Ultramax R600

Ultramax R600
High output, floor standing gas fired condensing
boilers with outputs from 150kW to 571kW
Delivering excellence with every feature
The Ultramax R600 series of boilers is packed with features that
are best in class and provide power, extreme efficiency, reliability,
and ultra low harmful emissions. The range includes 7 models
with outputs from 150 to 571kW.
Utilising the proven water cooled, downfiring, premix burner system coupled with an
all stainless steel heat exchanger assembly,
Ultramax R600 boilers have a class leading
NOx emission of less than 35mg/kWh @ 0%
O2 (which easily exceeds the requirements
for the best BREEAM score) and can return
efficiencies of up to 109%.
Designed to pass through standard doors, with
widths from 670mm and floor space
requirement is within the range 0.74 m2
to1.34m2. Each model is able to be equipped
with two return connections, allowing high
efficiency to be achieved when serving a mix of
higher and lower system load circuit
temperatures. Another feature is the option to
utilise room sealed or open flue systems.
The Ultramax R600 is suitable for use in single
boiler or multiple/cascade installations. If used
singly, plug and play optional extra low loss
headers are available, and if being used as
retrofit appliances onto aged systems, a
matched boiler protection plate heat
exchanger unit is available for total boiler
isolation. The modulating burner system allows
turndown ranging from 5:1 to 7:1 to return
optimum efficiency at low system loads.
2
Water cooled
down-firing
burner
Put your mind at rest
It’s easy to ignore your boiler and heating system - until it goes wrong
or breaks down. A system failure, especially one caused by lack of
maintenance, can be inconvenient and costly.
It isn’t hard to imagine the
At MHS Boilers we provide a
difficulties that problems with
lifetime maintenance and service
your heating system can cause.
solution for your heating system -
And in some situations lack of
enabling you to rest safe in the
heating and hot water can be
knowledge that we’ll take care of it.
critical. Similar to your car, a
For details of cost effective Service
regularly maintained heating
and Maintenance Plans from MHS
system will run more efficiently
Boilers, (with options for plans
and any potential problems can
which include labour and parts),
be resolved before they develop
go to the Maintenance and Service
into major system failure.
section at www.mhsboilers.com
Financially, planned maintenance
makes sense too. It avoids major
capital outlay and the associated
costs of system down time - plus it
can keep your fuel costs down as
well as ensuring you are
minimising your emissions.
Our highly skilled
and trained
service and
technical support
engineers are
only a phone
call away
3
Standard features
Exceptional high quality and unequalled lifetime
Water cooled combustion chamber
high efficiency through the use of corrosion resistant
stainless steel as a heat exchanger material.
The application of water cooling measures to the
combustion chamber removes all need for delicate high
temperature insulating materials creating a very robust and
reliable unit that may be wet cleaned if necessary.
Compact dimensions
Mindful that space is at a premium in commercial
buildings, the R600 range is frugal on its space
requirements, and with dimensions ranging from
1105mm to 1735mm long by 670mm or 770 mm wide,
all appliances will pass through a standard door. And for
those installations where access is particularly difficult,
the boilers can be disassembled for site handling as
piece parts.
Controls options
With the inclusion of optional extra control modules, up
to two heating circuits (with or without weather
compensation), and domestic hot water may controlled
in a single boiler installation.
If used in a modular/multiple boiler installation, the
standard in-built controllers are able to be configured
to operate in a master/slave arrangement to provide a
cascading control function. Up to 16 boilers may be
included in a cascade configuration.
See page 10 for details.
Extreme efficiency
The all stainless steel heat exchanger coupled with the
patented water cooled down-firing modulating premix
burner with turndown to between 14 to 20% (dependant
upon model), the Ultramax R600 boilers can return
efficiency of up to 109% net. Operating at this extremely
high efficiency, the boiler has almost no losses to the
chimney giving maximum fuel savings.
Two system water return connections
With a typical standard type of condensing boiler serving
a system consisting of multiple load circuits operating at
different temperatures, the boiler must operate at a flow
temperature equal to that demanded by the highest
temperature load circuit. This in many cases may prevent
the boiler from operating in condensation phase and
inhibit the efficiency.
The Ultramax R600 however, is not a typical standard type
of condensing boiler; it has the option for two return water
connections; a hot return for higher temperature load
circuits such as air handling units or hot water cylinders,
and a cool return connection for weather compensated
radiator circuits or under floor heating. In this way the cool
return water can be separated and passed through the
condensing section of the heat exchanger allowing the
boiler to operate at a higher efficiency than if the higher
and lower temperature return water was blended together
and passed through the entire water circuit of the boiler
heat exchanger.
Inherent reliability
With all solid state controls, and moving parts confined to
the gas valve and fan there is little to wear through usage.
Additionally all components are sensibly laid out within the
uncluttered frame making maintenance a simple task.
Very low operating noise
At just 59dbA, the Ultramax R600 series is extremely quiet
making them an ideal appliance to choose in noise
sensitive applications such as residential blocks, schools
and libraries etc.
Varied fluing possibilities
The appliance may take air for combustion from the room
or it may be room sealed using a parallel tubes
arrangement.
Warranty
As standard the heat exchanger carries a 5 year guarantee.
All guarantees are against manufacturing or material
defects only (see terms and conditions of sale).
4
Dimensions & clearances
Clearance
diagram
450
450
450
8 (D2)
800
L
B2
B3
B
L2
5 (D1)
1
2 (G)
3 (W1)
H2
413
112
1175
H
1440
*6 (W2)
4 (W2)
489
7
115 (3x)
B5
9
B4
Electrical connections
Gas supply
Water supply
1
2
3
4
5
6
Water return (cold)
Air intake
* Water 2nd return (hot)
7
8
9
Boiler water drain valve
Flue gas outlet
Condense drain flexible hose 25mm diameter
Dimension
R601
R602
R603
R604
R605
R606
R607
L
mm
1105
1260
1470
1220
1435
1585
1735
L2
mm
127.5
127.5
137.5
137.5
187.5
187.5
187.5
H
mm
1480
1480
1500
1500
1500
1500
1500
H2
mm
1120
1130
1130
1150
1245
1245
1245
B
mm
670
670
670
770
770
770
770
B2
mm
225
235
235
235
215
215
215
B3
mm
260
260
260
310
310
310
310
B4
mm
260
260
260
490
490
490
490
B5
mm
130
130
130
245
245
245
245
D1
mm(dia)
130
150
150
150
200
200
200
D2
mm(dia)
150
150
200
200
250
250
250
W1
R"/DN
R2"
R2"
R2"
DN65 PN16
DN65 PN16
DN65 PN16
DN65 PN16
W2
R"/DN
R2"
R2"
R2"
DN65 PN16
DN65 PN16
DN65 PN16
DN65 PN16
R1"
R1 1/2"
R1 1/2"
R1 1/2"
G
R
R 3/4"
R1"
R1"
* Facility achieved using optional extra, "water 2nd return connection kit".
5
Easy access to all components
Designed with maintenance in mind, all
components are easy to access; for
example the top cover of the burner
removes quickly for cleaning of the air/gas
ways if necessary.
There is inspection and cleaning access to
the combustion chamber and the integral
chimney section at the rear of the appliance
removes easily without the need for
supplementary support of the flue system
in the building.
Flue Systems
Room Sealed Application
Ultramax R600 boilers must be connected to a flue system
suitable for use with condensing boilers. All sections of the flue
must have a fall of at least 3 degrees back towards the boiler to
ensure that any condensation that forms in the flue is free
draining back to the boiler.
For the appliance to be operated as room sealed, taking air for
combustion from outside the building, an air duct must be
installed to connection 5(D1). The air duct must not be smaller
than the diameter of the air connection on the boiler.
The resistance of the air duct must be added to the resistance of
the flue gas system and the total must not exceed the maximum
system flue resistance detailed in the Technical data table
on page 7.
If the draught generated in the flue system is likely to exceed
30Pa, then a suitable draught reducing / stabilising device and a
lockable volume control damper must be incorporated into the
chimney system adjacent to the appliance.
The terminal of the flue system should be left open. Universal
Terminal Caps or Rain Caps MUST NOT BE USED, any rain that
enters the flue system will help to wash the flue and will drain
through the boiler's condensate waste outlet.
6
The air connection is located behind an access panel which must
be removed and discarded when creating a room sealed
arrangement. For standard arrangements (B23) where the air for
combustion is taken from the boiler room, it is not necessary to
remove the access panel.
For specific guidance on flue system design parameters, see the
R600 planning document available for viewing/downloading at
www.mhsboilers.com
Technical data
Boiler Model
R601
R602
R603
R604
R605
R606
R607
Nominal heat output 80/60°C
kW
23.3 – 142.1 39.5 – 190.1 39.5 – 237.2 39.5 – 285.2 76.6 – 380.2 76.6 – 475.3 76.6 – 539.0
Nominal heat output 40/30°C
kW
26.7 – 150.7 45.2 – 201.6 45.1 – 251.4 45.2 – 302.3 87.7 – 403.1 87.7 – 503.9 87.7 – 571.5
Gross
kW
27.2 – 160.1 46.1 – 215.3 46.1 – 268.6 46.1 – 323.0 89.3 – 430.6 89.3 – 538.3 89.3 – 610.5
Net
kW
24.5 – 145.0 41.5 – 194.0 41.5 – 242.0 41.5 – 291.0 80.5 – 388.0 80.5 – 485.0 80.5 – 550.0
Nominal heat input
Max flow temperature
°C
90
90
90
90
90
90
90
litres
27
31
35
61
68
75
82
Design temperature rise (∆t)
°C
20
20
20
20
20
20
20
Nominal water flow @ ∆t 20K
l/s
1.69
2.26
2.82
3.39
4.52
5.65
6.41
Hydraulic resistance at nominal
water flow
kPa
10
18
28
15
27
42
55
Min/Max operating pressure @ 90°C
bar
1.0 / 8.0
1.0 / 8.0
1.0 / 8.0
1.0 / 8.0
1.0 / 8.0
1.0 / 8.0
1.0 / 8.0
Gas consumption Nat Gas (G20)
@ max load
m3/h
13.3
17.8
22.2
26.7
35.6
44.5
50.5
Gas consumption LPG (G31)
@ max load
kg/h
11.3
15.2
18.9
22.7
30.3
37.9
43.0
Gas inlet press nom. Nat Gas (G20)
mbar
17/20
17/20
17/20
17/20
17/20
17/20
17/20
Gas inlet press min/max LPG (G31)
mbar
30/50
30/50
30/50
30/50
30/50
30/50
30/50
Approx flue gas volume max
@ max load
m3/hr
238.0
318.0
397.0
477.0
636.0
795
901.0
mg/kWh
15/35
15/35
15/35
15/35
15/35
15/35
15/35
Approx flue gas temperature
@ 80/60°C system operation min/max
°C
56/78
56/78
56/78
56/78
56/78
56/78
56/78
Maximum system flue resistance
Pa
160
160
200
200
200
250
250
Gas connection
-
R 3/4"
R 1"
R 1"
R 1"
R 11/2"
R 11/2"
R 11/2"
Flow/return connections
-
R 2"
R 2"
R 2"
Air supply connection
mm
125
125
150
150
200
200
200
Flue connection
mm
150
150
200
200
250
250
250
Condensate waste connection
mm
22
22
22
22
22
22
22
Nominal weight (dry)
kg
295
345
400
465
535
590
650
Electrical supply (50Hz)
V
230/400
230/400
230/400
230/400
230/400
230/400
230/400
Mains connection fuse rating
A
10
10
10
10
10
10
10
Power consumption boiler
(excl pump) min/max
W
43/158
35/200
35/230
35/260
61/470
61/470
61/770
Water content
NOx level @ 0% O2 (min/max)
DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16
Gas Category II 2H3P
Appliance Category B23,C13, C33, C43, C53, C63, C83
CE Product Identification Number 0063B03192
7
Enhancement optional extras
A range of easy-to-apply optional extra components are available to enhance the final installation of the Ultramax R600 series
boilers. The use of these additional components also contributes to the ease of materials ordering, simplifies installation tasks
and cuts installation time.
"Safety kit"; (flow pipe assembly)
including auto air vent and safety
valve (incl 90° bend to increase
installation flexibility)
"Pump kit (incl 90° bend to
increase installation flexibility)
"Low loss
header kit";
(incl 2 x 90°
bends to
increase
installation
flexibility)
* When installing a boiler as a retrofit appliance onto an aged system, serious consideration should be given to the
cleanliness / condition of the existing system and the damaging effects of accumulated dirt and sludge upon new
appliances. The use of a plate heat exchanger kit provides total water side isolation and gives peace of mind that the
investment in the new boiler is protected from damaging and efficiency reducing deposits from the old heating system. It
also means that costly and very often ineffective measures to clean-up an existing system can be avoided. Another benefit
is the possibility to retain an existing system’s open vented nature whilst creating a sealed system environment for the new
boiler on the primary side of the plate heat exchanger.
8
Enhancement optional extras
"Safety kit"; (flow pipe
assembly) including auto air
vent and safety valve (incl
90° bend to increase
installation flexibility)
*
"Plate heat exchanger
kit"; (incl expansion
vessel – plus 2 x 90°
bends to increase
installation flexibility)
"Pump kit" (incl 90°
bend to increase
installation flexibility)
Plate Heat Exchanger
(secondary side) technical data
Model
Type
R601
R602
R603
R604
R605
R606
R607
∆t 10K
l/s
3.38
4.5
5.66
-
∆t 15K
kPa
30.4
28.8
44.0
-
l/s
4.52
6.02
7.55
8.55
∆t 20K
kPa
28.8
48.7
15.6
19.7
l/s
1.69
2.25
2.83
3.38
4.52
5.66
6.41
kPa
8.1
14.0
21.5
16.6
28.9
14.3
18.0
9
Controls and Options
Ultramax R600 series boilers are equipped with a modulating control system (LMS 14 with AVS37 user interface). As standard
the boiler operates to provide a constant flow temperature and with the addition of an optional extra outside air temperature
sensor weather variable temperature can be delivered. Alternatively if required, the flow temperature can be controlled via a
0-10 Vdc signal in response to external temperatures. An indirect hot water storage cylinder plus two mixed flow or constant
temperature heating zones may also be controlled and each with independent time scheduling by using extension modules.
If installed as part of a multiple boiler installation, the in-built standard controllers can be configured to provide cascade
control, with the potential to control up to 16 boilers. A cascade master kit is required to be installed into one of the boilers
with each of the remaining boilers requiring a cascade slave kit. A cascade master kit incorporates an OCI 345 Bus
Communication Module and all necessary sensors. A cascade slave kit incorporates an OCI 345 Bus Communication Module.
The controls capability can be extended by including items from the following options:
AVS75
A single boiler may be equipped with up to two AVS75
extension modules.
Each module provides for the control of an additional heating
circuit with connections for:
• Heating circuit pump
• Variable flow temperature mixing valve
• Flow water temperature sensor
(The heating circuit may be constant temperature if required)
Additionally, (over and above that described above), an R600
boiler may be equipped with an AVS75 module configured to
control an external gas valve (for use in LPG installations for
example) or to perform a gas valve leak test function.
Room Units / Room
Temperature Sensors
RVS 63
This is an extension controller for the addition of two heating
circuits, which may either be weather dependant or constant
temperature.
Up to 15 RVS devices may be connected to a single boiler, with
one unit being able to be accommodated within the boiler
control panel. Additional units are housed within wall mounted
enclosures or can be supplied as loose items for build-in to a
control panel by others.
Each RVS 63 is used in conjunction with an AVS 37 user
interface panel.
Additionally, an RVS63, can be used as a cascade master
controller if required whereby all of the boilers become
slave units.
Each heating zone may have a room unit (remote controller) installed to allow not only room space temperature to be be monitored
and controlled but also allows the user to make adjustments to the time and temperature control parameters for the zone.
Hard wired unit QAA75
Wireless unit QAA78 (requires antenna to be connected to LMS14 or RVS63 as appropriate).
Wireless Outside Air Temperature Sensor
Where the system includes a requirement for weather dependant temperature control element, as an option, a wireless outside
air temperature sensor can be provided (requires antenna).
10
System water
Ultramax R600 series boilers must only be installed onto sealed and pressurised systems with a minimum static head of
10m. All systems must be thoroughly cleansed prior to the connection of the boiler and the system water must be dosed
with a good quality treatment to prevent corrosion within the system and the formation of scale within the boiler
waterways. The chloride content of the fill water must not exceed 50mg/l and the PH should be in the range 8.0 to 9.5.
Particular care must be taken when installing the boiler onto an old system, with consideration given to the installation of
the optional extra separation “plate heat exchanger kit” or a dirt arrester/filter.
For specialist advice and water treatment products, contact: Fernox, Tandem House, Marlowe way, Beddington Farm Road,
Croydon CR0 4XS. Tel: 0208 665 6666 or Betz Dearborn Ltd, Widnes, Cheshire WA8 8UD. Tel: 0151 495 1861
Installation requirements
Ultramax R600 series boilers should be installed in accordance with the relevant requirements of the Building Regulations, Health
and Safety Executive Regulation PM5, IEE Regulations, Gas Safety (Installation and Use) Regulations, National and Water Bylaws and
any Insurance Company requirements.
Codes of practice
The following list of codes of practice give guidance on the requirements for installation.
BS 6880: Part 1: 1988 Code of Practice for low temperature hot
water heating systems for output greater than 45kW.
BS 6644: 2011 Installation of gas-fired hot water boilers of rated
inputs between 70kW (net) and 1.8MW (net).
BS EN 12828: 2003 Heating systems in buildings - Design for
water based heating systems.
IGE/UP/2 Gas installation pipework and compressors on
industrial and commercial premises.
IGE/UP/10 Installation of gas appliances in industrial and
commercial premises, Part 1: Flued appliances.
CISBE Guide Reference sections B7, B11 and B13.
Filling the system
The Initial filling of a sealed heating system, and subsequent refilling, must be by a method that has been approved by the Water
Regulation Advisory Scheme (WRAS) for the type of heating system, i.e. Domestic (in-house) Fluid Category 3 (C-3). Non Domestic
(other than in-house) Fluid Category 4 (C-4).
For Category 4 systems
The approved method of filling must comprise of the following
components in the arrangement shown;
• Control Valve, on the Mains Cold Water pipework.
• Strainer.
• Verifiable Backflow Device with Reduced Pressure Zone (RPZ
Valve) Incorporating a ‘Type BA’ air gap.
• Tundish
• Control Valve, on the Heating System pipework.
MCWS
CV
Strainer
RPZ
CV
Heating
system
Tundish
11
Hydraulic system design
The following schematic diagrams give indications of typical hydraulic schemes that may be employed.
For further and more detailed guidance on system design and planning, please see the R600 Planning Document
which is available for viewing or downloading at www.mhsboilers.com
Typical hydraulic layout of single boiler system
Typical hydraulic layout of twin boiler system
Master
Slave
12
Hydraulic system design
Typical hydraulic layout of split system utilising 2nd return connection on boiler
Under-floor
heating
coils
13
Dimensions with optional low loss
header kit
A
B
B
A
A
Model
A
mm
1233
1299
1299
R601 - R603
R604 - R605
R606 - R607
Model
A
mm
923
1096
1096
R601 - R603
R604 - R605
R606 - R607
B
mm
545
611
611
Model
A
mm
928
1119
1119
R601 - R603
R604 - R605
R606 - R607
B
mm
545
611
611
B
B
B
A
A
A
Model
A
mm
1191
1320
1320
R601 - R603
R604 - R605
R606 - R607
B
mm
277
388
388
Model
R601 - R603
R604 - R605
R606 - R607
A
mm
277
388
388
B
mm
881
1119
1119
Model
A
mm
697
873
8733
R601 - R603
R604 - R605
R606 - R607
B
mm
886
1138
1138
A
B
A
B
B
A
Model
R601 - R603
R604 - R605
R606 - R607
14
A
mm
1191
1320
1320
B
mm
282
406
406
Model
R601 - R603
R604 - R605
R606 - R607
A
mm
697
873
873
B
mm
881
1119
1119
Model
R601 - R603
R604 - R605
R606 - R607
A
mm
886
1119
1119
B
mm
152
262
262
Dimensions with optional plate heat
exchanger kit
B
B
A
A
A
Model
A
mm
1421
1667
1542
R601 - R603
R604 - R605
R606 - R607
Model
A
mm
960
1133
1073
R601 - R603
R604 - R605
R606 - R607
B
mm
735
981
856
Model
R601 - R603
R604 - R605
R606 - R607
A
mm
1047
1222
1278
B
mm
735
981
857
A
mm
887
1243
1119
B
mm
1005
1243
1299
A
mm
1005
1243
1299
B
mm
252
362
361
A
B
B
B
A
A
Model
A
mm
1379
1690
1566
R601 - R603
R604 - R605
R606 - R607
B
mm
314
424
362
Model
A
mm
918
1156
1094
R601 - R603
R604 - R605
R606 - R607
B
mm
278
388
388
Model
R601 - R603
R604 - R605
R606 - R607
A
A
B
B
B
A
Model
R601 - R603
R604 - R605
R606 - R607
A
mm
1379
1690
1566
B
mm
401
511
567
Model
R601 - R603
R604 - R605
R606 - R607
A
mm
887
1243
1119
B
mm
918
1156
1094
Model
R601 - R603
R604 - R605
R606 - R607
15
3 Juniper West, Fenton Way, Southfields Business Park,
Basildon, Essex SS15 6SJ
Tel: 01268 546700 Fax: 01268 888250
www.mhsboilers.com
This publication is issued subject to alteration or withdrawal without notice.
The illustrations and specifications are not binding in detail. All offers and sales
are subject to the Company's current terms and conditions of sale.
RC/0713/6543