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Gas Condensing Stainless Steel Boiler
BUDERUS SSB BOILER
SSB85 | SSB120 | SSB160
Installation and Service Instructions for Contractors
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.
Explain to the owner or operator how to use the heating system using
the operating instructions. Make sure that they are familiar with all
required information for the safe and proper operation of the heating
system.
These instructions are available in English and French.
Please keep these instructions for future reference.
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Table of Contents
Related Manuals for Bosch BUDERUS SSB120
Summary of Contents for Bosch BUDERUS SSB120
- Page 1 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.
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Page 2: Table Of Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key to symbols and safety instructions Commissioning (for single application) Key to symbols . -
Page 3: Key To Symbols And Safety Instructions | 3
► Immediately correct all faults to prevent system damage. Observe these instructions for your safety. ► Only use original Bosch spare parts. Losses caused by the use of The burner and control must be correctly installed and adjusted to ensure parts not supplied by Bosch are excluded from the Bosch warranty. -
Page 4: Product Description
► The boiler is intended only for the use for which it was specifically • The gas-fired condensing SSB boilers are designed to be used in designed and built. Bosch is hereby excluded from any liability for central heating systems. Any other use is prohibited. -
Page 5: Proper Use
2 .4 Environmental responsibility / disposal Environmental responsibility is one of the fundamental company policies of the Bosch Group. We regard quality of performance, economy and environmental responsibility as equal objectives. Environmental protection laws and regulations are strictly adhered to. -
Page 6: Dimensions And Connections
6 | Product description 2 .5 Dimensions and Connections 10 1/2” (267mm) 11 1/2” (292mm) 12 1/2” (317mm) 11 3/16” (283mm) 15 9/32” (388mm) 20” (506mm) 18 1/16” (458mm) 14 1/4” (361mm) 9 1/2” (241mm) 5 3/8” (137mm) 1 15/16” (50mm) Tolerances on all dimensions shown is +/- 1/4”... - Page 7 Product description | 7 10 9/16” (268mm) 11 5/8” (293mm) 12 5/8” (318mm) 11 3/16” (283mm) 15 3/8” (388mm) 20” (508mm) 18 1/16” (458mm) 14 1/4” (361mm) 9 1/2” (241mm) 5 3/8” (137mm) 1 15/16” (58mm) Tolerances on all dimensions shown is +/- 1/4” (6.35mm) Fig.
- Page 8 8 | Product description 10 9/16” (268mm) 11 5/8” (293mm) 12 5/8” (318mm) 11 3/16” (283mm) 15 3/8” (388mm) 20” (508mm) 18 1/16” (458mm) 14 1/4” (361mm) 9 1/2” (241mm) 5 3/8” (137mm) 1 15/16” (58mm) Tolerances on all dimensions shown is +/- 1/4” (6.35mm) Fig.
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Page 9: Main Components
Product description | 9 2 .6 Main components Fig. 5 SSB160 (main components) [1] Main power switch [14] Supply temperature probe [2] System return [15] High limit temp. safety switch [3] Gas inlet [16] Heat exchanger [4] Flue exhaust [17] Condensate trap [5] Intake air [18] Low point drain valve [6] System supply... -
Page 10: Technical Data
10 | Product description 2 .7 Technical data Unit SSB85 SSB120 SSB160 Boiler Category ASME Sect.IV ASME Sect.IV ASME Sect.IV Type of Gas Natural Gas, Propane * Natural Gas, Propane * Natural Gas, Propane * Max input rate BTU/hr (kW) 85,300 (25) 119,420 (35) 160,364 (47) -
Page 11: Efficiency Curves
Product description | 11 2 .8 Efficiency Curves 100% 20% input 30% input 100% input Return Water Temperature (°F) @ 36 Degree Rise Fig. 6 Thermal Efficiency Curves SSB85* * Thermal Efficiency curve is for reference only as this is a residential boiler 100% 20% input 30% input... - Page 12 12 | Product description 100% 20% input 30% input 100% input Return Water Temperature (°F) @ 36 Degree Rise Fig. 8 Thermal Efficiency Curves SSB160* * Thermal Efficiency curve is for reference only as this is a residential boiler 6720818456 (2018/06) US...
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Page 13: Regulations
Regulations | 13 - In the event that the requirements of this subdivision can not be Regulations 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 Observe all rules, regulations, standards and guidelines battery operated carbon monoxide detector with an alarm shall be... -
Page 14: Installation
14 | Installation The recommended clearance for ease of installation and service are Installation illustrated in the following picture: 4 .1 Packaging and product identification The SSB is delivered strapped to a pallet, packed and protected in a cardboard carton. NOTICE: The packaging shows the characteristics of the 2”... -
Page 15: Water Chemistry Guidelines
Installation | 15 4 .3 Water Chemistry Guidelines In the following table are listed the chemical water specifications. Parameters Units Value NOTICE: If using anti-freeze: General feature Colorless, no sediment ► For freeze protection use only propylene glycol, with Dissolved Oxygen mg/l <... -
Page 16: Low Water Cut Off
16 | Installation 4 .4 .1 Low water cut off 4 .4 .4 Pressure relief valve (PRV) ASME approved A low water cut off (LWCO) is installed in the boiler, the manual reset The boiler is supplied with a pressure relief valve (PRV). The relief button is located on the front of the internal control box. -
Page 17: Pump
Installation | 17 4 .4 .6 Pump SSB85/120/160 boilers are fitted with a circulator pump. The graph in the following figure shows the head range of the pump depending on the flow rate compared to the relevant pressure drop. SSB85 – UPS15-58 SSB85 pressure drop speed3... - Page 18 18 | Installation SSB120 – UPS25-78 Head available for SSB120 the system at speed3 pressure drop speed3 speed2 speed1 Flow rate / GPM Fig. 13 SSB120 Pump curve SSB160 – UPS25-78 SSB160 pressure drop Head available for the system at speed3 speed3 speed2 speed1...
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Page 19: Condensate Removal
Installation | 19 4 .4 .7 Condensate removal specific purpose, because the acidic action of condensate will cause a rapid deterioration. The condensate water produced by the boiler during its normal operation is collected by a condensate trap (A) provided with the boiler and •... -
Page 20: Access To The Electrical Terminal Strip
20 | Installation The general electrical connection is shown in the following diagram : (**) Boiler Pump CH Pump DHW CASCADE DHW Tank Room Supply 120 V Main in Alarm 120 V Aux Pump LINK Switch Door Sensor Thermostat Sensor 3 Way 1 2 3 4 5 6 7 8 9 10 11 12 13 14 101 102 103 104 105 106 107 108 109... -
Page 21: Electrical Wiring Diagram
Installation | 21 4 .5 .5 Electrical wiring diagram Jumper factory installed LOW VOLTAGE HIGH VOLTAGE HIGH IN / OUT VOLTAGE PUMP CH PUMP DHW 120 V Supply CASCADE Room MAIN PUMP ALLARM 120 V AUX Sensor MAIN IN Tank LINK SWITCH DOOR... -
Page 22: Gas Supply Piping
22 | Installation 4 .6 Gas supply piping LP ORIFICE INSTALLATION (SSB85 – SSB120) Natural Gas to LP conversion 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 The heating unit is factory preset for operating with natural gas. -
Page 23: Venting And Air Piping System
Installation | 23 LP ORIFICE INSTALLATION (SSB160) 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 an authorized Servicing Center, according to the following procedure. -
Page 24: General Venting And Combustion Air Piping System
24 | Installation • Photo processing plants; ► The exhaust vent and the combustion air inlet lines must be supported to prevent sagging per the vent manufacturer’s instructions. • Auto body shops; ► Do not mix components from different systems. The vent system could •... -
Page 25: Connecting Flue Gas Accessories
Installation | 25 4 .7 .2 Connecting flue gas accessories Approved vent systems are: • Twin pipe, concentric pipe and 1 pipe using room air PVC / CPVC / • Stainless Steel • Approved materials PVC, CPVC, Stainless Steel, PP and PP-Flex (M&G Duravent PolyPro and Centrotherm InnoFlue) •... - Page 26 26 | Installation Fig. 28 Direct vent (sealed combustion) It is not recommended to terminate vent above any door or window, condensate can freeze causing ice formations. [1] Forced air inlet Do not use chimney as a raceway if another boiler or fireplace is vented [2] Gravity air inlet into or through chimney.
- Page 27 Installation | 27 Pipe diameter per boiler Standard Material Item Standard [USA] [Canada] 2” (60mm) 2” (60mm) 2” (60mm) PVC schedule 40, Flue gas or ANSI/ASTM D1785 3” (80mm) 3” (80mm) 3” (80mm) combustion air 4” (100mm) 4” (100mm) 4” (100mm) 2”...
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Page 28: Vent And Combustion Air Pipe Length [For Single Boiler Installations]
28 | Installation Wall Terminal Material Supplier Part Number 3" (80 mm) parallel stainless steel Fields 46546901 Ø 2” (60 mm) 196005 (PVC) Ø 3” (80 mm) PVC or CPVC IPEX System 636 196006 (PVC), 197009 (CPVC) Concentric kits Ø 2” (60 mm) 081216 Ø... -
Page 29: Approved Examples Of Horizontal And Vertical Venting Installation
Installation | 29 Defining the correct value to assign to par N° 99 follow this example: When using a SSB85 with 2” (60 mm) PP venting material the maximum equivalent length is 50 feet for both vent and combustion air piping. Consider the equivalent length of vent pipe is 36 ft. - Page 30 30 | Installation 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 Fig.
- Page 31 Installation | 31 Fig. 38 Horizontal concentric system (sealed combustion) Fig. 36 Horizontal venting system (sealed combustion) ; 3 is a wall termination Fig. 37 Horizontal venting system (sealed combustion); X≥4” (102 mm) Fig. 39 Vertical venting system (sealed combustion) ; ); X > 12” (305 mm);...
- Page 32 32 | Installation H>2.2 inch w.c. Fig. 40 Vertical venting system (sealed combustion) Fig. 42 Recommended additional condensate drain for high vent stack Flexible vent and combustion air pipe H>2.2 inch w.c. Fig. 41 Vertical venting system (sealed combustion) Fig. 43 Recommended additional condensate drain for long horizontal vent piping 6720818456 (2018/06) US...
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Page 33: Multiple Boiler
Installation | 33 4 .7 .6 Multiple boiler Air intake Vent WARNING: Do not connect SSB models 85, 120 and 160 to a shared/common or cascade vent system. Each boiler Vent must have a separate, dedicated vent system. Air intake When installing multiple air and vent terminations, be sure that: •... -
Page 34: Commissioning (For Single Application)
34 | Commissioning (for single application) 5 .2 Setting date and time Commissioning (for single application) Press the “menu” button and select “Settings” using the UP/DOWN button. Menu Domestic Hot Water Information Settings System Test Fig. 52 Press the “OK” button and select “General Settings” using the UP/DOWN button. -
Page 35: Setting Ch And Dhw Setpoint
Commissioning (for single application) | 35 Entering in “Time Zone Settings” menu it is possible to set the time zone parameter as shown in the following figure: CH setpoint cannot be changed when outdoor reset function is enabled. See section “5.5 Parameters list” for detailed instructions regarding outdoor reset. -
Page 36: Parameters List
36 | Commissioning (for single application) Selecting “Boiler Status” and pressing “OK” for the following values: Press the “OK” button. At this point is request a password [Password is required for boiler settings only]: • Flow Temperature • Return Temperature Password •... - Page 37 Commissioning (for single application) | 37 Below is a list of parameters: Number Description Unit Default Step CH Setpoint °C / °F 176 °F 68 °F 194 °F 0.9 °F Design Supply Temp °C / °F 176 °F 68 °F 194 °F 1.8 °F Baseline Supply Temp...
- Page 38 38 | Commissioning (for single application) Number Description Unit Default Step Frost Protection Off / On Disabled Disabled Enabled Frost Protection Setpoint °C / °F 50 °F 33.8 °F 68 °F 0.9 °F DHW Max Limit °C / °F 140 °F 104 °F 158 °F 0.9 °F...
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Page 39: Adjusting And Setting Co Limits
Commissioning (for single application) | 39 5 .7 Adjusting and setting CO limits NOTICE: Please verify parameter 99 is to be set first. CO2 + CO2 + Insert a combustion analyzer probe into the test port “A” as shown in Fig. Fig. -
Page 40: Setting Frost Protection
40 | Troubleshooting The fan will run at the minimum speed. Troubleshooting To adjust the CO value at the minimum power turn the screw “B” shown in Fig. 70 and in Fig. 71. WARNING: Close the gas cock prior to working on the gas Verify that the value of CO is stable and is within the range indicated in train or “boiler”. -
Page 41: Lockout Errors
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 . -
Page 42: Blocking Errors
42 | Troubleshooting Error Int . nr . Description Checks Solutions a- Check the integrity of Three times flame lost during one the wire connections of the a- If wires are damaged, replace "Too Many Flame Failures" demand spark and the earth on heat them exchanger "Flow Switch Not Closed Error"... - Page 43 Troubleshooting | 43 Error Int . nr . Description Checks Solutions a- Change the pump or restart it a- Check the pump to verify b- Open the valves on hydraulic the flow circulation circuit b- Check if the valves on “Overheat Error”...
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Page 44: Errors Not Shown On Display
44 | Troubleshooting 6 .2 Errors not shown on display Symptoms Possible solutions Check gas type. Combustion noise too loud; rumbling noises 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. -
Page 45: Maintenance
Maintenance | 45 Time interval Maintenance Maintenance Annually * Verify startup Annually * Verify the flame 7 .1 General Annually * Check relief valve Annually * Inspect the burner gasket NOTICE: The installer must inform the user about the (*) Annually or every 2000 hours. Which occurs first. contents of this section. -
Page 46: 46 | Installation Schemes
46 | Installation schemes The following system diagrams are showing primary/secondary piping. As Installation schemes alternative a appropriate sized low loss header can also be used. When using primary/secondary piping please follow the following guidelines: The following shows possible system diagrams. Secondary Secondary NOTICE: Application drawings in this manual are... -
Page 47: Settings
Installation schemes | 47 Wiring diagram for multiple zone with indirect tank (pump for each zone): Boiler Pump CH Pump DHW Alarm 120 V Aux 120 V Main in Pump CASCADE Outdoor DHW Tank Room Supply LINK Switch air sensor Sensor Thermostat Sensor... -
Page 48: Multiple Zone With Indirect Tank (Valve For Each Zone)
48 | Installation schemes 8 .2 Multiple zone with indirect tank (valve for each zone) Purge Drain Zone relay Outdoor air sensor (provided with boiler Pressure By-pass installed by others) Heating zone Auto-Fill Eliminator Flow Check Condensate drain Room Thermostat Expansion Tank Relief valve... -
Page 49: Settings
Installation schemes | 49 Wiring diagram for multiple zone with indirect tank (valve for each zone): Boiler Pump CH Pump DHW Alarm 120 V Aux 120 V Main in Pump CASCADE Outdoor DHW Tank Room Supply LINK Switch air sensor Sensor Thermostat Sensor... -
Page 50: Cascade
50 | Installation schemes 8 .3 Cascade Each cascade boiler has to be identified by an address (parameter N° 73 “Boiler Address” )different from the others. To define these address follow The SSB boilers can be connected together to form a cascade with a the steps below: maximum of 16 boilers. - Page 51 Installation schemes | 51 A recommended scheme for cascade installation is as follow: Purge Drain Indirect Heating Tank Heating Tank (optional) zone Return Outdoor air return sensor Auto-Fill Eliminator Indirect tank sensor (tank not shown) Condensate drain Room Thermostat Expansion Tank Relief valve pressure...
- Page 52 52 | Installation schemes For this installation the wiring is shown in figure below: Pump DHW Boiler Pump CH CASCADE DHW Tank Room Supply 120 V Main in Alarm 120 V Aux Pump LINK Switch Door Sensor Thermostat Sensor 3 Way 1 2 3 4 5 6 7 8 9 10 11 12 13 14 101 102 103 104 105 106 107 108 109 110 111 112...
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Page 53: Settings
Installation schemes | 53 8 .3 .1 Settings (*) NOTICE: The maximum amp load for each pump (in Set the parameters as indicated in the following table (for the parameter addition to the boiler pump) is 1 A when 1 or 2 pumps are list see section “5.5 Parameters list”): connected. -
Page 54: 54 | Commissioning Log For The Appliance
54 | Commissioning log for the appliance Commissioning log for the appliance Please complete a separate log for each appliance. Home owner/operator: Last name, first name Number, Street Telephone/fax ZIP code, town System installer: Order number: Appliance type FD (Date of manufacture): Date commissioned: �... - Page 55 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”) �...
- Page 56 56 | Spare parts Spare parts Fig. 83 6720818456 (2018/06) US...
- Page 57 7-738-004-907 Mounting bracket control board panel ■ ■ ■ 7-738-004-908 Alignment pin front side panels ■ ■ ■ 7-738-004-924 Logo Bosch front door ■ ■ ■ 7-738-005-176 Handle front panel ■ ■ ■ 7-738-004-920 Lock and lever front panel ■...
- Page 58 58 | Spare parts Shown on Fig. 86 - Fig. 87 Fig. 84 6720818456 (2018/06) US...
- Page 59 Spare parts | 59 Item (→ Fig. 84) Description Order number High limit sensor and screws ■ ■ ■ 7-738-004-926 Universal temperature detector and washer ■ ■ ■ 7-738-004-930 O-ring temperature detector 0.51x0.1in 13x2.62mm ■ ■ ■ 7-738-004-931 Automatic air vent 3/8" ■...
- Page 60 60 | Spare parts Fig. 85 6720818456 (2018/06) US...
- Page 61 Spare parts | 61 Item (→ Fig. 85) Description Order number Enclosure user interface ■ ■ ■ 7-738-005-037 Circuit Board user interface ■ ■ ■ 7-738-005-038 Keypad ■ ■ ■ 7-738-005-039 Service plug cover ■ ■ ■ 7-738-005-040 On Off power switch ■...
- Page 62 62 | Spare parts SSB85 - SSB120 19 20 Fig. 86 6720818456 (2018/06) US...
- Page 63 Spare parts | 63 Item (→ Fig. 86) Description Order number Heat exchanger SSB85 ■ 7-738-005-154 Heat exchanger SSB120 ■ 7-738-005-155 Washer for ignition electrode ■ ■ 7-738-005-034 Ignition electrode with washer ■ ■ 7-738-005-397 Sight glass for combustion ■ ■...
- Page 64 64 | Spare parts SSB160 ONLY Fig. 87 6720818456 (2018/06) US...
- Page 65 Spare parts | 65 Item (→ Fig. 87) Description Order number Heat exchanger SSB160 ■ 7-738-005-156 Washer for ignition electrode ■ 7-738-005-034 Ignition electrode with washer ■ 7-738-005-397 Sight glass for combustion ■ 7-738-005-031 Gasket premix burner tube ■ 7-738-004-985 Premix burner tube ■...
- Page 66 66 | Spare parts Notes 6720818456 (2018/06) US...
- Page 67 Spare parts | 67 Notes 6720818456 (2018/06) US...
- Page 68 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.