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Page 1: Hoval Max-3 plus (420-2700)

■ 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

Page 2: Hoval Max-3 plus (420-2700)

■ 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

Page 3: Hoval Max-3 plus (420-2700)

■ 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!

Page 4: Hoval Max-3 plus (420-2700)

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

Page 5: Hoval Max-3 plus (420-2700)

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

Page 6: Hoval Max-3 plus (420-2700)

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

Page 7: Hoval Max-3 plus (420-2700)

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

Page 8: Hoval Max-3 plus (420-2700)

■ 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

Page 9: Hoval Max-3 plus (420-2700)

■ 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

Page 10: Hoval Max-3 plus (420-2700)

■ 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

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1

8

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Page 11: Hoval Max-3 plus (420-2700)

■ 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

Page 12: Hoval Max-3 plus (420-2700)

■ 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)

Page 13: Hoval Max-3 plus (420-2700)

■ 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

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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

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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

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per

atu

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C)

420 530 620 750 1000 1250 1500 1800 2200 2700

Flu

e ga

s te

mpe

ratu

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°C)

Boiler output (kW)

Page 14: Hoval Max-3 plus (420-2700)

■ 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.

Page 15: Hoval Max-3 plus (420-2700)

■ 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

Page 16: Hoval Max-3 plus (420-2700)

■ 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

Page 17: Hoval Max-3 plus (420-2700)

■ 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

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