Bosch CONDENS 5000W Operating Instructions Manual

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

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

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.

Condens 5000 W – 6720644144 (2019/03) 4 Additional symbols 1.2 General safety instructions 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. Determined use The product may only be used for the heating of boiler water and for DHW heating. Any other use is considered inappropriate. We assume no liability for damage occurring due to non- permitted use. Symbol Explanation ▶ a step in an action sequence  a reference to a related part in the document • a list entry – a list entry (second level) Table 1

Explanation of symbols and safety instructions 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. 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.

Condens 5000 W – 6720644144 (2019/03) 6 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. 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:

Explanation of symbols and safety instructions – Warn your neighbours and leave the building immediately. – Call an approved contractor. – Have any defects rectified. 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.

Condens 5000 W – 6720644144 (2019/03) 8 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. 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)

Explanation of symbols and safety instructions – If devices with an air discharge to the outside are subsequently installed (e.g. extractor fans, kitchen fans or air conditioning units). 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.

10 2 Product details 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 Explanation of model code Z Central heating appliance S Cylinder connection W DHW heating B Condensing boiler technology 30 Output up to 30 kW 37 DHW output up to 37 kW -2 Version A Fan-assisted appliance without draught hood Condens 5000 W ZSB 30-2 A ZWB 37-2 A Table 2

Preparing the appliance for use 3 Preparing the appliance for use 3.1 Turn on the gas service cock ▶ Using a screwdriver, turn the square tap handle so that the slot is in line with the direction of flow. Slot at right-angles to direction of flow = off. Fig. 1 6 720 644 144-01 .1O

Condens 5000 W – 6720644144 (2019/03) 12 3.2 Turn on the isolators ▶ Using a screwdriver, turn the square tap handle so that the slot is in line with the direction of flow. Slot at right-angles to direction of flow = off. Fig. 2 6 720 644 143-02.1O

Preparing the appliance for use 3.3 Opening the control panel cover Fig. 3 6 720 612 660-01.2R

Condens 5000 W – 6720644144 (2019/03) 14 3.4 Check the central heating system pressure The normal operating pressure is 1 - 2 bar. If a higher setting is required, you will be informed by your installer. Fig. 4 6 720 644 144-03.1O 1 0 2 3 4 bar

Preparing the appliance for use 3.5 Top up the heating system The way in which the heating system is topped up is different on every system. Therefore, you should ask your installer to show you how it is done. Maximum pressure of 3 bar at maximum heating water temperature must not be exceeded (safety valve will open). CAUTION: Risk of damaging the appliance. ▶ Only top up the heating system when the appliance is cold.

16 4 Operation These Operating Instructions apply only to the boiler. Depending on the heating controller used, some functions may be controlled differently. The following possibilities for controlling the heating system may be employed: • weather-dependent controller built into the boiler  page 18, item 7. • weather-dependent controller external to the appliance • room thermostat Therefore, please read the operating instructions for the heating controller used. Page 39 contains brief operation instructions. You can fold this outwards and push the operating instructions into the appliance facia for safekeeping.

18 4.1 Overview of controls Fig. 6 6 720 644 144-04.1O 18 19 reset 10 11 12 eco 15 16 17 14 4 3 2 5 1 6 8 7 9 20 13

Operation [1] Flow temperature control [2] DHW temperature control [3] Chimney sweep button [4] Service button [5] Burner ON indicator [6] Main switch [7] Here, a weather-compensated control unit or a time switch (accessories) can be plugged in [8] Display [9] Pressure gauge [10] reset button [11] eco button [12] Holiday button [13] Drain from pressure relief valve (heating circuit) [14] Gas tap [15] CH return isolator [16] Filling loop (ZWB) [17] Cold water tap (ZWB), cylinder return (ZSB) [18] DHW connection (ZWB), cylinder flow (ZSB) [19] CH flow isolator [20] Condensate hose

20 4.2 Switching the appliance on/off Switching on ▶ Switch appliance on at the main switch. The display shows the heating water flow temperature. Fig. 7 Switching off the appliance ▶ Switch appliance off at the main switch. The display goes out. ▶ If the appliance is to be switched off for a longer period of time: observe correct frost protection procedures ( Section 4.8). If the display shows alternately with the flow temperature, the appliance will operate with the lowest output for 15 minutes. max 1 2 3 4 5 6 6 720 613 896-05.1O

Operation 4.3 Starting the central heating The maximum flow temperature can be matched to the heating system by the flow temperature controller. The current flow temperature is shown on the display. Setting on flow temperature controller ( Flow temperature Sample application 1 Approx. 35 °C 2 Approx. 43 °C 3 Approx. 50 °C Underfloor heating system 4 Approx. 60 °C 5 Approx. 67 °C 6 Approx. 75 °C Radiator heating system max. Approx. 90 °C Convector heating system Table 3 With underfloor heating systems, take care to observe the maximum permissible CH flow temperatures.

22 ▶ Turn flow temperature controller to adjust the maximum flow temperature. Fig. 8 When the burner is firing, the green indicator lamp lights up. eco reset 6 720 644 143-27.1O max 1 2 3 4 5 6 max 1 2 3 4 e 6 min

Operation 4.4 Setting the heating control unit Fig. 9 Follow the operating instructions for the heating controller used. Those instructions will tell you ▶ how to set the operating mode and the heating curve for weather-dependent controllers, ▶ how to adjust the room temperature, ▶ how to heat economically and save energy. 9 12 h 15 18 21 24 h 3 6 6 720 612 660-07.2O

24 4.5 Appliances with hot water cylinder: setting the hot water temperature ▶ Set the DHW temperature on the DHW temperature control . The set DHW temperature flashes on the display for 30 seconds. Fig. 10 WARNING: Danger of scalding! ▶ In normal operation, do not set the temperature higher than 60 °C. To prevent bacterial contamination such as legionella, we recommend setting the DHW temperature controller to “6” (60 °C). 6 720 644 143-28.1O max 1 2 3 4 5 6 reset eco max 1 2 3 4 e 6

Operation eco button Pressing and holding the eco button until it lights up switches between Comfort mode and Economy mode. Comfort mode, Eco button is not lit (default setting) In Comfort mode, the hot water cylinder has priority. The hot water cylinder is heated to the set temperature first. Then the appliance switches to central heating mode. Economy mode, Eco button lit In Economy mode, the appliance switches between central heating mode and hot water mode every ten minutes. DHW thermostat * DHW temperature min Approx. 5 °C (frost protection) e Approx. 55 °C 6 Approx. 60 °C max. Approx. 70 °C Table 4

26 4.6 ZWB appliances - setting hot water temperature ▶ Set the DHW temperature on the DHW temperature control . The set DHW temperature flashes on the display for 30 seconds. Fig. 11 eco button Pressing and holding the eco button until it lights up switches between Comfort mode and Economy mode. Comfort mode, (Eco button is not lit - default setting) The appliance is held constantly at the set temperature. This means that hot water is available almost instantaneously at the tap. Consequently the appliance will switch on at intervals, even if no hot water is being drawn. DHW thermostat * DHW temperature min Approx. 40 °C e Approx. 50 °C max. Approx. 60 °C Table 5 eco reset max 1 2 3 4 e 6 6 720 644 143-29.1O max 1 2 3 4 5 6

Operation Economy mode, Eco button lit • The water is not heated up until a hot water tap is turned on. • With a demand signal (only with start delay switched off for the supply of water preheated by solar energy). Briefly turning a hot water tap on and then off signals demand so that the water is then heated up to the set temperature. If a start delay for the supply of water preheated by solar energy has been set (service function b.F), the appliance does not switch on until the start delay has elapsed. The demand signal enables gas and water savings.

28 4.7 Summer mode (central heating off, DHW only) ▶ Note position of CH flow temperature control . ▶ Turn CH flow temperature control anti-clockwise as far as the stop . The heating circuit pump and consequently central heating are switched OFF. However, the DHW supply as well as the power supply to the heating programmer and timer remain 'live'. Fig. 12 Additional instructions are contained in the operating instructions for the heating programmer. NOTICE: Heating system at risk from frost. 6 720 644 143-30.1O eco reset max 1 2 3 5 6 max 1 2 3 4 e 6 min

Operation 4.8 Frost protection Frost protection for the heating system: ▶ Leave appliance switched on, set CH flow temperature control to position 1 at least. Fig. 13 ▶ Add anti-freeze to the heating water (see installation instructions) and drain the DHW circuit. Additional instructions are contained in the operating instructions for the heating programmer. Frost protection for the cylinder: ▶ Turn DHW temperature controller clockwise as far as it will go (5 °C). Fig. 14 eco reset max 1 2 3 5 6 max 1 2 3 4 e 6 6 720 644 143-31.1O min max 1 2 3 e 6 max 1 2 3 4 5 6 eco 6 720 644 143-32.1O min

30 4.9 Holiday mode To switch on holiday mode: ▶ Press and hold holiday button on the appliance until it lights up, and switch on holiday mode on the heating controller. In holiday mode, heating and DHW heating are switched off; frost protection remains active ( chap. 4.8). To switch off holiday mode: ▶ Press and hold holiday button on the appliance until it goes out, and cancel holiday mode on the heating controller. The appliance returns to operation in standard mode according to the settings at the heating control unit.

Operation 4.10 Further displays Display code Description Fault code ( chapter 7) Inspection due Pump anti-seize function active Trap filling function active Bleeding function active Excessively rapid increase in CH flow temperature (temp. gradient monitoring). Heating mode is disabled for two minutes. Drying function. If the floor drying function is activated on the weather- dependent controller, refer to controller instructions. Table 6

Condens 5000 W – 6720644144 (2019/03) 32 5 Carry out thermal disinfection To prevent the DHW becoming contaminated by bacteria such as legionella, we recommend you pasteurise the system after longer idle periods. Pasteurisation covers the DHW system including the draw-off points. For solar DHW cylinders, the solar portion of the cylinder is not covered. ▶ Turn off all hot water points. ▶ Warn occupants of risk of scalding. ▶ If the heating programmer has a DHW program, set the time and DHW temperature accordingly. ▶ If there is a circulation pump, set it to run continuously. With some heating controllers, thermal disinfection can be programmed for a fixed time; see heating controller operating instructions. DANGER: Risk of scalding! Hot water can result in severe scalding. ▶ Carry out thermal disinfection only outside the normal hours of use. ▶ The water in the tank will take a while to cool down to the set hot water temperature as a result of heat loss. Be aware that, after thermal disinfection, the hot water may be hotter than the set temperature.

Carry out thermal disinfection ▶ Turn hot water temperature control clockwise as far as the stop (approx. 70 °C). Fig. 15 ▶ Wait until the water reaches the maximum temperature. ▶ Draw off water in turn from the nearest to the furthest hot water point until hot water has been running out at a temperature of 70 °C for 3 minutes. ▶ Reset DHW temperature control, circulation pump and heating programmer to their standard settings. If you want to interrupt thermal disinfection: ▶ Switch the appliance off and then on again at the main switch. The appliance will start up again and the central heating flow temperature will be displayed. 6 720 644 143-33.1O max 1 2 3 4 5 6 reset eco max 1 2 3 4 e 6