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

Technical information
Assembly instructions
Oil/gas heating boilers
Max-3 plus (420-2700)
These instructions are applicable to the following types:

1-Max-3 plus (420)
1-Max-3 plus (530)
1-Max-3 plus (620)
1-Max-3 plus (750)
1-Max-3 plus (1000)
1-Max-3 plus (1250)
2-Max-3 plus (1500)
2-Max-3 plus (1800)
2-Max-3 plus (2200)
2-Max-3 plus (2700)
Hoval products must be installed and commissioned

tions are intended exclusively for the specialist. Electrielectrician.
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 fo r closed systems according to EN 12828.
1)
4 214 283 / 00 - UK - 03/15
see point 3.2
EN
TABLE OF CONTENTS
1.
Important information
2.
Assembly
3.
4.
Installation
1.1
1.2
1.3
1.4
2.1
2.1.1
2.2
2.3
2.4
2.5
2.6
2.7
3.1
3.1.1
3.2
3.3
3.4
3.5
4.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.2.3
4.3
4.3.1
4.3.2
4.4
4.4.1
4.5
4.6
4.6.1
4.7
4.7.1
4.8
4.9
4.10
4.11
4.12
4.13
4.14
Other instructions ........................................................................................................................... . . . . ................................4

Safety information ........................................................................................................................... . . . . ................................4
Regulations, official approvals ........................................................................................................................... . . . . ............4
Guarantee ........................................................................................................................... . . . . ............................................. 5
Installing, levelling, boiler plinth ....................................................................................................... . . . ............................... 5

Installation of the regulators Max-3 plus (420-2700)............................................................................ . .. ........................... .... 5
Mounting the thermal insulation Max-3 plus (420-750) ................................................................................................. . . . . 7
Mounting the cladding and boiler control Max-3 plus (420-750) ................................................................................... . . . . 9
Mounting the thermal insulation Max-3 plus (1000-1250) ............................................................................................ . . . .11
Mounting the cladding and boiler control Max-3 plus (1000,1250) ............................................................................. . . . .13
Mounting the thermal insulation Max-3 plus (1500-2700)
.
............................................................................................ . . . .15
Mounting the cladding and boiler control Max-3 plus (1500-2700) .............................................................................. . . . .17
Description of the boiler ........................................................................................................................... . . . . .................... 19

Max-3 plus (420-2700) complies with the following directives + standards
... .......................................................................19
Technical data Max-3 plus (420-2700) ................................................................................................................. . . . . ..........20
Dimensions Max-3 plus (420-1250) .................................................................................................................. . . . . ............22
Dimensions Max-3 plus (1500-2700) .................................................................................................................. . . . ............22
Dimensions without thermal insulation and casing Max-3 plus (420-2700)
.
................................................................... 23
Boilerhouse Ventilation ........................................................................................................................... . . . . ...................... 24
Ventilation ................................................................................................................................................................... . . . . 24
Air Supply by Mechanical Ventilation - General Guidelines ........................................................................................ . . . . 24
Open Vented / Pressurised Systems ........................................................................................................................... . . . . .24
Open Vented Systems........................................................................................................................... . . . . ...................... 24
Pressurised Systems ........................................................................................................................... . . . . ....................... 24
Requirements for pressure limiter(s) in accordance with BSEN12828 ............................................................... ................... . . . . 24
Flues and Chimneys ........................................................................................................................... . . . . .......................... 24

General Guidelines ........................................................................................................................... . . . . .......................... 24
Fan Dilution Systems - General Guidelines ................................................................................................................. . . . . 25
Installing the burner Max-3 plus .................................................................................................................. . . ..........
.................26
Combustion chamber resistance Max -3 plus (420-2700) ............................................................................................
. . . . 27
Fuel ...................................................................................................................... ..... . . . . ..................................................... 28
Electrical connection ........................................................................................................................... . . . . .......................... 28
Electrical connection of burner ........................................................................................................................... . . . . .........28
Flue gas and output diagram ........................................................................................................................... . . . . .............28
Flue gas and output diagram Max-3 plus (420-2700) .................................................................................................. . . . . 28
Minimum value limiting of boiler return temperature .................................................................................................. . . . . 29
Setting the temperature controller........................................................................................................................... . . . . .....29
Boiler safety valve ........................................................................................................................... . . . . .............................. 29
Filling pump ............................................................................................................. .............. . . . . ........................................ 29
Heating pump........................................................................................................................... . . . . ...................................... 29
Heating connections ........................................................................................................................... . . . . .......................... 29
Installing a flue gas thermometer (optional item) ........................................................................................................ . . . . 29
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TABLE OF CONTENTS
4.15
4.15.1
5.
5.1
5.2
5.3
5.4
5.4.1
5.5
6.
6.1
6.2
6.2.1
6.3
6.3.1
6.4
6.4.1
6.4.2
6.4.3
6.5
6.6
6.7
6.8
6.9
6.9.1
6.9.2
7.
7.1
Gas Boosters .............................................................................................................................. . ...................................... 29

Booster Installation .............................................................................................................................. . .......................... 29
Commissioning
Water quality .............................................................................................................................. . ....................................... 31
Filling the heating system .............................................................................................................................. . .................. 32
Filling the calorifier .............................................................................................................................. . ............................ 32
Commissioning .............................................................................................................................. . ................................... 32
Commissioning Report .............................................................................................................................. . ..................... 33
Hand-over to the user/safe-keeping .............................................................................................................................. . ..33
Maintenance
Information for combustion controller/chimney sweep regarding emission monitor key ............................................. 34
Operating Instructions .............................................................................................................................. . ....................... 35
Starting up after cleaning the boiler or a Summer shut down. ......................................................................................... . 35
Inspection & Servicing .............................................................................................................................. . ....................... 36
Periodic Inspection .............................................................................................................................. . .......................... 36
Boiler & Burner Servicing .............................................................................................................................. . .................. 37
Boiler Cleaning for Heating Surface .............................................................................................................................. . .37
Summer Shut Down .............................................................................................................................. . ......................... 38
Burner Maintenance .............................................................................................................................. . ......................... 38
Oil Burner Fault Finding Chart .............................................................................................................................. . ...........40
Gas Burner Fault Finding Chart .............................................................................................................................. . .........42
Cleaning .............................................................................................................................. . .............................................. 44
Adjusting the hinged flange .............................................................................................................................. . ...............45
Lubricating the seal and thread .............................................................................................................................. . .........45
Lubricating the seal .............................................................................................................................. . .......................... 45
Lubricating the thread .............................................................................................................................. . ...................... 45
Overview of settings
Table of parameters .............................................................................................................................. . ............................ 46
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IMPORTANT INFORMATION
1.
1.1
Important information
Other instructions
Depending on the application, any additional instructions can be found in the Hoval installation handbook! In
some cases the instructions are enclosed with the separately packed components.
Further information sources
- Hoval catalogue
- Standards, regulations
1.2
Safety information
The system may only be placed in operation if all the relevant standards and safety regulations have been complied with. At least the following conditions must be satis-
water boilers of rated inputs of between 70 kW (net)

and 1.8 MW (net) (2nd and 3rd family gases).
IGE/UP/10 Installation of flued gas appliances in industrial and commercial premises.
trial and commercial premises.

IGEM/UP/2 Installation pipework on industrial and commercial 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 repermit may be required.
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 interlocked 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 installation and operation, in addition to current IEE Regulations,
other relevant British Standards and codes of practise,
Building Regulations and Local Authority by-laws:
BS EN 12831 Heating systems in buildings
Methods for calculating the design heat load
BS EN 12828 Heating systems in buildings
Planning of hot water heating systems.
Construction, design, safety requirements.
Construction, design, safety requirements, design and

execution (for gas burner operation).
BS 18160 Domestic chimneys, requirements, design
and construction.
VDI 2035 Prevention of damage through corrosion and
scale formation in hot water heating systems.
4 214 283 / 00
ASSEMBLY
1.4
Guarantee
Proper function is only guaranteed providing these instructions are followed and the boiler is regularly maintained 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, fauldue to the use of force do not fall under our guarantee
obligations; this also applies to corrosion due to halogelogen 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

suitable plinth at least 150mm high to facilitate the fitting of
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 cladding:
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 incline to the rear, by placing suitable underlays beneath the
plinth rail to ensure effective venting.
Mount the door liner (cladding) before installing the
burner. (for heating trials, with the boiler not yet
thermally insulated).
2.1.1 Installation of the regulators Max-3 plus (420-2700)

The regulators in the combustion chamber must be
installed into the 3rd pass tube bank as shown below.
3rd pass tube bank
4 214 283 / 00
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) to2.
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!
1
2
3
2
Figure shows situation as delivered

(boiler door opens to the right)
Fig. 01
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Before commencing to mount the cladding,

check the dimension between the top edge of the boiler plinth rail
and the retaining rail.
The remaining insulating mats (7a/17, Fig. 06) are put in place later on.
Fig. 02
6.
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).
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).
3.
2. Secure insulating mats (1/1a) with plastic straps (2) and strap fasteners (2a):
- do not overtighten the straps (reduced insulating value)
1. Wrap the insulating mats (1/1a, Fig. 03) around the boiler body (joint at the side, black side outwards).
2.2
ASSEMBLY
+3
Max-3 plus (620, 750) = 1191,5 0
+3
Max-3 plus (420, 530) = 1072 0
5a
5b
5c
1a
2b
2a
Fig. 03
3a
ASSEMBLY
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Mounting the cladding and boiler control Max-3 plus (420-750)
4 214 283 / 00
22.
21. Fix lead-through (21).
15
15b
20. Fix the cladding covers (18/18a) with self-tapping screws and replace the cleaning cover.
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).
18. Mount cladding covers (18/18a).
17. Insert 2 insulating mats (17) left and right in longitudinal direction
(to prevent vertical air circulation).
Fig. 05
16. Fix the control box cover (9, Fig. 06) with self-tapping screws 3,5 x 6,5mm and serrated lock washers.
Attention: The capillaries must not be kinked!
9b
9a
Fig. 04
9c
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).
14.
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.
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).
11. Attach the bottom rear wall (11) to the special screws in the rear side walls.
10. Mount the rear right side wall (10, Fig. 06) at the bottom to the pins mounted to the boiler plinth rail.
9. Remove the control box cover (9, Fig. 06). Attach the control box (9a, Fig. 04) with the cut-out for special screws to the cladding cover (9b) and secure with 2
self-tapping screws and serrated lock washers (9c) 3,8 x 6,5mm.
8. Attach shield plate (8) to the front of the boiler (Fig. 08).
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).
2.3
ASSEMBLY
10
Fig. 07
Fig. 08
Fig. 06
7b
7a
17
14a
14c
9b
13
14b
14
15a
12
18
13a
18a
10
11
21
19
ASSEMBLY
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4 214 283 / 00
(The cleaning cover is replaced after mounting the cladding back wall (17, Fig. 13)
Before commencing to mount the cladding, check the dimension

between the top edge of the boiler plinth rail and the retaining rail.
The remaining insulating mats (7a/7b/15, Fig. 13) are put in place later on.
Fig. 09
6.
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).
3.
2. Secure insulating mats (1/1a) with plastic straps (2) and strap fasteners (2a):
2.4
ASSEMBLY
11
Max-3 plus (1000,1250) = 1391,5 +3

0
12
5a
5b
5c
1a
2b
2a
Fig. 10
3a
3b
ASSEMBLY
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Mounting the cladding and boiler control Max-3 plus (1000,1250)
4 214 283 / 00
22. Affix rating plate and manual storage case to the side.
21. Fix lead-through (21).
20. Fix all the cladding covers (16/19/19a) with self-tapping screws and replace
the cleaning cover.
19. Position cladding cover (19/19a).
18. Mount the middle side walls (18/18a) at the bottom to the pins mounted to the
boiler plinth rail.
11
11b
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).
16. Position cladding cover (16).
Fig. 12
15. Place 4 insulating mats (15) left and right in longitudinal direction (to prevent vertical air circulation).
14. Attach the bottom rear wall (14, Fig. 13) to the special screws in the rear side walls.
13. Mount the rear side walls (13/13a) at the bottom to the pins mounted to the boiler plinth rail (Fig. 14).
9b
9a
Fig. 11
9c
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).
10. Install burner connector plug (10, Fig. 13) in the left or right side wall (Observe boiler door opening side, see point, 4.6.1 on page 28). Attach 2 C-clips (10a)
to the top of each side wall. Mount the front side walls (10b/10c) at the bottom to the pins mounted to the boiler plinth rail and route burner cable (10d) upwards
to the control (cable routing according to Fig. 13). Mount cladding cover (9b, Fig. 11) and fix with self-tapping screws. Plug in the burner cable (10e, Fig. 13).
9. Remove the control box cover (9, Fig. 13). Attach the control box (9a, Fig. 11) with the cut-out for special screws to the cladding cover (9b) and secure with 2
self-tapping screws and serrated lock washers (9c) 3.8 x 6.5mm.
8. Attach shield plate (8, Fig. 15) to the front of the boiler.
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).
2.5
ASSEMBLY
13
14
Fig. 14
Fig. 15
Fig. 13
7c
7a
10c
18a
15
10e
9b
7b
19
19a
10
10d
10b
13a
11a
16
10a
18
13
14
17
21
ASSEMBLY
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4 214 283 / 00
the rear casing panel (14,15,16, Fig. 21).
Fig. 16
6.
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).
3.
2. Secure insulating mats (1) with plastic straps (2) and strap fasteners (2a):
2.6
ASSEMBLY
15
16
5a
5b
5c
1a
2b
2a
Fig. 17
3a
3b
ASSEMBLY
4 214 283 / 00
Mounting the cladding and boiler control Max-3 plus (1500-2700)
4 214 283 / 00
16. Fix bolts (25) with nuts and u-washers to the boiler door, then mount door cladding (25a, 25b).
15. Mount cladding cover (20,21,22,23,24).
13. Pull capillaries with the immersion sensors (19a, Fig. 20) through the opening (19, Fig. 18), push into
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 supporting 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 burner connector (18g, Fig. 21) at electrical box.
11. Mount the supporting plate (18, Fig. 18) into the side panel.
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.
9.
8. Mount the left side walls (11,12,13) (to the top longitudinal strutting an the boiler plinth rail).
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
2.7
Fig. 20
Fig. 19
Fig. 18
18f
19
18
19a
19c
0
18
12f
18c
18e
18d
18c
18b
18a
18e
18c
ASSEMBLY
17
18
25
25a
25b
19b
11
12
13
20
21
22
24
17b
23
17a
17
19
18g
10
Fig. 21
15
14
16
ASSEMBLY
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TECHNICAL INFORMATION
3.
3.1
Description of the boiler
The Max-3 plus boiler is a three pass design. The flue gases flow from the cylindrical combustion chamber into the
water cooled reversing elbows and through the second pass compartment into the front reversing chamber. The third pass compartment comprises a bank of special dimpled Rillenrohre tubes through which the flue gases are conducted to the flue gas collector. Regulators are also fitted in the third pass tube bank.
Max-3 plus (420-1250) type
3.1.1 Max-3 plus (420-2700) complies with the following directives + standards
We hereby declare that the product described, as an individual appliance, complies with the standards, guidelines
Directives:
90/396/EG
73/23/EWG
89/336/EWG
97/23/EG
Gas appliance directive

Low voltage directive
Electromagnetic compatibility directive
Pressure equipment directive (PED)
Regulations:
Stability
Constructional requirements
Low voltage
EMV
prEN14394:2001
EN303-1, EN303-2, EN303-3
DIN VDE 0722 / Ed. 04.83
EN 50082 Part 1 / Ed. 01.92
4 214 283 / 00
19
3.2
Technical data Max-3 plus (420-2700)
Type
Nominal output at 80/ 60 C
(420)
(530)
(620)
(750)
(1000)
kW
420
530
620
750
1000
Range of output at 80/ 60 C
kW
147-420
185-530
217-620
263-750
350-1000
Burner input maximum
kW
441
557
651
788
1050
Maximum operation temperature 1

Minimum operation temperature
Safety temperature limiter setting (water side) 2
C
C
C
C
C
90
110
Working / test pressure

Boiler efficiency at full load and 80/ 60 C
(net calorific value / gross calorific value) natural gas
Effciency at partial load 30%
(according to EN 303) natural gas
(net calorific value / gross calorific value)
Part L seasonal efficiency (gross calorific value)
for natural gas firing
Stand-by loss qB at 70 C
bar
6/9,6
6/9,6
6/9,6
6/9,6
6/9,6
95,2/ 85,8
95,2/ 85,8
95,2/ 85,8
95,2/ 85,8
95,2/ 85,8
97,1/ 87,5
97,1/ 87,5
97,1/ 87,5
97,1/ 87,5
97,1/ 87,5
87,2
87,2
87,2
87,2
87,2
Watt
1000
1035
1120
1180
1250
mbar
6,5
8,0
8,2
9,5
10,0
kg/h
680
859
1004
1215
1619
z-value
mbar
mbar
m/h
m/h
0,022
28,5
7,1
36,0
18,0
0,022
45,4
11,4
45,0
22,5
0,008
22,6
5,6
53,0
26,5
0,008
33,1
8,3
64,0
32,0
0,003
22,0
5,5
86,0
43,0
litres
m
mm
kg
kg
552
0,583
80
1111
943
520
0,602
80
1171
1000
969
0,846
80
1795
1590
938
0,872
80
1831
1620
1528
1,350
80
2535
2360
mm
606/1624
606/1624
684/1899
684/1899
782/2182
0,466
0,466
0,669
0,669
1,047
-50
-50
Flue gas resistance at nominal output

natural gas 10,8% CO2, 500 m above sea level
(Tolerance 20 %)
natural gas 10,8 % CO2

Flow resistance boiler 3
10 K
20 K
10 K
20 K
Boiler water content

Boiler gas volume
Insulation thickness boiler body
Dry weight (incl. casing) 4
Dry weight (without casing) 4
Combustion chamber dimension

-inside x length
Combustion chamber volume
90
90
90
see table operating conditions (below)
110
110
110
Dimensions
2
3
4
110
see table of dimensions
Maximum chimney draft

(at boiler flue connection)
90
Pa
-50
-50
-50
Limited by the boiler control to 90 C (U3.1) or to 105 C (U3.2)

Maximum safety temperature for boiler control U3.1: 110 C; for U3.2 : 120 C.
2
3
Flow resistance boiler in mbar = volume flow (m /h) x z
Excludes weight of burner.
Possible operating conditions:

Fuel
min. boiler temperature

min. return temperature
Return temperature control
(not by Hoval)
20
C
C
Heating oil EL
Natural Gas
65
55
75
65
required
required
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(1250)
(1500)
(1800)
(2200)
(2700)
kW
1250
1500
1800
2200
2700
Range of output
kW
437-1250
525-1500
630-1800
770-2200
945-2700
Burner input maximum

Maximum operation temperature 1
Minimum operation temperature
Safety temperature limiter setting (water side) 2
kW
1313
1575
1890
2310
2835
C
C
C
C
C
90
110
bar
6/9,6
6/9,6
6/9,6
6/9,6
6/9,6
95,2/ 85,8
95,2/ 85,8
95,2/ 85,8
95,2/ 85,8
95,2/ 85,8
97,1/ 87,5
97,1/ 87,5
97,1/ 87,5
97,1/ 87,5
97,1/ 87,5
87,2
87,2
87,2
87,2
87,2
Watt
1380
1850
1950
2100
2300
mbar
12,0
10,0
12,0
13,0
13,0
kg/h
2025
2429
2916
3564
4374
z-value
mbar
mbar
m/h
m/h
0,003
34,4
8,6
107,0
53,5
0,002
33,0
8,3
129,0
84,5
0,002
47,6
11,9
154,0
77,0
0,002
71,1
17,8
189,0
94,5
0,002
107,1
26,8
231,0
115,5
litres
m
mm
kg
kg
1478
1,390
80
2643
2460
2343
1,956
80
3614
3266
2750
2,510
80
4693
4288
3050
2,761
80
5077
4647
3550
3,037
80
5649
5189
mm
782/2182
880/2415
980/2595
980/2895
980/3200
1,047
1,58
2,07
2,30
2,41
Max-3 plus Type

Nominal output at 80/ 60 C
Working / test pressure

Boiler effciency at full load and 80/ 60 C
(net calorific value / gross calorific value) natural gas
Efficiency at partial load 30%
(according to EN 303) natural gas
(net calorific value / gross calorific value)
Part L seasonal efficiency (gross calorific value)
for natural gas firing
Stand-by loss qB at 70 C
Flue gas resistance at nominal output
natural gas 10,8 % CO 2 , 500 m over sea level
(Tolerance 20 %)
natural gas 10,8 % CO 2

Flow resistance boiler 3
10 K
20 K
10 K
20 K
Boiler water content

Boiler gas volume
Insulation thickness boiler body
4
Dry weight (incl. casing)
4
Dry weight (without casing)
Combustion chamber dimension

-inside x length
Combustion chamber volume
90
90
90
110
110
110
Dimensions
2
3
4
110
see table of dimensions
Maximum chimney draft

(at boiler flue connection)
90
Pa
-50
-50
-50
-50
-50
Limited by the boiler control to 90 C (U3.1 ) or to 105 C (U3.2)

Maximum safety temperature for boiler control U3.1: 110 C; for U3.2 : 120 C.
Flow resistance boiler in mbar = volume flow (m3/h) 2 x z
Excludes weight of burner.
Possible operating conditions:

Fuel
min. boiler temperature

min. return temperature
Return temperature control
(not by Hoval)
4 214 283 / 00
Heating oil EL
C
C
Natural Gas
65
55
75
65
required
required
21
Dimensions Max-3 plus (420 -1250)
3.3
(Dimensions in mm)
1
k
10
3
o
3
4
h h1
2
6
w
t u
s
9
g
a
8
3.4
f
l1
10
Dimensions Max-3 plus (1500-2700)

(Dimensions in mm)
1 Flow
(420-530)
(620-750)
(1000-1250)
(1500-2200)
(2700)
DN 100, PN 6
DN 125, PN 6
DN 150, PN 6
DN 150, PN 16
DN 200, PN 16
2 Return
(420-530)
(620-750)
(1000-1250)
(1500-2200)
(2700)
3
4
5
6
7
8
9
DN 100, PN 6
DN 125, PN 6
DN 150, PN 6
DN 150, PN 16
DN 200, PN 16
10
Max-3 plus
Type
Flue gas outlet

Cleaning opening
Flue gas collector-cleaning opening R1"
Drain R 1"
Cable routing
Control panel
Electrical connection
Sleeve Rp " with immersion pocket for
boiler temperature sensor
h1
l1
(420-530)
(620-750)
(1000-1250)
1060
1180
1370
1190
1310
1500
515
550
635
1770
2045
2330
181
181
181
1435
1555
1755
1230
1350
1549
950
1050
1250
104
105
107
2178
2452
2739
2074
2347
2632
641
666
681
100
95
111
299
349
349
54
55
77
34
35
37
175
170
175
(1500)
(1800)
(2200)
(2700)
1560
1720
1720
1750
1610
1770
1770
1800
665
735
735
755
2745
3115
3415
3745
205
205
205
205
1700
1860
1860
1890
1350
1480
1480
1410
90
70
70
70
3030
3400
3700
4030
2940
3330
3630
3960
710
720
720
720
90
90
90
90
447
447
447
647
70
70
70
70
55
50
50
50
60
65
65
65
Max-3 plus
Type
(420-530)
(620-750)
(1000-1250)
350
550
415
595
722
620
660
786
685
(1500)
(1800)
(2200)
(2700)
310
310
310
330
792 995 1790 665

845 1046 1950 775
845 1046 1950 775
743 946 1980 760
22
1330 450
1445 475
1660 590
x
1850
2040
2340
2670
Notes: A safety valve must be fitted in the

boiler flow pipework directly between the
boiler and the downstream isolating valve
(by the installer). If fitting a boiler altitude
gauge, a 3/8 BSP socket should be fitted by
the installer in the flow pipework adjacent to
the boiler to enable connection of the
altitude gauge pipework.
4 214 283 / 00
3.5
Dimensions without thermal insulation and casing Max-3 plus (420-2700)
in
te
rn
al
(Dimensions in mm)
4
1
2
3
4
Max-3 plus
Type
Flow
Return
Flue gas outlet
Drain
a*
(420-530)
(620-750)
(1000-1250)
1920
2195
2480
150
150
150
1770
2045
2330
277
228
228
2222
2498
2783
1060
1180
1370
1180
1300
1500
196
196
160
120
120
120
1060
1180
1380
1376
1496
1660
2077
2353
2638
175
172
198
460
485
500
1072
1192
1392
(1500)
(1800)
(2200)
(2700)
2909
3281
3581
3913
164
166
166
168
2569
2759
3059
3390
260
430
430
430
3053
3415
3715
4048
1560
1720
1720
1720
1680
1840
1840
1840
170
170
170
170
120
120
120
120
1560
1720
1720
1720
1850
2010
2010
2010
2973
3355
3655
3988
240
430
430
430
510
510
510
510
Max-3 plus
Type
(420-530)
(620-750)
(1000-1250)
175
170
175
350
550
415
950
1050
1250
475
535
630
990
1110
1298
1330
1445
1660
150
145
150
1140
1260
1450
(1500)
(1800)
(2200)
(2700)
60
65
65
65
310
310
310
310
1350
1480
1480
1410
725
805
805
820
1498
1656
1656
1656
1790
1950
1950
1980
145
145
145
145
* Max-3 plus (1500-2700) boiler socket is protruding
4 214 283 / 00
23
INSTALLATION
4.
Installation
4.1
Boilerhouse Ventilation
Boilerhouse ventilation should conform
with the relevant British Standards, Codes
of Practice etc.
4.2.2 Pressurised Systems
For independently pressurised systems the vent connecve (sized to the relevant British Standard) and a pressure
4.1.2
Ventilation
switch. No intervening valve is permissible between the
Sufficient air must be supplied to each boiler to ensure
safety valve and boiler.
that the requirements of combustion and cooling are met The pressure switch should be interlocked with the boilers
and to afford a general level of ventilation in the plant ro- control circuit to safely close the burner down in the event
om.
of pressure loss.
In ALL cases the necessary ventilation to the Hoval Max-3 The pressurisation unit control should also be interloplus boiler must be in line with the requirements set out in cked with the boiler(s) controls to safely close the burner
down in the event of malfunction.
BS 6644, IGE/UP 10 and any local requirements.
Cooling air around the boilers must be sufficient such that
the temperatures in the installation location do not exceed down for proving its operation periodically. It should be
those listed in BS 6644.
interlocked with the burner control system.
4.1.3 Air Supply by Mechanical Ventilation - General Guidelines
The supply of air to a space housing the boiler by mechanical means should be mechanical inlet with natural or
mechanical extraction. Mechanical extract ventilation with
natural inlet must not be used.
Any mechanical means of entering air into a basement
boilerhouse should have a balancing outlet so that the air
pressure in the boilerhouse does not exceed 0.05" W.G.
(12.5 Pa).
Where mechanical inlet and mechanical extract system is
applied, the design extraction rate should not exceed one
third of the design inlet rate.
All Max-3 plus models should have an associated pressure limiter device fitted in the system pipework, as close
as possible to the boiler itself (provided by the installer not supplied, fitted or wired by Hoval).
If the operating pressure of the heating system exceeds
the given pressure limit, or in the case of auxiliary power
interruption, the pressure limiter shall shut off the heating
equipment and interlock it against restarting. The pressure
limiter shall be adjusted so that it responds before the safety valve(s) operate.
4.3
ted with automatic controls interlocked

with the boiler controls to give a safe
shutdown or lockout in the event of a malfunction.
4.2
Open Vented / Pressurised Systems
4.2.1 Open Vented Systems
A primary make up water and expansion tank is

required for open vented systems. With low head
Department should be consulted.
The cold feed pipe should be connected into the
return water piping on the boiler side of any valve.
An open vented connection is provided at the
boiler rear. The vent pipe should be installed with
a continuous rise to a position over the primary
feed tank.
A safety valve should be installed in a tee piece as
near to the boiler as possible with no intervening
valve. It should be sized to the relevant British
Standard.
24
4.2.3 Pressure limiter (in accordance with BSEN12828

clause 4.6.2.2.2 - Heating Systems in Buildings).
Flues and Chimneys

given in CIBSE and HVCA guides and also
Hoval Technical Data Sheets. Flues should
conform to the relevant British Standards,
Codes of Practice etc.
4.3.1 General Guidelines
ver possible for multi-boiler plants so that combustion

conditions are not disturbed by the operation of other
boilers. Consideration should be given to the condition
and condensation problems.
4 214 283 / 00
INSTALLATION
radius bends without horizontal runs before entering the

main chimney at a 45 are recommended and will cause the least resistance.
Flues should not be less in diameter than the boiler outlet connection size.
should provide a negative pressure condition at the boiler flue outlet of 50 pascals.
for further details.
4.3.2 Fan Dilution Systems - General Guidelines

In circumstances where the provision of a conventional or
tion of the boiler plant, a fan dilution system may be used.
9.7 boiler rating (kW)
should be positioned to cause the least disturbance to

the other gas stream (i.e. not opposite to each other).
Dilution fan capacity (m3/s) =

at normal
temperature and
pressure (N.T.P)
at the point of intersection with the header.
To adjust for the normal diluted outlet temperature of

50
3600 0.8
Header cross sectional areas should take account of

sation should be drained at the base of the vertical run.
Horizontal runs should drain away from the boiler.
Steps should be taken in designing to prevent or minimise condensation forming by using double skin and/or
insulated flue systems and suitable insulated brick stack or double skin steel chimney. This helps preven t
Where high gas outlet velocities are required from the
chimney, a coned outlet can be used. The additional
loss of draught due to this should be taken into account
in the chimney design.
Flues should be supported independently to prevent
undue weight and forces due to expansion being transmitted to the boiler outlet connection.
neys for cleaning and inspection purposes. Square tees

the burner.
IMPORTANT
A condensate drain point is provided in
be piped to drain via a drain trap to pre-
IMPORTANT
A condensate trap must also be fitted on
the boiler flue outlet to prevent condensate entering the boiler.
4 214 283 / 00
The dilution air intake should be independent of the boilerhouse combustion and ventilation air supply.
Velocities in the fan intake and exit ducts should not exceed 7.5 l/s to avoid ductwork resonance noise.
is generally required.
Attention is also drawn to the need to include the fan and
its proving switches as in the normal routine boiler maintenance programme.
Chimney sizes and height will need to take into account the following:
1. Clean Air Act.
2. Local Regulations.
3. Environmental Protection Act 1990.
4. Considerations to adjacent buildings.
5. Transmission of noise, particularly low frequency
sound pressure levels in quiet periods of the day
very close.
6. Flue gases discharged to the atmosphere which contribute to health dangers should be minimised by
maintaining the burner and boiler to ensure correct
time to a minimum and to maintain low levels of
CO2 (Greenhouse effect); CO and NOx ( d a n g e
r o u s g a s e s ) . C u r r e n t regulations for NOx
limits (1993) are maximum 260 mg/kWh (148ppm
at 0% O2). Burners supplied with Hoval boilers fully
meet this requirement.
25
INSTALLATION
4.4
Installing the burner Max-3 plus

Type (420-530)
Type (620-2700)
15
60
45
15
Type (420530)
4 x M12 (45)
4 x M12 (15)
Type (620750)
6 x M12 (15)
Type (10002700)
6 x M16 (15)
Opening of the boiler door

boiler door opens to the right or left
(Dimensions in mm)
Dimensions
Max-3 plus
Type
Dimensions
(420-530)
(620-750)
(1000-1250)
290
350
400
330
400
450
515
550
635
250
310
330
606
684
782
1624
1899
2182
163
163
163
30
30
30
420
500
550
(1500)
(1800)
(2200)
(2700)
380
380
380
420
450
450
450
480
655
735
735
735
385
395
395
410
880
976
976
976
2415
2595
2905
3233
191
191
191
191
30
30
30
30
550
550
550
600x560
(Dimensions in mm)
26
G + H
Max-3 plus
Type
(420)
(530)
(620)
(750)
(1000)
(1250)
(1500)
(1800)
(2200)
(2700)
1060
1060
1180
1180
1370
1370
1393
1553
1553
1585
150
150
150
150
150
150
58
58
58
58
4 214 283 / 00
INSTALLATION
and screws. On installing, comply with the guidelines

and instructions for mounting the burner to the heat
producer.
Burner matching
The boiler will normally be supplied by Hoval complete
with a burner which is CE marked and is CE approved
ternative burner, to comply with CE Directives, the boiler
must only be used with a burner having CE marking in
accordance with Directive 90/396/EEC and Standard EN
676 (Gas) or EN 267 (Oil). The fuel suppy requirements
will be stated on the burner data plate.
The burner CE approval must also be based on a test in
a test tank having dimensions no larger than the relevant
boiler combustion chamber dimensions.
Please consult Hoval Technical Department for further information, if required.

Sealing of the burner draught tube
A small annular space is necessary around the burner
draught tube in the door refractory to allow the burner
to be withdrawn. Seal this gap with the ceramic strip
supplied.
With gas and dual-fuel burners, the burner housing
Noise damping
- Gas pipelines are to be installed so that no vibrations
can be transferred to the building.
- The burner can be covered with an acoustic hood.
- It is recommended to incorporate a noise damper
4.4.1 Combustion chamber resistance Max-3 plus (420-2700)
13
18000
1250
12
11
1000
2700
1500
750
10
Combustion chamber resistance (mbar)
2200
530
420
620
7
6
5
4
3
2
1
0
100
200
300
400
500
600
700
800
900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Boiler output (kW)
4 214 283 / 00
kW = Boiler output
mbar = Flue gas resistance =1.11 (Natural gas: CO2 = 10.8%)
500 m above sea level (Tolerance: +/- 20%)
27
INSTALLATION
4.5
Fuel
Important!
A single phase 230V supply is required for
the control panel operation. Single phase
burners are electrically supplied via the
control panel. Three phase burners require a separate three phase isolated supply
(by the installer) direct to the burner, in-
The boiler is only to be operated with the fuel stated

on the boiler rating plate.
Max-3 plus boilers are normally suitable for burning the
following fuels:
- Heating oil EL according to DIN 51 6093 / SN 181
160/Z
- Natural Gas and propane
4.6
for boiler/burner door opening. In this

plug/sockets will still run between the
control panel and the burner. All power supplies to the boiler/burner/other associated equipment (ie: gas booster, separate
oil pump, etc.) should be isolated via the
same switched isolator.
Electrical connection
The electrical connection must be made by a licensed

located in the boiler control panel.
4.6.1 Electrical connection of burner
4.7
Flue gas and output diagram
4.7.1 Flue gas and output diagram Max-3 plus

(420-2700)
130
125
- 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 plus (1250

Max-3 plus (1800
Max-3 plus (530
Max-3 plus (1000
Max-3 plus (1500
Max-3 plus (420
Max-3 plus (620
Max-3 plus (2200
Max-3 plus (2700
Max-3 plus (750
120
Flue gas temperature (C)
115
110
105
100
95
90
85
80
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Boiler output (kW)
cleaned, boiler flow temperature 80C,

return temperature 60C (in accordance
28
- Operation with heating oil EL, natural

11 with max. burner output
(CO2
- A reduction of the boiler water tempera

ture of -10 K causes a reduction of the
flue gas temperature of approx. 6-8 K.
+/- 0,09
- A change in the air index
causes a change in the flue gas temperature of approx. -/+8 K
4 214 283 / 00
INSTALLATION
4.8
Minimum value limiting of boiler return

temperature
Hydraulic and technical control measures are to be implemented to ensure that the minimum boiler feed and return
temperatures are not fallen below.
4.9
Flue gas
temperature sensor
STB
Setting the temperature controller
Boiler temperature controller, selectable TR 65-85C

The basic setting is made by the heating installer. Selection and setting of the different heating programs according to operating instructions.
4.10
Boiler safety valve
Heating installations and hot water supply systems are to

be protected against inadmissible overpressure by safety
valves. The blow-off pressure of the heating system safety valve must correspond to the maximum rated thermal
Fig. 22
it's downstream isolating valve.

The capillary must not be kinked.
4.11
Filling pump
(boiler with separate calorifier)
Important note:
Speed and output regulation must correspond to the remade by the heating specialist.
4.12
Heating pump
routed on the top, along the boiler insulating mat,

towards the back.
4.15
Gas Boosters
Speed and output regulation must correspond to the reA booster is required when the gas pressure at the burner
made by the heating specialist.
4.13
Heating connections
In the case of boiler installation in the domestic domain,

xible compensators.
4.14
Installing a flue gas thermometer (optional

item)
Important
If a critical system is served it is good practise to install a duty/standby gas booster
set.
Gas Regulations require that no more than 0.5" WG pressure is lost due to pipe work resistance between the supply meter and the gas inlet.
A 3/8 sleeve with a max. length of 25 mm is to be welded
4.15.1 Booster Installation
control panel; see Fig. 22.
It is usually preferably to locate the boosters as near as

possible to the burner served rather than close to the meter.
Leave adequate access for servicing drive belts, fan
bearing assemblies, electrical motors and any acoustic
shroud.
Ensure that the room in which the gas booster is to be
installed is well ventilated and free from dust.
capillary through the rear wall between the external and

round insulation.
Screw the sensor tube into the sleeve.
4 214 283 / 00
29
INSTALLATION
Before running the booster the machine should be cleaned thoroughly, taking particular care to make sure
that pulleys and the belt are free from abrasive dust
etc, which may have settled on the machine during installation.
If the booster is in the boilerhouse then the ventilation
and air inlet louvres for the boiler will also serve for the
booster to keep the ambient temperature satisfactory,
providing the full recommendations for free area and
Standard boosters are designed to operate in ambient
temperatures not exceeding 40C. When the booster
is housed separately to the boiler, ventilation must be
provided to keep the ambient temperature below this.
Ventilation openings in this case must be sized relative
to any heat emitters in the room and the effects of solar
gain.
The booster control enables the booster to work autostop any excessive increase in operating temperature
and we recommend that the booster should only operate in conjunction with the burner. Prolonged periods
ase in temperature, shortening the life of the booster
and increasing service frequency. If however the plant
is required to work under such conditions, consideration should be given to the use of a purpose-designed
bypass to dissipate the excess heat and the installation
of a twin duty stand-by system to allow for regular insoperated regularly or in rotation. If the booster is operating in rotation auto cycling may have been installed
as an option.
Do not test the fan chamber assembly by

hydraulic pressure: this practice will inevitably damage the fan bearing assembly.
All booster assemblies are tested for gas

tightness by means of air at a pressure of
0.69 bar during manufacture.
For the same reasons, connecting pipework needs to

be accurately aligned and properly supported. The use
booster and pipework is strongly recommended. These
work system and eliminate strain on the fan chamber.
NOTE:
Flexible piping should be examined by
the operator on a monthly basis. Change
if there are any signs of deterioration or
cracking.
Changes in pipework sizing are best made close to the
booster ports. The use of expanders and reducers are
recommended to minimise pressure losses.
Where it is necessary to reduce or increase pipe sizes,
by changing cross section of pipework in easy stages.
Connections for pressure testing or for pressure switches should be located at points in the system where
there is not excessive turbulence i.e. where there is a
straight run of pipework at both sides of the switch (i.e.
at least 10 diameters of straight pipe).
NOTE:
If a gas booster is located in a meter/
governor room then the associated
electrical equipment, i.e:- control panel,
motor, pressure switches should be suitable for use in a Zone 2 area with group II
A gases (refer to BS4683, part 3).
proximately 450mm high to raise the unit to a convenient level.
Noise attenuation and absence resonance are best

obtained by supporting the booster on anti-vibration
mounts.
30
4 214 283 / 00
COMMISSIONING
5.
Commissioning
5.1
Water quality
water are made of ferrous materials and stainless steel.

On account of the danger of stress cracking corrosion
in the stainless steel section of the boiler the chloride,
nitrate and sulphate content of the heating water must
not exceed 50 mg/l.
Heating Water
The European Standard EN 14868 and the
directive VDI 2035 must be observed.
In particular, attention must be paid to the following stipulations:
The pH value of the heating water should lie between

8.3 and 9.5 after 6-12 weeks of heating operation.
Filling and replacement water

For a plant using Hoval boilers untreated drinking water
cording to EN 14868).
ing and replacement water. However, as not all drinking
Plants with
- continuous oxygen intake (e.g. underfloor heating
systems without diffusion proof plastic piping) or
- intermittent oxygen intake (e.g. where frequent refilling is necessary)
must be equipped with separate circuits.
VDI 2035. Should the mains water available not be

suited for use then it must be desalinated and/ or be
treated with inhibitors. The stipulations of EN 14868
must be observed.
least 1x yearly. According to the inhibitor manufacturers

instructions, more frequent testing may be necessary.
to avoid overheating of the heating surfaces the values

given in the table should not be exceeded (dependent
on boiler performance ratings - for multi-boiler plants
rating of smallest boiler applies - and on the water content of the plant).
water in existing installations (e.g. exchange of boiler)

conforms to VDI 2035.
The Directive VDI 2035 applies equally to the replacement water.
is used throughout the total service life of the boiler

must not exceed three times the water capacity of the
plant.
New and if applicable existing installations need to be
NOTE:
No continous make-up of water should be
taking place during boiler operation. In
this event check where a leak may be occuring or if pumping over is taking place.
Maximum filling capacity based on VDI 2035
[mol/m3] 1
fH
dH
eH
~mg/l
Conductance 2
Boiler size of the
individual boiler
50 to 200 kW
200 to 600 kW
over 600 kW
1
2
<0,1
<1
<0,56
<0,71
<10
<20
0,5
5
2,8
3,6
50,0
100,0
1
10
5,6
7,1
100,0
200,0
1,5
15
8,4
10,7
150,0
300,0
2
20
11,2
14,2
200,0
400,0
NO REQUI50 l/kW 20 l/kW 20 l/kW

RE50 l/kW 50 l/kW 20 l/kW
MENT
2,5
25
14,0
17,8
250,0
500,0
3
30
16,8
21,3
300,0
600,0
>3,0
>30
>16,8
>21,3
>300
>600
always desalinate
Sum of alkaline earths

If the conductance in S/cm exceeds the tabular value an analysis of the water is necessary.
4 214 283 / 00
31
COMMISSIONING
5.2
Filling the heating system
Filling and topping up water must satisfy the quality requirements according to VDI 2035.
5.3
The boiler should not be operated without the calorifier
the burner has not been damaged in transit or during

installation and that it is a suitable type for the fuel
available on site. The nameplate on the burner indicates for which type of fuel it is designed.
5.4
excessive space in the refractory opening around the

burner has been sealed with the supplied ceramic material.
Filling the calorifier

(where installed)
Commissioning
It is essential that the following points are completed by the Heating Engineer before commissioning
is requested through Hoval.
all items, packed in transit, are removed from combustion chamber.

boiler control thermostats are adjusted to suit system
System full of water and vented
Heating load available e.g. pumps working

Fuel purged to burner isolation valve
Oil bled to boiler isolation cock
Electrical connections made and correctly fused
Correct boilerhouse ventilation
Other manufacturers equipment has been installed and commissioned as necessary, e.g. pressurisation units.
the limit and high/low stats are set in accordance with

control details. See section 4.5.
the boiler relief valve setting is suitable for the system
(The setting should be at least 0.5 bar above the pressure).
oil supply pressure and temperature is suitable.
If the above are not completed and commissioning

is unable to commence, clients will be charged for
the aborted visit.
commissioning is in accordance with burner makers requirements.
Hoval Service Engineers normally commission all

new boilers and they will check the following:
controls are proved and stats are adjusted in line with

temperature indicated on the boiler thermometer.
including circulation pumps.
refractory to reach a uniform temperature through its

thickness thereby preventing any damage.
burner is adjusted to give optimum combustion, to-
an independently pressurised system is operating correctly. Suppliers of the equipment should adjust their
equipment during commissioning.
open if manually operated and if electrically operated

that the burner is interlocked electrically to prevent operation until the damper is open.
the Heating Engineer will have the opportunity to receive instruction on the correct operation of the plant during commissioning and to aquaint himself with the fault
pages 40-43. He will also be advised
on how much of the action columns can be dealt with
by site staff.
the electrical installation with the appropriate wiring

diagram for the boiler and burner and for correct fan
rotation.
32
4 214 283 / 00
COMMISSIONING
5.4.1 Commissioning Report
All settings both on boiler and burner will be recorded on
a commissioning report which will be supplied to the customers representative.
Fig. 23
5.5
Hand-over to the user/safe-keeping
Obtain from the user a written statement that operating

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

against invalid overheating during emission monitoring / manual operation it is
necessary to implement appropriate safety
measures (e.g. safety temperature limiter
with pump switch-off). The duration of the
emission monitoring is limited to 20 minutes and shall be restarted, if necessary.
Scalding hazard due to hot water temperature, since the hot water temperature can
exceed the temperature setpoint!
Emissions metering
Immediate end
PRESS
SHORTLY
Remaining time display
REACTIONS for emissions metering

Time unit automatically 20 min. thereafter reverts
Boiler temperature - > maximum temperature restriction
Regulate to the maximum temperature the heating circuits and the water heaters (at the direct heating circle only,
if the warm water mode of operation is adjusted to parallel operation)
With 2-step heat generator both stages are in operation
Manual operation
Immediate end
PRESS
> 5 seconds
REACTIONS for manual operation
Set reference boiler temperature with button!
All heating pumps ON
Mixer without current - manual setting necessary!
The hot water temperature reaches the set DHW maximum temperature (expert level standard 65C).
34
4 214 283 / 00
6.2
Operating Instructions
PLEASE READ: Important Notes for the
Boiler Attendant
These instructions are the minimum necessary to enable

an operator to start, run and stop the boiler.
They cover also the simple routine servicing procedures
plicable irrespective of the fuel used - gas or oil - BS class
D (35 sec).
If the heating system designer or installer has prepared
the whole plant, those instructions should be referred to
Instruments and Controls

Instruments are generally mounted at the top front of the
present, an altitude gauge may also be provided.
The basic controls for any boiler will be:
a. A sequence-control box (mounted on the burner)
Sequencing of boilers under BMS control.

When a bank of boilers are sequenced to operate under the dictates of a BMS control system, it is very important that on-line boilers are properly matched to
the available heating load at any one time.
This will avoid too frequent cycling of the burners as
they stop and start (introducing cold pre and post
purge air into the boiler each time this happens).
Over time this can result in the boilers suffering from
thermal shock and premature failure of the pressure
parts.
6.2.1 Starting up after cleaning the boiler or a Summer shut down.

Ensure that fuel lines are fully purged and that fuel is
available at the burner at the correct pressure and temperature.
some time, or if a fuel supply pipe has been disconnected, purge the piping via the bleed nipple up stream of the
burner to ensure that a gas/air mixture is avoided.
NOTE:
A gas/air mixture is dangerous as it will
explode if subjected to a spark.
pre-purge, ignition, pilot or reduced start, and proviother unsafe condition.

This control box will have advisible indication of lock
out and a manual-reset button for use in the event of
b. A control thermostat which allows adjustment of the
panel facia to discourage unauthorised adjustment
after it has been set by the commissioning engineer.
c. A safety-limit thermostat which comes into operation
should the control thermostat fail to shut the burner
down.The limit stat is usually set at 10C above the
control thermostats maximum setting. No automatic
control may be interfered with by the boiler attendant
gineer.
There may be special burner controls equipment or
additional controls to be integrated with the standard
burner control equipment. The function and setting
of these will be covered by the suppliers e.g. BMS.,
sequence controls high and low pressure switches
and water level controls, associated with independendently pressurised systems.
4 214 283 / 00
a singlepipe supply system, ensure that air is bled from

the system if the oil pipe has been disconnected.
Ensure fuel supply valves are open. Where a pump is incorporated in an oil fuel supply system, ensure the pump
is switched ON. Check all switches, e.g. time switch, and
thermostats are in the calling for heat condition. Switch
ON electrical supply to the burner at the main switch.
Switch the control panel mounted switch to ON. The burner control box should now monitor the burner through its
Normal Running
The boiler will switch on/off under the dictates of the control thermostat. The boiler temperature at any particular
moment can be seen from the boiler thermometer.
Allow the boiler to reach its set temperature and then
check the burner flame through boiler door sight glass;
through the burner inspection window. If any deterioration
is noted, the heating engineer should ensure the necessary action is taken.
35
6.3
Inspection & Servicing
which may be drawn into the burner and cause damage.
red to carry out work other than the following: boiler

cleaning, inspection of components for damage, star-
Examine all fuel and water valves, connection and burner etc, for obvious signs of damage or leakage, and
for security.
In an open-vented heating system, check:
- Level of water in the feed and expansion tank.
- That the ball valve is free to operate correctly.
- All air vents are operating correctly.
NOTE:
No continuous make-up of water should
be taking place. (In this event check where a leak may be occurring or if pumping
over is taking place).
No special equipment is required for normal boiler

servicing.
Tools for cleaning the boiler heating surfaces are
provided with the boiler. If a hard scale forms from oil
um (e.g. Carbonex by Arrow Chemicals Ltd) is advantageous for softening and easier removal of such
deposits.
The service engineers equipment will include any netest kit.
6.3.1 Periodic Inspection

The following periodic inspections should be made between main servicing periods.
Examine boiler casing panels for obvious signs of damage, corrosion or other deterioration, and for security.
On the boiler door, examine the ceramic-strip seal, and

detected by heat marks or deterioration of the metal
ring holding the joint. In the event of such signs, replace
the burner tube and the door lining for deterioration.
Replace when required.
Initially examine boiler interior after one month when
using class D oil to determine necessity for boiler cleaning. When heavy oil is being used, examine after two
weeks. The amount of use, the number of cold starts
involved, and the mean operating temperatures all affect the rate of soot and scale formation.
A consistent pattern will then be established to determine the frequency of cleaning required. With gas much
longer periods between cleaning are usually possible.
If condensation occurs due to low return water temperatures then a build up can occur more quickly. Establish a pattern to see if cleaning can coincide with
service visits.
leads to wasted heat and an increase in the boilerhouse

ambient temperature).
Similarly inspect the cleaning explosion door at rear of

boiler.
On oil/gas burners periodically remove photo electric

ultraviolet cell and clean the window of the cell.
should initially be more frequent until a reason- able,

consistent pattern can be established.
partial blockage, debris, etc.

Ensure that condensation drains at the chimney base
connected to a drain pipe with a water trap.
36
at the initial commissioning. Report any unusual alterations in this respect.

Report any occurrences which indicate that the boiler, the
correctly.
4 214 283 / 00
6.4
Boiler & Burner Servicing
In addition to the periodic inspections given on page 36 it

is recommended that a complete check is carried
out on all components at appropriate intervals.
4. Where rigid fuel pipes to burner are employed, e.g.

gas burners, disconnect pipe(s) to allow the boiler
door to open.
5. Fully open the boiler door complete with burner.
NOTE:
Lengthy periods between cleaning should
only be resorted to when the periodic inspections prove this is possible.
service engineer, ideally under an annual sevice and

maintenance contract.
Hoval Service Department normally provides this service
and will be pleased to provide a written quotation on request. This would typically cover the operation, cleanliassociated controls. In the case of gas burners it would
include a check on the gas tightness of the gas control
valves at the burner if a gas leak detection unit is not
6. Clean the tubes using the supplied brush. Similarly

clean the combustion chamber when required. Avoid
damage to the ceramic sealing strip against which
the door closes.
NOTE:
Where any hard scaling is present, use a
propietary cleaning medium to soften and
assist removal.
could also be covered in this service.

Please note:
No adjustment of internal components is
permissible on either gas or oil burners
neer.
make a monthly leak test on these pipes.
6.4.1 Boiler Cleaning for Heating Surface

Frequency of cleaning will be dependent on usage in conjunction with the condition of the boiler at the periodic
inspections, but the minimum requirements when using
the various fuels are:
Gas (natural or LPG) - once per heating seaon
Oil BS Class D (35 sec) - twice per heating season
Oil heavy grades - 3 to 4 times per heating season
1. Run the boiler until the burner automatically switches
off under action of the control thermostat. (It is easier
to clean a warm boiler).
2. Switch OFF electrical supply to the burner. Where a
to the burner, disconnect at this point. Switch OFF
electrical supply to the booster.
NOTE:
Where heavy oil is being used on a circulatory fuel system, ensure that fuel
pump(s) heaters and tracers are left in
operation at all times.
3. Turn OFF all fuel shut-off valves at the burner.
4 214 283 / 00
7. Remove rear cleaning/explosion door. Clear loose

soot from the smoke outlet box and thoroughly clean
the box. Clean and examine the boiler backplate; no
hard deposit should be present. Remove any build
up occuring between the projecting tube ends.
8.
9. Check conditions of cleaning/explosion door gasket.
tighten the wing nuts only two full turns against spring
compression.
10. Check condition of boiler door ceramic seal. Insal around burner tube. Minor damage to insulating
le refractory (e.g. Pyruma) on refractory lined doors.
suffer damage in normal use but in the unlikely event
please consult Hoval. Any serious damage must be
reported to the Service Engineer for repair. Filler
material can be repaired similarly. The door sealing
strip must be in good condition and must be replaced
when an effective seal cannot be obtained under normal pressure. Replace sealing strip annually. Refer
to Burner Maintenance Instructions Page 38 whilst
the door is open.
11. Close the boiler door, and evenly tighten the nuts
using a tommy bar/spanner.
12. If disconnected, plug in the boiler/burner electrical
connection.
37
13. Check boiler door is effectively closed (ineffective
closure will be detectable by sight or smell).
14. It is recommended that, when the boiler has becomade by the Service Engineer.
15. If the boiler is not immediately to be used, switch OFF
electrical supply to burner and turn OFF fuel supply.
Where using heavy oil do not switch off fuel heaters
and tracers. Switch off electrical supply to gas booster.
Starting and Stopping

Emergency Stop
The burner can be stopped in an emergency by
switching off the mains isolating switch provided on the
line between the burner and the electric supply. The installer must identify the switch. Check position of this
switch or any panic button available.
Check the Burner Operation
call the service engineer.
6.4.2 Summer Shut Down

If the boiler is to be out of operation for a long period,
e.g. during the Summer, the boiler interior should be
thoroughly cleaned.
Atmospheric condensation, activating acidic deposits in
the boiler, is responsible for considerable corrosion and
metal wastage. Every effort should be made to reduce
this by the most thorough cleaning and by keeping the
boiler dry.
A tray of absorbing material placed in the combustion
chamber is helpful in this respect. Close the boiler door.
When cleaning the room housing the heater unit, always switch off the burner to reduce the amount of dust
and lint drawn in through the air inlet.
Preventive Maintenance
Consult your heating engineer for advice on regular
prevetive maintenance intervals.
16. Gas Supply
Should the gas supply be interrupted, the system may
require venting of air that may have accumulated,
before the burner is restarted. This is achieved by unscrewing the pressure test point situated down-stream
of the main govenor or combination valve and venting
the air to atmosphere until gas has reached the test
point.
6.4.3 Burner Maintenance

Before carrying out any work on the burner ensure
that the main electrical isolating switch is locked in
the OFF position and the fuel isolating valve closed.
operator and are intended to be of assistance in making

maintenance, cleaning and lubrication. Additional information can be obtained through your installer or from the
manufacturer.
Fuel
The unit is designed to burn the fuel stated on the burner nameplate. Under no circumstances must any
other type of oil or gas be used.
In the case of burner fuel conversion, check to see that
the fuel used corresponds with that marked on the new
burner nameplate.
38
WARNING:
No smoking or naked lights to be allowed
as a gas/air mixture is dangerous.
Periodical examination of all pipework should be carried out. The recommended method is to brush a soap
solution around all the jointed areas. A leak in the system would have the effect of forming bubbles.
CAUTION:
Do not place any items in the boiler combustion chamber as it is not suitable for
burning waste.
Oil pump
See burner manufacturers manual.
Gas train items and gas leak detectors
For maintenance of these units refer to the manufacturers manual.
4 214 283 / 00
Motor
Keep the burner motor clean and dry. Any deposits
of dust or lint should be blown out occasionally. On
motors provided with oiling holes, a few drops of high
quality SAE 20 oil should be injected every six months.
Surplus lubricant spreading from the bearings should
be wiped away. Some motors have sealed-for-life bearings; these require no maintenance.
Fan Runner
Keep the fan blades clean and free from oil and build up
of dust or deposits picked up from a dusty boilerhouse.
Oil Strainer/Filter
Replace filter element annually.
Nozzles, Flame Plate and Electrodes
Maintenance by the boiler operator is usually limited to
checking the condition of these items only whilst the
boiler door is open. Servicing the oil or gas nozzle,
which may require dismantling, and replacement of
parts should be left to the service engineer.
The boiler operator may wipe off deposits of soot and
disturb the parts. Check the electrodes are set correctly after referring to the burner manufacturers manual.
Flame Sensor
violet cell for gas or photo-electric cell for oil with methylated spirit on a lint free cloth. Do not handle window
NOTE:
ing to remove the burner inner assembly.
4 214 283 / 00
39
6.5
Oil Burner Fault Finding Chart

NOTE:
.
Symptom
Possible Cause
Action
A.
1.
Electrical supply failure
1.
Check the following:

a. Main isolating switch of the burner is on.
b. Overload protective device of
the burner motor.
2.
Control thermostat time or water 2.

pressure switches or other boiler
systems controls at fault
Check that power is available at the

control panel and all switches are
closed.
3.
Manual reset on limit thermostat 3.
Reset and check also control stat

setting and operation.
4.
When using heavy oil tempertures 4.

incorrect in oil piping or in burner
preheater
Check temperatures: ensure preheating equipment is operating.
No ignition spark.
1.
Switch off burner. Check spark plug

gap. Check H.T. leads and connections. Check and clean ignition
electrode(s) and insulator
2.
No oil spray into combustion cham- 2.

ber but pressure indicated on bur-
Open door and check whether oil

has been sprayed into combustion
chamber; if no evidence of spray,
clean or replace burner nozzle(s).
3.
No oil spray into combustion cham- 3.

ber and no pressure indicated on
the oil gauge.
Check as above. If no spray, check

the following:
c. There is oil in the fuel tank.
d. All necessary valves are open.
e.
f. There is no airlock in the fuel
pump (listen for any unusual
sound from pump).
g. For air leakage into the fuel
feed pump.
h.
closed in oil line.
Burner lights but rapidly 1.

extinguishes.
Dirty photocell (causing lockout 1.

action).
2.
Faulty photocell (causing lock-out 2.

action).
B.
C.
40
Burner will not start
Burner starts i.e. burner 1.

motor runs but will not
light and burner goes to
lockout.
Replace cell with new.
4 214 283 / 00
Symptom
D.
Possible Cause
- 1.
mes from burner. Flame
shape alters from normal. Boiler door becomes hotter than usual.
2.
Action
Air inlet damper accidently masked 1.
Clear obstruction.
Alteration to air inlet damper

sition.
Reset damper and make a combustion check (special instruments

required).
3.
po- 2.
- 3.
Replace nozzle(s).
ted.
4.
Incorrect nozzle(s).
4.
Replace with correct nozzle(s).
5.
Excessive oil pressure.
5.
Reset pump pressure regulator.
6.
cked or re
per closed.
- 6.
stricted. Flue dam-
7.
7.
Call Service Engineer to correct

and replace if necessary.
8.
Check for damage, replace if damage severe.
misplaced or faulty.
8.
4 214 283 / 00
Door refractory failure.
and check why it became closed.

Clear blockage or restriction.
41
6.6
Gas Burner Fault Finding Chart

NOTE:
.
Symptom
Possible Cause
Action
A.
1.
E lectrical supply failure
1.
Check:
a. Main isolator switch is on and
power is available at the control
panel.
b. Overload protective devices of
2.
Air pressure switch on burner not 2.

operating.
Switch contacts must be in the burner start position. Check switch is
3.
Control thermostat, time, water 3.

pressure switches or other boiler
system controls at fault.
Check:
That all switches are closed
Booster is not locked out due to low
inlet gas pressure and that pressure
switches function correctly.
4.
Reset and check. Also check control thermostat setting and operation.
No ignition spark.
1.
See action B1.
2.
Gas starvation.
2.
Purge gas pipe, check pilot valve

operation.
3.
Ultra-violet cell fault.
3.
Remove, clean and check connections and replace if necessary.
B.
Burner will not start
Burner starts i.e. burner 1.

motor runs but will not
light and burner goes to
lockout.
C.
Burner motor starts but 1.

stops and re-cycles.
Air pressure switch on the burner.
1.
Check:
c. burner damper is open to usual
extent.
d. air inlet to switch is not blocked.
e. switch is not stuck.
f. electrical connection.
D.
Burner shuts down du- 1.

ring operation and recycles.
As C1 above.
1.
As C1 above.
E.
Burner shuts down du- 1.

ring operation and goes
to lockout.
Flame failure.
1.
Check gas supply and pressure.
Ultra-violet cell fault.
2.
As B3 above.
2.
42
4 214 283 / 00
Symptom
F.
G.
H.
Possible Cause
Burner lights on pilot but 1.

burner locks out after 3 - 2.
4 seconds.
Smell of gas local to the 1.
appliance.
Combustion noise beco- 1.

- 2.
mes yellow. Boiler door
becomes hotter than
3.
usual.
4.
Ultra-violet cell faulty
Action
1.
As B3
Ultra-violet cell is not receiving a 2.
Clean cell and check correctly in-
Leakage from pipe line joints or pi- 1.

lot or that the main gas valves are
not gas tight.
Switch OFF burner and check pipe

line joints with soap solution.
2.
Close pilot manual valve and then

main manual valve at the burner to
see if this isolates the problem.
Call gas engineer to check the automatic valves. Do not operate until
this has been done.
Air inlet accidentally masked.
1.
Clear obstruction.
Air inlet damper position moved.
2.
Call Service Engineer to reset and

make a combustion check.
Burner head parts have moved, 3.

become worn or overheated.
Call Service Engineer to adjust

or replace and make combustion
check.
Gas pressure alteration.
5.
4.
- 5.
Check and clear restriction.
cked or restricted.
6.
4 214 283 / 00
Door refractory failed.
6.
Replace if damage is severe.
43
6.7
Cleaning
Inadequate cleaning not only results in increased fuel

consumption but also shortens the life of the boiler.
The boiler is to be cleaned by a specialist twice a year
Switch off the main switch
Remove burner plug and switch off the fuel supply
Unscrew the hexagon sealing nut with hole (1, Fig. 24)
using the steel mandrel supplied.
Attention: The sealing nuts without a hole must on no
account be unscrewed
Open the boiler door and swing out burner.
Remove the retarders from the third pass tube bank
(4, Fig. 26) and clean them.
Fig. 24
Thoroughly clean combustion chamber (2), second

a
compartment (3) and third compartment (4) using
brush or spray.
Take off the cleaning cover (5, Fig. 25) at the back, on
ector.
Brush off the boiler back wall and the space between
the ends of the pipes.
5
6
ector at the connector (6).

Refit the third pass tube bank retarders.
Reclose and seal the cleaning apertures.
Fig. 25
Close the boiler door and tighten the screws.

Plug the burner back in and switch on the boiler.
2
Fig. 26
44
4 214 283 / 00
6.8
Adjusting the hinged flange
After a long period of use, the contact pressure between

boiler doors and boiler body can diminish. This impairs
The boiler is therefore to be periodically checked for leaks
Procedure:
With the boiler door closed, screw lock nut (1, Fig. 27)
forward and tighten; in this way this side becomes the
fulcrum point.
ca. 1 cm
Open lock nut (1) and turn back approx. 1 cm.
Fig. 27
6.9
Lubricating the seal and thread
6.9.1 Lubricating the seal
Reversing chamber
Combustion chamber
6.9.2 Lubricating the thread
Apply protective agents if the boiler is out

of service for long periods
4 214 283 / 00
45
7.
Overview of settings
7.1
Table of parameters
Designation
Regulator
Factory
10
20
30
40
50
Setting range /
Setting values
Type of device:
DHW:
SW:
Address:
Surface operation
Key :
Heating curve HC
OFF
OFF, 0,20 .... 3,5
Heating curve MC1
1,0
OFF, 0,20 .... 3,5
Heating curve MC2
1,0
OFF, 0,20 .... 3,5
Daytime target temperature HC
*)
20C
5 .... 30C *)
Daytime target temperature MC1
*)
20C
5 .... 30C *)
Daytime target temperature MC2
*)
20C
5 .... 30C *)
Night-time target temperature HC
*)
16C
5 .... 30C *)
Night-time target temperature MC1 *)
16C
5 .... 30C *)
Night-time target temperature MC2 *)
16C
5 .... 30C *)
DHW target temperature
50C
5 ... DHW-Max.
*) Depending on the setting of system parameters 03 OPERATING MODE
Remote operation/room stations

Type
46
Heating circuit
Address
HW
SW
4 214 283 / 00
Table for Time programs

DHW circuit
Time program P1
Tag
Cycle 1
from
to
Cycle 2
from
to
Time program P2
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Time program P3
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Cycle 3
from
to
Mo
Tu
We
Th
Fr
Sa
Su
Direct circuit
Time program P1
Tag
Cycle 1
from
to
Cycle 2
from
to
Time program P2
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Time program P3
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Cycle 3
from
to
Mo
Tu
We
Th
Fr
Sa
Su
Mixer Circuit 1
Time program P1
Tag
Cycle 1
from
to
Cycle 2
from
to
Time program P2
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Time program P3
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Cycle 3
from
to
Mo
Tu
We
Th
Fr
Sa
Su
Mixer Circuit 2
Time program P1
Tag
Cycle 1
from
to
Cycle 2
from
to
Time program P2
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Time program P3
Cycle 3
from
to
Cycle 1
from
to
Cycle 2
from
to
Cycle 3
from
to
Mo
Tu
We
Th
Fr
Sa
Su
4 214 283 / 00
47
HYDRAULIC
Par.
Designation
Factory
10
20
30
40
50
Lev.
Function allocation of the output DHW charging pump
HF
Function allocation of the output Mixer circuit 1
HF
Function allocation of the output Mixer circuit 2
HF
Function allocation of the output Direct circuit Pump
HF
Function allocation of the variable output 1
OFF
HF
Function allocation of the variable output 2
OFF/ 4/ 43
HF
Function allocation of the variable input 1
OFF
HF
OFF
HF
10
OFF/ 2/ 33
HF
11
Indirect return increase
OFF
HF
12
Maximum limit energy management
80 C
HF
13
Activation cooling buffer
OFF
HF
14
Release contact cooling to KVLF
OFF
HF
SYSTEM
Par.
Designation
LANGUAGE Selection of the style-language
EN
10
20
30
40
50
Lev.
BE
Number of cleared switching time programs
Clearing for separate operating mode
Limit temperature for summer disconnection
22 C
HF
System frost protection
3 C
HF
P1
HF
HF
Demand contact module for VE1
HF
HF
Air conditioning zone
10
Building type
Automatic reversion time (surface end user level, except
info. level)
Pump and mixer compulsory operation
11
12
13
14
15
Logical fault signal

Automatic SET function
(after 24:00, is automatically set to OFF)
Blocking code for heating Installer
HF
-12 C
HF
HF
5 min
HF
ON
HF
OFF
HF
ON/ OFF
HF
OEM
OFF
HF
30 min
HF
HF
OFF
HF
18
Release cycle temperature
19
Frost protection mode
21
RTC adjustment
23
Blocking code operator level
24
Temperature display in Fahrenheit
OFF
OEM
26
First commissioning date (after 24:00)
OEM
27
Fault report (only TTT/UG)
HF
28
Fault stack 2
ON
HF
29
Characteristic curve emergency operation
0 C
HF
30
Thermostat function sensor allocation
31
Thermostat function reference value
32
33
RESET
48
Factory
AF
HF
1 C
HF
Thermostat function switching difference
3K
HF
Thermostat function anti-blocking protection

Top: ArtNo - HW Index
Bottom: Code:REV - Software version
Reset parameter values
ON
HF
-----
OEM
BE
4 214 283 / 00
DHW
Par.
Designation
DHW-NIGHT DHW - economy temperature
Factory
10
20
30
40
50
Lev.
40/ 45 C
BE
DHW-legionella protection-day
OFF
HF
DHW-egionella protection-time
HF
DHW-legionella protection-temperature
DHW-temperature recording
DHW-maximum temperature limit
DHW-mode of operation
2:00
50/ 55/ 65/
70 C
1
50/ 55/ 65/
70 C
1
DHW-tank discharge protection
DHW-charging temperature excess
10
DHW-switching difference
11
DHW-charging pump follow-on
12
ZKP-switching time program
13
ZKP-economy interval (pause)
14
ZKP-economy interval (period duration)
17
H-GEN behaviour during SLP follow-on time
18
DHW-parallel loading
19
DHW-time-out
20
PI-reference value control
21
22
PI-scanning time Ta
23
PI -reset time Tn
HF
HF
HF
HF
HF
ON/ OFF
7/ 20 K
HF
5K
0.5/ 1/ 2/ 5
min
AUTO
OEM
0 min
HF
OEM
HF
20 min
HF
AUTO/ OFF
HF
OFF
OFF/
30 min
OFF
HF
HF
0,1 %/ K
OEM
20 s
OEM
600 s/ C
OEM
HF
UNMIXED CIRC
Par.
Designation
Factory
10
20
30
40
50
Lev.
Type of reduced operation
ECO/ ABS
HF
Heating system (exponent)
DK= 1,30
HF
Room override (in connection with room sensor)
HF
Room factor
OFF
HF
Adaptation heating curve
OFF
HF
Switch-on optimisation
HF
Heating limit
0,5
OEM
Room frost protection limit
10 C
HF
Room thermostat function
OFF
HF
10
Outside temperature allocation
HF
11
Constant temperature reference value
20 C
HF
12
Minimum temperature limit
10 C
HF
13
Maximum temperature limit
55/ 75 C
HF
14
Temperature elevation Heating circuit
DK=0
HF
15
Pump follow-on
5 min
HF
16
Screed function
OFF
HF
23
Room control K-factor
HF
24
Room control Tn-factor
35 min
HF
25
Vacation mode
STBY
HF
36
Minimum value override

Name heating circuit (max. 5 letters)
4 214 283 / 00
OFF
HF
XXXXX
HF
49
MIX. VALVE-1
Par.
Designation
10
20
30
40
50
Lev.
ECO/ ABS
HF
MK= 1,10
HF
Room factor
HF
100 %
HF
ON
HF
HF
Heating limit
0,5
OEM
10 C
HF
OFF
HF
HF
20 C
HF
10
11
12
10 C
HF
13
55/ 75 C
HF
14
Temperature elevation/ abatement heating circuit
0/ 8 K
HF
15
Pump follow-on
5 min
HF
OFF
HF
2,0 %/ K
OEM
Scanning time Ta
20 s
OEM
I-portion Tn
270 s
OEM
21
Running time servomotor
150 s
HF
22
End position function, valve
OEM
23
HF
24
35 min
HF
25
Vacation mode
STBY
HF
36
OFF
HF
37
Mixer lead time
OFF
HF
HF
OFF
HF
16
Screed function
18
P-portion Xp
19
20
38
Regulation offset
50
Cooling switch-on point, OT
51
Cooling max. point, OT
52
53
35 C
HF
18 C
HF
24 C
HF
54
Cooling reference room temp. at switch-on point
23 C
HF
55
Cooling reference room temp. at max. point
28 C
HF
56
Min. temp. cooling
18 C
OEM
XXXXX
HF
50
Factory
4 214 283 / 00
MIX. VALVE-2
Par.
Designation
Factory
10
20
30
40
50
Lev.
ECO/ ABS
HF
MK= 1,10
HF
HF
100 %
HF
Room factor
ON
HF
HF
Heating limit
0,5
OEM
10 C
HF
OFF
HF
HF
20 C
HF
10
11
12
10 C
HF
13
55/ 75 C
HF
14
Temperature elevation/ abatement heating circuit
0/ 8 K
HF
15
Pump follow-on
5 min
HF
OFF
HF
2,0 %/ K
OEM
Scanning time Ta
20 s
OEM
I-portion Tn
270 s
OEM
21
Running time servomotor
150 s
HF
22
End position function, valve
OEM
23
HF
24
35 min
HF
25
Vacation mode
STBY
HF
36
OFF
HF
37
Mixer lead time
OFF
HF
16
Screed function
18
P-portion Xp
19
20
38
Regulation offset
HF
50
Cooling switch-on point, OT
OFF
HF
51
Cooling max. point, OT
35 C
HF
18 C
HF
52
53
24 C
HF
54
Cooling reference room temp. at switch-on point
23 C
HF
55
Cooling reference room temp. at max. point
28 C
HF
56
Min. temp. cooling
18 C
OEM
XXXXX
HF
4 214 283 / 00
51
HEAT GENER.
Par.
Designation
H-GEN model
Start-up protection H-GEN
Minimum temperature limit H-GEN
Maximum temperature limit H-GEN
Mode of action minimum temperature limit H-GEN
Sensor mode operation for H-GEN
Minimum burner running time
Factory
10
20
30
40
50
Lev.
1/ 2/ 5
HF
OFF/ 3
5/ 48/ 65/ 75
C
75/ 85 C
HF
HF
HF
HF
OEM
2 min
HF
Burner switching difference I
6K
HF
Burner switching difference II
12 K
HF
10
Time-out stage II
10
HF
11
Release mode stage II
HF
12
DHW charging mode 1-2 stage
HF
13
Lead time, boiler circuit pump
1 min
HF
14
Follow-on time, boiler circuit pump or parallel boiler release
5 min
HF
15
Search time feed pump, primary pump
5 min
HF
16
Exhaust gas temperature monitoring
OFF
HF
17
Exhaust gas limit value
18
Boiler gradient
19
Modulation P-portion Xp
20
Modulation scanning time Ta
21
Modulation adjustment time Tn
22
Modulation running time
23
Modulation starting time
24
Modulation start-up output
25
Outside temperature block
26
Basic charge elevation
27
29
Minimum temperature limit, heating circuits

Switching difference, minimum temperature limit Heating
circuits
H-GEN forced discharge
30
OEM Maximum limit
110 C
OEM
31
Minimum load control
OFF
OEM
34
Output limitation heating
100 %
HF
35
Output limitation hot water
100 %
HF
36
ET blocking 2.burner stage
OFF
HF
37
Running time meter
38
DHW release regulator (CD)
39
Emergency operation temperature H-Gen (e.g. for 70-8)
40
Heat balance (from V3.2)
41
Reset heat balance
28
HF
OFF
OEM
5 %/ K
OEM
20 s
OEM
180 s/ C
OEM
12 s
HF
200 s
HF
70
HF
OFF
OEM
0 K/ 10K
OEM
5/ 38/ 65 C
HF
2K
OEM
OFF
HF
HF
ON
HF
70 C
HF
ON
HF
HF
0,0 l/ min
42
43
200 C
0,0 l/ IMP
Density, medium
44
HF
1,00 kg/ l
HF
4,2
HF
RESET ST-1 Reset counters starts and running time, stage 1
OEM
RESET ST-2 Reset counters starts and running time, stage 2
OEM
52
4 214 283 / 00
RETURN CONTR
Par.
Designation
Minimum limit return temperature / reference value return
temperature
Switch-off difference
Pump follow-on time
Factory
10
20
30
40
50
Lev.
38 C
HF
2K
HF
1 min
HF
SOLAR
Par.
Designation
Factory
10
20
30
40
50
Lev.
Switch-on difference
10 K
HF
5K
HF
Minimum running time SOP
3 min
HF
Solar collector maximum temperature
100 C
HF
Solar tank maximum limit (KSPF)
65 C
HF
Solar mode of operation
HF
Heat generator cycle lock (only when parameter 06=1,3,4)
0,5 h
HF
Solar priority parallel changeover
10 K
HF
Solar heat balance
OFF
HF
9
SOLAR
RESET
Reset heat balance
11
12
Density, medium
13
HF
0,0 l/ min
0,0 l/ IMP
1,05 kg/ l
HF
3,6 KJ/ kgK
HF
HF
14
Final switching-off temperature
120 C
HF
15
Test cycle solar charging switch-over
10 min
HF
16
Switch-over temperature (SLVF)
60 C
HF
17
Solar minimum temperature
OFF
HF
SOLID FUEL
Par.
Designation
Factory
10
20
30
40
50
Lev.
Minimum temperature
60 C
HF
Maximum temperature
95 C
HF
Switch-on difference
10 K
HF
5K
HF
Clock block, heat generator
15
HF
4 214 283 / 00
53
BUFFER
Par.
Designation
Factory
10
20
30
40
50
Lev.
Minimum temperature
5/ 20 C
HF
Maximum temperature
95 C
HF
Temperature elevation, H-GEN
8/ 10/ 12K
HF
Switching difference
2/ 5/ 10K
HF
Forced discharge
OFF
HF
Skimming function switch-on difference
10 K
HF
Skimming function switch-off difference
5K
HF
Start-up protection
OFF
HF
Discharge protection
OFF
HF
10
Buffer mode of operation
2/ 3
HF
11
Pump follow-on time
3 min
HF
12
Switch-off reference value temp.
70 C
HF
13
H-GEN release temp. skimming function
60 C
HF
MAIN SUPPLY
Par.
Designation
Factory
10
Lev.
0 %/ K
HF
PI-scanning time Ta
20 s
HF
PI -reset time Tn
600 s/ C
HF
Designation
Factory
CASCADE
Par.
10
Lev.
3K
OEM
Connecting delay
20
OEM
Switch-off delay
OEM
Switching output stage sequence
65
OEM
Stage reversal
OFF
OEM
Control stage
BE
Peak load stage
OFF
OEM
Group switch-over
OFF
OEM
DHW fast activation
OFF
OEM
10
Peak load elevation
10 K
OEM
BUS
Par.
54
Designation
Factory
10
20
30
40
50
Lev.
Bus address central device
10
HF
Bus right RS direct circuit
HF
Bus right RS mixer circuit 1
HF
Bus right RS mixer circuit 2
HF
4 214 283 / 00
SERVICE
Par.
Designation
Factory
10
20
30
40
50
Lev.
Service 1 (Cleaning ST1 )

1
Suspend message CLEANING ST-1 for X days
BE
OFF
BE
OFF
BE
OFF
BE
Cleaning according to cleaning counter
Reset cleaning display 1
BE
Service 2 (Cleaning ST2)

6
Suspend message CLEANING ST-2 for X days
BE
OFF
BE
OFF
BE
OFF
BE
Cleaning according to cleaning counter
10
Reset cleaning display 2
BE
Service 3 (maintenance ST1 )

11
Suspend message MAINTENANCE ST-1 for X days
12
13
14
Maintenance according to maintenance counter
15
Reset maintenance display 1
HF
OFF
HF
OFF
HF
OFF
HF
HF
Service 2 (maintenance ST2 )

16
HF
17
Suspend message MAINTENANCE ST-2 for X days
OFF
HF
18
OFF
HF
OFF
HF
19
Maintenance according to maintenance counter
20
Reset maintenance display 2
HF
ALARM 1
Par.
Designation
10
20
30
40
50
Lev.
Alarm 1
OEM
Alarm 2
OEM
Alarm 3
OEM
4
5 ... 20
21
Alarm 4
OEM
Alarm 5 - 20
OEM
Reset fault signals
OEM
ALARM 2 (can ony be activated with H-Gen 5)

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

Status
56
Designation
Fault type
Code
System
External sensor
Interruption
10-0
System
External sensor
Short-circuit
10-1
System
Boiler sensor
Interruption
11-0
System
Boiler sensor
Short-circuit
11-1
Remark
System
Flow sensor 1
Interruption
12-0
MC1=off, YK1=no current
System
Flow sensor 1
Short-circuit
12-1
System
Storage sensor
Interruption
13-0
System
Storage sensor
Short-circuit
13-1
System
VE 2
Interruption
14-0
System
VE 2
Short-circuit
14-1
System
VE 2
Alarm
14-7
System
VE 3
Interruption
15-0
System
VE 3
Short-circuit
15-1
System
VE 3
Alarm
15-7
System
VE 1
Interruption
16-0
System
VE 1
Short-circuit
16-1
System
VE 1
Alarm
16-7
System
Solar tank sensor
Interruption (KSPF)
17-0
System
Solar tank sensor
Short-circuit (KSPF)
17-1
System
Flow sensor 2
Interruption
18-0
System
Flow sensor 2
Short-circuit
18-1
System
Collector sensor
Interruption (KVLF)
19-0
System
Collector sensor
Short-circuit (KVLF)
19-1
System
Room sensor (RS)
Interruption
20-0
System
Room sensor (RS)
Short-circuit
20-1
System
Burner 1
No switching off (1 min)
30-2
With par. log. alarm can be switched off
System
Burner 1
No switching on (10 min)
30-3
System
Burner 2
No switching off (1 min)
31-2

System
Burner 2
No switching on (10 min)
31-3
System
Exhaust gas temperature
Exceeding
33-5
System
Exhaust gas temperature
SLT triggered
33-8
System
Cleaning stage 1
Triggering by date
40-1
System
Cleaning stage 1
Triggering by interval
40-2
System
Cleaning stage 1
Triggering by counter
40-4
System
Maintenance stage 1
Triggering by date
41-1
System
Maintenance stage 1
41-2
System
Maintenance stage 1
41-4
System
Cleaning stage 2
Triggering by date
42-1
System
Cleaning stage 2
42-2
System
Cleaning stage 2
42-4
System
Maintenance stage 2
Triggering by date
43-1
System
Maintenance stage 2
43-2
System
Maintenance stage 2
43-4
4 214 283 / 00
FAULT REPORTING OVERVIEW TopTronicT

Status
Designation
Fault type
Code
Logical
Boiler temperature
Not reached (90 min)
50-4
Logical
Tank temperature
Not reached (4 h)
51-4
Logical
Flow temperature MC1
Not reached (1 h)
52-4
Logical
Flow temperature MC2
Not reached (1 h)
53-4
Logical
Room temperature HC
Not reached (3 h)
54-4
Logical
Room temperature MC1
Not reached (3 h)
55-4
Logical
Not reached (3 h)
56-4
Address collision
70-0
System
Room temperature MC2

Lock by energy supply company
ST 2
Activity
No T2B signal
70-1
System
Activity
70-6
System
Activity
System
System
Activity
HP return sensor
No FA signal
Regulator with address 10 is
missing
Data bus error
Return min. temp. below setpoint
System
HP return sensor
85-5
System
QF
System
QF
Return max. temp. exceeded

Heat source min. temp. below
setpoint
Heat source max. temp. exceeded
(cooling operation)
System
System
QF
WPS
Fault heat source sensor

Variable input HP fault
-87-7
System
System
System
System
Pulse counter
Fault
Fault
Fault
No pulse (5 min)
Warning
Lock-out
Blocking
90-0
W:XX
E:XX
B:XX
System
Remark
70-8
70-9
85-4
No Hoval regulator
86-4
86-5
Standard signal VE-x
SENSOR ALLOC.
Par.
1
Designation
Factory
10
20
30
40
50
Lev.
Balancing external sensor
OEM
Balancing room sensor (only adjustable with RS-T)
HF
Balancing heat generator
OEM
Balancing tank sensor
OEM
OEM
OEM
OEM
RS-T
Balancing solar collector sensor
Balancing solar buffer sensor
OEM
Balancing variable input 1
OEM
OEM
10
OEM
4 214 283 / 00
57
Conservation of Energy
Protection of the Environment
Hoval Limited, Northgate, Newark, Notts NG24 1JN
Telephone: 01636 593413 Fax: 01636 673532
e-mail: spares@hoval.co.uk or service@hoval.co.uk
Web Site: www.hoval.co.uk
Hoval follows a policy of continued improvement and reserves the right to change specifications without notice.
58
4 214 283 / 00
4 214 283 / 00
59
COPY FOR PLANT USER
Confirmation
The user (owner) of the system herewith conrms that
he has received adequate instruction in the operating and maintenance of the installation,
received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components.
and is consequently sufciently familiar with the installation.
Installation address:
Type:
Serial number:
Year of manufacture:
Place, Date:
System installer:
System user:
COPY OF SYSTEM INSTALLER
Confirmation
The user (owner) of the system herewith conrms that
he has received adequate instruction in the operating and maintenance of the installation,
received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components.
and is consequently sufciently familiar with the installation.
Installation address:
Type:
Serial number:
Year of manufacture:
Place, Date:
System installer:
System user:

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

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Technical information

These instructions are applicable to the following types:

Hoval products must be installed and commissioned

Max-3 plus boilers are suitable and approved as

4 214 283 / 00 - UK - 03/15

see point 3.2

Other instructions ........................................................................................................................... . . . . ................................4

Installing, levelling, boiler plinth ....................................................................................................... . . . ............................... 5

Description of the boiler ........................................................................................................................... . . . . .................... 19

Flues and Chimneys ........................................................................................................................... . . . . .......................... 24

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

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

trial and commercial premises.

1. Safety valve installed (closed system)

Regulations, official approvals

Construction, design, safety requirements.

Construction, design, safety requirements, design and

Installing, levelling, boiler plinth

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

It must be possible to fully swing open the hinged

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

3rd pass tube bank

Boiler door opens to the left

The cable must not contact any hot parts.

Boiler door hinges must be changed over only by

Figure shows situation as delivered

Mounting the thermal insulation Max-3 plus (420-750)

Before commencing to mount the cladding,

Mounting the cladding and boiler control Max-3 plus (420-750)

21. Fix lead-through (21).

18. Mount cladding covers (18/18a).

Attention: The capillaries must not be kinked!

Mounting the thermal insulation Max-3 plus (1000-1250)

Before commencing to mount the cladding, check the dimension

Max-3 plus (1000,1250) = 1391,5 +3

Mounting the cladding and boiler control Max-3 plus (1000,1250)

21. Fix lead-through (21).

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

16. Position cladding cover (16).

Attention: The capillaries must not be kinked!

Mounting the thermal insulation Max-3 plus (1500-2700)

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

Mounting the cladding and boiler control Max-3 plus (1500-2700)

15. Mount cladding cover (20,21,22,23,24).

Attention: The capillaries must not be kinked!

Description of the boiler

Max-3 plus (420-1250) type

Gas appliance directive

Technical data Max-3 plus (420-2700)

Range of output at 80/ 60 C

Burner input maximum

Maximum operation temperature 1

Safety temperature limiter setting (water side) 2

Working / test pressure

Flue gas resistance at nominal output

natural gas 10,8 % CO2

Boiler water content

Combustion chamber dimension

see table of dimensions

Maximum chimney draft

Limited by the boiler control to 90 C (U3.1) or to 105 C (U3.2)

Possible operating conditions: