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6 720 610 597 GB (03.02)

Installation regulations

11

2

Installation regulations

Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent per-
son. Failure to install correctly could lead to prosecu-
tion.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regula-
tions, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain cir-
cumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage result-
ing from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.

• BS 6798: Specification for the installation of gas

fired hot water boilers of rated input not exceeding
60kW

• BS 5449: Central Heating for Domestic Premises

• BS 5546: Installation of gas hot water supplies for

domestic purposes

• BS 5440:1: Flues and ventilation for gas appliances

of rated input not exceeding 70 kW (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

installations up to 28mm (R1).

• BS 7074:1: Code of practice for domestic heating

and hot water supply

• BS 7671: Requirements for Electrical Installation.

These instructions must be followed.

3

Installation

3.1

Important remarks

B

Appliance should only be installed in sealed central
heating and hot water systems.

B

To avoid gas formation in the system, galvanised
radiators or pipes must not be used.

B

If a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.

B

This appliance uses an automatically variable pump.
An auto-bypass must not be fitted.

B

Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
550811.

B

In our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.

B

Always turn off the gas cock before car-
rying out any work on components
which carry gas.

i

Fixing of the appliance, gas and flue con-
nections, commissioning of the system
and electrical connections may only be
carried out by competent persons author-
ised by CORGI.

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Содержание GREENSTAR HE combi Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 176: ...Appendix...

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