Hoval Uno-3 95 Technical Information And Assembly Instructions

Brand: Hoval

Model: Uno-3 95

Type: Technical Information And Assembly Instructions

This manual is also suitable for

Subject to modi cations |

Technical information

Assembly instructions

4 205 116 / 02 - 02/14

Hoval products must be installed and commissioned only

by appropriately qualied experts. These instructions

are intended exclusively for the specialist. Electrical

installations may only be carried out by a qualied

electrician.

Uno-3 (95-125) boilers are suitable and licensed for

use as heat generators for hot water heating systems

with a permissible ow temperature of up to 100 °C

They are designed for closed-circuit systems, but can

also be installed in open systems as per EN 12828.

See technical data

Uno-3 (95-125)

Oil/gas boilers

These instructions are applicable to the

following types:

7-Uno-3 (95,110,125)

7-Uno-3 b-i* (95,110,125)

* = Burner integrated

4 205 116 / 02

Table of Contents

1 Important information

1.1 Other instructions ................................................................................................................................... 3

1.2 Safety information ................................................................................................................................... 3

1.3 Regulations, ofﬁcial approvals .............................................................................................................. 3

1.4 Guarantee ................................................................................................................................................ 4

2. Installation

2.1 Setting up, levelling ................................................................................................................................ 5

2.2 Fitting the heat insulation ...................................................................................................................... 6

2.3 Fitting the casing .................................................................................................................................... 8

3 Technical information

3.1 Description of the boiler ....................................................................................................................... 10

3.1.1 The Uno-3 (95-125) complies with the following directives + standards ................................................ 10

3.2 Technical data Uno-3 (95-110) for Switzerland ................................................................................... 11

3.3 Technical data Uno-3 (110,125) for all other countries ...................................................................... 12

3.4 Dimensions ............................................................................................................................................ 13

3.5 Dimensions without heat insulation and casing (transport dimensions) ........................................ 13

4. Installation

4.1 Boiler room requirements .................................................................................................................... 14

4.2 Connection of the ﬂue gas system and ﬂue duct dimensions ......................................................... 14

4.3 Fitting the burner .................................................................................................................................. 16

4.3.1 Sound insulation ...................................................................................................................................... 16

4.4 Fuel ......................................................................................................................................................... 17

4.5 Electrical connection ............................................................................................................................ 17

4.5.1 Electrical connection of the burner .......................................................................................................... 17

4.6 Flue gas regulator set ........................................................................................................................... 17

4.6.1 Flue gas and performance diagrams ...................................................................................................... 18

4.7 Flow mixing loop / minimum limitation of the boiler return temperature ........................................ 19

4.8 Setting the temperature regulators ..................................................................................................... 19

4.9 Safety valves ......................................................................................................................................... 19

4.10 Charging pump (boiler with free-standing caloriﬁer) ........................................................................ 19

4.11 Heating pump ........................................................................................................................................ 19

5. Commissioning

5.1 Water quality .......................................................................................................................................... 20

Heating water .......................................................................................................................................... 20

Filling and replacement water ................................................................................................................. 20

5.2 Filling the heating system .................................................................................................................... 21

5.3 Filling the caloriﬁer (if present) ........................................................................................................... 21

5.4 Commissioning ..................................................................................................................................... 21

5.5 Oil/gas burner ........................................................................................................................................ 21

5.6 Handover to the operator / storage ..................................................................................................... 21

6. Maintenance

6.1 Information for ﬁre inspector / chimney sweep regarding emission monitor key .......................... 22

6.2 Cleaning ................................................................................................................................................. 23

6.2.1 Preparatory work ..................................................................................................................................... 23

6.2.2 Cleaning (dry or wet method) .................................................................................................................. 23

6.2.3 Putting into operation again .................................................................................................................... 23

7. Overview of settings

7.1 Table of parameters .............................................................................................................................. 24

7.2 Overview of alarms TopTronic

T .......................................................................................................... 34

4 205 116 / 02 Important notes

1 Important information

1.1 Other instructions

All instructions relevant to your system can be found

in the Hoval system manual! In exceptional cases,

the instructions can be found enclosed with the

components.

Further information sources

- Hoval catalogue

- Standards, regulations

1.2 Safety information

The system may only be placed in operation if all the

relevant standards and safety regulations have been

complied with. At least the following conditions must

be satisﬁed 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 sleeve.

4. System ﬁlled with water.

5. Expansion vessel connected.

6. Flue gas connectors connected to the ﬂue gas

pipeline at the chimney or ﬂue.

7. An adequate supply of fresh air must be guaranteed.

8. The burner is preset.

1.3 Regulations, ofﬁcial approvals

The following regulations are to be complied with for

installation 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

requirements.

- 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

appendix N-430 020.

Austria

- ÖNorm 7550

- ÖNorm B 8130 Open water heating systems;

safety devices.

- Norm 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

chimneys; terminology, calculation procedure.

- ÖNorm H 5171 Heating systems, construction

engineering requirements.

- ÖVGW TR-Gas G1 Technical directives for low

pressure gas installations.

- ÖNorm M 7445 Gas blower burner.

Switzerland

- Requirements of the VKF Cantonal Fire Insurance

Association.

- Fire brigade regulations.

- Requirements of the SVGW Swiss Association of

Gas and Water Suppliers.

- SWKI 91-1 Aeration and ventilation of the boiler

installation 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

heating 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.

4 205 116 / 02

Important notes

1.4 Guarantee

Proper function is only guaranteed providing these

instructions are followed and the boiler is regularly

maintained by a licensed specialist. (Maintenance

contract). The rectiﬁcation of faults and damage

as a result of contaminated operating materials

(gas, water, combustion air), unsuitable chemical

additives and an inadmissibly high lime content of the

heating water, improper handling, faulty installation,

unauthorised modiﬁcations and damage due to the use

of force do not fall under our guarantee obligations, this

also applies to corrosion due to halogen compounds,

e.g. from spray cans, paints, adhesives, halogenated

ﬂuids, solvents and cleanings agents.

4 205 116 / 02 Installation

1. Pull up the semicircular rivet (1).

2. Change over the swivel arm (2).

3. Insert the semicircular rivet (1) on the other side.

4. Fit the burner plug and the ﬁre protection switch

(if ﬁtted, Austrian version) on the other side

(see point 2.3, item 9 and point 4.5.1).

The cable must not touch any hot

parts!

Levelling

Using a spirit level, align the upper edge of the

boiler water jacket (longitudinal axis of the boiler)

until it is precisely horizontal or sloping very slightly

upwards towards the rear by inserting the plinth

rails correspondingly, to allow the boiler to vent

properly.

Before ﬁtting the burner, ﬁrst ﬁt the double

door (Pos. 8b, Figure 7) (door casing).

2. Installation

2.1 Setting up, levelling

A special foundation plate for the boiler is not an

essential, but it is recommended.

Space requirement

for mounting the thermal insulation and sheet metal

cladding:

at least 40 cm each on the left and right side of

the boiler.

If the space between the boiler and the wall is less,

all heat insulation and casing must be ﬁtted before

the boiler can be pushed into its ﬁnal position.

Do not connect lines until the heat insulation

and casing have been ﬁtted to the boiler!

There must always be enough space between

the back of the boiler and the wall to allow

easy access to the cleaning aperture in the

ﬂue gas collector.

There must be enough space to swing open the

boiler door, incl. the burner.

Do not overtighten boiler door screws.

Fig. 2

Boiler door pivotable to the left

It is possible to change the attachment of the boiler

door so that it opens towards the left. This can be of

advantage when installing the boiler in a corner.

Proceed as follows:

Close the boiler door and lock it in position

before changing the attachment of the door.

4 205 116 / 02

Installation

Fig. 3a

See separate assembly instructions for boilers with mounted caloriﬁer

2.2 Fitting the heat insulation

1. Mount the front retaining bracket (1) with hexagon screws M8, nuts and U-washers, aligned horizontally, to the front wall of the boiler.

- Attach C-clips.

2. Mount the rear retaining bracket (2) with hexagon screws M8, nuts and U-washers aligned horizontally.

- Attach C-clips.

3. Place the insulation mat (3) around the boiler body (with the joint at the top, black side facing outwards, see Figure 3).

4. Attach the insulation mat (3) using 2 plastic straps (4) and strap fasteners (4a):

- Tension springs (4b) serve for additional ﬁxing

- Do not overtighten the straps

(reduced insulating value)

5. Attach the insulation mats (5/5a/5b) to the pins provided on the rear wall of the boiler and secure with retaining discs, Fig. 4a (ø 38).

6. Attach insulation panels (6/6a/6b/6c) to the pins welded onto the ﬂue gas collector and secure with the retaining discs (ø 38) provided.

7. Attach insulation panel (7) to the pins welded onto the front wall of the boiler and secure with the retaining discs (ø 38) provided, Fig. 3a.

The remaining 3 insulation mats (8a,10) are ﬁtted after mounting the casing.

4 205 116 / 02 Installation

Figure 3

C-clips

4 205 116 / 02

Installation

2.3 Fitting the casing

8. Fix hexagon bolts with U-washers and hexagon nuts (8). Insert thermal insulation (8a) into the boiler door. Attach the door casing (8b) to the boiler

door using hexagon cap nut.

9. Attach the burner cable (9) to the right or left side wall (9a) (Fig. 4). See also point 4.5.1

Attach right and left side wall (9a) onto the front retaining brackets (1) and rear retaining brackets (2) with self-tapping screws ø 4.8 x 38 and pull

the burner cable upwards.

The cable must not touch any hot parts

10. Place 2 insulating mats (10) left and right in longitudinal direction (to prevent vertical air circulation).

11. Attach rear wall (11/11a) to the angled edges of the side walls (9a) with self-tapping screws ø 3.5 x 6.5.

2.4 Installation of boiler controller

12. Mount the special screw with nut (12, Fig. 5) on the cover plate (12a). Then place switch control box (12b) on the casing cover (12a) with the recess

for the special screw, push back and secure with self-tapping screws ø 3.5 x 6.5 and serrated washers (12c). Position cladding cover (12a, Fig. 7)

and ﬁx on the side walls with 2 self-tapping screws ø 4.8 x 12 and C-clips.

13. Pull the capillaries with the immersion sensors (13, Fig. 6) through the opening (13a, Fig. 5) in the cover, insert them into the immersion sleeve

(13b, Fig. 7) as far as the stop and ﬁx in position with retaining spring (13c, Fig. 6).

Attention: The capillaries must not be folded or kinked!

14. Attach cover plate (14) with self-tapping screws ø 3.5 x 6.5 and serrated washers.

15. Position cladding cover (15) and ﬁx left and right with 2 self-tapping screws ø 4.8 x 13.

16. Afﬁx labels and where applicable, mount manual holder on the side.

Figure 4

13c

Figure 6

12a

13a

12b

Figure 5

12c

13a

4 205 116 / 02 Installation

Figure 7

13b

12a

11a

4 205 116 / 02

Technical information

to the turning chamber, from where they ﬂow through

rectangular ducts (thermolytic heating surface) towards

the rear and reach the ﬂue gas collector.

The ﬂue gas temperatures can be varied within

a speciﬁc range through the installation of various

regulator combinations.

3 Technical information

3.1 Description of the boiler

The Uno-3 is a threepass boiler. At the end of the

circular cylindrical combustion chamber, the ﬂame

gases ﬂow through several cylindrical tubes arranged

above the combustion chamber and towards the front

Figure 8

3.1.1 The Uno-3 (95-125) 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)

Regulations: Stability prEN14394:2001

Building requirements EN303-1, EN303-2, EN303-3

Low voltage DIN VDE 0722 / Ed. 04.83

EMC EN 50082 Part 1 / Ed. 01.92

4 205 116 / 02 Technical information

Fuel Heating oil EL Natural gas H

Option 1 Option 2 Option 3 Option 1 Option 2 Option 3

min. ﬂue gas temperature °C 130 110 130 130 110 130

min. boiler temperature °C 48 50 52 58 60 62

min. return temperature °C 35 38 No lower limit 45 48 No lower limit

Return temperature controls

yes yes no yes yes no

Boiler start-up protection

no no yes no no yes

Boiler minimum temperature limit effective on group actuators

Type (95) (110)

• Nominal heat output at 80/60 °C

kW 95 110

• Thermal output kW 60-95 70-110

• Maximum heat input kW 102.1 118.3

• Maximum boiler operating temperature

°C 90 90

• Safety temperature limiter setting (water side)

°C 110 110

• Operating/test pressure at max. operating temperature 90 °C

bar 4.0/5.2 4.0/5.2

• Maximum boiler operating temperature

°C 105 105

• Safety temperature limiter setting (water side)

°C 120 120

• Operating pressure at max. operating temperature 105 °C

bar 3.0 3.0

• Minimum boiler operating temperature °C see table of operating conditions (below)

• Minimum boiler return temperature °C see table of operating conditions (below)

• Minimum ﬂue gas temperature at boiler °C see table of operating conditions (below)

•

Regulator set for 160 °C 3R5+ 3R5+

Flue gas temperature 1R2/290 2R3/290

• Boiler efﬁciency at full load and 80/60 °C

(related to net/ gross caloriﬁc value, heating oil EL)

% 92.6 / 87.4 92.7 / 89.5

• Boiler efﬁciency at partial load 30% and return 37 °C

(acc. to EN 303) (related to lower/upper caloriﬁc value heating oil EL)

% 94.8 / 89.4 94.8 / 89.5

• Standard efﬁciency at 75/60 °C (DIN 4702 Part 8)

(related to net/gross caloriﬁc value, (heating oil EL))

% 95.7 / 90.3 95.9 / 90.47

• Standby losses qB at 70 °C Watts 400 400

• Resistance on the heating gas side at nominal output

160 °C ﬂue gas temperature, 12.5 % CO

, 500 m above sea level

(tolerance ±20 %)

mbar 0.65 0.89

• Flue gas mass ﬂow at nominal output 12.5 % CO

heating oil kg/h 162 188

• Flow resistance boiler

z-value 0.2 0.2

• Hydraulic resistance at 10K mbar 13.35 17.90

• Hydraulic resistance at 20K mbar 3.34 4.47

• Water ﬂow rate at 10K m³/h 8.17 9.46

• Water ﬂow rate at 20K m³/h 4.09 4.73

• Boiler water content litres 250 250

• Boiler gas content m³ 0.1848 0.1848

• Insulation thickness of boiler body mm 80 80

• Weight (incl. casing) kg 391 391

•

Sound level

- Heating noise without absorber hood (EN 15036 Part 1) dB(A) 77 79

- Heating noise with absorber hood (EN 15036 Part 1) dB(A) 67 67

- Flue gas noise inside the ﬂue (EN 15036 Part 2) dB(A) 87 91

- Flue gas noise radiated from the mouth (DIN 45635 Part 47) dB(A) 79 84

• Combustion chamber dimensions Ø-inside x length mm ø440x974 ø440x974

• Combustion chamber volume m³ 0.148 0.148

•

Dimensions see Dimensions

• Maximum depression in ﬂue gas system (boiler connection) Pa 30 30

At nominal output, the pollutant limit values and ﬂue gas losses as per regulation LRV 92 (CH) are complied with.

Controller U3.1 and T2.2

Controller U3.2 and T0.2

Flow resistance boiler in mbar = ﬂow rate (m

/h)

x z

Data valid for Hoval oil compact heat station b-i

3.2 Technical data Uno-3 (95-110) for Switzerland

Possible operating conditions

4 205 116 / 02

Technical information

Type (110) (125)

• Nominal heat output at 80/60 °C kW 110 125

• Heat output range (heating oil EL, natural gas H: variant 1 and 3) kW 70-110 70-125

• Heat output range (heating oil EL, natural gas H: variant 2) kW 50-110 50-125

• Maximum heat input kW 118.3 135.8

• Maximum boiler operating temperature

°C 90 90

• Safety temperature limiter setting (water side)

°C 110 110

• Operating/test pressure at max. operating temperature 90 °C

bar 4.0/ 5.2 4.0/ 5.2

• Maximum boiler operating temperature

°C 105 105

• Safety temperature limiter setting (water side)

°C 120 120

• Operating pressure at max. operating temperature 105 °C

bar 3.0 3.0

• 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 3R5+2R3 3R5+2R3

• Boiler efﬁciency at full load and 80/60 °C

(related to lower/upper caloriﬁc value (heating oil EL))

% 92.7/ 87.6 92.8/ 87.6

• Boiler efﬁciency at partial load 30 % and return 37 °C

(acc. to EN 303) (related to lower/upper caloriﬁc value (heating oil EL))

94.8 /87.6 92.8 /87.6

• Standard efﬁciency at 75/60 °C (DIN 4702 Part 8)

(related to lower/upper caloriﬁc value (heating oil EL))

% 95.9/ 90.5 95.8/ 90.4

• Standby losses qB at 70 °C Watts 400 400

• Resistance on the heating gas side at nominal output

180 °C ﬂue gas temperature, 12.5 % CO

, 500 m above sea level

(tolerance ±20 %)

mbar 0.89 1.10

• Flue gas mass ﬂow at nominal output 12.5 % CO

heating oil kg/h 188 222

• Maximum ﬂue draught Pa 20 20

• Flow resistance boiler

z-value 0.2 0.2

• Hydraulic resistance at 10K mbar 17.90 24.80

• Hydraulic resistance at 20K mbar 4.47 5.80

• Water ﬂow rate at 10K m³/h 9.46 11.10

• Water ﬂow rate at 20K m³/h 4.73 5.40

• Boiler water content litres 250 250

• Boiler gas content m³ 0.1848 0.1848

• Insulation thickness of boiler body mm 80 80

• Weight (incl. casing) kg 391 391

• Sound level

- Heating noise without absorber hood (EN 15036 Part 1) dB(A) 79 80

- Heating noise with absorber hood (EN 15036 Part 1) dB(A) 67 67

- Flue gas noise inside the ﬂue (EN 15036 Part 2) dB(A) 91 91

- Flue gas noise radiated from the mouth (DIN 45635 Part 47) dB(A) 84 84

• Combustion chamber dimensions Ø-inside x length mm ø440x974 ø440x974

• Combustion chamber volume m³ 0.148 0.148

• Dimensions see Dimensions

• Maximum depression in ﬂue gas system (boiler connection) Pa 30 30

Controller U3.1 and T2.2

Controller U3.2 and T0.2, operating pressure may be increased to 4 or 5 bar in countries in which the Pressure Equipment Directive is not in force.

Flow resistance boiler in mbar = ﬂow rate (m³/h)

x z

Information applies to combinations with Hoval-tested oil burner

3.3 Technical data Uno-3 (110,125) for all other countries

Fuel Heating oil EL Natural gas H

Option 1 Option 2 Option 3 Option 1 Option 2 Option 3

min. ﬂue gas temperature °C 130 110 130 130 110 130

min. boiler temperature °C 48 50 52 58 60 62

min. return temperature °C 35 38 No lower limit 45 48 No lower limit

Return temperature controls

yes yes no yes yes no

Boiler start-up protection

no no yes no no yes

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.

Possible operating conditions

4 205 116 / 02 Technical information

3.4 Dimensions

3.5 Dimensions without heat insulation and casing (transport dimensions)

Boiler (without caloriﬁer) incl. swivel ﬂange, connections and ﬂue gas collector

1 Flow type 130-160 DN 50, PN 6

2 Return type DN 50, PN 6

3 Safety ﬂow R 1 ¼"

4 Flow for caloriﬁer R 1 ¼"

5 Return for caloriﬁer R 1 ¼"

6 Drain pipe R 1"

7 Flue gas outlet

8 Cleaning aperture

9 Boiler controller

10 Boiler door attached on the right (on the left if desired)

11 Burner absorber hood

12 Connection for burner cable

(burner plug)

13 E-cable infeed

(Third-party burner)

4 205 116 / 02

Technical information

Existing ﬂue gas systems may require upgrading

or adjustment of the ﬂue duct cross-section 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 speciﬁcation

c) establishing the correct ﬂue duct cross-section

dimension.

ref. 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).

to 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. 10)

Where possible, avoid 90° bends in the ﬂue gas system!

Flue gas pipes longer than 1 m are to be insulated.

4. Installation

4.1 Boiler room requirements

Regarding the building speciﬁcations for boiler rooms

and their supply and extract air handling, the current

building supervisory ofﬁce regulations speciﬁc to the

state or country are to be observed. In Germany the

ﬁring regulations 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/

occurs. An opening or line leading into the open air

of at least 150 cm

. For every kW in excess of 50 kW,

a further 2 cm

must be calculated. In rectangular

openings, the ratio of the sides should not exceed

1.5:1; if a grid is ﬁtted, an appropriate allowance must

be added so that the free cross-section area reaches

the amount given above.

In Austria ÖNorm H 5171 additionally stipulates a

ﬂue air aperture. This must have a minimum cross

section of 180 cm

up to a rated heat output of

100 kW. For every further kW, the cross-section must

be increased by 1 cm

The ﬂue gas system must be watertight, acid-

proof and approved for the corresponding

ﬂue gas temperatures.

As a general rule, only one heat generator should

be connected to the chimney! When using two

heat generators, the corresponding regulations

must be observed.

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 functional unit.

Moisture-resistant and acid-proof ﬂue gas

systems must be used in new installations.

Figure 10

4 205 116 / 02 Technical information

Normally only one heat producer may

be connected to the chimney!

Flue 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.

vom

Kessel

zum

Schornstein

to c)

Dimensioning the chimney cross section. The cross

sections 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 (95-125).

Inside diameter of ﬂue duct in mm

Boiler type

Uno-3

kW *

Chimney height

11-15 m

95 95 ~ 180

110 110 ~ 180

125 125 ~ 180

*kW = maximum boiler output

Basic data:

Flue gas pipeline 5 m long, 2 90° elbows and

1 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!

from the

boiler

to the

chimney

4 205 116 / 02

Technical information

4.3 Fitting the burner

- Depending on the size of the burner ﬂange,

an intermediate ﬂange may be required to attach

the burner.

- To allow the burner to be swung out 90° to the

left or right, the connections must be ﬂexible and

routed to the burner in sufﬁciently large loops.

- The cavity between burner pipe and boiler ﬂange

must be insulated with the ﬁreproof ﬁbre provided.

4.3.1 Sound insulation

- Gas pipes must be mounted in such a way that no

vibrations are transferred to the building.

- The burner can be equipped with a sound-absorbing

hood.

- We recommend that you install silencers downstream

of the boiler in the ﬂue gas pipe.

Do not overtighten boiler door screws.

Figure 11

innen

Figure 12

Uno-3

A B C D E F G H J L M

Ø Ø Ø

90-125

140 170 400 165 119 248 440 974 307 30 25

Fill the gap with insulating material

inside

4 205 116 / 02 Technical information

4.4 Fuel

The boiler is only to be operated with

the fuel stated on the boiler rating plate.

Uno-3 boilers are suitable for the combustion of the

following 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

A qualiﬁed technician must install the electrical supply

to the equipment. The electrical circuit diagram is

located in the electrical box.

Applicable only to Austria and Germany:

An electrical circuit diagram is supplied with the boiler

controls.

Please afﬁx the correct connection diagram to the

inside of the terminal cover.

Important!

A main switch must be installed on-site in the supply

line which performs an all-poles cut-out and has a

clearance of at least 3 mm between the open contacts.

Applicable only to Switzerland:

The system-related electrical circuit diagram must be

referred to when making the electrical connection!

4.5.1 Electrical connection of the burner

- The burner must be connected to the boiler with

the standard plug-in connection.

- The burner cable must be shortened so that the

plug-in connection has to be parted to swing out

the burner.

4.6 Flue gas regulator set

The ﬂue gas regulators ﬁtted in each case are listed

on a label on the boiler casing (side section Figure 7,

Pos. 9a).

The installer can change the ﬂue gas regulator set

ﬁtted and thus vary the ﬂue gas temperature within

a speciﬁc range.

Even in partial load operation, the ﬂue

gas temperature must not fall below

100 °C.

Inspection

hole

Regulators

Figure 13

4 205 116 / 02

Technical information

4.6.1 Flue gas and performance diagrams

Uno-3 (95)

°C

3R5+1R2/290

3R5+2R3/290

Uno-3 (110)

The curves shown here represent an average value based on measurements taken with burners from various

manufacturers. Deviations of ±10 % are normal.

kW = Heat capacity

°C = ﬂue gas temperature with heating oil EL,

Boiler ﬂow 80 °C

Return ﬂow 60 °C.

CO2 = 13 %

During the combustion of natural gas or heating oil L, the ﬂue gas temperature is approx. 15 °C higher.

Uno-3 (125)

°C

100

110

120

130

140

150

160

170

180

190

60 65 70 75 80 85 90 95

100

110

120

130

140

150

160

170

180

190

70 75 80 85 90 95 100 105 110

100

110

120

130

140

150

160

170

180

190

70 80 90 100 110 120 130

4 205 116 / 02 Technical information

Flue gas temperature under other operating

conditions

Inﬂuence of the boiler water temperature on the

ﬂue gas temperature

A change in the boiler water temperature of ±10 K

results in a change of approximately ±6 K in the

ﬂue gas temperature.

Inﬂuence of the CO

content in the ﬂue gases

A change in the CO

content of ±1 % changes the

ﬂue gas temperature by approx. ±8 °C.

Key to regulator designation

No. of regulators

Regulator width (example: 5 units)

3R5/290

Length of the regulators

4.7 Flow mixing loop / minimum limitation

of the boiler return temperature

Hydraulic and control measures must be provided

to ensure that the temperatures do not fall below

the permissible minimum boiler ﬂow and return

temperature under any operating conditions.

4.8 Setting the temperature regulators

- without heating regulator:

Set the boiler temperature in accordance with the

outside temperature.

- with heating regulator:

The heating regulator automatically sets the

correct boiler temperature. The boiler temperature

varies between the minimum and maximum boiler

temperatures entered.

If a caloriﬁer is connected, the priority circuit

disables the boiler temperature regulator

until the temperature is reached. The boiler

temperature can rise to approx. 85 °C.

4.9 Safety valves

The heating system and hot water supply must each be

protected with one safety valve against impermissibly

high pressures. The discharge capacity of the heating

system safety valve must correspond to the boiler’s

maximum nominal heat output. The valve is installed

in the safety ﬂow. In Germany, only safety valves

with the code letter "H" in the approval mark may

be connected, and they must always be connected

at the boiler safety ﬂow. Water shortage protection

in accordance with EN 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.

4 205 116 / 02

Commissioning

Heating Water

The European Standard EN 14868 and the

directive 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 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 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 2035

Total hardness of the ﬁ lling water up to ...

[mol/m

]

<0,1 0,5 1 1,5 2 2,5 3 >3,0

f°H <1 5 10 15 20 25 30 >30

d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8

e°H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3

~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300

Conductance

<20 100,0 200,0 300,0 400,0 500,0 600,0 >600

Boiler size of the

individual boiler

maximum ﬁ lling quantity without desalination

to 50 kW NO REQUIREMENT 20 l/kW

50 to 200 kW 50 l/kW 20 l/kW 20 l/kW always desalinate

Sum of alkaline earths

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

5. Commissioning

5.1 Water quality

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Hoval Uno-3 95 Technical Information And Assembly Instructions

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