Bosch | Greenstar 131 | Operating instructions | Bosch Greenstar 131 Operating instructions

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.
NOTICE:
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.
6 720 806 992-00-1O
Residential Gas Condensing Boiler
Greenstar
ZBR16-3A... | ZBR21-3A... | ZBR28-3A... | ZBR35-3A... | ZBR42-3A... | ZWB28-3A... | ZWB35-3A... | ZWB42-3A...
6 720 806 992 (2013/07) CA/US
Installation and Service Instructions for Contractors
2 | Contents
5.8.1 Installation of the exhaust and air intake system . . . . .
5.8.2 Approved examples of horizontal and vertical venting
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8.3 Vent and combustion air pipe lengths . . . . . . . . . . . . . .
5.9
Testing gas and water connections for leaks . . . . . . . .
Contents
1
Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . 3
1.1
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 3
6
2
3
4
5
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1
ZBR - Residential boiler for space heating and loading of
indirect fired DHW tanks . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2
ZWB - Residential combi boiler for space heating and DHW
generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Information about the appliance . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1
Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2
Overview of boiler types . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3
Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4
Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6
Product dimensions and minimum clearances . . . . . . . . 9
3.7
Appliance layout heating boiler ZBR..-3A . . . . . . . . . . . 10
3.8
Appliance layout combi boiler ZWB..-3A . . . . . . . . . . . 12
3.9
Electrical wiring heating boiler ZBR..-3A . . . . . . . . . . . 14
3.10 Electrical wiring combi boiler ZWB..-3A . . . . . . . . . . . . 16
3.11 Technical data heating boiler ZBR16-3A... . . . . . . . . . . 18
3.12 Technical data heating boiler ZBR21-3A... . . . . . . . . . . 19
3.13 Technical data heating boiler ZBR28-3A... . . . . . . . . . . 20
3.14 Technical data heating boiler ZBR35-3A... . . . . . . . . . . 21
3.15 Technical data heating boiler ZBR42-3A... . . . . . . . . . . 22
3.16 Technical data combi boiler ZWB28-3A... . . . . . . . . . . 23
3.17 Technical data combi boiler ZWB35-3A... . . . . . . . . . . 24
3.18 Technical data combi boiler ZWB42-3A... . . . . . . . . . . 25
3.19 Condensate composition . . . . . . . . . . . . . . . . . . . . . . . . 26
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1
Compliance with standards and regulations . . . . . . . . . 26
4.2
Operating limits of the boiler . . . . . . . . . . . . . . . . . . . . . 26
4.3
Additional regulations for installation in Massachusetts . .
27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
Notes on installation and operation . . . . . . . . . . . . . . . .
5.1.1 Notes on installation and operation . . . . . . . . . . . . . . . .
5.1.2 Other important information . . . . . . . . . . . . . . . . . . . . .
5.2
Comparing the size of the integrated expansion
vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
ZBR..-3A appliances (heating boilers): Selecting an
expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
Selecting the installation location . . . . . . . . . . . . . . . . .
5.5
Pre-installing pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6
Mounting the appliance . . . . . . . . . . . . . . . . . . . . . . . . .
5.7
Installing a low water cut off (LWCO) . . . . . . . . . . . . . .
5.8
Connecting flue gas accessories . . . . . . . . . . . . . . . . . .
6 720 806 992 (2013/07)
28
28
28
29
29
30
30
30
32
32
33
7
34
38
40
41
Making the electrical connections . . . . . . . . . . . . . . . . . . . . . .
6.1
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
Low voltage electrical connections in the Heatronic
boiler control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Open the Heatronic boiler control . . . . . . . . . . . . . . . . .
6.2.2 Connecting the outdoor temperature sensor . . . . . . . .
6.2.3 Connecting the DHW tank temperature sensor (only
heating boiler ZBR..-3A) . . . . . . . . . . . . . . . . . . . . . . . .
6.2.4 Connecting additional accessories . . . . . . . . . . . . . . . .
6.3
Electrical connections in the junction box (120 VAC) .
6.3.1 Mounting rails for junction box . . . . . . . . . . . . . . . . . . .
6.3.2 Connecting an external heating zone pump or DHW
recirculation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.3 DHW tank loading pump or 3-way valve with spring
return (only heating boiler ZBR..-3A) . . . . . . . . . . . . . .
6.3.4 Connecting mains power supply . . . . . . . . . . . . . . . . . .
6.4
Connecting the LWCO device . . . . . . . . . . . . . . . . . . . .
41
41
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
Before operating the appliance . . . . . . . . . . . . . . . . . . .
7.2
Switching the appliance ON/OFF . . . . . . . . . . . . . . . . .
7.3
Setting up space heating . . . . . . . . . . . . . . . . . . . . . . . .
7.4
Programming the FW 200 heating control unit . . . . . .
7.5
After commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6
ZBR..-3A appliances (heating boilers) with DHW tank:
Setting the DHW temperature . . . . . . . . . . . . . . . . . . .
7.7
ZWB..-3A appliances (combi boilers):
Setting the DHW temperature . . . . . . . . . . . . . . . . . . .
7.8
Setting manual summer mode . . . . . . . . . . . . . . . . . . . .
7.9
Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . .
7.10 Activating the key pad lock . . . . . . . . . . . . . . . . . . . . . .
47
47
48
48
48
48
42
42
42
42
43
44
44
44
45
45
46
49
49
49
50
50
8
ZBR..-3A appliances (heating boiler) with DHW tank:
Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9
Boiler circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.1
Pump anti-seize protection . . . . . . . . . . . . . . . . . . . . . . 51
9.2
Changing the pump curve of the boiler pump . . . . . . . . 51
10 Heatronic boiler control settings . . . . . . . . . . . . . . . . . . . . . . .
10.1 Guideline to service functions . . . . . . . . . . . . . . . . . . . .
10.2 Overview of the service functions . . . . . . . . . . . . . . . . .
10.2.1 First service level (press and hold the service button
until it lights up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.2 Second service level (at first service level, service
button lights up, press ECO button and key pad lock
button simultaneously until 8.A appears) . . . . . . . . . .
52
52
52
52
53
Greenstar
Key to symbols and safety instructions | 3
10.3 Description of the service functions . . . . . . . . . . . . . . . 53
10.3.1 First service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.3.2 Second service level . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
17 Commissioning log for the appliance . . . . . . . . . . . . . . . . . . . 75
18 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11 Gas type conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1 Converting to a different gas type . . . . . . . . . . . . . . . . .
11.2 Installation location higher than 2,000 feet (610 m)
above sea level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 Setting the gas-air ratio (CO2 or O2) . . . . . . . . . . . . . . .
11.4 Dynamic gas pressure test . . . . . . . . . . . . . . . . . . . . . .
59
59
59
60
61
12 Flue gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
12.1 Emissions test button . . . . . . . . . . . . . . . . . . . . . . . . . . 62
12.2 Measuring CO content of flue gas . . . . . . . . . . . . . . . . . 62
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1
Key to symbols and safety instructions
1.1
Key to symbols
Warnings
Warnings in this document are identified by a warning
triangle printed against a grey background.
13 Environmental responsibility/disposal . . . . . . . . . . . . . . . . . . 62
14 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
14.1 Description of various steps . . . . . . . . . . . . . . . . . . . . .
14.1.1 Calling up the latest fault (service function 6.A) . . . . .
14.1.2 Fresh water filter (only combi boiler ZWB..-3A) . . . . .
14.1.3 Plate type heat exchanger
(only combi boiler ZWB..-3A) . . . . . . . . . . . . . . . . . . . .
14.1.4 Checking the electrodes . . . . . . . . . . . . . . . . . . . . . . . .
14.1.5 Burner servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.1.6 Heat exchanger block inspection and cleaning . . . . . .
14.1.7 Condensate trap cleaning . . . . . . . . . . . . . . . . . . . . . . .
14.1.8 Checking the mixer diaphragm . . . . . . . . . . . . . . . . . . .
14.1.9 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.1.10Setting the boiler water pressure . . . . . . . . . . . . . . . . .
14.1.11Testing system water quality . . . . . . . . . . . . . . . . . . . . .
14.1.12Inspecting electrical wiring . . . . . . . . . . . . . . . . . . . . . .
14.2 Checklist for inspection and maintenance . . . . . . . . . .
62
63
63
63
63
64
65
65
67
67
67
67
67
67
68
15 Readings on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
16 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.2 Faults that are shown on the display . . . . . . . . . . . . . . .
16.3 Faults that are not shown on the display . . . . . . . . . . .
16.4 Check sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.4.1 Outdoor temperature sensor . . . . . . . . . . . . . . . . . . . . .
16.4.2 Additional supply temperature limiter . . . . . . . . . . . . .
16.4.3 Supply temperature sensor, External supply
temperature sensor, DHW tank temperature sensor,
DHW temperature sensor . . . . . . . . . . . . . . . . . . . . . . .
16.5 Replacement code plug . . . . . . . . . . . . . . . . . . . . . . . . .
Greenstar
70
70
71
73
74
74
74
Keywords at the start of a warning indicate the type and seriousness of
the ensuing risk if measures to prevent the risk are not taken. The
following keywords are defined and can be used in this document:
• NOTICE indicates that property damage may occur.
• CAUTION indicates that personal injury may occur.
• WARNING indicates that severe personal injury may occur.
• DANGER indicates that severe personal injury or death may occur.
Important information
Important information for the proper use of the boiler is
also provided in this manual. You will find the
information with a symbol shown on the left and
bordered by horizontal lines above and below the text.
Additional symbols
Symbol Explanation
▶
Sequence of steps

Cross-reference to other points in this document or to other
documents
•
Listing/list entry
–
Listing/list entry (2nd level)
Table 1
1.2
General safety instructions
If you hear gas leaking
▶ Leave the building immediately.
▶ Prevent others from entering the building.
▶ Notify the police and fire department from outside the building.
▶ From outside the building, call the gas supply company and a trained
and certified installer or service company.
74
74
6 720 806 992 (2013/07)
4 | Key to symbols and safety instructions
If you smell gas
▶ Turn off the gas shut-off valve.
▶ Open windows and doors
▶ Do not touch any electrical switch, telephone, and do not use outlets.
▶ Extinguish all open flames.
▶ Do not smoke!
▶ Do not use lighters!
▶ Warn all occupants of the building that they need to leave the building.
▶ Do not ring doorbells!
▶ Notify the police and fire department from outside the building.
▶ From outside the building, call the gas supply company and a trained
and certified installer or service company.
If you smell flue gas
▶ Switch off the heating system by shutting off the emergency shut-off
switch.
▶ Open windows and doors.
▶ Call a trained and certified installer or service company.
DANGER: Risk of fatal injury from failing to consider your own
safety!
▶ Never risk your own life. Your own safety must always take the highest
priority
NOTICE: Risk of appliance damage from improper operation of the
boiler!
▶ Only use the boiler for its intended purpose.
▶ Only operate the boiler if it has been installed and maintained per the
instructions provided in the Installation Manual.
▶ Do not attempt to operate an appliance if any part of it is not in
working order or is damaged.
▶ Use only original spare parts! The use of parts not supplied by the
manufacturer may cause damage to the boiler, other property and
personal injury. Also, boiler damage caused by the use of
unauthorized parts is not covered by the warranty.
DANGER: Risk of fire when soldering and brazing!
▶ Take appropriate protective measures when soldering and brazing
around combustible and flammable material.
NOTICE:
▶ The installation must comply with all applicable national, state, and
local codes, rules, and regulations.
▶ The operator is responsible for the operational safety and regulatory
compliance of the heating system.
▶ In the Commonwealth of Massachusetts, the appliance must be
installed by a licensed plumber or gas fitter.
▶ The venting system must not feed into or route through another air
extraction duct.
▶ The venting system must be inspected annually. All parts that show
any signs of damage or corrosion must be replaced.
▶ Never close off or reduce the size of the combustion air openings.
▶ The boiler must not be operated until any obstructions have been
removed.
DANGER: Risk of personal injury or death from explosion!
▶ Work on gas components may only be carried out by a trained and
certified installer or service company.
▶ Appliance installation, the connection of gas and vent piping, initial
commissioning, electrical connections, and service and maintenance
must only be carried out by a trained and certified installer or service
company.
DANGER: Risk of personal injury or death from fire!
▶ Do not use flammable or combustible material in the boiler room.
▶ It is recommended not to store any items within 16 inches (415mm)
of the appliance
CAUTION: Appliance damage from contaminated combustion air!
▶ Keep the combustion air free of corrosive substances, e.g.
halogenated hydrocarbons from painting operations or beauty
salons.
▶ Keep combustion air free from dust and lint, e.g. from laundry or
agricultural operations.
▶ If clean room air is not available, fresh outdoor combustion air must be
provided
DANGER: Risk of personal injury or death from electric shock.
▶ Before removing the front panel, disconnect the heating system from
the electrical power supply by shutting off the emergency shutoff
switch or the heating system circuit breaker.
▶ It is not enough to switch off the control panel. Power to the panel
must be disconnected! Ensure that the power is not restored
unintentionally by following proper lock out/tag out procedures.
▶ Only qualified electricians are permitted to carry out electrical work.
DANGER: Safety devices!
▶ Never shut off safety valves!
▶ Hot water may escape from the safety valve at any time when the
appliance is running.
DANGER: Risk of personal injury or death after a flood!
▶ Do not attempt to operate an appliance if any part of it has been under
water.
▶ An appliance that was subject to flooding must be replaced.
DANGER: Risk of personal injury or death from flue gas poisoning!
NOTICE:
▶ Do not install a thermostatic flue gas damper downstream of the draft
hood.
▶ Do not tamper with, remove, or attempt to repair the blocked vent
switch.
▶ When replacing the blocked vent switch, install the new part in the
original location.
▶ A blocked vent switch tripping more than once indicates a problem
with the venting system or chimney which must be repaired
immediately.
▶ Ensure none of the vent pipes and chimneys are damaged or blocked.
▶ Connect only one appliance to each venting system or chimney.
▶ Upon completion of the installation, these instructions should be
handed to the owner and operator of the appliance.
▶ The installer must instruct the owner and operator on the functionality
of the components and the proper operation of the boiler and the
heating system.
▶ The boiler must be serviced annually including the main burner,
ignition burner, the entire venting system, and the combustion air
supply. All parts that show any signs of damage or corrosion must be
replaced.
6 720 806 992 (2013/07)
Greenstar
Scope of delivery | 5
2
Scope of delivery
2.1
ZBR - Residential boiler for space heating and loading
of indirect fired DHW tanks
1
2
Contents of package 1:
1
Gas condensing boiler
2
Set of documents for appliance
3
Mounting bracket with mounting kit
4
Gas conversion kit
5
Adapter for connection of a LWCO
3
4
5
6
7
8
Contents of package 2:
6
Rail with connection box
7
Flue adapter1)
8
DHW tank temperature sensor (NTC)
9
Hydraulics 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
9
10
11
12
6 720 641 933-22.2O
Fig. 1
Scope of delivery heating boiler ZBR..-3A
1) Concentric vent kit available as accessory.
Greenstar
6 720 806 992 (2013/07)
6 | Scope of delivery
2.2
ZWB - Residential combi boiler for space heating and
DHW generation
1
2
Contents of package 1:
[1] Gas condensing boiler
[2] Set of documents for appliance
[3] Mounting bracket with mounting kit
[4] Gas conversion kit
[5] Adapter for connection of a LWCO
3
4
5
6
7
Contents of package 2:
[6] Rail with connection box
[7] Flue adapter1)
[8] Hydraulics connection plate with mounting kit
[9] External 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
8
9
10
11
6 720 641 933-04.2O
Fig. 2
Scope of delivery combi boiler ZWB..-3A
1) Concentric vent kit available as accessory.
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 7
3
3.3
Information about the appliance
Rating plate
The rating plate is located at the right side of the appliance.
ZBR appliances are residential boilers for central heating and loading of
an indirect fired DHW tank.
ZWB appliances are residential 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 Greenstar boiler is not for use in CSD-1 commercial installation.
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:
ZBR16-3
ZBR21-3
ZBR28-3
ZBR35-3
ZBR42-3
ZWB28-3
ZWB35-3
ZWB42-3
A
A
A
A
A
A
A
A
23
23
23
23
23
23
23
23
Table 2 Appliance types
Z
W
B
R
16
21
28
35
42
-3
A
23
Central heating appliance
DHW heating
Condensing technology
Constant temperature control
Output up to 54,600 BTU/hr (16 kW)
Output and DHW output up to 71,600 BTU/hr (21 kW)
Output and DHW output up to 95,500 BTU/hr (28 kW)
Output and DHW output up to 119,400 BTU/hr (35 kW)
Output and DHW output up to 143,300 BTU/hr (42 kW)
Version
Fan-supported appliance
Natural gas (NG)
6 720 641 933-84.2O
Fig. 3
The rating plate contains the appliance output, model number, approval
data and serial number.
3.4
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Greenstar
Position of the rating plate
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
6 720 806 992 (2013/07)
8 | Information about the appliance
3.5
Accessories
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.
• 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
– ICM for cascading up to 4 boilers
– optional concentric vent kit available for horizontal direct vent
terminations
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 9
Product dimensions and minimum clearances
≥ 4" *
(102 mm) *
≥ 4" *
(102 mm) *
17-21/64"
(440 mm)
33-15/32"
(850 mm)
3-11/32"
(85 mm)
≥ 15"
(381 mm)
3.6
≥ 4" **
(102 mm) **
33-15/16"
(862 mm)
1
2
7-7/8"
(200 mm)
13-57/64"
(353 mm)
1-3/16"
(30 mm)
33-27/64"
(849 mm)
≥ 4" *
(102 mm) *
9-29/64"
(240 mm)
3
6 720 641 933-01.2O
Fig. 4
[1]
[2]
[3]
(*)
(**)
Dimensions and minimum clearances (front view, rear view, side view)
Appliance jacket
Service cover
Hydraulics connection plate
Zero clearance from combustibles permitted, but 4" (102 mm)
recommended for serviceability
Distance to door, if mounted inside a closet
Greenstar
6 720 806 992 (2013/07)
10 | Information about the appliance
3.7
Appliance layout heating boiler ZBR..-3A
27
28
26
25
29
24
23
22
21
20
30
31
32
19
18
33
17
16
34
35
15
14
36
13
37
38
39
40
1
12
11
10
9
2
3
4
5
41
min
6
7
8
6 720 641 933-02.2O
Fig. 5
Appliance layout heating boiler ZBR..-3A
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 11
Key to Fig. 5:
[1] Heatronic boiler control
[2] ON/OFF switch
[3] Burner flame indicator
[4] Service button
[5] Emissions test button
[6] Boiler high limit dial
[7] Mounting socket for outdoor reset controls
[8] DHW thermostat
[9] Key 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] Pressure relief valve (heating zone)
[40] Safety relief valve discharge hose
[41] Boiler water pressure gauge
Greenstar
6 720 806 992 (2013/07)
12 | Information about the appliance
3.8
Appliance layout combi boiler ZWB..-3A
29
30
28
27
26
31
25
24
23
32
33
22
34
21
35
20
19
36
18
37
17
16
38
15
39
40
41
42
43
44
14
13
1
12
11
10
9
2
3
4
5
45
min
6
7
8
6 720 641 933-03.2O
Fig. 6
Appliance layout combi boiler ZWB..-3A
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 13
Key to Fig. 6:
[1] Heatronic boiler control
[2] ON/OFF switch
[3] Burner flame indicator
[4] Service button
[5] Emissions test button
[6] Boiler high limit dial
[7] Mounting socket for outdoor reset controls
[8] DHW thermostat
[9] Key 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
Greenstar
6 720 806 992 (2013/07)
14 | Information about the appliance
3.9
Electrical wiring heating boiler ZBR..-3A
19
20
18
16
6
21
17
23
15
9
22
8
5
5 6
7
24
3
4
4
LP NP
1
2
3
7
B
4
2
2
LS NS
L
F
A
10
11
8
8
L
9
7
1
N
N
9
B
4
6
14
25
13
Fig. 7
12
6 720 641 933-23.2O
Electrical wiring diagram heating boiler ZBR..-3A
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 15
Key to Fig. 7:
[1] Ignition transformer
[2] Boiler high limit dial
[3] 120 VAC connection
[4] DHW tank primary pump or 3-way valve 1)
[5] External heating pump for unmixed heating circuit (secondary
circuit) 2) or DHW recirculation pump 2)
[6] Fuse T 6.3 A (120 VAC)
[7] DHW thermostat
[8] External safety high limit or low water cut off (LWCO)
[9] BUS 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] 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 tank temperature sensor (NTC)
[23] Boiler circulator
[24] Additional supply temperature limiter
[25] External system supply temperature sensor
1) Set the service function 1.F, page 53
2) Set the service function 5.E,  page 56
Greenstar
6 720 806 992 (2013/07)
16 | Information about the appliance
3.10 Electrical wiring combi boiler ZWB..-3A
18
19
17
15
6
20
16
22
21
23
14
9
24
8
4
3
4
5 6
7
25
LP NP
1
2
3
6
B
4
2
2
F
LS NS
A
9
10
6
8
7
L
9
7
1
N
8
B
4
5
13
26
12
Fig. 8
11
6 720 641 933-24.2O
Electrical wiring diagram combi boiler ZWB..-3A
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 17
Key to Fig. 8:
[1] Ignition transformer
[2] Boiler high limit dial
[3] 120 VAC connection
[4] External heating pump for unmixed heating circuit (secondary
circuit) 1) or DHW recirculation pump 1)
[5] Fuse T 6.3 A (120 VAC)
[6] DHW thermostat
[7] External safety high limit or low water cut off (LWCO)
[8] BUS connection, e.g. heating control
[9] Room thermostat – dry contact
[10] Outdoor temperature sensor
[11] Code plug
[12] Diagnostic interface
[13] ON/OFF switch
[14] Gas valve
[15] Fan
[16] Flue gas temperature limiter
[17] Supply temperature sensor
[18] Flame rod electrode
[19] Ignition electrode
[20] Boiler block temperature limiter
[21] DHW temperature sensor
[22] Boiler circulator
[23] 3-way valve (Space heating/DHW heating)
[24] Flow meter (turbine)
[25] Additional supply temperature limiter
[26] External system supply temperature sensor
1) Set the service function 5.E,  page 56
Greenstar
6 720 806 992 (2013/07)
18 | Information about the appliance
3.11 Technical data heating boiler ZBR16-3A...
Input/Output
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Min. input rate 180/79 °F (82/26 °C)
Min. output rate 104/86 °F (40/30 °C)
Min. output rate 122/86 °F (50/30 °C)
Min. output rate 176/140 °F (80/60 °C)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3 MJ/m3)
Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)
Permissible inlet gas pressure
NG
LPG (propane)
Flue gas
Flue gas mass flow at maximum/minimum nominal output
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal
heat input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal
heat input
CO2 at max. nominal output
CO2 at minimum nominal output
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Dimensions, W x H x D
Unit
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
NG
57,200 (16.8)
54,900 (16.1)
54,300 (15.9)
50,800 (14.9)
12,900 (3.8)
12,600 (3.7)
12,600 (3.7)
11,300 (3.3)
LPG (propane)
56,400 (16.5)
55,300 (16.2)
54,600 (16.0)
51,200 (15.0)
21,500 (6.3)
21,500 (6.3)
21,500 (6.3)
19,400 (5.7)
ft3/hr (m3/h)
ft3/hr (m3/h)
56 (1.6)
–
–
22 (0.6)
in. W.C. (mbar)
in. W.C. (mbar)
3.5-10.5" (8.7-26.1)
–
–
8-13" (19.9-32.3)
gps
6.8/1.7
6.7/2.6
°F ( °C)
136/133 (58/56)
136/133 (58/56)
°F ( °C)
99/88 (37/31)
99/88 (37/31)
%
%
9.4
8.6
11.0
10.4
gph (l/h)
0.32 (1.2)
4.8
0.32 (1.2)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
120
120
60
60
205
205
<6
<6
33
33
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
103.6 (47)
103.6 (47)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 3 Technical data heating boiler ZBR16-3A...
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 19
3.12 Technical data heating boiler ZBR21-3A...
Input/Output
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Min. input rate 180/79 °F (82/26 °C)
Min. output rate 104/86 °F (40/30 °C)
Min. output rate 122/86 °F (50/30 °C)
Min. output rate 176/140 °F (80/60 °C)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)
Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1MJ/m3)
Permissible inlet gas pressure
NG
LPG (propane)
Flue gas
Flue gas mass flow at maximum/minimum nominal output
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal
heat input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal
heat input
CO2 at max. nominal output
CO2 at minimum nominal output
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Dimensions, W x H x D
Unit
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
NG
79,200 (23.2)
74,700 (21.9)
74,000 (21.7)
70,300 (20.6)
24,600 (7.2)
23,900 (7.0)
23,900 (7.0)
21,800 (6.4)
LPG (propane)
77,500 (22.7)
74,700 (21.9)
74,000 (21.7)
70,300 (20.6)
40,100 (11.7)
39,900 (11.7)
39,600 (11.6)
36,200 (10.6)
ft3/hr (m3/h)
ft3/hr (m3/h)
78 (2.2)
–
–
31 (0.9)
in. W.C. (mbar)
in. W.C. (mbar)
3.5-10.5" (8.7-26.1)
–
8-13" (19.9-32.3)
gps
9.4/3.2
9.2/4.8
°F ( °C)
145/133 (63/56)
145/133 (63/56)
°F ( °C)
115/90 (46/32)
115/90 (46/32)
%
%
9.4
8.6
11.0
10.4
gph (l/h)
0.5 (1.8)
4.8
0.5 (1.8)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
120
120
60
60
205
205
<6
<6
39
39
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
103.6 (47)
103.6 (47)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 4 Technical data heating boiler ZBR21-3A...
Greenstar
6 720 806 992 (2013/07)
20 | Information about the appliance
3.13 Technical data heating boiler ZBR28-3A...
Input/Output
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Min. input rate 180/79 °F (82/26 °C)
Min. output rate 104/86 °F (40/30 °C)
Min. output rate 122/86 °F (50/30 °C)
Min. output rate 176/140 °F (80/60 °C)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)
Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1MJ/m3)
Permissible inlet gas pressure
NG
LPG (propane)
Flue gas
Flue gas mass flow at maximum/minimum nominal output
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal
heat input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal
heat input
CO2 at max. nominal output
CO2 at minimum nominal output
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Dimensions, W x H x D
Unit
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
NG
100,800 (29.5)
93,800 (27.5)
93,100 (27.3)
89,400 (26.2)
24,600 (7.2)
23,900 (7.0)
23,900 (7.0)
21,800 (6.4)
LPG (propane)
98,600 (28.9)
93,800 (27.5)
93,100 (27.3)
89,400 (26.2)
40,100 (11.7)
39,900 (11.7)
39,600 (11.6)
36,200 (10.6)
ft3/hr (m3/h)
ft3/hr (m3/h)
99 (2.8)
–
–
39 (1.1)
in. W.C. (mbar)
in. W.C. (mbar)
3.5-10.5" (8.7-26.1)
–
8-13" (19.9-32.3)
gps
12.0/3.2
11.6/4.8
°F ( °C)
147/133 (64/56)
147/133 (64/56)
°F ( °C)
117/90 (47/32)
117/90 (47/32)
%
%
9.4
8.6
11.0
10.4
gph (l/h)
0.6 (2.3)
4.8
0.6 (2.3)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
120
120
60
60
205
205
<6
<6
39
39
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
103.6 (47)
103.6 (47)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 5 Technical data heating boiler ZBR28-3A...
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 21
3.14 Technical data heating boiler ZBR35-3A...
Input/Output
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Min. input rate 180/79 °F (82/26 °C)
Min. output rate 104/86 °F (40/30 °C)
Min. output rate 122/86 °F (50/30 °C)
Min. output rate 176/140 °F (80/60 °C)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)
Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1MJ/m3)
Permissible inlet gas pressure
NG
LPG (propane)
Flue gas
Flue gas mass flow at maximum/minimum nominal output
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal
heat input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal
heat input
CO2 at max. nominal output
CO2 at minimum nominal output
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Dimensions, W x H x D
Unit
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
NG
131,900 (38.6)
122,800 (36.0)
121,800 (35.7)
116,700 (34.2)
36,000 (10.5)
35,100 (10.3)
34,800 (10.2)
31,700 (9.3)
LPG (propane)
129,100 (37.8)
122,800 (36.0)
121,800 (35.7)
116,700 (34.2)
46,400 (13.6)
46,100 (13.5)
45,700 (13.4)
42,000 (12.3)
ft3/hr (m3/h)
ft3/hr (m3/h)
130 (3.7)
–
–
52 (1.5)
in. W.C. (mbar)
in. W.C. (mbar)
3.5-10.5" (8.7-26.1)
–
–
8-13" (19.9-32.3)
gps
15.7/4.5
15.2/5.6
°F ( °C)
162/135 (72/57)
162/135 (72/57)
°F ( °C)
127/91 (53/33)
127/91 (53/33)
%
%
9.4
8.6
11.0
10.4
gph (l/h)
0.8 (3.1)
4.8
0.8 (3.1)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
120
120
60
60
205
205
<6
<6
44
44
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
103.6 (47)
103.6 (47)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 6 Technical data heating boiler ZBR35-3A...
Greenstar
6 720 806 992 (2013/07)
22 | Information about the appliance
3.15 Technical data heating boiler ZBR42-3A...
Input/Output at elevation 0 - 2000 feet (0 - 610 m)
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Min. input rate 180/79 °F (82/26 °C)
Min. output rate 104/86 °F (40/30 °C)
Min. output rate 122/86 °F (50/30 °C)
Min. output rate 176/140 °F (80/60 °C)
Input/Output at elevation 2000 - 4500 feet (611 - 1372 m) above sea level
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Input/Output at elevation 4500 - 7000 feet (1373 - 2134 m) above sea level
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)
Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1MJ/m3)
Permissible inlet gas pressure
NG
LPG (propane)
Flue gas
Flue gas mass flow at maximum/minimum nominal output
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal heat
input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal heat
input
CO2 at max. nominal output
CO2 at minimum nominal output
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Dimensions, W x H x D
Unit
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
NG
151,600 (44.4)
137,500 (40.3)
137,500 (40.3)
134,400 (39.4)
36,000 (10.5)
35,500 (10.4)
35,100 (10.3)
31,700 (9.3)
LPG (propane)
148,300 (43.5)
137,500 (40.3)
137,500 (40.3)
134,400 (39.4)
46,400 (13.6)
46,400 (13.6)
46,100 (13.5)
42,000 (12.3)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
136,440 (40.0)
123,750 (36.3)
123,750 (36.3)
120,960 (35.5)
139,402 (40.9)
129,250 (37.9)
129,250 (37.9)
126,336 (37.0)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
125,828 (36.9)
114,125 (33.5)
114,125 (33.5)
111,552 (32.7)
129,021 (37.8)
119,625 (35.1)
119,625 (35.1)
116,928 (34.3)
ft3/hr (m3/h)
ft3/hr (m3/h)
149 (4.2)
–
–
59 (1.7)
in. W.C. (mbar) 3.5-10.5" (8.7-26.1)
in. W.C. (mbar)
–
–
8-13" (19.9-32.3)
gps
18.0/4.5
17.5/5.6
°F ( °C)
171/135 (77/57)
171/135 (77/57)
°F ( °C)
133/91 (56/33)
133/91 (56/33)
%
%
9.4
8.6
11.0
10.4
gph (l/h)
0.9 (3.5)
4.8
0.9 (3.5)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
120
120
60
60
205
205
<6
<6
45
45
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
103.6 (47)
103.6 (47)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 7 Technical data heating boiler ZBR42-3A...
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 23
3.16 Technical data combi boiler ZWB28-3A...
Input/Output
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Output rate domestic hot water (DHW), 113 °F (45 °C)
Output rate domestic hot water (DHW), 140 °F (60 °C)
Min. input rate 180/79 °F (82/26 °C)
Min. output rate 104/86 °F (40/30 °C)
Min. output rate 122/86 °F (50/30 °C)
Min. output rate 176/140 °F (80/60 °C)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)
Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1MJ/m3)
Permissible inlet gas pressure
NG
LPG (propane)
Expansion vessel
Pre-charge pressure
Total contents
DHW
Max. DHW flow rate
Nominal DHW flow rate (at 140 °F (60 °C) outlet temperature)
Outlet temperature
Max. cold water inlet temperature
Max. approved DHW pressure
Minimum water pressure
Flue gas
Flue gas mass flow at maximum/minimum nominal output
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal
heat input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal
heat input
CO2 at max. nominal output
CO2 at minimum nominal output
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Dimensions, W x H x D
Unit
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
NG
100,800 (29.5)
93,800 (27.5)
93,100 (27.3)
89,400 (26.2)
93,600 (27.4)
91,400 (26.8)
24,600 (7.2)
23,900 (7.0)
23,900 (7.0)
21,800 (6.4)
LPG (propane)
98,600 (28.9)
93,800 (27.5)
93,100 (27.3)
89,400 (26.2)
93,600 (27.4)
91,400 (26.8)
40,100 (11.7)
39,900 (11.7)
39,600 (11.6)
36,200 (10.6)
ft3/hr (m3/h)
ft3/hr (m3/h)
99 (2.8)
–
–
39 (1.1)
in. W.C. (mbar)
in. W.C. (mbar)
3.5-10.5" (8.7-26.1)
–
–
8-13" (19.9-32.3)
psi (bar)
Gal (L)
10.9 (0.75)
3.17 (12)
10.9 (0.75)
3.17 (12)
gpm (l/min)
gpm (l/min)
°F ( °C)
°F ( °C)
psi (bar)
psi (bar)
2.64 (10)
2.03 (7.7)
104 - 140 (40 - 60)
140 (60)
150 (10.3)
4.35 (0.3)
2.64 (10)
2.03 (7.7)
104 - 140 (40 - 60)
140 (60)
150 (10.3)
4.35 (0.3)
gps
12.0/3.2
11.7/4.9
°F ( °C)
147/133 (64/56)
147/133 (64/56)
°F ( °C)
117/90 (47/32)
117/90 (47/32)
%
%
9.4
8.6
11.0
10.4
gph (l/h)
0.6 (2.3)
4.8
0.6 (2.3)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
120
120
60
60
205
205
<6
<6
39
39
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
110.2 (50)
110.2 (50)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 8 Technical data combi boiler ZWB28-3A...
Greenstar
6 720 806 992 (2013/07)
24 | Information about the appliance
3.17 Technical data combi boiler ZWB35-3A...
Input/Output
Max. input rate 180/79 °F (82/26 °C)
Max. output rate 104/86 °F (40/30 °C)
Max. output rate 122/86 °F (50/30 °C)
Max. output rate 176/140 °F (80/60 °C)
Output rate domestic hot water (DHW), 113 °F (45 °C)
Output rate domestic hot water (DHW), 140 °F (60 °C)
Min. input rate 180/79 °F (82/26 °C)
Min. output rate 104/86 °F (40/30 °C)
Min. output rate 122/86 °F (50/30 °C)
Min. output rate 176/140 °F (80/60 °C)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)
Liquid Propane Gas – HD-S = 2,500 BTU/ft3 (93.1MJ/m3)
Permissible inlet gas pressure
NG
LPG (propane)
Expansion vessel
Pre-charge pressure
Total contents
DHW
Max. DHW flow rate
Nominal DHW flow rate (at 140 °F (60 °C) outlet temperature)
Outlet temperature
Max. cold water inlet temperature
Max. approved DHW pressure
Minimum water pressure
Flue gas
Flue gas mass flow at maximum/minimum nominal output
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal
heat input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal
heat input
CO2 at max. nominal output
CO2 at minimum nominal output
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Dimensions, W x H x D
Unit
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
BTU/hr (kW)
NG
131,900 (38.6)
122,800 (36.0)
121,800 (35.7)
116,700 (34.2)
120,500 (35.3)
118,700 (34.8)
36,000 (10.5)
35,100 (10.3)
34,800 (10.2)
31,700 (9.3)
LPG (propane)
129,100 (37.8)
122,800 (36.0)
121,800 (35.7)
116,700 (34.2)
120,500 (35.3)
118,700 (34.8)
46,400 (13.6)
46,100 (13.5)
45,700 (13.4)
42,000 (12.3)
ft3/hr (m3/h)
ft3/hr (m3/h)
130 (3.7)
–
–
52 (1.5)
in. W.C. (mbar)
in. W.C. (mbar)
3.5-10.5" (8.7-26.1)
–
–
8-13" (19.9-32.3)
psi (bar)
Gal (L)
10.9 (0.75)
3.17 (12)
10.9 (0.75)
3.17 (12)
gpm (l/min)
gpm (l/min)
°F ( °C)
°F ( °C)
psi (bar)
psi (bar)
3.963 (15)
2.6 (10)
104 - 140 (40 - 60)
140 (60)
150 (10.3)
4.35 (0.3)
3.963 (15)
2.6 (10)
104 - 140 (40 - 60)
140 (60)
150 (10.3)
4.35 (0.3)
gps
15.7/4.5
15.2/5.6
°F ( °C)
162/135 (72/57)
162/135 (72/57)
°F ( °C)
127/91 (53/33)
127/91 (53/33)
%
%
9.4
8.6
11.0
10.4
gph (l/h)
–
0.8 (3.1)
4.8
0.8 (3.1)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
120
120
60
60
205
205
<6
<6
44
44
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
110.2 (50)
110.2 (50)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 9 Technical data combi boiler ZWB35-3A...
6 720 806 992 (2013/07)
Greenstar
Information about the appliance | 25
3.18 Technical data combi boiler ZWB42-3A...
Input/Output at elevation 0 - 2000 feet (0 - 610 m)
Unit
Max. input rate 180/79 °F (82/26 °C)
BTU/hr (kW)
Max. output rate 104/86 °F (40/30 °C)
BTU/hr (kW)
Max. output rate 122/86 °F (50/30 °C)
BTU/hr (kW)
Max. output rate 176/140 °F (80/60 °C)
BTU/hr (kW)
Output rate domestic hot water (DHW), 113 °F (45 °C)
BTU/hr (kW)
Output rate domestic hot water (DHW), 140 °F (60 °C)
BTU/hr (kW)
Min. input rate 180/79 °F (82/26 °C)
BTU/hr (kW)
Min. output rate 104/86 °F (40/30 °C)
BTU/hr (kW)
Min. output rate 122/86 °F (50/30 °C)
BTU/hr (kW)
Min. output rate 176/140 °F (80/60 °C)
BTU/hr (kW)
Input/Output at elevation 2000 - 4500 feet (611 - 1372 m) above sea level
Max. input rate 180/79 °F (82/26 °C)
BTU/hr (kW)
Max. output rate 104/86 °F (40/30 °C)
BTU/hr (kW)
Max. output rate 122/86 °F (50/30 °C)
BTU/hr (kW)
Max. output rate 176/140 °F (80/60 °C)
BTU/hr (kW)
Output rate domestic hot water (DHW), 113 °F (45 °C)
BTU/hr (kW)
Output rate domestic hot water (DHW), 140 °F (60 °C)
BTU/hr (kW)
Input/Output at elevation 4500 - 7000 feet (1373 - 2134 m) above sea level
Max. input rate 180/79 °F (82/26 °C)
BTU/hr (kW)
Max. output rate 104/86 °F (40/30 °C)
BTU/hr (kW)
Max. output rate 122/86 °F (50/30 °C)
BTU/hr (kW)
Max. output rate 176/140 °F (80/60 °C)
BTU/hr (kW)
Output rate domestic hot water (DHW), 113 °F (45 °C)
BTU/hr (kW)
Output rate domestic hot water (DHW), 140 °F (60 °C)
BTU/hr (kW)
Gas connection value
Natural Gas – Hs = 1,010 BTU/ft3 (37.3MJ/m3)
ft3/hr (m3/h)
3
3
Liquid Propane Gas – HD-S = 2,500 BTU/ft (93.1MJ/m )
ft3/hr (m3/h)
Permissible inlet gas pressure
NG
in. W.C. (mbar)
LPG (propane)
in. W.C. (mbar)
Expansion vessel
Pre-charge pressure
psi (bar)
Total contents
Gal (L)
DHW
Max. DHW flow rate
gpm (l/min)
Nominal DHW flow rate (at 140 °F (60 °C) outlet temperature)
gpm (l/min)
Outlet temperature
°F ( °C)
Max. cold water inlet temperature
°F ( °C)
Max. approved DHW pressure
psi (bar)
Minimum water pressure
psi (bar)
Flue gas
Flue gas mass flow at maximum/minimum nominal output
gps
Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal
°F ( °C)
heat input
Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal
°F ( °C)
heat input
CO2 at max. nominal output
%
CO2 at minimum nominal output
%
NG
151,600 (44.4)
137,500 (40.3)
137,500 (40.3)
134,400 (39.4)
137,500 (40.3)
135,800 (39.8)
36,000 (10.5)
35,500 (10.4)
35,100 (10.3)
31,700 (9.3)
LPG (propane)
148,300 (43.5)
137,500 (40.3)
137,500 (40.3)
134,400 (39.4)
137,500 (40.3)
135,800 (39.8)
46,400 (13.6)
46,400 (13.6)
46,100 (13.5)
42,000 (12.3)
136,440 (40.0)
123,750 (36.3)
123,750 (36.3)
120,960 (35.5)
123,750 (36.3)
122,220 (35.8)
139,402 (40.9)
129,250 (37.9)
129,250 (37.9)
126,336 (37.0)
129,250 (37.9)
127,652 (37.4)
125,828 (36.9)
114,125 (33.5)
114,125 (33.5)
111,552 (32.7)
114,125 (33.5)
112,714 (33.0)
129,021 (37.8)
119,625 (35.1)
119,625 (35.1)
116,928 (34.3)
119,625 (35.1)
118,146 (34.6)
149 (4.2)
–
–
59 (1.7)
3.5-10.5" (8.7-26.1)
–
–
8-13" (19.9-32.3)
10.9 (0.75)
3.17 (12)
10.9 (0.75)
3.17 (12)
3.963 (15)
3.61 (11.4)
104 - 140 (40 - 60)
140 (60)
150 (10.3)
4.35 (0.3)
3.963 (15)
3.61 (11.4)
104 - 140 (40 - 60)
140 (60)
150 (10.3)
4.35 (0.3)
18.0/4.5
17.5/5.6
171/135 (77/57)
171/135 (77/57)
133/91 (56/33)
133/91 (56/33)
9.4
8.6
11.0
10.4
Table 10 Technical data combi boiler ZWB42-3A...
Greenstar
6 720 806 992 (2013/07)
26 | Regulations
Input/Output at elevation 0 - 2000 feet (0 - 610 m)
Condensate
Max. condensate quantity (tR = 86 °F (30 °C))
pH level, approx.
General
Voltage
Frequency
Max. power consumption (central heating mode)
Max. power consumption (Stand-by)
Sound pressure level
Max. supply temperature
Max. permissible operating pressure (PMS) heating
Permissible ambient temperature
Nominal water capacity (heating)
Weight (without packaging)
Unit
NG
LPG (propane)
gph (l/h)
–
0.9 (3.5)
4.8
0.9 (3.5)
4.8
VAC
Hz
W
W
dB(A)
°F ( °C)
psi (bar)
°F ( °C)
Gal (L)
lbs. (kg)
inch
(mm)
Dimensions, W x H x D
120
120
60
60
205
205
<6
<6
45
45
194 (90)
194 (90)
30 (2.07)
30 (2.07)
32 - 122 (0 - 50)
32 - 122 (0 - 50)
0.925 (3.5)
0.925 (3.5)
110.2 (50)
110.2 (50)
17-21/64" × 33-15/32" × 13-57/64"
(440 × 850 × 353)
Table 10 Technical data combi boiler ZWB42-3A...
3.19 Condensate composition
4.1
The condensate volume and ingredients may change with regionally and
seasonally varying gas quality and air quality. Typically the following
ingredients and concentrations can be expected:
The installation must conform to the requirements of the authority
having jurisdiction or, in the absence of such requirements, to the latest
edition of the National Fuel Gas Code, ANSI Z223.1./NFPA 54. In
Canada, installation must be in accordance with the requirements of
CAN/CSA B149.1, Natural Gas and Propane Installation Code.
Substance
Ammonium
Lead
Cadmium
Chrome
Halogenated hydrocarbons
Hydrocarbons
Copper
Nickel
Mercury
Sulfate
Zinc
Tin
Vanadium
pH-value
Value in ppm (mg/l)
1.2
 0.01
 0.001
 0.005
 0.002
0.015
0.028
 0.1
 0.0001
1
 0.015
 0.01
 0.001
4.8
Table 11 Typical condensate composition
4
Regulations
Observe all rules, regulations, standards and guidelines
applicable to the installation and operation of this
appliance in your country.
In the Commonwealth of Massachusetts, this appliance
must be installed by a licensed plumber and gas fitter.
Valves external to the boiler must be fitted with
T-handles and condensate piping must be installed in
accordance with the State Plumbing Code.
6 720 806 992 (2013/07)
Compliance with standards and regulations
This wall mounted condensing gas boiler complies in its design and
mode of operation with the American National Standard ANSI Z21.13/
CSA4.9, latest edition for Gas Fired Low Pressure Steam and Hot Water
Boilers.
Other confirmed approvals and certifications are indicated by labels on
the boiler.
Where required by the authority having jurisdiction, the installation must
conform to the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
Install CO detectors per local regulations. Boiler requires yearly
maintenance ( chapter 14, page 62).
4.2
Operating limits of the boiler
The heat exchanger has been designed and certified in accordance with
the ASME Boiler and Pressure Vessel Code, Section IV.
Maximum boiler temperature
Maximum operating pressure
194 °F (90 °C)
30 psi (2.07 bar)
Table 12 Operating limits
The hot water distribution system must comply with all applicable codes
and regulations. When replacing an existing boiler, it is important to
check the condition of the entire hot water distribution system to ensure
safe operation. Common practice calls for inspecting an existing system
in its entirety and bringing it up to code. All pipework should be properly
cleaned and flushed.
Greenstar
Regulations | 27
4.3
Additional regulations for installation in
Massachusetts
(a) For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for
residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination is less
than seven (7) feet [2150 mm] above finished grade in the area of the
venting, including but not limited to decks and porches, the following
requirements shall be satisfied:
• INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of
installation of the side wall horizontal vented gas fueled equipment,
the installing plumber or gasfitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed.
In addition, the installing plumber or gasfitter shall observe that a
battery operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling, building or
structure served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property owner to
secure the services of qualified licensed professionals for the
installation of hard wired carbon monoxide detectors.
– In the event that the side wall horizontally vented gas fueled
equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be
installed on the next adjacent floor level.
– In the event that the requirements of this subdivision can not be
met at the time of completion of installation, the owner shall have a
period of thirty (30) days to comply with the above requirements;
provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be
installed.
• APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above
provisions shall comply with NPA 720 and be ANSI/UL 2034 listed
and IAS certified.
• SIGNAGE. A metal or plastic identification plate shall be permanently
mounted to the exterior of the building at a minimum height of eight
(8) feet above grade directly in line with the exhaust vent terminal for
the horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one-half (½) inch in size,
“GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS”.
• INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspections, the inspector observes carbon
monoxide detectors and signage installed in accordance with the
provisions of 248 CRM 5.08(2)(a) 1 through 4.
instructions provided by the manufacturer for the installation of the
equipment and venting shall include:
• Detailed instructions for the installation of the venting system or the
venting system components; and
• A complete parts list for the venting system design or venting system.
(d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED. When the manufacturer of Product Approved
side wall horizontally vented gas fueled equipment does not provide the
parts for the venting of flue gases, but identifies special venting systems,
the following requirements shall be satisfied by the manufacturer:
• The referenced special venting systems shall be included with the
appliance or equipment installation instructions; and
• The special venting systems shall be Product Approved by the Board,
and the instructions for that system shall include a parts list and
detailed installation instructions.
(e) A copy of all instructions for all Product Approved side wall
horizontally vented gas fueled equipment, all venting instructions, all
parts lists for venting instructions, and/or venting design instructions
shall remain with the appliance or equipment at the completion of the
installation.
(b) EXEMPTIONS: The following equipment is exempt from 248 CRM
5.08(2)(a) 1 through 4:
• The equipment listed in Chapter 10 entitled “Equipment Not Required
To Be Vented” in the most current edition of NFPA 54 as adopted by
the board; and
• Product Approved side wall horizontally vented gas fueled equipment
installed in a room or structure separate from the dwelling, building or
structure used in whole or in part for residential purposes.
(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM REQUIRED. When the manufacturer of Product Approved side
wall horizontally mounted gas equipment provides a venting system
design or venting system components with the equipment, the
Greenstar
6 720 806 992 (2013/07)
28 | Installation
Recirculation pump/DHW recirculation lines
5
Installation
DANGER: Explosion!
▶ Close the gas cock prior to working on the gas train.
▶ Check for gas leaks after carrying out work on the gas
train.
Installation, power connection, connection on the gas
and flue gas side and commissioning must only be
carried out by a contractor certified for such work by the
state or local jurisdiction or the local gas or power utility.
5.1
Notes on installation and operation
When installing and operating the heating system observe the following:
• The elevation of the installation location above sea level must be taken
into account ( Chapter 11.2).
• Follow all local building regulations regarding the installation
conditions on site.
• The local building regulations regarding air supply and venting
systems and the chimney flue connection.
• Electrical code requirements for connection to the electrical power
supply.
• The technical regulations of the gas company regarding the
connection of the gas burner to the local gas main.
• The regulations and standards relating to the DHW heating system.
5.1.1 Notes on installation and operation
Total length DHW/recirculation line
33 ft (10 m)
33 - 66 ft (10 - 20 m)
66 - 98 ft (20 - 30 m)
Flow rate
0.66 gpm (2.5 l/min)
0.92 gpm (3.5 l/min)
1.32 gpm (5 l/min)
Table 13 Recommended flow rates
Use service function 6.d, to determine the current flow
rate ( page 56).
Electrical connection of the DHW recirculation pump
( page 44).
Connect the DHW recirculation line with the cold water inlet as close as
possible to the Hydraulics connection plate.
Open vented heating systems
▶ Convert open vented heating systems into closed systems.
Gravity heating systems
▶ Connect the appliance to the existing piping system via a low-loss
header with a sludge separator.
Galvanized radiators or pipes.
To prevent gas formation:
▶ Do not use galvanized radiators or pipes.
Plastic pipework
Fill and make-up water for the heating system
If using plastic pipework for the heating system (eg.underfloor/radiant
heating), the type of pipe that should be used must be oxygen tight.
Unsuitable fill and make-up water can result in the heating system
scaling up or failing prematurely.
Use of a room temperature control
Recommended steps for commissioning a new or retrofit boiler
installation
Water Chemistry Guidelines
▶ Flush the system with clean water.
▶ Isolate the boiler, fill the system with fresh water and a boiler cleaner,
run for 30 minutes to 1 hour. Under no circumstances may boiler
cleaner be pumped through the boiler.
▶ Thoroughly flush the system with fresh water. Ensure all zones and
loops are flushed.
▶ Empty out sediment traps.
▶ Systems containing antifreeze not approved by Bosch, must be
completely flushed to ensure no old fluid remains.
▶ Fill the system with fresh water and the proper amount of inhibitor.
▶ Verify the pH is within the proper range.
▶ Add additional inhibitor if pH is not within the proper range.
▶ Check pH annually.
▶ If using antifreeze, fill with approved antifreeze and fresh water.
▶ Always follow the cleaner, antifreeze, or additive manufacturer’s
instructions.
▶ Do not mix different manufacturer’s products
▶ Follow manufacturer’s data to determine the anti-freeze ratio for the
desired freeze protection temperature.
6 720 806 992 (2013/07)
▶ Do not install thermostatic valves on radiators in the primary room.
NOTICE: Primary-secondary piping or a low loss header
Radiant floor, panel radiator, multi zone and application
systems exceeding 70' (21 m) of 3/4" baseboard at a
20°F delta T and a flow rate of 4.0 gpm plus the
necessary supply and return piping, require primarysecondary piping or a low loss header for hydraulic
separation of the system from the boiler.
NOTICE: Insufficient antifreeze can accelerate
corrosion.
▶ Follow manufacturer's instructions on antifreeze
concentration.
▶ Frost protection level has to be checked annually
during the regular scheduled maintenance of the
condensing boiler.
NOTICE: System damage!
▶ It is the installer's responsibility to ensure that the
heating system is compatible with the boiler type and
size installed.
▶ pH-value of the heating water to be kept between 7
and 8.5.
Greenstar
Installation | 29
The following anti-freeze fluids and concentrations have been approved:
Chemical Name
Nalco (Varidos) FSK
Fernox Alphi 11
Intercool NFP-50 AA
Antifrogen N
NoBurst AL
Concentration
22 - 55 %
Observe manufacturer's instructions
0 - 39 %
Observe manufacturer's instructions
0 - 55 %
• Inspect the sewer pipes for suitability before disposing of untreated
boiler condensate into them.
• Verify with the local authority that disposing of untreated boiler
condensate into public sewer systems is permitted.
5.2
Comparing the size of the integrated expansion
vessel
Table 14 Anti-freeze
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).
Corrosion inhibitors
The following standard conditions were used:
The following anti-corrosion agents are approved:
• Precharge volume 20% of the rated volume in the expansion vessel
• Differential to the safety valve of 7.25 psi (0.5 bar)
• Precharge pressure of the expansion vessel equal to the static system
height above the boiler
• Maximum operating pressure: 30 psi (2.07 bar)
Chemical Name
Fernox F1
Nalco 77381
Sentinel X 100
Concentration
Observe manufacturer's instructions
1-2%
1.1 %
Table 15 Corrosion inhibitors
200
▶ System fluid pH must be maintained between 7 and 8.5 to prevent
system damage.
▶ Use only untreated water to fill the system.
▶ Do not use TSP (tri-sodium phosphate).
▶ Do not use fill water treated with salt bedding type exchangers (ion
exchanger).
▶ Never introduce non-approved boiler treatment or similar additives.
▶ Only use fill water with a hardness below 7 grains.
▶ Filling with chlorinated water is acceptable if chlorine levels are below
100 ppm.
▶ Do not use inhibitors or other additives unless listed in this document.
▶ Consult a local water treatment specialist for recommendations if any
of the above is outside the stated ranges.
▶ When using oxygen permeable PEX, the system must be separated
from the boiler by a heat exchanger.
▶ A correctly sized and working expansion vessel must be installed.
▶ Do not exceed the maximum permissible fl ow rate through the boiler.
Excessive flow can cause erosion damage to the heat exchanger.
▶ Eliminate System Leaks
Continuous addition of make-up water will constantly add oxygen to
the system and lead to corrosion. All system leaks must be repaired.
180
Boiler sealer
This boiler is not approved for use with boiler sealer.
LPG
To protect the appliance against high pressure (ANSI/Z223.1/NFPA54
(National fuel gas code) or CAN/CSA B 149.1 (Natural Gas and Propane
installation code)):
▶ Install a pressure regulator with a safety valve.
5.1.2 Other important information
• The installation of this boiler must comply with all national and local
code and regulations.
• Only operate this boiler with the combined air/flue system specifically
designed and approved for it.
• Only use approved venting systems per the manufacturer's
instructions.
• Do not dispose of untreated boiler condensate in septic systems.
Greenstar
B
I
tV/°F
160
140
120
III
100
80
II
A
0
20
40
60
80
VA/gal
Fig. 9
100
120
6720641933-13.1O
Operating capacity of the expansion vessel in °F and gallons
90
tV/°C
B
I
80
70
60
50
III
40
30
II
A
0
75
150
225
VA/l
300
375
450
6720641933-27.1O
Fig. 10 Operating capacity of the expansion vessel in °C and liters
Key to Fig. 9 and Fig. 10:
[I]
Precharge pressure 7.25 psi (0.5 bar) (default setting)
[II] Precharge pressure 10.9 psi (0.75 bar)
[III] Precharge pressure 14.5 psi (1.0 bar)
tV
Supply temperature in °F ( °C)
VA
System capacity in gallons (liters)
A
Within operating capacity of the expansion vessel (left of the
relevant curve)
B
Additional expansion vessel required (right of the relevant curve)
▶ If results are borderline: Determine precise vessel sizes.
▶ If the results are to the right of the curve: Install additional expansion
vessel.
6 720 806 992 (2013/07)
30 | Installation
5.3
ZBR..-3A appliances (heating boilers): Selecting an
expansion vessel
External expansion vessel
▶ Determine size of the expansion vessel.
Surface temperature
The max. surface temperature of this appliance is below 185 °F (85 °C).
According to ANSI/Z223.1/NFPA43 (National fuel gas code) and CAN/
DAS B 149.1 (Natural Gas and Propane installation code), the appliance
is approved for zero clearance to combustibles. For servicing a
clearance of 4" (102 mm) is recommended.
5.5
Pre-installing pipes
▶ Secure the installation template (supplied with the technical
documentation) to the wall; observe the minimum side clearances of
4 inches (102 mm) ( page 9).
▶ Drill holes for the appliance and for the hydraulics connection plate in
accordance with the mounting template.
( 17 11/18 in. )
6 720 641 933-20.2O
Fig. 11 Sample installation - expansion vessel
5.4
Selecting the installation location
Installation location requirements
Observe the current national and local codes and regulations.
▶ Observe country-specific requirements.
▶ Observe installation instructions of the venting system accessories
and their clearances.
Combustion air
To avoid corrosion, keep the supply of combustion air free of corrosive
substances; contained in solvents, paints, adhesives, propellants and
domestic cleaning agents.
Degreasing bath
Printing shops
Hair salons
Household sources
Cleaning and
degreasing agents
Trichloroethylene, tetrachloroethylene,
fluorinated hydrocarbons
Perchloroethylene, trichloroethylene,
methylchloroform
Trichloroethylene
Aerosol propellants, hydrocarbons containing
fluorine and chlorine
(difluorodichloromethane)
Perchloroethylene, methylchloroform,
trichloroethylene, methylene chloride, carbon
tetrachloride, hydrochloric acid
Workshop
Solvents and thinners Various chlorinated hydrocarbons
Aerosols
Chlorofluorinated hydrocarbons
(difluorodichloromethane)
Table 16 Corrosive materials
6 720 806 992 (2013/07)
6 720 641 933-45.2O
Industrial sources
Chemical cleaning
Fig. 12 Mounting template
NOTICE: For walls with insufficient load capacity, the
appliance and the hydraulics connection plate must be
mounted on a sheet of plywood or similar
reinforcement.
▶ Remove the mounting template.
Greenstar
Installation | 31
▶ Secure the hydraulics connection plate and the mounting bracket with
the mounting kits supplied.
1 3/8"
(35 mm)
1 31/32"
(50 mm)
5 1/8"
(130 mm)
10 15/64"
(260 mm)
=
=
6 720 641 933-15.1O
Fig. 15 Hydraulics connection plate for heating boiler
ZBR..-3A (top view)
1 3/16"
(30 mm)
7 7/8"
(200 mm)
=
1
2
=
3
4
5
6 720 641 933-90.1O
Fig. 16 Hydraulics connection plate for combi boiler
ZWB..-3A (front view)
6 720 641 933-30.1O
Fig. 13 Mounting of the hydraulics connection plate and the mounting
bracket
[1]
[2]
[3]
[4]
[5]
Heating supply, R 1" NPT
DHW, R 3/4" NPT
Gas, R 3/4" NPT
Cold water, R 3/4" NPT
Heating return, R 1" NPT
1
=
2
3
1 3/8"
(35 mm)
=
5 1/8"
(130 mm)
1 31/32"
(50 mm)
1 3/16"
(30 mm)
7 7/8"
(200 mm)
10 15/64"
(260 mm)
6 720 641 933-89.1O
=
=
Fig. 14 Hydraulics connection plate for heating boiler
ZBR..-3A (front view)
[1]
[2]
[3]
Heating supply, R 1" NPT
Gas, R 3/4" NPT
Heating return, R 1" NPT
Greenstar
6 720 641 933-14.1O
Fig. 17 Hydraulics connection plate for combi boiler
ZWB..-3A (top view)
▶ Determine pipe size for the gas supply.
▶ To fill and drain the system, install a fill and drain valve at the lowest
point.
6 720 806 992 (2013/07)
32 | Installation
5.6
Mounting the appliance
5.7
NOTICE: 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 5.1, page 28).
▶ Remove packaging, observing all notes and symbols.
▶ On the rating plate, check the identification of the target country and
suitability for the gas type supplied by the local gas utility company
( page 10).
Installing a low water cut off (LWCO)
The boiler is equipped with several sensors that prevent firing or running
the boiler in case of low water pressure or low water levels. Nevertheless
code may require the installation of a separate low water cut off (LWCO).
The boiler is equipped with a dedicated port for installation of a LWCO
on the supply pipe inside the boiler cabinet. This location represents the
minimum water level for safe operation of the boiler.
The LWCO device must be specified for an ambient temperature of
176 °F (80 °C) and a water temperature of 250 °F (121 °C). It needs a
dry contact.
The following LWCO is approved with the boiler:
• Hydrolevel Safgard 1100
The device is available at most Bosch wholesalers. It requires an
external 24VAC 20VA transformer provided on site.
Removing the cover
The cover is secured with two screws against
unintentional removal (electrical safety).
▶ Always keep the cover secured with these screws.
▶ Undo screws (step 1).
▶ Lift strap (step 2) and remove cover toward the front (step 3).
2
If other LWCO devices are to be used, they must be
installed external to the boiler.
The Hydrolevel Safgard 1100 is installed in the supply pipe to the left of
the heat exchanger.
▶ Disconnect the boiler from power by shutting off the emergency
shutoff switch or disengaging the heating system circuit breaker.
▶ Drain the boiler.
▶ Remove the safety clip from the dummy plug in the supply pipe
(step 1).
▶ Pull off the dummy plug (step 2) and place with the boiler
documentation.
▶ Ensure the O-ring remains in place on the pipe.
▶ Lubricate the O-ring.
3
2
1
1
6 720 641 933-64.1O
Fig. 19 Installing a LWCO device - removing dummy plug
1
6 720 641 933-96.2O
Fig. 18 Remove the cover
Hanging the appliance
▶ Place flat gaskets on the connections of the hydraulic bracket.
▶ Hang appliance on the mounting bracket.
▶ Tighten the union nuts on the pipe connections.
6 720 806 992 (2013/07)
Greenstar
Installation | 33
▶ Screw the LWCO as far as possible into LWCO adapter located in the
boiler accessory kit. Follow the Hydrolevel Safgard 1100
instructions.
In case of using the twin pipe adaptor:
The twin pipe adaptor is supplied with the boiler kit as
standard.
▶ Install the vent flange and gasket with the screws enclosed.
3
6 720 641 933-64.1O
Fig. 20 Installing a LWCO device - LWCO adapter
2
▶ Push the adapter with the LWCO onto the pipe (step 1) and secure
with the clip (step 2).
1
Ø1
6 720 612 737-01.1O
Ø1 > Ø2
Ø2
Fig. 22 Attaching the vent flange and gasket
[1]
[2]
[3]
Gasket
Vent flange
Screws
▶ Insert the flue gas adapter as far as it will go into the vent flange and
align it.
1
2
3
2
6 720 641 933-65.3O
Fig. 21 Installing a LWCO device – securing with a clip
▶ Connect the wires of the LWCO ( chapter 6.4, page 46).
4
The LWCO is positioned upright for technical reasons.
Tests have shown that all air will bleed from the pipe
during commissioning and full functionality is
established.
If fault d3 is displayed when commissioning the boiler,
purge the boiler properly and check the boiler water
pressure.
5.8
Connecting flue gas accessories
Optional vent systems are:
• Twin pipe PVC / CPVC 2" / 3"
• Twin pipe PP 3" (80 mm) (M&G DuraVent PolyPro GreenVent system)
• Concentric PP 3" / 5" (80/125 mm) (M&G DuraVent PolyPro
GreenVent system)
Greenstar
1
6 720 641 933-85.1O
Fig. 23 Flue gas adapter
[1]
[2]
[3]
[4]
Vent flange
Flue gas adapter
Combustion air test port
Flue gas test ports
▶ Tighten the screws.
6 720 806 992 (2013/07)
34 | Installation
5.8.1 Installation of the exhaust and air intake system
To avoid premature wear of the gaskets DO NOT use
lubricants.
NOTICE:
▶ Vent connectors serving appliances vented by natural
draft shall not be connected to any portion of
mechanical draft systems operating under positive
pressure.
In case of open venting:
▶ Use basket on the air intake.
In case of concentric venting system:
As an alternative to twin pipe venting, a bespoke
telescopic concentric vent kit can be obtained as an
accessory from Bosch Thermotechnology for a
horizontal direct vent wall termination. This vent system
can be used for vent lengths of 2 feet to 3 feet (610 mm
to 915 mm).
For more details on connecting the flue system, refer to
the installation instructions for the flue kit.
1
L
2
6 720 806 992-02.1O
NOTICE: Burner damage!
▶ Avoid drawing in combustion air excessively loaded
with dust or airborne particles.
DANGER:
▶ Ensure that the flue pipes and seals are not damaged.
▶ Use only sealing compounds (primer and glue)
approved with the vent material.
▶ Never install a barometric nor a thermally controlled
vent damper with this boiler.
▶ Connect only one boiler to each flue system or
chimney flue.
▶ Do not route the flue system piping through or inside
another duct that is used for exhausting air or other
flue gases.
▶ The condensate trap must be primed at all times.
Failure to do so may allow combustion gases to
escape into boiler room.
▶ External insulation on plastic vent pipe is prohibited.
Fig. 24 Horizontal venting system (telescopic concentric vent kit)
[1]
[2]
L
Intake
Exhaust
2 feet to 3 feet (610 mm to 915 mm)
Consult local and state codes pertaining to special
building code and fire department requirements. Adhere
to national code requirements.
▶ Install the concentric vent adaptor with the screws enclosed.
Observe the listed maximum lengths of vent system,
which are boiler model dependent ( chapter 5.8.3).
2
1
4
3
6 720 806992-01.1O
Fig. 25 Installing the concentric vent adaptor
[1]
[2]
[3]
[4]
Concentric vent adaptor
Screws
Combustion air test port
Flue gas test port
6 720 806 992 (2013/07)
Greenstar
Installation | 35
Direct vent installations (sealed combustion)
For direct vent applications all applicable items below must be met.
Vent termination must be at least 1 foot (305 mm) above grade,
anticipated snow line or roof surface (Canada
1-1/2 feet (457 mm) minimum) ( fig. 27 [YA], page 37).
Vent termination must be at least 7 feet (2135 mm) above a public
walkway ( fig. 27 [X5], page 37). Ensure that condensate spilling
from the termination does not create a hazard or a nuisance.
X
Vent termination must be 3 feet (915 mm) above any forced air intake
within 10 feet (3 050 mm) ( fig. 27 [1], [YB], page 37).
Do not extend exposed vent pipe outside the building beyond
recommended distance. Condensate could freeze and block vent pipe.
2
Vent should terminate at least 3 feet (915 mm) away from adjacent
walls, inside corners and 5 feet (1 525 mm) below roof overhang
( fig. 27 [X2], [X4], page 37).
1
X
It is not recommended to terminate vent above any door or window,
condensate can freeze causing ice formations.
Do not use chimney as a raceway if another boiler or fireplace is vented
into or through chimney.
X
X
6 720 641 933-19.1O
Fig. 26 Vent and combustion air pipe position of a sealed combustion
system
[1]
[2]
X
Intake
Exhaust
At least 1 foot (305 mm)
The termination shall terminate at least 1 foot (305 mm) below, 1 foot
(305 mm) horizontally from or 1 foot (305 mm) above any door,
window or gravity air inlet into any building ( fig. 27 [2], [X1], [X3],
page 37).
Pipe cement/primer
ZWB42-3A
PVC
CPVC
ZWB35-3A
PP
3" (80 mm) vent or
air pipe M&G/
DuraVent PolyPro
GreenVent
3"/5" (80/125 mm)
concentric M&G/
DuraVent PolyPro
GreenVentt
ZWB28-3A
PP
3" (76 mm) Vent or
air pipe and fitting
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
ANSI Cat IV
X
X
X
X
X
X
X
ANSI/ASTM D2564
ANSI/ASTM F493
X
X
X
X
X
X
X
X
X
X
X
X
X
X
ZBR35-3A
PP
2" (50 mm) Vent or
air pipe and fitting
All PP/PVC/CPVC combustion air and vent pipe materials and fittings
must comply with the following and must be UL approved venting
material:
ZBR28-3A
PP
Item
NOTICE: Damage of 2 inch PVC pipes.
▶ For ZBR42-3A and ZWB42-3A use 2 inch CPVC-pipes
or 3 inch pipes.
ZBR16-3A
Material
PVC schedule 40, 80
PVC-DWV
CPVC schedule 40, 80
PVC schedule 40, 80
PVC-DWV
CPVC schedule 40, 80
The exhaust pipe must be properly supported and
pitched a minimum of ¼ inch (6.35 mm) per foot back to
the boiler. This allows the condensate to properly drain.
ZBR42-3A
If multiple boilers are installed in a row, allow at least 1 foot (305 mm)
clearance between the vent termination of one and the combustion air
intake of the other.
All PVC/CPVC vent pipes must be glued, except for the flue gas adapterpipe connection.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
ANSI Cat IV
United states
ANSI/ASTM D1785
ANSI/ASTM D2665
ANSI/ASTM F441
ANSI/ASTM D1785
ANSI/ASTM D2665
ANSI/ASTM F441
Canada
ANSI Cat IV
BH Gas venting
systems,
ULC S636 1)
ANSI Cat IV
Table 17 Materials for pipe
1) Components of the certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings. Plastic components, and specified primers and glues of
the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts.
Greenstar
6 720 806 992 (2013/07)
36 | Installation
Roof terminals
Ø 3" / Ø 5" (Ø 76/125 mm)
Ø 3" / Ø 5" (Ø 76/125 mm)
Ø 3" / Ø 5" (Ø 80/125 mm)
Material
concentric PVC
concentric CPVC
concentric PP
Supplier
IPEX System 636
IPEX System 636
Duravent
Part number
196006
197009
3PPS-VK
Table 18 Roof terminals
Wall terminals
Ø 3" (Ø 76 mm)
90 °-elbow with
inlet screen
Ø 3" (Ø 76 mm) twin pipe termination
Ø 3" (Ø 76 mm) single pipe termination
Ø 3" / Ø 5" (Ø 80/125 mm) Bosch Greenstar
Horizontal Telescopic Terminal Kit
Flue System / Materials
parallel stainless steel
PVC (elbow)
stainless steel (screen)
PP
PP
M&G Dura Vent Poly Pro Green Vent System
Supplier
Flex-L
IPEX (elbow)
Langly Wire (screen)
Duravent
Duravent
Bosch
Part number
46546901
UL-S636 approval (elbow)
L2594 (screen)
3PPS-HTP
3PPS-HST
7738003218
Table 19 Wall terminals
NOTICE:
▶ DO NOT use cellular core pipe.
▶ DO NOT use PVC when using anti-freeze in the
primary circuit of the boiler. Use CPVC or stainless
steel only!
NOTICE:
▶ Vent terminations must keep the following minimum
clearances from electric meters, gas meters,
regulators and relief equipment: 4 feet (1220 mm)
[Canada 6 feet (1830 mm)] horizontally and in no
case above and below, unless a horizontal distance of
4 feet (1220 mm) [Canada 6 feet (1830 mm)] is
maintained.
6 720 806 992 (2013/07)
Greenstar
Installation | 37
3
X1
3
X3
X3
X2
X1
YB
X2
X3
X5
X1
X4
3
YA
3
YA
1
2
6 720 641 933-17.1O
Fig. 27 Vent and combustion air pipe position
Direct vent (sealed combustion):
[1] Forced Air Inlet
[2] Gravity Air Inlet
[3] Exhaust terminal
X1
1 foot (305 mm)
X2
3 feet (915 mm)
X3
1 foot (305 mm)
X4
5 feet (1 525 mm)
X5
7 feet (2 135 mm) above public walkway
YA
At least 1 feet (305 mm) above grade and snow line
YB
Exhaust terminal must be at least 3 feet (915 mm) above forced
air inlet within 10 feet (3 050 mm)
Fan assisted appliance (non-sealed combustion):
[1] Forced Air Inlet
[2] Gravity Air Inlet
[3] Exhaust terminal
X1
1 foot (305 mm)
X2
3 feet (915 mm)
X3
4 feet (1 220 mm)
X4
5 feet (1 525 mm)
X5
7 feet (2 135 mm) above public walkway
YA
At least 1 foot (305 mm) above grade and snow line
YB
Exhaust terminal must be at least 3 feet (915 mm) above forced
air inlet within 10 feet (3 050 mm)
Greenstar
6 720 806 992 (2013/07)
38 | Installation
NOTICE:
▶ Place pipe supports every 5 feet (1 525 mm) of
horizontal and vertical run, beginning with support
near boiler.
▶ The condensate must be disposed of in accordance
with applicable rules.
▶ Periodic cleaning of the vent terminal and
air-intake screens is mandatory.
▶ Avoid locating vent terminals near equipment or
building features which can be subject to degradation
from exhaust gases.
▶ If multiple boilers are installed in a row, allow at least
1 foot (305 mm) clearance between the vent
termination of one and the combustion air intake of
the other.
≥ 4"
(102 mm)
≥ 12"
(305 mm)
5.8.2 Approved examples of horizontal and vertical venting
installation
2
1
2
1
6 720 641 933-63.2O
1
Fig. 30 Horizontal venting system (sealed combustion)
2
3
2
6 720 641 933-06.2O
Fig. 28 Horizontal venting system (room air only)
1
2
1
2
2
≥ 4"
(102 mm)
6 720 641 933-05.2O
Fig. 31 Horizontal venting system (sealed combustion)
6 720 641 933-62.2O
Fig. 29 Horizontal venting system (room air only)
Key to Fig. 28 and Fig. 29:
[1] Intake
[2] Exhaust
6 720 806 992 (2013/07)
Key to Fig. 30 and Fig. 31:
[1] Intake, behind exhaust
[2] Exhaust
[3] Wall termination
Greenstar
Installation | 39
Y
1
2
6 720 641 933-09.2O
Fig. 32 Vertical venting system (sealed combustion)
X
X
Y
Y
1
2
1
2
6 720 641 933-10.1O
6 720 641 933-07.1O
Fig. 33 Vertical venting system (room air only)
Fig. 34 Vertical venting system (sealed combustion)
Key to Fig. 32, Fig. 33 and Fig. 34:
[1] Intake
[2] Exhaust
[3] Concentric termination
X
Greater than 12 inches (305 mm)
Y
12 inches (305 mm) above maximum snow level or at least
24 inches (610 mm) whichever is greater
Greenstar
6 720 806 992 (2013/07)
40 | Installation
X
X
Y
X
Y
1
Installations  Fig. 28, 29, 30, 32, 33 and 35
Separate terminations
2" PIPE
Maximum straight vent pipe length allowed for
Ø 2" pipe
ZBR16-3A
ZBR35-3A
ZBR21-3A
ZWB35-3A
ZBR28-3A
ZBR42-3A
Number of 90 °
ZWB28-3A
ZWB42-3A
elbows used
1
81 ft (24.6 m)
65 ft (19.8 m)
2
76 ft (23.1 m)
57 ft (17.3 m)
3
71 ft (21.6 m)
48 ft (14.6 m)
4
66 ft (20.1 m)
40 ft (12.2 m)
5
61 ft (18.6 m)
32 ft (9.8 m)
6
56 ft (17.1 m)
23 ft (7.0 m)
Table 20 Vent and combustion air pipe lengths with 2" diameter and
separate terminations
2
6 720 641 933-08.1O
Fig. 35 Vertical venting system (sealed combustion)
[1]
[2]
X
Y
Intake
Exhaust
Greater than 12 inches (305 mm)
12 inches (305 mm) above maximum snow level or at least
24 inches (610 mm) whichever is greater
Installations  Fig. 31 Stainless steel wall termination
2" PIPE
Maximum straight vent pipe length allowed for
Ø 2" pipe
ZBR16-3A
ZBR35-3A
ZBR21-3A
ZWB35-3A
ZBR28-3A
ZBR42-3A
Number of 90 °
ZWB28-3A
ZWB42-3A
elbows used
1
76 ft (23.1 m)
60 ft (18.3 m)
2
71 ft (21.6 m)
52 ft (15.9 m)
3
66 ft (20.1 m)
43 ft (13.1 m)
4
61 ft (18.6 m)
35 ft (10.7 m)
5
56 ft (17.1 m)
27 ft (8.2 m)
6
51 ft (15.6 m)
18 ft (5.5 m)
Table 21 Vent and combustion air pipe lengths with 2" diameter and the
stainless steel wall termination
1/4" per foot
(50 mm per meter)
6 720 641 933-78.1O
Fig. 36 Horizontal venting system (telescopic concentric vent kit)
5.8.3 Vent and combustion air pipe lengths
3" (76 mm) Vent and combustion air pipe
For all installation situations and for all appliances the maximum vent
and combustion air pipe length is 100 feet each, with no more than
8 elbows each.
Installations  Fig. 34 Concentric termination
2" PIPE
Maximum straight vent pipe length allowed for
Ø 2" pipe
ZBR16-3A
ZBR35-3A
ZBR21-3A
ZWB35-3A
ZBR28-3A
ZBR42-3A
Number of 90 °
ZWB28-3A
ZWB42-3A
elbows used
1
66 ft (20.1 m)
47 ft (14.3 m)
2
61 ft (18.6 m)
38 ft (11.6 m)
3
56 ft (17.1 m)
30 ft (9.1 m)
4
51 ft (15.6 m)
22 ft (6.7 m)
5
46 ft (14.1 m)
13 ft (4.0 m)
6
41 ft (12.5 m)
5 ft (1.5 m)
Table 22 Vent and combustion air pipe lengths with 2" diameter and the
concentric termination
2" (50 mm) Vent and combustion air pipe
The maximum combined vent and combustion air pipe length
( tab. 20, 21 and 22) depend on the installation situation, the
appliance type and the number of elbows used.
6 720 806 992 (2013/07)
Greenstar
Making the electrical connections | 41
Ø 3" / Ø 5" (Ø 80/125 mm) Concentric venting system
The maximum concentric pipe length ( tab. 23) depends on the
installation situation, the appliance type and the number of elbows used.
Installations  Fig. 36
Ø 3" / Ø 5"
(Ø 80/125 mm)
CONCENTRIC
PIPE
Maximum straight vent pipe length allowed for
Ø 3" / Ø 5" (Ø 80/125 mm) concentric pipe
ZBR16-3A
ZBR35-3A
ZBR21-3A
ZWB35-3A
ZBR28-3A
ZBR42-3A
Number of 90 °
ZWB28-3A
ZWB42-3A
elbows used
1
50 ft (15.2 m)
44 ft (13.4 m)
2
44 ft (13.4 m)
38 ft (11.6 m)
3
38 ft (11.6 m)
32 ft (9.8 m)
4
32 ft (9.8 m)
26 ft (7.9 m)
5
26 ft (7.9 m)
20 ft (6.1 m)
6
20 ft (6.1 m)
14 ft (4.3 m)
Table 23 Pipe lengths with Ø 3" / Ø 5" (Ø 80/125 mm) diameter and
termination
Fitting
Equivalent
ft
3
6
45 ° elbow
90 ° elbow
m
0.91
1.82
Table 24 Concentric pipe friction loss equivalent for fittings
Example:
• Model: ZBR28-3A
• 90 ° elbows used: 2
• 45 ° elbows used: 2
Maximum straight vent pipe allowed: 38ft (11.6 m)
5.9
Testing gas and water connections for leaks
NOTICE: System damage!
Pressure, control and safety equipment may be
damaged by excessive pressure.
▶ When you carry out a leakage test, make sure that no
pressure, control or safety equipment is installed that
cannot be isolated from the test pressure.
▶ The boiler and its dedicated shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 14" W.C. (35 mbar).
6
Making the electrical connections
6.1
General notes
DANGER: Risk of electric shock!
▶ Before working on the power supply (120 VAC),
disconnect the boiler from the grid by shutting off the
emergency shutoff switch or disengaging the heating
system circuit breaker. Take measures to prevent
accidental reconnection.
▶ It is not sufficient to simply shut off the controls.
▶ Observe all applicable electrical codes and
regulations.
Electrical components must be installed by a trained and certified
electrician and the installation must meet the National Electric Code as
well as all applicable local codes and regulations.
The boiler must be properly electrically grounded in accordance with the
requirements of the authority having jurisdiction or, in the absence of
such requirements with the National Electrical Code, ANSI/NFPA 70
and/or the Canadian Electrical Code Part I, CSA C221.1, Electrical
Code.
Provide a dedicated circuit breaker for the boiler and
heating system rated at least 15A. All line voltage wiring
must use at least AWG14 size cables.
All appliance modulation, control and safety components are tested and
pre-wired for use.
Observe safety precautions and all rules and regulations required by
local code and the National Electric Code.
Fuses
The appliance is protected with a fuse. It is located on the circuit board
( Fig. 8, page 16).
Replacement fuses can be found on the back of the cover
( Fig. 38).
Controls and modules
For installation and electrical connection of controls and modules, see
the installation instructions of the accessory.
Water connections
▶ Open the heating supply and return valves and fill the heating system.
▶ Check all connections for leakage (test pressure: Max. 30 psi (2.07
bar) on the pressure gauge).
Gas line
▶ Close the gas shutoff valve to protect the gas valve from damage.
▶ Check all connections for leakage (test pressure: Max. 60" W.C. (150 mbar)).
▶ Release pressure.
Greenstar
6 720 806 992 (2013/07)
42 | Making the electrical connections
6.2
Low voltage electrical connections in the Heatronic
boiler control
6.2.1 Open the Heatronic boiler control
▶ Secure the cable with the strain relief.
F
A
NOTICE: Small pieces of wire can cause shorts and
damage the electronics.
▶ Always strip cables away from electronics.
▶ Unhook the clip (step 1) and fold the Heatronic down (step 2).
1
6 720 641 933-35.1O
Fig. 39 Electrical wiring outdoor temperature sensor
6.2.3 Connecting the DHW tank temperature sensor (only heating
boiler ZBR..-3A)
Wire the DHW tank temperature sensor directly to the appliance
terminals. The sensor is provided with the appliance.
2
6 720 641 933-72.1O
Do not exceed a sensor cable length of 33 feet (10 m).
Fig. 37 Fold the Heatronic down
▶ Remove screws (step 1), unhook cable and remove cover (step 2).
1
1
▶ Punch out plastic insert.
▶ Plug connector into the circuit board.
▶ Insert the cable of the DHW tank temperature sensor.
▶ Secure the cable with the strain relief.
2
1
6 720 641 933-86.1O
Fig. 38 Remove the cover
6.2.2 Connecting the outdoor temperature sensor
▶ Connecting the controls automatically establishes the internal
communications BUS connection ( see installation instructions for
the controls).
▶ Punch out plastic insert.
▶ Connect cable of the outdoor temperature sensor according to
Fig. 39.
▶ Insert cable for the outdoor temperature sensor.
6 720 806 992 (2013/07)
6 720 641 933-73.1O
Fig. 40 Electrical connections DHW tank temperature sensor
Greenstar
Making the electrical connections | 43
6.2.4 Connecting additional accessories
Connecting the supply temperature sensor (e.g. for low-loss header
or system supply pipe)
▶ For splash-proof (IP) strain relief, cut the grommet to match the
diameter of the cable.
Do not exceed a sensor cable length of 33 feet (10 m).
Supply temperature sensor for system supply pipe
( Fig. 43 [2]) must be installed in closest vicinity with
boiler supply Tee.
3
4
6 720 641 933-91.1o
Fig. 41 Cut off grommets
2
▶ Feed cable through strain relief and connect accordingly.
▶ Secure the cable on the strain relief.
1
5
ϑ
Bosch room controls
Connect only Bosch room controls to the internal BUS of this boiler.
For installation and electrical connection of the FB 100 remote control,
see installation instructions for the remote control.
Connecting temperature guard TB 1 (external manual reset high
limit or low water cut off (LWCO))
This connection allows the installation of external safety switches.
• External manual reset high limit
• Low water cut-off (LWCO)
• Radiant overheat protection
≤ 4"
(102 mm)
6 720 641 933-97.1o
Fig. 43 Mounting supply temperature sensor right next to boiler supply
[1]
[2]
[3]
[4]
[5]
System secondary line – supply pipe 1-1/2"
Supply temperature sensor for system supply pipe
Boiler primary line – supply pipe 1"
Boiler primary line – return pipe 1"
System secondary line – return pipe 1-1/2"
B
LP NP
B
4
2
LS NS
1
F
9
A
8 7
TB1
ϑ
1 2 C
6 720 641 933-44.1O
Fig. 42 Electrical wiring TB1
When the temperature guard trips, central heating and DHW modes are
interrupted.
6 720 612 664-25.2O
Fig. 44 Electrical wiring of external supply temperature sensor
The service function 7.d connection of an external supply temperature
sensor is automatically set to 01 ( page 57).
Greenstar
6 720 806 992 (2013/07)
44 | Making the electrical connections
Connecting Third party room thermostats or zone controls
A voltage free (dry contact) third party room thermostat or heat demand
from a relay panel can be used to send an ON/OFF signal to the
appliance.
B
LP NP
Without accessories the appliance offers the connection of one heating
zone pump, one circulator of an unmixed heating circuit, or one DHW
recirculation pump.
The pump used must have the following connection values: 120 VAC,
max. 2 A.
B
▶ Route cable from pump to appliance.
▶ Insert cable into the junction box as shown in Fig. 48.
▶ Connect cable to the black plug according to Fig. 47.
4
2
LS NS
6.3.2 Connecting an external heating zone pump or DHW
recirculation pump
1
F
9
A
8 7
1
1
2
ϑ
2
3
6 720 641 933-70.1O
4
Fig. 45 Electrical wiring third party room thermostat or zone control
To communicate a heat demand the third party room thermostat or zone
control must connect pins 2 and 4.
6.3
Electrical connections in the junction box (120 VAC)
6.3.1 Mounting rails for junction box
▶ Hold the rail against the appliance from below (step 1) and fasten with
the screws from the outside or inside (step 2).
▶ Loosen junction box from the rail (step 3).
Fig. 47 Attach plug (external pump)
[1]
[2]
[3]
[4]
L (120 VAC, 60 Hz)
PE (GND, Ground)
N (Neutral)
Black plug (in the junction box upon delivery)
▶ Connect black plugs and insert grommet until stop.
2
L
1
L
2
6 720 641 933-41.1O
L
N
PE ite
wh ins z
Ma /60H
0V
2
1
N
PE d
re age p
r
Sto k pum
tan
N
PE ck
bla pump atingI II5I03
e II 1
CH ed h I II7I37 70
8
mix
for
6 720 641 933-40.1O
Fig. 48 Cable connected (external pump)
3
Fig. 46 Mounting rails for junction box
6 720 641 933-42.2O
▶ Use service function 5.E, to set connection to 01 (DHW recirculation
pump) ( page 56)
-or▶ Use service function 5.E to set connection to 02 (external heating
zone pump in an unmixed heating circuit) ( page 56).
-or▶ Use service function 5.E to set connection to 03 (external heating
pump) ( page 56).
The DHW recirculation pump is controlled by the Bosch
FW 200.
6 720 806 992 (2013/07)
Greenstar
Making the electrical connections | 45
6.3.3 DHW tank loading pump or 3-way valve with spring return
(only heating boiler ZBR..-3A)
The pump used must have the following connection values: 120 VAC,
max. 2 A.
▶ Route cable from pump or 3-way valve to appliance.
▶ Insert cable into the junction box as shown in Fig. 50.
▶ Connect cable to the red plug according to Fig. 49.
6.3.4 Connecting mains power supply
▶ Route the power cable (AC 120 V, 60 Hz) from the emergency shutoff
switch to the boiler.
▶ Insert cable into the junction box as shown in Fig. 52.
▶ Connect cable to the white plug according to Fig. 51.
1
2
3
1
2
3
4
4
6 720 641 933-36.1O
6 720 641 933-37.1O
Fig. 49 Attach plug (external DHW tank loading pump or 3-way valve)
[1]
[2]
[3]
[4]
L (120 VAC, 60 Hz)
PE (GND, Ground)
N (Neutral)
Red plug (in the junction box upon delivery)
Fig. 51 Attach plug (mains power supply)
[1]
[2]
[3]
[4]
L (120 VAC, 60 Hz)
PE (GND, Ground)
N (Neutral)
White plug (in the junction box upon delivery)
▶ Connect white plugs and insert grommet until stop.
▶ Connect red plugs and insert grommet until stop.
L
N
PE e
L whit s
z
in
Ma /60H
0V
12
N
PE d
L
re age p
r
Sto k pum
tan
N
PE k
L blac mp ting III 3
pu ea III 1 50
CH ed h I II7I37 70
8
mix
for
L
L
N
PE ite
wh ins z
Ma /60H
0V
12
N
PE d
re age p
r
Sto k pum
tan
N
PE ck
bla pump atingII II5I03
e I 1
H
C ed h I II7I37 70
8
mix
for
6 720 641 933-39.1O
6 720 641 933-38.1O
Fig. 50 Cable connected (external DHW tank loading pump or 3-way
valve)
Fig. 52 Cable connected (mains power supply)
▶ Mount junction box on the rail.
▶ Mount the 3-way valve for space heating operation when deenergized, and DHW tank loading when energized.
▶ Use service function 1.F to set pump mode. ( page 53).
Greenstar
6 720 806 992 (2013/07)
46 | Making the electrical connections
6.4
Connecting the LWCO device
▶ Connect the leads labeled SWITCH CONTACT (yellow) to the TB1
temperature guard ( Fig 42, page 43) on the Heatronic.
NOTICE: System damage or malfunction!
▶ Ensure the air box remains air-tight when routing the
LWCO cable to the outside.
▶ Do not route the LWCO cable through the ignition
cable grommet as appliance malfunction may occur.
1
2
3
4
5
6
▶ Punch a hole (maximum diameter 3/16" (5 mm)) through the fan
cable grommet (steps 1 – 3) and run the LWCO cable through it.
6 720 641 933-67.1O
Ø ≤ 3/16"
(~ 5 mm)
1
2
Fig. 54 Wires of a LWCO device with LWCO adapter
[1]
[2]
[3]
[4]
[5]
[6]
LWCO device (Hydrolevel Safgard 1100)
BOILER GROUND (green)
SWITCH CONTACT (yellow)
SWITCH CONTACT (yellow)
24V HOT (red)
24V COMMON (white)
3
6 720 641 933-87.1O
Fig. 53 Punch a hole in fan cable grommet for LWCO cable
▶ Install a 24VAC 20VA transformer near the boiler.
▶ Follow LWCO manufacturer’s instructions.
▶ Connect the lead labeled BOILER GROUND (green) to pin 2 (center,
 Fig. 51 [2]) of the white plug in the boiler junction box.
▶ Connect the leads labeled 24V HOT (red) and 24V COMMON (white)
to the external 24VAC transformer.
6 720 806 992 (2013/07)
Greenstar
Commissioning | 47
7
Commissioning
1
3
2
5
4
6
7
9
8
eco reset
10
11
12
18
17
16
15
14
13
19
6 720 641 933-25.1O
Fig. 55 Overview of the controls
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
Emissions test button
Service button
Burner operation indicator lamp
ON/OFF power switch
Key pad lock
ECO button
Reset button
Display
Automatic air vent (ZWB..-3A combi boilers only)
Boiler water pressure gauge
DHW thermostat
Safety relief valve discharge hose
Condensate drain hose
Heating return pipe
Cold water pipe (ZWB..-3A combi boilers only)
Gas pipe
DHW pipe (ZWB..-3A combi boilers only)
Supply pipe
Boiler high limit dial
Greenstar
7.1
Before operating the appliance
NOTICE: Commissioning without being properly filled
and purged will damage the appliance.
▶ Only operate this appliance after ensuring there is
sufficient water in the boiler and the system.
▶ Adjust the expansion vessel pre-charge pressure to the static head of
the heating system ( page 29).
▶ Open radiator and zone valves (as applicable).
▶ Open heating supply and return valves, fill heating system to 14.5 to
21.75 psi (1 - 1.5 bar) and close fill valve.
▶ Bleed all air from the system.
▶ If the boiler water pressure has dropped, fill the heating system again
to 14.5 to 21.75 psi (1 to 1.5 bar).
▶ On ZBR..-3A appliances (heating boilers) with a DHW tank, open the
cold water supply and open a DHW tap until water runs out.
▶ Verify that the gas type specified on the rating plate is the same as the
gas type used.
▶ Open the gas cock.
6 720 806 992 (2013/07)
48 | Commissioning
7.2
Switching the appliance ON/OFF
With radiant floor heating, limit the maximum
permissible supply temperature as recommended by the
manufacturer.
Startup
▶ Switch the appliance ON using the ON/OFF switch.
The display indicates the supply temperature of the hot water in °F. If
necessary, convert to °C ( Service function 0.E: Metric or US
customary units, page 57)
▶ In order to set the maximum supply temperature, turn the boiler high
limit dial
.
reset
2
1
4
5
6
max
eco
6 720 613 896-05.1O
3
3
3
4
2
2
5
1
Fig. 56 Switching the appliance ON/OFF
4
e
6
1
6
max
min
max
6 720 641 933-53.2O
When the appliance is switched ON for the first time, it
performs a once-only purging sequence. This involves
the heating zone pump switching on and off at intervals
(for approx. 4 minutes).
The display shows
in alternation with the supply
temperature.
Fig. 57 Switch on heat
If the burner is operating, the burner operation indicator lamp is
illuminated.
7.4
Observe the operating instructions for the heating
control included in the scope of delivery. There you can
read:
▶ How to set the operating mode and the heating curve
for outdoor reset controls
▶ How to adjust the room temperature
▶ How to heat economically and comfortably
▶ How the control can be mounted in the boiler or in the
living space
▶ Open the automatic vent [9] (only combi boiler
ZWB..-3A) and close it again when the purging sequence has finished
( page 47).
If the display shows
in alternation with the supply
temperature, the trap filling function is active
( page 56).
Shutdown
▶ Switch appliance OFF using the ON/OFF switch.
The display goes out.
▶ If the appliance is taken out of service for a longer period: Observe
frost protection ( Section 7.9).
7.3
Programming the FW 200 heating control unit
9
12 h
15
18
6
Setting up space heating
3
24 h
21
Set the maximum supply temperature based on the structure's heat loss
on design day.
Boiler high limit
dial
1
2
3
4
5
6
max
Typical supply
temperatures
approx. 95 °F
(35 °C)
approx. 109 °F
(43 °C)
approx. 122 °F
(50 °C)
approx. 140 °F
(60 °C)
approx. 153 °F
(67 °C)
approx. 167 °F
(75 °C)
approx. 194 °F
(90 °C)
Sample application
Frost protection
6 720 612 660-07.3TT
Fig. 58 FW 200 heating control
7.5
Radiant floor heating system
Panel radiator system
Cast iron radiator system
After commissioning
▶ Check flue path for tightness.
▶ Check gas supply dynamic pressure ( page 61).
▶ Check that condensate is being discharged from the condensate
hose. If that is not the case, switch the appliance first OFF and then
ON again using the ON/OFF switch. That activates the trap filling
sequence ( page 56). Repeat the procedure several times until
condensate starts running out.
▶ Complete commissioning report ( page 75).
Baseboard and convector
system
Table 25 Typical supply temperatures
6 720 806 992 (2013/07)
Greenstar
Commissioning | 49
7.6
ZBR..-3A appliances (heating boilers) with DHW tank:
Setting the DHW temperature
▶ Set the DHW temperature on the DHW thermostat
.
The set DHW temperature flashes on the display for 30 seconds.
3
2
1
4
3
2
5
6
max
1
7.7
ZWB..-3A appliances (combi boilers):
Setting the DHW temperature
▶ Set the DHW temperature on the DHW thermostat
.
The set DHW temperature flashes on the display for 30 seconds.
reset
reset
eco
eco
3
4
e
2
1
6
4
3
2
5
6
1
max
max
4
e
6
max
6 720 641 933-54.1O
6 720 641 933-55.1O
Fig. 59 Set the DHW temperature (heating boiler ZBR..-3A)
Fig. 60 Set the DHW temperature (combi boiler ZWB..-3A)
DHW thermostat
min
e
max
DHW thermostat
min
e
max
Typical DHW temperatures
approx. 59 °F (15 °C)
approx. 131 °F (55 °C)
approx. 158 °F (70 °C)
Table 26 Typical DHW temperatures for heating boiler
ZBR..-3A
WARNING: Danger of scalding!
▶ In normal operation, it is recommended to limit the
DHW temperature to 122 °F (50 °C) to limit the risk of
scalding.
▶ Install a tempering valve if running DHW temperatures
above 104 °F (40 °C).
▶ Only use temperatures up to 158 °F (70 °C) for
thermal disinfection ( page 50).
If there is reason for concern for contamination from
bacteria such as legionella, consider setting the DHW
thermostat
to at least “e” (131 °F (55 °C)).
This setting ensures an economical and comfortable
DHW generation. Consult your local water department or
municipality for further information.
ECO button
The default setting is DHW priority; the ECO button is not lit.
In order to switch between DHW tank priority and alternating
operation, press the ECO button.
• DHW priority
First, the DHW tank is heated up to the set temperature. The
appliance then goes into heating mode. Therefore, it can happen that
space heating is interrupted for a while and the room temperature
may drop.
DHW tank priority guarantees highest DHW comfort.
• Alternating operation
The appliance switches between space heating mode and DHW mode.
This prevents the room from cooling off too much.
Alternating operation guarantees an even room temperature with
somewhat less DHW convenience.
Typical DHW temperatures
approx. 104 °F (40 °C)
approx. 122 °F (50 °C)
approx. 140 °F (60 °C)
Table 27 Typical DHW temperatures for combi boiler
ZWB..-3A
ECO button
Pressing and holding the ECO button until it lights up switches between
Comfort mode and Economy mode.
• Comfort mode (default setting)
The appliance is continually maintained at the set temperature.
Consequently, DHW draws are immediate, however the appliance
may run even if no DHW is being drawn.
• Economy mode, ECO button lights up
– DHW is only generated when DHW is drawn.
– On demand: Quickly open and close a DHW tap to signal the
appliance to heat to the selected temperature. After a short wait
DHW will be available.
The DHW on demand signal allows maximum gas and
water savings.
7.8
Setting manual summer mode
In summer mode or warm weather shut down (WWSD), the heating zone
pump and consequently central heating are switched off. DHW
generation remains active following the DHW program.
See also the warm weather shutdown (WWSD) feature in
the operating instructions for the heating control
included in the scope of delivery.
NOTICE: Heating system at risk of freezing. In manual
summer mode, only the appliance is protected from
freezing.
▶ Observe frost protection measures where there is a
risk of frost ( Chapter 7.9).
▶ Make a note of the setting of the boiler high limit dial
Greenstar
.
6 720 806 992 (2013/07)
50 | ZBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection
▶ Turn the boiler high limit dial
counterclockwise to
.
reset
reset
eco
eco
4
3
3
5
2
1
e
2
min
max
3
6
1
6
4
5
1
max
e
2
6
1
6
max
max
min
6 720 615 065-13.1O
6 720 615 065-17.1O
Fig. 61 Summer mode
Fig. 64 Key pad lock
For further information, see the operating instructions for the heating
control included in the scope of delivery.
Unlocking the key pad:
7.9
4
3
2
Setting frost protection
▶ Press the key pad lock button until the display shows only the supply
temperature.
Frost protection of the heating system:
▶ Leave the appliance switched ON; set the boiler high limit to at least
95 °F (35 °C) (position 1,  Tab. 25, page 48).
eco
5
1
e
2
6
1
6
▶ Carry out thermal disinfection only outside the normal
hours of use, or install a tempering valve.
max
min
max
WARNING: Risk of scalding!
Hot water can result in severe scalding.
4
3
3
ZBR..-3A appliances (heating boiler) with
DHW tank: Thermal disinfection
Thermal disinfection covers the DHW system including the taps. For
solar DHW tanks, the solar portion of the tank is not covered.
reset
2
8
6 720 641 933-68.1O
Fig. 62 Frost protection of the heating system
-or- If you want to leave the appliance switched OFF:
▶ Mix Bosch-approved anti-freeze into the heating water ( Tab. 14,
page 28) and drain the DHW circuit.
For further information, see the operating instructions
for the heating control included in the scope of delivery.
▶ Close all DHW taps.
▶ Advise occupants of the risk of scalding if no tempering valve is
installed.
▶ Set the time and DHW temperature accordingly on the heating control
with DHW program.
▶ Set any DHW recirculation pump to continuous operation.
▶ Turn DHW thermostat clockwise to max (approx. 158 °F (70 °C)).
reset
Frost protection of the DHW tank:
eco
▶ Leave the appliance switched ON; set the boiler high limit to at least
95 °F (35 °C) (position 1,  Tab. 25, page 48).
▶ Turn the DHW thermostat
counterclockwise to min
(59 °F (15 °C)).
3
4
2
1
3
2
5
6
max
1
4
e
6
max
6 720 615 065-10.1O
reset
Fig. 65 Thermal disinfection
eco
3
2
1
4
3
5
2
6
max
1
min
e
6
max
6 720 641 933-69.1O
Fig. 63 Frost protection for the DHW tank
7.10 Activating the key pad lock
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
reset button. It can be used to limit unauthorized access to the boiler.
▶ Wait until the maximum temperature has been reached.
▶ Open all DHW taps, from the nearest to the one furthest away, and
draw off hot water until it reaches a minimum of 158 °F (70 °C) at all
taps for at least 3 minutes.
▶ Reset the DHW thermostat, DHW recirculation pump, and heating
control to standard operation.
Thermal disinfection can also be carried out
automatically and on a regular basis; see operating
instructions for the heating control included in the scope
of delivery.
Activating the key pad lock:
▶ Press the key pad lock button until
and the heating supply
temperature are alternating on the display.
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Boiler circulator | 51
9
Boiler circulator
9.1
Pump anti-seize protection
25
20
H / ft
This function prevents the heating zone pump from
seizing up following longer idle periods.
The appliance will briefly run the pump at least every 24 hours after its
last activation.
4
15
10
3
5
9.2
Changing the pump curve of the boiler pump
2
1
The speed of the boiler pump can be changed using the dial on the pump.
0
0
1
2
25
3
4
5
6
.
V / gpm
7
8
7
6
5
15
4
4
10
5
3
2
1
H/m
H / ft
20
3
3
2
1
1
0
0
1
2
3
4
5
.
V / gpm
6
7
8
6
2
0
0
7
400
800
.
V / l/h
1200
1600
6 720 641 933-61.1O
Fig. 67 Pump curve of the boiler pump combi boiler
ZWB..-3A
5
4
H/m
4
4
3
2
3
1
2
1
0
0
200 400 600 800 1000 1200 1400 1600
.
V / l/h
Key to Fig. 66 and Fig. 67:
[1] Residual head pressure at speed 1
[2] Residual head pressure at speed 2
[3] Residual head pressure at speed 3 (default setting)
[4] Head pressure of the boiler pump by itself (at speed 3)
H
Head pressure in feet of head (m)
Circulating water volume in gallons per minute (l/h)
V
In order to save as much energy as possible and keep any
water circulation noises to a minimum, select the lowest
possible pump speed.
6 720 641 933-59.1O
Fig. 66 Pump curve of the boiler pump heating boiler
ZBR..-3A
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52 | Heatronic boiler control settings
10
▶ Press and hold the service button until it illuminates. The display
shows a code such as 1.A (first service level). Press the ECO button
and key pad lock button simultaneously until the code 8.A appears
(second service level).
▶ On the second service level, select the service function 8.E and value
00. The appliance restarts with the default settings.
Heatronic boiler control settings
10.1 Guideline to service functions
The Heatronic allows easy setting and testing of many appliance
functions.
For an overview of service functions, see Chapter 10.2 on page 52.
3
reset
2
1
eco
3
3
4
2
1
4
2
5
1
6
max
4
5
e
6
max
min
6 720 641 933-52.1O
Fig. 68 Overview of the controls
[1]
[2]
[3]
[4]
[5]
Emissions test button
Service button
Display
ECO button, service functions “up”
Key pad lock, service functions “down”
Selecting a service function
The service functions are subdivided into two levels: The 1st level
includes service functions up to 0.E, the 2nd level includes service
functions starting with 8.A.
▶ Press and hold the service button
until it illuminates.
The display shows a code such as 1.A (first service level).
▶ Repeatedly press the key pad lock button or ECO button to scroll to
the desired service function.
▶ Press and release the emissions test button .
The emissions test button will light up and the display shows the
setting for the selected service function.
Adjust Value
▶ Repeatedly press the key pad lock button or ECO button to adjust the
value up or down.
▶ Record the value in the commissioning log ( page 75).
Saving the value
▶ Press and hold the emissions test button
(value saved).
until the display shows
The unit automatically exits the service level if no button
is pressed for 15 minutes.
Exiting the service function without saving values
▶ Briefly press the emissions test button .
The light of the emissions test button will go out.
Restoring factory settings
In order to reset all values for the service levels 1 and 2 to the factory
setting:
6 720 806 992 (2013/07)
10.2 Overview of the service functions
10.2.1 First service level (press and hold the service button
until it lights up)
Service function
Display
1.A
Maximum space heating output
1.b
Maximum DHW output
1.E
Pump mode for space heating operation
1.F
Pump mode
2.A
Heating circuit pump lockout time
2.b
Maximum supply temperature
2.C
Purging function
2.d
Thermal disinfection
2.F
Operating mode
3.A
Automatic anti-cycle function
3.b
Set anti-cycle time
3.C
Switching differential (hysteresis)
3.d
Minimum output (heating and DHW)
3.E
Cycle time, keeping DHW hot
3.F
Constant DHW period
4.b
Maximum heat exchanger temperature
4.d
Audible fault warning tone
4.E
Appliance type
4.F
Condensate trap filling sequence
5.A
Reset inspection interval
5.b
Fan post purge time
5.E
Functionality of black plug in boiler
junction box
5.F
Set inspection interval
6.A
Display the latest fault code
6.b
Room temperature control, current voltage,
terminal 2
6.C
Supply temperature required by outdoor
reset control
6.d
Current DHW turbine flow rate
7.A
Indicator lamp for burner operation / faults
7.b
3-way valve in center position
7.d
Connecting an external supply or low-loss
header temperature sensor
7.E
Building drying function
0.A
Do not use this setting!
0.d
Altitude adjustment
0.E
Metric or US customary units
Page
53
53
53
53
54
54
54
54
54
54
55
55
55
55
55
55
55
55
56
56
56
56
56
56
56
56
56
56
57
57
57
57
57
57
Table 28 Service functions, 1st level
Greenstar
Heatronic boiler control settings | 53
10.2.2 Second service level (at first service level, service button
lights up, press ECO button and key pad lock button
simultaneously until 8.A appears)
Service function
Display
8.A
Software version
8.b
Code plug number
8.C
GFA Gas burner control status
8.d
GFA Gas burner control fault
8.E
Restore boiler to factory settings
8.F
Permanent ignition
9.A
Constant mode
9.b
Current fan speed
9.C
Current boiler output
9.d
Set fan start speed
9.E
Turbine signal delay
9.F
Heating zone pump post purge
A.b
Display DHW temperature
A.C
Display DHW tank temperature
b.F
Solar DHW backup heating delay
C.d
Display current heat demand
Page
57
57
57
57
58
58
58
58
58
58
58
58
58
58
58
58
Table 29 Service functions, 2nd level
10.3 Description of the service functions
10.3.1 First service level
Service function 1.A: Maximum space heating output
Some gas supply companies offer a performance-dependent basic
price.
The output can be limited in percent between the minimum and
maximum nominal output to suit the specific heat demand.
Even if the heating output has been limited, the
maximum nominal output is still available for DHW
generation.
▶ Select service function 1.A.
▶ Select heat output in MBH (kW) and determine associated setting in
percent (%).
▶ Enter the setting ( 10.1).
▶ Save the setting ( 10.1).
▶ Record the set heat output in the commissioning log ( page 75).
▶ Exit the service functions.
The display returns to the supply temperature.
Default setting is the maximum nominal output: 100 (100 %).
Service function 1.b: Maximum DHW output
The hot water output can be adjusted between the minimum and
maximum DHW outputs to suit the heat transfer capacity of the DHW
tank coil.
▶ Select service function 1.b.
▶ Select the DHW output in MBH (kW) and determine the associated
setting in percent (%).
▶ Enter the setting ( 10.1).
▶ Save the setting ( 10.1).
▶ Record the set DHW output in the commissioning log ( page 75).
▶ Exit the service functions.
The display returns to the supply temperature.
Default setting is the maximum nominal output: 100 (100 %).
Service function 1.E: Pump mode for space heating operation
If an outdoor temperature sensor for an outdoor reset
control is connected, pump control mode 04 is
automatically set.
• Pump control mode 00 (automatic mode): The BUS control controls
the central heating pump.
• Pump control mode 01: For heating systems without control.
The supply temperature controls the central heating pump. When
there is a demand for heat, the central heating pump and the burner
start up.
• Pump control mode 02: Do not use.
• Pump control mode 03: The central heating pump runs continuously
(exceptions: See heating control operating instructions).
• Pump control mode 04: Intelligent control of central heating pump in
heating systems with outdoor reset control. The heating zone pump is
only switched on when needed.
Default setting is 00.
Service function 1. F: Pump mode (only heating boiler ZBR..-3A)
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
combi boiler ZWB..-3A appliances.
Based on this setting, the pump connected to the Heatronic or 3-way
valve are controlled according to the configuration of the heating
system.
The following settings are possible:
• Pump mode 00: The appliance is used only as central heating boiler.
• Pump mode 01: A 3-way valve for DHW tank loading is connected in
boiler circuit before low loss header (see also service function 2.A).
• Pump mode 02: Do not use this setting!
• Pump mode 03: A DHW tank pump is connected on the system side
after the low loss header.
In DHW mode, DHW tank loading pump runs.
In space heating mode, DHW tank loading pump does not run.
Default setting is 03.
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54 | Heatronic boiler control settings
Service function 2.A: Heating circuit pump lockout time (only
heating boiler ZBR..-3A)
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
combi boiler ZWB..-3A appliances.
This setting is only active if Service function
1. F: Pump mode is set to 01 (3-way valve).
Service function 2.d: Thermal disinfection (legionella protection)
WARNING: Risk of scalding!
Hot water can result in severe scalding.
▶ Carry out thermal disinfection only outside the normal
hours of use.
▶ Install a tempering valve if this function is enabled
permanently.
When this service function is enabled, the DHW is permanently heated
to approx. 158 °F (70 °C) if the DHW temperature dial has been turned
clockwise to max.
During the runtime of an external 3-way valve actuator, the space
heating pump is blocked. Select the run time of the 3-way valve actuator
between 01 - 24 (10 - 240) seconds according to the manufacturer's
documentation.
The following settings are possible:
• 00: Thermal disinfection not enabled
• 01: Thermal disinfection enabled
Default setting is 24 (240 seconds).
Default setting is 00 (disabled).
Service function 2.b: Maximum supply temperature
Service function 2.F: Operating mode
The values of this service function displayed depend on the setting of the
service function 0.E:
With this service function, you can temporarily change the appliance's
operating mode.
Service function 0.E is set to 00 (metric units):
• The maximum supply temperature can be adjusted between 35 and
88 (35 - 88 °C).
The following settings are possible:
• 00: Default mode; the appliance runs according to control settings.
• 01: The appliance runs for 15 minutes at minimum output. The
display shows 2.F. When this service function is aborted or has been
active for 15 minutes, the appliance reverts to default mode.
• 02: The appliance runs for 15 minutes at maximum output. The
display shows 2.F. When this service function is aborted or has been
active for 15 minutes, the appliance reverts to default mode.
Service function 0.E is set to 01 (US customary units):
• The maximum supply temperature can be adjusted between 96 and
190 (96 - 190 °F).
Default setting is 190 (190 °F (88 °C)).
Default setting is 00.
Service function 2.C: Purging function
When the appliance is switched ON for the first time, it
performs a once-only purging sequence. This involves
the heating zone pump switching on and off at intervals
(for approx. 4 minutes).
The display shows
in alternation with the supply
temperature.
This service function allows activating the purging
function manually, e.g. after servicing.
The following settings are possible:
• 00: Purging function off
• 01: Purging function is switched on and after completion
automatically reset to 00
• 02: Purging function is permanently on and is not reset to 00
Service function 3.A: Automatic anti-cycle function
If an outdoor reset control is connected, there is no need
to adjust this setting on the appliance.
The control automatically optimizes the anti-cycle time.
Use service function 3.A to set the automatic adaptation of the anti-cycle
time. This can be required in case of unfavorably-dimensioned heating
systems. Short cycling may increase boiler and system wear and tear,
increase emissions, reduce comfort, and should be avoided.
With auto-adaptation of the anti-cycle time disabled, the anti-cycle time
must be set using service function 3.b ( page 55).
The following settings are available:
• 00: Automatic adaptation of the anti-cycle time is disabled
• 01: Automatic adaptation of the anti-cycle time is enabled
Default setting is 00 (switched off).
Default setting is 00 for heating boilers ZBR..-3A appliances, otherwise
01.
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Heatronic boiler control settings | 55
Service function 3.b: Set anti-cycle time
Only if the automatic anti-cycle time is disabled (service function 3.A)
will this function be active.
If an outdoor reset control is connected, there is no need
to adjust this setting on the appliance.
The control automatically optimizes the anti-cycle time.
The anti-cycle time can be set from 00 to 15 (0 to 15 minutes).
With 00, the anti-cycle lock is switched off.
The shortest possible switching interval is 1 minute (recommended for
single zone or forced air heating systems).
Service function 3.F: Constant DHW period
(only combi boiler ZWB..-3A)
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
heating boiler ZBR..-3A appliances.
The constant DHW period specifies how long the space heating mode
remains disabled after DHW is drawn.
The duration for keeping DHW hot can be set from 00 to 30 (0 to 30
minutes).
Default setting is 01 (1 minute).
Default setting is 03.
Service function 3.C: Switching differential
Only if the automatic anti-cycle time is disabled (service function 3.A)
will this function be active.
If an outdoor reset control is connected, there is no need
to adjust this setting on the appliance.
The control automatically optimizes this setting.
The switching differential is the permitted boiler differential from the
target supply temperature. It can be set in increments of 1 °F (0.5 °C).
The minimum supply temperature is 95 °F (35 °C).
Service function 0.E is set to 00 (metric units):
• You can set the switching differential between 00 and 30 (0 - 30 °C).
Service function 0.E is set to 01 (US-customary units):
• You can set the switching differential between 00 and 54 (0 - 54 °F).
Default setting is 18 (18 °F (10 °C)).
Service function 3.d: Minimum output (heating and DHW)
The output for heating and DHW can be set to any level in percent
between the minimum and maximum nominal output.
The default setting is the minimum nominal output (heating and DHW)
and varies according to appliance.
Service function 4.b: Maximum heat exchanger temperature (only
combi boiler ZWB..-3A)
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
heating boiler ZBR..-3A appliances.
This function can be used to reduce limestone built-up in the heat
exchanger, which increases with temperature. The maximum heat
exchanger temperature can be set in steps of 1 °F (0.5 °C).
Service function 0.E is set to 00 (metric units):
• The maximum temperature for keeping the heat exchanger hot can be
set from 40 to 65 (40 to 65 °C).
Service function 0.E is set to 01 (US-customary units):
• The maximum temperature for keeping the heat exchanger hot can be
set from 104 to 150 (104 to 150 °F).
Default setting is 140 (140 °F (60 °C)).
Service function 4.d: Audible fault warning tone
The appliance can be set to sound an audible alarm to alert the operator
of a fault present. The audible warning tone can be deactivated with the
service function 4.d.
• 00: Warning tone off
• 01: Warning tone on
Default setting is 01 (ON).
Service function 3.E: Cycle time, keeping DHW hot (only combi
boiler ZWB..-3A)
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
heating boiler ZBR..-3A appliances.
This service function is only active in comfort mode.
It specifies the time from completion of preheating or DHW demand until
the next time the plate-type heat exchanger is heated up. This prevents
the plate-type heat exchanger from overheating.
Service function 4.E: Appliance type
This service function displays the appliance type detected.
Possible displays are:
• 00: Central heating only
• 01: Combi appliance
• 02: DHW tank temperature sensor (NTC) connected to Heatronic.
• 03: DHW tank thermostat connected to Heatronic.
• 04: Stratified DHW tank
• 05: Tank with NTC return
The cycle time can be set from 20 to 60 minutes.
Default setting is 20 (20 minutes).
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56 | Heatronic boiler control settings
Service function 4.F: Condensate trap filling sequence
DANGER: Risk of flue gas poisoning!
If the condensate trap is not filled, flue gas may escape
from the dry trap.
▶ Only deactivate the trap filling sequence for servicing
purposes.
▶ When servicing is complete, reactivate the trap filling
function.
Service function 5.F: Set inspection interval
This service function allows setting the number of months after which
the 'service due' reminder
appears on the display alternating with
the supply temperature.
The number of months can be set from 00 - 72 (0 to 72 months).
Default setting is 00 (disabled).
If U0 appears on the display, the function was already set
via the FW200 control.
The trap filling sequence ensures that the condensate trap is filled after
initial installation or after a longer downtime of the appliance.
The trap filling sequence is activated if:
• The appliance is switched OFF using the ON/OFF switch
• The burner has not been in use for at least 28 days
• You are switching between summer and winter mode
Service function 6.A: Display the latest fault code
The next time there is a demand for heat in central heating or hot water
mode, the appliance is held at low output for 15 minutes. The trap filling
sequence remains active until the appliance has completed 15 minutes
of operation at low output. The display shows
in alternation with the
supply temperature.
Service function 6.b: Room temperature control, current voltage,
terminal 2
The following settings are available:
• 00: Condensate trap filling sequence is off.
• 01: Trap filling program at the lowest output.
• 02: Trap filling sequence at set minimum output.
Default setting is 01.
Use this service function to display the most recent fault code.
The current voltage of the analog control at terminal 2 is displayed.
Possible displays are:
• 00 - 24: 0 V to 24 V in increments of 1 V
Service function 6.C: Supply temperature required by outdoor reset
control
This service function allows displaying the current target supply
temperature set by the outdoor reset control.
Service function 5.A: Reset inspection interval
This function enables resetting the indication
on the display after
completing inspection/servicing of the appliance.
Default setting 00.
Service function 5.b: Fan post purge time
Service function 6.d: Current DHW turbine flow rate (only combi
boiler ZWB..-3A)
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
heating boiler ZBR..-3A appliances.
This service function allows setting the time the fan purges after the
burner is shut off.
The current flow rate of the DHW turbine is displayed.
The post purge time can be set from 01 to 18 (10 - 180 seconds).
Service function 0.E is set to 00 (metric units):
• 0.0. - 99.9.: 0.0 to 99 l/min in increments of 0.1 l/min
Default setting is 03 (30 seconds).
Service function 5.E: Functionality of black plug in boiler junction
box
With this service function you can set the functionality of the black plug
in the boiler junction box ( page 45).
The following settings are possible:
• 00: Off - black connector in junction box is disabled (120VAC output
deactivated).
• 01: DHW recirculation pump enabled - see FW200 instructions on
how to set a recirculation pump program.
• 02: External heating zone pump in heating circuit without 3-way valve
controlled by FW 200.
• 03: External heating zone pump in heating circuit without mixer
controlled by Heatronic running in parallel with boiler pump in central
heating mode
Service function 0.E is set to 01 (US-customary units):
• 0.0. - 99.9.: 0.0 to 99 gpm in increments of 0.1 gpm
Service function 7.A: Indicator lamp for burner operation / faults
With this service function you can activate and deactivate the indicator
lamp for burner operation (continuously illuminated) and faults
(flashing).
The following settings are possible:
• 00: Off
• 01: On (burner operation) and flashing (fault present)
Default setting is 00.
Default setting is 03.
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Greenstar
Heatronic boiler control settings | 57
Service function 7.b: 3-way valve in center position
Service function 0.d: Altitude adjustment
After the value 01 has been saved, the 3-way valve moves to the center
position. This allows draining the system completely and removing the
motor easily.
Input and output rates are reduced at higher altitudes due to thin air with
reduced oxygen levels.
When you exit this service function, the appliance returns to setting 00.
Service function 7.d: Connecting an external supply or low-loss
header temperature sensor
Presence of an external supply or low loss header temperature sensor is
automatically detected by default; you do not need to change any
settings.
If a sensor is disconnected, change the setting back to
the default setting 00.
The following settings are available:
• 00: Once-only automatic detection of a sensor
• 01: External supply temperature sensor connected to Heatronic.
• 02: External supply temperature sensor connected to IPM2.
Default setting is 00.
Service function 7.E: Building drying function
This service function allows you to start and stop the building drying
function.
Never confuse the appliance building drying function
with the slab drying function of the outdoor reset control
FW200.
ZBR42-3A... and ZWB42-3A... appliances are derated at 3 % per
1000 feet (305 m).
ZBR16-3A..., ZBR21-3A..., ZBR28-3A..., ZBR35-3A..., ZWB28-3A...
and ZWB35-3A... appliances offer altitude adjustment which
compensates for the effects of thin air, and are therefore NOT derated
up to 6000 feet (1829 m). Above 6000 feet (1829 m) a rate of 3 % per
1000 feet (305 m) applies.
This service function is used to adjust the fan speed for high altitude
operation.
The following settings are available:
• 00: Normal
• 01: Medium
• 02: High
Setting
00
01
02
Elevation above sea level
0 ft – 2,000 ft (0 m – 610 m)
2,001 ft – 4,500 ft (611 m – 1 372 m)
above 4,500 ft (1 372 m)
Table 30 Altitude adjustment (service function 0.d)
Default setting is 00.
Service function 0.E: Metric or US customary units
With this service function you can set if Metric or US customary units are
displayed on the boiler.
The following settings are available:
• 00: °C, l/min (metric units)
• 01: °F, gpm (US-customary units)
When the building drying function is on, you cannot
adjust the appliance gas settings.
Default setting is 01.
10.3.2 Second service level
The following settings are available:
• 00: Off
• 01: Heating operation only in accordance with the appliance or
control setting, i.e. all other heat demands are blocked.
Default setting is 00.
Service function 0.A: Do not use this setting!
Default setting is 00 (disabled).
Service function 8.A: Software version
The current software version is displayed.
Service function 8.b: Code plug number
The last four digits of the code plug number are shown.
The code plug determines the appliance functions. If the
appliance has been converted from natural gas to LPG
(or vice versa), the code plug must be replaced.
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.
Service function 8.d: GFA Gas burner control unit fault
Internal parameter.
Greenstar
6 720 806 992 (2013/07)
58 | Heatronic boiler control settings
Service function 8.E: Restore boiler to factory settings
This function allows resetting all parameters of the boiler including all
service functions to their factory settings.
▶ Press and hold the service button
until it illuminates.
The display shows a code such as 1.A (first service level).
▶ Press and hold ECO button and key pad lock button simultaneously
until a service function, e.g. 8.A, is displayed (second service level).
▶ Repeatedly press the key pad lock button or ECO button until service
function 8.E is displayed.
▶ Press and release the emissions test button .
The emissions test button lights up and the display shows 00.
▶ Press and hold the emissions test button until the display shows
.
All settings are reset and the appliance restarts with the default
settings.
▶ Reset altered service functions to the settings recorded in the
commissioning log ( page 75).
Default setting is 50.
Service function 9.E: Turbine signal delay
(only combi boiler ZWB..-3A)
NOTICE: System damage or boiler malfunction!
▶ Never change the setting of this service function on
heating boiler ZBR..-3A appliances.
This service function allows setting a time delay to prevent the appliance
starting up as a result of transient pressure spikes in the water supply.
Through spontaneous pressure change in the water supply, the flow
meter (turbine) can signal that DHW is being drawn and cause the burner
to come on unnecessarily.
The turbine signal delay can be set from 02 to 08 (0.5 seconds to 2
seconds) in increments of 0.25 seconds.
Default setting is 04 (1 second).
Service function 8.F: Permanent ignition
Service function 9.F: Heating zone pump post purge
NOTICE: Ignition transformer damage.
▶ Never leave this function on for longer than 2 minutes
at a time.
This function enables permanent ignition without gas supply to test the
performance of all ignition related components.
The following settings are available:
• 00: Off
• 01: On
Default setting is 00.
Service function 9.A: Constant mode
This function sets one operating mode permanently ( Service function
2.F: Operating mode, page 54).
The following settings are available:
• 00: Default mode: the appliance runs according to control settings.
• 01: The appliance runs permanently at minimum output. The display
shows 9.A.
• 02: The appliance runs permanently at maximum output. The display
shows 9.A.
This service function allows setting a pump post purge time after the end
of the heat demand from the external control.
The pump post purge time can be set from 01 to 10 (1 to 10 minutes).
Default setting is 03.
Service function A.b: Display DHW temperature
This service function allows displaying the current DHW temperature.
Service function A.C: Display DHW tank temperature
This service function allows displaying the temperature of the DHW tank
temperature sensor.
Service function b.F: Solar DHW backup heating delay (only combi
boiler ZWB..-3A)
For systems with a solar thermal DHW tank in series before the DHW line
of the combi boiler. DHW heating by the boiler will be suppressed
expecting that solar thermal DHW will reach the hot water temperature
sensor prior eliminating the need to run the boiler. Set the heating delay
in accordance with system conditions.
Default setting is 00.
Service function 9.b: Current fan speed
This service function allows you to display the current fan speed in
revolutions per second (1/s).
Service function 9.C: Current boiler output
If this setting is enabled, the DHW demand signal is no
longer available  page 49.
The start delay can be set between 00 to 50 (0 to 50 seconds) in
increments of 1 second.
Default setting is 00.
This service function displays the current boiler output (in percent (%)).
Service function C.d: Display current heat demand
Service function 9.d: Set fan start speed
At higher elevations the boiler fan may need to spin faster upon startup
to ensure reliable ignition every time. The start speed of the boiler fan
can be set from 45 to 77 revolutions per second (1/s).
6 720 806 992 (2013/07)
Available displays are:
• 00: No heat demand
• 01: Space heating demand present
• 02: DHW heat demand present
Greenstar
Gas type conversion | 59
11
Gas type conversion
DANGER: Personal injury and property damage
▶ This conversion shall only be performed by a trained
and certified installer in accordance with the
manufacturer‘s instructions and all applicable codes
and requirements of the authority having jurisdiction.
▶ If the information in these instructions is not followed
exactly, or the installation, adjustment, modification,
operation or maintenance is carried out by an
unqualified person, a fire, explosion or generation of
large amounts of carbon monoxide may result causing
property damage, personal injury or loss of life.
▶ Before carrying out electrical work: Disconnect the
installation from the power supply at the emergency
shutoff switch or by disengaging the heating system
circuit breaker. Take measures to prevent accidental
reconnection.
▶ The installer is responsible for the proper conversion
of this appliance.
▶ The conversion is not complete until the operation of
the converted appliance is checked as specified in
these instructions.
▶ Replace the code plug in the Heatronic with the code plug from the gas
conversion kit.
6 720 641 933-57.1O
Fig. 69 Replacing the code plug
▶ Affix the gas type label from the gas conversion kit to the appliance.
The gas-air ratio must always be set on the basis of a CO2 or O2
reading taken at maximum nominal output and minimum nominal
output using an electronic flue gas analyzer.
Adjustment to different flue systems using throttle discs or baffles is not
necessary.
6 720 641 933-58.2O
NG
• Appliances are set at the factory to Wobbe index 1,333 BTU/ft3
(49.6 MJ/m3) at 60 °F (15 °C), 30" Hg (1016 hPa) and 7.0" W.C.
(17.4 mbar) gas supply pressure and sealed.
Fig. 70 Affixing the gas type label
▶ Always adjust the gas-air ratio (CO2 or O2,
 Section 11.3) after converting to a different gas type and measure
the CO content of the flue gas ( Section 12).
11.1 Converting to a different gas type
DANGER: Explosion!
▶ Close the gas cock prior to working on the gas train.
▶ Check for gas leaks after carrying out work on the gas
train.
A gas conversion kit is included in the scope of delivery.
▶ Fold the Heatronic down.
▶ Check the number on the code plug from the gas conversion kit (Code
plug number  table 43, page 74).
11.2 Installation location higher than 2,000 feet (610 m)
above sea level
Input and output rates are reduced at higher altitudes due to thin air with
reduced oxygen levels.
ZBR42-3A... and ZWB42-3A... appliances are derated at 3 % per
1000 feet (305 m).
ZBR16-3A..., ZBR21-3A..., ZBR28-3A..., ZBR35-3A..., ZWB28-3A...
and ZWB35-3A appliances offer altitude adjustment which
compensates for the effects of thin air, and are therefore NOT derated
up to 6000 feet (1829 m). Above 6000 feet (1829 m) a rate of 3 % per
1000 feet (305 m) applies.
The Bosch Greenstar boiler is factory set for installation
below 2000 feet (610 m) above sea level.
▶ Correction of the fan speed curve of the burner:
Use service function 0.d to adjust the elevation setting ( page 57).
Greenstar
6 720 806 992 (2013/07)
60 | Gas type conversion
11.3 Setting the gas-air ratio (CO2 or O2)
▶ Adjust the gas throttle to match the CO2 or O2 level for maximum
nominal output according to table 31.
▶ Switch the appliance OFF using the ON/OFF switch.
▶ Remove the cover ( page 32).
▶ Switch the appliance ON using the ON/OFF switch.
▶ Open one of the flue gas test ports.
6 7 2 0 6 1 2 6 5 9 -3 8 .1 R
Fig. 73 Set CO2 or O2 level for maximum nominal output
Gas type
NG
LPG (propane)
Maximum nominal
output
CO2
O2
9.4 %
4.0 %
11.0 %
4.2 %
Minimum nominal
output
CO2
O2
8.6 %
5.5 %
10.4%
5.1 %
Table 31 CO2 or O2 values at maximum and minimum nominal output
6 720 641 933-79.1O
Fig. 71 Open one of the flue gas test ports
▶ Insert the probe approx. 2-3/4 inches (70 mm) into the test port and
seal around it.
▶ Press and hold the emissions test button until it lights up.
The display shows the supply temperature alternating with
=
maximum set output in heating mode.
▶ Briefly press the emissions test button .
The display shows the supply temperature in alternation with
=
maximum nominal output.
▶ Measure the CO2 or O2 level and the CO content of the flue gas
( Section 12).
▶ Briefly press the emissions test button .
The display shows the supply temperature in alternation with
=
minimum nominal output.
▶ Measure the CO2 or O2 level and the CO content of the flue gas
( Section 12).
▶ Remove the sealed screw ( Fig. 74, [3]) from gas valve adjustment
screw ( Fig. 74, [2]) and set CO2 or O2 level for minimum nominal
output.
3
▶ On the gas throttle, break the seal at the slot and remove the cap.
2
2 .
1
6 720 641 933-81.1O
1 .
Fig. 74 Set CO2 or O2 level for minimum nominal output
6 7 2 0 6 1 2 6 5 9 -3 7 .1 R
Fig. 72 Remove seal from the gas throttle
6 720 806 992 (2013/07)
▶ Re-check settings at maximum and minimum nominal output and readjust if necessary.
▶ Repeatedly press the emissions test button
until the light goes
out.
The display returns to the supply temperature.
▶ Record the CO2 or O2 levels and the CO content of the flue gas in the
commissioning log.
▶ Reinstall the screw ( Fig. 74, [3]) to cover the gas valve adjustment
screw.
Greenstar
Gas type conversion | 61
▶ Remove flue gas probe and close the flue gas test port properly.
11.4
Dynamic gas pressure test
▶ Switch the appliance OFF and close the gas shut-off valve.
▶ Loosen the screw in the test port for gas inlet pressure
( Fig. 74, [1]) and connect a pressure gauge ( Fig. 76).
6 720 614 090-34.2O
Fig. 76 Dynamic gas pressure test port
6 720 641 933-80.1O
Fig. 75 Close flue gas test ports
▶ Turn on the gas cock and switch the appliance ON.
▶ Press and hold the emissions test button until it lights up.
The display shows the supply temperature alternating with
=
maximum set output in heating mode.
▶ Briefly press the emissions test button .
The display shows the supply temperature in alternation with
=
maximum nominal output.
▶ Check the required inlet gas pressure according to table 32.
Gas type
NG
LPG (propane)
Nominal
pressure
" W.C. (mbar)
7 (17.4)
11 (27.4)
Permissible pressure range
for maximum nominal output
" W.C. (mbar)
3.5-10.5 (8.7-26.1)
8-13 (19.9-32.3)
Table 32 Inlet gas pressure
Do not operate the appliance if the measured value is
below or above these values. Determine the cause and
eliminate the fault. If this is not possible, block the
appliance on the gas side and notify the gas supplier.
▶ Repeatedly press the emissions test button
until the light goes
out.
The display returns to the supply temperature.
▶ Switch the appliance OFF, turn off the gas cock, remove the pressure
gauge and tighten the screw in the test port for gas inlet pressure.
▶ Reinstall the cover.
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62 | Flue gas test
12
Flue gas test
13
12.1 Emissions test button
The following appliance outputs can be selected by pressing the
emissions test button until it lights up:
3
4
2
1
3
5
6
max
Packaging
eco
All packaging materials used are environmentally-friendly and
recyclable.
Old appliances
e
6
1
min
Environmental responsibility is one of the fundamental company
policies of the Bosch Group.
We regard quality of performance, economy and environmental
responsibility as equal objectives. Environmental protection laws and
regulations are strictly adhered to.
To protect the environment, we use the best possible technology and
materials taking into account economic points of view.
reset
4
2
Environmental responsibility/disposal
max
6 720 641 933-51.1O
Old appliances contain resources that must be submitted for recycling.
The components are easy to separate and the plastics are marked. This
allows the various components to be sorted for appropriate recycling or
disposal.
Fig. 77 Press the emissions test button
•
= Maximum set output in heating mode ( Maximum heating
output, page 53)
•
= Maximum nominal output
•
= Minimum nominal output
You have 15 minutes to complete the tests. After that,
the appliance returns to default mode.
12.2 Measuring CO content of flue gas
14
Inspection and maintenance
Regular service and maintenance are recommended for a long service
life of the appliance, for efficient and economical operation, and to keep
the environmental impact as low as possible. Owners/operators are
encouraged to sign a service and maintenance contract with a trained
and certified installer for annual servicing and maintenance of the boiler.
DANGER: Explosion!
▶ Close the gas cock prior to working on the gas train.
▶ Check for gas leaks after carrying out work on the gas
train.
Use a multiport flue gas probe for the measurements.
▶ Open one of the flue gas test ports ( Fig. 71).
▶ Insert the flue gas probe approx. 2-3/4 inches (70 mm) into the test
port and seal around it.
▶ Press the emissions test button to select
= maximum nominal
output.
▶ Measure the CO levels.
DANGER: Risk of flue gas poisoning.
The CO level in the flue gas must be below 200 ppm (air
free).
▶ If 9.4 Vol.%1) CO2 and a CO level under 200 ppm (af)
can not be achieved due to the gas supplied, use a
lower CO2 level with CO emissions under 200 ppm
(af) instead.
1) 9.4 Vol.% with NG and 11.0 Vol.% with LPG (propane)
▶ Repeatedly press the emissions test button
until the light goes
out.
The display returns to the supply temperature.
▶ Remove flue gas probe and close the flue gas test port properly
( Fig. 75).
6 720 806 992 (2013/07)
DANGER: Risk of flue gas poisoning.
▶ Check for leaks after carrying out work on the venting
system.
DANGER: Risk of electric shock!
▶ Always disconnect the appliance from the mains
power before performing any work. Disconnect the
emergency shutoff switch or disengage the heating
system circuit breaker. Take measures to prevent
accidental reconnection.
NOTICE: Insufficient antifreeze can accelerate
corrosion.
▶ Frost protection level has to be checked annually
during the regular scheduled maintenance of the
condensing boiler.
Greenstar
Inspection and maintenance | 63
Heat exchanger
NOTICE: Damage to the coating of the heat exchanger.
▶ Cleaning of the heat exchanger should not be
necessary until five years after the initial
commissioning.
▶ Only use a Bosch cleaning blade or Bosch cleaning
brush ( page 92).
▶ Only clean heat exchanger if soiling is clearly visible.
14.1.2 Fresh water filter (only combi boiler ZWB..-3A)
▶ Close cold water tap.
▶ Depressurize the cold water pipe.
▶ To access the filter remove the safety clip (step 1), pull out the pipe
(step 2), and remove the filter from the pipe (step 3).
▶ If necessary, clean with plastic brush under running water.
1
Heatronic boiler control
In case of a component defect, a fault is shown on the display.
The Heatronic boiler control monitors all safety and control
components.
NOTICE: The Heatronic boiler control can be damaged
by leaking water.
▶ Cover the Heatronic prior to working on water filled
components.
3
Notes on installation and operation
2
An overview of the faults can be found on page 71.
6 720 641 933-92.1o
• The following analytical tools are needed for service and
maintenance:
– Electronic flue gas analyzer for CO2, O2, CO, and flue gas
temperature
– Pressure gauge 0 to 12 inches W.C. (0 to 30 mbar)
– pH Test strips
– Glycol tester of antifreeze is being used
• Special tools are not required.
• Approved lubricants are:
– For parts touched by water: Unisilkon L 641
(part-# 8 709 918 413 0)
– or fittings: HFt 1 v 5 (part-# 8 709 918 010 0).
▶ Use part-# 8 719 918 658 0 as heat conducting paste.
▶ Use only genuine Bosch spare parts.
▶ Request spare parts ( Section 18, page 77).
▶ Replace removed gaskets and O-rings with new ones.
Fig. 78 Filter in fresh water pipe
(combi boiler ZWB..-3A only)
14.1.3 Plate type heat exchanger
(only combi boiler ZWB..-3A)
If the DHW output on the combi boiler is significantly reduced:
▶ Check filter in the cold water pipe for contamination ( Fig. 63).
▶ Depressurize the appliance.
▶ Remove plate type heat exchanger and replace
-or▶ Descale with descaling agent approved for stainless steel (Grade
316-1.4401).
To remove the plate type heat exchanger:
▶ Unplug electrical connections.
▶ Remove hose from safety relief valve.
After the inspection/maintenance
▶ Re-tighten all loosened threaded connections.
▶ Restart the appliance ( page 47).
▶ Check all connections for leaks.
▶ Check the gas-air ratio and adjust if necessary ( page 60).
14.1 Description of various steps
14.1.1 Calling up the latest fault (service function 6.A)
▶ Select service function 6.A ( page 56).
An overview of the faults can be found on page 71.
6 720 641 933-46.2O
Fig. 79 Unplugging electrical connections / removing hose from safety
relief valve
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64 | Inspection and maintenance
▶ Loosen/remove pipe connections.
▶ Remove the plate type heat exchanger.
6 720 641 933-50.2O
Fig. 83 Removing the plate heat exchanger
▶ Install new plate type heat exchanger with new gaskets and reconnect
the hydraulic assembly in reverse order.
▶ Check all connections used during maintenance for leaks.
6 720 641 933-47.2O
Fig. 80 Removing pipe connections
▶ Remove the boiler pressure gauge from the Heatronic boiler control.
14.1.4 Checking the electrodes
▶ Remove electrode set ( page 10 / 12) including gasket and check
electrodes for contamination; clean or replace, if required.
▶ Reinstall electrode set with new gaskets and check for leaks.
2-1/4 + 3/4 ft.-lbf.
(3 + 1 Nm)
6720641933-28.1O
6 720 641 933-48.2O
Fig. 84 Reinstalling the electrode set
Fig. 81 Removing the boiler pressure gauge
▶ Loosen the quick releases (steps 1 and 2) and remove the hydraulic
assembly in its entirety (step 3).
2.
Gas/Gaz?
1.
1.
3.
Fig. 82 Removing the hydraulic assembly
6 720 806 992 (2013/07)
6 720 641 933-49.2O
6 720 613 354-02.2O
Fig. 85 Check for leaks
Greenstar
Inspection and maintenance | 65
14.1.5 Burner servicing
14.1.6 Heat exchanger block inspection and cleaning
DANGER: Fire danger!
▶ Only operate the burner while installed in a boiler.
▶ Remove burner lid (steps 1 - 4).
4
2
NOTICE: Damage to the coating of the heat exchanger.
▶ 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 ( page 92).
▶ Only clean heat exchanger in case if soiling is clearly
visible.
▶ Remove the inspection cover ( page 10) and any sheet metal insert
below, if installed.
▶ Determine degree of soiling of the heat exchanger through visual
inspection.
If mechanical cleaning is required:
3
For cleaning the heat exchanger, Bosch offers the service accessory kit
which includes main heat exchanger gaskets, the heat exchanger brush
and heat exchanger cleaning blade (part-# 7719001998).
1
▶ Remove the condensate trap (steps 1 and 2) and place a suitable
container underneath.
6 720 641 933-95.1o
Fig. 86 Removing the burner cover
▶ Remove burner and clean its components.
1
2
6 720 641 933-93.1o
7 181 465 330-08.2R
Fig. 88 Removing the condensate trap
Fig. 87 Burner
▶ Reinstall burner in reverse order, including a new gasket if necessary.
▶ Adjust the gas-air ratio ( page 60).
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6 720 806 992 (2013/07)
66 | Inspection and maintenance
▶ With the cleaning blade, clean the heat exchanger block from the
bottom to the top.
▶ Rinse the heat exchanger with water from the top.
2
6 720 612 664-18.1R
Fig. 91 Rinsing the heat exchanger
▶ Clean the condensate tray (with reversed brush).
6 720 641 933-71.1O
Fig. 89 Cleaning the heat exchanger with the cleaning blade
▶ Clean the heat exchanger block with the brush from top to bottom.
6 720 610 332-75.2R
Fig. 92 Cleaning the condensate tray
▶ Rinse the heat exchanger with water from the top.
▶ Clean the condensate trap connection.
▶ Close the inspection opening again using a new gasket and tighten the
screws with approx. 3.69 ft.-lbf. (5 Nm).
6 720 612 563-14.1O
Fig. 90 Cleaning the heat exchanger with the cleaning brush
▶ Remove burner ( Chapter 14.1.5 “Burner servicing”).
6 720 806 992 (2013/07)
Greenstar
Inspection and maintenance | 67
14.1.7 Condensate trap cleaning
▶ Remove condensate trap (steps 1 and 2) and check heat exchanger
orifice for clear passage.
▶ Insert the diaphragm into the fan connector. Ensure the diaphragm is
oriented properly.
The diaphragm flaps must open upwards.
▶ Close the mixer unit.
14.1.9 Expansion vessel
1
Annual inspection of the expansion vessel is required.
▶ Depressurize the appliance.
▶ If necessary, adjust the expansion vessel pre-charge pressure to the
static head of the heating system ( page 29).
14.1.10Setting the boiler water pressure
2
Display on the pressure gauge
14.5 psi (1 bar) Minimum filling pressure (when system is cold)
14.5 psi to
Optimal filling pressure
21.75 psi
(1 bar to 1.5 bar)
30 psi (2.07 bar) Maximum pressure at maximum heating water
temperature must not be exceeded (safety valve
will spill).
Table 33 Operating pressure
6 720 641 933-93.1o
Fig. 93 Removing the condensate trap
▶ Remove and clean the condensate trap lid.
▶ Check condensate hose and clean if necessary.
▶ Fill the condensate trap with approx. 1 cup (1/4 l) of water and
reinstall it.
▶ If the indicator is below 14.5 psi (1 bar) when the system is cold, top
up the water. The indicator must be between 14.5 psi (1 bar) and
21.75 psi (1.5 bar).
If using a hose to fill the heating system, prefill the hose
with water to prevent air being introduced into the
system.
14.1.8 Checking the mixer diaphragm
▶ Open the mixer unit.
▶ Carefully remove the diaphragm from the fan air intake and check for
contamination and cracks.
▶ If the pressure is not held, check the expansion vessel and heating
system for leaks.
14.1.11Testing system water quality
▶ Take a representative sample of the system water and analyze pH
using a pH meter or pH test strips.
pH-value
7-8.5
4.5-7
3
Water preparation
Not needed
Required
Table 34 Water preparation for filling and maintaining the heating
system (pH-value)
▶ If the value is outside of the permitted range, drain the system, flush,
and refill with fresh water to prevent system damage or leaks.
▶ If the fill water does not meet the requirements of page 28, treat the
water to bring it within the permissible range.
▶ If antifreeze is being used in the system, check the frost protection
properties to ensure the site specific requirements are met.
1
14.1.12Inspecting electrical wiring
▶ Check electrical wiring for mechanical damage and replace defective
cables.
2
6 720 641 933-94.1o
Fig. 94 Opening the mixer unit
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6 720 806 992 (2013/07)
68 | Inspection and maintenance
14.2 Checklist for inspection and maintenance
▶ Use this form to guide you through the service and maintenance
procedure. Fill out each step according to the findings and work
performed.
Date 
1
Latest fault code from service function 6.A ( page 63).
2
Fresh water inlet filter (Combi boiler ZWB appliances only)
( page 63).
3
Visual inspection of the combustion air pipes and vent pipes.
4
Dynamic gas pressure ( page 61).
inches W.C.
(mbar)
5
Gas-air ratio at min./max. nominal output
( page 60).
min. %
max. %
6
Gas and water-side leak test ( page 41).
7
Inspect electrodes ( page 64).
8
Inspect heat exchanger block ( page 65).
9
Check burner ( page 65).
10
Inspect diaphragm in mixer unit ( page 67).
11
Clean condensate trap ( page 67).
12
With the system depressurized, check the
expansion vessel pre-charge pressure vs. the
static head of the heating system.
psi (bar)
13
Check the heating system filling pressure.
psi (bar)
14
Inspect electrical wiring for damage.
15
Check settings of the heating control.
16
Check set service functions according to commissioning report
( page 75).
Table 35 Maintenance and inspection checklist
6 720 806 992 (2013/07)
Greenstar
Readings on the display | 69
15
Status code Description
Acknowledge by pressing any button (except reset).
Readings on the display
The boiler display can provide the following information (Tab. 36
and 37):
Value displayed
Number or letter, dot
followed by letter
Letter followed by
number or letter
Three numbers (199)
One number (displayed
for longer) followed by
two numbers (displayed
briefly)
Two dashes followed by
two pairs of numbers
Two letters followed by
two pairs of numbers
Table 36 Display readings
Description
Service function
( Tab. 28 / 29, page 52)
Fault code
( Tab. 38, page 71) (exception:
b.A = service function)
Decimal value, e.g. supply
temperature
Decimal figure (three digits); first
digit is shown alternating with two
last digits
(e.g. 2.69..69 for 269)
Code is shown in three stages: 1.
Two dashes 2. First two
digits 3. Last two digits
(e.g. -- 10 04)
Code is shown in three stages: 1.
Two letters 2. First two
digits 3. Last two digits
(e.g. CF 10 20)
Range
Acknowledge by pressing two buttons
simultaneously
Acknowledge by pressing and holding for more than
3 seconds (Save function).
00..199
0..999
The display shows the supply temperature in alternation
with
. The appliance works for 15 minutes at the
minimum nominal output,  service function 2.F.
The display shows the supply temperature in alternation
with
. The appliance works with the set maximum
output in heating mode,  service function 1.A.
1000 ...
9999
The display shows the supply temperature in alternation
with
. The appliance works for 15 minutes at the
maximum nominal output,  service function 2.F.
The air purging function is active,  service function
2.C
The display shows the supply temperature in alternation
with
. The trap filling sequence is active,  service
function 4.F.
The display shows the supply temperature alternating
with
: Service reminder,  service function 5.A.
The display shows the supply temperature in alternation
with
. The pump may have seized,  fault E.9.
The display shows the supply temperature in alternation
with
. The temperature gradient limiter was
triggered. Excessive supply temperature increase:
Heating mode is suspended for two minutes.
Slab drying function of the FW200 outdoor reset control
( operating instructions) or building drying function
( service function 7.E) are activated.
Key pad lock enabled. To unlock the key pad, press
until the supply temperature is shown on the
display.
Table 37 Special displays
Greenstar
6 720 806 992 (2013/07)
70 | Faults
16
If the fault persists:
▶ Check the PCB and replace if required. Adjust the service functions in
accordance with the commissioning report ( page 75).
Faults
16.1 Troubleshooting
DANGER: Explosion!
▶ Close the gas cock prior to working on the gas train.
▶ Check for gas leaks after carrying out work on the gas
train.
DANGER: Risk of flue gas poisoning.
▶ Check for leaks after carrying out work on the venting
system.
DANGER: Risk of electric shock!
▶ Always disconnect the appliance from the mains
power before performing any work. Disconnect the
emergency shutoff switch or disengage the heating
system circuit breaker. Take measures to prevent
accidental reconnection.
WARNING: Danger of scalding!
Hot water can scald.
▶ Drain the appliance before working on components
that are water filled.
NOTICE: The Heatronic boiler control can be damaged
by leaking water.
▶ Cover the Heatronic prior to work on water filled
components.
The Heatronic boiler control monitors all safety and control
components.
If a fault arises during operation, an audible warning tone sounds.
Press a button to mute the warning sound.
The display indicates a fault code (e.g.
) and the reset button flashes.
If the reset button is flashing:
▶ Press the reset button and hold it until
appears on the display.
The appliance starts up again and the current supply temperature is
displayed.
If the reset button is not flashing:
▶ Switch the appliance OFF and ON again.
The appliance starts up again and the current supply temperature is
displayed.
An overview of the faults can be found on page 71.
An overview of the status codes can be found on
page 69.
6 720 806 992 (2013/07)
Greenstar
Faults | 71
16.2 Faults that are shown on the display
Display
A7
A8
Ad
b1
b2/b3/b4/
b5/b6
b7
C6
CC
d3
Description
DHW temperature sensor defective.
Elimination
▶ Check temperature sensor and leads for interruptions or shorts, and replace if
defective.
▶ Insert code plug correctly; replace if defective.
Communication fault.
▶ Check BUS communications wiring, replace if defective.
▶ Check control, replace if defective.
DHW tank temperature not detected.
▶ Check DHW tank temperature sensor and connecting lead, replace if defective.
▶ Reset the boiler to the factory default settings ( service function 8.E), reset the
IPM 2 (if installed) to the factory default settings and carry out the automatic
The DHW tank temperature sensor was recognized
system configuration.
before the connection was lost.
Code plug not detected.
Internal data error.
▶ Insert code plug correctly; replace if defective.
▶ Reset boiler to factory default setting ( service function 8.E).
Fault in the burner controls.
Fan not running.
Outdoor temperature sensor not recognized.
▶ Reset boiler to factory to default setting ( service function 8.E).
▶ Check fan leads and fan, replace if defective.
▶ Check outdoor temperature sensor and leads for interruptions, replace if
defective.
▶ Verify the outdoor temperature sensor is connected to terminals A and F.
▶ Check temperature sensor and leads for interruptions or shorts, and replace if
defective.
▶ Temperature guard TB1 has tripped. Check if jumper across 8-9 or PR-P0 is
missing.
▶ Reset external temperature limiter (if installed).Reset LWCO (if installed).
Temperature high limit defective.
External guard has tripped.
d5
Temperature limiter locked out.
External supply temperature sensor defective
(low-loss header).
E2
The external supply temperature sensor was
recognized on the BUS and then reconnected to
the appropriate terminal.
Supply temperature sensor defective.
E3
Additional supply temperature sensor defective.
E9
Heat exchanger safety high limit or flue gas
temperature limiter has tripped.
▶ Check temperature sensor and leads for interruptions or shorts, and replace if
defective.
▶ Check whether only one temperature sensor is connected; otherwise remove
second temperature sensor.
▶ Reset the boiler to the factory default settings ( service function 8.E), reset the
IPM 2 (if installed) to the factory default settings and carry out the automatic
system configuration.
▶ Check temperature sensor and leads for interruptions or shorts, and replace if
defective.
▶ Check temperature sensor and leads for interruptions or shorts, and replace if
defective.
▶ Check flue gas safety high limit and leads for interruptions or shorts, and replace
if defective.
▶ Check heat exchanger safety high limit and leads for interruptions or shorts, and
replace if defective.
▶ Check the operating pressure.
▶ Check temperature limit; replace if defective.
▶ Check pump capacitor; replace pump if defective.
▶ Check PCB fuse, replace if blown (6.3 A fuse according to IEC default).
▶ Purge the appliance
▶ Check heat exchanger on the DHW side; replace if clogged.
Table 38 Faults shown on the display
Greenstar
6 720 806 992 (2013/07)
72 | Faults
Display
EA
Description
No flame detected.
F0
GFA: Safety time expired.
Internal fault
F1
F7
Internal data error.
Flame detected even when burner is off.
FA
After switching gas off: Flame is detected.
Fd
Reset button pressed by mistake.
Temperature gradient limiter: Temperature rise
too fast
Elimination
▶ 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.
▶ Check flue gas system; clean or repair if defective.
▶ Check gas/air ratio; correct if out of range.
▶ Check gas valve; replace if defective.
▶ In room air operation, check air supply or ventilation apertures.
▶ Clean the condensate trap.
▶ Remove diaphragm at fan inlet connection and check for
contamination or cracks.
▶ Check heat exchanger for soiling ( Chapter 14.1.6, page 65).
▶ Check gas cock; replace if defective.
▶ Insert code plug correctly; replace if defective.
▶ Press reset for 3 seconds and release. When the button is released, the
appliance will restart.
▶ Check electrical plug-in contacts and ignition leads; replace PCB if defective.
▶ Check gas/air ratio; correct if out of specification.
▶ Reset boiler to the factory default setting ( service function 8.E).
▶ Check electrodes; replace if defective.
▶ Check flue gas system; clean or repair if defective.
▶ Check PCB for moisture; dry if needed.
▶ Check gas cock; replace if defective.
▶ Clean condensate trap.
▶ Check electrodes and leads; replace if defective.
▶ Check flue gas system; clean or repair if needed.
▶ Press reset button again.
▶ Check cable harness to safety high limit and gas cock for ground connection.
▶ Fully open service shut-off valves.
▶ Check electrical connection between heating zone pump and Heatronic.
▶ Check pump plug connection per installation instructions.
▶ Manually test operation of heating zone pump and replace if defective.
▶ Set pump speed correctly to match maximum output.
Table 38 Faults shown on the display
6 720 806 992 (2013/07)
Greenstar
Faults | 73
16.3 Faults that are not shown on the display
Appliance faults
Combustion noise too loud; rumbling noises
Flow noises
Heating-up takes too long
Flue gas readings incorrect; CO levels too high
Violent ignition, poor ignition
DHW has unpleasant odor or has a dark color
Set supply temperature (e.g. of the FW200
control) exceeded
Condensate in air box
DHW temperature is not reached (combi boiler
ZWB..-3A only)
Heatronic is flashing (i.e. all buttons, all display
segments, burner indicator etc. are flashing)
Elimination
▶ 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.
▶ Check gas/air ratio in the combustion air and flue gas; replace gas valve if defective.
▶ Set pump speed correctly to match maximum output.
▶ Set pump mode.
▶ Set pump speed correctly to match maximum output.
▶ Set pump mode.
▶ Check gas type.
▶ Check inlet gas pressure; adjust if defective.
▶ Check flue gas system; clean or repair if defective.
▶ Check gas/air ratio in flue gas; replace gas valve if defective.
▶ Check gas type.
▶ Check inlet gas pressure; adjust if defective.
▶ Check power supply.
▶ Check electrodes for visual damage; replace if defective.
▶ Check flue gas system; clean or repair if defective.
▶ Check gas/air ratio; replace gas valve if defective.
▶ Check gas valve; replace if defective.
▶ Check burner; replace if required.
▶ Perform thermal disinfection of the DHW circuit.
▶ Replace sacrificial anode in the tank (if installed).
▶ Consult local water department.
▶ Switch off automatic anti-cycle timer, i.e., set value to 0.
▶ Set the required anti-cycle timer, e.g. default setting of 3 minutes.
▶ Insert diaphragm in the mixer unit per installation instructions; replace if defective.
▶ Insert code plug correctly; replace if defective.
▶ Check whether voltage (120 VAC) is present between terminal 1 and terminal 3; repair if
defective.
▶ Check turbine; replace if defective.
▶ Replace fuse Si 3 (24 V) (6.3 A fuse according to IEC default).
Table 39 Faults not shown on the display
Greenstar
6 720 806 992 (2013/07)
74 | Faults
16.4 Check sensor values
16.4.1 Outdoor temperature sensor
Temperature °F ( °C )
Testing tolerance 10%
– 4 ( – 20)
3 ( – 16)
10 ( – 12)
17 ( – 8)
24 ( – 4)
32 (0)
39 (4)
46 (8)
50 (10)
59 (15)
68 (20)
77 (25)
Resistance [ ]
2,392
2,088
1,811
1,562
1,342
1,149
984
842
781
642
528
436
Table 40 Resistance table outdoor temperature sensor
16.4.2 Additional supply temperature limiter
Temperature °F ( °C)
Testing tolerance 10%
32 (0)
50 (10)
68 (20)
86 (30)
104 (40)
122 (50)
140 (60)
158 (70)
176 (80)
194 (90)
212 (100)
Resistance [ ]
33,555
21,232
13,779
9,128
6,205
4,298
3,025
2,176
1,589
1,177
886
Table 41 Resistance table supply temperature limiter
Temperature °F ( °C)
Testing tolerance 10%
131 (55)
140 (60)
149 (65)
158 (70)
167 (75)
176 (80)
185 (85)
194 (90)
203 (95)
212 (100)
Resistance [ ]
3,856
3,243
2,744
2,332
1,990
1,704
1,464
1,262
1,093
950
Table 42 Resistance table NTCs
16.5 Replacement code plug
Appliance
ZBR16-3A NG
ZBR16-3A LPG
ZBR21-3A NG
ZBR21-3A LPG
ZBR28-3A NG
ZBR28-3A LPG
ZBR35-3A NG
ZBR35-3A LPG
ZBR42-3A NG
ZBR42-3A LPG
ZWB28-3A NG
ZWB28-3A LPG
ZWB35-3A NG
ZWB35-3A LPG
ZWB42-3A NG
ZWB42-3A LPG
Order number
8 714 432 501 0
8 714 432 506 0
8 714 432 528 0
8 714 432 529 0
8 714 432 502 0
8 714 432 507 0
8 714 432 503 0
8 714 432 508 0
8 714 432 504 0
8 714 432 509 0
8 714 432 520 0
8 714 432 521 0
8 714 432 524 0
8 714 432 525 0
8 714 432 500 0
8 714 432 505 0
Table 43 Code plugs for all appliances
16.4.3 Supply temperature sensor, External supply temperature
sensor, DHW tank temperature sensor, DHW temperature
sensor
Temperature °F ( °C)
Testing tolerance 10%
68 (20)
77 (25)
86 (30)
95 (35)
104 (40)
113 (45)
122 (50)
Resistance [ ]
14,772
11,981
9,786
8,047
6,653
5,523
4,608
Table 42 Resistance table NTCs
6 720 806 992 (2013/07)
Greenstar
Commissioning log for the appliance | 75
17
Commissioning log for the appliance
Home owner/operator:
Last name, first name
Number, Street
Telephone/fax
ZIP code, town
System installer:
Order number:
(Complete a separate log for every appliance!)
Appliance type:
FD (Date of manufacture):
Date commissioned:
 Individual appliance
Installation
location:
 Basement |  Attic |  Garage |  other:
ft2 (m2)
Room air only: Number and size of ventilation openings
Vent pipe routing:
 Twin pipe system |  Concentric pipe system |  Room air |  Sealed combustion
 PVC |  CPVC |  PP |  2" |  3"
Total length: Approx. ...... ft (m) | Elbows 90 °: ...... Qty | Elbows 15 - 45 °: ......Qty
Flue tightness test completed:  yes |  no
CO2 value in the combustion air at maximum nominal output:
%
O2 value in the combustion air at maximum nominal output:
%
Notes regarding under or over pressure operation:
Gas setting and flue gas test:
Gas conversion:  NG |  LPG (propane)
Inlet gas pressure
Selected maximum output:
Gas flow rate at maximum nominal output:
Net calorific value HiB (per gas supplier):
CO2 at max. nominal output:
O2 at maximum nominal output:
CO at maximum nominal output:
" W.C.
(mbar) Gas static supply pressure:
" W.C.
(mbar)
MBH (kW) Selected minimum output:
MBH (kW)
gpm
(l/min) Gas flow rate at minimum nominal output:
gpm
(l/min)
MBTU/ft3
(kWh/m3)
% CO2 at minimum nominal output:
% O2 at minimum nominal output:
ppm CO at minimum nominal output:
%
%
ppm
Flue gas temperature at maximum nominal output:
°F ( °C) Flue gas temperature at minimum nominal output:
°F ( °C)
Maximum measured supply temperature:
°F ( °C) Minimum measured supply temperature:
°F ( °C)
System hydraulics:
 Low-loss header, type:

Additional expansion vessel
 Heating pump:
Size/pre-charge pressure:
 Primary secondary piping
Automatic air vent present?
 yes |  no
 DHW tank/type/number/heating surface output:
 System hydraulics checked, notes:
Greenstar
6 720 806 992 (2013/07)
76 | Commissioning log for the appliance
Modified service functions: (Select the modified service functions and enter the values here.)
Example: Service function 7.d changed from 00 to 01
Heating control:
 FW 200
 FB 100 × ...... Qty, coding heating zone(s):
 ISM 2
 IPM 2 × ...... Qty, coding heating zone(s):
Other:
 Heating control programmed, notes:
 Documented the modified settings of the heating control in the control operating/installation instructions
The following work has been carried out:
 Electrical connections checked, notes:
 Condensate trap filled
 Carry out a combustion air/flue gas test
 Function check carried out
 Tightness test carried out on the gas and water sides
Commissioning includes checking the settings, a visual heating leak test and a functional check of the boiler and control. The system installer
conducts a test of the heating system.
This system has been checked to the extent described.
___________________________________________________________
Name of service installing contractor
The documents have been handed over to the home owner/operator. The
home owner/operator has been instructed regarding safety and operation
of the boiler and accessories, including the need for regular scheduled
maintenance.
__________________________________________________________
Date, owner/operator signature
Affix the test report here.
____________________________________________________________
Date, system installer's signature
6 720 806 992 (2013/07)
Greenstar
Spare parts | 77
18
Spare parts
ZWB28-3A
ZWB35-3A
ZWB42-3A
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ZBR35-3A
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ZBR28-3A
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ZBR21-3A
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ZBR16-3A
Designation
Group 1 - Sheet metal
Group 2 - Burner/Heat exchanger
Group 3 - Gas valve
Group 4 - Pipes combi boiler ZWB..-3A
Group 5 - Pipes heating boiler ZBR..-3A
Group 6 - Control box
Group 7 - Hydraulic block combi boiler ZWB..-3A
Group 8 - Accessories for service/installation
ZBR42-3A
▶ Order spare parts by name and part number using the spare parts list.
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Spare parts list
 page 78
 page 80
 page 82
 page 84
 page 86
 page 88
 page 90
 page 92
Table 44 Spare part groups Greenstar
Greenstar
6 720 806 992 (2013/07)
78 | Spare parts
6 720 641 933-102.2O
Fig. 95 Group 1 - Sheet metal Greenstar
6 720 806 992 (2013/07)
Greenstar
ZWB35-3A
ZWB42-3A
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ZBR35-3A
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ZBR28-3A
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ZBR21-3A
ZWB28-3A
23
Designation
Outer jacket complete
Front cover
Screw M5X22 (10x)
Trade mark badge
Expansion vessel
Washer 18.6 X 13.5 X 1.5 (10x)
Brass adapter
Flue connection
Bracket
Washer 80 mm
Adapter USA
Silencer complete
Gasket
Throttle disc
Flue pipe gasket
Latch (1x)
Damper (2x)
Junction box USA ZBR - heating boiler
Junction box USA ZWB - combi boiler
Connection kit ZWB - combi boiler
Connection kit ZBR - heating boiler
ZBR16-3A
Item ( Fig. 95)
1
2
3
4
5
7
8
9
10
12
13
16
17
18
19
20
21
22
ZBR42-3A
Spare parts | 79
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Order number
8 718 222 866 0
8 718 222 827 0
8 713 403 026 0
8 716 011 807 0
8 715 407 328 0
8 710 103 045 0
8 710 103 209 0
8 710 735 296 0
8 711 304 860 0
8 711 004 232 0
8 718 226 289 0
8 710 725 353 0
8 711 004 278 0
8 710 100 209 0
8 722 933 330 0
8 718 224 302 0
8 718 224 267 0
8 737 701 425 0
8 737 701 563 0
8 718 661 616 0
8 718 661 617 0
Table 45 Group 1 - Sheet metal Greenstar
Greenstar
6 720 806 992 (2013/07)
80 | Spare parts
19
21
20
17
20
18
15
16
14
13
4
9
14
16
19
22
23
1
12
8
11
5
7
6
22
10
9
23
4
3
2
6 720 641 933-103.3O
Fig. 96 Group 2 - Burner/Heat exchanger Greenstar
6 720 806 992 (2013/07)
Greenstar
ZBR28-3A
ZBR35-3A
ZBR42-3A
ZWB28-3A
ZWB35-3A
ZWB42-3A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Designation
Heat exchanger block (incl. set of gaskets) incl. flue gas and
condensate collector (item 4)
Nut
Set of gaskets
Flue gas and condensate collector
Temperature limit sensor
Return pipe nut and safety pin
Temperature sensor
Cover
Gasket
Shield
Clip (10x)
Set of electrodes complete
Flame viewing window
Gasket (10)
Burner
Burner gasket
Top burner cover complete
Attachment nuts, washers, safety pins (set of 2)
Gasket
Bracket
Attachment bolt complete
Temperature limiter assy
Heat exchanger gasket
ZBR21-3A
Item ( Fig. 96)
1
ZBR16-3A
Spare parts | 81
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
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




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








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
























































Order number
8 737 701 797 0
8 713 301 196 0
8 710 103 206 0
8 718 006 944 0
8 722 963 858 0
8 719 928 487 0
8 714 500 087 0
8 711 000 262 0
8 710 103 153 0
8 718 003 836 0
8 710 100 190 0
8 718 107 089 0
8 715 600 018 0
8 711 004 264 0
8 718 006 658 0
8 711 004 168 0
8 715 416 029 0
8 710 305 296 0
8 729 000 183 0
8 718 005 603 0
8 710 305 297 0
8 710 506 267 0
8 710 103 155 0
Table 46 Group 2 - Burner/Heat exchanger Greenstar
Greenstar
6 720 806 992 (2013/07)
82 | Spare parts
1
2
16
20
13
17
14
15
3
16
18
21
19
12
19
11
9
19
10
4
9
29
29
9
7
8
6 720 641 933-104.1o
Fig. 97 Group 3 - Gas valve Greenstar
6 720 806 992 (2013/07)
Greenstar














































































ZWB42-3A



ZWB28-3A


ZBR42-3A


ZBR35-3A


ZWB35-3A
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
29
ZBR28-3A
4
Designation
Fan RG130 USA
Diaphragm
Air limiter
Air limiter
Gas valve USA, incl. 9 Washer 18.3x24.3 (item 4) and Port
screw (item 29).
Gas pipe below USA
Fibre gasket 25x30x1.5 (10x)
Washer 18.3x24.3 (10x)
Pipe
Gas pipe top USA
O-ring (10x)
Gas pipe
Cover
Safety clip 18mm (10x)
Gasket
Fan RG128 USA
O-ring (10x)
Screw m4x6 taptite zc pl p/h
Air limiter
Connecting flange
Port screw
ZBR21-3A
Item ( Fig. 97)
1
2
3
ZBR16-3A
Spare parts | 83





















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
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
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
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


















Order number
8 718 226 185 0
8 715 505 928 0
8 710 505 210 0
8 710 505 212 0
8 718 226 391 0
8 718 225 756 0
8 710 103 014 0
8 710 103 161 0
8 718 221 063 0
8 718 225 762 0
8 710 205 103 0
8 710 735 387 0
8 712 305 092 0
8 716 771 169 0
8 729 000 183 0
8 718 226 184 0
8 722 880 175 0
2 914 411 424 0
8 718 220 416 0
8 710 506 279 0
8 718 222 744 0
Table 47 Group 3 - Gas valve Greenstar
Greenstar
6 720 806 992 (2013/07)
84 | Spare parts
28
11
12
29
9
7
24
12
11
5
13
10
8
10
6
6
23
22
25
11
14
16
11
3
15
18
21
1
27
26
27
20
17
15
2
19
7
20
7
4
6 720 641 933-105.1o
Fig. 98 Group 4 - Pipes combi boiler ZWB..-3A Greenstar
6 720 806 992 (2013/07)
Greenstar
ZWB28-3A
ZWB35-3A
ZWB42-3A
ZBR42-3A
ZBR35-3A
ZBR28-3A
Designation
Condensate trap complete
Cup incl. gasket
Drain hose
Drain Tee
Expansion vessel connecting pipe complete
Safety clip 10mm (10x)
Gasket 18.6 X 13.5 X 1.5 (10x)
O-ring 12.5x3 WRAS / KTW (10x)
Supply pipe USA ZWB - combi boiler
Gasket 18.5x24.3 (10x)
O-ring 17x4 (10x)
Safety clip (10x)
Upper heating return pipe complete
Lower heating return pipe complete
Fibre gasket 23.9 X 17.2 X 1.5 (10x)
Safety clip inlet adapter
Fresh water inlet pipe
Safety clip supply sensor
DHW outlet pipe
Wire form spring 18mm (10x)
Supply pipe
Pressure gauge USA complete
O-ring 2.62 x 6.02 ID EPDM (10x)
Gasket 1" (10x)
O-ring 26.34 x 5.33 (5X)
Gasket set
O-ring 13.87 x 3.53 (10X)
Adapter LWCO
Temperature sensor
ZBR21-3A
Item ( Fig. 98)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
ZBR16-3A
Spare parts | 85




















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
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





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

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
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


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



















Order number
8 710 506 271 0
8 710 506 273 0
8 710 703 178 0
8 710 735 076 0
8 710 735 318 0
8 716 771 167 0
8 710 103 045 0
8 716 107 437 0
8 737 701 821 0
8 716 771 259 0
8 716 771 154 0
8 711 200 024 0
8 710 735 324 0
8 710 735 396 0
8 710 103 043 0
8 716 106 432 0
8 710 735 430 0
8 716 106 488 0
8 710 735 427 0
8 716 771 169 0
8 710 735 428 0
8 718 226 104 0
8 716 140 810 0
8 710 103 046 0
8 710 205 098 0
8 710 103 154 0
8 716 771 155 0
8 718 226 386 0
8 714 500 117 0
Table 48 Group 4 - Pipes combi boiler ZWB..-3A Greenstar
Greenstar
6 720 806 992 (2013/07)
86 | Spare parts
26
25
30
28
29
19
9
9
20
22
18
21
9
9
8
16
15
13
9
9
17
14
12
11
12
23
10
1
24
9
3
6
2
7
5
4
6 720 641 933-106.2O
Fig. 99 Group 5 - Pipes heating boiler ZBR..-3A Greenstar
6 720 806 992 (2013/07)
Greenstar























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




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



















ZWB42-3A
ZBR42-3A





























ZWB35-3A
ZBR35-3A





























ZWB28-3A
ZBR28-3A
Designation
Condensate trap complete
Cup incl. gasket
Drain hose
Drain Tee
Pressure gauge USA complete
Safety clip 10mm (10x)
O-ring 2.62 x 6.02 ID EPDM (10x)
Supply pipe USA ZB complete
Gasket 1" (10x)
PRV group USA complete USA
Safety clip 18mm (10x)
Safety clip 10mm (10x)
Dummy plug
Safety relief valve USA 30 psi
O-ring 13.87x3.53 (10x)
PRV drain adapter and hose complete
Fill and drain valve
Pump ZBR USA complete - heating boiler
Adapter pipe
Gasket 18.6 X 13.5 X 1.5 (10x)
Pump power cord USA
Plug complete
O-ring 26.34 x 5.33 (5X)
Gasket set
Temperature sensor
Air vent valve
Adapter LWCO
O-ring 17 x 4 (10x)
Safety clip (10x)
ZBR21-3A
Item ( Fig. 99)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
28
29
30
ZBR16-3A
Spare parts | 87
Order number
8 710 506 271 0
8 710 506 273 0
8 710 703 178 0
8 710 735 076 0
8 718 226 104 0
8 716 771 167 0
8 716 140 810 0
8 737 701 819 0
8 710 103 046 0
8 718 226 182 0
8 716 771 169 0
8 716 771 167 0
8 718 226 183 0
8 737 703 427 0
8 716 771 155 0
8 710 725 760 0
8 738 505 955 0
8 718 226 172 0
8 710 735 450 0
8 710 103 045 0
8 718 660 838 0
8 713 301 152 0
8 710 205 098 0
8 710 103 154 0
8 714 500 117 0
8 716 838 449 0
8 718 226 386 0
8 716 771 154 0
8 711 200 024 0
Table 49 Group 5 - Pipes heating boiler ZBR..-3A Greenstar
Greenstar
6 720 806 992 (2013/07)
88 | Spare parts
10
8
35
8
8
7
4
8
12
20
8
1
3
9
6
31
2
30
11
13
16
22
23
24
17
21
15
14
25
6 720 641 933-107.3O
Fig. 100 Group 6 - Control box Greenstar
6 720 806 992 (2013/07)
Greenstar
11
12
13
14
15
16
17
20
21
22
23
24
25
30
31
35
–
–
–
–
–
–
–
–
–
–
–
–
–
–
ZBR28-3A
ZBR35-3A
ZBR42-3A
ZWB28-3A
ZWB35-3A
ZWB42-3A
Designation
Heatronic control unit complete
Dial
Blind cover
Top cover
Set of connectors
Main circuit board
Plastic screw (10x)
Backpanel
Code plug 2501 (ZBR16-3A NG)
Code plug 2502 (ZBR21-3A NG)
Code plug 2502 (ZBR28-3A NG)
Code plug 2503 (ZBR35-3A NG)
Code plug 2504 (ZBR42-3A NG)
Code plug 2520 (ZWB28-3A NG)
Code plug 2524 (ZWB35-3A NG)
Code plug 2500 (ZWB42-3A NG)
Code plug 2506 (ZBR16-3A LPG)
Code plug 2503 (ZBR21-3A LPG)
Code plug 2507 (ZBR28-3A LPG)
Code plug 2508 (ZBR35-3A LPG)
Code plug 2509 (ZBR42-3A LPG)
Code plug 2521 (ZWB28-3A LPG)
Code plug 2525 (ZWB35-3A LPG)
Code plug 2505 (ZWB42-3A LPG)
Front cover
Grommet (10x)
Fan harness
Ignition harness
Ground cable
Pump power cord USA
Cable harness ZWB - combi boiler
Cable harness ZBR - heating boiler
Fuse
Internal main power cord complete (white plug)
Internal tank loading pump power cord complete (red plug)
Internal system pump power cord complete (black plug)
DHW tank temperature sensor
System supply temperature sensor
FW200 Bosch USA en-us, fr, es, de
Outdoor temperature sensor
Clip
Gas conversion kit ZBR16-3A from LPG (31) to NG (23)
Gas conversion kit ZBR21-3A from LPG (31) to NG (23)
Gas conversion kit ZBR28-3A from LPG (31) to NG (23)
Gas conversion kit ZBR35-3A from LPG (31) to NG (23)
Gas conversion kit ZBR42-3A from LPG (31) to NG (23)
Gas conversion kit ZWB28-3A from LPG (31) to NG (23)
Gas conversion kit ZWB35-3A from LPG (31) to NG (23)
Gas conversion kit ZWB42-3A from LPG (31) to NG (23)
Gas conversion kit ZBR16-3A from NG (23) to LPG (31)
Gas conversion kit ZBR21-3A from NG (23) to LPG (31)
Gas conversion kit ZBR28-3A from NG (23) to LPG (31)
Gas conversion kit ZBR35-3A from NG (23) to LPG (31)
Gas conversion kit ZBR42-3A from NG (23) to LPG (31)
Gas conversion kit ZWB28-3A from NG (23) to LPG (31)
Gas conversion kit ZWB35-3A from NG (23) to LPG (31)
Gas conversion kit ZWB42-3A from NG (23) to LPG (31)
ZBR21-3A
Item ( Fig. 100)
1
2
3
4
6
7
8
9
10
ZBR16-3A
Spare parts | 89

















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

















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


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



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
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

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




























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
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

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

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



























Order number
8 717 207 928 0
8 716 011 785 0
8 711 000 302 0
8 717 207 680 0
8 714 404 348 0
8 748 300 651 0
8 713 403 029 0
8 613 560 409 0
8 714 432 501 0
8 714 432 528 0
8 714 432 502 0
8 714 432 503 0
8 714 432 504 0
8 714 432 520 0
8 714 432 524 0
8 714 432 500 0
8 714 432 506 0
8 714 432 529 0
8 714 432 507 0
8 714 432 508 0
8 714 432 509 0
8 714 432 521 0
8 714 432 525 0
8 714 432 505 0
8 737 702 329 0
8 710 506 185 0
8 718 660 837 0
8 716 106 799 0
8 716 106 980 0
8 718 660 838 0
8 718 226 066 0
8 718 226 067 0
8 744 503 045 0
8 737 701 320 0
8 737 701 321 0
8 737 701 322 0
8 737 701 343 0
8 737 700 289 0
8 718 226 215 0
8 747 207 101 0
8 718 225 176 0
8 737 701 741 0
8 737 704 884 0
8 737 701 742 0
8 737 701 743 0
8 737 701 744 0
8 737 701 745 0
8 737 704 867 0
8 737 701 740 0
8 737 701 747 0
8 737 704 883 0
8 737 701 748 0
8 737 701 749 0
8 737 701 750 0
8 737 701 751 0
8 737 704 684 0
8 737 701 746 0
Table 50 Group 6 - Control box Greenstar
Greenstar
6 720 806 992 (2013/07)
90 | Spare parts
3
6
5
4
2
2
7
9
2
8
2
10
2
15
12
13
12
17
11
13
14
16
2
1
9 26
12
12
22
42
9
6
45
45
29
21
28
23
47
21
25
26
9
24
2
14
18
2
19
37
13
11
35
41
27
29
12
40
31
5
36
29
46
38
34
39
39
33
33
30
4
10
32
6 720 641 933-108.2O
Fig. 101 Group 7 - Hydraulic block combi boiler ZWB..-3A Greenstar
6 720 806 992 (2013/07)
Greenstar
ZWB35-3A
ZWB42-3A
ZBR42-3A
ZBR35-3A
ZBR28-3A
ZWB28-3A
39
40
41
42
45
46
47
Designation
Flat plate heat exchanger 20 plates
Flat plate heat exchanger gasket 15mm
Supply manifold complete
Screw M5x32
Rubber bushing
Gasket 18.5x24.3 (10x)
DHW temperature sensor
O-ring 7.75x2.1 (10x)
Safety clip 10mm (10x)
Screw & Gasket assembly M5x30
O-ring 12.5x3 WRAS / KTW (10x)
Safety clip 18mm (10x)
Safety clip 13mm (1x)
Dummy plug complete
O-ring 13.87 x 3.53 (10x)
PRV Tee complete
O-ring 17 x 4 (10x)
Boiler pump USA complete
Safety clip pump
O-ring 23x4 (10x)
Air vent valve
Return assembly complete
Safety clip supply sensor
Pressure relief valve DHW
O-ring 2.62 x 6.02 ID EPDM (10x)
Drain valve
Pressure relief valve USA complete
O-ring 13.87x3.53 (10x)
Safety clip inlet adapter
Diverter valve assembly
Diverter valve actuator motor
Screw M5 Stainless
Flow turbine adapter
Flow turbine complete
DHW filter insert
O-ring 22x3 EPDM (10x)
Flow regulator 15 l/m 4 gpm
Flow regulator 10 l/m 2.6 gpm
Silencer body
Dummy plug complete
O-ring (10x)
O-ring 12.5x3 WRAS / KTW (10x)
O-ring 17x4 (10x)
Diverter valve housing
PRV drain adapter and hose complete
ZBR21-3A
Item ( Fig. 101)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
ZBR16-3A
Spare parts | 91
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Order number
8 716 108 212 0
8 716 106 435 0
8 716 106 356 0
8 716 771 687 0
8 716 106 425 0
8 716 771 259 0
8 714 500 081 0
8 710 205 080 0
8 716 771 167 0
8 716 106 452 0
8 716 107 437 0
8 716 771 169 0
8 716 106 549 0
8 716 106 566 0
8 716 771 155 0
8 715 502 114 0
8 716 771 154 0
8 718 226 173 0
8 716 106 438 0
8 716 771 353 0
8 716 106 445 0
8 716 106 844 0
8 716 106 488 0
8 717 401 029 0
8 716 140 810 0
8 716 771 432 0
8 737 703 427 0
8 716 771 155 0
8 716 106 432 0
8 716 106 845 0
8 716 106 847 0
8 716 106 848 0
8 716 106 433 0
8 716 107 223 0
8 716 106 486 0
8 716 106 747 0
8 716 105 869 0
8 737 702 418 0
8 716 106 485 0
8 716 106 567 0
8 716 107 436 0
8 716 107 437 0
8 716 771 154 0
8 716 112 786 0
8 710 725 760 0
Table 51 Group 7 - Hydraulic block combi boiler ZWB..-3A Greenstar
Greenstar
6 720 806 992 (2013/07)
ZBR42-3A
ZWB28-3A
ZWB35-3A
ZWB42-3A
Brush set WB5
Cleaning blade WB5
Grease HFT1V5
Grease Unisilkon L641
Heat conducting paste
ZBR35-3A
–
–
–
–
–
ZBR28-3A
Designation
SAK3 – Heat exchanger service accessory kit (main heat
exchanger gaskets, heat exchanger brush, heat exchanger
cleaning blade)
ZBR21-3A
Item
–
ZBR16-3A
92 | Spare parts
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Order number
7 719 001 998
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7 719 002 502
7 719 002 503
8 709 918 010 0
8 709 918 413 0
8 719 918 658 0
Table 52 Group 8 - Accessories for service/installation Greenstar
6 720 806 992 (2013/07)
Greenstar
Index | 93
Index
A
Accessories ............................................................................... 8
Anti-freeze .............................................................................. 28
Appliance description ................................................................. 7
Appliance details ........................................................................ 9
Accessories .......................................................................... 8
Minimum clearances .............................................................. 9
Technical data
- ZBR16-3A... ................................................................ 18
- ZBR21-3A... ................................................................ 19
- ZBR28-3A... ................................................................ 20
- ZBR35-3A... ................................................................ 21
- ZBR42-3A... ................................................................ 22
- ZWB28-3A... ............................................................... 23
- ZWB35-3A... ............................................................... 24
- ZWB42-3A... ............................................................... 25
ZBR..-3A appliance layout..................................................... 10
ZWB..-3A appliance layout .................................................... 12
Appliance information ................................................................. 7
Appliance layout
ZBR..-3A ............................................................................ 10
ZWB..-3A ........................................................................... 12
Automatic anti-cycle time (service function 3.A) ........................... 54
B
Bleeding.................................................................................. 47
Bleeding function................................................................. 54
C
Call up last fault saved ............................................................... 63
Call up latest fault code ............................................................. 56
Changing the sensor curve of the heating pump ............................ 51
Check gas supply dynamic pressure ............................................ 61
Checking the electrical wiring ..................................................... 67
Checking the flue system ........................................................... 62
Checklist for inspection and maintenance .................................... 68
Combustion air......................................................................... 30
Commissioning ........................................................................ 47
Bleeding ............................................................................. 47
Commissioning log ................................................................... 75
Condensate composition ........................................................... 26
Condensate trap....................................................................... 67
Connecting
3-way valve (ZBR only) ......................................................... 45
DHW tank ........................................................................... 42
Supply temperature sensor ................................................... 43
Tank primary pump (ZBR only) .............................................. 45
Corrosion inhibitors .................................................................. 29
D
Details about the appliance
Proper use ........................................................................... 7
Scope of delivery................................................................... 5
Technical specifications
- ZBR16-3A................................................................... 18
- ZBR21-3A................................................................... 19
- ZBR28-3A................................................................... 20
- ZBR35-3A................................................................... 21
- ZBR42-3A................................................................... 22
- ZWB28-3A... ............................................................... 23
- ZWB35-3A... ............................................................... 24
- ZWB42-3A... ............................................................... 25
Type overview....................................................................... 7
DHW circulation....................................................................... 28
Dimensions ............................................................................... 9
Disposal ................................................................................. 62
E
ECO button .............................................................................
Electrical connection ................................................................
3-way valve (ZBR only).........................................................
Connecting accessories........................................................
Connecting LWCO device .....................................................
Connecting power supply .....................................................
DHW circulation pump .........................................................
DHW tank...........................................................................
Heating control, remote control units .....................................
Supply temperature sensor...................................................
Tank primary pump (ZBR only) ..............................................
Temperature limiter .............................................................
Electrical connections
Temperature limiter .............................................................
Electrical wiring
ZBR..-3A............................................................................
ZWB..-3A... ........................................................................
Energy saving ..........................................................................
Environmental responsibility .....................................................
Expansion vessel......................................................................
43
14
16
48
62
67
F
Fault codes ............................................................................. 70
Faults..................................................................................... 70
Not shown on the display...................................................... 73
Shown on the display ........................................................... 71
First service level ..................................................................... 53
Flue gas accessories................................................................. 33
Frost protection....................................................................... 50
Fuses .......................................................................... 14, 16, 41
G
Gas and water connections........................................................
Gas type .................................................................................
Adjustment.........................................................................
Conversion.........................................................................
Conversion kit.....................................................................
Gas/air ratio ............................................................................
Gravity heating systems ............................................................
Greenstar
49
67
45
43
46
45
44
42
43
43
45
44
41
59
59
59
59
60
28
6 720 806 992 (2013/07)
94 | Index
H
O
Heating control ........................................................................ 48
Heatronic
Service functions ..................................................... 52–58, 63
Settings.............................................................................. 52
Old appliances......................................................................... 62
Open vented heating systems .................................................... 28
Operating conditions .............................................. 18–20, 23–25
Operating pressure of the boiler ................................................. 67
Overview of the service functions ............................................... 52
I
Information about the appliance ................................................... 7
Inspection and maintenance ...................................................... 62
Inspection and maintenance steps
Call up last fault saved .......................................................... 63
Checking electrodes............................................................. 64
Checking the burner............................................................. 65
Checking the electrical wiring ................................................ 67
Checking the expansion vessel............................................... 67
Checking the heat exchanger block......................................... 65
Cleaning condensate trap...................................................... 67
Plate-type heat exchanger (ZWB..-3A) .................................... 63
Setting the boiler water pressure............................................ 67
Installation .............................................................................. 28
Installation location .............................................................. 30
Pre-installing pipes .............................................................. 30
Installation location
Combustion air.................................................................... 30
Heating appliance ................................................................ 30
Higher than 2000 feet (610 m) above sea level........................ 59
Installation location requirements .......................................... 30
Surface temperature ............................................................ 30
K
Key pad lock ............................................................................ 50
L
Liquified propane gas................................................................ 59
Low water cut off...................................................................... 32
LPG .................................................................................. 29, 59
M
Mains fuse ................................................................... 14, 16, 41
Maintenance and inspection log book .......................................... 68
Making the electrical connections ............................................... 41
Measuring CO content of flue gas ................................................ 62
Minimum clearances ................................................................... 9
Mounting the appliance ............................................................. 32
N
Natural gas .................................................................. 18–25, 59
NG ............................................................................. 18–25, 59
Nominal heating output
Maximum............................................................................ 53
Minimum ............................................................................ 55
Notes on inspection and maintenance ......................................... 62
6 720 806 992 (2013/07)
P
Packaging ............................................................................... 62
Piping systems, galvanized ........................................................ 28
Plastic pipework ...................................................................... 28
Proper use ................................................................................ 7
Protective measures for flammable building materials and built-in
furniture ............................................................................ 30
Pump anti-seizing protection ..................................................... 51
R
Radiators, galvanized ...............................................................
Recycling ................................................................................
Regulations .............................................................................
Requirements for the installation location ....................................
Room temperature-controlled control .........................................
28
62
26
30
28
S
Scope of delivery ....................................................................... 5
Sealant................................................................................... 29
Second service level ................................................................. 57
Service functions
3-way valve in center position
(service function 7.b) ...........................................................57
Adaptation to elevation above sea level
(service function 0.d) ...........................................................57
Anti-cycle time
(service function 3.b) ...........................................................55
Appliance type
(service function 4.E) ...........................................................55
Audible warning tone
(service function 4.d) ...........................................................55
Bleeding function
(service function 2.C) ...........................................................54
Building drying function
(service function 7.E) ...........................................................57
Code plug number
(service function 3.b) ...........................................................57
Condensate trap filling sequence
(service function 4.F) ...........................................................56
Connecting an external supply temperature sensor
(service function 7.d) ...........................................................57
Constant mode
(service function 9.A) ...........................................................58
Current fan speed
(service function 9.b) ...........................................................58
Current heat demand
(service function C.d) ...........................................................58
Current heating output
(service function 9.C) ...........................................................58
Current turbine flow rate (only ZWB..-3A)
(service function 6.d) ...........................................................56
DHW heating delay (solar module)
Greenstar
Index | 95
(service function b.F) .......................................................... 58
DHW output
(service function 1.b) .......................................................... 53
DHW temperature
(service function A.b) .......................................................... 58
Display inspection
(service function 5.F) .......................................................... 56
Fan post purge time
(service function 5.b) .......................................................... 56
GFA fault
(service function 8.d) .......................................................... 57
GFA status
(service function 8.C) .......................................................... 57
Indicator lamp for burner operation / faults
(service function 7.A) .......................................................... 56
Last fault saved
(service function 6.A) .....................................................56, 63
Maximum heating output
(service function 1.A) .......................................................... 53
Maximum supply temperature
(service function 2.b) .......................................................... 54
Metric or US customary units
(service function 0.E) .......................................................... 57
Minimum heating/DHW output
(service function 3.d) .......................................................... 55
Operating mode
(service function 2.F) .......................................................... 54
Permanent ignition
(service function 8.F) .......................................................... 58
Pump control mode for heating operation
(service function 1.E) .......................................................... 53
Pump lockout time (only ZBR..-3A)
(service function 2.A) .......................................................... 54
Pump mode (only ZBR..-3A)
(service function 1.F) .......................................................... 53
Pump post purge time (heating)
(service function 9.F) .......................................................... 58
Reset service reminder
(service function 5.A) .......................................................... 56
Restore appliance (Heatronic 3) to factory settings
(service function 8.E) .......................................................... 58
Set connection NP - LP
(service function 5.E) .......................................................... 56
Set start speed 1
(service function 9.d) .......................................................... 58
Software version
(service function 8.A) .......................................................... 57
Supply temperature required by outdoor reset control (service
function 6.C) ...................................................................... 56
Switching differential
(service function 3.C) .......................................................... 55
Temperature at tank temperature sensor
(service function A.C) .......................................................... 58
Turbine signal delay (only ZWB..-3A)
(service function 9.E) .......................................................... 58
Voltage terminal 2
Greenstar
(service function 6.b) ...........................................................56
Service level
First service level ................................................................ 53
Second service level ............................................................ 57
Set connection NP - LP.............................................................. 56
Settings
Changing sensor curve of the heating pump............................. 51
Shutdown ............................................................................... 48
Spare Parts ............................................................................. 77
Steps for inspection and maintenance......................................... 63
Summer mode......................................................................... 49
Surface temperature ................................................................ 30
Switching the appliance OFF ..................................................... 48
Switching the appliance ON ....................................................... 48
T
Technical data ................................................................... 18–25
ZBR16-3A.......................................................................... 18
ZBR21-3A.......................................................................... 19
ZBR28-3A.......................................................................... 20
ZBR35-3A.......................................................................... 21
ZBR42-3A.......................................................................... 22
ZWB28-3A... ...................................................................... 23
ZWB35-3A... ...................................................................... 24
ZWB42-3A... ...................................................................... 25
Technical specifications ...................................................... 18–25
Testing gas line ........................................................................ 41
Testing water connections......................................................... 41
Thermal disinfection................................................................. 50
Turning the space heating ON .................................................... 48
Type of gas................................................................................ 7
Type overview ........................................................................... 7
W
Water Chemistry Guidelines ...................................................... 28
Z
ZBR..-3A................................................................................. 10
ZWB..-3A................................................................................ 12
6 720 806 992 (2013/07)
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