Hoval UltraOil 50 Manual

UltraOil®(50)
Oil condensing boiler
These instructions apply to the following
models:
30-UltraOil®(50)
with TopTronic®T controls
The UltraOil®heating boiler is suitable for and approved
as a heating unit for hot-water systems with permitted
ow temperatures up to 90 °C1). It is designed primarily
for closed circuits, but is equally suitable for installation
in open circuits.
1) see chapter 3.2
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
4 210 256 / 01 - 01/12
This appliance is
only suitable for
operation with
heating oil EL
(low sulphur)

4 210 256 / 012 Table of contents
1. Important notes
1.1 Other instructions................................................................................................................................... 4
1.2 Safety instructions.................................................................................................................................. 4
1.3 Regulations, official approvals .............................................................................................................. 4
1.4 Guarantee ................................................................................................................................................ 5
2. Assembly
2.1 Installation, levelling............................................................................................................................... 5
2.2 Assembly of the condensate discharge and neutralisation box ........................................................ 5
2.2.1 Design variants ......................................................................................................................................... 6
2.3 Burner assembly ..................................................................................................................................... 7
3. Technical details
3.1 Description of the boiler....................................................................................................................... 10
3.1.1 The UltraOil®comply with the following directives and standards........................................................... 10
3.2 Technical information ........................................................................................................................... 11
3.3 Dimensions............................................................................................................................................ 12
3.4 Space requirements.............................................................................................................................. 13
4. Installation
4.1 Boiler room requirements .................................................................................................................... 14
4.2 Flue connection and chimney.............................................................................................................. 14
4.2.1 Exhaust gas flues approved by building regulations ............................................................................... 15
4.2.2 Example of an exhaust gas flue .............................................................................................................. 15
4.2.3 Project planning instructions ................................................................................................................... 15
4.2.4 Dimensioning flue gas system ................................................................................................................ 15
4.3 Fuel......................................................................................................................................................... 16
4.4 Electrical connection............................................................................................................................ 17
4.4.1 Safety measures relating to EMC assembly ........................................................................................... 18
4.5 Flue gas - output diagram .................................................................................................................... 19
4.6 Hydraulic integration ............................................................................................................................ 20
4.7 Condensate discharge.......................................................................................................................... 20
4.8 Setting the temperature controller ...................................................................................................... 20
4.9 Safety valves ......................................................................................................................................... 20
4.10 Loading pump (boiler with water heater)............................................................................................ 20
4.11 Heating pump ....................................................................................................................................... 20
5. Commissioning
5.1 Water quality.......................................................................................................................................... 21
Heating Water ......................................................................................................................................... 21
Filling and replacement water ................................................................................................................. 21
5.2 Filling the heating circuit...................................................................................................................... 22
5.3 Filling the water heater (if fitted).......................................................................................................... 22
5.4 Commissioning ..................................................................................................................................... 22
5.5 Oil burner ............................................................................................................................................... 22
5.6 Handover to the operator / storage ..................................................................................................... 22
5.7 Record - Activation of screed function ............................................................................................... 23

4 210 256 / 01 3 Table of contents
6. Maintenance
6.1 Information for combustion controller/chimney sweep regarding emission monitor key.................25
6.2 Cleaning the boiler................................................................................................................................ 26
6.2.1 Preparations for boiler and burner cleaning ............................................................................................ 26
6.2.2 Re-assembly of the boiler ....................................................................................................................... 26
6.3 Cleaning the combustion chamber and the aluFer®pipes................................................................ 28
Leakage testing....................................................................................................................................... 28
6.4 Servicing the neutralisation installation (if fitted).............................................................................. 29
Procedure for servicing the neutralisation installation............................................................................. 29
6.5 Safety temperature limiter - release .................................................................................................... 30
7. Overview of settings
7.1 Table of parameters .............................................................................................................................. 31
7.2 Fault Reporting overview TopTronic®T................................................................................................ 41

4 210 256 / 014 Important information
1. Important notes
1.1 Other instructions
According to the execution, any additionally neces-
sary instructions can be found in the Hoval instal-
lation handbook! In exceptional cases, the instruc-
tions are to be found with the components.
Further sources of information:
• Hoval catalogue
• standards, regulations
1.2 Safety instructions
The installation may only be put into operation if all
relevant standards and safety regulations have been
complied with. However, for a trial operation, the fol-
lowingare theminimumconditions requiringfulfilment:
1. a safety valve has been installed (closed-circuit
installation)
2. controls in operation
(connected to the power supply)
3. sensor for the safety temperature limiter is fitted
in the submerged sleeve
4. the system is filled with water
5. an expansion container is attached
6. exhaust connectionsconnected tothe exhaustflue
at the chimney
7. burner preset
1.3 Regulations, official approvals
For installation and operation of the system, the fol-
lowing regulations are to be observed:
Germany
• DIN EN 12831 Heating systems in buildings - pro-
cedure for calculating the standard heating load.
• DIN EN 12828 Heating systems in buildings - plan-
ning of hot water systems.
• DIN EN 13384 Exhaust gas systems - heat and
flow calculation methods.
• DIN 4755 Oil fired combustion systems: design,
construction and technical safety requirements.
• DIN 4756 Gas fired combustion systems: design,
construction and technical safety requirements,
planning and execution (for operation with gas
burners).
• DIN 18160 House chimneys, requirements, plan-
ning and execution.
• PED (Pressure Equipment Directive).
• TRD 721 Safety equipment to safeguard against
excess pressures / safety valves / for group II
steam boilers.
• VDI 2035 Prevention of damage by corrosion and
the formation of scale in hot water systems.
• DIN 57 116 / VDI 0116 Electrical equipment in
combustion systems (VDE regulation).
Austria
• ÖNorm B 8130 Open hot water systems, safety
installations.
• ÖNorm B 8131 Closed hot water systems, safety,
construction and testing regulations.
• ÖNorm B 8133 Water heating systems, technical
safety requirements.
• ÖNorm B 8136 Heating systems, space require-
ments and other building requirements.
• ÖNorm M 7515 Calculations of dimensions of
chimneys; definition of expressions, calculation
procedure.
• ÖNorm H 5170 Heating installations, building and
technical fire-protection regulations
• ÖVGW TR-gas (Austrian Gas and Water Confed-
eration - Technical Guidelines
Switzerland
• VKF-Association of Cantonal Fire Insurers
• Regulations of the fire police
• SVGW Swiss Gas and Water Federation
• SNV 27 10 20 Aeration and ventilation of the boiler
room
• SWKI 97-1 Water treatment for heating, steam and
air conditioning plant
• SWKI 80-2 Technical safety regulations for heating
installations
• KRW Corrosion caused by halides
• KRW/VSO/FKR Electrical connections on heating
boilers and burners ready to plug in
• Technical tank regulations TTV 1990.
and further prescriptions and standards published
by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and
the legislature.
In a similar manner, the regulations of the local build-
ing authorities, insurers and chimney inspectors must
be taken into account.When gas is used as fuel, the
regulations of the responsible gasworks must be
observed and an official authorisation may also be
required.

4 210 256 / 01 5 Assembly
1.4 Guarantee
Trouble-free functionality is only guaranteed when
both these and the operating instructions are meticu-
lously observed and the boiler is regularly serviced
by a qualified engineer (maintenance contract). Re-
pair of faults and damage caused by contaminated
operating materials (gas, water, combustion air),
unsuitable chemical additives in the heating water,
careless treatment, faulty installation, unauthorised
modifications and damage as a result of force are
not subject to our guarantee liability;this applies also
to corrosion caused by halides, e.g. emanating from
spray canisters, paints and varnishes, adhesives,
solvents and cleaning agents.
2. Assembly
2.1 Installation, levelling
The boiler is fixed to wooden transport chocks. For
transport 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 es-
sential, but it is recommended.
Space required
The flange of the boiler must be able to be swung out
fully, with burner installed (see chapter 3.4).
Installation of the boiler
1. Unbolt the boiler from the wooden pallet and
remove the transport securing devices.
2. Levelling the base:
The base must be levelled both lengthways and
crossways with a spirit level. This is carried out
by adjusting the nuts on the boiler feet. After this
adjustment, the upper (locking) nuts on the boiler
feet must be tightened thoroughly.
2.2 Assembly of the condensate dis-
charge and neutralisation box
For the condensate discharge, there a four versions
available.The assemblyis carriedout,according to the
version supplied, in accordance with the illustrations.
The condensate discharge must be
fabricated of corrosion resistant ma-
terial (see chapter 4.7).

4 210 256 / 016 Assembly
2.2.1 Design variants
i
Before commissioning, the neutrali-
sation box (if fitted) must be filled with
neutralisation granulate (figure, chap-
ter 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.
i
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.
i
The condensate delivery pump must
be installed in accordance with the
enclosed instructions.
3 21 4

4 210 256 / 01 7 Assembly
2.3 Burner assembly
1. Remove front cover (1, fig. 01), after first releas-
ing 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. Lift and remove the lid (2).
3. Remove the locking screw (3) on the left and
right.
4. Lift the side walls (4), by sliding them slightly to-
wards the front.
2
4
3
1
1a
Fig. 01
5. Remove the burner from the packaging.
6. Dismount the burner flange.To do so, loosen the
screw (6, fig. 02) and rotate the burner by 15°.
The required Allen key (5) is supplied with the
burner.
5 6
Fig. 02
7. Mount the burner flange including sealing to
the boiler flange in accordance with figure 03.
Mount the flange so that the “Warning” label is
facing outwards.
Tip to help assembly:
To simplify installation, the sealing on the burner
flange can be lubricated using a heat-resistant
paste (e.g. Kluberpaste UH1 84-201).
"Warning" label
Fig. 03
8. Insert the burner rotated by 15° (final position:
burner performance label facing outwards) into
the burner flange. Once the stop position has
been reached, rotate by 15° so that the exten-
sion piece fits beneath the head of the screw
(figure 05).

4 210 256 / 018 Assembly
Fig. 04
Head of screw
Fig. 05
9. Tighten the screw (6, fig. 02) to secure the burn-
er.
Insulate the space between the burn-
er pipe and the boiler flange with the
fireproof fibre supplied.
The circulating air-vents must not be
covered.
Ensure that,
- the fireproof fibre is packed firmly into the space in
order to prevent it falling out (figure 06)
Fireproof fibre
Fig. 06
10. Close the boiler flange with the burner once
again.
11. The oil feeds may be taken through the side
openings either on the right or the left.
12. Make plug-and-socket connections (7, fig. 07,
08). Pull the plug cable further out, to do this,
loosen the PG unions (8). The burner must be
connected to the boiler with the standard plug
connection.
The burner cable must be shortened so that to
swivel out the burner, it is essential to break the
plug connection.
7 8
Fig. 07

4 210 256 / 01 9 Assembly
Cable outlet
to the left
Cable outlet
to the right
4
Fig. 08
9
Fig. 09
13. Connect up the pipes (9, fig. 09).
Tip to help assembly: put the pipe in place and
twist it slightly.
14. Reattach the side walls (4, fig. 01), locking
screws (3), lid (2) and front cover (1).
Further information is to be obtained
from the instructions supplied togeth-
er with the burner.

4 210 256 / 0110 Technical information
3. Technical details
3.1 Description of the boiler
The Hoval UltraOil®is a low-pollutant, energy-saving
oil-fired heating boiler. The UltraOil®has a combus-
tion chamber arranged vertically fabricated from
rustless stainless steel as its primary heating surface
and a secondary heating surface of a corrosion-re-
sistant aluminium alloy. The secondary heating sur-
face is so designed that the water vapour contained
in the heating gas condenses and the heat of evapo-
ration is utilised for the heating circuit. The UltraOil®
is designed to be operated with heating oil EL.
3.1.1 The UltraOil®comply with the following
directives and standards
We hereby declare that the product described, as an
individual appliance, complies with the standards,
guidelines and technical specifications laid down.
Directives
92/42/EG "Boiler efficiency directive”
73/23/EWG “Low voltage directive”
89/336/EWG “Electromagnetic
compatibility directive”
Regulations
Stability prEN14394:2001
Constructional
requirements
EN303-1
EN303-2
prEN 15034
prEN 15035
Low voltage DIN VDE 0722 ed. 04.83
EMC EN EN 50082 Teil 1 ed. 01.92
EN 12828 prescribes low water level protection in closed
heating systems.
Substitute measures can be used in the case of boilers
with an output of up to 300 kW.
On boilers of type UltraOil (50), the safety disconnection
function during operation without water was tested. The
test was performed successfully.
i
Installation of low water level protection
on the UltraOil (50) is therefore not neces-
sary.

4 210 256 / 01 11 Technical information
3.2 Technical information
Type (50)
•Nominal output at 80/ 60 °C kW 48
•Nominal output at 40/ 30 °C kW 50
•Range of output at 80/ 60 °C kW 28 - 48
•Range of output at 40/ 30 °C kW 30 - 50
•Heat input kW 28,4 - 48,4
•Dimension see Dimensions
•Maximum boiler operation temperature °C 90
•Minimum boiler working temperature °C no lower limitation
•Minimum return flow temperature °C no lower limitation
•Minimum flue gas temperature at boiler °C no lower limitation
•Safety temperature limiter setting (water side) °C 110
•Operation / test pressure bar 3,0 / 4,5
•Boiler efficiency at full load and 80/ 60 °C
(related to net/ gross calorific value) % 98,7 / 93,1
•Boiler efficiency at full load and 40/ 30 °C
(related to net/ gross calorific value) % 103,5 / 97,6
•Efficiency at partial load 30% and return 27 °C (according to DIN 303)
(related to net/ gross calorific value) % 104,7 / 98,8
•Nominal efficiency (according to DIN 4702 part 8) at 75/ 60 °C
(related to net/ gross calorific value) % 102,0 / 96,2
•Nominal efficiency (according to DIN 4702 part 8) at 40/ 30 °C
(related to net/ gross calorific value) % 104,5 / 98,6
•Stand-by deficiency qB at 70 °C Watt 290
•Heating gas-side resistance with rated heating capacity,
12,5% CO2, 500 m over sea level (tolerance +/- 20%) mbar 0,75
•Quantity of condensate at 40/ 30 °C l/h 3,52
•Flow resistance of boiler 1zeta value 1,50
•Water-side resistance at 10 K mbar 27,70
at 20 K mbar 6,90
•Water flow rate at 10 K m3/h 4,29
at 20 K m3/h 2,15
•Boiler water content Liter 115
•Boiler gas contents m30,13
•Insulation thickness mm 50
•Weight (incl. casing, burner) kg 276
•Transport weight kg 261
•Min./ Max. electrical power consumption Watt 4 / 250
•Acoustic capacity incl. absorber hood 2
Ambient air dependent
- Heating noise (EN 15036 part 1) dB(A) 71
Ambient air independent
- Heating noise (EN 15036 part 1) dB(A) 67
- Aspiration noise is radiated from the mouth (DIN 45635) dB(A) 66
- Aspiration/ exhaust noise - LAS - is radiated from the mouth
Ambient air dependent and ambient air independent dB(A) -
- Exhaust noise in the pipe (EN 15036 part 2) 3dB(A) 85
- Exhaust noise is radiated from the mouth (DIN 45635 part 47) 3dB(A) 68
•Combustion chamber dimensions, inside ø x length mm ø425 x 551
•Combustion chamber volume m30,0781
•Flue gas mass flow at full out 12,5 % CO2Diesel oil kg/h 76
•Flue gas temperature at nominal output 80/ 60 °C °C 75
•Delivery pressure at flue gas outlet Pa 30
•Maximum chimney draft Pa 20
1Flow resistance of boiler in mbar = flow rate (m3/h)2 x zeta
2Details valid for Hoval oil-compact heat station b-i
3with integrated sound absorber

4 210 256 / 0112 Technical information
3.3 Dimensions
(All dimensions in mm)
1 Flow/ Safety flow R1½"
2 Low temperature-return R1½"
2a High temperature-return R1½"
3 Leadthrough for oil feed left or right
4 LAS flue gas/ supply air connection C100/150
5 Boiler control
6Condensation drainage (left or right) including siphon
DN25 and 2 m PVC pipe inner Ø 19 x 4 mm
7 Electrical connection left or right
8 Evacuation ½"
9 Connection set (option)
10 Heating fittings group or loading group (option)

4 210 256 / 01 13 Technical information
3.4 Space requirements
(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 with heating armature group
500 mm with heating armature group

4 210 256 / 0114 Installation
4. Installation
4.1 Boiler room requirements
Regarding the building specifications in respect of
boiler rooms and their ventilation and exhaust, the
currentbuildingsupervisory office regulations specific
to the state or country are to be observed.
The UltraOil®can be operated either dependent on
air from the boiler room, or independent of boiler
room air.
Not dependent upon boiler room air
As an appliance of type C53x or C63x the UltraOil®can
be installed to operate independent of boiler room
air, irrespective of size or ventilation of the room in
which it is installed.
We recommend it is installed in a separate room
in which, in accordance with pr. EN 15035, a small
amount of leakage of exhaust gas can be tolerated.
Not dependent upon boiler room air:
Ensure that there is an adequate fresh air supply
to the boiler room,
so that the amount of combustion air required for
operation of all the burners installed there can be
continuously replenished without hindrance and that
for the protection of operating personnel there is no
shortage of oxygen.
Binding values for the size of ventilation openings are
not generally specified in the relevant regulations;it is
merely required that no partial vacuum in excess of
3 N/m2 occurs. To comply with this requirement, for
up to a nominal thermal output of 50 kW, a ventilation
cross-section of at least 300 cm2must be provided.
In rectangular openings, the ratio of sides should not
exceed 1.5:1; if a grid is fitted, an appropriate adjust-
ment must be allowed so that the free cross-section
area reaches the amount given above.
4.2 Flue connection and chimney
The exhaust system must be gastight,
watertight, resistant to acids and be
approved for the corresponding ex-
haust gas temperatures up to 120 °C
and for operation at pressure.
Horizontal connections must be laid
with a gradient down towards the boil-
er of at least 50 mm per meter length,
to ensure that there is no hindrance to
condensate flowing back into the boil-
er. The whole exhaust system must be
designed to avoid condensate collect-
ing.
As a general rule, only one heat generator
should be connected to the chimney. For two
heat generators, the corresponding regulati-
ons are to be observed.
In the UltraOil®there is an exhaust gas safety
temperature limiter installed. For this reason,
no additional exhaust gas temperature limiter
is required for the exhaust gas system with a
maximum permitted exhaust gas temperature
of 120 °C.
Because of the moisture content in exhaust gases
at low temperatures and the additional condensate
which is thus caused in the chimney, it is not permit-
ted to connect oil condensing boilers to traditional
domestic chimneys.
The current official conditions and regulations are to
be observed in respect of the exhaust gas system
design.
There are two alternatives for exhaust gas system
design for oil condensing boilers:
a) the use of special exhaust gas systems approved
by the building authorities,
b) the use of moisture-resistant chimneys which are
approved for exhaust gas temperatures of over
40 °C, connected in the boiler installation room
by means of approved exhaust flues with the oil
condensing boiler.
In both cases, the cross-sections and maximum
lengths are to be calculated on the basis of the values
for exhaust gas mass flow, exhaust gas temperature
and the delivery pressure available at the exhaust
connections in accordance with the table in section
3.2 (DIN 4705).

4 210 256 / 01 15 Installation
4.2.1 Exhaust gas flues approved by building
regulations
The exhaust gases from the condenser oil-fired Hoval
UltraOil®boiler can be led away through a gas-tight,
exhaust gas flue resistant to high temperature and
to condensate. Only exhaust systems approved by
the respective country or state may be connected (in
Austria the approvals of the respective provinces are
to be observed). For transition from the exhaust gas
connection to the exhaust gas flue, the manufactur-
ers of the exhaust gas flues supply suitable boiler
connection fittings.
In planning and installation of the exhaust gas flue,
planning instructions and manufacturer’s instructions
for laying and building legislation regulations must be
observed. Discussions are recommended in good
time with the regional chimney inspector.
Your authorised Hoval agent will be pleased to sup-
ply you with an approved exhaust system to suit your
UltraOil®boiler.
4.2.2 Example of an exhaust gas flue
(Hoval exhaust gas system)
Falls erforderlich ist
ein Inspektions-T-
Stück einzusetzen
Gitter zur Schacht-
hinterlüftung
Verbrennungs-
luft
4.2.3 Project planning instructions
• The exhaust gas routing must be through tested
and approved exhaust gas pipework
• The exhaust gas pipework must be gastight, wa-
tertight, resistant to corrosion and acids and ap-
proved for use with exhaust gas temperatures of
up to 120 °C.
• The exhaust gas system must be suitable for op-
eration at pressure.
• The exhaust gas pipework is to be laid with gra-
dients to ensure that the condensate which oc-
curs in the exhaust gas system flows back into the
heating boiler and can be neutralised there before
discharge into the drainage.
• When using exhaust gas pipework of plastic, local
state or country regulations relating to the use of
the safety temperature limiter must be observed.
• The cross-sections are to be calculated for heat-
ing boilers without draughting requirement. Please
take note of the SIA recommendation No. 384/4
“Chimneys for building heating systems, determi-
nation of cross-sections”.
• In the exhaust gas pipework there must be a clos-
able exhaust gas measuring connection with cir-
cular internal diameter of between 10-21 mm in-
stalled. The connection must protrude beyond the
heat insulation.
D
D
1D
< 2D
2xD
4.2.4 Dimensioning flue gas system
Non-binding guide values:
The following formpieces have been taken into ac-
count in determining the dimensioning diagrams:
• 1 T-piece 90° for boiler connection
• 1 90° elbow to support the flue gas pipe in the shaft
• 1 component for the chimney end

4 210 256 / 0116 Installation
4.3 Fuel
The boiler may only be operated with
the fuel designated on the boiler’s rat-
ing plate.
The UltraOil®heating boilers are suitable for firing
with the following fuels:
• Heating oil EL low-sulphur in accordance with
DIN 51 603 / ÖNorm C 1109
• Eco heating oil low-sulphur SN 181 160-2 / 2008
If an existing oil heating installation is replaced by
Hoval UltraOil®, the following instructions regarding
the oil tank and its refilling must be observed:
• Hoval UltraOil®must only be operated with heat-
ing oil EL low-sulphur with sulphur content < 50
ppm (< 0,005 %).
• It is recommended to clean the oil tank before
refilling it.
• A residual amount of heating oil EL in the oil tank
may be mixed with heating oil EL low-sulphur,
provided that the residual amount does not
exceed the following values of the total content.
Residual amount heating oil EL
(sulphur content: 2000 ppm resp. 0,2 %)
max 3 % of tank volume
Residual amount heating oil EL
(sulphur content: 1000 ppm resp. 0,1 %)
max 5 % of tank volume
Residual amount eco heating oil EL
(sulphur content: 500 ppm resp. 0,05 %)
max 10 % of tank volume
• In order to reach the permissible mixture ratio
with heating oil EL low-sulphur taking account of
the residual amount of heating oil in the oil tank, a
100% tank filling is necessary.
Natural gas (conversion option to UltraGas®)
Note:
The data contained in the following diagrams repre-
sent guide values calculated at maximum output. An
exact calculation for the flue gas duct must be made
on-site.
Hoval UltraOil®(50)
Maximum horizontal length of the connecting line (m)
Maximum effective height, flue gas conduit (m)
0
5
10
15
20
25
30
35
40
0123456
1
1room air
dependent
∅100 mm,
Flue pipe horizontal ∅100 mm
0
5
10
15
20
25
30
35
40
012345
HorizontaleAbgasleitungslänge (m)
2
1
Maximal height in the pipe (m)
Horizontal flue gas pipe length (m)
1room air
independent
Combustion air duct separately ∅130 mm,
Flue pipe vertical ∅130 mm,
Flue pipe horizontal ∅130 mm
2room air
dependent
∅130 mm,
Flue pipe horizontal ∅100 mm,

4 210 256 / 01 17 Installation
1. Remove front cover (1, fig. 10), after first releas-
ing 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. Lift and remove the lid (2).
3. Remove lower front cover (3), after first releasing
the lateral locking bolt (3a) (turn approx. ¼ turn
to the left and pull out as far as the stop). Slightly
raise the lower front cover (3) and remove to-
wards the front.
4. Remove the locking screw (4) on the right.
5. Lift the switch control box (5) and fold it out.
The electrical connection is to be made in accordance
with the diagram supplied.
4.4 Electrical connection
The electrical connection must be made by a qualified
electrical engineer.
For Austria and Germany:
An electrical circuit diagram is supplied with the boiler
controls.An all-pole main switch with a minimum contact
spacing of 3 mm must be fitted in the power supply line.
For Switzerland the following applies:
For the electrical connection, the electric circuit dia-
gram specific to the plant must be observed.
Fig. 10
Cable feed-in
2
5
1
3
1a
3a
4

4 210 256 / 0118 Installation
Control power plug
for connecting the electrical
components e.g. sensors etc.
Strain-relief
all cables must be fit-
ted with strain-reliever
clamps.
Power supply 230V
Terminal strip
for external components
e.g. condensate pump-
ing station etc.
4.4.1 Safety measures relating to EMC as-
sembly
1. For regulator units with their own power supply,
separate laying of power leads and sensor or
bus-leads is absolutely essential. If using cable
channelling, only that fitted with separator strips
may be used.
2. The power connection to the heating equipment
(boiler-switchboard-regulator unit) must be desig-
ned as an independent electrical circuit. Neither
fluorescent lamps nor any other machinery which
might cause interference may be connected, nor
may it be possible to make such a connection.
Cut-out
Boiler room emergency
switch
Heater
Boiler room lighting and
sockets to be connected to
a separate circuit
3. The external sensor must not be installed in the
vicinity of transmitter or receiver fittings, for ex-
ample on a garage wall near receivers for remote
garage door openers, ham-radio aerials or radio
alarm systems, or in the immediate vicinity of
transmitters etc.
Recommended cable cross-sections and maxi-
mum permitted lengths of cable:
Cables carrying mains supply voltages: (power
connections, burners, pumps, setting motors
etc.): minimum 1mm
2
maximum permitted length: no restrictions, within
the framework of the building’s internal installati-
ons.
Sensor cables and cables carrying low voltages:
minimal 0.5 mm2
maximum permitted cable length: 50 m
Data bus cables: must be screened e.g. J-Y (ST)
2 x 0.6 mm
maximum permitted cable length: 100 m
Fig. 11

4 210 256 / 01 19 Installation
4.5 Flue gas - output diagram
The diagram show the exhaust gas temperature be-
haviour with Hoval burners.
Flow 40 °C Return flow 30 °C
Flow 80 °C Return flow 60 °C
kW = heating output
°C = exhaust gas temperature using heating oil EL,
CO2= 12.5%
°C
60
70
80
90
100
30
40
50
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
kW
kW
60
70
80
90
100
30
40
50
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
°C

4 210 256 / 0120 Installation
A: it is not required to neutralise condensate from a
condenser oil-fired boiler of up to 120 kW drained
togetherwith domestic waste waterfrom a private
household.
CH:For the UltraOil®, the fuel used must be heating
oil EL low-sulphur. As a rule, neutralisation of
the condensate is not necessary. Regarding the
discharge of condensate, local regulations must
be taken into account.
D: For the UltraOil®, the fuel used must be heat-
ing oil EL low-sulphur. Neutralisation is therefore
unnecessary.Regardingthedischarge of conden-
sate, the local regulations and the ATV (Sewage
Engineering Association) data-sheet must be
taken into account.
4.8 Setting the temperature controller
Basic setting of the controls will be undertaken by the
heating installation engineer. Choice and setting of
the various heating programmes in accordance with
the operating instructions.
4.9 Safety valves
The heating equipment and hot water system must be
protected with one safety valve each against unau-
thorised high pressures.Their blowingoffperformance
must correspond with the boiler’s maximum nominal
heating output.The valve is to be installed in the feed
line in the immediate vicinity of the boiler.
4.10 Loading pump (boiler with water
heater)
Rotation speed and performance must correspond
with the requirements of the water heater. Setting
carried out by the heating installation engineer.
4.11 Heating pump
Rotation speed and performance must correspond
with the requirements of the plant.They are to be set
by the heating installation engineer.
4.6 Hydraulic integration
Examples
Direct heating circuit
Fig. 12
Mixer circuit and water heater
M
Fig. 13
4.7 Condensate discharge
The condensate discharge must be manufactured of
corrosion-resistant material.
The following materials are suitable for the conden-
sate discharge:
- PVC
- PE
- PP
- RED
The minimum inner diameter of the
condensate drain must be 15 mm.The
condensate drain must be sufficiently
inclined.