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Bosch ZBR16-3A Installation And Service Instructions Manual
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Bosch ZBR16-3A Installation And Service Instructions Manual

Gas condensing boiler
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Gas Condensing Boiler
Greenstar
ZBR16-3A... | ZBR28-3A... | ZBR35-3A... | ZBR42-3A... | ZWB28-3A... | ZWB42-3A...
Installation and Service Instructions for Contractors
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.

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Summary of Contents for Bosch ZBR16-3A

  • Page 1 These instructions are available in English and French. Please keep these instructions for future reference. Gas Condensing Boiler Greenstar ZBR16-3A... | ZBR28-3A... | ZBR35-3A... | ZBR42-3A... | ZWB28-3A... | ZWB42-3A... Installation and Service Instructions for Contractors...

  • Page 2: Table Of Contents

    Electrical wiring combi boiler ZWB..-3A . 18 General notes ..... 52 3.11 Technical data heating boiler ZBR16-3A... 20 Low voltage electrical connections in the 3.12 Technical data heating boiler ZBR28-3A...
  • Page 3 Contents | 3 Commissioning ......58 14 Inspection and maintenance ....81 Before operating the appliance .

  • Page 4: Guideline To Symbols And Safety Instructions

    4 | Guideline to symbols and safety instructions Guideline to symbols and safety instructions Guideline to symbols Safety instructions Safety first. Never risk your health or your life. Your own Warnings safety must always take the highest priority. Warnings are indicated in the text by a Use approved personal protective devices and common warning triangle and a gray background.
  • Page 5 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.

  • Page 6: Scope Of Delivery

    6 | Scope of delivery Scope of delivery ZBR - Boiler for space heating and loading of indirect fired DHW tanks Contents of package 1: Gas condensing boiler Set of documents for appliance Mounting bracket with mounting kit Gas conversion kit Adapter for connection of a LWCO Contents of package 2: Rail with connection box...

  • Page 7: Zwb - Combi Boiler For Space Heating And Dhw Generation

    Scope of delivery | 7 ZWB - Combi boiler for space heating and DHW generation Contents of package 1: Gas condensing boiler Set of documents for appliance Mounting bracket with mounting kit Gas conversion kit Adapter for connection of a LWCO Contents of package 2: Rail with connection box Flue adapter...

  • Page 8: Information About The Appliance

    8 | Information about the appliance Information about the appliance ZBR appliances are boilers for central heating and loading Overview of boiler types of an indirect fired DHW tank. Table 2 describes the meaning of the model number: ZWB appliances are combi boilers for central heating and on demand DHW heating.

  • Page 9: Rating Plate

    Information about the appliance | 9 Rating plate Appliance description The rating plate is located at the right side of the • Appliance for wall installation, regardless of chimney appliance. and room size • Outdoor reset control FW 200 • Intelligent boiler pump control •...

  • Page 10: Accessories

    10 | Information about the appliance 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: –...

  • Page 11: Product Dimensions And Minimum

    Information about the appliance | 11 Product dimensions and minimum clearances ≥ 4" * ≥ 4" * (102 mm) * (102 mm) * 17-21/64" (440 mm) 3-11/32" (85 mm) ≥ 4" ** (102 mm) ** 9-29/64" (240 mm) 13-57/64" (353 mm) "...

  • Page 12: Appliance Layout Heating Boiler Zbr

    12 | Information about the appliance Appliance layout heating boiler ZBR..-3A 6 720 641 933-02.1O Fig. 5 Appliance layout heating boiler ZBR..-3A 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 13 Information about the appliance | 13 Key to Fig. 5: Heatronic boiler control ON/OFF switch Burner flame indicator Service button Emissions test button Boiler high limit dial Mounting socket for outdoor reset controls DHW thermostat Key pad lock ECO button Reset button Display Condensate trap...

  • Page 14: Appliance Layout Combi Boiler Zwb

    14 | Information about the appliance Appliance layout combi boiler ZWB..-3A 6 720 641 933-03.1O Fig. 6 Appliance layout combi boiler ZWB..-3A 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 15 Information about the appliance | 15 Key to Fig. 6: Heatronic boiler control ON/OFF switch Burner flame indicator Service button Emissions test button Boiler high limit dial Mounting socket for outdoor reset controls DHW thermostat Key pad lock ECO button Reset button Display Condensate trap...

  • Page 16: Electrical Wiring Heating Boiler Zbr

    16 | Information about the appliance Electrical wiring heating boiler ZBR..-3A LS NS 9 VAC 25 VAC 120 VAC 120 VAC 6 720 641 933-23.1O Fig. 7 Electrical wiring diagram heating boiler ZBR..-3A 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 17 Information about the appliance | 17 Key to Fig. 7: Ignition transformer Boiler high limit dial 120 VAC connection DHW tank primary pump or 3-way valve External heating pump for unmixed heating circuit (secondary circuit) or DHW recirculation pump Fuse T 6.3 A (120 VAC) DHW thermostat External safety high limit or low water cut off (LWCO) BUS connection, e.g.

  • Page 18: Electrical Wiring Combi Boiler Zwb

    18 | Information about the appliance 3.10 Electrical wiring combi boiler ZWB..-3A LS NS 9 VAC 25 VAC 120 VAC 120 VAC 6 720 641 933-24.1O Fig. 8 Electrical wiring diagram combi boiler ZWB..-3A 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 19 Information about the appliance | 19 Key to Fig. 8: Ignition transformer Boiler high limit dial 120 VAC connection External heating pump for unmixed heating circuit (secondary circuit) or DHW recirculation pump Fuse T 6.3 A (120 VAC) DHW thermostat External safety high limit or low water cut off (LWCO) BUS connection, e.g.

  • Page 20: Technical Data Heating Boiler Zbr16-3A

    20 | Information about the appliance 3.11 Technical data heating boiler ZBR16-3A... Unit LPG (propane) Output Maximum nominal output (P ) 104/86 °F (40/30 °C) BTU/hr (kW) 54,900 (16.1) 55,300 (16.2) Maximum nominal output (P ) 122/86 °F (50/30 °C) BTU/hr (kW) 54,300 (15.9)
  • Page 21 Weight (without packaging) lbs. (kg) 103.6 (47) 103.6 (47) inch 17-21/64" × 33-15/32" × 13-57/64" Dimensions, W x H x D (mm) (440 × 850 × 353) Tab. 4 Technical data heating boiler ZBR16-3A... Copyright (optional information) 6 720 643 068 (2011/06)

  • Page 22: Technical Data Heating Boiler Zbr28-3A

    22 | Information about the appliance 3.12 Technical data heating boiler ZBR28-3A... Unit LPG (propane) Output Maximum nominal output (P ) 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5) Maximum nominal output (P ) 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3)
  • Page 23 Information about the appliance | 23 Unit LPG (propane) General Voltage Frequency Max. power consumption (central heating mode) Max. power consumption (Stand-by) < 6 < 6 Noise level dB(A) ≤ 39 ≤ 39 Maximum supply temperature °F ( °C) 194 (90) 194 (90) Max.

  • Page 24: Technical Data Heating Boiler Zbr35-3A

    24 | Information about the appliance 3.13 Technical data heating boiler ZBR35-3A... Unit LPG (propane) Output Maximum nominal output (P ) 104/86 °F (40/30 °C) BTU/hr (kW) 122,800 (36.0) 122,800 (36.0) Maximum nominal output (P ) 122/86 °F (50/30 °C) BTU/hr (kW) 121,800 (35.7) 121,800 (35.7)
  • Page 25 Information about the appliance | 25 Unit LPG (propane) General Voltage Frequency Max. power consumption (central heating mode) Max. power consumption (Stand-by) < 6 < 6 Noise level dB(A) ≤ 44 ≤ 44 Maximum supply temperature °F ( °C) 194 (90) 194 (90) Max.

  • Page 26: Technical Data Heating Boiler Zbr42-3A

    26 | Information about the appliance 3.14 Technical data heating boiler ZBR42-3A... Unit LPG (propane) Output at elevation 0 - 2000 feet (0 - 610 m) Maximum nominal output (P ) 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Maximum nominal output (P ) 122/86 °F (50/30 °C) BTU/hr (kW)
  • Page 27 Information about the appliance | 27 Unit LPG (propane) Calculation values for calculating cross-section to EN 13384 Flue gas mass flow at maximum/minimum nominal output 18.0/4.5 17.5/5.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum °F ( °C) 171/135 (77/57) 171/135 (77/57) nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum...

  • Page 28: Technical Data Combi Boiler Zwb28-3A

    28 | Information about the appliance 3.15 Technical data combi boiler ZWB28-3A... Unit LPG (propane) Output at elevation 0 - 2000 feet (0 - 610 m) Maximum nominal output (P ) 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5) Maximum nominal output (P ) 122/86 °F (50/30 °C) BTU/hr (kW)
  • Page 29 Information about the appliance | 29 Unit LPG (propane) General Voltage Frequency Max. power consumption (central heating mode) Max. power consumption (Stand-by) < 6 < 6 Noise level dB(A) ≤ 39 ≤ 39 Maximum supply temperature °F ( °C) 194 (90) 194 (90) Max.

  • Page 30: Technical Data Combi Boiler Zwb42-3A

    30 | Information about the appliance 3.16 Technical data combi boiler ZWB42-3A... Unit LPG (propane) Output at elevation 0 - 2000 feet (0 - 610 m) Maximum nominal output (P ) 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Maximum nominal output (P ) 122/86 °F (50/30 °C) BTU/hr (kW)
  • Page 31 Information about the appliance | 31 Unit LPG (propane) Calculation values for calculating cross-section to EN 13384 Flue gas mass flow at maximum/minimum nominal output 18.0/4.5 17.5/5.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum °F ( °C) 171/135 (77/57) 171/135 (77/57) nominal heat input Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum...

  • Page 32: Condensate Composition

    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 Lead ≤...

  • Page 33: Regulations

    Regulations | 33 Regulations Observe all rules, regulations, standards and Operating limits of the boiler guidelines applicable to the installation and The heat exchanger has been designed and certified in operation of this appliance in your country. accordance with the ASME Boiler and Pressure Vessel Code, Section IV.

  • Page 34: Additional Regulations For Installation In Massachusetts

    34 | Regulations 4. INSPECTION. The state or local gas inspector of the side Additional regulations for installation in wall horizontally vented gas fueled equipment shall not Massachusetts approve the installation unless, upon inspections, the inspector observes carbon monoxide detectors and sig- (a) For all side wall horizontally vented gas fueled nage installed in accordance with the provisions of equipment installed in every dwelling, building or...

  • Page 35: Installation

    Installation | 35 Installation 5.1.1 Notes on installation and operation DANGER: Explosion! Fill and make-up water for the heating system B Close the gas cock prior to working on the gas train. Unsuitable fill and make-up water can result in the heating system scaling up or failing prematurely.

  • Page 36: Other Important Information

    36 | Installation Gravity heating systems Corrosion inhibitors B Connect the appliance to the existing piping system via The following anti-corrosion agents are approved: a low-loss header with a sludge separator. Designation Concentration Galvanized radiators or pipes. Nalco 77381 1 - 2 % To prevent gas formation: Sentinel X 100 1.1 %...

  • Page 37: Comparing The Size Of The Integrated Expansion Vessel

    Installation | 37 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: •...

  • Page 38: Zbr

    38 | Installation ZBR..-3A appliances (heating boilers): Selecting the installation location Selecting an expansion vessel Installation location requirements External expansion vessel Observe the current national and local codes and regulations. B Determine size of the expansion vessel. B Observe country-specific requirements. B Observe installation instructions of the venting system accessories and their clearances.

  • Page 39: Pre-Installing Pipes

    Installation | 39 B Secure the hydraulics connection plate and the Pre-installing pipes mounting bracket with the mounting kits supplied. B Secure the installation template (supplied with the technical documentation) to the wall; observe the minimum side clearances of 4 inches (102 mm) page 11).
  • Page 40 40 | Installation 7 7/8" 7 7/8" (200 mm) (200 mm) 6 720 641 933-89.1O Fig. 14 Hydraulics connection plate for heating boiler 6 720 641 933-90.1O ZBR..-3A (front view) Fig. 16 Hydraulics connection plate for combi boiler ZWB..-3A (front view) Heating supply, R 1"...

  • Page 41: Mounting The Appliance

    Installation | 41 Hanging the appliance Mounting the appliance B Place flat gaskets on the connections of the hydraulic bracket. NOTICE: Residue, metal shavings, and B Hang appliance on the mounting bracket. contaminants in the piping can damage the appliance. B Tighten the union nuts on the pipe connections.

  • Page 42: Installing A Low Water Cut Off (Lwco)

    Fig. 20 Installing a LWCO device - LWCO adapter • Hydrolevel Safgard 1100 B Push the adapter with the LWCO onto the pipe (step 1) The device is available at most Bosch wholesalers. and secure with the clip (step 2). It requires an external 24VAC 20VA transformer provided on site.

  • Page 43: Connecting Flue Gas Accessories

    Installation | 43 B Insert the flue gas adapter as far as it will go into the Connecting flue gas accessories 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.

  • Page 44: Installation Of The Exhaust And Air Intake System

    44 | Installation 5.8.1 Installation of the exhaust and air intake system Direct vent installations (sealed combustion) For direct vent applications all applicable items below NOTICE: must be met. B Vent connectors serving appliances vented by natural draft shall not be connected to any portion of mechanical draft systems operating under positive pressure.
  • Page 45 Installation | 45 Vent should terminate at least 3 feet (915 mm) away from The exhaust pipe must be properly adjacent walls, inside corners and 5 feet (1525 mm) below supported and pitched a minimum of ¼ inch roof overhang ( fig.
  • Page 46 46 | Installation NOTICE: NOTICE: B DO NOT use cellular core pipe. B Vent terminations must keep the following minimum clearances from electric meters, B DO NOT use PVC when using anti-freeze in gas meters, regulators and relief the primary circuit of the boiler. Use CPVC equipment: 4 feet (1220 mm) [Canada or stainless steel only! 6 feet (1830 mm)] horizontally and in no...

  • Page 47: Approved Examples Of Horizontal And Vertical Venting Installation

    Installation | 47 5.8.2 Approved examples of horizontal and vertical venting installation ≥ 4" (102 mm) 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.
  • Page 48 48 | Installation 6 720 641 933-09.1O Fig. 31 Vertical venting system (sealed combustion) 6 720 641 933-10.1O 6 720 641 933-07.1O Fig. 32 Vertical venting system (room air only) Fig. 33 Vertical venting system (sealed combustion) Key to Fig. 31, Fig. 32 and Fig. 33: Intake Exhaust Concentric termination...
  • Page 49 Installation | 49 6 720 641 933-08.1O Fig. 34 Vertical venting system (sealed combustion) Intake Exhaust Greater than 12 inches (305 mm) 12 inches (305 mm) above maximum snow level or at least 24 inches (610 mm) whichever is greater Copyright (optional information) 6 720 643 068 (2011/06)

  • Page 50: Vent And Combustion Air Pipe Lengths

    Fig. 27, 28, 29, 31, 32 and 34 Separate terminations 2" PIPE Maximum combined pipe length including elbows in feet (m) for 2" PIPE Maximum combined pipe length including elbows in feet (m) for ZBR16-3A ZBR35-3A Number of ZBR28-3A ZBR42-3A ZBR16-3A ZBR35-3A elbows...

  • Page 51: Testing Gas And Water Connections For Leaks

    Installation | 51 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.

  • Page 52: Making The Electrical Connections

    52 | Making the electrical connections Making the electrical connections General notes Low voltage electrical connections in the Heatronic boiler control DANGER: Risk of electric shock! B Before working on the power supply 6.2.1 Open the Heatronic boiler control (120 VAC), disconnect the boiler from the NOTICE: Small pieces of wire can cause grid by shutting off the emergency shutoff shorts and damage the electronics.

  • Page 53: Connecting The Outdoor Temperature Sensor

    Making the electrical connections | 53 6.2.2 Connecting the outdoor temperature sensor 6.2.3 Connecting the DHW tank temperature sensor (only heating boiler ZBR..-3A) B Connecting the controls automatically establishes the internal communications BUS connection ( Wire the DHW tank temperature sensor directly to the installation instructions for the controls).

  • Page 54: Connecting Additional Accessories

    ϑ B Secure the cable on the strain relief. Bosch room controls ≤ 4" Connect only Bosch room controls to the internal BUS of (102 mm) this boiler. 6 720 641 933-97.1o Fig. 41 Mounting supply temperature sensor right next to...

  • Page 55: Electrical Connections In The Junction Box

    B Use service function 5.E to set connection to 03 (external heating pump) ( page 71). 6 720 641 933-42.1O Fig. 44 Mounting rails for junction box The DHW recirculation pump is controlled by the Bosch FW 200. Copyright (optional information) 6 720 643 068 (2011/06)

  • Page 56: Dhw Tank Loading Pump Or 3-Way Valve

    56 | Making the electrical connections 6.3.3 DHW tank loading pump or 3-way valve with 6.3.4 Connecting mains power supply spring return (only heating boiler ZBR..-3A) B Route the power cable (AC 120 V, 60 Hz) from the The pump used must have the following connection emergency shutoff switch to the boiler.

  • Page 57: Connecting The Lwco Device

    Making the electrical connections | 57 B Connect the leads labeled SWITCH CONTACT (yellow) Connecting the LWCO device to the TB1 temperature guard ( Fig 40, page 54) on the Heatronic. NOTICE: System damage or malfunction! B Ensure the air box remains air-tight when routing the LWCO cable to the outside.

  • Page 58: Commissioning

    58 | Commissioning Commissioning eco reset 6 720 641 933-25.1O Fig. 53 Overview of the controls Emissions test button Service button Burner operation indicator lamp ON/OFF power switch Key pad lock ECO button Reset button Display Automatic air vent (ZWB..-3A combi boilers only) Boiler water pressure gauge DHW thermostat Safety relief valve discharge hose...

  • Page 59: Before Operating The Appliance

    Commissioning | 59 Before operating the appliance Switching the appliance ON/OFF NOTICE: Commissioning without being Startup properly filled and purged will damage the B Switch the appliance ON using the ON/OFF switch. appliance. The display indicates the supply temperature of the hot B Only operate this appliance after ensuring water in °F.

  • Page 60: Setting Up Space Heating

    60 | Commissioning Setting up space heating Programming the FW 200 heating control unit Set the maximum supply temperature based on the structure's heat loss on design day. Observe the operating instructions for the heating control included in the scope of Boiler high Typical supply delivery.

  • Page 61: Zbr

    Commissioning | 61 ECO button ZBR..-3A appliances (heating boilers) The default setting is DHW priority; the ECO button is not with DHW tank: Setting the DHW lit. temperature In order to switch between DHW tank priority and alternating operation, press the ECO button. B Set the DHW temperature on the DHW thermostat The set DHW temperature flashes on the display for •...

  • Page 62: Setting Manual Summer Mode

    -or- If you want to leave the appliance switched OFF: Setting manual summer mode B Mix Bosch-approved anti-freeze into the heating water In summer mode or warm weather shut down (WWSD), Tab. 15, page 36) and drain the DHW circuit.

  • Page 63: Activating The Key Pad Lock

    ZBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection | 63 ZBR..-3A appliances (heating 7.10 Activating the key pad lock boiler) with DHW tank: The key pad lock affects the boiler high limit dial, the DHW thermostat, and all buttons except the ON/OFF switch, Thermal disinfection emissions test button, and reset button.

  • Page 64: Boiler Circulator

    64 | Boiler circulator Boiler circulator 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. Changing the pump curve of the boiler pump The speed of the boiler pump can be changed using the dial on the pump.

  • Page 65: Heatronic Boiler Control Settings

    Heatronic boiler control settings | 65 Heatronic boiler control settings Adjust Value 10.1 Guideline to service functions B Repeatedly press the key pad lock button or ECO The Heatronic allows easy setting and testing of many button to adjust the value up or down. appliance functions.

  • Page 66: Overview Of The Service Functions

    66 | Heatronic boiler control settings 10.2.2 Second service level (at first service level, 10.2 Overview of the service functions service button lights up, press ECO button and key pad lock button simultaneously until e.g. 8.A 10.2.1 First service level (press and hold the service appears) button until it lights up)

  • Page 67: Description Of The Service Functions

    Heatronic boiler control settings | 67 Service function 1.E: Pump mode for space heating 10.3 Description of the service functions operation 10.3.1 First service level If an outdoor temperature sensor for an outdoor reset control is connected, pump Service function 1.A: Maximum space heating output control mode 04 is automatically set.

  • Page 68: Purging Function

    68 | Heatronic boiler control settings Service function 2.A: Heating circuit pump lockout time The following settings are possible: (only heating boiler ZBR..-3A) • 00: Purging function off • 01: Purging function is switched on and after NOTICE: System damage or boiler completion automatically reset to 00 malfunction! •...
  • Page 69 Heatronic boiler control settings | 69 Service function 3.A: Automatic anti-cycle function Service function 3.C: Switching differential Only if the automatic anti-cycle time is disabled (service If an outdoor reset control is connected, there function 3.A) will this function be active. is no need to adjust this setting on the appliance.

  • Page 70: Audible Fault Warning Tone

    70 | Heatronic boiler control settings Service function 3.F: Constant DHW period Service function 4.E: Appliance type (only combi boiler ZWB..-3A) This service function displays the appliance type detected. NOTICE: System damage or boiler Possible displays are: malfunction! • 00: Central heating only B Never change the setting of this service •...

  • Page 71: Fan Post Purge Time

    Heatronic boiler control settings | 71 Service function 5.b: Fan post purge time Service function 6.b: Room temperature control, current voltage, terminal 2 This service function allows setting the time the fan purges after the burner is shut off. The current voltage of the analog control at terminal 2 is displayed.

  • Page 72: B 3-Way Valve In Center Position

    Service function 7.d: Connecting an external supply or 3 % per 1000 feet (305 m). low-loss header temperature sensor ZBR16-3A..., ZBR28-3A..., ZBR35-3A... and ZWB28-3A... Presence of an external supply or low loss header appliances offer altitude adjustment which compensates temperature sensor is automatically detected by default;...

  • Page 73: Second Service Level

    Service function 8.C: GFA Gas burner control unit status Service function 2.F: Operating mode, page 68). Internal parameter. If you are on the line with Bosch The following settings are available: Technical Support you may be asked for this number.

  • Page 74: Set Fan Start Speed

    74 | Heatronic boiler control settings Service function 9.d: Set fan start speed Service function b.F: Solar DHW backup heating delay (only combi boiler ZWB..-3A) At higher elevations the boiler fan may need to spin faster upon startup to ensure reliable ignition every time. The For systems with a solar thermal DHW tank in series before start speed of the boiler fan can be set from 45 to the DHW line of the combi boiler.

  • Page 75: Gas Type Conversion

    Gas type conversion | 75 Gas type conversion DANGER: Personal injury and property 11.1 Converting to a different gas type damage DANGER: Explosion! B This conversion shall only be performed by B Close the gas cock prior to working on the a trained and certified installer in gas train.

  • Page 76: (610 M) Above Sea Level

    NOT derated up to 6000 feet (1829 m). Above 6000 feet (1829 m) a rate of 3 % per 1000 feet (305 m) applies. The Bosch Greenstar boiler is factory set for installation below 2000 feet (610 m) above sea level.
  • Page 77 Gas type conversion | 77 B On the gas throttle, break the seal at the slot and B Remove the sealed screw ( Fig. 72, [3]) from gas valve remove the cap. adjustment screw ( Fig. 72, [2]) and set CO or O level for minimum nominal output.

  • Page 78: Dynamic Gas Pressure Test

    78 | Gas type conversion Nominal Permissible pressure 11.4 Dynamic gas pressure test pressure range for maximum B Switch the appliance OFF and close the gas shut-off " W.C. nominal output valve. Gas type (mbar) " W.C. (mbar) B Loosen the screw in the test port for gas inlet pressure 7 (17.4) 3.5-10.5 (8.7-26.1) Fig.

  • Page 79: Flue Gas Test

    Flue gas test | 79 Flue gas test 12.1 Emissions test button 12.2 Measuring CO content of flue gas The following appliance outputs can be selected by Use a multiport flue gas probe for the measurements. pressing the emissions test button until it lights up: B Open one of the flue gas test ports ( Fig.

  • Page 80: Environmental Responsibility/Disposal

    80 | Environmental responsibility/disposal 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.

  • Page 81: Inspection And Maintenance

    B Check all connections for leaks. commissioning. B Check the gas-air ratio and adjust if necessary B Only use a Bosch cleaning blade or Bosch page 76). cleaning brush ( page 114).

  • Page 82: Description Of Various Steps

    82 | Inspection and maintenance 14.1.3 Plate type heat exchanger 14.1 Description of various steps (only combi boiler ZWB..-3A) If the DHW output on the combi boiler is significantly 14.1.1 Calling up the latest fault (service function 6.A) reduced: B Select service function 6.A ( page 71).

  • Page 83: Checking The Electrodes

    Inspection and maintenance | 83 B Remove the boiler pressure gauge from the Heatronic 14.1.4 Checking the electrodes boiler control. B Remove electrode set ( 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.

  • Page 84: Burner Servicing

    B Remove burner lid (steps 1 - 4). commissioning. B Only use a Bosch cleaning blade and Bosch cleaning brush ( page 114). B Only clean heat exchanger in case if soiling is clearly visible.
  • Page 85 Inspection and maintenance | 85 B With the cleaning blade, clean the heat exchanger block B Rinse the heat exchanger with water from the top. from the bottom to the top. 6 720 612 664-18.1R Fig. 89 Rinsing the heat exchanger B Clean the condensate tray (with reversed brush).

  • Page 86: Condensate Trap Cleaning

    86 | Inspection and maintenance 14.1.7 Condensate trap cleaning 14.1.8 Checking the mixer diaphragm B Remove condensate trap (steps 1 and 2) and check heat B Open the mixer unit. exchanger orifice for clear passage. B Carefully remove the diaphragm from the fan air intake and check for contamination and cracks.

  • Page 87: Expansion Vessel

    Inspection and maintenance | 87 14.1.9 Expansion vessel 14.1.11 Testing system water quality Annual inspection of the expansion vessel is required. B Take a representative sample of the system water and analyze pH using a pH meter or pH test strips. B Depressurize the appliance.

  • Page 88: Checklist For Inspection And Maintenance

    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 Latest fault code from service function 6.A ( page 82).

  • Page 89: Readings On The Display

    Readings on the display | 89 Readings on the display The boiler display can provide the following information Status (Tab. 35 and 36): code Description Acknowledge by pressing any button (except reset). Value displayed Description Range Number or letter, dot Service function followed by letter Tab.

  • Page 90: Faults

    90 | Faults Faults 16.1 Troubleshooting DANGER: Explosion! The Heatronic boiler control monitors all safety and control components. B Close the gas cock prior to working on the gas train. If a fault arises during operation, an audible warning tone B Check for gas leaks after carrying out work sounds.

  • Page 91: Faults That Are Shown On The Display

    Faults | 91 16.2 Faults that are shown on the display Display Description Elimination DHW temperature sensor defective. B Check temperature sensor and leads for interruptions or shorts, and replace if defective. B Insert code plug correctly; replace if defective. Communication fault.
  • Page 92 92 | Faults Display Description Elimination Supply temperature sensor defective. B Check temperature sensor and leads for interruptions or shorts, and replace if defective. Additional supply temperature sensor B Check temperature sensor and leads for interruptions or defective. shorts, and replace if defective. Heat exchanger safety high limit or flue gas B Check flue gas safety high limit and leads for interruptions or temperature limiter has tripped.
  • Page 93 Faults | 93 Display Description Elimination Flame detected even when burner is off. B Check electrodes; replace if defective. B Check flue gas system; clean or repair if defective. B Check PCB for moisture; dry if needed. After switching gas off: Flame is detected. B Check gas cock;...

  • Page 94: Faults That Are Not Shown On The Display

    94 | Faults 16.3 Faults that are not shown on the display Appliance faults Elimination Combustion noise too loud; rumbling noises B Insert code plug correctly; replace if defective. B Check gas type. B Check inlet gas pressure; adjust if defective. B Check flue gas system;...

  • Page 95: Check Sensor Values

    Faults | 95 16.4.3 Supply temperature sensor, External supply 16.4 Check sensor values temperature sensor, DHW tank temperature sensor, DHW temperature sensor 16.4.1 Outdoor temperature sensor Temperature °F ( °C) Temperature °F ( °C) Testing tolerance ± 10% Resistance [ Ω] Testing tolerance ±...

  • Page 96: Replacement Code Plug

    96 | Faults 16.5 Replacement code plug Appliance Order number ZBR16-3A NG 8 714 432 501 0 ZBR16-3A LPG 8 714 432 506 0 ZBR28-3A NG 8 714 432 502 0 ZBR28-3A LPG 8 714 432 507 0 ZBR35-3A NG...

  • Page 97: Commissioning Log For The Appliance

    Commissioning log for the appliance | 97 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: (Complete a separate log for every appliance!) FD (Date of manufacture): Date commissioned: Individual appliance Installation...
  • Page 98 98 | Commissioning log for the appliance Modified service functions: (Select the modified service functions and enter the values here.) 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 ×...

  • Page 99: Spare Parts

    Spare parts | 99 Spare parts B Order spare parts by name and part number using the spare parts list. Designation Spare parts list Group 1 - Sheet metal page 100 Group 2 - Burner/Heat exchanger page 102 Group 3 - Gas valve page 104 Group 4 - Pipes combi boiler ZWB..-3A page 106...
  • Page 100 100 | Spare parts 6 720 641 933-102.1o Fig. 93 Group 1 - Sheet metal Greenstar 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 101 Spare parts | 101 Item ( Fig. 93) Designation Order number Outer jacket complete 8 718 222 866 0 Front cover 8 718 222 827 0 Screw M5X22 (10x) 8 713 403 026 0 Trade mark badge 8 716 011 807 0 Expansion vessel 8 715 407 328 0 Washer 18.6 X 13.5 X 1.5 (10x)
  • Page 102 102 | Spare parts 6 720 641 933-103.2o Fig. 94 Group 2 - Burner/Heat exchanger Greenstar 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 103 Spare parts | 103 Item ( Fig. 94) Designation Order number Heat exchanger block (incl. set of gaskets) incl. 8 737 701 797 0 flue gas and condensate collector (item 4) 8 713 301 196 0 Set of gaskets 8 710 103 206 0 Flue gas and condensate collector 8 718 006 944 0 Temperature limit sensor...
  • Page 104 104 | Spare parts 6 720 641 933-104.1o Fig. 95 Group 3 - Gas valve Greenstar 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 105 Spare parts | 105 Item ( Fig. 95) Designation Order number Fan RG130 USA 8 718 226 185 0 Diaphragm 8 715 505 928 0 Air limiter 8 710 505 210 0 Air limiter 8 710 505 212 0 Gas valve USA, incl. 9 Washer 18.3x24.3 (item 4) 8 718 226 391 0 and Port screw (item 29).
  • Page 106 106 | Spare parts 6 720 641 933-105.1o Fig. 96 Group 4 - Pipes combi boiler ZWB..-3A Greenstar 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 107 Spare parts | 107 Item ( Fig. 96) Designation Order number Condensate trap complete 8 710 506 271 0 Cup incl. gasket 8 710 506 273 0 Drain hose 8 710 703 178 0 Drain Tee 8 710 735 076 0 Expansion vessel connecting pipe complete 8 710 735 318 0 Safety clip 10mm (10x)
  • Page 108 108 | Spare parts 6 720 641 933-106.1o Fig. 97 Group 5 - Pipes heating boiler ZBR..-3A Greenstar 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 109 Spare parts | 109 Item ( Fig. 97) Designation Order number Condensate trap complete 8 710 506 271 0 Cup incl. gasket 8 710 506 273 0 Drain hose 8 710 703 178 0 Drain Tee 8 710 735 076 0 Pressure gauge USA complete 8 718 226 104 0 Safety clip 10mm (10x)
  • Page 110 110 | Spare parts 6 720 641 933-107.2O Fig. 98 Group 6 - Control box Greenstar 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 111 Gas conversion kit ZWB42-3A from LPG (31) to NG (23) 8 737 701 740 0 – Gas conversion kit ZBR16-3A from LPG (31) to NG (23) 8 737 701 741 0 – Gas conversion kit ZBR28-3A from LPG (31) to NG (23) 8 737 701 742 0 –...
  • Page 112 112 | Spare parts 6 720 641 933-108.1o Fig. 99 Group 7 - Hydraulic block combi boiler ZWB..-3A Greenstar 6 720 643 068 (2011/06) Copyright (optional information)
  • Page 113 Spare parts | 113 Item ( Fig. 99) Designation Order number Flat plate heat exchanger 20 plates 8 716 108 212 0 Flat plate heat exchanger gasket 15mm 8 716 106 435 0 Supply manifold complete 8 716 106 356 0 Screw M5x32 8 716 771 687 0 Rubber bushing...
  • Page 114 114 | Spare parts Item ( Fig. 97) Designation Order number – SAK3 – Heat exchanger service accessory kit (main 7 719 001 998 heat exchanger gaskets, heat exchanger brush, heat exchanger cleaning blade) – Brush set WB5 7 719 002 502 –...

  • Page 115: Index

    Proper use ..............8 Appliance description ............. 9 Scope of delivery............6 Appliance details............11 Technical specifications Accessories ............... 10 - ZBR16-3A............20 Minimum clearances ..........11 - ZBR28-3A............22 Technical data - ZBR35-3A............24 - ZBR16-3A............20 - ZBR42-3A...
  • Page 116 116 | Index Gas and water connections ........... 51 Mains fuse............16, 18, 52 Gas type ................ 75 Maintenance and inspection log book ......88 Adjustment ..............75 Making the electrical connections ........ 52 Conversion ..............75 Measuring CO content of flue gas......... 79 Conversion kit ............
  • Page 117 Index | 117 (service function 0.E) ..........73 Minimum heating/DHW output Safety instructions ............4 (service function 3.d) ..........69 Scope of delivery............. 6 Operating mode Sealant ................36 (service function 2.F) ..........68 Second service level............73 Permanent ignition Service functions (service function 8.F) ..........73 3-way valve in center position Pump control mode for heating operation (service function 7.b) ..........
  • Page 118 118 | Index Technical data ......... 20, 22, 24, 26, 28, 30 ZBR16-3A..............20 ZBR28-3A..............22 ZBR35-3A..............24 ZBR42-3A..............26 ZWB28-3A..............28 ZWB42-3A..............30 Technical specifications ....20, 22, 24, 26, 28, 30 Testing gas line.............. 51 Testing water connections ..........51 Thermal disinfection............
  • Page 119 Index | 119 Copyright (optional information) 6 720 643 068 (2011/06)
  • Page 120 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-584-1681 www.bosch-climate.us U.S.A. Products manufactured by Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.bosch-thermotechnology.com Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.

This manual is also suitable for:

Zbr28-3a seriesZbr35-3a seriesZwb28-3a seriesZbr42-3a seriesZwb42-3a series

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