Hoval SR-plus 600, SR-plus 700, SR-plus 1500, SR-plus 1750, SR-plus 2000 Operating And Installation Instructions

...

Issued By TECHNICAL DEPT

Dated: August 2014 Approved KS

Operating and Installation

Instructions for the SR-plus

hot water boiler

0088

Contents

Page

Material in this publication may not be reproduced without the company's written permission.

Hoval reserve the right to change specications without notice.

Hoval Ltd, Northgate, Newark, Notts, NG24 1JN, Tel: 01636 672711 Fax: 01636 673532 e-mail: service@hoval.co.uk

Table of Contents

Introduction

Gas Safety(Installation & Use)

Sample Nameplate

Delivery, Ofoading , Storage.

Description of the SR-plus boiler

Technical & Performance Details

Installation

-Space requirements

- Noise levels

-Ventilation,

-Open Vented & Pressurised Systems

-Flues & Chimneys

-Filling the system with water/ water treatment

-Burner matching , Fitting the Burner

- Water ow & return temperatures

- Control details

- Boosters

Commissioning

Operating Instructions, including sequencing of boilers under BMS control

Maintenance

- Inspection & Servicing

- Boiler & Burner Servicing

- Summer Shutdown

- Burner Maintenance

Oil Burner Fault Finding Chart

Gas Burner Fault Finding Chart

6-8

9-15

16-17

19-22

20-21

23-24

25-26

IMPORTANT

These instructions should be read and understood before attempting to install, commission or oper-

ate this unit. The boiler has been tested to comply with the Gas Appliances Directive (90/396/EEC) & the Boiler Efciency Directive (92/42/EEC) Certication No. CE-0085 .

August 2014

Introduction

These instructions have been written to give a brief description of the SR-plus hot water boilers, their

installation, commissioning, operation and subsequent maintenance.

The installation of boilers and their ancillary equipment is normally carried out by the Heating Engineer, and

for the purpose of this manual he / she is regarded as the installer, and, as such, it is his / her responsibility

to ensure that he / she has read and understood the contents of this manual before installing the boiler.

It is essential that each boiler has all services connected to it before commissioning.

A note should be entered below by the person responsible for the plant, giving the boiler model, output, reference 'K' number, and burner reference number. These numbers are indicated on the appropriate nameplates.

For completion by Plantroom Attendant

Boiler Model: Burner Ref. No.

Output (kW): Fuel:

K No. Commissioning Date

For technical, servicing or parts enquiries,

telephone, fax or e-mail to Hoval

quoting the boiler(s) serial number, as above

The installation should be in accordance with current

I.E.E. Regulations, relevant British Standard and Codes of

Practice, Building Regulations and Local Authority Bylaws.

Hoval Engineers will normally commission the boiler and

if the heating engineer is present at the time, he will be

instructed on the day-to-day operation of the boiler. If this

is not possible, or additional training is required, this can be

arranged through Hoval.

The boiler combustion gures are recorded on the commis-

sioning report and a copy of this will be issued for retention

with this manual (see example).

Commissioning/Combustion Report

August 2014

Delivery, Ofoading & Storage

Boilers and associated equipment are normally delivered by our own transport on a mutually agreed date. The boiler can be ofoaded by the crane lorry if specically booked at the time of ordering. Adequate lifting points are provided on the boiler shell. All boilers are delivered tted with casings and control panel complete with ying lead.

On delivery, the installer should check all items against the delivery note and should then store them in a safe and dry place.

NOTE:

There are other small items such as ceramic strip packing, cleaning tools and safety

valves which are transported in the boiler combustion chamber. These should be removed, checked and stored also.

Gas Safety (Installation and Use) Regulations '98.

It is the law that all gas appliances are installed by a CORGI registered installer in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure that the law is complied with.

The Hoval SR-plus range, with both standard and low NOx burners, have been Certied against the requirements of prEN676 for natural gas.

The installation of the boiler must be in accordance with relevant British Standards, the Gas Safety Regulations, Building Regulations, I.E.E. Regulations and the by laws of the local Water Authorities. A at level re proof oor should be provided and the location should permit the provision of a satisfactory ue system and adequate air supply.

Gas Safety, Nameplate & Delivery

General

BS6644 Installation of Gas Fired ... BS6880 LowTemperature Hot Water CP342:2 Centralised Hot Water Supply

Hoval

Hoval, Northgate, Newark, Notts, NG24 1JN Tel: 01636 672711

Boiler Type K number Year

Output (gas/oil) kW Input (gas/oil) kW

Maximum Minimum Heat Output kW Output Gas Oil

Flue Temp (gas/oil)

C kW kW Pressurised Vented Operating temperature

Oil Min

C Maximum oC

Gas Min

C Maximum oC

Efciency class

NOx rating Working Test Pressure(max) bar Pressure bar Electrical connection

3N-/50Hz 400/230 v Power input

Maximum A

PI Number:0085 AQ 0670

0088

This appliance must be installed in accordance with the rules in force and used only in a sufciently ventilated space. consult insrtuctions before installation and use of this appliance

Sample nameplate

British Gas Publications

IGE-UP-1 Soundness testing and purging of industrial and commercial gas installations. IGE-UP-2 Gas installation pipework, boosters and compressors on industrial and commercial premises. IGE-UP-10 Installation of gas appliances in industrial commercial premises. Part 1: Flued Aplliances.

August 2014

Description of the SR-plus boiler

Applications

These boilers are intended for heating commercial and

industrial premises within the limits of temperature and

pressure stated in this manual. They may also be used

to supply D.H.W. to such premises in conjunction with an indirect calorier.

Benets & Features

• UK design & manufacture

• W h e r e a p p l i c a b l e f u l l c o m p l i a n c e w i t h t h e P r e s s u r e Equipment Regulations.

• no minimum ow rate

• compact, space saving design

• standing losses less than 0.4%

• nett efciency to 91.6%

• suitable for operation with a range of matched burners for use with oil, gas or dual fuel

General Details

The boilers are of mild steel welded construction in

which the outer shell forms a water space around the

combustion chamber.

The third pass water jacketed gas passage ways with

turbulators provide an effective secondary heating

surface. Flue gases pass to a rear mounted ue outlet

box and horizontal ue outlet. The ue outlet has a

spigot/ange for connecting to the installers ue pipe,

and is tted with a door for cleaning and access.

The SR-plus is tested and manufactured to European

boiler design codes and is offered in outputs from

500 to 4150KW. The boilers are suitable for working

pressures up to 6 bar and operating temperatures to

a maximum of 100 °C.

General

The maximum operating temperature is governed

by the pressure available at the highest point of the

system. Take the 17oC anti-ash margin from the

saturated temperature of steam at that pressure to nd

the maximum operating temperature.

Door Hinging

The hinged side door nuts are supplied with a locknut

at the back of the door boss. Hoval should be advised

of the door and gas burner handing when the boiler is

ordered or at the very earliest date.

For installation space requirements and for changing

door hinging see page 9.

On request

- ue gas thermometer

- separately mounted altitude gauge

- boiler door hinged on left hand side

- volt free contacts for B.M.S.

- hours run meter

- Modulating controller

Insulation / Cladding

100mm mineral bre wrap with woven aluminium

surface around boiler shell, complete with Hoval red

cladding panels.

Electrical Power Supply

A single phase 230V supply is required for the control panel operation. Single phase burners are electrically

supplied via the control panel. Three phase burners require a separate three phase isolated supply (by the

installer) direct to the burner, incorporating a exible connection to allow for boiler/burner door opening. In this case control cables tted with wieland plug/socket will still run between the control panel and the burner. All power supplies to the boiler/burner/other associated equipment (ie: gas booster, separate oil pump, etc.) should be isolated via the same switched isolator.

Operation

Normal operation is fully automatic in conjuction with a

simple time switch or other form of control i.e. BEMS

August 2014

SR-plus Technical & Performance Details

(1) Based on a maximum limit thermostat setting of 110

(2) Boiler efciencies at 100% load are based on a mean operating temperature

of 70

C, at 30% efciencies are based on a mean temperature of 50oC.

(3) Based on gross CV 38.5 MJ/m

(4) Based on gross CV 45.5 MJ/kg and specic gravity 0.835.

(5) Hydraulic resistance (mbar) = (Flow rate (m

/h))

x z

Figures are based on the maximum boiler outputs.

Type 500 600 700 900 1200 1500

• Maximum output kW 500 600 750 1000 1250 1500

• Minimum output kW 225 300 375 500 625 750

• Boiler input at maximum output kW 546.45 656.50 818.77 1094.09 1366.12 1646.54

• Boiler input at minimum output kW 240.60 322.23 401.50 534.76 667.74 803.86

• Maximum boiler operating temperature

(1)

°C 100 100 100 100 100 100

• Minimum return temperature (oil/gas) °C 60/55 60/55 60/55 60/55 60/55 60/55

• Minimum ue gas temperature °C 140 140 140 140 140 140

• Maximum working pressure / test pressure bar 6/9 6/9 6/9 6/9 6/9 6/9

• Boiler efciency net

(2)

at 100%PN % 91.5 91.4 91.6 91.4 91.5 91.1

at 30%PN % 93.5 93.1 93.4 93.5 93.6 93.3

• Standing losses qB at 70°C Watt 1250 1500 1725 1800 2375 2400

• Insulation thickness mm 100 100 100 100 100 100

• Fuel Consumption at maximum output Nat Gas

(3)

m3/hr 56.35 68.07 84.90 113.45 141.66 170.73

35 seconds oil

(4)

litres/hr 55.17 66.13 77.22 99.37 137.87 166.16

• Hydraulic resistance through the boiler

(5)

z-factor 0.020 0.020 0.010 0.011 0.011 0.009

• Hydraulic resistance with 11 K

T m bar 30.55 44.00 34.36 67.20 105.00 122.31

• Hydraulic resistance with 20 K

T m bar 9.25 13.31 10.39 20.33 31.77 37.43

• Water Flow rate with 11 K

T m3 / h 39.08 46.90 58.62 78.16 97.71 117.25

• Water Flow rate with 20 K

T m3 / h 21.50 25.80 32.24 42.99 53.74 64.49

• Boiler water content litres 800 770 1340 1250 1320 1330

• Dry Weight (without burner)

(6)

kg 1700 1754 2463 2616 3350 3650

Type 1750 2000 2250 2500 3000 3500 4000

• Maximum output kW 1760 2050 2350 2650 3000 3500 4150

• Minimum output kW 880 1025 1175 1325 1500 1750 2075

• Boiler input at maximum output kW 1931.94 2242.89 2573.93 2908.89 3285.87 3837.72 4555.43

• Boiler input at minimum output kW 945.22 1100.97 1260.73 1418.63 1602.56 1871.66 2226.40

• Maximum boiler operating temperature

(1)

°C 100 100 100 100 100 100 100

• Minimum return temperature (oil/gas) °C 60/55 60/55 60/55 60/55 60/55 60/55 60/55

• Minimum ue gas temperature °C 140 140 140 140 140 140 140

• Maximum working pressure / test pressure bar 6/9 6/9 6/9 6/9 6/9 6/9 6/9

• Boiler efciency net

(2)

at 100%PN % 91.1 91.4 91.3 91.1 91.3 91.2 91.1

at 30%PN % 93.1 93.1 93.2 93.4 93.6 93.5 93.2

• Standing losses qB at 70°C Watt 2475 2510 2530 2570 2960 3070 3160

• Insulation thickness mm 100 100 100 100 100 100 100

• Fuel Consumption at maximum output Nat Gas

(3)

m3/hr 200.33 232.58 266.90 300.97 340.35 397.51 455.30

35 seconds oil

(4)

litres/hr 194.96 226.34 259.75 276.93 330.87 387.86 443.09

• Hydraulic resistance through the boiler

(5)

z-factor 0.008 0.006 0.006 0.0015 0.0015 0.0015 0.0017

• Hydraulic resistance with 11 K

T m bar 151.40 154.06 202.45 64.36 82.48 112.96 166.19

• Hydraulic resistance with 20 K

T m bar 45.80 46.60 61.24 19.47 24.95 33.96 50.27

• Water Flow rate with 11 K

T m3 / h 137.57 160.24 183.69 207.14 234.49 277.57 312.66

• Water Flow rate with 20 K

T m3 / h 75.66 88.13 101.03 113.92 128.97 150.47 171.96

• Boiler water content litres 2150 2690 3350 3660 3670 4020 4130

- Dry Weight (without burner)

(6)

kg 4325 4600 5400 5900 6525 8700 10850

SR-plus 1750 - 4000

(6) Dry weights based on the 6 bar boiler. To calculate the weight of an 8 bar

version add 30%.

SR-plus 500 - 1500

August 2014

SR-plus Technical & Performance Details

Dimensions and Technical Information

SR-plus heating boiler (models 500 to 900)

Key

1 Flow 4 Hydraulic Drain 7 Flue gas Test Point

2 Return 5 Flue Outlet 8

Smokebox Condensate Drain Connection

3 Safety Valve Connection 6 Smokebox Cleaning Door 9 Control Panel

A single phase 230V supply is required for the control panel operation. Single phase burners are electrically supplied via the control panel. Three phase burners require a separate three phase isolated supply (by the installer

to allow for boiler/burner door opening. A separate

run between the control panel and the burner. All power supplies to the boiler/burner/other associated equipment (ie: gas booster, separate oil pump, etc.) should be isolated via the same switched isolator.

Burner

Elevation view

205

SR-

Plus

Model

kW Rating at high

A B C D E F G H J L M N

Flow/return

BS4504 PN16

Safety

valve

Flue I/D

Dry

Weight

Water

Content

litres

500 411-500 1413 1262 2323 1958 766 190 1320 920 280 766 1486 1371 100 N/B R 2" 250 1700 800

600 501-600 1413 1262 2323 1958 766 190 1320 920 280 766 1486 1371 100 N/B R 2" 250 1754 770

700 601-750 1582 1440 2809 2414 856 220 1780 1330 365 856 1650 1535 125 N/B R 2" 300 2463 1340

900

876-

1000

1582 1440 2809 2414 856 220 1780 1330 365 856 1650 1535 125 N/B R 2" 300 2616 1250

Rear view

Burner

205

Control panels are mounted on top of the boiler as standard up to SR-plus 900. Side mounting (left or right) can also be accommodated.

Note:

August 2014

SR-plus Technical & Performance Details

Dimensions and Technical Information

SR-plus heating boiler (models 1200 to 4000)

Key

1 Flow 4 Hydraulic Drain 7 Flue Gas Test Point

2 Return 5 Shell Access Connection 8 Flue Outlet

3 Safety Valve Connection 6 Smokebox Cleaning Door 9 Control Panel

10 Smokebox Condensate Drain Connection

connection to allow for boiler/burner door opening. A separate

the control panel and the burner. All power supplies to the boiler/ burner/other associated equipment (ie: gas booster, separate oil pump, etc.) should be isolated via the same switched isolator.

SR-

Plus

Model

kW Rating

at high

A B C D E F G H J L M N

Flow/Return

BS4504 PN16

Safety valve

Flanged

to BS4504

PN16

(from model

1750)

Flue I/D

Dry

Weight

Water

Content

litres

1200 1151-1250 1626 1500 2909 2514 876 220 1795 1345 380 876 1745 1630 125 N/B R2” 350 3350 1320

1500 1426-1500 1722 1590 2909 2514 927 220 1806 1356 466 927 1833 1718 150 N/B R2” 400 3650 1330

1750 1625-1760 1852 1720 3361 2966 992 220 2137 1687 500 992 1990 1875 150 N/B 100 N/B 400 4325 2150

2000 1900-2050 1952 1820 3381 2966 1042 240 2137 1687 590 1042 2090 1983 150 N/B 100 N/B 450 4600 2690

2250 2200-2350 2103 1970 3494 3069 1118 250 2200 1750 590 1118 2260 2145 150 N/B 100 N/B 450 5400 3350

2500 2450-2650 2143 2016 3585 3140 1135 270 2372 1922 600 1135 2323 2208 200 N/B 100 N/B 450 5900 3660

3000 2900-3000 2261 2120 3674 3219 1200 280 2502 2052 600 1200 2448 2333 200 N/B 100 N/B 500 6525 3670

3500 3250-3500 2477 2300 4235 3720 1327 340 2652 2112 812 1327 2628 2513 200 N/B 100 N/B 500 8700 4020

4000 3750-4150 2660 2400 4270 3759 1460 340 2662 2162 812 1460 2702 2587 200 N/B 100 N/B 550 10850 4130

Control panel can be mounted on left or right hand side.

Burner

Elevation view

Rear view

Burner

August 2014

Space requirements, boiler plant house noise levels

Space Requirements

Where ever possible space should be left around the boiler to enable all parts to be examined and the cubicle casings to be tted or removed easily.

Clearances

a) Back clearance is required for the system water, ue connections and access to cleaning door. b) Front clearance is required to swivel the boiler door ncluding burner by 90

, (standard to the right optional to left) Space requirements to right when right hinged 80mm (plus burner length). Clearance is equal to approximately the length of the boiler base (D) should be allowed for tube cleaning and tube repairs. Shorter clearances are possible subject to cleaning methods and plantroom layout. c) When the boiler is gas red, allowance must be made for bringing the gas piping up to the boiler front and to leaving space for the gas pipework at he side of the boiler or in the most suitable

direction

e) It is possible to install two boilers without intermediate space. (Important boiler door on left boiler must be swivelled to the left and boiler door on the right boiler to the right).

Additional points

When pipework is being connected to the boiler, care must be taken not to damage the casings, which are not designed to be stood on. External weight or thrust from system pipework attached to the boiler should be avoided by careful design of pipework runs and the use of expansion joints as required

Measures can be adopted to reduce noise levels if it is considered that any of the following sources will be objectionable:

1) Direct transmission through the building structure, e.g. rooftop boilerhouses causing vibration and sound to be transmitted to the space below.

2) Sound transmission through the boilerhouse fabric e.g. dwellings very close to the boilerhouse may be subject to objectionable noise from a building, without sound insulation, through the walls and air ventilation openings.

3) From the chimney outlet e.g. where dwellings are located very close by the boilerhouse or above the chimney outlet. Natural gas red plant has low frequency sound pressure levels which are disturbing to nearby residents when the boilers are operating, particularly at night.

The following are sound and vibration control measures which can be taken in respect of the points raised above:

• Acoustic burner and booster shrouds

• Acoustic air intake bafe or acoustic louvres.

• Heavy construction or sound insulated external walls, double glazing, heavy and close tting doors to the boilerhouse.

• Heavy construction ue with insulated cavity all round when the ue rises within the occupied areas of the building. Double skin insulated ues for ues installed outside the building.

• Flue noise attenuator.

• Anti-vibration mounts for the boiler case.

• Peripheral gaps around pipes to be sealed with suitable acoustic material.

• Anti-vibration connections to pipework and pumps.

• Heavy construction of suspended oor or ceiling.

Boiler Plant Noise Levels

Changing the door hinged side

The boiler door is substantially hinged to carry the full burner weight but no extra weight should be imposed.

1. Open the door as hinged and screw on two spare locknuts on the door hinge bolts to locate the door bosses on the new side.

2. Close the door. Adjust the locknuts temperorarily and replace one door nut tightly.

3. Change the other nut over with its plain diagonal counterpart from the other side of the door and tighten both.

4. Adjust the locknuts so that a seal is obtained all round the bre joint.

5. Open the door and remove the original locknuts.

Important

• Always have two nuts tightened to prevent the door falling.

• It is essential that the door seal is in place correctly after closing the door every time. Replace the joint if in doubt and check there are no fumes escaping.

This is a specialist subject and where noise due to vibration, combustion or mechanical sources is likely to be a problem, Hoval should be advised.

August 2014

+ 18 hidden pages

Hoval SR-plus 600, SR-plus 700, SR-plus 1500, SR-plus 1750, SR-plus 2000 Operating And Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual