Technical information Installation instructions. UltraOil (16-35) Oil condensing boiler. These instructions are applicable to the following

Transcription

1 Technical information Installation instructions UltraOil (16-35) Oil condensing boiler These instructions are applicable to the following types: Rated output levels at 40/30ºC 32-UltraOil (16) 32-UltraOil (20) 32-UltraOil (25) 32-UltraOil (35) with TopTronic T controller This appliance is only suitable for operation with heating oil EL (low sulphur) 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. The UltraOil heating boiler is suitable for and approved as a heating unit for hot-water systems with permitted flow temperatures up to 90 C 1). It is designed primarily for closed circuits, but is equally suitable for installation in open circuits. 1) see point 3.2 Subject to modifi cations / 02-01/14 EN

2 TABLE OF CONTENTS 1. Important information 1.1 Other instructions Safety instructions Warranty Assembly 2.1 Set-up, levelling Fitting the burner Condensate discharge Design variants Fitting the condensate drain (standard design) Fitting the neutralisation box (Option) Fitting the condensate delivery pump (Option) Fitting the neutralisation box and the condensate delivery pump (option) Fitting the flue gas silencer (Option) Technical information 3.1 Description of the boiler The UltraOil (16-35) meets the requirements of the following directives + standards Technical data Dimensions UltraOil (16-35) Space requirement UltraOil (16-35) Installation 4.1 Boiler room requirements Flue gas connection and chimney Project planning instructions Example of a flue gas conduit Fuel Electrical connection Safety measures relating to EMC assembly Flue gas performance diagrams Hydraulic integration Condensate discharge Setting the temperature regulators Safety valves Charging pump (boiler with water heater) Heating pump Commissioning 5.1 Water quality Heating Water Filling and replacement water Filling the heating system Filling the water heater (if fitted) Commissioning Oil burner Handover to the operator/storage / 02

3 TABLE OF CONTENTS 6. Maintenance 6.1 Information for combustion controller/chimney sweep regarding emission monitor key Cleaning the boiler Preparations for cleaning the boiler and burner Re-assembling the boiler Cleaning the combustion chamber and the alufer pipes Leakage testing Servicing the neutralisation installation (if fitted) Procedure for servicing the neutralisation installation Safety temperature limiter - Reset Resetting the fault message Flue gas STL or flue gas temperature limiter unblocking Resetting the fault message Flue gas STL Flue gas temperature limiter - reset Overview of settings 7.1 Table of parameters Fault reporting overview TopTronic T / 02 3

4 IMPORTANT INFORMATION 1. Important information 1.1 Other instructions All instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the instructions can be found in the documentation for the components! Further sources of information: Hoval catalogue standards, regulations 1.2 Safety instructions The installation may only be put into operation if all relevant standards and safety regulations have been complied with. However, for trial operation, the following are the minimum conditions requiring fulfilment: 1. A safety valve has been installed (closed-circuit installation) 2. Controls in operation (connected to the power supply) 3. The sensor for the safety temperature limiter is located in the immersion sleeve. 4. The system is filled with water 5. An expansion vessel is attached 6. Flue gas outlets connected to the flue gas conduit at the chimney 7. The burner is preset. Regulations, official approvals For installation and operation of the system, the following regulations are to be observed: Germany DIN EN Heating systems in buildings - procedure for calculating the standard heating load. DIN EN Heating systems in buildings - design of hot water systems. DIN EN Flue gas systems - heat and flow calculation methods. DIN 4755 Oil-fired combustion systems. Technical regulations for oil-fired installations (TRÖ) DIN 4756 Gas-fired combustion systems: design, construction and safety engineering requirements, design and construction (for operation with gas burners). DIN 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 installations - DVGW process sheet G600. VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water systems. DIN / VDI 0116 Electrical equipment in combustion systems (VDE regulations). Austria ÖNorm B 8130 Open hot water systems, safety installations. ÖNorm B 8131 Closed hot water systems, safety, construction and testing regulations. ÖNorm B 8133 Water heating systems, safety engineering requirements. ÖNorm B 8136 Heating systems, space requirements and other building requirements. ÖNorm M 7515 Calculations of dimensions of chimneys; terminology, calculation procedure. ÖNorm H 5170 Heating installations, building and technical 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 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 connections on heating boilers and burners Technical tank regulations TTV 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 local gasworks must be observed and official authorisation may also be required / 02

5 IMPORTANT INFORMATION 1.3 Warranty Fault-free operation can only only be guaranteed if these 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 contaminated operating materials (gas, water, combustion air), unsuitable chemical additives to the heating water, improper handling, faulty installation, unauthorised modifications and damage due to the use of force do not fall under our guarantee obligations; this also applies to corrosion due to halogen compounds, e.g. from spray cans, paints adhesives, halogenised refrigerants, solvents and cleansing agents / 02 5

6 ASSEMBLY 2. Assembly 2.1 Set-up, levelling The boiler is fixed to wooden transport chocks. For transport up and down stairs, it is wise to leave these timbers in place under the boiler. 2.2 Fitting the burner 1. Remove the absorber hood (1, Fig. 02), after first releasing the lateral locking bolt (2) (turn approx. ¼ turn to the left and pull out as far as the stop). A special foundation plate for the boiler is not an essential, but it is recommended. Space requirement For further information on space requirements, see chapter 3.4. The cleaning apertures must be easily accessible. Installing and levelling the boiler Remove 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). 1 2 Using a spirit level, set the boiler in longitudinal and transverse 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 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 required Allen key (2) is supplied with the burner. Fig. 01 Fig 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 / 02

7 ASSEMBLY Assembly aid: To simplify installation, the sealing on the burner flange can be lubricated using a heat-resistant paste (e.g. Kluberpaste UH ). Screw head Fig Fix the burner in position by tightening the screw (3, Fig. 03). Insulate the cavity between burner pipe and boiler flange with the fireproof fibre provided. Fig. 04 «Warning» sticker 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. 06). 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 fibre Fig. 07 Fig Close the boiler flange with the burner again / 02 7

8 ASSEMBLY 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. Cable outlet to the left Cable outlet to the right Fig Replace absorber hood (1, Fig. 02), attach with locking bolt (approx. ¼ turn to the right). Further information can be found in the instructions supplied with the burner / 02

9 ASSEMBLY 2.3 Condensate discharge i The condensate discharge must be manufactured of corrosion-resistant material. The following materials are suitable for the condensate discharge: Possibility 3 -see chapter 2.6 Siphon and condensate delivery pump Without neutralisation, condensate discharge into higher drain line. PVC, PE, PP, ABS Local regulations pertaining to the condensate discharge must be observed Design variants Possibility 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. 11 Possibility 4 - see chapter 2.7 Neutralisation box and condensate delivery pump With condensate neutralisation - condensate discharge into higher drain line. Fig. 09 Possibility 2 - see chapter 2.5 Execution with Neutralisation box For condensate discharge in lower drain line, incl. condensate neutralisation. Fig. 12 Fig / 02 9

10 ASSEMBLY 2.4 Fitting the condensate drain (standard design) 1. Remove front cover (1a, Fig. 13). Release lateral locking 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. 5. Fit drain (5) on siphon (3) and lead it outwards (optionally left or right side) through the aperture (5a). 6. Fit connecting line (5) to the drain line (2m hose enclosed 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. 1 The condensate drain must be made of corrosion-resistant material. 1a Fig 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 tighten securely (connection must be sealed) 4. Slide the siphon support (3a) under the siphon. 4 5a 3 2 3a 5 Fig / 02

11 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 neutralisation box (Fig. 15) and distribute evenly. 5. Fit rear cover (4, ffig. 17) 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. 1 Fig. 15 front neutralisation granulate 5 4 5a 2. Remove front cover (2a, Fig. 16). Release lateral locking 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. Fig. 17 5b 7. Slide the neutralisation box (6, Fig. 18) into the boiler until the hose of the siphon (1,Fig. 15) is directly beneath the drain connection. 2 2a Fig Fig 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). 3. Remove base plate (3, Fig. 16). Lift base plate straight upwards and remove / 02 11

12 ASSEMBLY 2.6 Fitting the condensate delivery pump (Option) Install the condensate delivery pump (11,Fig. 22) as shown in the drawing. Fig Slightly loosen the jubilee clip (8, Fig. 20) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed). 11 Fig Fill the neutralisation box with water. 11. Fit the front cover (10, Fig. 21) of the neutralisation box. 12. Fit base plate (3, Fig. 16) and front cover (2a). Fig. 22 Before commissioning the siphon must be filled with water in order to prevent flue gas leakage. Fig Before commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage. The condensate drain must be made of corrosion-resistant material / 02

13 ASSEMBLY 2.7 Fitting the neutralisation box and the condensate delivery pump (option) 1. Fit condensate delivery pump (1,Fig. 23) as shown in the drawing. 3. Remove front cover (2a, Fig. 25). Release lateral locking bolt (1, Fig. 22) (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 upwards and remove. 2 2a 1 3 Fig 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. Fig Remove the neutralisation box from its packaging. Remove the front and rear cover of the neutralisation box. Empty the neutralisation granulate into the neutralisation box (Figure 24) and distribute evenly a front neutralisation granulate 5b Fig. 26 Fig / 02 13

14 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. 11. Fill the neutralisation box with water. 12. Fit the front cover (9, Fig. 30) of the neutralisation box. 13. Fit base plate (3, Fig. 25) and front cover (2a). 6 Fig 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). 9 Fig. 30 Before commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage. The condensate drain must be made of corrosion-resistant material. Fig Slightly loosen the jubilee clip (8, Fig. 29) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed). Fig / 02

15 ASSEMBLY 2.8 Fitting the flue gas silencer (Option) The silencer must be installed vertically. The maximum permissible angle of inclination is 45! Fig / 02 15

16 TECHNICAL INFORMATION 3. Technical information 3.1 Description of the boiler The Hoval UltraOil is a low-pollutant, energy-saving oil-fired heating boiler. The UltraOil has a combustion chamber arranged vertically and fabricated from non-corroding stainless steel as its primary heating surface and a secondary heating surface made from corrosion-resistant aluminium alloy. The secondary heating surface is so designed 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 The UltraOil (16-35) meets the requirements of the following directives + standards We hereby declare that the product described, as an individual unit, complies with the standards, guidelines and technical specifications listed. Directives 92/42/EG 73/23/EWG 89/336/EWG "Efficiency directive" "Low-voltage directive" "Electromagnetic compatibility" Regulations Stability pren14394:2001 Building EN303-1 requirements EN303-2 pren pren Low voltage DIN VDE 0722 / Ed EMC EN Part 1 / Ed EN 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 disconnection 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 necessary. Fig / 02

17 TECHNICAL INFORMATION 3.2 Technical data Type (16) (20) (25) (35) Nominal heat output at 80/60 C kw Nominal heat output at 40/30 C kw Heat output range at 80/60 C kw Heat output range at 40/ 30 C kw Heat input kw Dimensions see Dimensional drawing Maximum boiler operating temperature C Minimum boiler operating temperature C no lower limit Minimum boiler return temperature C no lower limit Minimum flue gas temperature at boiler C no lower limit Safety temperature limiter setting (water side) C Operating / test pressure bar 3.0 / / / / 4.5 Boiler efficiency (full load) at 80/60 C (related to net/ gross calorific value) % 98.3 / / / / 92.9 Boiler efficiency (full load) at 40/30 C (related to net/ gross calorific value) % / / / / 97.7 Boiler efficiency at 30% partial load with return flow 27 C (in acc. with EN 303) % / / / / 98.3 ( related to net/ gross calorific value) Standard efficiency (in acc. with DIN 4702, Part 8) at 75/60 C (related to net / gross calorific value) % / / / / 95.0 Standard efficiency (in acc. with DIN 4702, Part 8) at 40/30 C (related to net / gross calorific value) % / / / / 98.2 Standby losses qb at 70 C Watt Combustion gas resistance at nominal output 12.5 % CO 2, 500m above sea level (tolerance +/- 20 %) mbar /30 Condensate rate at 40/30 C l/h Flow resistance boiler 1 z factor Hydraulic resistance at 10 K mbar Hydraulic resistance at 20 K mbar Water flow rate at 10 K m 3 /h Water flow rate at 20 K m 3 /h Boiler water content Litres Boiler gas content m Insulation thickness of boiler body mm Weight (incl. casing, burner) kg Transport weight kg Min. / max. electrical power consumption Watt 4 / / / / 213 Sound level incl. absorber hood 2 Room-air-dependent - Heating noise (EN part 1) db(a) Independent of room air - Heating noise (EN part 1) db(a) Intake noise radiated from the mouth (DIN 45635) db(a) Intake / flue gas noise - LAS - radiated from the mouth (DIN 45635) Room-air-dependent and independent of room air db(a) Flue gas noise inside the flue (EN part 2) db(a) Flue gas noise radiated from the mouth (DIN Part 47) db(a) Combustion chamber dimensions Ø-inside x length mm 294 x x x x 543 Combustion chamber volume m Flue gas mass flow at nominal output 12.5 % CO 2 heating oil kg/h Flue gas temperature at nominal output 80/ 60 C C Delivery pressure at flue gas outlet Pa Maximum chimney draught Pa Flow resistance boiler in mbar = flow rate (m 3 /h) 2 x z 2 Data valid for Hoval oil compact heat station b-i 3 Data without silencer, can be reduced by fitting a silencer Flue gas silencer to Hoval UltraOil Connection on both sides Total length Diameter external Attenuation Resistance Output Type mm mm db (A) Pa kw (16-25) E (35) E / 02 17

18 TECHNICAL INFORMATION 3.3 Dimensions UltraOil (16-35) (All dimensions in mm) Fig. 33 Type A B C D UltraOil (16,20) UltraOil (25,35) Heating flow / safety flow R1" 2 Low-temperature return R1" 3 High-temperature return R1" 4 Flue gas outlet DN80 5 Boiler controller 6 Condensate drain (left or right) incl. siphon DN25 and 2 m PVC continuous-flow tube inner Ø 19 x 4 mm 7 Evacuation 8 Electric cable infeed 9 Absorber hood 10 Heating fittings group or loading group (Option) / 02

19 TECHNICAL INFORMATION 3.4 Space requirement UltraOil (16-35) Fig. 34 min. 100 with silencer Boiler door incl. burner swings upward and to the left or outward. A = minimal 150 mm * Brennerserviceposition vorne - Kesselreinigung 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 / 02 19

20 INSTALLATION 4. Installation 4.1 Boiler room requirements Regarding the building specifications for boiler rooms and their supply and extract air handling, the current building supervisory office regulations specific to the state or country are to be observed. The UltraOil can be operated either dependent on room air or independent of room air. Not dependent upon room air As 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 operation 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 merely required that no partial vacuum in excess of 3 N/m2 occurs. To comply with this requirement, for up to a nominal 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 chimney Project planning instructions The flue gas must be routed through a tested and approved flue gas conduit. -- The flue gas conduit must be gastight, watertight, resistant to corrosion and acids and approved for use with flue gas temperatures of up to 120 C. -- The flue gas system must be suitable for operation at pressure. -- The flue gas conduit 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, observe 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 boilers 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 temperature limiter. For this reason, no additional flue gas temperature limiter is required for the flue gas system with a maximum permitted flue gas temperature of 120 C. -- A closable flue gas measurement nozzle with a circular internal diameter of between mm must be installed in the flue gas conduit. It must protrude beyond the thermal insulation. D 1D D 2xD < 2D Fig. 35 The flue gas measurement nozzle or flue gas measurement aperture must be closed during regular operation of the burner / 02

21 INSTALLATION Example of a flue gas conduit (Hoval flue gas system) 4.3 Fuel The boiler may only be operated with the fuel designated on the boiler rating plate. If necessary, insert Falls erforderlich ist an inspection ein Inspektions-T- Stück T-piece einzusetzen The UltraOil heating boilers are suitable for combustion of the following fuels: -- Heating oil EL low-sulphur in accordance withdin / ÖNorm C Eco heating oil low-sulphur SN / 2008 UltraOil (16-35) Hoval Grid Gitter for zur back Schachthinterlüftung of the ventilation shaft 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 (< %). -- 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 percentages of the total content. Residual amount heating oil EL (sulphur content: 2000 ppm / 0.2 %) max 3 % of tank volume Residual amount heating oil EL (sulphur content: 1000 ppm / 0.1 %) max 5 % of tank volume Residual amount eco heating oil EL (sulphur content: 500 ppm / 0.05 %) max 10 % of tank volume -- In order to reach the permissible mixture ratio with heating oil EL low-sulphur, taking account of the residual amount of heating oil in the oil tank, a 100% tank filling is necessary. -- Natural gas (conversion option to UltraGas ) -- Fig / 02 21

22 INSTALLATION 4.4 Electrical connection The electrical connection must be established by a licensed and qualified electrician. For Austria and Germany: An electrical circuit diagram is supplied with the boiler controls. An all-phase main switch with a minimum contact spacing of 3 mm must be fitted in the power supply line. For Switzerland the following applies: For 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 underside! 1. Schalldämmhaube (1, Fig. 23) abnehmen, dazu seitliche Sicherungsbolzen (2) lösen (ca. ¼- Drehung links und bis Anschlag herausziehen). 2. Untere Frontabdeckung (3) abnehmen, dazu seitliche Sicherungsbolzen (4) lösen (ca. ¼- Drehung links und bis Anschlag herausziehen). 3. Sicherungsschraube (5) entfernen, dazu Abdeckblech-Klemmleiste nach oben anheben (6) und wegnehmen. 4. Sicherungsschraube (7) entfernen und Elektrokasten herausklappen. 5. Kabeleinführung (9). Der Elektroanschluss soll anhand des beigelegten Schemas erfolgen A A Fig / 02

23 INSTALLATION Safety measures relating to EMC assembly 1. For regulator units with their own power supply, separate 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 (boiler control panel regulator unit) must be designed as an independent electrical circuit. Neither fluorescent lamps nor any other equipment which might cause interference may be connected, nor may it be possible to connect such equipment. Fuse Boiler room emergency switch Boiler room lighting and pwer sockets must be in a separate circuit Fig. 38 i The electrical connection must be carried out by an approved electrician. The connection diagram is located within the boiler control box. The electrical circuit diagram is supplied separately. Heat generator Fig 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 antennae, 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: (power supply, burners, pumps, actuators etc.): minimum 1mm2 Maximum permissible length: no restrictions, within the framework of the building s internal installations. Sensor cables and cables carrying low voltages: minimum 0.5 mm2 Maximum permissible cable length: 50 m Data bus lines: must be shielded e.g. J-Y (ST) 2 x 0.6 mm Maximum permissible cable length: 100 m / 02 23

24 INSTALLATION 4.5 Flue gas performance diagrams The 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 C 100 C kw kw UltraOil (20) Flow 80 C/ return flow 60 C Flow 40 C/ return flow 30 C C 100 C kw kw UltraOil (25) Flow 80 C/ return flow 60 C Flow 40 C/ return flow 30 C C 100 C kw kw UltraOil (35) Flow 80 C/ return flow 60 C Flow 40 C/ return flow 30 C C 100 C kw kw kw = heat output C = flue gas temperature using heating oil EL, CO 2 = 12.5% / 02

25 INSTALLATION 4.6 Hydraulic integration Examples Direct heating circuit 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 heating oil EL low-sulphur. As a rule, neutralisation of the condensate is not necessary. Local regulations pertaining to condensate discharge must be observed. D: For the UltraOil, the fuel used must be heating oil EL low-sulphur. Neutralisation is therefore unnecessary. Regarding the discharge of condensate, the local regulations and the ATV (Sewage Engineering Association) datasheet must be observed. Fig Setting the temperature regulators Basic 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. Mixer circuit and water heater 4.9 Safety valves The 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 output. The valve must be installed in the flow line in the immediate vicinity of the boiler. M 4.10 Charging pump (boiler with water heater) Speed of rotation and output must correspond to the requirements of the water heater. Setting carried out by the heating installation engineer. Fig Condensate discharge The boiler condensate drain must be made of corrosionresistant material. The following materials are suitable for the condensate drain: -- PVC -- PE -- PP -- ABS 4.11 Heating pump Speed of rotation and output must correspond to the requirements of the system. They are to be set by the heating installation engineer. A: The minimum inner diameter of the condensate drain must be 15 mm. The condensate drain must be sufficiently inclined / 02 25

26 COMMISSIONING 5. Commissioning 5.1 Water quality Heating Water The European Standard EN and the directive VDI 2035 must be observed. In particular, attention must be paid to the following stipulations: Hoval boilers and calorifi ers are designed for heating plants without signifi cant oxygen intake (plant type I according 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 refilling is necessary) must be equipped with separate circuits. Treated fi lling and replacement water must be tested at least 1x yearly. According to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refi lling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI The Directive VDI 2035 applies equally to the replacement 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 lling and replacement water. However, as not all drinking water is suitable for use as as fi lling and replacement water the water quality must fulfi l the standard set in VDI 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 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 content of the plant). The total amount of fi lling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. Maximum filling capacity based on VDI 2035 Total hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 Boiler size of the individual boiler maximum filling quantity without desalination to 50 kw NO REQUIREMENT 20 l/kw 1 Sum of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary / 02

27 COMMISSIONING 5.2 Filling the heating system Filling of the heating system must be carried out by trained personnel. The fill and make-up water must comply with the quality requirements in the relevant state or country (see chapter 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 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 burner Setting 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 instructions 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/storage Have 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 50). The system manufacturer is responsible for providing operating instructions for the whole plant. The technical information / installation instructions must be kept with the plant at all times / 02 27

28 COMMISSIONING Cross where applicable; cut out record and fasten to the control during the active screed function. Minimum requirements for the activation of the screed function: Minimum age cement screed 21 days Minimum age calcium sulphate screed 7 days Flow temperature monitor installed and connected For newly laid screed - see Recommendation of the Federal Association of Radiant Panel Heating. Heating circuit selection for screed function and necessary parameter settings Mixing circuit 1 Mixing circuit 1 Start MC1/MC2 level Parameters 13,16 PRESS Activate Installer level (Code entry) > 3 sec: Access to level Select / Confi rm Set Confi rm End / Exit Required parameter settings: Parameter level Par. No Setting Description MIX.VALVE (1 or 2) C Maximum fl ow temperature to be set MIX.VALVE (1 or 2) 16 Screed program to be set (for description see following page) Function heating (duration: Starting day + 7 days) 2 Surface-ready heating (duration: Starting day + 18 days) 3 Function and surface-ready heating (duration: Starting day + 25 days) Direct heating circuit (possible only with H-Gen without minimum H-Gen temperature - e.g. condensing boiler) Start HC level Parameters 13,16 PRESS H-GEN level Parameter 4 Characteristic heating curve Enable HC Activate Installer level (Code entry) > 3 sec: Access to level Select / Confi rm Set Confi rm End / Exit Required parameter settings: Parameter level Par. No Setting Description - Key DK... Activate heating characteristic curve, above 0 = OFF, e.g. ~ 0.8 for FBH UNMIXED CIRC C Maximum fl ow temperature to be set UNMIXED CIRC Screed program to be set (for description see following page) 1 Function heating (duration: Starting day + 7 days) 2 Surface-ready heating (duration: Starting day + 18 days) 3 Function and surface-ready heating (duration: Starting day + 25 days) HEAT GENER C Max. H-Gen temperature to be set, set as for max. fl ow temperature (after termination of screed function reset max. temperature to the value required). If the screed function is activated for the unmixed circuit, all the other circuits (MC, DHW) are switched off. In alternation with the basic display of the controller, the activated screed heating is displayed giving some information about the remaining term in days screed Record Screed heating activated by:... Screed heating activated on:... Screed heating ends on: Date and signature / 02

29 COMMISSIONING Parameter 16 Screed function (Parameter HC, MC1 or MC2) Example: Maximum fl ow temperature 40 C 1 Function heating T [ C] VLSol maximal 55 C maximum 55 C einstellbar! set level! 1=Funktionsheizen Starting day + 7 days 1 = Function heating START DAYS t [TAGE] On the starting day and for the three following days at 25 C constantly Subsequently for 4 days at the set fl ow maximum temp., but limited to a maximum of 55 C 2 Surface-ready heating T [ C] VLSol =Belegreifheizen Starting day + 18 days 2 = Surface-ready heating START DAYS t [TAGE] On the starting day and on the 1st day constantly at 25 C, on each further day the demand value rises by 5 C until the maximum fl ow temperature is reached. Subsequently the temperature is lowered again in the same gradations until the low point of 25 C is reached. Example: Set fl ow maximum temp.: 40 C Starting day + 1st day: 25 C 5th - 15th day: constant heating with the max. flow temperature 2nd day: 30 C 16th day: 35 C 3rd day: 35 C 17th day: 30 C 4th day: 40 C 18th day: 25 C 3 Function heating and surface-ready heating Starting day + 25 days T [ C] VLSol =Funktionsheizen 3 = Function heating and und surface-ready Belegreifheizen heating START [TAGE] t DAYS Combination of 1 function heating and subsequently 2 surface-ready heating / 02 29

30 MAINTENANCE 6. Maintenance 6.1 Information for combustion controller/chimney sweep regarding emission monitor key All other control elements of the control unit are described in the operating instructions. The emission monitor key can also be used to change over to manual operating mode. Emission monitor key / Manual operation To protect under floor heating systems against invalid overheating during emission monitoring / manual operation it is necessary to implement appropriate safety measures (e.g. safety temperature limiter with pump switch-off). The duration of the emission monitoring is limited to 20 minutes and shall be restarted, if necessary. Scalding hazard due to hot water temperature, since the hot water temperature can exceed the temperature setpoint! Emissions metering PRESS SHORTLY E SS O. Remaining time display Immediate end REACTIONS for emissions metering Time unit automatically 20 min. thereafter reverts Boiler temperature - > maximum temperature restriction Regulate to the maximum temperature the heating circuits and the water heaters (at the direct heating circle only, if the warm water mode of operation is adjusted to parallel operation) With 2-step heat generator both stages are in operation Manual operation PRESS > 5 seconds A UA. Immediate end REACTIONS for manual operation Set reference boiler temperature with button! All heating pumps ON Mixer without current - manual setting necessary! Note the maximum permissible temperature of the fl oor heating! The hot water temperature reaches the set DHW maximum temperature (expert level standard 65 C) / 02

31 MAINTENANCE 6.2 Cleaning the boiler The UltraOil may only be cleaned by a licensed specialist or Hoval customer service technician. Reliable and safe operation of the oil boiler, optimum efficiency and clean combustion can only be 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 maintenance contract with Hoval customer service, or with an authorised specialist dealer. In the case of oil-fired equipment already in operation during the construction phase (where there is increased occurrence 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 carried out Re-assembling the boiler If applicable, reattach neutralisation box (9, Fig. 44) and siphon/siphon base section/siphon support (7, 8, 8a). Attach the front cover of the boiler socket (10) Close the burner with boiler door (3, Fig. 42) 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 Preparations for cleaning the boiler and burner Set the operating mode on the boiler controller to Stand-By Wait approx. 1.5 minutes and then set the main switch of the boiler controller to 0 Remove absorber hood (1, Fig. 42). 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. 43) Depending on the design, unscrew or remove siphon trap (7, Fig. 43), siphon base section (8, fig. 38), siphon support (8a) or neutralisation box (9, Fig. 44). Danger: flue gas escaping through the siphon can endanger lives (poisoning). The siphon (page 31, Fig. 44, pos. 11) must always be filled with water. The condensate drain line must not be soiled or blocked. Before replacing the siphon, fill it with water. Check whether the condensate drain line is soiled/blocked. Undo the burner plug-in connections (burner cable, remote reset cable). Release the lock nuts (4, Fig. 42) 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 if fitted) as described in chapter 6.4. For cleaning the alufer -pipes, the best tool is the cleaning scraper available from Hoval (part no ). For a detailed description of how to clean the combustion chamber and the alufer pipes, see chapter / 02 31

32 MAINTENANCE Fig. 42 Design with condensate discharge Design with neutralisation box (if fitted) a Mount hose for Fig. 43 wet cleaning Fig / 02

33 MAINTENANCE 6.3 Cleaning the combustion chamber and the alufer pipes Cleaning scraper in the case of light dirt build-up Carry 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 individual fl ow ducts are free of deposits and combustion residue! in the case of heavy dirt build-up Carry 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 scrapers) to remove stubborn dirt build-up is available from Hoval, Art. No Before removing the drain hose, all dirt particles must be adequately rinsed out of the condensate drip tray. Flow duct alufer pipe 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. Leakage testing After cleaning or at least every fi ve years, the sealing between the combustion chamber and the condensate drip tray must be checked for leakage. This can be done by fi lling the boiler with water. 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 wearing of gloves and protective goggles. In addition, the instructions on the original packaging must be observed. 1 Filling level water / 02 33

34 MAINTENANCE 6.4 Servicing the neutralisation installation (if fitted) Siphon Neutralisation granules i Maintenance should be undertaken at least every second year, or after the neutralisation granules are exhausted (check the ph-value if appropriate with litmus paper test). Neutralisation granulate for refi lling can be ordered from Hoval under the following item no.: 1 pack (3 kg) neutralisation granules Part no 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 neutralisation granulate, since it is harmless, can be disposed of as domestic waste. Refi ll the neutralisation box with new granules. Attach the neutralisation box cover making sure that it is tight-closing. Push the neutralisation box back in. Before putting back into service, the siphon and the neutralisation box must be filled together with water. The water can be poured through the cleaning aperture into the neutralisation box and the siphon / 02

35 MAINTENANCE 6.5 Safety temperature limiter - Reset Fig. 45 Boiler water temperature limiter - Reset If the boiler temperature rises too high (>100 C), the system is switched off by the safety temperature limiter by means of a mechanical lockout. Press the reset button on the control panel (first remove the cover): the boiler is ready for operation again once the boiler water temperature is less than 80 C / 02 35

36 MAINTENANCE 6.6 Resetting the fault message Flue gas STL or flue gas temperature limiter unblocking Resetting the fault message Flue gas STL If the maximum permissible flue gas temperature is exceeded, the following fault message appears Flue gas temperature limiter - reset (if no flue gas sensor is fitted) If the flue gas temperature rises too high, the system is switched off by the flue gas safety temperature limiter by means of a mechanical lockout. Press the reset button: the boiler is now ready for operation again. Fig. 46 EXHAUST. ERROR STB Flue gas temperature limiter - Reset The fault message is reset by switching the main switch of the controller off and on. Fig. 47 The reason for the excessive flue gas temperature must be established by the installation engineer. Possible causes are: Strong dirt build-up on the heating surface Burner output setting too high Operation without jet inserts Fig. 48 The reason for the excessive flue gas temperature must be established by the installation engineer. Possible causes are: Strong dirt build-up on the heating surface Burner output setting too high Operation without jet inserts / 02