Hoval 2-Max-3 condens User manual

Subject to modifi cations | EN
Technical information
Assembly instructions
4 215 983 / 01 - 10/21
Oil/Gas condensing boiler
Max-3 condens (3000-5000), Max-3 condens E (3000-5000)
These instructions are applicable
to the following types:
2-Max-3 condens (3000)
2-Max-3 condens (4000)
2-Max-3 condens (5000)
2-Max-3 condens E (3000)
2-Max-3 condens E (4000)
2-Max-3 condens E (5000)
Hoval products must be installed and commissioned
by specialists only. These instructions are intended
for service engineers. Electrical installation must be
performed by a licensed electrical company.

4 215 983 / 012
TABLE OF CONTENTS
1. Important notices
1.1 General safety instructions.................................................................................................................................................3
1.2 Explanation of the symbols ................................................................................................................................................3
1.2.1 Warnings ..........................................................................................................................................................................3
1.2.2 Warning symbols...............................................................................................................................................................3
1.2.3 Information........................................................................................................................................................................3
1.3 On delivery...........................................................................................................................................................................4
1.4 Warranty...............................................................................................................................................................................4
1.5 Manuals................................................................................................................................................................................4
1.6 Regulations, official approvals ...........................................................................................................................................4
1.6.1 Germany §........................................................................................................................................................................4
1.6.2 Austria § ...........................................................................................................................................................................4
1.6.3 Switzerland § ....................................................................................................................................................................4
2. Installation
2.1 Setting up, levelling.............................................................................................................................................................5
2.2 Syphon assembly information ............................................................................................................................................5
3. Technical information
3.1 Description of the boiler .....................................................................................................................................................6
3.2 Technical data......................................................................................................................................................................7
3.2.1 Max-3 condens (3000-5000) for natural gas H...................................................................................................................7
3.2.2 Max-3 condens (3000-5000) for EL low-sulphur fuel oil (sulphur content < 50 mg/kg)........................................................8
3.2.3 Max-3 condens E (3000-5000) for natural gas H ...............................................................................................................9
3.2.4 Max-3 condens E (3000-5000) for EL eco fuel oil ............................................................................................................10
3.3 Dimensions........................................................................................................................................................................11
3.3.1 Max-3 condens (3000-5000) ........................................................................................................................................... 11
3.3.2 Max-3 condens E (3000-5000) ........................................................................................................................................12
4. Installation
4.1 Boiler room requirements .................................................................................................................................................13
4.2 Flue gas connection and dimensioning ...........................................................................................................................13
4.3 Installing burner Max-3 condens and Max-3 condens E (3000-5000) ..............................................................................14
4.3.1 Fuel ................................................................................................................................................................................15
4.3.2 Electrical connection.......................................................................................................................................................15
4.4 Flue gas and output diagram ............................................................................................................................................16
4.4.1 Max-3 condens (3000-5000) flue gas and output diagram ...............................................................................................16
4.4.2 Max-3 condens E (3000-5000) flue gas and output diagram............................................................................................17
4.5 Minimum value limiting of boiler return temperature ......................................................................................................18
4.6 Discharge of start-up condensate from the boiler ...........................................................................................................18
4.7 Setting the temperature controllers..................................................................................................................................18
4.8 Safety valves......................................................................................................................................................................18
4.9 Supply pump......................................................................................................................................................................18
4.10 Heating pump.....................................................................................................................................................................18
4.11 Heating connections .........................................................................................................................................................18
5. Commissioning
5.1 Water quality......................................................................................................................................................................19
5.2 Filling the calorifier ...........................................................................................................................................................20
5.3 Commissioning .................................................................................................................................................................20
5.4 Hand-over to the operator / safe-keeping.........................................................................................................................20
6. Maintenance (only for boiler controller with TopTronic®E control)
6.1 Information for combustion controller / chimney sweep regarding emission monitor key ...........................................21
6.2 Cleaning ............................................................................................................................................................................22
6.3 Lubrication of the seal and thread....................................................................................................................................22
6.3.1 Lubrication of the seal.....................................................................................................................................................22
6.3.2 Lubrication of the thread .................................................................................................................................................22
6.4 Cleaning the flue gas heat exchanger ..............................................................................................................................23

4 215 983 / 01 3
IMPORTANT NOTICES
1. Important notices
1.1 General safety instructions
The system may only be placed in operation
if all the relevant standards and safety regula-
tions have been complied with.
At least the following conditions must be satised for a
trial operation:
- Safety valve installed (system sealed)
- Control in operation (connected to the power supply)
- Sensor for the safety temperature limiter mounted in
the immersion sleeve
- System lled with water
- Expansion tank connected
- Flue gas outlet with ue gas line connected to ue gas
system.
- An adequate supply of fresh air must be guaranteed.
- Burner preset
- Safety equipment of the system is compliant with
EN 12828 (≦110 °C STB) or EN 12953-6 (> 111 °C to
≦120 °C STB).
- All piping on the boiler must be de-energised.Any voltage
present due to length extensions must be absorbed
through appropriate piping measures (expansion
bends, compensators, spring supports, etc.) and must
not a󰀨ect the boiler resistance connection piece.
WARNING
The heat generator can only be de-energised
by disconnection from the mains (e.g. all-
pole switch).
WARNING
All electrical power supply circuits must be
switched o󰀨 before accessing the terminals.
1.2 Explanation of the symbols
1.2.1 Warnings
!
DANGER
... indicates a situation of immediate danger
which will lead to serious or fatal injuries if
not avoided.
!
WARNING
... indicates a situation of possible danger
which can lead to serious or fatal injuries if
not avoided.
!
CAUTION
... indicates a situation of possible danger
which can lead to minor or slight injuries if
not avoided.
NOTICE
... indicates a situation of possible danger
which can lead to damage to property if not
avoided.
1.2.2 Warning symbols
The following warning signs are combined for the warning
notes with signal words CAUTION, WARNING and
DANGER.
!
General warning symbols
Warning of electrical voltage
1.2.3 Information
Information:
Provides important information.
§
Provides important information.
Refers to standards and directives.

4 215 983 / 014
IMPORTANT NOTICES
1.3 On delivery
Carry out a visual inspection immediately on receiving the
boiler. If any damage is found, take the necessary steps
as dened in the delivery contract. The respective risk
carrier bears the cost of repairs.
1.4 Warranty
The warranty does not cover defects attributable to:
• Failure to comply with these instructions
• Failure to comply with the operating instructions
• Incorrect installation
•Impermissible modications to the product
• Incorrect handling of the product
• Damage caused by the application of force
• Contaminated operating materials
(gas, water, combustion air)
• Unsuitable chemical additives to the heating water
•Corrosion caused by not observing the required water
quality
• Corrosion by halogen compounds
(e.g. paints, adhesives, solvents)
1.5 Manuals
All instructions relevant to your system can be found in
the Hoval system manual - please keep all manuals!
In exceptional cases, the instructions can be found with
the components!
Further sources of information:
• Hoval catalogue
• Standards, regulations
1.6 Regulations, ofcial approvals
The standards and directives stated under chapter 1.6.1
to 1.6.3 must be taken into account during installation and
operation of the system.
1.6.1 Germany §
•DIN EN 12831 Heating systems in buildings - Method
for calculation of the design heat load.
•DIN EN 303 Heating boilers with forced draught burners.
• DIN EN 12828 Sheet 1 and 2
Heating systems in buildings - design of water-based
heating systems.
•DIN 4755 Oil-red systems.
Design, construction and safety engineering require-
ments.
•DIN 4756 Gas-red systems; construction, execution,
technical safety requirements, planning and execution.
•DIN 18160 House chimneys; requirements, planning
and execution.
•TRD 702 Steam boiler plants with caloriers of the
group II.
•DIN EN 13384 Flue gas systems – Calculation methods
in heat and ow engineering.
•TRD 721 Safety devices against excess pressures /
safety valves / for steam boilers of Group II.
•VDI 2035 Prevention of damage by corrosion and the
formation of scale in hot water heating systems.
•DIN 57 116 / VDI 0116 Electrical equipment for ring
systems (VDE Regulation).
•For further standards applicable in Germany, see ap-
pendix N-430 020.
1.6.2 Austria §
• ÖNorm 7550
•ÖNorm B 8130 Open water heating systems;
safety devices.
•Norm B 8131 Closed water heating systems;
safety, execution and testing requirements
•ÖNorm B 8133 Hot water production systems;
technical safety requirements.
•ÖNorm B 8136 Heating systems, space requirements
and other building requirements.
•ÖNorm M 7515 Calculations of dimensions of chimneys;
terminology, calculation procedure.
• ÖNorm H 5171
•ÖVGW TR-gas (Austrian Gas and Water Confederation
- Technical Guidelines)
1.6.3 Switzerland §
• VKF - Association of Cantonal Fire Insurers
• Fire prevention authority regulations.
• SVGW Swiss Association for Gas and Water.
• SWKI 91-1 Aeration and ventilation of the boiler room.
•SWKI BT 102-01 Water quality for building services
systems.
•SWKI 93-1 Safety engineering installations for heating
systems.
• KRW Corrosion caused by halogen compounds.
•KRW/VSO/FKR Plug-in electrical connections on boil-
ers and burners
and further regulations and standards issued by CEN,
CEN ELEC, DIN, VDE, DVGW, TRD and the legislative
body.
The regulations of the local building authorities, insurance
companies and chimney sweeps must also be taken into
account. The regulations of the responsible gas supply
company are to be complied with if using gas. Approval
by the authorities may be required.

4 215 983 / 01 5
INSTALLATION
2. Installation
2.1 Setting up, levelling
No special foundation plate is required for erecting the
boiler (su󰀩cient supporting capacity for the boiler must
be guaranteed) - for operating weight, see chapter 3.
If there are boiler rooms in the domestic domain, vibration
dampers are to be mounted under the boiler plinth rails.
The distance from the wall behind the boiler
must always be su󰀩cient in order to gain ac-
cess to the cleaning opening in the ue gas
collector. It must be possible to swing open
the boiler door with the burner.
Levelling
Align the top edge of the boiler water jacket (boiler longi-
tudinal axis) exactly horizontal.
2.2 Syphon assembly information
When combusting hydrogenous fuels which cool down
below their dew points, the water vapour in the ue gas
condenses. This condensate must be diverted out of the
caloric value heat exchanger or the ue gas system.
The amount of the resulting condensate depends on the
water entry temperature in the heat exchanger, the excess
air in the ue gas and the load of the heat generator.
The following standard values can be assumed for the
resulting amount of condensation (at theoretical 100 %
condensation and consideration of an average humidity):
Natural gas: approx. 0.8 l/m3gas
Oil-ring: approx. 0.9 l/litre oil
The ue gas condensate must be introduced into the
public sewer network as prescribed. Neutralisation
equipment might be needed - please contact the nearest
Hoval branch.
In particular with oil-ring, the use and suitability of the
neutralisation equipment must be taken into account.
A syphon must be installed directly at the discharge of the
caloric value heat exchanger; it (including the connecting
piping between the heat exchanger and syphon) is to
be designed to be resistant to ue gas temperatures
up to 240 °C and must be lled with water before the
system is commissioned. The height of the syphon must
correspond at least with the ue gas counterpressure
of the heat exchanger (up to about 4 mbar) - start-up
pressure shocks of the burner or possible additional
counterpressure of the ue gas line must also be taken
into account.
The connection cables of the drainage piping must be
made of corrosion-resistant materials such as PVC or
stainless steel.
After a long system standstill, the water level of the syphon
must be checked and relled with water if necessary.

4 215 983 / 016
TECHNICAL INFORMATION
3. Technical information
3.1 Description of the boiler
The Max-3 condens and Max-3 condens E condensing boiler is constructed in 3-compartment form. The heating
gases ow from the cylindrical combustion chamber into the water-cooled reversing chamber and through the 2nd
compartment into the front reversing chamber. The 3rd compartment consists of straight tubes through which the
heating gases are conducted to the ue gas heat exchanger. In the ue gas heat exchanger, the heating gases are
further cooled to increase the boiler e󰀩ciency. Depending on the operating conditions, the system can be cooled below
the dew point, thereby using the caloric value.
Max-3 condens
Max-3 condens E

4 215 983 / 01 7
TECHNICAL INFORMATION
3.2 Technical data
3.2.1 Max-3 condens (3000-5000) for natural gas H
Type (3000) (4000) (5000)
Fuel Natural gas H Natural gas H Natural gas H
• Nominal heat output at 80/60 °C kW 3750 5006 6285
• Nominal heat output at 80/30 °C kW 3951 5283 6636
• Heat output range at 80/60 °C kW 768-3750 976-5006 1185-6285
• Heat output range at 80/30 °C kW 832-3951 1063-5283 1296-6636
• Combustion performance kW 792-3942 1005-5256 1220-6615
• Boiler operating temperature max. 2) °C 105 105 105
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
°C see table of operating conditions (below)
• Safety temperature limiter setting (water side) 3) °C 120 120 120
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler e󰀩ciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 95.1/85.7 95.3/85.8 95.0/85.6
• Boiler e󰀩ciency at 80/30 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 100.2/90.3 100.5/90.6 100.3/90.4
• Boiler e󰀩ciency at 30 % partial load (EN 303)
(related to net caloric value NCV / gross caloric value GCV)
% 107.9/97.2 106.7/96.1 107.5/96.8
• Nominal e󰀩ciency at 75/60 °C (DIN 4702-8)
(related to net caloric value NCV / gross caloric value GCV)
% 106.9/96.3 106.4/95.9 107.3/96.7
• Stand-by losses qB at 70 °C Watts 2125 2349 2566
• Flue gas temperature at nominal output 80/60 °C °C 128 126 132
• Combustion gas resistance at nominal output (natural gas H, 10.5 % CO2),
500 m above sea level (tolerance ± 20 %)
mbar 16.5 17.2 16.4
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO2)
kg/h 5820 7760 9767
• Flow resistance boiler 1) z-value 0.001 0.001 0.0004
• Flue gas heat exchanger ow resistance z-value 0.008 0.011 0.014
• Boiler water ow rate at 10 K m³/h 321 429 539
• Boiler water ow rate at 20 K m³/h 161 215 269
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.2 4.4 6.1
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 4.3 5.9 7.8
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6452 7172 7886
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7356 8714 -
- At operating / test pressure 10/16 bar kg 8489 10012 12038
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
half the length of the reversing chamber)
3436 3756 4006
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1) Flow resistance boiler in mbar = ow rate (m3/h)2x z
2) Limited by the boiler controller E13.4 TopTronic®E and T2.2 to 90 °C or by E13.5 TopTronic®E and T0.2 to 105 °C.
3) Max. safety temperature for boiler controller E13.4 TopTronic®E and T2.2: 110 °C or E13.5 TopTronic®E and T0.2: 120 °C.
Operating conditions:
Fuel EL low-sulphur fuel oil Natural gas H
Boiler operating temperature min. °C 65 75
Boiler return temperature min. 1) °C 55 65
Return temperature control 1) Yes Yes
1) Before entering boiler return

4 215 983 / 018
TECHNICAL INFORMATION
3.2.2 Max-3 condens (3000-5000) for EL low-sulphur fuel oil (sulphur content < 50 mg/kg)
Type (3000) (4000) (5000)
Fuel EL fuel oil
low-sulphur
EL fuel oil
low-sulphur
EL fuel oil
low-sulphur
• Nominal heat output at 80/60 °C kW 3750 5006 6285
• Nominal heat output at 80/30 °C kW 3877 5181 6502
• Heat output range at 80/60 °C kW 768-3750 976-5006 1185-6285
• Heat output range at 80/30 °C kW 815-3877 1039-5181 1265-6502
• Combustion performance kW 792-3942 1005-5256 1220-6615
• Boiler operating temperature max. 2) °C 105 105 105
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
°C see table of operating conditions (below)
• Safety temperature limiter setting (water side) 3) °C 120 120 120
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler e󰀩ciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 95.1/89.7 95.3/89.9 95.0/89.6
• Boiler e󰀩ciency at 80/30 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 98.4/92.8 98.6/93.0 98.3/92.7
• Boiler e󰀩ciency at 30 % partial load (EN 303)
(related to net caloric value NCV / gross caloric value GCV)
% 102.2/96.4 102.0/96.2 102.8/97.0
• Nominal e󰀩ciency at 75/60 °C (DIN 4702-8)
(related to net caloric value NCV / gross caloric value GCV)
% 101.2/95.5 101.7/95.9 102.6/96.8
• Stand-by losses qB at 70°C Watts 2125 2349 2566
• Flue gas temperature at nominal output 80/60 °C °C 128 126 132
• Combustion gas resistance at nominal output (natural gas H, 12.5 % CO2),
500 m above sea level (tolerance ± 20 %)
mbar 16.5 17.2 16.4
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO2)
kg/h 6120 8160 10200
• Flow resistance boiler 1) z-value 0.001 0.001 0.0004
• Flue gas heat exchanger ow resistance z-value 0.008 0.011 0.014
• Water ow rate at 10 K m³/h 321 429 539
• Water ow rate at 20 K m³/h 161 215 269
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.2 4.4 6.1
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 3.4 4.7 6.1
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6452 7172 7886
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7356 8714 -
- At operating / test pressure 10/16 bar kg 8489 10012 12038
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
half the length of the reversing chamber)
3436 3756 4006
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1) Flow resistance boiler in mbar = ow rate (m3/h)2x z
2) Limited by the boiler controller E13.4 TopTronic®E and T2.2 to 90 °C or by E13.5 TopTronic®E and T0.2 to 105 °C.
3) Max. safety temperature for boiler controller E13.4 TopTronic®E and T2.2: 110 °C or E13.5 TopTronic®E and T0.2: 120 °C.
Operating conditions:
Fuel EL low-sulphur fuel oil Natural gas H
Boiler operating temperature min. °C 65 75
Boiler return temperature min. 1) °C 55 65
Return temperature control 1) Yes Yes
1) Before entering boiler return

4 215 983 / 01 9
TECHNICAL INFORMATION
3.2.3 Max-3 condens E (3000-5000) for natural gas H
Type (3000) (4000) (5000)
Fuel Natural gas H Natural gas H Natural gas H
• Nominal heat output at 80/60 °C kW 3162 4215 5305
• Nominal heat output at 80/30 °C kW 3412 4546 5732
• Heat output range at 80/60 °C kW 774-3162 982-4215 1195-5305
• Heat output range at 80/30 °C kW 862-3412 1099-4546 1345-5732
• Combustion performance kW 794-3255 1007-4340 1225-5465
• Boiler operating temperature max. 2) °C 105 105 105
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
°C see table of operating conditions (below)
• Safety temperature limiter setting (water side) 3) °C 120 120 120
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler e󰀩ciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 97.1/87.5 97.1/87.5 97.1/87.5
• Boiler e󰀩ciency at 80/30 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 104.8/94.4 104.7/94.4 104.9/94.5
• Boiler e󰀩ciency at 30 % partial load (EN 303)
(related to net caloric value NCV / gross caloric value GCV)
% 108.4/97.7 108.2/97.5 109.0/98.2
• Nominal e󰀩ciency at 75/60 °C (DIN 4702-8)
(related to net caloric value NCV / gross caloric value GCV)
% 107.4/96.8 107.9/97.2 108.8/98.0
• Stand-by losses qB at 70°C Watts 2166 2383 2620
• Flue gas temperature at nominal output 80/60 °C °C 82 83 83
• Combustion gas resistance at nominal output (natural gas H, 10.5 % CO2),
500 m above sea level (tolerance ± 20 %)
mbar 12.2 13.4 12.0
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO2)
kg/h 4806 6408 8069
• Flow resistance boiler 1) z-value 0.001 0.001 0.0004
• Flue gas heat exchanger ow resistance z-value 0.01 0.016 0.018
• Boiler water ow rate at 10 K m³/h 271 361 455
• Boiler water ow rate at 20 K m³/h 136 181 227
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.5 4.6 6.5
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 5.0 6.7 9.0
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6525 7260 8030
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7668 9265 -
- At operating / test pressure 10/16 bar kg 8801 10563 12905
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
half the length of the reversing chamber)
3436 3756 4006
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1) Flow resistance boiler in mbar = ow rate (m3/h)2x z
2) Limited by the boiler controller T0.2 to 105 °C.
3) Max. safety temperature for boiler controller T0.2: 120 °C.
Operating conditions:
Fuel EL low-sulphur fuel oil
EL eco fuel oil
Natural gas H
Boiler operating temperature min. °C 65 75
Boiler return temperature min. 1) °C 55 65
Return temperature control 1) Yes Yes
1) Before entering boiler return

4 215 983 / 0110
TECHNICAL INFORMATION
3.2.4 Max-3 condens E (3000-5000) for EL eco fuel oil
Type (3000) (4000) (5000)
Fuel EL low-sulphur fuel oil/EL eco fuel oil
• Nominal heat output at 80/60 °C kW 3162 4215 5305
• Nominal heat output at 80/30 °C kW 3325 4431 5578
• Heat output range at 80/60 °C kW 774-3162 982-4215 1195-5305
• Heat output range at 80/30 °C kW 838-3325 1064-4431 1295-5578
• Combustion performance kW 794-3255 1007-4340 1225-5465
• Boiler operating temperature max. 2) °C 105 105 105
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
°C see table of operating conditions (below)
• Safety temperature limiter setting (water side) 3) °C 120 120 120
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler e󰀩ciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 97.1/91.6 97.1/91.6 97.1/91.6
• Boiler e󰀩ciency at 80/30 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
% 102.2/96.4 102.1/96.3 102.1/96.3
• Boiler e󰀩ciency at 30 % partial load (EN 303)
(related to net caloric value NCV / gross caloric value GCV)
% 103.4/97.5 103.2/97.4 104.0/98.1
• Nominal e󰀩ciency at 75/60 °C (DIN 4702-8)
(related to net caloric value NCV / gross caloric value GCV)
% 102.4/96.6 102.9/97.1 103.8/97.9
• Stand-by losses qB at 70°C Watts 2166 2383 2620
• Flue gas temperature at nominal output 80/ 60 °C °C 81 82 81
• Combustion gas resistance at nominal output (natural gas H, 12.5 % CO2),
500 m above sea level (tolerance ± 20 %)
mbar 12.2 13.4 12.0
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO2)
kg/h 5105 6807 8508
• Flow resistance boiler 1) z-value 0.001 0.001 0.0004
• Flue gas heat exchanger ow resistance z-value 0.01 0.016 0.018
• Water ow rate at 10 K m³/h 271 361 455
• Water ow rate at 20 K m³/h 136 181 227
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.5 4.6 6.5
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 4.0 5.3 7.1
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6525 7260 8030
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7668 9265 -
- At operating / test pressure 10/16 bar kg 8801 10563 12905
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
half the length of the reversing chamber)
3436 3756 4006
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1) Flow resistance boiler in mbar = ow rate (m3/h)2x z
2) Limited by the boiler controller T0.2 to 105 °C.
3) Max. safety temperature for boiler controller T0.2: 120 °C.
Operating conditions:
Fuel EL low-sulphur fuel oil
EL eco fuel oil
Natural gas H
Boiler operating temperature min. °C 65 75
Boiler return temperature min. 1) °C 55 65
Return temperature control 1) Yes Yes
1) Before entering boiler return

4 215 983 / 01 11
TECHNICAL INFORMATION
3.3 Dimensions
3.3.1 Max-3 condens (3000-5000)
(Dimensions in mm)
Type B L H H1 H2 D Di/Da H3 H4 H5 H6 H7 H8 L1 L2 L3 L4 A A1 A2 A3 A4
(3000) 2086 5277 2508 2393 1283 2070 450/458 2326 120 378 1783 1596 375 3943 168 155 207 1695 1150 520 3200 507
(4000) 2186 5597 2608 2493 1333 2170 500/508 2426 120 378 1896 1643 450 4263 168 155 207 2015 1150 640 3400 507
(5000) 2286 5964 2708 2593 1383 2270 550/558 2526 120 378 1983 1723 525 4511 282 155 207 2265 1155 550 3750 507
1 Boiler supply PN 16 (3000,4000) DN 200
(5000) DN 250
2 Boiler return PN 16 (3000,4000) DN 200
(5000) DN 250
3 Cleaning opening
4Flue gas collector cleaning connection / drainage
5 Drainage PN 16 R 1½″
6 5 immersion sleeves R ¾″ x 120 supply boiler
7Safety valve tting PN 16 (3000,4000) DN 80
(5000) DN 100
8 Sight glass
8A Sight glass (optional)
9 Smoke gas outlet
10 Exhaust gas heat exchanger
11 Flue gas heat exchanger
connections PN 16
(3000,4000) DN 150
(5000) DN 200
View A
Burner connection dimensions
Firing system dimensions
Screw connection ange
Max-3 condens (3000,4000)
6x M16
Screw connection ange
Max-3 condens (5000)
8x M16
Type A B C D E F G K L
(3000) 400 450 1283 400 900 3211 188 1410 450
(4000) 400 450 1333 400 990 3531 188 1510 450
(5000) 540 735 1383 296 1070 3781 305 1600 450

4 215 983 / 0112
TECHNICAL INFORMATION
Type B L H H1 H2 D Di/Da H3 H4 H5 H6 H7 H8 L1 L2 L3 L4 A A1 A2 A3 A4 A5
(3000) 2086 5587 2508 2393 1283 2070 450/458 2326 120 378 1808 1596 425 3943 168 155 207 1695 1150 520 3200 507 310
(4000) 2186 5907 2608 2493 1333 2170 500/508 2426 120 378 1896 1643 505 4263 168 155 207 2015 1150 640 3400 507 310
(5000) 2286 6269 2708 2593 1383 2270 550/558 2526 120 378 2008 1723 570 4511 282 155 207 2265 1155 550 3750 507 310
1 Boiler supply PN 16 (3000,4000) DN 200
(5000) DN 250
2 Boiler return PN 16 (3000,4000) DN 200
(5000) DN 250
3 Cleaning opening
4 Flue gas collector cleaning connection / drainage
5 Drainage PN 16 R 1½″
6 5 immersion sleeves R ¾″ x 120 supply boiler
Burner connection dimensions
Screw connection ange
Max-3 condens E (3000,4000)
6x M16
Screw connection ange
Max-3 condens E (5000)
8x M16
3.3.2 Max-3 condens E (3000-5000)
(Dimensions in mm)
7Safety valve tting PN 16 (3000,4000) DN 80
(5000) DN 100
8 Sight glass
8A Sight glass (optional)
9 Smoke gas outlet
10 Exhaust gas heat exchanger
11 Exhaust gas heat exchanger (3000,4000) DN 150
connections PN 16 (5000) DN 200
View A
The control can be tted on the right
or left side.
Firing system dimensions
Type A B C D E F G K L
(3000) 400 450 1283 400 900 3211 188 1410 450
(4000) 400 450 1333 400 990 3531 188 1510 450
(5000) 530 735 1383 296 1070 3781 305 1600 450

4 215 983 / 01 13
INSTALLATION
4.2 Flue gas connection and dimensioning
To guarantee economical and fault-free operation, boiler
and ue gas system must be mutually adapted to create
a functional unit.
NOTICE
If the ue gas temperature is under 160 °C,
the ue gas lines must be watertight, acid-
resistant and overpressure-tight.
NOTICE
Horizontal connecting pipes must be installed
with an inclination of at least 50 mm per metre
of their length installed in the direction of the
boiler to allow free return of condensation
wa ter towards the boiler. The whole ue gas
system must be installed so that condensate
can never collect at any point.
Renovation or ue gas line cross-section adjustment can
be necessary with existing ue gas systems, according to
the instructions of a specialist.
The function of the ue gas system, i.e. the production of
the necessary delivery pressure is basically dependent
on:
a. The type (nature) of the ue gas system (thermal in-
sulation, interior surface roughness, sealing etc.)
b. The connection of the boiler to the ue gas system
ac cor ding to specications
c. The correct size of the ue gas system
Flue gas systems according to EN 13384, part 2, execu-
tion types I and II are appropriate for modern ring sys-
tems (advice from the specialist is necessary). Pay atten-
tion to the ue gas temperature at nominal output; see
ue gas output diagram.
NOTICE
Normally only one heat generator may be
con nected to the ue gas system!
Where a transition element is necessary from the boiler
ue gas pipe to the chimney inlet, this should be executed
as a slender cone.
vom
Kessel
zum
Schornstein
from the
boiler
to the ue
gas system
Figure 01
4. Installation
4.1 Boiler room requirements
The valid building supervisory regulations for the instal-
lation location are applicable for the construction require-
ments for boiler rooms and their aeration and ventilation.
In Germany, the ring regulations for the individual states
are to be complied with.
Make sure there is an adequate supply of fresh air
to the boiler room
to ensure that the combustion air supply necessary for
all the ring systems operated there can ow in without
hin drance and that no oxygen deciency occurs for the
operating personnel.
Binding values for the size of supply air openings are not
generally specied in the relevant regulations; it is merely
required that no negative pressure in excess of 3 N/m2
occurs. With rectangular apertures the side ratio is not
to exceed 1.5 : 1 and an appropriate supplement is to
be made with grilles to ensure that the free cross-section
reaches the above values.

4 215 983 / 0114
INSTALLATION
4.3 Installing burner Max-3 condens
and Max-3 condens E (3000-5000)
For burner connection dimensions, see
chapter “3.3 Dimensions”, page 11.
1. Mount the burner to the boiler ange with the seal
and screws.
!
CAUTION
Failure to observe the guidelines and
standards for the installation of burners can
result in damage to property and personal
injury.
•
On installing, comply with the guidelines
and instructions for tting the burner to the
heat producer.
• Only burners tested according to EN 267 or
EN 676 may be used.
2. Insulate the space between the burner pipe and the
hinged ange.
3. For gas and dual-fuel burners:
If the weight of the burner (including attachments)
> 90 kg and the distance of the centre of gravity of
the burner to the door > 60 cm, support the burner
housing weight directly with a strut to the oor.
Noise damping
- Gas pipelines are to be installed so that no vibrations
can be transferred to the building.
- The burner can be covered with a noise-damping hood.
- It is recommended to incorporate a noise damper down-
stream of the boiler in the ue gas pipe.
Emissions
In order to comply with the Swiss Clean Air
Act (LRV), make sure that the maximum per-
missible furnace heat release (dimensions in-
cluding reversing chamber) of the respective
boiler manufacturer is not exceeded. In certain
situations, this can lead to a reduction in boiler
performance and must be taken into account
without fail when dimensioning the system.
Max-3 condens heating gas-side resistance
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000 6300 6600 6900
Heizgasseitiger Widerstand (mbar)
Kesselleistung (kW)
kW = Heizkesselleistung
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 60°C
mbar = Heizgasseitiger Widerstand bei =1.14 (Erdgas: CO2= 10.5%), 500 m ü.M. (Toleranz: +/- 20%)
kW = Boiler output
mbar = Flue gas resistance =1.14 (Natural gas: CO2= 10.5%)
500 above sea level (Tolerance: +/- 20%)
(5000)
(4000)
(3000)
Heating gas-side resistance (mbar)
Boiler output (kW)
kW = Boiler output
Boiler ow temperature 80 °C, return temperature 60 °C
mbar = Heating side resistance at λ = 1.14 (natural gas H, CO2= 10.5 %), 500 m above sea level (tolerance +/- 20 %)
Max-3 condens E heating gas-side resistance
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
Heizgasseitiger Widerstand (mbar)
Kesselleistung (kW)
kW = Heizkesselleistung
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 60°C
mbar = Heizgasseitiger Widerstand bei =1.14 (Erdgas: CO2= 10.5%), 500 m ü.M. (Toleranz: +/- 20%)
kW = Boiler output
mbar = Flue gas resistance =1.14 (Natural gas: CO2= 10.
5
500 above sea level (Tolerance: +/- 20%)
(5000)
(4000)
(3000)
Heating gas-side resistance (mbar)
Boiler output (kW)
kW = Boiler output
Boiler ow temperature 80 °C, return temperature 60 °C
mbar = Heating side resistance at λ = 1.14 (natural gas H, CO2= 10.5 %), 500 m above sea level (tolerance +/- 20 %)

4 215 983 / 01 15
INSTALLATION
4.3.1 Fuel
NOTICE
The boiler is only to be operated with the fuel
stated on the boiler rating plate.
Max-3 condens or Max-3 condens boilers are normally
suitable for burning the following fuels:
- EL low-sulphur fuel oil (sulphur content < 50 mg/kg) in
accordance with DIN 51 6093, or eco heating oil in ac-
cordance with SN 181160.2
- All combustible gases according to DVGW Work sheet
G 260
4.3.2 Electrical connection
A qualied technician must install the electrical
supply to the equipment. The connection dia-
gram is located in the electrical box of the heat
ge ne rator; the circuit diagram is supplied sep-
arately.
Electrical connection of burner
- The burner must be connected to the boiler with the
standard plug and socket connection.
- The burner cable must be installed so that the plug and
socket connection has to be disconnected in order to
swing out the burner.
Max-3 condens E heating gas-side resistance
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
Heizgasseitiger Widerstand (mbar)
Kesselleistung (kW)
kW = Heizkesselleistung
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 60°C
mbar = Heizgasseitiger Widerstand bei =1.14 (Erdgas: CO2= 10.5%), 500 m ü.M. (Toleranz: +/- 20%)
kW = Boiler output
mbar = Flue gas resistance =1.14 (Natural gas: CO2= 10.
5
500 above sea level (Tolerance: +/- 20%)
(5000)
(4000)
(3000)
Heating gas-side resistance (mbar)
Boiler output (kW)
kW = Boiler output
Boiler ow temperature 80 °C, return temperature 60 °C
mbar = Heating side resistance at λ = 1.14 (natural gas H, CO2= 10.5 %), 500 m above sea level (tolerance +/- 20 %)

4 215 983 / 0116
INSTALLATION
4.4 Flue gas and output diagram
4.4.1 Max-3 condens (3000-5000) flue gas and output diagram
Max-3 condens (VL 80 °C / RL 60 °C) flue gas and output diagram
72
76
80
84
88
92
96
100
104
108
112
116
120
124
128
132
136
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000 6300 6600
Abgastemperatur (°C)
Kesselleistung (kW)
(5000)
(
4000
)
(3000)
- Betrieb mit Erdgas,
λ=1.14 bei Brenner-Vollast
(CO2Erdgas H: 10.5%)
kW = Heizkesselleistung
°C = Abgastemperatur bei gereinigter Heizfläche,
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 60°C
‐Eine Reduktion der Kesseltemperatur um - 10K
bewirkt eine reduktion der Abgastemperatur um ca. 6 - 8 K
- Eine Veränderung der Luftzahl l um +/- 0.09 bewirkt eine
Veränderung der Abgastemperatur von +/- 8K
Flue gas temperature (°C)
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kW = Boiler output
°C = Flue gas temperature with reduced
heating surface, boiler ow temperature
80 °C, return temperature 60 °C (eld
measurement according to DIN 4702).
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO2natural gas H = 10.5 %)
- A reduction of the boiler water temperature of -10 K e󰀨ec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % e󰀨ectuates a
change in the ue gas temperature of approx. ± 8 K.
Max-3 condens (VL 80 °C / RL 30 °C) flue gas and output diagram
58
62
66
70
74
78
82
86
90
94
98
102
106
110
114
118
122
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000 6300 6600 6900
Abgastemperatur (°C)
Kesselleistung (kW)
(5000)
(
4000
)
(3000)
- Betrieb mit Erdgas,
λ=1.14 bei Brenner-Vollast
(CO2Erdgas H: 10.5%)
kW = Heizkesselleistung
°C = Abgastemperatur bei gereinigter Heizfläche,
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 30°C
‐Eine Reduktion der Kesseltemperatur um - 10K
bewirkt eine reduktion der Abgastemperatur um ca. 6 - 8 K
- Eine Veränderung der Luftzahl l um +/- 0.09 bewirkt eine
Veränderun
g
der Ab
g
astem
p
eratur von +/- 8K
Flue gas temperature (°C)
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kkW = Boiler output
°C = Flue gas temperature with reduced
heating surface, boiler ow temperature
80 °C, return temperature 30 °C (eld
measurement according to DIN 4702).
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO2natural gas H = 10.5 %)
- A reduction of the boiler water temperature of -10 K e󰀨ec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % e󰀨ectuates a
change in the ue gas temperature of approx. ± 8 K.
4.4.2 Max-3 condens E (3000-5000) flue gas and output diagram
Max-3 condens E (VL 80 °C / RL 60 °C) flue gas and output diagram
62
64
66
68
70
72
74
76
78
80
82
84
86
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
Abgastemperatur (°C)
Kesselleistung (kW)
(5000)
(
4000
)
(3000)
- Betrieb mit Erdgas,
λ=1.14 bei Brenner-Vollast
(CO2Erdgas H: 10.5%)
kW = Heizkesselleistung
°C = Abgastemperatur bei gereinigter Heizfläche,
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 60°C
‐Eine Reduktion der Kesseltemperatur um - 10K
bewirkt eine reduktion der Abgastemperatur um ca. 6 - 8 K
- Eine Veränderung der Luftzahl l um +/- 0.09 bewirkt eine
Veränderung der Abgastemperatur von +/- 8K
Flue gas temperature (°C)
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kkW = Boiler output
°C = Flue gas temperature with reduced
heat ing surface, boiler ow temperature
80 °C, return temperature 60 °C (eld
measurement according to DIN 4702).
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO2natural gas H = 10.5 %)
- A reduction of the boiler water temperature of - 10 K e󰀨ec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % e󰀨ectuates a
change in the ue gas temperature of approx. ± 8 K.
Max-3 condens E (VL 80 °C / RL 30 °C) flue gas and output diagram
38
40
42
44
46
48
50
52
54
56
58
60
62
64
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000
Abgastemperatur (°C)
Kesselleistung (kW)
(5000)
(
4000
)
(3000)
- Betrieb mit Erdgas,
λ=1.14 bei Brenner-Vollast
(CO2Erdgas H: 10.5%)
kW = Heizkesselleistung
°C = Abgastemperatur bei gereinigter Heizfläche,
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 30°C
‐Eine Reduktion der Kesseltemperatur um - 10K
bewirkt eine reduktion der Abgastemperatur um ca. 6 - 8 K
- Eine Veränderung der Luftzahl l um +/- 0.09 bewirkt eine
Veränderung der Abgastemperatur von +/- 8K
Flue gas temperature (°C)
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kW = Boiler output
°C = Flue gas temperature with reduced
heating surface, boiler ow temperature
80 °C, return temperature 30 °C (eld
measurement according to DIN 4702).
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO2natural gas H = 10.5 %)
- A reduction of the boiler water temperature of - 10 K e󰀨ec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % e󰀨ectuates
a change in the ue gas temperature of approx. ± 8 K.

4 215 983 / 01 17
INSTALLATION
4.4.2 Max-3 condens E (3000-5000) flue gas and output diagram
Max-3 condens E (VL 80 °C / RL 60 °C) flue gas and output diagram
62
64
66
68
70
72
74
76
78
80
82
84
86
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
Abgastemperatur (°C)
Kesselleistung (kW)
(5000)
(
4000
)
(3000)
- Betrieb mit Erdgas,
λ=1.14 bei Brenner-Vollast
(CO2Erdgas H: 10.5%)
kW = Heizkesselleistung
°C = Abgastemperatur bei gereinigter Heizfläche,
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 60°C
‐Eine Reduktion der Kesseltemperatur um - 10K
bewirkt eine reduktion der Abgastemperatur um ca. 6 - 8 K
- Eine Veränderung der Luftzahl l um +/- 0.09 bewirkt eine
Veränderung der Abgastemperatur von +/- 8K
Flue gas temperature (°C)
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kkW = Boiler output
°C = Flue gas temperature with reduced
heat ing surface, boiler ow temperature
80 °C, return temperature 60 °C (eld
measurement according to DIN 4702).
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO2natural gas H = 10.5 %)
- A reduction of the boiler water temperature of - 10 K e󰀨ec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % e󰀨ectuates a
change in the ue gas temperature of approx. ± 8 K.
Max-3 condens E (VL 80 °C / RL 30 °C) flue gas and output diagram
38
40
42
44
46
48
50
52
54
56
58
60
62
64
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000
Abgastemperatur (°C)
Kesselleistung (kW)
(5000)
(
4000
)
(3000)
- Betrieb mit Erdgas,
λ=1.14 bei Brenner-Vollast
(CO2Erdgas H: 10.5%)
kW = Heizkesselleistung
°C = Abgastemperatur bei gereinigter Heizfläche,
Kesselvorlauftemperatur 80°C, Rücklauftemperatur 30°C
‐Eine Reduktion der Kesseltemperatur um - 10K
bewirkt eine reduktion der Abgastemperatur um ca. 6 - 8 K
- Eine Veränderung der Luftzahl l um +/- 0.09 bewirkt eine
Veränderung der Abgastemperatur von +/- 8K
Flue gas temperature (°C)
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kW = Boiler output
°C = Flue gas temperature with reduced
heating surface, boiler ow temperature
80 °C, return temperature 30 °C (eld
measurement according to DIN 4702).
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO2natural gas H = 10.5 %)
- A reduction of the boiler water temperature of - 10 K e󰀨ec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % e󰀨ectuates
a change in the ue gas temperature of approx. ± 8 K.

4 215 983 / 0118
INSTALLATION
4.5 Minimum value limiting of boiler
return temperature
Hydraulic and control measures must be provided to en-
sure that the temperatures do not fall below the permis-
si ble minimum boiler ow and return temperature under
any operating conditions.
4.6 Discharge of start-up condensate
from the boiler
• When commissioning a cold boiler, condensate always
occurs within the boiler. This collects in the lower area
of the boiler (ue gas collector) and is then evaporated
through the boiler's continued heating up.
• The boiler should therefore – also for this reason – only
be started up without “network acceptance”, so that the
condensation temperature threshold (approx. 55 °C) is
exceeded as quickly as possible
• If necessary, the condensate which occurs can be
drained via the ue gas collector's cleaning tting (re-
move cap on the drain connection before starting the
burner, connect ball valve and temperature-resistant
drain hose).
NOTICE
•
When draining the condensate, it must be
en sured that no uncontrolled escape of ue
gas occurs in the installation room (do not
keep the ball valve open “constantly”, but
only drain o󰀨 the condensate “inter mit tently”).
•
The locally valid waste water regulations
must be observed when disposing of the
condensate!
As soon as the boiler has reached its minimum temper-
ature and this can be kept stable via the return boost,
the burner should be shut o󰀨 briey and the closure cap
mounted on the cleaning drain connection again.
• The drain connection on the boiler's ue gas collector is
not intended for the permanent connection of a drainage
line – frequent condensation in the area of the boiler is
impermissible!
4.7 Setting the temperature controllers
Basic setting of the controller is carried out by the heating
contractor.
4.8 Safety valves
The heating system and hot water supply must each be
protected with one safety valve against impermissible
over pressure. The discharge capacity of the heating sys-
tem safety valve must correspond to the boiler’s maxi-
mum nominal heat output. The valve is installed in the
safety ow. In Germany, only safety valves with the code
letter “H” in the approval mark may be connected, and
they must always be connected at the boiler safety ow.
4.9 Supply pump
(boiler with free-standing calorier)
Speed of rotation and output regulation must correspond
to the requirements of the free-standing calorier. Setting
carried out by the heating installation engineer.
4.10 Heating pump
Speed of rotation and output regulation must correspond
to the requirements of the system. They are to be set by
the heating installation engineer.
4.11 Heating connections
For boiler rooms adjacent to the domestic sphere, the
heat ing connections on the boiler are to be exibly con-
nected with compensators.

4 215 983 / 01 19
COMMISSIONING
5. Commissioning
5.1 Water quality
• Hoval boilers and caloriers are suitable for heating sys-
tems without signicant oxygen intake (system type I in
accordance with EN 14868).
• Systems with
- continuous oxygen intake (e.g. underoor heating
sys tems without di󰀨usion-proof plastic piping) or
- intermittent oxygen intake (e.g. requiring frequent top-
ping-up) must be equipped with a system separation.
• Treated heating water must be tested at least 1x per
year, or more frequently if specied by the manufacturer
of the inhibitor.
• On existing systems (for example if the boiler is re-
placed), where the quality of the existing heating water
meets the requirements of VDI 2035, re-lling of the
system is not recommended. The requirements of VDI
2035 also apply to replacement water.
• Before lling new systems and, where necessary, ex ist-
ing systems, the heating system must be professionally
cleaned and ushed. The boiler must not be lled until
the heating system has been ushed.
• All parts of the boiler/calorier which come into contact
with water are made of ferrous materials and stainless
steel.
• Due to the danger of stress corrosion, the sum of the
chloride, nitrate and sulphate contents of the heating wa-
ter must not exceed a total of 200 mg/l (ÖNORM H5195
stipulates that the limit value for chlorides is 30 mg/l).
• The pH-value of the heating water should be between
8.3 and 9.5 after 6 - 12 weeks of heating operation.
Filling and replacement water:
• As a rule, untreated domestic water is best suited as
l ling and replacement water for a system with Hoval
boilers. However, the quality of the untreated mains
water must still meet the requirements of VDI 2035 or
be demineralised and/or treated with inhibitors. The re-
quirements of EN 14868 must be met in this context.
• To maintain high boiler e󰀩ciency and prevent over-
heating of the heating surfaces, the values in table 1
must be upheld.
• The total quantity of lling and replacement water added
to the boiler over its service life must not be higher than
three times the system water content.
Table 1: Standard values for boiler and circuit water for circulation boiler (shell boiler)
Max. allowable operating pressure bar > 0.5 <= 25
General requirements colourless, free of undissolved substances
and foaming agents
pH value at 25 °C 8.2-11.5
Conductivity at 25 °C µS/cm < 1500
Total alkaline earths (Ca + Mg) 1) mmol/l < 0.02
°dH < 0.112
°fH < 0.19
Silica acidic capacity 8.2 2) (p-value) mmol/l 1-5
Silica (SiO2) mg/l < 100
Phosphate (P2O4) 3) mg/l 5-10
Sodium sulphite (Na2SO3) 3) mg/l 5-10
Iron mg/l < 0.2
Copper mg/l < 0.1
1) Previously specied in °dH, conversion: 1 mmol/l = 5.6 °dH (German hardness)
2) Previously specied as p-value, silica conversion 8.2 1 = p-value 1
3) Proof only required if respective dosing chemicals are used.
The following value does not have to be veried constantly during plant operation: silica (SiO2)

4 215 983 / 0120
COMMISSIONING
5.2 Filling the calorifier
(if fitted)
The boiler may be put into operation even when the
calori er is not lled.
5.3 Commissioning
Important:
At the time of initial commissioning, check that all safety
and control devices are functioning properly (in accor-
dance with the operating instructions).
The operation and maintenance of the system must be
explained to the user in detail.
In some areas, gas or dual-fuel systems may
only be commissioned by an engineer from
the local gasworks. Check with the local gas-
works to make sure.
5.4 Hand-over to the operator / safe-keeping
Have the operator conrm in writing that the operating and
maintenance procedures have been explained and that
he or she has received a copy of the relevant operating
manuals. The manufacturer of the unit is responsible for
providing operating instructions for the complete system.
This technical information / these assembly instructions
must not be destroyed after completing the commission-
ing procedures, but should be permanently stored with
the plant.