Subject to modifi cations | EN

Technical informationAssembly instructions

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

Uno-3 (95-125) boilers are suitable and licensed for use as heat generators for hot water heating systems with a permissible flow temperature of up to 100 °C1). They are designed for closed-circuit systems, but can also be installed in open systems as per EN 12828.1) See technical data

Uno-3 (95-125)Oil/gas boilers

These instructions are applicable to the following types:41-Uno-3 (95,110,125)

1. Important information1.1 Other instructions ...............................................................................................................................................................31.2 Safety information ...............................................................................................................................................................31.3 Regulations, official approvals ...........................................................................................................................................31.4 Guarantee ............................................................................................................................................................................4

2. Assembly2.1 Installation position .............................................................................................................................................................52.2 Setting up levelling ..............................................................................................................................................................52.3 Fitting the heat insulation ...................................................................................................................................................62.4 Fitting the casing .................................................................................................................................................................82.5 Installation of boiler controller ...........................................................................................................................................92.5.1 Boiler controller TopTronic® E ............................................................................................................................................92.5.2 Boiler controller T0.2 / T2.2 ...............................................................................................................................................9

3. Technical information3.1 Description of the boiler ...................................................................................................................................................103.1.1 The Uno-3 (95-125) complies with the following directives + standards ...........................................................................103.2 Technical data Uno-3 (95,110) for Switzerland ................................................................................................................. 113.3 Technical data Uno-3 (110,125) for the remaining countries ...........................................................................................123.4 Dimensions ........................................................................................................................................................................133.5 Dimensions without heat insulation and casing (transport dimensions) .......................................................................14

4. Installation4.1 Boiler room requirements .................................................................................................................................................164.2 Connection of the flue gas system and flue duct dimensions ........................................................................................164.3 Fitting the burner ...............................................................................................................................................................184.3.1 Sound insulation .............................................................................................................................................................184.4 Fuel ....................................................................................................................................................................................194.5 Electrical connection .........................................................................................................................................................194.5.1 Electrical connection of the burner ..................................................................................................................................194.5.2 Recommended cable cross sections: ..............................................................................................................................194.5.3 Safety measures relating to EMC assembly ....................................................................................................................194.6 Flue gas regulator set .......................................................................................................................................................204.6.1 Flue gas and performance diagrams ...............................................................................................................................214.7 Flow mixing loop / minimum limitation of the boiler return temperature .......................................................................224.8 Setting the temperature regulators ...................................................................................................................................224.9 Safety valves......................................................................................................................................................................224.10 Charging pump (boiler with free-standing calorifier).......................................................................................................224.11 Heating pump.....................................................................................................................................................................22

5. Commissioning5.1 Water quality ......................................................................................................................................................................235.2 Filling the heating system .................................................................................................................................................245.3 Filling the calorifier (if present) ........................................................................................................................................245.4 Commissioning ..................................................................................................................................................................245.5 Oil/gas burner ....................................................................................................................................................................245.6 Handover to the operator / storage ...................................................................................................................................24

6. Maintenance6.1 Information for fire inspector / chimney sweep regarding emission monitor key ..........................................................256.2 Cleaning .............................................................................................................................................................................266.2.1 Preparatory work.............................................................................................................................................................266.2.2 Cleaning (dry or wet method) ..........................................................................................................................................266.2.3 Putting into operation again ............................................................................................................................................266.3 Safety temperature limiter - Reset ....................................................................................................................................26

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TABLE OF CONTENTS

1. Important information1.1 Other instructionsAll instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the in-structions can be found enclosed with the components.Further information sources - Hoval catalogue - Standards, regulations

1.2 Safety informationThe system may only be placed in operation if all the rel-evant standards and safety regulations have been com-plied with. At least the following conditions must be satis-fied for a trial operation:1. Safety valve installed (closed system)2. Control in operation (connected to the mains current

supply system)3. Sensor for the safety temperature limiter mounted in

the immersion sleeve4. System filled with water5. Expansion vessel connected6. Flue gas connectors connected to the flue gas pipe-

line at the chimney or flue7. An adequate supply of fresh air must be guaranteed8. The burner is preset

1.3 Regulations, official approvalsThe following regulations are to be complied with for in-stallation and operation:

Germany - DIN EN 12831 Heating systems in buildings – Method for calculation of the design heat load.

- EN 303 Heating boilers with forced draught burners. - DIN EN 12828 Sheet 1 and 2Heating systems in buildings – design of water-based heating systems.

- DIN 4755 Oil-fired systems.Design, construction and safety engineering require-ments.

- DIN 4756 Gas-fired systems; construction, execution, technical safety requirements, planning and execution.

- DIN 18160 House chimneys; requirements, planning and execution.

- TRD 702 Steam boiler plants with calorifiers of the group II.

- DIN EN 13384 Chimneys – Thermal and fluid dynamic calculation methods.

- TRD 721 Safety devices against excess pressures / safety valves / for steam boilers of Group II.

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

- DIN 57 116 / VDI 0116 Electrical equipment for firing systems (VDE Regulation).

- For further standards applicable in Germany, see ap-pendix N-430 020.

Austria - ÖNorm 7550 - ÖNorm B 8130 Open water heating systems; safety de-vices.

- ÖNorm B 8131 Closed water heating systems; safety, execution and testing requirements.

- ÖNorm B 8133 Hot water production systems; technical safety requirements.

- ÖNorm B 8136 Heating systems, space requirements and other building requirements.

- ÖNorm M 7515 Calculations of dimensions of chim-neys; terminology, calculation procedure.

- ÖNorm H 5171 Heating systems, construction engi-neering requirements.

- ÖVGW TR-Gas G1 Technical directives for low pres-sure gas installations.

- ÖNorm M 7445 Gas blower burner

Switzerland - Requirements of the VKF Cantonal Fire Insurance As-sociation.

- Fire brigade regulations. - Requirements of the SVGW Swiss Association of Gas and Water Suppliers.

- SWKI 91-1 Aeration and ventilation of the boiler instal-lation room.

- SWKI 88-4 Water treatment for heating, steam and air conditioning systems.

- SWKI 93-1 Safety engineering installations for heating systems.

- KRW Corrosion through halogen compounds. - KRW/VSO/FKR Plug-in electrical connections on heat-ing boilers and burners

and further regulations and standards issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and the legislative body.

Also to be complied with are the regulations of the local building authorities, insurance companies and chimney sweeping operations. The regulations of the responsible gas supply company are also to be complied with and any necessary official approval obtained.

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IMPORTANT INFORMATION

1.4 GuaranteeProper function is only guaranteed providing these in-structions are followed and the boiler is regularly main-tained by a licensed specialist. (Maintenance contract). The rectification of faults and damage as a result of con-taminated operating materials (gas, water, combustion air), unsuitable chemical additives and an inadmissibly high lime content of the heating water, improper handling, faulty installation, unauthorised modifications and dam-age due to the use of force do not fall under our guaran-tee obligations, this also applies to corrosion due to halo-gen compounds, e.g. from spray cans, paints, adhesives, halogenated fluids, solvents and cleanings agents.

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IMPORTANT INFORMATION

2. Assembly

2.1 Installation position

Where limited space is available, the Uno-3 can be trans-ported standing on the door. Hex nuts are mounted be-hind the door as supports for this purpose (Fig. 01). After transport, they can simply be screwed back to the bracket.

Release and screw back 6 transport counter nuts before commissioning.

Counter nut

Fig. 01

2.2 Setting up levellingA special foundation plate for the boiler is not an essen-tial, but it is recommended.

Space requirementfor fitting the heat insulation and casing panelling:• at least 40 cm each on the left

and right side of the boiler,• controller side min. 70 cm.If the space between the boiler and the wall is less, all heat insulation and casing must be fitted before the boiler can be pushed into its final position.

Do not connect lines until the heat insulation and casing have been fitted to the boiler!

NOTEThere must always be enough space be-tween the back of the boiler and the wall to allow easy access to the cleaning aperture in the flue gas collector.

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

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:

NOTEClose the boiler door and lock it in position before changing the attachment of the door

1

2

Fig. 02

1. Pull up the semicircular rivet (1, Fig. 02).2. Change over the swivel arm (2).3. Insert the semicircular rivet (1) on the other side.4. Fit the burner plug and the fire protection switch (if

fitted, Austrian version) on the other side (9, Fig. 08 and point 4.5.1).

NOTEThe cable must not touch any hot parts!

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ASSEMBLY

Levelling:Using a spirit level, align the upper edge of the boiler wa-ter jacket (longitudinal axis of the boiler) until it is precise-ly horizontal or sloping very slightly upwards towards the rear by inserting the plinth rails correspondingly, to allow the boiler to vent properly.

Before fitting the burner, first fit the double door (8b, Fig. 05) (door casing).

2.3 Fitting the heat insulation

1. Mount the front retaining bracket (1, Fig. 04) with hexagon screws M8, nuts and U-washers, aligned horizontally, to the front wall of the boiler. - Attach C-clips.

2. Mount the rear retaining bracket (2) with hexagon screws M8, nuts and U-washers aligned horizontally. - Attach C-clips.

3. Place the insulation mat (3) around the boiler body (with the joint at the top, black side facing outwards).

4. Attach the insulation mat (3) using 2 plastic straps (4) and strap fasteners (4a): - Tension springs (4b) serve for additional fixing - Do not overtighten the straps (reduced insulating value)

5. Attach the insulation mats (5/5a/5b) to the pins pro-vided on the rear wall of the boiler and secure with retaining discs, Fig. 03 (ø 38).

6. Attach insulation panels (6/6a/6b/6c) to the pins weld-ed onto the flue gas collector and secure with the re-taining discs, Fig. 03 (ø 38) provided.

7. Attach insulation panel (7) to the pins welded onto the front wall of the boiler and secure with the retaining discs, Fig. 03 (ø 38) provided.

The remaining 3 insulation mats (8a/10, Fig. 05) are fitted after mounting the casing.

Fig. 03

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ASSEMBLY

Fig.

04

7

4a

6a

6c

55a

3

4b

C-c

lips

1

6b6

2

4

5b

C-c

lips

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ASSEMBLY

2.4 Fitting the casing1. Fix hexagon bolts with U-washers and hexagon nuts

(8, Fig. 05) Insert thermal insulation (8a) into the boil-er door. Attach the door casing (8b) to the boiler door using hexagon cap nut.

The boiler controller can be mounted on the right or left side panel (9a).

2. Attach the burner cable (9, Fig. 08) to the right or left side wall (9a, Fig. 05) and pull the burner cable through the opening (13a, Fig. 09, Fig. 10). See also point 4.5.1

NOTEThe cable must not touch any hot parts

Fig. 05

15

8a8b

9a

8

9a

13b

12

10

11a

11

8b 8

16

14

T0.2 / T2.2Fig. 06 Fig. 07

13c

13

13b

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ASSEMBLY

3. Attach right and left side wall (9a, Fig. 05) onto the front retaining brackets (1, Fig. 04) and rear retaining brack-ets (2, Fig. 04) with self-tapping screws ø 4,8 x 38.

9Fig. 08

4. Place 2 insulating mats (10, Fig. 05) left and right in longitudinal direction (to prevent vertical air circula-tion).

5. Attach rear wall (11/11a, Fig. 05) to the angled edges of the side walls (9a, Fig. 05) with self-tapping screws ø 3,5 x 6,5.

2.5 Installation of boiler controller2.5.1 Boiler controller TopTronic® E

12a

12b

1213a

12c

Fig. 09

6. Mount the special screws with nuts (12a, Fig. 09) on the side panel (9a, Fig. 05). Then hook the boiler controller (12, Fig. 09) into the side wall with the re-cesses for the special screws and secure it with the self-tapping screws ø 3,5 x 6,5 and serrated washers (12b, Fig. 09).

7. Pull the capillaries with the immersion sensors (13, Fig. 07) ) through the opening (13a, Fig. 09) in the side panel, insert them into the immersion sleeve (13b, Fig. 05 / Fig. 07) as far as the stop and fix in position with retaining spring (13c, Fig. 07).

NOTEThe capillaries must not be folded or kinked

8. Close the boiler controller and screw on (12c Fig. 09),

continue with point 12.

2.5.2 Boiler controller T0.2 / T2.2

16

12b

14

12a

13a Fig. 10

9. Mount the special screws with nuts (12a, Fig. 10) on the side panel (9a, Fig. 05). Then hook the boiler controller (16, Fig. 10) into the side wall with the re-cesses for the special screws and secure it with the self-tapping screws ø 3,5 x 6,5 and serrated washers (12b, Fig. 10).

10. Pull the capillaries with the immersion sensors (13,

Fig. 07) through the opening (13a, Fig. 10) in the side panel, insert them into the immersion sleeve (13b, Fig. 05 / Fig. 07) as far as the stop and fix in position with retaining spring (13c, Fig. 07).

NOTEThe capillaries must not be folded or kinked

11. Attach cover plate to the boiler controller (14, Fig. 06 / Fig. 10) with self-tapping screws ø 3,5 x 6,5 and ser-rated lock washers.

12. Place casing cover (15, Fig. 05) in position and attach on the left and right sides with 2 self-tapping screws ø 4,8 x 13.

13. Affix labels and where applicable, mount manual holder on the side.

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ASSEMBLY

The flue gas temperatures can be varied within a specific range through the installation of various regulator combi-nations.

3. Technical information3.1 Description of the boilerThe Uno-3 is a threepass boiler. At the end of the cir-cular cylindrical combustion chamber, the flame gases flow through several cylindrical tubes arranged above the combustion chamber and towards the front to the turning chamber, from where they flow through rectangular ducts (thermolytic heating surface) towards the rear and reach the flue gas collector.

3.1.1 The Uno-3 (95-125) complies with the following directives + standards

We hereby declare that the product described, as an individual appliance, complies with the standards, guidelines and technical specifications laid down.

Directives: 90/396/EC "Gas Equipment Directive" 92/42/EC "Efficiencydirective" 73/23/EEC "Low-voltage directive" 89/336/EEC "Electromagnetic compatibility" 97/23/EC "Pressure Equipment Directive" (PED) at maximum boiler temperature 90 °C

Regulations: Stability prEN14394:2001 Building requirements EN303-1, EN303-2, EN303-3 Low voltage DIN VDE 0722 / Éd. 04.83 EMC EN 50082 Part 1 / Éd. 01.92

Fig. 11

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TECHNICAL INFORMATION

3.2 Technical data Uno-3 (95,110) for Switzerland

Type (95) (110)

• Nominal heat output at 80/60 °C 1 kW 95 110• Heat output range (heating oil EL, Variant 2) kW 46-95 51-110• Maximum heat input kW 102,1 118,3• Maximum boiler operating temperature 2 °C 90 90• Safety temperature limiter setting (water side) 2 °C 110 110• Operating/test pressure at max. operating temperature 90 °C 2 bar 4,0/5,2 4,0/5,2• Maximum boiler operating temperature 3 °C 105 105• Safety temperature limiter setting (water side) 3 °C 120 120• Operating pressure at max. operating temperature 105°C 3 bar 3,0 3,0• Minimum boiler operating temperature °C see table of operating conditions (below)• Minimum boiler return temperature °C see table of operating conditions (below)• Minimum flue gas temperature at boiler °C see table of operating conditions (below)• Regulator set for 160 °C flue gas temperature 3R5+

1R2/2903R5+

2R3/290• Boiler efficiency at full load at 80/60 °C

(related to net/ gross calorific value, heating oil EL)% 92,6/87,4 92,7/89,5

• Boiler efficiency at partial load 30 % at return 37 °C(according to EN 303) (Relative to net/gross calorific value heating oil EL)

% 94,8/89,4 94,8/89,4

• Standard efficiency at 75/60 °C (DIN 4702 Part 8)(related to net/gross calorific value, heating oil EL)

% 95,7/90,3 95,9/90,47

• Standby loss qB at 70 °C Watt 400 400• Flue gas resistance at nominal output

160 °C flue gas temperature, 12.5 % CO2, 500 m above sea level (tolerance ± 20 %)

mbar 0,65 0,89

• Flue gas mass flow at nominal output12,5 % CO2 heating oil

kg/h 162 188

• Flow resistance boiler 4 z-value 0,2 0,2• Water flow resistance at 10 K mbar 13,35 17,90• Water flow resistance at 20 K mbar 3,34 4,47• Water flow volume at 10 K m3/h 8,17 9,46• Water flow volume at 20 K m3/h 4,09 4,73• Boiler water content litres 250 250• Boiler gas content m³ 0,1848 0,1848• Insulation thickness of boiler body mm 80 80• Weight (incl. casing) kg 391 391• Combustion chamber dimensions Ø-inside x length mm ø 440x974 ø 440x974• Combustion chamber volume m³ 0,148 0,148• Dimensions see Dimensions• Maximum draught/underpressure at flue gas outlet Pa -30 -30

1 At nominal output, the pollutant limit values and flue gas losses as per regulation LRV (92) are complied with.2 Boiler controller E13.4 TopTronic® E und T2.23 Boiler controller E13.5 TopTronic® E und T0.24 Flow resistance boiler in mbar = flow rate (m3/h)2 x z

Possible operating conditions: Heating oil EL Natural gas HFuel Variant 1 Variant 2 Variant 3 Variant 1 Variant 2 Variant 3

min. flue gas temperature °C 130 110 130 130 110 130min. boiler temperature °C 48 50 52 58 60 62min. return temperature °C 35 38 No lower limit 45 48 No lower limitReturn temperature control yes yes no yes yes noBoiler start protection 1 no no yes no no yes

1 Boiler minimum temperature limit effective on group actuators

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TECHNICAL INFORMATION

Type (110) (125)• Nominal heat output at 80/60 °C kW 110 125• Heat output range (heating oil EL, natural gas H: variant 1 and 3) kW 70-110 70-125• Heat output range (heating oil EL, natural gas H: variant 2) kW 50-110 50-125• Maximum heat input kW 118,3 135,8• Maximum boiler operating temperature 1 °C 90 90• Safety temperature limiter setting (water side) 1 °C 110 110• Operating/test pressure at max. operating temperature 90 °C 1 bar 4,0/5,2 4,0/5,2• Maximum boiler operating temperature 2 °C 105 105• Safety temperature limiter setting (water side) 2 °C 120 120• Operating pressure at max. operating temperature 105 °C 2 bar 3,0 3,0• Minimum boiler operating temperature °C see table of operating conditions (below)• Minimum boiler return temperature °C see table of operating conditions (below)• Minimum flue gas temperature at boiler °C see table of operating conditions (below)• Regulator set for 170 °C flue gas temperature 3R5+2R3 5R3+2R3• Boiler efficiency at full load at 80/60 °C

(related to net/ gross calorific value, heating oil EL)% 92,7/87,6 92,8/87,6

• Boiler efficiency at partial load 30 % at return 37 °C(according to EN 303) (Relative to net/gross calorific value heating oil EL)

% 94,8/89,4 94,9/89,5

• Standard efficiency at 75/60 °C (DIN 4702 Part 8)(related to net/gross calorific value, heating oil EL)

% 95,9/90,5 95,8/90,4

• Standby loss qB at 70 °C Watt 400 400• Flue gas resistance at nominal output

180 °C flue gas temperature, 12.5 % CO2, 500 m above sea level (tolerance ± 20 %)

mbar 0,89 1,10

• Flue gas mass flow at nominal output12,5 % CO2 heating oil

kg/h 188 222

• Flow resistance boiler 4 z-value 0,2 0,2• Water flow resistance at 10 K mbar 17,90 24,80• Water flow resistance at 20 K mbar 4,47 5,80• Water flow volume at 10 K m3/h 9,46 11,10• Water flow volume at 20 K m3/h 4,73 5,40• Boiler water content litres 250 250• Boiler gas content m³ 0,1848 0,1848• Insulation thickness of boiler body mm 80 80• Weight (incl. casing) kg 391 391• Combustion chamber dimensions Ø-inside x length mm ø440x974 ø440x974• Combustion chamber volume m³ 0,148 0,148• Dimensions see Dimensions• Maximum draught/underpressure at flue gas outlet Pa 30 30

1 Boiler controller E13.4 TopTronic® E und T2.22 Boiler controller E13.5 TopTronic® E und T0.24 Flow resistance boiler in mbar = flow rate (m3/h)2 x z

3.3 Technical data Uno-3 (110,125) for the remaining countries

Possible operating conditions: Heating oil EL Natural gas HFuel Variant 1 Variant 2 Variant 3 Variant 1 Variant 2 Variant 3

min. flue gas temperature °C 130 110 130 130 110 130min. boiler temperature °C 48 50 52 58 60 62min. return temperature °C 35 38 No lower limit 45 48 No lower limitReturn temperature control yes yes no yes yes noBoiler start protection 1 no no yes no no yes

1 If the boiler temperature is or drops below the minimum boiler temperature (variant 3) and there is no return maintenance then the load must be switched off using a corresponding control function.

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TECHNICAL INFORMATION

3.4 Dimensions

Fig. 12

1 Flow2 Return3 Safety flow R 1¼″ (95-110) 4 Flow for calorifier R 1¼″5 Return for calorifier R 1¼″6 Drain R 1″ (95-110) 7 Flue gas outlet Ø outside, wall thickness 3 mm8 Cleaning opening9 Boiler control panel (optional left or right)

10 Socket: width 50 mm11 Boiler door right swivelled (optional left swivelled)12 Flue gas collector-cleaning opening R1″13 Optional vibration damper, width 80 mm, height 50 mm14 Burner sound absorbing hood

- without rollers (95,110)

Uno-3Type

l b h a c d e f g i k m n o p qØ

r s t u v w

(95-125) 1328 780 1050 680 660 90 400 140 170; 4xM8 140 545 799 980 250 - 179 130 1080 104 192 530 640

Fig. 13

DN 50, PN 6 (95-110)}

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TECHNICAL INFORMATION

3.5 Dimensions without heat insulation and casing (transport dimensions)

Boiler (without calorifier) incl. swivel flange, connections and flue gas collector

Fig. 14

Required minimum width of door and corridor for bringing in the boilerThe following values are the calculated minimum values

K =B

× LT = Door width

T K = Corridor width

B = Boiler width

T =B

× LL = Maximum boiler length

T

K

T

< 150B

L

Fig. 15

Example calculation for the required corridor width

Door width T = 800

Uno-3 (95-125)680

K =800

x 1513 = Corridor width ≥ 1286

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TECHNICAL INFORMATION

Minimum overall unit dimensionsChaudière en position deboutBoiler uprightBoiler upright with swivel flange at bottom, transport on trolley or rollers provided by the client.

Example calculation for the required corridor widthDoor width T = 800

Uno-3 (110-125)680

K =800

x 1084 = Corridor width ≥ 922

Fig. 16

1 Transport board (by client) 3 Boiler door (can be removed)2 Pipe as roller (by client) 4 Threaded rod

Boiler heightwith socket and without socket and

Uno-3Type

flue gas collectorH1

flue gas collectorH2

WidthB

LengthL

(95-125) 1513 1080 680 1084

Measurements boiler doorSpace for use of a low lift elevating platform

Fig. 17

max. width forlow lift elevating

platform

Floor distance

Uno-3Type

with boiler door without boiler door

a b c

(95-125) 490 50 175

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TECHNICAL INFORMATION

Existing flue gas systems may require upgrad-ing or adjustment of the flue duct cross-sec-tion as indicated by a chimney engineer.

The correct functioning of the flue duct, i.e. the generation of the required delivery pressure depends on:a) the type (nature) of the chimney (thermal insulation,

interior surface roughness, sealing etc.)b) the connection of the boiler to the chimney according

to specificationc) establishing the correct flue duct cross-section dimen-

sion.

re: a)Chimneys according to EN 13384, part 2, execution types I and II are appropriate for modern firing systems (advice from the chimney specialist is necessary).

re: b)The flue gas pipe connecting the boiler to the flue gas system must be as short as possible and placed at an angle of 30-45°.

The entry location of the flue gas pipe must be carefully sealed.

The introduction of the flue gas pipe into the chimney (a) must be executed so that no condensate water can flow from the chimney into the flue gas pipe and the boiler (Fig. 18).

a

Fig. 18

Where possible, avoid 90° bends in the flue gas system!Flue gas pipes longer than 1 m are to be insulated.

4. Installation4.1 Boiler room requirementsRegarding the building specifications for boiler rooms and their supply and extract air handling, the current build-ing supervisory office regulations specific to the state or country are to be observed. In Germany the firing regula-tions for the individual Bundesländer are to be complied with.

Make sure there is an adequate supply of fresh air to the boiler room,to ensure that the combustion air supply necessary for all the firing systems operated there can flow in without hindrance and that no oxygen deficiency occurs for the 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 oc-curs. An opening or line leading into the open air of at least 150 cm2. For every kW in excess of 50 kW, a further 2 cm2 must be calculated. In rectangular openings, the ratio of the sides should not exceed 1.5:1; if a grid is fit-ted, an appropriate allowance must be added so that the free cross-section area reaches the amount given above.In Austria ÖNorm H 5171 additionally stipulates a flue air aperture. This must have a minimum cross section of 180 cm2 up to a rated heat output of 100 kW. For every further kW, the cross-section must be increased by 1 cm2.

NOTEThe flue gas system must be watertight, ac-id-proof and approved for the corresponding flue gas temperatures.

As a general rule, only one heat generator should be connected to the chimney! When using two heat generators, the corresponding regulations must be observed.

4.2 Connection of the flue gas system and flue duct dimensions

To guarantee economic and fault-free operation, boiler and chimney must be mutually adapted to create a func-tional unit.

Moisture-resistant and acid-proof flue gas systems must be used in new installations.

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INSTALLATION

!ATTENTIONNormally only one heat producer may be con nected to the chimney!

lue gas pipes longer than 1 m are to be insulated. If an adapter (reducer) from the flue gas outlet of the boiler to the entry point into the flue gas system is required, it must take the form of a slim cone.

De lachaudière

Versla cheminée

from the boiler

to the chimney

Fig. 19

re: c)Dimensioning the chimney cross section. The cross sec-tions are to be calculated for boilers without delivery pres-sure requirement according to EN 13384. (Please also observe DIN 18160, Part 1 "Domestic chimneys"). Take into consideration location-specific factors (hillside loca-tion of the building, chimney position, slope of the roof, chimney stack exit shape, etc.)!In Switzerland, take note of SIA Recommendation 384/4!

In Austria, calculation is performed as prescribed by ÖNorm M 7515.

Non-binding guide values for dimensioning of the flue duct for boiler types Uno-3 (95-125).

Inside diameter of flue duct in mm

Boiler typeUno-3 kW *

Chimney height 11-15 m

95 95 ~ 180110 110 ~ 180125 125 ~ 180

* kW = maximum boiler output

Basic data:Flue gas pipeline 5 m long, two 90° elbows and one 45° elbow, outside air 15°C, height above sea level max. 800 m, flue gas pipeline same ø as flue gas connector on boiler.

You are recommended however to use the services of the chimney specialist right from the planning stage!

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INSTALLATION

4.3 Fitting the burner - Depending on the size of the burner flange, an interme-diate flange may be required to attach the burner.

- To allow the burner to be swung out 90° to the left or right, the connections must be flexible and routed to the burner in sufficiently large loops.

- The cavity between burner pipe and boiler flange must be insulated with the fireproof fibre provided.

4.3.1 Sound insulation - Gas pipes must be mounted in such a way that no vi-brations are transferred to the building.

- The burner can be equipped with a sound-absorbing hood.

- We recommend that you install silencers downstream of the boiler in the flue gas pipe.

NOTEDo not overtighten boiler door screws.

Uno-3 A B C D E F G H J L MØ Ø Ø

90-125 140 170 400 165 119 248 440 974 307 30 25

Fig. 20

Fig. 21

Fill the gap with insulating material

A

EJ

GH

innenL

M

inside

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INSTALLATION

4.4 Fuel

!ATTENTIONThe boiler is only to be operated with the fuel stated on the boiler rating plate.

Uno-3 boilers are suitable for the combustion of the fol-lowing fuels: - Heating oil EL in accordance with DIN 51 603 / SN 181 160 / 2 / ÖNorm C 1109

- Heating oil L in accordance with ÖNorm C 1108 - All fuel gases as defined by DVGW process sheet G 260

4.5 Electrical connection

Electrical connections must be established by a licensed and qualified electrician. The connection diagram is located in the ter-minal box of the heat generator; the circuit diagram is supplied separately. Refer to this for the conductor cross section required for the mains supply.

WARNINGLe générateur de chaleur ne peut être mis hors tension qu’en le coupant du réseau (in-terrupteur multipôles par ex.).

WARNINGAll electric power supply circuits must be swit ched off before accessing the terminals.

Applicable only to Austria and Germany:An electrical circuit diagram is supplied with the boiler controls.Please affix the correct connection diagram to the inside of the terminal cover.

Important!A main switch must be installed on-site in the supply line which performs an all-poles cut-out and has a clearance of at least 3 mm between the open contacts.

Applicable only to Switzerland:The system-related electrical circuit diagram must be re-ferred to when making the electrical connection!

4.5.1 Electrical connection of the burner - The burner must be connected to the boiler with the stand ard plug-in connection.

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

4.5.2 Recommended cable cross sections:

Cable type Cross-section Length

Power supply of the heat generator (230V)

min. 1,5 mm2 with 13A Protection unlimited m

Power supply of the heat generator (400V)

min. 1,0 mm2 with 10A Protection unlimited m

Conduttori sotto tensione di rete di attuatori: min. 1,0 mm2 unlimited m

Low-voltage cables(sensors) min. 0,5 mm2 max. 50 m

Data bus lines (shielded cable) 2×2×0,6 mm2 max. 100 m

4.5.3 Safety measures relating to EMC assembly

1. In the case of control units with their own mains sup-ply, it is imperative that cables carrying mains volt-age are routed separately from sensor or data bus cables. 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 designed as an independent electrical circuit. Neither fluorescent lamps nor other sources of interference for the rel-evant machinery may be connected or capable of connection.

FuseBoiler roomemergency switch

Heat Generator

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

Fig. 22

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

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INSTALLATION

4.6 Flue gas regulator set

The flue gas regulators fitted in each case are listed on a label on the boiler casing (side section, 9a, Fig. 05).

The installer can change the flue gas regulator set fitted and thus vary the flue gas temperature within a specific range.

NOTEEven in partial load operation, the flue gas temperature must not fall below 100 °C.

Inspection hole

Regulators

Fig. 23

20 4 213 736 / 00

INSTALLATION

4.6.1 Flue gas and performance diagrams

Uno-3 (95)

kW°C

kW

°C3R5+1R2/290

3R5+2R3/290

3R5+2R3/290

Uno-3 (110)

The curves shown here represent an average value based on measurements taken with burners from various manufacturers. Deviations of ±10 % are normal.

kW = Heat capacity°C = flue gas temperature with heating oil EL, Boiler flow 80 °C Return flow 60 °C CO2 = 13 % During the combustion of natural gas or heating oil L, the flue gas temperature is approx. 15 °C higher.

Uno-3 (125)

°C

kW

100110120130140150160170180190

60 65 70 75 80 85 90 95100110120130140150160170180190

70 75 80 85 90 95 100 105 110

100110120130140150160170180190

70 80 90 100 110 120 130

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INSTALLATION

Heating Water

§The European Standard EN 14868 and the di-rective VDI 2035 must be observed.

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

plants without signifi cant oxygen intake (plant type I ac-cording to EN 14868).

• Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or

- intermittent oxygen intake (e.g. where frequent refill-ing 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 heating water in existing installations (e.g. exchange of boiler) conforms to VDI 2035.The Directive VDI 2035 applies equally to the replace-ment 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 corrosion 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 between 8.3 and 9.5 after 6-12 weeks of heating operation.

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

is generally best suited as heating medium, i.e. as fi ll-ing and replacement water. However, as not all drink-ing water is suitable for use as fi lling and replacement water the water quality must fulfi l the standard set in VDI 2035. Should the mains water available not be suit-ed 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 exceeded (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water con-tent 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 2035Totalhardnessofthefillingwaterupto...

[mol/m3] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0f°H <1 5 10 15 20 25 30 >30d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8e°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 >300Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600Boiler size of the individual boiler maximumfillingquantitywithoutdesalination

to 50 kW NO REQUIREMENT 20 l/kW50 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.

Flue gas temperature under other operating conditions

Influence of the boiler water temperature on the flue gas tem perature.A change in the boiler water temperature of ±10 K results in a change of approximately ±6 K in the flue gas tempe-rature.

Influence of the CO2 content in the flue gases.A change in the CO2 content of ±1 % changes the flue gas tem perature by approx. ±8 °C.

Key to regulator designation

No. of regulators Regulator width (example: 5 units)3R5/290 Length of the regulators

4.7 Flow mixing loop / minimum limitation of the boiler return temperature

Hydraulic and control measures must be provided to en-sure that the temperatures do not fall below the permis-sible minimum boiler flow and return temperature under any operating conditions.

4.8 Setting the temperature regulators - without heating regulator:Set the boiler temperature in accordance with the out-side temperature.

- with heating regulator:The heating regulator automatically sets the correct boiler temperature. The boiler temperature varies be-tween the minimum and maximum boiler temperatures entered.

If a calorifier is connected, the priority circuit disables the boiler temperature regulator until the temperature is reached. The boiler tem-perature can rise to approx. 85 °C.

4.9 Safety valvesThe heating system and hot water supply must each be protected with one safety valve against impermissibly high pressures. The discharge capacity of the heating system safety valve must correspond to the boiler’s maxi-mum nominal heat output. The valve is installed in the safety flow. In Germany, only safety valves with the code letter "H" in the approval mark may be connected, and they must always be connected at the boiler safety flow. Water shortage protection in accordance with EN 12828 Part 2 Section 9 is mandatory

4.10 Charging pump (boiler with free-standing calorifier)

Speed of rotation and output regulation must correspond to the requirements of the free-standing calorifier. Setting carried out by the heating installation engineer.

4.11 Heating pumpSpeed of rotation and output regulation must correspond to the requirements of the system. They are to be set by the heating installation engineer.

22 4 213 736 / 00

INSTALLATION

Heating Water

§The European Standard EN 14868 and the di-rective VDI 2035 must be observed.

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

plants without signifi cant oxygen intake (plant type I ac-cording to EN 14868).

• Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or

- intermittent oxygen intake (e.g. where frequent refill-ing 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 heating water in existing installations (e.g. exchange of boiler) conforms to VDI 2035.The Directive VDI 2035 applies equally to the replace-ment 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 corrosion 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 between 8.3 and 9.5 after 6-12 weeks of heating operation.

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

is generally best suited as heating medium, i.e. as fi ll-ing and replacement water. However, as not all drink-ing water is suitable for use as fi lling and replacement water the water quality must fulfi l the standard set in VDI 2035. Should the mains water available not be suit-ed 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 exceeded (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water con-tent 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 2035Totalhardnessofthefillingwaterupto...

[mol/m3] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0f°H <1 5 10 15 20 25 30 >30d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8e°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 >300Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600Boiler size of the individual boiler maximumfillingquantitywithoutdesalination

to 50 kW NO REQUIREMENT 20 l/kW50 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.

5. Commissioning5.1 Water quality

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COMMISSIONING

5.2 Filling the heating systemFilling of the heating system must be carried out by trained personnel. The filling and replacement water must comply with the quality requirements in the relevant state or country (VDI 2035 or SWKI 88-4 or ÖNORM H 5195).

5.3 Filling the calorifier (if present)The heating boiler may be put into operation even when the calorifier is not filled.

5.4 CommissioningImportant:On first commissioning, check that all safety and control devices are functioning properly (in accordance with the operating manual).The operation and maintenance of the system must be explained to the user in detail.

!ATTENTIONIn some areas, gas or dual-fuel systems may only be commissioned by an engineer from the local gasworks. Check with the local gas-works to make sure.

5.5 Oil/gas burnerSetting the burner must also be carried out by a special-ist, and the setting must correspond to the heat demand of the system.Please see the technical information / assembly instruc-tions supplied with the burner.

5.6 Handover to the operator / storageHave the operator confirm in writing that the operating and maintenance procedures have been explained and that he or she has received a copy of the relevant operat-ing manuals. (See sample on the last page). The manu-facturer of the unit is responsible for providing operating manuals for the complete system. This technical informa-tion / these installation instructions must not be destroyed after completing the commissioning procedures, but should be permanently stored with the unit.

24 4 213 736 / 00

COMMISSIONING

This chapter is exclusively intended to describe the function of emissions and manual operation settings for the fi ring monitoring technician / chimney sweep. All operating elements are described in the operating instructions.

!CAUTIONDanger of scalding with hot water, since the hot water temperature can exceed the target setpoint temperature.

NOTICEIn order to protect underfl oor heating systems against impermissible superheating during emissions measurement / manual operation, it is necessary to implement appropriate safety measures (e.g. pump switch-off with maximum thermostat). The output and duration of the emission measurement can be set in the "Emission" main menu, and reactivated if required.

Emission metering

Setting at: Home screen > Main menu (page 1) > Emission.

For detailed information see operating instructions, "Emission" chapter.

Power limitation with 2-stage burner:0 to 50% = 1st stage 51 to 100% = 2nd stage

REACTION to emission metering• Go back after expiry of the time unit/time specifi cation of return to the main menu• Setpoint temperature = Maximum temperature limit• Forced energy is used in an attempt to keep the corresponding heat generator temperature to 60 °C• Regulate heating circuits and the calorifi ers to their maximum temperature (in the direct heating circuit only if the hot

water basic program is set to parallel operation)

Manual mode

Settings under: Home screen > Main menu (page 2) > Manual operation.

For detailed information see operating instructions, "Emission" chapter.

REACTION for manual operation• Setting the required setpoint temperature using the selected heating or hot water circuit• All heating pumps ON• Note the maximum permissible temperature of surface heating!

6. Maintenance6.1 Information for fire inspector / chimney sweep regarding emission monitor key

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MAINTENANCE

6.2 CleaningCleaning should be performed at least twice per year. Cleaning at intermediate intervals is necessary if the flue gas temperature rises.

6.2.1 Preparatory work - Switch boiler off (controller: set switch to «O,» pull the burner plug)

- Interrupt the fuel supply - Open the boiler door - Remove regulators (Fig. 23) - Remove flue gas collector cleaning cover (back)

6.2.2 Cleaning (dry or wet method) - Clean combustion chamber, 2-pass (cylindrical tubes), 3-pass (ribbed heating surface) thoroughly with a brush or spray and then remove any combustion residue or sprayed liquid from the flue gas collector and from the combustion chamber.

For wet cleaning:Treat seals with graphite before carrying out wet cleaning.

- Dispose of the cleaning fluid (scrubbing liquid) in ac-cordance with regulations.

6.2.3 Putting into operation again - Insert the regulators - Fit cleaning cover - Close boiler door and reconnect burner plug.

NOTEDo not overtighten boiler door screws.

- Reconnect the fuel supply - Where applicable, refit front cover - Reset boiler switch to "autom." or "I".

6.3 Safety temperature limiter - ResetIf the boiler temperature rises too high (>100 °C), the sys-tem is switched off by the safety temperature limiter (STL) by means of a mechanical lockout. The malfunction must first be unlocked on the safety tem-perature limiter, then on the control panel.

- STL - Reset

Fig. 241. Open the switch control box2. Unscrew the protective cap3. Reset the STL

Reset on the control panel

Reset key

Fig. 25

Press the reset key on the control (first remove the cov-er): the boiler is ready for operation again once the boiler water temperature is less than 80 °C.

26 4 213 736 / 00

MAINTENANCE

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Confirmation

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 con-

cerning the heat generator and any further components.• and is consequently suffi ciently familiar with the installation.

Installation address: Type:

Serial number:

Year of manufacture:

Place, Date:

System installer: System user:

Confirmation

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 con-

cerning the heat generator and any further components.• and is consequently suffi ciently familiar with the installation.

Installation address: Type:

Serial number:

Year of manufacture:

Place, Date:

System installer: System user:

COPY FOR PLANT USER

COPY OF SYSTEM INSTALLER