Junkers SUPRAPUR KBR 120-3 A Technical Manual Download Page 80

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Flue systems

6 720 645 817

(2010/09)

11.2.3 Open flue routing via flue inside a chimney shaft (B

)

Fig. 48

Key

Tab. 46

6 720 643 417-30.1O

Open flue operation - observe
Feuerungsverordnung (FeuVO)
[Combustion Order - Germany]

Summary of Contents for SUPRAPUR KBR 120-3 A

Page 1: ...rofessionals Technical guide Gas condensing boiler SUPRAPUR Single boiler Cascade KBR 120 3 A MKB 240 3 A KBR 160 3 A MKB 320 3 A KBR 200 3 A MKB 400 3 A KBR 240 3 A MKB 480 3 A KBR 280 3 A MKB 560 3 A Output range from 28 kW to 560 kW 6 720 645 817 2010 09 ...

Page 2: ...imensions 27 2 3 1 Single appliance Suprapur KBR 27 2 3 2 Factory prepared cascade MKB 28 2 4 Pressure drop water side 29 2 5 Boiler efficiency 30 2 6 Standby loss 30 2 7 Flue gas temperature 31 2 8 Conversion factor for alternative system temperatures 31 3 Appliance layout 32 4 Product description 33 4 1 Gas condensing boiler with aluminium heat exchanger 33 4 1 1 Types and output 33 4 1 2 Possib...

Page 3: ...ries 72 10 1 Connection accessories 72 10 2 Cascade accessories 73 10 3 Other accessories 74 11 Flue systems 75 11 1 Flue system 75 11 1 1 Requirements 75 11 1 2 Plastic flue system 76 11 1 3 Flue gas parameters Suprapur single boiler KBR 77 11 1 4 Flue gas parameters Suprapur factory prepared 2 boiler cascade MKB 77 11 1 5 Sizing plastic flue systems open flue 77 11 2 Flue systems for open flue o...

Page 4: ...ration One unmixed heating circuit Weather compensated controller Features Generally we would recommend the installation of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select a corresponding expansion vessel Æ page 39...

Page 5: ...8 718 577 289 Connection accessories Boiler safety assembly for KBR 120 3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standard sieve DN 50 PN 6 80 9...

Page 6: ...tion of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select a corresponding expansion vessel Æ page 39 Install a mechanical safety limiter TB 1 in accordance with the underfloor heating system manufacturer s instructio...

Page 7: ...fety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standard sieve DN 50 PN 6 80 950 110 Dirt trap with standard sieve DN 65 PN 6 80 950 112 Gas tap R with TAE for KBR 120 3 A 7 747...

Page 8: ...ng circuit DHW cylinder Weather compensated controller Features Generally we would recommend the installation of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select a corresponding expansion vessel Æ page 39 Install a ...

Page 9: ...iler safety assembly for KBR 120 3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standard sieve DN 50 PN 6 80 950 110 Dirt trap with standard sieve DN...

Page 10: ...el One unmixed heating circuit One mixed heating circuit Weather compensated controller Features Generally we would recommend the installation of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select a corresponding expa...

Page 11: ...tion accessories Boiler safety assembly for KBR 120 3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standard sieve DN 50 PN 6 80 950 110 Dirt trap wit...

Page 12: ...alanced flue operation Two mixed heating circuits DHW cylinder Weather compensated controller Features Generally we would recommend the installation of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select a correspondin...

Page 13: ...3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standard sieve DN 50 PN 6 80 950 110 Dirt trap with standard sieve DN 65 PN 6 80 950 112 Gas tap R wit...

Page 14: ...g circuit Two mixed heating circuits Weather compensated controller Features Generally we would recommend the installation of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select a corresponding expansion vessel Æ page ...

Page 15: ...tion accessories Boiler safety assembly for KBR 120 3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standard sieve DN 50 PN 6 80 950 110 Dirt trap wit...

Page 16: ...ng circuit Three mixed heating circuits Weather compensated controller Features Generally we would recommend the installation of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select a corresponding expansion vessel Æ pa...

Page 17: ...iler for natural gas 21 8 718 577 289 Connection accessories Boiler safety assembly for KBR 120 3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standa...

Page 18: ... the heat source 3 Module position on the wall Heating system components Suprapur gas condensing boiler for balanced flue operation Two mixed heating circuits Two DHW circuits Weather compensated controller Features Generally we would recommend the installation of a low loss header on site to ensure reliable transfer of the required heating output The FW weather compensated controller is preferred...

Page 19: ...for natural gas 23 8 718 577 233 KBR 280 3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 289 Connection accessories Boiler safety assembly for KBR 120 3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950...

Page 20: ...lanced flue operation One unmixed heating circuit One DHW circuit Weather compensated controller Cascade switching module Features The on site installation of a low loss header is required to ensure the reliable transfer of the required heating output The FW weather compensated controller is preferred for its higher utilisation of condensing technology Determine the system water content and select...

Page 21: ...for KBR 120 3 A 7 747 003 386 Boiler safety assembly for KBR 160 280 3 A 7 747 003 387 Shut off gate valve set for KBR 120 3 A 7 747 301 389 Shut off gate valve set for KBR 160 280 3 A 7 747 301 390 Dirt trap with fine sieve DN 50 PN 6 80 950 210 Dirt trap with fine sieve DN 65 PN 6 80 950 212 Dirt trap with standard sieve DN 50 PN 6 80 950 110 Dirt trap with standard sieve DN 65 PN 6 80 950 112 G...

Page 22: ...air 50 30 C C 56 32 54 31 55 34 55 33 57 34 Minimum flue gas temperature full load partial load temperature pair 80 60 C C 75 57 75 56 75 59 75 58 75 59 Available draught flue system Pa 100 Type acc to DVGW regulations B23 B23P C53 C63 C93 open flue and balanced flue operation Gas Fan G1G 170 Gas valve Honeywell Kromschröder VR 4615V VR 415VE CG 20 CG 25 CG 25 Gas restrictor diameter Natural gas H...

Page 23: ... 32 54 31 55 34 55 33 57 34 Minimum flue gas temperature full load partial load temperature pair 80 60 C C 75 57 75 56 75 59 75 58 75 59 Available draught flue system Pa 100 Type acc to DVGW regulations B23 B23P C53 C63 C93 open flue and balanced flue operation Gas Fan G1G 170 Gas valve Honeywell Kromschröder VR 4615V VR 415VE CG 20 CG 25 CG 25 Gas restrictor diameter Natural gas H G20 Wobbe index...

Page 24: ...Y VK Y MAG ØAA GAS AL RK AA SV VK MAG 6 720 643 417 24 1O AKO 182 176 176 1515 1400 1 1 680 496 F B 34 15 25 120 Unit KBR 120 3 A MKB 240 3 A KBR 160 3 A MKB 320 3 A KBR 200 3 A MKB 400 3 A KBR 240 3 A MKB 480 3 A KBR 280 3 A MKB 560 3 A B mm 916 1124 1124 1332 1332 ØAA DN 160 160 200 200 200 XAA mm 293 345 397 449 501 YAA mm 470 470 495 495 495 ZAA mm 145 145 310 310 310 F mm 800 1008 1008 1216 1...

Page 25: ...ler cascade AA Flue gas connection AL Combustion air pipe connection balanced flue operation only GAS Gas connection RK Boiler return VK Boiler flow 1 Pump installation point boiler circuit 6 720 643 417 13 1O 717 1 TG TZ 615 1143 1018 YAA ØAA 1 YRK YVK 215 500 O M BG BK S N K XAA XGAS XAL AL GAS VK RK U 1517 R 1 ...

Page 26: ...4 436 488 540 Ø VK DN 65 DN 80 DN 80 DN 100 DN 100 YVK mm 1308 1299 1299 1299 1299 Ø RK DN 65 DN 80 DN 80 DN 100 DN 100 YRK mm 339 5 330 330 330 330 Ø GAS inch R R 1 R 1 R 1 R 1 XGAS mm 270 374 270 374 270 Ø AL DN 100 DN 100 DN 100 DN 100 DN 100 XAL mm 270 374 270 374 270 K mm 327 433 327 431 327 M mm 455 453 663 663 871 N mm 270 375 270 369 270 O mm 518 563 567 619 619 R mm 565 775 773 982 981 S ...

Page 27: ...ngle appliance Suprapur KBR Fig 12 Installed dimensions Suprapur single boiler Minimum handling details A C B D 6 720 644 748 07 1O Dimension Wall clearance in mm A 700 500 B 700 550 C 500 100 D 700 500 Tab 14 Recommended minimum wall clearances Unit KBR 120 3 A KBR 160 3 A KBR 200 3 A KBR 240 3 A KBR 280 3 A Minimum depth mm 612 612 612 612 612 Minimum width mm 855 1065 1065 1275 1275 Minimum hei...

Page 28: ...ction then C A mm 1320 1370 1370 1420 1420 S mm 419 367 515 454 407 Tab 16 Recommended minimum installed dimensions Suprapur factory prepared 2 boiler cascade A B 100 S C 800 A 6 720 644 748 09 1O Installation example The pipework for flue gas and heating water can be turned 180 Unit MKB 240 3 A MKB 320 3 A MKB 400 3 A MKB 480 3 A MKB 560 3 A Minimum depth mm 612 612 612 612 612 Minimum width mm 8...

Page 29: ...ctions of the gas condensing boiler It depends on the boiler size and the heating water flow rate Fig 14 Pressure drop on the heating water side without check valve x Flow rate in l h y Pressure drop on the heating water side in mbar Fig 15 Pressure drop on the heating water side with check valve cascade x Flow rate in l h y Pressure drop on the heating water side in mbar ...

Page 30: ...this loss is the cooling down of the boiler through radiation and convection during the standby time burner idle time Radiation and convection result in part of the output being transferred continuously from the boiler surface to the ambient air In addition to this surface loss the boiler can also cool down to a lesser degree through the chimney draught Fig 17 Standby loss relative to the rated he...

Page 31: ...te to system temperatures 50 30 C and 80 60 C Take a conversion factor into account when calculating the rated output at different system temperatures Fig 19 Conversion factor for deviating design return temperatures average of this series of boilers f Conversion factor ϑ Return temperature Example For a Suprapur gas condensing boiler with a rated output of 120 kW at a system temperature of 50 30 ...

Page 32: ...0 645 817 2010 09 32 3 Appliance layout Fig 20 1 Main PCB with programming unit 2 Gas burner 3 Boiler front panel 4 Siphon 5 Boiler block with thermal insulation 6 Burner controller 7 Gas valve 8 Boiler casing 9 Check valve ...

Page 33: ...240 kW to 560 kW 4 1 2 Possible applications The Suprapur gas condensing boiler is suitable for all heating systems compliant with DIN EN 12828 Preferred application areas are central heating and DHW heating in apartment buildings as well as in municipal and commercial buildings 4 1 3 Benefits in brief Excellent price performance ratio Easy system engineering as no minimum water circulation is req...

Page 34: ...single control system Matching flue gas and ventilation air systems Neutralising systems accessories no 1605 and no 1606 can be integrated inside the boiler consequently small installation space Supplied fully wired ready for connection Easy connection to the heating system because of fully assembled delivery from factory plus matching accessories 4 2 Gas burner 4 2 1 Burner and burner control uni...

Page 35: ...igned to ensure safety and the durability of the heat exchanger Take the boiler characteristics into consideration during system engineering 4 3 Delivery method The Suprapur is factory fitted with check valve and is delivered preset for natural gas H or L This enables rapid installation and easy quick connection to the heating system Conversion to a different gas type is easy The factory prepared ...

Page 36: ...reatment Ca HCO3 2 Concentration calcium hydrogen carbonatein mol m3 Q Boiler output in kW Vmax Maximum fill and top up water over the entire service life of the boiler in m3 Information about the calcium hydrogen carbonate Ca HCO3 2 concentration of the mains water can be obtained from your water supply utility If these details are not included in the water analysis the concentration of calcium h...

Page 37: ...ove the curves water treatment is required B Below the curves fill with untreated mains water that meets the requirements of the Drinking Water Order Germany HW Water hardness V Water volume over the total service life of the boiler 0 1 2 3 4 5 6 7 0 5 10 15 20 25 30 280 kW 240 kW 200 kW 160 kW 120 kW 6 720 643 417 14 1O V m3 HW dH B A 6 720 643 417 15 1O V m3 HW dH 0 2 4 6 8 10 12 14 16 0 5 10 15...

Page 38: ...zed or faulty expansion vessels MAG or open vented systems If a sealed unvented heating system is not feasible corrosion protection measures are required e g by adding approved chemicals or by system separation through the use of a heat exchanger Installation in existing heating systems dirt traps If the gas condensing boiler is installed in an existing heating system impurities may build up in th...

Page 39: ...xpansion vessel MAG Rough guide to selecting a diaphragm expansion vessel 1 MAG pre charge pressure Form 3 Formula for the MAG pre charge pressure minimum 0 5 bar p0 Pre charge pressure of the MAG in bar pst Static pressure of the heating system in bar subject to building height 2 System fill pressure Form 4 Formula for the system fill pressure minimum 1 0 bar pa System fill pressure in bar p0 Pre...

Page 40: ... l l l l 90 0 75 960 1200 1800 2400 1 00 850 1050 1575 2100 1 25 705 882 1323 1764 1 50 563 704 1056 1408 80 0 75 1155 1444 2166 2888 1 00 1020 1276 1914 2552 1 25 851 1064 1596 2128 1 50 681 852 1278 1704 70 0 75 1417 1772 2658 3544 1 00 1251 1564 2346 3128 1 25 1043 1304 1956 2608 1 50 835 1044 1566 2088 60 0 75 1792 2240 3360 4480 1 00 1580 1976 2964 3952 1 25 1315 1644 2466 3288 1 50 1052 1316...

Page 41: ...opylene PP pipes ABS ASA pipes Stainless steel pipes Borosilicate glass pipes If admixing of the condensate with domestic waste water in a ratio of at least 1 25 is assured Æ table 21 then the following may be used Fibre cement pipe Cast iron or steel pipes to DIN 19522 1 and DIN 19530 1 and 19530 2 Copper pipes are unsuitable for draining condensate Adequate admixing Adequate admixing of the cond...

Page 42: ... moisture resistant chimney With moisture resistant chimneys suitable for condensing boilers drain the condensate in accordance with the chimney manufacturer s instructions Via a stench trap with funnel the condensate from the chimney can be routed into the building drain together with the condensate from the gas condensing boiler Observe all relevant regulations concerning the building s drains a...

Page 43: ...ndation every two years The entire system should be checked annually for perfect function Regular inspection and if required maintenance are prerequisites for safe and economical operation 6 2 Fuels The Suprapur gas condensing boilers are suitable for natural gas H or L The gas quality must comply with the requirements of the DVGW Code of Practice G 260 Germany Industrial gases containing sulphur ...

Page 44: ...xpected also clean and seal the chimney shaft 6 5 Combustion air supply The conditions of installation rooms and the siting of gas appliances must comply with country specific regulations For open flue combustion equipment with a total rated output in excess of 50 kW the combustion air supply is deemed to be ensured if an aperture to the outside with a clear opening of at least 150 cm2 plus 2 cm2 ...

Page 45: ...onitored by appropriate safety equipment or flue gas will be routed via the air extractor systems or it will be ensured that such systems cannot create dangerous negative pressure 6 7 Sound insulation The quiet gas premix burner in the Suprapur generates only low noise emissions compared to conventional pressure jet gas burners This generally makes additional sound insulation measures to ensure ai...

Page 46: ...ctive depends on the amount of condensate to be treated and the neutralising system Replace the spent neutralising granulate when the pH level of the neutralised condensate falls below 6 5 Check the pH value of the neutralised condensate at least twice annually 7 1 1 Neutralising system no 1605 The neutralising system no 1605 comprises a plastic casing with a chamber to hold the neutralising granu...

Page 47: ...elivery head V Flow rate 7 1 3 Condensate lifting system no 1620 The condensate lifting system no 1620 was designed for installation inside condensing boilers where corrosive condensate according to the DWA Code of Practice ATV DVWK A 25 is generated The materials used in the system permit the routing of condensate with a pH value 2 4 without any problem For oil or gas condensing boilers with an o...

Page 48: ...s pipework and boilers Fit these near the lowest point of the heating system in an easily accessible position Clean the dirt traps every time the heating system is serviced 7 4 Low loss header Subject to the amount of water on the primary and secondary sides a lower flow temperature than that supplied by the boiler itself can be provided if a low loss header is installed Æ Fig 32 This is the case ...

Page 49: ... 2 5 bar 8 Pressure gauge 9 Low water indicator WMS not in systems 300 kW where instead a minimum pressure limiter or a replacement measure approved by the manufacturer is provided for each boiler 10 Non return valve 11 Boiler drain fill valve KFE 12 Expansion line 13 Shut off valve locked to prevent unintentional closure e g sealed cap valve 14 Drain upstream of diaphragm expansion vessel 15 Diap...

Page 50: ...ue connections are used ensure the draining of condensate from the flue system on site Adaptors or reducers are available for alternative connection diameters 7 9 Ventilation air connection bend A connection bend for balanced flue operation is available in translucent PP for the Suprapur KBR The connection bend DN 110 has an angle of 90 and a test port Adaptors are available for larger dimensions ...

Page 51: ...mperature dependent controller must be installed inside the room that is decisive for the temperature lead room Controllers are selected subject to the demand profile and their respective performance The following overview shows which controller can meet the essential requirements and which further function modules are required to achieve the stated aims The overview enables a preselection of the ...

Page 52: ... 1 y with IPM 1 Control of several DHW cylinders time program y with IPM 2 DHW circulation time program y y y Solar DHW heating y with ISM 1 y with ISM 1 y with ISM 1 Solar central heating backup DHW heating y with ISM 2 y with ISM 2 Cascade circuit with up to 4 appliances y with ICM y with ICM Screed drying program y y y Automatic summer winter changeover y y y Thermal disinfection y y y Solar op...

Page 53: ...d heating circuit and DHW heating Date and time automatic summer winter changeover Fault codes displayed in plain text Switching modules IPM 1 ISM 1 for mixed heating circuit solar DHW heating Preinstalled programs adjustable to customer s requirements Holiday function with date entry Intuitive menu prompts with plain text support Thermal disinfection possible DHW circulation pump program Screed d...

Page 54: ...ixed or unmixed and DHW heating Date and time automatic summer winter changeover Fault codes displayed in plain text Switching of IPM 1 IPM 2 ISM 1 and ISM 2 modules for two mixed heating circuits solar central heating backup Preinstalled programs adjustable to customer s requirements Holiday function with date entry Intuitive menu prompts with plain text support Thermal disinfection possible DHW ...

Page 55: ... of several DHW cylinders with IPM 1 or IPM 2 Optional FB 10 or FB 100 remote controls 7 day program with six switching times per day for two heating circuits mixed or unmixed and DHW heating Date and time automatic summer winter changeover Fault codes displayed in plain text Switching of IPM 1 IPM 2 ISM 1 and ISM 2 modules for two mixed heating circuits solar central heating backup Preinstalled p...

Page 56: ...er supply 230 V AC 50 Hz 4 A Standard delivery MF mixer circuit temperature sensor Part no 7 719 002 738 IPM 2 Application Load switching module for switching a heating circuit pump and mixer for up to two mixed heating circuits or Switching a cylinder primary pump and a DHW circulation pump for one cylinder circuit and a heating circuit pump and mixer for one mixed heating circuit Communication w...

Page 57: ...e condensing boiler and controller via 2 wire BUS 6 switching outputs 230 V AC 50 Hz 2 5 A max 80 W 6 sensor inputs Function status LED Installation Top hat profile rail installation or wall mounting height width depth 155 246 57 mm Power supply 230 V AC 50 Hz 2 5 A Standard delivery 1 x cylinder temperature sensor 1 x collector temperature sensor 1 x flow temperature sensor Part no 7 719 002 741 ...

Page 58: ...0 10 V 0 10 V interface e g for DDC or third party controls Boiler communication 4 x via 2 wire BUS Outputs 230 V AC 50 Hz For further modules ICM 230 V AC 50 Hz max 10 A For pump 230 V AC 50 Hz max 2300 W Fault display floating max 230 V 1 A Installation Wall mounting height width depth 165 235 52 mm Power supply 230 V AC 50 Hz 10 A Part no 7 719 002 949 Tab 30 FB 10 Application Remote control fo...

Page 59: ...times per day Date and time automatic summer winter changeover Preinstalled programs adjustable to customer s requirements Intuitive menu prompts with plain text support Holiday function with date entry Info function Room temperature hook up Optimised heating curves Adjustable heat up speed slow normal fast Remote management via Netcom 100 Installation Wall mounting height width depth 119 134 45 m...

Page 60: ... of cylinders is equipped with austenitic stainless steel on the DHW side This makes these cylinders neutral towards common potable water The following are selection criteria Required level of comfort number of occupants use measured variable NL factor Available boiler output Available space Cylinder selection according to NL factor NL factor according to DIN 4708 at max output Max output in kW Av...

Page 61: ...aximum permissible pressure upstream of these valves taps is restricted to 5 bar in accordance with DIN 4109 noise protection in buildings source Commentary DIN 1988 part 2 page 156 For systems with a higher static pressure install a pressure reducer The installation of a pressure reducer is a simple but highly effective measure to reduce excessive noise levels For example simply reducing the flow...

Page 62: ...To prevent this install a non return valve or check valve in the cylinder return Mixed installation According to DIN 1988 the installation of a nonferrous heavy metal fitting is adequate to protect materials with different potentials such as stainless steel and zinc plated steel against electrochemical corrosion In such cases this also includes DHW cylinders made from enamelled steel adaptor fitti...

Page 63: ...afety valve VSP Cylinder flow WW DHW connection Z DHW circulation connection ZP On site DHW circulation pump Parallel connection of two cylinders Fig 38 Connection in parallel AV Shut off valve DM Pressure reducer if required accessory E Drain KW Cold water connection MS Pressure gauge connector PV Test valve RSP Cylinder return RV Non return valve S Gate valve SV Safety valve VSP Cylinder flow WW...

Page 64: ...ing a DHW circulation line with a timer or demand controlled DHW circulation pump Æ page 63 For the best possible utilisation of the cylinder capacity and to prevent premature mixing we recommend restricting the cold water inlet to the cylinder to the following flow rate Constant DHW output The constant outputs shown in the specification refer to the following Flow temperature 90 C Outlet temperat...

Page 65: ...nder temperature sensor NTC MA Magnesium anode RSP Cylinder return SE 8 Switching insert with temperature controller accessory T Sensor well temperature display T1 Sensor well for cylinder temperature sensor NTC VSP Cylinder flow WW DHW outlet Z ZL DHW circulation connection 4132 33 1R 30 55 219 710 WW R 1 R 3 4 Z RSP KW E T MA SE 8 768 1124 1683 SK 300 1290 SK 400 1646 SK 500 1966 300 837 937 118...

Page 66: ...ture display SF Cylinder temperature sensor NTC VSP Cylinder flow Rp 1 fem thread WW DHW outlet SK 800 ZB Rp 1 male thread SK 1000 ZB Rp 1 male thread ZL DHW circulation connection Rp fem thread Wall clearances Fig 41 Recommended minimum wall clearances 6 720 640 088 01 2O SF T Ø 920 Ø 1040 1000 2180 2170 1245 1255 500 510 VSP RSP L KW R 1 E MA MA Rp 1 EL Rp 1 WW R 1 R 1 Rp 1 Rp 1 ZL Rp 350 360 Ø ...

Page 67: ...rop of the indirect coil in bar Δp Pressure drop Flow rate Pipework related pressure drop values have not been taken into account in the graphs Δp bar V m3 h 0 01 0 02 0 03 0 04 0 05 0 06 0 08 0 1 0 2 0 3 0 4 0 6 0 8 1 0 2 0 3 0 4 0 5 0 6 720 604 132 03 2O 1 2 3 V 0 4 0 2 0 01 0 02 0 03 0 04 0 05 0 06 0 08 0 1 0 2 0 3 0 4 0 8 0 6 0 001 0 002 0 003 0 004 0 005 0 006 0 008 4 0 3 0 2 0 1 0 8 0 6 0 m ...

Page 68: ...8 at max output 1 The performance factor NL corresponds to the number of residential units to be supplied each with 3 5 occupants one standard bath tub and two further draw off points 8 7 13 5 17 35 45 Further details Available amount of DHW without reheating 2 TSp 60 C and TZ 45 C TZ 40 C 2 Distribution losses outside the cylinder have not been taken into account l l 365 426 482 563 584 682 1010 ...

Page 69: ...ld water inlet RSP Cylinder return T Sensor well temperature display T1 Sensor well for cylinder temperature sensor NTC VSP Cylinder flow WW DHW outlet ZL DHW circulation connection Ø 660 1795 177 278 333 348 105 105 105 105 R 1 R 1 R R 1 R 1 T 6 720 643 417 28 1O 200 RSP T1 WW ZL KW VSP Fit drains on site to the cylinder connections for cold water KW and cylinder flow VSP ...

Page 70: ...l Fig 45 Pressure drop of the indirect coil in bar Δp Pressure drop Flow rate Pressure drop through the network has not been taken into account on this graph 6 720 615 094 02 2O Δp bar V m3 h 0 01 0 02 0 03 0 04 0 05 0 06 0 08 0 1 0 2 0 3 0 4 0 6 0 8 1 0 2 0 3 0 4 0 5 0 V ...

Page 71: ...er Heat transfer Indirect coil Number of coils Available capacity l 288 Heating water content l Heating surface m2 0 93 Performance factor NL 1 to DIN 4708 at max output 1 The performance factor NL corresponds to the number of residential units to be supplied each with 3 5 occupants one standard bath tub and two further draw off points 11 5 Further details Available amount of DHW without reheating...

Page 72: ...6 604 No 1603 Drain fill set G 1 With pressure gauge and connection for diaphragm expansion vessel 8 718 576 602 No 1604 Gas tap R 1straight through version With thermally activated shut off valve 80 949 220 MAG Diaphragm expansion vessel for sealed unvented heating systems Maximum operating temperature 120 C pre charge pressure 1 5 bar with mounting feet MAG 50 50 l volume MAG 80 80 l volume 7 71...

Page 73: ... gold contacts setting range 30 60 C 7 719 002 255 Designation accessory no Part no Hydraulic shut off set No 1644 for MKB 240 3 A No 1645 for MKB 320 3 A No 1646 for MKB 400 560 3 A 7 747 301 092 7 747 301 093 7 747 301 094 No 1647 Pump set cascade pipework for MKB 240 3 A 63 035 300 Pump set cascade pipework No 1648 for MKB 320 400 3 A No 1649 for MKB 480 560 3 A 63 035 301 63 040 088 Tab 41 Des...

Page 74: ... Without neutralising system max head 6 m 80 695 080 No 1605 Neutralising tank Incl granulate filling connection components inlet and drain hoses 8 718 576 749 No 1606 Neutralising tank with integral level controlled condensate pump 2 m head Incl granulate filling 8 718 577 421 Neutralising granulate Refill pack 7 115 120 Tab 42 ...

Page 75: ...ure so it cannot slip out of the boiler flue outlet particularly with the larger dimensions from DN 200 e g use a support Material requirements The flue material must be resistant to the flue gas temperatures that can occur It must be resistant against moisture and acidic condensate Stainless steel and plastic flues are suitable Flues are split into categories according to their maximum flue gas t...

Page 76: ...plastic flue systems offered by Junkers are approved in Germany The approval pamphlet is supplied with the boiler flue connection for every order Individual approval pamphlets can be requested for engineering purposes Chimney shaft requirements Inside buildings flue systems must be run through a chimney shaft not required in adequately ventilated installation rooms This must be made from non combu...

Page 77: ...8 8 DN 200 100 57 35 9 1 9 3 125 4 30 9 80 60 C 120 113 28 116 29 DN 160 100 75 57 9 1 9 3 53 7 13 2 160 150 38 155 38 8 DN 160 100 75 56 9 1 9 3 71 7 17 7 200 187 47 193 48 3 DN 200 100 75 58 9 1 9 3 89 3 21 8 240 225 57 232 58 DN 200 100 75 56 9 1 9 3 107 4 26 3 280 263 67 271 68 8 DN 200 100 75 58 9 1 9 3 125 4 30 9 Tab 44 Flue gas parameters Suprapur single boiler with consideration of the con...

Page 78: ...n from washers dryers chemical cleaners or paint shops Safety clearances towards combustible building materials Inflammable and explosive materials and liquids must not be stored or used in the vicinity of the gas condensing boiler At rated output the maximum surface temperature of the balanced flue systems and appliances is less than 85 C No special measures or safety clearances to protect flamma...

Page 79: ...is we recommend contacting your local flue gas inspector where appropriate The inspection apertures are shown for illustration purposes only For more detailed installation information see DIN 18160 5 The air grille cross sections are calculated according to one of the following formulae Form 6 Calculating the cross sections A of the air grilles A Cross section air grille PKessel Boiler output Fig ...

Page 80: ...7 2010 09 80 11 2 3 Open flue routing via flue inside a chimney shaft B23 Fig 48 Key Æ Tab 46 6 720 643 417 30 1O L 2 3 3 5 5 6 7 5 9 9 8 1 4 1 4 1 Open flue operation observe Feuerungsverordnung FeuVO Combustion Order Germany ...

Page 81: ...AZB 1314 AZB 1315 7 Cover grille AZB 1060 AZB 1060 AZB 1060 AZB 1060 8 Fascia AZB 1316 AZB 1317 AZB 1318 AZB 1319 9 87 bend 90 AZB 934 AZB 974 AZB 975 AZB 976 45 bend AZB 940 AZB 970 AZB 971 AZB 972 30 bend AZB 724 1 AZB 966 AZB 967 AZB 968 15 bend AZB 719 1 AZB 964 87 bend with inspection aperture AZB 997 AZB 998 AZB 999 AZB 1000 Installation aid AZB 1052 AZB 1053 AZB 1054 AZB 1055 Reduction adap...

Page 82: ...ue routing vertical via the roof B23 Fig 49 Key Æ Tab 49 Bend Equivalent pipe length 90 2 m 15 45 1 m Tab 48 Equivalent pipe lengths of bends 1 1 7 2 6 720 643 417 31 1O L 4 3 5 6 Open flue operation observe Feuerungsverordnung FeuVO Combustion Order Germany ...

Page 83: ...934 AZB 974 AZB 975 AZB 976 45 bend AZB 940 AZB 970 AZB 971 AZB 972 30 bend AZB 724 1 AZB 966 AZB 967 AZB 968 15 bend AZB 719 1 AZB 964 87 bend with inspection aperture AZB 997 AZB 998 AZB 999 AZB 1000 6 Support for flue system AZB 1327 AZB 1328 AZB 1329 AZB 1330 7 Flat roof flange AZ 136 AZB 1322 AZB 1344 AZB 1345 Reduction adaptor AZB 1346 AZB 1309 AZB 1347 Enlargement adaptor AZB 961 AZB 962 Ta...

Page 84: ... 720 645 817 2010 09 84 11 2 5 Open flue routing via flue over a facade B23 Fig 50 Key Æ Tab 52 6 720 643 417 32 1O L 2 5 6 8 7 4 4 3 3 1 Open flue operation observe Feuerungsverordnung FeuVO Combustion Order Germany ...

Page 85: ...1017 AZB 1018 5 Inspection aperture facade AZB 1023 AZB 1024 AZB 1025 AZB 1026 6 Wall duct AZB 1336 AZB 1337 AZB 1338 AZB 1339 7 Extension pipe 0 5 m Extension pipe 1 m AZB 977 AZB 718 1 AZB 978 AZB 982 AZB 979 AZB 983 AZB 980 AZB 984 8 Inspection aperture AZB 720 1 AZB 994 AZB 995 AZB 996 87 bend 90 AZB 934 AZB 974 AZB 975 AZB 976 45 bend AZB 940 AZB 970 AZB 971 AZB 972 30 bend AZB 724 1 AZB 966 ...

Page 86: ...ustion air supply so that for example no extract air is drawn in from chemical cleaners or paint shops Safety clearances towards combustible building materials Minimum safety clearances towards combustible building materials are not required Inflammable and explosive materials and liquids must not be stored or used in the vicinity of the gas condensing boiler At rated output the maximum surface te...

Page 87: ...e from the flue is routed directly into the stench trap siphon of the gas condensing boiler Inspection apertures According to DIN 18160 1 and DIN 18160 5 flue systems for balanced flue operation must be able to be inspected and cleaned easily and safely For this allow for inspection apertures Æ Fig 51 When arranging the inspection apertures comply with the requirements of DIN 18160 5 as well as al...

Page 88: ...6 720 645 817 2010 09 88 11 3 2 Balanced flue routing via flue inside a chimney shaft whilst drawing in combustion air in countercurrent C93 Fig 52 Key Æ Tab 55 6 720 643 417 33 1O L 2 3 3 5 5 6 5 4 8 8 7 1 4 1 4 1 ...

Page 89: ... 990 AZB 991 AZB 992 4 Extension pipe 0 5 m Extension pipe 1 m Extension pipe 2 m AZB 977 AZB 718 1 AZB 985 AZB 978 AZB 982 AZB 986 AZB 979 AZB 983 AZB 987 AZB 980 AZB 984 AZB 988 5 Inspection aperture AZB 720 1 AZB 994 AZB 995 AZB 996 6 Support inside the chimney shaft with stainless steel rail AZB 1302 AZB 1303 Support inside the chimney shaft with pipe AZB 1304 AZB 1305 AZB 1329 AZB 1330 Wall l...

Page 90: ...0 645 817 2010 09 90 11 3 3 Balanced flue routing via flue inside a chimney shaft whilst drawing in combustion air through a separate pipe C53 Fig 53 Key Æ Tab 57 6 720 643 417 34 1O 4 L 2 3 3 5 5 6 7 5 9 9 8 1 4 1 4 1 ...

Page 91: ...tension pipe 0 5 m Extension pipe 1 m Extension pipe 2 m AZB 977 AZB 718 1 AZB 985 AZB 978 AZB 982 AZB 986 AZB 979 AZB 983 AZB 987 AZB 980 AZB 984 AZB 988 5 Inspection aperture AZB 720 1 AZB 994 AZB 995 AZB 996 6 Support inside the chimney shaft with stainless steel rail AZB 1302 AZB 1303 Support inside the chimney shaft with pipe AZB 1304 AZB 1305 AZB 1329 AZB 1330 Wall lining AZB 1312 AZB 1313 A...

Page 92: ...h test port straight Ø 160 mm for KBR 120 160 3 A 7 747 003 467 AZB 718 1 AZB 977 AZB 985 Extension pipe flue side Ø 125 mm made from PP AZB 718 1 L 1000 mm AZB 977 L 500 mm AZB 985 L 2000 mm 7 719 002 896 7 746 900 697 7 746 900 705 AZB 720 1 Tee with inspection aperture flue side with cover 7 719 002 897 AZB 997 87 bend with inspection aperture flue side Ø 125 mm made from PP 7 746 900 717 AZB 9...

Page 93: ...for ventilation air connection from Ø 110 mm to Ø 160 mm made from PP for KBR 120 280 3 A for balanced flue operation 87 094 782 AZB 1346 Reduction adaptor for flue from Ø 160 mm to Ø 125 mm for KBR 120 160 3 A 87 094 754 AZB 1354 Reducer with test port 87 bend for KBR 120 3 A adaptor Ø 160 mm to Ø 125 mm 7 747 003 469 AZB 1355 Reducer with test port for KBR 120 3 A adaptor Ø 160 mm to Ø 125 mm 7 ...

Page 94: ...umber AZB 702 1 Chimney shaft pack Ø 125 mm made from PP 7 719 002 893 AZB 1316 Fascia with integral secondary ventilation Ø 125 mm pitch circle diameter 185 mm made from stainless steel 87 090 812 AZB 1060 Cover grille for ventilation air supply Ø 110 315 mm 7 746 901 009 AZB 1312 Wall lining Ø 125 mm made from stainless steel 87 090 792 AZB 1302 Support inside the chimney shaft for flue system Ø...

Page 95: ...90 762 AZB 1049 Terminal pipe Ø 125 mm made from stainless steel for optional replacement of terminal pipe made from PP 7 746 900 998 AZB 1052 Installation aid pipe clip with eyelets for pipes with Ø 125 mm 7 746 901 001 Standard delivery Designation description Part number Tab 60 Standard delivery Designation description Part number AZB 1323 Flue routing vertical Ø 125 mm made from stainless stee...

Page 96: ... Ø 125 185 mm made from stainless steel PP AZB 1001 L 500 mm AZB 1005 L 1000 mm 7 746 900 721 7 746 900 725 AZB 1023 Inspection aperture for facade solution Ø 125 185 mm made from stainless steel PP 7 746 900 986 AZB 1015 45 bend with inspection aperture for facade solution Ø 125 185 mm made from stainless steel PP 7 746 900 735 AZB 1336 Wall outlet 0 5 m long Ø 125 185 mm made from PE PP 87 090 9...

Page 97: ...AZB 1049 Terminal pipe Ø 125 mm made from stainless steel for optional replacement of terminal pipe made from PP 7 746 900 998 AZB 1056 Clamping strap Ø 185 mm 7 746 901 005 Standard delivery Designation description Part number Tab 62 Standard delivery Designation description Part number AZB 1350 Boiler flue connection with test port 87 bend Ø 160 mm for KBR 120 160 3 A 7 747 003 465 AZB 1352 Boil...

Page 98: ...nsion pipe flue side Ø 160 mm made from PP AZB 978 L 500 mm AZB 982 L 1000 mm AZB 986 L 2000 mm 7 746 900 698 7 746 900 702 7 746 900 706 AZB 994 Inspection aperture Ø 160 mm made from PP 7 746 900 714 AZB 998 87 bend with inspection aperture flue side Ø 160 mm made from PP 7 746 900 718 AZB 974 87 bend flue side Ø 160 mm made from PP 7 746 900 694 AZB 970 45 bend flue side Ø 160 mm made from PP 7...

Page 99: ... Enlargement adaptor for ventilation air connection from Ø 110 mm to Ø 160 mm made from PP for KBR 120 280 3 A for balanced flue operation 87 094 782 AZB 1347 Reduction adaptor for flue from Ø 200 mm to Ø 160 mm for KBR 200 240 280 3 A 87 094 756 AZB 1320 Universal roof tile Ø 160 mm black for roof pitch 25 45 87 090 906 AZB 1321 Universal roof tile Ø 160 mm terracotta for roof pitch 25 45 87 090 ...

Page 100: ...tainless steel 87 090 814 AZB 1060 Cover grille for ventilation air supply Ø 110 315 mm 7 746 901 009 AZB 1313 Wall lining Ø 160 mm made from stainless steel 87 090 794 AZB 1303 Support inside the chimney shaft for flue system Ø 160 mm with stainless steel rail 87 090 714 AZB 1305 Support inside the chimney shaft for flue system Ø 160 mm with 2 m pipe 87 090 724 AZB 990 Spacer Ø 160 mm made from P...

Page 101: ... 901 002 Standard delivery Designation description Part number Tab 64 Standard delivery Designation description Part number AZB 1324 Flue routing vertical Ø 160 mm made from stainless steel 87 090 942 AZB 1328 Support for flue system Ø 160 mm 1 m support pipe 87 090 992 Tab 65 Standard delivery Designation description Part number AZB 1332 Facade pack Ø 160 mm stainless steel with support bend and ...

Page 102: ...nless steel PP 7 746 900 979 AZB 1337 Wall outlet 0 5 m long Ø 160 225 mm made from PE PP 87 090 979 AZB 1046 Wall mounting bracket Ø 225 mm made from stainless steel 7 746 900 995 AZB 1042 Roof outlet for facade solution Ø 160 225 mm made from stainless steel PP 7 746 900 991 AZB 1359 Terminal piece Ø 160 225 mm made from stainless steel PP with clamping strap 87 090 972 Standard delivery Designa...

Page 103: ...Part number Tab 66 Standard delivery Designation description Part number AZB 1351 Boiler flue connection with test port 87 bend Ø 200 mm for KBR 200 240 280 3 A 7 747 003 466 AZB 1353 Boiler flue connection with test port straight Ø 200 mm for KBR 200 240 280 3 A 7 747 003 468 AZB 979 AZB 983 AZB 987 Extension pipe flue side Ø 200 mm made from PP AZB 979 L 500 mm AZB 983 L 1000 mm AZB 987 L 2000 m...

Page 104: ... 7 746 900 687 AZB 961 Enlargement adaptor for flue connection from Ø 160 mm to Ø 200 mm for KBR 120 160 3 A 7 746 900 681 AZB 1300 Enlargement adaptor for ventilation air connection from Ø 110 mm to Ø 125 mm made from PP for KBR 120 280 3 A for balanced flue operation 87 094 780 AZB 1301 Enlargement adaptor for ventilation air connection from Ø 110 mm to Ø 160 mm made from PP for KBR 120 280 3 A ...

Page 105: ...Ø 300 mm stainless steel 7 747 204 945 Standard delivery Designation description Part number Tab 67 Standard delivery Designation description Part number AZB 954 Chimney shaft pack Ø 200 mm made from PP 7 746 900 674 AZB 1318 Fascia with integral secondary ventilation Ø 200 mm pitch circle diameter 300 mm made from stainless steel 87 090 816 AZB 1060 Cover grille for ventilation air supply Ø 110 3...

Page 106: ...t cover Ø 200 mm made from stainless steel with terminal pipe made from PP 87 090 766 AZB 1051 Terminal pipe Ø 200 mm made from stainless steel for optional replacement of terminal pipe made from PP 7 746 901 000 AZB 1054 Installation aid pipe clip with eyelets for pipes with Ø 200 mm 7 746 901 003 Standard delivery Designation description Part number Tab 68 Standard delivery Designation descripti...

Page 107: ...ion Part number AZB 1333 Facade pack Ø 200 mm stainless steel with support bend and panel 87 090 953 AZB 1003 AZB 1007 Extension pipe for facade solution Ø 200 300 mm made from stainless steel PP AZB 1003 L 500 mm AZB 1007 L 1000 mm 7 746 900 723 7 746 900 727 AZB 1025 Inspection aperture for facade solution Ø 200 300 mm made from stainless steel PP 7 746 900 988 AZB 1017 45 bend with inspection a...

Page 108: ...et for facade solution Ø 200 300 mm made from stainless steel PP 7 746 900 992 AZB 1360 Terminal piece Ø 200 300 mm made from stainless steel PP with clamping strap 87 090 973 AZB 1051 Terminal pipe Ø 200 mm made from stainless steel for optional replacement of terminal pipe made from PP 7 746 901 000 AZB 1058 Clamping strap Ø 300 mm 7 746 901 007 Standard delivery Designation description Part num...

Page 109: ...lue connection with test port straight Ø 200 mm for KBR 200 240 280 3 A 7 747 003 468 AZB 980 AZB 984 AZB 988 Extension pipe flue side Ø 250 mm made from PP AZB 980 L 500 mm AZB 984 L 1000 mm AZB 988 L 2000 mm 7 746 900 700 7 746 900 704 7 746 900 708 AZB 996 Inspection aperture Ø 250 mm made from PP 7 746 900 716 AZB 1000 87 bend with inspection aperture flue side Ø 250 mm made from PP 7 746 900 ...

Page 110: ...argement adaptor for ventilation air connection from Ø 110 mm to Ø 125 mm made from PP for KBR 120 280 3 A for balanced flue operation 87 094 780 AZB 1301 Enlargement adaptor for ventilation air connection from Ø 110 mm to Ø 160 mm made from PP for KBR 120 280 3 A for balanced flue operation 87 094 782 AZB 1342 Special roof tiles Ø 250 Ø 350 mm 87 090 914 AZB 1345 Flat roof flange Ø 250 Ø 350 mm s...

Page 111: ...6 900 675 AZB 1319 Fascia with integral secondary ventilation Ø 250 mm pitch circle diameter 356 mm made from stainless steel 87 090 817 AZB 1060 Cover grille for ventilation air supply Ø 110 315 mm 7 746 901 009 AZB 1315 Wall lining Ø 250 mm made from stainless steel 87 090 797 AZB 1330 Support for flue system Ø 250 mm with 2 m pipe 87 090 728 AZB 992 Spacer Ø 250 mm made from stainless steel 7 7...

Page 112: ...ry Designation description Part number Tab 72 Standard delivery Designation description Part number AZB 1326 Flue routing vertical Ø 250 mm made from stainless steel 87 090 955 AZB 1330 Support for flue system Ø 250 mm with 2 m pipe 87 090 728 Tab 73 Standard delivery Designation description Part number AZB 1334 Facade pack Ø 250 mm stainless steel with support bend and panel 87 090 954 AZB 1004 A...

Page 113: ...inless steel PP 7 746 900 981 AZB 1339 Wall outlet 0 5 m long Ø 250 350 mm made from PE PP 87 090 981 AZB 1048 Wall mounting bracket Ø 350 mm made from stainless steel 7 746 900 997 AZB 1044 Roof outlet for facade solution Ø 250 350 mm made from stainless steel PP 7 746 900 993 AZB 1335 Terminal piece Ø 250 350 mm made from stainless steel with clamping strap 87 090 974 Standard delivery Designati...

Page 114: ...6 720 645 817 2010 09 114 Notes ...

Page 115: ...6 720 645 817 2010 09 115 Notes ...

Page 116: ...Bosch Thermotechnik GmbH Junkersstrasse 20 24 D 73249 Wernau www junkers com ...

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