Table Of Contents - Bosch Greenstar combi 100 p Installation And Service Instructions For Contractors

2 | Contents
Contents
1 Explanation of symbols and safety instructions. . . . . . . . . . . . 3
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 4
2 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Overview of boiler types . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Product dimensions and minimum clearances . . . . . . . . 7
3.7 ZWB..-3A appliance layout . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10 Condensate composition . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Compliance with standards and regulations . . . . . . . . . 13
4.2 Operating limits of the boiler . . . . . . . . . . . . . . . . . . . . . 14
4.3 Additional regulations for installations in the
Commonwealth of Massachusetts . . . . . . . . . . . . . . . . . 14
5 Examples of Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Multiple zones using zone valves with DHW. . . . . . . . . . 15
5.2 Multiple zones using circulators with DHW . . . . . . . . . . 17
6 Notes on installation and operation . . . . . . . . . . . . . . . . . . . . . 19
6.1 Notes on installation and operation . . . . . . . . . . . . . . . . 19
6.1.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.2 Other important information . . . . . . . . . . . . . . . . . . . . . 20
6.2 Selecting an external expansion vessel . . . . . . . . . . . . . 20
6.3 Selecting the installation location . . . . . . . . . . . . . . . . . 20
6.4 Pre-installing pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.5 Mounting the appliance. . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.6 Installing the low water cut off (LWCO) . . . . . . . . . . . . . 23
6.7 Connecting flue gas accessories . . . . . . . . . . . . . . . . . . 23
6.7.1 Installation of the exhaust and air intake system . . . . . . 24
6.7.2 Examples of approved horizontal and vertical
venting installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.7.3 Vent and combustion air pipe lengths . . . . . . . . . . . . . . 30
6.8 Testing gas and water connections for leaks . . . . . . . . . 31
6720872361 (2017/04)
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2 Low voltage electrical connections in the
Heatronic boiler control . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.1 Open the Heatronic boiler control . . . . . . . . . . . . . . . . . 32
7.2.2 Connecting the outdoor temperature sensor
(accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2.3 Connecting additional accessories . . . . . . . . . . . . . . . . 33
7.3 Connecting power supply . . . . . . . . . . . . . . . . . . . . . . . . 34
7.4 Connecting the LWCO device . . . . . . . . . . . . . . . . . . . . . 35
8 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.1 Before operating the appliance . . . . . . . . . . . . . . . . . . . 37
8.2 Switching the appliance ON/OFF. . . . . . . . . . . . . . . . . . 37
8.3 Switch on heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.4 Setting the DHW temperature . . . . . . . . . . . . . . . . . . . . 37
8.5 Setting manual summer mode . . . . . . . . . . . . . . . . . . . . 38
8.6 Setting frost protection. . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.7 Activating the key pad lock . . . . . . . . . . . . . . . . . . . . . . . 38
9 Boiler circulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.1 Pump anti-seize protection. . . . . . . . . . . . . . . . . . . . . . . 39
9.2 Changing the pump curve of the boiler pump . . . . . . . . 39
10 Heatronic boiler control settings . . . . . . . . . . . . . . . . . . . . . . . 39
10.1 Guideline to service functions . . . . . . . . . . . . . . . . . . . . 39
10.2 Overview of the service functions . . . . . . . . . . . . . . . . . 40
10.2.1 Service-level 1 (Press and hold the service button
until it lights up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.2.2 Second service level (at first service level, service
button lights up, press ECO button and key pad
lock button simultaneously until 8.A appears) . . . . . . . 40
10.3 Description of the service functions . . . . . . . . . . . . . . . 40
10.3.1 First service level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.3.2 Second service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11 Gas adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1 Converting to a different gas type . . . . . . . . . . . . . . . . . 45
11.2 Installation location higher than 2000 feet
(610 m) above sea level . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.3 Checking and setting the gas-air ratio (CO2 or
O2), if required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.4 Dynamic gas pressure test port . . . . . . . . . . . . . . . . . . . 47
12 Flue gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.1 Emissions test button . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.2 Measuring CO content of flue gas. . . . . . . . . . . . . . . . . . 48
13 Environmental protection and disposal . . . . . . . . . . . . . . . . . . 48
Greenstar combi 100 p / 151 p