Related Manuals for Junkers SUPERPURE KBR 160-3
Summarization of Contents
Explanation of symbols and safety instructions
Explanation of symbols
Defines warning symbols and signal words used in the text.
Safety Instructions
Provides critical safety warnings for gas, exhaust, flammable materials, and electrical hazards.
Product information
About this manual
Introduces the manual's purpose and target audience for tradesmen.
EC Declaration of Conformity
Confirms product compliance with European directives and national requirements.
Intended use
Specifies the authorized purpose of the boiler for heating water for systems.
Naming the boiler
Explains the components of the boiler designation (e.g., SUPERPURE KBR).
Scope of Delivery
Lists the components included with the boiler and available accessories.
Product Overview
Provides a general description and diagram of the boiler components.
Dimensions and Connections
Presents diagrams and tables detailing the boiler's dimensions and connection points.
Specifications
Lists technical specifications such as heat output, gas throughput, and electrical data.
Gas Flow
Details gas throughput values for different boiler sizes and gas types.
Country-specific gas categories and connection pressures
Outlines gas categories and required connection pressures for various countries.
Main circuit board connection diagram
Illustrates the wiring diagram for the main circuit board and its connections.
Plant example
Shows a simplified system example for a mixed heating circuit with hot water.
regulations
Standards and guidelines
Outlines country-specific regulations and standards for installation and operation.
Authorization and information requirements
Details reporting requirements to gas supply companies and permits.
Installation room
Specifies requirements for the installation room, including frost protection and fire hazards.
Combustion air connection
Details requirements for combustion air openings for open and balanced flue operation.
Quality of heating water
Stresses the importance of water quality for system longevity and efficiency.
Quality of piping
Addresses requirements for oxygen-tight plastic pipes in heating systems.
Frost protection
Advises on measures to prevent system damage due to freezing, like pump run-on times.
Inspection/Maintenance
Explains the necessity and reasons for periodic maintenance of heating systems.
Tools, Materials and Supplies
Lists standard and useful tools required for boiler installation and maintenance.
Validity of Regulations
States that changed regulations or supplements are valid at the time of installation.
Transporting the boiler
Check scope of delivery
Instructs to check packaging integrity and completeness of delivery.
Lifting and carrying the boiler
Details procedures for safely lifting and carrying the boiler using pipes.
installation
Requirements for the installation room
Specifies requirements for the installation room, including frost, fire, and contamination hazards.
Wall clearances
Details recommended and minimum wall distances for boiler installation.
Aligning the boiler
Instructs to level the boiler horizontally using foot screws for proper drainage.
Flue gas and air supply connection
Covers requirements for connecting flue gas and air supply lines, including safety.
Make hydraulic connections
Guides through connecting heating flow, return, and other hydraulic components.
Fill the heating system and check for leaks
Explains the process of filling the heating system and performing leak tests before commissioning.
Establish fuel supply
Details the safe connection of the gas supply, emphasizing specialist work.
Establish electrical connection
Covers safe mains connection, observing wiring diagrams and local regulations.
Align the boiler vertically
Describes how to ensure the boiler is vertically aligned using screws and a spirit level.
operation
Overview of the operating elements
Introduces the control panel elements like buttons, screen, and operating light.
Menu Structure
Outlines the available menus: Status, Information, Fault history, and Settings.
Commissioning
Check operating pressure
Guides on checking and setting the correct operating pressure for the heating system.
Note the gas characteristics
Instructs to obtain and record gas characteristic values from the supply company.
Check device equipment
Verifies that the burner is set for the correct gas type upon delivery.
Check tightness
Details procedures for checking gas lines and connections for leaks before initial commissioning.
Gas type conversion
Explains how to change the gas type and update the type plate if necessary.
Bleed the gas line
Describes the process of bleeding the gas line to remove air before operation.
Supply and exhaust air openings and the Check flue gas connection
Ensures proper air supply/exhaust and flue gas connection compliance with regulations.
Check supply air membrane
Verifies the presence and proper function of the supply air membrane.
Prepare the heating system for operation
Instructs to open shut-off valves and switch on the heating system.
Heating system on the control unit turn on
Guides on turning on the heating system via the main switch on the control unit.
Chimney sweep operation (service operation)
Explains how to activate and use chimney sweep mode for maintenance.
Display and change operating statuses/settings
Describes how to view and adjust operating statuses and settings via menus.
Check and adjust the CO2 setting at full load
Details the procedure for checking and adjusting the CO2 setting at full burner load.
Check and adjust CO2 setting at partial load
Guides on checking and adjusting the CO2 setting at partial burner load.
Recording measured values
Lists values to be measured and recorded in the commissioning log.
Functional Tests
Outlines essential functional tests for control, regulation, and safety devices.
Measure gas connection flow pressure
Details how to measure the gas connection flow pressure with the burner running.
Check tightness during operation
Instructs to check gas path seals for leaks under full load using a foaming agent.
Assembling the paneling parts
Guides on reattaching the front and side panels after maintenance or installation.
Inform operator, hand over technical documents
Covers familiarizing the operator with the system and handing over documentation.
Commissioning report
Provides a checklist for confirming and signing commissioning work.
Shut down the heating system
Shut down the heating system on the control unit
Explains how to safely switch off the heating system via the control unit.
heating system in case of emergency except put into operation
Advises on customer actions during emergencies like fire and behavior in case of frost.
Inspection and Maintenance
Prepare boiler for inspection
Details safety precautions before opening the boiler for inspection.
General Works
Lists general inspection tasks not detailed elsewhere, like checking system condition.
Internal leak test
Guides on determining test volume and performing internal leak tests on gas fittings.
Check the operating pressure of the heating system
Explains how to check and maintain the correct operating pressure for the heating system.
Measure CO2 content
Describes how to measure CO2 content in flue gas and adjust burner settings.
Determine the degree of contamination on the burner and heat exchanger
Details how to measure contamination levels on the burner and heat exchanger.
Clean burner and heat exchanger
Provides instructions for wet cleaning the burner and heat exchanger components.
Assemble dismantled parts
Instructs on reassembling boiler parts in reverse order, checking seals.
Check tightness during operation
Guides on checking gas path seals for leaks during full load operation.
Check ionization current
Explains how to check the ionization current for trouble-free burner operation.
Complete inspection and maintenance
Covers mounting cladding parts and confirming inspection in the maintenance log.
Inspection and Maintenance Records
Provides templates for recording inspection and maintenance activities.
Service and fault displays
Safety instructions for service work
Highlights safety precautions for service personnel, including gas, water, and electrical hazards.
Service and fault messages in the display
Explains the distinction between service and fault displays shown on the boiler.
Service Indicators
Describes service messages (e.g., H07) indicating required maintenance.
Fault Indications
Explains fault codes (e.g., E9) and how to reset blocking/latching faults.
Emergency Operation
Details how the boiler operates in emergency mode and how to reset faults.
Appendix
Voltage values for hot water, boiler, flow and return temperature sensors
Provides tables of resistance and voltage values for temperature sensors.
Sensor characteristics
Shows characteristic curves for boiler, return, and flow temperature sensors.
Flow resistance on the heating water side
Presents graphs illustrating flow resistance in the heating water circuit.
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