Service booklet for the Engineer for Gas Condensing Boilers 6 720 611 400-00.1O 7 181 465 347 (05.
Contents Contents Safety precautions 3 Symbols 3 1 4 Layout of Appliance 2 2.1 2.2 2.3 2.4 2.5 Operation Initialisation Standard display Displaying service functions Setting service functions Resetting service functions to factory settings 2.5.1 Resetting service functions 0.0 to 4.9 to their factory settings (Reset 1): 2.5.2 Resetting service functions 0.0 to 9.9 to the factory setting (Reset 2): 5 5 5 5 6 6.2 6.3 6.4 6.
Safety precautions Safety precautions Repairs B Repairs may only be carried out by an approved installer! B Before carrying out any work on the appliance, switch it off at the master switch! B Even when the appliance is switched off at the master switch, some components on the pcb inside the control box are still live. Therefore: B Before carrying out any work on the electrical parts of the appliance fully disconnect it from the power supply (e. g.
Layout of Appliance 1 Layout of Appliance 120 221.1 221.2 27 226 20 102 32.1 29 36 271 6 2 415 43 9 63 416 358 396 64 18 7 423 418 355 6.1 15 8.1 88 400 295 4 98 7 181 465 347-02.2O Fig. 1 4 6 6.1 7 8.1 9 15 18 20 27 29 32.
Operation 2 Operation Instructions on the use of the text display module are given in the operating and installation instructions for the boiler. a b c C 6 720 610 337-08.1R f Fig. 2 a b c d e f e d Controls Display “Up”/“More” button “Down”/“Less” button “Back” button “Next” button “Delete” button 2.1 2.3 Displaying service functions B Press any button to activate the main menu. B Press or button until the arrow cursor is pointing to Settings. B Press the button.
Operation 2.4 Setting service functions B Press any button to activate the main menu. B Press or button until the arrow cursor is pointing to Settings. B Press the button. B Press or button until the arrow cursor is pointing to Service. B Press the button. The cursor is pointing to Display service param. B Press and hold the button (for about 5 seconds) until the display shows Adjust service parameters and the first service function to be set, e. g. 2.0 Operating mode.
Boiler service functions 3 Boiler service functions 3.1 Summary Range adjustable from - to Text display message Display Reset Value 0.0 Last fault 00 - FF last fault code can be deleted 0 0.1 Flow temp. sensor 0 - 99˚C - - 0.2 Hot water temp. sensor 0 - 99˚C - - 0.3 Stor. tank temp.sensor1 (system boiler) 0 - 99˚C - - 0.4 Stor. tank temp.sensor2 (not applicable) - - - 1.2 Code plug 8714411 XXX 0 - 255 - - 1.4 Voltage at terminal 2 (not applicable) - - - 1.
Boiler service functions Text display message Display Range adjustable from - to Reset Value 3.4 Pump mode (not applicable) - - - 3.5 Pump blocking time (not applicable) - 0 - 240 s in 15-s increments 0s 3.6 Software version BF 11.XX - - 3.9 Link 8-9 open closed - - Link Ls-Lr open closed - - 4.0 Stor. tank. therm. (7-9) (system boiler) blocked heat demand - - 4.1 Room therm. LSM/LSM release (not applicable) - - - 4.2 Timer ch.
Boiler service functions Range adjustable from - to Text display message Display Reset Value 6.7 Pump off (hot water) (not applicable) - off on on 6.8 Cycle time (hot water) (combi only) - 20 - 60 min 20 min 6.9 Duration (hot water) (combi/system) - 0 - 30 min 1 min 7.0 Pump map (heating) - 0 Pump step adjustable 1 Const. pressure high 2 Const. pressure middle 3 Const. pressure low 4 Prop.pressure high 5 Prop.pressure low 3 Const. pressure low 7.1 Map pump step (heat.
Boiler service functions 3.2 Explanation of service functions 0.0 Last fault The last fault can also be recalled for servicing purposes when the appliance is functioning correctly. To delete the stored fault: B B B B Delete fault (no fault displayed). Press the button. Use the button to select yes. Press the button. If a list of the last 10 indicated faults is required for servicing purposes, look under Settings -> Service -> Further options -> Fault history. and – – .
Boiler service functions 2.5 Max. flow temperature The maximum CH flow temperature can be set to between 35˚C and 88˚C (factory setting). Even if the CH flow temperature control is set higher, the setting entered for 2.5 Max. flow temperatureis not exceeded. 2.6 Switch diff. flow NTC The switching difference is the permissible differential 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).
Boiler service functions 4.6 Internal regulator The boiler has an internal anti-cycle function which prevents the burner overheating if the heat output can not be dissipated even in Min mode. The appliance will then switch off even when the system is calling for heat. 6.6 Thermostore satisfied (not applicable) It will subsequently switch on again 6.8 Cycle time (hot water) (combi only) The appliance is supplied with the pre-heat cycle time set to 20 minutes.
Boiler service functions The factory setting is: 7.0 Pump map (heating) 3 Const. pressure low H 0,6 (bar) 0,5 1 2 0,4 0,3 3 7.1 Map pump step (heat.) This service function corresponds to the pump speed switch used on conventional heating pumps. However, the setting is only active if function 7.0 Pump map (heating), is set to Pump step adjustable. The factory setting is: 7.1 Map pump step (heat.
Boiler service functions 7.3 Air purge mode The first time the appliance is switched on, a once-only venting function is activated. The heating pump then switches on and off at intervals. This sequence lasts about 8 minutes. The text display shows 7.3 Air purge mode and the 2-digit display shows 00 in alternation with the CH flow temperature. The automatic (27) vent must be opened and then closed again once the venting sequence is complete.
Summary 4.2.1 Appliance faults Indication of faults Faults are indicated by a letter code. This helps to identify and eliminate the cause of the fault quickly and reliably. 4.1.1 ... on the boiler The text display shows the message Fault EA. Please call service, for example.At the same time, the fault code appears on the 2-digit display, in this example: EA.
Rectifying faults combi boiler Faults that are not displayed system boiler 4.2.2 Page Boiler indicates P1, P2, P3 at start-up and then restarts with P1..
Rectifying faults 4.3 Notes on using the fault code tables The procedure is best described with the aid of an example: • Work through the table from top to bottom and from left to right. • First make a note of the present settings and restore them before leaving the appliance. • Read question 1. (Check column)and depending on the answer (yes or no) read the action required from the relevant box and carry out the instruction given; ignore the other answer.
Rectifying faults Error A1 4.4 Error codes on the display A1 flashing. Controlled-characteristic pump has run dry Check 1. System pressure below 1.2 bar? Action yes: B Power OFF the appliance. B Check appliance and system for water leaks and repair as necessary. B Fill system, bleed and re-pressurise (see Installation Instructions). B Turn ON the appliance. A1? ↓2. 2. 3. 18 Audible bearing damage on pump? Activate venting sequence. no: ↓2. yes: B B B B B no: ↓3.
Rectifying faults Error A7 A7 flashing. Water NTC sensor defective Check 1. 2. 3. 1) Action B Activate menu option Show service parameters. B Select service function 0.2 Hot water temp. sensor. Is a temperature between 0 and 5˚C displayed? yes: no: ↓2. B Unplug 20-pin connector from PCB. E2 is displayed. B Check resistance from connections 3 to 4 on the cable side.
Rectifying faults Error A8 A8 flashing. No correct electrical connection Check 1. B Power OFF the appliance. B Check Wiring between Textdisplay and TR 2: – Terminal 3 on Textdisplay connected to Terminal 3 TR 2? – Terminal 4 ...Terminal 4 – Terminal F ...Terminal F? Action yes: ↓2. no: B Rewire correctly as specified in the installation instructions. B Turn ON the appliance. After 90 sec.: A8? B Power OFF the appliance. ↓2. 2. B Check continuity on wiring to TR 2. Is there continuity? yes: ↓3.
Rectifying faults Error Ad Ad flashing. DHW cylinder NTC sensor not detected Check 1. Is lead for DHW cylinder NTC sensor correctly routed, i.e. not through cable clamp? Action yes: ↓2. no: B Route connecting lead for DHW cylinder temperature sensor as specified in installation instructions. Ad? ↓2. 2. B Activate menu option Show service parameters. B Select 0.3 Stor. tank temp.sensor1.
Rectifying faults Error b1 b1 flashing. Code plug not detected. Check 1. b1 is shown on 2 digit display. (independent on what is shown on the text display). Action yes: B Power OFF the appliance. B Fit code plug (correctly), making sure code number is correct (see Appendix). B Turn ON the appliance. b1? ↓2. 2. 3. B Activate menu option Show service parameters. B Select 1.2 Code plug. B Compare number displayed with that shown in Appendix. No number or incorrect number (last three digits) displayed.
Rectifying faults Error C1 C1 flashing. Fan speed too low Check 1. Fan lead connector properly connected? Action yes: ↓2. no: B Power OFF the appliance. B Plug in connector. B Turn ON the appliance. C1? ↓2. 2. Is fan lead defective? B Measure the fan lead for continuity. Is there continuity for each one of the cores? yes: ↓3. no: B Power OFF the appliance. B Replace fan lead. B Turn ON the appliance. C1? ↓3. 3. Fan defective. yes: B B B B B Power OFF the appliance.
Rectifying faults Error d3 d3 flashing. Wrong signal from pin 8-9. Check 1. 2. Action B Measure voltage between Terminal 4 and Terminal 8. Voltage ≅ 24 V DC? yes: ↓2. no: ↓3. Link between terminals 8 and 9 connected? yes: B Power OFF the appliance. B Check link across 8-9 properly fitted, tighten screws properly. B Turn ON the appliance. d3? ↓3. no: 3. Terminal block defective. ↓3. B B B B B Power OFF the appliance. Disconnect the boiler electrical connection. Replace terminal strip.
Rectifying faults Error E2 E2 flashing. The flow temp. NTC sensor is damaged. Check 1. B Activate menu option Show service parameters. B Select 0.1 Flow temp. sensor. Is a temperature between 0 and 5˚C displayed? Action yes: The heating outlet NTC sensor is in short circuit: B Power OFF the appliance. B Replace CH flow NTC sensor; observe fitting instructions for NTC sensor when doing so. B Turn ON the appliance. E2? ↓2. 2. 3. B Unplug 20-pin connector from PCB.
Rectifying faults Error E9 E9 and flashing. Safety temperature limiter has tripped. Check 1. Is the heating pressure between 1 and 2 bar? Action yes: ↓2. no: B Top up system. B Vent appliance. B Press , restart the appliance. E9? ↓2. 2. Is the pump seized? yes: B Unblock the pump. If pump won’t start: B Power OFF the appliance. B Disconnect the boiler electrical connection. B Drain appliance. B Change the pump (see chapter 5.4).
Rectifying faults Error E9 E9 and flashing. Safety temperature limiter has tripped. Check 5. Is lead disconnected from CH flow safety temp. limiter? Action yes: B Power OFF the appliance. B Reconnect lead. B Turn ON the appliance. B Press , restart the appliance. E9? ↓6. 6. B Power OFF the appliance. B Disconnect lead to CH flow safety temperature limiter. B Measure the CH flow safety temperature limiter for continuity. Resistance very high? no: ↓6.
Rectifying faults Error EA EA and flashing. During operation: flame not detected Check 1. Is a burner flame visible? 2. Is the gas cock turned on? Action yes: ↓5. no: ↓2. yes: ↓3. no: B Open the gas cock. B Press , restart the appliance. EA? ↓3. 3. Is there air in the supply pipe? yes: B Vent supply pipe. B Press , restart the appliance. EA? ↓4. 4. Natural gas models: does the building have a supply pressure regulator? no: ↓4.
Rectifying faults Error EA EA and flashing. During operation: flame not detected Check 7. Is diaphragm in mixer unit fitted correctly (see installation instructions)? B Open mixer unit (29). B Check diaphragm for correct orientation, soiling and splitting. Is diaphragm OK? Action yes: B Close mixer unit. ↓8. no: B Insert diaphragm in the fan intake duct as per installation instructions so that the flaps open upwards. B Close mixer unit. EA? ↓8. 8. Check the gas valve.
Rectifying faults Error EA EA and flashing. During operation: flame not detected Check 10. Is flue gas CO2 level Action incorrect1)? yes: B Adjust to correct level. B Press , restart the appliance. EA? ↓11. 11. B Activate menu option Show service parameters. B Select 5.1 Permanent ignition (without Gas). Continuous ignition (without gas) OK? no: ↓11. yes: B Press button to select no. ↓12. no: B Press button to select no. ↓15. 12.
Rectifying faults Error EA EA and flashing. During operation: flame not detected 17. Check Action Check if the 20-pin connector lead assembly is damaged. B Power OFF the appliance. B Change the 20-pin connector lead assembly. B Turn ON the appliance. B Press , restart the appliance. EA? ↓18. 18. The PCB control board is damaged. B Make a note of the altered service settings (see table 1 on page 7). B Power OFF the appliance. B Disconnect the boiler electrical connection.
Rectifying faults Error F0 F0 (and possibly ) flashing. Internal failure 1. 2. 3. 4. Check Action B Activate menu option Show service parameters. B Select 9.3 GFA-Asic error (automatic ignition module, extended messages). A message is displayed. B Enter figure displayed in customer service record. B Select 5.2 GFA status/error . A message is displayed. B Enter figure displayed in customer service record. B Select Settings -> Further options-> Service->Display service param.
Rectifying faults Error F7 F7 and flashing. Although appliance switches off, flame still detected Check 1. Action Electrode(s) dirty or defective? yes: B Power OFF the appliance. B Remove electrode assembly and bracket and check for wear, deposits and mechanical damage. B Replace electrode assembly. B Turn ON the appliance. B Press , restart the appliance. F7? ↓2. no: B Refit electrode assembly. B Turn ON the appliance. B Press , restart the appliance. F7? ↓2. 2. 3.
Rectifying faults Error F7 FA and flashing. After appliance switches off flame is detected 2. 3. Check Action Electrode assembly defective? B Power OFF the appliance. B Remove electrode assembly. Electrode assembly burnt out? B Replace electrode assembly. B Turn ON the appliance. Problem with flue? B Check CO2 level in combustion air. Is CO2 level above 0,2 % ? B Press FA? ↓3. yes: The gas valve is damaged. B Check flue, clean if necessary. B Press , restart the appliance. FA? ↓4. no: 4.
Rectifying faults Error FC FC flashing. Text display module not detected 1. Check Action No fault or fault code FC displayed on text display? B Power OFF the appliance. B Fit code plug (correctly), making sure code number is correct (see Appendix). B Turn ON the appliance. FC? ↓2. 2. B Unplug text display module connector. B Connecting lead between text display module and Heatronic OK.? yes: B Plug in connector. FC? ↓3. no: B Replace text display module. FC? ↓3. 3.
Rectifying faults Error Fd 4.5 Faults that are not displayed 4.5.1 Appliance faults Boiler indicates P1, P2, P3 at start-up and then restarts with P1.. Check 1. Fuse T 1,6 A (312) defective. Action yes: B B B B B Power OFF the appliance. Disconnect the boiler electrical connection. Change the fuse. Reconnect the boiler electrical connection. Turn ON the appliance. Start sequence not completed? ↓2. no: 2. ↓2. B Make a note of the altered service settings (see table 1 on page 7).
Rectifying faults Error Fd Excessive burner noise, rumbling noises Check 4. 5. Action B Repair or replace components. B Grease seal before fitting. Make sure it is fitted in correct position. Is appliance’s internal air/flue channel leaking or blocked? B Open up heat exchanger and inspect. B Remove silencer, flue duct and air flow limit. B Open trap and inspect. Air channels dirty/clogged, seals defective or not correctly fitted? yes: no: ↓5. B Measure CO2 levels.
Rectifying faults Error Fd Flue gas levels incorrect, CO level too high Check 1. Does the gas supply type match the specifications on the appliance identification plate? Action yes: ↓2. no: B Convert appliance to correct gas type. Flue gas levels incorrect? 2. 2. B Test gas supply pressure - OK? Does pressure match figure specified in installation instructions? yes: ↓3. no: B Decommission appliance. Bei Erdgas: B Notify gas company. b 3. 4. 5.
Rectifying faults Error Fd Ignition too harsh, ignition poor Check 1. 2. Action B Activate menu option Show service parameters. B Select 5.1 Permanent ignition (without Gas). Continuous ignition (without gas) OK? yes: ↓6. no: ↓2. Ignition lead connected to ignition electrodes? yes: ↓3. no: B Connect cable to ignition electrodes. B Press button . Ignition poor? 3. 3. Ignition cable connector engaged in switchbox? yes: ↓4. no: B Power OFF the appliance.
Rectifying faults Error Fd Ignition too harsh, ignition poor Check 7. 8. 9. 10. Action B Test gas supply pressure - OK? Does pressure match figure specified in installation instructions? yes: ↓8. no: B Decommission appliance. In case of natural gas: B Notify gas company. Problem with flue? B Check CO2 level in combustion air. Is CO2 level above 0,2 % ? yes: B Check flue and repair or replace if necessary. no: ↓9. Flue gas CO2 levels measured at min. and max.
Rectifying faults Error Fd Hot water has unpleasant odour or is dark colour (system boiler) Check Action This is generally caused by the formation of hydrogen sulphide by sulphate-reducing bacteria. Such bacteria are found 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.
Rectifying faults Error Fd Inadequate hot water outlet temperature (combi boiler) Check 1. Pump set to mode 3? Action yes: ↓2. no: B Set pump switch to setting 3. Inadequate hot water outlet temperature ? ↓2. 2. B Unplug connector from Heatronic; is voltage between terminal 1 and terminal 3 230 V AC? yes: B B B B B no: B Make a note of the altered service settings (see table 1 on page 7). B Power OFF the appliance. B B B B B 42 Power OFF the appliance.
Rectifying faults Error Fd 4.5.2 Programmer faults Set room temperature not reached (TR 2) Check 1. Thermostatic valve(s) set too low? Action yes: B Turn up thermostatic valve(s). ↓2. 2. 3. CH flow temperature control on boiler set too low? no: ↓2. yes: B Turn up CH flow temperature control. no: ↓3. B Power OFF the appliance. B Check appliance and system for water leaks and repair as necessary. B Top up system. B Turn ON the appliance. B Activate menu option Show service parameters.
Rectifying faults Error Fd Set room temperature not reached (integrated text display) 4. Check Action Air in the heating system. B Power OFF the appliance. B Check appliance and system for water leaks and repair as necessary. B Top up system. B Turn ON the appliance. B Activate menu option Show service parameters. B Select 7.3 Air purge mode select setting on, autom. deactivat. and confirm. B Vent appliance. B Vent radiators. Set room temperature exceeded by large amount (TR 2) Check 1.
Rectifying faults Excessive fluctuations in room temperature (integrated text display) Check 1. 2. Action yes: no: ↓2. Room override has insufficient priority yes: B Increase room override priority (not text display). ↓2. ↓3. no: 3. B Switch on room override. TR2 without room override: B Periodic effect of external heat on room, e.g. from sunshine, lighting, TV, separate stove, fire, etc. ↓3. B Select better installation location. -orB Fit external room thermostat.
Replacement of Parts 5 Replacement of Parts B B B B B B B B Always disconnect the power supply to the appliance at the mains before carrying out any work on the electrical systems and components (fuse, circuit breaker). B Always turn off the gas cock before carrying out any work on components which carry gas. Lower the control box. Unscrew earth lead. Unscrew four fixing screws from cover plate. Prise off cover plate. Pull off transformer. Remove pcb holder. Remove the pcb control board.
Replacement of Parts 5.2 Fan Assembly 5.3 B Power OFF the appliance. B Undo lower pipe union on gas pipe (1.). B Remove fan lead and earth connector (2.). The earth connector has a positive clip fixing. B Remove fixing screws attaching fan to the burner cover (3.). B Remove three fan fixing screws. 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.). Primary Heat exchanger/Burner B Power OFF the appliance.
Replacement of Parts 5.4 Pump 5.5 B B B B B B B Power OFF the appliance. Disconnect the boiler electrical connection. Turn off service cocks. Drain appliance. Remove two top fixing screws from the control box. Lower the control box. Remove screw from underside of right-hand plastic cover plate. B Pull cover plate forwards to remove. B Unscrew the pump union nuts. Clean condensation trap In order to prevent spillage of condensate the condensation trap should be completely removed.
Replacement of Parts 5.7 B B B B B B B B B 3-way diverter valve 5.8 Power OFF the appliance. Disconnect the boiler electrical connection. Turn off service cocks. Drain appliance. Unplug connector from 3-way valve motor. Pull out retaining clip. Remove motor. Open pipe joints. Remove 3-way valve. B B B B Domestic Hot Water Heat Exchanger Power OFF the appliance. Turn off service cocks. Drain appliance. Open pipe joints. 7 181 465 330-06.1R 7 181 465 330-12.1 Fig. 15 Fig.
Appendix 6 Appendix 6.1 NTC values 6.1.1 Flue sensor 6.1.3 Flue temperature (˚C) Measurement tolerance ±10% Resistance (Ω) 20 124 900 40 53 290 60 24 890 80 12 550 100 6 777 120 3 873 140 2 328 160 1 455 180 948 200 540 Table 5 6.1.
Appendix 6.2 Electrical wiring diagram o - orange g - green bl - black r - red p - purple 33 365 364 61 317 366 363 367 ECO 4.1 25 V 230 V 153 310 136 400 135 230V/AC 312 328 313 151 124 789 p p p L N Ns Ls LR 302 300 161 84 3 4 F M 96 328.1 9 18 M M g 6 422 g 226 o o r r mains supply 52 o 52.1 56 o bl bl bl bl 36 bl 6.1 32 6 720 610 602 - 02.1O Fig. 16 4.1 6 6.1 9 18 32 33 36 52 52.
Appendix 6.3 Approved corrosion inhibitors and anti-freeze fluids for central heating water Corrosion inhibiter The following corrosion inhibiters are permitted: Manufacturer Product Concentration Fernox Copal 1% Schilling Chemie Varidos AP 1-2% Table 8 Anti-freeze fluid The following anti-freeze fluids are permitted: Manufacturer Product Concentration BASF Glythermin NF 20 - 62 % Schilling Chemie Varidos FSK 22 - 55 % Component Order no.
Appendix 6.5 Summary of BDH Information Sheet on Identifying Corrosion by CFCs The presence of halogenated hydrocarbons in the combustion air causes surface corrosion on affected metals. Particularly susceptible is the combustion chamber and the heat exchanger surfaces (including stainless steel) as well as the metal components in the flue socket, flue pipe connections and in the chimney.
Appendix 54 7 181 465 347 (05.
Appendix 7 181 465 347 (05.
