Bosch ZBR16-3A User manual

Operating Instructions
Gas Condensing Boiler
Greenstar
6 720 613 303-00.1O
ZBR16/28/35/42-3A... | ZWB28/42-3A...
6 720 644 013 (2011/02) CA/US

2| General information
6 720 644 013 (2011/02)
General information
This manual is available in English and French.
Keep this manual for future use.
CAUTION:
BObserve the safety instructions of this manual
before putting the heating appliance into
operation.

General information | 3
6 720 644 013 (2011/02)
WARNING: If the information in this manual is not
followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of
life.
BDo not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
BWhat to do if you smell gas
–Do not try to light any appliance.
–Do not touch any electrical switch; do not use
any phone in your building.
–Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
–If you cannot reach your gas supplier, call the
fire department.
BInstallation and service must be performed by a
trained and certified heating contractor, service
agency or the gas supplier.

4| Contents
6 720 644 013 (2011/02)
Contents
1 Guideline to symbols and safety instructions . . . . . . . . . 6
1.1 Guideline to symbols . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Information about the appliance . . . . . . . . . . . . . . . . . . . 11
2.1 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Overview of boiler types . . . . . . . . . . . . . . . . . . . . . 12
3 Preparing the appliance for operation . . . . . . . . . . . . . . 13
3.1 Opening the control panel cover . . . . . . . . . . . . . . 13
3.2 Checking the boiler water pressure . . . . . . . . . . . . 14
3.3 Topping up the heating system water . . . . . . . . . . . 15
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Overview of controls . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Switching the appliance ON/OFF . . . . . . . . . . . . . . 20
4.3 Turning the space heating ON . . . . . . . . . . . . . . . . 21
4.4 Programming the heating control unit . . . . . . . . . . 23
4.5 ZBR..-3A appliances with DHW tank:
Setting the DHW temperature . . . . . . . . . . . . . . . . . 24
4.6 ZWB..-3A appliances (combi boilers):
Setting the DHW temperature . . . . . . . . . . . . . . . . . 27
4.7 Setting manual summer mode . . . . . . . . . . . . . . . . 29
4.8 Setting frost protection . . . . . . . . . . . . . . . . . . . . . 30
4.9 Activating the key pad lock . . . . . . . . . . . . . . . . . . . 32
4.10 Display codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Contents | 5
6 720 644 013 (2011/02)
5 Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Energy saving tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 Environmental responsibility/disposal . . . . . . . . . . . . . . 41
10 Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6| Guideline to symbols and safety instructions
6 720 644 013 (2011/02)
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.
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.

Guideline to symbols and safety instructions | 7
6 720 644 013 (2011/02)
Important Information
Additional symbols
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
BSequence of steps
ÆCross-reference to other points in this docu-
ment or to other documents
•Listing/list entry
–Listing/list entry (2nd level)
Tab. 1

8| Guideline to symbols and safety instructions
6 720 644 013 (2011/02)
1.2 Safety instructions
If you smell gas
BTurn off the gas cock (Æpage 18).
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 20).
BOpen windows and doors.
BInform a trained and certified heating contractor.
For appliances operating on room air: Danger of flue gas
poisoning if supply of combustion air is insufficient
BSafeguard supply of combustion air.
BDo not cover or reduce the size of ventilation openings in
doors, windows and walls.
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 operate the appliance if the supply of combustion air is
insufficient.

Guideline to symbols and safety instructions | 9
6 720 644 013 (2011/02)
Danger of explosion of flammable gases.
BOnly employ a trained and certified contractor to carry out
work on the gas train.
Risk of scalding
BIf running at DHW temperatures above 104 °F (40 °C) ask a
trained and certified heating contractor to install a tempering
valve to prevent scalding.
BWhen the thermal disinfection function is enabled, DHW
temperatures above 140 °F (60 °C) can occur.
Risk of damage due to operator error
Operator errors can result in personal injury and damage to
property.
BEnsure that children never operate this appliance unsupervised
or play with it.
BEnsure that only people who know to operate this appliance
correctly have access to it.
Installation, conversion
Only have the appliance installed or modified by a trained and
certified heating contractor.
Never modify any parts that carry flue gas.
Never close the outlet of safety valves. Water may be expelled
from any safety valve during heat-up.

10 | Guideline to symbols and safety instructions
6 720 644 013 (2011/02)
Inspection and maintenance
The operator is responsible for safety and environmental
compliance of the heating system.
Sign 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.
Explosive and easily combustible materials
Never use or store easily combustible materials (paper, thinners,
paints, etc.) near the appliance.
Combustion air / room air
To prevent corrosion, keep the supply of combustion air /
room air free of corrosive substances (e.g. halogenated
hydrocarbons that contain chlorine or fluorine compounds).
Overheating of the appliance
Should overheating occur or the gas supply fail to shut off, do not
turn off or disconnect the electrical supply to the pump. Instead,
shut off the gas supply at a location outside of the appliance.
In case of water damage
Do not use this boiler if any part has been under water.
Immediately call a trained and certified service technician to
inspect the boiler and to replace any part of the control system
and any gas control which has been under water.

Information about the appliance | 11
6 720 644 013 (2011/02)
2 Information about the appliance
2.1 Certifications
2.2 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.
This product has been tested and certified for the
US and the Canadian market and complies with
all applicable standards required for the US and
the Canadian market.

12 | Information about the appliance
6 720 644 013 (2011/02)
2.3 Overview of boiler types
Z Central heating appliance
W DHW heating
B Condensing technology
R Constant temperature control
16…42 Output up to 54,600 / 95,500 / 119,400 /
143,300 BTU/hr (16 / 28 / 35 / 42 kW)
-3 Version
A Fan-supported appliance
Greenstar ZBR16-3A
ZBR28-3A
ZBR35-3A
ZBR42-3A
ZWB28-3A
ZWB42-3A
Tab. 2

Preparing the appliance for operation | 13
6 720 644 013 (2011/02)
3 Preparing the appliance for
operation
BIf existing, open the heating supply valve and the heating return
valve.
BIf existing, open the cold water valve and the DHW valve.
BWhen using ZBR..-3A appliances with DHW tank, open a DHW
tap until water runs out.
BOpen the gas cock.
3.1 Opening the control panel cover
Fig. 1
6 720 612 660-01.2R

14 | Preparing the appliance for operation
6 720 644 013 (2011/02)
3.2 Checking the boiler water pressure
The standard boiler water pressure is 14.5 - 21.75 psi (1 - 1.5 bar).
Should a higher boiler water pressure be required, refer to a
trained and certified heating contractor.
Fig. 2
6 720 641 934-04.2O
1
0
2
3
4
bar
psi
15
3045

Preparing the appliance for operation | 15
6 720 644 013 (2011/02)
3.3 Topping up the heating system water
Topping up the heating system water is different on every system.
Therefore, you should ask a trained and certified heating
contractor to show you how it is done.
Maximum pressure of 30 psi (2.07 bar) at maximum heating
water temperature must not be exceeded (safety valve will spill).

16 | Operation
6 720 644 013 (2011/02)
4 Operation
These operating instructions apply only to the boiler.
Depending on the heating control unit used, some functions may
vary.
The following options for controlling the heating system are
available:
•Outdoor reset control unit (Æpage 23, Fig. 7) installed in the
boiler (Æpage 18, [19])
•Outdoor reset control unit mounted on the wall
•Room thermostat
•Outdoor reset with room influence (room thermostat)
•Third party system control unit
Therefore, please read the operating instructions
for the heating control unit used.

Operation | 17
6 720 644 013 (2011/02)
Fig. 3
Page 42 contains a quick reference. You can fold
this outward and keep these operating
instructions in the control panel cover.
6 720 614 235-04.1O
max
1
2
34
5
6

18 | Operation
6 720 644 013 (2011/02)
4.1 Overview of controls
Fig. 4
12345678
10
9
11
12
14
15
1718 13 6 720 641 934-01.1O
16
19
eco
reset

Operation | 19
6 720 644 013 (2011/02)
1Emission test button for contractors (see installation
instructions)
2Service button for contractors (see installation
instructions)
3Burner ON indicator lamp
4ON/OFF switch
5Key pad lock
6ECO button
7Reset button
8Display
9Boiler water pressure gauge
10 DHW thermostat
11 Safety relief valve discharge hose
12 Condensate drain hose
13 Heating return pipe
14 Cold water pipe - combi boiler only
15 Gas pipe
16 DHW pipe - combi boiler only
17 Supply pipe
18 Boiler high limit dial
19 Mounting socket for outdoor reset controls

20 | Operation
6 720 644 013 (2011/02)
4.2 Switching the appliance ON/OFF
Startup
BSwitch the appliance ON using the ON/OFF switch.
The display shows the supply temperature.
Fig. 5
Shutdown
BSwitch the appliance OFF using the ON/OFF switch.
The diplay goes out.
BIf the appliance is taken out of service for a longer period:
Observe frost protection (ÆSection 4.8).
If the display shows in alternation with the
supply temperature, the appliance operates at its
lowest output for 15 minutes per the initial startup
sequence.
max
1
2
34
5
6
6 720 613 896-05.1O