Hoval Uno-3 95 Manual

Subject to modi cations | EN
Technical information
Assembly instructions
4 205 116 / 02 - 02/14
Hoval products must be installed and commissioned only
by appropriately qualied experts. These instructions
are intended exclusively for the specialist. Electrical
installations may only be carried out by a qualied
electrician.
Uno-3 (95-125) boilers are suitable and licensed for
use as heat generators for hot water heating systems
with a permissible ow temperature of up to 100 °C1).
They are designed for closed-circuit systems, but can
also be installed in open systems as per EN 12828.
1) See technical data
Uno-3 (95-125)
Oil/gas boilers
These instructions are applicable to the
following types:
7-Uno-3 (95,110,125)
7-Uno-3 b-i* (95,110,125)
* = Burner integrated

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4 205 116 / 02
Table of Contents
1 Important information
1.1 Other instructions................................................................................................................................... 3
1.2 Safety information................................................................................................................................... 3
1.3 Regulations, official approvals .............................................................................................................. 3
1.4 Guarantee ................................................................................................................................................ 4
2. Installation
2.1 Setting up, levelling ................................................................................................................................ 5
2.2 Fitting the heat insulation ...................................................................................................................... 6
2.3 Fitting the casing .................................................................................................................................... 8
3 Technical information
3.1 Description of the boiler....................................................................................................................... 10
3.1.1 The Uno-3 (95-125) complies with the following directives + standards ................................................ 10
3.2 Technical data Uno-3 (95-110) for Switzerland................................................................................... 11
3.3 Technical data Uno-3 (110,125) for all other countries...................................................................... 12
3.4 Dimensions............................................................................................................................................ 13
3.5 Dimensions without heat insulation and casing (transport dimensions)........................................ 13
4. Installation
4.1 Boiler room requirements .................................................................................................................... 14
4.2 Connection of the flue gas system and flue duct dimensions ......................................................... 14
4.3 Fitting the burner .................................................................................................................................. 16
4.3.1 Sound insulation...................................................................................................................................... 16
4.4 Fuel......................................................................................................................................................... 17
4.5 Electrical connection............................................................................................................................ 17
4.5.1 Electrical connection of the burner.......................................................................................................... 17
4.6 Flue gas regulator set........................................................................................................................... 17
4.6.1 Flue gas and performance diagrams ...................................................................................................... 18
4.7 Flow mixing loop / minimum limitation of the boiler return temperature ........................................ 19
4.8 Setting the temperature regulators ..................................................................................................... 19
4.9 Safety valves ......................................................................................................................................... 19
4.10 Charging pump (boiler with free-standing calorifier) ........................................................................ 19
4.11 Heating pump ........................................................................................................................................ 19
5. Commissioning
5.1 Water quality.......................................................................................................................................... 20
Heating water.......................................................................................................................................... 20
Filling and replacement water ................................................................................................................. 20
5.2 Filling the heating system .................................................................................................................... 21
5.3 Filling the calorifier (if present) ........................................................................................................... 21
5.4 Commissioning ..................................................................................................................................... 21
5.5 Oil/gas burner........................................................................................................................................ 21
5.6 Handover to the operator / storage ..................................................................................................... 21
6. Maintenance
6.1 Information for fire inspector / chimney sweep regarding emission monitor key.......................... 22
6.2 Cleaning................................................................................................................................................. 23
6.2.1 Preparatory work..................................................................................................................................... 23
6.2.2 Cleaning (dry or wet method).................................................................................................................. 23
6.2.3 Putting into operation again .................................................................................................................... 23
7. Overview of settings
7.1 Table of parameters .............................................................................................................................. 24
7.2 Overview of alarms TopTronic®T.......................................................................................................... 34

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4 205 116 / 02 Important notes
1 Important information
1.1 Other instructions
All instructions relevant to your system can be found
in the Hoval system manual! In exceptional cases,
the instructions can be found enclosed with the
components.
Further information sources
- Hoval catalogue
- Standards, regulations
1.2 Safety information
The system may only be placed in operation if all the
relevant standards and safety regulations have been
complied with. At least the following conditions must
be satisfied for a trial operation:
1. Safety valve installed (closed system).
2. Controlinoperation(connectedto themainscurrent
supply system).
3. Sensor for the safety temperature limiter mounted
in the immersion sleeve.
4. System filled with water.
5. Expansion vessel connected.
6. Flue gas connectors connected to the flue gas
pipeline at the chimney or flue.
7. An adequate supply of fresh air must be guaranteed.
8. The burner is preset.
1.3 Regulations, official approvals
The following regulations are to be complied with for
installation and operation:
Germany
- DIN EN 12831 Heating systems in buildings –
Method for calculation of the design heat load.
- EN303Heating boilerswithforceddraughtburners.
- DIN EN 12828 Sheet 1 and 2
Heating systems in buildings – design of water-
based heating systems.
- DIN 4755 Oil-fired systems.
Design, construction and safety engineering
requirements.
- DIN 4756 Gas-fired systems; construction,
execution,technicalsafety requirements,planning
and execution.
- DIN18160 House chimneys;requirements,planning
and execution.
- TRD 702 Steam boiler plants with calorifiers of
the group II.
- DIN EN 13384 Chimneys – Thermal and fluid
dynamic calculation methods.
- TRD721 Safetydevicesagainst excesspressures/
safety valves / for steam boilers of Group II.
- VDI 2035 Prevention of damage by corrosion and
theformation ofscale in hot waterheating systems.
- DIN 57 116 / VDI 0116 Electrical equipment for
firing systems (VDE Regulation).
- For further standards applicable in Germany, see
appendix N-430 020.
Austria
- ÖNorm 7550
- ÖNorm B 8130 Open water heating systems;
safety devices.
- NormB8131 Closed waterheating systems;safety,
execution and testing requirements.
- ÖNorm B 8133 Hot water production systems;
technical safety requirements.
- ÖNormB 8136 Heatingsystems,spacerequirements
and other building requirements.
- ÖNorm M 7515 Calculations of dimensions of
chimneys; terminology, calculation procedure.
- ÖNorm H 5171 Heating systems, construction
engineering requirements.
- ÖVGW TR-Gas G1 Technical directives for low
pressure gas installations.
- ÖNorm M 7445 Gas blower burner.
Switzerland
- Requirements of theVKF Cantonal Fire Insurance
Association.
- Fire brigade regulations.
- Requirements of the SVGW Swiss Association of
Gas and Water Suppliers.
- SWKI 91-1 Aeration and ventilation of the boiler
installation room.
- SWKI 88-4Water treatment for heating, steam and
air conditioning systems.
- SWKI 93-1 Safety engineering installations for
heating systems.
- KRW Corrosion through halogen compounds.
- KRW/VSO/FKR Plug-in electrical connections on
heating boilers and burners
and further regulations and standards issued by
CEN, CEN ELEC, DIN, VDE, DVGW, TRD and the
legislative body.
Also to be complied with are the regulations of the local
buildingauthorities,insurancecompanies andchimney
sweepingoperations.Theregulations of theresponsible
gas supply company are also to be complied with and
any necessary official approval obtained.

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4 205 116 / 02
Important notes
1.4 Guarantee
Proper function is only guaranteed providing these
instructions are followed and the boiler is regularly
maintained by a licensed specialist. (Maintenance
contract). The rectification of faults and damage
as a result of contaminated operating materials
(gas, water, combustion air), unsuitable chemical
additives and an inadmissibly high lime content of the
heating water, improper handling, faulty installation,
unauthorised modifications anddamageduetothe use
offorcedo notfallunder our guarantee obligations,this
also applies to corrosion due to halogen compounds,
e.g.from spray cans, paints, adhesives, halogenated
fluids, solvents and cleanings agents.

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4 205 116 / 02 Installation
1. Pull up the semicircular rivet (1).
2. Change over the swivel arm (2).
3. Insert the semicircular rivet (1) on the other side.
4. Fit the burner plug and the fire protection switch
(if fitted, Austrian version) on the other side
(see point 2.3, item 9 and point 4.5.1).
The cable must not touch any hot
parts!
Levelling
Using a spirit level, align the upper edge of the
boiler water jacket (longitudinal axis of the boiler)
until it is precisely horizontal or sloping very slightly
upwards towards the rear by inserting the plinth
rails correspondingly, to allow the boiler to vent
properly.
Before fitting the burner, first fit the double
door (Pos. 8b, Figure 7) (door casing).
2. Installation
2.1 Setting up, levelling
A special foundation plate for the boiler is not an
essential, but it is recommended.
Space requirement
for mounting the thermal insulation and sheet metal
cladding:
at least 40 cm each on the left and right side of
the boiler.
If the space between the boiler and the wall is less,
all heat insulation and casing must be fitted before
the boiler can be pushed into its final position.
Do not connect lines until the heat insulation
and casing have been fitted to the boiler!
There must always be enough space between
the back of the boiler and the wall to allow
easy access to the cleaning aperture in the
flue gas collector.
There must be enough space to swing open the
boiler door, incl. the burner.
Do not overtighten boiler door screws.
Fig. 2
1
2
Boiler door pivotable to the left
It is possible to change the attachment of the boiler
door so that it opens towards the left. This can be of
advantage when installing the boiler in a corner.
Proceed as follows:
Close the boiler door and lock it in position
before changing the attachment of the door.

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4 205 116 / 02
Installation
Fig. 3a
See separate assembly instructions for boilers with mounted calorifier 2.2 Fitting the heat insulation 1. Mount the front retaining bracket (1) with hexagon screws M8, nuts and U-washers, aligned horizontally, to the front wall of the boiler. - Attach C-clips. 2. Mount the rear retaining bracket (2) with hexagon screws M8, nuts and U-washers aligned horizontally. - Attach C-clips. 3. Place the insulation mat (3) around the boiler body (with the joint at the top, black side facing outwards, see Figure 3). 4. Attach the insulation mat (3) using 2 plastic straps (4) and strap fasteners (4a): - Tension springs (4b) serve for additional fixing - Do not overtighten the straps (reduced insulating value) 5. Attach the insulation mats (5/5a/5b) to the pins provided on the rear wall of the boiler and secure with retaining discs, Fig. 4a (ø 38). 6. Attach insulation panels (6/6a/6b/6c) to the pins welded onto the flue gas collector and secure with the retaining discs (ø 38) provided. 7. Attach insulation panel (7) to the pins welded onto the front wall of the boiler and secure with the retaining discs (ø 38) provided, Fig. 3a. The remaining 3 insulation mats (8a,10) are fitted after mounting the casing.

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4 205 116 / 02 Installation
Figure 3
7
4a
6a
6c
5
5a
3
4b
C-clips
1
6b
6
2
4
5b
C-clips

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4 205 116 / 02
Installation
2.3 Fitting the casing 8. Fix hexagon bolts with U-washers and hexagon nuts (8). Insert thermal insulation (8a) into the boiler door. Attach the door casing (8b) to the boiler
door using hexagon cap nut.
9. Attach the burner cable (9) to the right or left side wall (9a) (Fig. 4). See also point 4.5.1 Attach right and left side wall (9a) onto the front retaining brackets (1) and rear retaining brackets (2) with self-tapping screws ø 4.8 x 38 and pull
the burner cable upwards.
The cable must not touch any hot parts 10. Place 2 insulating mats (10) left and right in longitudinal direction (to prevent vertical air circulation). 11. Attach rear wall (11/11a) to the angled edges of the side walls (9a) with self-tapping screws ø 3.5 x 6.5. 2.4 Installation of boiler controller 12. Mount the special screw with nut (12, Fig. 5) on the cover plate (12a).Then place switch control box (12b) on the casing cover (12a) with the recess
for the special screw, push back and secure with self-tapping screws ø 3.5 x 6.5 and serrated washers (12c). Position cladding cover (12a, Fig. 7) and fix on the side walls with 2 self-tapping screws ø 4.8 x 12 and C-clips.
13. Pull the capillaries with the immersion sensors (13, Fig. 6) through the opening (13a, Fig. 5) in the cover, insert them into the immersion sleeve
(13b, Fig. 7) as far as the stop and fix in position with retaining spring (13c, Fig. 6).
Attention: The capillaries must not be folded or kinked! 14. Attach cover plate (14) with self-tapping screws ø 3.5 x 6.5 and serrated washers. 15. Position cladding cover (15) and fix left and right with 2 self-tapping screws ø 4.8 x 13. 16. Affix labels and where applicable, mount manual holder on the side.
Figure 4
9
13c Figure 6
12a
13a
12b
12
Figure 5
12c
13a
13

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4 205 116 / 02 Installation
Figure 7
15
8a
8b
9a
8
9a
13b
14
10
12a
11a
11

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4 205 116 / 02
Technical information
to the turning chamber, from where they flow through
rectangularducts(thermolyticheatingsurface)towards
the rear and reach the flue gas collector.
The flue gas temperatures can be varied within
a specific range through the installation of various
regulator combinations.
3 Technical information
3.1 Description of the boiler
The Uno-3 is a threepass boiler. At the end of the
circular cylindrical combustion chamber, the flame
gases flow through several cylindrical tubes arranged
above the combustion chamber and towards the front
Figure 8
3.1.1 The Uno-3 (95-125) complies with the following directives + standards
We hereby declare that the product described, as an individual appliance, complies with the standards,
guidelines and technical specifications laid down.
Directives: 90/396/EC "Gas Equipment Directive"
92/42/EC "Efficiency directive"
73/23/EEC "Low-voltage directive"
89/336/EEC "Electromagnetic compatibility"
97/23/EC "Pressure Equipment Directive" (PED)
Regulations: Stability prEN14394:2001
Building requirements EN303-1, EN303-2, EN303-3
Low voltage DIN VDE 0722 / Ed. 04.83
EMC EN 50082 Part 1 / Ed. 01.92