Install Instructions

2 | Table of Contents
Greenstar FS
6 720 810 590 (2015/05)
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 . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 KWB - Residential combi boiler for space heating and DHW
generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Information about the appliance . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Overview of boiler types . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Product dimensions and minimum clearances . . . . . . . . 7
3.7 Appliance layout heating boiler KBR..-3A . . . . . . . . . . . . 8
3.8 Appliance layout combi boiler KWB..-3A . . . . . . . . . . . 10
3.9 Electrical wiring heating boiler KBR..-3A . . . . . . . . . . . 12
3.10 Electrical wiring combi boiler KWB..-3A . . . . . . . . . . . . 14
3.11 Technical data heating boiler KBR 16-3 . . . . . . . . . . . . 16
3.12 Technical data heating boiler KBR 21 -3 . . . . . . . . . . . . 17
3.13 Technical data heating boiler KBR 28-3 . . . . . . . . . . . . 18
3.14 Technical data heating boiler KBR 35-3 . . . . . . . . . . . . 19
3.15 Technical data heating boiler KBR 42-3 . . . . . . . . . . . . 20
3.16 Technical data combi boiler KWB 28-3 . . . . . . . . . . . . . 21
3.17 Technical data combi boiler KWB 35 - 3 . . . . . . . . . . . . 22
3.18 Technical data combi boiler KWB 42 - 3 . . . . . . . . . . . . 23
3.19 Condensate composition . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Compliance with standards and regulations . . . . . . . . . 24
4.2 Operating limits of the boiler . . . . . . . . . . . . . . . . . . . . . 24
4.3 Additional regulations for installation in Massachusetts . .
25
5 Common Applications of KBR boilers . . . . . . . . . . . . . . . . . . . 26
5.1 Multiple zones using zone valves with DHW . . . . . . . . . 26
5.1.1 To utilize the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.2 Wiring - Multi zone with zone valves and LWCO . . . . . . 27
5.2 Multiple zones using circulators with DHW . . . . . . . . . . 28
5.2.1 To utilize the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.2 Wirin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1 Installation and operation . . . . . . . . . . . . . . . . . . . . . . . 30
6.1.1 Notes on installation and operation . . . . . . . . . . . . . . . . 30
6.1.2 Other important information . . . . . . . . . . . . . . . . . . . . . 31
6.2 Comparing the size of the integrated expansion vessel
(KWB-3A boiler only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3 KBR..-3A appliances (heating boilers): Selecting an
expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.4 Selecting the installation location . . . . . . . . . . . . . . . . . 32
6.5 Low Loss Header (LLH) utilization . . . . . . . . . . . . . . . . 32
6.5.1 To utilize the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.6 Locating the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.6.1 Positioning the appliance . . . . . . . . . . . . . . . . . . . . . . . 33
6.7 Installing a low water cut off (LWCO) . . . . . . . . . . . . . . 34
6.8 Connecting flue gas accessories . . . . . . . . . . . . . . . . . . 35
6.8.1 Installation of the exhaust and air intake system . . . . . 36
6.8.2 Approved examples of horizontal and vertical venting
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.8.3 Vent and combustion air pipe lengths . . . . . . . . . . . . . . 42
6.9 Testing gas and water connections for leaks . . . . . . . . 43
7 Making the electrical connections . . . . . . . . . . . . . . . . . . . . . 44
7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Electrical connections in the junction boxes . . . . . . . . 44
7.2.1 Access to junction boxes . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2.2 High voltage junction box . . . . . . . . . . . . . . . . . . . . . . . 44
7.2.3 Connecting an external heating zone pump or DHW
recirculation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2.4 DHW tank loading pump or 3-way valve with spring return
(only heating boiler KBR..-3A) . . . . . . . . . . . . . . . . . . . 45
7.2.5 Connecting mains power supply . . . . . . . . . . . . . . . . . . 45
7.2.6 Low voltage junction box . . . . . . . . . . . . . . . . . . . . . . . . 46
7.3 DHW tank temperature sensor connection . . . . . . . . . 46
7.4 Connecting the LWCO device . . . . . . . . . . . . . . . . . . . . 46
8 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.1 Before operating the appliance . . . . . . . . . . . . . . . . . . . 47
8.2 Switching the appliance ON/OFF . . . . . . . . . . . . . . . . . 47
8.3 Setting up space heating . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4 Programming the FW 200 heating control unit (optional
accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5 FW 200 outdoor reset heating control quick start (optional
accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5.1 Setting date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5.2 Setting constant heating (no night set back) . . . . . . . . 49
8.5.3 Setting type of heating system . . . . . . . . . . . . . . . . . . . 49
8.5.4 Adjusting warm weather shut down (WWSD) . . . . . . . 50
8.5.5 Resetting all settings (for installers only) . . . . . . . . . . . 50
8.6 After commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.7 KBR..-3A appliances (heating boilers) with DHW tank:
Setting the DHW temperature . . . . . . . . . . . . . . . . . . . 50
8.8 KWB..-3A appliances (combi boilers):
Setting the DHW temperature . . . . . . . . . . . . . . . . . . . 51
8.9 Setting manual summer mode . . . . . . . . . . . . . . . . . . . . 51
8.10 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.11 Activating the key pad lock . . . . . . . . . . . . . . . . . . . . . . 51
9 KBR..-3A appliances (heating boiler) with DHW tank: Thermal
disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52