Technical information Installation instructions. Modul-plus (F21-52) High performance calorifiers

Technical information Installation instructions Modul-plus (F21-52) High performance calorifiers These instructions apply to the following types: 5/6-Modul-plus F (21) 5/6-Modul-plus F (31) 5/6-Modul-plus F (41) 5/6-Modul-plus F (51) 5/6-Modul-plus F (32) 5/6-Modul-plus F (42) 5/6-Modul-plus F (52) Hoval products must be installed and commissioned only by appropriately qualified experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualified electrician. The calorifiers Modul-plus are suitable and approved as heat generators for hot water heating systems with permissible hot water temperatures up to 90 C 1 ). They are designed for closed systems, but can also be incorporated in open systems according to DIN 4751. 1) see section technical data Subject to modifi cations 4 210 200 855 690 / 00 07-02/13 08/16 EN

TABLE OF CONTENTS 1. Important information... 3 1.1 Important installation information...3 1.2 Delivery...3 1.3 Other instructions...3 2. Assembly... 5 2.1 Installation, levelling...5 2.1.1 Space requirements...5 2.2 Mounting the bottom guide rails...5 2.3 Mounting the insulation (Fig. 04)...6 2.4 Fitting the cladding (Fig. 07)...8 3. Technical information... 10 3.1 Description of the calorifier...10 3.2 Technical Data... 11 3.2.1 Hot water output at 70 C heating flow temperature...12 3.2.2 Hot water output at 80 C heating flow temperature...12 3.2.3 Hot water output at 90 C heating flow temperature...13 3.3 Dimensions...14 3.4 Transport dimensions...15 4. Installation... 16 4.1 Heating-side connections...16 4.2 Drinking water-side connections...16 4.2.1 Instructions concerning safety valve:...17 4.2.2 Instructions concerning the blow-off line:...17 4.2.3 Installing a pressure reducer...17 4.2.4 Measures to prevent the back-flow of heated water...17 4.3 Electrical connection...17 5. Commissioning... 18 6. Maintenance and regular inspection... 18 7. Warranty and guarantee... 18 2 4 200 690 / 07

IMPORTANT INFORMATION 1. Important information This system is only to be placed in operation when all relevant standards and safety regulations have been complied with. 1.1 Important installation information 1.2 Delivery The Modul-plus is delivered in three parts: Modul-plus Cardboard box containing the cladding, insulation and small assembly items and the bottom guide rail Electrical box, packed in a foam container The hot water storage tank must be installed in a frost-protected room. To restrict heat losses in the pipelines to a minimum the hot water storage tank should be erected as close as possible to the tap. These instructions are to be kept in the vicinity of the installation location. The installation, placing in operation and maintenance work is to be carried according to this document by a trained tradesman. Regular maintenance of the appliance is necessary for its safe and reliable operation. No modifications are to be carried out to the calorifier, otherwise the liabilities under the guarantee are waived. Heating and drinking water are not to come into contact with each other. In particular the service water is not to circulate through the heat exchanger. Fig. 01 1.3 Other instructions Depending on the model, any other necessary instructions are enclosed with the individually packed components. Burner Control Heating fittings group Accessories Further sources of information Hoval catalogue Standards, regulations 4 200 690 / 07 3

NOTES 4 4 200 690 / 07

ASSEMBLY 2. Assembly 2.1 Installation, levelling Before fitting the insulation and cladding, the calorifier must be levelled with a spirit level so that the longitudinal axis of the topmost boiler element is exactly horizontal. 2.1.1 Space requirements At least 40 cm to the left and right hand sides. If these distances cannot be observed, the calorifier must be insulated before being placed in position. 2.2 Mounting the bottom guide rails Check the dimension H between the retaining rail and the plinth rail (Fig. 02). The rails (1) are fixed to the plinth rail with hexagon screws (Fig. 03). Attention: For types F 32,42,52 - Hole A For types F 21,31,41,51 - Hole B 1 H Hole A Hole B Fig. 03 Fig. 02 Type H F 21,31,32 1454 F 41,42 1639 F 51,52 1999 4 200 690 / 07 5

ASSEMBLY 2.3 Mounting the insulation (Fig. 04) - - Wrap the mineral wool mats (1-5) (join at the top, black side outwards) around the calorifier and fix with the plastic straps (6). The plastic straps (6) (packed in the plastic bag) are joined by a strap fastener (7). Do not fasten too tightly as this will reduce the insulation value of the mats. Tension springs (8) serve for additional fixing. - - Next the hot water pipe at the top, inside the cladding is insulated with the mat (9) (fix with tension spring). - - Mount the thermal insulation covers (10) to the front side. 7 6 4 200 690 / 07

ASSEMBLY You must cut out the insulation in order to create space for the electrical box see drawing (shaded area)! 35 9 10 4,5 3 1,2 76 10 8 Fig. 04 6 7 4 200 690 / 07 7

ASSEMBLY 2.4 Fitting the cladding (Fig. 07) - - First the front base plate (11) is inserted from the front. Then the two base plates (12) are placed in position from the side, between the plinth rails. - - The front side plates (13) are first placed in the guide rails at the bottom (Fig. 10) and then attached at the top to the retaining rails. Push the side plates (13) back against the retaining rails as far as the stop (see Fig. 05). - - Then the other side plates (14,15) are fitted. Join the front side plates (13) to the bottom guide rails with spring clips (16, Fig. 08) Push the side plates (14,15) well forward so that there is no gap and then fix the plates at the back to the bottom guide rails with the clips. - - Fit the C-clips (17, Fig. 09) to the retaining rails. Now the front cladding covers (18.19) (with F31, 32, 51, 52) or the front cover (with F21, 41, 42) can be put in place. Then fit the further cover (20). Do not yet tighten the fixing screws at the side. i For the variant with built-in Correx external current anodes, proceed with the steps described in the enclosed assembly instructions! - - Place the cladding back wall (21) in position and fix with the self-tapping screws. - - Next the panel for the electrical box (22) is installed and fixed to the mounted screws with cap nuts (23). - - Mount the cable gland (24) in the panel with the plastic counter-nut. Close off the other holes with blanks (25). Now the electrical box (26) can be pushed in position. Beforehand, please route the capillaries to the rear, through the opening in the panel (22). - - Insert the immersion sensors for the temperature controller and the thermometer carefully into the immersion sleeve (27) of the corresponding module. Do not remove the plastic clip until the sensor bundle is inserted half way into the immersion sleeve. Then push the retaining spring (28, Fig. 06) on the immersion sleeve to prevent the thermometer and thermostat sensors from slipping out. - - With the placing in position of the front plate (29) and fixing it with the cap nuts (23), the mounting of the insulation and cladding to the high-performance calorifier module Modul-plus is completed. 28 Fig. 06 Fig. 05 8 4 200 690 / 07

ASSEMBLY 16 Fig. 08 29 23 25 24 22 23 26 27 20 21 18,19 14 11 Fig. 07 12 13 15 17 Fig. 09 Fig. 10 4 200 690 / 07 9

TECHNICAL INFORMATION 3. Technical information 3.1 Description of the calorifier The Modul-plus is a high-performance calorifier in cellular form. The calorifier part (cells and pipes) are of stainless steel, material No. 1.4401 and the heating jacket is of standard sheet steel. All cells have hand holes. The body is of sheet steel, with 2-colour (red/dark red) powder-paint finish. The thermal insulation is mineral wool matting with woven glass fibre and PU soft foam covers on the front. An electrical switch panel with thermometer and temperature controller is provided for installation in the front panel of the body. 10 4 200 690 / 07

TECHNICAL INFORMATION 3.2 Technical Data Type F (21) F (31) F (41) F (51) F (32) F (42) F (52) Module numbers 2 3 4 5 6 8 10 Calorifier Content litres 230 345 460 575 690 920 1150 Heating surface m 2 2.84 4.26 5.68 7.1 8.52 11.36 14.2 Max. hot water temperature C 95 95 95 95 95 95 95 Flow resistance 1 z value 1.4 2.4 3 3.6 0.74 0.9 1.1 Heat loss at 65 C W 254 254 265 286 276 288 312 Working pressure - normal type bar 6 6 6 6 6 6 6 - type high-rise building bar 10 10 10 10 10 10 10 Test pressure - normal type bar 12 12 12 12 12 12 12 - type high-rise building bar 16 16 16 16 16 16 16 Weight without casing - normal type kg 165 215 265 315 370 470 570 - type high-rise building kg 205 275 345 415 490 630 770 Weight casing kg 104 104 115 140 121 135 160 Heating Heating water content litres 30 45 60 75 90 120 150 Maximal heating water temperature C 110 110 110 110 110 110 110 Flow resistance 1 z value 2 2.8 3.6 4.7 0.78 1 1.4 Working pressure - normal type bar 5 5 5 5 5 5 5 - type high-rise building bar 8 8 8 8 8 8 8 Test pressure - normal type bar 8 8 8 8 8 8 8 - type high-rise building bar 12.8 12.8 12.8 12.8 12.8 12.8 12.8 1 Flow resistance (mbar) = volume flow (m³/h) 2 x z Flow resistance heating Flow resistance hot water 4 200 690 / 07 11

TECHNICAL INFORMATION 3.2.1 Hot water output at 70 C heating flow temperature Heating flow connected on the top of the calorifier (crosscurrent) Hot water output No. of modules Modulplus Content Heating surface Charging pump dm 3 /10 min. 2 dm 3 /h 3 Type dm 3 m 2 m 3 /h mbar 1 Type mwc 6 45 C 60 C 45 C kw 4 Flats 5 F (21) 2 230 2.84 3.5 25 SPS.../7,5 2.9 434 640 1520 61.8 7 8 120 SPS.../12 6.5 488 960 2110 86.2 11 4 40 SPS.../8 5.7 575 700 2100 85.4 12 F (31) 3 345 4.26 7 120 SPS.../12 7.7 600 900 2800 113.9 18 12 450 Stratos 40/12 4.5 635 1200 3600 146.5 25 4 55 SPS.../8 5.5 814 1100 2700 109.8 18 F (41) 4 460 5.68 8 240 SPS.../12 5.3 900 1700 4100 166.8 31 10.5 440 Stratos 40/12 5.5 942 2000 4850 197.3 39 4 75 SPS.../8 5.3 1028 1250 3750 152.6 29 F (51) 5 575 7.10 8 300 SPS.../12 4.7 1137 1900 5200 211.6 44 12 720 Stratos 50/16 7.5 1221 2400 6300 256.3 56 8 45 SPS.../12 7.2 1151 1400 4200 170.9 34 F (32) 6 690 8.52 14 165 Stratos 40/12 6.2 1200 1800 5600 227.9 49 18 300 Stratos 50/12 4.0 1234 2100 6200 252.3 56 24 530 Stratos 65/12 2.5 1271 2400 7200 293.0 67 8 62 SPS.../12 6.7 1628 2200 5400 219.7 49 F (42) 8 920 11.36 12 150 Stratos 40/12 7.4 1714 2800 6700 272.6 64 16 260 Stratos 40/12 4.5 1800 3400 8200 333.7 83 8 82 SPS.../12 6.9 2057 2500 7500 305.2 77 F (52) 10 1150 14.20 16 340 Stratos 40/12 3.7 2274 3800 104000 423.2 116 21 610 Stratos 50/16 4.9 2391 4500 11800 480.2 136 3.2.2 Hot water output at 80 C heating flow temperature Heating flow connected on the top of the calorifier (crosscurrent) Hot water output No. of modules Modulplus Content Heating surface Charging pump dm 3 /10 min. 2 dm 3 /h 3 Type dm 3 m 2 m 3 /h mbar 1 Type mwc 6 45 C 60 C 45 C kw 4 Flats 5 F (21) 2 230 2.84 3.5 25 SPS.../7,5 2.9 478 900 1880 76.5 10 8 120 SPS.../12 6.5 542 1300 2840 115.5 18 4 40 SPS.../8 5.7 652 1350 2800 113.9 18 F (31) 3 345 4.26 7 120 SPS.../12 7.7 706 1800 3650 148.5 25 12 450 Stratos 40/12 4.5 778 2400 4600 187.2 35 4 55 SPS.../8 5.5 907 1750 3350 136.3 24 F (41) 4 460 5.68 8 240 SPS.../12 5.3 1042 2700 5250 213.6 43 10.5 440 Stratos 40/12 5.5 1113 3200 6150 250.2 53 4 75 SPS.../8 5.3 1187 2200 4900 199.4 40 F (51) 5 575 7.10 8 300 SPS.../12 4.7 1356 3200 6600 268.6 59 12 720 Stratos 50/16 7.5 1477 3950 7900 321.5 74 8 45 SPS.../12 7.2 1305 2700 5600 227.9 49 F (32) 6 690 8.52 14 165 Stratos 40/12 6.2 1413 3600 7300 297.0 69 18 300 Stratos 50/12 4.0 1485 4200 8100 329.6 79 24 530 Stratos 65/12 2.5 1556 4800 9200 374.4 93 8 62 SPS.../12 6.7 1814 3500 6700 272.6 64 F (42) 8 920 11.36 12 150 Stratos 40/12 7.4 1970 4600 8700 354.0 89 16 260 Stratos 40/12 4.5 2113 5400 10500 427.3 114 8 82 SPS.../12 6.9 2374 4400 9800 398.8 107 F (52) 10 1150 14.20 16 340 Stratos 40/12 3.7 2713 6400 13200 537.2 157 21 610 Stratos 50/16 4.9 2877 7400 15600 634.8 195 12 4 200 690 / 07

TECHNICAL INFORMATION 3.2.3 Hot water output at 90 C heating flow temperature Use only if high performance is permanently expected (e.g. industry, commercial enterprise). Heating flow connected on the top of the calorifier (crosscurrent) Modulplus No. of modules Content Hot water output Heat surface Charging pump dm 3 /10 min. 2 dm 3 /h 3 Type dm 3 m 2 m 3 /h mbar 1 Type mwc 6 45 C 60 C 45 C kw 4 F (21) 2 230 2.84 3.5 25 SPS.../7,5 2.9 550 1360 2250 91.5 8 120 SPS.../12 6.5 650 1960 3480 141.6 4 40 SPS.../8 5.7 713 1850 3450 140.4 F (31) 3 345 4.26 7 120 SPS.../12 7.7 793 2550 4300 175.0 12 450 Stratos 40/12 4.5 893 3300 5800 236.0 4 55 SPS.../8 5.5 978 2250 4100 166.8 F (41) 4 460 5.68 8 240 SPS.../12 5.3 1157 3500 6400 260.4 10.5 440 Stratos 40/12 5.5 1250 4150 7500 305.2 4 75 SPS.../8 5.3 1329 3050 5650 229.9 F (51) 5 575 7.10 8 300 SPS.../12 4.7 1543 4350 7800 317.4 12 720 Stratos 50/16 7.5 1692 5250 9100 370.3 8 45 SPS.../12 7.2 1426 3700 6900 280.8 F (32) 6 690 8.52 14 165 Stratos 40/12 6.2 1585 5100 8600 350.0 18 300 Stratos 50/12 4.0 1671 5800 9800 398.8 24 530 Stratos 65/12 2.5 1785 6600 11600 472.0 8 62 SPS.../12 6.7 1956 4500 8200 333.7 F (42) 8 920 11.36 12 150 Stratos 40/12 7.4 2142 5800 10400 423.2 16 260 Stratos 40/12 4.5 2314 7000 12800 520.9 8 82 SPS.../12 6.9 2658 6100 11300 459.8 F (52) 10 1150 14.20 16 340 Stratos 40/12 3.7 3085 8700 15600 634.8 21 610 Stratos 50/16 4.9 3316 10 000 17500 712.2 1 mbar = flow resistance in the calorifier 1 Litres/10 min. = calorifier heated up to 60 C 3 Litres/h = continual output per hour, cold water temperature 10 C. 4 kw = power input at 45 C/ 10 C 5 Flats = number of flats with 1 bath each which can be supplied with hot water (1 bath, 3-4 rooms, 4 persons per flat) 6 mwc = residual overpressure 4 200 690 / 07 13

TECHNICAL INFORMATION 3.3 Dimensions Type F21, F (21), F41, F (41), F42 F (42) Type Typ F (21), F21, F F41 (41) Type Typ F (42) F42 1902 B 6 1 200 150 4 7 65 140 65 140 H 115 120 90 50 90 100 100 90 300 182 1905 5 395 3 2 790 Type F31, F (31), F51, F (51), F32, F F52 (32), F (52) Type F F31, (31), F51 F (51) Type Typ F (32), F32, F (52) F52 1902 B 6 4 150 170 7 65 140 65 140 1 H 120 90 115 50 100 100 90 90 300 182 1905 5 395 3 2 790 1 Hot Warmwasser water 2 2" 2 Cold Kaltwasser water 2 2" 3 Circulation Zirkulation 1 1" 4 Heating Vorlauf flow Heizung* * 5 Heating Rücklauf return Heizung* * 6 Control Elektrokasten panel 7 Electrical Elektro-Anschluss connection * Operating pressure 5 bar = standard flanges PN6 F 21-51 DN 50*Betriebsdruck 5 bar = Normflansche PN6 F 32-52 DN 65 F 21-51 DN50 F 32-52 DN65 * Operating pressure 8 & 10 bar = special flanges *Betriebsdruck D k 8 & 10 d bar = Spezial-Flansche F 21-51 DN 50 140 110 14 D k d F 32-52 DN 65 160 130 14 F 21-51 DN50 140 110 14 F 32-52 DN65 160 130 14 d k D Type B H Type B H F (21)/1615 530 Typ 1615 F (32)/1615 B H885 1615 F (31)/1615 530 1615 F (42)/1800 885 1800 F 21/1615 530 1615 F (41)/1800 530 1800 F (52)/2160 885 2160 F 31/1615 530 1615 F (51)/2160 530 2160 F 41/1800 530 1800 F 51/2160 530 2160 Variation because of the production tolerance possible Aufgrund von Fertigungstoleranzen Dimension +/- 10 mm Abweichungen möglich. Masse +/- 10mm Typ F 32/1615 F 42/1800 F 52/2160 B 885 885 885 H 1615 1800 2160 R 008 094-3 02 05.06.2014 SEEN Seite 1 / 2 14 4 200 690 / 07

TECHNICAL INFORMATION 3.4 Transport dimensions Type Width a Height b F (21) 395 1755 F (31) 395 1755 F (41) 395 1940 F (51) 395 2300 F (32) 790 1755 F (42) 790 1940 F (52) 790 2300 4 200 690 / 07 15

INSTALLATION 4. Installation 4.1 Heating-side connections Hydraulic examples Calorifier in a heat and power station 3 2 1 1 Loading pump controlled by the calorifier temperature control 2 Return flow prevention shutting tightly 3 Automatic ventilator 4 Sack to prevent an one-pipe-gravity-circulation. Height min. 3 x pipe diameter 5 Motor straight way valve. Valve moving time max. 2 min., with manual emergency function (e.g. spring return) 6 Motor three way valve, valve moving time max. 2 min., with manual emergency function 4 Connection to space heating district heating line max. 110 C, 8 bar (type high-rise building) (the appropriate factory guidelines have to be respected for long-distance heat supplies). 3 3 M 5 Calorifier in sub-station 4 M M 4 6 4.2 Drinking water-side connections Execution according to DIN 1988 part 2 and DIN 4753 part 1. Before establishing the hydraulic connection it is absolutely imperative to flush the supply pipelines out thoroughly. This will prevent the entry of metal chips and dirt into the water storage tank. Shut-off valves in the primary and secondary circuit permit maintenance to the storage tank and its components without the need to drain the complete system. These valves also permit the disconnection of the calorifier for pressure tests on the system, in the event of the test pressure being higher than the permissible operating pressure for the calorifier. Each closed drinking water calorifier is to be fitted with at least one approved (carrying a TÜV test mark) membrane safety valve. The nominal width of the safety valves is determined according to DIN 1988 part 2 sect. 4.3.4.1.1 Table 5. Rated volume Litre Heating capacity kw maximum Size of safety valve (size of inlet connector) minimum 200 75 R or Rp ½ >200 1000 150 R or Rp ¾ >1000 5000 250 R or Rp 1 >5000 >250 accord. to standards and regulations Schematic connection diagram of the sanitary connection 2 calorifiers connected in parallel 1 2 3 3 2 3 2 1 1 1 = cold water 2 = hot water 3 = circulation 16 4 200 690 / 07

INSTALLATION 4.2.1 Instructions concerning safety valve: it must be installed in the cold water line. there are to be no shut-off fittings between the safety valve and the storage tank. it is to be installed, easily accessible, close to the storage tank. The supply line is to be executed in at least the nominal width of the valve. It is to be installed sufficiently high to enable the following blow-off line to be installed with a downward gradient. Recommendation: Mount above the top surface of the storage tank, so that the storage tank does not have to be drained in the case of work / replacement. 4.3 Electrical connection Screws loosen Control 230 V 4.2.2 Instructions concerning the blow-off line: the end of the blow-off line must terminate 20-40 mm above a drain funnel and be placed where it is visible. The size of the line is to be at least identical to the outlet cross-section of the safety valve, a max. 2 m long and with no more than 2 bends. The drain line after the drain funnel must be at least double the cross-section of the blow-off line. A plate with the following notice must be placed in the vicinity of the safety valve blow-off line, where possible on the safety valve itself: The electrical circuit diagram is in the control. During heating, water can be discharged from the blow-off line for safety reasons! Do not seal off! 4.2.3 Installing a pressure reducer A pressure reducer is to be installed before the calorifier if the operating over-pressure exceeds 80 % of the safety valve response pressure. It is expedient to install the pressure reducer after the water meter system, so that approximately the same pressure conditions prevail in the building cold and hot water pipes. 4.2.4 Measures to prevent the back-flow of heated water A back-flow restrictor is to be installed in the cold water supply line, irrespective of the type of heating of the drinking water calorifier. In the case of closed drinking water calorifiers, shut-off devices are to be installed in the accessible vicinity before and after the back-flow restrictor for testing and replacement purposes. 4 200 690 / 07 17

COMMISSIONING / MAINTENANCE / WARRANTY 5. Commissioning Before filling the calorifier, the cold water supply line and the complete service water circuit are to be flushed. During filling, all the air present in the storage tank, the pipes and fittings is to be bled out. This will prevent disturbing pressure hammering effects in the hot water system. For this the storage tank is to be completely filled with water. At least one hot water outlet is to be open. Bleed the air from all hot water pipes and taps. After filling, the covers of the maintenance flange and all sanitary and heatingside connectors and connections are to be checked for leaks and sealed where necessary. During heating, water can be discharged from the blow-off line due to the expansion of the water. This is a perfectly normal phenomenon and must in no case be prevented. 7. Warranty and guarantee Claims under the manufacturer s guarantee can only be made if the following conditions are complied with: Guarantee conditions: Connection according to specifications by an authorised installation firm. Fitting of a fine filter in the cold water inlet. sanitary side: Water of drinking water quality standard; max. chloride content 30 mg Cl/litre, with the special model, max. 100 mg/litre resp.200 mg/litre with magnesium anode. heating side: The chloride content of the filling and replacement water for the heating system must be < 50 mg/l, otherwise it must be desalinated. 6. Maintenance and regular inspection Cleaning and decalcification of the module cells Regular cleaning and removal of sludge from the module cells is necessary for hygienic reasons. The cleaning intervals are dependent on water quality, operating temperature and hot water consumption. The cleaning work is only to be undertaken by the Hoval customer service agent or a specialist firm. Replacement flange seals are to be available and ready to hand before opening the cleaning flange. The old seals must be replaced. The sludge and lime deposits are washed off with a water jet and removed or extracted by vacuum through the cleaning flange. Lime encrustation on the tank walls must not be removed with metal objects. Chemical cleaning is only to be carried out by firms with the relevant equipment and experience. Refit the flange cover with new seals. Check for leaks. Observe the increase in pressure during the heating process and check the function of the safety valve. Safety device To avoid a possible over-pressure in the storage tank and the distribution circuit, the correct function of the safety device must be checked once a month. 18 4 200 690 / 07

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COPY FOR PLANT USER Confirmation The user (owner) of the system herewith confi rms that he has received adequate instruction in the operating and maintenance of the installation, received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components. and is consequently suffi ciently familiar with the installation. Installation address: Type: Serial number: Year of manufacture: Place, Date: System installer: System user: COPY OF SYSTEM INSTALLER Confirmation The user (owner) of the system herewith confi rms that he has received adequate instruction in the operating and maintenance of the installation, received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components. and is consequently suffi ciently familiar with the installation. Installation address: Type: Serial number: Year of manufacture: Place, Date: System installer: System user: