installation manual
Table Of Contents
- Contents
- 1 Key to symbols and safety instructions
- 1.1 Key to symbols
- 1.2 General safety instructions
- 2 Scope of delivery
- 3 Information about the appliance
- 3.1 Proper use
- 3.2 Overview of boiler types
- 3.3 Rating plate
- 3.4 Appliance description
- 3.5 Accessories
- 3.6 Product dimensions and minimum clearances
- 3.7 Appliance layout heating boiler ZBR..-3A
- 3.8 Appliance layout combi boiler ZWB..-3A
- 3.9 Electrical wiring heating boiler ZBR..-3A
- 3.10 Electrical wiring combi boiler ZWB..-3A
- 3.11 Technical data heating boiler ZBR16-3A...
- 3.12 Technical data heating boiler ZBR21-3A...
- 3.13 Technical data heating boiler ZBR28-3A...
- 3.14 Technical data heating boiler ZBR35-3A...
- 3.15 Technical data heating boiler ZBR42-3A...
- 3.16 Technical data combi boiler ZWB28-3A...
- 3.17 Technical data combi boiler ZWB35-3A...
- 3.18 Technical data combi boiler ZWB42-3A...
- 3.19 Condensate composition
- 4 Regulations
- 5 Installation
- 5.1 Notes on installation and operation
- 5.1.1 Notes on installation and operation
- Fill and make-up water for the heating system
- Recommended steps for commissioning a new or retrofit boiler installation
- Recirculation pump/DHW recirculation lines
- Open vented heating systems
- Gravity heating systems
- Galvanized radiators or pipes.
- Plastic pipework
- Use of a room temperature control
- Water Chemistry Guidelines
- Corrosion inhibitors
- Boiler sealer
- LPG
- 5.1.2 Other important information
- 5.1.1 Notes on installation and operation
- 5.2 Comparing the size of the integrated expansion vessel
- 5.3 ZBR..-3A appliances (heating boilers): Selecting an expansion vessel
- 5.4 Selecting the installation location
- 5.5 Pre-installing pipes
- 5.6 Mounting the appliance
- 5.7 Installing a low water cut off (LWCO)
- 5.8 Connecting flue gas accessories
- 5.9 Testing gas and water connections for leaks
- 5.1 Notes on installation and operation
- 6 Making the electrical connections
- 6.1 General notes
- 6.2 Low voltage electrical connections in the Heatronic boiler control
- 6.3 Electrical connections in the junction box (120 VAC)
- 6.4 Connecting the LWCO device
- 7 Commissioning
- 7.1 Before operating the appliance
- 7.2 Switching the appliance ON/OFF
- 7.3 Setting up space heating
- 7.4 Programming the FW 200 heating control unit
- 7.5 After commissioning
- 7.6 ZBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature
- 7.7 ZWB..-3A appliances (combi boilers): Setting the DHW temperature
- 7.8 Setting manual summer mode
- 7.9 Setting frost protection
- 7.10 Activating the key pad lock
- 8 ZBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection
- 9 Boiler circulator
- 10 Heatronic boiler control settings
- 10.1 Guideline to service functions
- 10.2 Overview of the service functions
- 10.3 Description of the service functions
- 10.3.1 First service level
- Service function 1.A: Maximum space heating output
- Service function 1.b: Maximum DHW output
- Service function 1.E: Pump mode for space heating operation
- Service function 1. F: Pump mode (only heating boiler ZBR..-3A)
- Service function 2.A: Heating circuit pump lockout time (only heating boiler ZBR..-3A)
- Service function 2.b: Maximum supply temperature
- Service function 2.C: Purging function
- Service function 2.d: Thermal disinfection (legionella protection)
- Service function 2.F: Operating mode
- Service function 3.A: Automatic anti-cycle function
- Service function 3.b: Set anti-cycle time
- Service function 3.C: Switching differential
- Service function 3.d: Minimum output (heating and DHW)
- Service function 3.E: Cycle time, keeping DHW hot (only combi boiler ZWB..-3A)
- Service function 3.F: Constant DHW period (only combi boiler ZWB..-3A)
- Service function 4.b: Maximum heat exchanger temperature (only combi boiler ZWB..-3A)
- Service function 4.d: Audible fault warning tone
- Service function 4.E: Appliance type
- Service function 4.F: Condensate trap filling sequence
- Service function 5.A: Reset inspection interval
- Service function 5.b: Fan post purge time
- Service function 5.E: Functionality of black plug in boiler junction box
- Service function 5.F: Set inspection interval
- Service function 6.A: Display the latest fault code
- Service function 6.b: Room temperature control, current voltage, terminal 2
- Service function 6.C: Supply temperature required by outdoor reset control
- Service function 6.d: Current DHW turbine flow rate (only combi boiler ZWB..-3A)
- Service function 7.A: Indicator lamp for burner operation / faults
- Service function 7.b: 3-way valve in center position
- Service function 7.d: Connecting an external supply or low-loss header temperature sensor
- Service function 7.E: Building drying function
- Service function 0.A: Do not use this setting!
- Service function 0.d: Altitude adjustment
- Service function 0.E: Metric or US customary units
- 10.3.2 Second service level
- Service function 8.A: Software version
- Service function 8.b: Code plug number
- Service function 8.C: GFA Gas burner control unit status
- Service function 8.d: GFA Gas burner control unit fault
- Service function 8.E: Restore boiler to factory settings
- Service function 8.F: Permanent ignition
- Service function 9.A: Constant mode
- Service function 9.b: Current fan speed
- Service function 9.C: Current boiler output
- Service function 9.d: Set fan start speed
- Service function 9.E: Turbine signal delay (only combi boiler ZWB..-3A)
- Service function 9.F: Heating zone pump post purge
- Service function A.b: Display DHW temperature
- Service function A.C: Display DHW tank temperature
- Service function b.F: Solar DHW backup heating delay (only combi boiler ZWB..-3A)
- Service function C.d: Display current heat demand
- 10.3.1 First service level
- 11 Gas type conversion
- 12 Flue gas test
- 13 Environmental responsibility/disposal
- 14 Inspection and maintenance
- Heat exchanger
- Heatronic boiler control
- Notes on installation and operation
- After the inspection/maintenance
- 14.1 Description of various steps
- 14.1.1 Calling up the latest fault (service function 6.A)
- 14.1.2 Fresh water filter (only combi boiler ZWB..-3A)
- 14.1.3 Plate type heat exchanger (only combi boiler ZWB..-3A)
- 14.1.4 Checking the electrodes
- 14.1.5 Burner servicing
- 14.1.6 Heat exchanger block inspection and cleaning
- 14.1.7 Condensate trap cleaning
- 14.1.8 Checking the mixer diaphragm
- 14.1.9 Expansion vessel
- 14.1.10 Setting the boiler water pressure
- 14.1.11 Testing system water quality
- 14.1.12 Inspecting electrical wiring
- 14.2 Checklist for inspection and maintenance
- 15 Readings on the display
- 16 Faults
- 17 Commissioning log for the appliance
- 18 Spare parts
- Index
62 | Flue gas test
Greenstar6 720 806 992 (2013/07)
12 Flue gas test
12.1 Emissions test button
The following appliance outputs can be selected by pressing the
emissions test button until it lights up:
Fig. 77 Press the emissions test button
• = Maximum set output in heating mode ( Maximum heating
output, page 53)
• = Maximum nominal output
• = Minimum nominal output
12.2 Measuring CO content of flue gas
Use a multiport flue gas probe for the measurements.
▶ Open one of the flue gas test ports ( Fig. 71).
▶ Insert the flue gas probe approx. 2-3/4 inches (70 mm) into the test
port and seal around it.
▶ Press the emissions test button to select = maximum nominal
output.
▶ Measure the CO levels.
▶ Repeatedly press the emissions test button until the light goes
out.
The display returns to the supply temperature.
▶ Remove flue gas probe and close the flue gas test port properly
( Fig. 75).
13 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.
Packaging
All packaging materials used are environmentally-friendly and
recyclable.
Old appliances
Old appliances contain resources that must be submitted for recycling.
The components are easy to separate and the plastics are marked. This
allows the various components to be sorted for appropriate recycling or
disposal.
14 Inspection and maintenance
Regular service and maintenance are recommended for a long service
life of the appliance, for efficient and economical operation, and to keep
the environmental impact as low as possible. Owners/operators are
encouraged to sign a service and maintenance contract with a trained
and certified installer for annual servicing and maintenance of the boiler.
You have 15 minutes to complete the tests. After that,
the appliance returns to default mode.
DANGER: Risk of flue gas poisoning.
The CO level in the flue gas must be below 200 ppm (air
free).
▶ If 9.4 Vol.%
1)
CO
2
and a CO level under 200 ppm (af)
can not be achieved due to the gas supplied, use a
lower CO
2
level with CO emissions under 200 ppm
(af) instead.
1) 9.4 Vol.% with NG and 11.0 Vol.% with LPG (propane)
max
1
2
34
5
6
eco
reset
6 720 641 933-51.1O
max
1
2
3
4
e
6
min
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.
DANGER: Risk of electric shock!
▶ Always disconnect the appliance from the mains
power before performing any work. Disconnect the
emergency shutoff switch or disengage the heating
system circuit breaker. Take measures to prevent
accidental reconnection.
NOTICE: Insufficient antifreeze can accelerate
corrosion.
▶ Frost protection level has to be checked annually
during the regular scheduled maintenance of the
condensing boiler.