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.