Installation and Service Instructions for Contractors Residential Gas Condensing Boiler Greenstar ZBR 21-3 A... | ZBR 28-3 A... | ZBR 35-3 A... | ZBR 42-3 A... | ZWB 28-3 A... | ZWB 35-3 A... | ZWB 42-3 A... WARNING: Improper installation, set-up, modification, operation or maintenance of the heating system can cause personal injury and property damage. Follow these instructions precisely.
Contents 6.9 Contents 7 1 Explanation of symbols and safety instructions. . . . . . . . . . . . 4 1.1 1.2 2 7.2.1 7.2.2 7.2.3 7.2.4 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1 2.2 3 ZBR...-3A - Residential boiler for space heating and loading of indirect fired DHW tanks . . . . . . . . . . . . . 6 ZWB...-3A - Residential combi boiler for space heating and DHW generation . . . . . . . . . . . . . . . . . . . . . . 7 7.2.5 7.
Contents 9 ZBR...-3A appliances (heating boiler) with DHW tank: Thermal disinfection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 10 Boiler circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 10.1 10.2 Pump anti-seize protection . . . . . . . . . . . . . . . . . . . . . . 54 Changing the pump curve of the boiler pump . . . . . . . . 54 11 Heatronic boiler control settings . . . . . . . . . . . . . . . . . . . . . . . 55 11.
Explanation of symbols and safety instructions 1 Explanation of symbols and safety instructions 1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing danger are not taken. The following keywords are defined and can be used in this document: DANGER DANGER indicates that severe or life-threatening personal injury will occur.
Explanation of symbols and safety instructions DANGER: Risk of personal injury or death from flue gas poisoning! ▶ Do not install a thermostatic flue gas damper downstream of the draft hood. ▶ Do not tamper with, remove, or attempt to repair the blocked vent switch. ▶ When replacing the blocked vent switch, install the new part in the original location. ▶ A blocked vent switch tripping more than once indicates a problem with the venting system or chimney which must be repaired immediately.
Scope of delivery 2 Scope of delivery 2.1 ZBR...
Scope of delivery 2.2 ZWB...
Product Description 3 Product Description ZBR...-3A appliances are residential boilers for central heating and loading of an indirect fired DHW tank. 3.3 Rating plate The rating plate is located at the right side of the appliance. ZWB...-3A appliances are residential combi boilers for central heating and on demand DHW heating. The appliances comply with South Coast Air Quality Management District (SCAQMD) 2012 requirements: (Type-1) 14 Ng/J NOx (and/or 20 ppm at 3% O2). 3.
Product Description Product dimensions and minimum clearances ≥ 4" * (102 mm) * ≥ 4" * (102 mm) * 17-21/64" (440 mm) 33-15/32" (850 mm) 3-11/32" (85 mm) ≥ 15" (381 mm) 3.6 ≥ 4" ** (102 mm) ** 33-15/16" (862 mm) 1 2 7-7/8" (200 mm) 13-57/64" (353 mm) 1-3/16" (30 mm) 33-27/64" (849 mm) ≥ 4" * (102 mm) * 9-29/64" (240 mm) 3 0010004928-001 Fig.
Product Description 3.7 Appliance layout heating boiler ZBR...-3A 27 28 26 25 29 30 24 23 22 31 32 21 20 19 18 17 16 15 33 34 35 36 14 13 37 38 39 12 1 2 3 4 5 11 10 9 8 40 min 6 7 0010016624-002 Fig. 5 10 Appliance layout ZBR...
Product Description Key to Fig.
Product Description 3.8 Appliance layout ZWB...-3A 30 31 29 28 27 25 24 23 32 33 34 26 22 35 21 36 20 19 18 37 17 38 16 15 39 14 40 41 42 43 13 12 1 2 3 4 5 11 10 9 8 44 min min 6 7 0010016625-002 Fig. 6 12 Appliance layout ZWB...
Product Description Key to Fig.
Product Description 3.9 Electrical wiring ZBR...-3A 19 20 18 16 6 21 17 23 15 9 22 8 5 5 6 7 24 3 4 4 LZ NZ 1 2 3 7 B 4 2 2 LS NS L F A 10 11 8 8 L 9 7 1 N N 9 B 4 6 14 25 13 Fig. 7 14 12 6 720 641 933-23.3O Electrical wiring diagram ZBR...
Product Description Key to Fig. 7: [1] Ignition transformer [2] Boiler high limit dial [3] 120 VAC connection [4] DHW tank primary pump or 3-way valve 1) [5] External heating pump for unmixed heating circuit (secondary circuit) 5 or DHW recirculation pump 2) [6] Fuse T 6.3 A (120 VAC) [7] DHW thermostat [8] External safety high limit or low water cut off (LWCO) [9] BUS connection, e.g.
Product Description 3.10 Electrical wiring ZWB...-3A 18 19 17 15 6 20 16 22 21 23 14 9 24 8 4 3 4 5 6 7 25 LZ NZ 1 2 3 6 B 4 2 2 F LS NS A 9 10 6 8 7 L 9 7 1 N 8 B 4 5 13 26 12 Fig. 8 16 11 6 720 641 933-24.3O Electrical wiring diagram ZWB...
Product Description Key to Fig. 8: [1] Ignition transformer [2] Boiler high limit dial [3] 120 VAC connection [4] External heating pump for unmixed heating circuit (secondary circuit) 4 or DHW recirculation pump 1) [5] Fuse T 6.3 A (120 VAC) [6] DHW thermostat [7] External safety high limit or low water cut off (LWCO) [8] BUS connection, e.g.
Product Description 3.11 Technical data ZBR...-3A ZBR 21-3 A... Input/Output Unit NG Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 79,200 (23.2) LPG (propane) 77,500 (22.7) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 74,700 (21.9) 74,700 (21.9) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 74,000 (21.7) 74,000 (21.7) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 70,300 (20.6) 70,300 (20.6) Min. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 24,600 (7.2) 40,100 (11.
Product Description ZBR 28-3 A... Input/Output ZBR 35-3 A... Unit NG LPG (propane) NG LPG (propane) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 100,800 (29.5) 98,600 (28.9) 131,900 (38.6) 129,100 (37.8) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5) 122,800 (36.0) 122,800 (36.0) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3) 121,800 (35.7) 121,800 (35.7) Max.
Product Description ZBR 42-3 A... Input/Output at elevation 0 - 2000 feet (0 - 610 m) Unit NG LPG (propane) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 151,600 (44.4) 148,300 (43.5) 137,500 (40.3) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 134,400 (39.4) 134,400 (39.4) Min. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 36,000 (10.
Product Description 3.12 Technical data ZWB...-3A ZWB 28-3 A... Input/Output ZWB 35-3 A... Unit NG LPG (propane) NG LPG (propane) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 100,800 (29.5) 98,600 (28.9) 131,900 (38.6) 129,100 (37.8) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5) 122,800 (36.0) 122,800 (36.0) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3) 121,800 (35.7) 121,800 (35.7) Max.
Product Description ZWB 42-3 A... Input/Output at elevation 0 - 2000 feet (0 - 610 m) Unit NG LPG (propane) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 151,600 (44.4) 148,300 (43.5) 137,500 (40.3) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 134,400 (39.4) 134,400 (39.
Regulations ZWB 42-3 A... Input/Output at elevation 0 - 2000 feet (0 - 610 m) Unit NG Sound pressure level dB(A) ≤ 45 ≤ 45 Max. supply temperature °F ( °C) 187 (86) 187 (86) Max. permissible operating pressure (PMS) heating Permissible ambient temperature Nominal water capacity (heating) Weight (without packaging) Dimensions, W x H x D LPG (propane) psi (bar) 30 (2.07) 30 (2.07) °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) gal (l) 0.925 (3.5) 0.925 (3.5) lbs. (kg) 110.2 (50) 110.
Regulations 4.
Examples of Installations 5 Examples of Installations 5.1 Multiple zones using zone valves with DHW 3 6 2 10 14 9 5 15 16 17 8 1 13 M 12 M 4 7 11 ϑ 18 X 6 720 806 992-03.2O Fig.
Examples of Installations CZM100 3 2 1 4 5 6 1 2 3 4 0 ≤ 24 V T0 VZ1 VZ2 VZ3 24VAC 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 120 V AC 120VAC N L PZ1 PZ2 N L N L CRC100 HC2 CRC200 HC1 ≤ 24 V PZ3 BUS BUS BUS BUS N L 1 2 1 2 1 2 1 2 1 2 10 24 V AC 120 V AC 24 V AC M 3 M 120 V AC 7 8 9 6 4 3 5 B LZ NZ 2 B 4 2 LS NS N L 9 L A 12 8 N 11 F 7 13 VF 1 14 6 720 806 992-04.2O Fig.
Examples of Installations 5.2 Multiple zones using circulators 3 2 6 9 5 8 10 14 15 16 17 1 13 12 4 7 11 ϑ 18 X 6 720 806 992-05.2O Fig.
Examples of Installations CZM100 3 2 1 4 5 6 1 2 3 4 0 ≤ 24 V T0 VZ1 VZ2 VZ3 24VAC 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 120/230 V AC 120/ 230VAC N L PZ1 N L PZ2 N L CRC100 HC3 CRC100 HC2 CRC200 HC1 ≤ 24 V PZ3 BUS BUS BUS BUS N L 1 2 1 2 1 2 1 2 6 3 120 V AC 3 5 4 7 8 9 B LZ NZ 2 B 4 2 LS NS N L 9 L A 11 8 N 10 F 7 12 VF 1 13 6 720 806 992-06.2O Fig. 12 Wiring [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] 28 PCB in heating boiler ZBR...
Notes on installation and operation 6 Notes on installation and operation 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. Recirculation pump/DHW recirculation lines Total length DHW/recirculation line ≤ 33 ft (10 m) 33 - 66 ft (10 - 20 m) 66 - 98 ft (20 - 30 m) Flow rate 0.66 gpm (2.5 l/min) 0.92 gpm (3.5 l/min) 1.
Notes on installation and operation The following anti-freeze fluids and concentrations have been approved: Chemical Name Nalco (Varidos) FSK Fernox Alphi 11 Intercool NFP-50 AA Antifrogen N NoBurst AL Concentration 22 - 55 % Observe manufacturer's instructions 0 - 39 % Observe manufacturer's instructions 0 - 55 % Table 11 Anti-freeze Corrosion inhibitors The following anti-corrosion agents are approved: Chemical Name Fernox F1 Nalco 77381 Sentinel X 100 Concentration Observe manufacturer's instructions
Notes on installation and operation 6.2 Comparing the size of the integrated expansion vessel The following diagrams allow verifying that the integrated expansion vessel has sufficient capacity for the intended application, or if an additional expansion vessel is needed (not for radiant floor heating). 6.3 Selecting an external expansion vessel (ZBR...-3A) ▶ Determine the size of the expansion vessel in compliance with local laws and regulations.
Notes on installation and operation 6.5 Pre-installing pipes ▶ Secure the installation template (supplied with the technical documentation) to the wall; observe the minimum side clearances of 4 inches (102 mm) ( page 9). ▶ Drill holes for the appliance and for the hydraulics connection plate in accordance with the mounting template. ▶ Secure the hydraulics connection plate and the mounting bracket with the mounting kits supplied. ( 17 11/18 in.
Notes on installation and operation 6.6 NOTICE Residue, metal shavings, and contaminants in the piping can damage the appliance. 1 3/8" (35 mm) 1 31/32" (50 mm) 5 1/8" (130 mm) 10 15/64" (260 mm) = Mounting the appliance = 6 720 641 933-15.1O ▶ Flush the piping thoroughly and completely to remove all residue. ▶ Follow the instructions with respect to water quality ( Chapter 6.1.1, page 29). ▶ Remove packaging, observing all notes and symbols.
Notes on installation and operation 6.7 Installing the low water cut off (LWCO) The boiler is equipped with a dedicated port for installation of a LWCO on the supply pipe inside the boiler cabinet. This location represents the minimum water level for safe operation of the boiler. ▶ Push the adapter with the LWCO onto the pipe (step 1) and secure with the clip (step 2). The LWCO device must be specified for an ambient temperature of 176 °F (80 °C) and a water temperature of 250 °F (121 °C).
Notes on installation and operation 6.8 Connecting flue gas accessories Optional vent systems are: • Twin pipe PVC / CPVC 2" / 3" • Twin pipe PP 2" (50 mm )/ 3" (80 mm) (M&G Duravent PolyPro and Centrotherm InnoFlue) • Concentric PP 3" / 5" (80/125 mm) (Bosch) ▶ Insert the flue gas adapter as far as it will go into the vent flange and align it. 3 In case of using the twin pipe adaptor: 2 The twin pipe adaptor is supplied with the boiler kit as standard and is certified as a part of the vent system.
Notes on installation and operation ▶ Install the concentric vent adaptor with the screws enclosed. Observe the listed maximum lengths of vent system, which are boiler model dependent ( chapter 6.8.3). 2 DANGER 1 Improper venting of the Greenstar boiler can result in excessive levels of carbon monoxide which can result in severe personal injury or death. 4 3 6 720 806 992-01.1O ▶ The boiler must be vented in accordance with the Venting of Equipment section of the latest edition of ANSI Z 223.
Notes on installation and operation If multiple boilers are installed in a row, allow at least 1 foot (305 mm) clearance between the vent termination of one and the combustion air intake of the other. Did not use the chimney as a conduit if the flue gases from a wallmounted gas condensing boiler or other combustion equipment are routed in or through the chimney.
Notes on installation and operation For installations in Canada, field supplied plastic vent piping must comply with CAN/CGA B149.1 (latest edition) and be certified to the Standard for Type BH Gas Venting systems. ULC S636 components of the listed system may not be combined with other venting systems or pipes/fittings that are not listed here.
Notes on installation and operation 3 X1 3 X3 X3 X2 X1 YB X2 X3 X5 X1 X4 3 YA 3 YA 1 2 6 720 641 933-17.1O Fig.
Notes on installation and operation Examples of approved horizontal and vertical venting installation NOTICE ▶ Place pipe supports every 5 ft (1525 mm) of horizontal and vertical run, beginning with support near wall-mounted gas condensing boiler. ▶ Remove condensate in accordance with applicable regulations. ▶ Regularly clean the vent terminal and safety mesh. ▶ Avoid locating vent terminal near equipment or items that could be adversely affected by flue gases.
Notes on installation and operation Y 1 2 6 720 641 933-09.2O Fig. 36 Vertical venting system (sealed combustion) X X Y Y 1 2 1 2 6 720 641 933-10.1O 6 720 641 933-07.1O Fig. 37 Vertical venting system (room air only) Fig. 38 Vertical venting system (sealed combustion) Key to Fig. 36, Fig. 37 and Fig.
Notes on installation and operation X X Y X 1/4" per foot (50 mm per meter) Y 1 6 720 641 933-78.1O Fig. 41 Horizontal venting system (telescopic concentric vent kit) 6.8.3 Vent and combustion air pipe lengths With Flex Pipe the maximum length is reduced by 50%. Flex Pipe according to the suppliers instructions for use in the vertical part of the installation only. 2 6 720 641 933-08.
Notes on installation and operation Installations Fig. 35 Stainless steel wall termination 2" PIPE Maximum straight vent pipe length allowed for Ø 2" pipe Number of 90° elbows ZBR 21-3A ZBR 35-3A used ZBR 28-3A ZWB 35-3A ZWB 28-3A ZBR 42-3A ZWB 42-3A 1 76 ft (23.1 m) 60 ft (18.3 m) 2 71 ft (21.6 m) 52 ft (15.9 m) 3 66 ft (20.1 m) 43 ft (13.1 m) 4 61 ft (18.6 m) 35 ft (10.7 m) 5 56 ft (17.1 m) 27 ft (8.2 m) 6 51 ft (15.6 m) 18 ft (5.
Electrical connection 7 Electrical connection 7.1 General notes 7.2 Low voltage electrical connections in the Heatronic boiler control 7.2.1 Open the Heatronic boiler control DANGER Risk of electric shock! ▶ Before working on the power supply (120 VAC), disconnect the boiler from the grid by shutting off the emergency shutoff switch or disengaging the heating system circuit breaker. Take measures to prevent accidental reconnection. ▶ It is not sufficient to simply shut off the controls.
Electrical connection ▶ Secure the cable with the strain relief. CRC200 BUS/ 1) BB BUS 6 720 811 153-05.1O Fig. 45 Schematic of electrical wiring of Bosch room control and boiler 1) Terminal at the boiler reads BUS or BB, both indicating connection of the 2-wired Bosch BUS system. 6 720 641 933-73.1O 7.2.3 Connecting the outdoor temperature sensor ▶ Set up WWSD according to the instruction manual of CRC200. ▶ Punch out plastic insert.
Electrical connection Connecting the supply temperature sensor (e.g. for low-loss header or system supply pipe) Do not exceed a sensor cable length of 33 feet (10 m). Connecting Third party room thermostats or zone controls A voltage free (dry contact) third party room thermostat or heat demand from a relay panel can be used to send an ON/OFF signal to the appliance. Supply temperature sensor for system supply pipe(Fig 50, [2]) must be installed in closest vicinity with boiler supply Tee.
Electrical connection 7.3 Electrical connections in the junction box (120 VAC) 7.3.1 Mounting rails for junction box ▶ Hold the rail against the appliance from below (step 1) and fasten with the screws from the outside or inside (step 2). ▶ Loosen junction box from the rail (step 3). ▶ Connect black plugs and insert grommet until stop.
Electrical connection 7.3.3 DHW tank loading pump or 3-way valve with spring return (only ZBR...-3A) The pump used must have the following connection values: 120 VAC, max. 2 A. ▶ Route cable from pump or 3-way valve to appliance. ▶ Insert cable into the junction box as shown in Fig. 57. ▶ Connect cable to the red plug according to Fig. 56. 7.3.4 Connecting mains power supply ▶ Route the power cable (AC 120 V, 60 Hz) from the emergency shutoff switch to the boiler.
Electrical connection 7.4 Connecting the LWCO device ▶ Connect the leads labeled SWITCH CONTACT (yellow) to the TB1 temperature switch ( Fig. 49, page 45) on the Heatronic. NOTICE System damage or malfunction! 1 ▶ Ensure the air box remains air-tight when routing the LWCO cable to the outside. ▶ Do not route the LWCO cable through the ignition cable grommet as appliance malfunction may occur. ▶ Push the existing cable grommet of the fan cable down through air box sheet.
Commissioning 8 Commissioning 1 3 2 5 4 6 7 8 9 eco reset 10 11 12 18 17 16 15 14 13 19 6 720 641 933-25.1O Fig. 62 Overview of the controls [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] 50 Emissions test button Service button Burner operation indicator lamp ON/OFF power switch Key pad lock ECO button Reset button Display Automatic air vent (ZWB...
Commissioning 8.1 Before operating the appliance 8.3 Set the maximum supply temperature based on the structure's heat loss on design day. NOTICE Commissioning without being properly filled and purged will damage the appliance. ▶ Only operate this appliance after ensuring there is sufficient water in the boiler and the system. ▶ Adjust the expansion vessel pre-charge pressure to the static head of the heating system ( page 31). ▶ Open radiator and zone valves (as applicable).
Commissioning 8.4 Programming the Bosch Room Controller 8.6 ▶ Set the DHW temperature on the DHW thermostat . The set DHW temperature flashes on the display for 30 seconds. Observe the operating instructions for the Bosch room controller included in the scope of delivery. There you can read: ▶ ▶ ▶ ▶ ZBR...
Commissioning 8.7 ZWB...-3A appliances (combi boilers): Setting the DHW temperature ▶ Set the DHW temperature on the DHW thermostat . The set DHW temperature flashes on the display for 30 seconds. NOTICE Heating system at risk of freezing. In manual summer mode, only the appliance is protected from freezing. ▶ Observe frost protection measures where there is a risk of frost ( chapter 8.9). reset eco 3 2 1 4 3 4 e 2 5 1 6 ▶ Note the supply temperature controller setting .
ZBR...-3A appliances (heating boiler) with DHW tank: Thermal disinfection 8.10 Activating the key pad lock The key pad lock affects the boiler high limit dial, the DHW thermostat, and all buttons except the ON/OFF switch, emissions test button, and reset button. It can be used to limit unauthorized access to the boiler. 10 Boiler circulator 10.
Heatronic boiler control settings 25 H / ft 20 11 Heatronic boiler control settings 11.1 Guideline to service functions The Heatronic allows easy setting and testing of many appliance functions. For an overview of service functions, see Chapter 11.2 on page 56. 4 15 3 10 reset 2 1 3 5 3 2 1 2 1 0 3 4 2 5 6 max 0 1 2 3 4 5 6 . V / gpm 7 4 3 3 2 2 0 400 800 .
Heatronic boiler control settings 11.2 Overview of the service functions 11.2.1 First service level (press and hold the service button until it lights up) Service function Display Page 11.2.2 Second service level (at first service level, service button lights up, press ECO button and key pad lock button simultaneously until 8.A appears) Service function 1.A Maximum space heating output 56 Display 1.b Maximum DHW output 57 8.A Software version Page 60 1.
Heatronic boiler control settings Service function 1.b: Maximum DHW output The hot water output can be adjusted between the minimum and maximum DHW outputs to suit the heat transfer capacity of the DHW tank coil. Service function 2.A: Heating circuit pump lockout time (only heating boiler ZBR...-3A) ▶ Select service function 1.b. ▶ Select the DHW output in MBH (kW) and determine the associated setting in percent (%). ▶ Enter the setting ( 11.1). ▶ Save the setting ( 11.1).
Heatronic boiler control settings The following settings are available: • 00: Thermal disinfection not enabled • 01: Thermal disinfection enabled Service function 3.b: Set anti-cycle time Only if the automatic anti-cycle time is disabled (service function 3.A) will this function be active. Default setting is 00 (disabled). Service function 2.F: Operating mode With this service function, you can temporarily change the appliance's operating mode.
Heatronic boiler control settings Service function 3.F: Constant DHW period (only combi boiler ZWB...-3A) NOTICE Service function 4.F: Condensate trap filling sequence DANGER Risk of flue gas poisoning. System damage or boiler malfunction! If the condensate trap is not filled, flue gas may escape from the dry trap. ▶ Never change the setting of this service function on heating boiler ZBR...-3A appliances. ▶ Only deactivate the trap filling sequence for servicing purposes.
Heatronic boiler control settings Service function 6.A: Display the latest fault code Use this service function to display the most recent fault code. Service function 6.b: Room temperature control, current voltage, terminal 2 The current voltage of the analog control at terminal 2 is displayed. Available displays are: • 00 - 24: 0 V to 24 V in increments of 1 V Service function 7.E: Building drying function This service function allows you to start and stop the building drying function.
Heatronic boiler control settings Service function 8.b: Code plug number The last four digits of the code plug number are shown. The code plug determines the appliance functions. If the appliance has been converted from natural gas to LPG (or vice versa), the code plug must be replaced. Service function 9.C: Current boiler output This service function displays the current boiler output (in percent (%)). Service function 9.
Gas adjustment 12 Gas adjustment 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.
Gas adjustment ▶ Measure the CO2 or O2 level and the CO content of the flue gas ( Section 13). ▶ On the gas throttle, break the seal at the slot and remove the cap. 2 . ▶ Remove screw ( Fig. 79, [3]) from the gas valve adjustment screw ( Fig. 79, [2]) and set CO2 or O2 value for minimum nominal output. 3 1 . 2 1 6 720 641 933-81.1O 6 7 2 0 6 1 2 6 5 9 -3 7 .1 R Fig.
Flue gas test 12.4 Dynamic gas pressure test port ▶ Switch the appliance OFF and close the gas shut-off valve. ▶ Loosen the screw in the test port for gas inlet pressure ( Fig. 52, [1]) and connect a pressure gauge ( Fig. 81). 13 Flue gas test 13.1 Emissions test button The following appliance outputs can be selected by pressing the emissions test button until it lights up: reset eco 3 2 1 4 3 5 4 e 2 6 6 1 max min max 6 720 614 090-34.2O 6 720 641 933-51.1O Fig.
Environmental protection and disposal 14 Environmental protection and disposal Heatronic boiler control In case of a component defect, a fault is shown on the display. Environmental protection is one of the fundamental company policies of the Bosch Group. Quality of products, efficiency and environmental protection are equally important objectives for us. Environmental protection laws and regulations are strictly adhered to.
Inspection and maintenance 15.1 Description of various steps ▶ Loosen/remove pipe connections. 15.1.1 Calling up the latest fault (service function 6.A) ▶ Select service function 6A (page 60). An overview of the faults can be found on page 74. 15.1.2 Fresh water filter (only combi boiler ZWB...-3A) ▶ Close cold water tap. ▶ Depressurize the cold water pipe. ▶ To access the filter remove the safety clip (step 1), pull out the pipe (step 2), and remove the filter from the pipe (step 3).
Inspection and maintenance 15.1.5 Burner servicing DANGER Fire danger! ▶ The burner may be operated only while installed in a wall-mounted gas condensing boiler. ▶ Remove burner lid (steps 1 - 4). 0010032724-001 Fig. 88 Removing the plate heat exchanger 4 ▶ Install new plate type heat exchanger with new gaskets and reconnect the hydraulic assembly in reverse order. ▶ Check all connections used during maintenance for leaks. 15.1.
Inspection and maintenance 15.1.6 Heat exchanger block inspection and cleaning NOTICE ▶ With the cleaning blade, clean the heat exchanger block from the bottom to the top. Damage to the coating of the heat exchanger. ▶ Cleaning of the heat exchanger should not be necessary until five years after the initial commissioning. ▶ Only use a Bosch cleaning blade and Bosch cleaning brush. ▶ Only clean heat exchanger when visibly dirty.
Inspection and maintenance 15.1.7 Cleaning condensate trap ▶ Remove condensate trap (steps 1 and 2) and check heat exchanger orifice for clear passage. ▶ Rinse the heat exchanger with water from the top. 2 1 6 720 612 664-18.1R 2 Fig. 96 Rinsing the heat exchanger ▶ Clean the condensate tray (with reversed brush). 6 720 641 933-93.1o Fig. 98 Removing the condensate trap ▶ Remove and clean the condensate trap lid. ▶ Check condensate hose and clean if necessary.
Inspection and maintenance 15.1.9 Checking the expansion vessel Annual inspection of the expansion vessel is required. ▶ Depressurize the appliance. ▶ If necessary, adjust the expansion vessel pre-charge pressure to the static head of the heating system. 15.1.10 Setting the boiler water pressure Display on the pressure gauge 14.5 psi (1 bar) Minimum filling pressure (when system is cold) 14.5 psi to Optimal filling pressure 21.75 psi (1 bar to 1.5 bar) 30 psi (2.
Inspection and maintenance 15.2 Maintenance and inspection checklist ▶ Use this form to guide you through the service and maintenance procedure. Fill out each step according to the findings and work performed. Date 1 Latest fault code from service function 6.A. 2 Fresh water inlet filter (Combi boiler ZWB appliances only). 3 Visual inspection of the combustion air pipes and vent pipes. 4 Dynamic gas pressure 5 Gas-air ratio at min./max. nominal output. 6 Gas and water-side leak test.
Readings on the display 16 Readings on the display The 7-segment display shows the following: Value displayed Description Number or letter, dot Servicefunction followed by letter ( Tab. 26/ 27, page 56/ 56) Letter followed by Fault code number or letter (Tab. 36, page 74) (exception: b.A = service function) Three numbers Decimal value, e.g.
Faults 17 Faults 17.1 Troubleshooting ▶ Switch the appliance OFF and ON again. The appliance starts up again and the current supply temperature is displayed. 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. An overview of the faults can be found on page 74. An overview of the status codes can be found on page 72. DANGER Risk of flue gas poisoning. ▶ Check for leaks after carrying out work on the venting system.
Faults 17.2 Faults that are shown on the display Display A7 Description DHW temperature sensor defective. A8 Communication fault. Ad DHW tank temperature not detected. The DHW tank temperature sensor was recognized before the connection was lost. b1 Code plug not detected. b2/b3/b4/ Internal data error. b5/b6 b7 Fault in the burner controls. C6 Fan not running. CC Outdoor temperature sensor not recognized.
Faults Display EA Description No flame detected. F0 GFA: Safety time expired. Internal fault Elimination ▶ Check that ground lead is properly connected, replace if defective. ▶ Check that gas cock is open. ▶ Check inlet gas pressure; correct if needed. ▶ Check power supply. ▶ Check electrodes for visual damage; replace if defective. ▶ Check flue gas system; clean or repair if defective. ▶ Check gas/air ratio; correct if out of range. ▶ Check gas valve; replace if defective.
Faults 17.3 Faults that are not shown on the display Appliance faults Combustion noise too loud; rumbling noises Flow noises Heating-up takes too long Flue gas readings incorrect; CO levels too high Violent ignition, poor ignition DHW has unpleasant odor or has a dark color Set supply temperature exceeded Condensate in air box DHW temperature is not reached (combi boiler ZWB...-3A only) Heatronic is flashing (i.e. all buttons, all display segments, burner indicator etc.
Faults 17.4 Check sensor values 17.4.3 Supply temperature sensor, External supply temperature sensor, DHW tank temperature sensor, DHW temperature sensor 17.4.1 Outdoor temperature sensor Temperature °F ( °C ) Testing tolerance ± 10% – 4 ( – 20) 3 ( – 16) 10 ( – 12) 17 ( – 8) 24 ( – 4) 32 (0) 39 (4) 46 (8) 50 (10) 59 (15) 68 (20) 77 (25) Resistance [ ] 2,392 2,088 1,811 1,562 1,342 1,149 984 842 781 642 528 436 Table 38 Resistance table outdoor temperature sensor 17.4.
Commissioning log for the appliance 18 Commissioning log for the appliance Home owner/operator: Last name, first name Number, Street Telephone/fax ZIP code, town System installer: Order number: Appliance type: (Complete a separate log for every appliance!) Serial number: Date commissioned: Individual appliance | Cascade, Number of appliances: ...... Installation location: Cellar | Attic | Other: ft2 (m2) Ventilation openings: Number: ......, Size: Approx.
Commissioning log for the appliance System hydraulics checked, notes: Modified service functions: Select the modified service functions and enter the values here. Heating control: Weather-compensated control Room temperature-dependent control Remote control × ...... Qty, heating zone(s) coding: Room temperature-dependent control × ...... Qty, heating zone(s) coding: Module × ......
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