Related Manuals for Bosch ZSB18 - 2A
Summary of Contents for Bosch ZSB18 - 2A
- Page 1 HYDRONIC GAS SYSTEM BOILER 18kW BOSCH CONDENS 5000W ZSB18 - 2A Installation and Servicing Instructions...
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Page 2: Table Of Contents
2 | Contents AU/NZ Contents Commissioning ....39 Key to symbols and safety precautions ..3 5.5.1 Checking the gas inlet pressure . -
Page 3: Key To Symbols And Safety Precautions
Failure to install this boiler correctly could lead to which is printed on a grey background. prosecution. If you are in any doubt contact the Robert Bosch Electrical hazards are identified by a technical hotline on: lightning symbol surrounded by a warning triangle. -
Page 4: Safety Precautions
4 | KEY TO SYMBOLS AND SAFETY PRECAUTIONS AU/NZ Safety precautions If you smell gas: Servicing B CALL THE FEDERAL GOVERNMENTS SAFETY Advise the user to have the system serviced annually by HOTLINE ON 13 17 92 an authorised person. Approved spares must be used to B LPG BOILERS CALL THE SUPPLIER‘S NUMBER ON help maintain the economy, safety and reliability of the THE SIDE OF THE LPG TANK/CYLINDER... - Page 5 AU/NZ KEY TO SYMBOLS AND SAFETY PRECAUTIONS | 5 Boiler features and checklist • Pre-wired and pre-plumbed • Galvanised steel inner frame • Digital control system • Intelligent controls • Automatic ignition • Direct burner ignition electrodes • Built-in frost protection •...
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Page 6: Boiler Information
6 | Boiler information AU/NZ Boiler information Boiler Depth to wall 330mm (When fitted to wall frame) 700mm* 400mm * 710mm to top of case front 6720646195-01.1Wo Fig. 1 Boiler carton contents Standard package: Hydronic system boiler Fascia panel Wall mounting frame Syphon assembly Hardware literature pack (see checklist) Metric to Imperial adapter pack... -
Page 7: Technical Data
AU/NZ Boiler information | 7 Technical data Description Natural gas UNIT 18kW Gas flow rate - Max. 10 minutes from lighting Natural gas G20 MJ/h 73.84 Liquefied petroleum gas (LPG) kg/h Central heating Maximum rated heat input (net) 18.48 Minimum heat input 5.54 Max. -
Page 8: Layout
8 | Boiler information AU/NZ Layout Fig. 2 Main boiler components 6 720 646 195a (2010/11) - Page 9 AU/NZ Boiler information | 9 Expansion vessel Hydraulic block mounting plate Sensor - boiler flow Left side hand-hold for lifting boiler Removable panel - for servicing Gas valve Electrode assembly Flue air pressure switch connection (not used) Overheat thermostat Securing nut - air/gas manifold clamp Fan guard Silicon tube - heat exchanger air vent Manual vent point...
- Page 10 10 | Boiler information AU/NZ Fig. 4 Additional components Burner ON indicator light (green) PRV pipe connection point Power ON/OFF indicator/fault diagnostic light (blue) CH return isolator Position for optional programmer Gas inlet connection BSP ¾ inch thread Reset button CH flow isolator System pressure gauge Condensate connection...
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Page 11: Pre-Installation
AU/NZ Pre-installation | 11 Pre-installation Cleaning primary systems Inhibitor NOTE: Add a suitable inhibitor or combined inhibitor/anti- B All the following pre-installation sections freeze, if the system is exposed to freezing conditions, to must be read and requirements met the heating system in accordance with the before starting boiler or flue installations. -
Page 12: Mains Supply
12 | Pre-installation AU/NZ Mains supply 3.2.1 Electrical supply 3.2.3 Gas supply • Supply: 240V - 50 Hz, 140 Watts • Boilers using natural gas (NG) must be connected to a governed meter. • Cable: PVC insulated 0.75 mm (24 x 0.2 mm) temperature rated to 90 °C. -
Page 13: Water System And Pipe Work
• All system connections, taps and mixing valves must be capable of sustaining a pressure up to 3 bar. SYSTEM MAKE UP • Bosch recommends that thermostatic radiator valves Make up Heating (TRV’s) be used on all radiators within the sleeping... - Page 14 14 | Pre-installation AU/NZ S and Y plan systems: S plan layout NOTE: The boiler is fitted with its own internal bypass. Diverter valve Radiator valve (flow) Lock shield valve (return) Bypass Tab. 9 6720644743-05.1Wo Fig. 7 S plan NOTE: Y plan layout B A drain point should be fitted at the with external diverter valve...
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Page 15: Condensate Pipe Work
AU/NZ Pre-installation | 15 Condensate pipe work NOTE: BWhere a new or replacement boiler is being installed and freezing conditions are possible, access to an internal “gravity 20mm discharge” point should be one of the factors considered in determining boiler location. -
Page 16: Pressure Relief Drain Line
16 | Pre-installation AU/NZ Pressure relief drain line NOTE: B The PRV is a safety device for the boiler and if activated may discharge boiling water steam through the relief valve drain line. B Care should be taken when siting the drain line so that it does not cause an obstruction or discharge above a window, entrance or other public access... -
Page 17: Boiler Location And Clearances
AU/NZ Pre-installation | 17 Boiler location and clearances 3.6.1 Installation 3.6.3 Compartments This boiler is only suitable for installing internally within • Minimum clearances must be maintained. a property at a suitable location onto a fixed, rigid • An access door is required to install, service and surface at least the same size as the boiler and capable maintain the boiler and any ancillary equipment. -
Page 18: Boiler Clearances - Unventilated Compartments
18 | Pre-installation AU/NZ 3.6.4 Boiler clearances - Unventilated compartments The tables below show the options for the minimum space required to install and service the boiler inside an unventilated compartment. Tab. 13 3.6.5 Installation clearances - unventilated compartments CAUTION: Clearances B Top and bottom clearances must not be reduced below the values shown in table 14 as they are the minimum clearances required for servicing. -
Page 19: Plumbing Manifold
AU/NZ Pre-installation | 19 Plumbing manifold 3.7.1 Connections WARNING: If fitting an optional integral diverter valve. B Refer to the “optional integral diverter valve” installation instructions. Heating System ¾ inch BSP thread compression fittings ¾ inch BSP thread Tab. 17 Use the fittings supplied in the hardware literature pack. -
Page 20: Flue Options
20 | Pre-installation AU/NZ Flue options The Condens 5000W series has the option of three NOTE: Effective flue lengths: horizontal RSF (60/100 telescopic, 60/100 extended B each 90° bend used is equivalent to telescopic and 80/125) flue systems and two vertical 2 metres of straight flue RSF (60/100 or 80/125) flue systems: B each 45°... - Page 21 AU/NZ Pre-installation | 21 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo 6 720 646 195a (2010/11)
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Page 22: Flue Terminal Positions
22 | Pre-installation AU/NZ Flue terminal positions Door Use as a guide only. Refer to AS5601 or local gas fitting rules for specific locations T = Flue terminal M = Gas meter W = Window I = Mechanical air inlet P = Electricity meter or fuse box Shaded area indicates prohibited area 6720646195-02.1Wo... -
Page 23: Installation
AU/NZ Installation | 23 Installation Handling instructions: WARNING: All the previous “pre- • It is advised that two people are used to carry the installation” sections must be read and the carton from the van to the point of delivery. requirements met before starting boiler or flue installation. -
Page 24: Wall Mounting Template & Flue Opening
24 | Installation AU/NZ Wall mounting template & flue opening WARNING: Before drilling Ensure there are no pipes, electrical cables or other hazards. Safety All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. Fixing the wall mounting frame B The boiler template shows the relative positions of the flue and the top and bottom fixing of the mounting... -
Page 25: Unpacking The Boiler
AU/NZ Installation | 25 Unpacking the boiler 1. Outer carton 2. Inner sleeve (unwrap from front) 3. Packing base 4. Protective wrapping 5. boiler outer case B Remove outer carton (1) and place safely away from the working area. B With the outer packaging removed and the inner sleeve (2) still in place gently lay the boiler on its back. -
Page 26: Boiler Connections
26 | Installation AU/NZ Boiler connections B Fit sealing washers to service valves before hanging CAUTION: Isolate the mains gas supply boiler. before starting any work and observe all B Fit the metric to imperial (15mm to R½ ) adapter (4) relevant safety precautions. - Page 27 AU/NZ Installation | 27 Hanging the boiler B Remove the screw from the control panel retaining bracket and lower the control panel into the service CAUTION: Caps or plastic strip fitted to position. pipes must be removed before hanging the B Make connections to the heating system.
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Page 28: Flue Installation
28 | Installation AU/NZ Flue installation Horizontal flue (60/100mm Ø ) 4.5.2 Reducing the telescopic flue length For vertical flues and 80/125mm horizontal flues, please Ensure that the “top” label is facing up refer to separate instructions supplied with the flue kit. before securing the flue section to the To ease assembly of flue components, apply turret. -
Page 29: Installing The Telescopic Flue
AU/NZ Installation | 29 4.5.3 Installing the telescopic flue Refer to figure 36. B Fit the screws removed in step 1 to secure flue turret. 1. Set the flue length to the distance required, secure B If fitting the outer seal from outside the building, slide with screws provided. -
Page 30: Flue Terminal Plume Re-Direction
30 | Installation AU/NZ 4.5.4 Flue terminal plume re-direction NOTE: Outlet position The flue discharge can be re-directed allowing some B The flue terminal outlet position must plume redirection control, alternatively, a complete follow those stated in the relevant boiler plume management system can be fitted to the flue instruction manual. -
Page 31: Condensate Connection
AU/NZ Installation | 31 Condensate connection Never terminate or discharge into any open source, including; sink, bath, shower, bidet, toilet etc. • Ensure that the condensate drain is a 20mm Ø plastic pipe. The pipe must fall at least 50mm per metre towards the outlet. -
Page 32: Electrical
32 | Installation AU/NZ Electrical Refer to figure 47. CAUTION: Isolate the mains electricity 1. Unscrew the three screws in the control panel. B Remove the plug from the mains socket 2. Remove the connections cover. to isolate the electrical supply before starting any work on the boiler and observe all relevant safety precautions. - Page 33 B Refer to manufacturers‘ instructions when connecting external parts to the wiring centre. B Robert Bosch cannot be held responsible for wiring errors. B There is an option to fit an internal diverter valve. This also requires fitting an extra harness and a code plug change.
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Page 34: Commissioning
34 | Commissioning AU/NZ Commissioning Pre-commissioning checks B Turn on the main gas supply, check the gas pipe work CAUTION: Isolate the mains electricity connections and rectify any leaks. supply before starting any work and B Check that the condensate pipe (1) has been observe all relevant safety precautions. -
Page 35: Filling The System
AU/NZ Commissioning | 35 Filling the system Water treatment 1. Turn on the water main and open the system valves. NOTE: 2. Open all radiator valves. B Artificially softened water must not be 3. Fill the system via an approved filling loop to between used to fill the CH system. -
Page 36: Starting The Boiler
36 | Commissioning AU/NZ Starting the boiler CAUTION: Running the boiler B Never run the boiler when the system is empty or partially filled. Fig. 56 Control panel Switching the boiler on/off: Turn the boiler CH temperature control (1) to maximum. The burner on indicator (2) illuminates green when the B Turn on mains power supply, the power on indicator burner has lit. -
Page 37: Commissioning
AU/NZ Commissioning | 37 Commissioning Gas pressure within the system NOTE: The combustion settings on this gas- fired boiler have been checked, adjusted and Refer to the figures below for natural gas pressures. preset at the factory for operation on the gas The pressure at the boiler must not be less than the type defined on the data plate. -
Page 38: Checking The Gas Rate
38 | Commissioning AU/NZ 5.5.2 Checking the gas rate B The gas rate should be measured at the gas meter after 10 minutes operation at maximum. See technical data section at the front of this manual. B Where a gas meter is not available (e.g. LP gas) the CO/CO must be checked to the units shown in the setting of the air/gas ratio, refer to section 6.6. -
Page 39: Finishing Commissioning
AU/NZ Commissioning | 39 Finishing commissioning 5.6.1 Replace outer casing: 5.6.3 Installing bottom panel B Replace outer casing making sure that the securing B The bottom panel slides onto two ledges (C) either points are properly located. side of the boiler frame. B Replace top two screws (1). -
Page 40: Service And Spares
40 | Service and spares AU/NZ Service and spares – Undo and remove two screws (1) securing boiler Inspection and service casing at the top of the boiler. – Undo but do not remove the two screws (2). CAUTION: Turn off the gas supply and –... -
Page 41: Check The Gas Inlet Pressure
AU/NZ Service and spares | 41 Check the gas inlet pressure Fan pressure test Refer to section 5.5.1 for more information This test is to determine if the heat cell requires cleaning/attention. NOTE: B Ensure that the gas inlet pressure is satisfactory with all other gas appliances Setting the boiler to maximum working. -
Page 42: Flue Gas Analysis
42 | Service and spares AU/NZ NOTE: Flue gas analysis The boiler must be run at maximum output Combustion test: for fan pressure test and the flue gas analysis. Air inlet sample point Flue gas sample point Tab. 25 Key to figure 68 FAN PRESSURE TEST Clean Heat Ex. -
Page 43: Setting The Air/Gas Ratio
AU/NZ Service and spares | 43 Setting the air/gas ratio – Remove dust cap with flat bladed screw driver. NOTE: Setting of the gas ratio must be – Using a 4mm Allen key adjust CO carried out by an authorised person. –... -
Page 44: Cleaning The Heat Exchanger
44 | Service and spares AU/NZ Cleaning the heat exchanger B Disconnect spark electrode and flame sensor NOTE: Combustion testing connections. B Combustion testing must be carried out 1. Refer to figure 72 and undo the securing nut on the by an authorised person. - Page 45 AU/NZ Service and spares | 45 Burner removal Baffle removal Refer to figure 74. Refer to figure 75. 1. Remove clamping plate. 1. Remove top baffle. 2. Remove spark/flame electrode assembly and seal 2. Remove lower baffle. from the top of the heat exchanger. If the lower baffle is stuck, it may be 3.
- Page 46 46 | Service and spares AU/NZ Access cover removal Refer to figure 76. 1. Remove the two pozi-drive screws 2. Remove the access cover 3. Remove the gasket. Fig. 77 Cleaning heat exchanger 6720643895-112.1Wo Fig. 76 Access cover removal NOTE: Heat exchanger baffles Cleaning the primary heat exchanger The baffles (1) and (2) must be refitted into the heat exchanger in the order shown in...
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Page 47: Replacement Of Parts
AU/NZ Service and spares | 47 Replacement of parts CAUTION: Turn off the gas supply and To gain access to the following components isolate the mains supplies before starting the outer case has to be removed: any work and observe all relevant safety B Primary sensor precautions. -
Page 48: Flue Overheat Thermostat (With Grommet)
48 | Service and spares AU/NZ 6.8.4 Flue overheat thermostat 6.8.5 Moving controls to service position (with grommet) To remove the following components To remove and replace the thermostat either: require the control box must be moved in to B Using a small terminal screwdriver, prise the the service position: thermostat and grommet from the plastic housing. -
Page 49: Gas Valve
AU/NZ Service and spares | 49 6.8.6 Gas valve 6.8.7 Air/gas manifold and fan assembly Refer to figure 83 The following components require the B Isolate gas supply at boiler isolating valve. air/gas manifold and fan assembly to be removed: 1. -
Page 50: Fan
50 | Service and spares AU/NZ B Rotate fan and air/gas manifold assembly (1.) around the top of the heat exchanger until the lug on the air/ gas manifold is visible. 6720643895-63.1Wo Fig. 86 Rotate the air/gas manifold assembly 6720643895-81.1Wo B Lift up assembly and remove from boiler. -
Page 51: Electrode Assembly And Burner
AU/NZ Service and spares | 51 6.8.9 Electrode assembly and burner 6.8.10 Heat exchanger Refer to figure 89. B Isolate flow and return valves then drain the boiler. B Disconnect spark electrodes and flame sensor B Remove syphon. connection. Refer to figure 90. B Remove clamping plate. - Page 52 52 | Service and spares AU/NZ Refer to figure 92. 1. Release the clip. 2. Move the lower exhaust connector up B Remove the complete exhaust assembly. Fig. 94 Heat exchanger removal B Reassemble and check combustion as stated in the Fig.
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Page 53: Access To Boiler Control Components
AU/NZ Service and spares | 53 6.8.11 Access to boiler control components 6.8.13 Transformer/PCB 1. Remove three screws. Refer to figure 98. 2. Remove cover from control. B Disconnect all electrical connections from the control. 1. Remove five screws retaining the rear panel of the control. -
Page 54: Replacing Controls
54 | Service and spares AU/NZ 6.8.14 Replacing controls Refer to figure 101. 1. Using a suitable tool, press the button upwards. NOTE: 2. Slide the control support bracket to the left. B Do not replace the control unit if a CO/CO analyser is NOT available. -
Page 55: Syphon Removal
AU/NZ Service and spares | 55 6.8.15 Syphon removal 6.8.16 Diverter valve motor (If fitted) To release the syphon from the sump: B Connect electrical power to the boiler. 1. Disconnect the discharge hose at the plumbing B Enter the service mode to ensure that the diverter manifold. -
Page 56: Auto Air Vent
56 | Service and spares AU/NZ 6.8.18 Auto air vent 6.8.19 Pump head B Ensure the boiler is fully drained). Removal of the syphon assembly will give B Disconnect the electrical connection from the bottom access to the auto air vent. Refer to page of the pump. -
Page 57: Pressure Gauge
AU/NZ Service and spares | 57 6.8.21 Pressure gauge 2. Undo the two screws securing the hydraulic block to the chassis (located top left / top right of the B Refer to figure 108 housing). B Ensure the boiler has been fully drained. 3. -
Page 58: Ch Pressure Relief Valve
58 | Service and spares AU/NZ 6.8.23 CH Pressure relief valve 6.8.25 Expansion vessel B Remove the hydraulic block from the boiler (see The expansion vessel can be replaced with the boiler in removing the hydraulic block). position if there is a side exit flue fitted and a minimum clearance of 340mm above the boiler casing. - Page 59 AU/NZ Service and spares | 59 Expansion vessel replacement (removing the boiler) B Isolate electrical supply. B Isolate system and gas connections at the service valves. B Drain the boiler. B Disconnect electrical supply and any external controls. B Disconnect flue connection from the boiler. B Undo connection to boiler at the service valves.
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Page 60: Short Parts List
60 | Service and spares AU/NZ Short parts list Burner Gas valve 8 717 204 453 0 8 718 120 619 0 8 716 111 325 0 Control board Control box Electrodes HT3 Bus enabled assembly (including gasket) 8 748 300 650 0 8 717 207 937 8 718 107 087 0 Gasket - burner... -
Page 61: Fault Finding And Diagnosis
(i.e. not a first installation error). This fault finding information is for guidance only. Robert Bosch cannot be held Preliminary electrical system checks are the first responsible for costs incurred by incorrectly electrical checks to be carried out during a fault-finding diagnosed faults. - Page 62 62 | Fault finding and diagnosis AU/NZ Blue light Lockout indication reset button Fault Possible solution/check Slow flash Flashing Ignition lockout B Gas present and at correct pressure? (mostly (reset B Gas valve off, required) – Check that there is 35V d.c. to each solenoid flashes –...
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Page 63: Circuit Diagram
TRANSFORMER ST17 Blue EMS BUS contacts Blue Purple (for FX controls not used) Purple Orange BOSCH 24V CONTROLS Orange PLUG IN POINT Green (NOT USED) Fuse F3, slow T 0.5 A 230V/AC Fuse F2, slow T1.6 A ST18 PRE WIRED LINK... -
Page 64: Boiler Function
64 | Fault finding and diagnosis AU/NZ Boiler function 6 720 646 195a (2010/11) -
Page 65: Protection Function
AU/NZ Fault finding and diagnosis | 65 Protection function AUTOMATIC INTERNAL FROST FUNCTION Internal boiler Internal boiler Pump switches off temperature Pump runs temperature after a 3 minute between rises above 9°C overrun period 8°C & 5°C Boiler automatic frost function (monitors internal boiler primary temperature) Internal boiler... - Page 66 66 | Fault finding and diagnosis AU/NZ Notes 6 720 646 195a (2010/11)
- Page 67 AU/NZ Fault finding and diagnosis | 67 Notes 6 720 646 195a (2010/11)
- Page 68 Australia Robert Bosch (Australia) Pty. Ltd. 1555 Centre Road, CLAYTON, Victoria 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...