6 720 806 992-00-1O Residential Gas Condensing Boiler Greenstar 6 720 806 993 (2013/03) CA/US ZBR16/21/28/35/42-3A... | ZWB28/35/42-3A...
| Contents Contents 1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 Information about the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents | 3 6 Energy saving tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 9 Environmental responsibility/disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 10 Quick reference . . . . . . . . . . . . . . .
| Key to symbols and safety instructions 1 Key to symbols and safety instructions 1.1 Key to symbols Warnings Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. The following keywords are defined and can be used in this document: • NOTICE indicates that property damage may occur.
Key to symbols and safety instructions | 5 1.2 Safety instructions General information This manual is available in English and French. ▶ Keep this manual for future use. ▶ Observe the safety instructions of this manual before putting the heating appliance into operation. If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
| Key to symbols and safety instructions For appliances operating on room air: Danger of flue gas poisoning if supply of combustion air is insufficient ▶ Safeguard supply of combustion air. ▶ Do not cover or reduce the size of ventilation openings in doors, windows and walls. ▶ Safeguard sufficient supply of combustion air also for appliances installed at a later date, e.g. kitchen exhaust fans, clothes dryers, and air conditioning units with vent to the outside.
Information about the appliance | 7 Sign a maintenance and inspection contract with a trained and certified contractor, covering an annual inspection and demand-dependent maintenance. This guarantees high efficiency and environmentally sound combustion. Explosive and easily combustible materials Never use or store easily combustible materials (paper, thinners, paints, etc.) near the appliance.
| Preparing the appliance for operation The commercial and industrial use of the appliance for generating process heat is not permitted. 2.
Preparing the appliance for operation | 9 3.1 Checking the boiler water pressure The standard boiler water pressure is 14.5 - 21.75 psi (1 - 1.5 bar). Should a higher boiler water pressure be required, refer to a trained and certified heating contractor. 2 1 30 15 3 45 0 psi 4 bar 6 720 641 934-04.2O Fig. 1 3.2 Topping up the heating system water Topping up the heating system water is different on every system.
| Operation 4 Operation These operating instructions apply only to the boiler. Depending on the heating control unit used, some functions may vary. The following options for controlling the heating system are available: • Outdoor reset control unit ( page 16, Fig.
Operation | 11 Page 29 contains a quick reference. You can fold this outward and keep these operating instructions in the control panel cover. 3 2 1 4 5 6 max 6 720 614 235-04.1O Fig.
| Operation 4.1 Overview of controls 1 2 3 4 5 6 7 8 9 reset 10 eco 11 19 18 17 16 15 14 13 12 6 720 641 934-01.1O Fig.
Operation | 13 [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] Emission test button for contractors (see installation instructions) Service button for contractors (see installation instructions) Burner ON indicator lamp ON/OFF switch Key pad lock ECO button Reset button Display Boiler water pressure gauge DHW thermostat Safety relief valve discharge hose Condensate drain hose Heating return pipe Cold water pipe - combi boiler only Gas pipe DHW pipe - combi boiler only
| Operation 4.2 Switching the appliance ON/OFF Startup 3 2 1 4 5 6 max 6 720 613 896-05.1O ▶ Switch the appliance ON using the ON/OFF switch. The display shows the supply temperature. Fig. 4 If the display shows in alternation with the supply temperature, the appliance operates at its lowest output for 15 minutes per the initial startup sequence. Shutdown ▶ Switch the appliance OFF using the ON/OFF switch. The diplay goes out.
Operation | 15 ▶ Adjusting the supply temperature with the boiler high limit dial : – Radiant floor heating: e.g. setting 3 (approx. 122 °F (50 °C)) – Panel or cast iron radiator heating: setting 6 (approx. 167 °F (75 °C)) – Heating with supply temperatures up to 194 °F (90 °C): setting max reset eco 3 3 4 2 1 2 5 4 e 6 1 6 max min max 6 720 641 933-53.1O Fig. 5 The burner ON indicator lamp lights up if the burner is operating.
| Operation 4.4 Programming the heating control unit Observe the operating instructions for the heating control unit included in the scope of delivery. There you can read: ▶ How to set the operating mode and the heating curve for outdoor reset controls ▶ How to adjust the room temperature ▶ How to heat economically and save energy 9 12 h 15 18 6 3 24 h 21 6 720 612 660-07.2O Fig. 6 4.5 ZBR..
Operation | 17 ▶ Set the DHW temperature on the DHW thermostat . The set DHW temperature flashes on the display for 30 seconds. reset eco 3 2 1 4 3 2 5 6 max 1 4 e 6 max 6 720 641 933-54.1O Fig. 7 If there is reason for concern for contamination from bacteria such as legionella, consider setting the DHW thermostat to at least “e” (131 °F (55 °C)). This setting ensures an economical and comfortable DHW generation. Consult your local water department or municipality for further information.
| Operation ECO button Pressing and holding the ECO button until it lights up switches between Comfort mode and Economy mode. • Comfort mode, ECO button is not lit (default setting) In Comfort mode, the DHW tank has priority. The DHW tank is heated to the set temperature first. Then the appliance switches to central heating mode. • Economy mode, ECO button lit In Economy mode, the appliance alternates between central heating mode and DHW mode. 4.6 ZWB..
Operation | 19 ECO button Pressing and holding the ECO button until it lights up switches between Comfort mode and Economy mode. • Comfort mode (default setting) The appliance is continually maintained at the set temperature. Consequently, DHW draws are immediate, however the appliance may run even if no DHW is being drawn. • Economy mode, ECO button lights up – DHW is only generated when DHW is drawn. – On demand: Quickly open and close a DHW tap to signal the appliance to heat to the selected temperature.
| Operation ▶ Turn the boiler high limit dial counterclockwise to . reset eco 4 3 3 5 2 1 e 2 6 1 6 max min max 6 720 641 933-82.1O Fig. 9 For further information, see the operating instructions for the heating control unit included in the scope of delivery. 4.8 Setting frost protection Frost protection of the heating system: ▶ Leave the appliance switched ON; turn the boiler high limit dial position 1. at least to reset eco 3 3 2 1 5 2 6 max 1 min 4 e 6 max 6 720 641 933-68.
Operation | 21 Frost protection of the DHW tank: counterclockwise to min (59 °F (15 °C)). ▶ Turn the DHW thermostat reset eco 3 4 3 2 5 1 e 2 6 max 1 6 min max 6 720 641 933-69.1O Fig. 11 4.9 Activating the key pad lock The key pad lock affects the supply temperature dial, the DHW thermostat, the service button and the ECO button. Activating the key pad lock: ▶ Press the key pad lock button until alternating on the display.
| Thermal disinfection 4.10 Display codes Display Description Fault-Code ( chapter 7) Inspection due Pump anti-seize function active Key pad lock active Condensate trap filling function active Bleeding function active Excessively rapid increase in supply temperature (temp. gradient monitoring). Heating mode is disabled for two minutes. If this message appears repeatedly, inform a trained and certified heating contractor. Drying function.
Thermal disinfection | 23 Thermal disinfection can also be carried out automatically and on a regular basis; see operating instructions for the heating control unit included in the scope of delivery. Thermal disinfection covers the DHW system including the taps. For solar DHW tanks, the solar portion of the tank is not covered. DANGER: Risk of scalding! Hot water can result in severe scalding. ▶ Carry out thermal disinfection only outside the normal hours of use.
| Energy saving tips ▶ Wait until the maximum temperature has been reached. ▶ Open all DHW taps, from the nearest to the one furthest away, and draw off DHW until water at a minimum of 158 °F (70 °C) has flown from all taps for at least 3 minutes. ▶ Reset the DHW thermostat, DHW recirculation pump, and heating control unit to standard operation. To cancel the thermal disinfection: ▶ Switch the appliance OFF and ON again. The appliance starts up again and the current supply temperature is displayed.
Energy saving tips | 25 Heating control unit Use a heating control unit with room temperature influence or an outdoor reset control unit and thermostatic valves. For further information, see the operating instructions for the heating control unit included in the scope of delivery. Thermostatic valves Fully open the thermostatic valves to ensure that the desired room temperature is reached in all cases.
| Troubleshooting 7 Troubleshooting The Heatronic boiler control monitors all safety and control components. If a fault arises during operation, an audible warning tone sounds. Press a button to mute the warning sound. The display indicates a fault code (e.g. flashing. ) and the reset button may also be If the reset button is flashing: ▶ Press the reset button and hold it until appears on the display. The appliance starts up again and the current supply temperature is displayed.
Maintenance | 27 Appliance details If you need to call a trained and certified heating contractor, you may be asked for details on your appliance. Those details can be found on the rating plate. Greenstar (e. g. ZBR 28-3 A ...): ........................................................................................................ Serial number: ........................................................................................................ Date commissioned: .......................................
| Environmental responsibility/disposal 9 Environmental responsibility/disposal Environmental responsibility is one of the fundamental company policies of the Bosch Group. We regard quality of performance, economy and environmental responsibility as equal objectives. Environmental protection laws and regulations are strictly adhered to. To protect the environment, we use the best possible technology and materials taking into account economic points of view.
Quick reference | 29 10 Quick reference DHW temperature Startup 6 720 613 896-05.1O 4 3 5 2 1 DANGER: Danger of scalding! ▶ In normal operation, it is recommended to limit the DHW temperature to 122 °F (50 °C) to limit the risk of scalding. 6 max Turning space heating ON reset eco 3 2 1 3 4 2 5 reset 4 e eco 6 1 6 max min max 3 6 720 641 933-53.1O 4 2 e 1 6 Heating control 4 3 2 5 1 6 max max 6 720 641 933-55.
| Index Index C Certifications.............................................................................................. 7 Cleaning the outer casing ........................................................................... 27 Commissioning ........................................................................................... 8 D Details about the appliance - proper use ............................................................................................ 7 - type overview...............
Index | 31 K Key pad lock..............................................................................................21 M Maintenance .............................................................................................27 O Old appliances ..........................................................................................28 Operation .................................................................................................10 Overview of controls .......................................
