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  4. ZSBR 7-30 RD 430i system
  5. Service Booklet

Worcester ZSBR 7-30 RD 430i system Service Booklet

Manual is about: gas condensing boiler

Summary of ZSBR 7-30 RD 430i system

  • Page 1

    Supplied by www.Heating spares.Co tel. 0161 620 6677 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 43...

  • Page 2: Contents

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 2 contents contents safety precautions 3 symbols 3 1 layout of appliance 4 2 operation 5 2.1 initialisation 5 2.2 standard display 5 2.3 displaying service functions 5 2.4 setting service functions 6 2.5 resetting service fun...

  • Page 3: Safety Precautions

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 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 swi...

  • Page 4: Layout of Appliance

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 4 layout of appliance 1 layout of appliance fig. 1 4 bosch heatronic 6 temperature limiter for heat exchanger 6.1 hot water ntc sensor (combi boiler) 7 testing point for gas supply pressure 8.1 pressure gauge 9 flue gas tempe...

  • Page 5: Operation

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 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. 2 controls a display b “up”/“more” button c “down”/“less” button d “back...

  • Page 6

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 6 operation 2.4 setting service functions b press any button to activate the main menu. B press or button until the arrow cursor is pointing to settings . B press the button. B press or button until the arrow cursor is pointi...

  • Page 7: Boiler Service Functions

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) boiler service functions 7 3 boiler service functions 3.1 summary text display message display range adjustable from - to reset value 0.0 last fault 00 - ff last fault code can be deleted 0 0.1 flow temp. Sensor 0 - 99˚c - - ...

  • Page 8

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 8 boiler service functions 3.4 pump mode (not applicable) - - - 3.5 pump blocking time (not applicable) - 0 - 240 s in 15-s increments 0 s 3.6 software version bf 11.Xx - - 3.9 link 8-9 open closed - - link ls-lr open closed ...

  • Page 9

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) boiler service functions 9 6.7 pump off (hot water) (not applicable) - off on on 6.8 cycle time (hot water) (combi only) - 20 - 60 min 20 min 6.9 duration (hot water) (combi/system) - 0 - 30 min 1 min 7.0 pump map (heating) -...

  • Page 10

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 10 boiler service functions 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 fa...

  • Page 11

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) boiler service functions 11 2.5 max. Flow temperature the maximum ch flow temperature can be set to between 35˚c and 88˚c (factory setting). Even if the ch flow temperature control is set higher, the setting entered for 2.5 m...

  • Page 12

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 12 boiler service functions 4.6 internal regulator the boiler has an internal anti-cycle function which pre- vents the burner overheating if the heat output can not be dissipated even in min mode. The appliance will then swit...

  • Page 13

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) boiler service functions 13 the factory setting is: 7.0 pump map (heating) 3 const. Pressure low fig. 3 constant pressure 1-5 caracteristics h pressure q water circulation rate fig. 4 proportional pressure if this parameter i...

  • Page 14

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 14 boiler service functions 7.3 air purge mode the first time the appliance is switched on, a once-only venting function is activated. The heating pump then switches on and off at intervals. This sequence lasts about 8 minute...

  • Page 15: Rectifying Faults

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) rectifying faults 15 4 rectifying faults 4.1 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 the text d...

  • Page 16

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 16 rectifying faults 4.2.2 faults that are not displayed appliance faults system boiler combi boiler page boiler indicates p1, p2, p3 at start-up and then restarts with p1.. X x 36 excessive burner noise, rumbling noises x x ...

  • Page 17

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) rectifying faults 17 4.3 notes on using the fault code tables the procedure is best described with the aid of an example: • work through the table from top to bottom and from left to right. • first make a note of the present ...

  • Page 18

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 18 rectifying faults error a1 4.4 error codes on the display a1 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 ...

  • Page 19

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 19 rectifying faults error a7 a7 flashing. Water ntc sensor defective check action 1. B activate menu option show serv- ice parameters. B select service function 0.2 hot water temp. Sensor. Is a temperature between 0 and 5˚c ...

  • Page 20

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 20 rectifying faults error a8 a8 flashing. No correct electrical connection check action 1. B power off the appliance. B check wiring between textdis- play and tr 2: – terminal 3 on textdisplay con- nected to terminal 3 tr 2?...

  • Page 21

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 21 rectifying faults error ad ad flashing. Dhw cylinder ntc sensor not detected check action 1. Is lead for dhw cylinder ntc sensor correctly routed, i.E. Not through cable clamp? Yes: ↓2. No: b route connecting lead for dhw ...

  • Page 22

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 22 rectifying faults error b1 b1 flashing. Code plug not detected. Check action 1. B1 is shown on 2 digit display. (independent on what is shown on the text display). Yes: b power off the appliance. B fit code plug (correctly...

  • Page 23

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 23 rectifying faults error c1 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. C1? ↓2. 2. Is fan lea...

  • Page 24

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 24 rectifying faults error d3 d3 flashing. Wrong signal from pin 8-9. Check action 1. B measure voltage between termi- nal 4 and terminal 8. Voltage ≅ 24 v dc? Yes: ↓2. No: ↓3. 2. Link between terminals 8 and 9 con- nected? Y...

  • Page 25

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 25 rectifying faults error e2 e2 flashing. The flow temp. Ntc sensor is damaged. Check action 1. B activate menu option show serv- ice parameters. B select 0.1 flow temp. Sensor. Is a temperature between 0 and 5˚c displayed? ...

  • Page 26

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 26 rectifying faults error e9 e9 and flashing. Safety temperature limiter has tripped. Check action 1. Is the heating pressure between 1 and 2 bar? Yes: ↓2. No: b top up system. B vent appliance. B press , restart the applian...

  • Page 27

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 27 rectifying faults error e9 5. Is lead disconnected from ch flow safety temp. Limiter? Yes: b power off the appliance. B reconnect lead. B turn on the appliance. B press , restart the appliance. E9? ↓6. No: ↓6. 6. B power o...

  • Page 28

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 28 rectifying faults error ea ea and flashing. During operation: flame not detected check action 1. Is a burner flame visible? Yes: ↓5. No: ↓2. 2. Is the gas cock turned on? Yes: ↓3. No: b open the gas cock. B press , restart...

  • Page 29

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 29 rectifying faults error ea 7. Is diaphragm in mixer unit fitted correctly (see installation instructions)? B open mixer unit (29). B check diaphragm for correct orienta- tion, soiling and splitting. Is diaphragm ok? Yes: b...

  • Page 30

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 30 rectifying faults error ea 10. Is flue gas co 2 level incorrect 1) ? Yes: b adjust to correct level. B press , restart the appliance. Ea? ↓11. No: ↓11. 11. B activate menu option show service parameters. B select 5.1 perma...

  • Page 31

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 31 rectifying faults error ea 17. Check if the 20-pin connector lead assembly is damaged. B power off the appliance. B change the 20-pin connector lead assembly. B turn on the appliance. B press , restart the appliance. Ea? ↓...

  • Page 32

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 32 rectifying faults error f0 f0 (and possibly ) flashing. Internal failure check action 1. B activate menu option show serv- ice parameters. B select 9.3 gfa-asic error (automatic ignition module, extended messages). A messa...

  • Page 33

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 33 rectifying faults error f7 f7 and flashing. Although appliance switches off, flame still detected check action 1. Electrode(s) dirty or defective? B power off the appliance. B remove electrode assembly and bracket and chec...

  • Page 34

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 34 rectifying faults error f7 2. Electrode assembly defective? B power off the appliance. B remove electrode assembly. Electrode assembly burnt out? B replace electrode assembly. B turn on the appliance. B press , restart the...

  • Page 35

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 35 rectifying faults error fc fc 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 ...

  • Page 36

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 36 rectifying faults error fd 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 power off the app...

  • Page 37

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 37 rectifying faults error fd 4. Is appliance’s internal air/flue chan- nel leaking or blocked? B open up heat exchanger and inspect. B remove silencer, flue duct and air flow limit. B open trap and inspect. Air channels dirt...

  • Page 38

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 38 rectifying faults error fd 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...

  • Page 39

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 39 rectifying faults error fd ignition too harsh, ignition poor check action 1. B activate menu option show serv- ice parameters. B select 5.1 permanent ignition (without gas). Continuous ignition (without gas) ok? Yes: ↓6. N...

  • Page 40

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 40 rectifying faults error fd 7. B test gas supply pressure - ok? Does pressure match figure speci- fied in installation instructions? Yes: ↓8. No: b decommission appliance. In case of natural gas: b notify gas company. 8. Pr...

  • Page 41

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 41 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...

  • Page 42

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 42 rectifying faults error fd inadequate hot water outlet temperature (combi boiler) check action 1. Pump set to mode 3? Yes: ↓2. No: b set pump switch to setting 3. Inadequate hot water outlet temperature ? ↓2. 2. B unplug c...

  • Page 43

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 43 rectifying faults error fd 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...

  • Page 44

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 44 rectifying faults error fd 4. Air in the heating system. B power off the appliance. B check appliance and system for water leaks and repair as necessary. B top up system. B turn on the appliance. B activate menu option sho...

  • Page 45

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) rectifying faults 45 excessive fluctuations in room temperature (integrated text display) check action 1. Tr2 without room override: b periodic effect of external heat on room, e.G. From sunshine, lighting, tv, separate stove...

  • Page 46: Replacement of Parts

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 46 replacement of parts 5 replacement of parts b the user should be recommended to have the appli- ance serviced regularly by a competent person. B information on servicing can be found in the installa- tion instructions for ...

  • Page 47: 1 .

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) replacement of parts 47 5.2 fan assembly b power off the appliance. B undo lower pipe union on gas pipe (1.). B remove fan lead and earth connector (2.). The earth connector has a positive clip fixing. B remove fixing screws ...

  • Page 48

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 48 replacement of parts 5.4 pump b power off the appliance. B disconnect the boiler electrical connection. B turn off service cocks. B drain appliance. B remove two top fixing screws from the control box. B lower the control ...

  • Page 49

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) replacement of parts 49 5.7 3-way diverter valve b power off the appliance. B disconnect the boiler electrical connection. B turn off service cocks. B drain appliance. B unplug connector from 3-way valve motor. B pull out ret...

  • Page 50: Appendix

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 50 appendix 6 appendix 6.1 ntc values 6.1.1 flue sensor 6.1.2 outside temperature sensor 6.1.3 ch flow ntc sensor, dhw cylinder ntc sensor 1 and hot water ntc sensor flue temperature (˚c) measurement tolerance ±10% resistance...

  • Page 51

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) appendix 51 6.2 electrical wiring diagram fig. 16 4.1 ignition transformer 6 temperature limiter, heat exchanger 6.1 hot water ntc sensor (combi only) 9 flue gas temperature limiter 18 pump 32 flame sensing electrode 33 ignit...

  • Page 52

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 52 appendix 6.3 approved corrosion inhibitors and anti-freeze fluids for central heating water corrosion inhibiter the following corrosion inhibiters are permitted: anti-freeze fluid the following anti-freeze fluids are permi...

  • Page 53

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) appendix 53 6.5 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...

  • Page 54

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) 54 appendix.

  • Page 55

    Supplied by www.Heating spares.Co tel. 0161 620 6677 7 181 465 347 (05.01) appendix 55.

  • Page 56

    Supplied by www.Heating spares.Co tel. 0161 620 6677.