Bosch Greenstar combi 100 p Installation And Service Instructions For Contractors
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Bosch Greenstar combi 100 p Installation And Service Instructions For Contractors

Residential gas condensing boiler
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Residential Gas Condensing Boiler
Greenstar combi 100 p / 151 p
ZWB28-3A... | ZWB42-3A...
Installation and Service Instructions for Contractors
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 trained and
certified installer or the gas supply company.
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.
0010004900-002

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  • Page 1 These instructions are available in English and French. Please keep these instructions for future reference. 0010004900-002 Residential Gas Condensing Boiler Greenstar combi 100 p / 151 p ZWB28-3A... | ZWB42-3A... Installation and Service Instructions for Contractors...

  • Page 2: Table Of Contents

    Measuring CO content of flue gas....48 13 Environmental protection and disposal ....48 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 3: Explanation Of Symbols And Safety Instructions

    17 Commissioning log for the appliance....60 people or property. Additional symbols Symbol Explanation ▶ Sequence of steps  Cross-reference to another part of the document • Listing/list entry – Listing/list entry (2nd level) Table 1 Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 4: General Safety Instructions

    DANGER: Risk of personal injury or death after a flood! ▶ Do not attempt to operate an appliance if any part of it has been under water. ▶ An appliance that was subject to flooding must be replaced. 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 5: Scope Of Delivery

    Gas conversion kit Adapter for connection of a LWCO 6 720 641 933-84.2O Fig. 2 Data plate location The rating plate contains the appliance output, model number, approval data and serial number. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 6: Appliance Description

    CZM 100 is an expansion module for several heating zones with valves or pumps. Optional combination with CRC 100 and CRC 200. • Bosch remote control FW 200 USA (part number 8 718 226 215 0): weather-compensated heating controller. Optional combination with ICM 100.

  • Page 7: Product Dimensions And Minimum Clearances

    Dimensions and minimum clearances (front view, rear view, side view) Outer jacket complete Front cover Hydraulics connection plate Zero clearance from combustibles permitted, but 4" (102 mm) recommended for serviceability (**) Distance to door, if mounted inside a closet Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 8: Zwb

    8 | Product Description ZWB..-3A appliance layout 6 720 641 933-03.2O Fig. 4 ZWB..-3A appliance layout 6720872361 (2017/04) Greenstar combi 100 p / 151 p...
  • Page 9 [38] Drain cock [39] Condensate drain hose [40] Boiler circulator [41] Pump speed switch [42] Pressure relief valve (heating zone) [43] Safety relief valve discharge hose [44] Boiler water pressure gauge Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 10: Electrical Wiring

    [23] Flow turbine complete Outdoor temperature sensor [24] Additional supply temperature limiter [10] Code plug [25] External system supply temperature sensor [11] Diagnostic interface [12] ON/OFF power switch [13] Gas valve 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 11: Technical Data

    Weight (without packaging) lbs. (kg) 110.2 (50) 110.2 (50) Dimensions, W x H x D inch 17-21/64" × 33-15/32" × 13-57/64" (mm) (440 × 850 × 353) Table 3 Technical data ZWB28-3A... Greenstar combi 100 p / 151 p 6720872361 (2017/04)
  • Page 12 133/91 (56/33) at max. nominal output 11.0 at minimum nominal output 10.4 Condensate Max. condensate quantity (t = 86 °F (30 °C)) gph (l/h) 0.9 (3.5) 0.9 (3.5) pH level, approx. – 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 13: Condensate Composition

    Controls and Safety Devices for. Automatically Fired Boilers, ANSI/ASME CSD-1. Install CO detectors per local regulations. Wall-mounted gas condensing boilers require yearly maintenance ( Chapter 14, page 48). Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 14: Operating Limits Of The Boiler

    “GAS VENT DIRECTLY BELOW. DO NOT BLOCK.” • CHECK. The state or local gas inspector of the side wall horizontally vented gas-fueled equipment shall not approve the installation unless, upon inspections, the inspector observes carbon monoxide 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 15: Examples Of Installations

    To heating zone 3 Bosch room temperature controller heating zone 3 (CRC100) Motorized valve heating zone 2 For all accessories not included in the package please refer to the Bosch To heating zone 2 Product Catalog. Bosch room temperature controller heating zone 2(CRC100)
  • Page 16 PCB in wall-mounted gas condensing boiler 120 V AC mains power (white plug) ( Chapter 7.3, page 34) 120 V AC, 60 Hz For all accessories not included in the package please refer to the Bosch System pump Product Catalog.

  • Page 17: Multiple Zones Using Circulators With Dhw

    Piping Pump heating zone 3 To heating zone 3 Bosch room temperature controller heating zone 3 (CRC100) For all accessories not included in the package please refer to the Bosch Pump heating zone 2 Product Catalog. To heating zone 2...
  • Page 18 [10] DHW temperature sensor (inside gas condensing boiler) [11] Optionally connect external system supply temperature sensor for system supply pipe here (with white plug) For all accessories not included in the package please refer to the Bosch Product Catalog. 6720872361 (2017/04)

  • Page 19: Notes On Installation And Operation

    ▶ Empty out sediment traps. Anti-freeze ▶ Systems containing antifreeze not approved by Bosch, must be completely flushed to ensure no old fluid remains. NOTICE: ▶ Fill the system with fresh water and the proper amount of inhibitor.

  • Page 20: Other Important Information

    Trichloroethylene, tetrachloroethylene, fluorinated ▶ Install a pressure regulator with a safety valve. hydrocarbons Degreasing bath Perchloroethylene, trichloroethylene, methylchloroform Printing shops Trichloroethylene Hair salons Aerosol propellants, hydrocarbons containing fluorine and chlorine (difluorodichloromethane) 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 21: Pre-Installing Pipes

    Cold water, R 3/4" NPT For walls with insufficient load capacity, the appliance and the Heating return, R 1" NPT hydraulics connection plate must be mounted on a sheet of plywood or similar reinforcement. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 22: Mounting The Appliance

    ▶ Place the gaskets on the pipe connections. ▶ Hang the appliance. ▶ Check the positioning of the gaskets on the pipe connections. ▶ Tighten the union nuts on the pipe connections. 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 23: Installing The Low Water Cut Off (Lwco)

    Ø > Ø • Hydrolevel Safgard 1100 The device is available at most Bosch wholesalers. It requires an Ø external 24VAC AC 20VA transformer provided on site. When a different LWCO is used, it must be installed outside the wall- mounted gas condensing boiler.

  • Page 24: Installation Of The Exhaust And Air Intake System

    As an alternative to twin pipe venting, a purposely designed and built telescopic concentric vent kit can be obtained as an accessory from Bosch Thermotechnology for a horizontal direct vent wall termination. This vent system can be used for vent lengths of 2 feet to 3 feet (610 mm to 915 mm).
  • Page 25 The flue pipe must be supported properly and angled downward at least ¼ inch (6.35 mm) per foot from the wall-mounted gas condensing boiler. This allows the condensate to drain away. Greenstar combi 100 p / 151 p 6720872361 (2017/04)
  • Page 26 Ø 3" (Ø 76 mm) twin pipe termination M&G Duravent PolyPro 3PPS-HTP Ø 3" (Ø 76 mm) single pipe termination M&G Duravent PolyPro 3PPS-HST Ø 3" / Ø 5" (Ø 80/125 mm) Bosch Greenstar Bosch 7738003218 Horizontal Telescopic Terminal Kit Table 13 Wall terminals 6720872361 (2017/04)
  • Page 27 Authority Having Jurisdiction. 2) A vent shall not terminate directly above a sidewalk or paved driveway that is located between 2 single family dwellings and serves both dwellings. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 28: Examples Of Approved Horizontal And Vertical Venting Installation

    6 720 641 933-05.2O Key to Fig. 25 and Fig. 26: Intake Fig. 28 Horizontal venting system (sealed combustion) Exhaust Key to Fig. 27 and Fig. 28: Intake, behind exhaust Exhaust Wall termination 6720872361 (2017/04) Greenstar combi 100 p / 151 p...
  • Page 29 Fig. 30 Vertical venting system (room air only) Fig. 31 Vertical venting system (sealed combustion) Key to Fig. 29, Fig. 30 and Fig. 31: Intake Exhaust Greater than 12 inches (305 mm) Greater than 12 inches (305 mm) Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 30: Vent And Combustion Air Pipe Lengths

    8 elbows each. Intake Exhaust Greater than 12 inches (305 mm) Greater than 12 inches (305 mm) 0010004964-001 Fig. 33 PolyPro Flex chimney cap (PP) flue gas routing (sealed combustion) Intake Exhaust 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 31: Testing Gas And Water Connections For Leaks

    Gas line ▶ Close the gas shutoff valve to protect the gas valve from damage. ▶ Check all connections for leakage (test pressure: Max. 60" W.C. (150 mbar)). ▶ Release pressure. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 32: Electrical Connection

    Replacement fuses can be found on the back of the cover ( Fig. 36, page 32.) Controls and modules For installation and electrical connection of controls and modules, see the installation instructions of the accessory. 6 720 641 933-86.1O Fig. 36 Remove the cover 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 33: Connecting The Outdoor Temperature Sensor

    ▶ Feed cable through strain relief and connect accordingly. ▶ Secure the cable on the strain relief. ϑ Bosch room controls Connect only Bosch room controls to the internal BUS of this boiler. ≤ 4" For installation and electrical connection, see the installation (102 mm) 6 720 641 933-97.1o...

  • Page 34: Connecting Power Supply

    6 720 641 933-70.2O Fig. 42 Electrical wiring third party room thermostat or zone control To communicate a heat demand the third party room thermostat or zone control must connect pins 2 and 4. 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 35: Connecting The Lwco Device

    ▶ Connect the two leads labeled 24 V HOT (red) and 24 V COMMON (white) to the external 24 VAC transformer. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 36: Commissioning

    [11] DHW thermostat [12] Safety relief valve discharge hose [13] Condensate drain hose [14] Heating return pipe [15] Cold water [16] Gas pipe [17] DHW [18] Supply pipe [19] Boiler high limit dial 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 37: Before Operating The Appliance

    ▶ If the appliance is taken out of service for a longer period: Observe approx. 122 °F (50 °C) frost protection ( Section 8.6). approx. 140 °F (60 °C) Table 21 Hot water temperature Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 38: Setting Manual Summer Mode

    Fig. 51 Frost protection of the heating system -or- If you want to leave the appliance switched OFF: ▶ Mix Bosch-approved anti-freeze into the heating water ( Tab. 19, The DHW on demand signal allows maximum gas and water savings.

  • Page 39: Boiler Circulator

    The light of the emissions test button will go out. In order to save as much energy as possible and keep any water circulation noises to a minimum, select the lowest possible pump speed. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 40: Overview Of The Service Functions

    Table 22 Service functions, 1nd level ▶ Select the DHW output in MBH (kW) and determine the associated setting in percent (%). ▶ Enter the setting ( 10.1). ▶ Save the setting ( 10.1). 6720872361 (2017/04) Greenstar combi 100 p / 151 p...
  • Page 41 • 01: Purging function is switched on and after completion Default setting is 00 (switched off). automatically reset to 00 • 02: Purging function is permanently on and is not reset to 00 Default setting is 01. Greenstar combi 100 p / 151 p 6720872361 (2017/04)
  • Page 42 • 00: Condensate trap filling sequence is off. Default setting is 01 (1 minute). • 01: Trap filling program at the lowest output. • 02: Trap filling sequence at set minimum output. Default setting is 01. 6720872361 (2017/04) Greenstar combi 100 p / 151 p...
  • Page 43 With this service function you can activate and deactivate the indicator lamp for burner operation (continuously illuminated) and faults (flashing). The following settings are available: • 00: Off • 01: On Default setting is 00. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 44: Second Service Level

    Service function 8.C: GFA Gas burner control unit status Service function 9.b: Current fan speed Internal parameter. If you are on the line with Bosch Technical Support This service function allows you to display the current fan speed in you may be asked for this number.

  • Page 45: Gas Adjustment

    • 02: DHW heat demand present ▶ Follow the instructions from the conversion kit. With the gas conversion kit there is no setting of the gasair ratio (CO ) necessary. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 46: Installation Location Higher Than 2000 Feet (610 M) Above Sea Level

    ▶ Briefly press the emissions test button The supply temperature alternates on the display with maximum nominal output. ▶ Measure the CO or O level and the CO content of the flue gas ( Section 12). 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 47: Dynamic Gas Pressure Test Port

    ▶ Switch the appliance OFF, turn off the gas cock, remove the pressure gauge and tighten the screw in the test port for gas inlet pressure. ▶ Reinstall the cover. 6 720 641 933-80.1O Fig. 60 Close flue gas test ports Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 48: Flue Gas Test

    ▶ Remove the flue gas probe and seal the flue gas test port properly (  Fig. 60, page 47). 1) 9.4 Vol.% with NG and 11.0 Vol.% with LPG (propane) 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 49: Description Of Various Steps

    ▶ If necessary, clean with plastic brush under running water. years after the initial commissioning. ▶ Only use a Bosch cleaning blade and Bosch cleaning brush. ▶ Only clean heat exchanger in case if soiling is clearly visible. Heatronic boiler control In case of a component defect, a fault is shown on the display.

  • Page 50: Checking Electrodes

    ▶ Loosen the quick releases (steps 1 and 2) and remove the hydraulic assembly in its entirety (step 3). Gas/Gaz? 0 010 006 918-001 Fig. 70 Check for leaks 6 720 641 933-49.2O Fig. 67 Removing the hydraulic assembly 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 51: Burner Servicing

    If mechanical cleaning is required: To clean of the heat exchanger, use Bosch burner gaskets, cleaning brush kit and cleaning blade, all of which are available as spare parts. ▶ Remove the condensate trap (steps 1 and 2) and place a suitable container underneath.
  • Page 52 ▶ Close the inspection opening again using a new gasket and tighten the screws with approx. 3.69 ft.-lbf. (5 Nm). 6 720 612 563-14.1O Fig. 75 Cleaning the heat exchanger with the cleaning brush ▶ Remove burner ( Chapter 14.1.5 “Burner servicing”). 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 53: Cleaning Condensate Trap

    14.1.12 Checking the electrical wiring ▶ Check electrical wiring for mechanical damage and replace defective cables. 6 720 641 933-94.1o Fig. 79 Opening the mixer unit Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 54: Maintenance And Inspection Checklist

    Check the heating system filling pressure. psi (bar) Inspect electrical wiring for damage. Check settings of the heating control. Check set service functions according to commissioning report. Table 29 Maintenance and inspection checklist 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 55: Readings On The Display

    ( operating instructions) or building drying function ( service function 7.E) are activated. Key pad lock enabled. To unlock the key pad, press until the supply temperature is shown on the display. Table 31 Special displays Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 56: Faults

    ▶ Check fan leads and fan, replace if defective. Outdoor temperature sensor not recognized. ▶ Check outdoor temperature sensor and leads for interruptions, replace if defective. ▶ Verify the outdoor temperature sensor is connected to terminals A and F. 6720872361 (2017/04) Greenstar combi 100 p / 151 p...
  • Page 57 Flame detected even when burner is off. ▶ Check electrodes; replace if defective. ▶ Check flue gas system; clean or repair if defective. ▶ Check PCB for moisture; dry if needed. Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 58: Faults That Are Not Shown On The Display

    Heatronic is flashing (i.e. all buttons, all display segments, ▶ Replace fuse Si 3 (24 V) (6.3 A fuse according to IEC default). burner indicator etc. are flashing) Table 33 Faults not shown on the display 6720872361 (2017/04) Greenstar combi 100 p / 151 p...

  • Page 59: Check Sensor Values

    140 (60) 3,025 ZWB42-3A LPG 8 714 432 505 0 158 (70) 2,176 Table 37 Code plug 176 (80) 1,589 194 (90) 1,177 212 (100) Table 35 Resistance table supply temperature limiter Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 60: Commissioning Log For The Appliance

    Minimum measured supply temperature: °F ( °C) System hydraulics:  Low-loss header, type:  Additional expansion vessel  Heating pump: Size/pre-charge pressure:  Hydraulic separation Automatic air vent present?  Yes |  No 6720872361 (2017/04) Greenstar combi 100 p / 151 p...
  • Page 61 Attention has been drawn to the requirement for regular maintenance of the above-mentioned heating system. ___________________________________________________________ __________________________________________________________ Name of service engineer Date, user's signature Affix the test report here. ____________________________________________________________ Date, system installer's signature Table 38 Commissioning log Greenstar combi 100 p / 151 p 6720872361 (2017/04)

  • Page 62: List Of Keywords

    External expansion vessel ........20 6720872361 (2017/04) Greenstar combi 100 p / 151 p...
  • Page 63 Heat output (service function 1.A) ......40 Hot water temperature (service function A.b) ....45 Greenstar combi 100 p / 151 p 6720872361 (2017/04)
  • Page 64 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-965-7581 www.bosch-climate.us U.S.A. Products manufactured by Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.bosch-thermotechnology.com Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.

This manual is also suitable for:

Greenstar combi 151 pZwb42-3a seriesZwb28-3a series

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