6 720 613 085-00.1O Hydronic Gas Condensing Boiler Condens 5000 W ZSB 30-2 A ...| ZWB 37-2 A ...
| Contents Contents 1 Key to symbols and safety instructions . . . . . . . 5 1.1 Explanation of symbols . . . . . . . . . . . . . . 5 1.2 Safety instructions . . . . . . . . . . . . . . . . . . 5 2 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 Product details . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . 7 3.2 Explanation of model code . . . . . . . . . . . 7 3.3 Gas type . . . . . . . . . . . . . . . .
Contents | 3 15 Inspection/Servicing . . . . . . . . . . . . . . . . . . . . . 55 15.1 Checklist for inspection/servicing (Inspection/Servicing report) . . . . . . . . 56 15.2 Description of various servicing operations . . . . . . . . . . . . . . . . . . . . . . . 57 15.2.1 Retrieving last fault stored (service function 6.A) . . . . . . . . . . . . . . 57 15.2.2 Checking electrodes . . . . . . . . . . . . . . . 57 15.2.3 Strainer in cold water pipe (ZWB) . . . . 57 15.2.4 Plate type heat exchanger (ZWB) .
| Contents 6 720 644 143 (2010/09)
Key to symbols and safety instructions | 5 1 Key to symbols and safety instructions 1.1 Explanation of symbols Warning symbols Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background. 1.2 Safety instructions If you smell gas B Turn off gas tap (Æ page 35). B Open windows and doors. B Do not operate any electrical switches. B Extinguish any naked flames.
| Standard delivery 2 Standard delivery Key: 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 9 8 10 6 720 64 4 143- 01 .1O Fig.
Product details | 7 3 Product details ZSB appliances are boilers for heating. They can be fitted with the diverter valve accessory to connect to an indirectly heated hot water cylinder. ZWB appliances are combi boilers for central heating (CH) and domestic hot water (DHW) heating according to the instantaneous water heating principle. 3.1 Intended use The appliance may only be installed in a sealed unvented central heating system. 3.
| Product details 3.5 Description of appliance • Wall mounted boiler; installation independent of chimney location or room size. • Intelligent heating circuit pump control when connected to an weather-dependent heating controller 3.6 Accessories Below is a list of typical accessories for this appliance. You can find comprehensive details of all available accessories in our catalogue.
Product details | 9 3.7 Dimensions and minimum clearances 5 125 min. min. A 80 5 760 780 85 B 2 440 200 0 55 3 360 C 1 340 6 720 644 143-02.2J Fig.
| Product details 3.8 Appliance layout 30 29 28 27 31 26 32 25 33 24 34 23 35 22 36 21 37 20 38 39 19 40 18 41 17 42 16 43 15 44 14 45 13 46 47 49 1 2 3 12 4 11 5 6 10 6 720 644 143-03.1O 7 Fig.
Product details | 11 Key to figure 3: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Heatronic 3 Main switch Burner ON indicator Service button Central heating boost button Here, a weather-compensated control unit or a time switch (accessories) can be plugged in CH Flow temperature control DHW temperature control Holiday button eco button reset button Display DHW (ZWB) CH flow Adaptor for condensate hose Condensate
| Product details 3.9 Electrical wiring diagram 9 8 10 11 7 12 6 5 15 17 4 k k 14 16 18 13 3 19 B B 4 2 1 F A 2 1 20 21 ST1 Fig.
Product details | 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 Spark transformer CH temperature control Wiring centre Safety solenoid Safety solenoid Gas valve Fan Flame sense eletrode Spark electrodes Flow NTC Heat exchanger overheat stat. Flue overheat stat. Earth Mains supply Pump Pump control Diverter valve (optional) Pump supply DHW temperature control Fluse slow T 0.5 A Fluse slow T 1.
| Product details 8 9 10 11 7 12 6 5 16 18 17 15 4 14 13 20 eutr iv 3 21 B B 4 2 1 F A 2 Ls Ns 1 22 23 24 Fig.
Product details | 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Spark transformer CH temperature control 230 V room stat/programmer Safety solenoid Safety solenoid Gas valve Fan Flame sense eletrode Spark electrodes Flow NTC Heat exchanger overheat stat. Flue overheat stat. Earth Mains supply DHW sensor Pump Pump control Diverter valve Flow turbine Pump supply DHW temperature control External frost stat (optional) Fluse slow T 0.5 A Fluse slow T 1.
| Product details 3.10 Specification ZSB 30-2 ... Unit kW kW kW MJ/h kW kW kW MJ/h kW MJ/h ZSB 30-2 ... Natural gas Propane 32.1 32.1 31.8 31.8 30.0 30.0 123.4 123.4 8.6 12.4 8.6 12.3 7.7 11.0 31.9 11.5 30.9 45.9 123.4 123.4 Butane 36.6 36.3 34.2 140.5 14.2 14.0 12.6 52.3 35.2 140.5 Max. heat output (Pmax) 40/30 °C Max. heat output (Pmax) 50/30 °C Max. heat output (Pmax) 80/60 °C Max. gas consumption (Qmax), central heating Min. heat output (Pmin) 40/30 °C Min. heat output (Pmin) 50/30 °C Min.
Product details | 17 3.11 Specification ZWB 37-2 ... Unit kW kW kW MJ/h kW kW kW MJ/h kW MJ/h ZWB 37-2 ... Natural gas Propane 32.1 32.1 31.8 31.8 30.0 30.0 123.4 123.4 10.6 15.7 10.5 15.5 9.4 13.9 39.1 57.9 37.0 37.0 147.7 147.7 Max. heat output (Pmax) 40/30 °C Max. heat output (Pmax) 50/30 °C Max. heat output (Pmax) 80/60 °C Max. gas consumption (Qmax), central heating Min. heat output (Pmin) 40/30 °C Min. heat output (Pmin) 50/30 °C Min. heat output (Pmin) 80/60 °C Min.
| Product details Unit General data Power supply voltage Frequency Max. power consumption (central heating mode) EMC limit class Sound pressure level (in heating mode) Appliance enclosure rating Max. flow temperature Max. permissible operating pressure (PMS) heating Permissible ambient temperature Nominal capacity of appliance heating Weight (excluding packaging) Dimensions, W x H x D 220 - 240 50 220 - 240 50 220 - 240 50 W ≤ dB(A) IP °C 160 B 45 X4D Approx. 90 160 B 45 X4D Approx.
Regulations | 19 4 Regulations Where no specific instruction is given, reference should be made to the following standards: • AS 5601 Gas Installations, • AS 1596 LPG storage and handling, • AS 4552 Gas fired water heaters for hot water supply and/or central heating, • AS/NZS 3000 Electrical Installations, • AS1697 Installation and maintenance of steel pipe systems for gas, • AS 4032 Water supply - valves for the control of hot water supply temperatures, • AS 3498 Authorization requirements for plumbing
| Pre-Installation 5 Pre-Installation 5.1 Water system and pipe work System fill A Plastic pipe work: 1 • Any plastic pipe work must have a polymeric barrier with 600 mm (minimum) length of copper pipe connected to the boiler. 5 2 SV • Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 °C.
Pre-Installation | 21 S and Y plan systems: NOTE: The boiler is fitted with its own internal bypass. 3 2 NOTE: B A drain point should be fitted at the lowest part of the heating circuit and beneath the boiler. 7 6 5 Optional diverter valve This boiler is designed to operate on a sealed system only and will require a second return pipe from the water cylinder to the wall mounting frame. 6720644143-40.1J Fig.
| Pre-Installation 5.2 Condensate pipe work NOTE: B Where a new or replacement boiler is being installed and freezing conditions are possible, access to an internal drain “gravity discharge” point should be one of the factors considered in determining boiler location. 1 2 3 20mm 6 4 B The condensate pipe must be a minimum of 40 mm Ø plastic pipe. 40mm Ø B The condensate pipe work must fall at least 50 mm per metre towards the outlet and should take the shortest practicable route.
Pre-Installation | 23 Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe can be used. 1 20mm 2 3 4 40/50mm Ø 40mm Ø 6720646195-16.1Wo Fig. 13 Disposal to a waste pipe A washing machine waste pipe or bifurcated pipe etc. can also be used. 1 20mm 2 3 4 40/50mm Ø 5 6720646195-17.1Wo Fig.
| Installation 6 Installation DANGER: Risk of explosion! B Isolate the gas supply before working on gas-carrying components. B Check for leaks before working on gascarrying components. Installation, power connection, connection on the gas and flue gas side and commissioning must only be carried out by a contractor approved for such work by the local gas or power supply utility.
Installation | 25 Mono-lever taps and thermostatic mixer taps All types of mono-lever taps and thermostatic mixer taps can be used. 6.3 Siting the appliance Regulations concerning the installation site LPG B Observe relevant national regulations. To protect the appliance against excessive pressure: B Consult the flue kit installation instructions for details of minimum clearances required for flue gas routing. B Fit a pressure regulator with a safety valve. 6.
| Installation Gas and water connections Pre-installing pipes 340 B Position mounting plate against the wall, observing minimum side clearances of 100 mm (Æ page 9). B Mark out four holes: 75 55 28 B Hook mounting rail into the mounting plate. Ø 3/4" Ø 1/2" Ø 3/4" Ø 1/2" Ø 3/4" 85 6.4 – One of holes A – One of holes B 65 65 65 65 – Hole C 364 – Hole D B Drill Ø 10 mm holes. 158 A B R 1/2" R 3/4" R 1/2" R 3/4" 120 R 3/4" 370 6 720 644 143-07.1O Fig.
Installation | 27 Pipework behind the appliance 1 2 3 2 3 The pipes can be routed behind the appliance in the guide on the mounting plate (Æ Fig. 18). 2 2 3 1 4 4 5 11 10 9 8 7 6 5 6 720 644 143-05.1O Fig.
| Installation 6.5 Preparing for fixing Fitting the appliance NOTE: Dirt and corrosion in the pipework can damage the appliance. B Flush out the system to remove all dirt residues. B Place sealing washers on the pre-plumbing jig connections. B Pull lever on pressure relief valve connection forwards and push down as far as it will go (Æ Fig. 12). B Remove packing, taking care to observe the instructions on the packing.
Installation | 29 Drain from pressure relief valve (heating circuit) Creating the condensate drain B Push lever on slider up until catch [1] rests on metal bracket [2] (Æ Fig. 13). B Push the condensate hose into the adaptor on the pre-plumbing jig. B Create the drain. B Do not use copper pipe. CAUTION: B Do not modify or seal off drain pipes. B Hoses must always slope downwards. 1 2 6 720 644 143-08.1O Fig.
| Installation Fitting the filling loop (ZWB) Filling the heating circuit (ZWB) B Close the isolating valves on the mains water inlet [9] and the CH return [1] connections. B Ensure that all system and boiler drain points are closed. B Remove the blanking plugs [2]. B Tigthen screw [1] on the filling loop as far as it will go (Æ Fig. 24). B Place the filter [7] into the inlet side of the filling loop [4] ensuring that the filter mesh faces into the filling loop.
Installation | 31 B Turn key [4] to position lower cover. , remove and insert into the Connecting the flue pipe B Push on the flue gas accessories and secure with the screws supplied. For more precise details of connecting the flue, refer to the installation instructions for the flue routing manual. 2 6 720 644 143-14.1O 1 Fig. 25 Fitting the lower cover B Push the lower cover into the two guide rails at the bottom of the appliance. 6 720 615 886-22.1O Fig.
| Installation 6.6 Checking the connections Water connections B Open the heating flow and return valves and fill the heating system. B Check sealing points for leaks (testing pressure: max. 2.5 bar (250 kPA) at the pressure gauge). B Open the cold water valve on the appliance and a turn on a hot water tap until water runs out. Max pressure: 10 bar (1000 kPA). Gas supply pipe B Close the gas valve to protect the gas valve from pressure damage. B Check sealing points for leaks.
Electrical connections | 33 7 Electrical connections 7.1 General information DANGER: Risk of electric shock! 7.2 Opening the Heatronic unit B Before carrying out work on electrical components, disconnect the power supply (230 V AC) (fuse, circuit breaker) and secure against unintentional reconnection. • Supply: 220 - 240 V, 50 Hz. Connecting accessories CAUTION: Cable offcuts can damage the Heatronic. B Always strip cables away from the Heatronic. B Slide the clip down and pivot the Heatronic.
| Electrical connections B To provide anti-splash protection (IP), always cut cable grip to fit cable diameter. 8-9 7.2.2 Connecting the DHW cylinder Replace existing cylinder temperature sensor with Bosch cylinder temperature sensor. Cylinders with Bosch cylinder temperature sensors are connected directly to the appliance PCB. 5-7 B Snap off the plastic tongue. 10-12 B Insert the cylinder temperature sensor lead. 13-14 6 720 612 259-30.1R Fig. 30 B Plug the connector into the PCB.
Commissioning | 35 8 Commissioning 7 8 9 6 5 4 3 reset 10 2 eco 11 1 12 13 20 19 18 14 17 16 15 6 720 644 143-17.1O Fig.
| Commissioning 8.1 Before commissioning NOTE: Commissioning without water destroys the appliance! B Never run the appliance without water in it. 8.2 Switching the appliance on/off Switching on B Switch appliance on at the main switch. The display shows the heating water flow temperature. B Adjust pre-charge pressure of expansion vessel to static head of the heating system (Æ page 25). B Open cold water tap (Æ Fig. 33, [17]) and one DHW tap until water flows out.
Commissioning | 37 8.3 Starting the central heating 8.4 The maximum flow temperature can be matched to the heating system by the flow temperature controller. The current flow temperature is shown on the display. Setting on flow tem-perature controller Flow temperature 1 Approx. 35 °C 2 Approx. 43 °C 3 Approx. 50 °C Setting the heating control unit Follow the operating instructions for the heating controller used.
| Commissioning 8.6 Appliances with hot water cylinder: setting the hot water temperature eco button Pressing and holding the eco button until it lights up switches between Comfort mode and Economy mode. WARNING: Danger of scalding! Comfort mode, Eco button is not lit (default setting) B In normal operation, do not set the temperature higher than 60 °C. In Comfort mode, the hot water cylinder has priority. The hot water cylinder is heated to the set temperature first.
Commissioning | 39 8.7 ZWB appliances - setting hot water temperature B Set the DHW temperature on the DHW temperature control . The set DHW temperature flashes on the display for 30 seconds. reset 8.8 Summer mode (central heating off, DHW only) B Note position of CH flow temperature control . B Turn CH flow temperature control anti-clockwise as far as the stop . The heating circuit pump and consequently central heating are switched OFF.
| Commissioning 8.10 Holiday mode 8.11 Fault mode To switch on holiday mode: All safety, modulation and control components are monitored by the Heatronic system. B Press and hold holiday button on the appliance until it lights up, and switch on holiday mode on the heating controller. In holiday mode, heating and DHW heating are switched off; frost protection remains active (Æ chap. 8.9). If a fault occurs during operation, a warning tone sounds. If you press a button, the warning tone stops.
Thermal disinfection on appliances with hot water cylinder | 41 9 Thermal disinfection on appliances with hot water cylinder To prevent the DHW becoming contaminated by bacteria such as legionella, we recommend you pasteurise the system after longer idle periods. With some heating controllers, thermal disinfection can be programmed for a fixed time; see heating controller operating instructions. Pasteurisation covers the DHW system including the draw-off points.
| Pump anti-seizing function 10 Pump anti-seizing function This function prevents the heating circuit pump and the 3-way valve seizing up during long periods of inactivity. Every time the pump is switched off, a timer starts to briefly switch on the heating circuit pump and the 3-way valve at regular intervals.
Heatronic settings | 43 11 Heatronic settings 11.1 General information The Heatronic unit enables easy setting and testing of a large number of appliance functions. For an overview of the service functions see chapter 11.2 on page 44. Settings on the Heatronic Service function Value 3 reset 2 1 eco 3 2 1 3 4 2 5 6 max 1 min 4 5 4 e 6 max 6 720 644 143-11.1O Fig.
| Heatronic settings 11.2.2 Service level 2 11.2 Overview of service functions Access from service level 1; service button lights up. B Press eco button and holiday button simultaneously until a code such as 8.A appears. 11.2.1 Service level 1 B Press service button until it illuminates. Service function Service function Display code Page Display code Page 8.A Software version 49 8.b Code plug number 49 8.C GFA status (not applicable) 49 45 8.
Heatronic settings | 45 11.3 Description of service functions 11.3.1 Service level 1 Service function 1.A: MAX. OUTPUT (HEATING) Some gas supply utilities charge a basic rate based on output. The heating output can be set to any level between min. rated heat output and max rated heat output to limit it to the specific heat requirements. Even if the output is limited, the full rated heat output remains available for hot water.
| Heatronic settings The following can be selected as the pump characteristic map: • 00 Pump step adjustable, service function 1.d (Æ page 46 ) • 01 Constant pressure high Service function 1.d: Map pump step (heating) This service function corresponds to the pump speed switch used on conventional heating pumps. However, the setting is only active if function 1.C (Pump map (heating)), is set to 0. The factory setting is 07.
Heatronic settings | 47 Service functions 2.C: Air purge mode The first time the appliance is switched on, a onceonlyventing function is activated. The heating pump then switches on and off at intervals. This sequence lasts about 8 minutes. The 2-digit display shows in alternation with the flow temperature. The automatic vent will open during venting and then close once the venting sequence is complete. The venting function can be activated after servicing. Service function 3.
| Heatronic settings Service function 4.F: Siphon-fill programme The syphon filling function ensures that the syphon trap is filled when the appliance is first installed or shut down for a long period. Flue gas is prevented from escaping into the room where the appliance is installed.
Heatronic settings | 49 11.3.2 Service level 2 Service function 8.A: Software version Service function 9.b: Actual fan speed The current fan speed is displayed in Hertz (Hz). The version number of the software is displayed. Service function 9.C: Actual heating output Service function 8.b: Code plug The 4-digit part number of the code plug (digits no. 7 upto 10 of order no.) is indicated. The code plug determines the appliance functions.
| Converting the appliance to different gas types 12 Converting the appliance to different gas types The gas-air ratio must always be set on the basis of a CO2 or O2 reading taken at maximum rated heat output and minimum rated heat output using an electronic tester. Adjustment to different flue systems using throttle discs or baffle plates is not necessary. 12.1 Gas-type conversion The following gas type conversion sets are available: Appliance Conversion to Order No. Z...
Converting the appliance to different gas types | 51 B Remove the gas throttle seat with a screw driver as shown in Fig. 49. B Remove the sealed brass screw from gas valve adjusting screw and set CO2 or O2 level for minimum rated heat output. 2 . 1 . 2 1 6 7 2 0 6 1 2 6 5 9 -3 7 .1 R 6 720 614 090-22.1O Fig. 49 B Adjust the gas flow throttle to set the CO2 or O2 level for maximum rated output according to the table. Fig.
| Converting the appliance to different gas types B Switch off the appliance and turn off the gas tap. B Repeatedly press the central heating boost button until the light goes out. The display will show the CH flow temperature again. B Undo the plug on the testing point for gas inlet pressure and connect a pressure gauge. B Switch off the appliance, turn off the gas cock, remove the pressure gauge and refit the plug. 12.3 Checking the gas supply pressure B Refit the outer casing. 6 720 614 090-34.
Flue gas testing | 53 13 Flue gas testing 13.1 Central heating boost button The following appliance outputs can be selected by pressing the central heating boost button until it lights up: B Remove sealing plug from combustion air testing point (2, Æ Fig. 54). B Insert a flue gas probe into the testing point socket and seal the testing point. B Press the central heating boost button to select maximum rated output. = reset eco 3 2 1 4 3 5 6 max 2 4 e 2 6 1 min 1 max 6 720 644 143-35.1O Fig.
| Environmental protection 14 Environmental protection Environmental protection is a fundamental corporate strategy of the Bosch Group. The quality of our products, their economy and environmental safety are all of equal importance to us and all environmental protection legislation and regulations are strictly observed. We use the best possible technology and materials for protecting the environment taking account of economic considerations.
Inspection/Servicing | 55 15 Inspection/Servicing To ensure that gas consumption and environmental impact remain as low as possible over an extended period of time, we recommend that you take out an inspection/servicing contract with an authorised contractor covering an annual inspection, and servicing at other times as required. Important notes For an overview of faults, see page 67.
| Inspection/Servicing 15.1 Checklist for inspection/servicing (Inspection/Servicing report) Date 1 Retrieve last fault stored on the Heatronic module, service function 6.A (Æ page 57). 2 On Logamax plus GB042-22K appliances, check filter in cold water pipe (Æ page 57). 3 Perform a visual check of the air/flue gas routing. 4 Check the gas supply pressure, (Æ page 52). mbar (kPa) 5 Check the gas-air ratio at min./max. and adjust if necessary (Æ page 50). min. % max.
Inspection/Servicing | 57 15.2 Description of various servicing operations 15.2.3 Strainer in cold water pipe (ZWB) B Undo cold water pipe and check filter for dirt. 1. 15.2.1 Retrieving last fault stored (service function 6.A) B Select service function 6.A (Æ page 43). For an overview of faults, see page 67. 15.2.2 Checking electrodes 3. B Remove electrode set (Æ page 10) and gasket. Check electrodes for dirt; clean or replace if required. B Refit electrode set and check for tightness (Fig. 56). 2.
| Inspection/Servicing 15.2.4 Plate type heat exchanger (ZWB) B Undo/remove pipe unions. If the DHW output is insufficient: B Check strainer in cold water pipe for dirt (Æ page 57). B Remove plate-type heat exchanger and replace -orB Descale only with a product that has been approved for stainless steel (1.4401). Remove the plate heat exchanger: B Disconnect electrical connectors. B Remove hose from pressure relief valve. 6 720 644 143-21.1O Fig. 59 B Undo the pressure gauge fastener.
Inspection/Servicing | 59 B Release the quick-acting closures and remove the hydraulic assembly completely. 15.2.5 Heat exchanger For cleaning the heat exchanger, use brush, accessory no. 1060, and cleaning blade, accessory no. 1061. B Check control pressure at maximum rated output at mixer unit. 2. 1. 1. 3. 6 720 644 143-23.1O Fig. 61 B Undo the plate-type heat exchanger. 6 720 644 143-25.1O Fig. 63 Appliance Control pressure Cleaning required? ZSB 30-2 A ≥ 3.9 mbar (0.39 kPa) No < 3.
| Inspection/Servicing B Remove the condensate siphon and place a suitable container below the condensate outlet. 1 B Clean the heat exchanger with the brush from top to bottom. 2 6 720 612 563-14.1O Fig. 66 B Remove burner (Æ chapter 15.2.6 “Checking the burner”) and flush the heat exchanger with water from above. 6 720 644 143-19.1O 2 Fig. 64 B With the cleaning blade, clean the heat exchanger from the bottom to the top. 6 720 612 664-18.1R Fig.
Inspection/Servicing | 61 15.2.6 Burner B Remove two screws [2] from top cover [1] and lift off cover (Æ Fig. 69). 1 2 2 7 181 465 330-08.2R Fig. 71 6 720 615 662-19.1O B Refit burner, possibly with a new gasket, in reverse order. B Adjust the gas-air ratio (Æ page 50). Fig. 69 B Remove clips [3], nuts [4] and [5] and two screws [7] (Æ Fig. 69). 3 5 4 6 7 7 6 720 615 662-20.1O Fig. 70 B Remove burner cover [6]. B Remove burner and clean its components.
| Inspection/Servicing 15.2.7 Diaphragm in mixer unit CAUTION: Ensure that the diaphragm is not damaged during its release and refitting! 15.2.8 Cleaning condensate trap B Remove condensate trap and check that the heat exchanger connection is clear. B Open the mixing chamber. B Carefully withdraw diaphragm from fan intake tube and check for soiling and splits. 1 2 6 720 615 662-21.1O 6 720 644 143-19.1O Fig. 72 B Carefully refit the diaphragm into the fan connector, in the correct position.
Inspection/Servicing | 63 15.2.10 Setting the heating system pressure NOTE: Risk of damaging the appliance. B Only top up the heating system when the appliance is cold. Pressure gauge reading 1 bar (100 kPa) Minimum system pressure (when cold) 1 - 2 bar (100 - 200 kPa) Optimum system pressure 3 bar (300 kPa) Maximum system pressure at highest heating water temperature: must not be exceeded (otherwise pressure relief valve opens).
| Displays 16 Displays The display shows the following (table 25 and 26): Value displayed Description Number or letter, dot followed by letter Service function (Ætable 15/ 16, page 44) Letter followed by number or letter Fault code flashes (Æ table 27, page 67) Two numbers Decimal figure, e.g. flow temperature 00..99 U followed by 0..9 Decimal figure;100..109 is displayed as U 0..U9 0..
Displays | 65 Special display Description Screed drying function of the weathercompensated controller (Æoperating instructions) or building drying function (Æservice function 7.E) operational.
| Fault mode 17 Fault mode 17.1 Troubleshooting DANGER: Risk of explosion! B Turn off gas valve before working on gascarrying components. B Check for leaks before working on gascarrying components. DANGER: Risk of poisoning! B Check for leaks before working on gascarrying components. DANGER: Risk of electric shock! B Before carrying out work on electrical components, disconnect the power supply (230 V AC) (fuse, circuit breaker) and secure against unintentional reconnection.
Fault mode | 67 17.2 Faults that are shown on the display Display code A7 A8 Description Remedy Temperature sensor for hot water is faulty. B Check temperature sensor and lead for breaks or short circuits, and replace if required. (ZWB) B Plug in boiler coding card correctly; replace if required. Communication fault. B Check BUS device connecting lead. B Check controller, replace if required. Ad Cylinder temperature sensor not detected. B Check cylinder temperature sensor and connecting lead.
| Fault mode Display code E9 Description Remedy Heat exchanger temperature limiter or flue gas temperature limiter has tripped. B Check heat exchanger temperature limiter and lead for breaks or short circuits; replace if required. B Check flue gas temperature limiter and lead for breaks or short circuits; replace if required. B Check the operating pressure of the heating system. B Check temperature limiter; replace if required. B Check pump starter; replace pump if required.
Fault mode | 69 Display code FA Description Remedy A flame is detected after the gas has been switched off. B Check gas valve; replace if required. B Clean condensate trap. B Check electrodes and lead; replace if required. B Check flue gas system; clean or repair if required. Fd Reset was pressed in error. B Press reset again. B Check cable harness to high limit safety cut-out and gas valve for earth connection.
| Fault mode 17.3 Faults that are not shown on the display Appliance faults Remedy Combustion noise too loud; rumbling noises B Plug in boiler coding card correctly; replace if required. B Check gas type. B Check gas supply pressure; adjust if required. B Check flue gas system; clean or repair if required. B Check gas/air ratio in the combustion air and flue gas; replace gas valve if required. Flow noises B Set pump stages or pump characteristic maps correctly and match to maximum output.
Fault mode | 71 17.4.2 Flow and DHW sensors 17.4 Sensor values 17.4.
| Fault mode 17.6 Settings for heating output with ZSB 30 ...23 17.7 Settings for heating output with ZSB 30 ...31 NG Propane Gross calorific value (MJ/m3) (15 °C): 37.8 Display Heat output (kW) Gas con~ sumption (MJ/m3) Heat output (kW) Gas con~ sumption (MJ/m3) 43 11.0 45.9 12.5 52.2 46 12.0 50.0 13.6 56.8 Net calorific value (MJ/m3) (15 °C): 34.0 Display Heat output (kW) Gas con~ sumption (MJ/m3) Gas flow rate1) (l/min) Butane 32 7.7 31.9 14 49 13.0 54.1 14.8 61.
Fault mode | 73 17.8 Settings for heating output with ZWB 37 ...23 17.9 Settings for heating output with ZWB 37 ...31 NG Propane Gross calorific value (MJ/m3) (15 °C): 37.8 Display Heat output (kW) Gas consumption (MJ/m3) Heat output (kW) Gas consumption (MJ/m3) 45 13.9 57.9 15.8 65.8 45 14.0 58.3 15.9 66.3 Net calorific value (MJ/m3) (15 °C): 34.0 Display Heat output (kW) Gas consumption (MJ/m3) Gas flow rate1) (l/min) Butane 32 9.4 31.9 17 47 15.0 62.4 17.0 70.9 34 10.
| Commissioning report for the appliance 18 Commissioning report for the appliance Customer/system user: Surname, first name Street, house number Telephone/fax Postcode, town System installer: Order number: Appliance type: (Complete a separate report for every appliance!) Serial number: Date commissioned: Individual appliance | Installation room: Cascade, number of appliances: ...... Cellar | Attic | Other: cm2 Ventilation apertures: Number: ......, size: approx.
Commissioning report for the appliance | 75 Modified service functions: (Select the modified service functions and enter the values here.) Example: service function 7.d changed from 00 to 01 “Heatronic settings” label filled out and affixed Heating control unit: FW 100 | FW 200 | FW 500 | FR 110 TA 250 | TA 270 | TA 300 FB 10 × ...... pce, heating circuit code(s): FB 100 × ...... pce, heating circuit code(s): FR 10 × ...... pce, heating circuit code(s): FR 100 × ......
| Index Index A Anti-freeze ........................................................... Appliance Switching off .................................................... Appliance commissioning report............................. Appliance details Specification - ZSB 30-2 .................................................... - ZWB 37-2... ................................................. Appliance layout ...................................................
Index | 77 M Maintenance operations Setting the heating system pressure ................... 63 Measuring CO content of flue gas ........................... 53 Minimum clearances ............................................... 9 Mono-lever taps .................................................... 25 N Natural gas ...................................................... 17, 50 O Open vented heating systems ................................ 24 Operating conditions........................................
| Notes 6 720 644 143 (2010/09)
| 79 Notes 6 720 644 143 (2010/09)
Australia Robert Bosch (Australia) Pty Ltd 1555 Centre Rd Clayton, VIC 3168 Phone 1300 30 70 37 Fax 1300 30 70 38 www.bosch.com.au/hotwater New Zealand Phone 0800 4 Bosch or 08 543 352 www.bosch.co.
