Ultramax R600 High output, floor standing gas fired condensing boilers with outputs from 150kW to 571kW
Delivering excellence with every feature The Ultramax R600 series of boilers is packed with features that are best in class and provide power, extreme efficiency, reliability, and ultra low harmful emissions. The range includes 7 models with outputs from 150 to 571kW. Utilising the proven water cooled, downfiring, premix burner system coupled with an all stainless steel heat exchanger assembly, Ultramax R600 boilers have a class leading NOx emission of less than 35mg/kWh @ 0% O 2 (which easily exceeds the requirements for the best REEM score) and can return efficiencies of up to 109%. Designed to pass through standard doors, with widths from 670mm and floor space requirement is within the range 0.74 m 2 to1.34m 2. Each model is able to be equipped with two return connections, allowing high efficiency to be achieved when serving a mix of higher and lower system load circuit temperatures. nother feature is the option to utilise room sealed or open flue systems. The Ultramax R600 is suitable for use in single boiler or multiple/cascade installations. If used singly, plug and play optional extra low loss headers are available, and if being used as retrofit appliances onto aged systems, a matched boiler protection plate heat exchanger unit is available for total boiler isolation. The modulating burner system allows turndown ranging from 5:1 to 7:1 to return optimum efficiency at low system loads. Water cooled down-firing burner 2
Put your mind at rest It s easy to ignore your boiler and heating system - until it goes wrong or breaks down. system failure, especially one caused by lack of maintenance, can be inconvenient and costly. It isn t hard to imagine the difficulties that problems with your heating system can cause. nd in some situations lack of heating and hot water can be critical. Similar to your car, a regularly maintained heating system will run more efficiently and any potential problems can be resolved before they develop into major system failure. Financially, planned maintenance makes sense too. It avoids major capital outlay and the associated costs of system down time - plus it can keep your fuel costs down as well as ensuring you are minimising your emissions. t MHS oilers we provide a lifetime maintenance and service solution for your heating system - enabling you to rest safe in the knowledge that we ll take care of it. For details of cost effective Service and Maintenance Plans from MHS oilers, (with options for plans which include labour and parts), go to the Maintenance and Service section at www.mhsboilers.com Our highly skilled and trained service and technical support engineers are only a phone call away 3
Standard features Exceptional high quality and unequalled lifetime high efficiency through the use of corrosion resistant stainless steel as a heat exchanger material. Compact dimensions Mindful that space is at a premium in commercial buildings, the R600 range is frugal on its space requirements, and with dimensions ranging from 1105mm to 1735mm long by 670mm or 770 mm wide, all appliances will pass through a standard door. nd for those installations where access is particularly difficult, the boilers can be disassembled for site handling as piece parts. Controls options With the inclusion of optional extra control modules, up to two heating circuits (with or without weather compensation), and domestic hot water may controlled in a single boiler installation. If used in a modular/multiple boiler installation, the standard in-built controllers are able to be configured to operate in a master/slave arrangement to provide a cascading control function. Up to 16 boilers may be included in a cascade configuration. See page 10 for details. Extreme efficiency The all stainless steel heat exchanger coupled with the patented water cooled down-firing modulating premix burner with turndown to between 14 to 20% (dependant upon model), the Ultramax R600 boilers can return efficiency of up to 109% net. Operating at this extremely high efficiency, the boiler has almost no losses to the chimney giving maximum fuel savings. Water cooled combustion chamber The application of water cooling measures to the combustion chamber removes all need for delicate high temperature insulating materials creating a very robust and reliable unit that may be wet cleaned if necessary. Two system water return connections With a typical standard type of condensing boiler serving a system consisting of multiple load circuits operating at different temperatures, the boiler must operate at a flow temperature equal to that demanded by the highest temperature load circuit. This in many cases may prevent the boiler from operating in condensation phase and inhibit the efficiency. The Ultramax R600 however, is not a typical standard type of condensing boiler; it has the option for two return water connections; a hot return for higher temperature load circuits such as air handling units or hot water cylinders, and a cool return connection for weather compensated radiator circuits or under floor heating. In this way the cool return water can be separated and passed through the condensing section of the heat exchanger allowing the boiler to operate at a higher efficiency than if the higher and lower temperature return water was blended together and passed through the entire water circuit of the boiler heat exchanger. Inherent reliability With all solid state controls, and moving parts confined to the gas valve and fan there is little to wear through usage. dditionally all components are sensibly laid out within the uncluttered frame making maintenance a simple task. Very low operating noise t just 59db, the Ultramax R600 series is extremely quiet making them an ideal appliance to choose in noise sensitive applications such as residential blocks, schools and libraries etc. Varied fluing possibilities The appliance may take air for combustion from the room or it may be room sealed using a parallel tubes arrangement. Warranty s standard the heat exchanger carries a 5 year guarantee. ll guarantees are against manufacturing or material defects only (see terms and conditions of sale). 4
Dimensions & clearances Clearance diagram 450 450 450 8 (D2) 800 L 1 3 2 5 (D1) L2 2 (G) 3 (W1) 4 (W2) 1175 489 413 112 H2 *6 (W2) 7 H 115 (3x) 1440 5 4 9 1 Electrical connections 2 Gas supply 3 Water supply 4 Water return (cold) 5 ir intake 6 * Water 2nd return (hot) 7 oiler water drain valve 8 Flue gas outlet 9 Condense drain flexible hose 25mm diameter Dimension R601 R602 R603 R604 R605 R606 R607 L mm 1105 1260 1470 1220 1435 1585 1735 L2 mm 127.5 127.5 137.5 137.5 187.5 187.5 187.5 H mm 1480 1480 1500 1500 1500 1500 1500 H2 mm 1120 1130 1130 1150 1245 1245 1245 mm 670 670 670 770 770 770 770 2 mm 225 235 235 235 215 215 215 3 mm 260 260 260 310 310 310 310 4 mm 260 260 260 490 490 490 490 5 mm 130 130 130 245 245 245 245 D1 mm(dia) 130 150 150 150 200 200 200 D2 mm(dia) 150 150 200 200 250 250 250 W1 R"/DN R2" R2" R2" DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16 W2 R"/DN R2" R2" R2" DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16 G R R 3 /4" R1" R1" R1" R1 1 /2" R1 1 /2" R1 1 /2" * Facility achieved using optional extra, "water 2nd return connection kit". 5
Easy access to all components Designed with maintenance in mind, all components are easy to access; for example the top cover of the burner removes quickly for cleaning of the air/gas ways if necessary. There is inspection and cleaning access to the combustion chamber and the integral chimney section at the rear of the appliance removes easily without the need for supplementary support of the flue system in the building. Flue Systems Ultramax R600 boilers must be connected to a flue system suitable for use with condensing boilers. ll sections of the flue must have a fall of at least 3 degrees back towards the boiler to ensure that any condensation that forms in the flue is free draining back to the boiler. If the draught generated in the flue system is likely to exceed 30Pa, then a suitable draught reducing / stabilising device and a lockable volume control damper must be incorporated into the chimney system adjacent to the appliance. The terminal of the flue system should be left open. Universal Terminal Caps or Rain Caps MUST NOT E USED, any rain that enters the flue system will help to wash the flue and will drain through the boiler's condensate waste outlet. Room Sealed pplication For the appliance to be operated as room sealed, taking air for combustion from outside the building, an air duct must be installed to connection 5(D1). The air duct must not be smaller than the diameter of the air connection on the boiler. The resistance of the air duct must be added to the resistance of the flue gas system and the total must not exceed the maximum system flue resistance detailed in the Technical data table on page 7. The air connection is located behind an access panel which must be removed and discarded when creating a room sealed arrangement. For standard arrangements (23) where the air for combustion is taken from the boiler room, it is not necessary to remove the access panel. For specific guidance on flue system design parameters, see the R600 planning document available for viewing/downloading at www.mhsboilers.com 6
Technical data oiler Model R601 R602 R603 R604 R605 R606 R607 Nominal heat output 80/60 C kw 23.3 142.1 39.5 190.1 39.5 237.2 39.5 285.2 76.6 380.2 76.6 475.3 76.6 539.0 Nominal heat output 40/30 C kw 26.7 150.7 45.2 201.6 45.1 251.4 45.2 302.3 87.7 403.1 87.7 503.9 87.7 571.5 Nominal heat input Gross kw 27.2 160.1 46.1 215.3 46.1 268.6 46.1 323.0 89.3 430.6 89.3 538.3 89.3 610.5 Net kw 24.5 145.0 41.5 194.0 41.5 242.0 41.5 291.0 80.5 388.0 80.5 485.0 80.5 550.0 Max flow temperature C 90 90 90 90 90 90 90 Water content litres 27 31 35 61 68 75 82 Design temperature rise ( t) C 20 20 20 20 20 20 20 Nominal water flow @ t 20K l/s 1.69 2.26 2.82 3.39 4.52 5.65 6.41 Hydraulic resistance at nominal water flow kpa 10 18 28 15 27 42 55 Min/Max operating pressure @ 90 C bar 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 Gas consumption Nat Gas (G20) @ max load Gas consumption LPG (G31) @ max load m 3 /h 13.3 17.8 22.2 26.7 35.6 44.5 50.5 kg/h 11.3 15.2 18.9 22.7 30.3 37.9 43.0 Gas inlet press nom. Nat Gas (G20) mbar 17/20 17/20 17/20 17/20 17/20 17/20 17/20 Gas inlet press min/max LPG (G31) mbar 30/50 30/50 30/50 30/50 30/50 30/50 30/50 pprox flue gas volume max @ max load m 3 /hr 238.0 318.0 397.0 477.0 636.0 795 901.0 NOx level @ 0% O 2 (min/max) mg/kwh 15/35 15/35 15/35 15/35 15/35 15/35 15/35 pprox flue gas temperature @ 80/60 C system operation min/max C 56/78 56/78 56/78 56/78 56/78 56/78 56/78 Maximum system flue resistance Pa 160 160 200 200 200 250 250 Gas connection - R 3 /4" R 1" R 1" R 1" R 1 1 /2" R 1 1 /2" R 1 1 /2" Flow/return connections - R 2" R 2" R 2" DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16 ir supply connection mm 125 125 150 150 200 200 200 Flue connection mm 150 150 200 200 250 250 250 Condensate waste connection mm 22 22 22 22 22 22 22 Nominal weight (dry) kg 295 345 400 465 535 590 650 Electrical supply (50Hz) V 230/400 230/400 230/400 230/400 230/400 230/400 230/400 Mains connection fuse rating 10 10 10 10 10 10 10 Power consumption boiler (excl pump) min/max W 43/158 35/200 35/230 35/260 61/470 61/470 61/770 Gas Category II 2H3P ppliance Category 23,C13, C33, C43, C53, C63, C83 CE Product Identification Number 006303192 7
Enhancement optional extras range of easy-to-apply optional extra components are available to enhance the final installation of the Ultramax R600 series boilers. The use of these additional components also contributes to the ease of materials ordering, simplifies installation tasks and cuts installation time. "Safety kit"; (flow pipe assembly) including auto air vent and safety valve (incl 90 bend to increase installation flexibility) "Pump kit (incl 90 bend to increase installation flexibility) "Low loss header kit"; (incl 2 x 90 bends to increase installation flexibility) * When installing a boiler as a retrofit appliance onto an aged system, serious consideration should be given to the cleanliness / condition of the existing system and the damaging effects of accumulated dirt and sludge upon new appliances. The use of a plate heat exchanger kit provides total water side isolation and gives peace of mind that the investment in the new boiler is protected from damaging and efficiency reducing deposits from the old heating system. It also means that costly and very often ineffective measures to clean-up an existing system can be avoided. nother benefit is the possibility to retain an existing system s open vented nature whilst creating a sealed system environment for the new boiler on the primary side of the plate heat exchanger. 8
Enhancement optional extras * "Plate heat exchanger kit"; (incl expansion vessel plus 2 x 90 bends to increase installation flexibility) "Safety kit"; (flow pipe assembly) including auto air vent and safety valve (incl 90 bend to increase installation flexibility) Plate Heat Exchanger (secondary side) technical data "Pump kit" (incl 90 bend to increase installation flexibility) Model Type t 10K t 15K t 20K l/s kpa l/s kpa l/s kpa R601 3.38 30.4 - - 1.69 8.1 R602 4.5 28.8 - - 2.25 14.0 R603 5.66 44.0 - - 2.83 21.5 R604 - - 4.52 28.8 3.38 16.6 R605 - - 6.02 48.7 4.52 28.9 R606 - - 7.55 15.6 5.66 14.3 R607 - - 8.55 19.7 6.41 18.0 9
Controls and Options Ultramax R600 series boilers are equipped with a modulating control system (LMS 14 with VS37 user interface). s standard the boiler operates to provide a constant flow temperature and with the addition of an optional extra outside air temperature sensor weather variable temperature can be delivered. lternatively if required, the flow temperature can be controlled via a 0-10 Vdc signal in response to external temperatures. n indirect hot water storage cylinder plus two mixed flow or constant temperature heating zones may also be controlled and each with independent time scheduling by using extension modules. If installed as part of a multiple boiler installation, the in-built standard controllers can be configured to provide cascade control, with the potential to control up to 16 boilers. cascade master kit is required to be installed into one of the boilers with each of the remaining boilers requiring a cascade slave kit. cascade master kit incorporates an OCI 345 us Communication Module and all necessary sensors. cascade slave kit incorporates an OCI 345 us Communication Module. The controls capability can be extended by including items from the following options: VS75 single boiler may be equipped with up to two VS75 extension modules. Each module provides for the control of an additional heating circuit with connections for: Heating circuit pump Variable flow temperature mixing valve Flow water temperature sensor (The heating circuit may be constant temperature if required) dditionally, (over and above that described above), an R600 boiler may be equipped with an VS75 module configured to control an external gas valve (for use in LPG installations for example) or to perform a gas valve leak test function. Room Units / Room Temperature Sensors Each heating zone may have a room unit (remote controller) installed to allow not only room space temperature to be be monitored and controlled but also allows the user to make adjustments to the time and temperature control parameters for the zone. Hard wired unit Q75 RVS 63 Wireless unit Q78 (requires antenna to be connected to LMS14 or RVS63 as appropriate). This is an extension controller for the addition of two heating circuits, which may either be weather dependant or constant temperature. Up to 15 RVS devices may be connected to a single boiler, with one unit being able to be accommodated within the boiler control panel. dditional units are housed within wall mounted enclosures or can be supplied as loose items for build-in to a control panel by others. Each RVS 63 is used in conjunction with an VS 37 user interface panel. dditionally, an RVS63, can be used as a cascade master controller if required whereby all of the boilers become slave units. Wireless Outside ir Temperature Sensor Where the system includes a requirement for weather dependant temperature control element, as an option, a wireless outside air temperature sensor can be provided (requires antenna). 10
System water Ultramax R600 series boilers must only be installed onto sealed and pressurised systems with a minimum static head of 10m. ll systems must be thoroughly cleansed prior to the connection of the boiler and the system water must be dosed with a good quality treatment to prevent corrosion within the system and the formation of scale within the boiler waterways. The chloride content of the fill water must not exceed 50mg/l and the PH should be in the range 8.0 to 9.5. Particular care must be taken when installing the boiler onto an old system, with consideration given to the installation of the optional extra separation plate heat exchanger kit or a dirt arrester/filter. For specialist advice and water treatment products, contact: Fernox, Tandem House, Marlowe way, eddington Farm Road, Croydon CR0 4XS. Tel: 0208 665 6666 or etz Dearborn Ltd, Widnes, Cheshire W8 8UD. Tel: 0151 495 1861 Installation requirements Ultramax R600 series boilers should be installed in accordance with the relevant requirements of the uilding Regulations, Health and Safety Executive Regulation PM5, IEE Regulations, Gas Safety (Installation and Use) Regulations, National and Water ylaws and any Insurance Company requirements. Codes of practice The following list of codes of practice give guidance on the requirements for installation. S 6880: Part 1: 1988 Code of Practice for low temperature hot water heating systems for output greater than 45kW. S 6644: 2011 Installation of gas-fired hot water boilers of rated inputs between 70kW (net) and 1.8MW (net). S EN 12828: 2003 Heating systems in buildings - Design for water based heating systems. IGE/UP/2 Gas installation pipework and compressors on industrial and commercial premises. IGE/UP/10 Installation of gas appliances in industrial and commercial premises, Part 1: Flued appliances. CISE Guide Reference sections 7, 11 and 13. Filling the system The Initial filling of a sealed heating system, and subsequent refilling, must be by a method that has been approved by the Water Regulation dvisory Scheme (WRS) for the type of heating system, i.e. Domestic (in-house) Fluid Category 3 (C-3). Non Domestic (other than in-house) Fluid Category 4 (C-4). For Category 4 systems The approved method of filling must comprise of the following components in the arrangement shown; Control Valve, on the Mains Cold Water pipework. Strainer. Verifiable ackflow Device with Reduced Pressure Zone (RPZ Valve) Incorporating a Type air gap. Tundish Control Valve, on the Heating System pipework. RPZ MCWS CV Strainer CV Heating system Tundish 11
Hydraulic system design The following schematic diagrams give indications of typical hydraulic schemes that may be employed. For further and more detailed guidance on system design and planning, please see the R600 Planning Document which is available for viewing or downloading at www.mhsboilers.com Typical hydraulic layout of single boiler system Typical hydraulic layout of twin boiler system Master Slave 12
Hydraulic system design Typical hydraulic layout of split system utilising 2 nd return connection on boiler 13
Dimensions with optional low loss header kit Model mm R601 - R603 1233 R604 - R605 1299 R606 - R607 1299 Model R601 - R603 923 545 R604 - R605 1096 611 R606 - R607 1096 611 Model R601 - R603 928 545 R604 - R605 1119 611 R606 - R607 1119 611 Model R601 - R603 1191 277 R604 - R605 1320 388 R606 - R607 1320 388 Model R601 - R603 277 881 R604 - R605 388 1119 R606 - R607 388 1119 Model R601 - R603 697 886 R604 - R605 873 1138 R606 - R607 8733 1138 Model R601 - R603 1191 282 R604 - R605 1320 406 R606 - R607 1320 406 Model R601 - R603 697 881 R604 - R605 873 1119 R606 - R607 873 1119 Model R601 - R603 886 152 R604 - R605 1119 262 R606 - R607 1119 262 14
Dimensions with optional plate heat exchanger kit Model mm R601 - R603 1421 R604 - R605 1667 R606 - R607 1542 Model R601 - R603 960 735 R604 - R605 1133 981 R606 - R607 1073 856 Model R601 - R603 1047 735 R604 - R605 1222 981 R606 - R607 1278 857 Model R601 - R603 1379 314 R604 - R605 1690 424 R606 - R607 1566 362 Model R601 - R603 918 278 R604 - R605 1156 388 R606 - R607 1094 388 Model R601 - R603 887 1005 R604 - R605 1243 1243 R606 - R607 1119 1299 Model R601 - R603 1379 401 R604 - R605 1690 511 R606 - R607 1566 567 Model R601 - R603 887 918 R604 - R605 1243 1156 R606 - R607 1119 1094 Model R601 - R603 1005 252 R604 - R605 1243 362 R606 - R607 1299 361 15
3 Juniper West, Fenton Way, Southfields usiness Park, asildon, Essex SS15 6SJ Tel: 01268 546700 Fax: 01268 888250 www.mhsboilers.com This publication is issued subject to alteration or withdrawal without notice. The illustrations and specifications are not binding in detail. ll offers and sales are subject to the Company's current terms and conditions of sale. RC/0713/6543