Bosch ZBR16-3A Installation And Service Instructions Manual Download Page 20

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Information about the appliance

6 720 643 068 (2011/06)

3.11 Technical data heating boiler ZBR16-3A...

Unit

LPG (propane)

Output

Maximum nominal output (P

max

) 104/86 °F (40/30 °C)

BTU/hr (kW)

54,900 (16.1)

55,300 (16.2)

Maximum nominal output (P

max

) 122/86 °F (50/30 °C)

BTU/hr (kW)

54,300 (15.9)

54,600 (16.0)

Maximum nominal output (P

max

) 176/140 °F (80/60 °C)

BTU/hr (kW)

50,800 (14.9)

51,200 (15.0)

Max. nominal thermal load (Q

max

) heating (H

) 180/79 °F (82/26 °C)

BTU/hr (kW)

51,500 (15.1)

51,900 (15.2)

Max. nominal thermal load (Q

max

) heating (H

) 180/79 °F (82/26 °C)

BTU/hr (kW)

57,200 (16.8)

56,400 (16.5)

Min. nominal output (P

min

) 104/86 °F (40/30 °C)

BTU/hr (kW)

12,600 (3.7)

21,500 (6.3)

Min. nominal output (P

min

) 122/86 °F (50/30 °C)

BTU/hr (kW)

12,600 (3.7)

21,500 (6.3)

Min. nominal output (P

min

) 176/140 °F (80/60 °C)

BTU/hr (kW)

11,300 (3.3)

19,400 (5.7)

Min. nominal thermal load (Q

min

) heating (H

) 180/79 °F (82/26 °C)

BTU/hr (kW)

11,600 (3.4)

19,800 (5.8)

Min. nominal thermal load (Q

min

) heating (H

) 180/79 °F (82/26 °C)

BTU/hr (kW)

12,900 (3.8)

21,500 (6.3)

Max. nominal thermal load (Q

max

) tank (H

) BTU/hr

(kW)

51,500 (15.1)

51,900 (15.2)

Max. nominal thermal load (Q

max

) tank (H

)

BTU/hr (kW)

57,200 (16.8)

56,400 (16.5)

Min. nominal thermal load (Q

min

) tank (H

)

BTU/hr (kW)

11,600 (3.4)

19,800 (5.8)

Min. nominal thermal load (Q

min

) tank (H

)

BTU/hr (kW)

12,900 (3.8)

21,500 (6.3)

Gas connection value

Natural Gas – H

= 1,010 BTU/ft

(37.3 MJ/m

)

/hr (m

/h)

56 (1.6)

–

Liquid Propane Gas – H

D-S

= 2,500 BTU/ft

(93.1 MJ/m

)

/hr (m

/h)

– 22

(0.6)

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)

Calculation values for calculating cross-section to EN 13384

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)

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

°F ( °C)

99/88 (37/31)

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)

0.32 (1.2)

pH level, approx.

4.8

Tab. 4 Technical data heating boiler ZBR16-3A...

Summary of Contents for ZBR16-3A

Page 1: ... 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 i...

Page 2: ...tts 34 5 Installation 35 5 1 Notes on installation and operation 35 5 1 1 Notes on installation and operation 35 5 1 2 Other important information 36 5 2 Comparing the size of the integrated expansion vessel 37 5 3 ZBR 3A appliances heating boilers Selecting an expansion vessel 38 5 4 Selecting the installation location 38 5 5 Pre installing pipes 39 5 6 Mounting the appliance 41 5 7 Installing a ...

Page 3: ... Setting the gas air ratio CO2 or O2 76 11 4 Dynamic gas pressure test 78 12 Flue gas test 79 12 1 Emissions test button 79 12 2 Measuring CO content of flue gas 79 13 Environmental responsibility disposal 80 14 Inspection and maintenance 81 14 1 Description of various steps 82 14 1 1 Calling up the latest fault service function 6 A 82 14 1 2 Fresh water filter only combi boiler ZWB 3A 82 14 1 3 P...

Page 4: ... before performing any work Disconnect the emergency shutoff switch or disengage the heating system circuit breaker B Take measures to prevent accidental reconnection For appliances operating on room air Danger of flue gas poisoning if supply of combustion air is insufficient B Safeguard supply of combustion air B The ventilation and exhaust openings must never be plugged The cross section of the ...

Page 5: ...s Perform maintenance annually Check the complete heating system for defects and malfunction Mitigate defects immediately to avoid larger scale system damage To prevent damage to the appliance or the system from descaling agents remove parts to be descaled during the process Explosive and easily combustible materials Never use or store easily combustible materials paper thinners paints etc near th...

Page 6: ...s 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 adapter 8 DHW tank temperature sensor NTC 9 Hydraulics connection plate with mounting kit 10 External supply temperature sensor NTC 11 Outdoor reset control FW 200 with mounting kit and outdoor temperature sensor 12 Set of documents fo...

Page 7: ...s 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 adapter 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 72...

Page 8: ...mage is excluded from the manufacturer s warranty The commercial and industrial use of the appliance for generating process heat is not permitted 3 2 Overview of boiler types Table 2 describes the meaning of the model number Z Central heating appliance W DHW heating B Condensing technology R Constant temperature control 16 Output up to 54 600 BTU hr 16 kW 28 Output and DHW output up to 95 500 BTU ...

Page 9: ... ZWB 3A only Display Automatic ignition Continuously controlled output Full protection via the Heatronic with flame rod and solenoid valves No minimum circulating water flow rate required Suitable for radiant floor heating Flue adapter for flue gas and combustion air with test ports Variable speed fan Gas premix burner Temperature sensor and temperature control for space heating Supply temperature...

Page 10: ... for system expansions ISM2 for solar systems DHW heating space heating support pool heating IPM2 for one or two heating zones with pump control and motorized mixing capability 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 11: ...w 1 Appliance 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 1O 4 10...

Page 12: ...formation 6 720 643 068 2011 06 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 1O 27 23 22 21 ...

Page 13: ...imum gas adjuster 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 temperatu...

Page 14: ...ation 6 720 643 068 2011 06 3 8 Appliance layout combi boiler ZWB 3A Fig 6 Appliance layout combi boiler ZWB 3A min 1 2 3 4 5 6 7 8 12 9 10 11 6 720 641 933 03 1O 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 15: ...xchanger 18 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 blo...

Page 16: ...011 06 3 9 Electrical wiring heating boiler ZBR 3A Fig 7 Electrical wiring diagram heating boiler ZBR 3A 120 VAC L N B B F A 6 720 641 933 23 1O 9 8 7 LP NP LS NS 4 2 1 2 3 6 7 4 5 8 9 L N 120 VAC 9 VAC 25 VAC 4 6 1 2 3 5 7 11 9 12 14 15 16 17 18 19 20 21 22 23 24 25 6 10 8 26 13 4 ...

Page 17: ...t 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 Transformer 16 Gas valve 17 Fan 18 Flue gas temperature limiter 19 Supply temperature sensor 20 Flame rod electrode 21 Ignition electrode 22 Boiler block temperature limiter 23 DHW tank temperature sensor NTC 24 Boile...

Page 18: ...2011 06 3 10 Electrical wiring combi boiler ZWB 3A Fig 8 Electrical wiring diagram combi boiler ZWB 3A 120 VAC 120 VAC 9 VAC 25 VAC L N B B F A 6 720 641 933 24 1O 9 8 7 LP NP LS NS 4 2 1 2 3 6 7 4 5 8 9 4 6 25 24 6 1 2 3 4 6 10 8 11 13 15 16 17 18 19 20 21 23 22 26 5 9 7 27 12 14 ...

Page 19: ... 8 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 15 Transformer 14 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 temperature sensor 23 Boiler circulator 24 3 way valve Space hea...

Page 20: ...F 82 26 C BTU hr kW 12 900 3 8 21 500 6 3 Max nominal thermal load Qmax tank Hi BTU hr kW 51 500 15 1 51 900 15 2 Max nominal thermal load Qmax tank Hs BTU hr kW 57 200 16 8 56 400 16 5 Min nominal thermal load Qmin tank Hi BTU hr kW 11 600 3 4 19 800 5 8 Min nominal thermal load Qmin tank Hs BTU hr kW 12 900 3 8 21 500 6 3 Gas connection value Natural Gas Hs 1 010 BTU ft3 37 3 MJ m3 ft3 hr m3 h 5...

Page 21: ...level dB A 33 33 Maximum supply temperature F C 194 90 194 90 Max permissible operating pressure PMS heating psi bar 30 2 07 30 2 07 Permissible ambient temperature F C 32 122 0 50 32 122 0 50 Nominal water capacity heating Gal L 0 925 3 5 0 925 3 5 Weight without packaging lbs kg 103 6 47 103 6 47 Dimensions W x H x D inch mm 17 21 64 33 15 32 13 57 64 440 850 353 Unit NG LPG propane Tab 4 Techni...

Page 22: ... F 82 26 C BTU hr kW 24 600 7 2 40 100 11 7 Max nominal thermal load Qmax tank Hi BTU hr kW 90 800 26 6 90 800 26 6 Max nominal thermal load Qmax tank Hs BTU hr kW 100 800 29 5 98 600 28 9 Min nominal thermal load Qmin tank Hi BTU hr kW 22 200 6 5 36 800 10 8 Min nominal thermal load Qmin tank Hs BTU hr kW 24 600 7 2 40 100 11 7 Gas connection value Natural Gas Hs 1 010 BTU ft3 37 3MJ m3 ft3 hr m3...

Page 23: ...level dB A 39 39 Maximum supply temperature F C 194 90 194 90 Max permissible operating pressure PMS heating psi bar 30 2 07 30 2 07 Permissible ambient temperature F C 32 122 0 50 32 122 0 50 Nominal water capacity heating Gal L 0 925 3 5 0 925 3 5 Weight without packaging lbs kg 103 6 47 103 6 47 Dimensions W x H x D inch mm 17 21 64 33 15 32 13 57 64 440 850 353 Unit NG LPG propane Tab 5 Techni...

Page 24: ...79 F 82 26 C BTU hr kW 36 000 10 5 46 400 13 6 Max nominal thermal load Qmax tank Hi BTU hr kW 118 700 34 8 118 700 34 8 Max nominal thermal load Qmax tank Hs BTU hr kW 131 900 38 6 129 100 37 8 Min nominal thermal load Qmin tank Hi BTU hr kW 32 400 9 5 42 700 12 5 Min nominal thermal load Qmin tank Hs BTU hr kW 36 000 10 5 46 400 13 6 Gas connection value Natural Gas Hs 1 010 BTU ft3 37 3MJ m3 ft...

Page 25: ...level dB A 44 44 Maximum supply temperature F C 194 90 194 90 Max permissible operating pressure PMS heating psi bar 30 2 07 30 2 07 Permissible ambient temperature F C 32 122 0 50 32 122 0 50 Nominal water capacity heating Gal L 0 925 3 5 0 925 3 5 Weight without packaging lbs kg 103 6 47 103 6 47 Dimensions W x H x D inch mm 17 21 64 33 15 32 13 57 64 440 850 353 Unit NG LPG propane Tab 6 Techni...

Page 26: ...00 feet 611 1372 m above sea level Maximum nominal output Pmax 104 86 F 40 30 C BTU hr kW 123 750 36 3 129 250 37 9 Maximum nominal output Pmax 122 86 F 50 30 C BTU hr kW 123 750 36 3 129 250 37 9 Maximum nominal output Pmax 176 140 F 80 60 C BTU hr kW 120 960 35 5 126 336 37 0 Max nominal thermal load Qmax heating Hi 180 79 F 82 26 C BTU hr kW 122 850 36 0 128 310 37 6 Max nominal thermal load Qm...

Page 27: ...minal output 8 6 10 4 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 205 205 Max power consumption Stand by W 6 6 Noise level dB A 45 45 Maximum supply temperature F C 194 90 194 90 Max permissible operating pressure PMS heating psi bar 30 2 07 30 2 07 Permis...

Page 28: ...U hr kW 100 800 29 5 98 600 28 9 Min nominal thermal load Qmin DHW Hi BTU hr kW 22 200 6 5 36 800 10 8 Min nominal thermal load Qmin DHW Hs BTU hr kW 24 600 7 2 40 100 11 7 Gas connection value Natural Gas Hs 1 010 BTU ft3 37 3MJ m3 ft3 hr m3 h 99 2 8 Liquid Propane Gas HD S 2 500 BTU ft3 93 1MJ m3 ft3 hr m3 h 39 1 1 Permissible inlet gas pressure NG in W C mbar 3 5 10 5 8 7 26 1 LPG propane in W ...

Page 29: ... level dB A 39 39 Maximum supply temperature F C 194 90 194 90 Max permissible operating pressure PMS heating psi bar 30 2 07 30 2 07 Permissible ambient temperature F C 32 122 0 50 32 122 0 50 Nominal water capacity heating Gal L 0 925 3 5 0 925 3 5 Weight without packaging lbs kg 110 2 50 110 2 50 Dimensions W x H x D inch mm 17 21 64 33 15 32 13 57 64 440 850 353 Unit NG LPG propane Tab 8 Techn...

Page 30: ... load Qmax heating Hi 180 79 F 82 26 C BTU hr kW 122 850 36 0 128 310 37 6 Max nominal thermal load Qmax heating Hs 180 79 F 82 26 C BTU hr kW 136 440 40 0 139 402 40 9 Max nominal output Pmax DHW Hi 113 F 45 C BTU hr kW 123 750 36 3 129 250 37 9 Max nominal output Pmax DHW Hs 140 F 60 C BTU hr kW 122 220 35 8 127 652 37 4 Max nominal thermal load Qmax DHW Hi BTU hr kW 122 850 36 0 128 310 37 6 Ma...

Page 31: ...ominal output 8 6 10 4 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 205 205 Max power consumption Stand by W 6 6 Noise level dB A 45 45 Maximum supply temperature F C 194 90 194 90 Max permissible operating pressure PMS heating psi bar 30 2 07 30 2 07 Permi...

Page 32: ...nd seasonally varying gas quality and air quality Typically the following ingredients and concentrations can be expected Substance Value in ppm mg l Ammonium 1 2 Lead 0 01 Cadmium 0 001 Chrome 0 005 Halogenated hydrocarbons 0 002 Hydrocarbons 0 015 Copper 0 028 Nickel 0 1 Mercury 0 0001 Sulfate 1 Zinc 0 015 Tin 0 01 Vanadium 0 001 pH value 4 8 Tab 10 Typical condensate composition ...

Page 33: ...Install CO detectors per local regulations Boiler requires yearly maintenance Æ chapter 14 page 81 4 2 Operating limits of the boiler The heat exchanger has been designed and certified in accordance with the ASME Boiler and Pressure Vessel Code Section IV The hot water distribution system must comply with all applicable codes and regulations When replacing an existing boiler it is important to che...

Page 34: ...um height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizon tally 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 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not appro...

Page 35: ...5 Connect the DHW recirculation line with the cold water inlet as close as possible to the Hydraulics connection plate Open vented heating systems B Convert open vented heating systems into closed systems DANGER Explosion B Close the gas cock prior to working on the gas train B Check for gas leaks after carrying out work on the gas train Installation power connection connection on the gas and flue...

Page 36: ...ly with all national and local code and regulations Only operate this boiler with the combined air flue system specifically designed and approved for it Only use approved venting systems per the manufacturer s instructions Do not dispose of untreated boiler condensate in septic systems Inspect the sewer pipes for suitability before disposing of untreated boiler condensate into them Verify with the...

Page 37: ... bar Fig 9 Operating capacity of the expansion vessel in F and gallons Fig 10 Operating capacity of the expansion vessel in C and liters Key to Fig 9 and Fig 10 I Precharge pressure 7 25 psi 0 5 bar default setting II Precharge pressure 10 9 psi 0 75 bar III Precharge pressure 14 5 psi 1 0 bar tV Supply temperature in F C VA System capacity in gallons liters A Within operating capacity of the expa...

Page 38: ...ce temperature of this appliance is below 185 F 85 C According to ANSI Z223 1 NFPA43 National fuel gas code and CAN DAS B 149 1 Natural Gas and Propane installation code the appliance is approved for zero clearance to combustibles For servicing a clearance of 4 102 mm is recommended 6 720 641 933 20 1O Industrial sources Chemical cleaning Trichloroethylene tetrachloroethyl ene fluorinated hydrocar...

Page 39: ...th the mounting template Fig 12 Mounting template B Remove the mounting template B Secure the hydraulics connection plate and the mounting bracket with the mounting kits supplied Fig 13 Mounting of the hydraulics connection plate and the mounting bracket NOTICE For walls with insufficient load capacity the appliance and the hydraulics connection plate must be mounted on a sheet of plywood or simil...

Page 40: ...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 17 Hydraulics connection plate for combi boiler ZWB 3A top view B Determine pipe size for the gas supply B To fill and drain the system install a fill and drain valve at the lowest point 6 720 641 933 89 1O 1 3 16 30 mm 7 7 8 200 mm 1 2 3 1 31 32 50 mm 5 1 8 130 mm 10 15 64 260 mm 1 3 8 35 mm...

Page 41: ...ep 3 Fig 18 Remove the cover Hanging the appliance B Place flat gaskets on the connections of the hydraulic bracket B Hang appliance on the mounting bracket B Tighten the union nuts on the pipe connections NOTICE Residue metal shavings and contaminants in the piping can damage the appliance B Flush the piping thoroughly and completely to remove all residue B Follow the instructions with respect to...

Page 42: ...tting off the emergency shutoff switch or disengaging the heating system circuit breaker B Drain the boiler B Remove the safety clip from the dummy plug in the supply pipe step 1 B Pull off the dummy plug step 2 and place with the boiler documentation B Ensure the O ring remains in place on the pipe B Lubricate the O ring Fig 19 Installing a LWCO device removing dummy plug B Screw the LWCO as far ...

Page 43: ...d align it Fig 23 Flue gas adapter 1 Vent flange 2 Flue gas adapter 3 Combustion air test port 4 Flue gas test ports B Tighten the screws B Insert the venting accessory as far as it will go into the vent flange Fig 24 Vent pipes In case of open venting use basket on the air intake For more details on connecting the flue system refer to the installation instructions for the flue kit 1 2 3 6 720 612...

Page 44: ... does not create a hazard or a nuisance Vent termination must be 3 feet 915 mm above any forced air intake within 10 feet 3050 mm Æ fig 26 1 YB page 46 Do not extend exposed vent pipe outside the building beyond recommended distance Condensate could freeze and block vent pipe NOTICE B Vent connectors serving appliances vented by natural draft shall not be connected to any portion of mechanical dra...

Page 45: ...3A ZWB28 3A ZWB42 3A PVC schedule 40 80 2 50 mm Vent or air pipe and fitting ANSI ASTM D1785 BH Gas venting systems ULC S636 1 1 Components of the certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings Plastic components and specified primers and glues of the certified vent system must be from a single system manufacturer and not intermixed with other sys...

Page 46: ...305 mm X2 3 feet 915 mm X3 4 feet 1220 mm X4 5 feet 1525 mm X5 7 feet 2135 mm above public walkway YA At least 1 foot 305 mm above grade and snow line YB Exhaust terminal must be at least 3 feet 915 mm above forced air inlet within 10 feet 3050 mm NOTICE B DO NOT use cellular core pipe B DO NOT use PVC when using anti freeze in the primary circuit of the boiler Use CPVC or stainless steel only NOT...

Page 47: ...ce 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 B Periodic cleaning of the vent terminal and air intake screens is mandatory B Avoid locating vent terminals near equipment or building features which can be subject to degradation from exhaust gases B If multiple boilers a...

Page 48: ...m room air only Fig 33 Vertical venting system sealed combustion Key to Fig 31 Fig 32 and Fig 33 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 1O Y 1 2 6 720 641 933 07 1O 1 Y X 2 6 720 641 933 10 1O 1 2 Y X ...

Page 49: ... optional information Fig 34 Vertical venting system sealed combustion 1 Intake 2 Exhaust 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 2 6 720 641 933 08 1O Y X 1 Y X X ...

Page 50: ...6 m 32 ft 9 8 m 6 56 ft 17 1 m 23 ft 7 0 m Tab 21 Vent and combustion air pipe lengths with 2 diameter and separate terminations Installations Æ Fig 30 Stainless steel wall termination 2 PIPE Maximum combined pipe length including elbows in feet m for Number of elbows ZBR16 3A ZBR28 3A ZWB28 3A ZBR35 3A ZBR42 3A ZWB42 3A 1 76 ft 23 1 m 60 ft 18 3 m 2 71 ft 21 6 m 52 ft 15 9 m 3 66 ft 20 1 m 43 ft ...

Page 51: ...the gas valve from damage B Check all connections for leakage test pressure Max 60 W C 150 mbar B Release pressure 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 B The boiler and its dedicated shutoff...

Page 52: ...ation and electrical connection of controls and modules see the installation instructions of the accessory 6 2 Low voltage electrical connections in the Heatronic boiler control 6 2 1 Open the Heatronic boiler control B Unhook the clip step 1 and fold the Heatronic down step 2 Fig 35 Fold the Heatronic down B Remove screws step 1 unhook cable and remove cover step 2 Fig 36 Remove the cover DANGER ...

Page 53: ...erature sensor B Secure the cable with the strain relief Fig 37 Electrical wiring outdoor temperature sensor 6 2 3 Connecting the DHW tank temperature sensor only heating boiler ZBR 3A Wire the DHW tank temperature sensor directly to the appliance terminals The sensor is provided with the appliance Do not exceed a sensor cable length of 33 feet 10 m B Punch out plastic insert B Plug connector into...

Page 54: ...rheat protection Fig 40 Electrical wiring TB1 When the temperature guard trips central heating and DHW modes are interrupted Connecting the supply temperature sensor e g for low loss header or system supply pipe Do not exceed a sensor cable length of 33 feet 10 m Fig 41 Mounting supply temperature sensor right next to boiler supply 1 System secondary line supply pipe 1 1 2 2 Supply temperature sen...

Page 55: ...irculator of an unmixed heating circuit or one DHW recirculation pump The pump used must have the following connection values 120 VAC max 2 A B Route cable from pump to appliance B Insert cable into the junction box as shown in Fig 46 B Connect cable to the black plug according to Fig 45 Fig 45 Attach plug external pump 1 L 120 VAC 60 Hz 2 PE GND Ground 3 N Neutral 4 Black plug in the junction box...

Page 56: ...en de energized and DHW tank loading when energized B Use service function 1 F to set pump mode Æ page 67 6 3 4 Connecting mains power supply B Route the power cable AC 120 V 60 Hz from the emergency shutoff switch to the boiler B Insert cable into the junction box as shown in Fig 50 B Connect cable to the white plug according to Fig 49 Fig 49 Attach plug mains power supply 1 L 120 VAC 60 Hz 2 PE ...

Page 57: ...nction box B Connect the leads labeled 24V HOT red and 24V COMMON white to the external 24VAC transformer B Connect the leads labeled SWITCH CONTACT yellow to the TB1 temperature guard Æ Fig 40 page 54 on the Heatronic Fig 52 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 COMMO...

Page 58: ... ECO button 7 Reset button 8 Display 9 Automatic air vent ZWB 3A combi boilers only 10 Boiler water pressure gauge 11 DHW thermostat 12 Safety relief valve discharge hose 13 Condensate drain hose 14 Heating return pipe 15 Cold water pipe ZWB 3A combi boilers only 16 Gas pipe 17 DHW pipe ZWB 3A combi boilers only 18 Supply pipe 19 Boiler high limit dial eco reset 1 2 3 4 5 6 7 8 9 11 10 12 13 15 16...

Page 59: ...s the supply temperature of the hot water in F If necessary convert to C Æ Service function 0 E Metric or US customary units page 73 Fig 54 Switching the appliance ON OFF B Open the automatic vent 9 only combi boiler ZWB 3A and close it again when the purging sequence has finished Æ page 58 Shutdown B Switch appliance OFF using the ON OFF switch The display goes out B If the appliance is taken out...

Page 60: ...ondensate starts running out B Complete commissioning report Æ page 97 Boiler high limit dial Typical supply temperatures Sample application 1 approx 95 F 35 C Frost protection 2 approx 109 F 43 C 3 approx 122 F 50 C Radiant floor heating system 4 approx 140 F 60 C Panel radiator system 5 approx 153 F 67 C Cast iron radiator system 6 approx 167 F 75 C max approx 194 F 90 C Baseboard and convector ...

Page 61: ...re flashes on the display for 30 seconds Fig 58 Set the DHW temperature combi boiler ZWB 3A ECO button Pressing and holding the ECO button until it lights up switches between Comfort mode and Economy mode Comfort mode default setting The appliance is continually maintained at the set DHW thermostat Typical DHW temperatures min approx 59 F 15 C e approx 131 F 55 C max approx 158 F 70 C Tab 25 Typic...

Page 62: ...at least 95 F 35 C position 1 Æ Tab 24 page 60 Fig 60 Frost protection of the heating system or If you want to leave the appliance switched OFF B Mix Bosch approved anti freeze into the heating water Æ Tab 15 page 36 and drain the DHW circuit Frost protection of the DHW tank B Leave the appliance switched ON set the boiler high limit to at least 95 F 35 C position 1 Æ Tab 24 page 60 B Turn the DHW...

Page 63: ...ants of the risk of scalding if no tempering valve is installed B Set the time and DHW temperature accordingly on the heating control with DHW program B Set any DHW recirculation pump to continuous operation B Turn DHW thermostat clockwise to max approx 158 F 70 C Fig 63 Thermal disinfection B Wait until the maximum temperature has been reached B Open all DHW taps from the nearest to the one furth...

Page 64: ...ual head pressure 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 140...

Page 65: ... emissions test button will light up and the display shows the setting for the selected service function Adjust Value B Repeatedly press the key pad lock button or ECO button to adjust the value up or down B Record the value in the commissioning log Æ page 97 Saving the value B Press and hold the emissions test button until the display shows value saved Exiting the service function without saving ...

Page 66: ...t inspection interval 70 5 b Fan post purge time 71 5 E Functionality of black plug in boiler junction box 71 5 F Set inspection interval 71 6 A Display the latest fault code 71 6 b Room temperature control current volt age terminal 2 71 6 C Supply temperature required by outdoor reset control 71 6 d Current DHW turbine flow rate 71 7 A Indicator lamp for burner operation faults 71 7 b 3 way valve...

Page 67: ...trols the central heating pump Pump control mode 01 For heating systems without control The supply temperature controls the central heating pump When there is a demand for heat the central heating pump and the burner start up Pump control mode 02 Do not use Pump control mode 03 The central heating pump runs continuously exceptions See heating control operating instructions Pump control mode 04 Int...

Page 68: ...has been turned clockwise to max The following settings are possible 00 Thermal disinfection not enabled 01 Thermal disinfection enabled Default setting is 00 disabled Service function 2 F Operating mode With this service function you can temporarily change the appliance s operating mode The following settings are possible 00 Default mode the appliance runs according to control settings 01 The app...

Page 69: ...ts of 1 F 0 5 C The minimum supply temperature is 95 F 35 C Service function 0 E is set to 00 metric units You can set the switching differential between 00 and 30 0 30 C Service function 0 E is set to 01 US customary units You can set the switching differential between 00 and 54 0 54 F Default setting is 18 18 F 10 C Service function 3 d Minimum output heating and DHW The output for heating and D...

Page 70: ...ank thermostat connected to Heatronic 04 Stratified DHW tank 05 Tank with NTC return Service function 4 F Condensate trap filling sequence The trap filling sequence ensures that the condensate trap is filled after initial installation or after a longer downtime of the appliance The trap filling sequence is activated if The appliance is switched OFF using the ON OFF switch The burner has not been i...

Page 71: ...72 0 to 72 months Default setting is 00 disabled Service function 6 A Display the latest fault code Use this service function to display the most recent fault code Service function 6 b Room temperature control current voltage terminal 2 The current voltage of the analog control at terminal 2 is displayed Possible displays are 00 24 0 V to 24 V in increments of 1 V Service function 6 C Supply tempe...

Page 72: ...the appliance or control setting i e all other heat demands are blocked Default setting is 00 Service function 0 A Do not use this setting Default setting is 00 disabled Service function 0 d Altitude adjustment Input and output rates are reduced at higher altitudes due to thin air with reduced oxygen levels ZBR42 3A and ZWB42 3A appliances are derated at 3 per 1000 feet 305 m ZBR16 3A ZBR28 3A ZBR...

Page 73: ...ton The emissions test button lights up and the display shows 00 B Press and hold the emissions test button until the display shows All settings are reset and the appliance restarts with the default settings B Reset altered service functions to the settings recorded in the commissioning log Æ page 97 Service function 8 F Permanent ignition This function enables permanent ignition without gas suppl...

Page 74: ...rnal control The pump post purge time can be set from 01 to 10 1 to 10 minutes Default setting is 03 Service function A b Display DHW temperature This service function allows displaying the current DHW temperature Service function A C Display DHW tank temperature This service function allows displaying the temperature of the DHW tank temperature sensor Service function b F Solar DHW backup heating...

Page 75: ... to a different gas type and measure the CO content of the flue gas Æ Section 12 DANGER Personal injury and property damage B This conversion shall only be performed by a trained and certified installer in accordance with the manufacturer s instructions and all applicable codes and requirements of the authority having jurisdiction B If the information in these instructions is not followed exactly ...

Page 76: ...the elevation setting Æ page 72 11 3 Setting the gas air ratio CO2 or O2 B Switch the appliance OFF using the ON OFF switch B Remove the cover Æ page 41 B Switch the appliance ON using the ON OFF switch B Open one of the flue gas test ports Fig 69 Open one of the flue gas test ports B Insert the probe approx 2 3 4 inches 70 mm into the test port and seal around it B Press and hold the emissions te...

Page 77: ...or O2 level for minimum nominal output Fig 72 Set CO2 or O2 level for minimum nominal output B Re check settings at maximum and minimum nominal output and re adjust if necessary B Repeatedly press the emissions test button until the light goes out The display returns to the supply temperature B Record the CO2 or O2 levels and the CO content of the flue gas in the commissioning log B Reinstall the ...

Page 78: ...e in alternation with maximum nominal output B Check the required inlet gas pressure according to table 31 B Repeatedly press the emissions test button until the light goes out The display returns to the supply temperature B 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 B Reinstall the cover 6 720 614 090 34 1...

Page 79: ...e test port and seal around it B Press the emissions test button to select maximum nominal output B Measure the CO levels B Repeatedly press the emissions test button until the light goes out The display returns to the supply temperature B Remove flue gas probe and close the flue gas test port properly Æ Fig 73 You have 15 minutes to complete the tests After that the appliance returns to default m...

Page 80: ...ctives Environmental protection laws and regulations are strictly adhered to To protect the environment we use the best possible technology and materials taking into account economic points of view Packaging All packaging materials used are environmentally friendly and recyclable Old appliances Old appliances contain resources that must be submitted for recycling The components are easy to separat...

Page 81: ...n 18 page 99 B Replace removed gaskets and O rings with new ones After the inspection maintenance B Re tighten all loosened threaded connections B Restart the appliance Æ page 58 B Check all connections for leaks B Check the gas air ratio and adjust if necessary Æ page 76 DANGER Explosion B Close the gas cock prior to working on the gas train B Check for gas leaks after carrying out work on the ga...

Page 82: ...combi boiler ZWB 3A only 14 1 3 Plate type heat exchanger only combi boiler ZWB 3A If the DHW output on the combi boiler is significantly reduced B Check filter in the cold water pipe for contamination Æ Fig 82 B Depressurize the appliance B Remove plate type heat exchanger and replace or B Descale with descaling agent approved for stainless steel Grade 316 1 4401 To remove the plate type heat exc...

Page 83: ...heat exchanger B Install new plate type heat exchanger with new gaskets and reconnect the hydraulic assembly in reverse order B Check all connections used during maintenance for leaks 14 1 4 Checking the electrodes B Remove electrode set Æ 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 F...

Page 84: ...leaning is required For cleaning the heat exchanger Bosch offers the service accessory kit which includes main heat exchanger gaskets the heat exchanger brush and heat exchanger cleaning blade part 7719001998 B Remove the condensate trap steps 1 and 2 and place a suitable container underneath Fig 86 Removing the condensate trap DANGER Fire danger B Only operate the burner while installed in a boil...

Page 85: ...ger with the cleaning brush B Remove burner Æ Chapter 14 1 5 Burner servicing B Rinse the heat exchanger with water from the top Fig 89 Rinsing the heat exchanger B Clean the condensate tray with reversed brush Fig 90 Cleaning the condensate tray B Rinse the heat exchanger with water from the top B Clean the condensate trap connection B Close the inspection opening again using a new gasket and tig...

Page 86: ...ndensate hose and clean if necessary B Fill the condensate trap with approx 1 cup 1 4 l of water and reinstall it 14 1 8 Checking the mixer diaphragm B Open the mixer unit B Carefully remove the diaphragm from the fan air intake and check for contamination and cracks Fig 92 Opening the mixer unit B Insert the diaphragm into the fan connector Ensure the diaphragm is oriented properly B Close the mi...

Page 87: ... flush and refill with fresh water to prevent system damage or leaks B If the fill water does not meet the requirements of page 35 treat the water to bring it within the permissible range B If antifreeze is being used in the system check the frost protection properties to ensure the site specific requirements are met 14 1 12 Inspecting electrical wiring B Check electrical wiring for mechanical dam...

Page 88: ...e Æ page 78 inches W C mbar 5 Gas air ratio at min max nominal output Æ page 76 min max 6 Gas and water side leak test Æ page 51 7 Inspect electrodes Æ page 83 8 Inspect heat exchanger block Æ page 84 9 Check burner Æ page 84 10 Inspect diaphragm in mixer unit Æ page 86 11 Clean condensate trap Æ page 86 12 With the system depressurized check the expansion vessel pre charge pressure vs the static ...

Page 89: ...n 3 seconds Save function The display shows the supply temperature in alter nation with The appliance works for 15 minutes at the minimum nominal output Æ service function 2 F The display shows the supply temperature in alter nation with The appliance works with the set maximum output in heating mode Æ service function 1 A The display shows the supply temperature in alter nation with The appliance...

Page 90: ...cordance with the commissioning report Æ page 97 DANGER Explosion B Close the gas cock prior to working on the gas train B Check for gas leaks after carrying out work on the gas train DANGER Risk of flue gas poisoning B Check for leaks after carrying out work on the venting system DANGER Risk of electric shock B Always disconnect the appliance from the mains power before performing any work Discon...

Page 91: ... default setting Æ service function 8 E C6 Fan not running B Check fan leads and fan replace if defective CC Outdoor temperature sensor not recog nized B Check outdoor temperature sensor and leads for interrup tions replace if defective B Verify the outdoor temperature sensor is connected to termi nals A and F d3 Temperature high limit defective External guard has tripped Temperature limiter locke...

Page 92: ... GFA Safety time expired B Check that ground lead is properly connected replace if defective B Check that gas cock is open B Check inlet gas pressure correct if needed B Check power supply B Check electrodes for visual damage replace if defective B Check flue gas system clean or repair if defective B Check gas air ratio correct if out of range B Check gas valve replace if defective B In room air o...

Page 93: ...Check flue gas system clean or repair if needed Fd Reset button pressed by mistake B Press reset button again B Check cable harness to safety high limit and gas cock for ground connection Temperature gradient limiter Temperature rise too fast B Fully open service shut off valves B Check electrical connection between heating zone pump and Heatronic B Check pump plug connection per installation inst...

Page 94: ...ly B Check electrodes for visual damage replace if defective B Check flue gas system clean or repair if defective B Check gas air ratio replace gas valve if defective B Check gas valve replace if defective B Check burner replace if required DHW has unpleasant odor or has a dark color B Perform thermal disinfection of the DHW circuit B Replace sacrificial anode in the tank if installed B Consult lo...

Page 95: ...10 781 59 15 642 68 20 528 77 25 436 Tab 39 Resistance table outdoor temperature sensor Temperature F C Testing tolerance 10 Resistance Ω 32 0 33 555 50 10 21 232 68 20 13 779 86 30 9 128 104 40 6 205 122 50 4 298 140 60 3 025 158 70 2 176 176 80 1 589 194 90 1 177 212 100 886 Tab 40 Resistance table supply temperature limiter Temperature F C Testing tolerance 10 Resistance Ω 68 20 14 772 77 25 11...

Page 96: ...6 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 8 714 432 503 0 ZBR35 3A LPG 8 714 432 508 0 ZBR42 3A NG 8 714 432 504 0 ZBR42 3A LPG 8 714 432 509 0 ZWB28 3A NG 8 714 432 520 0 ZWB28 3A LPG 8 714 432 521 0 ZWB42 3A NG 8 714 432 500 0 ZWB42 3A LPG 8 714 432 505 0 Tab 42 Code plugs for all appliances ...

Page 97: ...er 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 max nominal output C...

Page 98: ... carried out 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 Th...

Page 99: ...ZWB28 3A ZWB42 3A Spare parts list Group 1 Sheet metal Æ page 100 Group 2 Burner Heat exchanger Æ page 102 Group 3 Gas valve Æ page 104 Group 4 Pipes combi boiler ZWB 3A Æ page 106 Group 5 Pipes heating boiler ZBR 3A Æ page 108 Group 6 Control box Æ page 110 Group 7 Hydraulic block combi boiler ZWB 3A Æ page 112 Group 8 Accessories for service installation Æ page 114 Tab 43 Spare part groups Green...

Page 100: ...100 Spare parts Copyright optional information 6 720 643 068 2011 06 Fig 93 Group 1 Sheet metal Greenstar 22 5 6 8 7 16 17 18 19 12 3 1 3 1 2 4 20 21 12 9 23 23 6 720 641 933 102 1o ...

Page 101: ...0 103 045 0 8 Brass adapter 8 710 103 209 0 9 Flue connection 8 710 735 296 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 US...

Page 102: ...Spare parts Copyright optional information 6 720 643 068 2011 06 Fig 94 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 2o ...

Page 103: ...8 487 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...

Page 104: ...104 Spare parts Copyright optional information 6 720 643 068 2011 06 Fig 95 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 105: ...as 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 m...

Page 106: ...ht optional information 6 720 643 068 2011 06 Fig 96 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 107: ...54 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 ...

Page 108: ...pyright optional information 6 720 643 068 2011 06 Fig 97 Group 5 Pipes heating boiler ZBR 3A Greenstar 1 2 6 13 9 9 26 12 9 9 11 12 7 5 8 3 23 24 4 9 11 15 21 9 20 22 9 19 18 28 29 30 25 16 10 14 17 6 720 641 933 106 1o ...

Page 109: ... 716 771 169 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 8 718 226 180 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...

Page 110: ...110 Spare parts Copyright optional information 6 720 643 068 2011 06 Fig 98 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 2O 8 8 8 8 8 ...

Page 111: ...wer cord USA 8 718 660 838 0 17 Cable harness ZWB combi boiler 8 718 226 066 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 7...

Page 112: ...Group 7 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 12 29 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 1o ...

Page 113: ...1 O ring 23x4 10x 8 716 771 353 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 8 718 226 180 0 29 O ring 13 87x3 53 10x 8 716 771 155 0 30 Safety clip inlet a...

Page 114: ...SAK3 Heat exchanger service accessory kit main heat exchanger gaskets heat exchanger brush heat exchanger cleaning blade 7 719 001 998 Brush set WB5 7 719 002 502 Cleaning blade WB5 7 719 002 503 Grease HFT1V5 8 709 918 010 0 Grease Unisilkon L641 8 709 918 413 0 Heat conducting paste 8 719 918 658 0 Tab 51 Group 8 Accessories for service installation Greenstar ...

Page 115: ... composition 32 Condensate trap 86 Connecting 3 way valve ZBR only 56 DHW tank 53 Supply temperature sensor 54 Tank primary pump ZBR only 56 Corrosion inhibitors 36 D Details about the appliance Proper use 8 Scope of delivery 6 Technical specifications ZBR16 3A 20 ZBR28 3A 22 ZBR35 3A 24 ZBR42 3A 26 ZWB28 3A 28 ZWB42 3A 30 Type overview 8 DHW circulation 35 Dimensions 11 Disposal 80 E ECO button 6...

Page 116: ... Higher than 2000 feet 610 m above sea level 76 Installation location requirements 38 Surface temperature 38 K Key pad lock 63 L Liquified propane gas 75 Low water cut off 42 LPG 36 75 M Mains fuse 16 18 52 Maintenance and inspection log book 88 Making the electrical connections 52 Measuring CO content of flue gas 79 Minimum clearances 11 Mounting the appliance 41 N Natural gas 20 22 24 26 28 30 7...

Page 117: ...on faults service function 7 A 71 Last fault saved service function 6 A 71 82 Maximum heating output service function 1 A 67 Maximum supply temperature service function 2 b 68 Metric or US customary units service function 0 E 73 Minimum heating DHW output service function 3 d 69 Operating mode service function 2 F 68 Permanent ignition service function 8 F 73 Pump control mode for heating operatio...

Page 118: ...2 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 63 Turning the space heating ON 60 Type of gas 8 Type overview 8 Z ZBR 3A 12 ZWB 3A 14 ...

Page 119: ...Index 119 6 720 643 068 2011 06 Copyright optional information ...

Page 120: ...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 ...

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