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Bosch ZWB 42-3 A NG User Manual

Bosch ZWB 42-3 A NG
80 pages
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6721822579 (2021/01) US/CA
Installation and Service Instructions for Contractors
Residential Gas Condensing Boiler
Greenstar
0010004900-002
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.
These instructions are available in English and French.
Please keep these instructions for future reference.
ZBR 21-3 A... | ZBR 28-3 A... | ZBR 35-3 A... | ZBR 42-3 A... | ZWB 28-3 A... | ZWB 35-3 A... |
ZWB 42-3 A...

Table of Contents

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Bosch ZWB 42-3 A NG Specifications

General IconGeneral
BrandBosch
ModelZWB 42-3 A NG
CategoryBoiler
LanguageEnglish

Summary

Explanation of Symbols and Safety Instructions

Explanation of Symbols

Defines signal words and symbols used in warnings to indicate risk severity.

General Safety Instructions

Provides crucial safety advice for gas leaks, flue gas, and general operation.

Scope of Delivery

ZBR...-3A - Residential Boiler for Space Heating and DHW Tank Loading

Details the components included in the package for ZBR...-3A boilers.

ZWB...-3A - Residential Combi Boiler for Space Heating and DHW Generation

Lists the package contents for ZWB...-3A combi boilers.

Product Description

Proper Use

Specifies the intended use of the Greenstar boiler and prohibits improper applications.

Overview of Boiler Types

Lists available boiler models (ZBR/ZWB) with their specifications and meanings.

Rating Plate

Describes the location and information provided on the appliance's data plate.

Appliance Description

Details the key features and components of the boiler's design and functionality.

Accessories

Refers to the Bosch Product Catalog for a complete list of available accessories.

Product Dimensions and Minimum Clearances

Illustrates the physical dimensions and required installation clearances for the appliance.

Appliance Layout Heating Boiler ZBR...-3A

Provides a labeled diagram of the internal components of the ZBR...-3A heating boiler.

Appliance Layout ZWB...-3A

Presents a detailed diagram of the internal components of the ZWB...-3A combi boiler.

Electrical Wiring ZBR...-3A

Shows the electrical wiring diagram for the ZBR...-3A model, detailing connections.

Electrical Wiring ZWB...-3A

Displays the electrical wiring diagram specific to the ZWB...-3A combi boiler.

Technical Data ZBR...-3A

Lists detailed technical specifications, including input/output, gas, flue, and general data for ZBR...-3A.

Technical Data ZWB...-3A

Provides detailed technical specifications for ZWB...-3A models, including input/output and gas data.

Condensate Composition

Details the typical chemical composition and concentrations found in the boiler's condensate.

Regulations

Compliance with Standards and Regulations

Outlines applicable codes, standards, and regulations for installation and operation.

Operating Limits of the Boiler

Specifies the maximum temperature and operating pressure limits for the boiler.

Additional Regulations for Installations in Massachusetts

Lists specific installation requirements for Massachusetts, including CO detectors and signage.

Examples of Installations

Multiple Zones Using Zone Valves with DHW

Illustrates a piping diagram for a multi-zone system using zone valves and DHW.

Multiple Zones Using Circulators

Shows a piping diagram for a multi-zone system utilizing circulators.

Notes on Installation and Operation

Notes on Installation and Operation

General guidelines for installation, including elevation, local codes, and system water quality.

Other Important Information

Covers compliance with codes, venting systems, and disposal of condensate.

Water Supply Pressure

Details recommended and maximum water supply pressures and related precautions.

Comparing Integrated Expansion Vessel Size

Provides diagrams to verify the integrated expansion vessel's capacity for heating systems.

Selecting an External Expansion Vessel (ZBR...-3A)

Guides on selecting an external expansion vessel based on local regulations.

Selecting the Installation Location

Lists requirements for choosing an installation location, including codes and combustion air quality.

Pre-installing Pipes

Instructions for preparing and installing pipes using a mounting template before appliance installation.

Mounting the Appliance

Steps for mounting the appliance, including piping preparation and cover removal.

Installing the Low Water Cut Off (LWCO)

Details the installation process for the LWCO device, including safety precautions.

Connecting Flue Gas Accessories

Explains the types of optional vent systems and how to connect flue gas accessories.

Installation of Exhaust and Air Intake System

Covers the installation of exhaust and air intake systems, including safety notices.

Approved Horizontal and Vertical Venting Installation Examples

Provides illustrated examples of approved horizontal and vertical venting configurations.

Vent and Combustion Air Pipe Lengths

Specifies maximum vent and combustion air pipe lengths based on configuration and appliance type.

Testing Gas and Water Connections for Leaks

Outlines procedures for performing leakage tests on gas and water connections.

Electrical Connection

General Notes

Provides essential safety notes, electrical codes, and fuse information for boiler installation.

Low Voltage Connections in Heatronic Boiler Control

Details how to access and connect low voltage components to the Heatronic boiler control.

Electrical Connections in the Junction Box (120 VAC)

Explains how to make electrical connections within the 120 VAC junction box for various accessories.

Connecting the LWCO Device

Provides step-by-step instructions for connecting the LWCO device, including cable routing.

Commissioning

Before Operating the Appliance

Lists critical checks and procedures before the initial operation of the appliance.

Switching the Appliance ON/OFF

Describes how to turn the appliance on and off, including purging sequences.

Switch on Heat

Guides on setting the maximum supply temperature based on building heat loss.

Programming the Bosch Room Controller

Refers to the room controller's manual for setting operating modes and temperature.

After Commissioning

Lists final checks to be performed after the commissioning process is completed.

ZBR...-3A Appliances: Setting the DHW Temperature

Explains how to set the domestic hot water temperature for ZBR...-3A heating boilers.

ZWB...-3A Appliances: Setting the DHW Temperature

Details how to adjust the DHW temperature for ZWB...-3A combi boilers.

Setting Manual Summer Mode

Describes how to set the appliance for manual summer mode or warm weather shutdown.

Setting Frost Protection

Provides instructions for setting frost protection for both the heating system and DHW tank.

Activating the Key Pad Lock

Explains how to activate the key pad lock to prevent unauthorized access to boiler settings.

ZBR...-3A Appliances (Heating Boiler) with DHW Tank: Thermal Disinfection

Boiler Circulator

Pump Anti-Seize Protection

Explains the pump anti-seize function to prevent seizing during idle periods.

Changing the Pump Curve of the Boiler Pump

Guides on how to adjust the boiler pump's speed using the dial.

Heatronic Boiler Control Settings

Guideline to Service Functions

Introduces the Heatronic control's service functions and how to navigate them.

Overview of the Service Functions

Provides a comprehensive list of available service functions and their corresponding pages.

Gas Adjustment

Converting to a Different Gas Type

Details the process and precautions for converting the boiler to a different gas type.

Installation Location Higher Than 2,000 Feet (610 m)

Explains how altitude affects appliance performance and the need for adjustment.

Checking and Setting the Gas-Air Ratio (CO2 or O2)

Guides on checking and adjusting the gas-air ratio for optimal combustion.

Dynamic Gas Pressure Test Port

Explains how to use the dynamic gas pressure test port for testing inlet gas pressure.

Flue Gas Test

Emissions Test Button

Describes how to use the emissions test button to select different output modes for testing.

Measuring CO Content of Flue Gas

Provides instructions for measuring carbon monoxide levels in the flue gas safely.

Environmental Protection and Disposal

Packaging Method

Discusses Bosch's commitment to environmentally friendly packaging and recycling.

Old Appliances

Explains how old appliances can be recycled by separating components.

Inspection and Maintenance

Description of Various Steps

Details a comprehensive list of inspection and maintenance procedures for the boiler.

Maintenance and Inspection Checklist

Provides a checklist to guide technicians through the service and maintenance process.

Readings on the Display

Faults

Troubleshooting

Offers general troubleshooting advice and safety warnings for addressing faults.

Faults That Are Shown on the Display

Lists fault codes displayed by the appliance and their corresponding elimination steps.

Faults That Are Not Shown on the Display

Describes operational issues or faults that may not trigger a display code.

Check Sensor Values

Provides resistance tables for checking various temperature sensors for proper function.

Replacement Code Plug

Lists part numbers for replacement code plugs for various boiler models.

Commissioning Log for the Appliance

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