Bosch Greenstar Installation And Service Instructions Manual Download

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Information about the appliance

Greenstar

6 720 806 992 (2015/03)

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

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

Unit

LPG (propane)

Max. input rate 180/79 °F (82/26 °C)

BTU/hr (kW)

151,600 (44.4)

148,300 (43.5)

Max. output rate 104/86 °F (40/30 °C)

BTU/hr (kW)

137,500 (40.3)

Max. output rate 122/86 °F (50/30 °C)

BTU/hr (kW)

137,500 (40.3)

Max. output rate 176/140 °F (80/60 °C)

BTU/hr (kW)

134,400 (39.4)

Min. input rate 180/79 °F (82/26 °C)

BTU/hr (kW)

36,000 (10.5)

46,400 (13.6)

Min. output rate 104/86 °F (40/30 °C)

BTU/hr (kW)

35,500 (10.4)

46,400 (13.6)

Min. output rate 122/86 °F (50/30 °C)

BTU/hr (kW)

35,100 (10.3)

46,100 (13.5)

Min. output rate 176/140 °F (80/60 °C)

BTU/hr (kW)

31,700 (9.3)

42,000 (12.3)

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

Max. input rate 180/79 °F (82/26 °C)

BTU/hr (kW)

136,440 (40.0)

139,402 (40.9)

Max. output rate 104/86 °F (40/30 °C)

BTU/hr (kW)

123,750 (36.3)

129,250 (37.9)

Max. output rate 122/86 °F (50/30 °C)

BTU/hr (kW)

123,750 (36.3)

129,250 (37.9)

Max. output rate 176/140 °F (80/60 °C)

BTU/hr (kW)

120,960 (35.5)

126,336 (37.0)

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

Max. input rate 180/79 °F (82/26 °C)

BTU/hr (kW)

125,828 (36.9)

129,021 (37.8)

Max. output rate 104/86 °F (40/30 °C)

BTU/hr (kW)

114,125 (33.5)

119,625 (35.1)

Max. output rate 122/86 °F (50/30 °C)

BTU/hr (kW)

114,125 (33.5)

119,625 (35.1)

Max. output rate 176/140 °F (80/60 °C)

BTU/hr (kW)

111,552 (32.7)

116,928 (34.3)

Gas connection value

Natural Gas – H

= 1,010 BTU/ft

(37.3MJ/m

)

/hr (m

/h)

149 (4.2)

–

Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1MJ/m3)

/hr (m

/h)

–

59 (1.7)

Permissible inlet gas pressure

in. W.C. (mbar)

3.5-10.5" (8.7-26.1)

–

LPG (propane)

in. W.C. (mbar)

–

8-13" (19.9-32.3)

Flue gas

Flue gas mass flow at maximum/minimum nominal output

gps

18.0/4.5

17.5/5.6

Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal heat
input

°F ( °C)

171/135 (77/57)

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

°F ( °C)

133/91 (56/33)

at max. nominal output

9.4

11.0

at minimum nominal output

8.6

10.4

Condensate

Max. condensate quantity (t

= 86 °F (30 °C))

gph (l/h)

0.9 (3.5)

pH level, approx.

4.8

General

Voltage

VAC

120

Frequency

Max. power consumption (central heating mode)

205

Max. power consumption (Stand-by)

< 6

Sound pressure level

dB(A)



Max. supply temperature

°F ( °C)

190 (88)

Max. permissible operating pressure (P

) heating

psi (bar)

30 (2.07)

Permissible ambient temperature

°F ( °C)

32 - 122 (0 - 50)

Nominal water capacity (heating)

Gal (L)

0.925 (3.5)

Weight (without packaging)

lbs. (kg)

103.6 (47)

Dimensions, W x H x D

inch

(mm)

17-21/64" × 33-15/32" × 13-57/64"

(440 × 850 × 353)

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

Summary of Contents for Greenstar

Page 1: ...nformation 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 pr...

Page 2: ...s Selecting an expansion vessel 34 6 4 Selecting the installation location 34 6 5 Pre installing pipes 34 6 6 Mounting the appliance 36 6 7 Installing a low water cut off LWCO 36 6 8 Connecting flue gas accessories 37 6 8 1 Installation of the exhaust and air intake system 38 6 8 2 Approved examples of horizontal and vertical venting installation 42 6 8 3 Vent and combustion air pipe lengths 44 6 ...

Page 3: ...re 73 15 1 11Testing system water quality 73 15 1 12Inspecting electrical wiring 73 15 2 Checklist for inspection and maintenance 74 16 Readings on the display 75 17 Faults 76 17 1 Troubleshooting 76 17 2 Faults that are shown on the display 77 17 3 Faults that are not shown on the display 79 17 4 Check sensor values 80 17 4 1 Outdoor temperature sensor 80 17 4 2 Additional supply temperature limi...

Page 4: ...stream of the draft hood Do not tamper with remove or attempt to repair the blocked vent switch When replacing the blocked vent switch install the new part in the original location A blocked vent switch tripping more than once indicates a problem with the venting system or chimney which must be repaired immediately Ensure none of the vent pipes and chimneys are damaged or blocked Connect only one ...

Page 5: ... of delivery 2 1 ZBR Residential boiler for space heating and loading of indirect fired DHW tanks Fig 1 Scope of delivery heating boiler ZBR 3A Contents of package 1 1 Gas condensing boiler 2 Set of documents for appliance 3 Mounting bracket with mounting kit 4 Gas conversion kit 5 Adapter for connection of a LWCO Contents of package 2 6 Rail with connection box 7 Flue adapter1 8 DHW tank temperat...

Page 6: ...bracket with mounting kit 4 Gas conversion kit 5 Adapter for connection of a LWCO Contents of package 2 6 Rail with connection box 7 Flue adapter1 8 Hydraulics connection plate with mounting kit 9 External supply temperature sensor NTC 10 Outdoor reset control FW 200 with mounting kit and outdoor temperature sensor 11 Set of documents for outdoor reset control FW 200 6 720 641 933 04 2O 7 8 6 11 1...

Page 7: ...r 42 kW 3 Version A Fan supported appliance 23 Natural gas NG 3 3 Rating plate The rating plate is located at the right side of the appliance Fig 3 Position of the rating plate The rating plate contains the appliance output model number approval data and serial number 3 4 Appliance description Appliance for wall installation regardless of chimney and room size Outdoor reset control FW 200 Intellig...

Page 8: ...ting support pool heating IPM2 for one or two heating zones with pump control and motorized mixing capability ICM for cascading up to 4 boilers optional concentric vent kit available for horizontal direct vent terminations 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 ...

Page 9: ...ce jacket 2 Service cover 3 Hydraulics connection plate Zero clearance from combustibles permitted but 4 102 mm recommended for serviceability Distance to door if mounted inside a closet 17 21 64 440 mm 4 102 mm 4 102 mm 3 11 32 85 mm 33 15 32 850 mm 9 29 64 240 mm 7 7 8 200 mm 33 27 64 849 mm 1 3 16 30 mm 13 57 64 353 mm 33 15 16 862 mm 4 102 mm 15 381 mm 3 1 2 6 720 641 933 01 2O 4 102 mm ...

Page 10: ...6 720 806 992 2015 03 3 7 Appliance layout heating boiler ZBR 3A Fig 5 Appliance layout heating boiler ZBR 3A min 13 14 15 16 17 20 26 25 24 18 19 30 32 33 35 37 40 41 29 34 28 39 36 38 31 1 2 3 4 5 6 7 8 12 9 10 11 6 720 641 933 02 2O 27 23 22 21 ...

Page 11: ...djuster 17 Flue gas temperature limiter 18 Combustion air intake 19 Exhaust pipe 20 Boiler supply pipe 21 Connection for optional low water cut off LWCO 22 Additional supply temperature limiter 23 Manual air bleeder 24 Gas air premix chamber 25 Fan 26 Bracket 27 Wall hanging bracket 28 Exhaust pipe 29 Sight glass 30 Set of electrodes 31 Supply temperature sensor 32 Boiler block temperature limiter...

Page 12: ...0 806 992 2015 03 3 8 Appliance layout combi boiler ZWB 3A Fig 6 Appliance layout combi boiler ZWB 3A min 6 720 641 933 03 2O 1 2 3 4 5 6 7 8 12 9 10 11 13 16 17 19 20 21 23 22 25 28 18 26 27 30 31 32 36 37 38 33 34 35 14 15 29 24 45 44 39 40 41 42 43 ...

Page 13: ... Automatic air vent 19 Maximum gas adjuster 20 Flue gas temperature limiter 21 Combustion air intake 22 Supply pipe 23 Connection for optional low water cut off LWCO 24 Additional supply temperature limiter 25 Gas air premix chamber 26 Expansion vessel 27 Fan 28 Bracket 29 Wall hanging bracket 30 Exhaust pipe 31 Sight glass 32 Set of electrodes 33 Supply temperature sensor 34 Boiler block temperat...

Page 14: ... 992 2015 03 3 9 Electrical wiring heating boiler ZBR 3A Fig 7 Electrical wiring diagram heating boiler ZBR 3A L N B B F A 6 720 641 933 23 3O 9 8 7 LZ NZ LS NS 4 2 1 2 3 6 7 4 5 8 9 L N 4 6 1 2 3 5 7 11 9 12 14 15 16 17 18 19 20 21 22 23 24 6 10 8 25 13 4 ...

Page 15: ... or low water cut off LWCO 9 BUS connection e g heating control 10 Room thermostat dry contact 11 Outdoor temperature sensor 12 Code plug 13 Diagnostic interface 14 ON OFF switch 15 Gas valve 16 Fan 17 Flue gas temperature limiter 18 Supply temperature sensor 19 Flame rod electrode 20 Ignition electrode 21 Boiler block temperature limiter 22 DHW tank temperature sensor NTC 23 Boiler circulator 24 ...

Page 16: ...6 992 2015 03 3 10 Electrical wiring combi boiler ZWB 3A Fig 8 Electrical wiring diagram combi boiler ZWB 3A L N B B F A 6 720 641 933 24 3O 9 8 7 LZ NZ LS NS 4 2 1 2 3 6 7 4 5 8 9 4 6 24 23 6 1 2 3 4 6 10 8 11 13 14 15 16 17 18 19 20 22 21 25 5 9 7 26 12 ...

Page 17: ... BUS connection e g heating control 9 Room thermostat dry contact 10 Outdoor temperature sensor 11 Code plug 12 Diagnostic interface 13 ON OFF switch 14 Gas valve 15 Fan 16 Flue gas temperature limiter 17 Supply temperature sensor 18 Flame rod electrode 19 Ignition electrode 20 Boiler block temperature limiter 21 DHW temperature sensor 22 Boiler circulator 23 3 way valve Space heating DHW heating ...

Page 18: ...8 7 26 1 LPG propane in W C mbar 8 13 19 9 32 3 Flue gas Flue gas mass flow at maximum minimum nominal output gps 6 8 1 7 6 7 2 6 Flue gas temperature 176 140 F 80 60 C at maximum minimum nominal heat input F C 136 133 58 56 136 133 58 56 Flue gas temperature 104 86 F 40 30 C at maximum minimum nominal heat input F C 99 88 37 31 99 88 37 31 CO2 at max nominal output 9 4 11 0 CO2 at minimum nominal...

Page 19: ... 8 7 26 1 LPG propane in W C mbar 8 13 19 9 32 3 Flue gas Flue gas mass flow at maximum minimum nominal output gps 9 4 3 2 9 2 4 8 Flue gas temperature 176 140 F 80 60 C at maximum minimum nominal heat input F C 145 133 63 56 145 133 63 56 Flue gas temperature 104 86 F 40 30 C at maximum minimum nominal heat input F C 115 90 46 32 115 90 46 32 CO2 at max nominal output 9 4 11 0 CO2 at minimum nomi...

Page 20: ...8 7 26 1 LPG propane in W C mbar 8 13 19 9 32 3 Flue gas Flue gas mass flow at maximum minimum nominal output gps 12 0 3 2 11 6 4 8 Flue gas temperature 176 140 F 80 60 C at maximum minimum nominal heat input F C 147 133 64 56 147 133 64 56 Flue gas temperature 104 86 F 40 30 C at maximum minimum nominal heat input F C 117 90 47 32 117 90 47 32 CO2 at max nominal output 9 4 11 0 CO2 at minimum nom...

Page 21: ... 10 5 8 7 26 1 LPG propane in W C mbar 8 13 19 9 32 3 Flue gas Flue gas mass flow at maximum minimum nominal output gps 15 7 4 5 15 2 5 6 Flue gas temperature 176 140 F 80 60 C at maximum minimum nominal heat input F C 162 135 72 57 162 135 72 57 Flue gas temperature 104 86 F 40 30 C at maximum minimum nominal heat input F C 127 91 53 33 127 91 53 33 CO2 at max nominal output 9 4 11 0 CO2 at minim...

Page 22: ...114 125 33 5 119 625 35 1 Max output rate 122 86 F 50 30 C BTU hr kW 114 125 33 5 119 625 35 1 Max output rate 176 140 F 80 60 C BTU hr kW 111 552 32 7 116 928 34 3 Gas connection value Natural Gas Hs 1 010 BTU ft3 37 3MJ m3 ft3 hr m3 h 149 4 2 Liquid Propane Gas HD S 2 500 BTU ft3 93 1MJ m3 ft3 hr m3 h 59 1 7 Permissible inlet gas pressure NG in W C mbar 3 5 10 5 8 7 26 1 LPG propane in W C mbar ...

Page 23: ... 12 3 17 12 DHW Max DHW flow rate gpm l min 2 64 10 2 64 10 Nominal DHW flow rate at 140 F 60 C outlet temperature gpm l min 2 03 7 7 2 03 7 7 Outlet temperature F C 104 140 40 60 104 140 40 60 Max cold water inlet temperature F C 140 60 140 60 Max approved DHW pressure psi bar 150 10 3 150 10 3 Minimum water pressure psi bar 4 35 0 3 4 35 0 3 Flue gas Flue gas mass flow at maximum minimum nominal...

Page 24: ...Gal L 3 17 12 3 17 12 DHW Max DHW flow rate gpm l min 3 17 12 3 17 12 Nominal DHW flow rate at 140 F 60 C outlet temperature gpm l min 2 6 10 2 6 10 Outlet temperature F C 104 140 40 60 104 140 40 60 Max cold water inlet temperature F C 140 60 140 60 Max approved DHW pressure psi bar 150 10 3 150 10 3 Minimum water pressure psi bar 4 35 0 3 4 35 0 3 Flue gas Flue gas mass flow at maximum minimum n...

Page 25: ...at elevation 4500 7000 feet 1373 2134 m above sea level Max input rate 180 79 F 82 26 C BTU hr kW 125 828 36 9 129 021 37 8 Max output rate 104 86 F 40 30 C BTU hr kW 114 125 33 5 119 625 35 1 Max output rate 122 86 F 50 30 C BTU hr kW 114 125 33 5 119 625 35 1 Max output rate 176 140 F 80 60 C BTU hr kW 111 552 32 7 116 928 34 3 Output rate domestic hot water DHW 113 F 45 C BTU hr kW 114 125 33 5...

Page 26: ...ktheconditionoftheentirehotwaterdistributionsystemtoensure safe operation Common practice calls for inspecting an existing system initsentiretyandbringingituptocode Allpipeworkshouldbeproperly cleaned and flushed Condensate Max condensate quantity tR 86 F 30 C gph l h 0 9 3 5 0 9 3 5 pH level approx 4 8 4 8 General Voltage VAC 120 120 Frequency Hz 60 60 Max power consumption central heating mode W...

Page 27: ...um height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve ...

Page 28: ...6 DHW pump 7 To indirect tank 8 External system supply temperature sensor for system supply pipe to be installed in closest vicinity with boiler supply Tee 9 Boiler primary line supply pipe 1 10 Heating boiler ZBR 3A with FW 200 installed on front 11 Boiler primary line return pipe 1 12 From indirect tank 13 From heating zone 1 14 From heating zone 2 15 Expansion vessel X 4 pipe diameters on boile...

Page 29: ...ug for extermnal system pump chapter 7 3 2 page 48 7 System pump 8 DPDT Relay 9 Motorized valve heating zone 2 10 Motorized valve heating zone 1 11 24 V AC transformer 12 Outdoor temperature sensor 13 LWCO Low Water Cut Off 24V AC Transformer required 14 DHW temperature sensor connection with clear connector 15 External supply temperature sensor connection with white plug B B F A 6 720 806 992 04 ...

Page 30: ...xternal system supply temperature sensor for system supplypipe to be installed in closest vicinity with boiler supply Tee 8 Boiler primary line supply pipe 1 9 Heating boiler ZBR 3A with FW 200 installed on front 10 Boiler primary line return pipe 1 11 From indirect tank 12 From heating zone 1 13 From heating zone 2 14 Expansion vessel X 4 pipe diameters on boiler primery side here 4 1 ϑ 1 3 5 12 ...

Page 31: ...nal DHW tank chapter 7 3 3 page 49 5 DHW pump 6 Taco Circulator Relay SR504 7 Pump heating zone 1 8 Pump heating zone 2 9 Outdoor temperature sensor 10 LWCO Low Water Cut Off 24V AC Transformer required 11 DHW temperature sensor connection with clear connector 12 External supply temperature sensor connection with white plug B B F A 6 720 806 992 06 1O 9 8 7 LZ NZ 4 2 L N F V Zone 1 Zone 2 Zone 3 Z...

Page 32: ...nes Electrical connection of the DHW recirculation pump page 48 Connect the DHW recirculation line with the cold water inlet as close as possible to the Hydraulics connection plate Open vented heating systems Convert open vented heating systems into closed systems Gravity heating systems Connect the appliance to the existing piping system via a low loss header with a sludge separator Galvanized ra...

Page 33: ... untreated boiler condensate in septic systems Inspect the sewer pipes for suitability before disposing of untreated boiler condensate into them Verify with the local authority that disposing of untreated boiler condensate into public sewer systems is permitted 6 2 Comparing the size of the integrated expansion vessel The following diagrams allow verifying that the integrated expansion vessel has ...

Page 34: ...Pre installing pipes Secure the installation template supplied with the technical documentation to the wall observe the minimum side clearances of 4 inches 102 mm page 9 Drill holes for the appliance and for the hydraulics connection plate in accordance with the mounting template Fig 16 Mounting template Remove the mounting template Industrial sources Chemical cleaning Trichloroethylene tetrachlor...

Page 35: ...draulics connection plate for combi boiler ZWB 3A front view 1 Heating supply R 1 NPT 2 DHW R 3 4 NPT 3 Gas R 3 4 NPT 4 Cold water R 3 4 NPT 5 Heating return R 1 NPT Fig 21 Hydraulics connection plate for combi boiler ZWB 3A top view Determine pipe size for the gas supply To fill and drain the system install a fill and drain valve at the lowest point 6 720 641 933 30 1O 6 720 641 933 89 1O 1 3 16 ...

Page 36: ...of 176 F 80 C and a water temperature of 250 F 121 C It needs a dry contact The following LWCO is approved with the boiler Hydrolevel Safgard 1100 The device is available at most Bosch wholesalers It requires an external 24VAC 20VA transformer provided on site The Hydrolevel Safgard 1100 is installed in the supply pipe to the left of the heat exchanger Disconnect the boiler from power by shutting ...

Page 37: ...sket with the screws enclosed Fig 26 Attaching the vent flange and gasket 1 Gasket 2 Vent flange 3 Screws Insert the flue gas adapter as far as it will go into the vent flange and align it Fig 27 Flue gas adapter 1 Vent flange 2 Flue gas adapter 3 Combustion air test port 4 Flue gas test ports Tighten the screws The LWCO is positioned upright for technical reasons Tests have shown that all air wil...

Page 38: ...ed with the vent material Never install a barometric nor a thermally controlled vent damper with this boiler Connect only one boiler to each flue system or chimney flue Do not route the flue system piping through or inside another duct that is used for exhausting air or other flue gases The condensate trap must be primed at all times Failure to do so may allow combustion gases to escape into boile...

Page 39: ...ice formations Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney All PVC CPVC vent pipes must be glued except for the flue gas adapter pipe connection All PP PVC CPVC combustion air and vent pipe materials and fittings must comply with the following and must be UL approved venting material X X X X 1 2 6 720 641 933 19 1O The exhaust pipe must be prope...

Page 40: ...ts Material Item United states Canada ZBR16 3A ZBR28 3A ZBR35 3A ZBR42 3A ZWB28 3A ZWB35 3A ZWB42 3A Table 17 Materials for pipe Roof terminals Material Supplier Part number Ø 3 Ø 5 Ø 76 125 mm concentric PVC IPEX System 636 196006 Ø 3 Ø 5 Ø 76 125 mm concentric CPVC IPEX System 636 197009 Ø 3 Ø 5 Ø 80 125 mm concentric PP M G Duravent PolyPro and Centrotherm InnoFlue 3PPS VK TC M G Duravent or IC...

Page 41: ...feet 2135 mm 2 YA At least 1 foot 305 mm above grade or snow line YB Exhaust terminal must be at least 3 feet 915 mm above forced air inlet within 10 feet 3050 mm horizontally USA 6 feet 915 mm above forced air inlet Canada NOTICE Vent terminations must keep the following minimum clearances from electric meters gas meters regulators and relief equipment 4 feet 1220 mm Canada 6 feet 1830 mm horizon...

Page 42: ...ipe supports every 5 feet 1525 mm of horizontal and vertical run beginning with support near boiler The condensate must be disposed of in accordance with applicable rules Periodic cleaning of the vent terminal and air intake screens is mandatory Avoid locating vent terminals near equipment or buildingfeatureswhichcanbesubjecttodegradation from exhaust gases If multiple boilers are installed in a r...

Page 43: ... only Fig 38 Vertical venting system sealed combustion Key to Fig 36 Fig 37 and Fig 38 1 Intake 2 Exhaust 3 Concentric termination X Greater than 12 inches 305 mm Y 12 inches 305 mm above maximum snow level or at least 24 inches 610 mm whichever is greater 6 720 641 933 09 2O Y 1 2 6 720 641 933 07 1O 1 Y X 2 6 720 641 933 10 1O 1 2 Y X ...

Page 44: ...combined vent and combustion air pipe length tab 20 21 and 22 depend on the installation situation the appliance type and the number of elbows used 2 6 720 641 933 08 1O Y X 1 Y X X 6 720 806 922 08 2O 1 2 With Flex Pipe the maximum length is reduced by 50 Flex Pipe according to the suppliers instructions for use in the vertical part of the installation only Installations Fig 32 33 34 36 37 and 39...

Page 45: ...and the stainless steel wall termination Installations Fig 38 Concentric termination 2 PIPE Maximum straight vent pipe length allowed for Ø 2 pipe Number of 90 elbows used ZBR16 3A ZBR21 3A ZBR28 3A ZWB28 3A ZBR35 3A ZWB35 3A ZBR42 3A ZWB42 3A 1 66 ft 20 1 m 47 ft 14 3 m 2 61 ft 18 6 m 38 ft 11 6 m 3 56 ft 17 1 m 30 ft 9 1 m 4 51 ft 15 6 m 22 ft 6 7 m 5 46 ft 14 1 m 13 ft 4 0 m 6 41 ft 12 5 m 5 ft...

Page 46: ...Remove screws step 1 unhook cable and remove cover step 2 Fig 43 Remove the cover 7 2 2 Connecting the outdoor temperature sensor Connecting the controls automatically establishes the internal communications BUS connection see installation instructions for the controls Punch out plastic insert Connect cable of the outdoor temperature sensor according to Fig 44 Insert cable for the outdoor temperat...

Page 47: ...on of the FB 100 remote control see installation instructions for the remote control Connecting temperature guard TB 1 external manual reset high limit or low water cut off LWCO This connection allows the installation of external safety switches External manual reset high limit Low water cut off LWCO Radiant overheat protection Fig 47 Electrical wiring TB1 When the temperature guard trips central ...

Page 48: ...x Holdtherailagainsttheappliancefrombelow step1 andfastenwith the screws from the outside or inside step 2 Loosen junction box from the rail step 3 Fig 51 Mounting rails for junction box 7 3 2 Connecting an external heating zone pump or DHW recirculation pump Without accessories the appliance offers the connection of one heating zone pump one circulator of an unmixed heating circuit or one DHW rec...

Page 49: ... plug in the junction box upon delivery Connect red plugs and insert grommet until stop Fig 55 Cable connected external DHW tank loading pump or 3 way valve Mount the 3 way valve for space heating operation when de energized and DHW tank loading when energized Use service function 1 F to set pump mode page 59 7 3 4 Connecting mains power supply Routethepowercable AC 120 V 60Hz fromtheemergencyshut...

Page 50: ...e leads labeled 24V HOT red and 24V COMMON white to the external 24VAC transformer Connect the leads labeled SWITCH CONTACT yellow to the TB1 temperature guard Fig 47 page 47 on the Heatronic Fig 59 Wires of a LWCO device with LWCO adapter 1 LWCO device Hydrolevel Safgard 1100 2 BOILER GROUND green 3 SWITCH CONTACT yellow 4 SWITCH CONTACT yellow 5 24V HOT red 6 24V COMMON white NOTICE System damag...

Page 51: ...e charge pressure to the static head of the heating system page 33 Open radiator and zone valves as applicable Open heating supply and return valves fill heating system to 14 5 to 21 75 psi 1 1 5 bar and close fill valve Bleed all air from the system If the boiler water pressure has dropped fill the heating system again to 14 5 to 21 75 psi 1 to 1 5 bar On ZBR 3A appliances heating boilers with a ...

Page 52: ...forms a once only purging sequence This involves the heating zone pump switching on and off at intervals for approx 4 minutes The display shows in alternation with the supply temperature If the display shows in alternation with the supply temperature the trap filling function is active page 62 Boiler high limit dial Typical supply temperatures Sample application 1 approx 95 F 35 C Frost protection...

Page 53: ... All days Press the dial P1 will be highlighted Press the dial The display will fl ash Turn the dial one click clockwise to 12 00PM Press the dial to confirm the setting Turn the dial until Comfort appears The area around the display should fill in Press the dial to confirm the setting Press menu button to return to main display 8 5 3 Setting type of heating system To open INSTALLER SETTINGS press...

Page 54: ...from 50 F 10 C to 77 F 25 C Turning above 77 F 25 C will move it to 210 F 99 C which disables WWSD Press the dial to confirm the setting 8 5 5 Resetting all settings for installers only This function resets all settings on the MAIN MENU and the INSTALLER SETTINGS to their factory settings Following such a reset you will need to commission the system again If the default display is showing Simultan...

Page 55: ...pen and close a DHW tap to signal the appliance to heat to the selected temperature After a short wait DHW will be available 8 9 Setting manual summer mode Insummermodeorwarmweathershutdown WWSD theheatingzone pump and consequently central heating are switched off DHW generation remains active following the DHW program Make a note of the setting of the boiler high limit dial DHW thermostat Typical...

Page 56: ...supply temperature 9 ZBR 3A appliances heating boiler with DHW tank Thermal disinfection Thermal disinfection covers the DHW system including the taps For solar DHW tanks the solar portion of the tank is not covered Close all DHW taps Advise occupants of the risk of scalding if no tempering valve is installed SetthetimeandDHWtemperatureaccordinglyontheheatingcontrol with DHW program Set any DHW re...

Page 57: ...essure at speed 2 3 Residual head pressure at speed 3 default setting 4 Head pressure of the boiler pump by itself at speed 3 H Head pressure in feet of head m Circulating water volume in gallons per minute l h This function prevents the heating zone pump from seizing up following longer idle periods 0 2 5 7 8 1 4 3 6 15 20 25 10 5 0 H ft V gpm 1 2 3 4 400 800 1200 1600 200 600 1000 1400 7 0 6 5 4...

Page 58: ... button and key pad lock button simultaneously until the code 8 A appears second service level On the second service level select the service function 8 E and value 00 The appliance restarts with the default settings 11 2 Overview of the service functions 11 2 1 First service level press and hold the service button until it lights up The unit automatically exits the service level if no button is p...

Page 59: ...ump control mode 02 Do not use Pump control mode 03 The central heating pump runs continuously exceptions See heating control operating instructions Pumpcontrolmode04 Intelligentcontrolofcentralheatingpumpin heatingsystemswithoutdoorresetcontrol Theheatingzonepumpis only switched on when needed Default setting is 00 Service function 1 F Pump mode only heating boiler ZBR 3A Based on this setting th...

Page 60: ...liance runs for 15 minutes at minimum output The display shows 2 F When this service function is aborted or has been active for 15 minutes the appliance reverts to default mode 02 The appliance runs for 15 minutes at maximum output The display shows 2 F When this service function is aborted or has been active for 15 minutes the appliance reverts to default mode Default setting is 00 Service functi...

Page 61: ...g the space heating mode remains disabled after DHW is drawn The duration for keeping DHW hot can be set from 00 to 30 0 to 30 minutes Default setting is 01 1 minute Service function 4 b Maximum heat exchanger temperature only combi boiler ZWB 3A This function can be used to reduce limestone built up in the heat exchanger which increases with temperature The maximum heat exchanger temperature can ...

Page 62: ...nal heating zone pump in heating circuit without mixer controlled by Heatronic running in parallel with boiler pump in central heating mode Default setting is 03 Service function 5 F Set inspection interval This service function allows setting the number of months after which the service due reminder appears on the display alternating with the supply temperature The number of months can be set fro...

Page 63: ...appliances offer altitude adjustment which compensates for the effects of thin air and are therefore NOT derated up to 6000 feet 1829 m Above 6000 feet 1829 m a rate of 3 per 1000 feet 305 m applies This service function is used to adjust the fan speed for high altitude operation The following settings are available 00 Normal 01 Medium 02 High Default setting is 00 Service function 0 E Metric or U...

Page 64: ... startup to ensure reliable ignition every time The start speed of the boiler fan can be set from 45 to 77 revolutions per second 1 s Default setting is 50 Service function 9 E Turbine signal delay only combi boiler ZWB 3A Thisservicefunctionallowssettingatimedelaytopreventtheappliance starting up as a result of transient pressure spikes in the water supply Through spontaneous pressure change in t...

Page 65: ...ances offer altitude adjustment which compensates for the effects of thin air and are therefore NOT derated up to 6000 feet 1829 m Above 6000 feet 1829 m a rate of 3 per 1000 feet 305 m applies Correction of the fan speed curve of the burner Use service function 0 d to adjust the elevation setting page 63 DANGER Personal injury and property damage This conversion shall only be performed by a train...

Page 66: ...um nominal output according to table 31 Fig 79 Set CO2 or O2 level for maximum nominal output Briefly press the emissions test button The display shows the supply temperature in alternation with minimum nominal output Measure the CO2 or O2 level and the CO content of the flue gas Section 13 Removethesealedscrew Fig 80 3 fromgasvalveadjustment screw Fig 80 2 and set CO2 or O2 level for minimum nomi...

Page 67: ...ows the supply temperature in alternation with maximum nominal output Check the required inlet gas pressure according to table 32 Repeatedly press the emissions test button until the light goes out The display returns to the supply temperature Switch the appliance OFF turn off the gas cock remove the pressure gauge and tighten the screw in the test port for gas inlet pressure Reinstall the cover 6...

Page 68: ...ecycling The components are easy to separate and the plastics are marked This allows the various components to be sorted for appropriate recycling or disposal 15 Inspection and maintenance Regular service and maintenance are recommended for a long service lifeoftheappliance forefficientandeconomicaloperation andtokeep the environmental impact as low as possible Owners operators are encouraged to s...

Page 69: ...filter only combi boiler ZWB 3A Close cold water tap Depressurize the cold water pipe To access the filter remove the safety clip step 1 pull out the pipe step 2 and remove the filter from the pipe step 3 If necessary clean with plastic brush under running water Fig 84 Filter in fresh water pipe combi boiler ZWB 3A only 15 1 3 Plate type heat exchanger only combi boiler ZWB 3A If the DHW output on...

Page 70: ...emoving the plate heat exchanger Installnewplatetypeheatexchangerwithnewgasketsandreconnect the hydraulic assembly in reverse order Check all connections used during maintenance for leaks 15 1 4 Checking the electrodes Remove electrode set page 10 12 including gasket and check electrodes for contamination clean or replace if required Reinstall electrode set with new gaskets and check for leaks Fig...

Page 71: ...ng is required For cleaning the heat exchanger use Bosch main heat exchanger gaskets the heat exchanger brush and the heat exchanger cleaning blade which are available as spare parts Remove the condensate trap steps 1 and 2 and place a suitable container underneath Fig 94 Removing the condensate trap DANGER Fire danger Only operate the burner while installed in a boiler 1 2 4 6 720 641 933 95 1o 3...

Page 72: ...ger with the cleaning brush Remove burner Chapter 15 1 5 Burner servicing Rinse the heat exchanger with water from the top Fig 97 Rinsing the heat exchanger Clean the condensate tray with reversed brush Fig 98 Cleaning the condensate tray Rinse the heat exchanger with water from the top Clean the condensate trap connection Closetheinspectionopeningagainusinganewgasketandtightenthe screws with appr...

Page 73: ...pansion vessel and heating system for leaks 15 1 11Testing system water quality Take a representative sample of the system water and analyze pH using a pH meter or pH test strips If the value is outside of the permitted range drain the system flush and refill with fresh water to prevent system damage or leaks If the fill water does not meet the requirements of page 32 treat the water to bring it w...

Page 74: ...67 inches W C mbar 5 Gas air ratio at min max nominal output page 66 min max 6 Gas and water side leak test page 45 7 Inspect electrodes page 70 8 Inspect heat exchanger block page 71 9 Check burner page 71 10 Inspect diaphragm in mixer unit page 73 11 Clean condensate trap page 73 12 With the system depressurized check the expansion vessel pre charge pressure vs the static head of the heating sys...

Page 75: ...nd holding for more than 3 seconds Save function Thedisplayshowsthesupplytemperatureinalternation with The appliance works for 15 minutes at the minimum nominal output service function 2 F Thedisplayshowsthesupplytemperatureinalternation with The appliance works with the set maximum output in heating mode service function 1 A Thedisplayshowsthesupplytemperatureinalternation with The appliance work...

Page 76: ...e commissioning report page 81 DANGER Explosion Close the gas cock prior to working on the gas train Check for gas leaks after carrying out work on the gas train DANGER Risk of flue gas poisoning Check for leaks after carrying out work on the venting system DANGER Risk of electric shock Always disconnect the appliance from the mains power before performing any work Disconnect the emergency shutoff...

Page 77: ...sensor and leads for interruptions or shorts and replace if defective Temperature guard TB1 has tripped Check if jumper across 8 9 or PR P0 is missing Reset external temperature limiter if installed Reset LWCO if installed d5 External supply temperature sensor defective low loss header The external supply temperature sensor was recognized on the BUS and then reconnected to the appropriate terminal...

Page 78: ...nd ignition leads replace PCB if defective Check gas air ratio correct if out of specification F1 Internal data error Reset boiler to the factory default setting service function 8 E F7 Flame detected even when burner is off Check electrodes replace if defective Check flue gas system clean or repair if defective Check PCB for moisture dry if needed FA After switching gas off Flame is detected Chec...

Page 79: ...ectrodes for visual damage replace if defective Check flue gas system clean or repair if defective Check gas air ratio replace gas valve if defective Check gas valve replace if defective Check burner replace if required DHW has unpleasant odor or has a dark color Perform thermal disinfection of the DHW circuit Replace sacrificial anode in the tank if installed Consult local water department Set su...

Page 80: ...0 1 177 212 100 886 Table 41 Resistance table supply temperature limiter Temperature F C Testing tolerance 10 Resistance 68 20 14 772 77 25 11 981 86 30 9 786 95 35 8 047 104 40 6 653 113 45 5 523 122 50 4 608 131 55 3 856 140 60 3 243 149 65 2 744 158 70 2 332 167 75 1 990 176 80 1 704 185 85 1 464 194 90 1 262 203 95 1 093 212 100 950 Table 42 Resistance table NTCs Appliance Order number ZBR16 3...

Page 81: ...Notes regarding under or over pressure operation Gas setting and flue gas test Gas conversion NG LPG propane Inlet gas pressure W C mbar Gas static supply pressure W C mbar Selected maximum output MBH kW Selected minimum output MBH kW Gas flow rate at maximum nominal output gpm l min Gas flow rate at minimum nominal output gpm l min Net calorific value HiB per gas supplier MBTU ft3 kWh m3 CO2 at m...

Page 82: ...ut Tightness test carried out on the gas and water sides Commissioning includes checking the settings a visual heating leak test and a functional check of the boiler and control The system installer conducts a test of the heating system This system has been checked to the extent described ___________________________________________________________ Name of service installing contractor The document...

Page 83: ...WB28 3A ZWB35 3A ZWB42 3A Spare parts list Group 1 Sheet metal page 84 Group 2 Burner Heat exchanger page 86 Group 3 Gas valve page 88 Group 4 Pipes combi boiler ZWB 3A page 90 Group 5 Pipes heating boiler ZBR 3A page 92 Group 6 Control box page 94 Group 7 Hydraulic block combi boiler ZWB 3A page 96 Group 8 Accessories for service installation page 98 Table 44 Spare part groups Greenstar ...

Page 84: ...84 Spare parts Greenstar 6 720 806 992 2015 03 Fig 101 Group 1 Sheet metal Greenstar 6 720 641 933 102 2O ...

Page 85: ...10 735 296 0 10 Bracket 8 711 304 860 0 12 Washer 80 mm 8 711 004 232 0 13 Adapter USA 8 718 226 289 0 16 Silencer complete 8 710 725 353 0 17 Gasket 8 711 004 278 0 18 Throttle disc 8 710 100 209 0 19 Flue pipe gasket 8 722 933 330 0 20 Latch 1x 8 718 224 302 0 21 Damper 2x 8 718 224 267 0 22 Junction box USA ZBR heating boiler 8 737 701 425 0 Junction box USA ZWB combi boiler 8 737 701 563 0 23 ...

Page 86: ...86 Spare parts Greenstar 6 720 806 992 2015 03 Fig 102 Group 2 Burner Heat exchanger Greenstar 22 15 13 14 16 20 17 4 6 7 20 21 18 12 10 23 11 9 5 8 3 2 1 4 9 16 19 19 6 720 641 933 103 3O 14 22 23 ...

Page 87: ...87 0 7 Temperature sensor 8 714 500 087 0 8 Cover 8 711 000 262 0 9 Gasket 8 710 103 153 0 10 Shield 8 718 003 836 0 11 Clip 10x 8 710 100 190 0 12 Set of electrodes complete 8 718 107 089 0 13 Flame viewing window 8 715 600 018 0 14 Gasket 10 8 711 004 264 0 15 Burner 8 718 006 658 0 16 Burner gasket 8 711 004 168 0 17 Top burner cover complete 8 715 416 029 0 18 Attachment nuts washers safety pi...

Page 88: ...88 Spare parts Greenstar 6 720 806 992 2015 03 Fig 103 Group 3 Gas valve Greenstar 1 19 21 19 13 14 15 17 18 2 3 20 19 16 16 10 29 12 9 11 9 8 7 9 29 4 6 720 641 933 104 1o ...

Page 89: ...pipe below USA 8 718 225 756 0 8 Fibre gasket 25x30x1 5 10x 8 710 103 014 0 9 Washer 18 3x24 3 10x 8 710 103 161 0 10 Pipe 8 718 221 063 0 11 Gas pipe top USA 8 718 225 762 0 12 O ring 10x 8 710 205 103 0 13 Gas pipe 8 710 735 387 0 14 Cover 8 712 305 092 0 15 Safety clip 18mm 10x 8 716 771 169 0 16 Gasket 8 729 000 183 0 17 Fan RG128 USA 8 718 226 184 0 18 O ring 10x 8 722 880 175 0 19 Screw m4x6...

Page 90: ...s Greenstar 6 720 806 992 2015 03 Fig 104 Group 4 Pipes combi boiler ZWB 3A Greenstar 7 8 6 23 11 15 15 18 7 6 5 22 1 2 21 14 19 17 3 25 26 16 27 20 27 11 7 20 11 10 13 12 29 4 10 24 28 9 11 12 6 720 641 933 105 1o ...

Page 91: ...0 12 Safety clip 10x 8 711 200 024 0 13 Upper heating return pipe complete 8 710 735 324 0 14 Lower heating return pipe complete 8 710 735 396 0 15 Fibre gasket 23 9 X 17 2 X 1 5 10x 8 710 103 043 0 16 Safety clip inlet adapter 8 716 106 432 0 17 Fresh water inlet pipe 8 710 735 430 0 18 Safety clip supply sensor 8 716 106 488 0 19 DHW outlet pipe 8 710 735 427 0 20 Wire form spring 18mm 10x 8 716...

Page 92: ...re parts Greenstar 6 720 806 992 2015 03 Fig 105 Group 5 Pipes heating boiler ZBR 3A Greenstar 1 2 6 9 9 26 7 5 8 3 23 24 4 9 21 9 20 22 9 19 18 28 29 30 25 6 720 641 933 106 2O 13 12 9 9 11 12 15 16 10 14 17 ...

Page 93: ...6 771 169 0 12 Safety clip 10mm 10x 8 716 771 167 0 13 Dummy plug 8 718 226 183 0 14 Safety relief valve USA 30 psi 8 737 703 427 0 15 O ring 13 87x3 53 10x 8 716 771 155 0 16 PRV drain adapter and hose complete 8 710 725 760 0 17 Fill and drain valve 8 738 505 955 0 18 Pump ZBR USA complete heating boiler 8 718 226 172 0 19 Adapter pipe 8 710 735 450 0 20 Gasket 18 6 X 13 5 X 1 5 10x 8 710 103 04...

Page 94: ...94 Spare parts Greenstar 6 720 806 992 2015 03 Fig 106 Group 6 Control box Greenstar 2 1 21 22 23 24 17 16 3 4 10 6 11 30 9 12 7 20 14 15 25 13 6 720 641 933 107 3O 8 8 8 8 8 31 35 ...

Page 95: ... 718 226 066 0 Cable harness ZBR heating boiler 8 718 226 067 0 20 Fuse 8 744 503 045 0 21 Internal main power cord complete white plug 8 737 701 320 0 22 Internal tank loading pump power cord complete red plug 8 737 701 321 0 23 Internal system pump power cord complete black plug 8 737 701 322 0 24 DHW tank temperature sensor 8 737 701 343 0 25 System supply temperature sensor 8 737 700 289 0 30 ...

Page 96: ... Hydraulic block combi boiler ZWB 3A Greenstar 14 2 2 2 2 1 3 7 6 5 4 8 12 9 11 12 10 13 15 17 18 19 6 45 22 21 2 2 4 10 5 30 27 26 9 23 24 25 21 11 13 2 2 33 33 31 32 46 28 16 12 9 29 9 12 42 12 41 40 36 29 29 35 37 38 39 39 34 26 45 13 14 47 6 720 641 933 108 2O ...

Page 97: ...1 353 0 22 Air vent valve 8 716 106 445 0 23 Return assembly complete 8 716 106 844 0 24 Safety clip supply sensor 8 716 106 488 0 25 Pressure relief valve DHW 8 717 401 029 0 26 O ring 2 62 x 6 02 ID EPDM 10x 8 716 140 810 0 27 Drain valve 8 716 771 432 0 28 Pressure relief valve USA complete 8 737 703 427 0 29 O ring 13 87x3 53 10x 8 716 771 155 0 30 Safety clip inlet adapter 8 716 106 432 0 31 ...

Page 98: ...92 2015 03 Item Designation ZBR16 3A ZBR21 3A ZBR28 3A ZBR35 3A ZBR42 3A ZWB28 3A ZWB35 3A ZWB42 3A Order number Brush set WB5 7 719 002 502 Cleaning blade WB5 7 719 002 503 Table 52 Group 8 Accessories for service installation Greenstar ...

Page 99: ...e sensor 47 Tank primary pump ZBR only 49 Corrosion inhibitors 33 D Default settings 54 Details about the appliance Proper use 7 Scope of delivery 5 Technical specifications ZBR16 3A 18 ZBR21 3A 19 ZBR28 3A 20 ZBR35 3A 21 ZBR42 3A 22 ZWB28 3A 23 ZWB35 3A 24 ZWB42 3A 25 Type overview 7 DHW circulation 32 Dimensions 9 Disposal 68 E ECO button 55 Electrical connection 73 3 way valve ZBR only 49 Conne...

Page 100: ...18 25 65 NG 18 25 65 Nominal heating output Maximum 59 Minimum 61 Notes on inspection and maintenance 68 O Old appliances 68 Open vented heating systems 32 Operating conditions 18 20 23 25 Operating pressure of the boiler 73 Overview of the service functions 58 P Packaging 68 Piping systems galvanized 32 Plastic pipework 32 Programming Resetting to default settings All settings 54 Proper use 7 Pro...

Page 101: ...2 A 60 Pump mode only ZBR 3A service function 1 F 59 Pump post purge time heating service function 9 F 64 Reset service reminder service function 5 A 62 Restore appliance Heatronic 3 to factory settings service function 8 E 64 Set functionality of black plug connection NZ LZ service function 5 E 62 Set start speed 1 service function 9 d 64 Software version service function 8 A 63 Supply temperatur...

Page 102: ...102 Index Greenstar 6 720 806 992 2015 03 ...

Page 103: ...Index 103 6 720 806 992 2015 03 Greenstar ...

Page 104: ......

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