Bosch Greenstar 131 Operations Instructions

Installation and Service Instructions for ContractorsResidential Gas Condensing BoilerGreenstar6 720 806 992-00-1OZBR16-3A... | ZBR21-3A... | ZBR28-3A

10 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.7 Appliance layout heating boiler ZBR..-3AFig. 5 Appliance layout heating boil

Information about the appliance | 116 720 806 992 (2013/07)GreenstarKey to Fig. 5:[1] Heatronic boiler control[2] ON/OFF switch[3] Burner flame indica

12 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.8 Appliance layout combi boiler ZWB..-3AFig. 6 Appliance layout combi boiler Z

Information about the appliance | 136 720 806 992 (2013/07)GreenstarKey to Fig. 6:[1] Heatronic boiler control[2] ON/OFF switch[3] Burner flame indica

14 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.9 Electrical wiring heating boiler ZBR..-3AFig. 7 Electrical wiring diagram he

Information about the appliance | 156 720 806 992 (2013/07)GreenstarKey to Fig. 7:[1] Ignition transformer[2] Boiler high limit dial[3] 120 VAC connec

16 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.10 Electrical wiring combi boiler ZWB..-3AFig. 8 Electrical wiring diagram com

Information about the appliance | 176 720 806 992 (2013/07)GreenstarKey to Fig. 8:[1] Ignition transformer[2] Boiler high limit dial[3] 120 VAC connec

18 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.11 Technical data heating boiler ZBR16-3A...Input/Output Unit NG LPG (propane)Ma

Information about the appliance | 196 720 806 992 (2013/07)Greenstar3.12 Technical data heating boiler ZBR21-3A...Input/Output Unit NG LPG (propane)Ma

2 | ContentsGreenstar6 720 806 992 (2013/07)Contents1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . 31.1 Key to symbol

20 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.13 Technical data heating boiler ZBR28-3A...Input/Output Unit NG LPG (propane)Ma

Information about the appliance | 216 720 806 992 (2013/07)Greenstar3.14 Technical data heating boiler ZBR35-3A...Input/Output Unit NG LPG (propane)Ma

22 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.15 Technical data heating boiler ZBR42-3A...Input/Output at elevation 0 - 2000 f

Information about the appliance | 236 720 806 992 (2013/07)Greenstar3.16 Technical data combi boiler ZWB28-3A...Input/Output Unit NG LPG (propane)Max.

24 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.17 Technical data combi boiler ZWB35-3A...Input/Output Unit NG LPG (propane)Max.

Information about the appliance | 256 720 806 992 (2013/07)Greenstar3.18 Technical data combi boiler ZWB42-3A...Input/Output at elevation 0 - 2000 fee

26 | RegulationsGreenstar6 720 806 992 (2013/07)3.19 Condensate compositionThe condensate volume and ingredients may change with regionally and season

Regulations | 276 720 806 992 (2013/07)Greenstar4.3 Additional regulations for installation in Massachusetts(a) For all side wall horizontally vented

28 | InstallationGreenstar6 720 806 992 (2013/07)5 Installation5.1 Notes on installation and operationWhen installing and operating the heating system

Installation | 296 720 806 992 (2013/07)GreenstarThe following anti-freeze fluids and concentrations have been approved:Corrosion inhibitorsThe follow

Key to symbols and safety instructions | 36 720 806 992 (2013/07)Greenstar10.3 Description of the service functions . . . . . . . . . . . . . . . 53

30 | InstallationGreenstar6 720 806 992 (2013/07)5.3 ZBR..-3A appliances (heating boilers): Selecting an expansion vesselExternal expansion vessel▶ De

Installation | 316 720 806 992 (2013/07)Greenstar▶ Secure the hydraulics connection plate and the mounting bracket with the mounting kits supplied.Fig

32 | InstallationGreenstar6 720 806 992 (2013/07)5.6 Mounting the appliance▶ Remove packaging, observing all notes and symbols.▶ On the rating plate,

Installation | 336 720 806 992 (2013/07)Greenstar▶ Screw the LWCO as far as possible into LWCO adapter located in the boiler accessory kit. Follow the

34 | InstallationGreenstar6 720 806 992 (2013/07)In case of open venting:▶ Use basket on the air intake.In case of concentric venting system:Fig. 24

Installation | 356 720 806 992 (2013/07)GreenstarDirect vent installations (sealed combustion)For direct vent applications all applicable items below

36 | InstallationGreenstar6 720 806 992 (2013/07)Roof terminals Material Supplier Part numberØ 3" / Ø 5" (Ø 76/125 mm) concentric PVC IPEX S

Installation | 376 720 806 992 (2013/07)GreenstarFig. 27 Vent and combustion air pipe positionDirect vent (sealed combustion):[1] Forced Air Inlet[2

38 | InstallationGreenstar6 720 806 992 (2013/07)5.8.2 Approved examples of horizontal and vertical venting installationFig. 28 Horizontal venting s

Installation | 396 720 806 992 (2013/07)GreenstarFig. 32 Vertical venting system (sealed combustion)Fig. 33 Vertical venting system (room air only

4 | Key to symbols and safety instructionsGreenstar6 720 806 992 (2013/07)If you smell gas▶ Turn off the gas shut-off valve.▶ Open windows and doors▶

40 | InstallationGreenstar6 720 806 992 (2013/07)Fig. 35 Vertical venting system (sealed combustion)[1] Intake[2] ExhaustX Greater than 12 inches (3

Making the electrical connections | 416 720 806 992 (2013/07)GreenstarØ 3" / Ø 5" (Ø 80/125 mm) Concentric venting systemThe maximum concent

42 | Making the electrical connectionsGreenstar6 720 806 992 (2013/07)6.2 Low voltage electrical connections in the Heatronic boiler control6.2.1 Open

Making the electrical connections | 436 720 806 992 (2013/07)Greenstar6.2.4 Connecting additional accessories▶ For splash-proof (IP) strain relief, cu

44 | Making the electrical connectionsGreenstar6 720 806 992 (2013/07)Connecting Third party room thermostats or zone controlsA voltage free (dry cont

Making the electrical connections | 456 720 806 992 (2013/07)Greenstar6.3.3 DHW tank loading pump or 3-way valve with spring return (only heating boil

46 | Making the electrical connectionsGreenstar6 720 806 992 (2013/07)6.4 Connecting the LWCO device▶ Punch a hole (maximum diameter 3/16" (5 mm)

Commissioning | 476 720 806 992 (2013/07)Greenstar7 CommissioningFig. 55 Overview of the controls[1] Emissions test button[2] Service button[3] Burn

48 | CommissioningGreenstar6 720 806 992 (2013/07)7.2 Switching the appliance ON/OFFStartup▶ Switch the appliance ON using the ON/OFF switch.The displ

Commissioning | 496 720 806 992 (2013/07)Greenstar7.6 ZBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature▶ Set the DHW te

Scope of delivery | 56 720 806 992 (2013/07)Greenstar2 Scope of delivery2.1 ZBR - Residential boiler for space heating and loading of indirect fired D

50 | ZBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfectionGreenstar6 720 806 992 (2013/07)▶ Turn the boiler high limit dial count

Boiler circulator | 516 720 806 992 (2013/07)Greenstar9 Boiler circulator9.1 Pump anti-seize protectionThe appliance will briefly run the pump at leas

52 | Heatronic boiler control settingsGreenstar6 720 806 992 (2013/07)10 Heatronic boiler control settings10.1 Guideline to service functionsThe Heatr

Heatronic boiler control settings | 536 720 806 992 (2013/07)Greenstar10.2.2 Second service level (at first service level, service button lights up, p

54 | Heatronic boiler control settingsGreenstar6 720 806 992 (2013/07)Service function 2.A: Heating circuit pump lockout time (only heating boiler ZBR

Heatronic boiler control settings | 556 720 806 992 (2013/07)GreenstarService function 3.b: Set anti-cycle timeOnly if the automatic anti-cycle time i

56 | Heatronic boiler control settingsGreenstar6 720 806 992 (2013/07)Service function 4.F: Condensate trap filling sequenceThe trap filling sequence

Heatronic boiler control settings | 576 720 806 992 (2013/07)GreenstarService function 7.b: 3-way valve in center positionAfter the value 01 has been

58 | Heatronic boiler control settingsGreenstar6 720 806 992 (2013/07)Service function 8.E: Restore boiler to factory settings This function allows re

Gas type conversion | 596 720 806 992 (2013/07)Greenstar11 Gas type conversionThe gas-air ratio must always be set on the basis of a CO2 or O2 reading

6 | Scope of deliveryGreenstar6 720 806 992 (2013/07)2.2 ZWB - Residential combi boiler for space heating and DHW generationFig. 2 Scope of delivery

60 | Gas type conversionGreenstar6 720 806 992 (2013/07)11.3 Setting the gas-air ratio (CO2 or O2)▶ Switch the appliance OFF using the ON/OFF switch.▶

Gas type conversion | 616 720 806 992 (2013/07)Greenstar▶ Remove flue gas probe and close the flue gas test port properly.Fig. 75 Close flue gas tes

62 | Flue gas testGreenstar6 720 806 992 (2013/07)12 Flue gas test12.1 Emissions test buttonThe following appliance outputs can be selected by pressin

Inspection and maintenance | 636 720 806 992 (2013/07)GreenstarHeat exchangerHeatronic boiler controlIn case of a component defect, a fault is shown o

64 | Inspection and maintenanceGreenstar6 720 806 992 (2013/07)▶ Loosen/remove pipe connections.Fig. 80 Removing pipe connections▶ Remove the boiler

Inspection and maintenance | 656 720 806 992 (2013/07)Greenstar14.1.5 Burner servicing▶ Remove burner lid (steps 1 - 4).Fig. 86 Removing the burner

66 | Inspection and maintenanceGreenstar6 720 806 992 (2013/07)▶ With the cleaning blade, clean the heat exchanger block from the bottom to the top.Fi

Inspection and maintenance | 676 720 806 992 (2013/07)Greenstar14.1.7 Condensate trap cleaning▶ Remove condensate trap (steps 1 and 2) and check heat

68 | Inspection and maintenanceGreenstar6 720 806 992 (2013/07)14.2 Checklist for inspection and maintenance▶ Use this form to guide you through the s

Readings on the display | 696 720 806 992 (2013/07)Greenstar15 Readings on the displayThe boiler display can provide the following information (Tab. 3

Information about the appliance | 76 720 806 992 (2013/07)Greenstar3 Information about the applianceZBR appliances are residential boilers for central

70 | FaultsGreenstar6 720 806 992 (2013/07)16 Faults16.1 TroubleshootingThe Heatronic boiler control monitors all safety and control components. If a

Faults | 716 720 806 992 (2013/07)Greenstar16.2 Faults that are shown on the displayDisplay Description EliminationA7 DHW temperature sensor defective

72 | FaultsGreenstar6 720 806 992 (2013/07)EA No flame detected.GFA: Safety time expired.▶ Check that ground lead is properly connected, replace if de

Faults | 736 720 806 992 (2013/07)Greenstar16.3 Faults that are not shown on the displayAppliance faults EliminationCombustion noise too loud; rumblin

74 | FaultsGreenstar6 720 806 992 (2013/07)16.4 Check sensor values16.4.1 Outdoor temperature sensor16.4.2 Additional supply temperature limiter16.4.3

Commissioning log for the appliance | 756 720 806 992 (2013/07)Greenstar17 Commissioning log for the applianceHome owner/operator: Last name, first na

76 | Commissioning log for the applianceGreenstar6 720 806 992 (2013/07)Modified service functions: (Select the modified service functions and enter t

Spare parts | 776 720 806 992 (2013/07)Greenstar18 Spare parts▶ Order spare parts by name and part number using the spare parts list.DesignationZBR16-

78 | Spare partsGreenstar6 720 806 992 (2013/07)Fig. 95 Group 1 - Sheet metal Greenstar6 720 641 933-102.2O

Spare parts | 796 720 806 992 (2013/07)GreenstarItem ( Fig. 95) DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder numb

8 | Information about the applianceGreenstar6 720 806 992 (2013/07)3.5 Accessories• FB 100 room control• Modules for system expansions:– ISM2 for sola

80 | Spare partsGreenstar6 720 806 992 (2013/07)Fig. 96 Group 2 - Burner/Heat exchanger Greenstar2215131416201746720211812102311958321491619196 720

Spare parts | 816 720 806 992 (2013/07)GreenstarItem ( Fig. 96) DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder numb

82 | Spare partsGreenstar6 720 806 992 (2013/07)Fig. 97 Group 3 - Gas valve Greenstar11921191314151718232019161610291291198792946 720 641 933-104.1o

Spare parts | 836 720 806 992 (2013/07)GreenstarItem ( Fig. 97) DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder numb

84 | Spare partsGreenstar6 720 806 992 (2013/07)Fig. 98 Group 4 - Pipes combi boiler ZWB..-3A Greenstar786231115151876522122114191732526162720271172

Spare parts | 856 720 806 992 (2013/07)GreenstarItem ( Fig. 98) DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder numb

86 | Spare partsGreenstar6 720 806 992 (2013/07)Fig. 99 Group 5 - Pipes heating boiler ZBR..-3A Greenstar12699267583232449219202291918282930256 720

Spare parts | 876 720 806 992 (2013/07)GreenstarItem ( Fig. 99) DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder numb

88 | Spare partsGreenstar6 720 806 992 (2013/07)Fig. 100 Group 6 - Control box Greenstar21212223 241716341061130912720141525136 720 641 933-107.3O888

Spare parts | 896 720 806 992 (2013/07)GreenstarItem ( Fig. 100) DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder num

Information about the appliance | 96 720 806 992 (2013/07)Greenstar3.6 Product dimensions and minimum clearancesFig. 4 Dimensions and minimum cleara

90 | Spare partsGreenstar6 720 806 992 (2013/07)Fig. 101 Group 7 - Hydraulic block combi boiler ZWB..-3A Greenstar14222213765481291112101315171819645

Spare parts | 916 720 806 992 (2013/07)GreenstarItem ( Fig. 101) DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder num

92 | Spare partsGreenstar6 720 806 992 (2013/07)Item DesignationZBR16-3AZBR21-3AZBR28-3AZBR35-3AZBR42-3AZWB28-3AZWB35-3AZWB42-3AOrder number – SAK3

Index | 936 720 806 992 (2013/07)GreenstarIndexAAccessories ... 8Anti-free

94 | IndexGreenstar6 720 806 992 (2013/07)HHeating control ... 48HeatronicService

Index | 956 720 806 992 (2013/07)Greenstar(service function b.F) ..... 58DHW output (service fun