Benchmark CS1 Installation And Servicing Instructions

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Page 1

Installation and Servicing Instructions

CS1

Wall mounted condensing boiler for central heating

ZB 7-28 CS1

6 720 610 577-00.10

GC-Number: 41 108 02

6 720 610 601 GB (03.02) OSW

Page 2

Contents

Safety precautions 3

Symbols 3

1 Details of the appliance 4

1.1 EC Declaration of Conformity 4

1.2 Standard package 4

1.3 Description of appliance 4

1.4 Accessories 5

1.5 Casing dimensions 5

1.6 Layout of appliance 6

1.7 Function (with optional extra motorised valve) 7

1.8 Electrical wiring diagram 8

1.9 Technical data 9

2 Installation regulations 10

3 Installation 11

3.1 Important remarks 11

3.2 Sealed systems 11

3.3 Siting the appliance 13

3.4 Wall mounting frame assembly 14

3.5 Pre-piping the system 14

3.6 Fitting the appliance 15

3.7 Checking the connections 16

3.8 Flue Systems 16

3.8.1 Siting the Flue Terminal 17

3.8.2 Installation of the flue 18

3.8.3 Flue duct preparation and assembly 20

4 Electrical connections 21

4.1 Connecting the appliance 21

4.2 Mains Voltage external controls connections 22

4.3 Wiring to your system 22

4.3.1 Pre-wired Remote S Plan 22

5 Commissioning 23

5.1 Commissioning 23

5.2 Switching the appliance on/off 24

5.3 Switching on the central heating 24

5.4 System controls 24

5.5 Appliances with optional plug-in diverter valve: Setting hot water temperature 25

5.6 Frost protection 25

5.7 Pump anti-seize function 25

5.8 Fault Condition 25

6 Individual settings 26

6.1 Mechanical settings 26

6.1.1 Checking the size of the expansion vessel 26

6.1.2 Setting the central heating flow temperature 26

6.1.3 Changing the heating pump characteristic 26

6.2 Settings on the Bosch Heatronic 27

6.2.1 Operating the Bosch Heatronic 27

6.2.2 Selecting the pump control mode for central heating mode (Service Function 2.2) 27

6.2.3 Setting the anti-cycle time (Service Function 2.4) 27

6.2.4 Setting the maxim CH flow temperature (Service Function 2.5) 28

6.2.5 Setting the switching difference (Service Function 2.6) 28

6.2.6 Setting the heating output (Service Function 5.0) 28

6.3 Setting the gas/air ratio 28

7 Converting the appliance to

different gas types 29

7.1 Setting the gas/air ratio 29

7.2 Testing combustion air/flue gas at set heat output 31

7.2.1 Testing the O

or CO

level in the

combustion air 31

7.2.2 Testing CO and CO

8 Maintenance 32

8.1 Pre-Service Check List 33

8.2 Description of servicing operations 34

8.3 Replacement of Parts 37

8.3.1 PCB control board and transformer 37

8.3.2 Fan Assembly 38

8.3.3 Pump 38

8.3.4 3-way diverter valve 38

8.3.5 3-way diverter valve motor 39

8.3.6 Sensors 39

8.3.7 Gas Valve 39

8.3.8 Electrode assembly 39

8.3.9 Pressure gauge 40

8.3.10Expansion vessel 40

8.3.11Pressure Relief Valve 40

8.3.12Burner 40

8.3.13Primary Heat Exchanger 40

9 Appendix 41

9.1 Fault Codes 41

9.2 Short parts list 42

9.3 Heating/hot water output settings (N.G) 42

9.4 Heating/hot water output settings (L.P.G) 42

9.5 Operational Flow diagrams 43

9.5.1 Central heating function 43

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Safety precautions

If you smell gas

Turn off gas service cock at the meter. Open windows and doors. Do not operate any electrical switches. Extinguish any naked flames. Telephone your gas company.

If you smell fumes from the appliance

Switch off appliance (see page 24). Open windows and doors.

Fitting and modifications

Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance with the Gas Safety (Installation and Use) Regulations 1998.

Flue systems must not be modified in any ways other than as described in the fitting instructions.

This appliance is for use on sealed primary systems only.

Maintenance

The user is recommended: to have the system

regularly serviced in order to ensure that it functions reliably and safely.

Use only original spare parts!

Symbols

Safety instructions in this document

are identified by a warning-triangle symbol and are printed on a grey background.

Notes containing important information

are identified by the symbol shown on the

left. They are bordered by horizontal lines above and below the text.

Combustible materials

Do not store or use any combustible materials (paper, thinners, paints etc.) in the vicinity of the appliance.

Health and safety

This appliance contains no asbestos products. There is no potential hazard due to the appliance

being electrically unsafe. There are no substances used in the construction

that are a potential hazard in relation to the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).

Combustion air/Ambient atmosphere

The combustion air/ambient atmosphere should be kept free of chemically aggressive substances (e.g. halogenated hydrocarbons which contain chlorine or fluorine compounds). This will prevent corrosion.

Instructions to the customer

Explain to the customer how the appliance works and how to operate it.

Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it.

These instructions are to be left with the user or at the Gas meter.

Important: These instructions apply in the UK only.

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Details of the appliance

1 Details of the appliance

1.1 EC Declaration of Conformity

This appliance is in accordance with the applicable requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.

Category UK

Appliance Type

Table 1

1.2 Standard package

• Gas condensing boiler for central heating

• Wall mounting frame

• Clamp for securing flue duct kit

• Fixings (screws etc.)

• Set of documentation for appliance

• Pre-plumbing manifold

• Condensate drain pipe.

CE-0085 BL 0507

2H 3P

, C

1.3 Description of appliance

• Wall-mounted appliance, siting 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 incorporating Bosch Heatronic

with flame ionisation monitoring, solenoid valves and temperature sensors

• Concentric flue/air duct with testing point for

/CO

• Regulated speed fan

• Pre-mix burner

• Temperature control for central heating

• Safety temperature limiter in 24 V electrical circuit

• Three-speed central heating pump with automatic

vent

• Relief valve, pressure gauge, expansion vessel

• Flue gas temperature limiter (105 °C)

• Condensate Trap

• Connecting possibility for S-Plan System.

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1.4 Accessories

• Standard horizontal flue kit at 100 mm outside diameter for flues upto 4 m in length.

• Flue duct kits for horizontal (125 mm outside diameter) for flue lengths upto 13 m and vertical flue systems for flue lengths upto 15 m. Fitting instructions are sent with these kits.

• Heating programmers

• Timer

• Security kit

• Motorised valve is available as an optional extra. If this option is used then the DT2, TR2 Optimising Room Thermostat and the Night Set Back Module will be required.

1.5 Casing dimensions

Details of the appliance

min.

101

103

min.

600

120

850

861

906

200

440

360 395

200

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Fig. 1

Manifold assembly

101 Outer case 103 Facia cover

Standard Concentric Horizontal Flue System: min. 310 mm Alternative Concentric Flue System: min. 250 mm Standard Concentric Horizontal Flue System: 158 mm Alternative Concentric Flue System: 121 mm Standard Concentric Horizontal Flue System: 105 mm Alternative Concentric Flue System: 130 mm

For servicing the appliance

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Details of the appliance

1.6 Layout of appliance

221.1

221.2

226

271

120

349

234.1

234

102

32.1

415

416

358

295

417

Fig. 2

Heatronic control Heat exchanger safety temperature limiter Testing point for gas supply pressure

8.1 Pressure gauge

Flue gas temperature limiter Relief valve Pump

18.1 Pump speed selector switch

Expansion vessel Automatic air vent Air gas Mixer unit

32.1 Electrode assembly

Temperature sensor in CH flow CH flow Adjustable gas flow restrictor Adjusting screw for min. gas flow volume

102 Inspection window 120 Fixing points

221.1 Flue duct

423

18.1

418

8.1

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221.2 Combustion air intake 226 Fan assembly 295 Appliance type sticker 234 Testing point for combustion products

234.1 Testing point for combustion air 271 Flue duct 349 Cover plate for twin flue duct connection 358 Condensate trap 415 Cover plate for cleaning access 416 Condensate collector 417 Clip for fixing outer case 418 Data plate 423 Siphon

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1.7 Function (with optional extra motorised valve)

Details of the appliance

Fig. 3

Bosch Heatronic control Temperature limiter, heat exchanger Testing point for gas supply pressure

8.1 Pressure gauge

Flue gas temperature limiter Manifold Safety valve Central heating pump

20 Expansion vessel 26 Charging valve 27 Automatic vent 29 Mixer unit

29.1 Bi-metallic thermostat for combustion air compensation

30 Burner 32 Flame sensing electrode 33 Igniter electrode 35 Heat exchanger with cooled combustion chamber 36 Temperature sensor in CH flow 43 CH flow 45 Gas 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 Adjustable gas flow restrictor 64 Adjusting screw for min. gas inlet flow volume 69 Control valve

71 Storage water heater outflow (only with motorised valve) 72 Storage water heater return (only with motorised valve) 84 Motor (optional extra) 88 3-way valve (optional extra) 221 Flue duct 226 Fan 229 Inner casing 234 Testing point for flue gas

234.1 Testing point for combustion air 317 Display 358 Condensate trap 423 Siphon 443 Diaphragm

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Details of the appliance

1.8 Electrical wiring diagram

364

4.1

365

317

o - orange bl - black r - red

366

367

ECO

363

25 V

153

230V/AC

135

302

230 V

328

NLs

136

151

328.1

mains supply

Fig. 4

4.1 Ignition transformer 6 Temperature limiter, heat exchanger 9 Flue gas temperature limiter 18 Pump 32 Flame sensing electrode 33 Ignition electrode 36 Temperature sensor in CH flow 52 Solenoid valve 1

52.1 Solenoid valve 2 56 Gas valve CE 427 61 Reset button 84 Motor (optional extra) 135 Master switch 136 Temperature control for 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 314 Connector for programmer TA212E 315 Terminal block for programmer 317 Digital display 318 Connector for timer 328 Terminal block for AC 230 V Mains supply

310

226

313

312

315

1247

300

314

r r

52.1

161

bl bl bl

328.1 Link 363 Indicator lamp for burner 364 Indicator lamp for power supply 365 “Chimney sweep” button 366 Service button 367 ECO button

318

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p p

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1.9 Technical data

Details of the appliance

Units Natural gas Propane

Max. rated heat output net 40/30˚C central heating Max. rated heat output net 50/30˚C central heating Max. rated heat output net 80/60˚C central heating

kW kW kW

29.3

29.0

27.4

29.3

29.0

27.4 Max. rated heat input net kW 27.7 27.7 Min. rated heat output net 40/30˚C

Min. rated heat output net 50/30˚C Min. rated heat output net 80/60˚C

kW kW kW

8.4

8.3

7.4

11.6

11.4

10.5 Min. rated heat input net kW 7.6 10.8 Maximum gas flow rate – After 10 minutes from lighting Natural gas G20 (CVnet 34.02 MJ/m

LPG (CVnet 88 MJ/m

) kg/h - 2.1

/h 2.9 -

Gas supply pressure

Natural gas G20 (CVnet 34.02 MJ/m

LPG (CVnet 88 MJ/m

) mbar - 37

) mbar 20 -

Expansion vessel

Charge pressure bar 0.75 0.75 Total capacity l 10 10 Flue Flue gas temp. 80/60˚C, rated/min. load ˚C 67/55 67/55 Flue gas temp. 40/30˚C, rated/min. load ˚C 43/32 43/32 Residual delivery pressure

(inc. pressure drop in air intake duct) Pa 80 80

level at max. rated heat output

level at min. rated heat output

-class 5 5

% %

9.2

8.8

10.8

10.5

SEDBUK figure, Band A % 90.7 90.7

Condensate

Max. condensation rate (t

= 30˚C) l/h 2.3 2.3

pH-value, approx. 4.8 4.8

General Data

Electrical power supply voltage AC ... V 230 230 Frequency Hz 50 50 Max. power consumption W 101 101 Noise output level dB(A) 36 36 Appliance protection rating IP X4D X4D Max. CH flow temperature ˚C nom. 90 nom. 90 Max. permissible operating pressure (CH) bar 2.5 2.5 Permissible ambient temperatures ˚C 0 - 50 0 - 50 Nominal capacity of appliance l 3.75 3.75 Weight (excluding packing) kg 46 46

Table 2

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Installation regulations

Condensate analysis, mg/l

Ammonium 1.2 Nickel 0.15 Lead ≤ 0.01 Mercury ≤ 0.0001 Cadmium ≤ 0.001 Sulphate 1 Chromium ≤ 0.005 Zinc ≤ 0.015

Halogenated hydrocarbons ≤ 0.002

Hydrocarbons 0.015 Vanadium ≤ 0.001

Copper 0.028 pH-value 4.8

Tin ≤ 0.01

Table 3

Flue system

HORIZONTAL 100 mm – Standard

Overall Diameter of Duct mm 100

Flue Terminal / Duct Assembly Length

Extension Duct Length mm 1000

mm 600

Max. 4 m

Table 4

ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125 Max.

13 m (inclu-

Flue Terminal / Duct Assembly mm 1030

ding turret)

Table 5

VERTICAL 125 mm FLUE SYSTEM

Overall Diameter of Duct mm 125 Max.

15 m

Flue Terminal / Duct Assembly mm 1360

2 Installation regulations

Gas Safety (Installation & Use) Regulations 1998: All gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution. 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 Regulations, 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 circumstances, the installer can be held responsible, not only for mistakes on his part but also for damage resulting 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 28 mm (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.

Table 6

Elbow - 90 ° Equivalent length 2 m Bend - 45 ° Equivalent length 1m

Gas supply

Total length of gas supply pipe (metres)

369

Gas discharge rate (m

8.7 5.8 4.6 22

18.0 12.0 9.4 28

/h)

Table 7

Pipe diameter (mm)

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Installation

3 Installation

B Always turn off the gas cock before car-

rying out any work on components which carry gas.

Fixing of the appliance, gas and flue connections, commissioning of the system

and electrical connections may only be carried out by competent persons authorised by CORGI.

3.1 Important remarks

B Appliance should only be installed in sealed central

heating 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 Add a suitable anti-freeze fluid compatible with alu-

minium 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.

3.2 Sealed systems

The appliance must not be operated without the system being full of water, properly vented and pressurised.

The expansion vessel has a volume of 10 litres and is charged to a pressure of 0.75 bar.

The water capacity of the system is shown in table 10, page 26. If a greater capacity is required then an additional expansion vessel must be fitted into the system return as close to the appliance as possible. The system pressure can be set up to a maximum of 1.5 bar with 1 bar being the normal setting.

If the system pressure is greater than 2.5 bar when the appliance is operating at maximum temperature then an additional expansion vessel must be fitted into the system return as close to the appliance as possible.

The filling point must be at low level and arranged as shown in figs. 5 and 8.

The pressure relief valve is set to operate at 3 bar. There must be no connection to the mains without the

approval of the local water company. All connections in the system must be capable of withstanding a pressure of up to 3 bar and the radiator valves conform to the requirements of BS 2767:10.

If Thermostatic Radiator Valves are fitted then it is recommended that primary radiator is left open.

Repeated venting probably indicates a leak and this must be rectified to ensure the proper operation of the appliance.

No galvanised radiators or pipes must be used. If any system water treatment is required then

only products suitable for use with Aluminium shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the manufacturers instructions. The use of any other substances will invalidate the guarantee. The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated.

A drain cock to BS2879 must be fitted to the lowest point of the system.

IMPORTANT: Check that no dirt is left in the water pipework as this could damage the appliance. Thoroughly flush the heating system and the mains water supply before fitting the appliance to the wall in accordance with the recommendations of BS7593:1992.

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Installation

Note:

A drain cock should be fitted at the lowest

LV LV

point of the heating circuit and beneath the appliance

Radiator Valve - Flow RV Lockshield Valve - Return LV

LV LV

Fig. 5 System layout if using built-in diverter valve

Note:

A drain cock should be fitted at the lowest point of the heating circuit and beneath the appliance

LV LV

APPLIANCE

Refer to

Appliance

Diagram

Heating Return

Heating Flow

Stop Valve Fixed Cylinder Type

APPLIANCE

Refer to

Appliance

Water

Flow

Diagram

Water

Flow

CYLINDER

Safety Discharge

Hot Water Flow

INDIRECT CYLINDER

INDIRECT

Cylinder Return

6 720 610 601-04.1O

Mains Cold Water

Cylinder Return

Radiator Valve - Flow RV Lockshield Valve - Return LV

Fig. 6 System layout if using external diverter valve

Heating Return

Heating Flow

Diverter

Valve

Stop Valve Fixed Cylinder Type

Safety Discharge

Hot Water Flow

Mains Cold Water

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Installation

Note:

A drain cock should be fitted at the lowest

LV LV

point of the heating circuit and beneath the appliance

Radiator Valve - Flow RV Lockshield Valve - Return LV

LV LV

Fig. 7 System layout if using twin zone valves (S) plan

Sealed system filling and make up

Heating return

Non return

valve

Non return

valve

Heating return

Hose union

APPLIANCE

Refer to

Appliance

Water

Flow

Diagram

Heating Return

Heating Flow

CH Zone Val ve

Stop Valve Fixed Cylinder Type

Safety Discharge

DHW Zone Valve

Auto

air vent

Non return valve

INDIRECT CYLINDER

Mains Cold Water

Cylinder Return

Hot Water Flow

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Make up

vessel

Stop cock

Test cock

Temporary hose

Fig. 8

3.3 Siting the appliance

Regulations concerning the Installation Site

B Relevant national regulations must be complied with

section 3.8.1.

B Consult the installation instructions for details of min-

imum clearances required.

Combustion 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 fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and household cleaners, for example.

Stop

cock

Fill point

1000mm (39 in) above the highest point of the system.

6 720 611 137 - 29.1O

Surface temperature

The max. surface temperature of the casing and the flue is less than 85 °C. This means that, no special safety precautions are required with regard to flammable building materials and fitted furniture. The specified clearences must be maintained.

Cupboard/Compartment

The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS 6798 and BS 5440:2 are followed. The low casing losses from the appliance eliminate the need for ventilation openings in the compartment.

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Installation

3.4 Wall mounting frame assembly

B Take the wall mounting frame out of the package and

screw together with 6 screws as shown in fig. 9. Use the inner lugs on the top and bottom horizontal sections for the appliances that are 440 mm wide.

6 720 610 576-04.1O

Fig. 9

B Hold the wall-mounting frame against the wall ensur-

ing that it is vertical.

B Mark the position of the flue duct hole if a rear flue is

to be used. Refer to fig. 1 and 18.

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.

B Screw the pre-plumbing manifold with two screws to

the wall mounting frame.

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Fig. 11

3.5 Pre-piping the system

200

171

172112

4743

Fig. 10

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120-130

260

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Fig. 12 Manifold

43 CH flow 47 CH return 112 Gas cock 171 Optional cylinder flow (used only with motorised valve) 172 Optional cylinder return (used only with motorised valve)

B A drain tap should be fitted at the lowest point of the

central heating system.

B WRAS approved filling loop must be fitted.

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Installation

Condensate Termination and Route

The condensate connection on the British Gas/Bosch appliances is in 22 mm plastic. The pipe should be extended and run away from the appliance with a constant fall of 2.5 ° or 40 mm in every metre.

The condensate pipe can terminate into any of four areas:

Boiler

Ø 22 min.

Siphon

No length restriction

The gradient of the discharge pipe should be 2.5° (40 mm/m) minimum

An internal waste system

Boiler

No length restriction

The gradient of the discharge pipe should be 2.5° (40 mm/m) minimum

The rainwater system

Sink

75 min. trap

Ø 22 min.

75 min. trap

Invert

Open end of pipe direct into gully, below ground but above water level

Internal soil and vent stack

450 min.

Boiler

External length of

Siphon

Ø 22 min.

Use waterproof pipe work insulation in very exposed positions

The gradient of the discharge pipe should be

2.5° (40 mm/m) minimum

An external waste system

Boiler

Sink

Siphon

Ø 22 min.

The gradient of the discharge pipe should be 2.5° (40 mm/m) minimum

An external purpose made soakaway

pipe 2m min.

Open end of pipe direct into gully, below ground but above water level.

No length restriction

Open end of pipe

75 min. trap

direct into gully, below ground but above water level

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Fig. 13

Whilst all of the above methods are acceptable it is always the best practice to terminate the condense pipe via an internal waste system.This will eliminate the need for any external condensate pipe runs which can be susceptible to freezing in extreme weather.

External condensate pipework

All British Gas/Bosch condensing boilers have within a syphonic condensate trap. Rather than the condensate constantly dripping into the discharge pipe, the condensate is collected into a trap which releases it in 100 ml quantities. This will help prevent freezing occurring.

If there is no alternative and the condensate pipe has to be externally run, the following should be considered:

• The pipe run should take the shortest practical route.

• The pipework should be insulated with weather resistant insulation.

• The pipe should terminate as close as possible to the ground or drain, whilst still allowing the condensate to safely disperse. This would prevent wind blowing up the pipe.

• The pipework should be installed with the minimum of horizontal runs and with a downward slope of at least 2.5 °.

3.6 Fitting the appliance

Benchmark: For optimum performance after installation, this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS5793:1992 “Treatment of water in domestic hot water central heating systems”.

Fig. 14 Position of the condensate drain

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B Remove packing, taking care to observe the instruc-

tions on the packing.

B Lie the boiler on its back.

Removing the outer case

The outer case is secured against unauthorised removal by two clips (electrical

safety). Always secure the outer case with those clips again after refitting.

B Turn the clips with a screwdriver (1.). B Slide the outer case upwards and then forwards to

remove (2.).

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Installation

B Remove the plastic caps from the boiler connec-

tions.

6 720 610 332-07.1R

Fig. 15

Fixing the appliance

B Fit the washers onto the gas and water connections. B Lift the boiler onto the wall-mounting frame. The lugs

pass through the rectangular holes in the boiler back panel.

B Take care not to disturb the washers on the connec-

tions.

Connecting the flue assembly

B Fit flue duct connector onto appliance flue spigot. B Secure with the two screws supplied.

1 .

2 .

3.7 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 the heating system through a WRAS approved filling loop.

B Check all seals and unions for leaks (testing pres-

sure max. 3.0 bar as indicated by pressure gauge).

B Check all connections for leaks.

Gas supply pipe

B Check that the seal is in place before tightening the

connection.

B Turn off gas cock to protect gas valve against dam-

age from excessive pressure.

B Check gas supply pipe. B Release the pressure on the gas supply pipe.

3.8 Flue Systems

The only flue systems that may be used are those supplied with the boiler. The flue system must be installed in accordance with the requirements of BS 5440:1.

Standard 100 mm flue system

The standard concentric flue system provides for a horizontal length of upto 4 m. Full instructions for fitting this flue are in Subsection 3.8.2 “Installation of the flue”.

Alternative 125 mm diameter flue systems Installation instructions for the alternative flue

systems are sent with the appropriate flue kit.

Systems are available to give a maximum horizontal length of 13 m.

A vertical flue system upto a height of 15 metres is available.

45° and 90° flue bends can be used with a corresponding reduction in flue length of 2 m for each 90° bend and 1 m for each 45° bend used.

6 7 2 0 6 1 0 3 3 2 - 0 9 . 2 R

Fig. 16

B For remaining installation of flue assembly, refer to

the relevant installation instructions.

IMPORTANT: Any horizontal flue system fitted to a condensing boiler must incline towards the appliance at an angle of 3 % (30 mm per metre length) to prevent condensate dripping from the flue terminal. This

means that the clearance above the appliance must be increased to match the duct length. Refer to fig. 1 on page 5.

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Installation

3.8.1 Siting the Flue Terminal

The flue must be installed in accordance with BS 5440:1 and the Building Regulations. Flue terminals in carports and under balconies are to be avoided. The terminal must be positioned so that it does not cause an obstruction nor the combustion products a nuisance. See fig. 17 and table 8. The terminal will, at times, give out a plume of water vapour and consideration must be given to this when choosing a terminal position. Keep clear of security

lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which people have access then a guard must be fitted. The guard must be evenly spaced about the terminal with a space of 50 mm in each direction and fixed with plated screws. A guard Type K6 for the standard horizontal flue, can be obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.

Fig. 17

Minimum dimensions of flue terminal positions (all types) (see fig. 17)

Dimension Terminal Position (kW input expressed in net) Balanced flues room sealed: Fanned draught

D Below gutters, soil pipes or drain pipes 75 mm

E Below eaves 200 mm

G From a vertical drain pipe or soil pipe 150 mm

H From an internal or external corner 300 mm

I Above ground roof or balcony level 300 mm

J From a surface facing the terminal 600 mm

K From a terminal facing the terminal 1200 mm

L From an opening in the car port (e. g. door, window) into the dwelling 1200 mm

M Vertically from a terminal on the same wall 1500mm

N Horizontally from a terminal on the same wall 300 mm

O From the wall on which the terminal is mounted Not applicable

P From a vertical structure on the roof Not applicable

Q Above intersection with roof Not applicable

Directly below an opening, air brick, opening windows, etc. 300 mm

Above an opening, air brick, opening window, etc. 300 mm

Horizontally to an opening, air brick, opening window, etc. 300 mm

Below balconies or car port roof (lowest point) 200 mm

Table 8

1) In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.

2) Not recommended.

6 720 610 601 GB (03.02)

Page 18

Installation

3.8.2 Installation of the flue

The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm require extension duct assemblies. NOTE: Flue lengths between 650 mm and 730 mm cannot be accomodated. Refer to fig. 19, 20, 21.

Standard system comprise: Flue turret - Flue turret clamp - Terminal assembly - Wall sealing - plates. Extension kit comprises: Air duct - Flue duct - Duct clamp. Refer to fig. 22.

Instructions for fitting other flue systems are packed with the relevant flue kit. Check that the position chosen for the appliance is satisfactory. Refer to fig. 18.

Flue Turret

Maximum 650 mm

No Clamp

Terminal Assembly

Outer Wall

6 720 610 602 - 08.1O

Centre line of flue/air duct

Centre line of flue opening and appliance

Appliance

Standard Horizontal Flue 158 mm Optional Horizontal Flue 121 mm

Top of the

wall

mounting

frame

Drilling point for flue duct opening

120

3 %

(30 mm/metre)

6 720 610 602-07.2O

Fig. 18 Marking the position of the side flue opening

Fig. 19 Standard Flue

6 720 610 601 GB (03.02)

Page 19

Flue Turret

No Clamp

Fig. 20 Flue with one extension

Maximum 1600mm

Extension Duct

Clamp

Installation

Terminal Assembly

Outer Wall

6 720 610 602 - 09.1O

Flue Turret

No Clamp

Fig. 21 Flue with extensions

Flue Turret

Extension Duct

Clamp

Extension Duct

Extension Air Duct

Clamp

Terminal Assembly

Outer Wall

6 720 610 602 - 10.1O

Duct Clamp

Fig. 22 Flue components

6 720 610 601 GB (03.02)

Extension Flue Duct

Terminal Assembly

Wall Sealing Plates

6 720 610 602 - 11.1O

Page 20

Installation

3.8.3 Flue duct preparation and assembly

Measure the flue length L. Refer to fig. 23, 24.

120

Outer Wall Face

Flue Terminal

Raised Ring locating the terminal relative to the outside wall face

NOTE: THE FLUE MUST BE INCLINED T O THE

BOILER

6 720 610 602 - 12.1O

Fig. 23 Flue length - rear

NOTE: THE FLUE MUST BE INCLINED T O THE

BOILER

Fig. 24 Flue length - side

Mark off the lengths shown onto the ducts and cut to length. The cuts must be square and free from burrs. Terminal assembly outer (air) duct - L- 70 mm, inner (flue) duct - L- 50 mm.The measurement is made from the ridge at the terminal indicating the outer face of the wall. Refer to fig. 25. Extension air duct - L- 70mm, flue duct - L- 50 mm. The measurement is from the formed end.

6 720 610 602 - 13.1O

6 720 610 576 - 20.1O

Fig. 25 Flue terminal position

Assemble flue system completely. Push the ducts fully together and clamp in the positions. The slope of the terminal outlet must face downwards.

The assembly will be made easier if a solvent free grease is lightly applied i.e Vaseline, to the male end of the ducts.

NOTE: An inner wall sealing plate is provided which should be fitted to the ducts before assembly.

Push the assembly through the wall and fix the turret to the appliance with the clamp. Refer to fig. 26.

Flue Turret

Air and Flue Duct Entry into silicone

Clamp

rubber seals

Flue Socket on Boiler

6 720 610 602 - 14.1O

Fig. 26 Flue turret

Ensure that the turret is fully entered into the socket on the boiler. From the outside fix the outer wall plate to the terminal and, after ensuring the duct is properly i nclined towards the boiler, fix the plate to the wall.

If the terminal is within 2 m of the ground where there is access then an approved terminal guard must be fitted. The guard must give a clearance of at least 50 mm around the terminal an be fixed with corrosion resistant screws.

6 720 610 601 GB (03.02)

Page 21

Electrical connections

6 720 610 332 -11.1R

6 720 610 332-12.1R

13-14

10-12

8-9

5-7

4130-14.1R

4 Electrical connections

B Always disconnect the power supply to

the appliance at the mains before carrying out any work on the electrical systems and components.

All control and safety systems are built into the appliance.

B Allow mains cable to protrude at least 50 cm from

wall.

B To make splash-water proof (IP): cut the cable grom-

met hole size to match diameter of cable, see fig. 29.

It must be possible to isolate the appliance. The appliance must be earthed.

The appliance must be connected to the mains through a 6 A double pole isolator with a contact separation 3 mm in all poles and supplying the appliance and controls only. The wiring must comply with the current requirements of the IEE Wiring Regulations and any local regulations which apply.

• Supply: 230 V ~ 50 Hz, 140 Watts

• Mains cable: PVC insulated 0.75 mm2

(24 x 0.20 mm) to BS6500-Table 6. Temperature rated 100˚C.

• Protection IPX4D

• External fuse 3 A.

B Remove screw and slide terminal cover forwards to

remove. Refer to fig. 28.

Fig. 28

B Cut cable grommet to diameter of cable.

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 horizontal position and pushing firmly upwards at the rear of the supports to release the cover. Lift cover from the appliance.

After installation (or in the event of an electrical fault) the electrical system shall be checked for short circuits, fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.

B Pull out cover panel at the bottom and remove. Refer

to fig. 27.

Fig. 29

B Feed cable through cable grommet and connect the

mains supply cable, see fig. 30.

B Secure cable in cable grommet by means of cable

grip.

Fig. 30

Fig. 27

6 720 610 601 GB (03.02)

6 720 610 332-10.1R

Page 22

Electrical connections

4.2 Mains Voltage external controls connections

NOTE: Only double insulated controls not requiring an earth can be used

ched Liv

Neutral

Liv

Swit

230 V R

oom Thermostat Connections

230 V r

oom thermostat and

Programmer Connections

ST8

Remove Link

Neutral

Motor

Live

230 V Pr

Swit

e h c

eutr

ST8

ched Live

Neutr

Swit

Live

Motor

ogrammer Connections

ST8

Series connection

Live

6 720 610 576 - 22.1O

to be made

safe

ched Liv

Fig. 31

4.3 Wiring to your system

The following diagrams show the wiring options for your system. Any other combinations of wiring are not recommended as it would increase complexity of the system. Please also follow wiring instructions of any proprietary system. Worcester Heat Systems cannot be held responsible for any incorrect wiring external from the boiler.

Mains electrical supply: The boiler should be connected to the mains supply as described in Section 4.1. This also provides the electrical supply to the system. Note:

In all cases this must be the only electrical supply to the system. This ensures the safety of a single

fused supply. Pump: The boiler is fitted with an internal pump. These diagrams show connection details of two popu-

lar proprietary systems (Honeywell and Siebe, formerly ACL ), for systems from other manufacturers instructions or contact Worcester Technical Service 08705 266 241 for assistance.

Upon completion of the electrical connections check for earth continuity, correct polarisation and resistance to earth.

4.3.1 Pre-wired Remote S Plan

If the system is fully pre-wired at a juction box remotely from the boiler, it can be easily connected back to the boiler.

Drop down the facia and gain access to the boiler wiring centre as described in section 4.1.

Connect the junction box as shown (see fig. 32) Important notes:

• Observe wiring details given in Section .

• Remove the pre-fitted link from LS and LR.

• If a room thermostat is required, it can be wired to the remote junction box according to the proprietary instructions.

• If a frost thermostat is required, it can be wired to the remote junction box.

Permanent Mains supply (NOT ALLOWED)

Outside of Boiler

Inside of Boiler

6 720 610 603 -04.2O

RemotePre-wired Junction Box

External pump (DISCONNECT AND REMOVE)

Boiler/pump demand from junction box.

Timer

Tank Stat

Terminal Strip

L out

MAINS ONLY

NSLSL

Room Stat

System

Water

Valve/s)

ELN

Mains electrical supply to junction box (NO OTHER SUPPLY TO JUNCTION BOX ALLOWED)

Fig. 32

6 720 610 601 GB (03.02)

Page 23

Commissioning

5 Commissioning

364

135

295

136

365

317 366 367

ECO

363

310

358

8.1

170

171

172

173

Fig. 33

8.1 Pressure gauge

Safety valve Automatic vent Reset button

135 Master switch 136 Temperature control for central heating 170 Service cocks on CH flow and return 171 Optional cylinder flow (used only with motorised valve) 172 Gas cock (shown in on position) 173 Optional cylinder return (used only with motorised valve) 295 Appliance type sticker 310 Temperature control for hot water 317 Multifunction display 358 Condensate trap 363 Indicator lamp for burner 364 Indicator lamp for power supply 365 “Chimney sweep” button 366 Service button 367 ECO button

170

6 720 610 576-07.2O

5.1 Commissioning

Never run the appliance when empty or

unpressurised.

The operational CO tory and no adjustment is necessary when

installing a natural gas fired appliance.

Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance with the guidelines given in BS 7593:1992 - Treatment of water in domestic hot water systems. Full instructions are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should be used in accordance with the inhibitor manufacturers instructions.

To drain the appliance shut the system valves and open the system drain point.

Suitable flushing agents and inhibitors are available from Betz/Dearborn Tel.: 0151 4209563, Fernox Tel.: 01799 550811 and Salamander Tel.: 0121 378 0952. Instructions for use are supplied with the these products.

level is set at the fac-

6 720 610 601 GB (03.02)

Page 24

Commissioning

B Before commissioning, the gas supply pres-

sure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7). Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or above 24 mbar. LPG appliances must not be operated if the supply pressure is not 37 mbar at the inlet to the appliance.

B Unscrew the condensation trap (358) and pull out,

fill with approx. 1/4 l of water and refit. Refer to fig. 33.

B Adjust charge pressure of expansion vessel to static

head of the central heating system (see page 26).

B Open all system radiator valves. B Turn on service valves (170), fill central heating sys-

tem to pressure of 1 - 2 bar through the WRAS approved filling loop. Refer to fig. 33.

B Vent radiators. B Refill heating system and set the pressure to 1 bar. B Turn on cold water service cock (173). Refer to

fig. 33.

B Check that the gas type specified on the identifica-

tion plate matches that of the gas supply.

B Turn on gas cock (172). Refer to fig. 33.

Switching off the appliance

B Set the master switch to (0).

The green indicator lamp goes out.

B Always disconnect the appliance from

the power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or components.

5.3 Switching on the central heating

The central heating flow temperature is adjustable between 35˚C and 88˚C. Refer to table 11, page 26.

B Turn the temperature control to set the flow tem-

perature to a level appropriate to the type of central heating system:

– Underfloor heating: e.g. setting “3”

(approx. 50˚C)

– Low-temperature heating: setting “E”

(approx. 75˚C)

– Central heating systems for flow temperatures up

to 88 °C: limited “max” setting for low-temperature operation (see page 26).

When the burner is alight, the red indicator lamp lights up.

5.2 Switching the appliance on/off

Switching on

B Switch on the appliance at the master switch (I).

The indicator lamp shows green and the display will show the central heating flow temperature, when the appliance is operating in the central heating mode.

6 720 610 333-04.1O

Fig. 34

If the display alternates between -II- and the central heating flow temperature, the

trap filling programme is active.

The trap filling programme ensures 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 or the mains supply has been interrupted. For that reason, the appliance remains at minimum heating output for 15 minutes.

6 720 610 333-05.1O

Fig. 35

5.4 System controls

B Set room thermostat to the desired room tempera-

ture.

B Set outside - temperature driven control unit, if fitted.

Refer to the instructions with the control.

B Set the thermostatic radiator valves to the desired

settings.

6 720 610 601 GB (03.02)

Page 25

Commissioning

5.5 Appliances with optional plug-in diverter valve: Setting hot water temperature

B Do not set the temperature higher than

60˚C for normal operation.

B Only use temperatures of up to 70˚C

temporarily for thermal disinfection purposes.

B Set the hot water temperature by means of the tem-

perature control on the appliance.

6 720 610 333-07.1O

Fig. 36

Control Setting Water Temperature

Anti-clockwise limit approx. 10˚C

(frost protection)

 approx. 60˚C

5.6 Frost protection

Frost protection is only guaranteed from the external room temperature thermostat.

B Leave master switch switched on.

If the appliance is to be left for long periods switch the central heating off:

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.

5.7 Pump anti-seize function

This function prevents the central heating pump seizing after long periods of inactiv-

ity.

Every time the pump is switched off, a timer is started. If after 24 hours the pump has not run again, it is switched on for a period of 5 minutes.

5.8 Fault Condition

A list of faults that may occur is given on page 41.

Clockwise limit approx. 70˚C

Table 9

ECO button

Pressing and holding the ECO button switches from

Comfort mode to ECO-mode.

Comfort mode, ECO button is not lit (factory setting)

Comfort mode the hot water tank has priority. The hot water cylinder is first heated up to the set temperature. The appliance then switches to central heating mode.

ECO mode, button is lit

In ECO mode the appliance switches between central heating mode and cylinder charging mode every 12 minutes.

In the unlikely event of a fault occuring while the appliance is in operation:

The display then shows a fault code and the button may also flash.

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 not flash: B Switch the appliance off and then on again at the

master switch. The appliance will start up again and the central heating flow temperature will be displayed.

6 720 610 601 GB (03.02)

Page 26

Individual settings

6 Individual settings

6.1 Mechanical settings

6.1.1 Checking the size of the expansion vessel

Maximum pressure at maximum CH flow temperature is

2.5 bar. If the pressure is greater than this then fit an extra expansion vessel. Refer to table 10.

System Capacity – BS 7074:1

Expansion Vessel Pressure and System Capacity

Expansion Vessel litres 10

Expansion Vessel Charge Pressure

System pressure and capacity

1 bar litres 82

1.5 bar litres 46

Table 10

6.1.2 Setting the central heating flow temperature

The central heating flow temperature can be set to between 50˚C and 88˚C.

With underfloor heating systems, observe the maximum permissible flow tempera-

tures.

bar 0.75

B Rotate yellow button through 180° and replace (dot

facing inwards). The CH flow temperature is no longer limited.

Control setting CH flow temperature

1 approx. 50˚C 2 approx. 55˚C 3 approx. 60˚C 4 approx. 65˚C 5 approx. 70˚C

E approx. 75˚C

max approx. 88˚C

Table 11

6.1.3 Changing the heating pump characteristic

The speed of the central heating pump can be altered on the pump terminal box.

At switch position 1, maximum output is not delivered if hot water mode is active.

Position 1 must not be used on combi appliances.

0,7

(bar)

0,6

0,5

Limited maximum setting for low-temperature operation

The temperature control is factory limited to setting E, giving a maximum flow temperature of 75˚C.

Adjustment of the heating output to the calculated heat demand is not required by the heating systems regulations.

Removing the maximum setting limit

For heating systems which require higher flow temperatures, the maximum setting limit can be removed.

B Lift off the yellow button on the temperature control

with a screwdriver.

6 720 610 332-27.1O

Fig. 37

0,4

0,3

0,2

0,1

200 400 600 800

Fig. 38

1 Pump characteristic for switch position 1 2 Pump characteristic for switch position 2 3 Pump characteristic for switch position 3 H Residual delivery pressure Q Water circulation rate

1200

6 720 610 576-23.2O

14001000 1600

(l/h)

6 720 610 601 GB (03.02)

Page 27

Individual settings

6.2 Settings on the Bosch Heatronic

6.2.1 Operating the Bosch Heatronic

The Bosch Heatronic enables easy setting and checking of a large number of appliance functions.

This description is limited to those functions required for commissioning.

For a full description of all available functions, please refer to the Service booklet for the Engineer, order no. 7 181 465 346.

2 1

Fig. 39 Appliance controls

1 Service button 2 “Chimney sweep” button 3 Temperature control for central heating 4 Temperature control for hot water 5 Display

Selecting service function:

The service functions are subdivided into two levels: Level 1 comprises service functions up to function 4.9, while Level 2 consists of the service functions from 5.0 upwards.

B To select a service function on Level 1: press and

hold the button until the display shows – –.

B To select a service function on Level 2: press and

hold the buttons and simultaneously until the display shows = =.

B Then turn the temperature control to select the

required function.

Service function Code no. See page

Pump control mode 2.2 27 Anti-cycle time 2.4 27 Max. CH flow

temperature

Switching difference 2.6 28 Max. heating output 5.0 28

Table 12

The service function 5.0 may be reset.

6 720 610 332-30.1O

Note the positions of the temperature controls and . After completing the set-

tings, return the temperature controls to their original positions.

2.5

Entering a setting

B To enter the setting for a function, turn the tempera-

ture control .

Storing a setting

B Level 1: press and hold the button until the dis-

play shows [ ].

B Level 2: press and hold the and buttons simul-

taneously until the display shows [ ].

After completing the settings

B Reset the temperature controls and to their

original positions.

6.2.2 Selecting the pump control mode for central heating mode (Service Function 2.2)

If an outside temperature driven control unit is connected, pump control mode 3 is

automatically activated

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 setting)

For heating systems with room thermostat. The central heating flow temperature control controls only the gas, the pump is not affected. The room thermostat controls both the gas and the pump. The pump and fan have an overrun time of between 15 s and 3 min.

• Control Mode 3

The pump is controlled by the outside temperature driven control unit. In summer mode, the pump operates only for hot water mode.

6.2.3 Setting the anti-cycle time (Service Function 2.4)

This service function is only active if Service Function

2.7, automatic anti-cycle time, is deactivated.

The anti-cycle time can be set to between 0 and 15 minutes (is factory set to 3 minutes).

If the setting 0 is entered, the anti-cycle time is inactive. The shortest possible anti-cycle time is 1 minute (rec-

ommended for single-pipe and hot-air heating systems).

If the appliance is connected to an outside-temperature controlled heating pro-

grammer, the anti-cycle time does not need to be set on the appliance and is optimised by the programmer instead.

6 720 610 601 GB (03.02)

Page 28

Individual settings

6.2.4 Setting the maxim CH flow temperature (Service Function 2.5)

The maximum CH flow temperature can be set to between 35˚C and 88˚C (factory setting).

6.2.5 Setting the switching difference (Service Function 2.6)

If the appliance is connected to an outside-temperature controlled programmer,

the programmer sets the switching difference. It does not need to be set on the appliance.

The switching difference is the permissible divergence from the specified CH flow temperature. It can be set in increments of 1 K. The adjustment range is 1 to 30 K (is factory set to 0 K). The minimum CH flow temperature is 30˚C.

6.2.6 Setting the heating output (Service Function 5.0)

The heating output can be set to any level between min. rated heat output and max rated heat output to limit it to the specific heat requirements.

The full rated heat output is still available for hot water or charging the hot water cyl-

inder even if the heating output has been limited.

B Turn the temperature control until the display

shows 5.0. After a short delay, the display then shows the set heating output in percent.

6 720 610 332-51.1O

Fig. 41

B Refer to the settings tables for heating and cylinder

charging output to obtain the relevant code for the desired heating output in kW (see page 42).

B Turn the temperature control until the display

shows the desired code number. The display and the and buttons will flash.

B Measure the gas flow rate and compare with the fig-

ures specified for the code number displayed. If figures do not match, adjust the code number!

B Press and hold the and buttons simultane-

ously until the display shows [ ]. The heating output is now stored.

The factory setting is the max. rated heat output. B Set the room thermostat and thermostatic radiator

valves to max. temperature.

B Press and hold the and buttons simultane-

ously until the display shows = =. The and buttons will light up.

6 720 610 332-50.1O

Fig. 40

6 720 610 332-52.1O

Fig. 42

B Return the temperature controls and to their

original positions. The display will revert to the CH flow temperate.

6.3 Setting the gas/air ratio

The appliance is set at the factory and adjustment is not necessary.

6 720 610 601 GB (03.02)

Page 29

Converting the appliance to different gas types

6 7 2 0 6 1 0 3 3 2 - 5 7 . 2 R

2 3 4

6 720 610 332-60.1O

7 Converting the appliance to different gas types

The setting is factory sealed at maximum. Adjustment to the rated heat input and min. heat input is not necessary.

Checking the gas supply pressure

B Check the gas supply pressure at the gas supply

pressure testing point.

Natural gas appliances must not be operated if the gas supply pressure is below

18 mbar or above 24 mbar.

LPG appliances must not be operated if the supply pressure is below or above 37 mbar.

Natural gas

• Appliances for natural gas type G20 are factory set to Wobbe-Index 15 kWh/m3 and 20 mbar supply pressure and sealed.

Conversion kits

For conversion

Model

from ... Order no.

7.1 Setting the gas/air ratio

The gas/air ratio may only be adjusted on the basis of a CO2 measurement at max. heat output and min. heat output using an electronic tester.

B Switch off the appliance at the master switch (O). B Remove the outer case (see page 16, refer to

fig. 15).

B Switch on the appliance at the master switch (I). B Set room thermostat to maximum temperature. B Open thermostatic radiator valves. B Unscrew sealing plug from flue gas testing

point (234). Refer to fig. 43.

B Insert testing probe about 135 mm into the flue gas

testing point and seal testing point.

ZB 7-28 N.G to L.P.G 7 710 149 049

ZB 11-28 L.P.G to N.G 7 710 239 085

Table 13

• Instructions are sent with each conversion kit.

Fig. 43

B Press and hold button until the display shows – –.

The button will light up.

6 720 610 332-32.1O

Fig. 44

B Turn the temperature control until the display

shows 2.0 . After a short delay, the current operating mode setting will be displayed (0. = Normal mode).

6 720 610 601 GB (03.02)

Fig. 45

Page 30

Converting the appliance to different gas types

B Turn the temperature control until the display

shows 2. (= max. rated heat output). The display and the button will flash.

6 720 610 332-61.1O

Fig. 46

B Measure the CO2 level. B Prise off the seal on the gas flow restrictor. B Adjust the gas flow restrictor (63) to obtain the CO2

level given in Table 14. Refer to fig. 47.

6 720 610 332-64.1R

Fig. 47

CO2 reading at max. rated heat

Gas Type

Natural gas type

output

9.2 % 8.8 %

G20 LPG G31

10.8 % 10.5 %

(propane)

Table 14

B Turn the temperature control anti-clockwise until

the display shows 1. (= min. rated heat output). The display and the button will flash.

CO2 reading at min. rated heat output

B Remove the seal from the gas valve adjusting

screw (64) and adjust the CO2 level to the figure given in Table 14 for min. rated heat output.

3928-74.1R

Fig. 49

B Recheck the levels at min. and max. rated heat output

and re-adjust if necessary.

B Turn the temperature control anti-clockwise as

far as the stop so that the display shows 0. (= Normal operating mode). 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 temperature.

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 outer case and secure. B Set room thermostat and thermostatic radiator valves

to the desired temperature.

6 720 610 332-63.1O

Fig. 48

B Measure the CO2 level.

6 720 610 601 GB (03.02)

Page 31

Converting the appliance to different gas types

7.2 Testing combustion air/flue gas at set heat output

7.2.1 Testing the O2 or CO2 level in the combus-

tion air

By testing the O2 or CO2 level in the combustion air the gas tightness of a type C13

or C33 flue system can be checked. The O2 level must not be less than 20,6 %. The CO2 level must not exceed 0,2 %.

B Press and hold 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.

In “chimney sweep” mode, the appliance switches to max. rated heat output or the

set heating output. You then have 15 minutes in which to measure the levels. After that, the appliance switches back from “chimney sweep” mode to normal mode.

B Remove sealing plug from combustion air testing

point (234.1, Fig. 50).

B Insert testing probe about 80 mm into the testing

point and seal testing point.

7.2.2 Testing CO and CO

B Press and hold 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.

You have 15 minutes in which to measure the levels. After that, the appliance switch-

es back from “chimney sweep” mode to normal mode.

B Remove sealing plug from flue gas testing point

(234, fig. 50).

B Insert testing probe about 135 mm into the testing

point and seal testing point.

B CO- and CO2 levels. B Refit sealing plug. B Press and hold button until the display shows – –.

The button will stop flashing and the display shows the CH flow temperature.

2 3 4

2 3 4 . 1

6 7 2 0 6 1 0 3 3 2 - 6 5 . 2 R

Fig. 50

B Measure O2 and CO2 levels. B Refit sealing plug. B Press and hold button until the display shows – –.

The button will stop flashing and the display shows the CH flow temperature.

6 720 610 601 GB (03.02)

Page 32

Maintenance

8 Maintenance

B Always disconnect the appliance from

the electrical power supply (fuse, circuit breaker) before carrying out any work on the electrical systems or components.

B Always turn off the gas cock before car-

rying out any work on components which carry gas.

There is a special Service booklet for the Engineer, order no. 7 181 465 346, avail-

able to competent persons.

All safety and control systems are monitored by the Bosch Heatronic. In the event

of a component fault, the display shows a fault code.

B The User should be recommended to have the appli-

ance serviced regularly by a competent person (see Maintenance Contract).

B Use only genuine spare parts B Refer to the Spare Parts List when ordering spare

parts.

B Always renew seals and O-rings removed during

servicing or repair work.

B Use only the following types of grease:

– Water valve: WRAS approved silicon based

grease

– Unions: approved sealant.

B To drain the appliance shut the system valves and

open the pressure relief valve.

B 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.

6 720 610 601 GB (03.02)

Page 33

8.1 Pre-Service Check List

1 Call up the last fault stored by the

Bosch Heatronic, Service Function .0, (see page 34).

2 Check ionisation current, Service

Function 3.3, (see page 34).

3 Perform visual check of air/flue

duct.Visual check of diaphragm for soiling and splits (see page 36).

Maintenance

Date

4 Check gas supply pressure

(see page 29).

5 Test combustion air/flue gas

(see page 31).

6 Check CO2 setting for min./

max. (gas/air ratio) (see page 29).

7 Check gas and water systems for

leaks (see page 16).

8 Check heat exchanger

(see page 34).

9 Check burner (see page 35).

10 Clean condensation trap

(see page 35).

11 Check charge pressure of

expansion vessel matches static head of heating system.

12 Check central heating system

pressure.

mbar

min. %

max. %

mbar

13 Check electrical wiring for damage.

14 Check heating programmer settings.

15 Check appliances that are part of

the heating system.

Table 15

6 720 610 601 GB (03.02)

Page 34

Maintenance

8.2 Description of servicing operations

The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.2.

Check “Last fault stored”:

B Select Service Function .0 (see page 27 “Selecting

service function”).

There is a list of the fault codes in the Appendix (see page 41).

To delete “Last fault stored”: B Turn temperature control anti-clockwise as far as

the stop.

B Press and hold the button until the display

shows [ ]. The last fault stored has now been deleted.

Checking the ionisation current, Service Function 3.3

B Select Service Function 3.3 (see page 27 “Select-

ing service function”).

B Remove the fan and the burner as described in the

text headed “Burner” (see page 35).

6 720 610 332-72.1R

Fig. 52

B Loosen any deposits in the heat exchanger from top

to bottom using the cleaning blade. Refer to fig. 53.

If the display shows 2 or 3, the ionisation current is OK. If the display shows 0 or 1, the electrode assembly (32.1, page 6) must be cleaned or replaced.

Primary Heat exchanger

There is a special accessory kit (no. 840) for cleaning the heat exchanger, order no. 7 719 001 996.

B Check control pressure on the air - gas mixer unit at

max. rated heat output using an electronic manometer.

6 720 610 332-69.1R

Fig. 51

The heat exchanger should only be cleaned if the control pressure is

2.2 mbar (depression) or less.

6 720 610 332-73.1R

Fig. 53

B Clean the heat exchanger from top to bottom using

the brush. Refer to fig. 54.

6 720 610 332-74.1R

Fig. 54

B Flush the heat exchanger from the top. Refer to

fig. 55.

B Remove cleaning access cover (415, page 6) and

the metal plate below it, if present. Refer to fig. 2.

B Unscrew condensation trap and place suitable con-

tainer underneath. Refer to fig. 52.

6 720 610 601 GB (03.02)

Page 35

B Clean out the condensate collector and trap connec-

7 181 465 330-08.1R

tion (with other end of brush).

6 720 610 332-75.2R

Fig. 55

B Refit the clean-out cover using a new seal and

tighten screws to torque of approx. 5 Nm.

Maintenance

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. 56.

B Unscrew and remove the two hexagon screws secur-

ing the fan (3.).

B Slacken fully the rear securing bolt (4.). B Remove the burner coverplate.

7 181 465 330-04.1R

Fig. 56

B Remove the burner skin and clean components. Do

not use a wire brush. Refer to fig. 57.

Fig. 57

B Re-assemble burner in reverse order using a new

seal.

B Adjust gas/air ratio. Refer to section 7.2.

Condensation trap

In order to prevent spillage of condensate, the condensation trap should be completely removed, (see page 34, fig. 52).

B Unscrew condensation trap and check connection

to heat exchanger is clear.

B Remove condensation trap cover and clean. B Fill condensation trap with approx. 1/4 l of water and

refit.

Electrode assembly

B Switch off the master switch. B Pull off the leads from the electrodes. Refer to fig. 2. B Unscrew the two fixing screws and carefully remove

the electrode assembly. Refer to fig. 51.

B Clean the electrodes with a non-metallic brush. (The

spark gap should be 4 mm ± 1 mm.)

B Replace and re-connect the assembly taking care

not to mislay the inspection window.

6 720 610 601 GB (03.02)

Page 36

Maintenance

6 720 610 602

- 16.

Siphon

Condensate

Drain

Diaphragm in mixer unit

B Take care not to damage diaphragm

(443) when removing and refitting it.

B Open mixer unit (29). B Carefully withdraw diaphragm (443) from fan intake

tube and check for soiling and splits.

443

B Refit and prime the siphon.

Fig. 59

Expansion vessel

The expansion vessel should be checked once a year.

6 720 610 790-07.2R

Fig. 58

B Carefully refit diaphragm (443) the correct way

round into the fan intake tube.

The flaps of the diaphragm (443) must open upwards.

B Seal the mixer unit (29).

Siphon

B Unscrew the clip and disconnect the pipe to the

siphon.

B Remove the yellow plug to drain the siphon. B Unscrew the securing nut from beneath the side

facia and remove the siphon. Refer to figure below.

B Depressurise appliance. B If necessary, adjust expansion vessel charge pres-

sure to static head of the heating system.

Heating system pressure

Fill the system using the WRAS approved filling loop.

B The pointer on the pressure gauge should be 1 bar. B If the pointer is below 1 bar (when the system is

cold), water should be added until the pointer is 1 bar again.

B Max. pressure of 2.5 bar when the heating system

water is at maximum temperature must not be exceeded. If this pressure is exceeded then an extra expansion vessel must be fitted in the system return as close to the appliance as possible.

B If the system does not retain the pressure, the expan-

sion vessel and the heating system should be checked for leaks.

Electrical wiring

B Check the electrical wiring for physical damage and

replace any damaged wires.

6 720 610 601 GB (03.02)

Page 37

Maintenance

7 181 465 329

02.1R

7 181 465 330-10.1R

8.3 Replacement of Parts

Before changing 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 for removal using new seals or o-rings as appropriate.

8.3.1 PCB control board and transformer

B Switch off the appliance. B Disconnect appliance from the power supply. B Unplug all connectors from the control box (inc.

keyed plug). Access is gained by removing the covers. Refer to fig. 27, 28.

B Remove screw holding power connector earth lead

and remove earth lead.

B Remove two top fixing screws from the control box.

Refer to fig. 60.

B Remove the pcb control board.

Fig. 61

Fuses

B Remove the connections covers. Refer to fig. 27,

28.

The fuses are located adjacent to the mains connector block and connector ST18. Refer to fig. 4.

Fig. 60

B Lower the control box. B Unscrew earth lead. B Unscrew four fixing screws from cover plate. Refer to

Fuse, item 312, is only replaceable by removing the pcb.

Spare fuses are fixed to the connections cover. A fuse pack is available: Part number 8 744 503 010 0.

fig. 61.

B Prise off cover plate. B Pull off transformer. B Remove pcb holder.

6 720 610 601 GB (03.02)

Page 38

Maintenance

8.3.2 Fan Assembly

8.3.3 Pump

B Switch off the appliance. B Disconnect appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to

fig. 63.

B Lower switchbox (2.). B Unscrew and remove the siphon by releasing the

jubilee clip. Refer to fig. 59.

B Unscrew the pump union nuts (3). Refer to fig. 63. B Carefully remove the pump and disconnect the

leads.

Alternatively B After removing the siphon release the four Allen

screws and remove and replace the pump head.

Fig. 62

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. 62.

B Remove fan lead and earth 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 pipe and mixer unit by

twisting the mixer unit to release it (4.).

7 181 465 330-05.1R

Fig. 63

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. Refer to

fig. 64.

B Pull out retaining clip. B Remove motor. B Disconnect the relief valve drain. B Disconnect the pressure gauge by withdrawing the

clip and pulling out the capillary head.

B Undo pipe unions by withdrawing the clips.

6 720 610 601 GB (03.02)

Page 39

Maintenance

B Remove 3-way valve.

Fig. 64

After refitting:

8.3.7 Gas Valve

B Check that the gas cock is turned off. B Lower the control panel. Refer to fig. 63. B Pull off the solenoid connections at the rear of the

valve.

B Undo the union, within the inner casing, securing the

valve to the gas/air tube. Refer to fig. 62.

B Remove the white plastic cap from the gas valve. B Release the gas inlet union at the manifold assembly. B Unscrew the two screws securing the gas valve

assembly bracket to the back panel and withdraw the assembly.

B Transfer the bracket and inlet pipe assembly to the

new gas valve.

B Check for gas soundness when the new gas valve

has been fitted.

B Recheck the combustion performance as described

in section 7.1.

7 181 465 330-12.1

B Fill system, bleed and re-pressurise

(see Installation Instructions).

8.3.5 3-way diverter valve motor

B Switch off the appliance. B Turn off the service cocks. B Unplug connector from 3-way valve motor. Refer to

fig. 64.

B Pull out retaining clip. B Remove motor.

8.3.6 Sensors

B Check that the appliance is electrically isolated.

Central Heating Flow Temperature Sensor – Item 36, fig. 2, 60

B Pull-off the connector. B Release the sensor clip and withdraw the sensor. B Apply heat transfer paste to the replacement sensor.

Safety Temperature Limiter – Item 6, fig. 2, 60

B Pull-off the connectors. B Unscrew the sensor.

Flue Temperature Limiter – Item 9, fig. 2, 60

B Pull-off the connectors. B Unscrew the sensor.

6 720 610 602 - 04.1O

Fig. 65

8.3.8 Electrode assembly

B Refer to section 8.2. B Use a new seal if the existing seal is damaged.

6 720 610 601 GB (03.02)

Page 40

Maintenance

8.3.9 Pressure gauge

B Drain the appliance. B Lower the facia. Refer to fig. 63. B Twist the pressure gauge head anti-clockwise to

release it from the casing. Refer to fig. 2.

B Disconnect the capillary head from the rear by with-

drawing the clip and pulling out the head. Refer to fig. 57.

8.3.10 Expansion vessel

B Drain the appliance. 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 system.

8.3.11 Pressure Relief Valve

B Drain the appliance. B Disconnect the drain pipe from the valve. Refer to

fig. 33.

B Pull-out the clip securing the valve. B Pull-out the valve. B Ensure that the replacement valve is fully entered

before fitting the clip.

B Ensure that all the seals are in place and all of the

connections are tight before re-commissioning the appliance.

8.3.12 Burner

B Refer to section 8.2.

8.3.13 Primary Heat Exchanger

B Drain the appliance. B Check that the gas supply is turned off. B Check that the appliance is electrically isolated. B Remove the fan assembly complete with the gas/air

tube and mixer assembly. Refer to section 8.3.2.

B Remove the burner. Refer to section 8.2. B Disconnect the sensors. Refer to section 8.3.6. 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 to the top pump con-

nection at the base of the heat exchanger.

B Unscrew and remove the condensate trap. Refer to

section 8.2.

B Unscrew and remove the two screws securing the

heat exchanger top bracket to the rear panel.

B Lift up the flue duct, item 271, refer to fig. 2. B Pull forward from the top and lift the heat exchanger

from the casing.

B Transfer components, as necessary, to the new heat

exchanger.

6 720 610 602 - 06.10

Fig. 66

6 720 610 601 GB (03.02)

Page 41

Appendix

9 Appendix

9.1 Fault Codes

More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.

Display code

A8 Break in communication Check connecting lead to programmer

AC Module not detected. Check connecting lead between TA211E/TR212E

b1 Keyed plug not detected. Insert keyed plug correctly, test and replace if neces-

C1 Fan speed too low. Check fan lead and connector, and fan; replace as

d3 Jumper 8-9 not detected. Connector not connected, link missing, underfloor

E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting lead.

Description Remedy

and Heatronic

sary.

necessary.

heating limiter tripped.

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? Check gas supply pressure,

power supply, igniter electrode and lead, ionisation sensing electrode and lead, flue duct and CO

F0 Internal error. Check electrical connector contacts, programmer

interface module ignition leads are not loose; replace pcb if necessary.

F7 Flame detected even though appliance switched off. Check electrode assembly, dry pcb. Flue clear?

FA Flame detected after gas shut off. Check gas valve and wiring to gas valve. Clean con-

densation trap and check electrode assembly. Flue clear?

Fd Reset button pressed by mistake. Press reset button again

P1, P2, P3, P1...

Please wait, initialisation in progress. 24 V fuse blown. Replace fuse.

level.

Table 16

6 720 610 601 GB (03.02)

Page 42

Appendix

9.2 Short parts list

Key Description Qty GC Spare part number

1 Sensor - Flue gas temp. 1 8 729 000 144 0

2 Sensor - CH flow temp. 1 8 714 500 087 0

3 Control board 1 8 748 300 418 0

4 Gas valve 1 8 747 003 516 0

5 Fan assembly 1 8 717 204 373 0

6 Fan washer 1 8 729 000 183 0

7 Expansion vessel 1 8 715 407 236 0

8 Relief valve 1 8 717 401 012 0

9 Electrode assembly 1 8 718 107 077 0

10 Electrode lead 1 8 714 401 999 0

11 Pump 1 8 717 204 384 0

12 Pressure gauge 1 8 717 208 079 0

13 Burner skin seal 1 8 711 004 168 0

14 Transformer - facia 1 8 747 201 358 0

15 Heat exchanger washer 1 8 710 103 153 0

16 Washer set Condensation Trap 1 8 710 103 154 0

17 Fuse set 1 8 744 503 010 0

18 Primary heat exchanger 1 8 715 406 615 0

Table 17

9.3 Heating/hot water output settings (N.G)

Natural gas G20

Display code

30 8.2 8.3 14.5

40 11.0 11.1 19.4

50 13.7 13.9 24.2

60 16.5 16.6 29.1

70 19.2 19.4 33.9

80 21.9 22.2 38.8

90 24,7 24.9 43.6

100 27.4 27.7 48.5

Heat output, kW

Heat input, kW

Gas vol. flow rate (l/min at t

= 80/60˚C)

V/tR

9.4 Heating/hot water output settings (L.P.G)

Propane

Display code

40 11.0 11.1 50 13.7 13.9 60 16.5 16.6 70 19.2 19.4 80 21.9 22.2 90 24,7 24.9 100 27.4 27.7

Table 19

Heat output kW Heat input kW

Table 18

6 720 610 601 GB (03.02)

Page 43

9.5 Operational Flow diagrams

9.5.1 Central heating function

Boiler

match

control

setting.

and CH

operates to

system load

Minimum

heat input

for 15min.

above set value.

Over temperature

shut-down if water

temperature is 5°C

Yes

long

Boiler

period.*

unused for

Appendix

3 mins.

run for upto

Pump and Fan

OFF.

closes.

Red light

Gas valve

6 720 610 576 - 25.1O

90 secs.

Fan min.

speed for

secs.

reduces

over 15

Gas valve shuts.

Pump remains ON.

Fan speed

satisfied.

CH demand

periods. (More than 24 hours without a demand).

OFF

Burner

start speed

stabilises at

for 5-10 secs

* NOTE: The sequence ensures that the condensate siphon is not empty

after long

Yes

Fan to

Pump ON

programmer or

link ON

AND

start speed.

Gas valve opens.

demand.

Ignition sequence

ON.

AND

(if fitted) ON

programmer

Electronic facia

CH control knob

Burner lights.

Red light ON.

5 seconds.

Ignition spark for

gas from burner.

Fan runs to purge

is below set value.

Burner remains OFF

until flow temperature

and/or mains

Room thermostat

Fig. 67

6 720 610 601 GB (03.02)

ON.

light

Green

ON.

Mains

switch

before lock-out.

Repeats 5 times

Page 44

AppendixAppendix

EXCELLENCE COMES AS STANDARD

Manufactured exclusively for British Gas by The Bosch Group

Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.

Telephone: (01905) 754624 Fax: (01905) 754619

Page 45

Service booklet for the Engineer for Gas Condensing Boilers

6 720 610 577-00.10

ZWB 7-29 CC1 ZB 7-28 CS1 ZWB 7-27 HE combi ZWB 7-25 HE combi ZWB 7-30 HE combi ZB 7-27 HE system ZB 7-28 HE system

GC-Number: 47 108 05

GC-Number: 41 108 02

GC-Number: 47 311 55 GC-Number: 47 311 73

GC-Number: 47 311 74 GC-Number: 41 311 49 GC-Number: 41 311 58

Greenstar 29 HE Conventional

GC-Number: Natural Gas: 41 311 56; LPG: 41 311 57

7 181 465 346 GB (03.02) OSW

Page 46

Table of contents

Warnings 3

Symbols 3

1 Layout of Appliance 4

1.1 combi 4

1.2 system 5

2 Bosch Heatronic board functions 6

2.1 Initialisation 6

2.2 Temperature display 6

2.3 Indication of faults 6

2.4 Special programme visualisation 6

2.5 Boiler service functions 8

2.5.1 First Service Level 8

2.5.2 Secondary Service Level 11

3 Failure identification procedure 13

3.1 Notes on using the fault code tables 13

3.2 Summary 14

3.2.1 Appliance faults 14

3.2.2 Faults that are not displayed 14

3.3 Error codes on the display 15

3.4 Faults that are not displayed 42

3.4.1 Appliance faults 42

3.4.2 Programmer faults 48

4 Appendix 52

4.1 NTC values 52

4.1.1 Outside temperature sensor 52

4.1.2 CH flow NTC sensor, heat store NTC sensor, constant hot water NTC sensor and hot water NTC sensor 52

4.2 Electronic schemes 53

4.3 List of most important replacement parts 54

4.4 Approved corrosion inhibitors and anti-freeze fluids for central heating water 55

4.4.1 Frost protection 55

4.4.2 Sealing agents 55

4.5 Summary of BDH Information Sheet on Identifying Corrosion by CFCs 55

7 181 465 346 GB (03.02)

Page 47

Warnings

Repairs

Repairs may only be carried out by an approved installer!

Before carrying out any work on the appliance, switch it off at the master switch!

Even when the appliance is switched off at the master switch, some components on the PCB control board inside the control box are still live. Therefore:

Before carrying out any work on the electrical parts of the appliance fully disconnect it from the power supply (e. g. by means of fuse or circuit breaker)!

Flue ducting must not be modified in any way.

Use only original spare parts!

Instructions to the customer

Explain to the customer how the appliance works and how to operate it.

Advise the customer that he/she must not make any modifications to the appliance or carry out any repairs on it.

Symbols

Safety instructions

are identified by a warning-triangle symbol and are printed on a grey background.

Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions.

•

Caution

could result.

•

Warning

ous damage to property could result.

•

Danger

result. In particularly serious cases, lives could be at risk.

Notes contain important information in cases where there is no risk of personal injury or damage to property.

indicates that minor damage to property

indicates that minor personal injury or seri-

indicates that serious personal injury could

Notes

are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text.

in this document

7 181 465 346 GB (03.02)

Page 48

Layout of Appliance

1 Layout of Appliance

1.1 combi

221.1

221.2

226

271

358

120

349

234.1

234

102

32.1

415

416

355

6.1

295

417

Fig. 1

Heatronic control

Heat exchanger safety temperature limiter

6.1

Hot water NTC sensor

Testing point for gas supply pressure

8.1

Pressure gauge

Flue gas temperature limiter

Relief valve

Pump

18.1

Pump speed selector switch

Expansion vessel

Automatic air vent

Air gas Mixer unit

32.1

Electrode assembly

Temperature sensor in CH flow

CH flow

Adjustable gas flow restrictor

Adjusting screw for min. gas flow volume

3-way valve (combi)

DHW flow switch (combi)

102

Inspection window

6 720 610 576-02.2O

120

221.1

221.2 226 295 234

234.1 271 349 355 358 415 416 417 418 423

423

18.1

418

8.1 88

Fixing points Flue duct Combustion air intake Fan assembly Appliance type sticker Testing point for combustion products Testing point for combustion air Flue duct Cover plate for twin flue duct connection Plate-type domestic hot water heat exchanger Condensate trap Cover plate for cleaning access Condensate collector Clip for fixing outer case Data plate Siphon

7 181 465 346 GB (03.02)

Page 49

1.2 system

Layout of Appliance

221.1

221.2

226

271

358

120

349

234.1

234

102

32.1

415

416

295

417

Fig. 2

Heatronic control

Heat exchanger safety temperature limiter

Testing point for gas supply pressure

8.1

Pressure gauge

Flue gas temperature limiter

Relief valve

Pump

18.1

Pump speed selector switch

Expansion vessel

Automatic air vent

Air gas Mixer unit

32.1

Electrode assembly

Temperature sensor in CH flow

CH flow

Adjustable gas flow restrictor

Adjusting screw for min. gas flow volume

102

Inspection window

120

Fixing points

221.1

Flue duct

221.2

Combustion air intake

226

Fan assembly

295

Appliance type sticker

234

Testing point for combustion products

6 720 610 596-01.2O

234.1 271 349 358 415 416 417 418 423

423

18.1

418

8.1

Testing point for combustion air Flue duct Cover plate for twin flue duct connection Condensate trap Cover plate for cleaning access Condensate collector Clip for fixing outer case Data plate Siphon

7 181 465 346 GB (03.02)

Page 50

Bosch Heatronic board functions

2 Bosch Heatronic board func-

tions

2.1 Initialisation

When it is switched on, the appliance performs a selftest which takes about 5 seconds. While the test is in progress, the display shows the following sequence of codes:

-> P2 -> P3 -> P4 -> P5 ->

On completion of the test sequence the appliance is ready for operation.

2.2 Temperature display

The display shows the current flow temperature in central heating and hot water modes. The display range extends from 00 ˚C to 99 ˚C.

If a service function requires the display of a temperature greater than 99 ˚C, the display alternates between initially showing the first digit and then the remaining two digits.

E.g.

: display showing 1. followed by

169˚C

For outside temperatures, the display shows a minus sign followed by the negative temperature in alternation.

2.3 Indication of faults

Faults are indicated by a letter code. This helps to identify and eliminate the cause of the fault quickly and reliably.

The fault codes displayed are grouped into four categories:

•

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 3:

The appliance continues to operate with limited function.

•

Category 4:

The appliance is disabled and locked ( flashes) until the cause of the fault has been eliminated and the appliance unlocked.

Unlocking the appliance:

Press and hold the button until the display shows

– –

69.

indicates

2.4 Special programme visualisation

The display shows for example 45 ous working at the minimum sanitary/heating power)

The display shows alternatively the temperature and

. The function is memorised in the Service mode.

– –

• The appliance works continuously at the sanitary or heating minimum power.

Press the button until the symbol the display. The button is lighted.

Turn the temperature control until function appears on the display. After a short delay, the display shows 1 for minimum output.

Turn the temperature control completely anticlockwise until the display shows 0 .

Press the button until the symbol the display. The display shows the heating outlet temperature.

The display shows for example 55 (continuous working at the maximum power)

The display shows alternatively the temperature and The function is memorised in the Service mode.

• The appliance works continuously at the maximum power.

Press the button until the symbol the display. The button is lighted.

Turn the temperature control until function appears on the display. After about 5 seconds the display will show 2 for the maximum power.

Turn the temperature control completely anticlockwise until the display shows 0 .

Press the button until the symbol the display. The display shows the heating outlet temperature.

Display shows 45 -II- 45 (trap filling programme)

The trap filling programme ensures that the condensation trap is filled after the appliance is first installed or if it has been switched off for a long period.

The trap filling programme is activated if:

• the appliance is switched on at the master switch

• the burner has not been in operation for at least 48 hours

• the appliance is switched from summer to winter mode.

45 (continu-

– –

appears on

– –

[ ]

appears on

– –

appears on

[ ]

appears on

2.0

– –

7 181 465 346 GB (03.02)

Page 51

The next time the central heating or heat store calls for heat, the appliance is held at a low heat output for 15 minutes. The display shows

-II-

in alternation with the

CH flow temperature.The factory setting is 1 (enabled).

If the condensation trap is not filled with water, flue gas can escape!

B The trap filling programme should only

be disabled in order to carry out servicing work.

B Always re-enable the trap filling pro-

gramme after completing servicing work.

To switch off the trap filling programme to carry out servicing work:

Press and hold the and buttons simultaneously until the display shows

= =

The and buttons will light up.

Turn the temperature control until the display shows

8.5

. After a short delay, the display then shows the trap filling programme setting (1. = Enabled).

Turn the temperature control until the display shows 0. (= Disabled). The display and the and buttons will flash.

B Press and hold the and buttons simultane-

ously until the display shows [ ]. The trap filling programme is now disabled.

B Regulate the temperature control and the tem-

perature control on the previously set positions. The display shows the heating outlet temperature.

Display shows

(venting function)

The first time the appliance is switched on, it automatically activates a one-off venting sequence in which the heating pump switches on and off at intervals for about 8 minutes.

This function can be activated on Service Level 2, Service Code 7.3, if it is required at any other time.

Bosch Heatronic board functions

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Bosch Heatronic board functions

2.5 Boiler service functions

B Press the button until the symbol [ ] appears on

the display.

2.5.1 First Service Level

Operating

The display shows the heating outlet temperature.

B Regulate the temperature control and the tem-

perature control on the previously set positions.

In order to change or check the values of the service functions:

B Press the button until the symbol

– –

appears on the display. The button is lighted.

B Turn the temperature control until the desired

function number appears on the display.

Once changed or checked the function value:

In order to reset the main menu function values to their default values:

B Power OFF the appliance. B Press the button and keep it pressed. B Switch on the appliance, press and hold the but-

ton until the display shows r1 followed by [ ].

Values that can be modified:

Description Display Reset Value

.0 Show the last error code. 0 - FF Clear only

2.0 Identification of the function mode (0 = normal, 1= min, 2 = max) 0 - 2 0

2.2 Identification of the pump function mode 1 - 3 2

2.3 Max. output in heat store heating mode 28 - 99 99

2.4

Anti-cycle time

0 - 15 min 3 min

2.5 Max. CH flow temperature 35 - 88˚C 88˚C

2.6 Minimum hysteresis in heating mode (∆T) 0 - 30 K 0 K

2.7 Activation of automatic anti-cycle time (0 = Disabled; 1 = Enabled) 0, 1 1

3.4 Pump mode 0 - 3

Table 1 First Service Level; Values that can be modified

1) If appliance is used in conjunction with type TA... programmer, only effective if Service Code 2.7 is set to “0” (= "Disabled”)!

2) The reset value is dependent on the code plug.

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Bosch Heatronic board functions

Values that can only be read:

Description Display Reset Value

.1 Heating outlet temperature. 0 - 99˚C -

.2 Sanitary outlet temperature. 0 - 99˚C -

.3 Heat store NTC sensor (ZSB.) 0 - 99˚C

.4 Constant hot water NTC sensor (ZWB.) 0 - 99˚C -

1.2 Order no. for code plug: 8 714 411 XXX 0 - 255 -

1.4 Temperature voltage signal (Terminal 2) from room thermostat

5 - 22 VDC -

(eg. TRQ 21, TR 100)

1.5 Specified CH flow temperature from programmer 0 - 99˚C -

1.6 Outside temperature from TA 211 E or room temperature from

-20 +30˚C -

TR 212 E

1.7 Status TR 2 (0 = Not present 1 = Frost protection 3 = Auto 4 = Day,

0 - 4 -

Night 5=Error)

1.8 Terminal 2 on programmer interface module 0 - 24 VDC -

1.9 Identification code for the external module:

0, 2, 4, 5 = no module connected,

0 - 8, 53, 56

3 = ADM, 6 = TA 211E, 53 = ADM, 56 = TR 212 E).

2.9 Instantaneous power. 0 - 99 % -

3.0 Fan speed 0 - 105 -

3.3 Quality of the ionisation signal:

0 - 3 0 = no ionisation, 1 = weak ionisation, 2 = medium ionisation, 3 = high ionisation.

3.6 Software version 3 x 2 positions

Table 2 First Service Level; Values that can only be read

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Bosch Heatronic board functions

Values that can only be read - only left display digit:

Description Display XY Reset Value

3.9 External switch (points 8 - 9). 0 = closed

1 = Heating demand

4.1 External demand for heat via LSM 0 = closed 1 = Heating demand

4.2 Programmable clock:

1st channel (Heating).

4.3 Automatic pump shut OFF with RAM module

(point 5)

0 = closed 1 = Heating demand

4.4 Heating demand. 0 = closed 1 = Heating demand

4.5 Sanitary demand. 0 = closed 1 = Heating demand

Table 3 First Service Level; Values that can only be read - only left display digit

Values that can only be read - only right display digit:

Description Display XY Reset Value

3.9 External 2-point demand for heat via 230 V AC

(Terminals Ls - Lr)

4.0 Heat store demand for heat via

heat store thermostat (Terminals 7-9)

0 = closed 1 = Heating demand

4.1 LSM Enable 0 = closed 1 = Heating demand

4.2 Programmable clock:

2nd channel (DHW – Maintaining).

0 = closed 1 = Heating demand

4.3 Heating demand from TA 211 E 0 = closed 1 = Heating demand

4.4 Heat store demand for heat via heat store NTC

sensor

0 = closed 1 = Heating demand

4.5 Sanitary heat exchanger temperature maintaining. 0 = closed 1 = Heating demand

4.6 Anti-cycle time 0 = closed 1 = Heating demand

Table 4 First Service Level; Values that can only be read - only right display digit

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Bosch Heatronic board functions

2.5.2 Secondary Service Level

B Press buttons and simultaneously until the

symbol [ ] appears on the display.

Operation

In order to change or check the values of the service functions:

B Press buttons and simultaneously until the

symbol = = appears on the display. The buttons and are lighted.

B Turn the temperature control until the desired

function number appears on the display.

The display shows the heating outlet temperature.

B Regulate the temperature control and the tem-

perature control on the previously set positions.

To reset all settings on Service Levels 1 and 2 to the factory setting:

B Power OFF the appliance. B Press buttons and simultaneously and keep

them pressed.

Once changed or checked the function value:

B Switch on appliance, press and hold the and

buttons until the display shows r2 followed by [ ].

Values that can be modified:

Description Display Reset Value

5.0 Reduced max. heating output 0 - 99 % and sealed 99

5.1 Continuous ignition (for testing ignition without

gas)

0 = off 1 = on

5.5 Increased min. heating and heat store charging

0 - 99 % 0

output

5.9 Starting speed option (if flame propagation is poor, set high starting speed)

0 = First start at low speed; 1 = First start at high speed)

6.7 Pump deactivation in HW mode, ZW only. 0 = off, 1 = on 1

6.8 Cycle time for heat exchanger constant hot water

0 - 60 min 0

function on ZW model.

6.9 Constant hot water 0 - 30 min 3

7.3 Venting function 0 = off,

1 = On for 8 cycles then permanently off (i.e. set to 0) 2 = on

7.7 Temperature-dependent output reduction 0 = off;

1 = Heating on 2 = Hot water on 3 = Heating and hot water on

8.5 Trap filling programme 0 = off

1 = on

Table 5 Secondary Service Level; Values that can be modified

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Bosch Heatronic board functions

Values that can only be read:

Description Display Reset Value

5.2 Automatic gas igniter status and/or fault 00 - FF -

9.3 Automatic gas igniter Asic fault code 00 - FF -

Table 6 Secondary Service Level; Values that can only be read

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3 Failure identification procedure

Failure identification procedure

3.1 Notes on using the fault code tables

The procedure is best described with the aid of an example:

• Work through the table from top to bottom and from

left to right.

• First make a note of the present settings and restore

them before leaving the appliance.

• Read question 1. (Check column)and depending on

the answer (yes or no) read the action required from the relevant box and carry out the instruction given; ignore the other answer. For example: if the burner flame is visible, follow the instructions for yes, i.e. ↓5.!

• ↓5. means go to number 5., ignoring the steps in

between.

EA and flashing.

Flame not detected

In this example: check the flue is clear by testing

the CO2 level.

• If the appliance is locked ( button is flashing), press the button. Important: after unlocking the appliance, always restart it (i.e. switch off and then on again). Only then is it possible to say whether or not the fault has been eliminated.

• If the fault has been rectified, the appliance will then start up without indicating a fault and the fault isolation procedure is complete.

• If the fault is still present after performing the action specified and, if necessary, restarting the appliance, move on to the next step in the fault isolation procedure.

• If another fault code is displayed, work through the fault code table for that code.

Check Action

B Note the setting of the temperature controls

1. Is a burner flame visible? yes: ↓ 5. no: ↓ 2.

2. Is the gas cock turned on? yes: ↓ 5.

no: B Open the gas cock.

B Press , restart the appliance.

EA? ↓3.

3. Has the thermal cut-out on the gas

cock tripped?

4. ... ...

5. ... Problem with flue?

B Check CO2 level in combustion

air. Is CO2 level above 0,2 % ?

yes: ... no: ↓ ...

yes: Check flue. no: ↓ ...

Return to normal operation:

and .

Table 7

7 181 465 346 GB (03.02)

B Press the button until the symbol [ ] appears

on the display.

B Regulate the temperature control and the

temperature control on the previously set positions.

Page 58

Failure identification procedure

3.2 Summary

3.2.1 Appliance faults 3.2.2 Faults that are not displayed

Appliance faults

A5 3 X 15

A7 3 X 17

A8 3 X X X 19

AC 3 X X X 20

Ad 3 X 22

b1 2 X X X 24

C1 2 X X X 25

CC 3 X X X 26

d3 2 X X X 27

E2 2 X X X 28

E9 4 X X X 30

EA 4 X X X 32

Category

ZB ...A

ZB ...A Conventional

ZWB ...A

Page

Appliance faults

Excessive burner noise, rumbling noises

Flue gas levels incorrect, CO level too high

Ignition too harsh, ignition poor. X X 44

Boiler indicates P1, P2, P3 at start-up and then restarts with P1,...

Loose or broken contact on heat store NTC sensor

Specified CH flow temperature from TA... programmer exceeded

Table 9

Programmer faults

Set room temperature not reached.

X 48

ZB ...A

X X 42

X X 43

X X 46

X X 47

TR 2 and

TR 212 E

ZWB ...A

TA 211E

and DT 2

Page

F0 4/2XXX 37

F7 4 X X X 38

FA 4 X X X 39

Fd 4 X X X 41

Table 8

Set room temperature exceeded.

Set room temperature not reached.

Set room temperature exceeded by large amount.

Excessive fluctuations in room temperature

Temperature rises instead of falling

Room temperature too high in Economy mode

Incorrect or no modulation X X 51

Heat store fails to heat up X

Table 10

X 49

X 50

X X 50

X X 51

X X 50

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3.3 Error codes on the display

A5 flashing.

Heat store NTC sensor 2 defective

Check Action

B Press button . B Select service function .3 .

Is a temperature between 0. and

5. displayed?

B Note the setting of the temperature controls

yes:

no: ↓3.

B Flue gas connector corroded

↓2.

Failure identification procedure

and .

dirty?. Change relative parts.

, damaged or

2. Heat store NTC:

B Unplug connector. B Short circuit the connector.

Display changes to temperature between 99. and 95.

3. Temperature between 95. and 99. is

displayed. B Unplug connector.

After max. 60 sec.: Does the displayed code change to a value between 0. and 5.?

4. B Unplug 20-pin connector from

PCB. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.?

yes: B Power OFF the appliance.

B Change NTC sensor. B Plug the connection wire. B Turn ON the appliance.

A5? ↓3.

no: B Change the 20-pin connector lead assembly.

↓3.

yes: B Power OFF the appliance.

B Change NTC sensor. B Plug the connection wire. B Turn ON the appliance.

A5? ↓4.

no: ↓4. 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 connection. B Turn ON the appliance.

7 181 465 346 GB (03.02)

↓5.

no: B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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 settings previously noted down.

Page 60

Failure identification procedure

A5 flashing.

Heat store NTC sensor 2 defective

Check Action

5. To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

1) For notes, refer to Appendix

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A7 flashing.

Hot water NTC sensor defective

Check Action

B Press button . B Select service function .2 .

Is a temperature between 0. and

5. displayed?

yes:

no: ↓3.

Failure identification procedure

B Note the setting of the temperature controls

and .

B Flue gas connector corroded

dirty? Change relative parts.

↓2.

, damaged or

2. Hot water NTC sensor:

B Unplug connector. B Short circuit the connector.

Display changes to temperature 99.

3. Temperature between 95. and 99. is

displayed. B Unplug connector.

After max. 60 sec.: Does the displayed code change to a value between 0. and 5.?

yes: B Power OFF the appliance.

B Drain the hot water circuit. B Disconnect the boiler electrical connection. B Change NTC sensor. B Plug the connection wire. B Reconnect the boiler electrical connection. B Turn ON the appliance.

A7? ↓3.

no: B Change the 20-pin connector lead assembly.

↓3.

yes: B Power OFF the appliance.

B Disconnect the boiler electrical connection. B Change NTC sensor. B Refill the hot water circuit. B Check the built-in NTC sensor for leaks. B Plug the connection wire. B Reconnect the boiler electrical connection. B Turn ON the appliance.

7 181 465 346 GB (03.02)

A7? ↓4.

no: ↓4.

Page 62

Failure identification procedure

A7 flashing.

Hot water NTC sensor defective

Check Action

4. B Unplug 20-pin connector from PCB. After max. 60 sec.: Does the displayed code change to a value between 0. and 5.?

5. To return to normal function mode:

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 connection. B Turn ON the appliance.

↓5.

no: B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

↓5.

1) For notes, refer to Appendix

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

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A8 flashing.

No correct electrical connection

Check Action

1. TR 2 connected? yes: A8? ↓2.

no: B Power OFF the appliance.

B Connect TR 2. B Turn ON the appliance.

A8? ↓2.

Failure identification procedure

2. Mode selector switch is between two settings

3. B Power OFF the appliance. Wiring between TR 2 and TR 212 E

OK?

• Terminal 3 on TR 2 connected to

Terminal 3 on TR 212 E?

• Terminal 4... Terminal 4....

4. TR 2 defective B Power OFF the appliance.

yes: B Turn ON the appliance.

no: B Rewire correctly as specified in the installation

B Turn switch until it clicks into position. A8? ↓3.

↓4.

instructions.

B Turn ON the appliance.

After 90 sec.: A8? ↓4.

B Change TR 2. B Turn ON the appliance.

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Failure identification procedure

AC flashing.

Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.)

Check Action

B Note the setting of the temperature controls

and .

2. Are 24 V DC cables routed along-

3. Connecting lead between PCB con-

4. TA 211 E connected? yes: ↓5.

B Press button . B Select service function 1.9 .

Code 0., 2., 4., 5. is displayed.

side 230 V AC cables?

trol board and TA 211 E or TA 212 E defective.

yes: No modul detected.

B Disconnect connecting lead between PCB con-

B Re-connect connecting lead.

AC? ↓3.

no: ↓2.

yes: B Ensure cable separation conforms to minimum

no: ↓3.

B Power OFF the appliance. B Replace connecting lead between PCB control

B Turn ON the appliance.

AC? ↓4.

no: ↓8.

trol board and TA 211 E or TA 212 E.

requirements as per installation instructions and/ or use shielded cable.

board and programmer interface module or TA 211 E.

5. B Select service function 1.6 . Outside temperature between -20 and +30 ˚C is displayed. Does temperature displayed match true outside temperature?

6. If remote control installed:

B Select service function 1.7 .

Remote control status 0. is displayed .

yes: ↓7.

no: B Power OFF the appliance.

B Replace outside temperature sensor. B Turn ON the appliance.

AC? ↓7.

yes: B Power OFF the appliance.

B Plug the connection wire. B Turn ON the appliance.

AC? ↓7.

no: ↓7.

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Failure identification procedure

AC flashing.

Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.)

Check Action

7. Remote control status still 0.? yes: B Power OFF the appliance. Remote control:

B Replace top section. B Turn ON the appliance.

AC? ↓8.

no: ↓8.

8. The PCB control board is damaged. B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

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Failure identification procedure

Ad flashing.

Heat store NTC sensor 1 not detected (ZB...).

Check Action

B Note the setting of the temperature controls

and .

1. Is connecting lead for heat store NTC sensor 1 correctly routed, i.e. not through cable grommet?

3. Heat store -NTC 1:

B Press button . B Select service function .3 .

Is a temperature between 0. and

5. displayed?

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 99. and 95.

yes: ↓2.

no: B Route connecting lead for heat store tempera-

ture sensor as specified in installation instructions.

yes: Is NTC sensor connector corroded, damaged or

dirty?

B Power OFF the appliance. B Change NTC sensor. B Turn ON the appliance.

B Press button .

Ad? ↓3.

no: ↓4.

yes: B Power OFF the appliance.

B Change NTC sensor. B Turn ON the appliance.

B Press button .

↓4.

no: B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

↓4.

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Page 67

Ad flashing.

Heat store NTC sensor 1 not detected (ZB...).

Check Action

Failure identification procedure

4. Temperature between 99. and 95. is displayed.

B Unplug 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 NTC sensor. B Turn ON the appliance.

no: B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

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Failure identification procedure

b1 flashing.

The Heatronic does not recognise the code key.

Check Action

1. B Power OFF the appliance.

2. Code plug loose, incorrect or defective.

3. The PCB control board is damaged. B Make a note of the altered service settings (see

B Replace code plug, check code number is cor-

rect.

B Turn ON the appliance. b1? ↓3.

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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C1 flashing.

Fan speed too low

Check Action

Failure identification procedure

1. Fan lead connector properly connected?

2. Is fan lead defective? B Is impedance reading between the

two connectors for one of the cores infinity?

3. Are the differential pressure switch contacts closed?

B Press button . B Select service function 3.8 .

Is left digit of display showing 1?

4. Fan defective? yes: B Power OFF the appliance.

yes: ↓2.

no: B Power OFF the appliance.

B Plug in connector. B Turn ON the appliance.

C1? ↓2.

yes: B Power OFF the appliance.

B Replace fan lead. B Turn ON the appliance.

C1? ↓3.

no: ↓3. yes: ↓4. no: ↓4.

B Plug the connection wire. B Replace fan. B Plug the connection wire. B Turn ON the appliance.

C1? ↓5.

no: ↓5.

5. The PCB control board is damaged. B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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Page 70

Failure identification procedure

CC flashing.

Outside temperature NTC sensor not detected. (Boiler heating as if outside temperature is -20˚C)

Check Action

1. Outside temperature sensor AF2 connected to Terminals A and F on TA 211 E?

2. B Power OFF the appliance. B Disconnect outside temperature

sensor and test resistance R = ∞ or R = 0?

yes: ↓2.

no: B Power OFF the appliance.

B Connect outside temperature sensor to Termi-

nals A and F on TA 211 E.

B Turn ON the appliance. CC? ↓2.

B Change the external sensor. B Turn ON the appliance.

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Page 71

d3 flashing.

Wrong signal from pin 8-9 (open?).

Check Action

Failure identification procedure

1. B Turn ON the appliance. B Measure voltage between Termi-

nal 4 and Terminal 8. Voltage ≅ 24 V DC?

2. Existing heat store thermostat connected to Terminals 7, 8 and 9?

3. Break in connecting lead? yes: B Power OFF the appliance.

4. The PCB control board is damaged. B Make a note of the altered service settings (see

yes: ↓2. no: ↓3.

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? ↓3.

no: ↓4.

B Plug the connection wire. B Turn ON the appliance.

d3? ↓4.

no: ↓4.

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

7 181 465 346 GB (03.02)

Page 72

Failure identification procedure

E2 flashing.

The heating outlet NTC sensor is damaged.

Check Action

B Note the setting of the temperature controls

and .

B Press button . B Select service function .1 .

Is a temperature between 0. and

5. displayed?

2. Temperature for heating outlet NTC sensor between 95. and 99. is displayed.

3. Check if the 20-pin connector lead assembly is damaged.

yes: The heating outlet NTC sensor is in short circuit:

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? ↓2.

no: ↓2.

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.

B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change the 20-pin connector lead assembly. B Reconnect the boiler electrical connection. B Turn ON the appliance.

E2? ↓4.

4. The PCB control board is damaged. B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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Page 73

E2 flashing.

The heating outlet NTC sensor is damaged.

Check Action

Failure identification procedure

To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

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Page 74

Failure identification procedure

E9 and flashing.

Safety temperature limiter has tripped.

Check Action

1. Is the heating pressure between 1 and 2 bar?

2. Is the pump blocked? yes: B Unblock the pump.

3. Lead disconnected from safety temperature limiters?

yes: ↓2.

no: B Top up system.

B Vent appliance. B Press , restart the appliance.

E9? ↓2.

If pump won’t start:

B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change the pump. B Reconnect the boiler electrical connection. B Turn ON the appliance.

B Press , restart the appliance.

E9? ↓3.

no: ↓3.

yes: B Power OFF the appliance.

B Connect lead. B Turn ON the appliance.

4. B Power OFF the appliance. B Unplug the connector from the

cut-off device.

B Measure the NTC electrical resist-

ance.

R = ∞?

B Press , restart the appliance.

E9? ↓4.

no: ↓4.

yes: B Change the over heating cut-off device.

B Connect flue gas safety temperature limiter lead. B Turn ON the appliance.

B Press , restart the appliance.

E9? ↓5.

no: B Connect flue gas safety temperature limiter lead.

B Turn ON the appliance.

↓5.

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Page 75

E9 and flashing.

Safety temperature limiter has tripped.

Check Action

Failure identification procedure

5. Is lead disconnected from CH flow safety temp. limiter?

6. B Power OFF the appliance. B Disconnect lead to CH flow safety

temperature limiter.

B Measure the CH flow safety tem-

perature limiter. R = ∞?

7. B Power OFF the appliance. B Remove fuse SI 3 from appliance

PCB control board and test for continuity. R = ∞?

yes: B Power OFF the appliance.

B Reconnect lead. B Turn ON the appliance.

B Press , restart the appliance.

↓6.

no: ↓6.

yes: B Change CH flow safety temperature limiter.

B Connect CH flow safety temperature limiter lead. B Turn ON the appliance.

B Press , restart the appliance.

E9? ↓7.

no: B Connect CH flow safety temperature limiter lead.

B Turn ON the appliance.

↓7.

yes: B Change the fuse.

B Turn ON the appliance. B Press , restart the appliance.

E9? ↓8.

no: B Remount the fuse.

B Turn ON the appliance.

↓8.

8. The PCB control board is damaged. B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

7 181 465 346 GB (03.02)

Page 76

Failure identification procedure

EA and flashing.

No flame ionisations signal

Check Action

1. Is the flame present? yes: ↓6. no: ↓2.

2. Is the gas cock open? yes: ↓3.

no: B Open the gas cock.

B Note the setting of the temperature controls

and .

B Press , restart the appliance.

EA? ↓3.

3. Is there air in the supply pipe? yes: B Vent supply pipe.

B Press , restart the appliance.

EA? ↓4.

no: ↓4.

4. Did the thermal security of the gas

cock lock out?

yes: B Reset security.

B Press , restart the appliance.

EA? ↓5.

no: ↓5.

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EA and flashing.

No flame ionisations signal

Check Action

Failure identification procedure

5. Natural gas models: does the building have a supply pressure regulator?

LPG models: is the flow rate of the gas supply to the appliance correct?

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 Is correct code plug fitted? B Press , restart the appliance.

EA? ↓6.

no: ↓6. yes: ↓6.

no: B Is there enough gas in the supply cylinder?

B Is there air in the supply pipe? B Is the solenoid valve in the "meter cabinet” open-

ing?

B Is the supply pressure OK? (if the supply pres-

sure is too high, check the pressure regulator in the “meter cabinet” and on the LPG supply cylinder).

B Press , restart the appliance.

EA? ↓6.

6. Is the ground connection correct? yes: ↓7.

no: B Correct the electrical ground connection.

B Press , restart the appliance.

EA? ↓7.

7. Two phase net: Is there a resistor fitted between Pe and N?

yes: ↓8.

no: B Power OFF the appliance.

B Disconnect the boiler electrical connection. B Insert a 2 MΩ resistance between the ground

B Reconnect the boiler electrical connection. B Turn ON the appliance.

B Press , restart the appliance.

EA? ↓11.

and the N connection.

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Failure identification procedure

EA and flashing.

No flame ionisations signal

Check Action

8. Is diaphragm in the mixer unit correctly fitted and functional?

B Open mixer unit (29). B Check diaphragm for correct ori-

entation, soiling and splitting. Is diaphragm OK?

9. Is the condensation trap blocked? yes: B Clean out condensation trap discharge pipe.

10. 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 ± 40Ω ?

yes: B Close mixer unit.

↓9.

no: B Insert diaphragm in the fan intake duct as per

installation instructions so that the flaps open upwards.

B Close mixer unit. EA? ↓9.

B Press , restart the appliance.

EA? ↓13.

no: ↓10.

yes: B Reconnect the gas valve.

B Turn ON the appliance. B Press , restart the appliance.

EA? ↓11.

no: B Change the gas valve.

B Reconnect the gas valve. B Turn ON the appliance.

11. Problem with flue? B Check CO2 level in combustion

air. Is CO2 level above 0,2 % ?

B Open up heat exchanger - is it

dirty?

12.

Is flue gas CO2 level incorrect1)?

B Press , restart the appliance.

EA? ↓11.

yes: B Check flue and clean if necessary.

B Press , restart the appliance.

EA? ↓12.

no: ↓12.

yes: B Adjust to correct level.

B Press , restart the appliance.

EA? ↓13.

no: ↓13.

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EA and flashing.

No flame ionisations signal

Check Action

Failure identification procedure

13.

14. Ignition lead connected to ignition

15. Ignition cable connector engaged in

16. Is the ignition electrical wire

B Press buttons and simulta-

neously.

B Select service-function 5.1.

Continuous ignition (without gas) OK?

electrodes?

switchbox?

damaged?

yes:

no:

yes: ↓15.

no: B Connect cable to ignition electrode.

yes: ↓16.

no: B Power OFF the appliance.

yes: B Power OFF the appliance.

B Press buttons and simultaneously.

↓14.

B Press buttons and simultaneously.

↓17.

B Press , restart the appliance.

EA? ↓15.

B Engage ignition cable connector in switchbox. B Turn ON the appliance.

B Press , restart the appliance.

EA? ↓16.

B Change the ignition electrical wire. B Turn ON the appliance.

17.

18. Electrode assembly defective?

B Press button . B Select service-function 3.3.

Is the ionisation quality 2. or 3. ?

B Power OFF the appliance. B Remove electrode assembly.

Electrodes worn out?

B Press , restart the appliance.

EA? ↓17.

no: ↓17. yes: ↓19. no: ↓18.

yes: B Replace electrode assembly.

B Turn ON the appliance. B Press , restart the appliance.

EA? ↓19.

no: B Refit electrode assembly.

B Turn ON the appliance. B Press , restart the appliance.

EA? ↓19.

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Failure identification procedure

EA and flashing.

No flame ionisations signal

Check Action

19. Check if the 20-pin connector lead assembly is damaged.

20. The PCB control board is damaged. B Make a note of the altered service settings (see

B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change the 20-pin connector lead assembly. B Turn ON the appliance. B Reconnect the boiler electrical connection.

B Press , restart the appliance.

EA? B Power OFF the appliance.

↓20.

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

1) See installation instructions

To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

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F0 (and possibly ) flashing.

Internal failure

Check Action

Failure identification procedure

B Note the setting of the temperature controls

and .

B Press buttons and simulta-

neously.

B Select service function 9.3 .

A service code is displayed.

2. B Select service function 5.2 . A service code is displayed.

4. The PCB control board is damaged. B Make a note of the altered service settings (see

flashing?

yes:

no: ↓4.

B Enter figure displayed in customer service record.

↓2.

B Enter figure displayed in customer service record.

↓3.

B Press button .

B Initiate demand for heat by pressing button

and then press again after 30 seconds to cancel.

B Initiate two more demands for heat as above. F0? ↓4.

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

7 181 465 346 GB (03.02)

To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

Page 82

Failure identification procedure

F7 and flashing.

Although appliance switches off, flame still detected

Check Action

1. Electrode(s) dirty or defective. B Power OFF the appliance. B Replace electrode assembly. B Turn ON the appliance.

B Press , restart the appliance.

F7? ↓2.

2. B Power OFF the appliance.

B Disconnect the boiler electrical

connection.

B Remove PCB control board.

PCB control board damp?

3. Problem with flue?

B Check CO2 level in combustion

air. Is CO2 level above 0,2 % ?

4. The PCB control board is damaged. B Make a note of the altered service settings (see

yes: B Dry PCB control board (e.g. with hair dryer).

B Look for point where damp is entering switchbox

and seal as necessary (cable grommets properly fitted, ...?).

B Refit PCB control board. B Reconnect the boiler electrical connection. B Turn ON the appliance.

B Press , restart the appliance.

F7? ↓3.

no: ↓3.

yes: B Check flue and repair or replace if necessary. no: ↓4.

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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Failure identification procedure

FA and flashing.

Although appliance switches off, flame still detected

Check Action

B Note the setting of the temperature controls

and .

B Power OFF the appliance.

1. Condensation trap blocked? yes: B Clean condensation trap discharge pipe. B Press , restart the appliance.

FA? ↓2.

no: ↓2.

2. Electrode assembly defective?

B Power OFF the appliance. B Remove electrode assembly.

Electrode assembly burnt out?

3. Problem with flue?

B Check CO2 level in combustion

air. Is CO2 level above 0,2 % ?

4. The gas valve is damaged. B Change the gas valve.

yes: B Replace electrode assembly.

B Turn ON the appliance. B Press , restart the appliance.

FA?

B Power OFF the appliance. ↓3.

no: B Refit electrode assembly.

B Turn ON the appliance. B Press , restart the appliance.

FA? ↓3.

yes: B Check flue and repair or replace if necessary.

B Press , restart the appliance.

FA?

B Power OFF the appliance. ↓4.

no: ↓4.

B Turn ON the appliance.

7 181 465 346 GB (03.02)

B Press , restart the appliance.

FA?

B Power OFF the appliance. ↓5.

Page 84

Failure identification procedure

FA and flashing.

Although appliance switches off, flame still detected

Check Action

5. Check if the 20-pin connector lead assembly is damaged.

6. The PCB control board is damaged. B Make a note of the altered service settings (see

B Power OFF the appliance. B Disconnect the boiler electrical connection. B Change the 20-pin connector lead assembly. B Turn ON the appliance. B Reconnect the boiler electrical connection.

B Press , restart the appliance.

FA? B Power OFF the appliance.

↓6.

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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Fd and flashing.

Button pressed without necessity

Check Action

Failure identification procedure

2. The PCB control board is damaged. B Make a note of the altered service settings (see

Button is flashing. B Press , restart the appliance.

Fd? ↓2.

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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Failure identification procedure

3.4 Faults that are not displayed

3.4.1 Appliance faults

Excessive burner noise, rumbling noises

Check Action

B Note the setting of the temperature controls

and .

1. Does the gas supply type match the specifications on the appliance identification plate?

2. B Test gas supply pressure - OK?

Does pressure match figure specified in installation instructions?

3. Problem with flue? B Check CO

level in combustion

air. Is CO2 level above 0,2 % ?

4. Cascade system: Is the appliance min. output high enough to open the shut-off device?

5. Is appliance’s internal air/flue channel leaking or blocked?

B Open up heat exchanger and

inspect.

B Remove silencer, flue duct and air

flow limit.

B Open trap and inspect.

Air channels dirty/clogged, seals defective or not correctly fitted?

yes: ↓2.

no: B Convert appliance to correct gas type.

↓2.

yes: ↓3.

no: B Decommission appliance.

For natural gas:

B Notify gas company.

yes: B Check flue and repair or replace if necessary. no: ↓3.

yes: ↓5.

no:

B Press buttons and simultaneously. B Select Service Function 5.5 . B Increase min. output.

yes: B Repair or replace components.

B Grease seal before fitting. B Make sure it is fitted in correct position.

no: ↓6.

6. B Measure CO2 levels.

CO2 levels in flue gas at min and max output do not match figures

specified in installation instructions.

yes: B Adjust CO2 level as per installation instructions.

no: B Turn off gas cock.

B Power OFF the appliance. B Change the gas valve. B Open the gas cock. B Turn ON the appliance. B Check appliance for leaks.

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Excessive burner noise, rumbling noises

Check Action

Failure identification procedure

B Press buttons and simulta-

B Set to 1 for high start-up speed.

neously.

B Select service-function 5.9.

0 is displayed.

Flue gas levels incorrect, CO level too high

Check Action

1. Does the gas supply type match the

yes: ↓2.

specifications on the appliance identification plate?

no: B Convert appliance to correct gas type.

↓2.

2. B Test gas supply pressure - OK? yes: ↓3.

no: B Decommission appliance.

B Notify gas company.

3. Problem with flue? B Check CO2 level in combustion

yes: B Check flue and repair or replace if necessary. no: ↓4.

air. Is CO

level above 0,2 % ?

4. Flue gas CO

levels measured at

yes: B Adjust CO2 levels.

min. and max. load do not match specified levels?

no: ↓5.

B Measure CO2 levels.

5. Gas volumetric flow too high when CO2 level correctly set.

yes: B Reduce gas volumetric flow rate by means of

adjusting screw on gas valve and/or gas flow restrictor.

B Check CO2 adjustment.

no: ↓6.

6. B Turn off gas cock.

B Power OFF the appliance. B Change the gas valve. B Open the gas cock. B Turn ON the appliance. B Check appliance for leaks.

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Failure identification procedure

Ignition too harsh, ignition poor

Check Action

B Note the setting of the temperature controls

and .

B Press buttons and simulta-

neously.

B Select service-function 5.1.

Continuous ignition (without gas) OK?

2. Ignition lead connected to ignition electrodes?

3. Ignition cable connector engaged in switchbox?

yes: ↓6. no: ↓2.

yes: ↓3.

no: B Connect cable to ignition electrodes.

B Press button .

Ignition poor? ↓3.

yes: ↓4.

no: B Power OFF the appliance.

B Engage ignition cable connector in switchbox. B Turn ON the appliance.

B Press button .

Ignition poor? B Power OFF the appliance.

↓4.

4. Is the ignition electrical wire damaged?

5. Electrode assembly defective?

B Power OFF the appliance. B Remove electrode assembly.

Electrodes worn out?

yes: B Power OFF the appliance.

B Change the ignition electrical wire. B Turn ON the appliance.

B Press button .

Ignition poor? B Power OFF the appliance.

↓5.

no: ↓5.

yes: B Replace electrode assembly.

B Turn ON the appliance. B Press , restart the appliance.

Ignition poor? ↓6.

no: B Refit electrode assembly.

B Turn ON the appliance. B Press , restart the appliance.

Ignition poor? ↓6.

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Ignition too harsh, ignition poor

Check Action

Failure identification procedure

6. Does the gas supply type match the

yes: ↓7.

specifications on the appliance identification plate?

no: B Carry out gas type conversion as described in

7. B Test gas supply pressure - OK? yes: ↓8.

no: B Decommission appliance.

B Notify gas company.

8. Problem with flue? B Check CO2 level in combustion

yes: B Check flue and repair or replace if necessary.

↓9.

air. Is CO2 level above 0,2 % ?

9. Flue gas CO2 levels measured at

no: ↓9.

yes: B Adjust CO2 level as per installation instructions.

min. and max. load do not match specified levels.

no: ↓10.

B Measure CO2 levels.

10. Burner not correctly fitted or defective?

B Replace burner and seal if necessary. B Ensure seal is fitted in correct position.

B Remove burner.

Cover fixings not tight or seal defective or not correctly fitted or burner defective!

installation instructions.

To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

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Failure identification procedure

Loose or broken contact on heat store NTC sensor

Check Action

1. Heat store NTC sensor lead is not fitted as described in the installation instructions (i.e. the cable does not pass through the cable grip in the

B Record condition of appliance as found in cus-

tomer service record.

B Route cable as specified in installation instruc-

tions.

switchbox).

Boiler indicates P1, P2, P3 at start-up and then restarts with P1..

Check Action

1. Fuse T 1,6 A (312) defective. yes: B Turn ON the appliance.

B Change the fuse. B Power OFF the appliance.

Start sequence not completed? ↓2.

no: ↓2.

2. The PCB control board is damaged. B Make a note of the altered service settings (see

table 1, "First Service Level; Values that can be modified" at page 8 and table 5, "Secondary Service Level; Values that can be modified" at page 11).

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Specified CH flow temperature from TA... programmer exceeded

Check Action

B Note the setting of the temperature controls

and .

If outside-temperature controlled programmer (TA...) is connected to boiler:

• The anti-cycle time is adjusted by the programmer to the suit the system.

• The factory setting for the anti-cycle time (3 min.) and the heating mode hysteresis setting, if applicable, are deactivated.

• In cyclic mode, the switching of the boiler on or off is subject to a time delay in order to prevent divergence 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 temperature is reached even though a lower CH flow temperature has been specified.

Failure identification procedure

B Press button . B Select service-function 2.7.

B Disable automatic anti-cycle time, i.e. change

setting to 0.

Read off status of automatic anticycle time (0 = Disabled, 1 = Enabled).

2. B Select service-function 2.4. Read off anti-cycle time setting

B Set anti-cycle time as required, e.g. factory set-

ting 3 min.

(0 ... 15 min).

To return to normal function mode:

B Press buttons and simultaneously. B Regulate the temperature control and the

temperature control on the previously set positions.

Hot water has unpleasant odour or is dark colour

Check Action

This is generally caused by the formation of hydrogen sulphide by sulphate-reducing bacteria. Such bacteria are found in water which is very low in oxygen and live off the hydrogen produced by the anode.

1. B Clean the hot water cylinder.

B Replace the sacrificial anode. B Heat cylinder to a temperature ≥60˚C

2. B Replace magnesium sacrificial anode with impressed-current anode. The conversion costs are payable by the operator!

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Failure identification procedure

Condensation in the flue pipe

Check Action

1. Is diaphragm in mixer unit fitted correctly (see installation instructions)?

B Open mixer unit (29).

B Fit diaphragm as per installation instructions or

replace.

B Close mixer unit.

B Check diaphragm for correct ori-

entation, soiling and splitting.

3.4.2 Programmer faults

Set room temperature not reached (TR 2 and TR 212 E)

Check Action

1. Thermostatic valve(s) set too low? yes: B Turn up thermostatic valve(s).

↓2.

no: ↓2.

2. CH flow temperature control on

yes: B Turn up CH flow temperature control.

boiler set too low?

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 Select Service Function 7.3 .

Select 1 (on, automatically deactivated) and confirm.

B Vent appliance. B Vent radiators. B Turn ON the appliance.

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Failure identification procedure

Set room temperature not reached (TA 211 E und DT 2)

Check Action

1. Thermostatic valve(s) set too low? yes: B Turn up thermostatic valve(s).

↓2.

no: ↓2.

2. Heating characteristic set too low? yes: B Correct heating characteristic.

↓3.

no: ↓3.

3. CH flow temperature control on

yes: B Turn up CH flow temperature control.

boiler set too low?

↓4.

no: ↓4.

4. Is heat store temperature unreacha-

yes: B Turn up CH flow temperature control. ble (CH flow temperature control set too low)?

↓5.

no: ↓5.

5. 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 Select Service Function 7.3 .

Select 1 (on, automatically deactivated) and confirm.

B Vent appliance B Vent radiators. B Turn ON the appliance.

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Failure identification procedure

Set room temperature exceeded by large amount

Check Action

1. Do radiators get too hot? yes: TR 2:

B Decrease setting of “Heating” control

TA 211 E: B Correct heating characteristic.

↓2.

no: ↓2.

2. Bad choice of location for programmer, e.g. outside wall, near window, in draught, on hollow wall, etc.

yes: B Select better installation location.

-or-

B Fit external room thermostat.

↓3.

no: ↓3.

3. B Turn down thermostatic valve(s).

Excessive fluctuations in room temperature (TA 211 E)

Check Action

1. Periodic effect of external heat on

yes: B Eliminate external heat sources if possible. room, e.g. from sunshine, lighting, TV, separate stove, fire, etc.

↓2.

no: ↓2.

2. Bad choice of location for programmer, e.g. outside wall, 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 yes: B Set economy temperature lower .

or B Set to Frost Protection instead of Economy. or B Set start time for Frost protection/Economy

earlier.

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Temperature rises instead of falling

Check Action

Timer clock (DT 2) incorrectly set B Check setting and correct as necessary.

Incorrect or no modulation

Check Action

Programmer incorrectly wired B Check wiring against wiring diagram and correct

Failure identification procedure

as necessary.

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Appendix

4 Appendix

4.1 NTC values

4.1.1 Outside temperature sensor

Outside temperature (˚C) Measurement tolerance ±±±±10% Resistance (ΩΩΩΩ)

-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 11

4.1.2 CH flow NTC sensor, heat store NTC sensor, constant hot water NTC sensor and hot water NTC sensor

Temperature (˚C) Measurement tolerance ±±±±10% Resistance (ΩΩΩΩ)

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 12

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4.2 Electronic schemes

364

4.1

o - orange g - green bl - black r - red p - purple

365

317

366

367

ECO

363

Appendix

25 V

153

230V/AC

135

302

230 V

328

NLs

136

151

328.1

mains supply

4.1 Ignition transformer 6 Heat exchanger overheat cut-out

6.1 Flue gas NTC sensor

6.3 Hot water sensor 18 Central heating pump 32 Flame sensing electrode 33 Spark electrodes 36 Temperature sensor in CH flow 52 Safety gas valve 1

52.1 Safety gas valve 2 56 CE 428 gas valve 61 Reset button 84 Motor (ZWB/ZB) 96 Microswitch, water switch (ZWB) 135 Main power switch 136 Heating outlet temperature potentiometer 151 Fuse T 2,5 A, 230 V AC 153 Transformer 161 Bridge 226 Fan 300 Code key 302 Ground electrical connection 310 Sanitary outlet temperature potentiometer 312 Fuse T 1,6 A, 24 V DC 313 Fuse T 0,5 A, 5 V DC 314 Strip connector for TA 211 E fitted programmer 315 Terminal block for programmer 317 Digital display 318 Internal programmable clock connection 328 230 V AC connection

310

226

313

312

315

1247

300

161

314

328.1 Bridge 363 Flame presence led 364 Electrical power led (0/I) 365 Chimney cleaner button 366 Technique service button 367 ECO button

52.1

318

p p

g g

r r

bl bl bl bl

6 720 610 576-08.2O

6.1

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Appendix

4.3 List of most important replacement parts

Component Order no. Remarks

Switchbox

PCB control board

Transformer 8 747 201 358

Ignition lead 8 714 401 999

20-pin connector lead assembly

Fuse 1 904 552 730 T 0,5 A

Fuse 1 904 552 740 T 1,6 A

Fuse 1 904 521 342 T 2,5 A

Set of fuses 8 744 503 010

Switchbox kpl. 8 717 207 514 with DT 2

8 748 300 385

8 714 402 087 ZB...

8 714 402 086 ZWB...

Component Order no. Remarks

Temperature sensor, CH flow

Electrode assembly

Gas valve

Gas valve 8 747 003 516 CE 427

Other components

Fan 8 717 204 343

Gas supply pipe 8 710 725 500

Plate-type heat exchanger

Overflow trap 8 710 725 328

Diaphragm in the mixer unit

Table 13

8 714 500 087 NTC

8 718 107 077

8 715 406 651 ZWB...

8 715 505 801

Switchbox kpl. 8 717 207 513 without DT 2

Code plug included in

Conversion kit G20 -> G31

Conversion kit G31 -> G20

Conversion kit G20 -> G31

Conversion kit G31 -> G20

Conversion kit G20 -> G31

Conversion kit G31 -> G20

Conversion kit G20 -> G31

Conversion kit G31 -> G20

7 710 149 048 ZWB

7/11-29 A

7 710 239 084 ZWB

7/11-29 A

7 710 149 049 ZB

7/11-28 A

7 710 239 085 ZB

7/11-28 A

7 710 149 044 ZWB

7/11-27 A

7 710 239 080 ZWB

7/11-27 A

7 710 149 045 ZB

7/11-27 A

7 710 239 081 ZB

7/11-27 A

Heat exchanger

Temperature limiter

Table 13

8 729 000 144 110˚C

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Appendix

4.4 Approved corrosion inhibitors and anti-freeze fluids for central heating water

If any system water treatment is required then only products suitable for use with Aluminium shall be used i.e Fernox- Copal or Superconcentrate or Sentinal X100, in accordance with the manufacturers instructions. The use of any other substances will invalidate the guarantee. The pH value of the system water must be less than 8 or the appliance guarantee will be invalidated.

4.4.1 Frost protection

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, Fernox Tel.: 01799 550811 and Salamander Tel.: 0121 378 0952.

4.4.2 Sealing agents

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.

4.5 Summary of BDH Information Sheet on Identifying Corrosion by CFCs

The presence of halogenated hydrocarbons in the combustion air causes surface corrosion on affected metals. Particularly susceptible is the combustion chamber and the heat exchanger surfaces (including stainless steel) as well as the metal components in the flue socket, flue pipe connections and in the chimney.

The halogen compounds present in the combustion air produce highly corrosive hydrochloric acid in the flame and in some cases - depending on the precise composition of the combustion air - hydrofluoric acid, both of which accumulate in the boiler and remain active over long periods.

In order to limit the damage, the source of the air contamination must be located and sealed off. If this is not possible, the combustion air must be drawn from an alternative clean source.

Halogens can occur in the following locations:

Commercial and industrial sources

Dry cleaners Trichloroethylene, tetrachlo-

roethylene, fluorinated hydrocarbons

Degreasing baths Perchloroethylene, trichlo-

roethylene, methyl chloroform

Printers Trichloroethylene

Hairdressers Aerosol spray propellants,

hydrocarbons containing fluorine and chlorine (freons)

Sources in the home

Cleaning and degreasing agents

Home workshops

Solvents and thinners

Spray cans Chlorofluorohydrocarbons

Table 14

Perchloroethylene, methyl chloroform, trichloroethylene, methylene chloride, carbon tetrachloride, hydrochloric acid

Various chlorinated hydrocarbons

(freons)

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