Worcester ZBR 8-35 ICS1 Service Booklet Download

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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

181

465

347

(01.

07)

Summary of Contents for ZBR 8-35 ICS1

Page 1: ... 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 ...

Page 2: ... 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 4 3 How to use the fault tables 16 4 4 Faults indicated on display 17 4 5 Faults that are not displayed 36 4 5 1 Appliance faults 36 4 5 2 Programmer faults 41 5 Appendix 45 5 1 NTC values 45 5 1 1 ...

Page 3: ...cations 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 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 seri ous damage ...

Page 4: ...iter 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 Silencer Fan Fan connector Mixer unit Condensation trap Gas supply pipe Flue gas safety temperature limiter Testing points flue gas air Inspection opening Water switch ZSBR Change over valve motor C...

Page 5: ...Press 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 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 buttons to enter...

Page 6: ...55 1 5 Required flow temp 0 99 C 1 9 Module detection no module detected bus module 2 0 Operating mode normal Min Max normal 2 2 Pump switch mode 1 3 2 2 3 Stor tank charge output 0 100 100 2 4 Anti cycle mode 0 15 min 3 min 2 5 Max flow temperature 35 88 C 88 C 2 6 Switch diff flow temperature 0 30 C 0 C 2 7 Autom anti cycle mode on off on 2 9 Actual output 0 100 3 0 Fan speed 0 255 U s 3 3 Ionis...

Page 7: ...locked 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 27 100 100 5 1 Permanent ignition no yes no 5 2 GFA status error 00h FFh 5 5 Min output 27 100 27 5 8 Cyclic boiler starts on off on 5 9 Fan speed start low high low 6 7 Pump off hot water off on off...

Page 8: ... off on on 7 3 Air purge mode off on autom deaktivat permanent on on autom deaktiv at off 7 4 Actual map pump step 1 8 7 5 Map pump load index 0 255 7 6 Map pump type 0 99 7 7 Output reduction off only in heating mode only in hot water mode in heat hot water mode only in heating mode 8 5 Siphonfillprogram on boiler min output on adjust min output off on boiler min output 9 2 Hot water on demand of...

Page 9: ...ccording 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 temperature and Max mode the appliance runs constantly at maxi mum output The text display shows Max mode The 2 digit dis play alternates between the CH flow temperature and 2 3 Stor tank charge outp The h...

Page 10: ...sed 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 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 adju...

Page 11: ... 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 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...

Page 12: ...map 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 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...

Page 13: ...on 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 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 t...

Page 14: ...rogrammer 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 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 tex...

Page 15: ... 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 temperature too high in Economy mode X 43 Incorrect or no modulation X 43 Heat store fails to heat up 44 Table 4 Appliance faults ZBR A ZSBR A ZWBR A Page Table 3 ...

Page 16: ...mplete 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 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...

Page 17: ...water 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 setting On autom deactivat and confirm B Vent appliance1 B Vent radiators 3 1 See installation instructions 3 Audible bearing damage on pump yes B Power OFF the appliance B Drain appliance B Replace pump B...

Page 18: ...er 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 ...

Page 19: ... 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 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 hot water NTC sensor B Plug the connection wire B Turn ON the appliance...

Page 20: ... 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 installation instructions B Turn ON the appliance after 90 sek A8 3 3 Lead s defective B Check leads for continuity and replace as necessary A8 4 4 TR 2 defective B Power OFF the appliance B Change TR 2 ...

Page 21: ... 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 heat store NTC sensor 1 no B Power OFF the appliance B Disconnect the boiler electrical connection B Change PCB control board B Reconnect the boiler electrical connection B Turn ON the appliance 4 Te...

Page 22: ...Select 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 the appliance B Replace code plug1 making sure code number is correct B Turn ON the appliance b1 4 1 For order no refer to Appendix 4 The PCB control board is damaged B Power OFF the appliance B Discon...

Page 23: ...es 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 Turn ON the appliance C6 4 no 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 co...

Page 24: ...FF 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 heat store thermostat con nected 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 5 no 5 5 The...

Page 25: ...no 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 instructions for NTC sensor when doing so B Turn ON the appliance E2 3 no 3 3 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 ...

Page 26: ...ctrical 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 ON the appliance B Press does appliance restart E9 4 no 4 4 B Power OFF the appliance B Unplug the connector from the cut off device B Measure the NTC electrical resist ance R yes B Change the over h...

Page 27: ...urn 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 connection B Change PCB control board B Reconnect the boiler electrical connection B Turn ON the appliance E9 and flashing Safety temperature limiter has tripped Check Action ...

Page 28: ...s 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 outside correct range B Press does appliance restart EA 6 no 6 LPG models is the flow rate of the gas supply to the appliance correct yes 6 no B Is there enough gas in the supply cylinder B Is there air ...

Page 29: ...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 Unplug the connectors from the gas valve B Measure the gas valve coils I and II electrical resistance R 164 40 Ω yes B Reconnect the gas valve B Turn ON the appliance B Press does appliance restart EA 1...

Page 30: ...nition 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 appliance B Press does appliance restart EA 15 15 Ignition cable defective yes B Power OFF the appliance B Replace ignition cable B Turn ON the appliance B Press does appliance restart EA 16 no 16 16 ...

Page 31: ...ppliance restart EA 18 18 Check if the 20 pin connector lead assembly is damaged B Power OFF the appliance B Change the 20 pin connector lead assembly B Turn ON the appliance B Press does appliance restart EA 19 19 The PCB control board is damaged B Power OFF the appliance B Disconnect the boiler electrical connection B Change PCB control board B Reconnect the boiler electrical connection B Turn O...

Page 32: ...vice 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 for heat by pressing the but ton and then cancel after 30 seconds by pressing the button again B Initiate demand for heat twice more as described above F0 4 no 4 5 The PCB control board is damaged B ...

Page 33: ... 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 3 no 3 3 Is there a problem with the flue B Check CO2 level in combustion air 0 2 CO2 yes B Check flue and repair or replace if necessary no 4 4 The PCB control board is damaged B Power OFF the appl...

Page 34: ...stion 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 appliance B Press does appliance restart FA B Power OFF the appliance 5 5 Check if the 20 pin connector lead assembly is damaged B Change the 20 pin connector lead assembly B Turn ON the appliance B ...

Page 35: ...lug 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 Replace text display module Fd and flashing Reset button pressed inadvertently Check Action 1 B Press button again 2 The PCB control board is damaged B Disconnect the boiler electrical connection B Ch...

Page 36: ...vert 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 flue and repair or replace if necessary no 4 4 B Remove silencer flue pipe and mixer unit Is internal flue pipe silencer dirty or clogged or are seals defective or incorrectly fitted yes B Repair or ...

Page 37: ...gas 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 specified levels 1 B Measure CO2 levels yes B Adjust CO2 levels no 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 ...

Page 38: ...er 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 no 5 5 Electrode assembly defective B Power OFF the appliance B Remove electrode assembly Electrodes worn out yes B Replace electrode assembly B Turn ON the appliance B Press does appliance restart Ig...

Page 39: ...d 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 Action Heat store NTC sensor lead is not fit ted as described in the installation instructions i e the cable does not pass through the cable grip in the switchbox B Record condition of appliance as found...

Page 40: ...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 tempe rature is reached even though a lower CH flow temperature has been specified 1 B Activate menu option Show service parameters B Se...

Page 41: ...ol 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 up system B Activate menu option Show service parame ters B Select 7 3 Aeration mode select setting On autom deactivat and confirm B Vent appliance1 B Vent radiators B Turn ON the appliance 1 See ins...

Page 42: ...ntrol 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 heating system 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 parame ters B Select 7 3 Aeration mode s...

Page 43: ...ation 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 correct as necessary Room temperature too high in Economy mode Check Action Building retains heat well yes B Set economy temperature lower or B Set earlier start time for Economy mode Incorrect or no modul...

Page 44: ...store fails to heat up Check Action 1 with TR 2 CH flow temperature control on boiler set too low B Increase CH flow temperature control setting 2 Hot water temperature control on boiler set too low B Increase hot water temperature control setting ...

Page 45: ... NTC sensor Outside temperature C Measurement tolerance 10 Resistance Ω 20 2 392 16 2 088 12 1 811 8 1 562 4 1 342 0 1 149 4 984 8 842 10 781 15 642 20 528 25 436 Table 5 Temperature C Measurement tolerance 10 Resistance Ω 20 14 772 25 11 981 30 9 786 35 8 047 40 6 653 45 5 523 50 4 608 55 3 856 60 3 243 65 2 744 70 2 332 75 1 990 80 1 704 85 1 464 90 1 262 95 1 093 100 950 Table 6 ...

Page 46: ... 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 328 1 Link 363 Indicator lamp for burner 364 Indicator lamp for power supply 365 Chimney sweep button 366 Service button 367 ECO button 400 Textdisplay 422 Connecting TR2 6 9 32 33 36 52 1 52 56 61 23...

Page 47: ...8 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 ...

Page 48: ...th 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 good corrosion inhibiting properties also suitable for aluminium 20 62 Corrosion inhibitor Schilling Chemie Varidos KK Corrosion inhibitor 0 5 Schilling Chemie Varidos 1 1 Corrosion inhibitor 1 2 Sch...

Page 49: ... 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 unaffected area Halogens can occur in the following areas Industrial sources Dry cleaners Trichloroethylene tetrachlo roethylene fluorinated hydro carbons Degreasing baths Perchloroethylene trichlo ro...

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

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

Page 52: ...Appendix ...

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Worcester ZBR 8-35 ICS1, Service Booklet

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