Hoval BIC 960 Reference guide

Subject to modi cations | EN
Instructions for customer
service engineers
4 205 503 / 14 - 10/15
Modications to the automatic gas ring device should
only be performed by authorised persons. This manual
is therefore intended for use by qualied engineers.
These instructions apply to the following
types:
UltraGas®
10/20/21/30/40/41-UltraGas®(15)
10/20/21/30/40/41-UltraGas®(20)
10/20/21/30/40/41-UltraGas®(27)
10/20/21/30/40/41-UltraGas®(35)
10/20/21/30/40/41-UltraGas®(50)
10/20/30/41-UltraGas®(70)
10/20/30-UltraGas®(90)
30/41-UltraGas®(100)
10/11/20/21/30/41-UltraGas®(125)
10/11/20/21/30/41-UltraGas®(150)
10/11/20/21/30/41-UltraGas®(200)
10/11/20/21/30/41-UltraGas®(250)
10/11/20/21/30/41-UltraGas®(300)
10/11/20/21/30/41-UltraGas®(350)
10/11/20/21/30/31/41-UltraGas®(400)
10/11/20/21/30/31/41-UltraGas®(450)
10/11/20/21/30/31/41-UltraGas®(500)
11/20/21/30/31/41-UltraGas®(575)
10/11/20/21/30/31/41-UltraGas®(650)
11/20/21/30/31/41-UltraGas®(720)
21/30/41-UltraGas®(850)
21/30/41-UltraGas®(1000)
CompactGas®
1-CompactGas®(200-280)
Automatic gas firing device BIC 960
TopTronic® T / TopTronic®E
UltraGas®(15-1000)
CompactGas®(200-280)

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TABLE OF CONTENTS
1. Overview.................................................................................................................................................. 3
2. Description of functions ......................................................................................................................... 4
2.1 General.................................................................................................................................................................................4
2.2 Water heater-Charging ........................................................................................................................................................4
2.3 Emission measuring and/or test function for gas valve setting........................................................................................4
2.4 Main switch..........................................................................................................................................................................4
2.5 Main gas valve (possibly LPG-valve) / heating room fan...................................................................................................4
2.6 External burner switch ........................................................................................................................................................4
2.7 Short description of the functions of the BIC 960 automatic firing device.......................................................................5
2.8 Access to the automatic firing device ................................................................................................................................6
2.9 Reference values in the case of bus interruption ..............................................................................................................6
3. Description of the parameters................................................................................................................ 6
4. Sensor characteristic curves................................................................................................................ 12
5. Display of information via the automatic firing device ....................................................................... 13
6. Monitoring of warnings and/or faults................................................................................................... 14
7. Operation using a laptop ...................................................................................................................... 16
8. Interfaces to BIC 960............................................................................................................................. 16
9. Connections to the BIC960................................................................................................................... 17
10. NTC Protection...................................................................................................................................... 18
11. Frost protection .................................................................................................................................... 19
12. Water pressure...................................................................................................................................... 19
13. Automatic firing unit BIC 960 - Parameter lists ................................................................................... 20
13.1 Generation overview (boiler).............................................................................................................................................20
13.2 Generation overview (automatic gas firing device) .........................................................................................................22
13.3 10/20 - UG (15-90) ..............................................................................................................................................................23
13.4 21 - UG (15-50) ...................................................................................................................................................................25
13.5 30 - UG (15-90) ...................................................................................................................................................................27
13.6 40/41 - UG (15-90) ..............................................................................................................................................................29
13.7 10 - UG (125-300) ...............................................................................................................................................................31
13.8 10 - UG (350-650) ...............................................................................................................................................................33
13.9 11/20/21/30/31/41 - UG (125-400) .......................................................................................................................................35
13.10 11/20/21/30/31/41 - UG (450-1000) .....................................................................................................................................37
13.11 1 - CompactGas®(200-280)................................................................................................................................................39

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OVERVIEW
1. Overview
BIC 960 Automatic gas ring device
with Bus connection to TopTronic®T / TopTronic®E
1........ Gas pressure regulator
2 / 3... Gas valve
4........ Fan
5 / 6... Boiler sensor with two sensor elements
7........ Flue gas sensor (only with UltraGas®)
8........ Ionisation electrode (+ ignition)
9........ Ignition electrode (double ignition)
10...... Water pressure sensor
123
P
4
5 6 8 9
T
7T
10
P

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DESCRIPTION OF FUNCTIONS
2. Description of functions
2.1 General
The BIC 960 automatic ring device is designed for use in a modulating gas boiler. There for a PWM fan is triggered
by the automatic ring device. This fan has a supply voltage of 230V which is shut-off by an internal relay during
downtimes in order to reduce stand-by losses. Fan revolution speed modulation is controlled via an internal PID con-
troller in order to maintain the desired ow temperature. The ow reference value is not determined in the automatic
ring device, but is calculated and passed on via the heating controller.
The BIC 960 automatic ring device can be used in connection with the TopTronic®T/UG heating controller or
TopTronic® E basic module heat generator, why the BIC 960 is installed in the background, i.e. the circuit board is
not visible from the outside, and complete operation is controlled via the heating controller. The result is a unique
principle of operation at boiler level via one interface.
2.2 Water heater-Charging
Switch-over between hot water charging and heating demand is controlled by the heating controller.
2.3 Emission measuring and/or test function for gas valve setting
There is a specic key on the heating control unit allocated for emission measurements and/or gas valve adjustment.
By using the emission key, a mode of operation is initiated in which the automatic ring device operates in heating
mode, with an assigned reference value of 80°C, and in which power output can be adjusted manually using the
rotary button. After 20 minutes emission testing operation is ended automatically, and the boiler reverts to the prior
operation mode. It is important to ensure that the heat produced during emission testing can also be discharged.
When setting boiler performance in terms of percentage values, ensure that 1% is the set minimum performance and
100% is the set maximum performance. In between, there is a linear relationship, on which is it possible to set the
desired boiler performance.
2.4 Main switch
The main switch is located on the front of the heating control unit. It takes care for the power supply of the heating
control unit and of the automatic ring device, located in the background. When the switch is turned off, frost protec-
tion is not active.
2.5 Main gas valve (possibly LPG-valve) / heating room fan
An external main gas valve (possibly a uid gas valve) and/or a heating room fan can be controlled by the automatic
ring device. The output is activated a set time (depending on the parameter settings) before activation of the burner
start. This application requires a suitable parameterisation of the automatic ring device. Ensure that the heat-
ing controller display shows the blocking B:04 (main gas valve) possibly LPG-valve)/ heating room fan) during the
burner start delay. Blocking is no longer shown beginning with BIC 960 V.3, but the waiting time has been retained.
2.6 External burner switch
Locking or activation of the automatic ring device takes place via the heating controller. The parameters must be
set to allow a suitable variable input, as described in the Customer-service technicians introduction to the heating
controller.
A further possibility is provided by blocking input X9-1/X9-4 via which the automatic ring unit can be set to blocked
status. In this case no error message is displayed at the heating controller.

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DESCRIPTION OF FUNCTIONS
2.7 Short description of the functions of the BIC 960 automatic firing device
Since the automatic ring device can only perform in connection with the heating controller, many common functions
are already given via this. The list below contains only those characteristics which are integrated in the automatic
ring device:
- Modulating operating mode
- Combined electrode for ignition and ame monitoring (Ionisation)
- Main gas valve (possibly LPG-valve) and/or heating room fan acitvatable
- Inputs for Flow sensor 1
Flow sensor 2
Flue gas sensor
Water pressure sensor
Safety and limit value thermostat (external exhaust gas temperature switch possible)
Air pressure switch (not used)
Gas pressure switch
- “Alarm” and “Flame monitoring” status outputs
- Additional (external) ignition can be attached
- RS 485- connection to heating controller
- RS 232-connection to PC
- Number of start-up attempts: maximum 4
- Safety time: 5 secs
- Pre-ignition: 5 secs
- Pre-venting: 50 secs
- Pump after-run time (230V AC): 5 min after heating demand
Faults:
If there is a fault, an error code will appear on the display of the heating controller. Pressing the reset button, located
under the hinged cover on the front of the unit, will release the automatic burner, and the boiler will resume opera-
tion, if the fault has been rectied. For more detailed information, see section 7.
Fuses:
The BIC 960 has 3 safety fuses: 2AT Mains
4AT Pump
4AT Burner fan
What happens when the fuses blow
4AT (Pump) Pump fails to start.
4AT (Burner fan) Burner fan fails to start. If a rotation set value has been allocated for the burner fan,
an error message E:18 (“Fan rotation speed below limit”) will appear after a short
period of time, indicating that the fuse has blown.
2AT (Mains) there is no communication between the automatic ring unit and the heating control-
ler. As a result an error message is displayed on the heating controller.

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DESCRIPTION OF THE PARAMETERS
2.8 Access to the automatic firing device
The boiler is operated in the same way as described in the operating instructions of the heating controller. The auto-
matic ring device operating in the background can be accessed using a special menu tree on the heating controller.
This menu allows access to the “BOILER CONTR” or “AUTO M/C” submenu, where it is possible to view an informa-
tion level and a parameter level.
‟INFORMATION”: As well as actual system values, which can be displayed via the Info-key, this option also al-
lows specic state variables to be viewed.
(for further information see “Display of Information from the Automatic Firing Device”)
‟PARAMETER”: Depending on the user level, which can be reached using various code levels, it is possible to
amend certain parameters. If using a Notebook (SITBIC960lab - Software), parameter settings
are also dependant on the code level. (for more information about controlling the automatic
ring device using a laptop, see ‟operating using a laptop”).
Attention: Afteraresetattheheatingcontrollertheparametersattheautomaticgasringdevicewill
 notberesettedtobasicsetting!
2.9 Reference values in the case of bus interruption
If there is an interruption in the bus connection between the heating controller and the automatic ring device, the
automatic ring device begins to operate in emergency mode, which means that a set value of 75°C (parameter 8) is
adopted. In addition, an error message is displayed on the heating controller.
3. Description of the parameters
The parameters can be set using the parameter tree of the heating controller, and also using the SITBIC960lab -
Software on a Notebook. On SITBIC960lab-software, the parameters are not indicated with a number, but with a
number and letter combination, which can be seen below in brackets.
Parameter 1 (2AA/32769): Blocking temperature
The value of the parameter determines at what boiler sensor temperature the burner is switched off.
(“B:08”)
Parameter 2 (2AC/32770): Maximum reference value
The reference value, which is set in manual operation, and/or which is calculated by the TopTronicT®/UG in auto-
matic operation, is here limited to a set value.
Parameter 3 (2AD/32771): Switch-off hysteresis above reference value
If during a heat demand, the temperature rises above the reference value plus the value entered here, the burner
switches off. See functional drawing 1.
Parameter 4 (2AE/32772): Switch-on difference relating to tripping point
When the temperature falls below the reference value + switch-off hysteresis (Parameter 3) – switch-on difference
(Parameter 4), the burner demand is activated. See functional drawing 1.
Temperature °C
Par. 3
Par. 4
Functional drawing 1

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DESCRIPTION OF THE PARAMETERS
Parameter 5 (2AF/32773): Proportional part
The Proportional part in heating operation is a boiler specic value (not plant specic) and must not be changed.
Parameter 6 (2AG/32774): Integral part
The Integral part in heating operation is a boiler specic value (not plant specic) and must not be changed.
Parameter 7 (2AH/32775): Differential part
The Differential part in heating operation is a boiler specic value (not plant specic) and must not be changed.
Parameter 8 (2AI/32776): Reference value when bus-interruption
If there is no bus connection between the automatic ring device and the heating controller, the automatic ring de-
vice adopts the reference value entered here.
Parameter 9 (2AJ/32777): Max. temperature rise at low ow temperature
The temperature gradient dened here can be exceeded, up to the “low” ow temperature set in Parameter 11 (see
functional drawing 2). If this is exceeded, is resulted in a reduction in the number of rotations to the minimum rotation
number.
Parameter 10 (2AK/32778): Max. temperature rise at high ow temperature
The temperature gradient dened here is deemed to be exceeded if it rises above the “high” ow temperature set in
Parameter 12 (see functional drawing 2). If this is exceeded, is resulted in a reduction in the number of rotations to
the minimum rotation number.
Parameter 11 (2AL/32779): “Low” ow temperature
The parameter, necessary for controlling the temperature increase at low ow temperatures, can be assigned a
value here. See functional drawing 2.
Parameter 12 (2AM/32780): “High” ow temperature
The parameter, necessary for controlling the temperature increase at high ow temperatures, can be assigned a
value here. See functional drawing 2.
Linearised area
0
2
4
6
8
10
12
14
16
50 60 70 80 90
Allowable gradient
(°C/sec)
Flow temperature (°C)
Functional drawing 2
Parameter 13 (2BC/32781): Lock-out ue gas temperature
If the ue gas temperature, entered here, is exceeded, the automatic ring device is locked-out (“E:25”).
Parameter 14 (2BD/32782): Blocking ue gas temperature
If the ue gas temperature, entered here, is exceeded, the automatic ring device is blocked (“B:07”).

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DESCRIPTION OF THE PARAMETERS
Parameter 15 (2CA/32783): Gas pressure switch attached
This parameter denes whether or not a gas pressure switch is attached to the boiler.
Parameter 16 (2DA/32784): Water pressure sensor attached
This parameter denes whether or not a water pressure sensor is attached to the boiler.
Parameter 17 (2DB/32785): Water pressure warning
If the water pressure falls below the value set under this parameter, “W:01” appears on the display and the boiler
output reduces to the level set under Parameter 24.
Parameter 18 (2DC/32786): Water pressure hysteresis
The water pressure warning is only lifted, when the water pressure rises to Parameter 17 + Parameter 18.
Parameter 19 (2DD/32787): Blocking pressure min
If water pressure falls below the value set here, the burner switches off. The blocking notication “B:05” is shown on
the display.
Parameter 20 (2DE/32788): Blocking pressure min - hysteresis
Blocking caused by insufcient water pressure is only lifted when the water pressure rises back to Parameter 19 +
Parameter 20.
Parameter 21 (2DF/32789): Blocking pressure max
If water pressure rises above the value set here, the burner switches off. The blocking notication “B:05” is shown on
the display.
Parameter 22 (2DG/32790): Blocking pressure max - hysteresis
Blocking caused by too high water pressure is only lifted when the water pressure falls below Parameter 21 – Pa-
rameter 22.
Parameter 23 (2DH/32791): Lock-out pressure max
If water pressure rises above the value set here, this causes a lock-out. Locking notication “E:16” is shown on the
display.
Parameter 24 (2DI/32792): Max. boiler performance at pressure warning
If a pressure warning (see parameter 17) is triggered during boiler operation, boiler output is reduced to the value set
here.
Parameter 25 (2EC/32793): Ionisation warning
If, during operation, the ionisation ow falls below this level, a warning “W:02” is shown.

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DESCRIPTION OF THE PARAMETERS
Parameter 26 (2FA/32794): Number of hall impulses per revolution
The value set under this parameter determines how many impulses per revolution of the fan are returned to the
automatic ring device. The value is dependant on the used fan.
Parameter 27 (2FF/32795): Fan speed during the rst period of pre-venting
The pre-venting phase is divided into two periods. In the rst period, the fan speed set here operates for 25 seconds.
See functional drawing 3.
Parameter 28 (2FG/32796): Fan speed at start
In the second period of the pre-venting phase, which also lasts 25 seconds, the fan operates at the speed set here,
and at the end of this period, the burner ignites. See functional drawing 3.
Parameter 29 (2FH/32797): Maximum fan speed
This parameter denes the maximum speed of the fan.
Parameter 30 (2FI/32798): Minimum fan speed
This parameter denes the minimum speed of the fan.
Gas pressure
External gas
solenoid
valve/LGP
Burner fan
Int. Ignition
Gassolenoid
valve
Flame
t
Par.39
25 s
50 s
5 s
4 s
5 s 30 s 25 s
50 s
5 s
4 s
5 s 10 s
Par.48
Par.37
Example:
False start
Example:
Successful start
Modulating
operation
Switch-
off
Time
Ext. Ignition
Functional drawing 3
Status

10 4 205 503 / 14
DESCRIPTION OF THE PARAMETERS
Parameter 31 (2FJ/32799): Upward ramp of the fan during venting
If the number of rotations changes during venting, a higher number of rotations can be achieved using the upward
ramp set here.
Parameter 32 (2FK/32800): Downward ramp of the fan during venting
If the number of rotations changes during venting, a lower number of rotations can be achieved using the downward
ramp set here.
Parameter 33 (2FL/32801): Upward ramp of the fan during operation
If the number of rotations changes during operation, a higher number of rotations is limited using the upward ramp
set here.
Parameter 34 (2FM/32802): Downward ramp of the fan during operation
If the number of rotations changes during operation, a lower number of rotations is limited using the downward ramp
set here.
Parameter 35 (2FN/32803): Post-venting of the fan after lock-out
If lock-out occurs (not on the occurrence of a blocking or other boiler switch-off) post-venting occurs for the period
set under this parameter, and at a speed set under Parameter 36.
Parameter 36 (2FO/32804): Fan speed after a normal switch-off or after lock-out/blocking
After lock-out and/or blocking has occurred, or after switch-off has occurred in normal operation, the fan will operate
at the speed set here for the period of time set under Parameter 35 or Parameter 37.
Parameter 37 (2FR/32805): Fan afterrun time after operation or blocking
After a heat demand and/or after blocking of the boiler, the fan operates for the period of time dened here, and at
the speed set under Parameter 36.
Parameter 38 (2FU/32806): Fan speed at boiler freeze protection
If the boiler is not in operation and the temperature of ow temperature sensor 1 falls below the 3°C limit, the boiler
starts up and operates with the fan speed set here until the switch-off limit of 10°C is exceeded.
Parameter 39 (2GA/32807): Waiting time after opening main gas valve or activation of heating room fan
If there is a burner demand, the boiler start is delayed for the period of time set here. During this waiting period,
which is necessary for the opening of the main gas valve or for pre-venting using the heating room fan, the blocking
notication “B:04” is shown. This blocking is no longer shown as of BIC 960 V.3. The ext. gas valve closes again as
soon as the burner has switched off.
Parameter 40 (2GB/32808): External main gas valve/heating room fan available
This parameter denes whether or not an external main gas valve or a heating room fan is available.
Parameter 41 (2HA/32809): Afterrun heating pump or shut-off valve
If the boiler switches off because there is no longer a demand for heat, an afterrun of the heating pump or shut-off
valve occurs. The duration of this afterrun can be set using this parameter.
Note: if the boiler switches off due to blocking or lock-out, or because the reference value + hysteresis has been
exceeded, this afterrun period does not occur, and the pump and/or shut-off valve continue to operate indenitely.