HRS

Storage Calorifiers

Standard or bespoke d e s i g n s
Various shell materials available
Supplied p l a i n or fully insulated
26 standard models ava il abl e

HRS
Storage Calorifier
Introduction:
The HRS Storage Calorifiers offer a high quality
solution for domestic hot water heating. The
standard range are manufactured from either
stainless steel,
copper, copper-lined steel,
galvanised steel or glass lined steel & the Heater
Battery is manufactured from either copper or
stainless steel AISI 316L and Electrical Heaters are
manufactured from Nicalloy 825 offering a
hygienic, reliable long life. The heaters are
withdrawable for cleaning and inspection purposes.

Design & Manufacturing Standards:

All our Calorifiers are manufactured in
accordance with the European Pressure Equipment
Directive 97/23/EC. The standard units fall
within the Group 2 Liquids category, Chart 4, thus
having a PED Category of SEP (Full details
available from our technical office). All wiring
and electrical assemblies conform to the latest
IE E regulations.
The design and manufacture of Calorifiers is
generally carried out in accordance with BS853
1996 Part 1Grade A.
Calorifiers that fall outside the scope of BS853
Part 1are manufactured in accordance with BS853
Part 2 with PD5500:2009 being offered as an
alternative design code where the scope of BS853
is insufficient or specific site requirements need
the higher specification design and manufacturing
code. Other design standards are also available
should it be required.

The HRS Storage Calorifiers are also designed to

be used with electricity as the primary heat input,
ideal for applications where there are no boilers
or other water generating equipment available.
Although electricity is associated with high
running costs, it is also a very efficient means of
heating domestic hot water due to all the power
used being converted into heat. Utilizing
electricity also negates the need for extra space
within the plant room to cover the duty so Storage Volume & Recovery Period:
boilers that need to be installed for heating
The storage volume of the cylinder (capacity)
applications can be smaller, thus freeing space for
and recovery period (heat-up period) determine
other applications
the primary power input required (kW) and thus
With particular attention paid to the design and the output (litres/hour). The recovery period is
layout of the units, the H R S C a l o r i f i e r s offer the time it takes to heat the water up from cold
an excellent product both aesthetically and (usually 10-25oC) to the working temperature
technically. The units are bespoke and thus can be (usually 60-65oC) in minutes or hours. Long
designed around constraints within the plant recovery times require low primary power input
room and also special attention is paid to where whereas short recovery times require high primary
the terminating connections need to be on the power input.
unit so it ties well with the system pipe work,
The actual storage volume requirements can be
helping to reduce on-site costs with labour and
roughly calculated using the table below which
material savings.
should give good results. A study of the
application should be made to determine actual
requirements taking space, weight loadings and
Why HRS?
power supply into account when selecting a
HRS Hevac Ltd has many years' experience in the volume.
design and manufacturing of Storage Calorifiers.
Recovery
Storage/Person
Type of Building
Period
(Hrs)
By using only the highest quality materials and
(Litres)
Hotel
45
2
components, we can guarantee long life of our
School/College
5
3
Calorifiers removing the inconvenience of Unit
Boarding
School
25
2
failure.
Student Apartments
Houses/Apartments
Factories/Offices
Hospital Wards

35
45
5
30

3
2
3
1

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
Storage Calorifier
Calorifier Material Selection:
Material selection of a Calorifier is generally carried out to suit site requirements and
specification, the pressure of the Calorifier and also the physical dimensions of the
cylinder. Due to the high quality of materials used, longevity is extended much
beyond that of inferior materials such as enamelled or glass-lined cylinders which
are susceptible to corrosion and decay. Our standard materials used include:
Copper:
Solid copper is a proven reliable product by being virtually impervious to attack by aggressive
water, used throughout the world with its' long life making it a popular material selection. Shells
manufactured from copper gain a coating of copper oxides on the surface which protects if from
attack. Where water is aggressive, an aluminium anode can be fitted i n the shell which also
deposits an aluminium film on the surface which permanently protects the shell from corrosion.
The anode does not need replacing throughout the life of the Calorifier. Due to low material
design strengths, solid copper may become uneconomical to use on cylinders with larger diameters
and high pressures and thus, we would offer a copper-lined steel option as below. It is to be noted
that copper shells should not be used in conjunction with galvanised steel pipe work or fittings due
to incompatibility of the 2 materials.
Copper-Lined Steel:
Where having a solid copper shell is impractical due to high pressures, we would offer a copperlined steel shell Calorifier. This type of manufacture combines the high strength of carbon steel
with the corrosion resistance of copper. The process involves manufacturing a carbon steel outer
shell and then lining internally w i t h copper sheets which is welded together t o form a
waterproof surface with all wetted parts within the Calorifier being manufactured from copper.
Anti-vacuum valves are fitted as standard to copper-lined cylinders to avoid the vessel collapsing
under vacuum conditions w h e n draining down without a suitable vent.
Galvanised Steel:
Galvanised steel shells are also available. The shells are manufactured from carbon steel and then
hot-dipped in a galvanising tank. This deposits a layer of zinc on the surface. Galvanised shells
offer excellent corrosion protection in hard water areas. Galvanised Calorifiers should not be
used on soft water areas as soft water prevents formation of a protective layer on the surface of
the shell. Magnesium anodes should be fitted to galvanised cylinders which gives the shell its'
protective coating. Anodes should be replaced annually to ensure long life of the Calorifier.
Copper pipe work or fitting should not be used in conjunction with galvanised shells
Stainless Steel:
Stainless steel Calorifiers are becoming more common for domestic hot water heating due to
high material strengths and potable water compatibility. Calorifiers with s t a i n l e s s steel shells
installed in systems with h i g h chloride c o n t e n t m a y be unsuitable as the chlorides can attack the
welds.
Glass lines Steel:
The shell is manufactured from Carbon Steel and then internally lined with glass or enamel. The
lining is hygienic and resistant to corrosion and scale formation. These are supplied with
Magnesium anode which can provide additional Cathodic protection and can easily be checked and
replaced.

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
Storage Calorifier
Selection & Sizing of Calorifier:
Storage Size & Heating Load:
We cannot make an exact calculation of hot water
consumption in a public area; the demand will
fluctuate throughout the day. So it is better to
collect the possible data available to calculate the
peak load demand, otherwise we can make
general calculation based on hot water
requirement per person and the recovery required
for different applications, as discussed above.
In general the calculations are made based on
heating water from 20oC to 650C. If the required
temperature is below 65oC either hot water
demand has to increase or heating load should go
down.
Flow rate:
Flow rate will depend on the demand for hot
water. It will be maximum during peak demand.
Heating load should be calculated to satisfy the
maximum flow rate.

Sample Heating Load calculation:

Considering Hotel:
Normal recovery time is 2hours
General hot water demand = 45 Litres/Person
Maximum demand
= 125 x 45
= 5625 L
Acceptable peak Demand = 0.7 x 5625
= 3940 L
Max. Flow rate required = 3940L / 2hrs
= 0.55 L/S
Heating Duty Required
= 0.55 x 4.2 x 45
= 104 kW
So a Calorifier of capacity 4000 L with a heater of
duty 105 kW will be sufficient for the application.
The specified system can supply the maximum
flow rate based on the peak demand.

Capacity
Litres

Dia.
mm

H.O/E
mm

Max.
Ht.

Access
Size

Connections
C

230

500

1300

1525

DN250

1.1/2" BSP

3/4" BSP

1.1/2" BSP

1/2" BSP

3/8" BSP

3/4" BSP

3/4"BSP

270

500

1550

1775

DN250

1.1/2" BSP

3/4" BSP

1.1/2" BSP

1/2" BSP

3/8" BSP

3/4" BSP

3/4"BSP

300

600

1180

1405

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

360

600

1410

1635

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

400

700

1155

1380

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

450

700

1300

1525

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

500

700

1450

1675

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

550

700

1605

1830

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

600

700

1740

1965

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

700

800

1775

2000

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

800

800

1780

2005

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

900

800

1990

2215

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

1000

900

1765

1990

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

1200

900

2120

2345

DN250

2" BSP

1" BSP

2" BSP

1/2" BSP

3/8" BSP

1" BSP

1" BSP

1500

1000

2125

2350

DN450

DN65 PN16

1.1/2"BSP

DN65 PN16

1/2" BSP

3/8" BSP

1.1/2"BSP

1.1/2"BSP

1750

1000

2480

2705

DN450

DN65 PN16

1.1/2"BSP

DN65 PN16

1/2" BSP

3/8" BSP

1.1/2"BSP

1.1/2" BSP

2000

1100

2350

2575

DN450

DN80 PN16

2" BSP

DN80 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

2250

1200

2220

2445

DN450

DN80 PN16

2" BSP

DN80 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

2500

1200

2460

2685

DN450

DN100PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

3000

1200

2950

3175

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

4000

1450

2700

2925

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

5000

1600

2775

3000

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

6000

1800

2640

2865

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

7000

1800

3040

3315

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

8000

1800

3430

3705

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

9000

2000

3175

3450

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

10000

2000

3495

3770

DN450

DN100 PN16

2" BSP

DN100 PN16

1/2" BSP

3/8" BSP

2" BSP

2" BSP

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
STORAGE CALORIFIERS


Key:
A. Primary Inlet
B. Primary Outlet
C. Hot Water Outlet
D. Secondary Return
E. Cold Feed
F. Thermometer
G. Pressure Gauge












A,B

H. Safety Valve
J. Drain
K. Thermostats (1 BSP)
L. Inspection Opening
M. Immersion Heater
N. Anti-Vacuum Valve


H


C
D,E

D,K
The Standard
HRS Storage Calorifiers have

Higher pressures are also available.

L
C
F





100





''





D



Y
K
L
M


A



J



75

X-150


Vertical Models


100




C









D

M
A
B

M
A
B


150

HRS
Storage Calorifier
Immersion Heaters:
Fixed Rod Elements:
The rod element comprises of a resistance heating coil surrounded by
compacted magnesium oxide powder enclosed in a tubular metal sheath.
The element is brazed to the heater boss or flange. If an element fails the
entire heater must be replaced. These heaters are generically screwed BSP.
Our standard element material on is Nicalloy 825. This is a high alloy
stainless steel and has excellent corrosion resisting properties.
Generally this material can be used in hard and aggressive waters
and a range of chemical solutions.
Glanded Rod Elements:
The rod element comprises of a resistance heating coil surrounded by
compacted magnesium oxide powder enclosed in a tubular metal sheath.
The element is brazed to glands that are bolted to the element flange. If
an element fails the individual element can be replaced, however, the
vessel must be drained and the heater removed from the vessel.
Removable Core Elements:
A removable core element comprises of resistance wire wound inside
ceramic formers. Removable core elements are inserted into element tubes
which are expanded, brazed or welded into the heater flange. If an element
fails the individual element can be replaced without draining or
removing the heater from the vessel. Because removable core elements
operate at much lower watts densities compared to rod elements and
have much heavier wall thicknesses the range of conditions that they can
operate in is far wider.
Our standard sheath material on is copper, generally suitable for use in hard and aggressive water
conditions, particularly waters with high chlorine concentrations such as desalinated water.
Element Watts Density:
Element watts density is defined as the amount of watts given out per unit surface area of element. High
element watts density reduces the life of an element and increases significantly the effect of corrosion
on the element sheath. High element watts density causes water to boil around the element and produces
a noise similar to that of a boiling kettle. Where an immersion heater has been fitted close to sleeping
accommodation it has been known for this noise to keep people awake at night.
Due to their design, removable core elements operate at low watts-densities, which generally allow
them to operate with significantly l es s corrosion problems compared with rod elements. Generally
removable core element wat t densities are below 3.1W/cm 2 (20 W/in2)
With the exception of domestic heaters and some light industrial heaters the standard watts density for
rod element heaters is 9.3W/cm2 ( 60W/in2 ) with a standard watts density on our flanged heaters
being 7.4 W/cm2. This is suitable for heating most types of water. Where water conditions ar e very
hard or aggressive particularly in respect of desalinated water or where chemical solutions are being
heated, please contact our technical department to obtain the correct element specification.

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
Storage Calorifier
Control Panel:
The control panels are bespoke, specific to each project and are designed and manufactured with
the highest quality components. The panels can be supplied w i t h e i t h e r t e m p e r a t u r e
based, timed or thyristor control as standard. The panels are wired through a low water switch
in the tank to ensure the heaters are not running dry.
Typical Electrical Specification:
Isolator with compatible door interlocking handle.
Relays will be Finder Fl5534-8230-0040 or equivalent.
Enclosure for the control panel to be made of sheet steel with an IP rating of IP69X,this will
be at least IP54 once assembled.
MCB D type triple p o l e CE Marked & Independently tested and approved to EN60947 &
EN60898 with a breaking capacity of 10 KA
2A C type single pole MCB for control supply CE Marked & Independently tested
and approved to EN60947 & EN60898 with a breaking capacity of 10KA
Cable terminals to be 10mm rated at ------A for power
Cable terminals to be 2.5mm rated at 24A for control
Cable terminals to be 2.5mm rated at 24A for BMS signals
Pilot lamps to be 230Vac led bezel style 22mm with various colours with IP rated seal.
Contactor details as per data sheet
Typical Control Philosophy:
Panel is to operate in multi stages through independent timer control per stage.
Once there is a demand for heat from the control thermostat within the immersion
heater the first stage contactor will be energized to give power to the first stage.
If the heat has not been satisfied after the given time the timer will bring in stage two.
This continues until heat has been satisfied through timers two and three until all stages are
energized and/or until heat has been satisfied.
The l o w t e m p e r a t u r e relay w i l l be con tr ol l ed via a separate thermostat. This is
to provide indication that the vessel is under temperature only.
The low level switch will inhibit any operation as not to allow the immersion heaters to
operate unless the tank is sufficiently filled with water.
The high temperature thermostat has a built in manual reset facility that will require
manual intervention to reset.

Control Panel
Typical Timed Control Type

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
Storage Calorifier
Heater Battery:
U- tube is the most common heat exchanger used in Calorifier manufacturing. HRS U tubes are made
with high efficiency tubes unaffected by thermal expansion provide high level of reliability.
The tubes in the heater batteries are available in plain copper, making them suitable for both hard and
soft water areas. Standard batteries are manufactured using copper integron tubes. The heater battery
is also available in stainless steel AISI 316L offering a hygienic, reliable long life. The heater is
withdrawable for cleaning and inspection purposes. So space must be allotted for withdrawal of the
batteries. If withdrawal distance is not known, assume the distance being equal to the vessel diameter.
The standard range of battery duties are based on a 1-hour recovery period raising water from 10 to
60C with a primary medium of water at 82 to 71C. Bespoke Calorifier designs are available along
with other duties, working pressures and primary mediums. Please contact our sales department for
further details.
Primary Side Flow rate Requirement:
Considering the heating load 100 kW
As per standard Primary side Temperatures:
Inlet
= 82oC
Outlet
= 71oC
Heating Duty = 100kW
Flow rate
= 100/(4.2 x 11)
= 2.17 L/S
The selected U-tube will be capable to produce
100kW heating duty if there is a primary flow of
2.17 L/s
Heating
Duty
kW

Heat Transfer
Area
m2

Inlet Size
mm

20
30
40
50
60
70
80
90
100
125
150
200
250
300
400
500

1.20
1.80
2.40
3.00
3.60
4.20
4.80
5.40
6.00
7.50
9.00
12.00
15.00
18.00
24.00
30.00

20
25
25
32
32
40
40
40
40
50
50
65
65
80
80
100

Flange Size

Length

Outlet Size
mm

mm

mm

20
25
25
32
32
40
40
40
40
50
50
65
65
80
80
100

125
150
150
150
200
200
200
250
250
250
250
300
300
350
400
400

410
565
715
870
725
825
925
695
760
910
1060
1065
1290
1185
1125
1350

Based on HRS standard, subject to change

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
Storage Calorifier
HRS Storage Calorifiers are suitable for both vented and unvented (pressurised) systems. HRS
offer Calorifiers suitable for both types of systems with equipment to ensure correct operation
being offered

Vented Systems:
The Calorifiers can be either vented from the secondary flow connection of a dedicated vent
connection which allows air to exit the Calorifier, air to enter the Calorifier during drain down
and also thermal expansion of the water when heating up. The vent connection or pipe should
never be blocked or valved off, with exception to vent/bypass valves on multi-Calorifier
installations.
Unvented Systems:
Unvented systems (otherwise known as sealed or pressurised systems) are more common in
installations than vented systems due to building regulations. They are also used when it is not
practical to fit a vent. There is additional equipment to be installed in unvented systems:
The shell should be designed at a pressure calculated after thermal expansion of the cold
water
Pressure/temperature safety valves should be fitted (in case of control failure)
An expansion vessel should be fitted (to accommodate the thermal expansion)
A cold feed kit (isolating valve, strainer & pressure reducing/regulating valve &
check valve) should be fitted to regulate the cold feed pressure and stop backflow
from the Calorifier into the cold water system. A booster set may have a pressure
reducing valve fitted as standard (on fixed speed pump units)

Different Model HRS Calorifiers:

HRS storage Calorifiers are available for different models based on the applications.
HRS Calorifiers can be used as Electrical Calorifiers with Electrical Heaters or Single Duty Calorifiers
with U- tube Heat exchangers together with Boiler/Solar System as heating source or Double Duty
Calorifier with Electrical back up heater.

Electrical Calorifiers
Type: EC
Storage Volume: _ _ _ _
Heating Duty: _ _
Ex: EC/5000/135

Hot Water Calorifier

Type: SDC- Single Duty Calorifier
DDC- Double Duty Calorifier
Storage Volume: _ _ _
Primary Heating Duty: _ _
Back up Duty: _ _
Ex: DDC/5000/120/40
SDC/5000/120

Hot Water Storage Tank

Type: ST- Storage Tank

Ex: ST/5000

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
Storage Calorifier
Accessories:
Thermometer:
This is to measure the temperature inside the tank.
This is located near to the top to get the
temperature of water reaching the outlet so we can
get the secondary side flow temperature.

Pressure gauge:
Pressure gauge is placed near to top of the tank.
This is used to measure the pressure inside the
tank. During running condition it will help to
monitor the pressure not to exceed the designed
pressure.

Supports:
HRS Calorifiers are supplied with legs
permanently fixed to the shell before dispatching
from the factory.

Manhole:
The manholes are providing for internal
inspection if Tank and heater. Heater can be
inspected by removing it from outside but by
using the manhole we can do the same without
disturbing the heaters.
HRS standard manholes are in the form of flanged
neck piece extended away from the Calorifier
body

Anodes:
Anodes can be provided based on the shell
material or as per requirement. Normally anodes
are providing with glass lined Calorifiers to
protect the shell from corrosion. Magnesium
anode is the commonly used one. The life time of
the anode will depends on the quality of water and
it should be removed in adequate intervals based
on the lifetime.

High limit Cut-out:

Electrical Calorifier should be with High limit
cut-out. This will act as immediate monitor of
overheating. It is fitted with manual reset button
to regain the original condition after any
malfunctioning.

Safety Valve:
All Hot Water application tanks should be fitted
with safety valve to protect the Calorifier against
high pressure which can occur due to malfunction
of controls or incorrect operation. We are
providing combined pressure-temperature relief
valve for protection.

Insulation:
The Calorifier shell should require thermal
insulation to prevent the unnecessary heat loss.
During the running time of Calorifier, it may be
standing for hours with hot water. If the tank is
without adequate insulation the stored water will
loos temperature.
HRS standard tanks are supplied with compressed
50mm thick mineral wool insulation encased in
stucco aluminium cladding. Normal thermal
conductivity of insulation is 0.04w/mk.

Anti-Vacuum Valve:
This only in case of Copper lined Calorifiers. All
copper lined Calorifier must be protected against
partial vacuum and all HRS Copper lined
Calorifiers are fitted with anti-vacuum valve. This
should not be removed except for periodic
inspection.

Control Thermostat:

This is for Electric Calorifiers. The heating

control depends on the feedback from the control
Low Level Switch:
thermostat. So the accuracy of control depends on
This is also for electric Calorifiers only. All
Electrical Calorifiers should be fitted with the low the selection of control thermostat. In Electric
Calorifiers the control may be by no of control
level switch and it should be fitted above the
Electric heater. This is to make sure the Electrical switches located at different levels or may be a
heaters are not running in dry, which can damage single temperature switch will activate the heating
process and will be continued by timer control
it.
relay in different steps.

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com

HRS
Storage Calorifier

Expansion Vessel:
Expansion vessels are used with the closed hot water system and domestic hot water system to absorb
excess water pressure caused by the thermal expansion. The expansion vessel are small tank having
two part isolated by a rubber diaphragm. One part a whole tank which is connected to the hot water
line and so will contain water. The other part is dry side which contain dry air or other gases under
pressure. During normal working condition with normal pressure the diaphragm will push against the
water inlet but when the line pressure is exceeding the force will reverse and the diaphragm will moves
comprising the air on its other side.

HRS Funke Heat Exchangers FZCO, PO Box 262243, Dubai UAE Tel (00971) 48865540 Fax (00971) 48865541, www.hrsfunke.com