Explanation of symbols and safety instructions General safety instructions Explanation of symbols and safety instructions If you hear gas leaking! Explanation of symbols ▶ Leave the building immediately. ▶ Prevent others from entering the building. Warnings ▶ Notify the police and fire department from outside the building. In warnings, signal words at the beginning of a warning are used to ▶...
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Explanation of symbols and safety instructions DANGER: Risk of personal injury or death from flue gas poisoning! NOTICE: ▶ Do not install a thermostatic flue gas damper downstream of the draft ▶ Upon completion of the installation, these instructions should be hood.
Flue adapter DHW tank temperature sensor (NTC) Hydraulics connection plate with mounting kit [10] External supply temperature sensor (NTC) [11] Bosch Room Controller with an integrated temperature sensor and set of documents 6 720 641 933-22.3O Fig. 1 Scope of delivery heating boiler ZBR...-3A 1) Concentric vent kit available as accessory.
Rail with connection box Flue adapter Hydraulics connection plate with mounting kit External supply temperature sensor (NTC) [10] Bosch Room Controller with an integrated temperature sensor and set of documents 6 720 641 933-04.3O Fig. 2 Scope of delivery combi boiler ZWB...-3A 1) Concentric vent kit available as accessory.
(ZBR...-3A only) • Flue gas temperature limiter • DHW priority (ZWB...-3A only) • Motorized 3-way valve (ZWB...-3A only) • Hydraulics connection plate Accessories Refer to the Bosch Product Catalog for a complete overview of all available accessories. Greenstar – 6721822579 (2020/03)
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Product Description Key to Fig. 5: Heatronic boiler control ON/OFF switch Burner flame indicator Service button Emissions test button Boiler high limit dial DHW thermostat Key pad lock ECO button [10] Reset button [11] Display [12] Condensate trap [13] Test ports for inlet gas pressure [14] Adjustment screw, minimum gas volume [15] Maximum gas adjuster [16] Flue gas temperature limiter...
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Product Description Key to Fig. 7: Ignition transformer Boiler high limit dial 120 VAC connection DHW tank primary pump or 3-way valve External heating pump for unmixed heating circuit (secondary circuit) 5 or DHW recirculation pump Fuse T 6.3 A (120 VAC) DHW thermostat External safety high limit or low water cut off (LWCO) BUS connection, e.g.
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Product Description Key to Fig. 8: Ignition transformer Boiler high limit dial 120 VAC connection External heating pump for unmixed heating circuit (secondary circuit) 4 or DHW recirculation pump Fuse T 6.3 A (120 VAC) DHW thermostat External safety high limit or low water cut off (LWCO) BUS connection, e.g.
Regulations Additional regulations for installations in the • Detailed instructions for the installation of the venting system or the venting system components; and Commonwealth of Massachusetts • a comprehensive parts list for the design and the components of the (a) For all side wall side horizontally vented gas fueled equipment venting system.
Motorized valve heating zone 2 To heating zone 2 Bosch room temperature controller heating zone 2 (CRC100) For all accessories not included in the package please refer to the Bosch Motorized valve heating zone 1 Product Catalog. To heating zone 1...
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PCB in heating boiler ZBR...-3A White plug for mains power supply, 120 V AC, 60 Hz ( chapter 7.3.4, page 48) For all accessories not included in the package please refer to the Bosch 120 V AC, 60 Hz Product Catalog.
Fig. 11 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...
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PCB in heating boiler ZBR...-3A White plug for mains power supply, 120 V AC, 60 Hz ( chapter 7.3.4, page 48) For all accessories not included in the package please refer to the Bosch 120 V AC, 60 Hz Product Catalog.
▶ Empty out sediment traps. Insufficient antifreeze can accelerate corrosion. ▶ Systems containing antifreeze not approved by Bosch, must be ▶ Follow manufacturer's instructions on antifreeze concentration. completely flushed to ensure no old fluid remains. ▶ Frost protection level has to be checked annually during the regular ▶...
Notes on installation and operation The following anti-freeze fluids and concentrations have been approved: 6.1.2 Other important information • The installation of this boiler must comply with all national and local Chemical Name Concentration code and regulations. Nalco (Varidos) FSK 22 - 55 % •...
Notes on installation and operation Comparing the size of the integrated expansion Selecting an external expansion vessel (ZBR...-3A) vessel ▶ Determine the size of the expansion vessel in compliance with local laws and regulations. The following diagrams allow verifying that the integrated expansion vessel has sufficient capacity for the intended application, or if an additional expansion vessel is needed (not for radiant floor heating).
Notes on installation and operation Pre-installing pipes ▶ Secure the hydraulics connection plate and the mounting bracket with the mounting kits supplied. ▶ Secure the installation template (supplied with the technical documentation) to the wall; observe the minimum side clearances of 4 inches (102 mm) (...
Notes on installation and operation Mounting the appliance 5 1/8" NOTICE: (130 mm) Residue, metal shavings, and contaminants in the piping can damage the appliance. ▶ Flush the piping thoroughly and completely to remove all residue. ▶ Follow the instructions with respect to water quality ( Chapter 6.1.1, page 29).
• Hydrolevel Safgard 1100 Ø > Ø The device is available at most Bosch wholesalers. It requires an external 24VAC AC 20VA transformer provided on site. Ø When a different LWCO is used, it must be installed outside the wall- mounted gas condensing boiler.
• Twin pipe PP 2" (50 mm )/ 3" (80 mm) (M&G Duravent PolyPro and Centrotherm InnoFlue) • Concentric PP 3" / 5" (80/125 mm) (Bosch) In case of using the twin pipe adaptor: The twin pipe adaptor is supplied with the boiler kit as standard and is certified as a part of the vent system.
Notes on installation and operation ▶ Install the concentric vent adaptor with the screws enclosed. Observe the listed maximum lengths of vent system, which are boiler model dependent ( chapter 6.8.3). DANGER: Improper venting of the Greenstar boiler can result in excessive levels of carbon monoxide which can result in severe personal injury or death.
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M&G Duravent Approved Polypropylene PolyPro and Centrotherm InnoFlue PP rigid venting 3"/5" (80/125 mm) ANSI Cat IV concentric (Bosch, Approved Polypropylene manufactured by M&G Duravent) PP-Flex 3" (80 mm) vent or air ANSI Cat IV BH Gas venting systems, pipe M&G Duravent...
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Notes on installation and operation 6 720 641 933-17.1O Fig. 31 Vent and combustion air pipe position Forced Air Inlet Gravity Air Inlet Exhaust terminal 1 foot (305 mm) Clearance in accordance with local installation codes and the requirements 1 foot (305 mm) 3 feet (915 mm) in Canada for models ZBR 35-3 A and ZBR 42-3 A Clearance in accordance with local installation codes and the...
Notes on installation and operation 6.8.2 Examples of approved horizontal and vertical venting ≥ 4" installation (102 mm) NOTICE: ▶ Place pipe supports every 5 ft (1525 mm) of horizontal and vertical run, beginning with support near wall-mounted gas condensing boiler.
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Notes on installation and operation 6 720 641 933-09.2O Fig. 36 Vertical venting system (sealed combustion) 6 720 641 933-10.1O 6 720 641 933-07.1O Fig. 37 Vertical venting system (room air only) Fig. 38 Vertical venting system (sealed combustion) Key to Fig. 36, Fig. 37 and Fig. 38: Intake Exhaust Greater than 12 inches (305 mm)
Notes on installation and operation 1/4" per foot (50 mm per meter) 6 720 641 933-78.1O Fig. 41 Horizontal venting system (telescopic concentric vent kit) 6.8.3 Vent and combustion air pipe lengths With Flex Pipe the maximum length is reduced by 50%. Flex Pipe according to the suppliers instructions for use in the vertical part of the installation only.
Connecting the BUS-system Replacement fuses can be found on the back of the cover ( Fig. 43, Connect only Bosch room controls to the internal BUS of this boiler. For page 44). further details see the technical documentation of the BUS system components (e.
BUS/ CRC200 6 720 811 153-05.1O Fig. 45 Schematic of electrical wiring of Bosch room control and boiler 6 720 641 933-73.1O Terminal at the boiler reads BUS or BB, both indicating Fig. 47 Electrical connections DHW tank temperature sensor connection of the 2-wired Bosch BUS system.
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Electrical connection Connecting the supply temperature sensor (e.g. for low-loss header or system supply pipe) Do not exceed a sensor cable length of 33 feet (10 m). LS NS Supply temperature sensor for system supply pipe(Fig 50, [2]) must be installed in closest vicinity with boiler supply Tee.
▶ Use service function 5.E to set connection to 03 (external heating pump). 6 720 641 933-42.3O Fig. 53 Mounting rails for junction box The DHW recirculation pump is controlled by the Bosch Room Controller. 7.3.2 Connecting an external heating zone pump or DHW recirculation pump...
Electrical connection 7.3.3 DHW tank loading pump or 3-way valve with spring return 7.3.4 Connecting mains power supply (only ZBR...-3A) ▶ Route the power cable (AC 120 V, 60 Hz) from the emergency The pump used must have the following connection values: 120 VAC, shutoff switch to the boiler.
Electrical connection Connecting the LWCO device ▶ Connect the leads labeled SWITCH CONTACT (yellow) to the TB1 temperature switch ( Fig. 49, page 45) on the Heatronic. NOTICE: System damage or malfunction! ▶ Ensure the air box remains air-tight when routing the LWCO cable to the outside.
Commissioning Before operating the appliance Switch on heat Set the maximum supply temperature based on the structure's heat loss NOTICE: on design day. Commissioning without being properly filled and purged will Boiler high Typical supply Sample application damage the appliance. limit dial temperatures ▶...
▶ Set the DHW temperature on the DHW thermostat The set DHW temperature flashes on the display for 30 seconds. Observe the operating instructions for the Bosch room controller included in the scope of delivery. There you can read: ▶ How to set the operating mode ▶...
-or- • Economy mode, ECO button lights up ▶ If you want to leave the appliance switched OFF: Mix Bosch-approved – DHW is only generated when DHW is drawn. anti-freeze into the heating water ( Tab. 29, page) and drain the –...
ZBR...-3A appliances (heating boiler) with DHW tank: Thermal disinfection 8.10 Activating the key pad lock Boiler circulator The key pad lock affects the boiler high limit dial, the DHW thermostat, and all buttons except the ON/OFF switch, emissions test button, and 10.1 Pump anti-seize protection reset button.
Heatronic boiler control settings Heatronic boiler control settings 11.1 Guideline to service functions The Heatronic allows easy setting and testing of many appliance functions. For an overview of service functions, see Chapter 11.2 on page 56. reset 6 720 641 933-52.1O V / gpm Fig.
Heatronic boiler control settings 11.2 Overview of the service functions 11.2.2 Second service level (at first service level, service button lights up, press ECO button and key pad lock button 11.2.1 First service level (press and hold the service button simultaneously until 8.A appears) until it lights up) Service function...
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Heatronic boiler control settings Service function 1.b: Maximum DHW output Service function 2.A: Heating circuit pump lockout time (only heating boiler ZBR...-3A) The hot water output can be adjusted between the minimum and maximum DHW outputs to suit the heat transfer capacity of the DHW NOTICE: tank coil.
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Heatronic boiler control settings Service function 2.d: Thermal disinfection (legionella protection) Service function 3.b: Set anti-cycle time Only if the automatic anti-cycle time is disabled (service function 3.A) WARNING: will this function be active. Danger of scalding! Hot water can scald. If an outdoor reset control is connected, there is no need to adjust this ▶...
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This service function displays the appliance type detected. deactivated). Available displays are: • 01: DHW recirculation pump enabled - See Bosch room controller • 00: Central heating only instructions on how to set a recirculation pump program. • 01: Combi appliance •...
Heatronic boiler control settings Service function 6.A: Display the latest fault code Service function 7.E: Building drying function Use this service function to display the most recent fault code. This service function allows you to start and stop the building drying function.
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Default setting is 50. Service function 9.E: Turbine signal delay (only combi boiler ZWB...- Service function 8.C: GFA Gas burner control unit status Internal parameter. If you are on the line with Bosch Technical Support you may be asked for this number. NOTICE: Service function 8.d: GFA Gas burner control unit fault...
Gas adjustment 12.2 Installation location higher than 2,000 feet Gas adjustment (610 m) above sea level Input and output rates are reduced at higher altitudes due to thin air with DANGER: reduced oxygen levels. Personal injury and property damage ZBR 42-3A... and ZWB 42-3A... appliances are derated at 3% per ▶...
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Gas adjustment ▶ Measure the CO or O level and the CO content of the flue gas ▶ Remove screw ( Fig. 79, [3]) from the gas valve adjustment screw ( Section 13). ( Fig. 79, [2]) and set CO or O value for minimum nominal output.
Flue gas test 12.4 Dynamic gas pressure test port Flue gas test ▶ Switch the appliance OFF and close the gas shut-off valve. ▶ Loosen the screw in the test port for gas inlet pressure ( Fig. 52, 13.1 Emissions test button [1]) and connect a pressure gauge (...
▶ Cleaning of the heat exchanger should not be necessary until five years after the initial commissioning. ▶ Only use a Bosch cleaning blade and Bosch cleaning brush. ▶ Only clean heat exchanger when visibly dirty. Greenstar – 6721822579 (2020/03)
Inspection and maintenance 15.1 Description of various steps 15.1.1 Calling up the latest fault (service function 6.A) ▶ Select service function 6A (page 60). An overview of the faults can be found on page 74. 15.1.2 Fresh water filter (only combi boiler ZWB...-3A) ▶...
Inspection and maintenance 15.1.5 Burner servicing DANGER: Fire danger! ▶ The burner may be operated only while installed in a wall-mounted gas condensing boiler. ▶ Remove burner lid (steps 1 - 4). 0010032724-001 Fig. 88 Removing the plate heat exchanger ▶...
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.
Inspection and maintenance ▶ Rinse the heat exchanger with water from the top. 15.1.7 Cleaning condensate trap ▶ Remove condensate trap (steps 1 and 2) and check heat exchanger orifice for clear passage. 6 720 612 664-18.1R Fig. 96 Rinsing the heat exchanger ▶...
Inspection and maintenance 15.1.9 Checking the expansion vessel 15.1.11 Testing system water quality Annual inspection of the expansion vessel is required. ▶ Take a representative sample of the system water and analyze pH using a pH meter or pH test strips. ▶...
Inspection and maintenance 15.2 Maintenance and inspection checklist ▶ Use this form to guide you through the service and maintenance procedure. Fill out each step according to the findings and work performed. Date Latest fault code from service function 6.A. Fresh water inlet filter (Combi boiler ZWB appliances only).
Readings on the display Status Description Readings on the display code The 7-segment display shows the following: Acknowledge by pressing any button (except reset). Value displayed Description Range Number or letter, dot Service function ( Tab. 26/ 27 followed by letter page 56/ 56) Letter followed by Fault code...
Faults ▶ Switch the appliance OFF and ON again. Faults The appliance starts up again and the current supply temperature is displayed. 17.1 Troubleshooting DANGER: An overview of the faults can be found on page 74. Explosion! An overview of the status codes can be found on page 72. ▶...
Faults 17.2 Faults that are shown on the display Display Description Elimination DHW temperature sensor defective. ▶ Check temperature sensor and leads for interruptions or shorts, and replace if defective. ▶ Insert code plug correctly; replace if defective. Communication fault. ▶...
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Faults Display Description Elimination No flame detected. ▶ Check that ground lead is properly connected, replace if defective. ▶ Check that gas cock is open. ▶ Check inlet gas pressure; correct if needed. ▶ Check power supply. ▶ Check electrodes for visual damage; replace if defective. ▶...
Faults 17.3 Faults that are not shown on the display Appliance faults Elimination Combustion noise too loud; rumbling noises ▶ Insert code plug correctly; replace if defective. ▶ Check gas type. ▶ Check inlet gas pressure; adjust if defective. ▶ Check flue gas system; clean or repair if defective. ▶...
Faults 17.4 Check sensor values 17.4.3 Supply temperature sensor, External supply temperature sensor, DHW tank temperature sensor, DHW temperature 17.4.1 Outdoor temperature sensor sensor Resistance [ ] Temperature °F ( °C ) Resistance [ ] Temperature °F ( °C) Testing tolerance ±...
Commissioning log for the appliance Commissioning log for the appliance Home owner/operator: Last name, first name Number, Street Telephone/fax ZIP code, town System installer: Order number: Appliance type: (Complete a separate log for every appliance!) Serial number: Date commissioned: Individual appliance | Cascade, Number of appliances: .....
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Commissioning log for the appliance System hydraulics checked, notes: Modified service functions: Select the modified service functions and enter the values here. Heating control: Weather-compensated control Room temperature-dependent control Remote control × ..Qty, heating zone(s) coding: ...
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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.