WARNING: Improper installation, set-up, modification, operation or maintenance of the heating system can cause personal injury and property damage. Follow these instructions precisely. If you require assistance or further information, contact a trained and certified installer or the gas supply company. WARNING: The operating instructions are part of the technical documents that must be handed over to the owner or operator of the heating system.
| Contents 5.8.1 Installation of the exhaust and air intake system . . . . . 5.8.2 Approved examples of horizontal and vertical venting installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.3 Vent and combustion air pipe lengths . . . . . . . . . . . . . . 5.9 Testing gas and water connections for leaks . . . . . . . . Contents 1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . .
Key to symbols and safety instructions | 3 10.3 Description of the service functions . . . . . . . . . . . . . . . 53 10.3.1 First service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 10.3.2 Second service level . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 17 Commissioning log for the appliance . . . . . . . . . . . . . . . . . . . 75 18 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 11 Gas type conversion . . . . . . .
| Key to symbols and safety instructions If you smell gas ▶ Turn off the gas shut-off valve. ▶ Open windows and doors ▶ Do not touch any electrical switch, telephone, and do not use outlets. ▶ Extinguish all open flames. ▶ Do not smoke! ▶ Do not use lighters! ▶ Warn all occupants of the building that they need to leave the building. ▶ Do not ring doorbells! ▶ Notify the police and fire department from outside the building.
Scope of delivery | 5 2 Scope of delivery 2.
| Scope of delivery 2.
Information about the appliance | 7 3 3.3 Information about the appliance Rating plate The rating plate is located at the right side of the appliance. ZBR appliances are residential boilers for central heating and loading of an indirect fired DHW tank. ZWB 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.
| Information about the appliance 3.5 Accessories Here you will find a list of typical accessories for this appliance. Refer to the Bosch Product Catalog for a complete overview of all available accessories.
Information about the appliance | 9 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 6 720 641 933-01.2O Fig.
| Information about the appliance 3.7 Appliance layout heating boiler ZBR..-3A 27 28 26 25 29 24 23 22 21 20 30 31 32 19 18 33 17 16 34 35 15 14 36 13 37 38 39 40 1 12 11 10 9 2 3 4 5 41 min 6 7 8 6 720 641 933-02.2O Fig. 5 Appliance layout heating boiler ZBR..
Information about the appliance | 11 Key to Fig.
| Information about the appliance 3.8 Appliance layout combi boiler ZWB..-3A 29 30 28 27 26 31 25 24 23 32 33 22 34 21 35 20 19 36 18 37 17 16 38 15 39 40 41 42 43 44 14 13 1 12 11 10 9 2 3 4 5 45 min 6 7 8 6 720 641 933-03.2O Fig. 6 Appliance layout combi boiler ZWB..
Information about the appliance | 13 Key to Fig.
| Information about the appliance 3.9 Electrical wiring heating boiler ZBR..-3A 19 20 18 16 6 21 17 23 15 9 22 8 5 5 6 7 24 3 4 4 LP NP 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 12 6 720 641 933-23.2O Electrical wiring diagram heating boiler ZBR..
Information about the appliance | 15 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) 2) 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.
| Information about the appliance 3.10 Electrical wiring combi boiler ZWB..-3A 18 19 17 15 6 20 16 22 21 23 14 9 24 8 4 3 4 5 6 7 25 LP NP 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 11 6 720 641 933-24.2O Electrical wiring diagram combi boiler ZWB..
Information about the appliance | 17 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) 1) 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.
| Information about the appliance 3.11 Technical data heating boiler ZBR16-3A... Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 °F (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min. output rate 176/140 °F (80/60 °C) Gas connection value Natural Gas – Hs = 1,010 BTU/ft3 (37.
Information about the appliance | 19 3.12 Technical data heating boiler ZBR21-3A... Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 °F (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min. output rate 176/140 °F (80/60 °C) Gas connection value Natural Gas – Hs = 1,010 BTU/ft3 (37.
| Information about the appliance 3.13 Technical data heating boiler ZBR28-3A... Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 °F (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min. output rate 176/140 °F (80/60 °C) Gas connection value Natural Gas – Hs = 1,010 BTU/ft3 (37.
Information about the appliance | 21 3.14 Technical data heating boiler ZBR35-3A... Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 °F (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min. output rate 176/140 °F (80/60 °C) Gas connection value Natural Gas – Hs = 1,010 BTU/ft3 (37.
| Information about the appliance 3.15 Technical data heating boiler ZBR42-3A... Input/Output at elevation 0 - 2000 feet (0 - 610 m) Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 °F (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min.
Information about the appliance | 23 3.16 Technical data combi boiler ZWB28-3A... Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Output rate domestic hot water (DHW), 113 °F (45 °C) Output rate domestic hot water (DHW), 140 °F (60 °C) Min. input rate 180/79 °F (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min.
| Information about the appliance 3.17 Technical data combi boiler ZWB35-3A... Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Output rate domestic hot water (DHW), 113 °F (45 °C) Output rate domestic hot water (DHW), 140 °F (60 °C) Min. input rate 180/79 °F (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min.
Information about the appliance | 25 3.18 Technical data combi boiler ZWB42-3A... Input/Output at elevation 0 - 2000 feet (0 - 610 m) Unit Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) Output rate domestic hot water (DHW), 113 °F (45 °C) BTU/hr (kW) Output rate domestic hot water (DHW), 140 °F (60 °C) BTU/hr (kW) Min.
| Regulations Input/Output at elevation 0 - 2000 feet (0 - 610 m) Condensate Max. condensate quantity (tR = 86 °F (30 °C)) pH level, approx. General Voltage Frequency Max. power consumption (central heating mode) Max. power consumption (Stand-by) Sound pressure level Max. supply temperature Max. permissible operating pressure (PMS) heating Permissible ambient temperature Nominal water capacity (heating) Weight (without packaging) Unit NG LPG (propane) gph (l/h) – 0.9 (3.5) 4.8 0.9 (3.5) 4.
Regulations | 27 4.
| Installation Recirculation pump/DHW recirculation lines 5 Installation 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. Installation, power connection, connection on the gas and flue gas side and commissioning must only be carried out by a contractor certified for such work by the state or local jurisdiction or the local gas or power utility. 5.
Installation | 29 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 % • Inspect the sewer pipes for suitability before disposing of untreated boiler condensate into them.
| Installation 5.3 ZBR..-3A appliances (heating boilers): Selecting an expansion vessel External expansion vessel ▶ Determine size of the expansion vessel. Surface temperature The max. surface temperature of this appliance is below 185 °F (85 °C). According to ANSI/Z223.1/NFPA43 (National fuel gas code) and CAN/ DAS B 149.1 (Natural Gas and Propane installation code), the appliance is approved for zero clearance to combustibles. For servicing a clearance of 4" (102 mm) is recommended. 5.
Installation | 31 ▶ Secure the hydraulics connection plate and the mounting bracket with the mounting kits supplied. 1 3/8" (35 mm) 1 31/32" (50 mm) 5 1/8" (130 mm) 10 15/64" (260 mm) = = 6 720 641 933-15.1O Fig. 15 Hydraulics connection plate for heating boiler ZBR..-3A (top view) 1 3/16" (30 mm) 7 7/8" (200 mm) = 1 2 = 3 4 5 6 720 641 933-90.1O Fig. 16 Hydraulics connection plate for combi boiler ZWB..-3A (front view) 6 720 641 933-30.1O Fig.
| Installation 5.6 Mounting the appliance 5.7 NOTICE: Residue, metal shavings, and contaminants in the piping can damage the appliance. ▶ Flush the piping thoroughly and completely to remove all residue. ▶ Follow the instructions with respect to water quality ( Chapter 5.1, page 28). ▶ Remove packaging, observing all notes and symbols. ▶ On the rating plate, check the identification of the target country and suitability for the gas type supplied by the local gas utility company ( page 10).
Installation | 33 ▶ Screw the LWCO as far as possible into LWCO adapter located in the boiler accessory kit. Follow the Hydrolevel Safgard 1100 instructions. In case of using the twin pipe adaptor: The twin pipe adaptor is supplied with the boiler kit as standard. ▶ Install the vent flange and gasket with the screws enclosed. 3 6 720 641 933-64.1O Fig. 20 Installing a LWCO device - LWCO adapter 2 ▶ Push the adapter with the LWCO onto the pipe (step 1) and secure with the clip (step 2).
| Installation 5.8.1 Installation of the exhaust and air intake system To avoid premature wear of the gaskets DO NOT use lubricants. NOTICE: ▶ Vent connectors serving appliances vented by natural draft shall not be connected to any portion of mechanical draft systems operating under positive pressure. In case of open venting: ▶ Use basket on the air intake.
Installation | 35 Direct vent installations (sealed combustion) For direct vent applications all applicable items below must be met. Vent termination must be at least 1 foot (305 mm) above grade, anticipated snow line or roof surface (Canada 1-1/2 feet (457 mm) minimum) ( fig. 27 [YA], page 37). Vent termination must be at least 7 feet (2135 mm) above a public walkway ( fig. 27 [X5], page 37). Ensure that condensate spilling from the termination does not create a hazard or a nuisance.
| Installation Roof terminals Ø 3" / Ø 5" (Ø 76/125 mm) Ø 3" / Ø 5" (Ø 76/125 mm) Ø 3" / Ø 5" (Ø 80/125 mm) Material concentric PVC concentric CPVC concentric PP Supplier IPEX System 636 IPEX System 636 Duravent Part number 196006 197009 3PPS-VK Table 18 Roof terminals Wall terminals Ø 3" (Ø 76 mm) 90 °-elbow with inlet screen Ø 3" (Ø 76 mm) twin pipe termination Ø 3" (Ø 76 mm) single pipe termination Ø 3" / Ø 5" (Ø 80/125 mm) Bosch Greenstar Horizontal Telescopic Terminal Kit Flue System / Materia
Installation | 37 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.
| Installation NOTICE: ▶ Place pipe supports every 5 feet (1 525 mm) of horizontal and vertical run, beginning with support near boiler. ▶ The condensate must be disposed of in accordance with applicable rules. ▶ Periodic cleaning of the vent terminal and air-intake screens is mandatory. ▶ Avoid locating vent terminals near equipment or building features which can be subject to degradation from exhaust gases.
Installation | 39 Y 1 2 6 720 641 933-09.2O Fig. 32 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. 33 Vertical venting system (room air only) Fig. 34 Vertical venting system (sealed combustion) Key to Fig. 32, Fig. 33 and Fig.
| Installation X X Y X Y 1 Installations Fig. 28, 29, 30, 32, 33 and 35 Separate terminations 2" PIPE Maximum straight vent pipe length allowed for Ø 2" pipe ZBR16-3A ZBR35-3A ZBR21-3A ZWB35-3A ZBR28-3A ZBR42-3A Number of 90 ° ZWB28-3A ZWB42-3A elbows used 1 81 ft (24.6 m) 65 ft (19.8 m) 2 76 ft (23.1 m) 57 ft (17.3 m) 3 71 ft (21.6 m) 48 ft (14.6 m) 4 66 ft (20.1 m) 40 ft (12.2 m) 5 61 ft (18.6 m) 32 ft (9.8 m) 6 56 ft (17.1 m) 23 ft (7.
Making the electrical connections | 41 Ø 3" / Ø 5" (Ø 80/125 mm) Concentric venting system The maximum concentric pipe length ( tab. 23) depends on the installation situation, the appliance type and the number of elbows used. Installations Fig. 36 Ø 3" / Ø 5" (Ø 80/125 mm) CONCENTRIC PIPE Maximum straight vent pipe length allowed for Ø 3" / Ø 5" (Ø 80/125 mm) concentric pipe ZBR16-3A ZBR35-3A ZBR21-3A ZWB35-3A ZBR28-3A ZBR42-3A Number of 90 ° ZWB28-3A ZWB42-3A elbows used 1 50 ft (15.2 m) 44 ft (13.
| Making the electrical connections 6.2 Low voltage electrical connections in the Heatronic boiler control 6.2.1 Open the Heatronic boiler control ▶ Secure the cable with the strain relief. F A NOTICE: Small pieces of wire can cause shorts and damage the electronics. ▶ Always strip cables away from electronics. ▶ Unhook the clip (step 1) and fold the Heatronic down (step 2). 1 6 720 641 933-35.1O Fig. 39 Electrical wiring outdoor temperature sensor 6.2.
Making the electrical connections | 43 6.2.4 Connecting additional accessories Connecting the supply temperature sensor (e.g. for low-loss header or system supply pipe) ▶ For splash-proof (IP) strain relief, cut the grommet to match the diameter of the cable. Do not exceed a sensor cable length of 33 feet (10 m). Supply temperature sensor for system supply pipe ( Fig. 43 [2]) must be installed in closest vicinity with boiler supply Tee. 3 4 6 720 641 933-91.1o Fig.
| Making the electrical connections 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. B LP NP Without accessories the appliance offers the connection of one heating zone pump, one circulator of an unmixed heating circuit, or one DHW recirculation pump. The pump used must have the following connection values: 120 VAC, max. 2 A.
Making the electrical connections | 45 6.3.3 DHW tank loading pump or 3-way valve with spring return (only heating boiler 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. 50. ▶ Connect cable to the red plug according to Fig. 49. 6.3.4 Connecting mains power supply ▶ Route the power cable (AC 120 V, 60 Hz) from the emergency shutoff switch to the boiler.
| Making the electrical connections 6.4 Connecting the LWCO device ▶ Connect the leads labeled SWITCH CONTACT (yellow) to the TB1 temperature guard ( Fig 42, page 43) on the Heatronic. NOTICE: System damage or malfunction! ▶ 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.
Commissioning | 47 7 Commissioning 1 3 2 5 4 6 7 9 8 eco reset 10 11 12 18 17 16 15 14 13 19 6 720 641 933-25.1O Fig. 55 Overview of the controls [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] 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 7.2 Switching the appliance ON/OFF With radiant floor heating, limit the maximum permissible supply temperature as recommended by the manufacturer. Startup ▶ Switch the appliance ON using the ON/OFF switch. The display indicates the supply temperature of the hot water in °F. If necessary, convert to °C ( Service function 0.E: Metric or US customary units, page 57) ▶ In order to set the maximum supply temperature, turn the boiler high limit dial .
Commissioning | 49 7.6 ZBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature ▶ Set the DHW temperature on the DHW thermostat . The set DHW temperature flashes on the display for 30 seconds. 3 2 1 4 3 2 5 6 max 1 7.7 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.
| ZBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection ▶ Turn the boiler high limit dial counterclockwise to . reset reset eco eco 4 3 3 5 2 1 e 2 min max 3 6 1 6 4 5 1 max e 2 6 1 6 max max min 6 720 615 065-13.1O 6 720 615 065-17.1O Fig. 61 Summer mode Fig. 64 Key pad lock For further information, see the operating instructions for the heating control included in the scope of delivery. Unlocking the key pad: 7.
Boiler circulator | 51 9 Boiler circulator 9.1 Pump anti-seize protection 25 20 H / ft This function prevents the heating zone pump from seizing up following longer idle periods. The appliance will briefly run the pump at least every 24 hours after its last activation. 4 15 10 3 5 9.2 Changing the pump curve of the boiler pump 2 1 The speed of the boiler pump can be changed using the dial on the pump. 0 0 1 2 25 3 4 5 6 .
| Heatronic boiler control settings 10 ▶ Press and hold the service button until it illuminates. The display shows a code such as 1.A (first service level). Press the ECO button and key pad lock button simultaneously until the code 8.A appears (second service level). ▶ On the second service level, select the service function 8.E and value 00. The appliance restarts with the default settings. Heatronic boiler control settings 10.
Heatronic boiler control settings | 53 10.2.2 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 Display 8.A Software version 8.b Code plug number 8.C GFA Gas burner control status 8.d GFA Gas burner control fault 8.E Restore boiler to factory settings 8.F Permanent ignition 9.A Constant mode 9.b Current fan speed 9.C Current boiler output 9.d Set fan start speed 9.E Turbine signal delay 9.
| Heatronic boiler control settings Service function 2.A: Heating circuit pump lockout time (only heating boiler ZBR..-3A) NOTICE: System damage or boiler malfunction! ▶ Never change the setting of this service function on combi boiler ZWB..-3A appliances. This setting is only active if Service function 1. F: Pump mode is set to 01 (3-way valve). Service function 2.d: Thermal disinfection (legionella protection) WARNING: Risk of scalding! Hot water can result in severe scalding.
Heatronic boiler control settings | 55 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. If an outdoor reset control is connected, there is no need to adjust this setting on the appliance. The control automatically optimizes the anti-cycle time. The anti-cycle time can be set from 00 to 15 (0 to 15 minutes). With 00, the anti-cycle lock is switched off.
| Heatronic boiler control settings Service function 4.F: Condensate trap filling sequence DANGER: Risk of flue gas poisoning! If the condensate trap is not filled, flue gas may escape from the dry trap. ▶ Only deactivate the trap filling sequence for servicing purposes. ▶ When servicing is complete, reactivate the trap filling function. Service function 5.
Heatronic boiler control settings | 57 Service function 7.b: 3-way valve in center position Service function 0.d: Altitude adjustment After the value 01 has been saved, the 3-way valve moves to the center position. This allows draining the system completely and removing the motor easily. Input and output rates are reduced at higher altitudes due to thin air with reduced oxygen levels. When you exit this service function, the appliance returns to setting 00. Service function 7.
| Heatronic boiler control settings Service function 8.E: Restore boiler to factory settings This function allows resetting all parameters of the boiler including all service functions to their factory settings. ▶ Press and hold the service button until it illuminates. The display shows a code such as 1.A (first service level). ▶ Press and hold ECO button and key pad lock button simultaneously until a service function, e.g. 8.A, is displayed (second service level).
Gas type conversion | 59 11 Gas type conversion 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 type conversion 11.3 Setting the gas-air ratio (CO2 or O2) ▶ Adjust the gas throttle to match the CO2 or O2 level for maximum nominal output according to table 31. ▶ Switch the appliance OFF using the ON/OFF switch. ▶ Remove the cover ( page 32). ▶ Switch the appliance ON using the ON/OFF switch. ▶ Open one of the flue gas test ports. 6 7 2 0 6 1 2 6 5 9 -3 8 .1 R Fig. 73 Set CO2 or O2 level for maximum nominal output Gas type NG LPG (propane) Maximum nominal output CO2 O2 9.4 % 4.0 % 11.
Gas type conversion | 61 ▶ Remove flue gas probe and close the flue gas test port properly. 11.4 Dynamic gas pressure test ▶ Switch the appliance OFF and close the gas shut-off valve. ▶ Loosen the screw in the test port for gas inlet pressure ( Fig. 74, [1]) and connect a pressure gauge ( Fig. 76). 6 720 614 090-34.2O Fig. 76 Dynamic gas pressure test port 6 720 641 933-80.1O Fig. 75 Close flue gas test ports ▶ Turn on the gas cock and switch the appliance ON.
| Flue gas test 12 Flue gas test 13 12.1 Emissions test button The following appliance outputs can be selected by pressing the emissions test button until it lights up: 3 4 2 1 3 5 6 max Packaging eco All packaging materials used are environmentally-friendly and recyclable. Old appliances e 6 1 min 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.
Inspection and maintenance | 63 Heat exchanger NOTICE: 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 or Bosch cleaning brush ( page 92). ▶ Only clean heat exchanger if soiling is clearly visible. 14.1.2 Fresh water filter (only combi boiler ZWB..-3A) ▶ Close cold water tap. ▶ Depressurize the cold water pipe.
| Inspection and maintenance ▶ Loosen/remove pipe connections. ▶ Remove the plate type heat exchanger. 6 720 641 933-50.2O Fig. 83 Removing the plate heat exchanger ▶ 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. 6 720 641 933-47.2O Fig. 80 Removing pipe connections ▶ Remove the boiler pressure gauge from the Heatronic boiler control. 14.1.
Inspection and maintenance | 65 14.1.5 Burner servicing 14.1.6 Heat exchanger block inspection and cleaning DANGER: Fire danger! ▶ Only operate the burner while installed in a boiler. ▶ Remove burner lid (steps 1 - 4). 4 2 NOTICE: 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 ( page 92).
| Inspection and maintenance ▶ With the cleaning blade, clean the heat exchanger block from the bottom to the top. ▶ Rinse the heat exchanger with water from the top. 2 6 720 612 664-18.1R Fig. 91 Rinsing the heat exchanger ▶ Clean the condensate tray (with reversed brush). 6 720 641 933-71.1O Fig. 89 Cleaning the heat exchanger with the cleaning blade ▶ Clean the heat exchanger block with the brush from top to bottom. 6 720 610 332-75.2R Fig.
Inspection and maintenance | 67 14.1.7 Condensate trap cleaning ▶ Remove condensate trap (steps 1 and 2) and check heat exchanger orifice for clear passage. ▶ Insert the diaphragm into the fan connector. Ensure the diaphragm is oriented properly. The diaphragm flaps must open upwards. ▶ Close the mixer unit. 14.1.9 Expansion vessel 1 Annual inspection of the expansion vessel is required. ▶ Depressurize the appliance.
| Inspection and maintenance 14.2 Checklist for inspection and maintenance ▶ 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 ( page 63). 2 Fresh water inlet filter (Combi boiler ZWB appliances only) ( page 63). 3 Visual inspection of the combustion air pipes and vent pipes. 4 Dynamic gas pressure ( page 61). inches W.C.
Readings on the display | 69 15 Status code Description Acknowledge by pressing any button (except reset). Readings on the display The boiler display can provide the following information (Tab.
| Faults 16 If the fault persists: ▶ Check the PCB and replace if required. Adjust the service functions in accordance with the commissioning report ( page 75). Faults 16.1 Troubleshooting 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. DANGER: Risk of flue gas poisoning. ▶ Check for leaks after carrying out work on the venting system.
Faults | 71 16.2 Faults that are shown on the display Display A7 A8 Ad b1 b2/b3/b4/ b5/b6 b7 C6 CC d3 Description DHW temperature sensor defective. Elimination ▶ Check temperature sensor and leads for interruptions or shorts, and replace if defective. ▶ Insert code plug correctly; replace if defective. Communication fault. ▶ Check BUS communications wiring, replace if defective. ▶ Check control, replace if defective. DHW tank temperature not detected.
| Faults Display EA Description No flame detected. F0 GFA: Safety time expired. Internal fault F1 F7 Internal data error. Flame detected even when burner is off. FA After switching gas off: Flame is detected. Fd Reset button pressed by mistake. Temperature gradient limiter: Temperature rise too fast 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.
Faults | 73 16.3 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 (e.g. of the FW200 control) 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 16.4 Check sensor values 16.4.1 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 40 Resistance table outdoor temperature sensor 16.4.
Commissioning log for the appliance | 75 17 Commissioning log for the appliance Home owner/operator: Last name, first name Number, Street Telephone/fax ZIP code, town System installer: Order number: (Complete a separate log for every appliance!) Appliance type: FD (Date of manufacture): Date commissioned: Individual appliance Installation location: Basement | Attic | Garage | other: ft2 (m2) Room air only: Number and size of ventilation openings Vent pipe routing: Twin pipe system |
| Commissioning log for the appliance Modified service functions: (Select the modified service functions and enter the values here.) Example: Service function 7.d changed from 00 to 01 Heating control: FW 200 FB 100 × ...... Qty, coding heating zone(s): ISM 2 IPM 2 × ......
Spare parts | 77 18 Spare parts ZWB28-3A ZWB35-3A ZWB42-3A ZBR35-3A ZBR28-3A ZBR21-3A ZBR16-3A Designation Group 1 - Sheet metal Group 2 - Burner/Heat exchanger Group 3 - Gas valve Group 4 - Pipes combi boiler ZWB..-3A Group 5 - Pipes heating boiler ZBR..-3A Group 6 - Control box Group 7 - Hydraulic block combi boiler ZWB..
| Spare parts 6 720 641 933-102.2O Fig.
ZWB35-3A ZWB42-3A ZBR35-3A ZBR28-3A ZBR21-3A ZWB28-3A 23 Designation Outer jacket complete Front cover Screw M5X22 (10x) Trade mark badge Expansion vessel Washer 18.6 X 13.5 X 1.
| Spare parts 19 21 20 17 20 18 15 16 14 13 4 9 14 16 19 22 23 1 12 8 11 5 7 6 22 10 9 23 4 3 2 6 720 641 933-103.3O Fig.
ZBR28-3A ZBR35-3A ZBR42-3A ZWB28-3A ZWB35-3A ZWB42-3A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Designation Heat exchanger block (incl. set of gaskets) incl.
| Spare parts 1 2 16 20 13 17 14 15 3 16 18 21 19 12 19 11 9 19 10 4 9 29 29 9 7 8 6 720 641 933-104.1o Fig.
ZWB42-3A ZWB28-3A ZBR42-3A ZBR35-3A ZWB35-3A 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 29 ZBR28-3A 4 Designation Fan RG130 USA Diaphragm Air limiter Air limiter Gas valve USA, incl. 9 Washer 18.3x24.3 (item 4) and Port screw (item 29). Gas pipe below USA Fibre gasket 25x30x1.5 (10x) Washer 18.3x24.
| Spare parts 28 11 12 29 9 7 24 12 11 5 13 10 8 10 6 6 23 22 25 11 14 16 11 3 15 18 21 1 27 26 27 20 17 15 2 19 7 20 7 4 6 720 641 933-105.1o Fig. 98 Group 4 - Pipes combi boiler ZWB..
ZWB28-3A ZWB35-3A ZWB42-3A ZBR42-3A ZBR35-3A ZBR28-3A Designation Condensate trap complete Cup incl. gasket Drain hose Drain Tee Expansion vessel connecting pipe complete Safety clip 10mm (10x) Gasket 18.6 X 13.5 X 1.5 (10x) O-ring 12.5x3 WRAS / KTW (10x) Supply pipe USA ZWB - combi boiler Gasket 18.5x24.3 (10x) O-ring 17x4 (10x) Safety clip (10x) Upper heating return pipe complete Lower heating return pipe complete Fibre gasket 23.9 X 17.2 X 1.
| Spare parts 26 25 30 28 29 19 9 9 20 22 18 21 9 9 8 16 15 13 9 9 17 14 12 11 12 23 10 1 24 9 3 6 2 7 5 4 6 720 641 933-106.2O Fig. 99 Group 5 - Pipes heating boiler ZBR..
ZWB42-3A ZBR42-3A ZWB35-3A ZBR35-3A ZWB28-3A ZBR28-3A Designation Condensate trap complete Cup incl. gasket Drain hose Drain Tee Pressure gauge USA complete Safety clip 10mm (10x) O-ring 2.62 x 6.
| Spare parts 10 8 35 8 8 7 4 8 12 20 8 1 3 9 6 31 2 30 11 13 16 22 23 24 17 21 15 14 25 6 720 641 933-107.3O Fig.
11 12 13 14 15 16 17 20 21 22 23 24 25 30 31 35 – – – – – – – – – – – – – – ZBR28-3A ZBR35-3A ZBR42-3A ZWB28-3A ZWB35-3A ZWB42-3A Designation Heatronic control unit complete Dial Blind cover Top cover Set of connectors Main circuit board Plastic screw (10x) Backpanel Code plug 2501 (ZBR16-3A NG) Code plug 2502 (ZBR21-3A NG) Code plug 2502 (ZBR28-3A NG) Code plug 2503 (ZBR35-3A NG) Code plug 2504 (ZBR42-3A NG) Code plug 2520 (ZWB28-3A NG) Code plug 2524 (ZWB35-3A NG) Code plug 2500 (ZWB42-3A NG) Code
| Spare parts 3 6 5 4 2 2 7 9 2 8 2 10 2 15 12 13 12 17 11 13 14 16 2 1 9 26 12 12 22 42 9 6 45 45 29 21 28 23 47 21 25 26 9 24 2 14 18 2 19 37 13 11 35 41 27 29 12 40 31 5 36 29 46 38 34 39 39 33 33 30 4 10 32 6 720 641 933-108.2O Fig. 101 Group 7 - Hydraulic block combi boiler ZWB..
ZWB35-3A ZWB42-3A ZBR42-3A ZBR35-3A ZBR28-3A ZWB28-3A 39 40 41 42 45 46 47 Designation Flat plate heat exchanger 20 plates Flat plate heat exchanger gasket 15mm Supply manifold complete Screw M5x32 Rubber bushing Gasket 18.5x24.3 (10x) DHW temperature sensor O-ring 7.75x2.1 (10x) Safety clip 10mm (10x) Screw & Gasket assembly M5x30 O-ring 12.5x3 WRAS / KTW (10x) Safety clip 18mm (10x) Safety clip 13mm (1x) Dummy plug complete O-ring 13.87 x 3.
ZBR42-3A ZWB28-3A ZWB35-3A ZWB42-3A Brush set WB5 Cleaning blade WB5 Grease HFT1V5 Grease Unisilkon L641 Heat conducting paste ZBR35-3A – – – – – ZBR28-3A Designation SAK3 – Heat exchanger service accessory kit (main heat exchanger gaskets, heat exchanger brush, heat exchanger cleaning blade) ZBR21-3A Item – ZBR16-3A 92 | Spare parts Order number 7 719 001 998 7 719 002 502 7 719 002
Index | 93 Index A Accessories ............................................................................... 8 Anti-freeze .............................................................................. 28 Appliance description ................................................................. 7 Appliance details ........................................................................ 9 Accessories .......................................................................... 8 Minimum clearances .............
| Index H O Heating control ........................................................................ 48 Heatronic Service functions ..................................................... 52–58, 63 Settings.............................................................................. 52 Old appliances......................................................................... 62 Open vented heating systems .................................................... 28 Operating conditions .......................
Index | 95 (service function b.F) .......................................................... 58 DHW output (service function 1.b) .......................................................... 53 DHW temperature (service function A.b) .......................................................... 58 Display inspection (service function 5.F) .......................................................... 56 Fan post purge time (service function 5.b) ..........................................................
