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
52 | Commissioning
Greenstar FS
6 720 810 590 (2015/05)
Fig. 58
[1] Maximum Base Line Adjustment 186 °F (85 °C)
[2] Minimum Base Line Adjustment 50 °F (10 °C)
[3] Maximum Design Temperature Adjustment 186 °F (85 °C)
[4] Minimum Design Temperature Adjustment 86 °F (30 °C)
AT Outdoor temperature
VL Supply temperature
▶Turn the dial counter-clockwise until Maximum heating
supply temperature is highlighted.
▶Press the dial .
▶ Turn the dial to set the desired value.
▶ Press the dial to confirm the setting.
▶ Press menu button to return to main display.
8.5.4 Adjusting warm weather shut down (WWSD)
▶To open INSTALLER SETTINGS: press and hold the menu button
for approx. 5 seconds.
System configuration will be highlighted.
▶ Turn the dial one click counter-clockwise to highlight Heating
parameters.
▶Press the dial .
Heating circuit 1 will be highlighted.
▶Turn the dial counter-clockwise until Heating OFF at outdoor
temperature is highlighted.
▶ Press the dial and the display will fl ash.
The default value is 68 °F (20 °C) and is adjustable from 50 °F (10 °C)
to 77 °F (25 °C). Turning above 77 °F (25 °C) will move it to 210 °F
(99 °C), which disables WWSD.
▶ Press the dial to confirm the setting.
8.5.5 Resetting all settings (for installers only)
This function resets all settings on the MAIN MENU and the INSTALLER
SETTINGS to their factory settings. Following such a reset, you will
need to commission the system again!
If the default display is showing:
▶ Simultaneously press and hold the menu button and the delete
button until a count down display appears.
▶ Continue holding the menu button and the delete button
until the message appears that the reset is completed.
▶Press .
All settings have now been reset to their factory settings with the
exception of the date and time, which remain unchanged.
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. If that is not the case, switch the appliance first OFF and then
ON again using the ON/OFF switch. That activates the trap filling
sequence ( page 59). Repeat the procedure several times until
condensate starts running out.
▶ Complete commissioning report ( page 78).
8.7 KBR..-3A appliances (heating boilers) with DHW
tank: Setting the DHW temperature
▶ Set the DHW temperature on the DHW thermostat .
The set DHW temperature flashes on the display for 30 seconds.
Fig. 59 Set the DHW temperature (heating boiler KBR..-3A)
ECO button
The default setting is DHW priority; the ECO button is not lit.
In order to switch between DHW tank priority and alternating
operation, press the ECO button.
• DHW priority
First, the DHW tank is heated up to the set temperature. The
appliance then goes into heating mode. Therefore, it can happen that
space heating is interrupted for a while and the room temperature
6 720 806 992-07.1O
68 50 32 14 - 4
68
86
104
122
140
158
176
194
1
3
4
2
50
VL / °F
AT / °F
20 10 0 - 10 - 20
20
30
40
50
60
70
80
90
10
VL / °C
AT / °C
menu
menu
menu
menu
DHW thermostat Typical DHW temperatures
min approx. 59 °F (15 °C)
e approx. 131 °F (55 °C)
max approx. 158 °F (70 °C)
Table 17 Typical DHW temperatures for heating boiler KBR..-3A
WARNING: Danger of scalding!
▶ In normal operation, it is recommended to limit the
DHW temperature to 122 °F (50 °C) to limit the risk
of scalding.
▶ Install a tempering valve if running DHW
temperatures above 104 °F (40 °C).
▶ Only use temperatures up to 158 °F (70 °C) for
thermal disinfection ( page 54).
If there is reason for concern for contamination from
bacteria such as Legionella, consider setting the DHW
thermostat to at least “e” (131 °F (55 °C)).
This setting ensures an economical and comfortable
DHW generation. Consult your local water department or
municipality for further information.
6 720 641 933-54.1O
max
1
2
34
5
6
reset
eco
max
1
2
3
4
e
6