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
Index | 93
6 720 806 992 (2013/07)Greenstar
Index
A
Accessories ............................................................................... 8
Anti-freeze .............................................................................. 28
Appliance description ................................................................. 7
Appliance details........................................................................ 9
Accessories .......................................................................... 8
Minimum clearances .............................................................. 9
Technical data
- ZBR16-3A... ................................................................ 18
- ZBR21-3A... ................................................................ 19
- ZBR28-3A... ................................................................ 20
- ZBR35-3A... ................................................................ 21
- ZBR42-3A... ................................................................ 22
- ZWB28-3A... ............................................................... 23
- ZWB35-3A... ............................................................... 24
- ZWB42-3A... ............................................................... 25
ZBR..-3A appliance layout..................................................... 10
ZWB..-3A appliance layout .................................................... 12
Appliance information................................................................. 7
Appliance layout
ZBR..-3A ............................................................................ 10
ZWB..-3A ........................................................................... 12
Automatic anti-cycle time (service function 3.A) ........................... 54
B
Bleeding.................................................................................. 47
Bleeding function................................................................. 54
C
Call up last fault saved............................................................... 63
Call up latest fault code ............................................................. 56
Changing the sensor curve of the heating pump ............................ 51
Check gas supply dynamic pressure ............................................ 61
Checking the electrical wiring..................................................... 67
Checking the flue system ........................................................... 62
Checklist for inspection and maintenance .................................... 68
Combustion air......................................................................... 30
Commissioning ........................................................................ 47
Bleeding............................................................................. 47
Commissioning log ................................................................... 75
Condensate composition ........................................................... 26
Condensate trap....................................................................... 67
Connecting
3-way valve (ZBR only) ......................................................... 45
DHW tank ........................................................................... 42
Supply temperature sensor ................................................... 43
Tank primary pump (ZBR only) .............................................. 45
Corrosion inhibitors.................................................................. 29
D
Details about the appliance
Proper use ........................................................................... 7
Scope of delivery................................................................... 5
Technical specifications
- ZBR16-3A................................................................... 18
- ZBR21-3A................................................................... 19
- ZBR28-3A................................................................... 20
- ZBR35-3A................................................................... 21
- ZBR42-3A................................................................... 22
- ZWB28-3A... ............................................................... 23
- ZWB35-3A... ............................................................... 24
- ZWB42-3A... ............................................................... 25
Type overview....................................................................... 7
DHW circulation....................................................................... 28
Dimensions............................................................................... 9
Disposal ................................................................................. 62
E
ECO button ............................................................................. 49
Electrical connection ................................................................ 67
3-way valve (ZBR only)......................................................... 45
Connecting accessories........................................................ 43
Connecting LWCO device ..................................................... 46
Connecting power supply ..................................................... 45
DHW circulation pump ......................................................... 44
DHW tank........................................................................... 42
Heating control, remote control units ..................................... 43
Supply temperature sensor................................................... 43
Tank primary pump (ZBR only) .............................................. 45
Temperature limiter............................................................. 44
Electrical connections
Temperature limiter............................................................. 43
Electrical wiring
ZBR..-3A............................................................................ 14
ZWB..-3A... ........................................................................ 16
Energy saving .......................................................................... 48
Environmental responsibility ..................................................... 62
Expansion vessel...................................................................... 67
F
Fault codes ............................................................................. 70
Faults..................................................................................... 70
Not shown on the display...................................................... 73
Shown on the display........................................................... 71
First service level ..................................................................... 53
Flue gas accessories................................................................. 33
Frost protection....................................................................... 50
Fuses .......................................................................... 14, 16, 41
G
Gas and water connections........................................................ 41
Gas type ................................................................................. 59
Adjustment......................................................................... 59
Conversion......................................................................... 59
Conversion kit..................................................................... 59
Gas/air ratio ............................................................................ 60
Gravity heating systems ............................................................ 28