Junkers SUPERPURE KBR 120-3 Product manual

Gas condensing boiler
6720641801(2010/11)DE/AT/CH
Installation and maintenance guide for professionals
SUPERPURE
KBR 120-3
KBR 200-3
KBR 280-3
KBR 160-3
KBR 240-3
Machine Translated by Google

Table of Contents
Table of Contents
2
1 Explanation of symbols and safety instructions . 4 1.1 Explanation
of symbols . . . . . . . . . . . . . . . . . . . . . . 4 1.2 Safety
Instructions . . . . . . . . . . . . . . . . . . . 4
5.3 Aligning the boiler . . . . . . . . . . . . . . . . . 21
5.8.2 Heating controller and modules (accessories)
6.1
connection pressures . . . . . . . . . . . . . . . . . . . . . 11 2.11
Main circuit board connection diagram . . . . . . . . 12 2.12 System
example . . . . . . . . . . . . . . . . . . . . . 14
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 5.7
Establishing the fuel supply . . . . . . . . 27 5.8 Making the electrical
connection . . . . . . . 27
2 Product information . . . . . . . . . . . . . . . . . . . . 6 2.1 About these
instructions . . . . . . . . . . . . . . . . . . . 6 2.2 EC Declaration of
Conformity . . . . . . . . . . . . . . 6 2.3 Intended use . . . . . . . . 6 2.4
Naming the boiler . . . . . . . . . . . . 6 2.5 Scope of
delivery . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.6 Product
overview . . . . . . . . . . . . . . . . . . . . . 7 2.7 Dimensions and
Connections . . . . . . . . . . 8 2.8 Technical
data . . . . . . . . . . . . . . . . . . . . 10 2.9 Gas
throughput . . . . . . . . . . . . . . . . . . . . . . . 11 2.10 Country-specific
gas categories and
5.8.5 Assembling the cover hood . . . . . . . . . . . . . . 29
200 to 280 kW . . . . . . . . . . . . . . . . . . . . . .40 7.5.4
Updating the nameplate . . . . . . . . . . . . . . . . 40 7.6 Bleeding the
gas line . . . . . . . . . . . . . . . . . . 41 7.7 Checking the air inlet and
outlet openings and the flue gas connection . . . . . . . . . . . . . . .
.41 7.8 Checking the supply air membrane . . . . . . . . . . . . . . . .
42 7.9 Prepare the heating system for operation . . . 42 7.10
Heating system on the control unit
mount . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.2.1 Status display . . . . . . . . . . . . . . . . . . . . . . . 32 6.2.2
"Information" menu . . . . . . . . . . . . . . . . . . . 33 6.2.3 "Fault history"
menu . . . . . . . . . . . . . . 34 6.2.4 "Settings" menu . . . . . . . . . . . . . . . . .
35 6.2.5 Chimney sweep operation (service operation) . 36 6.2.6
Key lock . . . . . . . . . . . . . . . . . . . . . . . . 36
turn on . . . . . . . . . . . . . . . . . . . . . . . . . .42 7.11 Chimney
sweep operation (service operation) . 43 7.12 Display operating
states/settings
Fit the vent or safety assembly (on
site) . . . . . . . . . . . . . . . . . .24 5.5.5 Installing the
condensate drain . . . . . . . . . 24 5.5.6 Connection for diaphragm
expansion tank
5.5.4 safety valve and automatic
6.2 Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . 32
5.8.3 Connecting external heating controllers and
5.4 Flue gas and air supply connection . . . . . . . . . . . 21 5.4.1
Establishing the flue gas connection . . . . . . . . . . . . 21 5.4.2
Making the supply air connection
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Overview of the
operating elements . . . . . . . . . 31
5.1 Requirements for the installation room. . . . . 20 5.2 Wall
distances . . . . . . . . . . . . . . . . . . . . . . 20
5.8.1 Establishing the mains connection . . . . . . . . . . . . . . 28
5.6 Filling the heating system and tightness
5.9 Aligning the boiler vertically . . . . . . . . 30
4 Transporting the boiler . . . . . . . . . . . . . . . 18 4.1 Checking the
scope of delivery. . . . . . . . . . . . . . . . . . 18 4.2 Lifting and carrying
the boiler . . . . . . . . . . 18 4.3 Transporting the boiler on
rollers . . . . . 19
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 37 7.1 Checking
the operating pressure . . . . . . . . . . . . . . . . . 37 7.2 Noting gas
characteristics . . . . . . . . . . . . . . . 38 7.3 Checking the
equipment . . . . . . . . . . . . . . 38 7.4 Checking for
leaks . . . . . . . . . . . . . . . . . 39 7.5 Changing the gas
type. . . . . . . . . . . . . . . . . . . . 39 7.5.1 Conversion for boiler size
120 kW . . . . 39 7.5.2 Conversion for the 160 kW boiler size . 40
7.5.3 Conversion for the boiler sizes from
let and change. . . . . . . . . . . . . . . . . .43
mount . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.8.4 Establishing the mains connection . . . . . . . . . . . . . . 29
connect . . . . . . . . . . . . . . . . . . . . . . . . . .28
3 regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.1 Standards
and guidelines . . . . . . . . . . . . . . . 15 3.2 Approval and information
requirements . 15 3.3 Installation room . . . . . . . . . . . . . . . . . . . . . . . .
15 3.4 Combustion air connection . . . . . . . . . . . 16 3.5 Quality of
the heating water . . . . . . . . . . . . . 16 3.6 Quality of the
pipelines . . . . . . . . . . . . . 16 3.7 Frost
protection . . . . . . . . . . . . . . . . . . . . . . . . . 16 3.8 Inspection/
Maintenance . . . . . . . . . . . . . . . . . . 17 3.9 Tools, materials and
aids . . 17 3.10 Validity of the regulations . . . . . . . . . . . . . 17
(open flue operation) . . . . . . . . . 22 5.5 Making hydraulic
connections . . . . . 22 5.5.1 Connecting the heating
flow . . . . . . . . . . . 23 5.5.2 Connecting the heating
return . . . . . . . . . . 24 5.5.3 Installing the hot water storage
tank . . . . . . . 24
6 720 641 801 (2010/11)
Machine Translated by Google

11.3 Service displays. . . . . . . . . . . . . . . . . . . . . 66 11.4 Error
displays . . . . . . . . . . . . . . . . . . . . 66 11.4.1Locking fault displays
Determine heat exchanger . . . . . . . . . . . . . . 57 10.6.1
Determining the degree of soiling . . . . . . . . . . 57 10.7 Cleaning
the burner and heat exchanger . . . . 58 10.7.1Removing the
burner . . . . . . . . . . . . . . . . . . . . 58 10.7.2Wet cleaning of the heat
exchanger . . . . . . . . . . 59 10.7.3Cleaning the
burner . . . . . . . . . . . . . . . . . . . . . . 60 10.8 Assembling the
dismantled parts . . . . . . . . . . . . 61 10.9 Checking for leaks during
operation . . . . . . . . 61 10.10 Checking the ionization
current . . . . . . . . . . . . . . . . 61 10.11 Completing inspection and
maintenance . . . . . 61 10.11.1Mounting the paneling
parts . . . . . . . . . . . 61 10.11.2 Confirm inspection and
maintenance . . . . . 61 10.12 Inspection and maintenance logs . . . .
62
7.13 Check CO2 setting at full load
11.4.2Detecting faults . . . . . . . . . . . . . . . . . . 67 11.4.3Faults
shown on the display
12.3 Flow resistance on the heating water side 77
Flow and return temperature sensors. . . 75 12.2 Sensor
characteristics . . . . . . . . . . . . . . . . . . . . . 76
9 Environmental Protection/Disposal . . . . . . . . . . . . . . 51
7.15.2CO value . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.15 Recording measured values . . . . . . . . . . . . . . . . 46
7.18 Checking for leaks during operation . . . . . . . . 48
take . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.16 Functional tests . . . . . . . . . . . . . . . . . . . 46 7.16.1Measuring
the ionization current . . . . . . . . . . . . . . . 46
decommission . . . . . . . . . . . . . . . . 50
and adjust . . . . . . . . . . . . . . . . . . . . . . . 43
7.14 Check CO2 setting at partial load
Index . . . . . . . . . . . . . . . . . . . . 78
will . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11 Service and fault displays . . . . . . . . . . 65 11.1 Safety instructions
for service work . . 65 11.2 Service and fault messages on the
display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.19 Assembling the cladding parts . . . . . . . . . . . . 48 7.20 Inform
operator, hand over technical documents . . . . . . . . . . . . . . . . 48
7.21 Commissioning report . . . . . . . . . . . . . . . 49
10 Inspection and Maintenance . . . . . . . . . . . . . . . . . 52 10.1
Preparing the boiler for inspection . . . . 52 10.2 General
work . . . . . . . . . . . . . . . . . . . 52 10.3 Internal leak
test . . . . . . . . . . . . . . . 53 10.3.1 Determining the test
volume . . . . . . . . . . . . . . . . . 53 10.3.2 Carrying out a leak
test . . . . . . . . . . 54 10.4 Checking the operating pressure of the
heating system 56 10.5 Measuring the CO2
content . . . . . . . . . . . . . . . . . . 56 10.6 Degree of contamination at
the burner and
reset to default: . . . . . . . . . . . . . . . . . . . . . . . . 66
7.15.1 Delivery pressure. . . . . . . . . . . . . . . . . . . . . . . . . 46
12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 12.1 Voltage
ratings for hot water, boiler,
8.2.1 Behavior in an emergency . . . . . . . . . . . . . . . . . . . 50
8.2 Heating system out of order in an emergency
7.17 Measuring the gas connection flow pressure . . . . . . . 47
and adjust . . . . . . . . . . . . . . . . . . . . . . . 44
11.5 Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8 Decommissioning the heating system . . . 50 8.1 Heating system
on the control unit
6 720 641 801 (2010/11)
Table of Contents
3
Machine Translated by Google

1 Explanation of symbols and safety instructions
of the text limited.
B If you hear it escaping, leave the building immediately. Prevent entry by
third parties, inform the police and fire brigade from outside the building
People or things become with the ne
B Before opening the boiler:
B Extinguish open flames. Do not smoke. No fire
• DANGER means that life-threatening people
Warnings in the text are marked with a
B Shut down the heating system (Æ page 50).
meaning
switch secure.
Explanation of symbols and safety instructions
In the event of danger from electricity, the exclamations
Important information
B Only allow work on gas-carrying components to be carried out by an
approved specialist company.
mix
B Inform the system operator of the defect and the danger in writing.
•
B Do not operate electrical switches, pull plugs, use telephones or ring bells.
B Notify an authorized specialist company.
document or to other documents
voltage, colors, etc.) should not be used or stored near the boiler.
Signal words at the beginning of a warning indicate the type and
severity of the consequences if the measures to prevent the danger are not
followed.
Important information without dangers for
Æ
B Close the gas tap (Æ page 50).
Danger if you smell exhaust gas
symbol
B Heating system against unintentional reactivation
B If the defect is not remedied immediately, the boiler must not be
operated.
It is not enough to switch off the controller.
B Warn residents from outside , but don't
Danger of poisoning. Insufficient air supply can lead to dangerous
exhaust emissions
Danger from explosion of flammable gases
B Open windows and doors.
Cross-reference to other places in
B Easily flammable materials (paper, thinner
to.
ring. Call the gas supply company and approved specialist company.
are reduced or closed.
B
marked with a gray warning triangle and framed.
Risk of explosion if you smell gas
Personal injury can occur.
More symbols
Table 1
light stuff.
damage can occur.
Enumeration/list entry (2nd level)
• NOTICE means that property damage can occur
marked with the following symbol. They are represented
by lines above and below
Switch off the power to the heating system with the heating emergency
switch or disconnect the heating system from the mains using the
corresponding house fuse.
B Open windows and doors.
• WARNING indicates that serious personal injury can occur.
action step
Danger from explosive and highly flammable materials
–
symbol in the warning triangle replaced by a lightning bolt.
B Make sure that the supply and exhaust air openings are not
Danger from electric current when the boiler is open
Enumeration/list entry
4
Warnings
• CAUTION means mild to moderate
1.1 Explanation of symbols 1.2 Safety Instructions
6 720 641 801 (2010/11)
Machine Translated by Google

6 720 641 801 (2010/11)
personal safety always comes first.
only use if they are intended for this application.
Danger from not paying attention to your own safety in emergencies,
e.g. B. in case of fire
B DHW tank for heating only
Instruction of the customer
Any repair work should only be carried out by an authorized specialist
company. In front
B Only use original spare parts.
B Do not close or reduce the size of the ventilation openings in doors,
windows and walls in room air-dependent operation . When
installing gap-tight windows, ensure the supply of combustion air.
Installation, conversion:
Working on the boiler
or carry out repairs.
During heating, water can escape from the safety valve of the hot
water storage tank.
tolerability of the heating system (Federal Immission Control Act).
risk of scalding
B Never endanger your life. the
B Inform customers about how the boiler works and show them how
to operate it.
use of hot water.
Observe the writings (Æ chapter 3, page 15).
B Other combinations, accessories and wearing parts
Explanation of symbols and safety instructions
B If the defect is not remedied immediately, the boiler must not be
operated.
Caution system damage
B Installation, commissioning, inspection and
B Maintenance and repairs may only be carried out by
authorized specialist companies.
B customers indicate that he has no changes
B Allow the boiler to cool down before inspection and
maintenance. Temperatures in excess of 60 °C can
occur in the heating system.
B Do not modify exhaust-carrying parts.
B Never close the safety valves
B The operator is responsible for safety and environmental protection
5
Machine Translated by Google

2 Product information
6 720 641 801 (2010/11)
1) Safety valve or safety group are for the
Function and security required.
1
type name
piece of packaging
component
6
• Installation and maintenance manual
Maximum heating power in kW
Use the boiler exclusively for heating water for heating systems and/or
for indirect heating of drinking water, e.g. B. Use hot water tank. Any
other use is not intended.
• 280
1 foil pack
R1¼"
Product details
• Water quality log
Tab. 3 Scope of delivery
Tab. 4 Required accessories
• 120
Technical documentation
piece
• Operation manual
The documents mentioned above are also available via Junkers on the
Internet.
Foot screw set
Boiler connection elbow
SUPERPURE:
component
Observe the information on the type plate of the boiler.
The boiler is tested according to EN 677.
1
Only use the boiler for its intended purpose and in compliance with the
installation and maintenance instructions.
• 240
1
R1" (at 120 kW)
Boiler fully assembled with casing
or security
• Spare Parts Catalog
3rd generation of controllers
back of this guide.
Table 2
to
(at 160 to 240 kW)
KBR
following parts together:
The design and operating behavior of this product comply with the
European directives and the supplementary national requirements.
Conformity is proven with the CE marking.
The following components are available as accessories.
The following documents are available for the boiler:
These installation and maintenance instructions are aimed at tradesmen
who – due to their professional training and experience – have knowledge
of how to work with heating systems and gas installations.
• 200
palette
According to § 7, paragraph 2.1 of the ordinances for the
revision of the first and amendment of the fourth ordinance for
the implementation of the Federal Immission Control Act, the
nitrogen oxide content in the exhaust gas determined under
test conditions according to DIN 4702, Part 8, March 1990
edition, is below 80 mg/kWh.
• Planning document
If you have any suggestions for improving the above documents or if you
discover any irregularities, please contact us. You will find the address
details and Internet address on the back of this document.
1
1
Gas condensing boiler
1 carton
safety valve
-3
1 foil pack
Group 1)
1
The designation of the boiler consists of the
Accesories
You can request the product's declaration of conformity. To do this,
contact the address on the
boiler connector
These installation and maintenance instructions contain important
information on the safe and proper installation, commissioning and
maintenance of the gas condensing boiler.
• 160
2.2 EC Declaration of Conformity
2.4 Naming the boiler
2.3 Intended use2.1 About this manual
2.5 Scope of Delivery
Machine Translated by Google

2.6 Product Overview
7
Boiler block with thermal protection
4
burner machine
check valve
6 720 641 801 (2010/11)
gas fitting
5
1
2
boiler front wall
siphon
3
Main circuit board with operating unit
8th
9
gas burner
6
boiler casing
• Equipment frame with casing
The boiler is a gas condensing boiler with aluminum
• Main circuit board with operating unit
The controller monitors and controls all electrical components of the boiler.
The boiler block transfers the heat generated by the burner to the
heating water. The thermal protection reduced
The boiler consists of:
7
• Gas burner
Product details
Figure 1 Product overview
• Boiler block with thermal protection
the energy loss.
nium heat exchanger.
Machine Translated by Google

ST
MAG connection diaphragm expansion tank
Combustion air line connection (only for room air-
independent operation
Table 5 Connections
RK
picture 2
AL
boiler return
Connection flue gas
GAS gas connection
VK
aa
Product details
connections
Connection safety valve or safety
group
AKO condensate outlet
Boiler flow
8th 6 720 641 801 (2010/11)
1) Not included in the delivery
2.7 Dimensions and Connections
Machine Translated by Google

345
7
1216
DN
514
Connection ST
160
231
Dimension A 13001300
145
mm
Product details
200
160
mm
514
rp 2"
Width B 1332
mm
Dimension YMAG
495
R 1"
4
293
231
514
Combustion air line diameter AL
(only balanced flue)
110
R 1½"
240
335
mm
495495
Connection VK and RK
(DN 65)
dimension F 12161008
522
200
Dimension YAA
110
Tab. 6 Dimensions and connection dimensions
1124
1308
200
916
397
470
mm
number of members 8th
1124
449
mm
110
PN6 standard flange
120
Dimension XRK (= XAL = XGAS) 231335
470
310
R¾"
5
800
1300
110
(mm)
9
Boiler size (power in kW) 280
1300
(mm)
310
Ø GAS
(DN 50)
Diameter exhaust pipe Ø AA 200160
110
mm
Dimension ZAA
514
R1¼"
6
1332
mm
1008
145 310
DN
Dimension XAA 501
6 720 641 801 (2010/11)
Machine Translated by Google

2.8 Specifications
67.6
Boiler water content
57
4
16
Temperature pairing 80/60 °C
150
Rated load kW 115.9
gas fitting
10
4615V
200
gas
89.3
59
Exhaust mass flow 80/60 °C
full load %
31
12.6
87.2
°C
heating water circuit
Minimum exhaust gas temperature 80/60 °C full load
280
225
58
120
°C
rated heat output
28
fan
25.0
part load
14.1
mm 15.7
Exhaust mass flow 50/30 °C
21.5
< 75
11.1
54
13.6
57
°C
14.2
operation
8th
75.2
< 75
number of members
gas
Temperature pairing 50/30 °C
mbar
VR
6
g/s
87.8
70.2
30
33.4
Wobbe index 12.8 kWh/m3
34
part load
55
g/s
part load
the
< 75
room air dependent and room air independent
280
240
rated heat output
33
part load kW
85
107.4
VR
200
57.9
12.9
53.8
125.4
natural gas L (Germany),
28.4
Wobbe index 14.9 kWh/m3
available
53.7
9.3
°C
32
7
Available delivery pressure of the exhaust
system
Boiler size (power in kW)
Full load kW 113
l
23.0
Honeywell
70.2
42
193
see diagram, page 77
full load
56.2
g/s 125.9
g/s
natural gas H (G20),
Not
9.1
Minimum exhaust gas temperature 50/30 °C full load 56
271
55
father
59
Tab. 7 Technical data
31
27
106.0
38.8
160
CG 20 CG 25 CG 25
155
Kromschroeder
187
29
full load
gas throttle diameter
81.3
throttle
21:6
Design (according to DVGW regulations)
56
240
79.2
°C
< 75
Product details
Maximum flow temperature
24
5
69.6
part load kW
160
Full load kW 120
38
20
G1G 170
415VE
part load kW
62
10.1
nominal heat load
part load %
100
CO2 content of natural gas
< 75
mm 15.0
263
part load
34
232
Pressure loss on the heating water side
B23, B23P, (C63(x))
6 720 641 801 (2010/11)
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2.9 Gas Flow
2.10 Country-specific gas categories and
connection pressures
240
230/50
205
Tab. 7 Technical data
120
G20/G25
100
50
power consumption
45
1400
Wobbe index 12.8
kWh/m3
Mains connection pressure
AT, CH
Tab. 9 Country-specific gas categories and connection pressures
Product details
280
width x depth x height 612x
natural gas H (G20)
placed
11
Permissible operating pressure
V/Hz
1400
boiler
240
200
330
612x
17.6
Gas type specified on
delivery or corresponding
gas type conversion kits
included
country
20
The boiler can be supplied from the factory for:
IPX0D
1400
weight
kW
30.7
mbar1)
20
power connection
190
612x
Natural gas L (DE)
612x
200
EN
240
delivery dimensions 1267x
50
1267x
13.2
Pin code
STB protection temperature
50
bar
612x
330
m3/h
12.3
16.4
20.4
24.6
28.7
Tab. 8 Gas throughput (related to 15 °C gas temperature and 1013 mbar air pressure)
20
160
Degree of protection
Part load W 40
1059x
size
20
4
Device dimensions and weight
300
26.3
delivery in
• Natural gas L (DE) (20 mbar)
Boiler size (power in kW)
230
1059x
kg
160
G20
mbar
120
270
265
m3/hr
gas category
gas throughput
280
°C
mm 851x
14001400
21:9
Wobbe index 14.9
kWh/m3
Set to mains
connection pressure at
• Natural gas H or E (G20, 20 mbar)
electrical data
Full load W 150
I2ELL
I2H
6 720 641 801 (2010/11)
1) The gas supply company must comply with the minimum and maximum pressures (according to the national regulations of the public gas supply company
care).
Machine Translated by Google

1) The total current must not exceed 6.3 A.
Product details
Figure 3 Main circuit board connection diagram
12 6 720 641 801 (2010/11)
2.11 Main circuit board connection diagram
Machine Translated by Google

Danger switches and protective measures
B Provide a stationary mains connection
(no safety plug).
Product details
B Do not use the protective conductor (green/
yellow) as a control line.
B installation, fuse, on/off switch,
Fuse 6.3 AT (6.3 x 32 mm) on the main
circuit board.
NOTICE: System damage due to incorrect
installation!
DANGER: Danger to life from electric current!
The boiler has a fuse:
ten.
13
according to local regulations.
B Ensure that the mains connection is in phase
2
15 low voltages
Legend for figure 3:
component 2
5
14 burner control bus line,
(remove the jumper when connecting)
Mains supply burner control 230 V/50 Hz
main switch
11 FA - outdoor temperature sensor
13 2-wire BUS
PH-HK1 - heating pump
8th
3
1
power input
6
16 control voltage 230 V~
4
Connection to burner controls
component 1
Fuse, 6.3 AF (6.3x32mm)
12 EV - external locking
Connection to FW... or FR... controllers, to modules IPM...,
ISM..., ICM and others
9
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10 WA - heat request (external)
Main circuit board with operating unit
PZB feeder pump
7
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You can find a representation suitable for
installation and other system examples in the
planning document.
Product details
14
Figure 4 Simplified system example for a mixed heating circuit with hot water
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WW Hot water outlet
AV
MAG membrane expansion tank
circulation pump
ZP
flow temperature sensor
HK
storage charging pump
vf
M
shut-off valve
storage tank temperature sensor
week
heating pump
SF
AF
MF
HW hydraulic switch
P
3-way mixer
WS shared hot water tank
heating circuit
circulation
temperature monitor
FW200 weather compensated controller
cold water inlet
Z
check valve
outdoor temperature sensor
LP
TB
RV
IPM 2 heating circuit module
mixer circuit temperature sensor
2.12 Plant example
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3.3 Installation room
3.2 Authorization and information requirements
3.1 Standards and guidelines
B Make sure that the installation of a gas condensing boiler is reported to
and approved by the responsible gas supply company.
en, hairdressing salons and farms (dung).
Store liquids in the immediate vicinity of the boiler.
• EMC Directive 2004/108/EC
NOTICE: System damage due to frost!
The following also applies to Switzerland :
The boilers have been tested in accordance with the requirements of
the Air Pollution Control Ordinance (LRV, Annex 4) and the guidelines
for fire police regulations of the VKF and approved by the SVGW. During
installation, the guidelines for the construction and operation of gas
furnaces G3 d/f, the SVGW gas guidelines G1 and cantonal fire police
regulations must be observed. Regardless of the installation room, only
type B11BS (with exhaust gas monitoring) is permitted.
15
Combustion air or contaminated air around the boiler!
• the local building regulations regarding the installation conditions,
• the technical rules of the gas supply company regarding the connection
of the gas burner to the local
• Gas Appliances Directive 2009/142/EC
choose the pending mode of operation with a separate,
hermetically sealed installation room that is provided
with a fresh air supply.
Investments.
For installation and operation, the following country-specific
•EN677
DANGER: Risk of fire from flammable materials or liquids!
In Austria , comply with the local building regulations and the ÖVGW
guideline G1 or G2 (ÖVGW TR gas or liquid gas) during installation. A
conversion to liquid gas is not possible. The requirements according to the
country agreement Art. 15a B-VG with regard to emissions and efficiency
are met.
B Never operate the boiler in places
Inform the master chimney sweep and the sewage authorities.
• the local building regulations for access and
B Make sure that regional permits are required for the flue gas system and
the condensate connection to the public sewage system.
technical equipment of the water heating system,
or chemically aggressive environment. This can
e.g. B. Paint shop
B The heating system in a frost-proof
• Low Voltage Directive 2006/95/EC
public gas network,
B No flammable materials or
regulations
• Efficiency Directive 92/42/EEC
B Never use a boiler in a dusty place
B In this case, always a room air-independent
• the provisions for the electrical connection to the power supply,
• EN437, EN483
Observe regulations and standards:
NOTE: Boiler damage due to contamination
exhaust air devices and the chimney connection,
The boiler meets the following requirements in terms of its design and
operating behavior:
• the installation guide for manufacturers of heating systems
on which trichloroethene or hydrogen halides or other
aggressive chemical agents are being worked on or
are stored there. These substances are z. B. in spray
cans, bestimm th adhesives, solvents or cleaning
agents and paints.
• the regulations and standards on safety
B Contact the relevant district before starting installation
set up a room.
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3 regulations
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B boiler is not designed as a gravity system
For room ventilation, the installation room must have an upper
and lower opening to the outside of at least 150 cm2 or lines
to the outside with equivalent flow cross-sections.
provide.
The following applies to balanced flue operation:
B To verify the water quality
Factor for increasing the economy, functional
reliability, service life and operational readiness of
a heating system
KBR-280
B If with room temperature compensated Be
Poor water quality leads to damage in heating systems due
to scale formation and corrosion.
KBR-200
be provided with ventilation air openings. Do not place any
objects in front of these openings.
530 cm2
16
When using plastic pipes in the heating system, e.g. B.
for underfloor heating, these lines must be oxygen-tight
according to DIN 4726/
KBR-120
370cm2
If the boiler is operated dependent on the room air, the
installation room must be equipped with the necessary combustion
s, the values required in the “water quality log”
must be recorded.
Ø Combustion air openings
NOTICE: Boiler damage due to corrosion!
NOTICE: System damage due to freezing!
B Do not place any objects in front of the combustion air
openings.
Table 10
a line can freeze (e.g. radiators in the
garage), set the pump run-on time to 24
hours.
regulations
B Combustion air opening according to Table 10
ge.
610 cm2
For open flue operation:
KBR-240
The water quality is an important one
450cm2
KBR-160
gen or open heating system.
Since there is no such thing as pure water for heat transfer,
you need to pay attention to the water quality. One
4729. If the plastic lines do not meet these standards, the
system must be separated by heat exchangers.
B Always keep the combustion air openings clear.
boiler size
290cm2
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3.7 Frost protection
3.6 Quality of piping
3.5 Quality of heating water
3.4 Combustion air connection
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In addition, the following is useful:
Changed regulations or supplements are also valid at the time of
installation and must be complied with.
• to achieve a high level of operational safety,
• to ensure environmentally friendly combustion on a high level
B Carry out maintenance as required. Around
,
• to obtain high efficiency and the
To avoid damage to the heating system, rectify any
defects immediately.
to operate the heating system sparingly,
or inadequate cleaning and maintenance!
approx. 2 m long) for carrying or
• 2 pipes (approx. R 1¼
Heating systems require periodic maintenance for the following reasons:
B Inspect the heating system once a year and clean if
necessary.
5 pipes (approx. R 1¼ ,
0.7 m long) as base for rolling the boiler.
maintenance interval
to keep level.
The standard tools from the field of heating construction and gas and
water installation are required for the installation and maintenance of the
boiler.
17
regulations
NOTE: Boiler damage due to missing
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phone
3.10 Validity of Regulations
3.9 Tools, Materials and Supplies
3.8 Inspection/Maintenance
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4.1 Check scope of delivery
4.2 Lifting and carrying the boiler
This chapter describes how to transport the boiler safely.
B Locking screw [3] of the front panel at the top of the
NOTE: Boiler damage due to dirt
B Check delivery for completeness (Æ Table 3 and
,
B Packaging upon delivery for integrity
B Transport markings on the Ver
(R 1¼
Figure 5 Dismantle the front panel and side panels
The scope of delivery of the boiler contains shock-
sensitive components.
Unscrew the front and back of the boiler.
lose weight.
B Boiler connections before ver
When dismantled the front wall and side walls
NOTE: Boiler damage from impact
Turn out the middle of the boiler.
Table 4, page 6).
B Raise the side panels [2] slightly and remove.
tongue!
B To lift the boiler off the pallet [2], the two locking screws [1] at the bottom
of the boiler must be unscrewed.
check.
Dismantle the front wall and side walls
transport boilers
note the packaging.
Fig. 6 Lift the boiler off the pallet
Lift the boiler off the pallet
B In case of further transport, protect all components from
impact.
approx. 2 m long) to be carried to the installation site.
the boiler with the help of 2 pipes
Protect against dirt by leaving all protective caps on
the connections.
kung!
B Locking screws [3] of the side panels on the
18
B Slightly lift the front panel [1] and move it forward
If the boiler is not yet to be put into operation after
unpacking:
B Dispose of packaging in an environmentally friendly manner.
2front wall
locking screws
1
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2
locking screws
3
1
Side wall
palette
Transport 4 boilers
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B So that the floor panel is not dented
Fig. 8 Transporting the boiler on rollers (dimensions in mm)
push through.
B boiler with at least 4 people
To lift and to carry.
Commercial transport rollers can be used.
B Secure the boiler against slipping.
If the path to the installation site is level, the boiler can also be rolled. To
do this, use at least 5 pieces of pipe approx. 700 mm long (diameter R
1¼ ") as a base for rolling.
B Pipes through holes in the front of the boiler
WARNING: Risk of injury from incorrect lifting and
carrying!
transport to the installation site.
is to ensure that the load is evenly distributed
on the load-bearing parts.
B Carry the boiler to the installation site.
Transport the boiler with the help of pipes
B Only lift the boiler at the designated points.
Fig. 7 Transporting the boiler using pipes
19
lay.
B Pieces of pipe about 400 mm apart on the floor
B Secure the pipes against slipping at the positions [1] shown in Figure
7, e.g. B. with tape.
transport boilers
B Lift the boiler onto the pipe sections and carefully
Pipe
2Position for securing the boiler against slipping
1
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4.3 Transport the boiler on rollers
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5.2 Wall clearances
5.1 Requirements for the installation room
This chapter explains how to install the boiler. In detail these are:
Use halogenated hydrocarbons (e.g. in
spray cans, solvents and cleaning agents,
paints, adhesives).
500
Tab. 11 Recommended and minimum wall distances (dimensions
in mm).
B Ambient temperatures greater than 0 °C and
be level.
Wall distance (mm)
Hot water tanks, pipe connections, exhaust silencers
or other components on the exhaust side, etc., must
be taken into account.
100
D
• Fuel connection
Impermissible ambient temperatures can damage
the heating system
B
the.
• Exhaust connection
Any additionally required wall bracket
550
20
B heating system in a frost-proof
500
B Do not use or store easily flammable materials
(paper, curtains, clothing, thinner, paint, etc.) near
the boiler.
Install the boiler with the recommended wall clearances. If
the distances are reduced to the minimum, access to the boiler is
difficult.
B Do not store or use these substances in the
boiler room.
Figure 9 Wall clearances in the installation room (boiler positioned
on the left or right)
B No cleaning agents containing chlorine and
less than 35 °C.
minimal
700
DANGER: Danger from explosive and highly
flammable materials!
500
NOTICE: Boiler damage due to contaminated
combustion air!
installation
The installation surface or foundation must be level and
ren.
NOTICE: Boiler damage due to overheating!
• Hydraulic connection
states of other components, such as e.g. B.
700
C
700
A
B Avoid heavy dust accumulation (construction dust).
• Lineup
set up room.
Use the sound insulation measures offered by the manufacturer
(exhaust silencers, compensators).
B With a sensitive boiler environment (e.g. housing construction)
NOTICE: System damage due to frost!
recommended
measure
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5 installation
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