AHG Solutions Guide_Edition 2.7

Solutions Guide Edition 2.7

Contents 

Contents 

Contents 

Company Overview 2 

The Automatic Heating Advantage 4 

Sales & Technical Support 6 

Service & Maintenance 8 

Heat Pumps 10 

Air to Water Heat Pumps 11 

Water to Water Heat Pumps 59 

Condensing & Conventional Boilers 66 

Condensing Boilers 67 

Conventional Boilers 113 

Gas, Dual Fuel & Oil Burners 125 

Flue Systems 137 

Biomass Boilers 152 

Wood Boilers 154 

Pellet Boilers 160 

Expansion & Deaeration 164 

Expansion Tanks & Pressurisation Systems 165 

Dirt and Air Separation 189 

Backflow Prevention & Water Makeup 217 

Thermal Storage 222 

Hot Water Storage Tanks for Domestic Water 224 

Buffer Storage Tanks for Heating and Cooling 238 

HVAC Pumps 246 

Saer Pumps 248 

Wilo Pumps 250 

Grundfos Pumps 252 

Inertia Bases 256 

HVAC Accessories 258 

Condensate Neutralisers 260 

Hydraulic Separators 266 

Heat Exchangers 268 

Valves and Gauges 270 

Water Treatment Products 278 

Prefabrication 282 

1

Company Overview 

Contents 


Automatic Heating takes a whole-of-life, holistic 

approach to the manufacture, supply and service 

of our comprehensive range of water-based 

heating and cooling solutions. 

Our success is built on this approach, coupled with a thorough understanding of mechanical engineering 

principles and customer focus that has evolved through 90 years of experience in this technically 

demanding and rapidly changing industry. 

We offer system solutions in their entirety, meaning all components can be selected from one convenient 

trusted source. Importantly, this full product range is supported by Automatic Heating’s dedicated presales 

and after-sales support capability, and nationwide service network. 

Our Vision 

To offer each client an irrefutable case for energy efficient 

systems, which are integrated and attainable, high quality 

and sustainable, with numerous benefits demonstrable 

through advanced technical specification services and 

generously shared expertise. 

We have been challenging 

ourselves for over 90 years 

to find the most energyefficient 

way to achieve our 

mission, and will never stop 

perfecting this pursuit. 

Our Mission 

Our business exists to create comfort; in warmth that 

consoles, calms, relaxes and heals, and through cooling 

that soothes the body and mind. We sell complex 

products and execute advanced technical planning, for 

the purpose of achieving simple feelings that often go 

unnoticed. But that, in itself, is the mission, for when our 

work goes unnoticed, that is when we know we have 

succeeded in providing effective solutions that create the 

perfect indoor environment. 

We have been challenging ourselves for over 90 years 

to find the most energy-efficient way to achieve our 

mission, and will never stop perfecting this pursuit. As 

a family business, it is our personal mission to provide 

quality innovation through professional support and 

impeccable service to the Mechanical Services and 

Hydronic Heating Industries, which make our mission 

achievable. 

2

Contents 


Our Purpose 

Automatic Heating Global’s purpose is to design, deliver 

and maintain sustainable, energy efficient solutions that 

enables others to live and work well. 

Our Brands 

Our Values 

• Help from the heart 

• Solve it for the Customer 

• Trust is Fundamental 

• Champion Sustainability 

• Show initiative 

Automatic Heating is pleased to represent the following global brands. As 

leading forces for quality and innovation in the commercial HVAC sector for 

many years, these trusted manufacturers continue to open up new horizons in 

heating and cooling technology and sustainability. 

3

The Automatic Heating Advantage 

Contents 

The Automatic 

Heating Advantage 

Automatic Heating’s Revere CO 2 

Heat Pumps bring an exciting and promising aspect of non-fossil fueled 

sustainable high temperature hot water heating to the commercial HVAC market in Australia. 

Here For The Long Haul 

Since our beginnings in a small 

workshop in Park Street, South 

Melbourne in 1926, Automatic 

Heating has evolved into a truly 

innovative, national company. 

Now in our fourth generation, 

Automatic Heating continues to be 

synonymous with the strengths that 

have made us who we are today: 

first-class engineering, friendly 

customer service based on a sound 

understanding of the underlying 

technology and a passion for 

innovation and sustainability. 

We continue to increase our 

competitiveness through state-ofthe-art 

production methods, ongoing 

product development and processoriented 

management – opening up 

the markets of the future with a longterm, 

solution-based approach. 

Sustainable Integrated Solutions 

Our vision is to be the leading provider 

of innovative and energy efficient 

products to the Australian HVAC 

industry, with a strong emphasis 

on sustainability to help customers 

reduce their carbon footprint. 

The best way to achieve a sustainable 

result is to design integrated solutions 

that are energy efficient in all facets of 

their construction. Our product range 

reflects this, with integrated solutions 

offered in their entirety from one 

convenient source. 

Each product we stock is a leader 

in its category, sourced globally 

from some of the most progressive 

and technologically advanced 

manufacturers in the world. 

Even though these products may 

have been tried and tested in some 

of the world’s most demanding 

environments, Automatic Heating 

ensures they are suited to Australian 

conditions and certified where 

necessary, giving you complete 

confidence that you are investing in 

proven, leading-edge technology of 

unrivalled quality. 

At Automatic Heating, we would like 

to see your next HVAC project go 

down in history as a shining example 

of innovation, exemplary design and 

sustainability. We invite you to partner 

with us to promote sustainable climate 

mechanics and help shape a brighter 

and more sustainable future. 

Let’s work together now for 

a better future 

4

Contents 

The Automatic Heating Advantage 

Expert design 

and technical support 

Extensive stock 

holding facilities 

Comprehensive 

Product Range 

As the leading provider of Waterbased 

Heating & Cooling to the 

Commercial HVAC market across 

Australia, Automatic Heating is able to 

provide superior design and technical 

support to ensure that our products 

meet or exceed your specifications. 

We also provide support in the 

commissioning and certification of 

products from relevant authorities. 

Our products are easy for you to 

specify, or we can assist you. We 

take care to ensure our advanced 

specification and design services will 

add value to our client’s offering and 

optimise the project outcome. 

The knowledge and experience of four 

generations is at your disposal when 

working with Automatic Heating. 

Automatic Heating maintains an 

extensive range of stock products 

including a vast range of spare parts 

to support and meet your project 

requirements. 

With nearly 3,000m2 of warehousing 

we carry an extensive inventory 

– from the smallest fittings to the 

largest boilers. 

Our head office is located within 

the Northpoint Enterprise Park in 

Melbourne’s northern suburbs. 

We are closely positioned to major 

arterial roads and are only 20 

minutes from the Melbourne CBD. 

Automatic Heating maintains an 

extensive range of stock products 

including a vast range of spare 

parts to support and meet your 

project requirements. 

Regularly searching the globe for 

the newest and most innovative 

products, we can assist in the design 

of integrated systems for your next 

project, saving you time and effort by 

providing the best equipment for the 

job from a single reliable source. 

• CO2 High Temperature Heat Pumps 

• Condensing and Conventional 

Boilers 

• Gas, Oil And Dual Fuel Burners 

• Flue Systems 

• Biomass Boilers 

• Expansion Tanks & Deaeration 

Systems 

• Dirt and Air Separation 

• Backflow Prevention 

• Thermal Storage 

• HVAC Pumps 

• HVAC Accessories 

Warranty Commitment 

All our products come with a 

minimum 12-month warranty 

commitment*, with full access to the 

Service Department who can manage 

the ongoing wellbeing of the system. 

* Warranties of up to 10 years apply to some products - 

conditions apply 

5

Sales & Technical Support 

Contents 

Sales & Technical 

Support 

Our products may be easy to specify but 

we understand the limited resources, 

tight deadlines, and cost pressures our 

customers face on a daily basis. 

Hence, our experienced sales and technical support 

staff are available to provide technical advice as well as 

advanced specification and design services to help you 

make the right choice every time. 

Then we’ll be as hands-on as required through 

installation and commissioning to ensure your 

investment operates efficiently from day one. 

The desired result is project outcomes that maximise 

ease of installation, operational performance and energy 

efficiency for the benefit of the environment, the project, 

the client and the HVAC industry. 

We believe in creating genuine relationships with clients, 

which we maintain through consistently adding value 

in the form of expert advice, technical support, quality 

products, innovation and flexibility. 

Automatic Heating are here & always willing 

to offer solutions to solve any project demand. 

Speak to us today about your next project. 

Our technical team can offer specialist advice, 

making your life a lot easier. 

6

Contents 

Sales & Technical Support 

Complimentary Services 

We offer the following complimentary services to any 

professional involved in designing or building sustainable, 

comfortable indoor environments for the Australian 

community. 

• Quotations for project budgeting 

• Payback calculations 

• Technical advice 

• System design advice 

• Product selections 

• Product specifications 

• Energy efficiency modelling 

• System schematic drawings 

• DWG/Revit drawings 

• On-site assessments, recommendations and troubleshooting 

• In-house technical training presentations 

• Product display and showrooms 

• Technical information webinars 

CAD Drawings 

To ensure clients obtain maximum value from this service, it is 

important to provide as much detail as possible, including: 

• Existing plantroom conditions including room size and 

placement of existing equipment and services 

• The new equipment that is required to be accommodated in 

the plantroom 

• Any access considerations or contingencies applicable to the 

plantroom or building 

Our Technical Manager is available to assist you with any 

queries and can arrange a site visit if necessary. 

48-Hour ‘SpecTech’ Service 

From the moment we receive your enquiry we work hard to 

ensure you get a response containing specification details, 

technical information, and budget costs, all within 2 working 

days. 

Face-to-Face Visits 

The friendly team members at Automatic Heating are happy 

to visit you at your office or on-site to work collaboratively 

in finding the most appropriate solution for your needs and 

budget. 

Training & Product Demonstrations 

Our DWG drawings and revolutionary Revit drawings offer 

you greater insight into your chosen products and how they 

interact with one another in a HVAC system. Our expert team 

can assess the system schematic with you and offer helpful 

advice to ensure the success of your project. 

Mechanical Plantroom Design and Layout 

Automatic Heating Technical Staff are available to 

provide training and product demonstrations to our 

clients and consultants at their premises or at a 

convenient conference venue. We also cater for morning 

tea or lunchtime technical presentations. 

Contact Automatic Heating on 03 9330 3300 for further 

information or to arrange a visit from one of our 

Technical Sales Specialists. 

Planning is crucial to any project and when space or access 

is limited, it becomes even more important. Automatic 

Heating have the capacity to provide technical drawings and 

3D renders to assist in visualisation and space optimisation 

of your plantroom design. 

7

Service & Maintenance 

Contents 


Take our word for it .... 

Prevention is better than Cure 

The old adage “a stitch in time, saves nine” is an 

understatement in the context of boiler maintenance. 

With boilers often in constant service and fulfilling critical 

heating functions within buildings ranging from domestic 

residences to major airports, it makes sense to keep them 

running at peak performance. Unfortunately, all too often, 

boiler maintenance remains unscheduled and overlooked 

until boiler failure becomes a reality and a lack of heating 

starts impacting on people and critical functions throughout 

the household or organisation. 

Annual Service 

Every boiler, cooler and pump requires maintenance to 

ensure reliable and efficient operation. An un serviced 

system can quickly become a costly asset, experiencing 

premature failures that can damage both the system and 

potentially the surrounding areas. Regular preventative 

maintenance will ensure optimum performance is being 

achieved and running costs are being kept to a minimum. 

Our nationwide service network offers fixed price, 

tailored service contracts to allow you to budget for the 

maintenance of your plant with confidence, while our 

extensive range of spare parts can be relied upon at any 

time - even long after your purchase. Tailored service 

contracts mean that you only pay for the level of servicing 

you require and the fixed price enables you to budget for the 

cost of the plant over the coming years. 

Key reasons for having your boiler serviced annually 

1. Regulatory Compliance – Government regulations set 

out minimum service requirements for all commercial 

buildings in order to meet health and safety standards. 

These regulations also stipulate how long service 

records should be kept. Annual servicing of your 

heating plant and maintenance of accurate service 

records provides a level of insurance not only against 

heating failure but against costly litigation resulting 

from an appliance rendered dangerous through 

neglect. 

2. Keeping your building safe – Having your boiler 

serviced helps to highlight any potential dangers and 

risks associated with your boiler and flue. When your 

boiler stops working efficiently, it’s possible for toxic 

carbon monoxide gases to be released. These gases 

are extremely dangerous and pose serious risks to 

anyone exposed to them, yet are ordinarily hard to 

detect. 

3. Identify Problems Early – During a service, potential 

problems are identified early and can help to minimise 

further damage to the boiler and save costly future 

repairs. 

4. Reduce your Fuel Bills – During an annual boiler 

service, your boiler parts are cleaned and the boiler 

efficiency is checked. A properly maintained boiler 

running at optimum efficiency ensures ongoing energy 

savings are maintained. 

8

Contents 


5. Keeping your Warranty Valid – Many boiler warranties 

are valid subject to having an annual service carried 

out. For many boiler manufacturers, failing to service 

your boiler using an appropriately certified heating 

engineer can invalidate your warranty altogether, 

leaving you liable for costly repair bills. 

6. Cheaper than Replacing a Boiler – If your boiler is 

left faulty for long periods of time, much larger and 

more complicated issues can arise, perhaps even 

resulting in your boiler needing replacing. Recognising 

any problems early on can reduce the amount of 

permanent damage caused to your boiler and keep it 

running for longer. 

Commissioning 

Once a system is engineered and installed, essential 

checks should be made to ensure maximum safety from 

the very start. The Automatic Heating commissioning 

service involves checking that your systems have been 

installed correctly as specified and includes various 

testing procedures to ensure satisfactory performance and 

compliance with appropriate regulations. 

The commissioning process is the most important part 

of any installation before it is set into full operation. In 

addition, the Automatic Heating team can also program your 

system, set it up and, where required, train your operator. 

On Site Inspection and Audit 

Where needed, we can organise one of our experts to 

perform an on site inspection and audit. This will provide 

you with a report on our findings and a recommendation on 

which step to make next, whether it be maintenance, repair 

or replacement of your equipment. 

Repairs 

Qualified Technicians 

It is important that whoever services your boiler is suitably 

qualified, experienced and equipped with the parts needed 

to complete the service. This minimises costs and downtime 

and ensures warranties remain valid. Automatic Heating 

technicians are fully trained and qualified to service our 

equipment and their fully stocked vans carry the parts 

needed to complete each job. 

Their professional competence and high level of practical 

and diagnostic experience means you can be assured your 

products are always running at optimum performance 

when maintained by the Automatic Heating Service Team. 

Support anytime, anywhere 

Our service technicians are available for emergency callouts 

and frequently provide support to clients in remote 

areas. 

From our Melbourne Head Office, our Operation and 

Maintenance Department uses state of the art technology to 

remotely monitor our O&M sites - as well as offering email, 

SMS and mobile notification to ensure online operation for 

your total peace of mind. 

The Automatic Heating Service team is available to repair 

your system even outside of the warranty period. 

Our highly responsive technicians are trained in all areas 

and applications of the most technical of systems with the 

ability to quickly diagnose and fix problems on site, in most 

situations. We understand every minute of downtime is a 

cost to a business which is why we do everything possible 

to provide a solution, even if it is an interim measure to get 

your system back up and running as quickly as possible. 

Parts & Consumables 

We maintain an extensive range of genuine spare parts for 

all commercial boilers, cooling systems, water heaters and 

pressurisation units, to ensure our technicians can respond 

quickly to our client’s servicing needs. 

Your spare parts from Automatic Heating have quality 

assurance conformity and carry a 12 month warranty. Using 

genuine parts means you benefit from any technological 

improvements that may have been made as part of our 

policy of continuous product improvement. We are always 

looking to make our commercial heating, cooling and hot 

water products even more efficient. 

9

HEAT PUMPS 

Heat Pumps 

Contents 

10

Contents 

Air to Water 

Heat Pumps 

Air to Water Heat Pumps 

HEAT PUMPS 

Air to Water Heat Pumps offer unrivaled efficiencies of up to 350%. 

Air to Water Heat Pumps can provide efficient heating and cooling for your home or 

commercial building, especially if you live in a warm to moderate climate. An air to water 

heat pump can deliver from 1.5 to 3 times more thermal energy to a building than the 

electricity it uses. This can happen due to the fact that the heat pump transfers heat, rather 

than transforming it from a type of fuel like regular combustion heating systems do. 

CO 2 

Heat Pumps 

R32 Heat Pumps 

Revere CO 2 

15-66.4kW pg 12 

Revere R32 Inverter pg 22 

R410A Heat Pumps 

Revere R410A Inverter pg 23 Revere R410A pg 26 

Galleti MPI DC 8-29kW pg 30 

Galleti MPE 4-76kW pg 34 Galleti HiRef HPS 43-216kW pg 42 Galleti EvitecH 50-180kW pg 46 

Galleti SCX 80-360kW pg 52 

11

HEAT PUMPS 

Revere CO 2 - Air to Water Heat Pumps 

Revere CO 2 


A Sustainable Technology 

Regardless of political agendas or incentives, consumers worldwide are 

increasingly pursuing sustainable, cost effective alternatives to traditional fossil 

fuelled equipment for their hot water and space heating requirements. Using 

natural CO 2 

as the refrigerant and achieving a high coefficient of performance 

(COP), CO₂ heat pumps offer both ecological and financial benefits. 

Contents 

The unique capacity of the Revere CO 2 

Heat Pump to 

produce 90°C hot water makes it suitable for use in a wide 

range of industrial, commercial and residential projects, 

including food processing plants, dairies, shopping centres, 

apartments, hotels, restaurants, hospitals, aged care, 

recreational and educational facilities. Revere can also 

be adopted with a high level of safety as the absence of 

combustion reduces the risk of fire. 

Instead of the more conventional ammonia or haloalkane 

(R134A) refrigerant gases, Revere CO 2 

Heat Pumps use 

supercritical carbon dioxide as the refrigerant. 

The technology offers a means of energy conservation and 

reduces the emission of greenhouse gas. 

From the energy output side, the operational characteristics 

of the heat pump are different to conventional systems 

(such as electric/gas/oil boilers or electric heaters). With 

conventional systems, 1kW input of energy provides less 

than 1 kW of output energy or heat. With a CO 2 

heat pump 

system, every 1kW of input energy consumed produces 

an average of 3.9 x the input as output energy or heat by 

extracting heat from the outside air. 

Summary 

Producing 90°C hot water with an average COP of 3.9, 

makes Revere CO₂ Heat Pumps an ideal energy efficient 

domestic hot water and space heating system for industrial, 

commercial and residential applications. This ability to 

convert 1kW of input energy into 3.9kW of output energy 

represents an ongoing economical and sustainable water 

heating solution. 

About Itomic Nihon 

Itomic Nihon has been a leading manufacturer of hot 

water heaters in Japan since 1948. With over 2500 Itomic 

Revere CO 2 

Heat Pumps installed globally, this product 

continues to demonstrate its worth as a proven and reliable 

non-fossil fuel water heating system. 

12

Contents 

Revere CO 2 

- Air to Water Heat Pumps 

Revere CO 2 Heat Pump Features & Advantages 

HEAT PUMPS 

Heats up to 90°C - Due to its innovative design, the 

Revere CO 2 

Heat Pump can produce hot water up to 90°C 

at low and high ambient temperatures (-20°C to 43°C) 

Flexible - The same system can be simultaneously used for 

Space Heating & Domestic Hot Water 

Ultra quiet operation – 60dBa 

No combustion - reduces fire risk 

Suitable for up to 60°C ΔT (flow 90°C, return 30°C) 

Suits Australian conditions – accommodates ambient 

operating temperatures from -5°C to 43°C (Special unit 

available for -15°C or -20°C) 

Safe - Non-flammable CO₂ refrigerant 

Programmable – can be set to operate during off peak 

times to benefit from low cost power 

30% Space Saving due to Y Frame design (CHP-80) 

Versatile - Suitable for a wide range of purposes, from 

small facilities to large buildings where hot water or 

heating is required. 

Eco friendly - The Revere CO 2 

Heat Pump uses natural 

CO₂ refrigerant. This refrigerant has a global warming 

potential (GWP) of about 1/1700 that of R410 and zero 

ozone-depleting potential (ODP). 

Energy efficient - Under optimal conditions, Revere 

CO 2 

Heat Pumps achieve an exceptional coefficient of 

performance (up to 4.2) which equates to higher energy 

efficiency. Compared to the traditional electric hot water 

heater, the CO 2 

hot water heat pump can save up to 75% 

heating energy. Further energy cost savings can be 

achieved through operation during off peak hours, subject 

to off-peak electrical power supply. 

Anti-freeze/Cold Area Units - the heat pump is fitted with a 

defrost solenoid valve which will open when the evaporator 

ices up. The hot gas will then flow through the evaporator 

and melts the ice. Water cannot be stored during defrosting. 

One pass heating - It is suitable for heating water from low 

to high temperatures (large temperature difference) in one 

pass. 

Reduces storage requirements - Since this hot water heat 

pump can heat water up to 90ºC, the size of the storage tank 

can be reduced. 

Volume of hot 

water used (L) 

Calculated necessary 

volume of hot water (L) 

Monday 

Necessary hot water volume and operating 

time calculated from 4 weeks of operation data 

Tuesday Wednesday Thursday Friday Saturday Sunday 

Week 1 

Week 2 

Week 3 

Week 4 

Energy Saving Function - This function is an energy-saving 

function that learns operation patterns from the four previous 

weeks to prevent unnecessary heating and temperature 

decreases in stored water through natural heat loss. The use 

of this function based on operation data stops the unit from 

boiling water unnecessarily. 

Running Cost Comparison 

Cents / kwH 

7 

28 29.6 

APPROX 

1/4 

RUNNING COST 

Revere CO 2 

Heat Pump 

Electric Water 

Heater 

LPG 

Fueled Boiler 

Revere offers Significantly lower running costs & CO₂ emissions 

13

HEAT PUMPS 

Revere CO 2 


How It Works 

The Revere CO 2 

Hot water heat pump is an energy efficient electric heat pump that uses heat extracted 

from the air to heat water for industrial, commercial and residential applications. A hot water heat pump 

removes energy from a low temperature source (ambient air or waste water) and moves it to a high 

temperature hot water tank. 

Contents 

Heat 

pump 

unit 

Compressor 

Hot 

90°C 

Hot water 

supply 

Air 

Heat 

exchanger 

(for air) 

CO 2 

refrigerant 

cycle 

Heat exchanger 

(for water 

heating) 

Water is 

heated 

Sealed 

storage tank 

Hot water supply 

Heating 

Refrigerant flow 

Fan 

Cold 

Expansion valve 

Water pump 

Cold water 

supply 

Advantages of using CO 2 

as a refrigerant 

This heat pump uses CO₂ as a refrigerant. CO₂ is a natural refrigerant and has an ozone depletion 

potential (ODP) of zero and a global warming potential (GWP) of 1. CO 2 

refrigerant is a non HFC 

refrigerant. Traditional HFC refrigeration systems affect climate change in two distinct ways: direct and 

indirect contribution. Direct contribution results from the release of refrigerants into the atmosphere. 

Indirect contribution refers to the energy used to operate traditional refrigeration equipment. The less 

energy required to operate the equipment, the lower the impact on the environment. 

Refrigerant Characteristics 

HFC 

Natural Refrigerant 

Refrigerant 

R410A R407C R744(CO 2 

) 

Ozone depletion potential 0 0 0 

Global warming potential 1975 1653 1 

Combustible No No No 

Toxicity Low Low Low 

14

Contents 

Revere CO 2 


HEAT PUMPS 

CHP-15HF 

CHP-26H4 

CHP-080Y2 

General Performance Data of a Standard Unit 

Product Code 

Power supply 

Total power input@ 25ºC 

ambient(kW) 

Heating output @ 25ºC 

ambient (kW) 

Average COP* 

Dimension 

L x W x H(mm) 

CHP-15F 3 phase 415V/50Hz 4.16 15 4.0 900 x 450 x 1850 

CHP-26H4 3 phase 415V/50Hz 6.7 29.3 3.9 1300 x 890 x 1705 

CHP-080Y2 3 phase 415V/50Hz 18.8 78.4 3.8 1790 x 1010 x 2000 

* Average COP based on constant hot water supply at 65ºC and ambient temperature range of -7ºC to 43ºC. 

CO2 heat pump system for 

DHW and space heating on 

skid frame. 

15

HEAT PUMPS 

Revere CO 2 


Designed for Space and Energy Efficiency 

With a heating performance of 80 kW, the 

CHP-080Y2 was developed to reduce high 

hot water supply costs and large space 

requirements that inevitably occur in facilities 

requiring a large hot water supply. 

The structure of the Y-shaped frame reduces 

power consumption and allows units to 

be installed close together. The heating 

performance can be switched between three 

modes in order to adjust the energy to suit 

how you use hot water, and performance does 

not decrease* in temperatures down to -15°C. 

This flexible system is suitable for a wide 

range of facilities that use large volumes of 

hot water, and is durable enough to provide a 

steady hot water supply for a long time. 

* Energy-saving mode only 

Contents 

Product Quick Check 

Type 

CO₂ Heat Pump 

Range 

12-80kW 

Efficiency Average COP 3.9 

Fuel Type Electricity 

Outdoor option Yes 

Cascadeable 

Max Pressure 

Zero Nox 

Building J Code 

2018 compliant 

Yes 

490 kPa 

Yes 

Yes 

16

Contents 

Performance Data 

Revere CO 2 


HEAT PUMPS 

Product Code 

Constant Supply Hot Water at 65°C 

Heating Ability 

kW 

A / B / C* 

Storage Capacity 

L/h 

A / B / C* 

Supply Water → Hot Water 

°C 

A / B / C* 

Power Consumption 

Kw 

A / B / C* 

Average COP 

CHP-15F 15 / 15 / 15 230 / 269 / 315 9→65 / 17→65 / 24→65 3.6 / 3.4 / 3.13 4.2 

CHP-26H4 24.0 / 26.3 / 29.3 369 / 471 / 615 9→65 / 17→65 / 24→65 6.20 / 6.55 / 6.70 3.9 

CHP-080Y2 61.1 / 65.6 / 66.4 938 / 1175 / 1392 9→65 / 17→65 / 24→65 16.1 / 16.1 / 14.9 3.6 

Product Code 

Constant Supply Hot Water at 90°C 

Heating Ability 

kW 

A / B / C* 

Storage Capacity 

L/h 

A / B / C* 

Supply Water → Hot Water 

°C 

A / B / C* 

Power Consumption 

Kw 

A / B / C* 

Average COP 

CHP-15F 15 / 15 / 15 159 / 177 / 177 9→90 / 17→90 / 24→90 4.68 / 4.48 / 4.16 4.2 

CHP-26H4 24.5 / 25.5 / 27.0 260 / 300 / 352 9→90 / 17→90 / 24→90 7.40 / 7.50 / 7.80 3.9 

CHP-080Y2 58.9 / 63.9 / 62.7 625 / 752 / 817 9→90 / 17→90 / 24→90 18.3 / 19.3 / 17.8 3.6 

* Ambient Temperatures - A: DB7°C / WB6°C (Winter) - B: DB16°C / WB12°C (Intermediate) - C: DB25°C / WB21°C (Summer) 

Specifications 

Product Code CHP-15F CHP-26H4 CHP-080Y2 

Power Supply 

Design pressure at refrigerant 

side 

MPa 

Low pressure side 8 / High pressure 

side 13.2 

3 phase 415V 50Hz 

Low pressure side 7.5 / High pressure side 14 

Compressor Type Horizontal scroll compressor Semi-hermetic reciprocating compressor 

Compressor Motor Type 

Three-phase induction motor 

Inverter drive three-phase induction 

motor 

Compressor Rated Output kW 1.9kW x 2 8.4 15.8 

Crankcase Heater W N/A 100 140 

Fan W Propeller fan (47Wx2) Propeller fan (110Wx2) Propeller fan (300Wx2) 

Pump W 30 Seal-less, AC200V - 100W Seal-less, DC282V - 140W 

Air heat exchanger 

Protection Devices 

Supply hot water heat exchanger 

High pressure switch 

High·low pressure sensor 

Fuse (fan & pump) 

Forced cooling cross fin 

Compressor motor excessive temperature protection 

Compressor rupture disk 

Over current relay (compressor) 

Forced circulation double-piping type 

High pressure switch 

High·low pressure sensor 

Compressor over heat 

cut out device 

Compressor pressure 

relief valve 

Over current relay (fan) 

Over current protection 

Refrigerant / filling volume kg CO 2 

(R744)/ 2 x 1.18 CO 2 

(R744)/ 6.8 CO 2 

(R744)/ 11.3 

Dimensional Data 

Product Code 

Dimensions 

H x W x D 

Product mass/Operating weight 

kg 

CHP-15F 1850 x 900 x 450 174 / 177 

CHP-26H4 1705 x 1300 x 890 480 / 500 

CHP-080Y2 2000 x 1790 x 1010 690 / 710 

17

HEAT PUMPS 

Revere CO 2 


CHP-15F Dimensional Data and Installation Guide 

Contents 

Dimensions 

Operation output, Error output, External input terminal board 

Terminal - Remote controller, HP communication×2 

Supply hot water stop valve terminal board 

Power source terminal board 

Air discharge outlet 

Grounding terminal 

(Inside the electric device BOX) 

Air suction inlet 

91 for rear leg 

Heat pump outlet piping (B side) connection (R3/4) 

Heat pump intlet piping (A side) connection (R3/4) 

91 for rear leg 

Grounding 

Drain piping connection for venting air (R1/2) 

terminal 

(Make sure the connection for the possible successive drainage) 

Anchor bolt position, Piping connection (Top view) 

Product mass 

Operating 

weight 

Drain hole ( 

35 hole) 

Remote control cord & others lead-in position 

Connection for heat pump outlet piping (B side) 

Connection for heat pump inlet piping (A side) 

Power cable lead-in position 

Connection for air vent drain piping 

Use four M12 anchor bolts with the 

buried length of more than 60mm 

Drain hole ( 

20 hole) 

Anchor bolt notch hole 

(M21 for bolt×4 spots) 

Installation Guidelines 

FRONT VIEW SHOWING FRONT VIEW TOP SPACE SHOWING TOP SPACE 

REQUIRED FOR REQUIRED MAINTENANCE FOR MAINTENANCE 

PLAN VIEW SHOWING PLAN VIEW SHOWING • This unit is not for indoor 

CLEARANCE SPACES CLEARANCE REQUIRED SPACES REQUIRED installation. Outdoor 

installation only. 

• Consult your sales store 

when obstacles are at three 

directions, and for a built-in 

installation. 

• Do not set this unit in a closed 

depression with all sides 

deeper than 1.0M 

ARROW DENOTES AIR ARROW INPUT DENOTES AIR INPUT 

AND OUTPUT DIRECTION AND OUTPUT DIRECTION 

18

Contents 

Revere CO 2 


CHP-26H4 Dimensional Data and Installation Guide 

HEAT PUMPS 

Dimensions 

100 

25 

A Anchor bolt fitting holes (4 Ø15 holes) 

B O peration check window (front) 

C External signal connection port (sensor, etc.,Ø 24 holes) 

D Power source port ( Ø39 hole) 

E C ontrol board position (front) 

F Hot water outlet Rc3/4 (20 A, C AC 406) 

G Supply water inlet Rc3/4 (20 A, C AC 406) 

H Air heat exchanger room drain Rc1 (25 A, C 3604BD) 

I Drain outlet Rc3/4 (20 A, C AC 406) 

143 

72 

Cover 

Internal operating section 

(shown with cover open) 

Remote control cord slot 

10 13 

(83.5) (29.8) 

(attachment pitch) 

(29.7) 

Remote control cord terminal strip 

2-M3 (included) 

Top view 

Dedicated Remote Control 

815 

80 

1300 

Air outlet 

Air outlet 

Air inlet 

Air inlet 

B 

F 

12 

1705 

1525 

C 

G 

H 

165 

350 

75 

75 

170 

70 

130 

860 

100 

195 

A 

900 

195 

I 

145 

890 

5 

1290 5 

E 

D 

155 900 

195 

5 

Left view 

Front view 

Back view 


TOP VIEW OF HEAT PUMP UNIT 

700 mm or more 

FRONT VIEW OF HEAT PUMP UNIT 

3 m or more 

• Install the heat pump unit outdoors, with 

adequate ventilation 

• Install in a location where cold air from the 

air outlets of the heat pump unit or operating 

sounds will not disturb neighbours, or take 

soundproofing measures. 

• The diagram shows the space required for 

maintenance and inspections. It may not 

be possible to perform maintenance or 

inspections without the necessary space. 

Make sure to leave sufficient space when 

designing the layout. 

Front of heat 

pump unit 


Pipe Slot 

19

HEAT PUMPS 

Revere CO 2 


Contents 

CHP-080Y2 Dimensional Data and Installation Guide 

Dimensions 

100 

25 

143 

72 

Internal operating section 

(shown with cover open) 

(83.5) (29.8) 

(attachment pitch) 

Cover 

(29.7) 

Remote control cord terminal strip 

2-M3 (included) 

Front 

Remote control cord slot 

Dedicated Remote Control 

10 13 

Air Outlet 

Air Outlet 

Air Suction Inlet 

Air Suction Inlet 

Air heat exchange 

room drain 

Rc1(25A) 

CAC406 

Operation Check Window 

(Front) 

Control Panel 

(Front) 

External Signal Connection 

(Ø Sensor 22 Holes, 

Ø Grommet 17 Holes) 

Remote Control Line Connection 

(Ø 22 Holes, Ø Grommet 17 Holes) 

Hot 

Water Inlet 

Rc1(25A) 

CAC406 

Cold 

Water Inlet 

Rc1(25A) 

CAC406 

Anchor bolt Mounting Hole 

(6 x Ø 15 Holes) 

Cable Connection 


Power Connection 


Remote Control Line Connection 


Cable Connection 


Power Connection 

(Ø 44 Holes Grommet, Ø 36 Holes) 

Drain Outlet 

Rc3/4(20A) 

CAC406 

Maintenance Window 

Distant Control Panel Connection 


Distant Control Panel Connection 


Bottom: External Signal Connection 

(Sensor Ø 22 Holes, Ø Grommet 17 Holes) 

Cross Section A-A 

Installation 

Guidelines 

3 m or 

more 


500 mm 

or more 




• Install the heat pump unit outdoors, with adequate ventilation 

• Install in a location where cold air from the air outlets of the heat pump unit or operating sounds will not 

disturb neighbours, or take soundproofing measures. 

• The diagram shows the space required for maintenance and inspections. It may not be possible to perform 

maintenance or inspections without the necessary space. Make sure to leave sufficient space when designing 

the layout. 


20

Contents 

Case Studies 

Revere CO 2 


HEAT PUMPS 

Yarra’s Edge Tower 1 

1 x Revere CO 2 

Heat Pump 

At Yarra’s Edge Tower 1, one of 

Melbourne’s finest waterside highrise 

apartments, Automatic Heating 

installed a new and improved 

hybrid system that features a high 

efficiency heat pump, high efficiency 

condensing boilers and twin coil 

storage tanks. Two atmospheric 

500kW boilers used for domestic 

hot water were replaced with an 

Revere 15kW High Temperature 

CO2 Heat Pump, five Meridian 150kW 

condensing boilers and Plate Heat 

Exchangers. This hybrid solution 

ensures that the new system will 

run as efficiently, sustainably, and 

economically as possible. 

Williamstown 

Industrial Application 

2 x 15kW Revere CO 2 

Air to Water heat pumps 

2 x 400L Twin Coil Watermark 

Stainless Steel Tanks 

Prefab skid frame with above 

equipment provides 90°C hot water 

for industrial process applications. 

Monash University 

Clayton Campus 

James Gormley Bike 

Arrival Station 

1 x 15kW Revere CO 2 

Air to Water heat pump 

2 x 750L Twin Coil Watermark 

Stainless Steel Tanks 

Prefab skid frame with above 

equipment provides DHW for 

28 showers and hot water for 

hydronic heating 

21

HEAT PUMPS 

Revere R32 Inverter - Air to Water Heat Pumps 

Revere 

R32 Inverter 

Air to Water Heat Pump 

With the advanced new technology of 

an EVI DC Inverter, the Revere R32 

Inverter Air to Water Heat Pump can 

be used in extremely cold area for 

heating/cooling, hot water. 

Contents 

1315 

mm 

395 

mm 

1000 mm 

Condition Unit Heating Cooling 

Ambient Temp. (DB/WB) ºC 7/6 7/6 2/1 2/1 -7/-8 -7/-8 35/24 

Water Temp. (In/Out) ºC 30/35 50/55 30/35 50/55 30/35 50/55 12/7 

Capacity Range kW 6.0~20.0 5.5~18.0 5.5~17.0 5.5~15.0 4.6~14.5 4.5~14.0 4.2~14.0 

Power Input Range kW 1.5~5.0 2.0~7.5 1.5~5.0 2.2~7.4 1.5~5.0 2.2~7.3 1.8~7.5 

EVI DC Inverter Technology 

With advanced new technology of EVI DC Inverter, the 

unit is capable of producing 60ºC domestic hot water. 

And according to laboratory testing (basing on ErP test 

standard), the energy level can reach A++. 

Smart Colorful Touch Display 

R32 wire controller is with a 5-inch smart colorful touch 

display which is installed on the wall. Featuring 0.5ºC 

precise control, water temperature curve display, easy 

timing, one-key mute and more, it provides an easy and 

convenient user experience. 

Intelligent Defrosting 

Intelligent defrosting uses the pressure sliding defrosting 

technology to figure out the exact defrosting time and start 

pressure according to the real ambient temperature. It saves 

energy and makes the heat pump work in high efficiency. 

Model - AHG R32 AW Unit Value 

Frequency Hz 30~90 

ErP Level (35°C & 55ºC) 

A++ 

Power Supply 

380~415V, 3N, 50/60Hz 

Electric Heater kW / 

Max. Running Current A 13.5 

Refrigerant Type 

R32 

Refrigerant Quantity kg 1.8 

Compressor Brand 

Panasonic 

Water Pump 

Grundfos 

Water Connection inch 1.2 

Water Flow m 3 /h 2.15 

Water Pressure Drop kPa 45 

Water Pump Head m 4 

DC Motor Quantity 2 

DC Motor Power Input (max/min) W 130/45 

DC Motor Speed (max/min) RPM 850/300 

Noise* dB(A) 55 

Net Weight kg 155 

Gross Weight kg 175 

Net Dimension (L x W x H) mm 1000 x 395 x 1315 

Shipping Dimension (L x W x H) mm 1070 x 415 x 1330 

Operation Ambient Temp. ºC -25~43 

Max. Outlet Water Temp. ºC 60 

* Noise test is based on JB/T4330-1999 at 1 meter distance. 

22

Contents 

Revere R410A Inverter 


Revere R410A Inverter - Air to Water Heat Pumps 

HEAT PUMPS 

Works efficiently with floor heating, water 

fan coils or radiators for heating, cooling and 

sanitary hot water. 

Features 

Smart Colorful Touch Display 

5” smart colorful touch display which is installed on the wall. 

Applicable to RS485 communication, it is easy & convenient to 

operate. 

MITSUBISHI Compressor 

This range features Mitsubishi compressors for reliable operation 

and optimum performance. 

Riffled Copper 

Tube 

Gas Refrigerant 

Shell 

Cooling Water 

Liquid Refrigerant 

5.0MPa 

Pressure Test 

No welding point inside 

the water coil, 

no refrigerant leakage. 

Louvred Fins 

Spiral copper coil enlarges the water heat exchanging area 

so that the water can sufficiently exchange heat with gas. 

Finned Heat Exchanger 

The finned heat exchanger uses riffled copper tube which greatly 

improves the heating efficiency. Louvered fins with greater airflow 

distribution effectively improve the heat exchanging efficiency. 

Tube-in-shell Heat Exchanger 

The small gap between the refrigerant circuit & shell makes the 

lubricant flow smoothly and prevents lubricant retention. Water 

and refrigerant circuit is of counter current design, ensuring the 

refrigerant outlet subcooling. 

23

HEAT PUMPS 


Advanced Heat Pump Technology 

Contents 

Temperature 

20º 

Little temperature fluctuation 

The compressor adjusts the frequency 

according to the water temperature. 

13bar 

Defrosting 

Pressure 

Traditional 

Pressure Sliding 

AHGR410AW 

Series 

Heating 

Fast start-up 

o 

C 

Ambient Temperature 

0.5ºC Precise Control 

The units can change the operating frequency of the 

compressors automatically according to the heating or 

cooling demand. When the target temperature is reached, the 

units run at a lower frequency, and the temperature control 

accuracy can be as precise as 0.5ºC. 

Energy Saving up to 30% 

With the use of inverter compressors, brushless DC fan 

motors and PFC control method, the units can regulate 

the running capacity. With no frequent start-ups and stop 

runnings, the units work in stable condition with high 

efficiency. The energy consumption is 30% less than that of 

common fixed speed heat pump units. 

Intelligent Defrosting 

Traditional Defrosting Method 

Traditional defrosting method is with fixed defrosting time and 

start temperature. Once the ambient temperature reaches or 

is lower than -7ºC, the unit will start defrosting. This can lead 

to energy wastage when defrosting is not needed and reduced 

heating performance. 

Intelligent Defrosting Method 

The AHGR410AW series intelligent defrosting uses the 

pressure sliding defrosting technology to figure out the exact 

defrosting time and start pressure according to the real 

ambient temperature. It saves energy and makes the heat 

pump work in high efficiency. 

Temperature 

Too hot 

Fast 

heating 

Set temperature 

Too cold 

Start up 

Common fixed speed heat pumps 

AHG inverter heat pumps 

Speed up Heating/Cooling Time 

When there is a large difference between the actual temperature 

and the programmed temperature, the unit can run at a higher 

frequency to make fast heating or cooling to increase or decrease 

the temperature rapidly. 

No Frosting in the Bottom of 

Air Exchanger 

With the use of the special liquid distribution technology, in heating 

mode, the temperature of refrigerant in the air exchanger’s bottom 

copper tube will not decrease in order to ensure smooth drainage 

with no ice. 

24

Contents 

Application 

Sanitary Hot 

Water 


Radiator 

HEAT PUMPS 

Fan Coil 

AHG Heat Pump 

Floor 

Heating 

Technical Data 

Model AHGR410AW6 AHGR410AW10 AHGR410AW17 AHGR410AW25 

Heating Capacity Range kW 1.9~6.4 2.5~10.8 5.0~17.3 7.0~25.1 

BTU/h 6460~21760 8500~36720 17000~58820 23800~85340 

Heating Power Input Range kW 0.6~2.0 0.8~2.77 1.2~4.55 2.5~6.54 

Cooling Capacity Range kW 1.6~5.4 2.0~10.0 5.0~14.5 7.0~20.0 

BTU/h 5440~18360 6800~34000 17000~49300 23800~68000 

Cooling Power Input Range kW 0.6~1.9 1.0~3.4 1.6~5.6 2.5~9.0 

Frequency Hz 30~90 30~90 30~90 30~90 

ErP Level (35ºC) - A++ A++ A++ 

ErP Level (55ºC) - A+ A++ A++ 

Power Supply 220-240V~ /50Hz 380-415V/3N~/50Hz/60Hz 

Electric Heater kW - 3.0 - - 

Max. Running Current A 8.7 18.0+13.7 27.0 14.0 

Refrigerant Type R410A R410A R410A R410A 

Refrigerant Quantity kg 1.7 2.4 3.2 4.4 

Compressor Brand Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric 

Water Pump Brand WILO GRUNDFOS GRUNDFOS GRUNDFOS 

Water Connection 1” 1” 1 1/4” 1 1/4” 

Water Flow m3/h 1.0 1.6 2.8 4.2 

Water Pressure Drop kPa 10 22 52 45 

Water Pump Head m 5.2 10 17 18 

DC Fan Motor Quantity 1 1 2 2 

DC Motor Power Input (max) W 136 136 272 340 

DC Motor Power Input (min) W 18 18 36 50 

DC Fan Speed (max) rpm 850 850 850 900 

DC Fan Speed (min) rpm 300 300 300 300 

Pressure Sensor 1 Bar 0~20 0~20 0~20 0~20 

Pressure Sensor 2 Bar 0~45 0~45 0~45 0~45 

Noise dB(A) 54 54 58 62 

Net Weight kg 98 110 163 219 

Gross Weight kg 115 123 180 243 

Net Dimension(L/W/H) mm 1052/490/790 980/465/910 990/437/1315 1175/450/1588 

Shipping Dimension (L/W/H) mm 1070/510/945 1050/500/1060 1080/445/1480 1290/530/1760 

Operation Ambient Temp. ºC -15~43 -20~52 -20~52 -20~52 

Heating: Ambient Temp. (DB/WB): 7ºC/6ºC; Water Temp. (In/Out): 30ºC/35ºC. Cooling: Ambient Temp. (DB/WB): 35ºC/24ºC; Water Temp. (In/Out): 12ºC/7ºC. 

Subject to change without notice. 

25

HEAT PUMPS 

Revere R410A - Air to Water Heat Pumps 

Revere R410A 


Hot Water Solutions for Sanitary Hot Water and House Heating 

Contents 

R410A + EVI 

• Ambient Temp. Range - 30ºC to 45ºC 

• Higher Reliability 

• Increased Heating Capacity 

• Up to 65ºC Outlet Water 

• Best Seasonal Efficiency 

Dedicated Heat Pump Technology 

Outlet Water Temperature (ºC) 

Ambient Temp. (ºC) 

GB29541-2013 

R410A Series Heat Pumps 

Standard Heat Pumps 

High COP 

Adopting R410A refrigerant and circulating heating 

method, R410A Heat Pump is able to maintain a COP as 

high as 4.67. 

Water Temperature (up to 60ºC) 

Thanks to EVI technology, R410A Series features a wide 

operating temperature range. It means they can reach 

high water temperature (55-60ºC) even in cold climate 

ranging from -20ºC to 45ºC, and can work safely and 

reliably at ambient temperature. as low as -30ºC with 

Wet Injection technology. 

26

Contents 

Features 


HEAT PUMPS 

R410A EVI 

• Axial and radial compliance for 

high reliability 

• 25% further heating capacity, & 

10% higher heating COP with EVI 

technology 

Superheat Management 

• TEV increases heating capacity and 

extends the operational life 

• EEV increases COP and limits the 

discharge temperature under safe 

level 

• Less defrosting time and more 

energy-saving 

Reliable Heat Exchanger 

• No ice build up even at ambient 

temperatures as low as -30°C and 

continuous running for 20 hours 

• Patented heat exchanger 

for R410A 

• Overall insulation with low heat loss 

• Monobloc design saves space 

Application Examples 

Commercial Hot Water Supply 

Hotels, Hospitals, SPA, Holiday Center 

Residential Hot Water/Heating 

Houses, Apartments, Villas 

R410A Heat Pump 

Water Tank 

Sanitary Water 

Radiator 

Shower 

Hot Water Pipe 

Floor 

Heating 

Fan Coil 

R410A 

Heat 

Pump 

Rinsing Water 

27

HEAT PUMPS 



Contents 

AHG15AAW 

AHG15TAW 

AHG24AW 

AHG24TAW 

AHG30TAW AHG45TAW AHG90TAW 

Model AHG15AAW AHG15TAW AHG24AW AHG24TAW AHG30TAW AHG45TAW AHG90TAW 

Hot Water Condition 

A 20°C / 15°C 

W 15°C to 55°C 

*Heating Condition 

A 7°C / 6°C 

W 50°C / 55°C 

**Heating Condition 

A 7°C / 6°C 

W 30°C / 35°C 

Cooling Condition 

A 35°C / 24°C 

W 12°C / 7°C 

Heating Cap. (kW) 18.6 18.5 27.2 27.2 36.5 50 100 

Power Input (kW) 4.1 4 6.9 6.6 7.8 10.8 22 

COP (W/W) 4.54 4.63 3.94 4.12 4.67 4.63 4.55 

Hot Water (L/h) 400 398 585 585 800 1075 2150 

Heating Cap. (kW) 13.8 14.6 22.6 22.6 31.4 43 86 

Power Input (kW) 5.4 5 8.9 8.9 10.6 14.5 29 

COP (W/W) 2.56 2.92 2.54 2.54 2.96 2.97 2.97 

Heating Cap. (kW) 14.9 15.7 24.4 24.4 31.1 42 84 

Power Input (kW) 3.6 3.3 5.9 5.8 7.4 10 20 

COP (W/W) 4.14 4.76 4.14 4.21 4.20 4.20 4.20 

Cooling Cap. (kW) 10.8 11.3 14.4 17.8 18 27.3 59 

Power Input (kW) 4.2 3.9 7.6 7 7.5 10.6 21.9 

EER (W/W) 2.58 2.9 1.89 2.54 2.40 2.58 2.69 

Maximum Power Input kW 7.9 7.9 10.2 10.2 12 20.8 41.5 

Maximum Current A 35.7 13 46.4 18.7 19 37 74 

Power Supply 

200-240V~ 

50Hz 

380-415V 

3N~/50Hz 

200-240V~ 

50Hz 

380-415V/3N~/50Hz 

Compressor Type Copeland R410A EVI Scroll Hitachi R410A EVI Rotary Copeland R410A EVI Scroll 

Compressor Quantity 1 1 2 2 2 1 2 

Fan Quantity / 2 2 2 2 2 1 2 

Fan Motor Power Input W 85 x 2 85 x 2 110 x 2 110 x 2 300 x 2 1100 x 1 1100 x 2 

Water Flow Volume m 3 /h 1.65 1.65 2.6 2.6 5.2 8.5 17 

Water Pressure Drop kPa 29 29 29.6 29.6 53 60 65 

Suggested Water 

Temp Differential 

°C 5 5 5 5 5 5 5 

Water Connection inch 1.25 1.25 1.5 1.5 1.5 2 3 

Noise dB(A) 63 63 64 64 65 71 73 

Air Discharge Type Horizontal Vertical 

Refrigerant (R410A) Quantity kg 3 3 2.2 × 2 2.6 × 2 7.5 9 9 × 2 

Operation Range °C -25~45 -30~45 

Condenser 

Patented Tube in Shell Heat Exchanger 

Maximum Outlet Water Temp. °C 60 

Net Weight kg 150 140 208 215 331 475 778 

Gross Weight kg 162 152 222 229 366 500 843 

Net Dimensions (L/W/H) mm 1000/415/1315 1000/415/1315 1175/400/1588 1175/400/1588 1556/605/1850 1413/845/2000 2180/1080/2100 

Shipping Dimensions (L/W/H) mm 1080/445/1470 1080/445/1470 1200/450/1600 1200/450/1600 1630/700/2010 1490/900/2160 2260/1130/2260 

28

Contents 


HEAT PUMPS 

29

HEAT PUMPS 

Galleti MPI DC - Air to Water Heat Pumps 

Galletti MPI DC 

Air to Water Chillers & Heat Pumps 8 - 29 kW 

Outdoor Packaged Unit with BLDC Compressor 

Contents 

Large operating range and energy efficiency 

under every condition. 

The MPI DC series consists of 6 heat pump models and 5 

cold only models and is intended mainly for residential or 

light commercial applications. Due to the control managed 

by a software program developed by Galletti, the MPI 

DC series’ adjustment logic makes it possible to adjust 

the water delivery temperature to the set value and to 

control the compressor so that the power generated by the 

machine is adjusted to the thermal load required by the 

system. This represents a strategic feature in the limiting of 

energy consumption, because the effective thermal load of 

an air conditioning system is less than 60% of the nominal 

load most of the time. 

The BLDC technology upon which is based the compressor’s 

electric motor guarantees the ability to change the rotation 

speed in a frequency range between 30 and 120 Hz, thereby 

reducing at the same time the power consumption and 

thus maintaining a high level of efficiency in the operation 

at partial load and improved isentropic efficiency. These 

units’ large operating range, which is also achieved due 

to the variable flow water circulator they are equipped 

with as a standard feature, guarantees operation with air 

temperatures from -15 °C up to 52 °C, while in heating 

mode it is possible to produce hot water up to 58 °C. This 

allows their use as a single generator in addition to summer 

air conditioning, even in medium-temperature heating 

systems and for the production of DHW. Furthermore, the 

innovative Smart Defrost System guarantees that defrosting 

always occurs in the most efficient manner even under the 

most extreme environmental conditions. 

Advantages 

• Twin-rotary or scroll compressor driven by an electronic 

control BLDC motor 

• Electronically controlled electric expansion valve 

• Modulating hydraulic pump with stainless steel impeller 

• Optional internal buffer tank 

MPI DC can be the only heat generator in low-power systems 

due to its large operating range that includes both low winter 

temperatures and high summer temperatures. 

30

Contents 

Main Components 

• Structure 

It is constructed of galvanized and painted sheet metal that 

is resistant to corrosive agents. Compressor compartment 

closed and accessible from three sides due to easily 

removable panels, available also with internal coating of 

soundproofing material. 

• Compressor 

Hermetic twin-rotary or scroll compressor driven by 

a permanent magnet BLDC motor and controlled by a 

trapezoidal wave inverter. It is attached to the base by 

means of rubber dampers to reduce the transmission of 

vibrations. 

• Heat exchanger 

Finned heat exchanger constructed with copper pipes 

mechanically attached to aluminium fins, carefully designed 

to minimize the defrosting phases and optimize heat 

exchange efficiency in every operating phase. 


• Electronically controlled electric expansion valve 

Key component for the proper functioning of the unit. 

The PID control algorithm allows it to quickly adapt to all 

operating conditions and to keep the cooling cycle stable. 

• Hydraulic Kit 

Variable flow centrifugal circulator with stainless steel 

impeller. An expansion vessel and the automatic filling 

tap are also included. An inertial buffer tank built into the 

structure is available as an optional accessory. 

• DHW Kit 

A system that makes it possible to transform the MPI 

DC heat pumps into multi-purpose units that are able 

not only to meet the requirements of the air conditioning 

system, but also to produce domestic hot water as a 

priority by means of the Galletti TP or TN series thermal 

storage tanks. It is comprised of a microprocessor 

control unit with LCD display and a 3-way motorized 

valve. Also, anti-Legionnaire’s disease cycles can be 

activated by means of a heating element. 

HEAT PUMPS 

Configuration 

The models are completely configurable by selecting the 

version and the options. An example of configuration is 

shown below. 

Fields 

Version 1 2 3 4 5 6 7 8 9 10 11 12 13 

MPIDC014H0AC A 2 0 0 E P 3 0 2 0 G 0 2 

Available Versions 

Cooling Only Versions 

MPIDC…CMAC 

MPIDC…C0AC 

Water chiller 240V - 1 - 50 Hz 

Water chiller 400V - 3N - 50 Hz 

Versions with Reversible Heat Pump 

MPIDC…HMAC 

MPIDC…H0AC 

Configuration Options 

1 - Expansion Valve 

A Electronic 240V 

Air to Water heat pump 240V - 1 - 50 Hz 

Air to Water heat pump 400V - 3N - 50 Hz 

2 - Pump User Side And Accessories 

1 1 Modulating standard pump, system side 

2 1 EC pump, system side 

3 - Buffer Tank 

0 Absent 

S Present, system side 

4 - Desuperheater 

0 Absent 

5 - Fans 

C Standard with condensation control 

E BLDC with electronic control 

6 - Antifreeze Kit 

0 Absent 

E Base (plate exchangers only) 

P Additional protection for 1 pump 

S Additional protection for 1 pump and tank 

7 - Sound Insulation 

0 Absent 

1 Compressor compartment soundproofing 

2 Compressor silencing housings 

3 Opt 1 + Opt 2 

8 - Cooling Accessories 

0 None 

M Refrigerant pressure gauges 

9 - Remote Control / Communication 

0 Absent 

2 RS485 (Carel / Modbus) 

S Simplified remote control 

X Advanced remote control (PCOXS) 

10 - Special Heat Exchangers 

0 Standard 

R Copper / copper 

C Cataphoresis 

B Fins pre-coated with epoxy paint 

I Hydrophilic 

11 - Condenser Protective Grille 

0 Absent 

G Present 

12 - Compressor Options 

0 Absent 

4 Exchanger heating cable (Heat Pump only) 

13 - Microprocessor control 

2 pCOXS controller 

Accessories 

• Base rubber vibration dumpers 

• Base spring vibration dumpers 

• Simplified remote control 

• MYCHILLER BASE (RS485 is a mandatory accessory) 

• MYCHILLER PLUS (RS485 is a mandatory accessory) 

31

HEAT PUMPS 


Rated Technical Data 

Water Chillers 

Contents 

Model 010 M 014 018 023 029 

Product Code MPIDCC010M MPIDCC014 MPIDCC018 MPIDCC023 MPIDCC029 

Power Supply V - ph - Hz 240-1-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 

Cooling Capacity (1) (E) kW 10.5 14.2 18 22.8 28.9 

Power Input (1) (E) kW 3.35 4.78 7.63 7.77 12.3 

EER (1) (E) 3.07 2.9 2.31 2.88 2.31 

ESEER (E) 4.17 4.09 4.03 3.87 3.98 

Eurovent Efficiency Class B B E C E 

Water flow (1) l/h 1826 2454 3132 3935 4992 

Water Pressure Drop (1) (E) kPa 23 30 47 27 42 

Available Pump Head (1) kPa 142 162 132 130 84 

Maximum current absorption A 16 20 20 35 35 

Startup current A 10 10 10 10 10 

No. of compressors / circuits 1/1 1/1 1/1 1/1 1/1 

Expansion vessel dm3 5 5 5 5 5 

Buffer tank volume dm3 30 30 30 50 50 

Sound power level (2) (E) dB(A) 70 71 71 74 74 

Transport weight kg 210 210 210 285 285 

Operating weight kg 235 235 235 335 335 

Heat Pumps 

Model 008 M 010 M 014 018 023 029 

Product Code MPIDCH008M MPIDCH010M MPIDCH014 MPIDCH018 MPIDCH023 MPIDCH029 

Power Supply V-ph-Hz 240-1-50 240-1-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 

Cooling Capacity (1) (E) kW 7.93 10.3 13.9 17.7 22.3 28.3 

Power Input (1) (E) kW 2.65 3.42 4.89 7.81 7.9 12.5 

EER (1) (E) 3 3.02 2.85 2.26 2.83 2.27 

ESEER (E) 3.81 4.09 4.06 3.96 3.78 3.91 

Eurovent Efficiency Class B B C F C F 

Water flow (1) l/h 1366 1783 2407 3067 3861 4903 

Water Pressure Drop (1) (E) kPa 5 22 29 44 26 40 

Available Pump Head (1) kPa 68 142 163 133 131 84 

Heating capacity (2) (E) kW 8.92 11.5 15.8 21.8 24.7 34 

Power input (2) (E) kW 2.84 3.64 5.08 7.7 8.02 12 

COP (2) (E) 3.14 3.17 3.11 2.83 3.09 2.83 

Eurovent Efficiency Class (Heating) B B B C B C 

Water flow (2) l/h 1545 1974 2727 3752 4273 5853 

Water pressure drop (2) (E) kPa 7 23 31 55 29 51 

Available Pump Head (2) kPa 65 137 155 109 116 45 

Maximun current absorption A 16 16 20 20 35 35 

Startup current A 10 10 10 10 10 10 

No. of compressors / circuits 1/1 1/1 1/1 1/1 1/1 1/1 

Expansion vessel dm3 1 5 5 5 5 5 

Buffer tank volume dm3 20 30 30 30 50 50 

Sound power level (3) (E) dB(A) 68 70 71 71 74 74 

Transport weight kg 144 220 220 220 300 300 

Operating weight kg 153 240 240 240 347 347 

32

Contents 

Dimensional Drawings 


HEAT PUMPS 

MPI DC 008 

1241 

582 

405.3 

7 

1216 451 

7 

4 

3 

6 

5 2 

464 

558.5 

758 

1,5 m 

173 

103 

Legend 

129 

97 

122 

148 107 

186 186 

472 

8 

8 

1 Water inlet 1” female 

2 Water outlet 1” female 

3 Safety valve discharge outlet provided with rubber ring holder 

4 Water supply ½” male (optional tap) 

492 

1 

1 m 

1 m 

1,5 m 

5 Water drainage ½” female 

6 Power supply Ø 28 mm 

7 Electric control board 

8 Fastening points for vibration dampers (accessory) 

MPI DC 010 / 014 / 018 

7 

1249 

1224 

2 

3 

300 

284 

210 

1 

4 

1223.5 

6 

948 

1053 

1098 

1152 

1,5 m 

340.5 

127 

1,5 m 

1 m 

clear area 

195.5 

8 

900 124.5 

8 

527 

560 

5 

345.5 

Legend 

1 Water inlet 1” ¼ female 

2 Water outlet 1” ¼ female 







MPI DC 023 / 029 

1590 

1564 

605 

6 

2 

3 

1 

297.8 

291 

201 

4 

7 

1273 

150 

983 

1021.5 

1126 

1171.5 

1,5 m 

568 

207 1112.4 

241.5 

601 

8 8 

Legend 





5 

358.3 

127 

350.5 

1,5 m 





1 m 

clear area 

33

HEAT PUMPS 

Galleti MPE - Air to Water Heat Pumps 

Galletti MPE 


Outdoor Packaged Unit 

Contents 

Efficiency under all operating conditions. 

MPE water chillers and heat pumps are designed for 

outdoor installation in both residential and industrial 

applications. The range uses R410A refrigerant, which 

assures high levels of performance with relatively low 

energy consumption and features 25 models in the chiller 

and heat pump version, with cooling capacities ranging 

from 4 to 76 kW and heating capacities from 5 to 85 kW. 

The finned block heat exchangers have been optimised 

for R410A and use 8 mm copper pipes, which permit a 

better heat exchange and quiet operation of the fans. Their 

generous sizing guarantees the production of chilled water 

even with outdoor air temperatures as high as 51°C. 

In the MPET models, with a double compressor on the 

same cooling circuit, the working temperature range is 

extended further and efficiency at partial loads increases. 

In demanding working conditions the microprocessor 

controller activates the capacity control mode, doubling the 

condensing surface available to the single compressor. 

The self-adaptive logic allows the setpoint to be adjusted 

automatically according to the outdoor temperature in 

order to reduce consumption and broaden the working 

temperature range. 

The unit can also function in systems with a low water 

content, even without the use of a water buffer tank, thanks 

to the automatic adjustment which limits the number 

of compressor starts and thus extends the life of the 

compressors themselves. 

The exclusive Smart Defrost System (optional feature 

available with the advanced controller) can correctly 

identify an impairment of performance in the outdoor 

exchanger due to the formation of ice and minimise the 

process time in relation to normal operation of the unit. 

Advantages 

• Completely configurable range 

• Dual-compressor version that guarantees high efficiency 

at partial loads 

• Production of chilled water up to an air temperature of 51ºC 

• Built-in hydronic unit 

MPE heat pumps and water chillers are designed for heating 

or cooling the water to be used in air-conditioning systems for 

residential or commercial use. 

34

Contents 


• Structure 

Painted galvanised sheet steel structure (RAL9002) for an 

attractive look and effective resistance to corrosive agents. 

Fastening devices are made of non-oxidizable carbon steel 

that has undergone surface-passivating treatments. 

• Customised hydraulic kit 

The structure can accommodate hydronic kits with pump, 

expansion tank, and buffer tank. High head pump made 

entirely of stainless steel, already configured for use 

with mixtures of water and ethylene glycol up to 35% and 

provided with internal thermal protection. 

• Fan drive assembly 

Electric fan with external rotor motor directly keyed to the 

axial fan, with internal thermal protection on the windings. 


• Finned block heat exchanger 

Made of 8mm diameter copper pipes and aluminium fins. 

The heat exchangers’ particular design makes it possible to 

speed up to the maximum the defrost phases in the versions 

with heat pump with obvious benefits to seasonal efficiency 

while operating in heating mode. 

• Electronic microprocessor controller 

The electronic controller enables the complete control of the 

MPE unit. It can be easily accessed through a polycarbonate 

flap with IP65 protection rating. It implements the 

compressor regulation logic and allows the complete 

management of the unit’s other parts, the reversal of the 

cooling cycle, and the alarms. 

HEAT PUMPS 

Configuration 


version and the options. An example of configuration is 

shown below. 

Optional 

Version 1 2 3 4 5 6 7 8 9 10 11 12 13 

MPE008C0AA A 1 S 0 E 0 3 M 2 0 G 2 1 



MPE..C0AA 

MPE..CMAA 

MPE..C2AA 

MPE..C4AA 

400V - 3N - 50 Hz power supply 

240V - 1 - 50 Hz power supply 

Circuit breakers & 400V - 3N - 50 Hz power supply 

Circuit breakers & 240V - 1 - 50 Hz power supply 


MPE..H0AA 

MPE..HMAA 

MPE..H2AA 

MPE..H4AA 

400V - 3N - 50 Hz power supply 

240V - 1 - 50 Hz power supply 

Circuit breakers & 400V - 3N - 50 Hz power supply 

Circuit breakers & 240V - 1 - 50 Hz power supply 



0 Traditional 

A Electronic 240V 

B Floor Pack (incl. electronic valve & condensation control) 

2 - Pump and Accessories 

0 Absent 

1 Pump + expansion tank + filling tap 

2 Dual pump + expansion tank + filling tap 

3 - Inertial Buffer Tank 

0 Absent 

S Present 

4 - Partial Heat Recovery 

0 Absent 

D Desuperheater with pump contact 

5 - Air Flow Modulation 

0 Absent 

C Condensation control with fans adjusted by potentiometer 

E Condensation control, “EC brushless” electronically controlled fans 


0 Absent 

E For units with evaporator only 

P For units with evaporator, pump and expansion tank 

S For units with evaporator, pump, expansion tank and tank 


0 Absent 

1 Compressor compartment soundproofing 


3 Opt 1 + Opt 2 


0 None 


9 - Remote Control 

0 Absent 

2 Output RS485 (Modbus or Carel protocol) 


M BASE microprocessor remote control (Modbus disabling) 

X ADVANCED microprocessor remote control 

L LON FTT 10 serial card 


0 Standard 

R Copper / copper 



11 - Heat Exchanger Protective Grille 

0 Absent 

G Present 


0 Absent 

1 Power factor correction capacitors 

2 Soft starter 

3 Power factor correction capacitors + soft starter 

4 Low Air to Water temperature (crankcase heating element) 


1 BASE control microprocessor 

2 ADVANCED control microprocessor 

3 ADVANCED control microprocessor + GSM kit 

4 ADVANCED control microprocessor + clock card 

Accessories 

- Base rubber vibration dumpers 

- Base spring vibration dumpers 

- Inertial tank module for under-base installation 

- Tank module connection kit 

- Simplified remote control 

- MYCHILLER BASE (RS485 is a mandatory accessory) 

- MYCHILLER PLUS (RS485 is a mandatory accessory) 

35

HEAT PUMPS 


Rated Technical Data MPE-C (Cooling only versions) 

Contents 

Model 004 M 005 M 007 M 008 M 008 010 M 

Product Code MPEC004M MPEC005M MPEC007M MPEC008M MPEC008 MPEC010M 

Power supply V-ph-Hz 240-1-50 240-1-50 240-1-50 240-1-50 400-3N-50 240-1-50 

Cooling capacity 1 E kW 4.1 5.09 6.64 8.43 8.3 9.17 

Total power input 1 E kW 1.35 1.71 2.28 3.11 3.38 3.31 

EER 1 E 3.03 2.98 2.92 2.71 2.45 2.77 

ESEER E 3.54 3.39 3.32 3.36 2.98 3.38 

Eurovent Efficiency class B B B C E C 

Water flow rate in cooling mode 1 I/h 706 876 1145 1452 1429 1590 

Water pressure drop 1 E kPa

Contents 


HEAT PUMPS 

Model 027 028 032 035 040 054 066 

Product Code MPEC027 MPEC028 MPEC032 MPEC035 MPEC040 MPEC054 MPEC066 

Power supply V-ph-Hz 400-3N-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 

Cooling capacity 1 E kW 26.4 27.9 31.3 34.7 39.4 53.7 65.6 

Total power input 1 E kW 9.52 8.87 10.3 11.7 13 18.2 24.6 

EER 1 E 2.77 3.14 3.03 2.96 3.02 2.95 2.66 

ESEER E 3.36 3.77 3.63 3.61 3.68 3.6 3.3 

Eurovent Efficiency class C A B B B B D 

Water flow rate in cooling mode 1 I/h 4565 4823 5415 6008 6816 8829 11342 

Water pressure drop 1 E kPa 34 40 51 41 43 55 59 

Available pressure head 1 kPa 123 141 126 130 119 110 95 

Maximum absorbed current (without accs) A 34 36 37 42 43 45 46 

Startup current A 132 133 166 161 163 163 165 

Startup current with softstarter kit A 91 91 114 111 112 110 112 

No. of scroll compressor/ circuits 1/1 1/1 1/1 1/1 1/1 1/1 1/1 

Buffer tank volume dm 3 5 8 8 8 8 8 8 

Expansion vessel dm 3 50 125 125 125 125 125 125 

Sound power level 2 E dB(A) 72 73 73 73 75 78 78 

Weight without accessories kg 285 370 370 390 390 500 530 

Weight with pump and full tank kg 332 492 492 513 513 620 650 

Model T30 T34 T40 T45 T54 T61 T69 T76 

Product Code MPECT30 MPECT34 MPECT40 MPECT45 MPECT54 MPECT61 MPECT69 MPECT76 

Power supply V-ph-Hz 400-3N-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 400-3N-50 

Cooling capacity 1 E kW 29.8 33.9 39.3 44.2 54.2 61.4 69.3 75.6 

Total power input 1 E kW 10.6 12.8 13.9 16.8 18.7 21.7 24.1 28 

EER 1 E 2.82 2.64 2.82 2.64 2.9 2.83 2.88 2.7 

ESEER E 4.17 4.11 4.15 4.04 4.03 4.01 4.18 4.16 

Eurovent Efficiency class C D C D B C C C 

Water flow rate in cooling mode 1 I/h 5156 5854 6799 7648 9378 10629 11989 13075 

Water pressure drop 1 E kPa 30 38 45 57 53 66 52 60 

Available pressure head 1 kPa 150 134 117 97 138 120 128 114 

Maximum absorbed current (without accs) A 40 46 50 57 48 53 57 69 

Startup current A 86 96 127 130 177 187 202 229 

Startup current with softstarter kit A 46 51 71 82 105 110 119 134 

No. of scroll compressor/ circuits 2/1 2/1 2/1 2/1 2/1 2/1 2/1 2/1 

Buffer tank volume dm 3 8 8 8 8 8 8 8 8 

Expansion vessel dm 3 125 125 125 125 125 125 125 125 

Sound power level 2 E dB(A) 72 72 72 72 81 81 81 81 

Weight without accessories kg 410 410 430 430 557 692 692 786 

Weight with pump and full tank kg 532 533 553 553 665 800 800 894 

1 

Water temperature 12/7 °C, outdoor air temperature 35 °C (UNI EN 14511:2011) 

2 

Water temperature 40/45 °C, outdoor air temperature 7 °C D.B. - 6 °C W.B. (UNI EN 14511:2011) 

E 

EUROVENT certified data 

37

HEAT PUMPS 


Rated Technical Data MPE-H (Versions with reversible heat pump) 

Contents 

Model 004 M 005 M 007 M 008 M 008 010 M 

Product Code MPEH004M MPEH005M MPEH007M MPEH008M MPEH008 MPEH010M 

Power supply V-ph-Hz 240-1-50 240-1-50 240-1-50 240-1-50 400-3N-50 240-1-50 

Cooling capacity 1 E kW 4.02 4.99 6.51 8.26 8.13 8.99 

Total power input 1 E kW 1.35 1.71 2.28 3.11 3.38 3.31 

EER 1 E 2.97 2.92 2.86 2.65 2.41 2.72 

ESEER E 3.47 3.32 3.26 3.29 2.92 3.31 

Eurovent Efficiency class B B C D E C 

Water flow rate in cooling mode 1 I/h 692 859 1122 1423 1400 1559 

Water pressure drop 1 E kPa

Contents 


HEAT PUMPS 

Model 027 028 032 035 040 054 066 

Product Code MPEH027 MPEH028 MPEH032 MPEH035 MPEH040 MPEH054 MPEH066 


Cooling capacity 1 E kW 25.9 27.3 30.6 34 38.6 51.6 62.3 

Total power input 1 E kW 9.51 8.86 10.3 11.7 13 18.2 24.6 

EER 1 E 2.72 3.08 2.97 2.9 2.97 2.84 2.54 

ESEER E 3.29 3.7 3.56 3.54 3.61 3.5 3.2 

Eurovent Efficiency class C B B B B C D 

Water flow rate in cooling mode 1 I/h 4474 4833 5307 5888 6681 8932 10776 



Heating capacity 2 E kW 30.1 31.5 35.9 39.5 45.2 61.4 75.8 

Total power input 2 E kW 9.11 9.38 10.8 11.9 13.5 18.9 23.8 

COP 2 E 3.3 3.36 3.34 3.33 3.36 3.25 3.19 

Efficiency class Eurovent A A A A A A B 

Water flow rate in heating mode 2 l/h 5187 5396 6173 6813 7800 10575 13063 



Maximum absorbed current (without accs) A 34 36 37 42 43 45 46 

Startup current A 132 133 166 161 163 163 165 

Startup current with softstarter kit A 91 91 114 111 112 110 112 

No. of scroll compressor/ circuits 1/1 1/1 1/1 1/1 1/1 1/1 1/1 

Buffer tank volume dm 3 5 8 8 8 8 8 8 

Expansion vessel dm 3 50 125 125 125 125 125 125 

Sound power level 3 E dB(A) 72 73 73 73 75 78 78 

Weight without accessories kg 300 400 400 420 420 530 560 

Weight with pump and full tank kg 347 522 522 543 543 650 680 

Model T30 T34 T40 T45 T54 T61 T69 T76 

Product Code MPEHT30 MPEHT34 MPEHT40 MPEHT45 MPEHT54 MPEHT61 MPEHT69 MPEHT76 


Cooling capacity 1 E kW 29.3 33.2 38.5 43.3 53.1 60.2 68.1 74.1 

Total power input 1 E kW 10.6 12.8 13.9 16.7 18.7 21.7 24 28 

EER 1 E 2.76 2.59 2.77 2.59 2.84 2.78 2.83 2.65 

ESEER E 4.09 4.03 4.06 3.96 4.01 3.99 4.16 4.15 

Eurovent Efficiency class C D C D C C C D 

Water flow rate in cooling mode 1 I/h 5053 5737 7495 7495 9189 10423 11766 12818 



Heating capacity 2 E kW 34.6 39.5 46.7 53.2 60.4 68.1 77 85.4 

Total power input 2 E kW 11.1 13.1 14.3 16.7 19 22.1 23.9 27.4 

COP 2 E 3.12 3.02 3.25 3.18 3.19 3.08 3.22 3.11 

Efficiency class Eurovent B B A B B B A B 

Water flow rate in heating mode 2 l/h 5976 6818 8042 9155 10412 11733 13292 14730 



Maximum absorbed current (without accs) A 40 46 50 57 48 53 57 69 

Startup current A 86 96 127 130 177 187 202 229 

Startup current with softstarter kit A 46 51 71 82 105 110 119 134 

No. of scroll compressor/ circuits 2/1 2/1 2/1 2/1 2/1 2/1 2/1 2/1 

Buffer tank volume dm 3 8 8 8 8 8 8 8 8 

Expansion vessel dm 3 125 125 125 125 125 125 125 125 

Sound power level 3 E dB(A) 72 72 72 72 81 81 81 81 

Weight without accessories kg 430 430 430 450 660 702 702 792 

Weight with pump and full tank kg 552 552 553 573 768 810 810 900 

1 

Water temperature 12/7 °C, outdoor air temperature 35 °C (UNI EN 14511:2011) 

2 

Water temperature 40/45 °C, outdoor air temperature 7 °C D.B. - 6 °C W.B. (UNI EN 14511:2011) 

3 

Sound power level measured according to UNI EN ISO 9614 

E 


39

HEAT PUMPS 



Contents 

MPE 004 - 008 

366.2 

451 

989 

153.3 

3 

4 

757.5 

7 

224 

6 

60 

407.5 

464 

558.5 

1,5 m 

121.5 

Legend 

5 

148 2 1 

472 

186 590 

186 

492 

8 

8 8 8 





121.5 

966 

1,5 m 





1 m 

1 m 

clear area 

7 

MPE 010 - 015 

1247.5 

1224 

564 

2 

3 

299 

282 

209 

1 

4 

1223.5 

6 

948 

953 

1053 

1098 

1,5 m 

527 

195.5 900 124.5 

560 

8 

8 8 8 

5 

127 

1,5 m 

1 m 

clear area 

Legend 








8 Vibration dampers 

MPE 018 - 027 

1588 

1565 

605 

2 

4 

3 

1 

298 

201 

186 

7 

1273.5 

6 

150.5 

650.5 

983 

1126 

1171.5 

1,5 m 

207 

1112 

241.5 

8 8 

568 

601 

5 

378 

127 

1,5 m 

1 m 

clear area 

Legend 









40

Contents 

MPE 028 - 040 / T30 - T45 


HEAT PUMPS 

1987.5 

951 

2 

4 

3 

356 

319 

201 

1 

7 

1450.5 

100 

6 

682 

1012 

1108 

1223 

1 m 

1,5 m 

914 

8 8 

947 

5 254 

303.7 729.8 623.8 303.7 

8 8 

8 

1965 

138.5 

139.5 

379.5 

MPE 28-45 WITH TANK 

MPE 30-45 T 

1 m 

1,5 m 

Legend 









MPE 054 - 066 

2008 

951 

1965 

310.8 

280 

194.5 

1 

979 

7 

1452 

10 

9 

4 

6 

2 

376 

3 

557.8 

768.5 

970 

1069 

1190 

1 m 

914 

947 

304 730 624 304 

8 

8 8 

5 

138.5 

139.5 

379.5 

1,5 m 

1 m 

1,5 m 

Legend 




4 Water supply ½” male 


6 Power supply 



9 Desuperheater water inlet 1” female 

10 Desuperheater water outlet 1” female 

MPE T54 - T76 

2112 

2091 

1183 

5 

5 

4 

1733 

1 2 

1 m 

345 

345 

1,5 m 

155.5 

243 

243 

598 578 

303 688 794 303 

6 6 6 

1144 

1 m 

1,5 m 

3 

Legend 






6 Fastening points for vibration dampers 

41

HEAT PUMPS 

Galleti HPS - Air to Water Heat Pumps 

Galletti HiRef HPS 

Reversible High Temperature Heat Pumps 

Air Cooled for Cold Climates 43 - 216 kW 

Contents 

HPS is the range of Air to Water reversible 

heat pumps made by HiRef designed 

to operate with extremely low outdoor 

temperatures. 

In fact, the use of compressors with EVI vapour injection 

technology allows the production of hot water up to 58°C 

and to operate with outdoor temperatures of down to -15 

°C. This is combined with a special focus on noise (the 

“Low-Noise” version is standard equipment) and using 

different layouts of the refrigerating circuit in order to meet 

the needs of any system applications 

Advantages 

• Production of Hot Water up to 58°C 

• EVI compressors with vapour injection. 

• Electronically controlled expansion valve. 

• Smart Kit for “cold” start up. 

• Coils with hydrophilic treatment and larger fin pitch. 

• Defrost ice trays with electrical heaters. 

• Optional EC fans. 

• Available as multfunction version for 2- or 4- pipe systems. 

42

Contents 

Galletti HPS Features and Advantages 


HEAT PUMPS 

T water OUT [°C] 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

-20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 

Air T IN [°C] 

Production of Hot Water up to 58°C 

The HPS range is able to produce 

water at 58°C, as well as to operate 

with outdoor temperatures of down 

to -15 °C. 

Option also available for production 

of Hot Water up to 62°C 

Plate heat 

Solenoid valve 

Expansion 

valve 

Thermostatic lamination 

valve 

Condenser 

Steam injection 

Evaporator 

Compressor 

Units Optimised for 

Climates Down to -15°C 

The Scroll compressors of the 

HPS range relies on the vapour 

injection technology: a small flow 

of refrigerant in the vapour state 

at medium pressure is “injected” 

in the scrolls into the compression 

chamber. This system allows an 

increase both of cooling capacity 

(thus heating capacity) and of 

efficiency and, above all, an extension 

of the working range of the heat 

pump, which makes the HPS range 

the ideal solution in case of very cold 

outdoor conditions. 

Extremely Low-Noise 

All the units in the HPS range are supplied in the “Low 

Noise” version as standard equipment; this version features 

fan speed management, anti-vibration piping on the 

refrigerating circuit, compartment of the compressors and 

of the pumping kit in a box with soundproof material: this to 

guarantee the lowest sound emission at all working points. 

Smart Defrost System 

The defrosting cycle of the evaporating coil during the 

wintertime has a significant impact on the operating costs 

of the entire system. The Smart Defrost System® by HiRef 

(covered by patent) can detect a performance drop in the 

heat exchange due to icing and to shorten the defrost 

time. The hydrophilic treatment of the coils speeds up the 

defrosting process, so that only the first thin layer of ice on 

the fins needs to melt. 

Efficiency and Reliability 

According to the Installation Needs 

The available configurations for the refrigerating circuit 

are designed to guarantee both redundancy and efficiency 

at partial loads. In particular, depending on the size of the 

machine and on the particular needs of the installation, 

the units consist of two compressors on two circuits for 

high system redundancy, or by four compressors (double 

tandem) on two circuits for a system that is, at the same 

time, redundant and efficient at partial loads. 

43

HEAT PUMPS 


Performance and Dimensional Data 

Contents 

D 

L 

H 

Model 041 051 071 081 101 134 164 204 

Product Code GHPS041 GHPS051 GHPS071 GHPS081 GHPS101 GHPS134 GHPS164 GHPS204 

Water 

40/45°C; 

Outdoor air 

7°C 

Water 

50/58°C; 

Outdoor air 

7°C 

Water 

38/48°C; 

Outdoor air 

15°C 

Heating Capacity kW 42.7 53.4 73.3 90.3 111.1 145.8 179.3 215.6 

Total Power Input kW 12.1 15.4 21.2 25.6 30.4 44.3 53.7 62.2 

COP (UNI 14511) 3.53 3.47 3.46 3.53 3.65 3.29 3.34 3.47 

Heating Capacity kW 43.9 53.6 75.1 92 113.2 149.3 183.1 220.9 

Total Power Input kW 15.6 19.7 27.2 33.1 40.1 56.5 68.9 81.6 

COP (UNI 14511) 2.81 2.72 2.76 2.78 2.82 2.64 2.66 2.71 

Heating Capacity kW 24.1 30.2 42.1 52.1 62.2 83.8 104 123.8 

Total Power Input kW 10.5 13.5 18.2 22.1 26 38.6 46.9 53.5 

COP (UNI 14511) 2.3 2.24 2.31 2.36 2.39 2.17 2.22 2.31 

Sound Power Low noise version db(a) 81 81 82 83 85 85 86 88 

Dimensions 

L 

2090 2090 2792 2792 3540 3538 3538 3538 

D mm 1183 1183 1183 1183 1183 1653 1653 1653 

H 1735 1735 1735 1735 1679 1884 1884 2284 

Available also for 60 Hz power supply 

44

Contents 

Case Study 


HEAT PUMPS 

Nightingale Apartments 

1 x Galletti HPS Heat Pump 

This revolutionary Nightingale 

Apartment project utilised the 

eco-friendly and energy efficient 

virtues of the Galletti HPS heat 

pump to help achieve their 

remarkable sustainability goals. 

Delivering a 100% fossil fuel free 

heating solution, the Galletti HPS 

Heat Pump was combined with 

twin coil Thermex Stainless Steel 

tanks to provide high temperature 

hot water for Domestic Hot Water 

and Hydronic Heating. A custom 

prefabricated skid streamlined the 

installation process. 

45

HEAT PUMPS 

Galleti EvitecH - Air to Water Heat Pumps 

Galletti EvitecH 

Contents 

Air Heat Pumps with wide working range 50 - 180 kW 


Reliability and efficiency 

in every climatic condition. 

EvitecH is Galletti’s new high efficiency multiscroll units 

equipped with R4 l 0A steam injection compressor. The 

range consists of 10 air-water models available as chiller 

and heat pump, with cooling capacities from 50 to 180 kW. 

The main strong point of this series is the large operating 

field, both in terms of maximum hot water temperature 

(65°C with -11 °C of external air temperature) and minimum 

air temperature at which the continuous operation is 

allowed (-20°C) 

The range allows high configurability from an acoustic 

point of view, having a wide range of accessories de signed 

to reduce noise emissions. The advanced control, always 

present in the whole range, allows a continuous monitoring 

of the operating parameters, advanced ad justment logics, 

and connectivity. 

The modular structure with V configuration condens ing 

coils is designed to optimize air-side heat exchange, to 

ensure structural strength with a reduced footprint, and to 

maintain maximum accessibility to the basic components. 

In addition to high efficiency in terms of nominal condi tions 

(Eurovent A-class), in order to increase the efficien cy at 

partial loads, the whole range consists of tandem solutions 

(2 compressors on a single refrigerant circuit). The 

configuration of units with the Hydro Smart Flow kit allows 

an increase of the efficiency and extends the working area 

of the cooling mode. 

Advantages 

• Class A in heat pump operating mode 

• Production of hot water up to 65°C 

• Full load operation up to -20°C outside air temperature 

• High efficiency under part load conditions 

• Possibility to configure low-noise versions 

• Counterflow solutions in every operating mode 

EvitecH heat pumps are designed 

for heating or cooling the water to 

be used in air-conditioning systems 

for residential, commercial or 

industrial use. 

The execution with injection steam 

com pressors (EVI) guarantees the 

production of hot water at high 

temperatures even in very harsh 

outdoor conditions (outdoor air 

temperature down to -20°C). 

46

Contents 


• Structure 

The range, starting from size 72, is designed modularly, replicating 

the optimized structure ofV configura tion condensing coils and 

fans. Its design ensures stability and sturdiness even during 

the most critical phas es (such as transportation), and maximum 

accessibility to compo nents in every unit. 

• Hydro smart flow 

The HSF kit (standard for models 52 and 62) is placed on the 

unit’s hydronic side and consists of a 4-way valve and a kit. Hydro 

Smart Flow, which is activated at the time of seasonal changeover, 

reverses the direction of the water fiow over the plates to be 

consistent with the fiow of the refrigerant. In this manner heat 

exchange always occurs in counterfiow, thus optimizing the unit’s 

operation in the summer and winter seasons and extending the 

unit’s operating range. 

• Upwind 

EvitecH is designed with an inno vative technology which allows the 

refrigerant to get into the battery from the same direction when the 

cycle is inverted, with a constant counter-current exchange with 

air. This advanced technology considerably reduces the risk of ice 

generation on the finned heat exchangers. 

Configuration 


version and the options. See below for an example. 

Fields 

Version 1 2 3 4 5 6 7 8 9 10 11 12 13 

EVI082HSOA A 1 S 0 C 0 2 M 0 P 0 0 2 

To verify the compatibility of the options, use the selection software or the price list. 


Versions with reversible heat pump 

EVI..HSOA 400V-3N-50Hz power supply+ circuit breakers 

EVI..HS1A 400V-3-50Hz power supply + transformer + circuit breakers 

EVI..HS2A 400V-3N-50Hz power supply+ circuit breakers 



0 Mechanical 

A Electronic 

2 - Water Pump and Accessories 

0 Absent 

1 LP pump + expansion vessel 

2 LP run and standby double pump + expansion vessel 

3 HP pump + expansion vessel 

4 HP run and standby double pump + expansion vessel 

A LP inverter pump + expansion vessel 

B LP run and standby double inverter pump + expansion vessel 

C HP inverter pump + expansion vessel 

D HP run and standby double inverter pump + expansion vessel 

3 - Water Buffer Tank 

0 Absent 

H Present+ Hydro smart flow 

S Selected 

4 - Partial Heat Recovery 

0 Absent 

D Desuperheater with water pump free contact 


C Condensation control by phase-cut fans 

E Condensation control performed by EC fans 

6 - Antifreezing Kit 

0 Absent 

E Plate exchanger 

P Plate exchanger and water pump 

S Plate exchanger, water pump and inertial tank 


• Scroll compressors with vapour injection 

The range consists of single and dual-circuit models in order to 

offer maximum redundancy. The distribution of load in multiple 

power steps and the use of tandem solutions (2 compressors 

on a single circuit) ensures maximum efficiency at partial loads 

and therefore greatly increases seasonal efficiency. lntercooled 

compression with steam injection allows a better control of the 

end-compression temperature, keeping it within the limits imposed 

by the compressor envelope, even in the most unfavorable working 

conditions (low evaporation pressures and high compression 

pressures), this results in one of the largest operating field in the 

market. 

• 3-Way valve 

This is a smart kit able to convert EvitecH heat pumps in multifunction 

units in order to fulfill every necessity of the hydraulic airconditioning 

plant. It allows domestic hot water priority production 

thanks to Galletti thermal accumulators of the TP or TN series. The 

switching of the valve is managed by the on-board microprocessor 

control of the unit. 

7 - Acoustic Insulation and Attenuation 

0 Absent 

1 Compressor sound blanket and compressor compartment 

sound proofing 

2 Fans noise reduction (AXITOP) 

3 Fans noise reduction (AXITOP) + compressor sound blanket 

+ compartment acoustic insulation 

8 - Refrigerant Pipework Accessories 

0 Absent 


9 - Remote Control / Serial Communication 

0 Absent 

2 RS485 serial board (Carel/ Modbus protocol) 

B BACNET IP/ PCOWEB serial board 

F BACNET MS/TP / PCONET serial board 

G BACNET IP/ PCOWEB serial board+ supervision software Gweb 

L LON FTT1 O serial board 

S Remote simplified user panel 

T Touch screen remote user panel 

X Remote user panel for advanced controller 

10 - Special Coils / Protective Treatments 

0 Standard 


I Hydrophilic 

P Pre-painted fins with epoxy painting 

R Copper-copper 

11 - Anti Vibration Shock Mounts 

0 Absent 

G Rubber anti vibration shock mounts 

M Spring anti vibration shock mounts 

12 - Coil Protection Grill 

0 Absent 

F Outdoor finned coil heat exchanger protection filters 

G Selected 

13 - Onboard Controller 

1 Advanced 

2 Advanced + touchscreen user panel + USB 

Accessories 

A 

B 

C 

D 

E 

F 

G 

H 

I 

M 

N 

O 

3 way valve for DHW production 

Hydro smart flow (water tank not allowed) 

Pair of couplings Victaulic 

ON/OFF status of the compressors 

Remote control for step capacity limit 

Configurable digital alarm board 

Soft starter 

Power factor capacitors 

Filter isolation valves kit (solenoid valve and isolation valve) 

0-10 V signal for external user pump control (on-board pump excluded) 

Compressor tandem/trio isolation valves 

Anti-intrusion grille 

47 

HEAT PUMPS

HEAT PUMPS 


Rated Technical Data Models 052-092 

Contents 

Model 052 062 072 082 092 

Product Code 

Power supply V-ph-Hz 400-3N-50 

Cooling capacity 1 E kW 50.3 60.7 71.0 80.0 90.3 

Total power input 1 E kW 17.9 21.4 24.2 27.0 31.3 

EER 1 E 2.80 2.84 2.94 2.96 2.88 

SEER 2 E 3.68 3.68 3.83 3.80 3.85 

Water flow 1 I/h 8675 10485 12269 13823 15588 

Water pressure drop 1 E kPa 21 30 29 37 27 

Available pressure head - LP pumps 1 kPa 171 155 150 194 189 

Heating capacity 3 E kW 59.9 70.5 83.1 92.4 105 

Total power input 3 E kW 18.2 21.2 25.5 27.9 31.S 

COP 3 E 3.30 3.33 3.25 3.31 3.32 

SCOP 2 E 2.81 2.89 2.88 2.93 2.96 

Heating energy efficiency class 4 A+ 

SCOP 2 3.52 3.60 3.50 3.58 3.61 


Water flow 3 l/h 10247 12066 14219 15795 17924 



Maximum absorbed current A 55 65 73 74 63 


Startup current with softstarter kit A 111 130 153 154 144 

Compressor/ circuits 2/1 

Expansion vessel volume dm 3 8 8 18 18 18 

Buffer tank volume dm 3 125 125 350 350 350 

Sound power level 6 E dB(A) 82 82 83 83 83 

Transport weight unit with pump & tank kg 692 713 1004 1020 1025 

Operating weight unit with pump & full tank kg 800 821 1354 1370 1375 

1 

Outdoor air temperature 35°C, water temperature l 2°C / 7°C (EN14511:2013) 

2 

η efficiency values for heating and cooling are respectively calculated by the following formulas: [η= SCOP / 2,5 - F(1)-F(2)] e [η=SEER/ 2,5-F(1)-F(2)]. 

For further information, please refer to the technical document”ErP 2009/125/EC DIRECTIVE” in the catalogue introducing pages, or to the EN14825:2017 regulation. 

3 

Outdoor air temperature dry bulb 7 °C / wet bulb 6°C, water temperature 40°C / 45°C (EN14511:2013) 

4 

Seasonal energy efficiency class for MEDIUM TEMPERATURE room heating under AVERAGE climatic conditions [EUROPEAN REGULATION No 811/2013] 

5 

Seasonal energy efficiency class for LOW TEMPERATURE room heating under AVERAGE climatic conditions [EUROPEAN REGULATION No 811/2013] 

6 

Sound power level measured according to ISO 9614 

E 


48

Contents 

Rated Technical Data Models 104-184 


HEAT PUMPS 

Model 104 124 154 174 184 

Product Code 


Cooling capacity 1 E kW 104 124 150 171 181 


EER 1 E 2.84 2.74 2.93 2.93 2.88 

SEER 2 E 4.09 4.09 3.64 3.78 3.79 

Water flow 1 I/h 17916 21276 25906 29549 31296 



Heating capacity 3 E kW 119 139 173 194 207 


COP 3 E 3.42 3.41 3.35 3.43 3.42 

SCOP 2 E 2.99 3.08 2.89 3.02 3.02 


SCOP 2 3.79 3.91 3.49 3.63 3.66 

Heating energy efficiency class 5 A+ A++ A+ A+ A+ 

Water flow 3 l/h 20289 23834 29636 33295 35408 



Maximum absorbed current A 92 112 147 136 125 


Startup current with softstarter kit A 148 177 227 217 207 

Compressor/ circuits 4/2 

Expansion vessel volume dm 3 18 18 24 24 24 

Buffer tank volume dm 3 350 350 450 450 450 

Sound power level 6 E dB(A) 84 86 86 86 86 

Transport weight unit with pump & tank kg 2127 2218 1955 1956 1996 

Operating weight unit with pump & full tank kg 2577 2668 2405 2406 2446 

1 

Outdoor air temperature 35°C, water temperature l 2°C / 7°C (EN14511:2013) 

2 

η efficiency values for heating and cooling are respectively calculated by the following formulas: [η= SCOP / 2,5 - F(1)-F(2)] e [η=SEER/ 2,5-F(1)-F(2)]. 

For further information, please refer to the technical document”ErP 2009/125/EC DIRECTIVE” in the catalogue introducing pages, or to the EN14825:2017 regulation. 

3 

Outdoor air temperature dry bulb 7 °C / wet bulb 6°C, water temperature 40°C / 45°C (EN14511:2013) 

4 

Seasonal energy efficiency class for MEDIUM TEMPERATURE room heating under AVERAGE climatic conditions [EUROPEAN REGULATION No 811/2013] 

5 

Seasonal energy efficiency class for LOW TEMPERATURE room heating under AVERAGE climatic conditions [EUROPEAN REGULATION No 811/2013] 

6 

Sound power level measured according to ISO 9614 

E 


49

HEAT PUMPS 



EVITECH 52 - 62 

Contents 

Legend 



3 Water drainage 1/2” female 



6 Fastening points for vibration dampers 

EVITECH 72 - 82 - 92 

Legend 


2 Water inlet Victaulic 2 1/2’’ 

3 Water outlet Victaulic 2 1/2” 

4 Vibration dumpers 

50

Contents 


HEAT PUMPS 

EVITECH 104 - 124 

Legend 


2 Water inlet Victaulic 2 1/2’’ 

3 Water outlet Victaulic 2 1/2” 


EVITECH 154 - 174 - 184 

Legend 


2 Water inlet Victaulic 4” 

3 Water outlet Victaulic 4” 



6 Victaulic adapter from 4”to 3”to be mounted on-site 

7 Water outlet, evaporator only 

51

HEAT PUMPS 

Galleti SCX - Air to Water Heat Pumps 

Galletti SCX 



Contents 

High configurability and efficiency at partial loads. 

SCX is the new series of air-cooled heat pumps and 

chillers designed to meet the requirements of efficiency, 

configurability, reliability, and ease of maintenance. 

The series comprises 22 models with cooling capacities 

ranging from 80 to 360 kW. They are available both in 

models with a cooling function only and in models with heat 

pump operation. 

The finned block heat exchanger is generously sized to 

optimize operation as both evaporator and condenser by 

type of fin and circuit. 

The solution of a single heat exchanger with delivered 

power of up to 160 kW was adopted due to the complete 

accessibility to the internal water and cooling circuit for 

the periodic inspection and maintenance operations. The 

solution of a single heat exchanger makes it possible to 

reduce the space necessary for the installation of the units. 

The electric axial fans with blades with an exclusive 

aerodynamic profile (HyBlade®) are characterized by 

extraordinary aeraulic and acoustic performance and 

represent the current state of the art for axial fans. 

The AxiTop® diffuser allows fan efficiency to be further 

increased with benefits in terms of noise level (together 

with condensation control) and unit efficiency. 

The SCX design adopts innovative solutions in the use and 

arrangement of the hydronic kit’s internal components, 

which is simplified to reduce the number of connections 

and minimize the water side head loss inside the machine. 

Every model is completely configurable with a choice of 

control, hydraulic, acoustic, and heat recovery options that 

do not result in any change to the dimensions. 

Advantages 

• Completely configurable range 

• Incorporable hydronic kits 

• HyBlade® fans 

• Tandem and trio solutions for high efficiency at partial loads 

• Remote connectivity with the most common protocols 

The choice to install scroll compressors in a tandem or trio 

configuration on the same cooling circuit is a move in the right 

direction in terms of machine efficiency at partial loads, which is 

the normal operating condition for air conditioning systems. 

52

Contents 


• Structure 

Made in galvanised steel sheet with a polyester powder coating for 

outdoors. Base with reinforcement modules for eliminating any 

deformities resulting from impacts sustained in the transportation 

and handling phase. 

• Scroll compressors 

Scroll type compressors in a tandem or trio configuration that can 

be sound insulated. The adopted components’ efficiency, reliability, 

and noise emission levels represent the state of the art for scroll 

compressors. 

• Electronic microprocessor controller 

In standard or advanced version, it enables the complete control 

of the units. It can be easily accessed through a polycarbonate 

flap with IP 65 protection rating. The electronic control system 

allows the setpoint to be adjusted automatically according to the 

outdoor temperature in order to reduce consumption and broaden 

Configuration 

The models are completely configurable by selecting the version 

and the options. An example of configuration is shown below. 

Optional 

Version 1 2 3 4 5 6 7 8 9 10 11 12 13 

SCX162CS0A 0 1 0 S C P 1 0 L 0 T 0 2 



SCX..CS0A 

SCX..CS1A 

SCX..CS2A 

SCX..CS3A 

SCX..CS4A 

SCX..CS5A 

400V-3N-50Hz power supply 

240V-3-50Hz power supply 

400V-3N-50Hz power supply + circuit breakers 

240V-3-50Hz power supply + circuit breakers 

400V-3-50Hz power supply + transformer 


+ circuit breakers 


SCX..HS0A 

SCX..HS1A 

SCX..HS2A 

SCX..HS3A 

SCX..HS4A 

SCX..HS5A 

400V-3N-50 Hz power supply 

240V-3-50 Hz power supply 

400V-3N-50 Hz power supply + circuit breakers 

240V-3-50 Hz power supply + circuit breakers 



+ circuit breakers 



0 Traditional A Electronic 240V 

2 - Pump and Accessories 

0 Absent 

1 Standard pump + expansion tank + filling tap 

2 Dual standard pump + expansion tank + filling tap 

3 HP pump + expansion tank + filling tap 

4 Dual HP pump + expansion tank + filling tap 

5 Option 1 + inverter (only with advanced microprocessor) 




3 - Inertial Buffer Tank 

0 Absent S Present 

4 - Partial Heat Recovery (the condensation control must be added) 

0 Absent 

D Desuperheater with pump contact (recovery 25%) 


0 Absent 

C Condensation control with fans adjusted by potentiometer 

E Condensation control with BLDC fans 


the working temperature range. The advanced version makes it 

possible to construct LAN networks for the parallel control of 4 

units and the management of BACNET and LON communication 

protocols, as well as the modulation of the pump assembly, of the 

Smart Defrost System. 

• Fan drive assembly 

Electric fan with 6-pole external rotor motor directly keyed to 

the axial fan, with internal thermal protection on the windings, 

complete with safety grille and dedicated supporting structure. 

Electric fans with BLDC motor are available on request. 

• Heat exchanger 

Made of 8mm diameter copper pipes and aluminium fins. The 

special engineering of the heat exchangers allows defrost cycles 

to be carried out at maximum speed in the models with heat pump 

operation, which brings clear benefits in terms of the integrated 

efficiency of the whole cycle. 


0 Absent 

E For units with evaporator only 

P For units with evaporator, pump and expansion tank 

S For units with evaporator, pump, expansion tank and tank 


0 Absent 

1 Sound attenuation of the fans (AXITOP®) 


3 Opt 1 + Opt 2 


0 None 


R Filter taps 

9 - Remote Control 

0 Absent 

2 Output RS485 (Modbus or Carel protocol) 


M BASE microprocessor remote control (Modbus disabling) 

X ADVANCED microprocessor remote control 

L LON FTT 10 serial card 

B BACNET serial card 


0 Standard 

R Copper 


I Hydrophilic 


11 - Protection of Heat Exchangers 

0 Absent 

G Protective grille 

T Anti-hail-proof 


0 Absent 

1 Power factor correction capacitors 

2 Soft starter 

3 Power factor correction capacitors + soft starter 

4 Low Air to Water temperature (crankcase heating element) 

5 Opt 4 + Opt 2 


1 BASE control microprocessor 

2 ADVANCED control microprocessor 

3 ADVANCED control microprocessor + GSM kit 

Accessories 

A Base rubber vibration dumpers 

B Base spring vibration dumpers 

C Pair of VIC-TAULIC quick couplings 

D Service kit for diagnosis 

E ON/OFF status of the compressors 

F Remote control for power step limits 

G Configurable digital 

alarm card 

H Unit lifting pipes 

- MYCHILLER BASE* 

- MYCHILLER PLUS* 

*(RS485 is a mandatory 

accessory) 

HEAT PUMPS 

53

HEAT PUMPS 


Rated Technical Data SCX-C (Cooling only versions) 

Contents 

Model 082 092 102 112 122 142 162 

Product Code SCXCS082 SCXCS092 SCXCS102 SCXCS112 SCXCS122 SCXCS142 SCXCS162 


Cooling capacity 1 E kW 78.2 94 98.6 111 121 135 153 

Power supply 1 E kW 27.1 34.5 34.4 37.8 42.8 51.1 56.5 

EER 1 E 2.88 2.73 2.87 2.93 2.83 2.64 2.72 

ESEER E 3.81 3.59 3.49 3.90 3.76 3.41 3.79 

Eurovent Efficiency Class C C C B C D C 

Water flow 1 l/h 12909 15523 16433 18479 20203 22410 25069 


Standard pump available pressure head 1 kPa 138 117 110 106 96 172 168 

Maximum current absorption A 69 76 78 90 99 111 123 

Start up current A 189 269 237 279 286 329 329 

Start up current with softstarter kit A 168 253 214 257 259 296 296 

No. of compressors / circuits 2/1 2/1 2/1 2/1 2/1 2/1 2/1 

Water tank volume dm3 200 200 340 340 340 340 340 

Expansion vessel dm3 12 12 12 12 12 12 12 

Sound pressure level 2 dB(A) 80 83 85 86 86 86 86 

Operating weight of base unit kg 655 735 735 735 1015 1060 1090 

Operating weight of unit with pump and full tank kg 890 971 1112 1112 1392 1440 1470 

Model 174 194 204 192 212 243 214 224 

Product Code SCXCS174 SCXCS194 SCXCS204 SCXCS192 SCXCS212 SCXCS243 SCXCS214 SCXCS224 


Cooling capacity 1 E kW 173 184 194 185 199 233 208 222 

Power supply 1 E kW 61.3 61.1 66.5 62.9 69.3 82.6 71.2 76.1 

EER 1 E 2.83 3.02 2.92 2.94 2.88 2.83 2.92 2.91 

ESEER E 3.82 3.94 4.15 4.09 4.02 3.8 4.16 4.2 

Eurovent Efficiency Class C B B B C C B B 

Water flow 1 l/h 30559 32764 34053 30785 33188 37977 35375 37984 


Standard pump available pressure head 1 kPa 150 137 124 172 177 168 154 145 

Maximum current absorption A 151 149 159 142 155 194 192 218 

Start up current A 288 290 295 420 431 376 337 344 

Start up current with softstarter kit A 230 231 233 386 389 312 275 279 

No. of compressors / circuits 4/2 4/2 4/2 2/1 2/1 3/1 4/2 4/2 

Water tank volume dm3 750 750 750 600 600 600 750 750 

Expansion vessel dm3 24 24 24 24 24 24 24 24 

Sound pressure level 2 dB(A) 84 86 86 88 90 88 87 88 

Operating weight of base unit kg 1442 1462 1462 1450 1400 1600 1472 1622 

Operating weight of unit with pump and full tank kg 2266 2286 2286 2050 2101 2170 2366 2366 

Model 244 264 284 304 324 344 364 

Product Code SCXCS244 SCXCS264 SCXCS284 SCXCS304 SCXCS324 SCXCS344 SCXCS364 


Cooling capacity 1 E kW 231 264 282 302 316 341 353 

Power supply 1 E kW 82.1 95.9 103 109 115 126 134 

EER 1 E 2.81 2.76 2.74 2.78 2.75 2.71 2.63 

ESEER E 4.08 3.99 3.58 3.64 3.6 3.75 3.65 

Eurovent Efficiency Class C C C C C C D 

Water flow 1 l/h 37554 43886 47205 50072 52134 56162 58226 


Standard pump available pressure head 1 kPa 147 158 148 139 140 133 122 

Maximum current absorption A 192 218 229 241 253 267 306 

Start up current A 351 365 408 416 426 428 526 

Start up current with softstarter kit A 281 285 298 324 327 328 419 

No. of compressors / circuits 4/2 4/2 4/2 4/2 4/2 4/2 4/2 

Water tank volume dm3 750 750 750 750 750 750 750 

Expansion vessel dm3 24 24 24 24 24 24 24 

Sound pressure level 2 dB(A) 88 88 89 89 89 91 92 

Operating weight of base unit kg 1622 1882 1914 1949 1949 1949 1949 

Operating weight of unit with pump and full tank kg 2480 2480 2800 2835 2835 2870 2870 

1 

Water temperature 12/7°C; outdoor air temperature 35°C (14511:2011). 2 Sound power level measured according to UNI EN ISO 9614. E EUROVENT certified data 

54

Contents 

SCX-H (Versions with reversible heat pump) 


HEAT PUMPS 

Model 082 092 102 112 122 142 162 174 194 204 192 

Product Code SCXHS82 SCXHS92 SCXHS102 SCXHS112 SCXHS122 SCXHS142 SCXHS162 SCXHS174 SCXHS194 SCXHS204 SCXHS192 


Cooling capacity 1 E kW 74.7 89.8 95 107 117 130 145 169 180 187 178 

Power supply 1 E kW 27.3 34.5 34.7 38.6 43.7 51.6 57.8 61.5 62.7 66.8 61.4 

EER 1 E 2.74 2.6 2.74 2.77 2.67 2.55 2.51 2.74 2.88 2.81 2.9 

ESEER E 3.63 3.45 3.35 3.71 3.59 3.16 3.51 3.7 3.76 3.99 4.07 

Eurovent Efficiency Class C D C C D D D C C C B 

Water flow 1 l/h 12909 15523 16433 18479 20203 22152 25069 29128 31126 32350 30785 

Water pressure drop 1 E kPa 17 24 27 22 26 31 25 38 43 38 18 

Standard pump available 

pressure head 1 kPa 148 118 112 110 100 177 175 156 140 130 161 

Heating capacity 3 E kW 88.3 106 109 125 137 156 173 195 207 215 206 

Power input 3 E kW 28.1 34.6 35.7 39 43.4 49.6 54.9 63.5 65.7 70.7 61.7 

COP 3 E 3.14 3.07 3.05 3.2 3.15 3.14 3.15 3.07 3.15 3.05 3.34 

Eurovent Efficiency Class B B B B B B B B B B A 

Water flow 3 l/h 15142 18199 18649 21405 23428 26670 29653 34140 36210 37720 35315 




Maximum current 

absorption 

A 69 76 78 90 99 111 123 151 149 159 142 

Start up current A 189 269 237 279 286 329 329 288 290 295 420 

Start up current with 

softstarter kit 

A 168 253 214 257 259 296 296 230 231 233 386 

No. of compressors/circuits 2/1 2/1 2/1 2/1 2/1 2/1 2/1 4/2 4/2 4/2 2/1 

Water tank volume dm3 200 200 340 340 340 340 340 750 750 750 600 

Expansion vessel dm3 12 12 12 12 12 12 12 24 24 24 24 

Sound pressure level 2 dB(A) 80 83 85 86 86 86 86 84 86 86 88 

Operating weight of 

base unit 

Operating weight of unit 

with pump and full tank 

kg 655 735 735 735 1015 1060 1090 1445 1465 1465 1400 

kg 890 971 1112 1112 1392 1440 1470 2266 2286 2286 2050 

Model 212 243 214 224 244 264 284 304 324 344 364 

Product Code 

SCXHS212 SCXHS243 SCXHS214 SCXHS224 SCXHS244 SCXHS264 SCXHS284 SCXHS304 SCXHS324 SCXHS344 SCXHS364 


Cooling capacity 1 E kW 192 220 195 209 222 254 274 290 302 325 336 

Power supply 1 E kW 71.3 84.9 72.7 78.4 82.5 97 103.7 109.7 117.8 128.6 134.4 

EER 1 E 2.7 2.59 2.68 2.67 2.73 2.62 2.64 2.64 2.56 2.53 2.5 

ESEER E 3.78 3.49 3.8 3.79 3.74 3.8 3.45 3.46 3.35 3.51 3.42 

Eurovent Efficiency Class D D D D C D D D D D D 

Water flow 1 l/h 33188 37977 33606 36085 38280 43886 47205 50072 52134 56162 58226 




Heating capacity 3 E kW 224 260 231 244 256 293 318 339 352 378 392 

Power input 3 E kW 70.4 81.8 75 78.8 82.7 99.6 106.7 117.1 118.6 122.7 128.1 

COP 3 E 3.18 3.18 3.08 3.1 3.09 2.94 2.98 2.9 2.97 3.08 3.06 

Eurovent Efficiency Class B B B B B C C C C B B 

Water flow 3 l/h 38349 44655 40490 42770 44760 53570 55740 59430 61800 66340 68770 




Maximum current 

absorption 

A 155 194 192 218 192 218 229 241 253 267 306 

Start up current A 431 376 337 344 351 365 408 416 426 428 526 

Start up current with 

softstarter kit 

A 389 312 275 279 281 285 298 324 327 328 419 

No. of compressors/circuits 2/1 3/1 4/2 4/2 4/2 4/2 4/2 4/2 4/2 4/2 4/2 

Water tank volume dm3 600 600 750 750 750 750 750 750 750 750 750 

Expansion vessel dm3 24 24 24 24 24 24 24 24 24 24 24 

Sound pressure level 2 dB(A) 90 88 87 88 88 88 89 89 89 91 92 

Operating weight of 

base unit 

Operating weight of unit 

with pump and full tank 

kg 1400 1465 1515 1515 1625 1625 1945 1980 1980 2015 2015 

kg 2101 2170 2366 2366 2480 2480 2800 2835 2835 2870 2870 

1 

Water temperature 12/7°C; outdoor air temperature 35°C (14511:2011). 

2 

Sound power level measured according to UNI EN ISO 9614. 

3 

Water temperature 40/45 °C, outdoor air temperature 7 °C D.B. - 6 °C W.B. (14511:2011). 

E 


55

HEAT PUMPS 



SCX 082 - 092 

Contents 

2577 

1286 

1577 

2 

AIR 

9 

1 

3 

7 

66 

1208 

689 

495 

60 

150 

155 

121 

4 

AIR 

2173 

218 2114 

218 

366 1819 

366 

5 

8 

6 

10 

Legend 

1 Water inlet (Victaulic 2”) 

2 Water outlet, evaporator only (Victaulic 2”) 

3 Water outlet (Victaulic 2”) 

4 Water filling 

1 m 

5 Water drainage 

6 Fastening points 



9 User interface 

10 Power supply input 

1,5 m 

1 m 

1,5 m 

SCX 106 - 162 

Legend 


2 Water outlet, 

evaporator only (Victaulic 2” ½) 

3 Water inlet (Victaulic 2” ½) 

1490 

2 

3503 

3 

7 

1286 

AIR 

8 

4 Water outlet (Victaulic 2” ½ ) 



1 

80 

1354 

4 

AIR 

26 

2168 





A Version with 2 pumps 

B Version with 

buffer tank only 

1208 

689 

494.5 

491.5 800 920 800 491.5 

302 

6 

149 

2899 302 

6 

5 

1236 

9 

A 

B 

4 

4 

10 

549 

236.5 

1 m 

1615 

1490 

1,5 m 

1,5 m 

1 m 

56

Contents 


HEAT PUMPS 

SCX 174 - 244 

1746 

4524 

8 

259 805 

2 3 

406 

2167 

AIR 

9 

29 

60 

AIR 

AIR 

1 

128 

661 

1202.5 

1571.5 

1687 436.5 1480 740 1480 387 6 

10 

581.5 1190 1030 1190 532 

4 

5 

B 

Legend 



3 Water outlet, evaporator 

only version (Victaulic 3”) 









B Version with 

buffer tank only 

7 

A 

4 

1 m 

4 

251.5 

1,5 m 

950 

1,5 m 

791 

1 m 

467 

SCX 264 - 364 

2194 4507 

1 

4 

5 

2174 

41 

2 

1585 

AIR 

AIR 

674.5 

598 

2140 

417.5 1480 740 1480 387 

3 

562.5 

1190 1030 1190 532 

6 

A 

Legend 

5 








1,5 m 

1 m 

1,5 m 

1 m 

674.5 

704 

57

HEAT PUMPS 

Contents 

58

Contents 

Water to Water Heat Pumps 

HEAT PUMPS 

Water to Water 

Heat Pumps 

CO 2 

Heat Pump 

Revere CO 2 

pg 60 

R134A Heat Pump 

Revere R134A pg 62 

59

HEAT PUMPS 

Revere CO 2 

- Water to Water Heat Pumps 

Revere CO 2 


Heat Pump 

Industrial and Commercial Hot Water 

and Chilled Water Supply 

Contents 

AS3498 Lic WM71504 

Boiler and Water Chiller 

All-in-One Machine 

Performs the functions both of Boiler and 

Water Chiller all in one machine. 

Both 65º hot water and 7º chilled water can be supplied 

simultaneously. 

Effective Utilization 

of Unused Waste Heat 

Unused low temperature waste heat from the plant or 

cooling water can be used as heat source. 

Compact Design 

Easy installation due to a 10% reduction in size. 

Applications 

Highest 

Total COP 

9.3 

Reduction of Existing Water Chiller Power 

Consumption 

Performance of existing water chiller is increased and also its 

power consumption is decreased by utilizing its chilled water 

as a heat source. 

Equalization of Electricity Power Load 

Storing hot water and chilled water using off peak tariff 

of electricity, the peak cut of electricity demand can be 

achieved. 

Hot water and Chilled water supply 

12℃ 

65℃, 90 ℃ 

7℃ 

Use of chilled water 

Fermentation tank cooling 

Jacket cooling 

Vacuum cooling 

Domestic 

hot water 

Use of hot water 

Hot water tank 

Water 

supply 

AHGWW-HTC 

Space cooling 

Product cooling 

Product heating 

Washing machine parts 

Machine washing 

and cleaning 

Pre-heating of 

Boiler water supply 

Water chiller 

12℃ 

Chilled water tank 

7℃ 

Hot water and Chilled water supply 

Domestic 

hot water 

65℃, 90 ℃ 

Hot water tank 

Water 

supply 

Markets 

Food & Beverage processing plants, Abattoirs, Automotive and 

various Manufacturing plants, Hotels, Hospitals, Aquatic Centres, etc. 

AHGWW-HTC 

3712℃ 

Heat Recovery 

Air-compressor cooling water 

Combustion furnace cooling water 

Water chiller cooling water 

Unused energy utilization 

Septic tank waste heat recovery 

Ground water 

Geothermal heat 

60

Contents 


Revere CO 2 

- Water to Water Heat Pumps 

HEAT PUMPS 

Model Revere CO 2 

Power 

3-phase 415V AC 50Hz/60Hz 

Water Heat Source Brine 1 Chilled Water 2 Chilled Water 3 Heat Recovering 4 

Temperature In / Out (ºC) -5 / -9 12 / 7 15 / 10 37 / 32 

Water (ºC) 17 17 17 17 

Capacity 

Heating (kW) 53.2 85.8 91.9 116.8 

(Hot Water Supply Cooling (kW) 37.9 64 69.5 94.8 

65ºC) 

Power Consumption (kW) 18.4 22.1 22.4 22.7 

Outer Dimensions (mm) W1,100 × L1,200 × H1,893 

Weight (kg) 

985 (Net), 1,007 (Operating) 

Compressor Motor 25kW x 4P 

Star-up Method 

Inverter 

External Connection Water Inlet Rc3/4 (20A tap female, SUS316) 

Hot Water Outlet 

Rc3/4 (20A tap female, SUS316) 

Chilled Water Inlet 

Chilled Water Outlet 

Rc2 (50A tap female, SUS316) 

Rc2 (50A tap female, SUS316) 

Heat Exchanger Hot Water Chilled Water 

Operating Ranges Fluid Water Water / Brine 

Inlet Temp. (ºC) 5 to 65 -5 to 37 

Outlet Temp. (ºC) 65 or 90 -9 to 32 

Flow Rate (L/min) 5 to 35 100 to 284 

Water Pressure (MPa) 0.25 to 0.5 0.1 to 1.0 

Ambient Temp. (ºC) -10 ~ 43 

Colour Enclosure / Base Munsell N8.0 approximate color / Munsell N1.0 approximate color 

Noise (dBA) 57 

Note: Please install an approval pressure limiting valve if the inlet water pressure is to exceed the values. 


Outer Dimensions 

Maintenance Space 

1100 

1893 

1200 

1100 

Front View 

Rear View 

900 600 

1100 

Top View 

Subject to change without notice. 

Maintenance Space 

61

HEAT PUMPS 

Revere R134A - Water to Water Heat Pumps 

Revere R134A 


Heat Pump 

With the outlet water temperature from 

55ºC to 80ºC, as well as space cooling, 

Revere R134A Water to Water Heat 

Pump is clearly your smartest choice. 

Contents 

High Efficiency 

The unit is capable of producing high temperature outlet 

water and simultaneously performs free cooling. The 

double effects that it uses the same amount of energy but 

provides both hot water and cool air which can lead to 

greater cost-savings. 

Flexible Installation 

The unit can adjust to various installation locations, such as 

inside a basement, on the ground floor and even on the roof, 

which makes it flexible for fast, low-cost installation. 

Combination with Existing Air Cooled Water Chiller 

When the unit is working for water heating and space 

cooling, the existing air cooled water chillers can be shut off 

according to different requirement and condition. 

Environmental Friendly 

With hi-output, the energy efficiency and environmental 

value of the unit can radically surpass that of a single effect 

system which can only produce either hot water or cool 

air and traditional system that is driven by primary energy 

resources, which lessens the impact on the environment. 

High ROI 

The double effects and high COP offered by the unit is 

beneficial in lowering energy bills in the long run. 

Application in Various Projects 

The unit can be used in commercial and industrial projects, 

such as hotels, schools, holiday resorts and factories. 

Revere R134A 250S 500S 

Testing Condition 

Water Source Inlet/Outlet: 20/15ºC 

Heating Side Inlet/Outlet: 65/75ºC 

Heating Capacity(kW) 64.0 129.0 

Cooling Capacity(kW) 40.0 80.0 

Power Input(kW) 20.0 40.0 

IEER(W/W) 5.2 5.2 

Power Supply V/Ph/Hz 380~415/3/50 

Compressor Type 

Copeland R134a EVI Scroll 

Compressor Quantity 2 4 

Evaporator Type Tube in Shell Heat Exchanger 

Water Flow(m 3 /h) 6.8 13.6 

Connection Size(inch) 2.5 2.5 

Condenser Type Tube in Shell Heat Exchanger 

Water Flow(m 3 /h) 5.6 11.1 

Connection Size(inch) 2.5 2.5 

Noise dB(A) 56 58 

Refrigerant Type 

Controller 

R134a 

AHG Controller 

Suggest Outlet Water Temp. Range ºC 55 ~ 75 

Max. Outlet Water Temp. ºC 80 

Casing 

Galvanized Metal 

Net Dimensions(L/W/H) mm 1172/900/1365 1600/1130/1500 

Net Weight kg 455 866 

The data above is only a reference, for specific data, please refer to the nameplate on the unit. 

62

Contents 

Revere R134A - Water to Water Heat Pumps 

HEAT PUMPS 

63

HEAT PUMPS 

Heat Pump Application Examples - Air to Water Heat Pumps 

Heat Pump 


Comfort 

Air Conditioning for 

Residential Applications 

Contents 

Air conditioning plant with a multifunction heat pump, 

hydronic terminals and a DCV unit with heat recovery. 

The integrated HVAC control manages the heat pump, 

the back-up devices and the PV system to privilege 

the energy self-consumption. 

Centralized system with a multifunction heat pump for 

air conditioning by means of hydronic terminals and 

for swimming pool water heating. In the wellness area 

a dehumidifier treats the ambient air with renewal and 

heat recovery. A supervision system manages the whole 

plant to reach high efficiency levels. 

Data Center and 

Telecom Cooling 

Data Center cooling system with a water-towater 

chiller combined with a Free-Cooling kit 

and an external DryCooler. The chilled water 

ring provides cooling capacity to the CRAC 

units and recovers the heat rejected by the 

computers by a multifunction heat pump. A 

small server room is refrigerated by a split DX 

unit and a monobloc telecom unit is outdoor 

mounted to a shelter. 

64

Contents 

Heat Pump Application Examples - Air to Water Heat Pumps 

Air Conditioning 

of a Fitness & 

Wellness Center 

Air conditioning and DHW production plant for 

a fitness & wellness center. Two geothermal 

multifunction heat pumps provide cooling 

and heating to the hydronic terminals and 

the AHUs, warm up the swimming pool 

and produce DHW. The AHU, with onboard 

control, gives the needed comfort level to the 

swimming pool area and to the fitness area. 

HEAT PUMPS 

Process Cooling 

and Offices Air 

Conditioning 

Process cooling and air conditioning plant. 

Two multifunction geothermal heat pumps 

provide cooling to the industrial process, while 

recovering the heat rejection and transferring 

it to the hydronic terminal and the AHU. The 

offices get fresh air from the AHU while 

the sensible cooling capacity is provided by 

hydronic terminals. A small server room 

is refrigerated by a DX computer room air 

conditioning unit. 

Commercial 

Refrigeration and 

Shopping Center 

Air Conditioning 

Fully integrated plant for LT and NT 

refrigeration and for air conditioning. The 

heat recovered by the rejection from the 

refrigerated cabinets is used to heat up 

the shops by means of fancoils and water 

cassettes: the necessary cooling and heating 

capacity is provided by a multifunction heat 

pump while fresh air is treated by a rooftop 

with onboard Free-Cooling module with heat 

recovery. A small server room is refrigerated 

by an “in-rack” DX unit and a monobloc 

telecom unit is outdoor mounted to a shelter. 

65

Condensing & Conventional Boilers 

Contents 

CONDENSING & 

CONVENTIONAL BOILERS 

66

Contents 

Condensing Boilers 

CONDENSING & 



Condensing Boilers offer several significant advantages: 

• Lower emissions 

• Reduced fuel usage 

• Justified return on investment 

The “Greener” boiler technology utilised in condensing systems utilises the latent heat in flue gases 

which can lead to gross operating efficiencies of up to 98%. By using Condensing Technology, operating 

costs can be reduced by 15-20% resulting in substantial long term running cost savings. 

Eurogen 200-2160kW pg 70 

Euromax 175-1250kW pg 76 

Meridian 24-150kW pg 80 

Modulex EXT 150-1200kW pg 92 

Moorea I 125-600kW pg 104 Accessories pg 110 

67


Contents 

CONDENSING & 


Introduction to 


Condensing water heaters have been manufactured since the 1980s, and now 

represent a fully mature technology used extensively throughout the world. 

What is a Condensing Boiler? 

The condensing water heater is a system of technologies, 

consisting of the water heater itself fuelled by gas or 

oil, the flue stack, and the condensate collection system. 

Condensing water heaters operate at around 90-98% gross 

efficiency, compared with 80-85% gross efficiency for 

conventional water heaters. 

They achieve higher efficiencies by using newer technology 

and by condensing the water vapour that is produced during 

combustion and trapped in the flue gases. 

In traditional water heater technologies, the latent heat 

contained in the water vapour is allowed to escape through 

the flue. Condensing water heaters reclaim that latent heat 

by condensing the water vapour and transferring its heat 

to the return water via a secondary heat exchanger with a 

resultant increase in water heating efficiency. 

The flue stack temperature is considerably 

reduced and the return water temperature 

raised. Hence the term ‘Condensing Water 

Heater’. 

These potential efficiency gains are achieved if the water 

heater is operating in or near condensing mode, which 

requires the temperature of the water returning from the 

building to the water heater to be as low as possible. Having 

said that, condensing water heaters will achieve increased 

efficiencies over non-condensing water heaters even in 

a situation utilizing the existing building return water 

temperature, due to the larger surface area of the heat 

exchanger in a condensing water heater and the reduced 

flue temperature. 

Optimum return water temperatures are achieved when 

the return water is below the dew point of the water vapour 

in the flue gas. The dew point is determined by several 

variables, including altitude, outdoor air temperature, and 

the type of fuel the water heater consumes. The critical 

variable, however, is combustion efficiency: excess oxygen 

in the combustion process leads to lower efficiency and 

requires a lower dew point before condensation can 

begin. In general, with efficient combustion, return water 

temperatures (RWT) should be below 54°C, with lower RWT 

resulting in more condensation and greater efficiency. 

Condensing water heaters require Stainless Steel flues to 

prevent corrosion. The condensate produced is also slightly 

acidic so a condensate neutraliser is required before piping 

condensate to the drain. Plastic piping must be used for the 

condensate drain to prevent corrosion. 

Why is a condensing boiler “greener” than a 

non-condensing one? 

A condensing boiler makes better use of the heat that 

it generates from burning fuels such as gas or oil. In a 

conventional boiler some of this heat is wasted because 

the boiler releases very hot waste gases from its flue. A 

condensing boiler uses some of the heat from these waste 

gases to heat water returning from your central heating 

system, so it requires less heat from the burner. This makes 

your condensing boiler more efficient. The efficiency of a 

boiler is normally expressed as a percentage – some new 

condensing boilers can be up to 98% efficient compared to 

non-condensing ones that are around 80 to 83% efficient, 

and older boilers that are only 70% to 75% efficient. 

How does a condensing boiler reduce carbon 

dioxide emissions? 

BOILER EFFICIENCY % 

110 

100 

90 

GROSS EFFICIENCY 

NET EFFICIENCY 

80 

20 30 40 50 54 60 70 80 

RETURN WATER TEMPERATURE ºC 

Carbon dioxide savings come from burning less fuel to 

meet your heating needs. Imagine that one unit of fuel 

potentially contains enough energy to heat your home for 

an hour. Burning that fuel in a boiler that is 100% efficient 

would heat your home for an hour. Burning that unit of fuel 

in a boiler that is 90% efficient would only give you enough 

to heat your home for 54 minutes, and if it’s 75% efficient 

you’d only get 45 minutes per unit. So, the lower the 

efficiency of your boiler the more units of fuel you need to 

burn to keep your home at the right temperature. The more 

fuel you burn, the more carbon dioxide you emit. 

68

Contents 


How does a condensing boiler work? 

Like conventional boilers, a condensing boiler burns fuel 

to heat the water in a metal heat exchanger. A condensing 

boiler uses an extra-large heat exchanger (or sometimes 

two) to maximize heat transfer from the burner and recover 

useful heat from the flue gases. In condensing mode the 

flue gases give up their latent heat and can exit the flue in a 

visible plume of water vapour at 70-90°C – they’re usually 

180-200°C in a non-condensing boiler. At the same time 

condensate, is produced which must be drained away. 

Are they only efficient when in 

condensing mode? 

A condensing boiler is always more efficient than a 

conventional non-condensing boiler, due to its larger and 

more efficient heat exchanger. The rating represents the 

average annual efficiency the boiler can achieve in typical 

conditions, making reasonable assumptions about how 

it’s used, the climate, controls, and other influences. This 

indicates how efficient your boiler will be taking into account 

its efficiency in condensing and non condensing mode. 

Is it worth changing a five-year-old 

conventional boiler for a new 

condensing one? 

Gas prices are rising, so efficiency is crucial. To comply 

with new building regulations, new or replacement boilers 

must have an energy gross efficiency of at least 90%. 

Condensing Boiler Vapour Plume 

They produce a visible plume of vapour when they are 

operating, so the flue terminal needs to be sited carefully to 

avoid the steam creating a nuisance. 

They produce an acidic condensate that must be passed 

through a condensate neutraliser and plumbed into a 

suitable drain. 

CONDENSING & 


Latent Heat of 

Evaporation 10.2% 

Fume 

Latent Heat of 

Evaporation 

Fume 

Insulation 

and loss 

through 

convection 

& radiation 

< 1% 

CONVENTIONAL 

BOILER BOILER 

Latent Heat 

Losses 2% 

Condensing 

CONDENSING CONDENSING 

BOILER BOILER 

Rated Thermal Efficiency 78% Rated Thermal Efficiency

Eurogen - Condensing Boilers 

Contents 

CONDENSING & 


Eurogen 

Condensing Boilers 200 - 2160kW 

High Water Volume Condensing Boilers with 

large capacity range. 

Eurogen Condensing Boilers are distinguished by their 

engineering excellence and superior design features. 

Manufactured in Europe by Unical and exclusively 

distributed in Australia by AHG, Eurogen provides 

a premium high efficiency heating solution built for 

performance and longevity. Its durability can be attributed 

to its full 316 Stainless Steel combustion chamber and heat 

exchanger, while its high efficiency is derived from its three 

pass design and unique, patented heat transfer system. 

Available in output ranges from 200kW to 2160kW, Eurogen 

Condensing Boilers constitute a range of reverse-flame 

condensing boilers which fully conform to Australian 

Standards and are manufactured from AISI 316L stainless 

steel . The third pass of exhaust gases is through stainless 

steel tubes fitted with aluminium fins to maximise heat 

exchange. The boiler includes low temperature (Rbt) and 

high temperature (Rat) connections to keep return water 

temperatures as low as possible to maximise condensing 

benefit. Together with very low standby and chimney 

losses, net efficiencies of up to 109% can be achieved. 

Two return water connections are available allowing the 

differentiation of high or low temperature return water 

to create the optimum efficiency result depending on the 

application. 

Supplied with 1:5 modulating power burners. 

Certified 

Efficiency 

 


Type 

Range 

Efficiency 

Fuel Type 

Condensing Forced Draft 

200-2160kW 

Gas Approval Type Type B 

109% (Nett) 98% (Gross) 

Natural Gas, LPG, 

Dual Fuel (Natural Gas/LPG) 


Modulation 1:5 

Cascadeable Yes 

Max Pressure 600kpa 

Low Nox Yes 

Building J Code Yes 


70



CONDENSING & 


Full 316 Stainless 

Steel combustion 

chamber and heat 

exchanger for 

maximum 

durability 

Enterprise Power 

burner with dual 

fuel standby 

capability 

High water content allows greater 

water temperature and flow variations 

Patented Multi Radial flue gas 

fins for superior heat transfer 

Features 

• High efficiency condensing boiler ≤ 109% Nett. Exceptional 

heat transfer is achieved via the patented multi radial flue 

gas fins. Eurogen also incorporates 100 mm heat insulation 

to minimise radiation losses. 

• Balanced combustion chamber geometry for rapid heat 

transmission and clean and complete combustion. 

• Dual fuel burner configurations are available 

• Compact footprint and versatile design - three pass flue 

gas exhausts in two cylindrically arranged, stacked boiler 

drums. The 860mm boiler width (up to EG570) allows ease 

of plant room access and installation and the door can be 

hinged as right or left handed. 

• Large water volume provides good thermal stratification 

and allows the system to operate with just one primary 

pump, thereby reducing power usage. 

• Variable water flow allows varying of the water flow rate 

to match the combustion rate of the burner. As the burner 

modulates from high fire to low fire, the water flow can 

be varied from high to low. This maintains a constant ΔT 

through the boiler. Whether 20° or 30° ΔT is required, this 

can be maintained through all phases of combustion by 

varying the water flow to match the burner modulation. This 

maximises the amount of heat extracted from the flue gases 

and thereby increases efficiency. 

Advantages 

• Fully Stainless Steel - All parts of the Eurogen Condensing 

Boiler that come in contact with flue gas or condensate 

are made from stainless steel. This feature ensures the 

longevity of the boiler through resistance to corrosion from 

the acidic condensate created inside the boiler. 

• Certified Efficiency - The Eurogen Condensing Boiler is 

manufactured in Italy and is professionally designed and 

built to perform to specification. Certified test results 

from a reputable laboratory are available prove its stated 

efficiency. 

• No return water temperature limitation - Eurogen 

accommodates lower return water temperatures and can 

operate at a ΔT of up to 30°C. 

71



Technical Drawings 

CONDENSING & 


High Temperature 

C.H Return 

Low Temperature 

C.H Return 

C.H. flow 

Smoke 

Chamber 

Flue 

Connection 

Condensate 

Evacuation 

Boiler Drain 

Burner 

Progressive 

Smoke Pipe 

The Eurogen Condensing Fire Tube Boiler combustion process is designed to maximise efficiency 

and performance. The hot combustion gases first pass down the centre and return along the wall 

of the combustion chamber. On reaching the specially contoured door of the boiler the gases are 

directed down into the stainless steel condensing tubes which comprise the heat exchanger and 

feature aluminium internal fins designed to maximise heat extraction. 


Product Code 

Output 

50/30°C 

kW 

Net 

Efficiency 

50/30°C 

% 

Net 

Efficiency 

Part Load 

50/30ºC 

% 

Output 

80/60°C 

kW 

Net 

Efficiency 

80/60°C 

% 

Nominal 

Input 

MJ/hr 

Modulation 

Ratio 

Flow Rate 

Min/Max 

L/s** 

Waterside 

Pressure 

Drop kPa* 

Combustion 

Side 

Pressure 

Drop mbar 

Total 

Water 

Volume 

litres 

Dry 

Power Supply 

Weight 

V/A/Hz 

Kg 

EG200NG280MMDSAUA032 200 107 109 182.7 97.72 672.84 1.5 1.20/2.39 3.8 1.86 260 525 240/0.5/50 

EG290NG400MMDMAUA032 290 107 109 265.6 98.2 975.6 1:5 1.73/3.46 2.5 2.54 305 660 240/0.9/50 

EG400NG550MMDSAUA140EA 400 107 109 367.1 98.2 1345.68 1:5 2.39/4.78 3.2 3.23 332 800 240/0.62/50 

EG480NG550MMDSAUA140EA 480 107 109 440.7 99.2 1614.96 1:5 2.87/5.73 2 3.43 544 1007 240/1.24/50 

EG570P61MMDSAUA150EA 570 107 109 523.3 98.2 1917.72 1:5 3.41/6.81 2.9 3.92 515 1137 240/2.2/50 

EG700P65MMDSAUA150EA 700 107 109 642.6 98.2 2355.12 1:5 4.18/8.36 3 4.6 625 1376 415/4.4/50 

EG900P71MMDSAUA150EA 900 107 109 826.2 98.2 3027.96 1:5 5.38/10.75 3.7 5.88 664 1613 415/4.4/50 

EG1140P71MMDSAUA150EA 1140 107 109 1046.6 98.2 3835.44 1:5 6.81/13.62 3.5 7.35 1107 2158 415/6.0/50 

EG1420R75AMMDSAUA165EA 1420 107 109 1303.6 98.2 4777.56 1:5 8.48/16.96 4 8.82 1157 2443 415/6.0/50 

EG1820R92AMMDSAUA180EA 1820 107 109 1670.8 98.2 6123.24 1:5 10.87/21.74 3.9 9.02 1936 3458 415/8.0/50 

EG2160R92AMMDSAUA180EA 2160 107 109 1983 98.2 7267.32 1:5 12.90/25.80 5.5 9.8 1904 3765 415/11.0/50 

* Pressure losses for a water flow rate corresponding to a Δt of 15K 

** Minimum flow rate is for low load only. 

72




EG200 – EG2160 

CONDENSING & 


Legend 

1 Panel board 

2 Flame sight glass 

T1 C.H. flow 

T2 Low temperature C.H. return 

T3 High temperature C.H. return 

T4 Expansion vessel connection 

T5 Boiler drain 

T6 Burner connection 

T7 Flue connection 

T8 Condensate drain 

Model A B C D E F G H I L M N O P* Q* R* S 

EG200 720 1450 1132 190 205 48 374 790 255 320 250 625 255 1248 610 1311 45 

EG290 790 1465 1282 190 235 55 402 900 231 359 250 625 275 1385 680 1314 60 

EG400 790 1755 1282 190 235 65 402 900 271 379 450 655 275 1385 680 1614 60 

EG480 854 1770 1472 190 270 67 494 1062 306 358 500 606 306 1585 750 1606 65 

EG570 854 1940 1472 190 270 67 490 1062 306 358 500 776 306 1585 750 1776 65 

EG700 894 1970 1612 190 292 65 523 1161 275 388 500 807 316 1715 790 1787 65 

EG900 894 2340 1612 190 292 65 523 1161 405 388 500 1047 316 1715 790 2157 65 

EG1140 1064 2360 1802 190 317 57 551 1287 289 624 900 547 390 1911 960 2157 55 

EG1420 1064 2740 1802 190 317 57 552 1287 459 624 900 757 390 1911 960 2537 55 

EG1820 1204 2980 2052 190 387 53 681 1493 372 563 785 1260 432 2165 1100 2752 95 

EG2160 1204 3204 2052 190 387 54 681 1493 371 563 1010 1260 432 2165 1100 2977 95 

All measurements in mm. *Minimum dimensions for boiler room access requirements 

T1 T2 T3 T4 T5 T6 T7 T8 

Model 

ISO 7/1UNI 2276 PN6 ISO 7/1 Ø mm Øi mm Øe mm 

EG200 DN 65 DN 65 DN 65 Rp 1½ Rp ¾ 180 202 40 

EG290 DN 80 DN 80 DN 80 Rp 2 Rp 1 180 252 40 

EG400 DN 80 DN 80 DN 80 Rp 2 Rp 1 180 252 40 

EG480 DN 100 DN 100 DN 100 Rp 2 Rp 1 220 302 40 

EG570 DN 100 DN 100 DN 100 Rp 2 Rp 1 220 302 40 

EG700 DN 125 DN 125 DN 125 DN 65 Rp 1 270 352 40 

EG900 DN125 DN125 DN125 DN 65 Rp 1 270 352 40 

EG1140 DN 150 DN 150 DN 150 DN 80 Rp 1½ 320 402 40 

EG1420 DN 150 DN 150 DN 150 DN 80 Rp 1½ 320 402 40 

EG1820 DN 200 DN 200 DN 200 DN 100 Rp 1½ 320 452 40 

EG2160 DN 200 DN 200 DN 200 DN 100 Rp 1½ 320 452 40 

73



Case Studies 

CONDENSING & 


Ravenhall Prison 

3 x Eurogen 2160kW 

Opening in late 2017, Ravenhall 

Correctional Centre redefines 

the role of the modern prison in 

contributing to safer Victorian 

Communities. AHG supplied 3x 

Eurogen Condensing Boilers to 

provide heating & domestic hot 

water for the prison buildings. 

567 Collins Street, 

Melbourne 



567 Collins Street is a 26-level 

premium grade office tower 

located on Melbourne’s prestigious 

Collins Street, between King and 

Spencer streets. AHG supplied 

3x Eurogen Condensing Boilers 

to provide 4,200kW of heating & 

domestic hot water. 

74



Canberra Airport 



With the aim of developing 

Australia’s Greenest airport, 

the New Canberra Airport was 

designed to a high environmental 

standard, employing a variety of 

building and services systems 

including high quality and long life 

building materials. AHG supplied 

3x Eurogen Condensing Boilers 

to provide heating to the terminal 

buildings. 

CONDENSING & 


75

Euromax - Condensing Boilers 

Contents 

CONDENSING & 


Euromax 

Condensing Boilers 175 – 1250kW 

High Water Volume Condensing Boilers with 

large capacity range. 

Euromax Condensing Boilers are distinguished by their 

robust engineering, cost effective design and wide range of 

features. Manufactured to AHG specifications and exclusively 

distributed in Australia by AHG, Euromax provides a high 

efficiency heating solution built for performance and 

longevity. Its durability can be attributed to its full 316 

Stainless Steel combustion chamber and heat exchanger, 

while its high efficiency is derived from its three pass design 

and effective heat transfer system. 

Available in output ranges from 175kW to 1250kW, Euromax 

Condensing Boilers constitute a range of 3 pass condensing 

boilers which fully conform to Australian Standards and are 

manufactured from AISI 316L stainless steel . The third pass 

of exhaust gases is through stainless steel tubes fitted with 

stainless steel fins to maximise heat exchange. The boiler 

includes low temperature (Rbt) and high temperature (Rat) 

connections to keep return water temperatures as low as 

possible to maximise condensing benefit. Together with very 

low standby and flue losses, net efficiencies of up to 107% 

can be achieved. Two return water connections are available 

allowing the differentiation of high or low temperature return 

water to create the optimum efficiency result depending on 

the application. 

Supplied with 1:5 modulating power burners 


Type 

Range 

Efficiency 

Fuel Type 

Outdoor option 


175-1250kW 

108% (Nett) 97% (Gross) 

Natural Gas, LPG, Light Oil, Dual Fuel 

(NG/LPG or NG/Light OIl) 

Yes 

Gas Approval Type Type B 




Low Nox Yes 

Building J Code Yes 


76

Contents 


Features 

• High efficiency condensing boiler ≤ 98% Net 

• No return flow temperature limitation 

• Three pass flue gas exhausts in two cylindrically arranged, 

stacked boiler drums 

• All parts in contact with flue gas or condensate are made from 

stainless steel 

• Minimum load according to the modulation range of the burner 

• Large water volume for good thermal stratification 

• Balanced combustion chamber geometry for rapid heat 

transmission and clean and complete combustion 

• Optimised 860mm boiler width for ease of installation 

• Operating overpressure 600 kPa 

• 100 mm heat insulation for the minimisation of radiation losses 

• Boiler doors hinged right hand or left hand 

Advantages 

• Fully Stainless Steel - All parts of the Euromax Condensing 

Boiler that come in contact with flue gas or condensate 

are made from stainless steel. This feature ensures the 

longevity of the boiler through resistance to corrosion from 

the acidic condensate created inside the boiler. 

• No return water temperature limitation - Euromax 

accommodates lower return water temperatures and can 

operate at a ΔT of up to 30°C. 

• Suitable for Dual Fuel applications - The Euromax range 

is suitable for use with natural gas, LPG or light oil burners 

and has been successfully used for dual fuel (natural gas/ 

LPG or natural gas/light oil) applications where backup fuel 

supply is required, such as hospitals. 

CONDENSING & 


CH Flow 

Burner 

CH Return 

Smoke Chamber 

Condensate Drain 

77


Contents 


CONDENSING & 


Product Code 

Output 

50/30°C 

kW 

Net 

Efficiency 

50/30°C % 

Output 

80/60°C 

kW 

Net 

Efficiency 

80/60°C % 

Nominal 

Input MJ/ 

hr 

Modulation 

Ratio 

Flow Rate 

Min/Max 

L/s** 

Waterside 

Pressure 

Drop kPa 

Combustion 

Side 

Pressure 

Drop mbar 

Total 

Water 

Volume 

litres 

Dry 

Weight 

Kg 

Power 

Supply 

V/A/Hz 

EM175NG280MPRSAUA032 179 100.35 175 94.9 700 1:5 1.07/2.14 2.1 1.6 490 367 240/0.5/50 

EM230NG280MPRSAUA032 244 101.15 230 95.1 920 1:5 1.46/2.91 2.3 2.0 520 483 240/0.5/50 

EM290NG400MPRSAUA040 309 101.77 290 95.25 1160 1:5 1.85/3.69 2.4 2.3 580 609 240/0.9/50 

EM350NG550MMDSAUA140EA 375 102.74 350 95.6 1400 1:5 2.24/4.48 2.5 3.3 620 770 240/1.24/50 

EM450NG550MMDSAUA140EA 501 100.45 465 94.9 1860 1:5 2.99/5.98 2.5 2.7 520 957 240/1.24/50 

EM600P61MMDSAUA150EA 677 97.37 625 93.7 2500 1:5 4.05/8.09 3 3.1 540 1167 240/2.2/50 

EM800P65MMDSAUA150EA 870 98.1 810 93.84 3240 1:5 5.20/10.39 3.2 5.2 720 1410 415/3.0/50 

EM1000P71MMDSAUA150EA 1074 98.4 1000 93.92 4000 1:5 6.42/12.83 3.2 4.6 810 1535 415/4.4/50 

EM1250P71MMDSAUA150EA 1314 98.9 1250 94 4950 1:5 7.85/15.70 3.4 6.5 960 1702 415/6.0/50 

** Minimum flow rate is for low load only. 


Euromax 175 - 350kW 

Euromax 465 - 1250kW 

Model 

Capacity 

(kW) 

L mm L1 mm B1 mm H1 mm H2 mm øD mm 

Water Outlet 

Nozzle T1 

Water Inlet 

Nozzle T2 

Safety 

Connection T3 

Water 

Volume lt 

EM175 175 1690 1300 875 1250 1413 200 DN 80 DN 80 DN 40 490 

EM230 230 1790 1400 875 1250 1413 200 DN 80 DN 80 DN 40 520 

EM290 290 1940 1550 900 1300 1465 250 DN 100 DN 100 DN 50 580 

EM350 350 2095 1700 900 1300 1465 250 DN 100 DN 100 DN 50 620 

EM465 465 2215 1802 830 1595 1710 300 DN 100 DN 100 DN 50 520 

EM625 625 2240 1801 930 1738 1850 300 DN 100 DN 100 DN 50 540 

EM810 810 2640 2200 930 1738 1850 300 DN 125 DN 125 DN 65 720 

EM1000 1000 2465 2000 1010 1922 2037 400 DN 125 DN 125 DN 65 810 

EM1250 1250 2865 2400 1010 1922 2037 400 DN 150 DN 150 DN 80 960 

78

Contents 


Case Studies 

Watermarc 

Aquatic Centre 

4 x Euromax 1250kW 

WaterMarc Aquatic Centre is the 

largest aquatic and leisure facility 

in the north of Victoria and is home 

to the premier gym and indoor 

swimming pool in the area. AHG 

supplied 4x Euromax Condensing 

Boilers to provide heating for the 

pool water and Aquatic Centre. 

CONDENSING & 


180 Brisbane 


180 Brisbane sets a new 

benchmark for commercial office 

accommodation in Brisbane’s CBD 

by being awarded its 6 star Green 

Star Office Design v3 rating. AHG 


Boilers to provide heating for the 

building. 

Melbourne Markets 


The new Epping facility features 

up to 120,000m² of warehousing 

space to provide for the efficient 

integration of supply chain 

logistics, making it the largest 

warehousing precinct of any 

central market in Australia. AHG 


Boilers to provide heating to the 

facility plus office & administration 

areas. 

79

Meridian - Condensing Boilers 

Contents 

CONDENSING & 


Meridian 

Wall Mounted 24 - 100kW 

Floor Standing 120 - 150kW 

Meridian Condensing Boilers provide very 

high power outputs and efficiency in compact 

formats for the ultimate installation flexibility. 

They are available in both wall hung and floor 

standing models. 

Compact, versatile and highly efficient, Meridian Condensing 

Boilers are packed with features that save on space, 

installation time and energy. Meridian Condensing Boilers 

work at very high and constant efficiencies reaching up to 

108.6% enabling seasonal savings up to 35% 

Features include electronic starting with flame ionization 

and continuous modulating control from 20% to 100% 

electronically managed by a new microprocessor on both 

hydraulic circuits. The “ecological burner” produces a “cool 

flame“ combustion which considerably reduces nitrogen 

oxide and carbon monoxide emissions. 

• Boiler heat exchanger is completely fabricated from stainless 

steel for a long service life and maximum reliability 

• Floor Standing boilers can be bolted together for cascading 

• Self diagnostic electronic system 

• Anti-seizing pump system 

State of the art features make meridian boilers versatile and 

suitable for many different applications. 

Wall Mounted 

Australian Approved 

Type A Gas Appliance 

Up to 

20% 

Time Saving on 

installation 

Floor Standing 


Type 


Range 

24-157kW 

Efficiency 108.6% (Net) 97.8% (Gross) 


Fuel Type Natural Gas, LPG (selected models) 

Gas Approval Type Type A 


Cascadeable 

Max Pressure 

Low Nox 



Yes 

300kPa (24-50kW) 

500kPa (75-150kW) 

Yes 

Yes 

80

Contents 


Features 

• Australian Approved Type A Appliance means no individual 

approval inspection is necessary 

• Tower module available, incorporates a secondary pump 

and expansion tank and is designed to complement the 

water heating units 

• Stainless steel boiler and heat exchanger provides long 

service life and maximum reliability 

• Wall hung and floor standing models to suit various 

installation requirements 

• Low nox emissions providing environmentally friendly 

heating 

Advantages 

• Inbuilt pumps & headers - The Meridian floor standing 

Boilers reduce install time by up to 30% and eliminates 

installation errors due to the innovative design of having 

the primary pumps and flow/returns headers incorporated 

inside the boiler. 

• Cascadeable - Thanks to the inbuilt headers, Meridian 

boilers can be cascaded together saving plantroom space 

and providing sequence control of multiple units with BMS 

feedback. 

• Isolation valves - Isolation valves fitted to each boiler allow 

service or maintenance work to be carried out without 

disturbing the cascade arrangement. 

CONDENSING & 


Bolt Together 

Cascade Ability 

Stainless Steel 

Heat Exchanger 

Check Valve 

Isolation Valve 

Primary Pump 



Inbuilt Hydraulic 

Header 

81


Contents 

CONDENSING & 


Installation Examples 

Model 120 - 150 (8 x 2 Boilers) c/w HS2 - 1320F Hydraulic Separator 

Meridian Boilers can be cascaded 

to suit many project types & sizes 

offering a vast variety of solutions 

for your needs 

Plan View 

Front View 

End View 

82

Contents 


Clearance Diagram - Meridian Model 120 - 150 x 3 in series setup 

Top View 

Front View 

Side View 

CONDENSING & 


Hydraulic Separator Connection Details 

Suction of pump must come from 

the top of the hydraulic separator 

and pump to the field. 

Water and Gas connections can be 

either left or right hand side. 

83


Contents 


CONDENSING & 


Meridian Wall-Hung - 24-100kW 

• Type A Appliance 

• High Efficiency 

• Compact Size 

• Cascadable 

• In Built Variable Speed Pump 

(24, 32, 50kW only) 

Meridian 

1 

Meridian 

2 

• Australian Gas Approval 

Number: GSCS20215 

Overview 

Gas Pressure Range 

1.1 - 2.7 kPa 

Min Water Pressure 

100kPa 

Meridian 100 x 2 with hydraulic separator 

Max Water Pressure 

300kPa (24, 32, 50) – 500kPa (75, 100) 

Model 

Output 

50/30ºC 

kW 

Net 

Efficiency 

50/30ºC % 

Output 

80/60°C 

kW 

Net 

Efficiency 

80/60°C 

% 

Nominal 

Input 

MJ/hr 

Modulation 

Ratio 

Secondary 

Side Flow 

Rate min/ 

max L/s * 

Water 

Pressure 

Loss kPa 

Total 

Water 

Volume 

litres 

Dry 

Weight 

kg 

Dimensions 

(mm) 

H W D 

Air 

Flue 

Intake 

Connection 

size 

size mm** 

mm 

Power 

Supply 

V/A/Hz 

Indoor - Natural Gas 

M24-I 25.3 106 23.5 98 96 1:8 0.04/0.30 21 3.5 42 850 450 280 Ø60/100 Ø80 240/0.6/50 

M32-I 31.8 106 29.4 98 117 1:9 0.04/0.38 20 3.5 42 850 450 280 Ø60/100 Ø80 240/0.6/50 

M50-I 50.28 106.3 47.2 98 192 1:5 0.12/0.60 25 5 50 750 400 420 Ø80 Ø64 240/0.6/50 

M75-I 75.8 106 67.9 97 280 1:5 0.83/0.91 25 6 65 880 495 500 Ø80 - 240/0.6/50 

M100-I 97.1 106 87.6 97.3 360 1:5 1.05/1.16 26 8 75 880 495 500 Ø100 - 240/0.6/50 

Indoor - LPG 

M32LPG-I 31.8 106 29.4 98 120 1:9 0.04/0.38 20 3.5 42 850 450 280 Ø60/100 Ø80 240/0.6/50 

M50LPG-I 50.28 106.3 47.2 98 192 1:5 0.12/0.60 25 5 50 750 400 420 Ø80 Ø64 240/0.6/50 

M100LPG-I 97.1 106 87.6 97.3 360 1:5 1.05/1.16 26 8 75 880 495 500 Ø100 - 240/0.6/50 

Outdoor - Natural Gas 

M24-O 25.3 106 23.5 98 96 1:8 0.04/0.30 21 3.5 42 1061 450 276 - - 240/0.6/50 

M32-O 31.8 106 29.4 98 117 1:9 0.04/0.38 20 3.5 42 1061 450 306 - - 240/0.6/50 

M50-O 50.28 106.3 47.2 98 192 1:5 0.12/0.60 25 5 50 1061 400 446 - - 240/0.6/50 

M75-O 75.8 106 67.9 97 280 1:5 0.83/0.91 25 6 65 1091 495 526 - - 240/0.6/50 

M100-O 97.1 106 87.6 97.3 360 1:5 1.05/1.16 26 8 75 1091 495 526 - - 240/0.6/50 

Outdoor - LPG 

M32LPG-O 31.8 106 29.4 98 120 1:9 0.04/0.38 20 3.5 42 1061 450 306 - - 240/0.6/50 

M50LPG-O 50.28 106.3 47.2 98 192 1:5 0.12/0.60 25 5 50 1061 400 446 - - 240/0.6/50 

M100LPG-O 97.1 106 87.6 97.3 360 1:5 1.05/1.16 26 8 75 1091 495 526 - - 240/0.6/50 

** The size of the main flue may vary from the flue connection size subject to various installation criteria. 

For assistance with sizing your flue, please discuss your project details with our technical support team. 

H 

H 

D 

W W 

Indoor 

Outdoor 

D 

84

Contents 


Meridian Floor Standing - 120-157kW 

• Type A Appliance 

• High Efficiency 

• Compact Size 

• Cascadable 

• In Built Header 

Meridian 

1 

Meridian 

2 

CONDENSING & 


• In Built Variable Speed Pump 

• Australian Gas Approval 

Number: GSCS20215, 

VGC40016 (M120LPG) 

Overview 

Gas Pressure Range 

1.1 - 2.7 kPa 

Min Water Pressure 

100kPa 

Max Water Pressure 500kPa 

Meridian 150 x 2 with hydraulic separator 

Model 

Output 

50/30ºC 

kW 

Indoor - Natural Gas 

Net 

Efficiency 

50/30ºC % 

Output 

80/60°C 

kW 

Net 

Efficiency 

80/60°C 

% 

Nominal 

Input 

MJ/hr 

Modulation 

Ratio 

Secondary 

Side Flow 

Rate min/ 

max L/s* 

Water 

Pressure 

Loss kPa 

Total 

Water 

Volume 

litres 

Dry 

Weight 

kg 

Dimensions 

(mm) 

H W D 

Air 

Flue 

Intake 

Connection 

size 

size mm** 

mm 

Power 

Supply 

V/A/Hz 

M120-IV 120 108.6 107 97.2 450 1:5 0.29/1.43 17 32 200 1207 550 875 Ø100 - 240/2.1/50 

M150-IV 157 108.6 144.1 97.3 592 1:5 0.38/1.88 27 32 200 1207 550 875 Ø100 - 240/2.5/50 

Indoor - LPG 

M120LPG-IV 120 108.6 107 97.2 396 1:5 0.29/1.43 17 32 200 1207 550 875 Ø100 - 240/2.1/50 

Outdoor - Natural Gas 

M120-OV 120 108.6 107 97.2 450 1:5 0.29/1.43 17 32 200 1243 550 895 Ø100 - 240/2.1/50 

M150-OV 157 108.6 144.1 97.3 592 1:5 0.38/1.88 27 32 200 1243 550 895 Ø100 - 240/2.5/50 

Outdoor - LPG 

M120LPG-OV 120 108.6 107 97.2 396 1:5 0.29/1.43 17 32 200 1243 550 895 Ø100 - 240/2.1/50 

All secondary pumps must suck from the top of the hydraulic separator and pump into the field. 

** The size of the main flue may vary from the flue connection size subject to various installation criteria. 

For assistance with sizing your flue, please discuss your project details with our technical support team. 

H 

H 

D 

W 

D 

W 

Indoor 

Outdoor 

85


Contents 

CONDENSING & 


Meridian Tower 

Floor Standing 

Secondary Header Unit 

• Ease & speed of installation 

• Compact size 

• In-built expansion tank 

• In-built header 

• In-built secondary pump 

• Australian Approved 

• Max Water Pressure 500kPa 

H 

W 

D 


Indoor 

Outdoor 

Model 

Max Flow Rate 

L/s 

Max Head 

kPa 

Expansion Tank 

L 

MT360-I 5.55 265 50 1207 550 895 

MT150-I 3 210 50 1207 550 895 

MT360-O 5.55 265 50 1243 550 895 

MT150-O 3 210 50 1243 550 895 

Height 

mm 

Width 

mm 

Depth 

mm 

Meridian 1 Meridian 2 Meridian 

Tower 

Unit 

Meridian 150 x 2 with Tower Unit 

86

Contents 


Meridian P&I Tower Setup 

Nat Gas 

Meridian Heat Exchanger no. 1 Meridian Heat Exchanger no. 2 Tower Unit 

EN50 (50L) 

Expansion 

Tank 

CONDENSING & 


Supply 

Secondary Pump 

Ø80mm to 

Heating System 

Return 

Note: Install Dosing Pot across pump 

15mm Fill Valve Ass’y 

Meridian Prefabricated Base Frames 

An example Meridian base frame configuration is illustrated below. 

These prefabricated supply options offer substantial time and cost savings on site. 

87


Contents 

Case Studies 

CONDENSING & 


Grenda Aquatic Centre 

3 x Meridian 150kW 

Australian Trucking 

Association 

Forest, ACT 


Warrnambool Aged Care 


88

Contents 


Langham Hotel 


CONDENSING & 


150 Lonsdale St 


Glenfield College, 

Auckland NZ 


89


Contents 

Case Studies 

CONDENSING & 


121 Queen St 


128 Jolimont St 

East Melbourne 


Lorne Hospital 


90

Contents 


Botannica Melbourne 

Building 8 


CONDENSING & 


Sofitel 


St Kilda Town Hall 


91

Modulex EXT - Condensing Boilers 

Contents 

CONDENSING & 


Modulex EXT 

Condensing Boiler 150 – 1200kW 

Modulex EXT is a new range of floorstanding 

condensing boilers that 

provides an infinitely flexible solution 

for buildings requiring a high output 

heating system. 

There are eight floor-standing boilers to choose from, 

with outputs ranging from 150kW to 1200kW. Each 

one is made up of a number of self-contained heat 

generating modules forming what is, in essence, 

a series of boilers linked together within a single 

casing. This modular design enables Modulex EXT 

boilers to optimise energy efficiency and comfort 

levels for building occupiers like no other boilers 

available today. 

Each linked module shares a single set of ancillary 

components including flow and return pipes, 

electronic controls and flue. This greatly eases the 

installation process and, along with the internal easy 

access layout of each boiler, simplifies servicing. 

Compact overall dimensions and ultra-low operating 

noise levels gives the system designer greater 

flexibility when it comes to positioning the boiler 

within the building. With a host of benefits for the 

consultant, contractor, client and building occupier, 

Modulex EXT boilers provide the perfect heating 

solution for a wide range of projects from hotels to 

office buildings, schools to sports centres. 


Type 

Condensing Premixed 

Range 

150-1200kW 

Efficiency 109% (Nett) 98% (Gross) 

Fuel Type Natural Gas, LPG 

Gas Approval Type Type B approved to AS3814 





Low Nox Yes 


2019 Compliant 

Yes 

92

Contents 


Each heat generating module within our Modulex EXT 

boilers is self-contained, with its own downfiring premix 

gas burner, fan, ignition and safety controls. As 

system load decreases, a built-in Boiler Cascade Manager 

modulates the boiler down to the combined minimum. As 

loads continue to reduce, individual modules are switched 

off as necessary down to a minimum output of a single 

module – 12kW for 150-350kW models and 22kW for 440- 

1200kW models. This ensures optimum load matching 

and minimises wasteful boiler cycling, maximising energy 

efficiency in the process. The combination of a high 

modulation ratio up to 1:54 and a high output plus very low 

water content ensures rapid warm-up and turn-down times 

for Modulex EXT boilers. They are subsequently also able to 

respond quickly to changing demands throughout the day. 

Thanks to their modular design, Modulex EXT boilers will 

continue to operate even in the unlikely event that a single 

module malfunctions. 

CONDENSING & 


Features 

• Exceptional energy efficiency 

(up to 109% at the minimum modulated capacity) 

• Low noise 

• Ultra low emissions 

• Full BMS capability. 

Allows monitoring of performance and faults 

• Variable Water Flow rate - Allows the boiler to operate at a 

constant 20°ΔT – maintaining the boiler at the most efficient 

duty point. 

• Able to be supplied as dismantled - When needing to achieve 

installation in tight plant rooms or inaccessible areas, this 

feature can enable much better access and often saves 

significant costs involved in placing equipment via a crane 

from outside the building. 

Advantages 

• High turndown ratio of up to 1:54 - This provides significant 

energy savings, particularly for part load or low load 

requirements. It also stops boiler cycling and contributes to 

its very quiet operation. 

• Multi burner construction - If one burner requires 

maintenance, the other burners can continue to operate, 

providing built-in redundancy. 

• Small space saving footprint - This makes it easy to install 

in plant rooms where floor space is at a premium. 

Full BMS 

capability 

Allows monitoring 

of performance 

and faults 

Low nox


Contents 

Technical Features 

CONDENSING & 


Modulating Pump 

Cross Section of the 

Premix Multi-Burner 

Working & Safety Temp 

Sensors Ignition Electrodes & 

Ionisation Probes 

Built-In Non Return 

Smoke Valves 

Premix Burners Working at 

Constant CO 2 

Standardized Hydraulic Manifolds 

Primary Circuits With 

Additional Safety Devices Kit 

Maximum Saving & Seasonal Efficiency 

High efficiency thanks to: 

• Certified efficiency up to 109% at the minimum modulated 

capacity 

• Seasonal efficiency: + 30% if compared with the 

conventional heaters 

• Large modulation ratio: up to 1:54 

• Modulating pump directly managed by the heater to assure 

the maximum condensation at all times 

Total Safety 

• High reliability due to MULTI BURNER composition and to the 

low number of parts in movement 

• Working and safety temperature sensors on every casting 

section 

• Premixing within the fan with non return built-in valve 

• Auxiliary electronic circuits 

• Emergency operation in case the E8 controller is out of 

service 

Low Environmental Impact 

• Low polluting emissions :

Contents 


Pre-assembled Thermal Elements 

MODULEX EXT is an assembly of thermal modules, together 

making a complete unit. Every unit is constituted by preassembled 

thermal elements, in Al/Si/Mg. Every element 

supplies, in continuous and progressive way, from 12 to 50 

kW for the models up to 350 kW, and from 22 up to 108 kW 

for larger models. 

More than 10 years experience assure: 

• Resistance to the corrosion of the acidic condensate 

• Very high thermal efficiency 

The basic element is formed by two aluminium alloy 

castings that, on the smoke side, have dense fins, with 

increasing height toward the smoke discharge, placed in 

lower part of the casting, in order to increase its exchange 

surface. 

Inside the castings there are the water channels that zigzag 

cross the casting, granting an exceptional heat transfer 

from combustion gases to the water. 

Every thermal element is equipped with: 

• Premix modulating burner 

• Two stage modulating gas valve 

• Electronic ignition and ionization 

• NTC working temperature sensor 

• Safety thermostats 

• Flame sight glass 

The smoke and acidic condensate of the thermal elements 

are collected in a stainless steel tray. 

CONDENSING & 


Air/Gas 

Mixture 

Burner 

Combustion 

Chamber 

Condensate 

Finned 

Casting 

Water 

Gas Valve 

Burner Cover 

Gas Pipe 

Ignition Electrode 

Ignition Probe 

Local NTC 

Temp. Sensor 

Limit Thermostat 

Aluminium Alloy 

Heat Exchanger 

Condensate 

Level Sensor 

Condensate & 

Smoke Tray - Chimney 

Connection 

Frame 

Fan 

Burner 

Automatic Air 

Vent 

Global NTC Flow 

Temp. Sensor 

Central 

Heating Flow 

Global NTC 

Return Temp. 

Sensor 

Central Heating 

Return 

Drain Tap 

Condensate 

Evactuation 

95


Contents 

Output Flexibility and Efficiency 

CONDENSING & 


The MODULEX EXT 

exceeded all industry 

requirements when it 

was first conceived over 

a decade ago. These days 

the high standards and 

benchmark qualities of this 

groundbreaking heater are 

a must in today’s world. 

Setting option according to the 

thermal needs of the C.H. system 

This function enables you to 

drastically reduce the number of 

switching ON and OFF of the heater 

(Possible customization of the 

requested output) 

Advantages: 

• Higher efficiency and lower flue 

losses when burner is OFF 

• Longer lasting of the parts in 

movement and of the ignition 

systems 

Very low water content and high 

modulation speed with maximum 

output ratio up to 1:54 

On average a heater operates at 

50% of the thermal need of the C.H. 

installation and can descend below 

30%. MODULEX EXT adjusts in real 

time the output to meet demand, 

because it is not influenced by the 

thermal inertia, thanks to its low 

water content and, being equipped 

with modulating pump, it further 

reduces the electricity used. 

Class A, variable speed, electronic 

pumps, for the maximum 

condensate production 

This function promotes the 

production of condensate and 

therefore the fast economic recovery 

of the investment. All this in order to 

offer the user the possibility to save 

with the maximum comfort both, for 

C.H. and D.H.W. production, with a 

lower noise level than the traditional 

boilers 

Comparison of the steady state condition reaching time between a 

modulex and a high intertia/water content heater 

Temperature (ºC) 

Nominal Load 100 (%) 

80 

70 

60 

50 

40 

30 

20 

10 

100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 

MODULEX Ext Low Water Content Heater 

Time (min) 

T1 T2 T3 T4 

Time 

High Water Content Heater 

After the time “T1” from the starting, MODULEX EXT succeeds in satisfying the 30% of the 

load unlike a traditional heater that, in the same time, is just at 15%. After the time “T2” 

MODULEX EXT is at 50% of the load, while the traditional one is at 30%. After the time “T3” 

MODULEX EXT is at 100% of the load and the traditional one is only at 70%. This clearly 

displays the speed of the Modulex EXT Heater 

Effciency (%) 

110 

108 

106 

104 

102 

100 

98 

+3% 

96 

190 170 150 100 70 48 

Output (kW) 

12 

Modulating flow rate pump 

Constant flow rate pump 

Efficiency comparison between pump with modulating flow rate versus a 

heater with constant flow rate 

96

Contents 


MODULEX EXT has a certified 

efficiency that, for all models 

above 350 kW, when working in 

condensation, progressively increase 

up to 109% when the output is 

reduced. 

The genius of the thermo-controller 

E8 is that it keeps ON the greatest 

number of elements as possible, 

working at the smallest possible 

output (as shown in the examples 

beside). 

The system will always work in the 

conditions of maximum possible 

efficiency, independently from the 

supplied output. 

When the requested output is less 

than the capacity available the design 

of the Modulex regulates evenly 

reducing the output of each module 

to suit. Once the minimum level for 

a module is reached it is disabled in 

cascade sequence. 

This modular system is such that 

as the number of modules used 

decreases - the efficiency increases. 

The flexibility of this modular 

conception is ground breaking and 

brings vast cost savings through 

increased efficiency. 

To avoid one element module being 

over used more than others, the 

thermo-controller automatically 

alternates usage of all element 

modules evenly. 

Efficiency (%) 

Modulex EXT Efficiency 

109 

108 

107 

106 

104 

102 

12 22 50 110 

Output (kW) 

Modulex EXT 150 | 350 

Modulex EXT 440 | 900 

Output sharing of MODULEX EXT of 4 modules of 50 kW 

Max Output 

50% Output 

50kW 50kW 50kW 50kW 

25kW 25kW 25kW 25kW 

Total Efficiency η = 102 


CONDENSING & 


25% Output 

Min Output 

12kW 

12kW 

12kW 

12kW 

12kW 

Off 

Off 

Off 

Total Efficiency η = 106.5 


97


Contents 


CONDENSING & 


With the cascade installation, the 

boiler output range can be widened 

to well in excess of 1200kW, 

multiplying output and modulation in 

order to satisfy any design demand. 

The space saving (in particular the 

boilers can be installed up to 40cm 

from the boiler house walls) features 

of the Modulex Boiler are tailored 

specifically with service and easy 

access in mind. Replacement of 

old obsolete boilers is also another 

benefit that a small foot print allows. 

Modulex EXT cascade installation 

using a single hydraulic separator 

Modulex EXT installation using a hydraulic separator 

Modulex EXT installation using a plate heat exchanger 

98

Contents 



Product 

Code 

Output 

(50/30ºc) 

kW 

Net 

Efficiency 

(50/30ºc) % 

Output 

(80/60ºc) 

kW 

Net 

Efficiency 

(80/60ºc) % 

Nominal 

Input 

MJ/hr 

Burner 

Quantity 

Modulation 

Ratio 

Flow Rate 

Min/Max 

(l/s)* 

Waterside 

Pressure 

Drop kPa 

Total Water 

Volume 

litres 

Dry 

Weight 

Kg 

Power Supply 

V/A/Hz 

MX150EXT 150 100.8 146.1 97.4 540 3 x 50kW 01:12 1.17/2.33 16 14 236 240/0.875/50 

MX200EXT 200.4 100.2 195.2 97.6 720 4 x 50kW 01:16 1.56/3.11 16 18 295 240/1.208/50 

MX250EXT 251.4 100.5 244.5 97.8 900 5 x 50kW 01:20 1.95/3.89 16 22 325 240/1.508/50 

MX300EXT 302.7 100.9 294 98 1080 6 x 50kW 01:24 2.34/4.68 16 26 386 240/1.771/50 

MX350EXT 354.6 101.9 342.2 98.2 1260 7 x 50kW 01:28 2.74/5.48 16 31 419 240/2.112/50 

MX440EXT 445 104 424.35 98.23 1600 4 x 110kW 01:19 3.38/6.76 15 67 501 240/2.608/50 

MX550EXT 557.8 104 530.44 98.23 2000 5 x 110kW 01:25 4.23/8.45 18 80 595 240/3.262/50 

MX660EXT 670.1 104 636.53 98.23 2400 6 x 110kW 01:29 5.07/10.14 20 94 657 240/3.916/50 

MX770EXT 783.2 104 742.62 98.23 2800 7 x 110kW 01:34 5.92/11.83 22 108 754 240/4.566/50 

MX900EXT 900.3 104 849.05 98.27 3200 8 x 110kW 01:39 6.76/13.51 20 122 906 240/5.216/50 

MX1000EXT 1011 104 946.7 98.27 3500 9 x 110kW 1:44 11.3/15.05 26 140 981 240/5.868/50 

MX1100EXT 1223 104 1052 98.27 3888 10 x 110kW 1:49 12.5/16.7 26 154 1090 240/6.520/50 

MX1200EXT 1237 104 1157 98.27 4276.8 11 x 110kW 1:54 13.8/18.4 26 168 1200 240/7.172/50 

* Requested rated flow rate in l/s (Δt=20K) / Maximum flow rate in l/s (Δt=15K). Primary pump must be controlled by the boiler. 

CONDENSING & 


99

Menu 

Menu 


Contents 


CONDENSING & 


MX150EXT - MX350EXT 

FRONT VIEW 

FRONT 

RIGHT SIDE 

Delivery condition for right 

hand side RIGHT connection 

TOP VIEW 

RIGHT SIDE 


hand side connection RIGHT SIDE 


hand side connection 

RIGHT SIDE 

RIGHT SIDE 


hand side Delivery connection condition for right 


MX440EXT - MX900EXT 62 

TOP VIEW 

TOP VIEW 

FRONT VIEW 

TOP 

G Gas Inlet M Water Delivery 

S Drain R System Return 



TOP VIEW 

TOP VIEW 

L 

PRE-CUT 

FLOW 

LEFT SIDE 

PRE-CUT 

RETURN 

LEFT SIDE 

LEFT SIDE 

PRE-CUT 

FLOW 

LEFT SIDE 

PRE-CUT 

RETURN 

LEFT SIDE 

LEFT SIDE 

RIGHT SIDE 



LEFT 

PRE-CUT 

GAS 

LEFT SIDE PRE-CUT 

GAS 

LEFT SIDE 

LEFT SIDE 

LEFT SIDE 

Delivery condition 

for right hand side 

connection 

G Gas Inlet 

S Drain 

G Gas Inlet 

S Drain 

G Gas Inlet 

S Drain 

M Water Delivery 

R System Return 

TOP VIEW 





FRONT 


S G Drain Gas Inlet R M System Water Delivery Return 

309 Gas Inlet L1 

S Drain G Gas R System Inlet 

M Return Water 

Water 

Delivery 

Delivery 

S 

Drain 

Drain 

R 

System 

System 

Return 

Return 

S 

PRE-CUT 

FLOW 

LEFT SIDE 

1 61 7 

1448 

PRE-CUT 

RETURN 

LEFT SIDE 

RIGHT 

PRE-CUT 

FLOW 

LEFT SIDE 

PRE-CUT 

RETURN 

LEFT SIDE 

PRE-CUT 

GAS 

LEFT SIDE 

Ø 350 

PRE-CUT 

GAS 

LEFT SIDE 

2310 

S 

G 

G Gas Inlet 

S Drain 



1 61 7 

1448 

1 61 7 

1448 

Ø 350 

Ø 350 

62 

2310 

S L 

S 

2310 


S 

S Drain G Gas R System Inlet M Return Water Delivery 


309 L1 

TOP 

1002 

1002 

1 61 7 

3 96 1 4 5 3 0 7 41 5 

1448 

M 

R 

151 

111 

53 

3 96 1 4 5 3 0 7 41 5 

S 

M 

R 

363 349 53 

948 151 

974 

LEFT 

111 

G 

S 

363 349 

948 

974 

Ø 350 

2310 

S 

100 

415 

G 

G 

M 

5

Menu 

Menu 

Contents 

G Gas Inlet 

S Drain 




MX1000EXT - MX1200EXT 

G Gas Inlet G Gas Inlet M W 

S Drain S Drain R Sy 

62 

62 

FRONT 

L 

L 

RIGHT 

CONDENSING & 


1 61 7 

1448 

1 61 7 

1448 

S 

G Gas Inlet 

S Drain 


S S 


Ø 350 

Ø 350 

309 309 L1 L1 

2310 

LEFT 

TOP 

G 

Ø 350 

S 

1002 

3 96 1 4 5 3 0 7 41 5 

M 

R 

2310 

151 

111 

53 

S 

363 349 

948 

974 

Model Width L mm Depth P mm Height mm 

Connections Flow 

mm 

Connections 

Return mm 

Gas Connections 

mm 

Flue Diameter 

mm 

MX150EXT 764 770 1150 64 (2 ½) 64 (2 ½) 50(2) 150* 

MX200EXT 1032 770 1150 64 (2 ½) 64 (2 ½) 50(2) 150* 

MX250EXT 1032 770 1150 64 (2 ½) 64 (2 ½) 50(2) 200 

MX300EXT 1300 770 1150 64 (2 ½) 64 (2 ½) 50(2) 200 

MX350EXT 1300 770 1150 64 (2 ½) 64 (2 ½) 50(2) 200 

MX440EXT 1087 946 1448 100 (4) 100 (4) 80(3) 300 

MX550EXT 1355 946 1448 100 (4) 100 (4) 80(3) 300 

MX660EXT 1355 946 1448 100 (4) 100 (4) 80(3) 300 

MX770EXT 1623 946 1448 100 (4) 100 (4) 80(3) 300 

MX900EXT 1623 946 1448 100 (4) 100 (4) 80(3) 300 

MX1000EXT 2025 974 1448 125 (5) 125 (5) 80(3) 350 

MX1100EXT 2025 974 1448 125 (5) 125 (5) 80(3) 350 

MX1200EXT 2025 974 1448 125 (5) 125 (5) 80(3) 350 

*the flue connection adapter 150/200 is included in the boiler delivery 

101


Contents 

Case Studies 

CONDENSING & 


Crown Plaza Hotel 

4 x Modulex EXT 900kW 

360 Collins St 


385 Bourke St 


102

Contents 


Blue Cross Aged Care 


CONDENSING & 


Collins Place 


IBM Building Melbourne 


103

Moorea I - Condensing Boilers 

Contents 

CONDENSING & 


Moorea I 


125 – 610kW 

The new floor standing condensing gas 

boiler, Moorea I, represents the highest 

evolution stage within the middle output 

range of gas fired condensing boilers. 

The continuous development of floor standing 

condensing boilers has identified a smaller foot print, 

improved modulation range and reduced operating 

noise as key product features. Moorea I is improved in 

all three areas. 

Available in eight outputs; 170, 215, 260, 300, 400, 

470, 540 and 610kW, the Moorea I is designed with the 

customer, installer and specifier in mind. Using the 

very latest heating technology with a heat exchanger 

made from aluminium/silicon with a 10 year warranty* 

and a combustion system which delivers exceptional 

energy efficiency as well as advanced ultra low NOx 

performance of 35mg/kWh (Class 5). 

*Conditions apply 

Integrated 

Controller 

Painted 

Cover 

Control 

Panel 

with LED 

Screen 

Variable 

Speed Fan 

Aluminium 

Alloy Heat 

Exchanger 

Gas 

Valve 

Condensate 

Recovery 

Tank 


Type 

Range 

Efficiency 

Fuel Type 

Condensing Premixed 

170-610kW 

108% (Nett) 97.5% (Gross) 

Natural Gas - all models 

LPG - Models MR170I-MR300I only 



Yes 

Modulation 1:6.25 



Low Nox Yes 



Yes 

104

Contents 


Features 

• Very high efficiency up to 108 % 

• Wide modulation range 

• No capacity constraints 

• Low pollution discharges 

• Small footprint & weight limits 

• Install up to 16 boilers in cascade 

• Very quiet operation 

Advantages 

• Outputs available from 125 to 610 kW 

• Maximum energy utilisation 

• Efficiency of up to 108% net (97.5% gross) 

• High modulation range from 16% to 100% of nominal 

output (6.25 to 1) 

• Heat exchanger profile designed to ensure highly 

efficient heat transfer 

• Compact dimensions and small footprint 

• Lightweight aluminium/silicon heat exchanger 

• Top mounted hydraulic and flue connections revised 

• Easier to connect and less space needed for 

working access 

• NOx 35mg/kWh 

CONDENSING & 



Cascade without 

booster pump 

Not to be used if there are any 

high temperature circuits 60/80 

°C (no instant DHW) the motorised 

2-channel valves isolate the boilers 

when they are not operating. On 

start up the boilers are blocked until 

their respective isolating valves are 

fully open. The Cascade function is 

integrated and a BUS module just 

needs to be added to each boiler 

regulator. 

Moorea I HTE 

125-610 

Hot Water Tank 

Optimising the condensing 

"Cold" returns are used more, 

Thanks to the buffer tank, short 

cycles at high temperature are made 

smoother: loop losses, low drawing. 

The time for the boiler to reach its 

temperature is covered by the buffer 

tank; the tank's contents must be at 

least 2.5 l /kW of installed power at 

high temperature. 

Moorea I HTE 

125-610 

Primary Buffer Tank 

105


Contents 


CONDENSING & 


Model 

Output 50/30°C 

kW Min/Max* 

Net 

Efficiency 

50/30°C % 

Output 80/60°C 

kW Min/Max* 

Net 

Efficiency 

80/60°C % 

Nominal 

Input MJ/ 

hr 

Modulation 

Ratio 

Flow Rate 

Min/Max 

L/s** 

Waterside 

Pressure 

Drop kPa 

Total 

Water 

Volume 

litres 

Dry 

Weight 

Kg 

Power Supply 

V/A/Hz 

MR170I 29.8/181.3 106.8 26.8/165.8 97.6 675 1:6.08 2.03/4.06 4 34 255 240/0.833/50 

MR215I 37.4/229.6 106.9 33.5/210.1 97.8 860 1:6.14 2.57/5.14 4 38 285 240/1.375/50 

MR260I 44.9/278.1 107.1 40.2/254.5 98 998 1:6.19 3.11/6.21 4 45 305 240/1.458/50 

MR300I 52.3/322.1 107.2 45.9/294.3 98.1 1176 1:6.16 3.58/7.17 4 53 340 240/1.708/50 

MR400I 88.9/426 109.4 80.4/393.8 106.4 1565 1:4.79 4.78/9.56 10 73 540 240/1.929/50 

MR470I 102.8/496.6 109.3 93.0/459.0 106.1 1839 1:4.83 5.61/11.23 12 84 598 240/2.429/50 

MR540I 117.7/570.3 109.2 106.6/526.9 106.2 2113 1:4.85 6.45/12.9 12 97 636 240/3.291/50 

MR610I 131.5/644.8 109.1 119.2/595.7 106.3 2386 1:4.90 7.29/14.57 13 108 674 240/3.125/50 

* Output calculations based on Natural Gas 

** Requested rated flow rate in l/s (Δt=20K) / Maximum flow rate in l/s (Δt=10K). Primary pump must be controlled by the boiler. 


MR170I - MR300I (Indoor) 

K 

K 

K 

J 

J 

J 

I 

I 

I 

Front View 

Side View 

Back View 

Top View 

MR400I - MR610I (Indoor) 

K 

G 

H 

I 

669 

G 505 

214 

L M N 

659 

Front View 

Side View 

Back View 

Top View 

Model 

A 

Gas 

Supply 

B 

Safety 

Valve 

C 

Flue 

mm 

D 

HHW Outlet/ 

Flow 

E 

HHW Inlet/ 

Return 

F 

Condensate 

Drain mm 

MR170I-I 1 ½” 1” Ø160 DN 65 PN6 DN 65 PN6 Ø25 401 301 134 687 1008 - - - 

MR215I-I 1 ½” 1 1/4” Ø200 DN 65 PN6 DN 65 PN6 Ø25 514 351 163 851 1171 - - - 



MR400I-I 2" 2" Ø250 DN 80 PN6 DN 80 PN6 Ø32 709 - - - 1882 642 798 442 




G 

mm 

H 

mm 

I 

mm 

J 

mm 

K 

mm 

L 

mm 

M 

mm 

N 

mm 

106

Contents 


MR170 - MR300 (Outdoor) 

CONDENSING & 


Front View 

Side View 

Top View 

MR400 - MR610 (Outdoor) 

Front View 

Side View 

Top View 

Model 

A 

Gas 

Supply 

B 

Safety 

Valve 

C 

Flue 

mm 

D 

HHW Outlet/ 

Flow 

E 

HHW Inlet/ 

Return 

F 

Condensate 

Drain mm 

MR170I-O 1-1/2” 1” ø160 DN 65 PN6 DN 65 PN6 ø25 401 315 148 702 1036 - - - 

MR215I-O 1-1/2” 1-1/4” ø200 DN 65 PN6 DN 65 PN6 ø25 514 365 177 865 1199 - - - 



MR400I-O 2” 2” ø250 80 DIN-6 80 DIN-6 ø32 709 524 234 1241 1920 662 798 461 

MR470I-O 2” 2” ø250 80 DIN-6 80 DIN-6 ø32 1018 524 234 1551 2230 662 1010 559 

MR540I-O 2” 2” ø250 80 DIN-6 80 DIN-6 ø32 1018 524 234 1551 2230 662 1010 559 

MR610I-O 2” 2” ø250 80 DIN-6 80 DIN-6 ø32 1018 524 234 1551 2230 662 1010 559 

G 

mm 

H 

mm 

I 

mm 

J 

mm 

K 

mm 

L 

mm 

M 

mm 

N 

mm 

107


Contents 

Case Studies 

CONDENSING & 


333 George St 

Sydney 

4 x Moorea 260kW 

Calvary Bruce Hospital 

Canberra 


Clyde Hub 

Sydney 

2 x Moorea Outdoor Units 

108

Contents 


420 Collins St 

Melbourne 


CONDENSING & 


Frankston Target 


Ryde Hospital NSW 


109

Accessories - Condensing Boilers 

Contents 

Options & Accessories 

CONDENSING & 


Duraflex Hydraulic Separators 

See pg 266 for more information 

Meridian Hydraulic Separators 


Heat Exchangers 


Stainless Steel Flue System 


110

Contents 

Accessories - Condensing Boilers 

Condensate Neutralisers 


CONDENSING & 


Cascade Controller - to suit Meridian Boilers 

AH240 - Touch Screen HMI 3.5” - Integrated Cascade Controller 

System can be set-up in such a way as to have the following features; 

• Stage PID Control of 8 x Boilers to maintain HHW Flow Temp. 

• Lead/Lag rotation of boilers based on time. 

• Fixed Setpoint, Set Point Reset from Outside Air or Night Setback 

• Setpoint (Selectable) 

• Remote Setpoint Input (0-10VDC) for setpoint signal by external BMS. (Selectable) 

• System Initiation by Remote VFC (eg On/Off Switch, External BMS, etc), 

• 365 Day Timeclock, Outside Air Temp. or Room Temp. (Selectable) 

Suitable for no. of Water Heaters 2-4 2-4 5-8 9-12 4-8 

Product Code SEQCON SEQCON1 SEQCON2 SEQCON3 SEQCON4 

Touch Screen Control 

Lead/Lag Control 

Remote Setpoint Input (0-10VDC) 

for Setpoint Signal by External 

BMS 

 

Outside Air Compensation 

365 Day Time Clock * 

Domestic Hot Water Control 

Available 

Delta T-Graph with Flow & Return 

Water Temperature Display 

*AH240 and PL1101A PLC 

 

 

Outputs/BMS interaction 

• Flow temperature 

• Outside air temperature 

• Which boilers are running 

• What percentage of output 

they are running at 

• Adjustable setpoints 

- Flow temperatures 

- Outside air compensation 

- Timeclock adjustments 

- Boiler cycling (duty/ 

standby rotation) 

111

Contents 

CONDENSING & 


112

Contents 

Conventional Boilers 

CONDENSING & 


Conventional Boilers 

The use of boilers is the most common form of central heating and 

process heating throughout the world. 

Forced draft boilers use a circular drum that allows the combustion of gas or oil which then exits 

through tubes surrounded by water - transferring the heat. Atmospheric heaters use natural 

draft to combust fuel by mixing the gas and air in a venturi. This then heats a cast iron or copper 

tube filled with flowing water. 

Arizona Steel Boilers 

150-3500kW pg 114 

XRE Sectional Cast Iron Boilers 

150-1450kW pg 120 

113

Arizona - Conventional Boilers 

Contents 

CONDENSING & 


Arizona 

Conventional Steel Boilers 

Standard and High Efficiency HR 150 – 3500kW 

Arizona is a range of pressurised steel boilers suitable for use with 

forced draft air burners running on diesel or gas. The Full Mild Steel 

scotch marine construction unit comes equipped with fully modulating 

power dual fuel or gas burner. 

Note: control panel shown for illustrative purposes only and may not be used on actual boiler. 

High efficiency HR Range 

The Arizona High Efficiency HR range have an increased 

efficiency of 5.0 % from the standard Arizona unit. They 

feature special turbulators which increase the heating 

surface of the boiler. These three pass wet back design 

Arizona HR Boilers have the furnace back plate which is 

continually cooled from the return water ensuring the most 

amount of efficiency is reached on every application. 

Arizona HR boilers are ideal for applications where 

improved efficiency is a criteria without the need to 

progress to a condensing boiler. The HR range sit 

between standard boilers and condensing boilers in 

operating efficiency. 


Type 

Range 

Efficiency 

Fuel Type 

Steel Fire Tube 

150-3500kW 

Gross 83% (Standard) 

Gross 87% Nett 95% (High Efficiency) 





Modulation up to 1:5 



114

Contents 


Features and Advantages 

Three Pass Performance - The Arizona is a high output 

boiler made entirely of carbon steel to allow it to operate 

at different powers within a set range. Arizona is a scotch 

marine boiler featuring three combustion gas passes. The 

cylindrical combustion chamber has a wet back, which 

improves heat exchange between the combustion gases 

and the water. The front door is lined with specially shaped 

firebrick to make it easier for the combustion gas to enter 

the tubes. The combustion gas passes through the tubes at 

very high speed and turbulence, and into the rear smoke 

chamber. The turbulence is accentuated by specially 

designed turbofans that help increase heat exchange. 

Anti Condensation - An exclusive system has been 

implemented to prevent the formation of condensation. 

The smoke tubes and turbo fins are specially designed 

to guarantee a high and rapid heat exchange for the 

combustible gases. The shape of the rear section of the 

smoke tubes protects the welds by raising the temperature 

in the area as far as possible. 

Uniform Temperature Distribution - The internal panelling 

has been designed to allow the water inside the boiler 

to be distributed optimally and evenly, depending on the 

temperature. This ensures maximum safety and reduces 

scale deposits which reduce the surface area and make the 

boiler less efficient. 

Very Low Pressure Drop - The very low pressure drop 

across the boilers allow for smaller primary pumps with 

less head pressure required reducing the motor Kw’s 

Australian Approved and Globally Recognised - All the 

components are fully Australian approved and have proven 

very successful in Europe and throughout the world. 

Crane Lift Packages Available - Outdoor “crane-liftable” 

versions available in all sizes. 

CONDENSING & 


High Water Content - The High water content is ideal for 

large systems with long operating hours. 

Expansion - The firebox of the Arizona boiler is designed to 

expand to increase the elasticity of the entire structure and 

enable it to withstand stress better. 

115


Contents 


CONDENSING & 


Standard Efficiency 

Product 

Code 

Output 

80/60°C 

kW 

Net 

Efficiency 

80/60°C % 

Nominal 

Input 

MJ/hr 

Burner 

Selection 

Modulation 

Ratio 

Flow 

Rate 

l/s 

Waterside 

Pressure 

Drop 

(ΔT=12°C) 

kPa 

Combustion 

Side Pressure 

Drop mbar 

Total 

Water 

Volume 

litres 

Dry 

Weight 

Kg 

Power 

Supply 

V/A/Hz 

AS150 150 92.02 650 NG200 up to 1:5 1.79 1.4 1.2 172 346 240/0.75/50 

AS200 200 91.74 870 NG280 up to 1:5 2.39 1.5 1.9 172 346 240/1.04/50 

AS250 250 91.91 1090 NG350 up to 1:5 2.99 1.5 2 220 431 240/1.54/50 

AS300 300 92.31 1300 NG400 up to 1:5 3.58 1.6 2 300 475 240/1.54/50 

AS350 350 92.11 1520 NG550 up to 1:5 4.18 1.8 2.9 356 542 240/2.58/50 

AS400 400 92.38 1750 NG550 up to 1:5 4.78 2 4.1 360 584 240/2.58/50 

AS500 500 92.25 2170 P61 up to 1:5 5.97 2.2 4.2 540 853 415/1.53/50 

AS620 620 92.26 2690 P65 up to 1:5 7.41 2.7 6.4 645 963 415/2.09/50 

AS750 750 92.25 3250 P71 up to 1:5 8.96 2.5 5.2 855 1205 415/3.06/50 

AS850 850 92.29 3690 P71 up to 1:5 10.15 2.7 7.2 855 1205 415/3.06/50 

AS950 950 92.23 4120 P71 up to 1:5 11.35 3.2 5.2 950 1417 415/3.06/50 

AS1020 1020 92.22 4430 P71 up to 1:5 12.18 2.6 4 1200 1843 415/3.06/50 

AS1200 1200 92.24 5200 R75A-1 up to 1:5 14.33 3 5.5 1200 1843 415/4.17/50 

AS1300 1300 92.26 5640 R75A-1 up to 1:5 15.53 3.2 6.5 1200 1843 415/4.17/50 

AS1400 1400 92.29 6070 R75A-1 up to 1:5 16.72 2.8 6.5 1500 2600 415/4.17/50 

AS1600 1600 92.33 6930 R75A-1 up to 1:5 19.11 3.2 6.5 1500 2600 415/4.17/50 

AS1800 1800 92.31 7800 R91A up to 1:5 21.50 3.7 7 1650 2750 415/5.56/50 

AS2000 2000 92.29 8660 R93A up to 1:5 23.89 3.5 6 2000 3650 415/10.43/50 

AS2400 2400 92.31 10400 R93A up to 1:5 28.67 4 7.5 2300 3900 415/10.43/50 

AS3000 3000 92.31 13000 R512A up to 1:5 35.83 4.9 8 3150 5200 415/12.8/50 

AS3500 3500 92.30 15200 R512A up to 1:5 41.81 6 9 3650 5700 415/12.8/50 

Maximum operating pressure 500kPa. Higher pressure boilers available. 

Larger Boiler sizes available. Available as Dual Fuel (Natural Gas/LPG, Natural Gas/Light Oil) 

HR High Efficiency 

Product 

Code 

Output 

80/60°C 

kW 

Net 

Efficiency 

80/60°C % 

Nominal 

Input MJ/ 

hr 

Burner 

Selection 

Modulation 

Ratio 

Flow 

Rate 

L/S 

Waterside 

Pressure 

Drop 

(ΔT=12°C) 

kPa 

Combustion 

Side Pressure 

Drop mbar 

Total 

Water 

Volume 

litres 

Dry 

Weight 

Kg 

Power 

Supply 

V/A/Hz 

AS150HR 150 95.06 568.08 NG200 up to 1:5 1.79 1.4 1.3 172 356.5 240/0.75/50 

AS200HR 200 95.4 756 NG280 up to 1:5 2.39 1.5 2.2 172 356.5 240/1.04/50 

AS250HR 250 94.88 948.6 NG350 up to 1:5 2.99 1.5 2.4 220 442 240/1.54/50 

AS300HR 300 95.09 1,135.80 NG400 up to 1:5 3.58 1.6 2.4 300 488.5 240/1.54/50 

AS350HR 350 95.37 1,321.20 NG550 up to 1:5 4.18 1.8 3.4 356 558 240/2.58/50 

AS400HR 400 95.24 1,512.00 NG550 up to 1:5 4.78 2 4.7 360 599.5 240/2.58/50 

AS500HR 500 95.42 1,886.40 P61 up to 1:5 5.97 2.2 4.8 540 870.5 415/1.53/50 

AS620HR 620 95.53 2,336.40 P65 up to 1:5 7.41 2.7 7.3 645 980.5 415/2.09/50 

AS750HR 750 95.42 2,829.60 P71 up to 1:5 8.96 2.5 5.8 855 1229.5 415/3.06/50 

AS850HR 850 95.4 3,207.60 P71 up to 1:5 10.15 2.7 8 855 1229.5 415/3.06/50 

AS950HR 950 95.25 3,589.20 P71 up to 1:5 11.35 3.2 5.9 950 1445.5 415/3.06/50 

AS1020HR 1020 95.42 3,848.40 P71 up to 1:5 12.18 2.6 4.5 1200 1880 415/3.06/50 

AS1200HR 1200 95.31 4,532.40 R75A-1 up to 1:5 14.33 3 6.2 1200 1880 415/4.17/50 

AS1300HR 1300 95.31 4,910.40 R75A-1 up to 1:5 15.53 3.2 7.3 1200 1880 415/4.17/50 

AS1400HR 1400 95.37 5,284.80 R75A-1 up to 1:5 16.72 2.8 6.6 1500 2665 415/4.17/50 

AS1600HR 1600 95.52 6,030.00 R75A-1 up to 1:5 19.11 3.2 7.1 1500 2665 415/4.17/50 

AS1800HR 1800 95.49 6,786.00 R91A up to 1:5 21.50 3.7 7.6 1650 2815 415/5.56/50 

AS2000HR 2000 95.51 7,538.40 R93A up to 1:5 23.89 3.5 6.6 2000 3730 415/10.43/50 

AS2400HR 2400 95.31 9,064.80 R93A up to 1:5 28.67 4 8.1 2300 3980 415/10.43/50 

AS3000HR 3000 95.48 11,311.20 R512A up to 1:5 35.83 4.9 8.6 3150 5306 415/12.8/50 

AS3500HR 3500 95.37 13,212.00 R512A up to 1:5 41.81 6 9.6 3650 5806 415/12.8/50 

Maximum operating pressure 600kPa. Higher pressure boilers available. 

Larger Boiler sizes available. Available as Dual Fuel (Natural Gas/LPG, Natural Gas/Light Oil) 

116

Contents 



Arizona 150-1300kW 

241 

Ø b 

Ø c 

Legend 

N1 Boiler Supply 

N2 Boiler Return 

N3 1/2” connection for 

additional equipment 

N4 Drain 

N5 Safety valve/s connection 

N6 1/2” bulb-holding well 

N8 1/2” inspection well 

CONDENSING & 


Dimensional N1 Boiler supply Data applies to Standard and High Efficiency HR Models 

N2 Boiler return 

N3 1/2" connection for additional equipment 

N4 Model Connection for system H loading/unloading H1 H2 H4 H6 H10 L L2 P P2 P3 P4 P5 P6 Øb Øc N1 N2 N4 N5 


N6 AS150 1/2" bulb-holding 1080 well 905 440 961 440 54.5 800 750 1364 1000 513 475 452 200-250 160 250 50 50 1 - 

N8 1/2" inspection well 

AS200 1080 905 440 961 440 54.5 800 750 1364 1000 513 475 452 200-250 160 250 50 50 1 - 

AS250 1080 905 440 961 440 54.5 800 750 1614 1250 513 725 376 200-250 160 250 50 50 1 - 

AS300 1180 1005 490 1061 490 54.5 900 850 1614 1295 523 700 467 200-250 180 250 65 65 1 - 

AS350 1180 1005 490 1061 490 54.5 900 850 1864 1500 523 980 437 200-250 180 250 65 65 1 - 

AS400 1190 1015 500 1095 500 50 940 890 1872 1502 600 850 422 230-280 225 250 80 80 1 1-1/4 

AS500 1380 1205 610 1285 610 60 1160 1110 1946 1502 663 850 437 270-320 225 300 80 80 1-1/4 1-1/4 

AS620 1380 1205 610 1285 610 60 1160 1110 2235 1792 663 1150 427 270-320 225 300 80 80 1-1/4 1-1/4 

AS750 1510 1335 675 1417 675 60 1290 1240 2247 1753 704 1100 451 270-320 280 350 100 100 1-1/4 1-1/2 

AS850 1510 1335 675 1417 675 60 1290 1240 2247 1753 704 1100 451 270-320 280 350 100 100 1-1/4 1-1/2 

AS950 1510 1335 675 1417 675 60 1290 1240 2497 2003 704 1200 596 270-320 280 350 100 100 1-1/4 1-1/2 

AS1020 1660 1485 750 1568 750 60 1440 1390 2477 2003 704 1200 596 270-320 280 400 125 125 1-1/4 1-1/2 

AS1200 1660 1485 750 1568 750 60 1440 1390 2477 2003 704 1200 596 270-320 280 400 125 125 1-1/4 1-1/2 

AS1300 1660 1485 750 1568 750 60 1440 1390 2477 2003 704 1200 596 270-320 280 400 125 125 1-1/4 1-1/2 

Arizona 1400-3500kW 

Legend 

Ø b 

Ø c 

N1 Boiler Supply 

N2 Boiler Return 

N3 1” connection for 

additional equipment 

N4 Drain 


N6 1/2” bulb-holding well 

N8 1/2” inspection well 

Dimensional Data applies to Standard and High Efficiency HR Models 

N1 Boiler supply 

N2 Boiler return 

Model H H1 H2 

N3 1" connection for additional equipment 

H4 H6 H10 L L2 P P2 P3 P4 P5 P6 Øb Øc N1 N2 N4 N5 

N4 AS1400 Connection 1746 for system 1630 loading/unloading 880 880 150 1470 1270 2886 2300 831 1300 755 350-400 320 400 150 150 1-1/4 1-1/2 

N5 AS1600 Safety valve/s 1746 connection 1630 880 880 150 1470 1270 2886 2300 831 1300 755 350-400 320 400 150 150 1-1/4 1-1/2 

N6 1/2" bulb-holding well 

AS1800 1746 1630 880 880 150 1470 1270 3096 2510 771 1850 475 450-500 320 400 150 150 1-1/4 1-1/2 

N8 1/2" inspection well 

AS2000 1876 1760 945 945 150 1600 1400 3220 2510 903 1550 767 450-500 360 500 200 200 1-1/4 1-1/2 

AS2400 1876 1760 945 945 150 1600 1400 3480 2770 903 1950 627 450-500 360 500 200 200 1-1/4 1-1/2 

AS3000 2146 2030 1080 1080 150 1870 1670 3480 2770 903 2050 527 450-500 400 550 200 200 1-1/4 1-1/2 

AS3500 2146 2030 1080 1080 150 1870 1670 3935 3225 903 2050 982 450-500 400 550 200 200 1-1/4 1-1/2 

117


Contents 

Case Studies 

CONDENSING & 


The Age Building 

Melbourne 

2 x Arizona Boiler 

Central Park / 

Frasers Property 

Sydney 

3 x Arizona 2000kW 

SAHMRI 

Adelaide 


118

Contents 


Chadstone 

Shopping Centre 

Thermal Plant 



CONDENSING & 


Hoyts Cinema Complex 


Bio Science 


119

XRE - Conventional Boilers 

Contents 

CONDENSING & 


XRE 

Cast Iron Sectional Boilers 

150 – 1450kW 

Note: control panel shown for illustrative purposes only and may not be used on actual boiler. 

XRE Cast Iron Sectional Boilers, being of modular construction, are ideal 

for retrofitting into plant rooms with limited access as they are supplied 

unassembled and can fit through a standard doorway. They are able to 

be fitted with either oil, gas or Low NOx burners. 

The XRE provides high energy output whilst offering 

significant energy savings and reduced environmental 

impact. It is ideally suited to underfloor heating 

applications. 

Exchange surface are arranged in parallel streams for 

higher performance and the crossed girder construction 

ensures excellent distribution of mechanical forces. 

The large heat exchange surface in the combustion 

chamber allows better and more efficient exchanger/ 

burner combinations. XRE boilers display high combustion 

efficiency of up to 83% depending on configuration. 

Increased insulation results in a remarkable reduction 

in heat losses and energy consumption. Double layers of 

100mm glass wool let the boiler operate efficiently and 

quietly for your peace of mind. 

The XRE has been designed for ease of installation and 

problem free maintenance. Hinged door and reversible door 

hatch provide easy access. For low temperature operation 

modulated down to 40°C. 


Type 

Range 

Cast Iron Sectional 

105-335kW (XRE3) 

390-780kW (XRE4) 

695-1450kW (XRE5) 

Efficiency Gross 83% 

Fuel Type 





Modulation up to 1:10 


Max Pressure 600 kPa 

120

Contents 


XRE3 105 - 330kW 


Product 

Code 

Output 

80/60°C kW 

Nominal 

Input MJ/hr 

Burner 

Selection 

Modulation 

Ratio 

Waterside 

pressure loss 

at Δ t = 15 

KkPa 

Flow Rate 

(ΔT 15K) l/s 

Combustion 

Side Pressure 

Drop mbar 

Total Water 

Volume 

litres 

Dry Weight 

Kg 

Power 

Supply 

V/A/Hz 

XRE34 130 560 GS140 up to 1:3 0.5 2.1 0.3 102 620 240/0.75/50 

XRE35 169 730 GS200 up to 1:3 0.9 2.7 0.6 120 740 240/0.75/50 

XRE36 210 910 GS280 up to 1:3 1.5 3.3 1.1 140 850 240/1.04/50 

XRE37 249 1080 GS350 up to 1:3 2.1 4.0 1.6 160 985 240/1.54/50 

XRE38 291 1260 GS400 up to 1:3 3.0 4.6 2.2 182 1110 240/1.54/50 

XRE39 338 1460 GS550 up to 1:3 5.0 5.4 2.5 204 1230 240/2.58/50 

CONDENSING & 



Model A B C Y P ØD 

XRE34 995 900 750 292 595 180 

XRE35 1165 1070 920 292 765 180 

XRE36 1335 1240 1090 292 935 180 

XRE37 1505 1410 1260 292 1105 180 

XRE38 1675 1580 1430 292 1275 200 

XRE39 1845 1750 1600 292 1445 200 

All measurements in mm 

121


Contents 

XRE4 390 - 780kW 

CONDENSING & 



Product 

Code 

Output 

80/60°C 

kW 

Nominal 

Input 

MJ/hr 

Burner 

Selection 

Modulation 

Ratio 

Waterside 

pressure loss at 

Δ t = 15 K kPa 

Flow 

Rate 

(ΔT 15K) 

l/s 

Combustion Side 

Pressure Drop 

mbar 

Total Water 

Volume litres 

Dry Weight Kg 

Power Supply 

V/A/Hz 

XRE408 390 1712 NG550 up to 1:3 2.00 6.2 1.1 370 1805 240/2.58/50 

XRE409 450 1975 P61 up to 1:5 2.70 7.1 1.5 412 2075 415/1.53/50 

XRE410 540 2370 P61 up to 1:5 3.70 8.6 2 455 2240 415/1.53/50 

XRE411 600 2634 P65 up to 1:5 4.70 9.5 2.5 500 2460 415/2.09/50 

XRE412 670 2940 P65 up to 1:5 6.25 10.6 2.5 542 2640 415/2.09/50 

XRE413 720 3160 P65 up to 1:5 7.85 11.4 2.5 585 2880 415/2.09/50 

XRE414 780 3424 P71 up to 1:5 11.00 12.4 2.5 630 3060 415/3.06/50 


540 

291 44 

30 

240 

680 

(1) 

1740 

L000056-B 

Mk Tapp 

Heati 

Heati 

Rp 2 

Sludg 

Ø Rp 

Integ 

Model 

ØA ext 

ØB 

inch 

ØC D E J L S 

XRE408 250 2-1/2 z 235 1427 1800 1505 1183 

XRE409 250 2-1/2 * 235 1427 1950 1665 1343 

XRE410 250 2-1/2 * 235 1427 2120 1825 1503 

XRE411 300 3 * 254 1447 2305 1985 1663 

Legend 

Mk Tapped Connection 

1 Heating outlet - weld 

2 Heating inlet - weld 

3 Rp 2 draining outlet 

4 Sludge removal hole Ø Rp 2 1/2 - plugged 

5 Integrated flow switch 

XRE412 300 3 * 254 1447 2465 2145 1823 

XRE413 300 3 * 254 1447 2625 2305 1983 

XRE414 300 3 * 254 1447 2785 2465 2143 

All measurements in mm unless specified otherwise. 

* Plate intact or pre-drilled to the diameter specificed on order. 

122

Contents 


XRE5 695 – 1450kW 


Product 

Code 

Output 

80/60°C 

kW 

Nominal 

Input 

MJ/hr 

Burner 

Selection 

Modulation 

Ratio* 

Waterside 

pressure 

loss at Δ t = 

15 K kPa 

Flow Rate 

(ΔT 15K) l/s 

Combustion 

Side Pressure 

Drop mbar 

Total Water 

Volume litres 

Dry Weight 

Kg 

Power Supply 

V/A/Hz 

XRE514 812 3550 P71 up to 1:5 3.00 12.9 2.30 655 3170 415/3.06/50 

CONDENSING & 


XRE515 870 3820 P71 up to 1:5 3.47 13.8 2.40 695 3365 415/3.06/50 

XRE516 928 4075 P71 up to 1:5 1.17 14.7 2.50 732 3565 415/3.06/50 

XRE517 986 4328 P71 up to 1:5 1.35 15.7 2.60 770 3760 415/3.06/50 

XRE518 1044 4585 P71 up to 1:5 1.40 16.6 2.70 810 3960 415/3.06/50 

XRE519 1102 4840 P71 up to 1:5 1.85 17.5 2.85 850 4130 415/3.06/50 

XRE520 1160 5090 P71-1 up to 1:5 2.15 18.4 3.00 905 4350 415/3.06/50 

XRE521 1218 5345 P71-1 up to 1:5 2.40 19.3 3.10 945 4540 415/3.06/50 

XRE522 1276 5600 R75A-1 up to 1:5 2.65 20.3 3.20 985 4740 415/4.17/50 

XRE523 1334 5856 R75A-1 up to 1:5 2.90 21.2 3.30 1020 4930 415/4.17/50 

XRE524 1400 6110 R75A-1 up to 1:5 3.20 22.2 3.40 1060 5110 415/4.17/50 

XRE525 1450 6365 R75A-1 up to 1:5 3.50 23.0 3.50 1095 5297 415/4.17/50 

Maximum operating pressure 600kPa. *Higher modulation available if required 


Legend 

1 Heating outlet ØE (to be welded) 

2 Heating inlet ØE (to be welded) 

3 Draining Rp 3/4 

4 Flow switch detector 

5 Min. height for 

maintenance = 850mm 

Model A B C D ØE ØF G H K 

XRE514 1674 1744 1488 217 139.7 400 - -2 10 

XRE515 1785 1744 1488 188 139.7 400 150 -31 -19 

XRE516 1896 1966 1488 189 139.7 400 150 -30 -18 

XRE517 2007 1966 1488 210 139.7 400 370 -9 3 

XRE518 2118 2188 1504 236 159 400 370 -8 4 

XRE519 2229 2188 1504 257 159 400 370 13 25 

Model A B C D ØE ØF G H K 

XRE520 2380 2450 1504 208 159 400 650 -36 -24 

XRE521 2491 2450 1504 209 159 * 650 -35 -23 

XRE522 2602 2672 1504 230 159 * 650 -14 -2 

XRE523 2713 2672 1504 231 159 * 980 -13 -1 

XRE524 2824 2894 1504 252 159 * 980 8 20 

XRE525 2935 2894 1504 253 159 * 980 9 21 


123

Enterprise Natural Gas Burners - Gas, Dual Fuel & Oil Burners 

Contents 

CONDENSING & 


124

Contents 

Gas, Dual Fuel & Oil Burners 

CONDENSING & 


Gas, Dual Fuel 

& Oil Burners 

Continued investment in research and development ensures our burners 

deliver optimised performance and minimum ecological impact. 

Our burners can be equipped with the most modern automatic mechanical or electronic 

modulation systems that maintain the correct gas/air ratio. In this way, the burner’s thermal load 

is adapted with precision to the need for heat in every moment of operation in order to guarantee 

optimised output at every point in combustion. 

Enterprise Natural Gas Burners pg 126 

Enterprise Light Oil Burners pg 133 Enterprise Dual Fuel Burners pg 134 

LMV Electronic Burner Control pg 135 

125


Contents 

Enterprise Natural Gas Burners 

CONDENSING & 


35 - 8,000kW 

The Enterprise natural gas burners cover a firing range from 35kW to 

10,000kW and are suitable for small, medium and large applications. 

The Enterprise burners are designed to be aesthetic 

and functional but at the same time gives prominence to 

innovative technologies; in fact all components can be fitted 

onto a backing plate which can be moved and attached 

to special fixings within the burner to make maintenance 

easier. 

The models can be supplied for operations as follows: 

• TN: On / Off 

• PR: Progressive 

• AB: High / Low 

• MD: Modulating 

Low NOx models 

Enterprise gas burners are also available in Low NOx 

models. 

Our low NOx burners benefit from the installation of an 

innovative combustion head that re-distributes the gaseous 

element according to different weights and in a negative 

pressure zone, which allows a portion of the combusted 

gases to re-circulate 

Enterprise burners feature a high performance combustion 

head which ensures safety and increased efficiency. These 

units also feature simplified maintenance through convenient 

access to essential areas. A cam driven by the modulating 

motor ensures a smooth transition from low to high fire. 

Low NOx burner combustion head 

Modbus OCI-412 

126

Contents 


Enterprise Natural Gas Burners 20kW - 85kW 


Back Pressure in combustion chamber (mbar) 

NG35 TN 

NG70 TN 

NG70 AB 

NG90 TN 

NG90 AB 

CONDENSING & 


Output (kW) 

Product Code 

Thermal Output 

Minimum kW 


Maximum kW 

Electrical Supply 

AC volts/Hz 

Motor Output 

W 

Gas Train Diameter 

inch 

NG 35.TN.15 20 41 240/50 75 1/2 

NG 70.TN.15 30 70 240/50 100 1/2 

NG 70.AB.15 19 68 240/50 100 1/2 

NG 90.TN.15 40 85 240/50 100 3/4 

NG 90.TN.20 40 85 240/50 100 3/4 

NG 90.AB.15 22 85 240/50 100 3/4 

NG 90.AB.20 22 85 240/50 100 3/4 

Valve train sizes may vary according to specified gas pressure. 


Model A B min/max C min/max D E F G H K J L 

NG35 338 78/100 240/262 269 14 255 Ø80 Ø95 145 86 194 

NG70 365 78/91 274/287 304 14 291 Ø80 Ø95 145 - 218 

NG90 365 66 299 304 14 291 Ø80 Ø95 145 99 218 

Model M N O min/max P Q min/max R min/max S T U min/max V W X 

NG35 M8 155 96/120 112 258 91/113 167 6 45/67 94 400 266 

NG70 M8 155 96/120 112 271/284 105/118 167 2 - - 438 291 

NG90 M8 155 96/120 112 292/363 125/196 167 2 - - 438 291 

All measurements in mm. 

127


Contents 


CONDENSING & 



Back Pressure in combustion chamber (mbar) 

NG120 TN 

NG140 TN 

NG200 TN 

NG200 AB-PR-MD 

NG140 AB-PR-MD 

Output (kW) 

Product Code 


Minimum kW 


Maximum kW 


AC volts/Hz 

Motor Output 

W 


inch 

NG 120.TN.20 60 120 240/50 180 3/4 

NG 140.TN.20 60 170 240/50 180 3/4 

NG 140.TN.25 60 170 240/50 180 1 

NG 140.AB.20 35 170 240/50 180 3/4 

NG 140.AB.25 35 170 240/50 180 1 

NG 200.TN.20 85 200 240/50 180 3/4 

NG 200.TN.25 85 200 240/50 180 1 

NG 200.AB.20 42 200 240/50 180 3/4 

NG 200.AB.25 42 200 240/50 180 1 



R min/max 

Q min/max 

S 

Y 

W 

J 

X 

G 

K 

P 

M 

L 

B min 

O max 

O min 

K 

H 

P 

N 

D 

T 

O min 

B max 

C min/max 

O max 

A 

Model 

A 

B 

min/max 

C 

min/max 

D G H J K L M N 

O 

min/max 

P 

Q 

min/max 

R 

min/max 

S T W X Y 

NG120 560 85/170 390/475 373 101 128 158 188 245 M8 188 108/158 133 376/461 201/286 175 32 537 340 108 

NG140 560 85/170 390/475 373 101 128 158 188 245 M8 188 108/158 133 420/506 201/286 220 32 560 340 108 

NG200 560 85/170 390/475 373 117 137 158 188 245 M8 188 108/158 133 376/461 201/286 175 32 537 340 108 


128

Contents 




Back-pressure in combustion chamber (mbar) 

NG280 AB 

NG280 TN 

NG350 PR 

NG350 TN 

NG400 PR 

NG400 TN 

NG550 PR 

NG550 TN 

CONDENSING & 


Power (kW) 

Product Code 


Minimum kW 



Maximum kW 


AC volts/Hz 

Motor Output 

W 


inch 

NG280.TN 95 300 240/50 250 1, 1-1/4, 1-1/2 

NG280.AB 65 300 240/50 250 1, 1-1/4, 1-1/2 

NG350.TN 115 330 240/50 370 1, 1-1/4, 1-1/2 

NG350.PR 80 330 240/50 370 1, 1-1/4, 1-1/2 

NG350.MD 80 330 240/50 370 1, 1-1/4, 1-1/2 

NG400.TN 185 420 240/50 450 1, 1-1/4, 1-1/2,2 

NG400.PR 115 420 240/50 450 1, 1-1/4, 1-1/2,2 

NG400.MD 115 420 240/50 450 1, 1-1/4, 1-1/2,2 

NG550.TN 245 570 240/50 620 1-1/4. 1-1/2,2 

NG550.PR 160 570 240/50 620 1-1/4. 1-1/2,2 

NG550.MD 160 570 240/50 620 1-1/4. 1-1/2,2 


Model A B C F G H J K1 K2 M N 

O 

min/max 

P Q R S T X Y 

NG280 732 162.5 570 396 117 137 348 215 223 M10 219 131/179 155 541 366 175 128 491 108 

NG350 748 178 570 396 125 164 348 215 223 M10 219 131/179 155 541 366 175 89 491 144 

NG400 768 198 570 396 144 164 348 215 223 M10 219 131/179 155 541 366 175 89 491 144 

NG550 893 198 570 396 144 164 348 215 223 M10 247 131/179 155 541 366 175 89 491 144 


129

P 

K 

O 

P 

K 


Contents 

CONDENSING & 





P61 AB-PR-MD 

P65 AB-PR-MD 

P71 AB-PR-MD..0.xx 

P71 AB-PR-MD..1.xx 

R75A AB-PR-MD 

Power (kW) 

Product Code 


Minimum kW 


Maximum kW 


AC volts/Hz 

Motor Output 

kW 


inch 

P61 160 800 415/50 1.1 2-2-1/2 

P65 270 970 415/50 1.5 2-2-1/2 

P71 300 1200 415/50 2.2 2-2-1/2-3 

P71.1 300 1650 415/50 2.2 2-2-1/2-3 

R75A 320 2050 415/50 3 2-2-1/2-3 


BB 

CC 

Y 

AA 

Z 

G 

J 

L 

W 

U 

E 

D 

F 

B 

R 

S 

Q 

C 

A 

V 

K 

K 

P 

P 

P60 

N 

H 

P65, P72, 73A 

N 

H 

O Min. 

O Max. 

M 

Boiler drilling 

O 

Burner flange 

M 

Boiler drilling 

O Min. 

O Max. 

Burner flange 

Type Model AS AL AA B(S*) B(L*) BB C CC D E F G H J K L M N O min/max P Q R S U V W Y Z 

P61 M-.xx.x.IT.A.0.32 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 190 341 112 229 444 - 464 162 120 

P61 M-.xx.x.IT.A.0.40 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 190 439 112 327 444 - 464 162 120 

P61 M-.xx.x.IT.A.0.50 1079 1169 99 343 433 314 736 298 812 500 312 184 204 210 240 344 M10 269 190 190 190 447 112 335 444 - 464 162 120 

P61 M-.xx.x.IT.A.0.65 1079 1169 99 343 433 314 736 298 997 685 312 184 204 250 240 420 M10 269 190 190 190 515 112 403 540 313 540 162 120 

P65 M-.xx.x.IT.A.0.40 1129 1219 130 326 416 373 803 316 900 568 332 184 218 208 300 376 M10 330 216 250 233 457 130 327 519 - 531 198 155 

P65 M-.xx.x.IT.A.0.50 1129 1219 130 326 416 373 803 316 900 568 332 184 218 208 300 376 M10 330 216 250 233 465 130 335 519 - 531 198 155 

P65 M-.xx.x.IT.A.0.65 1129 1219 130 326 416 373 803 316 998 666 332 184 218 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 155 

P71 M-.xx.x.IT.A.1.40 1188 1298 130 385 495 373 803 316 1026 694 332 234 264 208 300 376 M10 330 216 250 233 457 130 327 519 - 531 198 155 

P71 M-.xx.x.IT.A.1.50 1188 1298 130 385 495 373 803 316 1026 694 332 234 264 208 300 376 M10 330 216 250 233 465 130 335 519 - 531 198 155 

P71 M-.xx.x.IT.A.1.65 1188 1298 130 385 495 373 803 316 1104 772 332 234 264 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 155 

P71 M-.xx.x.IT.A.1.80 1188 1298 130 385 495 373 803 316 1106 774 332 234 264 275 300 407 M10 330 216 250 233 574 130 444 565 344 562 198 155 

R75A M-.xx.S.IT.A.1.50 1429 - 138 503 - 374 926 330 1062 700 362 254 270 229 300 420 M10 330 216 250 233 465 130 335 525 - 575 210 155 

R75A M-.xx.S.IT.A.1.65 1429 - 138 503 - 374 926 330 1139 777 362 254 270 296 300 420 M10 330 216 250 233 533 130 403 570 313 575 210 155 

R75A M-.xx.S.IT.A.1.80 1429 - 138 503 - 374 926 330 1141 779 362 254 270 296 300 428 M10 330 216 250 233 574 130 444 570 344 583 210 155 


130

L Z 

W 

AN 

J 

G 

Y 

P 

O min 

K 

Contents 




R91A PR-MD 

R92A PR-MD 

R93A PR-MD 

R512A PR-MD 

R515A PR-MD 

R520A PR-MD 

R525A PR-MD 

CONDENSING & 



Power (kW) 

Product Code 


Minimum kW 


Maximum kW 


AC volts/Hz 

Motor Output 

kW 


inch 

R91A 480 2670 415/50 4 2 

R92A 480 3050 415/50 5.5 2 

R93A 550 4100 415/50 7.5 2 

R512A 600 4500 415/50 9.2 2 

R515A 770 5200 415/50 11 2 

R520A 1000 6400 415/50 15 2 

R525A 2000 8000 415/50 18.5 2 


R91A, R92A, R93A 

B 

AA 

A 

C 

P 

K 

O max 

øH 

N 

M 

O min 

O max 

R 

Q 

S 

V 

Suggested 

boiler drilling 

Burner 

flange 

Type Model A AA AN B BB C CC D E F G H J K L M N O min/max P Q R S U V W Y Z 

R91A M-.xx.S.IT.A.1.50 1495 135 550 490 441 1005 507 1160 765 435 265 295 447 360 464 M12 424 280 310 300 532 148 384 624 190 649 228 185 

R91A M-.xx.S.IT.A.1.65 1495 135 564 490 441 1005 507 1406 971 435 265 295 447 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 

R91A M-.xx.S.IT.A.1.80 1495 135 579 490 441 1005 507 1437 1002 435 265 295 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185 

R91A M-.xx.S.IT.A.1.100 1495 135 592 490 441 1005 507 1520 1085 435 265 295 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 185 

R92A M-.xx.S.IT.A.1.50 1495 135 550 490 441 1005 507 1160 725 435 269 299 447 360 464 M12 424 280 310 300 532 148 384 624 190 649 228 185 

R92A M-.xx.S.IT.A.1.65 1495 135 564 490 441 1005 507 1406 971 435 269 299 442 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 

R92A M-.xx.S.IT.A.1.80 1495 135 579 490 441 1005 507 1437 1002 435 269 299 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185 

R92A M-.xx.S.IT.A.1.100 1495 135 592 490 441 1005 507 1520 1859 435 269 299 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 185 

R93A M-.xx.S.IT.A.1.50 1500 135 550 495 493 1005 507 1160 725 435 304 344 447 360 464 M12 424 280 310 300 532 148 384 624 190 649 228 185 

R93A M-.xx.S.IT.A.1.65 1500 135 564 495 493 1005 507 1406 971 435 304 344 447 360 464 M12 424 280 310 300 632 148 484 846 292 649 228 185 

R93A M-.xx.S.IT.A.1.80 1500 135 579 495 493 1005 507 1520 1002 435 304 344 447 360 464 M12 424 280 310 300 683 148 535 875 313 649 228 185 

R93A M-.xx.S.IT.A.1.100 1500 135 592 495 493 1005 507 1160 1085 435 304 344 447 360 464 M12 424 280 310 300 790 148 642 942 353 649 228 185 


131

L Z 

W 

AN 

J 

G 

Y 

P 


Contents 


R512A, R515A, R520A, R525A 

CONDENSING & 


C C 

B 

AD 

AA 

A 

C 

M 

U 

E 

D 

F 

R 

Q 

S 

V 

Suggested 

boiler drilling 

Burner flange 

Type Model A AA AD AN B BB C CC D E F G H J K L M N O P Q R S U V W Y Z 

R512A M-.xx.S.IT.A.1.50 1683 220 35 595 530 517 1153 532 1590 946 644 340 380 494 540 494 M14 552 390 390 763 149 614 845 190 764 328 270 

R512A M-.xx.S.IT.A.1.65 1683 220 35 611 530 517 1153 532 1613 969 644 340 380 494 540 494 M14 552 390 390 636 149 487 845 292 764 328 270 

R512A M-.xx.S.IT.A.1.80 1683 220 35 626 530 517 1153 532 1645 1002 644 340 380 494 540 494 M14 552 390 390 687 149 538 875 313 764 328 270 

R512A M-.xx.S.IT.A.1.100 1683 220 35 595 530 517 1153 532 1726 1082 644 340 380 494 540 494 M14 552 390 390 791 149 642 942 353 764 328 270 

R515A M-.xx.S.IT.A.1.50 1683 220 35 595 530 517 1153 532 1590 946 644 380 420 494 540 494 M14 552 390 390 763 149 614 845 190 764 328 270 

R515A M-.xx.S.IT.A.1.65 1683 220 35 611 530 517 1153 532 1613 969 644 380 420 494 540 494 M14 552 390 390 636 149 487 845 292 764 328 270 

R515A M-.xx.S.IT.A.1.80 1683 220 35 626 530 517 1153 532 1645 1002 644 380 420 494 540 494 M14 552 390 390 687 149 538 875 313 764 328 270 

R515A M-.xx.S.IT.A.1.100 1683 220 35 639 530 517 1153 532 1726 1082 644 380 420 494 540 494 M14 552 390 390 791 149 642 942 353 764 328 270 

R520A M-.xx.S.IT.A.1.50 1683 220 35 595 530 517 1153 532 1590 946 644 400 440 494 540 494 M14 552 390 390 755 149 614 844 190 764 328 270 

R520A M-.xx.S.IT.A.1.65 1683 220 35 611 530 517 1153 532 1613 669 644 400 440 494 540 494 M14 552 390 390 636 149 487 845 292 764 328 270 

R520A M-.xx.S.IT.A.1.80 1683 220 35 626 530 517 1153 532 1645 1002 644 400 440 494 540 494 M14 552 390 390 687 149 538 875 313 764 328 270 

R520A M-.xx.S.IT.A.1.100 1683 220 35 639 530 517 1153 532 1726 1082 644 400 440 494 540 494 M14 552 390 390 791 149 642 942 353 764 328 270 


132

Contents 

Enterprise Light Oil Burners - Gas, Dual Fuel & Oil Burners 

Enterprise Light Oil Burners 

21 - 4,100kW 

The Enterprise light oil burners cover a 

firing range from 21kW to 4,100kW and are 

suitable for small and medium applications. 

CONDENSING & 


Combustion air can be easily set by the adjusting screw 

without removing the cover. The cover, easily removable, is 

heat resistant (ABS material). 

The burner is designed to be aesthetic and functional but at 

the same time gives prominence to innovative technologies; 

in fact all components can be fitted into a backing plate 

which can be moved and attached to special fixings within 

the burner to make maintenance easier. 

The models can be supplied for operations as follows: 

• TN: On / Off 

• AB: High / Low 

• PR: Progressive 

• MD: Modulating 


head which ensures safety and increased efficiency to 

minimise environmental impact. These units also feature 

simplified maintenance through convenient access to 

essential areas. 


Product Code 


Minimum kW 


Maximum kW 


AC volts/Hz 

Motor Output 

W 

Light Oil Consumption 

Rate Kg/h min/max 

LO 35.TN 21 41 240/50 75 1.8/3.5 

LO 60.AB 25 60 240/50 100 2.0/5.0 

LO 90.TN 40 85 240/50 150 3.0/7.0 

LO 90.AB 24 85 240/50 150 2.0/7.0 

LO140.TN 80 160 240/50 180 16/35 

LO140.AB 38 160 240/50 180 9.7/35 

LO200.TN 80 200 240/50 180 17/47 

LO200.AB 38 200 240/50 180 13/47 

LO280.TN 70 310 240/50 250 16/35 

LO400.TN 195 420 240/50 370 16/35 

LO400.AB 115 420 240/50 370 9.7/35 

LO550.TN 200 560 240/50 620 17/47 

LO550.AB 160 560 415/50 620 13/47 

PG 60.AB 145 698 415/50 1100 12.5/60 

PG 60.PR 151 791 415/50 1100 13/68 

PG70.XX 291 1047 415/50 2200 25/90 

PG81.XX 264 1900 415/50 3000 40/135 

PG91 1047 2093 415/50 4000 - 

PG91 698 2093 415/50 4000 - 

PG92 849 2558 415/50 5500 - 

PG93 550 4100 415/50 7500 - 

133

Enterprise Dual Fuel Burners - Gas, Dual Fuel & Oil Burners 

Contents 

CONDENSING & 


Enterprise Dual Fuel Burners 

35 - 13,000kW 

The Enterprise dual fuel range are suitable 

for use with either natural gas/LPG or 

natural gas/light oil. This range of burners 

cover a firing range from 35kW to 13,000kW. 

These burners have been carefully designed to provide 

maximum efficiency with either gas or light oil. Fuel change 

over is achieved by the “flick of a switch” which prompts 

the burner to carry out a controlled shutdown. The high 

performance fuel pump is driven by a separate motor and 

only operates when oil firing operation is selected. 

The compact dimensions of these units greatly simplify 

maintenance. They all feature an aluminium die cast 

housing, an easily removed cover and a grill on the air 

inlet to prevent foreign materials being drawn into the fan. 

The combustion head is adjusted by means of a graduated 

screw. 


head which ensures safety and increased efficiency to 

minimise environmental impact. These units also feature 

simplified maintenance through convenient access to 

essential areas. 


Product Code 


Minimum kW 


Maximum kW 


AC volts/Hz 

Motor Output 

kW 

Pump Motor 

kW 

HS5 35 70 240/50 0.10 0.10 23 

HS10 65 140 240/50 0.15 0.10 30 

HS18 80 200 240/50 0.15 0.10 31 

HP20 85 230 240/50 0.37 0.10 70 

HP30 65 350 240/50 0.37 0.10 70 

HP 60.xx.40 170 523 415/50 1.10 0.55 115 

Dry Weight 

Kg 

HP 60.xx 170 880 415/50 1.10 0.55 125 

HP 72.xx 330 1200 415/50 2.20 0.55 145 

HP 72.xx 330 1550 415/50 2.20 0.55 145 

HP 73A.xx 330 2300 415/50 3.00 0.55 155 

HP91A 480 2670 415/50 4.00 0.55 290 

HP92A 480 3050 415/50 5.50 1.10 300 

HP93A 550 4100 415/50 7.50 1.10 315 

HP512A 600 4500 415/50 9.20 1.10 340 

HP515A 770 5200 415/50 11.00 1.50 360 

HP520A 1000 6400 415/50 15.00 1.50 375 

HP525A 2000 8000 415/50 18.50 4.00 390 

HP1025 2550 8700 415/50 18.50 4.00 610 

HP1030 2550 10600 415/50 22.00 4.00 680 

HP1040 2550 13000 415/50 30.00 4.00 680 

134

Contents 

LMV Electronic Burner Control - Gas, Dual Fuel & Oil Burners 

LMV Electronic Burner Control 

CONDENSING & 


Electronic Cam and Control System for medium and high power gas, 

light oil, heavy oil and mixed fuel burners. 

Automatic Heating, has adopted an electronic cam and 

control system in its line of Enterprise burners. 

This innovative system, which has been divided into two 

types of flame control box, can be used for both commercial 

(from 140 kW) and industrial applications (up to 70 MW). 

Burners designed for use with a single or mixed fuel with 

continuous or intermittent operation and permits the 

command and control of all the various elements that plan a 

part in the correct mixture of the fuel and combustion air by 

means of an appropriately programmed flame control box. 

This versatile solution oriented to the future permits the 

achievement of the maximum precision in combustion 

adjustment. 

The system can also be expanded through interface with 

an oxygen control probe and/or a fan speed adjustment 

inverter in order to improve performance even further, in 

this way obtaining the highest savings in energy in terms of 

both the fuel and the electric power required. 

The command and control system is composed of a 

twin-microprocessor electronic unit for the integration 

of all burner command and control functions, and a local 

programming and adjustment unit. 

Integrated functions include air/fuel ratio adjustment (with 

work point configuration possibility), PID temperature or 

pressure regulator, gas valve leakage control, adjustable 

cycle times, pre-configured fuel trains and input/output 

configuration. 

The programming levels are protected by password for the 

three types of user (manufacturer, servicing personnel, final 

user); dialogue between the servocontrol and the sensors is 

performed using twin-channel CAN Bus protocol in order to 

guarantee the greatest safety and reliability, and the unit can 

be installed directly in the machine or inside a separate electric 

control panel positioned no further away than 100 meters. 

Using the appropriate designated optional software the 

system can be configured directly by PC. 

Accessories 

• Electronic Control Box LMV 51.100 (without O2 trim) 

• Electronic Control Box LMV 52.200 (with O2 trim) 

• Programme (AZL 5xx) 

• Servomotor Air (SQM 4xx) 

• Servomotor Gas (SQM 4xx) 

• Servomotor Oil (SQM 4xx) 

Features 

• BMS Compatible 

• 10-1 Turn Down Range 

Flame control box integrated functions: 

• Burner control 

• Electronic cam 

• Power regulator 

• Gas valve leakage control system 

• Oxygen control 

• Inverter control 

• Dialogue with BMS systems or PLC (MOD Bus) 

• Burner commissioning and configuration via PC-tool 

• Simple programming with AZL and PC-tool 

• Complete self-diagnostic function (error memory, number 

of firings, burner operation time, clock, etc.) 

• 3 levels of parameter access: (manufacturer, servicing 

personnel, final user) 

• Remote diagnostics 

• All components can be easily interchanged 

• Parameter upgrading with PC-tool 

• Dialogue with MOD Bus protocol 

135

Contents 

CONDENSING & 


136

Contents 

Flue Systems 

CONDENSING & 


Flue Systems 

The Stainless Steel Fluing System offers considerable cost and time savings over 

conventional stainless steel welded flues. Available in sizes from 80 – 500mm 

diameter, this product will suit your requirements for any size boiler installation 

Advantages 

• Available in sizes 80 – 500mm diameter 

• Quick installation 

• Stainless Steel AISI 316L construction 

• No welding required on site 

Stainless Steel Flue System pg 138 Flue Dilution pg 148 

Draft Regulators pg 149 

Coaxial Flue System pg 150 

137

Stainless Steel Flue System - Flue Systems 

Contents 

Stainless Steel Flue System 

CONDENSING & 


The new Stainless Steel Fluing System offers 

considerable cost and time savings over 

conventional stainless steel welded flues. 

Available in sizes from 80 – 500mm diameter, this product 

will suit your requirements for any size boiler installation. 

Advantages 


PSCTSR18 

PSED02 

• Available in sizes 80 – 500mm diameter 

• Stainless Steel AISI 316L construction 

• Quick installation 

• No welding required on site 

• Suitable for Condensing Boilers 

PSCQ45 

PSCN90 

PSED01 

PSFB19 

PSFMR14 

PSFB19 

PSGT70 

PSED02 

PSED03 

PSRT08 

138

Contents 

Stainless Steel Flue Systems - Flue Systems 

Single Wall Stainless Steel Flue 

CONDENSING & 


PSED01 

Straight Element L 1000 

Product Code Height mm Diameter mm 

PSED01100 940 100 

PSED01120 940 120 

PSED01160 940 160 

PSED01200 940 200 

PSED01250 940 250 

PSED01300 940 300 

PSED01350 940 350 

PSED01400 940 400 

PSED01500 940 500 

PSED02 



PSED0280 440 80 

PSED02100 440 100 

PSED02120 440 120 

PSED02160 440 160 

PSED02200 440 200 

PSED02250 440 250 

PSED02300 440 300 

PSED02350 440 350 

PSED02400 440 400 

PSED02500 440 500 

PSED03 



PSED0380 270 80 

PSED03100 270 100 

PSED03120 270 120 

PSED03160 270 160 

PSED03200 270 200 

PSED03250 270 250 

PSED03300 270 300 

PSED03350 270 350 

PSED03400 270 400 

PSED03500 270 500 

D 

245 min - 

400 max 

H 

E 

PSET04 

Telescopic Element* 


PSET0480 250-450 80 

PSET04100 250-450 100 

PSET04120 250-450 120 

PSET04160 250-450 160 

PSET04200 250-450 200 

PSET04250 250-450 250 

PSET04300 250-450 300 

PSET04350 250-450 350 

PSET04400 250-450 400 

PSET04500 250-450 500 

*working length min.245 - max.400 

PSCQ45 

45° Elbow 

Product Code H mm D mm E mm 

PSCQ4580 129 80 29 

PSCQ45100 133 100 32 

PSCQ45120 140 120 35 

PSCQ45160 154 160 41 

PSCQ45200 168 200 47 

PSCQ45250 186 250 54 

PSCQ45300 204 300 62 

PSCQ45350 221 350 69 

PSCQ45400 239 400 76 

PSCQ45500 274 500 91 

PSCN90 

90° Elbow 

Product Code H mm D mm E mm 

PSCN9080 136 80 81 

PSCN90100 145 100 92 

PSCN90120 153 120 104 

PSCN90160 178 160 123 

PSCN90200 195 200 140 

PSCN90250 219 250 168 

PSCN90300 245 300 198 

PSCN90350 276 350 221 

PSCN90400 301 400 246 

PSCN90500 351 500 296 

139

55 

90 

96 

190 

290 

580 


Contents 

O UTLET diam. 

CONDENSING & 


145 

Fume Direction 

MALE diam. 

ANTI - BIRD MESH 

MESH NO T LARG ER THAN 20X20 mm 

PSRT08 

Tee 90° 

Product Code H mm D mm 

PSRT0880 270 80 

PSRT08100 270 100 

PSRT08120 270 120 

PSRT08160 270 160 

PSRT08200 440 200 

PSRT08250 440 250 

PSRT08300 440 300 

PSRT08350 490 350 

PSRT08400 540 400 

PSRT08500 640 500 

Flue Reducer 

M+F 

Product Code dm mm DF mm 

PSRT0180100 80 100 

PSRT0180160 80 160 

PSRT01100120 100 120 

PSRT01100160 100 160 

PSRT01100200 100 200 

PSRT01100300 100 300 

PSRT01110120 110 120 

PSRT01110160 110 160 

PSRT01110200 110 200 

PSRT01150160 150 160 

PSRT01150200 150 200 

PSRT01160200 160 200 

PSRT01200300 200 300 

PSRT01250300 250 300 

PSRT01300350 300 350 

PSRT01300400 300 400 

PSRT01400450 400 450 

PSRT01450500 450 500 

PSCTSR18 

Flue Terminal c/w Anti-bird Mesh 

Product Code 

Male 

Dia 

mm 

Outlet 

Dia. 

mm 

Thickness 

mm 

PSCTSR18D80 80 70 0.5 

PSCTSR18D100 100 80 0.5 

PSCTSR18D120 120 100 0.5 

PSCTSR18D160 160 140 0.5 

PSCTSR18D200 200 170 0.5 

PSCTSR18D300 300 260 0.5 

PSCTSR18D400 400 350 0.6 

PSCTSR18D500 500 435 0.6 

PSCTSR18D600 600 525 0.6 

ø DF 

ø dm 

ø 300 MALE 

PSTC80D 

SS Flue Plug / End Cap with 

Side Condensation Drain 

Product Code 

Dia. mm 

PSTC80D200 200 

PSTC80D300 300 

PSTC85 

SS Flue Plug / End Cap with 

Condensation Drain 

Product Code 

Dia. mm 

PSTC8580 80 

PSTC85100 100 

PSTC85120 120 

PSTC85160 160 

PSTC85200 200 

PSTC85300 300 

PSTC85400 400 

PSTC85500 500 

PSTC85600 600 

PSTR16D300 

M/F 90º Tee 


PSTC85600 160 300 

140

Contents 


CONDENSING & 


PSFMR14 

Adjustable Wallband 

Product Code D mm A mm 

PSFMR1480 80 102 

PSFMR14100 100 116 

PSFMR14120 120 130 

PSFMR14160 160 169 

PSFMR14200 200 188 

PSFMR14250 250 223 

PSFMR14300 300 259 

PSFMR14350 350 293 

PSFMR14400 400 328 

PSFMR14500 500 399 

PSFB19 

Locking Band 

Product Code D mm B mm 

PSFB1980 80 95 

PSFB19100 100 115 

PSFB19120 120 135 

PSFB19160 160 175 

PSFB19200 200 215 

PSFB19250 250 265 

PSFB19300 300 315 

PSFB19350 350 365 

PSFB19400 400 415 

PSFB19500 500 515 

PSGT70 

Silicon Gasket (Red)* 

Product Code 

D mm 

PSGT7080 80 

PSGT70100 100 

PSGT70120 120 

PSGT70160 160 

PSGT70200 200 

PSGT70250 250 

PSGT70300 300 

PSGT70350 350 

PSGT70400 400 

PSGT70500 500 

*Suitable for Non-condensing & Wood 

Boilers only (max temp 200ºC) 

Not suitable for Condensing Boilers 

DF 

DM 

PSGT71 

Silicon Gasket (Black)* 

Product Code 

D mm 

PSGT7180 80 

PSGT71100 100 

PSGT71120 120 

PSGT71160 160 

PSGT71200 200 

PSGT71250 250 

PSGT71300 300 

PSGT71350 350 

PSGT71400 400 

PSGT71500 500 

* Suitable for Condensing Boilers only 

(max temp 120ºC) 

PPH Flue Piece M/F White 

Straight Element L.205mm 

Product Code 

Dia. mm 

PABED20D100 100 

PPH Flue Non-return Valve 

110F/100M with Siphon 

Product Code 

Dia. mm 

PAVC01D110100 110/100 

141


Contents 

Flue Installation Instructions 

CONDENSING & 


4 

3 

2 

1 


1 

2 

3 

4 

All flue parts are to be assembled in a consistent 

fume direction (as indicated by arrows) 

Gaskets must be placed inside the female socket, 

with the profiled face always pointing inwards 

towards the centre, smooth side outwards 

seated in the groove. Condensing Boilers - Black 

Gaskets, Non Condensing Boilers - Red Gaskets 

Using silicone spray on the male element, join 

together gently ensuring gasket remains in 

groove. 

Fasten the locking band around the ridges of the 

male and female joint, taking care to ensure that 

the pointed arrow is fitted to match the direction 

of flow. The locking band will only fit properly in 

one direction. 

142

Contents 


Meridian Flue Manifold Kit (MFMK) 

7 

8 

CONDENSING & 


6 

11 

5 

9 

10 

4 

3 

2 

1 

Final Assembly 

Installation Notes and Part Numbers 

Item Notes Part Code Part Description Quantity 

1 

Insert the plastic flue piece (ø100mm) 

into the boiler 

2 Install the check valve 

PABED20D100 PPH Flue Piece M/F White Straight Element L.205mm 1 

PAVC01D110100 PPH Flue Non-return Valve 110F/100M with Siphon 1 

3 Install the Flue reducer (ø160mm to ø110mm) 

4 Install the straight flue piece (ø160mm) 

5 Install the 45° flue bend 

6 

Connect the common flue (ø300mm) with the 45° 

flue bend. 

7 Refer note 2 on pg 142 




PSRT01110160 SS Flue Reducer M&F ø110mm x ø160mm 1 

PSED02160 SS Flue Piece ø160mm x 500mmL 1 

PSCQ45160 SS Flue Bend ø160mm 45° 1 

PSTR16D300 SS Flue 90° Tee ø300mm reduced to ø160mm (Meridian Flue Manifold) 1 

PSGT71300 SS Flue EPDM Gasket ø300mm (Suitable up to 120°C) 1 

PSFB19300 SS Flue Locking Band ø300mm 1 

PSGT71160 SS Flue EPDM Gasket ø160mm (Suitable up to 120°C) 3 

PSFB19160 SS Flue Locking Band ø160mm 3 

11 

Connection of ø160mm flue to ø300mm flue at 45 

angle is to encourage condensate to flow through 

ø300mm flue to drain point rather than drain back 

into boiler via the ø160mm flue 

143


Contents 

Twin Wall Stainless Steel Flue 

PDAR62 

Anti-wind Cap 

Product Code Di mm De mm D1 mm 

PDAR62200 200 250 420 

PDED01 M/F 


Product Code Di mm De mm H mm 

PDED01200 200 250 940 

PDED02 M/F 



PDED02200 200 250 440 

150mm 

CONDENSING & 


PDED03 M/F 



PDED03200 200 250 270 

PDTD08 90° Tee with 

150mm Single-wall Outlet 


PDTD08200150 200 250 440 

PDRB82 

135° Tee 

Product Code Di mm De mm H mm A mm 

PDRB82200 200 250 592 330 


Di 

PDCQ45 M/F 

45° Elbow 

Product Code Di mm De mm H mm E mm 

PDCQ45200 200 250 166 89 

PDRC09 F/F 

Boiler Adapter 

Product Code Di mm De mm 

PDRC09150 150 200 

PDRC09200 200 250 

PSRC09 

Double 

Product Code 

Di mm 

PSRC09D150 150 

144

Contents 


Twin Wall Stainless Steel Flue 2 

CONDENSING & 



PDMI42 M/F 

Inspection Element 


PDMI42200 200 250 

PDTC80 Blind Cap with 

Side Condensation Drain 


PDTC80200 200 250 

PDRT01 

Flue Enlarger 


PDRT01150200 150 200 

PDFMR14 


Product Code Di mm De mm A mm 

PDFMR1480 80 130 137 

PDFMR14100 100 150 152 

PDFMR14130 130 180 172 

PDFMR14150 150 200 188 

PDFMR14180 180 230 212 

PDFMR14200 200 250 223 

PDFMR14250 250 300 259 

PDFMR14300 300 350 293 

PDFMR14350 350 450 364 

PDFMR14400 400 500 399 

PDFMR14450 450 550 434 

PDFMR14500 500 600 469 

PDFB19 

Locking Band 


PDFB1980 80 130 

PDFB19100 100 150 

PDFB19130 130 180 

PDFB19150 150 200 

PDFB19180 180 230 

PDFB19200 200 250 

PDFB19250 250 300 

PDFB19300 300 350 

PDFB19350 350 450 

PDFB19400 400 500 

PDFB19450 450 550 

PDFB19500 500 600 

145


Contents 

CONDENSING & 


Firex Flue 

Typical Flue Installation 

1 

2 

Part Numbers 

Item Part Code Part Description 

1 

2 

3 

4 

5 

PDAR62200 

PDFMR1425 

PDED01200 

PDED02200 

PDFB19200 

Anti-wind Cap Ø 200mm 


M/F Straight Element 

L.1000mm Ø 200mm 


L.500mm Ø 200mm 

Locking Band Ø 200mm 

3 

6 

7 

8 

PSACGTAT 

PDED03200 

PDTD08200/150 

SS Flue Fibreglass Tape Gasket 10m 

adhesive Roll (up to 550ºC) 


L.330mm Ø 200mm 

90° Tee with Single-wall Outlet Ø 150mm 

9 

PSRC09D150 

F/F Sleeve 

10 

KWZ150 

SS Flue Draft Regulators Ø 150mm 

11 

PDRB82200 

135° Tee Ø 200mm 

12 

PDCQ45200 

M/F 45° Elbow Ø 200mm 

4 

5 

6 

13 

14 

15 

PDRT01150200 

PDRC09150 

PDRC09200 

PDMI42200 

Flue enlarger 150mm to 200mm 

*This part is required for boilers with 150mm outlets 

e.g. Firex 34 

F/F Boiler Adapter Ø 150mm (for Firex 34) 

F/F Boiler Adapter Ø 200mm (for Firex 45 

and above) 

M/F Inspection Element Ø 200mm 

7 

16 

PDTC80200 

Blind Cap with Side Condensation Drain 

Ø 200mm 

WARNING 

8 

• The appliance and flue-system must be installed 

in accordance with AS/NZS 2918 and the relevant 

building code or codes. 

9 

10 

• Any modification of the appliance that has not been 

approved in writing by the testing authority will be in 

breach of the approval granted for compliance with 

AS/NZS 4013. 

11 

• A triple skin flue is required within the ceiling space. 

To comply with this requirement, we recommend that 

the section of double wall flue passing through the 

ceiling space be encased within 300mm diameter 

single wall flue. 

• Once the flue has been installed and approved by a 

professional installer, the flue must not be modified 

in any way. 

15 

12 14 

13 

*This part is 

only required 

for boilers with 

150mm outlets 

e.g. Firex 34 

16 

Ensure condensate drain 

contains water trap to 

prevent fumes escaping 

from the flue 

146

Contents 


CONDENSING & 


147

Flue Dilution - Flue Systems 

Contents 

Flue Dilution 

CONDENSING & 


Introduction to Flue Dilution 

A flue dilution system is normally installed where there are difficulties in the provision of a conventional 

flue, or indeed where savings can be made if the only other alternative is a high rise flue. Using flue 

dilution, boiler fumes can be discharged from the side of a building including at low level. 

How Does It Work? 

The general principle is that ambient air from outside the building is mixed with the flue gas in order to 

dilute the CO² content to less than 1% when using natural gas or LPG boilers. 

As with all flue systems, local gas authority approval must also be sought for a flue dilution system. 

The shift in the commercial market towards condensing boilers, has had a significant evolutionary 

effect on flue dilution. The flue gas temperature from these appliances is far lower than traditional 

atmospheric boilers, and as a result condensation is created within the flue. By mixing this warm moist 

gas with cooler air, the mixed gas temperature is reduced further, creating more condensation. There are 

a few critical considerations: 

• Material of flue system – only use 316 grade stainless steel on condensing applications and flue dilution 

systems. 

• The flue system must be capable of handling condensation in large quantities. 

• Pluming at the flue discharge – suspended water molecules in the diluted flue gas will be discharged out 

through the grille to atmosphere. This pluming can often be significant and can cause a nuisance to local 

residents and building occupants. Therefore careful consideration of the discharge position is of utmost 

importance. 

For technical help on fan dilution systems, either email our Technical Department 

at sales@automaticheating.com.au or call on 1800 337 959 

Flue Dilution Fan Stainless Steel 

Product Code 

Flue gas pipe Nominal Ø mm 

RS-180 100–200 

RS-180 ES 100–200 

RS-180 ESP 100–200 

RS-225 ES 200–250 

RS-225 ESP 200–250 

Flue Dilution Fan Adaptor 

Product Code For chimney fan For pipe NW 

RSG 180/130 RS 180 130 

RSG 180/140 RS 180 140 

RSG 180/150 RS 180 150 

RSG 180/160 RS 180 160 

RSG 180/180 RS 180 180 

RSG 180/200 RS 180 200 

RSG 225/200 RS 225 200 

RSG 225/225 RS 225 225 

RSG 225/250 RS 225 250 

RSG 225/300 RS 225 300 

148

Contents 

Draft Regulator - Flue Systems 

Draft Regulators 

Introduction to 

Draft Regulators 

For proper operation and efficient fuel consumption in gas, 

oil & biomass heating boilers, draft must remain constant. 

When it is, combustion is more complete, fuels are utilized 

efficiently, and money is saved. 

Draft Regulators maintain consistent draft by counteracting 

the negative forces caused by changes in temperature and 

barometric pressure, as well as the effects of wind. 

How draft regulators work 

Static pressure of the cool air (1) illustration A exerts 

pressure on the outside of the furnace or boiler and the 

stack. The pressure difference between the room air and 

heated gas (air) causes products of combustion (2) to 

flow (draft) through the unit and rise up the flue. Room 

temperature air (3) enters through the barometric draft 

control (4) in the precise amount needed to overcome the 

excess drafts caused by temperature variations, wind 

fluctuations, and barometric pressure changes. Combustion 

of fuel is complete and the process is stabilized. The 

velocity of combustion gases through the heat exchanger is 

slowed so more heat is extracted. The unit operates more 

efficiently, reliably, and requires less maintenance. 


Typical Gas Installation 

CONDENSING & 


Steel Flue Draft Regulators 

Suitable for Non-Condensing Boilers 

Product Code Model Control Size Inches 

F250DAJ10 10" M + MG2 10 

F300DAJ12 12" M + MG2 12 

F350DAJ14 14" M + MG2 14 

F400DAJ16 16" M + MG2 16 

F450DAJ18 18" M + MG2 18 

F500DAJ20 20" M + MG2 20 

F600DAJ24 24" M + MG2 24 

F700DAJ28 28" M + MG2 28 

F800DAJ32 32" M + MG2 32 

Stainless Steel Flue Draft Regulators 

Suitable for Condensing Boilers 

Product 

Code 

Dia. mm 

Setting 

Range 

Air flow rate at Δp 

5 Pa 20 Pa 40 Pa 

KWZ130 130 10 – 25 Pa 75 m³/h 130 m³/h 160 m³/h 

KWZ150 150 10 – 35 Pa 140 m³/h 220 m³/h 300 m³/h 

KWZ180 180 10 – 60 Pa 190 m³/h 275 m³/h 360 m³/h 

KWZ250 250 10 – 50 Pa 220 m³/h 380 m³/h 525 m³/h 

To be installed on Tee with single-wall female outlet 

149

Coaxial Flue System - Flue Systems 

Contents 

Coaxial Flue System 

CONDENSING & 


ALU/PP 

Extension Pipe 

ALU/PP Vertical & Horizontal 

Condensation Drain 

ALU/PP Vertical Starting 

Pipe (with flue gas test point) 

Product Code 

Size 

ALUPPCEP250 250mm Ø60/100 

ALUPPCEP50 500mm Ø60/100 

ALUPPCEP1000 1000mm Ø60/100 

Product Code 

ALUPPCD 

Size 

145mm 

Product Code 

Size 

ALUPPCVSP Flanged Ø60/100 

Brown Flue 

Terminal and Tile 

ALU/PP 

Vertical Terminal Pipe 

ALU/PP 

Horizontal Terminal Pipe 

Product Code 

ALUPPHTP11300 

Description 

for 5°C to 30°C pitched 

roofs 1300mm long 

Product Code 

ALUPPCVTP 

Size 

Ø60/100 850mm long 

Product Code 

ALUPPCHTP 

ALUPPCHTP283 

Size 

Ø60/100 850mm long 

Ø60/100 283mm long 

Concentric Bend 

with Flange 

ALU/PP Starting Straight 

Piece Flanged 

Concentric 

Bend 45º 

Product Code 

ALUPPCSE90 

Description 

Starting Elbow 90 Flanged 

Ø60/100 

Product Code 

ALUPPCSSP 

Size 

Ø60/100 (M4) 

Product Code 

Size 

ALUPPCE45 Elbow 45° Ø60/100 

150

Contents 

Coaxial Flue Systems - Flue Systems 

CONDENSING & 


Concentric 

Bend 90º 

Product Code 

Size 

ALUPPCE90 Elbow 90° Ø60/100 

EPDM 

Wall Cover 

Product Code 

Description 

ALUPPCWC 10170 

Air Intake 

Plastic Terminal 

Product Code 

Size 

ALUPPEG Ø60/100 (13102) 

ALU/PP Flue Coaxial 

Exhaust Terminal 

ALU/PP Flue Coaxial Kit 

(Incl. Elbow and Terminal) 

Product Code 

ALUPPET 

Size 

Ø60/100 

(PACAS 01 D60-100) 

Product Code 

ALUPPPACKIT4 

Size 

Ø60/100 250mm Long 

151

Biomass Boilers 

Contents 

BIOMASS BOILERS 

152

Contents 




Biomass Heating systems offer an economical and enviro-friendly 

option for heating generation. 

Biomass Heating systems burn wood pellets or wood logs to provide warmth to power 

central heating for domestic or commercial applications. They provide low carbon heat 

due to the fact the carbon dioxide emitted when wood is burned is the same amount that 

has been absorbed over the months and years that the plant was growing. The process is 

sustainable as long as new plants continue to grow in place of those used for fuel. 

Firex Wood Boilers pg 154 Airex Wood Boilers pg 156 Fokolus Wood Boilers pg 158 

Pellexia Pellet Boilers pg 160 

153

Wood Boilers 

Firex Wood Boilers - Biomass Boilers 

Contents 

Firex 

Wood Boilers 28 – 45kW 

AHG introduces the Firex Wood Boiler as a 

solution to the increasing call for heating 

boilers that use renewable resources. 


With excellent thermal performance, the Firex is suitable 

for heating only, or heating and Domestic Hot Water 

production. Firex boilers are an efficient means of heating 

buildings in rural areas, particularly where no natural gas 

is available and where LPG is considered too expensive. 

Built for quality, durability, safety and ease of use, Firex 

wood fired hydronic boilers are available in 28, 35 and 45 

kW models . 

Bypass 

Wood Logs 

Store Door 

Primary 

Air Inlet 

Secondary 

Air Inlet 

Combustion 

Chamber Door 

Anti-smoke 

Door 

Secondary Air 

Channels 

Thermal 

Steel Tray 

Features 

• Reverse flame combustion 

• Overheat protection 

• Control panel with thermostatic control 

• Anti-smoke internal door with complete rotation 

• High efficiency combustion fan 

• 50mm thick insulation 

• Internal installation 

For Twin Wall Stainless Steel Flue System components 

suitable for Firex Boilers, please refer to pg 144 and 145 


Type 

Wood Log Boiler 

Range 

28-45kW 

Efficiency 81.5% 

Fuel Type Wood Logs 


Max Pressure 

Low Nox 



Yes, if installed inside a shed 

300kpa 

Yes 

Yes 

154

Contents 

Firex Wood Boilers - Biomass Boilers 


Product Code FWH34 FWH45 FWH55 

Nominal Output kW 28.23 35.1 45.2 

Nominal Input kW 34.65 43.04 55.45 

Efficiency % 81.5 81.6 81.5 

Boiler Class 3 3 3 

Max. Working Pressure bar 3 3 3 

Wood Logs Storage Volume l 108 160 218 

Wood Logs Length cm 50 50 70 

Smoke Temp. at Nom. Output ºC 284 279 283 

Boiler Water Content l 59 71 93 

Max. Electrical Absorbed W 163 163 163 

CO at 13% O2 mg/Nm3 369 402 423 

NOx at 13% 02 mg/Nm3 162 157 168 

OGC at 13% 02 mg/Nm3 11 8 12 

DUST at 13% 02 mg/Nm3 31 31 32 

Dry Weight kg 363 475 623 



Key 

Key: 

1. 1 - Panel Panel board board 

2. 2 - Primary Primary air air adjustment adjustment 

3. 3 - Secondary Secondary air air adjustment adjustment 

4. 

4 

- Flame 

Flame 

sight 

sight 

glass 

glass 

5. 

5 

- Cleaning 

Cleaning 

doors 

doors 

6. 

6 

- Rear 

Rear 

smoke 

smoke 

chambre 

chamber 

7. 

7 

- Loading 

Loading 

door 

door 

8. 

8 

- Sucking 

Sucking 

fan 

fan 

9. 

9 

- Lower 

Lower 

cleaning 

cleaning 

and 

and 

inspection door door 

T1 - C.H. flow 

T2 - C.H. return 

T1 

T3 

C.H. 

- Bulb 

flow 

holder for safety 

T2 C.H. thermostat, return working 

T3 Bulb thermostat, holder for high safety limit 

thermostat, working minimum 

thermostat, high thermometer limit 

T4 thermostat, - Bulb holder minimum connection for 

thermostat, thermal discharge thermometer valve 

T4 T5 Bulb - Chimney holder connection for 

T6 thermal - Safety discharge heat exchanger valve 

T5 Chimney 

connections 

connection 

T6 T7 Safety - Boiler heat drain exchanger 

connections 


Model A B C D E F G H 

Case Study 

T1 - T2 

UNI ISO 228/1 

T5 

Ø mm 

Connections 

T6 

UNI ISO 228/1 

T3 - T4 - T7 

UNI ISO 228/1 

FWH34 510 680 1230 190 78 1025 628 65 G 1 1/4 150 G ½ G ½ 

FWH45 610 680 1380 190 81 1150 628 65 G 1 ½ 200 G ½ G ½ 

FWH55 610 880 1380 190 81 1150 828 65 G 1 ½ 200 G ½ G ½ 

All measurements in mm unless specified. 

Rural Residence 

Trentham VIC 

1 x Firex Wood Boiler 

This Firex Wood Fired Boiler was 

installed at a rural property in 

Trentham VIC to provide hydronic 

heating to the house. 

155

Airex Wood Boilers - Biomass Boilers 

Contents 

Airex 



AHG introduces the Airex Wood Boiler as 

a solution to the increasing call for higher 

capacity boilers that use renewable resources. 

With excellent thermal performance, the Airex is 

suitable for heating only, or heating and Domestic Hot 

Water production and can be used in industrial process 

applications. Airex boilers are an efficient means of heating 

buildings & industrial process applications in rural areas, 

particularly where no natural gas is available and where 

LPG is considered too expensive. 

Built for quality, durability, safety and ease of use, Airex Wood 

Fired Boilers are available in 65, 80, 150 & 200 kW models. 

Features 









Type 


Range 

65-200kW 

Efficiency 89% 



Max Pressure 

Low Nox 




300kpa 

Yes 

Yes 

156

Contents 

Airex Wood Boilers - Biomass Boilers 


Product Code ARX65 ARX80 ARX150 ARX200 

Nominal Output* kW 65 80 149.3 199.7 

Max. Input kW 78.2 96 166.8 223.4 

Waterside Pressure Drop kPa** 0.6 1.0 3.9 3.9 

Combustion Side 

Pressure Drop 

Boiler Max working 

pressure 

mbar 0.03 0.05 

bar 3 3 3 3 

Total Water Volume Litres 170 220 430 493 

Wood Log Storage I 235 325 495 580 

Wood Loading Opening mm 340x520 340x520 514x594 514x594 

Wood Logs Length cm 70 100 100 120 

CO 10% O2 mg/Nm3 687 690 

NOx 10% O2 mg/Nm3 232 249 

Dust 10% O2 mg/Nm3 25 43 

Electrical Supply V/W 240/250 240/250 

Dry Weight kg 760 927 1475 1626 

6 

2 

1 

5 

4 

3 

7 

Key 

1 Burner in refractory 

stone, with cast 

iron fire bars and 

stainless steel grate 

2 Fan with acoustic 

protection 

3 Primary air adjustment 

4 Secondary air 

adjustment 

5 Combustion chamber 

6 Firewood store 

7 Catalyst in strengthened 

refractory concrete 

M C.H. Flow 

V Thermostatic Valves 

P Primary Air 

F Smokes 

R C.H. Return 


(*) Output obtained with good quality wood, having an humidity of 15%. 

(**) Pressure losses for a flow rate corresponding to a Δt of 15 K. 

Dimensional and Connection Data 

Product Code 

A 

mm 

B 

mm 

C 

mm 

D 

mm 

E 

mm 

F 

mm 

G 

mm 

H 

mm 

T1 

Rp 

ARX65 755 955 1405 190 160 315 1180 245 2 2 ½ - - 220 - ¾ ½ - ½ ½ 

ARX80 755 1255 1405 190 160 315 1180 245 2 2 ½ - - 220 - ¾ ½ - ½ ½ 

T2 

Rp 

T3 

Rp 

T4 

Rp 

T5 

Rp 

T6 Ø 

mm 

T7 

Rp 

T8 

Rp 

T9 

Rp 

T10 

Rp 

T11 

Rp 

T12 

Rp 

Airex 65-80 

D 

C 

Key 

A 

1 Panel board 

2 Door of firewood store 

3 Central door 

1 

2 

3 

4 

5 

6 

7 

8 

T8 

T6 

G 

9 

11 

10 

T2 

T3 

F 

H 

T1 

B 

1 

E 

30 

T8 

T9 

9 

10 

T2 

4 Inlet of primary / secondary air 

5 Adjusters of secondary air 

6 Adjuster of primary air 

T1 

T11 

T8 

T12 

T6 

10 

T3 

7 Combustion chamber door 


9 Fan 

10 Cleaning doors 

11 Rear smoke chamber 

12 Auxiliary boiler door 

13 Smoke chamber cleaning door 

14 Burner protection 

T1 Central heating flow 

T2 Main central heating return 


T4 Secondary C.H. return 

T5 Air venting & expansion vessel connexion 

T6 Chimney connection of wood fired boiler 

T7 Chimney connection of auxiliary boiler 

T8 Safety heat exchanger connections 

T9 Bulb holder connection for probes 

T10 Auxiliary boiler burner connection 

T11 Bulb holder for working, max., min. 

thermostats and thermometer 

T12 Bulb holder for safety thermostat 

Airex 150-200 

Key 

1 Panel board 

2 Wood storage door 

3 Primary air adjuster 

4 Secondary air adjuster 


6 Combustion chamber door 

7 Fan with inverter 

8 Lever for cleaning system activation 

T1 C.H. flow EN 1092-1 DN 65 PN 16 R3/4” 

T2 C.H. return EN 1092-1 DN 65 PN 16 

T3 Expansion vessel connection ISO 7/1 Rp1/2” 

T4 Chimney connection Øe 300 mm 

T5 Safety heat exchanger connections ISO 7/1 

T6 Boiler drain ISO 7/1 R3/4” 

157

Fokolus Wood Boilers - Biomass Boilers 

Contents 


Fokolus 


The force of steel, 

the heating energy of stone 

Obtaining energy for heating in different ways is essential, not 

only for the whole country, but also for each individual who 

has the opportunity. 

As part of Unical’s programme for exploiting biomass in 

order to attain a major harmony with the environment, we 

are pleased to present three new wood log boilers, ideal for 

those consumers who, aware of the energy problems they are 

facing, desire products easy to use, with high performances 

and reduced fuel consumption, without having to resort to 

onerous investments. 

Simplicity and perfection 

The range of FOKOLUS boilers sums up the most primitive 

features which wood evokes. On one hand nature and on 

the other the technology which Unical has been able to 

develop. With the combustion process, the whole cycle which 

characterizes renewable energies comes to a close. 

The results are: comfort, economics, friendly environmental, 

all offered “naturally” by FOKOLUS. 

Air Inlet Regulator Chain 

Refractory Catalyst 

Wood 

Storage and 

Combustion 

Chamber 

Door 

Fire Box 

Ash Pan Door 

Ash Pan 

Air Inlet Thermostatic Regulator 

By-pass 

Features 

Controlled combustion, long boiler operation 

and reduced emissions 

The optimization of combustion is guaranteed by the 

thermostatic primary air inlet regulator and by the 

micrometric secondary air regulator. 

However, it is the use of a special refractory catalyst, 

positioned in the combustion chamber’s upper vault, which 

favours the pyrolysis process of the cellulose and the 

reduction of CO emissions. 

Once this real and proper “stone catalyst” has reached the 

working temperature, it contributes determinedly to the 

wood’s complete combustion. 

The organic molecules are thus transformed in primary 

gaseous elements and solid residual products. The first 

are burnt, the latter, in the intensive heat, burn thanks to 

the secondary air, with the so called “slow flame”, which 

enables the boiler to operate for longer, and so reduces the 

need of refuelling. 

At the end of the process, the noncombustible ashes will fall 

into a large ash pan placed underneath the grate. 

The passage of the flue gasses takes place vertically, from 

the bottom to the topmost direction, then they enter the 

“tunnel” in the vault, built in a special refractory catalyst 

material, and enter head-on into the hollow space between 

the latter and the arched vault, soaked by the system’s 

water, then they flow out through the rear outlet. 


Type 


Range 

20-42kW 



Max Pressure 



300kPa 

Yes 

158

Contents 

Fokolus Wood Boilers - Biomass Boilers 

Heat transfer 

fins 

CH system flow 

4 

M 

Boiler body 

rock wool 

insulation 

M 

Flue 

chamber 

Flue 

outlet 

By-pass 

7 

5 

Overheating 

protection 

by cooling coil 

Secondary 

air inlet 

5 

6 

4 

3 

Combustion 

chamber 

Boiler water 

Bottom grate 

2 

6 

3 

1 

Refractory 

catalyst 

Wood 

7 

2 

1 


CH system 

return 

R 

Primary 

air inlet 

R 

Ash pan 

Dimensional and Technical Data 

Key 

1 Upper loading door 

2 Lower cleaning door 

3 Thermostatic air inlet regulator 

4 Secondary air inlet aperture 

5 Primary air inlet aperture 

6 Air inlet regulator chain 

7 By-pass opening handle with 

counterweight 

8 Rear smoke chamber 

9 Smoke chamber cleaning door 

T1 CH flow 

T2 CH return 

T3 Thermostatic air inlet regulator 

connection 

T4 Chimney connection 

T5 Safety heat exchanger connections 

T6 Bulb holder for thermometer 

T7 Bulb holder for thermal safety drain 

valve sensor 

Model FKH20 FKH30 FKH40 

Nominal Output* kW 20 33 42 

Nominal Input kW 31 50 61 

Pressure Losses Water Side** m w.c. 0,3 0,3 0,4 

Chimney Draught Required Pa 15 16 20 

Boiler Water Content l 35 53 67 

Max. Working Pressure bar 3 3 3 

Wood Storage Capacity l 70 125 165 

Wood Logs Length cm 33 50 70 

A mm 510 590 590 

B mm 776 946 1146 

F mm 416 586 786 

N mm 488 658 858 

O mm 490 570 570 

T1 - T2 UNI ISO 7/1 Rp 2 Rp 2 Rp 2 

T3 UNI ISO 7/1 Rp 3/4 Rp 3/4 Rp 3/4 

T4 Øe mm 200 200 200 

T5 UNI ISO 7/1 R 1/2 R 1/2 R 1/2 

T6 - T7 UNI ISO 7/1 Rp 1/2 Rp 1/2 Rp 1/2 

Weight kg 250 340 402 

* Output obtained with good quality wood with a maximum of 15% moisture content. ** Pressure losses with a water flow rate corresponding to a Δt of 15K. 

159

Pellet Boilers 

Pellexia Pellet Boilers - Biomass Boilers 

Contents 

Pellexia 

Pellet Boilers 34 – 80kW 

AHG introduces the Pellexia Pellet Boiler as 

a solution to the increasing call for biomass 

boilers that use renewable resources. 


With excellent thermal performance, the Pellexia is suitable for 

heating only, or heating and Domestic Hot Water production. 

Pellexia Pellet Boilers are an efficient means of heating buildings 

in rural areas, particularly where no natural gas is available and 

where LPG is considered too expensive. 

Built for quality, durability, safety and ease of use, Pellexia 

Hydronic Pellet Boilers are available in 34, 45 and 80 kW models 

Features 

• Automatic Pellet feeding 








1 

M 

2 

6 

Key 

3 

4 

5 

R 

10 

8 

1 Tools panel 

2 Flue connection 

3 Fan 

4 Smoking room 

5 Smoke chamber inspection door 

6 Upper boiler door 

7 Lower boiler door (combustion chamber) 

8 Burner 

9 Ash collection basin 

10 Photosensor 

M Heating system delivery 

R Heating system return smoke path 

7 

9 


Type 

Pellet Boiler 

Range 

34-80kW 


Fuel Type Pellet 


Max Pressure 

Low Nox 




300kpa 

Yes 

Yes 

160

Contents 

Pellexia Pellet Boilers - Biomass Boilers 


Product Code UP34 UP45 UP80 

Nominal Input min/max kW 10.7 / 34.9 13.2 / 44.1 23.9 / 80.1 

Output min/max kW 9.6 / 31.4 11.9 / 39.8 21.5 / 72.4 

Efficiency 80/60°C % 90.1 90.1 90.2 

Maximum Pellet Reservoir Capacity Kg/l 230/360 230/360 630/1000 

Autonomy (burner at min/max capacity) h 109/32 82/25 133/40 

Smoke Temperature min/max °C 97/158 102/166 93/170 

CO Value at 10% of O2 at Min. Power mg/Nm3 116 182 102.6 

CO Value at 10% of O2 at Max. Power mg/Nm3 459 476 217.1 

Pellet Consumption min/max Kg/h 2.1/7.1 2.8/9 4.78/16 

Dust at 10% of O2 mg/Nm3 18 19 14 

Dust at 13% of O2 mg/Nm3 13 14 10.1 

Electric Absorbtion at starting W 227 227 410 

Electric Absorbtion at steady state W 207 207 310 

Water Content l 67 82 110 

Max working pressure bar 3 3 3 

Min. Draught at the chimney base Pa 15 18 15 

(1) Pressure losses for a flow rate corresponding to a Δt of 15k. 



Pellexia 34-45 kW 

Front (34-45kW) 

Side (34kW) 

Side (45kW) 

Pellexia 80 kW 

Key 

Front 

Side 

T1 2“ delivery sleeve 

T2 2“ return sleeve 

T3 Smoke outlet (model 34-45) Øe 130 mm / (model 80) Øe 200 mm 

T4 Heat exchanger connection 3/4 “security 

Rear 

T5 Sensor sheath 1/2 “thermal discharge valve 

T6 1/2“ probe sheath 

T7 3/4“ expansion vessel connection 

T8 1/2“ safety valve connection 

161

Accessories - Biomass Boilers 

Contents 

Options & Accessories 

Twin Wall Stainless Steel 

Flue System Components 

pg 144 


Biomass Boiler Valves 

pg 270 

Steel Buffer Tanks 

pg 240 

Stainless Steel 2205 Tanks 

pg 224 

162

Contents 

Accessories - Biomass Boilers 


163

Expansion & Deaeration 

Contents 

EXPANSION & 

DEAERATION 

164

Contents 

Expansion Tanks & Pressurisation Systems 

Expansion Tanks & 

Pressurisation Systems 

Expansion tanks for use in a closed heating or cooling system are 

available in various types and sizes. 

The type and size of tank used is usually governed by the intended application and can range 

from simple expansion tanks which are pre-charged and sized according to the design 

fill pressure and requirements of the system, through to pump controlled pressurization 

systems which may include degassing functions. 

EXPANSION & 

DEAERATION 

Static Expansion Tanks pg 170 Pressurisation Systems pg 178 

165


Contents 

Introduction to Expansion Tanks 

& Pressurisation Systems 

EXPANSION & 

DEAERATION 

Why do we need 

Expansion tanks? 

Expansion Tanks & Pressurisation systems are critical to 

the successful operation of heating and cooling circuits and 

must essentially fulfil three fundamental tasks: 

• Maintaining the pressure within permissible limits at 

every point of the system, that is, the permissible working 

pressure must not be exceeded as well as maintaining 

a minimum pressure to prevent vacuum, cavitation and 

evaporation of the system liquid, e.g. in circuits with 

superheated water, solar systems. 

• To prevent a negative pressure at the highest points of the 

installation in order to avoid the intrusion of air into the 

piping network. 

• Compensation of volume fluctuations of the heating or 

cooling water due to temperature fluctuations. 

• Providing a water seal to prevent system-related water 

losses. 

With any heating or chilled water system there is expansion 

and contraction as the system water is heated or cooled. 

Because water is incompressible, the pressure in the 

system will increase or decrease accordingly. To prevent 

damage to the system components, expansion tanks are 

installed which contains the excess volume as the water 

heats and expands and allow that water to fill the vacuum 

created when the system water cools and contracts. 

Careful calculation, commissioning and maintenance are 

the prerequisite for the correct functioning of the overall 

system. 

Expansion tanks in open vs. 

closed systems 

Open header or feed tanks were an early form of 

expansion tank which were usually copper lined open 

tanks installed above the highest point of the system as 

the tanks relied on gravity to maintain system pressure. 

Apart from the connection to the system, the tanks 

were fitted an overflow outlet and a mains water inlet 

controlled by a floating ball valve which allowed the 

system water to be replenished automatically if needed. 

While functional, open header tanks fail to provide 

an optimal solution to the expansion problem due to 

several key issues. 

• Because the tanks are unsealed, the system water is 

constantly exposed to the air which allows the system 

water to absorb oxygen. Oxygen in the system leads to 

corrosion and decreased pump efficiency. 

• Depending on the design of the tank, there may be the 

potential for backflow if the water level rises above 

the mains inlet, leading to contamination of the water 

supply. 

• With any open tank, there is the potential for overflow 

which is normally piped to the nearest drain. Given that 

the tank needs to be elevated, if the drain becomes 

blocked or the tank leaks, the resulting spillage may 

cause damage to surrounding building surfaces. 

• Because the system is open, system pressure is limited 

to the head pressure achieved by the height of the 

tank. This may negatively impact pump performance 

due to insufficient NPSH (Net Positive Suction Head), 

potentially resulting in cavitation and pump failure. 

• Many modern boilers require controlled system 

pressures and water quality and are therefore not 

suited to open vented systems. 

To overcome these issues, most heating and cooling 

systems are now designed as closed systems which 

allows system pressure to be controlled and gases 

to be eliminated, resulting in greater efficiencies and 

improved performance across all components of the 

system. 

166

Contents 


Types of Expansion tanks 

Static Expansion tanks 

Static expansion tanks are available in a range of sizes to 

accommodate various system volumes and are supplied to 

order pre-charged with nitrogen to the pressure required 

for the intended installation. The pre-charged expansion 

tanks come in two types: 

• Diaphragm type, in which the diaphragm spans the middle 

of the tank. The water in the tank is in contact with the tank’s 

metal inner surface and therefore is unsuitable for potable 

water. 

• Bladder type, which contains a butyl bladder. Because 

the water in the tank is completely contained inside the 

membrane, the risk of corrosion is avoided and the tank is 

suitable for systems containing untreated water. 

Regular maintenance required for pre-charged expansion 

tanks includes complete draining and pressure testing at 

least annually. 

Diaphragm Type 

Bladder Type 

Pump-controlled Pressurisation Systems 

Pump-controlled Pressurisation Systems operate as 

pressure-maintaining stations with automatic water makeup 

and deaeration. Typically, a pump-controlled expansion 

tank comprises a tank fitted with a replaceable butyl (bag 

type) diaphragm, a pump and a control panel. This type of 

system represents a superior method of system pressure 

management, provides close pressure control, degassing, 

and water-makeup with BMS interface capabilities. 

Pressure control with this type of system is much more 

fine-tuned and up to 90% of the tank’s capacity can be 

utilized, compared to less than half that volume with a precharged 

tank (depending on system pressure). This saves 

a significant amount of plant room space and piping. One 

pump-controlled expansion tank can be substituted for four 

pre charge vessels. 

Examples of this type of expansion tank include Duraflex 

EcoPress and Duraflex EcoPress Compact. 

EXPANSION & 

DEAERATION 

167


Contents 

Expansion Tank Sizing, 

Commissioning & Maintenance 

Sizing an Expansion Tank 

Careful calculation of the expansion tank size is critical to the correct functioning of the system. 

Expansion Coefficient 

Calculate the expansion coefficient for your system by calculating the difference between the cold 

system water temperature (heating off) and the max working temperature. 

ºC Coefficient 

6 

0 0.00013 

EXPANSION & 

DEAERATION 

10 0.00025 

20 0.00174 

30 0.00426 

40 0.00782 

50 0.01207 

60 0.0145 

65 0.01704 

70 0.0198 

75 0.02269 

80 0.0258 

85 0.02899 

90 0.0324 

95 0.0396 

100 0.04343 

% Expansion 

5 

4 

3 

2 

1 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 

Water Temperature ºC 

Heating System 

The expansion tank sizing formula is as follows: 

(based on Boyles Law) 

Cooling System 

The vessel sizing formula is as follows: 

(based on Boyles Law) 

e x C 

Vt = 1 - (Pi/Pf) = 

Vu 

1 - (Pi/Pf) 

Vt = 

e x C 

1 - (Pi/Pf) 

where: 

Vu = 

Total useful volume of tank = Vi - Vf 

Vi = Initial volume 

Vf = Final volume 

e = Expansion coefficient 

Pi = Initial charge pressure (absolute) of vessel. 

This pressure must not be lower than the hydrostatic pressure at the point 

where the tank is connected to the system. 

Pf = Maximum operating pressure (absolute) of the 

relief (safety) valve 

taking into account any differences in level between the vessel 

and the safety valve. 

C = Total water capacity of the system in litres: 

boiler, pipework, radiators etc 

(as a general approximation, C is between 4 and 8 litres 

for every kW of boiler output) 

Note: Calculations must be done in Absolute Pressure 

e.g. 100kPa = 200kPa absolute. 

In standard heating systems: 

e = 0.04318 (Tmax = 99°C, Tmin = 10°C, Δt = 89ºC, C = 0.035) 

In standard cooling systems: 

e = 0.011 (Tmax = 50ºC, T min =4ºC) 

Pi = Maximum plant pressure, corresponding to the maximum 

achievable temperature, equal to the ambient temperature, 

which is recommended to be fixed at 50ºC 

Pf = The final working pressure achieved at minimum 

temperature, using 4ºC 

Example 

C = 500 litres 

Pi = 150kPa (250kPa Abs) 

Pf = 400kPa (500kPa Abs) 

V = 0.04318 x 500 = 43.2 litres 

1 - (250/500) 

Select the next largest sized tank 50 litres 

168

Contents 


Calculating Expansion Tank 

Pre-charge Pressure 

Please use the below calculation to correctly determine 

the expansion tank pre-charge pressure: 

Pi = [Hm x 10] + 20kPa 

where: 

Pi = Initial charge pressure (absolute) of vessel 

Hm = 

System height (metres) above the location of the 

expansion tank 

Installation 

1. The expansion tank must be installed on the suction 

side the system pump and preferably in the coolest 

part of the system e.g. on return to boiler. 

2. Ensure water entering the tank is less than 70ºC, 

to prevent premature diaphragm failure. If water 

temperature is higher than 70ºC, an intermediate tank 

must be installed between the expansion tank and the 

system. 

3. The expansion tank must be installed with a lockable 

service valve and drain point. This is to ensure the tank 

can be serviced properly in the future. 

4. The expansion tank must be installed with a pressure 

relief valve between the tank and the lockable service 

valve, to protect the tank from overpressure situations. 

5. The pressure relief valve rating must be no higher than 

the safe working pressure of the expansion tank. 

Commissioning 

Please follow the below 4 step process for commissioning 

an expansion tank: 

1. Disconnect 

a. Isolate the expansion tank from the system via the 

lockable service valve. This is crucial to ensure an 

accurate pressure reading. 

b. Disconnect from the system and drain the tank. 

2. Test 

a. Calculate the correct expansion tank 

pre-charge pressure. 

b. Test the pre-charge pressure in the expansion tank 

via the Schrader valve. 

3. Charge 

a. Charge the expansion tank to the correct (see note 

on calculating pre-charge pressure) pressure via the 

Schrader valve, using an air compressor or nitrogen 

canister. 

b. Recheck tank charge to ensure pre-charge pressure 

is holding. If a leak is found, the Schrader valve or 

the expansion tank will need replacing. 

4. Reconnect 

a. Reconnect the expansion tank to the system. 

b. Re-pressurise the system and check for leaks. 

Maintenance 

Please follow the below 5 step process for maintaining an 

expansion tank: 

1. Inspect 

a. Perform a visual check of expansion tank to ensure 

no obvious damage or corrosion is present. 

b. To check the integrity of the diaphragm, press 

down the Schrader valve. If water exits the valve, 

the diaphragm has ruptured and the expansion tank 

will need replacing. 

2. Disconnect 

a. Isolate the expansion tank from the system via the 

lockable service valve. This is crucial to ensure an 

accurate pressure reading. 

b. Disconnect from the system and drain the tank. 

3. Test 

a. Calculate the correct expansion tank 

(see note on calculating pre-charge pressure) 

b. Test the pre-charge pressure in the expansion tank 

via the Schrader valve. 

4. Charge 

a. Charge the expansion tank to the correct precharge 

pressure via the Schrader valve, using an air 

compressor or nitrogen canister. 

b. Recheck tank charge to ensure pressure is holding. 

If a leak is found, the Schrader valve or the 

expansion tank will need replacing. 

5. Reconnect 

a. Reconnect the expansion tank to the system. 

b. Re-pressurise the system and check for leaks. 

EXPANSION & 

DEAERATION 

169

Duraflex Forté - Static Expansion Tanks 

Contents 

Duraflex Forté 

6 Bar Rated 

Ø D 

DIAPHRAGM TYPE 

Ø D 

• For heating and chilled water 

applications 

Ø D 

• Threaded connections 

• Non-replaceable diaphragm, max. 

operating temperature 70°C 

• Meets or exceeds EC norms for 

pressure vessels 2014/108/EG 

H 

H 

H 

• Durable epoxy coating with 

attractive new colour 

• Factory pre-pressurised gas 

chamber (Nitrogen) 

8-25 litres 

h 

35-250 litres 300-1000 litres 

h 

EXPANSION & 

DEAERATION 

Model Volume (lt) Ø D mm H mm h mm A Weight kg Pre-Charge P. (bar) 

6 Bar 

DR8-3 8 206 305 - R 3/4 1.6 1.5 

DR12-3 12 280 275 - R 3/4 2.4 1.5 

DR18-3 18 280 380 - R 3/4 3.4 1.5 

DR25-3 25 280 490 - R 3/4 4.2 1.5 

DR35-3 35 354 460 130 R 3/4 4.8 1.5 

DR50-3 50 409 469 158 R 3/4 5.7 1.5 

DR80-3 80 480 565 166 R 1 8.7 1.5 

DR100-3 100 480 670 166 R 1 11.4 1.5 

DR140-3 140 480 912 175 R 1 13.1 1.5 

DR200-3 200 634 758 205 R 1 22 1.5 

DR250-3 250 634 888 205 R 1 24.7 1.5 

DR300-3 300 634 1092 235 R 1 27 1.5 

DR400-3 400 740 1102 245 R 1 47 1.5 

DR500-3 500 740 1312 245 R 1 52 1.5 

DR600-3 600 740 1531 245 R 1 66 1.5 

DR800-3 800 740 1996 245 R 1 96 1.5 

DR1000-3 1000 740 2406 245 R 1 118 1.5 

6 

5 

4 

Wall-hung Bracket 

• For vessels 8 - 25 litres 

• Holder with multiple connections 

Product No. 

DWB825 

% Expansion 

3 

2 

1 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 

Water Temperature ºC 

170

Contents 

Duraflex Cobalt - Static Expansion Tanks 

Duraflex Cobalt 

10, 16, 25 Bar Rated 

Ø D 

BLADDER TYPE 

Ø D 

• For potable water, water heating and 

hydro-pneumatic well applications 

Ø D 

• Bladder according to DIN EN 13831 

norm part 3 

• From 60 litres volume with 

replaceable bladder 

H 

H 

H 

• All vessel parts in contact with 

water are coated against corrosion 

• Meets or exceeds EC norms for 

pressure vessels 2014/108/EG 

A 

A 

h 

• Fitted with manometer from 

Ø 1000 mm 

8-25 litres 33 litres 50-500 litres 

• Threaded connections up to 1000l 

• Flanged connections above 1000l 

• Durable epoxy coating 

• Factory pre-pressurised gas 

chamber (Nitrogen) 

EXPANSION & 

DEAERATION 

Model Volume (lt) Ø D mm H mm h mm A Weight kg Pre-Charge P. (bar) 

10 Bar 

DX8-10 8 206 335 - G 3/4 1.7 4 

DX12-10 12 280 307 - G 3/4 2.4 4 

DX18-10 18 280 410 - G 3/4 2.8 4 

DX25-10 25 280 520 - G 3/4 3.7 4 

DX33-10 33 354 454 - G 3/4 5.7 4 

DX33 1 -10 33 354 520 66 G 3/4 6.5 4 

DX50-10 50 409 604 102 G 1 9.5 4 

DX60-10 60 409 734 161 G 1 11.2 4 

DX80-10 80 480 745 153 G 1 14.0 4 

DX100-10 100 480 850 153 G 1 16.0 4 

DX200-10 200 634 967 150 G 1 1/4 36.5 4 

DX300-10 300 634 1267 150 G 1 1/4 41.5 4 

DX400-10 400 740 1245 139 G 1 1/4 73.0 4 

DX500-10 500 740 1475 133 G 1 1/4 103.0 4 

DX600-10 600 740 1859 263 G 1 1/2 128.0 4 

DX800-10 800 740 2325 263 G 1 1/2 176.0 4 

DX1000-10 Ø740 1000 740 2805 263 G 1 1/2 214.0 4 

DX1000-10 Ø1000 1000 1000 2001 291 DN65/PN16 427.0 4 

16 Bar 

DX8-16 8 206 335 - G 3/4 2.7 4 

DX12-16 12 280 309 - G 3/4 3.5 4 

DX25-16 25 280 520 - G 3/4 5.6 4 

DX80-16 80 480 745 153 G 1 23.0 4 

DX100-16 100 480 850 153 G 1 27.0 4 

DX200-16 200 634 967 150 G 1 1/4 57.0 4 

DX300-16 300 634 1267 150 G 1 1/4 66.0 4 

DX400-16 400 740 1394 265 G 1 1/4 116.0 4 

DX500-16 500 740 1614 265 G 1 1/4 127.0 4 

DX600-16 600 740 1859 265 G 1 1/4 158.0 4 

DX800-16 800 740 2324 265 G 1 1/4 202.0 4 

DX1000-16 Ø740 1000 740 2604 265 G 1 1/4 244.0 4 

DX1000-16 Ø1000 1000 1000 2001 286 DN65/PN16 530.0 4 

25 Bar 

DX8-25 8 206 335 - G 3/4 3.5 4 

DX80-25 80 450 942 159 DN50/PN40 70.0 4 

DX120-25 120 450 1253 159 DN50/PN40 100.0 4 

DX180-25 180 450 1528 159 DN50/PN40 116.0 4 

DX300-25 300 750 1318 160 DN50/PN40 150.0 4 

1 

with legs 

171

Duraflex Joule - Static Expansion Tanks 

Contents 

Duraflex Joule 

BLADDER TYPE 

10, 16, 25 Bar Rated 

The Duraflex Joule series are designed for heating, chilled 

and condenser closed circuit applications 

• Suitable for glycol mixture up to 50% 

• Replaceable EPDM Bladder 

• Pressure gauge fitted (100L and above) 

• Electrostatic powder coat finish 

• Factory pre-pressurised gas chamber (nitrogen) 

• Max operating temperature -10°C / 70°C 

• Wall mount bracket available (8-25L) 

H 

ØD 

ØD 

H 

c 

c 

8-19L 24-35L 

EXPANSION & 

DEAERATION 

8-35L 

Model Volume (lt) Ø D mm H mm c mm Weight kg Pre-Charge P. (bar) 

10 Bar 

DJ008-10 8 220 296 1" M 2.9 2 

DJ012-10 12 220 410 1" M 3.5 2 

DJ019-10 19 280 434 1" M 4.5 2 

DJ024-10 24 280 484 1" M 4.9 2 

DJ035-10 35 354 465 1" M 6.0 2 

16 Bar 

DJ019-16 19 280 420 1" M 7.5 2 

DJ024-16 24 280 484 1" M 7.7 2 

25 Bar 

DJ019-25 19 280 426 1" M 11 2 

DJ024-25 24 280 476 1" M 13 2 

DJ035-25 35 354 451 1" M 17 2 

Wall-hung Bracket 

• For vessels 8 - 25 litres 

• Holder with multiple connections 

Product No. 

DWB825 

172

Contents 

Duraflex Joule - Static Expansion Tanks 

BLADDER TYPE 

ØD 

ØD 

ØD 

ØD 

H 

H 

H 

H 

h h h h 

c c c c 

50L 80-140L 200-500L 750-1000L 

50-1000L 

Model Volume (lt) Ø D mm H mm c mm h mm Weight kg Pre-Charge P. (bar) 

10 Bar 

DJ50-10 50 410 650 1" M 130 9.2 2 

DJ80-10 80 480 791 1" M 170 15 4 

DJ100-10 100 480 899 1" M 170 17 4 

DJ140-10 140 480 1137 1" M 170 24 4 

DJ200-10 200 634 1008 11/4" F 150 36 4 

DJ250-10 250 634 1123 11/4" F 150 41 4 

DJ300-10 300 634 1296 11/4" F 150 45 4 

DJ400-10 400 740 1427 11/4" F 185 65 4 

DJ500-10 500 740 1563 11/4" F 185 70 4 

DJ750-10 750 848 1736 2" F 185 122 4 

DJ1000-10 1000 848 2187 2" F 185 156 4 

16 Bar 

DJ50-16 50 410 650 1" M 125 15 2 

DJ80-16 80 480 791 1" M 160 22 4 

DJ100-16 100 480 899 1" M 160 25 4 

DJ140-16 140 480 1137 1" M 160 31 4 

DJ200-16 200 634 1008 11/4" F 145 56 4 

DJ300-16 300 634 1296 11/4" F 145 71 4 

DJ400-16 400 740 1427 11/4" F 180 154 4 

DJ500-16 500 740 1563 11/4" F 180 166 4 

DJ750-16 750 800 1981 2" F 180 223 4 

DJ1000-16 1000 800 2500 2" F 180 285 4 

25 Bar 

DJ50-25 50 410 600 3" 140 28 4 

DJ80-25 80 450 615 3" 160 39 4 

DJ100-25 100 450 949 3" 160 43 5 

DJ140-25 140 500 1104 3" 160 56 5 

DJ200-25 200 600 1015 11/4" F 140 115 5 

DJ300-25 300 640 1305 11/4" F 140 127 5 

DJ500-25 500 750 1498 11/4" F 185 172 5 

DJ750-25 750 750 1945 2" F 175 300 5 

DJ1000-25 1000 800 2498 2" F 210 330 5 

EXPANSION & 

DEAERATION 

173

Duraflex OEM & EN - Static Expansion Tanks 

Contents 

Duraflex OEM 

Slimline 3 Bar Rated 

• Flat vessel for heating (built-in boiler applications) 

• Non-replaceable diaphragm according to DIN EN 

13831 norm part 3, max. operating temperature 70°C 

• From 18 litres with suspension brackets 

• Meets or exceeds EC normsfor pressure vessels 

2014/108/EG 

• Durable epoxy coating 

• Factory pre-pressurised gas chamber (Nitrogen) 

H 

Ø D 

H 

Ø D 

A 

A 

8 litres 12-24 litres 

EXPANSION & 

DEAERATION 

Model Volume (lt) H mm d mm W mm A Weight kg Pre-Charge P. (bar) 

F8 8 389 389 88 G 3/8 6.3 0.75 

F12 12 444 350 108 G 1/2 7.7 1.0 

F15 15 444 350 134 G 3/4 8.2 1.0 

F18 18 444 350 158 G 3/4 8.7 1.0 

F24 24 444 350 180 G 3/4 9.4 1.0 

Duraflex EN 

Slimline 3 Bar Rated 

• For heating and chilled water applications 

• Suitable for anti-frost mixture up to 50% 

• Provided with suspension bracket for easy 

installation 

• Non-replaceable butyl bladder according to 

DIN EN 13831 norm part 3, max. operating 

temperature 70°C 

• Meets or exceeds EC norms for pressure vessels 

2014/108/EG 

• Durable epoxy coating with attractive new colour 

• Factory pre-pressurised gas chamber (Nitrogen) 

H 

Ø D 

A 

w 

d 

Model Volume (lt) Ø D mm H mm d mm W mm A Weight kg Pre-Charge P. (bar) 

EN8-3 8 280 287 163 52 G 1/2 2.8 1.0 

EN12-3 12 354 362 168 64 G 1/2 3.2 1.0 

EN18-3 18 354 362 222 76 G 3/4 4.7 1.0 

EN25-3 25 409 419 239 93 G 3/4 5.5 1.0 

EN35-3 35 480 457 240 97 G 3/4 7.3 1.0 

EN50-3 50 480 457 318 125 G 3/4 8.1 1.5 

EN80-3 80 634 612 325 135 G 3/4 14.5 1.5 

174

Contents 

EXPANSION & 

DEAERATION 

175

Duraflex Ecopress Compact - Pressurisation Systems 

Contents 

Duraflex EcoPress® Compact 


EXPANSION & 

DEAERATION 

The EcoPress Compact (compressor-controlled). 

EcoPress pressurization stations regulate the pressure on 

the gas side of the vessel by means of compressor: 

• When the set pressure is exceeded, the overflow valve 

opens and releases air from the expansion vessel. Due to 

the drop in pressure on the air side, water flows into the 

expansion vessel and pressure falls in the system. 

• If pressure falls below the set pressure, the compressor 

switches on and pumps air into the air side of the expansion 

vessel, forcing water into the system: the water level falls in 

the vessel and pressure rises in the system. 

• Additional units for water make-up and degassing can be 

added to the EcoPress. The possibility of the intelligent 

integration of a water make-up system is incorporated into 

the EcoPress Control. 

EcoPress Compact 

• Compact compressor-controlled pressurization station for 

heating and cooling water systems. 

• Perm. excess oprating presure 6 bar 

• Perm. flow temperature 120ºC 

• Perm. operating temperature 70ºC 

• Perm. ambient temperature 0-45ºC 

• Degree of protection IP 54 

Tanks 

• Nominal volume 200-500 litres 

Control Unit 

• Pressure maintenance with 1 or 2 compressors 

• Overflow valves 

176

Contents 

Duraflex EcoPress Compact - Pressurisation Systems 


EcoPress Model 

Operating 

Pressure kPa 

Operating Temp. 

ºC 

Enviro. Temp. ºC 

Noise Level dB 

Electrical Power 

kW 

Electrical V / Hz 

System 

Connection 

RC 200 ≤ 600 >0-70* >0-45 72 0.75 240 / 50† R1 

RC 300 ≤ 600 >0-70* >0-45 72 0.75 240 / 50† R1 

RC 400 ≤ 600 >0-70* >0-45 72 0.75 240 / 50† R1 

RC 500 ≤ 600 >0-70* >0-45 72 0.75 240 / 50† R1 

* Mounted in system return line, diaphragm load of the expansion vessel max. 70°C; please contact us if there is an expected continuous temperature < 0°C 

† Main switch, fixed connection to terminal strip. 


øD 

Model øD mm H mm h mm Weight kg 

RC 200 634 1320 135 52 

RC 300 634 1620 135 69 

RC 400 740 1620 135 80 

RC 500 740 1845 135 93 

H 

EXPANSION & 

DEAERATION 

BMS Modules 

h 

Type 

Weight kg 

LonWorks Digital 1.5 

LonWorks 1.9 

Profi bus-DP 1.9 

Ethernet 1.9 

BACnet-IP for Control Touch 0.4 

BACnet MS/TP for Control Touch 0.4 

Modbus RTU for Control Touch 0.4 

Profibus RTU for Control Touch 0.4 

I/O Modules 1 

Control Remote 


EcoPress 

Remote monitoring, diagnostics and at last remote-control 

maintenance are becoming increasingly important for the 

supervision of supply grid systems. For the responsible onsite 

operator, it is more and more difficult to find qualified 

support staff. Long distances to sites frequently prevent 

quick and continuous control. 

Type L mm W mm H mm Weight kg 

Control Remote 83 60 34 0.3 

EcoVac 

177

Duraflex EcoPress - Pressurisation Systems 

Contents 

Duraflex EcoPress® 


Pressure-maintaining station with automatic 

water make-up and deaeration. 

The pump-controlled EcoPress opens up a completely new 

dimension of pressure-maintaining stations for heating and 

cooling circuits. Its five functions are: 

• it keeps the system pressure within very restricted limits 

• it deaerates the content water 

• it makes up water automatically 

• maintaining system pressure within 50kPa 

• provides outputs to BMS systems 

EXPANSION & 

DEAERATION 

Thus, the Duraflex EcoPress is a solution to decrease air 

problems, especially within closed heating installations, 

which, according to a study of the Technical University of 

Dresden, arise in more than 50% of the installations. 

The Duraflex EcoPress ensures air-free installations up 

to the top floor and into the last corner. An additional 

advantage: A special data interface allows the integration 

into the modern facility management. 

The high efficiency of the EcoPress principle has been 

proven and tested in numerous application examples. The 

combination of pressure maintenance, deaeration, and 

water make-up complies with all requirements for air-free 

systems and requires only little maintenance. 

178

Contents 


Advantages 

EcoPress / EcoPress Giga advantages against a Fillset with Pre charge Vessels 

Pressure Control 

• Keeps pressure +/- 0.2 bar limits 

• Spill valves, proportionally controlled motorised ball valves 

and not solenoids 

• Ball valves afford tighter volume/pressure control without 

clogging (as per solenoid valves) 

• No water hammer – as sometimes happens with solenoids 

on other systems 

• No regular maintenance and checks as per pre charged 

vessels 

• Software with alarms protect the EcoPress/system via BMS 

• If unit is set up correctly then basically a “ fit and forget” 

type installation. 

• High Integrity information output to your BMS so system 

information may be mapped and safety parameters alarms 

to suit your requirements. 

Degassing 

• Integral atmospheric degassing facility (not available on fill, 

pre charge or other types) 

• If high temperature between 70ºC and 90ºC use Duraflex 

Vacuum Deaerator Degassing 

• Degassing helps to improve hydraulic balancing and 

ensures circulating pumps run to curve. The risk of 

mechanical seal failure and damage to windings on 

glandless pumps is significantly reduced due to good 

hydraulic properties. The flow characteristics of devices 

such as plate heat exchangers, boilers etc will be found to 

be as published. All of these factors enable the specified 

system performance to be readily achieved ensuring a 

timely handover to the final client. 

Space Savings 

• Acceptance Factor on these vessels 90% 

• One EcoPress vessel to 4 pre charge vessels (due to 

acceptance factors) 

• Cost savings on Vessel amount and also installation and 

materials (piping etc) 

Expansion Bend 

Guarantees the pressure 

compensation towards 

the atmosphere between 

the vessel wall and the 

diaphraghm 

Heavy Duty 

Steel Tank 

Technology and Alarm Safety 

• Microprocessor technology includes power fail safe relay 

/ soft starters / various alarms re high and low pressures 

and water reserve levels / error messages. Manual checks 

of pumps, spill valves & fill solenoid/fillset P plus many 

other features. Real time log of alarm conditions 

• All BMS outputs are volt free and most beneficial is an 

extension module which gives discrimination for HP/LP 

conditions etc. Analogue outputs enable remote monitoring 

of system pressure and vessel volume. 

• Pumped system integrity monitored by multiple filling 

safety alarms monitoring water make up duration and 

repetitive filling. 

Maintenance 

• The operating system is easily understood and works with 

pre-programmed defaults operating around a single setting 

for the operator. 

• Minimal maintenance with yearly warning in display when 

service is scheduled. 

• All default parameters may be changed by a Automatic 

Heating Service Engineer to suit your system/BMS 

requirements. 

Financial Benefits 

• Quicker handover of whole project to client due to optimised 

hydraulic performance. 

• Enhanced system control ensures an almost constant 

pressure regardless of temperature. Reduced risk of 

leakage from joints etc on existing pipe systems. 

• Less space taken with fewer vessels as space in many 

instances is a premium 

• Minimal maintenance cost with only “Health Check” cleaning 

of dirt traps and buffer vessel gas charge required. 

The sounding pipe 

Deaeration extracts the 

gasses from the tank 

and prevents de-aeration 

High-Quality Butyl 

Bladder 

Protects the expansion 

water from a direct air 

admission 

EXPANSION & 

DEAERATION 

Control Unit 

Guarantees maximum 

operating comfort. All 

Duraflex controls (EcoPress, 

EcoPress Giga, EcoPRess 

Compact, Duraflex Vacuum 

Deaerator have been 

designed according to a 

uniform design guideline 

Pressure Cell 

(Level measurement) enables the 

determination of the vessel fill level 

The pressure expansion 

relief at atmospheric 

pressure results in 

the deaeration of the 

expansion water 

Connection Set 

Connects the control unit with 

the DVG basic vessel. For 1-pump 

systems, the protected shut-off is 

integrated in the connection set. 

With respect to 2-pump systems, 

the protected shut-off is located on 

the control unit 

179


Contents 

EcoPress Working Principle 

For Heating 

1 Low temperature 

2 Temp. Increase 

3 Full Power 

4 Cooling Down 

5 Replenish 

EXPANSION & 

DEAERATION 

System pressure is 

constant, unit at rest 

with a small water 

reserve. 

For Cooling 

System pressure 

increase is detected. 

Hence, water flows 

into the bladder 

through the open valve 

and is de-aerated due 

to pressure drop. 

The unit reaches 

almost full capacity 

when the temperature 

increase is completed. 

Pressure is maintained. 

System pressure 

decreases; the 

deaerated water 

is pumped back to 

the system until 

pressure’s setpoint is 

restored. 

If the vessel’s water 

volume drops under 

critical level, the unit 

refills the bladder 

until minimum water 

reserve. 

1 Cooling Down 

2 Low Temperature 

3 Temp. Increase 

4 Full Power 

Water volume and 

thus pressure drops, 

the de-aerated water 

is pumped back to the 

system until pressure 

reaches defined level. 

The unit is at rest with 

a small amount of 

water. 

Water volume and 

system pressure 

increases subsequently, 

the overflow valve 

opens in order to 

allow water into the 

depressurised vessel 

until pressure stabilizes. 

The unit reaches 

almost full capacity 

when the temperature 

surge is completed 

all while maintaining 

pressure constant. 

180

Contents 



Duraflex EcoPress 1 up to 2 MW with 1 pump 

PIS 

VG basic vessel 

Max. 70 ºC 

PIS 

VS control unit 

Pressure Accumulating 

Vessel 

Expansion line 

Duraflex Fillset 

with contact 

water meter 

≥ 500 

Water 

Make-up 

Pressure maintenance, 

compensating for the 

expansion volume 

The pump and over flow valve are 

actuated in such a way that pressure 

remains constant within a range 

of around ± 0.2 bar. The expansion 

water is supplied to or discharged 

from the depressurised basic vessel 

in 2 separate expansion lines. 

TIME 

LIS 

LIS 

Discharge 

valve 

Duraflex EcoPress 2 - 1 up to 4 MW with 2 pumps 

VF secondary vessel 

VG basic vessel 

VS control 

unit 

PIS 

Pressure Accumulating 

Vessel 

Expansion line 

≥ 500 

Water 

Make-up 


with contact 

water meter 

Boiler/Chiller 

heating& 

cooling source 

Water Make-up 

The volume of discharged free gases 

and water losses are automatically 

replenished. The level measurement 

is carried out by evaluating the 

weight of the basic vessel. Water 

make-up based on the filling level 

in the basic vessel is monitored by 

a leakage monitor and interrupted 

in the event of any malfunctions. 

With the EcoPress 2, the signals 

of a contact water meter can be 

evaluated (Duraflex Fillset with 

contact water meter). 

TIME 

EXPANSION & 

DEAERATION 

Max. 70 ºC Max. 70 ºC 

LIS 

TIME 

Discharge 

valve 


heating& 


Deaeration 

A part flow of the heating water is 

released into the basic vessel and 

thus degassed. The deaeration mode 

can be selected from the following 

versions: 

• Continuous deaeration: constant 

deaeration after startup and repairs 

in the supply system, to allow all 

residual air to be removed from the 

system. 

• Follow-up deaeration: activated 

automatically after continuous 

deaeration and performed after 

every pump operation. 

• Interval deaeration: performed after 

a specified schedule. 

Note: The useful volume rate is 90 % for 

the pump controlled pressurisation units. 

Therefore according to calculations the 

required expansion tank size is smaller 

than static tank size. 

181


Contents 

EcoPress Control Units 

• EcoPress controller DV 1 with Control Basic 

• From EcoPress controller DV 2 with Control Touch & soft start 

• Perm. advance temperature 120°C 

• Perm. operating temperature 70°C 

• Perm. ambient temperature 0 - 45°C 

• Sound level approx. 55 dB(A) 

• Degree of protection: IP 54 

• Water make-up connection Rp 1/2” 

• Pump/overflow valve connection Rp 1/Rp 1 

• Common fault signal and RS 485 interface 

EXPANSION & 

DEAERATION 

DV Control Unit - 1 Pump 

DV Control Unit - 2 Pumps 

DV Control Unit - 1 Pump 

Type P0 Height Width Depth Connection Power Voltage Sound Level Weight 

bara mm mm mm kW V dB(A) kg 

DV 1 ≤ 2.5 680 530 580 2 x G 1 0.75 240/50 Hz 55 25 

DV 2-1/60 ≤ 4.8 920 470 730 2 x G 1 1.1 240/50 Hz 55 33 

DV 2-1/75 ≤ 6.5 920 530 640 2 x G 1 1.1 240/50 Hz 55 35 

DV 2-1/95 ≤ 8.0 920 530 640 2 x G 1 1.1 240/50 Hz 55 37 

DV 1-1/140 ≤ 13.5 920 530 640 2 x G 1 2.2 400/50 Hz 60 50 

* Control basic only. For 60 Hz operations , please consult us 

DV Control Unit - 2 Pumps 

Type P0 Height Width Depth Connection Power Voltage Sound Level Weight 

bar mm mm mm kW V dB(A) kg 

DV 2-2/35 ≤ 2.5 920 700 780 2 x G 1 1/4 1.2 240/50 Hz 55 54 

DV 2-2/60 ≤ 4.8 920 700 780 2 x G 1 1/4 2.2 240/50 Hz 55 58 

DV 2-2/75 ≤ 6.5 920 720 800 2 x G 1 1/4 2.2 240/50 Hz 55 72 

DV 2-2/95 ≤ 8.0 920 720 800 2 x G 1 1/4 2.2 240/50 Hz 55 76 

DV 1-2/140 ≤ 13.5 920 720 800 2 x G 1 1/4 4.4 400/50 Hz 60 80 

For 60 Hz operations , please consult us 

182

Contents 


EcoPress Tanks 

• Heavy duty steel tank 

• Approval in acc. with the 2014/108/EC directives 

• Replaceable butyl bladder in accordance with DIN EN 13831 

• Max. system temperature 120°C 

• Max. operation temperature 70°C 

• Durable epoxy coating with attractive grey colour 

Ø D 

Ø D 

H 

H 

EcoPress 

DV 

Control Unit 

= + 

DVG 

Basic Vessel 

Connection 

Set 

h 

h 

DVG Basic Vessel 

DVF Secondary Vessel 

DVG Basic Vessel DVG Secondary Vessel Ø D H h Connection Weight 

Part No. Part No. mm mm mm kg 

DVG 200 DVF 200 634 1060 146 G 1 41.4 

DVG 300 DVF 300 634 1360 146 G 1 52.2 

DVG 400 DVF 400 740 1345 133 G 1 72.2 

DVG 500 DVF 500 740 1560 133 G 1 81.8 

DVG 600 DVF 600 740 1810 133 G 1 96.8 

DVG 800 DVF 800 740 2275 133 G 1 109.9 

DVG 1000 Ø 740 DVF 1000 Ø 740 740 2685 133 G 1 156 

DVG 1000 Ø 1000 DVF 1000 Ø 1000 1000 2130 350 G 1 292.8 

DVG 1500 DVF 1500 1200 2130 350 G 1 320 

DVG 2000 DVF 2000 1200 2590 350 G 1 565 

DVG 3000 DVF 3000 1500 2590 380 G 1 795 

DVG 4000 DVF 4000 1500 3160 380 G 1 1080 

DVG 5000 DVF 5000 1500 3695 380 G 1 1115 

EXPANSION & 

DEAERATION 

EcoPress Connection Set 

Connection Set - 1 Pump 

VG vessel (Ø/mm) Weight kg 

480 - 740 2 

1000 - 1500 3 

Connection Set - 2 Pumps 

VG vessel (Ø/mm) Weight kg 

480 - 740 2 

1000 - 1500 3 

183


Contents 

Duraflex Control 

Control Basic 

Control Touch 

Remote Control 

• 2-line LCD display 

• 4.3” touch screen colour display 

• Remote control via secure server 

• 8 control keys 

• 2 status LED Integrated control of 

system pressure, deaeration and 

water make-up 

• Graphic user interface 

• Simply structured plain text menus 

including operating instructions and 

help texts 

• System monitoring via PC or mobile 

device at any time and everywhere 

• (Professional) remote servicing by 

Duraflex Customer Service 

EXPANSION & 

DEAERATION 

• Manual and automatic operation 

• Common fault output signal 

• Input, for contact water meter 

• RS-485 interface 

• Integrated control of system 

pressure, deaeration and water 

make-up 


• Permanent display of the most 

important operating parameters in 

the system diagram 

• Intelligent Plug & Play operational 

management 

• Evaluation and storage of the most 

important operational data 

• Extensive interfaces: 

- Input, for contact water meter 

- 2 x dry contact outputs for error 

messages 

- 2 x analogue outputs for pressure 

and vessel content 

- 2 x RS-485 interfaces 

- Plugs for Bluetooth module and 

HMS networks, as well as SD card 

• Duraflex Remote Portal with intuitive 

user interface 

• Simple management of multiple 

installations 

• Visualisation of all parameters 

• Diagrams for run-time monitoring 

• Alarm messages via e-mail or 

messaging 

• User-provided Internet or GSM 

connection 

• Factory-installed or retrofitting, 

independent of Touch or Basic 

184

Contents 


EcoPress Quick Selection 

Selection Example 

P0 

bar 

Output heat generator Q = 500 kW 

Water capacity VS = 5000 litres 

Design temperature T = 70/50 ºC 

Static height 

Hst = 30 m 

Expansion coefficient n = 0.0228 

P0 ≥ 

P0 ≥ 

Vn ≥ 

Vn ≥ 

Hst [m] 

bar + 0.2 bar 

10 

30 

10 

Ve + Vws 

DF 

bar + 0.2 bar = 3.2 bar 

5000 x (0.0228 + 0.005) 

= 155 liter 

0.9 

Selected: 

Control unit VS 2-1/60 

Expansion vessel VG 200 

Pressure Accumulating Vessel NG 80 

Connection set G 1” 

Make-up 


EXPANSION & 

DEAERATION 

• For cooling water systems up to 30°C only 

50% of the nominal heating power should be 

considered when selecting the control unit 

• In performance ranges > 2 MW we 

recommend using double pump systems 

EcoPress VG - VF Vessel Sizing 

Nominal volume Vn 

Approximate value from the diagram 

or 

Calculation acc. to formula 

Total thermal output of the heat generation system - MW 

Vn ≥ VA x 

0.031 [70°C] 

0.045 [90°C] 

0.054 [100°C] 

0.063 [110°C] 

Setting flow temperature 

Vn = Nominal volume, liter 

VA = System water content , liter 

• The nominal volumes can be distributed to 

several vessels 

(VG basic vessel and VF secondary vessel). 

Total thermal output of the heat generation system - MW 

185

Duraflex EcoPress Giga - Pressurisation Systems 

Contents 

Duraflex EcoPress® Giga 


The EcoPress Giga Pressure-maintaining 

station is a real power pack. 

The Duraflex EcoPress Giga pressure-maintaining 

program is tailored to the specific requirements of 

industrial and district heating. Within a capacity range 

of up to approximately 20 MW, EcoPress Giga models 

with a modular design are offered. The combination 

of various control and hydraulic systems allows us to 

achieve a customer-friendly range of various models while 

maintaining a high degree of standardization at the same 

time. In addition, the experts of our development team plan 

and construct larger systems upon individual request. 

EXPANSION & 

DEAERATION 

EcoPress Giga is a premium quality system with a flexible, 

modular design 

• For heat generating systems up to and over 120°C. 

• Heating capacity up to 30 MW, up to 15 MW/120°C, an 

automatic selection by the customer is possible 

• Two pressure-maintaining pumps 

• Built-in controlled water make-up 

• Fully automated operation for the integration into the 

modern facility management with numerous options 

• Possibility of triggering a ’Duraflex Vacuum Deaerator’ 

vacuum spray tube deaeration 

• Depending upon the performance, 2 or 3 parallel connected 

overflow 

• Valves with additional protection of the minimum operating 

pressure 

• Internationality: you can select from 8 languages in the 

control unit, any extension is possible 

186

Contents 

Duraflex EcoPress Giga - Pressurisation Systems 

Features 

Innovative Technology and Reliability 

The Duraflex EcoPress Giga offers by default an automatic, 

controlled water makeup. The water make-up is controlled 

in dependence on the water level in the GG primary vessel. 

An even more comfortable solution: Equip the Duraflex 

EcoPress Giga with the Duraflex EcoPress Vacuum 

Deaerator vacuum spray tube deaeration. It does not only 

free the make-up water from dissolved gases, but also 

ensures that the content water in the system is almost gasfree. 

“Air problems“ due to free gas bubbles at system high 

points, at circulating pumps or control valves are a thing of 

the past! 

Modular Design and Customisation 

• For heat generating systems up to and over 120°C. 

• Heating capacities up to 250 MW and more. 

• Pressures also above 40 bar. 

• Expansion volumes up to 160,000 liters. 

• Medium pressure maintenance in case of complicated 

pressure conditions. 

• Fully automated operation with individual operating 

program and SPS. 

• Suitable for high temperature hot water plants. 

The expansion bend 

ensures the pressure compensation 

towards the atmosphere between 

reservoir wall and diaphragm. 

GH Hydraulics 

The 10 design models of the GH 

hydraulic system allows the hydraulic 

adjustment to the most different 

systems and environments. 

The sounding pipe 

deaeration extracts the gasses 

from the tank and prevents a 

de-aeration. 

The high-quality butyl bladder 

protects the expansion water 

from direct air admission. 

Bladder Control 

By Cumtomer 

EXPANSION & 

DEAERATION 

GS Control unit 

The GS control in 6 basic models 

ensures an excellent operating 

comfort. All reflex controls have been 

designed according to a uniform 

design guide line. 

MBM ll bladder 

rupture detector 

(option) 

The flex-connection 

for the expansion line is 

required for the proper 

function of the level 

measurement. 

The pressure cell 

(level measurement) 

allows to determine the 

reservoir level. 

Over-flow line 

with patented motor 

ball-valve-auto function 

Min. press. limiter 

Safety valve 

for protection of the GG 

and GF vessels 

Water make-up 

solenoid valve 

Connection 

Expansion line DN 80/PN 16 

Dimensioning 

Connection 

GG Basic vessel DN 80/PN 6 

Shut-off 

protected against 

inadvertent closing 

Throttle valve 

Most reliable, silent pumps 

with soft start feature 

187

Contents 

EXPANSION & 

DEAERATION 

188

Contents 

Dirt and Air Separation 

Dirt and Air 

Separation 

Foreign particles and substances can significantly reduce the performance 

and service life of heating & cooling systems and increase service intervals. 

Our dirt & air separation solutions can help to prevent this and achieve optimum operating conditions. 

Duraflex separation technology uses mechanical separation processes, for which no auxiliary energy is 

needed. Duraflex Vacuum Deaerator degassing systems even degas dissolved gases in a vacuum. The 

process is electronically monitored and optimized by a Duraflex Control unit. 

EXPANSION & 

DEAERATION 

Air Separators pg 194 

Dirt Separators pg 198 Air and Dirt Separators pg 203 

Vacuum Deaerators pg 210 

189


Contents 

Introduction to Dirt & Air 

Separation 

Problems caused by dirt and air in heating & cooling systems 

• Increased system corrosion 

• Increased noise in radiators, heat exchangers, pipework and pumps 

• Increased wear and tear of heat exchangers, controllers, shut-off valves and pumps 

• Lower heat emissions or cooling efficiency 

• Increased energy costs 

• Increased maintenance costs 

EXPANSION & 

DEAERATION 

Corrosion in circulating pump 

190

Contents 


Air 

Due to the physical nature of water, it is impossible to 

prevent air from becoming trapped in the system. 

Air can enter through: 

• Filling and makeup water 

• System alterations and maintenance 

• Open header tanks 

• Micro leaks and diffusion through system components 

• Henry’s Law - “Gas is a natural constituent of water and 

other liquids. The presence and solubility depend on 

temperature and pressure within the liquid” (William Henry 

(1775 – 1836) 

Free Air 

Microbubbles 

Dissolved Air 

Once in the system, gas can be observed in 

three different forms 

As Henry’s Law describes, the presence and solubility of 

gas in a liquid depends on two elements – temperature and 

pressure. Whereas a hot water system causes the water to 

expand and the gas more easily removed, a chilled water 

system results in the water becoming dense and the gas 

more soluble. 

Similarly, where the system pressure is low, degassing is 

more easily achieved. But as the pressure increases, not 

only is the presence of gas greater but it also becomes 

much more difficult for traditional methods of removal – 

such as air vents – to release it. 

Free Air 

“Free” gas or air is both the most common and most easily 

removed, as it has not yet become soluble in the water. It 

can be found as air pockets and is typically released via 

simple air vents strategically placed around the system. 

A Duraflex EcoTop Automatic Air Vent removes free air 

quickly, offering continuous, maintenance-free operation 

and high reliability. 

Microbubbles 

Where gas has entered the liquid at some pressure, 

microbubbles are often formed. Smaller than one 

millimeter in diameter but larger than one micrometer, 

these bubbles of gas are created by turbulence in the water 

(often where there is a loss of pressure, such as a pumping 

pillar) and are commonly in hot water systems. 

Although visible to the eye, microbubbles cannot be 

removed by air vents as they are carried with the water 

stream. Rather, an air separator like a Duraflex EcoVent, 

which is suitable for heating systems up to 300 kpa, should 

be installed on the flow side of the heat source for effective 

deaeration. 

By slowing the water down as it passes through the mesh 

in the chamber, the microbubbles are broken up and the 

gas separates out of the water stream and is vented at the 

top of the chamber. 

Dissolved Air 

But where the pressure is higher and/or the temperature is 

low – as is common in chilled water systems – most gases 

become totally solubilised in the water. 

In much the same way carbon dioxide remains invisible in 

a bottle of lemonade until opened, the solubilised gas can 

only be removed from the water stream by reducing the 

pressure. 

A Duraflex Vacuum Deaerator removes dissolved air 

quickly, offering continuous operation and high reliability. 

EXPANSION & 

DEAERATION 

191


Contents 

Comparison of Different Deaeration Systems 

In order to illustrate the effectiveness of different deaeration systems, we would like to show the physically 

and technically achievable, minimum nitrogen content in the network water in dependence on the pressure 

conditions at the place of installation Nitrogen serves as “measurement gas” because it is an inert gas and 

is, thus, not consumed in secondary reactions. This leads to an unbiased measurement result. 

bubble-free 

EXPANSION & 

DEAERATION 

Achievable nitrogen concentration after thedeaeration in mg/l 

free bubbles in the water 

Pressure at the place of installation of the deaeration device in bar 

EcoVent 

Microbubble / Air Separators 

EcoPress / EcoPress Giga 

Atmospheric Deaerator 

Duraflex 

Vacuum Deaerator 

Mechanical Air Separators 

Can only work effectively if they are 

installed at high points. 

Atmospheric Deaerators 

Can prevent the formation of free 

gas bubbles in the circulation water. 

They are the best solution as a central 

bleeding device, but not for the 

purposeful oxygen separation. Erosion 

due to two-phase flow can be avoided 

to the greatest possible extent. 

Vacuum Deaerators 

Can reduce the overall gas content 

almost to zero. They combat 

corrosion (reactive gases) as well as 

erosion (inert gases). High degrees 

of separation are achieved using 

dynamic vacuum deaerators. 

192

Contents 


Dirt 

Due to the nature of fluid systems, it is impossible to 

prevent dirt from accumulating in the system. 

Dirt can accumulate through: 

• Dirt via the filling and makeup water 

• Sludge as a result of corrosion of system components 

• Calcification when heating 

• System alterations and maintenance 

• Open header tanks 

Any hydronic heating or cooling or domestic hot water 

system works at optimal efficiency when it’s running with 

perfectly clean water. The introduction of dirt, corrosion 

by-products and other particulates are detrimental to the 

health and longevity of the components and system as a 

whole. 

The removal of harmful dirt and sludge is an important step 

in the flow of a water based heating or cooling system and 

can be managed by the inclusion of dirt and air separators 

sometimes in tandem and sometimes in combined units. 

Air and dirt work together to attack any water based cycle 

that is housed in materials that are liable to corrosion. Most 

people have seen the thick black sludge that collects in the 

bottom of domestic radiators that we see when the central 

heating is drained, this is generally produced by corrosion 

of the components. Air makes the corrosion possible and 

the by-products help keep oxygen present to react further, 

removing both has many benefits. 

Dirt Particle Sizes 

Performance Range of Dirt Separator 

Hair 

Magnetite 

Visible to Human Eye 

Heamatite 

Standard Filter Range 

Sand 

Welding 

Particles 

0.001 0.01 0.1 1 10 mm 

1 µm 1000 µm 

• Fewer instances of downtime 

• Increased lifespan of components and system as a whole 

• Lower fuel costs 

• Lower environmental impact 

• Quieter operation 

• Lower cost of maintenance 

• Decreased wear and tear 

EXPANSION & 

DEAERATION 

Particle Removal 

Specialist equipment can be incorporated into any system 

to alleviate if not totally eradicate the whole issue cost 

effectively. We have dealt with the problems that air brings 

to the table in another article but in basic terms while 

isolated in a vessel full of water, air will rise and dirt will 

sink. Reservoirs for the trapped gas and collected solids 

can be above and below the plane of the pipework and 

automatically released or collected and removed. 

Various methods can be used to encourage the quicker 

separation at the required point in the system. Mesh, pall 

rings and perforated tubing can disrupt the flow and cause 

the dirt and corrosion particles to drop to the bottom and 

the air bubbles to rise to the top. 

The dirt is periodically decanted off as sludge and disposed 

responsibly where as the gases can be bled continuously 

and released to the atmosphere. 

193

Air Separators - Dirt and Air Separation 

Contents 

EcoTop 

Automatic Air Vent 

Fields of Application 

The automatic air vent in the Duraflex EcoTop series is an ongoing and effective 

way of removing air and other gases from heating, solar, and cooling systems, 

including under constant operating conditions, in filling processes after having 

emptied the system, and in new installations. The vents are applied at high points 

within the system or at specially identified collection points. 

Mode of Operation 

EXPANSION & 

DEAERATION 

In order to ensure ongoing safe and automatic operation, Duraflex EcoTop 

automatic air vents follow a sound engineering design formula: Gases collect in a 

generously sized chamber. This causes the water level in the chamber to drop and 

a float to fall, which opens the deaeration valve once it reaches a certain depth. 

The combination of a multiple-tested valve and a generously sized air chamber 

ensures flawless operation, even in extreme pressure fluctuations. 

Non-leak, non-shut-off 

deaeration valve 



EcoTop 

EcoTop 

EcoTop 

EcoTop 

Air chamber with special design: 

floating impurities do not reach the 

deaeration valve; high air chamber volume 


to counteract pressure fluctuations 

floating impurities do not reach the 

deaeration valve; high air chamber volume 

Solid construction 

to 

for 

counteract 

an 

pressure fluctuations 

extra-long service life 

Solid construction for an 

extra-long service life 

EcoTop 

EcoTop Function 

Diagram 

EcoTop Function 

Diagram 

Boiler 

EcoTop System Air Venting Sketch 

EcoTop 

Boiler 

Features 

• Brass casing 

• Multiple testing procedure on the deaeration valve 

• Vertical installation 

• Rp 1/2 system connection and a G 1/2 connection 

thread on the deaeration valve 

• Application limits 110 / 180°C and 10 bar 

Advantages 

• Reliable, automatic deaeration 

• Reduces flow noise, circulation problems, drop in 

performance and helps to avoid corrosion damage 

EcoTop System Air Venting Sketch 

• Optimum function reliability, even in tough conditions 

• Reduces maintenance requirements 

• Suitable for a variety of temperatures and applications 

T, brass - 110°C 10 bar 

Type Weight kg Connection Ø mm H mm 

EcoTop 1/2 0.7 G 1/2 female 63 120 

EcoTop 3/8 0.7 G 3/8 male 63 132 

T Solar, brass - 180°C 10 bar 

H 

Type Weight kg Connection Ø mm H mm 

EcoTop 1/2 S 0.7 G 1/2 female 63 120 

Ø 

194

Contents 


EcoVent (Brass) 

Micro Bubble Air Separators 

The core element is a tube mesh construction 

that has proven itself over the decades, with an 

extremely low rate of pressure loss in the flow 

direction and a high rate of pressure loss in the 

transverse direction. This drastically reduces 

the amount of turbulence and guides the gas 

bubbles to a part-stabilized area. 

Features 

• Volumetric Flow - 1.25 - 8 m3/h 

• Thermal EPP foam insulation - A22 - 2” 


deaeration Non-leak, valve non-shut-off 



its large Air volume chamber means with that special driving design: 

impurities 

its large 

do not 

volume 

reach the 

means 

deaeration 

that driving 

valve. 

The large distance between the water surface 

impurities do not reach the deaeration valve. 

and the valve ensures flawless operation, even 

The large distance between the water surface 

in high pressure fluctuations 

and the valve ensures flawless operation, even 

in high pressure fluctuations 

Several connections are available 

from A22 to 2” 

Several connections are available 

from A22 to 2” 

Boiler 

Boiler 

Duraflex 

EcoVent 

EcoVent “Brass” System Deaeration Sketch 

Duraflex 

EcoVent 

EXPANSION & 

DEAERATION 

EcoVent “Brass” (Brass) System Deaeration Sketch 

Brass, 110°C 10 bar - Horizontal 

Type Weight kg Connection V max m 3 /h L mm Ø mm H mm 

A 3/4 1.0 G 3/4 1.25 85 63 165 

A 1 1.1 G 1 2.00 88 63 180 

A1 1/4 1.3 G 1 1/4 3.70 88 63 202 

A1 1/2 1.5 G 1 1/2 5.00 88 63 236 

A 2 3.2 G 2 8.00 132 100 277 

for Solar Systems 

H 

Ø 

A 3/4 S 1.1 G 3/4 1.25 85 63 165 

A 1 S 1.2 G 1 2.00 88 63 180 

A1 1/4 S 1.4 G 1 1/4 3.70 88 63 202 

A1 1/2 S 1.6 G 1 1/2 5.00 88 63 236 

L 

Brass, 180°C 10 bar - Vertical 


A 3/4 1.0 G 3/4 1.25 85 63 165 

A 1 1.1 G 1 2.00 88 63 180 

Ø 

for Solar Systems 

A 3/4 SV 1.1 G 3/4 1.25 85 63 165 

A 1 SV 1.2 G 1 2.00 88 63 180 

H 

L 

195


Contents 

EcoVent (Steel) 

Micro Bubble Air Separators 

EXPANSION & 

DEAERATION 

Because micro-bubbles are carried along by the flow, special measures are 

required in order to remove them from the system efficiently. The casings of 

Duraflex EcoVent micro-bubble separators have a larger cross-section than 

the connection dimensions, which reduces the flow speed in the separator. At 

the same time, the volume flow is guided by a special wire mesh. The ensuing 

turbulence causes gas bubbles to move in an undetermined direction. Depending 

on the volume flow, density, and volume of the particles, parts of these gas 

bubbles are supported in their natural breakaway motion and removed from the 

system via the deaeration top section. 

Advantages 

• Removes free circulating air and gas bubbles 

• Robust heavy gauge steel construction 

• Functions in fully automated, continuous operation 

• Produces just a minimal, constant drop in pressure 

• Enables much faster hydraulic balancing after filling processes 

• Prevents development of noise, wear through corrosion, and loss in performance 

through the formation of larger air bubbles 

• Full range in terms of operating pressures, temperatures, and materials 

Features 

• Connection - DN 50 - DN 600 

• Volumetric flow - 12.5 - 1530 m 3 /h 

• Thermal EPP foam insulation - 

DN 50 - DN 150 

Integrated EcoTop 

automatic air vent 

Duraflex EcoVent 

(Steel) 

Boiler 

Several connections 

are available from 

DN 50 to DN 600 

EcoVent Function 

Diagram 

Steel, 110°C 10 bar - Flange connection 

Type Weight kg Connection V max m 3 /h L mm Ø mm H mm HD mm 

A 50 11 DN 50/PN 16 12.5 350 132 625 1 153 

A 65 12 DN 65/PN 16 20 350 132 625 1 163 

A 80 18 DN 80/PN 16 27 470 206 740 1 159 

A 100 21 DN 100/PN 16 47 475 206 740 1 169 

A 125 60 DN 125/PN 16 72 635 354 915 1 214 

A 150 64 DN 150/PN 16 108 635 354 915 1 229 

A 200 90 DN 200/PN 16 180 775 409 1125 284 

A 250 146 DN 250/PN 16 288 890 480 1402 351 

A 300 194 DN 300/PN 16 405 1005 634 1612 406 

A 350 Upon request DN 350/PN 16 500 1128 634 1950 501 





1 

Thermal insulation available 

H 

Ø 

L 

196

Contents 


EcoVent HF (Steel) 

High Flow Micro Bubble Air Separators 

Because micro-bubbles are carried along by the flow, special measures are required 

in order to remove them from the system efficiently. The casings of Duraflex EcoVent 

High Flow micro-bubble separators have a larger cross-section than the connection 

dimensions, which reduces the flow speed in the separator. At the same time, the 

volume flow is guided by a special wire mesh. The ensuing turbulence causes gas 

bubbles to move in an undetermined direction. Depending on the volume flow, 

density, and volume of the particles, parts of these gas bubbles are supported in 

their natural breakaway motion and removed from the system via the deaeration 

top section. 

Advantages 

• Removes free circulating air and gas bubbles 

• Functions in fully automated, continuous operation 

• Produces just a minimal, constant drop in pressure 

• Enables much faster hydraulic balancing after filling processes 

• Prevents development of noise, wear through corrosion, and loss in performance 

through the formation of larger air bubbles 

• Full range in terms of operating pressures, temperatures, and materials 

• Specially designed for bigger systems with longer heights and higher volumetric flow 

Features 


• Volumetric flow - 25 - 3000 m 3 /h 

EXPANSION & 

DEAERATION 

Integrated EcoTop 

automatic air vent 

Fan coil 

Higher body to ensure high 

performance deaeration 



DN 50 to DN 600 

Chiller 

Duraflex 

EcoVent 

Optional sludge 

drain connection 

EcoVent (Steel) High Flow System Deaeration Sketch 

Steel, 110°C 10 bar - Flange connection 

Type Weight kg Connection V max m 3 /h L mm Ø mm H mm HD mm 

A 50 HF 10 DN 50/PN 16 25 350 132 810 153 

A 65 HF 12 DN 65/PN 16 40 350 132 810 163 

A 80 HF 18 DN 80/PN 16 54 470 206 965 159 

A 100 HF 22 DN 100/PN 16 94 475 206 965 169 

A 125 HF 37 DN 125/PN 16 144 635 354 1225 214 

A 150 HF 45 DN 150/PN 16 215 635 354 1225 229 

A 200 HF 75 DN 200/PN 16 360 775 409 1495 284 

A 250 HF 119 DN 250/PN 16 575 890 480 1609 351 

A 300 HF 160 DN 300/PN 16 810 1005 634 2225 406 

A 350 HF Upon request DN 350/PN 16 1000 1128 634 2460 501 





H 

Ø 

L 

197

Dirt Separators - Dirt and Air Separation 

Contents 

EcoTrap (Brass) 

Dirt and Sludge Separator 

The core element is a tube mesh construction that has 

proven itself over the decades, with an extremely low rate 

of pressure loss in the fl ow direction and a high rate of 

pressure loss in the transverse direction. This drastically 

reduces the amount of turbulence and guides the sludge 

particles to a part-stabilized area. 

Features 


• Thermal EPP foam insulation - DN 20 - DN 40 and 2” 

EXPANSION & 

DEAERATION 

Several connections are available from 

A22 to 2” 

Through flow is not impeded by sludge 

Space-saving, perpendicular draining 

tap. The collected sludge is quickly and 

forcefully pressed out when the tap is 

opened so that it can be closed again 

right away. The entire process takes 

just a few seconds 

Boiler 

Duraflex 

EcoTrap 

Magnetic insert 

Suitable for-M models 

The capacity to capture large amounts 

of sludge results in longer intervals 

before cleaning becomes necessary 

EcoTrap (Brass) System Dirt and Sludge Separation Sketch 



D 3/4 0.9 G 3/4 1.25 85 63 103 2) 

D 1 1 G 1 2 88 63 120 2) 

D 1 1/4 1.2 G 1 1/4 3.7 88 63 140 2) 

D 1 1/2 1.3 G 1 1/2 5 88 63 174 2) 

D 2 3.1 G 2 8 132 100 215 

with Magnetic Insert 

H 

L 

D 3/4 M 1 G 3/4 1.25 85 63 103 2) 

D 1 M 1.1 G 1 2 88 63 120 2) 

D 1 1/4 M 1.3 G 1 1/4 3.7 88 63 140 2) 

D 1 1/2 M 1.4 G 1 1/2 5 88 63 174 2) 

D 2 M 3.3 G 2 8 132 100 215 

Ø 

Brass, 110°C 10 bar - Vertical 


D 3/4 V 1.4 G 3/4 1.25 84 63 144 2 

D 1 V 1.5 G 1 1.25 84 63 144 2 

with Magnetic Insert 

D 3/4 V - M 1.4 G 3/4 1.25 84 63 144 2 

D 1 V - M 1.5 G 1 1.25 84 63 144 2 

H 

L 

2) 


Ø 

198

Contents 


EcoTrap (Steel) 


The sludge/dirt separation in the Duraflex EcoTrap works on 

a similar principle to micro-bubble separation: The flow is 

guided through an area with a greater cross-section than the 

connection dimensions in order to reduce the flow speed. The 

ensuing turbulence caused by the tube mesh causes heavy 

materials to move in an undetermined direction. Depending 

on the volume flow, density, and volume, parts of these sludge 

particles are supported in their natural breakaway motion and 

guided to the bottom section of the casing. 

Features 



• Thermal EPP foam insulation - DN 50 - DN 150 

EXPANSION & 

DEAERATION 

Advantages 

• Removes free circulating dirt and sludge particles < 5 micrometer 

• Functions in fully automated continuous operation, produces just a 

minimal constant drop in pressure 

• Maintenance takes just 5 seconds Permanent free throughflow 

opening for the water 

• No shut-off valves or bypass lines required. Desludging possible 

during system operation 

• Full range in terms of operating pressures and materials 

• Continually ensures flawless functionality of heat generators, 

thermostat valves, etc. 

• Reduces the risk of system defects and breakdowns in the long term 



DN 50 - DN 600 

Through flow is not 

impeded by sludge 

The capacity to capture large 

amounts of sludge results in 

longer intervals before 

cleaning becomes necessary 

Magnetic insert: 

Magnetic removal can be 

boosted by insertion of 

Duraflex high performance 

magnets 

Steel, 110°C 10 bar - Flange Connection 

Type Weight kg Connection V max m 3 /h L mm Ø mm H mm HB mm 

D 50 11 DN 50/PN 16 12.5 350 132 521 1) 370 

D 65 12 DN 65/PN 16 20.0 350 132 521 1) 370 

D 80 18 DN 80/PN 16 27.0 470 206 636 1) 370 

D 100 21 DN 100/PN 16 47.0 470 206 636 1) 370 

D 125 60 DN 125/PN 16 72.0 635 354 811 1) 430 

D 150 64 DN 150/PN 16 108.0 635 354 811 1) 430 

D 200 110 DN 200/PN 16 180.0 775 409 1021 430 

D 250 146 DN 250/PN 16 288.0 890 480 1324 500 

D 300 194 DN 300/PN 16 405.0 1005 634 1535 500 

D 350 Upon Request DN 350/PN 16 500.0 1128 634 1890 600 





1) 


H 

Ø 

L 

199


Contents 

EcoTrap R (Steel) 


EXPANSION & 

DEAERATION 

The sludge/dirt separation in the Duraflex EcoTrap R works on a similar 

principle to micro-bubble separation: The flow is guided through an area 

with a greater cross-section than the connection dimensions in order to 

reduce the flow speed. The ensuing turbulence caused by the tube mesh 

causes heavy materials to move in an undetermined direction. Depending 

on the volume flow, density, and volume, parts of these sludge particles 

are supported in their natural breakaway motion and guided to the bottom 

section of the casing. 

Advantages 

• Removes free circulating dirt and sludge particles < 5 micrometer 

• Functions in fully automated continuous operation, produces just a minimal constant 

drop in pressure 

• Maintenance takes just 5 seconds Permanent free throughflow opening for the water 

• No shut-off valves or bypass lines required. Desludging possible during system 

operation 


• Continually ensures flawless functionality of heat generators, thermostat valves, etc. 

• Reduces the risk of system defects and breakdowns in the long term 

• Easier maintenance due to detachable base 

Features 





DN 50 - DN 600 



Fan coil 

Chiller 

Duraflex 

EcoTrap R 



longer intervals before cleaning 

becomes necessary. 

Maintenance is much easier with 

its detachable base 

EcoTrap (Steel) System Dirt and Sludge Separation Sketch 

Steel, 110°C 10 bar - Flange Connection with Inspection Flange 


D 50 R 11 DN 50/PN 16 12.5 350 132 521 1) 370 

D 65 R 12 DN 65/PN 16 20.0 350 132 521 1) 370 

D 80 R 18 DN 80/PN 16 27.0 470 206 636 1) 430 

D 100 R 21 DN 100/PN 16 47.0 470 206 636 1) 430 

D 125 R 60 DN 125/PN 16 72.0 635 354 811 1) 550 

D 150 R 64 DN 150/PN 16 108.0 635 354 811 1) 550 

D 200 R 110 DN 200/PN 16 180.0 775 409 1021 650 

D 250 R 146 DN 250/PN 16 288.0 890 480 1324 850 

D 300 R 194 DN 300/PN 16 405.0 1005 634 1535 1000 

D 350 R Upon request DN 350/PN 16 500.0 1128 634 1890 Upon request 





1) 


H 

Ø 

L 

200

Contents 


EcoTrap HF (Steel) 

High Flow Dirt & Sludge Separator 

The sludge/dirt separation in the Duraflex EcoTrap HF works on a similar principle 

to micro-bubble separation: The flow is guided through an area with a greater 

cross-section than the connection dimensions in order to reduce the flow speed. 

The ensuing turbulence caused by the tube mesh causes heavy materials to move 

in an undetermined direction. Depending on the volume flow, density, and volume, 

parts of these sludge particles are supported in their natural breakaway motion 

and guided to the bottom section of the casing. Specially designed for bigger 

systems with longer heights and higher volumetric flow. 

Features 


• Volumetric Flow - 25 - 3000 m 3 /h 

EXPANSION & 

DEAERATION 



DN 50 - DN 600 


impeded by sludge. 

Boiler 

Consumer 


performance dirt seperation 



longer intervals before 

cleaning becomes necessary. 

Boiler 

Duraflex 

EcoTrap HF 

Sludge drain connection 

EcoTrap (Steel) High Flow System Dirt and Sludge Separation Sketch 



D 50 HF 10 DN 50/PN 16 25.0 350 132 706 1) 430 

D 65 HF 12 DN 65/PN 16 40.0 350 132 706 1) 430 

D 80 HF 18 DN 80/PN 16 54.0 470 206 861 1) 430 

D 100 HF 22 DN 100/PN 16 94.0 470 206 861 1) 430 

D 125 HF 37 DN 125/PN 16 144.0 635 354 1121 1) 500 

D 150 HF 45 DN 150/PN 16 215.0 635 354 1121 1) 500 

D 200 HF 75 DN 200/PN 16 360.0 775 409 1391 500 

D 250 HF 119 DN 250/PN 16 575.0 890 480 1532 600 

D 300 HF 160 DN 300/PN 16 810.0 1005 634 2148 600 

D 350 HF 273 DN 350/PN 16 1000.0 1128 634 2400 700 

D 400 HF 354 DN 400/PN 16 1300.0 1226 750 2680 700 

D 450 HF 467 DN 450/PN 16 1700.0 1330 750 2970 700 

D 500 HF 701 DN 500/PN 16 2120.0 1430 1000 3100 700 

D 600 HF 913 DN 600/PN 16 3000.0 1630 1200 3250 700 

1) 


H 

Ø 

L 

201


Contents 

EcoTrap R-HF (Steel) 

High Flow Dirt & Sludge Separator 

The sludge/dirt separation in the Duraflex EcoTrap R - HF works on a 

similar principle to micro-bubble separation: The flow is guided through an 

area with a greater cross-section than the connection dimensions in order 

to reduce the flow speed. The ensuing turbulence caused by the tube mesh 

causes heavy materials to move in an undetermined direction. Depending 

on the volume flow, density, and volume, parts of these sludge particles 

are supported in their natural breakaway motion and guided to the bottom 

section of the casing. Specially designed for bigger systems with longer 

heights and higher volumetric flow. 

Features 

EXPANSION & 

DEAERATION 


• Volumetric Flow - 12.5 - 1530 m 3 /h 

Severel connection available 

from DN 50 to DN 600 



Fan coil 


performance dirt seperation 

Chiller 

Reflex 

EcoTrap R-HF 



longer intervals before cleaning 

becomes necessary. 

Maintenance is much easier with 

its detachable base 

Sludge drain connection 

EcoTrap (Steel) High Flow System with Inspection Flange 

Dirt and Sludge Separation Sketch 



D 50 R-HF 20 DN 50/PN 16 25.0 350 132 706 570 

D 65 R-HF 21 DN 65/PN 16 40.0 350 132 706 570 

D 80 R-HF 68 DN 80/PN 16 54.0 470 206 861 660 

D 100 R-HF 76 DN 100/PN 16 94.0 475 206 861 660 

D 125 R-HF 120 DN 125/PN 16 144.0 635 354 1121 870 

D 150 R-HF 140 DN 150/PN 16 215.0 635 354 1121 870 

D 200 R-HF 181 DN 200/PN 16 360.0 775 409 1391 1030 

D 250 R-HF 220 DN 250/PN 16 575.0 890 480 1532 1050 

D 300 R-HF 305 DN 300/PN 16 810.0 1005 634 2148 1600 

D 350 R-HF Upon request DN 350/PN 16 1000.0 1128 634 2400 Upon request 





H 

Ø 

L 

202

Contents 

Dirt and Air Separators - Dirt and Air Separation 

EcoTwin (Brass) 

Dirt and Air Separator 

The core element is a tube mesh construction that has 

proven itself over the decades, with an extremely low rate 

of pressure loss in the flow direction and a high rate of 

pressure loss in the transverse direction. This drastically 

reduces the amount of turbulence and guides the sludge 

particles to a part-stabilized area. 

Advantages 

• Removes free circulating dirt and sludge particles 

• Functions in fully automated continuous operation 

• Maintenance takes just 5 seconds 

• Permanent free throughflow opening for the water 

• No shut-off valves or bypass lines required. Desludging 

possible during system operation 


• Continually ensures flawless functionality of heat 

generators, thermostat valves, etc. 

• Reduces the risk of system defects and breakdowns in the 

long term 

Features 

• Dimension-dependent brass designs 

• Installation: horizontal, vertical 

• Connection options: thread and clamping ring, 

• Connection diameter A22 - 1” 

• Max. operating pressure: 10 bar 

• Max. operating temperature 110°C 

Boiler 

Duraflex 

EcoTwin 

EcoTwin “Brass” System combined micro-bubble, 

EcoTwin (Brass) System Combined Micro-bubble 

dirt and sludge separation sketch 


EXPANSION & 

DEAERATION 


Ø 


TW 1 1.7 G 1 2.00 84 63 261 

with Magentic Insert 

TW 1 M 187 G 1 2.00 84 63 261 

H 

L 

203


Contents 

EcoTwin (Steel) 


Advantages 

• Combines the protective functions of Duraflex EcoVent 

and EcoTrap in a single component in chilled water 

systems 

• Single installation, doubled effect 

• A more cost-effective solution than using both the 

individual components 


Features 

EXPANSION & 

DEAERATION 


• Volumetric flow - 12.5-405 m 3 /h 


Boiler 

Duraflex 

EcoTwin 

EcoTwin (Steel) System 

Combined Micro-bubble 




TW 50 13 DN 50/PN 16 12.5 350 132 785 370 

TW 65 13 DN 65/PN 16 20.0 350 132 785 370 

TW 80 37 DN 80/PN 16 27.0 470 206 940 370 

TW 100 43 DN 100/PN 16 47.0 475 206 940 370 

TW 125 70 DN 125/PN 16 72.0 635 354 1200 430 

TW 150 75 DN 150/PN 16 108.0 635 354 1200 430 

TW 200 108 DN 200/PN 16 180.0 775 409 1470 430 

TW 250 230 DN 250/PN 16 288.0 890 480 1916 500 

TW 300 300 DN 300/PN 16 405.0 1005 634 2237 500 

TW 350 Upon request DN 350/PN 16 500.0 1128 634 2600 600 





min. 50 mm 

H 

Ø 

HB 

L 

204

Contents 


EcoTwin R (Steel) 


Advantages 

• Combines the protective functions of Duraflex EcoVent and 

EcoTrap in a single component in chilled water systems 


• A more cost-effective solution than using both the individual 

components 



Features 




EXPANSION & 

DEAERATION 

Fan coil 

Chiller 

Duraflex 

EcoTwin R 

ing 

EcoTwin (Steel) System with Inspection Flange 





TW 50 R 13 DN 50/PN 16 12.5 350 132 785 370 

TW 65 R 13 DN 65/PN 16 20.0 350 132 785 370 

TW 80 R 37 DN 80/PN 16 27.0 470 206 940 550 

TW 100 R 43 DN 100/PN 16 47.0 475 206 940 550 

TW 125 R 70 DN 125/PN 16 72.0 635 354 1200 750 

TW 150 R 75 DN 150/PN 16 108.0 635 354 1200 750 

TW 200 R 108 DN 200/PN 16 180.0 775 409 1470 1000 

TW 250 R 230 DN 250/PN 16 288.0 890 480 1916 1350 

TW 300 R 300 DN 300/PN 16 405.0 1005 634 2237 1850 

TW 350 R Upon request DN 350/PN 16 500.0 1128 634 2600 Upon request 





H 

HB 

min. 50 mm 

Ø 

L 

205


Contents 

EcoTwin HF (Steel) 

High Flow Dirt and Air Separator 

Advantages 

EXPANSION & 

DEAERATION 

• Combines the protective functions of Duraflex EcoVent and 

EcoTrap in a single component in chilled water systems 


• A more cost-effective solution than using both the individual 

components 


• Specially designed for bigger systems with longer heights 

and higher volumetric flow 

Features 


• Volumetric flow - 25 -3000 m 3 /h 

Boiler 

Duraflex 

EcoTwin HC 

EcoTwin (Steel) High Flow System 





TW 50 HF 12 DN 50/PN 16 25.0 350 132 1050 430 

TW 65 HF 14 DN 65/PN 16 40.0 350 132 1050 430 

TW 80 HF 20 DN 80/PN 16 54.0 470 206 1285 430 

TW 100 HF 25 DN 100/PN 16 94.0 475 206 1285 430 

TW 125 HF 41 DN 125/PN 16 144.0 635 354 1710 500 

TW 150 HF 50 DN 150/PN 16 215.0 635 354 1710 500 

TW 200 HF 104 DN 200/PN 16 360.0 775 409 2035 500 

TW 250 HF 168 DN 250/PN 16 575.0 890 480 2764 600 

TW 300 HF 300 DN 300/PN 16 810.0 1005 634 3330 600 

TW 350 HF 331 DN 350/PN 16 1000.0 1128 634 3600 700 

TW 400 HF 429 DN 400/PN 16 1300.0 1226 750 4000 700 

TW 450 HF 573 DN 450/PN 16 1700.0 1330 750 4500 700 

TW 500 HF 853 DN 500/PN 16 2120.0 1430 1000 4900 700 

TW 600 HF 1217 DN 600/PN 16 3000.0 1630 1200 5800 700 

H 

HB 

min. 50 mm 

Ø 

L 

206

e high 

h deaeration 

Contents 


EcoTwin R HF (Steel) 

High Flow Dirt and Air Separator 

Advantages 

• Combines the protective functions of Duraflex EcoVent and EcoTrap in a 

single component in chilled water systems 


• A more cost-effective solution than using both the individual components 



Features 




EXPANSION & 

DEAERATION 

Fan coil 

Chiller 

Duraflex 

EcoTwin R-HC 

ure large 

esults in 

ore cleaning 

. 

h easier with 

EcoTwin (Steel) High Flow with Inspection Opening 

System Combined Micro-bubble 




TW 50 R-HF 21 DN 50/PN 16 25.0 350 132 1050 640 

TW 65 R-HF 22 DN 65/PN 16 40.0 350 132 1050 640 

TW 80 R-HF 71 DN 80/PN 16 54.0 470 206 1285 900 

TW 100 R-HF 78 DN 100/PN 16 94.0 475 206 1285 900 

TW 125 R-HF 114 DN 125/PN 16 144.0 635 354 1710 1300 

TW 150 R-HF 120 DN 150/PN 16 215.0 635 354 1710 1300 

TW 200 R-HF 200 DN 200/PN 16 360.0 775 409 2035 1600 

TW 250 R-HF 235 DN 250/PN 16 575.0 890 480 2764 2100 

TW 300 R-HF 340 DN 300/PN 16 810.0 1005 634 3330 2900 

TW 350 R-HF Upon request DN 350/PN 16 1000.0 1128 634 3600 Upon request 





H 

min. 50 mm 

HB 

Ø 

L 

207


Contents 

Pressure Loss Diagram for 

EcoVent, EcoTrap and EcoTwin Standard Models 

EXPANSION & 

DEAERATION 

Connection kvs, m3/h V max. m3/h 

Rp 3/4 10.7 1.25 

Rp 1 17.2 2.00 

Rp 1 1/4 31.8 3.70 

Rp 1 1/2 40.0 5.00 

Rp 2 56.1 7.50 

DN 50 72.2 12.50 

DN 65 121.7 20.00 

DN 80 158.5 27.0 

DN 100 244.3 47.0 

DN 125 351.3 72.0 

DN 150 487.9 108 

DN 200 780.6 180 

DN 250 1185.7 288 

DN 300 1696.4 405 

DN 350 1790.3 500 

DN 400 2242.7 650 

DN 450 2687.9 850 

DN 500 3196 1,060 

DN 600 4416.7 1,530 

Pressure Loss Calculation for all Volume Flows 

v 

Δp= ( Kvs ) 2 x 1 bar, V ≤ V max 

Example: 

Heating circuit 70/55°C, heat generator output 40 kW 

Volume Flow Calculation 

40kW 

s 1 m 

V = x 3.600 x 

3 

4.2 kJ / (kg K) . (70-55) K 

h 1.000 kg 

= 2.3 m 3 /h -> selected size Rp 1 1/4 

2.3 m 

Δp= ( 

3 ./h 

31.8 m ) x 1 bar = 5.23 x 10 -3 bar 

3 /h 

= 0.53 kPa 

208

Contents 

Accessory 

Duraflex Magnetic Separator 

• Solenoid insert for sludge separator 

• 110°C/10 bar 

• Magnetic bar screwed into thermowell/T-piece 

• For uptake of ferromagnetic substances 

Type Weight kg Area of Application Installation Length mm 

D 50 - 100 (60.3-114.3) 0.13 DN 50 - DN 100 300 

D 125 - 200 (139.7-219.1) 0.63 DN 125 - DN 200 350 

D 250 - 300 (273.0-323.9) 1.13 DN 250 - DN 300 400 

D 350 - 600 (355.6-610) 1.63 > DN 300 500 

EXPANSION & 

DEAERATION 

209

Vacuum Deaerators - Dirt and Air Separation 

Contents 

EXPANSION & 

DEAERATION 

Duraflex Vacuum 

Deaerator 30 

• Deaeration with intergrated water make-up systems used in conjunction 

with diaphragm expansion vessels or pressurisation systems 

• Ideally suited for offices and commercial buildings 

• Flexible adjustment of the Duraflex Vacuum Deaerator Magcontrol or 

Levelcontrol operating modes 

• Central deaeration of the water in the system and make-up water 

• Max. operating pressure: 8 bar 

• Max. operating temperature: 70°C 

• Microprocessor controller with plain text display for pressure 

• Floating contact for common message 

• Simple commissioning with auto setup 

• Patented, fully automatic overflow regulation 

• Safe control (water make-up using the actuator valve) 

• Water make-up is possible from a storage tank (on site) 

W 

Duraflex Vacuum Deaerator 30 Wall Mount 

D 

H 

WC 

DC 1 

DC 2 

Duraflex Vacuum Deaerator 30 Mobile 

The Duraflex Vacuum Deaerator 30 Mobile is based on the 

design of the standard unit Duraflex Vacuum Deaerator 

30. The unit is extended by a transport aid and is used for 

the mobile application of vacuum spray tube degassing of 

system and refill water for closed heating or chilled water 

circuits. 

Legend 

1 Controller 

2 Venting grille 

3 Dirt trap 

4 Airvent 

5 3 way motor ball valve 

6 Pressure transducer 

7 Vacuum degassing pump 

8 Removable front shell 

WC Make-up connection 

DC Degassing connection 

- DC 1 Gas-rich water inlet 

- DC 2 Degassed water outlet 


Product 

Code 

Type 

System Volume Vs 

(m 3 ) 70º 

Working Pressure (bar) 

70º 

Make-up Rate 

(m 3 /h) 

H x W X D mm Power W Voltage V Weight kg 

DS 30 30 ≤ 12* 0.5 - 3.0 ≤ 0.025 660 x 545 x 290 470 W / 10 A 240V / 50hz 13.0 

DS 30 GL 30/gl ≤ 4 0.5 - 3.0 ≤ 0.025 660 x 545 x 290 470 W / 10 A 240V / 50hz 13.0 

*Max. facility volumes for system degassing / max. water make-up quantities must be taken into account for the specific facility. 

210

Contents 


Duraflex Vacuum 

Deaerator 35 - 120 

• Vacuum spray-tube deaeration with intergrated water make-up 

systems used in conjunction with diaphragm expansion vessels or 

pressurisation systems 

• Ideally suited for high-rise buildings and district heating / cooling 

systems 

• Flexible adjustment of the Duraflex Vacuum Deaerator Magcontrol 

or Levelcontrol operating modes 

• Central deaeration of the water in the system and make-up water 

• Max. operating pressure: 

- 8 bar - type 35, 60 

- 10 bar - type 75, 95, 120 

• Max. flow temperature: 120°C 

• Microprocessor controller with plain text display for pressure 

• Floating contact for common message 

• Simple commissioning with auto setup 

• Patented, fully automatic overflow regulation 

• Safe control (water make-up using the actuator valve) 

• Water make-up is possible from a storage tank (on site) 

• Control Touch from Duraflex Vacuum Deaerator 120 


W 

Duraflex Vacuum Deaerator 35 - 95 Floor Standing 

D 

H 

EXPANSION & 

DEAERATION 

Product Code 

Type 

System Volume 

Vs (m 3 ) 

Working 

Pressure (bar) 

Make-up 

Rate (m 3 /h) 

H x W X D 

mm 

Power 

W 

Voltage 

V 

Weight 

kg 

Permissible maximum operating temperature: 70°C with Control Basic 

DS 35 CB 35 ≤ 220 0.5 - 2.5 ≤ 0.35 1,030 x 620 x 440 0.7 kW/10 A 240 V / 50 Hz 42.0 

DS 60 CB 60 ≤ 220 0.5 - 4.5 ≤ 0.55 1,215 x 685 x 440 1.1 kW/10 A 240 V / 50 Hz 40.0 

DS 75 CB 75 ≤ 220 0.5 - 5.4 ≤ 0.55 1,215 x 600 x 525 1.1 kW/10 A 240 V / 50 Hz 39.0 

DS 95 CB 95 ≤ 220 0.5 - 7.2 ≤ 0.55 1,215 x 600 x 525 1.1 kW/10 A 240 V / 50 Hz 40.0 

Permissible maximum operating temperature: 70°C with Control Touch 

DS 35 CT 35 ≤ 220 0.5 - 2.5 ≤ 0.35 1,030 x 620 x 440 0.7 kW/10 A 240 V / 50 Hz 30.0 

DS 60 CT 60 ≤ 220 0.5 - 4.5 ≤ 0.55 1,215 x 685 x 440 1.1 kW/10 A 240 V / 50 Hz 36.0 

DS 75 CT 75 ≤ 220 0.5 - 5.4 ≤ 0.55 1,215 x 600 x 525 1.1 kW/10 A 240 V / 50 Hz 41.0 

DS 95 CT 95 ≤ 220 0.5 - 7.2 ≤ 0.55 1,215 x 600 x 525 1.1 kW/10 A 240 V / 50 Hz 42.0 

DSMC 120 CT Magcontrol 120 ≤ 220 1.3 - 9.0 ≤ 0.55 1,215 x 600 x 525 1.5 kW/10 A 400 V / 50 Hz 43.0 

DSLC 120 CT Levelcontrol 120 ≤ 220 1.3 - 9.0 ≤ 0.55 1,215 x 600 x 525 1.5 kW/10 A 400 V / 50 Hz 43.0 

Permissible maximum operating temperature: 90°C with Control Touch 

DS 60 CT 90 60 ≤ 220 1.3 - 4.0 ≤ 0.55 1,215 x 685 x 440 1.1 kW/10 A 240 V / 50 Hz 40.0 

DS 75 CT 90 75 ≤ 220 1.3 - 4.9 ≤ 0.55 1,215 x 600 x 525 1.1 kW/10 A 240 V / 50 Hz 39.0 

DS 95 CT 90 95 ≤ 220 1.3 - 6.7 ≤ 0.55 1,215 x 600 x 525 1.1 kW/10 A 240 V / 50 Hz 40.0 

DSMC 120 CT 90 Magcontrol 120 ≤ 220 1.3 - 9.0 ≤ 0.55 1,215 x 600 x 525 1.5 kW/10 A 400 V / 50 Hz 43.0 

DSLC 120 CT 90 Levelcontrol 120 ≤ 220 1.3 - 9.0 ≤ 0.55 1,215 x 600 x 525 1.5 kW/10 A 400 V / 50 Hz 43.0 

Permissible maximum operating temperature: 70°C, suitable for glycol with Control Basic 

DS 60 GLCB 60 GL ≤ 50 0.5 - 4.5 ≤ 0.55 1,215 x 685 x 440 1.1 kW/10 A 240 V / 50 Hz 40.0 



Permissible maximum operating temperature: 70°C, suitable for glycol with Control Touch 

DS 60 GLCT 60 GL ≤ 50 0.5 - 4.5 ≤ 0.55 1,215 x 685 x 440 1.1 kW/10 A 240 V / 50 Hz 36.0 



DSMC 120 GLCT Magcontrol 120 GL ≤ 50 1.3 - 8.3 ≤ 0.55 1,215 x 600 x 525 1.5 kW/10 A 400 V / 50 Hz 43.0 

DSLC 120 GLCT Levelcontrol 120 GL ≤ 50 1.3 - 8.3 ≤ 0.55 1,215 x 600 x 525 1.5 kW/10 A 400 V / 50 Hz 43.0 

Special designs upon request: System volume > 220 m³ and operating pressure > 9.0 bar 

Magcontrol: For systems with diaphragm-type expansion vessels. Levelcontrol: For systems with pressurisation systems 

211


Contents 

Patented Technology for 

Optimum Degassing 

A 

B 

A Dipstick-Tube Degassing 

Allows gases to escape and is hermetically sealed 

B Vacuum Spray Tube 

The height and diameter are coordinated so that atomization of the 

water is guaranteed in a large free vacuum immediately after the 

start of the degassing cycle. 

C Control 

Degassing cycles run on an optimized timer program or are ideally 

controlled according to the gas content of the water. 

Circuit water rich in gas G 3/4 

Circuit water low in gas G 1 

Make-up water 

E 

D Hydraulics 

The control’s integrated plug & play operational management 

automatically coordinates the hydraulics with the regulating ball 

valves with the pressure conditions in the system. 

E Patented Valve Switch 

For fully automatic hydraulic balancing 

D 

C 

EXPANSION & 

DEAERATION 

Duraflex Vacuum Deaerator Working Principle 

0 

0 

0 

0 

-1 

bar 

-1 

bar 

-1 

bar 

-1 

bar 

M 

M 

M 

M 

M 

M 

M 

M 

1 Vacuum Generation 

2 Degassing Start 

3 Degassing 

4 Idling Time 

The pumps cuts in, the water 

level drops and a vacuum 

is generated in the vacuum 

spray tube. The circuit 

water (optionally make-up 

water) is atomised in the 

generated vacuum releasing 

the dissolved gases due to 

the vacuum and the large 

contact surface. 

The pump shuts down. 

Water is sprayed until 

the vacuum spray tube is 

completely filled. 

All released gases are 

reliably precipitated via the 

automatic fan. 

System pressure has built 

up in the spray tube. The 

system water within the 

tube is nearly gas-free 

and will be returned to the 

network in the following 

cycle. 

212

Contents 



Servitec 

Air Discharge ≥ 500 

LSL 

Control 

Unit 

Reflex Fillset 

PIS 

TIME 

Water 

Make-up 

Duraflex Vacuum Deaerator in magcontrol mode combined with expansion vessel system 

Reflex Fillset 

Water 

Make-up 

Reflex G 

Expansion 

Vessel 

Max. 70 ºC 

Discharge 

valve 


heating& 


PIS 

Filling - Make-Up, 

Pressure-Dependent- 

Magcontrol 

The pressure is shown in the display 

Excess and insufficient pressure 

levels are signaled Automatic, 

controlled make-up in the event that 

the system fails to reach the filling 

pressure of 0.2 bar Duraflex Vacuum 

Deaerator degassing of the make-up 

and filling water. 

TIME 

Degassing 

Vacuum degassing of a part flow 

of the circuit water takes place 

according to an optimized schedule 

using a selectable degassing mode. 

• Continuous degassing 

(after start-up) 

• Interval degassing 

(automatically activated after 

continuous degassing) 

EXPANSION & 

DEAERATION 

Servitec 

Air Discharge 

≥ 500 

LIS 

RG primary vessel 

RS control unit 

Water Make-up, Level- 

Dependent Levelcontrol 

LSL 

PIS 

TIME 

Max. 70 ºC 

PIS 

Solenoid 

valve 

Compressor 

Automatic, controlled water makeup 

if the minimum water level is not 

reached in the expansion vessel of 

the compressor controlled pressure - 

maintaining station Duraflex Vacuum 

Deaerator degassing of the make-up 

water 

Control 

Unit 

Flex duct 

LIS 

Discharge valve 

Duraflex Vacuum Deaerator in levelcontrol mode for systems with compressor controlled pressure maintaining station 

213


Contents 

BMS Modules 

Type 

Weight kg 

LonWorks Digital 1.5 

LonWorks 1.9 

Profi bus-DP 1.9 

Ethernet 1.9 

BACnet-IP for Control Touch 0.4 

BACnet MS/TP for Control Touch 0.4 

Modbus RTU for Control Touch 0.4 

Profibus RTU for Control Touch 0.4 

I/O Modules 1 

Control Remote 

EXPANSION & 

DEAERATION 


EcoPress 

Remote monitoring, diagnostics and at last remote-control 

maintenance are becoming increasingly important for the 

supervision of supply grid systems. For the responsible onsite 

operator, it is more and more difficult to find qualified 

support staff. Long distances to sites frequently prevent 

quick and continuous control. 

Type L mm W mm H mm Weight kg 

Control Remote 83 60 34 0.3 

EcoVac 

Optional: Duraflex Vacuum Deaerator 

for Large Scale Systems 

Special systems are constructed to match your particular 

specifications even for systems above 10,000 m 3 with 

working pressure above 9 bar. 

• Also, for systems with permissible operating temparature 

up to 90°C 

• Take advantage of our combined expertise and experience 

Consult your Duraflex Local representative or visit 

www.automaticheating.com.au for further information 

Tailor made Duraflex Vacuum Deaerator unit 

214

Contents 


Duraflex Control 

Control Basic 

Control Touch 

Remote Control 

• 2-line LCD display 

• 4.3” touch screen colour display 

• Remote control via secure server 

• 8 control keys 

• 2 status LED Integrated control of 

system pressure, deaeration and 

water make-up 

• Graphic user interface 

• Simply structured plain text menus 

including operating instructions and 

help texts 

• System monitoring via PC or mobile 

device at any time and everywhere 

• (Professional) remote servicing by 

Duraflex Customer Service 


• Common fault output signal 

• Input, for contact water meter 

• RS-485 interface 

• Integrated control of system 

pressure, deaeration and water 

make-up 


• Permanent display of the most 

important operating parameters in 

the system diagram 

• Intelligent Plug & Play operational 

management 

• Evaluation and storage of the most 

important operational data 

• Extensive interfaces: 

- Input, for contact water meter 

- 2 x dry contact outputs for error 

messages 

- 2 x analogue outputs for pressure 

and vessel content 

- 2 x RS-485 interfaces 

- Plugs for Bluetooth module and 

HMS networks, as well as SD card 

• Duraflex Remote Portal with intuitive 

user interface 

• Simple management of multiple 

installations 

• Visualisation of all parameters 

• Diagrams for run-time monitoring 

• Alarm messages via e-mail or 

messaging 

• User-provided Internet or GSM 

connection 

• Factory-installed or retrofitting, 

independent of Touch or Basic 

EXPANSION & 

DEAERATION 

215

Contents 

EXPANSION & 

DEAERATION 

216

Contents 

Backflow Prevention & Water Makeup 

Backflow Prevention 

& Water Makeup 

To ensure the safety of our community’s water supply, we need to 

reduce the risk of contamination. 

That means we need to make sure customers install and maintain backflow prevention 

devices on all HVAC heating, cooling & condenser water systems. 

EXPANSION & 

DEAERATION 

Reduced Pressure Zone Devices pg 218 Duraflex Ecofill Units pg 219 

217

Reduced Pressure Zone (RPZ) Devices - Backflow Prevention 

Contents 

Reduced Pressure Zone 

(RPZ) Devices 

Reduced Pressure Zone (RPZ) Devices 

are designed to prevent the return of 

contaminated water to the water supply 

system. AHG has a range of RPZ devices 

that are suitable for a range of low, medium 

and high Hazard applications. 

EXPANSION & 

DEAERATION 

Some examples of RPZ device applications are: 

• Chemically treated closed circuit heating or chilled water 

systems. 

• Hydronic heating systems. 

• Floor-coil heating systems. 

• Distribution branches from mains water supply to services 

and plantrooms. 

It is a statutory requirement that RPZ devices shall have an 

authorised maintenance program for device registration 

and annual test certification. All RPZ units are assembled 

in accordance with AS3500 National Plumbing and 

Drainage Code. 

RETURN from SYSTEM 

SUPPLY to SYSTEM 

PRESSURE 

RELIEF VALVE 

AUTO 

AIR VENT 

CWMA15 with RPZ VALVE 

BOILER 

or 

CHILLER 

ALTERNATIVE 

LOCATION of 

BOILER or 

CHILLER 

MAINS WATER 

SERVICE 

VALVE 

TUNDISH 

DRAIN to WASTE 

EXPANSION 

TANK 

PRESSURE 

RELIEF VALVE 

STRAINER PUMP CHECK 

VALVE 


Flomatic RPZ Valves C-W Ball valves & Y-strainer 

Model 

Connection Size 

Max Working 

Pressure kPa 

Max Supply 

Temp ºC 

FWMA015 15mm 1200 82 

FWMA020 20mm 1200 82 

FWMA025 25mm 1200 82 

FWMA032 32mm 1200 82 

FWMA040 40mm 1200 82 

FWMA050 50mm 1200 82 

FWMA065 65mm 1200 60 

FWMA080 80mm 1200 60 

FWMA100 100mm 1200 60 

Caleffi RPZ Valves C-W Ball valves & Y-strainer 

Model 

Connection Size 

Max Working 

Pressure kPa 

Max Supply 

Temp ºC 

C574015 15mm 1000 65 

C574020 20mm 1000 65 

C574025 25mm 1000 65 

C574032 32mm 1000 65 

C574040 40mm 1000 65 

C574050 50mm 1000 65 

C574065 65mm 1000 65 

C574080 80mm 1000 65 

C574100 100mm 1000 65 

218

Contents 

Duraflex EcoFill Units - Backflow Prevention 

Duraflex EcoFill® Units 

Backflow Prevention/Automatic Refill Units 

Duraflex Backflow Prevention/Refill Units are “Breaktank” Devices which combine 

Back Flow Prevention with automatic refilling of systems as required by AS3500 

National Plumbing and Drainage Code. 

They consist of a non-corrosive supply tank, fill valve, pressure pump and 

pressure switch. They are suitable for all HIGH HAZARD applications, such as; 

• Chemically treated closed circuit heating or cooling water systems 

• Programmed water supply for kitchen hood wash down cycles 

• Continuous water supply systems with potential for cross contamination 

e.g. photographic laboratories 

• Cleaning in place (CIP) systems such as tube-in-tube heat exchangers in wine and 

food industries 

• Hospitals and nursing homes 

When applied to closed circuit applications these units provide for a limited 

make up water supply. In the event of a major system leak the make up water is 

regulated, limiting water damage in the building. Designed and manufactured in 

Australia to comply with AS3500 National Plumbing and Drainage Code. 

Advantages 

Options 

Dimensions 

EXPANSION & 

DEAERATION 

• Provides backflow 

prevention 

• Ideal when mains water 

pressure is insufficient 

• Allows detailed monitoring 

of water usage 

• Dual pump for redundancy 


• Multiple inlet float valves 

• Hours run meter 

• Water flow meter 

• Voltage free alarm contacts 

• Dual pumps for high 

pressure applications 

• Break tanks of special sizes 

• Remote break tanks 

4 x ø8mm MOUNTING HOLES IN BACK 

A 

A 

ECOFILL 

K DRAIN 

L OUTLET 

L INLET 

D 

DOOR 

E 

LEFT HAND HINGE 

A 600mm 

C 260mm 

D 106mm 

E 110mm 

F 

G 

H I 

C 

F 120mm 

H 80mm 

K 40SWV 

L ø20mm 

700 

RETURN from SYSTEM 

SUPPLY to SYSTEM 

600 

PRESSURE 

RELIEF VALVE 

AUTO 

AIR VENT 

PRESSURE kPa 

500 

400 

300 

ARU2 - 505HY 

MAINS WATER 

ECOFILL 

TUNDISH 

SUPPLY TO SYSTEM 

DETACHABLE 

FLEXIBLE 

BOILER 

or 

CHILLER 

ALTERNATIVE 

LOCATION of 

BOILER or 

CHILLER 

ARU2 - 303HY 

200 

100 

0 

0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 

DRAIN to WASTE 

HOSE 

EXPANSION 

TANK 

ADJUSTABLE 

REDUCING VALVE 

and GAUGE 

PRESSURE 

RELIEF VALVE 

SERVICE 

VALVE 

STRAINER PUMP CHECK 

VALVE 

WATER FLOW l/sec 

Typical connection to closed expansion system 

Model Number 

Nom. Pump 

Working Range 

Pres. Switch 

Working Range 

Inlet Pressure 

Pump Motor 

Shipping 

weight 

Break 

Tank 

Mains 

Inlet 

Outlet to 

System 

L/Sec kPa kPa kPa Min kPa Max kPa kW / Volts / Amps kg Gross L Dia. mm Dia. mm 

STANDARD MODELS 

ARU 2-303 0.4 150 50 225 200 1000 0.37 / 240 / 2.1 35 12 20 20 

ARU 2-505 0.4 430 50 375 200 1000 0.60 / 240 / 5.0 38 12 20 20 

VOLT FREE MODELS include volt free contacts for low water and high / low pressure 

ARU 2-303 VF 0.4 150 50 225 200 1040 0.37 / 240 / 2.1 35 12 20 20 

ARU 2-505 VF 0.4 430 50 375 200 1000 0.60 / 240 / 5.0 38 12 20 20 

219

Case Studies - Expansion & Deaeration 

Contents 

Case Studies 

Darling Walk 

3x EcoPress Expansion Systems 

EXPANSION & 

DEAERATION 

New Royal Adelaide 

Hospital 


6x Duraflex Vacuum Deaerators 

Victorian Comprehensive 

Cancer Centre 



220

Contents 

Case Studies - Expansion & Deaeration 

Queensland 

Childrens Hospital 

1x EcoPress Expansion System 

Echuca Hospital 

EXPANSION & 

DEAERATION 

1x EcoPress Expansion System 

for high temperature solar 

heating plant. 

200 George St Sydney 



221

Thermal Storage 

Contents 

THERMAL STORAGE 

222

Contents 

Thermex® Thermal Storage 

Thermex® 

Thermal Storage 

Thermal storage is the application of storing thermal energy in 

materials for later utilisation in a heating or cooling system. 

Thermal storage can result in the reduction of operating costs by producing and storing 

the energy during periods of low energy supply cost (off-peak/night time) and utilising the 

stored energy during periods of high energy supply cost (peak/day time). 


Duplex 2205 Stainless Steel 

Hot Water Tanks 170L-5000L pg 224 

316L Stainless Steel 

Hot Water Tanks 200L-2,000L pg 232 

Duplex 2205 Stainless Steel Hot Water 

Calorifiers 500L-5,000L pg 236 

Steel Buffer Storage Tanks - 

Low Pressure 

300L-2000L pg 238 

Steel Buffer Storage Tanks 

300L-10,000L pg 242 

Custom Buffer Tanks 

300L-20,000L pg 242 

223

Hot Water Storage Tanks for Domestic Water 

Duplex 2205 Stainless Steel Hot Water Tanks - Thermex® Thermal Storage 

Contents 


Hot Water Tanks 

170L - 5000L 

If you are installing Thermex, you can be 

confident you are installing quality. 


Manufactured from high specification Duplex 2205 

Stainless Steel, our Thermex range is designed to resist all 

forms of corrosion, including crevice and stress corrosion. 

Its high mechanical strength promises durability, while 

automated welding procedures, post weld pickling and 

passivating treatment guarantee each individual weld is 

as strong as its parent metal. Our Thermex Stainless Steel 

Hot Water Tanks are pressure tested to a full 12 bar - four 

times their normal working pressure - and injected with 

50mm of our HCFC free Polyurethane insulation to achieve 

astonishingly low levels of heat loss, which maximises 

energy efficiency for your customers. 

Thermex Stainless Steel Hot Water Tanks provide a 

reliable and cost-effective solution to the domestic hot 

water heating and storage requirements of commercial & 

domestic premises, particularly hotels and apartments. 

These tanks are high quality, long service life stainless 

steel vessels for projects that have large volume heating/ 

domestic hot water/solar HVAC water systems. 

Available with twin coils, fully insulated and Watermark 

approved, Thermex Stainless Steel Hot Water Tanks provide 

quick recovery and are suited to high demand usage. Key 

supply advantages include large stock holdings in a range 

of sizes, including compact units designed to fit through 

standard doorways. 

Thermex range of tanks use high recovery smooth tube 

coils for optimal performance. No other coil type on the 

market today offers the same transfer rate as smooth 

stainless tube. 

20 

YEARS 

WARRANTY* 

Certificate 23261 



Product 

Material 

Range 170-5000L 

Stainless Steel Hot Water Tanks 


Suitable Heat Sources Gas, Oil, Wood, Pellet Boiler, 

Solar, Electric, Photovoltaic 

Available with Coils Yes 

Outdoor Suitable Yes (up to 1000L) 


Low Nox 

Yes 



Yes 

224

Contents 


Features 

• Superior Quality Duplex 2205 Stainless Steel 

• Smooth tube coil construction for durability and performance 

• Butt Welded process used on all joins 

• Large coil surface areas 

• No sacrificial anodes required 

• 100% pickled and passivated 

• Thick insulation polyurethane foam layer λ = 0,022 W/mK 

• Optional backup electric heating element 

Hot water outlet 

Metal outer casing 

T & P Valve 

Thermometer 

Top Heat 

Exchanger Coil 

Temperature Sensor 

Top Heat Exchanger Coil 


Bottom Heat Exchanger Coil 

Duplex Stainless 

Steel 316L Heat 

Exchanger Coil 

Secondary Return 

Heating Element Connection 

/ Inspection Port 

Temperature Sensor 

Cold water inlet 

Bottom Heat Exchanger Coil 

Pickled and 

passivated 

High Density rigid polyurethane 

foam, 50mm thick 

225


Contents 

Direct 

• Material - Stainless Steel 2205 

• Insulation: 170-1000L 

- 50mm Rigid Polyurethane 

- 1500-5000L Expanded Foam Jacket 

• Outer Casing - Painted Galvanised Carbon Steel* 

• Tank working Pressure - 700kPa 

• Temperature & Pressure Relief Valve 

rated 99°C / 700kPa 

Specifications 

170 - 1000L 

Model No. Capacity (litres) External Dia. (Ø) mm Total Height (H) mm Weight (Empty) kg 

TSSI170 170 550 1230 60 

TSSI200 200 550 1410 60 

TSSI300 300 620 1600 90 

TSSI400 400 710 1550 100 

TSSI500 500 710 1900 120 

TSSI750 750 920 1800 160 

TSSI1000 1000 920 2200 240 

170L - 1000L 

1500 - 5000L 


TSSI1500 1500 1150 2400 270 

TSSI2000 2000 1300 2400 340 

TSSI2500 2500 1400 2800 420 

TSSU3500 3500 1470 3300 655 

TSSU4000 4000 1470 3800 850 

TSSU4500 4500 1590 3300 885 

TSSU5000 5000 1590 3800 1140 

1500L - 5000L 

HOT OUTLET 

ISOLATOR 

SWITCH 

OFF-PEAK 

CONTROLLER 

COLD INLET 

226

Contents 


Indirect 2 Coils 

• Material - Stainless Steel 2205 

• Coil Material - AISI 316L 

• Insulation: 170-1000L 

- 50mm Rigid Polyurethane 

- 1500-5000L Expanded Foam Jacket 

• Outer Casing - Painted Galvanised Carbon Steel* 

• Coil Working Pressure - 600kPa 

• Tank working Pressure - 700kPa 

• Temperature & Pressure Relief Valve 

rated 99°C / 700kPa 

Specification 

170 - 1000L 

Model No. 

Capacity 

(Litres) 

Coil kW 

Top/ 

Bottom 

Coil Flow 

Rate L/s 

Top/Bottom 

Coil Pressure 

Drop (kPa) 

Top/Bottom 

First hour delivery 

Capacity (L) 

(2 coils in parallel) 

External Dia. 

(Ø) mm 

Total 

Height 

(H) mm 

TSSI2C170 170 20 / 22 0.24 / 0.26 2.98 / 3.33 1959 550 1230 60 

TSSI2C200 200 22 / 32 0.26 / 0.38 2.98 / 15.71 2502 550 1410 60 

TSSI2C300 300 24 / 36 0.29 / 0.43 9.6 / 19.5 2850 620 1600 90 

Weight 

(Empty) 

kg 

TSSI2C400 400 24 / 48 0.29 / 0.57 1.59 / 10.53 3456 710 1550 100 

TSSI2C500 500 36 / 60 0.43 / 0.72 4.5 / 19.13 4578 710 1900 120 

TSSI2C750 750 87 / 120 1.04 / 1.43 28.95 / 47.7 9576 920 1800 160 

TSSI2C1000 1000 87 / 160 1.04 / 1.91 9.23 / 55.67 11521 920 2200 240 

170L - 1000L 

1500 - 5000L 

TSSU2C1500 1500 120 / 180 1.43 / 2.15 27.03 / 50.9 14250 1150 2400 270 

TSSU2C2000 2000 160 / 200 1.91 / 2.39 18.46 / 35.18 17280 1300 2400 340 

TSSU2C2500 2500 180 / 240 2.15 / 2.87 30.16 / 78.54 20310 1400 2800 420 

TSSU2C3500 3500 185 / 250 2.21 / 2.99 14 / 29.5 10632 1470 3300 655 

TSSU2C4000 4000 220 / 285 2.63 / 3.4 22.5 / 36 12286 1470 3800 850 

TSSU2C4500 4500 220 / 320 2.63 / 3.82 22.5 / 43 13338 1590 3300 885 

TSSU2C5000 5000 220 / 355 2.63 / 4.24 22.5 / 52 14390 1590 3800 1140 

Note: Flow rates in the coil are based on 20° ΔT (Inlet/Outlet Temperature = 80/60°C) 

1500L - 5000L 


SENSOR CIRCUIT 

HOT OUTLET 

SOLAR 

CONTROLLER 

SOLAR 

PUMPING 

STATION 

EXPANSION 

VESSEL 

PRESSURE 

RELIEF 

SEALED SYSTEM 

BOILER 

CENTRAL HEATING SUPPLIED BY BOILER 

COLD INLET 

227


Contents 


HOT WATER OUTLET 

Ø 


Ø 

THERMOMETER 

T&P RELIEF 

VALVE 

BOILER 

FLOW 

MANOMETER 

T&P RELIEF 

VALVE 

THERMOMETER 

IMMERSION 

HEATER 

SECONDARY 

RETURN 

Ø 


BOILER 

FLOW 

SENSOR 

BOILER 

RETURN 

SOLAR 

FLOW 

SENSOR 

H 

T&P RELIEF 

VALVE 

IMMERSION 

HEATER 

SECONDARY 

RETURN 

COLD WATER 

INLET 

BOILER FLOW 

THEROMETER 

SENSOR 

BOILER 

RETURN 

SOLAR 

FLOW 

SENSOR 

SOLAR 

RETURN 

H 

SENSOR 

BOILER 

RETURN 

SOLAR 

FLOW 

SENSOR 

SOLAR 

RETURN 

IMMERSION HEATER 

INSPECTION 

SECONDARY 

RETURN 

COLD WATER 

INLET 

H 

COLD WATER 

INLET 

SOLAR 

RETURN 

DRAIN 

DRAIN 

170L - 500L 750L - 1000L 1500L - 5000L 

Drawing represented without thermal 

Note: Immersion socket allows for installation of electric element 

insulation (allow for 100mm insulation) 


Connections Note: All connections are female 

Model 

Cold 

Water 

Inlet 

Hot Water 

Outlet 

Secondary 

Return 

Primary 

Flow 

Top Coil 

Primary 

Return 

Primary 

Flow 

Bottom Coil 

Primary 

Return 

Sensor Immersion T&P Valve Drain 

170L - 300L 20NB 20NB 20NB 20NB 20NB 20NB 20NB 15NB 20NB 20NB - 

400L - 500L 25NB 25NB 20NB 25NB 25NB 25NB 25NB 15NB 25NB 20NB - 

750L 32NB 32NB 25NB 25NB 25NB 25NB 25NB 15NB 25NB 2 x 20NB 25NB 

1000L - 1500L 40NB 40NB 25NB 32NB 32NB 32NB 32NB 15NB 32NB 2 x 20NB 25NB 

2000L - 2500L 50NB 50NB 25NB 40NB 40NB 40NB 40NB 15NB 40NB 3 x 20NB 25NB 

3500L 50NB 50NB 25NB 40NB 40NB 40NB 40NB 15NB 40NB 3 x 20NB 25NB 

4000-5000 80NB 80NB 25NB 40NB 40NB 40NB 40NB 15NB 40NB 4 x 20NB 25NB 

228

Contents 


Immersion Elements 

• As supplementary heating device 

• Connection 1 ½” 

• Inbuilt thermostat 

Single Phase 

Part No. Output kW Voltage V Max temp ºC Tank Size 

TIHE2KW 2 240/1 PH 70 170L-500L 

TIHE3KW 3 240/1 PH 70 170L-500L 

3 Phase 

Part No. Output kW Voltage V Max temp ºC Tank Size 

TIHE6KW 6 400/3 PH 85 750L-1000L 

TIHE10KW 10 400/3 PH 85 750L-1000L 


229


Contents 


P & I Diagram - Meridian 2 x 120kW boilers C/W 1000L Thermex SS Tanks 

1000L Thermex 

S. S. Tank 

Meridian 120 

Heater No. 1 

Meridian 120 

Heater No. 2 

Supply 

Cold 

Water 

Fill 

Flange Connection 

C/W Spacer Piece 

Expansion 

Tank 35L 

Cold Water Supply 


P & I Diagram - Meridian 100kW Boiler C/W 2 x 500L Thermex SS Tanks 

DHW Supply 

DHW Supply 

Meridian 100 

500L 

Thermex S.S. Tank 


Cold 

Water 

Fill 


240V 10A 

GPO 

Scorpion SPA32/80 

Gas 

DHW Supply 

500L 

Thermex S.S. Tank 

Cold Fill 

FWMA015 

Expansion 

Tank 35 L 


230

Contents 



231

316L Stainless Steel Hot Water Tanks - Thermex® Thermal Storage 

Contents 


Hot Water Tanks 

200L - 5,000L 

These WaterMark approved high quality 316L 

Stainless Steel tanks are designed for the 

storage and production of Domestic Hot Water. 

The Direct model without coils can be used as 

a storage or buffer tank while the Indirect 2 

Coil model, which is manufactured with two 

spiral fixed coils, provides an efficient water 

heating and storage solution. 

Features 


• Cylinder: Stainless steel AISI 316 L, internally and externally 

100% pickled and passivated 

• Max. working pressure: 6 bar 

• Max. storage temperature: 95°C 

Available on Request: 

• Stainless steel immersion heaters, from 2 to 12 kW, together 

with a working thermostat and a hi-limit thermostat. 

• Metal or aluminium cladding. 

Direct 

• Welding process: PAW (Plasma Arc Welding) and TIG 

(Tungsten Inert Gas) welding process 

• Insulation: flexible polyurethane 100 mm with a 

removable outer PVC jacket. 

• Standard accessories: Inspection flange 

Direct 

Indirect 2 Coil 

Indirect 2 Coil 

• Heating coils: Spiral coil in AISI 316 L stainless steel. 

• Insulation: rigid polyurethane (50 mm) up to 500 

litres, flexible polyurethane (100 mm) over 500 litres, 

with a removable outer PVC jacket. 



Product Stainless Steel Hot Water Tanks 

Material Stainless Steel AISI 316 L 

Range Direct: 200-5000L 

Indirect 2 Coil: 200-2000L 

232

Contents 


Direct 


Legend 

e Cold Water Feed 

f Inspection Flange 

g Free Connection 

m Anode Connection 1" 1/4 

sc Drain 

r Secondary Return 

sd Probe Connection 1/2” 

u Hot Water Outlet 

z Heating el. Connection 1” 1/2 

Model 

Litres 

Ø Connections 

g-m r e-u z sd-t f 

Max working 

temp. ºC 

Tank max working 

pressure bar 

TSSI-ACX2 200 1” 1/4 1” 1” 1” 1/2 1/2" 220/300 95 6 

TSSI-ACX3 300 1” 1/4 1” 1” 1” 1/2 1/2" 220/300 95 6 

TSSI-ACX5 500 1” 1/4 1” 1” 1” 1/2 1/2" 220/300 95 6 

TSSI-ACX8 800 1” 1/4 1” 1/4 1” 1/4 1” 1/2 1/2" 300/380 95 6 

TSSI-ACX10 1000 1” 1/4 1” 1/4 1” 1/4 1” 1/2 1/2" 300/380 95 6 

TSSI-ACX15 1500 1” 1/4 1” 1/4 1” 1/2 1” 1/2 1/2" 300/380 95 6 

TSSI-ACX20 2000 1” 1/4 1” 1/4 2" 1” 1/2 1/2" 350/430 95 6 

TSSI-ACX25 2500 1” 1/4 1” 1/4 2" 1” 1/2 1/2" 350/430 95 6 

TSSI-ACX30 3000 1” 1/4 1” 1/4 2" 1” 1/2 1/2" 350/430 95 6 

TSSI-ACX40 4000 1” 1/4 1” 1/4 2” 1/2 1” 1/2 1/2" 350/430 95 6 

TSSI-ACX50 5000 1” 1/4 1” 1/4 2” 1/2 1” 1/2 1/2" 350/430 95 6 



Dimensions 

Model Litres A B C D E F H De 

TSSI-ACX2 200 275 575 915 1115 725 915 1470 650 

TSSI-ACX3 300 295 595 965 1135 745 965 1510 750 

TSSI-ACX5 500 270 570 1110 1670 970 1410 1950 800 

TSSI-ACX8 800 395 695 1235 1545 970 1385 1920 990 

TSSI-ACX10 1000 405 705 1245 1805 1105 1445 2190 1000 

TSSI-ACX15 1500 425 725 1265 1815 1115 1455 2200 1200 

TSSI-ACX20 2000 460 760 1300 1850 1150 1490 2280 1400 

TSSI-ACX25 2500 460 760 1300 2100 1275 1600 2530 1400 

TSSI-ACX30 3000 475 775 1315 2365 1415 1645 2800 1450 

TSSI-ACX40 4000 530 830 1370 2400 1450 1680 2880 1600 

TSSI-ACX50 5000 530 830 1370 2400 1450 1680 2910 1800 

Packaging 

Model Height Width Depth Weight kg 

TSSI ACX-2 1590 680 680 65 

TSSI ACX-3 1630 780 780 75 

TSSI ACX-5 2070 830 830 90 

TSSI ACX-8 2040 1020 1020 130 

TSSI ACX-10 2310 1030 1030 145 

TSSI ACX-15 2320 1230 1230 220 

TSSI ACX-20 2400 1430 1430 275 

TSSI ACX-25 2650 1430 1430 330 

TSSI ACX-30 2920 1480 1480 360 

TSSI ACX-40 3000 1630 1630 510 

TSSI ACX-50 3030 1830 1830 600 

233


Contents 

Indirect 2 Coils 



Legend 

es Coil Inlet 1” 

us Coil Outlet 1” 

ei Extra Coil Inlet 1” 

ui Extra Coil Outlet 1” 

r Secondary Return 3/4” (1” over 500l) 

z Heating el. Connection 1” 1/2 

t Thermometer 

a Anode Connection 1” 1/4 

e Cold Water Feed 

u Hot Water Outlet 

f Inspection Flange 


Model 

Litres 

Water Connections 

Flange f 

Ø mm 


e 

u 

Coil Duty* 

kW 

Continuous Rate 

∆T 35ºC 

l/h 

∆T 35ºC 

l/10’ 

Pressure 

Drop 

mBar 

Extra* 

Coil Duty 

kW 

Continuous Rate 

∆T 35ºC 

l/h 

∆T 35ºC 

l/10’ 

TSSI2C-DRX2 200 1” 1” 180 28.8 740 400 0.7 19.2 460 355 0.4 

TSSI2C-DRX3 300 1” 1” 180 41.6 1070 580 1.1 32 740 530 0.7 

TSSI2C-DRX5 500 1” 1” 180 62.4 1440 895 1.5 38.4 875 825 0.9 

TSSI2C-DRX8 800 1” 1/2 1” 1/2 180 86.4 1775 1360 1.9 48 1070 1275 1.1 

TSSI2C-DRX10 1000 1” 1/2 1” 1/2 180 96 1930 1650 2.1 60.8 1320 1575 1.4 

TSSI2C-DRX15 1500 2” 2” 290 118.4 2273 2410 2.6 73.6 1550 2325 1.6 

TSSI2C-DRX20 2000 2” 2” 290 153.6 2410 3100 3.6 96 2410 3050 2.1 

Primary Temperature 80/70ºC - Secondary Temperature 10/45ºC 

Pressure 

Drop 

mBar 

Dimensions 

Model Litres A B C D E F G H De 

TSSI2C-DRX2 200 110 190 340 630 740 840 950 1290 550 

TSSI2C-DRX3 300 120 230 405 790 900 1050 1200 1580 600 

TSSI2C-DRX5 500 145 240 395 840 950 1095 1250 1630 750 

TSSI2C-DRX8 800 170 275 425 870 1010 1200 1385 1735 990 

TSSI2C-DRX10 1000 170 275 430 1020 1160 1400 1635 2080 990 

TSSI2C-DRX15 1500 230 375 530 1110 1460 1460 1460 2115 1200 

TSSI2C-DRX20 2000 255 385 540 1270 1675 1675 1675 2350 1300 

Packaging 

Model Height Width Depth Weight kg 

TSSI2C-DRX2 1420 600 600 67 

TSSI2C-DRX3 1710 650 650 88 

TSSI2C-DRX5 1760 800 800 116 

TSSI2C-DRX8 1890 1100 1100 173 

TSSI2C-DRX10 2230 1100 1100 201 

TSSI2C-DRX15 2280 1300 1300 282 

TSSI2C-DRX20 2690 1400 1400 366 

234

Contents 



235

Duplex 2205 Stainless Steel Hot Water Calorifiers - Thermex® Thermal Storage 

Contents 


Hot Water Calorifiers 

500L - 5,000L 

Calorifier is a term used to describe 

an extensive range of industrial and 

commercial hot water heaters. 


High Performance tubular heat exchangers ensure 

Thermex calorifiers offer the most flexible and economic 

solution to provide your hot water heating requirements. 

Thermex Hot Water Calorifiers are designed for use with any 

primary heating source, for example a solar system or boiler, 

to provide hygienic water for a wide range of applications. 

Direct heating sources like solar and boilers can affect water 

quality so that an isolating medium such as a Thermex hot 

water calorifier is required. Thermex hot water calorifiers 

provide hygienic hot water, by using specially designed 

copper U-Tube heat exchangers. The calorifier will use the 

primary side hot water as an indirect heating source and will 

transfer energy to the cold water side. 

Electrical heaters can also be used with Thermex hot water 

calorifiers either as back up or to meet peak demand. 



Product 

Hot Water Calorifiers 

Material 


Range 500-5000L 

Suitable HVAC Systems Heating 

Outdoor Suitable 

Max Pressure 



Yes (when insulated and clad) 

700kpa 

Yes 


236

Contents 

Duplex 2205 Stainless Steel Hot Water Calorifiers - Thermex® Thermal Storage 


Model 

Capacity 

Dimension 

mm 

Supply Pressure 

kPa 

Max Pressure 

kPa 

DWC500 500 Ø 760 x 1600 H 600 900 

DWC1000 1000 Ø 760 x 2300 H 600 900 

DWC1500 1500 Ø 1067 x 2500 H 600 900 

DWC2000 2000 Ø 1200 x 2300 H 600 900 

DWC2500 2500 Ø 1200 x 2800 H 600 900 

DWC3000 3000 Ø 1270 x 2800 H 600 900 

DWC3500 3500 Ø 1270 x 3500 H 600 900 

DWC4000 4000 Ø 1370 x 3500 H 600 900 

DWC4500 4500 Ø 1550 x 3400 H 600 900 

DWC5000 5000 Ø 1550 x 3500 H 600 900 

Tanks available up to 150,000L. Custom built tanks made to any size. 


Case Study 

Victorian Comprehensive 

Cancer Centre 

2 x 10,000L Hot Water 

Calorifiers 

To produce domestic hot water for 

the hospital. 

237

Buffer Storage Tanks for Heating and Cooling 

Steel Buffer Storage Tanks - Low Pressure - Thermex® Thermal Storage 

Contents 

Steel Buffer Storage Tanks - 

Low Pressure 

300L - 2000L 

Duraflex Low Pressure Buffer Storage 

Tanks are suitable for use with all types of 

heating systems including gas, oil & wood 

boilers and solar. 

• Storage tank made of heavy gauge steel 

S235JRG2 (RSt 37-2) 

• Insulation: Removable 90 mm PU flexible foam with 

white foil cladding Untreated on the inside, with an outer 

plastic coating 

• Max. operating pressure for storage tank 3 bar 

(6 bar above 1500 litres) 

• Max operating pressure for heat exchanger 16 bar 

• Max. operating temperature for storage tank & heat 

exchanger 95°C 

Note: suitable for heating systems only 


SUITABLE FOR 

WOOD 

BOILERS 

SUITABLE FOR 

HEAT 

PUMPS 


Product 

Material 

Buffer Storage Tanks 

Steel 

Range 300-2000L 

Suitable HVAC Systems Gas, Oil, Wood, Pellet Boiler, 

Solar, Electric, Photovoltaic 


Max Pressure 




Storage Tank 300kpa 

(600kpa over 1500L) 

Yes 

238

Contents 

Steel Buffer Storage Tanks - Low Pressure - Thermex® Thermal Storage 


Direct 300-2000L 

Ø D 

Model Ø D mm Height H mm Couplings 9x 

Inclination 

Height mm 

Weight kg 

Heat Loss 

kWh/24h 

HF300 777 1320 Rp 1 ½ 1355 59.0 2.8 

HF500 777 1950 Rp 1 ½ 1974 72.0 3.4 

HF800 970 1825 Rp 1 ½ 1870 124.0 4.0 

HF1000 970 2115 Rp 1 ½ 2153 139.0 4.4 

HF1500 1180 2120 Rp 1 ½ 2178 186.0 5.1 

HF2000 1380 2122 Rp 1 ½ 2200 266.0 5.9 

H 

HF 200 - 2000 

Indirect 1 Coil - 300L-2000L 

Ø D 

Model Ø D mm Height 

H mm 

Couplings 

9x 

Inclination 

Height mm Weight kg Heating 

Surface m2 

Coil Heating 

Capacity kW 

Performance 

l/h 

HF300/1 777 1320 Rp 1 ½ 1355 82 1.34 24 507 3 

Heat Loss 

kWh/24h 

HF500/1 777 1950 Rp 1 ½ 1974 100 1.88 34 711 3.6 

HF800/1 970 1825 Rp 1 ½ 1870 197 3.76 68 1421 4.1 

HF1500/1 1180 2120 Rp 1 ½ 2178 272 4.48 81 1693 4.6 

HF1000/1 970 2115 Rp 1 ½ 2153 225 4.48 81 1693 5.3 

HF2000/1 1380 2122 Rp 1 ½ 2200 352 4.48 81 1693 6.2 

H 

HF 300 - 2000/1 

Indirect 2 Coils - 500L-2000L 

Model Ø D mm Height 

H mm 

Couplings 

9x 

Heating 

Inclination 

Height mm Weight kg Surface 

Top/Bottom 

m2 

Coil Heating 

Capacity kW 

Top/Bottom 

Performance 

l/h 

Top/Bottom 

Heat Loss 

kWh/24h 

HF500/2 777 1950 Rp 1 ½ 1974 125 1.17/1.88 21/34 442/711 3.6 

HF800/2 970 1825 Rp 1 ½ 1870 267 1.86/2.47 24/44 514/934 4.3 

HF1000/2 970 2115 Rp 1 ½ 2153 308 2.47/3.10 44/56 934/1172 4.7 

HF1500/2 1180 2120 Rp 1 ½ 2178 355 2.37/3.72 37/59 775/1236 6.4 

HF2000/2 1380 2122 Rp 1 ½ 2200 438 2.05/3.72 43/67 896/1406 5.5 

H 

Ø D 


HF 500 - 2000/2 

239

Steel Buffer Storage Tanks - Thermex® Thermal Storage 

Contents 

Steel Buffer Storage Tanks 

300L - 10,000L 

Buffer Tanks for Heating Systems 


The buffer tanks consist of a wide selection of mild steel 

vessels, designed to improve efficiency of renewable 

heating appliances such as biomass boilers, solid fuel or 

heat pump heating systems. 

Cylinder: mild steel 

Max. working pressure: 5 bar, 

Max. working temperature: 95°C 

Insulation: Insulation: rigid polyurethane from 30mm to 

110mm (from 300 to 1000 lt.), flexible polyurethane 100mm 

+ closed-cell polyethylene 20mm (1500 and 2000 lt.), 

flexible polyurethane 100mm (from 2500 to 10000 lt.) 

Outer jacket: external jacket in PVC 

Long retention of useful heating water, easy location in 

smaller spaces, and pass through doorways are granted. 

Heating coils: High efficiency and large surface spiral coils 

for connection to different primary heating sources. 

Max. working pressure: 9 bar 

PU - basic buffer tank with no coils inside. 

Ideal application when requiring a link between solid fuel, 

biomass and traditional energy sources 

PUW - buffer tank fitted with a single primary heating coil, 

suitable for solar thermal or other indirect heat sources. 

PUIW - buffer tank equipped with two primary heating coils 

for connection to multiple sources. 


Product 


Material 

Mild Steel 

Range 

300-10,000L 

Suitable HVAC Systems Chilled or Heating 


Max Pressure 




5 Bar 

Yes 

240

Contents 

Steel Buffer Storage Tanks - Thermex® Thermal Storage 


PU-3 - PU-100 PUW-3 - PUW-50 PUIW-3 - PUIW-50 

LEGEND 

ei Extra Coil Inlet 1” 

es Coil Inlet 1” 

g System Connection 

mc Connection to Gas Boiler 

mi Connection to Heating 

rc Return from Gas Boiler 

ri Return from Heating 

rp Extra Return from Heating 

S Basement for PU 60÷100 Only 

sa Air Discharge Connection 1” 

sc Drain 


t Thermometer Connection 1/2” 

ui Extra Coil Outlet 1” 

us Coil Outlet 1” 

Z Heating El. Connection 1”1/2 


Model 

mi-mc-rcrp-sc 

Ø connections 

Surface exchangers 

Dimensions 

Weight (kg) 

m 2 

Litres 

PU PUW PUIW A B C D E F G H De PU PUW PUIW 

PU PUW PUIW-3 1” 1/4 - 1 1+1 300 325 695 1065 1435 880 685 1075 1680 610 55 65 77 

PU PUW PUIW-5 1” 1/4 - 1,9 1.9+1.2 500 345 715 1085 1455 975 865 1135 1715 710 77 98 110 

PU PUW PUIW-8 1"1/2 - 2,5 2.5+1.5 800 290 660 1030 1400 845 770 1130 1740 990 109 137 154 

PU PUW PUIW-10 1"1/2 - 3,1 3.1+2.5 1000 290 780 1270 1760 1020 890 1280 2100 990 125 153 181 

PU PUW PUIW-15 1"1/2 - 3,8 3.8+2.8 1500 360 810 1260 1710 1085 920 1310 2140 1240 194 237 268 

PU PUW PUIW-20 1"1/2 - 4,6 4.6+2.8 2000 390 930 1470 2010 1200 990 1650 2470 1340 263 315 346 

PU PUW PUIW-25 2" - 5,0 5.0+4.0 2500 425 865 1305 1745 1145 985 1305 2220 1450 296 352 383 

PU PUW PUIW-30 2" - 6,0 6.0+4.2 3000 435 1035 1635 2235 1435 1115 1755 2720 1450 346 413 460 

PU PUW PUIW-40 2" - 7,0 7.0+5.0 4000 480 1080 1680 2280 1430 1160 1800 2810 1600 492 571 628 

PU PUW PUIW-50 2" - 8,0 8.0+5.0 5000 510 1110 1710 2310 1510 1190 1910 2870 1800 582 672 730 

PU-60 3” - - - 6000 635 1155 1675 2195 1415 - - 2790 2000 684 - - 

PU-80 3” - - - 8000 625 1385 2145 2905 1615 - - 3490 2000 823 - - 

PU-100 3” - - - 10000 625 1635 2645 3655 2365 - - 4240 2000 973 - - 

241

Custom Buffer Tanks - Thermex® Thermal Storage 

Contents 

Custom Buffer Tanks 

300L - 20,000L 

Thermex Mild Steel Buffer Storage Tanks are 

ideal for applications requiring large volume 

chilled water storage in heating or chilled 

water circuits. 


They can be used with chillers and boilers which do not 

have water volumes of sufficient size in relation to the 

chiller or boiler. The insufficiently sized systems do not 

have enough buffer capacity for the system water causing 

poor temperature control, erratic system operation and 

excessive chiller or boiler cycling. 

Thermex Mild Steel Buffer Storage Tanks solves this 

problem by adding water volume to buffer the system and 

reduces the rate of change of the return water. 

Chillers are designed to be useful in systems with a 

minimum water volume. The minimum water volume is 

based upon the chiller manufacturer's requirements. When 

chiller systems are properly sized, the chiller compressor 

will not short cycle. Without the proper amount of system 

water, the source temperature will be reached quickly and 

the compressor will shut off. Many chiller compressors 

can only start 3 times per hour. Insufficiently sized system 

problems can cause excessive compressor cycling, poor 

temperature control and erratic system operations. 

Features 

• When insulated, Thermex tanks comply to the BCA Section J 

insulation requirements 

• Are suitable for indoor and outdoor situations 

• Designed to AS1210 Unfired Pressure Vessels 

• Low profile to facilitate installation in low roof plant-rooms 

• Available in various materials and pressure ratings 

• Standard designs and custom-made designs 

10 

YEARS 

WARRANTY* 


Product 


Material 

Mild Steel 

Range 

200-20,000L 

Suitable HVAC Systems Chilled or Heating 


Max Pressure 




700 kpa 

Yes 


242

Contents 

Custom Buffer Tanks - Thermex® Thermal Storage 


Vertical Uninsulated 

Code Vol. L Height mm Dia. mm Dry Weight kg 

TSU00300L0518 300 1900 518 125 

TSU00400L0572 400 2060 572 160 

TSU00500L0610 500 2155 610 195 

TSU00600L0762 600 1845 762 230 

TSU00800L0914 800 1850 914 310 

TSU01000L0914 1000 2100 914 435 

TSU01250L0914 1250 2500 914 485 

TSU01500L1067 1500 2240 1067 620 

TSU02000L1216 2000 2250 1216 830 

TSU02500L1370 2500 2270 1370 915 

TSU03000L1520 3000 2300 1520 965 

TSU04100L1520 4100 2930 1520 1585 

TSU05000L1820 5000 2590 1820 1860 

TSU06000L1820 6000 2990 1820 2040 

TSU10200L2134 10200 2900 2134 2810 

TSU20000L2438 20000 5125 2438 5000 

Horizontal Uninsulated 

Code Vol. L Length mm Dia. mm Dry Weight kg 

TSU00300L0518HZ 300 1730 518 125 

TSU00400L0572HZ 400 1850 572 160 

TSU00500L0610HZ 500 2072 610 195 

TSU00600L0762HZ 600 1620 762 285 

TSU01000L0914HZ 1000 1872 914 390 

TSU01250L0914HZ 1250 2328 914 515 

TSU01500L0914HZ 1500 2672 914 620 

TSU02000L1067HZ 2000 2728 1067 830 

TSU03000L1520HZ 3000 2130 1520 1230 

TSU04000L1520HZ 4000 2670 1520 1550 


243

Buffer Storage Tanks - Thermal Storage 

Contents 

Available Options 

Flanged Nozzles 

Bends 

Hand Holes 

For connecting pipeline continuations. 

You are free to choose the number 

and position of the flanged nozzles. 

Increase the optimal utilisation of the 

height of a tank and avoid unused 

dead spaces. 

Necessary service openings for small 

tanks. (100 x 150 mm) 


Man Holes 

Necessary service openings for 

large tanks. (320 x 420 mm) 

Sparge Pipes 

Conduct the main volume flow without 

generating turbulence in the vessel. 

Diffuser Bends 

Reduce the inflow and outflow speeds 

of the fluid in the tank. 

Bushings 

Threaded Nozzles 

Perforated/Stratifying Sheets 

Used to connect measuring 

instruments such as thermometers 

and pressure gauges. 

For connecting pipeline continuations 

with a threaded transition. You are 

free to choose the number and 

position of the flanged nozzles. 

Enable necessary stratification 

within a tank 

244

Contents 

Buffer Storage Tanks - Thermal Storage 

Sizing of a Buffer Storage Tank 

The necessary volume for a buffer storage tank can be calculated based on a few parameters. 

The only factors needed here are the thermal output (heating or cooling output), the storage time 

and the temperature difference between the feed and return. 

This information is entered into the following formula: 

P × t 

V st 

= 

c × ΔT 

V st 

= Storage volume in m³ 

P = Heating/cooling rating in kW 

t 

= Storage time in h 

c = Heat capacity of the carrier fluid, in this case 1.163 kWh/(m³ × K) 

ΔT = Temperature difference in K 

Example: The minimum rating of a water chiller of 50 kW at a temperature difference of 5 kelvin 

between feed and return is intended to be stored for a period of 20 minutes (cycle frequency). 

V st 

= P × t 

c × ΔT 

V st 

= 50 kW × 1/3 h 

1.163 kWh/(m³ × K) × 5 K 

V st 

= 2.87 m³ 

Therefore, the storage volume required here is 2.87 m³, or 2,870 litres. 


Case Studies 

Buffer Storage Tank Piping Diagram 

Parliament House 

Chilled Water Systems 

2x 15,000L Chilled Water 

Buffer Tanks 

Complete with Phase Change 

Material to provide emergency 

cooling for Australian Parliament IT 

cooling Systems. 

245

HVAC Pumps 

Contents 

HVAC PUMPS 

246

Contents 

HVAC Pumps 

HVAC Pumps 

There are several types of pumps used in HVAC heating & cooling 

systems, but the most common used in today is the centrifugal pump. 

Types of centrifugal pumps include volute or axial flow pumps. The volute takes water 

from the impeller and discharges the water perpendicular to the shaft. A centrifugal pump 

with a diffuser casing (axial flow pump) discharges the water parallel to the pump shaft. 

Centrifugal pumps are available in many types including circulator, single- and multi-stage 

end-suction, single- and multi-stage split-case, and vertical in-line pumps. 

Saer Pumps pg 248 

Wilo Pumps pg 250 

Grundfos Pumps pg 252 

HVAC PUMPS 

Inertia Bases pg 256 

247

Saer Pumps 

Saer Pumps - HVAC Pumps 

Contents 

Saer Pumps 

Since 1951 SAER ELETTROPOMPE have been manufacturing water electric 

pumps and motors for the civil, industrial, agricultural and domestic field; 

the products are suitable for municipalities, firefighting applications and for 

conditioning and heating, naval and mining sector. 

HVAC PUMPS 

SAER produces centrifugal pumps from 0.37 to 300kW 50HZ, for fields such as domestic, building 

services, industrial, firefighting, irrigation, mining and naval.. 

The SAER range includes: centrifugal peripheral electric pumps, centrifugal single impeller electric 

pumps, centrifugal electric pumps with two opposite impellers, multistage horizontal and vertical 

centrifugal electric pumps, electric centrifugal self priming pumps, electric centrifugal gear pumps, 

normalized centrifugal monopoly pumps, centrifugal electric normalized pumps with stub shaft, 

centrifugal bare-shaft normalized electric pumps, centrifugal bare-shaft exceeding the norm electric 

pumps, swimming pool pumps, drainage pumps, centrifugal submersible radial and semi-axial electric 

submersible pumps, split casing pumps and booster sets. 

PUMP 

2 

YEARS 

WARRANTY 

* 

Conditions Apply* 

248

Contents 

Saer Pumps - HVAC Pumps 

Saer IR – Close Coupled Pump 

• Materials: cast iron, stainless steel. 

• Maximum Flow Rate: 450m3/h 

• Maximum Head: 129m 

• Maximum Power: 45kW 

Saer L - Vertical Inline Pumps 





Saer NCB – Long Coupled Pumps 





HVAC PUMPS 

Saer MK – Multi-Stage Vertical Pumps 





249

Wilo Pumps 

Wilo Pumps - HVAC Pumps 

Contents 

Wilo Pumps 

Circulators 

Wilo Star-Z 

• S804-lSK tailored for sanitary solar water application with low energy consumption 

• Star-Z 15-TT features integrated timer and thermostat plus isolation valve and nonreturn 

valve pre-mounted to pump 

• Star-Z 20/7-3 features sanitary stainless steel pump housing 

• Remaining units supplied with bronze housing 

Type 

Pipe 

Connection 

(RP) 

Nominal 

Diameter 

(mm) 

Overall 

Length 

(mm) 

Mains 

Connection 

Gross 

Weight 

(kg) 

Stock 

Code 

Article No. 

SB 04-lSK ½" N/A 84 1~230V 50 Hz 2.2 L 4132786 

Star-Z 15-TT ½" 15 138 1~230V 50 Hz 2.3 L 4110919 

Star-Z 20/7-3 ¾" 20 150 1~230V 50 Hz 2.9 L 4184746 

Star-Z 25/6-3 1" 25 180 1~230V 50 Hz 2.7 L 4047573 

Wilo TOP-Z 

• Manual power adjustment through 2-speed selector switch 

• Inbuilt motor thermal protection 

• Unique self venting design to ensure long-term operation 

• AII units supplied with bronze housing 

Type 

Pipe 

Connection 

(RP) 

Nominal 

Diameter 

(mm) 

Overall 

Length 

(mm) 

Mains 

Connection 

Gross 

Weight 

(kg) 

Stock 

Code 

Article No. 

TOP-Z 25/10-EM 1" 25 180 1~230V 50 Hz 7.8 L 2127302 

TOP-Z 30/10-EM 11/4" 30 180 1~230V 50 Hz 7.8 L 2127303 

HVAC PUMPS 

Wilo Star-RS 

• Designed for closed-loop and underfloor heating systems 

• Maximum fluid temperature 110°C 

• Sujtable for any installation position providing flexibility 

• Star-RS range supplied with cast iron pump housing 

Type 

Pipe 

Connection 

(RP) 

Nominal 

Diameter 

(mm) 

Overall 

Length 

(mm) 

Mains 

Connection 

Gross 

Weight 

(kg) 

Stock 

Code 

Article No. 

Star-RS 15/6-130 ½" 15 130 1~230V 50 Hz 2.3 L 4063803 

Star-RS 25/6-130 1" 25 130 1~230V 50 Hz 2.5 L 4033782 

Star-RS 25/6-180 1" 25 180 1~230V 50 Hz 2.7 L 4032956 

Star-RS 25/6-RG* 1" 25 180 1~230V 50 Hz 2.8 L 4035761 

250

Contents 

Wilo Pumps - HVAC Pumps 

Wilo TOP-S 

• Can be used for either heating or cooling water applications 

• Maximum fluid temperature 130ºC 

• Supplied with thermal insulation shell as standard 

• TOP-S range supplied with cast iron pump housing 

Type 

Pipe 

Connection 

(RP) 

Nominal 

Diameter 

(mm) 

Overall 

Length 

(mm) 

Mains 

Connection 

Gross 

Weight 

(kg) 

Stock 

Code 

Article No. 

TOP-S 25/7-EM 1" 25 180 1~230V 50 Hz 5.3 L 2048320 

TOP-S 25/7-DM 1" 25 180 3~400V 50 Hz 5.3 L 2048321 

TOP-S 25/10-EM 1" 25 180 1~230V 50 Hz 7.1 L 2061962 

TOP-S 30/5-EM 11/4" 30 180 1~230V 50 Hz 4.6 L 2044013 

TOP-S 30/10-EM 11/4" 30 180 1~230V 50 Hz 7.2 L 2066132 

Wilo Stratos 

• Energy savings through greater system efficiency with the Q-Limit function 

(volume flow limiter) 

• Constant pressure, variable pressure or temperature control modes available 

• Modular concept for connection of all conventional bus systems 

(e.g. Modbus, BACnet etc) 

• Permissible temperature range -10°C +110°C 

• Full motor protection with integrated trip electronics 

Type 

Pipe Connection 

(RP) 

Overall 

Length 

(mm) 

Mains Connection 

Stock 

Code 

Article No. 

Stratos 40/1-12 DN40 250 1~230V 50 Hz L 2090455 



Unions 

HVAC PUMPS 

Screwed connections for 

Cast Iron circulation pumps 

Screwed connections for 

domestic hot water circulation pumps 

Union inserts with female threads 

for connection to steel pipes (DIN 

2440) with Whitworth pipe thread in 

accordance with DIN 10226-1 

Article No. Connection To suit 

4092741 Rp 1” x G 1½” Nom. dia. 25 

4092742 Rp 11/4” x G 2” Nom. dia. 30 

1 set of screwed connections 

consisting of: 2 union nuts, 2 flat 

gaskets and 2 union inserts 

Brass material (MS) 

Fig. A: Special union inserts with 

Whitworth male thread (DIN EN 

10226-1) and female thread for 

choice between threaded connections 

and solder joints on copper pipe (DIN 

EN 1057) 

Fig. B: Union inserts with female 

threads for connection to copper 

pipes (DIN EN 1057) with Whitworth 

pipe thread in accordance with DIN 

EN 10226-1. 

Article No. Connection Fig. To suit 

4092743 Rp½” x G 1” A Nom. dia. 15 

4016172 Rp ¾” x G11/4” B Nom. dia. 20 

112047195 Rp 1” x G 1½” A Nom. dia. 25 

112082691 Rp 11/4” x G 2” A Nom. dia. 30 

1 set of screwed connections 

consisting of: 2 union nuts (GTW 

chromated), 2 flat gaskets and 2 

union inserts 

251

Grundfos Pumps 

Grundfos Pumps - HVAC Pumps 

Contents 

Grundfos 

Inline Circulators 

Grundfos are constantly striving to make their products more user friendly 

and reliable – and also energy saving and efficient so that users and the 

environment benefit from their improvements. 

Grundfos pumps are equipped with ultramodern electronics, allowing them to regulate their output 

according to current needs. 

UPA Homebooster 

Domestic boosting circulator with built in flow switch, stainless steel body 

Model Description Size mm Power volts/hz Union Set Pipe 

59-53-95-08 UPA15-90N 160 240/50 included 3/4"M 

Comfort – UPN – UP(S)B 

Domestic boosting circulator with built in flow switch, stainless steel body 

HVAC PUMPS 

Model Description Size mm Power volts/hz Union Set Pipe 

In-line Circulator Pumps for Hot Water, Comfort System includes Valve 

91-33-24-40 Comfort System – 240/50 – – 

91-33-32-37 Comfort System – 240/50 – – 

91-33-90-60 Raincover For Comfort – 240/50 – – 

Stainless Steel Body, Single Speed 

59-64-36-00 UP20-30N 150 240 / 50 00-52-99-82 3/4"F 

52-04-22-01 UP20-45N 150 240 / 50 00-52-99-82 3/4"F 

Stainless Steel Body 

96-91-30-96 UPS20-60N 150 240/50 00-52-99-82 3/4"F 

96-91-30-85 UPS25-60N 180 240/50 00-51-98-06 1"F 

95-90-64-48 UPS32-80N 180 240/50 00-50-99-71 1-1/4"F 

95-90-64-89 UP30-80N 180 415/50 00-50-99-71 1-1/4"F 

In-line Circulator Pumps for Heating and Cooling 

96-28-14-80 UPS25-60/130* 130 240/50 00-52-99-22 1"F 

96-28-14-86 UPS25-60/180* 180 240/50 00-52-99-22 1"F 

52-00-43-01 UPS25-80 180 240/50 00-52-99-22 1"F 

52-05-23-10 UPS32-80 180 240/50 00-50-99-22 1-1/4"F 

52-05-20-90 UP32-80 180 415/50 00-50-99-22 1-1/4"F 

96-28-89-65 ALPHA+ 25-60* 180 240/50 00-52-99-22 1"F 

* heating only 

252

Contents 


UPS & TP Inline Centrifugal Pump 

• UPS-B - bronze body fitted with a 3 speed rotor canned motor 

• TP-B - bronze body fitted with IP55, cl.F motor & 16mm BUBE mechanical seal 

• UPS - cast iron body fitted with a 3 speed rotor canned motor 

Model Description Power volts/hz Connection Size (DIN) 

for Hot Water 

96-40-21-08 UPS50-120/2FB 240/50 50 

96-40-21-10 UPS50-120/2FB 415/50 50 

96-40-20-31 TPS50-30/4FB 240/50 50 

96-40-20-93 TPS50-60/2FB 240/50 50 

for Heating and Cooling 

96-40-19-15 UPS40-60/2F 240/50 40 

96-40-19-17 UPS40-60/2F 415/50 40 

96-40-19-42 UPS40-120/2F 240/50 40 

96-40-19-44 UPS40-120/2F 415/50 40 

96-40-19-79 UPS40-180/2F 415/50 40 

96-40-20-55 UPS50-60/2F 415/50 50 

96-40-21-03 UPS50-120/2F 415/50 50 

96-40-21-36 UPS50-180/2F 415/50 50 

96-40-22-60 UPS65-60/2F 415/50 65 

96-40-22-80 UPS65-120/2F 415/50 65 

96-40-23-16 UPS65-180/2F 415/50 65 

96-40-23-91 UPS80-60/4F 415/50 80 

96-40-24-40 UPS80-120/2F 415/50 80 

UPE Magna - for Heating and Cooling 

Inline centrifugal pump with cast-iron body fitted with a permanent-magnet motor, 

controlled by a frequency converter 

Model Description Power volts/hz Connection Size (DIN) 

96-51-36-25 Magna UPE 32-120 240 / 50 32 

96-51-36-26 Magna UPE 40-120 240 / 50 40 

96-51-36-27 Magna UPE 50-60 240 / 50 50 

96-50-48-72 Magna UPE 50-120 240 / 50 50 

96-51-36-28 Magna UPE 65-60 240 / 50 65 

96-50-48-73 Magna UPE 65-120 240 / 50 65 

HVAC PUMPS 

253


Contents 

Grundfos 

Inline Centrifugal and End Suction 

The systematic improvements of the hydraulics, mechanics and motor construction 

of the Grundfos in-line pump has resulted in a particularly compact design. 

A significant increase in efficiency means that smaller pumps can be used in applications which previously 

required much larger solutions. The Grundfos range of end suction pumps are designed to work tirelessly 

in the most demanding environments. These pumps are ultra reliable and efficient and are optimised for a 

large range of applications involving high volumes of water or other liquids. 

TP Inline Centrifugal Pump 

Cast iron body fitted with IP55, cl.F motor 

HVAC PUMPS 

Model Description Output kW Power volts/hz Connection Size (DIN) 

4 Poles 

96-08-68-93 TP40-130/4 0.75 415/50 40 

96-08-68-94 TP40-160/4 1.1 415/50 40 

96-08-71-38 TP50-160/4 1.5 415/50 50 

96-08-71-39 TP50-190/4 2.2 415/50 50 

96-08-71-40 TP50-230/4 3 415/50 50 

96-08-74-61 TP65-130/4 1.5 415/50 65 

96-08-74-62 TP65-150/4 2.2 415/50 65 

96-08-74-63 TP65-170/4 3 415/50 65 

96-08-76-38 TP65-240/4 4 415/50 65 

96-10-88-73 TP80-110/4 2.2 415/50 80 

96-10-86-36 TP80-150/4 3 415/50 80 

96-10-88-75 TP80-170/4 4 415/50 80 

96-10-90-93 TP100-70/4 1.5 415/50 100 

96-10-90-94 TP100-90/4 2.2 415/50 100 

96-10-90-95 TP100-110/4 3 415/50 100 

63-10-93-41 TP100-130/4 4 415/50 100 

2 Poles 

96-40-20-83 TP50-60/2 0.37 415/50 50 

96-40-21-16 TP50-120/2 0.75 415/50 50 

96-40-21-48 TP50-180/2 0.75 415/50 50 

96-08-70-29 TP50-190/2 1.5 415/50 50 

96-08-70-30 TP50-240/2 2.2 415/50 50 

96-08-70-31 TP50-290/2 3 415/50 50 

96-08-72-24 TP50-360/2 4 415/50 50 

96-08-72-25 TP50-430/2 5.5 415/50 50 

96-08-72-26 TP50-440/2 7.5 415/50 50 

96-40-22-70 TP65-60/2 0.55 415/50 65 

96-40-22-93 TP65-120/2 1.1 415/50 65 

96-40-23-25 TP65-180/2 1.5 415/50 65 

96-08-73-59 TP65-190/2 2.2 415/50 65 

96-08-73-60 TP65-230/2 3 415/50 65 

96-08-75-53 TP65-260/2 4 415/50 65 

96-08-75-54 TP65-340/2 5.5 415/50 65 

96-08-75-55 TP65-410/2 7.5 415/50 65 

96-09-74-53 TP65-460/2 11 415/50 65 

96-09-74-54 TP65-550/2 15 415/50 65 

96-40-24-55 TP80-120/2 1.5 415/50 80 

96-10-85-05 TP80-140/2 2.2 415/50 80 

96-10-85-06 TP80-180/2 3 415/50 80 

96-10-87-59 TP80-210/2 4 415/50 80 

96-10-87-60 TP80-240/2 5.5 415/50 80 

96-10-87-61 TP80-250/2 7.5 415/50 80 

96-26-01-88 TP80-330/2 11 415/50 80 

96-26-01-89 TP80-400/2 15 415/50 80 

96-26-01-90 TP80-520/2 18.5 415/50 80 

96-10-92-21 TP100-160/2 4 415/50 100 

96-10-92-22 TP100-200/2 5.5 415/50 100 

96-10-92-23 TP100-240/2 7.5 415/50 100 

96-26-03-00 TP100-250/2 11 415/50 100 

96-26-03-01 TP100-310/2 15 415/50 100 

96-26-03-02 TP100-360/2 18.5 415/50 100 

96-26-03-03 TP100-390/2 22 415/50 100 

254

Contents 


NBG Single Stage End Suction - 4 Poles 

and CH Multi Stage General Transfer 

The Grundfos NBG range of end suction pumps are designed to work tirelessly in 

the most demanding environments. These pumps are ultra reliable and efficient 

and are optimised for a large range of applications involving high volumes of 

water or other liquids. 

• Single stage end suction pump fitted with 3 x 415V IP55 motor 

• Bronze wear rings as standard 

Series Description Connection Size Outlet (mm) 

50x32 NBG 50x32 series from 2.2kW to 5kW 32 





100x80 NBG 100x80 series from 1.1kW to 18.5kW 80 




CRI Vertical Multi Stage End Suction Pumps 

The Grundfos CRI range of vertical multi stage pumps are suitable for liquid 

transfer in – washing systems, cooling and air-conditioning systems, water supply 

systems, water treatment systems, fire fighting systems, industrial plants and 

boiler feeding systems. 

• Vertical multi stage fitted with IP55 motor 

• 304 stainless steel 

• Suitable for slightly aggressive liquids 

• 1 x 240V 50 Hz or 3 x 415V 50Hz 

• Also available in 50bar, 480m head versions 

Series Description Connection Size Outlet 

CRI 1 CRI 1 series from 0.37kW to 2.2kW Flange DIN/AS 






HVAC PUMPS 

NK End Suction Pumps 

• Single Stage Long Coupled End Suction 

• Bronze Wearing’s as standard 

Series Description Connection Size Outlet (mm) 

NK 40 NK 40 Series from 1.5kW to 7.5kW 40mm 

NK 50 NK 50 Series from 2.2kW to 11kW 50mm 


NK 80 NK 80 Series from 4kw to 45kW 80mm 


NK125 NK 125 Series from 7.5kW to 75kW 125mm 

NK 150 NK 150 Series from 22kW to 90kW 150mm 

NK 200 NK 200 Series from 45kW 200mm 

255

Inertia Bases 

Inertia Bases - HVAC Pumps 

Contents 

Inertia Bases 

Inertia bases and vibration mountings are designed to reduce the transmission of noise 

and vibration from HVAC equipment to building structures and associated pipework. 

When installed with rubber bellows or stainless steel hose & pump connectors they provide an ideal vibration and 

noise isolation solution. 

The inertia bases are specifically designed and engineered to receive poured concrete which are supplied empty for 

filling onsite. It is by adding this mass and by lowering equipment centre of gravity that enables the inertia base to 

provide a stable support. This is particularly important for equipment which exhibits high out-of-balance forces and 

are top-heavy such as pumps. The concrete base enables a reduction in motion from pump start up and minimises 

the effect of unequal load distribution. 


Inertia Pump Base 600W X 1250L 4 legs - (Product no. IPB61254) 

HVAC PUMPS 

TOP VIEW 

1250 

FRAME LENGTH 

100 1050 100 

950 

SIDE VIEW 

150 

600 

FRAME WIDTH 

60 

60 

C L 

C L 

75 

75 

720 

75 

800 

FRONT VIEW 

256

Contents 

HVAC PUMPS 

257

Heat HVAC Exchangers Accessories- HVAC Accessories 

Contents 

HVAC ACCESSORIES 

258

Contents 

Heat Exchangers - HVAC Accessories 

HVAC Accessories 

Whether you're a small hydronic heating contractor, service engineer or the 

purchasing manager for a large Mechanical Engineering contractor, we are 

here to provide you with the knowledge, products and level of service you 

need to deliver your projects on time. 

Our extensive product range, vast stock and same day delivery service backed by full technical 

support and after sales service department will help you get the job done on time, every time. 

Condensate Neutralisers pg 260 

Hydraulic Separators pg 266 

Heat Exchangers pg 268 

Valves and Gauges pg 270 Water Treatment Products pg 278 


259


Condensate Neutralisers - HVAC Accessories 

Contents 


Over the last decade, the number of condensing boilers and water heaters being installed 

has continued to rise every year and all indications are that this trend will continue 

and eventually become mandatory due to their higher energy efficiency and cleaner 

emissions, compared to standard boilers. 

Condensing boilers discharge a corrosive condensate as a by-product of their operation. Because of the long-term effects of the 

sustained introduction of this corrosive condensate into drains and sewer lines, there is a growing awareness of the need to educate 

code enforcement officials, contractors, building owners, facility managers and homeowners of the need to neutralize this corrosive 

outflow and the means available to do this. 


What is Condensing Boiler condensate? 

Condensing water heaters achieve higher energy efficiency than 

standard boilers by condensing the water vapour in the flue gasses 

and using the latent energy recovered through this process to heat 

the return water going into the water heater. The condensing process 

is achieved by passing the piped hot flue gases through the cooler 

return water flowing back into the boiler. Flue gas starts to condense 

when it drops below its dew point of 55°C. This is why condensing 

boilers are designed to accommodate a return water temperature of 

54°C or less. It is this resulting condensate liquid that is acidic and 

requires treatment to avoid damage to piping systems, sewerage 

systems and other items it may come in contact with. 

How much condensate is produced? 

A general rule of thumb, 3.5 litres of condensate is produced 

for every 30kw of input providing the boiler is operating in full 

condensing mode. A boiler having 30kW of input operates for 1200 

hours annually will produce approximately 4200 litres of condensate. 

Acidity levels 

The acidic level of the condensate is measured as pH. Most 

condensate from natural gas appliances will have a pH of between 

2.0 and 4 with 7 being neutral. The actual pH will vary according 

to the actual chemical makeup of the fuel that is being burned. 

Condensate contains different types of acids that are corrosive to 

many materials and contain concentrations of nitric, nitrous, sulfuric, 

and sulfurous and hydrochloric acids. These acids can become 

more concentrated by repeated condensing and evaporation on heat 

exchangers and flues. 

A pH of 4 can damage drainage pipes, septic tanks, treatment plants 

and other materials handling waste water. The pH scale is not linear. 

Each whole number step below 7 is 10 times more acidic than the 

next higher number. 

How to Treat Condensate 

Treated condensate should be as close to 7 (neutral) as possible 

with 5 being the minimum. Most national and state codes prohibit 

anyone from allowing acidic liquid into a drainage system without 

treating it to raise its pH. To increase the pH to acceptable levels, 

whereby it no longer has the potential to damage the sewer system 

or environment, a condensate neutraliser should be installed. 

Condensate neutralisers are designed specifically for this task, and 

consist of a tank or module containing alkaline limestone aggregate 

or chips. Automatic Heating offers several models that accommodate 

water flow rates from 6.05l/hr to 155l/hr depending on the size of 

the condensing water heater system. 

2.9 - 4.0 

Flue Gas Condensate 

The acid is converted to water, carbon dioxide and mineral salts 

when exposed to the media. The carbon dioxide will generally stay 

diluted in the water and pass out of the neutralizer. The mineral 

salts generally settle at the bottom of the neutralizer. Over time the 

media dissolves and must be replenished. If applied properly and 

maintained regularly, damage associated with acidic condensate in 

the drain piping can be avoided. 

Condensate drains 

The condensate expelled from a condensing water heater is acidic 

with a pH of between 2 and 4, so it is critical that the appropriate 

materials are used in all piping where this liquid is present. 

In high temperature areas, like the flue, stainless steel must be 

used to prevent corrosion. The low temperature piping, such as that 

which drains the condensate from the heat exchanger condensate 

draining system, should be PVC or ABS to also mitigate corrosion. 

This system normally consists of a short length of PVC or ABS pipe 

with a water trap to prevent exhaust gases from being expelled into 

the drain and building. 

Maintenance & Servicing 

The best way to check if the condensate neutraliser is working 

properly is to test the treated condensate with a pH meter. pH 

meters are available at a reasonable cost and should be added to the 

technician’s tool arsenal. All manufacturers of condensing boilers 

recommend annual maintenance and the service technician should 

check and service the condensate neutralizer during this service. 

It is the responsibility of the plumbing professional to follow state 

and local plumbing codes including proper disposal of condensate 

and equally important for the end user to provide ongoing 

maintenance ensuring proper function of the unit. Damage can occur 

underground and in unseen, remote locations. Imagine digging up 

your basement floor to replace a rotted out metallic drain line! 

In Conclusion 

• Condensate from condensing boilers is acidic and corrosive to 

many materials and should be treated to maintain a pH of no less 

than 5 before disposal. 

• There can be a wide variation of the pH of condensate from 

condensing appliances due to the chemical make-up of the 

gas being combusted or from the way in which the appliance is 

operating in a particular application. 

• A fully condensing appliance will produce up to 3.5 litres of 

condensate per hour for every 30kw of input. 

• The neutraliser media is reacting with the solution to raise the pH 

and does need to be replaced. Most manufacturers recommend 

replacing media and checking operation at least annually. 

Typical Houshold 

Sewage 

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

Battery Acid 

Gastric Acid 

Lemon 

Juice 

Vinegar 

Rain 

Water 

Clean Rain 

Water 

Distilled Water 

(Neutral) 

Tap 

Water 

Lake 

Water 

Ammonia 

ACIDIC 

BASIC 

260

Contents 


Defender Condensate 

Neutralisers 

Defender® condensate neutralisers should 

only be installed by a qualified professional. 

Read all instructions before installing. Perform steps in the order 

given. Failure to comply could result in a defective installation with 

the risk of property damage and personal injury. 

Do not allow flue gases to vent through condensate neutraliser. 

Vent in cap is designed to allow proper flow through neutraliser. 

All condensate drain lines must have a water trap before entering 

the neutraliser. 

Defender neutralisers should only be connected to a condensate 

outlet that is installed per the appliance manufacturer’s 

instructions. 

Dimensions 


B 

A 

I 

I 

C 

D 

J 

Inlet 

M 

K 

L 

Outlet 

J 

DCN1475 

DCN65V 

I 

I 

A 

B 

D 

F 

G 

J 

K 

L 

N 

C 

E 

H 

Inlet 

M 

Outlet 

DCN1750 

DCN175/350/600 

Model A B C D E F G H 

DCN1475 356 433 150 85.5 - - - - 

DCN1750 203 168 305 95 381 146 67 304.8 

Model kW I J K L M N 

DCN65V 65 15 BSP F 35 51 70 375 - 

DCN175 176 15 BSP F 64 114 121 324 86 

DCN350 352 15 BSP F 64 114 121 473 86 

DCN600 586 15 BSP F 64 114 121 705 86 


261


Contents 

Important 

All piping should be in accordance with relevant building and 

mechanical codes, as well as any local, state or federal regulations. 

The Condensate Neutraliser should be installed below all traps and 

condensate outlets. 

It is recommended that the installer maintain a pitch of 15mm per 

metre between the condensate neutraliser outlet and the pump or 

drain. 

Do not use pipe dope on threaded fittings - use only Teflon tape. 

Defender condensate neutralisers must NOT be installed in the 

vertical position (except for the DCN-65V vertical model) 

It is recommended that the neutraliser be installed before a 

condensate pump where needed. 

All condensate traps should be primed before commencing operation 

of the appliance. 

Defender Condensate Neutraliser media should be replaced at least 

once a year or when pH falls below local regulations. 

Defender Condensate Neutralisers are suitable for outdoor 

installation, however must be protected from sunlight and UV rays. 

Mounting Options 

It is recommended that Defender condensate neutralisers be installed 

as close as possible to the outlet of the condensate trap. 

Condensate neutraliser may be installed on level ground or mounting 

brackets (not provided). 

Defender condensate neutralisers may be installed on or above the 

floor so long as a pitch of 15mm per metre is maintained between the 

neutraliser outlet and the drain or pump. 

It is recommended that unions be installed to facilitate maintenance 

of the condensate neutraliser. 

Installation 

1. If using PVC pipe, apply Teflon tape to the threads of PVC socket 

adaptors and attach to neutraliser. Do not over tighten. 

2. Identify suitable location for assembled condensate neutraliser. 

Observe direction of flow as indicated on neutraliser. 

3. PVC unions should be secured at either end of the neutralizer. 

4. Prime and glue PVC pipe to fittings. 

Note: If using flexible tubing, be sure to use hose clamps at barb fittings. 

Note: PVC pipe is the preferred method for piping condensate drain lines. 

5. Route PVC pipe or tubing to drain or pump, maintaining a pitch of 

15mm per metre. 

6. Fill condensate trap with water until flow is established through 

neutralizer. 

7. Observe neutralizer during boiler operation to ensure unrestricted 

condensate flow. 

8. Location of unit must allow service access. 

Installation Advice 

It is recommended that the Condensate Neutraliser be installed as 

close as possible to the outlet of the gas trap. 

Do not allow flue gases to vent through the Condensate Neutraliser. 

All condensate drain lines must have a gas trap before entering the 

Neutraliser. 

All Neutralisers must be installed in the horizontal position except for 

model DCN-65V which must be installed in the vertical position. 

The Neutraliser media should be replaced at least once per year 

or when the pH level of condensate discharge falls below the level 

stipulated in your local regulations. 

Maintenance 

1. All service items should be undertaken by a qualified professional. 

2. Visually inspect unit for signs of leaking or damage. 

3. Neutraliser media should be replaced at least once a year or 

when pH falls below local regulations. Neutraliser efficiency can 

only be determined by measuring pH level of condensate outflow. 

Replacement media is available as a spare part. 

4. Treated condensate should be as close to 7 (neutral) as possible 

with 5 being the minimum. 

5. Disconnect condensate line from both the inlet and the outlet of 

the neutralizer. 

6. Unscrew cap and remove spent neutralizer media. Rinse empty 

neutralizer with water. 

7. Add replacement media and replace cap. 

8. Reattach neutralizer to condensate line and prime flue gas trap 

with a minimum of 1 gallon of water. 

9. Observe neutralizer during boiler operation to ensure unrestricted 

condensate flow. 


DCN1750 


DCN-65V 

DCN175/350/600 

262

Contents 


Defender Condensate Neutralisers 

Vertical 

Horizontal (Tube) 

Horizontal (Box) 

Part No. 

DCN65V 

Description 

Suitable for up to 65kW boilers 

Part No. 

DCN175 

DCN350 

DCN600 

Description 

suits up to 175kW 



Part No. 

DCN1475 

Description 


Horizontal (Box) 

UV Protection Spray Can 

Recharge Kit 

Part No. 

DCN1750 

Description 


Part No. 

KFPUVC 

Description 

Spray Can 

Part No. 

D65RCK-S 

D175RCK 

D350RCK 

D600RCK 

D1475RCK 

D1750RCK 

Description 

suits DCN65V 

suits DCN175 

suits DCN350 

suits DCN600 

suits DCN1475 

suits DCN1750 

Condensate Neutralisers are not suitable for installation in direct sunlight. 

If installed outside, please coat the neutraliser using UV Protection Spray 

The neutraliser kW ratings are based on 3.5pH output and are therefore only nominal and 

must be checked onsite after boiler operation. 


263


Contents 

Polypropelene Condensate Drain Pipes 

Elbow 

Tee 

Cap 

Part No. 

Description 

VS0504017 40mm 45º 

UM95310512) 40mm 87º 

Part No. 

UM95310513 

Description 

40mm 

Part No. 

VS0524001 

Description 

DN40mm 

Pipe (M+F) 

Pipe (F+F) 

Double Socket Pipe (F+F) 

Part No. 

UM95310515 

Description 

40mm x 1mtr (M+F) 

Part No. 

VS05020015 

Description 

40mm x 1mtr 

Part No. 

VS0501249 

VS0502037 

Description 

DN100mm x 500mm 

DN75mm x 500mm 


Eccentric Reducer 

Part No. 

Description 

VS0514005 75mm x 40mm 

VS0514008 110mm x 40mm 

Double Reducer 

Part No. 

Description 

VS0525003 DN100/40/40mm 

Joiner 

Part No. 

VS05280001 

Description 

40mm 

264

Contents 



265

Hydraulic Separators 

Hydraulic Separators - HVAC Accessories 

Contents 

Hydraulic Separators 

How does it work? 

The Hydraulic Separator efficiently separates the primary 

and secondary circuits by acting as a closely spaced tee, 

which is normally seen in a traditional primary-secondary 

piping. However it does more than just separating the 

circuits – this highly engineered product also acts as an air 

and dirt separator. The vessel is designed to create a low 

velocity area allowing air to rise to the top and sediment to 

sink to the bottom. 

Air Vent 

Flow Path #2: Flow in the secondary circuit is greater than 

flow in the primary circuit (refer to Figure 4). Since the 

flows are no longer balanced, the temperature going to the 

secondary circuit is no longer the same as the temperature 

from the boiler. This is primarily due to mixing of the supply 

and return fluids within the hydraulic separator body. To 

satisfy the system demand, a portion of the fluid returning 

from the system at Port 3 mixes with the fluid entering the 

hydraulic separator from the boiler at Port 1. This situation 

results in a lower temperature flow at T2 going to the system. 

From boiler 

Air rises 

to the 

top 

To system 

T 1 

> T 2 

Q 1 

= Q 4 

T 3 

= T 4 

Q 2 

= Q 3 

To boiler 

Insulation 

Sediment 

sinks 

to the 

bottom 

Drain Valve 

From system 

From boiler 

To boiler 

T T 1 

Q 4 

Q 3 

Q 1 

2 

Q 2 

Port 1 Port 2 

T 4 

T 3 

Port 4 

Port 3 

To system 

From system 

Figure 2: Primary-Secondary Header 

Figure 4 


There are three possible flow paths, which are all 

dependent on the flows within the primary and secondary 

circuits. 

Flow Path #1: Flow in the primary circuit is equal to flow in 

the secondary circuit (refer to Figure 3). This is an example 

of a balanced flow where the flow and temperature from 

the boiler is equal to that of the distribution system. The hot 

water from the boiler remains near the top two ports, Port 

1 and Port 2. A similar situation occurs on the bottom ports, 

Port 3 and Port 4 – the flow and temperature from the 

system are equal to the flow and temperature of the fluid 

going back to the boiler. In cases like this, mixing with the 

hydraulic separator body is very minimal. 

From boiler 

To boiler 

T T 1 

Q 4 

Q 3 

Q 1 

2 

Q 2 

Port 1 Port 2 

T 4 

T 3 

Port 4 

Port 3 

T 1 

= T 2 

Q 1 

= Q 4 

T 3 

= T 4 

Q 2 

= Q 3 

Figure 3 

To system 

From system 

Flow Path #3: Flow in the primary circuit is greater than 

flow in the secondary circuit (refer to Figure 5). This is 

another case of an unbalanced flow. This time, the system 

requirement is less than the boiler output. The flow 

returning from the system, Q3, mixes with the hot water 

from the boiler, Q1. This results in an increase in boiler 

return temperature. The formula to calculate T4 is shown in 

the appendix on the back page. 

From boiler 

To boiler 

T T 1 

Q 4 

Q 3 

Q 1 

2 

Q 2 

Port 1 Port 2 

T 4 

T 3 

Port 4 

Port 3 

T 1 

= T 2 

Q 1 

= Q 4 

T 3 

< T 4 

Q 2 

= Q 3 

Figure 5 

To system 

From system 

In all three cases described, the air and dirt are separated 

from the fluid as it enters the hydraulic separator body. The 

air rises to the top vessel and vented to the atmosphere 

via the automatic air vent while the sediment sinks to the 

bottom, which could be removed through the drain valve. 

266

Contents 

Hydraulic Separators - HVAC Accessories 

Benefits, Features and Functions 

• Hydraulically separates primary and secondary circuits 

• Separates and vents air from the system 

• Separates and collects impurities in the circuits 

• Provides ease of installation, no complicated piping 

• Painted steel body with brass air vents and drain valve 

Duraflex Hydraulic Separators 

Stainless Steel Single Input 

1x ½” drain valve, 1x ½” AAV, and insulation cover 

Part No. Connections Weight kg 

SSHS1-50S 4x 25mm BSP Steel 20 

SSHS1-150S 4x 40mm BSP Steel 40 

Single Input 

Part No. Connections Max kW Weight kg 

HS1-50CKIT 4 x 32mm Copper 50 7 

HS1-50SKIT 4 x 32mm BSP Steel 50 15 






HS1-350FKIT 4 x 65mm Flanged 350 40 






Double Input 

Triple Input 

Part No. Connections Max kW Weight kg 

HS2-150CKIT 4x 40mm & 2x 50 Copper 150 35 

HS2-300SKIT 4x 40mm & 2x 50mm BSP Screwed 300 50 

HS2-700FKIT 4x 65mm & 2x 80mm Flanged 700 65 



HS2-1320FKIT 6x 100mm Flanged 1320 130 



Part No. Connections (Flanged) Max kW Weight kg 

HS3-500FKIT 4x 80mm & 2x 125mm 500 70 

HS3-900FKIT 6x 65mm & 2x 100mm 900 95 

HS3-1950FKIT 6x 80mm & 2x 150mm 1950 160 

HS3-2500FKIT 6x 100mm & 2x 150mm 2500 200 

HS3-2600FKIT 6x 80mm & 2x 150mm 2600 210 

Meridian Hydraulic Separator 


Part No. 

Connections (Flanged) 

MHS1-600F 4 x 80mm (suits M120, M150) 

267

Heat Exchangers 


Contents 

Thermex Plate Heat Exchangers 

Thermex – Plate Heat Exchangers that can change with your requirements. 

Automatic Heating can offer plate heat exchangers using a combination of 

locally manufactured and imported components resulting in competitive 

pricing, short lead times and efficient after sales service. 


Each Thermex plate heat exchanger is selected using 

state-of-the-art software to match the specific performance 

requirements of individual applications. This sophisticated 

selection and sizing process, using programs that represent 

experience accumulated since 1940, and guarantees low 

cost and efficient thermal performance. 

Thermex plate heat exchangers incorporate an expandable 

design. Thermal performance can be adjusted by simply 

adding or removing or rearranging heat transfer plates. The 

Thermex construction typically allows for the addition of 

30% more heat transfer surface area without any changes 

to the unit foot-print. 

Thermex Construction 

A Thermex plate heat exchanger consists of a number of 

corrugated plates with gaskets placed in grooves along the 

edge. The adjacent plates come into contact with each other 

where the ridges meet. During assembly the channel plates 

are pressed together in a frame to form a tight and efficient 

heat exchanger. 

The heat transfer performance is naturally dependant on 

the size of the plate. The corrugated plate surface is shaped 

into a herringbone pattern with the angles of the chevrons 

determining the shape of the channels. By combining 

different plate patterns in the same plate pack the optimum 

solution for any heat transfer application can be found. 

Every Thermex plate heat exchanger is tailor made to 

meet the individual needs of the customer. 

The type of unit required and number of plates are 

determined by the customers specific duty requirements. 

Plate materials available include stainless steel, nickel 

alloys and titanium with support frames constructed from 

steel or stainless steel. Thermex plate heat exchangers can 

be supplied with various types of connections to facilitate 

installation. Standard materials for gaskets are Nitrile 

(NBR) or Ethylene propylene rubber (EDPM). Several other 

materials are also available. Ask your Automatic Heating 

representative for assistance when selecting a suitable 

material for your application. 

Thermex components have one of the best on-time shipping 

records for complete assemblies and spare parts. Many 

orders are despatched as fast as three working days, with 

deliveries for more complex specifications often shipped in 

less than three weeks. 

Applications 

• Automotive 

• Brewing 

• Chemical 

• Food and Beverage 

• HVAC 

• Marine 

• Metal Working 

• Petroleum 

• Power 

• Pulp and Paper 

• Steel 

• Textile 

268

Contents 


Tubular Heat Exchangers 

Hi Flow 

Maxi Flow 

Part No. 

THEHF13 

THEHF28 

THEHF40 

THEHF75 

Description 

13kW 

28kW 

40kW 

75kW 

Part No. 

THEMF135 

THEMF200 

THEMF260 

THEMF400 

Description 

135 - 40kW 

200 - 60kW 

260 - 75kW 

400 - 120kW 

SS316 - High Temperature 

Titanium 

Part No. 

Description 

THESS40 40kW (11312) 

THESS75 75kW (11314) 

Part No. 

Description 

THET28 28kW (11332) 

THET40 40kW (11333) 

THET75 75kW (11334) 


269

Valves and Gauges 

Valves and Gauges - HVAC Accessories 

Contents 

Gauges 

Autoheet Temperature Gauges 

Part No. Description Temperature Range 

ATGCH80 65mm Stem (XR025NC19PC), Bottom Entry -40 - 160ºC 

ATGCH100 100mm stem, brass pocket, Back Entry -20 - 60ºC 

ATGSS100B 100mm Stainless Steel, Bottom Entry -20 - 120ºC 

ATGSS100R 100mm Stainless Steel, Rear Entry -20 - 120ºC 

ATGSS80R 80mm Stainless Steel, Rear Entry -10 - 110ºC 

ATGSS80R2 80mm Stainless Steel, Rear Entry 100mm Stem -10 - 110ºC 

ATGB 100mm stem (XR040NC55PC), Bottom Entry 0 - 50ºC 

ATGR100 100mm Stem, Brass Pocket, Back Entry 0 - 120ºC 

ATGB100 100mm stem, Brass pocket, Bottom Entry 0 - 120ºC 

ATGSS80B 80mm Stainless Steel, Bottom Entry 0 - 150ºC 

Caleffi Temperature Gauges 

Part No. Description Temperature Range 

C688000 80mm Dia. Back Entry 50mm Stem, 1/2” Connection 0 - 120ºC 

C688010 80mm Dia. Back Entry 100mm Stem, 1/2” Connection 0 - 120ºC 

C688100 80mm Dia. Bottom Entry 55mm Stem, 1/2” Connection 0 - 120ºC 

Pressure 

0-400kPa / 0-800 kPa 

0-600kPa 

0-600kPa (Bottom Entry) 

Part No. 

APG100400 

APG100800 

Description 

100mm dia. 0-400kPa, 3/8” 

BSP bottom connection 

100mm dia. 0-800kPa, 3/8” 

BSP bottom connection 

Part No. 

C557106 

Description 

Back Entry, 1/4” connection 

Part No. 

C557306 

Description 

50mm Bottom entry 

Temperature / Pressure 


0 to 120ºC & 0-600kPa 

Part No. 

C503060 

C503160 

Description 

Back Entry, 1/2” connection 

Bottom Entry, 1/2” connection 

270

Contents 


Pressure Reducing Valves 

Caleffi 

Without Gauge 

100-600 kPa 

Part No. 

C533545 

Description 

15mm Fill Valve 

Part No. 

C535040 

C535050 

C535060 

C535070 

C535080 

C535090 

Description 

15mm 

20mm 

25mm 

32mm 

40mm 

50mm 

Arteclima 

20-400 kPa 

Part No. 

AR57012 

Description 

15mm Fill Valve 


271


Contents 

Air Release Valves 

Automatic Air Vents 

Part No. 

Description 

T1-2 EcoTop 

Part No. 

C502640-(301A) 

Description 

1/2" BSP 

Part No. 

C250032(300C) 

Description 

Solar 180º 10 Bar 

Part No. 

C501500 

Description 

3/4” BSP Maxcal Heavy Duty 

Part No. 

C502430-(301) 

Description 

3/8” BSP 

Part No. 

C502630 

Description 

3/8" BSP 


Part No. 

C502730-(302) 

Description 

3/8” BSP with Check Valve 

Combined Air Separator 

Part No. 

Description 

C302630-(326) 3 Bar Safety Valve 

272

Contents 


Flow Switches 

Caleffi Flow Switches 

Part No. 

C315500 

Description 

20mm Magnetic - 3/4” Male - 3/4” Male 

Part No. 

C626600 

Description 

Paddle Type fits 25mm Socket 25Ø - 200Ø Pipe 

Differential 

Bypass Valves 

Swing Check 

Valves 

Part No. 

C519500 

C519700 

Description 

20mm 

32mm 

Part No. 

SCV15B 

SCV20B 

SCV25B 

SCV32B 

SCV40B 

SCV50B 

Description 

15mm Brass 

20mm Brass 

25mm Brass 

32mm Brass 

40mm Brass 

50mm Brass 


273


Contents 

Mixing Valves 

Part No. 

C523063 

Description 

25mm 65º max 

Part No. 

C521319 

Description 

Antiscald 20mm 50º max - AS Approved DHW 


274

Contents 


Pressure Relief Valves 

Part No. 

ARSV15-3 

ARSV15-4 

ARSV15-5 

ARSV15-6 

Description 

15mm 300 kPa 56512BAR3 

15mm 400 kPa 56512BAR4 

15mm 500 kPa 56512BAR5 

15mm 600 kPa 56512BAR6 

Part No. 

C527410-(304) 

Description 

15mm 100 kPa 60kW 

Part No. 

C513430-(312) 

C513480-(313) 

Description 

15mm 300 kPa 50kW 

15mm 800 kPa 240kW 

Part No. 

C530530-(314) 

Description 

20mm 300 kPa 100kW 

Part No. 

C531540-(316) 

C531560-(317) 

C531580-(318) 

C531510-(319) 

Description 

20mm 400 kPa 120kW 

20mm 600 kPa 140kW 

20mm 800 kPa 175kW 

20mm 1000 kPa 220kW 

Part No. 

C527540-(304A) 

C527550-(305) 

Description 

20mm 400 kPa 310kW 

20mm 500 kPa 373kW 

Part No. 

C530630-(315) 

Description 

25mm 300 kPa 200kW 

Part No. 

C527630-(306) 

C527640-(306A) 

C527650-(307) 

C527660-(308) 

C527680-(308A) 

C527730-(309) 

C527740-(309A) 

C527750-(310A) 

C527760-(311) 

Description 

25mm 300 kPa 500kW 

25mm 400 kPa 630kW 

25mm 500kPa 766kW 

25mm 600 kPa 870kW 

25mm 800 kPa 1130kW 

32mm 300 kPa 700kW 

32mm 400 kPa 877kW 

32mm 500kPa 1055kW 

32mm 600 kPa 1200kW 

Adjustable 

Part No. 

SRV015 

SRV020 

SRV025 

SRV032 

SRV040 

SRV050 

Description 

15mm 100-1200kpa 

20mm 100-1200kpa 

25mm 100-1200kpa 

32mm 100-1200kpa 

40mm 100-1200kpa 

50mm 100-1200kpa 


275


Contents 

Pressure & Temperature 

Relief Valves 

Part No. 

HT703700 

HT705850 

Description 

20mm 700kPa 99C 

20mm 850kPa 99C 

Part No. 

PTR25S 

Description 

25mm 700 kPa (132kw) 

Vibration Eliminator / 

Expansion Joints 

EPDM Mid Steel Table E PN16 

Part No. 

ASF10-032 

ASF10-040 

ASF10-050 

ASF10-065 

ASF10-080 

ASF10-100 

Description 

32mm 

40mm 

50mm 

65mm 

80mm 

100mm 

Vacuum Breaker Valves 


Part No. 

AAD015G 

AAD020G 

AAD020N 

AAD025N 

AAD032N 

AAD040N 

AAD050N 

Description 

15mm (Gotz622-12) 

20mm (Gotz622-34) 

20mm (Niez91.3) 

25mm (Niez91.3) 

32mm (Niez91.3) 

40mm (Niez91.3) 

50mm (Niez91.3) 

276

Contents 


Biomass Boiler Valves 

Caleffi Heat Discharge Valve 

Laddomat Mixing Valve TV3S 

Part No. 

C543513 

Description 

For wood boilers 

Part No. 

L15100009 

L15080009 

L15025001 

L15040001 

L15025003 

L15040003 

L15100005 

L15060005 

L15080005 

Description 

Cu28 (compression) kvs10.0 

Cu28 (compression) kvs8.0 

R15 (1/2 inch FI) kvs2.5 




R25 (1 inch FI) kvs10.0 



Laddomat Thermal Charging Valve 

11-30, LM4 Pump 

11-100, LM6 Pump 

21-60, LM6 Pump 

21-100 

Part No. 

L11111363 

Description 

63ºC, R25, max 

boiler output 

60kW 

Part No. 

L11173461 

Description 

R32, 63ºC, max 

boiler output 

105kW 

Part No. 

L11263461 

Description 


boiler output 

80kW 

Part No. 

L11211171 

Description 


boiler output 

120kW 

Laddomat 

Thermomatic 

Actuator 

Part No. 

L125003 

L125001 

Description 

120secs 

60secs 

Laddomat 

Thermomatic 

Regulator 

Part No. 

L123002 

Description 

CC 

Laddomat 

Thermostat 

Cartridge 

Part No. 

Description 

L110078 1456, 78ºC 

L110063 

L110072 

5839 (63C) 

8719 (72C) 

Laddomat 

Thermostat w/ 

Capillary 

Part No. 

Description 

L131004 131-004 

L131019 Flue 131-019 


277

Water Treatment Products 

Water Treatment Products - HVAC Accessories 

Contents 

Corrosion Inhibitor 

& Water Treatment 

Sentinel X100 

Corrosion Inhibitor 

Corrosion Inhibitor Rapid Dose 

Corrosion Inhibitor Gel 

Part No. 

SX1001L 

SX10010L 

SX10020L 

Description 

1Litre - dilutes 100 litres 



Part No. 

SX100RD 

Description 

Rapid Dose 

Part No. 

SX100Gel 

Description 

Tube 275ml - dilutes 100 L 

Sentinel X200 

Sentinel X300 

Silencer 

Silencer Gel 

New System Cleaner 

Part No. 

SX2001L 

SX20010L 

SX20020L 

Description 

1 Litre 

10 Litre 

20 Litre 

Part No. 

SX200Gel 

Description 

Tube 275ml 

Part No. 

SX3001L 

SX30010L 

SX30020L 

Description 

1 Litre 

10 Litre 

20 Litre 

Sentinel X400 


Sludge Remover 

Part No. 

Description 

SX4001L 

1 Litre 

SX40010L 

10 Litre 

SX40020L 

20 Litre 

Sludge Remover Rapid Dose 

Part No. 

Description 

SX400RD 

Rapid Dose 

Sludge Remover Gel 

Part No. 

Description 

SX400Gel 

Tube 275ml 

278

Contents 


Sentinel x500 

Sentinel x800 

Inhibited Antifreeze 

Part No. 

Description 

SX5001L 

1 L 

SX5005L 

5 L 

SX50020L 

20 L 

Concentration depends on level of antifreeze required 

Sentinel Leak Sealer 

Jet Blast 

Part No. 

SX8001L 

Description 

1 L 

Leak Sealer 

Leak Sealer Rapid Dose 

Part No. 

SLS1L 

Description 

1 L 

Part No. 

SLSRD 

Description 

400ml Can 

Sentinel Accessories 

Part No. 

SSCP 

Description 

System Check Pack 

Part No. 

SX100QT 

Description 

Sentinel X100 Quick Tester 


279


Contents 

Defender 

Central Heating Inhibitor 

Inhibitor Test Kit 

Inhibitor Antifreeze 

Part No. 

DCHI5 

DCHI10L 

DCHI20L 

Description 

500ml - dilutes 100L 

10L - dilutes 1000L 


Part No. 

DITK 

Description 

50pack 

Part No. 

DIA5L 

DIA10L 

Description 

5L - See dosage info below 

10L - See dosage info below 

Central Heating Cleaner 

Power Flush Cleaner 

Central Heating Leak Sealer 

Part No. 

DCHC5 

DCHC10L 

Description 



Part No. 

DPFC5 

DPFC10L 

DPFC20L 

Description 




Part No. 

DCHLS5 

Description 


Dosage Rate Information 

Inhibitor Dosage Rates 

Minimum dosage rate: 

1% of system volume 

Antifreeze Dosage Rates 

Minimum dosage rate: 

25% of system volume 

Measured in PPM (mg/L) 

Measured in PPM (mg/L) 

0 25 50 75 100 

150 200 250 

Add more inhibitor 

Optimally 

Dosed 

Add more 

inhibitor 

Optimally Dosed 


Dilution % 

Freezing 

Point ºC (ºF) 

Slush Point 

ºC (ºF) 

25 -11 (12) -15 (5) 

30 -15 (5) -20 (-4) 

35 -18 (0) -24 (-11) 

40 -22 (-8) -30 (-22) 

280

Contents 


Jet Flush Machines 

Defender 

Jet Flush Machine 20 

Defender 

Jet Flush Machine 30 

Defender Jet Flush 

Machine 30 w/ Handle & Wheels 

Part No. 

DJF20 

Description 

17L tank, 2600l/h, 0.18HP 

Part No. 

DJF30 

Description 

27L tank, 5400l/h, 0.75HP 

Part No. 

DJF30W 

Description 

27L tank, 5400l/h, 0.75HP 

Defender Jet Flush 

Descaling Pump Adaptor 

Part No. 

DPA 

Description 

Pump Adaptor 

Dosing Pots 

Chemical Dosing Pot 

Part No. 

ADPOTSS015 

ADPOTSS025 

ADPOTSS045 

ADPOTSS100 

Description 






281

Prefabrication 

Contents 


Prefabrication is the practice of assembly components offsite, and moving them to 

the building site where they are placed into position. While nothing new, the practice 

is an emerging one in the HVAC industry and the advantages are significant. 

Why build on site if you don’t have to? That’s the question 

being asked across projects around the country, and while 

the HVAC industry has been relatively slow to come to the 

party, prefabricated HVAC plant is now a reality – and for 

good reasons. 

As well as delivering more accurate assembly, the process 

eliminates the costs and risks associated with on-site 

construction. 

Our European, American and Asian counterparts have been 

doing it for some time. Australian builders and building 

owners are now recognising the benefits. 

The emergence of 3D modelling, including BIM, is making 

the job easier — but such detail is not always required. 

Faster, less-complicated HVAC installs 

Take for example the recent refurbishment of the Harold 

Holt Swim Centre in Melbourne’s inner-east. 

Automatic Heating were approached by the mechanical 

services contractor to prefabricate a skidframe and 

platform to accommodate a new boiler plant. 

Built to fit precisely into the available space on the swim 

centre’s rooftop, the platform was constructed at Automatic 

Heating’s state-of-the-art assembly facility and transported 

to the site before being lifted into place by crane. 

And because the plant had been precommissioned in 

a controlled environment, commissioning on site was 

seamless. The new systems were up and running in a 

matter of hours. 

282

Contents 


The best practice in design 

Automatic Heating has long advocated the advantages 

of prefabricated plant where practical, as have many 

contractors in the industry. 

“Make no mistake – prefabrication is today’s best practice 

design,” says Terry Plaisted, sales manager for Automatic 

Heating. 

“As well as providing for an accurate installation, the 

reduced time onsite reduces labour costs, helps to 

condense construction timeframes and ultimately delivers 

financial savings to the project. 

And by prefabricating in a controlled environment, rather 

than in the challenging construction environment, the 

process leads to reduced risk and greater accuracy. 

“The level of accuracy that can be achieved in a controlled 

environment is much greater than that afforded on the 

construction site,” he says. “It stands to reason, therefore, 

that the prefabricated product is typically far superior 

which is good news for the engineer, contractor and 

equipment supplier.” 

Modular Flue Systems 

Automatic Heating’s stainless steel modular flues fit within 

any prefabrication strategy. 

The system is designed to eliminate the cost of 

transporting, craning and installing long, heavy lengths 

of flue into position on site, and makes the flueing of 

condensing boilers easy. 

They are simpler and lighter to install, and designed for 

temperatures as high as 400°C. 

Each flue length is designed to fit into another and they are 

available in different sizes and various lengths, plus elbows 

and accessories. 

Advantages 

Improved accuracy and efficiency 

Prefabrication in a controlled assembly environment leads 

to greater accuracy of plant construction and reduced 

labour costs compared to that on a busy construction site. 

Reduced risk and timeframes 

A prefabricated plant delivers less risk for all stakeholders 

— builder, engineer, contractor and equipment supplier — 

as well as reducing construction programs. 

Cleaner commissioning 

By prefabricating offsite, the plant can be precommissioned, 

potential issues identified and corrections made before the 

plant even reaches its final destination. 

Lifting the completed prefab 

frame at Harold Holt Swim 

Centre with the pipe work and 

hand rails assembled, which 

saves time on site. 

Precision engineering and 

quality assurance pays off as 

a platform is lowered onto 

the upright support frames 

fitted to the roof at Harold 

Holt Swim Centre. 

283


Contents 

Prefab Packages for Fast Installation or Rental 

Pictured below are some of our custom built heating and Domestic Hot Water system 

packages mounted on prefabricated skid frames for ast installation. These systems can 

be pre-commissioned for immediate serviceability and can be supplied on a rental basis 

where a temporary system is required. Each installation is designed to deliver optimal 

performance and energy efficiency and long term serviceability. 

284

Contents 


285

ABN 73 611 897 600 

Automatic Heating Global Pty Ltd 

Tel: 1800 337 959 / Fax: +61 3 9310 5655 

sales@automaticheating.com.au 

P.O. Box 35, Epping VIC 3076, Australia 

www.automaticheating.com.au 

V2.7 - 200130

AHG Solutions Guide_Edition 2.7

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