Bosch ZBR16-3A Quick guide

WARNING:
Improper installation, set-up, modification, operation
or maintenance of the heating system can cause
personal injury and property damage.
Follow these instructions precisely.
If you require assistance or further information, contact
a trained and certified installer or the gas supply
company.
WARNING:
The operating instructions are part of the technical
documents that must be handed over to the owner or
operator of the heating system.
Explain to the owner or operator how to use the heating
system using the operating instructions. Make sure that
they are familiar with all required information for the
safe and proper operation of the heating system.
NOTE:
In Massachusetts, this appliance must be installed by
a licensed plumber or gas fitter.
These instructions are available in English and French.
Please keep these instructions for future reference.
Installation and Service Instructions for Contractors
Gas Condensing Boiler
Greenstar
6 720 613 303-00.1O
ZBR16-3A... | ZBR28-3A... | ZBR35-3A... | ZBR42-3A... | ZWB28-3A... | ZWB42-3A...
6 720 643 068 (2011/06) CA/US

2| Contents
Copyright (optional information)6 720 643 068 (2011/06)
Contents
1 Guideline to symbols and safety instructions . . . . 4
1.1 Guideline to symbols . . . . . . . . . . . . . . . . . 4
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . 4
2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 ZBR - Boiler for space heating and
loading of indirect fired DHW tanks . . . . . .6
2.2 ZWB - Combi boiler for space heating and
DHW generation . . . . . . . . . . . . . . . . . . . . .7
3 Information about the appliance . . . . . . . . . . . . . . 8
3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Overview of boiler types . . . . . . . . . . . . . . 8
3.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Appliance description . . . . . . . . . . . . . . . . 9
3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Product dimensions and minimum
clearances . . . . . . . . . . . . . . . . . . . . . . . . .11
3.7 Appliance layout heating boiler ZBR..-3A . 12
3.8 Appliance layout combi boiler ZWB..-3A . 14
3.9 Electrical wiring heating boiler ZBR..-3A . 16
3.10 Electrical wiring combi boiler ZWB..-3A . 18
3.11 Technical data heating boiler ZBR16-3A... 20
3.12 Technical data heating boiler ZBR28-3A... 22
3.13 Technical data heating boiler ZBR35-3A... 24
3.14 Technical data heating boiler ZBR42-3A... 26
3.15 Technical data combi boiler ZWB28-3A... 28
3.16 Technical data combi boiler ZWB42-3A... 30
3.17 Condensate composition . . . . . . . . . . . . . 32
4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 Compliance with standards and
regulations . . . . . . . . . . . . . . . . . . . . . . . .33
4.2 Operating limits of the boiler . . . . . . . . . 33
4.3 Additional regulations for installation in
Massachusetts . . . . . . . . . . . . . . . . . . . . .34
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 Notes on installation and operation . . . . 35
5.1.1 Notes on installation and operation . . . . 35
5.1.2 Other important information . . . . . . . . . . 36
5.2 Comparing the size of the integrated
expansion vessel . . . . . . . . . . . . . . . . . . . 37
5.3 ZBR..-3A appliances (heating boilers):
Selecting an expansion vessel . . . . . . . . . 38
5.4 Selecting the installation location . . . . . . 38
5.5 Pre-installing pipes . . . . . . . . . . . . . . . . . 39
5.6 Mounting the appliance . . . . . . . . . . . . . 41
5.7 Installing a low water cut off (LWCO) . . 42
5.8 Connecting flue gas accessories . . . . . . . 43
5.8.1 Installation of the exhaust and air
intake system . . . . . . . . . . . . . . . . . . . . . . 44
5.8.2 Approved examples of horizontal and
vertical venting installation . . . . . . . . . . . 47
5.8.3 Vent and combustion air pipe lengths . . 50
5.9 Testing gas and water connections
for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Making the electrical connections . . . . . . . . . . . 52
6.1 General notes . . . . . . . . . . . . . . . . . . . . . 52
6.2 Low voltage electrical connections in the
Heatronic boiler control . . . . . . . . . . . . . . 52
6.2.1 Open the Heatronic boiler control . . . . . 52
6.2.2 Connecting the outdoor temperature
sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2.3 Connecting the DHW tank temperature
sensor (only heating boiler ZBR..-3A) . . . 53
6.2.4 Connecting additional accessories . . . . . 54
6.3 Electrical connections in the junction box
(120 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3.1 Mounting rails for junction box . . . . . . . . 55
6.3.2 Connecting an external heating zone
pump or DHW recirculation pump . . . . . . 55
6.3.3 DHW tank loading pump or 3-way valve
with spring return (only heating boiler
ZBR..-3A) . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3.4 Connecting mains power supply . . . . . . . 56
6.4 Connecting the LWCO device . . . . . . . . . 57

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7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1 Before operating the appliance . . . . . . . . 59
7.2 Switching the appliance ON/OFF . . . . . . . 59
7.3 Setting up space heating . . . . . . . . . . . . . 60
7.4 Programming the FW 200 heating
control unit . . . . . . . . . . . . . . . . . . . . . . . 60
7.5 After commissioning . . . . . . . . . . . . . . . . . 60
7.6 ZBR..-3A appliances (heating boilers) with
DHW tank: Setting the DHW temperature 61
7.7 ZWB..-3A appliances (combi boilers):
Setting the DHW temperature . . . . . . . . . 61
7.8 Setting manual summer mode . . . . . . . . . 62
7.9 Setting frost protection . . . . . . . . . . . . . . 62
7.10 Activating the key pad lock . . . . . . . . . . . 63
8 ZBR..-3A appliances (heating boiler) with
DHW tank: Thermal disinfection . . . . . . . . . . . . . 63
9 Boiler circulator . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.1 Pump anti-seize protection . . . . . . . . . . . 64
9.2 Changing the pump curve of the
boiler pump . . . . . . . . . . . . . . . . . . . . . . . 64
10 Heatronic boiler control settings . . . . . . . . . . . . . 65
10.1 Guideline to service functions . . . . . . . . . 65
10.2 Overview of the service functions . . . . . . 66
10.2.1 First service level . . . . . . . . . . . . . . . . . . . 66
10.2.2 Second service level . . . . . . . . . . . . . . . . . 66
10.3 Description of the service functions . . . . 67
10.3.1 First service level . . . . . . . . . . . . . . . . . . . 67
10.3.2 Second service level . . . . . . . . . . . . . . . . . 73
11 Gas type conversion . . . . . . . . . . . . . . . . . . . . . . . 75
11.1 Converting to a different gas type . . . . . . 75
11.2 Installation location higher than 2,000 feet
(610 m) above sea level . . . . . . . . . . . . . 76
11.3 Setting the gas-air ratio (CO2or O2) . . . . 76
11.4 Dynamic gas pressure test . . . . . . . . . . . 78
12 Flue gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.1 Emissions test button . . . . . . . . . . . . . . . 79
12.2 Measuring CO content of flue gas . . . . . . 79
13 Environmental responsibility/disposal . . . . . . . . . 80
14 Inspection and maintenance . . . . . . . . . . . . . . . . 81
14.1 Description of various steps . . . . . . . . . . 82
14.1.1 Calling up the latest fault (service
function 6.A) . . . . . . . . . . . . . . . . . . . . . . .82
14.1.2 Fresh water filter (only combi boiler
ZWB..-3A) . . . . . . . . . . . . . . . . . . . . . . . . .82
14.1.3 Plate type heat exchanger
(only combi boiler ZWB..-3A) . . . . . . . . . .82
14.1.4 Checking the electrodes . . . . . . . . . . . . . 83
14.1.5 Burner servicing . . . . . . . . . . . . . . . . . . . . 84
14.1.6 Heat exchanger block inspection and
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .84
14.1.7 Condensate trap cleaning . . . . . . . . . . . . 86
14.1.8 Checking the mixer diaphragm . . . . . . . . 86
14.1.9 Expansion vessel . . . . . . . . . . . . . . . . . . . 87
14.1.10 Setting the boiler water pressure . . . . . . 87
14.1.11 Testing system water quality . . . . . . . . . . 87
14.1.12 Inspecting electrical wiring . . . . . . . . . . . 87
14.2 Checklist for inspection and maintenance 88
15 Readings on the display . . . . . . . . . . . . . . . . . . . . 89
16 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
16.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . 90
16.2 Faults that are shown on the display . . . . 91
16.3 Faults that are not shown on the display 94
16.4 Check sensor values . . . . . . . . . . . . . . . . 95
16.4.1 Outdoor temperature sensor . . . . . . . . . . 95
16.4.2 Additional supply temperature limiter . . . 95
16.4.3 Supply temperature sensor, External
supply temperature sensor, DHW tank
temperature sensor, DHW temperature
sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
16.5 Replacement code plug . . . . . . . . . . . . . . 96
17 Commissioning log for the appliance . . . . . . . . . 97
18 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4| Guideline to symbols and safety instructions
Copyright (optional information)6 720 643 068 (2011/06)
1 Guideline to symbols and safety instructions
1.1 Guideline to symbols
Warnings
Signal words at the beginning of a warning are used to
indicate the type and seriousness of the ensuing risk if
measures for minimizing damage are not taken.
•NOTE indicates that damage to property may occur.
•CAUTION indicates possible minor to medium personal
injury.
•WARNING indicates possible severe personal injury.
•DANGER indicates a potential for loss of life.
Important Information
Additional symbols
1.2 Safety instructions
Safety first. Never risk your health or your life. Your own
safety must always take the highest priority.
Use approved personal protective devices and common
sense safety measures.
If you smell gas
BTurn off the gas cock (Æpage 58).
BOpen windows and doors.
BDo not operate any electrical switches.
BExtinguish all open flames.
BFrom outside the building, call gas utility company and
a trained and certified heating contractor.
If you smell flue gas
BSwitch OFF the appliance (Æpage 59).
BOpen windows and doors.
BInform a trained and certified heating contractor.
Danger of electric shock when the control panel is open
BAlways disconnect the appliance from the mains power
before performing any work. Disconnect the emergency
shutoff switch or disengage the heating system circuit
breaker.
BTake measures to prevent accidental reconnection.
For appliances operating on room air: Danger of flue gas
poisoning if supply of combustion air is insufficient
BSafeguard supply of combustion air.
BThe ventilation and exhaust openings must never be
plugged. The cross section of the ventilation and
exhaust openings must comply with the design
specifications at all times.
BSafeguard sufficient supply of combustion air also for
appliances installed at a later date, e.g. kitchen exhaust
fans, clothes dryers, and air conditioning units with vent
to the outside.
BNever install a barometric nor a thermally controlled
vent damper with this boiler.
BIf the ventilation and exhaust openings do not comply
with the specifications, the heating system must never
be operated.
BNotify operator and building owner of the defect in
writing.
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.
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.
Symbol Explanation
B Sequence of steps
Æ Cross-reference to other points in this
document or to other documents
• Listing/list entry
– Listing/list entry (2nd level)
Tab. 1 Additional Symbols

Guideline to symbols and safety instructions | 5
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Danger of explosion of flammable gases.
BOnly employ a trained and certified contractor to carry
out work on the gas train.
Installation and conversion
Only have the appliance installed or modified by a trained
and certified heating contractor.
Always follow state of the art construction techniques for
installation and maintenance, and observe all applicable
codes and regulations.
Never modify any parts that carry flue gas.
Only trained and certified contractors are permitted to
carry out electrical work. Follow applicable code.
The DHW tank may only be used for heating domestic hot
water.
Never close the outlet of safety valves. Water may be
expelled from any safety valve during heat-up.
Inspection and maintenance
The operator is responsible for the safety and
environmental compliance of the heating system.
It is recommended to arrange a maintenance and
inspection contract with a trained and certified
contractor, covering an annual inspection and demand-
dependent maintenance. This guarantees high efficiency
and environmentally sound combustion.
Do not attempt to repair parts that have built in safety
features. Always replace the part.
Only use original Bosch spare parts. Bosch does not
accept responsibility for damage caused by third party
spare parts.
Perform maintenance annually. Check the complete
heating system for defects and malfunction.
Mitigate defects immediately to avoid larger scale system
damage.
To prevent damage to the appliance or the system from
descaling agents, remove parts to be descaled during the
process.
Explosive and easily combustible materials
Never use or store easily combustible materials (paper,
thinners, paints, etc.) near the appliance.
Combustion air/room air
BTo prevent corrosion, keep the supply of combustion/
room air free of corrosive substances (e.g. halogenated
hydrocarbons that contain chlorine or fluorine
compounds).
BAvoid drawing in combustion air from outdoors that is
excessively loaded with dust or airborne particles.
Install adequate air filters under the following
circumstances:
–Air supply is contaminated with dust from dirt roads
and paths.
–Air supply is contaminated with dust from production
and processing facilities, e.g. quarries, mines, etc.
–Airborne seeds from thistles and similar plants.
–Halogen-hydrocarbon compounds, e.g. from paint
booths or hair salons.
Risk of system damage due to unsuitable fill water
Risk of system damage due to corrosion or scale formation
as the result of using fill and top-up water that does not
conform to the system-specific requirements.
Risk of system damage from freezing
The heating system can freeze up and burst in cold
weather if it is shut down or locked out.
BLeave the heating system turned on as much as
possible.
BProtect a disabled heating system from freezing by
draining the boiler and water pipes at the lowest point.

6| Scope of delivery
Copyright (optional information)6 720 643 068 (2011/06)
2 Scope of delivery
2.1 ZBR - Boiler for space heating and loading of indirect fired DHW tanks
Fig. 1 Scope of delivery heating boiler ZBR..-3A
Contents of package 1:
1Gas condensing boiler
2Set of documents for appliance
3Mounting bracket with mounting kit
4Gas conversion kit
5Adapter for connection of a LWCO
Contents of package 2:
6Rail with connection box
7Flue adapter
8DHW tank temperature sensor (NTC)
9Hydraulics connection plate with mounting kit
10 External supply temperature sensor (NTC)
11 Outdoor reset control FW 200 with mounting kit and outdoor
temperature sensor
12 Set of documents for outdoor reset control FW 200
6 720 641 933-22.1O
1
8
7
6
12
11
2
3
4
10
9
5

Scope of delivery | 7
6 720 643 068 (2011/06)Copyright (optional information)
2.2 ZWB - Combi boiler for space heating and DHW generation
Fig. 2 Scope of delivery combi boiler ZWB..-3A
Contents of package 1:
1Gas condensing boiler
2Set of documents for appliance
3Mounting bracket with mounting kit
4Gas conversion kit
5Adapter for connection of a LWCO
Contents of package 2:
6Rail with connection box
7Flue adapter
8Hydraulics connection plate with mounting kit
9External supply temperature sensor (NTC)
10 Outdoor reset control FW 200 with mounting kit and outdoor
temperature sensor
11 Set of documents for outdoor reset control FW 200
6 720 641 933-04.1O
7
8
6
11
10
1
2
3
4
5
9

8| Information about the appliance
Copyright (optional information)6 720 643 068 (2011/06)
3 Information about the appliance
ZBR appliances are boilers for central heating and loading
of an indirect fired DHW tank.
ZWB appliances are combi boilers for central heating and
on demand DHW heating.
The appliances comply with South Coast Air Quality
Management District (SCAQMD) 2012 requirements:
(Type-1) 14 Ng/J NOx(and/or 20 ppm at 3% O2).
3.1 Proper use
The appliance may only be installed in closed loop hot
water central heating systems.
Any other purpose is considered improper use. Any
resulting damage is excluded from the manufacturer's
warranty.
The commercial and industrial use of the appliance for
generating process heat is not permitted.
3.2 Overview of boiler types
Table 2 describes the meaning of the model number:
ZCentral heating appliance
WDHW heating
BCondensing technology
RConstant temperature control
16 Output up to 54,600 BTU/hr (16 kW)
28 Output and DHW output up to 95,500 BTU/hr (28 kW)
35 Output up to 119,400 BTU/hr (35 kW)
42 Output and DHW output up to 143,300 BTU/hr (42 kW)
-3 Version
AFan-supported appliance
23 Natural gas (NG)
ZBR16-3 A23
ZBR28-3 A23
ZBR35-3 A23
ZBR42-3 A23
ZWB28-3 A23
ZWB42-3 A23
Tab. 2 Appliance types
Appliance AHRI Efficiency Rating
ZBR16-3 96.1 %
ZBR28-3 95.9 %
ZBR35-3 95.0 %
ZBR42-3 94.3 %
ZWB28-3 95.9 %
ZWB42-3 94.3 %
Tab. 3 Initial AHRI Rating

Information about the appliance | 9
6 720 643 068 (2011/06)Copyright (optional information)
3.3 Rating plate
The rating plate is located at the right side of the
appliance.
Fig. 3 Position of the rating plate
The rating plate contains the appliance output, model
number, approval data and serial number.
3.4 Appliance description
•Appliance for wall installation, regardless of chimney
and room size
•Outdoor reset control FW 200
•Intelligent boiler pump control
•Heatronic boiler control with 2-wire BUS
•Three-speed boiler circulator
•Automatic air vent (combi boiler ZWB..-3A only)
•Display
•Automatic ignition
•Continuously-controlled output
•Full protection via the Heatronic with flame rod and
solenoid valves
•No minimum circulating water flow rate required
•Suitable for radiant floor heating
•Flue adapter for flue gas and combustion air with test
ports
•Variable speed fan
•Gas premix burner
•Temperature sensor and temperature control for space
heating
•Supply temperature sensor
•Temperature limiter
•Safety relief valve, pressure gauge
•Expansion vessel (combi boiler ZWB..-3A only)
•Connection possibility for DHW tank temperature
sensor (NTC) (heating boiler ZBR..-3A only)
•Flue gas temperature limiter
•DHW priority (combi boiler ZWB..-3A only)
•Motorized 3-way valve (combi boiler ZWB..-3A only)
•Hydraulics connection plate
6 720 641 933-84.1O

10 | Information about the appliance
Copyright (optional information)6 720 643 068 (2011/06)
3.5 Accessories
•FB 100 room control
•Modules for system expansions:
–ISM2 for solar systems (DHW heating, space heating
support, pool heating)
–IPM2 for one or two heating zones with pump control
and motorized mixing capability
Here you will find a list of typical accessories
for this appliance. Refer to the Bosch Product
Catalog for a complete overview of all
available accessories.

Information about the appliance | 11
6 720 643 068 (2011/06)Copyright (optional information)
3.6 Product dimensions and minimum clearances
Fig. 4 Dimensions and minimum clearances (front view, rear view, side view)
1Appliance jacket
2Service cover
3Hydraulics connection plate
(*) Zero clearance from combustibles permitted, but 4" (102 mm)
recommended for serviceability
(**) Distance to door, if mounted inside a closet
17-21/64"
(440 mm)
≥ 4" *
(102 mm) *
≥ 4" *
(102 mm) *
3-11/32"
(85 mm)
33-15/32"
(850 mm)
9-29/64"
(240 mm)
7-7/8"
(200 mm)
33-27/64"
(849 mm)
1-3/16"
(30 mm)
13-57/64"
(353 mm)
33-15/16"
(862 mm)
≥ 4" *
(102 mm) *
≥ 15"
(381 mm)
3
1
2
6 720 641 933-01.1O
≥ 4" **
(102 mm) **

12 | Information about the appliance
Copyright (optional information)6 720 643 068 (2011/06)
3.7 Appliance layout heating boiler ZBR..-3A
Fig. 5 Appliance layout heating boiler ZBR..-3A
min
13
14
15
16
17
20
26
25
24
18
19
30
32
33
35
37
40
41
29
34
28
39
36
38
31
1
2
3
4
5
678
12
9
10
11
6 720 641 933-02.1O
27
23
22
21

Information about the appliance | 13
6 720 643 068 (2011/06)Copyright (optional information)
Key to Fig. 5:
1Heatronic boiler control
2ON/OFF switch
3Burner flame indicator
4Service button
5Emissions test button
6Boiler high limit dial
7Mounting socket for outdoor reset controls
8DHW thermostat
9Key pad lock
10 ECO button
11 Reset button
12 Display
13 Condensate trap
14 Test ports for inlet gas pressure
15 Adjustment screw, minimum gas volume
16 Maximum gas adjuster
17 Flue gas temperature limiter
18 Combustion air intake
19 Exhaust pipe
20 Boiler supply pipe
21 Connection for optional low water cut off (LWCO)
22 Additional supply temperature limiter
23 Manual air bleeder
24 Gas/air premix chamber
25 Fan
26 Bracket
27 Wall hanging bracket
28 Exhaust pipe
29 Sight glass
30 Set of electrodes
31 Supply temperature sensor
32 Boiler block temperature limiter
33 Inspection and cleanout cover
34 Condensate collector
35 Boiler circulator
36 Pump speed switch
37 Condensate drain hose
38 Drain cock
39 Safety relief valve discharge hose
40 Pressure relief valve (heating zone)
41 Boiler water pressure gauge

14 | Information about the appliance
Copyright (optional information)6 720 643 068 (2011/06)
3.8 Appliance layout combi boiler ZWB..-3A
Fig. 6 Appliance layout combi boiler ZWB..-3A
min
1
2
3
4
5
678
12
9
10
11
6 720 641 933-03.1O
13
16
17
19
20
21
23
22
25
28
18
26
27
30
31
32
36
37
38
33
34
35
14
15
29
24
45
44
39
40
41
42
43

Information about the appliance | 15
6 720 643 068 (2011/06)Copyright (optional information)
Key to Fig. 6:
1Heatronic boiler control
2ON/OFF switch
3Burner flame indicator
4Service button
5Emissions test button
6Boiler high limit dial
7Mounting socket for outdoor reset controls
8DHW thermostat
9Key pad lock
10 ECO button
11 Reset button
12 Display
13 Condensate trap
14 Test ports for inlet gas pressure
15 Adjustment screw, minimum gas volume
16 DHW temperature sensor
17 Plate-type heat exchanger
18 Automatic air vent
19 Maximum gas adjuster
20 Flue gas temperature limiter
21 Combustion air intake
22 Supply pipe
23 Connection for optional low water cut off (LWCO)
24 Additional supply temperature limiter
25 Gas/air premix chamber
26 Expansion vessel
27 Fan
28 Bracket
29 Wall hanging bracket
30 Exhaust pipe
31 Sight glass
32 Set of electrodes
33 Supply temperature sensor
34 Boiler block temperature limiter
35 Inspection and cleanout cover
36 Condensate collector
37 Flow meter
38 3-way valve
39 Drain cock
40 Condensate drain hose
41 Boiler circulator
42 Pump speed switch
43 Pressure relief valve (heating zone)
44 Safety relief valve discharge hose
45 Boiler water pressure gauge

16 | Information about the appliance
Copyright (optional information)6 720 643 068 (2011/06)
3.9 Electrical wiring heating boiler ZBR..-3A
Fig. 7 Electrical wiring diagram heating boiler ZBR..-3A
120 VAC
L
N
B
B
F
A
6 720 641 933-23.1O
987
LP NP
LS NS
4
2
123 67
4589
L
N
120 VAC
9 VAC
25 VAC
4
6
1
2
3
5
7
11
9
12
14 15
16
17
18
19
20 21
22
23
24
25
6
10
8
26
13
4

Information about the appliance | 17
6 720 643 068 (2011/06)Copyright (optional information)
Key to Fig. 7:
1Ignition transformer
2Boiler high limit dial
3120 VAC connection
4DHW tank primary pump or 3-way valve 1)
5External heating pump for unmixed heating circuit (secondary circuit) 2) or DHW recirculation pump 2)
6Fuse T 6.3 A (120 VAC)
7DHW thermostat
8External safety high limit or low water cut off (LWCO)
9BUS connection, e.g. heating control
10 Room thermostat – dry contact
11 Outdoor temperature sensor
12 Code plug
13 Diagnostic interface
14 ON/OFF switch
15 Transformer
16 Gas valve
17 Fan
18 Flue gas temperature limiter
19 Supply temperature sensor
20 Flame rod electrode
21 Ignition electrode
22 Boiler block temperature limiter
23 DHW tank temperature sensor (NTC)
24 Boiler circulator
25 Additional supply temperature limiter
26 External system supply temperature sensor
1) Set the service function 1.F,Æpage 67
2) Set the service function 5.E, Æpage 71

18 | Information about the appliance
Copyright (optional information)6 720 643 068 (2011/06)
3.10 Electrical wiring combi boiler ZWB..-3A
Fig. 8 Electrical wiring diagram combi boiler ZWB..-3A
120 VAC
120 VAC
9 VAC
25 VAC
L
N
B
B
F
A
6 720 641 933-24.1O
987
LP NP
LS NS
4
2
123 67
4589
4
6
25
24
6
1
2
3
4
6
10
8
11
13
15
16
17
18
19 20
21
23
22
26
5
9
7
27
12
14

Information about the appliance | 19
6 720 643 068 (2011/06)Copyright (optional information)
Key to Fig. 8:
1Ignition transformer
2Boiler high limit dial
3120 VAC connection
4External heating pump for unmixed heating circuit (secondary circuit) 1) or DHW recirculation pump 1)
5Fuse T 6.3 A (120 VAC)
6DHW thermostat
7External safety high limit or low water cut off (LWCO)
8BUS connection, e.g. heating control
9Room thermostat – dry contact
10 Outdoor temperature sensor
11 Code plug
12 Diagnostic interface
13 ON/OFF switch
15 Transformer
14 Gas valve
16 Fan
17 Flue gas temperature limiter
18 Supply temperature sensor
19 Flame rod electrode
20 Ignition electrode
21 Boiler block temperature limiter
22 DHW temperature sensor
23 Boiler circulator
24 3-way valve (Space heating/DHW heating)
25 Flow meter (turbine)
26 Additional supply temperature limiter
27 External system supply temperature sensor
1) Set the service function 5.E, Æpage 71

20 | Information about the appliance
Copyright (optional information)6 720 643 068 (2011/06)
3.11 Technical data heating boiler ZBR16-3A...
Unit NG LPG (propane)
Output
Maximum nominal output (P
max
) 104/86 °F (40/30 °C) BTU/hr (kW) 54,900 (16.1) 55,300 (16.2)
Maximum nominal output (P
max
) 122/86 °F (50/30 °C) BTU/hr (kW) 54,300 (15.9) 54,600 (16.0)
Maximum nominal output (P
max
) 176/140 °F (80/60 °C) BTU/hr (kW) 50,800 (14.9) 51,200 (15.0)
Max. nominal thermal load (Q
max
) heating (H
i
) 180/79 °F (82/26 °C) BTU/hr (kW) 51,500 (15.1) 51,900 (15.2)
Max. nominal thermal load (Q
max
) heating (H
s
) 180/79 °F (82/26 °C) BTU/hr (kW) 57,200 (16.8) 56,400 (16.5)
Min. nominal output (P
min
) 104/86 °F (40/30 °C) BTU/hr (kW) 12,600 (3.7) 21,500 (6.3)
Min. nominal output (P
min
) 122/86 °F (50/30 °C) BTU/hr (kW) 12,600 (3.7) 21,500 (6.3)
Min. nominal output (P
min
) 176/140 °F (80/60 °C) BTU/hr (kW) 11,300 (3.3) 19,400 (5.7)
Min. nominal thermal load (Q
min
) heating (H
i
) 180/79 °F (82/26 °C) BTU/hr (kW) 11,600 (3.4) 19,800 (5.8)
Min. nominal thermal load (Q
min
) heating (H
s
) 180/79 °F (82/26 °C) BTU/hr (kW) 12,900 (3.8) 21,500 (6.3)
Max. nominal thermal load (Q
max
) tank (H
i
) BTU/hr (kW) 51,500 (15.1) 51,900 (15.2)
Max. nominal thermal load (Q
max
) tank (H
s
)BTU/hr(kW)57,200 (16.8) 56,400 (16.5)
Min. nominal thermal load (Q
min
) tank (H
i
)BTU/hr(kW)11,600 (3.4) 19,800 (5.8)
Min. nominal thermal load (Q
min
) tank (H
s
)BTU/hr(kW)12,900 (3.8) 21,500 (6.3)
Gas connection value
Natural Gas – H
s
= 1,010 BTU/ft
3
(37.3 MJ/m
3
)ft
3
/hr (m
3
/h) 56 (1.6) –
Liquid Propane Gas – H
D-S
= 2,500 BTU/ft
3
(93.1 MJ/m
3
)ft
3
/hr (m
3
/h) – 22 (0.6)
Permissible inlet gas pressure
NG in. W.C. (mbar) 3.5-10.5" (8.7-26.1) –
LPG (propane) in. W.C. (mbar) – 8-13" (19.9-32.3)
Calculation values for calculating cross-section to EN 13384
Flue gas mass flow at maximum/minimum nominal output gps 6.8/1.7 6.7/2.6
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum
nominal heat input °F ( °C) 136/133 (58/56) 136/133 (58/56)
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum
nominal heat input °F ( °C) 99/88 (37/31) 99/88 (37/31)
CO
2
at max. nominal output % 9.4 11.0
CO
2
at minimum nominal output % 8.6 10.4
Condensate
Max. condensate quantity (t
R
= 86 °F (30 °C)) gph (l/h) 0.32 (1.2) 0.32 (1.2)
pH level, approx. 4.8 4.8
Tab. 4 Technical data heating boiler ZBR16-3A...