636484

Junkers MKB 320-3 A Handleiding

59
Verklein
Vergroot
Pagina terug
1/116
Pagina verder
Wärme fürs Leben
Für den Fachmann
Warmth for life
For professionals
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)
Contents
6 720 645 817 (2010/09)
2
Contents
1 System schemes . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 System scheme 1: unmixed heating
circuit, low loss header . . . . . . . . . . . . . . 4
1.2 System scheme 2: unmixed underfloor
heating circuit, low loss header . . . . . . . 6
1.3 System scheme 3: mixed heating
circuit, DHW circuit, low loss header . . . 8
1.4 System scheme 4: one unmixed heating
circuit, one mixed heating circuit,
low loss header . . . . . . . . . . . . . . . . . . . 10
1.5 System scheme 5: two mixed
heating circuits, one DHW circuit,
low loss header . . . . . . . . . . . . . . . . . . . 12
1.6 System scheme 6: one unmixed heating
circuit, two mixed heating circuits,
low loss header . . . . . . . . . . . . . . . . . . . 14
1.7 System scheme 7: one unmixed heating
circuit, three mixed heating circuits,
low loss header . . . . . . . . . . . . . . . . . . . 16
1.8 System scheme 8: two mixed
heating circuits, two DHW circuits,
low loss header . . . . . . . . . . . . . . . . . . . 18
1.9 System scheme 9: one unmixed
heating circuit, one DHW circuit,
low loss header, cascade . . . . . . . . . . . 20
2 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1 Appliance parameters . . . . . . . . . . . . . . 22
2.1.1 Single appliance Suprapur KBR ... . . . . . 22
2.1.2 Factory-prepared cascade
Suprapur MKB ... . . . . . . . . . . . . . . . . . . 23
2.2 Dimensions and minimum clearances . . 24
2.2.1 Single appliance Suprapur KBR ... . . . . . 24
2.2.2 Factory-prepared 2-boiler
cascade MKB ... . . . . . . . . . . . . . . . . . . . 25
2.3 Installed dimensions . . . . . . . . . . . . . . . 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 Possible applications . . . . . . . . . . . . . . . 33
4.1.3 Benefits in brief . . . . . . . . . . . . . . . . . . . 33
4.1.4 Characteristics and special features . . . 34
4.2 Gas burner . . . . . . . . . . . . . . . . . . . . . . . 34
4.2.1 Burner and burner control unit . . . . . . . . 34
4.2.2 Burner function . . . . . . . . . . . . . . . . . . . . 35
4.3 Delivery method . . . . . . . . . . . . . . . . . . . 35
5 Engineering information and sizing
the heat source . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Operating conditions . . . . . . . . . . . . . . . 36
5.2 Water quality . . . . . . . . . . . . . . . . . . . . . 36
5.3 Important hydraulic system
components . . . . . . . . . . . . . . . . . . . . . . 39
5.3.1 Hydraulics for maximum utilisation
of the condensing effect . . . . . . . . . . . . 39
5.3.2 Underfloor heating system . . . . . . . . . . . 39
5.3.3 Diaphragm expansion vessel . . . . . . . . . 39
5.4 Condensate drainage . . . . . . . . . . . . . . . 41
5.4.1 Condensate drain from the
condensing boiler and the flue . . . . . . . 42
5.4.2 Condensate drain from a
moisture-resistant chimney . . . . . . . . . . 42
6 Regulations and operating conditions . . . . . . . 43
6.1 Extracts from regulations . . . . . . . . . . . . 43
6.2 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3 Operating conditions . . . . . . . . . . . . . . . 43
6.4 Combustion air . . . . . . . . . . . . . . . . . . . . 44
6.5 Combustion air supply . . . . . . . . . . . . . . 44
6.6 Siting combustion equipment . . . . . . . . 45
6.7 Sound insulation . . . . . . . . . . . . . . . . . . . 45
6.8 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . 45
Contents
6 720 645 817 (2010/09)
3
7 Accessories / Services . . . . . . . . . . . . . . . . . . . 46
7.1 Neutralising systems . . . . . . . . . . . . . . . 46
7.1.1 Neutralising system no. 1605 . . . . . . . . . 46
7.1.2 Neutralising system no. 1606 . . . . . . . . . 47
7.1.3 Condensate lifting system no. 1620 . . . 47
7.2 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.3 Dirt traps . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4 Low loss header . . . . . . . . . . . . . . . . . . . 48
7.5 Boiler safety set . . . . . . . . . . . . . . . . . . . 49
7.6 Safety equipment to DIN-EN 12828 . . . . 49
7.7 Shut-off set combined
with check valve . . . . . . . . . . . . . . . . . . 50
7.8 Boiler flue connection . . . . . . . . . . . . . . 50
7.9 Ventilation air connection bend . . . . . . . 50
7.10 Cleaning tool . . . . . . . . . . . . . . . . . . . . . 50
7.11 Services . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Heating controls . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1 Selection aids for controller
application . . . . . . . . . . . . . . . . . . . . . . 51
8.2 Overview of the BUS-regulated
controller functions . . . . . . . . . . . . . . . 52
8.3 Weather-compensated controllers . . . . . 53
8.4 Accessory for 2-wire BUS controller . . . 56
8.5 Cascade switching module
(0-10 V interface for systems
with Direct Digital Control (DDC)) . . . . 58
8.6 Accessories, weather-compensated
controller - remote control . . . . . . . . . . 58
8.7 Controller accessories -
outside temperature sensors . . . . . . . . 59
9 DHW heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.2 DHW cylinders series SK ... . . . . . . . . . . 65
9.3 DHW cylinders series SE ... . . . . . . . . . . 69
10 Installation accessories . . . . . . . . . . . . . . . . . . 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 operation . . . 78
11.2.1 General information for open
flue operation . . . . . . . . . . . . . . . . . . . . 78
11.2.2 Ventilation air/flue gas line . . . . . . . . . . . 79
11.2.3 Open flue routing via flue inside
a chimney shaft (B
23
) . . . . . . . . . . . . . . 80
11.2.4 Balanced flue routing, vertical
via the roof (B
23
) . . . . . . . . . . . . . . . . . . 82
11.2.5 Open flue routing via flue
over a facade (B
23
) . . . . . . . . . . . . . . . . 84
11.3 Flue systems for balanced
flue operation . . . . . . . . . . . . . . . . . . . . 86
11.3.1 General information for balanced
flue operation . . . . . . . . . . . . . . . . . . . . 86
11.3.2 Balanced flue routing via flue
inside a chimney shaft whilst
drawing in combustion air in
countercurrent (C
93
) . . . . . . . . . . . . . . . 88
11.3.3 Balanced flue routing via flue
inside a chimney shaft whilst
drawing in combustion air through
a separate pipe (C
53
) . . . . . . . . . . . . . . 90
11.4 Visual overview of flue accessories . . . . 92
11.4.1 Flue accessories Ø 125 mm . . . . . . . . . . 92
11.4.2 Flue accessories Ø 160 mm . . . . . . . . . . 97
11.4.3 Flue accessories Ø 200 mm . . . . . . . . . 103
11.4.4 Flue accessories Ø 250 mm . . . . . . . . . 109
System schemes
6 720 645 817 (2010/09)
4
1 System schemes
1.1 System scheme 1: unmixed heating circuit, low loss header
Hydraulic scheme with controller (schematic diagram)
Fig. 1
AF Outside temperature sensor
CUx Boiler control unit
FW 100 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 1 Load switching module for one heating circuit
P Heating circuit pump (secondary circuit)
VF Common flow temperature sensor
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Suprapur gas condensing boiler for balanced flue
operation
• 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).
Function description
The unmixed heating circuit with low loss header is
regulated by an FW 100 weather-compensated
controller. This always requires the IPM 1 load switching
module. A 2-wire BUS system enables communication
between the boiler control unit, the controller and the
load switching module.
6 720 643 417-02.1O
IPM 1
AF
FW 100
3
CUx
1
VF
T
T
P
3
Suprapur
KBR 120-280
HP
System schemes
6 720 645 817 (2010/09)
5
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. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
Controllers
FW 100 Weather-compensated controller 7 719 002 923
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 1 Load switching module for one heating circuit 7 719 002 738
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 1
System schemes
6 720 645 817 (2010/09)
6
1.2 System scheme 2: unmixed underfloor heating circuit, low loss header
Hydraulic scheme with controller (schematic diagram)
Fig. 2
AF Outside temperature sensor
CUx Boiler control unit
FW 100 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 1 Load switching module for one heating circuit
P Heating circuit pump (secondary circuit)
TB Temperature limiter
VF Common flow temperature sensor
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Suprapur gas condensing boiler for balanced flue
operation, without diaphragm expansion vessel
• One unmixed underfloor 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).
• Install a mechanical safety limiter (TB 1) in
accordance with the underfloor heating system
manufacturer's instructions.
Function description
The unmixed underfloor heating circuit with low loss
header is regulated by one FW 100 weather-
compensated controller. This always requires the IPM 1
load switching module. A 2-wire BUS system enables
communication between the boiler control unit, the
controller and the load switching module.
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.
1 MPI001 WF
3
AF
T
T
P
TB
CUx
1
VF
Suprapur
KBR 120-280
HP
3
6 720 643 417-01.1O
System schemes
6 720 645 817 (2010/09)
7
Parts list
Model code Description Part no. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
Controllers
FW 100 Weather-compensated controller 7 719 002 923
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 1 Load switching module for one heating circuit 7 719 002 738
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 2
System schemes
6 720 645 817 (2010/09)
8
1.3 System scheme 3: mixed heating circuit, DHW circuit, low loss header
Hydraulic scheme with controller (schematic diagram)
Fig. 3
AF Outside temperature sensor
CUx Boiler control unit
FW 100 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 2 Load switching module for two heating circuits
LP Cylinder primary pump
M 3-way mixer
MF Mixer circuit temperature sensor
P Heating circuit pump (secondary circuit)
SF Cylinder temperature sensor
ST DHW cylinder
TB Temperature limiter
VF Common flow temperature sensor
ZP DHW circulation pump
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Suprapur gas condensing boiler for balanced flue
operation
• One mixed heating 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 mechanical safety limiter (TB 1) in
accordance with the underfloor heating system
manufacturer's instructions.
• Install safety assembly to DIN 1988.
Function description
The mixed heating circuit with low loss header and
DHW heating are regulated by an FW 100 weather-
compensated controller. This always requires the IPM 2
load switching module. A 2-wire BUS system enables
communication between the boiler control unit, the
controller and the load switching module.
6 720 643 417-03.1O
3
AF
3
CUx 2 MPI001 W
F
T
T
M
M
P
MF
TB
VF
LP
1
ZP
SF
ST ...
Suprapur
KBR 120-280
HP
System schemes
6 720 645 817 (2010/09)
9
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. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
DHW cylinder
(Æ chapter 9 from page 60)
Controllers
FW 100 Weather-compensated controller 7 719 002 923
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 2 Load switching module for two heating circuits 7 719 002 739
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 3
System schemes
6 720 645 817 (2010/09)
10
1.4 System scheme 4: one unmixed heating circuit, one mixed heating circuit, low loss
header
Hydraulic scheme with controller (schematic diagram)
Fig. 4
AF Outside temperature sensor
CUx Boiler control unit
FW 200 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 2 Load switching module for two heating circuits
M 3-way mixer
MF Mixer circuit temperature sensor
P
1,2
Heating circuit pump (secondary circuit)
TB Temperature limiter
VF Common flow temperature sensor
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Suprapur gas condensing boiler for balanced flue
operation, without diaphragm expansion vessel
• 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 expansion vessel (Æ page 39).
• Install a mechanical safety limiter (TB 1) in
accordance with the underfloor heating system
manufacturer's instructions.
Function description
The heating circuits are regulated by an FW 200
weather-compensated controller. This always requires
the IPM 2 load switching module. A 2-wire BUS system
enables communication between the boiler control unit,
the controller and the load switching module.
6 720 643 417-04.1O
1
AF
3
T
T
P1
T
T
M
M
P2
MF
TB
IPM 2
CUx
FW 200
3
VF
Suprapur
KBR 120-280
HP
System schemes
6 720 645 817 (2010/09)
11
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. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
Controllers
FW 200 Weather-compensated controller 7 719 002 507
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 2 Load switching module for two heating circuits 7 719 002 739
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 4
System schemes
6 720 645 817 (2010/09)
12
1.5 System scheme 5: two mixed heating circuits, one DHW circuit, low loss header
Hydraulic scheme with controller (schematic diagram)
Fig. 5
AF Outside temperature sensor
CUx Boiler control unit
FW 200 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 1 Load switching module for one heating circuit
IPM 2 Load switching module for two heating circuits
LP Cylinder primary pump
M
1,2
3-way mixer
MF
1,2
Mixer circuit temperature sensor
P
1,2
Heating circuit pump (secondary circuit)
SF Cylinder temperature sensor
ST ... DHW cylinder
TB
1,2
Temperature limiter
VF Common flow temperature sensor
ZP DHW circulation pump
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Suprapur gas condensing boiler for balanced 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
corresponding expansion vessel (Æ page 39).
• Install a mechanical safety limiter (TB 1) in
accordance with the underfloor heating system
manufacturer's instructions.
• Install safety assembly to DIN 1988.
Function description
The heating circuits are regulated by an FW 200
weather-compensated controller. This always requires
the IPM 1 and IPM 2 load switching modules. A 2-wire
BUS system enables communication between the boiler
control unit, the controller and the load switching
modules.
6 720 643 417-06.1O
AF
T
T
M
M2
P2
MF2
TB2
LP
VF
1
3
IPM 1
CUx
FW 200
3
3
IPM 2
ZP
SF
ST ...
Suprapur
KBR 120-280
HP
T
T
M
M1
P1
MF1
TB1
System schemes
6 720 645 817 (2010/09)
13
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. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
DHW cylinder
(Æ chapter 9 from page 60)
Controllers
FW 200 Weather-compensated controller 7 719 002 507
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 1 Load switching module for one heating circuit 7 719 002 738
IPM 2 Load switching module for two heating circuits 7 719 002 739
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 5
System schemes
6 720 645 817 (2010/09)
14
1.6 System scheme 6: one unmixed heating circuit, two mixed heating circuits, low loss
header
Hydraulic scheme with controller (schematic diagram)
Fig. 6
AF Outside temperature sensor
CUx Boiler control unit
FB 100 Remote control
FW 200 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 1 Load switching module for one heating circuit
IPM 2 Load switching module for two heating circuits
M
2,3
3-way mixer
MF
2,3
Mixer circuit temperature sensor
P
1,3
Heating circuit pump (secondary circuit)
TB Temperature limiter
VF Common flow temperature sensor
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Suprapur gas condensing boiler for balanced flue
operation
• One unmixed heating 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 39).
• Install a mechanical safety limiter (TB 1) in
accordance with the underfloor heating system
manufacturer's instructions.
• Install safety assembly to DIN 1988.
Function description
The heating circuits are regulated by an FW 200
weather-compensated controller. This always requires
the IPM 1 and IPM 2 load switching modules. A 2-wire
BUS system enables communication between the boiler
control unit, the controller and the load switching
modules.
6 720 643 417-07.1O
IPM 2 IPM 1
AF
FB 100
VK
T
T
P1
T
T
M
M2
P2
MF2
TB
T
T
M
M3
P3
MF3
TB
1
CUx
FW 200
3
333
Suprapur
KBR 120-280
HP
System schemes
6 720 645 817 (2010/09)
15
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.
A FB 100 remote control is required for the third heating
circuit.
Parts list
Model code Description Part no. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
Controllers
FW 200 Weather-compensated controller 7 719 002 507
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 1 Load switching module for one heating circuit 7 719 002 738
IPM 2 Load switching module for two heating circuits 7 719 002 739
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 6
System schemes
6 720 645 817 (2010/09)
16
1.7 System scheme 7: one unmixed heating circuit, three mixed heating circuits, low loss
header
Hydraulic scheme with controller (schematic diagram)
Fig. 7
AF Outside temperature sensor
CUx Boiler control unit
FB 100 Remote control
FW 200 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 2 Load switching module for two heating circuits
M
2,4
3-way mixer
MF
2,4
Mixer circuit temperature sensor
P
1,4
Heating circuit pump (secondary circuit)
TB Temperature limiter
VF Common flow temperature sensor
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Suprapur gas condensing boiler for balanced flue
operation, without diaphragm expansion vessel
• One unmixed heating 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 page 39).
• Install a mechanical safety limiter (TB 1) in
accordance with the underfloor heating system
manufacturer's instructions.
Function description
The heating circuits are regulated by an FW 200
weather-compensated controller. This always requires
two IPM 2 load switching modules. A 2-wire BUS system
enables communication between the boiler control unit,
the controller and the load switching modules.
6 720 643 417-08.1O
IPM 2 IPM 2
AF
FB 100 FB 100
1
CUx
FW 200
333
3
3
VF
T
T
P1
T
T
M
M2
P2
MF2
TB
T
T
M
M3
P3
MF3
TB
T
T
M
M4
P4
MF4
TB
Suprapur
KBR 120-280
HP
System schemes
6 720 645 817 (2010/09)
17
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.
One FB 100 remote control is required for each of the
third and fourth heating circuits.
Parts list
Model code Description Part no. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
Controllers
FW 200 Weather-compensated controller 7 719 002 507
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 2 Load switching module for two heating circuits 7 719 002 739
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 7
System schemes
6 720 645 817 (2010/09)
18
1.8 System scheme 8: two mixed heating circuits, two DHW circuits, low loss header
Hydraulic scheme with controller (schematic diagram)
Fig. 8
AF Outside temperature sensor
CUx Boiler control unit
FW 500 Weather-compensated controller
HP Heating circuit pump (primary circuit)
IPM 2 Load switching module for two heating circuits
LP
1,2
Cylinder primary pump
M
1,2
3-way mixer
MF
1,2
Mixer circuit temperature sensor
P
1,2
Heating circuit pump (secondary circuit)
SF Cylinder temperature sensor
ST ... DHW cylinder
TB Temperature limiter
VF Common flow temperature sensor
ZP DHW circulation pump
1 Module position: on 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 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 instructions.
• Install safety assembly to DIN 1988.
6 720 643 417-09.1O
IPM 2
AF
LP1 LP2
TT
M
M1
P1
MF1
TB
TT
M
M2
P2
MF2
TB
IPM 2
3
3
VF
1
CUx
FW 500
3
Suprapur
KBR 120-280
HP
ZP
SF
ST ...
ZP
SF
ST ...
System schemes
6 720 645 817 (2010/09)
19
Function description
The heating circuits are regulated by an FW 500
weather-compensated controller. This always requires
two IPM 2 load switching modules. A 2-wire BUS system
enables communication between the boiler control unit,
the controller and the load switching modules.
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. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
DHW cylinder
(Æ chapter 9 from page 60)
Controllers
FW 500 Weather-compensated controller 7 719 002 966
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 2 Load switching module for two heating circuits 7 719 002 739
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 8
System schemes
6 720 645 817 (2010/09)
20
1.9 System scheme 9: one unmixed heating circuit, one DHW circuit, low loss header,
cascade
Hydraulic scheme with controller (schematic diagram)
Fig. 9
AF Outside temperature sensor
CUx Boiler control unit
FW 200 Weather-compensated controller
HP Heating circuit pump (primary circuit)
ICM Cascade switching module
IPM 2 Load switching module for two heating circuits
LP Cylinder primary pump
P Heating circuit pump (secondary circuit)
SF Cylinder temperature sensor
ST ... DHW cylinder
VF Common flow temperature sensor
ZP DHW circulation pump
1 Module position: on the heat source
3 Module position: on the wall
Heating system components
• Two Suprapur gas condensing boilers for balanced
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 a
corresponding expansion vessel (Æ page 39).
• Install safety assembly to DIN 1988.
Function description
The boiler cascade, the unmixed heating circuit and the
DHW circuit are regulated by an FW 200 weather-
compensated controller. This always requires two IPM 2
load switching modules. A 2-wire BUS system enables
communication between the boiler control units, the
controller and the load switching modules.
6 720 643 417-10.1O
3
IPM 2
AF
3
FW 200 ICM
3
CUx
1
ZP
SF
ST ...
LP
VF
TT
P
HP
Suprapur
MKB 240-560
HP
CUx
1
System schemes
6 720 645 817 (2010/09)
21
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. Pce 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 8 718 577 230
KBR 160-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 286
KBR 200-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 231
KBR 200-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 287
KBR 240-3 A 23 Suprapur gas condensing boiler for natural gas 23 8 718 577 232
KBR 240-3 A 21 Suprapur gas condensing boiler for natural gas 21 8 718 577 288
KBR 280-3 A 23 Suprapur gas condensing boiler 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 80 950 210
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 ¾ with TAE, for KBR 120-3 A 7 747 201 234
Gas tap R 1 ¼ with TAE, for KBR 160 ... 280-3 A 7 747 201 236
Compensator for gas connection, DN 25, for KBR 120-3 A 7 747 200 920
Compensator for gas connection, DN 32,
for KBR 160 ... 280-3 A
7 747 200 921
MAG ... (Æ page 72)
DHW cylinder
(Æ chapter 9 from page 60)
Controllers
FW 200 Weather-compensated controller 7 719 002 507
ICM Cascade switching module 7 719 002 949
Controller accessories
FB 100 Remote control 7 719 002 907
IPM 2 Load switching module for two heating circuits 7 719 002 739
TB 1 Temperature limiter 7 719 002 255
Other accessories
No. 1620 Condensate pump 80 695 080
No. 1605 Neutralising tank incl. neutralising granulate 8 718 576 749
No. 1606 Neutralising tank incl. condensate pump and neutralising
granulate
8 718 577 421
No. 1607 Neutralising granulate 7 115 120
Flue accessories (incl. boiler flue connection with test port)
(Æ chapter 11 from page 75)
Tab. 9
Specification
6 720 645 817 (2010/09)
22
2 Specification
2.1 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 – 4 5 6 7 8
Rated output full load/partial load
temperature pair 50/30 °C
kW 120/31 160/42 200/62 240/75 280/87
Rated output full load/partial load
temperature pair 80/60 °C
kW 113/28 150/38 187/56.2 225/67.6 263/79.2
Rated heat input full load/partial load kW 115.9/29 155/38.8 193/57.9 232/69.6 271/81.3
Flue gas mass flow rate full load/partial
load temperature pair 50/30 °C
g/s 53.8/10.1 70.2/12.9 87.8/21.5 106.0/23.0 125.9/28.4
Flue gas mass flow rate full load/partial
load temperature pair 80/60 °C
g/s 53.7/11.1 70.2/14.1 89.3/21.6 107.4/25.0 125.4/33.4
CO
2
content with natural gas full load/
partial load
% 9.1/9.3
Minimum flue gas temperature full load/
partial load temperature pair 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) –
B
23
, B
23P
, C
53
, (C
63
), C
93
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 14.9 kWh/m
3
Natural gas L (Germany),
Wobbe index 12.8 kWh/m
3
mm
mm
15.7
15.0
Gas
restrictor
not fitted
14.2
14.2
13.6
13.6
12.6
12.6
Heating water circuit
Boiler water capacity l 16 20 24 27 30
Pressure drop on heating water side mbar Æ Fig. 14, page 29
Maximum flow temperature °C 85
Safety temp. for high limit safety cut-out °C 100
Permissible operating pressure bar 4
Electrical data
IP rating – IPX0D
Power supply V/Hz 230/50
Power consumption full load/partial load W 150/40 190/45 230/50 270/50 330/50
Appliance dimensions and weight
Handling dimensions
Width × Depth × Height
mm
851 × 612
× 1400
1059 × 612
× 1400
1059 × 612
×1400
1267 × 612
× 1400
1267 × 612
× 1400
Weight kg 205 240 265 300 330
Tab. 10 Specification
Specification
6 720 645 817 (2010/09)
23
2.1.2 Factory-prepared cascade Suprapur MKB ...
Boiler size (output in kW) Unit
MKB
240-3 A
MKB
320-3 A
MKB
400-3 A
MKB
480-3 A
MKB
560-3 A
Number of sections – 8 10 12 14 16
Rated output full load/partial load
temperature pair 50/30 °C
kW 240/31 320/42 400/62 480/75 560/87
Rated output full load/partial load
temperature pair 80/60 °C
kW 226/28 300/38 374/56.2 450/67.6 526/79.2
Rated heat input full load/partial load kW 232/29 310/38.8 386/57.9 464/69.6 542/81.3
Flue gas mass flow rate full load/partial
load temperature pair 50/30 °C
g/s 53.8/10.1 70.2/12.9 87.8/21.5 106.0/23.0 125.9/28.4
Flue gas mass flow rate full load/partial
load temperature pair 80/60 °C
g/s 53.7/11.1 70.2/14.1 89.3/21.6 107.4/25.0 125.4/33.4
CO
2
content with natural gas full load/
partial load
% 9.1/9.3
Minimum flue gas temperature full load/
partial load temperature pair 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) –
B
23
, B
23P
, C
53
, (C
63
), C
93
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 14.9 kWh/m
3
Natural gas L (Germany),
Wobbe index 12.8 kWh/m
3
mm
mm
15.7
15.0
Gas
restrictor
not fitted
14.2
14.2
13.6
13.6
12.6
12.6
Heating water circuit
Boiler water capacity l 32 40 48 54 60
Pressure drop on heating water side mbar Æ Fig. 15, page 29
Maximum flow temperature °C 85
Safety temp. for high limit safety cut-out °C 100
Permissible operating pressure bar 4
Electrical data
IP rating – IP X0D
Power supply V/Hz 230/50
Power consumption full load/partial load W 300/40 380/45 460/50 540/50 660/50
Appliance dimensions and weight
Handling dimensions
Width × Depth × Height
mm
851 × 612
× 1400
1059 × 612
× 1400
1059 × 612
× 1400
1267 × 612
× 1400
1267 × 612
× 1400
Weight kg 410 480 530 600 660
Tab. 11 Specification
Specification
6 720 645 817 (2010/09)
24
2.2 Dimensions and minimum clearances
2.2.1 Single appliance Suprapur KBR ...
Fig. 10 Suprapur KBR 120 ... 280-3 A
AA Flue gas connection
AKO Condensate outlet
AL Combustion air pipe connection
(balanced flue operation only)
GAS Gas connection
MAG Connection for diaphragm expansion vessel
RK Boiler return
SV Safety valve or safety assembly connection
VK Boiler flow
1) Not part of the standard boiler delivery
1143
1018
615
100
X
GAS
, X
AL
, X
RK
Z
AA
X
AA
Y
AA
Y
VK
Y
MAG
Ø
AA
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
Ø
AA
DN 160 160 200 200 200
X
AA
mm 293 345 397 449 501
Y
AA
mm 470 470 495 495 495
Z
AA
mm 145 145 310 310 310
F mm 800 1008 1008 1216 1216
Y
MAG
mm 522 514 514 514 514
Ø
AL
DN 110 110 110 110 110
X
AL
mm 231 335 231 335 231
VK, RK – Rp 2 (DN 50) PN 6 standard flange (DN 65)
X
RK
mm 231 335 231 335 231
Y
VK
mm 1308 1300 1300 1300 1300
SV – R 1 R 1¼
ØGAS – R ¾ R 1½
X
GAS
mm 231 335 231 335 231
Tab. 12 Measurements and connection dimensions
Specification
6 720 645 817 (2010/09)
25
2.2.2 Factory-prepared 2-boiler cascade MKB ...
Fig. 11 Factory-prepared 2-boiler 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)
T
G
T
Z
615
1143
1018
Y
AA
Ø
AA
1)
Y
RK
Y
VK
215
500
OM
B
G
B
K
S
N
K
X
AA
X
GAS,
X
AL
AL
GAS
VK
RK
U
1517
R
1)
Specification
6 720 645 817 (2010/09)
26
Unit MKB 240-3 A MKB 320-3 A MKB 400-3 A MKB 480-3 A MKB 560-3 A
B
K
mm 994 1202 1202 1410 1410
B
G
mm 2041 2243 2421 2620 2573
T
G
mm 1842 1995 2135 2139 2135
T
Z
mm 640 795 935 939 935
ØAA – DN 200 DN 200 DN 250 DN 250 DN 250
Y
AA
mm 1335 1342 2126 2135 2130
X
AA
mm 332 384 436 488 540
ØVK – DN 65 DN 80 DN 80 DN 100 DN 100
Y
VK
mm 1308 1299 1299 1299 1299
ØRK – DN 65 DN 80 DN 80 DN 100 DN 100
Y
RK
mm 339.5 330 330 330 330
ØGAS inch R¾ R1¼ R1¼ R1¼ R1¼
X
GAS
mm 270 374 270 374 270
ØAL – DN 100 DN 100 DN 100 DN 100 DN 100
X
AL
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 mm 419 367 515 454 407
U mm 226 263 259 259 259
Tab. 13 Dimensions Suprapur – factory-prepared 2-boiler cascade
Specification
6 720 645 817 (2010/09)
27
2.3 Installed dimensions
Wherever possible, site the Suprapur gas condensing
boiler with the recommended wall clearances
(Æ Fig. 12). This ensures good accessibility for
installation, maintenance and service.
A reduction of the minimum clearances makes boiler
access more difficult.
2.3.1 Single 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 height mm 1405 1405 1405 1405 1405
Minimum weight kg 190 219 244 277 307
Tab. 15 Minimum handling details Suprapur single boiler
Specification
6 720 645 817 (2010/09)
28
2.3.2 Factory-prepared cascade MKB ...
Fig. 13 Installed dimensions Suprapur factory-prepared 2-boiler cascade (dim. in mm)
Minimum handling details
Unit MKB 240-3 A MKB 320-3 A MKB 400-3 A MKB 480-3 A MKB 560-3 A
A mm 700/500 700/500 700/500 700/500 700/500
B mm –/900 –/850 –/1000 –/940 –/890
C
1)
1) If the cascade pipework is installed in a different direction, 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 855 1065 1065 1275 1275
Minimum height mm 1405 1405 1405 1405 1405
Minimum weight kg 190 219 244 277 307
Tab. 17 Minimum handling details Suprapur factory-prepared 2-boiler cascade
Specification
6 720 645 817 (2010/09)
29
2.4 Pressure drop, water side
The pressure drop on the water side is the pressure
differential between the boiler flow and return
connections 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
Specification
6 720 645 817 (2010/09)
30
2.5 Boiler efficiency
The boiler efficiency η
K
identifies the ratio of heat output
to heat input subject to the return temperature.
Fig. 16 Boiler efficiency subject to boiler return
temperature (average for this series of boilers)
η
K
Boiler efficiency
ϑ Return temperature
1 Full load
2 Partial load
2.6 Standby loss
The standby loss q
B
is part of the rated heat input that
is required to achieve the specified boiler water
temperature. The cause of 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 heat input of
the boiler, subject to the average boiler water
temperature (average for this series of boilers)
q
B
Standby loss
ϑ
K
Average boiler water temperature
94
96
98
100
102
104
106
108
30 40 50 60 70
2
1
η
K
[%]
ϑ
[°C]
6 720 642 877-05.1il
0
0,1
0,2
30 40 50 60 70
q
B
[%]
ϑ
K
[°C]
6 720 642 877-06.1il
Specification
6 720 645 817 (2010/09)
31
2.7 Flue gas temperature
The flue gas temperature ϑ
A
is the temperature captured
inside the flue pipe, specifically at the boiler flue outlet.
It depends on the return temperature.
Fig. 18 Flue gas temperature subject to boiler return
temperature (average for this series of boilers)
ϑ
A
Flue gas temperature
ϑ Return temperature
1 Full load
2 Partial load
2.8 Conversion factor for alternative
system temperatures
In the tables containing the technical details of the
Suprapur gas condensing boilers, the rated output
figures relate 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 °C,
the rated output should be calculated at a system
temperature of 80/60 °C.
At a return temperature of 60 °C, a conversion factor of
0.935 results. At 80/60 °C, the rated output is therefore
112.2 kW.
30
35
40
45
50
55
60
65
70
30 40 50 60 70
2
1
80
75
ϑ
A
[°C]
ϑ
[°C]
6 720 642 877-07.1il
0,93
0,94
0,95
0,96
0,97
0,98
0,99
1,00
30 35 40 45 50 55 60
f
ϑ
[°C]
6 720 642 877-08.1il
Appliance layout
6 720 645 817 (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
Product description
6 720 645 817 (2010/09)
34
4.1.4 Characteristics and special features
Advanced boiler concept
• Heat exchanger made from high grade
aluminium-silicon sand casting
• Compact design and low weight
• Reduced pressure drop on the water side for
optimised and simple system technology
• With quiet modulating gas premix burner
• Low power consumption through variable speed fan
• With digital boiler and burner control units
• Suitable for new installations and modernisation
projects
Balanced flue
• Balanced flue operation possible (accessories)
High standard seasonal efficiency [to DIN] and
economic viability
• The optimised heating surfaces enable good heat
transfer with low flue gas losses and high condensing
output. This ensures high efficiency and good
economic viability. The result is standard seasonal
efficiency [to DIN] of up to 108 %.
• 4-star energy efficiency category to DIN-EN 483
Environmentally responsible
• Low nitrogen oxide emissions (standard emissions
factor < 45 mg/kWh). This corresponds to the highest
emissions category to DIN-EN 483 – category 5.
Advanced burner technology
• Modulating operation with digital combustion
management
• Very easy conversion to other gas types with only a
few steps
Matching system equipment
• Cascade solutions with up to eight boilers via a 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 unit
A highly premixing modulating gas premix burner with
clean combustion is used in the Suprapur gas
condensing boiler. The gas burner comprises a fan, gas
valve and, subject to boiler size, several burner rods.
Features
• Emissions, NO
x
<45mg/kWh and CO<15mg/kWh
(standard emissions factors) comply with the highest
emissions category – category 5 to DIN-EN 483
• Suitable for natural gas H and L
• Easy conversion to other natural gas types possible
• Modulation range:
– KBR 120/160-3 A: 25 % - 100 %
– KBR 200/240/280-3 A: 30 % - 100 %
– MKB 240/320-3 A: 12,5 % - 100 %
– MKB 400/480/560-3 A: 15 % - 100 %
Burner control unit
• Burner control unit
• Burner control and monitoring
• Safety functions for boiler operation
• Flue gas temperature monitoring
• Setting parameters and issuing fault codes via the
control system
• Display and calling up operating, service and fault
displays via the Service Diagnosis System (SDS)
0-10 V interface (DDC systems)
• Connection possible via the ICM cascade module
• Output and temperature-dependent boiler controls,
selectable via settings on the ICM
Changeover or conversion to LPG operation
is not possible.
Product description
6 720 645 817 (2010/09)
35
4.2.2 Burner function
The maximum ΔT between flow and return temperature
at rated output is 30 K.
From ΔT = 30 K, when no heat is being drawn off, the
burner modulates the boiler output down to the lowest
output. The boiler shuts down only if ΔT continues to rise
and exceeds 40 K.
If ΔT is too high, the boiler cannot transfer its maximum
output due to its safety circuit.
The restriction of the maximum temperature spread is
designed 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 cascade solution is delivered in
modules (two boilers, hydraulic pipework and flue gas
cascade).
For optimum operational reliability and durability, the
flue gas cascade is designed as a negative pressure flue
gas cascade requiring no additional components
(shut-off dampers).
Engineering information and sizing the heat source
6 720 645 817 (2010/09)
36
5 Engineering information and sizing the heat source
5.1 Operating conditions
Tab. 18 provides an overview of the conditions that must be observed, subject to the application and the local
system-specific circumstances.
5.2 Water quality
As there is no pure water for the heat transfer, observe
the water quality. Unsuitable water quality can damage
heating systems due to scaling and corrosion.
Fill the system with clean mains water only that meets
the requirements below.
To protect the appliance from scale damage throughout
its service life and ensure trouble-free, economical
operation, the overall quantity of hardness constituents
in the fill and top-up water of the heating circuit must be
limited.
To check the permitted amounts of water subject to the
fill water quality, either perform the following
calculations or consult the graphs.
Checking the maximum amounts of fill water subject to
water quality
The fill and top-up water has to meet certain
requirements depending on the total boiler output and
the resulting water volume of a heating system.
Use the following formula to calculate the maximum
amount of water that may be introduced without
treatment:
Form. 1 Calculation of the maximum amount of water that
may be introduced without treatment
Ca(HCO
3
)
2
Concentration calcium hydrogen carbonatein mol/m
3
Q Boiler output in kW
V
max
Maximum fill and top-up water over the entire service
life of the boiler in m
3
Information about the calcium hydrogen carbonate
(Ca(HCO
3
)
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 hydrogen carbonate can be calculated as
follows from carbonate hardness and calcium hardness.
Example
Calculation of the maximum permissible amount of fill
and top-up water V
max
for a heating system with a total
boiler output of 560 kW. The analysis values for
carbonate hardness and calcium hardness are quoted in
the older unit °dH.
Carbonate hardness: 15.7 °dH
Calcium hardness: 11.9 °dH
The following results from the carbonate hardness:
Ca(HCO
3
)
2
=15.7°dH×0.179 = 2.8mol/m
3
The following results from the calcium hardness:
Ca(HCO
3
)
2
=11.9°dH×0.179 = 2.13mol/m
3
The lower of the two values calculated from calcium and
carbonate hardness is decisive for calculating the
maximum permissible water volume V
max
.
Form. 2
Δϑ
max
Minimum
boiler water
flow rate
Max. water
flow rate
Minimum
boiler water
temperature
Operating
interruption
Heating circuit
control unit with
heating mixer
Minimum return
temperature
Full load = 30 K
Partial load = 40 K
No requirements
Results from
ΔT=8K
No requirements
To transfer the
max. output
ΔT must be < 30 K
Tab. 18 Suprapur operating conditions
V
max
0.0235
Q
Ca HCO
3
()
2
--------------------------------
×=
.
V
max
0.0235
560 kW
2.13 mol/m
3
------------------------------- -
× 6.2 m
3
==
Engineering information and sizing the heat source
6 720 645 817 (2010/09)
37
Limit curves
Fig. 22 Limit curves for water treatment – single boiler
Fig. 23 Limit curves for water treatment – factory-prepared 2-boiler cascade
Key to Fig. 22 and Fig. 23:
A Above 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]
H
W
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/m
3
H
W
/°dH
B
A
6 720 643 417-15.1O
V/m
3
H
W
/°dH
0
2
4
6
8
10
12
14
16
0 5 10 15 20 25 30
560 kW
480 kW
400 kW
320 kW
240 kW
B
A
Engineering information and sizing the heat source
6 720 645 817 (2010/09)
38
Water treatment measures
There are two methods for treating the fill and top-up
water for Suprapur gas condensing boilers:
• Use of fully desalinated fill water with a conductivity
of ≤ 10 μS/cm:
During the total desalination of the fill and top-up
water, not only the causes of hardness (Ca, Mg) but
also all other minerals are removed. This significantly
reduces the conductivity of the fill and top-up water.
The likelihood of corrosion forming shrinks as the con-
ductivity of the heating water drops. Operation with a
low salt content will at the same time reduce corro-
sion in the heating system.
• Use of partially softened fill and top-up water based
on sodium ion exchangers:
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
inadequately sized 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 the boiler,
leading to local overheating, corrosion and noise.
We therefore recommend the installation of a dirt trap
and blow-down facility. This should be installed
immediately between the boiler and the lowest position
with good accessibility, and should be cleaned during
every service.
Estimate of system capacity
Especially with older systems, the water capacity of the
entire system is often not known. The following graph
gives an estimate of the system capacity.
Fig. 24 Estimated water capacity of the system with
known system output
Q Total system output
V Water capacity
1 Steel/cast iron radiators with pipes sized for gravity
circulation and underfloor heating (20 l/kW)
2 Panel radiators (10 l/kW)
3 Convectors (6 l/kW)
0
1
2
3
4
5
6
7
8
9
10
11
12
0 100 200 300 400 500 600
1
2
3
V
[m
3
]
Q
[kW]
6 720 642 877-13.1il
.
Engineering information and sizing the heat source
6 720 645 817 (2010/09)
40
Example 2
Given
n Flow temperature (Æ table 19): ϑ
V
=50°C
o MAG pre-charge pressure (Æ table 19): p
0
=1.00bar
from example 1: system volume: V
A
=4000l
Actual
p A MAG with 200 l capacity is required (Æ table 19), as
the system volume determined in accordance with
Fig. 25 is smaller than the maximum permissible system
volume.
Flow temperature
ϑ
V
Pre-charge pressure
p
0
Diaphragm expansion vessel
80 l 100 l 150 l 200 l
Maximum permissible system volume V
A
°C bar 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 1974 2632
50 n 0.75 2326 2908 4362 5816
1.00 o 2054 2568 3852 5136 p
1.25 1712 2140 3210 4280
1.50 1369 1712 2568 3424
40 0.75 3107 3884 5826 7768
1.00 2742 3428 5142 6856
1.25 2284 2856 4284 5712
1.50 1827 2284 3426 4568
Tab. 19 Maximum system volume subject to the flow temperature and the required MAG pre-charge pressure.
Heating controls
6 720 645 817 (2010/09)
53
8.3 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
• DHW program for DHW cylinder (adjustable time and temperature)
• Solar DHW heating (with ISM 1)
• Solar-optimised heating circuit and DHW heating as options
• Optional FB 10 or FB 100 remote controls
• 7-day program with six switching times per day for one mixed or one unmixed 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 drying program
• Room temperature hook-up
• Optimised heating curves
• Adjustable heat-up speed (slow, normal, fast)
• Info function
• Remote management via Netcom 100
Installation
• Wall mounting (height/width/depth: 119/134/45 mm)
• Power supply 15 V via 2-wire BUS
Accessories
• IPM 1 load switching module
• ISM 1 solar module
• FB 10 remote control
• FB 100 remote control with plain text display
Part no. 7 719 002 923
Tab. 28
Heating controls
6 720 645 817 (2010/09)
59
8.7 Controller accessories - outside temperature sensors
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
• 2-wire BUS technology, reverse polarity protected connection
• Optional solar optimisation for the heating circuit
• Display of date and time (synchronised via BUS system) in plain text
• Plain text display of fault messages
• Switching the IPM 1 module (for mixed heating circuit)
• 7-day program with 6 switching 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 mm)
• Power supply 15 V via 2-wire BUS
Accessories
• IPM 1 load switching module
Part no. 7 719 002 907
VF Application
• Flow temperature sensor
• In conjunction with FW 100, FW 200 and IPM 1, IPM 2
Function
• In conjunction with the HW 50 or HW 90 low loss header, or on-site low loss header
Standard delivery
• Connecting lead, heat conducting paste, tie
Installation
• Can be plugged into the existing sensor well
• 2.0 m long connecting lead
Part no. 7 719 001 833
Tab. 32
Tab. 31
… 59 …

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