Bosch Conversion Guide

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6 720 646 558 (2013/07)Greenstar
Gas type conversion
The gas-air ratio must always be set on the basis of a CO
2
or O
2
reading taken at
maximum nominal output and minimum nominal output using an electronic flue
gas analyzer.
Adjustment to different flue systems using throttle discs or baffles is not necessary.
NG
• Appliances are set at the factory to Wobbe index 1,333 BTU/ft
3
(49.6 MJ/m
3
) at
60 °F (15 °C), 30" Hg (1016 hPa) and 7.0" W.C. (17.4 mbar) gas supply
pressure and sealed.
Converting to a different gas type
A gas conversion kit is included in the scope of delivery.
▶ Fold the Heatronic down.
▶ Check the number on the code plug from the gas conversion kit:
▶ Replace the code plug in the Heatronic with the code plug from the gas
conversion kit.
Fig. 1 Replacing the code plug
▶ Affix the gas type label from the gas conversion kit to the appliance.
Fig. 2 Affixing the gas type label
▶ Always adjust the gas-air ratio (CO
2
or O
2
,  Section “Setting the gas-air ratio”)
after converting to a different gas type and measure the CO content of the flue
gas ( “Installation and Service Instructions for Contractors”).
Installation location higher than 2,000 feet (610 m) above sea level
Input and output rates are reduced at higher altitudes due to thin air with reduced
oxygen levels.
ZBR42-3A... and ZWB42-3A... appliances are derated at 3 % per 1000 feet
(305 m).
ZBR16-3A..., ZBR21-3A..., ZBR28-3A..., ZBR35-3A..., ZWB28-3A... and
ZWB35-3A appliances offer altitude adjustment which compensates for the effects
of thin air, and are therefore NOT derated up to 6000 feet (1829 m). Above
6000 feet (1829 m) a rate of 3 % per 1000 feet (305 m) applies.
▶ Correction of the fan speed curve of the burner:
Use service function 0.d to adjust the elevation setting ( “Installation and
Service Instructions for Contractors”).
Setting the gas-air ratio (CO
2
or O
2
)
▶ Switch the appliance OFF using the ON/OFF switch.
▶ Remove the cover ( “Installation and Service Instructions for Contractors”).
▶ Switch the appliance ON using the ON/OFF switch.
▶ Open one of the flue gas test ports.
Fig. 3 Open one of the flue gas test ports
▶ Insert the flue gas probe approx. 2-3/4 inches (70 mm) into the test port and
seal around it.
▶ Press and hold the emissions test button until it lights up.
The display shows the supply temperature alternating with = maximum set
output in heating mode.
▶ Briefly press the emissions test button .
The display shows the supply temperature in alternation with = maximum
nominal output.
▶ Measure the CO
2
or O
2
level and the CO content of the flue gas ( “Installation
and Service Instructions for Contractors”).
DANGER: Personal injury and property damage
▶ This conversion shall only be performed by a trained and
certified installer in accordance with the manufacturer‘s
instructions and all applicable codes and requirements of the
authority having jurisdiction.
▶ If the information in these instructions is not followed exactly,
or the installation, adjustment, modification, operation or
maintenance is carried out by an unqualified person, a fire,
explosion or generation of large amounts of carbon monoxide
may result causing property damage, personal injury or loss of
life.
▶ Before carrying out electrical work: disconnect the
installation from the power supply at the emergency shutoff
switch or by disengaging the heating system circuit breaker.
Take measures to prevent accidental reconnection.
▶ The installer is responsible for the proper conversion of this
appliance.
▶ The conversion is not complete until the operation of the
converted appliance is checked as specified in these
instructions.
DANGER: Explosion!
▶ Close the gas cock prior to working on the gas train.
▶ Check for gas leaks after carrying out work on the gas train.
NG Code plug LPG Code plug
Appliance Order number Order number
ZBR16-3A 8 714 432 501 0 8 714 432 506 0
ZBR21-3A 8 714 432 528 0 8 714 432 529 0
ZBR28-3A 8 714 432 502 0 8 714 432 507 0
ZBR35-3A 8 714 432 503 0 8 714 432 508 0
ZBR42-3A 8 714 432 504 0 8 714 432 509 0
ZWB28-3A 8 714 432 520 0 8 714 432 521 0
ZWB35-3A 8 714 432 524 0 8 714 432 525 0
ZWB42-3A 8 714 432 500 0 8 714 432 505 0
6 720 641 933-57.1O
The Bosch Greenstar boiler is factory set for installation below
2000 feet (610 m) above sea level.
6 720 641 933-58.2O
6 720 641 933-79.1O