Technical information Assembly instructions · 2016. 6. 21. · - ÖNorm EN 13384 Flue gas systems...

These instructions apply to the following types:30-UltraOil® (110)30-UltraOil® (130)30-UltraOil® (160)30-UltraOil® (200)

with controller U3.4

UltraOil® (110-200)Oil condensing boiler

The UltraOil® boiler is designed and licensed for use as a heat generator for hot water heating systems with permissible flow temperatures of up to 90 °C1). It is designed primarily for closed circuits, but is equally suitable for installation in open circuits.1) see point 3.2

Hoval products must be installed and commissioned only by appropriately qualified experts. These instructions are intend-ed exclusively for the specialist. Electrical installations may only be carried out by a qualified electrician.

Subject to modifi cations | EN

Technical informationAssembly instructions

This appliance is

only suitable foroperation withheating oil EL(low sulphur)

4 210 258 / 00 - 07/11

4 210 258 / 00 2 Table of contents

1. Important information1.1 Other instructions ................................................................................................................................... 41.2 Safety instructions .................................................................................................................................. 41.3 Regulations, official approvals .............................................................................................................. 41.4 Warranty ................................................................................................................................................... 5

2. Installation position, transport2.1 Transport .................................................................................................................................................. 62.2 Installation position ................................................................................................................................ 6

3. Assembly3.1 Setting up, levelling ................................................................................................................................ 63.1.1 Boiler door pivotable to the left .................................................................................................................. 73.2 Fitting the thermal insulation ................................................................................................................. 83.3 Fitting the casing .................................................................................................................................... 93.4 Fitting the boiler controller .................................................................................................................. 103.5 Fitting the siphon .................................................................................................................................. 123.6 Fitting the burner .................................................................................................................................. 13

4. Technical information4.1 Description of the boiler ....................................................................................................................... 144.1.1 The UltraOil® meets the requirements of the following directives + standards ........................................ 144.2 Technical data ....................................................................................................................................... 154.3 Dimensions ............................................................................................................................................ 164.3.1 Mass without thermal insulation and casing ........................................................................................... 174.3.2 Installation kit (Option) ............................................................................................................................ 18

5. Installation5.1 Boiler room requirements .................................................................................................................... 195.2 Flue gas connection and chimney ...................................................................................................... 195.2.1 Flue gas conduits approved under building law ...................................................................................... 205.2.2 Project planning instructions ................................................................................................................... 205.3 Fuel ......................................................................................................................................................... 205.4 Electrical connection ............................................................................................................................ 215.4.1 Safety measures relating to EMC assembly ........................................................................................... 225.5 Flue gas performance diagrams .......................................................................................................... 235.6 Hydraulic integration ............................................................................................................................ 245.7 Condensate discharge .......................................................................................................................... 245.8 Setting the temperature regulators ..................................................................................................... 245.9 Safety valves ......................................................................................................................................... 245.10 Charging pump

(boiler with water heater) ...................................................................................................................... 245.11 Heating pump ....................................................................................................................................... 24

6. Commissioning6.1 Water quality .......................................................................................................................................... 256.1.1 Heating water .......................................................................................................................................... 256.1.2 Filling and replacement water ................................................................................................................. 256.2 Filling the heating system .................................................................................................................... 266.3 Filling the water heater

(if fitted) .................................................................................................................................................. 266.4 Commissioning ..................................................................................................................................... 266.5 Oil burner ............................................................................................................................................... 266.6 Handover to the operator/storage ....................................................................................................... 266.7 Record - Activation of screed function ............................................................................................... 27

4 210 258 / 00 3Table of contents

7. Maintenance7.1 Information for combustion controller/chimney sweep regarding emission monitor key ............. 297.2 Safety temperature limiter - Reset ....................................................................................................... 307.3 Cleaning the boiler ................................................................................................................................ 317.3.1 Preparations for cleaning the

boiler and burner ..................................................................................................................................... 317.3.2 Re-assembling the boiler ........................................................................................................................ 317.3.3 Cleaning the boiler room ......................................................................................................................... 317.4 Cleaning the combustion chamber and the aluFer® pipes ................................................................ 337.4.1 Leakage testing ....................................................................................................................................... 337.5 Servicing the neutralisation installation for types 23 and 24 (if fitted) ............................................ 347.5.1 Procedure for servicing the neutralisation installation ............................................................................. 34

8. Overview of settings8.1 Table of parameters .............................................................................................................................. 358.2 Fault Reporting overview TopTronic®T ................................................................................................ 45

4 210 258 / 00 4 Important information

1. Important information1.1 Other instructionsAll instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the instructions can be found in the documentation for the components!

Further sources of information:- Hoval catalogue- Standards, regulations

1.2 Safety instructionsThe system may only be put into operation if all relevant standards and safety regulations have been complied with. However, for trial operation, the following are the minimum conditions requiring fulfilment:1. Safety valve installed (closed system)2. Controls in operation (connected to the power sup-

ply)3. Sensor for the safety temperature limiter is located

in the immersion sleeve (see 2.2).4. The system is filled with water5. An expansion vessel is attached6. Flue gas outlets connected to the flue gas conduit

at the chimney7. Burner is preset.

1.3 Regulations, official approvalsFor installation and operation of the system, the fol-lowing regulations must be observed:

Germany- DIN EN 12831 Heating systems in buildings - Proce-

dure for calculation of the standard heating load.- DIN EN 12828 Heating systems in buildings - Design

of hot water heating systems.- DIN EN 13384 Flue gas systems - Heat and flow

calculation methods.- DIN 4755 Oil-fired combustion systems. Design, construction and safety engineering require-

ments- DIN 4756 Gas-fired combustion systems: design,

construction and safety engineering requirements, design and execution (for operation with gas burn-ers).

- DIN 18160 House chimneys, requirements, design and construction.

- PED (Pressure Equipment Directive).- TRD 721 Safety equipment to safeguard against

excess pressures / safety valves / for group II steam boilers.

- VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water heating systems.

- DIN 57 116 / VDI 0116 Electrical equipment in com-bustion systems (VDE regulations).

Austria- ÖNorm B 8130 Open hot water systems, safety

installations.- ÖNorm B 8131 Closed hot water systems; safety,

design and testing requirements- ÖNorm B 8133 Water heating systems, safety en-

gineering requirements.- ÖNorm B 8136 Heating systems, space require-

ments and other building requirements.- ÖNorm EN 12831 Heating systems in buildings -

Procedure for calculation of the standard heating load.

- ÖNorm EN 12828 Heating systems in buildings - Design of hot water heating systems.

- ÖNorm EN 13384 Flue gas systems - Heat and flow calculation methods.

- ÖNorm M 7515 Calculation of the dimensions of chimneys; terminology, calculation procedure.

- ÖNorm H 5171 Heating systems - Construction engineering requirements

- ÖVGW TR-Gas (Austrian Gas and Water Confed-eration - Technical Guidelines)

Switzerland- VKF - Association of Cantonal Fire Insurers- Fire prevention authority regulations- SN EN 12831 Heating systems in buildings - Proce-

dure for calculation of the standard heating load.- SN EN 12828 Heating systems in buildings - Design

of hot water heating systems.- SN EN 13384 Flue gas systems - Heat and flow

calculation methods.- SVGW Switzerland. Gas and water association.- SNV 27 10 20 Supply and extract air handling in the

boiler room.- SWKI 97-1 Water treatment for heating, steam and

air conditioning plants- SWKI 80-2 Safety engineering regulations for heat-

ing systems- KRW Corrosion caused by halogen compounds- KRW/VSO/FKR Ready-to-connect electrical con-

nections on boilers and burners.- Technical tank regulations TTV 1990.

and further regulations and standards prescribed by the CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by law.

4 210 258 / 00 5Installation position, transport

The regulations of the local building authorities, insur-ers and chimney inspectors must also be taken into account. When gas is used as a fuel, the regulations of the local gasworks must be observed and official authorisation may also be required.

1.4 WarrantyFault-free operation can only only be guaranteed if these instructions are followed and if the boiler is regularly serviced by a licensed specialist (mainte-nance contract). The rectification of faults and dam-age resulting from the use of contaminated operat-ing materials (gas, water, combustion air), unsuitable chemical additives to the heating water, improper handling, faulty installation, unauthorised modifica-tions and damage due to the use of force do not fall under our obligations under warranty; this also ap-plies to corrosion due to halogen compounds, e.g. from spray cans, paints, adhesives, solvents and cleansing agents.

4 210 258 / 00 6 Installation position, transport

2. Installation position, transport2.1 Transport

The UltraOil® is equipped with a flue gas collector made of plastic.Ensure that the flue gas collector is protected against damage during transport.

2.2 Installation positionA special installation kit is available from Hoval for vertical installation (see 4.3.1.1).

3. Assembly3.1 Setting up, levellingA special foundation plate for the boiler is not an es-sential, but it is recommended.

There should be a space of at least 50 cm be-tween the boiler and the wall on the left and right.

If the space between the boiler and the wall is less than 50 cm, all thermal insulation and casing must be fitted before the boiler can be pushed into its final position.

There must be enough space to swing open the boiler door, incl. the burner.

There must always be enough space between the back of the boiler and the wall to allow easy access to the clean-ing aperture in the flue gas collector.

Electrical cables must not touch hot parts!

4 210 258 / 00 7Assembly

3.1.1 Boiler door pivotable to the leftIt is possible to change the attachment of the boiler door so that it opens towards the left. This can be of advantage when installing the boiler in a corner.

Proceed as follows:

Close the boiler door and lock it in po-sition before changing the attachment of the door

1. Remove the top and bottom hinge nut (1, Fig-ure 1).

2. Fit the screw (2, Figure 1) (pivot point) on the other side of the door.

3. Reattach the hinge nut- do not tighten!

4. Fit the door handle on the other side of the door.5. Fit the burner plug on the other side.

The cable must not touch any hot parts.

Fig. 1

1

2

1

2

4 210 258 / 00 8 Assembly

3.2 Fitting the thermal insulation1. Check that the size of the right and left casing support rail (5) matches the dimensions given (tolerance ± 1mm).2. Place the insulation mat (6, Figure 2) around the boiler body (with the joint on the right, black side facing

outwards).3. Attach the insulation mats using two plastic tapes and tape locks (11, Figure 4):

- there are also tension springs (7, Figure 2) for additional attachment - Do not pull the tapes too tight (this would reduce the insulation value)

4. Place insulation mat (9) on the front of the boiler and insulation mat (8) on the back of the boiler and secure in position with the retaining discs(9, Figure 3) provided.

Fig. 2

9

1110

Fig. 3 Fig. 4

5

6

8

7

4 210 258 / 00 9Assembly

3.3 Fitting the casing1. Insert the burner reset button (20, Figure 8) in

the left or right side wall of the casing and plug the cables into the burner reset button as shown in the table below.

i The controller can be fitted on the right or left.

The burner reset button is fitted on the same side

as the controller.

Wire colourPlug

arrangementWire colour

brown 4 1black 5 2 light blue

6 3Button

2. Hook the side walls (21, 21a Figure 8) into the top and bottom rails (22, 22a).

i First, fit the front side walls.

Route the cable for the burner reset button forwards to the boiler door. Attach the cable to the casing side wall with the high-strength cable gland.

3. Fit two special screws (15, Figure 5) with counter nuts to the side wall (21, Figure 8) for the control-ler support.

i The controller can be fitted on the right or left.

15

16

Fig. 5

4. Hook the rear wall (23, Figure 8) into the screws fitted in the side walls.

4 210 258 / 00 10 Assembly

3.4 Fitting the boiler controller5. Remove the cover plate of the controller box

(24a Figure 8). Hook the switch control box (24) into the side wall (21) with the recesses for the special screws and secure it with two self-tap-ping screws Ø3.5x6.5 (16, Figure 5) and ser-rated washers.

6. Pull the capillaries with the immersion sensors (25, Figure 8) through the opening in the side wall, insert them into the immersion sleeve (25a) as far as the stop and fix in position with retaining spring (25b). Insert the burner plug (26).

Capillaries must not be folded or kinked

7. If the flue gas safety temperature limiter (17, Fig-ure 6) is preassembled in the controller, continue at Step 8. Fit the flue gas safety temperature limiter (17) with the flue gas temperature sen-sor (18) and establish plug-in connection in the controller.

17 18Fig. 6

8. Route the capillaries of the flue gas safety tem-perature limiter to the flue gas collector and plug into the opening (18, Figure 7) provided.

18Fig. 7

9. Attach cover plate (24a, Figure 8) with self-tapping screws Ø3.5x6.5 and serrated washers (24b).

10. Insert the rear casing cover (27, Figure 8).11. Screw on the front cover plate (28, Figure 8) us-

ing self-tapping screws Ø3.9x9.5 (28a) .12. Fit cover plate (29, Figure 8) using self-tapping

screws Ø3.5x9.5 (29a).13. Attach oil line holder (31, Figure 8) to cover (30)

and hook the cover into the side walls.14. Stick on labels and mount the holder for the sys-

tem manual (32, Figure 8) on the side.

4 210 258 / 00 11Assembly

3031

2728

28a

2929

a

2322a

24 24b

2526

2021

2221

a

Fig

. 8

24a

25a 25

b32

4 210 258 / 00 12 Assembly

3.5 Fitting the siphon

15. Attach the siphon (40, Figure 9), which is supplied loose.

Before commissioning, the siphon and the neutralisation box (if fitted) must be filled with water in order to prevent flue gas leakage.

16. Place the condensate box (option) (41) behind the boiler and establish the electrical connection.Fit connecting line between siphon and condensate box.

Fig. 9

4041

Optional

4 210 258 / 00 13Assembly

3.6 Fitting the burner

Open the boiler flange (4 locking screws) and check the installation position of the combus-tion chamber unit.

1. Attach sliding flange with seals to the boiler. Please note the correct boiler position.

2. Slide burner in until only dimension C (Figure 11) protrudes:

UltraOil® (110-160): Dimension C = 120mm UltraOil® (200): - - When attaching the burner, lift the burner cas-

ing slightly so that the screws (45, Figure 11) can be tightened.

3. Remove the lock nuts (46, Figure 11) of the boil-er flange.

Insulate the cavity between the burner tube and the boiler flange using the fireproof fibre provided (Figure 10).

Note that - the fireproof fibre must be packed firmly into

the cavity to prevent it falling out

4. Fit the recirculation pipe to the burner - Recommendation: Recirculation pipe flush with

the mouth of the burner tube.

Fireproof fibreFig. 10

5. Close the boiler flange with the burner again and tighten the lock nuts.

6. Establish the plug-in connections. Pull the plug cables out further by releasing the high-strength cable glands.

- The burner must be connected to the boiler with the standard plug-in connection.

- The burner cable must be shortened so that the plug-in connection has to be parted to swing out the burner.

7. Replace the absorber hood.

Further information can be found in the instructions supplied with the burner.

C

4546Fig. 11

4 210 258 / 00 14 Technical information

4. Technical information4.1 Description of the boilerThe Hoval UltraOil® is a low-pollutant and energy-saving oil-fired condensing boiler. The UltraOil® has an obliquely positioned combustion chamber fabri-cated from non-corroding stainless steel as its pri-mary heating surface and a secondary heating sur-face made from corrosion-resistant aluminium alloy. The secondary heating surface is so designed that the water vapour contained in the heating gas con-denses and the heat of evaporation is utilised for the heating circuit. The UltraOil® is designed exclusively for operation with low-sulphur heating oil EL.

4.1.1 The UltraOil® meets the requirements of the following directives + standards

We hereby declare that the product described, as an individual unit, complies with the standards, direc-tives and technical specifications listed.

Directives

92/42/EG "Efficiency directive"73/23/EWG "Low-voltage directive"89/336/EWG "Electromagnetic

compatibility"

Regulations

Stability prEN14394:2001Building require-

mentsEN303-1EN303-2prEN 15034

Low voltage DIN VDE 0722 / Ed. 04.83EMC EN 50082 Part 1 / Ed. 01.92

4 210 258 / 00 15Technical information

4.2 Technical data

Type (110) (130) (160) (200)• Nominal heat output at 80/ 60 °C kW 105 124 152 190• Nominal heat output at 40/ 30 °C kW 110 130 160 200• Heat output range at 80/ 60 °C kW 76,0 - 105,0 90,0 - 124,0 111,0 -152,0 133,0 - 190,0• Heat output range at 40/ 30 °C kW 80,0 - 110,0 95,0 - 130,0 116,0 -160,0 140,0 - 200,0• Heat input kW 77,0 - 105,8 91,0 - 125,2 112,0 - 154,0 135,0 - 193,0• Dimensions see dimensional drawing• Maximum boiler operating temperature °C 90 90 90 90• Minimum boiler operating temperature °C no lower limit• Minimum boiler return temperature °C no lower limit• Minimum flue gas temperature at boiler °C no lower limit• Safety temperature limiter setting (water side) °C 110 110 110 110• Operating / test pressure bar 4,0 / 5,2 4,0 / 5,2 4,0 / 5,2 4,0 / 5,2

•Boiler efficiency (full load) at 80/60 °C(related to net/ gross calorific value)

% 99,0 / 93,4 98,9 / 93,3 98,5 / 92,9 98,0 / 92,5

•Boiler efficiency (full load) at 40/30 °C(related to net/ gross calorific value)

% 104,0 / 98,1 103,8 / 97,9 103,5 / 97,6 103,1 / 97,3

•Boiler efficiency (partial load 30%) at return 27 °C(in acc. with EN 303) (related to net / gross calorific value)

% 105,0 / 99,1 104,8 / 98,9 104,5 / 98,6 104,0 / 98,1

•Standard efficiency (in acc. with DIN 4702, Part 8)at 75/60 °C (related to net / gross calorific value)

% 101,1 / 95,4 100,8 / 95,1 100,5 / 94,8 100,0 / 94,3

•Standard efficiency (in acc. with DIN 4702, Part 8)at 40/30 °C (related to net / gross calorific value)

% 104,3 / 98,4 104,2 / 98,3 104,1 / 98,2 103,6 / 97,7

• Standby losses qB at 70 °C Watt 500 500 500 520

•Combustion gas resistance at nominal output 12.5 % CO2, 500m above sea level (tolerance +/- 20 %)

mbar 0,24 0,34 0,45 0,67

• Condensate rate at 40/ 30 °C l/h 7,8 8,7 10,8 13,5• Flow resistance boiler 1 z factor 0,2 0,2 0,2 0,06• Hydraulic resistance at 10 K mbar 17,8 24,6 37,5 17,5• Hydraulic resistance at 20 K mbar 4,4 6,2 9,5 4,4• Water flow rate at 10 K m3/h 9,5 11,1 13,7 17,1• Water flow rate at 20 K m3/h 4,7 5,6 6,9 8,5• Boiler water content Litres 340 340 340 360• Boiler gas content m3 0,247 0,247 0,247 0,290• Insulation thickness of boiler body mm 80 80 80 80• Weight (incl. casing, burner) kg 420 420 420 450• Transport weight kg 370 370 370 390• Min./ max. electrical power consumption (in operation) Watt 4 / 320 4 / 320 4 / 370 4 / 500• Sound level incl. absorber hood 2

Room-air-dependent- Heating noise (EN 15036 Part 1) dB(A) 71 71 71 4

Room-air-dependent- Flue gas noise inside the flue (EN 15036 Part 2) 3 dB(A) 89 91 92 4

- Flue gas noise radiated from the mouth (DIN 45635 Part 47) 3 dB(A) 80 81 82 4

• Combustion chamber dimensions Ø-inside x length mm Ø524 x 800 Ø524 x 800 Ø524 x 800 Ø524 x 1000• Combustion chamber volume m3 0,172 0,172 0,172 0,215• Flue gas mass flow at nominal output 12.5 % CO2 heating oil kg/h 163,6 193,0 252,0 315,0• Flue gas temperature at nominal output 80/ 60 °C °C 68 70 75 80• Flue gas temperature at nominal output 40/ 30 °C °C 40 42 48 58• Delivery pressure at flue gas outlet Pa 20 20 10 10• Maximum chimney draught Pa 20 20 20 20

1 Flow resistance boiler in mbar = flow rate (m3/h)2 x z2 Data valid for Hoval oil compact heat station b-i3 Data without silencer, can be reduced by fitting a silencer4 Data unknown at time of printing

Oil burner to UltraOil® b-i (110) b-i (130) b-i (160) b-i (200)

• Operating mode 1-stage 2-stage 1-stage 2-stage 1-stage 2-stage 1-stage 2-stage• Firing output range kW 80 105,8 100 125,2 115 154,5 150 193• Fuel consumption kg/h 6,7 8,9 8,4 10,6 9,7 13,0 12,6 16,3


4.3 Dimensions

UltraOil® (110-200)(All dimensions in mm)

Space requirement - for fitting the side casing 400 mm. - The boiler can then be pushed to a position 100 mm away from the wall. - Allow space for vibration absorber if necessary (see Accessories).

UltraOil® (110-200)

1 Flow / safety flow DN65/PN6 2 Low temperature return DN65/PN6 3 High temperature return DN65/PN6 4 Flue gas outlet (plastic) D200 5 Siphon trap and 2 m PVC continuous-flow tube

DN25D19x3

6 Cleaning aperture D100 7 Evacuation R 1" 8 Electrical connection, optionally left or right 9 Boiler controller, optionally left or right 10 Condensate drain, optionally left or right R ¾ 11 Socket

A B C D E F G H I

UltraOil® (110-160) 280 610 1710 2200 153 243 290 395 740UltraOil® (200) 277 800 1918 2408 137 238 251 356 701

4 210 258 / 00 17Technical information

4.3.1 Mass without thermal insulation and casing

(All dimensions in mm)

Example calculation for the required corridor widthDoor width T = 800

UltraOil® (110-160) K =735

x 1881 = Korridorbreite ≥ 1728800

With installation kit

UltraOil® (110-160) K =735

x 1229 = Korridorbreite ≥ 1129800

Required minimum width of door and corridor for bring-ing in the boilerThe following values are the calculated minimum values

B K = x L T

T = Door widthK = Corridor widthB = Boiler widthL = Maximum boiler length

K

T

< 150B

L B T = x L K

A B

UltraOil® (110-160) 1524 1882UltraOil® (200) 1722 2073


4.3.2 Installation kit (Option)

(All dimensions in mm)

A B C D E

UltraOil® (110-160) 1230 1751 2000 2002 2027UltraOil® (200) 1264 1951 2195 2182 2220

4 210 258 / 00 19Installation

5. Installation5.1 Boiler room requirementsRegarding the building specifications for boiler rooms and their supply and extract air handling, the current building supervisory office regulations specific to the state or country are to be observed.

Ensure an adequate supply of fresh air to the boiler room to make sure that there is an unob-structed flow of the combustion air required for the operation of all combustion devices in the boiler room and so that there is no shortage of oxygen for operating personnel.Binding values for the size of supply air openings are not generally specified in the relevant regulations; it is merely required that no partial vacuum in excess of 3 N/m2 occurs. To comply with this requirement, a supply air cross-section of 300 cm2 is to be provided up to a nominal heat output of 50 kW. In the case of rectangular openings, the ratio of the sides should not exceed 1.5:1; if a grid is fitted, an appropriate allowance must be added so that the free cross-sec-tion area reaches the amount given above.

5.2 Flue gas connection and chimney

The flue gas system must be gastight, watertight, resistant to acids and ap-proved for use with the corresponding flue gas temperatures of up to 120 °C and for overpressure.

Horizontal connection lines must be routed with a downward slope of at least 50 mm per running metre of their length in the direction of the boiler to ensure that condensate can flow un-hindered back to the boiler. The whole flue gas system must be designed to prevent condensate collecting.

As a rule, only one heat generator should be connected to the chimney! If using two heat generators, observe the corresponding regula-tions.

The UltraOil® is delivered with a flue gas safety temperature limiter. For this reason, no addi-tional flue gas safety temperature limiter is re-quired for flue gas systems with a max. per-missible flue gas temperature of 120 °C.

As a result of the water vapour in the flue gas and the low flue gas temperature, condensate forms in the chimney. This means that oil condensing boil-ers cannot be connected to conventional domestic chimneys.

The valid official stipulations and regulations with regard to flue gas evacuation must be observed.

There are two possible ways to evacuate flue gas from oil condensing boilers:

a) the use of special flue gas conduits approved by the building authorities,

b) the use of moisture-resistant chimneys which are approved for flue gas temperatures of over 40 °C, connected to the oil condensing boiler in the boiler installation room by means of approved flue gas conduits.

In both cases, the cross-sections and maximum lengths must be calculated on the basis of the flue gas mass flow , flue gas temperature and available maximum delivery pressure at the flue gas outlet in ac-cordance with the table in section 4.2 (EN 13384).

4 210 258 / 00 20 Installation

5.2.1 Flue gas conduits approved under build-ing law

Only flue gas systems approved by the respective country or state may be connected (in Austria the approval requirements of the respective provinces must be observed). The manufacturers of the flue gas conduits supply suitable boiler connection fittings for the transition from the flue gas outlet to the flue gas conduit.

When designing and installing flue gas conduits, manufacturer’s instructions for design and routing and the requirements of building law must be observed. We recommend that you consult the regional chimney inspector in good time.

5.2.2 Project planning instructions- The flue gas must be routed through a tested and

approved flue gas conduit- The flue gas conduit must be gastight, watertight,

resistant to corrosion and acids and approved for use with flue gas temperatures of up to 120 °C.

- The flue gas system must be suitable for operation at pressure.

- The flue gas conduit is to be laid with gradients to ensure that the condensate which occurs in the flue gas system flows back into the heating boiler and can be neutralised there before discharge into the drainage system.

- When using flue gas conduits made from plastic, observe the country-specific regulations with regard to the use of the flue gas safety temperature limiter. (Included in the scope of delivery of the UltraOil®)

- The cross-sections are to be calculated for heating boilers without draughting requirements. Please take note of SIA recommendation No. 384/4 “Chim-neys for building heating systems, determination of cross-sections.”

- A closable flue gas measurement nozzle with a cir-cular internal diameter of between 10-21 mm must be installed in the flue gas conduit. It must protrude beyond the thermal insulation.

2 x

D

D

D1D

< 2

D

5.3 Fuel

The boiler may only be operated with the fuel designated on the boiler rat-ing plate.

The UltraOil® boiler is suitable for the combustion of the following fuels:- Low-sulphur heating oil EL in accordance with DIN

51 603 / ÖNorm C 1109- Eco heating oil low-sulphur SN 181 160-2 / 2008

If an existing oil heating installation is replaced by a Hoval UltraOil®, the following instructions regarding the oil tank and its refilling must be observed:- The Hoval UltraOil® must only be operated with low

sulphur heating oil EL with a sulphur content < 50 ppm (< 0.005 %).

- It is recommended that you clean the oil tank before refilling it.

- A residual amount of heating oil EL in the oil tank may be mixed with low sulphur heating oil EL, pro-vided that the residual amount does not exceed the following percentages of the total content.

Residual amount heating oil EL (sulphur content: 2000 ppm / 0.2 %) max 3 % of tank volume Residual amount heating oil EL (sulphur content: 1000 ppm / 0.1 %) max 5 % of tank volume Residual amount eco heating oil EL (sulphur content: 500 ppm / 0.05 %) max 10 % of tank volume

- In order to reach the permissible mixture ratio with heating oil EL low-sulphur, taking into account the residual amount of heating oil in the oil tank, a 100% tank filling is necessary.


5.4 Electrical connectionElectrical connections must be established by a li-censed and qualified electrician.

For Austria and Germany:An electrical circuit diagram is supplied with the boiler controls. An all-phase main switch with a minimum contact spacing of 3 mm must be fitted in the power supply line.

For Switzerland, the following applies:For electrical connection, the circuit diagram specific to the plant must be observed.

The electrical connection is to be made in accord-ance with the diagram supplied

Fig. 12

Cable feed-in

Boiler control panel for the connection:Remove screws and fold out


5.4.1 Safety measures relating to EMC as-sembly

1. For regulator units with their own mains connec-tion, separate routing of power leads and sensor or bus lines is absolutely essential. If using cable ducts, these must be equipped with separator strips.

2. The mains connection for the heating system (boiler control panel regulator unit) must be de-signed as an independent electrical circuit. Nei-ther fluorescent lamps nor any other equipment which might cause interference may be connect-ed, nor may it be possible to connect such equip-ment.

Fuse

Boiler room emergency switch

Heat generator

Boiler room lighting and power sockets must be in a separate circuit

3. The fresh air sensor must not be fitted in the vicin-ity of transmitters and receivers (on garage walls near receivers for garage door openers, amateur radio antennae, radio alarm installations or in the immediate vicinity of transmitters etc.)

Recommended cable cross-sections and maxi-mum permitted cable lengths:

Cables carrying mains supply voltages: (power supply, burners, pumps, actuators etc.): minimum 1mm2

Maximum permissible length:no restrictions, within the framework of the build-ing’s internal installations.Sensor cables and cables carrying low voltages: minimum 0.5 mm2

Maximum permissible cable length: 50 mData bus lines:always shielded, e.g. J-Y (ST) 2 x 0.6 mmMaximum permissible cable length: 100 m


5.5 Flue gas performance diagramsThe diagrams show the flue gas temperature characteristics with Hoval burners.

UltraOil® (110) UltraOil® (200)

Flu

e g

as t

emp

erat

ure

(°C

)

Abgaskurve UltraOil (110)

30

40

50

60

70

80

90

100

50.0 60.0 70.0 80.0 90.0 100.0 110.0Nennleistung (kW)

Ab

gas

tem

per

atu

r (°

C)

Flow 80°C Return flow 60°C


65°C

38°C

Flu

e g

as t

emp

erat

ure

(°C

)

40

50

60

70

80

90

0

10

20

30

90.0 100.0 110.0 120.0 130.0 140.0 150.0 160.0 170.0 180.0 190.0 200.0


Flow 80°C Return flow 60°C81°C

60°C

Nominal output (kW) Nominal output (kW)

UltraOil® (130)

Flu

e g

as t

emp

erat

ure

(°C

)


30

40

50

60

70

80

90

100

70.0 80.0 90.0 100.0 110.0 120.0 130.0Nennleistung (kW)

Ab

gas

tem

per

atu

r (°

C)



70°C

42°C

Nominal output (kW)

UltraOil® (160)

Flu

e g

as t

emp

erat

ure

(°C

)


30

40

50

60

70

80

90

100

90.0 100.0 110.0 120.0 130.0 140.0 150.0 160.0Nennleistung (kW)

Ab

gas

tem

per

atu

r (°

C)



74°C

47°C

Nominal output (kW)

°C = flue gas temperature using heating oil EL, CO2 = 12.5%


The minimum inner diameter of the condensate drain must be 15 mm. The condensate drain must be sufficiently inclined.

A: It is not necesary to neutralise condensate from an oil-fired condensing unit (up to 120 kW) drained together with domestic waste wa-ter from a private household.

CH: For the UltraOil®, the fuel used must be heating oil EL low-sulphur. As a rule, neutralisation of the condensate is not necessary. Local regula-tions pertaining to condensate discharge must be observed.

D: For the UltraOil®, the fuel used must be heat-ing oil EL low-sulphur. Neutralisation is there-fore unnecessary. Regarding condensate dis-charge, the local regulations and the technical bulletin of the ATV (Sewage Engineering As-sociation) must be observed.

The siphon must be filled with water before commissioning.

5.8 Setting the temperature regulatorsBasic setting of the controller has been carried out by the heating contractor. Selection and setting of the various heating programmes in accordance with the operating manual.

5.9 Safety valvesThe heating and hot water systems must each be protected with one safety valve against impermis-sibly high pressures. Their discharge capacity of the valves must correspond to the boiler’s maximum nominal heat output. The valve is to be installed in the flow line in the immediate vicinity of the boiler.

5.10 Charging pump (boiler with water heater)

Speed of rotation and output must correspond to the requirements of the water heater. Setting carried out by the heating installation engineer.

5.11 Heating pump Speed of rotation and output must correspond to the requirements of the system. They are to be set by the heating installation engineer.

5.6 Hydraulic integration

ExamplesDirect heating circuit

SLP

Dies ist einunerlaubter Weg!Gehen Sie einenSchritt zurück oderlöschen Sie diesesShape!Sie haben dieMöglichkeit einneues Shape zunehmen!!!hovhovalhhovalhovaalhovalho

UltraOil

P

KF

NT

HT

NT

HT

TT

DKP

B 1

RS-T

AF

TopTronic T

Fig. 13

Mixer circuit and water heater

SLP

Dies ist einunerlaubter Weg!Gehen Sie einenSchritt zurück oderlöschen Sie diesesShape!Sie haben dieMöglichkeit einneues Shape zunehmen!!!hovhovalhhovalhovaalhovalho

UltraOil

P

NT

HT

NT

HT

Dies ist einunerlaubterWeg!Gehen Sieeinen Schrittzurück oderlöschen Siedieses Shape!Sie haben dieMöglichkeit einneues Shapezu nehmen!!!hovhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalh

WW

T

KW

SF

SLP

RS-T

AF

TopTronic T

RS-T

1 HT NT

B1VF2

TT

MK2

MYK2

VF1

TT

MK1

MYK1

Fig. 14

5.7 Condensate dischargeThe boiler condensate drain must be made of corro-sion-resistant material.The following materials are suitable for the conden-sate drain:- PVC, PE, PP, ABS

4 210 258 / 00 25Commissioning

Heating Water

The European Standard EN 14868 and the directive VDI 2035 must be ob-served.

In particular, attention must be paid to the following stipulations:• Hoval boilers and calorifi ers are designed for heat-

ing plants without signifi cant oxygen intake (plant type I according to EN 14868).

• Plants with - continuous oxygen intake (e.g. underfloor heat-ing systems without diffusion proof plastic pip-ing) or

- intermittent oxygen intake (e.g. where frequent refilling is necessary)

must be equipped with separate circuits.

• Treated fi lling and replacement water must be tested at least 1x yearly. According to the inhibitor manufacturer‘s instructions, more frequent testing may be necessary.

• A refi lling is not necessary if the quality of the heat-ing water in existing installations (e.g. exchange of boiler) conforms to VDI 2035.The Directive VDI 2035 applies equally to the re-placement water.

• New and if applicable existing installations need to be adequately cleaned and fl ushed befor being fi lled. The boiler may only be fi lled after the heating system has been fl ushed!

• Parts of the boiler which have con tact with water are made of ferrous materials.

• On account of the danger of stress cracking corro-sion the chloride, nitrate and sulfate con tents of the heating water must not exceed 200 mg/l in total.

• The pH value of the heating water should lie be-tween 8.3 and 9.5 after 6-12 weeks of heating op-eration.

Filling and replacement water• For a plant using Hoval boilers untreated drinking

water is generally best suited as heating medium, i.e. as fi lling and replacement water. However, as not all drinking water is suitable for use as as fi lling and replacement water the water quality must ful-fi l the standard set in VDI 2035. Should the mains water available not be suited for use then it must be desalinated and/or be treated with inhibitors. The stipulations of EN 14868 must be observed.

• In order to maintain a high level of boiler effi ciency and to avoid overheating of the heating surfaces the values given in the table should not be exceed-ed (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant).

• The total amount of fi lling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant.

Maximum filling capacity based on VDI 2035

Total hardness of the fi lling water up to ...

[mol/m3] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0

f°H <1 5 10 15 20 25 30 >30

d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8

e°H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3

~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300

Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600

Boiler size of the individual boiler

maximum fi lling quantity without desalination

to 50 kW NO REQUIREMENT 20 l/kW

50 to 200 kW 50 l/kW 20 l/kW 20 l/kW always desalinate

1 Sum of alkaline earths2 If the conductance in µS/cm exceeds the tabular value an analysis of the water is necessary.

6. Commissioning6.1 Water quality

4 210 258 / 00 26 Commissioning

6.2 Filling the heating systemFilling of the heating system must be carried out by trained personnel. The fill and make-up water must comply with the quality requirements in the relevant state or country (see chapter 6.1).

6.3 Filling the water heater (if fitted)

The heating boiler may be put into operation even when the water heater is not filled.

6.4 Commissioning

Important:On first commissioning, check that all safety and control devices are functioning properly.Operation and maintenance of the system must be explained in detail to the operator.

The siphon must be filled with water before commissioning.

6.5 Oil burnerSetting the burner must also be carried out by a spe-cialist and the setting must correspond to the heat demand of the system.Please see the technical information / assembly in-structions supplied with the burner.

6.6 Handover to the operator/storageHave the operator confirm in writing that the operat-ing and service procedures have been explained and that he has received a copy of the relevant operat-ing manuals (see sample on page 48). The system manufacturer is responsible for providing operating manuals for the whole plant. The technical information/assembly instructions must be kept with the system at all times.

4 210 258 / 00 27Commissioning

Required parameter settings:Parameter level Par. No Setting Description

- Key DK ............... Activate heating characteristic curve, above 0 = OFF, e.g. ~ 0.8 for FBH

UNMIXED CIRC. 13 ...............°C Maximum fl ow temperature to be set

UNMIXED CIRC. 161 2 3

Screed program to be set (for description see following page)1 Function heating (duration: Starting day + 7 days)2 Surface-ready heating (duration: Starting day + 18 days)3 Function and surface-ready heating (duration: Starting day + 25 days)

HEAT GENER. 4 ...............°C Max. H-Gen temperature to be set, set as for max. fl ow temperature (after termination of screed function reset max. temperature to the value required).

If the screed function is activated for the unmixed circuit, all the other circuits (MC, DHW) are switched off.

In alternation with the basic display of the controller, the activated screed heating is displayed giving some information about the remaining term in days „screed - 18“.

RecordScreed heating activated by: ............................................Screed heating activated on: ............................................Screed heating ends on: ..................................................

..........................................................................................Date and signature

Required parameter settings:Parameter level Par. No Setting Description

MIX.VALVE (1 or 2) 13 ...............°C Maximum fl ow temperature to be set

MIX.VALVE (1 or 2) 161 2 3

Screed program to be set (for description see following page)1 Function heating (duration: Starting day + 7 days)2 Surface-ready heating (duration: Starting day + 18 days)3 Function and surface-ready heating (duration: Starting day + 25 days)

Direct heating circuit (possible only with H-Gen without minimum H-Gen temperature - e.g. condensing boiler)

Start

PRESS

HC level Parameters 13,16

H-GEN level Parameter 4

Characteristic heating curve

Enable HC

Activate Installer level (Code entry)

> 3 sec: Access to

level

Select / Confi rm Set Confi rm End / Exit

Heating circuit selection for screed function and necessary parameter settings Mixing circuit 1 Mixing circuit 1

Start

PRESS

MC1/MC2 level Parameters 13,16

Activate Installer level (Code entry)

> 3 sec: Access to

level

Select / Confi rm Set Confi rm End / Exit

Cross where applicable;cut out record and fasten to the control during the active screed function.

Minimum requirements for the activation of the screed function: Minimum age cement screed 21 days Minimum age calcium sulphate screed 7 days Flow temperature monitor installed and connected

For newly laid screed - see „Recommendation of the Federal Association of Radiant Panel Heating“.

6.7 Record - Activation of screed function

4 210 258 / 00 28 Commissioning

Parameter 16 „Screed function“(Parameter HC, MC1 or MC2)

Example:Maximum fl ow temperature 40°C

1 Function heating

- On the starting day and on the 1st day constantly at 25°C, on each further day the demand value rises by 5°C until the maximum fl ow temperature is reached. Subsequently the temperature is lowered again in the same gradations until the low point of 25°C is reached.

Example: Set fl ow maximum temp.: 40°C Starting day + 1st day: 25°C 5th - 15th day: constant heating with the max. fl ow temperature 2nd day: 30°C 16th day: 35°C 3rd day: 35°C 17th day: 30°C 4th day: 40°C 18th day: 25°C

2 Surface-ready heatingStarting day + 18 days

- Combination of 1 function heating and subsequently 2 surface-ready heating

3 Function heating and surface-ready heatingStarting day + 25 days

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 t [TAGE]

55

45

35

25

Funktionsheizen und Belegreifheizen

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 [TAGE]

55

45

35

25

3=Funktionsheizen und Belegreifheizen

T [°C]VLSol

3 = Function heating and surface-ready heating

START DAYS

- On the starting day and for the three following days at 25°C constantly- Subsequently for 4 days at the set fl ow maximum temp., but limited to a maximum of 55°C

Starting day + 7 days

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 t [TAGE]

55

45

35

25

Funktionsheizen

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 TAGE]

55

45

35

25

1=Funktionsheizen

maximal 55°C einstellbar!

T [°C]VLSol

1 = Function heating

START DAYS

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 t [TAGE]

55

45

35

25

Belegreifheizen

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 [TAGE]

55

45

35

25

2=Belegreifheizen

T [°C]VLSol

2 = Surface-ready heating

DAYSSTART

55°C maximum set level!

4 210 258 / 00 29Maintenance

All other control elements of the control unit are described in the operating instructions.The emission monitor key can also be used to change over to manual operating mode.

Emission monitor key / Manual operation To protect under fl oor heating systems against invalid overheating during emission monitoring / manual opera-tion it is necessary to implement ap-propriate safety measures (e.g. safety temperature limiter with pump switch-off). The duration of the emission moni-toring is limited to 20 minutes and shall be restarted, if necessary.

Scalding hazard due to hot water tem-perature, since the hot water tempera-ture can exceed the temperature set-point!

Emissions metering

Immediate end

PRESSSHORTLY

Remaining time display

REACTIONS for emissions metering- Time unit automatically 20 min. – thereafter reverts- Boiler temperature - > maximum temperature restriction- Regulate to the maximum temperature… the heating circuits and the water heaters

(at the direct heating circle only, if the warm water mode of operation is adjusted to parallel operation)- With 2-step heat generator both stages are in operation

Manual operation

Immediate end

PRESS> 5 seconds

REACTIONS for manual operation- Set reference boiler temperature with button!- All heating pumps ON- Mixer without current - manual setting necessary!- Note the maximum permissible temperature of the fl oor heating!- The hot water temperature reaches the set DHW maximum temperature

(expert level standard 65°C).

7. Maintenance7.1 Information for combustion controller/chimney sweep regarding emission monitor key

4 210 258 / 00 30 Maintenance

7.2 Safety temperature limiter - Reset

Boiler water temperature limiter - ResetIf the boiler temperature rises too high (>100 °C), the system is switched off by the safety temperature lim-iter by means of a mechanical lockout.Press the reset button on the control panel (first remove the cover); the boiler is now ready for operation again once the boiler water temperature is less than 80 °C.

Flue gas temperature limiter - Reset

If the flue gas temperature rises too high, the system is switched off by the flue gas safety temperature lim-iter by means of a mechanical lockout.Press the reset button on the control panel; the boiler is now ready for operation again.The reason for the excessive flue gas temperature must be established by the installation engineer.Possible causes are: - Strong dirt build-up on the heating surface - Burner output setting too high

i Depending on the design, you will find the flue gas safety tem-perature limiter in the controller or near the flue gas collector.

4 210 258 / 00 31Maintenance

7.3 Cleaning the boilerThe UltraOil® may only be cleaned by a licensed specialist or Hoval customer service technician.Reliable and safe operation of the oil boiler, optimum efficiency and clean combustion can only be guar-anteed if the unit is serviced and cleaned regularly.

The boiler must be cleaned at least once per year.

For this purpose, we recommend that you conclude a maintenance contract with Hoval customer serv-ice, or with an authorised specialist dealer.In the case of oil-fired equipment already in opera-tion during the construction phase (where there is increased occurrence of dust), inspection should be carried out once construction work has been com-pleted to ascertain the degree of dirt build-up. If nec-essary cleaning must be carried out.

7.3.1 Preparations for cleaning the boiler and burner

- Set the main boiler control switch to "0". - Await standby mode / fan follow-on time - Remove absorber hood - Undo the burner plug-in connections (burner ca-ble, remote reset cable).

- Release all 4 boiler door lock nuts. - Open the burner with the boiler door (51, Fig-ure 16) towards the right or left

- Clean the burner. - Remove the combustion chamber unit - Remove the cover from the cleaning aperture.

The siphon must be cleaned twice per year. In order to clean the siphon, the siphon base section (50, Figure 15) must be dismantled.

- Clean neutralisation box KB23,KB24 (if fitted) as described in chapter 7.5. Also remove and clean neutralisation box KB22 without granulate (if fit-ted).

- Unscrew the base section of the siphon (40, Fig-ure 9) to catch the washing water.

- The cleaning scraper included in the scope of de-livery is suitable for cleaning the aluFer® pipes. For a detailed description of how to clean the combus-tion chamber and the aluFer® pipes, see chapter 7.4.

7.3.2 Re-assembling the boiler - Where applicable, reattach the neutralisation box and siphon base section and fill with water.

- Fit the cleaning aperture cover. - Install the combustion chamber unit - Close the boiler door, tighten the lock nuts evenly - Plug in the burner plug. - Set the main boiler control switch to "1" - Measure combustion. If necessary, adjust the set-ting. Make a record of the measurement.

7.3.3 Cleaning the boiler roomThe boiler room must be kept clean and free of

dust!

Point out to the customer that the boiler room must be kept clean.

4 210 258 / 00 32 Maintenance

Fig. 15

Fig. 16

50

51

4 210 258 / 00 33Maintenance

in the case of light dirt build-upCarry out mechanical wet cleaning of the combus-tion chamber and the aluFer® pipes.

• The narrow cleaning scrapers (2 pieces) are used for the outer, the other two for the middle fl ow ducts.

• Only the bevelled cleaning scrapers need to be pushed through twice per duct (turned lengthwise through 180° each time).

• Before removing the drain hose, all dirt particles must be adequately rinsed out of the condensate drip tray.

in the case of heavy dirt build-upCleaning is performed as described «in the case of light dirt build-up», but fi rst, concentrated clean-ing agent is sprayed on and allowed to soak in for 10 minutes.

Do not use wire brushes or any sharp objects for cleaning. Ensure that the combustion cham-ber does not come into contact with iron, as this may cause corrosion. Care must be taken that stainless steel surfaces are not scratched or damaged in any way.

The only cleaning concentrates per-mitted are those approved for oil boil-ers having aluminium components such as Sotin 240 or Desoxin.

When working with the above clean-ing agents, regulations prescribe the wearing of gloves and protective gog-gles. In addition, the instructions on the original packaging must be ob-served.

Cleaning scraper

Flow duct

Bevelled cleaning scraper

aluFer® pipe

Leakage testingAfter cleaning or at least every fi ve years, the seal-ing between the combustion chamber and the con-densate drip tray must be checked for leakage. This can be done by fi lling the boiler with water.

635

1

1 Filling level water

7.4 Cleaning the combustion chamber and the aluFer® pipes

4 210 258 / 00 34 Maintenance

i Maintenance should be undertaken at least every second year, or after the neutralisation granules are exhausted (check the ph-value if appropriate with litmus paper test).

Neutralisation granulate for refi lling can be ordered from Hoval under the following item no.:

• 1 pack (3 kg) neutralisation granulesPart no. 2028 906One fi lling requires 4 packs of 3 kg each.

Procedure for servicing the neutralisation instal-lation• Set the main control switch to "0".• Undo the bolts and withdraw the neutralisation

box.• Only for neutralisation box of type KB24

Remove the condensate pump and clean the con-densate pump container.

• Remove the neutralisation granules and any de-posits from the neutralisation box. Any remaining neutralisation granulate, since it is harmless, can be disposed of as domestic waste.

• Refi ll the neutralisation box with new granules.

Attach the neutralisation box cover making sure that it is tight-closing.

• Push the neutralisation box back in.

Before putting back into service, the siphon and the neutralisation box must be fi lled together with water.

The water can be poured through the cleaning aperture into the neutralisa-tion box and the siphon.

Neutralisation boxType KB23

Neutralisation granules

Neutralisation box with feed pumpType KB24

Condensate pump container Neutralisation granules

7.5 Servicing the neutralisation installa-tion for types 23 and 24 (if fitted)

4 210 258 / 00 35Overview of settings

i Maintenance should be undertaken at least every second year, or after the neutralisation granules are exhausted (check the ph-value if appropriate with litmus paper test).

Neutralisation granulate for refi lling can be ordered from Hoval under the following item no.:

• 1 pack (3 kg) neutralisation granulesPart no. 2028 906One fi lling requires 4 packs of 3 kg each.

Procedure for servicing the neutralisation instal-lation• Set the main control switch to "0".• Undo the bolts and withdraw the neutralisation

box.• Only for neutralisation box of type KB24

Remove the condensate pump and clean the con-densate pump container.

• Remove the neutralisation granules and any de-posits from the neutralisation box. Any remaining neutralisation granulate, since it is harmless, can be disposed of as domestic waste.

• Refi ll the neutralisation box with new granules.

Attach the neutralisation box cover making sure that it is tight-closing.

• Push the neutralisation box back in.

Before putting back into service, the siphon and the neutralisation box must be fi lled together with water.

The water can be poured through the cleaning aperture into the neutralisa-tion box and the siphon.

Neutralisation boxType KB23

Neutralisation granules

Neutralisation box with feed pumpType KB24

Condensate pump container Neutralisation granules

Designation FactoryRegulator Setting range /

Setting values10 20 30 40 50

Type of device:

DHW:

SW:

Address:

Surface operation Key :

Heating curve HC OFF OFF, 0,20 .... 3,5

Heating curve MC1 1,0 OFF, 0,20 .... 3,5

Heating curve MC2 1,0 OFF, 0,20 .... 3,5

Daytime target temperature HC *) 20°C 5 .... 30°C *)

Daytime target temperature MC1 *) 20°C 5 .... 30°C *)

Daytime target temperature MC2 *) 20°C 5 .... 30°C *)

Night-time target temperature HC *) 16°C 5 .... 30°C *)

Night-time target temperature MC1 *) 16°C 5 .... 30°C *)

Night-time target temperature MC2 *) 16°C 5 .... 30°C *)

DHW target temperature 50°C 5 ... DHW-Max.

*) Depending on the setting of system parameters 03 OPERATING MODE

Remote operation/room stationsType Heating circuit Address HW SW

8. Overview of settings8.1 Table of parameters

4 210 258 / 00 36 Overview of settings

Table for Time programs

DHW circuitTime program P1 Time program P2 Time program P3

Tag Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3

from to from to from to from to from to from to from to from to from to

Mo

Tu

We

Th

Fr

Sa

Su

Direct circuitTime program P1 Time program P2 Time program P3



Mo

Tu

We

Th

Fr

Sa

Su

Mixer Circuit 1Time program P1 Time program P2 Time program P3



Mo

Tu

We

Th

Fr

Sa

Su

Mixer Circuit 2Time program P1 Time program P2 Time program P3



Mo

Tu

We

Th

Fr

Sa

Su


HYDRAULICPar. Designation Factory 10 20 30 40 50 Lev.

2 Function allocation of the output DHW charging pump 1 HF

3 Function allocation of the output Mixer circuit 1 3 HF

4 Function allocation of the output Mixer circuit 2 3 HF

5 Function allocation of the output Direct circuit Pump 2 HF

6 Function allocation of the variable output 1 OFF HF

7 Function allocation of the variable output 2 OFF/ 4/ 43 HF

8 Function allocation of the variable input 1 OFF HF

9 Function allocation of the variable input 2 OFF HF

10 Function allocation of the variable input 3 OFF/ 2/ 33 HF

11 Indirect return increase OFF HF

12 Maximum limit energy management 80 °C HF

13 Activation cooling buffer OFF HF

14 Release contact cooling to KVLF OFF HF

SYSTEMPar. Designation Factory 10 20 30 40 50 Lev.

LANGUAGE Selection of the style-language EN BE

2 Number of cleared switching time programs P1 HF

3 Clearing for separate operating mode 1 HF

4 Limit temperature for summer disconnection 22 °C HF

5 System frost protection 3 °C HF

6 Demand contact module for VE1 1 HF



9 Air conditioning zone -12 °C HF

10 Building type 2 HF

11 Automatic reversion time (surface end user level, except info. level) 5 Min HF

12 Pump and mixer compulsory operation ON HF

13 Logical fault signal OFF HF

14 Automatic SET function(after 24:00, is automatically set to OFF) ON/ OFF HF

15 Blocking code for heating Installer OEM

18 Release cycle temperature OFF HF

19 Frost protection mode 30 Min HF

21 RTC adjustment 0 HF

23 Blocking code operator level OFF HF

24 Temperature display in Fahrenheit OFF OEM

26 First commissioning date (after 24:00) - OEM

27 Fault report (only TTT/UG) 2 HF

28 Fault stack 2 ON HF

29 Characteristic curve emergency operation 0 °C HF

30 Thermostat function sensor allocation AF HF

31 Thermostat function reference value 1 °C HF

32 Thermostat function switching difference 3K HF

33 Thermostat function anti-blocking protection ON HFTop: ArtNo - HW IndexBottom: Code:REV - Software version ----- OEM

RESET Reset parameter values BE


DHWPar. Designation Factory 10 20 30 40 50 Lev.

DHW-NIGHT DHW - economy temperature 40/ 45 °C BE

2 DHW-legionella protection-day OFF HF

3 DHW-egionella protection-time 2:00 HF

4 DHW-legionella protection-temperature 50/ 55/ 65/ 70 °C HF

5 DHW-temperature recording 1 HF

6 DHW-maximum temperature limit 50/ 55/ 65/ 70 °C HF

7 DHW-mode of operation 1 HF

8 DHW-tank discharge protection ON/ OFF HF

9 DHW-charging temperature excess 7/ 20 K HF

10 DHW-switching difference 5 K OEM

11 DHW-charging pump follow-on 0.5/ 1/ 2/ 5 Min OEM

12 ZKP-switching time program AUTO HF

13 ZKP-economy interval (pause) 0 Min HF

14 ZKP-economy interval (period duration) 20 Min HF

17 H-GEN behaviour during SLP follow-on time AUTO/ OFF HF

18 DHW-parallel loading OFF HF

19 DHW-time-out OFF/30 Min HF

20 PI-reference value control OFF HF

21 PI-amplifi cation factor, P-portion Xp 0,1 %/ K OEM

22 PI-scanning time Ta 20 sec OEM

23 PI -reset time Tn 600 sec/ °C OEM

UNMIXED CIRCPar. Designation Factory 10 20 30 40 50 Lev.

1 Type of reduced operation ECO/ ABS HF

2 Heating system (exponent) DK= 1,30 HF

3 Room override (in connection with room sensor) 3 HF

4 Room factor OFF HF

5 Adaptation heating curve OFF HF

6 Switch-on optimisation 1 HF

7 Heating limit 0,5 OEM

8 Room frost protection limit 10 °C HF

9 Room thermostat function OFF HF

10 Outside temperature allocation 0 HF

11 Constant temperature reference value 20 °C HF

12 Minimum temperature limit 10 °C HF

13 Maximum temperature limit 55/ 75 °C HF

14 Temperature elevation Heating circuit DK=0 HF

15 Pump follow-on 5 Min HF

16 Screed function OFF HF

23 Room control K-factor 8 HF

24 Room control Tn-factor 35 MIN HF

25 Vacation mode STBY HF

36 Minimum value override OFF HF

Name heating circuit (max. 5 letters) XXXXX HF


MIX. VALVE-1Par. Designation Factory 10 20 30 40 50 Lev.


2 Heating system (exponent) MK= 1,10 HF


4 Room factor 100 % HF

5 Adaptation heating curve ON HF









14 Temperature elevation/ abatement heating circuit 0/ 8 K HF



18 P-portion Xp 2,0 %/ K OEM

19 Scanning time Ta 20 sec OEM

20 I-portion Tn 270 sec OEM

21 Running time servomotor 150 sec HF

22 End position function, valve 1 OEM





37 Mixer lead time OFF HF

38 Regulation offset 0 HF

50 Cooling switch-on point, OT OFF HF

51 Cooling max. point, OT 35 °C HF

52 Cooling reference fl ow temp. at switch-on point 18 °C HF

53 Cooling reference fl ow temp. at max. point 24 °C HF

54 Cooling reference room temp. at switch-on point 23 °C HF

55 Cooling reference room temp. at max. point 28 °C HF

56 Min. temp. cooling 18 °C OEM



MIX. VALVE-2Par. Designation Factory 10 20 30 40 50 Lev.


2 Heating system (exponent) MK= 1,10 HF


4 Room factor 100 % HF

5 Adaptation heating curve ON HF









14 Temperature elevation/ abatement heating circuit 0/ 8 K HF



18 P-portion Xp 2,0 %/ K OEM

19 Scanning time Ta 20 sec OEM

20 I-portion Tn 270 sec OEM

21 Running time servomotor 150 sec HF

22 End position function, valve 1 OEM





37 Mixer lead time OFF HF

38 Regulation offset 0 HF

50 Cooling switch-on point, OT OFF HF

51 Cooling max. point, OT 35 °C HF

52 Cooling reference fl ow temp. at switch-on point 18 °C HF

53 Cooling reference fl ow temp. at max. point 24 °C HF

54 Cooling reference room temp. at switch-on point 23 °C HF

55 Cooling reference room temp. at max. point 28 °C HF

56 Min. temp. cooling 18 °C OEM



HEAT GENER.Par. Designation Factory 10 20 30 40 50 Lev.

1 H-GEN model 1/ 2/ 5 HF

2 Start-up protection H-GEN OFF/ 3 HF

3 Minimum temperature limit H-GEN 5/ 48/ 65/ 75 °C HF

4 Maximum temperature limit H-GEN 75/ 85 °C HF

5 Mode of action minimum temperature limit H-GEN 1 HF

6 Sensor mode operation for H-GEN 1 OEM

7 Minimum burner running time 2 Min HF

8 Burner switching difference I 6 K HF

9 Burner switching difference II 12 K HF

10 Time-out stage II 10 HF

11 Release mode stage II 1 HF

12 DHW charging mode 1-2 stage 2 HF

13 Lead time, boiler circuit pump 1 Min HF

14 Follow-on time, boiler circuit pump or parallel boiler release 5 Min HF

15 Search time feed pump, primary pump 5 Min HF

16 Exhaust gas temperature monitoring OFF HF

17 Exhaust gas limit value 200 °C HF

18 Boiler gradient OFF OEM

19 Modulation P-portion Xp 5 %/ K OEM

20 Modulation scanning time Ta 20 sec OEM

21 Modulation adjustment time Tn 180 sec/ °C OEM

22 Modulation running time 12 sec HF

23 Modulation starting time 200 sec HF

24 Modulation start-up output 70 HF

25 Outside temperature block OFF OEM

26 Basic charge elevation 0 K/ 10K OEM

27 Minimum temperature limit, heating circuits 5/ 38/ 65 °C HF

28 Switching difference, minimum temperature limit Heating circuits 2 K OEM

29 H-GEN forced discharge OFF HF

30 OEM Maximum limit 110 °C OEM

31 Minimum load control OFF OEM

34 Output limitation heating 100 % HF

35 Output limitation hot water 100 % HF

36 ET blocking 2.burner stage OFF HF

37 Running time meter 1 HF

38 DHW release regulator (CD) ON HF

39 Emergency operation temperature H-Gen (e.g. for 70-8) 70 °C HF

40 Heat balance (from V3.2) ON HF

41 Reset heat balance HF

42 Volumetric fl ow rate0,0 l/ Min

HF0,0 l/ IMP

43 Density, medium 1,00 kg/ l HF44 Specifi c thermal capacity, medium 4,2 HF

RESET ST-1 Reset counters starts and running time, stage 1 OEMRESET ST-2 Reset counters starts and running time, stage 2 OEM

2

OFF

5 °C

10 K


RETURN CONTRPar. Designation Factory 10 20 30 40 50 Lev.

1 Minimum limit return temperature / referance value return temperature 38 °C HF

2 Switch-off difference 2 K HF

3 Pump follow-on time 1 Min HF

SOLARPar. Designation Factory 10 20 30 40 50 Lev.

1 Switch-on difference 10 K HF


3 Minimum running time SOP 3 Min HF

4 Solar collector maximum temperature 100 °C HF

5 Solar tank maximum limit (KSPF) 65 °C HF

6 Solar mode of operation 2 HF

7 Heat generator cycle lock (only when parameter 06=1,3,4) 0,5 h HF

8 Solar priority parallel changeover 10 K HF

9 Solar heat balance OFF HFSOLAR RESET Reset heat balance HF

11 Volumetric fl ow rate 0,0 l/ Min HF0,0 l/ IMP12 Density, medium 1,05 kg/ l HF

13 Specifi c thermal capacity, medium 3,6 KJ/ kgK HF

14 Final switching-off temperature 120 °C HF

15 Test cycle solar charging switch-over 10 Min HF

16 Switch-over temperature (SLVF) 60 °C HF

17 Solar minimum temperature OFF HF

SOLID FUELPar. Designation Factory 10 20 30 40 50 Lev.

1 Minimum temperature 60 °C HF

2 Maximum temperature 95 °C HF

3 Switch-on difference 10 K HF


5 Clock block, heat generator 15 HF


MAIN SUPPLYPar. Designation Factory 10 Lev.

1 PI-amplifi cation factor, P-portion Xp 0 %/ K HF

2 PI-scanning time Ta 20 sec HF

3 PI -reset time Tn 600 sec/ °C HF

CASCADEPar. Designation Factory 10 Lev.

1 Switch-off difference 3 K OEM

2 Connecting delay 20 OEM

3 Switch-off delay 5 OEM

4 Switching output stage sequence 65 OEM

5 Stage reversal OFF OEM

6 Control stage 1 BE

7 Peak load stage OFF OEM

8 Group switch-over OFF OEM

9 DHW fast activation OFF OEM

10 Peak load elevation 10 K OEM

BUSPar. Designation Factory 10 20 30 40 50 Lev.

1 Bus address central device 10 HF

2 Bus right RS direct circuit 1 HF

3 Bus right RS mixer circuit 1 1 HF

4 Bus right RS mixer circuit 2 1 HF

BUFFERPar. Designation Factory 10 20 30 40 50 Lev.

1 Minimum temperature 5/ 20 °C HF

2 Maximum temperature 95 °C HF

3 Temperature elevation, H-GEN 8/ 10/ 12K HF

4 Switching difference 2/ 5/ 10K HF

5 Forced discharge OFF HF

6 Skimming function switch-on difference 10 K HF

7 Skimming function switch-off difference 5 K HF

8 Start-up protection OFF HF

9 Discharge protection OFF HF

10 Buffer mode of operation 2/ 3 HF

11 Pump follow-on time 3 Min HF

12 Switch-off reference value temp. 70 °C HF

13 H-GEN release temp. skimming function 60 °C HF


SERVICEPar. Designation Factory 10 20 30 40 50 Lev.

Service 1 (Cleaning ST1 )

1 Suspend message «CLEANING ST-1» for X days 7 BE

2 Cleaning according to fi xed date OFF BE

3 Cleaning according to fi xed interval OFF BE

4 Cleaning according to cleaning counter OFF BE

5 Reset cleaning display 1 BE

Service 2 (Cleaning ST2)

6 Suspend message «CLEANING ST-2» for X days 7 BE

7 Cleaning according to fi xed date OFF BE

8 Cleaning according to fi xed interval OFF BE

9 Cleaning according to cleaning counter OFF BE

10 Reset cleaning display 2 BE

Service 3 (maintenance ST1 )

11 Suspend message «MAINTENANCE ST-1» for X days 7 HF

12 Maintenance according to fi xed date OFF HF

13 Maintenance according to fi xed interval OFF HF

14 Maintenance according to maintenance counter OFF HF

15 Reset maintenance display 1 HF

Service 2 (maintenance ST2 )

16 Suspend message «MAINTENANCE ST-2» for X days 7 HF

17 Maintenance according to fi xed date OFF HF

18 Maintenance according to fi xed interval OFF HF

19 Maintenance according to maintenance counter OFF HF

20 Reset maintenance display 2 HF

ALARM 1Par. Designation 10 20 30 40 50 Lev.

1 Alarm 1 OEM

2 Alarm 2 OEM

3 Alarm 3 OEM

4 Alarm 4 OEM

5 ... 20 Alarm 5 - 20 OEM

21 Reset fault signals OEM

ALARM 2 (can ony be activated with H-Gen 5)Par. Designation 10 20 30 40 50 Lev.

1 Alarm 1 OEM

2 Alarm 2 OEM

3 Alarm 3 OEM

4 Alarm 4 OEM

5 ... 20 Alarm 5 - 20 OEM

21 Reset fault signals OEM


FAULT REPORTING OVERVIEW TopTronic®TStatus Designation Fault type Code Remark

System External sensor Interruption 10-0

System External sensor Short-circuit 10-1

System Boiler sensor Interruption 11-0

System Boiler sensor Short-circuit 11-1

System Flow sensor 1 Interruption 12-0 MC1=off, YK1=no current

System Flow sensor 1 Short-circuit 12-1 MC1=off, YK1=no current

System Storage sensor Interruption 13-0

System Storage sensor Short-circuit 13-1

System VE 2 Interruption 14-0

System VE 2 Short-circuit 14-1

System VE 2 Alarm 14-7







System Solar tank sensor Interruption (KSPF) 17-0

System Solar tank sensor Short-circuit (KSPF) 17-1

System Flow sensor 2 Interruption 18-0 MC2=off, YK2=no current

System Flow sensor 2 Short-circuit 18-1 MC2=off, YK2=no current

System Collector sensor Interruption (KVLF) 19-0

System Collector sensor Short-circuit (KVLF) 19-1

System Room sensor (RS) Interruption 20-0

System Room sensor (RS) Short-circuit 20-1

System Burner 1 No switching off (1 min.) 30-2 With par. log. alarm can be switched off

System Burner 1 No switching on (10 min.) 30-3 With par. log. alarm can be switched off

System Burner 2 No switching off (1 min.) 31-2 With par. log. alarm can be switched off

System Burner 2 No switching on (10 min.) 31-3 With par. log. alarm can be switched off

System Exhaust gas temperature Exceeding 33-5

System Exhaust gas temperature SLT triggered 33-8

System Cleaning stage 1 Triggering by date 40-1

System Cleaning stage 1 Triggering by interval 40-2

System Cleaning stage 1 Triggering by counter 40-4

System Maintenance stage 1 Triggering by date 41-1

System Maintenance stage 1 Triggering by interval 41-2

System Maintenance stage 1 Triggering by counter 41-4

System Cleaning stage 2 Triggering by date 42-1

System Cleaning stage 2 Triggering by interval 42-2

System Cleaning stage 2 Triggering by counter 42-4

System Maintenance stage 2 Triggering by date 43-1

System Maintenance stage 2 Triggering by interval 43-2

System Maintenance stage 2 Triggering by counter 43-4

4 210 258 / 00 46

FAULT REPORTING OVERVIEW TopTronic®TStatus Designation Fault type Code Remark

Logical Boiler temperature Not reached (90 min.) 50-4

Logical Tank temperature Not reached (4 hr.) 51-4

Logical Flow temperature MC1 Not reached (1 hr.) 52-4

Logical Flow temperature MC2 Not reached (1 hr.) 53-4

Logical Room temperature HC Not reached (3 hr.) 54-4

Logical Room temperature MC1 Not reached (3 hr.) 55-4

Logical Room temperature MC2 Not reached (3 hr.) 56-4

System Lock by energy supply company ST 2 Address collision 70-0

System Activity No T2B signal 70-1

System Activity No FA signal 70-6

System Activity Regulator with address 10 is missing 70-8

System Activity Data bus error 70-9 No Hoval regulatorSystem HP return sensor Return min. temp. below setpoint 85-4System HP return sensor Return max. temp. exceeded 85-5

System QF Heat source min. temp. below setpoint 86-4

System QF Heat source max. temp. exceeded (cooling operation) 86-5

System QF Fault heat source sensor -- Standard signal «VE-x»System WPS Variable input HP fault 87-7System Pulse counter No pulse (5 min.) 90-0System Fault Warning W:XX Warning in automatic fi ring deviceSystem Fault Lock-out E:XX Fault in automatic fi ring deviceSystem Fault Blocking B:XX Fault in automatic fi ring device

SENSOR ALLOC.Par. Designation Factory 10 20 30 40 50 Lev.

1 Balancing external sensor 0 OEM

RS-T Balancing room sensor (only adjustable with RS-T) 0 HF

2 Balancing heat generator 0 OEM

3 Balancing tank sensor 0 OEM

4 Balancing fl ow sensor 1 0 OEM

5 Balancing fl ow sensor 2 0 OEM

6 Balancing solar collector sensor 0 OEM

7 Balancing solar buffer sensor 0 OEM

8 Balancing variable input 1 0 OEM



4 210 258 / 00 47

Copy of system installer

C O N F I R M AT I O N

The user (owner) of the system herewith confi rms that

- he has received adequate instruction in the operating and maintenance of the installation,

- received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components.

- and is consequently suffi ciently familiar with the installation.

Place, Date: Installation address: ...........................................................................

........................................................................................................................................ Type: .............................................................

Ser.No.: .............................................................

Year of manufacture: .........................................

System installer: System user:

............................................................................ ...........................................................................

Copy for plant user

C O N F I R M AT I O N

The user (owner) of the system herewith confi rms that

- he has received adequate instruction in the operating and maintenance of the installation,

- received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components.

- and is consequently suffi ciently familiar with the installation.

Place, Date: Installation address: ...........................................................................

........................................................................................................................................ Type: .............................................................

Ser.No.: .............................................................

Year of manufacture: .........................................

System installer: System user:

............................................................................ ...........................................................................

Technical information Assembly instructions · 2016. 6. 21. · - ÖNorm EN 13384 Flue gas systems...

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Transcript of Technical information Assembly instructions · 2016. 6. 21. · - ÖNorm EN 13384 Flue gas systems...