Bosch CONDENS 5000W Manuals

Information regarding routing flue gas Wall mounted gas fired condensing boilers Condens 5000 W 6 720 644 146-00.1O ZSB 30-2 A ... | ZWB 37-2 A ... 6 720 644 146 (2019/03) NZ/AU Condens 5000 W – 6720644146 (2019/03) 2 Contents Contents 1 Explanation of symbols and safety instructions . . . . . . . . . . . . 2 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 2 2 Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Wall mounted gas fired condensing boiler . . . . . . . . . . . . 4 2.3 Combination with flue duct kits . . . . . . . . . . . . . . . . . . . . 4 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.2 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.3 Routing the flue vertically . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.3.1 Extension with flue accessories . . . . . . . . . . . . . . . . . . . . 6 3.3.2 Routing the flue gas over the roof . . . . . . . . . . . . . . . . . . . 6 3.3.3 Installation location and balanced flue . . . . . . . . . . . . . . . 6 3.3.4 Layout of cleaning apertures: . . . . . . . . . . . . . . . . . . . . . . 6 3.4 Routing horizontal flues . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.4.1 Extension with flue accessories . . . . . . . . . . . . . . . . . . . . 6 3.4.2 Routing a balanced flue type C13 over the external wall . 6 3.4.3 Routing a balanced flue type C33 via the roof . . . . . . . . . 6 3.4.4 Layout of cleaning apertures . . . . . . . . . . . . . . . . . . . . . . 6 4 Fitted dimensions (in mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.1 Balanced flue as concentric pipe . . . . . . . . . . . . . . . . . . . 7 4.2 Vertical flue connection . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5 Flue lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.2 Determining the flue length . . . . . . . . . . . . . . . . . . . . . 11 5.2.1 Installation analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.2.2 Determining the parameters . . . . . . . . . . . . . . . . . . . . . 11 5.2.3 Calculation of the equivalent pipe length Lequiv . . . . . 11 5.3 Flue gas routing options . . . . . . . . . . . . . . . . . . . . . . . . 12 5.4 Example for calculating the flue lengths (Fig. 9) . . . . . 14 5.5 Template for calculating the flue length . . . . . . . . . . . . 15 1 Explanation of symbols and safety instructions 1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken. The following signal words are defined and can be used in this document: • DANGER indicates that severe or life-threatening personal injury will occur. • WARNING indicates that severe to life-threatening personal injury may occur. • CAUTION indicates that minor to medium personal injury may occur. • NOTICE indicates that material damage may occur. Important information Additional symbols 1.2 General safety instructions Notices for the target group These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life. ▶ Read the installation instructions (heat source, heating controller, etc.) before installation. ▶ Observe the safety instructions and warnings. ▶ Follow national and regional regulations, technical regulations and guidelines. ▶ Record all work carried out. If you are in any doubt contact the Robert Bosch technical hotline on: 1300 30 70 37 AU or 0800 54 33 52 NZ Determined use The product may only be used in a domestic situation for the heating of central heating water and for DHW heating in closed-loop DHW and heating systems. Any other use is considered inappropriate. Any damage that may result from misuse is excluded from liability. This appliance is not suitable to be used as a pool heater. If you smell gas A gas leak could potentially cause an explosion. If you smell gas, observe the following rules. ▶ Prevent flames or sparks: – Do not smoke, do not use a lighter or strike matches. – Do not operate any electrical switches or unplug any equipment. – Do not use the telephone or ring doorbells. This symbol indicates important information where there is no risk to people or property. Symbol Explanation ▶ Step in an action sequence  Cross-reference to another part of the document • List entry – List entry (second level) Table 1 Explanation of symbols and safety instructions Condens 5000 W – 6720644146 (2019/03) 3 ▶ Turn off the gas supply at the main shut-off valve or at the gas meter. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Move well away from the building: call the emergency services and the gas supplier. Danger to life from poisoning by flue gas There is a danger to life from escaping flue gas. ▶ Ensure that flues and gaskets are not damaged. Danger of death from poisoning by flue gas due to inadequate combustion Danger of death due to flue gas leak. If flues are damaged or leaking, or if you smell flue gas, observe the following rules. ▶ Close the fuel infeed. ▶ Open doors and windows. ▶ If necessary, warn all residents and leave the building. ▶ Prevent third parties from entering the building. ▶ Rectify any damage to the flue gas pipe immediately. ▶ Check the combustion air supply. ▶ Do not cover or reduce the size of ventilation openings in doors, windows and walls. ▶ Ensure that there is adequate combustion air supply, including for any appliances installed at a later date, e.g. extractor fans, kitchen fans or air conditioning units that discharge air to the outside. ▶ Never operate the device if there is insufficient combustion air supply. Open flued Appliance ▶ Do not use an unlined Masonry chimney as the flue for this appliance. Installation, commissioning and maintenance Installation, commissioning and maintenance must only be carried out by an approved contractor. ▶ Carry out a gas tightness test after completing work on gas-carrying components. ▶ In the case of open flue operation: Ensure that the installation location meets the ventilation requirements. ▶ Only use original spares. Electrical work Electrical work must only be carried out by electrical installation contractors. Before starting electrical work: ▶ Isolate all poles of the mains voltage and secure against reconnection. ▶ Make sure the mains voltage is disconnected. ▶ Observe the wiring diagrams of other system components as well. Handover to the user When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions. ▶ Explain how to operate the heating system and draw the user's attention to any safety relevant action ▶ Explain that conversions and repairs must only be carried out by a competent person. ▶ Point out the need for inspections and maintenance for safe and environmentally-compatible operation. ▶ Leave the installation instructions and the operating instructions with the user for safekeeping. ▶ Do not spray aerosols in the vicinity of this appliance while in operation. ▶ Do not use or store flammable materials in or near this appliance. ▶ Do not place articles on or against this appliance. ▶ Do not modify this appliance.

6 720 646 195 (2018/10) AU/NZ Installation and Maintenance Instructions Hydronic gas system boiler 18kW Bosch Condens 5000W 6720646195-00.1Wo ZSB18 - 2A Table of contents Bosch Condens 5000W – 6 720 646 195 (2018/10) 2 Table of contents 1 Explanation of symbols and safety instructions . . . . . . . . . . . 3 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 3 2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Boiler carton contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.1 Cleaning primary systems . . . . . . . . . . . . . . . . . . . . . . .11 3.2 Mains supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.2.1 Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.2.2 Equipotential (earth) bonding. . . . . . . . . . . . . . . . . . . .11 3.2.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.3 Water system and pipe work . . . . . . . . . . . . . . . . . . . . .11 3.4 Condensate pipe work. . . . . . . . . . . . . . . . . . . . . . . . . .13 3.4.1 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . .13 3.5 Pressure relief drain line . . . . . . . . . . . . . . . . . . . . . . . .14 3.6 Boiler location and clearances . . . . . . . . . . . . . . . . . . .15 3.6.1 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 3.6.2 Servicing clearances - ventilated compartment. . . . . .15 3.6.3 Compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 3.7 Plumbing manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 3.7.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 3.8 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 3.9 Flue options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 4.1 Unpacking the wall frame and ancillary items . . . . . . .20 4.2 Wall mounting template and flue opening. . . . . . . . . . .21 4.3 Unpacking the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . .22 4.4 Boiler connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 4.5 Flue installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 4.5.1 Measuring the flue (standard flue) . . . . . . . . . . . . . . . .25 4.5.2 Flue terminal plume re-direction. . . . . . . . . . . . . . . . . .27 4.6 Condensate connection. . . . . . . . . . . . . . . . . . . . . . . . .28 4.7 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 5 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 5.1 Pre-commissioning checks . . . . . . . . . . . . . . . . . . . . . .31 5.2 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.3 Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.4 Starting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 5.5 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 5.5.1 Checking the gas inlet pressure. . . . . . . . . . . . . . . . . . .34 5.5.2 Checking the gas rate. . . . . . . . . . . . . . . . . . . . . . . . . . .34 5.5.3 Domestic Hot Water: Controlling the hot water temperature.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.6 Starting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.6.1 Replace outer casing:. . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.6.2 Fitting fascia flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.6.3 Installing bottom panel . . . . . . . . . . . . . . . . . . . . . . . . .35 5.6.4 Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 6 Servicing and spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 6.1 Inspection and service: . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.2 Check the gas inlet pressure . . . . . . . . . . . . . . . . . . . . . 37 6.3 Checking flue integrity. . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.4 Fan pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.5 Flue gas analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.6 Setting the air/gas ratio. . . . . . . . . . . . . . . . . . . . . . . . . 39 6.6.1 Setting the CO/CO2. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6.7 Checking the heat exchanger . . . . . . . . . . . . . . . . . . . . 40 6.8 Replacement of parts . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6.8.1 Removing the outer case . . . . . . . . . . . . . . . . . . . . . . . . 43 6.8.2 Primary sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.8.3 Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.8.4 Flue overheat thermostat (with grommet) . . . . . . . . . . 43 6.8.5 Moving the control panel to the service position . . . . . 44 6.8.6 Gas valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 6.8.7 Air/gas manifold and fan assembly. . . . . . . . . . . . . . . . 45 6.8.8 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.8.9 Electrode assembly and burner . . . . . . . . . . . . . . . . . . 46 6.8.10 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.8.11 Access to boiler control components . . . . . . . . . . . . . . 48 6.8.12 PCB fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 6.8.13 Transformer/PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 6.8.14 Replacing the control panel. . . . . . . . . . . . . . . . . . . . . . 49 6.8.15 Syphon removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.8.16 Diverter valve motor (if option integral diverter valve fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.8.17 Diverter valve (if option integral diverter valve fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 6.8.18 Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.8.19 Pump head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.8.20 Drain tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.8.21 Pressure gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.8.22 Hydraulic block removal . . . . . . . . . . . . . . . . . . . . . . . . 52 6.8.23 CH pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . 53 6.8.24 Bypass valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.8.25 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.9 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 7 Fault finding and diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 7.1 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 7.1.1 Circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 7.2 Boiler operation function. . . . . . . . . . . . . . . . . . . . . . . . 59 7.3 Boiler prtection function . . . . . . . . . . . . . . . . . . . . . . . . 60 8 Technical Specifications/Logs . . . . . . . . . . . . . . . . . . . . . . . . . 61 8.1 Commissioning report for the appliance . . . . . . . . . . . 61 8.2 Inspection and maintenance checklist . . . . . . . . . . . . . 63 Explanation of symbols and safety instructions 3 Bosch Condens 5000W – 6 720 646 195 (2018/10) 1 Explanation of symbols and safety instructions 1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken. The following signal words are defined and can be used in this document: DANGER: DANGER indicates that severe or life-threatening personal injury will occur. WARNING: WARNING indicates that severe to life-threatening personal injury may occur. CAUTION: CAUTION indicates that minor to medium personal injury may occur. NOTICE: NOTICE indicates that material damage may occur. Important information The info symbol indicates important information where there is no risk to people or property. Additional symbols Table 1 1.2 General safety instructions PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. This installation manual is only applicable to the model of boiler stated on the front cover of this manual. This boiler must be installed by an authorised person only. Failure to install this boiler correctly could lead to prosecution. If you are in any doubt contact the Robert Bosch technical hotline on: 1300 30 70 37 AU or 0800 54 33 52 NZ Please leave these instructions, completed installation checklist and user manual with the customer after installing the boiler. Abbreviations used in this manual: Table 2 Abbreviations H If you smell gas: ▶Call the Federal Governments safety hotline on 13 17 92 ▶LPG boilers call the supplier’s number on the side of the LPG tank/cylinder. ▶Turn OFF the ECV (Emergency Control Valve) at the meter. ▶Do not turn electrical switches ON or OFF. ▶Do not strike makes or smoke. ▶Put out naked flames. ▶Open doors and windows. ▶Keep people away from the affected area. H Boiler operation This boiler must only be operated by a responsible adult who has been instructed in, understands, and is aware of the boiler's operating conditions and effects. Symbol Meaning ▶ a step in an action sequence  a reference to a related part in the document • a list entry – a list entry (second level) Ø Diameter NG Natural gas LPG Liquefied Petroleum Gas CH Central Heating DHW Domestic Hot Water PCB Printed Circuit Board PRV Pressure Relief Valve NTC Negative Temperature Coefficient (sensor) IP Ingress Protection RCD Residual Current Device TRV Thermostatic Radiator Valve approx. approximate BSP British Standard Pipe pH potential Hydrogen PVC Poly Vinyl Chloride RSF Room Sealed Flue kPa kilo Pascals

6720813952 (2019/02) AU Installation and maintenance instructions Wall mounted gas condensing boilers Condens 5000W ZBR 70-3 | ZBR 100-3 Table of contents Condens 5000W – 6720813952 (2019/02) 2 Table of contents 1 Explanation of symbols and safety instructions . . . . . . . . . . . 3 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 3 2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Appliance types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.3 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.5 Changing over the gas type . . . . . . . . . . . . . . . . . . . . . . . 5 2.6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.7 Removing the casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.8 Anti-Freeze Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.9 Pump test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.10 Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.11 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.12 Wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.13 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.14 Gas specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.15 Hydraulic resistances. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.16 Residual head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.1 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.2 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.3 Unpacking the wall mounted gas condensing boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.4 Check gas type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.5 Mounting the wall mounted gas condensing boiler . . . . 11 5.6 Remove the protective caps . . . . . . . . . . . . . . . . . . . . . 12 5.7 Connecting on the water and gas side . . . . . . . . . . . . . 12 5.8 Mounting the connection set (accessory) . . . . . . . . . . 12 5.8.1 Installing the gas isolator . . . . . . . . . . . . . . . . . . . . . . . . 12 5.8.2 Mounting the connection set. . . . . . . . . . . . . . . . . . . . . 13 5.9 Connection of heating pipes (without connection set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.9.1 Gas-side connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.9.2 Mounting the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.10 Install the low loss header . . . . . . . . . . . . . . . . . . . . . . . 14 5.11 Installing the siphon. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.12 Connecting the condensate drain. . . . . . . . . . . . . . . . . 15 5.13 Expansion vessel connection . . . . . . . . . . . . . . . . . . . . 15 5.14 Mounting the back panel insulation . . . . . . . . . . . . . . . 15 5.15 Connection of air supply and flue system. . . . . . . . . . . 15 5.15.1 Flue terminal positions . . . . . . . . . . . . . . . . . . . . . . . . . 15 6 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6.1 Control principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6.2 Connection of the control units. . . . . . . . . . . . . . . . . . . 17 6.3 Installation of the strain relief . . . . . . . . . . . . . . . . . . . . 17 6.4 Connecting the on/off room temperature- dependent control unit . . . . . . . . . . . . . . . . . . . . . . . . . 18 6.5 Connecting the modulating controller . . . . . . . . . . . . . 18 6.6 Connecting an external switching contact . . . . . . . . . . 18 6.7 Connecting an outside temperature sensor (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6.8 Connecting a cylinder temperature sensor. . . . . . . . . . 18 6.9 Connecting the 3-way valve . . . . . . . . . . . . . . . . . . . . . 18 6.10 Connecting the function module (accessory) . . . . . . . 18 6.11 Connecting the cylinder primary pump . . . . . . . . . . . . 19 6.12 Connecting the hot water circulation pump. . . . . . . . . 19 6.13 Connecting the pump . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6.14 Fit mains plug (if not preassembled) . . . . . . . . . . . . . . 19 7 Operating the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7.1 Information menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.2 Setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.3 Flue gas inspector mode . . . . . . . . . . . . . . . . . . . . . . . . 21 7.4 „Fault history“ menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.5 Key lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.1 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . 22 8.2 Purging the gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.3 Inspecting the flue system. . . . . . . . . . . . . . . . . . . . . . . 22 8.4 Adjusting the output . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8.5 Setting the maximum boiler temperature . . . . . . . . . . 22 8.6 Adjusting the pump connection set . . . . . . . . . . . . . . . 22 8.7 Testing the gas supply pressure . . . . . . . . . . . . . . . . . . 22 8.8 Measure gas/air ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 8.9 Measure the CO and CO2 content . . . . . . . . . . . . . . . . 24 8.10 Measure ionisation current . . . . . . . . . . . . . . . . . . . . . . 24 8.11 Testing for gas leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 8.12 Check the operating characteristics of the wall mounted gas condensing boiler . . . . . . . . . . . . . . . . . . 25 8.13 Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 8.14 Inform the user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 8.15 Commissioning report. . . . . . . . . . . . . . . . . . . . . . . . . . 25 9 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 9.1 Standard shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 9.2 Shutting down when there is a risk of frost . . . . . . . . . 25 10 Environmental protection/disposal . . . . . . . . . . . . . . . . . . . . 26 10.1 Environmental protection and disposal . . . . . . . . . . . . 26 11 Inspection and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 11.1 Important information. . . . . . . . . . . . . . . . . . . . . . . . . . 26 11.2 Remove the gas-air unit. . . . . . . . . . . . . . . . . . . . . . . . . 26 11.3 To clean the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 11.4 Cleaning the heat exchanger. . . . . . . . . . . . . . . . . . . . . 27 11.5 Checking the ignition system . . . . . . . . . . . . . . . . . . . . 27 11.6 Clean condensate trap/siphon . . . . . . . . . . . . . . . . . . . 28 11.7 Cleaning the condensate pan . . . . . . . . . . . . . . . . . . . . 29 11.8 Testing the gas supply pressure . . . . . . . . . . . . . . . . . . 29 11.9 Measure gas/air ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . 29 11.10 Measure CO/CO2 content. . . . . . . . . . . . . . . . . . . . . . . 30 11.11 Check flue gas pressure-relief valve . . . . . . . . . . . . . . . 30 11.12 Measure ionisation current . . . . . . . . . . . . . . . . . . . . . . 31 11.13 Testing for gas leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 11.14 Check for correct operating characteristics. . . . . . . . . 31 11.15 Inspection and maintenance reports . . . . . . . . . . . . . . 31 12 Display codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 12.1 Code types in the display . . . . . . . . . . . . . . . . . . . . . . . 32 12.2 Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 12.3 Operating and fault codes. . . . . . . . . . . . . . . . . . . . . . . 32 Explanation of symbols and safety instructions 3 Condens 5000W – 6720813952 (2019/02) 1 Explanation of symbols and safety instructions 1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken. The following signal words are defined and can be used in this document: DANGER: DANGER indicates that severe or life-threatening personal injury will occur. WARNING: WARNING indicates that severe to life-threatening personal injury may occur. CAUTION: CAUTION indicates that minor to medium personal injury may occur. NOTICE: NOTICE indicates that material damage may occur. Important information The info symbol indicates important information where there is no risk to people or property. Additional symbols Table 1 1.2 General safety instructions H Notes for the target group These installation instructions are intended for gas, plumbing, heating and electrical contractors. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life. ▶ Read the installation instructions (heat source, heating controller, etc.) before installation. ▶ Observe the safety instructions and warnings. ▶ Observe national and regional regulations, technical rules and guidelines. ▶ Record all work carried out. If you are in any doubt contact the Robert Bosch technical hotline on: 1300 30 70 37 AU or 0800 54 33 52 NZ H Determined use The product may only be used in a domestic situation for the heating of central heating water and for DHW heating in closed-loop DHW and heating systems. Any other use is considered inappropriate. Any damage that may result from misuse is excluded from liability. This appliance is not suitable to be used as a pool heater. H If you smell gas A gas leak could potentially cause an explosion. If you smell gas, observe the following rules. ▶ Prevent flames or sparks: – Do not smoke, do not use a lighter or strike matches. – Do not operate any electrical switches or unplug any equipment. – Do not use the telephone or ring doorbells. ▶ Turn off the gas supply at the main shut-off valve or at the gas meter. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Move well away from the building: call the emergency services and the gas supplier. H Danger to life from poisoning by flue gas There is a danger to life from escaping flue gas. ▶ Ensure that flues and gaskets are not damaged. H Risk to life from poisoning by flue gas due to inadequate combustion There is a risk to life from escaping flue gas. If flues are damaged or leaking, observe the following rules. ▶ Close off the fuel supply. ▶ Open windows and doors. ▶ If necessary, warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Rectify any damage to the flue immediately. ▶ Ensure that there is an adequate combustion air supply. ▶ Do not cover or reduce the size of ventilation apertures in doors, windows and walls. Symbol Meaning ▶ a step in an action sequence  a reference to a related part in the document • a list entry – a list entry (second level) Product Information Condens 5000W – 6720813952 (2019/02) 4 ▶ Ensure that there is an adequate combustion air supply, including for any heat sources, which have been installed at a later date, e.g. if there are extractor fans, kitchen fans or air conditioning units with an air discharge outside. ▶ Never operate the product if there is an insufficient combustion air supply. Open flued Appliance ▶ Do not use an unlined Masonry chimney as the flue for this appliance. H Installation, commissioning and maintenance Installation, commissioning and maintenance must only be carried out by an approved contractor. ▶ Carry out a gas tightness test after completing work on gas-carrying components. ▶ In the case of open flue operation:Ensure that the installation location meets the ventilation requirements. ▶ Only use original spares. H Electrical work Electrical work must only be carried out by contractors qualified in electrical installation. Before starting electrical work: ▶ Isolate all poles of the mains voltage and secure against reconnection. ▶ Using suitable means, test that the mains voltage is disconnected. ▶ Also observe the connection diagrams of other system components. H Handover to the user When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions. ▶ Explain how to operate the heating system and draw the user's attention to any safety relevant action ▶ Explain that conversions and repairs must only be carried out by a competent person. ▶ Point out the need for inspections and maintenance for safe and environmentally-compatible operation. ▶ Leave the installation instructions and the operating instructions with the user for safekeeping. ▶ Do not spray aerosols in the vicinity of this appliance while in operation. ▶ Do not use or store flammable materials in or near this appliance. ▶ Do not place articles on or against this appliance. ▶ Do not modify this appliance. 2 Product Information 2.1 Declaration of conformity The design and operating characteristics of this product comply with the European and national requirements. The CE marking declares that the product complies with all the applicable EU legislation, which is stipulated by attaching this marking. The complete text of the Declaration of Conformity is available on the Internet: www.bosch-climate.com.au. 2.2 Appliance types The appliance types stated may not be available in your country. For more information on availability, contact the manufacturer. You will find the address on the back cover of these instructions. This document refers to the following appliance types: • Condens 5000W ZBR 70-3 • Condens 5000W ZBR 100-3 The designation of the wall mounted condensing boiler comprises the following: • Bosch: manufacturer • Condens 5000W ZBR-3: product name • 70 or 100: type name 2.3 Data plate The data plate is on the top of the wall mounted gas condensing boiler to the left of the flue gas adapter ( figure 4, [8]). The data plate contains the serial number, gas group classification and approvals.

Operating Instructions Hydronic Gas Condensing Boiler Condens 5000 W 6 720 613 085-00.1O ZSB 30-2 A ...| ZWB 37-2 A ... 6 720 644 144 (2019/03) NZ/AU all-gui des.c om Contents Condens 5000 W – 6720644144 (2019/03) 2 Contents 1 Explanation of symbols and safety instructions . . . . . . . . . . . . . . . . . . . . . 3 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Product details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2 Explanation of model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3 Preparing the appliance for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.1 Turn on the gas service cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.2 Turn on the isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3 Opening the control panel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4 Check the central heating system pressure . . . . . . . . . . . . . . . . . . . 14 3.5 Top up the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4.1 Overview of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.2 Switching the appliance on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.3 Starting the central heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.4 Setting the heating control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.5 Appliances with hot water cylinder: setting the hot water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 4.6 ZWB appliances - setting hot water temperature . . . . . . . . . . . . . . . 26 4.7 Summer mode (central heating off, DHW only) . . . . . . . . . . . . . . . . 28 4.8 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4.9 Holiday mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4.10 Further displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5 Carry out thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3 Condens 5000 W – 6720644144 (2019/03) Explanation of symbols and safety instructions 6 Tips on saving energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 9 Environment / disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 10 Operating instructions quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 1 Explanation of symbols and safety instructions 1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken. The following signal words are defined and can be used in this document: • DANGER indicates that severe or life-threatening personal injury will occur. • WARNING indicates that severe to life-threatening personal injury may occur. • CAUTION indicates that minor to medium personal injury may occur. • NOTICE indicates that material damage may occur. Important information This symbol indicates important information where there is no risk to people or property.

6720813953 (2018/12) AU Operating Instructions Wall mounted gas condensing boilers Condens 5000W ZBR 70-3 | ZBR 100-3 Table of contents Condens 5000W – 6720813953 (2018/12) 2 Table of contents 1 Explanation of symbols and safety instructions 1.1 Explanation of symbols Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimising danger are not taken. The following signal words are defined and can be used in this document: DANGER: DANGER indicates that severe or life-threatening personal injury will occur. WARNING: WARNING indicates that severe to life-threatening personal injury may occur. CAUTION: CAUTION indicates that minor to medium personal injury may occur. NOTICE: NOTICE indicates that material damage may occur. Important information The info symbol indicates important information where there is no risk to people or property. Additional symbols Table 1 1.2 General safety instructions H Instructions for the target group These operating instructions are intended for the heating system user. All instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including possible loss of life. ▶ Read and retain the operating instructions (heat source, heating controller, etc.) prior to operation. ▶ Observe the safety instructions and warnings. H Determined use The product may only be used for the heating of boiler water and for DHW heating. 1 Explanation of symbols and safety instructions . . . . . . . . . . . 2 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 2 2 Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . 4 2.2 Appliance types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.1 Overview of components. . . . . . . . . . . . . . . . . . . . . . . . . 4 3.2 Opening the gas tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.3 Opening service valves . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.4 Switch on the wall mounted gas condensing boiler . . . . . 5 3.5 Check water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.6 Setting the maximum boiler temperature. . . . . . . . . . . . 5 3.7 Setting the user interface . . . . . . . . . . . . . . . . . . . . . . . . 5 4 Operating the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.1 Information menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4.2 Setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4.3 Anti-Freeze Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.4 Key lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.1 Standard shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5.2 Shutting down when there is a risk of frost. . . . . . . . . . . 7 6 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6.1 Refilling the heating system. . . . . . . . . . . . . . . . . . . . . . . 7 6.2 Cleaning the casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 Display rendition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7.1 Display codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7.2 A fault has occurred but no fault code is displayed . . . . . 9 8 Environmental protection/disposal . . . . . . . . . . . . . . . . . . . . . 9 Symbol Meaning ▶ a step in an action sequence  a reference to a related part in the document • a list entry – a list entry (second level) Explanation of symbols and safety instructions 3 Condens 5000W – 6720813953 (2018/12) Any other use is considered inappropriate. We assume no liability for damage occurring due to non-permitted use. H If you smell gas A gas leak could potentially cause an explosion. If you smell gas, observe the following rules. ▶ Prevent flames or sparks: – Do not smoke, do not use a lighter or strike matches. – Do not operate any electrical switches or unplug any equipment. – Do not use the telephone or ring doorbells. ▶ Turn off the gas supply at the main shut-off valve or at the gas meter. ▶ Open windows and doors. ▶ Warn your neighbours and leave the building. ▶ Prevent anyone from entering the building. ▶ Move well away from the building: call the emergency services and the gas supplier. H Danger to life from poisoning by flue gas There is a danger to life from escaping flue gas. ▶ Never modify any parts through which flue gas is routed. If flues are damaged or leaking, or if you smell flue gas, observe the following rules. ▶ Switch off the heat source. ▶ Open doors and windows ▶ Warn your neighbours and leave the building immediately. ▶ Prevent third parties from entering the building. ▶ Notify an approved contractor. ▶ Have any defects rectified. H Danger to life from carbon monoxide Carbon monoxide (CO) is a poisonous gas, which arises during the incomplete combustion of fossil fuels such as oil, gas or solid fuels. Dangers arise, if carbon monoxide escapes from the heating system due to a fault or a leak and collects unnoticed in enclosed spaces. You can neither see, taste nor smell carbon monoxide. To avoid danger from carbon monoxide: ▶ Have the heating system inspected and serviced regularly by an approved contractor. ▶ Use a CO detector, which gives an alarm in good time if CO escapes. ▶ If you suspect a CO leak: – Warn your neighbours and leave the building immediately. – Call an approved contractor. – Have any defects rectified. H Inspection and maintenance If there is a lack of cleaning, inspection or maintenance, or if these are carried out incorrectly, this may result in material damage and/or personal injury, including possible loss of life. ▶ Have work carried out only by an approved contractor. ▶ Have any defects rectified immediately. ▶ Have the heating system inspected once a year by an approved contractor, and have any required maintenance or cleaning work carried out. ▶ Have the heat source cleaned at least every two years. ▶ We recommend that you enter into a contract covering an annual inspection and needs-based maintenance with an approved contractor. H Conversion and repairs Improper modifications to the heat source or other parts of the heating system can result in personal injury and/or material damage. ▶ Have work carried out only by an approved contractor. ▶ Never remove the casing of the heat source. ▶ Never carry out any modifications to the heat source or to other parts of the heating system. ▶ Never close the outlet of the pressure relief valves. Heating systems with DHW cylinder: During heat- up, water can escape from the pressure relief valve of the DHW cylinder. H Open flue operation The installation location must be adequately ventilated, if the heat source draws its combustion air from the room. ▶ Never cover or reduce the size of ventilation openings in doors, windows and walls. ▶ Consult a contractor to ensure that ventilation requirements are met: – If structural modifications are made (e.g. replacing windows and doors) – If devices with an air discharge to the outside are subsequently installed (e.g. extractor fans, kitchen fans or air conditioning units). Product information Condens 5000W – 6720813953 (2018/12) 4 H Combustion air/ambient air The air in the installation location must be free of flammable or chemically aggressive substances. ▶ Do not store or use any highly flammable or explosive materials (paper, petrol, thinners, paints etc.) within the vicinity of the heat source. ▶ Do not store or use any corrosive substances (solvents, adhesives, chlorinated cleaning agents, etc.) within the vicinity of the heat source. Condensate tube Condensate is produced in this wall mounted gas condensing boiler and removed via a condensate tube. Modification or blocking of the condensate tube is not permitted. 2 Product information 2.1 Declaration of conformity The design and operating characteristics of this product comply with the European and national requirements. The CE marking declares that the product complies with all the applicable EU legislation, which is stipulated by attaching this marking. The complete text of the Declaration of Conformity is available on the Internet: www.bosch-climate.com.au. 2.2 Appliance types This document refers to the following appliance types: • Condens 5000W ZBR 70-3 • Condens 5000W ZBR 100-3 The designation of the wall mounted condensing boiler comprises the following: • Bosch: manufacturer • Condens 5000W ZBR-3: product name • 70 or 100: type name 3 Commissioning 3.1 Overview of components Fig. 1 Overview of components [1] Control panel [2] Pump [3] Shut-off valve with temperature sensor [4] Gas isolator [5] Pressure gauge 3.2 Opening the gas tap ▶ Push in the gas isolator and turn to the left so the tap lines up with the gas line. Fig. 2 Opening the gas tap 0010020117-001 4 3 5 3 2 1 0010020118-001

Installation and Servicing Instructions HYDRONIC GAS SYSTEM BOILER 18kW BOSCH CONDENS 5000W 6720646195-00.1Wo ZSB18 - 2A 6 720 646 195a (2010/11) 10 | Boiler information AU/NZ 6 720 646 195a (2010/11) Fig. 4 Additional components 1 Burner ON indicator light (green) 9 PRV pipe connection point 2 Power ON/OFF indicator/fault diagnostic light (blue) 10 CH return isolator 3 Position for optional programmer 11 Gas inlet connection BSP ¾ inch thread 4 Reset button 12 CH flow isolator 5 System pressure gauge 13 Condensate connection 6 ECO button (not used) 14 CH temperature control 7 DHW temperature control* 15 Service mode button 8 Boiler identification label Tab. 7 Additional boiler components 6720644743-04.1Wo 1 2 3 4 5 6 15 14 9 10 11 13 12 7 8 * The DHW temperature control is only operational when the “optional internal diverter valve” is fitted. 36 | Commissioning AU/NZ 6 720 646 195a (2010/11) 5.4 Starting the boiler Fig. 56 Control panel Switching the boiler on/off: B Turn on mains power supply, the power on indicator (5) illuminates blue. B Turn on any external controls B Set the thermostatic radiator controls to maximum temperature B Set the clock/programmer to continuously ON and the room thermostat to maximum temperature Turn the boiler CH temperature control (1) to maximum. The burner on indicator (2) illuminates green when the burner has lit. If the boiler fails to light, the blue power indicator (5) and reset button (7) will flash. To reset press and hold the reset button (7) for more than two seconds. The boiler will be reset. CAUTION: Running the boiler B Never run the boiler when the system is empty or partially filled. 1 2 3 4 5 6 7 8 9 6720643895-52.1Wo 1 Central heating temperature control 2 Burner indicator (green) 3 Service button 4 Cover or optional Programmer 5 Power ON and fault indicator (blue) 6 ECO button - not used 7 Reset button 8 DHW temperature control (only operational when option integral diverter valve is fitted) 9 System pressure gauge Tab. 23 Control panel legend NOTE: Reset B Do not press the blue power indicator (5) to reset the boiler.

USER MANUAL HYDRONIC GAS SYSTEM BOILER 18kW CONDENS 5000 W 6720643356-00.1Wo ZSB18 - 2A. 6 720 646 196 (2013/08) 6 720 646 196 (2013/08) Condens 5000 W Contents | 2 Contents 1 Symbols and safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.1 Operating the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.1.1 Switching off the central heating . . . . . . . . . . . . . . . . . . . 6 3.1.2 Boiler frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1.3 Setting the hot water temperature . . . . . . . . . . . . . . . . . 7 3.1.4 Boiler reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4 System pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1 Sealed heating systems . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.2 External filling loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5 Service clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6 Maintaining the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 7 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 8 Fault or breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 9 Tips on energy saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 10 Environment / disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11 Your guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6 720 646 196 (2013/08) Condens 5000 W Preface | 3 Preface Please read these instructions carefully These instructions are applicable to the Bosch boiler model stated on the front cover only. These instructions apply in AU/NZ only and must be followed except for any statutory obligation. After installation please leave this user manual, the installation instructions and completed installation checklist with the customer. Dedicated to heating comfort Thank you for purchasing a Condens 5000 hydronic system boiler manufactured by Bosch. The company prides itself on manufacturing boilers to the strictest quality control standards throughout every stage of production. Bosch has led the field in innovative boiler design and performance for almost 50 years. This heritage means all our products are of exceptional quality and proven reliability. The Condens 5000 in particular is extremely energy efficient, offering you economical running costs and value for money. Register the warranty within 30 days of installation for the reassurance of a two years parts and labour guarantee. 6 720 646 196 (2013/08) Condens 5000 W 4 | Symbols and safety precautions 1 Symbols and safety precautions 1.1 Explanation of symbols Warning symbols Signal words indicate the seriousness of the hazard in terms of the consequences of not following the safety instructions. • NOTICE indicates possible damage to property or equipment, but where there is no risk of personal injury. • CAUTION indicates possible personal injury. • WARNING indicates possible severe personal injury. • DANGER indicates possible risk to life. Important information Additional symbols 1.2 Safety precautions If you smell gas: ▶LPG boilers call the suppliers number on the side of the LPG tank/cylinder ▶Turn off the ECV (emergency control valve) at the meter ▶Do not turn any electrical switches on or off ▶Do not strike matches or smoke ▶Put out naked flames ▶Open doors and windows ▶Keep people away from the affected area Boiler operation: This boiler must only be operated by a responsible adult who has been instructed in, understands and is aware of the boiler's operating conditions and effects. Combustible and corrosive materials: Chemically aggressive substances can corrode the boiler and invalidate any warranty. ▶Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the vicinity of the boiler. Fittings and modifications: Only an authorised person can remove the outer case and carry out any work. ▶Do not remove the outer casing. Any misuse or unauthorised modifications to the boiler, flue or associated components and system will invalidate the warranty. ▶Do not modify the boiler or flue system in any way. Bosch accepts no liability arising from any such actions. This does not affect your statutory rights. Safety instructions in this document are framed and identified by a warning triangle which is printed on a grey background. Electrical hazards are identified by a lightning symbol surrounded by a warning triangle. Notes contain important information in cases where there is no risk of personal injury or material losses and are identified by the symbol shown on the left. They are bordered by horizontal lines above and below the text. Symbol Meaning ▶ a step in an action sequence  a reference to a related part in the document or to other related documents • a list entry – a list entry (second level) Table 1 Symbols