Subject to modifi cations | EN

Technical informationAssembly instructions

4 213 738 / 00 - 01/15

Hoval products must be installed and commissioned only by appropriately qualified experts. These instruc-tions are intended exclusively for the specialist. Elec-trical installations may only be carried out by a qualified electrician.

Uno-3 (320,360)Oil/gas boilers

These instructions apply to the following types:41-Uno-3 (320,360)

Uno-3 (320, 360) boilers are suitable and licensed for use as heat generators for hot water heating systems with a permissible flow temperature of up to 100 °C 1). They are designed for closed-circuit systems, but can also be installed in open systems as per EN 12828.1) See chapter 3.2

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TABLE OF CONTENTS

1. Important information1.1 Other instructions ...............................................................................................................................................................31.2 Safety information ...............................................................................................................................................................31.3 Regulations, official approvals ...........................................................................................................................................31.4 Guarantee ............................................................................................................................................................................4

2. Assembly2.1 Installation position .............................................................................................................................................................52.2 Setting up, levelling .............................................................................................................................................................52.3 Fitting the heat insulation ...................................................................................................................................................62.4 Fitting the casing .................................................................................................................................................................82.5 Fitting of the boiler controller ...........................................................................................................................................102.5.1 Boiler controller TopTronic® E ..........................................................................................................................................102.5.2 Boiler controller T0.2 / T2.2 .............................................................................................................................................10

3. Technical information3.1 Description of the boiler ................................................................................................................................................... 113.1.1 The Uno-3 (320, 360) complies with the following directives + standards ........................................................................ 113.2 Technical data Uno-3 (320, 360) ........................................................................................................................................123.3 Dimensions ........................................................................................................................................................................133.4 Dimensions without heat insulation and casing (transport dimensions) .......................................................................14

4. Installation4.1 Boiler room requirements .................................................................................................................................................164.2 Connection of the flue gas system and flue duct dimensions ........................................................................................164.3 Fitting the burner ...............................................................................................................................................................184.3.1 Sound insulation .............................................................................................................................................................184.4 Fuel ....................................................................................................................................................................................194.5 Electrical connection .........................................................................................................................................................194.5.1 Flue gas regulator set .....................................................................................................................................................194.5.2 Recommended cable cross sections: ..............................................................................................................................194.5.3 Safety measures relating to EMC assembly ....................................................................................................................194.6 Flue gas and performance diagrams ................................................................................................................................204.7 Flow mixing loop / minimum limitation of the boiler return temperature .......................................................................204.8 Setting the temperature regulators ...................................................................................................................................204.9 Safety valves......................................................................................................................................................................204.10 Charging pump (boiler with free-standing calorifier).......................................................................................................204.11 Heating pump.....................................................................................................................................................................20

5. Commissioning5.1 Water quality ......................................................................................................................................................................215.2 Filling the heating system .................................................................................................................................................225.3 Filling the calorifier (if present) ........................................................................................................................................225.4 Initial commissioning ........................................................................................................................................................225.5 Oil / gas burner ..................................................................................................................................................................225.6 Handover to the operator / storage ...................................................................................................................................22

6. Maintenance6.1 Information for fire inspector / chimney sweep regarding emission monitor key ..........................................................236.2 Cleaning .............................................................................................................................................................................246.2.1 Preparatory work.............................................................................................................................................................246.2.2 Cleaning (dry or wet method) ..........................................................................................................................................246.2.3 Putting into operation again ............................................................................................................................................246.3 Safety temperature limiter - Reset ....................................................................................................................................24

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IMPORTANT INFORMATION

1. Important information1.1 Other instructions

All instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the in-structions can be found enclosed with the components.Further information sources:• Hoval catalogue• Standards, regulations

1.2 Safety information

The system may only be placed in operation if all the rel-evant standards and safety regulations have been com-plied with. At least the following conditions must be satis-fied for a trial operation:

1. Safety valve installed (closed system)2. Control in operation (connected to the mains current

supply system)3. Sensor for the safety temperature limiter mounted in

the immersion sleeve4. System filled with water5. Expansion vessel connected6. Flue gas connectors connected to the flue gas pipe-

line at the chimney or flue7. An adequate supply of fresh air must be guaranteed8. The burner is preset

1.3 Regulations, official approvals

The following regulations are to be complied with for in-stallation and operation:

Germany - DIN EN 12831 Heating systems in buildings – Method for calculation of the design heat load.

- EN 303 Heating boilers with forced draught burners. - DIN EN 12828 Sheet 1 and 2 - Heating systems in buildings – design of water-based heating systems.

- DIN 4755 Oil-fired systems.Design, construction and safety engineering require-ments.

- DIN 4756 Gas-fired systems; construction, execution, technical safety requirements, planning and execution.

- DIN 18160 House chimneys; requirements, planning and execution.

- TRD 702 Steam boiler plants with calorifiers of the group II.

- DIN EN 13384 Chimneys – Thermal and fluid dynamic calculation methods.

- TRD 721 Safety devices against excess pressures / safety valves / for steam boilers of Group II.

- VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water heating systems.

- DIN 57 116 / VDI 0116 Electrical equipment for firing systems (VDE Regulation).

- For further standards applicable in Germany, see ap-pendix N-430 020.

Austria - ÖNorm 7550 - ÖNorm B 8130 Open water heating systems; safety de-vices.

- ÖNorm B 8131 Closed water heating systems; safety, execution and testing requirements.

- ÖNorm B 8133 Hot water production systems; technical safety requirements.

- ÖNorm B 8136 Heating systems, space requirements and other building requirements.

- ÖNorm M 7515 Calculations of dimensions of chim-neys; terminology, calculation procedure.

- ÖNorm H 5171 Heating systems, construction engi-neering requirements.

- ÖVGW TR-Gas G1 Technical directives for low pres-sure gas installations.

- ÖNorm M 7445 Gas blower burner

Switzerland - Requirements of the VKF Cantonal Fire Insurance As-sociation.

- Fire brigade regulations. - Requirements of the SVGW Swiss Association of Gas and Water Suppliers.

- SWKI 91-1 Aeration and ventilation of the boiler instal-lation room.

- SWKI 88-4 Water treatment for heating, steam and air conditioning systems.

- SWKI 93-1 Safety engineering installations for heating systems.

- KRW Corrosion through halogen compounds. - KRW/VSO/FKR Plug-in electrical connections on heat-ing boilers and burners

and further regulations and standards issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and the legislative body.

Also to be complied with are the regulations of the local building authorities, insurance companies and chimney sweeping operations. The regulations of the responsible gas supply company are also to be complied with and any necessary official approval obtained.

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IMPORTANT INFORMATION

1.4 Guarantee

Proper function is only guaranteed providing these in-structions are followed and the boiler is regularly main-tained by a licensed specialist. (Maintenance contract). The rectification of faults and damage as a result of con-taminated operating materials (gas, water, combustion air), unsuitable chemical additives and an inadmissibly high lime content of the heating water, improper handling, faulty installation, unauthorised modifications and dam-age due to the use of force do not fall under our guaran-tee obligations, this also applies to corrosion due to halo-gen compounds, e.g. from spray cans, paints, adhesives, halogenated fluids, solvents and cleanings agents.

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ASSEMBLY

2. Assembly2.1 Installation positionWhere 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 (Fig. 16). After transport, they can simply be screwed back to the bracket.

Release and screw back 6 transport counter nuts before commissioning.

Counter nut

Fig. 01

2.2 Setting up, levellingA special foundation plate for the boiler is not an essen-tial, but it is recommended.

Space requirementfor fitting the heat insulation and casing panelling:• at least 40 cm each on the left

and right side of the boiler,• controller side min. 70 cm.If the space between the boiler and the wall is less, all heat insulation and casing must be fitted before the boiler can be pushed into its final position (Fig. 18).

Do not connect lines until the heat insulation and casing have been fitted to the boiler!

NOTEThere must always be enough space be-tween the back of the boiler and the wall to allow easy access to the cleaning aperture in the flue gas collector.

There must be enough space to swing open the boiler door, incl. the burner.

Boiler door pivotable to the leftIt 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:

NOTEClose the boiler door and lock it in position before changing the attachment of the door!

12 Fig. 02

1. 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).

NOTEThe cable must not touch any hot parts!

LevellingUsing a spirit level, align the upper edge of the boiler wa-ter jacket (longitudinal axis of the boiler) until it is precise-ly horizontal or sloping very slightly upwards towards the rear by inserting the plinth rails correspondingly, to allow the boiler to vent properly.

Before fitting the burner, first fit the double door (Pos. 8a, Fig. 06) (door casing).

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ASSEMBLY2.

3 Fi

tting

the

heat

insu

latio

n

1.

Mou

nt th

e fro

nt re

tain

ing

brac

ket (

1, F

ig. 0

4) w

ith h

exag

on s

crew

s M

8, n

uts

and

U-w

ashe

rs, a

ligne

d ho

rizon

tally

, to

the

front

wal

l of t

he b

oile

r. -A

ttach

C-c

lips.

2.

Mou

nt th

e re

ar re

tain

ing

brac

ket (

2, F

ig. 0

4) w

ith h

exag

on s

crew

s M

8, n

uts

and

U-w

ashe

rs a

ligne

d ho

rizon

tally

. -A

ttach

C-c

lips.

3.

Pla

ce th

e in

sula

tion

mat

(3, 3

a, F

ig. 0

4) a

roun

d th

e bo

iler b

ody

(with

the

join

t at t

he to

p, b

lack

sid

e fa

cing

out

war

ds).

4.

Atta

ch th

e in

sula

tion

mat

(3,3

a, F

ig. 0

4) u

sing

4 p

last

ic s

traps

(4, F

ig. 0

4) a

nd s

trap

fast

ener

s (4

a, F

ig. 0

4):

-Te

nsio

n sp

rings

(4b,

Fig

. 04)

ser

ve fo

r add

ition

al fi

xing

. -D

o no

t ove

rtigh

ten

the

stra

ps (r

educ

ed in

sula

ting

valu

e).

5.

Atta

ch th

e in

sula

tion

mat

s (5

/5a/

5b, F

ig. 0

4) to

the

pins

pro

vide

d on

the

rear

wal

l of t

he b

oile

r and

sec

ure

with

reta

inin

g di

scs,

(Fig

. 03)

(ø 3

8).

Wra

p th

e in

sula

tion

mat

s (5

c, F

ig. 0

4) a

roun

d th

e co

nnec

tion

fittin

gs a

nd s

ecur

e w

ith te

nsio

n sp

rings

.

6.

Atta

ch in

sula

tion

pane

ls (6

/6a/

6b/6

c/6d

, Fig

. 04)

to th

e pi

ns w

elde

d on

to th

e flu

e ga

s co

llect

or a

nd s

ecur

e w

ith th

e re

tain

ing

disc

s (ø

38)

pro

vide

d.

7.

Atta

ch in

sula

tion

pane

ls (7

/7a/

7b/7

c/7d

, Fig

. 04)

to th

e pi

ns w

elde

d on

to th

e fro

nt w

all o

f the

boi

ler a

nd s

ecur

e w

ith th

e re

tain

ing

disc

s (ø

38)

pro

vide

d.

The

rem

aini

ng 2

insu

latio

n m

ats

(17,

Fig

. 06)

ar

e fit

ted

afte

r mou

ntin

g th

e ca

sing

.

Fig.

03

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ASSEMBLY

1C

-clip

s

2

3a

4b3

4

5a 6

6b6d 5 6a 5b

5c6c

7c7a7

7b

7d

4a

Fig.

04

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ASSEMBLY

2.4 Fitting the casing

8. Fit hexagon bolts with U-washers and hexagon nuts (8, Fig. 07). Insert thermal insulation (8a) into the boiler door. Attach the door casing to the boiler door using hexagon cap nut.

The boiler controller can be mounted on the right or left side panel (11a, Fig. 06).

9. Place support on the door hinge (9, Fig. 05).

10. Attach 4 special screws (9a, Fig. 06) with counter nuts to each side section (9b/9c, Fig. 06).

11. Fit burner plug (9d, Fig. 06) into the front left (or right) side section and route the burner cable (9e, Fig. 06) (possibly over the boiler) to the opening (13a, Fig. 09 / Fig. 10) for the controller (cable routing as shown in Fig. 06).

NOTEThe cable must not touch any hot parts

12. Place right and left side sections (9b/9c, Fig. 06) over the supports (9, Fig. 05) and attach to the front brack-ets (1, Fig. 04) with self-tapping screws ø 4,8 x 38.

13. Mount support (10, Fig. 05) with hexagon bolts and nuts on the water jacket base (back wall of boiler).

The support (10) must be aligned so that top edge of support (9) and top edge of support (10) are at the same height.

15. Hook lower right and left side wall (11, Fig. 06) into the side sections (9b/9c, Fig. 06) and attach to the rear retaining brackets (2, Fig. 04) with self-tapping screws ø 4,8 x 38.

16. Hook in the upper left and right side wall (11a, Fig. 06) and attach to the rear retaining brackets (2, Fig. 04) with self-tapping screws ø 4,8 x 38.

17. Insert 2 insulation mats (17, Fig. 06) (to prevent ver-tical circulation of air) longitudinally on the left and right.

18. Attach rear wall (14, Fig. 06) to the angled edges of the side walls (11, 11a) with self-tapping screws ø 4,8 x 38.

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ASSEMBLY

8

8a

8a

9b

19

17

18

18a

18b

Fig. 05

910

Fig. 06

Fig. 07 T0.2 / T2.2Fig. 08

12

12d

13

9e

14

11a

11

12

9a

9d

9c9e

13b

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ASSEMBLY

2.5 Fitting of the boiler controller2.5.1 Boiler controller TopTronic® E

19. Mount the special screws with nuts (12a, Fig. 09) on the side panel (11a, Fig. 06). Then hook the boiler controller (12, Fig. 09) into the side wall with the re-cesses for the special screws (11a, Fig. 06) and se-cure it with 2 self-tapping screws ø 3,5 x 6,5 and ser-rated lock washers (12b, Fig. 09).

12a

12b

1213a

12c

Fig. 09

20. Pull the capillaries with the immersion sensors (13, Fig. 11) through the opening (13a, Fig. 09) in the side panel, insert them into the immersion sleeve (13b, Fig. 06) as far as the stop and fix in position with re-taining spring(13c, Fig. 11).

21. Insert the burner plug (9e, Fig. 06).

NOTEThe capillaries must not be folded or kinked!

22. Close the boiler controller and screw on (12c Fig. 09),

continue with point 25

2.5.2 Boiler controller T0.2 / T2.2

12

12b

12d

12a

13a Fig. 10

23. Mount the special screws with nuts (12a, Fig. 10) on the side panel. (11a, Fig. 06). Then hook the boiler con troller (12, Fig. 10) onto the special screws and secure using self-tapping screws ø 3,5 x 6,5 and ser-rated lock washers (12b, Fig. 10).

24. Pull the capillaries with the immersion sensors (13, Fig. 11) through the opening (13a, Fig. 10) in the side panel, insert them into the immersion sleeve (13b, Fig. 06) as far as the stop and fix in position with re-taining spring (13c, Fig. 11).

25. Insert the burner plug (9e, Fig. 06).

NOTEThe capillaries must not be folded or kinked!

26. MAttach cover plate to the boiler controller(12d, Fig. 08) with self-tapping screws ø 3,5 x 6,5 and serrated lock washers.

27. Place casing cover (18/18a, Fig. 06) in position and attach on the left and right sides with self-tapping screws ø 3,5 x 9,5.

28. Affix labels and where applicable, mount manual hol-der on the side.

29. Remove transport lock, see point 2.1.

13c

13

13b

Fig. 11

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TECHNICAL INFORMATION

3. Technical information3.1 Description of the boiler

The Uno-3 is a threepass boiler. At the end of the cir-cular cylindrical combustion chamber, the flame gases flow through several cylindrical tubes arranged above the combustion chamber and towards the front to the turning chamber, from where they flow through rectangular ducts (thermolytic heating surface) towards the rear and reach the flue gas collector.

Fig. 12

3.1.1 The Uno-3 (320, 360) complies with the following directives + standards

We hereby declare that the product described, as an individual appliance, complies with the standards, guidelines and technical specifications laid down.

Directives: 90/396/EC «Gas Equipment Directive» 92/42/EC «Efficiency directive» 73/23/EEC «Low-voltage directive» 89/336/EEC «Electromagnetic compatibility» 97/23/EC «Pressure Equipment Directive» (PED) at maximum boiler temperature 90 °C

Regulations: Stability prEN14394:2001 Building requirements EN303-1, EN303-2, EN303-3 Low voltage DIN VDE 0722 / Edition 04.83 EMC EN 50082 Part 1 / Edition 01.92

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TECHNICAL INFORMATION

3.2 Technical data Uno-3 (320, 360)

Type (320) (360)

• Nominal heat output at 80/60 °C kW 320 360• Heat output range (heating oil EL, natural gas H: variant 1 and 3) kW 220-320 220-360• Heat output range (heating oil EL, natural gas H: variant 2) kW 140-320 140-360• Maximum heat input kW 344 390• Maximum boiler operating temperature 1 °C 90 90• Safety temperature limiter setting (water side) 1 °C 110 110• Operating/test pressure at max. operating temperature 90 °C 1 bar 4,0/5,2 4,0/5,2• Maximum boiler operating temperature 2 °C 105 105• Safety temperature limiter setting (water side) 2 °C 120 120• Operating pressure at max. operating temperature 105 °C 2 bar 4,0 4,0• Minimum boiler operating temperature °C see table of operating conditions (below)• Minimum boiler return temperature °C see table of operating conditions (below)• Minimum flue gas temperature at boiler °C see table of operating conditions (below)• Regulator set for 170 °C flue gas temperature - -• Boiler efficiency at full load at 80/60 °C

(related to net/gross calorific value, heating oil EL)% 93,5/88,2 92,5/87,3

• Boiler efficiency at partial load 30 % at return 37 °C (according to EN 303) (Relative to net/gross calorific value heating oil EL)

% 95,5/90,1 95,0/89,6

• Standard efficiency at 75/60 °C (DIN 4702 Part 8)(related to net/gross calorific value, heating oil EL)

% 96,6/91,1 95,8/90,4

• Standby loss qB at 70 °C Watt 670 670• Flue gas resistance at nominal output 180 °C flue gas temperature,

12,5 % CO2, 500 m above sea level (tolerance ± 20 %)mbar 2,5 3,4

• Flue gas mass flow at nominal output 12,5 % CO2 heating oil kg/h 542 610• Flow resistance boiler 4 z-value 0,022 0,022• Water flow resistance at 10 K mbar 16,51 20,94• Water flow resistance at 20 K mbar 4,10 5,2• Water flow volume at 10 K m3/h 27,43 30,86• Water flow volume at 20 K m3/h 13,71 15,43• Boiler water content litres 625 625• Boiler gas content m³ 0,402 0,402• Insulation thickness of boiler body mm 80 80• Weight (incl. casing) kg 920 920• Combustion chamber dimensions Ø-inside x length mm ø488x1634 ø488x1634• Combustion chamber volume m³ 0,3056 0,3056• Dimensions see Dimensions• Maximum draught/underpressure at flue gas outlet Pa 30 30

1 Boiler controller E13.4 TopTronic® E und T2.22 Boiler controller E13.5 TopTronic® E und T0.24 Flow resistance boiler in mbar = flow rate (m3/h)2 x z

Possible operating conditions:

Fuel Heating oil EL Natural gas H Heating oil LUno-3 Type (110-360) (110-360) (110-280) (320,360)

Variant 1 Variant 2 Variant 3 Variant 1 Variant 2 Variant 3

min. flue gas temperature °C 130 110 130 130 110 130 130 130min. boiler temperature °C 48 50 52 55 60 62 58 70min. return temperature °C 35 38 No lower

limit45 48 No lower

limit45 60

Return temperature control yes yes no yes yes no yes yesBoiler start protection 1 no no yes no no yes no no

1 If the boiler temperature is or drops below the minimum boiler temperature (variant 3) and there is no return maintenance then the load must be switched off using a corresponding control function.

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TECHNICAL INFORMATION

3.3 Dimensions

Fig. 13

1 Flow DN 80, PN 62 Return DN 80, PN 63 Thermostat immersion sleeve ¾″4 Drain pipe R 1½″5 Flue gas outlet Ø outside, plate thickness 3 mm6 Cleaning opening 455/95 mm7 Boiler controller on the right/left or top8 Plinth rail, width 50 mm9 Boiler door right swivelled (optional left swivelled)

10 Flue gas collector cleaning opening R1″11 Burner sound absorbing hood, feet on rollers,

height 50 mm, adjustable up to 170 mm12 Possible anti-vibration elements; width 80 mm, height 50 mm

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TECHNICAL INFORMATION

3.4 Dimensions without heat insulation and casing (transport dimensions)

Fig. 14

Uno-3 Width Length Height WeightType B L1 L2 H kg

320, 360 750 2114 1886 1481 800

Minimum overall unit dimensions boiler uprightBoiler (without calorifier) upright with swivel flange at bottom, transport on trolley or rollers provided by the client.

Required minimum width of door and corridor for bringing in the boilerThe following values are the calculated minimum values.

K

T

< 150B

L

Fig. 15

BK= x L

T

BT= x L

K

T Door widthK Corridor widthB Boiler widthL Maximum boiler length

Example calculation for the required corridor widthDoor width T = 800

750Uno-3 (320, 360) K = x 2114 = Corridor width ≥ 1982

800

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TECHNICAL INFORMATION

Fig. 16

1 Transport board (by client)2 Pipe as roller (by client)3 Boiler door (can be removed)4 Hinge bracket

Boiler heightwith socket and without socket and

Uno-3Type

flue gas collectorH1

flue gas collectorH2

WidthB

LengthL

(320, 360) 2114 1886 750 1481

Example calculation for the required corridor widthDoor width T = 800

750Uno-3 (320, 360) K = x 1481 = Corridor width ≥ 1389

800

Dimension of boiler doorSpace for using a trolley

Fig. 17

Max. width Floor distanceUno-3Type

for trolleya

with boiler doorb

without boiler doorc

(320, 360) 540 50 195

Swinging out of the boiler door and cowl dimensions

Fig. 18

Sound absorbing hoodType a b c d e 1) f g h

Uno-3 (320) depending on burner 606 depending on burner 400 depending on burner 2070 600Uno-3 (360) depending on burner 606 depending on burner 400 depending on burner 2070 600

1) Minimum distance 100 mm

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INSTALLATION

4. Installation4.1 Boiler room requirementsRegarding the building specifications for boiler rooms and their supply and extract air handling, the current build-ing supervisory office regulations specific to the state or country are to be observed. In Germany the firing regula-tions for the individual Bundesländer are to be complied with.

Make sure there is an adequate supply of fresh air to the boiler room,to ensure that the combustion air supply necessary for all the firing systems operated there can flow in without hindrance and that no oxygen deficiency occurs for the operating personnel.Binding values for the size of supply air openings are not generally specified in the relevant regulations; it is merely required that no partial vacuum in excess of 3 N/m2 oc-curs. An opening or line leading into the open air of at least 150 cm2. For every kW in excess of 50 kW, a further 2 cm2 must be calculated. In rectangular openings, the ratio of the sides should not exceed 1.5:1; if a grid is fit-ted, an appropriate allowance must be added so that the free cross-section area reaches the amount given above.In Austria ÖNorm H 5171 additionally stipulates a flue air aperture. This must have a minimum cross section of 180 cm2 up to a rated heat output of 100 kW. For every further kW, the cross-section must be increased by 1 cm2.

NOTEThe flue gas system must be watertight, ac-id-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.

4.2 Connection of the flue gas system and flue duct dimensions

To guarantee economic and fault-free operation, boiler and chimney must be mutually adapted to create a func-tional unit.

Moisture-resistant and acid-proof flue gas systems must be used in new installations.

Existing flue gas systems may require upgrad-ing or adjustment of the flue duct cross-sec-tion as indicated by a chimney engineer.

The correct functioning of the flue duct, i.e. the generation of the required delivery pressure depends on:a) the type (nature) of the chimney (thermal insulation,

interior surface roughness, sealing etc.)b) the connection of the boiler to the chimney according

to specificationc) establishing the correct flue duct cross-section dimen-

sion.

re: a)Chimneys according to EN 13384, part 2, execution types I and II are appropriate for modern firing systems (advice from the chimney specialist is necessary).

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 30-45°.

The entry location of the flue gas pipe must be carefully sealed.

The introduction of the flue gas pipe into the chimney (a) must be executed so that no condensate water can flow from the chimney into the flue gas pipe and the boiler Fig. 19.

a

Fig. 19

Where possible, avoid 90° bends in the flue gas system!Flue gas pipes longer than 1 m are to be insulated.

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INSTALLATION

NOTENormally only one heat producer may be con nected to the chimney.

lue gas pipes longer than 1 m are to be insulated. If an adapter (reducer) from the flue gas outlet of the boiler to the entry point into the flue gas system is required, it must take the form of a slim cone.

De lachaudière

Versla cheminée

from the boiler

to the chimney

re: c)Dimensioning the chimney cross section. The cross sec-tions are to be calculated for boilers without delivery pressure requirement according to EN 13384. (Please also observe DIN 18160, Part 1 «Domestic chimneys»). Take into consideration location-specific factors (hillside location of the building, chimney position, slope of the roof, chimney stack exit shape, etc.)!In Switzerland, take note of SIA Recommendation 384/4!

In Austria, calculation is performed as prescribed by ÖNorm M 7515.

Non-binding guide values for dimensioning of the flue duct for boiler types Uno-3 (320-360).

Inside diameter of flue duct in mm

Boiler typeUno-3 kW *

Chimney height11-15 m

(320) 320 ~ 300(360) 360 ~ 350

* kW = maximum boiler output

Basic data:Flue gas pipeline 5 m long, two 90° elbows and one 45° elbow, outside air 15 °C, height above sea level max. 800 m, flue gas pipeline same ø as flue gas connector on boiler.

You are recommended however to use the services of the chimney specialist right from the planning stage!

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INSTALLATION

4.3 Fitting the burner

• Depending on the size of the burner flange, an interme-diate flange may be required to attach the burner.

• To allow the burner to be swung out 90° to the left or right, the connections must be flexible and routed to the burner in sufficiently large loops.

• The cavity between burner pipe and boiler flange must be insulated with the fireproof fibre provided.

• In systems with ThermoCondensor, the burner must additionally absorb the resistance of the ThermoCon-densor and the flue.

Fig. 20

Uno-3 A B C D MØ Ø

(320, 360) 240 270; 4xM10 450 195 340

Fig. 21

Uno-3 E F G H L max. N OØ Ø

(320, 360) 335 240 488 1649 630 33 133

4.3.1 Sound insulation

• Gas pipes must be mounted in such a way that no vi-brations are transferred to the building.

• A foundation plate under the boiler unit.

• We recommend the following sound attenuation compo-nents:

• Heat and sound absorbing hood over the burner• Flue gas silencer in the exhaust gas pipe• Flexible exhaust gas pipe sleeves on the boiler exhaust

gas pipe• Vibration elements for the plinth rail

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INSTALLATION

4.4 Fuel

NOTEThe boiler may only be operated with the fuel designated on the boiler rating plate.

Uno-3 boilers are suitable for the combustion of the fol-lowing fuels:• Heating oil EL in accordance with DIN 51 603 / SN 181

160/2 / ÖNorm C 1109• Heating oil L in accordance with ÖNorm C 1108• all fuel gases as defined by DVGW process sheet

G 260.

4.5 Electrical connection

Electrical connections must be established by a licensed and qualified electrician. The connection diagram is located in the ter-minal box of the heat generator; the circuit diagram is supplied separately. Refer to this for the conductor cross section required for the mains supply.

WARNINGThe heat generator can be deprived of only separating it from the mains voltage (eg multipole switch).

WARNINGAll electric power supply circuits must be swit ched off before accessing the terminals.

For Switzerland, the following applies:For the electrical connection, the circuit diagram specific to the plant must be observed!

For Austria only:The diagram folder is located in the switch control box. Please affix the correct connection diagram to the inside of the terminal cover.An electrical circuit diagram is supplied with the boiler controls.An all-phase main switch with a minimum contact spacing of 3 mm must be fitted in the power supply line.

Applies only for Germany:The diagram folder is located in the switch control box.An electrical circuit diagram is supplied with the boiler controls.An all-phase main switch with a minimum contact spacing of 3 mm must be fitted in the power supply line.

4.5.1 Flue gas regulator set

• The flue gas regulators fitted in each case are listed on a label on the boiler casing.

• The installer can change the flue gas regulator set fitted and thus vary the flue gas temperature within a specific range.

4.5.2 Recommended cable cross sections:

Cable type Cross-section Length

Power supply of the heat generator (230V)

min 2,5 mm2 with 16A Protection unlimited m

Power supply of the heat generator (400V)

min 1,0 mm2 with 10A Protection unlimited m

Mains voltage cables of actuators min 1,0 mm2 unlimited m

Low-voltage cables(sensors) min 0,5 mm2 max. 50 m

Data bus lines (shielded cable) 2 x 2 x 0,6 mm2 max. 100 m

4.5.3 Safety measures relating to EMC assembly

1. In the case of control units with their own mains sup-ply, it is imperative that cables carrying mains volt-age are routed separately from sensor or data bus cables. If using cable ducts, these must be equipped with separator strips.

2. The mains connection for the heating system (boiler control panel regulator unit) must be designed as an independent electrical circuit. Neither fluorescent lamps nor other sources of interference for the rel-evant machinery may be connected or capable of connection.

FuseBoiler roomemergency switch

Heat Generator

Boiler room lighting and power sockets must be in a separate circuit

Fig. 22

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 an-tennae, radio alarm installations or in the immediate vicinity of large transmitters etc.).

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INSTALLATION

4.6 Flue gas and performance diagrams

Uno-3 (320)

kW

°C

100

110

120

130

140

150

160

170

180

140 160 180 200 220 240 260 280 300 320

Uno-3 (360)

kW

°C

100

110

120

130

140

150

160

170

180

120 140 160 180 200 220 240 260 280 300 320 340 360

kW = heat output°C = flue gas temperature with heating oil EL,

boiler flow 80 °Creturn flow 60 °CCO2 = 13 %During the combustion of natural gas or heating oil L, the flue gas temperature is approx. 15 °C higher.

4.7 Flow mixing loop / minimum limitation of the boiler return temperature

Hydraulic and control measures must be provided to en-sure that the temperatures do not fall below the permis-sible 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 out-side temperature.with heating regulator:The heating regulator automatically sets the correct boiler temperature. The boiler temperature varies be-tween 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 tem-perature 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 maxi-mum 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 12828 Part 2 Section 9 is mandatory.

4.10 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.

4.11 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.

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COMMISSIONING

Heating Water

§The European Standard EN 14868 and the di-rective VDI 2035 must be observed.

In particular, attention must be paid to the following stipu-lations:• Hoval boilers and calorifi ers are designed for heating

plants without signifi cant oxygen intake (plant type I ac-cording 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 refill-ing 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 replace-ment 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 ll-ing and replacement water. However, as not all drink-ing water is suitable for use 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 suit-ed 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 con-tent 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 2035Total hardness of the fi lling water up to ...

[mol/m3] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0f°H <1 5 10 15 20 25 30 >30d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8e°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 >300Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600Boiler size of the individual boiler maximum fi lling quantity without desalination

50 to 200 kW NO REQUI- 50 l/kW 20 l/kW 20 l/kWalways desalinate200 to 600 kW RE- 50 l/kW 50 l/kW 20 l/kW

over 600 kW MENT

1 Sum of alkaline earths2 If the conductance in µS/cm exceeds the tabular value an analysis of the water is necessary.

5. Commissioning5.1 Water quality

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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 gas-works to make sure.

5.5 Oil / gas burner

Setting the burner must also be carried out by a special-ist, and the setting must correspond to the heat demand of the system.Please see the technical information / assembly instruc-tions 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 operat-ing manuals. (See sample on the last page). The manu-facturer of the unit is responsible for providing operating manuals for the complete system. This technical informa-tion / these installation instructions must not be destroyed after completing the commissioning procedures, but should be permanently stored with the unit.

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MAINTENANCE

This chapter is exclusively intended to describe the function of emissions and manual operation settings for the fi ring monitoring technician / chimney sweep. All operating elements are described in the operating instructions.

!CAUTIONDanger of scalding with hot water, since the hot water temperature can exceed the target setpoint temperature.

NOTICEIn order to protect underfl oor heating systems against impermissible superheating during emissions measurement / manual operation, it is necessary to implement appropriate safety measures (e.g. pump switch-off with maximum thermostat). The output and duration of the emission measurement can be set in the "Emission" main menu, and reactivated if required.

Emission metering

Setting at: Home screen > Main menu (page 1) > Emission.

For detailed information see operating instructions, "Emission" chapter.

Power limitation with 2-stage burner:0 to 50% = 1st stage 51 to 100% = 2nd stage

REACTION to emission metering• Go back after expiry of the time unit/time specifi cation of return to the main menu• Setpoint temperature = Maximum temperature limit• Forced energy is used in an attempt to keep the corresponding heat generator temperature to 60 °C• Regulate heating circuits and the calorifi ers to their maximum temperature (in the direct heating circuit only if the hot

water basic program is set to parallel operation)

Manual mode

Settings under: Home screen > Main menu (page 2) > Manual operation.

For detailed information see operating instructions, "Emission" chapter.

REACTION for manual operation• Setting the required setpoint temperature using the selected heating or hot water circuit• All heating pumps ON• Note the maximum permissible temperature of surface heating!

6. Maintenance6.1 Information for fire inspector / chimney sweep regarding emission monitor key

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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.

6.2.1 Preparatory work

• Switch boiler off (controller: set switch to «O,» pull the burner plug)

• Interrupt the fuel supply• Open the boiler door• Remove flue gas collector cleaning cover (back)

6.2.2 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 ac-cordance with regulations.

6.2.3 Putting into operation again

• Insert the regulators• Fit cleaning cover• Close boiler door and reconnect burner plug

NOTEDo not overtighten boiler door screws.

• Reconnect the fuel supply• Where applicable, refit front cover• Reset boiler switch to «I»

6.3 Safety temperature limiter - Reset

If the boiler temperature rises too high (>100 °C), the sys-tem is switched off by the safety temperature limiter (STL) by means of a mechanical lockout. The malfunction must first be unlocked on the safety tem-perature limiter, then on the control panel.

- STL - Reset

Fig. 231. Open the switch control box2. Unscrew the protective cap3. Reset the STL

Reset on the control panel

Reset key

Fig. 24

Press the reset key on the control (first remove the cov-er): the boiler is ready for operation again once the boiler water temperature is less than 80 °C.

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Confirmation

The user (owner) of the system herewith confi rms that• he has received adequate instruction in the operating and maintenance of the installation,• received and taken note of the operating and maintenance instructions and, where applicable other documents con-

cerning the heat generator and any further components.• and is consequently suffi ciently familiar with the installation.

Installation address: Type:

Serial number:

Year of manufacture:

Place, Date:

System installer: System user:

Confirmation

The user (owner) of the system herewith confi rms that• he has received adequate instruction in the operating and maintenance of the installation,• received and taken note of the operating and maintenance instructions and, where applicable other documents con-

cerning the heat generator and any further components.• and is consequently suffi ciently familiar with the installation.

Installation address: Type:

Serial number:

Year of manufacture:

Place, Date:

System installer: System user:

COPY FOR PLANT USER

COPY OF SYSTEM INSTALLER