Page 1
Operating Instructions
Hydronic Gas Condensing Boiler
Condens 5000 W
6 720 613 085-00.1O
ZSB 30-2 A ...| ZWB 37-2 A ...
6 720 644 144 (2010/09) NZ/AU
Page 2
2
Contents
6 720 644 144 (2010/09)
Contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Product details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Explanation of model code . . . . . . . . . . . . . . . . . . . . 8
3 Preparing the appliance for use . . . . . . . . . . . . . . . . . . . . 9
3.1 Turn on the gas service cock . . . . . . . . . . . . . . . . . . 9
3.2 Turn on the isolators . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Opening the control panel cover . . . . . . . . . . . . . . 11
3.4 Check the central heating system pressure . . . . . . 12
3.5 Top up the heating system . . . . . . . . . . . . . . . . . . . 13
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Overview of controls . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Switching the appliance on/off . . . . . . . . . . . . . . . . 18
4.3 Starting the central heating . . . . . . . . . . . . . . . . . . 19
4.4 Setting the heating control unit . . . . . . . . . . . . . . . 21
4.5 Appliances with hot water cylinder:
setting the hot water temperature . . . . . . . . . . . . . . 22
4.6 ZWB appliances - setting hot water temperature . . 24
4.7 Summer mode (central heating off, DHW only) . . . 26
4.8 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.9 Holiday mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.10 Further displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Page 3
3
Contents
6 720 644 144 (2010/09)
5 Carry out thermal disinfection . . . . . . . . . . . . . . . . . . . . . 30
6 Tips on saving energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 Environment / disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10 Operating instructions quick reference . . . . . . . . . . . . . . 38
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Page 4
4 | Key to symbols and safety instructions
6 720 644 144 (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.
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.
Page 5
Key to symbols and safety instructions | 5
6 720 644 144 (2010/09)
Important information
Additional symbols
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
Page 6
6 | Key to symbols and safety instructions
6 720 644 144 (2010/09)
1.2 Safety instructions
If you smell gas
B Turn off gas tap (Æ page 16).
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 16).
B Open windows and doors.
B Inform your heating contractor.
Installation and conversion
B This appliance may only be installed or converted by an
approved installer.
B Never modify any parts of the flue system.
B If the appliance has a type B.. flue system: Do not seal off or
reduce the size of air vents in doors, windows or walls. If
draught-sealed windows are installed, ensure there is an
adequate supply of air to the appliance for combustion.
Thermal disinfection
B Risk of scalding!
It is imperative to monitor operation at temperatures over
60 °C (Æ page 30).
Page 7
Key to symbols and safety instructions | 7
6 720 644 144 (2010/09)
Risk of damage due to operator error
Operator errors can result in injury and damage to property.
B Ensure that children never operate this appliance unsupervised
or play with it.
B Ensure that only personnel who can operate this appliance
correctly have access to it.
Inspection/Maintenance
B We recommend that you take out a contract to have the
system regularly serviced in order to ensure that it functions
reliably and safely.
B The user is responsible for the general and environmental
safety of the system.
B Only use genuine spare parts!
Combustible materials
B Do not store or use any combustible materials (paper,
thinners, paints etc.) in the vicinity of the appliance.
Combustion air/Ambient air
B Keep combustion air/ambient air free of corrosive substances
(e.g. halogenated hydrocarbons which contain chlorine or
fluorine compounds). In that way corrosion can be prevented.
Page 8
8 | Product details
6 720 644 144 (2010/09)
2 Product details
2.1 Intended use
The appliance may only be installed in sealed hot-water central
heating systems to EN 12828.
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 appliance to generate
process heat is not permitted.
2.2 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
Condens 5000 W ZSB 30-2 A
ZWB 37-2 A
Table 2
Page 9
Preparing the appliance for use | 9
6 720 644 144 (2010/09)
3 Preparing the appliance for use
3.1 Turn on the gas service cock
B Using a screwdriver, turn the square tap handle so that the slot
is in line with the direction of flow.
Slot at right-angles to direction of flow = off.
Fig. 1
6 720 644 144-01 .1O
Page 10
10 | Preparing the appliance for use
6 720 644 144 (2010/09)
3.2 Turn on the isolators
B Using a screwdriver, turn the square tap handle so that the slot
is in line with the direction of flow.
Slot at right-angles to direction of flow = off.
Fig. 2
6 720 644 143-02.1O
Page 11
Preparing the appliance for use | 11
6 720 644 144 (2010/09)
3.3 Opening the control panel cover
Fig. 3
6 720 612 660-01.2R
Page 12
12 | Preparing the appliance for use
6 720 644 144 (2010/09)
3.4 Check the central heating system pressure
The normal operating pressure is 1 - 2 bar.
If a higher setting is required, you will be informed by your
installer.
Fig. 4
6 720 644 144-03.1O
1
0
2
3
4
bar
Page 13
Preparing the appliance for use | 13
6 720 644 144 (2010/09)
3.5 Top up the heating system
The way in which the heating system is topped up is different on
every system. Therefore, you should ask your installer to show you
how it is done.
Maximum pressure of 3 bar at maximum heating water
temperature must not be exceeded (safety valve will open).
CAUTION: Risk of damaging the appliance.
B Only top up the heating system when the
appliance is cold.
Page 14
14 | Operation
6 720 644 144 (2010/09)
4 Operation
These Operating Instructions apply only to the boiler.
Depending on the heating controller used, some functions may be
controlled differently.
The following possibilities for controlling the heating system may
be employed:
• weather-dependent controller built into the boiler Æ page 16,
item 7.
• weather-dependent controller external to the appliance
• room thermostat
Therefore, please read the operating instructions
for the heating controller used.
Page 15
Operation | 15
6 720 644 144 (2010/09)
Fig. 5
Page 38 contains brief operation instructions. You
can fold this outwards and push the operating
instructions into the appliance facia for
safekeeping.
max
6 720 613 086-04.1O
Page 16
16 | Operation
6 720 644 144 (2010/09)
4.1 Overview of controls
Fig. 6
6 720 644 144-04.1O
1819
reset
10
11
12
eco
15161714
4
3
2
5
1
6
8
7
9
20
13
Page 17
Operation | 17
6 720 644 144 (2010/09)
1 Flow temperature control
2 DHW temperature control
3 Chimney sweep button
4 Service button
5 Burner ON indicator
6 Main switch
7 Here, a weather-compensated control unit or a time switch
(accessories) can be plugged in
8 Display
9 Pressure gauge
10 reset button
11 eco button
12 Holiday button
13 Drain from pressure relief valve (heating circuit)
14 Gas tap
15 CH return isolator
16 Filling loop (ZWB)
17 Cold water tap (ZWB),
cylinder return (ZSB)
18 DHW connection (ZWB),
cylinder flow (ZSB)
19 CH flow isolator
20 Condensate hose
Page 18
18 | Operation
6 720 644 144 (2010/09)
4.2 Switching the appliance on/off
Switching on
B Switch appliance on at the main switch.
The display shows the heating water flow temperature.
Fig. 7
Switching off the appliance
B Switch appliance off at the main switch.
The display goes out.
B If the appliance is to be switched off for a longer period of time:
observe correct frost protection procedures (Æ Section 4.8).
If the display shows alternately with the flow
temperature, the appliance will operate with the
lowest output for 15 minutes.
m
a
x
1
2
3
4
5
6
6 720 613 896-05.1O
Page 19
Operation | 19
6 720 644 144 (2010/09)
4.3 Starting the central heating
The maximum flow temperature can be matched to the heating
system by the flow temperature controller. The current flow
temperature is shown on the display.
Setting on flow
temperature
controller
Flow
temperature
Sample
application
1 Approx. 35 °C
2 Approx. 43 °C
3 Approx. 50 °C Underfloor
heating system
4 Approx. 60 °C
5 Approx. 67 °C
6
Approx. 75 °C
Radiator heating
system
max. Approx. 90 °C Convector
heating system
Table 3
With underfloor heating systems, take care to
observe the maximum permissible CH flow
temperatures.
Page 20
20 | Operation
6 720 644 144 (2010/09)
B Turn flow temperature controller to adjust the maximum
flow temperature.
Fig. 8
When the burner is firing, the green indicator lamp lights up.
eco
reset
6 720 644 143-27.1O
max
1
2
3
4
5
6
max
1
2
3
4
e
6
min
Page 21
Operation | 21
6 720 644 144 (2010/09)
4.4 Setting the heating control unit
Fig. 9
Follow the operating instructions for the heating
controller used. Those instructions will tell you
B how to set the operating mode and the heating
curve for weather-dependent controllers,
B how to adjust the room temperature,
B how to heat economically and save energy.
9
12
h
15
18
21
24
h
3
6
6 720 612 660-07.2O
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22 | Operation
6 720 644 144 (2010/09)
4.5 Appliances with hot water cylinder: setting
the hot water temperature
B Set the DHW temperature on the DHW temperature control
.
The set DHW temperature flashes on the display for
30 seconds.
Fig. 10
WARNING: Danger of scalding!
B In normal operation, do not set the temperature
higher than 60 °C.
To prevent bacterial contamination such as
legionella, we recommend setting the DHW
temperature controller to “6” (60 °C).
6 720 644 143-28.1O
max
1
2
34
5
6
reset
eco
max
1
2
3
4
e
6
Page 23
Operation | 23
6 720 644 144 (2010/09)
eco button
Pressing and holding the eco button until it lights up switches
between Comfort mode and Economy mode.
Comfort mode, Eco button is not lit (default setting)
In Comfort mode, the hot water cylinder has priority. The hot
water cylinder is heated to the set temperature first. Then the
appliance switches to central heating mode.
Economy mode, Eco button lit
In Economy mode, the appliance switches between central
heating mode and hot water mode every ten minutes.
DHW thermostat DHW temperature
min Approx. 5 °C (frost
protection)
e Approx. 55 °C
6 Approx. 60 °C
max. Approx. 70 °C
Table 4
Page 24
24 | Operation
6 720 644 144 (2010/09)
4.6 ZWB appliances - setting hot water
temperature
B Set the DHW temperature on the DHW temperature control
.
The set DHW temperature flashes on the display for
30 seconds.
Fig. 11
DHW thermostat DHW temperature
min Approx. 40 °C
eApprox. 50°C
max. Approx. 60 °C
Table 5
eco
reset
max
1
2
3
4
e
6
6 720 644 143-29.1O
max
1
2
34
5
6
Page 25
Operation | 25
6 720 644 144 (2010/09)
eco button
Pressing and holding the eco button until it lights up switches
between Comfort mode and Economy mode.
Comfort mode, (Eco button is not lit - default setting)
The appliance is held constantly at the set temperature. This
means that hot water is available almost instantaneously at the
tap.
Consequently the appliance will switch on at intervals, even if no
hot water is being drawn.
Economy mode, Eco button lit
• The water is not heated up until a hot water tap is turned on.
• With a demand signal (only with start delay switched off for
the supply of water preheated by solar energy). Briefly turning
a hot water tap on and then off signals demand so that the
water is then heated up to the set temperature.
If a start delay for the supply of water preheated by
solar energy has been set (service function b.F), the
appliance does not switch on until the start delay
has elapsed.
The demand signal enables gas and water savings.
Page 26
26 | Operation
6 720 644 144 (2010/09)
4.7 Summer mode (central heating off, DHW
only)
B Note position of CH flow temperature control .
B Turn CH flow temperature control anti-clockwise as far as
the stop .
The heating circuit pump and consequently central heating are
switched OFF. However, the DHW supply as well as the power
supply to the heating programmer and timer remain 'live'.
Fig. 12
Additional instructions are contained in the operating instructions
for the heating programmer.
NOTE: Heating system at risk from frost.
6 720 644 143-30.1O
eco
reset
max
1
2
3
5
6
max
1
2
3
4
e
6
min
Page 27
Operation | 27
6 720 644 144 (2010/09)
4.8 Frost protection
Frost protection for the heating system:
B Leave appliance switched on, set CH flow temperature control
to position 1 at least.
Fig. 13
B Add anti-freeze to the heating water (see installation
instructions) and drain the DHW circuit.
Additional instructions are contained in the operating instructions
for the heating programmer.
Frost protection for the cylinder:
B Turn DHW temperature controller clockwise as far as it will go
(5 °C).
Fig. 14
eco
reset
max
1
2
3
5
6
max
1
2
3
4
e
6
6 720 644 143-31.1O
min
max
1
2
3
e
6
max
1
2
34
5
6
eco
6 720 644 143-32.1O
min
Page 28
28 | Operation
6 720 644 144 (2010/09)
4.9 Holiday mode
To switch on holiday mode:
B Press and hold holiday button on the appliance until it
lights up, and switch on holiday mode on the heating
controller.
In holiday mode, heating and DHW heating are switched off;
frost protection remains active (Æ chap. 4.8).
To switch off holiday mode:
B Press and hold holiday button on the appliance until it
goes out, and cancel holiday mode on the heating controller.
The appliance returns to operation in standard mode according
to the settings at the heating control unit.
Page 29
Operation | 29
6 720 644 144 (2010/09)
4.10 Further displays
Display
code
Description
Fault code (Æ chapter 7)
Inspection due
Pump anti-seize function active
Trap filling function active
Bleeding function active
Excessively rapid increase in CH flow temperature
(temp. gradient monitoring).
Heating mode is disabled for two minutes.
Drying function. If the floor drying function is activated
on the weather-dependent controller, refer to
controller instructions.
Table 6
Page 30
30 | Carry out thermal disinfection
6 720 644 144 (2010/09)
5 Carry out thermal disinfection
To prevent the DHW becoming contaminated by bacteria such as
legionella, we recommend you pasteurise the system after longer
idle periods.
Pasteurisation covers the DHW system including the draw-off
points. For solar DHW cylinders, the solar portion of the cylinder
is not covered.
B Turn off all hot water points.
B Warn occupants of risk of scalding.
B If the heating programmer has a DHW program, set the time
and DHW temperature accordingly.
B If there is a circulation pump, set it to run continuously.
With some heating controllers, thermal disinfection
can be programmed for a fixed time; see heating
controller operating instructions.
DANGER: Risk of scalding!
Hot water can result in severe scalding.
B Carry out thermal disinfection only outside the
normal hours of use.
B The water in the tank will take a while to cool
down to the set hot water temperature as a
result of heat loss. Be aware that, after thermal
disinfection, the hot water may be hotter than
the set temperature.
Page 31
Carry out thermal disinfection | 31
6 720 644 144 (2010/09)
B Turn hot water temperature control clockwise as far as the
stop (approx. 70 °C).
Fig. 15
B Wait until the water reaches the maximum temperature.
B Draw off water in turn from the nearest to the furthest hot
water point until hot water has been running out at a
temperature of 70 °C for 3 minutes.
B Reset DHW temperature control, circulation pump and heating
programmer to their standard settings.
If you want to interrupt thermal disinfection:
B Switch the appliance off and then on again at the
main switch.
The appliance will start up again and the central
heating flow temperature will be displayed.
6 720 644 143-33.1O
max
1
2
34
5
6
reset
eco
max
1
2
3
4
e
6
Page 32
32 | Tips on saving energy
6 720 644 144 (2010/09)
6 Tips on saving energy
Heating economically
The boiler is designed to provide a high level of comfort while
keeping gas consumption and the resulting environmental impact
as low as possible. The gas supply to the burner is controlled
according to the level of demand for heat. The boiler continues to
operate with a low flame if the demand for heat reduces. The
technical term for this process is modulating control. Modulating
control keeps temperature fluctuations small and provides even
distribution of heat throughout the home. This means that the
boiler may stay on for relatively long periods but will use less gas
than an appliance that continually switches on and off.
Inspection/Maintenance
To ensure that gas consumption and environmental impact
(pollution, etc.) remain as low as possible over an extended
period of time, we recommend that you take out an inspection/
maintenance contract with an authorised installer covering the
annual inspection and servicing and maintenance at other times
as required.
Heating control system
Additional instructions are contained in the operating instructions
for the heating controller.
Page 33
Tips on saving energy | 33
6 720 644 144 (2010/09)
Thermostat
Fully open the thermostat to ensure that the required room
temperature is reached in all cases. Only after the required
temperature has been reached and maintained for an extended
period of time should you change the setting for the heating curve
or the room temperature on the controller.
Underfloor heating
Do not set the heating-up temperature higher than the maximum
level recommended by the manufacturer.
Ventilating
Do not keep windows slightly open for ventilation purposes. This
would continuously cool down the room without significantly
improving the air in the room. It is better to ventilate fully for a
short time (with completely open windows).
Turn off the thermostat when ventilating.
Hot water
Always set the hot water temperature to as low as possible.
A lower setting on the thermostat means a higher rate of energy
savings.
Furthermore, higher hot water temperatures result in increased
limescale deposits and thereby impair the function of the
appliance (e.g. longer heating-up times or lower output).
Circulation pump
If there is a circulation pump for hot water, use a timer programme
to control its operation according to the specific requirements
(e.g. morning, afternoon, evening).
Page 34
34 | Troubleshooting
6 720 644 144 (2010/09)
7Troubleshooting
All safety, modulation and control components are monitored by
the Heatronic system.
If a fault occurs during operation, a warning tone sounds.
The display indicates a fault (e. g. ) and the reset-button may
also flash.
If the reset button flashes:
B Press and hold the reset button until the display shows .
The appliance will start up again and the flow temperature will
be displayed.
If the reset button does not flash:
B Switch the appliance off and then on again at the main switch.
The appliance will start up again and the central heating flow
temperature will be displayed.
If the fault persists:
B Contact your authorised contractor or customer service for
assistance, providing details of the fault and the appliance.
If you press a button, the warning tone stops.
An overview of the display indications can be found
on page 29.
Page 35
Troubleshooting | 35
6 720 644 144 (2010/09)
Appliance details
If you need to call Customer Services, it is helpful if you have the
precise details of your appliance at hand.
Those details can be found on the identification plate or
identification sticker inside the control panel cover.
Condens 5000 W (e. g. ZWB 37-2A...)..............................
Serial number.................................................................
Date commissioned: ........................................................
System installed by: ........................................................
Page 36
36 | Maintenance
6 720 644 144 (2010/09)
8 Maintenance
Inspection and maintenance
The operator is responsible for the safety and environmental
compatibility of the heating system (see local regulations).
It is therefore recommended that you enter into a maintenance
and inspection contract with an approved contractor that
provides annual inspection and maintenance. This ensures high
efficiency and environmentally compatible combustion.
Cleaning the outer casing
Wipe down with a damp cloth. Do not use any abrasive or
corrosive cleaning agents.
Page 37
Environment / disposal | 37
6 720 644 144 (2010/09)
9 Environment / disposal
Environmental protection is a fundamental corporate strategy of
Bosch Group.
The quality of our products, their economy and environmental
safety are all of equal importance to us and all environmental
protection legislation and regulations are strictly observed.
We use the best possible technology and materials for protecting
the environment taking account of economic considerations.
Packaging
We participate in the recycling programmes of the countries in
which our products are sold to ensure optimum recycling.
All of our packaging materials are environmental-friendly and can
be recycled.
Used appliances
Used appliances contain valuable materials that should be
recycled.
The various assemblies can be easily dismantled and synthetic
materials are marked accordingly. Assemblies can therefore be
sorted by composition and passed on for recycling or disposal.
Page 38
38 | Operating instructions quick reference
6 720 644 144 (2010/09)
10 Operating instructions
quick reference
Switching on
Switching on the central
heating
Heating control
Set weather-dependent heating
controller to the relevant
heating curve and operating
mode or set room thermostat to
the desired temperature
.
Domestic hot water
temperature
Eco button lit – Economy mode.
Eco button not lit – Comfort
mode.
Frost protection
m
a
x
1
2
3
4
5
6
6 720 613 896-05.1O
eco
reset
6 720 644 143-27.1O
max
1
2
3
4
5
6
max
1
2
3
4
e
6
min
WARNING:
Risk of scalding
B Do not set the
temperature
control to more
than “e”.
6 720 644 143-28.1O
max
1
2
34
5
6
reset
eco
max
1
2
3
4
e
6
eco
reset
max
1
2
3
5
6
max
1
2
3
4
e
6
6 720 644 143-31.1O
min
Page 39
Index | 39
6 720 644 144 (2010/09)
Index
A
Appliance
- Switching off......................................................................... 18
C
Carry out thermal disinfection................................................... 30
Central heating
- Switching on ................................................................... 19, 38
Comfort mode...................................................................... 23, 25
E
Eco button ........................................................................... 23, 25
Economy mode .................................................................... 23, 25
Environment / disposal .............................................................. 37
Explanation of model code .......................................................... 8
F
Frost protection......................................................................... 27
H
Heating control .......................................................................... 38
I
Intended use ................................................................................ 8
O
Operation................................................................................... 14
Page 40
40 | Index
6 720 644 144 (2010/09)
P
Packaging................................................................................... 37
Preparing the appliance for use................................................... 9
Product details ............................................................................ 8
- Explanation of model code ..................................................... 8
R
Recycling.................................................................................... 37
S
Safety instructions....................................................................... 6
Setting the heating control unit................................................. 21
Setting the hot water temperature
- Appliances with hot water cylinder ...................................... 22
Summer mode ........................................................................... 26
Switching off the appliance ....................................................... 18
Switching on the central heating......................................... 19, 38
T
Thermal disinfection .................................................................. 30
Troubleshooting......................................................................... 34
U
Used appliances......................................................................... 37
Page 41
| 41
6 720 644 144 (2010/09)
Notes
Page 42
42 |
6 720 644 144 (2010/09)
Notes
Page 43
| 43
6 720 644 144 (2010/09)
Notes
Page 44
Australia
Robert Bosch (Australia) Pty Ltd
1555 Centre Rd
Clayton, VIC 3168
Phone 1300 30 70 37
Fax 1300 30 70 38
www.bosch.com.au/hotwater
New Zealand
Phone 0800 4 Bosch or 08 543 352
www.bosch.co.nz
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