Worcester ZWBR 7-30 R 30 HE PLUS COMBI Service Booklet
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Worcester ZWBR 7-30 R 30 HE PLUS COMBI Service Booklet

Gas condensing boiler
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See also: Instructions for Installation and Servicing
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
Supplied By www.heating spares.co Tel. 0161 620 6677

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Summary of Contents for Worcester ZWBR 7-30 R 30 HE PLUS COMBI

  • Page 1 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...

  • Page 2: Table Of Contents

    Contents Contents Safety precautions Appendix NTC values 6.1.1 Flue sensor Symbols 6.1.2 Outside temperature sensor 6.1.3 CH flow NTC sensor, DHW cylinder NTC sensor 1 and hot water NTC sensor Layout of Appliance Electrical wiring diagram Approved corrosion inhibitors and anti-freeze fluids for central heating water Operation List of Code plugs used with...

  • Page 3: 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 4: Layout Of Appliance

    Layout of Appliance Layout of Appliance 221.1 221.2 32.1 7 181 465 347-02.2O Fig. 1 Bosch Heatronic Inspection window Temperature limiter for heat exchanger Fixing points Hot water NTC sensor (combi boiler) 221.1 Flue duct Testing point for gas supply pressure 221.2 Combustion air intake Pressure gauge Flue gas temperature limiter...

  • Page 5: Operation

    Operation Operation Instructions on the use of the text display module are Displaying service functions given in the operating and installation instructions for B Press any button to activate the main menu. the boiler. B Press button until the arrow cursor is pointing to Settings.

  • Page 6: Setting Service Functions

    Operation Setting service functions Resetting service functions to fac- tory settings B Press any button to activate the main menu. B Press button until the arrow cursor is 2.5.1 Resetting service functions 0.0 to 4.9 to pointing to Settings. their factory settings (Reset 1): B Press the button.

  • Page 7: Boiler Service Functions

    Boiler service functions Boiler service functions Summary Range adjustable Text display message Display from - to Reset Value Last fault 00 - FF last fault code can be deleted Flow temp. sensor 0 - 99˚C Hot water temp. sensor 0 - 99˚C Stor.
  • Page 8 Boiler service functions Range adjustable Text display message Display from - to Reset Value Pump mode (not applicable) Pump blocking time 0 - 240 s (not applicable) in 15-s increments Software version BF 11.XX Link 8-9 open closed Link Ls-Lr open closed Stor.
  • Page 9 Boiler service functions Range adjustable Text display message Display from - to Reset Value Pump off (hot water) (not applicable) Cycle time (hot water) 20 - 60 min 20 min (combi only) Duration (hot water) 0 - 30 min 1 min (combi/system) Pump map (heating) 0 Pump step adjustable...

  • Page 10: Explanation Of Service Functions

    Boiler service functions Explanation of service functions 0.0 Last fault – – The last fault can also be recalled for servicing pur- • Max mode: the appliance runs constantly at maxi- poses when the appliance is functioning correctly. mum output. The text display shows Max mode.
  • Page 11 Boiler service functions 2.5 Max. flow temperature 3.9 Link 8-9 / 3.9 Link Ls-Lr The maximum CH flow temperature can be set to between 35˚C and 88˚C (factory setting). Even if the When supplied, the appliance has a link fitted across CH flow temperature control is set higher, the setting terminals 8-9 (= Heat demand).
  • Page 12 Boiler service functions 4.6 Internal regulator 6.6 Thermostore satisfied The boiler has an internal anti-cycle function which pre- (not applicable) vents the burner overheating if the heat output can not 6.7 Pump off (hot water) be dissipated even in Min mode. The appliance will then (not applicable) switch off even when the system is calling for heat.
  • Page 13 Boiler service functions The factory setting is: 7.1 Map pump step (heat.) 7.0 Pump map (heating) 3 Const. pressure low 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 (bar) map (heating), is set to Pump step adjustable.
  • Page 14 Boiler service functions 7.3 Air purge mode 8.5 Siphon fill program The first time the appliance is switched on, a once-only The trap filling programme ensures that the condensa- venting function is activated. The heating pump then tion trap is filled when the appliance is first installed or switches on and off at intervals.

  • Page 15: Rectifying Faults

    Rectifying faults Rectifying faults Summary 4.2.1 Appliance faults 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 Appliance faults The text display shows the message Fault EA.

  • Page 16: Faults That Are Not Displayed

    Rectifying faults 4.2.2 Faults that are not displayed Appliance faults Page Boiler indicates P1, P2, P3 at start-up and then restarts with P1.. Excessive burner noise, rumbling noises Flue gas levels incorrect, CO level too high Ignition too harsh, ignition poor Loose or broken contact on DHW cylinder NTC sensor Hot water has unpleasant odour...

  • Page 17: Notes On Using The Fault Code Tables

    Rectifying faults Notes on using the fault code tables The procedure is best described with the aid of an example: In this example: check the flue is clear by testing the CO level. • Work through the table from top to bottom and from left to right.

  • Page 18: Error Codes On The Display

    Rectifying faults Error A1 Error codes on the 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 Fill system, bleed and re-pressurise (see Installa- tion Instructions).
  • Page 19 Rectifying faults Error A7 flashing. Water NTC sensor defective Check Action B Activate menu option Show serv- yes: DHW temperature limiter connector corroded ice parameters. damaged or dirty? B Select service function 0.2 Hot B Change relative parts. water temp. sensor. A7?↓2.
  • Page 20 Rectifying faults Error A8 flashing. No correct electrical connection Check Action ↓2. B Power OFF the appliance. yes: B Check Wiring between Textdis- B Rewire correctly as specified in the installation play and TR 2: instructions. – Terminal 3 on Textdisplay con- B Turn ON the appliance.
  • Page 21 Rectifying faults Error Ad flashing. DHW cylinder NTC sensor not detected Check Action ↓2. Is lead for DHW cylinder NTC sensor yes: correctly routed, i.e. not through B Route connecting lead for DHW cylinder tem- cable clamp? perature sensor as specified in installation instructions.
  • Page 22 Rectifying faults Error b1 flashing. Code plug not detected. Check Action B Power OFF the appliance. b1 is shown on 2 digit display. yes: (independent on what is shown on B Fit code plug (correctly), making sure code the text display). number is correct (see Appendix).
  • Page 23 Rectifying faults Error C1 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. C1? ↓2. ↓3. Is fan lead defective? yes: B Measure the fan lead for B Power OFF the appliance.
  • Page 24 Rectifying faults Error d3 flashing. Wrong signal from pin 8-9. Check Action ↓2. B Measure voltage between Termi- yes: nal 4 and Terminal 8. ↓3. Voltage ≅ 24 V DC? B Power OFF the appliance. Link between terminals 8 and 9 con- yes: nected? B Check link across 8-9 properly fitted, tighten...
  • Page 25 Rectifying faults Error E2 flashing. The flow temp. NTC sensor is damaged. Check Action B Activate menu option Show serv- yes: The heating outlet NTC sensor is in short circuit: ice parameters. B Power OFF the appliance. B Select 0.1 Flow temp. sensor. B Replace CH flow NTC sensor;...
  • Page 26 Rectifying faults Error E9 flashing. Safety temperature limiter has tripped. Check Action ↓ 2. Is the heating pressure between 1 and yes: 2 bar? B Top up system. B Vent appliance. B Press , restart the appliance. E9? ↓ 2. B Unblock the pump.
  • Page 27 Rectifying faults Error E9 flashing. Safety temperature limiter has tripped. Check Action B Power OFF the appliance. Is lead disconnected from CH flow yes: safety temp. limiter? B Reconnect lead. B Turn ON the appliance. B Press , restart the appliance. E9? ↓...
  • Page 28 Rectifying faults Error EA flashing. During operation: flame not detected Check Action ↓5. Is a burner flame visible? yes: ↓2. ↓3. Is the gas cock turned on? yes: B Open the gas cock. B Press , restart the appliance. EA? ↓3. B Vent supply pipe.
  • Page 29 Rectifying faults Error EA flashing. During operation: flame not detected Check Action B Close mixer unit. Is diaphragm in mixer unit fitted correctly yes: (see installation instructions)? ↓8. B Open mixer unit (29). B Insert diaphragm in the fan intake duct as per installa- B Check diaphragm for correct orienta- tion instructions so that the flaps open upwards.
  • Page 30 Rectifying faults Error EA flashing. During operation: flame not detected Check Action B Adjust to correct level. yes: Is flue gas CO level incorrect B Press , restart the appliance. EA? ↓11. ↓11. B Activate menu option Show service yes: B Press button to select no.
  • Page 31 Rectifying faults Error EA flashing. During operation: flame not detected Check Action B Power OFF the appliance. Check if the 20-pin connector lead assembly is damaged. B Change the 20-pin connector lead assembly. B Turn ON the appliance. B Press , restart the appliance.
  • Page 32 Rectifying faults Error F0 (and possibly ) flashing. Internal failure Check Action B Activate menu option Show serv- B Enter figure displayed in customer service record. ice parameters. ↓2. B Select 9.3 GFA-Asic error (automatic ignition module, extended messages). A message is displayed. B Select 5.2 GFA status/error .
  • Page 33 Rectifying faults Error F7 flashing. Although appliance switches off, flame still detected Check Action B Replace electrode assembly. Electrode(s) dirty or defective? yes: B Turn ON the appliance. B Power OFF the appliance. B Remove electrode assembly and B Press , restart the appliance.
  • Page 34 Rectifying faults Error F7 flashing. After appliance switches off flame is detected Check Action B Replace electrode assembly. Electrode assembly defective? B Power OFF the appliance. B Turn ON the appliance. B Remove electrode assembly. B Press , restart the appliance. Electrode assembly burnt out? FA? ↓3.
  • Page 35 Rectifying faults Error FC 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.

  • Page 36: Appliance Faults

    Rectifying faults Error Fd 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 Power OFF the appliance. Fuse T 1,6 A (312) defective. yes: B Disconnect the boiler electrical connection. B Change the fuse.
  • Page 37 Rectifying faults Error Fd Excessive burner noise, rumbling noises Check Action B Repair or replace components. Is appliance’s internal air/flue chan- yes: nel leaking or blocked? B Grease seal before fitting. Make sure it is fitted in B Open up heat exchanger and correct position.

  • Page 38: Flue Gas Levelss Incorrect, Co Levels Too High

    Rectifying faults Error Fd 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? Flue gas levels incorrect? 2. ↓3.

  • Page 39: Ignition Too Harsh, Ignition Poor

    Rectifying faults Error Fd Ignition too harsh, ignition poor Check Action ↓6. B Activate menu option Show serv- yes: ice parameters. ↓2. B Select 5.1 Permanent ignition (without Gas). Continuous ignition (without gas) ↓3. Ignition lead connected to ignition yes: electrodes? B Connect cable to ignition electrodes.

  • Page 40: Loose Or Broken Contact On Dhw Cylinder Ntc Sensor

    Rectifying faults Error Fd Ignition too harsh, ignition poor Check Action ↓8. B Test gas supply pressure - OK? yes: Does pressure match figure speci- B Decommission appliance. fied in installation instructions? In case of natural gas: B Notify gas company. B Check flue and repair or replace if necessary.

  • Page 41: Text Display Fails To Respond, No Display Or Display Incorrect

    Rectifying faults Error Fd Hot water has unpleasant odour or is dark colour (system boiler) Check Action This is generally caused by the formation of hydrogen sulphide by sulphate-reducing bacteria. Such bacteria are found in water which is very low in oxygen and live off the hydrogen produced by the anode. B Clean the hot water cylinder.

  • Page 42: Inadequate Hot Water Outlet Temperature (Combi Boiler)

    Rectifying faults Error Fd Inadequate hot water outlet temperature (combi boiler) Check Action ↓2. Pump set to mode 3? yes: B Set pump switch to setting 3. Inadequate hot water outlet temperature ? ↓2. B Unplug connector from Heatronic; B Power OFF the appliance. yes: is voltage between terminal 1 and B Disconnect the boiler electrical connection.

  • Page 43: Programmer Faults

    Rectifying faults Error Fd 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. B Turn up CH flow temperature control. CH flow temperature control on yes: boiler set too low? ↓3.

  • Page 44: Set Room Temperature Exceeded By Large Amount (Tr 2)

    Rectifying faults Error Fd Set room temperature not reached (integrated text display) Check Action B Power OFF the appliance. Air in the heating system. B Check appliance and system for water leaks and repair as necessary. B Top up system. B Turn ON the appliance.

  • Page 45: Excessive Fluctuations In Room Temperature

    Rectifying faults Excessive fluctuations in room temperature (integrated text display) Check Action B Switch on room override. TR2 without room override: yes: B Periodic effect of external heat on ↓2. room, e.g. from sunshine, lighting, ↓2. TV, separate stove, fire, etc. B Increase room override priority (not text display).

  • Page 46: Replacement Of Parts

    Replacement of Parts Replacement of Parts B Lower the control box. B Always disconnect the power supply to B Unscrew earth lead. the appliance at the mains before carry- B Unscrew four fixing screws from cover plate. ing out any work on the electrical sys- tems and components (fuse, circuit B Prise off cover plate.

  • Page 47: Fan Assembly

    Replacement of Parts Fan Assembly Primary Heat exchanger/Burner B Power OFF the appliance. B Power OFF the appliance. B Undo lower pipe union on gas pipe (1.). B Remove spring cotters from two front cover fixing assemblies. B Remove fan lead and earth connector (2.). The earth B Unscrew the two front fixing assemblies.

  • Page 48: Pump

    Replacement of Parts Pump Clean condensation trap B Power OFF the appliance. In order to prevent spillage of condensate the conden- sation trap should be completely removed. B Disconnect the boiler electrical connection. B Turn off service cocks. B Screw off the condensation trap and place a suitable container underneath.

  • Page 49: Way Diverter Valve

    Replacement of Parts 3-way diverter valve Domestic Hot Water Heat Exchanger B Power OFF the appliance. B Power OFF the appliance. B Disconnect the boiler electrical connection. B Turn off service cocks. B Turn off service cocks. B Drain appliance. B Drain appliance.

  • Page 50: Appendix

    Appendix Appendix NTC values 6.1.3 CH flow NTC sensor, DHW cylinder NTC sensor 1 and hot water NTC sensor 6.1.1 Flue sensor Temperature (˚C) Flue temperature (˚C) Measurement tolerance ±10% Measurement tolerance Resistance (Ω) ±10% Resistance (Ω) 14 772 124 900 11 981 53 290 9 786...

  • Page 51: Electrical Wiring Diagram

    Appendix 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 52: Approved Corrosion Inhibitors And Anti-Freeze Fluids For Central Heating Water

    Appendix Approved corrosion inhibitors and Component Order no. Remarks anti-freeze fluids for central heating water Conversion kit 8 714 411 064 0 ZWBR 7-32 G20 -> G31 Corrosion inhibiter Conversion kit 8 714 411 063 0 The following corrosion inhibiters are permitted: G31 ->...

  • Page 53: Summary Of Bdh Information Sheet On Identifying Corrosion By Cfcs

    Appendix Summary of BDH Information Sheet on Identifying Corrosion by CFCs The presence of halogenated hydrocarbons in the com- bustion air causes surface corrosion on affected met- als. Particularly susceptible is the combustion chamber and the heat exchanger surfaces (including stainless steel) as well as the metal components in the flue socket, flue pipe connections and in the chimney.
  • Page 54 Appendix 7 181 465 347 (05.01) Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 55 Appendix 7 181 465 347 (05.01) Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 56 Supplied By www.heating spares.co Tel. 0161 620 6677...

This manual is also suitable for:

Zwbr 11-35 r 35 he plus combiZwbr 7-32 rd 532i combiZwbr 11-37 rd 537i combiZwbr 11-42 rd 542i combiZwbr 11-40 r 40 he plus combiZsbr 7-30 rd 430i system

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