■ Description
Hoval Max-3 plus (420-2700)Oil/gas boiler
Subject to alterations, 1.8.2013 79
Hoval Max-3 plusOil/gas boiler
Boiler• High-efficiencyboileraccordingtoEN14394forfiringofheatingoilELandgas.
• Max-3plus(420-1250)complieswiththePressureEquipmentDirective97/23/EG
• Boilercompletelywelded• ForLowNOx-burnerwithinternfluegasre-
cir cu lation• Insulationattheboilerbody80mmmineralwoolmat
• Boilercompletelycasedwithsteelplate, redpowdercoated
• Fluegasoutlettotherear• Heatingflowconnectiontothetop,heatingreturnconnectionstotherear,incl.counterflanges,screwsandseals
Optional• Controlpanelwithboilercontrolandregula-torsindifferentexecutions
• FreestandingcalorifierseeCalorifiers• Boilerdoorswivelstotheleft• Deliveryinsinglepartsandweldingonsite(Max-3plus(420-1250)),timetodeliveryapprox.8weeks
Delivery• Boiler,insulationandcasing deliveredseparatelypacked
On site• Mountingofinsulationandcasing
Model rangeMax-3plus OutputType kW
(420) 147 - 420(530) 185 - 530(620) 217 - 620(750) 263 - 750(1000) 350 -1000(1250) 437 -1250(1500) 525 -1500(1800) 630 -1800(2200) 770 -2200(2700) 945 -2700
Control panel TopTronic®T/U3.1• Foroperatingtemperatureupto90°C• Formountingontopofboiler HovalMax-3plus(420-1250) mountingontop HovalMax-3plus(1500-2700) mountinglaterallyontheleftortheright
• Integratedcontrolfunctionfor: - 1mixingcircuit - 1heatingcircuitwithoutmixingoperation - domestichotwaterloadingcircuit
• Optiontoexpandthefunctionsby - differentKeyModulesand/or - mountingofanadditionalheatingregula-
torTopTronic®T/N(seeaccessories)• Mainswitch„I/O“• Safetytemperaturelimiter110°C• Fuse6.3A• Troubleindication“Burner”• Burnerrunningtimemeterandcount-up
counter• Boilersensor• LargeLCDdisplay• Rotarypushbutton
• Buttonfor - daytimeroomtemperature - nightroomtemperature - hotwatertemperature - operatingmodeselection(holiday,absent,heatingoperationprolongation,automatic,summer,heatingoperationcontinuous-reduced-frostprotection)
- adjustingtheheatingcurves - systeminformation - emissionmeasurement andmanualoperation
• OutdoorsensorAF200• Flowsensorwithplug• Calorifiersensorwithplug• Plugconnectionforburner• Connectionavailableforroomstations
Delivery• Controlpanelseparatelydelivered
On site• Mountingofthecontrolpanelattheboiler• Installationofthecontrolpanelformountingsideways
Control panel TopTronic®T/U3.2• Functionslikecontrolpanel TopTronic®T/U3.1,but:
• Foroperatingtemperatureupto105°C• Safetytemperaturelimiter120°C
Optional• Safetytemperaturelimiter130°C
Delivery• Controlpanelseparatelydelivered
On site• Mountingofthecontrolpanelattheboiler• Installationofthecontrolpanelformountingsideways
Permission BoilerDirective on appliances burninggaseous fuels 90/396/EGMax-3plus(420-1250):CE-Product-ID-No. CE-0085BL0015PED Pressure Equipment Directive 97/23 EG
■ Description
80 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)Oil/gas boiler
Control panel with thermostat T 2.2• ForsystemswithoutTopTronic®regulator.• Fordirect2-stageburnercontrol,require-mentstartingfromexternalcalorifier-orheaterinstructionispossible.
• Mainswitch„I/O“• Safetytemperaturelimiter110°C• Selectorswitchburnerload• Switchsummer/winter• 3boilertemperatureregulators30-90°C - temperatureregulatorforbaseloadheat-
ing - temperatureregulatorforfullloadheating - temperatureregulatorforcalorifier• Boilerandburnerbreakdownlamp• Plugconnectionforburner (withcableandplug)
Optional• 2runningtimemetersintegrated• 2burnerrunningtimemetersandcount-upcountersintegrated
• Fluegasthermometer,4,5mcapillarytube
Delivery• Controlpanelseparatelydelivered
On site• Mountingofthecontrolpanelattheboiler• Conversionoftheboilercontrolforsidemounting
Control panel with thermostat T 0.2• Forexternalcontrol• ForsystemswithoutTopTronic®regulator• Forspecialcontrolfunction
• Mainswitch„I/O“• Safetytemperaturelimiter120°C,• 3boilertemperatureregulators50-105°C - temperatureregulator
forbaseloadheating - temperatureregulatorforfullloadheating - temperatureregulatorforcalorifier• withoutburnerplugconnection
Optional• 2runningtimemetersintegrated• 2burnerrunningtimemetersandcount-upcountersintegrated
• Fluegasthermometer,4,5mcapillarytube• Safetytemperaturelimiter130°C
Delivery• Controlpanelseparatelydelivered
On site• Mountingofthecontrolpanelattheboiler• Conversionoftheboilercontrolforsidemounting
■ Part N°
Part N°
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 81
Boiler3-passboilermadeofsteelforoil/gas LowNOxfiring,withoutcontrolpanelForoperatingtemperatureof90°Cor105°C
Execution: complete deliveryBoiler,insulationandcasingseparatelypackedanddelivered.
WorkingMax-3plus Output pressureType kW bar
(420) 147 - 420 6(530) 185 - 530 6(620) 217 - 620 6
(750) 263 - 750 6(1000) 350 -1000 6(1250) 437 -1250 6(1500) 525 -1500 6
(1800) 630 -1800 6(2200) 770 -2200 6(2700) 945 -2700 6
Oil/gas boilerMax-3 plus (420-1250) PGSwithout control for mounting on site
Execution: delivery in single parts for mounting on siteInthePartN°forweldingonsite arecontained:- Welding- Mounting(Boilerdoor,fluegascollector)- Leakagedetectionunderpressure- Priming
InthePartN°forweldingonsite are notcontained:- Bringingtheindividualparts intotheboilerhouse
- Mountingofinsulationandcasing- Driveandspendthenight- Waterandelectriccurrentatplace(Mounting on site takes place according to the strict quality standards of the factory assembly)
Timetodeliveryapprox.8weeks
Max-3 plus Oil/gas boiler (420-2700)
7011 939 7011940 7011941 7011942 7011943 7011944 7011945 7011946 7011947 7011948
Thecondensatetrapmustimperativelybemountedonthefluegasoutletoftheboiler!
Theminimumboileroperatingtemperatureandtheminimumboilerreturntemperaturemustimperativelybeobserved (seetechnicaldata). Aconstantreturntemperaturecontrolmustbeprovided!
Boiler controller TopTronic®T/U3.1Max.operatingtemperature90°COperatingpressure4bar-Uno-3(50-160,360),Max-3(420-1250)Operatingpressure5bar-Uno-3(190-280)Formountingontopofboiler(sideways,changeonsite).Integratedcontrolfunctionfor-1mixingcircuit-1heatingcircuitwithoutmixer-domestichotwaterloadingcircuitincl.outdoorsensor,flowsensorandcalorifiersensorwithplugOptiontoexpandthefunctionsby-differentkeymodulesand/or-mountingofanadditionalheatingregulatorTopTronic®T/N(seeaccessories)
6020537
Boiler controller TopTronic®T/U3.2Max.operatingtemperature105°COperatingpressure3bar-Uno-3(50-160)Operatingpressure4bar-Uno-3(190-360)Max-3(420-1250)TheboilercomplieswiththePressureEquipmentDirective(PED)97/23/EC.Requestforcorrespondingboilerplaterequired.FunctionslikeboilercontrollerTopTronic®T/U3.1Delivery:Boilercontrollerseparatelydelivered
6020538
Contact sensor VF204canbeusedasfloworreturnflowsensorwith4mcable
2023 998
■ Part N°
Part N°
82 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)
Control panel with heating regulator TopTronic®T to Hoval Max-3 plus
Forindirectreturnhighattitude.Returnhighattitudethroughclosingoftheheatingcirclemixer(mainpumpnecessary)
M
T
Blind flange mademadeofsteelincl.setscrewsandgaskettoMax-3(420,530) 6002192Max-3(620,750) 6030026Max-3(1000-2200) 6002156Max-3(2700) 6017504
Intermediate flange drilled to match burnermadeofsteelincl.setscrewsandgaskettoMax-3(420,530) 6017595Max-3(620,750) 6017593Max-3(1000-2700) 6017594
Flue gas thermometer4m,capillarytube
241149
■ Part N°
Part N°
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 83
Control panel T 0.2• Foroperatingtemperatureupto105°C• Forexternalswitchingcommand• ForsystemswithoutTopTronic®regulator• Forspecialcontrolfunction withoutburnerplugconnection
- withoutburnerrunningtimemeter andcount-up-counter
6015016
- incl.2burnerrunningtimemeters integrated
6015475
- incl.2burnerrunningtimemeters andcount-up-countersintegrated
6015476
Control panel T 2.2• ForsystemswithoutTopTronic®regulator.• Fordirect2-stageburnercontrol, incl.plugconnectionforburnerrequirementstartingfromexternalcalorifier-orheaterinstructionispossible.
- withoutburnerrunningtimemeter andcount-up-counter
6015017
- incl.2burnerrunningtimemeters integrated
6015477
- incl.2burnerrunningtimemeters andcount-up-countersintegrated
6015478
Control panel with thermostat
Accessories to control panel with thermostat
Additional heating regulator set ZN1forextendingfunctionalityandimplementingfurtherheatingcircuitsConsistingof:Heating regulator TopTronic®T/Nfor-1mixercircuit-1heatingcircuitwithoutmixer-hotwaterloadingOnlyonekeymoduleperregulatorispossible!Flow sensor VF202Kwith2mcableandplug.CablesetforconnectingtheauxiliaryheatingregulatorTopTronic®T/Nwiththeboiler controllerMountingon-site
6020574
Room station RS-TforTopTronic®Teffectiveononemixingcircuit
2034939
Remote control RFF-TforTopTronic®Teffectiveononemixingcircuit
2022 239
Outdoor sensor AF 200(maybeincludedintheheatgeneratorscopeofdelivery)foronemixingcircuitorforthemeanvalue(perregulator2outdoortemperaturesensorspossible)
2022995
■ Part N°
Part N°
84 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)
Accessories to heat regulation system TopTronic®T
Key module 1 for Hoval TopTronic®Tfor2.mixingcircuitKey module consists of:Functionkey1,1flowsensorVF204Swithplug,2looseplugsOnly one key module is possible!
6012154 1
1
System approaches and applicationsseeHovalCD
Communication module/ remote connection seeControls
Kit BMS-Modul 0-10V(Building management system)Consistingof:BMS-ModuleandtrafoCan be installed in the boiler control panel!
6015195
Contact sensor VF204Scanbeusedasfloworreturnflowsensorwith4mcableandplug
6012688
Flue gas temperature sensor PT 1000/4L=2.5mincludingfixingscrews(installationonsite)
691357
Cable sensor KVT 20/5/6S5mcableandplug
6012687
■ Part N°
Part N°
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 85
Commissioning
Commissioningmustbemadebyworksser-viceorHovaltrainedauthorizedserviceman/companyisconditionforwarranty.
Forcommissioningandotherservices pleasecontactyourHovalsalesoffice.
Service
Flow temperature guardforunderfloorheatingsystem (perheatingcircuit1guard)15-95°C,differentialgap6K,capillarytubemax.700mm,setting(visiblefromtheoutside)insidethehousingcover.
clamp-on thermostat RAK-TW1000.SThermostatwithstrap,withoutcableandplug
242902
Immersion thermostat RAK-TW1000.S SB 150Thermostatwithpocket½“-depthofimmersi-on150mmbrassnickel-plated
6010082
Vibration elements for boiler socketForsoundandvibrationabsorbation. Madeofrubber.Crosssection80/50mm.
Delivery4vibrationelementsperboiler, mountedundertheboilersocket toMax-3plus LengthType Setofpieces mm
(420,530) 4 200 (620,750) 4 400(1000,1250) 4 500(1500,1800) 4 800(2200,2700) 6 800
6003739 6003741 6003742 6005623 6005624
■ Technical data
86 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)
Possible operating conditions
Fuel Heating oil EL Natural gas H
min.boilertemperature °C 65 75min.returntemperature °C 55 65
Returntemperaturecontrol yes yes
Max-3 plus
Type (420) (530) (620) (750) (1000) (1250)
•Nominaloutputat80/60°C kW 420 530 620 750 1000 1250•Rangeofoutput(at80/60°C) kW 147-420 185-530 217-620 263-750 350-1000 437-1250 •Burnerinputmaximum kW 441 557 651 788 1050 1313
•Maximumboileroperatingtemperature1 °C 90 90 90 90 90 90•Minimumboileroperatingtemperature °C seetableoperatingconditions(below)•Minimumboilerreturnflowtemperature °C seetableoperatingconditions(below)•Minimumfluegastemperatureatboiler °C seetableoperatingconditions(below)•Safetytemperaturelimitersetting °C 110 110 110 110 110 110 (waterside)2
•Working/testpressure bar 6/9,6 6/9,6 6/9,6 6/9,6 6/9,6 6/9,6•Boilerefficiencyatfullloadat80/60°C % 95,2/89,8 95,2/89,8 95,2/89,8 95,2/89,8 95,2/89,8 95,2/89,8(relatedtolower/uppercalorificvalue(heatingoilEL))•Boilerefficiencyatpartialload30% % 97,1/91,6 97,1/91,6 97,1/91,6 97,1/91,6 97,1/91,6 97,1/91,6(accordingtoEN303)(relatedtolower/uppercalorificvalue(heatingoilEL))•Standardefficiencyat75/60°C % 97,0/91,5 97,0/91,5 97,0/91,5 97,0/91,5 97,0/91,5 97,0/91,5(DIN4702part8)(relatedtolower/uppercalorificvalue(heatingoilEL))•Stand-bylossqBat70°C Watt 1000 1035 1120 1180 1250 1380
•Fluegasresistanceatnominaloutput mbar 5,6 6,3 6,0 7,5 8,3 9,8 10,8%CO2,500moversealevel(tolerance±20%)•Fluegasmassflowatnominaloutput kg/h 680 859 1004 1215 1619 2025 10,8%CO2 naturalgas
•Flowresistanceboiler3 z-value 0,022 0,022 0,008 0,008 0,003 0,003•Waterflowresistanceat 10K mbar 28,5 45,4 22,6 33,1 22,0 34,4•Waterflowresistanceat 20K mbar 7,1 11,4 5,6 8,3 5,5 8,6•Waterflowvolumeat 10K m³/h 36,0 45,0 53,0 64,0 86,0 107,0•Waterflowvolumeat 20K m³/h 18,0 22,5 26,5 32,0 43,0 53,5
•Boilerwatercontent Litre 552 520 969 938 1528 1478•Boilergasvolume m³ 0,583 0,602 0,846 0,872 1,350 1,390•Insulationthicknessboilerbody mm 80 80 80 80 80 80•Weight(incl.casing) kg 1111 1171 1795 1831 2535 2643Weight(withoutcasing) kg 943 1000 1590 1620 2360 2460 •Combustionchamberdimension Øinsidexlength mm 606/1624 606/1624 684/1899 684/1899 782/2182 782/2182•Combustionchambervolume m³ 0,466 0,466 0,669 0,669 1,047 1,047
•Dimensions seeDimensions
•Maximumdepressioninfluegassystem Pa 50 50 50 50 50 50(boilerconnection)
1 LimitedbytheboilercontrolU3.1andT2.2to90°CorU3.2andT0.2to105°C.2 MaximumsafetytemperatureforboilercontrolU3.1andT2.2:110°CorU3.2and=T0.2:120°C.3 Flowresistanceboilerinmbar=volumeflow(m3/h)2 xz
■ Technical data
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 87
Possible operating conditions
Fuel Heating oil EL Natural gas H
min.boilertemperature °C 65 75min.returntemperature °C 55 65
Returntemperaturecontrol yes yes
Max-3 plus
Type (1500) (1800) (2200) (2700)
•Nominaloutputat80/60°C kW 1500 1800 2200 2700•Rangeofoutput(at80/60°C) kW 525-1500 630-1800 770-2200 945-2700•Burnerinputmaximum kW 1575 1890 2310 2835
•Maximumboileroperatingtemperature1 °C 90 90 90 90•Minimumboileroperatingtemperature °C seetableoperatingconditions(below)•Minimumboilerreturnflowtemperature °C seetableoperatingconditions(below)•Minimumfluegastemperatureatboiler °C seetableoperatingconditions(below)•Safetytemperaturelimitersetting (waterside)2 °C 110 110 110 110
•Working/testpressure bar 6/9,6 6/9,6 6/9,6 6/9,6•Boilerefficiencyatfullloadat80/60°C % 95,2/89,8 95,2/89,8 95,2/89,8 95,2/89,8(relatedtolower/uppercalorificvalue(heatingoilEL))•Boilerefficiencyatpartialload30%(acc.toEN303) % 97,1/91,6 97,1/91,6 97,1/91,6 97,1/91,6(relatedtolower/uppercalorificvalue(heatingoilEL))•Standardefficiencyat75/60°C(DIN4702part8) % 97,0/91,5 97,0/91,5 97,0/91,5 97,0/91,5(relatedtolower/uppercalorificvalue(heatingoillEL))•Stand-bylossqBat70°C Watt 1850 1950 2100 2300
•Fluegasresistanceatnominaloutput, 10,8%CO2,500moversealevel(tolerance±20%) mbar 7,8 9,3 10,7 9,8•Fluegasmassflowatnominaloutput10,8%CO2 naturalgas kg/h 2429 2916 3564 4374
•Flowresistanceboiler3 z-value 0,002 0,002 0,002 0,002•Waterflowresistanceat 10K mbar 33,0 47,6 71,1 107,1•Waterflowresistanceat 20K mbar 8,3 11,9 17,8 26,8•Waterflowvolumeat 10K m³/h 129,0 154,0 189,0 231,0•Waterflowvolumeat 20K m³/h 84,5 77,0 94,5 115,5
•Boilerwatercontent Litre 2343 2750 3050 3550•Boilergasvolume m³ 1,956 2,510 2,761 3,037•Insulationthicknessboilerbody mm 80 80 80 80•Weight(incl.casing) kg 3614 4693 5077 5649Weight(withoutcasing) kg 3266 4288 4647 5189
•Combustionchamberdimension Øinsidexlength mm 880/2415 980/2595 980/2895 980/3200•Combustionchambervolume m³ 1,58 2,07 2,30 2,41
•Dimensions seeDimensions
•Maximumdepressioninfluegassystem Pa 50 50 50 50(boilerconnection)
1 LimitedbytheboilercontrolU3.1andT2.2to90°CorU3.2andT0.2to105°C.ForMax-3plus(1500-2700) withoperatingtemperatureupto105°C,individualapprovalinfactoryaccordingtoPressureEquipmentDirectiverequired.
2 MaximumsafetytemperatureforboilercontrolU3.1andT2.2:110°CorU3.2andT0.2:120°C. ForMax-3plus(1500-2700),individualapprovalinfactoryaccordingtoPressureEquipmentDirectiverequired.
3 Flowresistanceboilerinmbar=volumeflow(m3/h)2 xz
■ Dimensions
88 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)
Max-3 plus (420-1250)(Dimensionsinmm)
Max-3plus Type a b c f g h h1 i k l l1 m n Øo p q r
(420,530) 1060 1190 515 1770 181 1435 1230 950 104 2178 2074 641 100 299 54 34 175(620,750) 1180 1310 550 2045 181 1555 1350 1050 105 2452 2347 666 95 349 55 35 170(1000,1250)1370 1500 635 2330 181 1755 1549 1250 107 2739 2632 681 111 349 77 37 175
(1500) 1560 1609 665 2685 212 - 1710 1350 103 3040 2937 722 80 447 83 34 65(1800) 1720 1769 735 3055 214 - 1868 1460 103 3424 3322 724 80 447 83 52 65(2200) 1720 1769 735 3355 214 - 1870 1460 101 3724 3623 724 80 447 81 50 65(2700) 1750 1799 755 3700 212 - 1900 1410 82 4032 3950 722 80 647 82 51 65
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Max-3plus Type s t u v w
(420,530) 350 595 660 1330 450(620,750) 550 722 786 1445 475(1000,1250) 415 620 685 1660 590
6 DrainR1½" 7 Cablerouting 8 Controlpanel 9 Electricalconnection10 BushingRp¾“withimmersionsleeve
forboilertemperaturesensor
2 Return (420,530) DN100,PN6 (620,750) DN125,PN6 (1000-2200) DN150,PN6 (2700) DN200,PN6 3 Fluegasoutlet 4 Cleaningopening 5 FluegascollectorcleaningopeningR1"
Max-3 plus (1500-2700)(Dimensionsinmm)
(1500) 310 777 842 1790 695(1800) 310 890 952 1950 773(2200) 310 890 952 1950 773(2700) 370 917 982 1980 790
1 Flow (420,530) DN100,PN6 (620,750) DN125,PN6 (1000-2200) DN150,PN6 (2700) DN200,PN6
4 4
2
6
5
10
1
8
3
26
8
9
■ Dimensions
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 89
Base size
Dimensions without insulation and casingBoilerincl.flange,outletwithoutfluegascollector.
(Dimensionsinmm)
Required min. width of door and corridor to bring in the boilerThestatedmeasurementsareminimaldimensions
B K=xL T
B T=xL K
T = DoorwidthK = CorridorwidthB = BoilerwidthL = max.lengthofboiler
K
T
< 150B
L
1 Flow2 Return
3 Fluegasoutlet6 Drain
Max-3plusType a * b c d e f g h i k l m n o
(420,530) 1920 150 1770 277 2222 1060 1180 196 120 1060 1376 2077 175 460(620,750) 2195 150 2045 228 2498 1180 1300 196 120 1180 1496 2353 172 485(1000,1250) 2480 150 2330 228 2783 1370 1500 160 120 1380 1660 2638 198 500
(1500) 2685 164 2568 260 3083 1560 1680 162 120 1560 1842 2923 240 510(1800) 3055 166 2760 450 3467 1720 1840 162 120 1720 2002 3325 430 510(2200) 3355 166 3060 450 3767 1720 1840 162 120 1720 2002 3625 430 510(2700) 3700 164 3390 430 4075 1750 1870 169 120 1750 2039 3953 430 510
Max-3plusType p q r s v w x y z
(420,530) 1072 175 350 950 475 990 - - -(620,750) 1192 170 550 1050 535 1110 - - -(1000,1250) 1392 175 415 1250 630 1298 - - -
(1500) - 65 310 1350 725 1494 1790 153 -(1800) - 65 310 1460 805 1654 1950 153 -(2200) - 65 310 1460 805 1654 1950 153 -(2700) - 65 370 1410 820 1684 1980 153 -
*Max-3plus(1500-2700)socketprotudes
w=innerØ
■ Dimensions
90 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)
Furnace dimensions
Max-3 plus (420, 530)
15˚
45˚
Screw joint flange Max-3 plus (420, 530)4xM12(45°)4xM12(15°)
15˚
60˚
Screw joint flange Max-3 plus (620, 750)6xM12(15°)
Screw joint flange Max-3 plus (1000-2700)6xM16(15°)
Max-3 plus (620-2700)
Swinging out of boiler doorBoilerdoorisswivelingtotherightorleft(Dimensionsinmm)
Max-3plusType a b
(420) 1060 150 (530) 1060 150 (620) 1180 150 (750) 1180 150(1000) 1370 150(1250) 1370 150(1500) 1393 58(1800) 1553 58(2200) 1553 58(2700) 1585 58
G H
F
E
Dimensions
Max-3plusType A B C D E F G H M
(420,530) 290 330 515 250 606 1624 163 30 420(620,750) 350 400 550 310 684 1899 163 30 500(1000,1250) 400 450 635 330 782 2182 163 30 550
(1500) 380 450 655 385 880 2415 191 30 550(1800) 380 450 735 395 976 2595 191 30 550(2200) 380 450 735 395 976 2905 191 30 550(2700) 420 480 735 410 976 3233 191 30600x560
(Dimensionsinmm)
■ Technical data
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 91
Flue gas output diagrams
Flue gas temperature and output range
Inordertoreachagoodcombustionquality(optimumburn-out),theindicatedminimumperformancemustnotbeundercut.
Theminimumexhaustgastemperatureistobecoordinatedabsolutelywithfire-placecon-ditions,otherwisesulfuricacidformationcancausefire-placesootings.
Withnewinstallationsacid-proofchimneysaretobeplanned,ortheexhaustgastemperaturemustbeadjustedmorehighly(min.160°C).
kW = Boileroutput°C = Fluegastemperatureonaclean
surface,boilerflowtemperature80°C,returntemperature60°C
(inaccordancewithDIN4702).
- OperationwithheatingoilEL, λ =1,11withmax.burneroutput (CO2naturalgas=10,8%)
- Areductionoftheboilerwatertemperatureto-10Kcausesareductionofthefluegastemperatureofapprox.6-8K.
- AmodificationoftheCO2concentrationof +/-1%causesamodificationofthefluegastemperatureofapprox.-/+8K.
0
1
2
3
4
5
6
7
8
9
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11
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
heiz
gass
eitig
er W
ider
stan
d (m
bar)
Kesselleistung (kW)
420530620
750
1000
1250
1500
27001800
2200
Fluegasresistance(m
bar)
Boileroutput(kW)
Flue gas resistor
100.0
110.0
120.0
130.0
140.0
150.0
160.0
170.0
180.0
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
Kesselleistung (kW)
Ab
gas
tem
per
atu
r (°
C)
420 530 620 750 1000 1250 1500 1800 2200 2700
Flu
e ga
s te
mpe
ratu
re (
°C)
Boiler output (kW)
■ Engineering
92 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)
• Fordampingofflamenoiseitispossibletoinstallasilencerintothefluegastube(spaceshouldbeforeseenforlaterinstal-lation).
Chimney/ flue gas systemFlue gas pipe• Thefluegastubebetweenboilerandchim-neymustbeconnectedwithanangle30-45°tothechimney.
D
2 x D 1D
< 2D
D
• Thefluegastubemustbedesignedthatnocondensatewatercangetintotheboiler.Acondensatetrapmustimperativelybemoun-tedonthefluegasoutletoftheboiler.
• Acloseablefluegasmeasuringsocketwithaninnerdiameterof10-21mmmustbefore-seen.
Chimney• Thefluegassystemmustbehumidity-insen-sitiveandacid-proofandadmittedforfluegastemperaturesupto>160°C.
• Forexistingchimneyinstallationtherestora-tionmustbecarriedoutaccordingtothein-structionsofthechimneyconstructor.
• Calculationoftheprofileofthechimneyac-cordingtoEN13384-1and2.
• Itisrecommendabeltouseasecondaryairvalveforchimneydraftlimiting.Theairvalvemustbemountedafterthefluegassoundabsorber(iffitted).
Expansion tank/expansion• Ideally,thepressureexpansiontankshouldbeconnectedtotheheatingsystemasde-scribedinourexampleapplications,witharemovableorsealableactuationdevice.Thismeansthatitisnotnecessarytodraintheentiresysteminordertocarryoutwork.
Safety valve• Asafetyvalveanautomaticairventmustbeinstalledinthesafetyflow.
Standards and guidelinesThefollowingstandardsandguidelinesmustberespected:
• Technicalinformationandinstallationmanu-aloftheHovalcompany.
• Hydraulicandcontroltechnicalcontrolregu-lationsoftheHovalcompany.
• Localbuildinglaw• Fireprotectionstandards• DVGWguidelines• DINEN12828 Heatingsystemsinbuildingplansofhotwa-terheatingplants.
• DINEN12831heatingplantsinbuildings - procedureforcomputingthenormed
heatingcapacity• VDE0100
Water qualityHeating water:• TheEuropeanStandardEN14868andtheDirectiveVDI2035mustbeobserved.
• Hovalboilersandcalorifiersaredesignedforheatingplantswithoutsignificantoxygenin-take(planttypeIaccordingtoEN14868).
• Plantswith - continuous oxygenintake(e.g.under-
floorheatingsystemswithoutdiffusionproofplasticpiping)or
- intermittentoxygenintake(e.g.wherefrequentrefillingisnecessary)
mustbeequippedwithseparatecircuits.• Treatedheatingwatermustbetestedatleast1xyearly.Accordingtotheinhibitormanufacturer‘sinstructions,morefrequenttestingmaybenecessary.
• Arefillingisnotnecessaryifthequalityoftheheatingwaterinexistinginstallations(e.g.exchangeofboiler)conformsto VDI2035.TheDirectiveVDI2035appliesequallytothereplacementwater.
• Newandifapplicableexistinginstallationsmustbeadequatelycleanedandflushedbe-forebeingrecharged!Theboilermayonlybefilledaftertheheatingsystemhasbeenflushed.
• Partsoftheboilerwhichhavecontactwithwateraremadeofferrousmaterials.
• Onaccountofthedangerofstresscrackingcorrosionthechloride,nitrateandsulfatecon tentsoftheheatingwatermustnotex-ceed200mg/lintotal.
• hepHvalueoftheheatingwatershouldliebetween8.3and9.5after6-12weeksofheatingoperation.
Filling and replacement water:• ForaplantusingHovalboilersuntreateddrinkingwaterisgenerallybestsuitedasfil-lingandreplacementwater.However,thequalityoftheuntreateddrinkingwatermustatleastfulfilthestandardsetinVDI2035orbedesalinatedand/orbetreatedwithinhibi-tors.ThestipulationsofEN14868mustbeobserved.
• Inordertomaintainahighlevelofboileref-ficiencyandtoavoidoverheatingoftheheatingsurfacesthevaluesgivenintheta-bleshouldnotbeexceeded(dependentonboilerperformanceratings-formulti-boilerplantsratingofsmallestboilerapplies-andonthewatercontentoftheplant).
• Thetotalamountoffillingandreplacementwaterwhichisusedthroughoutthetotalser-vicelifeoftheboilermustnotexceedthreetimesthewatercapacityoftheplant.
Heating systemCombustion air• Thecombustionairsupplymustbewarran-ted.Theairopeningmustnotbelockable.
• Minimalfreecrosssectionforairopening6.5cm2per1kWboileroutput.
Oil burner mounting• Formountingoftheburneranadapterflangemayberequireddependingonthesi-zeoftheburnerflange.Theadaptorflangeincludingscrewsmustbedeliveredbytheburnercompany.
• Thepipesmustbefittedinsuchawaythattheboilerdoorcanbeopenedcompletely.
• Theconnectionsmustbeflexibleandleadinasufficientlargelooptotheburnersothattheboilerdoorcanbeswungoutaround90°totheleftorright.
• Thespacebetweenburnerpipeandswivelflangemustbeisolate.
(Deliverybytheburnercompany)
Electric connection of the burner• Controlvoltage1x230V• Burnermotor1x230V/3x400V.• Theburnermustbeconnectedtotheburnerconnectionplugoftheboiler.
• Forsafetyreasonstheelectricalcableoftheburnermustbethatshortthattheplugmustberemovedwhenswivellingboilerdoor.
Sound absorbing Soundabsorptionispossiblethroughthefol-lowingsteps:• Heatingroomwalls,ceilingandfloorshouldbeverysolidlybuilt,asoundabsorbershouldbemountedintotheairinlet.Pipeholdersandsupportshouldbeprotectedbymeansofanti-vibrationsleeves.
• Installsoundabsorberhoodforburner.• Iflivingroomsarelocatedaboveorundertheboilerroom,vibrationabsorbershavetobemountedtotheboilerbase.Pipesandfluegastubemustbeconnectedflexiblewithcompensators.
• Pumpshavetobeconnectedwithcompen-satorstothepipes.
Maximum filling quantity according to VDI 2035
Carbonate hardness of filling water up to .....[mol/m3] * <0,1 0,5 1 1,5 2 2,5 3 >3,0f°H <1 5 10 15 20 25 30 >30d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8e°H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300Conductance2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600Boiler size of the individual boiler maximum filling quantity without desalination
200to600kW 50l/kW 50l/kW 20l/kWalwaysdesalinate
over600kW
1 Totalofalkalineearths2 IftheconductanceinµS/cmexceedsthetabularvalueananalysisofthewaterisnecessary.
■ Engineering
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 93
Mounting on site
Max-3 plus (420, 530) Max-3 plus (620, 750)
Max-3 plus (420-1250)
Ifthelocalsituationdoesnotpermitbringinginthewholeboiler,thepossibilityoftheplaceassemblyexists.
• Theelementweldingonsiteincl.pressuretestaretobecoactivetoobtainfromHoval.
Dimensions and weights of the single parts
e
2
d
b
1
a
f
cd
ef
c
1
b
2
a d
d
Timetodeliveryapprox.8weeks
1
2a
b
d
d
e
c
f
1Fireroomcylinder2 Watermantle
Max-3 plus (1000-1250) Combustion chamber 1Max-3plus WeightType a b c kg
(420,530) 730 835 1725 325(620,750) 745 915 2000 410(1000,1250) 800 800 2180 375
Water mantle - half shell 2Max-3plus WeightType d e f kg
(420,530) 500 1000 1665 105(620,750) 560 1120 1940 135(1000,1250) 655 1310 2225 215
Dimensions and weights of the single parts
■ Engineering
94 Subject to alterations, 1.8.2013
Hoval Max-3 plus (420-2700)
Mounting on site
Required space for mounting and welding in the boiler room
Min. room dimensions in mm (420) (530) (620) (750) (1000) (1250)
Length 3700 3700 4500 4500 5000 5000
Width 2200 2200 2500 2500 3500 3500
Height 2500 2500 3000 3000 3200 3200
Assembly aids Ifnoconcretecoverispresent,atwhich achaincoursewithHiltipegscanbein- stalled,anappropriatescaffoldsforloads upto1000kgmustbepresent.
Power connection Apowerconnectionfortheweldingma- chinewitha5-pinplugsocket,3x400V mustbepresent.
Water connection Intheheatingroomawaterconnection(¾“) withfreshwaterforfillingandsqueezingoff theweldedboilerhastobepresent.
Important preparations
• Oldboilermustbedismantledand removed.
• Theheatingroom,ifnecessarywith boilerbase,mustbeavailablewith beginningofwork.
Boiler material
• TheboilermaterialisdeliveredbyHoval (insingleparts)andmustbebrought in on site.
• Ifbringingintheboilerpartsdoesnot takeplaceimmediatelyafterunloading, thepartsaretobestoredweather-pro tected.
Heating room preparation Required space Intheheatingroomsufficientspaceforthe assemblyoftheboilermustbeavailable (seespacerequirementbelow)
Planning hints
■ Examples
Hoval Max-3 plus (420-2700)
Subject to alterations, 1.8.2013 95
Notice :- Thishydraulicschematicisaprincipleschematic.Itdoesnotcontainalldetailsforinstallation.Theinstallationmustbedoneaccordingtolocalconditions,di-mensioningandregulations.
- Forunderfloorheating,aflowtempera-turemonitormustbebuilt-in.
- Shut-offdevicestothesafetyvalve(pressurizedexpansiontank,safetyval-ve,etc.)aretosafeagainstunintendedclosing!
- Mountbagstopreventsinglepipegravi-tycirculation!
RS-T RoomstationAF OutdoorsensorRLF ReturnsensorVF1 Flowsensor1VF2 Flowsensor2VF3 Flowsensor3VF4 Flowsensor4SF Calorifierheater sensor
B1 Flowtemperatureguard (ifrequired)MK1 Pumpmixingcircuit1MK2 Pumpmixingcircuit2MK3 Pumpmixingcircuit3MK4 Pumpmixingcircuit4SLP CalorifierloadingpumpZUP Feedpump
YK1 Actuatormixer1YK2 Actuatormixer2YK3 Actuatormixer3YK4 Actuatormixer4YKR ActuatorreturnmixerCW ColdWaterDHW DomesticHotWater
Hydraulic principle schematic Max-3 plus with heating regulator TopTronic®THydraulic schematic BBDT070
RS-T
AF
TopTronic T
RS-T
1
RS-T
TopTronic T
1
B1VF3
TT
MK3
MYK3
B1VF2
TT
MK2
MYK2
B1VF1
TT
MK1
M
B1VF2
TT
MK2
MYK2
B1VF3
TT
MK3
MYK3YK1
Dies ist einunerlaubterWeg!Gehen Sieeinen Schrittzurück oderlöschen Siedieses Shape!Sie haben dieMöglichkeit einneues Shapezu nehmen!!!hovhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalh
WW
T
KW
SF
SLP
Dies ist einunerlaubter Weg!Gehen Sie einenSchritt zurück oderlöschen Sie diesesShape!Sie haben dieMöglichkeit einneues Shape zunehmen!!!hovhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovavalhovalhovalhova
.
RLF
P
YKR
ZUP
CW
DHW
96