Technical information
Assembly instructions
Oil/Gas condensing boiler
Max-3 condens (3000-5000), Max-3 condens E (3000-5000)
These instructions are applicable
to the following types:
2-Max-3 condens (3000)
2-Max-3 condens (4000)
2-Max-3 condens (5000)
2-Max-3 condens E (3000)
2-Max-3 condens E (4000)
2-Max-3 condens E (5000)
Hoval products must be installed and commissioned
by specialists only. These instructions are intended
for service engineers. Electrical installation must be
performed by a licensed electrical company.
Subject to modifi cations |
4 215 983 / 01 - 10/21
EN
TABLE OF CONTENTS
1. Important notices
1.1 General safety instructions .................................................................................................................................................3
1.2 Explanation of the symbols ................................................................................................................................................3
1.2.1 Warnings ..........................................................................................................................................................................3
1.2.2 Warning symbols...............................................................................................................................................................3
1.2.3 Information ........................................................................................................................................................................3
1.3 On delivery ...........................................................................................................................................................................4
1.4 Warranty ...............................................................................................................................................................................4
1.5 Manuals ................................................................................................................................................................................4
1.6 Regulations, official approvals ...........................................................................................................................................4
1.6.1 Germany § ........................................................................................................................................................................4
1.6.2 Austria § ...........................................................................................................................................................................4
1.6.3 Switzerland § ....................................................................................................................................................................4
2. Installation
2.1 Setting up, levelling .............................................................................................................................................................5
2.2 Syphon assembly information ............................................................................................................................................5
3. Technical information
3.1 Description of the boiler .....................................................................................................................................................6
3.2 Technical data ......................................................................................................................................................................7
3.2.1 Max-3 condens (3000-5000) for natural gas H ...................................................................................................................7
3.2.2 Max-3 condens (3000-5000) for EL low-sulphur fuel oil (sulphur content < 50 mg/kg) ........................................................8
3.2.3 Max-3 condens E (3000-5000) for natural gas H ...............................................................................................................9
3.2.4 Max-3 condens E (3000-5000) for EL eco fuel oil ............................................................................................................10
3.3 Dimensions ........................................................................................................................................................................ 11
3.3.1 Max-3 condens (3000-5000) ........................................................................................................................................... 11
3.3.2 Max-3 condens E (3000-5000) ........................................................................................................................................12
4. Installation
4.1 Boiler room requirements .................................................................................................................................................13
4.2 Flue gas connection and dimensioning ...........................................................................................................................13
4.3 Installing burner Max-3 condens and Max-3 condens E (3000-5000) ..............................................................................14
4.3.1 Fuel ................................................................................................................................................................................15
4.3.2 Electrical connection .......................................................................................................................................................15
4.4 Flue gas and output diagram ............................................................................................................................................16
4.4.1 Max-3 condens (3000-5000) flue gas and output diagram ...............................................................................................16
4.4.2 Max-3 condens E (3000-5000) flue gas and output diagram ............................................................................................17
4.5 Minimum value limiting of boiler return temperature ......................................................................................................18
4.6 Discharge of start-up condensate from the boiler ...........................................................................................................18
4.7 Setting the temperature controllers ..................................................................................................................................18
4.8 Safety valves......................................................................................................................................................................18
4.9 Supply pump ......................................................................................................................................................................18
4.10 Heating pump.....................................................................................................................................................................18
4.11 Heating connections .........................................................................................................................................................18
5. Commissioning
5.1 Water quality ......................................................................................................................................................................19
5.2 Filling the calorifier ...........................................................................................................................................................20
5.3 Commissioning .................................................................................................................................................................20
5.4 Hand-over to the operator / safe-keeping .........................................................................................................................20
6. Maintenance (only for boiler controller with TopTronic® E control)
6.1 Information for combustion controller / chimney sweep regarding emission monitor key ...........................................21
6.2 Cleaning ............................................................................................................................................................................22
6.3 Lubrication of the seal and thread ....................................................................................................................................22
6.3.1 Lubrication of the seal .....................................................................................................................................................22
6.3.2 Lubrication of the thread .................................................................................................................................................22
6.4 Cleaning the flue gas heat exchanger ..............................................................................................................................23
4 215 983 / 012
IMPORTANT NOTICES
The system may only be placed in operation
if all the relevant standards and safety reg u la-
WARNING
WARNING
All electrical power supply circuits must be
!
DANGER
... indicates a situation of immediate danger
which will lead to serious or fatal injuries if
!
WARNING
... indicates a situation of possible danger
which can lead to serious or fatal injuries if
!
CAUTION
... indicates a situation of possible danger
which can lead to minor or slight injuries if
NOTICE
... indicates a situation of possible danger
which can lead to damage to property if not
!
1. Important notices
1.1 General safety instructions
tions have been complied with.
At least the following conditions must be satised for a
trial operation:
- Safety valve installed (system sealed)
- Control in operation (connected to the power supply)
- Sensor for the safety temperature limiter mounted in
the immersion sleeve
- System lled with water
- Expansion tank connected
- Flue gas outlet with ue gas line connected to ue gas
system.
- An adequate supply of fresh air must be guaranteed.
- Burner preset
- Safety equipment of the system is compliant with
EN 12828 (≦ 110 °C STB) or EN 12953-6 (> 111 °C to
≦ 120 °C STB).
- All piping on the boiler must be de-energised. Any voltage
present due to length extensions must be absorbed
through appropriate piping measures (expansion
bends, compensators, spring supports, etc.) and must
not aect the boiler resistance connection piece.
The heat generator can only be de-energised
by disconnection from the mains (e.g. allpole switch).
1.2 Explanation of the symbols
1.2.1 Warnings
not avoided.
not avoided.
not avoided.
avoided.
1.2.2 Warning symbols
The following warning signs are combined for the warning
notes with signal words CAUTION, WARNING and
DANGER.
General warning symbols
switched o before accessing the terminals.
4 215 983 / 01 3
Warning of electrical voltage
1.2.3 Information
Information:
Provides important information.
Provides important information.
Refers to stan dards and directives.
§
IMPORTANT NOTICES
1.3 On delivery
Carry out a visual inspection immediately on receiving the
boiler. If any damage is found, take the necessary steps
as dened in the delivery contract. The respective risk
carrier bears the cost of repairs.
1.4 Warranty
The warranty does not cover defects attributable to:
• Failure to comply with these instructions
• Failure to comply with the operating instructions
• Incorrect installation
• Impermissible modications to the product
• Incorrect handling of the product
• Damage caused by the application of force
• Contaminated operating materials
(gas, water, combustion air)
• Unsuitable chemical additives to the heating water
• Corrosion caused by not observing the required water
quality
• Corrosion by halogen compounds
(e.g. paints, adhesives, solvents)
1.5 Manuals
All instructions relevant to your system can be found in
the Hoval system manual - please keep all manuals!
In exceptional cases, the instructions can be found with
the components!
Further sources of information:
• Hoval catalogue
• Standards, regulations
1.6 Regulations, ofcial approvals
The standards and directives stated under chapter 1.6.1
to 1.6.3 must be taken into account during installation and
operation of the system.
• DIN EN 13384 Flue gas systems – Calculation methods
in heat and ow engineering.
• TRD 721 Safety devices against excess pressures /
safety valves / for steam boilers of Group II.
• VDI 2035 Prevention of damage by corrosion and the
formation of scale in hot water heating systems.
• DIN 57 116 / VDI 0116 Electrical equipment for ring
systems (VDE Regulation).
• For further standards applicable in Germany, see appen dix N-430 020.
1.6.2 Austria §
• ÖNorm 7550
• ÖNorm B 8130 Open water heating systems;
safety devices.
• Norm B 8131 Closed water heating systems;
safety, execution and testing requirements
• ÖNorm B 8133 Hot water production systems;
technical safety requirements.
• ÖNorm B 8136 Heating systems, space requirements
and other building requirements.
• ÖNorm M 7515 Calculations of dimensions of chimneys;
terminology, calculation procedure.
• ÖNorm H 5171
• ÖVGW TR-gas (Austrian Gas and Water Confederation
- Technical Guidelines)
1.6.3 Switzerland §
• VKF - Association of Cantonal Fire Insurers
• Fire prevention authority regulations.
• SVGW Swiss Association for Gas and Water.
• SWKI 91-1 Aeration and ventilation of the boiler room.
• SWKI BT 102-01 Water quality for building services
sys tems.
• SWKI 93-1 Safety engineering installations for heating
systems.
• KRW Corrosion caused by halogen compounds.
• KRW/VSO/FKR Plug-in electrical connections on boilers and burners
1.6.1 Germany §
• DIN EN 12831 Heating systems in buildings - Method
for calculation of the design heat load.
• DIN EN 303 Heating boilers with forced draught burners.
• DIN EN 12828 Sheet 1 and 2
Heating systems in buildings - design of water-based
heating systems.
• DIN 4755 Oil-red systems.
Design, construction and safety engineering requirements.
• DIN 4756 Gas-red systems; construction, execution,
technical safety requirements, planning and execution.
• DIN 18160 House chimneys; requirements, planning
and execution.
• TRD 702 Steam boiler plants with caloriers of the
group II.
and further regulations and standards issued by CEN,
CEN ELEC, DIN, VDE, DVGW, TRD and the legislative
body.
The regulations of the local building authorities, insurance
companies and chimney sweeps must also be taken into
account. The regulations of the responsible gas supply
company are to be complied with if using gas. Approval
by the authorities may be required.
4 215 983 / 014
INSTALLATION
The distance from the wall behind the boiler
must always be sucient in order to gain ac-
col lec tor. It must be possible to swing open
2. Installation
2.1 Setting up, levelling
No special foundation plate is required for erecting the
boiler (sucient supporting capacity for the boiler must
be guaranteed) - for operating weight, see chapter 3.
If there are boiler rooms in the domestic domain, vibration
dampers are to be mounted under the boiler plinth rails.
cess to the cleaning opening in the ue gas
the boiler door with the burner.
Levelling
Align the top edge of the boiler water jacket (boiler lon gitu dinal axis) exactly horizontal.
2.2 Syphon assembly information
When combusting hydrogenous fuels which cool down
below their dew points, the water vapour in the ue gas
condenses. This condensate must be diverted out of the
caloric value heat exchanger or the ue gas system.
The amount of the resulting condensate depends on the
water entry temperature in the heat exchanger, the excess
air in the ue gas and the load of the heat generator.
The following standard values can be assumed for the
resulting amount of condensation (at theoretical 100 %
condensation and consideration of an average humidity):
Natural gas: approx. 0.8 l/m3 gas
Oil-ring: approx. 0.9 l/litre oil
The ue gas condensate must be introduced into the
public sewer network as prescribed. Neutralisation
equipment might be needed - please contact the nearest
Hoval branch.
In particular with oil-ring, the use and suitability of the
neutralisation equipment must be taken into account.
A syphon must be installed directly at the discharge of the
caloric value heat exchanger; it (including the connecting
piping between the heat exchanger and syphon) is to
be designed to be resistant to ue gas temperatures
up to 240 °C and must be lled with water before the
system is commissioned. The height of the syphon must
correspond at least with the ue gas counterpressure
of the heat exchanger (up to about 4 mbar) - start-up
pres sure shocks of the burner or possible additional
counterpressure of the ue gas line must also be taken
into account.
The connection cables of the drainage piping must be
made of corrosion-resistant materials such as PVC or
stain less steel.
After a long system standstill, the water level of the syphon
must be checked and relled with water if necessary.
4 215 983 / 01 5
TECHNICAL INFORMATION
3. Technical information
3.1 Description of the boiler
The Max-3 condens and Max-3 condens E condensing boiler is constructed in 3-compartment form. The heating
gases ow from the cylindrical combustion chamber into the water-cooled reversing chamber and through the 2nd
compartment into the front reversing chamber. The 3rd compartment consists of straight tubes through which the
heating gases are conducted to the ue gas heat exchanger. In the ue gas heat exchanger, the heating gases are
further cooled to increase the boiler eciency. Depending on the operating conditions, the system can be cooled below
the dew point, thereby using the caloric value.
Max-3 condens
Max-3 condens E
4 215 983 / 016
TECHNICAL INFORMATION
3.2 Technical data
3.2.1 Max-3 condens (3000-5000) for natural gas H
Type (3000) (4000) (5000)
Fuel Natural gas H Natural gas H Natural gas H
• Nominal heat output at 80/60 °C kW 3750 5006 6285
• Nominal heat output at 80/30 °C kW 3951 5283 6636
• Heat output range at 80/60 °C kW 768-3750 976-5006 1185-6285
• Heat output range at 80/30 °C kW 832-3951 1063-5283 1296-6636
• Combustion performance kW 792-3942 1005-5256 1220-6615
• Boiler operating temperature max.
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
• Safety temperature limiter setting (water side)
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler eciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 80/30 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 30 % partial load (EN 303)
(related to net caloric value NCV / gross caloric value GCV)
• Nominal eciency at 75/60 °C (DIN 4702-8)
(related to net caloric value NCV / gross caloric value GCV)
• Stand-by losses qB at 70 °C Watts 2125 2349 2566
• Flue gas temperature at nominal output 80/60 °C °C 128 126 132
• Combustion gas resistance at nominal output (natural gas H, 10.5 % CO
500 m above sea level (tolerance ± 20 %)
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO
• Flow resistance boiler
1)
• Flue gas heat exchanger ow resistance z-value 0.008 0.011 0.014
• Boiler water ow rate at 10 K m³/h 321 429 539
• Boiler water ow rate at 20 K m³/h 161 215 269
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.2 4.4 6.1
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 4.3 5.9 7.8
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6452 7172 7886
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7356 8714 -
- At operating / test pressure 10/16 bar kg 8489 10012 12038
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
half the length of the reversing chamber)
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1)
Flow resistance boiler in mbar = ow rate (m3/h)2 x z
2)
Limited by the boiler controller E13.4 TopTronic® E and T2.2 to 90 °C or by E13.5 TopTronic® E and T0.2 to 105 °C.
3)
Max. safety temperature for boiler controller E13.4 TopTronic® E and T2.2: 110 °C or E13.5 TopTronic® E and T0.2: 120 °C.
2)
°C 105 105 105
°C see table of operating conditions (below)
3)
°C 120 120 120
% 95.1/85.7 95.3/85.8 95.0/85.6
% 100.2/90.3 100.5/90.6 100.3/90.4
% 107.9/97.2 106.7/96.1 107.5/96.8
% 106.9/96.3 106.4/95.9 107.3/96.7
),
mbar 16.5 17.2 16.4
2
kg/h 5820 7760 9767
)
2
z-value 0.001 0.001 0.0004
3436 3756 4006
Operating conditions:
Fuel EL low-sulphur fuel oil Natural gas H
Boiler operating temperature min. °C 65 75
Boiler return temperature min.
Return temperature control
1)
Before entering boiler return
1)
1)
°C 55 65
Yes Yes
4 215 983 / 01 7
TECHNICAL INFORMATION
3.2.2 Max-3 condens (3000-5000) for EL low-sulphur fuel oil (sulphur content < 50 mg/kg)
Type (3000) (4000) (5000)
Fuel EL fuel oil
low-sulphur
• Nominal heat output at 80/60 °C kW 3750 5006 6285
• Nominal heat output at 80/30 °C kW 3877 5181 6502
• Heat output range at 80/60 °C kW 768-3750 976-5006 1185-6285
• Heat output range at 80/30 °C kW 815-3877 1039-5181 1265-6502
• Combustion performance kW 792-3942 1005-5256 1220-6615
• Boiler operating temperature max.
2)
°C 105 105 105
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
• Safety temperature limiter setting (water side)
3)
°C see table of operating conditions (below)
°C 120 120 120
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler eciency at 80/60 °C in full-load operation
% 95.1/89.7 95.3/89.9 95.0/89.6
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 80/30 °C in full-load operation
% 98.4/92.8 98.6/93.0 98.3/92.7
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 30 % partial load (EN 303)
% 102.2/96.4 102.0/96.2 102.8/97.0
(related to net caloric value NCV / gross caloric value GCV)
• Nominal eciency at 75/60 °C (DIN 4702-8)
% 101.2/95.5 101.7/95.9 102.6/96.8
(related to net caloric value NCV / gross caloric value GCV)
• Stand-by losses qB at 70°C Watts 2125 2349 2566
• Flue gas temperature at nominal output 80/60 °C °C 128 126 132
• Combustion gas resistance at nominal output (natural gas H, 12.5 % CO
500 m above sea level (tolerance ± 20 %)
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO
• Flow resistance boiler
)
2
1)
),
mbar 16.5 17.2 16.4
2
kg/h 6120 8160 10200
z-value 0.001 0.001 0.0004
• Flue gas heat exchanger ow resistance z-value 0.008 0.011 0.014
• Water ow rate at 10 K m³/h 321 429 539
• Water ow rate at 20 K m³/h 161 215 269
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.2 4.4 6.1
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 3.4 4.7 6.1
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6452 7172 7886
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7356 8714 -
- At operating / test pressure 10/16 bar kg 8489 10012 12038
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
3436 3756 4006
half the length of the reversing chamber)
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1)
Flow resistance boiler in mbar = ow rate (m3/h)2 x z
2)
Limited by the boiler controller E13.4 TopTronic® E and T2.2 to 90 °C or by E13.5 TopTronic® E and T0.2 to 105 °C.
3)
Max. safety temperature for boiler controller E13.4 TopTronic® E and T2.2: 110 °C or E13.5 TopTronic® E and T0.2: 120 °C.
EL fuel oil
low-sulphur
EL fuel oil
low-sulphur
Operating conditions:
Fuel EL low-sulphur fuel oil Natural gas H
Boiler operating temperature min. °C 65 75
Boiler return temperature min.
Return temperature control
1)
Before entering boiler return
1)
1)
°C 55 65
Yes Yes
4 215 983 / 018
TECHNICAL INFORMATION
3.2.3 Max-3 condens E (3000-5000) for natural gas H
Type (3000) (4000) (5000)
Fuel Natural gas H Natural gas H Natural gas H
• Nominal heat output at 80/60 °C kW 3162 4215 5305
• Nominal heat output at 80/30 °C kW 3412 4546 5732
• Heat output range at 80/60 °C kW 774-3162 982-4215 1195-5305
• Heat output range at 80/30 °C kW 862-3412 1099-4546 1345-5732
• Combustion performance kW 794-3255 1007-4340 1225-5465
• Boiler operating temperature max.
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
• Safety temperature limiter setting (water side)
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler eciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 80/30 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 30 % partial load (EN 303)
(related to net caloric value NCV / gross caloric value GCV)
• Nominal eciency at 75/60 °C (DIN 4702-8)
(related to net caloric value NCV / gross caloric value GCV)
• Stand-by losses qB at 70°C Watts 2166 2383 2620
• Flue gas temperature at nominal output 80/60 °C °C 82 83 83
• Combustion gas resistance at nominal output (natural gas H, 10.5 % CO
500 m above sea level (tolerance ± 20 %)
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO
• Flow resistance boiler
1)
• Flue gas heat exchanger ow resistance z-value 0.01 0.016 0.018
• Boiler water ow rate at 10 K m³/h 271 361 455
• Boiler water ow rate at 20 K m³/h 136 181 227
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.5 4.6 6.5
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 5.0 6.7 9.0
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6525 7260 8030
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7668 9265 -
- At operating / test pressure 10/16 bar kg 8801 10563 12905
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
half the length of the reversing chamber)
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1)
Flow resistance boiler in mbar = ow rate (m3/h)2 x z
2)
Limited by the boiler controller T0.2 to 105 °C.
3)
Max. safety temperature for boiler controller T0.2: 120 °C.
2)
°C 105 105 105
°C see table of operating conditions (below)
3)
°C 120 120 120
% 97.1/87.5 97.1/87.5 97.1/87.5
% 104.8/94.4 104.7/94.4 104.9/94.5
% 108.4/97.7 108.2/97.5 109.0/98.2
% 107.4/96.8 107.9/97.2 108.8/98.0
),
mbar 12.2 13.4 12.0
2
kg/h 4806 6408 8069
)
2
z-value 0.001 0.001 0.0004
3436 3756 4006
Operating conditions:
Fuel EL low-sulphur fuel oil
Natural gas H
EL eco fuel oil
Boiler operating temperature min. °C 65 75
Boiler return temperature min.
Return temperature control
1)
Before entering boiler return
1)
1)
°C 55 65
Yes Yes
4 215 983 / 01 9
TECHNICAL INFORMATION
3.2.4 Max-3 condens E (3000-5000) for EL eco fuel oil
Type (3000) (4000) (5000)
Fuel EL low-sulphur fuel oil/EL eco fuel oil
• Nominal heat output at 80/60 °C kW 3162 4215 5305
• Nominal heat output at 80/30 °C kW 3325 4431 5578
• Heat output range at 80/60 °C kW 774-3162 982-4215 1195-5305
• Heat output range at 80/30 °C kW 838-3325 1064-4431 1295-5578
• Combustion performance kW 794-3255 1007-4340 1225-5465
• Boiler operating temperature max.
• Boiler operating temperature min. °C see table of operating conditions (below)
• Boiler return temperature min.
(directly in the boiler after the ue gas heat exchanger)
• Safety temperature limiter setting (water side)
• Operating/test pressure bar 6/9.6 6/9.6 10/16
• Operating/test pressure (optional) bar 10/16 10/16 -
• Boiler eciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 80/30 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV)
• Boiler eciency at 30 % partial load (EN 303)
(related to net caloric value NCV / gross caloric value GCV)
• Nominal eciency at 75/60 °C (DIN 4702-8)
(related to net caloric value NCV / gross caloric value GCV)
• Stand-by losses qB at 70°C Watts 2166 2383 2620
• Flue gas temperature at nominal output 80/ 60 °C °C 81 82 81
• Combustion gas resistance at nominal output (natural gas H, 12.5 % CO
500 m above sea level (tolerance ± 20 %)
• Flue gas mass ow at nominal output
(natural gas H, 10.5 % CO
• Flow resistance boiler
1)
• Flue gas heat exchanger ow resistance z-value 0.01 0.016 0.018
• Water ow rate at 10 K m³/h 271 361 455
• Water ow rate at 20 K m³/h 136 181 227
• Minimum ue gas heat exchanger ow rate at 60 °C return ow temperature m³/h 3.5 4.6 6.5
• Minimum ue gas heat exchanger ow rate at 30 °C return ow temperature m³/h 4.0 5.3 7.1
• Boiler water capacity (incl. ue gas heat exchanger) Litre 6525 7260 8030
• Insulation thickness of boiler body and ue gas heat exchanger mm 100 100 100
• Weight (incl. casing)
- At operating / test pressure 6/9.6 bar kg 7668 9265 -
- At operating / test pressure 10/16 bar kg 8801 10563 12905
• Combustion chamber internal dimensions mm 900 990 1070
• Combustion chamber length (with extension into the reversing chamber,
half the length of the reversing chamber)
• Combustion chamber volume m³ 2.186 2.891 3.602
• Dimensions See dimensional drawing
• Draught/underpressure at ue gas outlet max. Pa -50 -50 -50
1)
Flow resistance boiler in mbar = ow rate (m3/h)2 x z
2)
Limited by the boiler controller T0.2 to 105 °C.
3)
Max. safety temperature for boiler controller T0.2: 120 °C.
2)
°C 105 105 105
°C see table of operating conditions (below)
3)
°C 120 120 120
% 97.1/91.6 97.1/91.6 97.1/91.6
% 102.2/96.4 102.1/96.3 102.1/96.3
% 103.4/97.5 103.2/97.4 104.0/98.1
% 102.4/96.6 102.9/97.1 103.8/97.9
),
mbar 12.2 13.4 12.0
2
kg/h 5105 6807 8508
)
2
z-value 0.001 0.001 0.0004
3436 3756 4006
Operating conditions:
Fuel EL low-sulphur fuel oil
Natural gas H
EL eco fuel oil
Boiler operating temperature min. °C 65 75
Boiler return temperature min.
Return temperature control
1)
Before entering boiler return
1)
1)
°C 55 65
Yes Yes
4 215 983 / 0110
TECHNICAL INFORMATION
3.3 Dimensions
3.3.1 Max-3 condens (3000-5000)
(Dimensions in mm)
1 Boiler supply PN 16 (3000,4000) DN 200
(5000) DN 250
2 Boiler return PN 16 (3000,4000) DN 200
(5000) DN 250
3 Cleaning opening
4 Flue gas collector cleaning connection / drainage
5 Drainage PN 16 R 1½″
6 5 immersion sleeves R ¾″ x 120 supply boiler
7 Safety valve tting PN 16 (3000,4000) DN 80
8 Sight glass
8A Sight glass (optional)
9 Smoke gas outlet
10 Exhaust gas heat exchanger
11 Flue gas heat exchanger
connections PN 16
(5000) DN 100
(3000,4000) DN 150
(5000) DN 200
View A
Type B L H H1 H2 D Di/Da H3 H4 H5 H6 H7 H8 L1 L2 L3 L4 A A1 A2 A3 A4
(3000) 2086 5277 2508 2393 1283 2070 450/458 2326 120 378 1783 1596 375 3943 168 155 207 1695 1150 520 3200 507
(4000) 2186 5597 2608 2493 1333 2170 500/508 2426 120 378 1896 1643 450 4263 168 155 207 2015 1150 640 3400 507
(5000) 2286 5964 2708 2593 1383 2270 550/558 2526 120 378 1983 1723 525 4511 282 155 207 2265 1155 550 3750 507
Burner connection dimensions
Screw connection ange
Max-3 condens (3000,4000)
6x M16
Screw connection ange
Max-3 condens (5000)
8x M16
Firing system dimensions
Type A B C D E F G K L
(3000) 400 450 1283 400 900 3211 188 1410 450
(4000) 400 450 1333 400 990 3531 188 1510 450
(5000) 540 735 1383 296 1070 3781 305 1600 450
4 215 983 / 01 11
TECHNICAL INFORMATION
3.3.2 Max-3 condens E (3000-5000)
(Dimensions in mm)
1 Boiler supply PN 16 (3000,4000) DN 200
(5000) DN 250
2 Boiler return PN 16 (3000,4000) DN 200
(5000) DN 250
3 Cleaning opening
4 Flue gas collector cleaning connection / drainage
5 Drainage PN 16 R 1½″
6 5 immersion sleeves R ¾″ x 120 supply boiler
The control can be tted on the right
or left side.
7 Safety valve tting PN 16 (3000,4000) DN 80
(5000) DN 100
8 Sight glass
8A Sight glass (optional)
9 Smoke gas outlet
10 Exhaust gas heat exchanger
11 Exhaust gas heat exchanger (3000,4000) DN 150
connections PN 16 (5000) DN 200
View A
Type B L H H1 H2 D Di/Da H3 H4 H5 H6 H7 H8 L1 L2 L3 L4 A A1 A2 A3 A4 A5
(3000) 2086 5587 2508 2393 1283 2070 450/458 2326 120 378 1808 1596 425 3943 168 155 207 1695 1150 520 3200 507 310
(4000) 2186 5907 2608 2493 1333 2170 500/508 2426 120 378 1896 1643 505 4263 168 155 207 2015 1150 640 3400 507 310
(5000) 2286 6269 2708 2593 1383 2270 550/558 2526 120 378 2008 1723 570 4511 282 155 207 2265 1155 550 3750 507 310
Burner connection dimensions
Screw connection ange
Max-3 condens E (3000,4000)
6x M16
Screw connection ange
Max-3 condens E (5000)
8x M16
Firing system dimensions
Type A B C D E F G K L
(3000) 400 450 1283 400 900 3211 188 1410 450
(4000) 400 450 1333 400 990 3531 188 1510 450
(5000) 530 735 1383 296 1070 3781 305 1600 450
4 215 983 / 0112
INSTALLATION
NOTICE
NOTICE
boiler to allow free return of condensation
wa ter towards the boiler. The whole ue gas
sys tem must be installed so that condensate
NOTICE
Normally only one heat generator may be
Schornstein
4. Installation
4.1 Boiler room requirements
The valid building supervisory regulations for the in stalla tion location are applicable for the construction re quirements for boiler rooms and their aeration and ventilation.
In Germany, the ring regulations for the individual states
are to be complied with.
Make sure there is an adequate supply of fresh air
to the boiler room
to ensure that the combustion air supply necessary for
all the ring systems operated there can ow in without
hin drance and that no oxygen deciency occurs for the
op er at ing personnel.
Binding values for the size of supply air openings are not
generally specied in the relevant regulations; it is merely
required that no negative pressure in excess of 3 N/m2
occurs. With rectangular apertures the side ratio is not
to exceed 1.5 : 1 and an appropriate supplement is to
be made with grilles to ensure that the free cross-section
reaches the above values.
4.2 Flue gas connection and dimensioning
To guarantee economical and fault-free operation, boiler
and ue gas system must be mutually adapted to create
a functional unit.
If the ue gas temperature is under 160 °C,
the ue gas lines must be watertight, acid-
resistant and overpressure-tight.
Horizontal connecting pipes must be installed
with an inclination of at least 50 mm per metre
of their length installed in the direction of the
can never collect at any point.
Renovation or ue gas line cross-section adjustment can
be necessary with existing ue gas systems, according to
the instructions of a specialist.
The function of the ue gas system, i.e. the production of
the necessary delivery pressure is basically dependent
on:
a. The type (nature) of the ue gas system (thermal in-
su lation, interior surface roughness, sealing etc.)
b. The connection of the boiler to the ue gas system
ac cor ding to specications
c. The correct size of the ue gas system
Flue gas systems according to EN 13384, part 2, exe cu-
tion types I and II are appropriate for modern ring sys-
tems (advice from the specialist is necessary). Pay at ten-
tion to the ue gas temperature at nominal output; see
ue gas output diagram.
con nected to the ue gas system!
Where a transition element is necessary from the boiler
ue gas pipe to the chimney inlet, this should be executed
as a slender cone.
4 215 983 / 01 13
from the
boiler
to the ue
zum
gas system
Figure 01
INSTALLATION
For burner connection dimensions, see
!
CAUTION
Failure to observe the guidelines and
result in damage to property and personal
On installing, comply with the guidelines
In order to comply with the Swiss Clean Air
Act (LRV), make sure that the maximum permis sible furnace heat release (dimensions including reversing chamber) of the respective
boiler manufacturer is not exceeded. In certain
situations, this can lead to a reduction in boiler
performance and must be taken into account
10
11
12
13
14
15
16
17
18
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000 6300 6600 6900
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
(5000)
(4000)
(3000)
4.3 Installing burner Max-3 condens
and Max-3 condens E (3000-5000)
chapter “3.3 Dimensions”, page 11.
1. Mount the burner to the boiler ange with the seal
and screws.
standards for the installation of burners can
injury.
•
and instructions for tting the burner to the
heat producer.
• Only burners tested according to EN 267 or
EN 676 may be used.
2. Insulate the space between the burner pipe and the
hinged ange.
3. For gas and dual-fuel burners:
If the weight of the burner (including attachments)
> 90 kg and the distance of the centre of gravity of
the burner to the door > 60 cm, support the burner
housing weight directly with a strut to the oor.
Noise damping
- Gas pipelines are to be installed so that no vibrations
can be transferred to the building.
- The burner can be covered with a noise-damping hood.
- It is recommended to incorporate a noise damper down-
stream of the boiler in the ue gas pipe.
Emissions
without fail when dimensioning the system.
Max-3 condens heating gas-side resistance
(3000)
9
8
7
6
5
4
Heating gas-side resistance (mbar)
3
2
1
0
kW = Boiler output
Boiler ow temperature 80 °C, return temperature 60 °C
mbar = Heating side resistance at λ = 1.14 (natural gas H, CO
Boiler output (kW)
= 10.5 %), 500 m above sea level (tolerance +/- 20 %)
2
(4000)
(5000)
4 215 983 / 0114
INSTALLATION
NOTICE
A qualied technician must install the electrical
supply to the equipment. The connection diagram is located in the electrical box of the heat
ge ne rator; the circuit diagram is supplied sep-
10
11
12
13
14
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
Max-3 condens E heating gas-side resistance
(4000)
(3000)
9
8
7
6
5
4
3
Heating gas-side resistance (mbar)
2
1
0
Boiler output (kW)
kW = Boiler output
Boiler ow temperature 80 °C, return temperature 60 °C
mbar = Heating side resistance at λ = 1.14 (natural gas H, CO
(5000)
= 10.5 %), 500 m above sea level (tolerance +/- 20 %)
2
4.3.1 Fuel
4.3.2 Electrical connection
The boiler is only to be operated with the fuel
stated on the boiler rating plate.
a rately.
Max-3 condens or Max-3 condens boilers are normally
suitable for burning the following fuels:
- EL low-sulphur fuel oil (sulphur content < 50 mg/kg) in
ac cordance with DIN 51 6093, or eco heating oil in accor dance with SN 181160.2
- All combustible gases according to DVGW Work sheet
G 260
Electrical connection of burner
- The burner must be connected to the boiler with the
standard plug and socket connection.
- The burner cable must be installed so that the plug and
socket connection has to be disconnected in order to
swing out the burner.
4 215 983 / 01 15
INSTALLATION
100
104
108
112
116
120
124
128
132
136
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000 6300 6600
(
)
102
106
110
114
118
122
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000 6300 6600 6900
(
)
62
64
66
68
70
72
74
76
78
80
82
84
86
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
(5000)
(
4000
)
(3000)
38
40
42
44
46
48
50
52
54
56
58
60
62
64
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000
(5000)
(
4000
)
(3000)
4.4 Flue gas and output diagram
4.4.1 Max-3 condens (3000-5000) flue gas and output diagram
Max-3 condens (VL 80 °C / RL 60 °C) flue gas and output diagram
(3000)
96
92
Flue gas temperature (°C)
88
84
80
76
72
(5000)
4000
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kW = Boiler output
°C = Flue gas temperature with reduced
heating surface, boiler ow temperature
80 °C, return temperature 60 °C (eld
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO
natural gas H = 10.5 %)
2
- A reduction of the boiler water temperature of -10 K eec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % eectuates a
change in the ue gas temperature of approx. ± 8 K.
measurement according to DIN 4702).
Max-3 condens (VL 80 °C / RL 30 °C) flue gas and output diagram
(3000)
98
94
90
86
82
78
Flue gas temperature (°C)
74
70
66
62
58
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kkW = Boiler output
°C = Flue gas temperature with reduced
heating surface, boiler ow temperature
80 °C, return temperature 30 °C (eld
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO
natural gas H = 10.5 %)
2
measurement according to DIN 4702).
4000
- A reduction of the boiler water temperature of -10 K eec tuates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % eectuates a
change in the ue gas temperature of approx. ± 8 K.
(5000)
4 215 983 / 0116
INSTALLATION
86
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700
(
)
64
600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000
(
)
4.4.2 Max-3 condens E (3000-5000) flue gas and output diagram
Max-3 condens E (VL 80 °C / RL 60 °C) flue gas and output diagram
84
4000
(5000)
(3000)
82
80
78
76
74
72
70
Flue gas temperature (°C)
68
66
64
62
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kkW = Boiler output
°C = Flue gas temperature with reduced
heat ing surface, boiler ow temperature
80 °C, return temperature 60 °C (eld
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO
natural gas H = 10.5 %)
2
- A reduction of the boiler water temperature of - 10 K eec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % eectuates a
change in the ue gas temperature of approx. ± 8 K.
mea surement according to DIN 4702).
Max-3 condens E (VL 80 °C / RL 30 °C) flue gas and output diagram
62
60
58
56
54
52
50
48
46
Flue gas temperature (°C)
44
42
40
38
(3000)
4000
Boiler output (kW)
The data shown here represent an average value based on measurements taken with burners from various manufacturers.
kW = Boiler output
°C = Flue gas temperature with reduced
heating surface, boiler ow temperature
80 °C, return temperature 30 °C (eld
- Operation with natural gas H,
λ = 1.14 at full burner load
(CO
natural gas H = 10.5 %)
2
- A reduction of the boiler water temperature of - 10 K eec tu-
ates a reduction of the ue gas temperature of approx. 6-8 K.
- A change in the air index λ of +/- 0.09 % eectuates
a change in the ue gas temperature of approx. ± 8 K.
measurement according to DIN 4702).
(5000)
4 215 983 / 01 17
INSTALLATION
NOTICE
When draining the condensate, it must be
en sured that no uncontrolled escape of ue
gas occurs in the installation room (do not
keep the ball valve open “constantly”, but
The locally valid waste water regulations
must be observed when disposing of the
4.5 Minimum value limiting of boiler return temperature
Hydraulic and control measures must be provided to ensure that the temperatures do not fall below the per mis-
si ble minimum boiler ow and return temperature under
any operating conditions.
4.6 Discharge of start-up condensate from the boiler
• When commissioning a cold boiler, condensate always
oc curs within the boiler. This collects in the lower area
of the boiler (ue gas collector) and is then evaporated
through the boiler's continued heating up.
• The boiler should therefore – also for this reason – only
be started up without “network acceptance”, so that the
con den sation temperature threshold (approx. 55 °C) is
ex cee ded as quickly as possible
• If necessary, the condensate which occurs can be
drained via the ue gas collector's cleaning tting (re-
move cap on the drain connection before starting the
burner, connect ball valve and temperature-resistant
drain hose).
•
4.7 Setting the temperature controllers
Basic setting of the controller is carried out by the heating
contractor.
4.8 Safety valves
The heating system and hot water supply must each be
pro tected with one safety valve against impermissible
over pressure. The discharge capacity of the heating system safety valve must correspond to the boiler’s max imum nominal heat output. The valve is installed in the
safety ow. In Germany, only safety valves with the code
let ter “H” in the approval mark may be connected, and
they must always be connected at the boiler safety ow.
4.9 Supply pump
(boiler with free-standing calorier)
Speed of rotation and output regulation must correspond
to the requirements of the free-standing calorier. Setting
car ried out by the heating installation engineer.
4.10 Heating pump
Speed of rotation and output regulation must correspond
to the requirements of the system. They are to be set by
the heat ing installation engineer.
only drain o the condensate “inter mit tently”).
•
con den sate!
As soon as the boiler has reached its minimum tem pera ture and this can be kept stable via the return boost,
the burner should be shut o briey and the closure cap
mounted on the cleaning drain connection again.
• The drain connection on the boiler's ue gas collector is
not intended for the permanent connection of a drainage
line – frequent condensation in the area of the boiler is
impermissible!
4.11 Heating connections
For boiler rooms adjacent to the domestic sphere, the
heat ing connections on the boiler are to be exibly con-
nected with compensators.
4 215 983 / 0118
COMMISSIONING
5. Commissioning
5.1 Water quality
• Hoval boilers and caloriers are suitable for heating systems without signicant oxygen intake (system type I in
accordance with EN 14868).
• Systems with
- continuous oxygen intake (e.g. underoor heating
sys tems without diusion-proof plastic piping) or
- intermittent oxygen intake (e.g. requiring frequent topping-up) must be equipped with a system separation.
• Treated heating water must be tested at least 1x per
year, or more frequently if specied by the manufacturer
of the inhibitor.
• On existing systems (for example if the boiler is replaced), where the quality of the existing heating water
meets the requirements of VDI 2035, re-lling of the
sys tem is not recommended. The requirements of VDI
2035 also apply to replacement water.
• Before lling new systems and, where necessary, ex ist-
ing systems, the heating system must be professionally
cleaned and ushed. The boiler must not be lled until
the heating system has been ushed.
• All parts of the boiler/calorier which come into contact
with water are made of ferrous materials and stainless
steel.
• Due to the danger of stress corrosion, the sum of the
chlo ride, nitrate and sulphate contents of the heating water must not exceed a total of 200 mg/l (ÖNORM H5195
stipulates that the limit value for chlorides is 30 mg/l).
• The pH-value of the heating water should be between
8.3 and 9.5 after 6 - 12 weeks of heating operation.
Filling and replacement water:
• As a rule, untreated domestic water is best suited as
l ling and replacement water for a system with Hoval
boil ers. However, the quality of the untreated mains
wa ter must still meet the requirements of VDI 2035 or
be demineralised and/or treated with inhibitors. The requirements of EN 14868 must be met in this context.
• To maintain high boiler eciency and prevent over-
heating of the heating surfaces, the values in table 1
must be up held.
• The total quantity of lling and replacement water added
to the boiler over its service life must not be higher than
three times the system water content.
Table 1: Standard values for boiler and circuit water for circulation boiler (shell boiler)
Max. allowable operating pressure bar > 0.5 <= 25
General requirements colourless, free of undissolved substances
pH value at 25 °C 8.2-11.5
Conductivity at 25 °C µS/cm < 1500
Total alkaline earths (Ca + Mg)
Silica acidic capacity 8.2
Silica (SiO
Phosphate (P
Sodium sulphite (Na
Iron mg/l < 0.2
Copper mg/l < 0.1
1)
Previously specied in °dH, conversion: 1 mmol/l = 5.6 °dH (German hardness)
2)
Previously specied as p-value, silica conversion 8.2 1 = p-value 1
3)
Proof only required if respective dosing chemicals are used.
The following value does not have to be veried constantly during plant operation: silica (SiO
) mg/l < 100
2
3)
)
2O4
2SO3
1)
mmol/l < 0.02
°dH < 0.112
2)
(p-value) mmol/l 1-5
3)
)
°fH < 0.19
mg/l 5-10
mg/l 5-10
and foaming agents
)
2
4 215 983 / 01 19
COMMISSIONING
In some areas, gas or dual-fuel systems may
only be commissioned by an engineer from
the local gasworks. Check with the local gas-
5.2 Filling the calorifier
(if fitted)
The boiler may be put into operation even when the
calori er is not lled.
5.3 Commissioning
Important:
At the time of initial commissioning, check that all safety
and control devices are functioning properly (in ac cordance with the operating instructions).
The operation and maintenance of the system must be
explained to the user in detail.
works to make sure.
5.4 Hand-over to the operator / safe-keeping
Have the operator conrm in writing that the operating and
maintenance procedures have been explained and that
he or she has received a copy of the relevant operating
manuals. The manufacturer of the unit is responsible for
providing operating instructions for the complete sys tem.
This technical information / these assembly in struc tions
must not be destroyed after completing the com mis sioning procedures, but should be permanently stored with
the plant.
4 215 983 / 0120
MAINTENANCE (ONLY FOR BOILER CONTROLLER WITH TOPTRONIC® E CONTROL)
!
CAUTION
NOTICE
switch-o with maximum thermostat). The output and duration of the emission measurement can be set in
For detailed information see operating instructions,
Regulate heating circuits and the calori ers to their maximum temperature (in the direct heating circuit only if the hot
For detailed information see operating instructions,
6. Maintenance (only for boiler controller with TopTronic® E control)
6.1 Information for combustion controller / chimney sweep regarding emission monitor key
This chapter is exclusively intended to describe the function of emissions and manual operation settings for the ring
monitoring technician / chimney sweep. All operating elements are described in the operating instructions.
Danger of scalding with hot water, since the hot water temperature can exceed the target setpoint
temperature.
In order to protect under oor heating systems against impermissible superheating during emissions
measurement / manual operation, it is necessary to implement appropriate safety measures (e.g. pump
the “Emission” main menu, and reactivated if required.
Emission metering
Setting at:
Home screen > Main menu (page 1) > Emission.
“Emission” chapter.
Power limitation with 2-stage burner:
0 to 50% = 1st stage 51 to 100% = 2nd stage
REACTION to emission metering
• Go back after expiry of the time unit/time speci cation of return to the main menu
• Setpoint temperature = Maximum temperature limit
• Forced energy is used in an attempt to keep the corresponding heat generator temperature to 60 °C
•
water basic program is set to parallel operation)
Manual mode
Settings under:
Home screen > Main menu (page 2) > Manual operation.
“Emission” chapter.
REACTION for manual operation
• Setting the required setpoint temperature using the selected heating or hot water circuit
• All heating pumps ON
• Note the maximum permissible temperature of surface heating!
4 215 983 / 01 21
MAINTENANCE (ONLY FOR BOILER CONTROLLER WITH TOPTRONIC® E CONTROL)
!
CAUTION
!
CAUTION
circumstances be loosened. Otherwise the
6.2 Cleaning
Insucient cleaning not only leads to increased fuel con-
sumption, it also shortens the operating time of the boiler.
The boiler must be cleaned at least 1 x per
year by a chimney sweep.
(Observe local regulations).
• Disconnect the heat generator from the mains (main
switch, fuse).
• Unscrew the hexagon locking nuts with holes with the
sup plied steel spike (Figure 02).
The locking nuts without holes must under no
door panel can detach from the boiler.
Figure 02
• Tilt out the boiler door with boiler.
• Thoroughly clean the combustion chamber (2), second
compartment (3) and third compartment (4) with a brush
or by spraying.
• Remove the cleaning cover (5, Figure 03) behind on the
ue gas collector. Remove residues from the collector.
Brush the boiler rear wall and the space between the
pipe ends clean.
• Empty the ue gas collector at the outlet (6) during wet
cleaning.
• Sal the cleaning openings tight.
• Close the boiler doors and tighten screws.
• Insert burner connection plug and switch the boiler
back on.
6.3 Lubrication of the seal and thread
6.3.1 Lubrication of the seal
Reversing chamber
Combustion chamber
Cleaning opening (ue gas collector)
5
6
Figure 03
6.3.2 Lubrication of the thread
Hinged ange bottom/top
Cleaning opening (ue gas collector)
During long operating breaks,
preserve the boiler.
4 3 2
Figure 04
4 215 983 / 0122
MAINTENANCE (ONLY FOR BOILER CONTROLLER WITH TOPTRONIC® E CONTROL)
NOTICE
drainage line of the heat exchanger or
the boiler exhaust manifold drainage).
If needed, lay suitable drainage hoses.
Avoid al low ing an excessive amount of
wash so lu tion from entering the boiler
ing surfaces of the boiler and the ue gas
col lector must be rinsed with a neutral
li quid and dried directly after cleaning
work on the heat exchanger and before
6.4 Cleaning the flue gas heat exchanger
In principle, the cleaning intervals conform with the local
regulations.
To prevent malfunctions, we recommend checking the
heat exchanger, condensate drainage line and the neutral i sation equipment (if present) at least 1 x a year and
clean ing if necessary.
Cleaning process:
- Disconnect the heat generator from the mains (main
switch, fuse, etc.).
- Remove the insulation cover (1, Figure 05) on the side
opening of the heat exchanger and open the cover (2,
Figure 05).
- Remove the contact protection cover (3, Figure 05) on
the rear cleaning cover of the boiler exhaust manifold
and open the cover below.
- When the surface is lightly covered with dust, it is suf-
cient to blow out the pipes of the heat exchanger with
compressed air.
- If there is thick dirt build-up or scale deposits on the
straight tubes or the housing of the heat exchanger, it
can be cleaned safely by blowing out the straight tubes
with high-pressure water. Pressures between 50 and
200 bar are sucient.
- If oil or soot deposits have caused heavy contamination
in a loose structure, it can be cleaned with warm water
with the addition of an appropriate alkaline cleansing
agent or by blowing it out with a steam-jet degreaser.
- If brushes are used to clean the heat exchanger pipes,
only Perlon or stainless steel brushes can be used never use “normal” steel brushes!
- After cleaning, assemble the access panel (use a new
seal if necessary!), disassemble any connected water
drainage hoses and re-establish the normal operating
state, then put the system back into operation.
- After monitoring the seals of the access panel (caution:
hot surfaces!), the associated insulation contact pro tection covers must be reassembled without fail!
a. When wet cleaning the heat exchanger, it
must be ensured that the cleaning solution
can drain away (through the condensate
ue tube.
b. Any notes on safety and use of the clean-
ing agent must be observed and upheld.
c. “If wet cleaning has been done, the heat-
re com mis sioning the boiler.”
4 215 983 / 01 23
2
3
1
Figure 05
4 215 983 / 0124
4 215 983 / 01 25
COPY FOR PLANT USER
Confirmation
The user (owner) of the system herewith confi rms that
• he has received adequate instruction in the operating and maintenance of the installation,
• received and taken note of the operating and maintenance instructions and, where applicable other documents con-
cerning the installation and any further components.
• and is consequently suffi ciently familiar with the installation.
Installation address: Type:
Serial number:
Year of manufacture:
Place, Date:
System installer: System user:
COPY OF SYSTEM INSTALLER
Confirmation
The user (owner) of the system herewith confi rms that
• he has received adequate instruction in the operating and maintenance of the installation,
• received and taken note of the operating and maintenance instructions and, where applicable other documents con-
cerning the installation and any further components.
• and is consequently suffi ciently familiar with the installation.
Installation address: Type:
Serial number:
Year of manufacture:
Place, Date:
System installer: System user:
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