6 720 805 220-00.1T UPON COMPLETION OF THE INSTALLATION THE INSTALLER MUST INSTRUCT THE OWNER AND OPERATOR ON THE FUNCTIONALITY AND THE PROPER OPERATION OF THE BOILER AND THE HEATING SYSTEM THIS MANUAL SHOULD BE HANDED TO THE OWNER AND OPERATOR OF THE APPLIANCE. INSTALLER MUST REVIEW ALL SAFETY INSTRUCTIONS WITH THE OWNER AND OPERATOR. DANGER! The installation instructions included in this Manual are intended solely for use by a trained and certified installer, service company or the gas supply company.
| Contents Contents Condensate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining the condensate . . . . . . . . . . . . . . . . . . . . . . . . Neutralizing the condensate . . . . . . . . . . . . . . . . . . . . . 25 25 25 25 6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Control unit settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
Key to symbols and safety instructions | 3 1 Key to symbols and safety instructions 1.1 Explanation of symbols Warnings Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. The following keywords are defined and can be used in this document: • NOTE indicates that property damage may occur.
| Key to symbols and safety instructions DANGER: Risk of personal injury or death from fire! ▶ Do not use flammable or combustible material in the boiler room. ▶ It is recommended not to store any items within 16 inches (415mm) of the appliance CAUTION: Appliance damage from contaminated combustion air! ▶ Keep the combustion air free of corrosive substances, e.g. halogenated hydrocarbons from painting operations or beauty salons. ▶ Keep combustion air free from dust and lint, e.g.
Product Description | 5 2 maintaining the condensing effect and the water heating time around the tube bundle for as long as possible. Product Description The high efficiency SB Series boilers are designed to condense flue gases through a unique three-pass construction for installation in a mechanical room. While they are designed primarily for central heating purposes, in conjunction with a suitable storage tank they can also be used to produce domestic hot water.
| Product Description 2.1 Intended use WARNING: Risk of fatal Injury from explosion of flammable gases! ▶ Installation, connection of the fuel supply and flue pipe, commissioning, connection of the electrical power supply, servicing and repair may only be carried out by an authorized heating engineer. ▶ Any work on gas-carrying components may only be carried out by an authorized gas installer. This boiler must only be used for the purpose specified by the manufacturer and for which it is designed.
Product Description | 7 carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. – In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. • APPROVED CARBON MONOXIDE DETECTORS.
| Product Description 2.5 Scope of delivery The boilers SB625WS / SB745WS comes in two separate crates and one additional box. Boiler body: The instruction manual is an integral part of the boiler. Manuals are attached at the outside of the boiler. Replacement sealing rope for burner door and ceramic insulation are located behind the boiler door. Look at the attached red label at the burner observation port. Once located, read it thoroughly and keep it safe.
Product Description | 9 2.9 Dimensions and specifications Values obtained with RS.../M-burners. 2.9.1 Dimensions D H1 H F C L1 E A L B 6 720 805 218-13.1T Fig.
| Product Description 2.9.2 Technical Data Description Fuel Rated input (Nat. Gas) Rated input (#2 Oil) Gross output Sensible losses from stack Jacket losses with burner mounted Flue gas temperature (T) Flue gas mass flow rate1 Unit MBH (kW) GPH (LPH) MBH (kW) % 160 Gas 563 (164.9) 4.0 (15.1) 532 (159.7) 1.7 220 Gas 788 (230.9) 5.6 (21.2) 745 (218.2) 1.7 % 0.3 0.3 °F ( °C) lbs/sec (kg/sec) Fireside pressure drop2 Inch W.
Product Description | 11 2.9.3 Water connections The boilers are designed and made for use in central heating installations, but can also be used for domestic hot water production if connected to suitable sub-systems. Water fittings are as specified in the following table. B A E N M M 1 8 F D C 4 3 2 8 2 3/4” (70 mm) H 7 6 G L O I 5 6 720 805 218-18.1T Fig.
| Product Description Description 1 – Heating supply 2 – Heating return 1 (Low Temperature) 3 – Heating return 2 (High Temperature) 4 – Safety device fitting 5 – Boiler drain fitting 6 – Condensate drain fitting 7 – Flue gas exhaust fitting 8 – Instrument bulb/ probe sockets A – Distance from burner head to heating supply B – Distance from heating flow outlet to return 1 C – Distance between heating returns 1 & 2 D – Distance between heating return 2 and safety device fitting E – Distance between heatin
Water treatment | 13 3 Water treatment The quality of the fill and top-up water is an essential factor for increased efficiency, functional reliability, long service life and for maintaining the constant operational condition of a heating system. If the system is filled with water that has a high calcium hardness, this will be deposited on the heat exchanger surfaces and will obstruct the transfer of heat to the heating water.
| Water treatment of only 1 mm can cause severe overheating in metal parts and consequent damage through thermal stress. It is continuous topping up (automatic fill from incoming water) that causes thick deposits to form, leading to boiler breakdown. • ensure that no part of the system is made from materials that are permeable to gases (e.g. plastic pipes with no oxygen barrier used in floor heating systems).
Transport | 15 • CO2 (carbon dioxide) is generated as the carbonates of calcium and magnesium precipitate out. • the chemical oxidation of the metals in the system also generates hydrogen. 4 WARNING: Risk of injury from carrying heavy loads and inadequately securing loads for transport. ▶ Use suitable means of transportation, e.g. several pallet trucks, a forklift truck, crane or heavy duty rollers. ▶ Secure the load against falling. These gases must be eliminated as they are formed.
| Installation 5 Installation 5.1 Boiler Clearances A1 B1 B2 D B1 B2 C A2 6 720 805 218-52.1T Fig. 9 Installation site NOTICE: Risk of system damage through frost. ▶ Do not install the boiler outdoors; it is not designed to work outdoors and is not fitted with the necessary automatic anti-frost systems to do so. ▶ Ensure that the boiler installation room remains free from the risk of frost.
Installation | 17 Unit 160 Recommended Service A1 inch 36,00 (mm) (915) A2 inch 64,00 (mm) (1626) B1 inch 36,00 (mm) (915) B2 inch 36,00 (mm) (915) D inch 36,00 (mm) (915) Minimum Service A1 inch 24,00 (mm) (610) A2 inch 64,00 (mm) (1626) B1 inch 18,00 (mm) (457) B2 inch C+4 (mm) (C+100) 18,00 D inch (mm) (457) Clearance to combustibles A1 inch 18,00 (mm) (457) A2 inch 64,00 (mm) (1626) B1 inch 6,00 (mm) (152) B2 inch 6,00 (mm) (152) D inch 18,00 (mm) (457) 220 SB625WS 290 370 480 640 800 SB745WS 105
| Installation 2 1 3 17 4 19 5 6 18 7 8 16 9 15 10 14 10 13 12 11 6 720 805 218-32.1T Fig.
Installation | 19 5.3 Refitting the door hinges The boilers are pre-fitted with three hinges so that the opening direction of the door can be quickly reversed. Once you have checked that the default direction of opening is as required, or have reversed the direction of opening as instructed in section 5.3.1, remove the spare hinge assembly ‘B’ (screw, bushing and washer) opposite the pivot side of the door.
| Installation ▶ Insert a wrench through the top slot and hold the bushing [4] steady. System B (larger sizes) ▶ Open the door. ▶ With the aid of a small hacksaw or a file remove the knockout on the side opposite the leading edge of the door (both top and bottom). 4 6 720 805 218-48.1T Fig. 14 Insert spanner ▶ Unscrew the top bolt [5]. ▶ Remove the bushing [4] and washer [6]. 6 720 805 218-29.1T Fig.
Installation | 21 ▶ Remove the plug taking care not to lose the compressed spring inserted in the threaded tube. ▶ ▶ ▶ ▶ Remove the bolt [3] and the nuts [4]. Remove the nuts [4] that secure the hinge plate [5] to the door Remove the plate. Remount the hinge plate on the opposite side, ensuring that the cylinder projecting above the nut [6] enters into its slot. ▶ If necessary tighten the nut [6]to raise it. ▶ Tighten the bolt [3]. 6 720 805 218-49.1T Fig.
| Installation 5.4 5.3.2 Removing the hinge assembly “B” ▶ Ensure that the side safety bolt is tight. ▶ Remove the main fixing bolt. ▶ With the door open, remove the hinge assembly ‘B’ (bushing, bolt, and washer) opposite the pivot side of the door. Burners Installing the burner Follow the burner manufacturer’s instructions when fitting the burner. A pre-drilled burner plate is included with the boiler vessel.
Installation | 23 5.5 Combustion gas exhaust The flue gas exhaust and stack connection must be made in compliance with applicable laws and standards, using heat resistant, condensate resistant and stress resistant rigid pipe and sealed joints. The stack must be fitted with a condensate trap and drain and the flue gas exhaust pipe must be installed at a slope of at least 2° towards the boiler. All condensate should be treated through a neutralization media before being eliminated to the floor drain.
| Installation Polypropylene Venting (Model SB625WS Series Boilers only) The Model SB625WS Series Boilers may utilize an exhaust vent installed vertically through the roof or in a chimney chase. The configuration may be up to a maximum of 100 equivalent feet of venting. One 87 or 45 degree elbow is equivalent to 5 or 2.5 feet of venting, respectively. The chimney cap is equivalent to 3 feet of venting.
Installation | 25 5.9 Combustion Air from an adjacent room 5.11.2 Neutralizing the condensate Where combustion air is to be used from within the building, air must be provided into the equipment room through two permanent openings into the inferior building. Each opening must have a minimum free area of 1 square inch for each 1,000 Btuh of the total input rating of all fuel burning equipment in the space.
| Commissioning 6 ▶ Maintain the minimum differential between the selected shutdown temperature of the high limit safety cut-out, the temperature regulator, the maximum boiler water temperature and the maximum temperature demand ( table 13). Commissioning NOTICE: Risk of boiler damage through contaminated combustion air. ▶ Never operate the boiler in very dusty conditions, e.g. if building work is taking place in the installation room. ▶ Ensure adequate ventilation.
Commissioning | 27 Example DHW demand (where the 4000 series controls the DHW system): Sum of the set DHW temperature (140 °F) and parameter "Boiler rise" (40 °F) in the "DHW" menu: 140 °F+ 40 °F = Maximum temperature demand 180 °F Example heating circuits (where the 4000 series controls the heating circuits): Add of the set temperature of the heating circuit with mixing valve with the highest temperature required (15 °F) and parameter "Boiler rise" (160 °F) in the "Heating circuit data" menu: If there ar
| Commissioning 6.4 Making the electrical connection DANGER: Danger to life through electric shock! ▶ Before opening the boiler, isolate the heating system across all life phases and secure against unintentional reconnection. ▶ Carefully route the cables/leads and capillary tubes. ▶ Ensure that capillaries are never kinked. ▶ Only carry out electrical work if you are a competent person. If you are not suitably qualified, arrange for a qualified electrician to make the electrical connections.
Commissioning | 29 ▶ Insert the temperature sensor set as far as it will go into the test point (to the bottom). Use the mark to check whether the temperature sensors are correctly fitted. ▶ Secure the temperature sensor set in the test point with a sensor retainer. The plastic coil [2] for keeping the temperature sensors together is pushed back automatically when it is inserted.
| Commissioning 6.7 Filling the heating system CAUTION: Health risk through contaminated drinking water. ▶ Observe all country-specific regulations and standards regarding the prevention of drinking water contamination. 6.8 Preparing the heating system for operation Observe the following points during commissioning: ▶ The turbulators [2] are correctly positioned (horizontal) inside the heat exchanger tubes and the clips [1] are resting against the wall [3] of the heat exchanger.
Commissioning | 31 6.11 Commissioning report The boiler can be operated with a gas or dual fuel burner. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Commissioning steps Flush the heating system. Fill the heating system with water. Vent the heating system. Carry out tightness test. Switch on the control unit. ▶ Carefully complete the commissioning report for the relevant approved burner. ▶ Sign all completed commissioning work and enter the date.
| Shutting down 7 Shutting down NOTICE: Risk of system damage through frost. When there is a frost, the heating system can freeze up if it is not operational, e.g. because of a fault shutdown. ▶ When there is a risk of frost, protect your heating system against freezing up. ▶ If your heating system has been shut down for several days due to a fault shutdown and there is a risk of frost, drain the heating water at the drain & fill valve.
Inspection and maintenance | 33 8.2.2 Adjusting the door Make sure that the door presses uniformly all around the double seal to prevent dangerous fumes escaping into the air. Proceed as follows to adjust the door seals. System B (larger size) ▶ Put the door in its correct position. ▶ Tighten the main locking screws [1] until the packing starts to be compressed. System A ▶ Fit the door and tighten the main fixing bolts [2] until the seals start to compress.
| Inspection and maintenance ▶ If necessary, replace the gasket [1]. ▶ Clean all removed components, then follow the above steps in the reverse order to refit them. ▶ Open the door [1] and pull out the turbulators [2]. ▶ Use a flue brush [3] or other suitable tool to clean inside the combustion chamber and the flue gas pipes. 1 1 2 3 6 720 805 218-44.1T 6 720 805 218-42.1T Fig. 37 Replace gasket Fig. 35 Clean the boiler [1] [2] [3] [1] Door Turbulator Flue brush 8.
Inspection and maintenance | 35 8.4.2 Sealed unvented systems NOTICE: System damage through frequent topping up. Subject to the water quality, your heating system can be damaged through corrosion or scaling. ▶ Ensure that the heating system is vented correctly. ▶ Check the heating system for leaks and the expansion vessel for functionality. ▶ Observe the requirements regarding water quality. ▶ If water loss occurs frequently, locate the cause and rectify the problem without delay.
| Inspection and maintenance 8.5 Inspection and maintenance reports The inspection and maintenance reports provide an overview of the required inspection and service steps that should be carried out annually. Complete these reports after inspections and service. The report can also be used as copying template. ▶ Sign and date the completed inspection work. Warranty: Annual inspection and service are part of the warranty terms. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 12. 13.
Inspection and maintenance | 37 Confirm professional inspection with signature, date and company stamp.
| Spare parts 9 Spare parts The following replacement parts are available from Bosch Thermotechnology Corp. SB625WS-160/220/290 ( Fig. 38) Item no.
Spare parts | 39 22 22 22 22 12 13 17 22 13 11 13 24 11 16 15 14 6 5 32 22 19 18 4 7 20 8 1 21 25 22 27 6 720 805 218-54.1T Fig.
| Spare parts SB625WS-370/480/640 ( Fig. 39) Item no.
Spare parts | 41 22 22 22 22 22 1213 13 11 17 24 13 16 8 11 14 6 15 19 5 18 4 3 2 7 20 1 21 25 22 27 6 720 805 218-55.1T Fig.
| Spare parts SB745WS-800/1050/1300/1550 ( Fig. 40) Item no.
Spare parts | 43 Item no.
| Spare parts 22 22 22 22 22 22 22 12 22 13 12 13 13 11 17 25 16 13 6 15 11 8 14 19 5 18 4 3 2 7 14 21 20 1 22 26 22 28 22 6 720 805 218-56.1T Fig.
Troubleshooting | 45 10 Troubleshooting Problem The boiler does not reach its set temperature. Cause Heat exchanger dirty. Heat exchanger and burner mismatched. Insufficient gas flow burner. Control thermostat problem. The boiler keeps shutting down, and the control Control thermostat problem. panel warning light comes on. The boiler has reached the set temperature but the radiators are still cold. No water supply. Air in the circuit. Air in the circuit. Troubleshooting ▶ Clean the flue gas pipes.
| Environmental protection/disposal 11 Environmental protection/disposal Environmental protection is one of the fundamental company policies of the Bosch Group. We regard quality of performance, economy and environmental protection as equal objectives. Environmental protection laws and regulations are strictly adhered to. To protect the environment, we use the best possible technology and materials taking into account economic points of view.
Glossary | 47 12 Glossary Appearance The appearance of water depends on the presence of sediment, in suspension or in colloidal form, and on the presence of dissolved substances that create easily identifiable conditions like turbidity, colouration or foaming. These substances can lead to limescale, sludge, corrosion, abrasion, microbial growth and foaming.
| Glossary Checks As is the case with checks for water parameters, it is the responsibility of the system operator to ensure that any water treatment systems are functioning properly, in compliance with instructions and at the specified intervals. The supplier’s responsibility ends with the supply and commissioning of the right conditioning system for achieving and maintaining the required water parameters.
Index | 49 Index C Checking and correcting the water pressure ........................ Checking and correcting the water pressure in sealed unvented systems ......................................................... Commissioning Commissioning the burner ...................................... Commissioning the control unit ................................. Filling the heating system ....................................... Flushing the heating system .....................................
| Notes 6 720 805 218 (2016/02) SB625WS/SB745WS
| 51 Notes SB625WS/SB745WS 6 720 805 218 (2016/02)
