Technical information Installation instructions. Uno-3 ( ) Oil/gas boiler. These instructions apply to the following types:

Transcription

1 Technical information Installation instructions Uno-3 ( ) Oil/gas boiler These instructions apply to the following types: 41-Uno-3 (130, 160, 190, 220, 250, 280) 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 ( ) 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 technical data Subject to modifi cations / 00-07/15 EN

2 TABLE OF CONTENTS 1. Important information 1.1 Other instructions Safety instructions Regulations, official approvals Warranty Assembly 2.1 Installation position Setting up levelling Fitting the heat insulation Fitting the casing Installation of boiler controller Boiler controller TopTronic E Boiler controller T0.2 / T Technical information 3.1 Description of the boiler The Uno-3 ( ) complies with the following directives + standards Technical data Uno-3 ( ) Dimensions without heat insulation and casing (transport dimensions) Installation 4.1 Boiler room requirements Connection of the flue gas system and flue duct dimensions Fitting the burner Sound insulation Fuel Electrical connection Flue gas regulator set Recommended cable cross sections: Safety measures relating to EMC assembly Flue gas regulator set Flue gas and performance diagrams Flow mixing loop / minimum limitation of the boiler return temperature Setting the temperature regulators Safety valves Charging pump (boiler with free-standing calorifier) Heating pump Commissioning 5.1 Water quality Filling the heating system Filling the calorifier (if present) Initial commissioning Oil/gas burner Handover to the operator / storage Maintenance 6.1 Information for fire inspector / chimney sweep regarding emission monitor key Cleaning Preparatory work Cleaning (dry or wet method) Putting into operation again Safety temperature limiter - Reset / 00

3 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. 1.3 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 / 00 3

4 IMPORTANT INFORMATION 1.4 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 / 00

5 ASSEMBLY 2. Assembly 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 before commissioning. Counter nut There must be enough space to swing open the boiler door, incl. the burner. Boiler door pivotable to the left It is possible to change the attachment of the boiler door so that it opens towards the left. This can be of advantage when installing the boiler in a corner. Proceed as follows: NOTE Close the boiler door and lock it in position before changing the attachment of the door fig Setting up levelling A special foundation plate for the boiler is not an essential, but it is recommended. Space requirement for fitting the heat insulation and casing panelling: at least 40 cm each on the left and right side of the boiler. controller side min. 70 cm. If the space between the boiler and the wall is less than 50 cm, 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! NOTE 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. 2 fig Remove special screw (1). 2. Swing the arm (2) to the opposite side. 3. Refit the special screw (1) on the other side. 4. Fit the burner plug on the other side (see also point 4.5.1). NOTE The cable must not touch any hot parts! 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 (Pos. 8a, fig. 05) (door casing) / 00 5

6 ASSEMBLY 2.3 Fitting the heat insulation 1. Using M8 hex screws, nuts and washers, fit the front retaining bracket (1, fig. 04) to the front of the boiler in horizontally aligned position. - - Attach C-clips. 2. Using M8 hex screws, nuts and washers, fit the rear retaining bracket (2, fig. 04) in horizontally aligned position. - - Attach C-clips. 3. Place insulation mat (3) (on Uno-3 (250 / 280) = 2 mats) around the boiler body (with the joint at the top, black side facing outward). 4. Attach the insulation mat (3) using 2 (or 3) plastic straps (4) and strap fasteners (4a): - - There are also tension springs (4b) for additional attachment - - Do not overtighten the straps (reduced insulating value) 5. Attach the insulation mats (5/5a/5b/5c) to the pins provided on the rear wall of the boiler and secure with retaining discs (ø 38). For your information: The insulation mats protrude 80 mm on the left and right. Wrap the insulation mats (5d) 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) provided. 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. - - Insulation mat 7c (or 7d with boiler door pivotable to the right) can be cut for easier fitting. For your information: - - The insulation panels protrude 50 mm on the left and right. The remaining 2 insulation mats (17) are fitted after mounting the casing. fig / 00

7 ASSEMBLY 7 7a 7b 7c 7d 3 4a fig. 04 4b 4 6 6b 1 C-Clips 6d 5a 5 6c 5b 6a 5c 5d 2 C-Clips / 00 7

8 ASSEMBLY 2.4 Fitting the casing 8. Fit hexagon bolts with U-washers and hexagon nuts (8, fig. 07). Insert thermal insulation into the boiler door (8a). Attach the door casing to the boiler door using hexagon cap nut. The boiler controller can be mounted on the right or left side panel (11a, fig. 06). 9. Place support (9) on the door hinge (Figure 6a). 10. Attach 4 special screws (9a) with counter nuts to each side section (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 fig. 06). NOTE The cable must not touch any hot parts 11. Place right and left side sections (9b/9c, fig. 06) over the supports (9, fig. 05) and attach to the front brackets (1, fig. 04) with self-tapping screws ø 4.8 x Hook lower right and left side wall (10) into the side sections (9b/9c) and attach to the rear retaining brackets (2, fig. 09) with self-tapping screws ø 4.8 x Hook in the upper left and right side wall (11, 11a, fig. 06) and attach to the rear retaining brackets (2, fig. 09) with self-tapping screws ø 4.8 x Insert 2 insulation mats (12) (to prevent vertical circulation of air) longitudinally on the left and right. 15. Attach bottom and top rear wall (14,14a, fig. 06) to the angled edges of the side walls (10,11,11a, fig. 06) with self-tapping screws ø 3.5 x 9.5 and C-clips. Fit cover plate (14b, fig. 06) with self-tapping screws ø 3.5 x If necessary, remove controller box cover plate (19, fig. 06) / 00

9 ASSEMBLY 9 fig a a 9c 14b 8a 11a a 9d 16 9b 13 9e 12 9a fig e 12d fig. 07 T0.2 / T2.2 fig / 00 9

10 ASSEMBLY 2.5 Installation of boiler controller Boiler controller TopTronic E 17. Mount the special screws with nuts (12a, fig. 09) on the side panel. Then hook the boiler controller (12, fig. 06) into the side wall with the recesses for the special screws and secure it with 2 self-tapping screws ø3.5 x 6.5 and serrated washers (12b, fig. 09) Boiler controller T0.2 / T2.2 12a 12 12a 12c 12b 12b 13a 12d fig a Mount the special screws with nuts (12a, fig. 10) on the side panel. Then hook the boiler control (12, fig. 10) onto the special screws and secure using selftapping screws ø 3.5 x 6.5 and serrated lock washers (12b, fig. 10). 21. Pull the capillaries with the immersion sensors (15, Figure 18) through the opening (13a, fig. 09) in the side panel, insert them into the immersion sleeve (16, fig. 06) as far as the stop and fix in position with retaining spring (9e, fig. 06). fig Pull the capillaries with the immersion sensors (13, fig. 11) through the opening (13a, fig. 06) in the side panel, insert them into the immersion sleeve (15a, fig. 11) as far as the stop and fix in position with retaining spring (15c, fig. 06). NOTICE The capillaries must not be folded or kinked 19. Close the boiler controller and screw on (12c, fig. 09), continue with pint 23 NOTICE The capillaries must not be folded or kinked 22. Attach cover plate to the boiler controller (12d, fig. 10) with self-tapping screws ø 3.5 x 6.5 and serrated lock washers. 23. Place casing cover (18/18a) in position and attach on the left and right sides with self-tapping screws ø 3.5 x Affix labels and where applicable, mount manual holder on the side. 25. Remove transport lock, see point b 13c 13 fig / 00

11 TECHNICAL INFORMATION 3. Technical information 3.1 Description of the boiler The Max-3 or Max-3 plus boiler is constructed in 3-compartment form. The flue gases flow from the cylindrical combustion chamber into the water cooled reversing elbows and through the 2nd compartment into the front reversing chamber. The 3rd compartment comprises a specially formed beading pipe through which the flue gases are conducted to the flue gas collector. fig The Uno-3 ( ) 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/EG «Gas appliance directive» 73/23/EWG «Low voltage directive» 89/336/EWG «Electromagnetic compatibility directive» 97/23/EG «Pressure equipment directive» (PED) at maximum boiler temperature 90 C Regulations: Stability pren14394:2001 Constructional requirements EN303-1, EN303-2, EN303-3 Low voltage DIN VDE 0722 / Ed EMV EN Part 1 / Ed / 00 11

12 TECHNICAL INFORMATION 3.2 Technical data Uno-3 ( ) Type (130) 1 (160) (190) (220) (250) (280) Nominal heat output at 80/60 C 1 kw Heat output range (heating oil EL, Variant 2) kw Maximum heat input kw 139,8 173,1 206,0 236,6 269,1 302 Maximum boiler operating temperature 2 C Safety temperature limiter setting (water side) 2 C Operating/test pressure at max. operating temperature bar 4,0/5,2 4,0/5,2 5,0/6,5 5,0/6,5 5,0/6,5 5,0/6,5 90 C 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 3,0 3,0 4,0 4,0 4,0 4,0 Minimum boiler operating temperature C see table of operating conditions (below) Minimum boiler return temperature C see table of operating conditions (below) Minimum flue gas temperature at boiler C see table of operating conditions (below) Regulator set for 160 C flue gas temperature 9R3/290 6R5/290 6R5+ 6R2/290 9R5/290 6R5+ 3R3/290 6R5+ 6R2/290 Boiler efficiency at full load at 80/60 C % 92,8/87,6 92,5/87,3 92,2/87,0 92,6/87,6 92,8/87,6 92,6/87,4 (related to net/ gross calorific value, heating oil EL) Boiler efficiency at partial load 30% at return 37 C % 94,9/89,5 94,9/89,5 94,8/89,4 95,2/89,8 95,4/90,0 95,3/89,9 (according to EN 303) (Relative to net/gross calorific value heating oil EL) Normal degree of efficiency (DIN 4702 Part 8) (related to net/ gross calorific value, heating oil EL) % 96,1/90,7 96,1/90,7 96,2/90,8 96,0/90,6 96,3/90,4 95,9/90,5 Standby losses qb at 70 C Watt Resistance on the heating gas side at nominal output mbar 0,86 1,50 1,40 1,7 1,6 2,8 160 C flue gas temperature, 12.5% CO 2, 500 m above sea level (tolerance ± 20%) Flue gas mass flow at nominal output 12.5% CO 2 heating oil kg/h Flow resistance boiler 4 z-value 0,2 0,2 0,1 0,1 0,1 0,1 Hydraulic resistance at 10 K mbar 24,80 37,60 26,50 35,55 46,00 57,60 Hydraulic resistance at 20 K mbar 6,20 9,40 6,60 8,90 11,50 14,40 Water flow rate at 10 K m 3 /h 11,10 13,70 16,30 18,90 21,40 24,00 Water flow rate at 20 K m 3 /h 5,60 6,90 8,10 9,40 10,70 12,00 Boiler water content litres Boiler gas content m³ 0,236 0,236 0,322 0,322 0,428 0,428 Insulation thickness of boiler body mm Weight (incl. casing) kg Combustion chamber dimensions Ø-inside x length mm ø 440x974 ø 440x974 ø 490x974 ø 490x974 ø 488x1434 ø 488x1434 Combustion chamber volume m³ 0,148 0,148 0,184 0,184 0,268 0,268 Dimensions see dimensional drawing Maximum negative pressure in the flue pipe system (at the Pa boiler connection) At nominal output, the pollutant limit values and flue gas losses as per regulation LRV (92) are complied with. 2 Boiler controller E13.4 TopTronic E und T2.2 3 Boiler controllere13.5 TopTronic E und T0.2 4 Flow resistance boiler in mbar = flow rate (m 3 /h)2 x z 5 For Switzerland only Possible operating conditions Fuel Heating oil EL Natural gas H Heating oil L Variant 1 Variant 2 Variant 3 Variant 1 Variant 2 Variant 3 min. flue gas temperature C min. boiler temperature C min. return temperature C No lower limit No lower limit Return temperature controls yes yes no yes yes no yes yes Boiler start-up protection 1 no no yes no no yes no no 1 Boiler minimum temperature limit effective on group actuators / 00

13 TECHNICAL INFORMATION fig Flow type DN 50, PN 6 DN 65, PN 6 2 Return Typ DN 50, PN 6 DN 65, PN 6 3 Safety flow R 1 1/2 R 1 1/2 4 Flow for calorifier R 1 1/4 R 1 1/4 5 Return for calorifier R 1 1/4 R 1 1/4 6 Drain R 1 1/2 R 1 1/2 7 Flue gas outlet 8 Cleaning opening 9 Boiler controller, optionally left or right 10 Socket Width 50 mm 11 Boiler door attached on the right (Optional left) 12 Flue gas collector cleaning connection R 1 R 1 13 possible anti-vibration elements Width 80 mm, Height 50 mm 14 Burner absorber hood Uno-3 l b h a c d e f g i k m n o p q* r s t u v Ø / *q = flue gas outlet external diameter. Plate thickness 3 mm; adapter set for Uno-3 ( ): D qø 199, A qø 200 (with tape) / 00 13

14 TECHNICAL INFORMATION 3.3 Dimensions without heat insulation and casing (transport dimensions) fig. 13 Uno-3 Width Length Height Weight Type B with connections+ flue gas collector L1 without connections + flue gas collector L H kg Required minimum width of door and corridor for bringing in the boiler The following values are the calculated minimum values K = B T L T = Door width K = Corridor width B = Boiler width T = B T L L = Maximum boiler length Example calculation for the required corridor width K Door width T = 800 L B < 150 Uno-3 ( ) Uno-3 ( ) 680 K = 800 x 1515 = Door width K = 800 x 1535 = Door width 1439 fig. 14 T Uno-3 ( ) 750 K = 800 x 2015 = Door width / 00

15 TECHNICAL INFORMATION Minimum overall unit dimensions Boiler upright Boiler 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 = 800 Uno-3 ( ) 680 K = 800 x 1180 = Corridor width 1003 Uno-3 ( ) 750 K = 800 x 1335 = Corridor width 1252 fig. 15 fig Transport board (by client) 3 Boiler door (can be removed) 2 Pipe as roller (by client) 4 Threaded rod Uno-3 Type including connectors and flue gas collector Boiler height without connection b. Flue gas collector H2 Width B Length L Uno-3 Type available ground clearance max. Width doorwith boiler without boiler door for trolley a b c ( ) ( ) ( ) ( ) ( ) / 00 15

16 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. In Germany, the firing ordinances of the individual federal states must be observed. Ensure that there is an adequate supply of fresh air 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/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 also requires an extract air opening. Up to a nominal heat output of 100 kw, this opening must have a minimum cross-section of 180 cm 2. For every further kw, the cross-section must be increased by 1 cm 2. NOTE 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 crosssection 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) type (materials and characteristics) of the flue duct (thermal insulation, internal surface roughness, leaktightness etc.) b) connection of the boiler to the flue gas system accor ding to applicable regulations and standards d) correct dimensioning of the flue duct crosssection. re: a) Schornsteine gemäss EN 13384, Teil 2, Ausführungsart I und II entsprechen modernen Feuerungsanlagen (Beratung durch den Schornsteinfachmann ist erforderlich). re: b) The flue gas pipe connecting the boiler to the flue gas system must be as short as possible and placed at an angle of Carefully seal the flue gas pipe against the flue gas system. The insertion of the flue gas pipe into the flue gas system (a) must be carried out in such a way that no condensation water can flow from the flue gas system into the flue gas pipe and into the boiler. fig. 18 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 Connection of the flue gas system and flue duct dimensions Boiler and flue gas system must be mutually compatible and operate as a single functional unit in order to guarantee trouble-free and economical operation. Moisture-resistant and acid-proof flue gas systems must be used in new installations. fig. 18 Where possible, avoid 90 bends in the flue gas system! Flue gas pipes over 1 m in length must be insulated / 00

17 INSTALLATION NOTE As a general rule, only one heat generator may be connected to the chimney! Flue gas pipes over 1m in length must 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. vom from the Kessel boiler to zum the chimney Schornstein re: c) Dimensioning of the flue duct cross-section. The crosssections must be calculated for boilers without delivery pressure requirement in accordance with 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, SIA recommendation 384/4 must be observed! 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 ( ). Inside diameter of flue duct in mm Boiler type Uno-3 kw * ~ ~ ~ ~ ~ ~ 250 * kw = maximum boiler output Chimney height m Based on: flue gas conduit 5 m long, two 90 bends and one 45 bend, outside air 15 C, height above sea level max. 800 m, flue gas conduit of same ø as flue gas outlet on the boiler. However, it is always advisable to consult the chimney engineer in the planning stages! / 00 17

18 INSTALLATION 4.3 Fitting the burner fig. 19 Uno-3 A B C D E F G H L max M N O Ø Ø Ø Ø / 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 Sound insulation Gas pipes must be mounted in such a way that no vibrations are transferred to the building. The burner can be equipped with a sound-absorbing hood. We recommend that you install silencers downstream of the boiler in the flue gas pipe. fig / 00

19 INSTALLATION 4.4 Fuel NOTE The boiler may only be operated with the fuel designated on the boiler rating plate. Uno-3 boilers are suitable for the combustion of 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 fuel gases as defined by DVGW process sheet G Electrical connection Electrical connections must be established by a licensed and qualified electrician. The connection diagram is located in the terminal box of the heat generator; the circuit diagram is supplied separately. Refer to this for the conductor cross section required for the mains supply. WARNING The heat generator can be deprived of only separating it from the mains voltage (eg multipole switch). WARNING All electric power supply circuits must be switched off before accessing the terminals. For Switzerland, the following applies: For the electrical connection, the circuit diagram specific to the plant must be observed! 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 Flue gas regulator set The flue gas regulators fitted in each case are listed on a label on the boiler casing. The installer can change the flue gas regulator set fitted and thus vary the flue gas temperature within a specific range Recommended cable cross sections: Cable type Cross-section Length Power supply of the heat generator (230V) Power supply of the heat generator (400V) Mains voltage cables of actuators Low-voltage cables (sensors) Data bus lines (shielded cable) min 2,5 mm 2 with 16A Protection min 1,0 mm 2 with 10A Protection min 1,0 mm 2 min 0,5 mm 2 unlimited m unlimited m unlimited m max. 50 m 2 x 2 x 0,6 mm 2 max. 100 m Safety measures relating to EMC assembly 1. In the case of control units with their own mains supply, it is imperative that cables carrying mains voltage are routed separately from sensor or data bus cables. If using cable ducts, these must be equipped with separator strips. 2. The mains connection for the heating system (boiler control panel regulator unit) must be designed as an independent electrical circuit. Neither fluorescent lamps nor other sources of interference for the relevant machinery may be connected or capable of connection. Fuse Boiler room emergency switch Heat Generator Boiler room lighting and power sockets must be in a separate circuit 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 large transmitters etc.) / 00 19

20 INSTALLATION 4.6 Flue gas regulator set The flue gas regulators fitted in each case are listed on a label on the boiler casing (side section Figure 6, Pos. 9b/9c). The installer can change the flue gas regulator set fitted and thus vary the flue gas temperature within a specific range. NOTE Even in partial load operation, the flue gas temperature must not fall below 100 C. Regulators Inspection hole fig / 00

21 INSTALLATION Flue gas and performance diagrams Uno-3 (130) or Switzerland only C kw 9R5/290 Uno-3 (160) C kw 6R5/290 Uno-3 (190) C kw 6R5 + 6R2/290 Uno-3 (220) C kw 9R5/ / 00 21

22 INSTALLATION Uno-3 (250) kw C C 6R5 + 3R3/290 Uno-3 (280) kw C 6R5 + 6R2/290 The curves shown here represent an average value based on measurements taken with burners from various manufacturers. Deviations of ± 10% are normal. kw = heat output 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. Flue gas temperature under other operating conditions Influence of the boiler water temperature on the flue gas temperature A change in the boiler water temperature of ± 10 K results in a change of approximately ± 6K in the flue gas temperature. Influence of the CO 2 content in the flue gases A change in the CO 2 content of ± 1% changes the flue gas temperature by approx. ± 8 C. Key to regulator designation No. of regulators Regulator height (example: 5 units) 6R5/290 Length of the regulators / 00

23 INSTALLATION 4.7 Flow mixing loop / minimum limitation of the boiler return temperature Hydraulic and control measures must be provided to ensure that the temperatures do not fall below the permissible minimum boiler flow and return temperature under any operating conditions. 4.8 Setting the temperature regulators without heating regulator: Set the boiler temperature in accordance with the outside temperature. with heating regulator: The heating regulator automatically sets the correct boiler temperature. The boiler temperature varies between the minimum and maximum boiler temperatures entered. If a calorifier is connected, the priority circuit disables the boiler temperature regulator until the temperature is reached. The boiler 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 EN 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. They are to be set by the heating installation engineer / 00 23

24 COMMISSIONING 5. Commissioning 5.1 Water quality Heating Water The European Standard EN and the directive VDI 2035 must be observed. 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. 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! 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 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 REQUI- 50 l/kw 20 l/kw 20 l/kw 200 to 600 kw RE- 50 l/kw 50 l/kw 20 l/kw always desalinate over 600 kw MENT 1 Sum of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary / 00

25 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 calorifier (if present) The heating boiler may be put into operation even when the calorifier is not filled. 5.4 Initial 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 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. 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 30). The system manufacturer is responsible for providing operating instructions for the whole plant. This technical information / these installation instructions must not be destroyed after completing the commissioning procedures, but should be permanently stored with the unit / 00 25

26 MAINTENANCE 6. Maintenance 6.1 Information for fire inspector / chimney sweep regarding emission monitor key This chapter is exclusively intended to describe the function of emissions and manual operation settings for the fi ring monitoring technician / chimney sweep. All operating elements are described in the operating instructions.! CAUTION Danger of scalding with hot water, since the hot water temperature can exceed the target setpoint temperature. NOTICE In order to protect underfl oor heating systems against impermissible superheating during emissions measurement / manual operation, it is necessary to implement appropriate safety measures (e.g. pump switch-off with maximum thermostat). The output and duration of the emission measurement can be set in the "Emission" main menu, and reactivated if required. Emission metering Setting at: Home screen > Main menu (page 1) > Emission. For detailed information see operating instructions, "Emission" chapter. Power limitation with 2-stage burner: 0 to 50% = 1st stage 51 to 100% = 2nd stage REACTION to emission metering Go back after expiry of the time unit/time specifi cation of return to the main menu Setpoint temperature = Maximum temperature limit Forced energy is used in an attempt to keep the corresponding heat generator temperature to 60 C Regulate heating circuits and the calorifi ers to their maximum temperature (in the direct heating circuit only if the hot water basic program is set to parallel operation) Manual mode Settings under: Home screen > Main menu (page 2) > Manual operation. For detailed information see operating instructions, "Emission" chapter. REACTION for manual operation Setting the required setpoint temperature using the selected heating or hot water circuit All heating pumps ON Note the maximum permissible temperature of surface heating! / 00

27 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 regulators (fig. 20) Remove flue gas collector cleaning cover (back) 6.3 Safety temperature limiter - Reset If the boiler temperature rises too high (>100 C), the system is switched off by the safety temperature limiter (STL) by means of a mechanical lockout. The malfunction must first be unlocked on the safety temperature limiter, then on the control panel. -- TB-reset 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. 1. Open the switch control box 2. Unscrew the protective cap 3. Reset the STL Reset on the control panel fig Putting into operation again Insert the regulators Fit cleaning cover Close boiler door and reconnect burner plug. NOTE Do not overtighten boiler door screws. Reconnect the fuel supply Where applicable, refit front cover Reset boiler switch to «I» Reset key fig. 24 Press the reset key on the control (first remove the cover): the boiler is ready for operation again once the boiler water temperature is less than 80 C / 00 27

28 / 00

29 / 00 29

30 COPY FOR PLANT USER Confirmation The user (owner) of the system herewith confi rms that he has received adequate instruction in the operating and maintenance of the installation, received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components. and is consequently suffi ciently familiar with the installation. Installation address: Type: Serial number: Year of manufacture: Place, Date: System installer: System user: COPY OF SYSTEM INSTALLER Confirmation The user (owner) of the system herewith confi rms that he has received adequate instruction in the operating and maintenance of the installation, received and taken note of the operating and maintenance instructions and, where applicable other documents concerning the heat generator and any further components. and is consequently suffi ciently familiar with the installation. Installation address: Type: Serial number: Year of manufacture: Place, Date: System installer: System user: