Steel Shell Boilers. Max-3 plus kw. Max-3 E & Max-3 condens E kw. CompactGas kw. SR-plus and SR-H plus kw

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1 Steel Shell Boilers Max-3 plus kw Description 194 Technical Data and Dimensions 198 Typical Hydraulic Schematic 204 Engineering 205 Max-3 E & Max-3 condens E kw Description 207 Technical Data and Dimensions 214 Typical Hydraulic Schematic 224 Engineering 225 CompactGas kw Description 226 Technical Data and Dimensions 228 Typical Hydraulic Schematic 233 SR-plus and SR-H plus kw Description 235 Technical Data and Dimensions 237 Typical Hydraulic Schematic 241 High pressure, high temperature version of the SR-plus available on request July Rev

2 Max-3 plus ( ) DESCRIPTION Hoval Max-3 plus Economical Saving Energy Cost-effective solution due to low investment cost Highly efficient due to being fitted with additional retarders/ Power Saving due to large water capacity Ecological Low emissions Environmentally Friendly due to low NOx emissions Low CO 2 emissions due to minimal gas consumption Outstanding emissions values due to modulation of low NOx burners Easy to Use Simple Maintenance Easy to use due to intelligent design details. User friendly controls with TopTronic E system Service friendly due to easy front door access Sophisticated Versatile Option Large range of applications due to flexible combination options Space-saving due to compact design Simple installation due to one piece heat exchanger. 194 November Rev 01

3 Max-3 plus ( ) DESCRIPTION Hoval Max-3 plus Oil/gas boiler Boiler According to BSEN14394 Three-pass steel shell boiler manufactured to European Standards for firing with Gas Oil and Natural Gas Max-3 plus complies with the Pressure Equipment Directive 97/23/EG Additional retarders fitted for enhanced efficiency Boiler completely welded Suitable for use with a Low NOx-burner having internal flue gas re cir cu lation Insulation of the boiler body 80mm mineral wool mat Boiler completely cased with steel sheet panels, red powder coated Flue gas outlet to the rear Heating flow connection to the top, heating return connection to the rear, incl. mating flanges, nuts, bolts & washers and gaskets Optional Side mounted TopTronic E control panel with boiler control and limit thermostat suitable for different applications Free standing calorifier Boiler door hinges to the left Delivery Control panel TopTronic E13.4 For operating temperature up to 90 C For mounting on the left or the right hand side (right hand standard) Integrated control functions for: 1 mixing circuit 1 direct heating circuit 1 hot water loading circuit bivalent and cascade management Option to expand by max. 1 module expansion: module expansion heating circuit or module expansion heat accounting or module expansion universal Can be optionally networked with a total of up to 16 controller modules (incl. solar module) Consisting of: electrical box control panel TopTronic E control module TopTronic E basic module heat generator burner control function device OFA-200 safety temperature limiter 110 C burner cable cpl. 2-stage, L=5.0, 1 X outdoor sensor TF/2P/5/6T/S1, L=5.0, with plug contact sensor ALF/2P/4/t/S1, L=4.0m with plug Model range Max-3 plus Output kw (420) (530) (620) (750) (1000) (1250) (1500) (1800) (2200) (2700) Boiler, insulation & casing, control panel and burner delivered separately packed On site Fitting of insulation and casing, control panel, flue retarders and burner by the installer CE-Product-ID-No. CE-0085BL0015 according to Directive on appliances burning gaseous fuels 90/396/EG. Control panel TopTronic E13.5 As TopTronic E/E13.4, but: For operating temperature up to 105 C Safety temperature limiter 120 C Configuration as control panel TopTronic E/ E13.4 above The boiler complies with the PED Pressure Equipment Directive 97/23EG. November Rev

4 Max-3 plus ( ) DESCRIPTION 3rd pass 2nd pass 1st pass Clean combustion With the proven three-pass technique, the hot combustion gases are immediately moved out of the high- temperature zone. The flame temperature is reduced, and the pollutant emissions are minimised. Low operating costs of the Hoval 3-pass boiler can be taken for granted The Hoval three-pass boiler transforms the energy stored in oil and gas into valuable heat with impressive efficiency this is demonstrated in a full load boiler efficiency in excess of 95 %. You, as the investor, will benefit from this high efficiency in the form of substantially lower heating costs. The excellent insulation of the boiler lowers the stand-by losses and further reduces the energy consumption of the system. Maximum operating temperature is 90 C or 105 C depending on control panel type. Burners It is Hoval policy to supply boilers with matched burners from several recognised manufacturers. Details of gas pressures, noise levels, gas boosters, acoustic shrouds etc. are given on individual quotations. Dual fuel burners are available on request. Intelligent command centre for your heating system The TopTronic E control is the brain of every Hoval system. Innovative touchscreen technology ensures smooth, and continuously monitored operation. With the addition of an optional Gateway module, remote access is available from your PC, tablet or smartphone. Additionally, fault and other notifications can be ed to your mobile phone, so you can always be in touch with your system. Installation wherever you want it! The compact dimensions of the boiler means that the Max-3 plus is perfect for plant rooms with low ceilings. 196 November Rev 01

5 Max-3 plus ( ) DESCRIPTION Dimpled tubes Hoval s patented development for constant high efficiency The unique design of the dimpled tubes allows a guaranteed and permanent turbulence of the flue gases. This results in an optimised heat transfer and keeps the combustion efficiency constantly high. Additional retarders are fitted for enhanced efficiency. Control panel Fitted with microprocessor-based TopTronic E operating controls. Hinged door simplifies servicing Servicing the Hoval Max-3 plus combustion components is made easier thanks to the hinged boiler door. The service technician has access to the combustion chamber and to the burner head. The handing of the boiler door can be changed to suit site layout. Insulated hinged front door for easy cleaning and quick access to the combustion chamber. An optional burner acoustic shroud is available to reduce noise level to a minimum. November Rev

6 Max-3 plus ( ) TECHNICAL DATA Type (420) (530) (620) (750) (1000) Output at 80/60 C kw Range of output at 80/60 C kw Burner input maximum kw Maximum operation temperature 1 C Minimum operation temperature C See table operating conditions (below) Mininum boiler return flow temperature C See table operating conditions (below) Mininum flue gas temperature C See table operating conditions (below) Safety temperature limiter setting (water-side) 2 C Working/test pressure bar 6/9.6 6/9.6 6/9.6 6/9.6 6/9.6 Boiler efficiency at full loaf and 80/60 C (net calorific value/gross calorific value) natural gas Efficiency at partial load 30% (according to EN 303) natural gas (net calorific value/gross calorific value) Part L seasonal efficiency (gross calorific value) for natural gas firing % 95.2/ / / / /85.8 % 97.1/ / / / /87.5 % Stand-by loss qb at 70 C Watt Flue gas resistance at nominal output natural gas 10.8% CO m above sea level (Tolerance ± 20%) mbar Flue gas mass flow at nominal output kg/h natural gas 10.8% CO 2 Flow resistance of boiler 2 z-value Water-side resistance at 10k mbar Water-side resistance at 20k mbar Water flow volume at at 10k m 3 /h Water flow volume at at 20k m 3 /h Boiler water content litres Boiler gas volume m 3 0,583 0,602 0,846 0,872 1,350 Insulation thickness boiler body mm Dry weight (incl. casing) 4 kg Combustion chamber dimension mm 606 / / / / / 2182 Combustion chamber volume m Dimensions See table of dimensions Maximum draught in flue gas system (at boiler connection) Pa Limited by the boiler control to 90 C (E13.4) or to 105 C (E13.5). 2 Maximum safety temperature for boiler control E13.4: 110 C; for E13.5: 120 C. 3 Flow resistance boiler in mbar = volume flow (m 3 /h) 2 x z-value. 4 Excludes weight of burner. Possible operating conditions Fuel Heating Oil EL Natural Gas min. boiler temperature C min. return temperature C Return temperature control Required Required (not by Hoval) 198 November Rev 01

7 Max-3 plus ( ) TECHNICAL DATA Type (1250) (1500) (1800) (2200) (2700) Output at 80/60 C kw Range of output at 80/60 C kw Burner input maximum kw Maximum operation temperature 1 C Minimum operation temperature C See table operating conditions (below) Mininum boiler return flow temperature C See table operating conditions (below) Mininum flue gas temperature C See table operating conditions (below) Safety temperature limiter setting (water-side) 2 C Working/test pressure bar 6/9.6 6/9.6 6/9.6 6/9.6 6/9.6 Boiler efficiency at full loaf and 80/60 C (net calorific value/gross calorific value) natural gas Efficiency at partial load 30% (according to EN 303) natural gas (net calorific value/gross calorific value) Part L seasonal efficiency (gross calorific value) for natural gas firing % 95.2/ / / / /85.8 % 97.1/ / / / /87.5 % Stand-by loss qb at 70 C Watt Flue gas resistance at nominal output natural gas 10.8% CO m above sea level (Tolerance ± 20%) mbar Flue gas mass flow at nominal output kg/h natural gas 10.8% CO 2 Flow resistance of boiler 2 z-value Water-side resistance at 10k mbar Water-side resistance at 20k mbar Water flow volume at at 10k m 3 /h Water flow volume at at 20k m 3 /h Boiler water content litres Boiler gas volume m 3 1,390 1,956 2,510 2,761 3,037 Insulation thickness boiler body mm Dry weight (incl. casing) 4 kg Combustion chamber dimension mm 782/ / / / /3200 Combustion chamber volume m 3 1,047 1,58 2,07 2,30 2,41 Dimensions See table of dimensions Maximum draught in flue gas system (at boiler connection) Pa Limited by the boiler control to 90 C (E13.4) or to 105 C (E13.5). 2 Maximum safety temperature for boiler control E13.4: 110 C; for E13.5: 120 C. 3 Flow resistance boiler in mbar = volume flow (m 3 /h) 2 x z-value. 4 Excludes weight of burner. Possible operating conditions Fuel Heating Oil EL Natural Gas min. boiler temperature C min. return temperature C Return temperature control Required Required (not by Hoval) November Rev

8 Max-3 plus ( ) TECHNICAL DATA Flue gas temperature and output range In order to reach a good combustion quality, the indicated minimum temperature must be adhered to. With new installations acidic condensate-proof chimneys should be fitted, or the flue gas temperature must be adjusted higher (min. 160 C). The minimum flue gas temperature must be in accordance with the flue design, otherwise the formation of acidic condensate can cause long term damage Max-3 plus (1250) Max-3 plus (530) Max-3 plus (1000) Max-3 plus (1500) Max-3 plus (420) Max-3 plus (620) Max-3 plus (750) Max-3 plus (1800) Max-3 plus (2200) Max-3 plus (2700) Flue gas temperature ( C) kw = Boiler output C = Flue gas temperature with clean heating surfaces, boiler flow temperature 80 C, return temperature 60 C (in accordance with DIN 4702). Combustion chamber resistance Output (kw) - Operation with heating oil EL, natural gas λ = 1,11 with max. burner output (CO 2 natural gas = 10,8 %) - A reduction of the boiler water temperature of 10K causes a reduction of the flue gas temperature of approx. 6-8K. - A change in the CO 2 emission value of +/-1% causes a change in the flue gas temperature of approx. -/+8K Combustion chamber resistance (mbar) Boiler output (kw) kw = Boiler output mbar = Flue gas resistance λ = 1,11 (CO 2 natural gas = 10,8 %) 500 m above sea level (Tolerance +/- 20%) 200 November Rev 01

9 Max-3 plus ( ) DIMENSIONS Max-3 plus ( ) (Dimensions in mm) Max-3 plus ( ) (Dimensions in mm) 1 Flow (420,530) DN 100, PN 6 (620,750) DN 125, PN 6 (1000,1250) DN 150, PN 6 ( ) DN 150, PN 6 (2700) DN 200, PN 6 2 Return (420,530) DN 100, PN 6 (620,750) DN 125, PN 6 (1000,1250) DN 150, PN 6 ( ) DN 150, PN 6 (2700) DN 200, PN 6 3 Flue gas outlet 4 Cleaning opening 5 Flue gas collector cleaning opening R 1 6 Drain R 1½ 7 Cable routing 8 Control panel 9 Electrical connection 10 Bushing Rp ¾ with immersion sleeve for boiler temperature sensor Max-3 plus Type a b c f g h i k l l1 m n Ø o p q r (420,530) (620,750) (1000,1250) (1500) (1800) (2200) (2700) Max-3 plus Type s t u v w x (420,530) (620,750) (1000,1250) (1500) (1800) (2200) (2700) Notes: A safety valve must be fitted by the installer in the boiler flow pipework directly between the boiler and the downstream isolating valve. If fitting a boiler altitude gauge, a 3/8 BSP socket should be fitted by the installer in the flow pipework adjacent to the boiler to enable connection of the altitude gauge pipework. It is recommended to mount the Max-3 plus boiler onto a suitable plinth at least 150mm high to facilitate the fitting of a drain valve. Please also see important notes on the engineering guidelines page. November Rev

10 Max-3 plus ( ) DIMENSIONS inner Max-3 plus a * b c d e f g i k l m n o p (420,530) (620,750) (1000,1250) (1500) (1800) (2200) (2700) Max-3 plus q r s v w x y (420,530) (620,750) (1000,1250) (1500) (1800) (2200) (2700) * Max-3 plus ( ): Drain connection protudes past the base channel Required minimum width of door and corridor to bring in the boiler The stated measurements are minimal dimensions B K = T x L fdgdfgdfg B K = T x L T = Door width K = Corridor width B = Boiler width L = max. length of boiler K L B < 150 T 202 November Rev 01

11 Max-3 plus ( ) BURNER FLANGE DIMENSIONS Max-3 plus (420,530) Max-3 plus ( ) Screw joint flange Max-3 plus (420,530) 4 x M12 (45 ) 4 x M12 (15 ) Screw joint flange Max-3 plus (620,750) 6 x M12 (15 ) Screw joint flange Max-3 plus ( ) 6 x M16 (15 ) Swinging out of boiler door Boiler door is swivelling to the right or left (Dimensions in mm) Dimensions (Dimensions in mm) Max-3 plus Type A B C D E F G H M (420,530) (620,750) (1000,1250) (1500) (1800) (2200) (2700) Max-3 plus Type a b (420) (530) (620) (750) (1000) (1250) (1500) (1800) (2200) (2700) November Rev

12 Max-3 plus ( ) TYPICAL HYDRAULIC SCHEMATIC Hydraulic principle schematic Max-3 plus with heating controller TopTronic E Hydraulic schematic BEFE010 Important! Minimum return temperature must be adhered to. Hydraulic principle schematic Max-3 plus with heating controller TopTronic E Hydraulic schematic BEFE020 Notes : These hydraulic schematics are to be used for indicative purposes only. They do not contain all required items for the installation. The installation must comply with all relevant regulations. For underfloor heating, a flow temperature limiter must be installed. Safety valves must be fitted directly to the boilers (with no isolation valve). Lock shield valves must be used for the expansion vessel. Anti-thermal siphon loops must be installed to ensure natural circulation is not present. Pressure limiter (in accordance with BSEN12828 clause Heating Systems In Buildings). All Max-3 plus models should have an associated pressure limiter device fitted in the system pipework, as close as possible to the boiler itself (provided by the installer - not supplied, fitted or wired by Hoval). If the operating pressure of the heating system exceeds the given pressure limit, or in the case of auxiliary power interruption, the pressure limiter shall shut off the heating equipment and interlock against it restarting. The pressure limiter shall be adjusted so that it responds before the safety valve(s) operate. Not shown on these schematics. RBM Room station AF Outdoor sensor RLF Return sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 SLP Calorifier loading pump DKP Direct heating circuit ZUP Feed pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 YKR Actuator return mixer TTE-GW Gateway TTE-WEZ Base module heat generator TTE-FE HK Extension module 204 November Rev 01

13 Max-3 plus ( ) ENGINEERING Regulations and guidelines The following regulations and guidelines must be observed: Hoval technical information and installation instructions. Relevant British Standards and Guidelines. Hydraulic and technical control regulations. Water quality Heating water: European standard BSEN 14868:2005 and VDI guideline 2035 must be observed. Particular note must be taken of the following regulations. Hoval boilers and water heaters are suitable for heating systems without significant oxygenation (system type 1 in accordance below with BSEN 14868:2005). Systems with; Continuous oxygenation (e.g. floor heating without diffusion-proof plastic Flue gas system pipes) or, Flue systems must comply with current Intermittent oxygenation (e.g. frequent British Standards and legislation. topping up required) must be fitted with a The flue must be pressure tight, able to withstand slight positive over pressure. system separator. Treated heating water must be checked at Flue system must be able to cope with flue least once per year or more frequently as gas temperatures up to 190 C. specified by the inhibitor manufacturer. The flue should be able to withstand the If, in the case of existing systems (e.g. mildly acidic nature of any condensate that boiler replacement), the water quality of the might form. Any condensate should not be existing heating water complies with VDI allowed to collect in the flue and should be 2035, it is not recommended that the system drained via a suitable trapped drain not be refilled. VDI 2035 also applies to top-up back via the boiler. water. Before filling new systems, or, if applicable, existing systems, the heating system must be professionally cleaned and flushed. The heating system must be flushed before the boiler is filled. Components of the boiler / heat exchanger that come into contact with water are made of ferrous materials. Due to the risk of stress corrosion cracking, the combined chloride, nitrate and sulphate content of the heating water must not exceed a total of 200mg/l. Once the heating has been in operation for 6 12 weeks, the ph value of the heating water should be between 8.3 and 9.5. Water for filling and topping up the system: Untreated drinking water is generally most suitable for filling and topping up a system with a Hoval boiler. However, the water quality of the untreated drinking water must always comply with VDI 2035 or must be demineralised and/or treated with inhibitors. The specifications of BSEN 14868:2005 must be observed. In order to maintain the boiler s high efficiency level and to avoid overheating of the heating surfaces, the values in the table Important Notes! A condensate trap must be fitted on the boiler flue outlet to prevent condensate entering the boiler. A condensate drain point is provided in the flue outlet smoke box and this should be piped to drain via a drain trap to prevent flue gases escaping. No isolating valve should be fitted in this pipework. below must not be exceeded. These values are calculated in relation to the boiler output (the smallest individual boiler in the case of multiple boiler systems) and the water content of the system. The total quantity of water used to fill and top up the system during the boiler s life must not exceed a value equivalent to three times the water content of the system. Heating system Combustion air A suitable supply of combustion air must be guaranteed. It must not be possible to close the air supply opening. Minimum free area for the air supply opening at low level is 4cm 2 per 1kW boiler input. Minimum free area for the air supply opening at high level is 2cm 2 per 1kW boiler input. Chimney/flue gas system A flue gas sampling point with an internal diameter 10-21mm should be included adjacent to the flue spigot, extending through any thermal insulation. The pressure condition at the boiler spigot ideally should be balanced It can be slightly negative (up to -50Pa) or slightly positive depending on the matched burner. Check with Hoval Technical. A draught stabiliser may be required if the draught exceeds the figure indicated. D < 2D 2 x D 1D Flue gas test point D Burner mounting When mounting the burner an adapter flange may be required depending on the burner being used. If this is required this will be fitted to the boiler door and supplied with all additional fixings before it is dispatched from Hoval. The flexible oil pipes or gas pipework should be installed in such a manner that the door can be opened 90 with the burner still attached. All services must be fitted in such a manner that the boiler door can be opened fully. Electrical connection A single phase 230V supply is required for the control panel operation. Single phase burners are electrically supplied via the control panel. Three phase burners require a separate three phase isolated supply (by the installer) direct to the burner. In this case control cables fitted with wieland plug/sockets will still run between the control panel and the burner. All power supplies to the burner/boiler/other associated equipment (ie.: gas booster, separate oil pump, etc.) Noise attenuation The following steps can be taken to reduce noise: Make the walls, ceiling and floor of the boiler plant room as solid as possible, fit sound absorbers in the air supply ducting, provide conduit supports and brackets with sound dampening fittings. If there are living quarters either above or below the boiler plant room, fit rubber vibration strips underneath the base channels of the boiler and connect conduits flexibly with flexible connections. Connect circulating pumps to the network with flexible connections. In order to dampen flame noise in the flue, sound absorbers can be fitted in the flue system (consider leaving space for subsequent installation). Maximum filling quantity based on VDI 2035 Total hardness of filling water up to [mol/m 3 ] 1 < >3.0 f H < >30 d H < >16.8 e H < >21.3 ~mg/l < >300 Conductivity < >600 Boiler size of maximum filling quantity without demineralisation individual boiler 50 to 200kW NO REQUI- 50l/kW 20l/kW 20l/kW 200 to 600kW RE- 50l/kW 50l/kW 20l/kW Always desalinate over 600kW MENT 1 Total of alkaline earths 2 If the conductivity in µs/cm exceeds the value specified in the table a water analysis must be carried out November Rev

14 Hoval at Windsor Castle 206 November Rev 01 November Rev 01

15 Max-3 E ( ) DESCRIPTION Hoval Max-3 E ( ) Low consumption thanks to high efficiency rating Fewer harmful emissions thanks to sophisticated design and low-nox burner Long service life thanks to special return water inlet Assembly pipe A thermometer, thermostat and pressure gauge are fitted here. Return inlet with injection effect The return water is heated evenly, meaning no condensation can form on the flue surface. Retarders Improve the heat transfer and thus the efficiency rating. Highly efficient thermal insulation with aluminium cladding Large, thermally insulated boiler door Easy to open, providing easy access for maintenance work. Low-NOx burner helps significantly reduce harmful emissions Technical Data (3000) (4000) (5000) (6000) Thermal output range at 80/60 C kw Max. heating boiler operating temperature C Operating pressure (option) Boiler efficiency rating at partial load of 30% (in accordance with EN 303 and EN 304) bar 6/9.6 (10/16) 6/9.6 (10/16) 10/16 10/16 % 94.9/ / / /85.5 Boiler efficiency rating at full load 1 at 80/60 C 1 % 93.2/ / / /84.0 Boiler water volume l 6,400 7,100 7,800 9,900 Boiler dry weight including cladding (6/ /16 bar) kg 6,845/7,987 8,049/9,392 -/ /14,081 Dimensions W L H mm with regard to lower/upper heating value November Rev

16 Max-3 E ( ) DESCRIPTION Retarders inside the third pass tubes ensure increased efficiency Efficient three-pass technology in the Max-3 E The special return inlet increases the boiler s service life Retarders increase cost-effectiveness The E stands for efficiency, in the Max- 3 E, special retarders in the third pass ensure increased heat transfer in the heat exchanger. Fewer harmful emissions thanks to three-pass technology. While a low-nox burner reduces harmful emissions, the technology and design of the Max-3 E reduces them even further. In the first pass, a cylindrical combustion chamber directs the flue gases to the smooth tube flue surfaces. These are arranged around the combustion chamber and form the second and third passes. The flue surfaces have a large area and keep the temperature of the flue gases low, minimising loss. Spacious reversal chambers redirect the flue gases, allowing them to flow through the flue surfaces evenly. Guaranteed long service life. This return inlet is unique - and a typical innovation for Hoval. It works like an injector. The return water from the heating system enters at the top in the warm area of the heating boiler. A baffle plate turns the in-coming water by 90 and speeds it up. The water flowing out of the baffle plate pulls in hot boiler water, which mixes thoroughly with the colder return water. This increases the temperature of the return water and prevents condesation from forming on the flue surface, significantly enhancing the service life. Delivered ready-to-use and easy to maintain. The Max-3 E comes in four sizes. It is delivered assembled and readyto-use complete with full thermal insulation and cladding. Flexibly adjustable connections make for easy installation and reduce costs. Lifting hooks and a robust base frame make the boiler easy to transport to the boiler room. The large boiler door ensures easy access for cleaning. The tube nest area of the second pass can be easily accessed thanks to the large combustion and reversal chambers. In other words, the Max-3 E has its benefits for technical personnel too. 208 November Rev 01

17 Max-3 condens E ( ) DESCRIPTION Hoval Max-3 condens E ( ) Outstanding efficiency with integrated flue gas condensing heat exchanger Fewer harmful emissions thanks to sophisticated design and low-nox burner Long service life thanks to special return water inlet Flue gas condensing heat exchanger This allows the residual heat in the flue gas to be utilised as well. Return inlet with injection effect The return water is heated evenly, meaning no condensation can form on the flue surface. Assembly pipe A thermometer, thermostat and pressure gauge are fitted here Highly efficient thermal insulation with aluminium cladding Large, thermally insulated boiler door Easy to open, providing easy access for maintenance work Low-NOx burner Helps significantly reduce harmful emissions Type (3000) (4000) (5000) (6000) Thermal output range at 80/60 C kw Thermal output range at 80/30 C kw Ultra low Boiler efficiency rating at partial load of 30% sulphur 1 % 103.4/ / / /97.6 (in accordance with EN 303 and EN 304) fuel oil Boiler efficiency rating at full load 1 at 80/60 C % 97.1/ / / /91.7 Natural Gas H Thermal output range at 80/30 C kw Boiler efficiency rating at partial load of 30% 1 (in accordance with EN 303 and EN 304) % 108.4/ / / /97.7 Boiler efficiency rating at full load 1 at 80/60 C % 97.1/ / / /87.5 Max. heating boiler operating temperature C Operating/test pressure (option) bar 6/9.6 (10/16) 6/9.6 (10/16) 10/16 10/16 Boiler water volume (including gas heat exchanger) l Boiler dry weight including cladding (6/9.6 / 10/16 bar) kg 7668/ / /12,905 -/15,872 Dimensions W L H 1 with regard to lower/upper heating value mm November Rev

18 Max-3 condens E ( ) DESCRIPTION Technically sophisticated right through to the heat exchanger. Maximise potential with the flue gas condensing heat exchanger. The Max-3 Condens E is a three-pass hot water boiler that has all the benfits that set a Hoval product apart - and that s not all: an integrated flue gas condensing heat exchanger stands out for its large heat transfer surface, whose dimensions increase the rate of condensation. The large tube diameter of the gas heat exchanger also reduces hydraulic resistance, meaning a smaller pump is sufficient, which in turn consumes less power. Integrated flue gas condensing heat exchanger with low hydraulic resistance Delivered ready-to-use and easy to maintain. The Max-3 condens E comes in four sizes. It is delivered assembled and ready-to-use complete with full thermal insulation and cladding. Flexibly adjustable connections make for easy installation and reduce costs. Lifting hooks and a robust base frame make the boiler easy to transport to the boiler room. The large boiler door ensures easy access for cleaning. The tube nest area of the second pass can be easily accessed thanks to the large combustion and reversal chambers. In other words, the Max-3 condens E has its benefits for technical personnel too. 210 November Rev 01

19 Max-3 E ( ) DESCRIPTION Hoval Max-3 E oil/gas boiler Three-pass steel boiler for oil/gas firing. Mounted on steel frame, completely insulated and cased (manufactured to EN 14394). The control panel can be fitted on the right or left hand side. (standard is right hand side). Max-3 E type Output kw Operating pressure bar (3000) (3000) (4000) (4000) (5000) (6000) Delivery time will be advised at the time of quoting. Console for boiler control Console for attaching the boiler controller TopTronic E/E13.5 on the right or left hand side of the boiler (standard is right hand side) Katalogbilder Konsole 2-Max-3 ( ) / AMPA November Rev

20 Max-3 condens E ( ) DESCRIPTION Hoval Max-3 condens E oil/gas boiler Three-pass steel boiler for oil/gas firing with integrated flue gas condensing heat exchanger. Mounted on steel frame, completely insulated and cased. Boiler manufactured to EN The control panel can be fitted on the right or left hand side.(standard right hand side) The flue gas condensing heat exchanger connections are right handed as standard but can be supplied left handed (although this may extend the boiler delivery time) Max-3 Output Working condens E return 30 /natural gas pressure Type kw bar (3000) (3000) (4000) (4000) (5000) (6000) Delivery will be advised at the time of quoting. Console for boiler control Console for attaching the boiler controller TopTronic E/E13.5 on the right or left hand side of the boiler (standard is right hand side) Katalogbilder Konsole 2-Max-3 ( ) / AMPA 212 November Rev 01

21 Max-3 ( ) DESCRIPTION Boiler controller with TopTronic E control Boiler controller TopTronic E/E13.5 for mounting on heat generator right hand side (standard) or left hand side (configuration on request). Specify mounting variant in purchase order. Maximum operating temperature 105 C Safety temperature limiter 120 C Control functions integrated for 1 heating circuit with mixer 1 heating circuit without mixer 1 hot water loading circuit bivalent and cascade management Can be optionally expanded by max. 1 module expansion: module expansion heating circuit or module expansion heat accounting or module expansion universal Can be optionally networked with a total of up to 16 controller modules (incl. solar module) Consisting of: electrical box control panel TopTronic E control module TopTronic E basic module heat generator oil automatic function device OFA-200 safety temperature limiter burner cable cpl. 2-stage, L = 5.0 m 1x outdoor sensor AF/2P/K immersion sensor TF/2P/5/6T/S1, L = 5.0 m with plug contact sensor ALF/2P/4/T/S1, L = 4.0 m with plug November Rev

22 Max-3 E ( ) TECHNICAL DATA Max-3 E ( ) Type (3000) (4000) (5000) (6000) Nominal output at 80/60 C kw Heat output range (natural gas H: variant 2) kw Heat output range (heating ULS class A2*, natural gas H: variant 1, heating oil class C2 or D*) kw Heat input (net) kw Maximum boiler operation temperature 2 C Minimum boiler operation temperature C see table operating conditions (below) Minimum boiler return flow temperature (directly into the boiler downstream of the flue gas heat exchanger) C see table operating conditions (below) Safety temperature limiter setting (water side) 3 C Operating/test pressure bar 6/9.6 6/9.6 10/16 10/16 Operating/test pressure (option) bar 10/16 10/ Boiler efficiency at full load at 80/60 C % 93.2/ / / /84.0 (related to net calorific value NCV / gross calorific value GCV, natural gas H) Boiler efficiency at partial load 30 % and return 37 C (acc. to % 94.9/ / / /85.5 EN 303) (related to net calorific value NCV / gross calorific value GCV, natural gas H) Standard efficiency at 75/60 C (DIN 4702 Part 8) (related to net calorific value NCV / gross calorific value GCV, natural gas H) % 94.7/ / / /85.4 Standby losses qb at 70 C Watt Resistance on the heating gas side at nominal output mbar (natural gas H, 10.5 % CO 2 ). 500 m above sea level (tolerance ± 20 %) Flue gas mass flow at nominal output (natural gas H, 10.5 % CO 2 ) kg/h Flow resistance boiler 1 z-value Hydraulic resistance at 10 K mbar Hydraulic resistance at 20 K mbar Water flow rate at 10 K m³/h Water flow rate at 20 K m³/h Boiler water capacity litres Insulation thickness of boiler body mm Weight (incl. casing) at operating/test pressure 6/9.6 bar kg at operating/test pressure 10/16 bar kg Combustion chamber internal dimensions mm Combustion chamber length (with extension into the reversing chamber, half the length of the reversing chamber) mm Combustion chamber volume m³ Dimensions Maximum draught/underpressure at flue gas outlet Pa Flow resistance boiler in mbar = flow rate (m3/h)2 x z 2 Limited by the boiler controller E13.5 TopTronic E to 105 C. 3 Max. safety temperature for boiler controller E13.5 TopTronic E 120 C. Possible operating conditions: Fuel Ultra low sulphur heating oil, class A2* Natural gas H Heating oil class C2 or D* Variant 1 Variant 2 Variant 1 Variant 2 Variant 1 min. flue gas temperature C min. boiler temperature C min. return temperature C Return temperature control (Not by Hoval) * Classifications in accordance with BS2869. Required Required Required Required Required 214 November Rev 01

23 Max-3 E ( ) TECHNICAL DATA Flue gas output diagram 170 (3000) (4000) (5000) (6000) Flue gas temperature C Boiler output kw The data shown here represents an average value based on measurements taken with burners from various manufacturers. kw = Boiler output C = Flue gas temperature on a clean surface, boiler flow temperature 80 C, return temperature 60 C (in accordance with DIN 4702). Operation with natural gas H, λ = 1.14 with max. burner output (CO 2 natural gas H = 10.5 %) A reduction of the boiler water temperature of -10 K causes a reduction of the flue gas temperature of approx. 6-8 K. A change in the air index l of +/-0.09% causes a change in the flue gas temperature of approx. -/+8 K. Resistance on the boiler heating gas side (3000) (4000) (5000) (6000) Resistance on the boiler heating gas side mbar kw = Boiler output Boiler output kw mbar = Resistance on the heating gas side at λ = 1.14 (natural gas H: CO2 = 10.5 %), 500 above sea level (tolerance: +/- 20 %) November Rev

24 Max-3 Max-3E ( ) DIMENSIONS Max-3 E ( ) (Dimensions in mm) The control can be fitted on the right or left hand side (standard is right hand side). 1 Boiler flow PN 16 2 Boiler return PN Cleaning aperture (smoke box) Flue gas collector cleaning connection / drain Type (3000) (4000) (5000) (6000) 216 (3000,4000) (5000,6000) (3000,4000) (5000,6000) DN 200 DN 250 DN 200 DN Drain PN 16 5 immersion sleeves Safety valve fitting PN 16 View A R 1½ R ¾ x 120 boiler flow (3000,4000) DN 80 (5000,6000) DN Sight glass 8A Sight glass (optional) 9 Flue gas outlet B L H H1 H2 D Di/Da H3 H4 H5 H6 L1 L2 L3 L4 A A1 A2 A / / / / November Rev 01

25 Max-3E ( ) Max-3 TECHNICAL DATA Burner connection dimensions Flange screw connection Max-3 E (3000,4000) 6 x M16 Flange screw connection Max-3 E (5000,6000) 8 x M16 Firing system dimensions Type (3000) (4000) (5000) (6000) A B C D E F G K L November Rev

26 Max-3 condens E ( ) TECHNICAL DATA Max-3 condens E ( ) for natural gas H Type (3000) (4000) (5000) (6000) fuel natural gas H natural gas H natural gas H natural gas H Nominal output at 80/60 C kw Nominal output at 80/30 C kw Heat output range at 80/60 C kw Heat output range at 80/30 C kw Heat input (net) kw Maximum boiler operation temperature 2 C Minimum boiler operation temperature C see table operating conditions (below) Minimum boiler return flow temperature (directly into the boiler downstream of the flue gas heat exchanger) C see table operating conditions (below) Safety temperature limiter setting (water side) 3 C Operating/test pressure bar 6/9.6 6/9.6 10/16 10/16 Operating/test pressure (option) bar 10/16 10/ Boiler efficiency at full load at 80/60 C % 97.1/ / / /87.5 (related to net calorific value NCV / gross calorific value GCV) Boiler efficiency at full load at 80/30 C (related to net calorific value NCV / gross calorific value GCV) % 104.8/ / / /94.6 Boiler efficiency at partial load 30 % and return 27 C (acc. to % 108.4/ / / /97.7 EN 303) (related to net calorific value NCV / gross calorific value GCV) Standard efficiency at 75/60 C (DIN 4702 Part 8) (related to net calorific value NCV / gross calorific value GCV) % 107.4/ / / /97.5 Standby losses qb at 70 C Watt Flue gas temperature at nominal output 80/ 60 C C Resistance on the heating gas side at nominal output (natural gas H, 10.5 % CO 2 ), 500 above sea level (tolerance ± 20 %) Flue gas mass flow at nominal output (natural gas H, 10.5 % CO 2 ) mbar kg/h Flow resistance boiler 1 z-value Flue gas heat exchanger flow resistance z-value Boiler water flow rate at 10 K m³/h Boiler water flow rate at 20 K m³/h Minimum flue gas heat exchanger flow rate at 60 C return m³/h flow temperature Minimum flue gas heat exchanger flow rate at 30 C return flow temperature m³/h Boiler water capacity (incl. flue gas heat exchanger) litres Insulation thickness of boiler body and flue gas heat mm exchanger Weight (incl. casing) at operating/test pressure 6/9.6 bar kg at operating/test pressure 10/16 bar kg Combustion chamber internal dimensions mm Combustion chamber length (with extension into the reversing chamber, half the length of the reversing chamber) Combustion chamber volume m³ Dimensions see Dimensions Maximum draught/underpressure at flue gas outlet Pa Flow resistance boiler in mbar = flow rate (m3/h)2 x z 2 Limited by the boiler controller E13.5 TopTronic E to 105 C. 3 Max. safety temperature for boiler controller E13.5 TopTronic E 120 C. Operating conditions: Fuel Ultra low sulphur heating oil, class A2* Natural gas H min. boiler temperature C min. return temperature 1) C Return temperature control 1) Required Required (Not by Hoval) 1) Before entering boiler return * Classification in accordance with BS November Rev 01

27 Max-3 condens E ( ) TECHNICAL DATA Max-3 condens E ( ) for ultra low-sulphur heating oil to BS2869, class A2 (sulphur content < 50 ppm) Type (3000) (4000) (5000) (6000) Nominal output at 80/60 C kw Nominal output at 80/30 C kw Heat output range at 80/60 C kw Heat output range at 80/30 C kw Heat input (net) kw Maximum boiler operation temperature 2 C Minimum boiler operation temperature C see table operating conditions (below) Minimum boiler return flow temperature (directly into the boiler downstream of the flue gas heat exchanger) C see table operating conditions (below) Safety temperature limiter setting (water side) 3 C Operating/test pressure bar 6/9.6 6/9.6 10/16 10/16 Operating/test pressure (option) bar 10/16 10/ Boiler efficiency at full load at 80/60 C % 97.1/ / / /91.7 (related to net calorific value NCV / gross calorific value GCV) Boiler efficiency at full load at 80/30 C (related to net calorific value NCV / gross calorific value GCV) % 102.2/ / / /96.5 Boiler efficiency at partial load 30 % and return 27 C (acc. to % 103.4/ / / /97.6 EN 303) (related to net calorific value NCV / gross calorific value GCV) Standard efficiency at 75/60 C (DIN 4702 Part 8) (related to net calorific value NCV / gross calorific value GCV) % 102.4/ / / /97.4 Standby losses qb at 70 C Watt Flue gas temperature at nominal output 80/ 60 C C Resistance on the heating gas side at nominal output (natural gas H, 12.5 % CO 2 ), 500 above sea level (tolerance ± 20 %) Flue gas mass flow at nominal output (natural gas H, 12.5 % CO 2 ) mbar kg/h Flow resistance boiler 1 z-value Flue gas heat exchanger flow resistance z-value Boiler water flow rate at 10 K m³/h Boiler water flow rate at 20 K m³/h Minimum flue gas heat exchanger flow rate at 60 C m³/h return flow temperature Minimum flue gas heat exchanger flow rate at 30 C return flow temperature m³/h Boiler water capacity (incl. flue gas heat exchanger) litres Insulation thickness of boiler body and flue gas heat mm exchanger Weight (incl. casing) at operating/test pressure 6/9.6 bar kg at operating/test pressure 10/16 bar kg Combustion chamber internal dimensions mm Combustion chamber length (with extension into the reversing chamber, half the length of the reversing chamber) Combustion chamber volume m³ Dimensions see Dimensions Maximum draught/underpressure at flue gas outlet Pa Flow resistance boiler in mbar = flow rate (m3/h)2 x z 2 Limited by the boiler controller E13.5 TopTronic E to 105 C. 3 Max. safety temperature for boiler controller E13.5 TopTronic E 120 C. Operating conditions: Fuel Ultra low sulphur heating oil, class A2* Natural gas H min. boiler temperature C min. return temperature 1) C Return temperature control 1) Required Required (Not by Hoval) 1) Before entering boiler return * Classification in accordance with BS2869. November Rev

28 Max-3 condens E ( ) TECHNICAL DATA Flue gas output diagram (Flow/Return 80/60 C) 86 (3000) (4000) (5000) 82 (6000) Flue gas temperature C The data shown here represents an average value based on measurements taken with burners from various manufacturers. kw = Boiler output C = Flue gas temperature on a clean surface, boiler flow temperature 80 C, return temperature 60 C (in accordance with DIN 4702). Boiler output kw Operation with natural gas H, λ = 1.14 with max. burner output (CO 2 natural gas H = 10.5 %) A reduction of the boiler water temperature of -10 K causes a reduction of the flue gas temperature of approx. 6-8 K. A change in the air index l of +/-0.09% causes a change in the flue gas temperature of approx. -/+8 K. Resistance on the boiler heating gas side 13 (3000) (4000) (5000) (6000) 12 Resistance on the boiler heating gas side mbar Boiler output kw kw = Boiler output boiler flow temperature 80 C, return temperature 60 C mbar = Resistance on the heating gas side at λ = 1.14 (natural gas H: CO2 = 10.5 %), 500 above sea level (tolerance: +/- 20 %) 220 November Rev 01

29 Max-3 condens E ( ) TECHNICAL DATA Flue gas output diagram (Flow/Return 80/30 C) (3000) (4000) (5000) (6000) Flue gas temperature C The data shown here represents an average value based on measurements taken with burners from various manufacturers. kw = Boiler output C = Flue gas temperature on a clean surface, boiler flow temperature 80 C, return temperature 30 C (in accordance with DIN 4702). Boiler output kw Operation with natural gas H, λ = 1.14 with max. burner output (CO 2 natural gas H = 10.5 %) A reduction of the boiler water temperature of -10 K causes a reduction of the flue gas temperature of approx. 6-8 K. A change in the air index l of +/-0.09% effectuates a change in the flue gas temperature of approx. -/+8 K. November Rev

30 Max-3 condens E ( ) TECHNICAL DATA a) Conversion of the flue gas heat exchanger output at reduced boiler capacity and changed flue gas heat exchanger water entry temperature b) Flue gas temperature downstream of flue gas heat exchanger at reduced boiler capacity Nominal output of the flue gas heat exchanger at reduced boiler capacity or changed water entry temperature Figure 1: Conversion factor for calculating the actual heat exchanger output with reference to a water entry temperature of 30 C Heat exchanger output at full boiler load and water entry temperature 30 C Max-3 condens E (3000)(4000)(5000)(6000) Natural gas (H) kw Ultra low sulphur kw fuel oil The nominal output of the heat exchanger at reduced boiler capacity or with changed water entry temperatures can be approximately calculated as follows. Output adapted to the actual operating case ~ conversion factor from table figure 1 x conversion factor from figure 2 x heat exchanger full load output Example Boiler Max-3 condens E (4000) Maximum boiler output = 4800 kw Desired output = 3500 kw Accordingly, 3500 kw / 4800 kw = 73 % of the nominal output Water temperature entry into the heat exchanger = 40 C Read off from figures 1 and 2 Correction factor for reduced output from figure 1 = 0.70 Correction factor for increased water entry temperature from figure 2 = 0.85 Heat exchanger output catalogue specification at 30 C = 483 kw Result corresponding to above formula: Actual output = ~0.70 x 0.85 x 483 = ~287 kw Current total heat output of the boiler/heat exchanger combination = 3500 kw kw = ~3787 kw Correction Korrekturfaktor factor Boiler Kesselleistung output % % Figure 2: Conversion factor for calculating the heat exchanger output with other water entry temperatures Correction Korrekturfaktor factor Water Wassertemperatur temperature Eintritt heat exchanger Wärmetauscher entry C Figure 3: flue gas temperature depending on the boiler capacity and the water temperature (30 or 60 C) on entering the flue gas heat exchanger (average boiler size values) November Rev 01 Flue Abgastemperatur temperature ( C) ( C) Boiler Kesselleistung output in in % Water temperature 30 C (FGHE entry) Water temperature 60 C (FGHE entry)

31 Max-3 condens E ( ) DIMENSIONS Max-3 condens E ( ) 1 Boiler flow PN 16 2 Boiler return PN Cleaning aperture (smoke box) Flue gas collector cleaning connection / drain Drain PN 16 R 1½ 5 immersion sleeves R ¾ x 120 boiler flow Type (3000) (4000) (5000) (6000) View A The control panel can be fitted on the right or left handside (standard is right hand side). (Dimensions in mm) (3000,4000) (5000,6000) (3000,4000) (5000,6000) DN 200 DN 250 DN 200 DN 250 B L H H1 H2 D Di/Da H / / / / H4 H Safety valve fitting PN 16 (3000,4000) DN 80 (5000,6000) DN A Sight glass Sight glass (optional) Flue gas outlet Flue gas heat exchanger Flue gas heat exchanger connections PN 16 (3000,4000) DN 150 (right handed as standard) (5000,6000) DN 200 H6 H7 H8 L1 L2 L3 L4 A A1 A2 A3 A4 A Burner connection dimensions Flange screw connection Max-3 condens E (3000,4000) 6 x M16 Flange screw connection Max-3 condens E (5000,6000) 8 x M16 Firing system dimensions Type (3000) (4000) (5000) (6000) A B C D E F G K L November Rev

32 Max-3 E ( ) TYPICAL HYDRAULIC SCHEMATIC Typical hydraulic schematic Max-3 E ( ) with heating controller TopTronic E Max-3 plus RS-T Room station AF Outdoor sensor RLF Return sensor VF1 Flow sensor 1 VF2 Flow sensor 2 VF3 Flow sensor 3 VF4 Flow sensor 4 SF Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 MK3 Pump mixing circuit 3 MK4 Pump mixing circuit 4 SLP Calorifier loading pump ZUP Feed pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 YK3 Actuator mixer 3 YK4 Actuator mixer 4 YKR Actuator return mixer CWS Cold Water DHWS Domestic Hot Water Notes : This hydraulic schematic is to be used for indicative purposes only. It does not contain all required items for the installation. The installation must comply with all relevant regulations. For underfloor heating, a flow temperature limiter must be installed. Safety valves must be fitted directly to the boilers (with no isolation valve). Lock shield valves must be used for the expansion vessel. Anti-thermal siphon loops must be installed to ensure natural circulation is not present. Pressure limiter (in accordance with BSEN12828 clause Heating Systems In Buildings). All Max-3 E models should have an associated pressure limiter device fitted in the system pipework, as close as possible to the boiler itself (provided by the installer - not supplied, fitted or wired by Hoval). If the operating pressure of the heating system exceeds the given pressure limit, or in the case of auxiliary power interruption, the pressure limiter shall shut off the heating equipment and interlock against it restarting. The pressure limiter shall be adjusted so that it responds before the safety valve(s) operate. Not shown on this schematic. 224 November Rev 01

33 Max-3 E ( ) DESCRIPTION Regulations and guidelines The following regulations and guidelines must be observed: Hoval technical information and installation instructions. Relevant British Standards and Guidelines. Hydraulic and technical control regulations. Permitted operating pressure bar > 0.5 <= 25 General requirements colourless, free of undissolved substances and foaming agents ph value at 25 C Conductance at 25 C µs/cm < 1500 Total alkaline earths (Ca + Mg) 1 mmol/l < 0.02 dh < fh < 0.19 Silica acidic capacity mmol/l 1-5 (p-value) Silica (SiO 2 ) mg/l < 100 Phosphate (P 2 O 4 ) 3 mg/l 5-10 Sodium sulphite (Na 2 SO 3 ) 3 mg/l 5-10 Iron mg/l < 0.2 Copper mg/l < Previously specified in dh, conversion: 1 mmol/l = 5.6 dh (German hardness) 2 Previously specified as p-value, silica conversion = p-value 1 3 Proof only required if respective dosing chemicals are used. The following value does not have to be verified constantly during plant operation: silica (SiO 2 ) of the heating surfaces, the values in the table below must not be exceeded. These values are calculated in relation to the boiler output (the smallest individual boiler in the case of multiple boiler systems) and the water content of the system. The total quantity of water used to fill and top up the system during the boiler s life must not exceed a value equivalent to three times the water content of the system. Water quality Heating water: Combustion air European standard BSEN 14868:2005 and VDI A suitable supply of combustion air must be guideline 2035 must be observed. Particular note guaranteed. It must not be possible to close the air must be taken of the following regulations. supply opening. Hoval boilers and water heaters are suitable for Minimum free area for the air supply opening at heating systems without significant oxygenation low level is 4cm 2 per 1kW boiler input. (system type 1 in accordance below with BSEN Minimum free area for the air supply opening at 14868:2005). high level is 2cm 2 per 1kW boiler input. Systems with; Continuous oxygenation (e.g. floor heating without diffusion-proof plastic pipes) or, Flue gas system Intermittent oxygenation (e.g. frequent Flue systems must comply with current topping up required) must be fitted with a British Standards and legislation. system separator. The flue must be pressure tight, able to withstand slight positive over pressure. Treated heating water must be checked at least once per year or more frequently as specified by the inhibitor manufacturer. Flue system must be able to cope with flue If, in the case of existing systems (e.g. boiler gas temperatures up to 190 C. replacement), the water quality of the existing The flue should be able to withstand the heating water complies with VDI 2035, it is not mildly acidic nature of any condensate that recommended that the system be refilled. VDI might form. Any condensate should not be 2035 also applies to top-up water. allowed to collect in the flue and should be Before filling new systems, or, if applicable, drained via a suitable trapped drain not existing systems, the heating system must be professionally cleaned and flushed. The heating back via the boiler. system must be flushed before the boiler is filled. A flue gas sampling point with an internal diameter Components of the boiler / heat exchanger that 10-21mm should be included adja- come into contact with water are made of ferrous cent to the flue spigot, extending through material. any thermal insulation. Due to the risk of stress corrosion cracking, the The pressure condition at the boiler spigot combined chloride, nitrate and sulphate content ideally should be balanced It can be slightly negative (up to -50Pa) or slightly positive of the heating water must not exceed a total of 200mg/l. Once the heating has been in operation for 6 12 depending on the matched burner. Check weeks, the ph value of the heating water should with Hoval Technical. be between 8.3 and 9.5. A draught stabiliser may be required if the Water for filling and topping up the system: draught exceeds the figure indicated. Untreated drinking water is generally most suitable < 2D for filling and topping up a system with a Hoval boiler. However, the water quality of the untreated drinking water must always comply with VDI 2035 D or must be demineralised and/or treated with inhibitors. The specifications of BSEN 14868: x D 1D must be observed. In order to maintain the boiler s high efficiency level and to avoid overheating of the heating Flue gas surfaces, the values in the table below must not test point be exceeded.in order to maintain the boiler s D high efficiency level and to avoid overheating Table 1: Standard values for boiler and circuit water for circulation boiler (shell boiler) Burner mounting When mounting the burner an adapter flange may be required depending on the burner being used. If this is required this will be fitted to the boiler door and supplied with all additional fixings before it is dispatched from Hoval. The flexible oil pipes or gas pipework should be installed in such a manner that the door can be opened 90 with the burner still attached. All services must be fitted in such a manner that the boiler door can be opened fully. Electrical connection A single phase 230V supply is required for the control panel operation. Single phase burners are electrically supplied via the control panel. Three phase burners require a separate three phase isolated supply (by the installer) direct to the burner. In this case control cables fitted with wieland plug/ sockets will still run between the control panel and the burner. All power supplies to the burner/boiler/ other associated equipment (ie.: gas booster, separate oil pump, etc.) Noise attenuation The following steps can be taken to reduce noise: Make the walls, ceiling and floor of the boiler plant room as solid as possible, fit sound absorbers in the air supply ducting, provide conduit supports and brackets with sound dampening fittings. If there are living quarters either above or below the boiler plant room, fit rubber vibration strips underneath the base channels of the boiler and connect conduits flexibly with flexible connections. Connect circulating pumps to the network with flexible connections. In order to dampen flame noise in the flue, sound absorbers can be fitted in the flue system (consider leaving space for subsequent installation). Boiler start up from cold It is important to minimise the amount of condensate generated within the boiler during start-up from cold. The boiler should therefore only be allowed to circulate through local pipework until the return temperature is at least 55 C, before progressively allowing flow out to the system. A means of back-end (or return temperature) protection should be provided for each boiler to ensure minimum return temperature requirements are met. (not provided by Hoval) Important! A condensate trap must be fitted on the boiler flue outlet to prevent condensate entering the boiler. A condensate drain point is provided in the flue outlet smoke box and this should be piped to drain via a drain trap to prevent flue gases escaping. No isolating valve should be fitted in this pipework. Hydraulic Integration (Max-3 condens E boilers) If the flue gas condensing heat exchanger is integrated into a separate control and/or pump circuit, this must be equipped with at least a safety thermostat (installed directly downstream of or in the water outlet from the flue gas heat exchanger) and a safety valve. This equipment with a safety valve particularly applies if this circuit is designed so that it can be shut off. November Rev

34 CompactGas ( ) DESCRIPTION Hoval CompactGas Economical Super High Efficiency Low heating costs due to 96.5% efficiency rating Efficient fuel usage due to modulating burner technology and integrated Alufer technology Low emissions due to clean combustion Ecological Clean combustion offering low NOx outputs less than 80mg/kWh Lower CO 2 emissions due to minimal gas consumption Easy to Use Simple Maintenance Less cleaning required due to clean combustion Easy to use due to intelligent design details User Friendly touchscreen TopTronic E controller Versatile Option Space saving due to compact design Sophisticated Time saving installation due to flexible connection options Large range of applications due to flexible combination options. Chequer plate top significantly eases installation in a boiler room Flue outlet at the front of the boiler, for space saving installation Flue gas collector Large furnace chamber for optimal and clean combustion alufer heat exchanger ensures an excellent, uniform heat transmission and low flue gas temperatures Pivoting front door for simple cleaning and easy accessibility to the combustion chamber. 226 November Rev 01

35 CompactGas ( ) DESCRIPTION Featuring our patented alufer heat exchanger Hoval alufer technology The internationally patented alufer tube is a Hoval innovation in advanced heat transfer technology. It is constructed from an inner aluminium surface, heat shrunk within an outer carbon steel tube. The exceptional efficiency of the heat transfer is attributed to the following factors: The surface area for heat transfer is increased by a factor of five. High heat conductivity of aluminium being ten times greater than that of steel Optimised turbulence and heat exchange efficiency created by the multiple flow channels on the inner surface of the tube The CompactGas boiler is only suitable for firing with natural gas User-friendly operation The completely pivoting front door and the accessibility from the front significantly ease maintenance work and boiler and chimney cleaning. Large water capacity energy efficiency The large water capacity of the boiler allows for continuous operation of the burner and fewer starts. This significantly reduces gas consumption. Sophisticated management for your heating system The TopTronic control is the brain of every Hoval system. Innovative microprocessor technology ensures smooth and continuously monitored operation. The LCD display provides information on operating data, while a single rotary pushbutton and seven keys are used to activate heating programs and settings. If manual intervention is necessary, the required program can be found in seconds in the self-explanatory user guide. November Rev

36 CompactGas ( ) TECHNICAL DATA Type (700) (1000) (1400) (1800) (2200) (2800) Nominal output at 80/60 C 4 kw Range of output at 80/60 C kw Burner input maximum kw Maximum working temperature 1 C Minimum working temperature C Minimum boiler return temperature C Safety temperature limiter setting (water side) 2 C Working/test pressure bar 6/9 6/9 6/9 6/9 6/9 10/16 Boiler efficiency at full load at 80/60 C (net calorific value/gross calorific value) % 96.5/ / / / / /87.0 Efficiency at partial load 30% (EN 303) (net calorific value/gross calorific value) % 97.4/ / / / / /87.8 Standard efficiency 75/60 C (according to DIN 4702 part 8) (net calorific value/gross calorific value) % 97.4/ / / / / /87.9 Stand-by loss at 70 C Watt Flue gas temperature at nominal output at 80/60 C C Flue gas resistance at nominal output 10.5% CO 2 natural gas 500 m over sea level (Tolerance ± 20%) mbar Flue gas mass flow at nominal output 10.5% CO 2 natural gas kg/h Flow resistance boiler 3 z-value Water flow resistance at 20 K mbar Water flow volume at 20 K m³/h Boiler water content litres Insulation thickness boiler body mm Weight (incl. casing) 6 bar kg Weight (without casing) 6 bar kg Heating surface m² Combustion chamber dimension Ø inside x length mm 584/ / / / / /3272 Combustion chamber volume m³ Dimensions see Dimensions 1 Limited by the boiler control panel E13.4 to 90 C and C. 2 Maximum safety temperature for boiler control panel E13.4:110 C and for E13.5:120 C 3 Flow resistance boiler in mbar = volume flow (m 3 /h) 2 x z 4 The CompactGas boiler is only suitable for firing with natural gas For Engineering information please refer to page 205 which is also applicable to the CompactGas boiler 228 November Rev 01

37 CompactGas ( ) TECHNICAL DATA Type (3500) (4200) Nominal output at 80/60 C 5 kw Range of output at 80/60 C kw Burner input maximum kw Maximum working temperature 1 C Minimum working temperature C Minimum boiler return temperature C Safety temperature limiter setting C (water side) Working/test pressure bar 10/16 10/16 Boiler efficiency at full load at 80/60 C (net calorific value/gross calorific value) % 96/86,5 4 96/86,5 4 Efficiency at partial load 30% (EN 303) (net calorific value/gross calorific value) % 97/87,3 4 97/87,3 4 Standard efficiency 75/60 C (according to DIN 4702 part 8) (net calorific value/gross calorific value) % 97/87,4 4 97/87,4 4 Stand-by loss at 70 C Watt Flue gas temperature at nominal output at 80/60 C C Flue gas resistance at nominal output 10.5% CO 2 natural gas 500 m over sea level (Tolerance ± 20%) mbar 7,9 4 8,5 4 Flue gas mass flow at nominal output 10.5% CO 2 natural gas kg/h Flow resistance boiler 3 z-value 0, ,002 4 Water flow resistance at 20 K mbar ,8 4 Water flow volume at 20 K m³/h ,6 4 Boiler water content litres Insulation thickness boiler body mm Weight (incl. casing) 6 bar kg Weight (without casing) 6 bar kg Heating surface m² 178,33 217,21 Combustion chamber dimension Ø inside x length mm 1050/ /3308 Combustion chamber volume m³ 2,596 2,88 Dimensions see Dimensions 1 Limited by the boiler control panel E13.4 to 90 C and E13.5 to 105 C 2 Maximum safety temperature for boiler control panel E13.4:110 C and for E13.5=120 C 3 Flow resistance boiler in mbar = volume flow (m 3 /h) 2 x z 4..The values have been calculated resp. interpolated. They must be verified by means of tests. 5 The CompactGas boiler is only suitable for firing with natural gas For Engineering information please refer to page 205 which is also applicable to the CompactGas boiler November Rev

38 CompactGas ( ) TECHNICAL DATA Flue gas output diagram Flue gas temperature ( C) For guidance only kw = Boiler output C = Flue gas temperature on clean surface, boiler flow temperature 80 C, return temperature 60 C (in accordance with DIN 4702) Flue gas resistance Nominal output (kw) Operated with natural gas H, λ = 1,15 with max. burner output (CO 2 natural gas H = 10,5 %) A reduction of the boiler water temperature of -10 K causes a reduction of the flue gas temperature of approx. 6-8 K. A modification of lambda λ of ± 0,09 causes a modification of the flue gas temperature of ± 8 K Flue gas resistance (mbar) For guidance only Boiler output (kw) 230 November Rev 01

39 CompactGas ( ) DIMENSIONS Type a b c d e f g h i k (inside) (700) xM12 15 / (1000) xM (1400) xM (1800) xM (2200) xM (2800) xM (3500) xM (4200) xM Type l * m n o p q r s t u v w (700) (1000) (1400) (1800) (2200) (2800) (3500) x (4200) x * with Condensate trap: mm A condensate trap must be fitted at the flue gas outlet to prevent condensation entering the boiler Opening the boiler door boiler door opens to the right or left (dimensions in mm)) 1 Flow (700) DN 125, PN6 (1000) DN 125, PN6 (1400) DN 150, PN6 (1800) DN 150, PN6 (2200) DN 150, PN6 (2800) DN 200, PN 10 (3500) DN 200, PN 10 (4200) DN 200, PN 10 2 Return (700) DN 125, PN6 (1000) DN 125, PN6 (1400) DN 150, PN6 (1800) DN 150, PN6 (2200) DN 150, PN6 (2800) DN 200, PN10 (3500) DN 200, PN10 (4200) DN 200, PN10 3 Flue gas outlet 4 Draining R 1½ 5 Condensate drain D31/25 mm (on both sides) 6 Electrical connection (on both sides) 7 Control panel (optionally on the left or right hand side) 8 Sleeve Rp ¾ with immersion pocket for boiler temperature sensor CompactGas Type a b (700) (1000) (1400) (1800) (2200) (2800) (3500) (4200) November Rev

40 CompactGas ( ) DIMENSIONS Dimensions without insulation and casing Boiler incl. boiler door, outlet without flue gas condensate trap (dimensions in mm) Type a b * c d e f g h i k (inside) (700) xM (1000) xM (1400) xM (1800) xM (2200) xM (2800) xM (3500) xM (4200) xM Type l m n o p q r s t DN (700) , (1000) (1400) (1800) (2200) (2800) (3500) (4200) Combustion chamber dimensions Typ A B C D E (700) (1000) (1400) (1800) (2200) (2800) (3500) (4200) November Rev 01

41 CompactGas ( ) TYPICAL HYDRAULIC SCHEMATIC Notes : This hydraulic schematic is to be used for indicative purposes only. It does not contain all required items for the installation. The installation must comply with all relevant regulations. For underfloor heating, a flow temperature limiter must be installed. Safety valves must be fitted directly to the boilers (with no isolation valve). Lock shield valves must be used for the expansion vessel. Anti-thermal siphon loops must be installed to ensure natural circulation is not present. Pressure limiter (in accordance with BSEN12828 clause Heating Systems In Buildings). All CompactGas models should have an associated pressure limiter device fitted in the system pipework, as close as possible to the boiler itself (provided by the installer - not supplied, fitted or wired by Hoval). If the operating pressure of the heating system exceeds the given pressure limit, or in the case of auxiliary power interruption, the pressure limiter shall shut off the heating equipment and interlock against it restarting. The pressure limiter shall be adjusted so that it responds before the safety valve(s) operate. Not shown on these schematics. TTE-WEZ TopTronic E basic module heat generator (installed) VF1 Flow temperature sensor 1 B1.1 Flow temperature limit thermostat (if required) MK1 Pump mixer circuit 1 YK1 Actuator mixer 1 YKR Actuator, return mixer AF Outdoor sensor SF Calorifier sensor RLF Return sensor DKP Pump for heating circuit without mixer SLP Calorifier loading pump KKP Boiler circuit pump Optional RBM TTE-GW TopTronic E room control module TopTronic E Gateway TTE-FE HK TopTronic E module expansion heating circuit VF2 Flow temperature sensor 2 B1.2 Flow temperature limit thermostat (if required) MK2 Pump mixer circuit 2 YK2 Actuator mixer 2 November Rev

42 Hoval at Burj Khalifa, UAE Niovember Rev 01

43 SR-plus ( kw) DESCRIPTION Hoval SR-plus Economical Ecological Saving Energy Cost-efficient solution due to low investment cost Best effectiveness due to spiral retarders fitted on the gas side Low impact on the environment Environmentally friendly due to low NOx emissions Lower CO 2 emissions due to minimal fuel consumption Easy to Use Simple Maintenance Service friendly due to easy front door access Easy to use due to intelligent design details User Friendly touchscreen TopTronic E controller Versatile Option Space saving due to compact design Simple installation due to high flexibility in positioning Sophisticated User-friendly operation Flue gases pass to a rear mounted flue outlet box and horizontal flue outlet. The flue outlet has a spigot for connecting to the installers flue pipe, and is fitted with a door for cleaning and access. Operating Conditions The SR-plus is tested and manufactured to European boiler design codes and is offered in outputs from 500 to 3710kW. The boilers are suitable for working pressures up to 8 bar and operating temperatures to a maximum of 105 o C. On special request SR-plus boilers are available to model 3000 in accordance with BS855 PED for operation up to 132 o C and 4.5 bar operating pressure. SR-H plus boilers are also available including to model 4000 in accordance with BSEN12953 PED for operation up to 150 o C and 10 bar operating pressure. Intelligent command centre for your heating system All SR-plus boilers are supplied with a side-mounted TopTronic E/E13.5 control panel. This is mounted on the right hand side of the boiler as standard. The integral TopTronic E Controller provides for control of the gas, oil or dual fuel burner and as an optional extra can sequence up to eight boilers. Optional TopTronic E modules can also be fitted in the control panel depending on system requirements. Clean combustion Burners The boilers are of mild steel welded construction in which the outer shell forms a water space around the combustion chamber. The final pass water jacketed gas passage ways with plain smoke tubes and spiral retarders provide an effective secondary heating surface. With the proven three-pass technique, the hot combustion gases are immediately moved out of the high-temperature zone. The flame temperature is reduced, and the pollutant emissions are minimised. The SR-plus is suitable for operation with a range of matched burners for use with oil, gas, dual fuel or biogas. It is Hoval policy to supply boilers with matched burners from several recognised manufacturers. (Please see note 6 on page 237 regarding MCP variants) Details of gas pressures, noise levels, acoustic shrouds etc. are given on individual quotations. July Rev

44 SR-plus ( kw) DESCRIPTION Insulated hinged front door Doors can be hinged on either side Large combustion chamber Helps reduce NOx emissions TopTronic E/E13.5 Control Panel Mounted on the right hand side of the boiler as standard Chamber glass Features a combustion chamber Generous water volume Permits no minimum water flow rate Plain smoke tubes and spiral retarders Reduce laminar flow and increase efficiency Fully insulated combustion chamber For minimal standing losses Technical data (500) (600) (700) (1000 MCP) (1300 MCP) Output range at high fire kw Maximum operating temperature (1) o C 105 Maximum operating pressure bar 8 Water content litre Dry Boiler Weight (2,3) kg Dimensions W/H/L (4) mm 1290/1435/ /1590/ /1677/ /1765/2981 Technical data (1750 MCP) (2000 MCP) (2250 MCP) (2500 MCP) (3000 MCP) (3500 MCP) (4000 MCP) Output range at high fire kw Maximum operating temperature (1) o C 105 Maximum operating pressure bar 8 Water content litre Dry Boiler Weight (2,3) kg Dimensions W/H/L (4) mm 1765/1940/ /2048/ /2212/ /2295/ /2420/ /2630/ /2700/ 4251 (1) Based on a maximum limit thermostat setting of 120 C. Subject to modification (2) Excludes burner. Weights shown are for the 8 bar boiler (3) Width includes for side mounted control panel. (4) On special request boilers are available, in accordance with BS855PED, for operation up to 132 C with 4.5 bar operating pressure to model 3000 only. (5) SR-H plus boilers are also available in accordance with BS EN12953 PED for operation up to 150 C and 10 bar operating pressure (including model 4000). For detailed technical information please refer to separate manual 236 July Rev 02

45 SR-plus ( kw) TECHNICAL DATA Type (500) (600) (700) (1000 MCP) (1300 MCP) Maximum Output kw Minimum Output kw Burner input at maximum output kw Burner input at minimum output kw Maximum boiler operating temperature 1 C Minimum return temperature (oil/gas) C 60/55 60/55 60/55 60/55 60/55 Minimum flue gas temperature C Maximum working pressure bar Boiler efficiency nett 2 at 100%PN % at 30%PN % Standing losses at qb at 70 C Watt Insulation thickness mm Fuel Consumption at maximum output Nat Gas 3 m 3 /hr seconds oil 4 litres/hr Hydraulic resistance through the boiler 5 z-factor Hydraulic resistance with 11 K ΔT m bar Hydraulic resistance with 20 K ΔT m bar Water Flow rate with 11 K Δ m 3 /hr Water Flow rate with 20 K Δ T m 3 /hr Boiler water content litres Dry Weight (without burner) kg Type (1750 MCP) (2000 MCP) (2250 MCP) (2500 MCP) (3000 MCP) (3500 MCP) (4000 MCP) Maximum Output kw Minimum Output kw Burner input at maximum output kw Burner input at minimum output Maximum boiler operating temperature 1 C Minimum return temperature (oil/gas) C 60/55 60/55 60/55 60/55 60/55 60/55 60/55 Minimum flue gas temperature C Maximum working pressure bar Boiler efficiency nett 2 at 100%PN % at 30%PN % Standing losses at qb at 70 C Watt Insulation thickness mm Fuel Consumption at maximum output Nat Gas 3 m 3 /hr seconds oil 4 litres/hr Hydraulic resistance through the boiler 5 z-factor Hydraulic resistance with 11 K ΔT m bar Hydraulic resistance with 20 K ΔT m bar Water Flow rate with 11 K Δ m3/h Water Flow rate with 20 K Δ T m3/ Boiler water content litres Dry Weight (without burner) kg (1) Based on a maximum limit thermostat setting of 120 o C. (2) Boiler efficiencies at 100% load are based on a mean operating temperature of 70 o C, at 30% efficiencies are based on a mean temperature of 50 o C. (3) Based on gross CV 38.5 MJ/m 3. (4) Based on gross CV 45.5 MJ/kg and specific gravity (5) Hydraulic resistance (mbar) = (Flow rate (m 3 /h)) 2 x z Figures are based on the maximum boiler outputs. (6) MCP variants comply with the Medium Combustion Plant Directive which comes into effect on the 20th December Suitable for Gas firing only. Oil only suitable as a stand-by fuel burner, and its use must be limited to less than 500 run hours per annum. July Rev

46 SR-plus ( ) DIMENSIONS & TECHNICAL INFORMATION Control panel can be mounted on left or right hand side. (Standard right hand side). 1 3 C 2 G 560 H B 165 J M 9 N 7 5 A 10 L E Front view F D Side elevation view Note: The installer must ensure the condensate drain connection (8) is piped to drain via a drain trap to prevent flue gases escaping. Do not fit an isolation valve in this pipework. As well as the safety valve, the installer must provide i) for a pressurised system - an automatic air vent. ii) for an open vented system - a vent from the flow line. 1 Flow 2 Return 3 Safety valve connection 4 Hydraulic drain 5 Flue outlet 6 Smokebox cleaning door 7 Flue gas test point 8 Smokebox condensate drain 9 Boiler control panel 10 Burner mounting flange A single phase 230V supply is required for the control panel operation. Single phase burners are electrically supplied via the control panel. Three phase burners require a separate three phase isolated supply (by the installer direct to the burner, incorporating a flexible connection to allow for boiler/burner door opening. A separate control cable is fitted with wieland plug/sockets to run between the control panel and the burner. All power supplies to the boiler/ burner/other associated equipment (ie: gas booster, separate oil pump, etc.) should be isolated via the same switched isolator. SRplus Model kw Rating at high fire A B C D E F G H J L M N Flow/return flanged to BS4504 PN16 Safety valve Flue I/D Dry Weight kg Water Content litres N/B R 1" N/B R 1" N/B R 1 1/4 " July Rev 02

47 SR-plus (1000 MCP MCP) DIMENSIONS Control panel can be mounted on left or right hand side. (Standard right hand side). 3 2 C G H B 165 J N M A 10 L E 6 Front view E D Side elevation view 8 4 Note: The installer must ensure the condensate drain connection (8) is piped to drain via a drain trap to prevent flue gases escaping. Do not fit an isolation valve in this pipework. As well as the safety valve, the installer must provide i) for a pressurised system - an automatic air vent. ii) for an open vented system - a vent from the flow line. 1 Flow 2 Return 3 Safety valve connection 4 Hydraulic drain 5 Flue outlet 6 Smokebox cleaning door 7 Flue gas test point 8 Smokebox condensate drain 9 Boiler control panel 10 Burner mounting flange Please see note 6 on page 237 regarding the MCP variants below A single phase 230V supply is required for the control panel operation. Single phase burners are electrically supplied via the control panel. Three phase burners require a separate three phase isolated supply (by the installer direct to the burner, incorporating a flexible connection to allow for boiler/burner door opening. A separate control cable is fitted with wieland plug/sockets to run between the control panel and the burner. All power supplies to the boiler/ burner/other associated equipment (ie: gas booster, separate oil pump, etc.) should be isolated via the same switched isolator. SR-plus Model kw Rating at high fire A B C D E F G H J L M N Flow/Return flanged to BS4504 PN16 Safety valve Flue I/D Dry Weight kg Water Content litres 1000 MCP 1300 MCP 1750 MCP 2000 MCP 2250 MCP N/B R 1 1/ N/B R 1 1/ N/B R N/B R N/B R MCP N/B 65N/B PN MCP N/B 65N/B PN MCP N/B 65N/B PN MCP N/B 65N/B PN July Rev

48 SR-H plus ( & 1750 MCP MCP) DIMENSIONS Control panel can be mounted on left or right hand side. (Standard right hand side). 1 3 C 2 G 560 H B 165 J L M 9 N E 6 F Rear view D 8 4 Side elevation view Note: The installer must ensure the condensate drain connection (8) is piped to drain via a drain trap to prevent flue gases escaping. Do not fit an isolation valve in this pipework. As well as the safety valve, the installer should provide; i) For a pressurised system - an automatic air vent. ii) For an open vented system - a vent from the flow line. 1 Flow 2 Return 3 Safety valve connection 4 Hydraulic drain 5 Flue outlet 6 Smokebox cleaning door 7 Flue gas test point 8 Smokebox condensate drain 9 Boiler control panel supplied seperately for fitting and wiring by the installer Please see note 6 on page 237 regarding the MCP variants below A single phase 230V supply is required for the control panel operation. Single phase burners are electrically supplied via the control panel. Three phase burners require a seperate three phase isolated supply (by the installer direct to the burner, incorporating a flexible connection to allow for boiler/burner door opening. A separate control cable is fitted with wieland plug/sockets to run between the control panel and the burner. All power supplies to the boiler/burner/ other associated equipment (i.e.: gas booster, separate oil pump, etc.) should be isolated via the same switched isolator. SR-H plus Model kw Rating at high fire A B C D E F G H J L Flow/ Return flanged to BS4504 PN16 Safety valve flanged to BS4504 PN16 Drain flanged BS4504 PN16 Flue I/D Dry Weight kg Water Content litres NB 25NB 40NB NB 25NB 40NB NB 32NB 40NB MCP 2000 MCP 2500 MCP 3000 MCP 4000 MCP NB 40NB 40NB NB 50NB 40NB NB 50NB 40NB NB 50NB 40NB NB 65NB 40NB July Rev 02

49 SR-plus ( MCP) TYPICAL HYDRAULIC SCHEMATIC Notes : These hydraulic schematics are to be used for indicative purposes only. They do not contain all required items for the installation. The installation must comply with all relevant regulations. For underfloor heating, a flow temperature limiter must be installed. Safety valves must be fitted directly to the boilers (with no isolation valve). Lock shield valves must be used for the expansion vessel. Anti-thermal siphon loops must be installed to ensure natural circulation is not present. Pressure limiter (in accordance with BSEN12828 clause Heating Systems In Buildings). All SR-plus models should have an associated pressure limiter device fitted in the system pipework, as close as possible to the boiler itself (provided by the installer - not supplied, fitted or wired by Hoval). If the operating pressure of the heating system exceeds the given pressure limit, or in the case of auxiliary power interruption, the pressure limiter shall shut off the heating equipment and interlock against it restarting. The pressure limiter shall be adjusted so that it responds before the safety valve(s) operate. Not shown on these schematics. SR-Plus TTE-WEZ TopTronic E basic module heat generator (installed) VF1 Flow temperature sensor 1 B1.1 Flow temperature limit thermostat (if required) MK1 Pump mixer circuit 1 YK1 Actuator mixer 1 YKR Actuator, return mixer AF Outdoor sensor SF Calorifier sensor RLF Return sensor DKP Pump for heating circuit without mixer SLP Calorifier loading pump KKP Boiler circuit pump Optional RBM TTE-GW TopTronic E room control module TopTronic E Gateway TTE-FE HK TopTronic E module expansion heating circuit VF2 Flow temperature sensor 2 B1.2 Flow temperature limit thermostat (if required) MK2 Pump mixer circuit 2 YK2 Actuator mixer 2 Jully Rev

50 Hoval at Oxford University July Rev 02