Bosch ZSB 30-2 A Installation And Servicing Instructions Download Page 2

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Contents

6 720 644 143 (2010/09)

Contents

Key to symbols and safety instructions . . . . . . . 5

1.1

Explanation of symbols . . . . . . . . . . . . . . 5

1.2

Safety instructions . . . . . . . . . . . . . . . . . . 5

Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . 6

Product details . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1

Intended use . . . . . . . . . . . . . . . . . . . . . . 7

3.2

Explanation of model code . . . . . . . . . . . 7

3.3

Gas type . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.4

Type plate . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5

Description of appliance . . . . . . . . . . . . . 8

3.6

Accessories . . . . . . . . . . . . . . . . . . . . . . . 8

3.7

Dimensions and minimum clearances . . . 9

3.8

Appliance layout . . . . . . . . . . . . . . . . . . 10

3.9

Electrical wiring diagram . . . . . . . . . . . . 12

3.10

Specification ZSB 30-2 ... . . . . . . . . . . . 16

3.11

Specification ZWB 37-2 ... . . . . . . . . . . . 17

3.12

Condensate composition . . . . . . . . . . . . 18

Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.1

Water system and pipe work . . . . . . . . . 20

5.2

Condensate pipe work . . . . . . . . . . . . . 22

5.2.1

Internal connections . . . . . . . . . . . . . . . 22

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.1

Important notes . . . . . . . . . . . . . . . . . . . 24

6.2

Checking the size of the expansion
vessel . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.3

Siting the appliance . . . . . . . . . . . . . . . . 25

6.4

Pre-installing pipes . . . . . . . . . . . . . . . . 26

6.5

Fitting the appliance . . . . . . . . . . . . . . . 28

6.6

Checking the connections . . . . . . . . . . . 32

Electrical connections . . . . . . . . . . . . . . . . . . . . 33

7.1

General information . . . . . . . . . . . . . . . . 33

7.2

Connecting accessories . . . . . . . . . . . . . 33

7.2.1

Connecting the heating controller or
remote control units . . . . . . . . . . . . . . . 34

7.2.2

Connecting the DHW cylinder . . . . . . . . 34

7.2.3

Connecting temperature limiter TB 1
from the flow of an underfloor
heating system . . . . . . . . . . . . . . . . . . . 34

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.1

Before commissioning . . . . . . . . . . . . . 36

8.2

Switching the appliance on/off . . . . . . 36

8.3

Starting the central heating . . . . . . . . . 37

8.4

Setting the heating control unit . . . . . . 37

8.5

After commissioning . . . . . . . . . . . . . . . 37

8.6

Appliances with hot water cylinder:
setting the hot water temperature . . . . 38

8.7

ZWB appliances - setting hot water
temperature . . . . . . . . . . . . . . . . . . . . . 39

8.8

Summer mode (central heating off,
DHW only) . . . . . . . . . . . . . . . . . . . . . . . 39

8.9

Frost protection . . . . . . . . . . . . . . . . . . 39

8.10

Holiday mode . . . . . . . . . . . . . . . . . . . . 40

8.11

Fault mode . . . . . . . . . . . . . . . . . . . . . . 40

Thermal disinfection on appliances

with hot water cylinder . . . . . . . . . . . . . . . . . 41

10 Pump anti-seizing function . . . . . . . . . . . . . . . . 42

11 Heatronic settings . . . . . . . . . . . . . . . . . . . . . . . 43

11.1

General information . . . . . . . . . . . . . . . 43

11.2

Overview of service functions . . . . . . . 44

11.2.1 Service level 1 . . . . . . . . . . . . . . . . . . . 44
11.2.2 Service level 2 . . . . . . . . . . . . . . . . . . . 44
11.3

Description of service functions . . . . . 45

11.3.1 Service level 1 . . . . . . . . . . . . . . . . . . . 45
11.3.2 Service level 2 . . . . . . . . . . . . . . . . . . . 49

12 Converting the appliance to different

gas types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

12.1

Gas-type conversion . . . . . . . . . . . . . . . 50

12.2

Setting the gas-air ratio (CO

or O

) . . 50

12.3

Checking the gas supply pressure . . . . 52

13 Flue gas testing . . . . . . . . . . . . . . . . . . . . . . . . . 53

13.1

Central heating boost button . . . . . . . . 53

13.2

Checking flue system for leaks . . . . . . . 53

13.3

Measuring CO content of flue gas . . . . 53

14 Environmental protection . . . . . . . . . . . . . . . . . 54

Summary of Contents for ZSB 30-2 A

Page 1: ...Installation and servicing instructions for contractors Hydronic Gas Condensing Boiler Condens 5000 W 6 720 613 085 00 1O ZSB 30 2 A ZWB 37 2 A 6 720 644 143 2010 09 NZ AU ...

Page 2: ...g the DHW cylinder 34 7 2 3 Connecting temperature limiter TB 1 from the flow of an underfloor heating system 34 8 Commissioning 35 8 1 Before commissioning 36 8 2 Switching the appliance on off 36 8 3 Starting the central heating 37 8 4 Setting the heating control unit 37 8 5 After commissioning 37 8 6 Appliances with hot water cylinder setting the hot water temperature 38 8 7 ZWB appliances sett...

Page 3: ...e expansion vessel see also page 25 62 15 2 10 Setting the heating system pressure 63 15 2 11 Checking electrical wiring 63 16 Displays 64 17 Fault mode 66 17 1 Troubleshooting 66 17 2 Faults that are shown on the display 67 17 3 Faults that are not shown on the display 70 17 4 Sensor values 71 17 4 1 Outside temperature sensor for weather compensated controllers accessory 71 17 4 2 Flow and DHW s...

Page 4: ...4 Contents 6 720 644 143 2010 09 ...

Page 5: ...nd doors B Inform your heating contractor Explosive and easily flammable materials Never use or store easily flammable materials paper thinners paints etc near the appliance Combustion air ambient air To prevent corrosion keep the supply of combustion ambient air free of corrosive substances e g halogenated hydrocarbons that contain chlorine or fluorine compounds Thermal disinfection B Risk of sca...

Page 6: ...ppliances for ZSB appliances without cold and DHW water connections 5 Filling loop with key ZWB 6 Adaptors for ZWB appliances for appliances ZSB without adaptors for cold cold and DHW water connections 7 Lower cover 8 Pressure relief valve hose heating circuit 9 Fixing kit 10 Set of printed documents for the appliance 6 720 644 143 01 1O 1 2 8 9 10 3 4 6 7 5 ...

Page 7: ...of model code Z Central heating appliance S Cylinder connection W DHW heating B Condensing boiler technology 30 Output up to 30 kW 37 DHW output up to 37 kW 2 Version A Fan assisted appliance without draught hood 23 Natural gas H Note Appliances can be converted to LPG 31 LPG S2414 Special number for Australia New Zealand 3 3 Gas type The code number indicates the gas family according to AS 4552 3...

Page 8: ...ble for underfloor heating Connection option for concentric pipe for flue gas combustion air Ø 80 125 mm Ø 60 100 mm Variable speed fan Premix burner Temperature sensor and temperature control for central heating Temperature sensor in flow Safety temperature limiter in 24 V electrical circuit Pressure relief valve pressure gauge expansion vessel Optional for DHW cylinder temperature sensor NTC Flu...

Page 9: ...Fig 2 1 Pre plumbing jig 2 Casing 3 Fascia A Additional 30 mm above elbow B Using 100 mm flue kit 1112 mm 120 mm flue kit 1152 mm C 20 mm to reversible door 600 mm front clearance for service 440 min 5 0 6 7 2 360 85 3 125 80 min 5 0 8 7 6 720 644 143 02 2J 340 5 5 1 0 200 A B C ...

Page 10: ...etails 6 720 644 143 2010 09 3 8 Appliance layout Fig 3 6 720 644 143 03 1O 30 31 32 33 34 35 39 40 38 37 36 41 42 43 44 45 46 47 48 49 12 10 9 8 7 1 2 3 4 5 6 11 29 28 27 26 25 24 23 22 21 20 17 18 19 16 15 14 13 ...

Page 11: ...mperature sensor 20 Adjustable gas throttle 21 Test point for control pressure 22 Flue gas temperature limiter 23 Fan 24 Flow temperature sensor 25 Expansion vessel 26 Mixer unit 27 Bracket 28 Removable cover 29 Combustion air inlet 30 Flue pipe 31 Sight glass 32 Set of electrodes 33 Heat exchanger 34 Temperature limiter for heat exchanger 35 Access port for cleaning heat exchanger 36 Condensate t...

Page 12: ...12 Product details 6 720 644 143 2010 09 3 9 Electrical wiring diagram Fig 4 ZSB 30 2 ST1 k k B B 2 4 F 1 A 14 15 16 17 12 13 11 18 22 21 10 1 2 3 4 5 6 7 8 9 19 20 ...

Page 13: ...d 5 Safety solenoid 6 Gas valve 7 Fan 8 Flame sense eletrode 9 Spark electrodes 10 Flow NTC 11 Heat exchanger overheat stat 12 Flue overheat stat 13 Earth 14 Mains supply 15 Pump 16 Pump control 17 Diverter valve optional 18 Pump supply 19 DHW temperature control 20 Fluse slow T 0 5 A 21 Fluse slow T 1 6 A 21 Code plug ...

Page 14: ...14 Product details 6 720 644 143 2010 09 Fig 5 ZWB 37 2 Ls Ns r t u e v i B B 2 4 F 1 A 14 15 16 17 12 13 11 18 23 24 22 25 21 10 1 2 3 4 5 6 7 8 9 19 20 ...

Page 15: ...6 Gas valve 7 Fan 8 Flame sense eletrode 9 Spark electrodes 10 Flow NTC 11 Heat exchanger overheat stat 12 Flue overheat stat 13 Earth 14 Mains supply 15 DHW sensor 16 Pump 17 Pump control 18 Diverter valve 19 Flow turbine 20 Pump supply 21 DHW temperature control 22 External frost stat optional 23 Fluse slow T 0 5 A 24 Fluse slow T 1 6 A 25 Code plug ...

Page 16: ...ues for calculating cross section to EN 13384 Flue gas mass flow rate max min rated g s 13 6 3 7 12 8 5 2 12 8 5 2 Flue gas temperature 80 60 C max min rated C 76 58 76 58 76 58 Flue gas temperature 40 30 C max min rated C 55 33 55 33 55 33 Residual pump head Pa 80 80 80 CO2 at max rated output 9 6 10 8 12 2 CO2 min rated output 9 0 10 2 11 5 Flue gas rating group to G 636 G 635 G61 G62 G61 G62 G6...

Page 17: ...sible gas supply pressure NG kPa 1 1 3 0 LPG kPa 2 75 2 75 Expansion vessel Pre charge pressure kPa 75 75 75 Total capacity l 10 10 10 DHW Max DHW flow rate l min 13 0 13 0 13 0 Outlet temperature range C 40 60 40 60 40 60 Max cold water inlet temperature C 60 60 60 Max permissible water supply pressure kPa 1000 1000 1000 Min inlet pressure kPa 20 20 20 Specific flow rate acc to EN 625 D l min 16 ...

Page 18: ... Approx 90 Max permissible operating pressure PMS heating kPa 300 300 300 Permissible ambient temperature C 0 50 0 50 0 50 Nominal capacity of appliance heating l 3 75 3 75 3 75 Weight excluding packaging kg 48 5 48 5 48 5 Dimensions W x H x D mm 440 x 760 x 360 440 x 760 x 360 440 x 760 x 360 ZWB 37 2 Unit Natural gas Propane Butane Table 6 Material Value mg l Ammonium 1 2 Lead 0 01 Cadmium 0 001...

Page 19: ...r hot water supply and or central heating AS NZS 3000 Electrical Installations AS1697 Installation and maintenance of steel pipe systems for gas AS 4032 Water supply valves for the control of hot water supply temperatures AS 3498 Authorization requirements for plumbing products water heaters and hot water storage tanks AS 1910 Water supply float control valves for use in hot and cold water AS 3500...

Page 20: ...e fitted with lock shield valves and left open A drain point is required at the lowest part of the system An air vent is required at all the high points in the system Sealed primary system The CH sealed system must be filled using an approved filling loop or comply with figure 6 for system fill Do not use galvanised pipes or radiators System fill Fig 6 A System fill AA Auto air vent B System make ...

Page 21: ...itary fixtures used primarily for the purposes of personal hygiene Fig 8 S plan layout Fig 9 Y plan layout with external diverter valve Fig 10 System layout with optional internal diverter valve not supplied with boiler Legend to Fig 8 to Fig 10 1 Diverter valve 2 Radiater valve flow 3 Lock shield valve return 4 Bypass 5 Boiler flow 6 Cylindr return 7 Heating return NOTE The boiler is fitted with ...

Page 22: ...efore the self sealing device The self sealing device can be used on a gradient as long as it preceded by a vertically mounted tundish Fig 11 Disposal to soil vent stack vertical position Fig 12 Disposal to soil vent stack on gradient NOTE B Where a new or replacement boiler is being installed and freezing conditions are possible access to an internal drain gravity discharge point should be one of...

Page 23: ...ossible an internal kitchen or bathroom waste pipe can be used Fig 13 Disposal to a waste pipe A washing machine waste pipe or bifurcated pipe etc can also be used Fig 14 Bifurcated pipe disposal 20mm 1 40mm Ø 40 50mm Ø 4 2 3 6720646195 16 1Wo 20mm 1 40 50mm Ø 4 2 5 3 6720646195 17 1Wo ...

Page 24: ... in problems deposits in the heat exchanger We therefore advise against using them Water circulation noises To prevent water circulation noises B Fit an overflow valve or with two pipe heating systems a 3 way valve to the radiator furthest from the boiler DANGER Risk of explosion B Isolate the gas supply before working on gas carrying components B Check for leaks before working on gas carrying com...

Page 25: ...routing B Do not install the appliance outside If the appliance is fitted into a cupboard or a compartment is built around the compliance after installation then the compartment must be built from or lined with a non combustible material Combustion air In order to prevent corrosion the combustion air must not contain any corrosive substances Substances classed as corrosion promoting include haloge...

Page 26: ...ng plate with mounting rail to the wall using the screws provided do not tighten the two lower screws B Hook in pre plumbing jig and tighten screws Gas and water connections Fig 16 Pipe connections Additional adaptors are provided in the fittings kit for easy connection 6 720 615 662 06 1O A B C D It is very important to ensure that pipes are not secured in such a way that the fittings come under ...

Page 27: ...ZWB 8 Gas connection 9 ZWB DHW connection ZSB Cylinder flow 10 Heating flow 11 Condensate connector B The pipe for gas supply must be larger than 18 mm in diameter B For filling and draining the system fit drain fill valves at the lowest point of the system Pipework behind the appliance The pipes can be routed behind the appliance in the guide on the mounting plate Æ Fig 18 Fig 18 Pipework 1 Heati...

Page 28: ...ealing washers on the pre plumbing jig connections B Pull lever on pressure relief valve connection forwards and push down as far as it will go Æ Fig 12 Fig 20 Securing the appliance B Hook appliance into the mounting rail at the top and position it at the bottom on the prepared pipework connections B Tighten the union nuts on the pipe connections NOTE Dirt and corrosion in the pipework can damage...

Page 29: ... Push the condensate hose into the adaptor on the pre plumbing jig B Create the drain B Do not use copper pipe Fig 22 WARNING Risk of scalding Hot water or steam can lead to scalding B Stay clear of the pressure relief outlet during operation of the appliance 1 2 6 720 644 143 08 1O CAUTION B Do not modify or seal off drain pipes B Hoses must always slope downwards NOTE B Ensure there are no block...

Page 30: ...e filling loop B Fit two screws and washers 8 to each of the two connections 9 and 1 Do not try to turn the brass hexagon connectors Fig 23 Filling the heating circuit ZWB B Ensure that all system and boiler drain points are closed B Tigthen screw 1 on the filling loop as far as it will go Æ Fig 24 B Open the cold water supply tap 3 and heating return tap 2 B Insert key 4 in the filling direction ...

Page 31: ...he appliance Fig 26 Connecting the flue pipe B Push on the flue gas accessories and secure with the screws supplied Fig 27 Fitting the flue kit 1 Flue adaptor 2 Screws B Check the flue gas path for tightness Æ chapter 13 2 6 720 644 143 14 1O 6 720 644 143 18 1O For more precise details of connecting the flue refer to the installation instructions for the flue routing manual 6 720 615 886 22 1O 1 ...

Page 32: ...ling points for leaks testing pressure max 2 5 bar 250 kPA at the pressure gauge B Open the cold water valve on the appliance and a turn on a hot water tap until water runs out Max pressure 10 bar 1000 kPA Gas supply pipe B Close the gas valve to protect the gas valve from pressure damage B Check sealing points for leaks B Release the pressure on the gas supply pipe ...

Page 33: ...he appliance is protected by three fuses They are located on the circuit board Æ Fig 4 page 12 7 2 Connecting accessories Opening the Heatronic unit B Slide the clip down and pivot the Heatronic Fig 28 B Remove screws unhook cable and remove cover Fig 29 DANGER Risk of electric shock B Before carrying out work on electrical components disconnect the power supply 230 V AC fuse circuit breaker and s...

Page 34: ...n instructions 7 2 2 Connecting the DHW cylinder Cylinders with Bosch cylinder temperature sensors are connected directly to the appliance PCB B Snap off the plastic tongue B Insert the cylinder temperature sensor lead B Plug the connector into the PCB Fig 31 7 2 3 Connecting temperature limiter TB 1 from the flow of an underfloor heating system Only for underfloor heating systems connected direct...

Page 35: ...tic air vent valve 8 Display 9 Pressure gauge 10 reset button 11 eco button 12 Holiday button 13 Drain from pressure relief valve heating circuit 14 Gas tap 15 CH return isolator 16 Filling loop ZWB 17 Cold water tap ZWB cylinder return ZSB 18 DHW connection ZWB cylinder flow ZSB 19 CH flow isolator 20 Condensate hose 6 720 644 143 17 1O 18 19 reset 10 11 12 eco 15 16 17 14 4 3 2 5 1 6 8 7 9 20 13...

Page 36: ...ndensate pipe has been connected to the adaptor B Briefly open the pressure relief valve to test its operation 8 2 Switching the appliance on off Switching on B Switch appliance on at the main switch The display shows the heating water flow temperature Fig 34 B Open automatic air vent valve 7 and close again after venting Æ page 35 Switching off the appliance B Switch appliance off at the main swi...

Page 37: ...ate starts running out B Record the settings in the commissioning report Æ page 74 B Affix the Heatronic settings label to the casing in a clearly visible position Æ page 43 Setting on flow tem perature controller Flow temperature Sample application 1 Approx 35 C 2 Approx 43 C 3 Approx 50 C Underfloor heating system 4 Approx 60 C 5 Approx 67 C 6 Approx 75 C Radiator heating system max Approx 90 C ...

Page 38: ...is heated to the set temperature first Then the appliance switches to central heating mode Economy mode Eco button lit In Economy mode the appliance switches between central heating mode and hot water mode every ten minutes WARNING Danger of scalding B In normal operation do not set the temperature higher than 60 C To prevent bacterial contamination such as legionella we recommend setting the DHW ...

Page 39: ...mmer mode central heating off DHW only B Note position of CH flow temperature control B Turn CH flow temperature control anti clockwise as far as the stop The heating circuit pump and consequently central heating are switched OFF However the DHW supply as well as the power supply to the heating programmer and timer remain live Fig 39 Additional instructions are contained in the operating instructi...

Page 40: ...l components are monitored by the Heatronic system If a fault occurs during operation a warning tone sounds The display indicates a fault and the reset button may also flash If the reset button flashes B Press and hold the reset button until the display shows The appliance will start up again and the flow temperature will be displayed If the reset button does not flash B Switch the appliance off a...

Page 41: ... far as the stop approx 70 C Fig 42 B Wait until the water reaches the maximum temperature B Draw off water in turn from the nearest to the furthest hot water point until hot water has been running out at a temperature of 70 C for 3 minutes B Reset DHW temperature control circulation pump and heating programmer to their standard settings With some heating controllers thermal disinfection can be pr...

Page 42: ...seizing function Every time the pump is switched off a timer starts to briefly switch on the heating circuit pump and the 3 way valve at regular intervals This function prevents the heating circuit pump and the 3 way valve seizing up during long periods of inactivity ...

Page 43: ...y shows the setting for the selected service function Making a setting B Repeatedly press the holiday button or eco button until the required service function value is displayed B Enter the value on the Heatronic settings label supplied and affix in a clearly visible position Fig 44 Saving a setting B Press and hold chimney sweep button until the display shows Exiting the service function without ...

Page 44: ...e time 47 3 C Anti cycle flow temperature differential 47 3 E Pre heat cycle time hot water ZWB only 47 3 F Burner off after DHW demand hot water ZWB only 47 4 F Syphon fill programme 48 5 A Reset service reminder 48 5 b Fan run on time 48 6 A Last fault 48 6 d Actual flow rate turbine ZWB only 48 6 E Programmer input 48 7 A Fault indicator LED on off 48 Table 15 Service functions level 1 Service ...

Page 45: ... is maximum rated output display shows U0 B Select service function 1 b B Take the DHW output in kW and the associated parameter from the setting tables Æ page 72 to 73 B Enter the setting code B Measure the gas flow rate and compare with the figures for the setting shown If they do not match change the setting B Save the setting B Enter the selected DHW output on the Heatronic settings label supp...

Page 46: ...de 0 The BUS controller controls the central heating circuit pump Pump control mode 1 The pump is controlled by the central heating flow temperature control Pump control mode 2 factory setting For heating systems with room thermostat The central heating flow temperature control controls only the gas the pump is not affected The room thermostat controls both the gas and the pump The pump and fan ha...

Page 47: ...ory setting is 0 Service function 3 b Anti cycle time The anti cycle time is factory set to 3 minutes The shortest possible anti cycle time is 1 minute recommended for single pipe and hot air heating systems If the setting 0 is entered the anti cycle time is disabled B Enter the anti cycle time on the commissioning record enclosed with the appliance Service function 3 C Anti cycle flow temperature...

Page 48: ... hours has run out After the service inspection store 0 for resetting the service interval Service function 5 b Fan over run time B Set the time of fan over run after a boiler demand Service function 6 A Last fault The last fault can also be recalled for servicing purposes when the appliance is functioning correctly Service function 6 d Current turbine flow rate ZWB only The actual flow rate of th...

Page 49: ...nism Service function 9 A Operation mode permanent Set a fixed operation mode even when boiler has been switched off Service function 9 b Actual fan speed The current fan speed is displayed in Hertz Hz Service function 9 C Actual heating output This service function displays the current appliance heating output in percent Service function 9 d Start fan speed The actual start fan speed between 45 a...

Page 50: ... gas type conversion sets are available 12 2 Setting the gas air ratio CO2 or O2 B Switch appliance off at the main switch B Remove the outer casing Æ page 28 B Switch appliance on at the main switch B Remove sealing plug from flue gas testing point B Insert a flue gas probe approx 135 mm into the testing point socket and seal the testing point Fig 48 B Press and hold the cnetral heating boost but...

Page 51: ...crew and set CO2 or O2 level for minimum rated heat output Fig 51 B Re check settings at maximum and minimum rated output and re adjust if necessary B Repeatedly press the central heating boost button until the light goes out The display will show the CH flow temperature again B Record the CO2 or O2 levels in the commissioning log B Remove flue gas probe from flue gas testing point and refit seali...

Page 52: ...th maximum rated output B Check required gas supply pressure according to table B Repeatedly press the central heating boost button until the light goes out The display will show the CH flow temperature again B Switch off the appliance turn off the gas cock remove the pressure gauge and refit the plug B Refit the outer casing Gas type Permissible pressure range at max rated output mbar kPa NG 11 3...

Page 53: ... levels B Refit plug 13 3 Measuring CO content of flue gas Use a multiport flue gas probe for the measurements B Remove sealing plug from flue gas testing point 1 Æ Fig 54 B Insert a flue gas probe as far as it will go into the testing point socket and seal the testing point B Press the central heating boost button to select maximum rated output B Measure the CO levels B Repeatedly press the centr...

Page 54: ...he best possible technology and materials for protecting the environment taking account of economic considerations Packaging Where packaging is concerned we participate in country specific recycling processes that ensure optimum recycling All packaging materials are environmentally compatible and can be recycled Used appliances Old appliances contain materials that should be recycled The relevant ...

Page 55: ...ue when ordering spare parts B Always renew seals and O rings removed during servicing or repair work After inspection servicing B Retighten all loosened threaded fittings B Recommission the appliance Æ page 35 B Check all connections for leaks B Check the gas air ratio and adjust if necessary Æ page 50 DANGER Risk of explosion B Turn off gas valve before working on gas carrying components B Check...

Page 56: ... min max and adjust if necessary Æ page 50 min max 6 Check for leaks on the gas and water connections Æ page 32 7 Check heat exchanger Æ page 59 8 Check burner Æ page 61 9 Check electrodes Æ page 57 10 Check diaphragm in mixer unit Æ page 62 11 Clean condensate trap Æ page 62 12 Check the expansion vessel pre charge pressure matches the static head of the heating system bar kPa 13 Check the heatin...

Page 57: ...Checking electrodes B Remove electrode set Æ page 10 and gasket Check electrodes for dirt clean or replace if required B Refit electrode set and check for tightness Fig 56 Fig 55 Fig 56 15 2 3 Strainer in cold water pipe ZWB B Undo cold water pipe and check filter for dirt Fig 57 For an overview of faults see page 67 6 720 613 354 01 2O 3 1 Nm 1 6 20 613 3 4 02 2O Gas Gaz 6 720 612 659 48 1R 1 2 3...

Page 58: ...emove plate type heat exchanger and replace or B Descale only with a product that has been approved for stainless steel 1 4401 Remove the plate heat exchanger B Disconnect electrical connectors B Remove hose from pressure relief valve Fig 58 B Undo remove pipe unions Fig 59 B Undo the pressure gauge fastener Fig 60 6 720 644 143 20 1O 6 720 644 143 21 1O 6 720 644 143 22 1O ...

Page 59: ...2 5 Heat exchanger For cleaning the heat exchanger use brush accessory no 1060 and cleaning blade accessory no 1061 B Check control pressure at maximum rated output at mixer unit Fig 63 If cleaning is required B Remove the heat exchanger access panel Æ page 10 and any panel behind if installed 6 720 644 143 23 1O 1 2 3 1 6 720 644 143 24 1O Appliance Control pressure Cleaning required ZSB 30 2 A 3...

Page 60: ... exchanger with the brush from top to bottom Fig 66 B Remove burner Æ chapter 15 2 6 Checking the burner and flush the heat exchanger with water from above Fig 67 B Clean the condensate tray with reversed brush and the siphon connection Fig 68 B Close the heat exchanger access panel using a new gasket and tighten the screws to approx 5 Nm 6 720 644 143 19 1O 1 2 6 720 612 563 15 1O 6 720 612 563 1...

Page 61: ...Fig 69 Fig 69 B Remove clips 3 nuts 4 and 5 and two screws 7 Æ Fig 69 Fig 70 B Remove burner cover 6 B Remove burner and clean its components Fig 71 B Refit burner possibly with a new gasket in reverse order B Adjust the gas air ratio Æ page 50 6 720 615 662 19 1O 2 2 1 6 720 615 662 20 1O 3 5 4 7 7 6 7 181 465 330 08 2R ...

Page 62: ...ger connection is clear Fig 73 B Remove and clean the condensate siphon sump B Check condensate hose and clean if necessary B Fill condensation trap with approx 1 4 l of water and refit 15 2 9 Checking the expansion vessel see also page 25 The expansion vessel should be checked annually B Depressurise the appliance B If necessary adjust charge pre charge pressure of expansion vessel to the static ...

Page 63: ...ting system for leaks 15 2 11 Checking electrical wiring B Check electrical wiring for physical damage and replace faulty leads NOTE Risk of damaging the appliance B Only top up the heating system when the appliance is cold Pressure gauge reading 1 bar 100 kPa Minimum system pressure when cold 1 2 bar 100 200 kPa Optimum system pressure 3 bar 300 kPa Maximum system pressure at highest heating wate...

Page 64: ...isplay Description Acknowledge by pressing any key except reset Acknowledge by pressing two keys simultaneously Acknowledge by pressing and holding for more than 3 seconds Save function The display alternately shows the flow temperature and The appliance operates for 15 minutes at the minimum rated output The display shows the flow temperature alternating with The appliance works with the set maxi...

Page 65: ...0 644 143 2010 09 Screed drying function of the weather compensated controller Æoperating instructions or building drying function Æservice function 7 E operational Special display Description Table 26 Special displays ...

Page 66: ... required and set service functions as per Heatronic settings label Æ Fig 37 page 38 DANGER Risk of explosion B Turn off gas valve before working on gas carrying components B Check for leaks before working on gas carrying components DANGER Risk of poisoning B Check for leaks before working on gas carrying components DANGER Risk of electric shock B Before carrying out work on electrical components ...

Page 67: ...tor check fan replace as necessary CC Outside temperature sensor not detected B Check outside temperature sensor and connecting lead for breaks B Correctly connect outside temperature sensor to terminals A and F d3 External temperature limiter faulty External limiter has tripped Temperature limiter locked out B Check temperature limiter and lead for breaks or short circuits and replace if required...

Page 68: ...lean or repair if required B Check gas air ratio correct if required B For natural gas Check external gas flow limiter replace if required B For open flue operation check air supply or ventilation apertures B Clean out condensation trap discharge pipe B Remove diaphragm from fan inlet connection and check for contamination or tears B Clean heat exchanger B Check gas valve replace if required B Plu...

Page 69: ...ed B Clean condensate trap B Check electrodes and lead replace if required B Check flue gas system clean or repair if required Fd Reset was pressed in error B Press reset again B Check cable harness to high limit safety cut out and gas valve for earth connection Display code Description Remedy Table 27 Faults shown on the display ...

Page 70: ...oor B Check gas type B Check gas supply pressure adjust if required B Check power supply B Check electrodes with lead replace if required B Check flue gas system clean or repair if required B Check gas air ratio replace gas valve if required B For natural gas Check external gas flow limiter replace if required B Check burner replace if required Set flow temperature e g of the FW 100 controller exc...

Page 71: ...2 088 12 1 811 8 1 562 4 1 342 0 1 149 4 984 8 842 10 781 15 642 20 528 25 436 Table 29 Temperature C Measuring tolerance 10 Resistance k Ω 20 14 772 25 11 981 30 9 786 35 8 047 40 6 653 45 5 523 50 4 608 55 3 856 60 3 243 65 2 744 70 2 332 75 1 990 80 1 704 85 1 464 90 1 262 95 1 093 100 950 Table 30 Appliance Number ZSB 30 2 A 23 8 714 431 018 0 ZSB 30 2 A 31 8 714 431 019 0 ZWB 37 2 A 23 8 714 ...

Page 72: ...8 76 22 0 90 6 40 79 23 0 94 7 42 82 24 0 98 8 43 85 25 0 102 9 45 88 26 0 107 0 47 91 27 0 111 1 49 94 28 0 115 2 51 97 29 0 119 3 52 U0 100 30 0 123 4 54 Table 32 Propane Butane Display Heat output kW Gas con sumption MJ m3 Heat output kW Gas con sumption MJ m3 43 11 0 45 9 12 5 52 2 46 12 0 50 0 13 6 56 8 49 13 0 54 1 14 8 61 5 52 14 0 58 1 15 9 66 1 55 15 0 62 2 17 0 70 7 58 16 0 66 3 18 2 75 ...

Page 73: ... 21 0 86 6 38 64 22 0 90 7 40 66 23 0 94 7 42 69 24 0 98 8 44 71 25 0 102 9 45 74 26 0 107 0 47 76 27 0 111 1 49 79 28 0 115 2 51 81 29 0 119 3 53 84 30 0 123 4 54 Table 34 Propane Butane Display Heat output kW Gas con sumption MJ m3 Heat output kW Gas con sumption MJ m3 45 13 9 57 9 15 8 65 8 45 14 0 58 3 15 9 66 3 47 15 0 62 4 17 0 70 9 50 16 0 66 4 18 2 75 5 52 17 0 70 5 19 3 80 1 55 18 0 74 6 ...

Page 74: ...Notes regarding underpressure or overpressure operation Gas setting and flue gas test Selected gas type Natural gas H Natural gas L Natural gas LL Propane Butane Gas supply pressure kPa Gas static supply pressure mbar Selected maximum rated output kW Selected minimum rated output kW Gas flow rate at maximum rated output ltr min Gas flow rate at minimum rated output ltr min Net calorific value HiB ...

Page 75: ...ied out on the gas and water sides Commissioning includes checking the settings a visual boiler tightness test and a function check of the boiler and control unit The system installer conducts a test of the heating system If in the course of commissioning any small installation faults in Bosch components are noticed Bosch is always willing to remedy these installation faults after release by the c...

Page 76: ... 9 Display of faults 40 66 disposal 54 E Eco button 38 39 Economy mode 38 39 Electrical connections 33 Checking electrical wiring 63 Connecting accessories 33 Heating controller remote control units 34 Temperature limiter 34 Electrical wiring DHW cylinder 34 Environmental protection 54 Expansion vessel 62 Checking the size 25 Explanation of model code 7 F Fault mode 40 66 Faults 67 Faults that are...

Page 77: ...unction 7 A 48 Output service function 1 A 45 Permanent ignition service function 8 F 49 Permanent operating mode service function 9 A 49 Pump characteristic map service function 1 C 45 Pump curve service function 1 d 46 Pump run on time heating service function 9 F 49 Pump switching type for heating mode service function 1 E 46 Reset inspection service function 5 A 48 Restoring appliance Heatroni...

Page 78: ...78 6 720 644 143 2010 09 Notes ...

Page 79: ... 79 6 720 644 143 2010 09 Notes ...

Page 80: ...Australia Robert Bosch Australia Pty Ltd 1555 Centre Rd Clayton VIC 3168 Phone 1300 30 70 37 Fax 1300 30 70 38 www bosch com au hotwater New Zealand Phone 0800 4 Bosch or 08 543 352 www bosch co nz ...

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