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Benchmark CS1 Installation And Servicing Instructions

Wall mounted condensing boiler for central heating
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Installation and Servicing Instructions
CS1
Wall mounted condensing boiler for central heating
6 720 610 577-00.10
ZB 7-28 CS1
GC-Number: 41 108 02

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  • Page 1 Installation and Servicing Instructions Wall mounted condensing boiler for central heating 6 720 610 577-00.10 ZB 7-28 CS1 GC-Number: 41 108 02...

  • Page 2: Table Of Contents

    Contents Contents Safety precautions Individual settings Mechanical settings 6.1.1 Checking the size of the expansion vessel Symbols 6.1.2 Setting the central heating flow temperature 26 6.1.3 Changing the heating pump characteristic Settings on the Bosch Heatronic Details of the appliance 6.2.1 Operating the Bosch Heatronic EC Declaration of Conformity 6.2.2 Selecting the pump control mode for central...

  • 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 13 m and vertical flue systems for flue lengths upto 15 m.

  • Page 6: Layout Of Appliance

    Details of the appliance Layout of appliance 221.1 221.2 234.1 32.1 18.1 6 720 610 596-01.2O Fig. 2 Heatronic control 221.2 Combustion air intake Heat exchanger safety temperature limiter Fan assembly Testing point for gas supply pressure Appliance type sticker Pressure gauge Testing point for combustion products Flue gas temperature limiter...

  • Page 7: Function (With Optional Extra Motorised Valve)

    Details of the appliance Function (with optional extra motorised valve) Fig. 3 Bosch Heatronic control Storage water heater outflow (only with motorised valve) Temperature limiter, heat exchanger Storage water heater return (only with motorised valve) Testing point for gas supply pressure Motor (optional extra) Pressure gauge 3-way valve (optional extra)

  • Page 8: Electrical Wiring Diagram

    Details of the appliance Electrical wiring diagram o - orange bl - black r - red 25 V 230 V 230V/AC 1 2 4 7 8 9 328.1 mains supply 52.1 6 720 610 601-02.2O Fig. 4 Ignition transformer 328.1 Link Temperature limiter, heat exchanger Indicator lamp for burner Flue gas temperature limiter...

  • Page 9: Technical Data

    Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30˚C central heating 29.3 29.3 Max. rated heat output net 50/30˚C central heating 29.0 29.0 Max. rated heat output net 80/60˚C central heating 27.4 27.4 Max.

  • Page 10: Installation Regulations

    Installation regulations Condensate analysis, mg/l Installation regulations Ammonium 1.2 Nickel 0.15 Gas Safety (Installation & Use) Regulations 1998: All ≤ 0.01 Mercury ≤ 0.0001 Lead gas appliances must be installed by a competent per- son. Failure to install correctly could lead to prosecu- ≤...

  • Page 11: Installation

    Installation Installation Sealed systems The appliance must not be operated without the system B Always turn off the gas cock before car- being full of water, properly vented and pressurised. rying out any work on components The expansion vessel has a volume of 10 litres and is which carry gas.
  • Page 12 Installation Note: INDIRECT A drain cock CYLINDER should be fitted at the lowest point of the heating circuit and beneath APPLIANCE the appliance Refer to Appliance Water Flow Diagram Radiator Valve - Flow Safety Discharge Lockshield Valve - Return LV Hot Water Flow Mains Cold Water Stop Valve Fixed Cylinder Type...

  • Page 13: Siting The Appliance

    Installation Note: INDIRECT A drain cock CYLINDER should be fitted at the lowest point of the heating circuit and beneath APPLIANCE the appliance Refer to Appliance Water Flow Diagram Radiator Valve - Flow Safety Discharge Lockshield Valve - Return LV DHW Zone Valve Zone Mains Cold Water...

  • Page 14: Wall Mounting Frame Assembly

    Installation B Screw the pre-plumbing manifold with two screws to Wall mounting frame assembly the wall mounting frame. B Take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 9. Use the inner lugs on the top and bottom horizontal sec- tions for the appliances that are 440 mm wide.

  • Page 15: Fitting The Appliance

    Fitting the appliance should be 2.5° (40 mm/m) minimum The rainwater system An external purpose made soakaway Benchmark: For optimum performance 6 720 610 596 -03.1O after installation, this boiler and its asso- Fig. 13 ciated central heating system must be...

  • Page 16: Checking The Connections

    Installation B Remove the plastic caps from the boiler connec- Checking the connections tions. 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 17: Siting The Flue Terminal

    Installation 3.8.1 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 18: Installation Of The Flue

    Installation 3.8.2 Installation of the flue The standard 100 mm diameter horizontal flue system is suitable for lengths upto 4 m. Flues upto 650 mm do not require an extension duct assembly. Flues between 1600 mm and 4000 mm require exten- Terminal sion duct assemblies.
  • Page 19 Installation Terminal Assembly Flue Turret Maximum 1600mm Outer Wall Clamp Extension Clamp Duct 6 720 610 602 - 09.1O Fig. 20 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 20: Flue Duct Preparation And Assembly

    Installation 3.8.3 Flue duct preparation and assembly Measure the flue length L. Refer to fig. 23, 24. 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 21: Electrical Connections

    Electrical connections B Remove screw and slide terminal cover forwards to Electrical connections remove. Refer to fig. 28. B Always disconnect the power supply to the appliance at the mains before carry- ing out any work on the electrical sys- tems and components.

  • Page 22: Mains Voltage External Controls Connections

    Electrical connections Mains Voltage external controls 4.3.1 Pre-wired Remote S Plan connections If the system is fully pre-wired at a juction box remotely from the boiler, it can be easily connected back to the boiler. NOTE: Only double insulated controls not requiring an earth can be used Ns Ls L Drop down the facia and gain access to the boiler wir- Ns Ls L...

  • Page 23: Commissioning

    Appliance type sticker Temperature control for hot water Multifunction display Benchmark Water Treatment: For optimum perform- Condensate trap ance after installation, this boiler and its associated cen- Indicator lamp for burner tral heating system should be flushed in accordance...

  • Page 24: Switching The Appliance On/Off

    Commissioning B Before commissioning, the gas supply pres- Switching off the appliance sure must be checked at the gas supply pres- B Set the master switch to (0). sure test point (see page 6, fig. 2, item 7). The green indicator lamp goes out. Natural gas appliances must not be operated if the gas supply pressure is below 18 mbar or B Always disconnect the appliance from...

  • Page 25: Appliances With Optional Plug-In Diverter Valve: Setting Hot Water Temperature

    Commissioning Appliances with optional plug-in Frost protection diverter valve: Setting hot water Frost protection is only guaranteed from the external temperature room temperature thermostat. B Leave master switch switched on. B Do not set the temperature higher than 60˚C for normal operation. If the appliance is to be left for long periods switch the B Only use temperatures of up to 70˚C central heating off:...

  • Page 26: Individual Settings

    Individual settings Individual settings B Rotate yellow button through 180° and replace (dot Mechanical settings facing inwards). 6.1.1 Checking the size of the expansion vessel The CH flow temperature is no longer limited. Maximum pressure at maximum CH flow temperature is Control setting CH flow temperature 2.5 bar.

  • Page 27: Settings On The Bosch Heatronic

    Individual settings Settings on the Bosch Heatronic Entering a setting B To enter the setting for a function, turn the tempera- 6.2.1 Operating the Bosch Heatronic ture control The Bosch Heatronic enables easy setting and check- ing of a large number of appliance functions. Storing a setting This description is limited to those functions required B Level 1: press and hold the...

  • Page 28: Setting The Maxim Ch Flow Temperature (Service Function 2.5)

    Individual settings B Turn the temperature control 6.2.4 Setting the maxim CH flow temperature until the display (Service Function 2.5) shows 5.0. After a short delay, the display then shows the set The maximum CH flow temperature can be set to heating output in percent.

  • Page 29: Converting The Appliance To Different Gas Types

    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 30 Converting the appliance to different gas types B Turn the temperature control B Remove the seal from the gas valve adjusting until the display shows 2. (= max. rated heat output). screw (64) and adjust the CO level to the figure The display and the button will flash.

  • Page 31: 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 7.2.1 Testing the O or CO level in the combus- 7.2.2 Testing CO and CO tion air B Press and hold the button until the display By testing the O or CO level in the com-...

  • Page 32: 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 33: Pre-Service Check List

    Maintenance Pre-Service Check List Date Call up the last fault stored by the Bosch Heatronic, Service Function .0, (see page 34). Check ionisation current, Service Function 3.3, (see page 34). Perform visual check of air/flue duct.Visual check of diaphragm for soiling and splits (see page 36).

  • Page 34: Description Of Servicing Operations

    Maintenance B Remove the fan and the burner as described in the Description of servicing operations text headed “Burner” (see page 35). The combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 7.2. Check “Last fault stored”: B Select Service Function .0 (see page 27 “Selecting service function”).
  • Page 35 Maintenance B Clean out the condensate collector and trap connec- tion (with other end of brush). 6 720 610 332-75.2R Fig. 55 B Refit the clean-out cover using a new seal and tighten screws to torque of approx. 5 Nm. Burner B Check that the gas cock is turned off and the master switch is in the OFF position.
  • Page 36 Maintenance B Refit and prime the siphon. Diaphragm in mixer unit B Take care not to damage diaphragm (443) when removing and refitting it. B Open mixer unit (29). Condensate B Carefully withdraw diaphragm (443) from fan intake Drain tube and check for soiling and splits. Siphon 6 720 610 602 - 16.

  • Page 37: Replacement Of Parts

    Maintenance B Remove the pcb control board. Replacement of Parts Before changing any components check that the gas is turned off and that the appliance is electrically isolated. When necessary close the system valves and drain the appliance. Refitting is a reverse of the procedure for removal using new seals or o-rings as appropriate.

  • Page 38: Fan Assembly

    Maintenance 8.3.2 Fan Assembly 8.3.3 Pump B Switch off the appliance. B Disconnect appliance from the power supply. B Remove two switchbox fixing screws (1.). Refer to fig. 63. B Lower switchbox (2.). B Unscrew and remove the siphon by releasing the jubilee clip.

  • Page 39: 3-Way Diverter Valve Motor

    Maintenance B Remove 3-way valve. 8.3.7 Gas Valve B Check that the gas cock is turned off. B Lower the control panel. Refer to fig. 63. B Pull off the solenoid connections at the rear of the valve. B Undo the union, within the inner casing, securing the valve to the gas/air tube.

  • Page 40: Pressure Gauge

    Maintenance B Ensure that all the seals are in place and all of the 8.3.9 Pressure gauge connections are tight before re-commissioning the B Drain the appliance. appliance. B Lower the facia. Refer to fig. 63. B Twist the pressure gauge head anti-clockwise to release it from the casing.

  • Page 41: Appendix

    Appendix Appendix Fault Codes More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346. Display code Description Remedy Break in communication Check connecting lead to programmer Module not detected. Check connecting lead between TA211E/TR212E and Heatronic Keyed plug not detected.

  • Page 42: Short Parts List

    Appendix 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 Control board 8 748 300 418 0 Gas valve 8 747 003 516 0 Fan assembly 8 717 204 373 0 Fan washer...

  • Page 43: Operational Flow Diagrams

    Appendix Operational Flow diagrams 9.5.1 Central heating function Fig. 67 6 720 610 601 GB (03.02)
  • Page 44 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 45 Service booklet for the Engineer for Gas Condensing Boilers 6 720 610 577-00.10 ZWB 7-29 CC1 GC-Number: 47 108 05 ZB 7-28 CS1 GC-Number: 41 108 02 ZWB 7-27 HE combi GC-Number: 47 311 55 ZWB 7-25 HE combi GC-Number: 47 311 73...
  • Page 46 Table of contents Table of contents Warnings Symbols Layout of Appliance combi system Bosch Heatronic board functions Initialisation Temperature display Indication of faults Special programme visualisation Boiler service functions 2.5.1 First Service Level 2.5.2 Secondary Service Level Failure identification procedure Notes on using the fault code tables Summary 3.2.1 Appliance faults...

  • Page 47: Warnings

    Warnings Warnings 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 48: Layout Of Appliance

    Layout of Appliance Layout of Appliance combi 221.1 221.2 234.1 32.1 18.1 6 720 610 576-02.2O Fig. 1 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 49: System

    Layout of Appliance system 221.1 221.2 234.1 32.1 18.1 6 720 610 596-01.2O Fig. 2 Heatronic control 234.1 Testing point for combustion air Heat exchanger safety temperature limiter Flue duct Testing point for gas supply pressure Cover plate for twin flue duct connection Pressure gauge Condensate trap Flue gas temperature limiter...

  • Page 50: Bosch Heatronic Board Functions

    Bosch Heatronic board functions Bosch Heatronic board func- Special programme visualisation tions The display shows for example 45 45 (continu- – – ous working at the minimum sanitary/heating power) Initialisation The display shows alternatively the temperature When it is switched on, the appliance performs a self- .
  • Page 51 Bosch Heatronic board functions The next time the central heating or heat store calls for heat, the appliance is held at a low heat output for 15 minutes. The display shows -II- in alternation with the CH flow temperature.The factory setting is 1 (enabled). If the condensation trap is not filled with water, flue gas can escape! B The trap filling programme should only...

  • Page 52: Boiler Service Functions

    Bosch Heatronic board functions B Press the button Boiler service functions until the symbol [ ] appears on the display. 2.5.1 First Service Level The display shows the heating outlet temperature. B Regulate the temperature control and the tem- Operating perature control on the previously set positions.
  • Page 53 Bosch Heatronic board functions Values that can only be read: Description Display Reset Value Heating outlet temperature. 0 - 99˚C Sanitary outlet temperature. 0 - 99˚C Heat store NTC sensor (ZSB.) 0 - 99˚C Constant hot water NTC sensor (ZWB.) 0 - 99˚C Order no.
  • Page 54 Bosch Heatronic board functions Values that can only be read - only left display digit: Description Display XY Reset Value External switch (points 8 - 9). 0 = closed 1 = Heating demand External demand for heat via LSM 0 = closed 1 = Heating demand Programmable clock: 0 = closed...

  • Page 55: Secondary Service Level

    Bosch Heatronic board functions B Press buttons 2.5.2 Secondary Service Level simultaneously until the symbol [ ] appears on the display. Operation The display shows the heating outlet temperature. In order to change or check the values of the service B Regulate the temperature control and the tem- functions:...
  • Page 56 Bosch Heatronic board functions Values that can only be read: Description Display Reset Value Automatic gas igniter status and/or fault 00 - FF Automatic gas igniter Asic fault code 00 - FF Table 6 Secondary Service Level; Values that can only be read 7 181 465 346 GB (03.02)

  • Page 57: Failure Identification Procedure

    Failure identification procedure Failure identification procedure Notes on using the fault code In this example: check the flue is clear by testing the CO level. tables • If the appliance is locked ( button is flashing), The procedure is best described with the aid of press the button.

  • Page 58: Appliance Faults

    Failure identification procedure Summary 3.2.1 Appliance faults 3.2.2 Faults that are not displayed Appliance faults Excessive burner noise, rumbling noises Flue gas levels incorrect, CO level Appliance faults too high Ignition too harsh, ignition poor. Boiler indicates P1, P2, P3 at start-up and then restarts with P1,...

  • Page 59: Error Codes On The Display

    Failure identification procedure Error codes on the display flashing. Heat store NTC sensor 2 defective Check Action B Note the setting of the temperature controls yes: B Press button B Flue gas connector corroded , damaged or dirty?. Change relative parts. B Select service function .3 .
  • Page 60 Failure identification procedure flashing. Heat store NTC sensor 2 defective Check Action To return to normal function mode: B Press buttons simultaneously. B Regulate the temperature control and the temperature control on the previously set positions. For notes, refer to Appendix 7 181 465 346 GB (03.02)
  • Page 61 Failure identification procedure flashing. Hot water NTC sensor defective Check Action B Note the setting of the temperature controls yes: B Press button B Flue gas connector corroded , damaged or dirty? Change relative parts. B Select service function .2 . Is a temperature between 0.
  • Page 62 Failure identification procedure flashing. Hot water NTC sensor defective Check Action B Unplug 20-pin connector from B Power OFF the appliance. yes: PCB. B Disconnect the boiler electrical connection. After max. 60 sec.: B Change the 20-pin connector lead assembly. Does the displayed code change B Reconnect the boiler electrical connection.
  • Page 63 Failure identification procedure flashing. No correct electrical connection Check Action A8? ↓2. TR 2 connected? yes: B Power OFF the appliance. B Connect TR 2. B Turn ON the appliance. A8? ↓2. B Turn switch until it clicks into position. Mode selector switch is between two settings A8? ↓3.
  • Page 64 Failure identification procedure flashing. Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.) Check Action B Note the setting of the temperature controls yes: No modul detected. B Press button B Disconnect connecting lead between PCB con- B Select service function 1.9 .
  • Page 65 Failure identification procedure flashing. Module not detected. (Constant CH flow temperature according to CH temperature control on boiler.) Check Action B Power OFF the appliance. Remote control status still 0.? yes: Remote control: B Replace top section. B Turn ON the appliance. AC? ↓8.
  • Page 66 Failure identification procedure flashing. Heat store NTC sensor 1 not detected (ZB...). Check Action B Note the setting of the temperature controls ↓2. Is connecting lead for heat store yes: NTC sensor 1 correctly routed, i.e. B Route connecting lead for heat store tempera- not through cable grommet? ture sensor as specified in installation instruc- tions.
  • Page 67 Failure identification procedure flashing. Heat store NTC sensor 1 not detected (ZB...). Check Action B Power OFF the appliance. Temperature between 99. and 95. is yes: displayed. B Change NTC sensor. B Unplug connector. B Turn ON the appliance. After max. 60 sec.: B Make a note of the altered service settings (see Does the displayed code change table 1, "First Service Level;...
  • Page 68 Failure identification procedure flashing. The Heatronic does not recognise the code key. Check Action B Power OFF the appliance. B Replace code plug, check code number is cor- Code plug loose, incorrect or defec- tive. rect. B Turn ON the appliance. b1? ↓3.
  • Page 69 Failure identification procedure 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. B Power OFF the appliance. Is fan lead defective? yes: B Is impedance reading between the B Replace fan lead.
  • Page 70 Failure identification procedure flashing. Outside temperature NTC sensor not detected. (Boiler heating as if outside temperature is -20˚C) Check Action ↓2. Outside temperature sensor AF2 yes: connected to Terminals A and F on B Power OFF the appliance. TA 211 E? B Connect outside temperature sensor to Termi- nals A and F on TA 211 E.
  • Page 71 Failure identification procedure flashing. Wrong signal from pin 8-9 (open?). Check Action ↓2. B Turn ON the appliance. yes: B Measure voltage between Termi- ↓3. nal 4 and Terminal 8. Voltage ≅ 24 V DC? B Power OFF the appliance. Existing heat store thermostat con- yes: nected to Terminals 7, 8 and 9?
  • Page 72 Failure identification procedure flashing. The heating outlet NTC sensor is damaged. Check Action B Note the setting of the temperature controls yes: The heating outlet NTC sensor is in short circuit: B Press button B Power OFF the appliance. B Select service function .1 . B Replace CH flow NTC sensor;...
  • Page 73 Failure identification procedure flashing. The heating outlet NTC sensor is damaged. Check Action To return to normal function mode: B Press buttons simultaneously. B Regulate the temperature control and the temperature control on the previously set positions. 7 181 465 346 GB (03.02)
  • Page 74 Failure identification procedure flashing. Safety temperature limiter has tripped. Check Action ↓2. Is the heating pressure between 1 yes: and 2 bar? B Top up system. B Vent appliance. B Press , restart the appliance. E9? ↓2. B Unblock the pump. Is the pump blocked? yes: If pump won’t start:...
  • Page 75 Failure identification procedure 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. ↓6.
  • Page 76 Failure identification procedure flashing. No flame ionisations signal Check Action B Note the setting of the temperature controls ↓6. Is the flame present? yes: ↓2. ↓3. Is the gas cock open? yes: B Open the gas cock. B Press , restart the appliance. EA? ↓3.
  • Page 77 Failure identification procedure flashing. No flame ionisations signal Check Action B Check that it is fitted correctly and functioning Natural gas models: yes: does the building have a supply pres- properly and correct if necessary. sure regulator? B Check supply pressure, inform gas company if outside correct range.
  • Page 78 Failure identification procedure flashing. No flame ionisations signal Check Action B Close mixer unit. Is diaphragm in the mixer unit cor- yes: rectly fitted and functional? ↓9. B Open mixer unit (29). B Insert diaphragm in the fan intake duct as per B Check diaphragm for correct ori- installation instructions so that the flaps open entation, soiling and splitting.
  • Page 79 Failure identification procedure flashing. No flame ionisations signal Check Action yes: B Press buttons B Press buttons simulta- simultaneously. neously. ↓14. B Select service-function 5.1. Continuous ignition (without gas) B Press buttons simultaneously. ↓17. ↓15. Ignition lead connected to ignition yes: electrodes? B Connect cable to ignition electrode.
  • Page 80 Failure identification procedure flashing. No flame ionisations signal Check Action B Power OFF the appliance. Check if the 20-pin connector lead assembly is damaged. B Disconnect the boiler electrical connection. B Change the 20-pin connector lead assembly. B Turn ON the appliance. B Reconnect the boiler electrical connection.
  • Page 81 Failure identification procedure (and possibly ) flashing. Internal failure Check Action B Note the setting of the temperature controls B Enter figure displayed in customer service record. B Press buttons simulta- neously. ↓2. B Select service function 9.3 . A service code is displayed. B Select service function 5.2 .
  • Page 82 Failure identification procedure 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 , restart the appliance. F7? ↓2. B Power OFF the appliance. B Dry PCB control board (e.g.
  • Page 83 Failure identification procedure flashing. Although appliance switches off, flame still detected Check Action B Note the setting of the temperature controls B Power OFF the appliance. B Clean condensation trap discharge pipe. Condensation trap blocked? yes: B Press , restart the appliance. FA? ↓2.
  • Page 84 Failure identification procedure flashing. Although appliance switches off, flame still detected Check Action B Power OFF the appliance. Check if the 20-pin connector lead assembly is damaged. B Disconnect the boiler electrical connection. B Change the 20-pin connector lead assembly. B Turn ON the appliance.
  • Page 85 Failure identification procedure flashing. Button pressed without necessity Check Action B Press Button is flashing. , restart the appliance. Fd? ↓2. B Make a note of the altered service settings (see The PCB control board is damaged. table 1, "First Service Level; Values that can be modified"...

  • Page 86: Faults That Are Not Displayed

    Failure identification procedure Faults that are not displayed 3.4.1 Appliance faults Excessive burner noise, rumbling noises Check Action B Note the setting of the temperature controls ↓2. Does the gas supply type match the yes: specifications on the appliance iden- B Convert appliance to correct gas type.
  • Page 87 Failure identification procedure Excessive burner noise, rumbling noises Check Action B Set to 1 for high start-up speed. B Press buttons simulta- neously. B Select service-function 5.9. 0 is displayed. Flue gas levels incorrect, CO level too high Check Action ↓2.
  • Page 88 Failure identification procedure Ignition too harsh, ignition poor Check Action B Note the setting of the temperature controls ↓6. yes: B Press buttons simulta- neously. ↓2. B Select service-function 5.1. Continuous ignition (without gas) ↓3. Ignition lead connected to ignition yes: electrodes? B Connect cable to ignition electrodes.
  • Page 89 Failure identification procedure Ignition too harsh, ignition poor Check Action ↓7. Does the gas supply type match the yes: specifications on the appliance iden- B Carry out gas type conversion as described in tification plate? installation instructions. ↓8. B Test gas supply pressure - OK? yes: B Decommission appliance.
  • Page 90 Failure identification procedure Loose or broken contact on heat store NTC sensor Check Action B Record condition of appliance as found in cus- Heat store NTC sensor lead is not fitted as described in the installation tomer service record. instructions (i.e. the cable does not B Route cable as specified in installation instruc- pass through the cable grip in the tions.
  • Page 91 Failure identification procedure Specified CH flow temperature from TA... programmer exceeded Check Action B Note the setting of the temperature controls If outside-temperature controlled programmer (TA...) is connected to boiler: • The anti-cycle time is adjusted by the programmer to the suit the system. •...

  • Page 92: Programmer Faults

    Failure identification procedure Condensation in the flue pipe Check Action B Fit diaphragm as per installation instructions or Is diaphragm in mixer unit fitted cor- rectly (see installation instructions)? replace. B Open mixer unit (29). B Close mixer unit. B Check diaphragm for correct ori- entation, soiling and splitting.
  • Page 93 Failure identification procedure Set room temperature not reached (TA 211 E und DT 2) Check Action B Turn up thermostatic valve(s). Thermostatic valve(s) set too low? yes: ↓2. ↓2. B Correct heating characteristic. Heating characteristic set too low? yes: ↓3. ↓3.
  • Page 94 Failure identification procedure Set room temperature exceeded by large amount Check Action Do radiators get too hot? yes: TR 2: B Decrease setting of “Heating” control TA 211 E: B Correct heating characteristic. ↓2. ↓2. B Select better installation location. Bad choice of location for program- yes: mer, e.g.
  • Page 95 Failure identification procedure Temperature rises instead of falling Check Action B Check setting and correct as necessary. Timer clock (DT 2) incorrectly set Incorrect or no modulation Check Action B Check wiring against wiring diagram and correct Programmer incorrectly wired as necessary.

  • Page 96: Appendix

    Appendix Appendix NTC values 4.1.2 CH flow NTC sensor, heat store NTC sen- sor, constant hot water NTC sensor and 4.1.1 Outside temperature sensor hot water NTC sensor Outside temperature Temperature (˚C) (˚C) Measurement tolerance ± ± ± ± 10% Resistance (Ω...

  • Page 97: Electronic Schemes

    Appendix Electronic schemes 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 6 720 610 576-08.2O Ignition transformer 328.1 Bridge Heat exchanger overheat cut-out Flame presence led Flue gas NTC sensor...

  • Page 98: List Of Most Important Replacement Parts

    Appendix List of most important replacement parts Component Order no. Remarks Component Order no. Remarks Temperature 8 714 500 087 Switchbox sensor, CH flow PCB control 8 748 300 385 Electrode 8 718 107 077 board assembly Transformer 8 747 201 358 Gas valve Ignition lead 8 714 401 999...

  • Page 99: Approved Corrosion Inhibitors And Anti-Freeze Fluids For Central Heating Water

    Appendix Approved corrosion inhibitors and Summary of BDH Information anti-freeze fluids for central Sheet on Identifying Corrosion by heating water CFCs If any system water treatment is required then The presence of halogenated hydrocarbons in the com- only products suitable for use with Aluminium bustion air causes surface corrosion on affected met- shall be used i.e Fernox- Copal or Superconcen- als.

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