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Bosch Condens 5000W Installation And Maintenance Instructions Manual
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Bosch Condens 5000W Installation And Maintenance Instructions Manual

Hydronic gas system boiler 18kw
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Installation and Maintenance Instructions
Hydronic gas system boiler 18kW
Bosch Condens 5000W
ZSB18 - 2A

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Summary of Contents for Bosch Condens 5000W

  • Page 1 Installation and Maintenance Instructions Hydronic gas system boiler 18kW Bosch Condens 5000W ZSB18 - 2A...

  • Page 2: Table Of Contents

    Servicing and spares ....... . . 36 Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 3: Explanation Of Symbols And Safety Instructions

    If you are in any doubt contact the Robert Bosch technical hotline on: The following signal words are defined and can be used in this document: 1300 30 70 37 AU or 0800 54 33 52 NZ...
  • Page 4 The commercial and industrial use of the appliance to generate process heat is not permitted. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 5: Product Information

    – Fibre washer 18.6 x 13.5 x 1.5 – Fibre washer 23.9 x 17.2 x 1.5 – Bonded washer ¾ inch for gas Adapter, 22mm to R¾ Adapter, 15mm to R½ Syphon assembly Warranty return envelope Table 4 Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 6: Boiler Carton Contents

    * 710mm to top of case front 6720646195-01.2Wo Fig. 1 Boiler carton contents Standard package: Hydronic system boiler Fascia panel Wall mounting frame Syphon assembly Hardware literature pack (see checklist) Metric to Imperial adapter pack Bottom panel Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 7: Technical Data

    Nominal capacity of boiler litre Noise output level (Max Central Heating) Packaged boiler weight Total boiler weight 37.5 37.5 Lift weight 27.1 27.1 Efficiency 1) Propane Table 5 Technical data Bosch Condens 5000W Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 8: Layout

    Product Information Layout Fig. 2 Main boiler components Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 9 Cover - transformer and PCB Internal by-pass Gas inlet connection BSP ¾ inch thread CH flow connection to service valve CH flow isolator Pressure gauge connection point Table 6 Boiler components Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 10 CH temperature control DHW temperature control Service mode button Boiler identification label 1) The DHW temperature control is only operational when the “optional internal diverter valve” is fitted. Table 7 Additional boiler components Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 11: Pre-Installation

    • A drain point is required at the lowest part of the system. • An air vent is required at all the high points in the system. The boiler is equipped with an automatic internal by-pass. Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 12 Additional expansion vessel example Diverter valve (3 port valve) Radiator valve (flow) Key to figure 6: Lock shield valve (return) Boiler expansion vessel - CH Extra expansion vessel - CH return Pressure relief discharge Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 13: Condensate Pipe Work

    The self sealing device can be Condensate discharge used on a gradient as long as it preceded by a vertically mounted tundish. Air gap (20mm) Tundish Self sealing device Vent stack Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 14: Pressure Relief Drain Line

    Paved area Gravel pit not less than 100mmØ 40/50mm Ø 6720646195-17.1Wo Fig. 13 Bifurcated pipe disposal Key to figure 12: Condensate discharge Air gap (20mm) Tundish Self sealing device Dishwasher connection Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 15: Boiler Location And Clearances

    • If fitting the boiler into an airing cupboard use a noncombustible material to separate the boiler from the airing space. The material can be perforated up to a maximum hole size of 13mm. Table 11 Reduced front clearances Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 16: Plumbing Manifold

    CH flow 70 mm ¾ BSP 200 mm ¾ BSP CH return 330 mm ¾ BSP Condensate 35 mm 22 mm Pressure relief valve 367 mm ½ BSP Table 13 Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 17: Flue Options

    Pre-Installation Flue options The Condens 5000W series has the option of three horizontal RSF (60/ 100 telescopic, 60/100 extended telescopic and 80/125) flue systems and two vertical RSF (60/100 or 80/125) flue systems: The flue systems have different maximum flue lengths.
  • Page 18 Pre-Installation 350 mm - 570 mm 130 mm Min 500 mm 300 mm Flat roof 6720643895-12.1Wo Fig. 18 Flue options examples Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 19: Flue Options

    From a mechanical air inlet including a spa blower 1,000 Vertically below an opening window, door, non- mechanical air inlet or other opening into a building with the exception of sub-floor ventilation Table 15 Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 20: Installation

    [4] and syphon assembly [7] from the carton. NOTICE: Before installing the boiler! ▶ Ensure that the system has been cleaned as explained in section Cleaning primary systems on page 11 Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 21: Wall Mounting Template And Flue Opening

    150mm diameter hole is required to accommodate this. Flue outlet position marked and ready to drill hole ▶ Drill hole using a core drill or similar. ▶ Clear any debris from the site. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 22: Unpacking The Boiler

    The boiler will lie at an angle to the floor to allow the boiler outer casing [5] to be removed. ▶ The inner sleeve [2] opens as shown in figure 24. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 23: Boiler Connections

    3. CH return BSP 20 ▶ Fit the metric to imperial (15mm to R½) adapter [4] to the pressure relief valve connection [1]. 6720644743-16.1Wo Fig. 28 PRV connection in the down position Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 24 ▶ The pressure relief connector must be repositioned after the boiler has been correctly mounted to the wall mounting frame. To ease assembly of components, apply silicone lubricant to sealing surfaces. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 25: Flue Installation

    ▶ Extend tube [1] by withdrawing from tube [2] to achieve the flue length required, between 350 - 570mm. ▶ Secure with screw provided and seal joint with the aluminium tape supplied. Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 26 Fig. 36 Further terminal assembly reduction The aluminium tape is not required when reducing the terminal. 6720643895-35.2Wo Fig. 38 Aligning the flue turret ▶ Fit the screws removed in step 1 to secure flue turret. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 27: Flue Terminal Plume Re-Direction

    • The flue is set at an angle of 3° or 52mm per metre length. ±80° 180° 52mm 104mm 6720644842-10.1Wo Fig. 40 Slope for condensate disposal withing the flue system 6720643895-34.1Wo Fig. 41 Plume re-direction Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 28: Condensate Connection

    NOTICE: Syphon discharge hose connection ▶ Do not use solvents, adhesive or lubricant when pushing the pipe onto the rubber connector. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 29: Electrical

    Small pieces of wire can cause shorts and damage to electronics. ▶ When stripping wires always ensure copper strands do not fall into the control box. 6720644743-14.1Wo Fig. 46 Syphon drainage cap location Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 30 ▶ Refer to manufacturers‘ instructions when connecting external parts to the wiring centre. ▶ Robert Bosch cannot be held responsible for wiring errors. Fig. 49 Electrical connector information ▶ There is an option to fit an internal diverter valve. This also requires [SI1] Fuse F1 - 2.5A...

  • Page 31: Commissioning

    ▶ Close the water shut-off valves to the appliance. ▶ Label appropriately. Fig. 53 Identification plate Gas supply pipe work tightness check ▶ Turn on the main gas supply, check the gas pipe work connections and rectify any leaks. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 32: Filling The System

    ▶ Rotate the adjustable pointer on the pressure gauge to record the set heat exchanger. system pressure. ▶ Isolate and remove filling loop connection to system. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 33: Starting The Boiler

    ▶ Do not press the blue power indicator [5] to reset the boiler. ▶ Press and hold the reset button [7] for more than two seconds to reset the boiler if it fails to light. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 34: Commissioning

    ▶ Remove the manometer. ▶ Re-seal the screw in the gas inlet pressure test point. ▶ Open the gas isolation valve. ▶ Ensure that there are no gas leaks. ▶ Replace the outer case. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 35: Domestic Hot Water: Controlling The Hot Water Temperature

    ▶ Set up the controls and show the user how to operate all the controls shown in the user guide. ▶ Ensure that the user guide is left with the customer. Fig. 61 Fitting outer casing Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 36: Servicing And Spares

    Fig. 64 Moving the control panel into service position 1. Undo and remove two screws securing boiler casing at the top of the boiler. 2. Undo but do not remove the two screws. ▶ Pull case forward and remove. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 37: Check The Gas Inlet Pressure

    ▶ Remove the cover and connect a digital manometer to the fan pressure test point. 6720646195-11.1Wo Fig. 65 Flue integrity test Air intake sample point Flue gas sample point Fig. 67 Fan pressure test point Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 38: Flue Gas Analysis

    ▶ Check the exhaust path and flue for restriction. ▶ Clean the heat exchanger with a suitable cleaning tool. refer to section 6.7 "Checking the heat exchanger". ▶ Re-check the fan pressure readings Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 39: Setting The Air/Gas Ratio

    ▶ Return to maximum and re-check the CO/CO If correct, press the service button; the button will cease to be illuminated and the blue power indicator will be permanently illuminated. ▶ Re-assemble and refit boiler case. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 40: Checking The Heat Exchanger

    2. Pull the gas outlet elbow free from the gas valve. 6720643895-63.1Wo 6720643895-72.1Wo Fig. 75 Rotate air/gas manifold Fig. 73 Upper gas valve connection removal Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 41 If the lower baffle is stuck, it may be necessary to use the “baffle removal tool” from the heat exchanger cleaning kit part number: 7 716 192 312, as shown in figure 77. 6720643895-112.1Wo Fig. 78 Access cover removal Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 42: Replacement Of Parts

    ▶ The baffles [1] and [2] must be refitted into the heat exchanger in the order shown in figure 77. Failure to do so may result in damage to the boiler. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 43: Removing The Outer Case

    3. Slacken and remove fixing screw and thermostat [3]. ▶ When replacing ensure thermostat sits correctly on surface of the casting with the left hand side of thermostat sitting up against the shoulder. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 44: Moving The Control Panel To The Service Position

    2. Gently pull the panel forward. Fig. 86 Lower gas valve connection removal NOTICE: The gas valve will require setting: ▶ Follow procedure Setting the air/gas ratio. Fig. 84 Control panel to service position Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 45: Air/Gas Manifold And Fan Assembly

    After re-assembly ▶ Check the CO/CO2 levels as described in section 6.6 "Setting the Fig. 89 Air/gas manifold assembly dismantling air/gas ratio". 2. Remove the cover panel by removing retaining screw. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 46: Electrode Assembly And Burner

    ▶ Ensure that the new seal is fitted. CAUTION: Clamping plate ▶ Ensure that the clamping plate is firmly tightened down on top of the heat exchanger. ▶ Replace the clamping plate. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 47: Heat Exchanger

    2. Remove the nut from the bottom of the boiler. hook. 3. Rotate lever to release the return pipe. 3. Move the upper exhaust connector down. Fig. 95 Release the sump Fig. 93 Upper exhaust assembly Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 48: Access To Boiler Control Components

    6.8.11 Access to boiler control components Refer to figure 97. 1. Remove three screws. 2. Remove cover from control. Fig. 99 Spare fuses location T1.6L 250V T2.5H 250V T500L 250V Fig. 97 Removing the connection cover Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 49: Transformer/Pcb

    2. Carefully remove the system pressure gauge from the fascia by parting the plastic retaining lugs securing the gauge in place. Take care not to damage or kink the capillary tube. Fig. 103 Release control panel Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 50: Syphon Removal

    3. Withdraw the valve and clean the valve chamber if necessary. ▶ To refit, follow the above in reverse. ▶ Ensure any seals that have been disturbed are renewed. 6720644743-28.1Wo Fig. 105 Syphon removal Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 51: Auto Air Vent

    ▶ To refit, follow the above in reverse order. 6720644743-33.1Wo Fig. 110 Drain tap removal ▶ To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 52: Pressure Gauge

    ▶ Remove the rubber pipe connecting the sump and remove the syphon. Fig. 112 Hydraulic block removal part 2 ▶ To refit, follow the above in reverse. Ensure any seals that have been disturbed are renewed. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 53: Pressure Relief Valve

    ▶ Reassemble expansion vessel into wall frame and reconnect the flexible pipe to pump manifold and secure with the clip. 6720644743-37.1Wo Fig. 114 Removing the bypass valve ▶ To refit, follow the above in reverse. Ensure any seals renewed. Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 54 Fig. 116 Removing the expansion vessel from the wall frame ▶ Replace expansion vessel in the reverse order and refit the boiler to the mounting frame. ▶ Follow the commissioning procedure in this manual. Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 55: Short Parts List

    (grommet type) 8 744 503 010 0 8 716 107 224 0 8 716 206 213 0 Containing fuses: 3.15 Amp 2.5 Amp 1.6 Amp 0.5 Amp Table 19 Short parts list Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 56: Fault Finding And Diagnosis

    • Ensure the CH/DHW programmer/timer is functioning. • Ensure the room thermostat is functioning. This fault finding information is for guidance only. Robert Bosch cannot • Ensure the cylinder thermostat (if fitted) is functioning. be held responsible for costs incurred by incorrectly diagnosed faults.
  • Page 57 ▶ Press service button to return to normal. 5 pulses No light Not a fault code Service mode selected to maximum. ▶ Press service button to return to normal. Table 20 Fault finding guidance Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 58: Circuit Diagram

    BOSCH 24V CONTROLS Orange PLUG IN POINT Green (NOT USED) Fuse F3, slow T 0.5 A 230V/AC Fuse F2, slow T1.6 A ST18 PRE WIRED LINK DIAGNOSTIC CODE PLUG INTERFACE 6720646195-23.1Wo Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 59: Boiler Operation Function

    Fault finding and diagnosis Boiler operation function Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 60: Boiler Prtection Function

    PUMP ANTISEIZE FUNCTION Pump runs 5 seconds No central heating A central heating demand demand after every 24hrs from activated, pump runs a 24hr period last time pump ran normally 6720643895-111.1Wo Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 61: Technical Specifications/Logs

     Low loss header, type:  Additional expansion vessel  Heating circuit pump: Size/pre-charge pressure:  DHW cylinder/type/number/heating surface output Automatic air vent valve present?  Yes |  No  System hydraulics checked, Notes: Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 62 ___________________________________________________________ Name of service engineer __________________________________________________________ Date, user's signature Affix the test report here. ____________________________________________________________ Date, system installer's signature Table 21 Commissioning report Bosch Condens 5000W – 6 720 646 195 (2018/10)

  • Page 63: Inspection And Maintenance Checklist

    Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  13 Boiler left to customers settings 14 Signature Table 22 Inspection and maintenance checklist Bosch Condens 5000W – 6 720 646 195 (2018/10)
  • Page 64 Robert Bosch (Australia) Pty Ltd Thermotechnology Division 1555 Centre Road Clayton Victoria 3168 Australia Phone: 1300 30 70 37 Fax: 1300 30 70 38 www.bosch-climate.com.au New Zealand Phone: 0800 54 33 52 Fax: 0800 54 33 55 www.bosch-climate.co.nz...

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Zsb18-2a

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