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
94 | Index
Greenstar6 720 806 992 (2013/07)
H
Heating control ........................................................................ 48
Heatronic
Service functions ..................................................... 52–58, 63
Settings.............................................................................. 52
I
Information about the appliance ................................................... 7
Inspection and maintenance ...................................................... 62
Inspection and maintenance steps
Call up last fault saved .......................................................... 63
Checking electrodes............................................................. 64
Checking the burner............................................................. 65
Checking the electrical wiring ................................................ 67
Checking the expansion vessel............................................... 67
Checking the heat exchanger block......................................... 65
Cleaning condensate trap...................................................... 67
Plate-type heat exchanger (ZWB..-3A) .................................... 63
Setting the boiler water pressure............................................ 67
Installation .............................................................................. 28
Installation location.............................................................. 30
Pre-installing pipes .............................................................. 30
Installation location
Combustion air.................................................................... 30
Heating appliance ................................................................ 30
Higher than 2000 feet (610 m) above sea level........................ 59
Installation location requirements .......................................... 30
Surface temperature ............................................................ 30
K
Key pad lock ............................................................................ 50
L
Liquified propane gas................................................................ 59
Low water cut off...................................................................... 32
LPG .................................................................................. 29, 59
M
Mains fuse ................................................................... 14, 16, 41
Maintenance and inspection log book .......................................... 68
Making the electrical connections ............................................... 41
Measuring CO content of flue gas ................................................ 62
Minimum clearances ................................................................... 9
Mounting the appliance ............................................................. 32
N
Natural gas .................................................................. 18–25, 59
NG ............................................................................. 18–25, 59
Nominal heating output
Maximum............................................................................ 53
Minimum ............................................................................ 55
Notes on inspection and maintenance ......................................... 62
O
Old appliances......................................................................... 62
Open vented heating systems .................................................... 28
Operating conditions .............................................. 18–20, 23–25
Operating pressure of the boiler................................................. 67
Overview of the service functions ............................................... 52
P
Packaging ............................................................................... 62
Piping systems, galvanized........................................................ 28
Plastic pipework ...................................................................... 28
Proper use ................................................................................ 7
Protective measures for flammable building materials and built-in
furniture ............................................................................ 30
Pump anti-seizing protection ..................................................... 51
R
Radiators, galvanized ............................................................... 28
Recycling................................................................................ 62
Regulations ............................................................................. 26
Requirements for the installation location.................................... 30
Room temperature-controlled control ......................................... 28
S
Scope of delivery ....................................................................... 5
Sealant................................................................................... 29
Second service level................................................................. 57
Service functions
3-way valve in center position
(service function 7.b) ...........................................................57
Adaptation to elevation above sea level
(service function 0.d) ...........................................................57
Anti-cycle time
(service function 3.b) ...........................................................55
Appliance type
(service function 4.E) ...........................................................55
Audible warning tone
(service function 4.d) ...........................................................55
Bleeding function
(service function 2.C) ...........................................................54
Building drying function
(service function 7.E) ...........................................................57
Code plug number
(service function 3.b) ...........................................................57
Condensate trap filling sequence
(service function 4.F) ...........................................................56
Connecting an external supply temperature sensor
(service function 7.d) ...........................................................57
Constant mode
(service function 9.A) ...........................................................58
Current fan speed
(service function 9.b) ...........................................................58
Current heat demand
(service function C.d) ...........................................................58
Current heating output
(service function 9.C) ...........................................................58
Current turbine flow rate (only ZWB..-3A)
(service function 6.d) ...........................................................56
DHW heating delay (solar module)