Technical information Assembly instructions. UltraOil ( ) Oil condensing boiler

Technical information Assembly instructions UltraOil (110-200) Oil condensing boiler These instructions apply to the following types: 30-UltraOil (110) 30-UltraOil (130) 30-UltraOil (160) 30-UltraOil (200) with controller U3.4 This appliance is only suitable for operation with heating oil EL (low sulphur) Hoval products must be installed and commissioned only by appropriately qualified experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualified electrician. The UltraOil boiler is designed and licensed for use as a heat generator for hot water heating systems with permissible flow temperatures of up to 90 C 1). It is designed primarily for closed circuits, but is equally suitable for installation in open circuits. 1) see point 3.2 Subject to modifi cations 4 210 258 / 00-07/11 EN

1. Important information 1.1 Other instructions... 4 1.2 Safety instructions... 4 1.3 Regulations, official approvals... 4 1.4 Warranty... 5 2. Installation position, transport 2.1 Transport... 6 2.2 Installation position... 6 3. Assembly 3.1 Setting up, levelling... 6 3.1.1 Boiler door pivotable to the left... 7 3.2 Fitting the thermal insulation... 8 3.3 Fitting the casing... 9 3.4 Fitting the boiler controller... 10 3.5 Fitting the siphon... 12 3.6 Fitting the burner... 13 4. Technical information 4.1 Description of the boiler... 14 4.1.1 The UltraOil meets the requirements of the following directives + standards... 14 4.2 Technical data... 15 4.3 Dimensions... 16 4.3.1 Mass without thermal insulation and casing... 17 4.3.2 Installation kit (Option)... 18 5. Installation 5.1 Boiler room requirements... 19 5.2 Flue gas connection and chimney... 19 5.2.1 Flue gas conduits approved under building law... 20 5.2.2 Project planning instructions... 20 5.3 Fuel... 20 5.4 Electrical connection... 21 5.4.1 Safety measures relating to EMC assembly... 22 5.5 Flue gas performance diagrams... 23 5.6 Hydraulic integration... 24 5.7 Condensate discharge... 24 5.8 Setting the temperature regulators... 24 5.9 Safety valves... 24 5.10 Charging pump (boiler with water heater)... 24 5.11 Heating pump... 24 6. Commissioning 6.1 Water quality... 25 6.1.1 Heating water... 25 6.1.2 Filling and replacement water... 25 6.2 Filling the heating system... 26 6.3 Filling the water heater (if fitted)... 26 6.4 Commissioning... 26 6.5 Oil burner... 26 6.6 Handover to the operator/storage... 26 6.7 Record - Activation of screed function... 27 2 Table of contents 4 210 258 / 00

7. Maintenance 7.1 Information for combustion controller/chimney sweep regarding emission monitor key... 29 7.2 Safety temperature limiter - Reset... 30 7.3 Cleaning the boiler... 31 7.3.1 Preparations for cleaning the boiler and burner... 31 7.3.2 Re-assembling the boiler... 31 7.3.3 Cleaning the boiler room... 31 7.4 Cleaning the combustion chamber and the alufer pipes... 33 7.4.1 Leakage testing... 33 7.5 Servicing the neutralisation installation for types 23 and 24 (if fitted)... 34 7.5.1 Procedure for servicing the neutralisation installation... 34 8. Overview of settings 8.1 Table of parameters... 35 8.2 Fault Reporting overview TopTronic T... 45 4 210 258 / 00 Table of contents 3

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 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. Safety valve installed (closed system) 2. Controls in operation (connected to the power supply) 3. Sensor for the safety temperature limiter is located in the immersion sleeve (see 2.2). 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. Burner is preset. 1.3 Regulations, official approvals For installation and operation of the system, the following regulations must be observed: Germany - DIN EN 12831 Heating systems in buildings - Procedure for calculation of the standard heating load. - DIN EN 12828 Heating systems in buildings - Design of hot water heating systems. - DIN EN 13384 Flue gas systems - Heat and flow calculation methods. - 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 execution (for operation with gas burners). - DIN 18160 House chimneys, requirements, design and construction. - PED (Pressure Equipment Directive). - 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. 4 Important information - DIN 57 116 / 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, design and testing requirements - ÖNorm B 8133 Water heating systems, safety engineering requirements. - ÖNorm B 8136 Heating systems, space requirements and other building requirements. - ÖNorm EN 12831 Heating systems in buildings - Procedure for calculation of the standard heating load. - ÖNorm EN 12828 Heating systems in buildings - Design of hot water heating systems. - ÖNorm EN 13384 Flue gas systems - Heat and flow calculation methods. - ÖNorm M 7515 Calculation of the dimensions of chimneys; terminology, calculation procedure. - ÖNorm H 5171 Heating systems - Construction engineering requirements - ÖVGW TR-Gas (Austrian Gas and Water Confederation - Technical Guidelines) Switzerland - VKF - Association of Cantonal Fire Insurers - Fire prevention authority regulations - SN EN 12831 Heating systems in buildings - Procedure for calculation of the standard heating load. - SN EN 12828 Heating systems in buildings - Design of hot water heating systems. - SN EN 13384 Flue gas systems - Heat and flow calculation methods. - SVGW Switzerland. Gas and water association. - SNV 27 10 20 Supply and extract air handling in the boiler room. - SWKI 97-1 Water treatment for heating, steam and air conditioning plants - SWKI 80-2 Safety engineering regulations for heating systems - KRW Corrosion caused by halogen compounds - KRW/VSO/FKR Ready-to-connect electrical connections on boilers and burners. - Technical tank regulations TTV 1990. and further regulations and standards prescribed by the CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by law. 4 210 258 / 00

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. 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 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, solvents and cleansing agents. 4 210 258 / 00 Installation position, transport 5

2. Installation position, transport 2.1 Transport The UltraOil is equipped with a flue gas collector made of plastic. Ensure that the flue gas collector is protected against damage during transport. 2.2 Installation position A special installation kit is available from Hoval for vertical installation (see 4.3.1.1). 3. Assembly 3.1 Setting up, levelling A special foundation plate for the boiler is not an essential, but it is recommended. There should be a space of at least 50 cm between the boiler and the wall on the left and right. If the space between the boiler and the wall is less than 50 cm, all thermal insulation and casing must be fitted before the boiler can be pushed into its final position. There must be enough space to swing open the boiler door, incl. the burner. 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. Electrical cables must not touch hot parts! 6 Installation position, transport 4 210 258 / 00

3.1.1 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 1. Remove the top and bottom hinge nut (1, Figure 1). 2. Fit the screw (2, Figure 1) (pivot point) on the other side of the door. 3. Reattach the hinge nut - do not tighten! 4. Fit the door handle on the other side of the door. 5. Fit the burner plug on the other side. The cable must not touch any hot parts. 2 1 2 1 Fig. 1 4 210 258 / 00 Assembly 7

3.2 Fitting the thermal insulation 1. Check that the size of the right and left casing support rail (5) matches the dimensions given (tolerance ± 1mm). 2. Place the insulation mat (6, Figure 2) around the boiler body (with the joint on the right, black side facing outwards). 3. Attach the insulation mats using two plastic tapes and tape locks (11, Figure 4): -- there are also tension springs (7, Figure 2) for additional attachment -- Do not pull the tapes too tight (this would reduce the insulation value) 4. Place insulation mat (9) on the front of the boiler and insulation mat (8) on the back of the boiler and secure in position with the retaining discs(9, Figure 3) provided. 5 6 7 8 Fig. 2 9 10 11 8 Assembly Fig. 3 Fig. 4 4 210 258 / 00

3.3 Fitting the casing 1. Insert the burner reset button (20, Figure 8) in the left or right side wall of the casing and plug the cables into the burner reset button as shown in the table below. 4. Hook the rear wall (23, Figure 8) into the screws fitted in the side walls. i The controller can be fitted on the right or left. The burner reset button is fitted on the same side as the controller. Wire colour Plug arrangement Wire colour brown 4 1 black 5 2 light blue 6 3 Button 2. Hook the side walls (21, 21a Figure 8) into the top and bottom rails (22, 22a). i First, fit the front side walls. Route the cable for the burner reset button forwards to the boiler door. Attach the cable to the casing side wall with the high-strength cable gland. 3. Fit two special screws (15, Figure 5) with counter nuts to the side wall (21, Figure 8) for the controller support. i The controller can be fitted on the right or left. 15 16 Fig. 5 4 210 258 / 00 Assembly 9

3.4 Fitting the boiler controller 5. Remove the cover plate of the controller box (24a Figure 8). Hook the switch control box (24) into the side wall (21) with the recesses for the special screws and secure it with two self-tapping screws Ø3.5x6.5 (16, Figure 5) and serrated washers. 6. Pull the capillaries with the immersion sensors (25, Figure 8) through the opening in the side wall, insert them into the immersion sleeve (25a) as far as the stop and fix in position with retaining spring (25b). Insert the burner plug (26). 8. Route the capillaries of the flue gas safety temperature limiter to the flue gas collector and plug into the opening (18, Figure 7) provided. Capillaries must not be folded or kinked 7. If the flue gas safety temperature limiter (17, Figure 6) is preassembled in the controller, continue at Step 8. Fit the flue gas safety temperature limiter (17) with the flue gas temperature sensor (18) and establish plug-in connection in the controller. 18 Fig. 7 9. Attach cover plate (24a, Figure 8) with selftapping screws Ø3.5x6.5 and serrated washers (24b). 10. Insert the rear casing cover (27, Figure 8). 11. Screw on the front cover plate (28, Figure 8) using self-tapping screws Ø3.9x9.5 (28a). 12. Fit cover plate (29, Figure 8) using self-tapping screws Ø3.5x9.5 (29a). 13. Attach oil line holder (31, Figure 8) to cover (30) and hook the cover into the side walls. 14. Stick on labels and mount the holder for the system manual (32, Figure 8) on the side. Fig. 6 17 18 10 Assembly 4 210 258 / 00

28a 28 27 22a 23 29a 29 24 24a 25a 24b 25b 32 31 25 26 20 21 22 21a Fig. 8 30 4 210 258 / 00 Assembly 11

3.5 Fitting the siphon 15. Attach the siphon (40, Figure 9), which is supplied loose. Before commissioning, the siphon and the neutralisation box (if fitted) must be filled with water in order to prevent flue gas leakage. 16. Place the condensate box (option) (41) behind the boiler and establish the electrical connection. Fit connecting line between siphon and condensate box. Optional 41 12 Assembly 40 Fig. 9 4 210 258 / 00

3.6 Fitting the burner Open the boiler flange (4 locking screws) and check the installation position of the combustion chamber unit. 1. Attach sliding flange with seals to the boiler. Please note the correct boiler position. 2. Slide burner in until only dimension C (Figure 11) protrudes: UltraOil (110-160): Dimension C = 120mm UltraOil (200): - - When attaching the burner, lift the burner casing slightly so that the screws (45, Figure 11) can be tightened. 3. Remove the lock nuts (46, Figure 11) of the boiler flange. 5. Close the boiler flange with the burner again and tighten the lock nuts. 6. Establish the plug-in connections. Pull the plug cables out further by releasing the high-strength cable glands. - 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. 7. Replace the absorber hood. Further information can be found in the instructions supplied with the burner. C Insulate the cavity between the burner tube and the boiler flange using the fireproof fibre provided (Figure 10). Note that - the fireproof fibre must be packed firmly into the cavity to prevent it falling out 4. Fit the recirculation pipe to the burner - Recommendation: Recirculation pipe flush with the mouth of the burner tube. 46 45 Fig. 11 Fig. 10 Fireproof fibre 4 210 258 / 00 Assembly 13

4. Technical information 4.1 Description of the boiler The Hoval UltraOil is a low-pollutant and energysaving oil-fired condensing boiler. The UltraOil has an obliquely positioned combustion chamber fabricated from non-corroding stainless steel as its primary heating surface and a secondary heating surface made from corrosion-resistant aluminium alloy. The secondary heating surface is so designed that the water vapour contained in the heating gas condenses and the heat of evaporation is utilised for the heating circuit. The UltraOil is designed exclusively for operation with low-sulphur heating oil EL. 4.1.1 The UltraOil meets the requirements of the following directives + standards We hereby declare that the product described, as an individual unit, complies with the standards, directives and technical specifications listed. Directives 92/42/EG 73/23/EWG 89/336/EWG "Efficiency directive" "Low-voltage directive" "Electromagnetic compatibility" Regulations Stability pren14394:2001 Building requirements EN303-2 EN303-1 pren 15034 Low voltage DIN VDE 0722 / Ed. 04.83 EMC EN 50082 Part 1 / Ed. 01.92 14 Technical information 4 210 258 / 00

4.2 Technical data Type (110) (130) (160) (200) Nominal heat output at 80/ 60 C kw 105 124 152 190 Nominal heat output at 40/ 30 C kw 110 130 160 200 Heat output range at 80/ 60 C kw 76,0-105,0 90,0-124,0 111,0-152,0 133,0-190,0 Heat output range at 40/ 30 C kw 80,0-110,0 95,0-130,0 116,0-160,0 140,0-200,0 Heat input kw 77,0-105,8 91,0-125,2 112,0-154,0 135,0-193,0 Dimensions see dimensional drawing Maximum boiler operating temperature C 90 90 90 90 Minimum boiler operating temperature C no lower limit Minimum boiler return temperature C no lower limit Minimum flue gas temperature at boiler C no lower limit Safety temperature limiter setting (water side) C 110 110 110 110 Operating / test pressure bar 4,0 / 5,2 4,0 / 5,2 4,0 / 5,2 4,0 / 5,2 Boiler efficiency (full load) at 80/60 C (related to net/ gross calorific value) % 99,0 / 93,4 98,9 / 93,3 98,5 / 92,9 98,0 / 92,5 Boiler efficiency (full load) at 40/30 C (related to net/ gross calorific value) % 104,0 / 98,1 103,8 / 97,9 103,5 / 97,6 103,1 / 97,3 Boiler efficiency (partial load 30%) at return 27 C (in acc. with EN 303) (related to net / gross calorific value) % 105,0 / 99,1 104,8 / 98,9 104,5 / 98,6 104,0 / 98,1 Standard efficiency (in acc. with DIN 4702, Part 8) at 75/60 C % 101,1 / 95,4 100,8 / 95,1 100,5 / 94,8 100,0 / 94,3 (related to net / gross calorific value) Standard efficiency (in acc. with DIN 4702, Part 8) at 40/30 C (related to net / gross calorific value) % 104,3 / 98,4 104,2 / 98,3 104,1 / 98,2 103,6 / 97,7 Standby losses qb at 70 C Watt 500 500 500 520 Combustion gas resistance at nominal output 12.5 % CO 2, 500m above sea level (tolerance +/- 20 %) mbar 0,24 0,34 0,45 0,67 Condensate rate at 40/ 30 C l/h 7,8 8,7 10,8 13,5 Flow resistance boiler 1 z factor 0,2 0,2 0,2 0,06 Hydraulic resistance at 10 K mbar 17,8 24,6 37,5 17,5 Hydraulic resistance at 20 K mbar 4,4 6,2 9,5 4,4 Water flow rate at 10 K m 3 /h 9,5 11,1 13,7 17,1 Water flow rate at 20 K m 3 /h 4,7 5,6 6,9 8,5 Boiler water content Litres 340 340 340 360 Boiler gas content m 3 0,247 0,247 0,247 0,290 Insulation thickness of boiler body mm 80 80 80 80 Weight (incl. casing, burner) kg 420 420 420 450 Transport weight kg 370 370 370 390 Min./ max. electrical power consumption (in operation) Watt 4 / 320 4 / 320 4 / 370 4 / 500 Sound level incl. absorber hood 2 Room-air-dependent - Heating noise (EN 15036 Part 1) db(a) 71 71 71 4 Room-air-dependent - Flue gas noise inside the flue (EN 15036 Part 2) 3 db(a) 89 91 92 4 - Flue gas noise radiated from the mouth (DIN 45635 Part 47) 3 db(a) 80 81 82 4 Combustion chamber dimensions Ø-inside x length mm Ø524 x 800 Ø524 x 800 Ø524 x 800 Ø524 x 1000 Combustion chamber volume m 3 0,172 0,172 0,172 0,215 Flue gas mass flow at nominal output 12.5 % CO 2 heating oil kg/h 163,6 193,0 252,0 315,0 Flue gas temperature at nominal output 80/ 60 C C 68 70 75 80 Flue gas temperature at nominal output 40/ 30 C C 40 42 48 58 Delivery pressure at flue gas outlet Pa 20 20 10 10 Maximum chimney draught Pa 20 20 20 20 1 Flow resistance boiler in mbar = flow rate (m 3 /h) 2 x z 2 Data valid for Hoval oil compact heat station b-i 3 Data without silencer, can be reduced by fitting a silencer 4 Data unknown at time of printing Oil burner to UltraOil b-i (110) b-i (130) b-i (160) b-i (200) Operating mode 1-stage 2-stage 1-stage 2-stage 1-stage 2-stage 1-stage 2-stage Firing output range kw 80 105,8 100 125,2 115 154,5 150 193 Fuel consumption kg/h 6,7 8,9 8,4 10,6 9,7 13,0 12,6 16,3 4 210 258 / 00 Technical information 15

4.3 Dimensions UltraOil (110-200) (All dimensions in mm) Space requirement -- for fitting the side casing 400 mm. -- The boiler can then be pushed to a position 100 mm away from the wall. -- Allow space for vibration absorber if necessary (see Accessories). UltraOil (110-200) 1 Flow / safety flow DN65/PN6 2 Low temperature return DN65/PN6 3 High temperature return DN65/PN6 4 Flue gas outlet (plastic) D200 5 Siphon trap and 2 m PVC continuous-flow tube DN25 D19x3 6 Cleaning aperture D100 7 Evacuation R 1" 8 Electrical connection, optionally left or right 9 Boiler controller, optionally left or right 10 Condensate drain, optionally left or right R ¾ 11 Socket A B C D E F G H I UltraOil (110-160) 280 610 1710 2200 153 243 290 395 740 UltraOil (200) 277 800 1918 2408 137 238 251 356 701 16 Technical information 4 210 258 / 00

4.3.1 Mass without thermal insulation and casing (All dimensions in mm) A B UltraOil (110-160) 1524 1882 UltraOil (200) 1722 2073 Required minimum width of door and corridor for bringing in the boiler The following values are the calculated minimum values K = B T x L T = B K x L T = Door width K = Corridor width B = Boiler width L = Maximum boiler length K L B < 150 T Example calculation for the required corridor width Door width T = 800 UltraOil (110-160) K = 735 x 1881 = Korridorbreite 1728 800 With installation kit UltraOil (110-160) K = 735 x 1229 = Korridorbreite 1129 800 4 210 258 / 00 Technical information 17

4.3.2 Installation kit (Option) (All dimensions in mm) A B C D E UltraOil (110-160) 1230 1751 2000 2002 2027 UltraOil (200) 1264 1951 2195 2182 2220 18 Technical information 4 210 258 / 00

5. Installation 5.1 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. Ensure an adequate supply of fresh air to the boiler room to make sure that there is an unobstructed flow of the combustion air required for the operation of all combustion devices in the boiler room and so that there is no shortage of oxygen for 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. To comply with this requirement, a supply air cross-section of 300 cm 2 is to be provided up to a nominal heat output of 50 kw. In the case of 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. 5.2 Flue gas connection and chimney As a result of the water vapour in the flue gas and the low flue gas temperature, condensate forms in the chimney. This means that oil condensing boilers cannot be connected to conventional domestic chimneys. The valid official stipulations and regulations with regard to flue gas evacuation must be observed. There are two possible ways to evacuate flue gas from oil condensing boilers: a) the use of special flue gas conduits approved by the building authorities, b) the use of moisture-resistant chimneys which are approved for flue gas temperatures of over 40 C, connected to the oil condensing boiler in the boiler installation room by means of approved flue gas conduits. In both cases, the cross-sections and maximum lengths must be calculated on the basis of the flue gas mass flow, flue gas temperature and available maximum delivery pressure at the flue gas outlet in accordance with the table in section 4.2 (EN 13384). The flue gas system must be gastight, watertight, resistant to acids and approved for use with the corresponding flue gas temperatures of up to 120 C and for overpressure. Horizontal connection lines must be routed with a downward slope of at least 50 mm per running metre of their length in the direction of the boiler to ensure that condensate can flow unhindered back to the boiler. The whole flue gas system must be designed to prevent condensate collecting. As a rule, only one heat generator should be connected to the chimney! If using two heat generators, observe the corresponding regulations. The UltraOil is delivered with a flue gas safety temperature limiter. For this reason, no additional flue gas safety temperature limiter is required for flue gas systems with a max. permissible flue gas temperature of 120 C. 4 210 258 / 00 Installation 19

5.2.1 Flue gas conduits approved under building law Only flue gas systems approved by the respective country or state may be connected (in Austria the approval requirements of the respective provinces must be observed). The manufacturers of the flue gas conduits supply suitable boiler connection fittings for the transition from the flue gas outlet to the flue gas conduit. When designing and installing flue gas conduits, manufacturer s instructions for design and routing and the requirements of building law must be observed. We recommend that you consult the regional chimney inspector in good time. 5.2.2 Project planning instructions - The flue gas must be routed through a tested and approved flue gas conduit - The flue gas conduit must be gastight, watertight, resistant to corrosion and acids and approved for use with flue gas temperatures of up to 120 C. - The flue gas system must be suitable for operation at pressure. - The flue gas conduit is to be laid with gradients to ensure that the condensate which occurs in the flue gas system flows back into the heating boiler and can be neutralised there before discharge into the drainage system. - When using flue gas conduits made from plastic, observe the country-specific regulations with regard to the use of the flue gas safety temperature limiter. (Included in the scope of delivery of the UltraOil ) - The cross-sections are to be calculated for heating boilers without draughting requirements. Please take note of SIA recommendation No. 384/4 Chimneys for building heating systems, determination of cross-sections. - A closable flue gas measurement nozzle with a circular internal diameter of between 10-21 mm must be installed in the flue gas conduit. It must protrude beyond the thermal insulation. 5.3 Fuel The boiler may only be operated with the fuel designated on the boiler rating plate. The UltraOil boiler is suitable for the combustion of the following fuels: - Low-sulphur heating oil EL in accordance with DIN 51 603 / ÖNorm C 1109 - Eco heating oil low-sulphur SN 181 160-2 / 2008 If an existing oil heating installation is replaced by a Hoval UltraOil, the following instructions regarding the oil tank and its refilling must be observed: - The Hoval UltraOil must only be operated with low sulphur heating oil EL with a sulphur content < 50 ppm (< 0.005 %). - It is recommended that you clean the oil tank before refilling it. - A residual amount of heating oil EL in the oil tank may be mixed with low sulphur heating oil EL, provided that the residual amount does not exceed the following percentages of the total content. Residual amount heating oil EL (sulphur content: 2000 ppm / 0.2 %) max 3 % of tank volume Residual amount heating oil EL (sulphur content: 1000 ppm / 0.1 %) max 5 % of tank volume Residual amount eco heating oil EL (sulphur content: 500 ppm / 0.05 %) max 10 % of tank volume - In order to reach the permissible mixture ratio with heating oil EL low-sulphur, taking into account the residual amount of heating oil in the oil tank, a 100% tank filling is necessary. D 1D D 2 x D < 2D 20 Installation 4 210 258 / 00

5.4 Electrical connection Electrical connections must be established by a licensed and qualified electrician. For Austria and Germany: An electrical circuit diagram is supplied with the boiler controls. An all-phase main switch with a minimum contact spacing of 3 mm must be fitted in the power supply line. For Switzerland, the following applies: For electrical connection, the circuit diagram specific to the plant must be observed. The electrical connection is to be made in accordance with the diagram supplied Cable feed-in Boiler control panel for the connection: Remove screws and fold out Fig. 12 4 210 258 / 00 Installation 21

5.4.1 Safety measures relating to EMC assembly 1. For regulator units with their own mains connection, separate routing of power leads and sensor or bus lines is absolutely essential. 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 any other equipment which might cause interference may be connected, nor may it be possible to connect such equipment. Fuse Boiler room emergency switch Boiler room lighting and power sockets must be in a separate circuit Heat generator 3. The fresh air sensor must not be fitted in the vicinity of transmitters and receivers (on garage walls near receivers for garage door openers, amateur radio antennae, radio alarm installations or in the immediate vicinity of transmitters etc.) Recommended cable cross-sections and maximum permitted cable lengths: Cables carrying mains supply voltages: (power supply, burners, pumps, actuators etc.): minimum 1mm 2 Maximum permissible length: no restrictions, within the framework of the building s internal installations. Sensor cables and cables carrying low voltages: minimum 0.5 mm 2 Maximum permissible cable length: 50 m Data bus lines: always shielded, e.g. J-Y (ST) 2 x 0.6 mm Maximum permissible cable length: 100 m 22 Installation 4 210 258 / 00

5.5 Flue gas performance diagrams The diagrams show the flue gas temperature characteristics with Hoval burners. UltraOil (110) UltraOil (200) Flue gas temperature ( C) 100 90 80 70 Flow 80 C Return flow 60 C 65 C 60 50 40 Flow 40 C Return flow 30 C 38 C 30 50.0 60.0 70.0 80.0 90.0 100.0 110.0 Flue gas temperature ( C) 90 80 Flow 80 C Return flow 60 C 81 C 70 60 50 60 C 40 30 20 Flow 40 C Return flow 30 C 10 0 90.0 100.0 110.0 120.0 130.0 140.0 150.0 160.0 170.0 180.0 190.0 200.0 Nominal output (kw) Nominal output (kw) UltraOil (130) Flue gas temperature ( C) 100 90 80 70 Flow 80 C Return flow 60 C 70 C 60 50 40 Flow 40 C Return flow 30 C 42 C 30 70.0 80.0 90.0 100.0 110.0 120.0 130.0 Nominal output (kw) UltraOil (160) Flue gas temperature ( C) 100 90 80 Flow 80 C Return flow 60 C 74 C 70 60 50 Flow 40 C Return flow 30 C 47 C 40 30 90.0 100.0 110.0 120.0 130.0 140.0 150.0 160.0 Nominal output (kw) C = flue gas temperature using heating oil EL, CO 2 = 12.5% 4 210 258 / 00 Installation 23

5.6 Hydraulic integration Examples Direct heating circuit AF The minimum inner diameter of the condensate drain must be 15 mm. The condensate drain must be sufficiently inclined. TopTronic T RS-T B 1 T T A: It is not necesary to neutralise condensate from an oil-fired condensing unit (up to 120 kw) drained together with domestic waste water from a private household. P KF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraOil Sie haben die Möglichkeit ein neues Shape zu HT nehmen!!! HT hovhovalh NT hovalhova NT alhovalho Fig. 13 Mixer circuit and water heater AF DKP 1 HT NT TopTronic T RS-T RS-T VF1 T T VF2 T B1 T WW CH: For the UltraOil, the fuel used must be heating oil EL low-sulphur. As a rule, neutralisation of the condensate is not necessary. Local regulations pertaining to condensate discharge must be observed. D: For the UltraOil, the fuel used must be heating oil EL low-sulphur. Neutralisation is therefore unnecessary. Regarding condensate discharge, the local regulations and the technical bulletin of the ATV (Sewage Engineering Association) must be observed. The siphon must be filled with water before commissioning. 5.8 Setting the temperature regulators Basic setting of the controller has been carried out by the heating contractor. Selection and setting of the various heating programmes in accordance with the operating manual. P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraOil Sie haben die Möglichkeit ein neues Shape zu HT nehmen!!! hovhovalh NT hovalhova alhovalho Fig. 14 HT NT YK1 M MK1 YK2 M MK2 SLP KW SF Dies ist ein unerlaubter Weg! T Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh 5.9 Safety valves The heating and hot water systems must each be protected with one safety valve against impermissibly high pressures. Their discharge capacity of the valves must correspond to the boiler s maximum nominal heat output. The valve is to be installed in the flow line in the immediate vicinity of the boiler. 5.10 Charging pump (boiler with water heater) Speed of rotation and output must correspond to the requirements of the water heater. Setting carried out by the heating installation engineer. 5.7 Condensate discharge The boiler condensate drain must be made of corrosion-resistant material. The following materials are suitable for the condensate drain: - PVC, PE, PP, ABS 5.11 Heating pump Speed of rotation and output must correspond to the requirements of the system. They are to be set by the heating installation engineer. 24 Installation 4 210 258 / 00

6. Commissioning 6.1 Water quality Heating Water The European Standard EN 14868 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 2035. 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 2035. Should the mains water available not be suited for use then it must be desalinated and/or be treated with inhibitors. The stipulations of EN 14868 must be observed. In order to maintain a high level of boiler effi ciency and to avoid overheating of the heating surfaces the values given in the table should not be exceeded (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water 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 <1 5 10 15 20 25 30 >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 Boiler size of the individual boiler maximum filling quantity without desalination to 50 kw NO REQUIREMENT 20 l/kw 50 to 200 kw 50 l/kw 20 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. 4 210 258 / 00 Commissioning 25

6.2 Filling the heating system Filling of the heating system must be carried out by trained personnel. The fill and make-up water must comply with the quality requirements in the relevant state or country (see chapter 6.1). 6.3 Filling the water heater (if fitted) The heating boiler may be put into operation even when the water heater is not filled. 6.4 Commissioning Important: On first commissioning, check that all safety and control devices are functioning properly. Operation and maintenance of the system must be explained in detail to the operator. The siphon must be filled with water before commissioning. 6.5 Oil burner Setting the burner must also be carried out by a specialist and the setting must correspond to the heat demand of the system. Please see the technical information / assembly instructions supplied with the burner. 6.6 Handover to the operator/storage Have the operator confirm in writing that the operating and service procedures have been explained and that he has received a copy of the relevant operating manuals (see sample on page 48). The system manufacturer is responsible for providing operating manuals for the whole plant. The technical information/ assembly instructions must be kept with the system at all times. 26 Commissioning 4 210 258 / 00

6.7 Record - Activation of screed function Cross where applicable; cut out record and fasten to the control during the active screed function. Minimum requirements for the activation of the screed function: Minimum age cement screed 21 days Minimum age calcium sulphate screed 7 days Flow temperature monitor installed and connected For newly laid screed - see Recommendation of the Federal Association of Radiant Panel Heating. Heating circuit selection for screed function and necessary parameter settings Mixing circuit 1 Mixing circuit 1 Start PRESS MC1/MC2 level Parameters 13,16 Activate Installer level (Code entry) > 3 sec: Access to level Select / Confi rm Set Confi rm End / Exit Required parameter settings: Parameter level Par. No Setting Description MIX.VALVE (1 or 2) 13... C Maximum fl ow temperature to be set MIX.VALVE (1 or 2) 16 1 2 3 Screed program to be set (for description see following page) 1 Function heating (duration: Starting day + 7 days) 2 Surface-ready heating (duration: Starting day + 18 days) 3 Function and surface-ready heating (duration: Starting day + 25 days) Direct heating circuit (possible only with H-Gen without minimum H-Gen temperature - e.g. condensing boiler) Start HC level Parameters 13,16 H-GEN level Parameter 4 PRESS Characteristic heating curve Enable HC Activate Installer level (Code entry) > 3 sec: Access to level Select / Confi rm Set Confi rm End / Exit Required parameter settings: Parameter level Par. No Setting Description - Key DK... Activate heating characteristic curve, above 0 = OFF, e.g. ~ 0.8 for FBH UNMIXED CIRC. 13... C Maximum fl ow temperature to be set UNMIXED CIRC. 16 1 2 3 Screed program to be set (for description see following page) 1 Function heating (duration: Starting day + 7 days) 2 Surface-ready heating (duration: Starting day + 18 days) 3 Function and surface-ready heating (duration: Starting day + 25 days) HEAT GENER. 4... C Max. H-Gen temperature to be set, set as for max. fl ow temperature (after termination of screed function reset max. temperature to the value required). If the screed function is activated for the unmixed circuit, all the other circuits (MC, DHW) are switched off. In alternation with the basic display of the controller, the activated screed heating is displayed giving some information about the remaining term in days screed - 18. Record Screed heating activated by:... Screed heating activated on:... Screed heating ends on:...... Date and signature 4 210 258 / 00 Commissioning 27

Parameter 16 Screed function (Parameter HC, MC1 or MC2) Example: Maximum fl ow temperature 40 C 1 Function heating T [ C] VLSol 55 45 35 25 maximal 55 C maximum 55 C einstellbar! set level! 1=Funktionsheizen Starting day + 7 days 1 = Function heating START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 t DAYS [TAGE] - On the starting day and for the three following days at 25 C constantly - Subsequently for 4 days at the set fl ow maximum temp., but limited to a maximum of 55 C 2 Surface-ready heating T [ C] VLSol Starting day + 18 days 55 45 35 25 2=Belegreifheizen 2 = Surface-ready heating START 11 22 33 44 55 66 77 88 9910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 DAYS t [TAGE] - On the starting day and on the 1st day constantly at 25 C, on each further day the demand value rises by 5 C until the maximum fl ow temperature is reached. Subsequently the temperature is lowered again in the same gradations until the low point of 25 C is reached. Example: Set fl ow maximum temp.: 40 C Starting day + 1st day: 25 C 2nd day: 30 C 16th day: 35 C 3rd day: 35 C 17th day: 30 C 4th day: 40 C 18th day: 25 C 5th - 15th day: constant heating with the max. fl ow temperature 3 Function heating and surface-ready heating Starting day + 25 days T [ C] VLSol 55 45 35 25 3=Funktionsheizen 3 = Function heating and und surface-ready Belegreifheizen heating START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 [TAGE] t DAYS - Combination of 1 function heating and subsequently 2 surface-ready heating 28 Commissioning 4 210 258 / 00

7. Maintenance 7.1 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 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). 4 210 258 / 00 Maintenance 29

7.2 Safety temperature limiter - Reset Boiler water temperature limiter - Reset If the boiler temperature rises too high (>100 C), the system is switched off by the safety temperature limiter by means of a mechanical lockout. Press the reset button on the control panel (first remove the cover); the boiler is now ready for operation again once the boiler water temperature is less than 80 C. i Depending on the design, you will find the flue gas safety temperature limiter in the controller or near the flue gas collector. Flue gas temperature limiter - Reset If the flue gas temperature rises too high, the system is switched off by the flue gas safety temperature limiter by means of a mechanical lockout. Press the reset button on the control panel; the boiler is now ready for operation again. The reason for the excessive flue gas temperature must be established by the installation engineer. Possible causes are: --Strong dirt build-up on the heating surface --Burner output setting too high 30 Maintenance 4 210 258 / 00

7.3 Cleaning the boiler The UltraOil may only be cleaned by a licensed specialist or Hoval customer service technician. Reliable and safe operation of the oil boiler, optimum efficiency and clean combustion can only be guaranteed if the unit is serviced and cleaned regularly. The boiler must be cleaned at least once per year. For this purpose, we recommend that you conclude a maintenance contract with Hoval customer service, or with an authorised specialist dealer. In the case of oil-fired equipment already in operation during the construction phase (where there is increased occurrence of dust), inspection should be carried out once construction work has been completed to ascertain the degree of dirt build-up. If necessary cleaning must be carried out. 7.3.2 Re-assembling the boiler -- Where applicable, reattach the neutralisation box and siphon base section and fill with water. --Fit the cleaning aperture cover. --Install the combustion chamber unit -- Close the boiler door, tighten the lock nuts evenly -- Plug in the burner plug. -- Set the main boiler control switch to "1" -- Measure combustion. If necessary, adjust the setting. Make a record of the measurement. 7.3.3 Cleaning the boiler room The boiler room must be kept clean and free of dust! Point out to the customer that the boiler room must be kept clean. 7.3.1 Preparations for cleaning the boiler and burner -- Set the main boiler control switch to "0". -- Await standby mode / fan follow-on time --Remove absorber hood --Undo the burner plug-in connections (burner cable, remote reset cable). -- Release all 4 boiler door lock nuts. --Open the burner with the boiler door (51, Figure 16) towards the right or left --Clean the burner. --Remove the combustion chamber unit --Remove the cover from the cleaning aperture. The siphon must be cleaned twice per year. In order to clean the siphon, the siphon base section (50, Figure 15) must be dismantled. -- Clean neutralisation box KB23,KB24 (if fitted) as described in chapter 7.5. Also remove and clean neutralisation box KB22 without granulate (if fitted). -- Unscrew the base section of the siphon (40, Figure 9) to catch the washing water. -- The cleaning scraper included in the scope of delivery is suitable for cleaning the alufer pipes. For a detailed description of how to clean the combustion chamber and the alufer pipes, see chapter 7.4. 4 210 258 / 00 Maintenance 31

Fig. 15 50 51 Fig. 16 32 Maintenance 4 210 258 / 00

7.4 Cleaning the combustion chamber and the alufer pipes in the case of light dirt build-up Carry out mechanical wet cleaning of the combustion chamber and the alufer pipes. The narrow cleaning scrapers (2 pieces) are used for the outer, the other two for the middle fl ow ducts. Only the bevelled cleaning scrapers need to be pushed through twice per duct (turned lengthwise through 180 each time). Before removing the drain hose, all dirt particles must be adequately rinsed out of the condensate drip tray. Cleaning scraper Bevelled cleaning scraper in the case of heavy dirt build-up Cleaning is performed as described «in the case of light dirt build-up», but fi rst, concentrated cleaning agent is sprayed on and allowed to soak in for 10 minutes. Do not use wire brushes or any sharp objects for cleaning. Ensure that the combustion chamber does not come into contact with iron, as this may cause corrosion. Care must be taken that stainless steel surfaces are not scratched or damaged in any way. Flow duct alufer pipe The only cleaning concentrates permitted are those approved for oil boilers having aluminium components such as Sotin 240 or Desoxin. Leakage testing After cleaning or at least every fi ve years, the sealing between the combustion chamber and the condensate drip tray must be checked for leakage. This can be done by fi lling the boiler with water. When working with the above cleaning agents, regulations prescribe the wearing of gloves and protective goggles. In addition, the instructions on the original packaging must be observed. 635 1 1 Filling level water 4 210 258 / 00 Maintenance 33

7.5 Servicing the neutralisation installation for types 23 and 24 (if fitted) Neutralisation box Type KB23 i Maintenance should be undertaken at least every second year, or after the neutralisation granules are exhausted (check the ph-value if appropriate with litmus paper test). Neutralisation granules Neutralisation granulate for refi lling can be ordered from Hoval under the following item no.: 1 pack (3 kg) neutralisation granules Part no. 2028 906 One fi lling requires 4 packs of 3 kg each. Procedure for servicing the neutralisation installation Set the main control switch to "0". Undo the bolts and withdraw the neutralisation box. Only for neutralisation box of type KB24 Remove the condensate pump and clean the condensate pump container. Remove the neutralisation granules and any deposits from the neutralisation box. Any remaining neutralisation granulate, since it is harmless, can be disposed of as domestic waste. Refi ll the neutralisation box with new granules. Neutralisation box with feed pump Type KB24 Condensate pump container Neutralisation granules Attach the neutralisation box cover making sure that it is tight-closing. Push the neutralisation box back in. Before putting back into service, the siphon and the neutralisation box must be filled together with water. The water can be poured through the cleaning aperture into the neutralisation box and the siphon. 34 Maintenance 4 210 258 / 00

8. Overview of settings 8.1 Table of parameters Designation Factory Type of device: DHW: SW: Address: Surface operation Key : Regulator Setting range / 10 20 30 40 50 Setting values Heating curve HC OFF OFF, 0,20... 3,5 Heating curve MC1 1,0 OFF, 0,20... 3,5 Heating curve MC2 1,0 OFF, 0,20... 3,5 Daytime target temperature HC *) 20 C 5... 30 C *) Daytime target temperature MC1 *) 20 C 5... 30 C *) Daytime target temperature MC2 *) 20 C 5... 30 C *) Night-time target temperature HC *) 16 C 5... 30 C *) Night-time target temperature MC1 *) 16 C 5... 30 C *) Night-time target temperature MC2 *) 16 C 5... 30 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 4 210 258 / 00 Overview of settings 35