Hoval Max-3 plus series Manual

Technical information

Assembly instructions

Hoval products must be installed and commissioned

tions are intended exclusively for the specialist. Electri-

electrician.

Max-3 plus boilers are suitable and approved as

heat pro ducers for hot water heating systems with

permissible feed temperatures up to 110 °C1). They

are

designed forclosed systems according to EN 12828.

1) see point 3.2

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)

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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

2.2 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 boilercontrol 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

4.3 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

)0072-024(sulp3-xaMecnatsiser1.4.4 ................................................................................................ 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

4.2.3 Requirements for pressure limiter(s) in accordance with BSEN12828 42......................................................................................

2.1.1 Installation of the regulators Max-3 plus (420-2700)............................................................................. .. ............................... 5

Combustion chamber

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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

1.1 Other instructions

Depending on the application, any additional instructio-

ns can be found in the Hoval installation handbook! In

some cases the instructions are enclosed with the sep-

arately packed components.

Further information sources

- Hoval catalogue

- Standards, regulations

1.2 Safety information

The system may only be placed in operation if all the re-

levant standards and safety regulations have been com-

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.

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.

•

water boilers of rated inputs of between 70 kW (net)

and 1.8 MW (net) (2nd and 3rd family gases).

• -

trial and commercial premises.

• -

trial and commercial premises.

• IGEM/UP/2 Installation pipework on industrial and com-

mercial premises.

Regulations from the local building authority, insurance

companies and chimney sweeps must also be complied

with. When using gas as fuel, the regulations of the re-

permit may be required.

IGE/UP/10 Installation of flued gas appliances in indus-

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ASSEMBLY

1.4 Guarantee

Proper function is only guaranteed providing these inst-

ructions are followed and the boiler is regularly maintai-

ned by a licensed specialist (maintenance contract). The

minated operating materials (gas, water, combustion air),

unsuitable chemical additives and an inadmissibly high

lime content of the heating water, improper handling, faul-

due to the use of force do not fall under our guarantee

obligations; this also applies to corrosion due to haloge-

logen compounds, solvents and cleaning agents.

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

is not possible, or additional training is required, this can

be arranged through Hoval.

2. Assembly

2.1 Installing, levelling, boiler plinth

It is recommended to mount the Max-3 plus boiler onto a

the drain valve. For operating weights see chapter 3.

In the case of boiler installation in the domestic domain,

vibration dampers are to be mounted under the boiler

plinth rails.

Space requirement

for mounting the thermal insulation and sheet metal clad-

ding:

is to be at least 40 cm to the left and right hand sides

of the boiler.

completely thermally insulated and covered before being

introduced to the planned installation location.

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).

suitable plinth at least 150mm high to facilitate the fitting of

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-

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.

The cable must not contact any hot parts. Boiler door hinges must be changed over only by

Hoval Service!

Figure shows situation as delivered

(boiler door opens to the right)

Fig. 01

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ASSEMBLY

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):

-do not overtighten the straps (reduced insulating value)

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).

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.

Fig. 02

Max-3 plus (420, 530) = 1072

Max-3 plus (620, 750) = 1191,5

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ASSEMBLY

Fig. 03

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ASSEMBLY

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).

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) ø 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!