Max-3 Plus (420-2700) Technical Information & Assembly Instructions Manual PDF

Technical information
Assembly instructions
Oil/gas heating boilers

Max-3 plus (420-2700)
These instructions are applicable to the fol-

lowing types:
1-Max-3 plus (420)
1-Max-3 plus (530)
1-Max-3 plus (620)
1-Max-3 plus (750)
1-Max-3 plus (1000)
1-Max-3 plus (1250)
2-Max-3 plus (1500)
2-Max-3 plus (1800)
2-Max-3 plus (2200)
2-Max-3 plus (2700)
Hoval products must be installed and commissioned Max-3 plus boilers are suitable and approved as
- heat pro ducers for hot water heating systems with
tions are intended exclusively for the specialist. Electri- permissible feed temperatures up to 110 C1). They
are designed fo r closed systems according to EN 12828.
electrician. 1)
see point 3.2
4 214 283 / 00 - UK - 03/15 EN

TABLE OF CONTENTS
1. Important information
1.1 Other instructions ........................................................................................................................... . . . . ................................4
1.2 Safety information ........................................................................................................................... . . . . ................................4
1.3 Regulations, official approvals ........................................................................................................................... . . . . ............4
1.4 Guarantee ........................................................................................................................... . . . . ............................................. 5
2. Assembly
2.1 Installing, levelling, boiler plinth ....................................................................................................... . . . ............................... 5
2.1.1 Installation of the regulators Max-3 plus (420-2700)............................................................................ . .. ........................... .... 5
2.2 Mounting the thermal insulation Max-3 plus (420-750) ................................................................................................. . . . . 7
2.3 Mounting the cladding and boiler control Max-3 plus (420-750) ................................................................................... . . . . 9
2.4 Mounting the thermal insulation Max-3 plus (1000-1250) ............................................................................................ . . . .11
2.5 Mounting the cladding and boiler control Max-3 plus (1000,1250) ............................................................................. . . . .13
2.6 Mounting the thermal insulation Max-3 plus (1500-2700) . ............................................................................................ . . . .15
2.7 Mounting the cladding and boiler control Max-3 plus (1500-2700) .............................................................................. . . . .17
3. Technical information
3.1 Description of the boiler ........................................................................................................................... . . . . .................... 19
3.1.1 Max-3 plus (420-2700) complies with the following directives + standards ... .......................................................................19
3.2 Technical data Max-3 plus (420-2700) ................................................................................................................. . . . . ..........20
3.3 Dimensions Max-3 plus (420-1250) .................................................................................................................. . . . . ............22
3.4 Dimensions Max-3 plus (1500-2700) .................................................................................................................. . . . ............22
3.5 Dimensions without thermal insulation and casing Max-3 plus (420-2700) . ................................................................... 23
4. Installation
4.1 Boilerhouse Ventilation ........................................................................................................................... . . . . ...................... 24
4.1.2 Ventilation ................................................................................................................................................................... . . . . 24
4.1.3 Air Supply by Mechanical Ventilation - General Guidelines ........................................................................................ . . . . 24
4.2 Open Vented / Pressurised Systems ........................................................................................................................... . . . . .24
4.2.1 Open Vented Systems........................................................................................................................... . . . . ...................... 24
4.2.2 Pressurised Systems ........................................................................................................................... . . . . ....................... 24
4.2.3 Requirements for pressure limiter(s) in accordance with BSEN12828 ............................................................... ................... . . . . 24
4.3 Flues and Chimneys ........................................................................................................................... . . . . .......................... 24
4.3.1 General Guidelines ........................................................................................................................... . . . . .......................... 24
4.3.2 Fan Dilution Systems - General Guidelines ................................................................................................................. . . . . 25
4.4 Installing the burner Max-3 plus .................................................................................................................. . . .......... .................26
4.4.1 Combustion chamber resistance Max -3 plus (420-2700) ............................................................................................ . . . . 27
4.5 Fuel ...................................................................................................................... ..... . . . . ..................................................... 28
4.6 Electrical connection ........................................................................................................................... . . . . .......................... 28
4.6.1 Electrical connection of burner ........................................................................................................................... . . . . .........28
4.7 Flue gas and output diagram ........................................................................................................................... . . . . .............28
4.7.1 Flue gas and output diagram Max-3 plus (420-2700) .................................................................................................. . . . . 28
4.8 Minimum value limiting of boiler return temperature .................................................................................................. . . . . 29
4.9 Setting the temperature controller........................................................................................................................... . . . . .....29
4.10 Boiler safety valve ........................................................................................................................... . . . . .............................. 29
4.11 Filling pump ............................................................................................................. .............. . . . . ........................................ 29
4.12 Heating pump........................................................................................................................... . . . . ...................................... 29
4.13 Heating connections ........................................................................................................................... . . . . .......................... 29
4.14 Installing a flue gas thermometer (optional item) ........................................................................................................ . . . . 29
2 4 214 283 / 00
TABLE OF CONTENTS
4.15 Gas Boosters .............................................................................................................................. . ...................................... 29

4.15.1 Booster Installation .............................................................................................................................. . .......................... 29
5. Commissioning
5.1 Water quality .............................................................................................................................. . ....................................... 31
5.2 Filling the heating system .............................................................................................................................. . .................. 32
5.3 Filling the calorifier .............................................................................................................................. . ............................ 32
5.4 Commissioning .............................................................................................................................. . ................................... 32
5.4.1 Commissioning Report .............................................................................................................................. . ..................... 33
5.5 Hand-over to the user/safe-keeping .............................................................................................................................. . ..33
6. Maintenance
6.1 Information for combustion controller/chimney sweep regarding emission monitor key ............................................. 34
6.2 Operating Instructions .............................................................................................................................. . ....................... 35
6.2.1 Starting up after cleaning the boiler or a Summer shut down. ......................................................................................... . 35
6.3 Inspection & Servicing .............................................................................................................................. . ....................... 36
6.3.1 Periodic Inspection .............................................................................................................................. . .......................... 36
6.4 Boiler & Burner Servicing .............................................................................................................................. . .................. 37
6.4.1 Boiler Cleaning for Heating Surface .............................................................................................................................. . .37
6.4.2 Summer Shut Down .............................................................................................................................. . ......................... 38
6.4.3 Burner Maintenance .............................................................................................................................. . ......................... 38
6.5 Oil Burner Fault Finding Chart .............................................................................................................................. . ...........40
6.6 Gas Burner Fault Finding Chart .............................................................................................................................. . .........42
6.7 Cleaning .............................................................................................................................. . .............................................. 44
6.8 Adjusting the hinged flange .............................................................................................................................. . ...............45
6.9 Lubricating the seal and thread .............................................................................................................................. . .........45
6.9.1 Lubricating the seal .............................................................................................................................. . .......................... 45
6.9.2 Lubricating the thread .............................................................................................................................. . ...................... 45
7. Overview of settings
7.1 Table of parameters .............................................................................................................................. . ............................ 46
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IMPORTANT INFORMATION
1. Important information
water boilers of rated inputs of between 70 kW (net)
1.1 Other instructions and 1.8 MW (net) (2nd and 3rd family gases).
Depending on the application, any additional instructio-
IGE/UP/10 Installation of flued gas appliances in indus-
-
ns can be found in the Hoval installation handbook! In
trial and commercial premises.
some cases the instructions are enclosed with the sep-
-
arately packed components.
trial and commercial premises.
IGEM/UP/2 Installation pipework on industrial and com-
Further information sources
mercial premises.
- Hoval catalogue
- Standards, regulations
Regulations from the local building authority, insurance
companies and chimney sweeps must also be complied
1.2 Safety information with. When using gas as fuel, the regulations of the re-
The system may only be placed in operation if all the re-
levant standards and safety regulations have been com- permit may be required.
plied with. At least the following conditions must be satis-
1. Safety valve installed (closed system)

2. Control in operation (connected to the mains current
supply system)
3. Sensor for the safety temperature limiter mounted in
the immersion sleeve.
4.
5. Expansion vessel connected / pressurisation unit in-
terlocked with the burner.
6. -
7. An adequate supply of fresh air must be guaranteed.

8. Burner preset.
1.3 Regulations, official approvals

The following regulations are to be complied with installa-
tion and operation, in addition to current IEE Regulations,
other relevant British Standards and codes of practise,
Building Regulations and Local Authority by-laws:
BS EN 12831 Heating systems in buildings

Methods for calculating the design heat load
BS EN 12828 Heating systems in buildings
Planning of hot water heating systems.
Construction, design, safety requirements.
Construction, design, safety requirements, design and

execution (for gas burner operation).
BS 18160 Domestic chimneys, requirements, design
and construction.
VDI 2035 Prevention of damage through corrosion and
scale formation in hot water heating systems.
4 4 214 283 / 00
ASSEMBLY
1.4 Guarantee 2. Assembly

Proper function is only guaranteed providing these inst- 2.1 Installing, levelling, boiler plinth
ructions are followed and the boiler is regularly maintai- It is recommended to mount the Max-3 plus boiler onto a
ned by a licensed specialist (maintenance contract). The suitable plinth at least 150mm high to facilitate the fitting of
- the drain valve. For operating weights see chapter 3.
minated operating materials (gas, water, combustion air), In the case of boiler installation in the domestic domain,
unsuitable chemical additives and an inadmissibly high vibration dampers are to be mounted under the boiler
lime content of the heating water, improper handling, faul- plinth rails.
due to the use of force do not fall under our guarantee Space requirement
obligations; this also applies to corrosion due to haloge- for mounting the thermal insulation and sheet metal clad-
- ding:
logen compounds, solvents and cleaning agents.
is to be at least 40 cm to the left and right hand sides
of the boiler.
Hoval Engineers will normally commission the boiler and
if the heating engineer is present at the time, he will be
instructed on the day-to-day operation of the boiler. If this
completely thermally insulated and covered before being
is not possible, or additional training is required, this can
introduced to the planned installation location.
be arranged through Hoval.
The distance from the wall behind the boiler must
It must be possible to fully swing open the hinged

door to 90 of the boiler with the burner.
Levelling
Install with the top edge of the boiler water jacket (boiler
longitudinal axis) exactly horizontal or with a slight incli-
ne to the rear, by placing suitable underlays beneath the
plinth rail to ensure effective venting.
Mount the door liner (cladding) before installing the
burner. (for heating trials, with the boiler not yet
thermally insulated).
2.1.1 Installation of the regulators Max-3 plus (420-2700)

The regulators in the combustion chamber must be
installed into the 3rd pass tube bank as shown below.
3rd pass tube bank
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ASSEMBLY
Boiler door opens to the left

The boiler door hinges can be changed over to enable
the door to open to the left side. This can be useful where
space is limited.
The hinges are changed over as follows:

1. Tighten the top and bottom locknuts (1, Fig. 01) to-
2.
opening side, i.e.,
-
nuts and
-
nuts.
3. Unscrew locknut (3) and turn back approx. 1 cm.
4. Mount the burner plug connector on the other side.
Boiler door hinges must be changed over only by

The cable must not contact any hot parts. Hoval Service!
2 1 3
2
Figure shows situation as delivered

(boiler door opens to the right)
1
Fig. 01
6 4 214 283 / 00
2.2 Mounting the thermal insulation Max-3 plus (420-750)
1. Wrap the insulating mats (1/1a, Fig. 03) around the boiler body (joint at the side, black side outwards).
2. Secure insulating mats (1/1a) with plastic straps (2) and strap fasteners (2a):
-
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ASSEMBLY
- do not overtighten the straps (reduced insulating value)
3.
4. Place insulating mat (4, Fig. 03) on the pins welded to the rear wall of the boiler and secure with the retaining discs (Fig. 02).
5. Place insulating mats (5/5a/5b/5c, Fig. 03) on the pins mounted to the front wall of the boiler and secure with the retaining discs (Fig. 02).
6.
The remaining insulating mats (7a/17, Fig. 06) are put in place later on.
Before commencing to mount the cladding,

check the dimension between the top edge of the boiler plinth rail
and the retaining rail.
+3
+3
Fig. 02
Max-3 plus (420, 530) = 1072 0
Max-3 plus (620, 750) = 1191,5 0
7
8
3
1a 3a
ASSEMBLY
5b
2b
2 2a
5a 5c
Fig. 03
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2.3 Mounting the cladding and boiler control Max-3 plus (420-750)
7. Fix bolts (7, Fig. 06) with hexagon nuts and U-washers to the door and then mount insulating mat (7a) and door cladding (7b).
8. Attach shield plate (8) to the front of the boiler (Fig. 08).
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ASSEMBLY
9. Remove the control box cover (9, Fig. 06). Attach the control box (9a, Fig. 04) with the cut-out for special screws to the cladding cover (9b) and secure with 2
self-tapping screws and serrated lock washers (9c) 3,8 x 6,5mm.
10. Mount the rear right side wall (10, Fig. 06) at the bottom to the pins mounted to the boiler plinth rail.
11. Attach the bottom rear wall (11) to the special screws in the rear side walls.
12. Mount the rear left side wall (12) at the bottom to the pins mounted to the boiler plinth rail (Fig.07) and attach to the special screws of the rear wall (11).
13. Install burner connector plug (13) in the left or right front side wall (observe boiler door opening side, see point 4.6.1 on page 28). Attach C-clips (13a) to the
top of the side walls.
14.
15. Pull capillaries with immersion sensors (15, Fig. 05) as far as the stop in the immersion sleeve (15a, Fig. 06) and secure with retaining spring (15b, Fig. 05).
Attention: The capillaries must not be kinked!
16. Fix the control box cover (9, Fig. 06) with self-tapping screws 3,5 x 6,5mm and serrated lock washers.
17. Insert 2 insulating mats (17) left and right in longitudinal direction 9a
(to prevent vertical air circulation).
9c
18. Mount cladding covers (18/18a).
19. Attach the top rear wall (19) to the borrom rear wall (11) and attach the cladding covers
(18/18a) to the special screws on the top rear wall (19).
20. Fix the cladding covers (18/18a) with self-tapping screws and replace the cleaning cover.
21. Fix lead-through (21).
22.
15b 9b
15 Fig. 04
Fig. 05
9
10
18
18a
9
ASSEMBLY
9b
19
21
Fig. 08
8 14c
17 12
14a
7a
11
Fig. 07
7b 10
7
Fig. 06 8 13 14b 14 15a 13a
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2. Secure insulating mats (1/1a) with plastic straps (2) and strap fasteners (2a):
-
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ASSEMBLY
3.
(The cleaning cover is replaced after mounting the cladding back wall (17, Fig. 13)
5. Place insulating mats (5/5a/5b/5c, Fig. 10) on the pins mounted to the front wall of the boiler and secure with the retaining discs (Fig. 09).
6.
The remaining insulating mats (7a/7b/15, Fig. 13) are put in place later on.
Before commencing to mount the cladding, check the dimension

between the top edge of the boiler plinth rail and the retaining rail.
0
Fig. 09
Max-3 plus (1000,1250) = 1391,5 +3
11
12
3 3a 3b
1a
ASSEMBLY
5b
5
2 2a
2b
5a 5c
Fig. 10
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2.5 Mounting the cladding and boiler control Max-3 plus (1000,1250)
7. Fix bolts (7, Fig. 13) with hexagon nuts and U-washers to the door and then mount insulating mat (7a/7b) and door cladding (7c).
8. Attach shield plate (8, Fig. 15) to the front of the boiler.
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ASSEMBLY
9. Remove the control box cover (9, Fig. 13). Attach the control box (9a, Fig. 11) with the cut-out for special screws to the cladding cover (9b) and secure with 2
self-tapping screws and serrated lock washers (9c) 3.8 x 6.5mm.
10. Install burner connector plug (10, Fig. 13) in the left or right side wall (Observe boiler door opening side, see point, 4.6.1 on page 28). Attach 2 C-clips (10a)
to the top of each side wall. Mount the front side walls (10b/10c) at the bottom to the pins mounted to the boiler plinth rail and route burner cable (10d) upwards
to the control (cable routing according to Fig. 13). Mount cladding cover (9b, Fig. 11) and fix with self-tapping screws. Plug in the burner cable (10e, Fig. 13).
11. Pull capillaries with immersion sensors (11, Fig. 12) as far as the stop in the immersion sleeve (11a, Fig. 13) and secure with retaining spring (11b, Fig. 12).
13. Mount the rear side walls (13/13a) at the bottom to the pins mounted to the boiler plinth rail (Fig. 14).
14. Attach the bottom rear wall (14, Fig. 13) to the special screws in the rear side walls.
15. Place 4 insulating mats (15) left and right in longitudinal direction (to prevent vertical air circulation).
16. Position cladding cover (16).

9a
17. Attach the top rear wall (17) to the bottom rear wall (14) and attach the cladding cover (16)
to the special screws on the top rear wall (17). 9c
18. Mount the middle side walls (18/18a) at the bottom to the pins mounted to the
boiler plinth rail.
19. Position cladding cover (19/19a).
20. Fix all the cladding covers (16/19/19a) with self-tapping screws and replace
the cleaning cover.
21. Fix lead-through (21).
22. Affix rating plate and manual storage case to the side.
11b 9b
11 Fig. 11
Fig. 12
13
14
16
19a
ASSEMBLY
19
17
9
9b 21
Fig. 15 10e
8 15 13a
18a
10c
7a
14
Fig. 14
7c
13
18
Fig. 13 7b 8 10 10d 10b 11a 10a
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2. Secure insulating mats (1) with plastic straps (2) and strap fasteners (2a):
-
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ASSEMBLY
3.
the rear casing panel (14,15,16, Fig. 21).
5. Place insulating plates (5/5a/5b/5c, Fig. 17) on the pins moulded to the front wall of the boiler and secure with the retaining discs (Fig. 16).
6.
Fig. 16
15
16
3 3a 3b
1a
ASSEMBLY
5b
5
2 2a
2b
5a 5c
Fig. 17
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2.7 Mounting the cladding and boiler control Max-3 plus (1500-2700) 19 18 12f
7. Mount the right side walls (8,9,10, Fig. 21) to the top longitudinal strutting and the boiler plinth rail.
- Mount in order of position number
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ASSEMBLY
8. Mount the left side walls (11,12,13) (to the top longitudinal strutting an the boiler plinth rail).
9.
10. Route the burner cable (17) with the burner plug (17a) trough the prepared drill-holer in the side walls,
then attach the cable route with the collar (17b) to the side wall.
18f 18e 18c
11. Mount the supporting plate (18, Fig. 18) into the side panel.
12. Remove control box cover plate (19, Fig. 21). The control panel (18a, Fig. 19) must be turned. For Fig. 18
this purpose the pressure lock sleeves (18b, compress and pull away) as well as the earth screw and 0
serrated lock washer (18d) must be removed. Fix special screws (18f, Fig. 18) with locknut at sup- 18
porting plate (18). Position the control box (18e) with the cut-outs for special screws to the supporting
x 6,5mm and serrated lock washers (18c). Plug in bu-
rner connector (18g, Fig. 21) at electrical box.
13. Pull capillaries with the immersion sensors (19a, Fig. 20) through the opening (19, Fig. 18), push into
18a
18b
18c
18d
15. Mount cladding cover (20,21,22,23,24). 18e
16. Fix bolts (25) with nuts and u-washers to the boiler door, then mount door cladding (25a, 25b). 18c
Fig. 19
19c
19a
Fig. 20
17
18
24
23
22 15
21
ASSEMBLY
20 16
13
12
11
19b
25b 14
25 25a 10
Fig. 21
17b 17a 17 19 18g
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TECHNICAL INFORMATION
3. Technical information
3.1 Description of the boiler
The Max-3 plus boiler is a three pass design. The flue gases flow from the cylindrical combustion chamber into the
water cooled reversing elbows and through the second pass compartment into the front reversing chamber. The th-
ird pass compartment comprises a bank of special dimpled Rillenrohre tubes through which the flue gases are con-
ducted to the flue gas collector. Regulators are also fitted in the third pass tube bank.
Max-3 plus (420-1250) type
3.1.1 Max-3 plus (420-2700) complies with the following directives + standards
We hereby declare that the product described, as an individual appliance, complies with the standards, guidelines
Directives: 90/396/EG Gas appliance directive

73/23/EWG Low voltage directive
89/336/EWG Electromagnetic compatibility directive
97/23/EG Pressure equipment directive (PED)
Regulations: Stability prEN14394:2001

Constructional requirements EN303-1, EN303-2, EN303-3
Low voltage DIN VDE 0722 / Ed. 04.83
EMV EN 50082 Part 1 / Ed. 01.92
4 214 283 / 00 19
3.2 Technical data Max-3 plus (420-2700)
Type (420) (530) (620) (750) (1000)

Nominal output at 80/ 60 C kW 420 530 620 750 1000
Range of output at 80/ 60 C kW 147-420 185-530 217-620 263-750 350-1000
Burner input maximum kW 441 557 651 788 1050
Maximum operation temperature 1 C 90 90 90 90 90
Minimum operation temperature C see table operating conditions (below)
C see table operating conditions (below)
Safety temperature limiter setting (water side) 2 C 110 110 110 110 110
Working / test pressure bar 6/9,6 6/9,6 6/9,6 6/9,6 6/9,6
Boiler efficiency at full load and 80/ 60 C
% 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8
(net calorific value / gross calorific value) natural gas
Effciency at partial load 30%
(according to EN 303) natural gas % 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5
(net calorific value / gross calorific value)
Part L seasonal efficiency (gross calorific value)
% 87,2 87,2 87,2 87,2 87,2
for natural gas firing
Stand-by loss qB at 70 C Watt 1000 1035 1120 1180 1250
Flue gas resistance at nominal output
natural gas 10,8% CO2, 500 m above sea level mbar 6,5 8,0 8,2 9,5 10,0
(Tolerance 20 %)
kg/h 680 859 1004 1215 1619

natural gas 10,8 % CO2
Flow resistance boiler 3 z-value 0,022 0,022 0,008 0,008 0,003
10 K mbar 28,5 45,4 22,6 33,1 22,0
20 K mbar 7,1 11,4 5,6 8,3 5,5
10 K m/h 36,0 45,0 53,0 64,0 86,0
20 K m/h 18,0 22,5 26,5 32,0 43,0
Boiler water content litres 552 520 969 938 1528
Boiler gas volume m 0,583 0,602 0,846 0,872 1,350
Insulation thickness boiler body mm 80 80 80 80 80
Dry weight (incl. casing) 4 kg 1111 1171 1795 1831 2535
Dry weight (without casing) 4 kg 943 1000 1590 1620 2360
Combustion chamber dimension
mm 606/1624 606/1624 684/1899 684/1899 782/2182
-inside x length
Combustion chamber volume m 0,466 0,466 0,669 0,669 1,047
Dimensions see table of dimensions
Maximum chimney draft
Pa -50 -50 -50 -50 -50
(at boiler flue connection)
1
Limited by the boiler control to 90 C (U3.1) or to 105 C (U3.2)
2
Maximum safety temperature for boiler control U3.1: 110 C; for U3.2 : 120 C.
3 2
3
Flow resistance boiler in mbar = volume flow (m /h) x z
4 Excludes weight of burner.
Possible operating conditions:

Fuel Heating oil EL Natural Gas
min. boiler temperature C 65 75

min. return temperature C 55 65
Return temperature control required required

(not by Hoval)
20 4 214 283 / 00
Max-3 plus Type (1250) (1500) (1800) (2200) (2700)

Nominal output at 80/ 60 C kW 1250 1500 1800 2200 2700
Range of output kW 437-1250 525-1500 630-1800 770-2200 945-2700
Burner input maximum kW 1313 1575 1890 2310 2835
Maximum operation temperature 1 C 90 90 90 90 90
Minimum operation temperature C see table operating conditions (below)
Safety temperature limiter setting (water side) 2 C 110 110 110 110 110
Working / test pressure bar 6/9,6 6/9,6 6/9,6 6/9,6 6/9,6
Boiler effciency at full load and 80/ 60 C
% 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8
(net calorific value / gross calorific value) natural gas
Efficiency at partial load 30%
(according to EN 303) natural gas % 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5
(net calorific value / gross calorific value)
Part L seasonal efficiency (gross calorific value)
% 87,2 87,2 87,2 87,2 87,2
for natural gas firing
Stand-by loss qB at 70 C Watt 1380 1850 1950 2100 2300
Flue gas resistance at nominal output
natural gas 10,8 % CO 2 , 500 m over sea level mbar 12,0 10,0 12,0 13,0 13,0
(Tolerance 20 %)
kg/h 2025 2429 2916 3564 4374

natural gas 10,8 % CO 2
Flow resistance boiler 3 z-value 0,003 0,002 0,002 0,002 0,002
10 K mbar 34,4 33,0 47,6 71,1 107,1
20 K mbar 8,6 8,3 11,9 17,8 26,8
10 K m/h 107,0 129,0 154,0 189,0 231,0
20 K m/h 53,5 84,5 77,0 94,5 115,5
Boiler water content litres 1478 2343 2750 3050 3550
Boiler gas volume m 1,390 1,956 2,510 2,761 3,037
Insulation thickness boiler body mm 80 80 80 80 80
4
Dry weight (incl. casing) kg 2643 3614 4693 5077 5649
4
Dry weight (without casing) kg 2460 3266 4288 4647 5189
Combustion chamber dimension
mm 782/2182 880/2415 980/2595 980/2895 980/3200
-inside x length
Combustion chamber volume m 1,047 1,58 2,07 2,30 2,41
Dimensions see table of dimensions
Maximum chimney draft
Pa -50 -50 -50 -50 -50
(at boiler flue connection)
1
Limited by the boiler control to 90 C (U3.1 ) or to 105 C (U3.2)
2
Maximum safety temperature for boiler control U3.1: 110 C; for U3.2 : 120 C.
3
Flow resistance boiler in mbar = volume flow (m3/h) 2 x z
4 Excludes weight of burner.
Possible operating conditions:

Fuel Heating oil EL Natural Gas
min. boiler temperature C 65 75

min. return temperature C 55 65
Return temperature control required required

(not by Hoval)
4 214 283 / 00 21
3.3 Dimensions Max-3 plus (420 -1250)

(Dimensions in mm)
l
b m 10
1 8
8
k
n
7
3
o o 3
4
h h1 v 5
p
i w
2
c 2 t u
6 6 s
9 r
a g
f
q l1
10
8
3.4 Dimensions Max-3 plus (1500-2700)

(Dimensions in mm)
1 Flow (420-530) DN 100, PN 6 2 Return (420-530) DN 100, PN 6 3 Flue gas outlet

(620-750) DN 125, PN 6 (620-750) DN 125, PN 6 4 Cleaning opening
(1000-1250) DN 150, PN 6 (1000-1250) DN 150, PN 6 5 Flue gas collector-cleaning opening R1"
(1500-2200) DN 150, PN 16 (1500-2200) DN 150, PN 16 6 Drain R 1"
(2700) DN 200, PN 16 (2700) DN 200, PN 16 7 Cable routing
8 Control panel
9 Electrical connection
Sleeve Rp " with immersion pocket for
10
boiler temperature sensor
Max-3 plus
Type a b c f g h h1 i k l l1 m n o p q r
(420-530) 1060 1190 515 1770 181 1435 1230 950 104 2178 2074 641 100 299 54 34 175
(620-750) 1180 1310 550 2045 181 1555 1350 1050 105 2452 2347 666 95 349 55 35 170
(1000-1250) 1370 1500 635 2330 181 1755 1549 1250 107 2739 2632 681 111 349 77 37 175
(1500) 1560 1610 665 2745 205 - 1700 1350 90 3030 2940 710 90 447 70 55 60
(1800) 1720 1770 735 3115 205 - 1860 1480 70 3400 3330 720 90 447 70 50 65
(2200) 1720 1770 735 3415 205 - 1860 1480 70 3700 3630 720 90 447 70 50 65
(2700) 1750 1800 755 3745 205 - 1890 1410 70 4030 3960 720 90 647 70 50 65
Max-3 plus
Type s t u v w x Notes: A safety valve must be fitted in the
(420-530) 350 595 660 1330 450 - boiler flow pipework directly between the
(620-750) 550 722 786 1445 475 - boiler and the downstream isolating valve
(1000-1250) 415 620 685 1660 590 - (by the installer). If fitting a boiler altitude
(1500) 310 792 995 1790 665 1850
gauge, a 3/8 BSP socket should be fitted by
(1800) 310 845 1046 1950 775 2040 the installer in the flow pipework adjacent to
(2200) 310 845 1046 1950 775 2340 the boiler to enable connection of the
(2700) 330 743 946 1980 760 2670 altitude gauge pipework.
22 4 214 283 / 00
3.5 Dimensions without thermal insulation and casing Max-3 plus (420-2700)
(Dimensions in mm)
al
rn
te
in
1 Flow
2 Return
3 Flue gas outlet
4 Drain
Max-3 plus
Type a* b c d e f g h i k l m n o p
(420-530) 1920 150 1770 277 2222 1060 1180 196 120 1060 1376 2077 175 460 1072
(620-750) 2195 150 2045 228 2498 1180 1300 196 120 1180 1496 2353 172 485 1192
(1000-1250) 2480 150 2330 228 2783 1370 1500 160 120 1380 1660 2638 198 500 1392
(1500) 2909 164 2569 260 3053 1560 1680 170 120 1560 1850 2973 240 510
(1800) 3281 166 2759 430 3415 1720 1840 170 120 1720 2010 3355 430 510
(2200) 3581 166 3059 430 3715 1720 1840 170 120 1720 2010 3655 430 510
(2700) 3913 168 3390 430 4048 1720 1840 170 120 1720 2010 3988 430 510
Max-3 plus
Type q r s v w x y z
(420-530) 175 350 950 475 990 1330 150 1140
(620-750) 170 550 1050 535 1110 1445 145 1260
(1000-1250) 175 415 1250 630 1298 1660 150 1450
(1500) 60 310 1350 725 1498 1790 145

(1800) 65 310 1480 805 1656 1950 145
(2200) 65 310 1480 805 1656 1950 145
(2700) 65 310 1410 820 1656 1980 145
* Max-3 plus (1500-2700) boiler socket is protruding
4 214 283 / 00 23
INSTALLATION
4. Installation
4.1 Boilerhouse Ventilation
Boilerhouse ventilation should conform 4.2.2 Pressurised Systems
with the relevant British Standards, Codes For independently pressurised systems the vent connec-
of Practice etc. -
ve (sized to the relevant British Standard) and a pressure
4.1.2 Ventilation switch. No intervening valve is permissible between the
Sufficient air must be supplied to each boiler to ensure safety valve and boiler.
that the requirements of combustion and cooling are met The pressure switch should be interlocked with the boilers
and to afford a general level of ventilation in the plant ro- control circuit to safely close the burner down in the event
om. of pressure loss.
In ALL cases the necessary ventilation to the Hoval Max-3 The pressurisation unit control should also be interlo-
plus boiler must be in line with the requirements set out in cked with the boiler(s) controls to safely close the burner
BS 6644, IGE/UP 10 and any local requirements. down in the event of malfunction.
Cooling air around the boilers must be sufficient such that

the temperatures in the installation location do not exceed down for proving its operation periodically. It should be
those listed in BS 6644. interlocked with the burner control system.
4.1.3 Air Supply by Mechanical Ventilation - Gene- 4.2.3 Pressure limiter (in accordance with BSEN12828
ral Guidelines clause 4.6.2.2.2 - Heating Systems in Buildings).
The supply of air to a space housing the boiler by mecha- All Max-3 plus models should have an associated pres-
nical means should be mechanical inlet with natural or sure limiter device fitted in the system pipework, as close
mechanical extraction. Mechanical extract ventilation with as possible to the boiler itself (provided by the installer -
natural inlet must not be used. not supplied, fitted or wired by Hoval).
Any mechanical means of entering air into a basement If the operating pressure of the heating system exceeds
boilerhouse should have a balancing outlet so that the air the given pressure limit, or in the case of auxiliary power
pressure in the boilerhouse does not exceed 0.05" W.G. interruption, the pressure limiter shall shut off the heating
(12.5 Pa). equipment and interlock it against restarting. The pressure
Where mechanical inlet and mechanical extract system is limiter shall be adjusted so that it responds before the sa-
applied, the design extraction rate should not exceed one fety valve(s) operate.
third of the design inlet rate. 4.3 Flues and Chimneys
i ted with automatic controls interlocked
with the boiler controls to give a safe given in CIBSE and HVCA guides and also
shutdown or lockout in the event of a ma- Hoval Technical Data Sheets. Flues should
lfunction. conform to the relevant British Standards,
4.2 Open Vented / Pressurised Systems Codes of Practice etc.
4.2.1 Open Vented Systems 4.3.1 General Guidelines
A primary make up water and expansion tank is
required for open vented systems. With low head -
ver possible for multi-boiler plants so that combustion
Department should be consulted. conditions are not disturbed by the operation of other
The cold feed pipe should be connected into the boilers. Consideration should be given to the condition
return water piping on the boiler side of any valve.
An open vented connection is provided at the and condensation problems.
boiler rear. The vent pipe should be installed with
a continuous rise to a position over the primary
feed tank.
A safety valve should be installed in a tee piece as
near to the boiler as possible with no intervening
valve. It should be sized to the relevant British
Standard.
24 4 214 283 / 00
INSTALLATION
radius bends without horizontal runs before entering the

main chimney at a 45 are recommended and will cau-
se the least resistance. for further details.
Flues should not be less in diameter than the boiler out- 4.3.2 Fan Dilution Systems - General Guidelines
let connection size.
In circumstances where the provision of a conventional or
-
should provide a negative pressure condition at the boi- tion of the boiler plant, a fan dilution system may be used.
ler flue outlet of 50 pascals.
9.7 boiler rating (kW)
Dilution fan capacity (m3/s) =
should be positioned to cause the least disturbance to at normal 3600 0.8
the other gas stream (i.e. not opposite to each other). temperature and
pressure (N.T.P)
at the point of intersection with the header. To adjust for the normal diluted outlet temperature of
50
Header cross sectional areas should take account of
The dilution air intake should be independent of the boi-
- lerhouse combustion and ventilation air supply.
sation should be drained at the base of the vertical run.
Horizontal runs should drain away from the boiler. Velocities in the fan intake and exit ducts should not ex-
ceed 7.5 l/s to avoid ductwork resonance noise.
Steps should be taken in designing to prevent or minimi-
se condensation forming by using double skin and/or
insulated flue systems and suitable insulated brick sta-
ck or double skin steel chimney. This helps preven t
is generally required.
Where high gas outlet velocities are required from the Attention is also drawn to the need to include the fan and
chimney, a coned outlet can be used. The additional its proving switches as in the normal routine boiler main-
loss of draught due to this should be taken into account tenance programme.
in the chimney design.
Chimney sizes and height will need to take into ac-
Flues should be supported independently to prevent count the following:
undue weight and forces due to expansion being trans- 1. Clean Air Act.
mitted to the boiler outlet connection. 2. Local Regulations.
3. Environmental Protection Act 1990.
- 4. Considerations to adjacent buildings.
neys for cleaning and inspection purposes. Square tees 5. Transmission of noise, particularly low frequency
sound pressure levels in quiet periods of the day
the burner. very close.

6. Flue gases discharged to the atmosphere which co-
i IMPORTANT
A condensate drain point is provided in ntribute to health dangers should be minimised by
maintaining the burner and boiler to ensure correct
be piped to drain via a drain trap to pre-
time to a minimum and to maintain low levels of
CO2 (Greenhouse effect); CO and NOx ( d a n g e
r o u s g a s e s ) . C u r r e n t regulations for NOx
i IMPORTANT
A condensate trap must also be fitted on
limits (1993) are maximum 260 mg/kWh (148ppm
at 0% O2). Burners supplied with Hoval boilers fully
the boiler flue outlet to prevent condensa- meet this requirement.
te entering the boiler.
4 214 283 / 00 25
INSTALLATION
4.4 Installing the burner Max-3 plus

Type (420-530) Type (620-2700)
15
60
45
15
Type (420530) Type (620750)

4 x M12 (45) 6 x M12 (15)
4 x M12 (15)
Type (10002700)
6 x M16 (15)
Opening of the boiler door
F boiler door opens to the right or left
(Dimensions in mm)
G H
Dimensions Dimensions
Max-3 plus Max-3 plus

Type A B C D E F G + H M Type a b
(420-530) 290 330 515 250 606 1624 163 30 420 (420) 1060 150
(620-750) 350 400 550 310 684 1899 163 30 500 (530) 1060 150
(1000-1250) 400 450 635 330 782 2182 163 30 550 (620) 1180 150
(750) 1180 150
(1500) 380 450 655 385 880 2415 191 30 550 (1000) 1370 150
(1800) 380 450 735 395 976 2595 191 30 550 (1250) 1370 150
(2200) 380 450 735 395 976 2905 191 30 550 (1500) 1393 58
(2700) 420 480 735 410 976 3233 191 30 600x560 (1800) 1553 58
(2200) 1553 58
(Dimensions in mm) (2700) 1585 58
26 4 214 283 / 00
INSTALLATION
Please consult Hoval Technical Department for further in-

and screws. On installing, comply with the guidelines formation, if required.
and instructions for mounting the burner to the heat
producer. Sealing of the burner draught tube
A small annular space is necessary around the burner
Burner matching draught tube in the door refractory to allow the burner
to be withdrawn. Seal this gap with the ceramic strip
The boiler will normally be supplied by Hoval complete supplied.
with a burner which is CE marked and is CE approved With gas and dual-fuel burners, the burner housing
-
ternative burner, to comply with CE Directives, the boiler
must only be used with a burner having CE marking in Noise damping
accordance with Directive 90/396/EEC and Standard EN - Gas pipelines are to be installed so that no vibrations
676 (Gas) or EN 267 (Oil). The fuel suppy requirements can be transferred to the building.
will be stated on the burner data plate. - The burner can be covered with an acoustic hood.
- It is recommended to incorporate a noise damper
The burner CE approval must also be based on a test in
a test tank having dimensions no larger than the relevant
boiler combustion chamber dimensions.
4.4.1 Combustion chamber resistance Max-3 plus (420-2700)
13
1250 18000 2200 2700
12
11
1000 1500
10
750
530
9
Combustion chamber resistance (mbar)
620
8 420
0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Boiler output (kW) kW = Boiler output

mbar = Flue gas resistance =1.11 (Natural gas: CO2 = 10.8%)
500 m above sea level (Tolerance: +/- 20%)
4 214 283 / 00 27
INSTALLATION
4.5 Fuel Important!

A single phase 230V supply is required for
The boiler is only to be operated with the fuel stated the control panel operation. Single phase
on the boiler rating plate. burners are electrically supplied via the
control panel. Three phase burners requi-
Max-3 plus boilers are normally suitable for burning the re a separate three phase isolated supply
following fuels: (by the installer) direct to the burner, in-
- Heating oil EL according to DIN 51 6093 / SN 181
160/Z for boiler/burner door opening. In this
- Natural Gas and propane
plug/sockets will still run between the
control panel and the burner. All power s-
upplies to the boiler/burner/other associ-
ated equipment (ie: gas booster, separate
4.6 Electrical connection
oil pump, etc.) should be isolated via the
The electrical connection must be made by a licensed
same switched isolator.
located in the boiler control panel.
4.6.1 Electrical connection of burner

- The burner must be connected to the boiler with the
4.7 Flue gas and output diagram standard plug and socket connection.
- The burner cable must be installed so that the plug and
4.7.1 Flue gas and output diagram Max-3 plus socket connection has to be disconnected in order to
swing out the burner.
(420-2700)
130
Max-3 plus (1250 Max-3 plus (2700
Max-3 plus (530 Max-3 plus (1000 Max-3 plus (1500
125 Max-3 plus (750
120
115
110
Flue gas temperature (C)
105
100
95
90
85
80
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Boiler output (kW)
- Operation with heating oil EL, natural - A reduction of the boiler water tempera
11 with max. burner output ture of -10 K causes a reduction of the
cleaned, boiler flow temperature 80C, (CO2 flue gas temperature of approx. 6-8 K.
return temperature 60C (in accordance - A change in the air index +/- 0,09
causes a change in the flue gas tem-
perature of approx. -/+8 K
28 4 214 283 / 00
INSTALLATION
4.8 Minimum value limiting of boiler return

temperature
Hydraulic and technical control measures are to be imple- Flue gas
mented to ensure that the minimum boiler feed and return temperature sensor STB
temperatures are not fallen below.
4.9 Setting the temperature controller

Boiler temperature controller, selectable TR 65-85C
The basic setting is made by the heating installer. Selec-
tion and setting of the different heating programs accor-
ding to operating instructions.
4.10 Boiler safety valve

Heating installations and hot water supply systems are to
be protected against inadmissible overpressure by safety
valves. The blow-off pressure of the heating system safe-
ty valve must correspond to the maximum rated thermal
it's downstream isolating valve.

Fig. 22
The capillary must not be kinked.
4.11 Filling pump Important note:

(boiler with separate calorifier)
Speed and output regulation must correspond to the re-
made by the heating specialist. routed on the top, along the boiler insulating mat,
towards the back.
4.12 Heating pump 4.15 Gas Boosters

Speed and output regulation must correspond to the re-
A booster is required when the gas pressure at the burner
made by the heating specialist.
Important
4.13 Heating connections If a critical system is served it is good pra-
In the case of boiler installation in the domestic domain, ctise to install a duty/standby gas booster
- set.
xible compensators.
Gas Regulations require that no more than 0.5" WG pres-
sure is lost due to pipe work resistance between the sup-
4.14 Installing a flue gas thermometer (optional ply meter and the gas inlet.
item)
A 3/8 sleeve with a max. length of 25 mm is to be welded 4.15.1 Booster Installation
control panel; see Fig. 22. It is usually preferably to locate the boosters as near as
possible to the burner served rather than close to the me-
capillary through the rear wall between the external and ter.
round insulation. Leave adequate access for servicing drive belts, fan
Screw the sensor tube into the sleeve. bearing assemblies, electrical motors and any acoustic
shroud.
Ensure that the room in which the gas booster is to be
installed is well ventilated and free from dust.
4 214 283 / 00 29
INSTALLATION
Before running the booster the machine should be cle- For the same reasons, connecting pipework needs to
aned thoroughly, taking particular care to make sure be accurately aligned and properly supported. The use
that pulleys and the belt are free from abrasive dust
etc, which may have settled on the machine during in- booster and pipework is strongly recommended. These
stallation. -
work system and eliminate strain on the fan chamber.
If the booster is in the boilerhouse then the ventilation
and air inlet louvres for the boiler will also serve for the NOTE:
booster to keep the ambient temperature satisfactory, Flexible piping should be examined by
providing the full recommendations for free area and the operator on a monthly basis. Change
if there are any signs of deterioration or
cracking.
Standard boosters are designed to operate in ambient
temperatures not exceeding 40C. When the booster
Changes in pipework sizing are best made close to the
is housed separately to the boiler, ventilation must be
booster ports. The use of expanders and reducers are
provided to keep the ambient temperature below this.
recommended to minimise pressure losses.
Ventilation openings in this case must be sized relative
to any heat emitters in the room and the effects of solar
Where it is necessary to reduce or increase pipe sizes,
gain.
by changing cross section of pipework in easy stages.
The booster control enables the booster to work auto-
Connections for pressure testing or for pressure swit-
stop any excessive increase in operating temperature
ches should be located at points in the system where
and we recommend that the booster should only ope-
there is not excessive turbulence i.e. where there is a
rate in conjunction with the burner. Prolonged periods
straight run of pipework at both sides of the switch (i.e.
-
at least 10 diameters of straight pipe).
ase in temperature, shortening the life of the booster
and increasing service frequency. If however the plant
is required to work under such conditions, considerati- NOTE:
on should be given to the use of a purpose-designed If a gas booster is located in a meter/
bypass to dissipate the excess heat and the installation governor room then the associated
of a twin duty stand-by system to allow for regular ins- electrical equipment, i.e:- control panel,
motor, pressure switches should be sui-
operated regularly or in rotation. If the booster is ope- table for use in a Zone 2 area with group II
rating in rotation auto cycling may have been installed A gases (refer to BS4683, part 3).
as an option.
i Do not test the fan chamber assembly by

hydraulic pressure: this practice will ine-
vitably damage the fan bearing assembly.
i All booster assemblies are tested for gas

tightness by means of air at a pressure of
0.69 bar during manufacture.
-
proximately 450mm high to raise the unit to a conveni-
ent level.
Noise attenuation and absence resonance are best

obtained by supporting the booster on anti-vibration
mounts.
30 4 214 283 / 00
COMMISSIONING
5. Commissioning
water are made of ferrous materials and stainless steel.
5.1 Water quality
On account of the danger of stress cracking corrosion
Heating Water in the stainless steel section of the boiler the chloride,
nitrate and sulphate content of the heating water must
The European Standard EN 14868 and the
not exceed 50 mg/l.
directive VDI 2035 must be observed.
The pH value of the heating water should lie between
In particular, attention must be paid to the following stipu- 8.3 and 9.5 after 6-12 weeks of heating operation.
lations:
Filling and replacement water

cording to EN 14868). For a plant using Hoval boilers untreated drinking water
Plants with ing and replacement water. However, as not all drinking
- continuous oxygen intake (e.g. underfloor heating
systems without diffusion proof plastic piping) or
- intermittent oxygen intake (e.g. where frequent refill- VDI 2035. Should the mains water available not be
ing is necessary) suited for use then it must be desalinated and/ or be
must be equipped with separate circuits. treated with inhibitors. The stipulations of EN 14868
must be observed.
least 1x yearly. According to the inhibitor manufacturers

instructions, more frequent testing may be necessary. to avoid overheating of the heating surfaces the values
given in the table should not be exceeded (dependent
on boiler performance ratings - for multi-boiler plants
water in existing installations (e.g. exchange of boiler) rating of smallest boiler applies - and on the water con-
conforms to VDI 2035. tent of the plant).
The Directive VDI 2035 applies equally to the replace-
ment water.
is used throughout the total service life of the boiler
New and if applicable existing installations need to be must not exceed three times the water capacity of the
plant.
NOTE:
No continous make-up of water should be
taking place during boiler operation. In
this event check where a leak may be oc-
curing or if pumping over is taking place.
Maximum filling capacity based on VDI 2035
[mol/m3] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0

fH <1 5 10 15 20 25 30 >30
dH <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8
eH <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3
~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300
Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600
Boiler size of the
individual boiler
50 to 200 kW NO REQUI- 50 l/kW 20 l/kW 20 l/kW
200 to 600 kW RE- 50 l/kW 50 l/kW 20 l/kW always desalinate
over 600 kW MENT
1
Sum of alkaline earths
2
If the conductance in S/cm exceeds the tabular value an analysis of the water is necessary.
4 214 283 / 00 31
COMMISSIONING
5.2 Filling the heating system
Filling and topping up water must satisfy the quality requi-

rements according to VDI 2035.
5.3 Filling the calorifier the burner has not been damaged in transit or during
installation and that it is a suitable type for the fuel
(where installed) available on site. The nameplate on the burner indica-
The boiler should not be operated without the calorifier tes for which type of fuel it is designed.
excessive space in the refractory opening around the

burner has been sealed with the supplied ceramic ma-
5.4 Commissioning terial.
It is essential that the following points are comple- all items, packed in transit, are removed from combus-
ted by the Heating Engineer before commissioning tion chamber.
is requested through Hoval.
boiler control thermostats are adjusted to suit system
System full of water and vented

the limit and high/low stats are set in accordance with
Heating load available e.g. pumps working control details. See section 4.5.
Fuel purged to burner isolation valve
Oil bled to boiler isolation cock the boiler relief valve setting is suitable for the system
Electrical connections made and correctly fused (The setting should be at least 0.5 bar above the pres-
Correct boilerhouse ventilation sure).
Other manufacturers equipment has been ins-
talled and commissioned as necessary, e.g. press-
- oil supply pressure and temperature is suitable.
urisation units.

If the above are not completed and commissioning
is unable to commence, clients will be charged for commissioning is in accordance with burner makers re-
the aborted visit. quirements.
Hoval Service Engineers normally commission all controls are proved and stats are adjusted in line with
new boilers and they will check the following: temperature indicated on the boiler thermometer.

including circulation pumps. refractory to reach a uniform temperature through its
thickness thereby preventing any damage.
burner is adjusted to give optimum combustion, to-

an independently pressurised system is operating cor-
rectly. Suppliers of the equipment should adjust their
equipment during commissioning. the Heating Engineer will have the opportunity to recei-
ve instruction on the correct operation of the plant du-
ring commissioning and to aquaint himself with the fault
pages 40-43. He will also be advised
open if manually operated and if electrically operated on how much of the action columns can be dealt with
that the burner is interlocked electrically to prevent ope- by site staff.
ration until the damper is open.
the electrical installation with the appropriate wiring

diagram for the boiler and burner and for correct fan
rotation.
32 4 214 283 / 00
COMMISSIONING
5.4.1 Commissioning Report

All settings both on boiler and burner will be recorded on
a commissioning report which will be supplied to the cus-
tomers representative.
Fig. 23
5.5 Hand-over to the user/safe-keeping

Obtain from the user a written statement that operating
and maintenance instructions have been explained to
him and he has received the relevant operating instruc-
tions (see page 60 for a standard statement). The system
designer is responsible for providing operating instruc-
tions for the complete system. This technical information/
installation instructions are not to be destroyed after com-
missioning but kept permanently with the system.
4 214 283 / 00 33
OVERVIEW OF SETTINGS
6. Maintenance
6.1 Information for combustion controller/chimney sweep regarding emission monitor key
All other control elements of the control unit are described in the operating instructions.
The emission monitor key can also be used to change over to manual operating mode.
Emission monitor key / Manual operation

against invalid overheating during emis-
sion monitoring / manual operation it is
necessary to implement appropriate safety
measures (e.g. safety temperature limiter
with pump switch-off). The duration of the
emission monitoring is limited to 20 min-
utes and shall be restarted, if necessary.
Scalding hazard due to hot water tempera-

ture, since the hot water temperature can
exceed the temperature setpoint!
Emissions metering
Immediate end
PRESS Remaining time display

SHORTLY
REACTIONS for emissions metering

Time unit automatically 20 min. thereafter reverts
Boiler temperature - > maximum temperature restriction
Regulate to the maximum temperature the heating circuits and the water heaters (at the direct heating circle only,
if the warm water mode of operation is adjusted to parallel operation)
With 2-step heat generator both stages are in operation
Manual operation
Immediate end
PRESS
> 5 seconds
REACTIONS for manual operation

Set reference boiler temperature with button!
All heating pumps ON
Mixer without current - manual setting necessary!
The hot water temperature reaches the set DHW maximum temperature (expert level standard 65C).
34 4 214 283 / 00
6.2 Operating Instructions Sequencing of boilers under BMS control.

When a bank of boilers are sequenced to operate un-
PLEASE READ: Important Notes for the der the dictates of a BMS control system, it is very im-
Boiler Attendant portant that on-line boilers are properly matched to
the available heating load at any one time.
This will avoid too frequent cycling of the burners as
These instructions are the minimum necessary to enable they stop and start (introducing cold pre and post
an operator to start, run and stop the boiler. purge air into the boiler each time this happens).
They cover also the simple routine servicing procedures Over time this can result in the boilers suffering from
- thermal shock and premature failure of the pressure
plicable irrespective of the fuel used - gas or oil - BS class parts.
D (35 sec).
6.2.1 Starting up after cleaning the boiler or a Sum-
If the heating system designer or installer has prepared mer shut down.
the whole plant, those instructions should be referred to Ensure that fuel lines are fully purged and that fuel is
available at the burner at the correct pressure and tem-
perature.
Instruments and Controls
Instruments are generally mounted at the top front of the some time, or if a fuel supply pipe has been disconnec-
ted, purge the piping via the bleed nipple up stream of the
present, an altitude gauge may also be provided. burner to ensure that a gas/air mixture is avoided.
The basic controls for any boiler will be:
NOTE:
a. A sequence-control box (mounted on the burner) A gas/air mixture is dangerous as it will
explode if subjected to a spark.
pre-purge, ignition, pilot or reduced start, and provi-
other unsafe condition. a singlepipe supply system, ensure that air is bled from
This control box will have advisible indication of lock the system if the oil pipe has been disconnected.
out and a manual-reset button for use in the event of
Ensure fuel supply valves are open. Where a pump is in-
corporated in an oil fuel supply system, ensure the pump
b. A control thermostat which allows adjustment of the is switched ON. Check all switches, e.g. time switch, and
thermostats are in the calling for heat condition. Switch
panel facia to discourage unauthorised adjustment ON electrical supply to the burner at the main switch.
after it has been set by the commissioning engineer. Switch the control panel mounted switch to ON. The bur-
ner control box should now monitor the burner through its
c. A safety-limit thermostat which comes into operation
should the control thermostat fail to shut the burner
down.The limit stat is usually set at 10C above the Normal Running
control thermostats maximum setting. No automatic
control may be interfered with by the boiler attendant The boiler will switch on/off under the dictates of the con-
- trol thermostat. The boiler temperature at any particular
gineer. moment can be seen from the boiler thermometer.
There may be special burner controls equipment or Allow the boiler to reach its set temperature and then
additional controls to be integrated with the standard check the burner flame through boiler door sight glass;
burner control equipment. The function and setting -
of these will be covered by the suppliers e.g. BMS.,
sequence controls high and low pressure switches through the burner inspection window. If any deterioration
and water level controls, associated with indepen- is noted, the heating engineer should ensure the neces-
dendently pressurised systems. sary action is taken.
4 214 283 / 00 35
6.3 Inspection & Servicing

which may be drawn into the burner and cause dama-
ge.
-
red to carry out work other than the following: boiler
Examine all fuel and water valves, connection and bur-
cleaning, inspection of components for damage, star-
ner etc, for obvious signs of damage or leakage, and
for security.
In an open-vented heating system, check:

- Level of water in the feed and expansion tank.
- That the ball valve is free to operate correctly.
- All air vents are operating correctly.
NOTE:
No continuous make-up of water should
be taking place. (In this event check whe-
re a leak may be occurring or if pumping
over is taking place).
No special equipment is required for normal boiler On the boiler door, examine the ceramic-strip seal, and
servicing.
detected by heat marks or deterioration of the metal
Tools for cleaning the boiler heating surfaces are ring holding the joint. In the event of such signs, replace
provided with the boiler. If a hard scale forms from oil
- the burner tube and the door lining for deterioration.
um (e.g. Carbonex by Arrow Chemicals Ltd) is advan- Replace when required.
tageous for softening and easier removal of such
deposits. Initially examine boiler interior after one month when
using class D oil to determine necessity for boiler clea-
The service engineers equipment will include any ne- ning. When heavy oil is being used, examine after two
weeks. The amount of use, the number of cold starts
test kit. involved, and the mean operating temperatures all af-
fect the rate of soot and scale formation.
6.3.1 Periodic Inspection
A consistent pattern will then be established to determi-
The following periodic inspections should be made bet- ne the frequency of cleaning required. With gas much
ween main servicing periods. longer periods between cleaning are usually possible.
If condensation occurs due to low return water tempe-
Examine boiler casing panels for obvious signs of da- ratures then a build up can occur more quickly. Es-
mage, corrosion or other deterioration, and for security. tablish a pattern to see if cleaning can coincide with
service visits.
leads to wasted heat and an increase in the boilerhouse
ambient temperature).
should initially be more frequent until a reason- able,
consistent pattern can be established.
Similarly inspect the cleaning explosion door at rear of On oil/gas burners periodically remove photo electric
boiler. ultraviolet cell and clean the window of the cell.

partial blockage, debris, etc. at the initial commissioning. Report any unusual altera-
tions in this respect.
Ensure that condensation drains at the chimney base
Report any occurrences which indicate that the boiler, the
connected to a drain pipe with a water trap.
correctly.
36 4 214 283 / 00
6.4 Boiler & Burner Servicing 4. Where rigid fuel pipes to burner are employed, e.g.
gas burners, disconnect pipe(s) to allow the boiler
In addition to the periodic inspections given on page 36 it door to open.
is recommended that a complete check is carried
out on all components at appropriate intervals. 5. Fully open the boiler door complete with burner.
NOTE:
service engineer, ideally under an annual sevice and Lengthy periods between cleaning should
maintenance contract. only be resorted to when the periodic inspec-
tions prove this is possible.
Hoval Service Department normally provides this service
and will be pleased to provide a written quotation on re-
6. Clean the tubes using the supplied brush. Similarly
quest. This would typically cover the operation, cleanli-
clean the combustion chamber when required. Avoid
damage to the ceramic sealing strip against which
associated controls. In the case of gas burners it would
the door closes.
include a check on the gas tightness of the gas control
valves at the burner if a gas leak detection unit is not
could also be covered in this service. NOTE:

Where any hard scaling is present, use a
propietary cleaning medium to soften and
Please note:
assist removal.
No adjustment of internal components is
permissible on either gas or oil burners
7. Remove rear cleaning/explosion door. Clear loose
-
soot from the smoke outlet box and thoroughly clean
neer.
the box. Clean and examine the boiler backplate; no
hard deposit should be present. Remove any build
up occuring between the projecting tube ends.
make a monthly leak test on these pipes.
8.
6.4.1 Boiler Cleaning for Heating Surface
9. Check conditions of cleaning/explosion door gasket.
Frequency of cleaning will be dependent on usage in con-
junction with the condition of the boiler at the periodic tighten the wing nuts only two full turns against spring
inspections, but the minimum requirements when using compression.
the various fuels are:
10. Check condition of boiler door ceramic seal. Ins-
Gas (natural or LPG) - once per heating seaon -
Oil BS Class D (35 sec) - twice per heating season al around burner tube. Minor damage to insulating
Oil heavy grades - 3 to 4 times per heating season -
le refractory (e.g. Pyruma) on refractory lined doors.
1. Run the boiler until the burner automatically switches
off under action of the control thermostat. (It is easier suffer damage in normal use but in the unlikely event
to clean a warm boiler). please consult Hoval. Any serious damage must be
reported to the Service Engineer for repair. Filler
2. Switch OFF electrical supply to the burner. Where a material can be repaired similarly. The door sealing
strip must be in good condition and must be replaced
to the burner, disconnect at this point. Switch OFF when an effective seal cannot be obtained under nor-
electrical supply to the booster. mal pressure. Replace sealing strip annually. Refer
to Burner Maintenance Instructions Page 38 whilst
NOTE: the door is open.
Where heavy oil is being used on a cir-
culatory fuel system, ensure that fuel 11. Close the boiler door, and evenly tighten the nuts
pump(s) heaters and tracers are left in using a tommy bar/spanner.
operation at all times.
12. If disconnected, plug in the boiler/burner electrical
3. Turn OFF all fuel shut-off valves at the burner. connection.
4 214 283 / 00 37
13. Check boiler door is effectively closed (ineffective Starting and Stopping
closure will be detectable by sight or smell).
Emergency Stop
14. It is recommended that, when the boiler has beco- The burner can be stopped in an emergency by
switching off the mains isolating switch provided on the
made by the Service Engineer. line between the burner and the electric supply. The in-
staller must identify the switch. Check position of this
15. If the boiler is not immediately to be used, switch OFF switch or any panic button available.
electrical supply to burner and turn OFF fuel supply.
Where using heavy oil do not switch off fuel heaters Check the Burner Operation
and tracers. Switch off electrical supply to gas boos- -
ter.
call the service engineer.
6.4.2 Summer Shut Down When cleaning the room housing the heater unit, al-
ways switch off the burner to reduce the amount of dust
If the boiler is to be out of operation for a long period, and lint drawn in through the air inlet.
e.g. during the Summer, the boiler interior should be
thoroughly cleaned. Preventive Maintenance
Consult your heating engineer for advice on regular
Atmospheric condensation, activating acidic deposits in prevetive maintenance intervals.
the boiler, is responsible for considerable corrosion and
metal wastage. Every effort should be made to reduce 16. Gas Supply
this by the most thorough cleaning and by keeping the Should the gas supply be interrupted, the system may
boiler dry. require venting of air that may have accumulated,
before the burner is restarted. This is achieved by un-
A tray of absorbing material placed in the combustion screwing the pressure test point situated down-stream
chamber is helpful in this respect. Close the boiler door. of the main govenor or combination valve and venting
the air to atmosphere until gas has reached the test
point.
6.4.3 Burner Maintenance
WARNING:
Before carrying out any work on the burner ensure No smoking or naked lights to be allowed
that the main electrical isolating switch is locked in as a gas/air mixture is dangerous.
the OFF position and the fuel isolating valve closed.
Periodical examination of all pipework should be carri-
ed out. The recommended method is to brush a soap
operator and are intended to be of assistance in making solution around all the jointed areas. A leak in the sys-
tem would have the effect of forming bubbles.
maintenance, cleaning and lubrication. Additional infor-
mation can be obtained through your installer or from the CAUTION:
manufacturer. Do not place any items in the boiler com-
bustion chamber as it is not suitable for
Fuel burning waste.
The unit is designed to burn the fuel stated on the bur-
ner nameplate. Under no circumstances must any Oil pump
other type of oil or gas be used. See burner manufacturers manual.
In the case of burner fuel conversion, check to see that Gas train items and gas leak detectors
the fuel used corresponds with that marked on the new For maintenance of these units refer to the manufac-
burner nameplate. turers manual.
38 4 214 283 / 00
Motor
Keep the burner motor clean and dry. Any deposits
of dust or lint should be blown out occasionally. On
motors provided with oiling holes, a few drops of high
quality SAE 20 oil should be injected every six months.
Surplus lubricant spreading from the bearings should
be wiped away. Some motors have sealed-for-life bea-
rings; these require no maintenance.
Fan Runner
Keep the fan blades clean and free from oil and build up
of dust or deposits picked up from a dusty boilerhouse.
Oil Strainer/Filter
Replace filter element annually.
Nozzles, Flame Plate and Electrodes

Maintenance by the boiler operator is usually limited to
checking the condition of these items only whilst the
boiler door is open. Servicing the oil or gas nozzle,
which may require dismantling, and replacement of
parts should be left to the service engineer.
The boiler operator may wipe off deposits of soot and
disturb the parts. Check the electrodes are set correct-

ly after referring to the burner manufacturers manual.
Flame Sensor
-
violet cell for gas or photo-electric cell for oil with me-
thylated spirit on a lint free cloth. Do not handle window
NOTE:
-
ing to remove the burner inner assembly.
4 214 283 / 00 39
6.5 Oil Burner Fault Finding Chart
NOTE:
.
Symptom Possible Cause Action

A. Burner will not start 1. Electrical supply failure 1. Check the following:
a. Main isolating switch of the bur-
ner is on.
b. Overload protective device of
the burner motor.
2. Control thermostat time or water 2. Check that power is available at the
pressure switches or other boiler control panel and all switches are
systems controls at fault closed.
3. Manual reset on limit thermostat 3. Reset and check also control stat
setting and operation.
4. When using heavy oil tempertures 4. Check temperatures: ensure prehe-
incorrect in oil piping or in burner ating equipment is operating.
preheater
B. Burner starts i.e. burner 1. No ignition spark. 1. Switch off burner. Check spark plug
motor runs but will not gap. Check H.T. leads and connec-
light and burner goes to tions. Check and clean ignition
lockout. electrode(s) and insulator
2. No oil spray into combustion cham- 2. Open door and check whether oil
ber but pressure indicated on bur- has been sprayed into combustion
chamber; if no evidence of spray,
clean or replace burner nozzle(s).
3. No oil spray into combustion cham- 3. Check as above. If no spray, check
ber and no pressure indicated on the following:
the oil gauge. c. There is oil in the fuel tank.
d. All necessary valves are open.
e.
f. There is no airlock in the fuel
pump (listen for any unusual
sound from pump).
g. For air leakage into the fuel
feed pump.
h.
closed in oil line.
C. Burner lights but rapidly 1. Dirty photocell (causing lockout 1.

extinguishes. action).
2. Faulty photocell (causing lock-out 2. Replace cell with new.
action).
40 4 214 283 / 00

D. - 1. Air inlet damper accidently masked 1. Clear obstruction.
mes from burner. Flame
shape alters from nor-
mal. Boiler door beco-
mes hotter than usual.
2. Alteration to air inlet damper po- 2. Reset damper and make a com-
sition. bustion check (special instruments
required).
3. - 3. Replace nozzle(s).
ted.
4. Incorrect nozzle(s). 4. Replace with correct nozzle(s).
5. Excessive oil pressure. 5. Reset pump pressure regulator.
6. - 6.
cked or re stricted. Flue dam- and check why it became closed.
per closed. Clear blockage or restriction.
7. 7. Call Service Engineer to correct
misplaced or faulty. and replace if necessary.
8. Door refractory failure. 8. Check for damage, replace if dama-

ge severe.
4 214 283 / 00 41
6.6 Gas Burner Fault Finding Chart
NOTE:
.

A. Burner will not start 1. E lectrical supply failure 1. Check:
a. Main isolator switch is on and
power is available at the control
panel.
b. Overload protective devices of
2. Air pressure switch on burner not 2. Switch contacts must be in the bur-
operating. ner start position. Check switch is
3. Control thermostat, time, water 3. Check:

pressure switches or other boiler That all switches are closed
system controls at fault. Booster is not locked out due to low
inlet gas pressure and that pressure
switches function correctly.
4. Reset and check. Also check con-
trol thermostat setting and operati-
on.
B. Burner starts i.e. burner 1. No ignition spark. 1. See action B1.
motor runs but will not
light and burner goes to
lockout.
2. Gas starvation. 2. Purge gas pipe, check pilot valve
operation.
3. Ultra-violet cell fault. 3. Remove, clean and check connec-
tions and replace if necessary.
C. Burner motor starts but 1. Air pressure switch on the burner. 1. Check:
stops and re-cycles. c. burner damper is open to usual
extent.
d. air inlet to switch is not blocked.
e. switch is not stuck.
f. electrical connection.
D. Burner shuts down du- 1. As C1 above. 1. As C1 above.
ring operation and recy-
cles.
E. Burner shuts down du- 1. Flame failure. 1. Check gas supply and pressure.
ring operation and goes
to lockout.
2. Ultra-violet cell fault. 2. As B3 above.
42 4 214 283 / 00

F. Burner lights on pilot but 1. Ultra-violet cell faulty 1. As B3
burner locks out after 3 - 2. Ultra-violet cell is not receiving a 2. Clean cell and check correctly in-
4 seconds.
G. Smell of gas local to the 1. Leakage from pipe line joints or pi- 1. Switch OFF burner and check pipe
appliance. lot or that the main gas valves are line joints with soap solution.
not gas tight.
2. Close pilot manual valve and then
main manual valve at the burner to
see if this isolates the problem.
Call gas engineer to check the au-
tomatic valves. Do not operate until
this has been done.
H. Combustion noise beco- 1. Air inlet accidentally masked. 1. Clear obstruction.
- 2. Air inlet damper position moved. 2. Call Service Engineer to reset and
mes yellow. Boiler door make a combustion check.
becomes hotter than
3. Burner head parts have moved, 3. Call Service Engineer to adjust
usual.
become worn or overheated. or replace and make combustion
check.
4. Gas pressure alteration. 4.
5. - 5. Check and clear restriction.
cked or restricted.
6. Door refractory failed. 6. Replace if damage is severe.
4 214 283 / 00 43
6.7 Cleaning
Inadequate cleaning not only results in increased fuel
consumption but also shortens the life of the boiler.
The boiler is to be cleaned by a specialist twice a year
Switch off the main switch
Remove burner plug and switch off the fuel supply 1

Unscrew the hexagon sealing nut with hole (1, Fig. 24)
using the steel mandrel supplied.
Attention: The sealing nuts without a hole must on no
account be unscrewed
Open the boiler door and swing out burner.
Remove the retarders from the third pass tube bank

(4, Fig. 26) and clean them. Fig. 24
Thoroughly clean combustion chamber (2), second a

compartment (3) and third compartment (4) using
brush or spray.
Take off the cleaning cover (5, Fig. 25) at the back, on
- 5
ector.
Brush off the boiler back wall and the space between 6
the ends of the pipes.
-
ector at the connector (6).
Refit the third pass tube bank retarders.
Reclose and seal the cleaning apertures.
Close the boiler door and tighten the screws. Fig. 25
Plug the burner back in and switch on the boiler.
2
Fig. 26
44 4 214 283 / 00
6.8 Adjusting the hinged flange

After a long period of use, the contact pressure between
boiler doors and boiler body can diminish. This impairs
The boiler is therefore to be periodically checked for leaks
Procedure:
With the boiler door closed, screw lock nut (1, Fig. 27)
forward and tighten; in this way this side becomes the
fulcrum point.
Open lock nut (1) and turn back approx. 1 cm.

ca. 1 cm
Fig. 27 1 2 3
6.9 Lubricating the seal and thread

6.9.1 Lubricating the seal
Reversing chamber
Combustion chamber

6.9.2 Lubricating the thread

Apply protective agents if the boiler is out

of service for long periods
4 214 283 / 00 45
7. Overview of settings
7.1 Table of parameters
Regulator Setting range /

Designation Factory
10 20 30 40 50 Setting values
Type of device:
DHW:
SW:
Address:
Surface operation Key :
Heating curve HC OFF OFF, 0,20 .... 3,5
Heating curve MC1 1,0 OFF, 0,20 .... 3,5
Heating curve MC2 1,0 OFF, 0,20 .... 3,5
Daytime target temperature HC *) 20C 5 .... 30C *)
Daytime target temperature MC1 *) 20C 5 .... 30C *)
Daytime target temperature MC2 *) 20C 5 .... 30C *)
Night-time target temperature HC *) 16C 5 .... 30C *)
Night-time target temperature MC1 *) 16C 5 .... 30C *)
Night-time target temperature MC2 *) 16C 5 .... 30C *)
DHW target temperature 50C 5 ... DHW-Max.
*) Depending on the setting of system parameters 03 OPERATING MODE
Remote operation/room stations

Type Heating circuit Address HW SW
46 4 214 283 / 00
Table for Time programs
DHW circuit
Time program P1 Time program P2 Time program P3
Tag Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3
from to from to from to from to from to from to from to from to from to
Mo
Tu
We
Th
Fr
Sa
Su
Direct circuit
Mo
Tu
We
Th
Fr
Sa
Su
Mixer Circuit 1
Mo
Tu
We
Th
Fr
Sa
Su
Mixer Circuit 2
Mo
Tu
We
Th
Fr
Sa
Su
4 214 283 / 00 47
HYDRAULIC
Par. Designation Factory 10 20 30 40 50 Lev.
2 Function allocation of the output DHW charging pump 1 HF
3 Function allocation of the output Mixer circuit 1 3 HF
4 Function allocation of the output Mixer circuit 2 3 HF
5 Function allocation of the output Direct circuit Pump 2 HF
6 Function allocation of the variable output 1 OFF HF
7 Function allocation of the variable output 2 OFF/ 4/ 43 HF
8 Function allocation of the variable input 1 OFF HF
9 Function allocation of the variable input 2 OFF HF
10 Function allocation of the variable input 3 OFF/ 2/ 33 HF
11 Indirect return increase OFF HF
12 Maximum limit energy management 80 C HF
13 Activation cooling buffer OFF HF
14 Release contact cooling to KVLF OFF HF
SYSTEM
LANGUAGE Selection of the style-language EN BE
2 Number of cleared switching time programs P1 HF
3 Clearing for separate operating mode 1 HF
4 Limit temperature for summer disconnection 22 C HF
5 System frost protection 3 C HF
6 Demand contact module for VE1 1 HF
9 Air conditioning zone -12 C HF
10 Building type 2 HF
Automatic reversion time (surface end user level, except
11 5 min HF
info. level)
12 Pump and mixer compulsory operation ON HF
13 Logical fault signal OFF HF
Automatic SET function
14 ON/ OFF HF
(after 24:00, is automatically set to OFF)
15 Blocking code for heating Installer OEM
18 Release cycle temperature OFF HF
19 Frost protection mode 30 min HF
21 RTC adjustment 0 HF
23 Blocking code operator level OFF HF
24 Temperature display in Fahrenheit OFF OEM
26 First commissioning date (after 24:00) - OEM
27 Fault report (only TTT/UG) 2 HF
28 Fault stack 2 ON HF
29 Characteristic curve emergency operation 0 C HF
30 Thermostat function sensor allocation AF HF
31 Thermostat function reference value 1 C HF
32 Thermostat function switching difference 3K HF
33 Thermostat function anti-blocking protection ON HF
Top: ArtNo - HW Index
----- OEM
Bottom: Code:REV - Software version
RESET Reset parameter values BE
48 4 214 283 / 00
DHW
DHW-NIGHT DHW - economy temperature 40/ 45 C BE
2 DHW-legionella protection-day OFF HF
3 DHW-egionella protection-time 2:00 HF
50/ 55/ 65/
4 DHW-legionella protection-temperature HF
70 C
5 DHW-temperature recording 1 HF
50/ 55/ 65/
6 DHW-maximum temperature limit HF
70 C
7 DHW-mode of operation 1 HF
8 DHW-tank discharge protection ON/ OFF HF
9 DHW-charging temperature excess 7/ 20 K HF
10 DHW-switching difference 5K OEM
0.5/ 1/ 2/ 5
11 DHW-charging pump follow-on OEM
min
12 ZKP-switching time program AUTO HF
13 ZKP-economy interval (pause) 0 min HF
14 ZKP-economy interval (period duration) 20 min HF
17 H-GEN behaviour during SLP follow-on time AUTO/ OFF HF
18 DHW-parallel loading OFF HF
OFF/
19 DHW-time-out HF
30 min
20 PI-reference value control OFF HF
21 0,1 %/ K OEM
22 PI-scanning time Ta 20 s OEM
23 PI -reset time Tn 600 s/ C OEM
UNMIXED CIRC
1 Type of reduced operation ECO/ ABS HF
2 Heating system (exponent) DK= 1,30 HF
3 Room override (in connection with room sensor) 3 HF
4 Room factor OFF HF
5 Adaptation heating curve OFF HF
6 Switch-on optimisation 1 HF
7 Heating limit 0,5 OEM
8 Room frost protection limit 10 C HF
9 Room thermostat function OFF HF
10 Outside temperature allocation 0 HF
11 Constant temperature reference value 20 C HF
12 Minimum temperature limit 10 C HF
13 Maximum temperature limit 55/ 75 C HF
14 Temperature elevation Heating circuit DK=0 HF
15 Pump follow-on 5 min HF
16 Screed function OFF HF
23 Room control K-factor 8 HF
24 Room control Tn-factor 35 min HF
25 Vacation mode STBY HF
36 Minimum value override OFF HF
Name heating circuit (max. 5 letters) XXXXX HF
4 214 283 / 00 49
MIX. VALVE-1
2 Heating system (exponent) MK= 1,10 HF
4 Room factor 100 % HF
5 Adaptation heating curve ON HF
14 Temperature elevation/ abatement heating circuit 0/ 8 K HF
18 P-portion Xp 2,0 %/ K OEM
19 Scanning time Ta 20 s OEM
20 I-portion Tn 270 s OEM
21 Running time servomotor 150 s HF
22 End position function, valve 1 OEM
37 Mixer lead time OFF HF
38 Regulation offset 0 HF
50 Cooling switch-on point, OT OFF HF
51 Cooling max. point, OT 35 C HF
52 18 C HF
53 24 C HF
54 Cooling reference room temp. at switch-on point 23 C HF
55 Cooling reference room temp. at max. point 28 C HF
56 Min. temp. cooling 18 C OEM
50 4 214 283 / 00
MIX. VALVE-2
2 Heating system (exponent) MK= 1,10 HF
4 Room factor 100 % HF
5 Adaptation heating curve ON HF
14 Temperature elevation/ abatement heating circuit 0/ 8 K HF
18 P-portion Xp 2,0 %/ K OEM
19 Scanning time Ta 20 s OEM
20 I-portion Tn 270 s OEM
21 Running time servomotor 150 s HF
22 End position function, valve 1 OEM
37 Mixer lead time OFF HF
38 Regulation offset 0 HF
50 Cooling switch-on point, OT OFF HF
51 Cooling max. point, OT 35 C HF
52 18 C HF
53 24 C HF
54 Cooling reference room temp. at switch-on point 23 C HF
55 Cooling reference room temp. at max. point 28 C HF
56 Min. temp. cooling 18 C OEM
4 214 283 / 00 51
HEAT GENER.
1 H-GEN model 1/ 2/ 5 HF
2 Start-up protection H-GEN OFF/ 3 HF
5/ 48/ 65/ 75
3 Minimum temperature limit H-GEN HF
C
4 Maximum temperature limit H-GEN 75/ 85 C HF
5 Mode of action minimum temperature limit H-GEN 1 HF
6 Sensor mode operation for H-GEN 1 OEM
7 Minimum burner running time 2 min HF
8 Burner switching difference I 6K HF
9 Burner switching difference II 12 K HF
10 Time-out stage II 10 HF
11 Release mode stage II 1 HF
12 DHW charging mode 1-2 stage 2 HF
13 Lead time, boiler circuit pump 1 min HF
14 Follow-on time, boiler circuit pump or parallel boiler release 5 min HF
15 Search time feed pump, primary pump 5 min HF
16 Exhaust gas temperature monitoring OFF HF
17 Exhaust gas limit value 200 C HF
18 Boiler gradient OFF OEM
19 Modulation P-portion Xp 5 %/ K OEM
20 Modulation scanning time Ta 20 s OEM
21 Modulation adjustment time Tn 180 s/ C OEM
22 Modulation running time 12 s HF
23 Modulation starting time 200 s HF
24 Modulation start-up output 70 HF
25 Outside temperature block OFF OEM
26 Basic charge elevation 0 K/ 10K OEM
27 Minimum temperature limit, heating circuits 5/ 38/ 65 C HF
Switching difference, minimum temperature limit Heating
28 2K OEM
circuits
29 H-GEN forced discharge OFF HF
30 OEM Maximum limit 110 C OEM
31 Minimum load control OFF OEM
34 Output limitation heating 100 % HF
35 Output limitation hot water 100 % HF
36 ET blocking 2.burner stage OFF HF
37 Running time meter 1 HF
38 DHW release regulator (CD) ON HF
39 Emergency operation temperature H-Gen (e.g. for 70-8) 70 C HF
40 Heat balance (from V3.2) ON HF
41 Reset heat balance HF
0,0 l/ min
42 HF
0,0 l/ IMP
43 Density, medium 1,00 kg/ l HF
44 4,2 HF
RESET ST-1 Reset counters starts and running time, stage 1 OEM
RESET ST-2 Reset counters starts and running time, stage 2 OEM
52 4 214 283 / 00
RETURN CONTR
Minimum limit return temperature / reference value return
1 38 C HF
temperature
2 Switch-off difference 2K HF
3 Pump follow-on time 1 min HF
SOLAR
1 Switch-on difference 10 K HF
3 Minimum running time SOP 3 min HF
4 Solar collector maximum temperature 100 C HF
5 Solar tank maximum limit (KSPF) 65 C HF
6 Solar mode of operation 2 HF
7 Heat generator cycle lock (only when parameter 06=1,3,4) 0,5 h HF
8 Solar priority parallel changeover 10 K HF
9 Solar heat balance OFF HF
SOLAR
Reset heat balance HF
RESET
0,0 l/ min
11 HF
0,0 l/ IMP
12 Density, medium 1,05 kg/ l HF
13 3,6 KJ/ kgK HF
14 Final switching-off temperature 120 C HF
15 Test cycle solar charging switch-over 10 min HF
16 Switch-over temperature (SLVF) 60 C HF
17 Solar minimum temperature OFF HF
SOLID FUEL
1 Minimum temperature 60 C HF
2 Maximum temperature 95 C HF
3 Switch-on difference 10 K HF
5 Clock block, heat generator 15 HF
4 214 283 / 00 53
BUFFER
1 Minimum temperature 5/ 20 C HF
2 Maximum temperature 95 C HF
3 Temperature elevation, H-GEN 8/ 10/ 12K HF
4 Switching difference 2/ 5/ 10K HF
5 Forced discharge OFF HF
6 Skimming function switch-on difference 10 K HF
7 Skimming function switch-off difference 5K HF
8 Start-up protection OFF HF
9 Discharge protection OFF HF
10 Buffer mode of operation 2/ 3 HF
11 Pump follow-on time 3 min HF
12 Switch-off reference value temp. 70 C HF
13 H-GEN release temp. skimming function 60 C HF
MAIN SUPPLY
Par. Designation Factory 10 Lev.
1 0 %/ K HF
2 PI-scanning time Ta 20 s HF
3 PI -reset time Tn 600 s/ C HF
CASCADE
Par. Designation Factory 10 Lev.
1 Switch-off difference 3K OEM
2 Connecting delay 20 OEM
3 Switch-off delay 5 OEM
4 Switching output stage sequence 65 OEM
5 Stage reversal OFF OEM
6 Control stage 1 BE
7 Peak load stage OFF OEM
8 Group switch-over OFF OEM
9 DHW fast activation OFF OEM
10 Peak load elevation 10 K OEM
BUS
1 Bus address central device 10 HF
2 Bus right RS direct circuit 1 HF
3 Bus right RS mixer circuit 1 1 HF
4 Bus right RS mixer circuit 2 1 HF
54 4 214 283 / 00
SERVICE
Service 1 (Cleaning ST1 )
1 Suspend message CLEANING ST-1 for X days 7 BE
2 OFF BE
3 OFF BE
4 Cleaning according to cleaning counter OFF BE
5 Reset cleaning display 1 BE
Service 2 (Cleaning ST2)
6 Suspend message CLEANING ST-2 for X days 7 BE
7 OFF BE
8 OFF BE
9 Cleaning according to cleaning counter OFF BE
10 Reset cleaning display 2 BE
Service 3 (maintenance ST1 )
11 Suspend message MAINTENANCE ST-1 for X days 7 HF
12 OFF HF
13 OFF HF
14 Maintenance according to maintenance counter OFF HF
15 Reset maintenance display 1 HF
Service 2 (maintenance ST2 )
16 Suspend message MAINTENANCE ST-2 for X days 7 HF
17 OFF HF
18 OFF HF
19 Maintenance according to maintenance counter OFF HF
20 Reset maintenance display 2 HF
ALARM 1
Par. Designation 10 20 30 40 50 Lev.
1 Alarm 1 OEM
2 Alarm 2 OEM
3 Alarm 3 OEM
4 Alarm 4 OEM
5 ... 20 Alarm 5 - 20 OEM
21 Reset fault signals OEM
ALARM 2 (can ony be activated with H-Gen 5)

Par. Designation 10 20 30 40 50 Lev.
1 Alarm 1 OEM
2 Alarm 2 OEM
3 Alarm 3 OEM
4 Alarm 4 OEM
5 ... 20 Alarm 5 - 20 OEM
21 Reset fault signals OEM
4 214 283 / 00 55
FAULT REPORTING OVERVIEW TopTronicT

Status Designation Fault type Code Remark
System External sensor Interruption 10-0
System External sensor Short-circuit 10-1
System Boiler sensor Interruption 11-0
System Boiler sensor Short-circuit 11-1
System Flow sensor 1 Interruption 12-0 MC1=off, YK1=no current
System Flow sensor 1 Short-circuit 12-1 MC1=off, YK1=no current
System Storage sensor Interruption 13-0
System Storage sensor Short-circuit 13-1
System VE 2 Interruption 14-0
System VE 2 Short-circuit 14-1
System VE 2 Alarm 14-7
System Solar tank sensor Interruption (KSPF) 17-0
System Solar tank sensor Short-circuit (KSPF) 17-1
System Flow sensor 2 Interruption 18-0 MC2=off, YK2=no current
System Flow sensor 2 Short-circuit 18-1 MC2=off, YK2=no current
System Collector sensor Interruption (KVLF) 19-0
System Collector sensor Short-circuit (KVLF) 19-1
System Room sensor (RS) Interruption 20-0
System Room sensor (RS) Short-circuit 20-1
System Burner 1 No switching off (1 min) 30-2 With par. log. alarm can be switched off
System Burner 1 No switching on (10 min) 30-3 With par. log. alarm can be switched off
System Burner 2 No switching off (1 min) 31-2 With par. log. alarm can be switched off
System Burner 2 No switching on (10 min) 31-3 With par. log. alarm can be switched off
System Exhaust gas temperature Exceeding 33-5
System Exhaust gas temperature SLT triggered 33-8
System Cleaning stage 1 Triggering by date 40-1
System Cleaning stage 1 Triggering by interval 40-2
System Cleaning stage 1 Triggering by counter 40-4
System Maintenance stage 1 Triggering by date 41-1
System Maintenance stage 1 Triggering by interval 41-2
System Maintenance stage 1 Triggering by counter 41-4
System Cleaning stage 2 Triggering by date 42-1
System Cleaning stage 2 Triggering by interval 42-2
System Cleaning stage 2 Triggering by counter 42-4
System Maintenance stage 2 Triggering by date 43-1
System Maintenance stage 2 Triggering by interval 43-2
System Maintenance stage 2 Triggering by counter 43-4
56 4 214 283 / 00
FAULT REPORTING OVERVIEW TopTronicT

Status Designation Fault type Code Remark
Logical Boiler temperature Not reached (90 min) 50-4
Logical Tank temperature Not reached (4 h) 51-4
Logical Flow temperature MC1 Not reached (1 h) 52-4
Logical Flow temperature MC2 Not reached (1 h) 53-4
Logical Room temperature HC Not reached (3 h) 54-4
Logical Room temperature MC1 Not reached (3 h) 55-4
Logical Room temperature MC2 Not reached (3 h) 56-4
Lock by energy supply company
System Address collision 70-0
ST 2
System Activity No T2B signal 70-1
System Activity No FA signal 70-6
Regulator with address 10 is
System Activity 70-8
missing
System Activity Data bus error 70-9 No Hoval regulator
System HP return sensor Return min. temp. below setpoint 85-4
System HP return sensor Return max. temp. exceeded 85-5
Heat source min. temp. below
System QF 86-4
setpoint
Heat source max. temp. exceeded
System QF 86-5
(cooling operation)
System QF Fault heat source sensor -- Standard signal VE-x
System WPS Variable input HP fault 87-7
System Pulse counter No pulse (5 min) 90-0
System Fault Warning W:XX
System Fault Lock-out E:XX
System Fault Blocking B:XX
SENSOR ALLOC.
1 Balancing external sensor 0 OEM
RS-T Balancing room sensor (only adjustable with RS-T) 0 HF
2 Balancing heat generator 0 OEM
3 Balancing tank sensor 0 OEM
4 0 OEM
5 0 OEM
6 Balancing solar collector sensor 0 OEM
7 Balancing solar buffer sensor 0 OEM
8 Balancing variable input 1 0 OEM
4 214 283 / 00 57
Conservation of Energy
Protection of the Environment
Hoval Limited, Northgate, Newark, Notts NG24 1JN

Telephone: 01636 593413 Fax: 01636 673532
e-mail: spares@hoval.co.uk or service@hoval.co.uk
Web Site: www.hoval.co.uk
Hoval follows a policy of continued improvement and reserves the right to change specifications without notice.
58 4 214 283 / 00
4 214 283 / 00 59
COPY FOR PLANT USER
Confirmation
The user (owner) of the system herewith conrms 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 con-
cerning the heat generator and any further components.
and is consequently sufciently 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 conrms 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 con-
cerning the heat generator and any further components.
and is consequently sufciently familiar with the installation.
Installation address: Type:
Serial number:
Year of manufacture:
Place, Date:
System installer: System user:

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Technical information

Oil/gas heating boilers

These instructions are applicable to the fol-

4 214 283 / 00 - UK - 03/15 EN

4.15 Gas Boosters .............................................................................................................................. . ...................................... 29

1. Safety valve installed (closed system)

7. An adequate supply of fresh air must be guaranteed.

1.3 Regulations, official approvals

BS EN 12831 Heating systems in buildings

Construction, design, safety requirements.

Construction, design, safety requirements, design and

1.4 Guarantee 2. Assembly

It must be possible to fully swing open the hinged

2.1.1 Installation of the regulators Max-3 plus (420-2700)

3rd pass tube bank

Boiler door opens to the left

The hinges are changed over as follows:

Boiler door hinges must be changed over only by

Figure shows situation as delivered

- do not overtighten the straps (reduced insulating value)

Before commencing to mount the cladding,

Attention: The capillaries must not be kinked!

21. Fix lead-through (21).

- do not overtighten the straps (reduced insulating value)

Before commencing to mount the cladding, check the dimension

Attention: The capillaries must not be kinked!

16. Position cladding cover (16).

19. Position cladding cover (19/19a).

21. Fix lead-through (21).

Fig. 13 7b 8 10 10d 10b 11a 10a

- do not overtighten the straps (reduced insulating value)

the rear casing panel (14,15,16, Fig. 21).

17b 17a 17 19 18g

Max-3 plus (420-1250) type

Directives: 90/396/EG Gas appliance directive

Regulations: Stability prEN14394:2001

3.2 Technical data Max-3 plus (420-2700)

Type (420) (530) (620) (750) (1000)

kg/h 680 859 1004 1215 1619

Possible operating conditions:

min. boiler temperature C 65 75

Return temperature control required required

Max-3 plus Type (1250) (1500) (1800) (2200) (2700)

kg/h 2025 2429 2916 3564 4374

Possible operating conditions:

min. boiler temperature C 65 75

Return temperature control required required

3.3 Dimensions Max-3 plus (420 -1250)

3.4 Dimensions Max-3 plus (1500-2700)

1 Flow (420-530) DN 100, PN 6 2 Return (420-530) DN 100, PN 6 3 Flue gas outlet

(1500) 60 310 1350 725 1498 1790 145

* Max-3 plus (1500-2700) boiler socket is protruding

Cooling air around the boilers must be sufficient such that

radius bends without horizontal runs before entering the

the burner. very close.

4.4 Installing the burner Max-3 plus

Type (420530) Type (620750)

Max-3 plus Max-3 plus

Please consult Hoval Technical Department for further in-

4.4.1 Combustion chamber resistance Max-3 plus (420-2700)

Boiler output (kW) kW = Boiler output

4.5 Fuel Important!

4.6.1 Electrical connection of burner