Bosch SSB85 Service Manual
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Bosch SSB85 Service Manual

Ssb boiler, gas condensing stainless steel boiler
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Gas Condensing Stainless Steel Boiler
SSB BOILER
SSB85 | SSB120 | SSB160
Service Manual
WARNING:
Improper installation, set-up, modification, operation or maintenance of
the heating system can cause personal injury and property damage.
Follow these instructions precisely.
If you require assistance or further information, contact a licensed
contractor / gas fitter.
WARNING:
The operating instructions are part of the technical documents that
must be handed over to the owner or operator of the heating system.
Explain to the owner or operator how to use the heating system using
the operating instructions. Make sure that they are familiar with all
required information for the safe and proper operation of the heating
system.
These instructions are available in English and French.
Please keep these instructions for future reference.

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Summary of Contents for Bosch SSB85

  • Page 1 These instructions are available in English and French. Please keep these instructions for future reference. Gas Condensing Stainless Steel Boiler SSB BOILER SSB85 | SSB120 | SSB160 Service Manual...

  • Page 2: Table Of Contents

    Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key to symbols and safety instructions Commisioning Key to symbols .

  • Page 3: Key To Symbols And Safety Instructions

    ► Immediately correct all faults to prevent system damage. Observe these instructions for your safety. ► Only use original Bosch spare parts. Losses caused by the use of The burner and control must be correctly installed and adjusted to ensure parts not supplied by Bosch are excluded from the Bosch warranty.

  • Page 4: Product Description

    ► The boiler is intended only for the use for which it was specifically central heating systems. Any other use is prohibited. designed and built. Bosch is hereby excluded from any liability for damages caused to persons, animals or property resulting from •...

  • Page 5: Start/Stop Cycle

    Product description | 5 2 .3 Start/Stop cycle Fig. 1 Burner ignition cycle diagram If flame is detected at the end of the pre-spark period (Ignit_0) a lockout error occurs (This lockout has a maximum of 3 auto False flame detection resets).

  • Page 6: Boiler Components

    6 | Boiler components Boiler components Fig. 2 Boiler components [1] Pressure differential switch [8] Heat exchanger [2] Fan [9] Main controller [3] Burner head [10] Automatic air vent [4] Spark electrode [11] High limit temp. safety switch [5] Circulation pump [12] Supply temperature probe [6] Condensate trap [13] Gas valve...

  • Page 7: Main Components

    Main components | 7 Main components Fig. 3 Main components [1] Main power switch [15] High limit temp. safety switch [2] System return [16] Heat exchanger [3] Gas inlet [17] Condensate trap [4] Flue exhaust [18] Low point drain valve [5] Intake air [19] Circulation pump [6] System supply...

  • Page 8: Burner Head

    8 | Main components 4 .1 Burner head 4 .2 Heat exchanger The burner head (Fig. 4) is made of stainless steel, it supports a micro The heat exchanger (Fig. 7) is a single coil design made of stainless premix flame. The burner can be accessed by removing the larger four steel.

  • Page 9: Low Water Cut Off (Lwco)

    Main components | 9 4 .5 Low Water Cut Off (LWCO) Return temperature sensor The Low Water Cut off (LWCO) is installed on the supply pipe, at the highest position available. Using a dedicated wet sensor it checks the minimum level of water inside the boiler by way of an electrical signal ground.

  • Page 10: Flue Temperature Sensor

    The gas valve regulates the air/fuel ratio on the basis of combustion air delivery (the air/fuel ratio is 1:1). Fig. 17 Venturi SSB85 - SSB120 Component [1] Fan [2] Venturi [3] Air inlet [4] Gas inlet Tab. 2 Venturi SSB85 - SSB120 Fig. 15 Gas valve SSB85 - SSB120 6720866940 (2017/11) US...

  • Page 11: Condensate Trap

    Main components | 11 4 .13 Flue pressure switch Flue pressure switch is a safety device designed to turn off the burner in case of block vent (for example due to obstruction of condensate drain). The silicon pipe is connected on one end to the “+” port of pressure switch (Fig.

  • Page 12: Pressure Relief Valve

    Pressure relief valve The boiler is protected by a relief valve against overpressure. The 3/4” discharge outlet must be piped per local code requirements. Boiler model Pressure value SSB85 30 psi (2,07 bar) SSB120 30 psi (2,07 bar) SSB160 30 psi (2,07 bar) Tab.

  • Page 13: Control Panel (Lcd Display) | 13

    Control Panel (LCD Display) | 13 5 .2 Date and time setting Control Panel (LCD Display) Press the “menu” button and select “Settings” using the arrow buttons to select “Settings”. The homepage on the display shows the basic status of the boiler. Menu Domestic Hot Water Information...

  • Page 14: Setting Central Heating Ch And Dhw Setpoint

    14 | Control Panel (LCD Display) Entering the “Time Zone Settings” menu it is possible to set the time zone Fig. 33 parameter as shown on the following figure: CH and the DHW setpoint can be edit directly from the homepage of the display.

  • Page 15: Outdoor Reset (Climatic Compensation)

    Control Panel (LCD Display) | 15 5 .6 Parameters list Press “OK” and the display will show the following information: • Supply Temperature To have access to the parameter list press “menu” button and select “Settings” using the “UP/DOWN” keys “ / ”. •...
  • Page 16 Boiler Rotation Interval Days DHW Boiler Assign Tab. 7 Level 2 parameters (INSTALLER) (*) Depend on appliance type (**) The value for this parameter is: • 4 for SSB160 • 5 for SSB120 • 6 for SSB85 6720866940 (2017/11) US...

  • Page 17: Parameters Description | 17

    Parameters description | 17 Minimum CH and DHW power Parameters description (Also applicable to all other CH and DHW Modes) The minimum burner power during operation can be limited with 6 .1 Central Heating (CH) parameter P_Min. CH_Mode=1 Request for Heat with Outdoor Sensor and Room thermostat.

  • Page 18: Domestic Hot Water

    18 | Parameters description 6 .2 Domestic Hot Water Par .22: Baseline Outdoor Temp . Defines the maximum outdoor temperature to calculate the minimum Par .35 DHW_Mode supply temperature for CH Mode=0 No Domestic Hot Water Mode=1 External DHW tank with temperature probe. Par .23: Min Supply Temp .
  • Page 19 Parameters description | 19 Par .36 DHW Tank Hyst Down The differential for the DHW tank load. If the temperature decrease below “Par.48 DHW_Setpoint”–Par. 36 DHW_Hist_Down”, the call for heat is activated igniting the burner. Par .37 DHW Tank Hyst Up Differential setpoint for shutting off the call for heat.

  • Page 20: Pump Mode And Connections

    20 | Parameters description 6 .3 Pump mode and connections Pump mode = 2 (default) Boiler with a manifold and two pump circuits CH/DHW DHW_mode=0 (Ch only) DHW_mode=1 T_flue T_supply Safety Limit Primary J6-1 Heat Exchanger Primary GENERAL Heat Exchanger PUMP PUMP J6-3...

  • Page 21: Commisioning

    [8] Verify all electrical connections are correct; [9] Verify no electrical components were removed or tampered with; Fig. 49 Installation location for the LPG orifice - model SSB85 - SSB120 [10] Fill the condensate trap with water and ensure a continuous downward slope exists in the outlet tube.
  • Page 22 Orifice Venturi Gasket Orifice Fig. 51 Valve configuration - model SSB85 - SSB120 Gasket Use the control panel to enter in the parameter list and change the parameter no. 98 (Gas Type) from “NG” to “LPG”. Adjust the CO level according to the values shown in Tab.

  • Page 23: Co 2 Setting

     (all models); Inner Diameter LPG Orifices (mm) System Test Test State High Power Boiler model Inner diameter LPG orifices (mm) Fan Speed 0 rpm SSB85 5.5 Ø SSB120 5.0 Ø Ionisation 0.0 μA SSB160 6.25 Ø Tab. 8 Gas Orifice Diameter Fig.

  • Page 24: 24 | Maintenance Schedule & Procedures

    Combustion test Verify condition of flue and air system Annually * (including Venturi and fan) Annually * Check ignition electrode Fig. 61 Connectors SSB85 - SSB120 Cleaning the combustion chamber (including Annually * the burner tube) Annually * Clean condensate discharge...
  • Page 25 [4] Remove the fan unscrewing the 4 nuts that fix it to the heat exchanger (see picture below showing 3 out of 4 nuts); Fig. 63 Air inlet hose SSB85 - SSB120 Air inlet hose Fig. 67 Fan - 4 nuts [5] Remove the fan;...

  • Page 26: Cleaning The Heat Exchanger

    26 | Maintenance schedule & procedures [6] Remove the gasket; [3] Remove the exchanger top cap (including the insulation); Gasket Top cap + insulation Fig. 69 Gasket [7] Pull out the burner head. Rotate the burner head to align the mark (A) to the igniter (B);...
  • Page 27 Maintenance schedule & procedures | 27 Kit Contents: [8] Using the brush remove debris from the spiral tubes, vacuum the debris from the heat exchanger, without damaging the calorite disc; - 1 x Manual water pump and wand - 1 x Calorite disc protector plate - 1 x Bottle Atomizer Brush - 1 x Cleaning Brush...

  • Page 28: Cleaning The Ignition Electrode

    28 | Maintenance schedule & procedures 8 .6 Cleaning the Ignition Electrode 8 .7 Inspection, replacement and features of supply, return and flue NTC temperature sensors The ignition electrode requires annual maintenance to remove any potential oxide layer that may be generate during normal operation. The NTC sensor transduces a temperature value into an electrical Check the high voltage cable for cracks and oxidation on the plug.

  • Page 29: Electrical Supply

    Maintenance schedule & procedures | 29 Electrical supply Temperature °F (°C) Resistance [Ω] Testing tolerance ±10% 9 .1 Electrical supply wiring 32 (0) 27396 Connect the boiler to the main electrical supply, as required by local, state 41 (5) 22140 and federal codes.

  • Page 30: Main Electrical Supply

    30 | Electrical supply Electrical connection: (**) Pump CH Pump DHW DHW Tank Room Boiler CASCADE Supply 120 V Main in Alarm 120 V Aux Pump LINK Switch Door Sensor Thermostat Sensor 3 Way 1 2 3 4 5 6 7 8 9 10 11 12 13 14 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115...

  • Page 31: Electrical Wiring Diagram

    Electrical supply | 31 9 .8 Electrical wiring diagram Jumper factory installed LOW VOLTAGE HIGH VOLTAGE HIGH IN / OUT VOLTAGE PUMP CH PUMP DHW 120 V Supply CASCADE Room MAIN PUMP ALLARM 120 V AUX Sensor MAIN IN Tank LINK SWITCH DOOR...

  • Page 32: Lockout Errors List

    32 | Electrical supply 9 .9 Lockout errors list If an error is a “Lockout” error, it is necessary to press “RESET” button (after eliminating the reason for the failure) to restart the boiler. In the following table the “Lockout” errors are listed: Error Int .

  • Page 33: Blocking Errors List

    Electrical supply | 33 Error Int . nr . Description Checks Solutions a- Check the integrity of Three times flame lost during one the wire connections of the a- If wires are damaged, replace "Too Many Flame Failures" demand spark and the earth on heat them exchanger "Flow Switch Not Closed Error"...
  • Page 34 34 | Electrical supply Error Int . nr . Description Checks Solutions a- Change the pump or restart it a- Check the pump to verify b- Open the valves on hydraulic the flow circulation circuit b- Check if the valves on “Overheat Error”...

  • Page 35: Errors Not Shown On Display

    Electrical supply | 35 9 .11 Errors not shown on display Symptoms Possible solutions Check gas type. Combustion noise too loud; rumbling noises Check inlet gas pressure; adjust as needed. Check flue gas system; clean or repair as needed. Check gas/air ratio in the combustion air and flue gas; replace gas valve as needed. Set pump speed correctly to match maximum output.
  • Page 36 36 | Spare parts Spare parts Fig. 88 6720866940 (2017/11) US...
  • Page 37 7-738-004-907 Mounting bracket control board panel ■ ■ ■ 7-738-004-908 Alignment pin front side panels ■ ■ ■ 7-738-004-924 Logo Bosch front door ■ ■ ■ 7-738-005-176 Handle front panel ■ ■ ■ 7-738-004-920 Lock and lever front panel ■...
  • Page 38 38 | Spare parts Shown on Fig. 91 - Fig. 92 Fig. 89 6720866940 (2017/11) US...
  • Page 39 Spare parts | 39 Item (→ Fig. 89) Description Order number High limit sensor and screws ■ ■ ■ 7-738-004-926 Universal temperature detector and washer ■ ■ ■ 7-738-004-930 O-ring temperature detector 0.51x0.1in 13x2.62mm ■ ■ ■ 7-738-004-931 Automatic air vent 3/8" ■...
  • Page 40 40 | Spare parts Fig. 90 6720866940 (2017/11) US...
  • Page 41 Spare parts | 41 Item (→ Fig. 90) Description Order number Enclosure user interface ■ ■ ■ 7-738-005-037 Circuit Board user interface ■ ■ ■ 7-738-005-038 Keypad ■ ■ ■ 7-738-005-039 Service plug cover ■ ■ ■ 7-738-005-040 On Off power switch ■...
  • Page 42 42 | Spare parts SSB85 - SSB120 19 20 Fig. 91 6720866940 (2017/11) US...
  • Page 43 7-738-005-400 Gasket burner flange inner ring to fan ■ ■ 7-738-004-990 Fan + Venturi ■ ■ 7-738-005-159 Gasket venturi tube / gas valve SSB85/120 ■ ■ 7-738-005-409 Gas valve and washers ■ ■ 7-738-005-160 Washer gas pipe 3/4” 19.05mm ■...
  • Page 44 44 | Spare parts SSB160 ONLY Fig. 92 6720866940 (2017/11) US...
  • Page 45 Spare parts | 45 Item (→ Fig. 92) Description Order number Heat exchanger SSB160 ■ 7-738-005-156 Washer for ignition electrode ■ 7-738-005-034 Ignition electrode with washer ■ 7-738-005-397 Sight glass for combustion ■ 7-738-005-031 Gasket premix burner tube ■ 7-738-004-985 Premix burner tube ■...
  • Page 46 46 | Spare parts Notes 6720866940 (2017/11) US...
  • Page 47 Spare parts | 47 6720866940 (2017/11) US...
  • Page 48 United States and Canada Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-965-7581 www.boschheatingandcooling.com U.S.A. Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.

This manual is also suitable for:

Ssb160Ssb120

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