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
▶ 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.
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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.
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Information about the appliance | 7
2Information 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
2.3Overview of boiler types
Table 2 describes the meaning of the model number:
KBR16-3Heat only applianceA23
KBR21-3Heat only applianceA23
KBR28-3Heat only applianceA23
KBR35-3Heat only applianceA23
KBR42-3Heat only applianceA23
KWB28-3Combi applianceA23
KWB35-3Combi applianceA23
KWB42-3Combi applianceA23
Table 2 Appliance types
KFloor standing heating appliance
WDHW heating
BCondensing technology
RCon stant temperature control (modulating pump)
42 16...42 reference to output in kW.
42kW output equals 143 310BTU/hr
-3Version
AFan-supported appliance
23 Natural gas (NG)
3Preparing 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.
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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. 1Pressure 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.
6 720 810 589 (2015/05)Greenstar FS
4.1 Overview of controls
6720810589-03.1Wo
1
2
3
45
6
7
8
9
12
10
11
Fig. 2Control panel
[1] Emission test button for contractors (see installation instructions)
[2] Service button for contractors (see installation instructions)
[3] Burner operation indicator lamp
[4] ON/OFF switch
[5] Key pad lock
[6] ECO button
[7] Reset button
[8] Display
[9] System water pressure gauge
[10] DHW temperature control
[11] Blank panel for optional programmer
[12] Heating temperature control
Operation | 11
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12 | Operation
m
a
x
1
2
3
4
5
6
4.2 Switching the appliance ON/OFF
Startup
▶ Switch the appliance ON using the ON/OFF switch.
The display shows the supply temperature of the hot water in °F. If necessary,
convert to °C (à Service function 0.E: Metric or US customary units).
Fig. 3
If the display shows in alternation with the supply temperature,
the trap filling function is active.
Shutdown
▶ Switch the appliance OFF using the ON/OFF switch.
The display goes out.
▶ If the appliance is taken out of service for a longer period : Observe frost
protection ( Section 4.8).
4.3 Turning the space heating ON
The maximum supply temperature can be s et fr om 9 5 °F (35 ° C) u p to a ppr oxim ate ly
194 °F (90 °C). The current supply temperature is shown on the display.
With radiant floor heating, limit the maximum permissible supply
temperature as recommended by the manufacturer.
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Operation | 13
eco
reset
6 720 641 933-53.1O
max
1
2
3
4
5
6
max
1
2
3
4
e
6
min
▶ Adjusting the supply temperature with the heating temperature control:
– Radiant floor heating: e.g. setting 3 (approx. 122 °F (50 °C))
– Panel or cast iron radiator heating: setting 6 (approx. 167 °F (75 °C))
– Heating with supply temperatures up to 194 °F (90 °C): setting max
Fig. 4
The burner ON indicator lamp lights up if the burner is operating.
4.4 Programming the FW200 heating control unit (optional
accessory)
Observe the operating instructions for the heating control unit
included in the scope of delivery. There you can read how to:
▶ set the operating mode and the heating curve for weather
compensating controls
▶ adjust the room temperature
▶ heat economically and save energy
Fig. 5
4.5 KBR..-3A appliances with DHW tank:
Setting the DHW temperature
DANGER: Risk of scalding!
▶ In normal operation, it is recommended to limit the DHW
temperature to 122 °F (50 °C) to limit the risk of scalding.
▶ Only set temperatures up to 158 °F (70 °C) for thermal
disinfection ( page 20).
6 720 810 589 (2015/05)Greenstar FS
▶ Set the DH W temperature on the DHW thermostat .
6 720 641 933-54.1O
max
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2
34
5
6
reset
eco
max
1
2
3
4
e
6
The set DHW temperature flashes on the display for 30 seconds.
Fig. 6
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.
Always set the DHW temperature as low as possible. A lower setting
on the thermostat means a higher rate of energy savings.
Furthermore, higher DHW temperatures result in inc reased limescale
deposits and thereby may impair the function of the appliance (e.g.
longer times for heating up or lower output).
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16 | Operation
ECO button
Pressing and holding the ECO button until it lights up switches from Comfort mode
to Economy mode.
• Comfort mode, ECO button is not lit (default setting)
In Comfort mode, the DHW tank has priority. The DHW tank is heated to the set
temperature first. Then the appliance switches to central heating mode.
• Economy mode, ECO button lit
In Economy mode, the appliance alternates between central heating mode and
DHW mode.
4.6 KWB..-3A appliances (combi boilers):
Setting the DHW temperature
▶ Set the DHW temperature on the DHW temperature control .
The set DHW temperature flashes on the display for 30 seconds.
When the ECO button is unlit, the appliance is in Comfort mode.
Pressing and holding the ECO button until it lights up switches from Comfort mode
to 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.
The DHW on demand signal allows maximum gas and water savings.
4.7 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.
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
freezing ( page 18).
▶ Make a note of the setting of the Heating temperature control .
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18 | Operation
▶ Turn the heating temperature control counterclockwise to.
reset
eco
4
3
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2
1
6
max
3
e
2
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1
maxmin
6 720 641 933-82.1O
Fig. 8
For further information, see the operating instructions for the heating control unit
included in the scope of delivery.
4.8 Setting frost protection
Frost protection of the heating system:
▶ Leave the appliance switched ON; turn the heating temperature controlat
least to position 1.
reset
eco
4
3
5
2
1
6
max
Fig. 9
For further information, see the operating instructions for the heating control unit
included in the scope of delivery.
Alternatively if you prefer switching the appliance OFF:
▶ Ask a trained and certified heating contractor to mix anti-freeze (see installation
instructions) into the heating water. All DHW pipes and DHW tank must be
completely drained.
3
e
2
6
1
max
min
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Operation | 19
max
1
2
34
5
6
max
1
2
3
4
e
6
eco
reset
6 720 641 933-83.1O
min
Frost protection of the DHW tank:
▶ Turn the DHW thermostat counterclockwise to min (59 °F (15 °C)).
reset
eco
2
1
34
5
6
max
3
e
2
1
min
6
max
6 720 641 933-69.1O
Fig. 10
4.9 Activating the key pad lock
The key pad lock affects the supply temperature dial, the DHW thermostat, the
service button and the ECO button.
Activating the key pad lock:
▶ Press the key pad lock button until and the heating supply temperature are
alternating on the display.
Fig. 11
Unlocking the key pad:
▶ Press the key pad lock button until the display shows only the supply
temperature.
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20 | Thermal disinfection
4.10 Display codes
Display Description
Fault-Code ( chapter 7)
Inspection due
Pump anti-seize function active
Key pad lock active
Condensate trap filling function active
Venting function active
Excessively rapid increase in supply temperature (temp. gradient
monitoring).
Heating mode is disabled for two minutes.
If this message appears repeatedly, inform a trained and certified
heating contractor.
Drying function. If the slab drying function is activated on the
weather compensating control unit, refer to the operating
instructions for the heating control unit included in the scope of
delivery.
Table 6
5Thermal disinfection
When using KBR..-3A appliances with DHW tank it may be necessary to disinfect the
DHW tank and DHW system after long idle periods to prevent bacterial
contamination, for example from Legionella bacteria. This step is typically not
necessary if the potable water is chlorinated or ozonated.
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Thermal disinfection | 21
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max
1
2
34
5
6
reset
eco
max
1
2
3
4
e
6
Thermal disinfection can also be carried out automatically and on a
regular basis; see operating instructions for the heating control unit
included in the scope of delivery.
Thermal disinfection covers the DHW system including the taps. For solar DHW
tanks, the solar portion of the tank is not covered.
DANGER: Risk of scalding!
Hot water can result in severe scalding.
▶ Carry out thermal disinfection only outside the normal hours of use.
▶ The water in the tank will take a while to cool down to the set DHW
temperature as a result of heat loss. Be aware that, after thermal
disinfection, the DHW may be hotter than the set temperature.
▶ If the thermal disinfection feature is activated have a DHW blending
valve installed.
Performing a manual disinfection of the DHW tank and system
▶ Close all DHW taps.
▶ Advise occupants of the risk of scalding if no tempering valve is installed.
▶ Set the time and DHW temperature accordingly on the heating control with DHW
program.
▶ Set any DHW recirculation pump to continuous operation.
▶ Turn DHW thermostat clockwise to max (approx. 158 °F (70 °C)).
Fig. 12
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22 | Energy saving tips
▶ Wait until the maximum temperature has been reached.
▶ Open all DHW taps, from the nearest to the one furthest away, and draw off hot
water until it reaches a minimum of 158 °F (70 °C) at all taps for at least 3 minutes.
▶ Reset the DHW thermostat, DHW recirculation pump, and heating control unit to
standard operation.
To cancel the thermal disinfection:
▶ Switch the appliance OFF and ON again.
The appliance starts up again and the current supply temperature
is displayed.
6Energy saving tips
Heating economically
The boiler is designed to provide a high level of comfort while keeping gas
consumption and the resulting environmental impact as low as possible. The gas
supply to the burner is controlled according to the heat demand. The boiler
continues to operate on low fire if the demand for heat drops. The technical term for
this process is modulating control, and it reduces temperature fluctuations and
provides even distribution of heat throughout the home. This means that the boiler
may stay on for relatively long periods but will use less gas than an appliance that
continually cycles on and off.
Inspection/Maintenance
To ensure that gas consumption and environmental impact (pollution, etc.) remain
as low as possible over an extended period of time, we recommend that you sign an
inspection/maintenance contract with a trained and certified heating contractor
covering scheduled annual service and maintenance.
6 720 810 589 (2015/05)Greenstar FS
Energy saving tips | 23
Heating control unit
Use a heating control unit with room temperature influence or a weather
compensating control unit and thermostatic valves.
For further information, see the operating instructions fo r the heating control unit
included in the scope of delivery.
Thermostatic valves
Fully open the thermostatic valves to ensure that the desired room temperature is
reached in all cases. Allow several days for the system to stabilize after every
adjustment and only change the setting for the heating curve or the room
temperature on the control unit after the system had stabilized on the previous
settings.
Radiant floor heating
Do not set the supply temperature higher than the maximum level recommended by
the manufacturer.
Room venting
Do not keep windows cracked for ventilation purposes as it continuously cools down
the room without significantly improving the air quality in the room. It is better to vent
fully for a short time (with completely open windows).
Turn off the thermostats (if installed) in the room when venting.
Domestic hot water (DHW)
Always set the DHW temperature as low as possible.
A lower setting on the thermostat means a higher rate of energy savings.
Furthermore, higher DHW temperatures result in increased limescale deposits and
thereby may impair the function of the appliance (e.g. longer heating-up times or
lower output).
Recirculation pump
If there is a DHW recirculation pump installed, use a timer program to control its
operation according to the specific requirements (e.g. morning, afternoon,
evening).
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24 | Troubleshooting
7Troubleshooting
The Heatronic boiler control monitors all safety and control components.
If a fault arises during operation, an audible warning tone sounds.
Press a button to mute the warning sound.
The display indicates a fault code (e.g. ) and the reset button may also be
flashing.
If the reset button is flashing:
▶ Press the reset button and hold it until appears on the display.
The appliance starts up again and the current supply temperature is displayed.
If the reset button is not flashing:
▶ Switch the appliance OFF and ON again.
The appliance starts up again and the current supply temperature is displayed.
If the fault persists:
▶ Contact a trained and certified heating contractor for assistance, providing
details of the fault code and the appliance type and serial number.
An overview of the display codes can be found on page 20 .
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Maintenance | 25
Appliance details
If you need to call a trained and certified heating contractor, you may be asked for
details on your appliance.
Those details can be found on the rating plate.
The operator is responsible for the safety and environmental compatibility of the
heating system (see local regulations).
It is therefore recommended to sign a maintenance and inspection contract with a
trained and certified heating contractor that provides annual inspection and
maintenance. This ensures high efficiency and environmentally compatible
combustion.
Cleaning the outside of the boiler and the control unit
Wipe down with a damp cloth. Do not use any abrasive or corrosive cleaning agents.
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26 | Environmental responsibility/disposal
9Environmental responsibility/disposal
Environmental responsibility is one of the fundamental company policies of the
Bosch Group.
We regard quality of performance, economy and environmental responsibility as
equal objectives.
We adhere strictly to environmental protection laws and regulations.
We use the best possible technology and materials taking into account economic
points of view, to protect the environment.
Packaging
For packaging, we participate in the country-specific recycling systems, which
guarantee optimal recycling.
All packaging materials used are environmentally-friendly and recyclable.
Old appliances
Old appliances contain materials that should be recycled.
The components are easy to separate and the plastics are marked. This allows the
various components to be sorted for appropriate recycling or disposal.
6 720 810 589 (2015/05)Greenstar FS
10 Quick reference
eco
reset
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1
2
3
4
5
6
max
1
2
3
4
e
6
min
6 720 641 933-55.1O
max
1
2
34
5
6
reset
eco
max
1
2
3
4
e
6
max
1
2
34
5
6
max
1
2
3
4
e
6
eco
reset
6 720 641 933-83.1O
min
eco
reset
max
1
2
3
5
6
max
1
2
3
4
e
6
6 720 641 933-68.1O
min
Startup
Start upDHW temperature
DANGER: Risk of scalding!
▶ In normal operation, it is
recommended to limit the
4
3
5
2
1
6
m
a
x
Turning space heating ON
6 720 613 896-05.1O
DHW temperature to
122 °F (50 °C) to limit the
risk of scalding
Quick reference | 27
Heating control
Set the weather compensating control
unit to the relevant heating curve and
operating mode or set room thermostat
to the desired temperature.