Bosch KBR42-3A - Installation And Maintenance Instructions For Contractors Manual

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

Main Page

Default Chapter2
- Table of Contents2
Contents3
1 Symbols and Safety Instructions4
- Explanation of Symbols4
- General Safety Instructions4
2 Scope of Delivery6
- KBR - Residential Boiler for Space Heating and Loading of Indirect Fired DHW Tanks6
- KWB - Residential Combi Boiler for Space Heating and DHW Generation6
3 Information about the Appliance6
- Fig. 16
- Proper Use7
- Overview of Boiler Types7
- Rating Plate7
- Appliance Description7
- Accessories7
- Product Dimensions and Minimum Clearances8
- Ø18
- Ø28
- Appliance Layout Heating Boiler KBR10
- Heating Return11
- Heating Supply11
- Appliance Layout Combi Boiler KWB12
- Electrical Wiring Heating Boiler KBR14
- Electrical Wiring Combi Boiler KWB16
- Technical Data - Heating Boiler KBR 16-318
- Table 418
- Technical Data Heating Boiler KBR21-319
- Technical Data Heating Boiler KBR 28-320
- Technical Data Heating Boiler KBR 35-321
- Technical Data Heating Boiler KBR 42-322
- Technical Data Combi Boiler KWB 28-323
- Technical Data Combi Boiler 35-324
- Technical Data Combi Boiler KWB 42-325
- Condensate Composition26
4 Regulations26
- Compliance with Standards and Regulations26
- Operating Limits of the Boiler27
- Additional Regulations for Installations in the Commonwealth of Massachusetts27
5 Common Applications of KBR Boilers28
- Multiple Zones Using Zone Valves with DHW28
- Utilizing the LLH28
- Wiring - Multi Zone with Zone Valves and LWCO29
- Multiple Zones Using Circulators with DHW30
- To Utilize the LLH30
- Wiring31
6 Installation32
- Important Notes32
- Other Important Information33
- Water Supply Pressure33
- Comparing the Size of the Integrated Expansion Vessel (KWB-3A Boiler Only)34
  - Kbr34
- Selecting the Installation Location34
- Selecting the Installation Location35
- Low Loss Header (LLH) Utilization35
- To Utilize the LLH35
- Locating the Appliance36
- Positioning the Appliance36
- Installing a Low Water Cut off (LWCO)36
- Connecting the Flue Gas Accessories38
- Installation of the Exhaust and Air Intake39
- Approved Examples of Horizontal and Vertical Venting Installations43
- Vent and Combustion Pipe Lengths46
- Testing Gas and Water Connections for Leaks47
7 Elecrical Connection47
- Electrical Connections in the Junction Boxes47
- Access to Junction Boxes47
- Connecting the BUS-System47
- High Voltage Junction Box48
- Connecting an External Heating Zone Pump or DHW Recirculation Pump48
- DHW Tank Loading Pump or 3-Way Valve with Spring Return48
- Connecting Mains Power Supply49
- Low Voltage (LV) Junction Box49
- DHW Tank Temperature Sensor Connection50
- Connecting the LWCO Device50
8 Commissioning51
- Before Operating the Appliance51
- Switching the Appliance ON/OFF51
- Setting up Space Heating52
- Programming the Bosch Room Controller52
- After Commissioning52
- Kbr53
  - Tank: Setting the DHW Temperature53
- Kwb53
  - DHW Temperature53
- Setting Manual Summer Mode53
- Setting Frost Protection54
- Activating the Key Pad Lock54
9 Kbr54
- Disinfection54
10 Boiler Circulator55
- Pump Anti-Seize Protection55
- Changing the Pump Curve of the Boiler Pump55
11 Heatronic Boiler Control Settings56
- Guideline to Service Functions56
- Overview of Service Functions56
- 11.2.1 First Service Level56
- Second Service Level57
- Description of the Service Functions57
- 11.3.1 First Level Service57
- 11.3.2 Second Service Level61
12 Gas Type Conversion62
- Installation Location Higher than 2,000 Feet (610M) above Sea Level63
- Setting the Gas/Air Ratio (CO2 or O2)63
- Dynamic Gas Pressure Test64
13 Flue Gas Test65
- Emissions Test Button65
- Measuring CO Content of the Flue Gas65
14 Environmental Protection66
- Environmental Protection and Disposal66
15 Inspection and Maintenance66
- Description of Various Steps66
- Calling up the Latest Fault (Service Function 6.A)66
- 15.1.2 Fresh Water Filter in the Cold Water Pipe66
- Plate Type Heat Exchanger (Only Combi Boiler KWB66
- 15.1.4 Checking the Electrodes68
- 15.1.5 Burner Servicing68
- 15.1.6 Heat Exchanger Block Inspection and Cleaning69
- 15.1.7 Cleaning Condensate Trap70
- 15.1.8 Checking the Mixer Diaphragm70
- 15.1.9 Expansion Vessel71
- 15.1.10 Setting the Boiler Water Pressure71
- 15.1.11 Testing System Water Quality71
- 15.1.12 Checking the Electrical Wiring71
- Checklist for Annual Inspection and Maintenance72
16 Display73
- Readings on the Display73
17 Faults74
- Troubleshooting74
- Faults that Are Shown on the Display75
- Faults that Are Not Shown on the Display77
- Check Sensor Values78
- Outdoor Temperature Sensor78
- Accessory)78
- 17.4.2 Additional Supply Temperature Limiter78
- Supply Temperature Sensor, DHW Temperature Sensor, External Supply Temperature Sensor78
- 17.4.4 Replacement Code Plug78
18 Commissioning Log for the Appliance79
19 Spare Parts81
- Group 1 - Sheet Metal - Greenstar82
- Group 2 - Burner/Heat Exchanger - Greenstar84
- Group 3 - Gas Valve / Fan / Mixing Chamber - Greenstar86
- Group 4 - Pipes Combi Boiler KWB88
- Group 5 Pipes Heat Only Boiler KBR90
  - Greenstar92
- Group 6 - Control Box - Greenstar92
- Group 7 - Hydraulic Block - Combi Boiler KWB94
  - Greenstar94
- Group 8 - Accessories for Service/Installation - Greenstar96

Bosch KBR42-3A - Installation And Maintenance Instructions For Contractors Manual

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