Bosch CONDENS 5000W Owner's manual

Information regarding routing flue gas
Wall mounted gas fired condensing boilers
Condens 5000 W
6 720 644 146-00.1O
ZSB 30-2 A ... | ZWB 37-2 A ...
6 720 644 146 (2019/03) NZ/AU

Condens 5000 W – 6720644146 (2019/03)
2
Contents
Contents
1 Explanation of symbols and safety instructions . . . . . . . . . . . . 2
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Wall mounted gas fired condensing boiler . . . . . . . . . . . . 4
2.3 Combination with flue duct kits . . . . . . . . . . . . . . . . . . . . 4
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Routing the flue vertically . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3.1 Extension with flue accessories . . . . . . . . . . . . . . . . . . . . 6
3.3.2 Routing the flue gas over the roof . . . . . . . . . . . . . . . . . . . 6
3.3.3 Installation location and balanced flue . . . . . . . . . . . . . . . 6
3.3.4 Layout of cleaning apertures: . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Routing horizontal flues . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4.1 Extension with flue accessories . . . . . . . . . . . . . . . . . . . . 6
3.4.2 Routing a balanced flue type C13 over the external wall . 6
3.4.3 Routing a balanced flue type C33 via the roof . . . . . . . . . 6
3.4.4 Layout of cleaning apertures . . . . . . . . . . . . . . . . . . . . . . 6
4 Fitted dimensions (in mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Balanced flue as concentric pipe . . . . . . . . . . . . . . . . . . . 7
4.2 Vertical flue connection . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Flue lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Determining the flue length . . . . . . . . . . . . . . . . . . . . . 11
5.2.1 Installation analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.2 Determining the parameters . . . . . . . . . . . . . . . . . . . . . 11
5.2.3 Calculation of the equivalent pipe length Lequiv . . . . . 11
5.3 Flue gas routing options . . . . . . . . . . . . . . . . . . . . . . . . 12
5.4 Example for calculating the flue lengths (Fig. 9) . . . . . 14
5.5 Template for calculating the flue length . . . . . . . . . . . . 15
1 Explanation of symbols and safety instructions
1.1 Explanation of symbols
Warnings
In warnings, signal words at the beginning of a warning are used to
indicate the type and seriousness of the ensuing risk if measures for
minimising danger are not taken.
The following signal words are defined and can be used in this
document:
•DANGER indicates that severe or life-threatening personal injury will
occur.
•WARNING indicates that severe to life-threatening personal injury
may occur.
•CAUTION indicates that minor to medium personal injury may occur.
•NOTICE indicates that material damage may occur.
Important information
Additional symbols
1.2 General safety instructions
Notices for the target group
These installation instructions are intended for gas,
plumbing, heating and electrical contractors. All
instructions must be observed. Failure to comply with
instructions may result in material damage and
personal injury, including danger to life.
▶ Read the installation instructions (heat source,
heating controller, etc.) before installation.
▶ Observe the safety instructions and warnings.
▶ Follow national and regional regulations, technical
regulations and guidelines.
▶ Record all work carried out.
If you are in any doubt contact the Robert Bosch
technical hotline on:
1300 30 70 37 AU or 0800 54 33 52 NZ
Determined use
The product may only be used in a domestic situation
for the heating of central heating water and for DHW
heating in closed-loop DHW and heating systems.
Any other use is considered inappropriate. Any
damage that may result from misuse is excluded from
liability.
This appliance is not suitable to be used as a pool
heater.
If you smell gas
A gas leak could potentially cause an explosion. If you
smell gas, observe the following rules.
▶ Prevent flames or sparks:
– Do not smoke, do not use a lighter or strike
matches.
– Do not operate any electrical switches or unplug
any equipment.
– Do not use the telephone or ring doorbells.
This symbol indicates important information where
there is no risk to people or property.
Symbol Explanation
▶ Step in an action sequence
Cross-reference to another part of the document
• List entry
– List entry (second level)
Table 1

Explanation of symbols and safety instructions
Condens 5000 W – 6720644146 (2019/03) 3
▶ Turn off the gas supply at the main shut-off valve or
at the gas meter.
▶ Open windows and doors.
▶ Warn your neighbours and leave the building.
▶ Prevent anyone from entering the building.
▶ Move well away from the building: call the
emergency services and the gas supplier.
Danger to life from poisoning by flue gas
There is a danger to life from escaping flue gas.
▶ Ensure that flues and gaskets are not damaged.
Danger of death from poisoning by flue gas due to
inadequate combustion
Danger of death due to flue gas leak. If flues are
damaged or leaking, or if you smell flue gas, observe
the following rules.
▶ Close the fuel infeed.
▶ Open doors and windows.
▶ If necessary, warn all residents and leave the
building.
▶ Prevent third parties from entering the building.
▶ Rectify any damage to the flue gas pipe
immediately.
▶ Check the combustion air supply.
▶ Do not cover or reduce the size of ventilation
openings in doors, windows and walls.
▶ Ensure that there is adequate combustion air
supply, including for any appliances installed at a
later date, e.g. extractor fans, kitchen fans or air
conditioning units that discharge air to the outside.
▶ Never operate the device if there is insufficient
combustion air supply.
Open flued Appliance
▶ Do not use an unlined Masonry chimney as the flue
for this appliance.
Installation, commissioning and maintenance
Installation, commissioning and maintenance must
only be carried out by an approved contractor.
▶ Carry out a gas tightness test after completing work
on gas-carrying components.
▶ In the case of open flue operation: Ensure that the
installation location meets the ventilation
requirements.
▶ Only use original spares.
Electrical work
Electrical work must only be carried out by electrical
installation contractors.
Before starting electrical work:
▶ Isolate all poles of the mains voltage and secure
against reconnection.
▶ Make sure the mains voltage is disconnected.
▶ Observe the wiring diagrams of other system
components as well.
Handover to the user
When handing over, instruct the user how to operate
the heating system and inform the user about its
operating conditions.
▶ Explain how to operate the heating system and
draw the user's attention to any safety relevant
action
▶ Explain that conversions and repairs must only be
carried out by a competent person.
▶ Point out the need for inspections and maintenance
for safe and environmentally-compatible operation.
▶ Leave the installation instructions and the
operating instructions with the user for
safekeeping.
▶ Do not spray aerosols in the vicinity of this
appliance while in operation.
▶ Do not use or store flammable materials in or near
this appliance.
▶ Do not place articles on or against this appliance.
▶ Do not modify this appliance.

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Usage
2 Usage
2.1 General information
Before installing the appliance and flue gas routing, consult the
responsible building authorities and district flue gas inspector to
establish whether there are any objections.
The flue duct kit is a component of the CE-approved system. Therefore,
only genuine flue duct kits may be used.
The permissible maximum balanced flue line depends on the appliance
and the number of deflections in the balanced flue. For calculation, see
chapter 5 from page 11.
2.2 Wall mounted gas fired condensing boiler
2.3 Combination with flue duct kits
The following flue accessories can be used in flue gas systems for these
condensing boilers:
• Flue accessories, coaxial pipe Ø 60/100 mm
• Flue accessories, coaxial pipe Ø 80/125 mm
• Flue accessories, single pipe Ø 80 mm
For flue gas/flue gas accessory designations and the part numbers of the
original flue gas accessories, see the current pricelist.
3 Installation
3.1 General information
▶ Follow the instructions for the flue duct kit.
▶ Route horizontal flues with 3 ° gradient (= 5.2 %, 5.2 cm per metre)
in the flow direction of the flue gas.
▶ Insulate the combustion air line in humid rooms.
▶ Install cleaning apertures where they will be easily accessible.
▶ When installing cylinders, take their dimensions into consideration
when installing flue accessories.
▶ Before fitting the flue kits:
Apply a thin coating of solvent-free grease (e.g. Vaseline) to the joint
seals.
▶ When fitting the balanced flue, always push the pipe fully home into
the sockets.
Wall mounted gas fired condensing boiler
ZSB 30-2 A
ZWB 37-2 A
Table 2

Installation
Condens 5000 W – 6720644146 (2019/03) 5
3.2 Flue terminal positions
Use as a guide only. Refer to AS/NZ 5601 or gas fitting rules for specific
location.
Fig. 1 Flue terminal positions: Shaded area indicates prohibited area
D Door
I Mechanical air inlet
M Gas meter
T Flue terminal
W Window
• The location of the flue terminal must comply with the clearances
shown on this page.
If you are unsure about clearances not indicated here, in general refer
to AS/NZ 5601 or your local authority.
• All measurements are the minimum clearances required.
• Terminals must be positioned so to avoid combustion products
entering the building.
f
c
n
k
k
j
jj
hhe
T
e
h
T
g
P
W
d
b
d
T
g
c
a
M
D
I
Ref. Item Min. Clearance
mm
a Below eaves, balconies and other projections (Appliances over 50MJ/h) 300
b From the ground, above a balcony or other surface 300
c From a return wall or external corner 300
d From a gas meter 1000
e From an electricity meter or fusebox/breaker panel 500
f From a drain pipe or soil pipe 75
g Horizontally from any building structure or obstruction facing a flue terminal 500
h From any other flue terminal, cowl or combustion air intake 300
j Horizontally from any opening window, door, non-mechanical air inlet or other opening into a building with the
exception of sub-floor ventilation
300
k From a mechanical air inlet including a spa blower. 1000
n Vertically below an opening window, non-mechanical air inlet or any other opening into a building with the
exception of sub-floor ventilation
500
Table 3

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Installation
3.3 Routing the flue vertically
3.3.1 Extension with flue accessories
The flue accessory “vertical balanced flue” can be extended between the
boiler and the roof outlet at any point using the flue accessories “coaxial
extension”, “coaxial elbow” (15° - 90°) or “test aperture”.
3.3.2 Routing the flue gas over the roof
A clearance of 400 mm between the outlet of flue accessories and the
roof surface is adequate, as the rated output of the listed Buderus wall
mounted gas fired condensing boilers is below 50 kW.
3.3.3 Installation location and balanced flue
The following regulations apply:
• Installation of the wall mounted gas fired condensing boiler in a room
where only the roof structure lies above the ceiling:
– If a fire rating is required for the ceiling, then the balanced flue
must have the same fire rating between the top edge of the ceiling
and the roof skin, and must be made from non-flammable
materials.
– If no fire rating is demanded for the ceiling, then the balanced flue
must be routed through a duct made from non-flammable, solid
materials or a metal protective pipe (mechanical protection)
running from the top edge of the ceiling to the roof skin.
• If the balanced flue bridges floors in a multi-storey building, then the
balanced flue outside the installation room must be routed through a
duct with a fire rating of at least 90 minutes and, in buildings of low
height, of at least 30 minutes.
3.3.4 Layout of cleaning apertures:
• One cleaning aperture is sufficient for gas combustion equipment
tested together with a flue up to 4 m length.
• The lower cleaning aperture in the vertical flue section may be
arranged as follows:
– In the vertical flue section immediately above the introduction of
the joint
or
– In the side of the joint no more than 0.3 m away from the deviation
in the vertical flue section
or
– In the face of the straight joint, no more than 1 m away from the
deviation in the vertical flue section.
• Flues that cannot be cleaned directly from the terminal must be
equipped with a further upper cleaning aperture up to 5 m below the
terminal. Vertical flue sections with a sloping run greater than 30°
between the axis and the vertical require a clearance of no more than
0.3 m to the kinking points of the cleaning apertures.
• The upper cleaning apertures can be omitted in vertical sections,
provided that:
– The vertical flue section will only be run at a slope once up to 30°
and
– The lower cleaning aperture is not more than 15 m away from the
terminal.
• Install cleaning apertures where they will be easily accessible.
3.4 Routing horizontal flues
3.4.1 Extension with flue accessories
The flue accessory “horizontal flue” can be extended between the boiler
and the wall outlet at any point using the flue accessories “coaxial
extension”, “coaxial elbow” (15° - 90°) or “test aperture”.
3.4.2 Routing a balanced flue type C13 over the external wall
• Observe the relevant national regulations regarding the max.
permissible output.
• Observe the minimum clearances towards windows, doors, wall
protrusions and between terminals themselves.
• The terminal of a coaxial pipe must not be fitted in a sub-surface duct.
3.4.3 Routing a balanced flue type C33 via the roof
• With covering on site, maintain the minimum clearances to AS/NZ
5601. A clearance of 400 mm between the accessory terminal and
the roof surface is adequate, as the rated output of the listed Bosch
gas fired condensing boilers is below 50 kW. The Bosch dormers
meet the requirements regarding minimum dimensions.
• The flue accessory terminal must protrude above structures on the
roof, room openings and unprotected components made from
flammable materials, excluding roof cover, by at least 1000 m or
must be at least 1500 mm away from them.
• Local regulations specify no output limit in heating operation for the
routing a balanced flue horizontally above a roof with dormer.
3.4.4 Layout of cleaning apertures
• One cleaning aperture is sufficient for gas combustion equipment
tested together with a flue up to 4 m length.
• Provide at least one cleaning aperture in horizontal flue/joint
sections. The maximum clearance between cleaning apertures is 4
m. Size cleaning apertures at deviations 45° larger.
• One cleaning aperture in horizontal flue/joint sections is adequate, if
– the horizontal section ahead of the cleaning aperture is no longer
than 2 m
and
– the cleaning aperture in the horizontal section is no more than
0.3 m away from the vertical section,
and
– no more than two deviations are in the horizontal section
upstream of the cleaning aperture.
• An additional cleaning aperture may be required near the
combustion equipment, if brushing residues must be prevented from
entering the combustion equipment.

Fitted dimensions (in mm)
Condens 5000 W – 6720644146 (2019/03) 7
4 Fitted dimensions (in mm)
4.1 Balanced flue as concentric pipe
The horizontal flue connection is used for:
• Routing the flue inside a duct compliant with C33, C53, C93
• Routing the flue horizontally compliant with C13, C33
Fig. 2 Ø 80/125 mm
[1] Connection elbow 90° (Ø 80/125 mm) with measuring holes
As condensate drain:
▶ Route horizontal flues with 3 ° gradient (= 5.2 %,
5.2 cm per metre) in the flow direction of the flue
gas.
6 720 644 146-01.1O
≥ 100110
1
440≥ 100
85
≥ 100
360
760 750
5,2 %
K
S
S K
AZB Ø 80/125 mm
15 - 24 cm 155 mm
24 - 33 cm 160 mm
33 - 42 cm 165 mm
42 - 50 cm 170 mm
Table 4

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8
Fitted dimensions (in mm)
Fig. 3 Ø 60/100 mm
[1] Connection elbow 90° (Ø 60/100 mm) with measuring holes
≥ 10082
1
6 720 644 146-02.1O
440≥ 100
85
≥ 100
360
760 750
5,2 %
S
K
S K
AZB Ø 60/100 mm
15 - 24 cm 130 mm
24 - 33 cm 135 mm
33 - 42 cm 140 mm
42 - 50 cm 145 mm
Table 5

Fitted dimensions (in mm)
Condens 5000 W – 6720644146 (2019/03) 9
4.2 Vertical flue connection
Fig. 4 flat roof
[1] Balanced flue - vertical/extension pipe (Ø 60/100 mm or Ø 80/125 mm)
[2] Connection adaptor vertical (Ø 60/100 mm or Ø 80/125 mm) with measuring holes
500
2
1
6 720 644 146-04.1O
440≥ 100
85
≥ 100
360
760 750

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Fitted dimensions (in mm)
Fig. 5 pitched roof
[1] Balanced flue - vertical/extension pipe (Ø 60/100 mm or Ø 80/125 mm)
[2] Connection adaptor vertical (Ø 60/100 mm or Ø 80/125 mm) with measuring holes
2
1
6 720 644 146-06.1O
440≥ 100
85
≥ 100
360
760 750
500

Flue lengths
Condens 5000 W – 6720644146 (2019/03) 11
5 Flue lengths
5.1 General information
The condensing boilers are fitted with a fan that transports the flue gases
into the flue. Flow losses inside the flue decelerate the flue gases.
Consequently, flues must not exceed a specific length to ensure the flue
gases are securely propelled to the outside. This length is the maximum
equivalent pipe length Lequiv,max. It is subject to the boiler, the flue and
its routing. Flow losses are greater in ebows than in straight pipes. An
equivalent pipe length is therefore assigned to elbows that is greater
than their physical length. The sum of horizontal and vertical pipe
lengths as well as the equivalent pipe lengths for the elbows used,
results in the equivalent flue length Lequiv. This total length must be
shorter than the maximum equivalent pipe length Lequiv,max. In addition,
in some flue gas systems the length of horizontal flue Lwmust not exceed
a certain value Lw,max.
5.2 Determining the flue length
5.2.1 Installation analysis
▶ Determine the following from the given installation situation:
– Route of the flue
– Routing the flue gas to AS/NZ 5601
– Condensing boiler
– length of horizontal flue, Lw
– length of vertical flue, Ls
– Number of additional 90° deviations in the flue
– Number of 15 °, 30 ° and 45 ° elbowsin the flue
5.2.2 Determining the parameters
The flue may be routed as follows:
• Vertical flue (Tab. 6 on page 12 and Tab. 7 on page 13)
• Horizontal flue (Tab. 6 on page 12 and Tab. 7 on page 13)
▶ Determine the following from the respective table, subject to the
method of routing the flue to
AS/NZ 5601, condensing boiler and flue diameter:
– Maximum equivalent pipe length Lequiv,max
– Equivalent pipe length of elbows
– Poss. maximum horizontal pipe length Lw,max
5.2.3 Calculation of the equivalent pipe length Lequiv
The equivalent pipe length Lequiv is calculated from the sum of the
horizontal and vertical flue lengths (Lw, Ls) and the equivalent lengths of
elbows. The required 90° elbows are included in the maximum lengths.
Take every additional elbow with its equivalent length into
consideration.
The equivalent total pipe length must be shorter than the maximum
equivalent pipe length: Lequiv  Lequiv,max
For an example of calculating the flue length, see page 14.

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Flue lengths
5.3 Flue gas routing options
Lequiv,max maximum equivalent length
Lsvertical pipe length
Lwhorizontal pipe length
Fig. 6 C33
Routing the flue gas horizontally/vertically Ø 80/125 mm1)
compliant with C13, C33
1) The values given apply to Bosch accessories. For any other accessories, please refer to standard AS/NZ 5601.
equivalent lengths of additional
elbows 2)
2) 90° elbow on the appliance with horizontal flue has already been taken into consideration in the maximum lengths
vertical (LS) horizontal (LW)
[m] [m]
Appliance Lequiv,max [m] Lequiv,max [m]
ZSB 30-2 A 16 16 2 1
ZWB 37-2 A 18.4 17.2
Table 6 Pipe lengths for C13, C33
90°
15-
45
°
LS
L
W
Ø80/125
Ø80/125
6 720 612 691-14.1O
5,2 %

Flue lengths
Condens 5000 W – 6720644146 (2019/03) 13
Lequiv,max maximum equivalent length
Lsvertical pipe length
Lwhorizontal pipe length
Fig. 7 C33
Fig. 8 C13, Plume Management
Plume management kits are available for the 100 mm horizontal flue
options.
Plume management reduces the effective length of the flue, refer to the
manual supplied with the kits for complete installation instructions.
Routing the flue gas horizontally/vertically Ø 60/100 mm1)
compliant with C13, C33
1) The values given apply to Bosch accessories. For any other accessories, please refer to standard AS/NZ 5601.
equivalent lengths of additional
elbows 2)
2) 90° elbow on the appliance with horizontal flue has already been taken into consideration in the maximum lengths
vertical (LS) horizontal (LW)
[m] [m]
Appliance Lequiv,max [m] Lequiv,max [m]
ZSB 30-2 A 8721
ZWB 37-2 A 8.6 5.7
Table 7 Pipe lengths for C13, C33
90°
15-
45
°
LS
LW
Ø60/100
Ø60/100
6 720 612 634-10.1O
5,2 %
6720644146-03.1O

Condens 5000 W – 6720644146 (2019/03)
14
Flue lengths
5.4 Example for calculating the flue lengths (Fig. 9)
Installation analysis
Determine the following from the given installation situation:
• Method of routing the flue: vertical, Ø 80/125 mm
• Flue compliant with AS/NZ 5601: C33
• Condensing boiler: ZSB 30-2 A
• length of horizontal flue: Lw= 1 m
• length of vertical flue: Ls= 6 m
• Number of 90° deviations in the flue: 2
• Number of 15 °, 30° and 45° deviations in the
flue: 0
Determining the parameters
Determine the parameters from table 6 as the flue is routed through a
duct compliant with C33. The following values result from ZSB 30-2 A:
•L
equiv,max = 15 m
• equivalent length for 90° deviations: 2 m
• equivalent length for 15°, 30 °and
45°deviations: 1 m
Calculation of the equivalent pipe length Lequiv
The equivalent pipe length Lequiv is calculated from the sum of the
horizontal and vertical flue lengths (Lw, Ls) and the equivalent lengths of
elbows. The required 90° elbows are included in the maximum lengths.
Take every additional deviation with its equivalent length into
consideration.
The equivalent total pipe length must be shorter than the maximum
equivalent pipe length: Lequiv  Lequiv,max
The equivalent total pipe length with 11 m is less than the maximum
equivalent total length of 15 m. As a result, the flue is OK.
Length/Number equivalent
partial length
Total length
straight length LS6 m × 1 = 6 m
straight length LW1 m × 1 = 1 m
90° elbow 2 × 2 m = 4 m
45° elbow 0 × 1 m = 0 m
equivalent pipe length Lequiv 11 m
Maximum equivalent pipe length Lequiv,max 15 m
Lequiv Lequiv,max o.k.
Table 8

Flue lengths
Condens 5000 W – 6720644146 (2019/03) 15
Fig. 9
5.5 Template for calculating the flue length
Length/Number equivalent
partial length
Total length
straight length LS×=
straight length LW× =
90° elbow ×=
45° elbow × =
equivalent pipe length Lequiv
Maximum equivalent pipe length Lequiv,max
Lequiv Lequiv,max
Table 9
LS= 6 m
Ø80/125
LW= 1 m
Lequiv = 2 m
6 720 644 146-03.1O
Lequiv = 2 m