Bosch ZBR42-3A, ZBR28-3A, ZWB42-3A, ZBR16-3A, ZBR35-3A Installation And Service Instructions Manual

...

Page 1

WARNING:

Improper installation, set-up, modification, operation or maintenance of the heating system can cause personal injury and property damage. Follow these instructions precisely. If you require assistance or further information, contact a trained and certified installer or the gas supply company.

WARNING:

The operating instructions are part of the technical documents that must be handed over to the owner or operator of the heating system. Explain to the owner or operator how to use the heating system using the operating instructions. Make sure that they are familiar with all required information for the safe and proper operation of the heating system.

NOTE:

In Massachusetts, this appliance must be installed by a licensed plumber or gas fitter.

These instructions are available in English and French.

Please keep these instructions for future reference.

6 720 613 303-00.1O

Gas Condensing Boiler

Greenstar

Installation and Service Instructions for Contractors

6 720 643 068 (2011/06) CA/US

Page 2

2 | Contents

Contents

1 Guideline to symbols and safety instructions . . . . 4

1.1 Guideline to symbols . . . . . . . . . . . . . . . . . 4

1.2 Safety instructions . . . . . . . . . . . . . . . . . . . 4

2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 ZBR - Boiler for space heating and

loading of indirect fired DHW tanks . . . . . .6

2.2 ZWB - Combi boiler for space heating and

DHW generation . . . . . . . . . . . . . . . . . . . . .7

3 Information about the appliance . . . . . . . . . . . . . . 8

3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Overview of boiler types . . . . . . . . . . . . . . 8

3.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Appliance description . . . . . . . . . . . . . . . . 9

3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . 10

3.6 Product dimensions and minimum

clearances . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.7 Appliance layout heating boiler ZBR..-3A . 12

3.8 Appliance layout combi boiler ZWB..-3A . 14

3.9 Electrical wiring heating boiler ZBR..-3A . 16

3.10 Electrical wiring combi boiler ZWB..-3A . 18

3.11 Technical data heating boiler ZBR16-3A... 20

3.12 Technical data heating boiler ZBR28-3A... 22

3.13 Technical data heating boiler ZBR35-3A... 24

3.14 Technical data heating boiler ZBR42-3A... 26

3.15 Technical data combi boiler ZWB28-3A... 28

3.16 Technical data combi boiler ZWB42-3A... 30

3.17 Condensate composition . . . . . . . . . . . . . 32

4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.1 Compliance with standards and

regulations . . . . . . . . . . . . . . . . . . . . . . . .33

4.2 Operating limits of the boiler . . . . . . . . . 33

4.3 Additional regulations for installation in

Massachusetts . . . . . . . . . . . . . . . . . . . . .34

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 Notes on installation and operation . . . . 35

5.1.1 Notes on installation and operation . . . . 35

5.1.2 Other important information . . . . . . . . . . 36

5.2 Comparing the size of the integrated

expansion vessel . . . . . . . . . . . . . . . . . . . 37

5.3 ZBR..-3A appliances (heating boilers):

Selecting an expansion vessel . . . . . . . . . 38

5.4 Selecting the installation location . . . . . . 38

5.5 Pre-installing pipes . . . . . . . . . . . . . . . . . 39

5.6 Mounting the appliance . . . . . . . . . . . . . 41

5.7 Installing a low water cut off (LWCO) . . 42

5.8 Connecting flue gas accessories . . . . . . . 43

5.8.1 Installation of the exhaust and air

intake system . . . . . . . . . . . . . . . . . . . . . . 44

5.8.2 Approved examples of horizontal and

vertical venting installation . . . . . . . . . . . 47

5.8.3 Vent and combustion air pipe lengths . . 50

5.9 Testing gas and water connections

for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6 Making the electrical connections . . . . . . . . . . . 52

6.1 General notes . . . . . . . . . . . . . . . . . . . . . 52

6.2 Low voltage electrical connections in the

Heatronic boiler control . . . . . . . . . . . . . . 52

6.2.1 Open the Heatronic boiler control . . . . . 52

6.2.2 Connecting the outdoor temperature

sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.2.3 Connecting the DHW tank temperature sensor (only heating boiler ZBR..-3A) . . . 53

6.2.4 Connecting additional accessories . . . . . 54

6.3 Electrical connections in the junction box

(120 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.3.1 Mounting rails for junction box . . . . . . . . 55

6.3.2 Connecting an external heating zone

pump or DHW recirculation pump . . . . . . 55

6.3.3 DHW tank loading pump or 3-way valve with spring return (only heating boiler

ZBR..-3A) . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.3.4 Connecting mains power supply . . . . . . . 56

6.4 Connecting the LWCO device . . . . . . . . . 57

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Contents | 3

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.1 Before operating the appliance . . . . . . . . 59

7.2 Switching the appliance ON/OFF . . . . . . . 59

7.3 Setting up space heating . . . . . . . . . . . . . 60

7.4 Programming the FW 200 heating

control unit . . . . . . . . . . . . . . . . . . . . . . . 60

7.5 After commissioning . . . . . . . . . . . . . . . . . 60

7.6 ZBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature 61

7.7 ZWB..-3A appliances (combi boilers):

Setting the DHW temperature . . . . . . . . . 61

7.8 Setting manual summer mode . . . . . . . . . 62

7.9 Setting frost protection . . . . . . . . . . . . . . 62

7.10 Activating the key pad lock . . . . . . . . . . . 63

8 ZBR..-3A appliances (heating boiler) with

DHW tank: Thermal disinfection . . . . . . . . . . . . . 63

9 Boiler circulator . . . . . . . . . . . . . . . . . . . . . . . . . . 64

9.1 Pump anti-seize protection . . . . . . . . . . . 64

9.2 Changing the pump curve of the

boiler pump . . . . . . . . . . . . . . . . . . . . . . . 64

10 Heatronic boiler control settings . . . . . . . . . . . . . 65

10.1 Guideline to service functions . . . . . . . . . 65

10.2 Overview of the service functions . . . . . . 66

10.2.1 First service level . . . . . . . . . . . . . . . . . . . 66

10.2.2 Second service level . . . . . . . . . . . . . . . . . 66

10.3 Description of the service functions . . . . 67

10.3.1 First service level . . . . . . . . . . . . . . . . . . . 67

10.3.2 Second service level . . . . . . . . . . . . . . . . . 73

11 Gas type conversion . . . . . . . . . . . . . . . . . . . . . . . 75

11.1 Converting to a different gas type . . . . . . 75

11.2 Installation location higher than 2,000 feet

(610 m) above sea level . . . . . . . . . . . . . 76

11.3 Setting the gas-air ratio (CO

or O2) . . . . 76

11.4 Dynamic gas pressure test . . . . . . . . . . . 78

14 Inspection and maintenance . . . . . . . . . . . . . . . . 81

14.1 Description of various steps . . . . . . . . . . 82

14.1.1 Calling up the latest fault (service

function 6.A) . . . . . . . . . . . . . . . . . . . . . . . 82

14.1.2 Fresh water filter (only combi boiler

ZWB..-3A) . . . . . . . . . . . . . . . . . . . . . . . . .82

14.1.3 Plate type heat exchanger

(only combi boiler ZWB..-3A) . . . . . . . . . . 82

14.1.4 Checking the electrodes . . . . . . . . . . . . . 83

14.1.5 Burner servicing . . . . . . . . . . . . . . . . . . . . 84

14.1.6 Heat exchanger block inspection and

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .84

14.1.7 Condensate trap cleaning . . . . . . . . . . . . 86

14.1.8 Checking the mixer diaphragm . . . . . . . . 86

14.1.9 Expansion vessel . . . . . . . . . . . . . . . . . . . 87

14.1.10 Setting the boiler water pressure . . . . . . 87

14.1.11 Testing system water quality . . . . . . . . . . 87

14.1.12 Inspecting electrical wiring . . . . . . . . . . . 87

14.2 Checklist for inspection and maintenance 88

15 Readings on the display . . . . . . . . . . . . . . . . . . . . 89

16 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

16.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . 90

16.2 Faults that are shown on the display . . . . 91

16.3 Faults that are not shown on the display 94

16.4 Check sensor values . . . . . . . . . . . . . . . . 95

16.4.1 Outdoor temperature sensor . . . . . . . . . . 95

16.4.2 Additional supply temperature limiter . . . 95

16.4.3 Supply temperature sensor, External supply temperature sensor, DHW tank temperature sensor, DHW temperature

sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

16.5 Replacement code plug . . . . . . . . . . . . . . 96

17 Commissioning log for the appliance . . . . . . . . . 97

18 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

12 Flue gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

12.1 Emissions test button . . . . . . . . . . . . . . . 79

12.2 Measuring CO content of flue gas . . . . . . 79

13 Environmental responsibility/disposal . . . . . . . . . 80

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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4 | Guideline to symbols and safety instructions

1 Guideline to symbols and safety instructions

1.1 Guideline to symbols

Warnings

Warnings are indicated in the text by a warning triangle and a gray background.

In case of danger from electric shock, the exclamation point on the warning triangle is replaced with a flash.

Signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing damage are not taken.

• NOTE indicates that damage to property may occur.

• CAUTION indicates possible minor to medium personal

injury.

• WARNING indicates possible severe personal injury.

• DANGER indicates a potential for loss of life.

Important Information

Important information neither indicating personal injury nor damage to property are marked with this symbol. They are separated by lines above and below the text.

1.2 Safety instructions

Safety first. Never risk your health or your life. Your own safety must always take the highest priority.

Use approved personal protective devices and common sense safety measures.

If you smell gas

B Turn off the gas cock (Æ page 58).

B Open windows and doors.

B Do not operate any electrical switches.

B Extinguish all open flames.

B From outside the building, call gas utility company and

a trained and certified heating contractor.

If you smell flue gas

B Switch OFF the appliance (Æ page 59).

B Open windows and doors.

B Inform a trained and certified heating contractor.

Danger of electric shock when the control panel is open

B Always disconnect the appliance from the mains power

before performing any work. Disconnect the emergency shutoff switch or disengage the heating system circuit breaker.

B Take measures to prevent accidental reconnection.

Additional symbols

Symbol Explanation

Cross-reference to other points in this

•

–

Tab. 1 Additional Symbols

Sequence of steps

document or to other documents

Listing/list entry

Listing/list entry (2nd level)

For appliances operating on room air: Danger of flue gas poisoning if supply of combustion air is insufficient

B Safeguard supply of combustion air.

B The ventilation and exhaust openings must never be

plugged. The cross section of the ventilation and exhaust openings must comply with the design specifications at all times.

B Safeguard sufficient supply of combustion air also for

appliances installed at a later date, e.g. kitchen exhaust fans, clothes dryers, and air conditioning units with vent to the outside.

B Never install a barometric nor a thermally controlled

vent damper with this boiler.

B If the ventilation and exhaust openings do not comply

with the specifications, the heating system must never be operated.

B Notify operator and building owner of the defect in

writing.

Page 5

Guideline to symbols and safety instructions | 5

Danger of explosion of flammable gases.

B Only employ a trained and certified contractor to carry

out work on the gas train.

Installation and conversion

Only have the appliance installed or modified by a trained and certified heating contractor.

Always follow state of the art construction techniques for installation and maintenance, and observe all applicable codes and regulations.

Never modify any parts that carry flue gas.

Only trained and certified contractors are permitted to carry out electrical work. Follow applicable code.

The DHW tank may only be used for heating domestic hot water.

Never close the outlet of safety valves. Water may be expelled from any safety valve during heat-up.

Inspection and maintenance

The operator is responsible for the safety and environmental compliance of the heating system.

It is recommended to arrange a maintenance and inspection contract with a trained and certified contractor, covering an annual inspection and demanddependent maintenance. This guarantees high efficiency and environmentally sound combustion.

Do not attempt to repair parts that have built in safety features. Always replace the part. Only use original Bosch spare parts. Bosch does not accept responsibility for damage caused by third party spare parts.

Combustion air/room air

B To prevent corrosion, keep the supply of combustion/

room air free of corrosive substances (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds).

B Avoid drawing in combustion air from outdoors that is

excessively loaded with dust or airborne particles. Install adequate air filters under the following circumstances:

– Air supply is contaminated with dust from dirt roads

and paths.

– Air supply is contaminated with dust from production

and processing facilities, e.g. quarries, mines, etc.

– Airborne seeds from thistles and similar plants.

– Halogen-hydrocarbon compounds, e.g. from paint

booths or hair salons.

Risk of system damage due to unsuitable fill water

Risk of system damage due to corrosion or scale formation as the result of using fill and top-up water that does not conform to the system-specific requirements.

Risk of system damage from freezing

The heating system can freeze up and burst in cold weather if it is shut down or locked out.

B Leave the heating system turned on as much as

possible.

B Protect a disabled heating system from freezing by

draining the boiler and water pipes at the lowest point.

Perform maintenance annually. Check the complete heating system for defects and malfunction.

Mitigate defects immediately to avoid larger scale system damage.

To prevent damage to the appliance or the system from descaling agents, remove parts to be descaled during the process.

Explosive and easily combustible materials

Never use or store easily combustible materials (paper, thinners, paints, etc.) near the appliance.

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6 | Scope of delivery

2 Scope of delivery

2.1 ZBR - Boiler for space heating and loading of indirect fired DHW tanks

Contents of package 1:

1 Gas condensing boiler 2 Set of documents for appliance 3 Mounting bracket with mounting kit 4 Gas conversion kit 5 Adapter for connection of a LWCO

6 720 641 933-22.1O

Fig. 1 Scope of delivery heating boiler ZBR..-3A

Contents of package 2: 6 Rail with connection box

7 Flue adapter 8 DHW tank temperature sensor (NTC) 9 Hydraulics connection plate with mounting kit 10 External supply temperature sensor (NTC) 11 Outdoor reset control FW 200 with mounting kit and outdoor

temperature sensor

12 Set of documents for outdoor reset control FW 200

Page 7

2.2 ZWB - Combi boiler for space heating and DHW generation

Contents of package 1:

1 Gas condensing boiler 2 Set of documents for appliance 3 Mounting bracket with mounting kit 4 Gas conversion kit 5 Adapter for connection of a LWCO

Scope of delivery | 7

Fig. 2 Scope of delivery combi boiler ZWB..-3A

6 720 641 933-04.1O

Contents of package 2: 6 Rail with connection box 7 Flue adapter 8 Hydraulics connection plate with mounting kit 9 External supply temperature sensor (NTC) 10 Outdoor reset control FW 200 with mounting kit and outdoor

temperature sensor

11 Set of documents for outdoor reset control FW 200

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8 | Information about the appliance

3 Information about the appliance

ZBR appliances are boilers for central heating and loading

of an indirect fired DHW tank.

ZWB appliances are combi boilers for central heating and on demand DHW heating.

The appliances comply with South Coast Air Quality Management District (SCAQMD) 2012 requirements: (Type-1) 14 Ng/J NOx (and/or 20 ppm at 3% O2).

3.2 Overview of boiler types

Table 2 describes the meaning of the model number:

ZBR16-3

ZBR28-3

ZBR35-3

A 23

3.1 Proper use

The appliance may only be installed in closed loop hot water central heating systems.

Any other purpose is considered improper use. Any resulting damage is excluded from the manufacturer's warranty.

The commercial and industrial use of the appliance for generating process heat is not permitted.

ZBR42-3

ZWB28-3

ZWB42-3

A 23

Tab. 2 Appliance types

Z Central heating appliance W DHW heating B Condensing technology R Constant temperature control 16 Output up to 54,600 BTU/hr (16 kW) 28 Output and DHW output up to 95,500 BTU/hr (28 kW) 35 Output up to 119,400 BTU/hr (35 kW) 42 Output and DHW output up to 143,300 BTU/hr (42 kW)

-3 Version A Fan-supported appliance 23 Natural gas (NG)

Appliance AHRI Efficiency Rating

ZBR16-3

ZBR28-3

ZBR35-3

ZBR42-3

96.1 %

95.9 %

95.0 %

94.3 %

ZWB28-3

ZWB42-3

Tab. 3 Initial AHRI Rating

95.9 %

94.3 %

Page 9

Information about the appliance | 9

3.3 Rating plate

The rating plate is located at the right side of the appliance.

6 720 641 933-84.1O

Fig. 3 Position of the rating plate

The rating plate contains the appliance output, model number, approval data and serial number.

3.4 Appliance description

• Appliance for wall installation, regardless of chimney and room size

• Outdoor reset control FW 200

• Intelligent boiler pump control

• Heatronic boiler control with 2-wire BUS

• Three-speed boiler circulator

• Automatic air vent (combi boiler ZWB..-3A only)

• Display

• Automatic ignition

• Continuously-controlled output

• Full protection via the Heatronic with flame rod and

solenoid valves

• No minimum circulating water flow rate required

• Suitable for radiant floor heating

• Flue adapter for flue gas and combustion air with test

ports

• Variable speed fan

• Gas premix burner

• Temperature sensor and temperature control for space

heating

• Supply temperature sensor

• Temperature limiter

• Safety relief valve, pressure gauge

• Expansion vessel (combi boiler ZWB..-3A only)

• Connection possibility for DHW tank temperature

sensor (NTC) (heating boiler ZBR..-3A only)

• Flue gas temperature limiter

• DHW priority (combi boiler ZWB..-3A only)

• Motorized 3-way valve (combi boiler ZWB..-3A only)

• Hydraulics connection plate

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10 | Information about the appliance

3.5 Accessories

Here you will find a list of typical accessories for this appliance. Refer to the Bosch Product Catalog for a complete overview of all available accessories.

• FB 100 room control

• Modules for system expansions:

– ISM2 for solar systems (DHW heating, space heating

support, pool heating)

– IPM2 for one or two heating zones with pump control

and motorized mixing capability

Page 11

3.6 Product dimensions and minimum clearances

Information about the appliance | 11

≥ 4" *

(102 mm) *

≥ 4" *

(102 mm) *

17-21/64" (440 mm)

≥ 15"

3-11/32"

(381 mm)

(85 mm)

(850 mm)

33-15/32"

≥ 4" **

(102 mm) **

(862 mm)

33-15/16"

9-29/64"

(240 mm)

7-7/8"

(200 mm)

Fig. 4 Dimensions and minimum clearances (front view, rear view, side view)

1 Appliance jacket 2 Service cover 3 Hydraulics connection plate

33-27/64"

1-3/16"

(30 mm)

≥ 4" *

(102 mm) *

13-57/64"

(849 mm)

(*) Zero clearance from combustibles permitted, but 4" (102 mm)

recommended for serviceability

(**) Distance to door, if mounted inside a closet

(353 mm)

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6 720 641 933-01.1O

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12 | Information about the appliance

3.7 Appliance layout heating boiler ZBR..-3A

24 23 22 21 20

37 38

39 40

2 3 4

11 10

min

Fig. 5 Appliance layout heating boiler ZBR..-3A

6 720 641 933-02.1O

Page 13

Key to Fig. 5:

1 Heatronic boiler control 2 ON/OFF switch 3 Burner flame indicator 4 Service button 5 Emissions test button 6 Boiler high limit dial 7 Mounting socket for outdoor reset controls 8 DHW thermostat 9 Key pad lock 10 ECO button 11 Reset button 12 Display 13 Condensate trap 14 Test ports for inlet gas pressure 15 Adjustment screw, minimum gas volume 16 Maximum gas adjuster 17 Flue gas temperature limiter 18 Combustion air intake 19 Exhaust pipe 20 Boiler supply pipe 21 Connection for optional low water cut off (LWCO) 22 Additional supply temperature limiter 23 Manual air bleeder 24 Gas/air premix chamber 25 Fan 26 Bracket 27 Wall hanging bracket 28 Exhaust pipe 29 Sight glass 30 Set of electrodes 31 Supply temperature sensor 32 Boiler block temperature limiter 33 Inspection and cleanout cover 34 Condensate collector 35 Boiler circulator 36 Pump speed switch 37 Condensate drain hose 38 Drain cock 39 Safety relief valve discharge hose 40 Pressure relief valve (heating zone) 41 Boiler water pressure gauge

Information about the appliance | 13

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14 | Information about the appliance

3.8 Appliance layout combi boiler ZWB..-3A

25 24

20 19

39 40

41 42

43 44

2 3 4 5

min

Fig. 6 Appliance layout combi boiler ZWB..-3A

12 11 10

6 720 641 933-03.1O

Page 15

Key to Fig. 6:

1 Heatronic boiler control 2 ON/OFF switch 3 Burner flame indicator 4 Service button 5 Emissions test button 6 Boiler high limit dial 7 Mounting socket for outdoor reset controls 8 DHW thermostat 9 Key pad lock 10 ECO button 11 Reset button 12 Display 13 Condensate trap 14 Test ports for inlet gas pressure 15 Adjustment screw, minimum gas volume 16 DHW temperature sensor 17 Plate-type heat exchanger 18 Automatic air vent 19 Maximum gas adjuster 20 Flue gas temperature limiter 21 Combustion air intake 22 Supply pipe 23 Connection for optional low water cut off (LWCO) 24 Additional supply temperature limiter 25 Gas/air premix chamber 26 Expansion vessel 27 Fan 28 Bracket 29 Wall hanging bracket 30 Exhaust pipe 31 Sight glass 32 Set of electrodes 33 Supply temperature sensor 34 Boiler block temperature limiter 35 Inspection and cleanout cover 36 Condensate collector 37 Flow meter 38 3-way valve 39 Drain cock 40 Condensate drain hose 41 Boiler circulator 42 Pump speed switch 43 Pressure relief valve (heating zone) 44 Safety relief valve discharge hose 45 Boiler water pressure gauge

Information about the appliance | 15

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16 | Information about the appliance

3.9 Electrical wiring heating boiler ZBR..-3A

LS NS

9 VAC

120 VAC

25 VAC

14 15

120 VAC

Fig. 7 Electrical wiring diagram heating boiler ZBR..-3A

6 720 641 933-23.1O

Page 17

Information about the appliance | 17

Key to Fig. 7:

1 Ignition transformer 2 Boiler high limit dial 3 120 VAC connection 4 DHW tank primary pump or 3-way valve 5 External heating pump for unmixed heating circuit (secondary circuit) 2) or DHW recirculation pump 6 Fuse T 6.3 A (120 VAC) 7 DHW thermostat 8 External safety high limit or low water cut off (LWCO) 9 BUS connection, e.g. heating control 10 Room thermostat – dry contact 11 Outdoor temperature sensor 12 Code plug 13 Diagnostic interface 14 ON/OFF switch 15 Transformer 16 Gas valve 17 Fan 18 Flue gas temperature limiter 19 Supply temperature sensor 20 Flame rod electrode 21 Ignition electrode 22 Boiler block temperature limiter 23 DHW tank temperature sensor (NTC) 24 Boiler circulator 25 Additional supply temperature limiter 26 External system supply temperature sensor

1) Set the service function 1.F,Æ page 67

2) Set the service function 5.E, Æ page 71

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18 | Information about the appliance

3.10 Electrical wiring combi boiler ZWB..-3A

LS NS

9 VAC

120 VAC

25 VAC

120 VAC

Fig. 8 Electrical wiring diagram combi boiler ZWB..-3A

6 720 641 933-24.1O

Page 19

Key to Fig. 8:

1 Ignition transformer 2 Boiler high limit dial 3 120 VAC connection 4 External heating pump for unmixed heating circuit (secondary circuit) 5 Fuse T 6.3 A (120 VAC) 6 DHW thermostat 7 External safety high limit or low water cut off (LWCO) 8 BUS connection, e.g. heating control 9 Room thermostat – dry contact 10 Outdoor temperature sensor 11 Code plug 12 Diagnostic interface 13 ON/OFF switch 15 Transformer 14 Gas valve 16 Fan 17 Flue gas temperature limiter 18 Supply temperature sensor 19 Flame rod electrode 20 Ignition electrode 21 Boiler block temperature limiter 22 DHW temperature sensor 23 Boiler circulator 24 3-way valve (Space heating/DHW heating) 25 Flow meter (turbine) 26 Additional supply temperature limiter 27 External system supply temperature sensor

Information about the appliance | 19

or DHW recirculation pump

1) Set the service function 5.E, Æ page 71

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20 | Information about the appliance

3.11 Technical data heating boiler ZBR16-3A...

Unit NG LPG (propane)

Output

Maximum nominal output (P Maximum nominal output (P Maximum nominal output (P Max. nominal thermal load (Q Max. nominal thermal load (Q Min. nominal output (P Min. nominal output (P Min. nominal output (P

min

Min. nominal thermal load (Q Min. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q Min. nominal thermal load (Q Min. nominal thermal load (Q

Gas connection value

Natural Gas – Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft Liquid Propane Gas – H

Permissible inlet gas pressure

NG in. W.C. (mbar) 3.5-10.5" (8.7-26.1) – LPG (propane) in. W.C. (mbar) – 8-13" (19.9-32.3)

Calculation values for calculating cross-section to EN 13384

Flue gas mass flow at maximum/minimum nominal output gps 6.8/1.7 6.7/2.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum

nominal heat input CO2 at max. nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4

Condensate

Max. condensate quantity (tR = 86 °F (30 °C)) gph (l/h) 0.32 (1.2) 0.32 (1.2) pH level, approx. 4.8 4.8

Tab. 4 Technical data heating boiler ZBR16-3A...

) 104/86 °F (40/30 °C) BTU/hr (kW) 54,900 (16.1) 55,300 (16.2)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 54,300 (15.9) 54,600 (16.0)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 50,800 (14.9) 51,200 (15.0)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 51,500 (15.1) 51,900 (15.2)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 57,200 (16.8) 56,400 (16.5)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 12,600 (3.7) 21,500 (6.3) ) 122/86 °F (50/30 °C) BTU/hr (kW) 12,600 (3.7) 21,500 (6.3) ) 176/140 °F (80/60 °C) BTU/hr (kW) 11,300 (3.3) 19,400 (5.7)

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 11,600 (3.4) 19,800 (5.8)

min

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 12,900 (3.8) 21,500 (6.3)

min

) tank (Hi) BTU/hr (kW) 51,500 (15.1) 51,900 (15.2)

max

) tank (Hs)BTU/hr (kW)57,200 (16.8) 56,400 (16.5)

max

) tank (Hi)BTU/hr (kW)11,600 (3.4) 19,800 (5.8)

min

) tank (Hs)BTU/hr (kW)12,900 (3.8) 21,500 (6.3)

min

/hr (m3/h) 56 (1.6) –

= 2,500 BTU/ft3 (93.1 MJ/m3)ft

D-S

/hr (m3/h) – 22 (0.6)

°F ( °C)

136/133 (58/56) 136/133 (58/56)

99/88 (37/31) 99/88 (37/31)

Page 21

Information about the appliance | 21

Unit NG LPG (propane)

General

Voltage VAC 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (Stand-by) W <6 <6 Noise level dB(A) Maximum supply temperature °F ( °C) 194 (90) 194 (90) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs. (kg) 103.6 (47) 103.6 (47)

Dimensions, W x H x D

inch

(mm)

≤

17-21/64" × 33-15/32" × 13-57/64"

(440 × 850 × 353)

≤

Tab. 4 Technical data heating boiler ZBR16-3A...

6 720 643 068 (2011/06)Copyright (optional information)

Page 22

22 | Information about the appliance

3.12 Technical data heating boiler ZBR28-3A...

Unit NG LPG (propane)

Output

min

Min. nominal thermal load (Q Min. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q Min. nominal thermal load (Q Min. nominal thermal load (Q

Gas connection value

Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)ft Liquid Propane Gas – H

Permissible inlet gas pressure

NG in. W.C. (mbar) 3.5-10.5" (8.7-26.1) LPG (propane) in. W.C. (mbar) – 8-13" (19.9-32.3)

Calculation values for calculating cross-section to EN 13384

Flue gas mass flow at maximum/minimum nominal output gps 12.0/3.2 11.6/4.8 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum

nominal heat input CO2 at max. nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4

Condensate

Max. condensate quantity (tR = 86 °F (30 °C)) gph (l/h) 0.6 (2.3) 0.6 (2.3) pH level, approx. 4.8 4.8

Tab. 5 Technical data heating boiler ZBR28-3A...

) 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 89,400 (26.2) 89,400 (26.2)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 90,800 (26.6) 90,800 (26.6)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 100,800 (29.5) 98,600 (28.9)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 23,900 (7.0) 39,900 (11.7) ) 122/86 °F (50/30 °C) BTU/hr (kW) 23,900 (7.0) 39,600 (11.6) ) 176/140 °F (80/60 °C) BTU/hr (kW) 21,800 (6.4) 36,200 (10.6)

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 22,200 (6.5) 36,800 (10.8)

min

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 24,600 (7.2) 40,100 (11.7)

min

) tank (Hi) BTU/hr (kW) 90,800 (26.6) 90,800 (26.6)

max

) tank (Hs)BTU/hr (kW)100,800 (29.5) 98,600 (28.9)

max

) tank (Hi)BTU/hr (kW)22,200 (6.5) 36,800 (10.8)

min

) tank (Hs)BTU/hr (kW)24,600 (7.2) 40,100 (11.7)

min

/hr (m3/h) 99 (2.8) –

= 2,500 BTU/ft3 (93.1MJ/m3)ft

D-S

/hr (m3/h) – 39 (1.1)

°F ( °C)

147/133 (64/56) 147/133 (64/56)

117/90 (47/32) 117/90 (47/32)

Page 23

Information about the appliance | 23

Unit NG LPG (propane)

General

Dimensions, W x H x D

inch

(mm)

≤

17-21/64" × 33-15/32" × 13-57/64"

(440 × 850 × 353)

≤

Tab. 5 Technical data heating boiler ZBR28-3A...

6 720 643 068 (2011/06)Copyright (optional information)

Page 24

24 | Information about the appliance

3.13 Technical data heating boiler ZBR35-3A...

Unit NG LPG (propane)

Output

min

Min. nominal thermal load (Q Min. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q Min. nominal thermal load (Q Min. nominal thermal load (Q

Gas connection value

Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)ft Liquid Propane Gas – H

Permissible inlet gas pressure

NG in. W.C. (mbar) 3.5-10.5" (8.7-26.1) – LPG (propane) in. W.C. (mbar) – 8-13" (19.9-32.3)

Calculation values for calculating cross-section to EN 13384

Flue gas mass flow at maximum/minimum nominal output gps 15.7/4.5 15.2/5.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum

nominal heat input CO2 at max. nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4

Condensate

Max. condensate quantity (tR = 86 °F (30 °C)) gph (l/h) 0.8 (3.1) 0.8 (3.1) pH level, approx. 4.8 4.8

Tab. 6 Technical data heating boiler ZBR35-3A...

) 104/86 °F (40/30 °C) BTU/hr (kW) 122,800 (36.0) 122,800 (36.0)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 121,800 (35.7) 121,800 (35.7)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 116,700 (34.2) 116,700 (34.2)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 118,700 (34.8) 118,700 (34.8)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 131,900 (38.6) 129,100 (37.8)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 35,100 (10.3) 46,100 (13.5) ) 122/86 °F (50/30 °C) BTU/hr (kW) 34,800 (10.2) 45,700 (13.4) ) 176/140 °F (80/60 °C) BTU/hr (kW) 31,700 (9.3) 42,000 (12.3)

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 32,400 (9.5) 42,700 (12.5)

min

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 36,000 (10.5) 46,400 (13.6)

min

) tank (Hi) BTU/hr (kW) 118,700 (34.8) 118,700 (34.8)

max

) tank (Hs)BTU/hr (kW)131,900 (38.6) 129,100 (37.8)

max

) tank (Hi)BTU/hr (kW)32,400 (9.5) 42,700 (12.5)

min

) tank (Hs)BTU/hr (kW)36,000 (10.5) 46,400 (13.6)

min

/hr (m3/h) 130 (3.7) –

= 2,500 BTU/ft3 (93.1MJ/m3)ft

D-S

/hr (m3/h) – 52 (1.5)

°F ( °C)

162/135 (72/57) 162/135 (72/57)

127/91 (53/33) 127/91 (53/33)

Page 25

Information about the appliance | 25

Unit NG LPG (propane)

General

Dimensions, W x H x D

inch

(mm)

≤

17-21/64" × 33-15/32" × 13-57/64"

(440 × 850 × 353)

≤

Tab. 6 Technical data heating boiler ZBR35-3A...

6 720 643 068 (2011/06)Copyright (optional information)

Page 26

26 | Information about the appliance

3.14 Technical data heating boiler ZBR42-3A...

Unit NG LPG (propane)

Output at elevation 0 - 2000 feet (0 - 610 m)

min

Min. nominal thermal load (Q Min. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q Min. nominal thermal load (Q Min. nominal thermal load (Q

Output at elevation 2000 - 4500 feet (611 - 1372 m) above sea level

Maximum nominal output (P Maximum nominal output (P Maximum nominal output (P Max. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q

Output at elevation 4500 - 7000 feet (1373 - 2134 m) above sea level

Maximum nominal output (P Maximum nominal output (P Maximum nominal output (P Max. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal thermal load (Q

Gas connection value

Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)ft Liquid Propane Gas – H

Permissible inlet gas pressure

NG in. W.C. (mbar) 3.5-10.5" (8.7-26.1) – LPG (propane) in. W.C. (mbar) – 8-13" (19.9-32.3)

Tab. 7 Technical data heating boiler ZBR42-3A...

) 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 134,400 (39.4) 134,400 (39.4)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 136,500 (40.0) 136,500 (40.0)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 151,600 (44.4) 148,300 (43.5)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 35,500 (10.4) 46,400 (13.6) ) 122/86 °F (50/30 °C) BTU/hr (kW) 35,100 (10.3) 46,100 (13.5) ) 176/140 °F (80/60 °C) BTU/hr (kW) 31,700 (9.3) 42,000 (12.3)

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 32,400 (9.5) 42,700 (12.5)

min

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 36,000 (10.5) 46,400 (13.6)

min

) tank (Hi) BTU/hr (kW) 136,500 (40.0) 136,500 (40.0)

max

) tank (Hs)BTU/hr (kW)151,600 (44.4) 148,300 (43.5)

max

) tank (Hi)BTU/hr (kW)32,400 (9.5) 42,700 (12.5)

min

) tank (Hs)BTU/hr (kW)36,000 (10.5) 46,400 (13.6)

min

) 104/86 °F (40/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 120,960 (35.5) 126,336 (37.0)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 122,850 (36.0) 128,310 (37.6)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 136,440 (40.0) 139,402 (40.9)

max

) tank (Hi) BTU/hr (kW) 122,850 (36.0) 128,310 (37.6)

max

) tank (Hs)BTU/hr (kW)136,440 (40.0) 139,402 (40.9)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 111,552 (32.7) 116,928 (34.3)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 113,295 (33.2) 118,755 (34.8)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 125,828 (36.9) 129,021 (37.8)

max

) tank (Hi) BTU/hr (kW) 113,295 (33.2) 118,755 (34.8)

max

) tank (Hs)BTU/hr (kW)125,828 (36.9) 129,021 (37.8)

max

/hr (m3/h) 149 (4.2) –

= 2,500 BTU/ft3 (93.1MJ/m3)ft

D-S

/hr (m3/h) – 59 (1.7)

Page 27

Information about the appliance | 27

Unit NG LPG (propane)

Calculation values for calculating cross-section to EN 13384

Flue gas mass flow at maximum/minimum nominal output gps 18.0/4.5 17.5/5.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum

nominal heat input CO2 at max. nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4

Condensate

Max. condensate quantity (tR = 86 °F (30 °C)) gph (l/h) 0.9 (3.5) 0.9 (3.5) pH level, approx. 4.8 4.8

General

Dimensions, W x H x D

°F ( °C)

inch

(mm)

171/135 (77/57) 171/135 (77/57)

133/91 (56/33) 133/91 (56/33)

≤

17-21/64" × 33-15/32" × 13-57/64"

(440 × 850 × 353)

≤

Tab. 7 Technical data heating boiler ZBR42-3A...

6 720 643 068 (2011/06)Copyright (optional information)

Page 28

28 | Information about the appliance

3.15 Technical data combi boiler ZWB28-3A...

Unit NG LPG (propane)

Output at elevation 0 - 2000 feet (0 - 610 m)

min

Min. nominal thermal load (Q Min. nominal thermal load (Q Max. nominal output (P Max. nominal output (P

max

Max. nominal thermal load (Q Max. nominal thermal load (Q Min. nominal thermal load (Q Min. nominal thermal load (Q

Gas connection value

Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)ft Liquid Propane Gas – H

Permissible inlet gas pressure

NG in. W.C. (mbar) 3.5-10.5" (8.7-26.1) – LPG (propane) in. W.C. (mbar) – 8-13" (19.9-32.3)

Expansion vessel

Pre-charge pressure psi (bar) 10.9 (0.75) 10.9 (0.75) Total contents Gal (L) 3.17 (12) 3.17 (12)

DHW

Max. DHW flow rate gpm (l/min) 2.64 (10) 2.64 (10) Nominal DHW quantity (at 140 °F (60 °C) outlet temperature) gpm (l/min) 2.03 (7.7) 2.03 (7.7) Outlet temperature °F ( °C) 104 - 140 (40 - 60) 104 - 140 (40 - 60) Max. cold water inlet temperature °F ( °C) 140 (60) 140 (60) Max. approved DHW pressure psi (bar) 150 (10.3) 150 (10.3) Minimum water pressure psi (bar) 4.35 (0.3) 4.35 (0.3) Specific flow rate to EN 625 (D) gpm (l/min) 3.75 (14.2) 3.75 (14.2)

Calculation values for calculating cross-section to EN 13384

Flue gas mass flow at maximum/minimum nominal output gps 12.0/3.2 11.7/4.9 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum

nominal heat input CO2 at max. nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4

Condensate

Max. condensate quantity (tR = 86 °F (30 °C)) gph (l/h) 0.6 (2.3) 0.6 (2.3) pH level, approx. 4.8 4.8

Tab. 8 Technical data combi boiler ZWB28-3A...

) 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 89,400 (26.2) 89,400 (26.2)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 90,800 (26.6) 90,800 (26.6)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 100,800 (29.5) 98,600 (28.9)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 23,900 (7.0) 39,900 (11.7) ) 122/86 °F (50/30 °C) BTU/hr (kW) 23,900 (7.0) 39,600 (11.6) ) 176/140 °F (80/60 °C) BTU/hr (kW) 21,800 (6.4) 36,200 (10.6)

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 22,200 (6.5) 36,800 (10.8)

min

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 24,600 (7.2) 40,100 (11.7)

min

) DHW (Hi) 113°F (45°C) BTU/hr (kW) 93,600 (27.4) 93,600 (27.4) ) DHW (Hs) 140°F (60°C) BTU/hr (kW) 91,400 (26.8) 91,400 (26.8)

) DHW (Hi) BTU/hr (kW) 90,800 (26.6) 90,800 (26.6)

max

) DHW (Hs)BTU/hr (kW)100,800 (29.5) 98,600 (28.9)

max

) DHW (Hi)BTU/hr (kW)22,200 (6.5) 36,800 (10.8)

min

) DHW (Hs)BTU/hr (kW)24,600 (7.2) 40,100 (11.7)

min

/hr (m3/h) 99 (2.8) –

= 2,500 BTU/ft3 (93.1MJ/m3)ft

D-S

/hr (m3/h) – 39 (1.1)

°F ( °C)

147/133 (64/56) 147/133 (64/56)

117/90 (47/32) 117/90 (47/32)

Page 29

Information about the appliance | 29

Unit NG LPG (propane)

General

Dimensions, W x H x D

inch

(mm)

≤

17-21/64" × 33-15/32" × 13-57/64"

(440 × 850 × 353)

≤

Tab. 8 Technical data combi boiler ZWB28-3A...

6 720 643 068 (2011/06)Copyright (optional information)

Page 30

30 | Information about the appliance

3.16 Technical data combi boiler ZWB42-3A...

Unit NG LPG (propane)

Output at elevation 0 - 2000 feet (0 - 610 m)

min

Min. nominal thermal load (Q Min. nominal thermal load (Q Max. nominal output (P Max. nominal output (P

max

Max. nominal thermal load (Q Max. nominal thermal load (Q Min. nominal thermal load (Q Min. nominal thermal load (Q

Output at elevation 2000 - 4500 feet (611 - 1372 m) above sea level

Maximum nominal output (P Maximum nominal output (P Maximum nominal output (P Max. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal output (P Max. nominal output (P

max

Max. nominal thermal load (Q Max. nominal thermal load (Q

Output at elevation 4500 - 7000 feet (1373 - 2134 m) above sea level

Maximum nominal output (P Maximum nominal output (P Maximum nominal output (P Max. nominal thermal load (Q Max. nominal thermal load (Q Max. nominal output (P Max. nominal output (P

max

Max. nominal thermal load (Q Max. nominal thermal load (Q

Gas connection value

Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)ft Liquid Propane Gas – H

Permissible inlet gas pressure

NG in. W.C. (mbar) 3.5-10.5" (8.7-26.1) – LPG (propane) in. W.C. (mbar) – 8-13" (19.9-32.3)

Expansion vessel

Pre-charge pressure psi (bar) 10.9 (0.75) 10.9 (0.75) Total contents Gal (L) 3.17 (12) 3.17 (12)

DHW

Max. DHW flow rate gpm (l/min) 3.963 (15) 3.963 (15) Nominal DHW quantity (at 140 °F (60 °C) outlet temperature) gpm (l/min) 3.61 (11.4) 3.61 (11.4) Outlet temperature °F ( °C) 104 - 140 (40 - 60) 104 - 140 (40 - 60) Max. cold water inlet temperature °F ( °C) 140 (60) 140 (60) Max. approved DHW pressure psi (bar) 150 (10.3) 150 (10.3) Minimum water pressure psi (bar) 4.35 (0.3) 4.35 (0.3)

Tab. 9 Technical data combi boiler ZWB42-3A...

) 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 134,400 (39.4) 134,400 (39.4)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 136,500 (40.0) 136,500 (40.0)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 151,600 (44.4) 148,300 (43.5)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 35,500 (10.4) 46,400 (13.6) ) 122/86 °F (50/30 °C) BTU/hr (kW) 35,100 (10.3) 46,100 (13.5) ) 176/140 °F (80/60 °C) BTU/hr (kW) 31,700 (9.3) 42,000 (12.3)

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 32,400 (9.5) 42,700 (12.5)

min

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 36,000 (10.5) 46,400 (13.6)

min

) DHW (Hi) 113°F (45°C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) ) DHW (Hs) 140°F (60°C) BTU/hr (kW) 135,800 (39.8) 135,800 (39.8)

) DHW (Hi) BTU/hr (kW) 136,500 (40.0) 136,500 (40.0)

max

) DHW (Hs)BTU/hr (kW)151,600 (44.4) 148,300 (43.5)

max

) DHW (Hi)BTU/hr (kW)32,400 (9.5) 42,700 (12.5)

min

) DHW (Hs)BTU/hr (kW)36,000 (10.5) 46,400 (13.6)

min

) 104/86 °F (40/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 120,960 (35.5) 126,336 (37.0)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 122,850 (36.0) 128,310 (37.6)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 136,440 (40.0) 139,402 (40.9)

max

) DHW (Hi) 113°F (45°C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9) ) DHW (Hs) 140°F (60°C) BTU/hr (kW) 122,220 (35.8) 127,652 (37.4)

) DHW (Hi) BTU/hr (kW) 122,850 (36.0) 128,310 (37.6)

max

) DHW (Hs)BTU/hr (kW)136,440 (40.0) 139,402 (40.9)

max

) 104/86 °F (40/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1)

max

) 122/86 °F (50/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1)

max

) 176/140 °F (80/60 °C) BTU/hr (kW) 111,552 (32.7) 116,928 (34.3)

max

) heating (Hi) 180/79 °F (82/26 °C) BTU/hr (kW) 113,295 (33.2) 118,755 (34.8)

max

) heating (Hs) 180/79 °F (82/26 °C) BTU/hr (kW) 125,828 (36.9) 129,021 (37.8)

max

) DHW (Hi) 113°F (45°C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1) ) DHW (Hs) 140°F (60°C) BTU/hr (kW) 112,714 (33.0) 118,146 (34.6)

) DHW (Hi) BTU/hr (kW) 113,295 (33.2) 118,755 (34.8)

max

) DHW (Hs)BTU/hr (kW)125,828 (36.9) 129,021 (37.8)

max

/hr (m3/h) 149 (4.2) –

= 2,500 BTU/ft3 (93.1MJ/m3)ft

D-S

/hr (m3/h) – 59 (1.7)

Page 31

Information about the appliance | 31

Unit NG LPG (propane)

Calculation values for calculating cross-section to EN 13384

Flue gas mass flow at maximum/minimum nominal output gps 18.0/4.5 17.5/5.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum

nominal heat input CO2 at max. nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4

Condensate

Max. condensate quantity (tR = 86 °F (30 °C)) gph (l/h) 0.9 (3.5) 0.9 (3.5) pH level, approx. – 4.8 4.8

General

Dimensions, W x H x D

°F ( °C)

inch

(mm)

171/135 (77/57) 171/135 (77/57)

133/91 (56/33) 133/91 (56/33)

≤

17-21/64" × 33-15/32" × 13-57/64"

(440 × 850 × 353)

≤

Tab. 9 Technical data combi boiler ZWB42-3A...

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32 | Information about the appliance

3.17 Condensate composition

The condensate volume and ingredients may change with regionally and seasonally varying gas quality and air quality. Typically the following ingredients and concentrations can be expected:

Substance Value in ppm (mg/l)

Ammonium 1.2

Lead

Cadmium

Chrome

Halogenated

≤

0.01

0.001

0.005

0.002

hydrocarbons

Hydrocarbons 0.015

Copper 0.028

Nickel

Mercury

≤

0.1

≤

0.0001

Sulfate 1

Zinc

Tin

Vanadium

≤

0.015

0.01

0.001

pH-value 4.8

Tab. 10 Typical condensate composition

Page 33

4Regulations

Regulations | 33

Observe all rules, regulations, standards and guidelines applicable to the installation and operation of this appliance in your country.

In the Commonwealth of Massachusetts, this appliance must be installed by a licensed plumber and gas fitter. Valves external to the boiler must be fitted with T-handles and condensate piping must be installed in accordance with the State Plumbing Code.

4.1 Compliance with standards and regulations

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI Z223.1./NFPA 54. In Canada, installation must be in accordance with the requirements of CAN/CSA B149.1, Natural Gas and Propane Installation Code.

This wall mounted condensing gas boiler complies in its design and mode of operation with the American National Standard ANSI Z21.13/CSA4.9, latest edition for Gas Fired Low Pressure Steam and Hot Water Boilers.

4.2 Operating limits of the boiler

The heat exchanger has been designed and certified in accordance with the ASME Boiler and Pressure Vessel Code, Section IV.

Maximum boiler temperature 194 °F (90 °C)

Maximum operating pressure 30 psi (2.07 bar)

Tab. 11 Operating limits

The hot water distribution system must comply with all applicable codes and regulations. When replacing an existing boiler, it is important to check the condition of the entire hot water distribution system to ensure safe operation. Common practice calls for inspecting an existing system in its entirety and bringing it up to code. All pipework should be properly cleaned and flushed.

Other confirmed approvals and certifications are indicated by labels on the boiler.

Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Install CO detectors per local regulations. Boiler requires yearly maintenance (Æ chapter 14, page 81).

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34 | Regulations

4.3 Additional regulations for installation in Massachusetts

(a) For all side wall horizontally vented gas fueled

equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet [2150 mm] above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

– In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

– In the event that the requirements of this subdivision

can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each

carbon monoxide detector as required in accordance with the above provisions shall comply with NPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be

permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (½) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspections, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CRM 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CRM 5.08(2)(a) 1 through 4:

• The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the board; and

• Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for the installation of the equipment and venting shall include:

• Detailed instructions for the installation of the venting system or the venting system components; and

• A complete parts list for the venting system design or venting system.

ANUFACTURERS REQUIREMENTS - GAS EQUIPMENT

(d) M VENTING SYSTEM manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases, but identifies special venting systems, the following requirements shall be satisfied by the manufacturer:

1. The referenced special venting systems shall be included with the appliance or equipment installation instructions; and

2. The special venting systems shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all i nstructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or venting design instructions shall remain with the appliance or equipment at the completion of the installation.

NOT PROVIDED. When the

Page 35

5 Installation

Installation | 35

DANGER: Explosion!

B Close the gas cock prior to working on the

gas train.

B Check for gas leaks after carrying out work

on the gas train.

Installation, power connection, connection on the gas and flue gas side and commissioning must only be carried out by a contractor certified for such work by the state or local jurisdiction or the local gas or power utility.

5.1 Notes on installation and operation

When installing and operating the heating system observe the following:

• The elevation of the installation location above sea level must be taken into account (Æ Chapter 11.2).

• Follow all local building regulations regarding the installation conditions on site.

• The local building regulations regarding air supply and venting systems and the chimney flue connection.

• Electrical code requirements for connection to the electrical power supply.

• The technical regulations of the gas company regarding the connection of the gas burner to the local gas main.

• The regulations and standards relating to the DHW heating system.

5.1.1 Notes on installation and operation

Fill and make-up water for the heating system

Unsuitable fill and make-up water can result in the heating system scaling up or failing prematurely.

Water hardness in grains per gallon (Ca(HCO concentration in ppm)

soft: ≤9 grains (

≤

150 ppm)

medium: 9 - 14.6 grains (150 - 250 ppm)

hard: ≥14.6 (≥250 ppm) Required

Tab. 12 Water preparation for filling and maintaining the

heating system (water hardness)

pH-value Water preparation

7-8.5 Not needed

<7 or >8.5 Required

Tab. 13 Water preparation for filling and maintaining the

heating system (pH-value)

Recirculation pump/DHW recirculation lines

Total length DHW/ recirculation line

≤

33 ft (10 m) 0.66 gpm (2.5 l/min)

33 - 66 ft (10 - 20 m) 0.92 gpm (3.5 l/min)

3)2

Water preparation

Not needed

Recommended

Flow rate

66 - 98 ft (20 - 30 m) 1.32 gpm (5 l/min)

Tab. 14 Recommended flow rates

Use service function 6.d, to determine the current flow rate (Æ page 71).

Electrical connection of the DHW recirculation pump (Æ page 55).

Connect the DHW recirculation line with the cold water inlet as close as possible to the Hydraulics connection plate.

Open vented heating systems

B Convert open vented heating systems into closed

systems.

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36 | Installation

Gravity heating systems

B Connect the appliance to the existing piping system via

a low-loss header with a sludge separator.

Galvanized radiators or pipes.

To prevent gas formation:

B Do not use galvanized radiators or pipes.

Use of a room temperature control

B Do not install thermostatic valves on radiators in the

primary room.

Anti-freeze

NOTICE: Insufficient antifreeze can

accelerate corrosion.

B Follow manufacturer's instructions on

antifreeze concentration.

B Frost protection level has to be checked

annually during the regular scheduled maintenance of the condensing boiler.

NOTICE: System damage!

B It is the installer's responsibility to ensure

that the heating system is compatible with the boiler type and size installed.

B pH-value of the heating water to be kept in

the given ranges (Æ Tab. 13, page 35).

The following anti-freeze fluids are approved:

• Nalco (Varidos) FSK

• Alphi 11

• Glythermin NF

• Antifrogen N

• Intercool NFP-50 AA

• Tyfocor L

• NoBurst AL

Corrosion inhibitors

The following anti-corrosion agents are approved:

Designation Concentration

Nalco 77381 1 - 2 %

Sentinel X 100 1.1 %

Copal 1 %

Tab. 16 Corrosion inhibitors

Boiler sealer

This boiler is not approved for use with boiler sealer.

LPG

To protect the appliance against high pressure (ANSI/ Z223.1/NFPA54 (National fuel gas code) or CAN/CSA B

149.1 (Natural Gas and Propane installation code)):

B Install a pressure regulator with a safety valve.

5.1.2 Other important information

• The installation of this boiler must comply with all national and local code and regulations.

• Only operate this boiler with the combined air/flue system specifically designed and approved for it.

• Only use approved venting systems per the manufacturer's instructions.

• Do not dispose of untreated boiler condensate in septic systems.

• Inspect the sewer pipes for suitability before disposing of untreated boiler condensate into them.

• Verify with the local authority that disposing of untreated boiler condensate into public sewer systems is permitted.

The following concentrations are approved:

Designation Concentration

Nalco (Varidos) FSK 22 - 55 %

Glythermin NF 20 - 62 %

Intercool NFP-50 AA

Tyfocor L

NoBurst AL

0 - 39 %

25 - 80 %

0 - 55 %

Tab. 15 Anti-freeze

Page 37

Installation | 37

5.2 Comparing the size of the integrated expansion vessel

The following diagrams allow verifying that the integrated expansion vessel has sufficient capacity for the intended application, or if an additional expansion vessel is needed (not for radiant floor heating).

The following standard conditions were used:

• Precharge volume 20% of the rated volume in the

expansion vessel

• Differential to the safety valve of 7.25 psi (0.5 bar)

• Precharge pressure of the expansion vessel equal to the

static system height above the boiler

• Maximum operating pressure: 30 psi (2.07 bar)

200

180

160

/°F

140

120

100

0 20 40 80 100

III

VA/gal

120

6720641933-13.1O

/°C

Fig. 10 Operating capacity of the expansion vessel in °C

and liters

Key to Fig. 9 and Fig. 10:

I Precharge pressure 7.25 psi (0.5 bar) (default setting) II Precharge pressure 10.9 psi (0.75 bar) III Precharge pressure 14.5 psi (1.0 bar) t

Supply temperature in °F ( °C)

System capacity in gallons (liters)

A Within operating capacity of the expansion vessel (left of the

relevant curve)

B Additional expansion vessel required (right of the relevant

curve)

B If results are borderline: Determine precise vessel sizes.

B If the results are to the right of the curve: Install

additional expansion vessel.

III

0 75 150 300 375

225

VA/l

6720641933-27.1O

450

Fig. 9 Operating capacity of the expansion vessel in °F and

gallons

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38 | Installation

5.3 ZBR..-3A appliances (heating boilers): Selecting an expansion vessel

External expansion vessel

B Determine size of the expansion vessel.

5.4 Selecting the installation location

Installation location requirements

Observe the current national and local codes and regulations.

B Observe country-specific requirements.

B Observe installation instructions of the venting system

accessories and their clearances.

Combustion air

To avoid corrosion, keep the supply of combustion air free of corrosive substances; contained in solvents, paints, adhesives, propellants and domestic cleaning agents.

Industrial sources

Chemical cleaning Trichloroethylene, tetrachloroethyl-

ene, fluorinated hydrocarbons

Degreasing bath Perchloroethylene, trichloroethylene,

methylchloroform

Printing shops Trichloroethylene

Hair salons Aerosol propellants, hydrocarbons

containing fluorine and chlorine (diflu-

orodichloromethane)

Fig. 11 Sample installation - expansion vessel

6 720 641 933-20.1O

Household sources

Cleaning and

degreasing agents

Workshop

Solvents and thin-

ners

Aerosols Chlorofluorinated hydrocarbons (diflu-

Perchloroethylene, methylchloroform,

trichloroethylene, methylene chloride,

carbon tetrachloride, hydrochloric acid

Various chlorinated hydrocarbons

orodichloromethane)

Tab. 17 Corrosive materials

Surface temperature

The max. surface temperature of this appliance is below 185 °F (85 °C). According to ANSI/Z223.1/NFPA43 (National fuel gas code) and CAN/DAS B 149.1 (Natural Gas and Propane installation code), the appliance is approved for zero clearance to combustibles. For servicing a clearance of 4" (102 mm) is recommended.

Page 39

5.5 Pre-installing pipes

60/100

80/125

250

200

3°

150

100

111

B Secure the installation template (supplied with the

technical documentation) to the wall; observe the minimum side clearances of 4 inches (102 mm) (Æ page 11).

B Drill holes for the appliance and for the hydraulics

connection plate in accordance with the mounting template.

250

200

60/100

150

111 100

80/125

3°

Installation | 39

B Secure the hydraulics connection plate and the

mounting bracket with the mounting kits supplied.

Fig. 12 Mounting template

NOTICE: For walls with insufficient load capacity, the appliance and the hydraulics connection plate must be mounted on a sheet of plywood or similar reinforcement.

6 720 641 933-30.1O

Fig. 13 Mounting of the hydraulics connection plate and the

mounting bracket

6 720 641 933-45.1O

B Remove the mounting template.

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Page 40

40 | Installation

7 7/8"

1 3/16

(30 mm)

(200 mm)

1 2 3

6 720 641 933-89.1O

Fig. 14 Hydraulics connection plate for heating boiler

ZBR..-3A (front view)

1 Heating supply, R 1" NPT 2 Gas, R 3/4" NPT 3 Heating return, R 1" NPT

5 1/8

(130 mm)

7 7/8"

1 3/16

(30 mm)

(200 mm)

54321

6 720 641 933-90.1O

Fig. 16 Hydraulics connection plate for combi boiler

ZWB..-3A (front view)

1 Heating supply, R 1" NPT 2 DHW, R 3/4" NPT 3 Gas, R 3/4" NPT 4 Cold water, R 3/4" NPT 5 Heating return, R 1" NPT

5 1/8

(130 mm)

1 3/8

1 31/32

(50 mm)

10 15/64 (260 mm)

6 720 641 933-15.1O

Fig. 15 Hydraulics connection plate for heating boiler

ZBR..-3A (top view)

(35 mm)

1 31/32

(50 mm)

10 15/64

(260 mm)

1 3/8

(35 mm)

6 720 641 933-14.1O

Fig. 17 Hydraulics connection plate for combi boiler

ZWB..-3A (top view)

B Determine pipe size for the gas supply.

B To fill and drain the system, install a fill and drain valve

at the lowest point.

Page 41

5.6 Mounting the appliance

NOTICE: Residue, metal shavings, and

contaminants in the piping can damage the appliance.

B Flush the piping thoroughly and completely

to remove all residue.

B Follow the instructions with respect to

water quality (Æ Chapter 5.1, page 35).

B Remove packaging, observing all notes and symbols.

B On the rating plate, check the identification of the

target country and suitability for the gas type supplied by the local gas utility company (Æ page 12).

Removing the cover

The cover is secured with two screws against unintentional removal (electrical safety).

B Always keep the cover secured with these

screws.

Installation | 41

Hanging the appliance

B Place flat gaskets on the connections of the hydraulic

bracket.

B Hang appliance on the mounting bracket.

B Tighten the union nuts on the pipe connections.

B Undo screws (step 1).

B Lift strap (step 2) and remove cover toward the front

(step 3).

Fig. 18 Remove the cover

6 720 641 933-96.1o

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42 | Installation

5.7 Installing a low water cut off (LWCO)

The boiler is equipped with several sensors that prevent firing or running the boiler in case of low water pressure or low water levels. Nevertheless code may require the installation of a separate low water cut off (LWCO). The boiler is equipped with a dedicated port for installation of a LWCO on the supply pipe inside the boiler cabinet. This location represents the minimum water level for safe operation of the boiler.

The LWCO device must be specified for an ambient temperature of 176 °F (80 °C) and a water temperature of 250 °F (121 °C). It needs a dry contact.

The following LWCO is approved with the boiler:

• Hydrolevel Safgard 1100

The device is available at most Bosch wholesalers. It requires an external 24VAC 20VA transformer provided on site.

B Screw the LWCO as far as possible into LWCO adapter

located in the boiler accessory kit. Follow the Hydrolevel Safgard 1100 instructions.

6 720 641 933-64.1O

Fig. 20 Installing a LWCO device - LWCO adapter

B Push the adapter with the LWCO onto the pipe (step 1)

and secure with the clip (step 2).

If other LWCO devices are to be used, they must be installed external to the boiler.

The Hydrolevel Safgard 1100 is installed in the supply pipe to the left of the heat exchanger.

B Disconnect the boiler from power by shutting off the

emergency shutoff switch or disengaging the heating system circuit breaker.

B Drain the boiler.

B Remove the safety clip from the dummy plug in the

supply pipe (step 1).

B Pull off the dummy plug (step 2) and place with the

boiler documentation.

B Ensure the O-ring remains in place on the pipe.

B Lubricate the O-ring.

6 720 641 933-65.1O

Fig. 21 Installing a LWCO device – securing with a clip

B Connect the wires of the LWCO (Æ chapter 6.4,

page 57).

The LWCO is positioned upright for technical reasons. Tests have shown that all air will bleed from the pipe during commissioning and full functionality is established.

Fig. 19 Installing a LWCO device - removing dummy plug

6 720 641 933-64.1O

If fault d3 is displayed when commissioning the boiler, purge the boiler properly and check the boiler water pressure.

Page 43

5.8 Connecting flue gas accessories

Installation | 43

B Insert the flue gas adapter as far as it will go into the

vent flange and align it.

For more details on connecting the flue system, refer to the installation instructions for the flue kit.

B Install the vent flange and gasket with the screws

enclosed.

6 720 641 933-85.1O

Fig. 23 Flue gas adapter

1 Vent flange 2 Flue gas adapter 3 Combustion air test port 4 Flue gas test ports

B Tighten the screws.

B Insert the venting accessory as far as it will go into the

vent flange.

6 720 612 737-01.1O

Fig. 22 Attaching the vent flange and gasket

1 Gasket 2 Vent flange 3 Screws

6 720 641 933-26.1O

Fig. 24 Vent pipes

To avoid premature wear of the gaskets DO NOT use lubricants.

In case of open venting use basket on the air intake.

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Page 44

44 | Installation

5.8.1 Installation of the exhaust and air intake system

NOTICE:

B Vent connectors serving appliances vented

by natural draft shall not be connected to any portion of mechanical draft systems operating under positive pressure.

NOTICE: Burner damage!

B Avoid drawing in combustion air

excessively loaded with dust or airborne particles.

DANGER:

B Ensure that the flue pipes and seals are not

damaged.

B Use only sealing compounds (primer and

glue) approved with the vent material.

B Never install a barometric nor a thermally

controlled vent damper with this boiler.

B Connect only one boiler to each flue system

or chimney flue.

B Do not route the flue system piping through

or inside another duct that is used for exhausting air or other flue gases.

B The condensate trap must be primed at all

times. Failure to do so may allow combustion gases to escape into boiler room.

Consult local and state codes pertaining to special building code and fire department requirements. Adhere to national code requirements.

Observe the listed maximum lengths of vent system, which are boiler model dependent (Æ chapter 5.8.3).

Optional vent kits are:

• Concentric termination for horizontal/vertical

(Part-#196006)

• Stainless steel parallel wall terminal

(Part-#46546901)

Direct vent installations (sealed combustion)

For direct vent applications all applicable items below must be met.

6 720 641 933-19.1O

Fig. 25 Vent and combustion air pipe position of a sealed

combustion system

1 Intake 2 Exhaust X At least 1 foot (305 mm)

The termination shall terminate at least 1 foot (305 mm) below, 1 foot (305 mm) horizontally from or 1 foot (305 mm) above any door, window or gravity air inlet into any building (Æ fig. 26 [2], [X

If multiple boilers are installed in a row, allow at least 1 foot (305 mm) clearance between the vent termination of one and the combustion air intake of the other.

Vent termination must be at least 1 foot (305 mm) above grade, anticipated snow line or roof surface (Canada 1-1/2 feet (457 mm) minimum) (Æ fig. 26 [Y

Vent termination must be at least 7 feet (2135 mm) above a public walkway (Æ fig. 26 [X condensate spilling from the termination does not create a hazard or a nuisance.

Vent termination must be 3 feet (915 mm) above any forced air intake within 10 feet (3050 mm) (Æ fig. 26 [1],

], page 46).

Do not extend exposed vent pipe outside the building beyond recommended distance. Condensate could freeze and block vent pipe.

], [X3], page 46).

], page 46).

], page 46). Ensure that

Page 45

Installation | 45

Vent should terminate at least 3 feet (915 mm) away from adjacent walls, inside corners and 5 feet (1 525 mm) below roof overhang (Æ fig. 26 [X

], [X4], page 46).

It is not recommended to terminate vent above any door

The exhaust pipe must be properly supported and pitched a minimum of ¼ inch (6.35 mm) per foot back to the boiler. This allows the condensate to properly drain.

or window, condensate can freeze causing ice formations.

Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney.

All non-steel vent pipes must be glued, except for the flue gas adapter-pipe connection.

All non-steel combustion air and vent pipe materials and

NOTICE: Damage of 2 inch PVC pipes.

B For ZBR42-3A and ZWB42-3A use 2 inch

CPVC-pipes or 3 inch pipes.

fittings must comply with the following and must be UL approved venting material:

ZBR16-3A

ZBR28-3A

ZBR35-3A

Material Item United states Canada

PVC schedule 40, 80

PVC-DWV ANSI/ASTM D2665 XXX X

CPVC schedule 40, 80 ANSI/ASTM F441 XXXXXX

PVC schedule 40, 80

PVC-DWV ANSI/ASTM D2665 XXXXXX

CPVC schedule 40, 80 ANSI/ASTM F441 XXXXXX

2" (50 mm) Vent

or air pipe and

fitting

3" (76 mm) Vent

or air pipe and

fitting

ANSI/ASTM D1785

ANSI/ASTM D1785 XXXXXX

BH Gas venting

systems,

ULC S636

XXX X

ZBR42-3A

ZWB28-3A

ZWB42-3A

PVC

CPVC ANSI/ASTM F493 XXXXXX

Pipe cement/

primer

ANSI/ASTM D2564 XXXXXX

Tab. 18 Materials for pipe

1) Components of the certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings. Plastic components, and specified primers and glues of the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts.

Roof terminals Material Supplier Part number

Ø 3" / Ø 6" (Ø 76/150 mm) concentric PVC IPEX 196016

Tab. 19 Roof terminals

Wall terminals Flue System / Materials Supplier Part number

Ø 3" (Ø 76 mm) parallel stainless steel Flex-L 46546901

90°-elbow with

inlet screen

PVC (elbow)

stainless steel (screen)

IPEX (elbow)

Langly Wire (screen)

UL-S636 approval (elbow)

L2594 (screen)

Tab. 20 Wall terminals

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46 | Installation

NOTICE:

B DO NOT use cellular core pipe.

B DO NOT use PVC when using anti-freeze in

the primary circuit of the boiler. Use CPVC or stainless steel only!

NOTICE:

B Vent terminations must keep the following

minimum clearances from electric meters, gas meters, regulators and relief equipment: 4 feet (1220 mm) [Canada 6 feet (1830 mm)] horizontally and in no case above and below, unless a horizontal distance of 4 feet (1220 mm) [Canada 6 feet (1830 mm)] is maintained.

Fig. 26 Vent and combustion air pipe position

Direct vent (sealed combustion): 1 Forced Air Inlet 2 Gravity Air Inlet 3 Exhaust terminal

1 foot (305 mm)

3 feet (915 mm)

1 foot (305 mm)

5 feet (1525 mm)

7 feet (2135 mm) above public walkway

At least 1 feet (305 mm) above grade and snow line

Exhaust terminal must be at least 3 feet (915 mm) above

forced air inlet within 10 feet (3050 mm)

Fan assisted appliance (non-sealed combustion): 1 Forced Air Inlet 2 Gravity Air Inlet 3 Exhaust terminal X

1 foot (305 mm)

3 feet (915 mm)

4 feet (1220 mm)

5 feet (1525 mm)

7 feet (2135 mm) above public walkway

At least 1 foot (305 mm) above grade and snow line

Exhaust terminal must be at least 3 feet (915 mm) above

forced air inlet within 10 feet (3050 mm)

6 720 641 933-17.1O

Page 47

5.8.2 Approved examples of horizontal and vertical

venting installation

NOTICE:

B Place pipe supports every 5 feet (1525 mm)

of horizontal and vertical run, beginning with support near boiler.

B The condensate must be disposed of in

accordance with applicable rules.

B Periodic cleaning of the vent terminal and

air-intake screens is mandatory.

B Avoid locating vent terminals near equipment

or building features which can be subject to degradation from exhaust gases.

B If multiple boilers are installed in a row, allow

at least 1 foot (305 mm) clearance between the vent termination of one and the combustion air intake of the other.

≥ 12"

(305 mm)

Installation | 47

≥ 4"

(102 mm)

6 720 641 933-06.1O

Fig. 27 Horizontal venting system (room air only)

6 720 641 933-63.1O

Fig. 29 Horizontal venting system (sealed combustion)

6 720 641 933-05.1O

Fig. 28 Horizontal venting system (room air only)

Key to Fig. 27 and Fig. 28:

1 Intake 2 Exhaust

≥ 4"

(102 mm)

6 720 641 933-62.1O

Fig. 30 Horizontal venting system (sealed combustion)

Key to Fig. 29 and Fig. 30:

1 Intake, behind exhaust 2 Exhaust 3 Wall termination

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48 | Installation

1 2

6 720 641 933-09.1O

Fig. 31 Vertical venting system (sealed combustion)

6 720 641 933-07.1O

6 720 641 933-10.1O

Fig. 32 Vertical venting system (room air only) Fig. 33 Vertical venting system (sealed combustion)

Key to Fig. 31, Fig. 32 and Fig. 33:

1 Intake 2 Exhaust 3 Concentric termination X Greater than 12 inches (305 mm) Y 12 inches (305 mm) above maximum snow level or at least 24 inches (610 mm) whichever is greater

Page 49

Installation | 49

6 720 641 933-08.1O

Fig. 34 Vertical venting system (sealed combustion)

1 Intake 2 Exhaust X Greater than 12 inches (305 mm) Y 12 inches (305 mm) above maximum snow level or at least

24 inches (610 mm) whichever is greater

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50 | Installation

5.8.3 Vent and combustion air pipe lengths

3" (76 mm) Vent and combustion air pipe

For all installation situations and for all appliances the maximum vent and combustion air pipe length is 100 feet each, with no more than 8 elbows each.

2" (50 mm) Vent and combustion air pipe

The maximum combined vent and

combustion air pipe

length (Æ tab. 21, 22 and 23) depend on the installation situation, the appliance type and the number of elbows used.

Installations Æ Fig. 27, 28, 29, 31, 32 and 34 Separate terminations

2" PIPE Maximum combined pipe length

including elbows in feet (m) for

Number of elbows

ZBR16-3A ZBR28-3A

ZWB28-3A

81 ft (24.6 m) 65 ft (19.8 m)

76 ft (23.1 m) 57 ft (17.3 m)

71 ft (21.6 m) 48 ft (14.6 m)

66 ft (20.1 m) 40 ft (12.2 m)

61 ft (18.6 m) 32 ft (9.8 m)

56 ft (17.1 m) 23 ft (7.0 m)

ZBR35-3A ZBR42-3A

ZWB42-3A

Tab. 21 Vent and combustion air pipe lengths with

2" diameter and separate terminations

Installations Æ Fig. 30 Stainless steel wall termination

2" PIPE Maximum combined pipe length

including elbows in feet (m) for

Number of elbows

ZBR16-3A ZBR28-3A

ZWB28-3A

76 ft (23.1 m) 60 ft (18.3 m)

71 ft (21.6 m) 52 ft (15.9 m)

66 ft (20.1 m) 43 ft (13.1 m)

61 ft (18.6 m) 35 ft (10.7 m)

56 ft (17.1 m) 27 ft (8.2 m)

51 ft (15.6 m) 18 ft (5.5 m)

ZBR35-3A ZBR42-3A

ZWB42-3A

Tab. 22 Vent and combustion air pipe lengths with

2" diameter and the stainless steel wall termination

Installations Æ Fig. 33 Concentric termination

2" PIPE Maximum combined pipe length

including elbows in feet (m) for

Number of elbows

ZBR16-3A ZBR28-3A

ZWB28-3A

66 ft (20.1 m) 47 ft (14.3 m)

61 ft (18.6 m) 38 ft (11.6 m)

56 ft (17.1 m) 30 ft (9.1 m)

51 ft (15.6 m) 22 ft (6.7 m)

46 ft (14.1 m) 13 ft (4.0 m)

41 ft (12.5 m) 5ft (1.5m)

ZBR35-3A ZBR42-3A

ZWB42-3A

Tab. 23 Vent and combustion air pipe lengths with

2" diameter and the concentric termination

Page 51

5.9 Testing gas and water connections for

leaks

NOTICE: System damage!

Pressure, control and safety equipment may be damaged by excessive pressure.

B When you carry out a leakage test, make

sure that no pressure, control or safety equipment is installed that cannot be isolated from the test pressure.

B The boiler and its dedicated shutoff valve

must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 14" W.C. (35 mbar).

Water connections

B Open the heating supply and return valves and fill the

heating system.

B Check all connections for leakage (test pressure: Max.

30 psi (2.07 bar) on the pressure gauge).

Installation | 51

Gas line

B Close the gas shutoff valve to protect the gas valve from

damage.

B Check all connections for leakage (test pressure: Max.

60" W.C. (150 mbar)).

B Release pressure.

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52 | Making the electrical connections

6 Making the electrical connections

6.1 General notes

DANGER: Risk of electric shock!

B Before working on the power supply

(120 VAC), disconnect the boiler from the grid by shutting off the emergency shutoff switch or disengaging the heating system circuit breaker. Take measures to prevent accidental reconnection.

B It is not sufficient to simply shut off the

controls.

B Observe all applicable electrical codes and

regulations.

Electrical components must be installed by a trained and certified electrician and the installation must meet the National Electric Code as well as all applicable local codes and regulations.

The boiler must be properly electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements with the National Electrical Code, ANSI/NFPA 70 and/or the Canadian Electrical Code Part I, CSA C221.1, Electrical Code.

Provide a dedicated circuit breaker for the boiler and heating system rated at least 15A. All line voltage wiring must use at least AWG14 size cables.

6.2 Low voltage electrical connections in the Heatronic boiler control

6.2.1 Open the Heatronic boiler control

NOTICE: Small pieces of wire can cause

shorts and damage the electronics.

B Always strip cables away from electronics.

B Unhook the clip (step 1) and fold the Heatronic down

(step 2).

Fig. 35 Fold the Heatronic down

B Remove screws (step 1), unhook cable and remove

cover (step 2).

6 720 641 933-72.1O

All appliance modulation, control and safety components are tested and pre-wired for use.

Observe safety precautions and all rules and regulations required by local code and the National Electric Code.

Fuses

The appliance is protected with a fuse. It is located on the circuit board (Æ Fig. 8, page 18).

Replacement fuses can be found on the back of the cover (Æ Fig. 36).

Controls and modules

For installation and electrical connection of controls and modules, see the installation instructions of the accessory.

6 720 641 933-86.1O

Fig. 36 Remove the cover

Page 53

Making the electrical connections | 53

6.2.2 Connecting the outdoor temperature sensor

B Connecting the controls automatically establishes the

internal communications BUS connection (Æ see installation instructions for the controls).

B Punch out plastic insert.

B Connect cable of the outdoor temperature sensor

according to Fig. 37.

B Insert cable for the outdoor temperature sensor.

B Secure the cable with the strain relief.

6.2.3 Connecting the DHW tank temperature sensor (only heating boiler ZBR..-3A)

Wire the DHW tank temperature sensor directly to the appliance terminals. The sensor is provided with the appliance.

Do not exceed a sensor cable length of 33 feet (10 m).

B Punch out plastic insert.

B Plug connector into the circuit board.

B Insert the cable of the DHW tank temperature sensor.

B Secure the cable with the strain relief.

6 720 641 933-35.1O

Fig. 37 Electrical wiring outdoor temperature sensor

6 720 641 933-73.1O

Fig. 38 Electrical connections DHW tank temperature

sensor

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54 | Making the electrical connections

6.2.4 Connecting additional accessories

B For splash-proof (IP) strain relief, cut the grommet to

match the diameter of the cable.

6 720 641 933-91.1o

Fig. 39 Cut off grommets

B Feed cable through strain relief and connect

accordingly.

B Secure the cable on the strain relief.

Bosch room controls

Connect only Bosch room controls to the internal BUS of this boiler.

For installation and electrical connection of the FB 100 remote control, see installation instructions for the remote control.

Connecting temperature guard TB 1 (external manual reset high limit or low water cut off (LWCO))

This connection allows the installation of external safety switches.

• External manual reset high limit

• Low water cut-off (LWCO)

• Radiant overheat protection

Connecting the supply temperature sensor (e.g. for lowloss header or system supply pipe)

Do not exceed a sensor cable length of 33 feet (10 m).

Supply temperature sensor for system supply pipe (Æ Fig. 41 [2]) must be installed in closest vicinity with boiler supply Tee.

≤ 4"

(102 mm)

Fig. 41 Mounting supply temperature sensor right next to

boiler supply

1 System secondary line – supply pipe ≥ 1-1/2" 2 Supply temperature sensor for system supply pipe 3 Boiler primary line – supply pipe 1" 4 Boiler primary line – return pipe 1" 5 System secondary line – return pipe ≥ 1-1/2"

6 720 641 933-97.1o

LS NS

Fig. 40 Electrical wiring TB1

When the temperature guard trips, central heating and DHW modes are interrupted.

TB1

1 2

6 720 641 933-44.1O

6 720 612 664-25.2O

Fig. 42 Electrical wiring of external supply temperature

sensor

The service function 7.d connection of an external supply temperature sensor is automatically set to 01 (Æ page 72).

Page 55

Making the electrical connections | 55

Connecting Third party room thermostats or zone controls

A voltage free (dry contact) third party room thermostat or heat demand from a relay panel can be used to send an ON/OFF signal to the appliance.

6 720 641 933-70.1O

LS NS

Fig. 43 Electrical wiring third party room thermostat or

zone control

To communicate a heat demand the third party room thermostat or zone control must connect pins 2 and 4.

6.3.2 Connecting an external heating zone pump or DHW recirculation pump

Without accessories the appliance offers the connection of one heating zone pump, one circulator of an unmixed heating circuit, or one DHW recirculation pump.

The pump used must have the following connection values: 120 VAC, max. 2 A.

B Route cable from pump to appliance.

B Insert cable into the junction box as shown in Fig. 46.

B Connect cable to the black plug according to Fig. 45.

Fig. 45 Attach plug (external pump)

1 L (120 VAC, 60 Hz) 2 PE (GND, Ground) 3 N (Neutral) 4 Black plug (in the junction box upon delivery)

6 720 641 933-41.1O

6.3 Electrical connections in the junction box (120 VAC)

6.3.1 Mounting rails for junction box

B Hold the rail against the appliance from below (step 1)

and fasten with the screws from the outside or inside (step 2).

B Loosen junction box from the rail (step 3).

Fig. 44 Mounting rails for junction box

6 720 641 933-42.1O

B Connect black plugs and insert grommet until stop.

L PE N

black CH pump

I III III III

8 737 701 503

red Storage

tank pump

for mixed heating

6 720 641 933-40.1O

L PE N

white

Mains 120V/60Hz

L PE N

Fig. 46 Cable connected (external pump)

B Use service function 5.E, to set connection to 01 (DHW

recirculation pump) (Æ page 71)

-or-

B Use service function 5.E to set connection to 02

(external heating zone pump in an unmixed heating circuit) (Æ page 71).

-or-

B Use service function 5.E to set connection to 03

(external heating pump) (Æ page 71).

The DHW recirculation pump is controlled by the Bosch FW 200.

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56 | Making the electrical connections

6.3.3 DHW tank loading pump or 3-way valve with spring return (only heating boiler ZBR..-3A)

The pump used must have the following connection values: 120 VAC, max. 2 A.

B Route cable from pump or 3-way valve to appliance.

B Insert cable into the junction box as shown in Fig. 48.

B Connect cable to the red plug according to Fig. 47.

Fig. 47 Attach plug (external DHW tank loading pump or 3-

way valve)

1 L (120 VAC, 60 Hz) 2 PE (GND, Ground) 3 N (Neutral) 4 Red plug (in the junction box upon delivery)

6 720 641 933-37.1O

6.3.4 Connecting mains power supply

B Route the power cable (AC 120 V, 60 Hz) from the

emergency shutoff switch to the boiler.

B Insert cable into the junction box as shown in Fig. 50.

B Connect cable to the white plug according to Fig. 49.

6 720 641 933-36.1O

Fig. 49 Attach plug (mains power supply)

1 L (120 VAC, 60 Hz) 2 PE (GND, Ground) 3 N (Neutral) 4 White plug (in the junction box upon delivery)

B Connect white plugs and insert grommet until stop.

B Connect red plugs and insert grommet until stop.

L PE N

black CH pump

I III III III

8 737 701 503

for mixed heating

tank pump

6 720 641 933-38.1O

L PE N

white

Mains 120V/60Hz

L PE N

red Storage

Fig. 48 Cable connected (external DHW tank loading pump

or 3-way valve)

B Mount the 3-way valve for space heating operation

when de-energized, and DHW tank loading when energized.

B Use service function 1.F to set pump mode.

(Æ page 67).

L PE N

black CH pump

I III III III

8 737 701 503

for mixed heating

L PE N

white

Mains 120V/60Hz

L PE N

red Storage

tank pump

Fig. 50 Cable connected (mains power supply)

B Mount junction box on the rail.

6 720 641 933-39.1O

Page 57

6.4 Connecting the LWCO device

NOTICE: System damage or malfunction!

B Ensure the air box remains air-tight when

routing the LWCO cable to the outside.

B Do not route the LWCO cable through the

ignition cable grommet as appliance malfunction may occur.

B Punch a hole (maximum diameter 3/16" (5 mm))

through the fan cable grommet (steps 1 – 3) and run the LWCO cable through it.

Making the electrical connections | 57

B Connect the leads labeled SWITCH CONTACT (yellow)

to the TB1 temperature guard (Æ Fig 40, page 54) on the Heatronic.

3 4

6 720 641 933-67.1O

Fig. 52 Wires of a LWCO device with LWCO adapter

Ø ≤ 3/16"

(~ 5 mm)

6 720 641 933-87.1O

Fig. 51 Punch a hole in fan cable grommet for LWCO cable

B Install a 24VAC 20VA transformer near the boiler.

B Follow LWCO manufacturer’s instructions.

B Connect the lead labeled BOILER GROUND (green) to

pin 2 (center, Æ Fig. 49 [2]) of the white plug in the boiler junction box.

B Connect the leads labeled 24V HOT (red) and 24V

COMMON (white) to the external 24VAC transformer.

1 LWCO device (Hydrolevel Safgard 1100) 2 BOILER GROUND (green) 3 SWITCH CONTACT (yellow) 4 SWITCH CONTACT (yellow) 5 24V HOT (red) 6 24V COMMON (white)

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58 | Commissioning

7 Commissioning

eco

reset

6 720 641 933-25.1O

151618

Fig. 53 Overview of the controls

1 Emissions test button 2 Service button 3 Burner operation indicator lamp 4 ON/OFF power switch 5 Key pad lock 6 ECO button 7 Reset button 8 Display 9 Automatic air vent (ZWB..-3A combi boilers only) 10 Boiler water pressure gauge 11 DHW thermostat 12 Safety relief valve discharge hose 13 Condensate drain hose 14 Heating return pipe 15 Cold water pipe (ZWB..-3A combi boilers only) 16 Gas pipe 17 DHW pipe (ZWB..-3A combi boilers only) 18 Supply pipe 19 Boiler high limit dial

Page 59

Commissioning | 59

7.1 Before operating the appliance

NOTICE: Commissioning without being

properly filled and purged will damage the appliance.

B Only operate this appliance after ensuring

there is sufficient water in the boiler and the system.

B Adjust the expansion vessel pre-charge pressure to the

static head of the heating system (Æ page 37).

B Open radiator and zone valves (as applicable).

B Open heating supply and return valves, fill heating

system to 14.5 to 21.75 psi (1 - 1.5 bar) and close fill valve.

B Bleed all air from the system.

B If the boiler water pressure has dropped, fill the heating

system again to 14.5 to 21.75 psi (1 to 1.5 bar).

B On ZBR..-3A appliances (heating boilers) with a DHW

tank, open the cold water supply and open a DHW tap until water runs out.

B Verify that the gas type specified on the rating plate is

the same as the gas type used.

B Open the gas cock.

7.2 Switching the appliance ON/OFF

Startup

B Switch the appliance ON using the ON/OFF switch.

The display indicates the supply temperature of the hot water in °F. If necessary, convert to °C (Æ Service function 0.E: Metric or US customary units, page 73)

max

Fig. 54 Switching the appliance ON/OFF

When the appliance is switched ON for the first time, it performs a once-only purging sequence. This involves the heating zone pump switching on and off at intervals (for approx. 4 minutes). The display shows in alternation with the supply temperature.

B Open the automatic vent [9] (only combi boiler

ZWB..-3A) and close it again when the purging sequence has finished (Æ page 58).

6 720 613 896-05.1O

If the display shows in alternation with the supply temperature, the trap filling function is active (Æ page 70).

Shutdown

B Switch appliance OFF using the ON/OFF switch.

The display goes out.

B If the appliance is taken out of service for a longer

period: Observe frost protection (Æ Section 7.9).

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60 | Commissioning

7.3 Setting up space heating

Set the maximum supply temperature based on the structure's heat loss on design day.

Boiler high limit dial

1approx. 95°F

2approx. 109°F

3approx. 122°F

4approx. 140°F

5approx. 153°F

6approx. 167°F

max approx. 194 °F

Typical supply temperatures

(35 °C)

(43 °C)

(50 °C)

(60 °C)

(67 °C)

(75 °C)

(90 °C)

Sample application

Frost protection

Radiant floor heating system

Panel radiator system

Cast iron radiator system

Baseboard and convector system

7.4 Programming the FW 200 heating control unit

Observe the operating instructions for the heating control included in the scope of delivery. There you can read:

B How to set the operating mode and the

heating curve for outdoor reset controls

B How to adjust the room temperature

B How to heat economically and comfortably

B How the control can be mounted in the

boiler or in the living space

Fig. 56 FW 200 heating control

6 720 612 660-07.2O

Tab. 24 Typical supply temperatures

With radiant floor heating, limit the maximum permissible supply temperature as recommended by the manufacturer.

B In order to set the maximum supply temperature, turn

the boiler high limit dial .

reset

eco

max

min

6 720 641 933-53.1O

Fig. 55 Switch on heat

If the burner is operating, the burner operation indicator lamp is illuminated.

7.5 After commissioning

B Check flue path for tightness.

B Check gas supply dynamic pressure (Æ page 78).

B Check that condensate is being discharged from the

condensate hose. If that is not the case, switch the appliance first OFF and then ON again using the ON/ OFF switch. That activates the trap filling sequence (Æ page 70). Repeat the procedure several times until condensate starts running out.

B Complete commissioning report (Æ page 97).

Page 61

7.6 ZBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature

B Set the DHW temperature on the DHW thermostat .

The set DHW temperature flashes on the display for 30 seconds.

reset

eco

max

Fig. 57 Set the DHW temperature (heating boiler ZBR..-3A)

max

6 720 641 933-54.1O

Commissioning | 61

ECO button

The default setting is DHW priority; the ECO button is not lit. In order to switch between DHW tank priority and alternating operation, press the ECO button.

• DHW priority

First, the DHW tank is heated up to the set temperature. The appliance then goes into heating mode. Therefore, it can happen that space heating is interrupted for a while and the room temperature may drop. DHW tank priority guarantees highest DHW comfort.

• Alternating operation

The appliance switches between space heating mode and DHW mode. This prevents the room from cooling off too much. Alternating operation guarantees an even room temperature with somewhat less DHW convenience.

DHW thermostat Typical DHW temperatures

min approx. 59 °F (15 °C)

e approx. 131°F (55°C)

max approx. 158°F (70°C)

Tab. 25 Typical DHW temperatures for heating boiler

ZBR..-3A

WARNING: Danger of scalding!

B In normal operation, it is recommended to

limit the DHW temperature to 122 °F (50 °C) to limit the risk of scalding.

B Install a tempering valve if running DHW

temperatures above 104 °F (40 °C).

B Only use temperatures up to 158 °F (70 °C)

for thermal disinfection (Æ page 63).

If there is reason for concern for contamination from bacteria such as legionella, consider setting the DHW thermostat to at least “e” (131 °F (55 °C)). This setting ensures an economical and comfortable DHW generation. Consult your local water department or municipality for further information.

7.7 ZWB..-3A appliances (combi boilers): Setting the DHW temperature

B Set the DHW temperature on the DHW thermostat .

The set DHW temperature flashes on the display for 30 seconds.

reset

eco

max

Fig. 58 Set the DHW temperature (combi boiler ZWB..-3A)

DHW thermostat Typical DHW temperatures

min approx. 104 °F (40 °C)

e approx. 122 °F (50 °C)

max approx. 140 °F (60 °C)

Tab. 26 Typical DHW temperatures for combi boiler

ZWB..-3A

ECO button

Pressing and holding the ECO button until it lights up switches between Comfort mode and Economy mode.

max

6 720 641 933-55.1O

• Comfort mode (default setting)

The appliance is continually maintained at the set

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62 | Commissioning

temperature. Consequently, DHW draws are immediate, however the appliance may run even if no DHW is being drawn.

• Economy mode, ECO button lights up

– DHW is only generated when DHW is drawn.

– On demand: Quickly open and close a DHW tap to

signal the appliance to heat to the selected temperature. After a short wait DHW will be available.

The DHW on demand signal allows maximum gas and water savings.

7.9 Setting frost protection

Frost protection of the heating system:

B Leave the appliance switched ON; set the boiler high

limit to at least

95°F (35°C)

page 60).

Fig. 60 Frost protection of the heating system

(position 1, Æ Tab. 24,

reset

eco

max

min

6 720 641 933-68.1O

7.8 Setting manual summer mode

In summer mode or warm weather shut down (WWSD), the heating zone pump and consequently central heating are switched off. DHW generation remains active following the DHW program.

See also the warm weather shutdown (WWSD) feature in the operating instructions for the heating control included in the scope of delivery.

NOTICE: Heating system at risk of freezing. In manual summer mode, only the appliance is protected from freezing.

B Observe frost protection measures where

there is a risk of frost (Æ Chapter 7.9).

B Make a note of the setting of the boiler high limit

dial .

B Turn the boiler high limit dial counterclockwise

to .

reset

eco

-or- If you want to leave the appliance switched OFF:

B Mix Bosch-approved anti-freeze into the heating water

(Æ Tab. 15, page 36) and drain the DHW circuit.

For further information, see the operating instructions for the heating control included in the scope of delivery.

Frost protection of the DHW tank:

B Leave the appliance switched ON; set the boiler high

limit to at least

95°F (35°C)

(position 1, Æ Tab. 24,

page 60).

B Turn the DHW thermostat counterclockwise to min

(59 °F (15 °C)).

reset

eco

max

min

max

6 720 641 933-69.1O

Fig. 61 Frost protection for the DHW tank

max

min

6 720 615 065-13.1O

Fig. 59 Summer mode

For further information, see the operating instructions for the heating control included in the scope of delivery.

max

Page 63

ZBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection | 63

7.10 Activating the key pad lock

The key pad lock affects the boiler high limit dial, the DHW thermostat, and all buttons except the ON/OFF switch, emissions test button, and reset button. It can be used to limit unauthorized access to the boiler.

Activating the key pad lock:

B Press the key pad lock button until and the heating

supply temperature are alternating on the display.

reset

eco

max

Fig. 62 Key pad lock

Unlocking the key pad:

B Press the key pad lock button until the display shows

only the supply temperature.

min

6 720 615 065-17.1O

max

8 ZBR..-3A appliances (heating

boiler) with DHW tank: Thermal disinfection

Thermal disinfection covers the DHW system including the taps. For solar DHW tanks, the solar portion of the tank is not covered.

WARNING: Risk of scalding!

Hot water can result in severe scalding.

B Carry out thermal disinfection only outside

the normal hours of use, or install a tempering valve.

B Close all DHW taps.

B Advise occupants of the risk of scalding if no tempering

valve is installed.

B Set the time and DHW temperature accordingly on the

heating control with DHW program.

B Set any DHW recirculation pump to continuous

operation.

B Turn DHW thermostat clockwise to max (approx. 158 °F

(70 °C)).

reset

eco

max

6 720 615 065-10.1O

max

Fig. 63 Thermal disinfection

B Wait until the maximum temperature has been reached.

B Open all DHW taps, from the nearest to the one furthest

away, and draw off hot water until it reaches a minimum of 158 °F (70 °C) at all taps for at least 3 minutes.

B Reset the DHW thermostat, DHW recirculation pump,

and heating control to standard operation.

Thermal disinfection can also be carried out automatically and on a regular basis; see operating instructions for the heating control included in the scope of delivery.

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64 | Boiler circulator

9 Boiler circulator

9.1 Pump anti-seize protection

This function prevents the heating zone pump from seizing up following longer idle periods.

The appliance will briefly run the pump at least every 24 hours after its last activation.

9.2 Changing the pump curve of the boiler pump

The speed of the boiler pump can be changed using the dial on the pump.

H / ft

02 5781436

V / gpm

H / m

H / ft

0213546 87

V / gpm

H / m

400 800 1200 1600

V / l/h

Fig. 65 Pump curve of the boiler pump combi boiler

ZWB..-3A

Key to Fig. 64 and Fig. 65:

1 Residual head pressure at speed 1 2 Residual head pressure at speed 2 3 Residual head pressure at speed 3 (default setting) 4 Head pressure of the boiler pump by itself (at speed 3) H Head pressure in feet of head (m)

Circulating water volume in gallons per minute (l/h)

6 720 641 933-61.1O

400 800 1200 1600200 600 1000 1400

V / l/h

Fig. 64 Pump curve of the boiler pump heating boiler

ZBR..-3A

In order to save as much energy as possible and keep any water circulation noises to a minimum, select the lowest possible pump speed.

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Page 65

10 Heatronic boiler control settings

10.1 Guideline to service functions

The Heatronic allows easy setting and testing of many appliance functions.

For an overview of service functions, see Chapter 10.2 on page 66.

reset

eco

4 5

max

6 720 641 933-52.1O

2 1

max

Fig. 66 Overview of the controls

1 Emissions test button 2 Service button 3 Display 4 ECO button, service functions “up” 5 Key pad lock, service functions “down”

Selecting a service function

The service functions are subdivided into two levels: The

1st level includes service functions up to 0.E, the 2nd level includes service functions starting with 8.A.

B Press and hold the service button until it illuminates.

The display shows a code such as 1.A (first service level).

B Repeatedly press the key pad lock button or ECO

button to scroll to the desired service function.

B Press and release the emissions test button .

The emissions test button will light up and the display shows the setting for the selected service function.

min

Heatronic boiler control settings | 65

Adjust Value

B Repeatedly press the key pad lock button or ECO

button to adjust the value up or down.

B Record the value in the commissioning log (Æ page 97).

Saving the value

B Press and hold the emissions test button until the

display shows (value saved).

The unit automatically exits the service level if no button is pressed for 15 minutes.

Exiting the service function without saving values

B Briefly press the emissions test button .

The light of the emissions test button will go out.

Restoring factory settings

In order to reset all values for the service levels 1 and 2 to the factory setting:

B Press and hold the service button until it illuminates.

The display shows a code such as 1.A (first service level). Press the ECO button and key pad lock button simultaneously until e.g. 8.A appears (second service level).

B On the second service level, select the service function

8.E and value 00. The appliance restarts with the default settings.

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66 | Heatronic boiler control settings

10.2 Overview of the service functions

10.2.1 First service level (press and hold the service button until it lights up)

Service function

Display Page

1.A

1.b

1.E

1.F

2.A

2.b

2.C

2.d

2.F

3.A

3.b

3.C

3.d

3.E

3.F

4.b

4.d

4.E

4.F

5.A

5.b

5.E

5.F

6.A

6.b

6.C

6.d

7.A

7.b

7.d

7.E

0.A

0.d

0.E

Tab. 27 Service functions, 1st level

Maximum space heating output 67 Maximum DHW output 67 Pump mode for space heating operation 67 Pump mode 67 Heating circuit pump lockout time 68 Maximum supply temperature 68 Purging function 68 Thermal disinfection 68 Operating mode 68 Automatic anti-cycle function 69 Set anti-cycle time 69 Switching differential (hysteresis) 69 Minimum output (heating and DHW) 69 Cycle time, keeping DHW hot 69 Constant DHW period 70 Maximum heat exchanger temperature 70 Audible fault warning tone 70 Appliance type 70 Condensate trap filling sequence 70 Reset inspection interval 70 Fan post purge time 71 Functionality of black plug in boiler

junction box Set inspection interval 71 Display the latest fault code 71 Room temperature control, current volt-

age, terminal 2 Supply temperature required by outdoor

reset control Current DHW turbine flow rate 71 Indicator lamp for burner operation /

faults 3-way valve in center position 72 Connecting an external supply or low-

loss header temperature sensor Building drying function 72 Do not use this setting! 72 Altitude adjustment 72 Metric or US customary units 73

10.2.2 Second service level (at first service level, service button lights up, press ECO button and key pad lock button simultaneously until e.g. 8.A appears)

Service function

Display Page

8.A

8.b

8.C

8.d

8.E

8.F

9.A

9.b

9.C

9.d

9.E

9.F A.b

A.C

b.F

C.d

Software version 73 Code plug number 73 GFA Gas burner control status 73 GFA Gas burner control fault 73 Restore boiler to factory settings 73 Permanent ignition 73 Constant mode 73 Current fan speed 73 Current boiler output 73 Set fan start speed 74 Turbine signal delay 74 Heating zone pump post purge 74 Display DHW temperature 74 Display DHW tank temperature 74 Solar DHW backup heating delay 74 Display current heat demand 74

Tab. 28 Service functions, 2nd level

Page 67

10.3 Description of the service functions

Heatronic boiler control settings | 67

Service function 1.E: Pump mode for space heating operation

10.3.1 First service level

Service function 1.A: Maximum space heating output

Some gas supply companies offer a performancedependent basic price.

The output can be limited in percent between the minimum and maximum nominal output to suit the specific heat demand.

Even if the heating output has been limited, the maximum nominal output is still available for DHW generation.

B Select service function 1.A.

B Select heat output in MBH (kW) and determine

associated setting in percent (%).

B Enter the setting (Æ 10.1).

B Save the setting (Æ 10.1).

B Record the set heat output in the commissioning log

(Æ page 97).

B Exit the service functions.

The display returns to the supply temperature.

Default setting is the maximum nominal output: U0 (100 %).

Service function 1.b: Maximum DHW output

The hot water output can be adjusted between the minimum and maximum DHW outputs to suit the heat transfer capacity of the DHW tank coil.

B Select service function 1.b.

B Select the DHW output in MBH (kW) and determine the

associated setting in percent (%).

B Enter the setting (Æ 10.1).

B Save the setting (Æ 10.1).

B Record the set DHW output in the commissioning log

(Æ page 97).

B Exit the service functions.

The display returns to the supply temperature.

Default setting is the maximum nominal output: U0 (100 %).

If an outdoor temperature sensor for an outdoor reset control is connected, pump control mode 04 is automatically set.

• Pump control mode 00 (automatic mode): The BUS control controls the central heating pump.

• Pump control mode 01: For heating systems without control. The supply temperature controls the central heating pump. When there is a demand for heat, the central heating pump and the burner start up.

• Pump control mode 02: Do not use.

• Pump control mode 03: The central heating pump runs

continuously (exceptions: See heating control operating instructions).

• Pump control mode 04: Intelligent control of central heating pump in heating systems with outdoor reset control. The heating zone pump is only switched on when needed.

Default setting is 00.

Service function 1. F: Pump mode (only heating boiler ZBR..-3A)

NOTICE: System damage or boiler

malfunction! B Never change the setting of this service

function on combi boiler ZWB..-3A appliances.

Based on this setting, the pump connected to the Heatronic or 3-way valve are controlled according to the configuration of the heating system.

The following settings are possible:

• Pump mode 00: T heating boiler.

• Pump mode 01: A 3-way valve for DHW tank loading is connected in boiler circuit before low loss header (see also service function 2.A).

• Pump mode 02: Do not use this setting!

• Pump mode 03: A DHW tank pump is connected on the

system side after the low loss header. In DHW mode, DHW tank

space heating mode, DHW tank loading pump does

In not run.

he appliance is use

loading pump runs.

d only as central

Default setting is 03.

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68 | Heatronic boiler control settings

Service function 2.A: Heating circuit pump lockout time (only heating boiler ZBR..-3A)

NOTICE: System damage or boiler

malfunction!

B Never change the setting of this service

function on combi boiler ZWB..-3A appliances.

This setting is only active if Service function

1. F: Pump mode is set to 01 (3-way valve).

During the runtime of an external 3-way valve actuator, the space heating pump is blocked. Select the run time of the 3-way valve actuator between 01 - 24 (10 - 240) seconds

according to the manufacturer's documentation

Default setting is 24 (240 seconds).

Service function 2.b: Maximum supply temperature

The values of this service function displayed depend on the setting of the service function 0.E:

Service function 0.E is set to 00 (metric units):

• The maximum supply temperature can be adjusted between 35 and 88 (35 - 88 °C).

Service function 0.E is set to 01 (US customary units):

• The maximum supply temperature can be adjusted between 96 and 190 (96 - 190 °F).

The following settings are possible:

• 00: Purging function off

• 01: Purging function is switched on and after

completion automatically reset to 00

• 02: Purging function is permanently on and is not reset to 00

Default setting is 00 for heating boilers ZBR..-3A appliances, otherwise 01.

Service function 2.d: Thermal disinfection (legionella protection)

WARNING: Risk of scalding!

Hot water can result in severe scalding.

B Carry out thermal disinfection only outside

the normal hours of use.

B Install a tempering valve if this function is

enabled permanently.

When this service function is enabled, the DHW is permanently heated to approx. 158 °F (70 °C) if the DHW temperature dial has been turned clockwise to max.

The following settings are possible:

• 00: Thermal disinfection not enabled

• 01: Thermal disinfection enabled

Default setting is 00 (disabled).

Default setting is 190 (190 °F (88 °C)).

Service function 2.C: Purging function

This service function allows activating the purging function manually, e.g. after servicing.

Service function 2.F: Operating mode

With this service function, you can temporarily change the appliance's operating mode.

The following settings are possible:

• 00: Default mode; the appliance runs according to control settings.

• 01: The appliance runs for 15 minutes at minimum output. The display shows 2.F. When this service function is aborted or has been active for 15 minutes, the appliance reverts to default mode.

• 02: The appliance runs for 15 minutes at maximum output. The display shows 2.F. When this service function is aborted or has been active for 15 minutes, the appliance reverts to default mode.

Default setting is

00.

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Heatronic boiler control settings | 69

Service function 3.A: Automatic anti-cycle function

If an outdoor reset control is connected, there is no need to adjust this setting on the appliance. The control automatically optimizes the anticycle time.

Use service function 3.A to set the automatic adaptation of the anti-cycle time. This can be required in case of unfavorably-dimensioned heating systems. Short cycling may increase boiler and system wear and tear, increase emissions, reduce comfort, and should be avoided. With auto-adaptation of the anti-cycle time disabled, the anti-cycle time must be set using service function 3.b (Æ page 69).

The following settings are available:

• 00: Automatic adaptation of the anti-cycle time is disabled

• 01: Automatic adaptation of the anti-cycle time is enabled

Default setting is 00 (switched off).

Service function 3.C: Switching differential

Only if the automatic anti-cycle time is disabled (service function 3.A) will this function be active.

If an outdoor reset control is connected, there is no need to adjust this setting on the appliance. The control automatically optimizes this setting.

The switching differential is the permitted boiler differential from the target supply temperature. It can be set in increments of 1 °F (0.5 °C). The minimum supply temperature is 95 °F (35 °C).

Service function 0.E is set to 00 (metric units):

• You can set the switching differential between 00 and 30 (0 - 30 °C).

Service function 0.E is set to 01 (US-customary units):

• You can set the switching differential between 00 and 54 (0 - 54 °F).

Default setting is 18 (18 °F (10 °C)).

Service function 3.b: Set anti-cycle time

Only if the automatic anti-cycle time is disabled (service function 3.A) will this function be active.

If an outdoor reset control is connected, there is no need to adjust this setting on the appliance. The control automatically optimizes the anticycle time.

The anti-cycle time can be set from 00 to 15 (0 to 15 minutes).

With 00, the anti-cycle lock is switched off.

The shortest possible switching interval is 1 minute (recommended for single zone or forced air heating systems).

Default setting is 03.

Service function 3.d: Minimum output (heating and DHW)

The output for heating and DHW can be set to any level in percent between the minimum and maximum nominal output.

The default setting is the minimum nominal output (heating and DHW) and varies according to appliance.

Service function 3.E: Cycle time, keeping DHW hot (only combi boiler ZWB..-3A)

NOTICE: System damage or boiler

malfunction!

B Never change the setting of this service

function on heating boiler ZBR..-3A appliances.

This service function is only active in comfort mode.

It specifies the time from completion of preheating or DHW demand until the next time the plate-type heat exchanger is heated up. This prevents the plate-type heat exchanger from overheating.

The cycle time can be set from 20 to

t setting is 20 (20 minutes).

Defa

60 minutes.

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70 | Heatronic boiler control settings

Service function 3.F: Constant DHW period (only combi boiler ZWB..-3A)

NOTICE: System damage or boiler

malfunction!

B Never change the setting of this service

function on heating boiler ZBR..-3A appliances.

The constant DHW period specifies how long the space heating mode remains disabled after DHW is drawn.

The duration for keeping DHW hot can be set from 00 to

30 (0 to 30 minutes).

Default setting is 01 (1 minute).

Service function 4.b: Maximum heat exchanger temperature (only combi boiler ZWB..-3A)

NOTICE: System damage or boiler

malfunction!

B Never change the setting of this service

function on heating boiler ZBR..-3A appliances.

This function can be used to reduce limestone built-up in the heat exchanger, which increases with temperature. The maximum heat exchanger temperature can be set in steps of 1 °F (0.5 °C).

Service function 0.E is set to 00 (metric units):

• The maximum temperature for keeping the heat exchanger hot can be set from 40 to 65 (40 to 65 °C).

Service function 0.E is set to 01 (US-customary units):

• The maximum temperature for keeping the heat exchanger hot can be set from 104 to 150 (104 to 150 °F).

Default setting is 140 (140 °F (60 °C)).

Service function 4.d: Audible fault warning tone

The appliance can be set to sound an audible alarm to alert the operator of a fault present. The audible warning tone can be deactivated with the service function 4.d.

• 00: Warning tone off

• 01: Warning tone on

Default setting is 01 (ON).

Service function 4.E: Appliance type

This service function displays the appliance type detected.

Possible displays are:

• 00: Central heating only

• 01: Combi appliance

• 02: DHW tank temperature sensor (NTC) connected to

Heatronic.

• 03: DHW tank thermostat connected to Heatronic.

• 04: Stratified DHW tank

• 05: Tank with NTC return

Service function 4.F: Condensate trap filling sequence

DANGER: Risk of flue gas poisoning!

If the condensate trap is not filled, flue gas may escape from the dry trap.

B Only deactivate the trap filling sequence

for servicing purposes.

B When servicing is complete, reactivate the

trap filling function.

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

completed 15 minutes of operation at

the appliance h

as 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.

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Heatronic boiler control settings | 71

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 (Æ page 56).

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 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)

NOTICE: System damage or boiler

malfunction!

B Never change the setting of this service

function on heating boiler ZBR..-3A appliances.

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 5.F: Set inspection interval

This service function allows setting the number of months after which the 'service due' reminder appears

display

alternating with the supply temperature.

on the

The number of months can be set from 00 - 72 (0 to 72 months).

Default setting is 00 (disabled).

If U0 appears on the display, the function was already set via the FW200 control.

Service function 6.A: Display the latest fault code

Use this service function to display the most recent fault code.

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.

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72 | Heatronic boiler control settings

Service function 7.b: 3-way valve in center position

After the value 01 has been saved, the 3-way valve moves to the center position. This allows draining the system completely and removing the motor easily.

When you exit this service function, the appliance returns to setting 00.

Service function 7.d: Connecting an external supply or low-loss header temperature sensor

Presence of an external supply or low loss header temperature sensor is automatically detected by default; you do not need to change any settings.

If a sensor is disconnected, change the setting back to the default setting 00.

The following settings are available:

• 00: Once-only automatic detection of a sensor

• 01: External supply temperature sensor connected to

Heatronic.

• 02: External supply temperature sensor connected to IPM2.

Default setting is 00.

Service function 0.A: Do not use this setting!

Default setting is 00 (disabled).

Service function 0.d: Altitude adjustment

Input and output rates are reduced at higher altitudes due to thin air with reduced oxygen levels.

ZBR42-3A... and ZWB42-3A... appliances are derated at 3 % per 1000 feet (305 m).

ZBR16-3A..., ZBR28-3A..., ZBR35-3A... and ZWB28-3A... appliances offer altitude adjustment which compensates for the effects of thin air, and are therefore NOT derated up to 6000 feet (1829 m). Above 6000 feet (1829 m) a rate of 3 % per 1000 feet (305 m) applies.

This service function is used to adjust the fan speed for high altitude operation.

The following settings are available:

• 00: Normal

• 01: Medium

• 02: High

Setting Elevation above sea level

00 0 ft – 2,000 ft (0 m – 610 m)

01 2,001 ft – 4,500 ft (611 m – 1 372 m)

Service function 7.E: Building drying function

This service function allows you to start and stop the building drying function.

Never confuse the appliance building drying function with the slab drying function of the outdoor reset control FW200.

When the building drying function is on, you cannot adjust the appliance gas settings.

The following settings are available:

• 00: Off

• 01: Heating operation only in accordance with the

appliance or control setting, i.e. all other heat demands are blocked.

Default setting is 00.

02 above 4,500 ft (1 372 m)

Tab. 29 Altitude adjustment (service function 0.d)

Default setting is 00.

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Heatronic boiler control settings | 73

Service function 0.E: Metric or US customary units

With this service function you can set if Metric or US customary units are displayed on the boiler.

The following settings are available:

• 00: °C, l/min (metric units)

• 01: °F, gpm (US-customary units)

Default setting is 01.

10.3.2 Second service level

Service function 8.A: Software version

The current software version is displayed.

Service function 8.b: Code plug number

The last four digits of the code plug number are shown. The code plug determines the appliance functions. If the appliance has been converted from natural gas to LPG (or vice versa), the code plug must be replaced.

Service function 8.C: GFA Gas burner control unit status

Internal parameter. If you are on the line with Bosch Technical Support you may be asked for this number.

Service function 8.d: GFA Gas burner control unit fault

Internal parameter.

Service function 8.E: Restore boiler to factory settings

This function allows resetting all parameters of the boiler including all service functions to their factory settings.

B Press and hold the emissions test button until the

display shows . All settings are reset and the appliance restarts with the default settings.

B Reset altered service functions to the settings recorded

in the commissioning log (Æ page 97).

Service function 8.F: Permanent ignition

NOTICE: Ignition transformer damage.

B Never leave this function on for longer than

2 minutes at a time.

This function enables permanent ignition without gas supply to test the performance of all ignition related components.

The following settings are available:

• 00: Off

• 01: On

Default setting is 00.

Service function 9.A: Constant mode

This function sets one operating mode permanently (Æ Service function 2.F: Operating mode, page 68).

The following settings are available:

• 00: Default mode: the appliance runs according to control settings.

• 01: The appliance runs permanently at minimum output. The display shows 9.A.

• 02: The appliance runs permanently at maximum output. The display shows 9.A.

Default setting is 00.

B Press and hold the service button until it illuminates.

The display shows a code such as 1.A (first service level).

B Press and hold ECO button and key pad lock button

simultaneously until a service function, e.g. 8.A, is displayed (second service level).

B Repeatedly press the key pad lock button or ECO

button until service function 8.E is displayed.

B Press and release the emissions test button .

The emissions test button lights up and the display shows 00.

Service function 9.b: Current fan speed

This service function allows you to display the current fan speed in revolutions per second (1/s).

Service function 9.C: Current boiler output

unction displays the current boiler output (in

This service

percent (%)).

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74 | Heatronic boiler control settings

Service function 9.d: Set fan start speed

At higher elevations the boiler fan may need to spin faster upon startup to ensure reliable ignition every time. The start speed of the boiler fan can be set from 45 to

77 revolutions per second (1/s).

Default setting is 50.

Service function 9.E: Turbine signal delay (only combi boiler ZWB..-3A)

NOTICE: System damage or boiler

malfunction!

B Never change the setting of this service

function on heating boiler ZBR..-3A appliances.

This service function allows setting a time delay to prevent the appliance starting up as a result of transient pressure spikes in the water supply.

Through spontaneous pressure change in the water supply, the flow meter (turbine) can signal that DHW is being drawn and cause the burner to come on unnecessarily.

Service function b.F: Solar DHW backup heating delay (only combi boiler ZWB..-3A)

For systems with a solar thermal DHW ta nk in series b ef or e the DHW line of the combi boiler. DHW heating by the boiler will be suppressed expecting that solar thermal DHW will reach the hot water temperature sensor prior eliminating the need to run the boiler. Set the heating delay in accordance with system conditions.

If this setting is enabled, the DHW demand signal is no longer available Æ page 61.

The start delay can be set between 00 to 50 (0 to 50 seconds) in increments of 1 second.

Default setting is 00.

Service function C.d: Display current heat demand

Available displays are:

• 00: No heat demand

• 01: Space heating demand present

• 02: DHW heat demand present

The turbine signal delay can be set from 02 to 08 (0.5 seconds to 2 seconds) in increments of 0.25 seconds.

Default setting is 04 (1 second).

Service function 9.F: Heating zone pump post purge

This service function allows setting a pump post purge time after the end of the heat demand from the external control.

The pump post purge time can be set from 01 to 10 (1 to 10 minutes).

Default setting is 03.

Service function A.b: Display DHW temperature

This service function allows displaying the current DHW temperature.

Service function A.C: Display DHW tank temperature

This service function allows displaying the temperature of the DHW tank temperature sensor.

Page 75

11 Gas type conversion

Gas type conversion | 75

DANGER: Personal injury and property

damage

B This conversion shall only be performed by

a trained and certified installer in accordance with the manufacturer‘s instructions and all applicable codes and requirements of the authority having jurisdiction.

B If the information in these instructions is

not followed exactly, or the installation, adjustment, modification, operation or maintenance is carried out by an unqualified person, a fire, explosion or generation of large amounts of carbon monoxide may result causing property damage, personal injury or loss of life.

B Before carrying out electrical work:

Disconnect the installation from the power supply at the emergency shutoff switch or by disengaging the heating system circuit breaker. Take measures to prevent accidental reconnection.

B The installer is responsible for the proper

conversion of this appliance.

B The conversion is not complete until the

operation of the converted appliance is checked as specified in these instructions.

The gas-air ratio must always be set on the basis of a CO2

reading taken at maximum nominal output and

or O

minimum nominal output using an electronic flue gas analyzer.

11.1 Converting to a different gas type

DANGER: Explosion!

B Close the gas cock prior to working on the

gas train.

B Check for gas leaks after carrying out work

on the gas train.

A gas conversion kit is included in the scope of delivery.

B Fold the Heatronic down.

B Check the number on the code plug from the gas

conversion kit (Code plug number Æ table 42, page 96).

B Replace the code plug in the Heatronic with the code

plug from the gas conversion kit.

6 720 641 933-57.1O

Fig. 67 Replacing the code plug

B Affix the gas type label from the gas conversion kit to

the appliance.

Adjustment to different flue systems using throttle discs or baffles is not necessary.

• Appliances are set at the factory to Wobbe index

1,333 BTU/ft

(1016 hPa)

(49.6 MJ/m3) at 60 °F (15 °C), 30" Hg

and 7.0" W.C. (17.4 mbar) gas supply

pressure and sealed.

6 720 641 933-58.1O

Fig. 68 Affixing the gas type label

B Always adjust the gas-air ratio (CO

or O2,

Æ Section 11.3) after converting to a different gas type and measure the CO content of the flue gas (Æ Section 12).

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11.2 Installation location higher than 2,000 feet (610 m) above sea level

Input and output rates are reduced at higher altitudes due to thin air with reduced oxygen levels.

ZBR42-3A... and ZWB42-3A... appliances are derated at 3 % per 1000 feet (305 m).

The Bosch Greenstar boiler is factory set for installation below 2000 feet (610 m) above sea level.

B Correction of the fan speed curve of the burner:

Use service function 0.d to adjust the elevation setting (Æ page 72).

11.3 Setting the gas-air ratio (CO2 or O2)

B Switch the appliance OFF using the ON/OFF switch.

B Remove the cover (Æ page 41).

B Switch the appliance ON using the ON/OFF switch.

B Open one of the flue gas test ports.

6 720 641 933-79.1O

Fig. 69 Open one of the flue gas test ports

B Insert the probe approx. 2-3/4 inches (70 mm) into the

test port and seal around it.

B Press and hold the emissions test button until it

lights up. The display shows the supply temperature alternating with = maximum set output in heating mode.

B Briefly press the emissions test button .

The display shows the supply temperature in alternation with = maximum nominal output.

B Measure the CO

or O2 level and the CO content of the

flue gas (Æ Section 12).

Page 77

Gas type conversion | 77

B On the gas throttle, break the seal at the slot and

remove the cap.

2 .

1 .

6 7 2 0 6 1 2 6 5 9 - 3 7 . 1 R

Fig. 70 Remove seal from the gas throttle

B Adjust the gas throttle to match the CO

maximum nominal output according to table 30.

or O2 level for

B Remove the sealed screw (Æ Fig. 72, [3]) from gas valve

adjustment screw (Æ Fig. 72, [2]) and set CO

or O2

level for minimum nominal output.

6 720 641 933-81.1O

Fig. 72 Set CO

B Re-check settings at maximum and minimum nominal

output and re-adjust if necessary.

B Repeatedly press the emissions test button until the

light goes out. The display returns to the supply temperature.

B Record the CO

flue gas in the commissioning log.

B Reinstall the screw (Æ Fig. 72, [3]) to cover the gas

valve adjustment screw.

B Remove flue gas probe and close the flue gas test port

properly.

or O2 level for minimum nominal output

or O2 levels and the CO content of the

6 7 2 0 6 1 2 6 5 9 - 3 8 . 1 R

Fig. 71 Set CO

Gas type CO

or O2 level for maximum nominal output

Maximum

nominal output

Minimum

nominal output

NG 9.4 % 4.0 % 8.6 % 5.5 %

LPG (propane) 11.0 % 4.2 % 10.4% 5.1 %

Tab. 30 CO2 or O2 values at maximum and minimum nominal

output

B Briefly press the emissions test button .

The display shows the supply temperature in alternation with = minimum nominal output.

B Measure the CO

or O2 level and the CO content of the

flue gas (Æ Section 12).

6 720 641 933-80.1O

Fig. 73 Close flue gas test ports

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Page 78

78 | Gas type conversion

11.4 Dynamic gas pressure test

B Switch the appliance OFF and close the gas shut-off

valve.

B Loosen the screw in the test port for gas inlet pressure

(Æ Fig. 72, [1]) and connect a pressure gauge (Æ Fig. 74).

6 720 614 090-34.1O

Fig. 74 Dynamic gas pressure test port

B Turn on the gas cock and switch the appliance ON.

B Press and hold the emissions test button until it

lights up. The display shows the supply temperature alternating with = maximum set output in heating mode.

B Briefly press the emissions test button .

The display shows the supply temperature in alternation with = maximum nominal output.

B Check the required inlet gas pressure according to

table 31.

Gas type

Nominal

pressure

" W.C.

(mbar)

Permissible pressure

range for maximum

nominal output

" W.C. (mbar)

NG 7 (17.4) 3.5-10.5 (8.7-26.1)

LPG (propane) 11 (27.4) 8-13 (19.9-32.3)

Tab. 31 Inlet gas pressure

Do not operate the appliance if the measured value is below or above these values. Determine the cause and eliminate the fault. If this is not possible, block the appliance on the gas side and notify the gas supplier.

B Repeatedly press the emissions test button until the

light goes out. The display returns to the supply temperature.

B Switch the appliance OFF, turn off the gas cock, remove

the pressure gauge and tighten the screw in the test port for gas inlet pressure.

B Reinstall the cover.

Page 79

12 Flue gas test

Flue gas test | 79

12.1 Emissions test button

The following appliance outputs can be selected by pressing the emissions test button until it lights up:

reset

eco

max

min

Fig. 75 Press the emissions test button

• = Maximum set output in heating mode (Æ Maximum heating output, page 67)

• = Maximum nominal output

• = Minimum nominal output

You have 15 minutes to complete the tests. After that, the appliance returns to default mode.

6 720 641 933-51.1O

max

12.2 Measuring CO content of flue gas

Use a multiport flue gas probe for the measurements.

B Open one of the flue gas test ports (Æ Fig. 69).

B Insert the flue gas probe approx. 2-3/4 inches (70 mm)

into the test port and seal around it.

B Press the emissions test button to select =

maximum nominal output.

B Measure the CO levels.

DANGER: Risk of flue gas poisoning.

The CO level in the flue gas must be below 200 ppm (air free).

B If 9.4 Vol.%

200 ppm (af) can not be achieved due to the gas supplied, use a lower CO with CO emissions under 200 ppm (af) instead.

1) 9.4 Vol.% with NG and 11.0 Vol.% with LPG (propane)

B Repeatedly press the emissions test button until the

light goes out. The display returns to the supply temperature.

B Remove flue gas probe and close the flue gas test port

properly (Æ Fig. 73).

CO2 and a CO level under

level

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Page 80

80 | Environmental responsibility/disposal

13 Environmental responsibility/disposal

Environmental responsibility is one of the fundamental company policies of the Bosch Group. We regard quality of performance, economy and environmental responsibility as equal objectives. Environmental protection laws and regulations are strictly adhered to. To protect the environment, we use the best possible technology and materials taking into account economic points of view.

Packaging

All packaging materials used are environmentally-friendly and recyclable.

Old appliances

Old appliances contain resources that must be submitted for recycling. The components are easy to separate and the plastics are marked. This allows the various components to be sorted for appropriate recycling or disposal.

Page 81

14 Inspection and maintenance

Inspection and maintenance | 81

Regular service and maintenance are recommended for a long service life of the appliance, for efficient and economical operation, and to keep the environmental impact as low as possible. Owners/operators are encouraged to sign a service and maintenance contract with a trained and certified installer for annual servicing and maintenance of the boiler.

DANGER: Explosion!

B Close the gas cock prior to working on the

gas train.

B Check for gas leaks after carrying out work

on the gas train.

DANGER: Risk of flue gas poisoning.

B Check for leaks after carrying out work on

the venting system.

DANGER: Risk of electric shock!

B Always disconnect the appliance from the

mains power before performing any work. Disconnect the emergency shutoff switch or disengage the heating system circuit breaker. Take measures to prevent accidental reconnection.

NOTICE: Insufficient antifreeze can accelerate corrosion.

B Frost protection level has to be checked

annually during the regular scheduled maintenance of the condensing boiler.

Heat exchanger

NOTICE: Damage to the coating of the heat

exchanger.

B Cleaning of the heat exchanger should not

be necessary until five years after the initial commissioning.

B Only use a Bosch cleaning blade or Bosch

cleaning brush (Æ page 114).

B Only clean heat exchanger if soiling is

clearly visible.

Heatronic boiler control

In case of a component defect, a fault is shown on the display.

The Heatronic boiler control monitors all safety and control components.

NOTICE: The Heatronic boiler control can be damaged by leaking water.

B Cover the Heatronic prior to working on

water filled components.

Notes on installation and operation

An overview of the faults can be found on page 91.

• The following analytical tools are needed for service and maintenance:

– Electronic flue gas analyzer for CO

gas temperature

– Pressure gauge 0 to 12 inches W.C. (0 to 30 mbar)

– pH Test strips

– Glycol tester of antifreeze is being used

• Special tools are not required.

• Approved lubricants are:

– For parts touched by water: Unisilkon L 641

(part-# 8 709 918 413 0)

– or fittings: HFt 1 v 5 (part-# 8 709 918 010 0).

B Use part-# 8 719 918 658 0 as heat conducting paste.

B Use only genuine Bosch spare parts.

B Request spare parts (Æ Section 18, page 99).

B Replace removed gaskets and O-rings with new ones.

After the inspection/maintenance

B Re-tighten all loosened threaded connections.

B Restart the appliance (Æ page 58).

B Check all connections for leaks.

B Check the gas-air ratio and adjust if necessary

(Æ page 76).

, O2, CO, and flue

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Page 82

82 | Inspection and maintenance

14.1 Description of various steps

14.1.1 Calling up the latest fault (service function 6.A)

B Select service function 6.A (Æ page 71).

An overview of the faults can be found on page 91.

14.1.2 Fresh water filter (only combi boiler ZWB..-3A)

B Close cold water tap.

B Depressurize the cold water pipe.

B To access the filter remove the safety clip (step 1), pull

out the pipe (step 2), and remove the filter from the pipe (step 3).

B If necessary, clean with plastic brush under running

water.

14.1.3 Plate type heat exchanger (only combi boiler ZWB..-3A)

If the DHW output on the combi boiler is significantly reduced:

B Check filter in the cold water pipe for contamination

(Æ Fig. 82).

B Depressurize the appliance.

B Remove plate type heat exchanger and replace

-or-

B Descale with descaling agent approved for stainless

steel (Grade 316-1.4401).

To remove the plate type heat exchanger:

B Unplug electrical connections.

B Remove hose from safety relief valve.

Fig. 76 Filter in fresh water pipe

(combi boiler ZWB..-3A only)

6 720 641 933-46.1O

Fig. 77 Unplugging electrical connections / removing hose

from safety relief valve

B Loosen/remove pipe connections.

6 720 641 933-92.1o

6 720 641 933-47.1O

Fig. 78 Removing pipe connections

Page 83

Inspection and maintenance | 83

B Remove the boiler pressure gauge from the Heatronic

boiler control.

6 720 641 933-48.1O

Fig. 79 Removing the boiler pressure gauge

B Loosen the quick releases (steps 1 and 2) and remove

the hydraulic assembly in its entirety (step 3).

14.1.4 Checking the electrodes

B Remove electrode set (Æ page 12 / 14) including

gasket and check electrodes for contamination; clean or replace, if required.

B Reinstall electrode set with new gaskets and check for

leaks.

2-1/4 + 3/4 ft.-lbf.

(3 + 1 Nm)

6720641933-28.1O

Fig. 82 Reinstalling the electrode set

6 720 641 933-49.1O

Fig. 80 Removing the hydraulic assembly

B Remove the plate type heat exchanger.

6 720 641 933-50.1O

Fig. 81 Removing the plate heat exchanger

B Install new plate type heat exchanger with new gaskets

and reconnect the hydraulic assembly in reverse order.

B Check all connections used during maintenance for

leaks.

Gas/Gaz?

6 720 613 354-02.2O

Fig. 83 Check for leaks

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Page 84

84 | Inspection and maintenance

14.1.5 Burner servicing

DANGER: Fire danger!

B Only operate the burner while installed in a

boiler.

B Remove burner lid (steps 1 - 4).

Fig. 84 Removing the burner cover

B Remove burner and clean its components.

6 720 641 933-95.1o

14.1.6 Heat exchanger block inspection and cleaning

NOTICE: Damage to the coating of the heat

exchanger.

B Cleaning of the heat exchanger should not

be necessary until five years after the initial commissioning.

B Only use a Bosch cleaning blade and Bosch

cleaning brush (Æ page 114).

B Only clean heat exchanger in case if soiling

is clearly visible.

B Remove the inspection cover (Æ page 12) and any

sheet metal insert below, if installed.

B Determine degree of soiling of the heat exchanger

through visual inspection.

If mechanical cleaning is required:

For cleaning the heat exchanger, Bosch offers the service accessory kit which includes main heat exchanger gaskets, the heat exchanger brush and heat exchanger cleaning blade (part-# 7719001998).

B Remove the condensate trap (steps 1 and 2) and place

a suitable container underneath.

7 181 465 330-08.2R

Fig. 85 Burner

B Reinstall burner in reverse order, including a new gasket

if necessary.

B Adjust the gas-air ratio (Æ page 76).

6 720 641 933-93.1o

Fig. 86 Removing the condensate trap

Page 85

Inspection and maintenance | 85

B With the cleaning blade, clean the heat exchanger block

from the bottom to the top.

6 720 641 933-71.1O

B Rinse the heat exchanger with water from the top.

6 720 612 664-18.1R

Fig. 89 Rinsing the heat exchanger

B Clean the condensate tray (with reversed brush).

Fig. 87 Cleaning the heat exchanger with the cleaning blade

B Clean the heat exchanger block with the brush from top

to bottom.

6 720 612 563-14.1O

6 720 610 332-75.2R

Fig. 90 Cleaning the condensate tray

B Rinse the heat exchanger with water from the top.

B Clean the condensate trap connection.

B Close the inspection opening again using a new gasket

and tighten the screws with approx. 3.69 ft.-lbf. (5 Nm).

Fig. 88 Cleaning the heat exchanger with the cleaning

brush

B Remove burner (Æ Chapter 14.1.5 “Burner servicing”).

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Page 86

86 | Inspection and maintenance

14.1.7 Condensate trap cleaning

B Remove condensate trap (steps 1 and 2) and check heat

exchanger orifice for clear passage.

14.1.8 Checking the mixer diaphragm

B Open the mixer unit.

B Carefully remove the diaphragm from the fan air intake

and check for contamination and cracks.

6 720 641 933-94.1o

Fig. 92 Opening the mixer unit

6 720 641 933-93.1o

Fig. 91 Removing the condensate trap

B Remove and clean the condensate trap lid.

B Check condensate hose and clean if necessary.

B Fill the condensate trap with approx. 1 cup (1/4 l) of

water and reinstall it.

B Insert the diaphragm into the fan connector. Ensure the

diaphragm is oriented properly.

The diaphragm flaps must open upwards.

B Close the mixer unit.

Page 87

Inspection and maintenance | 87

14.1.9 Expansion vessel

Annual inspection of the expansion vessel is required.

B Depressurize the appliance.

B If necessary, adjust the expansion vessel pre-charge

pressure to the static head of the heating system (Æ page 37).

14.1.10 Setting the boiler water pressure

Display on the pressure gauge

14.5 psi

(1 bar)

14.5 psi to

21.75 psi

Minimum filling pressure (when system is cold)

Optimal filling pressure

(1 bar to

1.5 bar)

30 psi (2.07 bar)

Maximum pressure at maximum heating water temperature must not be exceeded (safety valve will spill).

Tab. 32 Operating pressure

B If the indicator is below 14.5 psi (1 bar) when the

system is cold, top up the water. The indicator must be between 14.5 psi (1 bar) and 21.75 psi (1.5 bar).

14.1.11 Testing system water quality

B Take a representative sample of the system water and

analyze pH using a pH meter or pH test strips.

pH-value Water preparation

7-8.5 Not needed

4.5-7 Required

Tab. 33 Water preparation for filling and maintaining the

heating system (pH-value)

B If the value is outside of the permitted range, drain the

system, flush, and refill with fresh water to prevent system damage or leaks.

B If the fill water does not meet the requirements of

page 35, treat the water to bring it within the permissible range.

B If antifreeze is being used in the system, check the frost

protection properties to ensure the site specific requirements are met.

14.1.12 Inspecting electrical wiring

B Check electrical wiring for mechanical damage and

replace defective cables.

If using a hose to fill the heating system, prefill the hose with water to prevent air being introduced into the system.

B If the pressure is not held, check the expansion vessel

and heating system for leaks.

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Page 88

88 | Inspection and maintenance

14.2 Checklist for inspection and maintenance

B Use this form to guide you through the service and maintenance procedure. Fill out each step according to the findings

and work performed.

Date

1 Latest fault code from service function

6.A (Æ

page 82).

2 Fresh water inlet filter (Combi boiler ZWB appliances

only) (

page 82).

3 Visual inspection of the combustion air pipes and vent

pipes.

4 Dynamic gas pressure (Æpage 78). inches

W.C. (mbar)

5 Gas-air ratio at min./max. nominal output

page 76).

(

min. % max. %

6 Gas and water-side leak test (Æpage 51).

7 Inspect electrodes (Æpage 83).

8 Inspect heat exchanger block (Æpage 84).

9 Check burner (Æpage 84).

10 Inspect diaphragm in mixer unit (Æpage 86).

11 Clean condensate trap (Æpage 86).

12 With the system depressurized, check the

expansion vessel pre-charge pressure vs. the

psi (bar)

static head of the heating system.

13 Check the heating system filling pressure. psi

(bar)

14 Inspect electrical wiring for damage.

15 Check settings of the heating control.

16 Check set service functions according to commissioning

report (Æ page 97).

Tab. 34 Maintenance and inspection checklist

Page 89

15 Readings on the display

Readings on the display | 89

The boiler display can provide the following information (Tab. 35 and 36):

Value displayed Description Range

Number or letter, dot

followed by letter Letter followed by

number or letter

Three numbers

≤

199)

( One number (dis-

played for longer) fol-

lowed by two

numbers (displayed

briefly) Two dashes followed

by two pairs of num-

bers

Two letters followed

by two pairs of num-

bers

Service function

Tab. 27 / 28, page 66)

( Fault code

(

Tab. 37, page 91) (excep-

tion: b.A = service function) Decimal value, e.g. supply

temperature Decimal figure (three digits);

first digit is shown alternating

with two last digits

(e.g. 2.69..69 for 269)

Code is shown in three stages:

1. Two dashes 2. First two

digits 3. Last two digits

(e.g. -- 10 04) Code is shown in three stages:

1. Two letters 2. First two

digits 3. Last two digits

(e.g. CF 10 20)

00..199

0..999

1000 ...

9999

Tab. 35 Display readings

Status

code

Description

Acknowledge by pressing any button (except reset).

Acknowledge by pressing two buttons

simultaneously

Acknowledge by pressing and holding for more

than 3 seconds (Save function).

The display shows the supply temperature in alter-

nation with . The appliance works for 15 minutes

at the minimum nominal output,

service function

The display shows the supply temperature in alter-

nation with . The appliance works with the set

maximum output in heating mode,

service function

The display shows the supply temperature in alter-

nation with . The appliance works for 15 minutes

at the maximum nominal output,

service function

The air purging function is active,

2.C

2.F

1.A

2.F

service function

The display shows the supply temperature in alter-

nation with . The trap filling sequence is active,

service function

The display shows the supply temperature alternat-

ing with : Service reminder,

service function

The display shows the supply temperature in alter-

nation with . The pump may have seized,

fault

E.9

The display shows the supply temperature in alter-

nation with . The temperature gradient limiter

was triggered. Excessive supply temperature

increase: Heating mode is suspended for two min-

utes. Slab drying function of the FW200 outdoor reset

control (

function ( Key pad lock enabled. To unlock the key pad, press

display.

operating instructions) or building drying

service function

until the supply temperature is shown on the

Tab. 36 Special displays

4.F

5.A

7.E

) are activated.

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Page 90

90 | Faults

16 Faults

16.1 Troubleshooting

DANGER: Explosion!

B Close the gas cock prior to working on the

gas train.

B Check for gas leaks after carrying out work

on the gas train.

DANGER: Risk of flue gas poisoning.

B Check for leaks after carrying out work on

the venting system.

DANGER: Risk of electric shock!

B Always disconnect the appliance from the

mains power before performing any work. Disconnect the emergency shutoff switch or disengage the heating system circuit breaker. Take measures to prevent accidental reconnection.

WARNING: Danger of scalding!

Hot water can scald.

B Drain the appliance before working on

components that are water filled.

NOTICE: The Heatronic boiler control can be damaged by leaking water.

B Cover the Heatronic prior to work on water

filled components.

The Heatronic boiler control monitors all safety and control components.

If a fault arises during operation, an audible warning tone sounds.

Press a button to mute the warning sound.

The display indicates a fault code (e.g. ) and the reset button flashes.

If the reset button is flashing:

B Press the reset button and hold it until appears on

the display. The appliance starts up again and the current supply temperature is displayed.

If the reset button is not flashing:

B Switch the appliance OFF and ON again.

The appliance starts up again and the current supply temperature is displayed.

An overview of the faults can be found on page 91. An overview of the status codes can be found on page 89.

If the fault persists:

B Check the PCB and replace if required. Adjust the

service functions in accordance with the commissioning report (Æ page 97).

Page 91

16.2 Faults that are shown on the display

Display Description Elimination

Faults | 91

b2/b3/ b4/b5/

DHW temperature sensor defective.

Communication fault.

DHW tank temperature not detected.

The DHW tank temperature sensor was recognized before the connection was lost.

Code plug not detected.

Internal data error.

Fault in the burner controls.

Fan not running.

Outdoor temperature sensor not recognized.

Check temperature sensor and leads for interruptions or shorts, and replace if defective.

Insert code plug correctly; replace if defective.

Check BUS communications wiring, replace if defective.

Check control, replace if defective.

Check DHW tank temperature sensor and connecting lead, replace if defective.

Reset the boiler to the factory default settings (Æservice function 8.E), reset the IPM 2 default settings and carry out the automatic system configuration.

Insert code plug correctly; replace if defective.

Reset boiler to factory default setting (Æservice function

8.E).

Reset boiler to factory to default setting (Æservice function

8.E).

Check fan leads and fan, replace if defective.

Check outdoor temperature sensor and leads for interruptions, replace if defective.

Verify the outdoor temperature sensor is connected to terminals A and F.

(if installed)

to the factory

Tab. 37 Faults shown on the display

Temperature high limit defective.

External guard has tripped.

Temperature limiter locked out.

External supply temperature sensor defective (low-loss header).

The external supply temperature sensor was recognized on the BUS and then reconnected to the appropriate terminal.

Check temperature sensor and leads for interruptions or shorts, and replace if defective.

Temperature guard TB1 has tripped. Check if jumper across 8-9 or PR-P0 is missing.

Reset external temperature limiter (if installed).

Reset LWCO (if installed).

Check temperature sensor and leads for interruptions or shorts, and replace if defective.

Check whether only one temperature sensor is connected; otherwise remove second temperature sensor.

Reset the boiler to the factory default settings (Æservice function 8.E), reset the IPM 2 (if installed) to the factory default settings and carry out the automatic system configuration.

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Page 92

92 | Faults

Display Description Elimination

Supply temperature sensor defective.

Additional supply temperature sensor defective.

Heat exchanger safety high limit or flue gas temperature limiter has tripped.

No flame detected.

GFA: Safety time expired.

Check temperature sensor and leads for interruptions or shorts, and replace if defective.

Check flue gas safety high limit and leads for interruptions or shorts, and replace if defective.

Check heat exchanger safety high limit and leads for interruptions or shorts, and replace if defective.

Check the operating pressure.

Check temperature limit; replace if defective.

Check pump capacitor; replace pump if defective.

Check PCB fuse, replace if blown (6.3 A fuse according to IEC default).

Purge the appliance

Check heat exchanger on the DHW side; replace if clogged.

Check that ground lead is properly connected, replace if defective.

Check that gas cock is open.

Check inlet gas pressure; correct if needed.

Check power supply.

Check electrodes for visual damage; replace if defective.

Check flue gas system; clean or repair if defective.

Check gas/air ratio; correct if out of range.

Check gas valve; replace if defective.

In room air operation, check air supply or ventilation apertures.

Clean the condensate trap.

Remove diaphragm at fan inlet connection and check for contamination or cracks.

Check heat exchanger for soiling (Æ Chapter 14.1.6, page 84).

Check gas cock; replace if defective.

Insert code plug correctly; replace if defective.

Internal fault

Internal data error.

Tab. 37 Faults shown on the display

Press reset for 3 seconds and release. When the button is released, the appliance will restart.

Check electrical plug-in contacts and ignition leads; replace PCB if defective.

Check gas/air ratio; correct if out of specification.

Reset boiler to the factory default setting (Æservice function

8.E).

Page 93

Display Description Elimination

Faults | 93

Flame detected even when burner is off.

After switching gas off: Flame is detected.

Reset button pressed by mistake.

Temperature gradient limiter: Temperature rise too fast

Tab. 37 Faults shown on the display

Check electrodes; replace if defective.

Check flue gas system; clean or repair if defective.

Check PCB for moisture; dry if needed.

Check gas cock; replace if defective.

Clean condensate trap.

Check electrodes and leads; replace if defective.

Check flue gas system; clean or repair if needed.

Press reset button again.

Check cable harness to safety high limit and gas cock for ground connection.

Fully open service shut-off valves.

Check electrical connection between heating zone pump and Heatronic.

Check pump plug connection per installation instructions.

Manually test operation of heating zone pump and replace if defective.

Set pump speed correctly to match maximum output.

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Page 94

94 | Faults

16.3 Faults that are not shown on the display

Appliance faults Elimination

Combustion noise too loud; rumbling noises

Flow noises

Heating-up takes too long

Flue gas readings incorrect; CO levels too high

Violent ignition, poor ignition

Insert code plug correctly; replace if defective.

Check gas type.

Check inlet gas pressure; adjust if defective.

Check flue gas system; clean or repair if defective.

Check gas/air ratio in the combustion air and flue gas; replace gas valve if

defective.

Set pump speed correctly to match maximum output.

Set pump mode.

Set pump speed correctly to match maximum output.

Set pump mode.

Check gas type.

Check inlet gas pressure; adjust if defective.

Check flue gas system; clean or repair if defective.

Check gas/air ratio in flue gas; replace gas valve if defective.

Check gas type.

Check inlet gas pressure; adjust if defective.

Check power supply.

Check electrodes for visual damage; replace if defective.

Check flue gas system; clean or repair if defective.

Check gas/air ratio; replace gas valve if defective.

Check gas valve; replace if defective.

Check burner; replace if required.

DHW has unpleasant odor or has a dark color

Set supply temperature (e.g. of the FW200 control)

exceeded

Condensate in air box

DHW temperature is not reached (combi boiler

ZWB..-3A only)

Heatronic is flashing (i.e. all buttons, all display seg-

ments, burner indicator etc. are flashing)

Tab. 38 Faults not shown on the display

Perform thermal disinfection of the DHW circuit.

Replace sacrificial anode in the tank (if installed).

Consult local water department.

Switch off automatic anti-cycle timer, i.e., set value to 0.

Set the required anti-cycle timer, e.g. default setting of 3 minutes.

Insert diaphragm in the mixer unit per installation instructions; replace if

defective.

Insert code plug correctly; replace if defective.

Check whether voltage (120 VAC) is present between terminal 1 and termi-

nal 3; repair if defective.

Check turbine; replace if defective.

Replace fuse Si 3 (24 V) (6.3 A fuse according to IEC default).

Page 95

16.4 Check sensor values

16.4.1 Outdoor temperature sensor

Temperature °F ( °C) Testing tolerance ± 10%

– 4 ( – 20) 2,392

3 ( – 16) 2,088

10 ( – 12) 1,811

17 ( – 8) 1,562

24 ( – 4) 1,342

32 (0) 1,149

39 (4) 984

46 (8) 842

50 (10) 781

59 (15) 642

68 (20) 528

77 (25) 436

Tab. 39 Resistance table outdoor temperature sensor

16.4.2 Additional supply temperature limiter

Temperature °F ( °C) Testing tolerance ± 10%

Resistance [ Ω]

Faults | 95

16.4.3 Supply temperature sensor, External supply temperature sensor, DHW tank temperature sensor, DHW temperature sensor

Temperature °F ( °C) Testing tolerance ± 10%

Resistance [ Ω]

68 (20) 14,772

77 (25) 11,981

86 (30) 9,786

95 (35) 8,047

104 (40) 6,653

113 (45) 5,523

122 (50) 4,608

131 (55) 3,856

140 (60) 3,243

149 (65) 2,744

158 (70) 2,332

167 (75) 1,990

176 (80) 1,704

185 (85) 1,464

194 (90) 1,262

203 (95) 1,093

32 (0) 33,555

50 (10) 21,232

68 (20) 13,779

86 (30) 9,128

104 (40) 6,205

122 (50) 4,298

140 (60) 3,025

158 (70) 2,176

176 (80) 1,589

194 (90) 1,177

212 (100) 886

Tab. 40 Resistance table supply temperature limiter

212 (100) 950

Tab. 41 Resistance table NTCs

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96 | Faults

16.5 Replacement code plug

Appliance Order number

ZBR16-3A NG 8 714 43

ZBR16-3A LPG 8 714 43

ZBR28-3A NG 8 714 43

ZBR28-3A LPG 8 714 43

ZBR35-3A NG 8 714 43

ZBR35-3A LPG 8 714 43

ZBR42-3A NG 8 714 43

ZBR42-3A LPG 8 714 43

ZWB28-3A NG 8 714 43

ZWB28-3A LPG 8 714 43

ZWB42-3A NG 8 714 43

ZWB42-3A LPG 8 714 43

Tab. 42 Code plugs for all appliances

2 501

2 506

2 502

2 507

2 503

2 508

2 504

2 509

2 520

2 521

2 500

2 505

Page 97

17 Commissioning log for the appliance

Home owner/operator:

Last name, first name Number, Street

Telephone/fax ZIP code, town

System installer

Order number:

Appliance type: (

FD (Date of manufacture):

Date commissioned:



Individual appliance

Installation

location:

Vent pipe routing:

Notes regarding under or over pressure operation:



Basement | Attic | Garage | other:

Room air only: Number and size of ventilation openings ft



Twin pipe system | Room air | Sealed combustion



PVC | 2" | 3"

Total length: Approx. ...... ft (m) | Elbows 90°: ...... Qty | Elbows 15 - 45 °: ......Qty

Flue tightness test completed:

value in the combustion air at maximum nominal output: %



yes | no

Commissioning log for the appliance | 97

Complete a separate log for every appliance!

(m2)

)

Gas setting and flue gas test:

Gas conversion: NG | LPG (propane)

" W.C.

Inlet gas pressure

(mbar) Gas static supply pressure:

MBH

Selected maximum output:

(kW) Selected minimum output:

gpm

Gas flow rate at maximum nominal output:

Net calorific value H

at max. nominal output: % CO2 at minimum nominal output: %

at maximum nominal output: % O2 at minimum nominal output: %

(per gas supplier):

(l/min) Gas flow rate at minimum nominal output:

MBTU/ft

(kWh/m3)

" W.C.

(mbar)

MBH

(kW)

gpm

(l/min)

CO at maximum nominal output: ppm CO at minimum nominal output: ppm

Flue gas temperature at maximum nominal output: °F ( °C) Flue gas temperature at minimum nominal output: °F ( °C)

Maximum measured supply temperature: °F ( °C) Minimum measured supply temperature: °F ( °C)

System hydraulics:



Low-loss header, type:



Heating pump: Size/pre-charge pressure:



Additional expansion vessel

Automatic air vent present?



Primary secondary piping



DHW tank/type/number/heating surface output:



System hydraulics checked, notes:



yes | no

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98 | Commissioning log for the appliance

Modified service functions:

Example: Service function 7.d changed from 00 to 01

Heating control:



FW 200



FB 100 × ...... Qty, coding heating zone(s):



ISM 2



IPM 2 × ...... Qty, coding heating zone(s):

Other:



Heating control programmed, notes:



Documented the modified settings of the heating control in the control operating/installation instructions

The following work has been carried out:



Electrical connections checked, notes:



Condensate trap filled



Function check carried out

(Select the modified service functions and enter the values here.)



Carry out a combustion air/flue gas test



Tightness test carried out on the gas and water sides

Commissioning includes checking the settings, a visual heating leak test and a functional check of the boiler and control. The system

installer conducts a test of the heating system.

This system has been checked to the extent described.

___________________________________________________________

Name of service installing contractor

____________________________________________________________

Date, system installer's signature

The documents have been handed over to the home owner/opera-

tor. The home owner/operator has been instructed regarding

safety and operation of the boiler and accessories, including the

need for regular scheduled maintenance.

__________________________________________________________

Date, owner/operator signature

Affix the test report here.

Page 99

18 Spare parts

B Order spare parts by name and part number using the

spare parts list.

Spare parts | 99

Designation

Group 1 - Sheet metal Group 2 - Burner/Heat exchanger Group 3 - Gas valve Group 4 - Pipes combi boiler ZWB..-3A Group 5 - Pipes heating boiler ZBR..-3A Group 6 - Control box Group 7 - Hydraulic block combi boiler ZWB..-3A Group 8 - Accessories for service/installation

Tab. 43 Spare part groups Greenstar

ZBR16-3A

 Æ

  Æ

 Æ

ZBR28-3A

ZBR35-3A

ZBR42-3A

ZWB28-3A

 Æ

ZWB42-3A

Spare parts list

page 100 page 102 page 104 page 106 page 108 page 110 page 112 page 114

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Page 100

100 | Spare parts

8 7

Fig. 93 Group 1 - Sheet metal Greenstar

6 720 641 933-102.1o