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- ZWBR 11-35 HE plus
- Installation And Servicing Instructions
Worcester ZWBR 11-35 HE plus Installation And Servicing Instructions
Summary of ZWBR 11-35 HE plus
Page 1
Installation and servicing instructions greenstar he plus combi wall mounted condensing boiler for central heating and mains fed domestic hot water 6 720 610 598-00.1o zwbr 7-28 he plus gc-number: 47 311 56 zwbr 11-35 he plus gc-number: 47 311 57 6 720 610 597 gb (01.07) osw.
Page 2: Contents
6 720 610 597 gb (01.07) 2 contents contents safety precautions 3 symbols 3 1 details of the appliance 4 1.1 ec declaration of conformity 4 1.2 standard package 4 1.3 description of appliance 4 1.4 accessories 5 1.5 casing dimensions 5 1.6 layout of appliance 6 1.7 function 7 1.8 electrical wiring d...
Page 3: Safety Precautions
6 720 610 597 gb (01.07) safety precautions 3 safety precautions if you smell gas y turn off gas service cock at the meter. Y open windows and doors. Y do not operate any electrical switches. Y extinguish any naked flames. Y telephone your gas company. If you smell fumes from the appliance y switch ...
Page 4: Details of The Appliance
6 720 610 597 gb (01.07) 4 details of the appliance 1 details of the appliance 1.1 ec declaration of conformity this appliance is in accordance with the applicable requirements of the gas appliance directive, boiler effi- ciency directive, electromagnetic compatibility direc- tive and the low voltag...
Page 5
6 720 610 597 gb (01.07) details of the appliance 5 1.4 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 10 m (zwbr 11-35) or 13 m (zwbr 7-28) and vertical flue systems ...
Page 6
6 720 610 597 gb (01.07) 6 details of the appliance 1.6 layout of appliance fig. 2 4 heatronic control 6 heat exchanger safety temperature limiter 6.1 hot water ntc sensor 7 testing point for gas supply pressure 8.1 pressure gauge 9 flue gas temperature limiter 15 relief valve 18 pump 20 expansion v...
Page 7
6 720 610 597 gb (01.07) details of the appliance 7 1.7 function fig. 3 4 bosch heatronic control 6 temperature limiter, heat exchanger 6.1 hot water ntc sensor 7 testing point for gas supply pressure 8.1 pressure gauge 9 flue gas temperature limiter 13 manifold 15 safety valve 18 central heating pu...
Page 8
6 720 610 597 gb (01.07) 8 details of the appliance 1.8 electrical wiring diagram fig. 4 4.1 ignition transformer 6 temperature limiter, heat exchanger 6.1 hot water ntc sensor 9 flue gas temperature limiter 18 pump 32 flame sensing electrode 33 ignition electrode 36 temperature sensor in ch flow 52...
Page 9
6 720 610 597 gb (01.07) details of the appliance 9 1.9 technical data units zwbr 7-28 natural gas zwbr 11-28 propane zwbr 11-35 natural gas zwbr 14-35 propane max. Rated heat output net 40/30 °c central heating max. Rated heat output net 50/30 °c central heating max. Rated heat output net 80/60 °c ...
Page 10
6 720 610 597 gb (01.07) 10 details of the appliance condensate analysis, mg/l flue system elbow - 90 ° bend - 45 ° equivalent length 2 m equivalent length 1m gas supply domestic water performance ammonium 1.2 nickel 0.15 lead ≤ 0.01 mercury ≤ 0.0001 cadmium ≤ 0.001 sulphate 1 chromium ≤ 0.005 zinc ...
Page 11: Installation Regulations
6 720 610 597 gb (01.07) installation regulations 11 2 installation regulations gas safety (installation & use) regulations 1998: all gas appliances must be installed by a competent per- son. Failure to install correctly could lead to prosecu- tion. The manufacturers notes must not be taken, in any ...
Page 12
6 720 610 597 gb (01.07) 12 installation 3.2 domestic hot water any regulations specified by the local water company must be observed. The final 600 mm of the mains cold water connection to the applaince should be made in copper tube only. The appliance is suitable for a mains supply having a maximu...
Page 13
6 720 610 597 gb (01.07) installation 13 fig. 5 sealed primary water system fig. 6 sealed primary water system - filling method 3.4 siting the appliance regulations concerning the installation site y relevant national regulations must be complied with section 3.9.1 . Y consult the installation instr...
Page 14
6 720 610 597 gb (01.07) 14 installation 3.5 wall mounting frame assembly y take the wall mounting frame out of the package and screw together with 6 screws as shown in fig. 7. Use the outer lugs on the top and bottom horizontal sec- tions for the appliances that are 512 mm wide. Fig. 7 y hold the w...
Page 15
6 720 610 597 gb (01.07) installation 15 condensate drain prepare the condensate discharge system. Refer to fig. 11. The condensate drainage pipe should be a standard drain pipe material , i . E. Pvc, pvc-u, abs etc. And should be at least 22 mm in diameter. A siphon with a 75 mm condensate seal is ...
Page 16
6 720 610 597 gb (01.07) 16 installation connecting the flue duct y fit flue duct connector onto appliance flue spigot. Y secure with the two screws supplied. Fig. 13 y for remaining installation of flue assembly, refer to the relevant installation instructions. 3.8 checking the connections water co...
Page 17
6 720 610 597 gb (01.07) installation 17 3.9.1 siting the flue terminal the flue must be installed in accordance with bs 5440:1 and the building regulations. Flue terminals in carports and under balconies are to be avoided. The terminal must be positioned so that it does not cause an obstruction nor...
Page 18
6 720 610 597 gb (01.07) 18 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- sion duct assemblies. Note: flue...
Page 19
6 720 610 597 gb (01.07) installation 19 fig. 17 flue with one extension fig. 18 flue with extensions fig. 19 flue components maximum 1600mm flue turret no clamp terminal assembly outer wall extension duct 6 720 610 602 - 09.1o clamp flue turret no clamp clamp extension duct clamp extension duct ter...
Page 20
6 720 610 597 gb (01.07) 20 installation 3.9.3 flue duct preparation and assembly measure the flue length l. Refer to fig. 20, 21. Fig. 20 flue length - rear fig. 21 flue length - side mark off the lengths shown onto the ducts and cut to length. The cuts must be square and free from burrs. Terminal ...
Page 21: Electrical Connections
6 720 610 597 gb (01.07) electrical connections 21 4 electrical connections all control and safety systems are built into the appli- ance. Y allow mains cable to protrude at least 50 cm from wall. Y to make splash-water proof (ip): cut the cable grom- met hole size to match diameter of cable, see fi...
Page 22
6 720 610 597 gb (01.07) 22 electrical connections y cut cable grommet to diameter of cable. Fig. 26 y feed cable through cable grommet and connect the mains supply cable, see fig. 27. Y secure cable in cable grommet by means of cable grip. Fig. 27 4.2 connecting tr2 room thermostat the tr2 should b...
Page 23: Commissioning
6 720 610 597 gb (01.07) commissioning 23 5 commissioning fig. 29 8.1 pressure gauge 15 safety valve 27 automatic vent 61 reset button 135 master switch 136 temperature control for central heating 170 service cocks on ch flow and return 171 hot water 172 gas cock (shown in off position) 173 cold wat...
Page 24
6 720 610 597 gb (01.07) 24 commissioning y unscrew the condensation trap (358) and pull out, fill with approx. 1/4 l of water and refit. Refer to fig. 29. Y adjust charge pressure of expansion vessel to static head of the central heating system (see page 32). Y open all system radiator valves. Y tu...
Page 25
6 720 610 597 gb (01.07) commissioning 25 5.5 setting the domestic hot water temperature and flow rate 5.5.1 domestic hot water temperature the hot water temperature can be set to between approx. 40 °c and 60 °c. This temperature is not shown on the display. Fig. 32 “eco” button by pressing and hold...
Page 26
6 720 610 597 gb (01.07) 26 commissioning 5.9 fault condition in the unlikely event of a fault occuring while the appli- ance is in operation: the display and the text display then show a fault code and the button may also flash. If the button flashes: y press and hold the button until the display s...
Page 27: Text Display
6 720 610 597 gb (01.07) text display 27 6 text display 6.1 general description • the text display is used to display information about the appliance and the system and to alter the settings displayed. • once the appliance has been in operation for one day, the text display module has a power buffer...
Page 28
6 720 610 597 gb (01.07) 28 text display y use the or button to set the day of the week. Y press the button to confirm the setting. The cursor then returns to the top line. -or- y press the button to confirm the setting and return to the previous menu (fig. 36 page 27). -or- y do not press any other...
Page 29
6 720 610 597 gb (01.07) text display 29 6.4 setting the time/day 6.4.1 setting the time and day for details of how to set the time and day, refer to page 27. 6.4.2 holidays in the holiday programme, the central heating runs in economy mode and the hot water is switched off (frost protection functio...
Page 30
6 720 610 597 gb (01.07) 30 text display 6.5.2 setting the economy temperature this option allows you to set the room temperature for economy mode ( off (economy) ). This function is only active if: • automatic mode or economy mode is set on the tr 2 room thermostat. Y from the main menu, select hea...
Page 31
6 720 610 597 gb (01.07) text display 31 6.8 settings 6.8.1 heating (tr 2) optimum start y from the main menu, select settings and from the first submenu, select heating. Y press or to switch optimum start on or off. Basic setting: “on” 6.8.2 hot water (storage tank, zsbr models only) the text displ...
Page 32: Individual Settings
6 720 610 597 gb (01.07) 32 individual settings 7 individual settings 7.1 mechanical settings 7.1.1 checking the size of the expansion vessel maximum pressure at maximum ch flow temperature is 2.5 bar. If the pressure is greater than this then fit an extra expansion vessel. Refer to table 11. System...
Page 33
6 720 610 597 gb (01.07) individual settings 33 y press the button to exit the menu. Setting service functions only the service functions that can be set are displayed. Y press any button to activate the main menu. Y press or button until the arrow cursor is pointing to settings. Y press the button....
Page 34
6 720 610 597 gb (01.07) 34 converting the appliance to different gas types 8 converting the appliance to different gas types the setting is factory sealed at maximum. Adjustment to the rated heat input and min. Heat input is not neces- sary. The gas/air ratio may only be adjusted on the basis of a ...
Page 35
6 720 610 597 gb (01.07) converting the appliance to different gas types 35 y measure the co level. If the co level is over 300 ppm, the gas volumetric flow rate is too high. Reduce the gas flow rate on the adjustable gas flow restrictor (63) until the co level is: – below 100 ppm at zwbr 7-28 – bel...
Page 36: Maintenance
6 720 610 597 gb (01.07) 36 maintenance y insert testing probe about 80 mm into the testing point and seal testing point. Fig. 42 y measure o 2 and co 2 levels. Y refit sealing plug. Y press and hold button until the display shows – –. The button will stop flashing and the display shows the ch flow ...
Page 37
6 720 610 597 gb (01.07) maintenance 37 9.1 pre-service check list date 1 call up the last fault stored by the text- display , (see page 31). 2 check ionisation current, service function 3.3, (see page 38). 3 perform visual check of air/flue duct. 4 check gas supply pressure (see page 34). Mbar 5 te...
Page 38
6 720 610 597 gb (01.07) 38 maintenance 9.2 description of servicing operations the combustion performance must be checked before and after any servicing work on the combustion and burner components. Refer to section 8.2. Checking the ionisation current, service function 3.3 y select service functio...
Page 39
6 720 610 597 gb (01.07) maintenance 39 y loosen any deposits in the heat exchanger from top to bottom using the cleaning blade. Refer to fig. 46. Fig. 46 y clean the heat exchanger from top to bottom using the brush. Refer to fig. 47. Fig. 47 y flush the heat exchanger from the top. Refer to fig. 4...
Page 40
6 720 610 597 gb (01.07) 40 maintenance condensation trap in order to prevent spillage of condensate the conden- sation trap should be completely removed, (see page 38, fig. 45). Y unscrew condensation trap and check connection to heat exchanger is clear. Y remove condensation trap cover and clean. ...
Page 41
6 720 610 597 gb (01.07) maintenance 41 9.3 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 ...
Page 42
6 720 610 597 gb (01.07) 42 maintenance 9.3.2 fan assembly fig. 54 y switch off the appliance. Y disconnect the appliance from the power supply. Y undo lower pipe union on gas pipe (1.). Refer to fig. 54. Y remove fan lead and earth connector (2.). The earth connector has a positive clip fixing. Y r...
Page 43
6 720 610 597 gb (01.07) maintenance 43 9.3.4 3-way diverter valve y switch off the appliance. Y disconnect appliance from the power supply. Y turn off service cocks. Y unplug connector from 3-way valve motor. Refer to fig. 56. Y pull out retaining clip. Y remove motor. Y disconnect the relief valve...
Page 44
6 720 610 597 gb (01.07) 44 maintenance 9.3.7 gas valve y check that the gas cock is turned off. Y lower the control panel. Refer to fig. 55. Y pull off the solenoid connections at the rear of the valve. Y undo the union, within the inner casing, securing the valve to the gas/air tube. Refer to fig....
Page 45
6 720 610 597 gb (01.07) maintenance 45 9.3.14 flow switch y shut the mains water inlet valve and drain the domes- tic hot water circuit. Y pull-off the connectors from the micro-switch. Y unscrew the inlet and union connection and remove the assembly. Y reset the domestic hot water flow rate on the...
Page 46: Appendix
6 720 610 597 gb (01.07) 46 appendix 10 appendix 10.1 fault codes more detailed fault finding procedures are described in the service booklet for the engineer number 7 181 465 347. Display code description remedy a1 pump has run dry check system pressure, add water and bleed system as necessary a7 h...
Page 47
6 720 610 597 gb (01.07) appendix 47 10.2 short parts list key description qty gc spare part number 1 sensor - flue gas temp. 1 8 729 000 144 0 2 sensor - ch flow temp. 1 8 714 500 087 0 3 sensor - dhw flow temp. 1 8 714 500 054 0 4 control board 1 8 748 300 418 0 5 gas valve zwbr 7-28 1 8 747 003 5...
Page 48
6 720 610 597 gb (01.07) 48 appendix 10.3 heating/hot water output settings zwbr 7-28 n.G. 10.4 heating/hot water output settings zwbr 11-28 l.P.G natural gas g20 display code heat output, kw heat input, kw gas vol. Flow rate (l/min at t v /t r = 80/60 °c) 30 8.5 8.6 15.0 40 11.3 11.4 20.0 50 14.1 1...
Page 49
6 720 610 597 gb (01.07) appendix 49 10.5 heating/hot water output settings zwbr 11-35 n.G. 10.6 heating/hot water output settings zwbr 14-35 l.P.G natural gas g20 display code heat output, kw heat input, kw gas vol. Flow rate (l/min at t v /t r = 80/60 °c) 30 10.5 10.7 18.6 40 14.1 14.2 24.9 50 17....
Page 50
6 720 610 597 gb (01.07) 50 appendix 10.7 operational flow diagrams 10.7.1 domestic hot water function fig. 60 mains switch on. Green light on. Burner lights. Red light on. Ignition spark for 5 seconds. Fan runs to purge gas from burner. Repeats 5 times before lock-out. Hot water demand. Pump on div...
Page 51
6 720 610 597 gb (01.07) appendix 51 10.7.2 central heating function fig. 61 mains switch on. Fan min. Speed for 90 secs. Green light on. Burner lights. Red light on. Ignition spark for 5 seconds. Fan runs to purge gas from burner. Repeats 5 times before lock-out. Room thermostat and/or mains progra...
Page 52
Appendix appendix excellence comes as standard worcester heat systems limited, cotswold way, warndon, worcester wr4 9sw. Telephone: (01905) 754624 fax: (01905) 754619.