Related Manuals for Benchmark ZWB 7-29 CC1
Summary of Contents for Benchmark ZWB 7-29 CC1
- Page 1 Installation and Servicing Instructions Wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 577-00.10 ZWB 7-29 CC1 GC-Number: 47 108 05...
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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 28 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 6 720 610 599-01.2O Fig. 2 Heatronic control Inspection window Heat exchanger safety temperature limiter Fixing points Hot water NTC sensor 221.1 Flue duct Testing point for gas supply pressure 221.2 Combustion air intake Pressure gauge Fan assembly... -
Page 7: Function
Details of the appliance Function 234.1 ϑ 29.1 52.1 ϑ 6 720 610 599-08.2O Fig. 3 Bosch Heatronic control Adjustable gas flow restrictor Temperature limiter, heat exchanger Adjusting screw for min. gas inlet flow volume Hot water NTC sensor Control valve Testing point for gas supply pressure Motor Pressure gauge... -
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 6 720 610 599-07.2O Fig. -
Page 9: Technical Data
Details of the appliance Technical data Units Natural gas Propane Max. rated heat output net 40/30˚C central heating 31.2 31.2 Max. rated heat output net 50/30˚C central heating 30.9 30.9 Max. rated heat output net 80/60˚C central heating 29.2 29.2 Max. -
Page 10: Installation Regulations
Installation regulations Condensate analysis, mg/l Domestic water performance Ammonium 1.2 Nickel 0.15 Domestic Temperature 14.2 Water Flow Rise 30 °C ≤ 0.01 Mercury ≤ 0.0001 Lead Rate l/min Temperature ≤ 0.001 Sulphate Cadmium Rise 35 °C 12.1 ≤ 0.005 Zinc ≤... -
Page 11: Installation
Installation Installation All types of single lever mixer taps and thermostatic mixer units suitable for a mains pressure of up to 10 bar can be used. B Always turn off the gas cock before car- The head of a loose-head shower must not be allowed rying out any work on components to fall within 25 mm of the top the bath to prevent the which carry gas. -
Page 12: Siting The Appliance
Installation If Thermostatic Radiator Valves are fitted then it is rec- substances will invalidate the guarantee. The pH ommended that the the primary radiator is left open. value of the system water must be less than 8 or the appliance guarantee will be invalidated. Repeated venting probably indicates a leak and this must be rectified to ensure the proper operation of the A drain cock to BS2879 must be fitted to the lowest... -
Page 13: 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. 7. Use the inner lugs on the top and bottom horizontal sec- tions for the appliances that are 440 mm wide. -
Page 14: 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. 11 ciated central heating system must be... -
Page 15: 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 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.
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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 B Remove screw and slide terminal cover forwards to Electrical connections remove. Refer to fig. 26. 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 21: Mains Voltage External Controls Connections
Electrical connections 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 Programmer Connections Series... -
Page 22: 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 23: 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 24: Setting The Domestic Hot Water Temperature And Flow Rate
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 43. In the unlikely event of a fault occuring while the appli- ance is in operation: The display then shows a fault code and the button may also flash. -
Page 26: 5.10 Digital Timer
Commissioning 5.10 Digital Timer 5.10.3 Programming 5.10.4 Setting time and day B Press repeatedly until the display shows PROG. B The hour setting flashes: change hour by pressing B Press and release ; the minutes setting flashes: set minutes by pressing B Press and release ;... - Page 27 Commissioning 5.10.6 Changing the Operating Mode B Press repeatedly until the display shows CH1 PROG or CH2 PROG. B Set mode by pressing – ON: Central heating on (CH 1)/hot water on (CH 2) – OFF: Central heating off/Economy (CH 1)/hot water “Comfort”...
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Page 28: Individual Settings
Individual settings B Rotate yellow button through 180° and replace (dot Individual settings facing inwards). The CH flow temperature is no longer limited. Mechanical settings Control setting CH flow temperature 6.1.1 Checking the size of the expansion vessel approx. 35˚C Maximum pressure at maximum CH flow temperature is approx. -
Page 29: 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 30: Setting The Maxim Ch Flow Temperature (Service Function 2.5)
Individual settings B Refer to the settings tables for heating and cylinder 6.2.4 Setting the maxim CH flow temperature (Service Function 2.5) charging output to obtain the relevant code for the desired heating output in kW (see page 45). The maximum CH flow temperature can be set to B Turn the temperature control between 35˚C and 88˚C (factory setting). -
Page 31: 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 32 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.
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Page 33: Testing Combustion Air/Flue Gas At Set Heat Output
Maintenance Testing combustion air/flue gas at You have 15 minutes in which to measure set heat output the levels. After that, the appliance switch- es back from “chimney sweep” mode to 7.2.1 Testing the O or CO level in the combus- normal mode. -
Page 34: 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 35). Check ionisation current, Service Function 3.3, (see page 35). Perform visual check of air/flue duct. Visual check of diaphragm for soiling and splits (see page 37). -
Page 35: Description Of Servicing Operations
Maintenance Description of servicing operations Primary Heat exchanger There is a special accessory kit (no. 840) for cleaning The combustion performance must be checked before the heat exchanger, order no. 7 719 001 996. and after any servicing work on the combustion and burner components. - Page 36 Maintenance B Loosen any deposits in the heat exchanger from top Burner to bottom using the cleaning blade. Refer to fig. 53. 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 37 Maintenance B Clean the electrodes with a non-metallic brush. (The Diaphragm in mixer unit spark gap should be 4,5 mm ± 0,5 mm.) B Take care not to damage diaphragm B Replace and re-connect the assembly taking care (443) when removing and refitting it. not to mislay the inspection window.
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Page 38: Replacement Of Parts
Maintenance B Remove the pcb control board. Electrical wiring B Check the electrical wiring for physical damage and replace any damaged wires. 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. -
Page 39: Fan Assembly
Maintenance 8.3.2 Fan Assembly 8.3.3 Pump B Switch off the appliance. B Disconnect the 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 the siphon by releasing the jubilee clip. -
Page 40: 3-Way Diverter Valve
Maintenance 8.3.4 3-way diverter valve 8.3.6 Sensors B Switch off the appliance. B Check that the appliance is electrically isolated. B Disconnect appliance from the power supply. Central Heating Flow Temperature Sensor – B Turn off service cocks. Item 36, fig. 2, 60 B Unplug connector from 3-way valve motor. -
Page 41: Gas Valve
Maintenance 8.3.7 Gas Valve 8.3.8 Domestic Hot Water Heat Exchanger B Check that the gas cock is turned off. B Refer to section 8.2. B Lower the control panel. Refer to fig. 63. B Use new seals when fitting the new heat exchanger. B Pull off the solenoid connections at the rear of the 8.3.9 Electrode assembly... - Page 42 Maintenance B Transfer components, as necessary, to the new heat 8.3.14 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.
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Page 43: 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 Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for circuit breaks/short circuits. -
Page 44: 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 Sensor - DHW flow temp. 8 714 500 054 0 Control board 8 748 300 418 0 Gas valve... -
Page 45: Heating/Hot Water Output Settings (N.g)
Appendix Heating/hot water output settings (N.G) Natural gas G20 Display Heat Heat Gas vol. flow code output input rate (l/min at 80/60˚C) 15.5 11.7 11.8 20.7 14.6 14.8 25.8 17.5 17.7 31.0 20.4 20.7 36.1 23.4 23.6 41.3 26.3 26.6 46.5 29.2 29.5... -
Page 46: Operational Flow Diagrams
Appendix Operational Flow diagrams 9.5.1 Domestic hot water function Fig. 68 6 720 610 599 GB (03.02) -
Page 47: Central Heating Function
Appendix 9.5.2 Central heating function Fig. 69 6 720 610 599 GB (03.02) - Page 48 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 49 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 50 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...
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Page 51: 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 52: 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 53: 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 54: 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 55 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...
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Page 56: 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 57 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 58 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...
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Page 59: 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 60 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)
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Page 61: 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 62: 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 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 86 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 87 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 88 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 89 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 90 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 91 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 92 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 93 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 94 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 95 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 96 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 97 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 98 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 99 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 100 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 101 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 102 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 103 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.
- Page 105 Users Instructions and Customer Care Guide RD 532 Condensing boiler RD 428 Condensing boiler 6 720 611 441-00.1O ZWB 7-32 RD 532 GC-Number: 47 108 13 ZB 7-28 RD 428 GC-Number: 41 108 07...
- 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 RD 532 Boilers: Setting the Hot Water Temperature Summer Mode, Hot Water Only (RD 532 Appliances) 16 Frost protection (RD 532 Appliances) Fault Condition Tips on saving energy...
- Page 107 Contents Your guarantee Guarantee registration Operating Instructions Quick Reference 6 720 610 600 GB (04.06)
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Page 108: Excellence Comes As Standard
British Gas/Scottish Gas Condensing appli- ance. Benchmark The “Benchmark” initiative is the new code of practice to encour- age the correct installation, commissioning and servicing of domestic central heating boilers and system equipment. -
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: General Notes
General notes 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 done. Repeated venting will reduce the quantity of water in the system and this must be replenished for safe and satisfactory operation of the appliance. Should water leaks be found in the system or excessive venting is required then a service engineer must be contacted to inspect the installation and rectify any fault.
- Page 112 General notes Thermostatic radiator valves It is recommended that this type of valve is fitted to all the radia- tors except one, usually radiator where the room thermostat is fit- ted. They should conform to the requirements of BS2767:10. Showers, bidets, taps and mixing valves – RD 532 Boilers Standard hot and cold taps and mixing valves must be suitable for operating at mains pressure.
- Page 113 General notes Alternatively the maximum temperature of the domestic hot water may be reset to about 45 °C which will reduce the risk of scale formation in these hard water areas. Ventilation This is a room sealed appliance and does not require any air for combustion from inside the house.
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Page 114: Controls
Controls Controls 317 366 367 310 422 6 720 610 600-01.1O 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 (RD 532) Display Indicator lamp for “burner on”... -
Page 115: 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 116 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.
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Page 117: 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 If the display alternates between -II- and the cen- tral heating flow temperature, the trap filling pro-... -
Page 118: 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 Controlling Central Heating B Set room thermostat to the desired room temperature. -
Page 119: Rd 532 Boilers: Setting The Hot Water Temperature
Operating the Appliance RD 532 Boilers: Setting the Hot Water Temperature Hot water temperature On RD 532 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 Control Setting Water Temperature... -
Page 120: Summer Mode, Hot Water Only (Rd 532 Appliances)
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 121: Fault Condition
Operating the Appliance Fault Condition In the unlikely event of a fault occuring while the appliance is in operation: The display then shows a fault code and the button may also flash. If the button flashes: B Press and hold the button until the display shows “–... -
Page 122: 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 con-trolled according to the level of demand for heat. -
Page 123: General Information
The information is printed on the appliance identification plate/ sticker (see page 10, item 295). Your installer will have completed the Benchmark “log-book” giv- ing details of the boiler together with name, address and registra- tion number. Have the “log-book” to hand when calling a Service Engineer. -
Page 124: Maintaining Your Appliance
Maintaining your appliance Maintaining your appliance Your new RD 532/RD 428 gas-fired appliance represents a long- term investment in a reliable, high quality product. In order to realise its maximum working life, and to ensure it con- tinues to operate at peak efficiency and performance, it is essen- tial that your boiler receives regular, competent servicing and maintenance checks beyond the initial 2 year guarantee period. -
Page 125: Fault Or Breakdown
Fault or breakdown Fault or breakdown This product is supported in the UK by Worcester Heat Systems Ltd. – part of the Bosch Group. A specialist factory trained field SERVICE ENGINEER is available to attend a breakdown or manufacturing fault occuring on this appliance. - Page 126 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 127 Serial number:..................(See identity label inside appliance casing) Type/size:....................Date of installation:................Check that the Benchmark “log-book” has been completed by your installer or service engineer. EXCELLENCE COMES AS STANDARD Manufactured exclusively for British Gas by The Bosch Group Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.