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
Commissioning | 53
6 720 810 590 (2015/05)
Greenstar FS
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.
8.8 KWB..-3A appliances (combi boilers):
Setting the DHW temperature
▶ Set the DHW temperature on the DHW thermostat .
The set DHW temperature flashes on the display for 30 seconds.
Fig. 60 Set the DHW temperature (combi boiler KWB..-3A)
ECO button
Pressing and holding the ECO button until it lights up switches between
Comfort mode and Economy mode.
• Comfort mode (default setting)
The appliance is continually maintained at the set temperature.
Consequently, DHW draws are immediate, however the appliance
may run even if no DHW is being drawn.
• Economy mode, ECO button lights up
– DHW is only generated when DHW is drawn.
– On demand: Quickly open and close a DHW tap to signal the
appliance to heat to the selected temperature. After a short wait
DHW will be available.
8.9 Setting manual summer mode
In summer mode or warm weather shut down (WWSD), the heating zone
pump and consequently central heating are switched off. DHW
generation remains active following the DHW program.
▶ Make a note of the setting of the boiler high limit dial .
▶ Turn the boiler high limit dial counterclockwise to .
Fig. 61 Summer mode
For further information, see the operating instructions for the heating
control included in the scope of delivery.
8.10 Setting frost protection
Frost protection of the heating system:
▶ Leave the appliance switched ON; set the boiler high limit to at least
95 °F (35 °C) (position 1, Tab. 16, page 50).
Fig. 62 Frost protection of the heating system
-or- If you want to leave the appliance switched OFF:
▶ Mix Bosch-approved anti-freeze into the heating water ( Tab. 5,
page 31) and drain the DHW circuit.
Frost protection of the DHW tank:
▶ Leave the appliance switched ON; set the boiler high limit to at least
95 °F (35 °C) (position 1, Tab. 16, page 50).
▶ Turn the DHW thermostat counterclockwise to min
(59 °F (15 °C)).
Fig. 63 Frost protection for the DHW tank
8.11 Activating the key pad lock
The key pad lock affects the boiler high limit dial, the DHW thermostat,
and all buttons except the ON/OFF switch, emissions test button, and
reset button. It can be used to limit unauthorized access to the boiler.
Activating the key pad lock:
▶ Press the key pad lock button until and the heating supply
temperature are alternating on the display.
DHW thermostat Typical DHW temperatures
min approx. 104 °F (40 °C)
e approx. 122 °F (50 °C)
max approx. 140 °F (60 °C)
Table 18 Typical DHW temperatures for combi boiler KWB..-3A
The DHW on demand signal allows maximum gas and
water savings.
See also the warm weather shutdown (WWSD) feature in
the operating instructions for the heating control
included in the scope of delivery.
NOTICE: Heating system at risk of freezing. In manual
summer mode, only the appliance is protected from
freezing.
▶ Observe frost protection measures where there is a
risk of frost ( Chapter 8.10).
6 720 641 933-55.1O
max
1
2
34
5
6
reset
eco
max
1
2
3
4
e
6
For further information, see the operating instructions
for the heating control included in the scope of delivery.
eco
reset
max
1
2
3
5
6
max
1
2
3
4
e
6
min
eco
reset
max
1
2
3
5
6
max
1
2
3
4
e
6
6 720 641 933-68.1O
min
max
1
2
3
e
6
max
1
2
34
5
6
eco
reset
min
6 720 641 933-69.1O