Planner Guide

High-output calorifier Modul-plus

Favourite choice for refined domestic

hot water convenience
Favourite choice for refined domestic hot water conveniences

1 Outstanding application for a Hoval Modul-plus system 4

1.1 Benefits of a Hoval Modul-plus system 4
1.2 Product overview 5

2 System P&I Diagram (Cascade with digital control panel) 6

3 Domestic hot water demand and selection of Modul-plus 8

3.1 Calculation of the maximum demand rate at 60°C 8
3.2 Calculation of the average demand rate at 60°C 9
3.3 Calculation of the 10 minutes peak demand rate at 60°C 9
3.4 Selection of Modul-plus calorifier 9

4 Required boiler output 12

5 General - Calculation of pressure losses 13

6 Pressure loss calculation (Heating distributor to Modul-plus) 14

6.1 Pressure losses in straight piping (Heating distributor to Modul-plus) 15
6.2 Pressure loss at individual points of resistance (Heating distributor to Modul-plus) 15
6.3 Total pressure loss P (Heating distributor to Modul-plus) 15
6.4 Pressure loss diagram Biral L804 16

7 Determination of the boiler volume flow 17

7.1 Determination of the boiler pump 17
7.2 Pressure loss calculation (Boiler to Heating distributor) 17

8 Selection of the correct control panel 17

9 System P&I Diagram (Single Boiler with thermostatic control panel) 18

10 Hoval burner matching list 19

10.1 Hoval boiler types 19
10.2 Oil burner 19
10.3 Gas burner 20
10.4 Low NOx burner 20
10.5 Dual burner 20

11 Determination of the expansion vessel 21

11.1 Individual plant protection 21
11.2 Total plant protection 21
11.3 Determination of the expansion vessel 21
11.4 Determination of thermal expansion coefficient (f) 21
11.5 Expansion volume (VN) 21
11.6 Selction of expansion vessel 21

12 Water quality - Desalination 22

12.1 Desalination table 22
12.2 Step 1 – Conductance of filling water 22
12.3 Step 2 – Hardness of filling water 23

13 Corrosion protect 23

3
 Favourite choice for refined domestic hot water conveniences

1 1 Outstanding application for a Hoval Modul-plus system

1.1. Benefits of a Hoval Modul-plus system
2 The Hoval Modul-plus system is an ideal solution for all
applications where a big demand of fresh domestic hot Our best cost of ownership philosophy is part of the

3 water is needed in a short time. Hoval Modul-plus system which means: Related over
Ideal fields of application would be for example: the product lifetime, the best price performance ratio
• Hospitals for our end-users.
4 • Hotels
• Sport centers This takes in consideration following aspects:
• Restaurants
5 • Universities
Planning costs 1. Planning
• Factories
• etc. Procurement costs 2. Purchase
6 3. Product
4. Administration

7 Installation costs 5. Installation

6. System integration
7. Commissioning
8
Operating costs  .Operating
8
9. Environmental
9 10. Maintenance
Service costs 11. Service
10 Disposal costs 12. Disposal

11 Hoval is worldwide
known as technological
12 leading supplier of
innovative easy- systems
for heat and ventilation
13 technology with a high
measurably economical
and ecological added
value for the customer.

Innovative
easy-systems
with measurable
added value

4
Favourite choice for refined domestic hot water conveniences

1. Planner: E
 asy to plan (providing fast information in the • Less fuel consumption since our hot water systems
required quality and quantity) operate on highest efficiency 1
2. Installer: Easy to purchase (one order, one supplier) • More safety by using two boilers with smaller capacity
3. Owner: instead of one large boiler
 roduct costs are not necessarily to be low
P
(high quality material and manufacturing, high • Less pipe work & fittings 2
efficiency, Swiss engineered products) • Less space required in comparison to storage tanks,
4. Installer: Administration cost (responsible one stop shop) therefore more usable space for other applications
3
• Less weight in comparison to storage tanks leads to less
5. Installer: Installation cost (principle P&I including all
static in the building construction
information and supply of components for a
perfect functional system)
• More than 35 years experience with semi-instantaneous 4
heaters
6. Installer: S
 ystem integration (Hoval System technology
and controls matches all building requirements,
and finally, behind all you will find the Hoval family; friendly, 5
eg. BMS, lead lag, etc.)
professional, solution oriented, enthusiastic and responsi-
7. Installer: C
 ommissioning costs (since all components
ble for energy and environment.
match from the beginning,checked by Hoval 6
engineers and Hoval on site engineers fast
commissioning is possible)
8. Owner:  unning cost (high efficiency, engineered pro-
R
7
ducts with focus to conservation of energy and
environment lead to low running cost. Cheap 1.2. Product overview 8
products are not always cheap in the long run
time.) The following Hoval Modul-plus types are available:
9. Owner:  nvironmental costs (all our products comply
E F21, F31, F41, F51 and F32, F42, F52 9
with the latest regulations and they are even
better)
10. Owner: M
 aintenance costs (engineered products with
You can combine all Hoval Modul-plus types with:
10
• Hoval Uno-3 (low temperature hot water boiler with
focus to easy maintenance lead to lower costs) possibility of low NOx firing)
11. Owner: S
 ervice cost’s (engineered quality products • Hoval Max-3 (traditional 3-pass hot water boiler with
possibility of low NOx firing)
11
usually need less Service in life)
12. Owner: D
 isposal cost’s (Construction in combination • Hoval CompactGas (new developed high efficiency near
with the selected materials allow a cost effec- condensing high temperature boiler with the possibility 12
tive disposal) on low NOx firing)
• Hoval UltraGas (fully condensing high efficiency, high
Last but not least, a Hoval Modul-plus system provides you tech and easy boiler) 13
further advantages, such as: • Hoval Biral pumps
• Thanks to the internal construction, long life time calcium • Hoval Control panel
carbonate or difficult / bad water qualities will not reduce • Hoval selected and matched control valves, safety
the long life time of Modul-plus valves, pressure gauges, etc.

All types of the Modul-plus can be used for different domestic hot water qualities.
Modul-plus type Maximum chloride content Working pressure [bar]
of drinking water [mg/liter] Drinking water Heating
30 6 5
100 6 5
F21, F31, F41, F51, 100 10 8
F32, F42, F 52 200 6 5
200 10 8
300 10 8

5
 Favourite choice for refined domestic hot water conveniences

1
2 System P&I Diagram (Cascade with digital control panel)

10

11

12

13

6
 Favourite choice for refined domestic hot water conveniences

10
Description
PositionPosition Description LegendLegend
10
40
10 Hoval Boiler
Hoval Boiler
40 Boiler control
Boiler control
panel panel
DHW :DHW
CW :CW
domestic
: domestic
hot water
Cold: water
hot water
Cold water
11
50 50 Safety Safety
valve valve C :C Circulation
: Circulation
60 60 Low waterLowprotection
water protection
70 70 Drain valve
Drain valve
80
90
80 Reduction
90 Pressure
Reduction
sleeve sleeve
Pressure
gauge gauge 12
100 100 Pushbutton
Pushbutton
valve valve
110 110 Intermediate
Intermediate
flange drilled
flange drilled
120 120 Burner Burner
130
140
150
130 Boiler loading
Boiler loading
140 3-way valve
150 Actuator
pump pump
3-way valve
Actuator
13
160 160 Fixed value
Fixedcontroller
value controller
170 170 Immersion
Immersion
sleeve sleeve
180 180 Immersion
Immersion
sensor sensor
190 190 Hoval calorifier
Hoval calorifier
Modul-plus
Modul-plus
220 220 Calorifier
Calorifier
Modul-plus
Modul-plus
control control
panel panel
230 230 Safety Safety
valve valve
240 240 Reduction
Reduction
sleeve sleeve
250 250 Drain valve
Drain valve
260 260 Calorifier
Calorifier
Modul-plus
Modul-plus
loadingloading
pump pump
270 270 Expansion
Expansion
tanks tanks
280 280 DHW circulation
DHW circulation
pump pump

System
System
P & IPdiagram
& I diagram
Modul
Modul
Plus Plus

Achtung!Achtung!
Für die Installation
Für die Installation
muss dasmussanlagenbezogene
das anlagenbezogeneSchemaSchemaverwendet verwendet
werden!werden!
Attention!
Attention!
This is just
Thisa is
schematic.
just a schematic.
For installation
For installation
please use please
the use
detail-plan!
the detail-plan! 16.03.2011
16.03.2011
Attenzione!
Attenzione!
Per la messa
Per lainmessa
opera,inutilizzare
opera, utilizzare
le schema le schema
dettagliato!
dettagliato!
Attention!
Attention!
Pour la réalisation
Pour la réalisation
pratiquepratique
de l‘installation,
de l‘installation,
il faut utiliser
il fautleutiliser
schéma le schéma
détaillé! détaillé!

7
 Favourite choice for refined domestic hot water conveniences

1 3 Domestic hot water demand and selection of Modul-plus

2 Four steps to design the main components of the the values below can be used for further calculation. The
Modul-plus hydraulic. load factors given in the end columns indicate the typical
3 distribution of the demands. It is highly recommended that
To be able to calculate the size of the Modul-plus and boiler these values are accepted by the design agency. One
capacity, it is necessary to know the peak demand rate and should always ask for details of hot water peak require-
4 the average demand rate. If no demand values are given, ment!

5
3.1. Step 1: Calculation of the maximum demand rate at 60°C
6
Private Public Average 10 min
Installation litres Kitchen Pantry Laboratory
7 per hour at 60° C Hand
Basin
Hand
Basin
Shower*) Bath Slop Sink Bar Sink Sink Sink Sink Load
Factor
Peak Load
Factor

Hospital 10 15 70 60 50 80 0.80 0.30

8 Hotel (> 100
rooms) and 5 15 50 50 50 100 80 0.75 0.25
residential hall
9
Day school 5 20 180 40 80 0.80 0.40
Sport centre 5 15 220 40 100 80 1.00 0.50
10 Restaurant 5 25 100 100 140 120 1.00 0.50
University 5 20 220 40 80 40 0.80 0.40
Offices 5 10 40 40 40 1.00 0.50
11 Factory 5 20 120 50 80 40 1.00 0.75

Apartments
5 50 100 45 0.50 0.20
12 (>30 units)

*) Where shower and bath are combined in one single cubicle it is only necessary to use
one demand rate and the total number of cubicles.
13

8
Favourite choice for refined domestic hot water conveniences

Example: Hotel with 200 rooms & restaurant

1
Consumption each item
Installation - Hotel Quanities Total
according table page 8
2
Hotel, Combined baths/showers*) 200 pcs. 50 l/h = 10'000 l/h
Hotel, Private hand basins*) 200 pcs. 5 l/h = 1'000 l/h
Hotel, Pubilc hand basins*) 10 pcs. 15 l/h = 150 l/h
3
Hotel, slop sinks*) 10 pcs. 50 l/h = 500 l/h
Hotel, Kitchen sinks*) 10 pcs. 80 l/h = 800 l/h 4
Restaurant, Kitchen Sinks*) 4 pcs. 140 l/h = 560 l/h
Maximum Demand Rate 13'010 l/h
5
Hotel, Average Load Factor 0.75
Hotel, 10 Minutes Peak Load Factor 0.25 6
*) estimated number of consumption fittings (to be checked locally)
7

8
3.2. Step 2: Calculation of the average 3.4. Step 4: Selection of Modul-plus calorifier
demand rate at 60°C
In the end, you have to decide which flow temperature for 9
You need this average demand on page 12 your plant you want.
for the required boiler output.
10
There are three tables:
Average Demand Rate =
Maximum Demand Rate x Average Load Factor Table 1, see page 10:
Hot water output at a flow temperature of 90°C
11
Average Demand Rate = Table 2, see page 11:
Hot water output at a flow temperature of 80°C 12
13'010 [ liters
hour
] x 0.75 = 9'757.5 [ liters
hour
] Table 3, see page 11:
Hot water output at a flow temperature of 70°C
13
The formula of how many Modul-plus calorifier are needed
3.3. Step 3: Calculation of the 10 minutes is the following:
peak demand rate at 60°C
Number of Modul plus calorifier =
Peak Demand Rate (10 min, 60°C) = Calculated Peak Demand Rate (10 min, 60°C)
Maximum Demand Rate x Peak Load Factor (10 min) litres /10 min (60°C, according table)

Peak Demand Rate (10 min, 60°C) = Remark: The result must always be rounded up to

13'010 x [ liters
h
] x 0.25 = 3'252.5 [ liters
10 min
] a whole number.

9
 Favourite choice for refined domestic hot water conveniences

In our example we have chosen a flow temperature of Modul-plus F52

1 90°C.
According to the table “Hot water output at a flow tempera- Number of Modul-plus calorifier F52 =
ture of 90°C” you can calculate the number of Modul-plus 3'252.5 /2315 = 1.4 (rounded up) = 2
2 calorifiers as follows:
What we have chosen for our example is 2 times Modul-
Modul-plus F32 plus F42 with Biral pump L804.
3 The calorifier Modul-plus F42 fits a little bit better in
Number of Modul-plus calorifier F32 = comparison to F52.
4 3'252.5 /1250 = 2.6 (rounded up) = 3

Modul-plus F42
5
Number of Modul-plus calorifier F42 =
3'252.5 /1790 = 1.81 (rounded up) = 2
6

7
Hot water outputs at a flow temperature of 90°C
8
Only to be used if high outputs are demanded constantlys (e.g. Hotels, Industriy and Trade).
Primary flow connection on the top of the Calorifier (counter flow).
9
Calorifier Modul-plus Hot Water Output

10 Type Number Volume Heating Loading Pump Biral Redline *Liter/10 min. *Liter/h
of Bottles Liter Surface m 2
Type m3/h mWS *mbar 60°C 45°C 60°C 45°C *kW
F21 2 230 2.84 L323 3.5 1.7 25 385 550 1360 2250 91.5
L402 8 2.0 120 455 650 1960 3480 141.80
11 F31 3 345 4.26 L323 4 1.5 40 499 713 1850 3450 140.4
L402 7 2.2 120 555 793 2550 4300 175.0
L654 12 5.5 450 625 893 3300 5800 236.0
12 F41 4 460 5.68 L323 4 1.5 55 685 978 2250 4100 166.8
L503 8 3.4 240 810 1157 3500 6400 260.4
L654 10.5 5.7 440 875 1250 4150 7500 305.2
13 F51 5 575 7.10 L323 4 1.5 75 930 1329 3050 5650 229.9
L504 8 4.3 300 1080 1543 4350 7800 317.4
L804 12 8.1 720 1185 1692 5250 9100 370.3
F32 6 690 8.52 L401 8 1.5 45 998 1426 3700 6900 280.8
L653 14 3.5 165 1110 1585 5100 8600 350.0
L654 18 4.8 300 1170 1671 5800 9800 398.8
L804 24 7.0 530 1250 1785 6600 11600 472.0
F42 8 920 11.36 L401 8 1.5 62 1370 1956 4500 8200 333.7
L653 12 3.7 150 1500 2142 5800 10400 423.2
L654 16 5.1 260 1620 2314 7000 12800 520.9
L804 21 7.3 440 1790 2544 7990 14000 569.7
F52 10 1150 14.20 L402 8 2.0 82 1860 2658 6100 11300 459.8
L654 16 4.8 340 2160 3085 8700 15600 634.8
L804 21 7.3 610 2315 3316 10000 17500 712.2

*mbar = Flow resistance in the calorifier

*Liter/10 min. = Calorifier heated up to 60°C
*Liter/h = Continuous output per hour (cold water inlet temperature 10°C)
*kW = Input required at 45°C/10°C

10
Favourite choice for refined domestic hot water conveniences

Hot water outputs at a flow temperature of 80° Primary flow connection on the top of the Calorifier (counter flow).
Calorifier Modul-plus Hot Water Output 1
Type Number Volume Heating Loading Pump Biral Redline *Liter/10 min. *Liter/h
of Bottles Liter Surface m 2
Type m3/h mWS *mbar 60°C 45°C 60°C 45°C *kW 2
F21 2 230 2.84 L323 3.5 1.7 25 335 478 900 1880 76.5
L402 8 2.0 120 380 542 1300 2840 115.5
F31 3 345 4.26 L323 4 1.5 40 457 652 1350 2800 113.9 3
L402 7 2.2 120 495 706 1800 3650 148.5
L654 12 5.5 450 545 778 2400 4600 187.2
F41 4 460 5.68 L323
L503
4
8
1.5
3.4
55
240
635
730
907
1042
1750
2700
3350
5250
136.3
213.6
4
L654 10.5 5.7 440 780 1113 3200 6150 250.2
F51 5 575 7.10 L323
L504
4
8
1.5
4.3
75
300
831
950
1187
1356
2200
3200
4900
6600
199.4
268.6
5
L804 12 8.1 720 1035 1477 3950 7900 321.5
F32 6 690 8.52 L401 8 1.5 45 914 1305 2700 5600 227.9
L653 14 3.5 165 990 1413 3600 7300 297.0 6
L654 18 4.8 300 1040 1485 4200 8100 329.6
L804 24 7.0 530 1090 1556 4800 9200 374.4
F42 8 920 11.36 L401 8 1.5 62 1270 1814 3500 6700 272.6 7
L653 12 3.7 150 1380 1970 4600 8700 354.0
L654 16 5.1 260 1480 2113 5400 10500 427.3
L804 21 7.3 440 1620 2290 5920 12480 507.9 8
F52 10 1150 14.20 L402 8 2.0 82 1662 2374 4400 9800 398.8
L654 16 4.8 340 1900 2713 6400 13200 537.2
L804 21 7.3 610 2015 2877 7400 15600 634.8 9
Hot water outputs at a flow temperature of 70°C Primary flow connection on the top of the Calorifier (counter flow).
Calorifier Modul-plus Hot Water Output
10
Type Number Volume Heating Loading Pump Biral Redline *Liter / 10 min. *Liter / h
of Bottles Liter Surface m 2
Type m3/h mWS *mbar 60°C 45°C 60°C 45°C *kW
11
F21 2 230 2.84 L323 3.5 1.7 25 304 434 640 1520 61.8
L402 8 2.0 120 342 488 960 2120 86.2
F31 3 345 4.26 L323 4 1.5 40 403 575 700 2100 85.4 12
L402 7 2.2 120 420 600 900 2800 113.9
L654 12 5.5 450 445 635 1200 3600 146.5
F41 4 460 5.68 L323
L503
4
8
1.5
3.4
55
240
570
630
814
900
1100
1700
2700
4100
109.8
166.8
13
L654 10.5 5.7 440 660 942 2000 4850 197.3
F51 5 575 7.10 L323 4 1.5 75 720 1028 1250 3750 152.6
L504 8 4.3 300 796 1137 1900 5200 211.6
L804 12 8.1 720 855 1221 2400 6300 256.3
F32 6 690 8.52 L401 8 1.5 45 806 1151 1400 4200 170.9
L653 14 3.5 165 840 1200 1800 5600 227.9
L654 18 4.8 300 864 1234 2100 6200 252.3
L804 24 7.0 530 890 1271 2400 7200 293.0
F42 8 920 11.36 L401 8 1.5 62 1140 1628 2200 5400 219.7
L653 12 3.7 150 1200 1714 2800 6700 272.6
L654 16 5.1 260 1260 1800 3400 8200 333.7
L804 21 7.3 440 1340 1940 3600 9490 384.1
F52 10 1150 14.20 L402 8 2.0 82 1440 2057 2500 7500 305.2
L654 16 4.8 340 1592 2274 3800 10400 423.3
L804 21 7.3 610 1674 2391 4500 11800 480.2

*mbar = Flow resistance in the calorifier *Liter/h = Continuous output per hour (cold water inlet temperature 10°C)
*Liter/10 min. = Calorifier heated up to 60°C *kW = Input required at 45°C/10°C
11
 Favourite choice for refined domestic hot water conveniences

1 4 Required boiler output

2 For applications such as first-class hotels, hospitals etc.

where hot water is of great importance, we recommend Required boiler output [kW] =
for safety and redundancy reasons, to choose two boilers
3 working as a cascade. Each of them being able to cover [ 2
] x 9'757.5 [ kg
]
3 h
2/3 of the total average hot water demand. This is for
4 safety reasons important if one boiler failed.
x 0.00116 [ kWh
] x (60 - 10) K = 377 kW
kg x K
Required boiler output [kW] =
5 We choose two heating boilers of the type Hoval Max-3
[ 2
3
] x Average Demand Rate x c x Δt (420), with a capacity range of - in depending of the used
burner - 320 up to 500 kW.
6
Average Demand Rate:
9757.5 [l/h], (1 liter of water = 1 kg)
7 Determination of the heating power
c: Specific thermal capacity of water If a heating circuit is required by the building, the engineer
(planner) must define the required capacity [kW].
8 [ 0.00116
kWh
kg x k
]
9 t1: DHW target temperature [60°C]
t2: Cold water temperature [10°C]
Δt: t1 - t2 Kelvin, [K]
10

11

12

13

12
Favourite choice for refined domestic hot water conveniences

5 General - Calculation of pressure losses 1

P = Δp + Z [mbar]
2
The total pressure losses are determined by adding the
individual pressure losses.
Δp = R x L 3
These are:
• Pressure losses in the piping, comprising: ξ values for calculating the pressure loss at the
Pressure losses in straight piping individual points of resistance 4
Pressure losses at the individual points of The zeta values of the fittings are dependent on their
resistance (fittings, heat exchanger, elbow
bends, etc.)
type and size. The manufacturer must provide these zeta
values!
5
The values in the table are based on comparative values
Calculation of total pressure losses which were determined in experiments. They can be used 6
as a rough guide.
P: Total pressure loss
Individual point of resistance ξ value
Δp: Pressure loss due to friction in straight piping 7
Straight-way cock 0.2
Z: Pressure loss at the individual points of resistance
Right angle stopcock 2
(fittings, heat exchanger, elbow bends, etc.)
Elbow bend 90° 0.5 8
R: Pressure gradients [ mbar
m
] Tiered elbow bend
Y-piece
0.5
1.5
L: Piping length [m] Straight-way T-piece 0.5 9
T-piece branch 1
10 20 32 50
Nominal width DN 15 25 40 >50
10
Straight-seated valve 10 7 5 4
Angled-seated valve 3.5 3 2.5 2
Non-return valve
Check valve
5
2
4
1.5
4
1.2
3.5
1
11
Fittings
12
Straight-way stopcock Elbow bend 90° T-piece straight stopcock
13

Angle-seated valves Straight-seated valve Non-return valve

13
 Favourite choice for refined domestic hot water conveniences

1
6 Pressure loss calculation
(Heating distributor to Modul-plus)
2

10

11

12

13 According to the pipe friction chart for steel pipes, a pipe Volume flow m =
diameter of DN 80 needs to be chosen for the piping
between heating distributor to Hoval Calorifier Modul-plus. 16'200 [ l
h
]= 16'200
3'600
[ L
s
] = 4.5 [ l
s
]
Maximum volume flow of the Biral pump L804 is 21 m3/h
(see page 10)
The pressure loss R in our case is:

In our example we have:

Q
100 [ Pa
m
]= 1 mbar
m
m= =
c x ΔT
At the end we get the result of a pipe diameter of DN 80
377 kW and a flow speed of 0.9 m/s.
= = 16.2 m3/h
(0.00116 kWh / kg x K) x 20 K
Assumption:
Maximum temperature rise, ΔT 20K

14
Favourite choice for refined domestic hot water conveniences

6.1. Pressure losses in straight piping (Heating The following individual points of resistance are used as
distributor to Modul-plus) examples for calculation: 1
The resistance of the piping is normally calculated by using Number ξ value ∑ξ
a design program. Elbow bend 90° 8 0.5 4.0
2
This procedure is indispensable for large systems with Straight-way cock 4 0.2 0.8
complex hydraulics. Non-return valve 1 4.0
∑ξ total
4.0
8.8
3
Δp = R x L
4
Δp: Pressure loss due to friction in
straight piping sections [mbar] ϑ: 1000 [
kg
m3
] (water)
5
R: Pressure loss (see diagram, page 14)

100 [ Pa
]= 1.0 mbar
v: 0.9 [
m
] (from pressure loss diagram, page 14 6
m m s

L: Piping length 21 m (flow and return pipes) 7

Z = 8.8 x [
1000 (kg/m3) x 0.9 (m/s)2
]
Δp = 1.0 [ mbar
m
] x 21 [m] = 21 [mbar] 200
8
= 35.64 ≈ 36 [mbar]
9
6.2. Pressure loss at individual points of resi-
stance (Heating distributor to Modul-plus) 10
6.3. Total pressure loss P (Heating distributor
ϑ x v2 to Modul-plus)
Z= ∑ξ x [ 200
] [mbar] 11
P = Δp + Z
Z: Pressure losses caused by individual points
of resistance [mbar] P = 21 mbar + 36 mbar = 57 mbar ≈ 0.6 MWC 12
ϑ: Density of medium in [ kg
m3
] (MWC = meter water column)
13
v: Flow speed [ m
s
]

15
 Favourite choice for refined domestic hot water conveniences

6.4. Pressure loss diagram Biral L804 The remaining pumping head ΔPp is:
1
The Modul-plus F42 data sheet also indicates the ΔPp = Maximum pump pressure ─ Pressure loss piping
required pump. In our case it is the Biral pump L804.
2 ─ pressure loss internal heat exchanger
With our given volume flow of 16.2 m3/h, the maximum

3 pump pressure is 7.5 MWC (see pump diagram below). ΔPp = 7.5 - 0.6 - 4.4 = 2.5 MWC = 250 mbar

The Modul-plus F42 internal pressure loss of the heat To make the pump exactly working at 7.5 [MWC] and 4.5
4 exchanger is 440 mbar ≈ 4.4 MWC (see table page 10). [l/s], that means on the operating point of the Biral L804 a
pressure loss of 250 mbar is missing. This pressure loss
can be realized by a flow control valve, with the result that
5 the pump has to work stronger to hold the flow at 4.5 [l/s].

7 [MWC]

8 Biral L804

10 ΔPp = 2.5 MWC

11
Modul-plus losses
12 internal heat exchanger

13
Piping losses

16
Favourite choice for refined domestic hot water conveniences

7 Determination of the boiler volume flow 1

Each Hoval calorifier Modul-plus needs according table 7.2. Pressure loss calculation 2
page 10 a Biral pump L804 with a volume flow of 16.2 m3 (Boiler to Heating distributor)
per hour. In total the whole system needs 32.4 m3 per hour.
The calculation of the pipe pressure losses is identical to
3
We would like to have a balanced system with two boilers the calculation we did on page 14 (Pressure loss calculati-
installed, the volume flow of each boiler has to be 16.2 m3 on, Heating distributor to Modul-plus). 4
per hour.

5
7.1. Determination of the boiler pump

The boiler volume flow is identical to the Modul-plus

6
volume flow. Therefore we choose once more a Biral L804
as boiler pump. 7

10
8 Selection of the correct control panel
11
Top Tronic T - Digital control panel
® Thermostatic control panel

The two boilers of our hydraulic are working as a cascade If you have a single boiler in combination with one Modul-
12
system. Therefore you have to choose as control panel a plus then it is also possible to design the hydraulic with
Hoval TropTronic®T. With the choice of the cascade and thermostatic control panels (Hydraulic, see page 18). 13
the TTT you will have an optimal efficiency of the system
(Hydraulic, see page 6).

Digital control panel Thermostatic control panel

How high is your operating temperature? 90°C 105°C How high is your operating temperature? 90°C 105°C
Your safety temperature for boiler control is 110°C 120°C Your safety temperature for boiler control is 110°C 120°C

Control panel Control panel Control panel Control panel

Your Hoval control panel is with TopTronic ® with TopTronic ® Your Hoval control panel is with thermostat with thermostat
T/U 3.1 T/U 3.2 T 2.2 T 0.2
If you have a building control system, you If you have a building control system, you
Mod Bus or GLT modul BMS Box
have to choose have to choose

17
 9
8
1

7
6
4

5
3
2

13
12
11
10

18
DHW
Position 40 T0.2/2.2
Descripton
10 Hoval boiler
40 Boiler control panel
50 Safety valve
60 Low water protection
70 Drain valve T
80 Reduction sleeve 0.5% P 90
90 60
Pressure gauge
100 220
100 Pushbutton valve
110 Intermediate flange drilled 50

120 Burner
130 Boiler loading pump
140 3-way valve
150 Actuator 10
160 Fixed value controller 190
170 Immersion sleeve
180 Immersion sensor CW
9 System P&I Diagram

190 Hoval calorifier Modul-plus 110

220 Calorifier Modul-plus control panel 120
C
240 250
230 Safety valve 80 70
240 Reduction sleeve 270
250 Drain valve 280
260 Calorifier Modul-plus loading pump
270 Expansion tanks 230
280 DHW circulation pump RKP 160
170
Legend T 180
Favourite choice for refined domestic hot water conveniences

DHW : Domestic hot water

CW : Cold water 130
C : Circulation
140
YKR
150
Position Description Legend

10 Hoval boiler DHW : domestic hot water

40 Boiler control panel CW : Cold water
50 Safety valve C : Circulation
60 Low water protection
70 Drain valve
80 Reduction sleeve
90 Pressure gauge
100 Pushbutton valve
110 Intermediate flange drilled
120 Burner
130 Boiler loading pump
140 3-way valve
150 Actuator
(Single Boiler with thermostatic control panel)

160 fixed value controller

9HUELQGXQJVKLQZHLVH  170 Immersion sleeve
+\GU ª 180 Immersion sensor
1RWLFH  1RWD  5HPDUTXH 6\VWHP 3 , GLDJUDP 0RGXOSOXV 190 Hoval calorifier Modul-plus
6LQJOH ERLOHU WKHUPRVWDWLF FRQWURO SDQHO 220 Calorifier Modul-plus control panel
230 Safety valve
'DWXP 1DPH 240 Reduction sleeve
$FKWXQJ  )U GLH ,QVWDOODWLRQ PXVV GDV DQODJHQEH]RJHQH 6FKHPD YHUZHQGHW ZHUGHQ   250 Drain valve
$WWHQWLRQ 7KLV LV MXVW D VFKHPDWLF )RU LQVWDOODWLRQ SOHDVH XVH WKH GHWDLOSODQ 9HUVLRQ   270 Expansion tanks
$WWHQ]LRQH 3HU OD PHVVD LQ RSHUD XWLOL]]DUH OH VFKHPD GHWWDJOLDWR 280 DHW circulation pump
 $WWHQWLRQ 3RXU OD UpDOLVDWLRQ SUDWLTXH GH O LQVWDOODWLRQ LO IDXW XWLOLVHU OH VFKpPD GpWDLOOp 'DWHL YVG
Hydr. Verbindungshinweis / System P&I diagram Modul Plus
Notice / Nota / Remarque: (Single Boiler, thermostatic control panel)
>> Achtung! Für die Installation muss das anlagenbezogene Schema verwendet werden! Datum Name
Attention! This is just a schematic. For installation please use the detail-plan! ... ...
Attenzione! Per la messa in opera, utilizzare le schema dettagliato! Version ... ...
1 Attention! Pour la réalisation pratique de l‘installation, il faut utiliser le schéma détaillé! Datei: ...
Favourite choice for refined domestic hot water conveniences

10 Hoval burner matching list 1

10.1 Hoval boiler types
2

4
Uno-3 CompactGas THD-- U
5

6
Max-3 THW -- I NT E THSD-- I E
7
10.2 Oil burner
The details in the tables are recommendations. Other combinations are possible. 8
Uno--3 Max --3 THW -- I NT E THW --I HT E THD-U THSD-I.. / ..E

9
(Model-No.) (Model-No.) (Model-No.) (Model-No.) (Model-No.) (Model-No.)

Oil burner SPARK 35 DSG; 2-stage 280

110
Oil burner BTL 14 P; 2-stage
125
Oil burner BTL 20 P; 2-stage 160 - 220 10
Oil burner BTL 26 P; 2-stage 250
320
Oil burner BL 45 P DACA; 2-stage 500
360
650
11
Oil burner TBL 60 P DACA; 2-stage 420
800
530
Oil burner TBL 85 P DACA; 2-stage
620
1000
12
Oil burner TBL 105 P DACA; 2-stage 750 1200
Oil burner TBL 130 P DACA; 2-stage 10 / 05 1500
Oil burner TBL 160 P DACA; 2-stage 1000 2000 13
Oil burner TBL 210 P; 2-stage 1250 13  /  08 2500
17  /  10 3000 25 / 20
Oil burner BT 250 DSG 4T; 2-stage
22  /  15 3500 30 / 25
Oil burner BT 300 DSG 4T; 2-stage 27  /  20 4000 35 / 30
Oil burner BT 250 DSPG; 2-stage progress 23  /  15
Oil burner BT 300 DSPG; 2-stage progress 28  /  20
45 / 40
Oil burn°er GI 350 DSPG; 2-stage progress 35  /  25 34 / 25
55 / 50
39 / 30
Oil burner GI 420 DSPG; 2-stage progress 40  /  30
43 / 35
54 / 45
45  /  35 59 / 50
Oil burner GI 510 DSPG; 2-stage progress 70 / 60
50 / 40 68 / 60
78 / 70
55 / 45 54  /  45
60 / 50 59  /  50 90 / 80
Oil burner GI 1000 DSPG; 2-stage progress
70 / 60 68  /  60 110 / 100
80 / 70 78  /  70

19
 Favourite choice for refined domestic hot water conveniences

10.3 Gas burner

1 Uno--3 Max --3 THW -- I NT E THW --I HT E THD-U THSD-I.. / ..E THSD-I.. / ..E
(Model-No.) (Model-No.) (Model-No.) (Model-No.) (Model-No.) (Model-No.) (Model-No.)
110
Gas burner two-stage & Low NOx; BTG 15P
125
2 Gas burner two-stage & Low NOx;BTG 20 P 160
190
Gas burner two-stage; BTG 28 P
220
3 Gas burner two-stage & Low NOx;TBG 35 P
Gas burner two-stage & Low NOx;TBG 45 P
250-320
360 500
650
Gas burner two-stage & Low Nox;TBG 60 P 420
800
4 Gas burner two-stage; TBG 85 P
530
620
1000
530
Gas burner two-stage; TBG 85 PN pneu m
620
5 Gas burner two-stage; TBG 120 P 750
1200
1500
Gas burner two-stage; TBG 120 PN pneu m 750 1000

6 Gas burner two-stage; TBG 120 P 1000

Gas burner two-stage; TBG 150 P 1000 1400 10 / 05 2000
Gas burner two-stage; TBG 150 PN pneu m 1000 1400
7 Gas burner two-stage; TBG 210 P 1250 1800 13 / 08 2500
Gas burner two-stage; TBG 210 PN pneu m 1250
Gas burner two-stage; TBG 210 PN pneu m 1800
8 Gas burner two-stage; BGN 250 P 2200 17 / 10 3000
3500 25 / 20
Gas burner two-stage; BGN 300 P 22 / 15
4000 30 / 25
9 Gas burner two-stage; BGN 300 P 2800
23 / 15
28 / 20

10.4 Low NOx burner

10 Gas burner pneu m & Low Nox, GI 1000 LX
80 / 70 78 / 70 110 / 100
90 / 80 89 / 80 130 / 120
35 / 25
34 / 25 45 / 40
Gas burner pneu. modul. GI 500 DSPGN ME 40 / 30
11 45 / 35
39 / 30 55 / 50

Gas burner pneu. modul. GI 500 DSPGN ME 43 / 35

50 / 40 48 / 40
Gas burner pneu. modul. GI 700 DSPGN ME 70 / 60
12 55 / 45 54 / 45
Gas burner pneu m & Low Nox, TBG 800 ME 70 / 60 68 / 60 90 / 80
Gas burner two-stage; BGN 350 P 27 / 20 35 / 30

13 10.5 Dual burner

1200
Dual burner two-stage; TBML 160PN 10 / 05
1500
Dual burner two-stage; COMIST 180 13 / 08 2000
2500 25 / 20
17 / 10
Dual burner two-stage; COMIST 250 23 / 15 3000 30 / 25
22 / 15
3500 35 / 30
Dual burner two-stage; COMIST 300 28 / 20 27 / 20 4000
45 / 40
Dual burner two-stage; GI MIST 350 DSPGM 35 / 25 34 / 25
55 / 50
Dual burner two-stage; GI MIST 420 DSPGM 40 / 30 39 / 30
45 / 35 43 / 35
Dual burner two-stage; GI MIST 510 DSPGM 70 / 60
50 / 40 48 / 40
55 / 45 54 / 45
60 / 50 59 / 50 90 / 80
Dual burner two-stage;GI MIST 1000 DSPGM
70 / 60 68 / 60 110 / 100
80 / 70 78 / 70
650
Dual burner two-stage; TBML 80PN 800
1000

20
Favourite choice for refined domestic hot water conveniences

11 Expansion vessel 1

11.1 Individual plant protection 11.5 Expansion volume (VN) 2

If flow and return pipes of total pipeline system can be VN = 1.1 x Va x f x X [liters] 3
interrupted by components (valves etc), each part of the
separately locked plant must be equipped with a single VN: Expansion volume
expansion vessel ! Va: Water volume of the plant: 2 x boiler, piping 4
(estimated)
= 2 x 552 + 420 = 1524 liters
11.2 Total plant protection f: Thermal expansion coefficient 5
Only one expansion vessel for the whole plant. You have to X: Allowance factor
be be sure that flow and return cannot be locked.
6
VN [Liter]=1.1*1524*0.029*1.5=72.93 ≈73.0 [Liter]
11.3 Determination of the expansion vessel 7
For reasons of simplification we decided to make a total plant 11.6 Selction of expansion vessel
protection with one expansion vessel for the whole plant. 8
Assumption: Plant height: 12 m = 1.2 bar

11.4 Determination of thermal Minimum pre – pressure [bar] = plant height [bar] + 0.3[bar]
9
expansion coefficient (f)
Minimum pre-pressure [bar]=1.2 [bar]+ 0.3[bar]=1.5 bar 10
T=
(Tv + Tr)
2
[°C ] Selection table for Reflex NG/ N
with safety valve 3 bar 11
T Average temperature [°C] capacity VN of the empty container in litres
at a pre-pressure of
Tv 90°C - Flow temperature
Type 0.5 bar 0.8 bar 1.0 bar 1.2 bar 1.5 bar 1.8 bar 2,1 bar
Tr 70°C - Return temperature
18/6 L 10 9 7 6 4 2 1,5
12
f Thermal expansion coefficient 25/6 L 14 12 10 8 6 3 2
35/6 L 20 17 14 12 8 5 2,5
(90 + 70)°C
50/6 L 25 22 18 15 11 7 3 13
T= = 80°C ==> f = 0.029 80/6 L 42 36 30 26 18 11 4
2
100/6 L 61 54 44 37 27 17 4,5
140/6 L 79 70 57 48 35 22 5
T [°C] 30 40 60 80 100 200/6 L 119 106 86 73 53 33 6
250/6 L 142 126 103 87 63 39 7,5
f 0.004 0.008 0.017 0.029 0.043 300/6 L 165 146 119 101 73 (VN) 45 9

400/6 L 210 187 151 128 93 58 11

500/6 L 269 239 194 164 119 74 14
600/6 L 324 288 234 198 144 90 18
Determination of allowance factor (X) 800/6 L 420 373 302 257 186 116 22
Boiler capacity <= 30 kW 30 kW - 150 kW > 150 kW 1000/6 L 525 467 380 321 233 145 28
max, possible
2m 5m 7m 9m 12 m 15 m 18 m
Allowance factor 3 2 1.5 plant height *
* Plant

height = centre of expansion chamber to topmost point of
the heating system / solar plant
The calculated boiler capacity is 377 kW.
Therefore the allowance factor has to be 1.5. Selection: Expansion chamber, type Reflex N 300/6

21
 Favourite choice for refined domestic hot water conveniences

1
12 Water quality – Desalination

2 To decide whether the plant filling water has to be desali- 12.2. Step 1 – Conductance of filling water
nated or not we need to know the following data:

3 • Heating power
We need to check the conductance of the filling water.
In our example we have a value of 520 μS/cm.
• Water volume of the plant
4 • Total hardness of filling water We have to search the intersection inside the installed boi-
• Conductance of filling water ler capacity. In our case the boiler with the lowest capacity
has 377 kW which refers to line “200 to 600 kW”.
5 With this data and maximum three further steps, we are The intersection gives us the result “Desalination or water
able to qualify if the plant has to be desalinated or not. analysis.

6 In our example: Now we have the choice to make a desalination - without

checking the water quality - or to check if the desalination
7 Heating power: 377 kW (lowest bolier capacity) is definitely a must.
Water volume of
the plant: 1524 liters
8 Filling water: Total hardness: 11 d°H
Conductance: 520 μS/cm Maximum filling quantity according to VDI 2035
(You get the filling water information from the water supply).
9 Degrees of water hardness
f°H < 1,0 < 5,0 < 10 < 15 < 20 < 25
Remark: If you have multiple boilers with different capa-
d°H < 0,56 < 2,8 < 5,6 < 8,4 < 11,2 < 14
cities installed, it is necessary to always operate
10 with the boiler of the lowest capacity. e°H < 0,71 < 3,6 < 7,1 < 10,7 < 14,2 < 17,8
Conductance (μS/cm) < 20 > 100 > 200 > 300 > 400 > 500

12.1 Desalination Table Boiler Capacity

11
50 to 200 kW
<= 20 l/kW
No desalination

Maximum filling quantity according to VDI 2035

necessary

12 Degrees of water hardness 200 to 600 kW

<= 50 l/kW
f°H < 1,0 < 5,0 < 10 < 15 < 20 < 25
over 600 kW Desalination or water analysis
d°H < 0,56 < 2,8 < 5,6 < 8,4 < 11,2 < 14
13 e°H < 0,71 < 3,6 < 7,1 < 10,7 < 14,2 < 17,8 Check if you have more than 20 liters per kW heating water,
<= 20 l/kW
Conductance (μS/cm) < 20 > 100 > 200 > 300 > 400 > 500 if yes desalination is necessary

Boiler Capacity Check if you have more than 50 liters per kW heating water,
<= 50 l/kW
if yes desalination is necessary
50 to 200 kW <= 20 l/kW
No desalination

f°H French degrees of water hardness

necessary

200 to 600 kW <= 50 l/kW d°H German degrees of water hardness

e°H English degrees of water hardness

over 600 kW Desalination or water analysis

In our example we would like to check if desalination is

Check if you have more than 20 liters per kW heating water,
<= 20 l/kW
if yes desalination is necessary definitely a must. This can be checked with the value
Check if you have more than 50 liters per kW heating water,
“Degrees of water hardness”. This value is a result of the
<= 50 l/kW
if yes desalination is necessary now necessary water analysis. We will do this in step 2.

f°H French degrees of water hardness

d°H German degrees of water hardness
e°H English degrees of water hardness

22
Favourite choice for refined domestic hot water conveniences

12.3 Step 2 – Hardness of filling water

13 Corrosion protection 1
Now we need to check the hardness of the filling water.
In our example we have an amount of 11 d°H (German
degrees of water hardness) of the filling water. A professional installation and commissioning as well
2
as compliance with the required operating parameters
First search the line in the table where d°H is written. Then are as a corrosion protection measure, mandatory.
3
find the appropriate cell in this row to which the specified
water hardness of 11°dH fits. In our case it is < 11.2 d°H As a rule, no additional corrosion protection measures
such as the addition of corrosion inhibitors are required. 4
Now we have to search the intersection inside the installed
boiler capacity. In our case the boiler with the lowest The treatment of water with chemicals should only be
capacity has 377 kW which refers to line “200 to 600 kW”. used if all other measures have been exhausted 5
After the water analysis the intersection gives us the result
“Desalination”. You have to desalinate the water!
6

Maximum filling quantity according to VDI 2035 7

Degrees of water hardness
f°H < 1,0 < 5,0 < 10 < 15 < 20 < 25
8
d°H < 0,56 < 2,8 < 5,6 < 8,4 < 11,2 < 14
e°H < 0,71 < 3,6 < 7,1 < 10,7 < 14,2 < 17,8
Conductance (μS/cm) < 20 > 100 > 200 > 300 > 400 > 500 9
Boiler Capacity

50 to 200 kW
<= 20 l/kW 10
No desalination
necessary

<= 50 l/kW
200 to 600 kW

over 600 kW Desalination or water analysis 11

<= 20 l/kW
Check if you have more than 20 liters per kW heating water,
if yes desalination is necessary 12
Check if you have more than 50 liters per kW heating water,
<= 50 l/kW
if yes desalination is necessary
13
f°H French degrees of water hardness
d°H German degrees of water hardness
e°H English degrees of water hardness

23
 Favourite choice for refined domestic hot water conveniences

24
Favourite choice for refined domestic hot water conveniences

25
 Favourite choice for refined domestic hot water conveniences

26
Favourite choice for refined domestic hot water conveniences

27
 Favourite choice for refined domestic hot water conveniences

28
Favourite choice for refined domestic hot water conveniences

29
 Favourite choice for refined domestic hot water conveniences

Disclaimer
Although Hoval does everything possible to ensure the
accuracy of all data within this document, we cannot be
held responsible for the contained information.

30
 Hoval heating technology
As an energy neutral supplier with a full range of
products, Hoval helps its customers to select
innovative system solutions for a wide range of energy
sources, such as heat pumps, biomass, solar energy,
gas, oil and district heating. Services range from
private residential units to large-scale industrial projects.

Hoval residential ventilation

Increased comfort and more efficient use of energy from
private housing to industrial halls: our controlled
residential ventilation products provide fresh, clean air
for living and working space. Our innovative system
for a healthy room climate uses heat and moisture
recovery, while at the same time protecting energy
resources and providing a healthier environment.

Hoval indoor climate systems

Supplying fresh air, removing extract air, heating,
cooling, filtering and distributing air, utilising heat gains
or recovering cold energy – no matter what the task,
Hoval indoor climate systems provide tailor-made
solutions with low planning and installation costs.

Responsibility for energy and environment.

The Hoval brand is internationally known as one of the leading
suppliers of indoor climate control solutions. More than 66 years of
experience have given us the necessary capabilities and motivation
to continuously develop exceptional solutions and technically
superior equipment. Maximising energy efficiency and thus
protecting the environment are both our commitment and our
2013 - 4212404

incentive. Hoval has established itself as an expert provider of

intelligent heating and ventilation systems that are exported to over
50 countries worldwide.

Your partner
Hoval Aktiengesellschaft
Austrasse 70, FL- 9490 Vaduz
Principality of Liechtenstein
(Swiss customs territory)
Phone +423 3992 400
Fax +423 3992 618
E-Mail: info@hoval.com
www.hoval.com