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Bosch Greenstar FS Series User Manual

Bosch Greenstar FS Series
100 pages
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6 720 810 590 (2020/04) CA/US
Installation and Maintenance Instructions for Contractors
Residential Gas Condensing Boiler
Greenstar FS/Combi FS
6720810590-00.2Wo
KBR16-3A | KBR21-3A | KBR28-3A | KBR35-3A | KBR42-3A | KWB28-3A | KWB35-3A | KWB42-3A

Table of Contents

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Bosch Greenstar FS Series Specifications

General IconGeneral
BrandBosch
ModelGreenstar FS Series
CategoryBoiler
LanguageEnglish

Summary

Symbols and Safety Instructions

1.1 Explanation of symbols

Explains the meaning of signal words used in warnings and their associated risks.

1.1.1 General safety instructions

Provides essential safety procedures for gas leaks, smell of gas, and flue gas.

DANGER: Risk of fire when soldering and brazing!

Highlights safety precautions for soldering and brazing near flammable materials.

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

Details safety measures related to flue gas and venting systems to prevent poisoning.

DANGER: Risk of personal injury or death from explosion!

Outlines safety requirements for working with gas components and installation.

DANGER: Risk of personal injury or death from fire!

Warns about combustible materials in the boiler room and clearance requirements.

CAUTION: Appliance damage from contaminated combustion air!

Advises on keeping combustion air free from corrosive substances and dust.

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

Emphasizes disconnecting power before any work and using qualified electricians.

DANGER: Safety devices!

Instructs not to shut off safety valves and warns about hot water escape.

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

States that flooded appliances must be replaced and not operated.

Scope of delivery

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

Details the contents of the package for KBR heating boilers.

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

Details the contents of the package for KWB combi boilers.

Information about the appliance

3.1 Proper use

Specifies that the appliance is for closed-loop hot water heating systems only.

3.2 Overview of boiler types

Explains the meaning of model numbers and appliance types (KBR/KWB).

3.3 Rating plate

Describes the location and information found on the appliance's rating plate.

3.4 Appliance description

Lists key features and components of the appliance, including Heatronic control.

3.5 Accessories

Mentions typical accessories available for the appliance and refers to the product catalog.

3.6 Product dimensions and minimum clearances

Provides detailed dimensions and required clearances for installation.

3.7 Appliance layout heating boiler KBR..-3A

Diagram showing the internal layout and numbered components of the KBR heating boiler.

3.8 Appliance layout combi boiler KWB..-3A

Diagram showing the internal layout and numbered components of the KWB combi boiler.

3.9 Electrical wiring heating boiler KBR..-3A

Wiring diagram for the KBR heating boiler, showing connections and components.

3.10 Electrical wiring Combi boiler KWB..-3A

Wiring diagram for the KWB combi boiler, showing connections and components.

3.11 Technical data - Heating boiler KBR 16-3

Provides detailed technical specifications for the KBR 16-3 heating boiler.

3.12 Technical data heating boiler KBR21-3

Provides detailed technical specifications for the KBR21-3 heating boiler.

3.13 Technical data heating boiler KBR 28-3

Provides detailed technical specifications for the KBR 28-3 heating boiler.

3.14 Technical data heating boiler KBR 35-3

Provides detailed technical specifications for the KBR 35-3 heating boiler.

3.15 Technical data heating boiler KBR 42-3

Provides detailed technical specifications for the KBR 42-3 heating boiler, including altitude adjustments.

3.16 Technical data combi boiler KWB 28-3

Provides detailed technical specifications for the KWB 28-3 combi boiler.

3.17 Technical data combi boiler 35-3

Provides detailed technical specifications for the KWB 35-3 combi boiler.

3.18 Technical data combi boiler KWB 42-3

Provides detailed technical specifications for the KWB 42-3 combi boiler, including altitude adjustments.

3.19 Condensate composition

Lists typical ingredients and concentrations found in boiler condensate.

Regulations

4.1 Compliance with standards and regulations

Outlines compliance with national and local codes, standards, and regulations for installation.

4.2 Operating limits of the boiler

Specifies the maximum boiler temperature and operating pressure limits.

4.3 Additional regulations for installations in the Commonwealth of Massachusetts

Details specific requirements for installations in Massachusetts, including CO detectors and signage.

Common applications of KBR boilers

5.1 Multiple zones using zone valves with DHW

Describes piping configurations for multi-zone systems using zone valves and DHW.

5.1.1 Utilizing the LLH

Step-by-step guide on how to utilize the Low Loss Header (LLH) for hydraulic separation.

5.1.2 Wiring - Multi zone with zone valves and LWCO

Wiring diagram for multi-zone systems with zone valves and LWCO, referencing control modules.

5.2 Multiple zones using circulators with DHW

Describes piping configurations for multi-zone systems using circulators and DHW.

5.2.1 Utilizing the LLH

Step-by-step guide on how to utilize the Low Loss Header (LLH) for hydraulic separation.

5.2.2 Wiring

Wiring diagram for multi-zone systems using circulators, referencing control modules.

Installation

6.1 Important notes

Provides crucial installation notes, including filling the system and recommended commissioning steps.

6.1.1 Other important information

Details important installation considerations like venting, plastic pipework, and room controllers.

6.2 Comparing the size of the integrated expansion vessel (KWB-3A boiler only)

Guides on verifying expansion vessel capacity and determining if an additional vessel is needed.

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

Instructions for selecting an external expansion vessel for KBR heating boilers.

6.4 Selecting the installation location

Provides requirements for selecting the installation location and notes on combustion air.

6.5 Selecting the installation location

Details installation location requirements and notes on combustion air, including corrosive materials.

6.6 Low Loss Header (LLH) utilization

Explains the use of a Low Loss Header (LLH) for hydraulic separation and flow rate management.

6.6.1 To utilize the LLH

Provides step-by-step instructions for utilizing the Low Loss Header (LLH).

6.7 Locating the appliance

Provides instructions for locating and positioning the appliance, including removing the cover.

6.7.1 Positioning the appliance

Details how to level the boiler for proper air escape and condensate drainage.

6.8 Installing a Low Water Cut off (LWCO)

Guides on installing the LWCO device, specifying approved models and requirements.

6.9 Connecting the flue gas accessories

Explains how to connect optional vent systems like twin pipe and concentric venting.

6.9 Using the twin pipe adapter

Instructions for attaching the vent flange and gasket when using the twin pipe adapter.

6.9.1 Installation of the exhaust and air intake

Provides critical safety warnings regarding carbon monoxide poisoning and proper venting.

Direct vent installations (sealed combustion)

Lists essential requirements for direct vent installations, including pipe support and termination clearances.

6.9.2 Approved examples of horizontal and vertical venting installations

Shows approved examples of venting systems and provides installation notes.

6.9.3 Vent and combustion pipe lengths

Details maximum vent and combustion pipe lengths based on appliance, elbows, and pipe type.

Electrical connection

7.1 Electrical connections in the junction boxes

Explains access to installer junction boxes for high and low voltage connections.

7.1.1 Access to junction boxes

Locates the high voltage and low voltage junction boxes for electrical connections.

7.1.2 Connecting the BUS-System

Instructions for connecting Bosch room controls to the boiler's internal BUS system.

7.1.3 High voltage junction box

Details connections for mains power, system circulator pump, and DHW tank circulator pump.

7.1.4 Connecting an external heating zone pump or DHW recirculation pump

Guides connecting external pumps and setting their function via service functions.

7.1.5 DHW tank loading pump or 3-way valve with spring return (only heating boilers KBR..-3A)

Instructions for connecting DHW tank pumps or 3-way valves for KBR heating boilers.

7.1.6 Connecting mains power supply

Details the procedure for connecting the mains power supply cable to the boiler.

7.1.7 Low voltage (LV) junction box

Explains the low voltage junction box connections for sensors, thermostats, and programmers.

Connecting external manual reset high limit or low water cut off (LWCO)

Instructions for connecting external safety switches like high limit or LWCO.

7.1.8 DHW tank temperature sensor connection

Guides on connecting the DHW tank temperature sensor to the low voltage connections.

7.1.9 Connecting the LWCO device

Step-by-step instructions for connecting the LWCO device, including transformer and wiring.

Commissioning

8.1 Before operating the appliance

Provides pre-operation checks, including filling, purging, and gas type verification.

8.2 Switching the appliance ON/OFF

Explains how to switch the appliance on and off using the ON/OFF switch and what the display shows.

8.3 Setting up space heating

Guides on setting the maximum supply temperature based on the building's heat loss.

8.4 Programming the Bosch room controller

Refers to the room controller's operating instructions for setup, mode adjustment, and mounting.

8.5 After commissioning

Lists post-commissioning checks including flue path tightness, gas pressure, and condensate discharge.

8.6 KBR..-3A appliances (heating boilers) with DHW tank: Setting the DHW temperature

Instructions for setting the DHW temperature on the thermostat for KBR heating boilers.

8.7 KWB..-3A appliances (combi boilers): Setting the DHW temperature

Instructions for setting the DHW temperature on the thermostat for KWB combi boilers.

ECO button

Explains DHW priority, alternating operation, and comfort vs. economy modes.

8.8 Setting manual summer mode

Describes setting manual summer mode to switch off heating while keeping DHW active.

8.9 Setting frost protection

Provides procedures for setting frost protection for the heating system and DHW tank.

8.10 Activating the key pad lock

Explains how to activate and unlock the key pad lock to prevent unauthorized access.

9 KBR...3A appliances with DHW tank: Thermal disinfection

Covers thermal disinfection for DHW systems, excluding solar tanks.

WARNING: Risk of scalding!

Warns about scalding risk from hot water and advises on disinfection procedures.

Boiler circulator

10.1 Pump anti-seize protection

Explains the function that prevents the heating zone pump from seizing during idle periods.

10.2 Changing the pump curve of the boiler pump

Guides on how to change the boiler pump speed using the dial on the pump.

Heatronic boiler control settings

11.1 Guideline to service functions

Introduces the Heatronic control and its service functions, divided into two levels.

11.2 Overview of service functions

Provides an overview of available service functions, categorized by first and second service levels.

11.2.1 First service level

Lists and describes service functions from 1.A to 7.E, including their purpose and default settings.

11.3 Description of the service functions

Provides descriptions for specific service functions, including limitations and system requirements.

11.3.1 First level service

Explains how to access and set service functions for maximum outputs and pump modes.

Gas type conversion

Service function A.b: Display DHW temperature

Allows displaying the current DHW temperature.

Service function A.C: Display DHW tank temperature

Allows displaying the temperature of the DHW tank sensor.

Service function b.F: Solar DHW back-up heating delay (only combi boiler KWB..-3A)

Sets DHW heating delay for solar thermal systems to prevent unnecessary boiler operation.

Service function C.d: Display current heat demand

Shows current heat demand status: no demand, space heating, or DHW demand.

DANGER: Personal injury and property damage

Warns about dangers of improper conversion, including fire, explosion, and carbon monoxide.

12.1 Installation location higher than 2,000 feet (610m) above sea level

Explains the derating of input/output rates at higher altitudes and altitude adjustment.

12.2 Setting the gas/air ratio (CO2 or O2)

Guides on setting the gas/air ratio using an electronic flue gas analyzer and test ports.

12.3 Dynamic gas pressure test

Provides instructions for performing a dynamic gas pressure test and checking inlet gas pressure.

Flue gas test

13.1 Emissions test button

Explains how to use the emissions test button to select different output modes for testing.

13.2 Measuring CO content of the flue gas

Guides on measuring CO levels in flue gas, including safety warnings for CO poisoning.

Environmental protection

14.1 Environmental protection and disposal

Highlights Bosch's commitment to environmental protection in product design and packaging.

Inspection and maintenance

15.1 Description of various steps

Introduces the importance of regular service and maintenance for appliance longevity and efficiency.

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

Explains how to access the latest fault code using service function 6.A.

15.1.2 Fresh water filter in the cold water pipe

Guides on how to remove, clean, or replace the fresh water filter in the cold water pipe.

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

Provides instructions for inspecting and descaling or replacing the plate type heat exchanger.

15.1.4 Checking the electrodes

Guides on how to remove, check, and reinstall the electrode set.

15.1.5 Burner servicing

Provides safety warnings regarding burner operation and step-by-step instructions for removing the burner cover.

15.1.6 Heat exchanger block inspection and cleaning

Details the inspection and cleaning procedure for the heat exchanger block, using specific tools.

15.1.7 Cleaning condensate trap

Guides on removing, cleaning, and reinstalling the condensate trap, including filling with water.

15.1.8 Checking the mixer diaphragm

Explains how to open the mixer unit and check the diaphragm for contamination or cracks.

15.1.9 Expansion vessel

Details the annual inspection requirement for the expansion vessel and how to adjust its pre-charge pressure.

15.1.10 Setting the boiler water pressure

Provides a table of operating pressures and guides on topping up water and checking for leaks.

15.1.11 Testing system water quality

Explains how to test system water quality using pH meters and the necessary actions if values are outside the range.

15.1.12 Checking the electrical wiring

Advises on checking electrical wiring for mechanical damage and replacing defective cables.

15.2 Checklist for annual inspection and maintenance

Provides a checklist to guide through the annual service and maintenance procedure, recording findings.

Display

16.1 Readings on the display

Explains the various readings shown on the 7-segment display, including service functions and fault codes.

Faults

17.1 Troubleshooting

Provides basic troubleshooting steps for common hazards like explosion, flue gas poisoning, electric shock, and freezing.

WARNING: Danger of scalding!

Warns about scalding risk from hot water and advises draining the appliance before working on water-filled components.

NOTICE: Risk of system damage from freezing!

Warns about system freezing if disabled by a fault and advises on immediate fault rectification or draining.

NOTICE: The Heatronic boiler control can be damaged by leaking water.

Advises covering the Heatronic control during work on water-filled components and notes audible warnings.

17.2 Faults that are shown on the display

Lists display codes for faults, their descriptions, and elimination steps, covering sensor defects and communication faults.

17.3 Faults that are not shown on the display

Describes common appliance faults not indicated on the display, such as loud combustion noise or flow noises.

17.4 Check sensor values

Provides tables for checking sensor values against resistance or temperature readings.

17.4.4 Replacement code plug

Lists order numbers for replacement code plugs for various appliance models.

Commissioning log for the appliance

Home owner/operator:

Fields to record home owner and operator details.

System installer:

Fields to record system installer details, order number, appliance type, and serial number.

Date commissioned:

Fields for recording commissioning date, installation location, and ventilation openings.

Vent pipe routing:

Checkboxes for vent pipe routing types and length details.

Gas setting and flue gas test:

Section for recording gas type, inlet/static pressures, output settings, and flue gas test results.

System hydraulics:

Checkboxes for system hydraulics, including LLH, heating pump, and DHW tank details.

System hydraulics checked, notes:

Space for notes regarding system hydraulics checks.

Modified service functions:

Section to record modified service functions and their entered values.

Heating control:

Checkboxes for heating control types and notes on settings.

The following work has been carried out:

Checklist for work performed, including electrical connections, condensate trap, function checks, and leak tests.

Name of service engineer

Field for the name of the service engineer.

Date, system installer's signature

Fields for the system installer's signature and date.

Date, user's signature

Field for the user's signature and instruction regarding test report affixing.

Spare parts

19.1 Group 1 - Sheet metal - Greenstar

Lists spare parts for sheet metal components of the Greenstar series.

19.2 Group 2 - Burner/Heat exchanger - Greenstar

Lists spare parts for the burner and heat exchanger components of the Greenstar series.

19.3 Group 3 - Gas valve / Fan / Mixing chamber - Greenstar

Lists spare parts for the gas valve, fan, and mixing chamber of the Greenstar series.

19.4 Group 4 - Pipes combi boiler KWB..3A - Greenstar

Lists spare parts for pipes specific to KWB combi boilers in the Greenstar series.

19.5 Group 5 Pipes Heat only boiler KBR..3A - Greenstar

Lists spare parts for pipes specific to KBR heat-only boilers in the Greenstar series.

19.6 Group 6 - Control box - Greenstar

Lists spare parts for the control box components of the Greenstar series.

19.7 Group 7 - Hydraulic block, Combi boiler KWB..3A - Greenstar

Lists spare parts for the hydraulic block of KWB combi boilers in the Greenstar series.

19.8 Group 8 - Accessories for service/installation - Greenstar

Lists spare parts for accessories used for service and installation of Greenstar appliances.

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