Ultramax R600

High output, floor standing gas fired condensingboilers with outputs from 150kW to 571kW

Delivering excellence with every feature

Utilising the proven water cooled, down-

firing, premix burner system coupled with an

all stainless steel heat exchanger assembly,

Ultramax R600 boilers have a class leading

NOx emission of less than 35mg/kWh @ 0%

O2 (which easily exceeds the requirements

for the best BREEAM score) and can return

efficiencies of up to 109%.

Designed to pass through standard doors, with

widths from 670mm and floor space

requirement is within the range 0.74 m2

to1.34m2. Each model is able to be equipped

with two return connections, allowing high

efficiency to be achieved when serving a mix of

higher and lower system load circuit

temperatures. Another feature is the option to

utilise room sealed or open flue systems.

The Ultramax R600 is suitable for use in single

boiler or multiple/cascade installations. If used

singly, plug and play optional extra low loss

headers are available, and if being used as

retrofit appliances onto aged systems, a

matched boiler protection plate heat

exchanger unit is available for total boiler

isolation. The modulating burner system allows

turndown ranging from 5:1 to 7:1 to return

optimum efficiency at low system loads.

2

The Ultramax R600 series of boilers is packed with features that

are best in class and provide power, extreme efficiency, reliability,

and ultra low harmful emissions. The range includes 7 models

with outputs from 150 to 571kW.

Water cooled

down-firing

burner

3

It’s easy to ignore your boiler and heating system - until it goes wrong

or breaks down. A system failure, especially one caused by lack of

maintenance, can be inconvenient and costly.

Put your mind at rest

It isn’t hard to imagine the

difficulties that problems with

your heating system can cause.

And in some situations lack of

heating and hot water can be

critical. Similar to your car, a

regularly maintained heating

system will run more efficiently

and any potential problems can

be resolved before they develop

into major system failure.

Financially, planned maintenance

makes sense too. It avoids major

capital outlay and the associated

costs of system down time - plus it

can keep your fuel costs down as

well as ensuring you are

minimising your emissions.

At MHS Boilers we provide a

lifetime maintenance and service

solution for your heating system -

enabling you to rest safe in the

knowledge that we’ll take care of it.

For details of cost effective Service

and Maintenance Plans from MHS

Boilers, (with options for plans

which include labour and parts),

go to the Maintenance and Service

section at www.mhsboilers.com

Our highly skilled

and trained

service and

technical support

engineers are

only a phone

call away

4

Exceptional high quality and unequalled lifetime

high efficiency through the use of corrosion resistant

stainless steel as a heat exchanger material.

Compact dimensionsMindful that space is at a premium in commercialbuildings, the R600 range is frugal on its spacerequirements, and with dimensions ranging from1105mm to 1735mm long by 670mm or 770 mm wide,all appliances will pass through a standard door. And forthose installations where access is particularly difficult, the boilers can be disassembled for site handling as piece parts.

Controls optionsWith the inclusion of optional extra control modules, up to two heating circuits (with or without weathercompensation), and domestic hot water may controlled in a single boiler installation.

If used in a modular/multiple boiler installation, thestandard in-built controllers are able to be configured to operate in a master/slave arrangement to provide acascading control function. Up to 16 boilers may beincluded in a cascade configuration.

See page 10 for details.

Extreme efficiencyThe all stainless steel heat exchanger coupled with thepatented water cooled down-firing modulating premixburner with turndown to between 14 to 20% (dependantupon model), the Ultramax R600 boilers can returnefficiency of up to 109% net. Operating at this extremelyhigh efficiency, the boiler has almost no losses to thechimney giving maximum fuel savings.

Water cooled combustion chamberThe application of water cooling measures to thecombustion chamber removes all need for delicate hightemperature insulating materials creating a very robust andreliable unit that may be wet cleaned if necessary.

Two system water return connectionsWith a typical standard type of condensing boiler servinga system consisting of multiple load circuits operating atdifferent temperatures, the boiler must operate at a flowtemperature equal to that demanded by the highesttemperature load circuit. This in many cases may preventthe boiler from operating in condensation phase andinhibit the efficiency. The Ultramax R600 however, is not a typical standard typeof condensing boiler; it has the option for two return waterconnections; a hot return for higher temperature loadcircuits such as air handling units or hot water cylinders,and a cool return connection for weather compensatedradiator circuits or under floor heating. In this way the coolreturn water can be separated and passed through thecondensing section of the heat exchanger allowing theboiler to operate at a higher efficiency than if the higherand lower temperature return water was blended togetherand passed through the entire water circuit of the boilerheat exchanger.

Inherent reliabilityWith all solid state controls, and moving parts confined to

the gas valve and fan there is little to wear through usage.

Additionally all components are sensibly laid out within the

uncluttered frame making maintenance a simple task.

Very low operating noiseAt just 59dbA, the Ultramax R600 series is extremely quietmaking them an ideal appliance to choose in noisesensitive applications such as residential blocks, schoolsand libraries etc.

Varied fluing possibilitiesThe appliance may take air for combustion from the roomor it may be room sealed using a parallel tubesarrangement.

WarrantyAs standard the heat exchanger carries a 5 year guarantee.All guarantees are against manufacturing or materialdefects only (see terms and conditions of sale).

Standard features

5

Dimensions & clearances

B3

B5B4

B2

1

2 (G)

3 (W1)

1175

489

413

115 (3x)

H2

1440H

112

4 (W2)

*6 (W2)

8 (D2)

L2

L B

7

9

5 (D1)

450 450

450

800

Dimension R601 R602 R603 R604 R605 R606 R607

L mm 1105 1260 1470 1220 1435 1585 1735

L2 mm 127.5 127.5 137.5 137.5 187.5 187.5 187.5

H mm 1480 1480 1500 1500 1500 1500 1500

H2 mm 1120 1130 1130 1150 1245 1245 1245

B mm 670 670 670 770 770 770 770

B2 mm 225 235 235 235 215 215 215

B3 mm 260 260 260 310 310 310 310

B4 mm 260 260 260 490 490 490 490

B5 mm 130 130 130 245 245 245 245

D1 mm(dia) 130 150 150 150 200 200 200

D2 mm(dia) 150 150 200 200 250 250 250

W1 R"/DN R2" R2" R2" DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16

W2 R"/DN R2" R2" R2" DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16

G R R 3/4" R1" R1" R1" R1 1/2" R1 1/2" R1 1/2"

1 Electrical connections

2 Gas supply

3 Water supply

4 Water return (cold)

5 Air intake

6 * Water 2nd return (hot)

7 Boiler water drain valve

8 Flue gas outlet

9 Condense drain flexible hose 25mm diameter

Clearance diagram

* Facility achieved using optional extra, "water 2nd return connection kit".

6

Easy access to all components

Designed with maintenance in mind, all

components are easy to access; for

example the top cover of the burner

removes quickly for cleaning of the air/gas

ways if necessary.

There is inspection and cleaning access to

the combustion chamber and the integral

chimney section at the rear of the appliance

removes easily without the need for

supplementary support of the flue system

in the building.

Flue SystemsUltramax R600 boilers must be connected to a flue systemsuitable for use with condensing boilers. All sections of the fluemust have a fall of at least 3 degrees back towards the boiler toensure that any condensation that forms in the flue is freedraining back to the boiler.

If the draught generated in the flue system is likely to exceed30Pa, then a suitable draught reducing / stabilising device and alockable volume control damper must be incorporated into thechimney system adjacent to the appliance.

The terminal of the flue system should be left open. UniversalTerminal Caps or Rain Caps MUST NOT BE USED, any rain thatenters the flue system will help to wash the flue and will drainthrough the boiler's condensate waste outlet.

Room Sealed ApplicationFor the appliance to be operated as room sealed, taking air forcombustion from outside the building, an air duct must beinstalled to connection 5(D1). The air duct must not be smallerthan the diameter of the air connection on the boiler. The resistance of the air duct must be added to the resistance ofthe flue gas system and the total must not exceed the maximumsystem flue resistance detailed in the Technical data table on page 7.

The air connection is located behind an access panel which mustbe removed and discarded when creating a room sealedarrangement. For standard arrangements (B23) where the air forcombustion is taken from the boiler room, it is not necessary toremove the access panel.

For specific guidance on flue system design parameters, see theR600 planning document available for viewing/downloading atwww.mhsboilers.com

7

Gas Category II 2H3PAppliance Category B23,C13, C33, C43, C53, C63, C83

CE Product Identification Number 0063B03192

Technical data

Boiler Model R601 R602 R603 R604 R605 R606 R607

Nominal heat output 80/60°C kW 23.3 – 142.1 39.5 – 190.1 39.5 – 237.2 39.5 – 285.2 76.6 – 380.2 76.6 – 475.3 76.6 – 539.0

Nominal heat output 40/30°C kW 26.7 – 150.7 45.2 – 201.6 45.1 – 251.4 45.2 – 302.3 87.7 – 403.1 87.7 – 503.9 87.7 – 571.5

Gross kW 27.2 – 160.1 46.1 – 215.3 46.1 – 268.6 46.1 – 323.0 89.3 – 430.6 89.3 – 538.3 89.3 – 610.5

Net kW 24.5 – 145.0 41.5 – 194.0 41.5 – 242.0 41.5 – 291.0 80.5 – 388.0 80.5 – 485.0 80.5 – 550.0

Max flow temperature °C 90 90 90 90 90 90 90

Water content litres 27 31 35 61 68 75 82

Design temperature rise (∆t) °C 20 20 20 20 20 20 20

Nominal water flow @ ∆t 20K l/s 1.69 2.26 2.82 3.39 4.52 5.65 6.41

Hydraulic resistance at nominal water flow kPa 10 18 28 15 27 42 55

Min/Max operating pressure @ 90°C bar 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0 1.0 / 8.0

Gas consumption Nat Gas (G20) @ max load m3/h 13.3 17.8 22.2 26.7 35.6 44.5 50.5

Gas consumption LPG (G31)@ max load kg/h 11.3 15.2 18.9 22.7 30.3 37.9 43.0

Gas inlet press nom. Nat Gas (G20) mbar 17/20 17/20 17/20 17/20 17/20 17/20 17/20

Gas inlet press min/max LPG (G31) mbar 30/50 30/50 30/50 30/50 30/50 30/50 30/50

Approx flue gas volume max @ max load m3/hr 238.0 318.0 397.0 477.0 636.0 795 901.0

NOx level @ 0% O2 (min/max) mg/kWh 15/35 15/35 15/35 15/35 15/35 15/35 15/35

Approx flue gas temperature @ 80/60°C system operation min/max °C 56/78 56/78 56/78 56/78 56/78 56/78 56/78

Maximum system flue resistance Pa 160 160 200 200 200 250 250

Gas connection - R 3/4" R 1" R 1" R 1" R 11/2" R 11/2" R 11/2"

Flow/return connections - R 2" R 2" R 2" DN65 PN16 DN65 PN16 DN65 PN16 DN65 PN16

Air supply connection mm 125 125 150 150 200 200 200

Flue connection mm 150 150 200 200 250 250 250

Condensate waste connection mm 22 22 22 22 22 22 22

Nominal weight (dry) kg 295 345 400 465 535 590 650

Electrical supply (50Hz) V 230/400 230/400 230/400 230/400 230/400 230/400 230/400

Mains connection fuse rating A 10 10 10 10 10 10 10

Power consumption boiler(excl pump) min/max W 43/158 35/200 35/230 35/260 61/470 61/470 61/770

Nominal heat input

8

Enhancement optional extrasA range of easy-to-apply optional extra components are available to enhance the final installation of the Ultramax R600 series

boilers. The use of these additional components also contributes to the ease of materials ordering, simplifies installation tasks

and cuts installation time.

"Pump kit (incl 90° bend toincrease installation flexibility)

"Safety kit"; (flow pipe assembly)including auto air vent and safetyvalve (incl 90° bend to increaseinstallation flexibility)

"Low lossheader kit"; (incl 2 x 90°bends toincreaseinstallationflexibility)

* When installing a boiler as a retrofit appliance onto an aged system, serious consideration should be given to the

cleanliness / condition of the existing system and the damaging effects of accumulated dirt and sludge upon new

appliances. The use of a plate heat exchanger kit provides total water side isolation and gives peace of mind that the

investment in the new boiler is protected from damaging and efficiency reducing deposits from the old heating system. It

also means that costly and very often ineffective measures to clean-up an existing system can be avoided. Another benefit

is the possibility to retain an existing system’s open vented nature whilst creating a sealed system environment for the new

boiler on the primary side of the plate heat exchanger.

9

Enhancement optional extras

*"Plate heat exchangerkit"; (incl expansionvessel – plus 2 x 90°bends to increaseinstallation flexibility)

"Safety kit"; (flow pipeassembly) including auto airvent and safety valve (incl90° bend to increaseinstallation flexibility)

"Pump kit" (incl 90°bend to increaseinstallation flexibility)

Plate Heat Exchanger (secondary side) technical data

ModelType

∆t 10K ∆t 15K ∆t 20Kl/s kPa l/s kPa l/s kPa

R601 3.38 30.4 - - 1.69 8.1R602 4.5 28.8 - - 2.25 14.0R603 5.66 44.0 - - 2.83 21.5R604 - - 4.52 28.8 3.38 16.6R605 - - 6.02 48.7 4.52 28.9R606 - - 7.55 15.6 5.66 14.3R607 - - 8.55 19.7 6.41 18.0

10

Room Units / RoomTemperature SensorsEach heating zone may have a room unit (remote controller) installed to allow not only room space temperature to be be monitoredand controlled but also allows the user to make adjustments to the time and temperature control parameters for the zone.

Hard wired unit QAA75

Wireless unit QAA78 (requires antenna to be connected to LMS14 or RVS63 as appropriate).

Wireless Outside Air Temperature SensorWhere the system includes a requirement for weather dependant temperature control element, as an option, a wireless outside air temperature sensor can be provided (requires antenna).

Controls and OptionsUltramax R600 series boilers are equipped with a modulating control system (LMS 14 with AVS37 user interface). As standardthe boiler operates to provide a constant flow temperature and with the addition of an optional extra outside air temperaturesensor weather variable temperature can be delivered. Alternatively if required, the flow temperature can be controlled via a0-10 Vdc signal in response to external temperatures. An indirect hot water storage cylinder plus two mixed flow or constanttemperature heating zones may also be controlled and each with independent time scheduling by using extension modules.If installed as part of a multiple boiler installation, the in-built standard controllers can be configured to provide cascadecontrol, with the potential to control up to 16 boilers. A cascade master kit is required to be installed into one of the boilerswith each of the remaining boilers requiring a cascade slave kit. A cascade master kit incorporates an OCI 345 BusCommunication Module and all necessary sensors. A cascade slave kit incorporates an OCI 345 Bus Communication Module.

AVS75A single boiler may be equipped with up to two AVS75extension modules.

Each module provides for the control of an additional heatingcircuit with connections for:

• Heating circuit pump

• Variable flow temperature mixing valve

• Flow water temperature sensor

(The heating circuit may be constant temperature if required)

Additionally, (over and above that described above), an R600boiler may be equipped with an AVS75 module configured tocontrol an external gas valve (for use in LPG installations forexample) or to perform a gas valve leak test function.

RVS 63This is an extension controller for the addition of two heatingcircuits, which may either be weather dependant or constanttemperature.

Up to 15 RVS devices may be connected to a single boiler, withone unit being able to be accommodated within the boilercontrol panel. Additional units are housed within wall mountedenclosures or can be supplied as loose items for build-in to acontrol panel by others.

Each RVS 63 is used in conjunction with an AVS 37 userinterface panel.

Additionally, an RVS63, can be used as a cascade mastercontroller if required whereby all of the boilers become slave units.

The controls capability can be extended by including items from the following options:

11

MCWS CV CVStrainerRPZ

Heatingsystem

Tundish

Filling the systemThe Initial filling of a sealed heating system, and subsequent refilling, must be by a method that has been approved by the WaterRegulation Advisory Scheme (WRAS) for the type of heating system, i.e. Domestic (in-house) Fluid Category 3 (C-3). Non Domestic(other than in-house) Fluid Category 4 (C-4).

For Category 4 systemsThe approved method of filling must comprise of the following

components in the arrangement shown;• Control Valve, on the Mains Cold Water pipework.• Strainer.• Verifiable Backflow Device with Reduced Pressure Zone (RPZ

Valve) Incorporating a ‘Type BA’ air gap.• Tundish• Control Valve, on the Heating System pipework.

Installation requirementsUltramax R600 series boilers should be installed in accordance with the relevant requirements of the Building Regulations, Healthand Safety Executive Regulation PM5, IEE Regulations, Gas Safety (Installation and Use) Regulations, National and Water Bylaws andany Insurance Company requirements.

Codes of practiceThe following list of codes of practice give guidance on the requirements for installation.

BS 6880: Part 1: 1988 Code of Practice for low temperature hotwater heating systems for output greater than 45kW.BS 6644: 2011 Installation of gas-fired hot water boilers of ratedinputs between 70kW (net) and 1.8MW (net).BS EN 12828: 2003 Heating systems in buildings - Design forwater based heating systems.

IGE/UP/2 Gas installation pipework and compressors onindustrial and commercial premises.IGE/UP/10 Installation of gas appliances in industrial andcommercial premises, Part 1: Flued appliances.CISBE Guide Reference sections B7, B11 and B13.

System waterUltramax R600 series boilers must only be installed onto sealed and pressurised systems with a minimum static head of10m. All systems must be thoroughly cleansed prior to the connection of the boiler and the system water must be dosedwith a good quality treatment to prevent corrosion within the system and the formation of scale within the boilerwaterways. The chloride content of the fill water must not exceed 50mg/l and the PH should be in the range 8.0 to 9.5.Particular care must be taken when installing the boiler onto an old system, with consideration given to the installation ofthe optional extra separation “plate heat exchanger kit” or a dirt arrester/filter.

For specialist advice and water treatment products, contact: Fernox, Tandem House, Marlowe way, Beddington Farm Road,Croydon CR0 4XS. Tel: 0208 665 6666 or Betz Dearborn Ltd, Widnes, Cheshire WA8 8UD. Tel: 0151 495 1861

12

Master

Slave

Typical hydraulic layout of single boiler system

Typical hydraulic layout of twin boiler system

Hydraulic system designThe following schematic diagrams give indications of typical hydraulic schemes that may be employed.

For further and more detailed guidance on system design and planning, please see the R600 Planning Documentwhich is available for viewing or downloading at www.mhsboilers.com

13

Hydraulic system design

Under-floor heating

coils

Typical hydraulic layout of split system utilising 2nd return connection on boiler

14

Dimensions with optional low loss header kit

A

A

B

A

B

Model Amm

R601 - R603 1233R604 - R605 1299R606 - R607 1299

Model A Bmm mm

R601 - R603 923 545R604 - R605 1096 611R606 - R607 1096 611

Model A Bmm mm

R601 - R603 928 545R604 - R605 1119 611R606 - R607 1119 611

A

B

A

B

A

B

Model A Bmm mm

R601 - R603 277 881R604 - R605 388 1119R606 - R607 388 1119

Model A Bmm mm

R601 - R603 697 886R604 - R605 873 1138R606 - R607 8733 1138

B

A

A

B

A

B

Model A Bmm mm

R601 - R603 697 881R604 - R605 873 1119R606 - R607 873 1119

Model A Bmm mm

R601 - R603 1191 277R604 - R605 1320 388R606 - R607 1320 388

Model A Bmm mm

R601 - R603 1191 282R604 - R605 1320 406R606 - R607 1320 406

Model A Bmm mm

R601 - R603 886 152R604 - R605 1119 262R606 - R607 1119 262

15

Dimensions with optional plate heatexchanger kit

A

A

B

A

B

Model A Bmm mm

R601 - R603 960 735R604 - R605 1133 981R606 - R607 1073 856

Model Amm

R601 - R603 1421R604 - R605 1667R606 - R607 1542

Model A Bmm mm

R601 - R603 1047 735R604 - R605 1222 981R606 - R607 1278 857

A

B

A

BA

B

Model A Bmm mm

R601 - R603 918 278R604 - R605 1156 388R606 - R607 1094 388

Model A Bmm mm

R601 - R603 887 1005R604 - R605 1243 1243R606 - R607 1119 1299

A

B

A

BA

B

Model A Bmm mm

R601 - R603 887 918R604 - R605 1243 1156R606 - R607 1119 1094

Model A Bmm mm

R601 - R603 1379 314R604 - R605 1690 424R606 - R607 1566 362

Model A Bmm mm

R601 - R603 1379 401R604 - R605 1690 511R606 - R607 1566 567

Model A Bmm mm

R601 - R603 1005 252R604 - R605 1243 362R606 - R607 1299 361

This publication is issued subject to alteration or withdrawal without notice.The illustrations and specifications are not binding in detail. All offers and salesare subject to the Company's current terms and conditions of sale.

RC/0713/6543

3 Juniper West, Fenton Way, Southfields Business Park,

Basildon, Essex SS15 6SJ

Tel: 01268 546700 Fax: 01268 888250

www.mhsboilers.com