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KBR16
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Bosch KBR16 Operating Instructions

Residential Gas Condensing Boiler
6720810590-00.2Wo
Greenstar FS/Combi FS
KBR16/21/28/35/42-3A... | KWB 28/35/42-3A...
Operating Instructions
6720810589 (2015/05) CA/US
2 | Contents

Contents

1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Information about the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Overview of boiler types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Preparing the appliance for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Checking the system water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Topping up the heating system water . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Overview of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Switching the appliance ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Turning the space heating ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Programming the heating control unit . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 KBR..-3A appliances with DHW tank: Setting the DHW temperature 13
4.6 KWB..-3A appliances (combi): Setting the DHW temperature . . . . 15
4.7 Setting manual summer mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.8 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9 Activating the key pad lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.10 Display codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Thermal disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Energy saving tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Environmental responsibility/disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Key to symbols and safety instructions | 3

1 Key to symbols and safety instructions

1.1 Key to symbols

Warnings

Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken.
Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken. The following keywor ds are defined and can be used in this document:
• DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION indicates a hazardous situation which, if not avoided, could result in minor to moderate injury.
NOTICE: Contains no warning triangle and indicates a situation that could result in damage to property or equipment, but no personal injury.

Important information

This symbol indicates important information where there is no risk to people or property. Important information for the proper use of the boiler is also provided in this manual. You will find the information with a symbol shown on the left and bordered by horizontal lines above and below the text.
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4 | Key to symbols and safety instructions

Additional symbols

Symbol Explanation
▶ Sequence of steps Cross-reference to other points in this document or to other documents
• Listing/list entry – Listing/list entry (2nd level)
Table 1

1.2 Safety instructions

General information
This manual is available in English and French.
▶ Keep this manual for future use. ▶ Observe the safety instructions of this manual before putting the heating
appliance into operation.
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
▶ Do not store or use gasoline or other flammable vapors and liquids in the vicinity
of this or any other appliance.
▶ What to do if you smell gas
– Do not try to light any appliance. – Do not touch any electrical switch; do not use any phone in your building. – Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
– If you cannot reach your gas supplier, call the fire department.
▶ Installation and service must be performed by a trained and certified heating
contractor, service agency or the gas supplier.
Key to symbols and safety instructions | 5
If you smell gas
▶ Turn off the gas cock ( page 11). ▶ Open windows and doors. ▶ Do not operate any electrical switches. ▶ Extinguish all open flames. ▶ From outside the building, call gas utility company and a trained and certified
heating contractor.
If you smell flue gas
▶ Switch OFF the appliance ( page 12). ▶ Open windows and doors. ▶ Inform a trained and certified heating contractor.
For appliances operating on room air: Danger of flue gas poisoning if supply of combustion air is insufficient
▶ Safeguard the supply of the combustion air. ▶ Do not cover or reduce the size of ventilation openings in doors, windows and
walls.
▶ Ensure that a sufficient supply of combustion air is also available for appliances
installed at a later date, e.g. kitchen exhaust fans, clothes dryers, and air conditioning units with a vent to the outside.
▶ Never operate the appliance if the supply of combustion air is insufficient.
Danger of explosion of flammable gases.
▶ Only employ a trained and certified contractor to carry out work on the gas train.
Risk of scalding
▶ If running at DHW temperatures above 104 °F (40 °C) ask a trained and certified
heating contractor to install a tempering valve to prevent scalding.
▶When the thermal disinfection function is enabled, DHW temperatures above
140 °F (60 °C) can occur.
Risk of damage due to operator error
Operator errors can result in personal injury and damage to property.
▶ Ensure that children never play with or operate this appliance unsupervised. ▶ Ensure that only people who know how to operate this appliance correctly have
access to it.
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6 | Key to symbols and safety instructions
Installation, conversion
Only have the appliance installed or modified by a trained and certified heating contractor. Never modify any parts that carry flue gas.
Never block the outlet of safety valves. Water may be expelled from any safety valve during heat-up.
Inspection and maintenance
The operator is responsible for safety and environmental compliance of the heating system.
Sign a maintenance and inspection contract with a trained and certified contractor, covering an annual inspection and demand-dependent maintenance. This guarantees high efficiency and environmentally sound combustion.
Explosive and easily combustible materials
Never use or store easily combustible materials (paper, thinners, paints, etc.) near the appliance.
Combustion air / room air
To prevent corrosion, keep the supply of combustion air / room air, free from corrosive substances (e.g. halogenated hydrocarbons that contain chlorine or fluorine compounds).
Overheating of the appliance
Should overheating occur or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location outside of the appliance.
In case of water damage
Do not use this boiler if any part has been under water. Immediately call a trained and certified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water.
Information about the appliance | 7

2 Information about the appliance

2.1 Certifications

This product has been tested and certified for the US and the Canadian market and complies with all applicable standards required for the US and the Canadian market.

2.2 Proper use

The appliance may only be installed in closed loop hot water central heating system s. Any other purpose is considered improper use. Any resulting damage is excluded from the manufacturer's warranty. The commercial and industrial use of the appliance for generating process heat is not permitted.
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8 | Preparing the appliance for operation

2.3 Overview of boiler types

Table 2 describes the meaning of the model number:
KBR16-3 Heat only appliance A23 KBR21-3 Heat only appliance A23 KBR28-3 Heat only appliance A23 KBR35-3 Heat only appliance A23 KBR42-3 Heat only appliance A23 KWB28-3 Combi appliance A23 KWB35-3 Combi appliance A23 KWB42-3 Combi appliance A23
Table 2 Appliance types
K Floor standing heating appliance WDHW heating BCondensing technology R Con stant temperature control (modulating pump) 42 16...42 reference to output in kW.
42kW output equals 143 310BTU/hr
-3 Version A Fan-supported appliance 23 Natural gas (NG)

3 Preparing the appliance for operation

▶ If existing, open the heating supply valve and the heating return valve. ▶ If existing, open the cold water valve and the DHW valve. ▶ When using KBR..-3A appliances with DHW tank, open a DHW tap until water runs
out. ▶ Open the gas cock. ▶ Open the con trol panel cover.
Preparing the appliance for operation | 9
6720810589-01.1Wo
1
0
2
3
4
bar
psi
15
30
45

3.1 Checking the system water pressure

The standard system water pressure is 14.5 - 21.75 psi (1 - 1.5 bar).
Should a higher system water pressure be required, refer to a trained and certified heating contractor.
Fig. 1 Pressure gauge

3.2 Topping up the heating system water

Topping up the heating system water is different on every system. Therefore, you should ask a trained and certified heating contractor to show you how it is done.
Maximum pressure of 30 psi (2.07 bar) at maximum heating water temperature must not be exceeded (safety valve will spill).
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10 | Operation

4Operation

These operating instructions apply only to the boiler. Depending on the heating control unit used, some functions may vary. The following options for controlling the heating system are available:
• Weather compensating control unit (page 14, Fig. 5) installed in the boiler
(page 11, [19])
• Weather compensating control unit mounted on the wall
• Room thermostat
• Weather compensating control with room influence (room thermostat)
• Third party system control unit
Therefore, please read the operating instructions for the heating control unit used.
Page 27 contains a quick reference.
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