Bosch CONDENS 5000W Handbuch

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

91011

13 12

* 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:

BTurn on mains power supply, the power on indicator

(5) illuminates blue.

BTurn on any external controls

BSet the thermostatic radiator controls to maximum

temperature

BSet 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

BNever run the boiler when the system is

empty or partially filled.

123456789

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

BDo not press the blue power indicator (5)

to reset the boiler.

Fault finding and diagnosis | 61AU/NZ

6 720 646 195a (2010/11)

7 Fault finding and diagnosis

7.1 Fault finding

The electronic control system for this boiler

incorporates a blue central indicator. This normally

confirms the permanent mains supply but, by flashing at

different rates during a fault, provides a guide to the

cause as listed.

This fault finding system assumes that the boiler has

been operating normally until the time of failure (i.e. not

a first installation error).

Preliminary electrical system checks are the first

electrical checks to be carried out during a fault-finding

procedure. On completion of the Service/Fault-Finding

task which has required the breaking and remaking of

electrical connections, check:

(a) Earth continuity,

(b) Short circuit check,

(d) Resistance to earth.

This fault finding information is for guidance

only. Robert Bosch cannot be held

responsible for costs incurred by incorrectly

diagnosed faults.

Blue light

indication

Lockout

reset button Fault Possible solution/check

Off Off No power at

control board

Permanent mains supply to boiler.

Fuse F1 - 2.5A or Fuse F3 - 0.5A.

Transformer (primary coil below 60 Ω, both secondary coil below

10 Ω).

Otherwise replace control board.

On Off Boiler not

operating

during central

heating demand

Live demand at ST10-LR(from external room thermostat/timer)

Fascia mounted timer (if fitted)

CH knob in winter position

Control board

Boiler operating

without live

demand at

ST10-LR(from

external room

thermostat

timer)

Some older thermostats (containing capacitors) may give a low

voltage return at ST10-LRwhen the thermostat contacts are

open.

Check that there is no permanent live at ST10-LRfrom another

source.

Boiler not

operating

during any

demand.

Fan

Control board

Tab. 28

62 | Fault finding and diagnosis AU/NZ

6 720 646 195a (2010/11)

Slow flash

(mostly

off,

flashes

on)

Flashing

(reset

required)

Ignition lockout BGas present and at correct pressure?

BGas valve

–Check that there is 35V d.c. to each solenoid

–Check the resistance of each solenoid:

Top solenoid = 380 Ω±10% (342 - 418 Ω)

Bottom solenoid = 190 Ω±10% (171 - 209 Ω)

BCombustion CO2level.

BFlue condition.

–Blocked flue?

BBlocked condensate pipe or frozen condensate.

BGas valve adjustment.

BIgnition electrodes/harness/connections.

–Check for condition and continuity

BOtherwise replace control board

Slow flash

(mostly

on,

flashes

off)

Flashing

(reset

required)

Flue overheat BHeat exchanger baffles removed and not refitted.

Fast flash Off Volatile lockout

Fan does not

run

BTemperature sensors

–Check condition and continuity of leads/sensors

BFan

–230V a.c. across the live (purple) and neutral (brown)

BFan lead

–Check continuity

BCode plug

–Is code plug missing or not inserted properly.

2 pulses No light Not a fault code Service mode selected to minimum, 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

Blue light

indication

Lockout

reset button Fault Possible solution/check

Tab. 28

Fault finding and diagnosis | 63AU/NZ

6 720 646 195a (2010/11)

7.1.1 Circuit diagram

FAN

FSFR NP LP

NSN

LSLR

ST8

ST9

ST17

ST18

ST5 ST4

ST10

Earth

MAINS

SUPPLY

PUMP

SUPPLY

SPARK

TRANSFORMER

ST1 DIAGNOSTIC

INTERFACE

CODE PLUG

Fuse F1, slow

2.5 A, AC 230 V

Fuse F3, slow T 0.5 A

Fuse F2, slow T1.6 A

ST6

EXTERNAL

FROST STAT

(OPTIONAL)

CH TEMPERATURE

CONTROL

Neutral Supply

230V WIRING CENTER/

JUNCTION BOX

BOSCH 24V CONTROLS

PLUG IN POINT

(NOT USED)

Live Supply

Live Return

Neutral

Live

Colour sequence †

Purple

Red

Orange

Colour sequence †

230V/AC

9V 25V

PRE WIRED LINK

EMS BUS contacts

(for FX controls not used)

PUMP

GAS

VALVE

SAFETY

SOLENOID

SAFETY

SOLENOID

FLAME SENSE

ELECTRODE

SPARK

ELECTRODES

OVERHEAT

STAT

FLUE

OVERHEAT

STAT

Green

DHW TEMPERATURE

CONTROL (NOT USED)

6720646195-23.1Wo

FLOW TEMP.

SENSOR (NTC)

† Fan wiring:

Live = purple

Neutral = brown

SI1

SI2

SI3

Blue

Australia

Robert Bosch (Australia) Pty. Ltd.

1555 Centre Road,

CLAYTON, Victoria 3168,

Phone: 1300 30 70 37

Fax: 1300 30 70 38

www.bosch.com.au/hotwater

New Zealand

Phone 0800 4 bosch or 08 543 352

www.bosch.co.nz

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