Bosch KBR16-3, KBR28-3, KBR35-3, KWB28-3, KBR42-3 Installation And Service Instructions Manual

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Installation and Service Instructions for Contractors

Residential Gas Condensing Boiler

Greenstar FS/Combi FS

6720810590-00.2Wo

WARNING:

Improper installation, set-up, modification, operation or maintenance of the heating system can cause personal injury and property damage. Follow these instructions precisely. If you require assistance or further information, contact a trained and certified installer or the gas supply company.

WARNING:

The operating instructions are part of the technical documents that must be handed over to the owner or operator of the heating system. Explain to the owner or operator how to use the heating system using the operating instructions. Make sure that they are familiar with all required information for the safe and proper operation of the heating system.

NOTICE:

In Massachusetts, this appliance must be installed by a licensed plumber or gas fitter.

These instructions are available in English and French.

Please keep these instructions for future reference.

Warranty information available at www.bosch-climate.us

Annual service is required

KBR16-3. |KBR21-3. |KBR28-3. |KBR35-3. |KBR42-3. |KWB28-3. |KWB35-3. |KWB42-3.

6720810590 (2015/05) CA/US

2 | Table of Contents

Greenstar FS

6 720 810 590 (2015/05)

Table of Contents

1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . 3

1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 4

2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 KBR - Residential boiler for space heating and loading of

indirect fired DHW tanks . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 KWB - Residential combi boiler for space heating and DHW

generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Information about the appliance . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.2 Overview of boiler types . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.4 Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.6 Product dimensions and minimum clearances . . . . . . . . 7

3.7 Appliance layout heating boiler KBR..-3A . . . . . . . . . . . . 8

3.8 Appliance layout combi boiler KWB..-3A . . . . . . . . . . . 10

3.9 Electrical wiring heating boiler KBR..-3A . . . . . . . . . . . 12

3.10 Electrical wiring combi boiler KWB..-3A . . . . . . . . . . . . 14

3.11 Technical data heating boiler KBR 16-3 . . . . . . . . . . . . 16

3.12 Technical data heating boiler KBR 21 -3 . . . . . . . . . . . . 17

3.13 Technical data heating boiler KBR 28-3 . . . . . . . . . . . . 18

3.14 Technical data heating boiler KBR 35-3 . . . . . . . . . . . . 19

3.15 Technical data heating boiler KBR 42-3 . . . . . . . . . . . . 20

3.16 Technical data combi boiler KWB 28-3 . . . . . . . . . . . . . 21

3.17 Technical data combi boiler KWB 35 - 3 . . . . . . . . . . . . 22

3.18 Technical data combi boiler KWB 42 - 3 . . . . . . . . . . . . 23

3.19 Condensate composition . . . . . . . . . . . . . . . . . . . . . . . . 24

4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.1 Compliance with standards and regulations . . . . . . . . . 24

4.2 Operating limits of the boiler . . . . . . . . . . . . . . . . . . . . . 24

4.3 Additional regulations for installation in Massachusetts . . 25

5 Common Applications of KBR boilers . . . . . . . . . . . . . . . . . . . 26

5.1 Multiple zones using zone valves with DHW . . . . . . . . . 26

5.1.1 To utilize the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.1.2 Wiring - Multi zone with zone valves and LWCO . . . . . . 27

5.2 Multiple zones using circulators with DHW . . . . . . . . . . 28

5.2.1 To utilize the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.2.2 Wirin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.1 Installation and operation . . . . . . . . . . . . . . . . . . . . . . . 30

6.1.1 Notes on installation and operation . . . . . . . . . . . . . . . . 30

6.1.2 Other important information . . . . . . . . . . . . . . . . . . . . . 31

6.2 Comparing the size of the integrated expansion vessel

(KWB-3A boiler only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.3 KBR..-3A appliances (heating boilers): Selecting an

expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.4 Selecting the installation location . . . . . . . . . . . . . . . . . 32

6.5 Low Loss Header (LLH) utilization . . . . . . . . . . . . . . . . 32

6.5.1 To utilize the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.6 Locating the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.6.1 Positioning the appliance . . . . . . . . . . . . . . . . . . . . . . . 33

6.7 Installing a low water cut off (LWCO) . . . . . . . . . . . . . . 34

6.8 Connecting flue gas accessories . . . . . . . . . . . . . . . . . . 35

6.8.1 Installation of the exhaust and air intake system . . . . . 36

6.8.2 Approved examples of horizontal and vertical venting

installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.8.3 Vent and combustion air pipe lengths . . . . . . . . . . . . . . 42

6.9 Testing gas and water connections for leaks . . . . . . . . 43

7 Making the electrical connections . . . . . . . . . . . . . . . . . . . . . 44

7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2 Electrical connections in the junction boxes . . . . . . . . 44

7.2.1 Access to junction boxes . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.2 High voltage junction box . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.3 Connecting an external heating zone pump or DHW

recirculation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.4 DHW tank loading pump or 3-way valve with spring return

(only heating boiler KBR..-3A) . . . . . . . . . . . . . . . . . . . 45

7.2.5 Connecting mains power supply . . . . . . . . . . . . . . . . . . 45

7.2.6 Low voltage junction box . . . . . . . . . . . . . . . . . . . . . . . . 46

7.3 DHW tank temperature sensor connection . . . . . . . . . 46

7.4 Connecting the LWCO device . . . . . . . . . . . . . . . . . . . . 46

8 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8.1 Before operating the appliance . . . . . . . . . . . . . . . . . . . 47

8.2 Switching the appliance ON/OFF . . . . . . . . . . . . . . . . . 47

8.3 Setting up space heating . . . . . . . . . . . . . . . . . . . . . . . . 48

8.4 Programming the FW 200 heating control unit (optional

accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8.5 FW 200 outdoor reset heating control quick start (optional

accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.5.1 Setting date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.5.2 Setting constant heating (no night set back) . . . . . . . . 49

8.5.3 Setting type of heating system . . . . . . . . . . . . . . . . . . . 49

8.5.4 Adjusting warm weather shut down (WWSD) . . . . . . . 50

8.5.5 Resetting all settings (for installers only) . . . . . . . . . . . 50

8.6 After commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.7 KBR..-3A appliances (heating boilers) with DHW tank:

Setting the DHW temperature . . . . . . . . . . . . . . . . . . . 50

8.8 KWB..-3A appliances (combi boilers):

Setting the DHW temperature . . . . . . . . . . . . . . . . . . . 51

8.9 Setting manual summer mode . . . . . . . . . . . . . . . . . . . . 51

8.10 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.11 Activating the key pad lock . . . . . . . . . . . . . . . . . . . . . . 51

9 KBR..-3A appliances (heating boiler) with DHW tank: Thermal

disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Key to symbols and safety instructions | 3

6 720 810 590 (2015/05)

Greenstar FS

10 Boiler circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

10.1 Pump anti-seize protection . . . . . . . . . . . . . . . . . . . . . . 53

10.2 Changing the pump curve of the boiler pump . . . . . . . 53

11 Heatronic boiler control settings . . . . . . . . . . . . . . . . . . . . . . . 54

11.1 Guideline to service functions . . . . . . . . . . . . . . . . . . . . 54

11.2 Overview of the service functions . . . . . . . . . . . . . . . . . 54

11.2.1 First service level (press and hold the service button until

it lights up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

11.2.2 Second service level (at first service level, service button lights up, press ECO button and key pad lock button

simultaneously until 8.A appears) . . . . . . . . . . . . . . . . 55

11.3 Description of the service functions . . . . . . . . . . . . . . . 55

11.3.1 First service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

11.3.2 Second service level . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

12 Gas type conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

12.1 Converting to a different gas type . . . . . . . . . . . . . . . . . 60

12.2 Installation location higher than 2,000 feet (610 m)

above sea level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

12.3 Setting the gas-air ratio (CO2 or O2) . . . . . . . . . . . . . . 61

12.4 Dynamic gas pressure test . . . . . . . . . . . . . . . . . . . . . . 62

13 Flue gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

13.1 Emissions test button . . . . . . . . . . . . . . . . . . . . . . . . . . 62

13.2 Measuring CO content of flue gas . . . . . . . . . . . . . . . . . 62

14 Environmental responsibility/disposal . . . . . . . . . . . . . . . . . 63

15 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 63

15.1 Description of various steps . . . . . . . . . . . . . . . . . . . . . 63

15.1.1 Calling up the latest fault (service function 6.A) . . . . . 63

15.1.2 Fresh water filter (only combi boiler KWB..-3A) . . . . . 63

15.1.3 Plate type heat exchanger (only combi boiler KWB..-3A) . 64

15.1.4 Checking the electrodes . . . . . . . . . . . . . . . . . . . . . . . . 65

15.1.5 Burner servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

15.1.6 Heat exchanger block inspection and cleaning . . . . . . 66

15.1.7 Condensate trap cleaning . . . . . . . . . . . . . . . . . . . . . . . 67

15.1.8 Checking the mixer diaphragm . . . . . . . . . . . . . . . . . . . 68

15.1.9 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

15.1.10Setting the boiler water pressure . . . . . . . . . . . . . . . . . 68

15.1.11Testing system water quality . . . . . . . . . . . . . . . . . . . . . 68

15.1.12Inspecting electrical wiring . . . . . . . . . . . . . . . . . . . . . . 68

15.2 Checklist for annual inspection and maintenance . . . . 69

16 Readings on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

17 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

17.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

17.2 Faults that are shown on the display . . . . . . . . . . . . . . . 72

17.3 Faults that are not shown on the display . . . . . . . . . . . 74

17.4 Check sensor values . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

17.4.1 Outdoor temperature sensor . . . . . . . . . . . . . . . . . . . . 75

17.4.2 Additional supply temperature limiter . . . . . . . . . . . . . 75

17.4.3 Supply temperature sensor, External supply temperature sensor, DHW tank temperature sensor, DHW temperature

sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

17.5 Replacement code plug . . . . . . . . . . . . . . . . . . . . . . . . . 75

18 Commissioning log for the appliance . . . . . . . . . . . . . . . . . . . 76

19 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Key to symbols and safety instructions

1.1 Key to symbols

Warnings

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 keywords 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.

Important information

Additional symbols

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.

NOTICE: Contains no warning triangle and indicates a situation that could result in damage to property or equipment, but no personal injury.

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.

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)

4 | Key to symbols and safety instructions

Greenstar FS

6 720 810 590 (2015/05)

1.2 General safety instructions

If you hear gas leaking

▶ Leave the building immediately. ▶ Prevent others from entering the building. ▶ Notify the police and fire department from outside the building. ▶ From outside the building, call the gas supply company and a trained

and certified installer or service company.

If you smell gas

▶ Turn off the gas shut-off valve. ▶ Open windows and doors ▶ Do not touch any electrical switch, telephone, and do not use outlets. ▶ Extinguish all open flames. ▶ Do not smoke! ▶ Do not use lighters! ▶ Warn all occupants of the building that they need to leave the

building. ▶ Do not ring doorbells! ▶ Notify the police and fire department from outside the building. ▶ From outside the building, call the gas supply company and a trained

and certified installer or service company.

If you smell flue gas

▶ Switch off the heating system by shutting off the emergency shut-off

switch. ▶ Open windows and doors. ▶ Call a trained and certified installer or service company.

DANGER: Risk of fatal injury from failing to consider your own safety!

▶ Never risk your own life. Your own safety must always take the

highest priority

NOTICE: Risk of appliance damage from improper operation of the boiler!

▶ Only use the boiler for its intended purpose. ▶ Only operate the boiler if it has been installed and maintained per the

instructions provided in the Installation Manual. ▶ Do not attempt to operate an appliance if any part of it is not in

working order or is damaged. ▶ Use only original spare parts! The use of parts not supplied by the

manufacturer may cause damage to the boiler, other property and

personal injury. Also, boiler damage caused by the use of

unauthorized parts is not covered by the warranty.

DANGER: Risk of fire when soldering and brazing!

▶ Take appropriate protective measures when soldering and brazing

around combustible and flammable material.

NOTICE:

▶ The installation must comply with all applicable national, state, and

local codes, rules, and regulations. ▶ The operator is responsible for the operational safety and regulatory

compliance of the heating system. ▶ In the Commonwealth of Massachusetts, the appliance must be

installed by a licensed plumber or gas fitter.

DANGER: Risk of personal injury or death from flue gas poisoning!

▶ Do not install a thermostatic flue gas damper downstream of the draft

hood. ▶ Do not tamper with, remove, or attempt to repair the blocked vent

switch. ▶ When replacing the blocked vent switch, install the new part in the

original location.

▶ A blocked vent switch tripping more than once indicates a problem

with the venting system or chimney which must be repaired

immediately. ▶ Ensure none of the vent pipes and chimneys are damaged or blocked. ▶ Connect only one appliance to each venting system or chimney. ▶ The venting system must not feed into or route through another air

extraction duct. ▶ The venting system must be inspected annually. All parts that show

any signs of damage or corrosion must be replaced. ▶ Never close off or reduce the size of the combustion air openings. ▶ The boiler must not be operated until any obstructions have been

removed.

DANGER: Risk of personal injury or death from explosion!

▶ Work on gas components may only be carried out by a trained and

certified installer or service company. ▶ Appliance installation, the connection of gas and vent piping, initial

commissioning, electrical connections, and service and maintenance

must only be carried out by a trained and certified installer or service

company.

DANGER: Risk of personal injury or death from fire!

▶ Do not use flammable or combustible material in the boiler room. ▶ It is recommended not to store any items within 16 inches (415mm)

of the appliance

CAUTION: Appliance damage from contaminated combustion air!

▶ Keep the combustion air free of corrosive substances, e.g.

halogenated hydrocarbons from painting operations or beauty

salons. ▶ Keep combustion air free from dust and lint, e.g. from laundry or

agricultural operations. ▶ If clean room air is not available, fresh outdoor combustion air must

be provided

DANGER: Risk of personal injury or death from electric shock.

▶ Before removing the front panel, disconnect the heating system from

the electrical power supply by shutting off the emergency shutoff

switch or the heating system circuit breaker. ▶ It is not enough to switch off the control panel. Power to the panel

must be disconnected! Ensure that the power is not restored

unintentionally by following proper lock out/tag out procedures. ▶ Only qualified electricians are permitted to carry out electrical work.

DANGER: Safety devices!

▶ Never shut off safety valves! ▶ Hot water may escape from the safety valve at any time when the

appliance is running.

DANGER: Risk of personal injury or death after a flood!

▶ Do not attempt to operate an appliance if any part of it has been

under water. ▶ An appliance that was subject to flooding must be replaced.

NOTICE:

▶ Upon completion of the installation, these instructions should be

handed to the owner and operator of the appliance. ▶ The installer must instruct the owner and operator on the

functionality of the components and the proper operation of the

boiler and the heating system. ▶ The boiler must be serviced annually including the main burner,

ignition burner, the entire venting system, and the combustion air

supply. All parts that show any signs of damage or corrosion must be

replaced.

Scope of delivery | 5

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Greenstar FS

2 Scope of delivery

2.1 KBR - Residential boiler for space heating and loading of indirect fired DHW tanks

Fig. 1 Scope of delivery heating boiler KBR..-3A

Contents of package 1: [1] Gas condensing boiler [2] Set of documents for appliance [3] Adapter for connection of a LWCO [4] Gas conversion kit [5] DHW tank temperature sensor (NTC) [6] Flue adapter

2.2 KWB - Residential combi boiler for space heating and DHW generation

Fig. 2 Scope of delivery combi boiler KWB..-3A

Contents of package 1: [1] Gas condensing boiler [2] Set of documents for appliance [3] Adapter for connection of a LWCO [4] Gas conversion kit [5] Flue adapter

1) Concentric vent kit available as accessory.

6720810590-06.1Wo

2) Concentric vent kit available as accessory.

6720810590-05.1Wo

6 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3 Information about the appliance

KBR appliances are natural gas, residential boilers for central heating

and loading of an indirect fired DHW tank.

KWB appliances are natural gas, residential combi boilers for central heating and on demand DHW heating.

The appliances comply with South Coast Air Quality Management District (SCAQMD) 2012 requirements: (Type-1) 14 Ng/J NO

(and/or

20 ppm at 3% O

3.1 Proper use

The appliance may only be installed in closed loop hot water central heating systems. 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.

3.2 Overview of boiler types

Table 1 describes the meaning of the model number:

K Floor standing heating appliance W DHW heating B Condensing technology R Constant temperature control

16...42 Reference to output in kW. 42kW output equals 143 310BTU/hr

-3 Version

A Fan-supported appliance 23 Natural gas (NG)

3.3 Rating plate

The rating plate is located at the right side of the appliance.

Fig. 3 Position of the rating plate

The rating plate contains the appliance output, model number, approval data and serial number.

3.4 Appliance description

• Appliance is a floor mounted installation

• Intelligent boiler pump control

• Heatronic boiler control

• Three-speed boiler circulator

• Automatic air vent (combi boiler only)

•Display

• Automatic ignition

• Continuously-controlled output

• Full protection via the Heatronic with flame rod and solenoid valves

• No minimum circulating water flow rate required

• Suitable for all hydronic emitters

• Flue adapter for flue gas and combustion air with test ports

• Variable speed fan

• Gas premix burner

• Heat exchanger temperature and high limit sensor

• LLH / Supply temperature sensor

•Temperature limiter

• Safety relief valve, pressure gauge

• Expansion vessel (combi boiler only)

• Connection possibility for DHW tank temperature sensor (NTC) (heating boiler only)

• Flue gas temperature limiter

• Connection for DHW...

• DHW (combi boiler only)

• Internal motorized 3-way valve (combi boiler only)

• Integrated low loss header with option to isolate flow

3.5 Accessories

• Weather compensation control FW200

• CRC100 or CRC200 user interfaces

• CZM100 Zoning module

• Optional concentric vent kit available for horizontal direct vent terminations

• Modules for system expansions: – ICM for cascading up to 4 boilers

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 1 Appliance types

6720810590-46.1Wo

Here you will find a list of typical accessories for this appliance. Refer to the Bosch Product Catalog for a complete overview of all available accessories.

Information about the appliance | 7

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Greenstar FS

3.6 Product dimensions and minimum clearances

Fig. 4

[M1] 18

” - (467mm)

[M2] 3

” - (88mm)

[M3] 9

” - (243.5mm) [M4] 10” - (253.5mm) [M5] 39

” - (1003mm)

[M6] 11

” - (301.5mm)

[M7] 7

” - (200mm) [M8] 4” - (101mm) [M9] 8

” - (207.3mm)

[M10] 3

” - (86.7mm)

[M11] 6

13/

16” - (173.3mm)

[M12] 4

” - (117.6mm)

[M13] 11

” - (283mm)

[M14] 5

” - (131mm)

[M15] 28

” - (713.5mm) [M16] 31” - (788mm) [Ø 1] 3

” - (80mm)

[Ø 2] 4

15/

” - (125mm)

Fig. 5 Dimensions and minimum clearances (front, rear, & side view)

[1] 453/4” - (1163mm) [2] 41

15/

16” - (1065mm)

[3] 27

16” - (700mm)

[4] **24

” - (600mm)

[5] 7

” - (200mm)

[6] ≥ 2

4” - (70mm)

[7] *4”

- (102mm)

[8] *4”

- (102mm) [9] 41” - (1042mm) [10] 18

” - (467mm)

[11] 19

” - (497mm)

(*) Zero clearance from combustibles permitted, but 4" (102 mm) recommended for

serviceability

(**) 1” (25mm) Distance to door, if mounted inside a closet with 24” (600mm) in front

of boiler for serviceability

M3 M4

M10

M11

M12

M14

M13

Ø1

Ø2

M15

M16

6720810590-36.1Wo

Symbol Description Connection size

Domestic water inlet ¾ ” - (19mm)

Domestic hot water outlet ¾ ” - (19mm)

Heating return 1¼ ” - (31.8mm)

Heating supply 1¼ ” - (31.8mm)

Gas inlet ¾ ” - (19mm)

6720810590-08.1Wo

8 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.7 Appliance layout heating boiler KBR..-3A

Fig. 6 Appliance layout heating boiler KBR..-3A

33 34

6720810590-35.1Wo

Information about the appliance | 9

6 720 810 590 (2015/05)

Greenstar FS

Key to Fig. 6 Heating boiler KBR..-3A:

[1] Pre-wired low voltage installer connection box [2] Pressure Relief Valve (PRV) [3] Condensate hose [4] Flue connector for twin pipe adaptor [5] Air/gas premix chamber [6] Pre-wired high voltage installer connection box [7] Manual air bleed [9] Additional supply temperature limiter [10] Connection of optional Low Water Cut Off (LWCO) [11] Flue gas temperature limiter [12] Cover for maximum gas adjuster [13] Gas valve [14] Gas connection [15] Heating return connection [16] Heating supply connection [17] Low Loss Header with flow sensor [18] Fan [19] Electrode set [20] Primary heat sensor [21] Maximum safety sensor [22] Inspection and clean out cover [23] Condensate collector [24] Boiler circulator [25] Drain cock [26] Condensate trap [27] Heatronic boiler control [28] ON/OFF switch [29] Burner on indicator [30] Service button [31] Emission test button [32] Boiler high limit dial [33] Mounting socket for outdoor reset control [34] DHW Setpoint Dial [35] Keypad lock button [36] ECO button [37] Reset button [38] Boiler water pressure gauge [39] Display [40] Gas valve minimum adjuster [41] Gas inlet pressure test point

10 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.8 Appliance layout combi boiler KWB..-3A

Fig. 7 Appliance layout combi boiler KWB..-3A

39 40

6720810590-34.1Wo

Information about the appliance | 11

6 720 810 590 (2015/05)

Greenstar FS

Key to Fig. 7 Combi boiler KWB..-3A:

[1] Pre-wired low voltage installer connection box [2] Pressure Relief Valve (PRV) [3] Condensate hose [4] DHW inlet [5] DHW outlet [6] Flue connector for twin pipe adaptor [7] Expansion vessel [8] Pre-wired high voltage installer connection box [9] Manual air bleed [10] Air/gas premix chamber [11] Connection for optional Low Water Cut Off (LWCO) [12] Additional supply temperature limiter [13] Flue gas temperature limiter [14] Cover for maximum gas adjuster [15] Air vent [16] DHW thermostat [17] Gas valve [18] Gas connection [19] Central heat return connection [20] Central heating supply connection [21] Low Loss Header and flow sensor [22] Fan [23] Electrode set [24] Primary heat sensor [25] Maximum safety sensor [26] Inspection and clean out cover [27] Condensate collector [28] Flow meter [29] Pump [30] Three way valve [31] Drain cock [32] Condensate trap [33] Heatronic boiler control [34] ON/OFF switch [35] Burner flame indicator [36] Service button [37] Emission test button [38] Boiler high limit dial [39] Mounting socket for outdoor reset control [40] DHW Setpoint Dial [41] Keypad lock button [42] ECO button [43] Reset button [44] Boiler water pressure gauge [45] Display [46] Gas valve minimum adjuster [47] Gas inlet pressure test point

12 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.9 Electrical wiring heating boiler KBR..-3A

Fig. 8 Electrical wiring diagram heating boiler KBR..-3A

6720810590-10.1Wo

LRLSNLN

789

LPNP

BUS

out sen

DHW sen

LWCO

Information about the appliance | 13

6 720 810 590 (2015/05)

Greenstar FS

Key to Fig. 8 Heating boiler KBR..-3A:

[T] Top of control board [1] Code plug [2] System supply temperature sensor [3] Diagnostic interface [4] ON/OFF switch [5] Fuse T 6.3 A (120 VAC) [6] Ignition transformer [7] Boiler high limit dial [8] High voltage - Installer connection box [9] External heating pump [10] DHW tank primary pump or 3 way valve [11] 120 VAC connection [12] Empty (future connectivity) [13] DHS Sen - Domestic Hot Water temperature sensor (NTC) [14] LWCO - Low Water Cut Off [15] Out Sen - Outdoor temperature sensor [16] BUS - BUS connection to programmer [17] Low voltage - Installer connection box [18] Ignition electrode [19] Boiler block temperature limiter [20] Boiler circulator [21] Flame rod electrode [22] LLH/Supply temperature sensor [23] Additional supply temperature limiter [24] Fan [25] Flue gas temperature limiter [26] Gas valve [27] DHW Setpoint Dial

14 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.10 Electrical wiring combi boiler KWB..-3A

Fig. 9 Electrical wiring diagram combi boiler KWB..-3A

BUS

out sen

DHW sen

LWCO

6720810590-09.1Wo

LRLSNLNS

789

LPNP

28 7

Information about the appliance | 15

6 720 810 590 (2015/05)

Greenstar FS

Key to Fig. 9 Combi boiler KWB..-3A:

[T] Top of control board [1] Code plug [2] System supply temperature sensor [3] Diagnostic interface [4] ON/OFF switch [5] Fuse T 6.3 A (120 VAC) [6] Ignition transformer [7] Boiler high limit dial [8] High voltage - Installer connection box [9] External heating pump [10] 120 VAC connection [11] Empty (future connectivity) [12] LWCO - Low Water Cut Of [13] Out Sen - Outdoor temperature sensor [14] BUS - BUS connection to programmer [15] Low voltage - Installer connection box [16] Ignition electrode [17] Boiler block temperature limiter [18] Flow meter (turbine) [19] 3 way valve (space heating/DHW heating) [20] Flame rod electrode [21] LLH/Supply temperature sensor [22] Boiler circulator [23] Additional supply temperature limiter [24] Flue gas temperature limiter [25] Fan [26] DHW temperature sensor [27] Gas valve [28] DHW Setpoint Dial

16 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.11 Technical data heating boiler KBR 16-3

Input/Output Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 57,200 (16.8) 56,400 (16.5) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 54,900 (16.1) 55,300 (16.2) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 54,300 (15.9) 54,600 (16.0) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 50,800 (14.9) 51,200 (15.0) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 12,900 (3.8) 21,500 (6.3) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 12,600 (3.7) 21,500 (6.3) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 12,600 (3.7) 21,500 (6.3) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 11,300 (3.3) 19,400 (5.7) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 56 (1.6) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 22 (0.6) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) - 8-13” (19.9-32.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 6.8/1.7 6.7/2.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input

°F ( °C) 136/133 (58/56) 136/133 (58/56)

Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal heat input

°F ( °C) 99/88 (37/31) 99/88 (37/31)

CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 33 ≤ 33 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 132(60) 132(60) Maximum overall dimensions W x H x D inch

(mm)

15/

x 41

x 21

557 x 1048 x 555

19/

x 41

x 21

557 x 1048 x 555

Information about the appliance | 17

6 720 810 590 (2015/05)

Greenstar FS

3.12 Technical data heating boiler KBR 21 -3

Input/Output Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 79,200 (23.2) 77,500 (22.7) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 74,700 (21.9) 74,700 (21.9) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 74,000 (21.7) 74,000 (21.7) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 70,300 (20.6) 70,300 (20.6) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 24,600 (7.2) 40,100 (11.7) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 23,900 (7.0) 39,900 (11.7) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 23,900 (7.0) 39,600 (11.6) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 21,800 (8.4) 36,200 (10.6) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 78 (2.2) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 31 (0.9) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) - 8-13” (19.9-32.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 9.4/3.2 9.2/4.8 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum nominal

heat input

°F ( °C) 145/133 (63/56) 145/133 (63/56)

Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal heat input

°F ( °C) 115/90 (46/32) 115/90 (46/32)

CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 39 ≤ 39 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 132(60) 132(60) Maximum overall dimensions W x H x D inch

(mm)

15/

x 41

x 21

557 x 1048 x 555

15/

x 41

x 21

557 x 1048 x 555

18 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.13 Technical data heating boiler KBR 28-3

Input/Output Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 100,800 (29.5) 98,600 (28.9) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 89,400 (26.2) 89,400 (26.2) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 24,600 (7.2) 40,100 (11.7) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 23,900 (7.0) 39,900 (11.7) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 23,900 (7.0) 39,600 (11.6) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 21,800 (6.4) 36,200 (10.6) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 99 (2.8) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 39 (1.1) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) - 8-13” (19.9-32.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 12.0/3.2 11.6/4.8 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input

°F ( °C) 147/133 (64/56) 147/133 (64/56)

Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal heat input

°F ( °C) 117/90 (47/32) 117/90 (47/32)

CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 39 ≤ 39 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 132(60) 132(60) Maximum overall dimensions W x H x D inch

(mm)

15/

x 41

x 21

557 x 1048 x 555

15/

x 41

x 21

557 x 1048 x 555

Information about the appliance | 19

6 720 810 590 (2015/05)

Greenstar FS

3.14 Technical data heating boiler KBR 35-3

Input/Output Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 131,900 (38.6) 129,100 (37.8) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 122,800 (36.0) 122,800 (36.0) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 121,800 (35.7) 121,800 (35.7) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 116,700 (34.2) 116,700 (34.2) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 36,000 (10.5) 46,400 (13.6) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 35,100 (10.3) 46,100 (13.5) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 34,800 (10.2) 45,700 (13.4) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 31,700 (9.3) 42,000 (12.3) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 130 (3.7) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 52 (1.5) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) - 8-13” (19.9-32.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 15.7/4.5 15.2/5.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input

°F ( °C) 162/135 (72/57) 162/135 (72/57)

Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal heat input

°F ( °C) 127/91 (53/33) 127/91 (53/33)

CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 44 ≤ 44 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 132(60) 132(60) Maximum overall dimensions W x H x D inch

(mm)

15/

x 41

x 21

557 x 1048 x 555

15/

x 41

x 21

557 x 1048 x 555

20 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.15 Technical data heating boiler KBR 42-3

Input/Output at elevation 0 - 2000 feet (0 - 610 metres) Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 151,600 (44.4) 148,300 (43.5) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 134,400 (39.4) 134,400 (39.4) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 36,000 (10.5) 46,400 (13.6) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 35,500 (10.4) 46,400 (13.6) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 35,100 (10.3) 46,100 (13.5) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 31,700 (9.3) 24,000 (12.3) Input/Output at elevation 2000 - 4500 feet ( 611 - 1372 metres) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 136,440 (40.0) 139,402 (40.9) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 120,960 (35.3) 126,336 (37.0) Input/Output at elevation 4500 - 7000 feet (1373 - 2134 metres) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 125,828 (36.9) 129,021 (37.8) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 111,552 (32.7) 116,928 (34.3) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 149 (4.2) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 59 (1.7) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) 8-13” (19.9-32.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 18.0/4.5 17.5/5.6 Flue gas temperature 176/140 °F (80/60 °C) at maximum/minimum

nominal heat input

°F ( °C) 171/135 (77/57) 171/135 (77/57)

Flue gas temperature 104/86 °F (40/30 °C) at maximum/minimum nominal heat input

°F ( °C) 133/91 (56/33) 133/91 (56/33)

CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 45 ≤ 45 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 132(60) 132(60) Maximum overall dimensions W x H x D inch

(mm)

15/

x 41

x 21

557 x 1048 x 555

15/

x 41

x 21

557 x 1048 x 555

Information about the appliance | 21

6 720 810 590 (2015/05)

Greenstar FS

3.16 Technical data combi boiler KWB 28-3

Input/Output Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 100,800 (29.5) 98,600 (28.9) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 93,800 (27.5) 93,800 (27.5) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 93,100 (27.3) 93,100 (27.3) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 89,400 (26.2) 89,400 (26.2) Output rate domestic hot water (DHW) 113 °F (45 °C) BTU/hr (kW) 93,600 (27.4) 93,600 (27.4) Output rate domestic hot water (DHW) 140 °F (60 °C) BTU/hr (kW) 91,400 (26.8) 91,400 (26.8) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 24,600 (7.2) 40,100 (11.7) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 23,900 (7.0) 39,900 (11.7) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 23,900 (7.0) 39,600 (11.6) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 21,800 (6.4) 36,200 (10.6) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 99 (2.8) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 39 (1.1) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) 8-13” (19.9-32.3) Expansion vessel Pre-charge pressure psi (bar) 10.9 (0.75) 10.9 (0.75) Total contents Gal (L) 3.17 (12) 3.17 (12) DHW Max. DHW flow rate gpm (l/min) 2.64 (10) 2.64 (10) Nominal DHW flow rate (at 140 °F (60 °C) outlet temperature) gpm (l/min) 2.03 (7.7) 2.03 (7.7) Outlet temperature °F ( °C) 104 - 140 (40 - 60) 104 - 140 (40 - 60) Max. cold water inlet temperature °F ( °C) 140 (60) 140 (60) Max. approved DHW pressure psi (bar) 150 (10.3) 150 (10.3) Minimum water pressure psi (bar) 4.35 (0.3) 4.35 (0.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 12.0/3.2 11.7/4.9 Flue gas temperature 176/140 °F (80/60 °C) at max./min. nominal heat input °F ( °C) 147/133 (64/56) 147/133 (64/56) Flue gas temperature 104/86 °F (40/30 °C) at max./min. nominal heat input °F ( °C) 117/90 (47/32) 117/90 (47/32) CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 39 ≤ 39 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 136.5(62) 136.5(62) Maximum overall dimensions W x H x D inch

(mm)

11/

x 41

x 21

602 x 1048 x 555

11/

x 41

x 21

602 x 1048 x 555

22 | Information about the appliance

Greenstar FS

6 720 810 590 (2015/05)

3.17 Technical data combi boiler KWB 35 - 3

Input/Output Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 131,900 (38.6) 129,100 (37.8) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 122,800 (36.0) 122,800 (36.0) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 121,800 (35.7) 121,800 (35.7) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 116,700 (34.2) 116,700 (34.2) Output rate domestic hot water (DHW) 113 °F (45 °C) BTU/hr (kW) 120,500 (35.3) 120,500 (35.3) Output rate domestic hot water (DHW) 140 °F (60 °C) BTU/hr (kW) 118,700 (34.8) 118,700 (34.8) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 36,000 (10.5) 46,400 (13.6) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 35,100 (10.3) 46,100 (13.5) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 34,800 (10.2) 45,700 (13.4) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 31,700 (9.3) 42,000 (12.3) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 130 (3.7) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 52 (1.5) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) 8-13” (19.9-32.3) Expansion vessel Pre-charge pressure psi (bar) 10.9 (0.75) 10.9 (0.75) Total contents Gal (L) 3.17 (12) 3.17 (12) DHW Max. DHW flow rate gpm (l/min) 3.17 (12) 3.17 (12) Nominal DHW flow rate (at 140 °F (60 °C) outlet temperature) gpm (l/min) 2.6 (10) 2.6 (10) Outlet temperature °F ( °C) 104 - 140 (40 - 60) 104 - 140 (40 - 60) Max. cold water inlet temperature °F ( °C) 140 (60) 140 (60) Max. approved DHW pressure psi (bar) 150 (10.3) 150 (10.3) Minimum water pressure psi (bar) 4.35 (0.3) 4.35 (0.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 15.7/4.5 15.2/5.6 Flue gas temperature 176/140 °F (80/60 °C) at max./min. nominal heat input °F ( °C) 162/135 (72/57) 162/135 (72/57) Flue gas temperature 104/86 °F (40/30 °C) at max./min. nominal heat input °F ( °C) 127/91 (53/33) 127/91 (53/33) CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 44 ≤ 44 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 136.5(62) 136.5(62) Maximum overall dimensions W x H x D inch

(mm)

11/

x 41

x 21

602 x 1048 x 555

11/

x 41

x 21

602 x 1048 x 555

Information about the appliance | 23

6 720 810 590 (2015/05)

Greenstar FS

3.18 Technical data combi boiler KWB 42 - 3

Input/Output Unit NG LPG (Propane)

Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 151,600 (44.4) 148,300 (43.5) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 134,400 (39.4) 134,400 (39.4) Output rate domestic hot water (DHW) 113 °F (45 °C) BTU/hr (kW) 137,500 (40.3) 137,500 (40.3) Output rate domestic hot water (DHW) 140 °F (60 °C) BTU/hr (kW) 135,800 (39.8) 135,800 (39.8) Min. input rate 180/79 (82/26 °C) BTU/hr (kW) 36,000 (10.5) 46,400 (13.6) Min. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 35,500 (10.4) 46,400 (13.6) Min. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 35,100 (10.3) 46,100 (13.5) Min. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 31,700 (9.3) 42,000 (12.3) Input/Output at elevation 2000 - 4500 feet ( 611 - 1372 metres) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 136,440 (40.0) 139,402 (40.9) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 123,750 (36.3) 129,250 (37.9) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 120,960 (35.5) 126,336 (37.0) Output rate domestic hot water (DHW) 113 °F (45 °C) BTU/hr (kW) 123,750 (36.3) 129,750 (37.9) Output rate domestic hot water (DHW) 140 °F (60 °C) BTU/hr (kW) 122,220 (35.8) 127,652 (37.4) Input/Output at elevation 4500 - 7000 feet (1373 - 2134 metres) Max. input rate 180/79 °F (82/26 °C) BTU/hr (kW) 125,828 (36.9) 129,021 (37.8) Max. output rate 104/86 °F (40/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1) Max. output rate 122/86 °F (50/30 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1) Max. output rate 176/140 °F (80/60 °C) BTU/hr (kW) 111,552 (32.7) 116,928 (34.3) Output rate domestic hot water (DHW) 113 °F (45 °C) BTU/hr (kW) 114,125 (33.5) 119,625 (35.1) Output rate domestic hot water (DHW) 140 °F (60 °C) BTU/hr (kW) 112,714 (33.0) 118,148 (34.6) Gas connection value Natural gas - Hs = 1,010 BTU/ft3 (37.3 MJ/m3)ft

/hr (m3/h) 149 (4.2) -

Liquid Propane Gas - HD-S = 2,500 BTU/ft3 (93.1 MJ/m3)ft

/hr (m3/h) - 59 (1.7) Permissible gas inlet pressure NG in. W.C. (mbar) 3.5-10.5” (8.7-26.1) LPG (Propane) in. W.C. (mbar) - 8-13” (19.9-32.3) Expansion vessel Pre-charge pressure psi (bar) 10.9 (0.75) 10.9 (0.75) Total contents Gal (L) 3.17 (12) 3.17 (12) DHW Max. DHW flow rate gpm (l/min) 3.963 (15) 3.963 (15) Nominal DHW flow rate (at 140 °F (60 °C) outlet temperature) gpm (l/min) 3.61 (11.4) 3.61 (11.4) Outlet temperature °F ( °C) 104 - 140 (40 - 60) 104 - 140 (40 - 60) Max. cold water inlet temperature °F ( °C) 140 (60) 140 (60) Max. approved DHW pressure psi (bar) 150 (10.3) 150 (10.3) Minimum water pressure psi (bar) 4.35 (0.3) 4.35 (0.3) Flue gas Flue gas mass flow at maximum/minimum nominal output gps 18.0/4.5 17.5/5.6 Flue gas temperature 176/140 °F (80/60 °C) at max./min. nominal heat input °F ( °C) 171/135 (77/57) 171/135 (77/57) Flue gas temperature 104/86 °F (40/30 °C) at max./min. nominal heat input °F ( °C) 133/91 (56/33) 133/91 (56/33) CO2 at maximum nominal output % 9.4 11.0 CO2 at minimum nominal output % 8.6 10.4 Condensate Maximum condensate quantity (tR = 86 °F (30 °C)) gph (i/h) 0.32 (1.2) 0.32 (1.2) pH level approx. 4.8 4.8 General

24 | Regulations

Greenstar FS

6 720 810 590 (2015/05)

3.19 Condensate composition

The condensate volume and ingredients may change with regionally and seasonally varying gas quality and air quality. Typically the following ingredients and concentrations can be expected:

4Regulations

4.1 Compliance with standards and regulations

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI Z223.1./NFPA 54. In Canada, installation must be in accordance with the requirements of CAN/CSA B149.1, Natural Gas and Propane Installation Code.

This floor standing condensing gas boiler complies in its design and mode of operation with the American National Standard ANSI Z21.13/ CSA4.9, latest edition for Gas Fired Low Pressure Steam and Hot Water Boilers.

Other confirmed approvals and certifications are indicated by labels on the boiler.

Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. Install CO detectors per local regulations. Boiler requires yearly maintenance ( chapter 15, page 65).

4.2 Operating limits of the boiler

The heat exchanger has been designed and certified in accordance with the ASME Boiler and Pressure Vessel Code, Section IV.

The hot water distribution system must comply with all applicable codes and regulations. When replacing an existing boiler, it is important to check the condition of the entire hot wate r distribution system to ensure safe operation. Common practice calls for inspecting an existing system in its entirety and bringing it up to code. All pipe work should be properly cleaned and flushed.

Voltage Vac 120 120 Frequency Hz 60 60 Max. power consumption (central heating mode) W 205 205 Max. power consumption (standby mode) W <6 <6 Sound pressure level dB (A) ≤ 45 ≤ 45 Max. supply temperature °F ( °C) 190 (88) 190 (88) Max. permissible operating pressure (PMS) heating psi (bar) 30 (2.07) 30 (2.07) Permissible ambient temperature °F ( °C) 32 - 122 (0 - 50) 32 - 122 (0 - 50) Nominal water capacity (heating) Gal (L) 0.925 (3.5) 0.925 (3.5) Weight (without packaging) lbs (kg) 136.5(62) 136.5(62) Maximum overall dimensions W x H x D inch

(mm)

11/

x 41

x 21

602 x 1048 x 555

11/

x 41

x 21

602 x 1048 x 555

Input/Output Unit NG LPG (Propane)

Substance Value in ppm (mg/l)

Ammonium 1.2 Lead ≤ 0.01 Cadmium ≤ 0.001 Chrome ≤ 0.005 Halogenated hydrocarbons ≤ 0.002 Hydrocarbons 0.015 Copper 0.028 Nickel ≤ 0.1 Mercury ≤ 0.0001 Sulfate 1 Zinc ≤ 0.015 Tin ≤ 0.01 Vanadium ≤ 0.001 pH-value 4.8

Table 2 Typical condensate composition

Observe all rules, regulations, standards and guidelines applicable to the installation and operation of this appliance according to local, state and federal regulations.

In the Commonwealth of Massachusetts, this appliance must be installed by a licensed plumber and gas fitter. Valves external to the boiler must be fitted with T-handles and condensate piping must be installed in accordance with the State Plumbing Code.

Maximum boiler temperature 190 °F (88 °C) Maximum operating pressure 30 psi (2.07 bar)

Table 3 Operating limits

Regulations | 25

6 720 810 590 (2015/05)

Greenstar FS

4.3 Additional regulations for installation in Massachusetts

(a) For all side wall horizontally vented gas fueled equipment installed in

every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet [2150 mm] above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

• INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. – In the event that the side wall horizontally vented gas fueled

equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

– In the event that the requirements of this subdivision can not be

met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

• APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NPA 720 and be ANSI/UL 2034 listed and IAS certified.

•SIGNAGE.

A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (½) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

• INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspections, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CRM 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CRM 5.08(2)(a) 1 thru 4:

• The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the board; and

• Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for the installation of the equipment and venting shall include:

• Detailed instructions for the installation of the venting system or the venting system components; and

• A complete parts list for the venting system design or venting system.

(d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases, but identifies special venting systems, the following requirements shall be satisfied by the manufacturer:

• The referenced special venting systems shall be included with the appliance or equipment installation instructions; and

• The special venting systems shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or venting design instructions shall remain with the appliance or equipment at the completion of the installation.

26 | Common Applications of KBR boilers

Greenstar FS

6 720 810 590 (2015/05)

5 Common Applications of KBR boilers

5.1 Multiple zones using zone valves with DHW

Fig. 10 Piping

[1] Supply to heating zone 2 [2] Motorized valve heating zone 2 [3] Supply to heating zone 1 [4] Motorized valve heating zone 1 [5] System pump [6] DHW pump [7] Supply to indirect tank [8] Drain/Bleed point [9] Boiler supply pipe 1¼ " [10] Low Loss Header [11] Heat only boiler [12] Boiler return pipe 1¼ " [13] Return from indirect tank [14] Return from heating zone 1 [15] Return from heating zone 2 [16] Drain/Bleed point [17] Combination fast fill/back flow preventer [18] Expansion (tank) vessel

5.1.1 To utilize the LLH

▶ Switch off and isolate the boiler ▶Drain the boiler ▶ Remove front panel ▶ Locate the LLH at the left-hand side of the lower section of the boiler

1. Unscrew the cap [a] from the body of the LLH [c] – This will break the label across the cap and body indicating that

the LLH has been employed

2. Withdraw the cap [a] and plunger assembly [b]

3. Unscrew the plunger assembly [b] from the cap [a],

4. Set the plunger assembly [b] aside

5. Re-fit the cap [a] without the plunger assembly [b]

6. Tighten the cap [a] and ensure it is secure.

Fig. 11 Utilizing the LLH

6720810590-15.1Wo

1 3 7

13 14 15

6720811590-37.1Wo

Common Applications of KBR boilers | 27

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Greenstar FS

5.1.2 Wiring - Multi zone with zone valves and LWCO

Fig. 12 Wiring

[1] High Voltage connection box [1a] 120 V AC mains power (white plug) [1b] DHW Storage tank circulator pump (red plug) [1c] System circulator pump (black plug) [2] Low Voltage connection box [2d] BUS EMS connection [2e] TT - Thermostat/On demand signal (pre-wired link) (dry signal) [2f] Out Sen - (Outdoor sensor, sold separately) [2g] LWCO - (pre-wired link) (Low Water Cut Off switch, sold

separately) [2h] DHW Sen - (Tank sensor) [2k] Empty (future connectivity) [3] CZM100 (Comfort Zone Manager 100) [4] PZ1 - System pump [5] VZ1, VZ2 - Zone valves [6] 24V Transformer [7] CRC100 or CRC200 Zone 1 (Comfort room controller) [8] CRC100 or CRC200 Zone 2 (Comfort room controller)

When using CZM100 and CRC100 or CRC200 controls the factory installed jumper at terminal [2e] remains.

The LWCO jumper on terminal [2g] is removed when using a LWCO. For LWCO function an external transformer is required

6720810590-72 .1Wo

BUSBUS

1212

BUS BUS

1 2

≤ 24 V

120VAC

120V AC

N NL NLL

PZ2 PZ3PZ1

1212

24VAC

3412

VZ1

3412

VZ2

34 12

VZ3

≤ 24 V

PZ1

DHW Tank Pump

Rear of Greenstar boiler

120 V AC

VZ1MVZ2

213

CZM100

1234

24 V AC

120 V AC

BUS

out sen

DHW sen

LWCO

BUS

Out Sen

DHW Sen

LWC O

f k

28 | Common Applications of KBR boilers

Greenstar FS

6 720 810 590 (2015/05)

5.2 Multiple zones using circulators with DHW

Fig. 13 Piping

[1] Supply to heating zone 2 [2] Pump heating zone 2 [3] Supply to heating zone 1 [4] Pump heating zone 1 [5] Supply to indirect tank [6] DHW pump [7] Drain/Bleed point [8] Boiler supply pipe 1¼ " [9] Low Loss Header [10] Heat only boiler [11] Boiler return pipe 1¼ " [12] Return from indirect tank [13] Return from heating zone 1 [14] Return from heating zone 2 [15] Grain/Bleed point x3 [16] Combination fast fill/back flow preventer [17] Expansion (tank) vessel

5.2.1 To utilize the LLH

▶ Switch off and isolate the boiler ▶Drain the boiler ▶ Remove front panel ▶ Locate the LLH at the left-hand side of the lower section of the boiler

1. Unscrew the cap [a] from the body of the LLH [c] – This will break the label across the cap and body indicating that

the LLH has been employed

2. Withdraw the cap [a] and plunger assembly [b]

3. Unscrew the plunger assembly [b] from the cap [a],

4. Set the plunger assembly [b] aside

5. Re-fit the cap [a] without the plunger assembly [b]

6. Tighten the cap [a] and ensure it is secure.

Fig. 14 Utilizing the LLH

6720810590-16.1Wo

1 3 5

12 13 14

2 4 6

6720811590-37.1Wo

Common Applications of KBR boilers | 29

6 720 810 590 (2015/05)

Greenstar FS

5.2.2 Wiring

Fig. 15 Wiring

separately) [2h] DHW Sen - (Tank sensor) [2k] Empty (future connectivity) [3] CZM100 (Comfort Zone Manager 100) [4] PZ1, PZ2 - Zone circulator pumps [5] CRC100 or CRC200 Zone 1 (Comfort room controller) [6] CRC100 or CRC200 Zone 2 (Comfort room controller)

When using CZM100 and CRC100 or CRC200 controls the factory installed jumper at terminal [2e] remains.

The LWCO jumper on terminal [2g] is removed when using a LWCO. For LWCO function an external transformer is required

BUSBUS

1212

BUS BUS

1 2

≤ 24 V

120VAC

120V AC

NNLNLL

PZ2 PZ3PZ1

121

1 2

24VAC

3 41 2

VZ1

3 41 2

VZ2

3 4 1 2

VZ3

≤ 24 V

PZ1

DHW Tank Pump

Rear of Greenstar boiler

120 V AC

CZM100

1234

BUS

out sen

DHW sen

LWCO

BUS

Out Sen

DHW Sen

LWC O

f k

PZ2

6720810590-71 .1Wo

30 | Installation

Greenstar FS

6 720 810 590 (2015/05)

6 Installation

6.1 Installation and operation

When installing and operating the heating system observe the following:

• The elevation of the installation location above sea level must be taken into account ( Chapter 12.2).

• Follow all local building regulations regarding the installation conditions on site.

• The local building regulations regarding air supply and venting systems and the chimney flue connection.

• Electrical code requirements for connection to the electrical power supply.

• The technical regulations of the gas company regarding the connection of the gas burner to the local gas main.

• The regulations and standards relating to the DHW heating system.

6.1.1 Notes on installation and operation

Fill and make-up water for the heating system

Unsuitable fill and make-up water can result in the heating system scaling up or failing prematurely.

Recommended steps for commissioning a new or retrofit boiler installation

▶ Flush the system with clean water. ▶ Isolate the boiler, fill the system with fresh water and a boiler cleaner,

run for 30 minutes to 1 hour. Under no circumstances may boiler cleaner be pumped through the boiler.

▶ Thoroughly flush the system with fresh water. Ensure all zones and

loops are flushed.

▶ Empty out sediment traps. ▶ Systems containing antifreeze not approved by Bosch, must be

completely flushed to ensure no old fluid remains.

▶ Fill the system with fresh water and the proper amount of inhibitor. ▶ Verify the pH is within the proper range. ▶ Add additional inhibitor if pH is not within the proper range. ▶ Check pH annually. ▶ If using antifreeze, fill with approved antifreeze and fresh water. ▶ Always follow the cleaner, antifreeze, or additive manufacturer’s

instructions.

▶ Do not mix different manufacturer’s products ▶ Follow manufacturer’s data to determine the anti-freeze ratio for the

desired freeze protection temperature.

Recirculation pump/DHW recirculation lines

Electrical connection of the DHW recirculation pump ( page 46). Connect the DHW recirculation line as close as possible to the cold water

inlet on the appliance.

Open vented heating systems

▶ Convert open vented heating systems into closed systems.

Gravity heating systems

▶ Connect the appliance to the existing piping system via an external

low-loss header with a sludge separator, refer to XXXX.

Galvanized radiators or pipes.

To prevent gas formation:

▶ Do not use galvanized radiators or pipes.

Plastic pipe work

If using plastic pipe work for the heating system (eg.underfloor/radiant heating), the type of pipe that should be used must be oxygen tight.

Use of a room temperature control

▶ Do not install thermostatic valves on radiators in the primary room.

Primary-secondary piping or a Low Loss Header (LLH)

Typically all multi zone applications with any combination of emitters like baseboard, panel radiator or radiant would require primary secondary piping or a low loss header for hydraulic separation.

In addition to that some larger single zone applications exceeding a flow rate of 4.0 gpm requires primary secondary piping or a low loss header to achieve hydraulic balance.

A Low Loss Header is used to achieve hydraulic balance on either side of the appliance, using the lowest pump speed that delivers heat to all the radiators in the system.

Radiant floor, panel radiator, multi zone and application systems exceeding 70' (21 m) of 3/4" baseboard at a 20°F delta T and a flow rate of 4.0 gpm plus the necessary supply and return piping, require primarysecondary piping or a low loss header for hydraulic separation of the system from the boiler.

DANGER: Explosion! ▶ Close the gas cock prior to working on the gas train. ▶ Check for gas leaks after c arrying out work on the gas

train.

Installation, power connection, connection on the gas and flue gas side and commissioning must only be carried out by a contractor certified for such work by the state or local jurisdiction or the local gas or power utility.

Transportation blank plugs ▶ Remove the blanking plugs from the appliance water

connections. There may be some water present from the appliance testing.

Total length DHW/recirculation line Flow rate

≤ 33 ft (10 m) 0.66 gpm (2.5 l/min) 33 - 66 ft (10 - 20 m) 0.92 gpm (3.5 l/min) 66 - 98 ft (20 - 30 m) 1.32 gpm (5 l/min)

Table 4 Recommended flow rates

Use service function 6.d, to determine the current flow rate ( page 60).

Enable the integrated Low Loss Header if hydraulic separation is required and not already provided by a configuration external to the appliance.

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