technical information installation instructions ultragas ... · 1.1 safety instructions the system...
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Subject to modifi cations | EN
Technical informationInstallation instructions
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UltraGas® (15-50)Condensing gas heating boilersfor natural gas and liquid gasfor modulating operation
These instructions apply to the following types:Rated output levels at 40/30ºC and for na-tural gas41-UltraGas® (15) 3,1 - 15,5 kW41-UltraGas® (20) 4,0 - 20,2 kW41-UltraGas® (27) 5,0 - 27,2 kW41-UltraGas® (35) 5,8 - 35,7 kW41-UltraGas® (50) 8,3 - 50,1 kW
Hoval products must be installed and commissioned only by appropriately qualified experts. These instruc-tions are intended exclusively for the specialist. Electri-cal installations may only be carried out by a qualified electrician.
The floor standing gas condensing boiler UltraGas® are designed and approved for use as heat generators for hot water heating systems with a permissible flow temperature of up to 85ºC1), in accordance with EN 483 and EN 677. They are designed for continuously adjustable reduced output operation in heating sys-tems. 1) See technical data
1. Important notes1.1 Safety instructions ..............................................................................................................................................................41.2 Key to symbols used ...........................................................................................................................................................41.2.1 Warnings ..........................................................................................................................................................................41.2.2 Symbols ............................................................................................................................................................................41.3 Acceptance of delivery ........................................................................................................................................................51.4 Scope of guarantee .............................................................................................................................................................51.5 Instruction manuals .............................................................................................................................................................51.6 Regulations, official permits ...............................................................................................................................................61.6.1 Germany § ........................................................................................................................................................................61.6.2 Austria § ...........................................................................................................................................................................61.6.3 Switzerland § ....................................................................................................................................................................6
2. Assembly2.1 Set-up, levelling ...................................................................................................................................................................7
3. Technical data3.1 Description of the boiler .....................................................................................................................................................83.2 Technical data ......................................................................................................................................................................93.3 Dimensions ........................................................................................................................................................................103.4 Space requirements .......................................................................................................................................................... 113.5 Boiler-Flow resistance ......................................................................................................................................................123.6 Brief description of the automatic firing device ...............................................................................................................12
4. Installation4.1 Safety information .............................................................................................................................................................134.2 Boiler room requirements .................................................................................................................................................134.2.1 Room air dependent installation ......................................................................................................................................134.2.2 Room sealed installation .................................................................................................................................................134.3 Flue gas connection and flue ............................................................................................................................................144.4 Condensate drainage ........................................................................................................................................................154.5 Design variants ..................................................................................................................................................................154.6 Fitting the condensate drain (standard design with siphon) ...........................................................................................164.7 Fitting the neutralisation box ............................................................................................................................................174.8 Fitting the condensate delivery pump ..............................................................................................................................184.9 Fitting the neutralisation box and the condensate delivery pump ..................................................................................194.10 Hydraulic connection ........................................................................................................................................................214.10.1 Customer-side requirements ...........................................................................................................................................214.10.2 Hydraulic interconnection ................................................................................................................................................214.11 Electrical connection .........................................................................................................................................................22
5. Commissioning5.1 Safety information .............................................................................................................................................................235.2 Filling with water ...............................................................................................................................................................235.3 Water quality ......................................................................................................................................................................245.4 Bleeding the air from the gas line .....................................................................................................................................255.5 Switching on the system ...................................................................................................................................................255.6 Gas inlet pressure .............................................................................................................................................................255.7 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas (flue gas measurement) .......265.8 Changing over to a different gas type ..............................................................................................................................275.9 Handover to the user .........................................................................................................................................................275.10 Record - Activation of screed function .............................................................................................................................28
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TABLE OF CONTENTS
6. Maintenance6.1 Safety information .............................................................................................................................................................306.2 Bleeding .............................................................................................................................................................................306.3 Water refilling ....................................................................................................................................................................306.4 Renewing fuse ...................................................................................................................................................................306.5 Information for combustion controller/chimney sweep regarding emission monitor key .............................................316.6 Cleaning .............................................................................................................................................................................326.6.1 Cleaning the burner cylinder ...........................................................................................................................................326.6.2 Cleaning the exterior of the combustion chamber and burner cylinder .............................................................................336.6.3 Leakage testing ..............................................................................................................................................................346.6.4 Cleaning/adjusting the ignition and ionisation device .......................................................................................................346.7 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas ...............................................346.8 Clean siphon or neutralisation box ..................................................................................................................................356.9.1 Procedure for servicing the neutralisation installation ......................................................................................................366.9 Maintenance of the Neutralisation equipment (if available) ............................................................................................36
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TABLE OF CONTENTS
1. Important notes1.1 Safety instructions
The system shall not be put into operation un-til all relevant standards and safety regulati-ons are met.
For a test run, the following minimum conditions must be satisfied: - Safety valve installed (closed system) - Controls operative (connected to power supply) - Sensor for safety temperature limiter is connected - (= boiler temperature sensor) - System filled with water - Siphon filled with water - Expansion tank connected - Flue gas adapter pipe with flue gas pipe connected to flue.
- Burner is preset (see point 6.7).
WARNINGThe heat generator can only be de-energised by disconnection from the mains (e.g. all-po-le switch).
WARNINGAll electric power supply circuits must be switched off before accessing the terminals.
1.2 Key to symbols used1.2.1 Warnings
!
DANGER... indicates a situation of immediate danger which will lead to serious or fatal injuries if not avoided.
!WARNING... indicates a situation of possible danger which can lead to serious or fatal injuries if not avoided.
!CAUTION... indicates a situation of possible danger which can lead to minor or slight injuries if not avoided.
NOTICE... indicates a situation of possible danger which can lead to damage to property if not avoided.
1.2.2 Symbols
!General warning of a danger zone.
«Warning: dangerous electrical voltage» as a warning for accident prevention.Ensures that people do not come into contact with electrical voltage. The danger sign with the black lighting symbol warns against the danger of electrical voltage.
Warning of cutting injuries:Avoid cutting injuries. Clearly indicate the dan-ger of cutting on sharp-edged parts to avoid serious and costly injuries.
«Warning of hot surface» sign for indicating safety.Indicates dangers of injury and burns on hot surfaces.
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IMPORTANT INFORMATION
Information:Provides important information.
Follow the instructions for use.Requirements to comply with the instructions.
Tool:Which tools and other equipment are requi-red.
§Provides important information. Refers to standards and directives.
1.3 Acceptance of deliveryA visual control of the heating boiler should be conducted upon delivery.In the event of damage, the necessary steps should be followed as specified in the delivery contract. The costs for correcting the damage shall be taken over by the indi-vidual risk bearer.
1.4 Scope of guaranteeThe guarantee does not cover defects caused by:• non-observance of these instructions • non-observance of the operating instructions • incorrect Installation • unauthorised alterations • improper use • contaminated operating media (gas, water, combustion
air) • unsuitable chemical additives to the heating water • damage due to the exercise of force • corrosion through halogen compounds • corrosion through nonconforming water quality
1.5 Instruction manualsA summary of all the instruction manuals relevant to this system can be found in the Hoval System User Guide! In exceptional cases the instructions are kept with the res-pective components!
Additional sources of information:• Hoval catalogue• Standards and regulations
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IMPORTANT INFORMATION
1.6 Regulations, official permitsWhen installing and operating the system, the standards and regulations spec i fied in point 1.6.1 to 1.6.3 must be complied with at all times.
1.6.1 Germany § - DIN EN 12831 Heating systems in buildings - Methods for calculating the design heat load
- DIN EN 13384 Flue gas systems - Heat and flow calcu-lation methods
- DIN EN 12828 Heating systems in buildings - Planning of hot water heating systems.
- DIN 4755 Oil fired combustion systems. - Construction, design, safety requirements. - DIN 4756 Gas fired combustion systems. Construction, design, safety requirements, design and execution (for gas burner operation).
- DIN 18160 Domestic chimneys, requirements, design and construction.
- TRD 702 Steam boilers with group II hot water gene-rators.
- TRD 721 Safety equipment against excessive pressure / safety valves for group II steam boilers.
- VDI 2035 Prevention of damage through corrosion and scale formation in hot water heating systems.
- DIN 57 116 / VDI 0116 Electrical equipment in combus-tion systems (VDE regulation).
- See enclosure N-430 020 for further standards appli-cable in Germany.
1.6.2 Austria § - OENORM 12831 Heating systems in buildings - Me-thods for calculating the design heat load
- OENORM 13384 Flue gas systems - - Heat and flow calculation methods - OENORM 12828 Heating systems in buildings - Plan-ning of hot water heating systems.
- ÖNorm B 8130 Open water heating systems; safety equipment.
- ÖNorm B 8131 Closed water heating systems; requirements to safety, construction and testing.
- ÖNorm B 8133 Hot water supply systems; safety requirements.
- ÖNorm B 8136 Heating systems, space and other building requirements.
- ÖNorm M 7515 Dimensioning of chimneys; definitions and calculation procedure.
- ÖNorm H 5171 Heating systems - construction requirements for buildings.
- ÖVGW TR-Gas
1.6.3 Switzerland § - SN EN 12831 Heating systems in buildings - Methods for calculating the design heat load
- SN EN 13384 Flue gas systems - Heat and flow calculation methods
- SN EN 12828 Heating systems in buildings - Planning of hot water heating systems.
- VKF - Association of Cantonal Fire Insurances. - Fire service regulations. - SVGW Switzerland. Association of the gas and water trade.
- SNV 27 10 20 Ventilation requirements for the boiler Installation room.
- SWKI BT102-01 Quality of water in installations of building technology.
- Technical tank regulations TTV 1990.
and further standards and regulations issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by the legislator. Regulations from the local building authority, insurance companies and chimney sweeps must also be complied with. When using gas as fuel, the regulations of the re-sponsible gas board must also be observed. An official permit may be required.
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IMPORTANT INFORMATION
2. Assembly2.1 Set-up, levellingThe boiler is fixed to wooden transport chocks. For trans-port up and down stairs, it is wise to leave these timbers in place under the boiler.
A special foundation plate for the boiler is not an essen-tial, but it is recommended.
Space requirementFor further information on space requirements, see chap-ter 3.4.
The cleaning apertures must be easily acces-sible.
Installing and levelling the boilerRemove transport chocks. Store nuts and washers. Lift the boiler on one side and put grub screws of boiler base from the bottom through the slot of the boiler sockets. Fix boiler feet using hexagonal nuts (Fig. 01).
Using a spirit level, set the boiler in longitudinal and trans-verse direction and position it with a slight forward tilt. This is done by adjusting the nuts on the boiler feet. After this adjustment, the upper (locking) nuts on the boiler feet must be tightened.
Fig. 01
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ASSEMBLY
3. Technical data3.1 Description of the boilerThe Hoval UltraGas® is a low emission, energy-saving condensing gas boiler comprising the Ultraclean burner system, a gas fired premix burner with combustion air fan. The Hoval UltraGas® has a vertically disposed com-bustion chamber of stainless steel as a primary heating surface and a secondary heating surface of a corrosion resistant aluminium alloy.
The secondary heating surface is designed so that part of the water vapour contained in the flue gas is condensed and the vaporisation heat it contains is utilised for the heating circuit. The gas burner is in the form of a break draught burner, which can easily be swung up for main-tenance purposes. The UltraGas® is designed to operate with natural and liquid gas. The figure below shows the design principle.
Fig. 02
Feed tube on left and/or right side
High temperature returnon left and/or right side
Low temperature returnon left and/or right side
Gas safety and control devices
Combustion air fan
Electrode for ignitionand flame monitoring
TopTronic® E controller
aluFer® heat exchanger
Condensate collection tray
Flue gas connection
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TECHNICAL INFORMATION
3.2 Technical data UltraGas® (15-50)
Type (15) (20) (27) (35) (50)
• Nominal output 80/60°C with natural gas 1 kW 3,0-14,3 3,8-18,7 4,5-25,0 5,2-32,8 7,5-46,1• Nominal output 40/30°C with natural gas 1 kW 3,3-15,5 4,3-20,3 5,0-27,2 5,8-35,7 8,3-49,9• Nominal output 80/60°C with liquid gas 2 kW 4,5-13,8 4,9-18,6 6,6-24,3 6,9-32,2 9,9-45,5• Nominal output 40/30°C with liquid gas 2 kW 5,0-15,3 5,5-20,7 7,3-27,0 7,7-35,7 10,9-49,9• Nominal load with natural gas 1 kW 3,1-14,5 4,0-19,0 4,7-25,4 5,4-33,3 7,7-46,9• Nominal load with liquid gas 2 kW 4,7-14,3 5,1-19,3 6,8-25,2 7,2-33,4 10,2-47,2
• Working pressure heating max./min. bar 3,0/1,0 3,0/1,0 3,0/1,0 3,0/1,0 3,0/1,0• Working temperature max. °C 85 85 85 85 85• Boiler water capacity l 57 55 51 81 75• Flow resistance boiler 3 z-value 3,5 3,5 3,5 1,1 1,1• Min. water circulation l/h 0 0 0 0 0• Boiler Weight (without water content, incl. casing) kg 131 135 143 161 174
• Boiler efficiency at full load at 80/60 °C (related to net/gross calorific value)
% 97,5/87,8 97/88,1 97,9/88,2 97,9/88,2 98,0/88,3
• Boiler efficiency at partial load 30% (according to EN 303) (related to net / gross calorific value)
% 107,9/97,2 108,0/97,3 108,0/97,3 108,1/97,4 108,1/97,4
• Standard efficiency 40/30°C % 109,5/98,6 109,5/98,6 109,5/98,6 109,5/98,6 109,5/98,6(net calorific value / gross calorific value) 75/60°C % 107/96,4 107/96,4 107/96,4 107,0/96,4 107,0/96,4
• Heat loss rate at 70°C Watt 160 160 160 220 220• Standard emission rate NOx. mg/kWh 25 26 28 31 29
CO. mg/kWh 11 11 10 11 4• Content of CO2 in the exhaust gas max./min. power % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8
• Dimensions See table of dimensions
• Connections Flow /Return Inches R 1″ R 1″ R 1″ R 1¼″ R 1¼″Gas Inches Rp ¾″ Rp ¾″ Rp ¾″ Rp ¾″ Rp ¾″Flue gas Ø mm E80 E80 E80 E80 E80
• Gas flow pressure min./ max.Natural gas E/LL mbar 18-50 18-50 18-50 18-50 18-50Liquid gas mbar 37-50 37-50 37-50 37-50 37-50
• Gas connection value at 0°C / 1013 mbar:Natural gas E - (Wo = 15,0 kWh/m3) Hu = 9,97 kWh/m3 m3/h 1,5 1,9 2,6 3,3 4,7Natural gas LL- (Wo = 12,4 kWh/m3) Hu = 8,57 kWh/m3 m3/h 1,7 2,2 3,0 3,9 5,5Propane gas (Hu = 25,9 kWh/m3) m3/h 0,6 0,8 1,0 1,3 1,8
• Operation voltage V/Hz 230/50 230/50 230/50 230/50 230/50• Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50• Min./Max. electrical power consumption Watt 22/44 22/62 22/56 26/95 28/119• Standby Watt 9 9 9 9 9• IP rating (integral protection) IP 20 20 20 20 20
• Acoustic capacity- Heating noise (EN 15036 part 1) (room air-dependent) dB(A) 57 61 66 62 60- Exhaust noise is radiated from the mouth
(DIN 45635 part 47) (room air-dependent/room air-independent)dB(A) 43 49 55 55 58
• Acoustic pressure level (depending on installation) 4 dB(A) 50 56 59 55 53
• Condensate quantity (Natural gas ) at 40/30°C l/h 1,3 1,8 2,4 3,1 4,4• pH value of the condensate pH ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2
• Value for flue calculationTemperature class T120 T120 T120 T120 T120Flue gas mass flow kg/h 23 31 42 55,0 78,0Flue gas temperature at nominal output and operation 80/60°C °C 62 63 64 65 68Flue gas temperature at nominal output and operation 40/30°C °C 45 45 45 46 46Mass flow combustion air Nm3/h 17 23 31 41 58Feed pressure for combustion air/ flue gas system Pa 100 100 100 120 120Maximal Draft / negative pressure flue gas outlet Pa - 50 - 50 - 50 - 50 - 50
1 Data related to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15,0 kWH/m3 operation at a Wobbe coefficient of 12,0 up to 15,7 kWh/m3 is possible (a readjustment may be necessary).
2 Data related to Hu.3 Flow resistance boiler in mbar = volume flow (m3/h)2 x z4 See also notes at „Engineering“.
• Boiler flow resistence see diagram.
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TECHNICAL INFORMATION
3.3 Dimensions
(Dimensions in mm)
Fig. 03
Type UltraGas® (15-27) (35,50)
1 Heating flow / safety flow R 1" R 1¼"2 Low temperature-return R 1" R 1¼"2a High temperature-return R 1" R 1¼"3 Gas connection Rp ¾" Rp ¾"4 Flue gas outlet DN80 DN805 Boiler control6 Condensate drain (left or right) incl.
siphon DN25 and 2 m PVC continuous-flow tube inner Ø 19 x 4 mm
7 Draining8 Electric cable entry point9 Sound absorber hood10 Heating armature group
or loading group (Option)
Type A B C D E F G H
UltraGas® (15-27) 1400 655 333 1320 1220 852 1184 144UltraGas® (35,50) 1640 895 573 1560 1460 930 1340 222
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TECHNICAL INFORMATION
3.4 Space requirements
(Dimensions in mm)
Fig. 04
Boiler door incl. burner swings upward and to the left or outward.
A = minimum 150 mm *Burner service position front - boiler cleaning from the right
A = optimum 300 mm *- Burner service position left - boiler cleaning from
the front- Boiler can be placed with the right side directly
against the wall- however, a minimum gap of 160 mm is required.
* without armature group, 500 mm with armature group
- The cleaning aperture must be easily accessible. - Ensure access to the area beh
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TECHNICAL INFORMATION
3.5 Boiler-Flow resistance
UltraGas® (15-27)
UltraGas® (35,50)
0
5
10
15
20
25
30
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5
[m3/h]
[mbar]
0
5
10
15
20
25
30
35
0 1 2 3
[m3/h]
[mbar]
3.6 Brief description of the automatic firing device
The automatic firing device BIC960 of the UltraGas® only operates in conjunction with the heating controller TopT-ronic® E/UG. For this reason, the automatic firing device only needs to take care of the last remaining functions to ensure the correct operation of a modulating gas boiler.
The automatic firing device comprises the following func-tions: - PWM fan control (230V AC) - Modulating operation - Common electrode for ignition and flame monitoring (ionisation)
- LPG valve and boiler room fan controllable - Inputs for - flow sensor 1 - flow sensor 2 - flue gas sensor - water pressure sensor - safety temperature limiter (not used) - air pressure switch (not used) - gas pressure switch - Status outputs “fault” and “flame signal” - Allows connection of additional (external) ignition de-vice
- RS 485 connection to TopTronic® E/UG - RS 232 connection to PC - Start attempts: maximum 4 - Safety period: 5 sec - Pre-ignition period: 5 sec - Pre-purging period: 50 sec - Follow-on time pump (230V AC): 5 min after heat de-mand
Sicherungen:The BIC 960 is fitted with 3 fuses:2AT Mains4AT Pump4AT Burner fan
Blowing of one of the two 4AT fuses securing the pump or the burner fan, respectively, will prevent the affected device from starting. A failure of the mains fuse of the automatic firing device is displayed on the TopTronic® E/UG by the failure message „B:30 Bus interruption to automatic device“. The failure appears when there is no communication between auto-matic firing device and TopTronic® E/UG.
m3/h = Volume flowmbar = Flow resistance
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TECHNICAL INFORMATION
4. Installation4.1 Safety information
CAUTIONSharp edges pose a cutting hazard. Handle the cladding parts with care and avo-id contact with sharp edges.
4.2 Boiler room requirements
§• The boiler room must satisfy the applicable
local building regulations.• The boiler room ventilation must satisfy the
applicable local regulations in this regard.• Boilers may not be installed in rooms con-
taining halogen compounds which can be carried into the combustion air (e.g. wash rooms, drying rooms, DIY rooms, hair dres-ser rooms).
• Halogen compounds can originate, for example, from cleaning and degreasing agents, solvents, glue, and bleaching lyes.
Ensure that the required combustion air can flow unhinde-red at all times. This is important for the correct operation of all the boilers installed therein and to protect the users from an oxygen depleted atmosphere. An adequate fresh air supply meeting the local regulations must be provided.
4.2.1 Room air dependent installation - The applicable regulations do not normally provide any specific data on the size of air intakes. They only requi-re the pressure in the boiler room not to be below 3 N/m2.
- This means that for a rated thermal output of up to 50 kW an air intake with a cross section of at least 300 cm2 must be available.
- For rectangular apertures the aspect ratio should not exceed 1.5:1. If a grid is fitted on the air intake, a sui-table allowance must be made to obtain an air intake cross section of 300 cm2.
4.2.2 Room sealed installationConfiguration based on a concentric flue system: - The suction air is supplied through a double-wall flue system.
- Ensure the boiler room is sufficiently ventilated.
Configuration using a separating piece (optional):
The following must be observed when laying out the intake pipe:• If the intake opening is installed on the
house facade near to a noise-sensitive area (e.g. bedroom windows, garden seating area, etc.) we recommend instal-ling a noise damper in the direct fresh air suction line.
• The intake opening must be easily acces-sible.
• No chemicals or poisonous substances may be stored close to the intake opening
• The intake opening may not be installed beside fume extraction outlets or other venting outlets.
• Ensure that the intake aperture is free from any obstructions at all times (leaves, snow, ...)
• A safety grid must be installed on the suc-tion opening on the outside wall.
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INSTALLATION
4.3 Flue gas connection and flueDue to the low flue gas temperatures, condensate forms within the flue. For this reason, Hoval gas heating boilers can not be connected to conventional house chimneys.
§The flue gas extraction system must comply with the following directives:• DVGW (TRGI)• ÖVGW• SVGW/VKFPursuant to the abovementioned regulations, a flue gas temperature limiter must be ins-talled in the boiler.
The flue gas system must meet the following requirements:• Gastight• Watertight• Acid-proof• Approved for flue gas temperatures of up to
120ºC (T 120)• Approved for overpressure
• Unhindered back flow of condensate into the boiler can only be ensured if:
• The gradient of the horizontal connection elements is at least 50 mm/m.
§Only one heat generator may be connected to the same chimney. If two heat generators are to be connected to the same chimney, the relevant regulations must be complied with.
• Cross sections and maximum lengths are calculated on the basis of graphs or tables. The tables can be obtained from the chim-ney or flue system manufacturer. The calcu-lation values can be obtained from the table under point 3.2.
• The flue gas conduit cross sections and lengths are calculated following the techni-cal data for the boiler.
• The concentric supply air/exhaust system of the boiler can also be conducted horizon-tally backwards. The Hoval remodelling set allows a remodelling on site.
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INSTALLATION
4.4 Condensate drainage• The condensate drainage pipes on the boi-
ler must be made of corrosion resistant ma-terial. The following materials are suitable for condensate drainage:
• PVC, PE, PP, ABS
• The local regulations regarding condensate drainage must be observed.
4.5 Design variantsPossibility 1 - see chapter 4.6• Execution with siphon• Condensate discharge into lower drain line.
Fig. 05
Possibility 2 - see chapter 4.7• Execution with neutralisation box• For condensate discharge in lower drain line, incl.con-
densate neutralisation.
Fig. 06
Possibility 3 - see chapter 4.8• Siphon and condensate delivery pump• Without neutralisation, condensate discharge into high-
er drain line.
Fig. 07
Possibility 4 - see chapter 4.9• Neutralisation box and condensate delivery pump• With condensate neutralisation - condensate discharge
into higher drain line.
Fig. 08
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INSTALLATION
4.6 Fitting the condensate drain (standard de-sign with siphon)
1. Remove front cover (1a, Fig. 09). Release lateral lo-cking bolt (1, Fig. 09) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove towards the front.
2. Remove base plate (2, Fig. 09). Lift base plate straight upwards and remove.
3. Screw siphon (3, Fig. 09) on the condensate tray (4, Fig. 09) and tighten securely (connection must be sealed)!
4.
NOTICESlide the siphon support (3a) under the siphon.
6. Fit drain (5, Fig. 09) on siphon (3, Fig. 09) and lead it outwards (optionally left or right side) through the aperture (5a, Fig. 09).
7. Fit connecting line (5, Fig. 09) to the drain line (2m hose enclosed with the boiler).
8. Reattach front cover (1a, Fig. 09) and base plate (2, Fig. 09).
NOTICEThe condensate drain must be madeof corrosion-resistant material.
!CAUTIONBefore commissioning, the siphon mustbe filled with water in order to preventflue gas leakage.
If a neutralisation box is to be fitted, youwill find the further installation steps onthe next page.
1
1a
2
3
5
5a
4
3a
Fig. 09
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INSTALLATION
4.7 Fitting the neutralisation box(if fitted)
1. Remove the neutralisation box from its packaging. Remove the front and rear cover of the neutralisation box.
2. Empty the neutralisation granulate (Neutroxid) into the neutralisation box and distribute evenly.
Neutralisation granulate (Neutroxide)
front
6
Fig. 10
3. Remove front cover (1a, Fig. 11). Release lateral locking bolt (1, Fig. 11) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove it to-wards the front.
4. Remove base plate (2, Fig. 11). Lift the base plate straight upwards and remove it.
1
1a
2
Fig. 11
5. Fit rear cover (9, Fig. 12) of the neutralisation box.6. Fit jubilee clip (10, Fig. 12) approx. 20mm from the
upper end of the hose and tighten slightly. The hose (10a, Fig. 12) of the connection eccentric (10b, Fig. 12) must be aligned towards the left.
109
10a
10b Fig. 12
7. Slide the neutralisation box (11, Fig. 13) into the boi-ler until the hose of the siphon (6, Fig. 10) is directly beneath the drain connection.
11Fig. 13
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INSTALLATION
4.8 Fitting the condensate delivery pump13. Install the condensate delivery pump (14, Fig. 17) as
shown in the drawing.
14
Fig. 17
8. The hose of the siphon (11, Fig. 14) can be easily pushed onto the drain connection of the condensate drip tray by lifting the neutralisation box (10a, Fig. 12).
11Fig. 14
9. Slightly loosen the jubilee clip (10, Fig. 15) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed).
10Fig. 15
10. Fill the neutralisation box with water.11. Fit the front cover (13, Fig. 16) of the neutralisation
box.12. Fit base plate (2, Fig. 16) and front cover (1a, Fig. 11).
2 13Fig. 16
!CAUTIONBefore commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage.
The condensate drain must be madeof corrosion-resistant material.
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INSTALLATION
4.9 Fitting the neutralisation box and the con-densate delivery pump
1. Fit condensate delivery pump. (14, Fig. 18).
14
Fig. 18
2. Remove the neutralisation box from its packaging. Vorderen und hinteren Remove the front and rear co-ver of the neutralisation box.
3. Empty the neutralisation granulate (Neutroxide) into the neutralisation box and distribute evenly.
Neutralisation granu-les (Neutroxide)
front
6
Fig. 19
4. Remove front cover (1a, Fig. 20). Release lateral lo-cking bolt (1, Fig. 20) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove towards the front.
5. Remove base plate (2, Fig. 20). Lift base plate straight upwards and remove.
1
1a
2
Fig. 20
6. Fit rear cover (9, Fig. 21) of the neutralisation box.7. Fit jubilee clip (10, Fig. 21) approx. 20mm from the
upper end of the hose and tighten slightly. The hose (10a, Fig. 21) of the connection eccentric (10b, Fig. 21) must be aligned towards the left.
109
10a
10bFig. 21
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INSTALLATION
8. Slide the neutralisation box (11, Fig. 22) into the boiler until the hose of the siphon (10a, Fig. 21) is directly beneath the drain connection.
11Fig. 22
9. The hose of the siphon (10a, Fig. 21) can be easily pushed onto the drain connection of the condensate drip tray by lifting the neutralisation box (11, Fig. 23).
11Fig. 23
10. Slightly loosen the jubilee clip (10, Fig. 24) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed).
10Fig. 24
11. Fill the neutralisation box with water.12. Fit the front cover (13, Fig. 25) of the neutralisation.13. Fit base plate (2, Fig. 25) and front cover (1a, Fig.
20).
2 13Fig. 25
!CAUTIONBefore commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage.
The condensate drain must be madeof corrosion-resistant material.
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INSTALLATION
4.10 Hydraulic connectionThe boiler comprises the following safety equipment, in accordance with EN 12828:• Minimum pressure limiter DBmin• Safety maximum pressure limiter DBmax• Hydraulic pressure monitor DBmax + 50%• Thermostat• Temperature monitor TBmax + 20%• Safety temperature limiter
To achieve an optimal efficiency, ensure that the return pipe is properly connected.
1
2
Fig. 26
1. High temperature return (e.g. venting group or calorifier)
2. Low temperature return (e.g. underfloor heating)
4.10.1 Customer-side requirementsA pressure expansion tank adapted to the heating sys-tem, water volume and static height.
4.10.2 Hydraulic interconnectionWhen combining a calorifier with floor heating, a mixer needs to be installed. A minimum amount of circulating water is not required.
Regarding suitable hydraulic connections, please observe the notes in the planning do-cumentation of the relevant Hoval sales com-pany!
Example: UltraGas® (15-50) with calorifier and direct heating circuit
Hydraulic schematic BDEE005
Fig. 27
NOTICEMake sure to close off unused connectors tightly.
TTE-WEZ TopTronic® E basic module heat generator (installed)B1 Flow temperature monitor (optional)AF Outside sensorDKP Pump for heating circuit without mixer
OptionalRBM TopTronic® E room control moduleTTE-GW TopTronic® Gateway
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INSTALLATION
4.11 Electrical connectionThe electrical connection must be carried out by an approved electrician. The connection diagram is located within the boiler control box. The electrical circuit dia-gram is supplied separately. Refer to this for the conductor cross section required for the mains supply.
The following applies to Austria and Germany:A connection diagram is provided with the boiler control unit.The power supply must be fitted with an omnipolar isolati-on switch with a contact gap of at least 3 mm.
The following applies to Switzerland:The electrical connections must comply with the system-specific electrical circuit diagram!
Safety measures for EMC installationBei Regelgeräten mit eigenem Netzanschluss, Netz- Fühler- bzw. Busleitungen getrennt verlegen.
CAUTIONDo not reach into the marked area (Fig. 28) when folding out the terminal box.Danger of cuts and pinching in the area of the trim strip (7).Wear gloves. Grip the terminal box by the left and right sides, not by the underside!
Cable trunking with dividing partitions should be used.
The mains connection for the heating system (boiler-con-trol panel-control unit) must be configured in form of an independent electric circuit.No other electrical loads (light, power outlets, ...) may be connected to that electric circuit.The external sensor may not be installed close to trans-mitters or receivers (garage door openers, amateur radio aerials, radio alarm systems,...).
Recommended conductor cross sections:Conductor type Cross section Length
Power supply of the heat generator (230 V)
min 1.5 mm2 with 13 A fuse unlimited m
Cables carrying mains supply voltages from actuators
min 1.0 mm2 unlimited m
Extra-low voltage cables(sensors) min 0.5 mm2 max. 50m
Data bus cables(screened) 2x2x0.6 mm2 max. 100m
The electrical connection must be connected in ac-cordance with the applicable standards of nationally or internationally recognised professional associations.
Procedure to remove the front covering panel1. Remove front cover (1, Fig. 28), after first releasing
the lateral locking bolt (1a, Fig. 28) (turn approx. ¼ turn to the left and pull out as far as the stop). Lift the front cover (1) straight upwards and remove towards the front.
2. Remove lower front cover (2, Fig. 28), after first relea-sing the lateral locking bolt (2a) (turn approx. ¼ turn to the left and pull out as far as the stop). Slightly rai-se the lower front cover (2 and 4, Fig. 28) and remove towards the front.
3. Remove the locking screw (3a, Fig. 28) on the right.4. Lift the switch control box (3, Fig. 28) and fold it out.5. Cable entry refer to the Technical Datasheet (6, Fig.
28).
The electrical connection is to be made in accordance with the diagram supplied.
1
3a
3
1a
6 5 4 27
Fig. 28
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INSTALLATION
5. Commissioning• After filling the system with water, bleed any
air and check for water leaks.• Before putting the boiler into operation, the
siphon and neutralisation tank needs to be filled with water.
• When starting up the system for the first time, the correct operation of all the safety and control devices must be verified.
• The operation and maintenance of the sys-tem must be explained to the user in detail.
• he combustion air needs to be filtered in very dusty environments.
• The gas flow pressure must be checked and the CO2 value set correctly.
5.1 Safety information
!
CAUTION• Sharp edges pose a cutting hazard. • Handle the cladding parts with care and
avoid contact with sharp edges!• Danger of injury for unqualified personnel. • Maintenance and cleaning work may only
be performed by trained personnel or by the Hoval Customer Service.
NOTICEDanger of damaging the system by filling it with incorrect liquids.• Water filled into the system must have drin-
king quality.
5.2 Filling with waterFilling of the heating system may only be carried out by qualified personnel.
§Die ÖNORM H5195, The European Standard EN 14868 and the Directive VDI 2035 must be observed (see point 5.3).
1. Open the isolating valves in the flow and return lines.2. Connect the water hose to the filling tap.3. Fill the heating system slowly.
Monitor the water level on the manometer.
• Use only chemical additives with suppliers’ confirmation of their safe usage.
• Anti-freeze additive may be filled up to a maximum of 40% and to a minimum accor-ding to the manufacturer’s information.
• The anti-freeze or anti-corrosion agent con-centration must be checked at least once per year.
• The identical product must be used when replenishing the anti-freeze or anti-corrosi-on agents.
• When transferring to operation without anti-freeze or anti-corrosion agents, the system is to be thoroughly flushed through several times before refilling with water.
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5.3 Water quality
24 4 213 772 / 00
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 / calorifi er which have contact with water are made of ferrous materials and stainless steel.
• On account of the danger of stress cracking corrosion in the stainless steel section of the boiler the chloride, nitrate and sulphate content of the heating water must not exceed 50 mg/l.
• 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 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 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
to 50 kW NO REQUIREMENT 20 l/kW
1 Sum of alkaline earths2 If the conductance in µS/cm exceeds the tabular value an analysis of the water is necessary.
5.4 Bleeding the air from the gas line
§Observe the relevant regulations when blee-ding the gas line
• Open the gas shut-off valve.• Bleed the air up to the gas armature.
5.5 Switching on the system• Switch on blocking switch to release the burner.
WARNINGThe heat generator is live when it has been connected to the mains.
5.6 Gas inlet pressureThe gas flow may only be adjusted and the heating system therefore started up, if the minimum flow pressure values are achieved (see point 5.7 Adjusting the gas flow).
The minimum flow pressure in the connector pipe must reach the following values:Natural Gas 18 to 50 mbar Liquid gas 37 to 50 mbar
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COMMISSIONING
5.7 Setting the gas flow rate CO2(O2) and mea-surement of NOx/CO content in the flue gas (flue gas measurement)
Torx T40, screwdriver, size 5 and/or allen key 4 mm
The Honeywell multiple actuator allows measuring the in-let pressure on meas uring nipple A.
A Measuring nipple gas inlet pressure B Measuring nipple gas outlet pressure C Gas choke D Offset screw
ABC
D
Fig. 29
Flow setting operation:To set the flow on the venturi, both flue gas values need to be controlled. e.g.: Set upper value - control lower value - value incorrect - set lower value - control upper value - ...
1. Press the emission monitoring key. After 20 min. the controller switches over to normal operation automatically.
2. Position the emission monitor in the flue gas duct.3. Set the boiler to maximum output (100%).4. Set the CO2 (O2) value by turning the chokescrew C.
The content in the flue gas must be between CO2 = 8.5 - 8.8 (O2 = 5,9 - 5,5) vol% (dry).
5. Set the boiler to minimum output (1%)6. Set the CO2 (O2) value by turning the choke screw D.
The content in the flue gas must be between CO2 = 8.5 - 8.8 (O2 = 5,9 - 5,5) vol% (dry).
7. Measurement of NOx and CO content. The mea-sured values must meet the limiting values prescri-bed by the regulations. Values exceeding these reference values are an indication of faulty burner setting, gas burner or heat exchanger contamination or gas burner defect.
NOTICEIf the limiting values prescribed by the regu-lations are exceeded, the boiler must be put out of operation and the corresponding mea-sures for repair work must be initiated.
8. Press the emission monitoring key.
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COMMISSIONING
5.8 Changing over to a different gas typeThis changeover may only be carried out by an authorised specialist or by theHoval Customer Service.
Changeover from natural gas H to natural gas LAn emission check is required when changing to a natural gas of lower calorific value; a correction of the CO2 (O2) value may be necessary (see point 6.7 Setting the gas flow rate).
Changeover from natural gas to liquid gas §The applicable local provisions for operating a boiler with liquid gas are to be complied with.VKF, DVGW, ÖVGW
Changeover only possible by means of a con-version kit.
NOTICEEnsure that the fuel type in the measuring device has been set correctly.
The conversion kit contains:• gas pressure switch• yellow sticker
Removing the gas pressure switch:1. Close the gas shut-off valve.2. Set the blocking switch to «0» and disconnect the
heat generator from the mains (main switch, fuse).3. Take off the boiler hood4. Remove the gas pressure switch
Install the liquid gas pressure switch:
NOTICEEnsure that the liquid gas line is free of any air. Any air in the liquid gas line can have a negative influence on the flue gas values.
1. Install the liquid gas pressure switch Set the AMP flat pin to position 1 and 3
2. Affix the yellow sticker on the boiler name plate3. Open the gas valve4. Set the main system switch to “1”
NOTICEAdjust fan speed of rotation according to the list of parameters “Liquid gas adaptations“.
5. Set the CO2 (O2) content to CO2 = 9.9 - 10.2 (O2 = 5,9 - 5,5) vol% (dry). (flow setting operation as described in section 6.7)
6. Install the boiler hood
5.9 Handover to the user
The manufacturer of the unit is responsible for providing operating instructions for the com-plete system.
The following must be carried out during handover to the user:• Provide instructions in the operation and maintenance
of the system• Handover of all the instruction manuals and documents• Explain to the user that these instructions must be kept
with the system at all times• Written confirmation of receipt of instruction• The handover report is on the last page of the docu-
ment.
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5.10 Record - Activation of screed function
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COMMISSIONING
Description of function
The control module of the TopTronic® E contains a functional sequence used for drying out screed fl oors. To start the screed drying, it is necessary for the individual functions to be set accordingly.
Heating-up phase( 04-061)
Start End
Current heat generator temperature = start temperature
Inertia phase(04-064)
Stabilisation temperature(04-063)
Cool down phase( 04-062)
Flow temperature
Days10
20 °C
25 °C
30 °C
35 °C
40 °C
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 d 1 d
5 K -5 K
Function Parameters Value DescriptionHeating-up phase 04-061 5 K/d Kelvin per day (rising)Stabilisation temperature 04-063 40.0 °C Set maximum temperatureInertia phase 04-064 10 Number of days in stabilisation temperatureCooling off phase 04-062 -5 K/d Kelvin per day (falling)Activate screed function 04-060 1 (ON) Start and stop screed drying
NOTICEThe graphic/table shows the factory settings. The time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen – and in particular, cracks.
REACTION screed function• Start/stop: Switch parameter 04-060 ON (1) or OFF (0) • Power failure in heating-up phase: program restart• Failure in the steady-state phase: Retain maximum temperature and add the failure time to the steady-state phase• Power failure in the cooling off phase: Measurement of actual fl ow value and continue cooling until start value
reached• Program end: Previous basic program active again
Settings in the TopTronic® E control module
Can only be set in the corresponding user level.
Settings under Start screen > Main menu > Service > H-GEN > Heating circuit > Heating circuit 1, 2, 3* > Screen > 04-060 to 04-064.
* If there are several heating circuits, a separate screed function must be assigned to each heating circuit.
Function display
1 2
No. Icon Function1 Screed drying active
Various settings can be made as well. Prioritisation of the screed func-tion means the settings are only ac-tive at the end of the function.
2 Information remaining run timeRequest of the active function phase, the ACT temperature as well as the remaining run time.
Logging
Please cut out the log and attach it to the controller during active screed function.
NOTICEThe time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen – and in particular, cracks.
Screed function activated by: Profi le and fl ow temperature discussed with:
Screed function activated on: Screed function ends on:
..........................................................................................Date and signature
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COMMISSIONING
Function display
1 2
No. Icon Function1 Screed drying active
Various settings can be made as well. Prioritisation of the screed func-tion means the settings are only ac-tive at the end of the function.
2 Information remaining run timeRequest of the active function phase, the ACT temperature as well as the remaining run time.
Logging
Please cut out the log and attach it to the controller during active screed function.
NOTICEThe time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen – and in particular, cracks.
Screed function activated by: Profi le and fl ow temperature discussed with:
Screed function activated on: Screed function ends on:
..........................................................................................Date and signature
6. MaintenanceNOTICEMissing or faulty cleaning and maintenance may cause damage to the installation.The heating installation must be surveyed and cleaned once a year.If required, installation maintenance must be carried out. Defects must be remedied im-mediately in order to prevent damages to the installation!
6.1 Safety informationCAUTIONSharp edges pose a cutting hazard.Handle the cladding parts with care and avo-id contact with sharp edges.
!CAUTIONDanger of injury for unqualified personnel.Maintenance and cleaning work may only be performed by trained personnel or by the Ho-val Customer Service.
NOTICEAfter repair work respectively exchanging boiler parts, a flue gas measurement accor-ding to point 6.7 must be carried out impe-ratively.
WARNINGThe heat generator must be de-energised for maintenance. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse).
WARNINGAll electric power supply circuits must be switched off before accessing the terminals.
Perform reset. See operating manual.
6.2 Bleeding1. Open all radiator valves.2. Heat up the system for at least half a day with a high
flow temperature.3. Turn off the boiler and wait 5 minutes.4. Bleed all the air form the system.
6.3 Water refilling
§The European Standard EN 14868 and the Directive VDI 2035 must be observed (see point 5.3).
The systems warns when the water pressure falls below 1 bar and the boiler output is redu-ced to 50%. If the water pressure falls below 0.5 bar, the boiler is set automatically to a fault state.
The system must be refilled with water when the pressure falls below the minimum system pressure:
5. Connect the filling hose to the water supply6. Remove the air from the filling hose7. Connect the filling hose to the filling and draining cock8. Top up with water (see point 5.2).
6.4 Renewing fuseWARNINGElectrical installations may only be carried out by a qualified electrician.
1. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse).
2. Remove the front casing according to the procedure in chapter 4.11.
3. Remove the cover from TopTronic® E - WEZ (press to the side and remove).
4. Renew fuse (T 10A 250V).
Fig. 30
5. Mount protecting cover, close casing.6. Restore the electrical power supply.
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MAINTENANCE
6.5 Information for combustion controller/chimney sweep regarding emission monitor key
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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!
6.6 CleaningThe boiler may only be cleaned by an autho-rised technician or by the Hoval Customer Service.
The Hoval gas heating boiler should be clea-ned and maintained once every year.
If the Hoval gas heating boiler was in operation during the building phase, it will be necessary to carry out a check for cleanliness. If the boiler is dirty, clean it.
6.6.1 Cleaning the burner cylinderThe burner cylinder must be cleaned if visible contamination exists (such as deposits, e.g. builder’s dust)
Adjustable spanner, screw driver, open end spanner SW 8, vacuum cleaner, compressed air, water.
Preparation:1. Set the blocking switch to «0» and disconnect the
heat generator from the mains (main switch, fuse).2. Close the main gas valve3. Remove the sound insulation covers4. Disconnect all the burner connector plugs5. Pull the corrugated hose (1, Fig. 31) off the venturi
tube on the burner (if present).6. Disconnect the earthing cable (2, Fig. 32) from the
burner cylinder7. Disconnect the gas connection from the gas arma-
tures.8. Unscrew the fan with the gas mixing unit in place
(3, Fig. 32)
Removal and cleaning:
CAUTIONDanger of burns, let the boiler cool down or wear protective clothing
1. Safety gloves must be worn when removing the bur-ner cylinder
2. Lift the burner cylinder out (4, Fig. 33).3. Clean the premix burner with compressed air inside
and out, or rinse thoroughly with water4. Remove dust and dirt particles with a vacuum cleaner
(Fig. 34).
Reassembly:1. Replace the gasket on the gas connection2. Reassemble the burner in reverse order3. Check for leaks4. Carry out a flue gas measuring according to point 5.7
1
Fig. 31
2
3
Fig. 32
4
Fig. 33
Fig. 34
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MAINTENANCE
6.6.2 Cleaning the exterior of the combustion cham-ber and burner cylinder
!
WARNINGChemical burn hazard through cleaning agents. Safety gloves and eye protection must be worn when using cleaning agents. Observe the information on the original pa-ckaging.
NOTICEThe system can be damaged when using in-correct cleaning agents.Use only cleaning agents approved for gas boilers with aluminium components.
Spray on the cleaning agent undiluted
Open end spanner SW 17, adjustable span-ner, screw driver, spray gun
Preparation:1. Set the main switch on the boiler control unit to “0”.
vom Netz trennen (Hauptschalter, Sicherung).2. Close the main gas valve3. Remove the sound insulation cover4. Disconnect all the burner connector plugs5. Pull the corrugated hose off the venturi tube on the
burner (if present)
Opening the combustion chamber:1. Loosen the cap nut SW172. Lift and turn the burner with the boiler door sideways
(8, Fig. 35)3. Remove the neutralisation box and siphon
or maintenance of the neutralisation unit see point 6.9)
8
Fig. 35
Reinigen:1. Spray the combustion chamber and aluFer® tubes
(10, Fig. 36). The best results are obtained with a spray gun with a suitable wide jet nozzle (fan or conical jet). We recommend, e.g.: Desoxin
2. Leave the applied cleaning agent to react as instruc-ted by the manufacturer
3. Then remove the contamination on the combustion chamber and aluFer® tubes by spraying them with clean water Use a powerful jet
4. Repeat the procedure in case of stubborn dirt5. Flush clean the bottom tube plate
Use an angled spray lance6. Clean and dry the boiler tray7.
Clean the siphon see point 6.8:• screw it off• clean it• screw it back on• fill it with water
8. Clean the fabric material in the burner cylinder with compressed air
9. Reconnect the gas and electrical connections10. Place the boiler into operation11. Carry out a flue gas measuring according to point 5.7.
Correct the settings, if necessary. Complete a measu-rement record.
10
Fig. 36
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MAINTENANCE
Ignition electrodeIgnition/ionisation electrode
Fig. 38
5 m
m
10 m
m
Fig. 39
4 m
m
Fig. 40
6.7 Setting the gas flow rate CO2(O2) and mea-surement of NOx/CO content in the flue gas
(according to point 5.7.)
Maintenance should be carried out at least every second year or after consumption of the neutralisation granulate (check pH value with litmus paper, if necessary).
6.6.3 Leakage testingAfter cleaning or at least every five years, the seal bet-ween the combustion chamber and the condensate drip tray must be checked for leakage. This can be done by filling the boiler with water.
80 1
1 Water fill level
Fig. 37
6.6.4 Cleaning/adjusting the ignition and ionisation device
The distance between the ignition electrode and the burner cylinder must be approx. 4 mm.
Fine sanding paper, long-nosed pliers, blow-torch, compressed air.
Preparation:1. Set the blocking switch to «0» and disconnect the
heat generator from the mains (main switch, fuse).2. Open the combustion chamber as described under
point 6.6.2.
Cleaning:1. Sand the ignition and ionisation device with fine san-
ding paper.2. Clear the sanding dust.
Adjustment:1. Heat the ignition electrode at the kink with the blow-
torch until it glows red (Fig. 38).2. Bend the ignition electrode with the long-nosed pliers
(Fig. 39). Distance to the burner cylinder 10 mm.
Assembly:1. Renew seal on gas connection.2. Assemble burner in the reverse order.3. Check for gas leaks.
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MAINTENANCE
6.8 Clean siphon or neutralisation box1. Set the main system switch to “0”2. Remove the front panel (1, Fig. 41)3. Unscrew resp. remove (according to execution) si-
phon (3, Fig. 41), siphon bottom part (2) , siphon sup-port (2a) or neutralisation box (4, Fig. 42)
4. Rinse siphon5. Check if siphon gaskets (3) are not damaged, replace
if necessary
!
CAUTIONDanger of poisoning!
If the siphon is not filled with water, or beco-mes blocked or contaminated by impurities, the flue gas emerging can represent a poten-tially fatal hazard.
Before reinserting, fill the siphon with water.
1
2
3
Mount hose forwet cleaning
Design with condensate discharge
2a
Fig. 41
Design with neutralisation box (if fitted)1. Set the main system switch to “0”2. Remove the front panel (1, Fig. 42)3. Clean the neutralisation box (4 - if fitted) accourding
to chapter 6.8
1
4
Mount hose forwet cleaning
Fig. 42
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6.9 Maintenance of the Neutralisation equip-ment (if available)
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MAINTENANCE
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 granulate for refi lling can be ordered from Hoval under the following item no.:
• 1 pack (3 kg) neutralisation granulesPart no. 2028 906One fi lling requires a pack of 3 kg
Procedure for servicing the neutralisation installation
WARNINGThe heat generator must be de-energised for maintenance. Set the blocking switch to «0» and disconnect the heat generator from the mains (e.g. main switch, fuse).
• Remove the front cover.• Undo the bolts and withdraw the neutralisation box.• Remove the neutralisation granules and any deposits
from the neutralisation box. Any remaining neutralisa-tion granulate, since it is harmless, can be disposed of as domestic waste.
• Refi ll the neutralisation box with new granules.
Attach the neutralisation box cover making sure that it is tight-closing.
• Push the neutralisation box back in.
!
WARNINGBefore putting back into service, the siphon and the neutralisation box must be fi lled to-gether with water.The water can be poured through the clea-ning aperture into the neutralisation box and the siphon.
Neutralisation granulesSiphon
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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