Bosch KBR42-3A Installation And Maintenance Instructions For Contractors

Contents
Greenstar FS/Combi FS – 6 720 810 590 (2020/04)
2
Contents
1 Symbols and Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.1 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . 4
2 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 KBR - Residential boiler for space heating and
loading of indirect fired DHW tanks . . . . . . . . . . . . . . . . . 6
2.2 KWB - Residential combi boiler for space heating
and DHW generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Information about the appliance. . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Overview of boiler types . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Product dimensions and minimum clearances . . . . . . . . 8
3.7 Appliance layout heating boiler KBR..-3A . . . . . . . . . . . 10
3.8 Appliance layout combi boiler KWB..-3A. . . . . . . . . . . . 12
3.9 Electrical wiring heating boiler KBR..-3A. . . . . . . . . . . . 14
3.10 Electrical wiring Combi boiler KWB..-3A . . . . . . . . . . . . 16
3.11 Technical data - Heating boiler KBR 16-3 . . . . . . . . . . . 18
3.12 Technical data heating boiler KBR21-3 . . . . . . . . . . . . . 19
3.13 Technical data heating boiler KBR 28-3. . . . . . . . . . . . . 20
3.14 Technical data heating boiler KBR 35-3. . . . . . . . . . . . . 21
3.15 Technical data heating boiler KBR 42-3. . . . . . . . . . . . . 22
3.16 Technical data combi boiler KWB 28-3 . . . . . . . . . . . . . 23
3.17 Technical data combi boiler 35-3. . . . . . . . . . . . . . . . . . 24
3.18 Technical data combi boiler KWB 42-3 . . . . . . . . . . . . . 25
3.19 Condensate composition . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Compliance with standards and regulations . . . . . . . . . 26
4.2 Operating limits of the boiler . . . . . . . . . . . . . . . . . . . . . 27
4.3 Additional regulations for installations in the
Commonwealth of Massachusetts . . . . . . . . . . . . . . . . . 27
5 Common applications of KBR boilers . . . . . . . . . . . . . . . . . . . . 28
5.1 Multiple zones using zone valves with DHW. . . . . . . . . . 28
5.1.1 Utilizing the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.2 Wiring - Multi zone with zone valves and LWCO. . . . . . . 29
5.2 Multiple zones using circulators with DHW . . . . . . . . . . 30
5.2.1 To utilize the LLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.2 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.1 Other important information . . . . . . . . . . . . . . . . . . . . . 33
6.1.2 Water supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Comparing the size of the integrated expansion
vessel (KWB-3A boiler only) . . . . . . . . . . . . . . . . . . . . . . 34
6.3 KBR..-3A appliances (heating boilers): Selecting
an expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4 Selecting the installation location . . . . . . . . . . . . . . . . . 34
6.5 Selecting the installation location . . . . . . . . . . . . . . . . . 35
6.6 Low Loss Header (LLH) utilization . . . . . . . . . . . . . . . . . 35
6.6.1 To utilize the LLH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.7 Locating the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.7.1 Positioning the appliance . . . . . . . . . . . . . . . . . . . . . . . . 36
6.8 Installing a Low Water Cut off (LWCO). . . . . . . . . . . . . . 36
6.9 Connecting the flue gas accessories . . . . . . . . . . . . . . . 38
6.9.1 Installation of the exhaust and air intake . . . . . . . . . . . . 39
6.9.2 Approved examples of horizontal and vertical
venting installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.9.3 Vent and combustion pipe lengths. . . . . . . . . . . . . . . . . 46
6.10 Testing gas and water connections for leaks . . . . . . . . . 47
7 Elecrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1 Electrical connections in the junction boxes . . . . . . . . . 47
7.1.1 Access to junction boxes . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1.2 Connecting the BUS-System . . . . . . . . . . . . . . . . . . . . . 47
7.1.3 High voltage junction box . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1.4 Connecting an external heating zone pump or
DHW recirculation pump . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1.5 DHW tank loading pump or 3-way valve with spring
return (only heating boilers KBR..-3A . . . . . . . . . . . . . . 48
7.1.6 Connecting mains power supply . . . . . . . . . . . . . . . . . . 49
7.1.7 Low voltage (LV) junction box . . . . . . . . . . . . . . . . . . . . 49
7.1.8 DHW tank temperature sensor connection . . . . . . . . . . 50
7.1.9 Connecting the LWCO device. . . . . . . . . . . . . . . . . . . . . 50
8 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1 Before operating the appliance . . . . . . . . . . . . . . . . . . . 51
8.2 Switching the appliance ON/OFF. . . . . . . . . . . . . . . . . . 51
8.3 Setting up space heating . . . . . . . . . . . . . . . . . . . . . . . . 52
8.4 Programming the Bosch room controller. . . . . . . . . . . . 52
8.5 After commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.6 KBR..-3A appliances (heating boilers) with DHW
tank: Setting the DHW temperature. . . . . . . . . . . . . . . . 53
8.7 KWB..-3A appliances (combi boilers): Setting the
DHW temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.8 Setting manual summer mode . . . . . . . . . . . . . . . . . . . . 53
8.9 Setting frost protection . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.10 Activating the key pad lock. . . . . . . . . . . . . . . . . . . . . . . 54
9 KBR...3A appliances with DHW tank: Thermal
disinfection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10 Boiler circulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.1 Pump anti-seize protection . . . . . . . . . . . . . . . . . . . . . . 55
10.2 Changing the pump curve of the boiler pump . . . . . . . . 55
11 Heatronic boiler control settings . . . . . . . . . . . . . . . . . . . . . . . 56
11.1 Guideline to service functions . . . . . . . . . . . . . . . . . . . . 56
11.2 Overview of service functions . . . . . . . . . . . . . . . . . . . . 56
11.2.1 First service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Bosch KBR42-3A Specifications

General

Brand	Bosch
Model	KBR42-3A
Category	Boiler
Language	English