Bosch ZSB 30-2, ZWB 37-2, ZSB 30-2 A, ZWB 37-2 A Installation And Servicing Instructions
Installation and servicing instructions for contractors
Hydronic Gas Condensing Boiler
Condens 5000 W
6 720 613 085-00.1O
ZSB 30-2 A ...| ZWB 37-2 A ...
6 720 644 143 (2010/09) NZ/AU
2 | Contents
6 720 644 143 (2010/09)
Contents
1 Key to symbols and safety instructions . . . . . . . 5
1.1 Explanation of symbols . . . . . . . . . . . . . . 5
1.2 Safety instructions . . . . . . . . . . . . . . . . . . 5
2 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Product details . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Explanation of model code . . . . . . . . . . . 7
3.3 Gas type . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Type plate . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Description of appliance . . . . . . . . . . . . . 8
3.6 Accessories . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Dimensions and minimum clearances . . . 9
3.8 Appliance layout . . . . . . . . . . . . . . . . . . 10
3.9 Electrical wiring diagram . . . . . . . . . . . . 12
3.10 Specification ZSB 30-2 ... . . . . . . . . . . . 16
3.11 Specification ZWB 37-2 ... . . . . . . . . . . . 17
3.12 Condensate composition . . . . . . . . . . . . 18
4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Water system and pipe work . . . . . . . . . 20
5.2 Condensate pipe work . . . . . . . . . . . . . 22
5.2.1 Internal connections . . . . . . . . . . . . . . . 22
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Important notes . . . . . . . . . . . . . . . . . . . 24
6.2 Checking the size of the expansion
vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Siting the appliance . . . . . . . . . . . . . . . . 25
6.4 Pre-installing pipes . . . . . . . . . . . . . . . . 26
6.5 Fitting the appliance . . . . . . . . . . . . . . . 28
6.6 Checking the connections . . . . . . . . . . . 32
7 Electrical connections . . . . . . . . . . . . . . . . . . . . 33
7.1 General information . . . . . . . . . . . . . . . . 33
7.2 Connecting accessories . . . . . . . . . . . . . 33
7.2.1 Connecting the heating controller or
remote control units . . . . . . . . . . . . . . . 34
7.2.2 Connecting the DHW cylinder . . . . . . . . 34
7.2.3 Connecting temperature limiter TB 1
from the flow of an underfloor
heating system . . . . . . . . . . . . . . . . . . . 34
8 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Before commissioning . . . . . . . . . . . . . 36
8.2 Switching the appliance on/off . . . . . . 36
8.3 Starting the central heating . . . . . . . . . 37
8.4 Setting the heating control unit . . . . . . 37
8.5 After commissioning . . . . . . . . . . . . . . . 37
8.6 Appliances with hot water cylinder:
setting the hot water temperature . . . . 38
8.7 ZWB appliances - setting hot water
temperature . . . . . . . . . . . . . . . . . . . . . 39
8.8 Summer mode (central heating off,
DHW only) . . . . . . . . . . . . . . . . . . . . . . . 39
8.9 Frost protection . . . . . . . . . . . . . . . . . . 39
8.10 Holiday mode . . . . . . . . . . . . . . . . . . . . 40
8.11 Fault mode . . . . . . . . . . . . . . . . . . . . . . 40
9 Thermal disinfection on appliances
with hot water cylinder . . . . . . . . . . . . . . . . . 41
10 Pump anti-seizing function . . . . . . . . . . . . . . . . 42
11 Heatronic settings . . . . . . . . . . . . . . . . . . . . . . . 43
11.1 General information . . . . . . . . . . . . . . . 43
11.2 Overview of service functions . . . . . . . 44
11.2.1 Service level 1 . . . . . . . . . . . . . . . . . . . 44
11.2.2 Service level 2 . . . . . . . . . . . . . . . . . . . 44
11.3 Description of service functions . . . . . 45
11.3.1 Service level 1 . . . . . . . . . . . . . . . . . . . 45
11.3.2 Service level 2 . . . . . . . . . . . . . . . . . . . 49
12 Converting the appliance to different
gas types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.1 Gas-type conversion . . . . . . . . . . . . . . . 50
12.2 Setting the gas-air ratio (CO2 or O2) . . 50
12.3 Checking the gas supply pressure . . . . 52
13 Flue gas testing . . . . . . . . . . . . . . . . . . . . . . . . . 53
13.1 Central heating boost button . . . . . . . . 53
13.2 Checking flue system for leaks . . . . . . . 53
13.3 Measuring CO content of flue gas . . . . 53
14 Environmental protection . . . . . . . . . . . . . . . . . 54
Contents | 3
6 720 644 143 (2010/09)
15 Inspection/Servicing . . . . . . . . . . . . . . . . . . . . . 55
15.1 Checklist for inspection/servicing
(Inspection/Servicing report) . . . . . . . . 56
15.2 Description of various servicing
operations . . . . . . . . . . . . . . . . . . . . . . . 57
15.2.1 Retrieving last fault stored
(service function 6.A) . . . . . . . . . . . . . . 57
15.2.2 Checking electrodes . . . . . . . . . . . . . . . 57
15.2.3 Strainer in cold water pipe (ZWB) . . . . 57
15.2.4 Plate type heat exchanger (ZWB) . . . . . 58
15.2.5 Heat exchanger . . . . . . . . . . . . . . . . . . 59
15.2.6 Burner . . . . . . . . . . . . . . . . . . . . . . . . . 61
15.2.7 Diaphragm in mixer unit . . . . . . . . . . . . 62
15.2.8 Cleaning condensate trap . . . . . . . . . . 62
15.2.9 Checking the expansion vessel
(see also page 25) . . . . . . . . . . . . . . . . . 62
15.2.10 Setting the heating system pressure . . 63
15.2.11 Checking electrical wiring . . . . . . . . . . 63
16 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
17 Fault mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
17.1 Troubleshooting . . . . . . . . . . . . . . . . . . 66
17.2 Faults that are shown on the
display . . . . . . . . . . . . . . . . . . . . . . . . . . 67
17.3 Faults that are not shown
on the display . . . . . . . . . . . . . . . . . . . . 70
17.4 Sensor values . . . . . . . . . . . . . . . . . . . . 71
17.4.1 Outside temperature sensor
(for weather-compensated controllers,
accessory) . . . . . . . . . . . . . . . . . . . . . . . 71
17.4.2 Flow and DHW sensors . . . . . . . . . . . . 71
17.5 Code Plug . . . . . . . . . . . . . . . . . . . . . . . 71
17.6 Settings for heating output with
ZSB 30 ...23 . . . . . . . . . . . . . . . . . . . . . . 72
17.7 Settings for heating output with
ZSB 30 ...31 . . . . . . . . . . . . . . . . . . . . . . 72
17.8 Settings for heating output with
ZWB 37 ...23 . . . . . . . . . . . . . . . . . . . . . 73
17.9 Settings for heating output with
ZWB 37 ...31 . . . . . . . . . . . . . . . . . . . . . 73
18 Commissioning report for the appliance . . . . . 74
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4 | Contents
6 720 644 143 (2010/09)
Key to symbols and safety instructions | 5
6 720 644 143 (2010/09)
1 Key to symbols and safety instructions
1.1 Explanation of symbols
Warning symbols
Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
• NOTICE indicates possible damage to property or
equipment, but where there is no risk of injury.
• CAUTION indicates possible injury.
• WARNING indicates possible severe injury.
• DANGER indicates possible risk to life.
Important information
Additional symbols
1.2 Safety instructions
If you smell gas
B Turn off gas tap (Æ page 35).
B Open windows and doors.
B Do not operate any electrical switches.
B Extinguish any naked flames.
B Leave the building and telephone your gas supply
utility and authorised contractor from an outside
phone.
If you smell flue gas from the appliance
B Switch off the appliance (Æ page 36).
B Open windows and doors.
B Inform your heating contractor.
Explosive and easily flammable materials
Never use or store easily flammable materials (paper,
thinners, paints, etc.) near the appliance.
Combustion air/ambient air
To prevent corrosion, keep the supply of combustion/
ambient air free of corrosive substances (e.g.
halogenated hydrocarbons that contain chlorine or
fluorine compounds).
Thermal disinfection
B Risk of scalding!
It is imperative to monitor operation at water
temperatures over 60 °C (Æ page 41).
Safety instructions in this document are
framed and identified by a warning triangle
which is printed on a grey background.
Electrical hazards are identified by a
lightning symbol surrounded by a warning
triangle.
Notes contain important information in
cases where there is no risk of personal
injury or material losses and are identified
by the symbol shown on the left. They are
bordered by horizontal lines above and
below the text.
Symbol Meaning
B a step in an action sequence
Æ a reference to a related part in the
document or to other related documents
• a list entry
– a list entry (second level)
Table 1
6 | Standard delivery
6 720 644 143 (2010/09)
2 Standard delivery
Fig. 1
Key:
1 Gas condensing boiler
2 Pre-plumbing jig
3 Mounting rail
4 Pre-plumbing jig for ZWB appliances
(for ZSB appliances without cold and DHW water
connections)
5 Filling loop with key (ZWB)
6 Adaptors for ZWB appliances
(for appliances ZSB without adaptors for cold cold and
DHW water connections)
7 Lower cover
8 Pressure relief valve hose (heating circuit)
9 Fixing kit
10 Set of printed documents for the appliance
6 720 644 143-01.1O
1
2
8
9
10
3
4
6
7
5
Product details | 7
6 720 644 143 (2010/09)
3 Product details
ZSB appliances are boilers for heating. They can be
fitted with the diverter valve accessory to connect to an
indirectly heated hot water cylinder.
ZWB appliances are combi boilers for central heating
(CH) and domestic hot water (DHW) heating according
to the instantaneous water heating principle.
3.1 Intended use
The appliance may only be installed in a sealed unvented
central heating system.
This appliance is intended for indoor use only. It is not
to be used as a pool heater.
Using the appliance for any other purpose will be
considered incorrect use. Bosch accepts no liability for
any damage resulting from such use.
The commercial and industrial use of the appliance to
generate process heat is not permitted.
3.2 Explanation of model code
Z Central heating appliance
S Cylinder connection
W DHW heating
B Condensing boiler technology
30 Output up to 30 kW
37 DHW output up to 37 kW
-2 Version
A Fan-assisted appliance without draught hood
23 Natural gas H
Note: Appliances can be converted to LPG.
31 LPG
S2414 Special number for Australia/New Zealand
3.3 Gas type
The code number indicates the gas family according to
AS 4552:
3.4 Type plate
The type plate [47] can be found on the inside of the
appliance at the bottom right (Æ Fig. 3, page 10).
It contains details of the output of the appliance, the
order number, the approval data and the date of
manufacture in encoded form.
ZSB 30-2 A 23 S2414
ZSB 30-2 A 31 S2414
ZWB 37-2 A 23 S2414
ZWB 37-2 A 31 S2414
Table 2
Code
number
Wobbe index
(W
S
) (15 °C) Gas type
23 12.2 - 55.0 MJ/m3NG
31 72.9 - 87.2 MJ/m3LPG
Table 3
LPG type1)
1) according to NZS 5435
Use
Commercial Propane recommended
Commercial Butane permitted
General Product permitted
Universal LPG (U-LPG) permitted
Table 4
8 | Product details
6 720 644 143 (2010/09)
3.5 Description of appliance
• Wall mounted boiler; installation independent of
chimney location or room size.
• Intelligent heating circuit pump control when
connected to an weather-dependent heating
controller
• Heatronic 3 controls with 2-wire BUS
• ZWB appliances can be supplied with water
preheated by solar energy, Æ page 24
• Optimised electronic heating circuit pump with:
– 2 proportional pressure curves
– 3 constant pressure curves
– 6 stages can be selected
– Run-dry protection and anti-seizing function
• Connecting lead with mains plug
• Display
• Automatic ignition
• Modulating output control
• Fully featured safety system provided by Heatronic
module with flame failure detection and solenoid
valves to EN 298
• No minimum water circulation rate required
• Suitable for underfloor heating
• Connection option for concentric pipe for flue gas/
combustion air Ø 80/125 mm, Ø 60/100 mm
• Variable speed fan
• Premix burner
• Temperature sensor and temperature control for
central heating
• Temperature sensor in flow
• Safety temperature limiter in 24 V electrical circuit
• Pressure relief valve, pressure gauge, expansion
vessel
• Optional for DHW cylinder temperature sensor (NTC)
• Flue gas temperature limiter
• DHW priority
• Plate type heat exchanger (ZWB)
• Motorised three-way valve (ZWB)
• Filling loop (ZWB)
• Pre-plumbing jig
3.6 Accessories
• Flue kits
• Weather-compensated controller, e.g. FW 100
• Room temperature controller, e.g. FR 10, FR 110
• Digital time switch, e.g. DT 10 RF, DT 20 RF
• Cylinder temperature sensor SF 2 for third party
cylinders
• Optional Diverter Valve Kit for DHW cylinder
connection including cylinder temperature sensor
(ZSB only).
Below is a list of typical accessories for this
appliance. You can find comprehensive
details of all available accessories in our
catalogue.
Product details | 9
6 720 644 143 (2010/09)
3.7 Dimensions and minimum clearances
Fig. 2
1 Pre-plumbing jig
2 Casing
3 Fascia
A Additional 30 mm above elbow
B Using 100 mm flue kit: 1112 mm /
120 mm flue kit: 1152 mm
C 20 mm to reversible door /
600 mm front clearance for service
440
min.
5
067
2
360
85
3
125
80
min.
5
087
6 720 644 143-02.2J
340
55
1
0200
A
B
C
10 | Product details
6 720 644 143 (2010/09)
3.8 Appliance layout
Fig. 3
6 720 644 143-03.1O
30
31
32
33
34
35
39
40
38
37
36
41
42
43
44
45
46
47
48
49
12
10
9
8
7
1
2
3
4
5
6
11
29
28
27
26
25
24
23
22
21
20
17
18
19
16
15
14
13
Product details | 11
6 720 644 143 (2010/09)
Key to figure 3:
1 Heatronic 3
2 Main switch
3 Burner ON indicator
4 Service button
5 Central heating boost button
6 Here, a weather-compensated control unit or a time switch
(accessories) can be plugged in
7 CH Flow temperature control
8 DHW temperature control
9 Holiday button
10 eco button
11 reset button
12 Display
13 DHW (ZWB)
14 CH flow
15 Adaptor for condensate hose
16 Condensate syphon
17 Gas supply pressure test port
18 Gas valve
19 DHW temperature sensor
20 Adjustable gas throttle
21 Test point for control pressure
22 Flue gas temperature limiter
23 Fan
24 Flow temperature sensor
25 Expansion vessel
26 Mixer unit
27 Bracket
28 Removable cover
29 Combustion air inlet
30 Flue pipe
31 Sight glass
32 Set of electrodes
33 Heat exchanger
34 Temperature limiter for heat exchanger
35 Access port for cleaning heat exchanger
36 Condensate tray
37 Automatic air vent valve
38 Plate-type heat exchanger (ZWB)
39 Turbine (ZWB)
40 Heating circuit pump
41 3-way diverter valve
42 Pressure relief valve (heating circuit)
43 Pressure gauge
44 Drain tap
45 Cold water inlet
46 Heating return
47 Type plate
48 Filling loop (ZWB)
49
Gas connection
12 | Product details
6 720 644 143 (2010/09)
3.9 Electrical wiring diagram
Fig. 4 ZSB 30-2
ST1
k
k
B
B
2
4
F
1
A
14
15
16
17
12
13
11
18
22
21
10
1
2
3
4
5
6
7
8
9
19
20
Product details | 13
6 720 644 143 (2010/09)
1 Spark transformer
2 CH temperature control
3 Wiring centre
4 Safety solenoid
5 Safety solenoid
6 Gas valve
7 Fan
8 Flame sense eletrode
9 Spark electrodes
10 Flow NTC
11 Heat exchanger overheat stat.
12 Flue overheat stat.
13 Earth
14 Mains supply
15 Pump
16 Pump control
17 Diverter valve (optional)
18 Pump supply
19 DHW temperature control
20 Fluse slow T 0.5 A
21 Fluse slow T 1.6 A
21 Code plug
14 | Product details
6 720 644 143 (2010/09)
Fig. 5 ZWB 37-2
Ls Ns
rtue
vi
B
B
2
4
F
1
A
14
15
16
17
12
13
11
18
23
24
22
25
21
10
1
2
3
4
5
6
7
8
9
19
20
Product details | 15
6 720 644 143 (2010/09)
1 Spark transformer
2 CH temperature control
3 230 V room stat/programmer
4 Safety solenoid
5 Safety solenoid
6 Gas valve
7 Fan
8 Flame sense eletrode
9 Spark electrodes
10 Flow NTC
11 Heat exchanger overheat stat.
12 Flue overheat stat.
13 Earth
14 Mains supply
15 DHW sensor
16 Pump
17 Pump control
18 Diverter valve
19 Flow turbine
20 Pump supply
21 DHW temperature control
22 External frost stat (optional)
23 Fluse slow T 0.5 A
24 Fluse slow T 1.6 A
25 Code plug
16 | Product details
6 720 644 143 (2010/09)
3.10 Specification ZSB 30-2 ...
ZSB 30-2 ...
Unit Natural gas Propane Butane
Max. heat output (P
max
) 40/30 °C kW 32.1 32.1 36.6
Max. heat output (P
max
) 50/30 °C kW 31.8 31.8 36.3
Max. heat output (P
max
) 80/60 °C kW 30.0 30.0 34.2
Max. gas consumption (Q
max
), central heating MJ/h 123.4 123.4 140.5
Min. heat output (P
min
) 40/30 °C kW 8.6 12.4 14.2
Min. heat output (P
min
) 50/30 °C kW 8.6 12.3 14.0
Min. heat output (P
min
) 80/60 °C kW 7.7 11.0 12.6
Min. gas consumption (Q
min
), central heating MJ/h 31.9 11.5 52.3
Max. heat output (PnW), DHW kW 30.9 45.9 35.2
Max. gas consumption (QnW), DHW MJ/h 123.4 123.4 140.5
Gas supply rate
Natural gas (gross heating value 37.8 MJ/m3)m
3
/h 3.2 - -
Butane/propane (gross heating value 50 MJ/kg) kg/h -2.42.8
Permissible gas supply pressure
NG kPa 1.1 - 3.0 - LPG kPa -2.752.75
Expansion vessel
Pre-charge pressure kPa 75 75 75
Total capacity l 10 10 10
Calculation values for calculating cross-section to EN 13384
Flue gas mass flow rate, max./min. rated g/s 13.6/3.7 12.8/5.2 12.8/5.2
Flue gas temperature 80/60 °C max./min. rated °C 76/58 76/58 76/58
Flue gas temperature 40/30 °C max./min. rated °C 55/33 55/33 55/33
Residual pump head Pa 80 80 80
CO2 at max. rated output % 9.6 10.8 12.2
CO2 min. rated output % 9.0 10.2 11.5
Flue gas rating group to G 636/G 635 G61/G
62
G61/G
62
G61/G
62
NOx class 555
Condensate
Max. condensate quantity (tR = 30 °C) l/h 2.7 2.7 2.7
pH level, approx. 4.8 4.8 4.8
General data
Power supply voltage AC ... V 220 - 240 220 - 240 220 - 240
Frequency Hz 50 50 50
Max. power consumption (central heating mode) W 150 150 150
EMC limit class - BBB
Noise output level ≤ dB(A) 43 43 43
Appliance enclosure rating IP X4D X4D X4D
Max. flow temperature °C Approx. 90 Approx. 90 Approx. 90
Max. permissible operating pressure (PMS) heating kPa 300 300 300
Permissible ambient temperature °C 0 - 50 0 - 50 0 - 50
Nominal capacity of appliance heating l 3.5 3.5 3.5
Weight (excluding packaging) kg 46.5 46.5 46.5
Dimensions, W x H x D mm 440 x 760 x 360 440 x 760 x 360 440 x 760 x 360
Table 5
Product details | 17
6 720 644 143 (2010/09)
3.11 Specification ZWB 37-2 ...
ZWB 37-2 ...
Unit Natural gas Propane Butane
Max. heat output (P
max
) 40/30 °C kW 32.1 32.1 36.6
Max. heat output (P
max
) 50/30 °C kW 31.8 31.8 36.3
Max. heat output (P
max
) 80/60 °C kW 30.0 30.0 34.2
Max. gas consumption (Q
max
), central heating MJ/h 123.4 123.4 140.5
Min. heat output (P
min
) 40/30 °C kW 10.6 15.7 17.9
Min. heat output (P
min
) 50/30 °C kW 10.5 15.5 17.7
Min. heat output (P
min
) 80/60 °C kW 9.4 13.9 15.9
Min. gas consumption (Q
min
), central heating MJ/h 39.1 57.9 65.9
Max. heat output (PnW), DHW kW 37.0 37.0 42.2
Max. gas consumption (QnW), DHW MJ/h 147.7 147.7 168.5
Gas supply rate
Natural gas H (gross heating value 37.8 MJ/m3)m3/h 3.9 - Butane/propane (gross heating value 50 MJ/kg) kg/h -2.93.4
Permissible gas supply pressure
NG kPa 1.1 - 3.0 - LPG kPa -2.752.75
Expansion vessel
Pre-charge pressure kPa 75 75 75
Total capacity l 10 10 10
DHW
Max. DHW flow rate l/min 13.0 13.0 13.0
Outlet temperature range °C 40 - 60 40 - 60 40 - 60
Max. cold water inlet temperature °C 60 60 60
Max. permissible water supply pressure kPa 1000 1000 1000
Min. inlet pressure kPa 20 20 20
Specific flow rate acc. to EN 625 (D) l/min 16.9 16.9 16.9
Calculation values for calculating cross-section to EN 13384
Flue gas mass flow rate, max./min. rated g/s 16.2/4.5 15.3/6.5 15.3/6.5
Flue gas temperature 80/60 °C max./min. rated °C 83/58 83/58 83/58
Flue gas temperature 40/30 °C max./min. rated °C 60/35 60/35 60/35
Residual pump head Pa 80 80 80
CO2 at max. rated output % 9.7 10.8 12.2
CO2 min. rated output % 9.1 10.2 11.5
Flue gas rating group to G 636/G 635 G61/G
62
G61/G
62
G61/G
62
NOx class 555
Condensate
Max. condensate quantity (tR = 30 °C) l/h 2.7 2.7 2.7
pH level, approx. 4.8 4.8 4.8
Table 6
18 | Product details
6 720 644 143 (2010/09)
3.12 Condensate composition
General data
Power supply voltage AC ... V 220 - 240 220 - 240 220 - 240
Frequency Hz 50 50 50
Max. power consumption (central heating
mode) W
160 160 160
EMC limit class - BBB
Sound pressure level (in heating mode) ≤ dB(A) 45 45 45
Appliance enclosure rating IP X4D X4D X4D
Max. flow temperature °C Approx. 90 Approx. 90 Approx. 90
Max. permissible operating pressure (PMS)
heating kPa
300 300 300
Permissible ambient temperature °C 0 - 50 0 - 50 0 - 50
Nominal capacity of appliance heating l 3.75 3.75 3.75
Weight (excluding packaging) kg 48.5 48.5 48.5
Dimensions, W x H x D mm 440 x 760 x 360 440 x 760 x 360 440 x 760 x 360
ZWB 37-2 ...
Unit Natural gas Propane Butane
Table 6
Material Value [mg/l]
Ammonium 1.2
Lead ≤ 0.01
Cadmium ≤ 0.001
Chrome ≤ 0.005
Halogenated hydrocarbons ≤ 0.002
Hydrocarbons 0.015
Copper 0.028
Nickel 0.1
Mercury ≤ 0.0001
Sulphate 1
Zinc ≤ 0.015
Tin ≤ 0.01
Vanadium ≤ 0.001
pH value 4.8
Table 7
Regulations | 19
6 720 644 143 (2010/09)
4Regulations
Where no specific instruction is given, reference should
be made to the following standards:
• AS 5601 Gas Installations,
• AS 1596 LPG storage and handling,
• AS 4552 Gas fired water heaters for hot water supply
and/or central heating,
• AS/NZS 3000 Electrical Installations,
• AS1697 Installation and maintenance of steel pipe
systems for gas,
• AS 4032 Water supply - valves for the control of hot
water supply temperatures,
• AS 3498 Authorization requirements for plumbing
products - water heaters and hot-water storage tanks.
• AS 1910 Water supply - float control valves for use in
hot and cold water, AS 3500 National plumbing and
drainage code.
20 | Pre-Installation
6 720 644 143 (2010/09)
5 Pre-Installation
5.1 Water system and pipe work
Plastic pipe work:
• Any plastic pipe work must have a polymeric barrier
with 600 mm (minimum) length of copper pipe
connected to the boiler.
• Plastic pipe work used for underfloor heating must be
correctly controlled with a thermostatic blending
valve limiting the temperature of the circuits to
approximately 50 °C.
Primary systems connections/valves:
• All system connections, taps and mixing valves must
be capable of sustaining a pressure up to 3 bar
(300 kPa).
• Bosch recommends that thermostatic radiator valves
(TRV’s) be used on all radiators within the sleeping
accommodation but not the radiator where the room
thermostat is sited. This must be fitted with lockshield valves and left open.
• A drain point is required at the lowest part of the
system.
• An air vent is required at all the high points in the
system.
Sealed primary system:
• The CH sealed system must be filled using an
approved filling loop or comply with figure 6 for
system fill.
• Do not use galvanised pipes or radiators.
System fill
Fig. 6
A System fill
AA Auto air vent
B System make up
CV Check valve
D 1000 mm (39 in.) above the highest point of the system
SV Stop valve
1 Heating return
2 Hose union
3 Temporary hose
4 Test point
5 Mains supply
6 Make-up vessel
7 Fill point
Fig. 7 Additional expansion vessel
1 Boiler expanison vessel - CH
2 Extra expanison vessel - CH return
3 Pressure relief discharge-
The boiler is equipped with an automatic
internal by-pass.
NOTE: Artificially softened water must not
be used to fill the CH system.
SV SV
CV
CV
SV
CV
A
6720644143-41.1J
D
1
3
4
6
7
2
B
1
5
1
2
3
6720644743-09.1Wo
Pre-Installation | 21
6 720 644 143 (2010/09)
S and Y plan systems:
Optional diverter valve
This boiler is designed to operate on a sealed system
only and will require a second return pipe from the water
cylinder to the wall mounting frame.
Hot water supplied to sanitary fixtures
In accordance with AS 3498 a temperature control
device such as a tempering valve must be fitted when
hot water is supplied to sanitary fixtures used primarily
for the purposes of personal hygiene.
Fig. 8 S plan layout
Fig. 9 Y plan layout with external diverter valve
Fig. 10 System layout with optional internal diverter
valve (not supplied with boiler)
Legend to Fig. 8 to Fig. 10:
1 Diverter valve
2 Radiater valve (flow)
3 Lock shield valve (return)
4 Bypass
5 Boiler flow
6 Cylindr return
7 Heating return
NOTE: The boiler is fitted with its own
internal bypass.
NOTE:
B A drain point should be fitted at the
lowest part of the heating circuit and
beneath the boiler.
3
2
1
4
M
M
6720644143-39.1J
3
2
1
M
6720644143-38.1J
3
2
6720644143-40.1J
5
6
7
22 | Pre-Installation
6 720 644 143 (2010/09)
5.2 Condensate pipe work
5.2.1 Internal connections
Where there is the possibility of freezing conditions and
In order to minimise the freezing risk during prolonged
cold spells, the following methods of installing
condensate drainage pipe should be adopted, in order of
priority.
Wherever possible, the condensate drainage pipe should
be routed and terminated so that the condensate drains
away from the boiler under gravity to a suitable internal
soil and vent stack. A suitable permanent connection to
the foul waste pipe should be used.
A self sealing device should be incorporated in the
drainage path, if possible, in an upright position.
A tundish should be used as a suitable air gap just before
the self sealing device. The self sealing device can be
used on a gradient as long as it preceded by a vertically
mounted tundish.
Fig. 11 Disposal to soil vent stack - vertical position
Fig. 12 Disposal to soil vent stack - on gradient
NOTE:
B Where a new or replacement boiler is
being installed and freezing conditions
are possible, access to an internal drain
“gravity discharge” point should be one
of the factors considered in determining
boiler location.
B The condensate pipe must be a minimum
of 40 mm Ø plastic pipe.
B The condensate pipe work must fall at
least 50 mm per metre towards the outlet
and should take the shortest practicable
route.
B Ensure that there are no blockages in the
pipe run.
Key to condensate illustrations
1 Condensate discharge
2Air gap (20mm)
3Tundish
4 Self sealing device
5 Dishwasher connection
6Vent stack
Table 8
20mm
1
40mm Ø
2
3
6
4
6720646195-18.1Wo
6720646195-19.1Wo
20mm
1
40mm Ø
40mm Ø
2
3
6
4
Pre-Installation | 23
6 720 644 143 (2010/09)
Alternatively if the first option is not possible an internal
kitchen or bathroom waste pipe can be used.
Fig. 13 Disposal to a waste pipe
A washing machine waste pipe or bifurcated pipe etc.
can also be used.
Fig. 14 Bifurcated pipe disposal
20mm
1
40mm Ø
40/50mm Ø
4
2
3
6720646195-16.1Wo
20mm
1
40/50mm Ø
4
2
5
3
6720646195-17.1Wo
24 | Installation
6 720 644 143 (2010/09)
6 Installation
6.1 Important notes
B Prior to installation, obtain the approval of the gas
supply utility.
Supply of water preheated by solar energy (only ZWB)
Heating system water
Unsuitable fill and top-up water in the heating system
can result in the heat exchanger scaling up and failing
prematurely.
Anti-freeze
The following anti-freeze fluids are permitted:
Corrosion inhibitor
The following corrosion inhibitors are permissible:
Open vented heating systems
B Open vented heating systems must be converted to
sealed systems.
Gravity fed heating systems
B Connect the appliance to the existing pipework via a
low loss header with a dirt separator.
Underfloor heating systems
B The appliance is suitable for underfloor heating
systems; observe permissible flow temperatures.
If a room thermostat is used
B Do not fit a thermostatic radiator valve to the radiator
in the primary room.
To increase efficiency of the sysetm, thermostatic
radiator valves should be used on all other radiators.
Sealants
In our experience, adding sealants to the heating water
may result in problems (deposits in the heat exchanger).
We therefore advise against using them.
Water circulation noises
To prevent water circulation noises:
B Fit an overflow valve, or, with two-pipe heating
systems, a 3-way valve to the radiator furthest from
the boiler.
DANGER: Risk of explosion!
B Isolate the gas supply before working on
gas-carrying components.
B Check for leaks before working on gas-
carrying components.
Installation, power connection, connection
on the gas and flue gas side and
commissioning must only be carried out by
a contractor approved for such work by the
local gas or power supply utility.
WARNING: Risk of scalding!
Hot water can lead to severe scalding.
NOTE: Excessive temperatures through
water preheated by solar energy can
damage the equipment.
B Install a solar transfer valve upstream of
the appliance and set to 60 °C.
B To prevent excessive lime scale being
deposited, set the thermostatic mixer to
55 °C when encountering a total
hardness of 15 °dH or higher.
Hardness range Water treatment
soft (≤ 8.4 °dH) not required
medium (8.4 - 14 °dH) recommended
hard (≥ 14 °dH) required
Table 9
Product Concentration
Varidos FSK 22 - 55 %
Alphi - 11 see manufacturer’s
instructions
Glythermin NF 20 - 62 %
Table 10
Designation Concentration
Fernox see supplier information
Sentinel see supplier information
Table 11
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