Testing Gas And Water Connections For Leaks; Making The Electrical Connections; General Notes - Bosch ZBR16-3A Series Installation And Service Instructions Manual

Installations  Fig. 35 Stainless steel wall termination
2" PIPE Maximum straight vent pipe length allowed
ZBR16-3A
ZBR21-3A
Number of 90 ° ZBR28-3A
elbows used ZWB28-3A
1 76 ft (23.1 m)
2
71 ft (21.6 m)
3 66 ft (20.1 m)
4 61 ft (18.6 m)
5 56 ft (17.1 m)
6 51 ft (15.6 m)
Table 21 Vent and combustion air pipe lengths with 2" diameter and the
stainless steel wall termination
Installations  Fig. 38 Concentric termination
2" PIPE Maximum straight vent pipe length allowed for
ZBR16-3A
ZBR21-3A
Number of 90 ° ZBR28-3A
elbows used ZWB28-3A
1 66 ft (20.1 m)
2 61 ft (18.6 m)
3
56 ft (17.1 m)
4 51 ft (15.6 m)
5 46 ft (14.1 m)
6 41 ft (12.5 m)
Table 22 Vent and combustion air pipe lengths with 2" diameter and the
concentric termination
Ø 3" / Ø 5" (Ø 80/125 mm) Concentric venting system
The maximum concentric pipe length ( tab. 23) depends on the
installation situation, the appliance type and the number of elbows used.
Installations  Fig. 41
Ø 3" / Ø 5" (Ø 80/
125 mm) Maximum straight vent pipe length allowed
CONCENTRIC PIPE for Ø 3" / Ø 5" (Ø 80/125 mm) concentric pipe
ZBR16-3A
ZBR21-3A
Number of 90 ° ZBR28-3A
elbows used ZWB28-3A
1 50 ft (15.2 m)
2 44 ft (13.4 m)
3 38 ft (11.6 m)
4 32 ft (9.8 m)
5 26 ft (7.9 m)
6 20 ft (6.1 m)
Table 23 Pipe lengths with Ø 3" / Ø 5" (Ø 80/125 mm) diameter and
termination
Greenstar
for Ø 2" pipe
ZBR35-3A
ZWB35-3A
ZBR42-3A
ZWB42-3A
60 ft (18.3 m)
52 ft (15.9 m)
43 ft (13.1 m)
35 ft (10.7 m)
27 ft (8.2 m)
18 ft (5.5 m)
Ø 2" pipe
ZBR35-3A
ZWB35-3A
ZBR42-3A
ZWB42-3A
47 ft (14.3 m)
38 ft (11.6 m)
30 ft (9.1 m)
22 ft (6.7 m)
13 ft (4.0 m)
5 ft (1.5 m)
ZBR35-3A
ZWB35-3A
ZBR42-3A
ZWB42-3A
44 ft (13.4 m)
38 ft (11.6 m)
32 ft (9.8 m)
26 ft (7.9 m)
20 ft (6.1 m)
14 ft (4.3 m)

Making the electrical connections | 45

Fitting
45 ° elbow
90 ° elbow
Table 24 Concentric pipe friction loss equivalent for fittings
Example:
• Model: ZBR28-3A
• 90 ° elbows used: 2
• 45 ° elbows used: 2
Maximum straight vent pipe allowed: 38ft (11.6 m)
6.9

Testing gas and water connections for leaks

NOTICE: System damage!
Pressure, control and safety equipment may be
damaged by excessive pressure.
▶ When you carry out a leakage test, make sure that no
pressure, control or safety equipment is installed that
cannot be isolated from the test pressure.
▶ The boiler and its dedicated shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 14" W.C. (35 mbar).
Water connections
▶ Open the heating supply and return valves and fill the heating system.
▶ Check all connections for leakage (test pressure: Max. 30 psi (2.07
bar) on the pressure gauge).
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.
7 Making the electrical connections
7.1

General notes

DANGER: Risk of electric shock!
▶ Before working on the power supply (120 VAC),
disconnect the boiler from the grid by shutting off the
emergency shutoff switch or disengaging the heating
system circuit breaker. Take measures to prevent
accidental reconnection.
▶ It is not sufficient to simply shut off the controls.
▶ Observe all applicable electrical codes and
regulations.
Electrical components must be installed by a trained and certified
electrician and the installation must meet the National Electric Code as
well as all applicable local codes and regulations.
The boiler must be properly electrically grounded in accordance with the
requirements of the authority having jurisdiction or, in the absence of
such requirements with the National Electrical Code, ANSI/NFPA 70
and/or the Canadian Electrical Code Part I, CSA C221.1, Electrical
Code.
Equivalent
ft m
3 0.91
6 1.82
6 720 806 992 (2015/03)