Worcester ZWBR 7-30 R 30 HE PLUS COMBI Installation and operation manual

Supplied By www.heating spares.co Tel. [phone]
Service booklet for the Engineer
for Gas Condensing Boilers
6 720 611 400-00.1O
ZWBR 7-30 R 30 HE plus combi GC-Number: 41 311 79
ZWBR 11-35 R 35 HE plus combi GC-Number: 41 311 80
ZWBR 11-40 R 40 HE plus combi GC-Number: 41 311 81
ZSBR 7-30 RD 430i system GC-Number: 41 108 06
ZWBR 7-32 RD 532i combi GC-Number: 41 108 10
ZWBR 11-37 RD 537i combi GC-Number: 41 108 11
ZWBR 11-42 RD 542i combi GC-Number: 41 108 12
7 181 465 347 (05.01) OSW

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2
Contents
Contents
Safety precautions 3
Symbols 3
1 Layout of Appliance 4
2Operation 5
2.1 Initialisation 5
2.2 Standard display 5
2.3 Displaying service functions 5
2.4 Setting service functions 6
2.5 Resetting service functions to factory
settings 6
2.5.1 Resetting service functions 0.0 to 4.9 to
their factory settings (Reset 1): 6
2.5.2 Resetting service functions 0.0 to 9.9 to
the factory setting (Reset 2): 6
3 Boiler service functions 7
3.1 Summary 7
3.2 Explanation of service functions 10
4 Rectifying faults 15
4.1 Indication of faults 15
4.1.1 ... on the boiler 15
4.2 Summary 15
4.2.1 Appliance faults 15
4.2.2 Faults that are not displayed 16
4.3 Notes on using the fault code tables 17
4.4 Error codes on the display 18
4.5 Faults that are not displayed 36
4.5.1 Appliance faults 36
4.5.2 Programmer faults 43
5 Replacement of Parts 46
5.1 PCB control board and transformer 46
5.2 Fan Assembly 47
5.3 Primary Heat exchanger/Burner 47
5.4 Pump 48
5.5 Clean condensation trap 48
5.6 Motor of 3-way diverter valve (Fig. 14) 48
5.7 3-way diverter valve 49
5.8 Domestic Hot Water Heat Exchanger 49
5.9 Electrode assembly 49
6Appendix 50
6.1 NTC values 50
6.1.1 Flue sensor 50
6.1.2 Outside temperature sensor 50
6.1.3 CH flow NTC sensor, DHW cylinder NTC
sensor 1 and hot water NTC sensor 50
6.2 Electrical wiring diagram 51
6.3 Approved corrosion inhibitors and
anti-freeze fluids for central heating water 52
6.4 List of Code plugs used with
this appliance 52
6.5 Summary of BDH Information Sheet on
Identifying Corrosion by CFCs 53

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Safety precautions
3
Safety precautions
Repairs
B Repairs may only be carried out by an approved
installer!
B Before carrying out any work on the appliance,
switch it off at the master switch!
B Even when the appliance is switched off at the mas-
ter switch, some components on the pcb inside the
control box are still live.
Therefore:
B 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)!
B Flue ducting must not be modified in any way.
B Use only original spare parts!
Instructions to the customer
B Advise the customer that he/she must not make any
modifications to the appliance or carry out any
repairs on it.
B Draw attention to the need for an annual service (or
maintenance contract if applicable).
Symbols
Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
• Caution indicates that minor damage to property
could result.
• Warning indicates that minor personal injury or seri-
ous damage to property could result.
• Danger indicates that serious personal injury could
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.
Safety instructions in this document
are identified by a warning-triangle sym-
bol and are printed on a grey back-
ground.
i
Notes are identified by the symbol shown
on the left. They are bordered by horizon-
tal lines above and below the text.

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Layout of Appliance
1 Layout of Appliance
Fig. 1
4 Bosch Heatronic
6 Temperature limiter for heat exchanger
6.1 Hot water NTC sensor (combi boiler)
7 Testing point for gas supply pressure
8.1 Pressure gauge
9 Flue gas temperature limiter
15 Relief valve
18 Pump
20 Expansion vessel
27 Automatic air vent
29 Air gas Mixer unit
32.1 Electrode assembly
36 Temperature sensor in CH flow
43 CH flow
63 Adjustable gas flow restrictor
64 Adjusting screw for min. gas inlet flow volume
88 3-way valve
98 DHW flow switch (combi)
102 Inspection window
120 Fixing points
221.1 Flue duct
221.2 Combustion air intake
226 Fan
271 Flue duct
295 Appliance type sticker
355 Plate-type domestic hot water heat exchanger (combi boiler)
358 Condensate trap
396 Condensation trap hose
400 Text display
415 Cover plate for cleaning access
416 Condensate collector
418 Data plate
423 Siphon
7 181 465 347-02.2O
29
98
102
226
271
416
20
43
9
63
358
64
7
355
6.1
4
415
6
36
32.1
295
8.1
18
27
88
15
120
418
400
396
423
221.2
2
221.1

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Operation
5
2 Operation
Instructions on the use of the text display module are
given in the operating and installation instructions for
the boiler.
Fig. 2 Controls
a Display
b “Up”/“More” button
c “Down”/“Less” button
d “Back” button
e “Next” button
f “Delete” button
2.1 Initialisation
When the appliance is switched on it performs a self-
test which takes about 5 seconds. While the self-test is
in progress, the text display shows Please wait... Ini-
tialising and the two-digit display shows the following
sequence of codes which appear for varying lengths of
time:
( P0 ,)
1)
P2 , P3 , P4 , P6
On completion of the test sequence the appliance is
ready for operation.
2.2 Standard display
The text display shows the time, the CH flow tempera-
ture and the room temperature of TR2 location (if fitted).
In addition, the 2-digit display also shows the current
CH flow temperature in Heating mode and Hot Water
mode (display range 00˚C to 99˚C).
2.3 Displaying service functions
B Press any button to activate the main menu.
B Press or button until the arrow cursor is
pointing to Settings .
B Press the button.
B Press or button until the arrow cursor is
pointing to Service .
B Press the button.
B Press button to select Display service
param.
Service function 0.0 Last fault is displayed.
B Press or button to cycle through the
current settings.
B Press button to exit the menu.
1) only for PCBs produced after 08/2004
c
b
a
fed
C
6 720 610 337-08.1R

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Operation
2.4 Setting service functions
B Press any button to activate the main menu.
B Press or button until the arrow cursor is
pointing to Settings .
B Press the button.
B Press or button until the arrow cursor is
pointing to Service .
B Press the button.
The cursor is pointing to Display service param.
B Press and hold the button (for about 5 sec-
onds) until the display shows Adjust service
parameters and the first service function to be set,
e. g. 2.0 Operating mode. If a fault has occurred,
the display will show 0.0 and the last fault.
BPress or button until the desired service
function is displayed.
BPress the button.
The first line of the display shows Change value,
the second line shows the value that can be
changed.
BUse the and buttons to enter the
required setting.
BPress the button.
The text display shows
A T T E N T I O N
Store settings ?
BPress or to select yes or no.
BPress to confirm your selection.
The text display shows Please wait..., and the serv-
ice function is then displayed with the new setting.
BPress the or button until the next func-
tion you wish to change is displayed.
-or-
BPress button to exit the menu.
2.5 Resetting service functions to fac-
tory settings
2.5.1 Resetting service functions 0.0 to 4.9 to
their factory settings (Reset 1):
BPower OFF the appliance.
BPress the button and keep it pressed.
BSwitch on the appliance, press and hold the but-
ton until the
display shows r1 followed by [ ] .
2.5.2 Resetting service functions 0.0 to 9.9 to
the factory setting (Reset 2):
BPower OFF the appliance.
BSimultaneously press and hold buttons and .
BSwitch on appliance, press and hold the and
buttons until the display shows r2 followed by [ ].
iTo reset all parameters (except service
settings) set on the text display module):
BPress and hold the button until the
settings are deleted.
C

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Boiler service functions
7
3 Boiler service functions
3.1 Summary
Text display message Display
Range adjustable
from - to Reset Value
0.0 Last fault 00 - FF last fault code can be
deleted 0
0.1 Flow temp. sensor 0 - 99˚C - -
0.2 Hot water temp. sensor 0 - 99˚C - -
0.3 Stor. tank temp.sensor1
(system boiler) 0 - 99˚C - -
0.4 Stor. tank temp.sensor2
(not applicable) -- -
1.2 Code plug 8714411 XXX 0 - 255 - -
1.4 Voltage at terminal 2
(not applicable) -- -
1.5 Required flow temp.
(for CH) 0 - 99˚C - -
1.8 Power set by module
(not applicable) -- -
1.9 Module detection (not applicable) - - -
2.0 Operating mode - normal
Min
Max
normal
2.2 Pump switch mode - 1 - 3 3
2.3 Stor. tank charge outp. - 0 - 100% 100 %
2.4 Anti-cycle mode - 0 - 15 min 3 min
2.5 Max. flow temperature - 35 - 88˚C 88˚C
2.6 Switch.diff.flow temp. - 0 - 30˚C 0,0 K
2.7 Autom. anti-cycle mode
(not applicable) -on off on
2.9 Actual output 0 - 100 % - -
3.0 Fan speed 0 - 255 Hz - -
3.3 Ionisation current no
low
middle
high
--
Table 1

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Boiler service functions
3.4 Pump mode (not applicable) - - -
3.5 Pump blocking time
(not applicable) -0- 240 s in 15-s increments 0 s
3.6 Software version BF 11.XX - -
3.9 Link 8-9 open
closed --
Link Ls-Lr open
closed --
4.0 Stor. tank. therm. (7-9)
(system boiler) blocked heat demand --
4.1 Room therm. LSM/LSM release
(not applicable) -- -
4.2 Timer ch. 1 (heating) blocked
heat demand --
Timer ch. 2 (hot wat.) blocked
heat demand --
4.4 Heat demand (heating) yes
no --
Heat demand (stor. tank)
(system boiler) yes no --
4.5 Heat demand (hot water). yes
no --
Keep hot period yes
no --
4.6 Internal regulator blocked
heat demand --
5.0 Max. output (heating) - 27 - 100% 100 %
5.1 Permanent ignition - no
yes no
5.2 GFA status/error (not applicable) - - -
5.5 Min. output (not applicable) - 27 - 100 % depends on boiler type
6.0 Starting load - 1 - 5 3
6.6 Thermostore satisfied
(not applicable) -- -
Text display message Display
Range adjustable
from - to Reset Value
Table 1

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Boiler service functions
9
6.7 Pump off (hot water)
(not applicable) - off on on
6.8 Cycle time (hot water)
(combi only) - 20 - 60 min 20 min
6.9 Duration (hot water)
(combi/system) -0- 30 min 1 min
7.0 Pump map (heating) - 0 Pump step adjustable
1 Const. pressure high
2 Const. pressure
middle
3 Const. pressure low
4 Prop.pressure high
5 Prop.pressure low
3 Const. pressure low
7.1 Map pump step (heat.) - 2 - 7 7
7.2 Antiblock. map pump. - off
on on
7.3 Air purge mode
(burner keeps off while air purge
mode is on)
- off
on autom. deactivat.
permanent on
off
7.4 Actual map pump step 2 - 7 - -
7.5 Map pump load index 0 - 255 - -
7.6 Map pump type 0 - 99
(0 = no
map pump
detected)
--
7.7 Output reduction - off
only in heating mode
only in hot wat. mode
in heat./hot wat. mode
in heat./hot wat. mode
8.5 Siphonfillprogram - on, boiler min.output,
on, adjust. min. output,
off
on, adjust. min. output
9.1 Min. fan overrun - 10 - 600 sec 30 sec
9.2 Hot water on demand - off
on on
9.3 GFA-Asic-error (not applicable)
Text display message Display
Range adjustable
from - to Reset Value
Table 1

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Boiler service functions
3.2 Explanation of service functions
0.0 Last fault
The last fault can also be recalled for servicing pur-
poses when the appliance is functioning correctly.
To delete the stored fault:
BDelete fault (no fault displayed).
BPress the button.
BUse the button to select yes.
BPress the button.
If a list of the last 10 indicated faults is required for serv-
icing purposes, look under Settings -> Service ->
Further options -> Fault history.
0.1 Flow NTC
The temperature measured by the NTC sensor on the
CH flow pipe is indicated.
0.2 Hot water NTC
The temperature measured by the NTC sensor on the
plate-type heat exchanger outflow is indicated.
0.3 Stor. tank temp.sensor 1 (system boiler only)
Indirectly heated DHW cylinder:
The temperature measured by NTC sensor 1 on the
DHW cylinder is indicated.
0.4 Stor. tank temp.sensor 2
(not applicable)
1.2 Code plug
The 10-digit part number of the code plug is indicated.
The code plug determines the appliance functions. If
the appliance is converted from natural gas to LPG or
vice versa (using conversion kit) the code plug also has
to be changed.
1.4 Voltage at terminal 2
(not applicable)
1.5 Desired flow temp.
The CH flow temperature is displayed.
1.8 Power set by module
(not applicable)
1.9 Module detection
(not applicable)
2.0 Operating mode
There are 3 operating modes to choose from.
•Normal mode: the appliance operates according to
the commands received from the programmer.
•Min mode: the appliance runs constantly at mini-
mum output.
The text display shows MIn mode. The 2-digit dis-
play alternates between the CH flow temperature
and – – .
•Max mode: the appliance runs constantly at maxi-
mum output.
The text display shows Max mode. The 2-digit dis-
play alternates between the CH flow temperature
and – –.
2.2 Pump switch mode
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 ther-
mostat 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 oper-
ates only for hot water mode.
2.3 Stor. tank charge output (system boiler only)
The DHW cylinder charging output can be set to any
level between the minimum and maximum rated heat
output for hot water according to the heat transfer
capacity of the DHW cylinder.
BEnter the DHW cylinder charging output setting on
the commissioning record enclosed with the appli-
ance.
2.4 Anti-cycle mode
This function is only active if service function 2.7
Autom. anti-cycle mode is disabled.
The anti-cycle time is factory set to 3 minutes.
The shortest possible anti-cycle time is 1 minute (rec-
ommended for single-pipe and hot-air heating systems).
If the setting 0 is entered, the anti-cycle time is inactive.
BEnter the anti-cycle time on the commissioning
record enclosed with the appliance.
iIf an outside temperature driven control
unit is connected, pump control mode 3 is
automatically activated.

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Boiler service functions
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2.5 Max. flow temperature
The maximum CH flow temperature can be set to
between 35˚C and 88˚C (factory setting). Even if the
CH flow temperature control is set higher, the setting
entered for 2.5 Max. flow temperatureis not
exceeded.
2.6 Switch diff. flow NTC
The switching difference is the permissible differential
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 45˚C.
BDisable anti-cycle time (setting 0. of service
function 2.4).
BThe switching difference setting should be entered
on the commissioning record supplied with the appli-
ance.
2.7 Autom. anti-cycle mode
With the textdisplay connected to the appliance, the
anti-cycle time is adjusted automatically. With service
funktion 2.7 automatic adjustment of the anti-cycle time
can be disabled. This may be necessary in the case of
unfavourably dimensioned heating systems.
If automatic adjustment of the anti-cycle time is disa-
bled, the length of the anti-cycle time must be set under
service function 2.4 Anti-cycle mode.
BIf automatic adjustment of the anti-cycle time has
been disabled, this should be entered on the com-
missioning record enclosed with the appliance.
2.9 Actual output
The actual output of the appliance at the time viewed is
displayed.
3.0 Fan speed
The current fan speed is displayed in Hertz (Hz).
3.3 Ionisation current
The burner flame is monitored by measuring the ionisa-
tion current generated during combustion. If no ionisa-
tion current is detected, the gas valve shuts off. This
ensures that unburned gas does not escape.
3.4 Pump mode (system boiler only)
(not applicable)
3.5 Pump blocking time
(not applicable)
3.6 Software version
The version number of the software is displayed.
3.9 Link 8-9 /
3.9 Link Ls-Lr
When supplied, the appliance has a link fitted across
terminals 8-9 (= Heat demand). If that connection is
opened (e.g. by a limiter for an underfloor heating sys-
tem), heating mode is disabled.
When supplied, the appliance has a link fitted across
terminals Ls-Lr (= Heat demand). If that connection is
opened (e. g. by an external 2-point programmer), heat-
ing mode is disabled.
4.0 Stor. tank therm. (7-9) (system)
When supplied, the appliance has no link across termi-
nals 7- 9 (= Disabled). If that connection is closed (e. g.
by a DHW cylinder thermostat) DHW cylinder charging
is enabled.
4.1 Room therm. LSM/LSM release
(not applicable)
4.2 Timer ch. 1 (heating) /
4.2 Timer ch. 2 (hot water)
Shows the status of channel 1 of the timer integrated in
the text display.
If that channel’s status is “Heat demand”, heating mode
will be activated according to the programmer com-
mands.
Shows the status of channel 2 of the timer integrated in
the text display.
If that channel’s status is “Heat demand”, hot water
mode will be activated according to the programmer
commands.
4.4 Heat demand (heating) /
4.4 Heat demand (stor. tank) (system only)
Heat demand (heating) shows the heat demand status
for the central heating system.
If this channel’s status is “Heat demand”, heating mode
will be activated according to the programmer com-
mands.
Heat demand shows the heat demand status for charg-
ing the DHW cylinder.
If this channel’s status is “Heat demand”, the DHW cyl-
inder will be charged according to the commands from
the DHW cylinder thermostat or NTC sensor.
4.5 Heat demand (hot water) /
4.5 DHW pre-heat activated (combi only)
Heat demand (hot water) shows the heat demand sta-
tus for the hot water function.
If this channel’s status is “Heat demand”, the hot water
function operates according to the commands from the
hot water NTC sensor.
Keep hot period shows the constant hot water circuit
status of the heat exchanger (ECO or Comfort mode).
If this channel’s status is “Heat demand”, Comfort
mode is active. If the status is “Disabled”, ECO mode
with demand detection is active.
iNote: 1K =
^1 ˚C.

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Boiler service functions
4.6 Internal regulator
The boiler has an internal anti-cycle function which pre-
vents the burner overheating if the heat output can not
be dissipated even in Min mode. The appliance will then
switch off even when the system is calling for heat.
It will subsequently switch on again
• after 5 seconds in hot water mode,
• after 30 seconds in DHW cylinder charging mode,
•after between 25 and 60 minutes (depending on the
setting of Service Function 6.8 Cycle time (hot
water)) in response to a call for heat for maintaining
cylinder temperature,
•after 0 to 15 minutes in heating mode (depending on
the setting for service function 2.4 Anti-cycle
mode).
The anti-cycle function is cancelled by another demand
for heat.
If the anti-cycle function is to be switched off manually:
Bswitching the appliance off and on again at the mas-
ter switch.
Bactivating Min or Max mode.
Bbriefly switching to summer mode on the tempera-
ture control for CH flow .
5.0 Max. output (heating)
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 factory setting is maximum rated output – display
shows „100 %“ .
5.1 Permanent ignition
This function allows permanent ignition without gas
supply to be activated for the purposes of checking the
ignition mechanism.
5.2 GFA status/error
(not applicable)
5.5 Min. output
(not applicable)
6.0 Starting load
The start speed of the combustion air fan can be
increased, where problems with excessive flue lengths
may interfere with ignition. Areas with variable wind
conditions may also benefit from this facility.
6.6 Thermostore satisfied
(not applicable)
6.7 Pump off (hot water)
(not applicable)
6.8 Cycle time (hot water) (combi only)
The appliance is supplied with the pre-heat cycle time
set to 20 minutes.
After pre-heating or a DHW demand, this function will
stipulate the period of time before the next permissible
pre-heat. This will prevent excessive pre-heat cycling.
6.9 Duration (hot water) (combi/system)
The appliance is supplied with the hot water duration
set to 1 minute.
The hot water duration specifies how long after hot
water is drawn heating mode remains disabled.
7.0 Pump map (heating)
The appliance is supplied with this function set to 3
Const. pressure low (see pump characteristics
below).
The pump map indicates how the pump is controlled in
heating mode. The pump switches between the various
pump speeds so as to reproduce the characteristic
curve selected.
Changing the pump characteristic can be helpful if a
lower pressure difference will guarantee the necessary
circulation on the basis of the system dimensions and
pump characteristic.
The pump map can be selected within:
•0 Pump step adjustable, see service function
7.1
Map pump step (heat.)
•1 Const. pressure high
•2 Const. pressure middle
•33
33 Const. pressure low
•4 Prop. pressure high
•5 Prop. pressure low.
iEven if the heating output is limited, the
full rated heat output remains available for
hot water or DHW cylinder charging.
iDo not run for more than 2 minutes!
iIn order to save as much energy as possi-
ble and to minimise the possibility of water
circulation noise, a low characteristic
should be chosen.

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Boiler service functions
13
The factory setting is:
7.0 Pump map (heating) 3 Const. pressure low
Fig. 3 Constant pressure
1-5 Caracteristics
HPressure
QWater circulation rate
Fig. 4 Proportional pressure
If this parameter is set to Pump step adjustable then
the pump speed set under function 7.1 Map pump
step (heat.) is active.
7.1 Map pump step (heat.)
This service function corresponds to the pump speed
switch used on conventional heating pumps.
However, the setting is only active if function 7.0 Pump
map (heating), is set to Pump step adjustable.
The factory setting is:
7.1 Map pump step (heat.) 7
Fig. 5 Caracteristics
2-7 Caracteristics
HPressure
QWater circulation rate
7.2 Antiblock. map pump
The appliance is supplied with this function activated.
If the pump threatens to jam, an oscillating pump action
is activated. Afterwards, the required operating mode is
continued.
200 400 600 800 1200 14001000 1600
0
0,6
0,5
0,4
0,3
0,2
0,1
0
(bar)
H
Q
(l/h)
6 720 610 587-43.1O
12
3
200 400 600 800 1200 14001000 1600
0
0,6
0,5
0,4
0,3
0,2
0,1
0
(bar)
H
Q
(l/h)
6 720 610 587-44.1
O
45
200 400 600 800 1200 14001000 1600
0
0,6
0,5
0,4
0,3
0,2
0,1
0
(bar)
H
Q
(l/h)
3
24567
6 720 610 587-45.1
O

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Boiler service functions
7.3 Air purge mode
The first time the appliance is switched on, a once-only
venting function is activated. The heating pump then
switches on and off at intervals. This sequence lasts
about 8 minutes.
The text display shows 7.3 Air purge mode and the
2-digit display shows 00 in alternation with the CH flow
temperature.
The automatic (27) vent must be opened and then
closed again once the venting sequence is complete.
• If the venting function is set to “On, autom. deacti-
vat.”, the function is set to “Off” once the sequence
has been completed.
7.4 Actual map pump step
Actual value of this parameter.
7.5 Map pump load index
Actual value of this parameter.
7.6 Map pump type
Encoded type of installed map pump.
7.7 Output reduction
The appliance is supplied with this function activated. It
prevents overload of the heat exchanger with high CH
flow temperatures.
The output of the burner is reduced according to the
CH flow temperature, i.e. up to 80˚C flow temperature,
full burner output is permitted. Above 80˚C, the burner
output is reduced as flow temperature increases up to
90˚C at which only minimum output is available (even
with maximum heat demand).
This function can be deactivated for hot water and/or
central heating mode.
8.5 Siphon fill program
The trap filling programme ensures that the condensa-
tion trap is filled when the appliance is first installed or
after it has been shut down for a long period: The con-
densation trap prevents flue gas escaping from the
appliance into the room in which it is installed.
The trap filling programme is activated:
• 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.
The next time the heating or hot water system calls for
heat, the appliance is held at minimum output for 15
minutes. The trap filling programme remains active until
the appliance has completed 15 minutes of operation at
minimum output.
The text display shows Siphonfillprogram on,
adjust. min.output and the 2-digit display alternates
between -II- and the CH flow temperature.
9.1 Min fan overrun
Minimal fan overrun time after a boiler demand.
9.2 Hot water on demand
The appliance is supplied with this function activated.
This function relates to ECO mode (the button
lights).
The demand detection function enables maximum gas
and water economy.
Briefly turning a hot water tap on and then off again sig-
nals demand to the appliance which then heats up the
water to the set temperature.
Hot water is then available at short notice.
9.3 GFA-Asic-error
(not applicable)
iThe venting function can be activated
manually after servicing.
If the condensation trap is not filled, flue
gas can escape!
BOnly deactivate the trap filling pro-
gramme in order to carry out servicing
work.
BAlways re-activate trap filling pro-
gramme once servicing is complete.

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Rectifying faults
15
4 Rectifying faults
4.1 Indication of faults
Faults are indicated by a letter code. This helps to iden-
tify and eliminate the cause of the fault quickly and reli-
ably.
4.1.1 ... on the boiler
The text display shows the message Fault EA. Please
call service, for example.At the same time, the fault
code appears on the 2-digit display, in this example:
EA.
You can view an explanatory description of the fault
indicated by going to Settings -> Service -> Display
service parameters , in this example: EA: During
operation: Flame not detected.
The fault codes displayed are grouped into four catego-
ries:
•Category 1:
The appliance is disabled until it has been switched
off and then on again.
•Category 2:
The appliance is disabled until the cause of the fault
has been eliminated.
•Category 3:
The appliance continues to operate with limited func-
tion.
•Category 4:
The appliance is disabled and locked ( flashes)
until the cause of the fault has been eliminated and
the appliance unlocked.
4.2 Summary
4.2.1 Appliance faults
iUnlocking the appliance:
BPress the reset button until the digit
– – appears on the display.
Once the appliance starts up success-
fully, the fault disappears from the text
display.
Appliance faults
Category system boiler combi boiler Page
A1 1 X X 18
A7 3 X X 19
A8 3 X X 20
Ad 3 X X 21
b1 2 X X 22
C1 2 X X 23
d3 2 X X 24
E2 2 X X 25
E9 4 X X 26
EA 4 X X 28
F0 2/4 X X 32
F7 4 X X 33
FA 4 X X 33
FC 3 X X 35
Fd 4 X X 35
Table 2

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Rectifying faults
4.2.2 Faults that are not displayed
Appliance faults
system boiler combi boiler
Page
Boiler indicates P1, P2, P3 at
start-up and then restarts with
P1..
XX 36
Excessive burner noise, rumbling
noises XX 36
Flue gas levels incorrect, CO
level too high XX 38
Ignition too harsh, ignition poor X X 39
Loose or broken contact on
DHW cylinder NTC sensor X 40
Hot water has unpleasant odour
or is dark colour (system boiler) X 41
Text display fails to respond, no
display or display incorrect XX 41
Condensation in the flue pipe X X 41
Inadequate hot water outlet tem-
perature (combi boiler) X 42
Table 3
Programmer faults Page
Set room temperature not reached (TR 2) 43
Set room temperature not reached (inte-
grated text display) 43
Set room temperature exceeded by large
amount (TR 2) 44
Heating up takes too long (integrated text
display) 44
Excessive fluctuations in room temperature
(integrated text display) 45
Room temperature too high in Economy
mode 45
Incorrect or no modulation 45
No programmer display or programmer dis-
play does not react 45
Table 4

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Rectifying faults
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4.3 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.
In this example: check the flue is clear by testing
the CO2level.
• If the appliance is locked ( button is flashing),
press the button.
•If the fault has been rectified, the appliance will then
start up without indicating a fault and the fault isola-
tion 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 proce-
dure.
• If another fault code is displayed, work through the
fault code table for that code.
Fig. 6 Example of fault code table
EAand flashing.
Flame not detected
Check Action
1. Is a burner flame visible? yes: ↓5.
no: ↓2.
2. Is the gas cock turned on? yes: Ø 5.
no: BOpen the gas cock.
BPress button .
EA? ↓3.
3. Has the thermal cut-out on the gas
cock tripped? yes: ...
no: ↓...
4. ... ...
5. ... Problem with flue?
BCheck CO2level in combustion
air.
Is CO2level above 0,2 % ?
yes: Check flue.
no: ↓...
7181465347-01.1O

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Rectifying faults
Error A1
4.4 Error codes on the display
A1flashing.
Controlled-characteristic pump has run dry
Check Action
1. System pressure below 1.2 bar? yes: BPower OFF the appliance.
BCheck appliance and system for water leaks and
repair as necessary.
BFill system, bleed and re-pressurise (see Installa-
tion Instructions).
BTurn ON the appliance.
A1? ↓2.
no: ↓2.
2. Audible bearing damage on pump? yes: BPower OFF the appliance.
BDisconnect the boiler electrical connection.
BDrain appliance.
BChange the pump (see chapter 5.4).
BFill system, bleed and re-pressurise (see Installa-
tion Instructions).
BReconnect the boiler electrical connection.
BTurn ON the appliance.
↓3.
no: ↓3.
3. Activate venting sequence. yes: BActivate menu option Show service parame-
ters.
BSelect 7.3 Air purge mode select setting on,
autom. deactivat. and confirm.
BVent appliance.
BVent radiators.

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Rectifying faults
Error A7
A7flashing.
Water NTC sensor defective
Check Action
1. BActivate menu option Show serv-
ice parameters.
BSelect service function 0.2 Hot
water temp. sensor.
Is a temperature between 0and
5˚C displayed?
yes: DHW temperature limiter connector corroded1),
damaged or dirty?
BChange relative parts.
A7?↓2.
1) For notes, refer to Appendix
no: ↓2.
2. BUnplug 20-pin connector from
PCB.
E2 is displayed.
BCheck resistance from connec-
tions 3 to 4 on the cable side.
Does the value match the ones
described in table 7, page 50?
yes: BMake a note of the altered service function set-
tings (see table 1 on page 7) in order to keep the
altered values.
BPower OFF the appliance.
BDisconnect the boiler electrical connection.
BChange PCB control board.
BReconnect the boiler electrical connection.
BTurn ON the appliance.
BRestore service settings previously noted down.
no: ↓3.
3. BUnplug NTC sensor from cable.
BCheck resistance of NTC sensor.
Does the value match the ones
described in table 7, page 50?
yes: BPower OFF the appliance.
BDisconnect the boiler electrical connection.
BChange the 20-pin connector lead assembly.
BReconnect the boiler electrical connection.
BTurn ON the appliance.
no: BChange NTC sensor.

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Rectifying faults
Error A8
A8flashing.
No correct electrical connection
Check Action
1. BPower OFF the appliance.
BCheck Wiring between Textdis-
play and TR 2:
– Terminal 3 on Textdisplay con-
nected to Terminal 3 TR 2?
– Terminal 4 ...Terminal 4
– Terminal F ...Terminal F?
yes: ↓2.
no: BRewire correctly as specified in the installation
instructions.
BTurn ON the appliance.
After 90 sec.:
A8?
BPower OFF the appliance.
↓2.
2. BCheck continuity on wiring to TR 2.
Is there continuity? yes: ↓3.
no: BReplace or repair wiring and/or connections.
BTurn ON the appliance.
After 90 sec.:
A8?
BPower OFF the appliance.
↓3.
3. BCheck resistance from connections
4 to F and 3 to 4.
Is resistance between XX and XX?
yes: BReplace TR 2.
no: ↓4.
4. The PCB control board is damaged. BMake a note of the altered service function set-
tings (see table 1 on page 7) in order to keep
the altered values.
BPower OFF the appliance.
BDisconnect the boiler electrical connection.
BChange PCB control board.
BReconnect the boiler electrical connection.
BTurn ON the appliance.
BRestore service settings previously noted down.