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 trained and certified installer or the gas supply company. WARNING: The operating instructions are part of the technical documents that must be handed over to the owner or operator of the heating system.
| Table of Contents 6.3 Table of Contents 1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4 2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 KBR - Residential boiler for space heating and loading of indirect fired DHW tanks . . . . . . . . . . . . . . . . .
Key to symbols and safety instructions | 3 17.4 17.4.1 17.4.2 17.4.3 10 Boiler circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 10.1 Pump anti-seize protection . . . . . . . . . . . . . . . . . . . . . . 53 10.2 Changing the pump curve of the boiler pump . . . . . . . 53 11 Heatronic boiler control settings . . . . . . . . . . . . . . . . . . . . . . . 54 11.1 Guideline to service functions . . . . . . . . . . . . . . . . . . . . 54 11.
| Key to symbols and safety instructions 1.2 General safety instructions If you hear gas leaking ▶ Leave the building immediately. ▶ Prevent others from entering the building. ▶ Notify the police and fire department from outside the building. ▶ From outside the building, call the gas supply company and a trained and certified installer or service company. If you smell gas ▶ Turn off the gas shut-off valve. ▶ Open windows and doors ▶ Do not touch any electrical switch, telephone, and do not use outlets.
Scope of delivery | 5 2 Scope of delivery 2.1 KBR - Residential boiler for space heating and loading of indirect fired DHW tanks 2.2 KWB - Residential combi boiler for space heating and DHW generation 1 1 2 2 3 3 4 4 5 6 5 6720810590-06.1Wo Fig. 1 Scope of delivery heating boiler KBR..-3A 6720810590-05.1Wo Fig. 2 Scope of delivery combi boiler KWB..
| Information about the appliance 3 The rating plate contains the appliance output, model number, approval data and serial number. Information about the appliance KBR appliances are natural gas, residential boilers for central heating and loading of an indirect fired DHW tank. KWB appliances are natural gas, residential combi boilers for central heating and on demand DHW heating.
Information about the appliance | 7 3.6 Product dimensions and minimum clearances Ø2 M1 M2 Ø1 M3 M4 M5 M16 M15 M6 M7 M8 M9 M11 M10 M14 M13 M12 6720810590-36.1Wo Fig. 4 [M1] [M2] [M3] [M4] [M5] [M6] [M7] [M8] [M9] [M10] [M11] [M12] [M13] [M14] [M15] [M16] [Ø 1] [Ø 2] 18 3/8” - (467mm) 3 1/2” - (88mm) 9 5/8” - (243.5mm) 10” - (253.5mm) 39 1/2 ” - (1003mm) 11 7/8” - (301.5mm) 77/8” - (200mm) 4” - (101mm) 8 3/16” - (207.3mm) 3 7/16” - (86.7mm) 6 13/16” - (173.3mm) 4 5/8” - (117.
| Information about the appliance 3.7 Appliance layout heating boiler KBR..-3A 4 5 18 6 1 7 19 9 20 10 2 21 11 22 23 12 24 3 13 25 14 26 15 16 17 27 39 28 38 29 37 30 36 31 35 40 41 32 Fig. 6 33 34 6720810590-35.1Wo Appliance layout heating boiler KBR..
Information about the appliance | 9 Key to Fig. 6 Heating boiler KBR..
| Information about the appliance 3.8 Appliance layout combi boiler KWB..-3A 6 7 1 22 8 9 2 23 10 11 24 12 25 13 26 27 14 28 15 3 16 29 17 30 18 31 4 32 5 19 20 21 33 45 34 44 35 43 36 42 37 41 46 47 38 Fig. 7 39 40 6720810590-34.1Wo Appliance layout combi boiler KWB..
Information about the appliance | 11 Key to Fig. 7 Combi boiler KWB..
| Information about the appliance 3.9 Electrical wiring heating boiler KBR..-3A 2 T 1 3 4 6 9 8 7 A 5 L F N NS LS LR 1 2 NP LP 4 B B 27 7 8 4 9 6 10 21 DHW sen 5 3 4 out sen 2 13 15 12 14 16 1 BUS TT LWCO 6 11 17 18 23 22 24 19 25 20 Fig. 8 6720810590-10.1Wo 26 Electrical wiring diagram heating boiler KBR..
Information about the appliance | 13 Key to Fig. 8 Heating boiler KBR..-3A: [T] Top of control board [1] Code plug [2] System supply temperature sensor [3] Diagnostic interface [4] ON/OFF switch [5] Fuse T 6.
| Information about the appliance 3.10 Electrical wiring combi boiler KWB..-3A 2 1 3 T 4 6 9 8 7 A 5 L F N NS LS LR 1 2 NP LP 4 B B 4 28 7 8 6 9 6 10 20 DHW sen 5 3 4 out sen 2 13 12 14 1 BUS TT LWCO 6 11 15 16 23 21 25 17 24 26 22 Fig. 9 19 6720810590-09.1Wo 18 27 Electrical wiring diagram combi boiler KWB..
Information about the appliance | 15 Key to Fig. 9 Combi boiler KWB..-3A: [T] Top of control board [1] Code plug [2] System supply temperature sensor [3] Diagnostic interface [4] ON/OFF switch [5] Fuse T 6.
| Information about the appliance 3.11 Technical data heating boiler KBR 16-3 Input/Output Unit NG LPG (Propane) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 57,200 (16.8) 56,400 (16.5) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 54,900 (16.1) 55,300 (16.2) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 54,300 (15.9) 54,600 (16.0) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 50,800 (14.9) 51,200 (15.0) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 12,900 (3.8) 21,500 (6.3) Min.
Information about the appliance | 17 3.12 Technical data heating boiler KBR 21 -3 Input/Output Unit NG LPG (Propane) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 79,200 (23.2) 77,500 (22.7) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 74,700 (21.9) 74,700 (21.9) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 74,000 (21.7) 74,000 (21.7) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 70,300 (20.6) 70,300 (20.6) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 24,600 (7.2) 40,100 (11.7) Min.
| Information about the appliance 3.13 Technical data heating boiler KBR 28-3 Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min. output rate 176/140 °F (80/60 °C) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3) Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.
Information about the appliance | 19 3.14 Technical data heating boiler KBR 35-3 Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min. output rate 176/140 °F (80/60 °C) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3) Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.
| Information about the appliance 3.15 Technical data heating boiler KBR 42-3 Input/Output at elevation 0 - 2000 feet (0 - 610 metres) Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Min. input rate 180/79 (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min. output rate 176/140 °F (80/60 °C) Input/Output at elevation 2000 - 4500 feet ( 611 - 1372 metres) Max.
Information about the appliance | 21 3.16 Technical data combi boiler KWB 28-3 Input/Output Unit NG LPG (Propane) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 100,800 (29.5) 98,600 (28.9) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 89,400 (26.2) 89,400 (26.2) Output rate domestic hot water (DHW) 113 °F (45 °C) BTU/hr (kW) 93,600 (27.
| Information about the appliance 3.17 Technical data combi boiler KWB 35 - 3 Input/Output Max. input rate 180/79 °F (82/26 °C) Max. output rate 104/86 °F (40/30 °C) Max. output rate 122/86 °F (50/30 °C) Max. output rate 176/140 °F (80/60 °C) Output rate domestic hot water (DHW) 113 °F (45 °C) Output rate domestic hot water (DHW) 140 °F (60 °C) Min. input rate 180/79 (82/26 °C) Min. output rate 104/86 °F (40/30 °C) Min. output rate 122/86 °F (50/30 °C) Min.
Information about the appliance | 23 3.18 Technical data combi boiler KWB 42 - 3 Input/Output Unit Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) Output rate domestic hot water (DHW) 113 °F (45 °C) BTU/hr (kW) Output rate domestic hot water (DHW) 140 °F (60 °C) BTU/hr (kW) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) Min.
| Regulations Input/Output Voltage Frequency Max. power consumption (central heating mode) Max. power consumption (standby mode) Sound pressure level Max. supply temperature Max. permissible operating pressure (PMS) heating Permissible ambient temperature Nominal water capacity (heating) Weight (without packaging) Maximum overall dimensions W x H x D 3.19 Condensate composition The condensate volume and ingredients may change with regionally and seasonally varying gas quality and air quality.
Regulations | 25 4.
| Common Applications of KBR boilers 5 Common Applications of KBR boilers 5.1 Multiple zones using zone valves with DHW 1 3 7 11 10 6 4 2 M 13 14 15 9 M 12 8 5 6720810590-15.1Wo 16 18 17 Fig.
Common Applications of KBR boilers | 27 5.1.2 Wiring - Multi zone with zone valves and LWCO When using CZM100 and CRC100 or CRC200 controls the factory installed jumper at terminal [2e] remains. The LWCO jumper on terminal [2g] is removed when using a LWCO.
| Common Applications of KBR boilers 5.2 Multiple zones using circulators with DHW 1 3 5 10 9 2 4 12 13 14 6 8 7 11 6720810590-16.1Wo 15 17 16 Fig.
Common Applications of KBR boilers | 29 5.2.2 Wiring When using CZM100 and CRC100 or CRC200 controls the factory installed jumper at terminal [2e] remains. The LWCO jumper on terminal [2g] is removed when using a LWCO.
| Installation Recirculation pump/DHW recirculation lines 6 Installation DANGER: Explosion! ▶ Close the gas cock prior to working on the gas train. ▶ Check for gas leaks after carrying out work on the gas train. Installation, power connection, connection on the gas and flue gas side and commissioning must only be carried out by a contractor certified for such work by the state or local jurisdiction or the local gas or power utility.
Installation | 31 Water Chemistry Guidelines NOTICE: Insufficient antifreeze can accelerate corrosion. ▶ Follow manufacturer's instructions on antifreeze concentration. ▶ Frost protection level has to be checked annually during the regular scheduled maintenance of the condensing boiler. NOTICE: System damage! ▶ It is the installer's responsibility to ensure that the heating system is compatible with the boiler type and size installed. ▶ pH-value of the heating water to be kept between 7 and 8.5.
| Installation 6.2 Comparing the size of the integrated expansion vessel (KWB-3A boiler only) The following diagrams allow verifying that the integrated expansion vessel has sufficient capacity for the intended application, or if an additional expansion vessel is needed (not for radiant floor heating). 6.3 KBR..-3A appliances (heating boilers): Selecting an expansion vessel External expansion vessel ▶ Determine size of the expansion vessel.
Installation | 33 6.5 Low Loss Header (LLH) utilization A Low Loss Header is primarily used on systems that require higher flow rate (gpm) requirements that exceed the flow rate (gpm) of the low mass heat exchanger. Typically systems that require additional zone pumps that are external to the appliance or exceed the single zone limitation of 4.5 gpm would require the low loss header. A Low Loss Header is used to achieve hydraulic separation between the appliance and system piping.
| Installation 6.6 Locating the appliance NOTICE: Residue, metal shavings, and contaminants in the piping can damage the appliance. ▶ Flush the piping thoroughly and completely to remove all residue. ▶ Follow the instructions with respect to water quality ( Chapter 6.1, page 30). ▶ Remove packaging, observing all notes and symbols. ▶ On the rating plate, check the identification of the target country and suitability for the gas type supplied by the local gas utility company ( page 8).
Installation | 35 6.7 Installing a low water cut off (LWCO) The boiler is equipped with several sensors that prevent firing or running the boiler in case of low water pressure or low water levels. Nevertheless code may require the installation of a separate low water cut off (LWCO) device. The boiler is equipped with a dedicated port for installation of a LWCO device on the supply pipe on the back of the boiler cabinet. This location represents the minimum water level for safe operation of the boiler.
| Installation 6.8 Connecting flue gas accessories 2 Optional vent systems are: • Twin pipe PVC / CPVC 2" / 3" • Twin pipe PP 2” (50mm) / 3" (80 mm) (M&G Duravent PolyPro and Centrotherm InnoFlue) • Concentric PP 3" / 5" (80/125 mm) (Bosch) 1 4 3 Using the twin pipe adaptor: The twin pipe adaptor is supplied with the boiler kit as standard and is certified as a part of the vent system.
Installation | 37 NOTICE: Vent connectors ▶ Vent connectors serving appliances vented by natural draft shall not be connected to any portion of mechanical draft systems operating under positive pressure. 2 NOTICE: Burner damage! ▶ Avoid drawing in combustion air excessively loaded with dust or airborne particles.
| Installation Vent termination must be at least 1 foot (305 mm) above grade, anticipated snow line or roof surface (Canada 1-1/2 feet (457 mm) minimum) ( fig. 31 [YA], page 40). All PVC/CPVC vent pipes must be glued, except for the flue gas adapterpipe connection. The exhaust pipe must be properly supported and pitched a minimum of ¼ inch (6.35 mm) per foot back to the boiler. This allows the condensate to properly drain.
Installation | 39 Roof terminals Ø 3" / Ø 5" (Ø 76/125mm) Ø 3" / Ø 5" (Ø 76/125mm) Ø 3" / Ø 5" (Ø 80/125mm) Material concentric PVC concentric CPVC concentric PP Ø 3" (Ø 80mm) PolyPro Flex Chimney Cap (PP) with base support PolyPro Support elbow Base Support + SW to Flex Coupler PolyPro Flex Chimney Cap (PP) Ø 2" (Ø 50mm) with base support PolyPro Support elbow Base Support + SW to Flex Coupler Supplier IPEX System 636 IPEX System 636 M&G Duravent PolyPro and Centrotherm InnoFlue.
| Installation NOTICE: ▶ Vent terminations must keep the following minimum clearances from electric meters, gas meters, regulators and relief equipment: 4 feet (1220 mm) [Canada 1830 mm] horizontally and in no case above and below, unless a horizontal distance of 4 feet (1220 mm) [Canada 1830 mm] is maintained. NOTICE: ▶ For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.
Installation | 41 Approved examples of horizontal and vertical venting installation NOTICE: ▶ Place pipe supports every 5 feet (1525 mm) of horizontal and vertical run, beginning with support near boiler. ▶ 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 Y 1 2 6 720 810 590-23.1W Fig. 36 Vertical venting system (sealed combustion) X X Y Y 1 2 1 2 6 720 810 590-25.1Wo 6 720 810 590-24.1Wo Fig. 37 Vertical venting system (room air only) Fig. 38 Vertical venting system (sealed combustion) Key to Fig. 36, Fig. 37 and Fig.
Installation | 43 X X Y X 5/8" per foot (52 mm per metre) Y 1 6 720 810 590-27.1Wo Fig. 41 Horizontal venting system (telescopic concentric vent kit) 6.8.3 With Flex pipe the maximum length is reduced by 50% Flex pipe according to the suppliers instructions for use in the vertical part of the installation only. 2 6 720 810 590-26.1Wo Fig.
| Installation Installations Fig. 35 Stainless steel wall termination 2" PIPE Maximum effective vent pipe length allowed for Ø 2" pipe KBR16-3 KBR35-3 KBR21-3 KWB35-3 Number of 90° KBR28-3 KBR42-3 elbows used KWB28-3 KWB42-3 1 76 ft (23.1 m) 60 ft (18.3 m) 2 71 ft (21.6 m) 52 ft (15.9 m) 3 66 ft (20.1 m) 43 ft (13.1 m) 4 61 ft (18.6 m) 35 ft (10.7 m) 5 56 ft (17.1 m) 27 ft (8.2 m) 6 51 ft (15.6 m) 18 ft (5.
Making the electrical connections | 45 7 Making the electrical connections 7.1 General notes 7.2 Electrical connections in the junction boxes 7.2.1 Access to junction boxes All the electrical connections are available via the two installer junction boxes, either high voltage (120 VAC) and low voltage (<24V DC).
| Making the electrical connections 7.2.3 Connecting an external heating zone pump or DHW recirculation pump Without accessories the appliance offers the connection of one heating zone pump, one circulator of an unmixed heating circuit, or one DHW recirculation pump. The pump used must have the following connection values: 120 VAC, max. 2 A. 7.2.4 DHW tank loading pump or 3-way valve with spring return (only heating boiler KBR..
Making the electrical connections | 47 7.2.5 Connecting mains power supply ▶ Route the power cable (AC 120 V, 60 Hz) from the emergency shutoff switch to the boiler. ▶ Insert cable into the junction box as shown in Fig. 49. ▶ Connect cable to the white plug according to Fig. 48. 7.2.6 Low voltage (LV) junction box The low voltage installer junction box provides connections to sensors, thermostat and programmers. Bosch room controls Connect only Bosch room controls to the internal BUS of this boiler.
| Making the electrical connections 7.3 DHW tank temperature sensor connection Before connecting the DHW tank temperature sensor to the Low voltage (LV) connections. ▶ Remove the pre fitted connector [1] from DHW tank temperature sensor lead [2]. ▶ The DHW tank temperature sensor lead can now be wired to the Low voltage (LV) connection “DHW Sen” position 5. 2 1 2 6720811590-80.1Wo Fig. 52 DHW tank sensor connector plug removal 7.
Commissioning | 49 Commissioning 1 2 3 12 4 11 5 6 7 8 9 6720810590-14.1Wo 8 10 Fig. 54 Overview of the controls 8.1 Emissions test button Service button Burner operation indicator lamp ON/OFF power switch Key pad lock ECO button Reset button Display System water pressure gauge DHW temperature control Blank panel for optional programmer Heating temperature control Before operating the appliance NOTICE: Commissioning without being properly filled and purged will damage the appliance.
| Commissioning When the appliance is switched ON for the first time, it performs a once-only purging sequence. This involves the heating zone pump switching on and off at intervals (for approx. 4 minutes). The display shows in alternation with the supply temperature. 8.
Commissioning | 51 8.5 FW 200 outdoor reset heating control quick start (optional accessory) ▶ Press the dial . P1 will be highlighted. ▶ Press the dial . The display will fl ash. ▶ Turn the dial one click clockwise to 12:00PM. ▶ Press the dial to confirm the setting. ▶ Turn the dial until Comfort appears. The area around the display should fill in. ▶ Press the dial to confirm the setting. menu ▶ Press menu button to return to main display.
| Commissioning ▶ Press . All settings have now been reset to their factory settings with the exception of the date and time, which remain unchanged. AT / °C 20 10 0 - 10 - 20 90 3 80 158 70 140 60 122 50 104 40 86 30 4 68 20 2 50 10 VL / °F 176 VL / °C 1 194 68 50 32 14 -4 8.6 After commissioning ▶ Check flue path for tightness. ▶ Check gas supply dynamic pressure ( page 64). ▶ Check that condensate is being discharged from the condensate hose.
Commissioning | 53 may drop. DHW tank priority guarantees highest DHW comfort. • Alternating operation The appliance switches between space heating mode and DHW mode. This prevents the room from cooling off too much. Alternating operation guarantees an even room temperature with somewhat less DHW convenience. ▶ Make a note of the setting of the boiler high limit dial ▶ Turn the boiler high limit dial counterclockwise to eco 4 3 5 2 KWB..
| KBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection reset eco 3 4 4 3 2 5 1 e 2 6 1 6 max max min 6 720 615 065-17.1O Fig. 64 Key pad lock Unlocking the key pad: ▶ Press the key pad lock button until the display shows only the supply temperature. 9 KBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection Thermal disinfection covers the DHW system including the taps. For solar DHW tanks, the solar portion of the tank is not covered.
Boiler circulator | 55 10 Boiler circulator 10.1 Pump anti-seize protection 25 20 The appliance will briefly run the pump at least every 24 hours after its last activation. 10.2 H / ft This function prevents the heating zone pump from seizing up following longer idle periods. 4 15 10 3 5 Changing the pump curve of the boiler pump 2 1 The speed of the boiler pump can be changed using the dial on the pump. 0 0 1 2 25 3 4 5 6 .
| Heatronic boiler control settings 11 Heatronic boiler control settings 11.1 Guideline to service functions ▶ Press and hold the service button until it illuminates. The display shows a code such as 1.A (first service level). Press the ECO button and key pad lock button simultaneously until the code 8.A appears (second service level). ▶ On the second service level, select the service function 8.E and value 00. The appliance restarts with the default settings.
Heatronic boiler control settings | 57 11.2.2 Second service level (at first service level, service button lights up, press ECO button and key pad lock button simultaneously until 8.A appears) ▶ Exit the service functions. The display returns to the supply temperature. Service function Display 8.A Software version 8.b Code plug number 8.C GFA Gas burner control status 8.d GFA Gas burner control fault 8.E Restore boiler to factory settings 8.F Permanent ignition 9.A Constant mode 9.b Current fan speed 9.
| Heatronic boiler control settings Service function 0.E is set to 00 (metric units): • The maximum supply temperature can be adjusted between 35 and 88 (35 - 88 °C). Service function 0.E is set to 01 (US customary units): • The maximum supply temperature can be adjusted between 96 and 190 (96 - 190 °F). Default setting is 190 (190 °F (88 °C)). Service function 2.C: Purging function When the appliance is switched ON for the first time, it performs a once-only purging sequence.
Heatronic boiler control settings | 59 It specifies the time from completion of preheating or DHW demand until the next time the plate-type heat exchanger is heated up. This prevents the plate-type heat exchanger from overheating. The cycle time can be set from 20 to 60 minutes. Default setting is 20 (20 minutes). Service function 3.F: Constant DHW period (only combi boiler KWB..-3A) NOTICE: System damage or boiler malfunction! ▶ Never change the setting of this service function on heating boiler KBR..
| Heatronic boiler control settings If U0 appears on the display, the function was already set via the FW200 control. Service function 7.E: Building drying function This service function allows you to start and stop the building drying function. Service function 6.A: Display the latest fault code Use this service function to display the most recent fault code. Never confuse the appliance building drying function with the slab drying function of the outdoor reset control FW200. Service function 6.
Heatronic boiler control settings | 61 Service function 8.b: Code plug number The last four digits of the code plug number are shown. The code plug determines the appliance functions. The code plug must be changed if the appliance has been converted from natural gas to LPG (or vice versa). Service function 8.C: GFA Gas burner control unit status Internal parameter. If you are on the line with Bosch Technical Support you may be asked for this number. Service function 8.
| Gas type conversion ▶ Affix the provided LP gas label from the gas conversion kit onto the original NG gas type label. It is important to cover the original gas type information located at the bottom of the original gas type label. Gas type conversion DANGER: Personal injury and property damage ▶ This conversion shall only be performed by a trained and certified installer in accordance with the manufacturer‘s instructions and all applicable codes and requirements of the authority having jurisdiction.
Gas type conversion | 63 12.3 ▶ ▶ ▶ ▶ Setting the gas-air ratio (CO2 or O2) Switch the appliance OFF using the ON/OFF switch. Remove the cover ( page 34). Switch the appliance ON using the ON/OFF switch. Unscrew a plug, indicated in the figure below, to open one of the flue gas test ports. 6 7 2 0 6 1 2 6 5 9 -3 8 .1 R Fig. 73 Set CO2 or O2 level for maximum nominal output Gas type NG LPG (propane) Maximum nominal output CO2 O2 9.4 % 4.0 % 11.0 % 4.2 % Minimum nominal output CO2 O2 8.6 % 5.5 % 10.
| Flue gas test 12.4 Dynamic gas pressure test ▶ Switch the appliance OFF and close the gas shut-off valve. ▶ Loosen the screw in the test port for gas inlet pressure ( Fig. 74, [1]) and connect a pressure gauge ( Fig. 75). 13 Flue gas test 13.1 Emissions test button The following appliance outputs can be selected by pressing the emissions test button until it lights up: reset eco 3 2 1 6 720 614 090-34.2O Fig.
Environmental responsibility/disposal | 65 14 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. To protect the environment, we use the best possible technology and materials taking into account economic points of view.
| Inspection and maintenance 1 3 2 6 720 641 933-92.1o Fig. 77 Filter in fresh water pipe (combi boiler KWB.-3A only) 15.1.3 Plate type heat exchanger (only combi boiler KWB..-3A) If the DHW output on the combi boiler is significantly reduced: ▶ Check filter in the cold water pipe for contamination ( Fig. 65). ▶ Depressurize the appliance. ▶ Remove the plate type heat exchanger and replace with a new unit. -or▶ Descale with descaling agent approved for stainless steel (Grade 316-1.4401).
Inspection and maintenance | 67 2. 2-1/4 + 3/4 ft.-lbf. (3 + 1 Nm) 1. 1. 6 720 641 933-28.1O Fig. 83 Reinstalling the electrode set 3. 6720810590-43.1Wo Fig. 81 Removing the hydraulic assembly ▶ Remove the plate type heat exchanger. Gas/Gaz? 6 720 613 354-02.2O Fig. 84 Check for gas leaks 15.1.5 Burner servicing 6 720 641 933-50.2O DANGER: Fire danger! ▶ Only operate the burner while installed in a boiler. Fig.
| Inspection and maintenance ▶ Remove the condensate trap (steps 1 and 2) and place a suitable container underneath. ▶ Remove the burner and clean the components. 1 2 7 181 465 330-08.2R Fig. 86 Burner ▶ Reinstall the burner in reverse order, including a new gasket. ▶ Adjust the gas-air ratio ( page 63). 6 720 641 933-93.1o 15.1.6 Heat exchanger block inspection and cleaning NOTICE: Damage to the coating of the heat exchanger.
Inspection and maintenance | 69 ▶ Clean the heat exchanger block with the brush from top to bottom. ▶ Clean the condensate tray (with reversed brush). 6 720 612 563-14.1O Fig. 89 Cleaning the heat exchanger with the cleaning brush ▶ Remove burner ( Chapter 15.1.5 “Burner servicing”). ▶ Rinse the heat exchanger with water from the top. 6 720 610 332-75.2R Fig. 91 Cleaning the condensate tray ▶ Rinse the heat exchanger with water from the top. ▶ Clean the condensate trap connection.
| Inspection and maintenance ▶ Fill the condensate trap with approximately 1 cup (1/4 litre) of water and reinstall it. 15.1.8 Checking the mixer diaphragm ▶ Open the mixer unit. ▶ Carefully remove the diaphragm from the fan air intake and check for contamination and cracks. ▶ If the indicator is below 14.5 psi (1 bar) when the system is cold, top up the water. The indicator must be between 14.5 psi (1 bar) and 21.75 psi (1.5 bar).
Inspection and maintenance | 71 15.2 Checklist for annual inspection and maintenance ▶ Use this form to guide you through the service and maintenance procedure. Fill out each step according to the findings and work performed. Date 1 Latest fault code from service function 6.A ( page 65). 2 Fresh water inlet filter (Combi boiler KWB appliances only) ( page 65). 3 Visual inspection of the combustion air pipes and vent pipes. 4 Dynamic gas pressure ( page 64). inches W.C.
| Readings on the display 16 Readings on the display The boiler display can provide the following information (Tab. 27 and 28): Value displayed Number or letter, dot followed by letter Letter followed by number or letter Three numbers (≤ 199) One number (displayed for longer) followed by two numbers (displayed briefly) Two dashes followed by two pairs of numbers Two letters followed by two pairs of numbers Table 27 Display readings Description Service function ( Tab.
Faults | 73 17 Faults 17.1 Troubleshooting DANGER: Explosion! ▶ Close the gas cock prior to working on the gas train. ▶ Check for gas leaks after carrying out work on the gas train. DANGER: Risk of flue gas poisoning. ▶ Check for leaks after carrying out work on the venting system. DANGER: Risk of electric shock! ▶ Always disconnect the appliance from the mains power before performing any work. Disconnect the emergency shutoff switch or disengage the heating system circuit breaker.
| Faults 17.2 Display A7 A8 Ad Faults that are shown on the display Description DHW temperature sensor defective. Elimination ▶ Check temperature sensor and leads for interruptions or shorts, and replace if defective. ▶ Insert code plug correctly; replace if defective. Communication fault. ▶ Check BUS communications wiring, replace if defective. ▶ Check control, replace if defective. DHW tank temperature not detected. ▶ Check DHW tank temperature sensor and connecting lead, replace if defective.
Faults | 75 Display EA Description No flame detected. F0 GFA: Safety time expired. Internal fault F1 F7 Internal data error. Flame detected even when burner is off. FA After switching gas off: Flame is detected. Fd Reset button pressed by mistake. Temperature gradient limiter: Temperature rise too fast Elimination ▶ Check that ground lead is properly connected, replace if defective. ▶ Check that gas cock is open. ▶ Check inlet gas pressure; correct if needed. ▶ Check power supply.
| Faults 17.3 Faults that are not shown on the display Appliance faults Combustion noise too loud; rumbling noises Flow noises Heating-up takes too long Flue gas readings incorrect; CO levels too high Violent ignition, poor ignition DHW has unpleasant odor or has a dark color Set supply temperature (e.g. of the FW200 control) exceeded Condensate in air box DHW temperature is not reached (combi boiler KWB..-3A only) Heatronic is flashing (i.e.
Faults | 77 17.4 Check sensor values 17.4.3 Supply temperature sensor, External supply temperature sensor, DHW tank temperature sensor, DHW temperature sensor 17.4.1 Outdoor temperature sensor Temperature °F ( °C ) Testing tolerance ± 10% – 4 ( – 20) 3 ( – 16) 10 ( – 12) 17 ( – 8) 24 ( – 4) 32 (0) 39 (4) 46 (8) 50 (10) 59 (15) 68 (20) 77 (25) Resistance [ Ω ] 2,392 2,088 1,811 1,562 1,342 1,149 984 842 781 642 528 436 Table 31 Resistance table outdoor temperature sensor 17.4.
| Commissioning log for the appliance 18 Commissioning log for the appliance Home owner/operator: Last name, first name Telephone/fax System installer: Number, Street ZIP code, town Order number: Appliance type: (Complete a separate log for every appliance!) FD (Date of manufacture): Date commissioned: Individual appliance Installation Basement | Attic | Garage | other: location: Room air only: Number and size of ventilation openings Vent pipe routing: Twin pipe system | Concentric pip
Commissioning log for the appliance | 79 Modified service functions: (Select the modified service functions and enter the values here.) Example: Service function 7.d changed from 00 to 01 Heating control: FW 200 FB 100 × ...... Qty, coding heating zone(s): ISM 2 IPM 2 × ......
| Spare parts 19 Spare parts KWB42-3 KWB35-3 KWB28-3 KBR42-3 KBR35-3 KWB28-3 KBR21-3 Designation KBR16-3 ▶ Order spare parts by name and part number using the spare parts list. Spare parts list Group 1 - Sheet metal page 82 Group 2 - Burner/Heat exchanger page 84 Group 3 - Gas valve page 86 Group 4 - Pipes combi boiler KWB..3A Group 5 - Pipes heating boiler KBR..
Spare parts | 81 6720810590-73.1Wo Fig.
KWB42-3 KWB35-3 KWB28-3 KBR42-3 KBR35-3 KBR28-3 KBR21-3 KBR16-3 82 | Spare parts Item ( Fig.
Spare parts | 83 19 20 21 17 31 33 33 24 15 14 13 12 16 9 16 1 19 4 5 8 11 7 6 3 9 36 10 4 23 3 2 6720810590-74.3Wo Fig.
Designation 1 Heat exchanger block 1 Heat exchanger block (incl. set of gaskets) 2 Nut 3 Set of washers 4 Flue gas collector 5 Temperature limit sensor 6 Sensor NTC - Control stat 7 KWB42-3A Item ( Fig.
Spare parts | 85 6720810590-75.1Wo Fig.
KWB42-3 KWB35-3 KWB28-3 KBR42-3 KBR35-3 KBR28-3 KBR21-3 KBR16-3 86 | Spare parts Item ( Fig.
Spare parts | 87 11 12 28 21 11 9 29 32 24 37 25 7 12 34 10 33 33 26 8 22 2 23 27 34 11 35 7 19 20 42 13 5 41 1 11 10 18 11 31 30 15 15 38 17 14 31 Item 39 (Flow sensor) not shown 36 27 7 6720810590-76.2Wo 38 Fig. 97 Group 4 - Pipes combi boiler KWB..
KWB42-3 KWB35-3 KWB28-3 KBR42-3 KBR35-3 KBR28-3 KBR21-3 KBR16-3 88 | Spare parts Item ( Fig. 97) Designation 1 Siphon Order number 8 710 506 271 0 2 Siphon cap 8 710 506 273 0 5 Pipe expansion vessel 8 716 117 514 7 Washer 16.6 x 13.5 x 1.5 (10x) 8 710 103 045 0 8 O-ring 12.5 x 3 WRAS/KTW (1x) 8 716 106 748 0 9 Pipe flow 8 716 117 515 10 Washer 18.5 x 24.
Spare parts | 89 28 38 25 29 14 33 29 9 34 9 9 8 19 22 23 40 13 1 9 12 15 24 31 18 9 11 10 2 31 32 7 36 41 30 5 Item 37 (Flow sensor) not shown 6 6720810590-77.2Wo Fig. 98 Group 5 Pipes heating boiler KBR..
KWB42-3 KWB35-3 KWB28-3 KBR42-3 KBR35-3 KBR28-3 KBR21-3 KBR16-3 90 | Spare parts Item ( Fig. 98) Designation 1 Siphon Order number 8 710 506 271 0 2 Cover 8 710 506 273 0 5 Pressure gauge USA 8 716 117 503 6 Retaining spring 10mm (10x) 8 716 771 167 0 7 O-ring 2.62 x 6.
Spare parts | 91 6720810590-78.1Wo Fig.
1 2 3 4 6 7 8 9 10 11 12 16 17 20 21 22 23 24 25 35 36 37 – – – – – – – – KWB42-3A KWB35-3A KWB28-3A KBR42-3A KBR35-3A KBR28-3A Designation Control unit HTS Bosch USA Rotary selector Cover Cover Set of connectors Printed Circuit Board Screw Backpanel Code plug 2500 NG (23) Code plug 2501 NG (23) Code plug 2502 NG (23) Code plug 2503 NG (23) Code plug 2504 NG (23) Code plug 2505 LPG
Spare parts | 93 6720810590-79.1Wo Fig. 100 Group 7 Hydraulic block combi boiler KWB..
KWB42-3 KWB35-3 KWB28-3 KBR42-3 KBR35-3 KBR28-3 KBR21-3 KBR16-3 94 | Spare parts Item ( Fig. 100) Designation 1 Flat plate heat exchanger 18 plates 8 716 108 212 0 2 Seal 15mm 8 716 106 435 0 3 Supply manifold complete 8 716 106 356 0 5 Rubber bushing 8 716 106 425 0 6 Washer 18.5 x 24.3 (10x) 8 716 771 259 0 7 Sensor NTC 8 716 117 532 8 O-ring 7.75 x 2.
Index | 95 Index A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Anti-freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Appliance details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Accessories 6 Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
| Index K Key pad lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 L Liquified propane gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Low water cut off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 LPG 31, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 M Mains fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index | 97 Pump lockout time (only KBR..-3A) (service function 2.A) . . . . . . . . . . . . . . . . . . . . . 57 Pump mode (only KBR..-3A) (service function 1.F) . . . . . . . . . . . . . . . . . . . . . 57 Pump post purge time (heating) (service function 9.F) . . . . . . . . . . . . . . . . . . . . . 61 Reset service reminder (service function 5.A) . . . . . . . . . . . . . . . . . . . . . 59 Restore appliance (Heatronic 3) to factory settings (service function 8.E) . . . . . . . . . . . . . . . . . . . .
| Notes 6 720 810 590 (2015/05) Greenstar FS
| 99 Notes Greenstar FS 6 720 810 590 (2015/05)
United States and Canada Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH03053 Tel. 603-552-1100 Fax 603-965-7581 www.bosch-climate.us U.S.A. Products manufactured by: Worcester, Bosch Group, Cotswold Way, Worcester WR4 9SW www.worcester-bosch.co.uk Bosch Thermotechnology Corp.
