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Bosch Greenstar ZBR16-3A Operating Instructions Manual

Gas condensing boiler
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Gas Condensing Boiler
Greenstar
ZBR16/28/35/42-3A... | ZWB28/42-3A...
Operating Instructions

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Summary of Contents for Bosch Greenstar ZBR16-3A

  • Page 1 Gas Condensing Boiler Greenstar ZBR16/28/35/42-3A... | ZWB28/42-3A... Operating Instructions...

  • Page 2: General Information

    2 | General information General information This manual is available in English and French. Keep this manual for future use. CAUTION: B Observe the safety instructions of this manual before putting the heating appliance into operation. 6 720 644 013 (2011/02)
  • Page 3 General information | 3 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. B Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

  • Page 4: Table Of Contents

    4 | Contents Contents Guideline to symbols and safety instructions ..6 Guideline to symbols ......6 Safety instructions .
  • Page 5 Contents | 5 Thermal disinfection ......34 Energy saving tips ....... 36 Troubleshooting .

  • Page 6: Guideline To Symbols And Safety Instructions

    6 | Guideline to symbols and safety instructions Guideline to symbols and safety instructions Guideline to symbols Warnings Warnings are indicated in the text by a warning triangle and a gray background. In case of danger from electric shock, the exclamation point on the warning triangle is replaced with a flash.
  • Page 7 Guideline to symbols and safety instructions | 7 Important Information Important information neither indicating personal injury nor damage to property are marked with this symbol. They are separated by lines above and below the text. Additional symbols Symbol Explanation Sequence of steps Æ...

  • Page 8: Safety Instructions

    8 | Guideline to symbols and safety instructions Safety instructions If you smell gas B Turn off the gas cock (Æ page 18). B Open windows and doors. B Do not operate any electrical switches. B Extinguish all open flames. B From outside the building, call gas utility company and a trained and certified heating contractor.
  • Page 9 Guideline to symbols and safety instructions | 9 Danger of explosion of flammable gases. B Only employ a trained and certified contractor to carry out work on the gas train. Risk of scalding B If running at DHW temperatures above 104 °F (40 °C) ask a trained and certified heating contractor to install a tempering valve to prevent scalding.
  • Page 10 10 | Guideline to symbols and safety instructions Inspection and maintenance The operator is responsible for safety and environmental compliance of the heating system. Sign a maintenance and inspection contract with a trained and certified contractor, covering an annual inspection and demand- dependent maintenance.

  • Page 11: Information About The Appliance

    Information about the appliance | 11 Information about the appliance Certifications This product has been tested and certified for the US and the Canadian market and complies with all applicable standards required for the US and the Canadian market. Proper use The appliance may only be installed in closed loop hot water central heating systems.

  • Page 12: Overview Of Boiler Types

    12 | Information about the appliance Overview of boiler types Greenstar ZBR16-3A ZBR28-3A ZBR35-3A ZBR42-3A ZWB28-3A ZWB42-3A Tab. 2 Central heating appliance DHW heating Condensing technology Constant temperature control 16…42 Output up to 54,600 / 95,500 / 119,400 / 143,300 BTU/hr (16 / 28 / 35 / 42 kW) Version Fan-supported appliance 6 720 644 013 (2011/02)

  • Page 13: Preparing The Appliance For Operation

    Preparing the appliance for operation | 13 Preparing the appliance for operation B If existing, open the heating supply valve and the heating return valve. B If existing, open the cold water valve and the DHW valve. B When using ZBR..-3A appliances with DHW tank, open a DHW tap until water runs out.

  • Page 14: Checking The Boiler Water Pressure

    14 | Preparing the appliance for operation Checking the boiler water pressure The standard boiler water pressure is 14.5 - 21.75 psi (1 - 1.5 bar). Should a higher boiler water pressure be required, refer to a trained and certified heating contractor. 6 720 641 934-04.2O Fig.

  • Page 15: Topping Up The Heating System Water

    Preparing the appliance for operation | 15 Topping up the heating system water Topping up the heating system water is different on every system. Therefore, you should ask a trained and certified heating contractor to show you how it is done. Maximum pressure of 30 psi (2.07 bar) at maximum heating water temperature must not be exceeded (safety valve will spill).

  • Page 16: Operation

    16 | Operation Operation These operating instructions apply only to the boiler. Depending on the heating control unit used, some functions may vary. The following options for controlling the heating system are available: • Outdoor reset control unit (Æ page 23, Fig. 7) installed in the boiler (Æ...
  • Page 17 Operation | 17 Page 42 contains a quick reference. You can fold this outward and keep these operating instructions in the control panel cover. 6 720 614 235-04.1O Fig. 3 6 720 644 013 (2011/02)

  • Page 18: Overview Of Controls

    18 | Operation Overview of controls reset 6 720 641 934-01.1O Fig. 4 6 720 644 013 (2011/02)
  • Page 19 Operation | 19 Emission test button for contractors (see installation instructions) Service button for contractors (see installation instructions) Burner ON indicator lamp ON/OFF switch Key pad lock ECO button Reset button Display Boiler water pressure gauge DHW thermostat Safety relief valve discharge hose Condensate drain hose Heating return pipe Cold water pipe - combi boiler only...

  • Page 20: Switching The Appliance On/Off

    20 | Operation Switching the appliance ON/OFF Startup B Switch the appliance ON using the ON/OFF switch. The display shows the supply temperature. Fig. 5 If the display shows in alternation with the supply temperature, the appliance operates at its lowest output for 15 minutes per the initial startup sequence.

  • Page 21: Turning The Space Heating On

    Operation | 21 Turning the space heating ON The maximum supply temperature can be set from 95 °F (35 °C) up to approx. 194 °F (90 °C). The current supply temperature is shown on the display. With radiant floor heating, limit the maximum permissible supply temperature.
  • Page 22 22 | Operation Boiler high Typical supply limit dial temperatures Sample application approx. 95 °F Frost protection (35 °C) approx. 109 °F (43 °C) approx. 122 °F Radiant floor heating (50 °C) system approx. 140 °F (60 °C) approx. 153 °F (67 °C) Radiator heating system approx.

  • Page 23: Programming The Heating Control Unit

    Operation | 23 Programming the heating control unit Observe the operating instructions for the heating control unit included in the scope of delivery. There you can read: B How to set the operating mode and the heating curve for outdoor reset controls B How to adjust the room temperature B How to heat economically and save energy 6 720 612 660-07.2O...

  • Page 24: Zbr

    24 | Operation ZBR..-3A appliances with DHW tank: Setting the DHW temperature DANGER: Danger of scalding! B In normal operation, it is recommended to limit the DHW temperature to 122 °F (50 °C) to limit the risk of scalding. B Only set temperatures up to 158 °F (70 °C) for thermal disinfection (Æ...
  • Page 25 Operation | 25 If there is reason for concern for contamination from bacteria such as legionella, consider setting the DHW thermostat to at least “e” (131 °F (55 °C)). This setting ensures an economical and comfortable DHW generation. Consult your local water department or municipality for further information.
  • Page 26 26 | Operation ECO button Pressing and holding the ECO button until it lights up switches between Comfort mode and Economy mode. • Comfort mode, ECO button is not lit (default setting) In Comfort mode, the DHW tank has priority. The DHW tank is heated to the set temperature first.

  • Page 27: Zwb

    Operation | 27 ZWB..-3A appliances (combi boilers): Setting the DHW temperature B Set the DHW temperature on the DHW thermostat The set DHW temperature flashes on the display for 30 seconds. reset 6 720 641 933-55.1O Fig. 9 DHW thermostat Typical DHW temperatures approx.
  • Page 28 28 | Operation ECO button Pressing and holding the ECO button until it lights up switches between Comfort mode and Economy mode. • Comfort mode (default setting) The appliance is continually maintained at the set temperature. Consequently, DHW draws are immediate, however the appliance may run even if no DHW is being drawn.

  • Page 29: Setting Manual Summer Mode

    Operation | 29 Setting manual summer mode In summer mode or warm weather shut down (WWSD), the heating zone pump and consequently central heating are switched off. DHW generation remains active following the DHW program. NOTICE: Heating system at risk of freezing. In manual summer mode, only the appliance is protected from freezing.

  • Page 30: Setting Frost Protection

    30 | Operation Setting frost protection Frost protection of the heating system: B Leave the appliance switched ON; turn the boiler high limit dial at least to position 1. reset 6 720 641 933-68.1O Fig. 11 For further information, see the operating instructions for the heating control unit included in the scope of delivery.
  • Page 31 Operation | 31 Frost protection of the DHW tank: B Turn the DHW thermostat counterclockwise to min (59 °F (15 °C)). reset 6 720 641 933-69.1O Fig. 12 6 720 644 013 (2011/02)

  • Page 32: Activating The Key Pad Lock

    32 | Operation Activating the key pad lock The key pad lock affects the supply temperature dial, the DHW thermostat, the service button and the ECO button. Activating the key pad lock: B Press the key pad lock button until and the heating supply temperature are alternating on the display.

  • Page 33: 4.10 Display Codes

    Operation | 33 4.10 Display codes Display Description Fault-Code (Æ chapter 7) Inspection due Pump anti-seize function active Key pad lock active Condensate trap filling function active Bleeding function active Excessively rapid increase in supply temperature (temp. gradient monitoring). Heating mode is disabled for two minutes. If this message appears repeatedly, inform a trained and certified heating contractor.

  • Page 34: Thermal Disinfection

    34 | Thermal disinfection Thermal disinfection When using ZBR..-3A appliances with DHW tank it may be necessary to disinfect the DHW tank and DHW system after longer idle periods to prevent bacterial contamination, for example from legionella bacteria. This step is typically not necessary if the drinking water is chlorinated or ozonated.
  • Page 35 Thermal disinfection | 35 Performing a manual disinfection of the DHW tank and system B Close all DHW taps. B Advise occupants of the risk of scalding if no tempering valve is installed. B Set the time and DHW temperature accordingly on the heating control unit with DHW program.

  • Page 36: Energy Saving Tips

    36 | Energy saving tips Energy saving tips Heating economically The boiler is designed to provide a high level of comfort while keeping gas consumption and the resulting environmental impact as low as possible. The gas supply to the burner is controlled according to the heat demand.
  • Page 37 Energy saving tips | 37 Thermostatic valves Fully open the thermostatic valves to ensure that the desired room temperature is reached in all cases. Allow several days for the system to stabilize after every adjustment and only change the setting for the heating curve or the room temperature on the control unit after the system had stabilized on the previous settings.

  • Page 38: Troubleshooting

    38 | Troubleshooting Troubleshooting The Heatronic boiler control monitors all safety and control components. If a fault arises during operation, an audible warning tone sounds. Press a button to mute the warning sound. The display indicates a fault code (e.g. ) and the reset button may also be flashing.
  • Page 39 Troubleshooting | 39 An overview of the display codes can be found on page 33. Appliance details If you need to call a trained and certified heating contractor, you may be asked for details on your appliance. Those details can be found on the rating plate. Greenstar (e.g.

  • Page 40: Maintenance

    40 | Maintenance Maintenance Inspection and maintenance The operator is responsible for the safety and environmental compatibility of the heating system (see local regulations). It is therefore recommended to sign a maintenance and inspection contract with a trained and certified heating contractor that provides annual inspection and maintenance.

  • Page 41: Environmental Responsibility/Disposal

    Environmental responsibility/disposal | 41 Environmental responsibility/ disposal Environmental responsibility is one of the fundamental company policies of the Bosch Group. We regard quality of performance, economy and environmental responsibility as equal objectives. Environmental protection laws and regulations are strictly adhered to.

  • Page 42: 10 Quick Reference

    Quick reference 10 Quick reference Startup DHW temperature DANGER: Danger of scalding! B In normal operation, it is recommended to limit the DHW Turning space heating ON temperature to 122 °F (50 °C) to limit the risk of reset scalding. 6 720 641 933-53.1O reset Heating control...

  • Page 43: Index

    Index | 43 Index Certifications ................11 Cleaning the outer casing ............40 Commissioning ................13 Details about the appliance - proper use................11 - type overview ................ 12 DHW temperature ..............24, 27 Disinfection................34 Disposal ..................41 ECO button ................26, 28 Energy saving tips ..............
  • Page 44 44 | Index General information..............2 Heating control ................23 Information about the appliance ..........11 Key pad lock ................32 Maintenance ................40 Old appliances ................41 Operation................... 16 Overview of controls..............18 Packaging................... 41 Proper use ................. 11 6 720 644 013 (2011/02)
  • Page 45 Index | 45 Recycling..................41 Safety instructions ............... 8 Summer mode................29 Supply temperature ..............21 Switching the appliance OFF ............. 20 Switching the appliance ON ............20 Thermal disinfection .............. 9, 34 Type overview ................12 6 720 644 013 (2011/02)
  • Page 46 46 | Notes 6 720 644 013 (2011/02)
  • Page 47 | 47 Notes 6 720 644 013 (2011/02)
  • Page 48 603-584-1681...

This manual is also suitable for:

Zbr28-3aZbr35-3aZwb28-3aZbr42-3aZwb42-3a

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