Installation and Servicing Instructions

Installation and Servicing Instructions
CC1
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

6 720 610 599 GB (03.02) OSW
Contents
Contents
Safety precautions 3 6 Individual settings 28

6.1 Mechanical settings 28
6.1.1 Checking the size of the expansion vessel 28
Symbols 3 6.1.2 Setting the central heating flow temperature 28
6.1.3 Changing the heating pump characteristic 28
6.2 Settings on the Bosch Heatronic 29
1 Details of the appliance 4 6.2.1 Operating the Bosch Heatronic 29
1.1 EC Declaration of Conformity 4 6.2.2 Selecting the pump control mode for central
1.2 Standard package 4 heating mode (Service Function 2.2) 29
1.3 Description of appliance 4 6.2.3 Setting the anti-cycle time
1.4 Accessories 5 (Service Function 2.4) 29
1.5 Casing dimensions 5 6.2.4 Setting the maxim CH flow temperature
1.6 Layout of appliance 6 (Service Function 2.5) 30
1.7 Function 7 6.2.5 Setting the switching difference
1.8 Electrical wiring diagram 8 (Service Function 2.6) 30
1.9 Technical data 9 6.2.6 Setting the heating output
(Service Function 5.0) 30
6.2.7 Constant hot water cycle time
2 Installation regulations 10 (Service Function 6.8) 30
6.3 Setting the gas/air ratio 30
3 Installation 11
3.1 Important remarks 11 7 Converting the appliance to
3.2 Domestic hot water 11 different gas types 31
3.3 Sealed systems 11 7.1 Setting the gas/air ratio 31
3.4 Siting the appliance 12 7.2 Testing combustion air/flue gas at
3.5 Wall mounting frame assembly 13 set heat output 33
3.6 Pre-piping the system 13 7.2.1 Testing the O2 or CO2 level in
3.7 Fitting the appliance 14 the combustion air 33
3.8 Checking the connections 15 7.2.2 Testing CO and CO2 33
3.9 Flue Systems 15
3.9.1 Siting the Flue Terminal 16
3.9.2 Installation of the flue 17 8 Maintenance 33
3.9.3 Flue duct preparation and assembly 19 8.1 Pre-Service Check List 34
8.2 Description of servicing operations 35
8.3 Replacement of Parts 38
4 Electrical connections 20 8.3.1 PCB control board and transformer 38
4.1 Connecting the appliance 20 8.3.2 Fan Assembly 39
4.2 Mains Voltage external controls connections 21 8.3.3 Pump 39
8.3.4 3-way diverter valve 40
8.3.5 3-way diverter valve motor 40
5 Commissioning 22 8.3.6 Sensors 40
5.1 Commissioning 22 8.3.7 Gas Valve 41
5.2 Switching the appliance on/off 23 8.3.8 Domestic Hot Water Heat Exchanger 41
5.3 Switching on the central heating 23 8.3.9 Electrode assembly 41
5.4 System controls 23 8.3.10Pressure gauge 41
5.5 Setting the domestic hot water temperature 8.3.11Expansion vessel 41
and flow rate 24 8.3.12Pressure Relief Valve 41
5.5.1 Domestic hot water temperature 24 8.3.13Burner 41
5.5.2 Hot water flow rate 24 8.3.14Flow switch 42
5.6 Summer mode (hot water only) 24 8.3.15Primary Heat Exchanger 42
5.7 Frost protection 24
5.8 Pump anti-seize function 24
5.9 Fault Condition 25 9 Appendix 43
5.10 Digital Timer 26 9.1 Fault Codes 43
5.10.1Basic Settings 26 9.2 Short parts list 44
5.10.2Button Functions 26 9.3 Heating/hot water output settings (N.G) 45
5.10.3Programming 26 9.4 Heating/hot water output settings (L.P.G) 45
5.10.4Setting time and day 26 9.5 Operational Flow diagrams 46
5.10.5Setting the timed periods 26 9.5.1 Domestic hot water function 46
5.10.6Changing the Operating Mode 27 9.5.2 Central heating function 47
5.10.7Deleting Settings 27
5.10.8Completing Programming 27
5.10.9Time Display 27
2 6 720 610 599 GB (03.02)

Safety precautions
Safety precautions Symbols

If you smell gas Safety instructions in this document
B Turn off gas service cock at the meter. are identified by a warning-triangle sym-
bol and are printed on a grey back-
B Open windows and doors.
ground.
B Do not operate any electrical switches.
B Extinguish any naked flames.
Notes containing important information
B Telephone your gas company.
If you smell fumes from the appliance

i are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.
B Switch off appliance (see page 23).
Fitting and modifications

B Fitting of the appliance or any controls to the appli-
ance may only be carried out by a competent engi-
neer in accordance with the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use on sealed primary systems
only.
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
B Use only original spare parts!
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, 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 electrically unsafe.
B There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
B The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Explain to the customer how the appliance works
and how to operate it.
B Advise the user that he/she must not make any mod-
ifications to the appliance or carry out any repairs on
it.
B These instructions are to be left with the user or at
the Gas meter.
B Important: These instructions apply in the UK only.
6 720 610 599 GB (03.02) 3

Details of the appliance
1 Details of the appliance 1.3 Description of appliance

• Wall-mounted appliance, siting not dependent on
1.1 EC Declaration of Conformity room size
• Natural gas models are low-emission appliances
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler • Multifunction display
Efficiency Directive, Electromagnetic Compatibility • Bosch Heatronic control system
Directive and the Low Voltage Directive. • Digital timer with 2 channels
PIN CE-0085 BL 0507 • Automatic ignition
• Modulating control
Category
UK II2H 3P • Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
Appliance Type C13, C33 temperature sensors
Table 1 • Concentric flue/air duct with testing point for
CO2/CO
• Regulated speed fan
1.2 Standard package • Pre-mix burner
• Gas condensing combination boiler for central heat- • Temperature control for central heating
ing and domestic hot water
• Temperature sensor in domestic hot water
• Wall mounting frame
• Safety temperature limiter in 24 V electrical circuit
• Clamp for securing flue duct kit
• Three-speed central heating pump with automatic
• Fixings (screws etc.) vent
• Set of documentation for appliance • Relief valve, pressure gauge, expansion vessel
• Pre-plumbing manifold • Flue gas temperature limiter (105 °C)
• Condensate drain pipe. • Hot water priority circuit
• Motorised 3-way valve
• Plate-type heat exchange
• Condensate Trap.
4 6 720 610 599 GB (03.02)

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 13 m and vertical flue
systems for flue lengths upto 15 m. Fitting instruc-
tions are sent with these kits.
• Heating programmers
• Security kit.
1.5 Casing dimensions
min. min.
Z
5* 5* 600*
Y X
120
906
850
861
101
13
103 200
30
35 360
440 *
200
395
6 720 610 601- 01.3O
Fig. 1
13 Manifold assembly
101 Outer case
103 Facia cover
X Standard Concentric Horizontal Flue System: min. 310 mm
Alternative Concentric Flue System: min. 250 mm
Y Standard Concentric Horizontal Flue System: 158 mm
Alternative Concentric Flue System: 121 mm
Z Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
* For servicing the appliance
6 720 610 599 GB (03.02) 5

1.6 Layout of appliance
120
221.1
221.2 349
234.1
234
27
226
20 102
32.1
29
36
271 6
415
43
9
63
416
358
18
64
423
7 18.1
355
418
6.1 15
8.1
88 CH
C
422
295 88
417 4
6 720 610 599-01.2O
Fig. 2
4 Heatronic control 102 Inspection window
6 Heat exchanger safety temperature limiter 120 Fixing points
6.1 Hot water NTC sensor 221.1 Flue duct
7 Testing point for gas supply pressure 221.2 Combustion air intake
8.1 Pressure gauge 226 Fan assembly
9 Flue gas temperature limiter 295 Appliance type sticker
15 Relief valve 234 Testing point for combustion products
18 Pump 234.1 Testing point for combustion air
18.1 Pump speed selector switch 271 Flue duct
20 Expansion vessel 349 Cover plate for twin flue duct connection
27 Automatic air vent 355 Plate-type domestic hot water heat exchanger
29 Air gas Mixer unit 358 Condensate trap
32.1 Electrode assembly 415 Cover plate for cleaning access
36 Temperature sensor in CH flow 416 Condensate collector
43 CH flow 417 Clip for fixing outer case
63 Adjustable gas flow restrictor 418 Data plate
64 Adjusting screw for min. gas flow volume 422 Digital timer
88 3-way valve (combi) 423 Siphon
98 DHW flow switch (combi)
6 6 720 610 599 GB (03.02)

1.7 Function
26 27 229 226 29 33 30 234.1 234
36 32
443 ϑ
20 221
6
35
29.1
9
63
358
52.1 69
64
56 18
52
57 88
55 7
4 61 317 422 8.1
355
ECO
15
3 4
0 2 5
90 96
1 E 95 423
CH 6.1
max max C
94 M
ϑ 93
91 97 98
84
13 43 44 45 46 47 6 720 610 599-08.2O
Fig. 3
4 Bosch Heatronic control 63 Adjustable gas flow restrictor
6 Temperature limiter, heat exchanger 64 Adjusting screw for min. gas inlet flow volume
6.1 Hot water NTC sensor 69 Control valve
7 Testing point for gas supply pressure 84 Motor
8.1 Pressure gauge 88 3-way valve
9 Flue gas temperature limiter 90 Venturi
13 Manifold 91 Pressure relief valve
15 Safety valve 93 Water flow regulator
18 Central heating pump 94 Diaphragm
20 Expansion vessel 95 Pushrod with switch cam
26 Charging Valve 96 Microswitch
27 Automatic vent 97 Valve for hot water flow volume
29 Mixer unit 98 Water valve
29.1 Bi-metallic thermostat for combustion air compensation 221 Flue duct
30 Burner 226 Fan
32 Flame sensing electrode 229 Inner casing
33 Igniter electrode 234 Testing point for flue gas
35 Heat exchanger with cooled combustion chamber 234.1 Testing point for combustion air
36 Temperature sensor in CH flow 317 Display
43 CH flow 355 Plate-type heat exchanger
44 Hot water flow 358 Condensate trap
45 Gas inlet 422 Digital timer
46 Cold water inlet 423 Siphon
47 CH return 443 Diaphragm
52 Solenoid valve 1
52.1 Solenoid valve 2
55 Filter
56 Gas valve CE 427
57 Main valve disc
61 Reset button
6 720 610 599 GB (03.02) 7

1.8 Electrical wiring diagram
o - orange g - green bl - black r - red p - purple

33
364 365 61 317 366 367 363
ECO
4.1
25 V
230 V
153 136 310
135 422
230V/AC
312 318
315
313 124 789
328 151 84
p
302
L N Ns Ls LR
300 314
p
p
M
161
96
328.1
g
9 6 g
M M o
r
r o
mains supply 18 226
52 52.1
56
o o
bl
36 6.1
bl
bl
bl bl
32
6 720 610 599-07.2O
Fig. 4
4.1 Ignition transformer 328.1 Link
6 Temperature limiter, heat exchanger 363 Indicator lamp for burner
6.1 Hot water NTC sensor 364 Indicator lamp for power supply
9 Flue gas temperature limiter 365 “Chimney sweep” button
18 Pump 366 Service button
32 Flame sensing electrode 367 ECO button
33 Ignition electrode 422 Digital timer
36 Temperature sensor in CH flow
52 Solenoid valve 1
52.1 Solenoid valve 2
56 Gas valve CE 427
61 Reset button
84 Motor, 3-way valve
96 Microswitch, hydraulic switch
135 Master switch
136 Temperature control for CH flow
151 Fuse, slow 2.5 A, AC 230 V
153 Transformer
161 Link
226 Fan
300 Code plug
302 Earth connection
310 Temperature control for hot water
312 Fuse, slow T 1,6 A
313 Fuse, slow T 0,5 A
314 Connector for programmer
315 Terminal block for programmer
317 Digital display
328 Terminal block for AC 230 V Mains supply
8 6 720 610 599 GB (03.02)

1.9 Technical data
Units Natural gas Propane

Max. rated heat output net 40/30˚C central heating kW 31.2 31.2
Max. rated heat input net kW 29.5 29.5
Min. rated heat output net 40/30˚C kW 8.4 11.6
Min. rated heat input net kW 7.6 10.8
Max. rated heat output net, domestic hot water kW 29.2 29.2
Max. rated heat input net, domestic hot water kW 29.5 29.5
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (CVnet 34.02 MJ/m3) m3/h 3.1 -
LPG (CVnet 88 MJ/m ) 3 kg/h - 2.3
Gas supply pressure
Natural gas G20 (CVnet 34.02 MJ/m3) mbar 20 -
LPG (CVnet 88 MJ/m ) 3 mbar - 37
Expansion vessel
Charge pressure bar 0.75 0.75
Total capacity l 10 10
Hot water specifications
Hot water flow rate (factory setting) l/min 8 8
Max. hot water flow rate l/min 14 14
Outlet temperature range ˚C 40 - 60 40 - 60
Max. permissible water supply pressure bar 10 10
Min. inlet pressure bar 0.2 0.2
Specific flow rate l/min 13.3 13.3
Flue
Flue gas temp. 80/60˚C, rated/min. load ˚C 67/55 67/55
Flue gas temp. 40/30˚C, rated/min. load ˚C 43/32 43/32
Residual delivery pressure
(inc. pressure drop in air intake duct) Pa 80 80
CO2 level at max. rated heat output % 9.2 10.8
CO2 level at min. rated heat output % 8.8 10.5
NOx-class 5 5
SEDBUK figure, Band A % 90.6 90.6
Condensate
Max. condensation rate (tR = 30˚C) l/h 2.5 2.5
pH-value, approx. 4.8 4.8
General Data
Electrical power supply voltage AC ... V 230 230
Frequency Hz 50 50
Max. power consumption W 106 106
Noise output level dB(A) 36 36
Appliance protection rating IP X4D X4D
Max. CH flow temperature ˚C nom. 90 nom. 90
Max. permissible operating pressure (CH) bar 2.5 2.5
Permissible ambient temperatures ˚C 0 - 50 0 - 50
Nominal capacity of appliance l 3.75 3.75
Weight (excluding packing) kg 46 46
Table 2
6 720 610 599 GB (03.02) 9

Installation regulations
Condensate analysis, mg/l Domestic water performance

Ammonium 1.2 Nickel 0.15 Domestic Temperature 14.2
Water Flow Rise 30 °C
Lead ≤ 0.01 Mercury ≤ 0.0001
Rate l/min
Temperature
Cadmium ≤ 0.001 Sulphate 1
Rise 35 °C 12.1
Chromium ≤ 0.005 Zinc ≤ 0.015
Temperature
Halogenated Tin ≤ 0.01 Rise 40 °C 10.6
hydrocarbons ≤ 0.002
Maximum Mains pressure bar 10.0
Hydrocarbons 0.015 Vanadium ≤ 0.001
Minimum Mains pressure bar 0.2
Copper 0.028 pH-value 4.8
Table 8
Table 3
Flue system
2 Installation regulations
HORIZONTAL 100 mm – Standard Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent per-
Overall Diameter of Duct mm 100 son. Failure to install correctly could lead to prosecu-
tion.
Flue Terminal / Duct mm 600 Max. The manufacturers notes must not be taken, in any way,
Assembly Length 4m as overriding statutory obligations.
The appliance must be installed in accordance with the
Extension Duct Length mm 1000 current IEE Wiring Regulations, local Building Regula-
tions, Building Standards (Scotland) (Consolidation),
Table 4 bye-laws of the local Water Company, Health and
ALTERNATIVE HORIZONTAL 125 mm FLUE Safety Document 635 (Electricity at Work Regulations
SYSTEM 1989) and any other local requirements.
Product Liability regulations indicate that, in certain cir-
Overall Diameter of Duct mm 125 Max. cumstances, the installer can be held responsible, not
13 m only for mistakes on his part but also for damage result-
Flue Terminal / Duct Assembly mm 1030 (inclu- ing from the use of faulty materials. We advise the
ding installer to avoid any risk by using only quality approved
turret) branded fittings.
The relevant British Standards should be followed i.e.
Table 5
• BS 6798: Specification for the installation of gas
VERTICAL 125 mm FLUE SYSTEM fired hot water boilers of rated input not exceeding
60kW
Overall Diameter of Duct mm 125
Max. • BS 5449: Central Heating for Domestic Premises
15 m
Flue Terminal / Duct Assembly mm 1360 • BS 5546: Installation of gas hot water supplies for
domestic purposes
Table 6
• BS 5440:1: Flues and ventilation for gas appliances
Elbow - 90 ° Equivalent length 2 m
of rated input not exceeding 70 kW (net): Flues
Bend - 45 ° Equivalent length 1m
• BS 5440:2: Flues and ventilation for gas appliances
Gas supply of rated input not exceeding 70 kW (net): Air
Supply
Total length of gas supply pipe Pipe diameter
(metres) (mm) • BS 6891: Installation of low pressure gas pipework
installations up to 28mm (R1).
3 6 9 • BS 7074:1: Code of practice for domestic heating
and hot water supply
Gas discharge rate (m3/h)
• BS 7671: Requirements for Electrical Installation.
8.7 5.8 4.6 22 These instructions must be followed.
18.0 12.0 9.4 28
Table 7
10 6 720 610 599 GB (03.02)

Installation
3 Installation All types of single lever mixer taps and thermostatic

mixer units suitable for a mains pressure of up to 10 bar
B Always turn off the gas cock before car- can be used.
rying out any work on components The head of a loose-head shower must not be allowed
which carry gas. to fall within 25 mm of the top the bath to prevent the
risk of water being drawn back into the mains. Alterna-
tively the shower must be fitted with an anti-syphonage
Fixing of the appliance, gas and flue con-
i nections, commissioning of the system
and electrical connections may only be
device at the point of the flexible hose connections.
Over-rim bidets may be connected to the appliance
carried out by competent persons author- provided that it is in accordance with the requirements
ised by CORGI. of the local water company. The outlet(s) should be
shrouded and unable to have any temporary hand held
spray attached. No anti-syphonage arrangements are
3.1 Important remarks necessary.
B Appliance should only be installed in sealed central In exceptionally hard water areas a device to prevent
heating systems. scale formation may be fitted or, alternatively, the maxi-
B To avoid gas formation in the system, galvanised mum temperature reset to about 45˚C which may
radiators or pipes must not be used. reduce the risk of scale formation. The installation of a
scale inhibitor assembly should be in accordance with
B If a room thermostat is used: do not fit a thermostatic the requirements of the local water company. Artificially
radiator valve on the radiator in the primary room. softened water must not be used to fill the central heat-
B Add a suitable anti-freeze fluid compatible with alu- ing system. An isolating valve should be fitted to allow
minium to the water in the central heating system. for servicing.
Suitable products are available from Betz-Dearborn Devices, such as water meters or back-flow pre-
Tel.: 0151 4209563 and Fernox Tel.: 01799 vention valves, capable of preventing the flow of
550811. expansion water must not be fitted unless sepa-
B In our experience, the addition of sealing agents to rate arrangements have been made.
the water in the central heating system can cause A Zilmet Z160 expansion vessel is the preferred type. A
problems (deposits in the heat exchanger). For that thread sealant compatible with potable water must be
reason we advise against their use. used. The vessel should be connected into the cold
water mains inlet pipe as close as possible to the appli-
3.2 Domestic hot water ance.
Any regulations specified by the local water company
must be observed. 3.3 Sealed systems
The final 600 mm of the mains cold water connection to The appliance must not be operated without the system
the applaince should be made in copper tube only. being full of water, properly vented and pressurised.
The appliance is suitable for a mains supply having a The expansion vessel has a volume of 10 litres and is
maximum pressure of 10 bar. A pressure reducing valve charged to a pressure of 0.75 bar.
must be fitted, if necessary. The water capacity of the system is shown in table 13,
The hot water outlet temperature is set to be capable of page 28. If a greater capacity is required then an addi-
achieving a maximum of 60˚C. The maximum tempera- tional expansion vessel must be fitted into the system
ture and the frequency of the recharge of the heat store return as close to the appliance as possible. The system
may be reset. pressure can be set up to a maximum of 1.5 bar with 1
A water flow rate of 10.6 l/min will give a temperature bar being the normal setting.
rise of 40˚C. If a higher rise is required then the flow If the system pressure is greater than 2.65 bar when the
must be reduced at the tap and the discharge temper- appliance is operating at maximum temperature then an
ature will rise up to the maximum set figure. additional expansion vessel must be fitted into the sys-
The temperature rise, upto the maximum set by the user, tem return as close to the appliance as possible.
is automatically maintained by the modulation of the The filling point must be at low level and arranged as
heat input. In winter, when the mains temperature is shown in figs. 5 and 6.
very low, the water flow, adjusted at the tap or shower, The pressure relief valve is set to operate at 3 bar.
should be reduced to maintain the required delivery
temperature. There must be no connection to the mains without the
approval of the local water company. All connections in
It is suggested that long pipe runs to taps or showers the system must be capable of withstanding a pressure
be insulated to prevent the rapid cooling of the water. of up to 3 bar and the radiator valves conform to the
requirements of BS 2767:10.
6 720 610 599 GB (03.02) 11

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
Repeated venting probably indicates a leak and this the appliance guarantee will be invalidated.
must be rectified to ensure the proper operation of the A drain cock to BS2879 must be fitted to the lowest
appliance. point of the system.
No galvanised radiators or pipes must be used. IMPORTANT: Check that no dirt is left in the
If any system water treatment is required then water pipework as this could damage the appli-
only products suitable for use with Aluminium ance. Thoroughly flush the heating system and
shall be used i.e Fernox- Copal or Superconcen- the mains water supply before fitting the appli-
trate or Sentinal X100, in accordance with the ance to the wall in accordance with the recom-
manufacturers instructions. The use of any other mendations of BS7593:1992.
APPLIANCE
Refer to Fig.1
Appliance
water flow
diagram A drain cock should be fitted at
the lowest point of the heating
circuit and the appliance
WRAS approved
filling loop
Lockshield
valve
Central heating return
Domestic
hot water Central heating flow
Radiator
valve
BS stop valve.
Fixed spindle type
Water
6 720 610 576 -09.3O
main
Fig. 5 Sealed primary water system
Sealed system filling and make up
Make up
vessel
Heating return Auto
Heating return air vent Non return
Non return Non return valve
valve valve Hose union
Stop 1000mm (39 in)

Stop cock cock above the highest
Test cock Fill point point of the system.
Temporary hose
6 720 611 137 - 29.1O
Fig. 6
3.4 Siting the appliance Surface temperature

The max. surface temperature of the casing and the flue
Regulations concerning the Installation Site is less than 85 °C.
B Relevant national regulations must be complied with This means that, no special safety precautions are
section 3.9.1. required with regard to flammable building materials
B Consult the installation instructions for details of min- and fitted furniture. The specified clearences must be
imum clearances required. maintained.
Combustion air Cupboard/Compartment

In order to prevent corrosion, the combustion air must The appliance can be installed in a cupboard/compart-
not contain any corrosive substances. ment need for airing clothes providing that the require-
ments of BS6798 and BS5440:2 are followed. The low
Substances classed as corrosion-promoting include casing losses from the appliance eliminate the need for
halogenated hydrocarbons which contain chlorine and ventilation openings in the compartment.
fluorine compounds and are contained in some sol-
vents, paints, adhesives, aerosol propellants and
household cleaners, for example.
12 6 720 610 599 GB (03.02)

Installation
3.5 Wall mounting frame assembly B Screw the pre-plumbing manifold with two screws to
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.
6 720 610 576-11.1O
Fig. 9
6 720 610 576-04.1O

3.6 Pre-piping the system
Fig. 7
B Hold the wall-mounting frame against the wall ensur- 200
ing that it is vertical.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 16.
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided. 171 112 172
43 47
50 35
120-130
260
6 720 610 576-06.1O
Fig. 10 Manifold
43 CH flow
47 CH return
112 Gas cock
171 Domestic hot water
172 Cold water relief
B A drain tap should be fitted at the lowest point of the

6 720 610 576-05.1O central heating system.
Fig. 8 B WRAS approved filling loop must be fitted.
6 720 610 599 GB (03.02) 13

Installation
Condensate Termination and Route External condensate pipework

The condensate connection on the British Gas/Bosch All British Gas/Bosch condensing boilers have within a
appliances is in 22 mm plastic. The pipe should be syphonic condensate trap. Rather than the condensate
extended and run away from the appliance with a con- constantly dripping into the discharge pipe, the con-
stant fall of 2.5 ° or 40 mm in every metre. densate is collected into a trap which releases it in
The condensate pipe can terminate into any of four 100 ml quantities.
areas: This will help prevent freezing occurring.
If there is no alternative and the condensate pipe has to
Boiler be externally run, the following should be considered:
Boiler
Siphon
Ø 22 min.
Sink • The pipe run should take the shortest practical route.
External length of
pipe 2m min.
No length
restriction 75 min. trap
Ø 22 min. Siphon
Open end of pipe

• The pipework should be insulated with weather
direct into gully,
Use waterproof pipe work
insulation in very exposed
positions
below ground but
above water level.
resistant insulation.
The gradient of the discharge pipe
should be 2.5° (40 mm/m) minimum
Open end of pipe direct
into gully, below ground
but above water level
The gradient of the discharge pipe should be
• The pipe should terminate as close as possible to the
2.5° (40 mm/m) minimum
An internal waste system An external waste system

ground or drain, whilst still allowing the condensate
to safely disperse. This would prevent wind blowing
Boiler Boiler up the pipe.
Internal soil
No length
Ø 22 min. and vent stack Sink restriction • The pipework should be installed with the minimum
No length
Siphon
Ø 22 min.
75 min. trap
Open end of pipe
direct into gully,
below ground but
of horizontal runs and with a downward slope of at
75 min. trap
restriction above water level
least 2.5 °.
450 min.
The gradient of the discharge pipe Invert The gradient of the discharge pipe
3.7 Fitting the appliance
The rainwater system An external purpose made soakaway
6 720 610 596 -03.1O Benchmark: For optimum performance

Fig. 11 after installation, this boiler and its asso-
ciated central heating system must be
Whilst all of the above methods are acceptable it is
flushed in accordance with the guide-
always the best practice to terminate the condense
lines given in BS5793:1992 “Treatment
pipe via an internal waste system.This will eliminate the
of water in domestic hot water central
need for any external condensate pipe runs which can
heating systems”.
be susceptible to freezing in extreme weather.
B Remove packing, taking care to observe the instruc-
tions on the packing.
B Lie the boiler on its back.
Removing the outer case

The outer case is secured against unau-
i thorised removal by two clips (electrical
safety).
Always secure the outer case with those
clips again after refitting.
B Turn the clips with a screwdriver.

B Slide the outer case upwards and then forwards to
remove.
6 720 610 602 - 03.1O
Fig. 12 Position of the condensate drain
14 6 720 610 599 GB (03.02)

Installation
B Remove the plastic caps from the boiler connec- 3.8 Checking the connections
tions.
Water connections
B Check that the O-rings or seals are in place before
2. tightening the connection.
B Turn on the service valves for central heating flow
CH
and return and fill the heating system through a
C
WRAS approved filling loop.

B Check all seals and unions for leaks (testing pres-
sure max. 3.0 bar as indicated by pressure gauge).
B Turn on cold water service cock and fill hot water
1. system (testing pressure max. 10 bar).
B Check all connections for leaks.
Gas supply pipe

B Check that the seal is in place before tightening the
connection.
6 720 610 599-02.1O
B Turn off gas cock to protect gas valve against dam-
Fig. 13 age from excessive pressure.
B Check gas supply pipe.
Fixing the appliance
B Release the pressure on the gas supply pipe.
B Fit the washers onto the gas and water connections.
B Lift the boiler onto the wall-mounting frame. The lugs 3.9 Flue Systems
pass through the rectangular holes in the boiler back
The only flue systems that may be used are those sup-
panel.
plied with the boiler.
B Take care not to disturb the washers on the connec- The flue system must be installed in accordance with
tions. the requirements of BS5440:1.
Connecting the flue duct Standard 100 mm flue system
B Fit flue duct connector onto appliance flue spigot. The standard concentric flue system provides for a hor-
B Secure with the two screws supplied. izontal length of upto 4 m. Full instructions for fitting this
flue are in Subsection 3.9.2 “Installation of the flue”.
Alternative 125 mm diameter flue systems

Installation instructions for the alternative flue systems
1 . are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
1
3
length of 13 m.
2 .
2
4
A vertical flue system upto a height of 15 metres is avail-

able.
45° and 90° flue bends can be used with a correspond-
ing reduction in flue length of 2m for each 90° bend and
1 m for each 45° bend used.
6 7 2 0 6 1 0 3 3 2 -0 9 .2 R
IMPORTANT: Any horizontal flue system fitted to a

Fig. 14
condensing boiler must incline towards the appliance at
B For remaining installation of flue assembly, refer to an angle of 3 % (30 mm per metre length) to prevent
the relevant installation instructions. condensate dripping from the flue terminal. This
means that the clearance above the appliance
must be increased to match the duct length.
Refer to fig. 1 on page 5.
6 720 610 599 GB (03.02) 15

Installation
3.9.1 Siting the Flue Terminal lighting, activated by passive infra-red sensing heads.
The flue must be installed in accordance with If the terminal is less than 2 m above a surface to which
BS 5440:1 and the Building Regulations. Flue termi- people have access then a guard must be fitted. The
nals in carports and under balconies are to be avoided. guard must be evenly spaced about the terminal with a
The terminal must be positioned so that it does not space of 50 mm in each direction and fixed with plated
cause an obstruction nor the combustion products a screws.
nuisance. See fig. 15 and table 9. A guard Type K6 for the standard horizontal flue, can be
The terminal will, at times, give out a plume of water obtained from Tower Flue Components, Vale Rise, Ton-
vapour and consideration must be given to this when bridge TN9 1TB.
choosing a terminal position. Keep clear of security
Fig. 15
Minimum dimensions of flue terminal positions (all types) (see fig. 15)
Dimension Terminal Position (kW input expressed in net) Balanced flues room sealed: Fanned draught
1)
A Directly below an opening, air brick, opening windows, etc. 300 mm
B 1) Above an opening, air brick, opening window, etc. 300 mm
1)
C Horizontally to an opening, air brick, opening window, etc. 300 mm
D Below gutters, soil pipes or drain pipes 75 mm
E Below eaves 200 mm
F 2) Below balconies or car port roof (lowest point) 200 mm
G From a vertical drain pipe or soil pipe 150 mm
H From an internal or external corner 300 mm
I Above ground roof or balcony level 300 mm
J From a surface facing the terminal 600 mm
K From a terminal facing the terminal 1200 mm
L From an opening in the car port (e. g. door, window) into the dwelling 1200 mm
M Vertically from a terminal on the same wall 1500mm
N Horizontally from a terminal on the same wall 300 mm
O From the wall on which the terminal is mounted Not applicable
P From a vertical structure on the roof Not applicable
Q Above intersection with roof Not applicable
Table 9
1) In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommo-
dating a built-in element such as a window frame.
2) Not recommended.
16 6 720 610 599 GB (03.02)

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. Assembly
NOTE: Flue lengths between 650 mm and 730 mm Flue
cannot be accomodated. Refer to Fig. 17, 18, 19. Turret Maximum 650 mm
Standard system comprise: Flue turret - Flue turret

clamp - Terminal assembly - Wall sealing - plates.
Extension kit comprises: Air duct - Flue duct - Duct Outer
Wall
clamp. Refer to Fig. 20. No
Clamp
Instructions for fitting other flue systems are packed 6 720 610 602 - 08.1O
with the relevant flue kit.
Check that the position chosen for the appliance is sat-
isfactory Refer to Fig. 16.
Fig. 17 Standard Flue
Centre line of Drilling point for

flue/air duct flue duct opening
H 3%
120
Centre (30 mm/metre)
line of
flue Top of the
opening wall
and mounting
appliance frame
Appliance
H
Standard Horizontal Flue 158 mm
6 720 610 602-07.2O
Optional Horizontal Flue 121 mm
Fig. 16 Marking the position of the side flue opening
6 720 610 599 GB (03.02) 17

Installation
Terminal
Assembly
Flue
Turret Maximum 1600mm
Outer
Wall
No Clamp
Clamp Extension
Duct
6 720 610 602 - 09.1O
Fig. 18 Flue with one extension
Terminal
Assembly
Flue
Turret
Outer
Clamp Wall
Clamp
No
Clamp Extension Extension
Duct Duct
6 720 610 602 - 10.1O
Fig. 19 Flue with extensions
Duct Clamp
Flue Extension Air Duct
Turret
Extension Flue Duct
Terminal Assembly Wall Sealing Plates
6 720 610 602 - 11.1O
Fig. 20 Flue components
18 6 720 610 599 GB (03.02)

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
120 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. 21 Flue length - rear Fig. 23 Flue terminal position

Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must face downwards.
The assembly will be made easier if a solvent free
L grease is lightly applied i.e Vaseline, to the male end of
the ducts.
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assem-
bly.
Push the assembly through the wall and fix the turret to
the appliance with the clamp. Refer to fig. 24.
NOTE: THE FLUE MUST BE INCLINED T O THE

BOILER 6 720 610 602 - 13.1O
Flue Turret
Fig. 22 Flue length - side
Mark off the lengths shown onto the ducts and cut to Air and
length. The cuts must be square and free from burrs. Flue Duct
Entry into
Terminal assembly outer (air) duct - L- 70 mm, inner silicone
(flue) duct - L- 50 mm.The measurement is made from Clamp rubber seals
the ridge at the terminal indicating the outer face of the
wall. Refer to fig. 23.
Extension air duct - L- 70mm, flue duct - L- 50 mm.
The measurement is from the formed end.
Flue Socket
on Boiler 6 720 610 602 - 14.1O
Fig. 24 Flue turret

Ensure that the turret is fully entered into the socket on
the boiler. From the outside fix the outer wall plate to the
terminal and, after ensuring the duct is properly i nclined
towards the boiler, fix the plate to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal an be fixed with corrosion resistant
srews.
6 720 610 599 GB (03.02) 19

Electrical connections
4 Electrical connections B Remove screw and slide terminal cover forwards to

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- 0
2
3 4
5
tems and components. 1

E
All control and safety systems are built into the appli- C
CH
ance.
B Allow mains cable to protrude at least 50 cm from
wall.
B To make splash-water proof (IP): cut the cable grom-
met hole size to match diameter of cable, see Fig. 27. 6 720 610 599 -03.1O
It must be possible to isolate the appliance. The appli-

Fig. 26
ance must be earthed.
B Cut cable grommet to diameter of cable.
The appliance must be connected to the mains through
a 6 A double pole isolator with a contact separation
3 mm in all poles and supplying the appliance and con- 0 3 4
trols only. The wiring must comply with the current 2
5
requirements of the IEE Wiring Regulations and any 1
E
local regulations which apply.
• Supply: 230 V ~ 50 Hz, 140 Watts
• Mains cable: PVC insulated 0.75 mm 2
(24 x 0.20 mm) to BS6500-Table 6.
Temperature rated 100˚C.
• Protection IPX4D
• External fuse 3 A. 8-9
5-7
4.1 Connecting the appliance
To gain access to the mains connection remove the 10-12 13-14
drop down facia cover. The drop down cover is 6 720 610 332-12.1R
removed by lowering it to the horizontal position and Fig. 27

pushing firmly upwards at the rear of the supports to B Feed cable through cable grommet and connect the
release the cover. Lift cover from the appliance. mains supply cable, see fig. 28.
After installation (or in the event of an electrical fault) the B Secure cable in cable grommet by means of cable
electrical system shall be checked for short circuits, grip.
fuse failure, incorrect polarity of connections, earth con-
tinuity and resistance to earth.
B Pull out cover panel at the bottom and remove. Refer L N NS L S L R
to fig. 25.
0 3 4
2
5
1
E 4130-14.1R
Fig. 28
6 720 610 332-10.1R
Fig. 25
20 6 720 610 599 GB (03.02)

Electrical connections
4.2 Mains Voltage external controls

connections
NOTE: Only double insulated controls not requiring an earth can be used
Ns Ls LR Ns Ls LR
ST8 ST8
Switched Live
Switched Live
Remove Link
Neutral
Neutral
Live
Live
Motor
230 V Room Thermostat Connections
230 V Programmer Connections
230 V room thermostat and Ns Ls LR

Programmer Connections ST8
Series
connection
Live
to be made
Sw
ed
itc
Neutral
safe
it ch
he
Ne
Live
d
ut
Live
Sw
ra
Li
l
ve
Motor
6 720 610 576 - 22.1O
Fig. 29
Note: If an external timer is used then the domestic hot
water pre-heat facility can only be isolated by actuating
the ECO-button.
6 720 610 599 GB (03.02) 21

Commissioning
5 Commissioning
27
136 365 61 317 366 367 358
ECO 422
2
364
363 8.1
135 E
310 CH
295 15
170
171 172 173 170
6 720 610 599-04.2O
Fig. 30
8.1 Pressure gauge 5.1 Commissioning
15 Safety valve
27 Automatic vent
61 Reset button Never run the appliance when empty or
135 Master switch unpressurised.
136 Temperature control for central heating
170 Service cocks on CH flow and return
171 Hot water
The operational CO2 level is set at the fac-
i
172 Gas cock (shown in on position)
173 Cold water service cock tory and no adjustment is necessary when
295 Appliance type sticker installing a natural gas fired appliance.
317 Multifunction display Benchmark Water Treatment: For optimum perform-
358 Condensate trap
363 Indicator lamp for burner
ance after installation, this boiler and its associated cen-
364 Indicator lamp for power supply tral heating system should be flushed in accordance
365 “Chimney sweep” button with the guidelines given in BS7593:1992 - Treatment
366 Service button of water in domestic hot water systems. Full instruc-
367 ECO button tions are supplied with proprietary cleansers sold for
422 Digital timer
this purpose. If an inhibitor is to be used after flushing,
it should be used in accordance with the inhibitor man-
ufacturers instructions.
To drain the appliance shut the system valves and open
the system drain point.
Suitable flushing agents and inhibitors are available
from Betz/Dearborn Tel.: 0151 4209563, Fernox Tel.:
01799 550811 and Salamander Tel.: 0121 378 0952.
Instructions for use are supplied with the these
products.
22 6 720 610 599 GB (03.02)

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
above 24 mbar. LPG appliances must not be
the power supply (fuse, circuit breaker)
operated if the supply pressure is not 37 mbar
before carrying out any work on the
at the inlet to the appliance.
electrical systems or components.
B Unscrew the condensation trap (358) and pull out,
fill with approx. 1/4 l of water and refit. Refer to
fig. 30. 5.3 Switching on the central heating
B Adjust charge pressure of expansion vessel to static The central heating flow temperature is adjustable
head of the central heating system (see page 28). between 35˚C and 88˚C. Refer to table 14, page 28.
B Open all system radiator valves. B Turn the temperature control to set the flow tem-
B Turn on service valves (170), fill central heating sys- perature to a level appropriate to the type of central
tem to pressure of 1 - 2 bar through the WRAS heating system:
approved filling loop. Refer to fig. 30. – Underfloor heating: e.g. setting “3”
B Vent radiators. (approx. 50˚C)
B Refill heating system and set the pressure to 1 bar. – Low-temperature heating: setting “E”
B Turn on cold water service cock (173). Refer to (approx. 75˚C)
fig. 30. – Central heating systems for flow temperatures up
B Check that the gas type specified on the identifica- to 88 °C: limited “max” setting for low-temperature
tion plate matches that of the gas supply. operation (see page 28).
When the burner is alight, the red indicator lamp
B Turn on gas cock (172). Refer to fig. 30.
lights up.
5.2 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 operating in the central heating mode.
6 720 610 333-05.1O
Fig. 32
5.4 System controls

B Set room thermostat to the desired room tempera-
ture.
B Set outside - temperature driven control unit, if fitted.
6 720 610 333-04.1O Refer to the instructions with the control.
B Set the thermostatic radiator valves to the desired
Fig. 31 settings.
If the display alternates between -II- and

i the central heating flow temperature, the
trap filling programme is active.
The trap filling programme ensures that the condensa-

tion trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
6 720 610 599 GB (03.02) 23

Commissioning
5.5 Setting the domestic hot water B To reduce the flow rate (min. 8 l/min):
temperature and flow rate turn screw on flow switch clockwise (–).
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. 40 °C and 60 °C.
This temperature is not shown on the display.
6720 610 332-25.1O

6 720 610 333-07.1O
Fig. 34
Fig. 33
Setting Hot Water temperature 5.6 Summer mode (hot water only)
Turn fully anti-clockwise approx. 40˚C With room thermostat
approx. 55˚C B Turn temperature control on the appliance anti-
Turn fully clockwise approx. 60˚C clockwise as far as the stop.
The central heating is now turned off. The hot water
Table 10
function and the mains power supply for the heating
“ECO” button programmer and timer remain switched on.
By pressing and holding the “ECO” button , until the
display lights, you can switch between Comfort mode 5.7 Frost protection
and Economy mode.
B Leave master switch switched on.
Comfort mode: button is not lit (factory setting)
If the appliance is to be left for long periods switch the
The appliance is held constantly at the set temperature. central heating off:
This means that hot water is available almost instanta-
neously at the tap. Consequently the appliance will B Add a suitable anti-freeze fluid to the water in the
switch on at intervals, even if no hot water is being central heating system.
drawn. Suitable products are available from Betz-Dearborn
Tel.: 0151 4209563 and Fernox Tel.: 01799
ECO mode with demand detection, button is lit 550811.
The demand detection function enables maximum gas
and water economy. 5.8 Pump anti-seize function
Briefly turning a hot water tap on and then off again sig-
nals demand to the appliance which then heats up the This function prevents the central heating
water to the set temperature.
Hot water is thus available in about 1 minute. i pump seizing after long periods of inactiv-
ity.
ECO mode, button is lit
Every time the pump is switched off, a timer is started.
Water is not heated up until hot water is drawn. This If after 24 hours the pump has not run again, it is
means that there is a longer waiting period before hot switched on for a period of 5 minutes.
water is available.
5.5.2 Hot water flow rate

The flow rate is factory set to 8 l/min.
Under standard conditions (2 bar) supply pressure, one
full turn is equivalent to approximately 2 l/min.
B To increase the flow rate (max. 14 l/min):
turn screw on flow switch anti-clockwise (+).
The outlet temperature will decrease relative to the
increase in the flow rate.
24 6 720 610 599 GB (03.02)

Commissioning
5.9 Fault Condition
A list of faults that may occur is given on

i 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.
If the button flashes:
B Press and hold the button until the display shows
“– –”.
The appliance will then start up again and the display
will show the central heating flow temperature.
If the button does not flash:
B Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the central heat-
ing flow temperature will be displayed.
6 720 610 599 GB (03.02) 25

Commissioning
5.10 Digital Timer 5.10.3 Programming
5.10.4 Setting time and day

B Press Ch
repeatedly until the display shows
PROG.
B The hour setting flashes: change hour by pressing
or .
Ch1 Ch2
B Press and release ; the minutes setting flashes:
ON AUTO ON AUTO
set minutes by pressing or .
CH
B Press and release ; the day setting flashes: set
C
day by pressing or . (1 = Monday, 2 = Tues-
day, etc.).
6 720 610 607-04.1R Changing between summer and winter time:
Fig. 35 B Adjust the time as described.
CH 1 Channel 1 B Do not alter the timed periods.
CH 2 Channel 2
C Clear 5.10.5 Setting the timed periods
Move to next setting Setting options:
Ch
Menu button
Set button • Max. 3 timed periods per day
Set button
• Same times for groups of days or different times for
The timer has two channels: each day
• Channel 1 (CH 1) timer program with 3 timed peri- • Possible day groupings:
ods each day for central heating – All days (1-7)
• Channel 2 (CH 2) timer program with 3 timed peri- – Monday to Friday (1-5)
ods each day for hot water “Comfort” mode. – Saturday and Sunday (6-7)
5.10.1 Basic Settings The timed periods can be set in
Channel 1 – CH 1 – Central heating, all days i increments of 10 minutes.
The timed periods are sorted in ascending
• ON : 6:00
order.
• OFF : 22:00.
Channel 2 – CH 2 – Hot water, all days B Press Ch
repeatedly until the display shows CH1
PROG or CH2 PROG: All days are shown (1-7).
• ON : 5:00
B Press or repeatedly until the desired day or
• OFF : 22:00. group of days is shown.
No other timed periods are programmed (––:––). B Press and release : the first ON time is displayed
(e.g. 6:00).
5.10.2 Button Functions
B Set the ON time by pressing or .
• Menu button : Ch
B Press and release : the first OFF time is dis-

– PROG: Time, Day played (e.g. 22:00).
– CH1 PROG: Timed periods, Channel 1 B Set the OFF time by pressing or .
– CH2 PROG: Timed periods, Channel 2
B Press and release : the second ON time is dis-
– CH1 PROG: Mode, Channel 1 played. Continue as with the first timed period.
– CH2 PROG: Mode, Channel 2
• C : Clear
• : Move to next setting
• Set button or :
– Press and release: changes setting by one unit
– Press and hold: changes setting continuously.
26 6 720 610 599 GB (03.02)

Commissioning
5.10.6 Changing the Operating Mode

I II III
B Press Ch
repeatedly until the display shows CH1 CH
PROG or CH2 PROG. 1 ON OFF ON OFF ON OFF
B Set mode by pressing or : 1
– ON: Central heating on (CH 1)/hot water on
(CH 2) 2
– OFF: Central heating off/Economy (CH 1)/hot
3
water “Comfort” mode, “ECO” mode off (CH 2)
– AUTO: The timer switches the central heating 4
(CH 1)/hot water (CH 2) on and off according to
the timed-period settings 5
5.10.7 Deleting Settings 6
Deleting an individual timed period: 7

B Select required timed period on the display (see
Table 11
chapter 5.10.5).
B Briefly press and release C . Hot water comfort mode
Resetting the timer completely: I II III

CH
B Press and hold C for approx. 15 seconds. 2 ON OFF ON OFF ON OFF
5.10.8 Completing Programming 1
B Press Ch
repeatedly until the normal display
appears. 2
-or- 3
B Do not press any buttons for 30 seconds.
4
5.10.9 Time Display
5
Time of day and timed periods are displayed either in
24-hour (default setting) or 12-hour format. 6
The time display format cannot be 7
i changed while programming.
Table 12
To change the time display format:

B Press and hold and simultaneously (for
about 10 seconds). In 12-hour time format, the dis-
play also shows am (morning) or pm pm (afternoon)
next to the time.
6 720 610 599 GB (03.02) 27

Individual settings
6 Individual settings B Rotate yellow button through 180° and replace (dot
facing inwards).
The CH flow temperature is no longer limited.
6.1 Mechanical settings
Control setting CH flow temperature
6.1.1 Checking the size of the expansion vessel
1 approx. 35˚C
Maximum pressure at maximum CH flow temperature is 2 approx. 43˚C
2.5 bar. If the pressure is greater than this then fit an
3 approx. 51˚C
extra expansion vessel. Refer to table 13.
4 approx. 59˚C
System Capacity – BS7074:1 5 approx. 67˚C
Expansion Vessel Pressure and System Capacity E approx. 75˚C
max approx. 88˚C
Expansion Vessel litres 10 Table 14
Expansion Vessel bar 0.75 6.1.3 Changing the heating pump characteristic
Charge Pressure The speed of the central heating pump can be altered
on the pump terminal box.
System 1 bar litres 82
pressure At switch position 1, maximum output is
and
capacity
1.5 bar litres 46
i not delivered if hot water mode is active.
Position 1 must not be used on combi ap-
Table 13 pliances.
6.1.2 Setting the central heating flow tempera- 0,7

ture H
(bar)
The central heating flow temperature can be set to 0,6
between 35˚C and 88˚C.
0,5
With underfloor heating systems, observe 3
i the maximum permissible flow tempera-

tures.
0,4
2
0,3
Limited maximum setting for low-temperature
operation 0,2
The temperature control is factory limited to setting E, 1
giving a maximum flow temperature of 75˚C. 0,1
Adjustment of the heating output to the calculated heat

0
demand is not required by the heating systems regula- 0 200 400 600 800 1000 1200 1400 1600
tions. Q (l/h)
6 720 610 576-23.2O
Removing the maximum setting limit
For heating systems which require higher flow temper- Fig. 37
atures, the maximum setting limit can be removed.
1 Pump characteristic for switch position 1
B Lift off the yellow button on the temperature control 2 Pump characteristic for switch position 2
3 Pump characteristic for switch position 3
with a screwdriver.
H Residual delivery pressure
Q Water circulation rate
6 720 610 332-27.1O
Fig. 36
28 6 720 610 599 GB (03.02)

Individual settings
6.2 Settings on the Bosch Heatronic Entering a setting
6.2.1 Operating the Bosch Heatronic B To enter the setting for a function, turn the tempera-
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 button until the dis-
for commissioning. play shows [ ].
For a full description of all available functions, please B Level 2: press and hold the and buttons simul-
refer to the Service booklet for the Engineer, order no. taneously until the display shows [ ].
7 181 465 346.
After completing the settings
2 5 1
B Reset the temperature controls and to their
original positions.
6.2.2 Selecting the pump control mode for cen-

tral heating mode (Service Function 2.2)
6 720 610 332-30.1O If an outside temperature driven control
3
Fig. 38 Appliance controls
4
i unit is connected, pump control mode 3 is
automatically activated
1 Service button
2 “Chimney sweep” button The choice of settings is as follows:
3 Temperature control for central heating • Control Mode 1
5 Display
For heating equipment without a control unit.
The pump is controlled by the central heating flow
Selecting service function: temperature control.
Note the positions of the temperature con- • Control Mode 2 (factory setting)
i trols and . After completing the set-
tings, return the temperature controls to
For heating systems with room thermostat.
The central heating flow temperature control controls
their original positions. only the gas, the pump is not affected. The room ther-
mostat controls both the gas and the pump.
The service functions are subdivided into two levels: The pump and fan have an overrun time of between
Level 1 comprises service functions up to function 4.9, 15 s and 3 min.
while Level 2 consists of the service functions from 5.0 • Control Mode 3
upwards. The pump is controlled by the outside temperature
B To select a service function on Level 1: press and driven control unit. In summer mode, the pump oper-
hold the button until the display shows – –. ates only for hot water mode.
B To select a service function on Level 2: press and
6.2.3 Setting the anti-cycle time
hold the buttons and simultaneously until the
(Service Function 2.4)
display shows = =.
This service function is only active if Service Function
B Then turn the temperature control to select the
2.7, automatic anti-cycle time, is deactivated.
required function.
The anti-cycle time can be set to between 0 and 15 min-
utes (is factory set to 3 minutes).
Service function Code no. See page
If the setting 0 is entered, the anti-cycle time is inactive.
Pump control mode 2.2 29
Anti-cycle time 2.4 29 The shortest possible anti-cycle time is 1 minute (rec-
Max. CH flow ommended for single-pipe and hot-air heating systems).
temperature 2.5 30 If the appliance is connected to an out-
Switching difference
Max. heating output
2.6
5.0
30
30
i side-temperature controlled heating pro-
grammer, the anti-cycle time does not
Constant hot water need to be set on the appliance and is op-
cycle time 6.8 30 timised by the programmer instead.
Table 15
The service function 5.0 may be reset.
6 720 610 599 GB (03.02) 29

Individual settings
6.2.4 Setting the maxim CH flow temperature B Refer to the settings tables for heating and cylinder
(Service Function 2.5) charging output to obtain the relevant code for the
The maximum CH flow temperature can be set to desired heating output in kW (see page 45).
between 35˚C and 88˚C (factory setting). B Turn the temperature control until the display
shows the desired code number.
6.2.5 Setting the switching difference The display and the and buttons will flash.
B Measure the gas flow rate and compare with the fig-
If the appliance is connected to an out- ures specified for the code number displayed. If fig-
i side-temperature controlled programmer,
the programmer sets the switching differ-
ures do not match, adjust the code number!
B Press and hold the and buttons simultane-
ence. ously until the display shows [ ].
It does not need to be set on the appli- The heating output is now stored.
ance.
The switching difference is the permissible divergence

from the specified CH flow temperature. It can be set in
increments of 1 K. The adjustment range is 1 to 30 K (is
factory set to 0 K). The minimum CH flow temperature
is 30˚C.
6 720 610 332-52.1O
6.2.6 Setting the heating output

Fig. 41
B Return the temperature controls and to their
The heating output can be set to any level between min.
original positions.
rated heat output and max rated heat output to limit it to
The display will revert to the CH flow temperate.
the specific heat requirements.
6.2.7 Constant hot water cycle time
The full rated heat output is still available
i for hot water or charging the hot water cyl-
inder even if the heating output has been
In Comfort mode “ECO light off” , the hot water inside
limited. the appliance is held constantly at the set temperature.
For that reason, the appliance switches on if the water
The factory setting is the max. rated heat output. temperature falls below a certain temperature. In order
to prevent it switching on and off too frequently, the
B Press and hold the and buttons simultane- constant hot water cycle time service function allows
ously until the display shows = =. you to set the minimum period between switching off
The and buttons will light up. and on again. This function has no effect on normal
demand for hot water and relates only to the constant
hot water function in Comfort mode.
The cycle time can be set to any period between 20 and
60 minutes (is factory set to 20 minutes).
6 720 610 332-50.1O

6.3 Setting the gas/air ratio
Fig. 39 The appliance is set at the factory and adjustment is not
necessary.
B Turn the temperature control until the display
shows 5.0.
After a short delay, the display then shows the set
heating output in percent.
6 720 610 332-51.1O
Fig. 40
30 6 720 610 599 GB (03.02)

Converting the appliance to different gas types
7 Converting the appliance to different gas types

The setting is factory sealed at maximum. Adjustment to 7.1 Setting the gas/air ratio
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 CO2 measurement at max. heat output
Checking the gas supply pressure and min. heat output using an electronic tester.
B Check the gas supply pressure at the gas supply B Switch off the appliance at the master switch (O).
pressure testing point. B Remove the outer case (see page 15, refer to
fig. 13).
Natural gas appliances must not be oper- B Switch on the appliance at the master switch (I).
i ated if the gas supply pressure is below
18 mbar or above 24 mbar. B Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 42.
LPG appliances must not be operated if
the supply pressure is below or above B Insert testing probe about 135 mm into the flue gas
37 mbar. testing point and seal testing point.
Natural gas
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m 3 and 20 mbar supply
pressure and sealed.
Conversion kits
For conversion 2 3 4
Model from ... Order no.
ZWB 7-29 N.G to L.P.G 7 710 149 048
ZWB 11-27 L.P.G to N.G 7 710 239 084 6 7 2 0 6 1 0 3 3 2 -5 7 .2 R
Table 16 Fig. 42
• Instructions are sent with each conversion kit. B Press and hold button until the display shows – –.
The button will light up.
6 720 610 332-32.1O
Fig. 43
shows 2.0 .
After a short delay, the current operating mode set-
ting will be displayed (0. = Normal mode).
6 720 610 332-60.1O
Fig. 44
6 720 610 599 GB (03.02) 31

Converting the appliance to different gas types
B Turn the temperature control until the display B Remove the seal from the gas valve adjusting
shows 2. (= max. rated heat output). screw (64) and adjust the CO 2 level to the figure
The display and the button will flash. given in Table 17 for min. rated heat output.
64
6 720 610 332-61.1O
Fig. 45
B Measure the CO2 level.
B Prise off the seal on the gas flow restrictor.
B Adjust the gas flow restrictor (63) to obtain the CO 2
3928-74.1R
level given in Table 17. Refer to fig. 46.
Fig. 48
B Recheck the levels at min. and max. rated heat output
and re-adjust if necessary.
B Turn the temperature control anti-clockwise as
63 far as the stop so that the display shows 0.
(= Normal operating mode).
The display and the button will flash.
B Press and hold the button until the display
shows [ ].
B Reset the temperature controls and to their
original positions.
6 720 610 332-64.1R The display will revert to the CH flow temperature.
Fig. 46 B Remove testing probe from the flue gas testing
point (234) and refit sealing plug.
CO2 reading CO2 reading B Re-seal gas valve adjusting screw and gas flow
at max. at min. restrictor.
rated heat rated heat B Replace outer case and secure.
Gas Type output output
Natural gas type 9.2 % 8.8 %
G20
LPG G31 10.8 % 10.5 %
(propane)
Table 17
B Turn the temperature control anti-clockwise until
the display shows 1. (= min. rated heat output).
The display and the button will flash.
6 720 610 332-63.1O
Fig. 47
B Measure the CO2 level.
32 6 720 610 599 GB (03.02)

Maintenance
7.2 Testing combustion air/flue gas at You have 15 minutes in which to measure
set heat output
i the levels. After that, the appliance switch-
es back from “chimney sweep” mode to
7.2.1 Testing the O2 or CO2 level in the combus-
normal mode.
tion air
By testing the O2 or CO2 level in the com- B Remove sealing plug from flue gas testing point
i bustion air the gas tightness of a type C13
or C33 flue system can be checked. The
(234, Fig. 49).
B Insert testing probe about 135 mm into the testing
O2 level must not be less than 20,6 %. point and seal testing point.
The CO2 level must not exceed 0,2 %.
B CO- and CO2 levels.
B Press and hold the button until the display B Refit sealing plug.
shows – –. B Press and hold button until the display shows – –.
“Chimney sweep” mode is now active. The button will stop flashing and the display
The button will light up and the display shows the shows the CH flow temperature.
CH flow temperature.
In “chimney sweep” mode, the appliance 8 Maintenance
i switches to max. rated heat output or the
set heating output. You then have 15 min- B Always disconnect the appliance from
utes in which to measure the levels. After the electrical power supply (fuse, circuit
that, the appliance switches back from breaker) before carrying out any work on
“chimney sweep” mode to normal mode. the electrical systems or components.
B Remove sealing plug from combustion air testing

point (234.1, fig. 49). B Always turn off the gas cock before car-
rying out any work on components
B Insert testing probe about 80 mm into the testing
which carry gas.
point and seal testing point.
There is a special Service booklet for the

i Engineer, order no. 7 181 465 346, avail-
able to competent persons.
All safety and control systems are moni-
2 3 4
i tored by the Bosch Heatronic. In the event
of a component fault, the display shows a
fault code.
2 3 4 .1
B The User should be recommended to have the appli-
ance serviced regularly by a competent person (see
6 7 2 0 6 1 0 3 3 2 -6 5 .2 R
Maintenance Contract).
Fig. 49 B Use only genuine spare parts
B Measure O2 and CO2 levels. B Refer to the Spare Parts List when ordering spare
parts.
B Refit sealing plug.
B Always renew seals and O-rings removed during
B Press and hold button until the display shows – –.
servicing or repair work.
The button will stop flashing and the display
shows the CH flow temperature. B Use only the following types of grease:
– Water valve: WRAS approved silicon based
7.2.2 Testing CO and CO 2 grease
B Press and hold the button until the display – Unions: approved sealant.
shows – –. B To drain the appliance shut the system valves and
“Chimney sweep” mode is now active. open the pressure relief valve.
The button will light up and the display shows the
B Upon completion of any electrical work check for
CH flow temperature.
earth continuity, correct polarisation and resistance
to earth.
6 720 610 599 GB (03.02) 33

Maintenance
8.1 Pre-Service Check List
Date
1 Call up the last fault stored by the

Bosch Heatronic, Service Function .0,
(see page 35).
2 Check ionisation current, Service

Function 3.3, (see page 35).
3 Perform visual check of air/flue duct.

Visual check of diaphragm for soiling
and splits (see page 37).
4 Check gas supply pressure mbar

(see page 31).
5 Test combustion air/flue gas

(see page 33).
6 Check CO2 setting for min./ min. %

max. (gas/air ratio)
(see page 31). max. %
7 Check gas and water systems for

leaks (see page 15).
8 On combi models, check hot water

outlet temperature (see page 35).
9 Check heat exchanger mbar

(see page 35).
10 Check burner (see page 36).
11 Clean condensation trap

(see page 37).
12 Check charge pressure of mbar
expansion vessel matches
static head of heating system.
13 Check central heating system mbar

pressure.
14 Check electrical wiring for damage.
15 Check heating programmer settings.
16 Check appliances that are part of

the heating system
Table 18
34 6 720 610 599 GB (03.02)

Maintenance
8.2 Description of servicing operations Primary Heat exchanger

The combustion performance must be checked before There is a special accessory kit (no. 840) for cleaning
and after any servicing work on the combustion and the heat exchanger, order no. 7 719 001 996.
burner components. Refer to section 7.2. B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manome-
Check “Last fault stored”:
ter.
B Select Service Function .0 (See page 29 “Selecting
Service Function”).
There is a list of the fault codes in the Appendix (see

page 43.
To delete “Last fault stored”:
B Turn temperature control anti-clockwise as far as
the stop.
B Press and hold the button until the display
shows [ ].
The last fault stored has now been deleted.
Checking the ionisation current, 6 720 610 332-69.1R
Service Function 3.3 Fig. 51

B Select Service Function 3.3 (See page 29 “Select-
ing Service Function”). The heat exchanger should only be
If the display shows 2 or 3, the ionisation current is OK. i cleaned if the control pressure is
3.0 mbar (depression) or less.
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced. B Remove cleaning access cover (415, page 6) and
Domestic hot water the metal plate below it, if present. Refer to fig. 2.
B Unscrew condensation trap and place suitable con-
If the flow rate is too slow:
tainer underneath. Refer to fig. 52.
B remove the domestic hot water heat exchanger and
B Remove the fan and the burner as described in the
replace,
text headed “Burner” (see page 36).
-or-
B descale with a descaling agent approved for use on
stainless steel.
B Before removing the heat exchanger shut the inlet
valve and drain the hot water circuit.
B Use new seals when replacing the heat exchanger.
6 720 610 332-72.1R
Fig. 52
7 181 465 330-06.1R
Fig. 50
6 720 610 599 GB (03.02) 35

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).
Refer to fig. 56.
B Unscrew and remove the two hexagon screws secur-
ing the fan (3).
B Slacken fully the rear securing bolt (4).
B Remove the burner coverplate.
4.
6 720 610 332-73.1R
Fig. 53 2.
B Clean the heat exchanger from top to bottom using 3.
the brush. Refer to fig. 54. 1.
7 181 465 330-04.1R
Fig. 56
B Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 57.
6 720 610 332-74.1R
Fig. 54
B Flush the heat exchanger from the top. Refer to
fig. 55.
B Clean out the condensate collector and trap connec-
tion (with other end of brush).
7 181 465 330-08.1R
6 720 610 332-75.2R
Fig. 57
Fig. 55
B Refit the clean-out cover using a new seal and B Re-assemble burner in reverse order using a new
tighten screws to torque of approx. 5 Nm. seal.
B Adjust gas/air ratio. Refer to section 7.2.
36 6 720 610 599 GB (03.02)

Maintenance
Diaphragm in mixer unit B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4,5 mm ± 0,5 mm.)
B Take care not to damage diaphragm
(443) when removing and refitting it. B Replace and re-connect the assembly taking care
not to mislay the inspection window.
B Open mixer unit (29). Siphon

B Carefully withdraw diaphragm (443) from fan intake B Unscrew the clip and disconnect the pipe to the
tube and check for soiling and splits. siphon.
B Remove the yellow plug to drain the siphon.
B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
B Refit and prime the siphon.
3.
443
29
Condensate
Drain
Siphon
1.
2. 6 720 610 602 - 16.1O
6 720 610 790-07.2R
Fig. 58 Fig. 59
B Carefully refit diaphragm (443) the correct way Expansion vessel

round into the fan intake tube. The expansion vessel should be checked once a year.
The flaps of the diaphragm (443) must B Depressurise appliance.
i open upwards. B If necessary, adjust expansion vessel charge pres-
sure to static head of the heating system.
B Seal the mixer unit (29).
Heating system pressure
Condensation trap Fill the system using the WRAS approved
In order to prevent spillage of condensate, the conden-
sation trap should be completely removed, (see
i filling loop.
page 35, fig. 52).

B The pointer on the pressure gauge should be 1 bar.
B Unscrew condensation trap and check connection B If the pointer is below 1 bar (when the system is
to heat exchanger is clear. cold), water should be added until the pointer is
B Remove condensation trap cover and clean. 1 bar again.
B Fill condensation trap with approx. 1/4 l of water and B Max. pressure of 2.5 bar when the heating system
refit. water is at maximum temperature must not be
exceeded. If this pressure is exceeded then an extra
Electrode assembly expansion vessel must be fitted in the system return
B Switch off the master switch. as close to the appliance as possible.
B Pull off the leads from the electrodes. Refer to fig. 2. B If the system does not retain the pressure, the expan-
B Unscrew the two fixing screws and carefully remove sion vessel and the heating system should be
the electrode assembly . Refer to fig. 51. checked for leaks.
6 720 610 599 GB (03.02) 37

Maintenance
Electrical wiring B Remove the pcb control board.

B Check the electrical wiring for physical damage and
replace any damaged wires.
8.3 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
new seals or o-rings as appropriate.
8.3.1 PCB control board and transformer

B Switch off the appliance.
B Disconnect appliance from the power supply.
B Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the cov-
ers. Refer to fig. 25, 26.
B Remove screw holding power connector earth lead
and remove earth lead.
B Remove two fixing screws from the control box.
Refer to fig. 60. 7 181 465 330-10.1R
Fig. 61
1
Fuses
3
2 4
3 4 1
B Remove the connections covers. Refer to fig. 25, 26.
3
2 4
2
5
1
E
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
CH
1
Fuse, item 312, is only replaceable by removing the

C
3
2 4
6 720 610 599-05.1O
pcb.
Spare fuses are fixed to the connections cover.
A fuse pack is available: Part number 8 744 503 010 0.
Fig. 60
B Lower the control box.

B Unscrew earth lead.
B Unscrew four fixing screws from cover plate. Refer to
fig. 61.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.
38 6 720 610 599 GB (03.02)

Maintenance
8.3.2 Fan Assembly 8.3.3 Pump

3. B Disconnect the appliance from the power supply.
B Remove two switchbox fixing screws (1.). Refer to
fig. 63.
2. B Lower switchbox (2.).
B Unscrew and remove the the siphon by releasing the
jubilee clip. Refer to fig. 59.
B Unscrew the pump union nuts (5.). Refer to fig. 63.
4. B Carefully remove the pump and disconnect the
leads.
Alternatively
B After removing the siphon release the four Allen
screws and remove and replace the pump head.
3.
1. 7 181 465 330-05.1R
Fig. 62
B Disconnect the appliance from the power supply.
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 62.
B Remove fan lead and earth connector (2.). The earth 1.
connector has a positive clip fixing. 1.
B Remove fixing screws attaching fan to the burner
CH
cover (3.).
B Remove fan together with gas pipe and mixer unit.
B Separate the fan from the pipe and mixer unit by
twisting the mixer unit to release it (4.). 2.
Fig. 63
6 720 610 599 GB (03.02) 39

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. Refer to B Pull-off the connector.
fig. 64.
B Release the sensor clip and withdraw the sensor.
B Pull out retaining clip.
B Apply heat transfer paste to the replacement sensor.
B Remove motor.
B Disconnect the relief valve drain. Safety Temperature Limiter – Item 6, fig. 2, 60
B Disconnect the pressure gauge by withdrawing the B Pull-off the connectors.
clip and pulling out the capillary head. B Unscrew the sensor.
B Undo pipe unions by withdrawing the clips.
Flue Temperature Limiter – Item 9, fig. 2, 60
B Remove 3-way valve.
B Pull-off the connectors.
B Unscrew the sensor.
Domestic Hot Water Temperature Sensor –

Item 6.1, fig. 2
B Check that the inlet water valve is closed and the
domestic hot water circuit is drained.
B Release and pull-off the connector.
B Unscrew the sensor.
7 181 465 330-12.1R
Fig. 64
After refitting:
B Fill system, bleed and re-pressurise
(see Installation Instructions).
8.3.5 3-way diverter valve motor

B Turn off the service cocks.
B Unplug connector from 3-way valve motor. Refer to
fig. 64.
B Pull out retaining clip.
B Remove motor.
40 6 720 610 599 GB (03.02)

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
valve.
B Undo the union, within the inner casing, securing the B Refer to section 8.2.
valve to the gas/air tube. Refer to fig. 62. B Use a new seal if the existing seal is damaged.
B Remove the white plastic cap from the gas valve. 8.3.10 Pressure gauge
B Release the gas inlet union at the manifold assembly.
B Drain the appliance.
B Unscrew the two screws securing the gas valve
B Lower the facia. Refer to fig. 63.
assembly bracket to the back panel and withdraw the
assembly. B Twist the pressure gauge head anti-clockwise to
release it from the casing. Refer to fig. 2.
B Transfer the bracket and inlet pipe assembly to the
new gas valve. B Disconnect the capillary head from the rear of the
diverter valve by withdrawing the clip and pulling out
B Check for gas soundness when the new gas valve
the head. Refer to fig. 64.
has been fitted.
B Recheck the combustion performance as described 8.3.11 Expansion vessel
in section 7.1.
B Undo the union connection at the base of the vessel.
Refer to fig. 2.
B Unscrew the top and bottom fixing screws and
remove the vessel.
B Set the pressure of the new vessel to that required
by the system.
8.3.12 Pressure Relief Valve

B Disconnect the drain pipe from the valve. Refer to
fig. 30.
B Pull-out the clip securing the valve.
B Pull-out the valve.
B Ensure that the replacement valve is fully entered
before fitting the clip.
8.3.13 Burner
B Refer to section 8.2.
6 720 610 602 - 04.1O
Fig. 65
6 720 610 599 GB (03.02) 41

Maintenance
8.3.14 Flow switch B Transfer components, as necessary, to the new heat

exchanger.
B Shut the mains water inlet valve and drain the domes-
tic hot water circuit. B Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
B Pull-off the connectors from the micro-switch.
appliance.
B Unscrew the inlet and union connection and remove
the assembly.
B Reset the domestic hot water flow rate on the new
assembly.
OUTLET
INLET
6 720 610 602 - 05.10
Fig. 66
8.3.15 Primary Heat Exchanger

6 720 610 602 - 06.10
B Check that the gas supply is turned off. Fig. 67
B Check that the appliance is electrically isolated.
B Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 8.3.2.
B Remove the burner. Refer to section 8.2.
B Disconnect the sensors. Refer to section 8.3.6.
B Undo the central heating flow union.
B Undo the top connection of the pump. Refer to
fig. 63.
B Undo the grey plastic cap, next to the top pump con-
nection at the base of the heat exchanger.
B Unscrew and remove the condensate trap. Refer to
section 8.2.
B Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
B Lift up the flue duct, item 271, refer to fig. 2.
B Pull forward from the top and lift the heat exchanger
from the casing.
42 6 720 610 599 GB (03.02)

Appendix
9 Appendix
9.1 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
A7 Hot water NTC sensor defective. Check hot water NTC sensor and connecting lead for
circuit breaks/short circuits.
A8 Break in communication Check connecting lead to programmer
AC Module not detected. Check connecting lead between TA211E/TR212E
and Heatronic
b1 Keyed plug not detected. Insert keyed plug correctly, test and replace if neces-
sary.
C1 Fan speed too low. Check fan lead and connector, and fan; replace as
necessary.
d3 Jumper 8-9 not detected. Connector not connected, link missing, underfloor
heating limiter tripped.
E2 CH flow NTC sensor defective Check CH flow NTC sensor and connecting lead.
E9 Safety temp. limiter in CH flow has tripped. Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA Flame not detected. Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0 Internal error. Check electrical connector contacts, programmer
interface module ignition leads are not loose; replace
pcb if necessary.
F7 Flame detected even though appliance switched off. Check electrode assembly, dry pcb. Flue clear?
FA Flame detected after gas shut off. Check gas valve and wiring to gas valve. Clean con-
densation trap and check electrode assembly. Flue
clear?
Fd Reset button pressed by mistake. Press reset button again
P1, P2, Please wait, initialisation in progress. 24 V fuse blown. Replace fuse.
P3, P1...
Table 19
6 720 610 599 GB (03.02) 43

Appendix
9.2 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 1 8 747 003 516 0
6 Fan assembly 1 8 717 204 373 0
7 Fan washer 1 8 729 000 183 0
8 Expansion vessel 1 8 715 407 236 0
9 Relief valve 1 8 717 401 012 0
10 Electrode assembly 1 8 718 107 077 0
11 Electrode lead 1 8 714 401 999 0
12 Pump 1 8 717 204 384 0
13 Pressure gauge 1 8 717 208 079 0
14 Burner skin seal 1 8 711 004 168 0
15 Transformer - facia 1 8 747 201 358 0
16 Flow switch 1 8 717 002 110 0
17 3-way diverter valve 1 8 717 010 062 0
18 Heat exchanger washer 1 8 710 103 153 0
19 Washer set Condensation Trap 1 8 710 103 154 0
20 Fuse set 1 8 744 503 010 0
21 Service set Water Valve 1 8 710 503 031 0
22 Domestic Hot Water 1 8 715 406 659 0
Heat Exchanger
23 Primary heat exchanger 1 8 715 406 615 0
Table 20
44 6 720 610 599 GB (03.02)

Appendix
9.3 Heating/hot water output settings

(N.G)
Natural gas G20
Display Heat Heat Gas vol. flow
code output input rate (l/min at
kW kW tV/tR =
80/60˚C)
30 8.8 8.9 15.5
40 11.7 11.8 20.7
50 14.6 14.8 25.8
60 17.5 17.7 31.0
70 20.4 20.7 36.1
80 23.4 23.6 41.3
90 26.3 26.6 46.5
100 29.2 29.5 51.6
Table 21
9.4 Heating/hot water output settings

(L.P.G)
Propane
Display code Heat output kW Heat input kW
40 11.7 11.8
50 14.6 14.8
60 17.5 17.7
70 20.4 20.7
80 23.4 23.6
90 26.3 26.6
100 29.2 29.5
Table 22
6 720 610 599 GB (03.02) 45

46
9.5
9.5.1
Fig. 68
Appendix
** NOTE:
Pump ON Fan to Ignition The appliance controls can be set to one of
Diverter valve start speed. Ignition sequence spark
operates. Gas valve opens. 5 secs
2 modes of operation.
1. “Comfort“ mode -
Full pre-heat
Burner shut-down if 2. “ECO“ mode -
primary temperature
Burner lights. exceeds 94 °C remains
a) Operates as an instantaneous combination
Pre-heat satisfied.
Red light ON. OFF until 78 °C boiler.
b) Demand Detection: a short demand (less
Over temperature
than 5 seconds) switches the control to
Domestic hot water function
Burner remains OFF “Comfort“ mode for 5 mins. Mini pre-heat.

Gas valve shuts. shut-down if water
until flow temperature
Pump remains ON. temperature is 8°C The Factory setting is “Comfort“ mode.
is below set value.
Operational Flow diagrams
above set value.
.
Heat input
Gas valve Fan runs for
Mains Green Hot Pump ON Fan to modulates to
Pre-heat Demand closes. upto 3 mins. Pre-heat
switch light water Diverter valve start speed. maintain the
mode.** ends. Red light Pump runs mode.**
ON. ON. demand. operates. Gas valve opens. delivery
OFF. for 30secs.
temperature.
Ignition sequence
Ignition spark for Burner lights. Yes

5 seconds. Red light ON.
No
Repeats 5 times Fan runs to purge

before lock-out. gas from burner.
6 720 610 576 - 24.1O
6 720 610 599 GB (03.02)

Over temperature 9.5.2
Burner remains OFF
Fig. 69
Gas valve shuts. shut-down if water
until flow temperature
Pump remains ON. temperature is 5°C
is below set value.
above set value.
Room thermostat
6 720 610 599 GB (03.02)

and/or mains
programmer or Boiler
link ON operates to
Pump ON Burner Fan speed Boiler Yes *
Mains Green AND Fan min. match
CH Fan to stabilises at reduces unused for Minimum
switch light Electronic facia speed for system load
demand. start speed. start speed over 15 long heat input
ON. ON. programmer 90 secs. and CH
Gas valve opens. for 5-10 secs secs. period.* for 15min.
(if fitted) ON control
Central heating function
AND setting.
CH control knob
No
ON. ce
Ignition sequence
Gas valve
Pump and Fan
Ignition spark for Burner lights. Yes CH demand closes.
run for upto
5 seconds. Red light ON. satisfied. Red light
3 mins.
OFF.
No
Repeats 5 times Fan runs to purge * NOTE: The sequence ensures that the condensate siphon is not empty
before lock-out. gas from burner. after long OFF periods. (More than 24 hours without a demand).
6 720 610 576 - 25.1O

Appendix
47
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
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
ZB 7-27 HE system GC-Number: 41 311 49
ZB 7-28 HE system GC-Number: 41 311 58
Greenstar 29 HE Conventional GC-Number: Natural Gas: 41 311 56; LPG: 41 311 57
7 181 465 346 GB (03.02) OSW
Table of contents
Table of contents
Warnings 3
Symbols 3
1 Layout of Appliance 4
1.1 combi 4
1.2 system 5
2 Bosch Heatronic board functions 6

2.1 Initialisation 6
2.2 Temperature display 6
2.3 Indication of faults 6
2.4 Special programme visualisation 6
2.5 Boiler service functions 8
2.5.1 First Service Level 8
2.5.2 Secondary Service Level 11
3 Failure identification procedure 13

3.1 Notes on using the fault code tables 13
3.2 Summary 14
3.2.1 Appliance faults 14
3.2.2 Faults that are not displayed 14
3.3 Error codes on the display 15
3.4 Faults that are not displayed 42
3.4.1 Appliance faults 42
3.4.2 Programmer faults 48
4 Appendix 52
4.1 NTC values 52
4.1.1 Outside temperature sensor 52
4.1.2 CH flow NTC sensor, heat store
NTC sensor, constant hot water
NTC sensor and hot water NTC sensor 52
4.2 Electronic schemes 53
4.3 List of most important replacement parts 54
4.4 Approved corrosion inhibitors and
anti-freeze fluids for central
heating water 55
4.4.1 Frost protection 55
4.4.2 Sealing agents 55
4.5 Summary of BDH Information Sheet
on Identifying Corrosion by CFCs 55
2 7 181 465 346 GB (03.02)

Warnings
Warnings Symbols
Repairs Safety instructions in this document
B Repairs may only be carried out by an approved are identified by a warning-triangle sym-
installer! bol and are printed on a grey back-
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- terms of the consequences of not following the safety
ter switch, some components on the PCB control instructions.
board inside the control box are still live. Therefore:
• Caution indicates that minor damage to property
B Before carrying out any work on the electrical parts could result.
of the appliance fully disconnect it from the power
• Warning indicates that minor personal injury or seri-
supply (e. g. by means of fuse or circuit breaker)!
ous damage to property could result.
B Flue ducting must not be modified in any way.
• Danger indicates that serious personal injury could
B Use only original spare parts! result. In particularly serious cases, lives could be at
Instructions to the customer risk.
B Explain to the customer how the appliance works
Notes are identified by the symbol shown
and how to operate it.
B Advise the customer that he/she must not make any i on the left. They are bordered by horizontal
lines above and below the text.
modifications to the appliance or carry out any
repairs on it. Notes contain important information in cases where
there is no risk of personal injury or damage to property.
7 181 465 346 GB (03.02) 3

Layout of Appliance
1 Layout of Appliance
1.1 combi
120
221.1
221.2 349
234.1
234
27
226
20 102
32.1
29
36
271 6
415
43
9
63
416
358
18
64
423
7 18.1
355
418
6.1 15
8.1
88
295 98
417 4
6 720 610 576-02.2O
Fig. 1
4 Heatronic control 120 Fixing points
6 Heat exchanger safety temperature limiter 221.1 Flue duct
6.1 Hot water NTC sensor 221.2 Combustion air intake
7 Testing point for gas supply pressure 226 Fan assembly
8.1 Pressure gauge 295 Appliance type sticker
9 Flue gas temperature limiter 234 Testing point for combustion products
15 Relief valve 234.1 Testing point for combustion air
18 Pump 271 Flue duct
18.1 Pump speed selector switch 349 Cover plate for twin flue duct connection
20 Expansion vessel 355 Plate-type domestic hot water heat exchanger
27 Automatic air vent 358 Condensate trap
29 Air gas Mixer unit 415 Cover plate for cleaning access
32.1 Electrode assembly 416 Condensate collector
36 Temperature sensor in CH flow 417 Clip for fixing outer case
43 CH flow 418 Data plate
63 Adjustable gas flow restrictor 423 Siphon
64 Adjusting screw for min. gas flow volume
88 3-way valve (combi)
98 DHW flow switch (combi)
102 Inspection window
4 7 181 465 346 GB (03.02)

Layout of Appliance
1.2 system
120
221.1
221.2 349
234.1
234
27
226
20 102
32.1
29
36
271 6
415
43
9
63
416
358
18
64
423
7 18.1
418
15
8.1
295
417 4
6 720 610 596-01.2O
Fig. 2
4 Heatronic control 234.1 Testing point for combustion air
6 Heat exchanger safety temperature limiter 271 Flue duct
7 Testing point for gas supply pressure 349 Cover plate for twin flue duct connection
8.1 Pressure gauge 358 Condensate trap
9 Flue gas temperature limiter 415 Cover plate for cleaning access
15 Relief valve 416 Condensate collector
18 Pump 417 Clip for fixing outer case
18.1 Pump speed selector switch 418 Data plate
20 Expansion vessel 423 Siphon
27 Automatic air vent
29 Air gas Mixer unit
32.1 Electrode assembly
43 CH flow
63 Adjustable gas flow restrictor
64 Adjusting screw for min. gas flow volume
102 Inspection window
120 Fixing points
221.1 Flue duct
221.2 Combustion air intake
226 Fan assembly
295 Appliance type sticker
234 Testing point for combustion products
7 181 465 346 GB (03.02) 5

Bosch Heatronic board functions
2 Bosch Heatronic board func- 2.4 Special programme visualisation

tions The display shows for example 45 – – 45 (continu-
ous working at the minimum sanitary/heating
2.1 Initialisation power)
The display shows alternatively the temperature
When it is switched on, the appliance performs a self- and – –. The function is memorised in the Service mode.
test which takes about 5 seconds. While the test is in
progress, the display shows the following sequence of • The appliance works continuously at the sanitary or
codes: heating minimum power.
P1 -> P2 -> P3 -> P4 -> P5 -> P6 B Press the button until the symbol – – appears on
On completion of the test sequence the appliance is the display.
ready for operation. The button is lighted.
B Turn the temperature control until function 2.0
2.2 Temperature display appears on the display.
After a short delay, the display shows 1 for minimum
The display shows the current flow temperature in cen- output.
tral heating and hot water modes. The display range
B Turn the temperature control completely anti-
extends from 00 ˚C to 99 ˚C.
clockwise until the display shows 0 .
If a service function requires the display of a tempera-
B Press the button until the symbol [ ] appears on
ture greater than 99 ˚C, the display alternates between
the display.
initially showing the first digit and then the remaining
The display shows the heating outlet temperature.
two digits.
E.g.: display showing 1. followed by 69. indicates The display shows for example 55 – – 55
169˚C. (continuous working at the maximum power)
For outside temperatures, the display shows a minus The display shows alternatively the temperature and – –.
sign followed by the negative temperature in alternation. The function is memorised in the Service mode.
• The appliance works continuously at the maximum
2.3 Indication of faults power.
Faults are indicated by a letter code. This helps to iden- B Press the button until the symbol – – appears on
tify and eliminate the cause of the fault quickly and reli- the display.
ably. The button is lighted.
The fault codes displayed are grouped into four catego- B Turn the temperature control until function 2.0
ries: appears on the display.
• Category 1: After about 5 seconds the display will show 2 for the
The appliance is disabled until it has been switched maximum power.
off and then on again. B Turn the temperature control completely anti-
clockwise until the display shows 0 .
• Category 2:
The appliance is disabled until the cause of the fault B Press the button until the symbol [ ] appears on
has been eliminated. the display.
• Category 3:
The appliance continues to operate with limited func- Display shows 45 -II- 45 (trap filling programme)
tion.
The trap filling programme ensures that the condensa-
• Category 4: tion trap is filled after the appliance is first installed or if
The appliance is disabled and locked ( flashes) it has been switched off for a long period.
until the cause of the fault has been eliminated and
The trap filling programme is activated if:
the appliance unlocked.
• the appliance is switched on at the master switch
Unlocking the appliance: • the burner has not been in operation for at least 48
i B Press and hold the
display shows – – .
button until the hours
• the appliance is switched from summer to winter
mode.
6 7 181 465 346 GB (03.02)

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
be disabled in order to carry out servic-
ing work.
B Always re-enable the trap filling pro-
gramme after completing servicing
work.
To switch off the trap filling programme to carry out

servicing work:
ously until the display shows = =.
The and buttons will light up.
shows 8.5.
After a short delay, the display then shows the trap
filling programme setting ( 1. = Enabled).
shows 0. (= Disabled).
The display and the and buttons will flash.
ously until the display shows [ ].
The trap filling programme is now disabled.
B Regulate the temperature control and the tem-
perature control on the previously set positions.
Display shows 00 (venting function)
The first time the appliance is switched on, it automati-
cally activates a one-off venting sequence in which the
heating pump switches on and off at intervals for about
8 minutes.
This function can be activated on Service Level 2, Serv-
ice Code 7.3, if it is required at any other time.
7 181 465 346 GB (03.02) 7

2.5 Boiler service functions B Press the button until the symbol [ ] appears on
the display.
2.5.1 First Service Level The display shows the heating outlet temperature.
Operating B Regulate the temperature control and the tem-
perature control on the previously set positions.
In order to change or check the values of the service
functions: In order to reset the main menu function values to their
B Press the button until the symbol – – appears on default values:
the display. B Power OFF the appliance.
The button is lighted. B Press the button and keep it pressed.
B Turn the temperature control until the desired B Switch on the appliance, press and hold the but-
function number appears on the display. ton until the
Once changed or checked the function value: display shows r1 followed by [ ].
Values that can be modified:
Description Display Reset Value
.0 Show the last error code. 0 - FF Clear only
2.0 Identification of the function mode (0 = normal, 1= min, 2 = max) 0-2 0
2.2 Identification of the pump function mode 1-3 2
2.3 Max. output in heat store heating mode 28 - 99 99
2.4 Anti-cycle time1) 0 - 15 min 3 min
2.5 Max. CH flow temperature 35 - 88˚C 88˚C
2.6 Minimum hysteresis in heating mode (∆T) 0 - 30 K 0K
2.7 Activation of automatic anti-cycle time (0 = Disabled; 1 = Enabled) 0, 1 1
3.4 Pump mode 0-3 2)
Table 1 First Service Level; Values that can be modified

1) If appliance is used in conjunction with type TA... programmer, only effective if Service Code 2.7 is set to “0” (= "Disabled”)!
2) The reset value is dependent on the code plug.
8 7 181 465 346 GB (03.02)

Values that can only be read:
.1 Heating outlet temperature. 0 - 99˚C -
.2 Sanitary outlet temperature. 0 - 99˚C -
.3 Heat store NTC sensor (ZSB.) 0 - 99˚C
.4 Constant hot water NTC sensor (ZWB.) 0 - 99˚C -
1.2 Order no. for code plug: 8 714 411 XXX 0 - 255 -
1.4 Temperature voltage signal (Terminal 2) from room thermostat 5 - 22 VDC -

(eg. TRQ 21, TR 100)
1.5 Specified CH flow temperature from programmer 0 - 99˚C -
1.6 Outside temperature from TA 211 E or room temperature from -20 +30˚C -
TR 212 E
1.7 Status TR 2 (0 = Not present 1 = Frost protection 3 = Auto 4 = Day, 0-4 -

Night 5=Error)
1.8 Terminal 2 on programmer interface module 0 - 24 VDC -
1.9 Identification code for the external module: 0 - 8, 53, -

0, 2, 4, 5 = no module connected, 56
3 = ADM, 6 = TA 211E, 53 = ADM, 56 = TR 212 E).
2.9 Instantaneous power. 0 - 99 % -
3.0 Fan speed 0 - 105 -
3.3 Quality of the ionisation signal: 0-3 -

0 = no ionisation,
1 = weak ionisation,
2 = medium ionisation,
3 = high ionisation.
3.6 Software version 3x2 -

positions
Table 2 First Service Level; Values that can only be read
7 181 465 346 GB (03.02) 9

Values that can only be read - only left display digit:
Description Display XY Reset Value
3.9 External switch (points 8 - 9). 0 = closed -

1 = Heating demand
4.1 External demand for heat via LSM 0 = closed -

1 = Heating demand
4.2 Programmable clock: 0 = closed -

1st channel (Heating). 1 = Heating demand
4.3 Automatic pump shut OFF with RAM module 0 = closed -

(point 5) 1 = Heating demand
4.4 Heating demand. 0 = closed -

1 = Heating demand
4.5 Sanitary demand. 0 = closed -

1 = Heating demand
Table 3 First Service Level; Values that can only be read - only left display digit
Values that can only be read - only right display digit:
Description Display XY Reset Value
3.9 External 2-point demand for heat via 230 V AC 0 = closed -

(Terminals Ls - Lr) 1 = Heating demand
4.0 Heat store demand for heat via 0 = closed -

heat store thermostat (Terminals 7-9) 1 = Heating demand
4.1 LSM Enable 0 = closed -

1 = Heating demand
4.2 Programmable clock: 0 = closed -

2nd channel (DHW – Maintaining). 1 = Heating demand
4.3 Heating demand from TA 211 E 0 = closed -

1 = Heating demand
4.4 Heat store demand for heat via heat store NTC 0 = closed -
sensor 1 = Heating demand
4.5 Sanitary heat exchanger temperature maintaining. 0 = closed -

1 = Heating demand
4.6 Anti-cycle time 0 = closed -

1 = Heating demand
Table 4 First Service Level; Values that can only be read - only right display digit
10 7 181 465 346 GB (03.02)

2.5.2 Secondary Service Level B Press buttons and 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: perature control on the previously set positions.
B Press buttons and simultaneously until the
To reset all settings on Service Levels 1 and 2 to the
symbol = = appears on the display.
factory setting:
The buttons and are lighted.
B Turn the temperature control until the desired B Power OFF the appliance.
function number appears on the display. B Press buttons and simultaneously and keep
them pressed.
Once changed or checked the function value:
B Switch on appliance, press and hold the and
buttons until the display shows r2 followed by [ ].
Values that can be modified:
5.0 Reduced max. heating output 0 - 99 % and sealed 99
5.1 Continuous ignition (for testing ignition without 0 = off 0

gas) 1 = on
5.5 Increased min. heating and heat store charging 0 - 99 % 0

output
5.9 Starting speed option (if flame propagation is 0 = First start at low speed; 0
poor, set high starting speed) 1 = First start at high speed)
6.7 Pump deactivation in HW mode, ZW only. 0 = off, 1 = on 1
6.8 Cycle time for heat exchanger constant hot water 0 - 60 min 0
function on ZW model.
6.9 Constant hot water 0 - 30 min 3
7.3 Venting function 0 = off, 1

1 = On for 8 cycles then
permanently off (i.e. set to 0)
2 = on
7.7 Temperature-dependent output reduction 0 = off; 3

1 = Heating on
2 = Hot water on
3 = Heating and hot water on
8.5 Trap filling programme 0 = off 1

1 = on
Table 5 Secondary Service Level; Values that can be modified
7 181 465 346 GB (03.02) 11

Values that can only be read:
5.2 Automatic gas igniter status and/or fault 00 - FF -
9.3 Automatic gas igniter Asic fault code 00 - FF -
Table 6 Secondary Service Level; Values that can only be read
12 7 181 465 346 GB (03.02)

Failure identification procedure
3 Failure identification procedure
3.1 Notes on using the fault code In this example: check the flue is clear by testing
tables the CO2 level.
• If the appliance is locked ( button is flashing),
The procedure is best described with the aid of
press the button. Important: after unlocking the
an example:
appliance, always restart it (i.e. switch off and then
• Work through the table from top to bottom and from on again). Only then is it possible to say whether or
left to right. not the fault has been eliminated.
• First make a note of the present settings and restore • If the fault has been rectified, the appliance will then
them before leaving the appliance. start up without indicating a fault and the fault isola-
• Read question 1. (Check column)and depending on tion procedure is complete.
the answer (yes or no) read the action required from • If the fault is still present after performing the action
the relevant box and carry out the instruction given; specified and, if necessary, restarting the appliance,
ignore the other answer. For example: if the burner move on to the next step in the fault isolation proce-
flame is visible, follow the instructions for yes, i.e. dure.
↓5.!
• If another fault code is displayed, work through the
• ↓5. means go to number 5., ignoring the steps in fault code table for that code.
between.
EA and flashing.
Flame not detected
Check Action
B Note the setting of the temperature controls

and .
1. Is a burner flame visible? yes: ↓ 5.
no: ↓ 2.
2. Is the gas cock turned on? yes: ↓ 5.
no: B Open the gas cock.
B Press , restart the appliance.
EA? ↓3.
3. Has the thermal cut-out on the gas yes: ...
cock tripped?
no: ↓ ...
4. ... ...
5. ... Problem with flue? yes: Check flue.
B Check CO2 level in combustion no: ↓ ...
air.
Is CO2 level above 0,2 % ?
Return to normal operation:
B Press the button until the symbol [ ] appears
on the display.
B Regulate the temperature control and the
temperature control on the previously set
positions.
Table 7
7 181 465 346 GB (03.02) 13

3.2 Summary
3.2.1 Appliance faults 3.2.2 Faults that are not displayed
ZWB ...A
ZB ...A Conventional
ZB ...A
Page
Appliance faults
Excessive burner noise, rumbling X X 42

Category
ZWB ...A
noises
ZB ...A
Page
Appliance faults Flue gas levels incorrect, CO level X X 43
too high
A5 3 X 15
Ignition too harsh, ignition poor. X X 44
A7 3 X 17
Boiler indicates P1, P2, P3 at X X 46
A8 3 X X X 19 start-up and then restarts
with P1,...
AC 3 X X X 20
Loose or broken contact on heat X X 46
Ad 3 X 22 store NTC sensor
b1 2 X X X 24 Specified CH flow temperature X X 47
from TA... programmer exceeded
C1 2 X X X 25
Table 9
CC 3 X X X 26
and DT 2
TR 2 and
TR 212 E
TA 211E
d3 2 X X X 27
Page
E2 2 X X X 28
Programmer faults
E9 4 X X X 30
Set room temperature not X 48
EA 4 X X X 32 reached.
F0 4/ X X X 37 Set room temperature X
2 exceeded.
F7 4 X X X 38 Set room temperature not X 49
reached.
FA 4 X X X 39
Set room temperature X 50
Fd 4 X X X 41 exceeded by large amount.
Table 8
Excessive fluctuations in X X 50
room temperature
Temperature rises instead of X X 51

falling
Room temperature too high X X 50

in Economy mode
Incorrect or no modulation X X 51
Heat store fails to heat up X

Table 10
14 7 181 465 346 GB (03.02)

3.3 Error codes on the display
A5 flashing.
Heat store NTC sensor 2 defective
Check Action

and .
1. B Press button . yes: B Flue gas connector corroded 1), damaged or
B Select service function .3 . dirty?. Change relative parts.
Is a temperature between 0. and ↓2.
5. displayed?
no: ↓3.
2. Heat store NTC: yes: B Power OFF the appliance.
B Unplug connector. B Change NTC sensor.
B Short circuit the connector. B Plug the connection wire.
Display changes to temperature B Turn ON the appliance.
between 99. and 95.
A5? ↓3.
no: B Change the 20-pin connector lead assembly.
↓3.
3. Temperature between 95. and 99. is yes: B Power OFF the appliance.
displayed. B Change NTC sensor.
B Unplug connector. B Plug the connection wire.
After max. 60 sec.:
B Turn ON the appliance.
Does the displayed code change
to a value between 0. and 5.? A5? ↓4.
no: ↓4.
4. B Unplug 20-pin connector from yes: B Power OFF the appliance.
PCB. B Disconnect the boiler electrical connection.
After max. 60 sec.:
B Change the 20-pin connector lead assembly.
to a value between 0. and 5.? B Reconnect the boiler electrical connection.
↓5.
no: B Make a note of the altered service settings (see
table 1, "First Service Level; Values that can be
modified" at page 8 and table 5, "Secondary
Service Level; Values that can be modified" at
page 11).
B Power OFF the appliance.
B Disconnect the boiler electrical connection.
B Change PCB control board.
B Reconnect the boiler electrical connection.
B Restore service settings previously noted down.
7 181 465 346 GB (03.02) 15

A5 flashing.
Heat store NTC sensor 2 defective
Check Action
5. To return to normal function mode:

B Press buttons and simultaneously.
positions.
1) For notes, refer to Appendix
16 7 181 465 346 GB (03.02)

A7 flashing.
Hot water NTC sensor defective
Check Action

and .
1. B Press button . yes: B Flue gas connector corroded 1), damaged or
B Select service function .2 . dirty? Change relative parts.
Is a temperature between 0. and ↓2.
5. displayed?
no: ↓3.
2. Hot water NTC sensor: yes: B Power OFF the appliance.
B Unplug connector. B Drain the hot water circuit.
B Short circuit the connector. B Disconnect the boiler electrical connection.
Display changes to B Change NTC sensor.
temperature 99.
B Plug the connection wire.
A7? ↓3.
no: B Change the 20-pin connector lead assembly.
↓3.
displayed. B Disconnect the boiler electrical connection.
B Unplug connector. B Change NTC sensor.
After max. 60 sec.:
B Refill the hot water circuit.
to a value between 0. and 5.? B Check the built-in NTC sensor for leaks.
A7? ↓4.
no: ↓4.
7 181 465 346 GB (03.02) 17

A7 flashing.
Hot water NTC sensor defective
Check Action
4. B Unplug 20-pin connector from yes: B Power OFF the appliance.

PCB. B Disconnect the boiler electrical connection.
After max. 60 sec.:
to a value between 0. and 5.? B Reconnect the boiler electrical connection.
↓5.
no: B Make a note of the altered service settings (see
page 11).
↓5.
5. To return to normal function mode:
positions.
1) For notes, refer to Appendix
18 7 181 465 346 GB (03.02)

A8 flashing.
No correct electrical connection
Check Action
1. TR 2 connected? yes: A8? ↓2.
no: B Power OFF the appliance.

B Connect TR 2.
A8? ↓2.
2. Mode selector switch is between two B Turn switch until it clicks into position.
settings
A8? ↓3.
3. B Power OFF the appliance. yes: B Turn ON the appliance.

Wiring between TR 2 and TR 212 E ↓4.
OK?
• Terminal 3 on TR 2 connected to no: B Rewire correctly as specified in the installation
Terminal 3 on TR 212 E? instructions.
• Terminal 4... Terminal 4....
After 90 sec.:
A8? ↓4.
4. TR 2 defective B Power OFF the appliance.

B Change TR 2.
7 181 465 346 GB (03.02) 19

AC flashing.
Module not detected.

(Constant CH flow temperature according to CH temperature control on boiler.)
Check Action

and .
1. B Press button . yes: No modul detected.

B Select service function 1.9 . B Disconnect connecting lead between PCB con-
Code 0., 2., 4., 5. is displayed. trol board and TA 211 E or TA 212 E.
B Re-connect connecting lead.
AC? ↓3.
no: ↓2.
2. Are 24 V DC cables routed along- yes: B Ensure cable separation conforms to minimum
side 230 V AC cables? requirements as per installation instructions and/
or use shielded cable.
no: ↓3.
3. Connecting lead between PCB con- B Power OFF the appliance.

trol board and TA 211 E or TA 212 E B Replace connecting lead between PCB control
defective. board and programmer interface module or TA
211 E.
AC? ↓4.
4. TA 211 E connected? yes: ↓5.
no: ↓8.
5. B Select service function 1.6 . yes: ↓7.

Outside temperature between -20
and +30 ˚C is displayed. no: B Power OFF the appliance.
Does temperature displayed B Replace outside temperature sensor.
match true outside temperature? B Turn ON the appliance.
AC? ↓7.
6. If remote control installed: yes: B Power OFF the appliance.

B Select service function 1.7 . B Plug the connection wire.
Remote control status 0. is dis- B Turn ON the appliance.
played .
AC? ↓7.
no: ↓7.
20 7 181 465 346 GB (03.02)

AC flashing.
Module not detected.

(Constant CH flow temperature according to CH temperature control on boiler.)
Check Action
7. Remote control status still 0.? yes: B Power OFF the appliance.
Remote control:
B Replace top section.
AC? ↓8.
no: ↓8.
8. The PCB control board is damaged. B Make a note of the altered service settings (see
page 11).
To return to normal function mode:

positions.
7 181 465 346 GB (03.02) 21

Ad flashing.
Heat store NTC sensor 1 not detected (ZB...).
Check Action

and .
1. Is connecting lead for heat store yes: ↓2.

NTC sensor 1 correctly routed, i.e.
not through cable grommet? no: B Route connecting lead for heat store tempera-
ture sensor as specified in installation instruc-
tions.
2. B Press button . yes: Is NTC sensor connector corroded, damaged or

dirty?
B Select service function .3 .
Is a temperature between 0. and B Power OFF the appliance.
5. displayed? B Change NTC sensor.
B Press button .
Ad? ↓3.
no: ↓4.
3. Heat store -NTC 1: yes: B Power OFF the appliance.

B Unplug connector from PCB con- B Change NTC sensor.
trol board. B Turn ON the appliance.
B Short circuit the connector using
B Press button .
wire jumper.
After max. 60 sec: ↓4.
Display changes to temperature
between 99. and 95. no: B Make a note of the altered service settings (see
page 11).
↓4.
22 7 181 465 346 GB (03.02)

Ad flashing.
Heat store NTC sensor 1 not detected (ZB...).
Check Action
displayed. B Change NTC sensor.
B Unplug connector. B Turn ON the appliance.
After max. 60 sec.:
Does the displayed code change no: B Make a note of the altered service settings (see
to a value between 0. and 5.? table 1, "First Service Level; Values that can be
page 11).

positions.
7 181 465 346 GB (03.02) 23

b1 flashing.
The Heatronic does not recognise the code key.
Check Action
1. B Power OFF the appliance.
2. Code plug loose, incorrect or defec- B Replace code plug, check code number is cor-
tive. rect.
b1? ↓3.
page 11).
24 7 181 465 346 GB (03.02)

C1 flashing.
Fan speed too low
Check Action
1. Fan lead connector properly con- yes: ↓2.

nected?
B Plug in connector.
C1? ↓2.
2. Is fan lead defective? yes: B Power OFF the appliance.

B Is impedance reading between the B Replace fan lead.
two connectors for one of the B Turn ON the appliance.
cores infinity?
C1? ↓3.
no: ↓3.
3. Are the differential pressure switch yes: ↓4.

contacts closed?
no: ↓4.
B Press button .
B Select service function 3.8 .
Is left digit of display showing 1?
4. Fan defective? yes: B Power OFF the appliance.

B Replace fan.
C1? ↓5.
no: ↓5.
page 11).
7 181 465 346 GB (03.02) 25

CC flashing.
Outside temperature NTC sensor not detected.

(Boiler heating as if outside temperature is -20˚C)
Check Action
1. Outside temperature sensor AF2 yes: ↓2.

connected to Terminals A and F on
TA 211 E? no: B Power OFF the appliance.
B Connect outside temperature sensor to Termi-
nals A and F on TA 211 E.
CC? ↓2.
2. B Power OFF the appliance. B Change the external sensor.

B Disconnect outside temperature B Turn ON the appliance.
sensor and test resistance
R = ∞ or R = 0?
26 7 181 465 346 GB (03.02)

d3 flashing.
Wrong signal from pin 8-9 (open?).
Check Action
1. B Turn ON the appliance. yes: ↓2.

B Measure voltage between Termi- no: ↓3.
nal 4 and Terminal 8.
Voltage ≅ 24 V DC?
2. Existing heat store thermostat con- yes: B Power OFF the appliance.
nected to Terminals 7, 8 and 9? B Fix the additional bridge 8-9 in the right position
and close the screws.
d3? ↓3.
no: ↓4.
3. Break in connecting lead? yes: B Power OFF the appliance.

d3? ↓4.
no: ↓4.
page 11).
7 181 465 346 GB (03.02) 27

E2 flashing.
The heating outlet NTC sensor is damaged.
Check Action

and .
1. B Press button . yes: The heating outlet NTC sensor is in short circuit:
B Select service function .1 . B Power OFF the appliance.
Is a temperature between 0. and B Replace CH flow NTC sensor; observe fitting
5. displayed? instructions for NTC sensor when doing so.
E2? ↓2.
no: ↓2.
2. Temperature for heating outlet NTC yes: The CH flow NTC sensor is interrupted :
sensor between 95. and 99. is dis- B Power OFF the appliance.
played.
B Replace CH flow NTC sensor; observe fitting
instructions for NTC sensor when doing so.
E2? ↓3.
no: ↓3.
3. Check if the 20-pin connector lead B Power OFF the appliance.

assembly is damaged. B Disconnect the boiler electrical connection.
E2? ↓4.
page 11).
28 7 181 465 346 GB (03.02)

E2 flashing.
The heating outlet NTC sensor is damaged.
Check Action

positions.
7 181 465 346 GB (03.02) 29

E9 and flashing.
Safety temperature limiter has tripped.
Check Action
1. Is the heating pressure between 1 yes: ↓2.

and 2 bar?
no: B Top up system.
B Vent appliance.
E9? ↓2.
2. Is the pump blocked? yes: B Unblock the pump.

If pump won’t start:
B Change the pump.
E9? ↓3.
no: ↓3.
3. Lead disconnected from safety tem- yes: B Power OFF the appliance.
perature limiters? B Connect lead.
E9? ↓4.
no: ↓4.
4. B Power OFF the appliance. yes: B Change the over heating cut-off device.
B Unplug the connector from the B Connect flue gas safety temperature limiter lead.
cut-off device. B Turn ON the appliance.
B Measure the NTC electrical resist-
ance.
E9? ↓5.
R = ∞?
no: B Connect flue gas safety temperature limiter lead.
↓5.
30 7 181 465 346 GB (03.02)

E9 and flashing.
Safety temperature limiter has tripped.
Check Action
5. Is lead disconnected from CH flow yes: B Power OFF the appliance.

safety temp. limiter? B Reconnect lead.
↓6.
no: ↓6.
6. B Power OFF the appliance. yes: B Change CH flow safety temperature limiter.
B Disconnect lead to CH flow safety B Connect CH flow safety temperature limiter lead.
temperature limiter. B Turn ON the appliance.
B Measure the CH flow safety tem-
perature limiter.
R = ∞? E9? ↓7.
no: B Connect CH flow safety temperature limiter lead.

↓7.
7. B Power OFF the appliance. yes: B Change the fuse.

B Remove fuse SI 3 from appliance B Turn ON the appliance.
PCB control board and test for
continuity.
R = ∞? E9? ↓8.
no: B Remount the fuse.

↓8.
page 11).
7 181 465 346 GB (03.02) 31

EA and flashing.
No flame ionisations signal
Check Action

and .
1. Is the flame present? yes: ↓6.
no: ↓2.
2. Is the gas cock open? yes: ↓3.
no: B Open the gas cock.

EA? ↓3.
3. Is there air in the supply pipe? yes: B Vent supply pipe.

EA? ↓4.
no: ↓4.
4. Did the thermal security of the gas yes: B Reset security.

cock lock out?
EA? ↓5.
no: ↓5.
32 7 181 465 346 GB (03.02)

EA and flashing.
Check Action
5. Natural gas models: yes: B Check that it is fitted correctly and functioning
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.
B Is correct code plug fitted?
EA? ↓6.
no: ↓6.
LPG models: yes: ↓6.

is the flow rate of the gas supply to
the appliance correct? no: B Is there enough gas in the supply cylinder?
B Is there air in the supply pipe?
B Is the solenoid valve in the "meter cabinet” open-
ing?
B Is the supply pressure OK? (if the supply pres-
sure is too high, check the pressure regulator in
the “meter cabinet” and on the LPG supply cylin-
der).
EA? ↓6.
6. Is the ground connection correct? yes: ↓7.
no: B Correct the electrical ground connection.

EA? ↓7.
7. Two phase net: yes: ↓8.

Is there a resistor fitted between Pe
and N? no: B Power OFF the appliance.
B Insert a 2 MΩ resistance between the ground
and the N connection.
EA? ↓11.
7 181 465 346 GB (03.02) 33

EA and flashing.
Check Action
8. Is diaphragm in the mixer unit cor- yes: B Close mixer unit.

rectly fitted and functional?
↓9.
B Open mixer unit (29).
B Check diaphragm for correct ori- no: B Insert diaphragm in the fan intake duct as per
entation, soiling and splitting. installation instructions so that the flaps open
Is diaphragm OK? upwards.
B Close mixer unit.
EA? ↓9.
9. Is the condensation trap blocked? yes: B Clean out condensation trap discharge pipe.
EA? ↓13.
no: ↓10.
10. Check the gas valve? yes: B Reconnect the gas valve.
B Power OFF the appliance. B Turn ON the appliance.
B Unplug the connectors from the B Press , restart the appliance.
gas valve.
B Measure the gas valve coils I and EA? ↓11.
II electrical resistance. no: B Change the gas valve.
R = 164 ± 40Ω ?
B Reconnect the gas valve.
EA? ↓11.
11. Problem with flue? yes: B Check flue and clean if necessary.
B Check CO2 level in combustion
air.
Is CO2 level above 0,2 % ? EA? ↓12.
B Open up heat exchanger - is it
no: ↓12.
dirty?
12. Is flue gas CO2 level incorrect1)? yes: B Adjust to correct level.
EA? ↓13.
no: ↓13.
34 7 181 465 346 GB (03.02)

EA and flashing.
Check Action
13. B Press buttons and simulta- yes: B Press buttons and simultaneously.
neously.
↓14.
B Select service-function 5.1.
Continuous ignition (without gas) no: B Press buttons and simultaneously.
OK?
↓17.
14. Ignition lead connected to ignition yes: ↓15.

electrodes?
no: B Connect cable to ignition electrode.
EA? ↓15.
15. Ignition cable connector engaged in yes: ↓16.

switchbox?
B Engage ignition cable connector in switchbox.
EA? ↓16.
16. Is the ignition electrical wire yes: B Power OFF the appliance.
damaged? B Change the ignition electrical wire.
EA? ↓17.
no: ↓17.
17. B Press button . yes: ↓19.

B Select service-function 3.3. no: ↓18.
Is the ionisation quality 2. or 3. ?
18. Electrode assembly defective? yes: B Replace electrode assembly.

B Remove electrode assembly. B Press , restart the appliance.
Electrodes worn out?
EA? ↓19.
no: B Refit electrode assembly.

EA? ↓19.
7 181 465 346 GB (03.02) 35

EA and flashing.
Check Action
EA?
↓20.
page 11).

positions.
1) See installation instructions
36 7 181 465 346 GB (03.02)

F0 (and possibly ) flashing.
Internal failure
Check Action

and .
1. B Press buttons and simulta- B Enter figure displayed in customer service record.
neously.
↓2.
B Select service function 9.3 .
A service code is displayed.
2. B Select service function 5.2 . B Enter figure displayed in customer service record.
A service code is displayed.
↓3.
3. flashing? yes: B Press button .
B Initiate demand for heat by pressing button

and then press again after 30 seconds to cancel.
B Initiate two more demands for heat as above.
F0? ↓4.
no: ↓4.
page 11).

positions.
7 181 465 346 GB (03.02) 37

F7 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.
F7? ↓2.
2. B Power OFF the appliance. yes: B Dry PCB control board (e.g. with hair dryer).
B Disconnect the boiler electrical B Look for point where damp is entering switchbox
connection. and seal as necessary (cable grommets properly
B Remove PCB control board. fitted, ...?).
PCB control board damp? B Refit PCB control board.
F7? ↓3.
no: ↓3.
3. Problem with flue? yes: B Check flue and repair or replace if necessary.
B Check CO2 level in combustion no: ↓4.
air.
page 11).
38 7 181 465 346 GB (03.02)

FA and flashing.
Check Action

and .
1. Condensation trap blocked? yes: B Clean condensation trap discharge pipe.

FA? ↓2.
no: ↓2.

Electrode assembly burnt out? FA?
↓3.

FA? ↓3.
B Check CO2 level in combustion B Press , restart the appliance.
air. FA?
Is CO2 level above 0,2 % ? B Power OFF the appliance.
↓4.
no: ↓4.
4. The gas valve is damaged. B Change the gas valve.

FA?
↓5.
7 181 465 346 GB (03.02) 39

FA and flashing.
Check Action

FA?
↓6.
page 11).
40 7 181 465 346 GB (03.02)

Fd and flashing.
Button pressed without necessity
Check Action
1. Button is flashing. B Press , restart the appliance.
Fd? ↓2.
page 11).
7 181 465 346 GB (03.02) 41

3.4 Faults that are not displayed

3.4.1 Appliance faults
Excessive burner noise, rumbling noises
Check Action

and .
1. Does the gas supply type match the yes: ↓2.

specifications on the appliance iden-
tification plate? no: B Convert appliance to correct gas type.
↓2.
2. B Test gas supply pressure - OK? yes: ↓3.

Does pressure match figure speci-
fied in installation instructions? no: B Decommission appliance.
For natural gas:
B Notify gas company.
air.
4. Cascade system: yes: ↓5.

Is the appliance min. output high
enough to open the shut-off device? no: B Press buttons and simultaneously.
B Select Service Function 5.5 .
B Increase min. output.
5. Is appliance’s internal air/flue chan- yes: B Repair or replace components.

nel leaking or blocked? B Grease seal before fitting.
B Open up heat exchanger and B Make sure it is fitted in correct position.
inspect.
B Remove silencer, flue duct and air no: ↓6.
flow limit.
B Open trap and inspect.
Air channels dirty/clogged, seals
defective or not correctly fitted?
6. B Measure CO2 levels. yes: B Adjust CO2 level as per installation instructions.
CO2 levels in flue gas at min and no: B Turn off gas cock.
max output do not match figures B Power OFF the appliance.
specified in installation instruc- B Change the gas valve.
tions.
B Open the gas cock.
B Check appliance for leaks.
42 7 181 465 346 GB (03.02)

Excessive burner noise, rumbling noises
Check Action
7. B Press buttons and simulta- B Set to 1 for high start-up speed.

neously.
0 is displayed.
Flue gas levels incorrect, CO level too high
Check Action

tification plate? no: B Convert appliance to correct gas type.
↓2.
no: B Decommission appliance.

air.
4. Flue gas CO2 levels measured at yes: B Adjust CO2 levels.

min. and max. load do not match
specified levels? no: ↓5.
B Measure CO2 levels.
5. Gas volumetric flow too high when yes: B Reduce gas volumetric flow rate by means of
CO2 level correctly set. adjusting screw on gas valve and/or gas flow
restrictor.
B Check CO2 adjustment.
no: ↓6.
6. B Turn off gas cock.

B Change the gas valve.
B Open the gas cock.
B Check appliance for leaks.
7 181 465 346 GB (03.02) 43

Ignition too harsh, ignition poor
Check Action

and .
1. B Press buttons and simulta- yes: ↓6.

neously.
no: ↓2.
Continuous ignition (without gas)
OK?
2. Ignition lead connected to ignition yes: ↓3.

electrodes?
no: B Connect cable to ignition electrodes.
B Press button .
Ignition poor? ↓3.
3. Ignition cable connector engaged in yes: ↓4.

switchbox?
B Engage ignition cable connector in switchbox.
B Press button .
Ignition poor?
↓4.
4. Is the ignition electrical wire dam- yes: B Power OFF the appliance.
aged? B Change the ignition electrical wire.
B Press button .
Ignition poor?
↓5.
no: ↓5.

Electrodes worn out?

44 7 181 465 346 GB (03.02)

Ignition too harsh, ignition poor
Check Action

tification plate? no: B Carry out gas type conversion as described in
installation instructions.
no: B Decommission appliance.

B Check CO2 level in combustion ↓9.
air.
Is CO2 level above 0,2 % ? no: ↓9.
9. Flue gas CO2 levels measured at yes: B Adjust CO2 level as per installation instructions.
min. and max. load do not match
specified levels. no: ↓10.
B Measure CO2 levels.
10. Burner not correctly fitted or defec- B Replace burner and seal if necessary.
tive? B Ensure seal is fitted in correct position.
B Remove burner.
Cover fixings not tight or seal
defective or not correctly fitted or
burner defective!

positions.
7 181 465 346 GB (03.02) 45

Loose or broken contact on heat store NTC sensor
Check Action
1. Heat store NTC sensor lead is not B Record condition of appliance as found in cus-
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.
switchbox).
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.
Start sequence not completed? ↓2.
no: ↓2.
page 11).
46 7 181 465 346 GB (03.02)

Specified CH flow temperature from TA... programmer exceeded
Check Action

and .
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 anti-cycle time (3 min.) and the heating mode hysteresis setting, if applica-
ble, are deactivated.
• In cyclic mode, the switching of the boiler on or off is subject to a time delay in order to prevent diver-
gence between the average CH flow temperature and the specified CH flow temperature.
As a result (depending on the heat draw), the specified CH flow temperature is briefly exceeded.
In extreme cases, it can happen that the burner does not switch off until the maximum CH flow temper-
ature is reached even though a lower CH flow temperature has been specified.
1. B Press button . B Disable automatic anti-cycle time, i.e. change

setting to 0.
Read off status of automatic anti-
cycle time (0 = Disabled, 1 = Ena-
bled).
2. B Select service-function 2.4. B Set anti-cycle time as required, e.g. factory set-
Read off anti-cycle time setting ting 3 min.
(0 ... 15 min).

positions.
Hot water has unpleasant odour or is dark colour
Check Action
This is generally caused by the formation of hydrogen sulphide by sulphate-reducing bacteria. Such bacteria are
found in water which is very low in oxygen and live off the hydrogen produced by the anode.
1. B Clean the hot water cylinder.

B Replace the sacrificial anode.
B Heat cylinder to a temperature ≥60˚C
2. B Replace magnesium sacrificial anode with

impressed-current anode.
The conversion costs are payable by the operator!
7 181 465 346 GB (03.02) 47

Condensation in the flue pipe
Check Action
1. Is diaphragm in mixer unit fitted cor- B Fit diaphragm as per installation instructions or
rectly (see installation instructions)? replace.
B Open mixer unit (29). B Close mixer unit.
B Check diaphragm for correct ori-
entation, soiling and splitting.
3.4.2 Programmer faults

Set room temperature not reached (TR 2 and TR 212 E)
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 yes: B Turn up CH flow temperature control.

boiler set too low?
no: ↓3.
3. 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.
Select 1 (on, automatically deactivated) and con-
firm.
B Vent appliance.
B Vent radiators.
48 7 181 465 346 GB (03.02)

Set room temperature not reached (TA 211 E und DT 2)
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 yes: B Turn up CH flow temperature control.

boiler set too low?
↓4.
no: ↓4.
4. Is heat store temperature unreacha- yes: B Turn up CH flow temperature control.

ble (CH flow temperature control set
too low)? ↓5.
no: ↓5.
5. 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.
Select 1 (on, automatically deactivated) and con-
firm.
B Vent appliance
B Vent radiators.
7 181 465 346 GB (03.02) 49

Set room temperature exceeded by large amount
Check Action
1. Do radiators get too hot? yes: TR 2:

B Decrease setting of “Heating” control
TA 211 E:
B Correct heating characteristic.
↓2.
no: ↓2.
2. Bad choice of location for program- yes: B Select better installation location.
mer, e.g. outside wall, near window, -or-
in draught, on hollow wall, etc.
B Fit external room thermostat.
↓3.
no: ↓3.
3. B Turn down thermostatic valve(s).
Excessive fluctuations in room temperature (TA 211 E)
Check Action
1. Periodic effect of external heat on yes: B Eliminate external heat sources if possible.
room, e.g. from sunshine, lighting, TV,
separate stove, fire, etc. ↓2.
no: ↓2.
2. Bad choice of location for program- B Select better installation location.

mer, e.g. outside wall, near window, -or-
in draught, on hollow wall, etc.
B Fit external room thermostat.
Room temperature too high in Economy mode
Check Action
Building retains heat well yes: B Set economy temperature lower .

or
B Set to Frost Protection instead of Economy.
or
B Set start time for Frost protection/Economy
earlier.
50 7 181 465 346 GB (03.02)

Temperature rises instead of falling
Check Action
Timer clock (DT 2) incorrectly set B Check setting and correct as necessary.
Incorrect or no modulation
Check Action
Programmer incorrectly wired B Check wiring against wiring diagram and correct
as necessary.
7 181 465 346 GB (03.02) 51

Appendix
4 Appendix
4.1 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
Measurement tolerance ±10% Ω)
Resistance (Ω
tolerance ±10% Ω)
Resistance (Ω
20 14 772
-20 2 392
25 11 981
-16 2 088
30 9 786
-12 1 811
35 8 047
-8 1 562
40 6 653
-4 1 342
45 5 523
0 1 149
50 4 608
4 984
55 3 856
8 842
60 3 243
10 781
65 2 744
15 642
70 2 332
20 528
75 1 990
25 436
80 1 704
Table 11
85 1 464
90 1 262
95 1 093
100 950
Table 12
52 7 181 465 346 GB (03.02)

Appendix
4.2 Electronic schemes
o - orange g - green bl - black r - red p - purple
33
364 365 61 317 366 367 363
ECO
4.1
25 V
230 V
153 136 310
135
230V/AC
312 318
315
313 124 789
328 151 84
p
302
L N Ns Ls LR
300 314
p
p M
161
96
328.1
g
9 6 g
M M o
r
r o
mains supply 18 226
52 52.1
56
o o
bl
36 6.1
bl
bl
bl bl
32
6 720 610 576-08.2O
4.1 Ignition transformer 328.1 Bridge

6 Heat exchanger overheat cut-out 363 Flame presence led
6.1 Flue gas NTC sensor 364 Electrical power led (0/I)
6.3 Hot water sensor 365 Chimney cleaner button
18 Central heating pump 366 Technique service button
32 Flame sensing electrode 367 ECO button
33 Spark electrodes
52 Safety gas valve 1
52.1 Safety gas valve 2
56 CE 428 gas valve
61 Reset button
84 Motor (ZWB/ZB)
96 Microswitch, water switch (ZWB)
135 Main power switch
136 Heating outlet temperature potentiometer
151 Fuse T 2,5 A, 230 V AC
153 Transformer
161 Bridge
226 Fan
300 Code key
302 Ground electrical connection
310 Sanitary outlet temperature potentiometer
312 Fuse T 1,6 A, 24 V DC
313 Fuse T 0,5 A, 5 V DC
314 Strip connector for TA 211 E fitted programmer
315 Terminal block for programmer
317 Digital display
318 Internal programmable clock connection
328 230 V AC connection
7 181 465 346 GB (03.02) 53

Appendix
4.3 List of most important replacement parts
Component Order no. Remarks Component Order no. Remarks
Switchbox Temperature 8 714 500 087 NTC

sensor, CH flow
PCB control 8 748 300 385
board Electrode 8 718 107 077
assembly
Transformer 8 747 201 358
Gas valve
Ignition lead 8 714 401 999
Gas valve 8 747 003 516 CE 427
20-pin connec- 8 714 402 087 ZB...
tor lead assem- Other components
bly
Fan 8 717 204 343
20-pin connec- 8 714 402 086 ZWB...
Gas supply pipe 8 710 725 500
tor lead assem-
bly Plate-type heat 8 715 406 651 ZWB...
exchanger
Fuse 1 904 552 730 T 0,5 A
Overflow trap 8 710 725 328
Fuse 1 904 552 740 T 1,6 A
Diaphragm in the 8 715 505 801
Fuse 1 904 521 342 T 2,5 A
mixer unit
Set of fuses 8 744 503 010 Table 13
Switchbox kpl. 8 717 207 514 with DT 2
Switchbox kpl. 8 717 207 513 without DT 2
Code plug included in
Conversion kit 7 710 149 048 ZWB

G20 -> G31 7/11-29 A

G31 -> G20 7/11-29 A
Conversion kit 7 710 149 049 ZB

G20 -> G31 7/11-28 A

G31 -> G20 7/11-28 A

G20 -> G31 7/11-27 A

G31 -> G20 7/11-27 A

G20 -> G31 7/11-27 A

G31 -> G20 7/11-27 A
Heat exchanger
Temperature 8 729 000 144 110˚C

limiter
Table 13
54 7 181 465 346 GB (03.02)

Appendix
4.4 Approved corrosion inhibitors and 4.5 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. Particularly susceptible is the combustion chamber
trate or Sentinal X100, in accordance with the and the heat exchanger surfaces (including stainless
manufacturers instructions. The use of any other steel) as well as the metal components in the flue
substances will invalidate the guarantee. The pH socket, flue pipe connections and in the chimney.
value of the system water must be less than 8 or The halogen compounds present in the combustion air
the appliance guarantee will be invalidated. produce highly corrosive hydrochloric acid in the flame
and in some cases - depending on the precise compo-
4.4.1 Frost protection
sition of the combustion air - hydrofluoric acid, both of
B Add a suitable anti-freeze fluid to the water in the which accumulate in the boiler and remain active over
central heating system. long periods.
Suitable products are available from Betz-Dearborn In order to limit the damage, the source of the air con-
Tel.: 0151 4209563, Fernox Tel.: 01799 550811 tamination must be located and sealed off. If this is not
and Salamander Tel.: 0121 378 0952. possible, the combustion air must be drawn from an
4.4.2 Sealing agents alternative clean source.
Halogens can occur in the following locations:
B In our experience, the addition of sealing agents to
the water in the central heating system can cause Commercial and industrial sources
problems (deposits in the heat exchanger). For that
reason we advise against their use. Dry cleaners Trichloroethylene, tetrachlo-
roethylene, fluorinated hydro-
carbons
Degreasing baths Perchloroethylene, trichlo-

roethylene, methyl chloroform
Printers Trichloroethylene
Hairdressers Aerosol spray propellants,

hydrocarbons containing fluo-
rine and chlorine (freons)
Sources in the home
Cleaning and Perchloroethylene, methyl

degreasing chloroform, trichloroethylene,
agents methylene chloride, carbon
tetrachloride, hydrochloric
acid
Home workshops
Solvents and thin- Various chlorinated hydrocar-

ners bons
Spray cans Chlorofluorohydrocarbons

(freons)
Table 14
7 181 465 346 GB (03.02) 55

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
6 720 610 600 GB (04.06) OSW
Contents
Contents
Excellence comes as standard 4
Safety precautions 5
1 General notes 6
2 Controls 10
3 Operating the Appliance 11

3.1 Preparation 11
3.2 Switching the Appliance On/Off 13
3.3 Switching on the Central Heating 14
3.4 Controlling Central Heating 14
3.5 RD 532 Boilers: Setting the Hot Water Temperature 15
3.6 Summer Mode, Hot Water Only (RD 532 Appliances) 16
3.7 Frost protection (RD 532 Appliances) 16
3.8 Fault Condition 17
4 Tips on saving energy 18
5 General Information 19
6 Maintaining your appliance 20
7 Service 20
8 Fault or breakdown 21
2 6 720 610 600 GB (04.06)

Contents
9 Your guarantee 22
10 Guarantee registration 23
11 Operating Instructions Quick Reference 24
6 720 610 600 GB (04.06) 3

Excellence comes as standard
Excellence comes as standard

Thank you for purchasing an RD 532/RD 428 condensing appli-
ance.
The RD 532/RD 428 Series has been developed by the Bosch
Group and the strictest quality control standards are demanded
throughout every stage of production.
Indeed, the Bosch Group have led the field in innovative appliance
design and performance for many years.
The result is that your new RD 532/RD 428 appliance offers you
the very best of everything – quality, efficiency, economical run-
ning costs, proven reliability and value for money.
What’s more, you also have the assurance of our no nonsense
2 year parts and labour guarantee.
And it’s backed up by British Gas - Offering a complete mainte-
nance scheme to keep your boiler operating at peak condition and
efficiency.
No wonder that more and more people are agreeing that when it
is gas, it has to be a 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.
The “log-book” is a vital document that must be completed by the
installer at the time of installation. It confirms that the boiler has
been installed and commissioned according to the manufacturers
instructions.
Without the completion of the “log-book”, manufacturers may
refuse to respond to a call–out from a householder, who will be
advised that he or she must call back the installer, who has not ful-
filled his obligations to record the information required by the ini-
tiative.
4 6 720 610 600 GB (04.06)

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.
If you smell gas:
B Turn off gas service cock at the meter.
B Open all doors and windows.
B Do not operate any electrical switches.
B Do not smoke.
B Extinguish any naked flames.
B Call your gas company.
If you smell fumes from the appliance:
B Switch off appliance.
B Inform your heating engineer.
Fitting and modifications
B Fitting of the appliance or any modifications to the appliance
may only be carried out by a competent person.
B Flue systems must not be modified in any way.
Maintenance
B We recommend that you take out a maintenance contract
with a competent installer and have the appliance serviced at
regular intervals.
B Ensure that your Service Engineer uses only genuine spare
parts!
6 720 610 600 GB (04.06) 5

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.
B There are no substances used in the construction that are a
potential hazard in relation to the COSHH Regulations (Con-
trol of Substances Hazardous to Health Regulations 1988).
Combustion Air/Ambient Air
B Keep combustion air/ambient air free of corrosive substances
(e.g. halogenated hydrocarbons which contain chlorine or flu-
orine compounds). In this way corrosion can be prevented.
1 General notes
To get the best from your appliance please read these instruc-
tions carefully.
Sealed heating systems
The appliance is fitted to a sealed heating system which is pre-
pressurised. Your installer will tell you of the minimum and maxi-
mum pressure which must be indicated on the pressure gauge.
Check regularly that the pressure is maintained and contact your
installer or maintenance engineer if there is a permanent signifi-
cant drop in the pressure. If the system loses pressure it should
be repressurised and the cause of the fall investigated.
Central heating systems
During the first few hours of operation of the central heating sys-
tem, check that all radiators are being heated at an even rate. If
the top of a radiator is at a lower temperature than the bottom then
it should be vented by releasing air through the venting screw at
the top of the radiator. Ask your installer to show you how this is
6 6 720 610 600 GB (04.06)

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.
Only additives that are compatible with aluminium may be used in
the system. Any incompatible additive used will invalidate the
guarantee.
Condensate drain
This is a condensing appliance and the terminal will, at times, give
out a plume of water vapour. This is quite normal.
The appliance produces quantities of condense which is dis-
charged regularly through the siphon.
Clearances
Your installer will have provided adequate space around the appli-
ance for safety and servicing access. Do not restrict this space
with the addition of cupboards, shelves etc. next to the appliance.
Left-hand side 10 mm
Right-hand side 10 mm
In Front 600 mm
Above Casing (Vert. Flue) 75 mm
Above Flue Turret 30 mm
Below 200 mm
Table 1
Room thermostat
A room thermostat may be fitted to control the central heating.
Refer to the instructions supplied with the thermostat for informa-
tion on siting and setting. A programmable thermostat may also
be used with this appliance to provide additional timed control of
the central heating.
6 720 610 600 GB (04.06) 7

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. Thermostatically controlled or pres-
sure equalising shower valves will guard against the flow of water
at too high a temperature.
Hot and cold mains fed water can be supplied directly to an over-
rim flushing bidet subject to local water company requirements.
With all mains fed systems the flow of water from individual taps
will vary with the number of outlets operated simultaneously and
the cold water mains supply pressure to the property.
Flow balancing using “ball-o-fix” type valves is recommended to
avoid an excessive reduction in flow to individual outlets.
For further information contact British Gas Technical Services
Department.
Hot and cold flow – RD 532 Boilers
The flow of water demanded from both hot and cold service out-
lets is dependent upon the mains supply, it may not be possible
in some installations to operate all outlets simultaneously.
Water mains failure – RD 532 Boilers
If there is a failure of the mains water supply then no water will be
available at a tap or shower until the mains supply is restored. The
appliance will still operate in the central heating mode.
Use in hard water areas – RD 532 Boilers
In exceptionally hard water areas a device to prevent scale forma-
tion may be fitted. Installation of a scale inhibitor assembly should
be in accordance with the requirements of the local water com-
pany. An isolating valve should be fitted to allow for servicing.
8 6 720 610 600 GB (04.06)

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. If the appliance is fitted into a
cupboard or a compartment is built around the appliance after
installation then the compartment must be separated from the
boiler space by a perforated non-combustible partition as
described in BS6798.
Notwithstanding the requirements of BS6798, there is no need
for ventilation openings to be provided in the compartment
because of the low heat loss from the casing.
Do not allow the flue terminal fitted on the outside wall to become
obstructed or damaged.
Pump
The pump will have been set by the manufacturer and must not be
manually re-adjusted.
6 720 610 600 GB (04.06) 9

Controls
2 Controls
136 365 61 317 366 367 363 310 422
ECO
364
8.1
135 E
CH
295
170
171 172 173 170
6 720 610 600-01.1O
8.1 System Pressure gauge

61 Reset button
135 Master switch
136 Central heating temperature control
170 Service valves in CH flow and return
171 Hot water
172 Gas isolation valve (open)
173 Cold water inlet
295 Identification sticker
310 Hot water temperature control (RD 532)
317 Display
363 Indicator lamp for “burner on”
364 Indicator lamp for “off/on”
365 “Chimney sweep” button
366 Service button
367 “ECO” button
422 Optional timer
10 6 720 610 600 GB (04.06)

Operating the Appliance
3 Operating the Appliance

3.1 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).
Groove at right angles to direction of flow = off.
Cold water inlet valve (173)

B Turn handle so that it is in line with direction of flow.
When handle is at right angles to direction of flow, the valve is
closed.
170
172 173
6 720 610 577-02.1O
6 720 610 600 GB (04.06) 11

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.
B The maximum operating pressure of 2.5 bar at maximum
central heating flow temperature must not be exceeded. If the
pressure increases to 3 bar then the relief valve (15) opens.
2
3
1
0 4
bar
8.1
CH
15
6 720 610 600-03.1O
12 6 720 610 600 GB (04.06)

3.2 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-

i tral heating flow temperature, the trap filling pro-
gramme is active.
The trap filling programme ensures that the condensation trap is

filled after the appliance has been installed or after the appliance
has been out of use for a long period. For that reason, the appli-
ance remains at minimum heating output for 15 minutes.
Switching off
B Switch off the appliance at the master switch (0).
The green indicator lamp goes out. The optional timer will con-
tinue running until the emergency supply is exhausted.
6 720 610 600 GB (04.06) 13

3.3 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
3.4 Controlling Central Heating

B Set room thermostat to the desired room temperature.
B Set room temperature controller unit, if fitted. Refer to the
instructions with the control.
B Set the thermostatic radiator valves to the desired settings.
14 6 720 610 600 GB (04.06)

3.5 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

Anti-clockwise limit approx. 40˚C
approx. 55˚C
Clockwise limit approx. 60˚C
Table 2
“ECO” button
By pressing and holding the “ECO” button , until the display
lights, you can switch between Comfort mode and Economy
mode.
Comfort mode: button is not lit (factory setting)
The appliance is held constantly at the set temperature. This
means that hot water is available almost instantaneously at the
tap. Consequently the appliance will switch on at intervals, even if
no hot water is being drawn.
6 720 610 600 GB (04.06) 15

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.
Hot water is thus available in about 1 minute.
ECO mode, button is lit
Water is not heated up until hot water is drawn. This means that
there is a longer waiting period before hot water is available.
3.6 Summer Mode, Hot Water Only

(RD 532 Appliances)
With room thermostat
B Turn temperature control on the appliance anti-clockwise
as far as the stop.
The central heating is now turned off. The hot water function
and the mains power supply for the heating programmer and
timer remain switched on.
3.7 Frost protection (RD 532 Appliances)

B Leave master switch switched on.
If the appliance is to be left for long periods switch the central

heating off:
B Add a suitable anti-freeze fluid to the water in the central heat-
ing system.
Suitable products are available from Betz-Dearborn Tel.: 0151
4209563, Fernox Tel.: 01799 550811 and Salamander on
0121 378 0952.
16 6 720 610 600 GB (04.06)

3.8 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 “– –”.
The appliance will then start up again and the display will show
the central heating flow temperature.
If the button does not flash:
B Switch the appliance off and then on again at the master
switch.
The appliance will start up again and the central heating flow
temperature will be displayed.
If the fault remains and can not be cleared:
B Call British Gas for assistance, giving a description of the fault
and, if possible, the fault code from the facia display.
6 720 610 600 GB (04.06) 17

Tips on saving energy
4 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. The boiler con-tinues to
operate with a low flame if the demand for heat reduces. The tech-
nical term for this process is modulating control. Modulating con-
trol keeps temperature fluctuations small and provides even
distribution of heat throughout the home. This means that the
boiler may stay on for relatively long periods but will use less gas
than an appliance that continually switches on and off.
Central heating systems with room thermostats/thermo-
static radiator valves
The central heating control on the boiler should be set to the max-
imum rated temperature of the central heating system or to posi-
tion “E”, when the maximum central heating water temperature
obtained is 75˚C.
The temperature can be set individually in each room (except pri-
mary room with the room thermostat) using the thermostatic radi-
ator valves. If you wish to have a lower temperature in the primary
room than in the other rooms, leave the room thermostat at the set
temperature and turn down the radiator using the radiator valve.
Reduced-output operation
Considerable fuel savings can be made by slightly reducing the
room temperature. Lowering the temperature by 1 °C can bring
about energy savings of up to 5 %. However, it is not advisable to
allow the room temperature to fall below +15 °C. The room tem-
perature for reduced-output mode can be set separately on the
room thermostat. Instructions are given in the control unit operat-
ing instructions.
18 6 720 610 600 GB (04.06)

General Information
Hot water
A lower setting on the hot water temperature control can result in
considerable energy savings.
For RD 532 appliances:
The on-demand activation using the ECO-button makes possi-
ble the maximum savings of gas and water.
Now you know how to heat your home economically with the RD
532/RD 428 gas condensing boiler. If you have any other ques-
tions, please contact your installer – or write to us.
5 General Information
Cleaning the Outer Case
Wipe down the outer case with a damp cloth. Do not use abrasive
or caustic cleaning agents.
Appliance details
If you ever need to call Customer Service it helps us a great deal
if you can provide precise details of your appliance.
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.
6 720 610 600 GB (04.06) 19

Maintaining your appliance
6 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.
To arrange for a British Gas three star cover agreement please
call 0845 9 60 50 40.
7 Service
If your RD 532/RD 428 appliance should fail to operate correctly
or requires servicing please call British Gas on:
0845 9 60 50 40.
20 6 720 610 600 GB (04.06)

Fault or breakdown
8 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.
No charge will be made for parts and/or labour providing:
• An appliance fault is found and the appliance has been
installed within the past 24 months. Reasonable evidence of
this must be supplied on request.
A call-out charge will be made where:
• The appliance has been installed for over 24 months.
OR
• Our Field Service Engineer finds no fault with the appliance
(see NOTE).
OR
• The cause of breakdown is misuse or with other parts of your
plumbing/heating system, or with equipment not supplied by
Worcester.
NOTE: No appliance fault is found on over 30 % of all service call
outs.
If in doubt contact our British Gas on 0845 9 60 50 40.
IN THE EVENT OF AN APPLIANCE FAULT OR BREAK-
DOWN please contact your Service Centre (see over). Your serv-
ice administrator will arrange for an engineer to call with the
minimum of delay; under normal circumstances this will be within
the period 1-3 working days (excluding weekends) for priority
breakdown situations (no hot water and/or heating service).
INVOICES FOR ATTENDANCE AND REPAIR WORK CAR-
RIED OUT ON THIS APPLIANCE BY ANY THIRD PARTY
WILL NOT BE ACCEPTED.
6 720 610 600 GB (04.06) 21

Your guarantee
9 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.
• That the householder may be asked to prove the date of instal-
lation, that the appliance was correctly commissioned and,
where appropriate, the first 2 year service has been carried out
to the satisfaction of Worcester Heat Systems Limited when
requested.
• That any product or part thereof returned for servicing under
the guarantee any components of the unit which are proved to
be faulty guarantee must be accompanied by a claim stating
the Model, Serial Number, Date of Installation.
• That Worcester Heat Systems Limited will not accept respon-
sibility for damage caused by faulty installation, neglect, mis-
use or accidental damage, the non observance of the
instructions contained in the Installation and Users Instructions
Leaflets.
• That the appliance has been used only for normal domestic
purposes for which it was designed.
• That this guarantee applies only to equipment purchased and
used in Great Britain.
This guarantee is given in addition to all your normal statutory
rights.
22 6 720 610 600 GB (04.06)

Guarantee registration
10 Guarantee registration
You should complete and return the postpaid Guarantee Regis-
tration Card within 14 days of purchase.
The card will register you as the owner of your new RD 532/
RD 428 appliance and will assist us in maintaining an effective
and efficient customer service by establishing a reference and
permanent record for your boiler.
This will not affect your statutory rights in any way.
Important:
For your own record:
Model
......................................................................................................................
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.
Telephone: (01905) 754624 Fax: (01905) 754619
SERIAL NUMBER. Copy the number off the Guarantee Card.
6 720 610 600 GB (04.06) 23

11 Operating Instructions Quick Reference
Switching on Controlling the central heat- Hot water only
ing
Set room thermostat to desired
temperature or the outside-tem-
perature control unit to the appro-
priate setting.
6 720 610 333-04.1O
Hot water temperature 6 720 610 333-09.1O
Switching the central heating
Fault Condition
on
If the button flashes, press and
hold-in to reset the appliance.
Refer to page 17.
Switching off
6 720 610 333-07.1O
6 720 610 333-05.1O
“ECO”-button lit –
Economy mode.
“ECO”-button not lit –
Comfort mode
6 720 610 333-11.1O

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Installation and Servicing Instructions

6 720 610 577-00.10

ZWB 7-29 CC1 GC-Number: 47 108 05

Safety precautions 3 6 Individual settings 28

2 6 720 610 599 GB (03.02)

Safety precautions Symbols

If you smell fumes from the appliance

Fitting and modifications

Health and safety

6 720 610 599 GB (03.02) 3

1 Details of the appliance 1.3 Description of appliance

4 6 720 610 599 GB (03.02)

1.5 Casing dimensions

6 720 610 601- 01.3O

6 720 610 599 GB (03.02) 5

1.6 Layout of appliance

6 720 610 599-01.2O

6 6 720 610 599 GB (03.02)

26 27 229 226 29 33 30 234.1 234

13 43 44 45 46 47 6 720 610 599-08.2O

6 720 610 599 GB (03.02) 7

1.8 Electrical wiring diagram

o - orange g - green bl - black r - red p - purple

6 720 610 599-07.2O

8 6 720 610 599 GB (03.02)

1.9 Technical data

Units Natural gas Propane

6 720 610 599 GB (03.02) 9

Condensate analysis, mg/l Domestic water performance

18.0 12.0 9.4 28

10 6 720 610 599 GB (03.02)

3 Installation All types of single lever mixer taps and thermostatic

6 720 610 599 GB (03.02) 11

Central heating return

Fig. 5 Sealed primary water system

Sealed system filling and make up

Stop 1000mm (39 in)

3.4 Siting the appliance Surface temperature

Combustion air Cupboard/Compartment

12 6 720 610 599 GB (03.02)

6 720 610 576-11.1O

6 720 610 576-04.1O

B A drain tap should be fitted at the lowest point of the

6 720 610 599 GB (03.02) 13

Condensate Termination and Route External condensate pipework

Open end of pipe

An internal waste system An external waste system

6 720 610 596 -03.1O Benchmark: For optimum performance

Removing the outer case

B Turn the clips with a screwdriver.

6 720 610 602 - 03.1O

Fig. 12 Position of the condensate drain

14 6 720 610 599 GB (03.02)

WRAS approved filling loop.

Gas supply pipe

Alternative 125 mm diameter flue systems

A vertical flue system upto a height of 15 metres is avail-

IMPORTANT: Any horizontal flue system fitted to a