Related Manuals for Bosch ZSB 30-2
Summary of Contents for Bosch ZSB 30-2
- Page 1 Hydronic Gas Condensing Boiler Condens 5000 W ZSB 30-2 A ...| ZWB 37-2 A ... Installation and servicing instructions for contractors...
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Page 2: Table Of Contents
Thermal disinfection on appliances 3.10 Specification ZSB 30-2 ....16 with hot water cylinder ....41 3.11... - Page 3 Contents | 3 15 Inspection/Servicing ..... 55 15.1 Checklist for inspection/servicing (Inspection/Servicing report) ..56 15.2 Description of various servicing operations .
- Page 4 4 | Contents 6 720 644 143 (2010/09)
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Page 5: Key To Symbols And Safety Instructions
Key to symbols and safety instructions | 5 Key to symbols and safety instructions Explanation of symbols Safety instructions Warning symbols If you smell gas B Turn off gas tap ( page 35). Safety instructions in this document are B Open windows and doors. framed and identified by a warning triangle B Do not operate any electrical switches. -
Page 6: Standard Delivery
6 | Standard delivery Standard delivery Key: Gas condensing boiler Pre-plumbing jig Mounting rail Pre-plumbing jig for ZWB appliances (for ZSB appliances without cold and DHW water connections) Filling loop with key (ZWB) Adaptors for ZWB appliances (for appliances ZSB without adaptors for cold cold and DHW water connections) Lower cover Pressure relief valve hose (heating circuit) -
Page 7: Product Details
Commercial Propane recommended Using the appliance for any other purpose will be Commercial Butane permitted considered incorrect use. Bosch accepts no liability for any damage resulting from such use. General Product permitted The commercial and industrial use of the appliance to... -
Page 8: Description Of Appliance
8 | Product details Description of appliance Accessories • Wall mounted boiler; installation independent of Below is a list of typical accessories for this chimney location or room size. appliance. You can find comprehensive • Intelligent heating circuit pump control when details of all available accessories in our connected to an weather-dependent heating catalogue. -
Page 9: Dimensions And Minimum Clearances
Product details | 9 Dimensions and minimum clearances min. min. 6 720 644 143-02.2J Fig. 2 Pre-plumbing jig Casing Fascia Additional 30 mm above elbow Using 100 mm flue kit: 1112 mm / 120 mm flue kit: 1152 mm 20 mm to reversible door / 600 mm front clearance for service 6 720 644 143 (2010/09) -
Page 10: Appliance Layout
10 | Product details Appliance layout 6 720 644 143-03.1O Fig. 3 6 720 644 143 (2010/09) - Page 11 Product details | 11 Key to figure 3: Heatronic 3 Main switch Burner ON indicator Service button Central heating boost button Here, a weather-compensated control unit or a time switch (accessories) can be plugged in CH Flow temperature control DHW temperature control Holiday button eco button reset button...
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Page 12: Electrical Wiring Diagram
12 | Product details Electrical wiring diagram Fig. 4 ZSB 30-2 6 720 644 143 (2010/09) - Page 13 Product details | 13 Spark transformer CH temperature control Wiring centre Safety solenoid Safety solenoid Gas valve Flame sense eletrode Spark electrodes Flow NTC Heat exchanger overheat stat. Flue overheat stat. Earth Mains supply Pump Pump control Diverter valve (optional) Pump supply DHW temperature control Fluse slow T 0.5 A...
- Page 14 14 | Product details Ls Ns Fig. 5 ZWB 37-2 6 720 644 143 (2010/09)
- Page 15 Product details | 15 Spark transformer CH temperature control 230 V room stat/programmer Safety solenoid Safety solenoid Gas valve Flame sense eletrode Spark electrodes Flow NTC Heat exchanger overheat stat. Flue overheat stat. Earth Mains supply DHW sensor Pump Pump control Diverter valve Flow turbine Pump supply...
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Page 16: Specification Zsb 30-2
16 | Product details 3.10 Specification ZSB 30-2 ... ZSB 30-2 ... Unit Natural gas Propane Butane Max. heat output (P ) 40/30 °C 32.1 32.1 36.6 Max. heat output (P ) 50/30 °C 31.8 31.8 36.3 Max. heat output (P ) 80/60 °C... -
Page 17: Specification Zwb 37-2
Product details | 17 3.11 Specification ZWB 37-2 ... ZWB 37-2 ... Unit Natural gas Propane Butane Max. heat output (P ) 40/30 °C 32.1 32.1 36.6 Max. heat output (P ) 50/30 °C 31.8 31.8 36.3 Max. heat output (P ) 80/60 °C 30.0 30.0... -
Page 18: Condensate Composition
18 | Product details ZWB 37-2 ... Unit Natural gas Propane Butane General data Power supply voltage AC ... V 220 - 240 220 - 240 220 - 240 Frequency Max. power consumption (central heating mode) EMC limit class Sound pressure level (in heating mode) ≤... -
Page 19: Regulations
Regulations | 19 Regulations Where no specific instruction is given, reference should be made to the following standards: • AS 5601 Gas Installations, • AS 1596 LPG storage and handling, • AS 4552 Gas fired water heaters for hot water supply and/or central heating, •... -
Page 20: Pre-Installation
• All system connections, taps and mixing valves must be capable of sustaining a pressure up to 3 bar (300 kPa). • Bosch recommends that thermostatic radiator valves (TRV’s) be used on all radiators within the sleeping accommodation but not the radiator where the room thermostat is sited. - Page 21 Pre-Installation | 21 S and Y plan systems: NOTE: The boiler is fitted with its own internal bypass. NOTE: B A drain point should be fitted at the lowest part of the heating circuit and beneath the boiler. Optional diverter valve This boiler is designed to operate on a sealed system only and will require a second return pipe from the water 6720644143-40.1J...
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Page 22: Condensate Pipe Work
22 | Pre-Installation Condensate pipe work 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 20mm of the factors considered in determining boiler location. - Page 23 Pre-Installation | 23 Alternatively if the first option is not possible an internal kitchen or bathroom waste pipe can be used. 20mm 40/50mm Ø 40mm Ø 6720646195-16.1Wo Fig. 13 Disposal to a waste pipe A washing machine waste pipe or bifurcated pipe etc. can also be used.
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Page 24: Installation
24 | Installation Installation Anti-freeze DANGER: Risk of explosion! The following anti-freeze fluids are permitted: B Isolate the gas supply before working on gas-carrying components. Product Concentration B Check for leaks before working on gas- Varidos FSK 22 - 55 % carrying components. -
Page 25: Checking The Size Of The Expansion
Installation | 25 Mono-lever taps and thermostatic mixer taps Siting the appliance All types of mono-lever taps and thermostatic mixer taps can be used. Regulations concerning the installation site B Observe relevant national regulations. B Consult the flue kit installation instructions for details To protect the appliance against excessive pressure: of minimum clearances required for flue gas routing. -
Page 26: Pre-Installing Pipes
26 | Installation Gas and water connections Pre-installing pipes B Hook mounting rail into the mounting plate. B Position mounting plate against the wall, observing Ø 3/4" Ø 3/4" Ø 1/2" Ø 3/4" Ø 1/2" minimum side clearances of 100 mm ( page 9). - Page 27 Installation | 27 Pipework behind the appliance The pipes can be routed behind the appliance in the guide on the mounting plate ( Fig. 18). 6 720 644 143-05.1O Fig. 17 Pipe connections Pre-plumbing jig Adaptor BSP 3/4" tapered thread with union nut G3/4" and olive to adapt to local piping connections Adaptor BSP 1/2"...
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Page 28: Fitting The Appliance
28 | Installation Preparing for fixing Fitting the appliance B Place sealing washers on the pre-plumbing jig connections. NOTE: Dirt and corrosion in the pipework B Pull lever on pressure relief valve connection forwards can damage the appliance. and push down as far as it will go ( Fig. - Page 29 Installation | 29 Drain from pressure relief valve (heating circuit) Creating the condensate drain B Push lever on slider up until catch [1] rests on metal B Push the condensate hose into the adaptor on the bracket [2] ( Fig. 13). pre-plumbing jig.
- Page 30 30 | Installation Fitting the filling loop (ZWB) Filling the heating circuit (ZWB) B Close the isolating valves on the mains water inlet [9] B Ensure that all system and boiler drain points are and the CH return [1] connections. closed.
- Page 31 Installation | 31 B Turn key [4] to position , remove and insert into the Connecting the flue pipe lower cover. B Push on the flue gas accessories and secure with the screws supplied. For more precise details of connecting the flue, refer to the installation instructions for the flue routing manual.
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Page 32: Checking The Connections
32 | Installation Checking the connections Water connections B Open the heating flow and return valves and fill the heating system. B Check sealing 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. -
Page 33: Electrical Connections
Electrical connections | 33 Electrical connections General information Connecting accessories DANGER: Risk of electric shock! Opening the Heatronic unit B Before carrying out work on electrical CAUTION: Cable offcuts can damage the components, disconnect the power Heatronic. supply (230 V AC) (fuse, circuit breaker) B Always strip cables away from the and secure against unintentional Heatronic. -
Page 34: Connecting The Heating Controller Or Remote Control Units
7.2.1 Connecting the heating controller or remote control units Only operate this appliance with a Bosch controller. Heating controller FW 100 can also be mounted right at the front in the Heatronic 3. For installation and electrical connection, see the relevant installation instructions. -
Page 35: Commissioning
Commissioning | 35 Commissioning reset 6 720 644 143-17.1O Fig. 33 Flow temperature control DHW temperature control Chimney sweep button Service button Burner ON indicator Main switch Automatic air vent valve Display Pressure gauge reset button eco button Holiday button Drain from pressure relief valve (heating circuit) Gas tap CH return isolator... -
Page 36: Before Commissioning
36 | Commissioning Before commissioning Switching the appliance on/off NOTE: Commissioning without water Switching on destroys the appliance! B Switch appliance on at the main switch. B Never run the appliance without water in The display shows the heating water flow temperature. -
Page 37: Starting The Central Heating
Commissioning | 37 Starting the central heating Setting the heating control unit The maximum flow temperature can be matched to the Follow the operating instructions for the heating system by the flow temperature controller. The heating controller used. Those instructions current flow temperature is shown on the display. -
Page 38: Appliances With Hot Water Cylinder: Setting The Hot Water Temperature
38 | Commissioning eco button Appliances with hot water cylinder: Pressing and holding the eco button until it lights up setting the hot water temperature switches between Comfort mode and Economy mode. WARNING: Danger of scalding! Comfort mode, Eco button is not lit (default setting) B In normal operation, do not set the In Comfort mode, the hot water cylinder has priority. -
Page 39: Zwb Appliances - Setting Hot Water Temperature
Commissioning | 39 ZWB appliances - setting hot water Summer mode (central heating off, temperature DHW only) B Set the DHW temperature on the DHW temperature B Note position of CH flow temperature control control B Turn CH flow temperature control anti-clockwise The set DHW temperature flashes on the display for as far as the stop... -
Page 40: Holiday Mode
40 | Commissioning 8.10 Holiday mode 8.11 Fault mode To switch on holiday mode: All safety, modulation and control components are monitored by the Heatronic system. B Press and hold holiday button on the appliance until it lights up, and switch on holiday mode on the If a fault occurs during operation, a warning tone heating controller. -
Page 41: Thermal Disinfection On Appliances With Hot Water Cylinder
Thermal disinfection on appliances with hot water cylinder | 41 Thermal disinfection on appliances with hot water cylinder To prevent the DHW becoming contaminated by bacteria such as legionella, we recommend you pasteurise the system after longer idle periods. With some heating controllers, thermal disinfection can be programmed for a fixed time;... -
Page 42: Pump Anti-Seizing Function
42 | Pump anti-seizing function Pump anti-seizing function This function prevents the heating circuit pump and the 3-way valve seizing up during long periods of inactivity. 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. -
Page 43: Heatronic Settings
Heatronic settings | 43 Heatronic settings 11.1 General information The Heatronic unit enables easy setting and testing of a Settings on the Heatronic large number of appliance functions. Service function Value For an overview of the service functions see chapter 11.2 on page 44. reset 6 720 644 143-11.1O Fig. -
Page 44: Overview Of Service Functions
44 | Heatronic settings 11.2.2 Service level 2 11.2 Overview of service functions Access from service level 1; service button lights up. B Press eco button and holiday button simultaneously 11.2.1 Service level 1 until a code such as 8.A appears. B Press service button until it illuminates. -
Page 45: Description Of Service Functions
Heatronic settings | 45 Service function 1.b: Max. output (hot water - only 11.3 Description of service functions ZWB) The hot water output can be set to any level between 11.3.1 Service level 1 minimum rated hot water output and maximum rated hot water output to limit it to the specific hot water Service function 1.A: MAX. -
Page 46: E Pump Switch Mode
46 | Heatronic settings The following can be selected as the pump characteristic Service function 1.d: Map pump step (heating) map: This service function corresponds to the pump speed switch used on conventional heating pumps. • 00 Pump step adjustable, service function 1.d However, the setting is only active if function 1.C (Pump page 46 ) map (heating)), is set to 0. -
Page 47: C Air Purge Mode
Heatronic settings | 47 Service functions 2.C: Air purge mode Service function 3.C: Anti-cycle flow temperature differential The first time the appliance is switched on, a once- onlyventing function is activated. The heating pump then The switching difference is the permissible differential switches on and off at intervals. -
Page 48: A Reset Service Reminder
48 | Heatronic settings Service function 4.F: Siphon-fill programme Service function 6.d: Current turbine flow rate (ZWB only) The syphon filling function ensures that the syphon trap is filled when the appliance is first installed or shut down The actual flow rate of the turbine is displayed. for a long period. -
Page 49: Service Level 2
Heatronic settings | 49 11.3.2 Service level 2 Service function 9.b: Actual fan speed The current fan speed is displayed in Hertz (Hz). Service function 8.A: Software version The version number of the software is displayed. Service function 9.C: Actual heating output This service function displays the current appliance Service function 8.b: Code plug heating output (in percent (%)). -
Page 50: Converting The Appliance To Different Gas Types
50 | Converting the appliance to different gas types Converting the appliance to different gas types The gas-air ratio must always be set on the basis of a 12.1 Gas-type conversion or O reading taken at maximum rated heat output and minimum rated heat output using an electronic The following gas type conversion sets are available: tester. - Page 51 Converting the appliance to different gas types | 51 B Remove the gas throttle seat with a screw driver as B Remove the sealed brass screw from gas valve shown in Fig. 49. adjusting screw and set CO or O level for minimum rated heat output.
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Page 52: Checking The Gas Supply Pressure
52 | Converting the appliance to different gas types B Repeatedly press the central heating boost button 12.3 Checking the gas supply pressure until the light goes out. The display will show the CH flow temperature again. B Switch off the appliance and turn off the gas tap. B Undo the plug on the testing point for gas inlet B Switch off the appliance, turn off the gas cock, pressure and connect a pressure gauge. -
Page 53: Flue Gas Testing
Flue gas testing | 53 Flue gas testing B Remove sealing plug from combustion air testing 13.1 Central heating boost button point (2, Fig. 54). The following appliance outputs can be selected by B Insert a flue gas probe into the testing point socket pressing the central heating boost button until it and seal the testing point. -
Page 54: Environmental Protection
54 | Environmental protection Environmental protection Environmental protection is a fundamental corporate strategy of the Bosch Group. The quality of our products, their economy and environmental safety are all of equal importance to us and all environmental protection legislation and regulations are strictly observed. -
Page 55: Inspection/Servicing
Inspection/Servicing | 55 Inspection/Servicing To ensure that gas consumption and environmental Important notes impact remain as low as possible over an extended For an overview of faults, see page 67. period of time, we recommend that you take out an inspection/servicing contract with an authorised contractor covering an annual inspection, and servicing at other times as required. -
Page 56: Checklist For Inspection/Servicing (Inspection/Servicing Report)
56 | Inspection/Servicing 15.1 Checklist for inspection/servicing (Inspection/Servicing report) Date Retrieve last fault stored on the Heatronic module, service function 6.A page 57). On Logamax plus GB042-22K appliances, check filter in cold water pipe ( page 57). Perform a visual check of the air/flue gas routing. -
Page 57: Description Of Various Servicing Operations
Inspection/Servicing | 57 15.2.3 Strainer in cold water pipe (ZWB) 15.2 Description of various servicing B Undo cold water pipe and check filter for dirt. operations 15.2.1 Retrieving last fault stored (service function 6.A) B Select service function 6.A ( page 43). -
Page 58: Plate Type Heat Exchanger (Zwb)
58 | Inspection/Servicing 15.2.4 Plate type heat exchanger (ZWB) B Undo/remove pipe unions. If the DHW output is insufficient: B Check strainer in cold water pipe for dirt page 57). B Remove plate-type heat exchanger and replace -or- B Descale only with a product that has been approved for stainless steel (1.4401). -
Page 59: Heat Exchanger
6 720 644 143-25.1O Fig. 63 Cleaning Appliance Control pressure required? ZSB 30-2 A ≥ 3.9 mbar (0.39 kPa) < 3.9 mbar (0.39 kPa) ZWB 37-2 A ≥ 3.9 mbar (0.39 kPa) < 3.9 mbar (0.39 kPa) 6 720 644 143-24.1O Fig. - Page 60 60 | Inspection/Servicing B Remove the condensate siphon and place a suitable B Clean the heat exchanger with the brush from top to container below the condensate outlet. bottom. 6 720 612 563-14.1O Fig. 66 B Remove burner ( chapter 15.2.6 “Checking the burner”) and flush the heat exchanger with water from above.
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Page 61: Burner
Inspection/Servicing | 61 15.2.6 Burner B Remove two screws [2] from top cover [1] and lift off cover ( Fig. 69). 7 181 465 330-08.2R Fig. 71 B Refit burner, possibly with a new gasket, in reverse order. 6 720 615 662-19.1O B Adjust the gas-air ratio ( page 50). -
Page 62: Diaphragm In Mixer Unit
62 | Inspection/Servicing 15.2.7 Diaphragm in mixer unit 15.2.8 Cleaning condensate trap B Remove condensate trap and check that the heat CAUTION: Ensure that the diaphragm is not exchanger connection is clear. damaged during its release and refitting! B Open the mixing chamber. B Carefully withdraw diaphragm from fan intake tube and check for soiling and splits. -
Page 63: Setting The Heating System Pressure
Inspection/Servicing | 63 15.2.10 Setting the heating system pressure NOTE: Risk of damaging the appliance. B Only top up the heating system when the appliance is cold. Pressure gauge reading 1 bar Minimum system pressure (when (100 kPa) cold) 1 - 2 bar Optimum system pressure (100 - 200 kPa) 3 bar... -
Page 64: Displays
64 | Displays Displays The display shows the following (table 25 and 26): Special display Description Value displayed Description Range Acknowledge by pressing any key (except Number or letter, Service function reset). dot followed by ( table 15/ 16, letter page 44) Acknowledge by pressing two keys Letter followed... - Page 65 Displays | 65 Special display Description Screed drying function of the weather- compensated controller ( operating instructions) or building drying function ( service function 7.E) operational. Table 26 Special displays 6 720 644 143 (2010/09)
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Page 66: Fault Mode
66 | Fault mode Fault mode All safety, modulation and control components are 17.1 Troubleshooting monitored by the Heatronic system. DANGER: Risk of explosion! If a fault occurs during operation, a warning tone sounds. B Turn off gas valve before working on gas- carrying components. -
Page 67: Faults That Are Shown On The Display
Fault mode | 67 17.2 Faults that are shown on the display Display code Description Remedy Temperature sensor for hot water is B Check temperature sensor and lead for breaks or short faulty. circuits, and replace if required. B Plug in boiler coding card correctly; replace if required. (ZWB) Communication fault. - Page 68 68 | Fault mode Display code Description Remedy Heat exchanger temperature limiter or B Check heat exchanger temperature limiter and lead for flue gas temperature limiter has tripped. breaks or short circuits; replace if required. B Check flue gas temperature limiter and lead for breaks or short circuits;...
- Page 69 Fault mode | 69 Display code Description Remedy A flame is detected after the gas has been B Check gas valve; replace if required. switched off. B Clean condensate trap. B Check electrodes and lead; replace if required. B Check flue gas system; clean or repair if required. Reset was pressed in error.
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Page 70: Faults That Are Not Shown On The Display
70 | Fault mode 17.3 Faults that are not shown on the display Appliance faults Remedy Combustion noise too loud; rumbling noises B Plug in boiler coding card correctly; replace if required. B Check gas type. B Check gas supply pressure; adjust if required. B Check flue gas system;... -
Page 71: Sensor Values
1 262 1 093 Table 30 17.5 Code Plug 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 8 714 431 014 0 ZWB 37-2 A 31... -
Page 72: Settings For Heating Output With Zsb 30
72 | Fault mode 17.6 Settings for heating output with 17.7 Settings for heating output with ZSB 30 ...23 ZSB 30 ...31 Propane Butane Gross calorific value (MJ/m ) (15 °C): 37.8 Display Heat Gas con~ Heat Gas con~ output sumption output sumption... -
Page 73: Settings For Heating Output With Zwb 37
Fault mode | 73 17.8 Settings for heating output with 17.9 Settings for heating output with ZWB 37 ...23 ZWB 37 ...31 Propane Butane Gross calorific value (MJ/m ) (15 °C): 37.8 Display Heat Gas con- Heat Gas con- output sumption output sumption... -
Page 74: Commissioning Report For The Appliance
74 | Commissioning report for the appliance Commissioning report for the appliance Customer/system user: Surname, first name Street, house number Telephone/fax Postcode, town System installer: Order number: Appliance type: (Complete a separate report for every appliance!) Serial number: Date commissioned: Individual appliance | Cascade, number of appliances: .. - Page 75 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 customer. This does not imply any liability for the installation performance.
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Page 76: Index
Switching off ..........Checking the size ......Appliance commissioning report ........Explanation of model code Appliance details Specification ............ - ZSB 30-2 ..........- ZWB 37-2............Fault mode ........... Appliance layout ..............Faults ....Faults that are not shown on the display ....... - Page 77 Index | 77 Pump switching type for heating mode (service function 1.E) ............46 Maintenance operations ....Reset inspection (service function 5.A) ....Setting the heating system pressure Restoring appliance (Heatronic 3) to standard ......Measuring CO content of flue gas settings (service function 8.E) .........49 ..........
- Page 78 78 | Notes 6 720 644 143 (2010/09)
- Page 79 | 79 Notes 6 720 644 143 (2010/09)
- 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...