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  4. ZBR 8-35 ICS1
  5. Service Booklet

Worcester ZBR 8-35 ICS1 Service Booklet

Summary of ZBR 8-35 ICS1

  • Page 1

    Service booklet for the engineer for gas condensing boilers 6 720 610 333-00.1r zsbr 7-28 ics1 gc-number: 41 108 04 zwbr 8-30 icc2 gc-number: 41 108 09 zbr 8-35 ics1 gc-number: 41 108 05 zwbr 11-37 icc1 gc-number: 41 108 10 zwbr 7-28 he plus gc-number: 47 311 56 zwbr 11-35 he plus gc-number: 47 311 ...

  • Page 2

    7 181 465 347 (01.07) 2 contents contents safety precautions 3 symbols 3 1 layout of appliance (zsbr/zwbr) 4 2 operation 5 2.1 standard display 5 2.2 displaying service functions 5 2.3 setting service functions 5 2.4 resetting service functions to factory settings 5 2.4.1 resetting service functions...

  • Page 3

    7 181 465 347 (01.07) safety precautions 3 safety precautions repairs b repairs may only be carried out by an approved installer! B before carrying out any work on the appliance, switch it off at the master switch! B even when the appliance is switched off at the mas- ter switch, some components on ...

  • Page 4

    7 181 465 347 (01.07) 4 layout of appliance (zsbr/zwbr) 1 layout of appliance (zsbr/zwbr) fan fixing screws burner fixing screws electrode assembly: flame sensing electrode ignition electro- des ch flow ntc sensor ch flow safety temperature limiter variable-charac- teristic pump automatic vent gas f...

  • Page 5

    7 181 465 347 (01.07) operation 5 2 operation instructions on the use of the text display module are given in the operating and installation instructions for the boiler. Fig. 1 controls a display b “up” or “more” button c “down”, or “less” button d “back” button e “nest” button f “delete” button 2.1...

  • Page 6

    7 181 465 347 (01.07) 6 boiler service functions 3 boiler service functions 3.1 summary text display message display range adjustable from - to reset value 0.0 last fault 00 - ff clear only 0 0.1 flow temp. Sensor 0 - 99 °c - - 0.2 hot water temp. Sensor 0 - 99 °c - - 0.3 stor. Tank temp. Sensor1 0 ...

  • Page 7

    7 181 465 347 (01.07) boiler service functions 7 3.9 link 8 - 9 open closed - - link ls-lr open closed - - 4.0 stor. Tank. Therm.. (7-9) blocked heat demand - - 4.1 room therm. Lsm blocked heat demand - - lsm release blocked heat demand - - 4.2 timer ch. 1 (heating) blocked heat demand - - timer ch....

  • Page 8

    7 181 465 347 (01.07) 8 boiler service functions 6.8 cycle time (hot water) - 0 - 60 min 0 min 6.9 duration (hot water) - 0 - 30 min 1 min 7.0 pump map (heating) - 0 pump step adjustable 1 const. Pressure high 2 const. Pressure middle 3 const. Pressure low 4 prop.Pressure high 5 prop.Pressure low 4 ...

  • Page 9

    7 181 465 347 (01.07) boiler service functions 9 3.2 explanation of service functions 0.0 last fault the last fault can also be recalled for servicing pur- poses when the appliance is functioning correctly. To delete the stored fault: b delete fault (no fault displayed). B press the button. B use th...

  • Page 10

    7 181 465 347 (01.07) 10 boiler service functions 2.7 autom. Anti-cycle mode if an outside-temperature controlled programmer is con- nected to the appliance, the anti-cycle time is adjusted automatically. Automatic adjustment of the anti-cycle time can be dis- abled. This may be necessary in the cas...

  • Page 11

    7 181 465 347 (01.07) boiler service functions 11 shows the status of channel 2 of the timer integrated in the text display module or the separate programmer. If that channel’s status is “heat demand”, hot water mode will be activated according to the programmer commands. 4.4 heat demand (heating)/ ...

  • Page 12

    7 181 465 347 (01.07) 12 boiler service functions if a stratified-charge tank is connected, it is useful to have the function activated. The delayed cut-in of the pump then prevents cold water being pumped through the tank and cooling it down. 6.8 cycle time (hot water) (zwbr... Only) the appliance ...

  • Page 13

    7 181 465 347 (01.07) boiler service functions 13 8.5 siphon fill program the trap filling programme ensures that the condensa- tion trap is filled when the appliance is first installed or after it has been shut down for a long period: the con- densation trap prevents flue gas escaping from the appl...

  • Page 14

    7 181 465 347 (01.07) 14 rectifying faults 4 rectifying faults 4.1 boiler failure codes indication 4.1.1 ... On the boiler in order to identify the specific boiler failure a two digit alphanumeric code is used. This allows a quick fault identification and solution. The text display shows the message...

  • Page 15

    7 181 465 347 (01.07) rectifying faults 15 loose or broken contact on heat store ntc sensor x x 39 specified ch flow tempera- ture from ta... Programmer exceeded x x 40 programmer faults tr 2 pag e set room temperature not reached x 41 set room temperature exceeded by large amount x 43 set room temp...

  • Page 16: E A

    7 181 465 347 (01.07) 16 rectifying faults 4.3 how to use the fault tables the procedure is explained using the fault code ea as an example: the table heading shows the fault code and a general description of the fault. In the example shown, you are instructed to note the current settings before goi...

  • Page 17: A 1

    7 181 465 347 (01.07) rectifying faults 17 4.4 faults indicated on display a 1 flashing. Controlled-characteristic pump has run dry check action 1. System pressure below 1.2 bar? Yes: b power off the appliance. B check appliance and system for water leaks and repair as necessary. B top up system. B ...

  • Page 18: A 5

    7 181 465 347 (01.07) 18 rectifying faults a 5 flashing. Heat store ntc sensor 2 defective check action 1. B activate menu option show service parameters. B select .4 stor.Tank temp.Sensor2 . Is a temperature between 0. And 5. Displayed? Yes: b is the connector for heat store ntc sensor 2 cor- roded...

  • Page 19: A 7

    7 181 465 347 (01.07) rectifying faults 19 a 7 flashing. Hot water ntc sensor defective check action 1. B activate menu option show service parameters. B select .2 hot water temp.Sensor . Is a temperature between 0. And 5. Displayed? Yes: b is the connector for hot water ntc sensor corro- ded 1) , d...

  • Page 20: A 8

    7 181 465 347 (01.07) 20 rectifying faults a 8 flashing. No correct electrical connection check action 1. Mode selector switch is between two settings b turn switch until it clicks into position. A8? ↓2. 2. B power off the appliance. Wiring between tr 2 and text- display ok? • terminal 3 on tr 2 con...

  • Page 21

    7 181 465 347 (01.07) rectifying faults 21 ad flashing. Heat store ntc sensor 1 not detected check action 1. Is lead for heat store ntc sensor correctly routed, i.E. Not through cable clamp? Yes: ↓2. No: b route connecting lead for heat store tempera- ture sensor as specified in installation instruc...

  • Page 22

    7 181 465 347 (01.07) 22 rectifying faults b1 flashing. Code plug not detected. Check action 1. No fault or fault code fc displayed on text display? Yes: b power off the appliance. B fit code plug (correctly), making sure code number (see appendix) is correct. B turn on the appliance. B1? ↓2. No: ↓2...

  • Page 23

    7 181 465 347 (01.07) rectifying faults 23 c1 flashing. Fan speed too low check action 1. Fan lead connector properly con- nected? Yes: ↓2. No: b power off the appliance. B plug in connector. B turn on the appliance. C6? ↓2. 2. Fan lead defective? Yes: b power off the appliance. B replace fan lead. ...

  • Page 24: D 3

    7 181 465 347 (01.07) 24 rectifying faults d 3 flashing. Wrong signal from pin 8-9. Check action 1. Jumper 8 - 9 fitted correctly? Yes: ↓2. No: b power off the appliance. B fit jumper 8 - 9 correctly, tighten screw. B turn on the appliance. D3? ↓2. 2. B turn on the appliance. B measure voltage betwe...

  • Page 25: E 2

    7 181 465 347 (01.07) rectifying faults 25 e 2 flashing. The heating outlet ntc sensor is damaged. Check action 1. B activate menu option show service parameters. B select .1 flow temp.Sensor. Is a temperature between 0. And 5. Displayed? Yes: the heating outlet ntc sensor is in short circuit: b pow...

  • Page 26: E 9

    7 181 465 347 (01.07) 26 rectifying faults e 9 and flashing. Safety temperature limiter has tripped. Check action 1. Is the heating pressure between 1 and 2 bar? Yes: b top up system. B vent appliance. B press , does appliance restart??? E9? ↓2. No: ↓2. 2. Is the pump blocked? Yes: b unblock the pum...

  • Page 27: E 9

    7 181 465 347 (01.07) rectifying faults 27 5. B power off the appliance. B remove fuse si 3 from appliance pcb control board and test for continuity. R = ∞? Yes: b change the fuse. B turn on the appliance. B press , does appliance restart??? E9? ↓6. No: b remount the fuse. B turn on the appliance. 6...

  • Page 28

    7 181 465 347 (01.07) 28 rectifying faults ea and flashing. During operation: flame not detected check action 1. Is the flame present? Yes: ↓6. No: ↓2. 2. Is the gas cock open? Yes: ↓3. No: b open the gas cock b press , does appliance restart??? Ea? ↓3. 3. Is there air in the supply pipe? Yes: b ven...

  • Page 29

    7 181 465 347 (01.07) rectifying faults 29 6. Is the ground connection correct? Yes: ↓7. No: b rewire correctly as specified in the installation instructions. B press , does appliance restart??? Ea? ↓7. 7. Two phase net: is there a resistor fitted between pe and n? Yes: ↓8. No: b power off the appli...

  • Page 30

    7 181 465 347 (01.07) 30 rectifying faults 11. Is flue gas co 2 level incorrect 1) ? Yes: b adjust to correct level. B press , does appliance restart??? Ea? ↓12. No: ↓12. 12. B activate menu option show serv- ice parameters. B select 5.1 permanent ignition. Continuous ignition ok? Yes: ↓13. No: ↓16....

  • Page 31

    7 181 465 347 (01.07) rectifying faults 31 17. Electrode assembly defective? B power off the appliance. B remove electrode assembly. Electrodes worn out? Yes: b replace electrode assembly. B turn on the appliance. B press , does appliance restart??? Ea? ↓18. No: b refit electrode assembly. B turn on...

  • Page 32: F 0

    7 181 465 347 (01.07) 32 rectifying faults f 0 (and possibly ) flashing. Internal failure check action 1. B activate menu option show service parameters. B select 9.3 gfa-asic-error. A message is displayed. B record figure displayed in service report. ↓2. 2. B select 5.2 gfa status / error. A messag...

  • Page 33: F 7

    7 181 465 347 (01.07) rectifying faults 33 f 7 and flashing. Although appliance switches off, flame still detected check action 1. Electrode(s) dirty or defective. B power off the appliance. B replace electrode assembly. B turn on the appliance. B press , does appliance restart??? F7? ↓2. 2. B power...

  • Page 34

    7 181 465 347 (01.07) 34 rectifying faults fa and flashing. After appliance switches off flame is detected check action 1. Is condensation trap in condensing boiler blocked? Yes: b clean condensation trap discharge pipe. B press , does appliance restart??? Fa? ↓2. No: ↓2. 2. Electrodes faulty. B rep...

  • Page 35: F C

    7 181 465 347 (01.07) rectifying faults 35 f c flashing. Text display module not detected check action 1. No fault or fault code fc displayed on text display? B power off the appliance. B fit code plug (correctly), making sure code number is correct (see appendix). B turn on the appliance. Fc? ↓2. 2...

  • Page 36

    7 181 465 347 (01.07) 36 rectifying faults 4.5 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 1. Fuse t 1.6 a (312) defective. Yes: b turn on the appliance. B change the fuse. B power off the appliance. Start sequ...

  • Page 37

    7 181 465 347 (01.07) rectifying faults 37 flue gas levels incorrect, co level too high check action 1. Does the gas supply type match the specifications on the appliance iden- tification plate? Yes: ↓2. No: b convert appliance to correct gas type 1) . 2. B test gas supply pressure 1) , - ok? Yes: ↓...

  • Page 38

    7 181 465 347 (01.07) 38 rectifying faults ignition too harsh, ignition poor check action 1. B activate menu option show service parameters. B select 5.1 permanent ignition. Continuous ignition ok? Yes: ↓6. No: ↓2. 2. Ignition lead connected to ignition electrodes? Yes: ↓3. No: b connect cable to ig...

  • Page 39

    7 181 465 347 (01.07) rectifying faults 39 7. B test gas supply pressure 1) - ok?. Yes: ↓8. No: b decommission appliance. B notify gas company. 8. Problem with flue? B check co 2 level in combustion air. > 0,2 % co 2 ? Yes: b check flue and repair or replace if necessary. Ignition poor? ↓8. No: ↓9. ...

  • Page 40

    7 181 465 347 (01.07) 40 rectifying faults specified ch flow temperature from ta... Programmer exceeded check action if outside-temperature controlled programmer (ta...) is connected to boiler: • the anti-cycle time is adjusted by the programmer to the suit the system. • the factory setting for the ...

  • Page 41

    7 181 465 347 (01.07) rectifying faults 41 4.5.2 programmer faults set room temperature not reached (tr 2) check action 1. Thermostatic valve(s) set too low? Yes: b turn up thermostatic valve(s). ↓2. No: ↓2. 2. Ch flow temperature control on boiler set too low? Yes: b turn up ch flow temperature con...

  • Page 42

    7 181 465 347 (01.07) 42 rectifying faults set room temperature not reached check action 1. Thermostatic valve(s) set too low? Yes: b turn up thermostatic valve(s). ↓2. No: ↓2. 2. Heating characteristic set too low? Yes: b correct heating characteristic. ↓3. No: ↓3. 3. Ch flow temperature control on...

  • Page 43

    7 181 465 347 (01.07) rectifying faults 43 set room temperature exceeded by large amount check action 1. Do radiators get too hot? Yes: tr 2: b decrease setting of “heating” control ↓2. No: ↓2. 2. Bad choice of location for program- mer, e.G. Outside wall, near window, in draught, on hollow wall, et...

  • Page 44

    7 181 465 347 (01.07) 44 rectifying faults heat store fails to heat up check action 1. With tr 2: ch flow temperature control on boiler set too low. B increase ch flow temperature control setting. 2. Hot water temperature control on boiler set too low b increase hot water temperature control setting...

  • Page 45

    7 181 465 347 (01.07) appendix 45 5 appendix 5.1 ntc values 5.1.1 outside temperature sensor 5.1.2 ch flow ntc sensor, heat store ntc sen- sor, constant hot water ntc sensor and hot water ntc sensor outside temperature ( °c) measurement tolerance ± 10% resistance ( Ω) -20 2 392 -16 2 088 -12 1 811 -...

  • Page 46

    7 181 465 347 (01.07) 46 appendix 5.2 electronic schemes fig. 2 4.1 ignition transformer 6 temperature limiter, heat exchanger 9 flue gas temperature limiter 18 pump 32 flame sensing electrode 33 ignition electrode 36 temperature sensor in ch flow 52 solenoid valve 1 52.1 solenoid valve 2 56 gas val...

  • Page 47

    7 181 465 347 (01.07) appendix 47 5.3 list of most important replacement parts component order no. Remarks switchbox pcb control board 8 748 300 385 transformer 8 747 201 358 ignition lead 8 714 401 878 20-pin connector lead assembly 8 714 401 912 fuse 1 904 522 730 t 0,5 a fuse 1 904 522 740 t 1,6 ...

  • Page 48

    7 181 465 347 (01.07) 48 appendix 5.4 approved corrosion inhibitors and anti-freeze fluids for central heating water manufacturer description remarks mixing concentra– tion % by weight with all anti-freeze fluids and corrosion inhibitors, it is extremely important to observe the manufacturer’s recom...

  • Page 49

    7 181 465 347 (01.07) appendix 49 5.5 detecting corrosion by cfcs halogenated hydrocarbons in the combustion air cause surface corrosion of the affected metal components. The combustion chamber and the boiler heating sur- faces (including stainless steel) are particularly suscep- tible to this type ...

  • Page 50

    7 181 465 347 (01.07) 50 appendix.

  • Page 51

    7 181 465 347 (01.07) appendix 51.

  • Page 52

    Appendix.