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.
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IMPORTANT INSTRUCTIONS

6
2. Assembly
2.1 Installation, levelling
A special foundation plate for the boiler is not an essen-
tial, but it is recommended.
Space required
the ange of the boiler must be able to be swung out fully,
with burner installed (see chapter 3.3).
CAUTION
Electric wires must not be permitted
to touch any hot parts!
Fig. 01
Installing the boiler
Fig. 1Remove the two upper bolts (1) at the foot (1a) of
the boiler.
Fig. 2Take o󰀨 the transverse timber beam at the front.
Fig. 3Use a winch (2) to lift the front of the boiler.
Fig. 4Take away the side beams (3) at the front sideways
(see Fig. 01). Fit the forward feet and bolt them into
place.
Fig. 5Use the winch (2) to lift the rear of the boiler.
Fig. 6Take away the side beams (3) at the rear sideways
(see Fig. 01). Fit the rear feet and bolt them into place.
Only to be observed if neutralisation is required:
Setting the height of the feet is carried out af
-
ter installation of the neutralisation tting
3
1a
1
2
Lifting eyes for crane hooks
a
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ASSEMBLY

7
2.2 Assembly of the heat insulation
Place the insulating mat (1, Fig. 02) around the UltraOil®
and x with plastic straps (1a) and strap fasteners (1b).
• as additional xings, tension springs can also be used
(1c)
• pull the straps tightly
1
1a
1b
1c
Fig. 02
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8
2.3 Assembly of the panelling
Fig. 1Attach the cable channels (2, Fig. 06) left and right
to the pins and x with the central hexagon nuts and
washers (3a) already mounted to the boiler.
Fig. 2Attach the side walls (4, Fig. 06) to the boiler and
x with the hexagon nuts and washers (4a) already
mounted to the boiler. Hook the side wall side onto
the screw head on the condensate drip tray at the
bot tom. Align the side walls centrally. Adjust the free
space for electrical box and rear wall. Then tighten
the hexag on nuts (4a).
Fig. 3Attach rear wall (terminal plate 5, Fig. 07) of the ter-
minal box using the 4 screws (5a).
Fig. 4Remove stud (6, Fig. 07) on the left or right. Hook
the terminal box (6a) in at the bottom, on the side
where the stud is located. Hold the terminal box in
horizontal position and tighten in position with the
second stud on the opposite side. Fold the terminal
box shut towards the top and hook it in.
Fig. 5Fit trim strips (7, Fig. 08)
- open terminal box to t the top screw (7a, Fig. 09)
- close terminal box again to t the bottom screw (7b,
Fig. 08)
Fig. 6Route cables and establish plug-in connections
(wiring in accordance with Fig. 11). Insert capillaries
with the immersion sensors (4a, Fig. 11) into the im-
mersion sleeve (4b, Fig. 10) and attach using retain-
ing spring (4c, Fig. 10). Route capillary of the ue gas
safety temperature limiter (4d, Fig. 11) to the rear, to
the ue gas pipe. Drill a hole of Ø 11.5 mm in the ue
gas con duit (on-site) and attach the sensor of the ue
gas safety temperature limiter using a Viton plug.
CAUTION
Make sure that the cable does
not touch any hot locations!
Fig. 7Drill a hole in the ue gas pipe (on site; 1, Fig. 03)
- Ø 11.5 mm,for a thin-walled steel pipe
- Ø 12.5 mm for a thick-walled pipe, e.g. made of plastic
12
Fig. 03
Fig. 8Fit the rubber stopper (2, Fig. 03) into the hole.
Fig. 04
Fig. 9Coat the sensor element with assembly lubricant
and insert the pressed part into the rubber stopper.
Fig. 05
Fig. 10Attach the lower rear wall (8, Fig. 11) to the side
walls. Mutually attach the rear walls (8a, 8b) and en-
gage together at the side walls.
Fit the burner before installing the absorber
hood, see chapter 2.6
Fig. 11Fit top side walls (9a, 9b, Fig. 11). Position the
lower edge of the top side walls (longitudinal bore
hole) on the special screws of the bottom side walls
and slide them in. Attach top side walls using 4 self-
tapping screws (9c) ø 3.5 x 10.
Fig. 12Attach upper rear walls (10, Fig. 11)
Fig. 13Put on cover plates (11, Fig. 11). Fit top front (11a),
position pins in slots and slide towards the rear. (When
removing, lift rst one side, then the other side).
Fig. 14Hook the front cover in (12, Fig. 11) at the bottom
and slide shut at the top. Attach with lateral locking
bolt (12a) (turn approx. ¼ turn to the right).
Fig. 15The remaining 3 casing walls (14, 14a, 15, Fig. 13)
are attached after mounting the condensate boxes.
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ASSEMBLY

9
!
WARNING
Secure service platform (7c, Fig. 08) in fold-
ed-up position using bolt (7a, Fig. 09)!
3a 244a 4a
Illustrated without burner
Fig. 06
5a
6
6a
Fig. 07
Fig. 08
Fig. 09
5
7b
7
7c
7a
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10
Neutralisation box
(if tted)
2 sensors
2
4a
Fig. 10
Fig. 11
4b
12
4c
9a
11a
12a
11 10
8a 8b
9b
89c
4d
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11
2.4 Assembly of the plinth panelling
Fit the syphon supplied separately (13, Fig. 12).
Fig. 1Place the condensate box (option) under the boiler
and make the electrical connections. Create connec-
tion between siphon and condensate box.
13
Fig. 12
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ASSEMBLY

12
Fig. 2Use the cap nuts already tted to bolt on the right
and left side walls (14, 14a, Fig. 13) to the base of
the boiler.
Fig. 3Hang the front (15) on the side walls (14, 14a).
14
14a
15
Fig. 13
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13
2.5 Installation of the flue gas orifice
The ue gas orice supplied with the boiler
must always be installed in the ue gas con
-
nector of the UltraOil®.
Fig. 4Place the ue gas orice in the ue gas connec-
tor so that the recesses at the bottom of the ue gas
orice are positioned on the lugs of the ue gas con-
nector.
Flue gas connector without ue gas orice Flue gas connector with built-in ue gas orice
Lug
Fig. 14
Recesses at the bottom of the ue gas orice
Fig. 15
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ASSEMBLY

14
2.6 Burner assembly
Fig. 1Remove front cover (1, Fig. 16), after rst 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.
Fig. 2Lift and remove the lid (2).
Fig. 3Remove the locking screw (3) on the left and right.
Fig. 4Lift the side walls (4), by sliding them slightly to-
wards the front.
2
4
3
1
1a
4
Fig. 16
Fig. 5Remove the burner from the packaging.
Fig. 6Dismount the burner ange. To do so, loosen the
screw (3, Fig. 17) and rotate the burner by 15°. The
required Allen key (2) is supplied with the burner.
23
Fig. 17
Fig. 7Mount the burner ange including sealing to the
boiler ange in accordance with Fig. 18. Mount the
ange so that the “Warning” label is facing outwards.
Tip to help assembly:
To simplify installation, the sealing on the burner ange
can be lubricated using a heat-resistant paste (e.g. Klu-
berpaste UH1 84-201).
“Warning” label
Fig. 18
Fig. 8Insert the burner rotated by 15° (nal position: burn-
er performance label facing outwards) into the burner
ange. Once the stop position has been reached, ro-
tate by 15° so that the extension piece ts beneath
the head of the screw (Fig. 19 and Fig. 20).
Fig. 19
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ASSEMBLY

15
Head of screw
Fig. 20
Fig. 9Tighten the screw (3, Fig. 17) to secure the burner.
Fig. 10Insulate the cavity between burner pipe and boiler
door with the reproof bre provided (Fig. 21).
- the reproof bre is packed rmly into the space in
order to prevent it falling out (Fig. 21).
NOTICE
The circulating air-vents must not be covered.
Fireproof bre
Fig. 21
Fig. 11Close the boiler ange with the burner once again.
Fig. 12The oil feeds may be taken through the side open-
ings either on the right or the left.
Fig. 13Make plug-and-socket connections (4, Fig. 23).
Pull the plug cable further out, to do this, loosen the
PG unions (7,8 Fig. 22).
- 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.
78Fig. 22
Cable outlet
to the left
Cable outlet
to the right
4
Fig. 23
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16
3. Technical details
3.1 Description of the boiler
The Hoval UltraOil® is a low-pollutant, energy-saving oil-
red heating boiler. The UltraOil® has a combustion cham-
ber arranged vertically fabricated from rustless stainless
steel as its primary heating surface and a secondary heat-
ing surface of a corrosion-resistant aluminium alloy. The
secondary heating surface is so designed that the water
vapour contained in the heating gas condenses and the
heat of evaporation is utilised for the heating circuit. The
UltraOil® is designed for operation with low-sulphur heat-
ing oil EL.
The UltraOil®
corresponds with the standards
and guidelines listed in the EU declaration of
conformity. The EU declaration of conformity
belonging to the product is found in the sys
-
tem book.
Installation of low water level protection on the
UltraOil® (65,80) is not necessary.
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17
3.2 Technical details
Type (65) (80)
•Nominal output 80/60 °C kW 62 77
•Nominal output 40/30 °C kW 65 80
•Range of output 80/60 °C kW 38-62 48-77
•Range of output 40/30 °C kW 41-65 52-80
•Heat input kW 39-63 50-78
Dimensions see dimensions
•Boiler operating temperature max. °C 90 90
•Boiler operating temperature min. °C no min. limit
•Return ow temperature min. °C no min. limit
•Flue gas temperature min. at the boiler °C no min. limit
•Safety temperature limiter setting (water side) °C 110 110
•Operating / test pressure bar 3.0/4.5 3.0/4.5
•Boiler e󰀩ciency at 80/60 °C in full-load operation
(net caloric value NCV / gross caloric value GCV) %98.5/92.9 98.4/92.6
•Boiler e󰀩ciency at 40/30 °C in full-load operation
(net caloric value NCV / gross caloric value GCV) %103.5/97.6 103.2/97.4
•Boiler e󰀩ciency at 30 % partial load (EN 303)
(net caloric value NCV / gross caloric value GCV) %104.5/98.6 104.2/98.3
•Stand-by deciency qB at 70 °C Watt 480 480
•Energie e󰀩ciency class
- without control ηs %94 94
- with control ηs %96 96
- with control and room sensor ηs %98 98
•Resistance on the heating gas side at nominal output
12,5 % CO2, 500 above sea level (tolerance +/- 20 %)
mbar 0.18 0.26
• Flow resistance boiler 1) z value 1.50 1.50
•Water resistance at 10 K mbar 46.9 71.4
at 20 K mbar 11.7 17.9
•Water ow volume at 10 K m3/h 5.6 6.9
at 20 K m3/h 2.80 3.45
•Boiler water capacity litres 135 135
•Boiler gas volume m30.18 0.18
•Insulation thickness boiler body mm 80 80
•Weight (incl. casing. burner) kg 360 360
•Weight of transport kg 317 317
•Electrical power consumption min./max. Watt 109/262 123/262
•Standby Watt 6 6
• Type of protection 2) IP 20 20
Acoustic power level incl. sound attenuation cowl
•Ambient air dependent
- Heating noise (EN 15036 part 1) dB(A) 69 65
•Ambient air independent
- Heating noise (EN 15036 part 1) dB(A) - -
- Aspiration noise is radiated from the mouth (DIN 45835) dB(A) - -
- Aspiration /exhaust noise - LAS - is radiated from the mouth (DIN 45835) 3) dB(A) - -
•Ambient air dependent and ambient air independent
- Exhaust noise in the pipe (EN 15036 part 2) 3) dB(A) 91 95
- Exhaust noise is radiated from the mouth (DIN 45635 Teil 47) 3) dB(A) 75 76
•Condensate rate (heating oil EL) at 40/30 °C l/h 4.0 5.0
•pH-value of the condensate approx. 3.2 3.2
•Construction type B23
•Flue gas system
- Temperature class T120 T120
- Flue gas mass ow at nominal output 12.5 % CO2heating oil EL kg/h 102 126
- Flue gas temperature at nominal output 80/60 °C °C 73 75
- Maximum supply pressure for supply air and flue gas line 4) Pa 50 50
- Maximum draught / underpressure at ue gas outlet Pa -20 -20
•Combustion chamber dimensions Ø inside x length mm 524 x 600 524 x 600
•Combustion chamber volume m30.129 0.129
1) Flow resistance boiler in mbar = Volume ow (m3/h)2 x z factor
2) Indication relates to protection against contact with dangerous components
3) UltraOil® (50): Sound absorber integrated
UltraOil® (16,20,25,35,65,80): Data without sound absorber. Reduction by installation of a sound absorber possible.
4) For dimensions of the ue gas line, see the heading “Flue gas line system”
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TECHNICAL DETAILS

18
3.3 Dimensions UltraOil®(65,80)
(All dimensions in mm)
Fig. 24
1Safety ow R1½"
2Flow heating/calorier R1½"
3Return ow, high temperature R1½"
4Return ow, low temperature R1½"
5Draining ½"
6Flue gas outlet inner Ø 155 mm
7Cleaning aperture Ø 155 mm
8 Condensate drain incl. syphon DN25
9 Control panel
10 Electric cable infeed
11 Boiler feet adjustable 20-80 mm
12 Lead-through for oil pipe on left or right side
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19
3.4 Space requirements UltraOil®(65,80)
(All dimensions in mm)
Fig. 25
- It must be possible to swing open the hinged door of
the boiler with the burner upward and rearward.
- The cleaning aperture must be easy to access.
- Boiler rear side must be accessible.
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20
3.5 Opening dimension UltraOil®(65,80)
(All dimensions in mm)
Boiler without casing and insulation
Fig. 26
Required min. width of door and corridor
to bring in the boiler.
The following values are the calculated minimum values.
150
K
L
B
T
B
K = x L
T
B
T = x L
K
Fig. 27
T = Door width
K = Corridor width
B = Boiler width
L = Max. length of boiler
Calculation example for the necessary corridor width
Door width T = 800
680
UltraOil® (65,80) K = ----- × 1072 = Corridor width ≥ 912
800
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TECHNICAL DETAILS