Install Instructions
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 Common Applications of ZBR boilers
- 6 Installation
- 6.1 Notes on installation and operation
- 6.1.1 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
- Primary-secondary piping or a low loss header
- Water Chemistry Guidelines
- Corrosion inhibitors
- Boiler sealer
- LPG
- 6.1.2 Other important information
- 6.1.1 Notes on installation and operation
- 6.2 Comparing the size of the integrated expansion vessel
- 6.3 ZBR..-3A appliances (heating boilers): Selecting an expansion vessel
- 6.4 Selecting the installation location
- 6.5 Pre-installing pipes
- 6.6 Mounting the appliance
- 6.7 Installing a low water cut off (LWCO)
- 6.8 Connecting flue gas accessories
- 6.9 Testing gas and water connections for leaks
- 6.1 Notes on installation and operation
- 7 Making the electrical connections
- 7.1 General notes
- 7.2 Low voltage electrical connections in the Heatronic boiler control
- 7.3 Electrical connections in the junction box (120 VAC)
- 7.4 Connecting the LWCO device
- 8 Commissioning
- 8.1 Before operating the appliance
- 8.2 Switching the appliance ON/OFF
- 8.3 Setting up space heating
- 8.4 Programming the FW 200 heating control unit
- 8.5 FW 200 heating control quick start
- 8.6 After commissioning
- 8.7 ZBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature
- 8.8 ZWB..-3A appliances (combi boilers): Setting the DHW temperature
- 8.9 Setting manual summer mode
- 8.10 Setting frost protection
- 8.11 Activating the key pad lock
- 9 ZBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection
- 10 Boiler circulator
- 11 Heatronic boiler control settings
- 11.1 Guideline to service functions
- 11.2 Overview of the service functions
- 11.3 Description of the service functions
- 11.3.1 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
- 11.3.2 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
- 11.3.1 First service level
- 12 Gas type conversion
- 13 Flue gas test
- 14 Environmental responsibility/disposal
- 15 Inspection and maintenance
- Heat exchanger
- Heatronic boiler control
- Notes on installation and operation
- After the inspection/maintenance
- 15.1 Description of various steps
- 15.1.1 Calling up the latest fault (service function 6.A)
- 15.1.2 Fresh water filter (only combi boiler ZWB..-3A)
- 15.1.3 Plate type heat exchanger (only combi boiler ZWB..-3A)
- 15.1.4 Checking the electrodes
- 15.1.5 Burner servicing
- 15.1.6 Heat exchanger block inspection and cleaning
- 15.1.7 Condensate trap cleaning
- 15.1.8 Checking the mixer diaphragm
- 15.1.9 Expansion vessel
- 15.1.10 Setting the boiler water pressure
- 15.1.11 Testing system water quality
- 15.1.12 Inspecting electrical wiring
- 15.2 Checklist for inspection and maintenance
- 16 Readings on the display
- 17 Faults
- 18 Commissioning log for the appliance
- 19 Spare parts
- Index
62 | Heatronic boiler control settings
Greenstar6 720 806 992 (2013/09)
Service function 4.F: Condensate trap filling sequence
The trap filling sequence ensures that the condensate trap is filled after
initial installation or after a longer downtime of the appliance.
The trap filling sequence is activated if:
• The appliance is switched OFF using the ON/OFF switch
• The burner has not been in use for at least 28 days
• You are switching between summer and winter mode
The next time there is a demand for heat in central heating or hot water
mode, the appliance is held at low output for 15 minutes. The trap filling
sequence remains active until the appliance has completed 15 minutes
of operation at low output. The display shows in alternation with the
supply temperature.
The following settings are available:
• 00: Condensate trap filling sequence is off.
• 01: Trap filling program at the lowest output.
• 02: Trap filling sequence at set minimum output.
Default setting is 01.
Service function 5.A: Reset inspection interval
This function enables resetting the indication on the display after
completing inspection/servicing of the appliance.
Default setting 00.
Service function 5.b: Fan post purge time
This service function allows setting the time the fan purges after the
burner is shut off.
The post purge time can be set from 01 to 18 (10 - 180 seconds).
Default setting is 03 (30 seconds).
Service function 5.E: Functionality of black plug in boiler junction
box
With this service function you can set the functionality of the black plug
in the boiler junction box ( page 49).
The following settings are possible:
• 00: Off - black connector in junction box is disabled (120VAC output
deactivated).
• 01: DHW recirculation pump enabled - see FW200 instructions on
how to set a recirculation pump program.
• 02: External heating zone pump in heating circuit without 3-way valve
controlled by FW 200.
• 03: External heating zone pump in heating circuit without mixer
controlled by Heatronic running in parallel with boiler pump in central
heating mode
Default setting is 03.
Service function 5.F: Set inspection interval
This service function allows setting the number of months after which
the 'service due' reminder appears on the display alternating with
the supply temperature.
The number of months can be set from 00 - 72 (0 to 72 months).
Default setting is 00 (disabled).
Service function 6.A: Display the latest fault code
Use this service function to display the most recent fault code.
Service function 6.b: Room temperature control, current voltage,
terminal 2
The current voltage of the analog control at terminal 2 is displayed.
Possible displays are:
• 00 - 24: 0 V to 24 V in increments of 1 V
Service function 6.C: Supply temperature required by outdoor reset
control
This service function allows displaying the current target supply
temperature set by the outdoor reset control.
Service function 6.d: Current DHW turbine flow rate (only combi
boiler ZWB..-3A)
The current flow rate of the DHW turbine is displayed.
Service function 0.E is set to 00 (metric units):
• 0.0. - 99.9.: 0.0 to 99 l/min in increments of 0.1 l/min
Service function 0.E is set to 01 (US-customary units):
• 0.0. - 99.9.: 0.0 to 99 gpm in increments of 0.1 gpm
Service function 7.A: Indicator lamp for burner operation / faults
With this service function you can activate and deactivate the indicator
lamp for burner operation (continuously illuminated) and faults
(flashing).
The following settings are possible:
• 00: Off
• 01: On (burner operation) and flashing (fault present)
Default setting is 00.
DANGER: Risk of flue gas poisoning!
If the condensate trap is not filled, flue gas may escape
from the dry trap.
▶ Only deactivate the trap filling sequence for servicing
purposes.
▶ When servicing is complete, reactivate the trap filling
function.
If U0 appears on the display, the function was already set
via the FW200 control.
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
heating boiler ZBR..-3A appliances.