Junkers SUPRAPUR KBR 120-3 A Technical Manual
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Junkers SUPRAPUR KBR 120-3 A Technical Manual

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Technical guide
Gas condensing boiler
SUPRAPUR
Single boiler:
KBR 120-3 A
KBR 160-3 A
KBR 200-3 A
KBR 240-3 A
KBR 280-3 A
Output range from
28 kW to 560 kW
Warmth for life
Wärme fürs Leben
Cascade:
MKB 240-3 A
MKB 320-3 A
MKB 400-3 A
MKB 480-3 A
MKB 560-3 A

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Summary of Contents for Junkers SUPRAPUR KBR 120-3 A

  • Page 1 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 Warmth for life Wärme fürs Leben...

  • Page 2: Table Of Contents

    Contents Contents System schemes ......4 Appliance layout ......32 System scheme 1: unmixed heating circuit, low loss header .
  • Page 3 Contents Accessories / Services ....46 11 Flue systems ......75 Neutralising systems .

  • Page 4: System Schemes

    System schemes System schemes System scheme 1: unmixed heating circuit, low loss header Hydraulic scheme with controller (schematic diagram) FW 100 IPM 1 Suprapur KBR 120-280 6 720 643 417-02.1O Fig. 1 Outside temperature sensor Features Boiler control unit • Generally, we would recommend the installation of a FW 100 Weather-compensated controller low loss header on site to ensure reliable transfer of Heating circuit pump (primary circuit)
  • Page 5 System schemes The controller is suitable for wall mounting inside the boiler room or in the living space. Installing it in the living space enables room temperature hook-up. Parts list Model code Description Part no. Price Condensing boiler KBR 120-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 229 KBR 120-3 A 21...

  • Page 6: System Scheme 2: Unmixed Underfloor Heating Circuit, Low Loss Header

    System schemes System scheme 2: unmixed underfloor heating circuit, low loss header Hydraulic scheme with controller (schematic diagram) Suprapur KBR 120-280 6 720 643 417-01.1O Fig. 2 Outside temperature sensor • The FW ... weather-compensated controller is Boiler control unit preferred for its higher utilisation of condensing FW 100 Weather-compensated controller technology.
  • Page 7 System schemes Parts list Model code Description Part no. Price Condensing boiler KBR 120-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 229 KBR 120-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 285 KBR 160-3 A 23 Suprapur gas condensing boiler for natural gas 23...

  • Page 8: System Scheme 3: Mixed Heating Circuit, Dhw Circuit, Low Loss Header

    System schemes System scheme 3: mixed heating circuit, DHW circuit, low loss header Hydraulic scheme with controller (schematic diagram) Suprapur KBR 120-280 ST ... 6 720 643 417-03.1O Fig. 3 Features Outside temperature sensor Boiler control unit • Generally, we would recommend the installation of a FW 100 Weather-compensated controller low loss header on site to ensure reliable transfer of Heating circuit pump (primary circuit)
  • Page 9 System schemes The controller is suitable for wall mounting inside the boiler room or in the living space. Installing it in the living space enables room temperature hook-up. Parts list Model code Description Part no. Price Condensing boiler KBR 120-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 229 KBR 120-3 A 21...

  • Page 10: System Scheme 4: One Unmixed Heating Circuit, One Mixed Heating Circuit, Low Loss Header

    System schemes System scheme 4: one unmixed heating circuit, one mixed heating circuit, low loss header Hydraulic scheme with controller (schematic diagram) FW 200 IPM 2 Suprapur KBR 120-280 6 720 643 417-04.1O Fig. 4 Features Outside temperature sensor Boiler control unit •...
  • Page 11 System schemes The controller is suitable for wall mounting inside the boiler room or in the living space. Installing it in the living space enables room temperature hook-up. Parts list Model code Description Part no. Price Condensing boiler KBR 120-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 229 KBR 120-3 A 21...

  • Page 12: System Scheme 5: Two Mixed Heating Circuits, One Dhw Circuit, Low Loss Header

    System schemes System scheme 5: two mixed heating circuits, one DHW circuit, low loss header Hydraulic scheme with controller (schematic diagram) FW 200 IPM 1 IPM 2 Suprapur KBR 120-280 ST ... 6 720 643 417-06.1O Fig. 5 Features Outside temperature sensor Boiler control unit •...
  • Page 13 System schemes The controller is suitable for wall mounting inside the boiler room or in the living space. Installing it in the living space enables room temperature hook-up. Parts list Model code Description Part no. Price Condensing boiler KBR 120-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 229 KBR 120-3 A 21...

  • Page 14: System Scheme 6: One Unmixed Heating Circuit, Two Mixed Heating Circuits, Low Loss Header

    System schemes System scheme 6: one unmixed heating circuit, two mixed heating circuits, low loss header Hydraulic scheme with controller (schematic diagram) FW 200 IPM 2 IPM 1 FB 100 Suprapur KBR 120-280 6 720 643 417-07.1O Fig. 6 Features Outside temperature sensor Boiler control unit •...
  • Page 15 System schemes The controller is suitable for wall mounting inside the A FB 100 remote control is required for the third heating boiler room or in the living space. Installing it in the living circuit. space enables room temperature hook-up. Parts list Model code Description...

  • Page 16: System Scheme 7: One Unmixed Heating Circuit, Three Mixed Heating Circuits, Low Loss Header

    System schemes System scheme 7: one unmixed heating circuit, three mixed heating circuits, low loss header Hydraulic scheme with controller (schematic diagram) FW 200 IPM 2 FB 100 IPM 2 FB 100 Suprapur KBR 120-280 6 720 643 417-08.1O Fig. 7 Features Outside temperature sensor Boiler control unit...
  • Page 17 System schemes The controller is suitable for wall mounting inside the One FB 100 remote control is required for each of the boiler room or in the living space. Installing it in the living third and fourth heating circuits. space enables room temperature hook-up. Parts list Model code Description...

  • Page 18: System Scheme 8: Two Mixed Heating Circuits, Two Dhw Circuits, Low Loss Header

    System schemes System scheme 8: two mixed heating circuits, two DHW circuits, low loss header Hydraulic scheme with controller (schematic diagram) FW 500 IPM 2 IPM 2 Suprapur KBR 120-280 ST ... ST ... 6 720 643 417-09.1O Fig. 8 Heating system components Outside temperature sensor Boiler control unit...
  • Page 19 System schemes Function description enables communication between the boiler control unit, the controller and the load switching modules. The heating circuits are regulated by an FW 500 weather-compensated controller. This always requires The controller is suitable for wall mounting inside the two IPM 2 load switching modules.

  • Page 20: System Scheme 9: One Unmixed Heating Circuit, One Dhw Circuit, Low Loss Header, Cascade

    System schemes System scheme 9: one unmixed heating circuit, one DHW circuit, low loss header, cascade Hydraulic scheme with controller (schematic diagram) FW 200 IPM 2 Suprapur MKB 240-560 ST ... 6 720 643 417-10.1O Fig. 9 Features Outside temperature sensor Boiler control unit •...
  • Page 21 System schemes The controller is suitable for wall mounting inside the boiler room or in the living space. Installing it in the living space enables room temperature hook-up. Parts list Model code Description Part no. Price Condensing boiler KBR 120-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 229 KBR 120-3 A 21...

  • Page 22: Specification

    Specification Specification Appliance parameters 2.1.1 Single appliance Suprapur KBR ... Boiler size (output in kW) Unit KBR 120-3 A KBR 160-3 A KBR 200-3 A KBR 200-3 A KBR 240-3 A Number of sections – Rated output full load/partial load 120/31 160/42 200/62...

  • Page 23: Factory-Prepared Cascade Suprapur Mkb

    Specification 2.1.2 Factory-prepared cascade Suprapur MKB ... Boiler size (output in kW) Unit 240-3 A 320-3 A 400-3 A 480-3 A 560-3 A Number of sections – Rated output full load/partial load 240/31 320/42 400/62 480/75 560/87 temperature pair 50/30 °C Rated output full load/partial load 226/28 300/38...

  • Page 24: Dimensions And Minimum Clearances

    Specification Dimensions and minimum clearances 2.2.1 Single appliance Suprapur KBR ... 1515 1400 1143 1018 Ø 6 720 643 417-24.1O Fig. 10 Suprapur KBR 120 ... 280-3 A Flue gas connection MAG Connection for diaphragm expansion vessel AKO Condensate outlet Boiler return Combustion air pipe connection Safety valve or safety assembly connection...

  • Page 25: Factory-Prepared 2-Boiler Cascade Mkb

    Specification 2.2.2 Factory-prepared 2-boiler cascade MKB ... Ø GAS, 1143 1018 6 720 643 417-13.1O Fig. 11 Factory-prepared 2-boiler cascade Flue gas connection Combustion air pipe connection (balanced flue operation only) GAS Gas connection Boiler return Boiler flow Pump installation point, boiler circuit 6 720 645 817 (2010/09)
  • Page 26 Specification Unit MKB 240-3 A MKB 320-3 A MKB 400-3 A MKB 480-3 A MKB 560-3 A 1202 1202 1410 1410 2041 2243 2421 2620 2573 1842 1995 2135 2139 2135 Ø AA – DN 200 DN 200 DN 250 DN 250 DN 250 1335...

  • Page 27: Installed Dimensions

    Specification Installed dimensions Wherever possible, site the Suprapur gas condensing A reduction of the minimum clearances makes boiler boiler with the recommended wall clearances access more difficult. Fig. 12). This ensures good accessibility for installation, maintenance and service. 2.3.1 Single appliance Suprapur KBR ... 6 720 644 748-07.1O Fig.

  • Page 28: Factory-Prepared Cascade Mkb

    Specification 2.3.2 Factory-prepared cascade MKB ... ≥ 100 6 720 644 748-09.1O Fig. 13 Installed dimensions Suprapur factory-prepared 2-boiler cascade (dim. in mm) Unit MKB 240-3 A MKB 320-3 A MKB 400-3 A MKB 480-3 A MKB 560-3 A 700/500 700/500 700/500 700/500...

  • Page 29: Pressure Drop, Water Side

    Specification Pressure drop, water side The pressure drop on the water side is the pressure connections of the gas condensing boiler. It depends on differential between the boiler flow and return the boiler size and the heating water flow rate. Fig.

  • Page 30: Boiler Efficiency

    Specification Boiler efficiency Standby loss The boiler efficiency η identifies the ratio of heat output The standby loss q is part of the rated heat input that to heat input subject to the return temperature. is required to achieve the specified boiler water temperature.

  • Page 31: Flue Gas Temperature

    Specification Flue gas temperature Conversion factor for alternative system temperatures The flue gas temperature ϑ is the temperature captured inside the flue pipe, specifically at the boiler flue outlet. In the tables containing the technical details of the It depends on the return temperature. Suprapur gas condensing boilers, the rated output figures relate to system temperatures 50/30 °C and 80/60 °C.

  • Page 32: Appliance Layout

    Appliance layout Appliance layout Fig. 20 Main PCB with programming unit Gas burner Boiler front panel Siphon Boiler block with thermal insulation Burner controller Gas valve Boiler casing Check valve 6 720 645 817 (2010/09)

  • Page 33: Product Description

    Balanced flue operation is possible condensate pan – easy burner removal via an additional air inlet connector. Optimised heating • Matching system technology from Junkers, e.g. surfaces and specific water routing aid the achievement matching flue and ventilation accessories for easy and...

  • Page 34: Characteristics And Special Features

    Product description Gas burner 4.1.4 Characteristics and special features Advanced boiler concept 4.2.1 Burner and burner control unit • Heat exchanger made from high grade A highly premixing modulating gas premix burner with aluminium-silicon sand casting clean combustion is used in the Suprapur gas •...

  • Page 35: Burner Function

    Product description Delivery method 4.2.2 Burner function The maximum ΔT between flow and return temperature The Suprapur is factory-fitted with check valve and is at rated output is 30 K. delivered preset for natural gas H or L. This enables rapid installation and easy, quick connection to the From ΔT = 30 K, when no heat is being drawn off, the heating system.

  • Page 36: Engineering Information And Sizing

    Engineering information and sizing the heat source Engineering information and sizing the heat source Operating conditions Tab. 18 provides an overview of the conditions that must be observed, subject to the application and the local system-specific circumstances. Minimum Max. water Minimum Operating Heating circuit...
  • Page 37 Engineering information and sizing the heat source Limit curves V / m 280 kW 240 kW 200 kW 160 kW 120 kW / °dH 6 720 643 417-14.1O Fig. 22 Limit curves for water treatment – single boiler V / m 560 kW 480 kW 400 kW...
  • Page 38 The fill and top-up water must have a residual hardness of 5 °dH to 7 °dH. Only use chemicals approved by Junkers. Additional protection against corrosion Damage through corrosion occurs if oxygen constantly enters the heating water, for example through...

  • Page 39: Important Hydraulic System Components

    Engineering information and sizing the heat source Important hydraulic system components 5.3.1 Hydraulics for maximum utilisation of the 3. System volume condensing effect Subject to various heating system parameters, the system volume can be checked on the graph in Fig. 25. Always use the Suprapur gas condensing boilers with a low loss header.
  • Page 40 Engineering information and sizing the heat source Example 2 Given Flow temperature ( table 19): ϑ = 50 °C MAG pre-charge pressure ( table 19): p = 1.00 bar from example 1: system volume: V = 4000 l Actual A MAG with 200 l capacity is required ( table 19), as the system volume determined in accordance with Fig.

  • Page 41: Condensate Drainage

    Engineering information and sizing the heat source Condensate drainage Materials for condensate lines Suitable materials for condensate lines in accordance Route the condensate from condensing boilers correctly with DWA Code of Practice ATV-DVWK-A 25 [Germany] into the public sewage system. It is essential to are the following: determine whether the condensate must be neutralised prior to discharge into the sewer system.

  • Page 42: Condensate Drain From The Condensing Boiler And The Flue

    Engineering information and sizing the heat source 5.4.1 Condensate drain from the condensing boiler 5.4.2 Condensate drain from a moisture-resistant and the flue chimney To ensure the condensate created in the flue can drain With moisture-resistant chimneys (suitable for via the condensing boiler, route the flue inside the condensing boilers), drain the condensate in installation room with a slight fall (≥...

  • Page 43: Regulations And Operating Conditions

    Regulations and operating conditions Regulations and operating conditions Extracts from regulations Inspection/maintenance Keep the system in good order and clean it regularly The Suprapur gas condensing boilers meet the (recommendation: every two years). The entire system requirements of DIN-EN 677, the EC Efficiency Directive, should be checked annually for perfect function.

  • Page 44: Combustion Air

    Regulations and operating conditions Combustion air Combustion air supply Where combustion air is concerned, ensure that it is not The conditions of installation rooms and the siting of gas heavily contaminated with dust and contains no appliances must comply with country-specific halogenated compounds.

  • Page 45: Siting Combustion Equipment

    Regulations and operating conditions Siting combustion equipment Sound insulation Subject to the regulations of the relevant country, gas The quiet gas premix burner in the Suprapur generates combustion equipment with a total rated output in only low noise emissions, compared to conventional excess of 50 kW may only be installed in rooms: pressure-jet gas burners.

  • Page 46: Accessories / Services

    Accessories / Services Accessories / Services Neutralising systems The neutralising system is filled with neutralising granulate. Through contact between the condensate and Neutralising systems no. 1605 and no. 1606 can be used the neutralising agent, the condensate pH level will be if the condensate needs to be neutralised.

  • Page 47: Neutralising System No. 1606

    Accessories / Services 7.1.2 Neutralising system no. 1606 7.1.3 Condensate lifting system no. 1620 The neutralising system no. 1606 comprises a plastic The condensate lifting system no. 1620 was designed for casing with a chamber to hold the neutralising granulate, installation inside condensing boilers where corrosive a back-up area for the neutralised condensate and a condensate according to the DWA Code of Practice...

  • Page 48: Pumps

    Accessories / Services Dirt traps H / m Deposits in heating systems can lead to local overheating, noise and corrosion. Any resulting boiler damage falls outside the warranty obligations. To remove dirt deposits, flush the new heating system thoroughly prior to installing and commissioning a boiler.

  • Page 49: Boiler Safety Set

    Accessories / Services Safety equipment to DIN-EN 12828 The maximum flow temperature drops As standard, the Suprapur KBR ... is equipped with a low through mixing to a lower temperature level water indicator (minimum pressure switch) and boiler in the low loss header. drain &...

  • Page 50: Shut-Off Set Combined With Check Valve

    Flow piece in cascade pipework 7.11 Services When using shut-off valves, install the check valve in the Junkers offers setup optimisation for the gas burner, flow direction downstream of the shut-off valve. boiler and the control unit parameters as part of the commissioning service.

  • Page 51: Heating Controls

    Heating controls Heating controls A control unit is required to operate gas condensing boilers. The Junkers control systems are of modular design. This enables the system to be matched inexpensively to the individual application and equipment installed in the planned heating system.

  • Page 52: Overview Of The Bus-Regulated Controller Functions

    Heating controls Overview of the BUS-regulated controller functions Weather-compensated controller Controller FW 100 FW 200 FW 500 1 unmixed heating circuit 1 mixed heating circuit (with IPM 1) (with IPM 1) (with IPM 1) 2 mixed heating circuits – (with IPM 2) (with IPM 2) 4 mixed heating circuits –...

  • Page 53: Weather-Compensated Controllers

    Heating controls Weather-compensated controllers FW 100 Application • Weather-compensated flow temperature controller • Constant output control • Communication with the heat source via 2-wire BUS Function • 2-wire BUS technology, reverse polarity protected connection • Controls one mixed or unmixed heating circuit •...
  • Page 54 Heating controls FW 200 Application • Weather-compensated flow temperature controller • Constant output control • Communication with the condensing boiler via 2-wire BUS Function • 2-wire BUS technology, reverse polarity protected connection • Controls two mixed heating circuits without remote control •...
  • Page 55 Heating controls FW 500 Application • Weather-compensated flow temperature controller • Constant output control • Communication with the condensing boiler via 2-wire BUS Function • 2-wire BUS technology, reverse polarity protected connection • Controls two mixed heating circuits without remote control •...

  • Page 56: Accessory For 2-Wire Bus Controller

    Heating controls Accessory for 2-wire BUS controller IPM 1 Application • Load switching module for switching a heating circuit pump and mixer for one mixed or unmixed heating circuit • Switching the cylinder primary pump and DHW circulation pump for one cylinder circuit •...
  • Page 57 Heating controls ISM 1 Application • Solar module for solar DHW heating in conjunction with Fx controller • Communication with the condensing boiler and controller via 2-wire BUS • 3 switching outputs 230 V AC, 50 Hz, 2.5 A, max. 80 W •...

  • Page 58: Cascade Switching Module (0-10 V Interface For Systems With Direct Digital Control (Ddc))

    Heating controls Cascade switching module (0-10 V interface for systems with Direct Digital Control (DDC)) Application • Cascade module for switching two condensing boilers (MKB 240-3 A to MKB 560-3 A) in conjunction with FW 200 or FW 500 • Communication with the condensing boilers and the controller via 2-wire BUS •...

  • Page 59: Controller Accessories - Outside Temperature Sensors

    Heating controls FB 100 Application • Remote control for weather-compensated operation with room temperature hook-up in conjunction with FW 100 or FW 200 • May be used for heating circuits 3 and 4 of the FW 200 controller • Communication with the controller via 2-wire BUS Function •...

  • Page 60: Dhw Heating

    The SE ...-1 series of cylinders is equipped with Selecting DHW cylinders austenitic stainless steel on the DHW side. This makes Junkers KBR 120-280-3 A gas condensing boilers can be these cylinders neutral towards common potable water. combined with the following cylinder models from the...
  • Page 61 DHW circulation pump. When making the cold and hot water connections at the cylinder, observe DIN 1988 and the regulations of the local water board. For Junkers DHW cylinders up to 200 l capacity, 6 720 645 817 (2010/09)
  • Page 62 DHW heating Cylinder connection on the heating side Mixed installation The sizing of the connection lines for the cylinder flow The following section only applies to and return is based on a temperature differential of 20 K. enamelled DHW cylinders, not stainless Table 35 shows the resulting internal diameters.
  • Page 63 DHW heating DHW circulation line Parallel connection of two cylinders Junkers cylinders must be equipped with their own DHW circulation connection. Seal this connection if no DHW circulation line is connected. DHW circulation is only permitted with reference to the...
  • Page 64 DHW heating DHW expansion vessel Overheating/flow limitation Installing an expansion vessel that is suitable for Junkers DHW cylinders are optimised for maximum drinking water can prevent unnecessary water loss. output (N factor). In case of frequent successive Install it in the cold water supply line between the short-term drawing events, the set temperature may cylinder and the safety assembly.

  • Page 65: Dhw Cylinders Series Sk

    DHW heating DHW cylinders series SK ... Installation and connection dimensions SK 300/400/500-3 ZB > R 1 / SE 8 SK300/400 > 1000 R 1 / SK500 R 1 / KW/E R 1 / 4132-33.1R Fig. 39 Installation and connection dimensions SK 300/400/500-3 ZB (dimensions after a slash denote the next cylinder size up) Drain Cold water inlet...
  • Page 66 DHW heating Installation and connection dimensions SK 800/1000-ZB Ø 920 / Ø 1040 Rp 1 R 1¼ / R 1½ ≥ 1000 Rp ¾ Rp 1½ Rp 1½ R 1½ Rp 1 6 720 640 088-01.2O Fig. 40 Connection point for on-site draining Rp 1 (fem. thread) Wall clearances Connection point for on-site air vent valve Rp 1 (fem.
  • Page 67 DHW heating Pressure drop of the indirect coil SK 800/1000-ZB Pipework-related pressure drop values have p (bar) not been taken into account in the graphs. SK 300/400/500-3 ZB Δp / bar 0,08 0,06 0,05 0,04 0,03 0,02 0,01 0,008 0,08 0,006 0,005 0,06...
  • Page 68 DHW heating Specification Cylinder type Unit SK 300-3 ZB SK 400-3 ZB SK 500-3 ZB SK 800 ZB SK 1000-ZB Heat exchanger Heat transfer – Indirect coil Indirect coil Indirect coil Indirect coil Indirect coil Number of coils – Available capacity Heating water content 36.1 42.1...

  • Page 69: Dhw Cylinders Series Se

    DHW heating DHW cylinders series SE ... Installation and connection dimensions SE 300-1 WW ZL KW V R ¾ 105 105 105 105 Ø 660 6 720 643 417-28.1O Fig. 44 Installation and connection dimensions SE 300-1 Cold water inlet Cylinder return Sensor well, temperature display Sensor well for cylinder temperature sensor (NTC)
  • Page 70 DHW heating Pressure drop of the indirect coil Δp / bar 0,08 0,06 0,05 0,04 0,03 0,02 0,01 0,6 0,8 1,0 3,0 4,0 5,0 V / m 6 720 615 094-02.2O Fig. 45 Pressure drop of the indirect coil in bar Pressure drop Δp Flow rate...
  • Page 71 DHW heating Specification Cylinder type Unit SE 300-1 Heat exchanger Heat transfer – Indirect coil Number of coils – – Available capacity Heating water content – Heating surface 0.93 Performance factor N to DIN 4708 at max. output – 11.5 Further details Available amount of DHW (without reheating) = 60 °C and...

  • Page 72: Installation Accessories

    Installation accessories Installation accessories 10.1 Connection accessories Designation/accessory no. Part no. No. 1600 8 718 576 603 Boiler safety assembly G 1½ With diaphragm safety valve ¾", 3 bar No. 1601 8 718 576 606 Heating circuit connection set G 1½ angled version For heating circuit flow and return, with shut-off valves No.

  • Page 73: Cascade Accessories

    Installation accessories Designation/accessory no. Part no. No. 885 7 719 002 146 Waste set incl. fixing parts and drain hose for safety valve TB 1 7 719 002 255 Temperature limiter for underfloor heating system Contact thermostat with gold contacts, setting range 30 ... 60 °C Tab.

  • Page 74: Other Accessories

    Installation accessories 10.3 Other accessories Designation/accessory no. Part no. No. 1620 80 695 080 Condensate pump Without neutralising system; max. head 6 m No. 1605 8 718 576 749 Neutralising tank Incl. granulate filling, connection components, inlet and drain hoses No.

  • Page 75: Flue Systems

    Flue systems Flue systems 11.1 Flue system Material requirements The flue material must be resistant to the flue gas 11.1.1 Requirements temperatures that can occur. It must be resistant against moisture and acidic condensate. Stainless steel and Standards, regulations and directives plastic flues are suitable.

  • Page 76: Plastic Flue System

    Rectangular chimney shaft chimney shaft Approval [mm] [mm] The plastic flue systems offered by Junkers are approved [in Germany]. The approval pamphlet is supplied with DN 125 Ø 180 180 × 180 the boiler flue connection for every order. Individual DN 160 Ø...

  • Page 77: Flue Gas Parameters Suprapur - Single Boiler Kbr

    Flue systems 11.1.3 Flue gas parameters Suprapur – single boiler KBR ... Rated output Rated heat Flue Available Flue gas Flue gas mass input outlet draught temperature content flow rate System Boiler Full Partial Full Partial Full Partial Full load/ Full Partial temperature...

  • Page 78: Flue Systems For Open Flue Operation

    Flue systems 11.2 Flue systems for open flue operation Safety clearances towards combustible building materials 11.2.1 General information for open flue operation • Inflammable and explosive materials and liquids must not be stored or used in the vicinity of the gas Regulations condensing boiler.

  • Page 79: Ventilation Air/Flue Gas Line

    Flue systems 11.2.2 Ventilation air/flue gas line Junkers sets The flue that is part of the Junkers set is made from plastic. It is installed as a complete pipe system or as a connection piece between the gas condensing boiler and a moisture-resistant chimney.

  • Page 80: Open Flue Routing Via Flue Inside A Chimney Shaft

    Flue systems 11.2.3 Open flue routing via flue inside a chimney shaft (B 6 720 643 417-30.1O Fig. 48 Tab. 46 Open flue operation - observe Feuerungsverordnung (FeuVO) [Combustion Order - Germany] 6 720 645 817 (2010/09)
  • Page 81 Flue systems Flue accessories Ø 125 mm Ø 160 mm Ø 200 mm Ø 250 mm Description page 92 ff.) page 97 ff.) page 103 ff.) page 109 ff.) AZB 1350 Boiler flue connection, 87° bend AZB 1350 AZB 1351 AZB 1351 AZB 1351 AZB 1352...

  • Page 82: Balanced Flue Routing, Vertical Via The Roof (B 23 )

    Flue systems Bend Equivalent pipe length 90° 15° - 45° Tab. 48 Equivalent pipe lengths of bends 11.2.4 Balanced flue routing, vertical via the roof (B 6 720 643 417-31.1O Fig. 49 Tab. 49 Open flue operation - observe Feuerungsverordnung (FeuVO) [Combustion Order - Germany] 6 720 645 817 (2010/09)
  • Page 83 Flue systems Flue accessories Ø 125 mm Ø 160 mm Ø 200 mm Ø 250 mm page 92 ff.) page 97 ff.) page 103 ff.) page 109 ff.) Description AZB 1350 Boiler flue connection, 87° bend AZB 1350 AZB 1351 AZB 1351 AZB 1351 AZB 1352...

  • Page 84: Open Flue Routing Via Flue Over A Facade (B 23 )

    Flue systems 11.2.5 Open flue routing via flue over a facade (B 6 720 643 417-32.1O Fig. 50 Tab. 52 Open flue operation - observe Feuerungsverordnung (FeuVO) [Combustion Order - Germany] 6 720 645 817 (2010/09)
  • Page 85 Flue systems Flue accessories Ø 125 mm Ø 160 mm Ø 200 mm Ø 250 mm Description page 92 ff.) page 97 ff.) page 103 ff.) page 109 ff.) AZB 1350 Boiler flue connection, 87° bend AZB 1350 AZB 1351 AZB 1351 AZB 1351 AZB 1352...

  • Page 86: Flue Systems For Balanced Flue Operation

    Flue systems 11.3 Flue systems for balanced flue Safety clearances towards combustible building materials operation • Minimum safety clearances towards combustible 11.3.1 General information for balanced flue building materials are not required. operation • Inflammable and explosive materials and liquids must not be stored or used in the vicinity of the gas Regulations condensing boiler.
  • Page 87 [where A calculation to DIN-EN 13384 is required. This can be appropriate]. performed by Junkers. The inspection apertures are shown for illustration For this, the following details are required: purposes only. For more detailed installation •...

  • Page 88: Balanced Flue Routing Via Flue Inside A Chimney Shaft Whilst Drawing In Combustion Air In Countercurrent (C 93 )

    Flue systems 11.3.2 Balanced flue routing via flue inside a chimney shaft whilst drawing in combustion air in countercurrent 6 720 643 417-33.1O Fig. 52 Tab. 55 6 720 645 817 (2010/09)
  • Page 89 Flue systems Flue accessories Ø 125 mm Ø 160 mm Ø 200 mm Ø 250 mm Description page 92 ff.) page 97 ff.) page 103 ff.) page 109 ff.) AZB 1350 Boiler flue connection, 87° bend AZB 1350 AZB 1351 AZB 1351 AZB 1351 AZB 1352...

  • Page 90: Balanced Flue Routing Via Flue Inside A Chimney Shaft Whilst Drawing In Combustion Air Through A Separate Pipe (C 53 )

    Flue systems 11.3.3 Balanced flue routing via flue inside a chimney shaft whilst drawing in combustion air through a separate pipe (C 6 720 643 417-34.1O Fig. 53 Tab. 57 6 720 645 817 (2010/09)
  • Page 91 Flue systems Flue accessories Ø 125 mm Ø 160 mm Ø 200 mm Ø 250 mm Description page 92 ff.) page 97 ff.) page 103 ff.) page 109 ff.) AZB 1350 Boiler flue connection, 87° bend AZB 1350 AZB 1351 AZB 1351 AZB 1351 AZB 1352...

  • Page 92: Visual Overview Of Flue Accessories

    Flue systems 11.4 Visual overview of flue accessories 11.4.1 Flue accessories Ø 125 mm General flue accessories Standard delivery Designation/description Part number AZB 1350 7 747 003 465 Boiler flue connection with test port, 87° bend Ø 160 mm for KBR 120/160-3 A AZB 1352 7 747 003 467 Boiler flue connection with test port, straight...
  • Page 93 Flue systems Standard delivery Designation/description Part number AZB 724/1 7 719 002 895 30° bend, flue side, Ø 125 mm, made from PP AZB 719/1 7 719 002 894 15° bend, flue side, Ø 125 mm, made from PP AZB 1300 87 094 780 Enlargement adaptor for ventilation air connection from Ø...
  • Page 94 Flue systems Standard delivery Designation/description Part number AZB 925 7 719 002 857 Universal roof tile, Ø 125 mm, black for roof pitch 25° - 45° AZ 136 7 719 000 838 Flat roof flange, Ø 125 mm Tab. 59 Special flue accessories for routing the flue through a chimney shaft Standard delivery Designation/description...
  • Page 95 Flue systems Standard delivery Designation/description Part number AZB 713/1 7 719 002 898 Spacer for flue inside chimney shaft, Ø 125 mm AZB 1308 87 090 762 Chimney shaft cover, Ø 125 mm, made from stainless steel with terminal pipe made from PP AZB 1049 7 746 900 998 Terminal pipe, Ø...
  • Page 96 Flue systems Special flue accessories for routing the flue on a facade Standard delivery Designation/description Part number AZB 1331 87 090 951 Facade pack Ø 125 mm, stainless steel with support bend and panel AZB 1001, AZB 1005 Extension pipe for facade solution, Ø 125/185 mm, made from stainless steel/PP AZB 1001: L = 500 mm...

  • Page 97: Flue Accessories Ø 160 Mm

    Flue systems Standard delivery Designation/description Part number AZB 1027 7 746 900 990 Roof outlet for facade solution, Ø 125/185 mm, made from stainless steel/PP AZB 1358 87 090 971 Terminal piece, Ø 125/185 mm, made from stainless steel/PP with clamping strap AZB 1049 7 746 900 998 Terminal pipe, Ø...
  • Page 98 Flue systems Standard delivery Designation/description Part number AZB 1351 7 747 003 466 Boiler flue connection with test port, 87° bend Ø 200 mm for KBR 200/240/280-3 A AZB 1353 7 747 003 468 Boiler flue connection with test port, straight Ø...
  • Page 99 Flue systems Standard delivery Designation/description Part number AZB 966 7 746 900 686 30° bend, flue side, Ø 160 mm, made from PP AZB 964 7 746 900 684 15° bend, flue side, Ø 160 mm, made from PP AZB 1300 87 094 780 Enlargement adaptor for ventilation air connection from Ø...
  • Page 100 Flue systems Special flue accessories for routing the flue through a chimney shaft Standard delivery Designation/description Part number AZB 953 7 746 900 673 Chimney shaft pack, Ø 160 mm, made from PP AZB 1317 87 090 814 Fascia with integral secondary ventilation, Ø...
  • Page 101 Flue systems Standard delivery Designation/description Part number AZB 1050 7 746 900 999 Terminal pipe, Ø 160 mm, made from stainless steel for optional replacement of terminal pipe made from PP AZB 1053 7 746 901 002 Installation aid, pipe clip with eyelets for pipes with Ø...
  • Page 102 Flue systems Standard delivery Designation/description Part number AZB 1024 7 746 900 987 Inspection aperture for facade solution, Ø 160/225 mm, made from stainless steel/PP AZB 1016 7 746 900 979 45° bend, with inspection aperture for facade solution, Ø 160/225 mm, made from stainless steel/PP AZB 1337 87 090 979 Wall outlet, 0.5 m long, Ø...

  • Page 103: Flue Accessories Ø 200 Mm

    Flue systems Standard delivery Designation/description Part number AZB 1050 7 746 900 999 Terminal pipe, Ø 160 mm, made from stainless steel for optional replacement of terminal pipe made from PP AZB 1057 7 746 901 006 Clamping strap, Ø 225 mm Tab.
  • Page 104 Flue systems Standard delivery Designation/description Part number AZB 999 7 746 900 719 87° bend with inspection aperture, flue side, Ø 200 mm, made from PP AZB 975 7 746 900 695 87° bend, flue side, Ø 200 mm, made from PP AZB 971 7 746 900 691 45°...
  • Page 105 Flue systems Standard delivery Designation/description Part number AZB 1347 87 094 756 Reduction adaptor for flue from Ø 200 mm to Ø 160 mm for KBR 200/240/280-3 A AZB 1341 87 090 912 Special roof tiles, Ø 200/Ø 300 mm AZB 1344 7 747 204 945 Flat roof flange, Ø...
  • Page 106 Flue systems Standard delivery Designation/description Part number AZB 1329 87 090 726 Support inside the chimney shaft for flue system Ø 200 mm, with 2 m pipe AZB 991 7 746 900 711 Spacer, Ø 200 mm, made from stainless steel AZB 1310 87 090 766 Chimney shaft cover, Ø...
  • Page 107 Flue systems Standard delivery Designation/description Part number AZB 1329 87 090 726 Support inside the chimney shaft for flue system Ø 200 mm, with 2 m pipe Tab. 69 Special flue accessories for routing the flue on a facade Standard delivery Designation/description Part number AZB 1333...
  • Page 108 Flue systems Standard delivery Designation/description Part number AZB 1338 87 090 980 Wall outlet, 0.5 m long, Ø 200/300 mm, made from PE/PP AZB 1047 7 746 900 996 Wall mounting bracket, Ø 300 mm, made from stainless steel AZB 1043 7 746 900 992 Roof outlet for facade solution, Ø...

  • Page 109: Flue Accessories Ø 250 Mm

    Flue systems 11.4.4 Flue accessories Ø 250 mm General flue accessories Standard delivery Designation/description Part number AZB 1351 7 747 003 466 Boiler flue connection with test port, 87° bend Ø 200 mm for KBR 200/240/280-3 A AZB 1353 7 747 003 468 Boiler flue connection with test port, straight Ø...
  • Page 110 Flue systems Standard delivery Designation/description Part number AZB 972 7 746 900 692 45° bend, flue side, Ø 250 mm, made from PP AZB 968 7 746 900 688 30° bend, flue side, Ø 250 mm, made from PP AZB 962 7 746 900 682 Enlargement adaptor for flue connection from Ø...
  • Page 111 Flue systems Special flue accessories for routing the flue through a chimney shaft Standard delivery Designation/description Part number AZB 955 7 746 900 675 Chimney shaft pack, Ø 250 mm, made from PP AZB 1319 87 090 817 Fascia with integral secondary ventilation, Ø 250 mm, pitch circle diameter 356 mm, made from stainless steel AZB 1060...
  • Page 112 Flue systems Standard delivery Designation/description Part number AZB 1311 87 090 767 Chimney shaft cover, Ø 250 mm, made from stainless steel AZB 1055 7 746 901 004 Installation aid, pipe clip with eyelets for pipes with Ø 250 mm Tab.
  • Page 113 Flue systems Standard delivery Designation/description Part number AZB 1026 7 746 900 989 Inspection aperture for facade solution, Ø 250/300 mm, made from stainless steel/PP AZB 1018 7 746 900 981 45° bend, with inspection aperture for facade solution, Ø 250/350 mm, made from stainless steel/PP AZB 1339 87 090 981 Wall outlet, 0.5 m long, Ø...
  • Page 114 Notes 6 720 645 817 (2010/09)
  • Page 115 Notes 6 720 645 817 (2010/09)
  • Page 116 Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.junkers.com...

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