SSB800 SA SSB1000 SA SSB1000 TL

Transcription

1 WARNING: If the informtion in these instructions is not followed exctly, fire or explosion my result cusing property dmge, personl injury or deth. Do not store or use gsoline or other flmmble vpors nd liquids in the vicinity of this or ny other pplince. WHAT TO DO IF YOU SMELL GAS: Do not try to light ny pplince, Do not touch ny electricl switch; do not use ny phone in your building, Immeditely cll your gs supplier from neighbor s phone. Follow the gs supplier s instructions, If you cnnot rech your gs supplier, cll the fire deprtment. Qulified instller, service gency or the gs supplier must perform instlltion nd service. FOR YOUR SAFETY: Improper instlltion nd/or opertion could crete crbon monoxide gs in flue gses which could cuse serious injury, property dmge, or deth. Improper instlltion nd/or opertion will void the wrrnty. These instructions re vilble in English nd French. Plese keep these instructions for future reference. Gs Condensing Stinless Steel Boiler BUDERUS BOILER 800 SA 1000 SA 1000 TL Instlltion nd Service Instructions for Contrctors

2 2 Contents 1 Key to symbols nd sfety instructions Key to symbols Sfety instructions Generl wrning Product description Introduction Scope of delivery Proper use Environmentl responsibility / disposl Dimensions nd Connections Technicl dt Min components Efficiency Curves Regultions Complince with stndrds nd regultions Operting limits of the boiler Additionl regultions for instlltion in Msschusetts Instlltion Pckging nd product identifiction Site preprtion Instlltion clernces Setting the Unit Boiler loction Wter chemistry guidelines Hydrulic connection Low wter cutoff No Flow test procedure High limit sfety switch Pressure relief vlve instlltion Expnsion tnk Pump Condenste drin nd piping Electricl Connection Power supply cble connection Access to the electricl terminl strips Enble/Disble(Room Thermostt Connection) Outdoor Temperture Sensor Electricl wiring digrm Gs supply piping Gs Supply Specifictions Mnul Gs Shutoff Vlve Externl Gs Supply Regultor Gs Type Conversion Adjusting nd setting CO2 limits Venting nd ir piping system Combustion ir Ducted combustion ir Introduction Filling the condenste system Filling the boiler heting system Wrnings concerning the gs supply Confirming the Unit s Gs Type Gs Type Conversion Boiler strtup procedure Minimum Wter Flow (Het Exchnger Protection) Heting System Pressure Test Boilers cscde instlltion nd strt-up (FOR 1000 TL ONLY) Boilers Cscde: Set Boiler Address Boilers Cscde: Set Power switch S Opertion Introduction Control pnel description Touchscreen control pnel menus Splsh/Home Screen Cscde Screen Boiler Screen Module Screen Performnce Screen Error Screen Service Screen Module Test Screen...37 Appendix A - Wiring digrm Appendix B - Connection digrm Appendix C - Mintennce Appendix D - Troubleshooting tble Appendix E - Boiler Instlltion (exmple drwings) Appendix F - Exhust terminls nd Air inlet Clernces Appendix G - Sensor Resistnce Appendix H - De-rting for ltitude instlltion Appendix I - Venting size dt Spre prts Commissioning... 31

3 Key to symbols nd sfety instructions 3 1 Key to symbols nd sfety instructions 1.1 Key to symbols Wrnings Wrnings in this document re identified by wrning tringle printed ginst grey bckground. Keywords t the strt of wrning indicte the type nd seriousness of the ensuing risk if mesures to prevent the risk re not tken. The following keywords re defined nd cn be used in this document: DANGER indictes hzrdous sitution which, if not voided, will result in deth or serious injury. WARNING indictes hzrdous sitution which, if not voided, could result in deth or serious injury. CAUTION indictes hzrdous sitution which, if not voided, could result in minor to moderte injury. NOTICE is used to ddress prctices not relted to personl injury. Importnt informtion m This symbol indictes importnt informtion where there is mno risk to people or property. 1.2 Sfety instructions Observe these instructions for your sfety. The burner nd control must be correctly instlled nd djusted to ensure sfe nd economicl opertion of the gs boiler. Red this instlltion nd mintennce mnul crefully nd note the detils on the boiler nmeplte before plcing the boiler in opertion. Risk of ftl injury from explosion of flmmble gses If you smell gs there is dnger of explosion. Never work on gs lines unless you re licensed contrctor / gs fitter. Mke sure tht licensed contrctor / gs fitter instlls the boiler, connects gs nd vent, plces the boiler in opertion, connects the electricl power, nd mintins nd repirs the boiler. No open flme! No smoking! Do not use lighters. Prevent sprk formtion. Do not operte electricl switches, including telephones, plugs or door bells. Close min gs vlve. Open doors nd windows. Wrn other occupnts of the building, but do not use door bells. Cll gs compny from outside the building. If gs cn be herd escping, leve the building immeditely, prevent other people from entering, notify police nd fire deprtments from outside the building Risk to life from electricl shock. Disconnect the power supply to the boiler heting system before conducting ny work on it, e.g. turn off the heting system emergency switch outside the boiler room. It is not sufficient just to turn off the control. Do not crry out electricl work unless you re qulified for this type of work. Before servicing disconnect electricl power nd lock out to prevent ccidentl reconnection. Observe nd follow the locl, stte nd federl instlltion regultions. Risk of ftl injury from flue gs poisoning Insufficient ventiltion or combustion ir vilbility my cuse dngerous flue gs leks or formtion. Mke sure tht inlets nd outlets re not reduced in size or closed. If fults re not corrected immeditely, the boiler must not be operted until ll fults hve been corrected. Inform the system opertor nd/or owner of the fult nd the dnger in writing. When working on the flue gs venting equipment or vent dmper lekge of flue gses my endnger the lives of people. Crefully observe proper opertion of the vent dmper. Do not strt up the boiler unless the vent dmper is operting properly. Use only originl prts when replcing prts. When replcing the vent dmper, instll the new one in the specified position. Risk to life by poisoning by spillge of flue gses If the blocked vent switch trips frequently the fult must be corrected nd proper opertion of the blocked vent switch test must be conducted. Risk to life by poisoning by lekge of flue gses Mke sure tht the boiler is not equipped with thermlly controlled flue gs vent dmper fter the open drft hood. Risk of ftl injury from neglecting your own sfety in cse of emergency, such s with fire Never put yourself t risk. Your own sfety must lwys tke priority. Fire dnger due to flmmble mterils or liquids Mke sure tht there re no flmmble mterils or liquids in the immedite vicinity of the boiler. Mintin minimum distnce of 15 inches from the boiler. Instlltion nd mintennce Observe ll current stndrds nd guidelines pplicble to the instlltion nd opertion of the boiler heting system s pplicble in your stte or locl jurisdiction. Clen nd service the boiler system once yer. Check tht the complete heting system opertes correctly. Immeditely correct ll fults to prevent system dmge. Only use originl Bosch spre prts. Losses cused by the use of prts not supplied by Bosch re excluded from the Bosch wrrnty. 1.3 Generl wrning The instlltion must conform to the requirements of the uthority hving jurisdiction or, in the bsence of such requirements, to the ltest edition of the Ntionl Fuel Gs Code, ANSI Z223.1./NFPA 54. In Cnd, instlltion must be in ccordnce with the requirements of CAN/CSA B149.1, Nturl Gs nd Propne Instlltion Code. Where required by locl, stte nd federl regultions, the system must comply with the Americn Society of Mechnicl Engineers Sfety Code for Controls nd Sfety Devices for Automticlly Fired Boilers (ASME CSD-1). The hot wter distribution system must comply with ll pplicble codes nd regultions. When replcing n existing boiler, it is importnt to check the condition of the entire hot wter distribution system to ensure sfe opertion. Vlves externl to the boiler must be fitted with T-hndles nd condenste piping must be instlled in ccordnce with the Stte Plumbing Code.

4 4 Product description NOTICE: This boiler must be instlled by licensed contrctor/ gs fitter. Filure to do so shll void the product wrrnty. The boiler is intended only for the use for which it ws specificlly designed nd built. Bosch is hereby excluded from ny libility for dmges cused to persons, nimls or property resulting from instlltion errors, improper djustment, mintennce or use. In order to ensure sfety nd correct opertion, the instlltion shll lwys tke plce in full complince with the pplicble codes nd following with the instructions provided by the mnufcturer, nd must lwys be crried out by licensed contrctor / gs fitter only. The equipment must be instlled in pproprite plce nd in combintion with pproprite systems s specified by code. The unit my be exposed to tempertures between 5 deg F (-15 C) nd 158 deg F (70 C) in its originl pckging. After removing the pckging check the integrity nd completeness of delivery nd in cse of non-complince, contct your deler. If there is wter loss, disconnect the boiler from the min power supply, close the wter supply nd immeditely cll technicl ssistnce or instller/locl contrctor. Periodiclly check tht the condenste drin is free from obstruction. Periodiclly check the system pressure. System pressure should be checked when the system is in stndby mode nd no cll for het is present. Mintennce is mndtory nd shll be crried out t lest once yer. This mnul shll be red crefully, in order to instll nd operte the boiler ppropritely, nd sfely. Boiler instlltions, settings nd service should only be performed by experienced licensed contrctor / gs fitter. End Users should only mke djustments with the ssistnce of licensed contrctor / gs fitter. Any mintennce, opertion or service before disconnecting the boiler from the min power supply is forbidden. Do not remove or modify sfety equipment. Do not pull or twist the electricl wires, from the boiler, even if the device is disconnected from the min power supply. Do not obstruct or reduce the ventiltion openings. Do not instll the unit outdoors. Do not leve ny combustibles or continers of flmmble substnces in the room where the boiler is instlled. Keep pckging mteril out of rech of children s it cn be potentilly dngerous. Dispose of pckging mteril s required by lw. The opening of metl csing of the device nd removing of the cover re prohibited to the end user. Any service on the boiler must be crried out by uthorized personl. It s prohibited to dispose the product s domestic wste. The seprte disposl of household pplince voids possible negtive consequences for the environment nd humn helth deriving from inpproprite disposl nd llows to recover the mterils it is mde of in order to chieve significnt svings in energy nd resources. 2 Product description 2.1 Introduction The gs-fired condensing boilers re designed to be used in centrl heting systems. Any other use is prohibited. This boiler cn be connected to n indirect storge tnk for the production of domestic hot wter. There re severl options for venting including single pipe nd two pipe. See section 4.7 Venting nd ir piping system for detils. The qulity of the system wter is very importnt. Poor wter qulity cn dmge heting systems nd boilers due to scle formtion nd corrosion (see wter qulity section). The boilers cn lso function directly with ny hydronic emitter. When instlling the boiler nd system connections, the instller must consider the totl hed loss nd flow rtes in order to dequtely size piping nd circultor pumps. The boiler cn be connected to room thermostt or by 0-10V input. An outdoor ir temperture sensor must be connected to the boiler for n outdoor reset supply temperture control for incresed fuel efficiency nd comfort. 2.2 Scope of delivery Fig SA SA Scope of delivery Component Qty Pckging method [1] Gs condensing boiler 1 Pllet [2] Set of documents for pplince 1 Plstic pckge [3] LP conversion kit 1 Plstic pckge [4] Sensor for DHW 1 Crdbord box on pllet [5] Outdoor sensor 1 Crdbord box on pllet [6] Adpter for condenste drin system (1 ) 1 Crdbord box on pllet [7] Adpter for relief vlves drin system (2 ) 1 Crdbord box on pllet [8] Adpter for flue venting system (6 PP to CPVC) 1 Crdbord box on pllet

5 Product description Proper use The boilers re designed for lrge residentil, commercil nd industril pplictions. The boilers re delivered in complince with CSD-1 Commercil pplictions. The pplince my only be instlled in closed loop hot wter centrl heting systems. Any other purpose is considered improper use. Any resulting dmge is excluded from the mnufcturer s wrrnty. In some heting pplictions like pool, sp or process wter heting het exchnger must be instlled Environmentl responsibility / disposl Environmentl responsibility is one of the fundmentl compny policies of the Bosch Group. We regrd qulity of performnce, economy nd environmentl responsibility s equl objectives. Environmentl protection lws nd regultions re strictly dhered to. To protect the environment, we use the best possible technology nd mterils tking into ccount economic points of view. Pckging All pckging mterils used re environmentlly-friendly nd recyclble Fig TL Scope of delivery Component Qty Pckging method [1] Gs condensing boiler 1 Pllet [2] Set of documents for pplince 1 Plstic pckge [3] LP conversion kit 1 Plstic pckge [4] Sensor for DHW 1 Crdbord box on pllet [5] Outdoor sensor 1 Crdbord box on pllet [6] Adpter for condenste drin system (1 ) 1 Crdbord box on pllet [7] Adpter for relief vlves drin system (2 ) 1 Crdbord box on pllet [8] Stub for cscde connection of ir 10 1 Crdbord box on pllet [9] Stub for cscde connection of venting 10 1 Crdbord box on pllet [10] Stub for cscde connection of condenste 1 Crdbord box on pllet [11] Stub for cscde connection of relief vlves 1 Crdbord box on pllet [12] Bus connecting cble 1 Crdbord box on pllet [13] Bolts 20 Crdbord box on pllet [14] Nuts 20 Crdbord box on pllet [15] Gskets 5 2 Crdbord box on pllet [16] Gskets 3 1 Crdbord box on pllet

6 6 Product description 2.5 Dimensions nd Connections " A C B D E " 3" G F A Flue exhust 6 (160mm) B Intke ir 6 (160mm) C Gs inlet 2 NPT D System return 3 E System supply 3 F Relief vlves outlet 2 (60mm) (dpter: 1-1/2 NPT threded femle) G Condenste outlet 1-1/2 (50mm) (dpter: PVC femle coupling 1 ) Fig SA, 1000 SA (dimension in inches) " A C B D E " 5" G F A Flue exhust 10 (250mm) B Intke ir 10 (250mm) C Gs inlet 3 flnged D System return 5 E System supply 5 F Relief vlves outlet 2 (60mm) (dpter: 1-1/2 NPT threded femle) G Condenste outlet 1-1/2 (50mm) (dpter: PVC femle coupling 1 ) Fig TL (dimension in inches)

7 Product description Technicl dt Unit 800 SA 1000 SA 1000 TL Boiler Ctegory ASME Sect.IV Type of Gs Nturl Gs, Propne* Mx input rte BTU/hr 798,000 1,024,000 1,024,000 (kw) (234) (300) (300) Min input rte BTU/hr 79, , ,000 (kw) (23) (29) (29) Turndown Rte 10:1 10:1 10:1 Gs Connections Ø Inch 2 (NPT) 2 (NPT) 3 (flnged) Mx. NG Pressure Inch W.C (mbr) (50) (50) (50) Recommended NG Pressure Inch W.C (mbr) (20) (20) (20) Min. NG Pressure Inch W.C (mbr) (8.7) (8.7) (8.7) Mx. LPG Pressure Inch W.C (mbr) (50) (50) (50) Min. LPG Pressure Inch W.C (mbr) (19.9) (19.9) (19.9) CO2 Working Rnge (NG) % CO2 Working Rnge (LP) % Wter Connections Ø Inch Mx. Allowble Working Pressure (MAWP) PSI (br) (5.5) (5.5) (5.5) Wter Volume Gllon (liter) (50) (60) (75) Vent/Air Intke Connections Ø Inch (Ø mm) (160) (160) (160) Vent Mterils CPVC, PP, Stinless Steel AL29-4C Mx operting temperture F ( C) (90) (90) (90) Mx HE llowble temperture F ( C) (98.9) (98.9) (98.9) Ambient storge temperture F 5 to to to 158 ( C) (-15 to 70) (-15 to 70) (-15 to 70) Ambient functioning F 32 to to to 120 temperture ( C) (0 to 49) (0 to 49) (0 to 49) Surfce het exchnger per module SQFT (m2) (2.5) (4) (4) Stndrd Listings & Approvls CSA, ASME, AHRI Electricl Req. 120V/1PH/60Hz 15.1 FLA* 15.1 FLA* 15.1 FLA* Weight (dry) lbs (kg) (390) (450) (510) Dimension WxHxD Inch 35.4x70.9x x70.9x x70.9x31.5 (mm) 900x1800x x1800x x1800x800 (*) FLA (Full Lod Amperge) mximum current drwn by the boiler if ll pumps rech rted horsepower

8 8 Product description 2.7 Min components Fig. 5 [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] 9 Het exchnger Flowmeter Temp./pressure guge Relief vlve Pump Mnul stop vlve Wter supply heder Wter return heder Minimum wter pressure switch Min power switch Fn Gs mnifold Flue mnifold Touchscreen Service disply Module power switch Gs pressure switch Gs vlve min components

9 Product description Efficiency Curves Therml Efficiency 100% 98% 96% 100% input 30% input 20% input 94% 92% 90% 88% 80% Return wter temperture ( F)@36 Degree Rise Fig. 6 Efficiency Curves 800 SA, 1000 SA, 1000 TL

10 10 Regultions 3 Regultions m Observe m Vlves m m ll rules, regultions, stndrds nd guidelines pplicble to the instlltion nd opertion of this pplince in your country. externl to the boiler must be fitted with T-hndles nd condenste piping must be instlled in ccordnce with the Stte Plumbing Code. 3.1 Complince with stndrds nd regultions The instlltion must conform to the requirements of the uthority hving jurisdiction or, in the bsence of such requirements, to the ltest edition of the Ntionl Fuel Gs Code, ANSI Z223.1./NFPA 54. In Cnd, instlltion must be in ccordnce with the requirements of CAN/CSA B149.1, Nturl Gs nd Propne Instlltion Code. This condensing gs boiler complies in its design nd mode of opertion with the Americn Ntionl Stndrd ANSI Z21.13/CSA4.9, ltest edition for Gs Fired Low Pressure Stem nd Hot Wter Boilers. Other confirmed pprovls nd certifictions re indicted by lbels on the boiler. Where required by the uthority hving jurisdiction, the instlltion must conform to the Stndrd for Controls nd Sfety Devices for Automticlly Fired Boilers, ANSI/ASME CSD-1. Instll CO detectors per locl regultions. Boiler requires yerly mintennce (see section Appendix C - Mintennce ). 3.2 Operting limits of the boiler The het exchnger hs been designed nd certified in ccordnce with the ASME Boiler nd Pressure Vessel Code, Section IV. The hot wter distribution system must comply with ll pplicble codes nd regultions. When replcing n existing boiler, it is importnt to check the condition of the entire hot wter distribution system to ensure sfe opertion. Common prctice clls for inspecting n existing system in its entirety nd bringing it up to code. All pipework should be properly clened nd flushed. 3.3 Additionl regultions for instlltion in Msschusetts () For ll side wll horizontlly vented gs fueled equipment instlled in every dwelling, building or structure used in whole or in prt for residentil purposes, including those owned or operted by the Commonwelth nd where the side wll exhust vent termintion is less thn seven (7) feet [2150 mm] bove finished grde in the re of the venting, including but not limited to decks nd porches, the following requirements shll be stisfied: INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of instlltion of the side wll horizontl vented gs fueled equipment, the instlling plumber or gsfitter shll observe tht hrd wired crbon monoxide detector with n lrm nd bttery bckup is instlled on the floor level where the gs equipment is to be instlled. In ddition, the instlling plumber or gsfitter shll observe tht bttery operted or hrd wired crbon monoxide detector with n lrm is instlled on ech dditionl level of the dwelling, building or structure served by the side wll horizontl vented gs fueled equipment. It shll be the responsibility of the property owner to secure the services of qulified licensed professionls for the instlltion of hrd wired crbon monoxide detectors. -- In the event tht the side wll horizontlly vented gs fueled equipment is instlled in crwl spce or n ttic, the hrd wired crbon monoxide detector with lrm nd bttery bck-up my be instlled on the next djcent floor level. - - In the event tht the requirements of this subdivision cn not be met t the time of completion of instlltion, the owner shll hve period of thirty (30) dys to comply with the bove requirements; provided, however, tht during sid thirty (30) dy period, bttery operted crbon monoxide detector with n lrm shll be instlled. APPROVED CARBON MONOXIDE DETECTORS. Ech crbon monoxide detector s required in ccordnce with the bove provisions shll comply with NPA 720 nd be ANSI/UL 2034 listed nd IAS certified. SIGNAGE. A metl or plstic identifiction plte shll be permnently mounted to the exterior of the building t minimum height of eight (8) feet bove grde directly in line with the exhust vent terminl for the horizontlly vented gs fueled heting pplince or equipment. The sign shll red, in print size no less thn one-hlf (.) inch in size, GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS. INSPECTION. The stte or locl gs inspector of the side wll horizontlly vented gs fueled equipment shll not pprove the instlltion unless, upon inspections, the inspector observes crbon monoxide detectors nd signge instlled in ccordnce with the provisions of 248 CRM 5.08(2)() 1 through 4. (b) EXEMPTIONS: The following equipment is exempt from 248 CRM 5.08(2)() 1 through 4: The equipment listed in Chpter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 s dopted by the bord; nd Product Approved side wll horizontlly vented gs fueled equipment instlled in room or structure seprte from the dwelling, building or structure used in whole or in prt for residentil purposes. (c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the mnufcturer of Product Approved side wll horizontlly mounted gs equipment provides venting system design or venting system components with the equipment, the instructions provided by the mnufcturer for the instlltion of the equipment nd venting shll include: Detiled instructions for the instlltion of the venting system or the venting system components; nd A complete prts list for the venting system design or venting system. (d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the mnufcturer of Product Approved side wll horizontlly vented gs fueled equipment does not provide the prts for the venting of flue gses, but identifies specil venting systems, the following requirements shll be stisfied by the mnufcturer: The referenced specil venting systems shll be included with the pplince or equipment instlltion instructions; nd The specil venting systems shll be Product Approved by the Bord, nd the instructions for tht system shll include prts list nd detiled instlltion instructions. (e) A copy of ll instructions for ll Product Approved side wll horizontlly vented gs fueled equipment, ll venting instructions, ll prts lists for venting instructions, nd/or venting design instructions shll remin with the pplince or equipment t the completion of the instlltion.

11 Instlltion 11 4 Instlltion 4.1 Pckging nd product identifiction The is delivered strpped to pllet, pcked nd protected in crdbord crton. WARNING: m In NOTICE: The pckging shows the chrcteristics of the product: model, power, fuel type nd version. In cse of devition from the order, contct your locl deler. After removing the pckging check the condition nd completeness of delivery. Keep the pcking mteril out of rech of children s it my be dngerous. Dispose of pckging in n environmentlly responsible mnner. m order to ensure proper product identifiction do not remove or tmper with ny product identifiction tgs or lbels. 4.2 Site preprtion Ensure tht the site selected for instlltion of the 800 SA, 1000 SA nd 1000 TL Boiler includes: Access to AC Input Power t 120 VAC, Phse-Neutrl, FLA Access to Nturl Gs line t recommended pressure of 8 inches W.C. (or higher) for 798,000 BTU/hr energy input for the 800 SA, 1,024,000 BTU/hr energy input for the 1000 SA nd 1000 TL Instlltion clernces The models 800 SA, 1000 SA nd 1000 TL re pckged in n enclosure hving identicl size. The unit must be instlled with the prescribed clernces for service s shown in Fig. 7. The minimum clernce dimensions, required by BOSCH, re listed below. However, if Locl Building Codes require dditionl clernces, these codes shll supersede BOSCH s requirements. Minimum cceptble clernces required re s follows: Minimum cceptble clernces required re s follows: 800 SA SA TL Recommended Service Clernces Required Service Combustibles Side inches Front inches Rer 20 2 inches Top 12 6 inches All gs piping, wter piping nd electricl conduit or cble must be rrnged so tht they do not interfere with the removl of ny pnels, or inhibit service or mintennce of the unit. WARNING: Keep the unit re cler nd free from ll combustible mterils nd flmmble vpors or liquids. CAUTION: While pckged in the shipping continer, the unit must be moved by pllet jck or forklift from the SIDE ONLY. FOR MASSACHUSSETTS ONLY: For Msschusetts instlltions: the instlltion must comply with ll requirements specified.

12 12 Instlltion RECOMMENDED SERVICE CLEARANCES REQUIRED SERVICE COMBUSTIBLES 12 (305mm) (800mm) 6 (153mm) (800mm) (1900mm) (1900mm) 20 (**) (407mm) 2 (**) (51mm) 24 (*) (610mm) 24 (*) (610mm) 12 (*) (305mm) 12 (*) (305mm) FRONT 40 (1016mm) FRONT 40 (1016mm) (*) Excluding the side where the connections re mde. (**) 24 clernce recommended for 1000 TL (*) Excluding the side where the connections re mde. (**) 6 clernce required for 1000 TL Fig SA, 1000 SA nd 1000 TL Clernce

13 Instlltion Setting the Unit Remove the top nd side crbord pnels nd the plstic film. Lift the unit off the shipping skid with forklift nd position it on the floor in the desired loction. WARNING: WARNING: When lifting or moving the boiler: do not ttempt to mnipulte the boiler using the top corner tripods or ny other component of the boiler. When lifting or moving the boiler with forklift: mke sure the forks re longer thn the boiler size (width or depth) so tht forks stick out s per Fig. 8. In multiple unit instlltions, it is importnt to pln the position of ech unit in dvnce. Sufficient spce for piping connections nd future service/ mintennce requirements must lso be tken into considertion. All piping must include mple provisions for expnsion. 4 4 Fig SA, 1000 SA nd 1000 TL Crne Lifting Hndling The unit must be instlled on concrete flt floor, with no grdient in ny direction, to ensure proper condenste nd wter dringe (see Fig. 10). Fig SA, 1000 SA nd 1000 TL Forklift Hndling WARNING: Alwys keep the boiler in the upright position. If crne is required, the boiler must be lifted through bnds. WARNING: WARNING: When lifting the boiler with crne: use bnds, no chins. Bnds must comply with federl, stte nd locl rules. When lifting the boiler with crne: the bnds must be positioned ccording to the Fig. 9. Fig SA, 1000 SA nd 1000 TL Instlltion

14 14 Instlltion AIR H J G A FLUE RETURN E C B GAS I K F D SUPPLY L Fig TL Cscde Instlltion The cscde instlltion of TL boilers should be crried out ccording to the following procedure (exmple: 2 boilers): [1] Set the position of one of the two boilers, connecting it to the system supply/return pipe; [2] Using jckpllet, move the second boiler close to the first one, with gp not less thn 4ft; [3] Insert the component A (item [9] on Fig. 2) on the venting mnifold of the first boiler. Do the sme with component B (item [8] on Fig. 2) on the ir hole, only in cse of seled combustion instlltion type; [4] Insert the component C (item [6] on Fig. 2) on the condenste mnifold of the first boiler. Do the sme with component D (item [7] on Fig. 2) on the relief vlves drin mnifold; [5] Still using jckpllet, move closer the second boiler, ligning it to the components just instlled on the first boiler; [6] When the gp between the boilers is pproximtely 4 to 8in., insert two bolts in the lower holes of the 5 supply heder, two bolts in the lower holes of the 5 return heder nd two bolts in the lower holes of the 3 gs mnifold; [7] Put the sels E, F nd G crefully, in verticl position, on top of the bolts; [8] Progressively close the gp between the boilers, using the jckpllet, checking the sels sty in proper position; [9] Push the second boiler ginst the first one until the gp is pproximtely 1in.; [10] Insert ll remining bolts nd tighten them firmly with the relevnt nuts; [11] Add ll relevnt cps nd blnk flnges on the free sides of the boilers (components H, I, J, K nd L on Fig. 11), with their sels; [12] Insert the boiler supply temperture sensor (vilble pre-wired into the electricl box of ech boiler) on one of the two wells vilble on ech supply heder (select the proper well ccording to the wter flow direction); [13] Connect the bus cble (item [12] of Fig. 2) between the CASCADE LINK connections vilble on ech Low voltge terminl strip; [14] Complete the instlltion connecting the wter, gs venting, condenste, relief vlves, ir (in cse of seled combustion) pipes.

15 Instlltion Boiler loction This boiler is suitble for indoor instlltions. To operte properly nd sfely this boiler requires continuous supply of ir for combustion. Instll this boiler in clen, dry loction with dequte ir supply. Do not locte this boiler in n re where it will be subject to freezing. The boiler should be locted close to floor drin in n re where lekge from the pplince or connections will not result in dmge to the djcent re or to lower floors in the structure. DO NOT instll this pplince in ny loction where gsoline or flmmble vpors re likely to be present. DO NOT instll this pplince on top of crpet flooring. Applince must be instlled on level floor. Mintin required clernces from combustible surfces. 4.3 Wter chemistry guidelines Excessive wter hrdness cusing lime buildup in the stinless steel coils or tubes is not fult of the pplince nd is not covered by wrrnty. Wter hrdness must fll within the following limits: Prmeters Units Vlue Generl feture - Colorless, no sediment PH vlue PH Min 6.5; Mx 9 Dissolved Oxygen mg/l < 0,05 Totl iron (Fe) mg/l < 0,3 Totl copper (Cu) mg/l < 0,1 N2SO3 mg/l < 10 N2H4 mg/l < 3 PO4 mg/l < 15 CCO3 ppm Min 50 ; Mx 150 Trisodium Phosphte ppm bsent Chlorine ppm < 100 Pressure PSI Min 7.25; Mx 80 Glycol % Mx 40% (only propylene glycol) Before nd during ssembly, the system must be kept free of impurities, construction dust, snd, copper dust, grese, crbon deposits s well s welding flux residue. Before connecting the boiler to the heting system, flush the heting system to remove sediment, flux, dirt, nd other foreign mtter. Do not use clening fluids tht re not comptible with the boiler mterils, including cids (e.g. hydrochloric cid nd similr ones) t ny concentrtion. Introducing fresh wter to the system increses the oxygen presence nd cn cuse corrosion of metllic components. Immeditely repir ny drips or leks in the system to void constnt introduction of ir into the system. Excessive fluctution in pressure chnges in the system cn cuse ftigue nd stress on the het exchnger. This is detrimentl to the integrity of the boiler nd system components, it is mndtory to mintin constnt operting pressure. Avoid n utomtic wter fill system. Use only untreted wter to fill the system. Do not use TSP (tri-sodium phosphte) Do not use fill wter treted with slt bedding type exchngers (ion exchnger). Consult locl wter tretment specilist for recommendtions if ny of the bove tble is outside the stted rnges. When using oxygen permeble PEX, the system must be seprted from the boiler by het exchnger. A correctly sized nd working expnsion vessel must be instlled. Excessive flow cn cuse erosion dmge to the het exchnger. CAUTION: For freeze protection use only propylene glycol, with scle inhibitors, with mximum volume [concentrtion] of 40% of glycol. Frost protection nd inhibitor level hs to be checked nnully during the regulr scheduled mintennce of the condensing boiler. CAUTION: The boiler, when used in connection with refrigertion system, must be instlled so the chilled medium is piped in prllel with the boiler with pproprite vlves to prevent the chilled medium from entering the boiler. CAUTION: The boiler piping system of hot wter boiler connected to heting coils locted in ir hndling units where they my be exposed to refrigerted ir circultion must be equipped with flow control vlves or other utomtic mens to prevent grvity circultion of the boiler wter during the cooling cycle. A minimum wter pressure is required for optimum performnce. Minimum wter pressure required: 7.25 psi (0.5 br). 4.4 Hydrulic connection The Boiler utilizes 3 flnges for models 800 SA/ 1000 SA nd 5 flnges for model 1000 TL for the wter system supply nd return piping connections. The physicl loction of the supply nd return piping connections is on the side of the unit s shown in Fig Fig. 13. Fig NPT Gs Connection 6 PP Flue Venting 6 Air Intke 3 Flnged Wter Return 1 1/2 Condenste outlet 2 Relief vlves outlet 800 SA nd 1000 SA Connections 3 Flnged Wter Supply

16 16 Instlltion 3 Flnged Gs Connection 10 PP Flue Venting 10 Air Intke 5 Flnged Wter Return 1 1/2 Condenste outlet 2 Relief vlves outlet 5 Flnged Wter Supply Fig TL Connections CAUTION: Before connecting the boiler to the heting system, flush the heting system to remove sediment, flux, dirt, nd other foreign mtter. The het exchnger my be dmged by sediment or corrosion. CAUTION: Do not use clening fluids tht re not comptible with the boiler mterils, including cids (e.g. hydrochloric cid nd similr ones) t ny concentrtion. CAUTION: Introducing fresh wter to the system increses the oxygen presence nd cn cuse corrosion of metllic components. Immeditely repir ny drips or leks in the system to void constnt introduction of ir into the system. CAUTION: Excessive fluctution in pressure chnges in the system cn cuse ftigue nd stress on the het exchnger. This is detrimentl to the integrity of the boiler nd system components, it is mndtory to mintin constnt operting pressure Low wter cutoff A low wter cut off (LWCO) is instlled on ech module of the boiler. To check the functionlity of LWCO go to the Module Test screen on the Touchscreen (see section Opertion) nd then click on LWCO test. On the screen will pper the error Low Wter Cutoff Error. At this point press the reset button. The error will turn off No Flow test procedure To simulte no wter flow condition, the following steps should be followed: Turn power off to boiler Disconnect module 1 pump power Turn power on to boiler Press Test mode button on module 1 screen Select high power Module 1 will subsequently shut down s result of no flow error. Repet the sme process for ech module of the boiler / cscde High limit sfety switch A high limit sfety switch is instlled on ech module of the boiler. To test the High limit sensor functionlity, there re two options vilble: A Electronic test (defult): to simulte high limit lockout go to the Module Test screen on the Touchscreen (see Module Test Screen pg. 37) nd then click on High limit test button. The system genertes high limit lockout signl tht shut the module down (nd mkes the reset button vilble on the screen). Pressing the reset button the module restrts; B Physicl test: to trip the high limit sensor by incresing the wter temperture up to 208 F, go to the Service disply nd enble the physicl high limit test Settings->Boiler Settings->Boiler Prmeters->(183) High Limit Test Then move to the Module Test screen on the Touchscreen (see Module Test Screen pg. 37) nd click on High limit test button. Follow the step by step procedure described below: Progressively close the return mnul stop vlve to reduce the flow into the module under test; Check the module supply temperture on the screen; Reduce the flow until the control will disply Mx. Thermostt Lock error nd the module stops; At this point press the reset button to restrt the module. CAUTION: The Physicl test is not recommended: forcing the boiler to low wter flow condition my expose the het exchnger to potentil overheting. The Mnufcturer declines ny responsibility on dmges derived from this kind of test Pressure relief vlve instlltion ASME rted Pressure Relief Vlves re fctory instlled in ech module of boilers. The pressure rting for the relief vlves is 75 PSI. The relief vlves re instlled on ech hot wter supply pipe of the modules s shown in Fig.8. The relief vlves drin pipes re connected to the mnifold running t the bottom of the boiler. The mnifold must be routed to nerby floor drin. Relief vlves should be mnully operted t lest once yer. If relief vlve dischrges periodiclly, this my be due to therml expnsion in closed wter supply system. Contct the wter supplier or locl plumbing inspector on how to correct this sitution.

17 Instlltion 17 Do not plug the relief vlve Expnsion tnk An expnsion tnk must be instlled in the hydrulic system. The expnsion tnk must be properly sized for the boiler nd the system volume, temperture WARNING: nd An pressure. undersized expnsion tnk will cuse lekge of wter from the pressure relief vlve nd introduce fresh wter into the system. Excessive ddition of mkeup wter cn cuse corrosion of metllic components nd compromise the functionlity of the boiler. Fig PSI Relief vlve (one for ech module) Pressure Relief Vlve Loction Refer to instructions provided by the mnufcturer of the expnsion tnk for detils on its instlltion nd sizing Pump SA nd 1000 TL re fitted with circultor pump on ech module. The grph in the following figure shows the hed rnge of the pump depending on the flow rte compred to the relevnt pressure drop. m It m is importnt to ensure the pump hs the correct flow rte for the system to void low wter circultion sitution. In event of n indequte flow rte, the sfety devices of the boiler will utomticlly stop the burner. 800 SA p / Feet of Hed Mx. pump speed Hed vilble for the system t 29.6GPM (min. wter mx. power with T 54 F / 30 C) Hed vilble for the system t 44.4GPM (recommended wter mx. power with T 36 F / 20 C) 6 3 Fig SA Pressure drop Flow rte / GPM

18 18 Instlltion 1000 SA p / Feet of Hed Mx. pump speed Hed vilble for the system t 37.8GPM (min. wter mx. power with T 54 F / 30 C) Hed vilble for the system t 56.8GPM (recommended wter mx. power with T 36 F / 20 C) Fig SAPressure drop Flow rte / GPM /1000 TL p / Feet of Hed Hed vilble for the system t 37.8GPM (min. wter mx. power with T 54 F / 30 C) Mx. pump speed Hed vilble for the system t 56.8GPM (recommended wter mx. power with T 36 F / 20 C) Fig TL Pressure drop Flow rte / GPM

19 Instlltion Condenste drin nd piping The boiler is designed to condense wter vpor from the flue products. Ech module of the boiler is equipped with condenste drin system (see Fig. 18), connected to the condenste horizontl mnifold. Horizontl Condenste Mnifold Condenste Syphon Fig. 18 WARNING: Condenste Drin System At the Strt-up nd fter prolonged shutdown of the boiler, the syphon must be filled with wter prior to restrt it, otherwise combustion gses will enter the room with risk of n excessive level of crbon monoxide. The instlltion must hve provisions for suitble dringe or collection of the condenste out of the boiler trps. The condenste wter shll be dischrged t tmospheric pressure, by dripping into suitble drin, nd shll be neutrlized prior to drining per locl codes. The condenste drin tube must pitch wy from the boiler (1/4 slope per foot) nd must never reduce its dimeter downstrem. Never use copper pipes or of other mteril not intended for the specific purpose, becuse the ction of condenste will cuse rpid deteriortion. Check tht the condenste drin pipe is dequtely sloping towrds the dischrge point voiding high points, which cn inhibit the flow of condenste. The condenste pipe must be instlled in such wy so s to void the freezing of the liquid. WARNING: Verify condenste disposl / neutrliztion is in ccordnce with locl, stte nd federl regultions. If floor drin is not vilble, condenste pump cn be used to remove the condenste to drin. The mximum condenste flow rte is 6.2 GPH for 800 SA nd 7.9 GPH for 1000 SA / 1000 TL. The drin line must be removble for routine mintennce. CAUTION: Use PVC, CPVC, stinless steel, luminum or polypropylene for condenste drin piping (Fig. 20). DO NOT use crbon or copper components. Relief vlves drin Condenste drin The procedure for filling the trps nd syphon with wter is shown on the Fig. 19: Disconnect the condenste pipe Fig. 20 Condenste Drin nd Relief Vlves Mnifold Loctions Fill the syphon with wter Electricl Connection The voltge configurtion of 800 SA, 1000 SA nd 1000 TL is s follows: 120VAC, 1-Phse, 60 Hz Ech boiler must be connected to dedicted electricl circuit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER. Fig. 19 Wter Filling of Condenste System

20 20 Instlltion Power supply cble connection The power supply cble cn be inserted into the boiler using one of the three holes on the top pnel (or one of the three holes on the bck pnel), s shown on fig. 18. Ech boiler is equipped with min 2-pole service switch ccessible on the front door, to quickly nd sfely disconnect electricl service Loosen the screws of the cover nd remove pnel to ccess the internl connections shown in Fig. 23. Power supply cble Electricl box (open view) Fig. 21 Power supply cble connection Fig. 23 Electricl box To ccess the electricl box, open the front door (see Fig. 22). The mjority of the components re instlled in the electricl box. Some of them re mounted on DIN ril. 905 PB Service Disply Front Door Cover Pnel Electricl box (C) (B) (C) (C) (A) (D) Fig. 24 (A) (B) (C) (D) Electricl Box Lyout = High Voltge Terminl Strip = Low Voltge Terminl Strip = 905 MN Controllers = Pumps relys Fig. 22 Electricl Internl Lyout

21 Instlltion 21 Front Door Cover (removed) 905 TS touchscreen (bckside view) Min Switch (bckside view) 905 TS touchscreen Power Supply (24V) Enble/Disble(Room Thermostt Connection) The Room Thermostt (Enble/Disble) terminls (dry contcts) come pre-wired closed (jumped) from the fctory. For connecting room thermostt, the jumper must be removed nd the thermostt wires must be connected to terminls 9 nd 10, s shown in Fig Outdoor Temperture Sensor If outdoor temperture sensor is to be used, the outdoor probe needs to be connected to terminls 3 nd 4 s shown in Fig. 26. The outdoor probe shll be instlled on n outer wll, North or North/Est, wy from windows, door, nd ventiltion grids. Never instll the probe in position exposed to the sun. The mximum length is 300 (100 meters), if the cble length exceeds 32 (10 meters) shielded cble is required nd shll be connected to chssis ground. NOTE: All sensors nd low voltge wiring shll not be routed in direct contct or ner high voltge power Electricl wiring digrm See Appendix A - Wiring digrm Fig. 25 Front Door: Bckside lyout NOTE: All electricl conduit nd hrdwre must be instlled so tht it does not interfere with the removl of ny unit covers, inhibit service/ mintennce, or prevent ccess between the unit nd wlls or nother unit. 4.5 Access to the electricl terminl strips Ech unit is fully wired from the fctory with n internl operting control system. No field control wiring is required for norml opertion. However, the control system used with ll boilers does llow for some dditionl control nd monitoring fetures. Wiring connections for these fetures re mde on the Input / Output (I/O) terminl strips locted behind the removble cover of the electricl box, s shown in Fig. 26. NOTE: Any electricl lod connected to the terminl strip (externl pumps, ir dmper, lrm) must be powered through rely, not included in the boiler, to be provided nd wired by the instller. HIGH VOLTAGE TERMINAL STRIP MAIN SUPPLY PUMP RELAY ON/OFF MODULES 120 VAC Min Pump Pump CH 3 WAY CH Pump DHW/ 3-WAY DHW ALARM EXT. IGNITER EXT. IGNITER L N L N L N L N L N L N L N L N LOW VOLTAGE TERMINAL STRIP Enble Disble Fig. 26 I/O Terminl Strips

22 22 Instlltion 4.6 Gs supply piping 800 SA nd 1000 SA boilers contin 2 inch NPT gs inlet connection on the upper side of the unit s shown in Fig TL is equipped with 3 inch flnged connection, still on the upper side of the unit Fig. 13. WARNING: CAUTION: The boiler nd its gs connection must be lek tested before plcing the boiler in opertion. Never use mtches, cndles, flmes or other sources of ignition to check for gs leks. Mny of the sops used for gs pipe lek testing re corrosive to metls. Therefore, piping must be rinsed thoroughly with clen wter fter lek checks hve been completed. NOTE: All gs piping must be rrnged so tht it does not interfere with removl of ny covers, inhibit service/mintennce, or restrict ccess between the unit nd wlls, or nother unit. NOTE: The boiler shll be instlled such tht the gs ignition system components re protected from wter (dripping, sprying, rin, etc.) during pplince opertion nd service (circultor replcement, condenste trp, control replcement, etc.). Prior to instlltion, ll pipes should be de-burred nd internlly clered of ny scle, metl chips or other foreign prticles. Do Not instll ny flexible connectors or unpproved gs fittings. Piping must be supported from the floor, ceiling or wlls only nd must not be supported by the unit. A suitble piping compound, pproved for use with nturl gs, should be used. Any excess must be wiped off to prevent clogging of components. To void unit dmge when pressure testing gs piping, isolte the unit from the gs supply piping. At no time should the gs pressure pplied to the unit exceed 20 W.C. Lek test ll externl piping thoroughly using sop nd wter solution or suitble equivlent. The gs piping used must meet ll pplicble codes. A sediment trp / drip leg must be instlled on the gs supply piping. Instlltion of union t the pplince gs line connection is required for ese of service Gs Supply Specifictions The gs supply input specifictions to the unit for Nturl Gs re s follows: The mximum sttic pressure to the unit must not exceed 20 W.C. The gs supply piping nd pressure to the unit must be of sufficient cpcity to provide 788 cfh for 800 SAA nd 1010 cfh for 1000 SA / 1000 TL, while mintining the recommended gs pressure t 8 W.C. (or higher) for burners operting t mximum cpcity Mnul Gs Shutoff Vlve A mnul shut-off vlve must be instlled in the gs supply line upstrem of the boiler. Mximum llowble gs pressure to the boiler is 20 W.C. Should overheting occur or the gs supply fils to shut off, do not turn off or disconnect the electricl supply to the pump. Insted, shut off the gs supply t loction externl to the pplince Externl Gs Supply Regultor An externl gs pressure regultor is required on the gs inlet piping under most conditions. Regultors must conform to the following specifictions: The externl nturl gs regultor must be cpble of regulting ) 100, ,000 BTU/HR for 800 SA b) 100,000 1,024,000 BTU/HR for 1000 SA / 1000 TL of nturl gs while mintining recommended gs pressure of 8.0 W.C. (or higher) to the boiler. A regultor MUST be used when gs supply pressure will exceed 20 W.C. The following re BOSCH s recommendtions for instlltion of gs pressure regultor, unless superseded by stte nd locl codes nd the regultor mnufcturer s specifictions: Horizontl instlltion of gs pressure regultors is recommended unless stted otherwise by the regultor mnufcturer. Consult the mnufcturer for dditionl recommendtions nd instlltion options. For ll boilers, when instlled horizontlly the required distnce between the gs pressure regultor nd the nerest pipe fitting, elbow or vlve is 10 feet. When pipe size reduction is required, use only bell reducers. MASSACHUSETTS INSTALLATIONS ONLY For Msschusetts instlltions, mndtory externl gs supply regultor must be instlled. The gs supply regultor must be properly vented to outdoors. Consult the locl gs utility for detiled requirements concerning venting of the supply gs regultor. The Commonwelth of Msschusettes prohibits the use of copper tubing for the gs line. NOTE: It is the responsibility of the customer to source nd purchse the pproprite gs regultor s described bove Gs Type Conversion The heting unit is fctory preset for operting with nturl gs. This set-up cn be chnged using the conversion kits supplied by the mnufcturer, on demnd. The kit (identified exteriorly by prt number) consists of: two (2) orifices (one for ech gs vlve), mrked to indicte their size; one (1) conversion lbel including the following: -- boiler model number; -- the gs to which the boiler hs been converted; -- minimum nd mximum inlet gs pressures of the converted boiler; -- mnifold pressure; -- input rting; -- identifiction of the conversion kit by prt number. one (1) step by step instruction document. WARNING: The conversion kit shll be instlled by qulified service gency in ccordnce with the mnufcturer s instructions nd ll pplicble codes nd requirements of the uthority hving jurisdiction. If the informtion in these instructions is not followed exctly, fire, n explosion or production of crbon monoxide my result cusing property dmge, personl injury or loss of life. The qulified service gency is responsible for the proper instlltion of the kit. The instlltion is not proper nd complete until the opertion of the converted pplince is checked s specified in mnufcturer s instructions supplied with the kit.

23 Instlltion 23 The gs-ir rtio must lwys be set on the bsis of CO2 or O2 reding tken t mximum nominl output nd minimum nominl output using n electronic flue gs nlyzer. SWITCHING FROM NATURAL GAS TO LP Close the gs shutoff vlve Disconnect the electric power supply from the boiler WARNING: To void electricl shock, it is mndtory to disconnect the boiler from the power supply using service disconnect externl switch. Open the front pnels Unscrew the swivel joint indicted in Fig. 27 to seprte the vlve from the connection pipe with the fn Adjusting nd setting CO2 limits Insert combustion nlyzer probe into the test port shown in Fig. 28 Go to the Touchscreen nd ccess the Module screen (s described on Module Screen pg. 36) relevnt to the module under nlysis; Press MODULE TEST button; Press HIGH POWER button. Wit 2 or 3 minutes to rech stedy stte conditions nd record the CO2 vlue. Test port of the module LP Orifice Swivel joint Fig. 28 Test Port for Combustion Anlysis (vilble on ech module) Fig. 27 Nturl Gs to LP Gs Conversion Seprting the two components, the hole where the gs psses with its gsket cn be ccessed Plce the provided metl orifice (Fig. 27) below the existing gsket. Boiler Model N on orifice 800 SA 10, SA 9, TL 9,5 Tighten the swivel joint nd lek test the converted boiler prior to plcing into opertion. WARNING: NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS. Use very mild sop nd rinse joints nd piping thoroughly fter lek checks hve been completed. Switch the min power supply to ON Press Menu button on Service disply, select Settings, then Applince Configurtion: Scroll to (98) Applince Setting nd modify the vlue ccording to the tble below; Model Gs type PARAMETER #98 SETTING 800 SA NG SA LP SA / 1000 TL NG SA / 1000 TL LP 16 Scroll down to Configurtion Confirmed nd chnge to Yes; Wit for Updting Applince process completion, then move bck to the Home screen; Wit 20secs (t lest) for dt trnsfer to Min controller. Reopen the gs shut-off vlve Adjust the CO2 prmeter s explined in next chpter Affix the gs type lbel from the gs conversion kit to the pplince, s close s possible to existing rting lbel. To djust the CO2 vlue t the mximum power turn the screw A (rotte counter-clockwise to increse CO2) shown in Fig. 28, llen type wrench is necessry for this djustment. Verify tht the vlue of CO2 is stble nd is within the rnge indicted in the following tble (be creful to mke smll chnges nd confirm tht the vlue is stble before mking dditionl djustment). Press LOW POWER : the fn will run t the minimum speed. Fig. 29 Screw B CO2 Adjustment Screw A To djust the CO2 vlue t the minimum power turn the screw B (rotte clockwise to increse CO2) shown in Fig. 29. Verify tht the vlue of CO2 is stble nd is within the rnge indicted in the following tble (be creful to mke smll chnges nd confirm tht the vlue is stble before mking dditionl djustment). Press Reset nd the boiler returns to the stnd by mode. Combustion Vlues Gs Type Mx. Fire CO2% Min. Fire CO2% Nturl Gs LP Gs

24 24 Instlltion 4.7 Venting nd ir piping system boilers must be vented nd supplied with combustion nd ventiltion ir s described in this section. Instlltion must comply with locl requirements nd with the Ntionl Fuel Gs Code ANSI Z boilers vent nd ir piping cn be instlled through the roof or through sidewll. Any of the vent/ir piping methods covered in this mnul cn be used. Do not ttempt to instll the boilers using ny other mens. Suitble, UL pproved, positive pressure, wtertight vent mterils MUST be used for sfety nd UL certifiction. 800 SA, 1000 SA nd 1000 TL boilers cn use the following mteril for venting: Approved Vent pipes Mteril ABS PVC Schedule 40, 80 Single wll glvnized steel CPVC Schedule 40, 80 Polypropylene PP PP-Flex AL29-4C stinless steel PVC CPVC Item Combustion ir Combustion ir Combustion ir Flue gs or combustion ir Flue gs or combustion ir Flue gs or combustion ir Flue gs or combustion ir pipe cement/ primer pipe cement/ primer Stndrd [USA] ANSI/ASTM D1527 ANSI/ASTM D guge ANSI/ASTM F441 ANSI Ct IV Approved Polypropylene ANSI Ct IV Approved Polypropylene UL 1738 ANSI/ASTM D2564 ANSI/ASTM F493 Stndrd [CANADA] BH Gs venting systems, ULC S636( 1 ), Clss IIB CPVC, Clss IIC - Polypropylene Mx. Flue Temp. ( F) , limited only by rting of sels Approved Mnufcturers Centrotherm Eco Systems (InnoFlue SW - 3+mm thick rigid polypropylene) (1) Components of the certified vent systems must not be interchnged with other vent systems or unlisted pipe fittings. Plstic components nd specified primers nd glues of the certified vent system must be from single system mnufcturer nd not intermixed with other system mnufcturer s vent system prts. For instlltion in Cnd, field supplied plstic vent piping must comply with CAN/CSA B149.1 (ltest edition) nd be certified by the locl jurisdiction. List of dpters provided with the boiler for connection to CPVC or stinless steel venting systems: Model Description Mnufcturer 800/1000 SA 6 PP to CPVC flue dpter Centrotherm Roof/Wll terminl Mteril Mnufcturer 6 Pitched roof flshing Stinless steel 10 Pitched roof flshing Stinless steel 6 Flt roof flshing Stinless steel 10 Pitched roof flshing Stinless steel 6 Chimney cover SS with PPs gry end pipe 10 Chimney cover SS with PPs gry end pipe Stinless steel/ PPs Stinless steel/ PPs 6 End pipe PPs gry PPs 10 End pipe PPs gry PPs 6 Termintion tee Blck PP 10 Termintion tee Blck PP 6 PPs to PVC Termintion kit PPs 6 Bird screen PPs 10 Bird screen Stinless steel Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Centrotherm Innoflue Prt Number IAPRF06 IAPRF10 IAFRF06 IAFRF10 ISCM06 ISCM10 ISEP0620 ISEP0639 ISEP106 ISTT0620 ISTT1020 ISLTK06 IASPP06 IASSS10 For specific venting components (terminls, fittings), contct the respective vent mnufcturer. boilers re equipped with flue/condenste pressure switch on ech module, ble to switch off the burner in cse of vent or condenste blockge. WARNING: Do not ttempt to restrt the boiler in cse of vent or condenste blockge, contct qulified contrctor. Filure to comply with this WARNING could result in the ccumultion of crbon monoxide gs which cn cuse severe personl injury or deth. DANGER: It is extremely importnt to follow these venting instructions crefully. Filure to do so will cuse severe personl injury, deth or substntil property dmge.7 DANGER: Use of cellulr core PVC (ASTM F891), cellulr core CPVC or Rdel (polyphenosulfone) in venting systems is prohibited. DANGER: Covering non-metllic vent pipe nd fittings with therml insultion is prohibited. Filure to do so will cuse severe personl injury, deth or substntil property dmge. WARNING: Do not connect this gs pplince with ny other pplince unless pproved by mnufcturer. Filure to comply with this WARNING could result in the ccumultion of crbon monoxide gs which cn cuse severe personl injury or deth.

25 Instlltion 25 Fig. 30 Fig. 31 DANGER: 800 SA, 1000 SA Combustion Air nd Flue Gs Connections 6" Flue Gs Connection 6" Air Intke 10" Flue Gs Connection 10" Air Intke 1000 TL Combustion Air nd Flue Gs Connections The condenste trps must be filled with wter or combustion gses will enter the room with risk of n excessive level of crbon monoxide. Vent connectors serving pplinces vented by nturl drft shll not be connected to ny portion of mechnicl drft systems operting under positive pressure. Ensure tht the flue pipes nd sels re not dmged. Use only primer nd glue compounds pproved for use with the vent mteril used. Never instll brometric or thermlly controlled vent dmper with this boiler. Do not route the flue system piping through or inside nother duct tht is used for exhusting ir or other flue gses. The condenste trp must be primed t ll times. Filure to do so my llow combustion gses to escpe into boiler room. The unit is to be used for either direct vent instlltion or for instlltion using room ir for combustion. When room ir is used, it is necessry to provide n dequte opening for the fresh ir intke. You must use ny of the vent/ir piping methods shown in this mnul. Be sure to locte the unit such tht the vent nd combustion ir piping cn be routed through the building nd properly terminted. The boiler / vent instlltion must be in ccordnce with Venting of Applinces, of the ltest edition of the Ntionl Fuel Gs Code, ANSI Z223.1/NFPA or pplicble provisions of the locl, stte nd federl building codes. All vent pipes must be instlled ccording to the vent mnufcturer s instructions. The exhust vent nd the combustion ir inlet lines must be supported to prevent sgging per the vent mnufcturer s instructions. Do not mix components from different systems. The vent system could fil, cusing lekge of flue products into the living spce. Use only pproved mterils. The vent system shll be instlled so s to prevent the ccumultion of condenste. Consult locl nd stte codes pertining to specil building code nd fire deprtment requirements. Adhere to ntionl code requirements. Observe the listed mximum lengths of vent system, which re boiler model dependent. To void moisture nd frost build-up nd to mintin clernces to openings on djcent structures, 45 nd 90 elbows or tees my be ttched to the end of the vent termintion pipe to direct exhust plumes wy from the djcent structure. The totl llowble vent length, mximum number of elbows nd distnce to ir intke restrictions must be dhered to. Due to the high efficiency of the unit it my dischrge wht looks like white smoke especilly when the outside ir temperture is cold. This is due to the presence of wter vpor, normlly present in the exhust gses. At the time of removl of n existing boiler, the following steps shll be followed with ech pplince remining connected to the common venting system plced in opertion, while the other pplinces remining connected to the common venting system re not in opertion. [1] Sel ny unused openings in the common venting system. [2] Visully inspect the venting system for proper size nd horizontl pitch nd determine there is no blockge or restriction, lekge, corrosion nd other deficiencies which could cuse n unsfe condition. [3] Insofr s is prcticl, close ll building doors nd windows nd ll doors between the spce in which the pplinces remining connected to the common venting system re locted nd other spces of the building. Turn on clothes dryers nd ny pplince not connected to the common venting system. Turn on ny exhust fns, such s rnge hoods nd bthroom exhusts, so they will operte t mximum speed. Do not operte summer exhust fn. Close fireplce dmpers. [4] Plce in opertion the pplince being inspected. Follow the lighting instructions. Adjust thermostt so pplince will operte continuously. [5] Test for spillge t the drft hood relief opening fter 5 minutes of min burner opertion. Use the flme of mtch or cndle, or smoke from cigrette, cigr, or pipe. [6] After it hs been determined tht ech pplince remining connected to the common venting system properly vents when tested s outlined bove, return doors, windows, exhust fns, fireplce dmpers, nd ny other gs-burning pplince to their previous condition of use. [7] Any improper opertion of the common venting system should be corrected so the instlltion conforms with the Ntionl Fuel Gs Code, ANSI Z223.1/NFPA 54, nd/or the Nturl Gs nd Propne Instlltion Code, CAN/CSA B When resizing ny portion of the common venting system, the common venting system should be resized to pproch the minimum size s determined using the pproprite tbles in Chpter 13 of the Ntionl Fuel Gs Code, ANSI Z223.1/NFPA 54, nd/or the Nturl Gs nd Propne Instlltion Code, CAN/CSA B149.1.

26 26 Instlltion VENTING CONFIGURATIONS: The following figures show the cceptble piping instlltion for venting nd combustion ir for both, Stnd Alone nd Cscde configurtions. EXHAUST EXHAUST BOILER BOILERS Fig. 32 All Combustion Air from Adjcent Indoor Spces through indoor Combustion Air Openings EXHAUST EXHAUST BOILER BOILERS Fig. 33 All Combustion Air from Outdoors - Through Ventilted Attic

27 Instlltion 27 EXHAUST EXHAUST BOILER BOILERS Fig. 34 All Combustion Air From Outdoors - Inlet Air From Ventilted Crwl Spce nd Outlet Air to Ventilted Attic EXHAUST EXHAUST BOILER AIR DUCT BOILERS AIR DUCT AIR DUCT AIR DUCT Fig. 35 All Combustion Air from Outdoors through Horizontl Ducts

28 28 Instlltion EXHAUST EXHAUST BOILER BOILERS Fig. 36 All Combustion Air from Outdoors through Single Combustion Air Opening EXHAUST EXHAUST BOILER BOILERS Fig. 37 Seled Combustion locted on sme side with Exhust (horizontl)

29 Instlltion 29 EXHAUST EXHAUST BOILER BOILERS Fig. 38 Seled Combustion locted on sme side with Exhust (verticl) EXHAUST EXHAUST BOILER BOILERS Fig. 39 Seled Combustion locted on side wll

30 30 Instlltion BOILER BOILERS EXHAUST EXHAUST Fig. 40 Exhust locted on side wll It is not recommended to terminte vent bove ny door or window, condenste cn freeze cusing ice formtions. Do not use chimney s rcewy if nother boiler or fireplce is vented into or through chimney. Becuse the unit is cpble of dischrging low temperture exhust gses, horizontl runs must slope upwrds not less thn ¼ in/ft (21 mm/m) from the boiler to the vent terminl. Also, the horizontl portions of the venting system shll be supported to prevent sgging t intervls in ccordnce with nd components used per vent mnufcturer s instlltion instructions. While there is positive flue pressure during opertion, the combined pressure drop of vent nd combustion ir systems must not exceed the following equivlent length: PIPE SIZE - 6 PIPE SIZE - 10 Model MAX. equiv. MAX. equiv. MAX. equiv. MAX. equiv. (m) (ft) (m) (ft) 800 SA SA TL Fittings s well s pipe lengths must be clculted s prt of the equivlent length, ccording to the following tble: Model 45 ELBOW ELBOW - 10 equiv. (m) equiv. (ft) equiv. (m) equiv. (ft) 800 SA SA TL Model 90 ELBOW ELBOW - 10 equiv. (m) equiv. (ft) equiv. (m) equiv. (ft) 800 SA SA TL These fctors must be plnned into the vent instlltion. If the mximum llowble equivlent lengths of piping re exceeded, the unit will not operte properly or relibly. For Msschusetts instlltions, contct compnies ble to provide vent systems which conform to ll pplicble requirements for instlltions within the Commonwelth of Msschusetts. For multiple boilers instlltion, common venting shll be done ccording to exmples on Appendix E - Boiler Instlltion (exmple drwings). 4.8 Combustion ir Provisions for combustion nd ventiltion ir in ccordnce with the section Air for Combustion nd Ventiltion, of the Ntionl Fuel Gs Code, ANSI Z223.1/NFPA 54, or Cluse 8.2, 8.3 or 8.4 of Nturl Gs nd Propne Instlltion Code, CAN/CSA B149.1, or pplicble provisions of the locl building codes. These codes should be consulted before permnent design is determined. boilers cn tke combustion ir from the spce in which re instlled, or the combustion ir cn be ducted directly to the unit. Ventiltion ir must be provided in either cse. In cold climtes it is recommended to provide motorized ir inlet dmper to control the supply of combustion ir nd prevent nuisnce condenstion.

31 Commissioning 31 The combustion ir must be free of: Permnent wve solutions; Chlorinted wxes/cleners; Chlorine-bsed swimming pool chemicls; Clcium chloride Sodium chloride used for wter softening; Refrigernt leks; Pint or vrnish removers; Hydrochloric cid/muritic cid; Cements nd glues; Antisttic fbric softeners used in clothes dryers; Chlorine-type bleches, detergents, nd clening solvents found in household lundry rooms; Adhesives used to fsten building products nd other similr products. To prevent contmintion do not connect the combustion ir inlet nd exhust ner: Dry clening/lundry res nd estblishments; Swimming pools; Metl fbriction plnts; Beuty shops; Refrigertion repir shops; Photo processing plnts; Auto body shops; Plstic mnufcturing plnts; Furniture refinishing res nd estblishments; Remodeling res; Grges with workshops Whenever the environment contins these types of chemicls, combustion ir MUST be supplied from clen re outdoors for the protection nd longevity of the equipment nd wrrnty vlidtion. The more common methods of combustion ir supply re outlined in the following sections Ducted combustion ir For ducted combustion ir instlltions, the ir ductwork must then be ttched directly to the ir inlet connection on the sheet metl enclosure. When combustion ir is tken through the roof, field-supplied rin cp or n elbow rrngement must be used to prevent entry of rin wter. The ducts must be routed to the boiler s directly s possible, with ll joints seled, nd supported by dequte hngers. In ducted combustion ir ppliction, the combustion ir ducting pressure losses must be tken into ccount when clculting the totl mximum llowble venting run (see tble on pge Venting Configurtions: The following figures show the cceptble piping instlltion for venting nd combustion ir for both, Stnd Alone nd Cscde configurtions. pge 26). For dditionl detils, see Appendix F - Exhust terminls nd Air inlet Clernces. 5 Commissioning 5.1 Introduction Before strting the boiler, the user must be correctly instructed by the instller, on how to operte the heter, in prticulr: Mke sure tht the user understnds tht combustion ir nd ventiltion openings must not be restricted, closed, or modified in ny wy. Mke sure tht the user is informed of ll the specil mesures to be tken for combustion ir inlet nd dischrging flue gses, nd tht these must not be modified in ny wy. Mke sure tht the user keeps this mnul nd ll other documenttion included with the boiler. Mke sure tht the user understnds never to tmper with gs control settings nd the risk of CO poisoning should n unuthorized individul do so. Mke sure tht the user knows how to djust tempertures nd controls. WARNING: Do not ttempt to dry fire the unit. Strting the unit without full wter level cn seriously dmge the unit nd my result in injury to personnel or property dmge. This sitution will void ny wrrnty. CAUTION: All of the instlltion procedures in Instlltion pge 11 must be completed before ttempting to strt the unit. 5.2 Filling the condenste system The condenste system must be filled with wter ccording to the Section Pressure relief vlve instlltion pge 16. WARNING: At the Strt-up nd fter prolonged shutdown of the boiler, the condenste trps nd the syphon must filled with wter prior to restrt it, otherwise combustion gses will enter the room with risk of n excessive level of crbon monoxide. 5.3 Filling the boiler heting system To fill the heting system, proceed s follows: Open ny utomtic ir vents in the heting system. Open the fill vlve nd proceed to fill the heting system nd boiler until the pressure guge (shown on Fig. 48), reds the pressure for which the heting system is sized. The heting system wter pressure must be higher thn 7.5 PSI. Check tht there is no wter leking from the fittings. If there is, the leks must be repired. Close ll wter shutoff vlves in the boiler. Open return vlve in system heder to llow the wter to fill the return heder in the boiler. Strting t one module, open the return shutoff vlve llowing the wter to fill the pump nd het exchnger. The utomtic vent vlve should strt to relese the ir from the het exchnger. Once ir hs stopped, open the supply vlve on the outlet of the het exchnger llowing the wter to fill the supply heder in the boiler. Move up to the next module nd repet this process. Once both modules hve been done, open the supply vlve on the system heder. Check the pressure guge during the purging process. If the pressure hs dropped, re-open the fill vlve to bring the pressure bck to the desired vlue.

32 32 Commissioning 5.4 Wrnings concerning the gs supply When strting up the unit for the first time the following must be checked: Tht the unit is supplied with the type of fuel tht it is configured to use. Tht the gs supply system is provided with ll the sfety devices nd controls required under current ntionl nd locl codes. The ignition system shutoff device must be tested by closing mnul gs vlve nd hving ignition system cycle until unit goes into sfety shutoff. Tht the vent nd combustion ir terminls re properly connected nd free from ny blockges. Tht the condenste drin tube is properly connected Confirming the Unit s Gs Type The type of gs nd the gs supply pressure tht the unit is set up for is listed on the rting lbel. The Series boilers cn operte using one of the following two gses: NATURAL GAS Mximum supply pressure = 20 W.C. (50.0 mbr). Minimum supply pressure = 3.5 W.C. (8.7 mbr). PROPANE (LP) GAS Mximum supply pressure = 20 W.C. (50.0 mbr). Minimum supply pressure = 8 W.C. (19.9 mbr) Gs Type Conversion If the gs vilble t the instlltion site is not the type the boiler is configured to use, the boiler must be converted. Specil conversion kits re vilble for this purpose inside the boiler. The gs conversion procedure my be found in Section Gs Type Conversion pg. 22. Conversion must be crried out by qulified technicin. 5.5 Boiler strtup procedure To strt the boiler, do the following: Open the mnul gs shut off vlve. Turn ON the min power switch. Push ll Module power switches to ON ( Electricl box pge 20). To help removing the ir from the hydrulic circuit, the De-iring function cn be strted for ech module. When ctivted, the De-Air sequence strts t every power ON nd consists of controlled cycling of the pumps OFF nd ON tht tkes 14 minutes, during which no demnd will be served. If the wter pressure is too low nd the wter pressure switch is in error, the sequence will be suspended until the pressure switch is ON gin. This function cn be strted through the Service disply, connecting it to ech module nd switching the De_Air_Config prmeter from 0 to 1. More detils re vilble on the Control System Mnul. The Touchscreen Control Pnel will switch on. The Splsh/Home screen consists of the BOSCH logo: Fig. 41 Touchscreen Control Pnel Splsh/Home screen By touching the logo, the Cscde screen will be ccessed: Fig. 42 Settings Cscde Screen Pushing the Settings button, the Settings screen will show up: Fig. 43 Reset Curve Lnguge Demo option Settings screen Dte & Time Units conversion Module input rte Dte nd Time cn be djusted through the screen below: Fig. 44 Dte & Time screen

33 Commissioning 33 After the Dte & Time setting, if n outdoor probe is connected, the Reset Curve screen must be ccessed (through the Settings screen) to set the curve prmeters: CH Setpoint Mximum CH Setpoint Minimum OFF Voltge ON/OFF ON Hysterese Fig. 45 Reset Curve screen Adjusting the prmeters on tht screen, the reset curve below will modify shpe nd slope to meet the needs of the specific ppliction. Reset Curve Design Boiler Reset Cuve Boiler Mild Wether Fig. 46 C F CH SETPOINT ( C/ F ) Reset Curve F C Reset Curve Outdoor Design Reset Curve Boiler Mximum Reset Curve Boiler Minimum OUTDOOR TEMP. ( C/ F) )Reset Curve Outdoor Mild Wether 2) Wrm Wether Shutdown The boiler will fire only when there is cll for het nd the heting temperture setting is higher thn the ctul supply temperture. Hold buttons + or - on the Cscde screen (Fig. 53) to select the desired heting temperture. If the externl temperture sensor is connected (see Section Outdoor Temperture Sensor pg. 21), check tht the clculted temperture is higher thn the ctul boiler temperture nd tht the outdoor temperture is lower thn wrm wether shut down temperture. Fig VDC Control mode The CH setpoint Min nd CH setpoint Mx prmeters cn be djusted to provide the desired temperture djustment bnd. A het request will be generted by n input of 1.5 volts or higher. The setpoint modultion will occur between 2 nd 9 volts. The request for het will be removed when the voltge drops below 1 volt. All other sfety nd control functions ssocited with the boiler will rect normlly to dverse condition nd override control of the nlog signl to prevent n upset condition Minimum Wter Flow (Het Exchnger Protection) This unit is self-protected ginst low wter flow. A flow meter continuously monitors the wter flow to ech module. If the wter flow decreses below the minimum stted (defult threshold: 50l/min = 13.2GPM), the burner utomticlly shuts off Heting System Pressure Test If the pressure inside the heting circuit flls below the minimum pressure for the system (7.5 PSI), the pplince switches off nd the 905PB inner disply shows Low wter pressure to indicte tht it is necessry to restore the correct pressure. Open the filling vlve nd check the pressure on the temperture/ pressure guge of Fig. 48. The error will dispper when the pressure is bck t the right vlue. To prevent ccidentl relief vlve openings, fill the heting circuit slowly. The boiler CH setpoint cn be controlled by n nlog input signl provided by remote mens such s Building Mngement System or system controller. The nlog input 0-10 VDC, is used to djust the boiler setpoint between the CH_Setpoint_Min nd the CH_Setpoint_Mx settings (Fig. 47). To enble this opertion mode, the prmeter CH mode must be set to 4 (see Control System Mnul for ccessing the prmeter list). NOTE: to enble CH mode 4, terminls 9 nd 10 (Enble/Disble) on Low voltge strip must be jumpered. Temperture/Pressure Guge Fig. 48 Temperture/Pressure Guge loction

34 34 Commissioning 5.6 Boilers cscde instlltion nd strt-up (FOR 1000 TL ONLY) Appendix E shows n exmple of 1000 TL boilers instlled in cscde of three units. The built-in control system is cpble to mnge up to 4 boilers s single, coordinted heting system. The logicl scheme is: Demnd: 0-10V / OpenTherm / On-Off T outside System sensor D2 is Cscde system sensor Boiler sensor RS485 RS232 Touch Screen 900PB J6 90xMN - D1 J8 Iso + Power Boiler mnger & Cscde mnger S1 = on Power Supply J8 90xMN - D2 S1 = off MANAGING BOILER Boiler sensor RS485 RS232 Touch Screen 900PB J6 90xMN - D1 Boiler mnger & J8 Iso Cscde mnger S1 = off BMS bus Power Supply J8 90xMN - D2 S1 = off DEPENDENT BOILER MAX 4 BOILERS Fig. 49 Cscde instlltion scheme After the electricl wiring of the Mnging controllers of ech boiler of the cscde (through the Cscde link connections on the Low voltge terminl strips), the following steps must be done: Boilers Cscde: Set Boiler Address Assign the Boiler Address in the Mnging bords of ech boiler of the cscde, following the pth below on the Sevice disply: Menu->Setting->Boiler Settings->Boiler Cscde Settings->(73) Boiler Address BOILER Mnging (73) Boiler Address Mnging Dependent 1 Dep Boilers Cscde: Set Power switch S1 On the Mnging controller of the Cscde Mnging boiler, the Power Switch S1 must be in ON position (see picture below). The S1 switch must be in OFF position on ll other controllers of the boilers in the cscde. S1 J8 J11 Dip Switch MN Fig. 50 Set Power switch S1

35 Opertion 35 6 Opertion 6.1 Introduction The informtion in this Chpter provides guide to the opertion of the Boiler using the Control Pnel mounted on the front of the unit. It is impertive tht the initil strtup of this unit be performed by fctory trined personnel. Opertion prior to initil strtup by fctory trined personnel my void the equipment wrrnty. In ddition, the following WARNINGS nd CAUTIONS must be observed t ll times. WARNING: Electricl voltges in this system include 120 nd 24 volts AC. It must be serviced only by fctory certified service technicins. WARNING: Do not ttempt to dry fire the unit. Strting the unit without full wter level cn seriously dmge the unit nd my result in injury to personnel or property dmge. This sitution will void ny wrrnty. CAUTION: All of the instlltion procedures in Chpter 4 Instlltion pg. 11 must be completed before ttempting to strt the unit. 6.2 Control pnel description All Series Boilers utilize the Touchscreen Control Pnel shown in Fig. 52. This Touchscreen pnel contins the bsic controls for monitoring the boiler. All other controls, indictors nd displys necessry to operte, djust nd troubleshoot the boiler re vilble on the 905PB inner disply shown in Fig. 22. Additionl informtion on these items is provided in the individul operting procedures nd menu descriptions provided in this Chpter. 905TS Touchscreen 6.3 Touchscreen control pnel menus The Touchscreen Control Pnel incorportes menu structure which permits the opertor to monitor nd set up (bsic settings only) the unit. The menu structure consists of four mjor screens nd four secondry ones Splsh/Home Screen Fig. 52 BOSCH Screen The BOSCH logo is the entry point of the Control System. Just touching it, the system moves to the first operting screen, the Cscde one Cscde Screen Home Performnce Stts Errors Service Settings Bck Actul Supply Temperture CH Temperture Setting Fig. 53 Cscde Screen The Cscde screen shows the current configurtion of the plnt, mde by one or more cscded boilers. Fig. 51 Touchscreen Control Pnel Through this screen, the following ctions cn be done: Adjust the temperture setpoint using the + nd - buttons; Access the Boiler screen of the desired boiler, just touching it on the screen; Home button: move bck to the BOSCH screen; Performnce button: move to the Performnce screen of the cscde; Stts button: not ctive; Errors button: move to the Errors screen; Service button: move to Service screen; Settings button: move to Settings screen; Bck button: move to the previous screen.

36 36 Opertion Boiler Screen Through this screen, the following ctions cn be done: Check the sttus of the modules (ON, OFF, in error); See the current supply temperture t the boiler heder; Access the Module screen of the desired module, just touching it on the screen; Use the side buttons to perform the ctions listed below: Home button: move bck to the BOSCH screen; Performnce button: move to the Performnce screen of the boiler; Stts button: not ctive; Errors button: move to the Errors screen; Service button: move to Service screen; Settings button: move to Settings screen; Bck button: move to the previous screen. Fig. 55 Module screen IMPORTANT: When resetting Locking error of the Mnging module, the whole boiler will be switched OFF nd then restrted Performnce Screen The Control system is ble to show the rel time performnce of the plnt, strting from 12 hours before the current time. The screen shows different informtion ccording to the context. Fig. 54 Boiler screen Module Screen Through this screen, the following ctions cn be done: See the current vlue of mny prmeters: wter supply&return temperture, flue temperture, wter flowrte, fn speed, ioniztion current, burner nd pump sttus, ny error ON or service required; Use the side buttons to perform the ctions listed below: Home button: move bck to the BOSCH screen; Performnce button: move to the Performnce screen of the module; Stts button: not ctive; Errors button: move to the Errors screen; Service button: move to Service screen; MODULE TEST button: move to the Module test screen; Reset button: clen ny Locking error relevnt to the module; Bck button: move to the previous screen. The Cscde Performnce screen includes the trend of: Current power input; Trgeted temperture setpoint; Current supply temperture. The Boiler Performnce screen includes the trend of: Current power input; Trgeted temperture setpoint; Current supply temperture. The Module Performnce screen includes the trend of: Current power input; Trgeted temperture setpoint; Current supply temperture. Current return temperture; Current fn speed; Current ionistion current; Current flue temperture. Fig. 56 Service screen

37 Opertion Error Screen For ech boiler, the Error screen shows the list of the lst 48 errors occurred on its own modules. The errors re listed in chronologicl order. Shutdown_Period (fctory setting) fter the service reminder becme ctive (messge is displyed). The owner/user hs wrning before the pplince will ctully shutdown. Re-enbling the pplince is only possible by resetting the Service Reminder (Shutdown) which is done by the instller Module Test Screen This screen is designed to support the instller nd service ctivities. When pushing the Module Test button on Module screen, new set of buttons ppers on the left side of the screen. Fig. 57 Error screen Service Screen The Service screen shows the min prmeters of the Service Reminder function. Fig. 59 Module Test Screen Setup, djustments nd checks of combustion prmeters cn be done using the Low Power, Ignition Power nd High Power buttons. Pushing the LWCO test button the system crries out the Low Wter Cut Off functionlity test. Fig. 58 Service screen The Service Reminder will remind the owner/user of the pplince to service the pplince t specified Service_Intervl (fctory setting). When service is not done within the specified time, service reminder will be shown on the screen, lternting with the norml sttus disply. The Service_Intervl cn be set s the number of burn hours or the number of opertionl (pplince is powered) hours. This cn be done by setting the Service_Hour_Counter (fctory) prmeter. When the Service Reminder is ctive, the time before service is ctully done is logged by the 900PB (in hours). This time is clled the Service Overdue time. With this log the fctory cn red bck how long service ws overdue on the system/pplince which cn be useful when hndling wrrnty clims. A mximum of 15 Service moments cn be logged by the 900PB, when the log is full it will overwrite the oldest log entry. Ech time the Service Reminder is being reset, new service moment is counted nd the Service Overdue counter will be stored in the log/history. There re two types of service reminders: (Norml) Service Reminder nd Service Shutdown. The (norml) Service Reminder will only show the service reminder messge on the screen nd will log how mny hours the service is overdue, nd the pplince will remin fully opertionl. The Service Shutdown hs the sme functionlity s the Service Reminder but will shut-down the pplince fter the specified Service_ Fig. 60 LWCO test button Screen In ddition, the High Limit button llows to crry out the high limit temperture switch functionlity test.

38 38 WIRING DIAGRAM Appendix A - Wiring digrm red red J5-3 red TRANSF.IGNITE R blw NO COM RELAY A1 A2 red red TRANSF.IGNITE R NO COM RELAY A1 A2 HIGH VOLTAGE TERMINAL STRIP MAIN SUPPLY 120 VAC L N PUMP RELAY Min Pump 3 WAY CH Pump DHW/ ON/OFF MODULES ALARM EXT. IGNITER EXT. IGNITER Pump CH 3-WAY DHW L N L N L N L N L N L N L N J3-4 SLAVE 2 J3-9 SLAVE 2 R2 A2 A1 COM COM NO NO PUMP 2 J3-4 MASTER J3-9 MASTER R1 A2 A1 COM COM NO NO PUMP L 120VAC N MANAGING J3-2 MANAGING J3-7 MANAGING J3-5 MANAGING J3-10 MANAGING DEPENDENT DEPENDENT J6-4 MANAGING bl w J5-3 red blw bl w J3-3 J3-8 J3-1 J3-7 J3-6 J3-8 J3-6 J3-8

39 WIRING DIAGRAM 39 Boiler Supply Sensor DHW Tnk Sensor Enble Disble

40 40 WIRING DIAGRAM WIRING DIAGRAM - MANAGING FLOWMETER MIN+MAX GAS PRESSURE SWITCH WATER PRESSURE SWITCH FLUE / J8-2 h J8-1 b J7-4 h J7-3 h J7-2 b J7-2 b MANAGING J6-13 h J6-6 b J6-14 h J6-7 b J7-6 b J7-7 bl J7-8 h J7-9 b J7-10 h J9-4 h J9-2 b J6-11 h J6-4 b J6-5 b J6-12 h J3-2 bl J3-3 bl J3-7 w J3-1 b J3-4 b J3-5 bl J3-10 w J3-9 h J3-8 w J3-6 J6-8 h J6-1 b J6-2 bl J1-5 bl J1-1 w J6-10 h J6-3 b EXCON 4201 J2-3 gr J2-2 gr J1-4 gr 204 FLUE SENSOR 203 RETURN T. SENSOR SERVICE DISPLAY 213 GAS VALVE AIR PRESSURE SWITCH CONDENSATE PRES. SWITCH 2 1 J11-1 LWCO ARGUS LINK PARALLEL CONNECTION SLAVE 2/3/ J5-2 w J5-1 bl J12-2 b J12-5 h J12-4 h J12-1 b J2-1 gr J4-2 bl J4-3 w J4-6 bl J4-5 grey J4-4 h J4-1 br UNIT FLOW TEMP. 202 SAFETY LIMIT 212 WATER THERM. J9-3 J RELAY R1-A1 RELAY R1-A2 J2-4 gr 216 FAN FAN PWM 2 1 PARALLEL CONNECTION POWER SUPPLY

41 WIRING DIAGRAM 41 WIRING DIAGRAM - DEPENDENT ARGUS LINK J8-2 h J8-1 b RELAY R2 RELAY R2 LWCO DEPENDENT J3-9 h J3-4 b J12-5 h J12-2 b 202 UNIT FLOW TEMP. J12-1 b J12-4 h 212 SAFETY LIMIT WATER THERMOSTAT J7-8 h FLOWMETER J7-7 bl J7-6 b J7-3 h J7-2 b FLUE CONDENSATE PRESS. SWITCH J6-12 h J6-5 b 204 FLUE TEMP. SENSOR J6-10 h J6-3 b J6-6 b J6-13 h J6-8 h J6-1 b J6-2 bl 203 SYSTEM SENSOR UNIT RETURN TEMP. SENSOR Pin 6 Pin 3 Pin GAS VALVE POWER SUPPLY 216 FAN J2-4 gr J5-2 w 2 PWM 1 J5-1 bl J1-4 gr J1-5 bl J1-1 w J2-1 gr J4-2 bl J4-3 w J4-6 bl J4-5 grey J4-4 h J4-1 br

42 42 CONNECTION DIAGRAM Appendix B - Connection digrm CONNECTION DIAGRAM 905MN CONTROL BOARD Int. ioniztion 0-10V input Open Thermostt interfce or Room Thermostt ON/OFF Burner Ignition Sprk Return REMOTE DISPLAY MAINS SUPPLY PROG. INPUT 5: 1) T_Return DHW_STAT T_DHW_OUT/T_Store PROG. INPUT 6: 1) T_Flue_1 (sensor) (flue gs sensor/switch) PROG. OUTPUT 4 CONFIG. 1 3) DHW Pump PROG. INPUT 7: 3) T_System PROG. OUTPUT 1 2) CH Pump T_Outdoor PROG. INPUT 1: 3) Flue Pressure switch PROG. OUTPUT 3 9) Ext. Igniter PROG. INPUT 2: 3) Het Exchnge_Flow sensor PROG. INPUT 3: 3) Min/Mx Gs Pressure switch Sensor PROG. OUTPUT 5 1) Generl Pump PROG. OUTPUT 2 6) Alrm Rely PROG. INPUT 8: 2) Wter Pressure switch (NC) in series with Air Pressure switch Generl Pump Control FAN PWM interfce Sfety Limit (ECO) 24VDC T_Supply_1 HALL HALL Supply Low Wter Cut Off 1 (Sfe) Low Wter Cut Off 2 (Not functionl) GAS VALVE AL-BUS/PC Connection AL-BUS Power DIPSWITCH

43 CONNECTION DIAGRAM 905PB DISPLAY CONNECTION DIAGRAM 43 CONNECTION DIAGRAM 905PB DISPLAY 905PB05_3R Connector J7 J25 Function PC interfce Connection to MN control/modbus RS485 / Mod BUS AL-BUS GND B A AL AL +24V J25-1 J25-2 J25-3 J25-4 J25-5 J25-6 PBOX_3R 905PB05_3R Disply: RJ-11 Connector: : GND/VSS 2: ModBus_B (= Dt -) 3: ModBus_A (= Dt +) 3: AL_Comm 5: VSS To 905MN 6: +24V AL-BUS J7-01 J7-02 J25 Wire Colors: J25-1: Grey J25-2: Blck J25-3: Green J25-4: Yellow J25-5: Red J25-6: Blue CONNECTION DIAGRAM 905TS (Touchscreen) AND 905PB DISPLAY Modbus connection digrm between the 900PB nd 900TS Pins on connector COM1 of the 900TS: Primry connection to 900PB: Communiction Pin Function Connect to COM2 (Mster) 5 GND 900 PB (J25-1) 7 RS PB (J25-3) 8 RS PB (J25-2) Optionl secondry interfce: Communiction Pin Function Connect to COM1 (Slve) 2 RS 232 RXD Externl Adpter RS RS 232 TXD Externl Adpter RS GND