Technical information Installation instructions

Transcription

1 EN Technical information Installation instructions Oil/gas boiler Uno-3 ( ) Hoval products must be installed and commissioned only by appropriately qualifi ed experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualifi ed electrician. This manual is valid for the following types: 7-Uno-3 (130, 160, 190, 220, 250, 280) 7-Uno-3 b-i * (130, 160, 190, 220, 250, 280) and for the same types with increased operating pressure (H) * = burner integrated 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 point / 01-08/09 Subject to modifi cations

2 Table of contents / 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 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 ( ) complies with the following directives + standards Technical data Uno-3 ( ) Dimensions 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 Electrical connection of the burner 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 Heating water Filling and replacement water 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 Overview of settings 7.1 Table of parameters Overview of alarms TopTronic T

3 / 01 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 enclosed with the components. Further sources of information - Hoval catalogue - Standards, regulations 1.2 Safety instructions The system 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 system) 2. Controller 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. It must be ensured that there is an adequate supply of fresh air. 8. The burner is preset 1.3 Regulations, official approvals For installation and operation of the system, the following regulations must be observed: Germany - DIN EN Heating systems in buildings - Procedure for calculation of the standard heating load. - DIN EN 303 Boilers with fan blowers. - DIN EN Sheet 1 and 2 Heating systems in buildings - Design for waterbased heating systems. - DIN 4755 Oil-fired combustion systems. Design, construction and safety engineering requirements. - DIN 4756 Gas-fired combustion systems: Design, construction and safety engineering requirements, design and construction. - DIN Domestic chimneys, requirements, design and execution. - TRD 702 Steam boiler plants with calorifiers of the group II. - DIN EN Chimneys - thermal and fluid dynamic calculation methods. - TRD 721 Safety equipment to safeguard against excess pressures / safety valves / for group II steam boilers. - VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water heating systems. - DIN / VDI 0116 Electrical equipment in combustion systems (VDE regulations). - For further standards applicable in Germany, see supplement N Austria - ÖNorm ÖNorm B 8130 Open hot water systems, safety installations. - ÖNorm B 8131 Closed hot water systems; safety, design and testing regulations - ÖNorm B 8133 DHW heating systems; safety engineering requirements. - ÖNorm B 8136 Heating systems, space requirements and other building requirements. - ÖNorm M 7515 Calculation of chimney dimensions; definition of terms, calculation methods. - ÖNorm H 5171 Heating systems, construction engineering requirements - ÖVGW TR-Gas G1 Technical guidelines for low pressure gas installations - ÖNorm M 7445 Gas fan blowers Switzerland - VKF - Association of Cantonal Fire Insurers - Fire prevention authority regulations. - SVGW Switzerland. Gas and water association. - SWKI 91-1 Guidelines on boiler room ventilation. - SWKI 88-4 Water treatment for heating, steam and air conditioning plants. - SWKI 93-1 Safety engineering installations for heating systems. - KRW Corrosion caused by halogen compounds. - KRW/VSO/FKR Ready-to-connect electrical connections on boilers and burners 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. 3

4 Important information / Warranty Fault-free operation can only be guaranteed if these instructions and the instructions in the operating manual are followed and if the boiler is regularly serviced by a licensed specialist. (service contract). The rectification of faults and damage resulting from the use 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 obligations under warranty; this also applies to corrosion due to halogen compounds, e.g. from spray cans, paints, adhesives, halogenated refrigerants, solvents and cleansing agents. 4

5 / 01 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: Close the boiler door and lock it in position before changing the attachment of the door 2.2 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. 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! 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. 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). 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, Figure 6) (door casing)

6 Assembly / 01 See separate assembly instructions for boilers with mounted calorifier 2.3 Fitting the heat insulation 1. Using M8 hex screws, nuts and washers, fit the front retaining bracket (1) 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) 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. 6

7 / 01 Assembly 7 7a 7b 7c 7d 3 4a 4b Fig b 1 C-clips 6d 5a 5 6c 5b 6a 5c 5d 2 C-clips 7

8 Assembly / Fitting the casing 8. Using a hex nut and washer, attach bolt (8) to the door and then fit the door casing (8a). 9. Place support (9) on the door hinge (Figure 6a). 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 Figure 6). Place right and left side sections (9b/9c) over the supports (9) and attach to the front brackets (1, Figure 3) 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, Figure 3) with self-tapping screws ø 4.8 x Attach upper right and left side wall (11,11a) (proceed as for lower side walls, see point 10). 12. Insert 2 insulation mats (12) (to prevent vertical circulation of air) longitudinally on the left and right. 13. Applies only where the controller is fitted on the side (see point 2.5): Fit 2 special screws (13, Figure 4) with counter nuts to the side wall on which you are mounting the controller. 14. Attach bottom and top rear wall (14,14a) to the angled edges of the side walls (10,11,11a) with self-tapping screws ø 3.5 x 9.5 and C-clips. Fit cover plate (14b) with self-tapping screws ø 3.5 x 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 a 15. Remove controller box cover plate (15, Figure 6). Hook the switch control box (15a, Figure 4) into the side wall (11a, Figure 6) with the recesses for the special screws and secure with 2 self-tapping screws ø3.5 x 6.5 and serrated washers (15b). 16. Pull the capillaries with the immersion sensors (16, Figure 5) through the opening (16a, Figure 4) in the side wall, insert them into the immersion sleeve (16b, Figure 6) as far as the stop and fix in position with retaining spring (16c, Figure 5). Insert the burner plug (16d). Caution: The capillaries must not be folded or kinked! 17. Attach cover plate (15) with self-tapping screws ø3.5 x 6.5 and serrated washers. 18. Place casing cover (18,18a) in position and attach on the right and left side with self-tapping screws ø4.8 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 point c 15b 16a 16 Fig. 5 Fig. 4 8

9 / 01 Assembly Fig. 6a 8a 9 8 8a 9c Fig. 6 19a 18 9d 9b 16b 9e 18a 16d 15 9a 14 11a 10 14a 14b 9

10 Assembly / Fitting the boiler controller at the top 15. Remove controller box cover plate (15, Figure 7). The control panel (15a, Figure 7a) 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 7) and secure with self-tapping screws (ø4.8 x 38). 16. Pull the capillaries with the immersion sensors (16, Figure 5, Page 8) through the opening (16a, Figure 7a) in the cover, insert them into the immersion sleeve (16b, Figure 7) as far as the stop and fix in position with retaining spring (16c, Figure 5, Page 8). Insert the burner plug (16d). Caution: The capillaries must not be folded or kinked! 17. Attach cover plate (15) with self-tapping screws ø3.5 x 6.5 and serrated washers. 18. Fit casing cover (18) and secure on the right and left sides with self-tapping screws ø4.8 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 point b c 15f 15h 15a 15d 15e Fig. 7a 16a 10

11 / 01 Assembly e 16d 19a Fig b 11

12 Installation 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 / 01 rectangular ducts (thermolyt. 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 ( ) complies with the following directives + standards We hereby declare that the product described, as an individual unit, complies with the standards, guidelines and technical specifications listed below. Directives: 90/396/EC "Gas appliances directive" 92/42/EC "Efficiency directive" 73/23/EEC "Low-voltage directive" 89/336/EEC "Electromagnetic compatibility" 97/23/EC "Pressure equipment directive" (PED) Regulations: Stability pren14394:2001 Building requirements EN303-1, EN303-2, EN303-3 Low voltage DIN VDE 0722 / Ed EMC EN Part 1 / Ed

13 / 01 Installation 3.2 Technical data Uno-3 ( ) Type (130) 1 (160) (190) (220) (250) (280) Nominal heat output at 80/60 C 2 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 3 C Safety temperature limiter setting (water side) 3 C Operating/test pressure at max. operating temperature 90 C 3 bar 4.0/ / / / / /6.5 Maximum boiler operating temperature 4 C Safety temperature limiter setting (water side) 4 C Operating pressure at max. operating temperature 105 C 4 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 160 C 9R3/290 6R5/290 6R5+ 9R5/290 6R5+ 6R5+ flue gas temperature 6R2/290 3R3/290 6R2/290 Boiler efficiency at 80/60 C (related to net/ gross calorific value, heating oil EL) % 92.8 / / / / /87.6 Normal degree of efficiency (DIN 4702 Part 8 75/60 C) (related to net/ gross calorific value, heating oil EL) % 96.1 / / / / /9.4 95/90 Standby losses qb at 70 C Watts Resistance on the heating gas side at nominal output 160 C flue gas temperature, 12.5% CO 2, 500 m above sea level mbar (tolerance ± 20%) Flue gas mass flow at nominal output 12.5% CO 2 heating oil kg/h Flow resistance boiler 5 z-value Hydraulic resistance at 10K mbar Hydraulic resistance at 20 K mbar Water flow rate at 10 K m³/h Water flow rate at 20 K m³/h Boiler water content litres Boiler gas content m³ Insulation thickness of boiler body mm Weight (incl. casing) kg Sound level 6 - Heating noise without absorber hood (EN Part 1) db(a) Heating noise with absorber hood (EN Part 12) 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 ø440x974 ø440x974 ø490x974 ø490x974 ø488x1434ø488x1434 Combustion chamber volume m³ Dimensions see dimensional drawing Maximum negative pressure in the flue pipe system (at the boiler connection) Pa For Switzerland only 2 At nominal output, the pollutant limit values and flue gas losses as per regulation LRV (92) are complied with. 3 Controller U3.1 and T2.2 4 Controller U3.2 and T2.2 5 Flow resistance boiler in mbar = flow rate (m 3 /h) 2 x z 6 Data valid for Hoval oil compact heat station b-i 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 13

14 Installation / Dimensions } 1 Flow type DN 50, PN 6 2 Return type DN 65, PN 6 3 Safety flow R 1 1 / 2 4 Flow for calorifier R 1 1 / 4 5 Return for calorifier R 1 1 / 4 6 Drain pipe R 1 1 / 2 7 Flue gas outlet 10 8 Cleaning aperture 9 Boiler controller optionally on the right, left or top 10 Plinth rail: width 50 mm 11 Boiler door attached on the right (on the left if desired) 12 Flue gas collector cleaning connection R 1 13 possible anti-vibration elements, width 80 mm, height 50 mm 14 Burner absorber hood Fig. 8 Uno-3 l w h h1 a c d e f g i k m n o P q* r s t u Ø / *q = flue gas outlet external diameter. Plate thickness 3 mm; adapter set for Uno-3 ( ): D qø 199, A qø 200 (with tape) 3.4 Dimensions without heat insulation and casing (transport dimensions) Boiler (without calorifier) incl. swivel flange, connections and flue gas collector Fig. 9 Uno-3 Width Length Height Weight Type B with connections + flue gas collector L1 without connections + flue gas collector L2 H kg

15 / 01 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. 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, leak-tightness etc.) b) connection of the boiler to the flue gas system according to applicable regulations and standards c) correct dimensioning of the flue duct cross-section. re: a) Flue gas systems in accordance with EN 13384, Part 2, types I and II, conform to state-of-the-art combustion systems (a chimney engineer must be consulted). 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. 10) The flue gas system must be watertight, acid-proof and approved for the corresponding flue gas temperatures. As a general rule, only one heat generator should be connected to the chimney! When using two heat generators, the corresponding regulations must be observed. 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. Fig. 10 Where possible, avoid 90 bends in the flue gas system! Flue gas pipes over 1 m in length must be insulated. Moisture-resistant and acid-proof flue gas systems must be used in new installations. 15

16 Installation / 01 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 Kessel zum Schornstein re: c) Dimensioning of the flue duct cross-section. The cross-sections 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 * 16 Chimney height m ~ ~ ~ ~ ~ ~ 250 *kw = maximum boiler output 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!

17 / 01 Installation 4.3 Fitting the burner Fig. 11 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

18 Installation 4.4 Fuel 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 Heating oil L in accordance with ÖNorm C all fuel gases as defined by DVGW process sheet G / 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. Even in partial load operation, the flue gas temperature must not fall below 100 C. 4.5 Electrical connection All electrical connections must be carried out by a licensed electrician. Regulators 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 Electrical connection of the burner - 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. Inspection hole Fig

19 / 01 Installation Flue gas and performance diagrams Uno-3 (130) for Switzerland only C kw 9R3/290 Uno-3 (160) C kw 6R5/290 Uno-3 (190) C kw 6R5 + 6R2/290 Uno-3 (220) C kw 9R5/290 19

20 Installation / 01 Uno-3 (250) kw C C Uno-3 (280) kw C 6R5 + 3R3/290 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. CO2 = 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 20

21 / 01 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. 21

22 Commissioning / 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 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. 22

23 / 01 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 40). 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. 23

24 Maintenance / Maintenance 6.1 Information for fire inspector / 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 switchoff). 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). 24

25 / 01 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 (Figure 13) - 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 - Insert the regulators - Fit 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" 25

26 Overview of settings / 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 26

27 / 01 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 27

28 Overview of settings / 01 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 28

29 / 01 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 OEM 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 sec OEM 23 PI -reset time Tn 600 sec/ C OEM HF HF 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 29

30 Overview of settings / 01 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 sec OEM 20 I-portion Tn 270 sec OEM 21 Running time servomotor 150 sec 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 30

31 / 01 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 sec OEM 20 I-portion Tn 270 sec OEM 21 Running time servomotor 150 sec 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 31

32 Overview of settings / 01 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 sec OEM 21 Modulation adjustment time Tn 180 sec/ C OEM 22 Modulation running time 12 sec HF 23 Modulation starting time 200 sec 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 32