Bosch CONDENS 5000W User manual

USER MANUAL
HYDRONIC GAS SYSTEM BOILER 18kW
CONDENS 5000 W
6720643356-00.1Wo
ZSB18 - 2A.
6 720 646 196 (2013/08)

6 720 646 196 (2013/08)Condens 5000 W
Contents | 2
Contents
1 Symbols and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Operating the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.1 Switching off the central heating . . . . . . . . . . . . . . . . . . . 6
3.1.2 Boiler frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.3 Setting the hot water temperature . . . . . . . . . . . . . . . . . 7
3.1.4 Boiler reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 System pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Sealed heating systems . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 External filling loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Service clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Maintaining the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Fault or breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9 Tips on energy saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10 Environment / disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11 Your guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
12 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6 720 646 196 (2013/08)Condens 5000 W
Preface | 3
Preface
Please read these instructions carefully
These instructions are applicable to the Bosch boiler model
stated on the front cover only.
These instructions apply in AU/NZ only and must be followed
except for any statutory obligation.
After installation please leave this user manual, the installation
instructions and completed installation checklist with the
customer.
Dedicated to heating comfort
Thank you for purchasing a Condens 5000 hydronic system
boiler manufactured by Bosch. The company prides itself on
manufacturing boilers to the strictest quality control standards
throughout every stage of production.
Bosch has led the field in innovative boiler design and
performance for almost 50 years. This heritage means all our
products are of exceptional quality and proven reliability.
The Condens 5000 in particular is extremely energy efficient,
offering you economical running costs and value for money.
Register the warranty within 30 days of installation for the
reassurance of a two years parts and labour guarantee.

6 720 646 196 (2013/08) Condens 5000 W
4 | Symbols and safety precautions
1 Symbols and safety precautions
1.1 Explanation of symbols
Warning symbols
Signal words indicate the seriousness of the hazard in terms of
the consequences of not following the safety instructions.
•NOTICE indicates possible damage to property or
equipment, but where there is no risk of personal injury.
•CAUTION indicates possible personal injury.
•WARNING indicates possible severe personal injury.
•DANGER indicates possible risk to life.
Important information
Additional symbols
1.2 Safety precautions
If you smell gas:
▶LPG boilers call the suppliers number on the side of the
LPG tank/cylinder
▶Turn off the ECV (emergency control valve) at the meter
▶Do not turn any electrical switches on or off
▶Do not strike matches or smoke
▶Putoutnakedflames
▶ Open doors and windows
▶ Keep people away from the affected area
Boiler operation:
This boiler must only be operated by a responsible adult who
has been instructed in, understands and is aware of the boiler's
operating conditions and effects.
Combustible and corrosive materials:
Chemically aggressive substances can corrode the boiler and
invalidate any warranty.
▶ Do not store or use any combustible materials (paper,
thinners, paints etc.) inside or within the vicinity of the
boiler.
Fittings and modifications:
Only an authorised person can remove the outer case and carry
out any work.
▶ Do not remove the outer casing.
Any misuse or unauthorised modifications to the boiler, flue or
associated components and system will invalidate the
warranty.
▶ Do not modify the boiler or flue system in any way.
Bosch accepts no liability arising from any such actions. This
does not affect your statutory rights.
Safety instructions in this document are
framed and identified by a
warning triangle which is printed on a grey
background.
Electrical hazards are identified by a
lightning symbol surrounded by a warning
triangle.
Notes contain important information in
cases where there is no risk of
personal injury or material losses and are
identified by the symbol shown on the left.
They are bordered by horizontal lines above
and below the text.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the
document or to other related documents
• a list entry
– a list entry (second level)
Table 1 Symbols

6 720 646 196 (2013/08)Condens 5000 W
General information | 5
2 General information
Servicing
▶ The boiler must be serviced annually by an authorised person.
▶ Always use original spares, to help maintain the economy, safety and reliability of the boiler and have the service record
completed in the service checklist.
The completed service checklist will be required in the event of any warranty work.
3Controls
▶ To gain access to the boiler controls open the flap and release.
Fig. 1 Control panel fascia
Ensure that the service engineer completes the service checklist after each service. The service checklist and
service interval record can be found at the rear of the installation instructions.
12345678
6720643356-13.1Wo
9
Boiler
Controls
1Central heating temperature control 6 ECO button (non functional)
2Burner indicator (green) 7 Reset button
3Service button 8 Hot water temperature control*
4Cover or optional programmer 9 System pressure gauge
5Power ON and fault indicator (blue) * Requires optional integral diverter kit to be
functional
Table 2

6 720 646 196 (2013/08) Condens 5000 W
6 | Controls
3.1 Operating the boiler
Setting the central heating temperature
1. Turn the central heating temperature control knob to the desired level.
1. The Burner indicator (green) will illuminate to show that the boiler is running.
Fig. 2 Central heating temperature control
3.1.1 Switching off the central heating
1. Turn the temperature control knob to the snowflake symbol to switch off the central heating.
Fig. 3 Switch off central heating
The temperatures quoted in the figure below are only approximate.
Min
1
2
3
4
5
6
Max
---
---
---
---
---
---
---
---
40 °C
47 °C
53 °C
61 °C
68 °C
74 °C
80 °C
82 °C
1
2
34
5
6
max
6720643356-05.1Wo
1.
2.
1
2
34
5
6
max
reset
eco
1
2
34
e
6
maxmin
6720643356-06.1Wo
1.

6 720 646 196 (2013/08)Condens 5000 W
Controls | 7
3.1.2 Boiler frost protection
If the temperature within the boiler falls below 8°C the pump will run to circulate water and prevent the system freezing.If the
temperature within the boiler falls below 5°C the boiler will fire periodically, bringing the boiler temperature up to 12°C to avoid the
possibility of the system freezing.This process will be repeated until such time that the boiler temperature does not drop below 5°C.
3.1.3 Setting the hot water temperature
1. Turn the hot water temperature control knob to the desired level.
2. The ECO button is non operational with this type of boiler.
Fig. 4 Hot water temperature
Optional integral diverter valve kit with cylinder temperature sensor is required to be able to set the hot water
temperature.
Otherwise the temperature is factory set to approximately 55°C.
1
2
34
5
6
max
reset
eco
1
2
34
e
6
maxmin
6720644864-01.1Wo
1.
2.

6 720 646 196 (2013/08) Condens 5000 W
8 | Controls
3.1.4 Boiler reset
In the event of a fault, the reset button will flash once per second and the blue mains indicator light will flash.
1. To reset the boiler press the reset button for approximately five seconds.
When the boiler resets the reset button will no longer be illuminated.
2. The mains indicator will no longer be flashing.
Fig. 5 Reset button and mains light
If the fault remains and cannot be cleared by pressing the reset button, contact Robert Bosch for assistance on:
1300 30 70 37
1
2
34
5
6
max
reset
eco
1
2
34
e
6
maxmin
6720643356-09.1Wo
1.
2.

6 720 646 196 (2013/08)Condens 5000 W
System pressure | 9
4 System pressure
4.1 Sealed heating systems
This boiler is fitted to a sealed heating system which is pre-pressurised. The optimum pressure is indicated on the pressure gauge
shown in figure 6.
▶ Check regularly that the pressure is maintained.
Fig. 6 Optimum pressure when cold (area A)
▶ Contact your installer or authorised person if a permanent significant decrease in pressure is indicated on the pressure gauge.
The filling method on this boiler will be an external filling loop, with fitted valves and a flexible hose. The filling loop should ideally be
located close enough to the boiler so that the pressure gauge can be monitored during filling.
6720643356-11.1Wo
2
3
1
04
bar
1
A
Min
1 bar
1.5 bar
Max

6 720 646 196 (2013/08) Condens 5000 W
10 | System pressure
4.2 External filling loop
Once the external filling loop has been located, follow the instructions for re-pressurising the system.
1. Unscrew blanking cap.
2. Attach the hose to the valves, screw on hand-tight.
3. Turn the handle/screwdriver slot through 90° to open the valves.
4. The handle/screwdriver slot will be in-line with the valves
Fig. 7 External filling loop
5. When the pressure reaches between the 1 and 1.5 bar marks (zone A), turn the handle/screwdriver slot back, through 90°, to
close the valve.
6. The handle/screwdriver slot will be at 90° to the valves
7. Remove the hose and replace the blanking caps.
External filling loop valve must be installed according to local authorities regulations to protect the potable water
supply.
6720643356-12.2Wo
1. 2.
7.
3. 3.
4.4.
5.
5.
6.6.
2
3
1
04
bar
1
A
Min
1 bar
1.5 bar
Max

6 720 646 196 (2013/08)Condens 5000 W
Service clearances | 11
5 Service clearances
Your installer will have provided adequate space around the boiler for safety and servicing access.
Fig. 8 Service clearances
6 Maintaining the boiler
Your new Condens 5000 hydronic boiler represents a long term investment in a reliable, high quality product.
In order to realise its maximum working life, and to ensure it continues to operate at peak efficiency and performance, ensure that
your boiler receives annual servicing from an authorised person beyond the 2 year guarantee period.
If your Condens 5000 should fail to operate correctly or requires servicing please contact Robert Bosch on: 1300 30 70 37.
Details of the boiler can be found under the controls covers flap on the boiler.
CAUTION: Restricted space.
The boiler may overheat.
▶ Do not restrict this space with the addition of cupboards, shelves etc. next to the boiler.
+ 30 mm
above elbow
5 mm
600 mm
5 mm
200 mm
6720643356-01.1Wo

6 720 646 196 (2013/08) Condens 5000 W
12 | Fault finding
7Faultfinding
If a boiler fault occurs, please read the following page thoroughly before contacting Robert Bosch.
Problem Cause Remedy
Desired room temperature is not
reached
Thermostatic radiator valve(s) set too low ▶ Increase thermostatic radiator valve
setting(s)
Temperature control for central heating
flow on boiler set too low
▶ Increase central heating flow
temperature control setting
Air trapped in heating system ▶ Bleed radiators and recharge heating
system
Desired room temperature exceeded by
large amount
Radiators are too hot ▶ Turn down thermostatic radiator
valves/room thermostat
▶ Reduce central heating temperature
by turning down the Central Heating
control on boiler
Heating stays on for too long Clock is incorrectly set ▶ Check setting and adjust
No ON/OFF mains indicator Momentary power failure ▶ Switch off boiler at master switch,
wait a few seconds then switch on
again
Hot water cylinder temperature too low Temperature set too low ▶ Check setting and adjust
Hot water cylinder temperature too high Temperature set too high ▶ Check setting and adjust
Table 3

6 720 646 196 (2013/08)Condens 5000 W
Fault or breakdown | 13
8Faultorbreakdown
This boiler is supported in AU and NZ by Robert Bosch.
Service Engineers are available to attend a breakdown occurring on this boiler.
• No charge will be made for parts and/or labour providing:
A boiler fault is found and the appliance has been installed within the past 24 months. Reasonable evidence of this must be
supplied on request. i.e. the service checklist.
• A call-out charge will be made where:
– The boiler has been installed for over 24 months.
– Evidence cannot be provided that the first year service inspection has been carried out (i.e. an entry in the service
checklist).
– Our Service Engineer finds no fault with the boiler.
– The cause of breakdown is misuse or with other parts of your plumbing/heating system, or with equipment not supplied by
Robert Bosch.
Technical Support
In the event of a boiler fault or breakdown please contact Robert Bosch on: 1300 30 70 37.
Your advisor will arrange for an engineer to call with the minimum of delay, for priority breakdown situations (no hot water and /or
heating).
Invoices for attendance and repair work carried out on this boiler by any third party will not be accepted.
No boiler fault is found on over 30% of all service calls.
In the case of a suspected fault, refer to the fault finding section of this guide.

6 720 646 196 (2013/08) Condens 5000 W
14 | Tips on energy saving
9 Tips on energy saving
Heating economically
The Condens 5000 provides a high level of comfort whilst keeping gas consumption and the environment effects as low as possible.
The gas supply to the burner is controlled according to the level of demand for heat. The boiler operates with a low flame if the
demand for heat reduces. The technical term for this process is modulating control.
Modulating control reduces temperature fluctuations and provides an even distribution of heat throughout the home. This means
that the boiler may stay on for relatively long periods of time but will use less gas than a boiler that continually switches on and off.
Central heating systems with room thermostats and radiator valves
With modern heating systems set around a 20 °C heat loss, the optimum setting for a condensing boiler will be approximately
between one and two on the central heating temperature control. The system must be balanced correctly and the radiators may
need upgrading. This allows the boiler to condense as much as possible for the central heating system.
The temperature of each room can be set individually (except primary room with the room thermostat) using the thermostatic
radiator valves.
Room thermostats
Reducing the setting of the room thermostat by 1 °C can reduce fuel consumption by up to 10%.
New control systems
Upgrade your heating control system if necessary with the latest equipment available. The minimum level of control is a
programmer, interlocking room thermostat and thermostatic radiator valves.
Curtains
Lined curtains, or heavier full length curtains can provide excellent insulation. However,
always ensure that the curtains do not drape over radiators.
WARNING: Air vents
▶ Do not block or seal any air vents that are installed to ensure that the central heating boiler operates safely.

6 720 646 196 (2013/08)Condens 5000 W
Environment / disposal | 15
10 Environment / disposal
Environmental protection is a fundamental corporate strategy of the Bosch Group.
The quality of our products, their economy and environmental safety are all of equal importance to us and all environmental
protection legislation and regulations are strictly observed.
We use the best possible technology and materials for protecting the environment taking account of economic considerations.
Packaging
We participate in the recycling programmes of the countries in which our products are sold to ensure optimum recycling.
All of our packaging materials are environmentally compatible and can be recycled.
USED APPLIANCES
▶ All Condens 5000 gas boilers are 100% recycleable.
The various assemblies can be easily dismantled and synthetic materials are marked accordingly. Assemblies
can therefore be sorted by composition and passed on for recycling.

6 720 646 196 (2013/08) Condens 5000 W
16 | Your guarantee
11 Your guarantee
This boiler is guaranteed against faulty materials or workmanship for a period of 2 years from the date of installation provided the
warranty card is returned within 30 days, subject to the following terms and conditions:
• During the period of this guarantee any components of the boiler which are proven to be faulty or defective in manufacture will
be exchanged or repaired free of charge by Robert Bosch (Australia) Pty Ltd - Thermotechnology Division.
• The householder may be asked to prove the date of installation, that the boiler was correctly commissioned and, where
appropriate, the first year‘s service has been carried out to the satisfaction of Robert Bosch (Australia) Pty Ltd -
Thermotechnology Division, when requested. These should be part of the service checklist.
• The boiler has been used only for the normal domestic purposes for which it was designed.
This guarantee does not affect your statutory rights.
Registering your boiler
Returning the card will register you as the owner of your new Condens 5000 hydronic boiler and will assist us in maintaining an
effective and efficient customer service by establishing a reference and permanent record for your boiler.
For your own record:
Please ensure that the service checklist has been completed by your installer or service engineer.
Model
Serial No.1)
1) See identity label on control panel/flap or service checklist.
Type/size
Date of installation
Name of Installer
Telephone number of Installer
Table 4

6 720 646 196 (2013/08)Condens 5000 W
Glossary | 17
12 Glossary
Central heating systems
All radiators must be heated at an even rate. If the top of a radiator is at a lower temperature than the bottom then it should be vented
by releasing air through the venting screw at the top of the radiator. Ask your installer to show you how this is done.
This boiler is fitted to a sealed system. Should water leaks be found or if excessive venting is required, then a service engineer must
be contacted to inspect the installation and rectify any fault.
Only additives that are compatible with aluminium may be used in the system. Any incompatible additive used will invalidate the
guarantee.
Pluming and condensate drain
This is a condensing boiler and the flue terminal will, at times give out a plume of water vapour. This is quite normal.
The boiler produces condensate which is discharged regularly by a syphon within the boiler via a plastic pipe to a drain. This pipe
must not be blocked or altered in any way.
Room thermostat / programmer
A room thermostat / programmer must be fitted to control the central heating. This controls the times and temperatures of the
central heating, preventing the boiler from firing unnecessarily. Refer to the instructions supplied with the thermostat and
programmer for further information.
Thermostatic radiator valves
Bosch recommend, as a minimum, that thermostatic radiator valves are fitted in sleeping accommodation. It is recommended that
this type of valve is fitted to all but one of the radiators. The remaining radiator, where the room thermostat is located, must be
uncontrolled and left open.
Pump over run function
After the boiler has finished a demand for central heating or hot water, the pump continues to run for three minutes to dissipate the
heat from within the boiler.
Pump anti-seizure
If there has been no heating demand for 24 hours the boiler will run the system pump for a few seconds to reduce the possibility of
pump seizure during long periods of inactivity.

6 720 646 196 (2013/08) Condens 5000 W
18 |
Notes

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| 19