Install Instructions
Table Of Contents
- Table of Contents
- 1 Key to symbols and safety instructions
- 1.1 Key to symbols
- 1.2 General safety instructions
- 2 Scope of delivery
- 3 Information about the appliance
- 3.1 Proper use
- 3.2 Overview of boiler types
- 3.3 Rating plate
- 3.4 Appliance description
- 3.5 Accessories
- 3.6 Product dimensions and minimum clearances
- 3.7 Appliance layout heating boiler KBR..-3A
- 3.8 Appliance layout combi boiler KWB..-3A
- 3.9 Electrical wiring heating boiler KBR..-3A
- 3.10 Electrical wiring combi boiler KWB..-3A
- 3.11 Technical data heating boiler KBR 16-3
- 3.12 Technical data heating boiler KBR 21 -3
- 3.13 Technical data heating boiler KBR 28-3
- 3.14 Technical data heating boiler KBR 35-3
- 3.15 Technical data heating boiler KBR 42-3
- 3.16 Technical data combi boiler KWB 28-3
- 3.17 Technical data combi boiler KWB 35 - 3
- 3.18 Technical data combi boiler KWB 42 - 3
- 3.19 Condensate composition
- 4 Regulations
- 5 Common Applications of KBR boilers
- 6 Installation
- 6.1 Installation and operation
- 6.1.1 Notes on installation and operation
- Fill and make-up water for the heating system
- Recommended steps for commissioning a new or retrofit boiler installation
- Recirculation pump/DHW recirculation lines
- Open vented heating systems
- Gravity heating systems
- Galvanized radiators or pipes.
- Plastic pipe work
- Use of a room temperature control
- Primary-secondary piping or a Low Loss Header (LLH)
- Water Chemistry Guidelines
- Corrosion inhibitors
- Boiler sealer
- LPG
- 6.1.2 Other important information
- 6.1.1 Notes on installation and operation
- 6.2 Comparing the size of the integrated expansion vessel (KWB-3A boiler only)
- 6.3 KBR..-3A appliances (heating boilers): Selecting an expansion vessel
- 6.4 Selecting the installation location
- 6.5 Low Loss Header (LLH) utilization
- 6.6 Locating the appliance
- 6.7 Installing a low water cut off (LWCO)
- 6.8 Connecting flue gas accessories
- 6.9 Testing gas and water connections for leaks
- 6.1 Installation and operation
- 7 Making the electrical connections
- 8 Commissioning
- 8.1 Before operating the appliance
- 8.2 Switching the appliance ON/OFF
- 8.3 Setting up space heating
- 8.4 Programming the FW 200 heating control unit (optional accessory)
- 8.5 FW 200 outdoor reset heating control quick start (optional accessory)
- 8.6 After commissioning
- 8.7 KBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature
- 8.8 KWB..-3A appliances (combi boilers): Setting the DHW temperature
- 8.9 Setting manual summer mode
- 8.10 Setting frost protection
- 8.11 Activating the key pad lock
- 9 KBR..-3A appliances (heating boiler) with DHW tank: Thermal disinfection
- 10 Boiler circulator
- 11 Heatronic boiler control settings
- 11.1 Guideline to service functions
- 11.2 Overview of the service functions
- 11.3 Description of the service functions
- 11.3.1 First service level
- Service function 1.A: Maximum space heating output
- Service function 1.b: Maximum DHW output
- Service function 1.E: Pump mode for space heating operation
- Service function 1. F: Pump mode (only heating boiler KBR..-3A)
- Service function 2.A: Heating circuit pump lockout time (only heating boiler KBR..-3A)
- Service function 2.b: Maximum supply temperature
- Service function 2.C: Purging function
- Service function 2.d: Thermal disinfection (legionella protection)
- Service function 2.F: Operating mode
- Service function 3.A: Automatic anti-cycle function
- Service function 3.b: Set anti-cycle time
- Service function 3.C: Switching differential
- Service function 3.d: Minimum output (heating and DHW)
- Service function 3.E: Cycle time, keeping DHW hot (only combi boiler KWB..-3A)
- Service function 3.F: Constant DHW period (only combi boiler KWB..-3A)
- Service function 4.b: Maximum heat exchanger temperature (only combi boiler KWB..-3A)
- Service function 4.d: Audible fault warning tone
- Service function 4.E: Appliance type
- Service function 4.F: Condensate trap filling sequence
- Service function 5.A: Reset inspection interval
- Service function 5.b: Fan post purge time
- Service function 5.E: Functionality of black plug in boiler junction box
- Service function 5.F: Set inspection interval
- Service function 6.A: Display the latest fault code
- Service function 6.b: Room temperature control, current voltage, terminal 2
- Service function 6.C: Supply temperature required by weather compensation control
- Service function 6.d: Current DHW turbine flow rate (only combi boiler KWB..-3A)
- Service function 7.A: Indicator lamp for burner operation / faults
- Service function 7.b: 3-way valve in center position
- Service function 7.d: Connecting an external supply or low-loss header temperature sensor
- Service function 7.E: Building drying function
- Service function 0.A: Do not use this setting!
- Service function 0.d: Altitude adjustment
- Service function 0.E: Metric or US customary units
- 11.3.2 Second service level
- Service function 8.A: Software version
- Service function 8.b: Code plug number
- Service function 8.C: GFA Gas burner control unit status
- Service function 8.d: GFA Gas burner control unit fault
- Service function 8.E: Restore boiler to factory settings
- Service function 8.F: Permanent ignition
- Service function 9.A: Constant mode
- Service function 9.b: Current fan speed
- Service function 9.C: Current boiler output
- Service function 9.d: Set fan start speed
- Service function 9.E: Turbine signal delay (only combi boiler KWB..-3A)
- Service function 9.F: Heating zone pump post purge
- Service function A.b: Display DHW temperature
- Service function A.C: Display DHW tank temperature
- Service function b.F: Solar DHW backup heating delay (only combi boiler KWB..-3A)
- Service function C.d: Display current heat demand
- 11.3.1 First service level
- 12 Gas type conversion
- 13 Flue gas test
- 14 Environmental responsibility/disposal
- 15 Inspection and maintenance
- Heat exchanger
- Heatronic boiler control
- Notes on installation and operation
- After the inspection/maintenance
- 15.1 Description of various steps
- 15.1.1 Calling up the latest fault (service function 6.A)
- 15.1.2 Fresh water filter (only combi boiler KWB..-3A)
- 15.1.3 Plate type heat exchanger (only combi boiler KWB..-3A)
- 15.1.4 Checking the electrodes
- 15.1.5 Burner servicing
- 15.1.6 Heat exchanger block inspection and cleaning
- 15.1.7 Condensate trap cleaning
- 15.1.8 Checking the mixer diaphragm
- 15.1.9 Expansion vessel
- 15.1.10 Setting the boiler water pressure
- 15.1.11 Testing system water quality
- 15.1.12 Inspecting electrical wiring
- 15.2 Checklist for annual inspection and maintenance
- 16 Readings on the display
- 17 Faults
- 18 Commissioning log for the appliance
- 19 Spare parts
- Index
Regulations | 25
6 720 810 590 (2015/05)
Greenstar FS
4.3 Additional regulations for installation in Massachusetts
(a) For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for
residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination is less
than seven (7) feet [2150 mm] above finished grade in the area of the
venting, including but not limited to decks and porches, the following
requirements shall be satisfied:
• INSTALLATION OF CARBON MONOXIDE DETECTORS.
At the time of installation of the side wall horizontal vented gas fueled
equipment, the installing plumber or gas fitter shall observe that a
hard wired carbon monoxide detector with an alarm and battery
back-up is installed on the floor level where the gas equipment is to
be installed. In addition, the installing plumber or gas fitter shall
observe that a battery operated or hard wired carbon monoxide
detector with an alarm is installed on each additional level of the
dwelling, building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility of the
property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon monoxide
detectors.
– In the event that the side wall horizontally vented gas fueled
equipment is installed in a crawl space or an attic, the hard wired
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 can not 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.
Each carbon monoxide detector as required in accordance with the
above provisions shall comply with NPA 720 and be ANSI/UL 2034
listed and IAS certified.
•SIGNAGE.
A metal or plastic identification plate shall be permanently mounted to
the exterior of the building at a minimum height of eight (8) feet above
grade directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or equipment. The
sign shall read, in print size no less than one-half (½) inch in size, “GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
• INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspections, the inspector observes carbon
monoxide detectors and signage installed in accordance with the
provisions of 248 CRM 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS:
The following equipment is exempt from 248 CRM 5.08(2)(a) 1 thru 4:
• The equipment listed in Chapter 10 entitled “Equipment Not
Required To Be Vented” in the most current edition of NFPA 54 as
adopted by the board; and
• Product Approved side wall horizontally vented gas fueled
equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential
purposes.
(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM REQUIRED.
When the manufacturer of Product Approved side wall horizontally
mounted gas equipment provides a venting system design or venting
system components with the equipment, the instructions provided by
the manufacturer for the installation of the equipment and venting shall
include:
• Detailed instructions for the installation of the venting system or the
venting system components; and
• A complete parts list for the venting system design or venting system.
(d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED.
When the manufacturer of Product Approved side wall horizontally
vented gas fueled equipment does not provide the parts for the venting
of flue gases, but identifies special venting systems, the following
requirements shall be satisfied by the manufacturer:
• The referenced special venting systems shall be included with the
appliance or equipment installation instructions; and
• The special venting systems shall be Product Approved by the Board,
and the instructions for that system shall include a parts list and
detailed installation instructions.
(e) A copy of all instructions for all Product Approved side wall
horizontally vented gas fueled equipment, all venting instructions, all
parts lists for venting instructions, and/or venting design instructions
shall remain with the appliance or equipment at the completion of the
installation.