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
38 | Installation
Greenstar FS
6 720 810 590 (2015/05)
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 [Y
A
], page 40).
Vent termination must be at least 7 feet (2135 mm) above a public
walkway ( fig. 31 [X
5
], page 40). Ensure that condensate spilling
from the termination does not create a hazard or a nuisance.
Vent termination must be 3 feet (915 mm) above any forced air intake
within 10 feet (3050 mm) ( fig. 31 [1], [Y
B
], page 40).
Do not extend exposed vent pipe outside the building beyond
recommended distance. Condensate could freeze and block vent pipe.
Vent should terminate at least 3 feet (915 mm) away from adjacent
walls, inside corners and 5 feet (1525 mm) below roof overhang
( fig. 31 [X
2
], [X
4
], page 40).
It is not recommended to terminate vent above any door or window,
condensate can freeze causing ice formations.
Do not use chimney as a raceway if another boiler or fireplace is vented
into or through chimney.
All PVC/CPVC vent pipes must be glued, except for the flue gas adapter-
pipe connection.
All PP/PVC/CPVC combustion air and vent pipe materials and fittings
must comply with the following and must be UL approved venting
material:
For installations in Canada, field supplied [plastic vent piping must comply with CAN/CGA B149.1 (latest edition) and be certified to the Standard for
Type BH Gas Venting systems. ULC S636 Components of this listed system shall not be interchanged with other vent systems or unlisted pipe/fittings.
All plastic components and specified primers and glues of certified vent systems must be from a single manufacturer and not intermingled with other
system manufacturer's vent system parts.
The supplied vent connector and separate available vent termination are certified as a part of the Greenstar Boiler
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.
NOTICE: Combustion air and vent pipe materials for
KBR42-3A & KWB42-3A.
Heat damage to 2 inch PVC pipes.
▶ KBR42-3A & KWB42-3A appliances combustion air
and vent pipes, use 2 inch CPVC-pipes or 3 inch
pipes.
Material Item United states Canada
KBR16-3
KBR21-3
KBR28-3
KBR35-3
KBR42-3
KWB28-3
KWB35-3
KWB42-3
PVC schedule 40, 80 2" (50 mm) Vent or air pipe and fitting ANSI/ASTM D1785
BH Gas venting systems,
ULC S636
1)
,
Class IIA - PVC,
Class IIB - CPVC,
Class IIC - Polypropylene
(certified to ULC S636)
1) Components of the certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings. Plastic components, and specified primers and glues of
the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts.
XXXX X X
PVC-DWV ANSI/ASTM D2665 XXXX X X
CPVC schedule 40, 80 ANSI/ASTM F441 XXXXXXXX
PVC schedule 40, 80 3" (76 mm) Vent or air pipe and fitting ANSI/ASTM D1785 XXXXXXXX
PVC-DWV ANSI/ASTM D2665 XXXXXXXX
CPVC schedule 40, 80 ANSI/ASTM F441 XXXXXXXX
PP rigid venting 2" (50 mm) vent or air pipe
M&G Duravent PolyPro and
Centrotherm InnoFlue
ANSI Cat IV XXXX X X
PP rigid venting 3" (80 mm) vent or air pipe
M&G Duravent PolyPro and
Centrotherm InnoFlue
ANSI Cat IV XXXXXXXX
PP rigid venting 3"/5" (80/125 mm) concentric
Bosch (manufactured by M&G
Duravent)
ANSI Cat IV XXXXXXXX
PP rigid venting ANSI Cat IV XXXXXXXX
PP Flex Same as 3” PP above ANSI Cat IV XXXXXXXX
PP Flex Same as 2” PP above ANSI Cat IV XXXXXXXX
PVC Pipe cement/primer ANSI/ASTM D2564 XXXXXXXX
CPVC ANSI/ASTM F493 XXXXXXXX
Table 8 Materials for pipe