By Appointment to

Her Majesty the Queen

Boiler Manufacturers & Engineers
Hoval Ltd Newark

Revision No.1
Dated: JAN 06

Issued By
Approved

IJR
KS

Technical Dept

Table of Contents

Page

Contents
Introduction

Description of F Modul plus Calorifier

Technical and Performance Details

5-7
8

Delivery / Positioning Instructions

Assembly Instructions

9-13

Installation and Piping Layouts

14-15

Unvented Systems

16-20

Commissioning & Operation

21

Inspection and Maintenance

22

Anode Protection

23

Immersion heaters

24

Immersion heater wiring diagrams

25

Fault Finding Chart

26

Wiring Diagrams for Open Vented Calorifiers

27

Wiring Diagrams for Unvented Calorifiers

28

Notes

29

These instructuctions should be read and understood before attempting to install,

commission or operate this unit.

Material in this publication may not be reproduced without

Hoval's written permission.
Hoval Ltd, Northgate, Newark, Notts NG24 1JN Tel: 01636 672711 Fax: 01636 673532
e-mail: [email protected]
web site: www.hoval.co.uk
Hoval reserve the right to change specifications without notice.

Introduction

Introduction
These instructions have been written to give a brief description of the F Modulplus Calorifier, its installation, commissioning, operation and subsequent maintenance.
The installation of calorifiers and their ancillary equipment is normally carried out by a heating
engineer. For the purpose of this manual he is regarded as the installer, and, as such, it is his
responsibility to ensure that he has read and understood the contents of this manual before
installing the calorifier.
It is essential that each calorifier has all services permanently connected to it before commissioning is requested.
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.

Commissioning/Combustion Report

Commissioning should be arranged via the

heating engineer. Hoval engineers are available
to carry out this work if requested. Where the
calorifier installation is part of a Hoval boiler
package it will normally be commissioned at
the same time and entry made on the report
opposite

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

For completion by Plantroom Attendant

Calorifier Model:

Output l/hr:

Boiler type / Model:

K Number:

Date of installation:

For technical, servicing or parts enquiries,

telephone, fax or e-mail to Hoval Ltd quoting
the calorifier(s) K. number, as above

Description of F Modul Calorifier

Description of F Modul plus Calorifier

Applications
F Modul plus calorifiers are designed to operate
with the full range of Hoval boilers up to 4.5 Bar
(standard model) and 6.90 Bar (high pressure
model) primary pressure, and are intended for the
production and supply of DHW to commercial and
industrial premises.
The F Modul-plus is available in seven model sizes
with high performance outputs up to 10,000 litres
per hour.

A drain must be fitted in the secondary cold feed

General Details
The construction of the F Modul plus is in the form
of a series of horizontal bottles, linked in modular
fashion, and comprising a high grade stainless
steel inner vessel with a rippledwall to enhance
heat exchanger efficiency. This is surrounded by
a mild steel primary water jacket, which is encased
with steel sheet insulated panels. The assembly
is mounted on two base channels running from
front to back. On all seven models, the secondary
flow and primary inlet are from the top and the secondary return, cold feed and primary outlet connections are at the bottom.
Performance of the seven F Modul plus models
covers a range of outputs up to an hourly rating of
10,000 litres/hour. Higher outputs can be provided
by arranging the units in modular formation. For
most typical applications (other than process water generation) the key requirement is for adequate
quantities of hot water over a relatively short period. On this basis, the F Modul plus will provide
significantly higher flow rates than its continuously
hourly rate.

Key Features
Minimum floor area, fits through standard
doorway.

Suitable for use with any make of boiler

High efficiency heat transfer for rapid
D.H.W. regeneration.
Recirculation design removes danger of
temperature stratification.
Optimum D.H.W. storage - sufficient for quick
draw-off but with lower standing losses than
conventional large volume calorifiers.

site pipework to fasciliitate draining and flushing

out. (CIBSE TM 13:2000
Recommendations to prevent Legionella
Bacteria Contamination).
Very low primary and secondary resistances.
Electric immersion heaters can be fitted by
prior arrangement.
Large heating surface, suitable for operation
with lower temperature primary feed from
condensing boilers. (Duty reduced - contact
Hoval).
See later section for unvented systems and
the additional equipment required.
Where access is a problem the bottles can be
split (flanged), This is an optional extra.
Suitable for primary flow temperatures upto 90
Deg C.
Suitable for secondary pressures upto 9.66
Bar.

Internal view of F Modul plus Calorifier

F42 Modul plus Calorifier

Technical and Performance Details

Technical and Performance Details F Modul plus Calorier

Technical Data.
Model

Primay Details
Contents Flow rate

Secondary outputs at 60oC based on 10oC cold feed

Resistance

Contents

At 82oC Primary ow At 90oC Primary ow Resistance

peak

continuous

peak

continuous

litres

l/s

mbar

litres

l/10 mins

l/hour

l/10 mins

l/hour

F21

30

2.27

120

230

405

1750

455

1960

12

F31

45

1.94

120

345

495

1800

555

2550

24

3.33

430

545

2400

625

3300

30

F41

60

2.92

440

460

800

3400

875

4150

80

F51

75

2.22

300

575

950

3200

1080

4350

120

3.33

720

140

F32

90

4.55

220

7.05

595

690

mbar #

1035

3950

1185

5250

1136

4546

1170

5800

33

1227

5682

1250

6600

39

F42

120

5.46

446

920

1727

6800

1740

8100

93

F52

150

4.44

340

1150

1900

6400

2160

8700

130

5.83
610
2015
7400
2315
10000
150
* Resistance is for primary ow rate listed
+ For DHW outputs below 60oC, external blending to a lower temperature is recommended.
# Resistance at the peak 10 minute draw off rate. For resistance at other draw off rates See Graphs on page 6.

Pressures
Standard Model Pressures
System

High Pressure Model Pressures**

Operating Pressures

Test Pressures

Operating

Test Pressures

Pressure Bar

Bar

Bar

Bar

Primary Side

4.48

6.90

6.90

10.0

Secondary Side

5.87

11.73

9.66

15.0

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

Weights
Model

Dry Weight kg

Dry weight Excl. Casings kg

Total weight kg

F21

269

165

529

F31

319

215

709

F41

380

265

900

F51

455

315

1105

F32

491

370

1271

F42

605

470

1645

F52

730

570

2030

Chloride.

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

To calculate the load on the boiler

for the calorier primary supply.

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

3600
Q
T1
T2
S.H.

= Calorier hourly output

= Temperature cold feed
= Temperature DHW ow
= Specic heat (4.187)

Litres (kg)
o
C
o
C
kJ/kgoC

Note for Hydraulic Testing: The primary

jacket should not be pressurised without
rst lling and sealing the inner stainless
steel vessel.
An adjustable secondary thermostat has
a sensing point which ensures that the
main body of water is held uniformly,
without stratication at the required
pre-set level, normally 60oC - 65oC.

Legionellae The safe temperature for storage is now considered to be a minimum of 60 C to prevent the risk of
o

legionella bacteria contamination. For kitchen and similar duties requiring 60oC water, the supply can be direct from the
calorier. For washing and showering duties which require a 42oC supply, mixing or blending with cold water, external to the
calorier, is required and will increase the secondary output listed on page 5 by about 25%.
When temporarily operating the primary side only, the pressure should not
exceed 1 bar g and the secondary side should be vented.

Technical and Performance Details

Hydraulic Resistance (Primary)

Hydraulic Resistance (Secondary)

M3 / h / 3.6 = l/s

Width
a
530
530
530
530
885
885
885

6 Electrical box
7 Electrical connection

Front View

Type F31, F51, F32,

F52

Side View

T & P Valve on
Unvented Systems

T & P Valve on
Unvented Systems

Type F32, F52

Type F42

3. Technical data

Rear View

Type F31, F51

3
2

Type F21, F41,

12

2"2BSP Male
2BSP Male
2"1BSP Male
1"F21-F51 = DN50 PN6
F32-F52
F21
- F51= =DN65
NWPN6
50
F32 - F52 = NW 65

Height
b
1615
1615
1800
2160
1615
1800
2160

Type F21, F41, F42

Dimensions

Connections
1. Secondary Flow
1 Hot water
2. Cold Feed
2
Cold water
3. Circulation
4. Primary
Flow
3 Circulation
5. Primary
Return
4 feed
6. Control panel
5
return
7. Electrical Connection

F21
F31
F41
F51
F32
F42
F52

Type

3.3 Dimensions

Technical and Performance Details

4 200 690 / 01

Delivery Positioning Instructions

Delivery and Positioning Instructions

Transport Dimensions

Delivery

Positioning / Clearance
Position the calorifiers as required, ensuring that
side and inspection opening clearances are adequate.
At least 400mm side clearance is required for
fitting the casings. If this space is not available,
the calorifier insulation and casings must be fitted before positioning the calorifier.
Ensure that the calorifier is level using a spirit
level along the top calorifier bottle.

The F Modul plus calorifiers are delivered in

three pieces:- The Modul bottles and frame.
- The casings and lagging in a cardboard box.
- The Calorifier control panel in a box.

Assembly Instructions

Assembly Instructions
Mounting the support rails
Ensure that the dimensions between the top casing rails and the base channels are as per H.

Before fitting the insulation and casings, fix the

bottom guide rails (1) to the base channels.
For types F32, F42 and F52 use Hole A.
For types F21, F31, F41 and F51 use Hole B.

Hole A.
Hole B.

10

Assembly Instructions

Fitting the insulation

Wrap the insulation matress (1,2,3,4 & 5) around
the calorifier(black side outwards), join the insulation at the top using tension springs (8). Secure with the plastic straps (6). These plastic
straps are secured using the strap fastener (7).

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

Figure B

Figure D

Assembly Instructions

Figure E

Figure A
Figure C

11

For instructions on how to fit the casings please see page 12.

12

Assembly Instructions

Fitting the Casings

(i)

Fit the front base panel (11) from the front. Then the middle and rear base panels (12) are
placed in position from the side, between the plinth channels.
(ii) The front side panels (13) are first placed in the bottom guide rails (Fig. A) and then attached
to the top casing rails. Push the side panels (13) back against the casing rails as far as it
goes.(Fig B)
(iii) Fit the other side panels (14,15). Join the front side panels (13) to the bottom guide rails with
spring clips (16, Fig. C). Push the side panels (14,15) up against the front side panels so that
there isnt a gap and then fix the panels at the back to the bottom guide rails with the spring
clips.
(iv) Fit the C-clips (17, Fig. D) to the cubicle retaining rails.
(v) Now the front lids (18.19) (on the F31, 32, 51, 52 models) or the front lid (on the F21, 41, 42
models) should be put in place. Then fit the other lids (20). Do not tighten the fixing screws at
this stage.
(vi) Fix the back panel (21) in position using the self-tapping screws.
(vii) Fit the support panel for the electrical control panel (22) and fix to the mounted screws with
dome nuts (23).
(viii) Mount the cable gland (24) in the support panel with the plastic counter-nut. Blank off the other
holes with blank grommets (25).
(ix) Push into position the electrical control panel (26). Beforehand, please route the capillaries to
the rear, through the opening in the support panel (22).
(x) Carefully Insert the thermometer and thermostat sensors into the immersion pocket (27) of
the corresponding bottle. Do not remove the plastic clip until the sensor bundle is inserted half
way into the immersion pocket. The sensor for a limit thermostat (on unvented systems) must
be mounted in the topmost bottle.

Do not kink the capillaries.

(xi) Then push the retaining spring (28, Fig. E) on the immersion pocket to prevent the thermometer
and thermostat sensors from slipping out.
(xii) Finally fit the front panel (29) and fix it with the dome nuts (23).

Assembly Instructions

13

Wiring up the unit.

A copy of the wiring diagram is both in the control panel and at the back of this manual.
Unvented systems require a hand reset limit stat.
Vented DHW calorifiers only require a control
stat.
The electrical installation should conform with all
relevent British Standards / I.E.E. Regulations.
This diagram should be checked for correct application.

To gain acess to the back of the control panel,

remove the two dome screws and remove the
orange support casing which houses the control
panel.
There are also two screws which can be removed
to get inside the control panel.
Ensure that the thermostats and the thermometer capiliaries are fitted in the pocket in the
calorifier bottle.

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

14

Installation and Piping Layouts

Installation

Fit unions to all pipe connections ensuring that joint

seals are fitted. Fit isolating valves to all pipework.

To facilitate venting during drain

down, ensure that a manual vent
valve is fitted in both the primary
inlet and the secondary flow between the calorifier and the isolating valves. On open vented
systems the vent should be
taken from the same place.

Note: The F Modul plus calorifier

isnt fitted with a DHW or primary
drain tapping. Therefore the primary drain must be fitted in the
site pipework off the primary outlet connection and the DHW
drain should be fitted in the cold
feed.

Piping layout
For the general design of water circuits refer to
current British Standards and Codes of Practice.
A simple pumped primary flow and return, adequately vented, is all that is needed. Secondary

connections are quite conventional. Connect the

calorifier(s) to the rest of the system according
to the chosen layout. Examples of both primary
and secondary systems are shown below:

Recommended Primary
primary Systems
systems (open vented).
Recommended

B
Primary
from
Main Headers.
Primary ConnectionsConnections
from Main Headers. Temperature control
by pump.
Temperature control by pump.
1

Primary Connections from Main Headers.

Temperature control by diverting valve.

AAV

AAV

Secondary
Water
Primary
Water

4 (if Required)

Primary
Water

Secondary
Water

5
3

AAV

3
6

Key

Anti-thermal
loop

(1) Safety Valve recommended if not

on adjacent boiler or system.
(2) Spring loaded non-return valve.
(3) Isolating valves.
(4) Primary pump (For diagram B
the main circulating pump may be

6
3

used if sufficient head is available).

(5) Thermostat (linked to primary
pump to control calorifier DHW temperature, for Diagram A).For diagram
B the thermostat controls the diverting valve.

On Unventedsystems there is also

a limit stat fitted.
(6) Drain cock.
(7) Diverting valve (use 30 second
motor).

15

Installation and Piping Layouts

Recommended Primary Systems (open vented) Continued
Recommended Primary Systems Continued.

Primary Connections direct from boiler.

Temperature control by diverting valve.

Primary Connections direct from boiler.

Temperature control by pump.
AAV

2
3

Primary
Water

AAV

Secondary
Water

Flow
3

Primary
Water

4 (if Required)

Secondary
Water

Boiler
6

Flow

Anti-thermal
loop

Boiler
Boiler

Return

Key

(1) Safety Valve recommended if not

on adjacent boiler or system.
(2) Spring loaded non-return valve.
(3) Isolating valves.
(4) Primary pump (For diagram D
the main circulating pump may be

Return

used if sufficient head is available).

(5) Thermostat (linked to primary
pump to control calorifier DHW temperature, diagram C). For diagram
D the thermostat controls the diverting valve.

On Unventedsystems there is also

a limit stat fitted.
(6) Drain cock.
(7) Diverting valve (use 30 second
motor).

Recommended Secondary Systems.

Secondary
Connections
Unvented
Secondary
Connections
UNVENTED.

Secondary Connections OPEN VENTED.

4

Vent

Cold
water
mains

Vent
Valve

AAV

3
4

T & P Relief Valve

in socket provided

Primary
Water

Water
Primary Water

Secondary
Water

Secondary
Secondary
Water
Water

Primary

Cold
Feed

2
6

11

Unvented kits available

Manual
on request.
See page 17.

Secondary
Return

Secondary
Circulating
Pump

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

8
Cold
water
5
mains

Cold
Feed

7
3
6

10 1

3 2 12 3

9
33

Secondary
Return

10
3

Secondary Circulating Pump

Key
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Expansion Relief Valve adjacent to calorier

Spring loaded non return valve
Isolating valves
Temperature and pressure relief valve
Strainer
Pressure reducing valve
Double check valve
Expansion vessel
Lock shield valve
Drain valve
Manual vent valve
Secondary circulating pump

16

Unvented Systems

Definition

An unvented hot water system differs from conventional

open vented systems in that no vent pipe is provided
and it is connected to the mains water supply, eliminating
the need for the provision of cold water storage tanks in
the roof space. The functions, therefore, of the open
vents and cold feeds have to be performed in other
ways. There are two basic types of unvented system:
(1) Direct off the mains,
(2) Boosted water supply.

An expansion relief valve should be fitted in the cold

feed between the expansion vessel and the calorifier.
No means of isolating the calorifier from this valve
should be installed.
A temperature and pressure relief valve should be
fitted directly in the calorifier as a thermal protection
to prevent the DHW reaching 100 deg C.
A hand reset limit stat should be fitted in the calorifier
to prevent the DHW overheating.

Boosted water supply

Direct off the mains

Where mains pressure is sufficient the system can be

connected straight off the mains. However, between
the cold water supply and the DHW generator (i.e. the
F Modul plus calorifier) there must be an unvented
system kit fitted.

Unvented
Kit.
Unvented System
System kit
11

T & P Relief Valve.

Hand reset
stat.

Hand reset limit stat tted

limitin control panel

Expansion relief
valve c/w tundish.

Expansion
Cold Vessel.
water

mains
Check
valve.

PRV.

10 1
6

9
3

10

Key

Strainer.
1. Expansion Relief Valve
2.
3.
4.
5.

Cold
Feed

Manual vent valve *

Isolating valves *
T & P relief valve
Strainer

6. Pressure reducing valve

7. Double check valve
8. Expansion vessel
9. Lock shield valve
10. Drain valve*
* Not Hoval supply.

Where mains water pressure is insufficient a cold

water booster set can be fitted. Normally these sets
have integral pressure controls, in the form of either
pressure transducers, pressure switches, and or
pressure regulating valves. They also have a non return
valve which prevents back-feeding. Systems where a
booster set is installed should not have a vent and as
such are unvented.
Boosted systems should have an unvented system kit
fitted down-stream from the booster set.
This kit should contain a minimum of the following
items: An expansion vessel should be fitted between the
non-return valve and the calorifier to take up expanded
water during heat-up.

Warning: Some pressure booster

sets have an accumulator (expansion vessel). This is to reduce the
amount of pump starts and should
not be confused with the system
expansion vessel.

An expansion relief valve should be fitted in the cold

feed between the expansion vessel and the calorifier.

No means of isolating the calorifier from this valve
should be installed.

As shown in the above diagram, an unvented system kit A temperature and pressure relief valve should be
fitted directly in the calorifier as a thermal protection
comprises of the following components: Strainer (this is optional, but good practice, to prevent to prevent the DHW reaching 100 deg C.
A hand reset limit stat should be fitted in the calorifier
debris passing through the valves)
Pressure regulating valve (PRV), this allows the to prevent the DHW overheating.
pressure to be reduced and controlled at a preset Balanced Unvented Systems
pressure. A pressure gauge is supplied to indicate
Some systems may be fitted with blending valves or
system pressure.
mixers that require a balanced hot and cold water
Double check valve, this prevents the expanded water supply. When sizing the strainer, the PRV, and check
back-feeding into the mains supply and additionally valve care must be taken to ensure they can pass the
seals the system.
flow rates at the required pressure.
An expansion vessel should be fitted between the non Hoval standard unvented system kits are sized to
return valve and the calorifier to take up expanded reduce incoming pressure to 3 bar at a flow rate that
water during heat-up.
meets the peak output of the calorifier only.

17

Unvented Systems
A separate Strainer and PRV can be fitted to both
the hot and cold water services to give balanced
system pressures. Alternatively, a larger Strainer
and PRV can be installed to cope with both hot
and cold water demands.

Warning: On balanced systems

with a common PRV, Strainer and
Double check valve, ensure that
the valves are sufficiently sized
to cope with both hot and cold
water demand.

Cold water booster sets tend to be sized on the

total demand of the system and subsequently
give a balanced condition.

Hoval Unvented System Kits

Hoval have carefully sized and selected a range
of standard unvented system kits suitable for
installation with the F Modul plus range of
calorifiers.
The various valves and fittings should be installed
in the sequence shown on the right.

Unvented
System
Unvented
SystemKit.
kit
Unvented System kit

Hand reset limit

stat.

Expansion relief
valve c/w tundish.
Cold
Expansion
ColdVessel.

Please note that these kits are only sized for the
cold feed going into one of the F Modul plus
calorifiers.

PRV.
Key

Strainer
F21 & F31

P.R.V.

Double
Check
Valve

water
water
mains
mains

Check valve.

33
4 4

Hand reset limit stat tted

in control panel

The size of the standard unvented kits are shown

in the table below.

Using the PRV from a standard Hoval unvented

kit to provide a balanced hot and cold water
supply may cause pressure and water flow
problems. Ensure that the PRV can cope with
the demand from both the hot and cold water
services.

211

T & P Relief Valve.

33

88

55

66

77

99

10 1
10
1

33

1010

Key

1. Expansion Relief Valve

Strainer.
1. Expansion Relief Valve
2. Manual vent valve *
2. Manual vent valve *
3. Isolating valves *
3. Isolating valves *
4. T & P relief valve
4. T & P relief valve
5. Strainer
5. Strainer

Cold
Feed

6. Pressure reducing valve

6. Pressure reducing valve
7. Double check valve
7. Double check valve
8. Expansion vessel
8. Expansion vessel
9. Lock shield valve
9. Lock shield valve
10. Drain valve*
10. Drain valve
* Not Hoval supply.
* Not Hoval supply.

Expansion
Relief
Valve &
Tundish

T&P
Relief
Valve

80 litre

HP80-6T

HP130-6T

Expansion
Vessel

1.1/2

1.1/2

1.1/2

130 litre

F32

1.1/2

1.1/2

1.1/2

130 litre

2 x 1 HP130-6T2

F42 & F52

240 litre

2 x 1

F41 & F51

HP240-6T2

18

Unvented Systems

Multi-calorifier Installations

Temperature
and Pressure
Relief Valve

Temperature
and Pressure
Relief Valve

Shared Unvented System Kits

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

Pressure
Reducing
Valve

Isolation valve

Cold
Feed

Strainer

Double
Check
Valve

Isolation valve

Cold
Feed

Strainer

Drain cock
by installer

Expansion
Relief Valve
and Tundish

Isolating
Valve

Isolating
Valve

Expansion
Relief Valve
and Tundish

Expansion
Vessel

Drain Cock
By the
Installer

Expansion
Vessel

Pressure
Reducing
Valve

Drain cock
by installer

Joining Pipe.
Double
Check
Valve
Drain Cock
By the
Installer

Common Unvented System Kit.

Temperature
and Pressure
Relief Valve

Temperature
and Pressure
Relief Valve

More than one calorifier can be

installed off a single common
cold feed. Each calorifier must
have its own T & P valve and
expansion relief valve. No
means of isolating these safety
valves from the calorifier should
be installed.
Expansion
Vessel

Pressure
Reducing
Valve
Strainer

Cold
Feed Isolation valve

Drain cock
by installer

Double
Check
Valve

Isolating
Valve

Drain Cock
By the
Installer

Drain cock
by installer
Expansion
Relief Valve
and Tundish
Isolating
Valve

Expansion
Relief Valve
and Tundish

19

Unvented
Systems
Unvented
Systems

BalancedBalanced
Hot and Cold
water
supplies.
Hot and
Cold
water supplies.

Unvented
SystemSystem
with balanced
Unvented
with balanced
hot andhot
cold
water
services.
and cold water services.

Temperature
and Pressure
Relief Valve

Temperature
and Pressure
Relief Valve

The hot and

water
supplies
Thecold
hot and
cold
water supplies
can be balanced
by utilizing
can be balanced
bythe
utilizing the
same strainer
PRVand
to PRV to
sameand
strainer
control the
two supply
lines.
control
the two
supply lines.
Note it may
beitnecessary
to
Note
may be necessary
to
increase increase
the size of
these
the
size two
of these two
fittings in fittings
comparison
to the nonin comparison
to the nonBalanced Cold Water
SupplyCold Water Supply
Balanced
return valve
in the
calorifier
cold
return
valve
in the calorifier
cold
feed line.feed line.
Expansion
Vessel

Isolation valve

Expansion
Vessel
Drain cock

by installer

Pressure
Reducing
Valve

Isolation valve

Cold
Feed

Strainer

Cold
Feed

Strainer

Pressure
Reducing
Double
Valve
Check
Valve

Expansion
Relief Valve
and Tundish
Isolating
Valve

Isolating
Valve

Double
Check
Valve
Drain Cock
By the
Installer

Expansion
Relief Valve
and Tundish

Drain Cock
By the
Installer

Balanced
hot andhot
cold
water
Balanced
and
cold water
services
using two
PRVs.
services
using
two PRVs.

Temperature
and Pressure
Relief Valve

Temperature
and Pressure
Relief Valve

The hot and

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

Balanced Cold Water

Supply
Balanced
Cold Water Supply

Isolation valve

Cold
Feed

Strainer

Cold
Feed

Pressure
Reducing
Valve

Strainer

Pressure
Reducing
Double
Valve
Check
Valve

Expansion
Vessel

Expansion
Vessel
Drain cock
by installer

Isolating
Valve

Double
Check
Valve
Drain Cock
By the
Installer

Drain Cock
By the
Installer

Expansion
Relief Valve
and Tundish
Isolating
Valve

Expansion
Relief Valve
and Tundish

19

20

Unvented Systems

Fitting the Unvented System Kit.

Fit the components as indicated. In the suggested
schematics detailed on previous pages.
All components must be installed in a frost free area.
Ensure that valves and fittings are fitted correctly to
suit the direction of flow.
Set the Pressure reducing valve (PRV) to 3 bar.
Pipe off expansion relief valve via the tundish provided
to a gulley.

Installation of the Expansion

Vessel.

Expansion
Vessel

Fit a lock shield valve and drain

to allow the expansion vessel to
be isolated and drained for
periodic inspection.

Pipe expansion vessel into cold feed. Fit a lock shield

valve and drain between the vessel and the cold feed
line. This will allow the expansion vessel gas charge to
be checked during maintenance. This is shown on the
right.

Isolation valve
Strainer

Pressure
Reducing
Valve

Cold
Feed

Drain Cock
(By the
Installer)
Lock Shield
Valve (By the
Installer)

Double
Check
Valve

Isolation valve

Maintenance of Unvented System Kit.

Expansion Vessel Sizing.

Clean out strainer on commissioning and annually.

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

Vessel Efficiency

Check Expansion relief valve setting annually by

twisting the cap on top of the valve.
Check expansion vessel gas charge pressure, isolate
the vessel, drain off any water in the vessel and test the
gas pressure using a tyre gauge.

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

Max Pressure is final desired working pressure + 1.

Min Pressure is pressure setting on PRV + 1.
C.o.E. at 60 Deg C is approx 0.02

Fault Finding.
Symptom

Possible Cause(s)

Remedial Action

(A) Reduction in water flow

Blockage in strainer
Blockage in PRV
Wrong PRV pressure setting

Clean out strainer.

Clean out secondary strainer in PRV.
Check PRV pressure setting alter if necessary.

(B)Discharge from expansion

Relief valve.

Debris on valve seat

Wrong incoming pressure
Expansion vessel diaphram
Failure.
Insufficient Expansion vessel
volume.

Twist test knob and replace if necessary.

Adjust the pressure setting on PRV.
Check expansion vessel gas charge.
Check expansion vessel size.

Commissioning & Operation

21

Commissioning & Operation

Commissioning Instructions
Pre-commissioning:
Important: Always fill the secondary side of the calorifier before
the primary. Pressurising the primary when the secondary is
empty may cause the secondary
bottle to collapse.

Warning: To avoid Legionellae, ensure the calorifier control stat is set

at a minimum of 60 deg C.

Commissioning
Flush all swarf, filings and other debris out of (1) Light the boiler (refer to the appropriate boiler

the system, preferably using a proprietary flushing agent. Do not wash particles into the calorifier,
this could cause subsequent corrosion.
Once the secondary side is fully flooded and
sealed, fill the primary system completely and
treat the water with a good corrosion inhibitor
(e.g. Fernox). Corrosion inhibitors are not used
in secondary (tap) water.
Ensure that all joints are water tight and all
pipework is vented.
Check that all electrical connections are complete and correct.
Ensure that the thermostat(s) are wired up and
the sensor probes are fitted in the stat pocket.
The thermostat may be wired into the boiler controls to activate the pumps or a motorised valve.
The control thermostat can be adjusted to operate between 30 deg C and 80 deg C and is usually set to 60 deg C.

operating instructions).
(2) Adjust the calorifier thermostat to the required
operating temperature.
(3) Check that the thermostat is operating correctly.
(4) Ensure that the primary pump is working or
primary primary circuit is established.
(5) Check that the operating temperature remains
constant.

Operating Instructions
The calorifier thermostat when wired to the primary circulating pump or diverting valve provides
completely automatic control. It is necessary only
to adjust the thermostat if the occasion demands.

22

Inspection and Maintenance

Inspection and Maintenance

Draining Down

Periodic Inspection

Note: The primary side of the

calorifier MUST always be
drained before the secondary.
The secondary MUST always be
filled before the primary.
FOLLOW THE PROCEDURE
BELOW:

The user is advised to carry out periodic inspection between main servicing periods and it is recommended that the specialist servicing company
also carries them out.
Note: Before opening the inspection
covers always ensure you have a
new inspection cover joint. Each
bottle has two covers (one at each
end, (e.g. 20 on a F52 calorifier).

Model
ALL F Modul plus

Joint Cat No.

414008

Inspect the calorifier casing for obvious signs

of damage, corrosion or deterioration.

Inspect the calorifier siting for signs of crack
ing or settling.
Inspect all pipes and connections for obvious
damage or deterioration.
Remove calorifier front/rear panel and exam
ine interior for corrosion and deterioration.
If anodes are fitted, check for deterioation.

(1) Ensure that both primary and secondary

pumps are switched off.
(2) Isolate the primary inlet and outlet.
(3) Fit hose to primary drain which should be installed in primary outlet and run the hose to
a gulley.
(4) Open primary vent valve.
(5) Open primary drain.
(6) Isolate all secondary connections.
(7) Fit hose to the secondary drain which is lo
cated underneath the calorifier and run the hose
to a gulley.
(8) (On sealed systems) Open manual secondary vent valve (this should be fitted in secondary
flow between calorifier and isolating valve).
(9) Open secondary drain valve.

When filling the calorifier follow the

above procedure but in reverse.
Cleaning
The period between cleaning will depend on operating temperature and hardness of water. Local conditions will serve as a guide. Normally descaling will be required less often than with conventional calorifiers.
The following procedure should be adopted:
(1) Remove calorifier front / rear casing panel.
(2) Remove cleanout cover for calorifier internals.
(3) Scrape the inside surface with a non ferrous
scraper when deposits of scale are found.
Note: Chemical cleaning can be carried out if required, but such work should be undertaken in
accordance with the instructions of the de-scaling compound manufacturer.
We recommend chemical treatment specialist
such as Aquazur. After chemically cleaning the
DHW calorifier internal, ensure that the unit is
thorougly flushed out with clean water.
Following cleaning, replace inspection cover using a new gasket to prevent leaks.

23

Inspection and Maintenance

Anode Protection
Periodic Inspection
Units fitted with sacrificial magnesium anodes (3) Carefully rest the new anode in the slot on
should be checked on a twice yearly basis to the plastic support pipe.
assess the deterioration of the anode.
(4) Screw the new anode to the socket in the
To inspect the anodes follow the procedure be- inspection cover and replace rubber gaskets and
carefully fit the covers.
low:Note: Before opening the inspection
covers always ensure you have a
new inspection cover joint. Each
bottle has two covers (one at each
end, (e.g. 20 on a F52 calorifier).

Example - F31

Magnesium Anode

(1) Drain the calorifier down.

Note: Follow the draining down
procedure on page 22.

(2)Carefully undo the nut holding the inspection

cover in place. Support the inspection cover by
holding the fixing stud. Carefully remove the inspection cover bracket and allow the inspection
cover to rest on the stud.
(3) Using a torch assess the state of the anode.
Note when the anode is about 10mm in diameter new anodes should be fitted.
(4) If the anodes are greater than 10mm in diameter, replace the rubber gaskets and carefully refit the covers.

Plastic Support Pipe

Rubber Door Joint
Inspection Cover

Part Description
Magnesium Anode
Inspection Cover
Rubber Door Joint
Plastic Support Pipe

Cat Number
628998
628996
414008
528289

(5) Once all of the covers have been fitted, refill

the calorifier, (Secondary side first, then the
Please note you will need one of each of
Primary side).

the above per bottle.

Fitting New Anodes

If new anodes are required:
(1) Unscrew the old anodes off the inspection
covers.
(2) Carefully remove the old anode, making sure
that you do not dislodge the plastic support pipe
at the other end.

Please contact our spares department to

order replacement parts.

24

Immersion Heaters

Immersion heaters
Operation

General

All work should be carried out by suitably qualified

personnel.
Heaters must be handled with care and stored in
dry conditions.
Adequate withdrawal space must be provided to
allow the removal of the heater assembly.
Carefully remove all protective packaging and
visually inspect unit for any transit damage.
All prevailing rules, regulations and bylaws in force
at the time and place of installation must be
observed.
Heaters must only be immersed in the fluid they
are designed to heat.
The introduction of alternative fluids even in small
concentrations for purposes such as sterilising
may cause serious damage to the heater and will
invalidate the warranty.
Any modification not carried out by Heatex Limited
or its approved agent will invalidate certification
and warranty.
Precautions must be taken to prevent damage to
enclosure seals.

Ensure that the active sections of all the heating

elements are fully immersed in the fluid to be
heated at all times whilst energized.
Heat is transferred by means of electric heating
elements.
Control of the heater is facilitated by
thermostats, thermocouples or RTDs and
reference should be made to the wiring diagram
inside cover to ensure that these are correctly
connected and set prior to energising the heater.
Where a manual reset thermostat or cut-out is
installed, the terminal box cover will have to be
removed after isolating the heater to enable a
reset to be carried out.

Maintenance
All prevailing site safety regulations shall be
adhered to at all times.
Equipment is to be fully isolated from the
electrical supply and locked off before and whilst
any work is being carried out.

Installation

The heater should be securely fixed in position and

all terminal connections checked for tightness
before energising.
The installed orientation of horizontally mounted
heaters must be such that any thermostats or
other temperature sensors are uppermost.
Sealing gaskets must be undamaged.
The terminal box must not be used for tightening
heater into tank or vessel.

Electrical Supply Connection

Refer to wiring diagram on page 25.

The cable entry or gland plate is positioned on the
side of the terminal box.
Before connection ensure that the supply
corresponds with that specified on the rating label.
Ensure that the sizes and types of cables to be
used are suitably rated for the load and temperature
of the unit.
Each heater must be protected by a suitably rated
over current device.
The cables must enter the heater terminal box via
a suitable cable gland to maintain the IP rating and
be fitted by a qualified person.

Routine Maintenance
3 Monthly

6 Monthly

Earth Connection
An earth connection is provided inside the terminal box.

Isolate the electrical supply and remove the

cover.
Ensure the terminal box is clean and dry
internally.
Ensure the electrical terminals are intact and
secure.
Check that the heating element insulation
resistance is at least 2 mega ohms.
Check the continuity of all elements.
Refit cover with new gasket if required.
Ensure that earth continuity is maintained
between all exposed conductive material and
main site structure.

Annually

THESE HEATERS MUST BE EARTHED

Generally inspect the equipment for external

damage or leaks.

Carry out all 3 monthly and 6 monthly checks

as above.
Check for element failure or low insulation
resistance.
If heaters are being left unused for a period
greater than 3 months, carry out 6 monthly
maintenance before energizing.

Immersion heater Electrical Diagrams

Immersion heater wiring diagrams

25

26

Fault finding

Fault Finding Chart

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

Symptom

Possible Cause

Action

A. Primary Water
Circuit Inefficient

(1) Leakage in system.

(1) Check pipe connection. Renew

if required.

(2) Pump faulty or inoperative.

(2) Refer to appropriate pump part

document.

(3) Boiler faulty or inoperative.

(3) Refer to appropriate boiler part

document.

(4) Circuit not properly vented.

(4) Vent primary system.

(5) Pump not of sufficient duty.

(5) Change pump speed or pump.

Symptom

Possible Cause

Action

A. Secondary water
temperature not as
setting on thermostat.

(1) Leakage in system.

(1) Check pipe connection. Renew

if required.

(2) Pump faulty or inoperative.

(2) Refer to appropriate pump part

document.

(3) Thermostat faulty.

(3) Check and replace if required.

(4) Electrical fault in control system. (4) Refer to appropriate control system part document.
(5) Calorifier scaled up.

(5) Mechanically / chemically descale as necessary.

(6) Calorifier not large enough for load (6) Change calorifier or add calorifier / buffer vessel.
imposed.
(7) Low primary temperature.

(7) Turn up boiler thermostats / increase primary flow rate.

(8) Diverting valve bypassing.

(8) Check primary pipe cools when

hot water not required.

Electrical Diagrams

Wiring Diagrams for Open Vented Calorifiers

27

28

Electrical Diagrams

Wiring Diagrams for Unvented Calorifiers

Notes

29

Conservation of Energy
Protection of the Environment
Hoval Limited, Northgate, Newark, Notts NG24 1JN
Telephone: 01636 672711 Fax: 01636 673532
e-mail: [email protected]
web: www.hoval.co.uk