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Revision No.2

Dated: November 2015

4214947-00

By Appointment toHer Majesty the Queen

Boiler Manufacturers & EngineersHoval Ltd Newark

Installation, Operating and Maintenance Manual for F Modul plus Calorifiers

2 Table of Contents

3

4

5-7

8

9-13

14-15

16-20

21

22

23

24

25

26

27

28

29

These instructuctions should be read and understood before attempting to install,commission or operate this unit.

Introduction

Description of F Modul plus Calorifier

Technical and Performance Details

Delivery / Positioning Instructions

Assembly Instructions

Installation and Piping Layouts

Unvented Systems

Commissioning & Operation

Inspection and Maintenance

Anode Protection

Immersion heaters

Immersion heater wiring diagrams

Fault Finding Chart

Wiring Diagrams for Open Vented Calorifiers

Wiring Diagrams for Unvented Calorifiers

Notes

Material in this publication may not be reproduced without Hoval’s written permission.

Hoval reserve the right to change specifications without notice.

Contents Page

3Introduction

These instructions have been written to give a brief description of the F Modul-plus Calorifier, its installation, commissioning, operation and subsequent mainte-nance.

The installation of calorifiers and their ancillary equipment is normally carried out by a heatingengineer. For the purpose of this manual he is regarded as the installer, and, as such, it is hisresponsibility to ensure that he has read and understood the contents of this manual beforeinstalling the calorifier.

It is essential that each calorifier has all services permanently connected to it before commis-sioning is requested.

The installation should be in accordance withcurrent I.E.E. regulations, relevant British Stan-dard and Codes of Practice, Building Regula-tions and Local Authority Bylaws.

Commissioning should be arranged via theheating engineer. Hoval engineers are availableto carry out this work if requested. Where thecalorifier installation is part of a Hoval boilerpackage it will normally be commissioned atthe same time and entry made on the reportopposite

Commissioning/Combustion Report

A note should be entered below by the person responsible for the plant, giving the boiler, calorifiermodel and its output and reference serial number, as indicated on the nameplate.

November 2015 4214947-00

Introduction

Calorifier Model:

Boiler type / Model:

Date of installation:

Output l/hr:

Serial Number:

For completion by Plantroom Attendant

For technical, servicing or parts enquiries, telephone, fax or email to Hoval Ltd quoting the calorifier(s)

serial number, as above.

4 Description of F Modul Calorifier

F Modul plus calorifiers are designed to operatewith the full range of Hoval boilers up to 4.5 Bar(standard model) and 6.90 Bar (high pressuremodel) primary pressure, and are intended for theproduction and supply of DHW to commercial andindustrial premises.The F Modul-plus is available in seven model sizeswith high performance outputs up to 10,000 litresper hour.

General DetailsThe construction of the F Modul plus is in the formof a series of horizontal bottles, linked in modularfashion, and comprising a high grade stainlesssteel inner vessel with a “rippled”wall to enhanceheat exchanger efficiency. This is surrounded bya mild steel primary water jacket, which is encasedwith steel sheet insulated panels. The assemblyis mounted on two base channels running fromfront to back. On all seven models, the secondaryflow and primary inlet are from the top and the sec-ondary return, cold feed and primary outlet con-nections are at the bottom.

Applications

Performance of the seven F Modul plus modelscovers a range of outputs up to an hourly rating of10,000 litres/hour. Higher outputs can be providedby arranging the units in modular formation. Formost typical applications (other than process wa-ter generation) the key requirement is for adequatequantities of hot water over a relatively short pe-riod. On this basis, the F Modul plus will providesignificantly higher flow rates than its continuouslyhourly rate.

Key Features• Minimum floor area, fits through standard

doorway.• Suitable for use with any make of boiler• High efficiency heat transfer for rapid

D.H.W. regeneration.• Recirculation design removes danger of

temperature stratification.• Optimum D.H.W. storage - sufficient for quick

draw-off but with lower standing losses thanconventional large volume calorifiers.

• A drain must be fitted in the secondary cold feedsite pipework to fasciliitate draining and flushingout. (CIBSE TM 13:2000Recommendations to prevent LegionellaBacteria Contamination).

• Very low primary and secondary resistances.• Electric immersion heaters can be fitted by

prior arrangement.• Large heating surface, suitable for operation

with lower temperature primary feed fromcondensing boilers. (Duty reduced - contactHoval).

• See later section for unvented systems andthe additional equipment required.

• Where access is a problem the bottles can besplit (flanged), This is an optional extra.

• Suitable for primary flow temperatures upto 90Deg C.

• Suitable for secondary pressures upto 9.66Bar.

Internal view of F Modul plus Calorifier

F42 Modul plus Calorifier

November 2015 4214947-00

Description of F Modul plus Calorifier


Technical Data.

Rating kW = Q x S.H. x (T2 - T1 )

Q = Calori er hourly output - Litres (kg)T1 = Temperature cold feed - oC T2 = Temperature DHW ow - oCS.H. - kJ/kgoC

To calculate the load on the boiler .

Note for Hydraulic Testing: The primary jacket should not be pressurised without

steel vessel.

An adjustable secondary thermostat has a sensing point which ensures that the main body of water is held uniformly,

pre-set level, normally 60oC - 65oC.

3600

Legionellae The safe temperature for storage is now considered to be a minimum of 60oC to prevent the risk of legionella bacteria contamination. For kitchen and similar duties requiring 60oC water, the supply can be direct from the calori er oC supply, mixing or blending with cold water, external to the calori er, is required and will increase the secondary output listed on page 5 by about 25%.

When temporarily operating the primary side only, the pressure should not exceed 1 bar g and the secondary side should be vented.

Chloride.The maximum allowable chloride content of DHW cold feed water is 100mg/litre, (or up to 200 mg/litre where optional tted).

5

Model Primay Details Secondary outputs at 60oC based on 10oC cold feed Contents Flow rate Resistance Contents o At 90o Resistance peak continuous peak continuous litres l/s mbar litres l/10 mins l/hour l/10 mins l/hour mbar #

F21 30 120 230 1960 12

F31 120 555 2550

3.33 00 625 3300 30

60 2.92

F51 2.22 300 950 3200 120

3.33 1035 3950 1 5250

F32 90 220 690 1136 1 33

595 1250 6600 39

120 920 93

F52 150 1150 1900 2160 130

610 2015 2315 10000 150* Resistance is for primary ow rate listed+ For DHW outputs below 60oC, external blending to a lower temperature is recommended.# Resistance at the peak 10 minute draw off rate. For resistance at other draw off rates See Graphs on page 6.

Pressures **serusserP ledoM erusserP hgiH serusserP ledoM dradnatS System Operating Test Pressures Operating Pressures Test Pressures Pressure Bar Bar Bar Bar

Primary Side 6.90 6.90 10.0

Secondary Side 1 9.66 15.0** To meet the requirements of M&E3, high pressure primary water units can be tted with a bursting disc.

Weights Model Dry Weight kg Dry weight Excl. Casings kg Total weight kg

F21 269 165 529

F31 319 215

265 900

F51 315 1105

F32

605

F52 2030

November 2015

6

Hydraulic Resistance (Primary)

Hydraulic Resistance (Secondary)


M / h / 3.6 = l/s3

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7Technical and Performance Details

Dimensionss

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8

Transport Dimensions

Delivery Positioning Instructions

The F Modul plus calorifiers are delivered inthree pieces:-- The Modul bottles and frame.- The casings and lagging in a cardboard box.- The Calorifier control panel in a box.

Delivery

Positioning / ClearancePosition the calorifiers as required, ensuring thatside and inspection opening clearances are ad-equate.At least 400mm side clearance is required forfitting the casings. If this space is not available,the calorifier insulation and casings must be fit-ted before positioning the calorifier.Ensure that the calorifier is level using a spiritlevel along the top calorifier bottle.

November 2015 4214947-00

Delivery and Positioning Instructions

9Assembly Instructions

Mounting the support rails

Ensure that the dimensions between the top cas-ing rails and the base channels are as per H.

Before fitting the insulation and casings, fix thebottom guide rails (1) to the base channels.For types F32, F42 and F52 use Hole A.For types F21, F31, F41 and F51 use Hole B.

Hole A.

Hole B.

November 2015 4214947-00


10 Assembly Instructions

Fitting the insulationWrap the insulation matress (1,2,3,4 & 5) aroundthe calorifier(black side outwards), join the insu-lation at the top using tension springs (8). Se-cure with the plastic straps (6). These plasticstraps are secured using the strap fastener (7).

Do not fasten too tightly as this will effect the in-sulation properties of the matress.Fit the pipe insulation (9) and secure using ten-sion springs.Fit the bottle end covers (10) at both ends.

November 2015 4214947-00

11Assembly Instructions

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November 2015 4214947-00

12

Fitting the Casings

(i) Fit the front base panel (11) from the front. Then the middle and rear base panels (12) areplaced in position from the side, between the plinth channels.

(ii) The front side panels (13) are first placed in the bottom guide rails (Fig. A) and then attachedto the top casing rails. Push the side panels (13) back against the casing rails as far as itgoes.(Fig B)

(iii) Fit the other side panels (14,15). Join the front side panels (13) to the bottom guide rails withspring clips (16, Fig. C). Push the side panels (14,15) up against the front side panels so thatthere isn‘t a gap and then fix the panels at the back to the bottom guide rails with the springclips.

(iv) Fit the C-clips (17, Fig. D) to the cubicle retaining rails.(v) Now the front lids (18.19) (on the F31, 32, 51, 52 models) or the front lid (on the F21, 41, 42

models) should be put in place. Then fit the other lids (20). Do not tighten the fixing screws atthis stage.

(vi) Fix the back panel (21) in position using the self-tapping screws.(vii) Fit the support panel for the electrical control panel (22) and fix to the mounted screws with

dome nuts (23).(viii) Mount the cable gland (24) in the support panel with the plastic counter-nut. Blank off the other

holes with blank grommets (25).(ix) Push into position the electrical control panel (26). Beforehand, please route the capillaries to

the rear, through the opening in the support panel (22).(x) Carefully Insert the thermometer and thermostat sensors into the immersion pocket (27) of

the corresponding bottle. Do not remove the plastic clip until the sensor bundle is inserted halfway into the immersion pocket. The sensor for a limit thermostat (on unvented systems) mustbe mounted in the topmost bottle.

(xi) Then push the retaining spring (28, Fig. E) on the immersion pocket to prevent the thermometerand thermostat sensors from slipping out.

(xii) Finally fit the front panel (29) and fix it with the dome nuts (23).


Do not kink the capillaries.

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13

Wiring up the unit.A copy of the wiring diagram is both in the con-trol panel and at the back of this manual.Unvented systems require a hand reset limit stat.Vented DHW calorifiers only require a controlstat.The electrical installation should conform with allrelevent British Standards / I.E.E. Regulations.This diagram should be checked for correct ap-plication.

To gain acess to the back of the control panel,remove the two dome screws and remove theorange support casing which houses the controlpanel.There are also two screws which can be removedto get inside the control panel.Ensure that the thermostats and the thermom-eter capiliaries are fitted in the pocket in thecalorifier bottle.

Before attempting to wire the unit, always refer to the relevant wiring diagram.


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14

Installation


Note: The F Modul plus calorifierisn’t fitted with a DHW or primarydrain tapping. Therefore the pri-mary drain must be fitted in thesite pipework off the primary out-let connection and the DHWdrain should be fitted in the coldfeed.

Piping layoutFor the general design of water circuits refer tocurrent British Standards and Codes of Practice.A simple pumped primary flow and return, ad-equately vented, is all that is needed. Secondary

To facilitate venting during draindown, ensure that a manual ventvalve is fitted in both the primaryinlet and the secondary flow be-tween the calorifier and the iso-lating valves. On open ventedsystems the vent should betaken from the same place.

Recommended Primary Systems

Key(1) Safety Valve recommended if noton adjacent boiler or system.(2) Spring loaded non-return valve.(3) Isolating valves.(4) Primary pump (For diagram “B”the main circulating pump may be

used if sufficient head is available).(5) Thermostat (linked to primarypump to control calorifier DHW tem-perature, for Diagram A).For diagramB the thermostat controls the divert-ing valve.

On Unventedsystems there is alsoa limit stat fitted.(6) Drain cock.(7) Diverting valve (use 30 secondmotor).

A B

connections are quite conventional. Connect thecalorifier(s) to the rest of the system accordingto the chosen layout. Examples of both primaryand secondary systems are shown below:

Fit unions to all pipe connections ensuring that jointseals are fitted. Fit isolating valves to all pipework.

1AAV 2

3

4

5

3

36

Primary Connections from Main Headers. Temperature control by pump.

Primary Water

Secondary Water

Anti-thermal loop

AAV

1

AAV

5

4 (if Required)

36

Primary Connections from Main Headers. Temperature control by diverting valve.

3

7

Primary WaterSecondaryWater

Primary Connections from Main Headers. Temperature control by pump.

Recommended primary systems (open vented).

November 2015 4214947-00


15

Recommended Primary Systems Continued.


C

Key(1) Safety Valve recommended if noton adjacent boiler or system.(2) Spring loaded non-return valve.(3) Isolating valves.(4) Primary pump (For diagram “D”the main circulating pump may be

used if sufficient head is available).(5) Thermostat (linked to primarypump to control calorifier DHW tem-perature, diagram C). For diagramD the thermostat controls the divert-ing valve.

On Unventedsystems there is alsoa limit stat fitted.(6) Drain cock.(7) Diverting valve (use 30 secondmotor).

D

Recommended Secondary Systems.

Key(1) Relief valve adjacent to calorifier.(2) Spring loaded non-return valve.(3) Isolating valves.(4) Open vent.(5) Unvented system kit.(6) Secondary drain valve.

Manual Vent Valve

T & P Relief Valve in socket provided

Secondary Connections UNVENTED.

Primary Water

SecondaryWater

2 3 33 3

6

ColdFeed

Secondary Return

3

5

Primary Connections direct from boiler. Temperature control by pump.

1

AAV 2

3

45

3

3 6

Primary Water

Secondary Water

Flow

Return

Boiler

Anti-thermal loop

1

AAV

5

4 (if Required)

6

Primary Connections direct from boiler. Temperature control by diverting valve.

3

7

SecondaryWater

Return

3

Flow

Boiler

3

3

Boiler

Primary Water

AAV

Secondary Connections OPEN VENTED.

Primary Water

SecondaryWater

1

2 3 3

33

6

Vent

Cold Feed

Secondary Return

31

4

SecondaryCirculating

Pump Secondary Circulating Pump

Secondary Water

Primary Water

Key1. Expansion Relief Valve adjacent to calori er2. Spring loaded non return valve3. Isolating valves4. Temperature and pressure relief valve5. Strainer6. Pressure reducing valve7. Double check valve8. Expansion vessel9. Lock shield valve10. Drain valve11. Manual vent valve12. Secondary circulating pump

15 26

3

3

3 337

8

9

10

10

12

114

Secondary Connections Unvented

Cold water mains

Cold water mains

Recommended Primary Systems (open vented) Continued

Unvented kits available on request. See page 17.

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16 Unvented Systems

DefinitionAn unvented hot water system differs from conventionalopen vented systems in that no vent pipe is providedand it is connected to the mains water supply, eliminatingthe need for the provision of cold water storage tanks inthe roof space. The functions, therefore, of the openvents and cold feeds have to be performed in otherways. There are two basic types of unvented system:(1) Direct off the mains,(2) Boosted water supply.

Direct off the mainsWhere mains pressure is sufficient the system can beconnected straight off the mains. However, betweenthe cold water supply and the DHW generator (i.e. theF Modul plus calorifier) there must be an unventedsystem kit fitted.

Warning: Some pressure boostersets have an accumulator (expan-sion vessel). This is to reduce theamount of pump starts and shouldnot be confused with the systemexpansion vessel.

This kit should contain a minimum of the followingitems:-• An expansion vessel should be fitted between the

non-return valve and the calorifier to take up expandedwater during heat-up.

• An expansion relief valve should be fitted in the coldfeed between the expansion vessel and the calorifier.No means of isolating the calorifier from this valveshould be installed.

• A temperature and pressure relief valve should befitted directly in the calorifier as a thermal protectionto prevent the DHW reaching 100 deg C.

• A hand reset limit stat should be fitted in the calorifierto prevent the DHW overheating.

Balanced Unvented SystemsSome systems may be fitted with blending valves ormixers that require a balanced hot and cold watersupply. When sizing the strainer, the PRV, and checkvalve care must be taken to ensure they can pass theflow rates at the required pressure.Hoval standard unvented system kits are sized toreduce incoming pressure to 3 bar at a flow rate thatmeets the peak output of the calorifier only.

As shown in the above diagram, an unvented system kitcomprises of the following components:-• Strainer (this is optional, but good practice, to prevent

debris passing through the valves)• Pressure regulating valve (PRV), this allows the

pressure to be reduced and controlled at a presetpressure. A pressure gauge is supplied to indicatesystem pressure.

• Double check valve, this prevents the expanded waterback-feeding into the mains supply and additionallyseals the system.

• An expansion vessel should be fitted between the nonreturn valve and the calorifier to take up expandedwater during heat-up.

• An expansion relief valve should be fitted in the coldfeed between the expansion vessel and the calorifier.No means of isolating the calorifier from this valveshould be installed.

• A temperature and pressure relief valve should befitted directly in the calorifier as a thermal protectionto prevent the DHW reaching 100 deg C.

• A hand reset limit stat should be fitted in the calorifierto prevent the DHW overheating.

Boosted water supplyWhere mains water pressure is insufficient a coldwater booster set can be fitted. Normally these setshave integral pressure controls, in the form of eitherpressure transducers, pressure switches, and orpressure regulating valves. They also have a non returnvalve which prevents back-feeding. Systems where abooster set is installed should not have a vent and assuch are unvented.Boosted systems should have an unvented system kitfitted down-stream from the booster set.

T & P Relief Valve.

Hand reset limit stat.

Expansion relief valve c/w tundish.

Expansion Vessel.

Check valve.

PRV.

Strainer.

Unvented System Kit.

Cold Feed

Unvented System kit

1

5 6

3

3

3 7

8

9

10

10

114

Cold water mains

Key

1. Expansion Relief Valve2. Manual vent valve *3. Isolating valves *4. T & P relief valve5. Strainer

6. Pressure reducing valve7. Double check valve8. Expansion vessel9. Lock shield valve10. Drain valve** Not Hoval supply.

in control panel

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Unvented Systems

17

Cold water booster sets tend to be sized on thetotal demand of the system and subsequentlygive a balanced condition.

A separate Strainer and PRV can be fitted to boththe hot and cold water services to give balancedsystem pressures. Alternatively, a larger Strainerand PRV can be installed to cope with both hotand cold water demands.

F21 1” 1” 1” 80 litre ¾” 1½” HP80-1”

Strainer P.R.V.

DoubleCheckValve

ExpansionVessel

ExpansionRelief

Valve &Tundish

T & PReliefValve*

F31 80 litre ¾ ” 2” HP80-1”

F41 1.1/2” 1.1/2” 1.1/2” 150 litre ¾” 2½” HP150-1½”

F51 150 litre ¾” HP150-1½”

Warning: On balanced systemswith a common PRV, Strainer andDouble check valve, ensure thatthe valves are sufficiently sizedto cope with both hot and coldwater demand.

Hoval Unvented System Kits

Hoval have carefully sized and selected a rangeof standard unvented system kits suitable forinstallation with the F Modul plus range ofcalorifiers.

The various valves and fittings should be installedin the sequence shown on the right.

The size of the standard unvented kits are shownin the table below.

Please note that these kits are only sized for thecold feed going into one of the F Modul pluscalorifiers.

Using the PRV from a standard Hoval unventedkit to provide a balanced hot and cold watersupply may cause pressure and water flowproblems. Ensure that the PRV can cope withthe demand from both the hot and cold waterservices.

Unvented Systems

T & P Relief Valve.

Hand reset limit stat.

Expansion relief valve c/w tundish.

Expansion Vessel.

Check valve.

PRV.

Strainer.

Unvented System Kit.

ColdFeed

Unvented System kit

1

5 6

3

3

3 7

8

9

10

10

24

Coldwatermains

Key


6. Pressure reducing valve7. Double check valve8. Expansion vessel9. Lock shield valve10. Drain valve

* Not Hoval supply.

Unvented System kit

1

5 6

3

3

3 7

8

9

10

10

114

Coldwatermains

Key


6. Pressure reducing valve7. Double check valve8. Expansion vessel9. Lock shield valve10. Drain valve** Not Hoval supply.

in control panel

00-74941245102 rebmevoN

F32

F42

F52

150 litre ¾”2” 2” 2” 300 litre ¾” HP300-2”

2” 2” 2” 300 litre ¾”

1” 1” 1”

1.1/2”1.1/2”1.1/2”HP150-1½”

2½”

HP300-2”

1.1/2” 1.1/2” 1.1/2”

*Supplied factory fitted with unvented calorifier(discharge pipe(s) by others - not suppliedby Hoval).

2 x 2”2 x 2½”

2 x 2½”

18

Multi-calorifier Installations

Unvented Systems

Common Unvented System Kit.

Cold Feed

More than one calorifier can be installed off a single common cold feed. Each calorifier must have it’s own T & P valve and expansion relief valve. No means of isolating these safety valves from the calorifier should be installed.

Drain Cock By the Installer

Strainer

PressureReducingValve Double

CheckValve

ExpansionVessel

ExpansionRelief Valve and Tundish

ExpansionRelief Valve and Tundish

Temperatureand Pressure Relief Valve

Temperatureand Pressure Relief Valve

IsolatingValve

IsolatingValve

Shared Unvented System Kits Feeding Two or More Calorifiers.

Two or more calorifiers can be installed with individual unvented system kits. Where the expansion vessels have been sized to share the total system expansion, the two feed lines can be joined by a pipe to allow both vessels to be used when one calorifier is isolated.

Cold Feed Drain Cock

By the Installer

Strainer

Pressure Reducing Valve Double

Check Valve

Expansion Vessel

Expansion Relief Valve and Tundish

Temperature and Pressure Relief Valve

Isolating Valve

Expansion Vessel


Cold Feed Drain Cock

By the Installer

Strainer


Check Valve

Expansion Relief Valve and Tundish Isolating

Valve

Joining Pipe.

ExpansionVessel

Drain cock by installer








Isolation valve

Isolation valve

Isolation valve

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19

Balanced Hot and Cold water supplies.

Unvented Systems

Unvented System with balancedhot and cold water services.

Cold Feed

The hot and cold water supplies can be balanced by utilizing the same strainer and PRV to control the two supply lines. Note it may be necessary to increase the size of these two fittings in comparison to the non-return valve in the calorifier cold feed line.


Strainer


Check Valve

Expansion Vessel



Isolating Valve

Balanced Cold Water Supply

Balanced hot and cold water services using two PRVs.

Cold Feed

The hot and cold water supplies can be balanced using two separate PRVs.


Strainer


Check Valve

Expansion Vessel



Isolating Valve




Isolation valve

Isolation valve

Strainer

PressuReducValve


Isolation valve

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20

Fitting the Unvented System Kit.

Fit the components as indicated. In the suggestedschematics detailed on previous pages.

All components must be installed in a frost free area.

Ensure that valves and fittings are fitted correctly tosuit the direction of flow.

Set the Pressure reducing valve (PRV) to 3 bar.

Pipe off expansion relief valve via the tundish providedto a gulley.

Pipe expansion vessel into cold feed. Fit a lock shieldvalve and drain between the vessel and the cold feedline. This will allow the expansion vessel gas charge tobe checked during maintenance. This is shown on theright.

Installation of the Expansion Vessel.

Cold Feed

Fit a lock shield valve and drain to allow the expansion vessel to be isolated and drained for periodic inspection. Drain Cock

(By the Installer)

Strainer


Check Valve

Expansion Vessel

Lock Shield Valve (By the Installer)

Maintenance of Unvented System Kit.

Clean out strainer on commissioning and annually.

Check Expansion relief valve setting annually bytwisting the cap on top of the valve.

Check expansion vessel gas charge pressure, isolatethe vessel, drain off any water in the vessel and test thegas pressure using a tyre gauge.

Fault Finding.

Symptom Possible Cause(s) Remedial Action

(A) Reduction in water flow Blockage in strainer Clean out strainer.Blockage in PRV Clean out secondary strainer in PRV.Wrong PRV pressure setting Check PRV pressure setting alter if necessary.

(B)Discharge from expansion Debris on valve seat Twist test knob and replace if necessary. Relief valve. Wrong incoming pressure Adjust the pressure setting on PRV.

Expansion vessel diaphram Check expansion vessel gas charge.Failure.Insufficient Expansion vessel Check expansion vessel size.volume.

Expansion Vessel Sizing.Expansion Vessel Volume = System content (l) x C.o.E.

Vessel Efficiency

Vessel Efficiency = Max Pressure (Bar Abs) - Min Pressure (Bar Abs) Max Pressure (Bar Abs)

Where: Max Pressure is final desired working pressure + 1.Min Pressure is pressure setting on PRV + 1.C.o.E. at 60 Deg C is approx 0.02

Unvented Systems

Isolation valve

Isolation valve

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21

Commissioning Instructions

• Flush all swarf, filings and other debris out ofthe system, preferably using a proprietary flush-ing agent. Do not wash particles into the calorifier,this could cause subsequent corrosion.• Once the secondary side is fully flooded andsealed, fill the primary system completely andtreat the water with a good corrosion inhibitor(e.g. Fernox). Corrosion inhibitors are not usedin secondary (tap) water.• Ensure that all joints are water tight and allpipework is vented.• Check that all electrical connections are com-plete and correct.•Ensure that the thermostat(s) are wired up andthe sensor probes are fitted in the stat pocket.The thermostat may be wired into the boiler con-trols to activate the pumps or a motorised valve.The control thermostat can be adjusted to oper-ate between 30 deg C and 80 deg C and is usu-ally set to 60 deg C.

Pre-commissioning:

Important: Always fill the second-ary side of the calorifier beforethe primary. Pressurising the pri-mary when the secondary isempty may cause the secondarybottle to collapse.

Commissioning

(1) Light the boiler (refer to the appropriate boileroperating instructions).(2) Adjust the calorifier thermostat to the requiredoperating temperature.(3) Check that the thermostat is operating cor-rectly.(4) Ensure that the primary pump is working orprimary primary circuit is established.(5) Check that the operating temperature remainsconstant.

Operating Instructions

The calorifier thermostat when wired to the pri-mary circulating pump or diverting valve providescompletely automatic control. It is necessary onlyto adjust the thermostat if the occasion demands.

Warning: To avoid Legionellae, en-sure the calorifier control stat is setat a minimum of 60 deg C.


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22

Periodic Inspection

Note: Before opening the inspectioncovers always ensure you have anew inspection cover joint. Eachbottle has two covers (one at eachend, (e.g. 20 on a F52 calorifier).

CleaningThe period between cleaning will depend on op-erating temperature and hardness of water. Lo-cal conditions will serve as a guide. Normally de-scaling will be required less often than with con-ventional calorifiers.


(1) Ensure that both primary and secondarypumps are switched off.(2) Isolate the primary inlet and outlet.(3) Fit hose to primary drain which should be in-stalled in primary outlet and run the hose toa gulley.

When filling the calorifier follow theabove procedure but in reverse.

The user is advised to carry out periodic inspec-tion between main servicing periods and it is rec-ommended that the specialist servicing companyalso carries them out.

(4) Open primary vent valve.(5) Open primary drain.(6) Isolate all secondary connections.(7) Fit hose to the secondary drain which is located underneath the calorifier and run the hoseto a gulley.(8) (On sealed systems) Open manual second-ary vent valve (this should be fitted in secondaryflow between calorifier and isolating valve).(9) Open secondary drain valve.

Model Joint Cat No.

ALL F Modul plus 414008

Draining Down

Note: The primary side of thecalorifier MUST always bedrained before the secondary.The secondary MUST always befilled before the primary.FOLLOW THE PROCEDUREBELOW:

• Inspect the calorifier casing for obvious signsof damage, corrosion or deterioration.

• Inspect the calorifier siting for signs of cracking or settling.

• Inspect all pipes and connections for obviousdamage or deterioration.

• Remove calorifier front/rear panel and examine interior for corrosion and deterioration.

• If anodes are fitted, check for deterioation.

The following procedure should be adopted:(1) Remove calorifier front / rear casing panel.(2) Remove cleanout cover for calorifier internals.(3) Scrape the inside surface with a non ferrousscraper when deposits of scale are found.Note: Chemical cleaning can be carried out if re-quired, but such work should be undertaken inaccordance with the instructions of the de-scal-ing compound manufacturer.We recommend chemical treatment specialistsuch as Aquazur. After chemically cleaning theDHW calorifier internal, ensure that the unit isthorougly flushed out with clean water.

Following cleaning, replace inspection cover us-ing a new gasket to prevent leaks.

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23

Periodic Inspection

Note: Before opening the inspectioncovers always ensure you have anew inspection cover joint. Eachbottle has two covers (one at eachend, (e.g. 20 on a F52 calorifier).


Units fitted with sacrificial magnesium anodesshould be checked on a twice yearly basis toassess the deterioration of the anode.

To inspect the anodes follow the procedure be-low:-

(1) Drain the calorifier down.

(2)Carefully undo the nut holding the inspectioncover in place. Support the inspection cover byholding the fixing stud. Carefully remove the in-spection cover bracket and allow the inspectioncover to rest on the stud.

(3) Using a torch assess the state of the anode.Note when the anode is about 10mm in diam-eter new anodes should be fitted.

(4) If the anodes are greater than 10mm in diam-eter, replace the rubber gaskets and carefully re-fit the covers.

(5) Once all of the covers have been fitted, refillthe calorifier, (Secondary side first, then thePrimary side).

Fitting New AnodesIf new anodes are required:

(1) Unscrew the old anodes off the inspectioncovers.

(2) Carefully remove the old anode, making surethat you do not dislodge the plastic support pipeat the other end.

Note: Follow the draining downprocedure on page 22.

Part Description Cat NumberMagnesium Anode 628998Inspection Cover 628996Rubber Door Joint 414008Plastic Support Pipe 528289

Please note you will need one of each ofthe above per bottle.

Please contact our spares department toorder replacement parts.

Magnesium Anode

Plastic Support Pipe

Rubber Door Joint

Inspection Cover

Example - F31

(3) Carefully rest the new anode in the slot onthe plastic support pipe.

(4) Screw the new anode to the socket in theinspection cover and replace rubber gaskets andcarefully fit the covers.

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24 Immersion Heaters

General• All work should be carried out by suitably qualified

personnel.• Heaters must be handled with care and stored in

dry conditions.• Adequate withdrawal space must be provided to

allow the removal of the heater assembly.• Carefully remove all protective packaging and

visually inspect unit for any transit damage.• All prevailing rules, regulations and bylaws in force

at the time and place of installation must beobserved.

• Heaters must only be immersed in the fluid theyare designed to heat.

• The introduction of alternative fluids even in smallconcentrations for purposes such as sterilisingmay cause serious damage to the heater and willinvalidate the warranty.

• Any modification not carried out by Heatex Limitedor its approved agent will invalidate certificationand warranty.

• Precautions must be taken to prevent damage toenclosure seals.

Installation• The heater should be securely fixed in position and

all terminal connections checked for tightnessbefore energising.

• The installed orientation of horizontally mountedheaters must be such that any thermostats orother temperature sensors are uppermost.

• Sealing gaskets must be undamaged.• The terminal box must not be used for tightening

heater into tank or vessel.

Electrical Supply Connection• Refer to wiring diagram on page 25.• The cable entry or gland plate is positioned on the

side of the terminal box.• Before connection ensure that the supply

corresponds with that specified on the rating label.• Ensure that the sizes and types of cables to be

used are suitably rated for the load and temperatureof the unit.

• Each heater must be protected by a suitably ratedover current device.

• The cables must enter the heater terminal box viaa suitable cable gland to maintain the IP rating andbe fitted by a qualified person.

Earth Connection

Operation• Ensure that the active sections of all the heating

elements are fully immersed in the fluid to beheated at all times whilst energized.

• Heat is transferred by means of electric heatingelements.

• Control of the heater is facilitated bythermostats, thermocouples or RTDs andreference should be made to the wiring diagraminside cover to ensure that these are correctlyconnected and set prior to energising the heater.

• Where a manual reset thermostat or cut-out isinstalled, the terminal box cover will have to beremoved after isolating the heater to enable areset to be carried out.

THESE HEATERS MUST BE EARTHEDAn earth connection is provid-ed inside the terminal box.

Routine Maintenance

Maintenance• All prevailing site safety regulations shall be

adhered to at all times.• Equipment is to be fully isolated from the

electrical supply and locked off before and whilstany work is being carried out.

3 Monthly• Generally inspect the equipment for external

damage or leaks.

6 Monthly• Isolate the electrical supply and remove the

cover.• Ensure the terminal box is clean and dry

internally.• Ensure the electrical terminals are intact and

secure.• Check that the heating element insulation

resistance is at least 2 mega ohms.• Check the continuity of all elements.• Refit cover with new gasket if required.• Ensure that earth continuity is maintained

between all exposed conductive material andmain site structure.

Annually• Carry out all 3 monthly and 6 monthly checks

as above.• Check for element failure or low insulation

resistance.

• If heaters are being left unused for a periodgreater than 3 months, carry out 6 monthlymaintenance before energizing.

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Immersion Heaters

25Immersion heater Electrical Diagrams

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Immersion heater Electrical Diagrams

26 Fault finding

Please carry out checks as per the list below when faults occur. If you cannot rectify the fault,contact Hoval Customer Services or your installer. Telephone number and e-mail addressare shown on the rear cover.

Symptom Possible Cause Action

A. Primary WaterCircuit Inefficient

(1) Leakage in system.

(2) Pump faulty or inoperative.

(3) Boiler faulty or inoperative.

(4) Circuit not properly vented.

(5) Pump not of sufficient duty.

(1) Check pipe connection. Renewif required.

(2) Refer to appropriate pump partdocument.

(3) Refer to appropriate boiler partdocument.

(4) Vent primary system.

(5) Change pump speed or pump.

Symptom Possible Cause Action

A. Secondary watertemperature not assetting on thermostat.

(1) Leakage in system.

(2) Pump faulty or inoperative.

(3) Thermostat faulty.

(4) Electrical fault in control system.

(5) Calorifier scaled up.

(6) Calorifier not large enough for loadimposed.

(7) Low primary temperature.

(8) Diverting valve bypassing.

(1) Check pipe connection. Renewif required.

(2) Refer to appropriate pump partdocument.

(3) Check and replace if required.

(4) Refer to appropriate control sys-tem part document.

(5) Mechanically / chemically de-scale as necessary.

(6) Change calorifier or add calorifi-er / buffer vessel.

(7) Turn up boiler thermostats / in-crease primary flow rate.

(8) Check primary pipe cools whenhot water not required.

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Fault Finding Chart

27Electrical Diagrams

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Wiring Diagrams for Open Vented Calorifiers

28 Electrical Diagrams

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Wiring Diagrams for Unvented Calorifiers

29Notes

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Conservation of EnergyProtection of the Environment

Hoval Limited, Northgate, Newark, Notts NG24 1JNTelephone: Service Desk - 01636 593413

Spares Desk - 01636 593412 Fax - 01636 673532

e-mail: [email protected] and [email protected] Site: www.hoval.co.uk

November 20154214947-00

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