WARNING: Improper installation, set-up, modification, operation or maintenance of the heating system can cause personal injury and property damage. Follow these instructions precisely. If you require assistance or further information, contact a licensed contractor / gas fitter. WARNING: The operating instructions are part of the technical documents that must be handed over to the owner or operator of the heating system.
| Contents 1 2 4.7.5 Key to symbols and safety instructions . . . . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 General warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 Introduction . . . . . . . .
Key to symbols and safety instructions | 3 1 Key to symbols and safety instructions 1.1 Key to 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.
| Product description NOTICE: ►► This boiler must be installed by a licensed contractor/ gas fitter. Failure to do so shall void the product warranty. ►► The boiler is intended only for the use for which it was specifically designed and built. Bosch is hereby excluded from any liability for damages caused to persons, animals or property resulting from installation errors, improper adjustment, maintenance or use.
Product description | 5 2.3 Proper use 2.4 Environmental responsibility / disposal ►► The SSB Boilers are designed for large residential, commercial and light industrial applications. ►► The SSB 512 is delivered in compliance with CSD-1 Commercial Applications. ►► The appliance may only be installed in closed loop hot water central heating systems. ►► Any other purpose is considered improper use. Any resulting damage is excluded from the manufacturer’s warranty.
| Product description 2.5 Dimensions and Connections F 15 7/32” (386mm) 16 19/32” (422mm) G 58 7/8” (1496mm) 61 9/16” (1564mm) 49 27/32” (1266mm) 48 7/16” (1231mm) 47 1/32” (1195mm) 5 7/16” (138mm) 56 7/16” (1434mm) 60 3/16” (1529mm) 18” (457mm) 16 17/32” (420mm) 21 21/32” (550mm) 23 31/32” (609mm) 21 5/8” (549mm) 5 1/2” (140mm) 10 1/16” (256mm) 2 3/32” (53mm) Fig.
Product description | 7 F 15 7/32” (386mm) 16 19/32” (422mm) G 58 7/8” (1496mm) 61 9/16” (1564mm) 49 27/32” (1266mm) 48 7/16” (1231mm) 47 1/32” (1195mm) 5 7/16” (138mm) 56 7/16” (1434mm) 60 3/16” (1529mm) 18” (457mm) 16 17/32” (420mm) 21 21/32” (550mm) 23 31/32” (609mm) 21 5/8” (549mm) 5 1/2” (140mm) 10 1/16” (256mm) 2 3/32” (53mm) Fig.
| Product description F 15 7/32” (386mm) 16 19/32” (422mm) G 58 7/8” (1496mm) 61 9/16” (1564mm) 49 27/32” (1266mm) 48 7/16” (1231mm) 47 1/32” (1195mm) 5 7/16” (138mm) 56 7/16” (1434mm) 60 3/16” (1529mm) 18” (457mm) 16 17/32” (420mm) 21 21/32” (550mm) 23 31/32” (609mm) 21 5/8” (549mm) 5 1/2” (140mm) 10 1/16” (256mm) 2 3/32” (53mm) Fig.
Product description | 9 2.6 Main components 1 2 3 4 5 6 7 8 29 9 28 10 27 11 26 12 25 13 24 14 15 16 23 17 18 22 21 19 20 Fig. 5 [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] SSB512 (main components) Main power switch System return Removable display Flue exhaust Intake air Gas inlet System supply Pressure Relief Valve Tridicator Air pressure switch Heat exchanger supply pipe Max pressure switch [For SSB 512 Only] Min pressure switch [For SSB 512 only].
| Product description 2.7 Technical data Boiler Category Type of Gas Max input rate Min input rate Turndown Gas Connections (NPT) Max. NG Pressure Min. NG Pressure Max. LPG Pressure Min. LPG Pressure Water Connections Max.
Product description | 11 2.8 Efficiency Curves 100% 20% input 98% 30% input 100% input Thermal Efficiency 96% 94% 92% 90% 88% 86% 70 80 90 100 110 120 130 140 150 160 170 Return Water Temperature (°F) @ 36 Degree Rise Fig.
| Product description 100% 20% input 98% 30% input 100% input Thermal Efficiency 96% 94% 92% 90% 88% 86% 70 80 90 100 110 120 130 140 150 160 170 Return Water Temperature (°F) @ 36 Degree Rise Fig.
Regulations | 13 3 Regulations Observe all rules, regulations, standards and guidelines applicable to the installation and operation of this appliance in your country. mm In the Commonwealth of Massachusetts, this appliance must be installed by a licensed plumber or gas fitter. Valves external to the boiler must be fitted with T-handles and condensate piping must be installed in accordance with the State Plumbing Code. mm 3.1 Compliance with standards and regulations 3.
| Installation 4 Installation 4.1 Packaging and product identification The recommended clearance for ease of installation and service are illustrated in the following picture: 20” (500mm) The SSB is delivered strapped to a pallet, packed and protected in a cardboard carton. NOTICE: The packaging shows the characteristics of the product: model, power, fuel type and version. In case of deviation from the order, contact your local dealer.
Installation | 15 4.3 Water Chemistry Guidelines NOTICE: If using anti-freeze: ►► Follow the boiler manufacturer’s instructions on antifreeze concentration. ►► Frost protection and inhibitor level has to be checked annually during the regular scheduled maintenance of the condensing boiler. In the following table are listed the chemical water specifications.
| Installation 4.4.1 Low water cut off A low water cut off (LWCO) is installed in the boiler, the manual reset button is located on the front of the internal sliding wiring center. To check the functionality of LWCO press the test button (the top button shown in Fig. 10). The LED on the block will light and in the screen will appear the error “MN: Low Water Cutoff Error”. At this point press the reset button (the bottom button). The LED will turn off. 4.4.
Installation | 17 4.4.5 Pump SSB boilers must be fitted with a circulator pump. The graph in the following figure shows the pressure drop through the boiler circuit depending on the flow rate. SSB255 ∆ p / Feet of Head 8 7 6 5 4 3 2 1 0 0 5 10 15 20 Flow rate / GPM Fig. 12 SSB255 Pressure drop It is important to ensure the pump has the correct flow rate for the system to avoid a low water circulation situation.
| Installation SSB399 ∆ p / Feet of Head 18 16 14 12 10 8 6 4 2 0 0 5 10 15 20 25 30 35 Flow rate / GPM Fig. 13 SSB399 Pressure drop SSB512 ∆ p / Feet of Head 40 35 30 25 20 15 10 5 0 0 5 10 15 20 25 30 35 40 Flow rate / GPM Fig.
Installation | 19 4.4.6 Condensate removal The condensate water produced by the boiler during its normal operation is collected by two plastic pipes (A and B) provided with the boiler and connected with a plastic collector inside the case. A third tube (C) collects the condensate output from the collector [Arrow is the direction of flow of condensate]. stream.
| Installation The general electrical connection is shown in the following diagram : CASCADE LINK MOD BUS Gas Switch Out Door DHW Tank Room Sensor Thermostat L 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pump DHW Pump CH Boiler Pump Supply Sensor N L 3 Way N L N Alarm L N L (**) 120 V Main in 120 V Aux N N L 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 Relay (*) Furnished and Installed by others Outdoor sensor DHW tank sensor or aquastat Room thermostat Re
Installation | 21 4.5.
| Installation 4.6 Gas supply piping Verify that the type and the pressure of the gas supplied correspond with those required for the boiler. When field converting the boiler from Natural to LP gas be sure to adhere the new gas label on the boiler. The minimum and maximum pressure for natural gas are 3.5” W.C. (8.72 mbar) and 10.5” W.C. (26.15 mbar) respectively. The minimum and maximum pressure for LP gas are 8” W.C. (19.9 mbar) and 13” W.C. (32.3 mbar) respectively. 4.6.
Installation | 23 LP conversion kit installation (SSB399 - SSB512) Natural Gas to LP conversion The heating unit is factory preset for operating with natural gas. This set-up can be changed using the conversion kits supplied by the manufacturer. NOTICE: This change may only be performed by a qualified installer or service technician, according to the following procedure.
| Installation • Remodeling areas; • Garages with workshops. 4.7.1 General venting and combustion air piping system The SSB boilers require an approved vent system-designed for positive pressure. Vent connectors serving appliances vented by natural draft shall not be connected to any portion of mechanical draft systems operating under positive pressure. Ensure that the flue pipes and seals are not damaged. Use only primer and glue compounds approved for use with the vent material used.
Installation | 25 4.7.2 Connecting flue gas systems Optional vent systems are: • Twin pipe, concentric pipe and 1 pipe using room air • Approved materials PVC, CPVC, Stainless Steel, PP and PP-Flex (M&G Duravent PolyPro and Centrotherm InnoFlue) • Sealed combustion or room air intake • Terminations can be either horizontal or vertical • The diameters of the flue outlet and combustion air intake inlet are designed to fit standard PP, PVC, CPVC and stainless steel pipes.
| Installation X3 YB X3 X5 X3 3 X2 X2 X1 X1 X4 3 X1 3 YA 3 YA 1 2 Fig.
Installation | 27 Material Item PVC schedule 40, 80 1 PVC-DWV CPVC schedule 40, 80 Flue gas or combustion air Flue gas or combustion air Flue gas or combustion air PP Flue gas or combustion air PP-Flex Flue gas or combustion air Stainless Steel AL29-4C PVC CPVC Tab.
| Installation Wall Terminal 3" (80 mm) 3” (125 mm) 4” (100mm) Concentric kits 3” (125mm) Wall termination kit 3” (125 mm) 4” (100mm) Low profile termination kit 3” (80 mm) twin pipe termination 4” (100 mm) twin pipe termination Material parallel stainless steel Supplier Flex-L Part Number 46546901 PVC or CPVC IPEX IIa 196006 (PVC), 197009 (CPVC) 196021 (PVC), 197021 (CPVC) PVC IPEX IIa 081219 PVC IPEX IIa 196985 196986 PVC/parallel stainless steel ANSI/ASTM D1785 or Field Controls 4660020
Installation | 29 4.7.5 Approved examples of horizontal and vertical venting installation Place pipe supports every 5 feet (1,525 mm) of horizontal and vertical run, beginning with support near boiler. mm 2 2 • The condensate must be disposed of in accordance with applicable rules. • Periodic cleaning of the vent terminal and air-intake screens is mandatory. • Avoid locating vent terminals near equipment or building features which can be subject to degradation from exhaust gases.
| Installation X X X Y 2 Y X 1 Y 2 1 1 2 Fig. 32 Horizontal venting system (sealed combustion); X≥4” (102 mm); Y ≥12” (305 mm) Fig. 34 Vertical venting system (sealed combustion); X > 12” ; Y 12” above maximum snow level or at least 24” whichever is greater Y 2 2 1 Fig. 33 Vertical venting system (sealed combustion); Y 12” above maximum snow level or at least 24” whichever is greater 6720818454 (2016/02) US 2 1 Fig.
Installation | 31 3 2 2 1 1 Fig. 38 Horizontal concentric system (sealed combustion) Fig. 36 Horizontal venting system (sealed combustion) ; 3 is a wall termination 1 X Y X 2 1 2 Fig. 37 Horizontal venting system (sealed combustion); X≥4” (102 mm) SSB Fig.
| Installation 4.7.6 Multiple boiler When installing multiple air and vent terminations, be sure that: • The clearance between the vent and air termination are in accordance with the figures shown in this chapter • All vent pipes and air inlet must terminate at the same height X 2 1 Y Fig. 42 Concentric vent and combustion air vertical termination; X ≥ 12” ; Y ≥ 12” (18” for Canada and/or per CAN/CSA B149.1) above highest snow level. Maximum 24” above roof X Combustion air intake Fig.
Installation | 33 Air intake Air intake Vent Vent Y % range of the length of the vent and combustion air pipe installed referred to the maximum equivalent length* Altitude From From From From (ft) 0% to 25% 25% to 50% 50% to 75% 75% to 100% 0-2000 255900 255900 255900 255900 3000 247685 243608 239531 235455 4000 239469 235527 231586 227645 5000 231254 227447 223641 219835 6000 223038 219367 215696 212025 7000 214823 211287 207751 204215 8000 206607 203206 199806 196405 9000 198391 195126 191861 188595
| Commissioning (for single boiler application) 5 Commissioning (for single boiler application) Setting date and time Press the “menu” button and select “Settings” using the UP/DOWN button. Menu Domestic Hot Water Information Settings System Test 8 1 5.2 7 Fig. 50 Press the “OK” button and select “General Settings” using the UP/DOWN button. 2 3 4 6 5 Settings General Settings Boiler Settings Fig. 48 No. 1 2 3 4 5 6 7 8 Fig.
Commissioning (for single boiler application) | 35 Entering in “Time Zone Settings” menu it is possible to set the time zone parameter as shown in the following figure: Time Zone Settings Time Zone Correction Daylight Savings Time UTC +00.00 Disabled Fig.
| Commissioning (for single boiler application) 5.6 • State • Error The display shows four lines at a time: 115.0 °F 110.0 °F 111.0 °F 50.0 °F Fig. 62 Using the “UP/Down” button it is possible to scroll list. 5.5 Parameters list To have access to the parameter list press “menu” button and select “Settings” using the UP/DOWN button: Menu Domestic Hot Water Information Settings System Test Outdoor reset Setp.
Commissioning (for single boiler application) | 37 Below is a list of parameters: Number Description 3 CH Setpoint 19 Design Supply Temp 21 Baseline Supply Temp 48 DHW/Tank Setpoint 64 Preheat Mode 72 Permit emergency mode Tab. 14 Level 1 parameters Unit °C / °F °C / °F °C / °F °C / °F - Default 176 °F 176 °F 104 °F 120.2 °F Comfort Yes Min 68 °F 68 °F 68 °F 104 °F Eco No Max 194 °F 194 °F 194 °F 140 °F Comfort Yes Step 0.9 °F 1.8 °F 1.8 °F 0.
| Commissioning (for single boiler application) Number Description 93 Fan Speed Minimum 94 Fan Speed Ignition 97 Appliance Model ** 98 Gas Type 99 Flue length range Tab.
Commissioning (for single boiler application) | 39 5.7 Adjusting and setting CO2 limits NOTICE: Please verify parameter 99 is to be set first. Insert a combustion analyzer probe into the test port “A” as shown in Fig. 67. CO2 + B A A Fig. 68 Gas valve screw regulation for SSB255 A A Fig. 67 CO2 + CO2 + ►► Press “Menu” key.
| Troubleshooting Verify that the value of CO2 is stable and is within the range indicated in the following table (be careful to make small changes and confirm that the value is stable before making additional adjustment). Select “Low Power” using “UP/Down” button and press “OK”: System Test Test State Fan Speed Ionisation Low Power 0 rpm 0.0 μA The fan will run at the minimum speed. To adjust the CO2 value at the minimum power turn the screw “B” shown in Fig. 68 and in Fig. 70.
Troubleshooting | 41 6.1.1 Lockout errors If an error is a “Lockout” error, it is necessary to press “RESET” button (after eliminating the reason for the failure) to restart the boiler. In the following table the “Lockout” errors are listed: Error Int. nr.
| Troubleshooting Error Int. nr. Description "Too Many Flame Failures" 31 Three times flame lost during one demand "Flow Switch Not Closed Error" "Flow Switch Not Open Error" "Flag Byte Integrity Error" "Ad Hi Cpl Error" "Ad Lo Cpl Error" "Register Error" Tab.
Troubleshooting | 43 Error “Overheat Error” "T Supply Open" "T Return Open" "T Dhw Out Open" 70 72 73 76 Description Checks Supply temp exceed the limit a- Check the pump to verify the flow circulation b- Check if the valves on hydraulic circuit are open c- Check the supply temperature sensor Supply sensor open a- Check the integrity of the wire connections b- Check the supply temperature sensor Return sensor open a- Check the integrity of the wire connections b- Check the return temperature
| Troubleshooting 6.2 Errors not shown on display Symptoms Combustion noise too loud; rumbling noises Flow noises Heating-up takes too long Flue gas readings incorrect; CO levels too high Hard ignition, poor ignition Tab. 20 6.3 Possible solutions Check gas type. Check inlet gas pressure; adjust as needed. Check flue gas system; clean or repair as needed. Check gas/air ratio in the combustion air and flue gas; replace gas valve as needed. Set pump speed correctly to match maximum output.
Maintenance | 45 Maintenance 7.1 General NOTICE: The installer must inform the user about the contents of this section. The user must make the necessary arrangements with qualified service agency for the care and periodic maintenance of the boiler. CAUTION: Lack of care and maintenance of this boiler and equipment may cause an unsafe condition.
| Applications 8 The following system diagrams are showing primary/secondary piping. As alternative a appropriate sized low loss header can also be used. When using primary/secondary piping please follow the following guidelines: Applications The following shows possible system diagrams. Secondary Supply NOTICE: Application drawings in this manual are conceptual only and do not purport to address all design, installation, code, or safety considerations.
Applications | 47 Wiring diagram for multiple zone with indirect tank (pump for each zone): CASCADE LINK MOD BUS Gas Switch Out Door DHW Tank Room Sensor Thermostat L 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pump DHW Pump CH Boiler Pump Supply Sensor GND N L GND 3 Way N L GND N L Alarm 120 V Aux GND GND N L 120 V Main in N L 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 Outdoor sensor (5) GND 117 N 118 Relay (*) Furnished and Installed by others DHW tank sensor
| Applications 8.2 Multiple zone with indirect tank (valve for each zone) Purge Drain Zone relay Outdoor air sensor XX 1 5 (optional) Pressure By-pass Heating zone Auto-Fill Air Eliminator Flow Check Condensate drain Room Thermostat 2 Expansion Tank Relief valve and pressure gauge 3 Back-flow preventer Isolation valve Supply sensor 4 Domestic Hot Water ... Zone Valve Fig.
Applications | 49 Wiring diagram for multiple zone with indirect tank (valve for each zone): CASCADE LINK MOD BUS Gas Switch Out Door DHW Tank Room Sensor Thermostat L 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pump DHW Pump CH Boiler Pump Supply Sensor GND N L GND 3 Way N L GND N L Alarm 120 V Aux GND GND N L 120 V Main in N L 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 Outdoor sensor (5) GND 117 N 118 Relay (*) Furnished and Installed by others DHW tank senso
| Applications 8.3 Cascade connection The SSB boilers can be connected together to form a cascade with a maximum of 16 boilers. In this case, one boiler will be the manager of the other boilers connected. This boiler is named “Primary”. The other one(s) are named “Secondary”.
Applications | 51 A recommended scheme for cascade installation is as follow: 3 Purge Drain Heating Return Outdoor air sensor (optional) Indirect return Auto-Fill Indirect Tank Heating zone 6 7 Air Eliminator Condensate drain 1 Indirect tank sensor (tank not shown) 2 Room Thermostat Expansion Tank 8 Relief valve and pressure gauge 9 Back-flow preventer 4 Shut-off valve Supply sensor 5 Circulator Primary Bolier Secondary Bolier Fig.
| Applications For this installation the wiring is shown in figure below: CASCADE LINK MOD BUS Gas Switch Out Door DHW Tank Room Sensor Thermostat GND L 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pump DHW Pump CH Boiler Pump Supply Sensor N L GND 3 Way N L GND N L Alarm 120 V Aux GND GND N L 120 V Main in N L 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 GND 117 N 118 (4) Cascade link Relay (*) Furnished and Installed by others L GND N Boiler pump 120 V Line
Applications | 53 (*) NOTICE: The maximum amp load for each pump is 1 A when 2 or 3 pumps are connected. For this reason, if the power consumption of each pump is higher than 84 watt, use a relay as shown in figure. If just one pump is connected, the maximum amp load of this single pump is 2 A. For this reason if the power consumption of the pump is higher than 168 watt, use a relay as shown in Fig. 81. 8.3.
| Commissioning log for the appliance 9 Commissioning log for the appliance Please complete a separate log for each appliance.
Commissioning log for the appliance | 55 Modified service functions: (select the modified service functions and enter the values here). Example: Vent Length Parameter changed from 1 to 2 Heating control 850 MIN: Vent length setting (par.99 “Flue length range”) � 1 | � 2 | � 3 | � 4 Gas type setting (par 98 “Gas Type”) � NG | � LPG CH set point (par. 3) : DHW set point (par.
| Spare parts 10 Spare parts 6 4 10 17 7 2 23 19 18 22 13 9 22 8 12 20 23 19 24 14 17 21 15 1 16 25 11 3 5 Fig.
SSB SSB512 Description Panel front Panel left side front Panel right side front Panel left side rear Panel right side rear Panel top front Panel top rear Panel top rear Cover control board Mounting bracket control board panel Panel control board Adjustable leveling leg Right frame Right frame Right frame Left frame Left frame Left frame Mounting bracket pressure differential switch Mounting bracket return pipe Mounting bracket condensate collector Handle Front Panel Lock and lever front panel Alignment pi
| Spare parts 37 19 15 38 21 26 16 12 27 37 26 21 24 Shown on Fig. 85 - Fig. 86 2 1 36 3 13 41 11 12 42 4 5 6 8 7 10 9 35 33 20 7 5 21 6 30 21 44 34 32 24 25 23 Fig.
8 9 10 11 12 13 15 15 16 16 19 19 20 21 23 24 25 25 25 26 27 27 28 29 30 31 32 33 34 35 35 35 36 37 37 38 38 41 42 43 44 45 SSB SSB512 7 Description High limit sensor and screws LWCO probe LWCO adapter and O-ring O-ring LWCO adapter Universal temperature detector and washer Washer temperature detector O-ring HX supply manifold and return adapter 1.42x0.14in 36,1x3,5mm EPDM Boiler Supply manifold U-clip boiler supply manifold hx side 2.12x1.
| Spare parts 1 2 4 3 5 6 19 8 7 9 10 20 24 25 16 15 21 6.5 11 13 18 17 6.75 23 12 14 Fig.
SSB SSB512 Description Enclosure user interface Circuit Board user interface Keypad Service plug cover On Off power switch Display cable Conduit for display cable Terminal block low voltage Terminal block line voltage Control Board Transformer 24V 0.6 amps LWCO circuit board Fuse carrier Red LED light Fuse 6 A Fuse 0.
| Spare parts SSB255 ONLY 35 23 34 14 22 11 18 19 12 17 10 31 8 6 7 5 32 9 30 13 15 16 25 26 24 4 27 33 3 2 1 Fig.
Item (→ Fig. 85) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 22 23 24 25 26 27 30 31 32 33 34 35 SSB Description Flanged exhaust connector O-ring flanged exhaust connector 6.5x0.23in 165x6mm EPDM Heat Exchanger SSB255 O-ring burner flange 6.60x0.20in 167.7x5.
| Spare parts SSB399 - SSB512 43 44 23 22 14 16 16 17 14 15 13 18 12 14 14 39 17 19 21 20 40 39 11 10 8 7 5 9 25 6 26 24 4 42 27 41 3 2 1 Fig.
Description Flanged exhaust connector O-ring flanged exhaust connector 6.5x0.23in 165x6mm EPDM Heat exchanger SSB-399 Heat exchanger SSB-512 O-ring burner flange 6.60x0.20in 167.7x5.
| Spare parts Notes 6720818454 (2016/02) US SSB
Spare parts | 67 Notes SSB 6720818454 (2016/02) US
6720818454 (2016/02) US United States and Canada Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-965-7581 www.boschheatingandcooling.com U.S.A. Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.
