technical information installation instructions …...the rectification of faults and damage as a...
TRANSCRIPT
Subject to modifi cations | EN
Technical informationInstallation instructions
This appliance isonly suitable foroperation withheating oil EL(low sulphur)
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Hoval products must be installed and commissioned only by appropriately qualified experts. These instruc-tions are intended exclusively for the specialist. Elec-trical installations may only be carried out by a qualified electrician.
The 41-UltraOil® heating boiler is suitable for and ap-proved as a heating unit for hot-water systems with permitted flow temperatures up to 90 °C1). It is desig-ned primarily for closed circuits, but is equally suitable for installation in open circuits.1) see point 3.2
UltraOil® (16-35)Oil condensing boiler
These instructions are applicable to the following types:Rated output levels at 40/30 ºC41-UltraOil® (16)41-UltraOil® (20)41-UltraOil® (25)41-UltraOil® (35)
with TopTronic® E controller
1. Important information1.1 Other instructions ...............................................................................................................................................................41.2 Safety instructions ..............................................................................................................................................................41.3 Regulations, official approvals ...........................................................................................................................................41.4 Warranty ...............................................................................................................................................................................4
2. Assembly2.1 Set-up, levelling ...................................................................................................................................................................52.2 Fitting the burner .................................................................................................................................................................52.3 Condensate discharge ........................................................................................................................................................82.3.1 Design variants .................................................................................................................................................................82.4 Fitting the condensate drain (standard design) .................................................................................................................92.5 Fitting the neutralisation box (Option) .............................................................................................................................102.6 Fitting the condensate delivery pump (Option)................................................................................................................ 112.7 Fitting the neutralisation box and the condensate delivery pump (option) ....................................................................122.8 Fitting the flue gas silencer (Option) ................................................................................................................................14
3. Technical information3.1 Description of the boiler ...................................................................................................................................................153.1.1 The UltraOil® (16-35) meets the requirements of the following directives + standards ......................................................153.2 Technical data ....................................................................................................................................................................163.3 Dimensions UltraOil® (16-35) .............................................................................................................................................173.4 Space requirement UltraOil® (16-35) ..................................................................................................................................18
4. Installation4.1 Boiler room requirements .................................................................................................................................................194.2 Flue gas connection and chimney ....................................................................................................................................194.2.1 Project planning instructions ...........................................................................................................................................194.3 Example of a flue gas conduit
(Hoval flue gas system) .......................................................................................................................204.4 Fuel ....................................................................................................................................................................................204.5 Electrical connection .........................................................................................................................................................214.5.1 Safety measures relating to EMC assembly ....................................................................................................................224.6 Flue gas performance diagrams .......................................................................................................................................234.7 Hydraulic integration .........................................................................................................................................................244.8 Condensate discharge ......................................................................................................................................................244.9 Setting the temperature regulators ...................................................................................................................................244.10 Safety valves......................................................................................................................................................................244.11 Charging pump (boiler with water heater) ........................................................................................................................244.12 Heating pump.....................................................................................................................................................................24
5. Commissioning5.1 Water quality ......................................................................................................................................................................255.1.1 Heating Water .................................................................................................................................................................255.1.2 Filling and replacement water .........................................................................................................................................255.2 Filling the heating system .................................................................................................................................................265.3 Filling the water heater (if fitted) ......................................................................................................................................265.4 Commissioning ..................................................................................................................................................................265.5 Oil burner ...........................................................................................................................................................................265.6 Handover to the operator/storage .....................................................................................................................................265.7 Record - Activation of screed function .............................................................................................................................27
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TABLE OF CONTENTS
6. Maintenance6.1 Information for combustion controller/chimney sweep regarding emission monitor key .............................................296.2 Renewing fuse ...................................................................................................................................................................306.3 Cleaning the boiler and leakage test ................................................................................................................................306.3.1 Preparations for cleaning the boiler and burner ...............................................................................................................306.3.2 Re-assembling the boiler ................................................................................................................................................306.3.3 Cleaning the combustion chamber and the aluFer® pipes ................................................................................................326.4 Servicing the neutralisation installation (if fitted) ...........................................................................................................336.4.1 Procedure for servicing the neutralisation installation ......................................................................................................336.5 Safety temperature limiter - Reset ....................................................................................................................................34
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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 inst-ructions can be found in the documentation for the com-ponents!
Further sources of information:• Hoval catalogue• standards, regulations
1.2 Safety instructionsThe installation may only be put into operation if all rele-vant standards and safety regulations have been com-plied with. However, for trial operation, the following are the minimum conditions requiring fulfilment:1. A safety valve has been installed (closed-circuit ins-
tallation)2. Controls in operation (connected to the power supply)3. The sensor for the safety temperature limiter is loca-
ted in the immersion sleeve.4. The system is filled with water5. An expansion vessel is attached6. Flue gas outlets connected to the flue gas conduit at
the chimney7. The burner is preset.
The heat generator can only be de-ener-gised by disconnection from the mains (fuse).
All electric power supply circuits must be switched off before accessing the termi-nals.
1.3 Regulations, official approvalsFor installation and operation of the system, the following regulations are to be observed:
Germany• DIN EN 12831 Heating systems in buildings - procedu-
re for calculating the standard heating load.• DIN EN 12828 Heating systems in buildings - design of
hot water systems.• DIN EN 13384 Flue gas systems - heat and flow calcu-
lation methods.• DIN 4755 Oil-fired combustion systems.• Technical regulations for oil-fired installations (TRÖ)• DIN 4756 Gas-fired combustion systems: design, con-
struction and safety engineering requirements, design and construction (for operation with gas burners).
• DIN 18160 House chimneys, requirements, design and execution.
• PED (Pressure Equipment Directive).• TRD 721 Safety equipment to safeguard against excess
pressures / safety valves / for group II steam boilers.
• DVGW-TRGI - Technical regulations for gas installati-ons - DVGW process sheet G600.
• VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water systems.
• DIN 57 116 / VDI 0116 Electrical equipment in combus-tion systems (VDE regulations).
Austria• ÖNorm B 8130 Open hot water systems, safety instal-
lations.• ÖNorm B 8131 Closed hot water systems, safety, con-
struction and testing regulations.• ÖNorm B 8133 Water heating systems, safety enginee-
ring 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 5170 Heating installations, building and tech-
nical fire-protection regulations• ÖVGW TR-gas (Austrian Gas and Water Confederation
- Technical Guidelines)
Switzerland• VKF - Association of Cantonal Fire Insurers• Fire prevention authority regulations• 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 heating
systems• KRW Corrosion caused by halogen compounds• KRW/VSO/FKR Ready-to-connect electrical connec-
tions on heating 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.
The regulations of the local building authorities, insurers and chimney inspectors must also be taken into account. When gas is used as a fuel, the regulations of the lo-cal gasworks must be observed and official authorisation may also be required.1.4 WarrantyFault-free operation can only only be guaranteed if the-se instructions are followed and if the boiler is regularly serviced 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 to the heating water, improper handling, faulty installation, unauthorised modi-fications and damage due to the use of force do not fall under our guarantee obligations; this also applies to cor-rosion due to halogen compounds, e.g. from spray cans, paints adhesives, halogenised refrigerants, solvents and cleansing agents
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IMPORTANT INFORMATION
2. Assembly2.1 Set-up, levellingThe boiler is fixed to wooden transport chocks. For trans-port up and down stairs, it is wise to leave these timbers in place under the boiler.
A special foundation plate for the boiler is not an essen-tial, but it is recommended.
Space requirementFor further information on space requirements, see chap-ter 3.4.
The cleaning apertures must be easily ac-cessible.
Installing and levelling the boilerRemove transport chocks. Store nuts and washers. Lift the boiler on one side and put grub screws of boiler base from the bottom through the slot of the boiler sockets. Fix boiler feet using hexagonal nuts (Fig. 01).
Using a spirit level, set the boiler in longitudinal and trans-verse direction and position it with a slight forward tilt. This is done by adjusting the nuts on the boiler feet. After this adjustment, the upper (locking) nuts on the boiler feet must be tightened.
Fig. 01
2.2 Fitting the burner1. Remove the absorber hood (1, Fig. 02), after first re-
leasing the lateral locking bolt (2) (turn approx. ¼ turn to the left and pull out as far as the stop).
1
2
Fig. 02
2. Remove the burner from the packaging.
3. Dismantle the burner flange. To do this, release screw (3, Fig. 03) and turn the burner through 15°. The re-quired Allen key (2) is supplied with the burner.
2 3Fig. 03
4. Fit the burner flange incl. sealing on the boiler flange as shown (Fig. 04) - fit flange so that the «Warning» sticker is at the front.
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ASSEMBLY
Assembly aid:To simplify installation, the sealing on the burner flange can be lubricated using a heat-resistant paste (e.g. Kluberpaste UH1 84-201).
«Warning» stickerFig. 04
5. Insert the burner in the burner flange, still turned through 15° (final position: burner rating plate at the front), and when it reaches the stop, turn it through 15° so that the projection hangs under the screw head (Fig. 05).
Fig. 05
Screw headFig. 06
6. Fix the burner in position by tightening the screw (3, Fig. 03).
Fill the cavity between burner pipe and boiler door with the fireproof fibre provided.
The recirculation slots must remain open.
Note that - the fireproof fibre must be packed firmly into the cavity to prevent it falling out (Fig. 07)
Fireproof fibreFig. 07
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ASSEMBLY
7. Close the boiler flange with the burner again.8. The oil lines can be routed through the absorber hood
on the right or left side.9. Establish the plug-in connections (4, Fig. 08). Pull the
plug cables out further by releasing the high-strength cable glands (5). - 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.
4 5
Cable outletto the left
Cable outletto the right 4
Fig. 08
10. Replace absorber hood (1, Fig. 02), attach with lo-cking bolt (approx. ¼ turn to the right).
Further information can be found in the instructions supplied with the burner.
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ASSEMBLY
2.3 Condensate discharge
i The condensate discharge must be ma-nufactured of corrosion-resistant materi-al. The following materials are suitable for the condensate discharge:
PVC, PE, PP, ABS
Local regulations pertaining to the con-densate discharge must be observed.
2.3.1 Design variantsPossibility 1 - see chapter 2.4• Stand version with siphon• With neutralisation, condensate discharge into lower
drain line.• Drain optionally on the left or right side.
Fig. 09
Possibility 2 - see chapter 2.5• Execution with Neutralisation box• For condensate discharge in lower drain line, incl. con-
densate neutralisation.
Fig. 10
Possibility 3 -see chapter 2.6• Siphon and condensate delivery pump• Without neutralisation, condensate discharge into high-
er drain line.
Fig. 11
Possibility 4 - see chapter 2.7• Neutralisation box and condensate delivery pump• With condensate neutralisation - condensate discharge
into higher drain line.
Fig. 12
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ASSEMBLY
2.4 Fitting the condensate drain (standard design)
1. Remove front cover (1a, Fig. 13). Release lateral lo-cking bolt (1) (turn approx. ¼ turn to the left and pull out as far as the stop). Lift the front cover straight upwards and remove towards the front.
1
1a
Fig. 13
2. Remove base plate (2, Fig. 14). Lift the base plate straight upwards and remove it.
3. Screw siphon (3) on the condensate tray (4) and tigh-ten securely (connection must be sealed)
4. Slide the siphon support (3a) under the siphon.
2
3
5
5a4
3a
Fig. 14
5. Fit drain (5) on siphon (3) and lead it outwards (optio-nally left or right side) through the aperture (5a).
6. Fit connecting line (5) to the drain line (2m hose enc-losed with the boiler).
7. Reattach front cover (1a, Fig. 13) and base plate (2, Fig. 14).
Before commissioning the siphon must be filled with water in order to prevent flue gas leakage.
The condensate drain must be made of corrosion-resistant material.
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ASSEMBLY
2.5 Fitting the neutralisation box (Option)1. Remove the neutralisation box from its packaging.
Remove the front and rear cover of the neutralisation box. Empty the neutralisation granulate into the neut-ralisation box (Fig. 15) and distribute evenly.
neutralisation granulatefront
1
Fig. 15
2. Remove front cover (2a, Fig. 16). Release lateral lo-cking bolt (2) (turn approx. ¼ turn to the left and pull out as far as the stop). Lift the front cover straight upwards and remove it towards the front.
2
2a
3
Fig. 16
3. Remove base plate (3, Fig. 16). Lift base plate straight upwards and remove.
4. Fit rear cover (4, Fig. 17) of the neutralisation box.
5. Fit jubilee clip (5) approx. 20mm from the upper end of the hose and tighten slightly. The hose (5a) of the connection eccentric (5b) must be aligned towards the left.
54
5a
5b Fig. 17
6. Slide the neutralisation box (6, Fig. 18) into the boiler until the hose of the siphon (1,Fig. 15) is directly be-neath the drain connection.
6Fig. 18
7. The hose of the siphon (5a, Fig. 17) can be easily pushed onto the drain connection of the condensate drip tray by lifting the neutralisation box (7, Fig. 19).
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ASSEMBLY
7Fig. 19
8. Slightly loosen the jubilee clip (8, Fig. 20) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed).
8Fig. 20
9. Fill the neutralisation box with water.10. Fit the front cover (10, Fig. 21) of the neutralisation
box. 11. Fit base plate (3, Fig. 16) and front cover (2a).
10Fig. 21
Before commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage.
The condensate drain must be madeof corrosion-resistant material.
2.6 Fitting the condensate delivery pump (Op-tion)
Install the condensate delivery pump (11, Fig. 22) as shown in the drawing.
11
Fig. 22
Before commissioning the siphon must be filled with water in order to prevent flue gas leakage.
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ASSEMBLY
2.7 Fitting the neutralisation box and the con-densate delivery pump (option)
1. Fit condensate delivery pump (1, Fig. 23) as shown in the drawing. Route the cable to the controller and connect according to the diagram.
1
Fig. 23
2. Remove the neutralisation box from its packaging. Remove the front and rear cover of the neutralisation box. Empty the neutralisation granulate into the neut-ralisation box (Fig. 24) and distribute evenly.
neutralisation granulatefront
2
Fig. 24
3. Remove front cover (2a, Fig. 25). Release lateral lo-cking bolt (2) (turn approx. ¼ to the left and pull out as far as the stop). Lift the front cover straight upwards and remove towards the front.
4. Remove base plate (3). Lift base plate straight up-wards and remove.
2
2a
3
Fig. 25
5. Fit rear cover (4, Fig. 26) of the neutralisation box.6. Fit jubilee clip (5) approx. 20mm from the upper end
of the hose and tighten slightly. The hose (5a) of the connection eccentric (5b) must be aligned towards the left.
54
5a
5bFig. 26
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ASSEMBLY
7. Slide the neutralisation box (6, Fig. 27) into the boiler until the hose of the siphon (5a, Fig. 26) is directly beneath the drain connection.
6Fig. 278. The hose of the siphon (5a, Fig. 26) can be easily
pushed onto the drain connection of the condensate drip tray by lifting the neutralisation box (7, Fig. 28).
7Fig. 28
9. Slightly loosen the jubilee clip (8, Fig. 29) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed).
8Fig. 29
10. Fill the neutralisation box with water.11. Fit the front cover (9, Fig. 30) of the neutralisation
box.12. Fit base plate (3, Fig. 25) and front cover (2a).
9Fig. 30
Before commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage.
The condensate drain must be madeof corrosion-resistant material.
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ASSEMBLY
2.8 Fitting the flue gas silencer (Option)
The silencer must be installed vertically. The maximum permissible angle of incli-nation is 45°!
Fig. 31
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ASSEMBLY
3. Technical information3.1 Description of the boilerThe Hoval UltraOil® is a low-pollutant, energy-saving oil-fired heating boiler. The UltraOil® has a combustion chamber arranged vertically and fabricated from non-cor-roding stainless steel as its primary heating surface and a secondary heating surface made from corrosion-resistant aluminium alloy. The secondary heating surface is so de-signed that the water vapour contained in the heating gas condenses and the heat of evaporation is utilised for the heating circuit. The UltraOil® is designed exclusively for operation with low-sulphur heating oil EL.
Fig. 32
3.1.1 The UltraOil® (16-35) meets the requirements of the following directives + standards
We hereby declare that the product described, as an in-dividual unit, complies with the standards, guidelines and technical specifications listed.
Directives92/42/EG "Efficiency directive"73/23/EWG "Low-voltage directive"89/336/EWG "Electromagnetic
compatibility"
RegulationsStability prEN14394:2001Buildingrequirements
EN303-1EN303-2prEN 15034prEN 15035
Low voltage DIN VDE 0722 / Ed. 04.83EMC EN 50082 Part 1 / Ed. 01.92
EN 12828 prescribes low water level protection in closed heating systems.Substitute measures can be used in the case of boilers with an output of up to 300 kW.On boilers of type UltraOil (16-35), the safety disconnec-tion function during operation without water was tested. The test was performed successfully.
i Installation of low water level protection on the UltraOil (16-35) is therefore not ne-cessary.
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TECHNICAL INFORMATION
3.2 Technical data
Type (16) (20) (25) (35)• Nominal output 80/60 °C kW 15 19 24 33• Nominal output 40/30 °C kW 16 20 25 35• Range of output 80/60 °C kW 11 - 15 14 - 19 15 - 24 21 - 33• Range of output 40/30 °C kW 12 - 16 14 - 20 16 - 25 22 - 35• Heat input kW 11.3 - 15.5 13.8 - 19.5 15.4 - 24.5 20.9 - 33.8• Dimension Space requirements • Max. boiler working temperature °C 90 90 90 90• Min. boiler working temperature °C no min. limit• Min. return flow temperature °C no min. limit• Min. flue gas temperature °C no min. limit• Safety temperature limiter setting (water side) °C 110 110 110 110• Working / test pressure bar 3.0/4.5 3.0/4.5 3.0/4.5 3.0/4.5• Boiler efficiency with max. burner output at 80/60 °C
(related to net / gross calorific value) % 98.3/92.7 98.5/92.9 98.2/92.6 98.5/92.9• Boiler efficiency with max. burner output at 40/30 °C
(related to net / gross calorific value) % 103.5/97.6 103.9/98.0 103.8/97.9 103.6/97.7• Boiler efficiency at partial load 30 % at return flow 30 °C (according to EN 303)
(related to net / gross calorific value) % 103.9/98.0 104.2/98.3 104.1/98.2 104.2/98.3• Nominal efficiency at 75/60 °C (according to DIN 4702 part 8)
(related to net / gross calorific value) % 100.1/94.4 100.4/94.7 100.4/94.7 100.7/95.0• Nominal efficiency at 40/30 °C (according to DIN 4702 part 8)
(related to net / gross calorific value) % 103.7/97.8 104.0/98.1 104.0/98.1 104.1/98.2• Stand-by deficiency qB at 70 °C Watt 220 230 240 250• Combustion gas resistance, 12.5 % CO2, 500 m above sea, level (Tolerance +/- 20 %) mbar 0.30 0.29 0.29 0.30• Condensate rate at 40/30 °C l/h 1.07 1.31 1.65 2.28• Flow resistance boiler 1 z value 3.5 3.5 3.5 3.4• Water resistance at 10 K mbar 6.6 10.6 16.6 30.6
at 20 K mbar 1.7 2.6 4.2 7.7• Water flow volume at 10 K m3/h 1.38 1.74 2.18 3.00
at 20 K m3/h 0.69 0.87 1.09 1.50• Boiler water capacity litres 66 63 68 65• Boiler gas volume m3 0.034 0.035 0.046 0.076• Insulation thickness boiler body mm 80 80 80 80• Weight (incl. casing, burner) kg 140 145 157 164• Weight of transport kg 134 139 151 158• Min. / Max. electrical power consumption 4 Watt 6/125 6/147 6/175 6/215• Type of protection 2 IP 20 20 20 20• Acoustic power incl. sound absorber hood
Ambient air dependent - Heating noise (EN 15036 part 1) dB(A) 61 62 66 63
Ambient air independent - Heating noise (EN 15036 part 1) dB(A) 53 54 57 60 - Aspiration noise is radiated from the mouth (DIN 45835) dB(A) 60 62 66 62 - Aspiration /exhaust noise - LAS - is radiated from the mouth (DIN 45835) 3 dB(A) 70 73 77 79
Ambient air dependent and ambient air independent - Exhaust noise in the pipe (EN 15036 part 2) 3 dB(A) 83 86 88 93 - Exhaust noise is radiated from the mouth (DIN 45635 part 47) 3 dB(A) 69 71 75 76
• Combustion chamber dimensions Ø inside x length mm 294 x 403 294 x 403 294 x 543 294 x 543• Combustion chamber volume m3 0.027 0.027 0.037 0.037• Flue gas mass flow at nominal output 12.5% CO2 heating oil kg/h 24 31 38 53• Flue gas temperature at nominal output 80/60 °C °C 75 75 75 75• Flue gas temperature at nominal output 40/30 °C °C 58 53 56 57• Supply pressure for supply air/flue gas line Pa 50 50 50 40• Maximum draught/underpressure at flue gas outlet Pa -20 -20 -20 -20
1 Flow resistance boiler in mbar = Volume flow (m3/h)2 x z factor2 Indication relates to protection against contact with dangerous components3 Data without sound absorber. Reduction by installation of a sound absorber possible4 Depending on the number of controller modules/module expansions fitted, there is an increase in the max. electrical power consumption.
Flue gas silencer
to Hoval UltraOil®Connection
on both sides Total lengthDiameterexternal Attenuation Resistance Output
Type mm mm dB (A) Pa kW
(16-25) E80 810 160 11 12 25(35) E100 810 160 8 10 35
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TECHNICAL INFORMATION
3.3 Dimensions UltraOil® (16-35)
(All dimensions in mm)
Fig. 33
Type A B C D
UltraOil (16,20) 1550 805 486 1485UltraOil (25,35) 1690 945 626 1625
1 Heating flow / safety flow R1"2 Low-temperature return R1"3 High-temperature return R1"4 Flue gas outlet DN805 Control panel6 Condensate drain (left or right) incl. siphon DN25
and 2 m PVC continuous-flow tube inner Ø 19 x 4 mm
7 Evacuation8 Electric cable infeed9 Absorber hood10 Heating fittings group or loading group (Option)
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TECHNICAL INFORMATION
3.4 Space requirement UltraOil® (16-35)
min. 50 mmwith silencer
Fig. 34
Boiler door incl. burner swings upward and to the left or outward.
A = minimal 150 mm *Brennerserviceposition vorne - Kesselreini-gung von rechts
A = optimum 300 mm * - Burner service position left - boiler cleaning from the front
- A minimum gap of 160 mm is required to the right of the boiler
* without fittings,500 mm with fittings
• The cleaning aperture must be easily accessible.• Ensure access to the area behind the boiler.
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TECHNICAL INFORMATION
4. Installation4.1 Boiler room requirementsRegarding the building specifications for boiler rooms and their supply and extract air handling, the current buil-ding supervisory office regulations specific to the state or country are to be observed.
The UltraOil® can be operated either dependent on room air or independent of room air.
Not dependent upon room airAs a unit of type C53 or C63, the UltraOil® can be set up and operated independent of room air irrespective of the size and ventilation of the room in which it is installed.We recommend it is installed in a separate room in which, in accordance with pr. EN 15035, a small amount of leakage of flue gas can be tolerated.
Dependent on room air:Ensure that there is an adequate fresh air supply to the boiler room,so that the amount of combustion air required for opera-tion of all the burners installed there can be continuously replenished without hindrance and that for the protection of operating personnel there is no shortage of oxygen.Binding values for the size of supply air openings are not generally specified in the relevant regulations; it is me-rely required that no partial vacuum in excess of 3 N/m2 occurs. To comply with this requirement, for up to a nomi-nal heat output of 50 kW, a ventilation cross-section of at least 300 cm2 must be provided. In 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-section area reaches the amount given above.
4.2 Flue gas connection and chimney4.2.1 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, resis-tant 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 must be routed with an upward slope (at least 50 mm per running metre) so that the condensate that forms flows back into the boiler.
• When using flue gas conduits made from plastic, ob-serve the country-specific regulations with regard to the use of the flue gas safety temperature limiter.
• The cross-sections are to be calculated for heating boi-lers without draughting requirements.
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.
The UltraOil® is equipped with a flue gas safety tem-perature limiter. For this reason, no additional flue gas temperature limiter is required for the flue gas system with a maximum permitted flue gas tempe-rature of 120 °C.
• A closable flue gas measurement nozzle with a circular internal diameter of between 10-21 mm must be ins-talled in the flue gas conduit. It must protrude beyond the thermal insulation.
D
D1D
< 2
D
2xD
Fig. 35
The flue gas measurement nozzle or flue gas measurement aperture must be closed during regular operation of the burner.
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INSTALLATION
4.3 Example of a flue gas conduit (Hoval flue gas system)
Falls erforderlich ist ein Inspektions-T-Stück einzusetzen
Gitter zur Schacht-hinterlüftung
UltraOil(16-35)
Hoval
Grid for back ventilation of the
shaft
If necessary, insert an inspection
T-piece
Fig. 36
4.4 Fuel
The boiler may only be operated with the fuel designated on the boiler rating plate.
The UltraOil® heating boilers are suitable for combustion of the following fuels: - Heating oil EL low-sulphur in accordance withDIN 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: - Hoval UltraOil® must only be operated with heating oil EL low-sulphur with 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 heating oil EL low-sulphur, provided that the residual amount does not exceed the following per-centages of the total content.
- Residual amount heating oil EL(sulphur content: 2000 ppm / 0.2 %)max 3 % of tank volumeResidual amount heating oil EL(sulphur content: 1000 ppm / 0.1 %)max 5 % of tank volumeResidual 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 hea-ting oil EL low-sulphur, taking account of the residual amount of heating oil in the oil tank, a 100% tank filling is necessary.
- Natural gas (conversion option to UltraGas®)
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INSTALLATION
4.5 Electrical connection
i A qualified technician must install the electrical supply to the equipment.The connection diagram is located in the terminal box of the heat generator; the circuit diagram is supplied separately. Refer to this for the conductor cross sec-tion required for the mains supply.
For Austria and Germany:An electrical circuit diagram is supplied with the boiler controls. An all-phase main switch with a minimum con-tact spacing of 3 mm must be fitted in the power supply line.
For Switzerland the following applies:For the electrical connection, the circuit diagram specific to the plant must be observed.
Do not reach into the marked area (Fig. 37) when folding out the switch control box.Danger of cuts and pinching in the area of the trim strip (A).Wear gloves. Grip the switch control box by the left and right sides, not by the un-derside!
1. Remove noise damping cover (1, Fig. 37). Release lateral locking bolt (2) (approx. ¼ turn to the left).
2. Remove front cover (3) Release lateral locking bolt (4) (approx. ¼ turn to the left).
3. Remove screws (5). Lift terminal strip cover plate straight upwards (6) and remove it.
4. Remove screws (7) and fold out electrical box (8). The electrical connection has to be made on the ba-sis of the enclosed diagram.
5. Introduction cable (9).
The electrical connection is to be made in accordance with the diagram supplied.
1
2
3
5
4
7
8
9
6
A
A
Fig. 37
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INSTALLATION
Mains supply 230V
Cable grip Protect all cables against strain with the enclosed cable grips when the controller is folded open.
Fig. 38
Controller modules are only connected with 3 lines (no +) of the bus system.Control modules are connected with 4 li-nes because these have to be supplied.
4.5.1 Safety measures relating to EMC assembly1. For regulator units with their own power supply, sepa-
rate laying of power leads and sensor or bus-leads is absolutely essential. If using cable channelling, only that fitted with separator strips may be used.
2. The mains connection for the heating system (boi-ler control panel regulator unit) must be designed as an independent electrical circuit. Neither fluorescent lamps nor any other equipment which might cause in-terference may be connected, nor may it be possible to connect such equipment.
FuseBoiler roomemergency switch
Heat generator
Boiler room lighting and pwer sockets must be in a separate circuit
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 transmitters etc.
Recommended cable cross-sections and maximum permitted cable lengths:Cables carrying mains supply voltages from actuators:(burner, pumps, actuators etc.): min. 1mm2
Maximum permissible length:no restrictions, within the framework of the building’s in-ternal installations.Sensor cables and cables carrying low voltages: minimum 0.5 mm2
Maximum permissible cable length: 50 mData bus lines:4-wire bus, twisted, shielded, minimum 0.5 mm2
Maximum permissible cable length: 100 m
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INSTALLATION
4.6 Flue gas performance diagramsThe diagrams show the flue gas temperature characteristics with Hoval burners.UltraOil® (16)Flow 80 °C/ return flow 60 °C Flow 40 °C/ return flow 30 °C
70
80
90
100
30
40
50
60
70
10 12 14 16
°C
kW
70
80
90
100
30
40
50
60
70
10 12 14 16
°C
kWUltraOil® (20)Flow 80 °C/ return flow 60 °C Flow 40 °C/ return flow 30 °C
70
80
90
100
30
40
50
60
70
14 16 18 20
°C
kW
70
80
90
100
30
40
50
60
70
14 16 18 20
°C
kWUltraOil® (25)Flow 80 °C/ return flow 60 °C Flow 40 °C/ return flow 30 °C
70
80
90
100
30
40
50
60
70
15 17 19 21 23 25
°C
kW
70
80
90
100
30
40
50
60
70
15 17 19 21 23 25
°C
kWUltraOil® (35)Flow 80 °C/ return flow 60 °C Flow 40 °C/ return flow 30 °C
70
80
90
100
30
40
50
60
70
20 25 30 35
°C
kW
70
80
90
100
30
40
50
60
70
20 25 30 35
°C
kWkW = heat output°C = flue gas temperature using heating oil EL, CO2 = 12.5%
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INSTALLATION
4.7 Hydraulic integration
Examples
Direct heating circuit
Fig. 39
Mixer circuit and water heater
Fig. 40
4.8 Condensate dischargeThe boiler condensate drain must be made of corrosion-resistant material.The following materials are suitable for the condensate drain:
- PVC - PE - PP - ABS
The minimum inner diameter of the con-densate drain must be 15 mm. The con-densate drain must be sufficiently incli-ned.
A: it is not necessary to neutralise condensate from an oil-fired condensing unit of up to 120 kW drained together with domestic waste water from a private household.
CH: For the UltraOil®, the fuel used must be hea-ting oil EL low-sulphur. As a rule, neutralisati-on of the condensate is not necessary. Local regulations pertaining to condensate dischar-ge must be observed.
D: For the UltraOil®, the fuel used must be heating oil EL low-sulphur. Neutralisation is therefore unnecessary. Regarding the di-scharge of condensate, the local regulations and the ATV (Sewage Engineering Associati-on) data-sheet must be observed.
4.9 Setting the temperature regulatorsBasic setting of the controller is carried out by the heating contractor. Selection and setting of the various heating programmes in accordance with the operating manual.
4.10 Safety valvesThe heating system and hot water system must each be protected with one safety valve against unauthorised high pressures. The discharge capactiy of the valves must correspond with the boiler’s maximum nominal heat out-put. The valve must be installed in the flow line in the immediate vicinity of the boiler.
4.11 Charging pump (boiler with water heater)Speed of rotation and output must correspond to the re-quirements of the water heater. Setting carried out by the heating installation engineer.
4.12 Heating pumpSpeed of rotation and output must correspond to the re-quirements of the system. They are to be set by the hea-ting installation engineer.
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INSTALLATION
5. Commissioning5.1 Water quality
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COMMISSIONING
Heating Water
The European Standard EN 14868 and the directive 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 / calorifi er which have contact with water are made of ferrous materials and stainless steel.
• On account of the danger of stress cracking corrosion in the stainless steel section of the boiler the chloride, nitrate and sulphate content of the heating water must not exceed 50 mg/l.
• 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 drinking water is suitable for use as 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 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 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 2035Total hardness of the fi lling water up to ...
[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 maximum fi lling quantity without desalination
50 to 200 kW NO REQUI- 50 l/kW 20 l/kW 20 l/kWalways desalinate200 to 600 kW RE- 50 l/kW 50 l/kW 20 l/kW
over 600 kW MENT
1 Sum of alkaline earths2 If the conductance in µS/cm exceeds the tabular value an analysis of the water is necessary.
5.2 Filling the heating systemFilling of the heating system must be carried out by trai-ned personnel. The fill and make-up water must com-ply with the quality requirements in the relevant state or country (see chapter 5.1).
5.3 Filling the water heater (if fitted)The heating boiler may be put into operation even when the water heater is not filled.
5.4 Commissioning
The heat generator must be de-energised for maintenance. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse).
All electric power supply circuits must be switched off before accessing the termi-nals.
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.
Before commissioning, the neutralisation box (where fitted) must be filled with water.
5.5 Oil burnerSetting the burner must also be carried out by a specialist and the setting must correspond to the heat demand of the system.Please see the technical information / assembly instruc-tions supplied with the burner.
Burners are fitted with oil preheating and when restarted are ready for operation again after about 2 minutes’ delay.
5.6 Handover to the operator/storageHave the operator confirm in writing that the methods of operating and service procedures have been explained and that he has received a copy of the relevant operating instructions (see sample 36). The system manufacturer is responsible for providing operating instructions for the whole plant. The technical information / installation inst-ructions must be kept with the plant at all times.
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5.7 Record - Activation of screed function
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Description of function
The control module of the TopTronic® E contains a functional sequence used for drying out screed fl oors. To start the screed drying, it is necessary for the individual functions to be set accordingly.
Heating-up phase( 04-061)
Start End
Current heat generator temperature = start temperature
Inertia phase(04-064)
Stabilisation temperature(04-063)
Cool down phase( 04-062)
Flow temperature
Days10
20 °C
25 °C
30 °C
35 °C
40 °C
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 d 1 d
5 K -5 K
Function Parameters Value DescriptionHeating-up phase 04-061 5 K/d Kelvin per day (rising)Stabilisation temperature 04-063 40.0 °C Set maximum temperatureInertia phase 04-064 10 Number of days in stabilisation temperatureCooling off phase 04-062 -5 K/d Kelvin per day (falling)Activate screed function 04-060 1 (ON) Start and stop screed drying
CAUTION: The graphic/table shows the factory settings. The time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen – and in particular, cracks.
REACTION screed function• Start/stop: Switch parameter 04-060 ON (1) or OFF (0) • Power failure in heating-up phase: program restart• Failure in the steady-state phase: Retain maximum temperature and add the failure time to the steady-state phase• Power failure in the cooling off phase: Measurement of actual fl ow value and continue cooling until start value
reached• Program end: Previous basic program active again
Settings in the TopTronic® E control module
i Can only be set in the corresponding user level.
Settings under Start screen > Main menu > Service > H-GEN > Heating circuit > Heating circuit 1, 2, 3* > Screen > 04-060 to 04-064.
* If there are several heating circuits, a separate screed function must be assigned to each heating circuit.
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COMMISSIONING
Function display
1 2
No. Icon Function1 Screed drying active
Various settings can be made as well. Prioritisation of the screed func-tion means the settings are only ac-tive at the end of the function.
2 Information remaining run timeRequest of the active function phase, the ACT temperature as well as the remaining run time.
Logging
Please cut out the log and attach it to the controller during active screed function.
The time profi le and the maximum fl ow temperature must be discussed with the screed layer, oth-erwise there could be damage to the screen – and in particular, cracks.
Screed function activated by: Profi le and fl ow temperature discussed with:
Screed function activated on: Screed function ends on:
..........................................................................................Date and signature
6. Maintenance6.1 Information for combustion controller/chimney sweep regarding emission monitor key
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MAINTENANCE
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.
Danger of scalding with hot water, since the hot water temperature can exceed the target setpoint temperature.
In order to protect underfl oor heating systems against impermissible superheating during emis-sions 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 meas-urement can be set in the "Emission" main menu, and reactivated if required.
Emission metering
Setting at: Home screen > Main menu (page 1) > Emission.
i For detailed information see operating instruc-tions, "Emission" chapter
i 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.
i For detailed information see operating instruc-tions, "Manual operation" 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!
6.2 Renewing fuse
Electrical installations may only be car-ried out by a qualified electrician.
1. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse).
2. Remove the front casing according to the procedure in chapter 4.5
3. Remove the cover from TopTronic® E - WEZ (press to the side and remove).
4. Renew fuse (T 10A 250V).
5. Mount protecting cover, close casing.6. Restore the electrical power supply.
6.3 Cleaning the boiler and leakage testThe UltraOil® may only be cleaned by a licensed specia-list or Hoval customer service technician.Reliable and safe operation of the oil boiler, optimum ef-ficiency and clean combustion can only be guaranteed if the unit is serviced and cleaned regularly.
Inspection and cleaning must be carried out annually. For this purpose, we recommend that you conclude a main-tenance contract with Hoval customer service, or with an authorised specialist dealer.In the case of oil-fired equipment already in operation du-ring the construction phase (where there is increased oc-currence of dust), inspection should be carried out once construction work has been completed to ascertain the degree of dirt build-up. If necessary cleaning must be car-ried out.
6.3.1 Preparations for cleaning the boiler and burner
The heat generator must be de-energised for maintenance. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse).
All electric power supply circuits must be switched off before accessing the termi-nals.
• Remove absorber hood (1, Fig. 41). To do this, release lateral locking bolts (2) (turn approx. ¼ turn to the left and pull out as far as the stop)
• Remove front cover of the boiler base (10, Fig. 42)• Depending on the design, unscrew or remove siphon
trap (7, Fig. 42), siphon base section (8, Fig. 42), si-phon support (8a) or neutralisation box (9, Fig. 43).
Danger: flue gas escaping through the si-phon can endanger lives (poisoning).The siphon (8, Fig. 42) must always be filled with water. The condensate drain line must not be soiled or blocked. • Before replacing the siphon, fill it with wa-
ter.• Check whether the condensate drain line is
soiled/blocked.
• Undo the burner plug-in connections (burner cable, re-mote reset cable).
• Release the lock nuts (4, Fig. 41)• Pull the burner with the boiler door (3) upwards, turn it
to the side and lower it again• Clean burner• Clean neutralisation box (9, Fig. 43 - if fitted) as descri-
bed in chapter 6.4.• The cleaning scraper included in the scope of delivery
is suitable for cleaning the aluFer® pipes. For a detailed description of how to clean the combustion chamber and the aluFer® pipes, see chapter 6.3.3.
6.3.2 Re-assembling the boiler• If applicable, reattach neutralisation box (9, Fig. 43)
and siphon/siphon base section/siphon support (7, 8, 8a, Fig. 42).
• Attach the front cover of the boiler socket (10)• Close the burner with boiler door (3, Fig. 41)• Tighten the lock-nuts (4)• Reconnect the burner plug-in connections (burner
cable, remote reset cable)• Replace absorber hood (1) and attach with locking bolt
(turn approx. ¼ turn to the right).• Set the main boiler control switch to „I“
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MAINTENANCE
1
2
3
4
5
Fig. 41
10
9
6
10
8
6 7
Mount hose forwet cleaning
Design with condensate discharge Design with neutralisation box(if fitted)
Fig. 42 Fig. 43
8a
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6.3.3 Cleaning the combustion chamber and the aluFer® pipes
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MAINTENANCE
in the case of light dirt build-upCarry out wet cleaning of the combustion chamber and the aluFer® pipes.
• Ensure that each individual aluFer® pipe is thoroughly rinsed. After completing cleaning, check that the indi-vidual fl ow ducts are free of deposits and combustion residue!
in the case of heavy dirt build-upCarry out mechanical wet cleaning of the combustion chamber and the aluFer® pipes after spraying them with concentrated cleaning agent.
• Allow the concentrate to soak in for at least 10 minutes before cleaning.
• Using the cleaning scraper, thoroughly clean the fl ow channels.
• A special cleaning set (contains four cleaning scrap-ers) to remove stubborn dirt build-up is available from Hoval, Art. No. 6022 844.
• Before removing the drain hose, all dirt particles must be adequately rinsed out of the condensate drip tray.
Do not use wire brushes or any sharp objects for cleaning. Ensure that the combustion chamber 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 permitted are those approved for oil boilers having aluminium components such as Sotin 240 or Desoxin.
When working with the above cleaning agents, regulations prescribe the wear-ing of gloves and protective goggles. In addition, the instructions on the original packaging must be observed.
Cleaning scraper
Flow duct
aluFer® pipe
Leakage testingAfter cleaning or at least every fi ve years, the sealing be-tween the combustion chamber and the condensate drip tray must be checked for leakage. This can be done by fi lling the boiler with water.
80 1
1 Filling level water
6.4 Servicing the neutralisation installation (if fitted)
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i Maintenance should be undertaken at least every second year, or after the neu-tralisation granules are exhausted (check the ph-value if appropriate with litmus pa-per test).
Neutralisation granulate for refi lling can be ordered from Hoval under the following item no.:
• 1 pack (3 kg) neutralisation granulesPart no. 2028 906
Procedure for servicing the neutralisation installation• Set the main control switch to "0".• Remove the front cover.• Undo the bolts and withdraw the neutralisation box.• Remove the neutralisation granules and any deposits
from the neutralisation box. Any remaining neutralisa-tion 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 mak-ing sure that it is tight-closing.
• Push the neutralisation box back in.
Before putting back into service, the si-phon and the neutralisation box must be fi lled together with water.
The water can be poured through the cleaning aperture into the neutralisation box and the siphon.
Neutralisation granulesSiphon
6.5 Safety temperature limiter - Reset
If the boiler temperature rises too high (>100 °C), the system is switched off by the safety temperature limiter (STL) by means of a mechanical lockout. The malfunction must first be unlocked on the safety temperature limiter, then on the control panel.
1. STL reset - Open the terminal box according to chapter 4.5 - Unscrew the protective cap - Reset the STL
Fig. 44
2. Reset on the control panel - Press the reset key on the control (first remove the cover): the boiler is ready for operation again once the boiler water temperature is less than 80 °C.
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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