Bosch ZSB 30-2 A Operations Instructions

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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 view 0
1 2 3 4 5 6 ... 79 80

Summary of Contents

Page 1 - Condens 5000 W

Installation and servicing instructions for contractorsHydronic Gas Condensing BoilerCondens 5000 W6 720 613 085-00.1OZSB 30-2 A ...| ZWB 37-2 A ...6

Page 2 - Contents

10 | Product details6 720 644 143 (2010/09)3.8 Appliance layoutFig. 36 720 644 143-03.1O30313233343539403837364142434445464748491210987123456112928272

Page 3

Product details | 116 720 644 143 (2010/09)Key to figure 3:1 Heatronic 32 Main switch3 Burner ON indicator4 Service button5 Central heating boost butt

Page 4 - 4

12 | Product details6 720 644 143 (2010/09)3.9 Electrical wiring diagramFig. 4 ZSB 30-2 ST1kkBB24F1A 141516171213111822 21101234567891920

Page 5 - 1.2 Safety instructions

Product details | 136 720 644 143 (2010/09)1 Spark transformer2 CH temperature control3 Wiring centre4 Safety solenoid5 Safety solenoid6 Gas valve7 Fa

Page 6 - 2 Standard delivery

14 | Product details6 720 644 143 (2010/09)Fig. 5 ZWB 37-2Ls Nsrtuevi BB24F1A141516171213111823 2422 2521101234567891920

Page 7 - 3 Product details

Product details | 156 720 644 143 (2010/09)1 Spark transformer2 CH temperature control3 230 V room stat/programmer4 Safety solenoid5 Safety solenoid6

Page 8 - 3.6 Accessories

16 | Product details6 720 644 143 (2010/09)3.10 Specification ZSB 30-2 ...ZSB 30-2 ...Unit Natural gas Propane ButaneMax. heat output (Pmax) 40/30 °C

Page 9 - Product details

Product details | 176 720 644 143 (2010/09)3.11 Specification ZWB 37-2 ...ZWB 37-2 ...Unit Natural gas Propane ButaneMax. heat output (Pmax) 40/30 °C

Page 10 - 3.8 Appliance layout

18 | Product details6 720 644 143 (2010/09)3.12 Condensate composition General dataPower supply voltage AC ... V 220 - 240 220 - 240 220 - 240Frequenc

Page 11 - Product details

Regulations | 196 720 644 143 (2010/09)4RegulationsWhere no specific instruction is given, reference should be made to the following standards:• AS 56

Page 12 - 3.9 Electrical wiring diagram

2 | Contents6 720 644 143 (2010/09)Contents1 Key to symbols and safety instructions . . . . . . . 51.1 Explanation of symbols . . . . . . . . . . .

Page 13 - Product details

20 | Pre-Installation6 720 644 143 (2010/09)5 Pre-Installation5.1 Water system and pipe workPlastic pipe work:• Any plastic pipe work must have a poly

Page 14 - Fig. 5 ZWB 37-2

Pre-Installation | 216 720 644 143 (2010/09)S and Y plan systems:Optional diverter valveThis boiler is designed to operate on a sealed system only and

Page 15 - Product details

22 | Pre-Installation6 720 644 143 (2010/09)5.2 Condensate pipe work5.2.1 Internal connectionsWhere there is the possibility of freezing conditions an

Page 16 - 6 720 644 143 (2010/09)

Pre-Installation | 236 720 644 143 (2010/09)Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe can be used.

Page 17

24 | Installation6 720 644 143 (2010/09)6 Installation6.1 Important notesB Prior to installation, obtain the approval of the gas supply utility.Supply

Page 18 - 3.12 Condensate composition

Installation | 256 720 644 143 (2010/09)Mono-lever taps and thermostatic mixer tapsAll types of mono-lever taps and thermostatic mixer taps can be use

Page 19 - 4Regulations

26 | Installation6 720 644 143 (2010/09)6.4 Pre-installing pipesB Hook mounting rail into the mounting plate.B Position mounting plate against the wal

Page 20 - 5 Pre-Installation

Installation | 276 720 644 143 (2010/09)Fig. 17 Pipe connections1 Pre-plumbing jig2 Adaptor BSP 3/4" tapered thread with union nut G3/4" and

Page 21 - 6720644143-40.1J

28 | Installation6 720 644 143 (2010/09)6.5 Fitting the applianceB Remove packing, taking care to observe the instructions on the packing.B Check the

Page 22 - 5.2 Condensate pipe work

Installation | 296 720 644 143 (2010/09)Drain from pressure relief valve (heating circuit)B Push lever on slider up until catch [1] rests on metal bra

Page 23 - 6720646195-17.1Wo

Contents | 36 720 644 143 (2010/09)15 Inspection/Servicing . . . . . . . . . . . . . . . . . . . . . 5515.1 Checklist for inspection/servicing (Inspe

Page 24 - 6 Installation

30 | Installation6 720 644 143 (2010/09)Fitting the filling loop (ZWB)B Close the isolating valves on the mains water inlet [9] and the CH return [1]

Page 25 - 6.3 Siting the appliance

Installation | 316 720 644 143 (2010/09)B Turn key [4] to position , remove and insert into the lower cover. Fig. 25Fitting the lower coverB Push the

Page 26 - 6.4 Pre-installing pipes

32 | Installation6 720 644 143 (2010/09)6.6 Checking the connectionsWater connectionsB Open the heating flow and return valves and fill the heating sy

Page 27 - 6 720 644 143-05.1O

Electrical connections | 336 720 644 143 (2010/09)7 Electrical connections7.1 General information• Supply: 220 - 240 V, 50 Hz.• The appliance must be

Page 28 - 6 720 644 143-06.1O

34 | Electrical connections6 720 644 143 (2010/09)B To provide anti-splash protection (IP), always cut cable grip to fit cable diameter.Fig. 30B Feed

Page 29 - 6 720 644 143-15.1O

Commissioning | 356 720 644 143 (2010/09)8 CommissioningFig. 331 Flow temperature control2 DHW temperature control3 Chimney sweep button4 Service butt

Page 30

36 | Commissioning6 720 644 143 (2010/09)8.1 Before commissioningB Adjust pre-charge pressure of expansion vessel to static head of the heating system

Page 31 - 6 720 615 886-22.1O

Commissioning | 376 720 644 143 (2010/09)8.3 Starting the central heatingThe maximum flow temperature can be matched to the heating system by the flow

Page 32 - 6.6 Checking the connections

38 | Commissioning6 720 644 143 (2010/09)8.6 Appliances with hot water cylinder: setting the hot water temperatureB Set the DHW temperature on the DHW

Page 33 - 6 720 612 659-15.1R

Commissioning | 396 720 644 143 (2010/09)8.7 ZWB appliances - setting hot water temperatureB Set the DHW temperature on the DHW temperature control .T

Page 34 - 6 720 612 259-30.1R

4 | Contents6 720 644 143 (2010/09)

Page 35 - 6 720 644 143-17.1O

40 | Commissioning6 720 644 143 (2010/09)8.10 Holiday modeTo switch on holiday mode: B Press and hold holiday button on the appliance until it light

Page 36 - 8.1 Before commissioning

Thermal disinfection on appliances with hot water cylinder | 416 720 644 143 (2010/09)9 Thermal disinfection on appliances with hot water cylinderTo p

Page 37 - 8.5 After commissioning

42 | Pump anti-seizing function6 720 644 143 (2010/09)10 Pump anti-seizing functionEvery time the pump is switched off, a timer starts to briefly swit

Page 38

Heatronic settings | 436 720 644 143 (2010/09)11 Heatronic settings11.1 General informationThe Heatronic unit enables easy setting and testing of a la

Page 39 - 8.9 Frost protection

44 | Heatronic settings6 720 644 143 (2010/09)11.2 Overview of service functions11.2.1 Service level 1B Press service button until it illuminates.11

Page 40 - 8.11 Fault mode

Heatronic settings | 456 720 644 143 (2010/09)11.3 Description of service functions11.3.1 Service level 1Service function 1.A: MAX. OUTPUT (HEATING) S

Page 41

46 | Heatronic settings6 720 644 143 (2010/09)The following can be selected as the pump characteristic map:• 00 Pump step adjustable, service function

Page 42 - 10 Pump anti-seizing function

Heatronic settings | 476 720 644 143 (2010/09)Service functions 2.C: Air purge modeThe first time the appliance is switched on, a once-onlyventing fun

Page 43 - 11 Heatronic settings

48 | Heatronic settings6 720 644 143 (2010/09)Service function 4.F: Siphon-fill programmeThe syphon filling function ensures that the syphon trap is f

Page 44

Heatronic settings | 496 720 644 143 (2010/09)11.3.2 Service level 2Service function 8.A: Software versionThe version number of the software is displa

Page 45

Key to symbols and safety instructions | 56 720 644 143 (2010/09)1 Key to symbols and safety instructions1.1 Explanation of symbolsWarning symbolsSign

Page 46 - 6 720 612 126-45.1

50 | Converting the appliance to different gas types6 720 644 143 (2010/09)12 Converting the appliance to different gas typesThe gas-air ratio must al

Page 47

Converting the appliance to different gas types | 516 720 644 143 (2010/09)B Remove the gas throttle seat with a screw driver as shown in Fig. 49.Fig.

Page 48

52 | Converting the appliance to different gas types6 720 644 143 (2010/09)12.3 Checking the gas supply pressureB Switch off the appliance and turn of

Page 49

Flue gas testing | 536 720 644 143 (2010/09)13 Flue gas testing13.1 Central heating boost buttonThe following appliance outputs can be selected by pre

Page 50 - 6 720 612 688-32.1O

54 | Environmental protection6 720 644 143 (2010/09)14 Environmental protectionEnvironmental protection is a fundamental corporate strategy of the Bos

Page 51

Inspection/Servicing | 556 720 644 143 (2010/09)15 Inspection/ServicingTo ensure that gas consumption and environmental impact remain as low as possib

Page 52

56 | Inspection/Servicing6 720 644 143 (2010/09)15.1 Checklist for inspection/servicing (Inspection/Servicing report)Date1 Retrieve last fault stored

Page 53 - 6 720 612 688-35.1O

Inspection/Servicing | 576 720 644 143 (2010/09)15.2 Description of various servicing operations15.2.1 Retrieving last fault stored (service function

Page 54 - 14 Environmental protection

58 | Inspection/Servicing6 720 644 143 (2010/09)15.2.4 Plate type heat exchanger (ZWB)If the DHW output is insufficient:B Check strainer in cold water

Page 55 - 15 Inspection/Servicing

Inspection/Servicing | 596 720 644 143 (2010/09)B Release the quick-acting closures and remove the hydraulic assembly completely.Fig. 61B Undo the pla

Page 56 - (Inspection/Servicing report)

6 | Standard delivery6 720 644 143 (2010/09)2 Standard deliveryFig. 1Key:1 Gas condensing boiler2 Pre-plumbing jig3 Mounting rail4 Pre-plumbing jig fo

Page 57 - 6 720 612 659-48.1R

60 | Inspection/Servicing6 720 644 143 (2010/09)B Remove the condensate siphon and place a suitable container below the condensate outlet.Fig. 64B Wit

Page 58 - 6 720 644 143-22.1O

Inspection/Servicing | 616 720 644 143 (2010/09)15.2.6 BurnerB Remove two screws [2] from top cover [1] and lift off cover (Æ Fig. 69). Fig. 69B Remov

Page 59 - 6 720 644 143-24.1O

62 | Inspection/Servicing6 720 644 143 (2010/09)15.2.7 Diaphragm in mixer unitB Open the mixing chamber.B Carefully withdraw diaphragm from fan intake

Page 60 - 6 720 612 664-18.1R

Inspection/Servicing | 636 720 644 143 (2010/09)15.2.10 Setting the heating system pressureB If the gauge is below 1 bar (100 kPa) (when the system is

Page 61

64 | Displays6 720 644 143 (2010/09)16 DisplaysThe display shows the following (table 25 and 26):Value displayed Description RangeNumber or letter, do

Page 62 - 6 720 615 662-21.1O

Displays | 656 720 644 143 (2010/09)Screed drying function of the weather-compensated controller (Æoperating instructions) or building drying function

Page 63

66 | Fault mode6 720 644 143 (2010/09)17 Fault mode17.1 TroubleshootingAll safety, modulation and control components are monitored by the Heatronic sy

Page 64 - 16 Displays

Fault mode | 676 720 644 143 (2010/09)17.2 Faults that are shown on the displayDisplay codeDescription RemedyA7 Temperature sensor for hot water is fa

Page 65

68 | Fault mode6 720 644 143 (2010/09)E9 Heat exchanger temperature limiter or flue gas temperature limiter has tripped.B Check heat exchanger tempera

Page 66 - 17 Fault mode

Fault mode | 696 720 644 143 (2010/09)FA A flame is detected after the gas has been switched off.B Check gas valve; replace if required.B Clean conden

Page 67

Product details | 76 720 644 143 (2010/09)3 Product detailsZSB appliances are boilers for heating. They can be fitted with the diverter valve accessor

Page 68

70 | Fault mode6 720 644 143 (2010/09)17.3 Faults that are not shown on the displayAppliance faults RemedyCombustion noise too loud; rumbling noises B

Page 69

Fault mode | 716 720 644 143 (2010/09)17.4 Sensor values17.4.1 Outside temperature sensor (for weather-compensated controllers, accessory)17.4.2 Flow

Page 70

72 | Fault mode6 720 644 143 (2010/09)17.6 Settings for heating output with ZSB 30 ...2317.7 Settings for heating output with ZSB 30 ...31NG Gross cal

Page 71 - 17.5 Code Plug

Fault mode | 736 720 644 143 (2010/09)17.8 Settings for heating output with ZWB 37 ...2317.9 Settings for heating output with ZWB 37 ...31NG Gross cal

Page 72 - ZSB 30 ...31

74 | Commissioning report for the appliance6 720 644 143 (2010/09)18 Commissioning report for the applianceCustomer/system user:Surname, first name St

Page 73 - ZWB 37 ...31

Commissioning report for the appliance | 756 720 644 143 (2010/09)Modified service functions: (Select the modified service functions and enter the val

Page 74

76 | Index6 720 644 143 (2010/09)IndexAAnti-freeze ... 24ApplianceSwitching off...

Page 75

Index | 776 720 644 143 (2010/09)MMaintenance operationsSetting the heating system pressure ... 63Measuring CO content of flue gas...

Page 76

78 | 6 720 644 143 (2010/09)Notes

Page 77

| 796 720 644 143 (2010/09)Notes

Page 78

8 | Product details6 720 644 143 (2010/09)3.5 Description of appliance• Wall mounted boiler; installation independent of chimney location or room size

Page 79

AustraliaRobert Bosch (Australia) Pty Ltd1555 Centre RdClayton, VIC 3168Phone 1300 30 70 37Fax 1300 30 70 38www.bosch.com.au/hotwaterNew ZealandPhone

Page 80

Product details | 96 720 644 143 (2010/09)3.7 Dimensions and minimum clearancesFig. 21 Pre-plumbing jig2 Casing3 FasciaA Additional 30 mm above elbowB

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