Hoval Max-3 plus Series Manual

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

2 4 214 283 / 00
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

4 4 214 283 / 00
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.
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.
•
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-

54 214 283 / 00
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-
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.
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)
1
2
3
3
1
2
Fig. 01
1

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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)
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.
Fig. 02
Max-3 plus (420, 530) = 1072
Max-3 plus (620, 750) = 1191,5
+3
0
+3
0

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ASSEMBLY
Fig. 03
1
4
3a
3
5
5a
5b
5c
2a
2b
2
1a
6

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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!
16. Fix the control box cover (9, Fig. 06) with self-tapping screws ø 3,5 x 6,5mm and serrated lock washers. 17. Insert 2 insulating mats (17) left and right in longitudinal direction
(to prevent vertical air circulation).
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.
Fig. 04
9b
Fig. 05
15b
15
9a
9c

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ASSEMBLY
Fig. 06
Fig. 07
7b
7
7a
8 13a
9b
9
15a
10
14
13 14b
11
18 18a
19
Fig. 08
8
14a17
21
12
14c

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ASSEMBLY
2.4 Mounting the thermal insulation Max-3 plus (1000-1250) 1. Wrap the insulating mats (1/1a, Fig. 10) 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)
3.
(The cleaning cover is replaced after mounting the cladding back wall (17, Fig. 13)
4. Place insulating mat (4, Fig. 10) on the pins welded to the rear wall of the boiler and secure with the retaining discs (Fig. 09). 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.
Fig. 09
Max-3 plus (1000,1250) = 1391,5 +3
0

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ASSEMBLY
Fig. 10
1a
1
22a
2b
33a
3b
4
5b
5
6
5c
5a

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ASSEMBLY
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. 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) ø 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
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).
Attention: The capillaries must not be kinked!
12. Fix the control box cover (9, Fig. 13) with self-tapping screws ø 3,5 x 6,5mm and serrated lock washers. 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). 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).
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.
Fig. 11
Fig. 12
11b
11
9a
9c
9b
Affix rating plate and manual storage case to the side. 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).

14 4 214 283 / 00
ASSEMBLY
Fig. 13
Fig. 14
7c
7
7a
810a
9b
9
11a
13
10b
10 10d
14
19 19a
17
Fig. 15 8
10c
15
7b
16
18
21
13a
18a
10e

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ASSEMBLY
2.6 Mounting the thermal insulation Max-3 plus (1500-2700) 1. Wrap the insulating mats (1/1a, Fig. 17) around the boiler body (joint at the side, black side outwards). 2. Secure insulating mats (1) with plastic straps (2) and strap fasteners (2a):
-
-do not overtighten the straps (reduced insulating value)
3.
the rear casing panel (14,15,16, Fig. 21).
4. Place insulating mat (4, Fig. 17) on the pins welded to the rear wall of the boiler and secure with the retaining discs (Fig. 16). 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

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ASSEMBLY
Fig. 17
1a
1
22a
2b
33a
3b
4
5b
5
6
5c
5a

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ASSEMBLY
2.7 Mounting the cladding and boiler control Max-3 plus (1500-2700)
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
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.
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
this purpose the pressure lock sleeves (18b, compress and pull away) as well as the earth screw and
serrated lock washer (18d) must be removed. Fix special screws (18f, Fig. 18) with locknut at sup- 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-
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
Attention: The capillaries must not be kinked!
14. Fix the control box cover (19, Fig. 21) with self-tapping screws ø3,5 x 6,5mm and serrated lock washers. 15. Mount cladding cover (20,21,22,23,24). 16. Fix bolts (25) with nuts and u-washers to the boiler door, then mount door cladding (25a, 25b).
Fig. 18
18e 18c
1819 12f
18f
18c
180°
18d 18c 18b 18e 18a
Fig. 19
Fig. 20
19c 19a
rner

18 4 214 283 / 00
ASSEMBLY
24
23
22
21
20
11
12
19b 25b 25a
25
17b 17a 18g1917
10
9
8
15
16
14
13
Fig. 21

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TECHNICAL INFORMATION
3. Technical information
3.1 Description of the boiler
water cooled reversing elbows and through the second pass compartment into the front reversing chamber. The th-
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
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.
The Max-3 plus boiler is a three pass design. The flue gases flow from the cylindrical combustion chamber into the

20 4 214 283 / 00
TECHNICAL INFORMATION
3.2 Technical data Max-3 plus (420-2700)
Type (420) (530) (620) (750) (1000)
0001057026035024WkC°06/08tatuptuolanimoN
• Range of output at 80/ 60 °C kW 147-420 185-530 217-620 263-750 350-1000
0501887156755144WkmumixamtupnirenruB•
Maximum operation temperature 1°C 90 90 90 90 90
)woleb(snoitidnocgnitarepoelbateesC°erutarepmetnoitarepomuminiM•
•)woleb(snoitidnocgnitarepoelbateesC°
•)woleb(snoitidnocgnitarepoelbateesC°
• Safety temperature limiter setting (water side) 2°C 110 110 110 110 110
6,9/66,9/66,9/66,9/66,9/6raberusserptset/gnikroW•
• Boiler efficiency at full load and 80/ 60 °C
(net calorific value / gross calorific value) natural gas % 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8 95,2/ 85,8
• Effciency at partial load 30%
(according to EN 303) natural gas
(net calorific value / gross calorific value)
% 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5 97,1/ 87,5
•
for natural gas firing % 87,2 87,2 87,2 87,2 87,2
05210811021153010001ttaWC°07taBqssolyb-dnatS•
• Flue gas resistance at nominal output
(Tolerance ± 20 %)
mbar 6,5 8,0 8,2 9,5 10,0
•
natural gas 10,8 % CO2 kg/h 680 859 1004 1215 1619
• Flow resistance boiler 3z-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 m³/h 36,0 45,0 53,0 64,0 86,0
•20 K m³/h 18,0 22,5 26,5 32,0 43,0
8251839969025255sertiltnetnocretawrelioB•
053,1278,0648,0206,0385,0³memulovsagrelioB•
0808080808mmydobreliobssenkcihtnoitalusnI•
53521381597117111111gk)gnisac.lcni(thgiew•
0632026109510001349gk)gnisactuohtiw(thgiew
• Combustion chamber dimension
Ø-inside x length mm 606/1624 606/1624 684/1899 684/1899 782/2182
740,1966,0966,0664,0664,0³memulovrebmahcnoitsubmoC•
• Dimensions see table of dimensions
•
(at boiler flue connection) Pa -50 -50 -50 -50 -50
Possible operating conditions:
saGlarutaNLEliognitaeHleuF
5756C°erutarepmetreliob.nim
5655C°erutarepmetnruter.nim
Return temperature control
(not by Hoval)
deriuqerderiuqer
1Limited by the boiler control to 90 °C (U3.1) or to 105 °C (U3.2)
2Maximum safety temperature for boiler control U3.1: 110 °C; for U3.2: 120 °C.
3Flow resistance boiler in mbar = volume flow (m /h) x z
4Excludes weight of burner.
10,8% CO2, 500 m above sea level
Dry
Dry•
4
4
2
Maximum chimney draft
3
natural gas
Part L seasonal efficiency (gross calorific value)