British Gas ICC2 combi ZWBR 8-30 ICC2 Installation And Servicing Instructions
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British Gas ICC2 combi ZWBR 8-30 ICC2 Installation And Servicing Instructions

Wall mounted condensing boiler for central heating and mains fed domestic hot water
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Installation and Servicing Instructions

ICC2 combi
Wall mounted condensing boiler for central heating and mains
fed domestic hot water
6 720 610 598-00.1O
ZWBR 8-30 ICC2
GC-Number: 41 108 09
ZWBR 11-37 ICC2
GC-Number: 41 108 10

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Summary of Contents for British Gas ICC2 combi ZWBR 8-30 ICC2

  • Page 1: Installation And Servicing Instructions

    Installation and Servicing Instructions ICC2 combi Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 598-00.1O ZWBR 8-30 ICC2 GC-Number: 41 108 09 ZWBR 11-37 ICC2 GC-Number: 41 108 10...

  • Page 2: Table Of Contents

    Contents Contents Hot water 6.6.1 Hot water programme 6.6.2 Hot water immediately i Info Safety precautions Settings 6.8.1 Heating (if TR 2 is connected) 6.8.2 Hot Water (Storage Tank, Symbols ZSBR models only) 6.8.3 Service Individual timer programmes Details of the appliance EC Declaration of Conformity Standard package Individual settings...

  • Page 3: Safety Precautions

    Safety precautions Safety precautions Symbols Safety instructions in this document If you smell gas are identified by a warning-triangle sym- B Turn off gas service cock at the meter. bol and are printed on a grey back- B Open windows and doors. ground.

  • Page 4: Details Of The Appliance

    Details of the appliance Details of the appliance Description of appliance • Wall-mounted appliance, siting not dependent on room size EC Declaration of Conformity • Natural gas models are low-emission appliances This appliance is in accordance with the applicable • Multifunction display requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility •...

  • Page 5: Accessories

    Details of the appliance 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 10 m (ZWBR 11-37) or 13 m (ZWBR 8-30) and vertical flue systems for flue lengths 12 m (ZWBR 11-37) or 15m (ZWBR 8- 30).

  • Page 6: Layout Of Appliance

    Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 6 720 610 597 - 02.1O Fig. 2 Heatronic control Fixing points Heat exchanger safety temperature limiter 221.1 Flue duct Hot water NTC sensor 221.2 Combustion air intake Testing point for gas supply pressure Fan assembly Pressure gauge Appliance type sticker...

  • Page 7: Function

    Details of the appliance Function 234.1 ϑ 29.1 52.1 ϑ 6 720 610 597- 03.2O Fig. 3 Bosch Heatronic control Adjusting screw for min. gas flow volume Temperature limiter, heat exchanger Control valve Hot water NTC sensor Motor Testing point for gas supply pressure 3-way valve Pressure gauge Venturi...

  • Page 8: Electrical Wiring Diagram

    Details of the appliance Electrical wiring diagram o - orange g - green bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 602 - 02.1O Fig.

  • Page 9: Technical Data

    Details of the appliance Technical data ZWBR 8-30 ZWBR 11-30 ZWBR 11-37 ZWBR 14-37 Units Natural gas Propane Natural gas Propane Max. rated heat output net 40/30˚C central heating 32.3 32.3 39.7 39.7 Max. rated heat output net 50/30˚C central heating 31.9 31.9 39.2...

  • Page 10: Installation Regulations

    Installation regulations Condensate analysis, mg/l Domestic water performance Ammonium 1.2 Nickel 0.15 ZWBR ZWBR ≤ 0.01 Mercury ≤ 0.0001 8-30 11-37 Lead ≤ 0.001 Sulphate Cadmium Domestic Tempera- 30 °C 14.6 18.0 Water Flow ture Rise ≤ 0.005 Zinc ≤ 0.015 Chromium Rate l/min ≤...

  • Page 11: Installation

    Installation Installation It is suggested that long pipe runs to taps or showers be insulated to prevent the rapid cooling of the water. All types of single lever mixer taps and thermostatic B Always turn off the gas cock before car- mixer units suitable for a mains pressure of up to 10 bar rying out any work on components can be used.

  • Page 12: Siting The Appliance

    Installation of up to 3 bar and the radiator valves conform to the manufacturers instructions. The use of any other requirements of BS2767:10. substances will invalidate the guarantee. The pH value of the system water must be less than 8 or If Thermostatic Radiator Valves are fitted then it is rec- the appliance guarantee will be invalidated.

  • Page 13: Wall Mounting Frame Assembly

    Installation B Screw the pre-plumbing manifold with two screws to Cupboard/Compartment the wall mounting frame. The appliance can be installed in a cupboard/compart- ment need for airing clothes providing that the require- ments of BS6798 and BS5440:2 are followed. The low casing losses from the appliance eliminate the need for ventilation openings in the compartment.

  • Page 14: Fitting The Appliance

    Condensate Termination and Route External condensate pipework The condensate connection on the British Gas/Bosch All British Gas/Bosch condensing boilers have within a appliances is in 22 mm plastic. The pipe should be syphonic condensate trap. Rather than the condensate extended and run away from the appliance with a con- constantly dripping into the discharge pipe, the con- stant fall of 2.5 °...

  • Page 15: Checking The Connections

    Installation B Lift off the top fixing lugs and slide the case forwards Checking the connections and remove (3). 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.

  • Page 16: Siting The Flue Terminal

    Installation 3.9.1 Siting the Flue Terminal lighting, activated by passive infra-red sensing heads. If the terminal is less than 2 m above a surface to which The flue must be installed in accordance with people have access then a guard must be fitted. The BS 5440:1 and the Building Regulations.

  • Page 17: Installation Of The Flue

    Installation 3.9.2 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 exten- Terminal sion duct assemblies.
  • Page 18 Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp Extension Clamp Duct 6 720 610 602 - 09.1O Fig. 18 Flue with One Extension Terminal Assembly Flue Turret Outer Wall Clamp Clamp Extension Extension Clamp Duct Duct 6 720 610 602 - 10.1O Fig.

  • Page 19: Flue Duct Preparation And Assembly

    Installation 3.9.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 21, 22. Outer Wall Flue Terminal Face Raised Ring locating the terminal relative to the outside wall face 6 720 610 576 - 20.1O NOTE: THE FLUE MUST BE INCLINED T O THE BOILER 6 720 610 602 - 12.1O Fig.

  • Page 20: Electrical Connections

    Electrical connections Electrical connections Connecting the appliance To gain access to the mains connection remove the B Always disconnect the power supply to drop down facia cover. The drop down cover is the appliance at the mains before carry- removed by lowering it to the horizontal position and ing out any work on the electrical sys- pushing firmly upwards at the rear of the supports to tems and components.

  • Page 21: Connecting Tr2 Room Thermostat

    Electrical connections B Cut cable grommet to diameter of cable. Mains Voltage external controls connections NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Ns Ls L Remove Link Motor 230 V R oom Thermostat Connections 230 V Pr ogrammer Connections 230 V r oom thermos t at and Ns Ls L...

  • Page 22: Commissioning

    Commissioning Commissioning 317 366 367 6 720 610 597 - 05.1O Fig. 30 Pressure gauge Commissioning Safety valve Automatic vent Never run the appliance when empty or Reset button unpressurised. Master switch Temperature control for central heating Service cocks on CH flow and return Hot water The operational CO level is set at the fac-...

  • Page 23: Switching The Appliance On/Off

    Commissioning B Before commissioning, the gas supply pres- B Open automatic vent (27) and re-close after venting sure must be checked at the gas supply pres- (page 22). sure test point (see page 6, fig. 2, item 7). Switching off the appliance Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or B Set the master switch to (0).

  • Page 24: Setting The Domestic Hot Water

    Commissioning B To reduce the flow rate (min. 8 l/min): Setting the domestic hot water turn screw on flow switch clockwise (–). temperature and flow rate The outlet temperature will increase relative to the 5.5.1 Domestic hot water temperature decrease in the flow rate. The hot water temperature can be set to between approx.

  • Page 25: Fault Condition

    Commissioning Fault Condition A list of faults that may occur is given on page 46. In the unlikely event of a fault occuring while the appli- ance is in operation: The display and the textdisplay then show a fault code and the button may also flash.

  • Page 26: Text Display

    Text Display B To start programming, press any button, e. g. Text Display The display lighting switches on and the main menu is displayed: General Description /holidays • The text display is used to display information about the appliance and the system and to alter the set- tings displayed.

  • Page 27: Deleting A Setting

    Text Display B Press the button to confirm the setting. The Menu structure cursor then returns to the top line. Submenu -or- Main Parameters to B Press the button to confirm the setting and menu change/select return to the previous menu (fig. 37 page 26). Time/ Time/day - - Hours...

  • Page 28: Setting The Time/Day

    Text Display Setting the time/day Setting switching times and operating mode B From the main menu select Heating and then from 6.4.1 Setting the time and day the first submenu, select Heating program. For details of how to set the time and day, refer to B Select Monday - Friday, Saturday and Sunday or page 26.

  • Page 29: Manual Operating Mode (If Tr2 Is Not Connected)

    Text Display B Press 6.5.3 Manual operating mode (if TR2 is not con- to switch Hot water immedi- nected) ately on or off. For selecting an operating mode that is different from i Info the one set in the heating programme (Automatic mode).

  • Page 30: Settings

    Text Display B Press the Settings button. The display shows Change value. 6.8.1 Heating (if TR 2 is connected) B Press to set the number of seconds in 24 hours. Optimum Start B From the main menu, select Settings and from the Basic setting: “+ 0 s”...

  • Page 31: Individual Settings

    Individual settings Individual settings Mechanical settings Control setting CH flow temperature 7.1.1 Checking the size of the expansion vessel approx. 35˚C approx. 43˚C Maximum pressure at maximum CH flow temperature is 2.5 bar. If the pressure is greater than this then fit an approx.

  • Page 32: Setting The Anti-Cycle Time (Service Function 2.4)

    Individual settings Setting service functions 7.2.3 Setting the maximum CH flow tempera- ture (Service Function 2.5) Only the service functions that can be set are displayed. The maximum CH flow temperature can be set to B Press any button to activate the main menu. between 35˚C and 88˚C (factory setting).
  • Page 33 Converting the appliance to different gas types Converting the appliance to different gas types The setting is factory sealed at maximum. Adjustment to Setting the gas/air ratio the rated heat input and min. heat input is not neces- The gas/air ratio may only be adjusted on the sary.
  • Page 34 Converting the appliance to different gas types B Adjust the gas flow restrictor (63) to obtain the CO B Recheck the levels at min. and max. rated heat output level given in Table 15. Refer to fig. 41. and re-adjust if necessary. B Press until the display shows normal.

  • Page 35: Testing Combustion Air/Flue Gas At Set Heat Output

    Converting the appliance to different gas types Testing combustion air/flue gas at set heat output 8.2.1 Testing the O or CO level in the 8.2.2 Testing CO and CO combustion air B Press and hold the button until the display By testing the O or CO level in the com-...

  • Page 36: Maintenance

    Maintenance 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.

  • Page 37: Pre-Service Check List

    Maintenance Pre-Service Check List Date Call up the last fault stored by the text- display , (see page 30). Check ionisation current, Service Function 3.3, (see page 38). Perform visual check of air/flue duct. Visual check of diaphragm for soiling and splits (see page 40).

  • Page 38: Description Of Servicing Operations

    Maintenance B Check control pressure on the air - gas mixer unit at Description of servicing operations max. rated heat output using an electronic manome- The combustion performance must be checked before ter. and after any servicing work on the combustion and burner components.
  • Page 39 Maintenance B Loosen any deposits in the heat exchanger from top Burner to bottom using the cleaning blade. Refer to fig. 47. 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).
  • Page 40 Maintenance Condensation trap The flaps of the diaphragm (443) must In order to prevent spillage of condensate the conden- open upwards. sation trap should be completely removed, (see page 38, fig. 46). B Seal the mixer unit (29). B Unscrew condensation trap and check connection Diaphragm in mixer unit for ZWBR 11-37 ICC2 to heat exchanger is clear.

  • Page 41: Pcb Control Board And Transformer

    Maintenance Siphon Replacement of Parts B Unscrew the clip and disconnect the pipe to the Before changing any components check that the gas is siphon. turned off and that the appliance is electrically isolated. B Remove the yellow plug to drain the siphon. When necessary close the system valves and drain the appliance.

  • Page 42: Fan Assembly

    Maintenance B Remove the pcb control board. 9.3.2 Fan Assembly Fig. 56 Fuses Fig. 57 B Remove the connections covers. Refer to fig. 25, B Switch off the appliance. B Undo lower pipe union on gas pipe (1.). Refer to fig.

  • Page 43: 3-Way Diverter Valve

    Maintenance B Remove 3-way valve. Alternatively B After removing the siphon release the four Allen screws and remove and replace the pump head. Fig. 59 After refitting: B Fill system, bleed and re-pressurise (see Installation Instructions). 9.3.5 3-way diverter valve motor Fig.

  • Page 44: Gas Valve

    Maintenance Domestic Hot Water Temperature Sensor – 9.3.8 Domestic Hot Water Heat Exchanger Item 6.1, fig. 2 B Refer to section 9.2. B Check that the inlet water valve is closed and the B Use new seals when fitting the new heat exchanger. domestic hot water circuit is drained.
  • Page 45 Maintenance B Transfer components, as necessary, to the new heat 9.3.14 Flow switch exchanger. B Shut the mains water inlet valve and drain the domes- B Ensure that all the seals are in place and all of the tic hot water circuit. connections are tight before re-commissioning the B Pull-off the connectors from the micro-switch.

  • Page 46: Appendix

    Appendix Appendix 10.1 Fault Codes More detailed fault finding procedures are described in the Service Booklet for the Engineer number 7 181 465 347. Display code Description Remedy pump has run dry Check system pressure, add water and bleed system as necessary Hot water NTC sensor defective.

  • Page 47: 10.2 Short Parts List

    Appendix 10.2 Short parts list Description Qty GC Spare part number Sensor - Flue gas temp. 8 729 000 144 0 Sensor - CH flow temp. 8 714 500 087 0 Sensor - DHW flow temp. 8 714 500 054 0 Control board pcb 8 748 300 418 0 Gas valve ZWBR 8-30...

  • Page 48: 10.3 Heating/Hot Water Output Settings

    Appendix 10.3 Heating/hot water output settings 10.5 Heating/hot water output settings ZWBR 8-30 N.G. ZWBR 11-37 N.G. Natural gas G20 Natural gas G20 Display Heat Heat Gas vol. flow rate Display Heat Heat Gas vol. flow rate code output, input, (l/min at code output,...

  • Page 49: 10.7 Operational Flow Diagrams

    Appendix 10.7 Operational Flow diagrams 10.7.1 Domestic hot water function Fig. 63 6 720 610 602 GB (03.02)
  • Page 50 Appendix 10.7.2 Central heating function Fig. 64 6 720 610 602 GB (03.02)
  • Page 51 Appendix 6 720 610 602 GB (03.02)
  • Page 52 Appendix Appendix 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 53 Service Booklet for the Engineer for Gas Condensing Boilers ZSBR 7-28 ICS1 GC-Number: 41 108 04 ZWBR 8-30 ICC2 GC-Number: 41 108 09 ZBR 8-35 ICS1 GC-Number: 41 108 05 ZWBR 11-37 ICC1 GC-Number: 41 108 10 ZWBR 7-28 HE plus GC-Number: 47 311 56 ZWBR 11-35 HE plus GC-Number: 47 311 57...
  • Page 54 Contents Contents Safety precautions Symbols Layout of Appliance (ZSBR/ZWBR) Operation Standard display Displaying service functions Setting service functions Resetting service functions to factory settings 5 2.4.1 Resetting service functions 0.0 to 4.9 to their factory settings (Reset 1): 2.4.2 Resetting service functions 0.0 to 9.9 to the factory setting (Reset 2): Boiler service functions Summary...

  • Page 55: Safety Precautions

    Safety precautions Safety precautions Symbols Safety instructions in this document Repairs are identified by a warning-triangle sym- B Repairs may only be carried out by an approved bol and are printed on a grey back- installer! ground. B Before carrying out any work on the appliance, switch it off at the master switch! Signal words indicate the seriousness of the hazard in B Even when the appliance is switched off at the mas-...

  • Page 56: Layout Of Appliance (Zsbr/Zwbr)

    Layout of Appliance (ZSBR/ZWBR) Layout of Appliance (ZSBR/ZWBR) Testing points: flue gas Fan fixing screws Automatic vent Burner fixing screws Fan connector Electrode assembly: Flame sensing electrode Mixer unit Ignition electro- Silencer CH flow NTC CH flow sensor Gas supply pipe Flue gas safety CH flow safety...

  • Page 57: Operation

    Operation Operation B Press the Instructions on the use of the text display module are button. given in the operating and installation instructions for The cursor is pointing to Display service the boiler. parameters. B Press and hold the button (for about 5 sec- onds) until the display shows shows Adjust service parameters and the first service function to be set, e.g.

  • Page 58: Boiler Service Functions

    Boiler service functions Boiler service functions Summary Range adjustable Reset Text display message Display from - to Value Last fault 00 - FF Clear only Flow temp. sensor 0 - 99 °C Hot water temp. sensor 0 - 99 °C Stor.
  • Page 59 Boiler service functions Range adjustable Reset Text display message Display from - to Value Link 8 - 9 open closed Link Ls-Lr open closed Stor. tank. therm.. (7-9) blocked heat demand Room therm. LSM blocked heat demand LSM release blocked heat demand Timer ch.
  • Page 60 Boiler service functions Range adjustable Reset Text display message Display from - to Value Cycle time (hot water) 0 - 60 min 0 min Duration (hot water) 0 - 30 min 1 min Pump map (heating) 0 Pump step adjustable 4 Prop.

  • Page 61: Explanation Of Service Functions

    Boiler service functions Explanation of service functions • Min mode: the appliance runs constantly at minimum output. 0.0 Last fault The text display shows MIn mode. The 2-digit dis- play alternates between the CH flow temperature The last fault can also be recalled for servicing pur- poses when the appliance is functioning correctly.
  • Page 62 Boiler service functions 2.7 Autom. anti-cycle mode 3.5 Pump blocking time (ZBR.. models only) If an outside-temperature controlled programmer is con- nected to the appliance, the anti-cycle time is adjusted Only applies if service function 3.4, Pump automatically. mode, is set to Pump mode 1 (external 3- Automatic adjustment of the anti-cycle time can be dis- way valve for heat store charging is con- abled.
  • Page 63 Boiler service functions Shows the status of channel 2 of the timer integrated in The heating output can be limited to any level between the text display module or the separate programmer. the min. rated heat output and the max. rated heat out- If that channel’s status is “Heat demand”, hot water put to suit the specific heat requirements.
  • Page 64 Boiler service functions If a stratified-charge tank is connected, it is useful to 7.2 Antiblock. map pump (not ZBR...) have the function activated. The appliance is supplied with this function activated. The delayed cut-in of the pump then prevents cold If the pump threatens to jam, an oscillating pump action water being pumped through the tank and cooling it is activated.
  • Page 65 Boiler service functions 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.

  • Page 66: Rectifying Faults

    Rectifying faults Rectifying faults Boiler failure codes indication Summary 4.1.1 ... on the boiler 4.2.1 Appliance faults In order to identify the specific boiler failure a two digit alphanumeric code is used. This allows a quick fault identification and solution. The text display shows the message Fault EA.
  • Page 67 Rectifying faults Appliance faults Loose or broken contact on heat store NTC sensor Specified CH flow tempera- ture from TA... programmer exceeded Table 3 Programmer faults Set room temperature not reached Set room temperature exceeded by large amount Set room temperature not reached Temperature rises instead of falling...

  • Page 68: How To Use The Fault Tables

    Rectifying faults How to use the fault tables The procedure is explained using the fault code If the fault is now cured, the appliance will revert to nor- EA as an example: mal operation and the fault-finding process is complete. Now simply re-check the setting of the two temperature The table heading shows the fault code and a general controls.

  • Page 69: Faults Indicated On Display

    Rectifying faults Faults indicated on display flashing. Controlled-characteristic pump has run dry Check Action B Power OFF the appliance. System pressure below 1.2 bar? yes: B Check appliance and system for water leaks and repair as necessary. B Top up system. B Turn ON the appliance.
  • Page 70 Rectifying faults flashing. Heat store NTC sensor 2 defective Check Action B Activate menu option B Is the connector for heat store NTC sensor 2 cor- yes: Show service parameters. roded , damaged or dirty? Replace affected components. B Select .4 Stor.tank temp.sensor2 .
  • Page 71 Rectifying faults flashing. Hot water NTC sensor defective Check Action B Activate menu option B Is the connector for hot water NTC sensor corro- yes: Show service parameters. , damaged or dirty? Replace affected com- ponents. B Select .2 Hot water temp.sensor . ↓2.
  • Page 72 Rectifying faults flashing. No correct electrical connection Check Action B Turn switch until it clicks into position. Mode selector switch is between two settings A8? ↓2. B Power OFF the appliance. B Turn ON the appliance. yes: Wiring between TR 2 and text- ↓3.
  • Page 73 Rectifying faults flashing. Heat store NTC sensor 1 not detected Check Action ↓2. Is lead for heat store NTC sensor yes: correctly routed, i.e. not through B Route connecting lead for heat store tempera- cable clamp? ture sensor as specified in installation instruc- tions.
  • Page 74 Rectifying faults flashing. Code plug not detected. Check Action B Power OFF the appliance. No fault or fault code FC displayed yes: on text display? B Fit code plug (correctly), making sure code number (see Appendix) is correct. B Turn ON the appliance. b1? ↓2.
  • Page 75 Rectifying faults flashing. Fan speed too low Check Action ↓2. Fan lead connector properly con- yes: nected? B Power OFF the appliance. B Plug in connector. B Turn ON the appliance. C6? ↓2. Fan lead defective? yes: B Power OFF the appliance. B Replace fan lead.
  • Page 76 Rectifying faults flashing. Wrong signal from pin 8-9. Check Action ↓2. Jumper 8 - 9 fitted correctly? yes: B Power OFF the appliance. B Fit jumper 8 - 9 correctly, tighten screw. B Turn ON the appliance. d3? ↓2. ↓3. B Turn ON the appliance.
  • Page 77 Rectifying faults flashing. The heating outlet NTC sensor is damaged. Check Action B Activate menu option yes: The heating outlet NTC sensor is in short circuit: Show service parameters. B Power OFF the appliance. B Select .1 Flow temp.sensor. B Replace CH flow NTC sensor; observe fitting Is a temperature between 0.
  • Page 78 Rectifying faults flashing. Safety temperature limiter has tripped. Check Action B Top up system. Is the heating pressure between 1 yes: and 2 bar? B Vent appliance. B Press , does appliance restart??? E9?↓2. ↓2. Is the pump blocked? yes: B Unblock the pump.
  • Page 79 Rectifying faults flashing. Safety temperature limiter has tripped. Check Action B Power OFF the appliance. B Change the fuse. yes: B Remove fuse SI 3 from appliance B Turn ON the appliance. PCB control board and test for B Press , does appliance restart??? continuity.
  • Page 80 Rectifying faults flashing. During operation: flame not detected Check Action ↓6. Is the flame present? yes: ↓2. ↓3. Is the gas cock open? yes: B Open the gas cock B Press , does appliance restart??? EA? ↓3. B Vent supply pipe. Is there air in the supply pipe? yes: B Press...
  • Page 81 Rectifying faults flashing. During operation: flame not detected Check Action ↓7. Is the ground connection correct? yes: B Rewire correctly as specified in the installation instructions. B Press , does appliance restart??? EA? ↓7. ↓8. Two phase net: yes: Is there a resistor fitted between Pe B Power OFF the appliance.
  • Page 82 Rectifying faults flashing. During operation: flame not detected Check Action B Adjust to correct level. Is flue gas CO level incorrect yes: B Press , does appliance restart??? EA? ↓12. ↓12. ↓13. B Activate menu option Show serv- yes: ice parameters. ↓16.
  • Page 83 Rectifying faults flashing. During operation: flame not detected Check Action B Replace electrode assembly. Electrode assembly defective? yes: B Power OFF the appliance. B Turn ON the appliance. B Remove electrode assembly. B Press , does appliance restart??? Electrodes worn out? EA? ↓18.
  • Page 84 Rectifying faults (and possibly ) flashing. Internal failure Check Action B Activate menu option B Record figure displayed in service report. Show service parameters. ↓2. B Select 9.3 GFA-Asic-error. A message is displayed. B Select 5.2 GFA status / error. B Record figure displayed in service report.
  • Page 85 Rectifying faults flashing. Although appliance switches off, flame still detected Check Action B Power OFF the appliance. Electrode(s) dirty or defective. B Replace electrode assembly. B Turn ON the appliance. B Press , does appliance restart??? F7? ↓2. B Power OFF the appliance. B Dry PCB control board (e.g.
  • Page 86 Rectifying faults flashing. After appliance switches off flame is detected Check Action B Clean condensation trap discharge pipe. Is condensation trap in condensing yes: boiler blocked? B Press , does appliance restart??? FA? ↓2. ↓2. Electrodes faulty. B Replace electrode assembly. B Turn ON the appliance.
  • Page 87 Rectifying faults flashing. Text display module not detected Check Action B Power OFF the appliance. No fault or fault code FC displayed on text display? B Fit code plug (correctly), making sure code number is correct (see Appendix). B Turn ON the appliance. FC? ↓2.

  • Page 88: Faults That Are Not Displayed

    Rectifying faults Faults that are not displayed 4.5.1 Appliance faults Boiler indicates P1, P2, P3 at start-up and then restarts with P1.. Check Action B Turn ON the appliance. Fuse T 1.6 A (312) defective. yes: B Change the fuse. B Power OFF the appliance.
  • Page 89 Rectifying faults Flue gas levels incorrect, CO level too high Check Action ↓2. Does the gas supply type match the yes: specifications on the appliance iden- B Convert appliance to correct gas type tification plate? ↓3. B Test gas supply pressure , - OK? yes: B Decommission appliance.
  • Page 90 Rectifying faults Ignition too harsh, ignition poor Check Action ↓6. B Activate menu option yes: Show service parameters. ↓2. B Select 5.1 Permanent ignition. Continuous ignition OK? ↓3. Ignition lead connected to ignition yes: electrodes? B Connect cable to ignition electrode. B Press button Ignition poor? ↓3.

  • Page 91: Loose Or Broken Contact On Heat Store Ntc Sensor

    Rectifying faults Ignition too harsh, ignition poor Check Action ↓8. B Test gas supply pressure - OK?. yes: B Decommission appliance. B Notify gas company. B Check flue and repair or replace if necessary. Problem with flue? yes: B Check CO level in combustion Ignition poor? ↓8.

  • Page 92: Specified Ch Flow Temperature From Ta

    Rectifying faults Specified CH flow temperature from TA... programmer exceeded Check Action 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.

  • Page 93: Programmer Faults

    Rectifying faults 4.5.2 Programmer faults Set room temperature not reached (TR 2) Check Action B Turn up thermostatic valve(s). Thermostatic valve(s) set too low? yes: ↓2. ↓2. CH flow temperature control on yes: B Turn up CH flow temperature control. boiler set too low? ↓3.
  • Page 94 Rectifying faults Set room temperature not reached Check Action Thermostatic valve(s) set too low? yes: B Turn up thermostatic valve(s). ↓2. ↓2. B Correct heating characteristic. Heating characteristic set too low? yes: ↓3. ↓3. B Turn up CH flow temperature control. CH flow temperature control on yes: boiler set too low?

  • Page 95: Set Room Temperature Exceeded By Large Amount

    Rectifying faults Set room temperature exceeded by large amount Check Action Do radiators get too hot? yes: TR 2: B Decrease setting of “Heating” control ↓2. ↓2. B Select better installation location Bad choice of location for program- yes: mer, e.g. outside wall, near window, ↓3.

  • Page 96: Heat Store Fails To Heat Up

    Rectifying faults Heat store fails to heat up Check Action with TR 2: B Increase CH flow temperature control setting. CH flow temperature control on boiler set too low. B Increase hot water temperature control setting. Hot water temperature control on boiler set too low 7 181 465 347 (01.07)
  • Page 97 Appendix Appendix NTC values 5.1.2 CH flow NTC sensor, heat store NTC sen- sor, constant hot water NTC sensor and 5.1.1 Outside temperature sensor hot water NTC sensor Outside temperature Temperature ( °C) ( °C) Measurement Resistance tolerance ± 10% ( Ω) Measurement Resistance...

  • Page 98: Electronic Schemes

    Appendix Electronic schemes o - orange bl - black r - red p - purple 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 603 - 03.1O Fig. 2 Ignition transformer Temperature limiter, heat exchanger Code plug Flue gas temperature limiter...

  • Page 99: List Of Most Important Replacement Parts

    Appendix List of most important replacement parts Component Order no. Remarks Component Order no. Remarks Switchbox Heat exchanger PCB control 8 748 300 385 board Temperature lim- 8 729 000 144 110 °C iter STB Transformer 8 747 201 358 Flue gas temper- 8 729 000 144 Ignition lead...
  • Page 100 Appendix Approved corrosion inhibitors and anti-freeze fluids for central heating water Mixing concentra– tion % by Manufacturer Description Remarks weight With all anti-freeze fluids and corrosion inhibitors, it is extremely important to observe the manufacturer’s recom- mended concentration levels and to check the concentration regularly. In the case of anti-freeze fluids, it should be noted that the efficiency of fluid-to-fluid heat transfer diminishes as the anti-freeze concentration increases.

  • Page 101: Detecting Corrosion By Cfcs

    Appendix Detecting corrosion by CFCs Halogenated hydrocarbons in the combustion air cause surface corrosion of the affected metal components. The combustion chamber and the boiler heating sur- faces (including stainless steel) are particularly suscep- tible to this type of attack as are the metal components in the flue socket, flue joints and the chimney.
  • Page 102 Appendix 7 181 465 347 (01.07)
  • Page 103 Appendix 7 181 465 347 (01.07)
  • Page 104 Appendix...
  • Page 105 Users Instructions and Customer Care Guide RD 532i/RD 537i/RD 542i combi Condensing boiler RD 430i system Condensing boiler 6 720 610 598 - 00.2O ZWBR 7-32 RD 532i GC-Number: 47 108 10 ZWBR 11-37 RD 537i GC-Number: 47 108 11 ZWBR 11-42 RD 542i GC-Number: 47 108 12 System boiler 7-30 RD 430i...
  • Page 106 Contents Contents Excellence comes as standard Safety precautions General notes Controls Operating the Appliance Preparation Switching the Appliance On/Off Switching on the Central Heating Controlling Central Heating Combination Boilers: Setting Hot Water Temperature System boiler with Storage Tank Summer Mode, Hot Water Only (Combi Appliances) Frost protection (Combi Appliances) Fault Condition Text Display...
  • Page 107 Contents 4.5.1 Heating program 4.5.2 Setting the Economy temperature (if TR2 is connected) 28 4.5.3 Manual operating mode (if TR2 is not connected) Hot water 4.6.1 Hot water program 4.6.2 Hot water immediately (System models) i Info Settings 4.8.1 Heating (if TR 2 is connected) 4.8.2 Hot Water (Storage Tank, System boiler models only) 4.8.3 Service Individual timer programmes...

  • Page 108: Excellence Comes As Standard

    What’s more, you also have the assurance of our no nonsense 2 year parts and labour guarantee. And it’s backed up by British Gas - Offering a complete mainte- nance scheme to keep your boiler operating at peak condition and efficiency.

  • Page 109: Safety Precautions

    Safety precautions Safety precautions Gas Safety (Installation and Use) Regulations 1998 It is the law that all gas appliances are installed by a competent person in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your inter- est, and that of safety, to ensure compliance with the law.
  • Page 110 Safety precautions Combustible materials B Do not store or use any combustible materials (paper, thin- ners, paints etc.) in the vicinity of the appliance. Health and safety B This appliance contains no asbestos products. B There is no potential hazard due to the appliance being electri- cally unsafe.

  • Page 111: General Notes

    General notes General notes To get the best from your appliance please read these instructions carefully. Sealed heating systems The appliance is fitted to a sealed heating system which is pre- pressurised. Your installer will tell you of the minimum and maxi- mum pressure which must be indicated on the pressure gauge.
  • Page 112 General notes Clearances Your installer will have provided adequate space around the appli- ance for safety and servicing access. Do not restrict this space with the addition of cupboards, shelves etc. next to the appliance. Left-hand side 10 mm Right-hand side 10 mm In Front 600 mm...
  • Page 113 Flow balancing using “ball-o-fix” type valves is recommended to avoid an excessive reduction in flow to individual outlets. For further information contact British Gas Technical Services Department. Hot and cold flow – Combination Boilers...
  • Page 114 General notes Do not allow the flue terminal fitted on the outside wall to become obstructed or damaged. Pump The pump is a fully modulating type to which the parameters have been set by the manufacturer and must not be adjusted. 6 720 610 604 GB (03.06)

  • Page 115: Controls

    Controls Controls 61 317 366 367 6 720 610 598 - 01.2O Fig. 1 System Pressure gauge Reset button Master switch Central heating temperature control Service valves in CH flow and return Hot water Gas isolation valve (open) Cold water inlet Identification sticker Hot water temperature control Display...

  • Page 116: Operating The Appliance

    Operating the Appliance Operating the Appliance Preparation Turn on the gas cock (172). B Press in the handle and turn it anti-clockwise as far as the stop (when handle is in line with direction of flow, the cock is open). Central heating system valves (170) B Using a spanner, turn square nut until groove is in line with direction of flow (see detail).
  • Page 117 Operating the Appliance Check the central heating system pressure B The pointer on the pressure gauge (8.1) should be about 1 bar. B If the pointer is below 1 bar (when the system is cold), top up the system with water until the pointer is 1 bar. Your installer will have shown you how to do this.

  • Page 118: Switching The Appliance On/Off

    Operating the Appliance 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 oper- ating in the central heating mode. 6 720 610 333-04.1O Fig.

  • Page 119: Switching On The Central Heating

    Operating the Appliance Switching on the Central Heating B Turn the central heating temperature control to the desired level: – “Min” setting: 35°C – Low-temperature heating: setting “E” (approx. 75°C) – “Max” setting: 88°C When the burner is lit, the red indicator lamp is illuminated. 6 720 610 333-05.1O Fig.

  • Page 120: Combination Boilers: Setting Hot Water Temperature

    Operating the Appliance Combination Boilers: Setting the Hot Water Temperature Hot water temperature On combi models, the hot water temperature can be set to between approx. 40°C and 60°C using the temperature control The domestic hot water temperature is not shown on the display. 6 720 610 333-07.1O Fig.

  • Page 121: System Boiler With Storage Tank

    Operating the Appliance ECO mode with demand detection, button is lit The demand detection function enables maximum gas and water economy. Briefly turning a hot water tap on and then off again signals demand to the appliance which then heats up the water to the set temperature.

  • Page 122: Summer Mode, Hot Water Only (Combi Appliances)

    Operating the Appliance Control Setting Water Temperature Anti-clockwise limit approx. 10°C (frost protection) approx. 60°C Clockwise limit approx. 70°C Table 3 ECO button Pressing and holding the ECO button , until it lights up switches from Comfort mode to ECO-mode. Comfort mode, ECO button is not lit (factory setting) In Comfort mode the hot water tank has priority.

  • Page 123: Frost Protection (Combi Appliances)

    If the fault remains and can not be cleared: B Call British Gas for assistance, giving a description of the fault and, if possible, the fault code from the facia display. 6 720 610 604 GB (03.06)

  • Page 124: Text Display

    Text Display Text Display General Description • The text display is used to display information about the appli- ance and the system and to alter the settings displayed. • Once the appliance has been in operation for one day, the text display module has a power buffer period of about 10 hours during which it will run without the mains power supply.
  • Page 125 Text Display • Domestic Hot Water temperature (System boiler if a Storage Tank is accorded). Additional indication if a special programme is active: • x holidays • Hot water immediately • Constant on (comfort, if TR2 is not connected) • Constant off (economy, if TR2 is not connected). Other special operating modes may be displayed during commis- sioning, servicing, etc.
  • Page 126 Text Display B Confirm the selection by pressing the button. The corresponding submenu is displayed: 6 720 610 598-05.2O Fig. 10 Submenu: Time/day In the submenus, the top line indicates what action is required. The bottom line shows the previous menu level, if applicable (see Fig.

  • Page 127: Deleting A Setting

    Text Display B Use the button to set the minutes. B Confirm the setting by pressing the button. B Use the button to set the day of the week. B Press the button to confirm the setting. The cursor then returns to the top line.

  • Page 128: Menu Structure

    Text Display Menu structure Submenu Parameters to Main menu 1. change/select Time/day/hol- Time/day - Hours idays - Minutes - Day of week Holidays Days holiday Heating Heating - Day program - 1st operating mode - 1st switching point - 6th switching point Set econ- 5...30°C omy temp.

  • Page 129: Setting The Time/Day

    Text Display Submenu Parameters to Main menu change/select Settings Heating Optimum Start Off/On Hot water Only charging times/ (System times and temperatures boiler-mod- els) Service Display service param. Further Language -English/ options -Français/ -Deutsch -Time correction -LCD contrast Operating times Fault history Setting the time/day...
  • Page 130 Text Display ically cancels Economy mode at midnight on the last day and returns to Automatic mode. The day on which you enter the days holiday counts as the first day of the holiday, i.e. the unit starts the holiday program immediately. Only in- clude the day on which you are returning if you don’t want the heating to return to the normal pro- gram on that day!

  • Page 131: Heating Program

    Text Display Heating 4.5.1 Heating program Basic setting (Automatic mode) • The appliance switches automatically between normal heating, Economy mode and Frost protection mode according to the timer settings entered. • Basic setting: – Heating starts at 6:00 am – Economy starts at 10:00 pm Setting options •...

  • Page 132: Setting The Economy Temperature (If Tr2 Is Connected)

    Text Display B Press . The display shows Set 1. operating mode. B Set the desired first operating mode (Heating, Economy or Frost protection). B Press . The display shows Set 1. time period. B Set the desired first time period. B Press .

  • Page 133: Manual Operating Mode (If Tr2 Is Not Connected)

    Text Display 4.5.3 Manual operating mode (if TR2 is not connected) For selecting an operating mode that is different from the one set in the heating programme (Automatic mode). • You can choose between Automatic, Constant on (comfort) and Constant off (economy). •...

  • Page 134: Hot Water

    Text Display Hot water General description • Combi models only: The basic settings provide a straightfor- ward timer programme: enabled from 5:00 am, disabled from 10:00 pm. The ECO button must not be lit (Comfort mode). • System models (with Storage Tank): The basic settings pro- vide a timer programme: enable from 5:00 am, disable from 10:00 pm.

  • Page 135: Hot Water Program

    Text Display 4.6.1 Hot water program • Up to six switching points per day can be set. • There are two operating modes: Blocked and Released. B From the main menu, select Hot water and then from the first submenu, select Hot water program. B Set the days of the week, Blocked/Released (operating mode) in the same way as for the switching points and modes for heating as described on page 27.

  • Page 136: Info

    Text Display i Info B Select Info from the main menu. You can view the following information: Display text Description Room temperature Current temperature in the room (if TR 2 connected) where TR 2 is installed Required room temper- Required temperature in room where ature (if TR 2 connected) TR 2 is installed Operating mode...

  • Page 137: Settings

    Text Display Settings 4.8.1 Heating (if TR 2 is connected) Optimum Start B From the main menu, select Settings and from the first sub- menu, select Heating. B Press to switch Optimum Start on or off. 4.8.2 Hot Water (Storage Tank, System boiler models only) The text display can control the hot water either with Times and temperatures or only times.
  • Page 138 Text Display Service parameters Language Available languages are: English, Français (French), Deutsch (German). B From the main menu, select Settings, from the first submenu select Service, from the Second submenu select Further options, and from the third submenu select Language. B Press to select the desired language.
  • Page 139 Text Display water) since commissioning. B From the main menu, select Settings, from the first submenu select Service, from the Second submenu select Further options, and from the third submenu select Operating times. Fault history This option displays any faults that have occurred for the informa- tion of the service engineer.

  • Page 140: Individual Timer Programmes

    Text Display Individual timer programmes Heating periods for central heating Switching point Status Monday Tuesday Wednesday Thursday Friday Saturday Sunday Enable/disable hot water function Switching point Status Monday Tuesday Wednesday Thursday Friday Saturday Sunday 6 720 610 604 GB (03.06)

  • Page 141: Fault Finding

    Fault finding Fault finding Problem Cause Remedy Desired room Thermostatic Increase thermo- temperature is not valve(s) set too static valve set- reached ting(s) Temperature con- Increase CH flow trol for CH flow temperature con- set too low trol setting Air trapped in Bleed radiators heating system and heating sys-...

  • Page 142: Tips On Saving Energy

    Tips on saving energy Tips on saving energy Heating economically The boiler is designed to provide a high level of comfort while keeping gas consumption and the resulting environmental effect as low as possible. The gas supply to the burner is controlled according to the level of demand for heat.

  • Page 143: General Information

    General Information Hot water A lower setting on the hot water temperature control can result in considerable energy savings. For combi appliances: The on-demand activation using the ECO-button makes possi- ble the maximum savings of gas and water. Now you know how to heat your home economically with the RD 532i/RD 537i/RD 542i /RD 430i gas condensing boiler.

  • Page 144: Maintaining Your Appliance

    2 year guarantee period. To arrange for a British Gas three star cover agreement please call 0845 9 60 50 40. Service...

  • Page 145: Fault Or Breakdown

    NOTE: No appliance fault is found on over 30 % of all service call outs. If in doubt contact our British Gas on 0845 9 60 50 40. IN THE EVENT OF AN APPLIANCE FAULT OR BREAKDOWN please contact your Service Centre (see over). Your service administrator will arrange for an engineer to call with the minimum of delay;...

  • Page 146: Your Guarantee

    Your guarantee Your guarantee This appliance is guaranteed against faulty material or workman- ship for a period of 24 calendar months from the date of installa- tion subject to the following conditions and exceptions. • That during the currency of this guarantee any components of the unit which are proved to be faulty or defective in manufac- ture will be exchanged or repaired free of material charges and free of labour charges by Worcester Heat Systems Limited.

  • Page 147: Guarantee Registration

    Guarantee registration Guarantee registration You should complete and return the postpaid Guarantee Regis- tration Card within 14 days of purchase. The card will register you as the owner of your new RD 532i/RD 537i/RD 542i /RD 430i appliance and will assist us in maintaining an effective and efficient customer service by establishing a refer- ence and permanent record for your boiler.

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