Technical information Assembly instructions. Uno-3 (320, 360) Oil/gas boilers

Transcription

1 Technical information Assembly instructions Uno-3 (320, 360) Oil/gas boilers These instructions are applicable to the following types: 7-Uno-3 (320, 360) 7-Uno-3 b-i * (320, 360) * = Burner integrated Hoval products must be installed and commissioned only by appropriately qualified experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualified electrician. Uno-3 (320, 360) boilers are suitable and licensed for use as heat generators for hot water heating systems with a permissible flow temperature of up to 100 C 1 ). They are designed for closed-circuit systems, but can also be installed in open systems as per EN ) See chapter 3.2 Subject to modifi cations / 02-12/13 EN

2 TABLE OF CONTENTS 1. Important notes 1.1 Other instructions Safety instructions Regulations, official approvals Warranty Installation 2.1 Installation position Setting up, levelling Fitting the thermal insulation Fitting the casing Fitting the boiler controller on the side Fitting the boiler controller at the top Technical information 3.1 Description of the boiler The Uno-3 (320, 360) complies with the following directives + standards Technical data Uno-3 (320, 360) Dimensions Overall dimensions and space requirements Installation 4.1 Boiler installation room requirements Flue connection and dimensioning Installing the burner Noise damping Fuel Electrical connection Electrical connection of burner Flue gas and performance diagrams Flow mixing loop / minimum limitation of the boiler return temperature Setting the temperature controllers Safety valves Charging pump (boiler with free-standing calorifier) 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/gas burners Handover to the operator/storage Maintenance 6.1 Information for combustion controller / chimney sweep regarding emission monitor key Cleaning Preparatory work Cleaning (dry or wet method) Putting into operation again Overview of settings 7.1 Table of parameters Overview of alarms TopTronic T / 02

3 IMPORTANT NOTES 1. Important notes 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 enclosed with the components. Further information sources Hoval catalogue Standards, regulations 1.2 Safety instructions The system may only be placed in operation if all the relevant standards and safety regulations have been complied with. At least the following conditions must be satisfied for a trial operation: 1. Safety valve installed (system sealed). 2. Control system in operation (connected to the power supply). 3. Sensor for the safety temperature limiter mounted in the immersion sleeve. 4. System filled with water. 5. Expansion tank connected. 6. Flue gas outlet with flue gas conduit connected to flue gas system. 7. An adequate supply of fresh air must be guaranteed. 8. Burner preset. 1.3 Regulations, official approvals The following regulations are to be complied with for installation and operation: Germany DIN EN Heating systems in buildings Method for calculation of the design heat load. EN 303 Heating boilers with forced draught burners. DIN EN Sheet 1 and 2 Heating systems in buildings design of water-based heating systems. DIN 4755 Oil-fired systems. Design, construction and safety engineering requirements. DIN 4756 Gas-fired systems; construction, execution, technical safety requirements, planning and execution. DIN House chimneys; requirements, planning and execution. TRD 702 Steam boiler plants with calorifiers of the group II. DIN EN Flue gas systems Calculation methods in heat and flow engineering. TRD 721 Safety devices against excess pressures / safety valves / for steam boilers of Group II. VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water heating systems. DIN / VDI 0116 Electrical equipment for firing systems (VDE Regulation). For further standards applicable in Germany, see appendix N Austria ÖNorm ÖNorm B 8130 Open water heating systems; safety devices. Norm B 8131 Closed water heating systems; safety, execution and testing requirements. ÖNorm B 8133 Hot water production systems; technical safety requirements. ÖNorm B 8136 Heating systems, space requirements and other building requirements. ÖNorm M 7515 Calculations of dimensions of chimneys; terminology, calculation procedure. ÖNorm H 5171 Heating systems, construction engineering requirements. ÖVGW TR-Gas G1 Technical directives for low pressure gas installations. ÖNorm M 7445 Gas blower burner. Switzerland VKF Association of Cantonal Fire Insurers Fire prevention authority regulations. Requirements of the SVGW Swiss Association of Gas and Water Suppliers. SWKI 91-1 Aeration and ventilation of the boiler installation room. SWKI 88-4 Water treatment for heating, steam and air conditioning systems. SWKI 93-1 Safety engineering installations for heating systems. KRW Corrosion caused by halogen compounds. KRW/VSO/FKR Plug-in electrical connections on heating boilers and burners and further regulations and standards issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and the legislative body. Also to be complied with are the regulations of the local building authorities, insurance companies and chimney sweeping operations. The regulations of the responsible gas supply company are also to be complied with and any necessary official approval obtained / 02 3

4 IMPORTANT NOTES 1.4 Warranty Proper function is only guaranteed providing these instructions are followed and the boiler is regularly maintained 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 and an inadmissibly high lime content of 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, halogenated fluids, solvents and cleanings agents / 02

5 ASSEMBLY 2. Installation 2.1 Installation position Where limited space is available, the Uno-3 can be transported standing on the door. Hex nuts are mounted behind the door as supports for this purpose. After transport, they can simply be screwed back to the bracket. Release and screw back 6 transport counter nuts (1, Figure 01) before commissioning Setting up, levelling A special foundation plate for the boiler is not an essential, but it is recommended. Space requirement For mounting the thermal insulation and sheet metal cladding: at least 40 cm each on the left and right side of the boiler. If the space between the boiler and the wall is less, all heat insulation and casing must be fitted before the boiler can be pushed into its final position. Do not connect lines until the heat insulation and casing have been fitted to the boiler! There must always be enough space between the back of the boiler and the wall to allow easy access to the cleaning aperture in the flue gas collector. There must be enough space to swing open the boiler door, incl. the burner. Figure 01 Levelling Using a spirit level, align the upper edge of the boiler water jacket (longitudinal axis of the boiler) until it is precisely horizontal or sloping very slightly upwards towards the rear by inserting the plinth rails correspondingly, to allow the boiler to vent properly. Before fitting the burner, first fit the double door (8a, Figure 05) (door casing) / 02 5

6 ASSEMBLY 2.3 Fitting the thermal insulation 1. Mount the front retaining bracket (1, Detail A, Figure 02) with hexagon screws M8, nuts and U-washers, aligned horizontally, to the front wall of the boiler. Attach C-clips. 2. Mount the rear retaining bracket (2, Detail B) with hexagon screws M8, nuts and U-washers aligned horizontally. Attach C-clips. 3. Place the insulation mat (3, 3a) around the boiler body (with the joint at the top, black side facing outwards, see Figure 3). 4. Attach the insulation mat (3, 3a) using 4 plastic straps (4) and strap fasteners (4a, Detail C): - - tension springs (4b) serve for additional fixing - - Do not overtighten the straps (reduced insulating value) 5. Attach the insulation mats (5/5a/5b) to the pins provided on the rear wall of the boiler and secure with retaining discs (ø 38). Wrap the insulation mats (5c) around the connection fittings and secure with tension springs. 6. Attach insulation panels (6/6a/6b/6c/6d) to the pins welded onto the flue gas collector and secure with the retaining discs (ø 38). 7. Attach insulation panels (7/7a/7b/7c/7d) to the pins welded onto the front wall of the boiler and secure with the retaining discs (ø 38) provided. i The remaining 2 insulation mats (12, Figure 05) are fitted after mounting the casing / 02

7 ASSEMBLY 7 7a 7c Detail C 4a 7d 4 3 7b 4b 3a 6 6b C-clips 5a 5c 6c Detail A 1 6d 5 6a 5b Detail B Figure / 02 7

8 ASSEMBLY 2.4 Fitting the casing 8. Fix bolts (8, Detail D, Figure 05) with hexagon nuts M8 and U-washers to the door and then mount door cladding (8a). 9. Place support (9) on the hinge holder (Figure 6a). Attach 4 special screws (9a, Detail E) with counter nuts to the side sections (9b/9c). Fit burner plug (9d) into the front left (or right) side section and route the burner cable (9e) (possibly over the boiler) to the opening for the controller (cable routing as shown in Figure 05). Place right and left side sections (9b/9c) into the support (9) and attach to the front brackets with self-tapping screws ø 4.8 x Mount support (10, Detail F) with hexagon bolts and nuts on the water jacket base (back wall of boiler). Important: support (10) must be aligned so that top edge of support (9) and top edge of support (10) are at the same height. 11. Hook lower right and left side wall (11) into the side sections (9b/9c) and attach to the front and rear retaining brackets with self-tapping screws ø 4.8 x 38. Hook upper right and left side wall (11a) into the side sections (9b/9c) as well as into support (10) and attach to the front and rear retaining brackets with self-tapping screws ø 4.8 x Place 2 insulating mats (12) left and right in longitudinal direction (to prevent vertical air circulation). 13. Only applies if mounting the controller on the side (see chapter 2.5): Fit 2 special screws (13, Figure 03) with counter nuts to the side wall on which you are mounting the controller. 14. Attach rear wall (14, Figure 05) to the angled edges of the side walls (11, 11a) with self-tapping screws ø 4.8 x 38 and C-clips. 2.5 Fitting the boiler controller on the side The controller must be mounted on the side of the Uno-3. If this causes problems due to limited space, it is also possible to fit the controller on the top of the Uno-3. You will find a description of how to do this on the next page. 15. Remove the control box cover plate (15, Figure 05). Hook the switch control box (15a, Figure 03) into the side wall (11a, Figure 05) with the recesses for the special screws and secure it with 2 self-tapping screws ø3.5 x 6.5 and serrated washers (15b, Figure 4). 16. Pull the capillaries with the immersion sensors (16, Figure 04) through the opening (16, Figure 03) in the side wall, insert them into the immersion sleeve (16b, Figure 05) as far as the stop and fix in position with retaining spring (16c, Figure 04). Attention: The capillaries must not be folded or kinked! 17. Attach cover plate (15, Figure 05) with self-tapping screws ø3.5 x 6.5 and serrated washers. 18. Position cladding cover (18, 18a, 18b) and fix left and right with 2 self-tapping screws ø 4,8 x 38 each. (Model with accessible covers, see separate instructions) 19. Fit cover plate (19, 19a) with self-tapping screws ø 3.5 x Affix labels and where applicable, mount manual holder on the side. 21. Remove transport lock (see chapter 2.1) a 16c 16 15a 15b Figure 03 Figure / 02

9 ASSEMBLY 8a 9 Detail F Detail D b 8a 19a 18 18a 9d 16b 9c 9e 11 Detail E 18b 9a 14 11a 15 Figure / 02 9

10 ASSEMBLY 2.6 Fitting the boiler controller at the top 15. Remove the control box cover plate (15, Figure 05). The control panel (15a, Figure 06) must be turned around. To do this, remove the pressure lock sleeves (15b, press together and pull off) and the earthing screw and serrated washer (15c). Attach the special screws (15d) in the casing cover (15e) with counter nuts. Position switch control box (15f) on the casing cover (15e) with the recesses for the special screws and secure with 2 self-tapping screws ø3.5 x 6.5 and serrated washers (15h). Fit casing cover (15e, Figure 07) and secure with self-tapping screws (ø4.8 x 38). 16. Pull the capillaries with the immersion sensors (16, Figure 04) through the opening (16a, Figure 06) in the cover, insert them into the immersion sleeve (16b, Figure 07) as far as the stop and fix in position with retaining spring (16c, Figure 04). Insert the burner plug (16d, Figure 07). 17. Attach cover plate (15) with self-tapping screws ø3.5 x 6.5 and serrated washers. 18. Position cladding cover (18, 18a) and fix left and right with self-tapping screws ø 4,8 x 38. (Model with accessible covers, see separate instructions) 19. Fit cover plate (19, 19a) with self-tapping screws ø 3.5 x Affix labels and where applicable, mount manual holder on the side. 21. Remove transport lock (see chapter 2.1). Attention: The capillaries must not be folded or kinked! 15b c 15f 15h 15a 15d 15e Figure 06 16a / 02

11 ASSEMBLY 18 18a 16b 15 15e 16d 19a Figure / 02 11

12 TECHNICAL INFORMATION 3. Technical information 3.1 Description of the boiler The Uno-3 is a threepass boiler. At the end of the circular cylindrical combustion chamber, the flame gases flow through several cylindrical tubes arranged above the combustion chamber and towards the front to the turning chamber, from where they flow through rectangular ducts (thermolytic heating surface) towards the rear and reach the flue gas collector. The flue gas temperatures can be varied within a specific range through the installation of various regulator combinations The Uno-3 (320, 360) complies with the following directives + standards We hereby declare that the product described, as an individual appliance, complies with the standards, guidelines and technical specifications laid down. Directives 90/396/EC 92/42/EC 73/23/EEC 89/336/EEC 97/23/EC "Gas Equipment Directive" "Efficiency directive" "Low-voltage directive" "Electromagnetic compatibility" "Pressure Equipment Directive" (PED) Regulations Stability pren14394:2001 Building EN303-1, EN303-2, EN303-3 requirements Low voltage DIN VDE 0722/ Ed EMC EN Part 1/ Ed Figure / 02

13 TECHNICAL INFORMATION 3.2 Technical data Uno-3 (320, 360) Type (320) (360) 1 Nominal heat output at 80/60 C kw Heat output range (heating oil EL, natural gas H: variant 1 and 3) kw Heat output range (heating oil EL, natural gas H: variant 2) kw Maximum heat input kw Maximum boiler operating temperature 2 C Safety temperature limiter setting (water side) 2 C Operating/test pressure at max. operating temperature 90 C 1 bar 4.0/ /5.2 Maximum boiler operating temperature 3 C Safety temperature limiter setting (water side) 3 C Operating pressure at max. operating temperature 105 C 3 bar Minimum boiler operating temperature C see table of operating conditions (below) Minimum boiler return temperature C see table of operating conditions (below) Minimum flue gas temperature at boiler C see table of operating conditions (below) Regulator set for 170 C flue gas temperature - - Boiler efficiency at full load at 80/60 C (related to lower/upper calorific value (heating oil EL)) % 93.5/ /87.3 Boiler efficiency at partial load 30 % at return 37 C (acc. to EN 303) (related to lower/upper calorific value (heating oil EL)) % 95.5/ /89.6 Standard efficiency at 75/60 C (DIN 4702 Part 8) (related to lower/upper calorific value (heating oil EL)) % 96.6/ / 90.4 Standby losses qb at 70 C Watts Resistance on the heating gas side at nominal output 180 C flue gas temperature, 12.5 % CO 2, 500 m above sea level (tolerance ±20 %) mbar Flue gas mass flow at nominal output 12.5 % CO 2 heating oil kg/h Maximum flue draught Pa Flow resistance boiler 4 z-value Hydraulic resistance at 10K mbar Hydraulic resistance at 20K mbar Water flow rate at 10K m³/h Water flow rate at 20K m³/h Boiler water capacity Litres Boiler gas content m³ Insulation thickness of boiler body mm Weight (incl. casing) kg Combustion chamber dimensions Ø-inside x length mm ø488x1634 ø488x1634 Combustion chamber volume m³ Dimensions see dimensional drawing Maximum depression in flue gas system (boiler connection) Pa Not available in Switzerland 2 Controller U3.1 and T2.2 3 Controller U3.2 and T0.2 4 Flow resistance boiler in mbar = flow rate (m³/h) 2 x z Possible operating conditions Fuel Heating oil EL Natural gas H Heating oil L Uno-3 type ( ) ( ) ( ) ( ) Option 1 Variant 2 Option 3 Option 1 Variant 2 Option 3 min. flue gas temperature C min. boiler temperature C min. return temperature C No lower No lower limit limit Return maintenance yes yes no yes yes no yes yes Boiler start-up protection 1 no no yes no no yes no no 1 If the boiler temperature is or drops below the minimum boiler temperature (variant 3) and there is no return maintenance then the load must be switched off using a corresponding control function / 02 13

14 TECHNICAL INFORMATION 3.3 Dimensions (All dimensions in mm) 5 q v u h 205 g k i a b m 860 s t l 8 e f d 1 Flow DN 80, PN 6 2 Return DN 80, PN 6 3 Thermostat immersion sleeve ¾ 4 Drain pipe R 1½ 5 Flue gas outlet Ø external, plate thickness 3 mm 6 Cleaning aperture 455/95 mm 7 Boiler controller on the right/left or top 8 Plinth rail, width 50 mm 9 Boiler door attached on the right (on the left if desired) 10 Flue gas collector cleaning connection R 1" 11 Burner sound attenuation cowl; feet on rollers, height 50 mm, adjustable up to 170 mm 12 Possible anti-vibration elements; width 80 mm, height 50 mm Uno-3 Type l b h a d e f g i k m q Ø s t u v ( ) ; 4xM Overall dimensions and space requirements Boiler (without calorifier) incl. swivel flange, connections and flue gas collector. Uno-3 Type Width B Length L1 Length L2 Height H Weight kg (320.36) / 02

15 TECHNICAL INFORMATION Minimum overall unit dimensions boiler upright Boiler (without calorifier) upright with swivel flange at bottom, transport on trolley or rollers provided by the client. Example calculation for the required corridor width Door width T = Uno-3 (320, 360) K= x 1481= Corridor width Dimension of boiler door Space for using a trolley 1 Transport board (by client) 2 Pipe as roller (by client) 3 Boiler door (can be removed) 4 Hinge bracket Uno-3 Type Boiler height with without connection b. connection b. Flue gas collector Flue gas collector H1 H2 Width B Length L Uno-3 Type Max. width for trolley a Available ground clearance with boiler door b without boiler door c (320, 360) (320, 360) Required minimum width of door and corridor for bringing in the boiler The following values are the calculated minimum values. K B K= x L T B T= x L K T K B L Door width Corridor width Boiler width Maximum boiler length L B < 150 Example calculation for the required corridor width Door width T = Uno-3 (320, 360) K= x 2114 = Corridor width T / 02 15

16 TECHNICAL INFORMATION Tilting out of the boiler door and cowl dimensions b a f g e c h d d Sound reducing cover Type a b c d e 1) f g h Uno-3 (320) depending on burner 606 depending on burner 400 depending on burner Uno-3 (360) depending on burner 606 depending on burner 400 depending on burner ) Minimum distance 100 mm / 02

17 INSTALLATION 4. Installation 4.1 Boiler installation 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. In Germany the firing regulations for the individual Bundesländer are to be complied with. Make sure there is an adequate supply of fresh air to the boiler room, to ensure that the combustion air supply necessary for all the firing systems operated there can flow in without hindrance and that no oxygen deficiency occurs for the operating personnel. Binding values for the size of supply air openings are not generally specified in the relevant regulations; it is merely required that no partial vacuum in excess of 3 N/m 2 occurs. An opening or line leading into the open air of at least 150 cm 2. For every kw in excess of 50 kw, a further 2 cm 2 must be calculated. 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. In Austria ÖNorm H 5171 additionally stipulates a flue air aperture. This must have a minimum cross section of 180 cm 2 up to a rated heat output of 100 kw. For every further kw, the cross-section must be increased by 1 cm 2. The flue gas system must be watertight, acid-proof and approved for the corresponding flue gas temperatures. Existing flue gas systems may require upgrading or adjustment of the flue duct cross-section as indicated by a chimney engineer. The correct functioning of the flue duct, i.e. the generation of the required delivery pressure depends on: a) the type (nature) of the chimney (thermal insulation, interior surface roughness, sealing etc.). b) the connection of the boiler to the chimney according to specification. c) the correct chimney cross section dimensioning. ref. a) Chimneys according to EN 13384, part 2, execution types I and II are appropriate for modern firing systems (advice from the chimney specialist is necessary). to b) The flue gas pipe connecting the boiler to the flue gas system must be as short as possible and placed at an angle of The entry location of the flue gas pipe must be carefully sealed. The introduction of the flue gas pipe into the chimney (A) must be executed so that no condensate water can flow from the chimney into the flue gas pipe and the boiler (Figure 09). 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. A 4.2 Flue connection and dimensioning To guarantee economic and fault-free operation, boiler and chimney must be mutually adapted to create a functional unit. Moisture-resistant and acid-proof flue gas systems must be used in new installations. Figure 09 Where possible, avoid 90 bends in the flue gas system! Flue gas pipes longer than 1 m are to be insulated / 02 17

18 INSTALLATION Normally only one heat producer may be connected to the chimney! Flue gas pipes longer than 1 m are to be insulated. If an adapter (reducer) from the flue gas outlet of the boiler to the entry point into the flue gas system is required, it must take the form of a slim cone. from vom the boiler Kessel zum to the chimney Schornstein Figure 10 to c) Dimensioning the chimney cross section. The cross sections are to be calculated for boilers without delivery pressure requirement according to EN (Please also observe DIN 18160, Part 1 "Domestic chimneys"). Take into consideration location-specific factors (hillside location of the building, chimney position, slope of the roof, chimney stack exit shape, etc.)! In Switzerland, take note of SIA Recommendation 384/4! In Austria, calculation is performed as prescribed by ÖNorm M Non-binding guide values for dimensioning of the flue duct for boiler types Uno-3 (320, 360). Inside diameter of flue duct in mm Boiler type Uno-3 kw * Chimney height m (320) 320 ~ 300 (360) 360 ~ 350 *kw = maximum boiler output Based on: Flue gas pipeline 5 m long, 2 90 elbows and 1 45 elbow, outside air 15 C, height above sea level max. 800 m, flue gas pipeline same ø as flue gas connector on boiler. You are recommended however to use the services of the chimney specialist right from the planning stage! / 02

19 INSTALLATION 4.3 Installing the burner Depending on the size of the burner flange, an intermediate flange may be required to attach the burner. To allow the burner to be swung out 90 to the left or right, the connections must be flexible and routed to the burner in sufficiently large loops. The cavity between burner pipe and boiler flange must be insulated with the fireproof fibre provided. In systems with ThermoCondensor, the burner must additionally absorb the resistance of the ThermoCondensor and the flue. f Uno-3 E F G H L max. N O Ø Ø Figure 11 Uno-3 A B C D M Ø Ø (320, 360) ; 4xM (320, 360) Noise damping Gas pipelines are to be installed so that no vibrations can be transferred to the building. A foundation plate under the boiler unit. We recommend the following sound attenuation components: Heat and sound attenuation cowl over the burner Flue gas silencer in the exhaust gas pipe Flexible exhaust gas pipe sleeves on the boiler exhaust gas pipe Vibration elements for the plinth rail / 02 19

20 INSTALLATION 4.4 Fuel The boiler is only to be operated with the fuel stated on the boiler rating plate. 4.6 Flue gas and performance diagrams Uno-3 (320) Uno-3 boilers are normally suitable for burning the following fuels: Heating oil EL in accordance with DIN / SN /2 / ÖNorm C 1109 Heating oil L in accordance with ÖNorm C 1108 All combustible gases in accordance with DVGW Work sheet G Electrical connection A qualified technician must install the electrical supply to the equipment. The electrical circuit diagram is located in the electrical box. For Switzerland, the following applies: The system-related electrical circuit diagram must be referred to when making the electrical connection! For Austria only: The diagram folder is located in the switch control box. Please affix the correct connection diagram to the inside of the terminal cover. 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. Applies only for Germany: The diagram folder is located in the switch control box. 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. C Uno-3 (360) C kw kw = Heat output kw C = Flue gas temperature with heating oil EL Boiler flow 80 C Return flow 60 C CO 2 = 13 % During the combustion of natural gas or heating oil L, the flue gas temperature is approx. 15 C higher Electrical connection of burner The burner must be connected to the boiler with the standard plug and socket connection. The burner cable must be shortened so that the plug-in connection has to be parted to swing out the burner / 02

21 INSTALLATION 4.7 Flow mixing loop / minimum limitation of the boiler return temperature Hydraulic and control measures must be provided to ensure that the operating conditions are complied with in terms of boiler flow and return temperatures. 4.8 Setting the temperature controllers Boiler temperature controller, selectable TR 50 C 85 C 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. If a calorifier is connected, the priority circuit disables the boiler temperature regulator until the temperature is reached. The boiler temperature can rise to approx. 85 C. 4.9 Safety valves The heating system and hot water supply must each be protected with one safety valve against impermissibly high pressures. The discharge capacity of the heating system safety valve must correspond to the boiler s maximum nominal heat output. The valve is installed in the safety flow. In Germany, only safety valves with the code letter "H" in the approval mark may be connected, and they must always be connected at the boiler safety flow. Water shortage protection in accordance with DIN 4751 Part 2 Section 9 is mandatory Charging pump (boiler with free-standing calorifier) Speed of rotation and output regulation must correspond to the requirements of the free-standing calorifier. Setting carried out by the heating installation engineer Heating pump Speed of rotation and output regulation must correspond to the requirements of the system and the regulations. They are to be set by the heating installation engineer / 02 21

22 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 which have con tact with water are made of ferrous materials. On account of the danger of stress cracking corrosion the chloride, nitrate and sulfate con tents of the heating water must not exceed 200 mg/l in total. The ph value of the heating water should lie between 8.3 and 9.5 after 6-12 weeks of heating operation. Filling and replacement water For a plant using Hoval boilers untreated drinking water is generally best suited as heating medium, i.e. as fi 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 50 to 200 kw NO REQUIRE- 50 l/kw 20 l/kw 20 l/kw 200 to 600 kw MENT 50 l/kw 50 l/kw 20 l/kw always desalinate 1 Sum of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary / 02

23 COMMISSIONING 5.2 Filling the heating system Filling of the heating system must be carried out by trained personnel. The filling and replacement water must comply with the quality requirements in the relevant state or country (VDI 2035 or SWKI 88-4 or ÖNORM H 5195). 5.3 Filling the water heater (if fitted) The heating boiler may be put into operation even when the calorifier is not filled. 5.4 Commissioning Important: On first commissioning, check that all safety and control devices are functioning properly (in accordance with the operating manual). The operation and maintenance of the system must be explained to the user in detail. In some areas, gas or dual-fuel systems may only be commissioned by an engineer from the local gasworks. Check with the local gasworks to make sure. 5.5 Oil/gas burners 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. 5.6 Handover to the operator/storage Have the operator confirm in writing that the operating and maintenance procedures have been explained and that he or she has received a copy of the relevant operating manuals. (See sample on page 40). The manufacturer of the unit is responsible for providing operating manuals for the complete system. This technical information / these installation instructions must not be destroyed after completing the commissioning procedures, but should be permanently stored with the unit / 02 23

24 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 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 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

25 MAINTENANCE 6.2 Cleaning Cleaning should be performed at least twice per year. Cleaning at intermediate intervals is necessary if the flue gas temperature rises Preparatory work Switch boiler off (controller: set switch to "O", pull the burner plug) Interrupt the fuel supply Open the boiler door Remove flue gas collector cleaning cover (back) Cleaning (dry or wet method) Clean combustion chamber, 2-pass (cylindrical tubes), 3-pass (ribbed heating surface) thoroughly with a brush or spray and then remove any combustion residue or sprayed liquid from the flue gas collector and from the combustion chamber. For wet cleaning: Treat seals with graphite before carrying out wet cleaning. Dispose of the cleaning fluid (scrubbing liquid) in accordance with regulations Putting into operation again Mount the cleaning cover Close boiler door and reconnect burner plug. Do not overtighten boiler door screws. Reconnect the fuel supply Where applicable, refit front cover Reset boiler switch to "I" / 02 25

26 OVERVIEW OF SETTINGS 7. Overview of settings 7.1 Table of parameters Designation Factory Type of device: DHW: SW: Address: Surface operation Key : Regulator Setting range / Setting values Heating curve HC OFF OFF, 0, ,5 Heating curve MC1 1,0 OFF, 0, ,5 Heating curve MC2 1,0 OFF, 0, ,5 Daytime target temperature HC *) 20 C C *) Daytime target temperature MC1 *) 20 C C *) Daytime target temperature MC2 *) 20 C C *) Night-time target temperature HC *) 16 C C *) Night-time target temperature MC1 *) 16 C C *) Night-time target temperature MC2 *) 16 C C *) DHW target temperature 50 C 5... DHW-Max. *) Depending on the setting of system parameters 03 OPERATING MODE Remote operation/room stations Type Heating circuit Address HW SW / 02

27 OVERVIEW OF SETTINGS Table for Time programs DHW circuit Time program P1 Time program P2 Time program P3 Tag Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 from to from to from to from to from to from to from to from to from to Mo Tu We Th Fr Sa Su Direct circuit Time program P1 Time program P2 Time program P3 Tag Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 from to from to from to from to from to from to from to from to from to Mo Tu We Th Fr Sa Su Mixer Circuit 1 Time program P1 Time program P2 Time program P3 Tag Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 from to from to from to from to from to from to from to from to from to Mo Tu We Th Fr Sa Su Mixer Circuit 2 Time program P1 Time program P2 Time program P3 Tag Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 from to from to from to from to from to from to from to from to from to Mo Tu We Th Fr Sa Su / 02 27

28 OVERVIEW OF SETTINGS HYDRAULIC Par. Designation Factory Lev. 2 Function allocation of the output DHW charging pump 1 HF 3 Function allocation of the output Mixer circuit 1 3 HF 4 Function allocation of the output Mixer circuit 2 3 HF 5 Function allocation of the output Direct circuit Pump 2 HF 6 Function allocation of the variable output 1 OFF HF 7 Function allocation of the variable output 2 OFF/ 4/ 43 HF 8 Function allocation of the variable input 1 OFF HF 9 Function allocation of the variable input 2 OFF HF 10 Function allocation of the variable input 3 OFF/ 2/ 33 HF 11 Indirect return increase OFF HF 12 Maximum limit energy management 80 C HF 13 Activation cooling buffer OFF HF 14 Release contact cooling to KVLF OFF HF SYSTEM Par. Designation Factory Lev. LANGUAGE Selection of the style-language EN BE 2 Number of cleared switching time programs P1 HF 3 Clearing for separate operating mode 1 HF 4 Limit temperature for summer disconnection 22 C HF 5 System frost protection 3 C HF 6 Demand contact module for VE1 1 HF 7 Demand contact module for VE2 1 HF 8 Demand contact module for VE3 1 HF 9 Air conditioning zone -12 C HF 10 Building type 2 HF 11 Automatic reversion time (surface end user level, except info. level) 5 min HF 12 Pump and mixer compulsory operation ON HF 13 Logical fault signal OFF HF 14 Automatic SET function (after 24:00, is automatically set to OFF) ON/ OFF 15 Blocking code for heating Installer OEM 18 Release cycle temperature OFF HF 19 Frost protection mode 30 min HF 21 RTC adjustment 0 HF 23 Blocking code operator level OFF HF 24 Temperature display in Fahrenheit OFF OEM 26 First commissioning date (after 24:00) - OEM 27 Fault report (only TTT/UG) 2 HF 28 Fault stack 2 ON HF 29 Characteristic curve emergency operation 0 C HF 30 Thermostat function sensor allocation AF HF 31 Thermostat function reference value 1 C HF 32 Thermostat function switching difference 3K HF 33 Thermostat function anti-blocking protection ON HF Top: ArtNo - HW Index OEM Bottom: Code:REV - Software version RESET Reset parameter values BE HF / 02

29 OVERVIEW OF SETTINGS DHW Par. Designation Factory Lev. DHW-NIGHT DHW - economy temperature 40/ 45 C BE 2 DHW-legionella protection-day OFF HF 3 DHW-egionella protection-time 2:00 HF 4 DHW-legionella protection-temperature 50/ 55/ 65/ 70 C 5 DHW-temperature recording 1 HF 6 DHW-maximum temperature limit 50/ 55/ 65/ 70 C 7 DHW-mode of operation 1 HF 8 DHW-tank discharge protection ON/ OFF HF 9 DHW-charging temperature excess 7/ 20 K HF 10 DHW-switching difference 5 K OEM 11 DHW-charging pump follow-on 0.5/ 1/ 2/ 5 min 12 ZKP-switching time program AUTO HF 13 ZKP-economy interval (pause) 0 min HF 14 ZKP-economy interval (period duration) 20 min HF 17 H-GEN behaviour during SLP follow-on time AUTO/ OFF HF 18 DHW-parallel loading OFF HF 19 DHW-time-out OFF/ 30 min 20 PI-reference value control OFF HF 21 PI-amplifi cation factor, P-portion Xp 0,1 %/ K OEM 22 PI-scanning time Ta 20 s OEM 23 PI -reset time Tn 600 s/ C OEM HF HF OEM HF UNMIXED CIRC Par. Designation Factory Lev. 1 Type of reduced operation ECO/ ABS HF 2 Heating system (exponent) DK= 1,30 HF 3 Room override (in connection with room sensor) 3 HF 4 Room factor OFF HF 5 Adaptation heating curve OFF HF 6 Switch-on optimisation 1 HF 7 Heating limit 0,5 OEM 8 Room frost protection limit 10 C HF 9 Room thermostat function OFF HF 10 Outside temperature allocation 0 HF 11 Constant temperature reference value 20 C HF 12 Minimum temperature limit 10 C HF 13 Maximum temperature limit 55/ 75 C HF 14 Temperature elevation Heating circuit DK=0 HF 15 Pump follow-on 5 min HF 16 Screed function OFF HF 23 Room control K-factor 8 HF 24 Room control Tn-factor 35 min HF 25 Vacation mode STBY HF 36 Minimum value override OFF HF Name heating circuit (max. 5 letters) XXXXX HF / 02 29

30 OVERVIEW OF SETTINGS MIX. VALVE-1 Par. Designation Factory Lev. 1 Type of reduced operation ECO/ ABS HF 2 Heating system (exponent) MK= 1,10 HF 3 Room override (in connection with room sensor) 3 HF 4 Room factor 100 % HF 5 Adaptation heating curve ON HF 6 Switch-on optimisation 1 HF 7 Heating limit 0,5 OEM 8 Room frost protection limit 10 C HF 9 Room thermostat function OFF HF 10 Outside temperature allocation 0 HF 11 Constant temperature reference value 20 C HF 12 Minimum temperature limit 10 C HF 13 Maximum temperature limit 55/ 75 C HF 14 Temperature elevation/ abatement heating circuit 0/ 8 K HF 15 Pump follow-on 5 min HF 16 Screed function OFF HF 18 P-portion Xp 2,0 %/ K OEM 19 Scanning time Ta 20 s OEM 20 I-portion Tn 270 s OEM 21 Running time servomotor 150 s HF 22 End position function, valve 1 OEM 23 Room control K-factor 8 HF 24 Room control Tn-factor 35 min HF 25 Vacation mode STBY HF 36 Minimum value override OFF HF 37 Mixer lead time OFF HF 38 Regulation offset 0 HF 50 Cooling switch-on point, OT OFF HF 51 Cooling max. point, OT 35 C HF 52 Cooling reference fl ow temp. at switch-on point 18 C HF 53 Cooling reference fl ow temp. at max. point 24 C HF 54 Cooling reference room temp. at switch-on point 23 C HF 55 Cooling reference room temp. at max. point 28 C HF 56 Min. temp. cooling 18 C OEM Name heating circuit (max. 5 letters) XXXXX HF / 02

31 OVERVIEW OF SETTINGS MIX. VALVE-2 Par. Designation Factory Lev. 1 Type of reduced operation ECO/ ABS HF 2 Heating system (exponent) MK= 1,10 HF 3 Room override (in connection with room sensor) 3 HF 4 Room factor 100 % HF 5 Adaptation heating curve ON HF 6 Switch-on optimisation 1 HF 7 Heating limit 0,5 OEM 8 Room frost protection limit 10 C HF 9 Room thermostat function OFF HF 10 Outside temperature allocation 0 HF 11 Constant temperature reference value 20 C HF 12 Minimum temperature limit 10 C HF 13 Maximum temperature limit 55/ 75 C HF 14 Temperature elevation/ abatement heating circuit 0/ 8 K HF 15 Pump follow-on 5 min HF 16 Screed function OFF HF 18 P-portion Xp 2,0 %/ K OEM 19 Scanning time Ta 20 s OEM 20 I-portion Tn 270 s OEM 21 Running time servomotor 150 s HF 22 End position function, valve 1 OEM 23 Room control K-factor 8 HF 24 Room control Tn-factor 35 min HF 25 Vacation mode STBY HF 36 Minimum value override OFF HF 37 Mixer lead time OFF HF 38 Regulation offset 0 HF 50 Cooling switch-on point, OT OFF HF 51 Cooling max. point, OT 35 C HF 52 Cooling reference fl ow temp. at switch-on point 18 C HF 53 Cooling reference fl ow temp. at max. point 24 C HF 54 Cooling reference room temp. at switch-on point 23 C HF 55 Cooling reference room temp. at max. point 28 C HF 56 Min. temp. cooling 18 C OEM Name heating circuit (max. 5 letters) XXXXX HF / 02 31

32 OVERVIEW OF SETTINGS HEAT GENER. Par. Designation Factory Lev. 1 H-GEN model 1/ 2/ 5 HF 2 Start-up protection H-GEN OFF/ 3 HF 3 Minimum temperature limit H-GEN 5/ 48/ 65/ 75 C 4 Maximum temperature limit H-GEN 75/ 85 C HF 5 Mode of action minimum temperature limit H-GEN 1 HF 6 Sensor mode operation for H-GEN 1 OEM 7 Minimum burner running time 2 min HF 8 Burner switching difference I 6 K HF 9 Burner switching difference II 12 K HF 10 Time-out stage II 10 HF 11 Release mode stage II 1 HF 12 DHW charging mode 1-2 stage 2 HF 13 Lead time, boiler circuit pump 1 min HF 14 Follow-on time, boiler circuit pump or parallel boiler release 5 min HF 15 Search time feed pump, primary pump 5 min HF 16 Exhaust gas temperature monitoring OFF HF 17 Exhaust gas limit value 200 C HF 18 Boiler gradient OFF OEM 19 Modulation P-portion Xp 5 %/ K OEM 20 Modulation scanning time Ta 20 s OEM 21 Modulation adjustment time Tn 180 s/ C OEM 22 Modulation running time 12 s HF 23 Modulation starting time 200 s HF 24 Modulation start-up output 70 HF 25 Outside temperature block OFF OEM 26 Basic charge elevation 0 K/ 10K OEM 27 Minimum temperature limit, heating circuits 5/ 38/ 65 C HF 28 Switching difference, minimum temperature limit Heating circuits 2 K OEM 29 H-GEN forced discharge OFF HF 30 OEM Maximum limit 110 C OEM 31 Minimum load control OFF OEM 34 Output limitation heating 100 % HF 35 Output limitation hot water 100 % HF 36 ET blocking 2.burner stage OFF HF 37 Running time meter 1 HF 38 DHW release regulator (CD) ON HF 39 Emergency operation temperature H-Gen (e.g. for 70-8) 70 C HF 40 Heat balance (from V3.2) ON HF 41 Reset heat balance HF 42 Volumetric fl ow rate 0,0 l/ min 0,0 l/ IMP 43 Density, medium 1,00 kg/ l HF 44 Specifi c thermal capacity, medium 4,2 HF RESET ST-1 Reset counters starts and running time, stage 1 RESET ST-2 Reset counters starts and running time, stage 2 HF HF OEM OEM / 02

33 OVERVIEW OF SETTINGS RETURN CONTR Par. Designation Factory Lev. 1 Minimum limit return temperature / reference value return temperature 38 C HF 2 Switch-off difference 2 K HF 3 Pump follow-on time 1 min HF SOLAR Par. Designation Factory Lev. 1 Switch-on difference 10 K HF 2 Switch-off difference 5 K HF 3 Minimum running time SOP 3 min HF 4 Solar collector maximum temperature 100 C HF 5 Solar tank maximum limit (KSPF) 65 C HF 6 Solar mode of operation 2 HF 7 Heat generator cycle lock (only when parameter 06=1,3,4) 0,5 h HF 8 Solar priority parallel changeover 10 K HF 9 Solar heat balance OFF HF SOLAR RESET Reset heat balance 11 Volumetric fl ow rate 0,0 l/ min 0,0 l/ IMP 12 Density, medium 1,05 kg/ l HF 13 Specifi c thermal capacity, medium 3,6 KJ/ kgk HF 14 Final switching-off temperature 120 C HF 15 Test cycle solar charging switch-over 10 min HF 16 Switch-over temperature (SLVF) 60 C HF 17 Solar minimum temperature OFF HF HF HF SOLID FUEL Par. Designation Factory Lev. 1 Minimum temperature 60 C HF 2 Maximum temperature 95 C HF 3 Switch-on difference 10 K HF 4 Switch-off difference 5 K HF 5 Clock block, heat generator 15 HF / 02 33

34 OVERVIEW OF SETTINGS BUFFER Par. Designation Factory Lev. 1 Minimum temperature 5/ 20 C HF 2 Maximum temperature 95 C HF 3 Temperature elevation, H-GEN 8/ 10/ 12K HF 4 Switching difference 2/ 5/ 10K HF 5 Forced discharge OFF HF 6 Skimming function switch-on difference 10 K HF 7 Skimming function switch-off difference 5 K HF 8 Start-up protection OFF HF 9 Discharge protection OFF HF 10 Buffer mode of operation 2/ 3 HF 11 Pump follow-on time 3 min HF 12 Switch-off reference value temp. 70 C HF 13 H-GEN release temp. skimming function 60 C HF MAIN SUPPLY Par. Designation Factory 10 Lev. 1 PI-amplifi cation factor, P-portion Xp 0 %/ K HF 2 PI-scanning time Ta 20 s HF 3 PI -reset time Tn 600 s/ C HF CASCADE Par. Designation Factory 10 Lev. 1 Switch-off difference 3 K OEM 2 Connecting delay 20 OEM 3 Switch-off delay 5 OEM 4 Switching output stage sequence 65 OEM 5 Stage reversal OFF OEM 6 Control stage 1 BE 7 Peak load stage OFF OEM 8 Group switch-over OFF OEM 9 DHW fast activation OFF OEM 10 Peak load elevation 10 K OEM BUS Par. Designation Factory Lev. 1 Bus address central device 10 HF 2 Bus right RS direct circuit 1 HF 3 Bus right RS mixer circuit 1 1 HF 4 Bus right RS mixer circuit 2 1 HF / 02