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
Spare parts | 91
6 720 806 992 (2013/07)Greenstar
Item ( Fig. 101) Designation
ZBR16-3A
ZBR21-3A
ZBR28-3A
ZBR35-3A
ZBR42-3A
ZWB28-3A
ZWB35-3A
ZWB42-3A
Order number
1 Flat plate heat exchanger 20 plates 8 716 108 212 0
2 Flat plate heat exchanger gasket 15mm 8 716 106 435 0
3 Supply manifold complete 8 716 106 356 0
4 Screw M5x32 8 716 771 687 0
5 Rubber bushing 8 716 106 425 0
6 Gasket 18.5x24.3 (10x) 8 716 771 259 0
7 DHW temperature sensor 8 714 500 081 0
8 O-ring 7.75x2.1 (10x) 8 710 205 080 0
9 Safety clip 10mm (10x) 8 716 771 167 0
10 Screw & Gasket assembly M5x30 8 716 106 452 0
11 O-ring 12.5x3 WRAS / KTW (10x) 8 716 107 437 0
12 Safety clip 18mm (10x) 8 716 771 169 0
13 Safety clip 13mm (1x) 8 716 106 549 0
14 Dummy plug complete 8 716 106 566 0
15 O-ring 13.87 x 3.53 (10x) 8 716 771 155 0
16 PRV Tee complete 8 715 502 114 0
17 O-ring 17 x 4 (10x) 8 716 771 154 0
18 Boiler pump USA complete 8 718 226 173 0
19 Safety clip pump 8 716 106 438 0
21 O-ring 23x4 (10x) 8 716 771 353 0
22 Air vent valve 8 716 106 445 0
23 Return assembly complete 8 716 106 844 0
24 Safety clip supply sensor 8 716 106 488 0
25 Pressure relief valve DHW 8 717 401 029 0
26 O-ring 2.62 x 6.02 ID EPDM (10x) 8 716 140 810 0
27 Drain valve 8 716 771 432 0
28 Pressure relief valve USA complete 8 737 703 427 0
29 O-ring 13.87x3.53 (10x) 8 716 771 155 0
30 Safety clip inlet adapter 8 716 106 432 0
31 Diverter valve assembly 8 716 106 845 0
32 Diverter valve actuator motor 8 716 106 847 0
33 Screw M5 Stainless 8 716 106 848 0
34 Flow turbine adapter 8 716 106 433 0
35 Flow turbine complete 8 716 107 223 0
36 DHW filter insert 8 716 106 486 0
37 O-ring 22x3 EPDM (10x) 8 716 106 747 0
38 Flow regulator 15 l/m 4 gpm 8 716 105 869 0
Flow regulator 10 l/m 2.6 gpm 8 737 702 418 0
39 Silencer body 8 716 106 485 0
40 Dummy plug complete 8 716 106 567 0
41 O-ring (10x) 8 716 107 436 0
42 O-ring 12.5x3 WRAS / KTW (10x) 8 716 107 437 0
45 O-ring 17x4 (10x) 8 716 771 154 0
46 Diverter valve housing 8 716 112 786 0
47 PRV drain adapter and hose complete 8 710 725 760 0
Table 51 Group 7 - Hydraulic block combi boiler ZWB..-3A Greenstar