Select 7 3 Air purge mode select s...

Page 44: ...temperature not reached integrated text display Check Action Set room temperature exceeded by large amount TR 2 Check Action 1 Do radiators get too hot yes B Decrease setting of Heating control 2 no...

Page 45: ...all near window in draught on hollow wall etc B Select better installation location or B Fit external room thermostat Room temperature too high in Economy mode Check Action Building retains heat well...

Page 46: ...the cov ers B Remove text display and unplug connector from the PCB B Remove screw holding power connector earth lead and remove earth lead B Remove two top fixing screws from the control box Fig 7 B...

Page 47: ...ixing screws B Remove fan together with gas pipe and mixer unit B Separate the fan from the pipe and mixer unit by twisting the mixer unit to release it 4 Fig 9 5 3 Primary Heat exchanger Burner B Pow...

Page 48: ...ove B Unscrew the pump union nuts Fig 12 After refitting B Fill system bleed and re pressurise see Installation Instructions 5 5 Clean condensation trap In order to prevent spillage of condensate the...

Page 49: ...lation Instructions 5 8 Domestic Hot Water Heat Exchanger B Power OFF the appliance B Turn off service cocks B Drain appliance B Open pipe joints Fig 15 B Remove the domestic hot water heat exchanger...

Page 50: ...sistance 20 124 900 40 53 290 60 24 890 80 12 550 100 6 777 120 3 873 140 2 328 160 1 455 180 948 200 540 Table 5 Outside temperature C Measurement tolerance 10 Resistance 20 2 392 16 2 088 12 1 811 8...

Page 51: ...r CH flow 151 Fuse slow 2 5 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...

Page 52: ...22 55 Table 9 Component Order no Remarks Code plug included in Conversion kit G20 G31 8 714 411 062 0 ZWBR 7 30 Conversion kit G31 G20 8 714 411 059 0 Conversion kit G20 G31 8 714 411 114 0 ZWBR 11 35...

Page 53: ...ccumulate in the boiler and remain active over long periods In order to limit the damage the source of the air con tamination must be located and sealed off If this is not possible the combustion air...

Page 54: ...Supplied By www heating spares co Tel 0161 620 6677 7 181 465 347 05 01 54 Appendix...

Page 55: ...Supplied By www heating spares co Tel 0161 620 6677 7 181 465 347 05 01 Appendix 55...

Page 56: ...Supplied By www heating spares co Tel 0161 620 6677...

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