Hoval UltraGas 70 User manual

The oor standing gas condensing boiler UltraGas®(15-
90) are designed and approved for use as heat genera-
tors for hot water heating systems with a permissible
ow temperature of up to 85ºC1), in accordance with EN
483 and EN 677. They are designed for continuously
adjustable reduced output operation in heating systems.
1) See technical data
Rated output levels at 40/30ºC and for
natural gas
30-UltraGas® (70) 13,6 - 69,9 kW
30-UltraGas® (90) 16,1 - 91,5 kW
UltraGas®(70,90)
Condensing gas heating boilers
for natural gas and liquid gas
for modulating operation
Hoval products must be installed and commissioned
only by appropriately qualied experts. These instruc-
tions are intended exclusively for the specialist. Electri-
cal installations may only be carried out by a qualied
electrician.
Subject to modifi cations | EN
Technical information
Installation instructions
4 210 266 / 03 - 04/12

4 210 266 / 032
1. Safety instructions
1.1 Key to symbols used ............................................................................................................................. 4
2. Important notes
2.1 Acceptance of delivery .......................................................................................................................... 5
2.2 Scope of guarantee................................................................................................................................. 5
2.3 Instruction manuals ............................................................................................................................... 5
2.4 Regulations, official permits ................................................................................................................. 5
2.4.1 Germany ................................................................................................................................................... 6
2.4.2 Austria ....................................................................................................................................................... 6
2.4.3 Switzerland................................................................................................................................................ 6
3. Assembly
3.1 Placement ................................................................................................................................................ 7
4. Technical data
4.1 Description of the boiler......................................................................................................................... 8
4.2 Technical data ......................................................................................................................................... 9
4.3 Dimensions / Space requirements ...................................................................................................... 10
4.4 Space requirements.............................................................................................................................. 11
4.5 Boiler-Flow resistance.......................................................................................................................... 12
4.6 Brief description of the automatic firing device ................................................................................ 13
5. Installation
5.1 Safety information................................................................................................................................. 14
5.2 Boiler room requirements .................................................................................................................... 14
5.2.1 Room air dependent installation.............................................................................................................. 14
5.2.2 Room sealed installation......................................................................................................................... 14
5.3 Flue gas connection and flue............................................................................................................... 15
5.4 Condensate drainage............................................................................................................................ 15
5.4.1 Design variants ....................................................................................................................................... 16
5.5 Gas connection ..................................................................................................................................... 17
5.6 Hydraulic connection............................................................................................................................ 18
5.6.1 Customer-side requirements................................................................................................................... 18
5.6.2 Hydraulic interconnection........................................................................................................................ 18
6. Commissioning
6.1 Safety information ................................................................................................................................ 20
6.2 Filling with water................................................................................................................................... 20
6.3 Water quality.......................................................................................................................................... 21
6.3.1 Heating Water ......................................................................................................................................... 21
6.4 Bleeding the air from the gas line ....................................................................................................... 22
6.5 Switching on the system ...................................................................................................................... 22
6.6 Gas inlet pressure................................................................................................................................. 22
6.7 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas (flue gas
measurement)........................................................................................................................................ 23
6.8 Changing over to a different gas type................................................................................................. 24
6.9 Handover to the user ............................................................................................................................ 24
6.10 Record - Activation of screed function ............................................................................................... 25

4 210 266 / 03 3 Table of contents
7. Maintenance
7.1 Safety information ................................................................................................................................ 27
7.2 Bleeding ................................................................................................................................................ 27
7.3 Water refilling ....................................................................................................................................... 27
7.4 Information for combustion controller/chimney sweep regarding emission monitor key ............. 28
7.5 Cleaning................................................................................................................................................. 29
7.5.1 Cleaning the burner cylinder .................................................................................................................. 29
7.5.2 Cleaning the exterior of the combustion chamber and burner cylinder .................................................. 30
7.5.3 Cleaning/adjusting the ignition and ionisation device.............................................................................. 31
7.6 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas............... 32
7.7 Servicing the neutralisation installation (if fitted).............................................................................. 33
7.8 Clean siphon.......................................................................................................................................... 34
8. Overview of settings
8.1 Table of parameters .............................................................................................................................. 35
8.2 Automatic firing device UltraGas®(70,90)........................................................................................... 42
8.3 Fault Reporting overview TopTronic®T................................................................................................ 47
8.4 Automatic firing device (Warning, Blocking, Lock-out)..................................................................... 49

4 210 266 / 034 Safety instructions
1. Safety instructions
The system shall not be put into operation until all relevant standards and
safety regulations 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).
1.1 Key to symbols used
Tools:
Shows the tools required for the following work.
Instruction:
Prompts you to carry out an action.
Result:
Shows the expected reaction to your action.
Note:
Provides important information
Safety information:
Indicates an immediate hazard to persons
Safety information:
Warning of dangerous electrical voltage
Warning information
Indicates danger to machines and Installations
Provides important information.
Reference to standards and regulations.
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4 210 266 / 03 5 Important notes
2. Important notes
2.1 Acceptance of delivery
A 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 individual risk
bearer.
2.2 Scope of guarantee
The 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
2.3 Instruction manuals
A 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 respective compo-
nents!
Additional sources of information:
- Hoval catalogue
- Standards and regulations
2.4 Regulations, official permits
When installing and operating the system, the standards and regulations
specified in point 2.4.1 to 2.4.3 must be complied with at all times.
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4 210 266 / 036 Important notes
2.4.1 Germany
DIN EN 12831 Heating systems in buildings - Methods for calculating the design heat load
DIN EN 13384 Flue gas systems - Heat and flow calculation 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 execu-
tion (for gas burner operation).
DIN 18160 Domestic chimneys, requirements, design and construction.
TRD 702 Steam boilers with group II hot water generators.
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 combustion systems
(VDE regulation).
See enclosure N-430 020 for further standards applicable in Germany.
2.4.2 Austria
OENORM 12831 Heating systems in buildings - Methods for calculating the design heat load
OENORM 13384 Flue gas systems - Heat and flow calculation methods
OENORM 12828 Heating systems in buildings - Planning 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
2.4.3 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 responsible gas board must also
be observed. An official permit may be required.
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4 210 266 / 03 7 Assembly
4. Using a winch (4, fig. 3) raise the front of the boi-
ler and remove the front crossbeam (5).
6 Fig. 4
5. Push the lateral bars (4, fig. 4) out on the front
and lower the boiler back onto the floor.
7 8
Fig. 5
6. Remove screws (3, fig. 2) at the back. Lift rear
wall and cover and take off the rear wall towards
the bottom. Using a winch (7, fig. 5) raise the
boiler at the back in the centre (8) and remove
crossbeam and side beams. Lower the boiler
back onto the floor.
7. Affix the enclosed type sticker visibly on the boi-
ler.
3. Assembly
3.1 Placement
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Hoval recommends the Installation of the heat-
ing boiler on a foundation plate.
Fig. 1 1
1. Remove wooden crate (1, fig. 1)
Caution: sharp edges (Figure 2)!
Fig. 2 3 2
2. Remove transportation straps (2, fig. 2)
3. Remove front screws (3)
Fig. 3 4 5

4 210 266 / 038 Technical data
4. Technical data
4.1 Description of the boiler
TheHovalUltraGas®isalow emission,energy-saving
condensing gas boiler comprising the Ultraclean
burner system, a gas fired premix burner with com-
bustion air fan. The Hoval UltraGas®has a vertically
disposed combustion chamber of stainless steel as
a primary heating surface and a secondary heat-
ing 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 maintenance purposes.The UltraGas®
is designed to operate with natural and liquid gas.The
figure below shows the design principle.
Concentric flue gas connection
Connection hose for room sealed
operation
Feed tube on left and/or right side
Internal flue gas conduit
High temperature return on
left and/or right side
Low temperature return
on left and/or right side
Gas safety and
control devices
Combustion air fan
Electrode for ignition and
flame monitoring
TopTronic®Tcontroller
aluFer®heat exchanger
Condensate collection tray
Horizional flue gas pipe optional

4 210 266 / 03 9 Technical data
4.2 Technical data
UltraGas®(70,90)
Type (70) (90)
•Nominal output 80/60°C with natural gas 1kW 12,2 - 63,3 14,4 - 83,3
•Nominal output 40/30°C with natural gas 1kW 13,6 - 69,9 16,1 - 91,5
•Nominal output 80/60°C with liquid gas 3kW 15,4 - 63,3 17,4 - 83,3
•Nominal output 40/30°C with liquid gas 3kW 17,1 - 69,9 19,3 - 91,5
•Nominal load with natural gas 1kW 12,5 - 65,5 14,7 - 86,0
•Nominal load with liquid gas 3kW 16,0 - 65,5 18,0 - 86,0
•Working pressure heating max./min. bar 4,0 / 1,0 4,0 / 1,0
•Working temperature max.. °C 85 85
•Boiler water capacity l 157 149
•Min. water circulation l/h 0 0
•Boiler Weight (without water) kg 249 268
•Boiler efficiency at partial load 30% (according to EN 303)
(related to net / gross calorific value) % 107,1 / 96,5 107,2 / 96,6
•Standard efficiency (according to DIN 4702 part 8)40/30°C % 109,6 / 98,7 109,6 / 98,7
(net calorific value / gross calorific value) 75/60°C % 107,1 / 96,5 107,1 / 96,5
•Heat loss rate at 70°C Watt 290 290
•Standard emission rate Nitrogen oxides mg/kWh 32 39
Carbon monoxide mg/kWh 3 3
•Content of CO2in the exhaust gas max./min. power % 9,0 / 8,8 9,0 / 8,8
•Dimensions See table of dimensions
•Connections Flow /Return Zoll R 1 ½" R 1 ½"
Gas Zoll R ¾" R ¾"
Flue gas / combustion
air Ø mm C100/150 C100/150
•Gas flow pressure min./ max.
Natural gas E/LL mbar 18-50 18-50
Liquid gas mbar 37-50 37-50
•Gas connection value at 0°C / 1013 mbar:
Natural gas E - (Wo = 15,0 kWh/m3) Hu = 9,97 kWh/m3m3/h 6,6 8,6
Natural gas LL- (Wo = 12,4 kWh/m3) Hu = 8,57 kWh/m3m3/h 7,6 10,0
Propangas (Hu = 25,9 kWh/m3) m3/h 2,5 3,3
•Operation voltage V/Hz 230/50 230/50
•Control voltage V/Hz 24/50 24/50
•Min./Max. electrical power consumption Watt 27 / 93 28 / 138
•Standby Watt 12 12
•IP rating (integral protection) IP 20 20
•Acoustic capacity
- Heating noise (EN 15036 part 1) (room air-dependent) dB(A) 64 67
- Exhaust noise is radiated from the mouth
(DIN 45635 part 47) (room air-dependent/room air-independent) dB(A) 55 59
•Acoustic pressure level (depending on installation)2dB(A) 57 59
•Condensate quantity (Natural gas ) at 40/30°C l/h 6,2 8,1
•pH value of the condensate ca. 4,2 ca. 4,2
•Value for flue calculation
Temperature class T120 T120
Flue gas mass flow kg/h 109,0 143,0
Flue gas temperature at nominal output and operation 80/60°C °C 63 65
Flue gas temperature at nominal output and operation 40/30°C °C 43 43
Mass flow combustion air Nm3/h 81 106
Feed pressure for combustion air/ flue gas system Pa 130 130
Maximal Draft / negative pressure flue gas outlet Pa - 50 - 50
1Data reladet to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kWH/m3operation at a
Wobbe oefficient of 12,0 up to 15,7 kWh/m3is possible without new settings.
2See also notes at „Engineering“.
3Data reladet to Hu.

4 210 266 / 0310 Technical data
4.3 Dimensions / Space requirements
UltraGas®(70,90) with connection set AS40-S/NT/ HT and heating armature groupe HA40
(All dimensions in mm)
Type UltraGas®(70) (90)
1. Flow Heating R1½" R1½"
2. Low temperature-return R1½" R1½"
2a. High temperature-return R1½" R1½"
3. Electrical connection left or right R ¾" R ¾"
4. Gas connection left or right C100/150 C100/150
4a. Flue gas connection rear (option) E100/150 E 100
5. Control panel
6. Condensate drain (left or right)
incl. siphon DN25 and 2 m PVC
continuous-flow tube inner Ø 19x4
mm
7. Electrical connection left or right
8. Draining
9. Connection set (option)
10. Heating armature group or
loading group (option)

4 210 266 / 03 11 Technical data
4.4 Space requirements
UltraGas®(70,90)
(All dimensions in mm)
Boiler door incl. burner swivels upwards and to the left or to the
front.
A= minimal 150 mm *
Burner service position front - boiler cleaning from the right
A= optimal 300 mm *
Burner service position left - boiler cleaning from the front
* without heating armature group
500 mm with heating armature group

4 210 266 / 0312 Technical data
4.5 Boiler-Flow resistance
m3/h = Through put flow rate
mbar = Flow resistance
UltraGas®(70,90)
0
10
20
30
40
50
60
70
80
90
100
0
12345678
[mbar]
[m3/h]

4 210 266 / 03 13 Technical data
4.6 Brief description of the automatic firing device
The automatic firing device BIC960 of the UltraGas®only operates in conjunction with the heating control-
ler TopTronic®T/UG. For this reason, the automatic firing device only needs to take care of the last re-
maining functions to ensure the correct operation of a modulating gas boiler.
The automatic firing device comprises the following functions:
- 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 device
- RS 485 connection to TopTronic®T/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 demand
Fuses:
The BIC 960 is fitted with 3 fuses: 2AT Mains
4AT Pump
4AT 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®T/UG by the failure
message „DATABUS ERROR 70-6“. The failure appears when there is no communication between auto-
matic firing device and TopTronic®T/UG .

4 210 266 / 0314 Installation
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5. Installation
5.1 Safety information
Caution!
Sharp edges pose a cutting hazard.
Handle the cladding parts with care and avoid contact with sharp edges.
5.2 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 containing halogen compounds which can be carried
into the combustion air (e.g. wash rooms, drying rooms, DIY rooms, hair dresser 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 unhindered 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.
5.2.1 Room air dependent installation
The applicable regulations do not normally provide any specific data on the size of air intakes.
They only require 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 cm2must be available.
For rectangular apertures the aspect ratio should not exceed 1.5:1. If a grid is fitted on the air
intake, a suitable allowance must be made to obtain an air intake cross section of 300 cm2.
If the combustion air is aspirated from within
the boiler room, it is possible to remove the
air intake hose (1) to reduce suction noise.
5.2.2 Room sealed installation
Configuration based on a concentric flue system:
The suction air is supplied through a double-wall flue
system.
Ensure the boiler room is sufficiently ventilated.

4 210 266 / 03 15 Installation
Configuration using a separating piece (optional):
i
•
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 in-
stalling a noise damper in the direct
fresh air suction line.
• The intake opening must be easily ac-
cessible.
• No chemicals or poisonous substances
may be stored close to the intake open-
ing
• The intake opening may not be ins-
talled beside fume extraction outlets or
other venting outlets.
• Ensure that the intake aperture is free
from any obstructions at all times (lea-
ves, snow, ...)
•
A safety grid must be installed on the
suction opening on the outside wall.
5.3 Flue gas connection and flue
Due to the low flue gas temperatures, condensate
forms within the flue. For this reason, Hoval gas
heating boilers can not be connected to convention-
al house chimneys.
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The flue gas extraction system must
comply with the following directives:
• DVGW (TRGI)
• ÖVGW
• SVGW/VKF
Pursuant to the abovementioned regula-
tions, a flue gas temperature limiter must
be installed in the boiler.
The flue gas system must meet the follo-
wing 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 connec-
tion elements is at least 50 mm/m.
• Only one heat generator may be con-
nected to the same chimney.
• If two heat generators are to be con-
nected to the same chimney, the rele-
vant 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
chimney or flue system manufacturer.
• The calculation values can be obtained
from the table under point 4.2.
•
The flue gas conduit cross sections
and lengths are calculated following
the technical data for the boiler.
• The concentric supply air/exhaust sys-
tem of the boiler can also be conducted
horizontally backwards. The Hoval re-
modelling set allows a remodelling on
site
5.4 Condensate drainage
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The condensate drainage pipes on the
boiler must be made of corrosion resis-
tant material.
The following materials are suitable for
condensate drainage:
PVC, PE, PP, ABS
The local regulations regarding conden-
sate drainage must be observed.

4 210 266 / 0316 Installation
5.4.1 Design variants
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Before commissioning, the neutralisation
box (if fitted) must be filled with neutrali-
sation granulate (figure, chapter 6.4).
Before putting into service, the si-
phon and the neutralisation box must
be filled with water.
The water can be filled through the
cleaning opening into the neutralisa-
tion box and the siphon.
Possibility 1
• Stand version with siphon
• With neutralisation, condensate discharge into
lower drain line.
• Drain optionally on the left or right side.
1
3
2
Possibility 2
• Design with neutralisation box
• For condensate discharge in lower drain line, incl.
condensate neutralisation.
1
3
2
Possibility 3
• Siphon and condensate delivery pump
• Without neutralisation, condensate discharge into
higher drain line.
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The condensate delivery pump must be
installed in accordance with the enclosed
instructions.
1 2
Possibility 4
• Neutralisation box and condensate delivery pump
• With condensate neutralisation - condensate dis-
charge into higher drain line.
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The condensate delivery pump must be
installed in accordance with the enclosed
instructions.
3 21 4

4 210 266 / 03 17 Installation
5.5 Gas connection
Hazard!
Explosion hazard due to leaky gas connection.
Check the gas connection for gas tightness after completing the boiler installation.
The gas connection can be located on the left or right hand side of the boiler.
The gas line is supplied loose with the boiler. The connection diameter is ¾“.
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Check for gas tightness after installation!

4 210 266 / 0318 Installation
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High temperature return (e.g. venting group or calorifier)
Low temperature return (e.g. underfloor heating)
AF Outside sensor 1
VF1 Flow sensor 1
SF Calorifier sensor
B1 Flow temperature monitor
(optional)
MK1 Pump mixing circuit 1
SLP Calorifier - loading pump
YK1 Actuator mixer 1
5.6 Hydraulic connection
The boiler comprises the following safety equipment, in accordance with EN 12828:2003:
- 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 con-
nected.
5.6.1 Customer-side requirements
A pressure expansion tank adapted to the heating system, water volume
and static height.
5.6.2 Hydraulic interconnection
When combining a calorifier with floor heating, a mixer needs to be installed.
A minimum amount of circulating water is not required.
UltraGas®(70,90) with calorifier
and direct heating circuit
Regarding suitable hydraulic connections,please observe the notes in
the planning documentation of the relevant Hoval sales company!
Example
Make sure to
close off un-
used connec-
tors tightly
RS-T
AF
TopTronic T
WW
Dies ist ein
unerlaubter
Weg!
Gehen Sie
einen Schritt
zurück oder
löschen Sie
dieses Shape!
Sie haben die
Möglichkeit ein
neues Shape
zu nehmen!!!
hovhovalhoval
hovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhov
alhovalhovalho
valh
T
KW
SF
SLP
Dies ist ein
unerlaubter Weg!
Gehen Sie einen
Schritt zurück oder
löschen Sie dieses
Shape!
Sie haben die
Möglichkeit ein
neues Shape zu
nehmen!!!
hovhovalh
hovalhova
alhovalho
UltraGas
(35-90)
P
NT
HT
NT
HT
TT
MK1
M
YK1
B1VF1

4 210 266 / 03 19 Installation
5.7 Electrical connection
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- The electrical connection must be car-
ried out by an approved electrician.
- The connection diagram is located wi-
thin the boiler control box.
- The electrical circuit diagram is sup-
plied separately.
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
isolation 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 installation:
Control units with their own mains connection re-
quire the mains, sensor and bus cables to be routed
separately.
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Cable trunking with dividing parti-
tions should be used.
The mains connection for the heating system (boi-
ler-control 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
transmitters or receivers (garage door openers,
amateur radio aerials, radio alarm systems,...).
Recommended conductor cross sections:
Conductor type Cross section Length
Mains voltage cables min. 1,0 mm² unlimited m
Extra-low voltage cables
(sensors) min. 0,5 mm² max. 50 m
Data bus cables (screened) 2 x 0,6 mm² max. 100 m
Procedure to remove the front covering panel
1. Remove front cover (1, fig. 6), after first releasing
the lateral locking bolt (1a) (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), after first releasing
the lateral locking bolt (2a) (turn approx. ¼ turn
to the left and pull out as far as the stop). Slight-
ly raise the lower front cover (2) and remove to-
wards the front.
3. Remove the locking screw (3a) on the right.
4. Lift the switch control box (3) and fold it out.
5. Cable entry refer to the Technical Datasheet (Di-
mensions, point 4.3, item 7)
The electrical connection is to be made in accordance
with the diagram supplied.
1
1a
2
2a
3a
3
Fig. 6

4 210 266 / 0320 Commissioning
6. 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 TopTronic®T 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 system must be explained to the user
in detail.
The combustion air needs to be filtered in very dusty environments.
The gas flow pressure must be checked and the CO2value set correctly.
6.1 Safety information
Caution!
Sharp edges pose a cutting hazard.
Handle the cladding parts with care and avoid contact with sharp edges.
Caution!
Danger of injury for unqualified personnel.
Maintenance and cleaning work may only be performed by trained personnel
or by the Hoval Customer Service.
Caution!
Danger of damaging the system by filling it with incorrect liquids.
Water filled into the system must have drinking quality.
6.2 Filling with water
Filling of the heating system may only be carried out by qualified personnel.
The European Standard EN 14868 and the Directive VDI 2035 must be
observed (see point 6.3).
Open the isolating valves in the flow and return lines.
Connect the water hose to the filling tap.
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
according to the manufacturer’s information.
The anti-freeze or anti-corrosion agent concentration must be checked at
least once per year.
The identical product must be used when replenishing the anti-freeze or anti-
corrosion 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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