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
92 | Spare parts
Greenstar FS
6 720 810 590 (2015/05)
Item( Fig. 99) Designation
KBR16-3A
KBR21-3A
KBR28-3A
KBR35-3A
KBR42-3A
KWB28-3A
KWB35-3A
KWB42-3A
Order number
1 Control unit HTS Bosch USA 8 737 704 671 0
2 Rotary selector 8 716 011 785 0
3 Cover 8 711 000 302 0
4 Cover 8 717 207 680 0
6 Set of connectors 8 714 404 348 0
7 Printed Circuit Board 8 748 300 739 0
8 Screw 8 713 403 029 0
9 Backpanel 8 613 560 409 0
10 Code plug 2500 NG (23) 8 714 432 500 0
Code plug 2501 NG (23)
8 714 432 501 0
Code plug 2502 NG (23)
8 714 432 502 0
Code plug 2503 NG (23)
8 714 432 503 0
Code plug 2504 NG (23)
8 714 432 504 0
Code plug 2505 LPG (31)
8 714 432 505 0
Code plug 2506 LPG (31)
8 714 432 506 0
Code plug 2507 LPG (31)
8 714 432 507 0
Code plug 2508 LPG (31)
8 714 432 508 0
Code plug 2509 LPG (31)
8 714 432 509 0
Code plug 2520 NG (23)
8 714 432 520 0
Code plug 2521 LPG (31)
8 714 432 521 0
Code plug 2524 NG (23
8 714 432 524 0
Code plug 2525 LPG (31)
8 714 432 525 0
Code plug 2528 NG (23
8 714 432 528 0
Code plug 2529 LPG (31)
8 714 432 529 0
11 Cover 8 737 702 329 0
12 Grommet (10x) 8 710 506 185 0
16 Earth harness 8 716 117 523
17 Harness low voltage appliance 8 716 117 524
20 Fuse 8 744 503 045 0
21 Harness accessories 8 716 117 525
22 Cable storage tank pump 8 716 117 526
23 Cable mains 120V 8 716 117 527
24 Cable CH pump 8 716 117 528
25 Cable power cord fan assembly 8 716 117 529
35 Cable pump harness USA 8 716 117 530
36 Ignition harness 8 716 106 799 0
37 M4 x 14 PT POZI PAN Z/P screw 2 914 201 304 0
– LPG conversion kit 42kw 8 716 117 521
– LPG conversion kit 35kw 8 716 117 534
– LPG conversion kit 28kw 8 716 117 535
– LPG conversion kit 21kw 8 716 117 536
– LPG conversion kit 16kw 8 716 117 538
– LPG conversion kit 42kw 8 716 117 539
– LPG conversion kit 35kw 8 716 117 540
– LPG conversion kit 28kw 8 716 117 541
Table 41 Group 6 - Control box Greenstar