Hoval UltraOil 65 Manual

Subject to modifi cations | EN
Technical information
Installation instructions
4 213 787 / 01 - 04/21
This appliance is
only suitable for
operation with
heating oil EL
(low sulphur)
Hoval products must be installed and commissioned
only by appropriately qualied experts. These instruc-
tions are intended exclusively for the specialist. Elec-
trical installations may only be carried out by a qualied
electrician.
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
UltraOil®(65,80)
Oil condensing boiler
These instructions apply
to the following models:
41 - UltraOil®(65)
41 - UltraOil® (80)
with TopTronic® E controller

2
TABLE OF CONTENTS
1. Important instructions
1.1 Other instructions ...............................................................................................................................................................4
1.2 Safety precautions...............................................................................................................................................................4
1.3 Explanation of the symbols ................................................................................................................................................4
1.3.1 Warnings ..........................................................................................................................................................................4
1.3.2 Warning symbols...............................................................................................................................................................4
1.3.3 Information........................................................................................................................................................................4
1.4 Regulations, official approvals ...........................................................................................................................................5
1.5 Guarantee ............................................................................................................................................................................5
2. Assembly
2.1 Installation, levelling ...........................................................................................................................................................6
2.2 Assembly of the heat insulation .........................................................................................................................................7
2.3 Assembly of the panelling...................................................................................................................................................8
2.4 Assembly of the plinth panelling ......................................................................................................................................11
2.5 Installation of the flue gas orifice.....................................................................................................................................13
2.6 Burner assembly................................................................................................................................................................14
3. Technical details
3.1 Description of the boiler ...................................................................................................................................................16
3.2 Technical details................................................................................................................................................................17
3.3 Dimensions UltraOil®(65,80).............................................................................................................................................18
3.4 Space requirements UltraOil®(65,80) ...............................................................................................................................19
3.5 Opening dimension UltraOil®(65,80) ................................................................................................................................20
4. Installation
4.1 Boiler room requirements .................................................................................................................................................21
4.2 Flue connection and chimney...........................................................................................................................................21
4.2.1 Exhaust gas flues permitted by Building Regulations.......................................................................................................22
4.2.2 Example of an exhaust gas flue ......................................................................................................................................22
4.2.3 Projecting instructions.....................................................................................................................................................22
4.2.4 Dimensioning flue gas system.........................................................................................................................................23
4.2.5 Fuel ................................................................................................................................................................................23
4.3 Electrical connection.........................................................................................................................................................24
4.3.1 Safety measures relating to EMC assembly ....................................................................................................................26
4.3.2 Recommended cable cross sections and permissible maximum length of cable ..............................................................28
4.4 Flue gas - output diagram .................................................................................................................................................29
4.5 Hydraulic integration.........................................................................................................................................................30
4.6 Condensate discharge ......................................................................................................................................................30
4.7 Setting the temperature controller....................................................................................................................................30
4.8 Safety valves......................................................................................................................................................................30
4.9 Loading pump (boiler with water heater)..........................................................................................................................30
4.10 Heating pump.....................................................................................................................................................................30
5. Commissioning
5.1 Water quality in heating systems......................................................................................................................................31
5.1.1 Heating Water.................................................................................................................................................................31
5.1.2 Filling and replacement water .........................................................................................................................................31
5.2 Filling the heating circuit ..................................................................................................................................................33
5.3 Filling the water heater (if fitted) ......................................................................................................................................33
5.4 Commissioning..................................................................................................................................................................33
5.5 Oil burner...........................................................................................................................................................................33
5.6 Handover to the operator / storage...................................................................................................................................33
5.7 Record - Activation of screed function.............................................................................................................................34
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TABLE OF CONTENTS
6. Maintenance
6.1 Information for combustion controller/chimney sweep regarding emission monitor key .............................................36
6.2 Safety temperature limiter - Reset ....................................................................................................................................37
6.3 Renewing fuse ...................................................................................................................................................................38
6.4 Cleaning the boiler and leakage test ................................................................................................................................38
6.4.1 Preparation for cleaning the boiler and burners...............................................................................................................38
6.4.2 Boiler assembly ..............................................................................................................................................................39
6.4.3 Cleaning the boiler room.................................................................................................................................................39
6.4.4 Cleaning the combustion chamber and the aluFer®pipes ................................................................................................41
6.5 Servicing the neutralisation installation for types 23 and 24 (if fitted)...........................................................................42
6.5.1 Procedure for servicing the neutralisation installation......................................................................................................42
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1. Important instructions
1.1 Other instructions
You will nd all instructions relevant for your installation
collated in the Hoval installation manual! In exceptional
cases, the instructions are to be found with the compo-
nents!
Further sources of information:
- Hoval catalogue
- Standards, regulations
1.2 Safety precautions
The installation may only be put into operation if all rel-
evant standards and safety regulations have been com-
plied with. However, for a trial operation, the following are
the minimum conditions requiring fullment:
Fig. 1a safety valve has been installed
(closed-circuit installation)
Fig. 2controls in operation (connected to the power sup-
ply)
Fig. 3sensor for the safety temperature limiter is tted in
the submerged sleeve (see section 2.2).
Fig. 4the system is lled with water
Fig. 5an expansion container is attached
Fig. 6exhaust connections connected to the exhaust ue
at the chimney
Fig. 7burner preset
WARNING
The heat generator can only be de-energised
by disconnection from the mains (fuse).
WARNING
All electric power supply circuits must be
switched o󰀨 before accessing the terminals.
1.3 Explanation of the symbols
1.3.1 Warnings
!
DANGER
... indicates a situation of immediate danger
which will lead to serious or fatal injuries if
not avoided.
!
WARNING
... indicates a situation of possible danger
which can lead to serious or fatal injuries if
not avoided.
!
CAUTION
... indicates a situation of possible danger
which can lead to minor or slight injuries if
not avoided.
NOTICE
... indicates a situation of possible danger
which can lead to damage to property if not
avoided.
1.3.2 Warning symbols
The following warning signs are combined for the warn-
ing notes with signal words CAUTION, WARNING and
DANGER.
!
General warning symbols
Warning of electrical voltage
Warning of cutting injuries
1.3.3 Information
Information:
Provides important information.
§
Provides important information.
Refers to standards and directives.
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IMPORTANT INSTRUCTIONS

5
1.4 Regulations, official approvals
For installation and operation of the system, the following
regulations are to be observed:
Germany
• DIN EN 12831 Heating systems in buildings – proce-
dure for calculating the standard heating load.
• DIN EN 12828 Heating systems in buildings - planning
of hot water systems.
• DIN EN 13384 Exhaust gas systems – thermal and uid
dynamic calculation methods.
• DIN 4755 Oil-red systems: design, construction and
technical safety requirements.
• DIN 4756 Gas-red systems: design, construction and
technical safety requirements, planning and execution
(for operation with gas burners).
• DIN 18160 House chimneys, requirements, planning
and execution.
• PED (Pressure Equipment Directive).
• TRD 721 Safety equipment to safeguard against ex-
cess pressures / safety valves / for group II steam boil-
ers.
• VDI 2035 Prevention of damage by corrosion and the
formation of scale in hot water systems.
• DIN 57 116 / VDI 0116 Electrical equipment for ring
systems (VDE regulation).
Austria
• ÖNorm (Austrian standard) B 8130 Open hot water sys-
tems, safety installations.
• ÖNorm B 8131 Closed-circuit hot water systems, safe-
ty, construction and testing regulations.
• ÖNorm B 8133 Water heating systems, technical safety
requirements.
• ÖNorm B 8136 Heating systems, space requirements
and other building requirements.
• ÖNorm EN 12831 Heating installations in buildings –
procedure for calculating the standard heating load.
• ÖNorm EN 12828 Heating systems in buildings: plan-
ning of hot water heating systems.
• ÖNorm EN 13384 Exhaust gas systems – procedure
for heat and technical gasow calculations.
• ÖNorm M 7515 Calculation of chimney dimensions;
denition of expressions, calculation procedures.
• ÖNorm H 5171 Heating systems – technical building
requirements.
• ÖVGW TR gas.
Switzerland
• VKF-Association of Cantonal Fire Insurers.
• Regulations of the re police.
• SN (Swiss standard) EN 12831 Heating installations in
buildings – procedure for calculating the standard heat-
ing load.
• SN EN 12828 Heating systems in buildings - planning
of hot water heating systems.
• SN EN 13384 Exhaust gas systems - procedure for
heat and technical gasow calculations.
• 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 in-
stallations.
• KRW Corrosion caused by halides.
• KRW/VSO/FKR Electrical connections on heating boil-
ers 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 leg-
islature.
In a similar manner, the regulations of the local building
authorities, insurers and chimney inspectors must be tak-
en into account. When gas is used as fuel, the regulations
of the responsible gasworks must be observed and an
o󰀩cial authorisation may also be required.
1.5 Guarantee
Trouble-free functionality is only guaranteed when both
these and the operating instructions are meticulously ob-
served and the boiler is regularly serviced by a qualied
engineer (maintenance contract). Repair of faults and
damage caused by contaminated operating materials
(gas, water, combustion air), unsuitable chemical addi-
tives in the heating water, careless treatment, faulty in-
stallation, unauthorised modications and damage as a
result of force are not subject to our guarantee liability;
this applies also to corrosion caused by halides, e.g. em-
anating from spray canisters, paints and varnishes, adhe-
sives, solvents and cleaning agents.
4 213 787 / 01
IMPORTANT INSTRUCTIONS