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Bosch Condens 5000W Installation And Maintenance Instructions Manual
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Bosch Condens 5000W Installation And Maintenance Instructions Manual

Wall mounted gas condensing boiler
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Installation and maintenance instructions
Wall mounted gas condensing boilers
Condens 5000W
ZBR 70-3 | ZBR 100-3

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Summary of Contents for Bosch Condens 5000W

  • Page 1 Installation and maintenance instructions Wall mounted gas condensing boilers Condens 5000W ZBR 70-3 | ZBR 100-3...

  • Page 2: Table Of Contents

    (accessory) ........18 Connecting a cylinder temperature sensor..18 Condens 5000W – 6720813952 (2019/02)

  • Page 3: Explanation Of Symbols And Safety Instructions

    Explanation of symbols and safety instructions If you are in any doubt contact the Robert Bosch Explanation of symbols and safety instructions technical hotline on: 1300 30 70 37 AU or 0800 54 33 52 NZ Explanation of symbols Warnings...

  • Page 4: Product Information

    The designation of the wall mounted condensing boiler comprises the following: ▶ In the case of open flue operation:Ensure that the • Bosch: manufacturer installation location meets the ventilation • Condens 5000W ZBR-3: product name requirements. • 70 or 100: type name ▶ Only use original spares. Data plate...

  • Page 5: Scope Of Delivery

    If the wall mounted gas condensing boiler can be converted for another gas type, corresponding information will be provided in the gas data ( chapter 2.14, page 10). Condens 5000W – 6720813952 (2019/02)

  • Page 6: Pump Test

    Condensate pipe, Ø external diameter 24 mm Connection set for gas connection, R 1" female thread Connection set for flow, G 1½ '' male thread with flat gasket Heating flow, G 1½ '' screw fitting with female thread Condens 5000W – 6720813952 (2019/02)

  • Page 7: Product Overview

    Connection set (accessories): [28] Pump [29] Drain & fill valve (DFV) [30] Service valve [31] Gas isolator [32] Drain cock [33] Manometer [34] Pressure Relief Valve 0010009976-001 Fig. 4 Condens 5000W ZBR-3 with connection set Condens 5000W – 6720813952 (2019/02)

  • Page 8: Wiring Diagram

    [29] Pump connection set, external pump 230 V AC, max. 250 W [12] Flow temperature sensor [13] Safety temperature sensor [14] Flame sense electrode [15] Earth [16] Turquoise - no function [17] Grey - no function [18] Blue - outside temperature sensor Condens 5000W – 6720813952 (2019/02)

  • Page 9: Specifications

    Heating return pipe, male thread with flat gasket inch G1½ Gas line inch Electrical power consumption WILO Stratos PARA 25/1-8, min./max. 8 / 140 Table 2 Specifications The information in brackets corresponds to the information on the data plate. Condens 5000W – 6720813952 (2019/02)

  • Page 10: Gas Specification

    Type B2, B3 and B5 boilers with a rated heat valve input no greater than 1000 kW Resistance of wall mounted gas condensing boiler Table 5 Regulations, standards and guidelines [l/h] Flow rate [mbar] Residual head Condens 5000W – 6720813952 (2019/02)

  • Page 11: Transport

    V ▶ Flush and clean the heating system if necessary. ▶ Only use untreated mains water. ▶ Do not use any chemical additives (e.g. inhibitors or pH-increasing or reducing agents) other than those approved by Bosch Thermotechnik. Product Concentration...

  • Page 12: Remove The Protective Caps

    • Using the connection set (accessory) ( chapter 5.8) using an approved sealant [1]. • Without using the connection set ( chapter 5.9). ▶ Mount the gas isolator G 1" in the gas line [2]. Condens 5000W – 6720813952 (2019/02)

  • Page 13: Mounting The Connection Set

    Damage to appliance due to excessive operating pressure. ▶ Mount a pressure relief valve between the wall mounted gas 0010009994-001 condensing boiler and shut-off valve. Fig. 16 Connection of the heating water pipework Flow pipe Pressure Relief Valve Condens 5000W – 6720813952 (2019/02)

  • Page 14: Install The Low Loss Header

    5.11 Installing the siphon ▶ Removing the transport protection. 0010009999-001 0010009997-001 Fig. 20 Mounting the flexible hose Fig. 18 Remove the transport protection T piece ▶ Fill the condensate trap with water. Flexible hose tube Condens 5000W – 6720813952 (2019/02)

  • Page 15: Connecting The Condensate Drain

    Western Australia refer to SECWA rules and regulations. ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned to avoid combustion products entering the building. The fixing method must be sufficient to hold the weight of the boiler. Condens 5000W – 6720813952 (2019/02)

  • Page 16: Electrical Connection

    NOTICE: 0010010003-001 Short circuit. Fig. 25 Principle of weather-compensated control ▶ Only use original cables if they must be replaced. Wall mounted gas condensing boiler Room temperature-dependent controller Thermostatically controlled radiator valve Condens 5000W – 6720813952 (2019/02)

  • Page 17: Connection Of The Control Units

    0010010005-001 Fig. 27 Removing the cover ▶ Connect the components to the relevant plug. 0010010006-001 Fig. 28 Terminal strips 24 V AC terminal strip 230 V AC terminal strip 0010010008-001 Fig. 30 Tightening the screw Condens 5000W – 6720813952 (2019/02)

  • Page 18: Connecting The On/Off Room Temperature-Dependent Control Unit

    “d3” appears in the display of the wall mounted gas condensing boiler. All standard, potential-free switching contacts can be connected for use as external switching contact. ▶ Remove the jumper of the red plug [1]. Condens 5000W – 6720813952 (2019/02)

  • Page 19: Connecting The Cylinder Primary Pump

    (240 V AC) (fuse, circuit breaker) and secure against “Info” unintentional reconnection. The status of the wall mounted gas condensing boiler can be read out via key. Display Condens 5000W – 6720813952 (2019/02)

  • Page 20: Information Menu

    “OFF” appears in the display when heating Setup menu mode is switched off. The text “menu” is displayed for 1 second. No information about DHW mode is shown here. Heating mode is switched on. Setting: On, Off. Condens 5000W – 6720813952 (2019/02)

  • Page 21: Flue Gas Inspector Mode

    Fig. 41 Display - Lock ▶ Hold down to switch off the flue gas inspector mode. Disable ▶ Press the keys again simultaneously for 5 seconds to remove the key block; the word “Lock” disappears. Condens 5000W – 6720813952 (2019/02)

  • Page 22: Commissioning

    The output of the wall mounted gas condensing boiler can be adapted to 0010010025-001 the heat energy demand via the setup menu. Proceed as follows: Fig. 42 Open the burner pressure nipple at the type 70 Condens 5000W – 6720813952 (2019/02)

  • Page 23: Measure Gas/Air Ratio

    ▶ Check that the measured value is not less than the permissible value ▶ Connect pressure gauge. ( tab. 3, page 3). ▶ Set pressure gauge to “0”. Hold the pressure gauge at the same height when the measurement is in progress. Condens 5000W – 6720813952 (2019/02)

  • Page 24: Measure The Co And Co2 Content

    ▶ Measure the CO content. ▶ Push on the plug of the ionisation cable. ▶ Establish and eliminate the cause of a possible high CO content. ▶ Bring wall mounted gas condensing boiler into operation. Condens 5000W – 6720813952 (2019/02)

  • Page 25: Testing For Gas Leaks

    ▶ Take the wall mounted gas condensing boiler out of operation via the ON/OFF switch. ▶ Close gas isolation valve. ▶ Drain the entire heating system. ▶ If installed, drain the entire potable water system. Condens 5000W – 6720813952 (2019/02)

  • Page 26: Environmental Protection/Disposal

    ▶ Use only original spare parts. ▶ When carrying out the work, check all removed gaskets for damage, deformation or ageing and replace if necessary. 0010010041-001 Fig. 53 Detaching the air intake pipe (Detail: Type 70) Condens 5000W – 6720813952 (2019/02)

  • Page 27: To Clean The Burner

    Fig. 58 Cleaning the heat exchanger 11.5 Checking the ignition system NOTICE: Damage to the hot surface igniter. The glow ignitor unit is made of breakable material. ▶ Handle with care. 0010010046-001 Fig. 56 Removing the burner gasket Condens 5000W – 6720813952 (2019/02)

  • Page 28: Clean Condensate Trap/Siphon

    ▶ Align gasket [2] carefully on the burner. 0010010055-001 Fig. 62 Removing the condensate trap Swivel joint Condensate trap ▶ Flush out condensate trap. ▶ Fill the siphon completely with water. ▶ Reattach the siphon. ▶ Tighten the swivel joint hand-tight. Condens 5000W – 6720813952 (2019/02)

  • Page 29: Cleaning The Condensate Pan

    ▶ Undo the nozzle pressure test nipple [1] by turning it through 2 revolutions. 0010010057-001 6 720 807 034-67.1DDC Fig. 64 Opening the snap fasteners of the condensation catch pan Fig. 66 Opening the burner pressure test nipple at Type 70 Condens 5000W – 6720813952 (2019/02)

  • Page 30: Measure Co/Co2 Content

    ▶ Close the inspection aperture of the flue gas pressure-relief valve. 0010010059-001 Fig. 68 Setting the gas/air ratio at the Type 70 Differential pressure incorrect Differential pressure correct 0010010061-001 Fig. 70 Checking the flue gas pressure-relief valve Inspection aperture Flue gas pressure-relief valve Condens 5000W – 6720813952 (2019/02)

  • Page 31: 11.12 Measure Ionisation Current

    ▶ Consult the instruction manual for the control valve.       13. Final inspection check, take measurements and document measurement and test results. Confirm correct inspection Company stamp/signature/date Table 13 Inspection and maintenance reports Condens 5000W – 6720813952 (2019/02)

  • Page 32: Display Codes

    Component test phase. 2 7 0 The wall mounted gas condensing boiler ramps up. 2 8 3 The wall mounted gas condensing boiler is preparing for a burner start. The fan and pump are activated. Condens 5000W – 6720813952 (2019/02)
  • Page 33 ▶ Check the function of the wall mounted gas condensing boiler by replacing the boiler return temperature sensor. 2 3 2 The external switching contact has opened. ▶ Check the jumper at the connection of the external switching contact. ▶ Check external switching contact. Condens 5000W – 6720813952 (2019/02)
  • Page 34 ▶ Check whether it is possible to achieve a sufficient flow via the heating system. ▶ Check cabling and function of pump and flow temperature sensor. Replace the component if necessary. Condens 5000W – 6720813952 (2019/02)
  • Page 35 ▶ Check plug and wiring of the burner control unit. ▶ Check the operating characteristics of the wall mounted gas condensing boiler by replacing the burner control unit. Condens 5000W – 6720813952 (2019/02)
  • Page 36 DHW ▶ Refill the heating system. mode. H r E The wall mounted gas condensing boiler is reset. The wall mounted gas condensing boiler is reset. Table 14 Operating and fault codes Condens 5000W – 6720813952 (2019/02)
  • Page 40 Robert Bosch (Australia) Pty Ltd Thermotechnology Division 1555 Centre Road Clayton Victoria 3168 Australia Phone: 1300 30 70 37 Fax: 1300 30 70 38 www.bosch-climate.com.au New Zealand Phone: 0800 54 33 52 Fax: 0800 54 33 55 www.bosch-climate.co.nz...

This manual is also suitable for:

Zbr 70-3Zbr 100-3

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